S46MC-C VOLUME II

EDITION 2 MAINTENANCE
 Instructions for Main Engine

Type S46MC-C

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

Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS AND 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 the above engine type. Deviations
may be found in a specific plant. In addition, the books can be used for reference purposes, for
instance in correspondance 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)

Examble: M/S Nybo - 7730 B&W - 90201 - 00 - 059

10 off (piston ring)

Furthermore, to ensure optimum efficiency, reliability and lifetime of the engine and its
components, only original spare parts should be used.

The designation 'D' used in texts and illustrations refers to the information given on the data-
sheets inserted in the respective books.

As reliable and economical operation of the diesel engines is conditional on correct operation
and maintenance, it is essential that the engine-room personnel is fully acquainted with the
contents of this book.

This book is subject to copyright protection. The book must not, either wholly or partly, 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

Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen Telex :16592 manbw dk
Denmark Telefax:+45 33 85 10 30
 Cross Section through Engine Plate 90001-51

S46MC-C
S46MC-C Table of Contents 900
Volume II – Maintenance
S46MC-C
018
Table of Contents
900

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

Instructions for Main Engine

900 Introduction
900 018 Table of contents
90001 051 Cross Section through Engine
900-1 218 Checking and Maintenance Schedules

901 Cylinder Cover

101-1 019 Cylinder Cover, Data
901-1 205 Cylinder Cover x x x
90151 182 Cylinder Cover Panel
90161 086 Cylinder Cover – Tools
90162 017 Cylinder Cover – Tools

902 Piston with Rod and Stuffing Box

102-1 023 Piston, Data
902-1 222 Piston x x x x
102-2 021 Piston Rod Stuffing Box
902-2 206 Piston Rod Stuffing Box x x x x
90251 228 Piston and Piston Rod Panel
90261 079 Piston and Piston Rod – Tools

903 Cylinder Liner and Cylinder Lubrication

103-1 024 Cylinder Liner, Data
903-1 220 Cylinder Liner x x x x
103-2 011 Cylinder Lubricators
903-2 219 Cylinder Lubricators x x x x
90361 078 Cylinder Liner – Tools

When referring to this page, please quote Table of Contents Edition 018 Page 1 (6)
MAN B&W Diesel A/S
900 Table of Contents S46MC-C
Volume II – Maintenance

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

904 Crosshead with Connecting Rod

104-1 020 Crosshead Bearing, Data
904-1 205 Crosshead Bearing x x x
104-2 021 Crosshead, Data
904-2 206 Crosshead x x
104-3 009 Reciprocating Parts, Data
904-3 204 Reciprocating Parts x
104-4 017 Crankpin Bearing, Data
904-4 215 Crankpin Bearing x x x
104-5 020 Connecting Rod, Data
904-5 204 Connecting Rod x x
90451 123 Connecting Rod and Crosshead Panel
90461 046 Connecting Rod – Tools
90462 021 Connecting Rod – Tools

905 Crankshaft, Thrust Bearing and Turning Gear

105-1 002 Crankshaft Deflection, Data
905-1 205 Crankshaft Deflection x
105-2 022 Main Bearing, Data
905-2 225 Main Bearing x x x x
105-3 019 Thrust Bearing, Data
905-3 206 Thrust Bearing x x x
105-5 016 Axial Vibration Damper, Data
905-5 217 Axial Vibration Damper x x x x
105-8 002 Angle Encoder, Data
905-8 202 Angle Encoder x x x x

90551 201 Panels for Crankshaft, Thrust Shaft,

Main Bearing, Etc. Panel
90561 062 Main Bearing and Thrust Bearing – Tools
90562 118 Crankshaft – Tools

Page 2 (6) When referring to this page, please quote Table of Contents Edition 018
MAN B&W Diesel A/S
S46MC-C Table of Contents 900
Volume II – Maintenance

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

90563 013 Turning Wheel – Tools

90564 018 Crankshaft – Tools

906 Mechanical Control Gear

106-1 020 Chain, Data
906-1 212 Chain x x x
106-2 008 Chain Tightener, Data
906-2 217 Chain Tightener x
106-3 012 Camshaft, Data
906-3 204 Camshaft x x
106-4 014 Camshaft Bearings, Data
906-4 204 Camshaft Bearings x x x x
90651 169 Chain Drive and Camshaft Panel
90661 056 Camshaft – Tools

907 Starting Air System

107-1 008 Starting Air Distributor, Data
907-1 209 Starting Air Distributor x x
107-2 015 Starting Air Valve, Data
907-2 203 Starting Air Valve x x x

908 Exhaust Valve

108-1 003 High-Pressure Pipe, Data
908-1 204 High-Pressure Pipe x x x
108-2 018 Exhaust Valve, Data
908-2 204 Exhaust Valve x x x x
108-3 014 Exhaust Valve Actuator, Data
908-3 216 Exhaust Valve Actuator x x x x
108-4 016 Exhaust Valve Roller Guide, Data
908-4 204 Exhaust Valve Roller Guide x x x x
108-5 003 Exhaust Valve Cam, Data

When referring to this page, please quote Table of Contents Edition 018 Page 3 (6)
MAN B&W Diesel A/S
900 Table of Contents S46MC-C
Volume II – Maintenance

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

908-5 204 Exhaust Valve Cam x

108-7 016 Exhaust Valve Special Running, Data
908-7 214 Exhaust Valve Special Running
90851 127 Exhaust Valve Panel
90861 029 Exhaust Valve – Tools
90861 035 Exhaust Valve – Extra Tools
90863 013 Exhaust Valve – Extra Tools

909 Fuel Oil System

109-1 028 Fuel Pump Lead, Data
909-1 228 Fuel Pump Lead x x
109-3 022 Fuel Pump Cam, Data
909-3 213 Fuel Pump Cam x
109-4 020 Fuel Pump, Data
909-4 208 Fuel Pump x x x
109-5 020 Fuel Pump Top Cover, Data
909-5 209 Fuel Pump Top Cover x x x
109-6 004 Fuel Pump Barrel Assembly, Data
909-6 206 Fuel Pump Barrel Assembly x
109-7 004 Fuel Pump Suction Valve, Data
909-7 206 Fuel Pump Suction Valve x
109-8 005 Fuel Pump Puncture Valve, Data
909-8 206 Fuel Pump Puncture Valve x
109-9 004 Fuel Pump Shock Absorber, Data
909-9 205 Fuel Pump Shock Absorber x x
109-11 025 Fuel Valve, Data
909-11 205 Fuel Valve x x x x
109-12 023 Spindle Guide, Data
909-12 205 Spindle Guide x
109-13 016 Non-return Valve, Data
909-13 204 Non-return Valve x

Page 4 (6) When referring to this page, please quote Table of Contents Edition 018
MAN B&W Diesel A/S
S46MC-C Table of Contents 900
Volume II – Maintenance

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

109-14 029 Fuel Oil High-Presseure Pipe, Data

909-14 210 Fuel Oil High-Presseure Pipe x x x
109-15 024 Fuel Pump Roller Guide, Data
909-15 204 Fuel Pump Roller Guide x x x x
109-16 010 Fuel Valve – Tools
909-16 203 Fuel Pump Emergency Running
90951 371 Fuel Valve and Fuel Pump Panel
90961 057 Fuel Valve – Tools
90962 058 Mouting Tools for Fuel Pump Seals
90963 007 Fuel Valve – Tools

910 Turbocharger System

110-1 021 Air Cooler Element, Data
910-1 222 Air Cooler Element x x x x
110-2 002 Non-Return Valve, Data
910-2 211 Non-Return Valve x
110-3 003 Auxiliary Blower, Data
910-3 204 Auxiliary Blower x
110-5 002 Turbocharger Turbine, Data
910-5 203 Turbocharger Turbine x
110-6 011 Water Mist Catcher, Data
910-6 214 Water Mist Catcher x x
91051 044 Cooler and Turbocharger Panel
91061 062 Turbocharger System – Tools

911 Safety Equipment

111-1 019 Safety Valve, Data
911-1 204 Safety Valve x x x
111-2 009 Relief Valve, Data
911-2 205 Relief Valve x

When referring to this page, please quote Table of Contents Edition 018 Page 5 (6)
MAN B&W Diesel A/S
900 Table of Contents S46MC-C
Volume II – Maintenance

No. Edition Title Workcards in Procedures

Checking Dismantling Overhaul/ Mounting
Adjustment

912 Assembly of Large Parts

112-1 002 Holding Down and End Chock Bolts, Data
912-1 205 Holding Down and End Chock Bolts (Cast x
Iron)
782225 000 Checking Hydraulically Tightened Holding
Down Bolts, MC Engines
782226 002 Checking Side Chocks and End Chocks with
Bolts, MC Engines
112-2 002 Holding Down and End Chock Bolts, Data
912-2 204 Holding Down and End Chock Bolts (Epoxy) x
782225 000 Checking Hydraulically Tightened Holding
Down Bolts, MC Engines
782226 002 Checking Side Chocks and End Chocks with
Bolts, MC Engines
112-3 002 Stay Bolts, Data
912-3 202 Stay Bolts x
91261 062 Large Parts – Tools
91263 046 Hydraulic Tools

913 General Tools

913-1 203 Hydraulic Tools
913-5 203 Torque Spanner
913-6 203 Tightening Gauge
913-7 203 Screws and Nuts
913-11 203 Lubricating Procedures
91351 022 Accessories for Hydraulic Tools
91356 049 Lifting Tools
91361 045 Spanners
91362 049 Spanners
91363 032 Spanners
91364 055 Spanners, etc.
91366 060 Instruments

Page 6 (6) When referring to this page, please quote Table of Contents Edition 018
MAN B&W Diesel A/S
 Checking and Maintenance Schedules 900-1

Checking and Maintenance Schedules

S46MC-C
900-1 218

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 900-1 Edition 218 Page 1 (5)
MAN B&W Diesel A/S
 Checking and Maintenance Schedules 900-1

V : See Volume ! “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
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 C* C** O 903-2

904 Crosshead with Connecting Rod

-1 Crosshead Bearing C O

-2 Crosshead O

-3 Reciprocating Parts C 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 O

-5 Axial Vibration Damper C,O

-8 Angle Encoder C

* check inlet accumulator nitrogen pressure, ** check outlet accumulator nitrogen pressure

When referring to this page, please quote Maintenance Schedules 900-1 Edition 218 Page 2 (5)
!"#$%&'$()*+*,$"-.
 Checking and Maintenance Schedules 900-1

V : See Volume ! “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
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 A

-3 Camshaft C C A,C

-4 Camshaft Bearings C O,C

907 Starting Air System

-1 Starting Air Distributor C C A

-2 Starting Air Valve O,C

Governor 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

-2 VIT System (where used) A

-3 Fuel Pump Cam A 909-1

-4 Fuel Pump O

When referring to this page, please quote Maintenance Schedules 900-1 Edition 218 Page 3 (5)
!"#$%&'$()*+*,$"-.
 Checking and Maintenance Schedules 900-1

V : See Volume ! “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
Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P
-5 Fuel Pump Top Cover O

-6 Fuel Pump Barrel Assembly O

-7 Fuel Pump Suction Valve O

-8 Fuel Pump Puncture Valve O

-9 Fuel Pump Shock Absorber C O

-11 Fuel Valve O

-12 Spindle Guide O

-13 Non-Return Valve O

-14 Fuel Oil High-Pressure Pipes O

-15 Fuel Pump Roller Guide C C,O

910 Turbocharger System

-1 Air Cooler Element O O V

-2 Non-Return Valve C O

-3 Auxiliary Blower O

-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

Checking and adjustment of turning gear M

switch

When referring to this page, please quote Maintenance Schedules 900-1 Edition 218 Page 4 (5)
!"#$%&'$()*+*,$"-.
 Checking and Maintenance Schedules 900-1

V : See Volume ! “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
Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P

912 Assembly of Large Parts

-1 Holding Down and End Chock Bolts (Cast C C

Iron)

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

-3 Stay Bolts C C

913 General Tools

-1 Hydraulic Tools

-5 Torque Spanner

-6 Tightening Gauge

-7 Screws and Nuts

-11 Lubricating Procedures

When referring to this page, please quote Maintenance Schedules 900-1 Edition 218 Page 5 (5)
!"#$%&'$()*+*,$"-.
 Cylinder Cover 101-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

19
101-1
Special Data
S46MC-C Cylinder 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
50-300 Nm
Ref. Description Value Unit

D-1 Weight of exhaust valve stud 6 kg

1 x 3 m, 8 x 1 m
D-2 Weight of cyl. cover compl. 1360 kg

D-3 Weight of cooling jacket 37 kg

D-4 Screwing-in torque – 200 Nm

exhaust valve studs

D-5 Screwing-in torque – 145 Nm

starting valve studs

D-6 Screwing-in torque – 140 Nm

fuel valve studs

D-7 Weight of high-pressure 32 kg

pipe (exhaust valve)

D-8 Hydraulic pressure for

cylinder cover:
– dismantling 1500–1650 bar
– tightening 1500 bar

D-9 Tightening torque – 100 Nm

fuel oil high-pressure pipe
(fuel pump/fuel valve)

D-10 Tightening torque – 36 Nm

high-pressure pipe
(exhaust valve)

D-11 Weight of fuel oil

high-pressure pipes 8 kg

When referring to this page, please quote Data Sheet 101-1 Edition 19 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
Data

Plate
90151 Plate
90951
1165513-9

1165517-6

Spare Parts

Plate – Item No. Description Qty

90101-111 114 O-rings 2

90101-111 138 Sealing ring 1
90302-129 201 O-rings 4

Page 2 (2) When referring to this page, please quote Data Sheet 101-1 Edition 19
MAN B&W Diesel A/S
S46MC-C Cylinder Cover 901-1.2
Dismantling
Cylinder Cov er
S46MC-C
205
Dismantling
901-1.2

1.
1. Set blocking device A on the main starting
valve in the BLOCKED position.

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve D.

Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the control air and safety air supply.

Vent the manoeuvring system through the
ball valve.

Also shut off the air supply on the reduction

unit for the hydraulic/pneumatic exhaust
valve, and vent the system.
GN901-1.2 203 01

When referring to this page, please quote Procedure 901-1.2 Edition 205 Page 1 (10)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover S46MC-C
Dismantling

2. 2. Remove the cooling water inlet and outlet

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 the fuel valves and pump.

Dismount the control air pipe from the start-

ing valve.
GN901-1.2 203 02

Remove the starting air pipe.

3. Remove the screws which fasten the high-

pressure pipe to the oil cylinder on the ex-
3. haust valve and the hydraulic activator, and
lift the high-pressure pipe away.

Dismount the drain oil pipe between the ex-

haust valve and the hydraulic activator, the
air pipe for the pneumatic exhaust valve,
D-7 and the pipes for the sealing air arrange-
ment.

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

GN901-1.2 203 03

the intermediate pipe and the exhaust re-

ceiver. The four lowermost screws need not
be dismantled, just loosened.

4. Remove the protective caps from the cylin-

der cover nuts.
GN901-1.2 203 04

Page 2 (10) When referring to this page, please quote Procedure 901-1.2 Edition 205
MAN B&W Diesel A/S
S46MC-C Cylinder Cover 901-1.2
Dismantling

5. Place eight spacer rings over the nuts, and 5.

screw the eight hydraulic jacks onto the D-8
studs.

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 nuts,

vent the system and increase the pressure
as stated in Data.
For operation of the hydraulic tools, see
Chapter 913.

GN901-1.2 203 05
Loosen the nuts by applying the tommy bar
through the slots in the spacer rings.

Relieve the system of pressure.

6.
Disconnect the high-pressure hoses from
the jacks.

Finally, remove the hydraulic jacks and

spacer rings, and unscrew the nuts.

6. Hook the engine room crane on to the lifting

attachment on top of the exhaust valve.

Lift away the cylinder cover complete, and

land it on a couple of wooden planks.

7. Remove and discard the sealing ring be-

GN901-1.2 203 06

tween cylinder cover and cylinder liner.

7.
GN901-1.2 203 07

When referring to this page, please quote Procedure 901-1.2 Edition 205 Page 3 (10)
MAN B&W Diesel A/S
901-1.3 Cylinder Cover S46MC-C
Overhaul
Overhaul
901-1.3

1. 1. Dismount all valves and pipes on the cylin-

der cover.

Dismount all studs on the top of the cylinder

cover.

2. Unscrew 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

GN901-1.3 203 01

screws to force the jacket/cover apart.

3. Remove and discard the O-rings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.
2.
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
reference (camshaft side).

Mount and tighten the screws for the cool-

ing jacket.
GN901-1.3 203 02

3.
4.
GN901-1.3 203 03

Page 4 (10) When referring to this page, please quote Procedure 901-1.3 Edition 205
MAN B&W Diesel A/S
S46MC-C Cylinder Cover 901-1.3
Overhaul

5. Recondition the valve bores as follows: 5.

Fuel valve bore

6. The tool consists of a common spindle with

handle, and of 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. Carborun-

GN901-1.3 203 05
dum 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
not damaged.
GN901-1.3 203 06

7.
GI901-3.1 98 05

When referring to this page, please quote Procedure 901-1.3 Edition 205 Page 5 (10)
MAN B&W Diesel A/S
901-1.3 Cylinder Cover S46MC-C
Overhaul

8. Starting valve bore

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.
GN901-1.3 203 08

9.
GN901-1.3 203 09

Page 6 (10) When referring to this page, please quote Procedure 901-1.3 Edition 205
MAN B&W Diesel A/S
S46MC-C Cylinder Cover 901-1.3
Overhaul

10. Lubricate the threads with ‘Never Seize' or 10.

Molybdenum Disulphide (MoS 2) and mount
the valve studs.

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 per-
matex to prevent water or oil from entering
the bores during operation of the engine.

GN901-1.3 203 10
Provide the water connection flanges with
new gaskets, and keep the cylinder cover
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 901-1.3 Edition 205 Page 7 (10)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover S46MC-C
Mounting
Mounting
901-1.4

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

D-2 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-
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

with new O-rings and lubricate them with
GN901-1.4 203 01

grease or soft soap.

Mount a new ‘klinger’ sealing ring in the

groove of the flange of the intermediate
2. pipe.

Lower the cover carefully into position.

During the landing, carefully check that the

cooling water connecting pipes engage cor-
rectly 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
the studs.
GN901-1.4 203 02

Connect the high-pressure pump to the

jacks by means of the distributor block and
the high-pressure hoses.
3.
D-8 Use the vent screws of the hydraulic nuts to
vent the system, and then increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Chapter 913.

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

spacer rings from the nuts.
GN901-1.2 203 05

Page 8 (10) When referring to this page, please quote Procedure 901-1.4 Edition 205
MAN B&W Diesel A/S
S46MC-C Cylinder Cover 901-1.4
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 ex-
haust valve.

Mount the screws of the flange between the

intermediate pipe and the exhaust receiver.

Note!

GN901-1.4 203 04
Lubricate the screws with ‘Never Seize’
or Molybdenum Disulphide (MoS 2) before
mounting.

5. Mount the insulating jacket around the in- 5.

termediate pipe.
GN901-1.4 203 05

When referring to this page, please quote Procedure 901-1.4 Edition 205 Page 9 (10)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover S46MC-C
Mounting

6. 6. Mount the return oil pipe, the sealing air

pipe and the air pipe for pneumatic closing
of the exhaust valve.

Mount the high-pressure pipe for the hy-

D-10 draulic valve gear.
See Procedure 908-1.3.

7. Mount the starting air pipe and control air

pipe for the starting valve.
D-7
Mount the cooling water inlet and outlet
pipes on the exhaust valve.
GN901-1.4 203 06

Mount the drain pipe on the intermediate

pipe between the exhaust valve and the cyl-
inder cover.

7. Using a crowfoot wrench and torque span-

ner, mount the fuel oil high-pressure pipes
between the fuel pump and the fuel valves
(checking that the pipes fit properly at the
seats and that all parts are clean and pro-
vided with new O-rings). 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 cool-
GN901-1.4 203 07

ing water outlet valve.

D-9 Open the fuel oil, lubricating oil and air sup-
plies to the alarm system.

Caution !

The air supply to the exhaust valve must

always be connected before starting the
camshaft oil pumps.

This is very important, because other-

wise the valve will open more than
intended.

Page 10 (10) When referring to this page, please quote Procedure 901-1.4 Edition 205
MAN B&W Diesel A/S
 Cylinder Cover Panel Plate 90151-182

S46MC-C
Plate 90151-182 Cylinder Cover Panel

Item Item
Part Description Part Description
No. No.

010 *) Tool panel

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

010- *) Tool panel, complete

201 with tools

*) Optional extras
 Cylinder Cover - Tools Plate 90161-86

S46MC-C
Plate 90161-86 Cylinder Cover - Tools

Item Item
Part Description Part Description
No. No.

015 Hydraulic jack

027 O-ring with back-up ring, 65/75 mm
039 O-ring with back-up ring, 85/95 mm
040 Stud setter M 42x4.5
052 Spacer ring for cylinder cover and
exhaust valve
064 Spacer ring for crosshead bearing
076 Hydraulic tools for cylinder cover,
exhaust valve and crosshead bearing
088 Hydraulic tools for cylinder cover
 Cylinder Cover - Extra Tools Plate 90162-17

S46MC-C
Plate 90162-17 Cylinder Cover - Extra Tools

Item Item
Part Description Part Description
No. No.

010 Grinding machine for liner and cover

 Piston 102-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

23
102-1
Special Data
S46MC-C Piston

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
10–120, 50–300, 280–760 Nm
X Shut off lubrication oil
Lock turbocharger rotors
2 x M12

Data
Ref. Description Value Unit

D-1 Radial width:

– new piston ring 16 mm
– worn piston ring 13.5 mm
D-2 Maximum vertical height:
– groove No. 1 12.765 mm
– groove Nos. 2, 3 and 4 9.765 mm
D-3 Max. permissible burn-away:
– standard piston top 14 mm
– inconel piston top 8 mm
D-4 Nominal height:
– piston ring No. 1 11.9 mm
– piston ring Nos. 2, 3 and 4 8.9 mm
D-5 Minimum ring gap
– ring No. 1 3.2 mm
– ring Nos. 2, 3 and 4 2,3 mm
D-6 Vertical clearance new parts 0.35-0.40 mm
D-7 Piston complete 700 kg
D-8 Piston crown 169 kg
D-9 Piston skirt 39 kg
D-10 Tightening torque – 80 Nm
piston skirt
D-11 Piston cooling pipe 17 kg
D-12 Tightening torque – 80 Nm
cooling pipe
D-13 Piston rod 463 kg
D-14 Tightening torque – 300 Nm
piston crown/rod
D-15 Test pressure 7 bar
D-16 Cyl. cover with exhaust valve 1360 kg
D-17 Screwing-in torque – 400 Nm
cylinder cover studs
D-18 Tightening torque of piston 430 Nm
or tightening angle 40 °
D-19 Tightening torque – 80 Nm
stuffing box

When referring to this page, please quote Data Sheet 102-1 Edition 23 Page 1 (2)
MAN B&W Diesel A/S
102-1 Piston
Data

Plate
90251

1165516-4

Spare Parts

Plate – Item No. Description Qty

90301-xxx 363 Gasket 1

90201-xxx 072 Piston ring No. 1 1
90201-xxx 084 Piston ring No. 2 1
90201-xxx 096 Piston ring No. 3 1
90201-xxx 106 Piston ring No. 4 1
90201-xxx 047 Locking wire 1
90201-xxx 167 D-ring 1
90201-xxx 179 D-ring 1
90101-xxx 138 Gasket 1

Page 2 (2) When referring to this page, please quote Data Sheet 102-1 Edition 23
MAN B&W Diesel A/S
 Piston 902-1.1
Checking
222
Piston
S46MC-C
902-1.1
Checking

1.
Scavenge port inspection

To detect possible leakages from the piston or

cylinder cover, keep the cooling water and cool-
ing oil circulating during the scavenge port in-
spection.

1. Remove the inspection covers on the cam-

shaft side of the cylinder frame.

Note!

GN902-1.1 204 01
The scavenge port inspection can also
be carried out from within the scavenge
air receiver.

Clean the openings.

2.
Begin the inspection at the cylinder whose
piston is nearest BDC.

2. With the piston in BDC, inspect the piston

crown and the cylinder wall.

Note down the results.

See Volume I, Operation, Chapter 707.

3. Turn the engine. While the piston is passing

the scavenge air ports, inspect the piston
rings, the ringlands and the piston skirt.

Check the movability and the tension of the

GN902-1.1 204 07

piston rings, by pressing against them with

a wooden stick.

Note down the results.

3.
HG902-1.1 201 03

When referring to this page, please quote Procedure 902-1.1 Edition 222 Page 1 (19)
!"#$%&'$()*+*,$"-.$
902-1.1 Piston
Checking

4. 4. After turning the piston upwards, past the

scavenge air ports, inspect the piston rod
and the lower part of the cylinder wall.

Note down the results.

5. Re-mount the inspection covers on the cyl-

inder frame. If necessary, replace the gas-
kets.

Piston rings and piston crown

6. Remove the piston from the cylinder and

GN902-1.1 204 04

place it on the piston support.

See Procedure 902-1.2.

6.
GN902-1.4 204 02

Page 2 (19) When referring to this page, please quote Procedure 902-1.1 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.1
Checking

7. Take off the piston rings by means of the 7.

ring expander.

Clean and inspect the rings.

8. Measure and record the radial width and

the height of the rings.
See Volume I, Operation, Chapter 707.

Worn rings must be replaced if the radial

width is less than stated in Data.

9. Piston rings with milled pressure relief

grooves must be replaced if the radial depth
of the grooves has worn down to less than
1 mm.

GN902-1.1 222 14

8.

New
D-1
AM902-3.0 54 02

Worn

9.
GN902-1.1 204 09

When referring to this page, please quote Procedure 902-1.1 Edition 222 Page 3 (19)
!"#$%&'$()*+*,$"-.$
902-1.1 Piston
Checking

10. 10. Clean the ring grooves and check them for
burn marks or other deformation.
D-2
Measure the ring grooves with a dial gauge
or a caliper gauge.

Clearance in piston ring grooves:

Max. 2 mm 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

KM902-3.0 47 05

chromium layer.

11. The nominal heights of ring grooves and

piston rings are as stated in Data.

11. 12. Clean the piston crown and check the burn-
away by means of the template. For maxi-
mum permissible burn-away value, see Da-
ta.

Check the burn-away on the whole circum-

ference of the piston crown.
GN902-1.1 204 11

12.
D-3
AM902-3.0 77 04

Page 4 (19) When referring to this page, please quote Procedure 902-1.1 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.1
Checking

13. Before mounting a new piston ring, meas- 13.

ure the piston ring gap.

Insert the piston ring in either a new cylin-

der liner or in the bottom of a used cylinder
(below the ring travel zone) during the
measuring.

For minimum ring gap, see Data. D-5

14. Fit the piston rings (alternately right-hand
and left-hand cuts with the ring gaps stag-

GN902-1.1 222 13
gered 180° and with the TOP mark upwards)
by means of the ring expander.

The ring expander prevents unintended de-

formation of the rings.
14.
15. Check the vertical clearance between the
new piston ring and the new or recondi-
tioned ring groove with a feeler gauge. See
Data.
GN902-1.1 222 14

15.

D-6
KC902-3.0 83 06

When referring to this page, please quote Procedure 902-1.1 Edition 222 Page 5 (19)
!"#$%&'$()*+*,$"-.$
902-1.2 Piston
Dismantling
Dismantling
902-1.2

1. 1. Turn the crosshead down far enough to give

access to the piston rod stuffing box, the
tightening screws for the piston rod, and to
the telescopic pipe.

2. Release the stuffing box by removing the

innermost screws from the stuffing box
flange.

Note!

Do NOT remove the outermost screws

from the flange.

3. Remove the screws from the piston rod.

GN902-1.2 204 01

2.
GN902-1.2 204 02

3.
GN902-1.2 204 03

Page 6 (19) When referring to this page, please quote Procedure 902-1.2 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.2
Dismantling

4. Mount the two distance pieces on the piston 4.

rod foot to protect the lower scraper ring
and to guide the stuffing box.

5. Dismount the cylinder cover.

See Procedure 901-1.2.

Carefully smooth out any wear ridges at the

top of the cylinder liner by using a hand
grinder.
See Procedure 903-1.3.

GN902-1.2 204 04
6. Turn the crosshead to TDC, while checking
that the guide pins of the distance pieces
enter the holes in the stuffing box.

5.

D-16
GN902-1.2 204 05

6.
GN902-1.2 204 06

When referring to this page, please quote Procedure 902-1.2 Edition 222 Page 7 (19)
!"#$%&'$()*+*,$"-.$
902-1.2 Piston
Dismantling

7. 7. The top of the piston is now free of the cyl-

inder liner.

If necessary, remove one or two cylinder

cover studs, using a stud setter.

Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two ‘fixed’ claws of the tool fit into
the lifting groove of the piston.

Fit the third, adjustable, claw of the tool to

the lifting groove and tighten it up against
GN902-1.2 204 07

the stop of the tool.

8. Place the two halves of the support around

one of the openings in the platform.

8. Lift the piston out of the cylinder and lower

the piston rod foot and stuffing box through
the opening in the platform.

Place the two halves of the support around

the piston rod and secure the two halves
with screws.

9. Place a cover over the opening for the pis-

ton rod stuffing box in the bottom of the cyl-
inder unit.

Clean, measure and recondition the cylin-

der liner.
See Procedure 903-2.1.
GN902-1.2 204 08

9.
GN902-1.2 204 09

Page 8 (19) When referring to this page, please quote Procedure 902-1.2 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.2
Dismantling

10. Turn the crosshead down far enough to per- 10.

mit mounting of the protective rubber cover
on the crosshead bearing cap.

The protective rubber cover should remain

in place to protect the crosshead bearing
journal from impurities until the piston is re-
mounted.

Low lifting height

If the space conditions above the engine make

it impossible to remove the piston in the normal

GN902-1.2 204 10
way, the piston can be removed as follows:

11. Remove one or two cylinder cover studs,

using the stud setter.

Lift the piston high enough to give ample 11.

room over the cylinder cover studs.

Mount the clamp on the piston rod so that

its distance piece lies true against the pis-
ton.
GN902-1.2 204 11

When referring to this page, please quote Procedure 902-1.2 Edition 222 Page 9 (19)
!"#$%&'$()*+*,$"-.$
902-1.2 Piston
Dismantling

12. 12. Place the supporting tools on the cylinder

cover studs and lower the piston until the
clamp rests on the tools.

Remove the lifting tool from the piston.

Hook the transverse piece on to the crane

and attach it to the clamp for tilting the pis-
ton.

13. Lift the piston to the maximum crane height.

Run the crane athwartship and, at the same
time, tilt the piston.

Keep the piston rod clear of the cylinder lin-

er and studs while carrying out the tilting.

When space conditions permit, straighten

up the piston and lead it over to the cut-out
in the platform for overhauling the piston.

When the piston is at a suitable height

GN902-1.2 204 12

above the platform cut-out, position the pis-

ton support around the piston rod and
clamp.

Now lower the piston while guiding the sup-

13. port to the platform cut-out.

After landing the piston and ensuring that it

rests correctly on the support, remove the
tilting tool.

Note!

On engines with extremely low lifting

height, use the engine room double-jib
crane instead of the transverse piece.
GN902-1.2 204 13

Page 10 (19) When referring to this page, please quote Procedure 902-1.2 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.3
Overhaul
902-1.3
Overhaul

1. Position new O-rings on the platform 1.

around the piston overhaul cut-out.

2. Ease the piston down so that the stuffing

box is below the floor.

Lift the O-rings and assemble the two

halves of the piston support around the pis-
ton rod.

Position the O-rings on the piston support.

3. Dismount the locking wire and screw up the

GN902-1.3 204 01
support screws of the piston support to a
position just below the piston skirt.

Remove the piston skirt screws.

GN902-1.3 204 02 2.

3.
GN902-1.3 204 03

When referring to this page, please quote Procedure 902-1.3 Edition 222 Page 11 (19)
!"#$%&'$()*+*,$"-.$
902-1.3 Piston
Overhaul

4. 4. Screw the four screws of the support down-

wards until the skirt rests on the support.

If the skirt will not budge, free it by means

of two dismantling screws.

5. Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown.

Lift away the piston crown.

6. Dismount the bolts of the cooling oil pipe

GN902-1.3 204 04

flange.

Mount the eye bolts and lift out the cooling

oil pipe.

5.
GN902-1.3 204 05

6.
GN902-1.3 204 06

Page 12 (19) When referring to this page, please quote Procedure 902-1.3 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.3
Overhaul

Alternatively, the piston can be dismantled 7.

in the following way:

Note!

Tilting of the piston must only take place

with the piston rod stuffing box mounted
on the piston rod.

7. While the complete piston is hanging from

the lifting tool, mount the collar round the
piston rod so that the distance pieces of the
collar obtain contact with the piston.

Lower the piston so that the collar rests on

the platform.

Remove the lifting tools from the top of the

piston crown.

Hook the engine room crane on to the lifting

crossbar and hook the chains of the lifting
crossbar on to the shackles of the collar.

8. Lift the piston, tilt it to the horizontal posi-

tion, and land it in this position on a couple
GN902-1.3 204 07

of wooden blocks. Remove the lifting cross-

bar and chains from the collar.

9. Attach the lifting tool to the bottom of the

piston rod foot. Hook the crane on to the lift-
ing tool. 8.

Lift the foot of the piston rod clear of the

wooden block. Move the piston rod stuffing
box up the piston rod until it is in contact
GN902-1.3 204 08

with the collar. Remove the two distance

pieces from the piston rod foot.

Note!
9.
During the lift, follow with the crane to
keep the crane positioned vertically
above the foot of the piston rod.

Keep lifting until the piston rod is in a verti-

cal position.
GN902-1.3 204 09

When referring to this page, please quote Procedure 902-1.3 Edition 222 Page 13 (19)
!"#$%&'$()*+*,$"-.$
902-1.3 Piston
Overhaul

10. 10. Place the piston in an upright position with

the piston crown resting on wooden blocks.

Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown. Lift the piston rod away and land
it in a horizontal position on a couple of
wooden blocks.

11. Remove the locking wire and the screws in

the skirt and mount two eye bolts in the
holes intended for dismantling screws. Lift
the skirt and land it on a couple of planks.
GN902-1.3 204 10

12. Thoroughly clean and inspect all parts of

the piston.
Regarding check of the piston crown, see
Procedure 902-1.1.
11.
Replace all sealing rings of the piston. All
the new sealing rings must be coated with
lubricating oil before the piston is assem-
bled.

Coat all screws with Molybdenum Disul-

phide (MoS 2).

Assemble the piston in the reverse order to

disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.
GN902-4.3 92 04

Tighten all the screws diagonally to the

torque stated in Data.

12.
GN902-1.3 204 12

Page 14 (19) When referring to this page, please quote Procedure 902-1.3 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.3
Overhaul

13. Lock all the screws with locking wire. 13.

Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
See Procedure 913-7.

14. Fill the piston and piston rod with lubricat-

ing oil.

Mount the pressure-testing tool around the

base of the piston rod.

Pressure-test the piston at the pressure

HM902-4.2 52 07
stated on the data sheet.

Check the contact surfaces of the piston

and the sealing rings for tightness.
14.
Check that there are no cracks in the piston
crown.
MB902-4.0 96 14

When referring to this page, please quote Procedure 902-1.3 Edition 222 Page 15 (19)
!"#$%&'$()*+*,$"-.$
902-1.4 Piston
Mounting
Mounting
902-1.4

2. 1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1.

Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.

2. Mount the lifting tool on the piston crown.

3. Ensure that the stuffing box is correctly po-

sitioned over the guide pins in the distance
pieces mounted on the piston rod foot.

Coat the O-rings of the stuffing box with oil.

4. Remove the protective rubber cover from

the crosshead.
GN902-1.4 204 02

3.
GN902-1.4 204 03

4.
GN902-1.2 204 10

Page 16 (19) When referring to this page, please quote Procedure 902-1.4 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.4
Mounting

5. Remove the cover from the piston rod stuff- 5.

ing box opening in the bottom of the cylin-
der unit.

6. Turn the crosshead to a position 45° from

TDC.

Mount the guide ring for piston rings on the

cylinder liner.

7. Lower the piston into the cylinder liner –

while guiding the piston rod foot through the
cut-out in the stuffing box flange – until the

GN902-1.2 204 09
piston rings are inside the liner, corre-
sponding to the lifting tool lacking about 30
mm in landing on the guide ring.

GN902-1.4 204 06 6.

7.
GN902-1.4 204 07

When referring to this page, please quote Procedure 902-1.4 Edition 222 Page 17 (19)
!"#$%&'$()*+*,$"-.$
902-1.4 Piston
Mounting

8. 8. Turn the crosshead to TDC while checking

that the guide ring of the crosshead enters
the centre hole in the piston rod.

9. After turning the piston fully to TDC, un-

screw the adjustable claw of the lifting tool
and pull the lifting tool free of the lifting
groove in the piston

Remove the lifting tool and the guide ring

for piston rings.

Turn the crosshead with the piston rod and

the telescopic pipe down far enough to per-
GN902-1.4 204 08

mit tightening of the piston rod screws.

10. Remove the distance pieces from the piston

rod foot.
9.
Mount and tighten the piston rod screws.
See Data.

Lock the screws with locking wire.

Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
See Procedure 913-7.
GN902-1.4 204 09

10.
GN902-1.2 204 03

Page 18 (19) When referring to this page, please quote Procedure 902-1.4 Edition 222
!"#$%&'$()*+*,$"-.
 Piston 902-1.4
Mounting

11. Tighten down the piston rod stuffing box by 11.

means of the screws through the inner
holes in the stuffing box flange. See Data.

12. Mount the cylinder cover studs with the stud

setter. See Data.

Carefully clean the surfaces around the

base of the mounted studs and refill the
roots properly with Permatex 3.

13. Smear the piston rod with molybdenum di-

sulphide, and turn the crankshaft a couple

GN902-1.2 204 02
of revolutions.

Mount the cylinder cover.

See Procedure 901-1.4.

14. Start the engine and keep it running for 12.

about 15 minutes at a number of revolutions
corresponding to very slow.

Then stop the engine and inspect the piston

rod and stuffing box.
GN902-1.4 204 12

13.

D-16
GN902-1.2 204 05

When referring to this page, please quote Procedure 902-1.4 Edition 222 Page 19 (19)
!"#$%&'$()*+*,$"-.$
 Piston Rod Stuffing Box 102-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

21
102-2
Special Data PistonS46MC-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 10 - 120 Nm
X Shut off lubrication oil
Lock turbocharger rotors

Data
Ref. Description Value Unit
D-1 Stuffing box complete 61 kg

D-2 Stuffing box half 19 kg

D-3 Tightening torque –

stuffing box halves 80 Nm

D-4 Tightening torque –

stuffing box flanges 80 Nm

D-5 Tightening torque –

inner screws 80 Nm

D-6 Horizontal clearance –

uppermost rings 0.16-0.28 mm

D-7 Horizontal clearance –

lowermost rings 0.08-0.13 mm

D-8 Ring-end clearances –

uppermost rings 4 x 6 mm

D-9 Ring-end clearances –

lowermost rings 3 x 3 mm

D-10 Check length for the six

uppermost springs:
– F0 = 0 N................. L0 = 550 mm
– F1 = 99 +/– 7 N....... L1 = 716 mm
– F2 = 120 +/– 8 N..... L2 = 750 mm

D-11 Check length for the four

lowermost springs:
– F0 = 0 N................. L0 = 453 mm
– F1 = 108 +/– 8 N....... L1 = 666 mm
– F2 = 139 +/– 10 N..... L2 = 728 mm

When referring to this page, please quote Data Sheet 102-2 Edition 21 Page 1 (2)
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data

Plate
90251

1165516-4

Spare Parts

Plate – Item No. Description Qty

90205-xxx 037 Scraper rings 4

90205-xxx 050 O-ring 1
90205-xxx 133 Lamellae for scraper rings 16
90205-xxx 157 Top scraper ring 1
90205-xxx 169 Pack sealing ring 3
90205-xxx 170 Cover sealing ring 2
90205-xxx 216 Spring 6
90205-xxx 228 Spring 4

Page 2 (2) When referring to this page, please quote Data Sheet 102-2 Edition 21
MAN B&W Diesel A/S
S46MC-C Piston Rod Stuffing Box 902-2.1
Checking
Pis ton Rod Stuffing Box
S46MC-C
206
Checking
902-2.1

1.
1. After the piston rod stuffing box has been
dismantled, check the following clearanc- D-6
es:.
See Procedure 902-2.2.

Uppermost scraper ring and sealing rings

D-7
Vertical clearance between sealing ring
section and groove. (D-6)

Clearance at ring ends (scraper ring).

Total clearance (scraper ring). (D-8)

Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D-8)

Lowermost scraper rings

Vertical clearance between scraper ring

and groove. (D-7) D-8 D-9
GM902-5 90 01

Clearance at ring ends.

Total clearance. (D-9)

The ring clearances stated in Data apply to

2.
new rings.

As a general guide, it is recommended –

depending on the overhauling intervals and
one’s own experience – to replace sealing
rings and scraper rings when the specified
clearance values D-8 and D-9 have been
halved.

2. Check the length of the springs at different

loads. Adjust the loads to achieve the
lengths stated in Data.
HM902-5.0 70 02

If the loads necessary are outside the limits

stated in Data, the springs must be discard-
ed.

When referring to this page, please quote Procedure 902-2.1 Edition 206 Page 1 (9)
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box S46MC-C
Dismantling
Dismantling
902-2.2

1. Outside the engine

Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.
See Procedure 902-1.2.

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:
GN902-2.3 204 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,

2. 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 screws.

2. Remove the O-ring of the stuffing box. If the

O-ring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.

If the overhaul is carried out inside the en-

gine, the O-ring has to be reused.
HC902-5.1 98 03

Remove the nuts from the stuffing box as-

sembling bolts.

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

3. stuffing box half.

Mount two eye bolts in the stuffing box half

D-2 and remove it from the worktable.
GN902-2.3 204 14

Page 2 (9) When referring to this page, please quote Procedure 902-2.2 Edition 206
MAN B&W Diesel A/S
S46MC-C Piston Rod Stuffing Box 902-2.2
Dismantling

Inside the engine 1.

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

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

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

Mount the rubber hose around the piston

rod to protect the crosshead bearing from
impurities.

2. Remove the drain oil pipe and all innermost

GN902-2.2 203 01
screws and all outer screws except for two
screws placed diametrically opposite in the
stuffing box flange, longitudinally to the en-
gine.

3. Mount the worktable round the piston rod 2.

so that the two remaining screws can be
loosened through the worktable holes.
MB902-5.2 94 02

3.
MB902-5.2 94 03

When referring to this page, please quote Procedure 902-2.2 Edition 206 Page 3 (9)
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box S46MC-C
Dismantling

4. 4. Remove the two long screws 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.

Remove the two long dismantling screws

MB902-5.2 94 04

from the stuffing box and mount them in the

worktable.

6. By means of the four short screws in the

5. worktable, press the stuffing box out of the
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
MB902-5.2 94 05

6.
MB902-5.2 94 06

Page 4 (9) When referring to this page, please quote Procedure 902-2.2 Edition 206
MAN B&W Diesel A/S
S46MC-C Piston Rod Stuffing Box 902-2.3
Overhaul
Overhaul
902-2.3

1. Remove the remaining stuffing box half and 3.

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

2. Measure the vertical clearance (D-8, D-9)

between the ring segments to determine
whether replacement is necessary.
See Procedure 902-2.1.

Note!

Dismantle and stack the rings in the

same order as when fitted in the stuffing
box.

HM902-5.0 70 02
Carefully clean all the ring segments.

Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces 4.
have scratches or marks, replace the rings.

3. Check the lengths of the springs.

See Procedure 902-2.1.

4. Inspect the surface of the piston rod. If

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
prove necessary to machine-grind the sur-
GN902-2.3 204 19

face in a workshop.

5. Clean the halves of the stuffing box hous-

ing.

When referring to this page, please quote Procedure 902-2.3 Edition 206 Page 5 (9)
MAN B&W Diesel A/S
902-2.4 Piston Rod Stuffing Box S46MC-C
Mounting
Mounting
902-2.4

1. 1. 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,

HM902-5.1 70 09

and hook the spring ends together.

Repeat this procedure for the remaining

scraper rings.

2. On top of the scraper rings, assemble the

cover sealing rings, the pack sealing ring
and the top scraper ring units (each con-
sisting 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 cover sealing ring

above the 8-part pack sealing ring. Push
the two rings together in such a manner
that the guide pins in the lower sealing ring
GN902-2.3 204 09

engage with the two holes in the upper

sealing ring.

Finally, assemble the uppermost ring unit

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

2. 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.

3. Using a feeler gauge, measure the horizon-

tal clearance of the rings.
See Procedure 902-2.1.
GN902-2.3 204 10

Page 6 (9) When referring to this page, please quote Procedure 902-2.4 Edition 206
MAN B&W Diesel A/S
S46MC-C Piston Rod Stuffing Box 902-2.4
Mounting

4. Then place the other half of the stuffing box 4.

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

Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.

Outside the engine

5. Mount eye bolts and wire ropes, and lift the

stuffing box a little. Remove the worktable.

6. Lower the stuffing box until it rests against

GN902-2.3 204 11
the distance pieces on the piston rod foot.
D-3
Mount a new O-ring in the stuffing box
groove.

Remove wire ropes and eye bolts. 5.

For mounting of the stuffing box and the
piston, see Procedure 902-1.4.
HC902-5.1 98 13

6.
GN902-1.4 204 03

When referring to this page, please quote Procedure 902-2.4 Edition 206 Page 7 (9)
MAN B&W Diesel A/S
902-2.4 Piston Rod Stuffing Box S46MC-C
Mounting

1. Inside the engine

1. After overhauling, support the stuffing box

halves on top of the four screws.

Mount the two long screws from the workta-

ble in the stuffing box.

Unscrew the short screws so that the stuff-

ing box lands on the flange.

2. Turn the piston upwards until the stuffing

box is in place in the cylinder frame.

Note!

Make sure that the two guide pins in the

MB902-5.2 94 06

flange enter the guide holes in the bottom

of the cylinder frame.

3. Mount two screws in the flange through the

2. holes in the worktable.
MB902-5.2 94 08

3.
MB902-5.2 94 09

Page 8 (9) When referring to this page, please quote Procedure 902-2.4 Edition 206
MAN B&W Diesel A/S
S46MC-C 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.

MB902-5.2 94 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.
MB902-5.2 94 11

6.
GN902-2.2 203 01

When referring to this page, please quote Procedure 902-2.4 Edition 206 Page 9 (9)
MAN B&W Diesel A/S
 Piston and Piston Rod Panel Plate 90251-228

S46MC-C
Plate 90251-228 Piston and Piston Rod Panel

Item Item
Part Description Part Description
No. No.

014 *) Tool panel

026 Name plate
040 Lifting tool for piston rod
063 Lifting and tilting screw
075 Template for piston top
087 Distance piece for stuffing box
099 Cover
109 Hook for mounting of spring
110 Pressure testing
122 Worktable
134 Piston ring expander
146 Support
158 Guide screw for piston crown
160 Dismantling screw

014- *) Tool panel, complete

160 with tools

*) Optional extras
 Piston and Piston Rod - Tools Plate 90261-79

S46MC-C
Plate 90261-79 Piston and Piston Rod - Tools

Item Item
Part Description Part Description
No. No.

019 Guide ring for piston

020 Lifting tool for piston
032 Lifting crossbar
044 Lifting collar
056 Support for piston
 Cylinder Liner 103-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

24
103-1
Special Data
S46MC-C Cylinder 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 280–760 Nm
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Cylinder diameter, new 460 mm

D-2 Cylinder liner, complete 1525 kg

D-3 Cooling jacket 160 kg

D-4 Screwing-in torque –

cylinder cover studs 400 Nm

D-5 Cylinder cover stud 22 kg

D-6 Screwing in torque

– lifting screw 200 Nm

When referring to this page, please quote Data Sheet 103-1 Edition 24 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data

Plate
90251

1165516-4

Spare Parts

Plate – Item No. Description Qty

90101-xxx 138 Sealing ring 1

90302-xxx 201 O-ring 8
90302-xxx 071 O-ring 2
90302-xxx 095 O-ring 1
90302-xxx 129 Gasket 4
90811-xxx 102 Gasket 1

Page 2 (2) When referring to this page, please quote Data Sheet 103-1 Edition 24
MAN B&W Diesel A/S
 Cylinder Liner 903-1.1
Checking
220
Cylinder Liner
S46MC-C
903-1.1
Checking

/0
1. Dismount the cylinder cover and piston.
See Procedure 901-1.2.
See Procedure 902-1.2. (12
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 evaluate the condition of the cyl-

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.
30
Using a grinding machine, remove the wear
ridges at the top and bottom of the cylinder
liner (where the piston rings reverse direc-
tion), so that a smooth transition is formed.

Check the lubricating points of the cylinder

by pumping cylinder oil to each individual
lubricating point with the Alpha lubricator.

Clean any blocked lubricating duct.

Mount the piston and cylinder cover. 40

See Procedure 902-1.4.
See Procedure 901-1.4.

When referring to this page, please quote Procedure 903-1.1 Edition 220 Page 1 (9)
!"#$%&'$()*+*,$"-.$
903-1.2 Cylinder Liner
Dismantling
Dismantling
903-1.2

20 1. Dismount the cylinder cover.

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 grind away the wear ridges at
the top of the liner with a hand-grinder.
D-6 See Procedure 903-1.3.

Dismount the piston.

See Procedure 902-1.2.

Mount the two lifting screws in the cylinder

liner.

Note!

Tighten the lifting screws to the torque

stated in Data.

/0 Check with a 0.05 mm feeler gauge that

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.
Screw off the four screws on the distributor
block to separate the block.

Dismount the four cooling water pipes – be-

tween the cooling jacket and cylinder cover
– and clean them carefully.

Page 2 (9) When referring to this page, please quote Procedure 903-1.2 Edition 220
!"#$%&'$()*+*,$"-.
 Cylinder Liner 903-1.2
Dismantling

3. Remove the screws of the cooling water in- 30

let pipe.

4. Attach the crane to the lifting crossbar.

Hook the chains from the lifting crossbar on

to the lifting screws and lift the cylinder liner
with the cooling jacket out of the cylinder
frame.

Note!

Low lifting height in the engine room may

require the removal of one or more cylin-
der cover studs before dismantling the
cylinder liner.

Land the cylinder liner vertically on, for in- 40

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.

When referring to this page, please quote Procedure 903-1.2 Edition 220 Page 3 (9)
!"#$%&'$()*+*,$"-.$
903-1.2 Cylinder Liner
Dismantling

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

porting the cylinder liner.

Note!

The cylinder liner is not in balance, even

with the cooling jacket mounted.

To keep the liner in a horizontal position

during transportation, use e.g. a wire
rope connected from the scavenge ports
to the traverse as shown on the sketch.

(1/

Page 4 (9) When referring to this page, please quote Procedure 903-1.2 Edition 220
!"#$%&'$()*+*,$"-.
 Cylinder Liner 903-1.3
Overhaul
903-1.3
Overhaul

1. Unscrew the nuts on the non-return valves 20

and remove the valves.

Remove and discard the sealing rings on

the distributor block.

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 screws on

the cooling jacket and haul tight.

Remove the two lifting screws in the cylin-

der liner. /0

Remove the four clamps which fix the cool-

ing jacket to the cylinder liner.

3. Lift away the cooling jacket by means of the

tackles and land it on the wooden planks.

30

(13

When referring to this page, please quote Procedure 903-1.3 Edition 220 Page 5 (9)
!"#$%&'$()*+*,$"-.$
903-1.3 Cylinder Liner
Overhaul

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

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.

Using a grinding machine, remove the wear

ridges at the top and bottom of the cylinder
liner (where the piston rings reverse direc-
tion), so that a smooth transition is formed.

Clean the cylinder liner and the cooling

jacket both internally and externally. Pay
special attention to the O-ring grooves and
lubricating ducts.

5. Replace the two uppermost O-rings on the

cylinder liner.

50

Page 6 (9) When referring to this page, please quote Procedure 903-1.3 Edition 220
!"#$%&'$()*+*,$"-.
 Cylinder Liner 903-1.3
Overhaul

6. Lower the cooling jacket on to the cylinder 60

liner.

Note!

Make sure that the scratch marks in the

camshaft side of the cylinder liner and
cooling jacket coincide. (13
7. 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. Mount the non-return valves for cylinder lu-

brication. Tighten the nuts and connect the
lubricating oil pipes. 70

Clean the distributor block and mount new

sealing rings.

80

When referring to this page, please quote Procedure 903-1.3 Edition 220 Page 7 (9)
!"#$%&'$()*+*,$"-.$
903-1.4 Cylinder Liner
Mounting
Mounting
903-1.4

20 1. Loosen the water connections on the cool-

ing jacket.

Mount the two lifting screws in the cylinder

liner.

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-

(1/ tle lubricating oil on the ring.

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 new sealing rings on the distributor

block for cylinder lubricating oil.

Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connec-
tions on the cooling jacket.
/0
If one or more cylinder cover studs have
been removed during the dismantling of the
cylinder cover, remount the studs using the
stud setter and a torque wrench, see Data.

(14

Page 8 (9) When referring to this page, please quote Procedure 903-1.4 Edition 220
!"#$%&'$()*+*,$"-.
 Cylinder Liner 903-1.4
Mounting

3. Fit a new gasket between the cooling water 30

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

4. Mount and tighten the four screws in the

cylinder lubricator and oil distributor block.

Vent the cylinder lubricating system by

pressing the “Pre-lub” button on the Alpha
panel 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-

vidual lubricating point functions correctly.

5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil and
mount the piston. 40
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.

60

When referring to this page, please quote Procedure 903-1.4 Edition 220 Page 9 (9)
!"#$%&'$()*+*,$"-.$
 Cylinder Lubricators 103-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

11
103-2
Special Data
S46MC-C 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 lubrication oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Nitrogen pressure

– inlet accumulator 25-30 bar

D-2 Nitrogen pressure

– outlet accumulator 1.5 bar

When referring to this page, please quote Data Sheet 103-2 Edition 11 Page 1 (2)
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
Data

Spare Parts

Plate – Item No. Description Qty

90306-xxx 085 O-ring 2

90306-xxx 239 O-ring 1
90306-xxx 240 Feedback sensor (pick-up), complete 1
90306-xxx 431 O-ring 1
90306-xxx 502 O-ring 12
90306-xxx 514 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 103-2 Edition 11
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.1
Checking
219
Cylinder Lubricators
S46MC-C
903-2.1
Checking

1.
With stopped engine:

1. Press the PRE-LUB.-button on the HMI con-

trol panel, and check that all lubricators are
operating correctly by watching the LEDs
on the intermediate boxes for each lubrica-
tor, placed next to the lubricators.

With running engine:

2. Check that all lubricators are operating cor-

rectly by watching the LEDs on the interme-
diate boxes for each lubricator.

If the installation is provided with a meas-

uring tank, the cylinder oil feed rate can be
checked as follows:

• Close the valve for the cylinder oil main

supply line on the side of the measuring
tank.

• Start a stopwatch at the instant the oil

level passes the upper measuring mark
in the sight glass. Stop the watch when
the oil level passes the lower measuring
mark. Note down the time and the engine
load/rpm.
EN903-2.1 219 01

3. Open the valve for the cylinder oil main sup-

ply line on the measuring tank.

Calculation of cylinder oil feed rate:

Vt!"!# " 1000 "! 3600 3.

Q=
P "! t
Q = Cylinder oil feed rate (g/kWh)
t = time taken to consume the amount
of oil in the tank (sec)
V t = Amount of oil in tank between
measuring marks (l)
# = Specific density (kg/l)
P = Engine load (kW)
EN903-2.1 219 03

When referring to this page, please quote Procedure 903-2.1 Edition 219 Page 1 (8)
!"#$%&'$()*+*,$"-.$
903-2.1 Cylinder Lubricators
Checking

4. Example:
Tank contains four litres of cylinder oil.
Time t taken to consume four litres is meas-
ured to be 25 min. and 35 sec. (1535 sec).
Specific density #! = 0.94.
Engine load P is 6300 kW.

Calculation of cylinder oil feed rate:

D-2 4 !"! 0.94!" 1000 "! 3600

Q= = 1.4 g/kWh
6300 "! 1535
D-1
EN903-2.1 219 04

If the engine load P is inserted in the for-

mula, in terms of bhp, the result Q will be
in g/bhph.
For evaluation, see Volume I, Section
707.14.

4. Measuring the nitrogen pre-pressure can

only be done with stopped engine and pres-
sure-free lubrication system.

Stop both oil pumps. Close the inlet valve

and open the equalizing valve on the re-
spective lubricator.

The nitrogen pressure in the inlet accumu-

lator (0.7 litre) can be checked without dis-
mounting the accumulator. A 0-60 bar
pressure gauge must be used on the pres-
sure setting tool, see Data.

To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), use a 0-10
bar pressure gauge on the pressure setting
tool. The accumulator or the lubricator with
accumulator must be dismounted.
See Procedure 903-2.2.

For nitrogen pressure in the outlet accumu-

lator, see Data.

For use of the nitrogen pressure-setting

tool, see the supplier’s instruction.

Page 2 (8) When referring to this page, please quote Procedure 903-2.1 Edition 219
!"#$%&'$()*+*,$"-.
 Cylinder Lubricators 903-2.2
Dismantling
Dismantling
903-2.2

Dismantling of lubricator: 1.

The engine must be stopped and blocked be-

fore dismounting a lubricator. Stop the cylinder
oil pump station.

1. Close the supply valve for the lubricator and

open the equalizing valve (turn both han-
dles to a horizontal position).

Disconnect the electrical plug on the side of

the lubricator.

EN903-2.2 219 01
2. Unscrew the three screws in the bottom of
the lubricator and disconnect the cover with
pertaining pipes.

3. Unscrew the four screws on the side that

secure the lubricator to the hydraulic block, 4.
and remove the lubricator.

Dismantling of accumulators:

4. The engine must be stopped and blocked

before the accumulator is dismounted.

Stop the cylinder oil pump station.

Close the supply valve for the lubricator and
open the equalizing valve.

Note!
EN903-2.2 219 02

When the oil pressure is released, a

nitrogen pre-pressure of 25-30 bar will
remain in the accumulator.

4.
Carefully, unscrew the accumulator to re-
lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the
hydraulic block.
EN903-2.2 219 04

When referring to this page, please quote Procedure 903-2.2 Edition 219 Page 3 (8)
!"#$%&'$()*+*,$"-.$
903-2.3 Cylinder Lubricators
Overhaul
903-2.3
Overhaul

1. 1. Place the lubricator in a bench vice with

soft “jaws”.

Remove the adjusting screw with bushings.

Unscrew the oil accumulator.

Discard the O-ring from the adjusting

screw.

2. Remove the screws from the cylinder block.

3. Pull up the cylinder block.

EN903-2.3 219 01

Remove the spring and actuator piston with

plungers.

Remove and discard the O-ring from the

cylinder block.
2.
Remove the cover for the non-return valves.
Take out springs and balls. Remove and
discard the O-rings.
EN903-2.3 219 02

3.
EN903-2.3 219 03

Page 4 (8) When referring to this page, please quote Procedure 903-2.3 Edition 219
!"#$%&'$()*+*,$"-.
 Cylinder Lubricators 903-2.3
Overhaul

4. Remove the cover from the terminal box, 4.

and disconnect the wires for the feedback
(pick-up) sensor.

Carefully, unscrew the feedback sensor and

remove and discard the O-ring.

Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.

EN903-2.3 219 04
5. Inspect the plungers, actuator piston and
cylinder block for wear, using a magnifying
glass.

Check that the balls from the non-return 5.

valves are in good condition.

Check the seats for the non-return valves.

6. Before mounting the feedback sensor,

check that the sensor is flush with the sen-
sor housing.

Mount the feedback sensor or a new one, if

necessary, with a new O-ring.

Check with an object with a straight edge

EN903-2.3 219 05

(e.g. the end of a calliper) that the end of

the feedback sensor does not protrude into
the actuator piston cylinder.

Connect the wires and mount the cover on

the terminal box. 6.

1 1
2 Solenoid valve
EN903-2.3 219 06

2
3 BN (brown)
4 BK (black) Feedback sensor
BU (blue)
5

When referring to this page, please quote Procedure 903-2.3 Edition 219 Page 5 (8)
!"#$%&'$()*+*,$"-.$
903-2.3 Cylinder Lubricators
Overhaul

7. 7. Fit the cylinder block with new O-rings.

Assemble the non-return valves in the cyl-

inder block.

Mount the cover with the three inner

screws.

Check with a small screwdriver that the

springs are corretly centered.

8. Fit the cylinder block with a new O-ring.

Pre-assemble the cylinder block with the
EN903-2.3 219 07

actuator piston and plungers to ensure cor-

rect guidance of the plungers, before finally
assembling the cylinder block unit.

Mount the spring and press down the actu-

8. ator piston with plungers. Mount an M6 x 60
screw with a disc to keep the spring com-
pressed.

9. Mount the cylinder block assembly in the

cylinder housing.

Mount the screws and tighten the block to

the housing.

Remove the M6 x 60 screw with disc.

EN903-2.3 219 08

9.
EN903-2.3 219 09

Page 6 (8) When referring to this page, please quote Procedure 903-2.3 Edition 219
!"#$%&'$()*+*,$"-.
 Cylinder Lubricators 903-2.3
Overhaul

10. Mount the adjusting screw fitted with a new 10.

O-ring and the distance bushing.

Mount the oil accumulator.

11. If the lubricator is not to be mounted on the

engine immediately after overhauling, cover
all openings with plastic to prevent dirt from
entering the lubricator during storage.

Cover all surfaces with a thin layer of oil.

EN903-2.3 219 01

When referring to this page, please quote Procedure 903-2.3 Edition 219 Page 7 (8)
!"#$%&'$()*+*,$"-.$
903-2.4 Cylinder Lubricators
Mounting
Mounting
903-2.4

1. 1. Before mounting the accumulator, check

the nitrogen pressure, see Data.

Mount the accumulator.

2. Mount new O-rings on the hydraulic block

and on the cover with pipes.

Mount the lubricator and tighten the screws

on the hydraulic block.

Tighten the screws in the bottom of the lu-

bricator to the pipe connection.
EN903-2.4 219 01

3. Close the equalizing valve and open the

supply valve (handles to be in a vertical po-
sition).

2. Mount the electrical plug. Check the injec-

tion of cylinder oil on the LED on the inter-
mediate box for the specific lubricator.

For checking injection timing, see Proce-

dure 905-8.1.
EN903-2.4 219 02

3.
EN903-2.4 219 03

Page 8 (8) When referring to this page, please quote Procedure 903-2.4 Edition 219
!"#$%&'$()*+*,$"-.
 Cylinder Liner - Tools Plate 90361-78

S46MC-C
Plate 90361-78 Cylinder Liner - Tools

Item Item
Part Description Part Description
No. No.

036 Cylinder gauge, complete

 Crosshead Bearing 104-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

20
104-1
Special Data
S46MC-C Crosshead 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
2 x 2400 kg, 2 x 600 kg
X Shut off lubricating oil
Lock turbocharger rotors 50-300 Nm, 280-760 Nm

Data
Ref. Description Value Unit
3 x M12, 4 x M20
D-1 Top clearance in crosshead
bearing:
Max. 0.50 mm 1 x 1.5 m, 4 x 3 m
Min. 0.20 mm

D-2 Oil wedge length, L = 10 mm

2 x 1000 kg
2 x 2000 kg
D-3 Hydraulic pressure
– dismantling 1500-1650 bar
– tightening 1500 bar

D-4 Crosshead bearing cap 130 kg

D-5 Crosshead + piston compl. 1950 kg

D-6 Bearing shell, lower 24 kg

D-7 Crosshead, complete 1200 kg

D-8 Piston rod

– tightening torque or 430 Nm
– tightening angle 40 °

When referring to this page, please quote Data Sheet 104-1 Edition 20 Page 1 (2)
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data

Plate
90451
1165515-2.1

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 104-1 Edition 20
MAN B&W Diesel A/S
S46MC-C Crosshead Bearing 904-1.1
Checking
Cros shead Bearing
S46MC-C
205
Checking
904-1.1

2.
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.

For the top 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 crankthrow concerned to 90° be-

GN904-1.1 203 02
fore BDC on the exhaust side.

3. Measure the clearance in the crosshead

bearing by inserting a feeler gauge be-
tween the bearing cap and the crosshead
journal, exactly next to the landing surface 3.
for the piston rod foot. See Data. 4.

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
crosshead bearing must be disassembled
for inspection.
See Procedure 904-1.2. D-1
5. The wear limit for a crosshead bearing shell
GN904-1.1 203 04

is confined to a 50% reduction of the oil

wedge length (L). See Data.

6. For further external inspection of the cross-

head bearing, see Chapter 708, ‘Bearings’
in the instruction book, Volume I, OPERA- 5.
TION.

D-2
GN904-1.1 203 05

When referring to this page, please quote Procedure 904-1.1 Edition 205 Page 1 (10)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing S46MC-C
Dismantling
Dismantling
904-1.2

1. This procedure has been divided into two dis-

mantling situations, as follows:

• 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.
GN904-1.1 203 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.
GN904-1.2 203 02

3.
GN902-1.2 204 03

Page 2 (10) When referring to this page, please quote Procedure 904-1.2 Edition 205
MAN B&W Diesel A/S
S46MC-C 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 remain suspended from the two
chains.

With piston removed:

GN904-1.2 203 04
6. Turn to BDC.

7. Hold 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.
GN904-1.2 203 05

7.

D-3
GN904-1.2 203 07

When referring to this page, please quote Procedure 904-1.2 Edition 205 Page 3 (10)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing S46MC-C
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 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.
Check the upper part of the journal.
GN904-1.2 203 08

9.
GN904-1.2 203 09

10.
D-4
GN904-1.2 203 10

Page 4 (10) When referring to this page, please quote Procedure 904-1.2 Edition 205
MAN B&W Diesel A/S
S46MC-C Crosshead Bearing 904-1.2
Dismantling

11. Place the bearing cap on one side on a 11.

couple of wooden planks.

12. Fasten tackles to the fixed lifting brackets

on the frame box wall.

13. Turn the crosshead upwards until the piston

rod lands on the crosshead. Ensure that the
guide ring in the crosshead fits correctly in

GN904-1.2 203 11
the centre hole of the piston rod.

Do not remove the chains or lifting eye

bolts.
12.

GN904-1.2 203 12

13.
GN904-1.2 203 13

When referring to this page, please quote Procedure 904-1.2 Edition 205 Page 5 (10)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing S46MC-C
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
GN904-1.2 203 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’.
GN904-1.2 203 15

16.
17. D-5
GN904-1.2 203 16

Page 6 (10) When referring to this page, please quote Procedure 904-1.2 Edition 205
MAN B&W Diesel A/S
S46MC-C 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 door in the camshaft side,
using the tackles.
D-6
Dismount the lock screws, and turn the
bearing shell so far up that an eye bolt can
be mounted.

Lift the bearing shell out of the engine.

GN904-1.2 203 18

When referring to this page, please quote Procedure 904-1.2 Edition 205 Page 7 (10)
MAN B&W Diesel A/S
904-1.4 Crosshead Bearing S46MC-C
Mounting
Mounting
904-1.4

1. With the piston mounted/

With the piston removed:
D-6
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-

GN904-1.4 203 01

les, for assembling the crosshead and the

connecting rod.

Take care that the guide shoes do not dam-

2. age the bearing shell.

D-7 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.
GN904-1.4 203 02

3.
GN904-1.4 203 03

Page 8 (10) When referring to this page, please quote Procedure 904-1.4 Edition 205
MAN B&W Diesel A/S
S46MC-C Crosshead Bearing 904-1.4
Mounting

4.
4. Lift the bearing cap into the engine. Lower D-4
the bearing cap onto the crosshead and re-
move the tackles. Remove the lifting attach-
ments from the connecting rod.

Note!

Take care that the bearing studs do not

damage the crosshead.

5. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.

GN904-1.4 203 04
For operation of hydraulic jacks, see Sec-
tion 913.

6. Mount the piston.

See Procedure 902-1.4.
5.
With the 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.

D-3
GN904-1.2 203 07

7.
GN904-1.4 203 07

When referring to this page, please quote Procedure 904-1.4 Edition 205 Page 9 (10)
MAN B&W Diesel A/S
904-1.4 Crosshead Bearing S46MC-C
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 one of the screws

works loose.
See Procedure 913-7.

9.
GN904-1.4 203 09

Page 10 (10) When referring to this page, please quote Procedure 904-1.4 Edition 205
MAN B&W Diesel A/S
 Crosshead 104-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

21
104-2
Special Data
S46MC-C 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 50-300 Nm
X Shut off lubricating oil 1 x 1.5 m
Lock turbocharger rotors 4x3m

Data 2 x M12
4 x M30
Ref. Description Value Unit

D-1 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar

D-2 Crosshead bearing cap 130 kg

D-3 Crosshead complete 1200 kg

!"#"!$$$"%&
D-4 Connecting rod 825 kg

D-5 Guide shoe 275 kg

D-6 Cooling oil outlet pipe 8.5 kg

D-7 Outlet pipe

– tightening torque 50 Nm

D-8 Guide plate

– tightening torque 135 Nm

D-9 Nuts on guide strips

– tightening torque 200 Nm

D-10 Telescopic pipe

– tightening torque 50 Nm
– tightening angle 25 °

When referring to this page, please quote Data Sheet 104-2 Edition 21 Page 1 (2)
MAN B&W Diesel A/S
104-2 Crosshead
Data

Plate
90451
1165515-2.1

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 104-2 Edition 21
MAN B&W Diesel A/S
S46MC-C Crosshead 904-2.2
Dismantling
Cros shead
S46MC-C
206
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.

Loosen the nuts, remove the hydraulic jacks

and unscrew the nuts. D-6
D-1
GN904-2.2 204 04

When referring to this page, please quote Procedure 904-2.2 Edition 206 Page 1 (7)
MAN B&W Diesel A/S
904-2.2 Crosshead S46MC-C
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.
GN904-1.2 203 06

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.

D-3 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.
GN904-2.2 203 05

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
D-4 wooden planks in the bottom of the bed-
plate.
GN904-2.2 203 06

Page 2 (7) When referring to this page, please quote Procedure 904-2.2 Edition 206
MAN B&W Diesel A/S
S46MC-C 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 a lifting eye bolt in one of the guide

shoes, and hook on a tackle.

Squeeze in a plank between the guide

shoes.

9. Suspend two tackles from the eye bolts in

the top of the crankcase in the fore-and-aft

GN904-2.2 204 08
direction.

Mount an eye bolt in the top of each guide

shoe.
9.
Mount the guide shoe extractor tool on the
guide shoe. D-5
Hook the tackles on to the eye bolts in the
guide shoes, haul tight and, at the same
time, using the guide shoe extractor tool,
pull the crosshead towards the extractor
tool until it is free of the opposite guide
shoe.

Follow the movement of the crosshead with

the engine room crane.
GN904-2.2 204 09

Lift up the free guide shoe.

10. Using the guide shoe extractor tool, push

the crosshead away from the remaining
guide shoe, until the crosshead is free of 10.
the guide shoe.

Follow the movement of the crosshead with

the engine room crane.

Dismount the guide shoe extractor tool.

Lift up the guide shoe.

GN904-2.2 204 10

When referring to this page, please quote Procedure 904-2.2 Edition 206 Page 3 (7)
MAN B&W Diesel A/S
904-2.2 Crosshead S46MC-C
Dismantling

11. 11. Turn the crosshead 90°.

D-5 12. Mount the wire guide tool in the framebox

door opening.

By means of wire rope and tackles, remove

the crosshead from the engine.

Protect the crosshead, for instance with

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

If necessary, remove the guide shoes from

the engine.
GN904-2.2 204 11

12.
GN904-2.2 203 11

Page 4 (7) When referring to this page, please quote Procedure 904-2.2 Edition 206
MAN B&W Diesel A/S
S46MC-C Crosshead 904-2.4
Mounting
Mounting
904-2.4

1. Attach the flat-plaited wire strap to the en- 1. D-3

gine room crane. D-5
Lift the crosshead into the engine, using
wire rope, tackles, and the engine room
crane.

2. Turn the crosshead 90°.

3. Lower one guide shoe and mount the guide

shoe extractor tool.

Use the guide shoe extractor tool to pull the

GN904-2.2 203 11
crosshead so far through the guide shoe
that the other guide shoe can be lowered.

Follow the movement of the crosshead with

the engine room crane.
3.
4. Lower the other guide shoe.

Use the guide shoe extractor tool to push

the crosshead towards the second guide
shoe.

Follow the movement of the crosshead with

the engine room crane.
GN904-2.2 204 10

4.
GN904-2.2 204 09

When referring to this page, please quote Procedure 904-2.4 Edition 206 Page 5 (7)
MAN B&W Diesel A/S
904-2.4 Crosshead S46MC-C
Mounting

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

D-8 D-9 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.
GN904-2.2 203 07

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-
sition, lower the crosshead and land it on
the connecting rod.
D-4
Remove the lifting attachments from the
connecting rod head.

Remove the lifting tool from the crosshead.

GN904-2.4 203 06

7.
GN904-2.2 203 05

Page 6 (7) When referring to this page, please quote Procedure 904-2.4 Edition 206
MAN B&W Diesel A/S
S46MC-C Crosshead 904-2.4
Mounting

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

gine. D-2
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.

GN904-1.2 203 06
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.
D-1
11. Mount the lubricating oil pipes on the main
D-10
bearing caps.
D-7
12. Mount the piston.
See Procedure 902-1.4.
GN904-2.2 203 03

10.

D-1
GN904-2.2 204 03

When referring to this page, please quote Procedure 904-2.4 Edition 206 Page 7 (7)
MAN B&W Diesel A/S
S46MC-C Reciprocating Parts 104-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

09
104-3
Special Data
S46MC-C Reciprocating Parts

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
X Lock turbocharger rotors

Data

Acceptance criteria with

piston in centre
(F-A direction)
Meas. Value
points

PF+PA Nmax 0.5 mm

Omax 0.7 mm

E+G Nmax 0.5 mm

H+F Nmin 0.2 mm

Omax 0.8 mm

J, L Nmax 0.9 mm

K, M Nmin 0.5 mm
Omax 1.1 mm

ZF/ZA Omax 4.0 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 Sheet 104-3 Edition 09 Page 1 (2)
MAN B&W Diesel A/S
104-3 Reciprocating Parts S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 104-3 Edition 09
MAN B&W Diesel A/S
S46MC-C Reciprocating Parts 904-3.1
Checking
Reciprocating Parts
S46MC-C
204
Checking
904-3.1

1.
In order to achieve uniform measuring condi-
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.

Bend each end approx. 250 mm up along

the framebox side. See T.

MA904-5.0 72 01
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
3.
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. Turn the engine in ASTERN direction to 45°

after BDC (the guide shoe must rest against
the crosshead guide).

3. Mount the tool between the guide shoe/

guide strip. For this purpose, use the third
threaded hole from bottom of guide shoe
GN904-3.1 203 03

(this hole is normally used for fastening the

guide strip to the shoe).

By means of the two screws in the middle

of the tool, pull the guide shoes until they
rest lightly against the end face of cross-
head.

Note!

When the tool is mounted, it is not possi-

ble to turn past TDC and BDC.

When referring to this page, please quote Procedure 904-3.1 Edition 204 Page 1 (3)
MAN B&W Diesel A/S
904-3.1 Reciprocating Parts S46MC-C
Checking

4. 4. Check the centering of the piston in the cyl-

inder liner by measuring the clearance
(from the scavenge air space with a long
feeler gauge) between the piston skirt and
the cylinder liner in the Fore and Aft posi-
tions (PF-PA).

Make sure that the piston is clear of the cyl-

inder liner in the fore-and-aft direction.

5. Measure the clearance between the guide

strips and crosshead guides (J, K, L and
M).

Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.
GN904-3.1 203 04

5.
GN904-3.1 203 05

Page 2 (3) When referring to this page, please quote Procedure 904-3.1 Edition 204
MAN B&W Diesel A/S
S46MC-C Reciprocating Parts 904-3.1
Checking

6. Check the clearance between guide shoe 6.

and crosshead guide (E, F, G and H) with
a feeler gauge.

7. It is recommended that the measured re-

sults are noted down so that possible later
changes can be ascertained.

GN904-3.1 203 06

7.
GN904-3.1 203 07

When referring to this page, please quote Procedure 904-3.1 Edition 204 Page 3 (3)
MAN B&W Diesel A/S
 Crankpin Bearing 104-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

17
104-4
Special Data
S46MC-C 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
2 x 5 m – 1800 kg
X Shut off lubricating oil
Lock turbocharger rotors
2 x 1.5 m, 1 x 3 m
Data
Ref. Description Value Unit
4 x 1000 kg, 2 x 2500 kg

D-1 Clearances in crankpin 2 x M10

bearing: 2 x M30
max. 0.46 mm
min. 0.24 mm

D-2 Hydraulic pressure:

– dismantling 1500-1650 bar
– tightening 1500 bar

D-3 Crankpin bearing – 15 kg 2 x 3000 kg

upper shell

D-4 Crankpin bearing – 12 kg

lower shell

D-5 Crankpin bearing cap + 135 kg

shell + bearing studs

When referring to this page, please quote Data Sheet 104-4 Edition 17 Page 1 (2)
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

Plate
90451
1165515-2.1

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 104-4 Edition 17
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.1
Checking
215
Crankpin Bearing
S46MC-C
904-4.1
Checking

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.

GN902-1.2 204 01
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

An average wear rate of 0.01 mm per D-1

10,000 hours is regarded as normal.

6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in 5.
the instruction book, Volume I, OPERA-
TION.
GN904-4.1 215 05

When referring to this page, please quote Procedure 904-4.1 Edition 215 Page 1 (7)
!"#$%&'$()*+*,$"-.$
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.
GN904-4.2 203 02

For operation of the hydraulic jacks, see

Section 913.

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.

D-2
GN904-4.2 203 03

4.

D-5
GN904-4.2 203 04

Page 2 (7) When referring to this page, please quote Procedure 904-4.2 Edition 215
!"#$%&'$()*+*,$"-.
 Crankpin Bearing 904-4.2
Dismantling

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

remove the whole bearing cap from the
crankcase.

Suspend a tackle from the lifting bracket on

the inside camshaft side of the frame box
above the crankcase door opening.

Hook the tackle on to an eye bolt on one

side of the bearing cap. D-5
Mount the wire guide in the top of the
crankcase door opening.

Using the tackle from the frame box inside

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

GN904-4.2 203 05
of the crankcase.

6. Place the bearing cap on one side on a

couple of planks.

Dismount the bearing shell lock screws and 6.

replace the bearing shell by a new one. D-4
The bearing shells must be replaced in
pairs.
GN904-4.2 203 06

7. Turn to TDC.

Mount the four supports for guide shoes on

the crosshead guides.

Carefully turn the crank down until the 7.

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.
GN904-4.2 203 07

When referring to this page, please quote Procedure 904-4.2 Edition 215 Page 3 (7)
!"#$%&'$()*+*,$"-.$
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’.
GN904-4.2 203 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.

11. Dismount the bearing shell lock screws.

Carefully lower the bearing shell.

GN904-4.2 203 09

11.

D-3
GN904-4.2 215 11

Page 4 (7) When referring to this page, please quote Procedure 904-4.2 Edition 215
!"#$%&'$()*+*,$"-.
 Crankpin Bearing 904-4.4
Mounting
Mounting
904-4.4

1. If necessary, replace the bearing shells with 1.

new ones. The bearing shells must be re-
placed in pairs.

Bearing shells of three mm undersize are

available as spares in case of journal recti-
fication.

HM904-6.0 61 16
Coat the bearing shell surfaces and the
journal with clean oil.

The excess height X is to ensure the cor- 3.

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

2. Lift the upper bearing shell for the crankpin

concerned into the crankcase.

3. Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.

D-3
GN904-4.4 215 03

When referring to this page, please quote Procedure 904-4.4 Edition 215 Page 5 (7)
!"#$%&'$()*+*,$"-.$
904-4.4 Crankpin Bearing
Mounting

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

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.

5. Turn the crosshead to TDC.

Remove the guide shoe support brackets

from the crosshead guides.
GN904-4.4 203 04

5.
GN904-4.4 203 05

Page 6 (7) When referring to this page, please quote Procedure 904-4.4 Edition 215
!"#$%&'$()*+*,$"-.
 Crankpin Bearing 904-4.4
Mounting

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

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.

7. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.
D-5
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-
GN904-4.4 203 06

pin bearing cap. See Data.

For operation of hydraulic jacks, see Sec-

tion 913.

Remove the tackles from the top of the 7.

frame box.

D-2
GN904-4.4 203 07

When referring to this page, please quote Procedure 904-4.4 Edition 215 Page 7 (7)
!"#$%&'$()*+*,$"-.$
 Connecting Rod 104-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

20
104-5
Special Data
S46MC-C Connecting Rod

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
2 x M10
X Shut off lubricating oil
Lock turbocharger rotors
4 x 1,5 m, 1 x 3 m
Data
Ref. Description Value Unit
3 x 3000 kg
D-1 Hydraulic pressure:
– dismantling 1500-1650 bar
– tightening 1500 bar

D-2 Crankpin bearing cap +

shell + bearing studs 135 kg

D-3 Connecting rod 825 kg

When referring to this page, please quote Data Sheet 104-5 Edition 20 Page 1 (2)
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

Plate
90451
1165515-2.1

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 104-5 Edition 20
MAN B&W Diesel A/S
S46MC-C Connecting Rod 904-5.2
Dismantling
Connecting Rod
S46MC-C
20
Dismantling
904-5.2

1.
1. Turn the crank to BDC.

Dismount the nuts from the crosshead

bearing studs.
See Procedure 904-1.2.

2. Mount two shackles in the top of the crank-

case in the lifting brackets, in the athwart-
ship direction, and suspend two tackles.

3. Turn the crank to TDC.

Dismount the crankpin bearing cap, and re-

GN904-1.2 203 07
move the bearing cap from the engine.
See Procedure 904-4.2.

GN904-4.2 203 02 2.

3.
D-1

D-2
GN904-4.2 203 04

When referring to this page, please quote Procedure 904-5.2 Edition 204 Page 1 (7)
MAN B&W Diesel A/S
904-5.2 Connecting Rod S46MC-C
Dismantling

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-
GN904-4.2 203 07

necting rod.

Fasten tackles to lifting brackets A and B on

the frame box wall, and attach the tackle
hooks to the mentioned lifting attachments
5. on the connecting rod head.

D-3 Haul the tackles tight.

Also mount a lifting attachment on the lower

end of the connecting rod, on the exhaust
side.

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.
GN904-5.2 203 05

Turn the crankthrow to 90° before BDC.

6.
GN904-5.2 203 06

Page 2 (7) When referring to this page, please quote Procedure 904-5.2 Edition 204
MAN B&W Diesel A/S
S46MC-C Connecting Rod 904-5.2
Dismantling

7. Shift tackle B from the lifting attachment on 7.

one side of the connecting rod to the lifting
attachment on the other side.
A
AA

B
Dismount the lifting attachment on the cam-
shaft side of the connecting rod.

Attach a tackle to lifting bracket C on the

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

Mount the wire guide on the door frame.

EN904-5.2 204 07
Turn the crankthrow towards TDC while ‘fol-
lowing’ with the tackles, thus continuously
supporting and guiding the connecting rod
towards the doorway.
8.
8. Attach a tackle to the gallery-mounted lift-
ing bracket E, and hook on to the lifting at-
tachment on the connecting rod. A B E

Shift tackle A from the lifting attachment on

the head of the connecting rod to the lifting
attachment at the bottom of the connecting
rod. C

Turn the crank carefully upwards while ‘fol-

lowing’ with tackles A, B, C and E, guiding
the head of the connecting rod out of the
doorway.
EN904-5.2 204 08

Shift the tackles from one lifting attachment

to the other as necessary.

9. Mount a strap around the connecting rod 9.

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

Remove tackles A and E.

C
Continue turning upwards till about 30° af-
ter TDC while ‘following’ with the tackles
and the engine room crane.
EN904-5.2 204 09

When referring to this page, please quote Procedure 904-5.2 Edition 204 Page 3 (7)
MAN B&W Diesel A/S
904-5.2 Connecting Rod S46MC-C
Dismantling

10. 10. Shift the tackle from lifting bracket C to A.

AAaaaaaa
Lift the connecting rod out of the engine,
a B E
using the tackles and the engine room
crane.

Remove the tackles, and lift the connecting

rod away by means of the engine room
C
crane.
EN904-5.2 204 10

Page 4 (7) When referring to this page, please quote Procedure 904-5.2 Edition 204
MAN B&W Diesel A/S
S46MC-C Connecting Rod 904-5.4
Mounting
Mounting
904-5.4

1. Equip the connecting rod with the same lift- 2.

ing attachments as mentioned under dis-
mantling.
A B E

Turn the crank to a position about 25° past

TDC on the camshaft side.

Apply clean lubricating oil to the crankpin

bearing shell and journal. C

2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine
room crane and the tackles attached to lift-

EN904-5.4 204 10
ing brackets A and B.

3. When the end of the connecting rod rests

on the crankpin journal, attach a tackle to
bracket C and the lower end of the connec-
ting rod. 3.

4. Turn the crankthrow towards BDC, past

A B E
TDC, while ‘following’ with the tackles and
the engine room crane.

Shift tackle B from the lower end to the up-

per end of the connecting rod.
C
Attach a tackle to bracket E and the upper
end of the connecting rod.

Haul tight and remove the strap around the

connecting rod.
EN904-5.4 204 03

4.

A B E

C
EN904-5.4 204 04

When referring to this page, please quote Procedure 904-5.4 Edition 204 Page 5 (7)
MAN B&W Diesel A/S
904-5.4 Connecting Rod S46MC-C
Mounting

5. 5. Turn the crankthrow to 90° before BDC.

Shift tackle A from the lower end to the top

A B E
of the connecting rod.

Remove the tackle at E.

Shift tackle B from the lifting attachment on

C
one side to the other side of the connecting
rod.

Remove the tackle at C and the wire guide

on the door frame.
EN904-5.4 204 05

Remove the lifting attachment at the lower

end of the connecting rod.

6. Turn the crankthrow towards TDC while ‘fol-

6. lowing’ with the tackles.

Caution!

Take care that the studs do not damage

the crosshead bearing shell.

7. When the crank is in TDC, mount the crank-

pin bearing cap.
See Procedure 904-4.4.
EN904-5.4 204 06

7.
GN904-4.4 203 07

Page 6 (7) When referring to this page, please quote Procedure 904-5.4 Edition 204
MAN B&W Diesel A/S
S46MC-C Connecting Rod 904-5.4
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.

GN904-1.4 203 08
GN904-1.2 203 07 9.

When referring to this page, please quote Procedure 904-5.4 Edition 204 Page 7 (7)
MAN B&W Diesel A/S
 Connecting Rod and Crosshead Panel Plate 90451-123

S46MC-C
Plate 90451-123 Connecting Rod and Crosshead Panel

Item Item
Part Description Part Description
No. No.

011 *) Tool panel

023 Name plate
047 Wire guide
059 Bracket for support of crosshead
060 Bracket for support of crosshead
072 Chain for suspending of piston
084 Torque wrench offset tool
096 Retaining tool for telescope pipe
106 Rubber cover for crosshead
118 Rubber cover for crosshead
120 Lifting tool for crosshead
131 Alignment tool
143 Lifting attachment

011- *) Tool panel, complete

143 with tools

*) Optional extras
 Connecting Rod - Tools Plate 90461-46

S46MC-C
Plate 90461-46 Connecting Rod - Tools

Item Item
Part Description Part Description
No. No.

089 Hydraulic tools for crankpin bearings

and end chock bolt
090 Hydraulic jack
100 Spacer ring
112 O-ring with back-up ring, 105/115 mm
124 O-ring with back-up ring, 75/85 mm
148 Stud setter M 52 x 5
 Connecting Rod - Tools Plate 90462-21

S46MC-C
Plate 90462-21 Connecting Rod - Tools

Item Item
Part Description Part Description
No. No.

011 Guide shoe extractor, complete

MC-(C) Crankshaft Deflection 105-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
105-1
Special Data
MC-(C) Crankshaft Deflection

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 Sheet 105-1 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
105-1 Crankshaft Deflection MC-(C)
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 105-1 Edition 02
MAN B&W Diesel A/S
MC-(C) Crankshaft Deflection 905-1.1
Checking
Crankshaft Deflection
MC-(C)
205
Checking
905-1.1

1.
Crankshaft deflection readings should be taken
while the ship is afloat (i.e. not while in dry
dock).

As the alignment is influenced by the engine

temperature as well as the loading conditions,
the deflection measurements should, for com-
parison, always be made under nearly the
same temperature and load conditions.

1. Place a dial gauge axially in the crankthrow

opposite the crankpin, as illustrated on the
sketch. The correct mounting position is

HM905-2.0 46 01
marked with punch marks on the crank-
throw. See also Chapter 708 in Volume I.

2. “Closing” of the crankthrow (compression of

the gauge) is regarded as negative.
2.
3. Set the dial gauge to zero at the B1 side
near BDC. Whilst turning clockwise, take
the readings for instance when the throw
passes the positions:

B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
1/2 (B2+B1) = B
XZ905-1.1 204 02

3.
XZ905-1.1 204 03

When referring to this page, please quote Procedure 905-1.1 Edition 205 Page 1 (2)
MAN B&W Diesel A/S
905-1.1 Crankshaft Deflection MC-(C)
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. This pres-
sure may otherwise falsify the readings.

If the crankshaft deflection (alignment indi-

cator) is approaching the tolerance limits
(see Vol. I, OPERATION), the bearing
shells of the two adjacent main bearings
must be dismantled and inspected.
See Procedure 905-2.3 for overhaul of
main bearing.

If the bearing shells are found to be in good

order, please contact MAN B&W Diesel or
the engine manufacturer for checking of the
bedplate alignment.

If the excessive crankshaft deflection is

found at the aftmost cylinder of the engine,
HM905-2.0 46 01

also the alignment of the propeller shaft/

drive shaft must be checked by a jack-up
test.

Page 2 (2) When referring to this page, please quote Procedure 905-1.1 Edition 205
MAN B&W Diesel A/S
 Main Bearing 105-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

22
105-2
Special Data
S46MC-C 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. ............................................... 0.58 mm
Min. ................................................ 0.40 mm

D-1 Main bearing cap 235 kg

D-2 Main bearing shells

– upper 14 kg !"#"$%%"&'
– lower 16 kg

D-3 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar

When referring to this page, please quote Data Sheet 105-2 Edition 22 Page 1 (2)
MAN B&W Diesel A/S
105-2 Main Bearing
Data

Plate Plate
Plate Plate
90451
90551 90451
90551

1165515-2
1165515-2.1
1165498-3
1165498-3

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 105-2 Edition 22
MAN B&W Diesel A/S
 Main Bearing 905-2.1
Checking
225
Main Bearing
S46MC-C
905-2.1
Checking

1.
1. If there is too large a difference in the
crankshaft deflection readings (autolog),
check the individual bearings.
See Procedure 905-1.1.

2. Calibrate the main bearing measuring tool:

Insert the measuring tool in the calibration

block.

Set the dial-gauge to 0 (zero).

Remove the screws for the lub. oil pipe from

MB905-2.0 41 01
the main bearing cap.

3. Insert the measuring tool and check the

clearance between the upper shell and the
journal.
3.
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.

An appreciable increase in clearance may

be an indication of loose staybolts or wear
of the lower shell.

4. After measuring, dismount the bearing cap

and the upper shell. For further inspection
of the bearing, see Procedure 905-2.2.
GN905-2.1 204 03

Inspect the bearing and the journal (see

Volume I, OPERATION, Chapter 708,
‘Bearings’).
4.
EN905-2.1 225 04

When referring to this page, please quote Procedure 905-2.1 Edition 225 Page 1 (13)
!"#$%&'$()*+*,$"-.$
905-2.2 Main Bearing
Dismantling
Dismantling
905-2.2

In the following, the main bearings are divided

into three categories:

• The main bearings (marked A).

• The thrust shaft end journal bearing

(marked B).

• The axial vibration damper end bearing

EN905-2.2 206 00

(marked C).

Check and write down the top clearances be-

C A B fore carrying out any dismantling.

1. Dismantling of main bearings (A)

1. Disconnect the lubricating oil inlet pipe from

the main pipe.

2. Turn the crankthrow so that it points to-

wards the exhaust side of the engine.

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.
EN905-2.2 206 01

2.
GN905-2.2 204 02

Page 2 (13) When referring to this page, please quote Procedure 905-2.2 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.2
Dismantling

3. Remove the rectangular nut washers from 3.

the bearing cap.

Attach the lifting tool to the bearing cap.

Mount the pulley, drive the wire rope

through and secure it with the locking pins.

Rig up a tackle outside the engine, connect

it to the wire rope on the lifting tool and haul
tight.

Note!

EN905-2.2 225 03
Before lifting the cap, make sure that
there are marking scratches on the cap
to indicate its correct position.
4.
4. Lift the cap free of the studs and the crank
web.
D-1
5. Move the bearing cap to the middle of the
crank section.
EN905-2.2 225 04

5.
EN905-2.2 225 05

When referring to this page, please quote Procedure 905-2.2 Edition 225 Page 3 (13)
!"#$%&'$()*+*,$"-.$
905-2.2 Main Bearing
Dismantling

6. 6. Rig up a tackle outside the engine and con-

nect it to the lifting tool on the bearing cap.

By slackening off the wire rope, and tight-

ening the second tackle, pull the bearing
cap towards the crankcase door.

7. Hook on an additional tackle above the

crankcase door, and support the weight of
the cap, using the other tackles.

Mount the chain guide in the crankcase

doorway.
EN905-2.2 225 06

Disconnect the wire rope from the pulley,

and lift the bearing cap out of the engine.

8. Mount the lifting attachment on the upper

7. shell, and lift the shell out of the engine.

9. If the crankshaft is to be turned while the

bearing cap is not in place, use the two
stops to prevent the lower shell from being
rolled out.
EN905-2.2 225 07

8.

D-2
EN905-2.2 225 08

Page 4 (13) When referring to this page, please quote Procedure 905-2.2 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.2
Dismantling

10. Remove the screws from the crosspiece 10.

(only screwed in for safe keeping) and
screw them into the threaded holes of the
hydraulic jacks (for tightening the cylinder
cover).

Replace the snap-on connectors of the hy-

draulic jacks with angular snap-on connec-
tors.

11. Place the crosspiece in the bedplate with

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

Tighten the screws against the crank webs.

12. Connect the hydraulic jacks to the high-

pressure pump and raise the pressure until
the crankshaft has been lifted to a height
corresponding to the clearance in the adja-
cent bearing.
EN905-2.2 206 10

Note down the pressure for future refer-

ence.

If a higher lift is needed, loosen the adja-

cent main bearing caps. 11.
12.
EN905-2.2 206 11

When referring to this page, please quote Procedure 905-2.2 Edition 225 Page 5 (13)
!"#$%&'$()*+*,$"-.$
905-2.2 Main Bearing
Dismantling

13. 13. Dismount the lock screws from the lower

shell.

Place the dismantling tool on the top of the

lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
groove in the bearing shell.

Pull the lower bearing shell round and up

until it lies over the main bearing journal.

Take out the lower shell from the crankcase

in the same way as the upper shell.
GN905-2.2 204 12

Page 6 (13) When referring to this page, please quote Procedure 905-2.2 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.2
Dismantling

Dismantling of journal bearing in the thrust

shaft end (B).

14. Remove the end cover of the scraper ring

housing.

Disconnect the lubricating oil pipe from the

main pipe.

EN905-2.2 206 00
Remove the protective shield.

Turn the crankthrow so that it points to- B

C A
wards the exhaust side of the engine.

15. Mount the spacers and the hydraulic jacks 14.

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

Mount the crossbar and the lifting attach-

ment on the bearing cap.
EN905-2.2 206 14

15.
EN905-2.2 206 15

When referring to this page, please quote Procedure 905-2.2 Edition 225 Page 7 (13)
!"#$%&'$()*+*,$"-.$
905-2.2 Main Bearing
Dismantling

16. 16. Remove the rectangular nut washers from

the bearing cap.

Mount the lifting attachments with the two

wire ropes on the bearing cap and, by al-
ternate use of tackles, lift the cap out of the
engine.

17. Mount the lifting attachment on the upper

shell, and lift the shell out of the engine.

18. Dismount the other protective shield.

Disconnect the lubricating oil pipes above

EN905-2.2 206 16

the segment stops.

17.
EN905-2.2 206 17

18.
EN905-2.2 206 18

Page 8 (13) When referring to this page, please quote Procedure 905-2.2 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.2
Dismantling

19. Turn the engine until the threaded hole in 19.

the chain wheel is at TDC.

Position the two crosspieces so that they

rest on the segment stops on each side of
the chain wheel.

Position the crosspiece for lifting the thrust

shaft so that its legs rest on the two cross-
pieces.

Screw the draw stud into the chain wheel.

EN905-2.2 206 19
Set up a dial gauge so that the lift of the
thrust shaft can be measured.

Lift the thrust shaft to a height correspond-

ing to the clearance in the adjacent bearing.
20.
20. Screw the hydraulic jack (for camshaft
bearings) on to the draw stud, and check
that the hydraulic jack is in contact with the
crosspiece on the whole circumference,
otherwise the position of the crosspiece/
draw stud must be corrected.

21. Dismount the lock screws from the lower

shell.

Place the dismantling tool on the top of the

lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
GN905-2.2 204 19

groove in the bearing shell.

Pull the lower bearing shell round and up

until it lies over the main bearing journal.
21.
Take out the lower shell from the crankcase
in the same way as the upper shell.
EN905-2.2 206 21

When referring to this page, please quote Procedure 905-2.2 Edition 225 Page 9 (13)
!"#$%&'$()*+*,$"-.$
905-2.2 Main Bearing
Dismantling

Dismantling of main bearing in the axial vi-

bration damper end (C)

22. Disconnect the lubricating oil pipes on the

main bearing cap.

Follow the procedure for dismantling of

main bearings marked A.
EN905-2.2 206 00

The clearance between the axial vibration

damper and the journal can be the decisive
factor in judging how much the crankshaft
C A B
can be lifted.

22.

Note!

Never remove the tools for lifting the

crankshaft before remounting the lower
main bearing shell (only bearing C)
GN905-2.2 204 21

Page 10 (13) When referring to this page, please quote Procedure 905-2.2 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.3
Overhaul
905-2.3
Overhaul

1. Clean and inspect the bearing shells. For 1.

judging the condition of the bearing, see 2.
Volume I, Chapter 708, ‘Bearings’.

If the bearing shells are damaged, contact

MAN B&W Diesel for advice.

If replacement of a bearing shell is neces-

sary, both shells must be replaced, as the
guide pin holes of the two shells are
reamed together.

2. Before remounting:

GN905-2.3 204 01
• Check the bearing support for damage
and burrs. If damage is found, contact
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.

When referring to this page, please quote Procedure 905-2.3 Edition 225 Page 11 (13)
!"#$%&'$()*+*,$"-.$
905-2.4 Main Bearing
Mounting
Mounting
905-2.4

1. 1. Position the guide tool for the lower bearing

shell on the main bearing support.

Lubricate the journal with clean oil.

Then place the dismantling tool and the

lower bearing shell on the journal.

Push the lower bearing shell downwards

while holding the shell back with the dis-
mantling tool.

Check that the bearing shell is positioned

GN905-2.4 204 01

with the same distance on both sides.

2. When the lower bearing shell has been

mounted, remove the dismantling tool and
the guide tool.
4.
Mount the lock screws in the bearing sup-
port.

3. Lower the crankshaft.

4. When mounting the upper bearing shell,

make sure that its edge does not rest on the
tip of the bedplate or the lock screws. If so,
place the special tool between the studs
and press the shell into the correct position.

5. Mount the bearing cap, making sure that

the guide pin enters correctly in the bearing
GN905-2.4 204 04

cap and the support.

5.
GN905-2.4 204 05

Page 12 (13) When referring to this page, please quote Procedure 905-2.4 Edition 225
!"#$%&'$()*+*,$"-.
 Main Bearing 905-2.4
Mounting

6. Mount the rectangular nut washers, the 7.

nuts, the spacers, the hydraulic jacks, and
tighten the nuts. See Data.

After tightening the bearing cap, check the

clearance once more.

If a new bearing shell has been mounted,

remember to note down the new top clear-
ance in the Adjustment Sheet. See Volume
I, OPERATION, Chapter 701.

Mounting of end cover in thrust shaft end

7. Tighten all screws marked A before mount-

ing the screws marked B.

GN905-2.4 204 07

When referring to this page, please quote Procedure 905-2.4 Edition 225 Page 13 (13)
!"#$%&'$()*+*,$"-.$
 Thrust Bearing 105-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

19
105-3
Special Data
S46MC-C Thrust Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
2 x 1 m, 1 x 3 m
Shut off cooling water
Shut off fuel oil
M12
X Shut off lubricating oil
Lock turbocharger rotors
2 x 900 kg

Data
Ref. Description Value Unit
500 kg
D-1 Stopper 37 kg

D-2 Thrust bearing segment 23 kg

D-3 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar

When referring to this page, please quote Data Sheet 105-3 Edition 19 Page 1 (2)
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data

Plate
90551
1165498-3

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 105-3 Edition 19
MAN B&W Diesel A/S
S46MC-C Thrust Bearing 905-3.1
Checking
Thrust Bearing
S46MC-C
206
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.
For dismantling the segment stopper, see Pro-
cedure 905-3.2.

1. There is a wear groove of 1 mm in the up-

permost thrust segment. (The segment with
thermometers).

Insert the feeler gauge in this groove on the

foremost side of the thrust collar.

If a feeler gauge of 0.1 mm is not able to EN905-3.1 206 01

enter the wear groove, the thrust bearing

must be overhauled.

When referring to this page, please quote Procedure 905-3.1 Edition 206 Page 1 (5)
MAN B&W Diesel A/S
905-3.2 Thrust Bearing S46MC-C
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.

Mount the crossbar.

2. Remove the protective shields from the

thrust collar.

Loosen and remove the nuts from the seg-

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

Remove the stoppers from the chain drive

above the thrust segments ( AHEAD or
ASTERN) that are to be taken out.
EN905-3.2 206 01

2.
GN905-3.2 204 02

Page 2 (5) When referring to this page, please quote Procedure 905-3.2 Edition 206
MAN B&W Diesel A/S
S46MC-C Thrust Bearing 905-3.2
Dismantling

3. Suspend a tackle from the crossbar above 3.

the segments which are to be removed.

For turning-up the thrust segments, mount

the segment tool on the chainwheel.

4. Turn up the segments by turning the en-

gine, and remove them from the chain cas-
ing.

GN905-3.2 204 03

4.
GN905-3.2 204 04

When referring to this page, please quote Procedure 905-3.2 Edition 206 Page 3 (5)
MAN B&W Diesel A/S
905-3.4 Thrust Bearing S46MC-C
Mounting
Mounting
905-3.4

1. 1. Suspend a tackle from the crossbar above

the segments which are to be mounted.

Mount the segment tool on the chainwheel.

Land the segment on the journal and re-

move the eye bolt from the segment.

Turn the shaft a little. Land the next seg-

ment. Repeat this process until all seg-
ments have been mounted.

2. After the last segment has been mounted,

turn the segment tool up and dismount it.
GN905-3.4 204 01

2.
GN905-3.4 204 02

Page 4 (5) When referring to this page, please quote Procedure 905-3.4 Edition 206
MAN B&W Diesel A/S
S46MC-C Thrust Bearing 905-3.4
Mounting

3. Mount the protective shields for the thrust 5.

collar.

4. Mount the segment stopper.

Mount the hydraulic jacks and tighten the

nuts on the stopper. See data.

Mount the lub. oil pipes on the side plate of

the chain tightener and the lub. oil pipe for
the thrust segments.

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

ments, the protective shield and the lub. oil
pipe on the bearing.

6. When mounting the end cover, ensure that

all screws marked A are tightened before
tightening the screws marked B. EN905-3.2 206 05

6.
GN905-2.4 204 07

When referring to this page, please quote Procedure 905-3.4 Edition 206 Page 5 (5)
MAN B&W Diesel A/S
 Axial Vibration Damper 105-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

16
105-5
Special Data
S46MC-C Axial Vibration Damper

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
140 – 760 Nm
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors 2x1m
1x3m

Data
Ref. Description Value Unit M12
D-1 Damper housing, upper part 150 kg

D-2 Hydraulic pressure 1500 bar

– tightening

D-3 Hydraulic pressure

– dismantling 1500-1650 bar 1 x 1000 kg

D-4 Screwing-in torque

– outer studs 300 Nm

D-5 Tightening torque

– nuts on inner studs 250 Nm

D-6 Tightening torque

– horizontal screws 450 Nm
or tightening angle 25 °

D-7 Clearance at joints 5 mm

Calibration of springs:
Spring for the middle oil seal
L0 0 N – Check length 1938 mm
L1 55 +/– 7 N – Check length 2555 mm
L2 83 +/– 10N – Check length 2880 mm

Spring for the outer oil seal

L0 0 N – Check length 1509 mm
L1 39 +/– 5 N – Check length 1852 mm
L2 60 +/– 8 N – Check length 2037 mm

Limits for axial vibration – S46MC

Cyl. 4 5 6 7 8
S1 mm 1.2 1.5 1.8 2.1 2.5
S2 mm 6.3 7.7 9.2 10.7 12.7

When referring to this page, please quote Data Sheet 105-5 Edition 16 Page 1 (2)
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
Data

Spare Parts

Plate – Item No. Description Qty

91211-xxx 019 Spring – middle oil seal 1

91211-xxx 020 Spring – side oil seals 2
91211-xxx 127 Oil seal – side oil seals 2
91211-xxx 139 Oil seal – middle oil seal 1

Page 2 (2) When referring to this page, please quote Data Sheet 105-5 Edition 16
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.1
Checking
Axial Vibration Damper
S46MC-C
217
905-5.1
Checking

1.
Electronic

1. For checking the effectiveness of the axial

vibration damper in service, a proximeter
probe with bracket is built on the lower part
of the damper housing.

Note!

The proximeter probe is not standard for

all engines.
For engines without a proximeter probe,
see instead Mechanical checking on
page 2.

The cable from the probe is connected to a

monitoring box which is mounted on the ex-
haust side of the framebox and towards the
forward end of the engine.
KM905-7.1 35 01

2. The peak-to-peak value displayed in mm on

the monitoring box should be compared
with the original values obtained during the
sea trial, and with the limits given below.

If the peak-to-peak value does not exceed

the permissible values, S1, it is not neces-
sary to overhaul the damper.

For S1-Limits for permissible peak-to-peak

values, see Data.

When referring to this page, please quote Procedure 905-5.1 Edition 217 Page 1 (6)
!"#$%&'$()*+*,$"-.$
905-5.1 Axial Vibration Damper
Checking

4. Mechanical

3. When checking the effectiveness of the ax-

ial vibration damper in service (which is
recommended every 8000 hours), a special
measuring tool has to be mounted in the
shield on the forward end of the engine, in
order to measure the axial movement of the
crankshaft fore end.

The actual measurement obtained should

be compared with the original values ob-
tained during the sea trial, and with the lim-
its given on the next page.

4. The following procedure should be fol-

lowed:

Stop the engine.

Dismount the cover on top of the angle en-

coder housing at the front of the engine.
MN905-5.1 214 04

Apply Molykote TM on the side of the shaft

cam.

5. Mount the axial vibration measuring tool

with the screws from the cover.
5.
Attach a pencil to the arm.

Note!

To obtain the correct measurement, the

tip of the pencil should protrude 10 mm
from the end of the arm.
MN905-5.1 214 05

Page 2 (6) When referring to this page, please quote Procedure 905-5.1 Edition 217
!"#$%&'$()*+*,$"-.
 Axial Vibration Damper 905-5.1
Checking

6. The measurement should be taken at the 6.

same r/min as used during the sea trials
(preferably 90% and 100% of MCR).

Start the engine and pull the measuring

arm against the shaft cam with 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.

To ensure a certain inertia, the backing

plate should have a mass of approx. 1-2 kg.

The axial movement recorded on the paper

block must be measured with a calliper as
shown in the sketch.

If the peak-to-peak distance a in mm does

not exceed the values, S2, it is not neces-
sary to overhaul the damper.
MN905-5.1 214 06

For S-2-Limits, see Data.

7. Note that the S2-limits are only valid for a

standard measuring tool with
7.
L1 = 35 mm and L2 = 178 mm.

If a non-standard measuring tool is used,

the S2-limits must be adjusted as follows:
10 mm

/0
.0$2 3$.1
/1

For S1-limits, see Data.

MA905-5.1 212 07

When referring to this page, please quote Procedure 905-5.1 Edition 217 Page 3 (6)
!"#$%&'$()*+*,$"-.$
905-5.2 Axial Vibration Damper
Dismantling
Dismantling
905-5.2

1. 1. Dismantling of the axial vibration damper is

carried out from cyl. No. 1 or from the front
end of the engine.

Disconnect and remove the oil pipes from

D-3 the foremost bearing cap and the axial vi-
bration damper housing.

Loosen and remove the screws and nuts

from the damper housing upper part.

For use of hydraulic tools, see Procedure

913-1.
GN905-5.2 204 01

2. Only the upper part of the housing needs to

be removed, while the lower half remains
mounted on the bedplate.

2. Mount a lifting eye bolt on the upper part.

3. By means of tackle and wire rope, separate

and raise the upper part of the damper
housing to a position in which it is possible
to change the oil seals and springs.

Keep the upper part in position by inserting

two screws in the damper housing.

D-1
GN905-5.2 204 02

3.
D-1
GN905-5.2 204 03

Page 4 (6) When referring to this page, please quote Procedure 905-5.2 Edition 217
!"#$%&'$()*+*,$"-.
 Axial Vibration Damper 905-5.3
Overhaul
905-5.3
Overhaul

1. Dismantle and remove the springs from the 1.

teflon rings.

Remove and discard the teflon rings.

When mounting new teflon rings, first insert

the lower half of the rings in the lower hous-
ing.

Then press the tension springs into the

groove between the teflon ring half and the
housing.

HG905-5.2 201 01
Note!

The lower half of the teflon rings will

protrude above the centreline.
2.
2. Mount all the upper halves of the teflon
rings in such a way that there is a clearance D-7
at the joints of both the small and the large
rings. See Data.

Now hook the tension springs into place,

ensuring that they are centralised in the
grooves of the teflon rings.
HG905-5.2 201 02

When referring to this page, please quote Procedure 905-5.3 Edition 217 Page 5 (6)
!"#$%&'$()*+*,$"-.$
905-5.4 Axial Vibration Damper
Mounting
Mounting
905-5.4

1. 1. Remove the screws securing the upper part

of the damper housing.

If studs have been removed, re-mount them

at this stage.
For tightening pressure, see Data.

Lower the upper part of the damper housing

on to the lower part.

Use the guide pins in the upper part of the

damper housing to guide the upper part into
its correct position.

2. Mount the horizontal screws.

Mount the nuts on the vertical studs, and

tighten by using the hydraulic jacks for the
outer nuts. Tighten the inner nuts to the
specified torque. See Data.

Tighten the horizontal screws, see Data.

GN905-5.4 204 01

Note!

Use either the tightening torque or the

2. tightening angle.

Remove the lifting eye bolt.

Reconnect the oil pipes.

D-5

D-2

D-6
GN905-5.4 204 02

Page 6 (6) When referring to this page, please quote Procedure 905-5.4 Edition 217
!"#$%&'$()*+*,$"-.
 Angle Encoder 105-8
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
105-8
Special Data
S46MC-C Angle Encoder

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

D-1 Pin gauge for top dead centre

of crankthrow No. 1
Check measurement 682 mm

D-2 Screws for housing

– tightening torque 40 Nm

L1 Check distance 80+/–0.5 mm

When referring to this page, please quote Data Sheet 105-8 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
105-8 Angle Encoder
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 105-8 Edition 02
MAN B&W Diesel A/S
 Angle Encoder 905-8.1
Checking
Angle Encoder
S90MC-C
202
Checking
905-8.1

1.
1. Turn the crankthrow for cylinder 1 to TDC.

Check the TDC of cylinder 1 against the

mark on the turning wheel.

2. Check the TDC position with the pin gauge

HM906-7.0 56 01
on the crankthrow.

3. Check that power is supplied to the inter-

mediate box.

The green indicator should now light. 2.

D-1
For adjustment of the angle encoder, see
Procedure 905-8.3.

BG906-7.0 58 02

3.
MN905-8.1 202 03

When referring to this page, please quote Procedure 905-8.1 Edition 202 Page 1 (5)
MAN B&W Diesel A/S
905-8.2 Angle Encoder
Dismantling
Dismantling
905-8.2

1. 1. Remove the inspection cover and loosen

the screws on the flexible coupling.

2. Remove the encoder by loosening the three

adjusting screws on the front flange.

Remove the flexible coupling and the inter-

mediate shaft.

3. Screw out the flange screws and remove

the encoder housing. Take care not to dam-
age the guide pins.
MN905-8.2 202 01

2.
MN905-8.2 202 02

3.
MN905-8.2 202 03

Page 2 (5) When referring to this page, please quote Procedure 905-8.2 Edition 202
MAN B&W Diesel A/S
 Angle Encoder 905-8.3
Adjustment
Adjustment
905-8.3

1. Turn the crankthrow for cylinder 1 to TDC. 1.

Check the TDC of cylinder 1 against the

mark on the turning wheel.

Check the TDC position with the pin gauge

HM906-7.0 56 01
on the crankthrow.

2. Loosen the adjusting screws which fasten

the encoder to the housing. Slowly turn the
encoder until the green indicator lights on
the intermediate box. 2.

Tighten the screws to secure the encoder in

D-1
correct position.

BG906-7.0 58 02

2.
MN905-8.3 202 02

When referring to this page, please quote Procedure 905-8.3 Edition 202 Page 3 (5)
MAN B&W Diesel A/S
905-8.4 Angle Encoder
Mounting
Mounting
905-8.4

1. 1. Before the angle encoder housing is mount-

ed, it is necessary to check the encoder
shaft throw.

Mount a dial micrometer gauge and turn the

engine to check the shaft throw.

If the shaft throw is more than +/– 0.5 mm,

carefully bend the shaft to minimize the
throw and repeat the check.

2. Mount the encoder housing. The two guide

pins indicate the correct positioning of the
housing. Tighten the screws. See Data.

3. Mount the intermediate shaft and the en-

coder. Check the distance L 1. See Data.

For adjustment of the distance L 1, move the

intermediate shaft and tighten the locking
screw.
MN905-8.4 202 01

2. D-2
MN905-8.2 202 03

3.
MN905-8.4 202 03

Page 4 (5) When referring to this page, please quote Procedure 905-8.4 Edition 202
MAN B&W Diesel A/S
 Angle Encoder 905-8.4
Mounting

4. Remove the encoder and mount the flexible 4.

coupling.

Mount the encoder with the adjustment

screws.

5. Tighten the screws on the flexible coupling.

Mount the top cover on the angle encoder

housing.

Adjust the angle encoder.

See Procedure 905-8.3.

MN905-8.4 202 04
MN905-8.2 202 01
5.

When referring to this page, please quote Procedure 905-8.4 Edition 202 Page 5 (5)
MAN B&W Diesel A/S
 Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel Plate 90551-201

S46MC-C
Plate 90551-201 Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel

Item Item
Part Description Part Description
No. No.

015 *) Tool panel

027 Name plate
040 Retaining tool for bearing shells
064 Lifting tool
076 Mounting tool for thin bearing shell
090 Dismantling tool for main bearing shell
100 Tool for segments
111 Lifting tool for main bearing shell
123 Lifting tool for main bearing cap
135 Pulley for wire

015- *) Tool panel, complete

135 with tools

*) Optional extras
 Main Bearing - Tools Plate 90561-62

S46MC-C
Plate 90561-62 Main Bearing - Tools

Item Item
Part Description Part Description
No. No.

021 O-ring with back-up ring, 70/80 mm

033 O-ring with back-up ring, 60/70 mm
045 Lifting tool
057 Nut
069 Hydraulic jack
070 Extension stud
082 Supporting block
094 Hydraulic tool for main bearing,
complete
 Crankshaft Plate 90562-118

S46MC-C
Plate 90562-118 Crankshaft - Tools

Item Item
Part Description Part Description
No. No.

015 Crossbar
039 Measuring tool for main bearing
040 Lifting tool for thrust shaft
052 Lifting tool for crankshaft
 Crankshaft - Hydraulic Tools Plate 90563-13

S46MC-C
Plate 90563-13 Tuning Wheel - Tools

Item Item
Part Description Part Description
No. No.

010 Hydraulic jack

022 O-ring with back-up ring, 60/70 mm
034 O-ring with back-up ring, 50/60 mm
046 Spacer ring
058 Stud setter M30x3.5
071 Hydraulic tools for crankshaft, complete
 Crankshaft - Tools Plate 90564-18

Crankshaft - Tools
18
90564

When referring to this page, please quote Plate 90564 Edition 18

MAN B&W Diesel A/S
Plate 90564-18 Crankshaft - Tools

Item Item
Part Description Part Description
No. No.

016 Measuring tool for axial movement

 Chain 106-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

20
106-1
Special Data
S46MC-C Chain

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

D-1 Max. wear of teeth

on chain wheel 2.5 mm

D-2 Original length

(chain pitch x 10 links) 714 mm

D-3 10 links measurements

+ 1% of a tensioned chain
= scrapping of chain 721 mm

When referring to this page, please quote Data Sheet 106-1 Edition 20 Page 1 (2)
MAN B&W Diesel A/S
106-1 Chain
Data

Plate
90651
1165514-0

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 106-1 Edition 20
MAN B&W Diesel A/S
 Chains 906-1.1
Checking
Chains
S46MC-C
212
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 D-1.
KG906-1.0 33 04

5. If abnormal wear is observed at the bottom

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.

Measure the geometry of the bottom and 5.

note down all available measurements in-
cluding D-A and D-B on the drawing. D-B is
best found by placing a short straight-edge
between the tip of the two teeth.

For assessing the measurement results,

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.
KG906-1.0 37 05

When referring to this page, please quote Procedure 906-1.1 Edition 212 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
D-2 the assembled link have been marked with
year, month, day and chain number.

Example:
D-3
No. 1 order,
840520 1A
840520 1B
HM906-1.0 32 00

(840520 1C, possible 3rd chain)

No. 2 order,
840520 2A
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 and comparing the result
with the value 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 906-1.1 Edition 212
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.

EN906-1.2 212 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.

2. Mount a wire round the link rollers a short

distance from the disassembly point, and
tighten the wire lightly with a tackle.

Protect the link rollers over which the wire

GN906-1.2 203 02

is wrapped.

Note!

If the chain is to be completely removed, 3.

contact MAN B&W Diesel for further
information.

The riveting of the pins that are to be

pressed out is to be drilled or ground away.

3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter-
nately tightening the screws on the tool.
GN906-1.2 203 03

When referring to this page, please quote Procedure 906-1.2 Edition 212 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 906-1.4 Edition 212
MAN B&W Diesel A/S
S46MC-C Chain Tightener 106-2
Data (For 4-6 cyl. engines only)

SAFETY PRECAUTIONS Standard Tools: See Section 913

08
106-2
Special Data
S46MC-C Chain Tightener

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

D-1 Clearance 0.1 mm

D-2 Tightening angle 1020 °

(= 17 hexagons)

D-3 Reduced tightening angle 900 °

(= 15 hexagons)

D-4 Max. distance 300 mm

When referring to this page, please quote Data Sheet 106-2 Edition 08 Page 1 (2)
MAN B&W Diesel A/S
106-2 Chain Tightener S46MC-C
(For 4-6 cyl. engines only) Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 106-2 Edition 08
MAN B&W Diesel A/S
 Chain Tightener 906-2.3
Adjustment
217
Chain Tightener
S46MC-C
Adjustment
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.

3. Tighten nut B on the chain tightener bolt

until there is a clearance between the shaft
and the nut as stated in D-1.

Then tighten nut B as stated in D-2 (see

Data).

GN906-2.3 203 01
EN906-2.3 215 02 2.

3. (/0

(/1
GN906-2.3 203 03

When referring to this page, please quote Procedure 906-2.3 Edition 217 Page 1 (2)
!"#$%&'$()*+*,$"-.$
906-2.3 Chain Tightener
Adjustment

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.
GN906-2.3 203 04

7. If the chain is worn (X >220 mm), repeat the

procedure from step 1, but tighten nut B
only to the reduced tightening angle, see
Data.

5. If distance X exceeds the max. distance

(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.
GN906-2.3 203 05

6. 2
GN906-2.3 203 06

Page 2 (2) When referring to this page, please quote Procedure 906-2.3 Edition 217
!"#$%&'$()*+*,$"-.
 Camshaft 106-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

12
106-3
Special Data
S46MC-C 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

D-1 Pin gauge for top dead centre

of crankthrow No. 1
Check measurement 602 mm

D-2 Pin gauge for camshaft

Check measurement 340 mm

D-3 Max. permissible change in

lead angle 2°
corresponding to 3.5 mm

D-2

D-1

When referring to this page, please quote Data Sheet 106-3 Edition 12 Page 1 (2)
MAN B&W Diesel A/S
106-3 Camshaft
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 106-3 Edition 12
MAN B&W Diesel A/S
S46MC-C Camshaft 906-3.1
Checking
Camshaft
S46MC-C
204
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, D-1.

GN906-3.1 203 02

When referring to this page, please quote Procedure 906-3.1 Edition 204 Page 1 (3)
MAN B&W Diesel A/S
906-3.1 Camshaft S46MC-C
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 D-3.

4. Check and, if necessary adjust the cylinder

lubricator. See Procedure 903-2.1.

Check the setting of the starting air distrib-

D-2 utor. See Procedure 907-1.1.

5. When checking the camshaft position, also

check the running surface of the cams.

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.
D-3
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 906-3.1 Edition 204
MAN B&W Diesel A/S
S46MC-C 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.

GN906-3.3 203 01

When referring to this page, please quote Procedure 906-3.3 Edition 204 Page 3 (3)
MAN B&W Diesel A/S
 Camshaft Bearing 106-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

14
106-4
Special Data
S46MC-C Camshaft 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

D-1 Weight of bearing cap 12.8 kg

D-2 Tightening torque –

screws for bearing cap 125 Nm

D-3 Clearance between cap/

bearing housing 3+/–0.3 mm

D-4 Max. wear on bearing shell 0.10 mm

When referring to this page, please quote Data Sheet 106-4 Edition 14 Page 1 (2)
MAN B&W Diesel A/S
106-4 Camshaft Bearing
Data

Plate
90651
1165514-0

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 106-4 Edition 14
MAN B&W Diesel A/S
S46MC-C Camshaft Bearing 906-4.1
Checking
Camshaft Bearing
S46MC-C
204
Checking
906-4.1

1.
1. 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. In the event of any signs
of anomalies, the bearing shell must be dis-
mantled for closer investigation and, if nec-
essary, the bearing shell must be replaced.

If no anomalies are found during the visual

inspection, dismantling need only be car-
ried out in connection with Class surveys.

GN906-4.1 203 01

When referring to this page, please quote Procedure 906-4.1 Edition 204 Page 1 (6)
MAN B&W Diesel A/S
906-4.2 Camshaft Bearing S46MC-C
Dismantling
Dismantling
906-4.2

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 cover from the cam-

shaft housing.
GN906-4.2 203 01

Dismount the lubricating oil connecting pipe

and the plug screws from the baseplate
over the bearing in question.

Lift the roller guide of the exhaust valve hy-

2. draulic pump. See Procedure 908-7.

2. Loosen the bearing cap screws through the

holes in the baseplate.

Remove the screws from the bearing cap.

Mount two 10 mm eye bolts in the pertain-

ing threads on top of the bearing cap.

3. Slide the bearing cap carefully towards the

exhaust cam disc.

Turn the bearing cap and pull it out through

GN906-4.2 203 02

the inspection opening.

3.

D-1
GN906-4.2 203 03

Page 2 (6) When referring to this page, please quote Procedure 906-4.2 Edition 204
MAN B&W Diesel A/S
S46MC-C Camshaft Bearing 906-4.2
Dismantling

4. Place the hydraulic jack in the camshaft 4.

housing underneath the circular part of the
exhaust cam.

Place a dial gauge on the camshaft, and lift

the camshaft 0.30 mm.

5. 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.

GN906-4.2 203 04
GN906-4.2 203 05 5.

When referring to this page, please quote Procedure 906-4.2 Edition 204 Page 3 (6)
MAN B&W Diesel A/S
906-4.3 Camshaft Bearing S46MC-C
Overhaul
Overhaul
906-4.3

1. 1. For assessment of the bearing condition,

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
surface.

By closely examining the sliding surface of

the bearing shell visually, an impression
can be formed of whether the lubrication of
the bearing surface has been insufficient or
GN906-4.3 203 01

entirely missing. Normally, camshaft bear-

ing damage only occurs due to faulty lubri-
D-4 cation.

Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.

Page 4 (6) When referring to this page, please quote Procedure 906-4.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Camshaft Bearing 906-4.4
Mounting
Mounting
906-4.4

1. Clean the bearing journal, the bearing sup- 2.

port and the bearing shell.

2. Coat the bearing shell with oil, mount the

shell on the camshaft, and turn it into place.

3. Place the bearing cap on the camshaft next

to the exhaust cam.

Note!

Be careful not to scratch the exhaust cam

roller surface.

GN906-4.4 203 02
Turn the bearing cap to an upright position
and slide it carefully onto the bearing shell.

Remove the eye bolts and mount the outer- 3.

most bearing cap screw.

4. Tighten the outermost screw lightly until the

clearance given in D-3 is reached. Then
mount and tighten the innermost screw with
a torque spanner. See Data D-2. This pro-
cedure ensures that the outermost screw
will obtain the correct torque.

Check the torque on the outermost screw

with a torque spanner.
GN906-4.4 203 03

4.
GN906-4.4 203 04

When referring to this page, please quote Procedure 906-4.4 Edition 204 Page 5 (6)
MAN B&W Diesel A/S
906-4.4 Camshaft Bearing S46MC-C
Mounting

5. 5. Check the clearance D-3. Then mount the

lubricating oil pipe and the plug screw in the
baseplate.

6. Lower the camshaft into position. Remove

the hydraulic jack from the camshaft hous-
ing.

7. Clean the camshaft housing and mount the

inspection covers.
GN906-4.4 203 05

6.
GN906-4.4 203 06

7.
GN906-4.4 203 07

Page 6 (6) When referring to this page, please quote Procedure 906-4.4 Edition 204
MAN B&W Diesel A/S
 Chain Drive and Camshaft Panel Plate 90651-169

S46MC-C
Plate 90651-169 Chain Drive and Camshaft Panel

Item Item
Part Description Part Description
No. No.

019 *) Tool panel

020 Name plate
044 Pin spanner for fuel cams
056 Chain assembling tool
068 Chain opener
152 Hydraulic jack for lift of camshaft

019- *) Tool panel, complete

152 with tools

*) Optional extras
 Camshaft - Tools Plate 90661-56

S46MC-C
Plate 90661-56 Camshaft - Tools

Item Item
Part Description Part Description
No. No.

025 Pin gauge for camshaft

050 Pin gauge for crankshaft
 Starting Air Distributor 107-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

08
107-1
Special Data 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 50-300 Nm
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Clearance between gear

wheel and bushing:
Min. 0.9 mm
Max. 1.6 mm

When referring to this page, please quote Data Sheet 107-1 Edition 08 Page 1 (2)
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 107-1 Edition 08
MAN B&W Diesel A/S
 Starting Air Distributor 907-1.1
Checking
Starting Air D is tributor
209
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
3. If the check pin cannot enter the slot, i.e. if
the slot is not aligned with the hole in the
distributor housing, the air distributor must
be adjusted.
See Procedure 907-1.3.
2.

K S
GN907-1.1 207 02

When referring to this page, please quote Procedure 907-1.1 Edition 209 Page 1 (3)
MAN B&W Diesel A/S
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

D-1 between the gear wheel and the bush-
ing.

K S
GN907-1.1 207 02

3.

D-1
GN907-1.3 207 03

Page 2 (3) When referring to this page, please quote Procedure 907-1.3 Edition 209
MAN B&W Diesel A/S
 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, D-2.

Mount the lower half of the gearwheel drive

cover.

5. Remove check pin K from the distributor

D-2
housing and mount the gasket and plug
screw.

GN907-1.3 207 04

5.
K
S
GN907-1.3 203 02

When referring to this page, please quote Procedure 907-1.3 Edition 209 Page 3 (3)
MAN B&W Diesel A/S
 Starting Air Valve 107-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

15
107-2
Special Data
S46MC-C Starting Air Valve

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

D-1 Weight of starting air valve 20 kg

D-2 Tightening-up torque 180 Nm

D-3 Valve tightening 175 Nm

or 60 °

When referring to this page, please quote Data Sheet 107-2 Edition 15 Page 1 (2)
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data

Plate
90151

1165513-9

Spare Parts

Plate – Item No. Description Qty

90704-xxx 100 O-ring 1

90704-xxx 041 Packing 1

Page 2 (2) When referring to this page, please quote Data Sheet 107-2 Edition 15
MAN B&W Diesel A/S
S42-50MC-C Starting Air Valve 907-2.2
Dismantling
Starting Air Valve
S42-50MC-C
203
Dismantling
907-2.2

1.
1. Shut off the starting air and control air inlet.

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.

GN907-2.2 203 01 2.

D-1
GN907-2.2 203 02

When referring to this page, please quote Procedure 907-2.2 Edition 203 Page 1 (5)
MAN B&W Diesel A/S
907-2.3 Starting Air Valve S42-50MC-C
Overhaul
Overhaul
907-2.3

1. 1. Remove the top cover fixing screws and re-

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.

GN907-2.3 203 01

2.
GN907-2.3 203 02

Page 2 (5) When referring to this page, please quote Procedure 907-2.3 Edition 203
MAN B&W Diesel A/S
S42-50MC-C Starting Air Valve 907-2.3
Overhaul

3. Grind the valve housing seating with the 3.

grinding ring after applying grinding paste.
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.

Lubricate all internal parts (sliding surfac-

es) with, for instance, Molybdenum Disul-
phide, MoS 2 .

5. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring and the piston. GN907-2.3 203 03

5.
GN907-2.3 203 05

When referring to this page, please quote Procedure 907-2.3 Edition 203 Page 3 (5)
MAN B&W Diesel A/S
907-2.3 Starting Air Valve S42-50MC-C
Overhaul

6. 6. Mount the nut on the valve spindle and

D-2 tighten the nut, see D-2.

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 mounted

in the engine immediately after the over-
haul, all openings of the valve should be
covered with plastic to prevent dirt from en-
tering the valve during storage.
GN907-2.3 203 06

7.

D-1
GN907-2.3 203 07

Page 4 (5) When referring to this page, please quote Procedure 907-2.3 Edition 203
MAN B&W Diesel A/S
S42-50MC-C Starting Air Valve 907-2.4
Mounting
Mounting
907-2.4

1. Carefully clean the starting valve bore in 1.

the cylinder cover and, if necessary, recon-
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,
MoS 2 .
For overhaul, see Procedure 907-2.3.

2. Mount the valve in the cylinder cover.

GN907-2.4 203 01
3. Mount the nuts and tighten-up alternately,
in at least three steps, to an angle of 40°.

Loosen the nuts again and repeat the pro-

cedure to reach the full tightening angle or 2.
torque, D-3.

Mount the control air pipes and turn on

starting air and control air.

D-1
GN907-2.4 203 02

3.

D-3
GN907-2.4 203 03

When referring to this page, please quote Procedure 907-2.4 Edition 203 Page 5 (5)
MAN B&W Diesel A/S
S46MC-C High-Pressure Pipe 108-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

03
108-1
Special Data
S46MC-C 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 32 kg

D-2 Tightening torque –

High-pressure pipe 36 Nm

When referring to this page, please quote Data Sheet 108-1 Edition 03 Page 1 (2)
MAN B&W Diesel A/S
108-1 High-Pressure Pipe S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

90806-59 083 O-ring 2

90806-59 095 O-ring 2
90806-59 178 O-ring 2

Page 2 (2) When referring to this page, please quote Data Sheet 108-1 Edition 03
MAN B&W Diesel A/S
S42-46MC-C High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
S42-46MC-C
204
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 908-1.2 Edition 204 Page 1 (3)
MAN B&W Diesel A/S
908-1.3 High-Pressure Pipe S42-46MC-C
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 908-1.3 Edition 204
MAN B&W Diesel A/S
S42-46MC-C 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

See Procedure 908-3.1.

2.

D-2
GN908-1.4 203 02

When referring to this page, please quote Procedure 908-1.4 Edition 204 Page 3 (3)
MAN B&W Diesel A/S
 Exhaust Valve 108-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

18
108-2
Special Data
S46MC-C Exhaust Valve

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
10–120 Nm
X Shut off lubricating oil
X Lock turbocharger rotors
2 x M10, 2 x M12

Data

Ref. Description Value Unit

D-1 Exhaust valve, complete 400 kg
D-2 Exhaust valve housing 260 kg 4 x 1 m, 1 x 3 m
D-3 Oil cylinder 54 kg
D-4 Air cylinder 22 kg
D-5 Spindle 35 kg
D-6 Bottom piece 42 kg
D-7 Oil cylinder,
inside diameter max. 65.7 mm
D-8 Piston rings, min. thickness 2.6 mm
D-9 Min. distance to piston 47.0 mm
D-10 Max. distance to piston 51.2 mm
D-11 Min. diameter of spindle stem 54.8 mm
D-12 Tightening torque, oil cylinder 70 Nm
D-13 Tightening torque, 50 Nm
throttle valve
D-14 Tightening torque,
safety valve 50 Nm
D-15 Opening pressure,
safety valve 21 bar
D-16 Grinding angle –
valve spindle 30.4 °
D-17 Grinding angle –
bottom piece 30.0 °
D-18 Max. grinding of seat 2.3 mm
D-19 Gap of bottom piece 1.0 mm
D-20 Max. burn-off of spindle 8.0 mm
D-21 Max. grinding of spindle 2.0 mm
D-22 Hydraulic pressure
– dismantling 1500-1650 bar
D-23 Hydraulic pressure
– mounting 1500 bar
D-24 Max. diameter, top 55.5 mm
D-25 Max. diameter, bottom 57.0 mm

When referring to this page, please quote Data Sheet 108-2 Edition 18 Page 1 (2)
MAN B&W Diesel A/S
108-2 Exhaust Valve
Data

Plate
90851
1165495-8

Spare Parts

Plate – Item No. Description Qty

90801-xxx 157 Lock washer 8
90801-xxx 169 Sealing ring 1
90801-xxx 170 Sealing ring 1
90801-xxx 204 Sealing ring 1
90801-xxx 265 Disc 1
90801-xxx 289 Gasket 1
90801-xxx 407 Packing 2
90801-xxx 419 Sealing ring 1
90801-xxx 468 O-ring 1
90801-xxx 481 Sealing ring 2
90801-xxx 527 Spring pin 1
90801-xxx 564 Sealing ring 1
90801-xxx 647 Piston ring 2
90801-xxx 779 Gasket 1
90801-xxx 838 O-ring 2

Page 2 (2) When referring to this page, please quote Data Sheet 108-2 Edition 18
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.1
Checking
Exhaust Valv e
S46MC-C
13204
Checking
908-2.1

1.
1. Before mounting an overhauled exhaust
valve in the engine, it is recommended to
check the valve as follows:

• Lift up the valve with the engine room D-1

crane (which makes the valve open).

• Connect compressed air to the pneu-

matic piston. The valve should now
close.

• Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3 , to
ensure that there is a clearance between
the outer parts of the seating faces of
valve housing and the spindle.
See Procedure 908-2.3.

• After shutting-off the compressed air

supply and releasing the vent plug screw
located just above the ball cock on the air
cylinder, the exhaust valve should open.
EN908-2.1 204 01

• After doing this a couple of times, leave

the valve closed and shut-off the com-
pressed air. The valve should remain
closed for at least fifteen minutes.

When referring to this page, please quote Procedure 908-2.1 Edition 204 Page 1 (18)
MAN B&W Diesel A/S
908-2.2 Exhaust Valve S46MC-C
Dismantling
Dismantling
908-2.2

1. 1. Close the cooling water inlet and outlet, and

drain the exhaust valve.

Dismount the high-pressure pipe for the hy-

draulic valve actuation.
See Procedure 908-1.2.

Disconnect the cooling water outlet pipe

from the exhaust valve.

Dismount the return oil pipe from the ex-

haust valve.
GN908-2.2 203 01

2. Dismount the air pipes for the sealing air ar-

rangement and the pneumatic exhaust
valve.

Remove the screws of the cooling water in-

2. let flange at the side of the exhaust valve.

3. Remove the plate jacket with insulation

from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the inlet pipe of the exhaust receiver.

Note!

The four lowermost screws need only be

loosened, not removed.
EN908-2.2 204 02

3.
GN908-2.2 203 03

Page 2 (18) When referring to this page, please quote Procedure 908-2.2 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.2
Dismantling

4. Remove the protective caps from the ex- 4.

haust valve studs, and mount the four hy-
draulic jacks.
D-22
Connect the high-pressure pump to the
jacks by means of the distributor block and
four high-pressure hoses.

Bleed the hydraulic system and raise the

pressure as stated in Data. Then loosen
and remove the nuts.
See Procedure 913-1.

GN908-2.2 203 04
5. Attach the crane to the lifting tool fitted on
top of the valve and lift away the exhaust
valve.

Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat- 5.
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.
D-1
EN908-2.2 204 05

When referring to this page, please quote Procedure 908-2.2 Edition 204 Page 3 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul
Overhaul
908-2.3

1. 1. Place the exhaust valve on a wooden sup-

port on the platform.

D-3 Remove the eight nuts and the safety

strap from the oil cylinder.

2. Lift away and place the oil cylinder on a

wooden support.

Dismount and inspect the O-rings and the

thrust piece of the hydraulic high-pressure
pipe for marks.
EN908-2.3 204 01

Replace the O-rings and thrust piece, if

necessary.

Check that the exhaust valve rotation indi-

cator can slide freely in its tube.
2.
3. Loosen and remove the plug screw from the
oil cylinder to gain access to the orifice
plug.

Unscrew and clean the orifice plug.

Check and clean the bore for the orifice

plug in the oil cylinder.
EN908-2.3 204 02

3.
EN908-2.3 204 03

Page 4 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

4. Place the oil cylinder in a horizontal posi- 4.

tion.
D-7
Remove and discard the sealing ring.

Remove the flange and take out the piston.

Inspect the bore of the oil cylinder for scor-

EN908-2.3 204 04
ing and check its measurements.

If the diameter of the bore exceeds the val-

ue stated in Data, send the oil cylinder to
an MAN B&W authorized workshop for re-
pair. 5.

5. Release the vent plug screw located just

above the ball cock on the air cylinder to let
the air escape from below the piston.

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.

6. Pass lifting straps through the four bores of

DM908-2.0 109 05

the valve housing and 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 seal-
ing arrangement at the bottom of the air cyl- 6.
inder pass the groove for the conical ring at
the top of the spindle.

D-2
EN908-2.3 204 06

D-5

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 5 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

7. 7. Unscrew and remove the lock screws which

retain the bottom piece. Lift up the valve
housing a distance of approx. 10 mm. If the
bottom piece has become stuck, use a tin
hammer to release it. Lift away the valve
housing and land it on a couple of wooden
planks.

Remove the O-rings from the bottom piece

and clean all the cooling bores.

Bottom piece:

8. Inspect the seating of the bottom piece

carefully for damage and check with the
bottom piece template.

Note!

Before using the bottom piece template,

thoroughly clean the contact faces on the
valve housing seat with a steel brush.
D-6
EN908-2.3 204 07

All measurements should be taken at four

diametrically opposite points on the cir-
cumference of the bottom piece seating.
8.
Take measurements G 2 and G 3, using a
feeler gauge. Compare the results with the
figures stated in Data D-18 and D-19.

9. IF burn marks are visible on the bottom

piece seating OR G 3 does not equal D-19,
THEN the valve housing seat must be
ground.

IF the template rests on the lower surface

in the groove, i.e. G 2 = 0, THEN the bottom
piece seating must not be ground, regard-
less of burn marks or G 3. Instead the bot-
tom piece must be reconditioned.

Contact MAN B&W Diesel for advice on re-

conditioning.

D-17
HC908-2.0 117 08

Page 6 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

10. If it is necessary to grind the seating, pro- 10.

ceed as follows:

Mount the support grinder on the slide rest

of the lathe and attach a dial gauge to the
support grinder. Mount the grinding tem-
plate in the centre chuck as shown.

Adjust the angle of the slide rest as stated

in Data. Let the point of the dial gauge slide
across the surface of the grinding template
marked: Bottom Piece.

Fine-adjust the angle of the slide rest until

a deviation no larger than 0.03 mm is ob- D-17
served when sliding the dial gauge across
the surface of the grinding template.

Note!

As the grinding angle is very important to

the operation of the exhaust valve, make
absolutely sure to adjust the slide rest
correctly.
GM908-2.0 120 10

Remove the grinding template and the dial

gauge. Mount the bottom piece in the cen-
tre chuck as shown. Use a dial gauge to
check that the bottom piece is perfectly
centered.

Regarding the use of the support grinder,

see separate instructions from the support
grinder manufacturer.

During grinding, use the bottom piece tem-

plate frequently to ensure that maximum
grinding is not exceeded, see step 9.

After grinding, inspect the bottom piece

seating again, using a feeler gauge and the
bottom piece template, to measure how
much has been ground away. Grind the re-
cess so that gap G 3 equals D-19 as stated
on the Data sheet.

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 7 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

11. Valve spindle

11. Inspect the seating of the valve spindle for

burn marks.

Check the burn-off F1 of the valve spindle

by measuring at each of the points A, B, C,
D and E, indicated by means of notches in
the spindle template.

Note!

Before using the spindle template, clean

the contact faces on the valve spindle
thoroughly with a steel brush.
HC908-2.0 117 11

All measurements should be taken at four

diametrically opposite points on the cir-
cumference of the valve spindle.

12. 12. Measure gap G1 between the spindle tem-

plate and the seating of the spindle.

13. IF burn marks are visible on the seating of

the spindle, the valve must be ground.

IF gap G 1 exceeds the max. value D-21,

see Data, OR the burn-off F 1 exceeds the
max. burn-off D-20, the spindle must not be
ground. Instead the spindle must be recon-
ditioned.

Contact MAN B&W Diesel for advice on re-

D-16
KC908-2.0 107 08

conditioning.

Page 8 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

14. Mount the support grinder on the slide rest 14.

of the lathe and attach a dial gauge to the
support grinder. Mount the grinding tem-
plate in the centre chuck as shown.

Adjust the angle of the slide rest as stated D-16

in Data. Let the point of the dial gauge slide
across the surface of the grinding template
marked: Spindle.

Fine-adjust the angle of the slide rest until

a deviation no larger than 0.03 mm is ob-
served when sliding the dial gauge across
the surface of the grinding template.

GM908-2.0 120 14
Note!

As the grinding angle is very important to

15.
the operation of the exhaust valve, make
absolutely sure to adjust the slide rest
correctly.

Remove the grinding template and the dial

gauge. Mount the spindle in the centre
chuck as shown. Use a dial gauge to check
that the spindle is perfectly centered D-11
Regarding the use of the support grinder,
see separate instructions from the support
grinder manufacturer.

During grinding, measure gap G 1 frequent-

ly. The max. grinding of the spindle, see
Data, must not be exceeded.

If the max. grinding limit is reached, and

GM908-2.0 96 09

burn marks are still visible on the seating of

the spindle, contact MAN B&W Diesel for
advice on reconditioning.

15. Check the spindle stem for wear in the area

between 220 mm and 330 mm measured
from the top of the spindle.

If the stem diameter is less than stated in

Data, or the hard facing layer is worn away,
contact MAN B&W Diesel for advice.

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 9 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

16. 16. Dismount the air piston from the air cylin-
D-7 der, and check the teflon guide ring and te-
flon sealing ring for wear.

Mount two eye screws in the air cylinder

D-4 and dismount the air cylinder.

17. Clean the air cylinder and check the run-

ning surface for wear or possible scores.

Remove the four screws inside the air cyl-

inder.

Dismount and check the flanges and the

sealing rings of the sealing air arrange-
ment.

Fit new O-rings and sealing rings when

EN908-2.3 204 16

mounting the flanges in the bottom of the

air cylinder.

Make sure to mount the sealing rings cor-

17. rectly, see the sketch.
D-4 Tighten the four screws.

18. Remove the protective cap from the safety

valve, dismount the valve from the air cylin-
der, and replace the gasket and sealing
ring.
EN908-2.3 204 17

18.
GG908-2.0 104 14

D-14

Page 10 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

19. Place the valve in the pressure testing de- 19.

vice.

Connect the testing device with the high-

pressure pump by means of a hose.

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
D-15
pressure is indicated.

Tighten the lock nut and test the opening

MC908-2.0 94 17
pressure once more.

When mounting the safety valve in the air

cylinder, use only the machined faces on
the valve housing and tighten, see Data. 20.

Finally, mount the protective cap.

20. Inspect the bushing in the spindle guide for

wear. See Data.
D-24
If it proves necessary to replace the bush-
ing, pull it clear by means of four disman-
tling screws.

21. Mount the bottom piece (with new O-rings) D-25

on the valve housing and secure with the
screws.
BG908-2.0 99 17

Mount the valve spindle in the valve hous-

ing.

21.
D-2
EN908-2.3 204 21

D-6

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 11 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

22. 22. Remove the filter plug screw from the air
cylinder.

Clean and check the filter plug screw, and

replace the O-ring.

After checking, re-mount the filter plug

screw.
EN908-2.3 204 22

23. Remove the screws, cover, spring and seal-

ing air valve spindle from the air cylinder.

Clean the valve spindle and check the seal-

ing rings and the spring. If necessary, re-
23.
place them.

Blow through the sealing air bore in the air

cylinder with compressed air to remove any
obstructions.

After checking, mount the valve spindle and

spring, and tighten the cover.
EN908-2.3 204 23

24. After overhauling and remounting the valve

spindle and bottom piece in/on the valve
housing, mount a new O-ring in the groove
in the top of the exhaust valve housing,
24. guide the air cylinder with the sealing air ar-
rangement down over the valve spindle.

Caution!

To avoid damage, take great care when

the internal rings (well-coated with ordi-
nary lube oil) pass the groove for the con-
ical locking ring.
EN908-2.3 204 24

Page 12 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

25. Remove the sealing rings of the air piston 25.

(two outside rings and one inside ring).

Caution!

Be careful not to damage the edges of

the ring grooves in the piston.

Mount the new sealing rings in the grooves

of the air piston.

Caution!

MB908-2.0 90 15
Before mounting, heat the new teflon
rings in 100°C hot water for at least five
minutes.
26.
When mounting the teflon rings, be care-
ful not to damage the running surfaces.

After mounting, compress the teflon rings

by means of the conical ring. This is done
by pressing the air piston through the con-
EN908-2.3 204 26

ical ring.

26. Fill the sealing air chamber and the lower

part of the air cylinder with clean lubricating
oil.
27.
27. Fit the conical guide ring for the air piston
on the air cylinder.

Lower the air piston over the valve spindle

down into the air cylinder.

Caution!

To avoid damage, take great care when

the internal sealing ring in the air piston
passes the groove for the conical locking
ring.

Remove the conical guide ring from the air

cylinder.
EN908-2.3 204 27

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 13 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

28. 28. Mount the conical locking ring and lift the
air piston up around the locking ring.

Remove the eye screws.

Mount the flange on top of the air piston

and, by means of the four screws, tighten
the air piston and the flange together.

29. Remove the piston rings from the oil piston

and check them for wear.

If the thickness of the rings has worn down

to the minimum, see Data, discard the rings
EN908-2.3 204 28

and mount new ones.

Check that the TOP mark on the piston

rings faces upwards, when mounting.
29.
30. Mount the piston on top of the spindle and
check the functioning of the damper piston.

Connect compressed air supply to the

space below the air piston, so as to keep
the valve closed, and to keep the air cylin-
der in close contact with the valve housing.

Place the measuring tool on the air cylinder

across the piston.
KG908-2.0 102 22

D-8

30.
EN908-2.3 204 30

Page 14 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.3
Overhaul

31.
31. Check the mesh of the damper piston by D-9
checking the distance from the upper edge
of the crossbar to the top of the damper pis-
ton. See Data. D-10
If the measurement is outside the value
stated in Data, adjustment must take place
by changing the disc in the damper piston
as follows:

32. Place the piston in the special tool.

Press out the disc with the centre screw.

EN908-2.3 204 31
If necessary, change also the spring and
the piston.

33. Assemble the damper piston with the new

disc in the special tool. 32.

Place the piston upside down in the tool

and press the disc into place in the piston.

Check the mesh once more, repeating

points 30 and 31.
MA908-2.0 103 25

33.
S8211427.WPG

When referring to this page, please quote Procedure 908-2.3 Edition 204 Page 15 (18)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve S46MC-C
Overhaul

34. 34. After carefully cleaning and visually check-

ing all the parts, assemble all parts of the
oil cylinder. See Data.
D-13
Mount a new sealing ring in the inner
groove of the oil cylinder.

35. Mount the overhauled oil cylinder on top of

the air cylinder.

Mount the safety strap and tighten the nuts.

See Data.

Disconnect the compressed air.

EN908-2.3 204 34

36. Blow compressed air into the control air in-

let of the sealing air valve to check that the
sealing air valve operates correctly.
35.
D-3

D-12
EN908-2.3 204 35

36.
EN908-2.3 204 36

Page 16 (18) When referring to this page, please quote Procedure 908-2.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve 908-2.4
Mounting
Mounting
908-2.4

1. After fitting new O-rings on the seat and the 1.

water connection, lift the overhauled ex-
haust valve.

Lubricate the O-rings and the threads of the D-1

studs with molybdenum disulphide (MoS 2).

Position the valve in the cylinder cover

bore, guiding it in accordance with the ex-
haust flanges and the water connection.

Note!

Before mounting the valve on the engine,

connect compressed air to the air cylin-
der to keep the exhaust valve closed dur-
ing the mounting.

2. Mount the nuts and the hydraulic jacks.

Raise the pressure to the value indicated in
Data and tighten up the nuts.
EN908-2.4 204 01

Relieve the system of pressure, remove the

hydraulic jacks and the high-pressure hose,
and fit the protective caps.

2.

D-23
GN908-2.2 203 04

When referring to this page, please quote Procedure 908-2.4 Edition 204 Page 17 (18)
MAN B&W Diesel A/S
908-2.4 Exhaust Valve S46MC-C
Mounting

3. 3. Connect the intermediate pipe to the flange

at the exhaust receiver.

Attach the insulation jacket.

4. Mount the cooling water inlet and outlet

pipes on the exhaust valve.

Mount the high-pressure pipe, the return oil

pipe, the sealing air arrangement and the
air pipe for the pneumatic exhaust valve.

Open the lub. oil supply and the cooling wa-

ter supply to the exhaust valve.
GN908-2.4 203 03

Disconnect the compressed air and con-

nect the normal air supply.

4. Caution!

The air supply to the exhaust valve

must always be connected before
turning on the oil supply to the
exhaust valve actuator.

This is very important, because

otherwise the valve will open more
than normal.
EN908-2.4 204 04

Page 18 (18) When referring to this page, please quote Procedure 908-2.4 Edition 204
MAN B&W Diesel A/S
 Exhaust Valve Actuator 108-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

14
108-3
Special Data Exhaust Valve Actuator

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
10-120 Nm, 140-760 NM
X Shut off lubricating oil
Lock turbocharger rotors
2 x M12

Data
Ref. Description Value Unit

D-1 Weight of high-pressure pipe 24 kg

D-2 Weight of hydraulic actuator 59 kg

D-3 Oil cylinder,

inside diameter max. 71.2 mm

D-4 Piston rings, min. thickness 2.6 mm

D-5 Hydraulic actuator

– tightening torque or 300 Nm

D-7 Locking plate

– tightening torque 10 Nm

D-8 High-pressure pipe,

tightening torque 36 Nm

When referring to this page, please quote Data Sheet 108-3 Edition 14 Page 1 (2)
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data

Spare Parts

Plate – Item No. Description Qty

90805-xxx 410 Piston rings 2

90806-xxx 375 Non-return valve complete 1

Page 2 (2) When referring to this page, please quote Data Sheet 108-3 Edition 14
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.1
Checking
Exhaust Valv e Actuator
216
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.

2. Leakages in the exhaust valve can be

measured – during running of the engine –
by collecting the oil from the drain pipe C
leading from the exhaust valve to the hy-
draulic actuator.

For a normal system, the oil quantity will be

smaller than the number of litres per hour
stated in Data.

Leakages may also be caused by leaky

non-return valves and loose pressure pipe
connections.

If the pipe connections are tight and the

leak oil amount from the exhaust valve is
correct, any abnormally large leakages
must originate from the hydraulic actuator
from which leak oil quantities cannot be di-
rectly registered.

The hydraulic actuator is then to be disman-

tled for checking of the parts.
See Procedure 908-3.2
HM908-3.0 70 1/3

When referring to this page, please quote Procedure 908-3.1 Edition 216 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.
D-1
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 screws of the pressure flange

of the high-pressure pipe and lift away the
GM908-3.0 78 01

high-pressure pipe.

2. Release the mountings for the indicator

drive from the actuator housing.
2.
Fit eye bolts in the lifting holes of the actu-
D-2 ator housing and hook on a tackle.

Unscrew the nuts on the two short studs,

then loosen the nuts on the long studs suc-
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.

HG908-3.3 201 02

3. Remove the locking plate for the piston.

Turn the piston 90° to release it from the
bayonet joint.
3.
Remove the piston from the roller guide.

4. Overhaul the actuator housing and the pis-

ton as required.
See Procedure 908-3.3.
HM908-3.0 70 03

Page 2 (4) When referring to this page, please quote Procedure 908-3.2 Edition 216
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.3
Overhaul
Overhaul
908-3.3

1. Clean the piston in kerosene and blow dry 1.

with compressed air. D-4
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.

D-3
JM908-3.0 73 05

When referring to this page, please quote Procedure 908-3.3 Edition 216 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
D-7 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.
D-2
3. Mount the oil inlet pipe and the drain pipe
from the exhaust valve.

Mount the hydraulic high pressure pipe.

See Procedure 908-1.3.

D-5
HG908-3.4 201 02

3.

D-8
HG908-3.4 201 03

Page 4 (4) When referring to this page, please quote Procedure 908-3.4 Edition 216
MAN B&W Diesel A/S
 Exhaust Valve Roller Guide 108-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

16
108-4
Special Data
S46MC-C Exhaust Valve Roller Guide

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

D-1 Weight of roller guide,

complete 28 kg

D-2 Max. clearance

roller/bushing/shaft pin 0.5 mm

D-3 Weight of hydraulic actuator, 55 kg

complete

When referring to this page, please quote Data Sheet 108-4 Edition 16 Page 1 (2)
MAN B&W Diesel A/S
108-4 Exhaust Valve Roller Guide
Data

Plate
90851
1165495-8

Spare Parts

Plate – Item No. Description Qty

90301-xxx 326 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 108-4 Edition 16
MAN B&W Diesel A/S
S46MC-C Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valv e Roller Guide
S46MC-C
204
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 908-5.

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 D-2
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 908-4.1 Edition 204 Page 1 (4)
MAN B&W Diesel A/S
908-4.2 Exhaust Valve Roller Guide S46MC-C
Dismantling
Dismantling
908-4.2

1. 1. Dismantle the hydraulic actuator above the

exhaust valve roller guide.
See Procedure 908-3.2.

2. Mount the roller guide lifting tool as follows:

D-3 • 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.

D-1
GN908-4.2 203 02

Page 2 (4) When referring to this page, please quote Procedure 908-4.2 Edition 204
MAN B&W Diesel A/S
S46MC-C Exhaust Valve Roller Guide 908-4.3
Overhaul
Overhaul
908-4.3

1. Inspect and check the exhaust valve roller 1.

guide.
See Procedure 909-15.1.

2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if

• irregularities when turning the roller,

D-1
• 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,

EN908-4.3 204 01

contact an MAN B&W authorized repair

shop.

3. If no irregularities are found, just clean and

lubricate the roller guide before remounting 3.
it in the roller guide bushing.

D-1
EN908-4.3 204 02

When referring to this page, please quote Procedure 908-4.3 Edition 204 Page 3 (4)
MAN B&W Diesel A/S
908-4-4 Exhaust Valve Roller Guide S46MC-C
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

D-1 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.

2.

D-3
GN908-4.2 203 01

Page 4 (4) When referring to this page, please quote Procedure 908-4-4 Edition 204
MAN B&W Diesel A/S
S46-50MC/MC-C Exhaust Valve Cam 108-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

03
108-5
Special Data
S46-50MC/MC-C Exhaus t Valve Cam

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

When referring to this page, please quote Data Sheet 108-5 Edition 03 Page 1 (2)
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam S46-50MC/MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 108-5 Edition 03
MAN B&W Diesel A/S
S46-50MC/MC-C Exhaust Valve Cam 908-5.1
Checking
Exhaust Valv e Cam
S46-50MC/MC-C
204
Checking
908-5.1

For checking the position of the exhaust cam,

turn the engine in AHEAD direction until the roll-
er guide (measured on the activator plunger)
has been lifted 10 mm.

If the cam has been correctly adjusted, the

crankthrow for the cylinder concerned will then
be in a position of A° past its TDC.

To check the lead angle, continue turning in

AHEAD direction until the roller guide has been
lifted 10 mm, corresponding to a turn of B° of
the crankshaft.

The lead angle is then

180° - A° + B°
2

The correct position of the cam must be within

+/-0.5°.

The illustration shows the position of the ex-

haust cam for a 6-cyl. standard engine, when
the piston of the cylinder concerned is in TDC.
See the adjustment sheet in Volume I, OPER-
ATION, Chapter 701, for the “lead angle” of the
plant in question.

The cam lead can be checked visually by read-

ing directly the scale position of the exhaust
cam over the marking scratch 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.

When referring to this page, please quote Procedure 908-5.1 Edition 204 Page 1 (1)
MAN B&W Diesel A/S
 Exhaust Valve 108-7
Special Running - Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

16
108-7
Special Data
S46MC-C Exhaust 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
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of high-pressure pipe 32 kg

When referring to this page, please quote Data Sheet 108-7 Edition 16 Page 1 (2)
MAN B&W Diesel A/S
108-7 Exhaust Valve
Special Running - Data

Plate
90851
1165495-8

Spare Parts

Plate – Item No. Description Qty

90301-xxx 326 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 108-7 Edition 16
MAN B&W Diesel A/S
 Exhaust Valve 908-7
Special Running
214
Exhaust Valve
S46MC-C
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.

2. Dismantle the hydraulic high-pressure

GN908-7 203 03
pipe.See Procedure 908-1.3.

3. Dismantle the connecting sleeve and the oil

inlet pipe. Discard the sealing rings. Blank
off the connection from the main oil pipe 4.
with a plug screw.

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

screw the spindle into the top of the actua-
tor piston.
GN908-4.1 203 01

Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible.

Tighten the upper nut of the tool against the 5.

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 908-7 Edition 214 Page 1 (3)
!"#$%&'$()*+*,$"-.$
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 908-7 Edition 214
!"#$%&'$()*+*,$"-.
 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. Mount the oil inlet pipe and the connecting
sleeve on the actuator housing, after fitting
new sealing rings on the connecting sleeve.

12. Mount the hydraulic high-pressure pipe.

See Procedure 908-1.2.

13. Engage the fuel pump roller guide.

See Procedure 909-16.
GN908-7 203 11

When referring to this page, please quote Procedure 908-7 Edition 214 Page 3 (3)
!"#$%&'$()*+*,$"-.$
 Exhaust Valve Panel Plate 90851-127

S46MC-C
Plate 90851-127 Exhaust Valve Panel

Item Item
Part Description Part Description
No. No.

016 Tool panel *)

028 Name plate
030 Gauge for valve seat
041 Tightening gauge
053 Lifting tool for roller guide
065 Lifting tool for spindle
077 Cone ring
089 Pressure testing device 0-50 bar
090 Lifting tool for exhaust valve
100 Tool for opening for exhaust valve
112 Measuring tool
124 Tool for hydraulic piston
136 Lifting tool for exhaust valve gear
148 Gauge for valve spindle

016- *) Tool panel, complete

148 with tools

*) Optional extras
Plate 90861-29 Exhaust Valve - Tools

Item Item
Part Description Part Description
No. No.

010 Support grinding machine, complete

When ordering spare parts, please refer

to the Chris Marine manual
 Exhaust Valve - Extra Tools Plate 90861-35

S46MC-C
Plate 90861-35 Exhaust Valve - Extra Tools

Item Item
Part Description Part Description
No. No.

046 Grinding machine, complete

When ordering spare parts, please refer

to the Chris Marine manual
 Exhaust Valve - Extra Tools Plate 90863-13

S46MC-C
Plate 90863-13 Exhaust Valve - Extra Tools

Item Item
Part Description Part Description
No. No.

011 Worktable
 Fuel Pump Lead 109-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

28
109-1
Special Data Fuel Pump Lead

X Stopped engine
10 – 120 Nm
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 0 – 200 mm
Lock turbocharger rotors

Data
Ref. Description Value Unit

1 mm change of the fuel

pump lead, caused by turning
the cam disc, alters pmax 5.0 bar

D-1 Measuring tool constant 79.7 mm

D-2 Max. number of shims 16

One shim alters pmax 2.5 bar

D-3 Tightening torque –

puncture valve 650 Nm

D-4 Tightening torque –

top cover nuts 210 Nm

D-5 Tightening torque –

top cover studs 100 Nm

When referring to this page, please quote Data Sheet 109-1 Edition 28 Page 1 (2)
MAN B&W Diesel A/S
109-1 Fuel Pump Lead
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90901-xxx 149 Shim 2

Page 2 (2) When referring to this page, please quote Data Sheet 109-1 Edition 28
MAN B&W Diesel A/S
 Fuel Pump Lead 909-1.1
Checking
228
Fuel Pump Lead
S70MC-C
909-1.1
Checking

The fuel pump lead a (= the effective lead) is

defined as the distance the top of the fuel pump
plunger is lifted above the upper edge of the up- X
per cut-off holes in the fuel pump barrel, when D-1
the piston of the cylinder concerned is in TDC.

Barrel + Top cover = s

Tool length = s + “D-1”

Fuel pump lead a = x – “D-1”. S

a
0

XZ S909-1.0 17 01

When referring to this page, please quote Procedure 909-1.1 Edition 228 Page 1 (5)
!"#$%&'$()*+*,$"-.$
909-1.1 Fuel Pump Lead
Checking

1. 1. To be able to measure the fuel pump lead,

it is necessary to dismantle one of the high-
pressure pipes and the combined puncture/
suction valve from the top cover.

Note!

Before dismantling any part of the fuel

pump, make sure the pump has been
relieved of pressure and that all oil has
been drained off.

Shut off the fuel oil inlet.

Open the fuel pump drain cock, and drain

off the oil.

Dismount one of the high-pressure pipes.

See Procedure 909-14.2.

Dismount the air pipe on the puncture

XZ S909-1.1 17 01

valve.

Dismount the combined puncture/suction

valve.

2.
2.

Note!

The correct distance x can only be meas-

ured when the fuel pump plunger is in its
HM906-7.0 56 01

delivery stroke.

Turn the engine in AHEAD direction until the

main piston of the cylinder concerned is ex-
actly at TDC.
See Procedure 906-7.

Page 2 (5) When referring to this page, please quote Procedure 909-1.1 Edition 228
!"#$%&'$()*+*,$"-.
 Fuel Pump Lead 909-1.1
Checking

3. Mount the measuring tool on top of the fuel 3.

pump plunger, through the hole in the fuel
pump top cover.

Measure the distance x from the top of the

measuring tool to the top of the fuel pump
top cover.

The fuel pump lead is then calculated as:

a = x – "D-1"

Note down the result for future reference.

For adjustment of fuel pump lead, see Pro-

cedure 909-1.2.

XZ S909-1.1 17 04

When referring to this page, please quote Procedure 909-1.1 Edition 228 Page 3 (5)
!"#$%&'$()*+*,$"-.$
909-1.3 Fuel Pump Lead
Adjustment
Adjustment
909-1.3

1. To insert or remove shims from the fuel pump,

use the following procedure:

Note!

If the required adjustment of the fuel

pump lead cannot be attained by insert-
ing or removing shims (see Data D-2),
the adjustment must be carried out on
the fuel cam disc.
See Procedure 909-3.3.

1. Dismount the high-pressure pipes.

XZ S909-1.2 17 01

Dismount the drain oil pipe on the top cov-

er.

Dismount the top cover fixing nuts. Remove

the two screws in the threaded holes of the
2. top cover.

2. Screw the two dismantling screws (from the

tool panel) into the threaded holes of the
top cover, thus lifting the top cover to pro-
vide space for inserting or removing shims.

The number of shims can now be adjusted.

See Data D-2.
GN909-1.3 205 02

Note down the new shim thickness.

3. Replace the dismantling screws with the

two original screws, and press down the top
cover.
3.
Mount the nuts for fastening the top cover,
and tighten them diagonally, see Data D-4.

If any of the top cover studs have come

loose, tighten them, see Data D-5.
GN909-1.3 205 03

Page 4 (5) When referring to this page, please quote Procedure 909-1.3 Edition 228
!"#$%&'$()*+*,$"-.
 Fuel Pump Lead 909-1.3
Adjustment

4. Measure the fuel pump lead again and note 5.

down the result for future reference.
See Procedure 909-1.1.

5. Close the drain cock in the pump housing.

Mount the combined puncture/suction valve

in the top cover, see Data D-3.

Connect the drain oil pipe to the top cover

and the pipe connection to the puncture
valve.

Mount the two high-pressure pipes on the

top cover/fuel valves. See Procedure 909-
14.4

6. Open the fuel oil inlet

GN909-1.3 205 05

When referring to this page, please quote Procedure 909-1.3 Edition 228 Page 5 (5)
!"#$%&'$()*+*,$"-.$
 Fuel Pump Cam 109-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

22
109-3
Special Data
S46MC-C Fuel Pump Cam

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

When referring to this page, please quote Data Sheet 109-3 Edition 22 Page 1 (2)
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
Data

Plate Plate
Plate
90951 90651
90651

1165514-0
1165517-6

Spare Parts

Plate – Item No. Description Qty

90301-118 326 O-ring 1

90901-155 627 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-3 Edition 22
MAN B&W Diesel A/S
 Fuel Pump Cam 909-3.3
Adjustment
Fuel Pump Cam
213
Adjustment
909-3.3

1.
1. Remove the inspection cover from the cam-
shaft 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.

GN909-3.3 203 01
2. Dismount the pipe connections and the
puncture valve from the fuel pump top cov-
er, and mount the measuring tool.
See Procedure 909-1.1. 2.

Turn the engine until the piston concerned

is in TDC.

Measure the fuel pump lead using the

measuring tool and compare the fuel pump
lead with the value in the adjustment sheet.
See Procedure 909-1.1.

3. Turn the camshaft until there is access to

the oil ducts in the fuel cam through the in-
spection hole.

Remove the plugs from the oil ducts (using,

for instance, a screw-driver).
BM909-1.1 217 03

Insert three copper gaskets in each oil duct.

Mount snap-on couplings in the oil ducts,

but do not tighten them.

Fit hoses between the snap-on couplings 3.

and the distributor block and between the
distributor block and the hydraulic high-
pressure pump.
GN909-3.3 204 04

When referring to this page, please quote Procedure 909-3.3 Edition 213 Page 1 (2)
MAN B&W Diesel A/S
909-3.3 Fuel Pump Cam
Adjustment

4. 4. Mount the special spanner on the fuel 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
up the snap-on couplings.

Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.

Turn the cam disc, using the fitted spanner,

until the desired change of the lead is read
GN909-3.3 204 05

directly on the measuring tool.(The neces-

sary turning of the cam disc is calculated as
described in Procedure 909-1).

To increase lead and p max:

– turn the cam disc AHEAD.

To reduce lead and p max :

– turn the cam disc ASTERN .

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 pump lead again.
See Procedure 909-1.1, and re-adjust the
cam if required.

Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.

6. Mount the inspection cover on the camshaft

housing.

7. Mount a new O-ring on the puncture valve.

Mount the puncture valve and the fuel oil
high pressure pipes.
See Procedure 909-8.4 and 909-14.4.

Page 2 (2) When referring to this page, please quote Procedure 909-3.3 Edition 213
MAN B&W Diesel A/S
 Fuel Pump 109-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

20
109-4
Special Data
S46MC-C Fuel Pump

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
140–760 Nm
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Tightening torque -

pump housing nuts 300 Nm

D-2 Tightening angle

pump housing nuts 60 °

D-3 Weight of pump housing 73 kg

When referring to this page, please quote Data Sheet 109-4 Edition 20 Page 1 (2)
MAN B&W Diesel A/S
109-4 Fuel Pump
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90901-xxx 054 Packing 2

90901-xxx 066 Plug screw 2
90901-xxx 294 Felt ring 1
90901-xxx 424 Restriction ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-4 Edition 20
MAN B&W Diesel A/S
S46MC-C Fuel Pump 909-4.2
Dismantling
Fuel Pump
S46MC-C
208
Dismantling
909-4.2

2.
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 fuel pump top cover/plunger

barrel assembly.
See Procedure 909-5.2.

2. Remove the fuel oil inlet pipe between the

fuel pump and the fuel oil inlet valve.

Discard the gaskets.

3. Remove the nuts at the base of the fuel

GN909-4.2 207 02
pump.

Mount the lifting tool and lift the fuel pump

housing away. See Data D-3.

3.
Note!

Take care not to damage the threads of

the studs.

Land the fuel pump on wooden planks.

GN909-4.2 207 03

When referring to this page, please quote Procedure 909-4.2 Edition 208 Page 1 (5)
MAN B&W Diesel A/S
909-4.3 Fuel Pump S46MC-C
Overhaul
Overhaul
909-4.3

1. 1. Tilt the fuel pump housing into a horizontal

position on the wooden planks.

2. Remove the bottom plate from the fuel

pump housing.

If the bottom plate sticks, loosen it by

screwing two M10x70 mm screws into the
threaded holes of the bottom plate.

3. Dismantle the:

• Fuel oil index arm.

GN909-4.3 207 01

• Regulating guide.

2.
GN909-4.3 207 02

3.
GN909-4.3 207 03

Page 2 (5) When referring to this page, please quote Procedure 909-4.3 Edition 208
MAN B&W Diesel A/S
S46MC-C Fuel Pump 909-4.3
Overhaul

4. Dismantle and inspect the erosion plugs on 4.

both sides of the fuel pump housing.

If heavily eroded, replace the erosion plugs.

5. Clean all the parts in diesel oil or kerosene.

Blow dry with compressed air.

Warning!

Always use eye protection when working

with compressed air.

GN909-4.3 204 04
6. Mount a new sealing ring in the pointer for
the fuel oil index arm.

Note! 6.

Soak the sealing ring in lubricating oil

before mounting.

7. Clean all inside surfaces of the fuel pump

housing.
HC909-3.4 121 11

When referring to this page, please quote Procedure 909-4.3 Edition 208 Page 3 (5)
MAN B&W Diesel A/S
909-4.3 Fuel Pump S46MC-C
Overhaul

9. 8. Lubricate the following with molybdenum di-

sulphide grease (MoS 2):

• All internal surfaces of the fuel pump

housing.

• The sliding surfaces of all the parts of the

regulating system.

• The teeth of the:

– Regulating guide.
– Fuel index arm.
GN909-4.3 207 09

9. Mount the fuel oil index arm.

Adjust the position of the fuel oil index arm

so that the scratch mark on the fuel oil in-
dex arm is aligned with the centre of the
10. fuel pump housing.

Mount the fuel oil index pointer.

10. Mount the regulating guide in the fuel pump

housing, ensuring that the scratch mark on
the regulating guide is aligned with the
scratch mark on the fuel oil index arm.

11. Mount the bottom plate on the fuel pump

housing.
GN909-4.3 207 10

11.
GN909-4.3 207 11

Page 4 (5) When referring to this page, please quote Procedure 909-4.3 Edition 208
MAN B&W Diesel A/S
S46MC-C Fuel Pump 909-4.4
Mounting
Mounting
909-4.4

1.
Note!

Before mounting the fuel pump housing,

make sure that all sliding faces and
threads are cleaned and lubricated with
molybdenum disulphide grease (MoS 2).

See Procedure 913-11. D-1

1. Lower the fuel pump housing on to the D-2
pump base, taking care not to damage the
threads of the studs.

Remove the lifting tool.

Mount and tighten the nuts at the base of

the fuel pump housing. See Data D-1, D-2.

2. Mount the fuel oil inlet pipe between the

fuel pump and the fuel inlet valve.
GN909-4.4 207 02

3. Mount the fuel pump top cover/plunger-bar-

rel assembly.
See Procedure 909-5.4.

2.
GN909-4.4 207 03

When referring to this page, please quote Procedure 909-4.4 Edition 208 Page 5 (5)
MAN B&W Diesel A/S
 Fuel Pump Top Cover 109-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

20
109-5
Special Data
S46MC-C Fuel Pump Top Cover

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water 10 - 120 Nm
X Shut off fuel oil 140 - 760 Nm
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of barrel/plunger+

top cover 51 kg

D-2 Tightening torque

top cover nuts 210 Nm

D-3 Screwing-in torque

top cover studs 100 Nm

D-4 Tightening torque

pump barrel/top cover 30 Nm

D-5 Tightening torque

puncture valve 650 Nm

D-6 Tightening torque

fuel oil high-pressure pipe 100 Nm

D-7 Max. milling/grinding

diameter of seat 18 mm

When referring to this page, please quote Data Sheet 109-5 Edition 20 Page 1 (2)
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90901-xxx 149 Shim 2

90901-xxx 341 Sealing ring 1
90901-xxx 353 Back-up ring 2
90901-xxx 365 Sealing ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-5 Edition 20
MAN B&W Diesel A/S
S46MC-C Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
S46MC-C
209
Dismantling
909-5.2

1.
1. Close the oil inlet valve to the fuel oil pump
and drain the pump.

Dismount the drain oil pipe from the top

cover and the air pipe connection to the
puncture valve.

Dismount the high pressure pipes.

Dismount the puncture valve from the top

cover.

Dismount the fuel index pointer.

GN909-5.2 208 01
2. Dismount the suction valve by means of the
extractor tool.

At this stage, it is practical to measure the

lead of the fuel pump. 2.
See Procedure 909-1.1.

3. Remove the top cover fixing nuts, as well as

the two screws in the top cover.

Loosen the top cover by means of the two

dismantling screws from the tool panel.

Release the link for the regulating drive and

pull out the toothed rack as far as possible.
GN909-5.2 205 02

3.
GN909-1.3 205 01

When referring to this page, please quote Procedure 909-5.2 Edition 209 Page 1 (7)
MAN B&W Diesel A/S
909-5.2 Fuel Pump Top Cover S46MC-C
Dismantling

4. 4. Mount the lifting tool (Pos. 021) on the fuel

pump top cover. Screw the centre screw of
the tool into the pump plunger. Ensure that
the stop ring on the centre screw is loose.

Pull the centre screw of the tool to lift the

plunger clear of the bayonet joint in the roll-
er guide and the milled recess of the regu-
lating guide.

To do this it may be necessary to move the

toothed rack and the centre screw of the
tool in relation to each other.

When the plunger has been lifted clear of

the roller guide and regulating guide, lock
GN909-5.2 208 04

the centre screw in this position with the

stop ring.

5. Lift the top cover and barrel with plunger

5. out of the fuel pump housing as an one unit,
D-1. Remove the shims if any.

6. Set up the pump unit in a bench vice pro-

D-1 vided with ´soft` jaws. Dismount the lifting
tool. Take care that the plunger does not
slide out of the barrel.

Press the plunger to the top of the barrel

and remove the barrel/plunger assembly
from the top cover.

Send the barrel/plunger assembly to an

MAN B&W authorised workshop for over-
haul, or overhaul it on board.
See Procedure 909-6.3.
GN909-5.2 205 05

6.
GN909-5.2 205 06

Page 2 (7) When referring to this page, please quote Procedure 909-5.2 Edition 209
MAN B&W Diesel A/S
S46MC-C Fuel Pump Top Cover 909-5.3
Overhaul
Overhaul
909-5.3

1. Remove and discard the sealing rings. 1.

D-7
Carefully clean and examine the top cover.

Reconditioning of the seatings for the high-

pressure pipes is carried out by milling ac-
cording to the following procedure:

Fill the oil ducts in the top cover with Vase-

line or heavy grease.

During the work the miller is guided by the

guide screwed into the thread for the high-
pressure pipe.

Turn the miller by means of, e.g. a tap

wrench, while tightening the guide screw
lightly to provide a suitable pressure be-
tween miller and seat.

During the milling, add drilling oil emulsion

liberally.
GN909-5.3 205 01

For the max. milling/grinding diameter of

the seat, see Data D-7.

2. After completing the milling, blow out the

Vaseline/grease from the oil ducts by 2.
means of compressed air.

Warning!

Always use eye protection when working

with compressed air.

Clean the top cover with diesel oil, and blow

dry with compressed air.
GN909-5.3 205 02

When referring to this page, please quote Procedure 909-5.3 Edition 209 Page 3 (7)
MAN B&W Diesel A/S
909-5.3 Fuel Pump Top Cover S46MC-C
Overhaul

3. 3. Mount the sealing rings in the ring grooves.

Sealing between the top cover and the fuel

pump housing is provided by an O-ring.

Sealing between the top cover and pump

barrel is provided by two back-up rings and
an O-ring in between.

Prepare the back-up rings by twisting the

rings in the hand, in such a way that the di-
ameter of the rings becomes smaller than
the diameter of the ring groove in which the
GN909-5.3 205 03

rings are to be mounted.

‘Screw’ the back-up rings onto the top cov-

er, into the groove.

4. Finally, insert the O-ring between the back-

D-4 up rings in the ring groove.

Mount the O-ring which seals between top

cover/fuel pump housing.

4. Mount the overhauled top cover on top of

the pump barrel, guided by the guide pin.
Tighten the screws, see Data D-4.
GN909-5.2 205 06

Page 4 (7) When referring to this page, please quote Procedure 909-5.3 Edition 209
MAN B&W Diesel A/S
S46MC-C Fuel Pump Top Cover 909-5.4
Mounting
Mounting
909-5.4

1. Mount the supplied measuring pin on the 1.

centre screw of the lifting tool (Pos. 021).
Loosen the stop ring on the centre screw.

Place the tool on the pump housing and

press down the centre screw until the
measuring pin reaches the thrust piece of
the roller guide. Lock the centre screw in
this position with the stop ring.

Keep the stop ring tightened in this position

until the plunger has been correctly mount-
ed.

Note!

GN909-5.4 208 01
The engine must not be turned until the
mounting of the barrel/plunger assembly
has been completed.

2.
2. Remove the tool from the pump housing
and remove the measuring pin from the
centre screw.

Mount the tool on the barrel/plunger and

top-cover assembly.

Tighten the tool to the top cover by means

of the two screws, and attach the plunger to
the centre screw.

The tool is now firmly attached to the as-

sembly, enabling the correct position to be
obtained during mounting.

Pull the regulating toothed rack out as far

as possible.

Pull the plunger as high up in the barrel as

possible.

Carefully lower the assembly into the pump

GN909-5.4 208 02

housing (taking special care not to damage

the O-ring and back-up rings on the barrel).

Adjust the top cover so that the guide pin

enters the hole in the pump housing. Lower
the top cover on to the pump housing.

When referring to this page, please quote Procedure 909-5.4 Edition 209 Page 5 (7)
MAN B&W Diesel A/S
909-5.4 Fuel Pump Top Cover S46MC-C
Mounting

3. 3. Press the plunger down into contact with

the thrust piece of the roller guide.

If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
and regulating block of the plunger fit prop-
erly in the cutout of the regulating guide.

Check that the stop ring of the centre screw

is in full contact with the flange of the tool,
as when measuring.

When the plunger is in place, press the reg-

GN909-5.4 208 03

ulating toothed bar in, causing the plunger

foot to interlock with the bayonet joint of the
roller guide.

Check through the inspection cover on the

4. fuel pump base and by pulling the centre
screw of the tool, that the plunger is cor-
rectly engaged.

When pulling on the centre screw it must

not be possible to lift the plunger more than
a few mm.

4. Unscrew the centre screw from the plunger

and remove the tool from the top cover.

5. Screw the two dismantling screws from the

tool panel into the threaded holes of the top
GN909-5.4 208 024

cover, thus lifting the top cover to provide

space for inserting shims.

6. Insert shims between the pump housing

and the top cover. (If the barrel assembly is
5. the same as that dismounted, insert the
same number of shims as were removed).
If a new barrel assembly is mounted, insert
the number of shims specified in the test
bed report.
GN909-1.3 205 02

Page 6 (7) When referring to this page, please quote Procedure 909-5.4 Edition 209
MAN B&W Diesel A/S
S46MC-C Fuel Pump Top Cover 909-5.4
Mounting

7. Replace the dismantling screws with the 7.

two screws for mounting the lifting tool, and
press down the top cover.

Mount the nuts for fastening the top cover,

tightening them diagonally, see Data D-2.

If any of the fuel pump top cover studs have

come loose, tighten them, see Data D-3.

8. Measure the fuel pump lead and adjust the

number of shims, if necessary.
See Procedure 909-1.1.

9. Mount the suction valve and the puncture

valve in the top cover, see Data D-5.

Connect the drain oil pipe to the top cover

and the pipe connection to the puncture
valve.

Mount the two high-pressure pipes on the

top cover/fuel valves, see Data D-6.
GN909-1.3 205 03

Mount the fuel index pointer

Mount the link for the regulating drive.

9.
Open the fuel oil inlet.
GN909-5.4 208 09

When referring to this page, please quote Procedure 909-5.4 Edition 209 Page 7 (7)
MAN B&W Diesel A/S
S46MC-C Fuel Pump Barrel Assembly 109-6
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

04
109-6
Special Data
S46MC-C Fuel Pump Barrel As sembly

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

D-1 Weight of barrel assembly 31 kg

D-2 Weight of plunger 6 kg

When referring to this page, please quote Data Sheet 109-6 Edition 04 Page 1 (2)
MAN B&W Diesel A/S
109-6 Fuel Pump Barrel Assembly S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

90901-155 233 Sealing ring 1

90901-155 245 Back-up ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-6 Edition 04
MAN B&W Diesel A/S
S46MC-C Fuel Pump Barrel Assembly 909-6.3
Overhaul
Fuel Pump Barrel Assembly
S46MC-C
206
Overhaul
909-6.3

2.
1. For dismantling the fuel pump barrel as-
sembly, see Procedure 909-5.2 (fuel pump
top cover).

2. Set up the pump unit in a bench vice pro-

D-1
vided with ´soft` jaws (see Data D-1).

Remove and discard the sealing ring on the

barrel.

3. Pull the plunger carefully out of the barrel

(see Data D-2).

GN909-6.3 205 01
Carefully clean the plunger (for example in
clean kerosene) and blow it dry with com-
pressed air.

Warning! 3.

Always use eye protection when working

with compressed air.

Check the plunger for wear or seizure

marks.
D-2
Clean the barrel and blow it dry with com-
pressed air.

Check the barrel for wear or seizure marks.

GN909-6.3 205 02

Note!

If either the plunger or the barrel shows

signs of wear or seizure marks, both
parts must be replaced, as they are
ground to match and cannot be replaced
individually.

When referring to this page, please quote Procedure 909-6.3 Edition 206 Page 1 (2)
MAN B&W Diesel A/S
909-6.3 Fuel Pump Barrel Assembly S46MC-C
Overhaul

4. 4. Mount a new sealing ring.

The sealing ring on the pump barrel con-

sists of an O-ring and a back-up ring.

Prepare the back-up ring by twisting the

ring in the hand, in such a way that the di-
ameter of the ring becomes smaller than
the diameter of the barrel.

‘Screw’ the back-up ring on to the barrel,

into the groove.
GN909-6.3 205 03

Finally, position the O-ring in the ring

groove.

The O-ring must be above the back-up ring.

4. 5. Lubricate the plunger with molybdenum di-

sulphide grease (MoS 2).

Carefully slide the plunger into the barrel

and press it to the bottom

Note!
GN909-6.3 205 04

Do not use force as this will damage the

sliding surface of the plunger or barrel.

If the barrel assembly is not to be mounted

immediately, cover all openings with plastic
to prevent dirt from entering the barrel as-
sembly during storage.

For mounting the fuel pump barrel assem-

bly, see Procedure 909-5.4 (fuel pump top
cover).

Page 2 (2) When referring to this page, please quote Procedure 909-6.3 Edition 206
MAN B&W Diesel A/S
S/L26-50MC/MC-C Fuel Pump Suction Valve 109-7
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

04
109-7
Special Data
S/L26-50MC/MC-C Fuel Pump Suc tion Valve

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

When referring to this page, please quote Data Sheet 109-7 Edition 04 Page 1 (2)
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve S/L26-50MC/MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 109-7 Edition 04
MAN B&W Diesel A/S
L/S26-50MC/MC-C Fuel Pump Suction Valve 909-7.3
Overhaul
Fuel Pump Suction Valve
L/S26-50MC/MC-C
206
Overhaul
909-7.3

1.
1. Set up the suction valve in a bench vice
with “soft” jaws and press down the spring
by means of the cone to release the valve
spindle from the two-part conical ring.

Clean the parts thoroughly in clean diesel

oil and blow dry with compressed air.

2. Inspect the seat on the valve spindle and

the seat on the valve housing for damage.

If the seats are damaged, a new or recon-

ditioned suction valve must be fitted. (Send

GN909-7.3 205 05
the damaged valve to an authorized MAN
B&W repair shop for reconditioning).

3. After cleaning and inspecting all the parts,

lubricate these with molybdenum disul-
phide (MoS 2) and assemble the suction 2.
valve.

Check the seats for tightness by filling the

inlet hole with diesel oil and waiting 5 min-
utes. No oil may pass through the seats.

4. If the suction valve is not to be mounted on

the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.
GN909-7.3 205 06

3.
GN909-7.3 205 07

When referring to this page, please quote Procedure 909-7.3 Edition 206 Page 1 (1)
MAN B&W Diesel A/S
S46MC-C Fuel Pump Puncture Valve 109-8
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

05
109-8
Special Data
S46MC-C Fuel Pump Puncture Valve

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

When referring to this page, please quote Data Sheet 109-8 Edition 05 Page 1 (2)
MAN B&W Diesel A/S
109-8 Fuel Pump Puncture Valve S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

90901-xxx 485 Sealing ring 1

90901-xxx 497 Sealing ring 1
90901-xxx 520 Sealing ring 1
90901-xxx 593 Sealing ring 1
90901-xxx 627 Sealing ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-8 Edition 05
MAN B&W Diesel A/S
S/L26-50MC/MC-C Fuel Pump Puncture Valve 909-8.3
Overhaul
Fuel Pump Punc ture Valve
S/L26-50MC/MC-C
206
Overhaul
909-8.3

1.
1. Remove and discard the O-ring from the
puncture valve housing.

Set up the puncture valve in a bench vice

with “soft” jaws.

Loosen and remove the two screws and dis-

mount the plug.

Insert an M6 screw in the air piston, and re-

move 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 and discard the O-rings from the
plug and the flexible connection. Clean all
the parts thoroughly in clean diesel oil.

Check all seats in the valve housing and on

the valve slide, and recondition, if neces-
sary.
BG909-3.3 80 07

2. Mount the two O-rings in the ring groove on

the rod of the air piston and position the
large cone on the rod. Place the sealing
ring on the cone and, by means of the 2.
pusher, push the sealing ring on to the O-
rings in the groove. Remove the pusher and
the large cone.

Finally, compress the sealing ring by means

of the ‘sizer’ tool.
BG909-3.3 80 08

When referring to this page, please quote Procedure 909-8.3 Edition 206 Page 1 (2)
MAN B&W Diesel A/S
909-8.3 Fuel Pump Puncture Valve S/L26-50MC/MC-C
Overhaul

3. 3. Mount the O-ring in the ring groove on top

of the piston. Position the cone on the pis-
ton head.

Place the sealing ring on the cone and, us-

ing the pusher, push the sealing ring onto
the O-ring in the groove.

Remove the pusher and the cone.

Finally, compress the sealing ring by means

of the ‘sizer’ tool.

4. Before assembling the puncture valve, lu-

bricate all parts with molybdenum disul-
phide, (MoS 2). Mount new O-rings on the
housing and the plug.

Mount a new O-ring on the flexible connec-

tion and place it in the lower housing.

Mount the spring and air piston in the upper

housing and assemble the two housings by
BG909-3.3 80 09

means of the plug and the two screws.

For mounting of valves on top cover, see

Procedure 909-5.4.
4.
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.
BG909-3.3 80 11

Page 2 (2) When referring to this page, please quote Procedure 909-8.3 Edition 206
MAN B&W Diesel A/S
S46-50MC-C Fuel System Shock Absorber 109-9
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

04
109-9
Special Data
S46-50MC-C Fuel Sy stem Shock Absorber

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

D-1 Shock absorber 20 kg

When referring to this page, please quote Data Sheet 109-9 Edition 04 Page 1 (2)
MAN B&W Diesel A/S
109-9 Fuel System Shock Absorber S46-50MC-C
Data

Spare Parts

Plate – Item No. Description Qty

90915-024 241 Packing 1

90915-024 265 Wear ring 1
90915-024 277 Sealing ring 1
90915-024 289 Packing 1
90915-024 290 Locking plate 4

Page 2 (2) When referring to this page, please quote Data Sheet 109-9 Edition 04
MAN B&W Diesel A/S
MC/MC-C Fuel System Shock Absorber 909-9.1
Checking
Fuel System Shoc k Absorber
MC/MC-C
204
Checking
909-9.1

To ensure satisfactory operation, the function-

ing of the fuel oil system shock absorber should
be checked at regular intervals. Normally, in-
spection is necessary only at the intervals stat-
ed 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 909-9.1 Edition 205 Page 1 (3)
MAN B&W Diesel A/S
909-9.3 Fuel System Shock Absorber MC/MC-C
Overhaul
Overhaul
909-9.3

1.

Note !

Before dismantling any part of the fuel oil

system, make sure that the system has
been relieved of pressure and that all oil
has been drained off.

1. Remove the shock absorber drain pipe.

Loosen the screws holding the shock ab-
sorber and remove it from the fuel oil sys-
tem.
GN909-9.3 205 01

2. Remove the plug from the end cover of the

shock absorber. Fit a threaded rod between
the piston and the end cover to counteract
the force of the springs. Loosen the screws
2. 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
shock absorber housing and a new wear
ring on the piston.
HG909-9.2 201 02

5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
the threaded rod.
4. 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. Remove the threaded

rod and insert the plug.
HG909-9.2 201 04

Page 2 (3) When referring to this page, please quote Procedure 909-9.3 Edition 205
MAN B&W Diesel A/S
MC/MC-C Fuel System Shock Absorber 909-9.3
Overhaul

7. Fit a new gasket and mount the shock ab-

sorber. 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 909-9.3 Edition 205 Page 3 (3)
MAN B&W Diesel A/S
 Fuel Valve 109-11
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

25
109-11
Special Data
S46MC-C 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 10-120 Nm
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Max. diameter 18 mm

D-2 Weight of fuel valve 7 kg

D-3 Opening pressure 350-380 bar

D-4 Tightening torque 25 Nm

When referring to this page, please quote Data Sheet 109-11 Edition 25 Page 1 (2)
MAN B&W Diesel A/S
109-11 Fuel Valve
Data

Plate Plate
90151 90951
1165513-9

1165517-6

Spare Parts

Plate – Item No. Description Qty

90910-xxx 089 O-ring 1

90910-xxx 124 O-ring 1
90910-xxx 148 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-11 Edition 25
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.1
Checking
Fuel Valve
S46MC-C
205
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 Programme.
See Chapter 900-1.

We recommend that fuel valves that are dis-

mantled from the engine should be disassem-
bled, cleaned, inspected and re-assembled
before testing.

GN909-11.1 204 01
See Procedure 909-11.3.

All fuel valves must be function-tested before

being mounted in the cylinder cover.

1. Pressure testing pump 2.

If an air supply of 10 bar is not available,

working air of seven bar can be used.
D-4
Regarding the operation of the pressure
testing pump, see the supplier’s instruc-
tions.

Note!

The high-pressure pump should be peri-

odically checked in accordance with the
supplier’s instructions.

Prescribed oil

Hydraulic oil (rust-preventing) with a viscos-

ity of between 7 and 10 cSt at 50°C.

Note: use clean oil only.

2. Setting-up the fuel valve

Place the fuel valve in the test rig and se-

cure it with the tubular spacers and nuts.
GN909-11.1 204 02

Tighten the nuts to the torque stated in Da-

ta. Mount the oil pipe between the pressure
testing pump and the fuel valve.

When referring to this page, please quote Procedure 909-11.1 Edition 205 Page 1 (12)
MAN B&W Diesel A/S
909-11.1 Fuel Valve S46MC-C
Checking

3. 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 pressure until
straight jets of oil are ejected from the noz-
zle holes (no atomization).

C. Acceptance criteria:
There is to be a continuous jet of oil through
all of the nozzle holes.

D. Cause of fault:
If the jets do not fulfil the above point C, the
cause may be:

• Dirt in the nozzle holes.

• The nozzle is not mounted correctly.

GN909-11.1 204 04

Page 2 (12) When referring to this page, please quote Procedure 909-11.1 Edition 205
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.1
Checking

5. Atomization test 6.

Testing of the atomization of the fuel valve

is not considered necessary, as the capac- D-3
ity of the fuel pump on the engine is sub-
stantially larger than the capacity of the
pressure testing pump.

This always ensures proper atomization of

the fuel during operation of the engine, pro-
vided that the results of tests 4, 6, 7 and 8
are satisfactory.

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 a continuous

oil flow can be observed through the nozzle
holes.

C. Acceptance criteria:
Check the opening pressure on the pres-
sure gauge.

D. Cause of fault:
If the opening pressure is higher than spec-
ified in D-3, 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 D-3, 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
GN909-11.1 204 06

must be repeated from step 4.

When referring to this page, please quote Procedure 909-11.1 Edition 205 Page 3 (12)
MAN B&W Diesel A/S
909-11.1 Fuel Valve S46MC-C
Checking

7. 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
position.

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.

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.
GN909-11.1 204 07

Page 4 (12) When referring to this page, please quote Procedure 909-11.1 Edition 205
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.1
Checking

D. Causes 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

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

GN909-11.1 204 07

guide, replace if necessary.

See Procedure 909-12.3.

When referring to this page, please quote Procedure 909-11.1 Edition 205 Page 5 (12)
MAN B&W Diesel A/S
909-11.1 Fuel Valve S46MC-C
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

position.

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
in the uppermost groove of the fuel valve
housing is defective, and must be replaced.
GN909-11.1 204 08

Page 6 (12) When referring to this page, please quote Procedure 909-11.1 Edition 205
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2

1. Close the fuel oil inlet and outlet valves, 1.

and drain the high-pressure pipe and the
fuel valve.

Unscrew the union nut by means of the

hook spanner and take the union nut with
protective hose up along the pipe. Unscrew
the union nipple at both ends of the pipe
(fuel valve and fuel pump).

Remove the high-pressure pipe.

Disconnect the return oil pipe from the fuel

GN909-11.2 204 01
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 2.
the valve clear of the top cover.

If the valve is not to be overhauled immedi-

ately, the valve should be placed immersed
in diesel oil until overhauling.
GN909-11.2 204 02

3.

D-2
EN909-11.2 205 03

When referring to this page, please quote Procedure 909-11.2 Edition 205 Page 7 (12)
MAN B&W Diesel A/S
909-11.3 Fuel Valve S46MC-C
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, and compressed air for further removal
of liquid or solid impurities. Whenever fuel
valves are overhauled, all sealing rings should
be discarded and replaced by new, faultless
sealing rings before reassembly.

1. Remove and discard the O-rings.

Disassemble the fuel valve by screwing off

the union nut with a hook spanner while re-
taining the valve in, for instance, a bench
vice provided with “soft” jaws.

Pull the valve head clear of the valve hous-

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.

GN909-11.3 204 01

Page 8 (12) When referring to this page, please quote Procedure 909-11.3 Edition 205
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.3
Overhaul

2. Carefully clean and examine all surfaces of 2.

the:

• Fuel valve housing

• Fuel valve head

• Thrust spindle
D-1
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

When referring to this page, please quote Procedure 909-11.3 Edition 205 Page 9 (12)
MAN B&W Diesel A/S
909-11.3 Fuel Valve S46MC-C
Overhaul

3. 3. The complete spindle guide, including the

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

from the spindle guide unless the spindle
guide has been dismantled. Otherwise
GN909-11.3 204 03

the cut-off slide screwed into the spindle

may be damaged.

4. The non-return valve should be sent to an

authorised MAN B&W repair shop for over-
4. haul. If this is not possible, the non-return
valve may be overhauled on board.
See Procedure 909-13.3.

5. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.

Note!

Make sure that the fuel nozzle engages

correctly with the guide pin in the fuel
valve housing. This can be ascertained
GN909-11.3 204 04

by attempting to turn the nozzle after

mounting. It must not be possible to turn
the nozzle.

5.
GN909-11.3 204 05

Page 10 (12) When referring to this page, please quote Procedure 909-11.3 Edition 205
MAN B&W Diesel A/S
S46MC-C Fuel Valve 909-11.3
Overhaul

6. Mount: 6.

• 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.

7. Place the union nut on the valve housing

and set up the housing in a bench vice.

Fit the valve head with new O-rings.

Make sure that the guide pin between valve

housing and valve head is intact, and press
the valve head down into the 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.

See that the guide pin between valve hous-

ing and valve head engages correctly so as
to prevent relative turning of the parts.
GN909-11.3 204 06

Assemble the valve by means of the union

nut. However, proper tightening together
will not be obtained until the valve is cor-
rectly mounted in the cylinder cover or
pressure testing rig.
7.
After overhaul, the fuel valve must be test-
ed in the test rig.
See Procedure 909-11.1.

8. 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.
GN909-11.3 204 07

When referring to this page, please quote Procedure 909-11.3 Edition 205 Page 11 (12)
MAN B&W Diesel A/S
909-11.4 Fuel Valve S46MC-C
Mounting
Mounting
909-11.4

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
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. Mount the valve in position in the cylinder

cover.
GN909-11.4 204 01

Mount the tubular spacers and nuts. Tight-

en the nuts as stated in Data.

3. Lubricate the thread on the union nipple of

2. the fuel oil pipe with a heat resistant anti
seize grease before mounting.
D-4
Note!

It is recommended to overhaul the fuel oil

pipe before mounting.
See Procedure 909-13.3.

As a minimum, the distance between the

fuel oil pipe ends and the thrust bushings
must be checked and, if necessary,
adjusted.
GN909-11.2 204 02

Mount the overhauled fuel oil pipe using a

crowfoot wrench head and a torque span-
ner. Tighten the union nipples at both ends
3. of the fuel oil pipe to the torque stated in
Data.

Mount and tighten the union nuts.

Reconnect the return oil pipe to the fuel

valve.

Turn on the fuel oil supply.

Note!

All fuel valves must be function-tested

GN909-11.4 204 02

before being mounted in the cylinder

cover, see Procedure 909-11.1.

Page 12 (12) When referring to this page, please quote Procedure 909-11.4 Edition 205
MAN B&W Diesel A/S
 Spindle Guide 109-12
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

23
109-12
Special Data
S46MC-C Spindle 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

D-1 Tightening angle 21 °

D-2 Max. deviation 0.01 mm

When referring to this page, please quote Data Sheet 109-12 Edition 23 Page 1 (2)
MAN B&W Diesel A/S
109-12 Spindle Guide
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90910-xxx 077 Spindle guide, complete 1

90910-xxx 065 Fuel nozzle 1
90910-xxx 041 Cut-off slide 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-12 Edition 23
MAN B&W Diesel A/S
MC-C Spindle Guide 909-12.3
Overhaul
Spindle Guide
MC-C
205
Overhaul
909-12.3

2.
Note!

This instruction is only valid for spindle

guides of the mini-sac/cut-off slide
design.

Extreme care and accuracy should be

exercised when carrying out this opera-
tion.

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!

The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually. Similarly the fuel noz-
zle and cut-off slide are matched parts
which may not be replaced individually.

2. Place the spindle guide in a bench vice pro-

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.

3. The cut-off slide is screwed into the spindle

and secured with Loctite. To release the
Loctite, place the spindle with the cut-off
slide in an oven preheated to approx.
GN909-12.3 204 02

250°C for a minimum period of 30 minutes.

Note!

Do not attempt to remove the cut-off 3.

slide from the spindle until the Loctite has
been released, as this would damage the
cut-off slide or the thread in the spindle. 250°C

When the Loctite has been released, mount

the spindle in a bench vice provided with
“soft” jaws and unscrew the cut-off slide
from the spindle.
GN909-12.3 204 03

Clean the threads of the spindle and cut-off

slide. The thread of the spindle should pref-
erably be cleaned with an M3 tap.

When referring to this page, please quote Procedure 909-12.3 Edition 205 Page 1 (6)
MAN B&W Diesel A/S
909-12.3 Spindle Guide MC-C
Overhaul

4. 4. 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.

5. Clean all the parts of the spindle guide in

gas oil and blow clean.

Clean all parts again in kerosene or ´Elec-

trocleaner´ and blow dry with compressed
air.

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.
GN909-12.3 204 04

5.
GN909-12.3 204 05

Page 2 (6) When referring to this page, please quote Procedure 909-12.3 Edition 205
MAN B&W Diesel A/S
MC-C Spindle Guide 909-12.3
Overhaul

6. Remove deposits or very fine scratches by 6.

placing the spindle, thrust piece or spindle
guide respectively in a lathe, as shown, and
polishing with a very fine conventional pol-
ishing linen ´grade 360´.

Use also a little oil for the polishing (a

coarser polishing linen must absolutely
not be used).

After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat

GN909-12.3 204 06
on spindle/guide. 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, 7.
the complete spindle guide must be dis-
carded.

7. Clean any carbon deposits from the central

bore of the fuel nozzle and the spray holes,
using gas oil and the special drills supplied.

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).
MC909-6.1 69 03

When referring to this page, please quote Procedure 909-12.3 Edition 205 Page 3 (6)
MAN B&W Diesel A/S
909-12.3 Spindle Guide MC-C
Overhaul

8. 8. Mount the spindle in a bench vice provided

with “soft” jaws. Apply a little Loctite type
620 to the thread of the cut-off slide.
175°C
Screw the cut-off slide into the spindle and
tighten as stated in Data.

Place the spindle with the cut-off slide in an

D-1 oven preheated to 175+/-5°C for a period of
GN909-12.3 204 08

30 minutes to harden the Loctite and en-

sure better heat-resistance.

Note!
9.
Do not exceed the hardening tempera-
ture of 175+/-5°C, as this will have an
adverse effect on the Loctite.

9. When the spindle with the cut-off slide has

cooled down, place it in the special tool as
shown. Screw out the adjustment screw un-
til it is no longer in contact with the cut-off
slide, and tighten the wing nut until it is only
just possible to turn the spindle. Set the
dial-gauge to zero.

10. Turn the spindle with the cut-off slide one

full revolution by hand. Note the deviation of
GN909-12.3 204 09

the cut-off slide on the dial-gauge. If the de-

viation exceeds the maximum value stated
in Data, the cut-off slide must be corrected.

To correct the cut-off slide, turn the spindle

10. with the cut-off slide until the largest devia-
tion is shown on the dial-gauge. Then turn
the spindle with the cut-off slide 180°.

Screw in the adjustment screw until the cut-

D-2 off slide has been given a lasting deforma-
tion to cancel out the original deviation.

Take care not to screw in the adjustment

screw too much, as this will merely result in
a deviation in the opposite direction of the
original deviation.

11. Screw out the adjustment screw and repeat

step 10 until the deviation of the cut-off
slide is within the specified limits.
GN909-12.3 204 10

Page 4 (6) When referring to this page, please quote Procedure 909-12.3 Edition 205
MAN B&W Diesel A/S
MC-C Spindle Guide 909-12.3
Overhaul

12. Place the fuel nozzle and the spindle guide 12.
on the plane of a drilling machine or hy-
draulic press and press the parts together
using the mounting tools.

13. Lubricate the spindle with the cut-off slide

with a little Molybdenum Disulphide (MoS 2),
See Procedure 913-11, and insert it in the
spindle guide and nozzle.

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.

14. If the spindle cannot slide freely, repeat

step 10.

If the spindle still cannot slide freely, mark

the sides of the fins of the cut-off slide with
a very thin layer of dark marking-colour.
GN909-12.3 204 12

Insert the spindle with the cut-off slide in

the spindle guide again and slide it back
and forth a couple of times. Then remove it
from the spindle guide and examine on
which of the fins the marking colour has
been worn off. 13.

Using fine emery cloth ‘grain size 80’, care-

fully grind a little material off the side of the
fin on which the marking colour has been
worn off.
GN909-12.3 204 13

14.
GN909-12.3 204 14

When referring to this page, please quote Procedure 909-12.3 Edition 205 Page 5 (6)
MAN B&W Diesel A/S
909-12.3 Spindle Guide MC-C
Overhaul

15. 15. Lubricate the sliding surfaces of the spin-

dle, spindle guide and thrust piece with Mo-
lybdenum Disulphide (MoS 2 ).
See Procedure 913-11.

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 spindle guide on to the thrust

piece.

16. 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
GN909-12.3 204 15

Page 6 (6) When referring to this page, please quote Procedure 909-12.3 Edition 205
MAN B&W Diesel A/S
 Non-return valve 109-13
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

16
109-13
Special Data
S46MC-C Non-return valve

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

When referring to this page, please quote Data Sheet 109-13 Edition 16 Page 1 (2)
MAN B&W Diesel A/S
109-13 Non-return valve
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90910-xxx 185 Spring 1

90910-xxx 197 Non-return valve, complete 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-13 Edition 16
MAN B&W Diesel A/S
MC/MC-C Non-return valve 909-13.3
Overhaul
Non-return valve
MC/MC-C
204
Overhaul
909-13.3

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.

Note!

MC909-6.3 69 01
Except for the slide valve spring, defec-
tive parts cannot be replaced individually
by new ones.
2. A
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. B C D

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 with
compressed air as shown in Fig. 2.
MC909-6.3 69 02

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 Fig.
3. 3.
MC909-6.3 69 03

When referring to this page, please quote Procedure 909-13.3 Edition 204 Page 1 (2)
MAN B&W Diesel A/S
909-13.3 Non-return valve MC/MC-C
Overhaul

4. 4. Examine the slide faces of movable parts

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).
MC909-6.2 69 04

5. Check spring C for the thrust piece for out-

side wear marks. If defective, it should be
exchanged.

5. Check the seat on thrust piece D/vent slide,

and the seat on vent slide/housing. Use an
inspection lamp and an 8-10 times enlarge-
ment 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.
MC909-6.3 69 05

6. Mount the non-return valve as follows:

• Lubricate all movable parts with molyb-

denum disulphide (MoS 2).
6.
• Place the loosely-assembled non-return
valve on the plane of a drilling machine,
with the tool positioned as shown in Fig.
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 over-
haul, cover all openings of the non-return
valve with plastic to prevent dirt from enter-
MC909-6.3 69 06

ing the valve during storage.

Page 2 (2) When referring to this page, please quote Procedure 909-13.3 Edition 204
MAN B&W Diesel A/S
 Fuel Oil High-Pressure Pipes 109-14
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

29
109-14
Special Data
S46MC-C Fuel Oil High-Pressure Pipes

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 10-120 Nm
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Distance from pipe end to 11 mm

thrust bushing lower edge
(fuel pump end and fuel valve
end)

D-2 Weight of fuel oil pipe 7 kg

D-3 Tightening torque – 100 Nm

fuel oil high pressure pipe

When referring to this page, please quote Data Sheet 109-14 Edition 29 Page 1 (2)
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipes
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90913-xxx 048 O-ring 2

90913-xxx 107 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-14 Edition 29
MAN B&W Diesel A/S
S46-50MC-C Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S46-50MC-C
210
Dismantling
909-14.2

2.
High-Pressure Pipe with Protective Hose

1. Close the fuel oil inlet and outlet valves.

2. Unscrew the union nipple from the fuel

valve.

3. 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.

GN909-14.2 210 02
Note!

It is recommended always to overhaul

the high-pressure pipe before remounting 3.
it on the engine.
See Procedure 909-14.3.

The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.
GN909-14.2 210 03

4.

D-1
GN909-14.2 210 04

When referring to this page, please quote Procedure 909-14.2 Edition 210 Page 1 (3)
MAN B&W Diesel A/S
909-14.3 Fuel Oil High-Pressure Pipe S46-50MC-C
Overhaul
Overhaul
909-14.3

1. Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before re-
mounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.

If the pipe ends require reconditioning, proceed

as follows:

1. Lift up the union nut.

Remove the spring ring from the two-part

sleeve. Remove the sleeve.
GQ909-7.1 87 01

2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.

2.
Note!

The two pipe ends are of different

designs – see sketch.

Turn the upper tightening ring (A) until the

miller presses against the pipe end.

Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
KB909-7.1 77 03

During the milling process, add drilling oil

emulsion liberally.

3. After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.

3. Remove and discard both the internal and

external O-rings. Mount new O-rings.

Mount the two-part sleeve and lock the

sleeve with the spring ring.

Ensure that all parts are completely clean

before mounting the high-pressure pipe.
GQ909-7.1 87 03

Page 2 (3) When referring to this page, please quote Procedure 909-14.3 Edition 210
MAN B&W Diesel A/S
S46-50MC-C Fuel Oil High-Pressure Pipe 909-14.4
Mounting
Mounting
909-14.4

1. Ensure that the fuel valve is fitted with a 3.

new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.

2. 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.

3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
D-1

GN909-14.4 210 03
Screw the union nipples onto the fuel valve
and into the fuel pump top cover, by hand.

Note!
4.
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.

4. Use a crowfoot wrench and a tightening

spanner to tighten the union nipple at the D-2
fuel valve to the torque stated in Data.
GN909-14.4 210 04

5. Use a crowfoot wrench and a tightening

spanner to tighten the union nipple at the
fuel pump to the torque stated in Data.

6. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and 5.
outlet valves.

D-2
GN909-14.4 210 05

When referring to this page, please quote Procedure 909-14.4 Edition 210 Page 3 (3)
MAN B&W Diesel A/S
 Fuel Pump Roller Guide 109-15
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

24
109-15
Special Data
S46MC-C Fuel Pump Roller Guide

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
2 x M10
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of pump base 31 kg

D-2 Weight of housing for the

sealing arrangement 63 kg

D-3 Weight of fuel pump roller

guide 42 kg

D-4 Max. clearance,

roller/bushing/shaft pin 0.5 mm

D-5 Max. clearance,

roller guide/guide plate > 0 mm

When referring to this page, please quote Data Sheet 109-15 Edition 24 Page 1 (2)
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
Data

Plate
90851
1165495-8

Spare Parts

Plate – Item No. Description Qty

90301-xxx 326 O-ring 1

90902-xxx 418 Axial scraper-ring 1
90902-xxx 431 Scraper-ring 1
90902-xxx 467 Locking wire 4
90902-xxx 526 Packing 1
90902-xxx 538 Packing 1
90902-xxx 671 Sealing ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-15 Edition 24
MAN B&W Diesel A/S
S50MC-C Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
S50MC-C
204
Checking
909-15.1

3.
Roller guide mounted in engine

1. The fuel pump roller guide can be partially

checked while mounted in the engine, using
the following procedure:

2. Lift the fuel pump roller guide.

See Procedure 909-16.

3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.

Turn the engine to provide the maximum

GN909-1.1 205 10
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.

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 909-16.

When referring to this page, please quote Procedure 909-15.1 Edition 204 Page 1 (8)
MAN B&W Diesel A/S
909-15.1 Fuel Pump Roller Guide S50MC-C
Checking

6. Roller guide removed from engine

D-3 A more suitable and reliable method is to check

the roller guide and the bearing clearance after
the roller guide has been dismounted:

5. Dismount the roller guide from the engine.

See Procedure 909-15.2.

6. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.

7. 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. See Data D-4.
GN909-15.1 204 06

7.
D-4
GN909-15.1 204 07

Page 2 (8) When referring to this page, please quote Procedure 909-15.1 Edition 204
MAN B&W Diesel A/S
S50MC-C Fuel Pump Roller Guide 909-15.2
Dismantling
Dismantling
909-15.2

3.
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/barrel assembly

from the fuel pump.
See Procedure 909-5.3.

2. Dismantle the fuel pump housing.

GN909-15.2 204 03
See Procedure 909-4.2.

Note!

When lifting the fuel pump housing, take

4.
care not to damage the threads on the
studs.

3. Loosen and remove the screws from the

sealing cap on top of the roller guide.

Remove the sealing cap from the roller

guide/sealing arrangement housing.

Remove and discard the O-ring from the

groove in the top of the roller guide.

4. Remove the cover on the camshaft housing

GN909-1.1 205 10

to inspect the position of the roller guide.

Turn the engine until the roller guide is at
BDC.

When referring to this page, please quote Procedure 909-15.2 Edition 204 Page 3 (8)
MAN B&W Diesel A/S
909-15.2 Fuel Pump Roller Guide S50MC-C
Dismantling

5. 5. Loosen the nuts on the two threaded studs

successively until the roller guide springs
D-1 are relieved.

Remove the nuts, mount two eye screws in

the pump base and lift it away.

Dismount the two eye screws from the

pump base and mount them in the housing
for the fuel oil sealing arrangement.

Note!
D-2
When lifting, take care that the bushing
of the sealing arrangement slides against
the neck of the roller guide without
scratching.

Remove the springs from the roller guide.

6. Mount the roller guide lifting tool as follows:

GN909-15.2 204 05

• Lift the lock plate of the tool up on the

shaft of the tool.

• Position the tool so that its foot rests on

6. the thrust piece in the bayonet joint of the
D-3 roller guide.

• 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.

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.

Land the roller guide on wooden planks.

7. Check the roller guide.

See Procedure 909-15.1.
GN909-15.2 204 06

Page 4 (8) When referring to this page, please quote Procedure 909-15.2 Edition 204
MAN B&W Diesel A/S
S50MC-C Fuel Pump Roller Guide 909-15.3
Overhaul
Overhaul
909-15.3

1. Inspect and check the fuel pump roller 1.

guide.
See Procedure 909-15.1.

2. It is recommended that the roller guide

should ONLY be disassembled if
D-4
• 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,

GN909-15.1 204 06

contact an MAN B&W authorized repair

shop.

3. If no irregularities are found, just clean and

lubricate the roller guide before mounting it 3.
in the roller guide bushing.

D-3
GN909-15.3 204 03

When referring to this page, please quote Procedure 909-15.3 Edition 204 Page 5 (8)
MAN B&W Diesel A/S
909-15.4 Fuel Pump Roller Guide S50MC-C
Mounting
Mounting
909-15.4

1. 1. Lubricate the roller guide with plenty of

D-3 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.

2. After mounting the roller guide, check the

clearance between the roller guide and the
guide plate mounted in the roller guide
bushing.

Turn the camshaft so that the roller guide is

lifted approx. 20 mm.

The clearance A between the roller guide

and the guide plate must be the same at
both ends, see Data D-5.
GN909-15.4 204 01

2.

D-5
GN909-15.4 204 02

Page 6 (8) When referring to this page, please quote Procedure 909-15.4 Edition 204
MAN B&W Diesel A/S
S50MC-C Fuel Pump Roller Guide 909-15.4
Mounting

3. Turn the engine until the roller guide is at 4.

BDC.

4. Mount the springs and the spring seat discs

D-3
over the roller guide.

Mount the housing for the fuel oil sealing ar-

rangement over the roller guide and the
springs.

Mount the pump base on the housing.

Mount two nuts on the threaded studs.

GN909-15.2 204 05
Tighten the nuts until the pump base and
the housing for the fuel oil sealing arrange-
ment are fastened tightly to the roller guide
bushing.
5.
5. Replace the scraper rings by loosening and
removing the screws and nuts from the bot-
tom of the cap. Remove the retaining flange
and ring holder with scraper ring.

6. Replace the axial scraper ring in the bottom

of the cap. Check that the O-ring and scrap-
er ring are mounted correctly. See the
sketch.
GN909-15.4 203 07

6.
GN909-15.4 203 08

When referring to this page, please quote Procedure 909-15.4 Edition 204 Page 7 (8)
MAN B&W Diesel A/S
909-15.4 Fuel Pump Roller Guide S50MC-C
Mounting

7. 7. 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.

8. 8. Check that the O-ring and scraper ring are

mounted correctly. See the sketch.

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.

9. Mount a new O-ring in the groove on top of

the roller guide.
GN909-15.4 203 10

Mount the sealing cap on top of the roller

guide, over the sealing bush inside the
pump base.

9. Tighten the screws and lock with locking

wire.

10. Mount the fuel pump housing.

See Procedure 909-4.4.

Mount the top cover/barrel assembly.

See Procedure 909-5.4.
GN909-15.4 204 09

Page 8 (8) When referring to this page, please quote Procedure 909-15.4 Edition 204
MAN B&W Diesel A/S
 Fuel Pump Special Running 109-16
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

10
109-16
Special Data
S46MC-C Fuel Pump Special Running

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
10-120 Nm
Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Tightening torque –

puncture valve 650 Nm

D-2 Tightening torque –

high pressure pipe 100 Nm

When referring to this page, please quote Data Sheet 109-16 Edition 10 Page 1 (2)
MAN B&W Diesel A/S
109-16 Fuel Pump Special Running
Data

Plate
90951

1165517-6

Spare Parts

Plate – Item No. Description Qty

90301-xxx 326 O-ring 1

Page 2 (2) When referring to this page, please quote Data Sheet 109-16 Edition 10
MAN B&W Diesel A/S
S42-50MC/MC-C Fuel Pump Emergency Running 909-16

Fuel Pump Emergenc y Running

S42-50MC/MC-C
203
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

GN909-16 202 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 fuel oil high pressure pipes
and the puncture valve from the fuel pump
top cover.

Screw a plug-screw into the control air pipe

of the puncture valve.

3. Dismount the suction valve by means of the

extractor tool.

Note!
GN909-1.1 205 03

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.
4.
4. Remove the inspection cover on the cam-
shaft housing. Turn the engine until the fuel
pump roller is at on the circular part of the
cam.
GN909-16 201 03

When referring to this page, please quote Procedure 909-16 Edition 203 Page 1 (3)
MAN B&W Diesel A/S
909-16 Fuel Pump Emergency Running S42-50MC/MC-C

5. 5. Mount the lifting tool on the fuel pump top

cover.

Turn the uppermost nut to screw the spindle

of the lifting tool into the fuel pump plunger.

6. Tighten the lowermost nut on the tool to pull

the roller guide upwards as far as possible.

Lock the tool in this position by means of

the lock nut.

7. Turn the engine one full revolution and in-

GN909-16 202 04

spect through the opening in the camshaft

housing to make sure that the roller guide
is clear of the fuel cam.

6. 8. The engine can now operate on the remain-

ing cylinders. See Volume I, Section 704.
GN909-16 202 05

7.
GN909-16 201 03

Page 2 (3) When referring to this page, please quote Procedure 909-16 Edition 203
MAN B&W Diesel A/S
S42-50MC/MC-C Fuel Pump Emergency Running 909-16

Re-engagement of fuel pump 9.

Warning!

Re-engagement of the fuel pump must

only take place at engine standstill.

9. Remove the cover on the camshaft hous-

ing. Turn the engine until the circular sec-
tion of the fuel cam is positioned upwards.

10. Lower the roller guide on to the fuel cam in

GN909-16 201 03
the reverse order to lifting.

11. Remove the lifting tool and re-mount the

suction valve and the puncture valve. (See
Data D-1).
11.
Remove the plug screw from the control air
pipe.
D-1
D-2
Note!

It is recommended always to mount new

or overhauled suction and puncture
valves.

Mount the fuel oil high pressure pipes. (See

Data D-2).
EN909-16 203 11

When referring to this page, please quote Procedure 909-16 Edition 203 Page 3 (3)
MAN B&W Diesel A/S
 Fuel Valve and Fuel Pump Panel Plate 90951-371

S46MC-C
Plate 90951-371 Fuel Valve and Fuel Pump Panel

Item Item
Part Description Part Description
No. No.

010 *) Tool panel

021 Name plate
045 Measuring tool for fuel pump lead
057 Lifting tool
069 Lifting tool
070 Lifting tool
082 Lifting tool for fuel pump roller guide
094 Milling tool for seats for fuel oil pipes
104 Milling tool for fuel oil pipes
116 Crowfoot spanner, 32 mm
128 Crowfoot spanner, 41 mm
153 Flange for dismantling of non-return
valve
165 Grinding mandrel for fuel valve lead
177 Grinding mandrel for holder outside
189 Grinding mandrel for holder inside
190 Grinding mandrel
200 Dismantling screw
212 Cleaning set
248 Hook spanner, 80/90 mm
250 Drift for spindle guide
285 Extractor for suction valve
297 Socket wrench
307 Assembly tool for spindle guide

010- *) Tool panel, complete

307 with tools

*) Optional extras
 Fuel Valve - Tools Plate 90961-57

S46MC-C
Plate 90961-57 Fuel Oil System - Tools

Item Item
Part Description Part Description
No. No.

014 Test rig, complete

038 High-pressure hose
051 Table
063 High-pressure pump
075 Probe light with magnifier, complete
087 Connection piece
099 Gasket
109 Plug screw
110 Angle union
122 Hose
134 Test rig
 Mounting Tools for Fuel Pump Seal Plate 90962-58

S46MC-C
Plate 90962-58 Mounting Tools for Fuel Pump Seals

Item Item
Part Description Part Description
No. No.

021 Sizer
033 Pusher
045 Cone/Sizer
057 Cone
069 Pusher
 Fuel Valve - Tools Plate 90963-07

S46-50MC-C
Plate 90963-07 Fuel Valve - Tools

Item Item
Part Description Part Description
No. No.

015 Pulling tool for nozzle

027 Measuring tool for cut-off slide
039 Mounting tool for nozzle and spindle
guide
040 Test tool for fuel valve
 Air Cooler Element 110-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

21
110-1
Special Data
S46MC-C 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 1200 kg

When referring to this page, please quote Data Sheet 110-1 Edition 21 Page 1 (2)
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data

Plate
91051
1165490-9

Spare Parts

Plate – Item No. Description Qty

See special instructions from air cooler element manufacturer.

Page 2 (2) When referring to this page, please quote Data Sheet 110-1 Edition 21
MAN B&W Diesel A/S
 Air Cooler Element 910-1.1
Checking
222
Air Cooler Element
S46MC-C
910-1.1
Checking

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

Compare these measurements with the

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

2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of

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

A decrease in the air temperature drop

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

If the measurements indicate fouling of the

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

4. Remove the inspection cover from the air

cooler.
GN910-1.1 207 04

5. Visually inspect the air cooler element

through the opening.

If the air side of the element is fouled, clean

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

When referring to this page, please quote Procedure 910-1.1 Edition 222 Page 1 (7)
!"#$%&'$()*+*,$"-.$
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2

2. 1. Close the cooling water inlet and outlet

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

2. Dismount the cooling water inlet and outlet

pipes from the end cover.

Remove and discard the gaskets.

3. Dismantle the screws and pull out the cool-

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

2.
GN910-1.2 207 02

3.
GN910-1.2 207 03

Page 2 (7) When referring to this page, please quote Procedure 910-1.2 Edition 222
!"#$%&'$()*+*,$"-.
 Air Cooler Element 910-1.2
Dismantling

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

cover.

Attach two tackles to the lifting bracket, one

horizontally and one vertically.

Using the vertical tackle, lift the air cooler

element approx. 2-3 mm.

Using the horizontal tackle, pull out the air

cooler element approx. half a metre.

5. Mount the two guide rails on the frame

EN910-1.2 222 04
around the air cooler element.

6. Using the horizontal tackle, pull out the air

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

Mount lifting wire ropes between the two

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

Remove the two tackles and lift the air cool-

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

Note!

During the lift, take care not to damage

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

When referring to this page, please quote Procedure 910-1.2 Edition 222 Page 3 (7)
!"#$%&'$()*+*,$"-.$
910-1.3 Air Cooler Element
Overhaul
910-1.3
Overhaul

1. Cleaning the air side:

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

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

It is recommended to use one of the follow-

ing cleaning fluids, or a similar product.

• Product: ACC 9, produced by

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

• Product: 80B, produced by

Vecom Int., Maassluis, Holland

2. Do not start cleaning until the engine has

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

Remove the covers on the scavenge air re-

ceiver to let vapours escape.

3. Follow the detailed cleaning instructions

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

4. Continue the cleaning process for at least

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

the frequency with which cleaning is carried

out and on the chemical product used.

5. After cleaning, flush the cooler with clean

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

6. Inspect the air cooler element by removing

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

Page 4 (7) When referring to this page, please quote Procedure 910-1.3 Edition 222
!"#$%&'$()*+*,$"-.
 Air Cooler Element 910-1.3
Overhaul

Cleaning the water side 2.

1. Dismantle the air cooler element and re-

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

2. Dismantle the front end cover of the air

cooler element. Remove and discard the
gasket.

3. Dismantle the aft end cover of the air cooler

element. Remove and discard the gasket.

4. Clean the water side of the cooler element

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

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

ends of the tube using a brass or copper
plug.

In the event of leakages between a tube

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

5. Clean and check the inside of the front end

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

Note!
GN910-1.3 207 03

If damaged, the coating inside the covers

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

7. Re-mount the air cooler element in the

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

When referring to this page, please quote Procedure 910-1.3 Edition 222 Page 5 (7)
!"#$%&'$()*+*,$"-.$
910-1.4 Air Cooler Element
Mounting
Mounting
910-1.4

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

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

Hook a tackle on to the bracket at the front

of the air cooler element.

Remove the lifting wire ropes and shackles.

2. Push the air cooler element inwards ap-

prox. one metre.

Remove the guide rails from the air cooler

housing.
EN910-1.2 222 06

3. Clean the frame around the air cooler ele-

ment and the contact surface of the front
end cover.
2.
Apply a thin layer of silicone paste to the
frame around the air cooler element and
the contact surface of the front end cover.

Push the air cooler element fully into the air

cooler housing.
EN910-1.4 222 02

3.
EN910-1.4 222 03

Silicone

Page 6 (7) When referring to this page, please quote Procedure 910-1.4 Edition 222
!"#$%&'$()*+*,$"-.
 Air Cooler Element 910-1.4
Mounting

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

end cover.

Remove the tackle and the lifting bracket

from the front end cover.

5. Mount the cooling water inlet and outlet

pipes on the front end cover.

6. Close the drain cocks and open the cooling

water inlet and outlet valves.

Note!

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

GN910-1.2 207 02 5.

6.
GN910-1.4 207 06

When referring to this page, please quote Procedure 910-1.4 Edition 222 Page 7 (7)
!"#$%&'$()*+*,$"-.$
 Non-Return Valve 110-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
110-2
Special Data
MC Non-Return Valve

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 Sheet 110-2 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
110-2 Non-Return Valve
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 110-2 Edition 02
MAN B&W Diesel A/S
 Non-Return Valve 910-2.3
Overhaul
Non-Return Valv e
211
Overhaul
910-2.3

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

Both sets of non-return valves are accessed via

the scavenge air receiver.

Note!

Access to the scavenge air receiver must

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

BM910-2.3 208 01
Main Non-Return Valve

1. The main non-return valve consists of four

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

2. Remove the screws holding the valve flap.

Remove the valve from the engine.

3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.

Clean the valve shaft and the slide bearings

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

After the overhaul, it must be possible to

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

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

scavenge air cooler housing.
BM910-2.3 208 02

3.
BM910-2.3 208 03

When referring to this page, please quote Procedure 910-2.3 Edition 211 Page 1 (2)
MAN B&W Diesel A/S
910-2.3 Non-Return Valve
Overhaul

5. Non-Return Valve for Auxiliary Blowers

5. Inside the scavenge air cooler housing, lift

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

6. Remove the screws behind the valve flap.

Remove the valve from the engine.

7. Remove the spring pins from the valve shaft

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

Clean the valve shaft, the slide rings and

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

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

scavenge air cooler housing.
BM910-2.3 208 06

7.
BM910-2.3 208 07

Page 2 (2) When referring to this page, please quote Procedure 910-2.3 Edition 211
MAN B&W Diesel A/S
S46MC-C Auxiliary Blower 110-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

03
110-3
Special Data
S46MC-C Auxiliary 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
1000 kg
Ref. Description Value Unit

D-1 Weight of blower unit,

complete *) up till 820 kg

*) Depending on electric
motor type and number of cyl-
inders of engine (size and
capacity of auxiliary blower)

When referring to this page, please quote Data Sheet 110-3 Edition 03 Page 1 (2)
MAN B&W Diesel A/S
110-3 Auxiliary Blower S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 110-3 Edition 03
MAN B&W Diesel A/S
S46MC-C Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
S46MC-C
204
Overhaul
910-3.3

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

The overhaul can be carried out either by

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

2. Complete Blower Unit

Hook a shackle and a tackle to the lifting

bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates. D-1
Remove all screws in the outlet flange of

GN910-3.3 203 02
the blower unit.

Remove all screws in the lower inlet flange

of the blower unit.
3.
Remove all screws in the upper inlet flange
of the blower unit.

Lift away the blower unit and land it on

wooden planks for further dismantling/over-
haul.

3. Blower Wheel

Remove the safety guard and the driving

GN910-3.3 203 03

belt.

4. Remove the screws in the blower flange

and lift away the blower flange complete
with blower wheel and bearing housing.
4.
For overhaul of blower wheel and bearings,
see blower manufacturer’s instructions.
GN910-3.3 203 04

When referring to this page, please quote Procedure 910-3.3 Edition 204 Page 1 (2)
MAN B&W Diesel A/S
910-3.3 Auxiliary Blower S46MC-C
Overhaul

5. Electric Motor

The electric motors can be dismantled with-

out removing the blower housing.

Remove the safety guard and the driving

belt.

Hook a shackle and a tackle to the motor.

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

Remove all screws in the flange of the mo-

tor.

Lift away the motor and land it on wooden

planks for further dismantling/overhaul.

Page 2 (2) When referring to this page, please quote Procedure 910-3.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Turbocharger Turbine 110-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
110-5
Special Data
S46MC-C Turbocharger Turbine

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

When referring to this page, please quote Data Sheet 110-5 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
110-5 Turbocharger Turbine S46MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 110-5 Edition 02
MAN B&W Diesel A/S
S46MC-C Turbocharger Turbine 910-5.3
Cleaning
Turbocharger Turbine
S46MC-C
203
Cleaning
910-5.3

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 activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.

Note!

We do not recommend the use of rice or

grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.

It is not always possible to remove thick depos-

its 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 turbocharger

turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.

When referring to this page, please quote Procedure 910-5.3 Edition 203 Page 1 (2)
MAN B&W Diesel A/S
910-5.3 Turbocharger Turbine S46MC-C
Cleaning

Cleaning Procedure:

1. Carry out cleaning for every 24 to 50 hours

of operation, based on observations.

2. Preferably clean the turbocharger at full

load. Do not clean below half load.

3. Close valve A.

4. Open valves B and C, to blow out any de-

posits and/or condensate in the connecting
pipe.
XX706-12 40B

After about two minutes, close valves B and

C.

5. Slowly open valve A to relieve the pressure

in the tank.

6. Fill the tank with the quantity of granules

specified in the table.

7. Close valve A.

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

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

9. Slowly open valve A to relieve the pressure

in the tank.
HM910-5.3 50 02

Caution!

1.The drain openings in the gas casings

must remain closed while dry cleaning
the turbine.

2. It is possible that during dry cleaning

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

Page 2 (2) When referring to this page, please quote Procedure 910-5.3 Edition 203
MAN B&W Diesel A/S
 Water Mist Catcher 110-6
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

11
110-6
Special Data Water Mist Catcher

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
X Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
1000 kg

Data
Ref. Description Value Unit

D-1 Water mist catcher 80 kg

When referring to this page, please quote Data Sheet 110-6 Edition 11 Page 1 (2)
MAN B&W Diesel A/S
110-6 Water Mist Catcher
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 110-6 Edition 11
MAN B&W Diesel A/S
 Water Mist Catcher 910-6.2
Dismantling
214
Water Mist Catcher
S46MC-C
Dismantling
910-6.2

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

2. To dismantle the water mist catcher, dis-

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

3. Via access through the upper part of the

EN910-6.2 214 02
scavenge air cooler housing, loosen the
four screws which press against the water
mist catcher.

4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the 3.
water mist catcher.

Attach a tackle to the eye bolt and tighten

up the tackle.

5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
EN910-6.2 214 03

4.
GN910-6.2 205 06

When referring to this page, please quote Procedure 910-6.2 Edition 214 Page 1 (3)
!"#$%&'$()*+*,$"-.$
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4

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

side of the water mist catcher with plenty of
grease.

Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.

Note!

Make sure to mount the water mist

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

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

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

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

3. Via access through the upper part of the

scavenge air cooler housing, tighten the
four screws which press against the water
mist catcher.
GN910-6.4 205 02

3.
EN910-6.4 214 03

Page 2 (3) When referring to this page, please quote Procedure 910-6.4 Edition 214
!"#$%&'$()*+*,$"-.
 Water Mist Catcher 910-6.4
Mounting

4. Clean the water mist catcher cover and ap- 4.

ply a thin layer of silicone paste along the
edges of the cover. Mount the cover.

Clean the upper cover and apply a thin lay-

er of silicone paste along the edges of the
cover. Mount the cover.

EN910-6.2 214 02

When referring to this page, please quote Procedure 910-6.4 Edition 214 Page 3 (3)
!"#$%&'$()*+*,$"-.$
 Cooler and Turbocharger Panel Plate 91051-44

S46MC-C
Plate 91051-44 Cooler and Turbocharger Panel

Item Item
Part Description Part Description
No. No.

010 *) Tool panel

021 Name plate
045 Lifting attachment
057 Guide rail for air cooler fore end, left
069 Guide rail for air cooler fore end, right
094 Screw
212 Pulling tool
224 Eye bolt

010- *) Tool panel, complete

224 with tools

*) Optional extras
 Turbocharger System - Tools Plate 91061-62

S46MC-C
Plate 91061-62 Turbocharger System - Tools

Item Item
Part Description Part Description
No. No.

014 Travelling trolley

 Safety Valve 111-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

19
111-1
Special Data
S46MC-C Safety Valve

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 3m
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Tightening torque for

valve housing 45 Nm

D-2 Opening pressure 200 bar

+/–5

When referring to this page, please quote Data Sheet 111-1 Edition 19 Page 1 (2)
MAN B&W Diesel A/S
111-1 Safety Valve
Data

Plate
90151

1165513-9

Spare Parts

Plate – Item No. Description Qty

91101-xxx 105 mild steel disc 1

Page 2 (2) When referring to this page, please quote Data Sheet 111-1 Edition 19
MAN B&W Diesel A/S
S46MC-C Safety Valve 911-1.2
Dismantling
Safety Valve
S46MC-C
204
Dismantling
911-1.2

1.
1. Remove the guard surrounding the safety
valve.

2. Unscrew the safety valve from the exten-

sion pipe.

GN911-1.2 203 01

2.
GN911-1.2 203 02

When referring to this page, please quote Procedure 911-1.2 Edition 204 Page 1 (4)
MAN B&W Diesel A/S
911-1.3 Safety Valve S46MC-C
Overhaul (adjustment)
Overhaul (adjustment)
911-1.3

1. 1. If necessary, dismantle the safety valve and

clean all the parts in either gas oil, kero-
sene, or ‘electro-cleaner’.

2. Assemble the safety valve in two steps:

• Insert the valve flap and the stop ring in

the valve guide and screw on the valve
housing.

• Tighten the housing to D-1, loosen and

tighten again to D-1.

3. Then mount:
HM911-1.0 27 01

• the valve spindle

• the spring
2.
• the adjusting screw

• the lock nut

HM911-1.0 27 02

3.
HM911-1.0 27 03

Page 2 (4) When referring to this page, please quote Procedure 911-1.3 Edition 204
MAN B&W Diesel A/S
S46MC-C Safety Valve 911-1.3
Overhaul (adjustment)

4. To set the safety valve opening pressure: 4.

• Set up the safety valve in the testing

device.

• Connect the testing device to the hydrau-

lic pump.

• Loosen the lock nut on the safety valve.

• Turn the adjusting screw until the valve

just closes.

• Bleed the valve and hose until oil, without

HM911-1.0 27 04
air bubbles, flows out from the openings
of the safety valve.

• Tighten the adjusting screw of the safety

valve until the correct pressure is indi-
cated (see D-2).

• Tighten the lock nut.

• Test the opening pressure.

• Remove the valve from the testing

device.

When referring to this page, please quote Procedure 911-1.3 Edition 204 Page 3 (4)
MAN B&W Diesel A/S
911-1.4 Safety Valve S46MC-C
Mounting
Mounting
911-1.4

1. 1. Pierce the bore in the extension pipe, and

blow it clean.

Clean the sealing ring grooves.

2. Mount a new or overhauled safety valve

and a new sealing ring on the extension
pipe.

When mounting the safety valve on the ex-

tension pipe, apply tools only on the hexa-
gon on the safety valve.
GN911-1.4 203 01

3. Mount the guard surrounding the safety

valve.

2.
GN911-1.2 203 02

3.
GN911-1.2 203 01

Page 4 (4) When referring to this page, please quote Procedure 911-1.4 Edition 204
MAN B&W Diesel A/S
 Relief Valve 111-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

09
111-2
Special Data
S46MC-C Relief Valve

X Stopped engine
Block the starting mechanism
Shut off starting air supply
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 Sheet 111-2 Edition 09 Page 1 (2)
MAN B&W Diesel A/S
111-2 Relief Valve
Data

Plate
90551
1165498-3

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 111-2 Edition 09
MAN B&W Diesel A/S
MC-C Relief Valve 911-2.1
Checking
Relief Valve
MC-C
205
Checking
911-2.1

1.
1. Test the functioning of the relief valves on
the crankcase wall by means of the tool
supplied.

2. Screw the tool into the valve plate nut.

3. Turn the nut of the tool 20-25 revolutions to

open the valve.

4. Turn the nut back and remove the tool.

HM911-2.0 27 01
GN911-2.0 27 02 2.

3.
GN911-2.0 27 03

When referring to this page, please quote Procedure 911-2.1 Edition 205 Page 1 (1)
MAN B&W Diesel A/S
MC/MC-C Holding Down and End Chock Bolts 112-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
112-1
Special Data
MC/MC-C Holding Down and End Chock Bolts

Stopped engine 1x3m

2x1m
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 1500 bar

D-2 Tightening pressure for

end chock bolts 1500 bar

D-3 Increased tightening pressure

(only for initial tightening of
end chock bolts) 1650 bar

D-4 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 Cast Iron supporting chocks

When referring to this page, please quote Data Sheet 112-1 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
112-1 Holding Down and End Chock Bolts MC/MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 112-1 Edition 02
MAN B&W Diesel A/S
S46MC-C Holding Down and End Chock Bolts 912-1.1
Checking
Holding Down and End Chock Bolts
S46MC-C
205
Checking
912-1.1

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.

For the initial tightening of the end chock bolts,

raise the pump pressure to the value indicated
on the Data sheet. Then tighten the nut firmly
and relieve the hydraulic tool completely of
pressure. After about two minutes, raise the
pressure again until the nut can be loosened.
Now adjust the pressure to the normal tighten-
ing pressure indicated, tighten the nut firmly,
and relieve the system of pressure.

For the initial tightening of end chock bolts, the

following alternative procedure can be followed:

Tighten the bolts to the increased pressures

stated on the Data sheet and leave the bolts so
tightened until after the sea trials, following
which they are to be retightened to the normal
value indicated on the Data sheet and on the
hydraulic tightening tool.

When referring to this page, please quote Procedure 912-1.1 Edition 205 Page 1 (3)
MAN B&W Diesel A/S
912-1.1 Holding Down and End Chock Bolts S46MC-C
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.

Before checking the bolt tightening, check

the fitting of the supporting chocks as far as
conditions of access permit.

To check the bolt tightening, raise the pres-

sure on the hydraulic tool slowly while con-
stantly attempting to loosen the nut with the
tommy bar. The oil pressure indicated on
the pressure gauge when the nut comes
loose (‘loosening pressure’) is noted down
in the checking table, see drawing Nos.
782225-0 and 782226-2, following which
the bolts are tightened to the normal tight-
ening pressure.

The condition of the bolted joints, and thus

the general condition of the foundation, can
EN912-1.1 205 01

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 correct
fitting of the relative chocks shall always be
checked with loose bolts. If the chocks are
in position and correctly fitted, the bolts
should be taken out for inspection of
threads and contact faces.

Cast Iron Supporting Chocks

2. The supporting chocks shall be so adapted

that a 5/100 mm feeler gauge cannot enter
at more than 5 per cent of the entire circum-
ference. Whether the chocks are in position
can, when the respective bolts have been
loosened, be checked by gently tapping on
the chocks with a hook iron.

When a loose chock has been moved into

position, the fitting of the adjacent chocks
shall be checked with a feeler gauge.

If several chocks positioned next to each

other have worked loose, crankshaft deflec-
tion readings must be taken after the
chocks have been refitted.

Page 2 (3) When referring to this page, please quote Procedure 912-1.1 Edition 205
MAN B&W Diesel A/S
S46MC-C Holding Down and End Chock Bolts 912-1.1
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

GN912-2.1 203 03
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.

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 on drawing No. 782226-2, and the
measurements found are entered in the rel-
evant table. These results are used to de-
termine 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 on

drawing No. 782226-2.

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 912-1.1 Edition 205 Page 3 (3)
MAN B&W Diesel A/S
 !"#$%&'()*+,-./0&$.00+)1&("2#'#,)*30,&'()435')63027)))4-5(8)9:;;;<=>
?!)@'(&'#7

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
!"#$%&'()))*+) ,-./012$&314.&,-5/06&724&824&,-5/06&#19-&:5;96
<,&82$12.6

Port side Starboard side

Chock Point Cylinder
Point Chock
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

c, d, e, f, c, d, e, f,
g g

Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure Point Point sure Bolt Ch
2 ) ation ation (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. No. 2

1
AFT
MC/MC-C Holding Down and End Chock Bolts 112-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
112-2
Special Data
MC/MC-C 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 1500 bar

D-2 Tightening pressure for

end chock bolts 1500 bar

D-3 Increased tightening pressure

(only for initial tightening of
end chock bolts) 1650 bar

D-4 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 Sheet 112-2 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts MC/MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 112-2 Edition 02
MAN B&W Diesel A/S
S46MC-C Holding Down and End Chock Bolts 912-2.1
Checking
Holding Down and End Chock Bolts
S46MC-C
204
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.

For the initial tightening of the end chock bolts,

raise the pump pressure to the value indicated
on the Data sheet. Then tighten the nut firmly
and relieve the hydraulic tool completely of
pressure. After about two minutes, raise the
pressure again until the nut can be loosened.
Now adjust the pressure to the normal tighten-
ing pressure indicated, tighten the nut firmly,
and relieve the system of pressure.

For the initial tightening of end chock bolts, the

following alternative procedure can be followed:

Tighten the bolts to the increased pressures

stated on the Data sheet and leave the bolts so
tightened until after the sea trials, following
which they are to be retightened to the normal
value indicated on the Data sheet and on the
hydraulic tightening tool.

When referring to this page, please quote Procedure 912-2.1 Edition 204 Page 1 (3)
MAN B&W Diesel A/S
912-2.1 Holding Down and End Chock Bolts S46MC-C
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 table, see drawing Nos.
782225-0 and 782226-2, following which
the bolts are tightened to the normal tight-
ening 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

EN912-1.1 205 01

cent of the tightening pressure, the relative

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 (3) When referring to this page, please quote Procedure 912-2.1 Edition 204
MAN B&W Diesel A/S
S46MC-C 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 on drawing No. 782226-2, 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 on

drawing No. 782226-2.

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 912-2.1 Edition 204 Page 3 (3)
MAN B&W Diesel A/S
!"#$%&'()))*+) ,-./012$&314.&,-5/06&724&824&,-5/06&#19-&:5;96
<,&82$12.6

Port side Starboard side

Chock Point Cylinder
Point Chock
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

c, d, e, f, c, d, e, f,
g g

Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure Point Point sure Bolt Ch
2 ) ation ation (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. No. 2

1
AFT
 !"#$%&'()*+,-./0&$.00+)1&("2#'#,)*30,&'()435')63027)))4-5(8)9:;;;<=>
?!)@'(&'#7

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
MC-C Stay Bolts 112-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

02
112-3
Special Data
MC-C Stay Bolts

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 1x3m
2x1m
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar

When referring to this page, please quote Data Sheet 112-3 Edition 02 Page 1 (2)
MAN B&W Diesel A/S
112-3 Stay Bolts MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data Sheet 112-3 Edition 02
MAN B&W Diesel A/S
MC-C Stay Bolts 912-3.1
Checking
Stay Bolts
MC-C
202
Checking
912-3.1

1.
1. Before retightening the stay bolts, remove
the protective caps.

2. Retighten the stay bolts in pairs, working

from fore to aft of the engine.

3. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other, transversally

GN912-3.1 202 01
across the engine.

Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
2.

GN912-3.1 202 03

3.
GN912-3.1 202 02

When referring to this page, please quote Procedure 912-3.1 Edition 202 Page 1 (2)
MAN B&W Diesel A/S
912-3.1 Stay Bolts MC-C
Checking

4. 4. Maintain the hydraulic pressure at the value

indicated in D-1, and retighten the stay bolt
nuts with a tommy bar. Before relieving the
system of pressure, check with a feeler
gauge that the nuts bear against the con-
tact face.

5. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below D-1 and check if the nuts are loose.

If the nuts are not loose:

Tighten the stay bolts to D-1.
HM912-3.0 28 04

If any of the nuts are loose:

Tighten all stay bolts once again to D-1.

5. 6. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 05

6.
GN912-3.1 202 06

Page 2 (2) When referring to this page, please quote Procedure 912-3.1 Edition 202
MAN B&W Diesel A/S
 Large Parts - Tools Plate 91261-62

S46MC-C
Plate 91261-62 Large Parts - Tools

Item Item
Part Description Part Description
No. No.

011 Hydraulic jack

023 O-ring with back-up ring, 90/100 mm
035 O-ring with back-up ring, 70/80 mm
047 Spacer ring
059 Hydraulic tools for stay bolt, complete
060 Stud setter M45x4.5
 Hydraulic Tools for Holding-Down Bolts Plate 91263-46
and End Chock bolts
S46MC-C
Epoxy
Plate 91263-46 Hydraulic Tools for Holding-Down Bolts and End Chock Bolts

Item Item
Part Description Part Description
No. No.

012 O-ring with back-up ring, 65/75 mm

036 O-ring with back-up ring, 60/70 mm
048 Hydraulic jack for holding-down bolts, M
33x3.5
061 Spacer ring
132 Hydraulic tools for holding-down bolts,
complete
MC Hydraulic Tools 913-1

Hydraulic Tools
MC
203
913-1

A. Snap-on coupling 1.

B. Tool attachment thread

C. Bleed screw

D. Piston

E. Cylinder

F. Sealing rings

G. Spacer ring

H. Tommy bar

I. Nut

J. Stud or bolt

GN913-1 203 01
K. Extension stud

L. Lifting tool

S. Clearance

U. Milled recess for feeler gauge

Studs or bolts provided with threads for attach-

ing hydraulic tools and with circular nuts must
only be loosened and tightened up by means of
the hydraulic tools supplied.

The jack(s) is/are connected, via a distributor

block, to a high-pressure pump, which is set to
deliver hydraulic oil at the pressure indicated on
the jack and on the data sheet in the relevant
section of this instruction book. The stud or bolt
concerned is thereby lengthened relative to the
oil pressure applied and the piston area, and
the nut can be loosened or tightened, as re-
quired, with the aid of a tommy bar.

The jacks must never be overloaded or exposed

to blows or impacts. They are marked with a
“Max. lift”, which must not be exceeded.
GN913-1 203 02

1. The hydraulic tools, except those for the

main bearings, consist of a jack with an in-
ternal thread to suit the tool attachment
thread on the stud or bolt, and a spacer ring
which is to be placed under the jack and
around the nut that is to be loosened or
tightened.

When referring to this page, please quote Procedure 913-1 Edition 203 Page 1 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC

3. 2. For the main bearings, the hydraulic tool

consists of a double jack with two extension
studs. This jack is designed for the simulta-
neous dismantling of both nuts on one side
of the main bearing.

3. The hydraulic jacks are so designed that, in

the event that the “Max. lift” limit is exceed-
ed, the pressure is relieved at the bottom of
the pressure chamber and the oil 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 cas-
es 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 normal-
ly alkaline and can thus damage the back-
up rings.
GN913-1 203 03

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.

Page 2 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Hydraulic Tools 913-1
Loosening of Nut
Loosening of Nut
913-1

Single Hydraulic Jack 1.

1. Carefully clean the tool attachment thread,

the nut and the surrounding parts.

Grease the tool attachment thread with mo-

lybdenum disulphide grease or with graph-
ite and oil or similar.

Place the spacer ring around the nut in

such a position that the tommy bar can be
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.

Connect the hydraulic jack, the distributor

block and the high pressure pump by
means of high pressure hoses.
GN913-1 203 04

Unscrew the jack to create a clearance be-

tween the jack and spacer ring. See sketch.

Loosen the bleed screw in the jack and fill

up the system with oil until oil without bub- 2.
bles, flows out of the bleed hole. Then tight-
en the bleed screw again.

When loosening nuts on very long bolts

(e.g. staybolts) it is recommended to un-
screw the jack an additional half turn.

The clearance between the jack and spacer

ring ensures dismantling of the jack after
loosening the nut.

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.
GN913-1 203 05

When referring to this page, please quote Procedure 913-1 Edition 203 Page 3 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC
Loosening of Nut

3. 3. Increase the oil pressure to the prescribed

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.
GN913-1 203 06

Note!

Make sure not to exceed the “max lift”

stamped on the jack.
4.
HM913-1.1 10 04

5.
GN913-1 203 08

Page 4 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Hydraulic Tools 913-1
Loosening of Nut

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

GN913-1 203 09
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.
8.
7. Press the pistons 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 the
jacks bear firmly against each other and
against the spacer ring.
GN913-1 203 11

8. The clearance between the pistons and the

cylinder of the top jack is adjusted by un-
screwing the upper nuts 1 turn ! 3 mm.

The clearance between the jack and spacer

ring ensures dismounting of the jack after
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
bubbles, flows out of the bleed holes.

Re-tighten the bleed screws.

When referring to this page, please quote Procedure 913-1 Edition 203 Page 5 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC
Loosening of Nut

9. 9. Increase the oil pressure to the prescribed

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.
GN913-1 203 12

Note!

Make sure not to exceed the “max lift”

stamped on the jack.

Page 6 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Hydraulic Tools 913-1
Tightening of Nut
Tightening of Nut
913-1

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 molyb-
denum disulphide grease or with graphite
and oil or similar.

Fit the round nut on the thread and tighten

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 jack

GN913-1 203 04

firmly together.

Screw the hydraulic jack on to the tool at-

tachment thread.
2.
Make sure that the cylinder of the jack
bears firmly against the spacer ring and
that the parts are guided correctly together

Connect the hydraulic jack, the distributor

block and the high-pressure pump by
means of high-pressure hoses.

Loosen the bleed screw in the jack and fill

up the system with oil, until oil without bub-
bles flows out of the bleed hole.

Re-tighten the bleed screw.

GN913-1 203 05

When referring to this page, please quote Procedure 913-1 Edition 203 Page 7 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC
Tightening of Nut

3. 3. Increase the oil pressure to the prescribed

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.

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-
GN913-1 203 17

der ‘Loosening’, points 6-7-8, and then

tighten the nut again according to the pro-
cedure under ‘Tightening', points 17-18-19.

4.
GN913-1 203 18

Page 8 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Hydraulic Tools 913-1
Tightening of Nut

Double Hydraulic Jack 7.

7. 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-
ite and oil.

Fit the round nuts on the threads and tight-

en them with the tommy bar.

Check with a feeler gauge that the contact

JG913-1.2 20 07
faces of the nuts bear on the entire circum-
ference.

Mount the extension studs on the main

bearing studs.
8.
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.

8. 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

GN913-1 203 22

jacks and the spacer ring are guided cor-

rectly together.

Screw the upper nuts on to the threads of

9.
the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.

9. 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
bubbles, flows out of the bleed holes.
GN913-1 203 23

Re-tighten the bleed screws.

When referring to this page, please quote Procedure 913-1 Edition 203 Page 9 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC
Tightening of Nut

10. 10. Increase the oil pressure to the prescribed

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
spacer ring.

11. 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.

12. Relieve the system of pressure, disconnect

the pump, and remove the hydraulic tools.

13. When new studs, bolts or nuts are tight-

GN913-1 203 24

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-
11. cedure under ‘Tightening', points 24-25-26.
GN913-1 203 25

Page 10 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Hydraulic Tools 913-1
Maintenance
Maintenance
913-1

1. The hydraulic jacks require no maintenance 1.

except replacement of defective sealing
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 separat-

ed by taking out the bleed screw and press-
ing the parts apart with the help of
compressed air.

Warning!

Always use eye protection when working

with compressed 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.

Keep the sliding surfaces and threads coat-

GN913-1 203 28

ed with acid-free grease or molybdenum di-

sulphide grease.

2. The pistons and cylinders of the double

jacks are separated in the same easy way 2.
as described for the single jack.
GN913-1 203 29

When referring to this page, please quote Procedure 913-1 Edition 203 Page 11 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools MC
Maintenance

3. 3. When changing the sealing rings, first

mount the back-up ring and then the O-ring.

Warning!

Note that the back-up ring (1) must be

away from the pressure chamber and
the O-ring (2) close to the pressure
chamber.

See the sketch for the correct mounting of

both the upper and the lower sealing rings.
The same principle applies to all the jacks.

4. After fitting the sealing rings, coat the pis-

ton and cylinder with molybdenum disul-
phide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
GN913-1 203 30

Page 12 (12) When referring to this page, please quote Procedure 913-1 Edition 203
MAN B&W Diesel A/S
MC Torque Spanner 913-5

Torque Spanner
MC
203
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 referring to this page, please quote Procedure 913-5 Edition 203 Page 1 (1)
MAN B&W Diesel A/S
MC Tightening Gauge 913-6

Tightening Gauge
MC
203
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 ! M20: 50 Nm,
– thread > M20: 100 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
HM913-6.0 04 01 and XT913-6.04

marks coincide.

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.
See Procedure 913-5.

When referring to this page, please quote Procedure 913-6 Edition 203 Page 1 (1)
MAN B&W Diesel A/S
MC Screws and Nuts 913-7
Locking
Screws and Nuts
MC
203
Locking
913-7

1
All screwed and bolted connections inside the
engine, as well as all 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.

1. Lock washers, tab washers, locking plates,

etc., must always be replaced. The tab-like
projections, etc., on the washers are to be
bent back over one of the flats of the screw

HM913-7.1 03 01
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 2
punch mark each time it is loosened.
HM913-7.1 03 02

3
HM913-7.1 03 03

When referring to this page, please quote Procedure 913-7 Edition 203 Page 1 (3)
MAN B&W Diesel A/S
913-7 Screws and Nuts MC
Locking

Locking wire should be fitted after the screws

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 lock-
ing wire. Do not secure more than four units in
a series, unless otherwise specified.

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-
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.

Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
HM913-7.2 03 01

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

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. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes ori-
ented in different angles.
HM913-7.2 03 02

Page 2 (3) When referring to this page, please quote Procedure 913-7 Edition 203
MAN B&W Diesel A/S
MC Screws and Nuts 913-7
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
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. 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. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible. HM913-7.2 03 03

When referring to this page, please quote Procedure 913-7 Edition 203 Page 3 (3)
MAN B&W Diesel A/S
MC Lubricating Procedures 913-11

Lubric ating Procedures

MC
203
913-11

Molybdenum Disulphide (MoS 2)

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 (MoS 2) 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 913-11 Edition 203 Page 1 (1)
MAN B&W Diesel A/S
 Accessories for Hydraulic Tools Plate 91351-22

S50/60MC-C
Plate 91351-22 Accessories for Hydraulic Tools

Item Item
Part Description Part Description
No. No.

010 Flexible high-pressure hose, (1.5 m),

complete
022 Flexible high-pressure hose, (3 m),
complete
034 Flexible high-pressure hose, (5 m),
complete
046 3-way distributing piece, complete
058 5-way distributing piece, complete
083 Flexible high-pressure hose
095 Flexible high-pressure hose
105 Flexible high-pressure hose
117 Gasket
129 Snap-on coupling, female with
protective plug
142 Screwed connection, 90 degrees
178 Distributing piece with needle valves
201 3-way distributing piece
213 5-way distributing piece
237 Wrench
249 Bleeder screw
250 Snap-on coupling, male with protective
cap
262 Manuel high-pressure pump
274 Pneumatic/hydraulic high-pressure
pump
321 Tommy bar 4.5 mm
333 Tommy bar 7 mm
345 Tommy bar 9 mm
357 Tommy bar 12 mm
370 Gasket, 6 mm mild steel
382 Gasket, 9 mm mild steel
404 9-way distributing piece, complete
416 9-way distributing piece

This plate is a standard plate, some of the

tools shown are optional extras
 Lifting Tools, Etc. Plate 91356-49

S46MC-C
Plate 91356-49 Lifting Tools, Etc.

Item Item
Part Description Part Description
No. No.

018 Wire
043 Aluminium gangway
079 Chain tackle
080 Chain tackle
092 Chain tackle
102 Chain tackle
114 Pull-lift
 Spanners Plate 91361-45

S46-50MC-C

Combination spanner

Size MAN B&W Standard No. Size MAN B&W Standard No.

10 EN554K10 24 EN554K24

11 EN554K11 27 EN554K27

12 EN554K12 30 EN554K30

13 EN554K13 32 EN554K32

14 EN554K14 34 EN554K34

15 EN554K15 36 EN554K36

16 EN554K16 41 EN554K41

17 EN554K17 46 EN554K46

18 EN554K18 50 EN554K50

19 EN554K19 55 EN554K55

21 EN554K21 60 EN554K60

22 EN554K22

Single-ended spanner

Size MAN B&W Standard No. Size MAN B&W Standard No.

65 EN551F65 75 EN551F75

70 EN551F70 85 EN551F85
 Spanners Plate 91362-49

S50MC-C

Ring impact spanner

Size MAN B&W Standard No. Size MAN B&W standard No.

30 EN554L30 55 EN554L55

32 EN554L32 60 EN554L60

34 EN554L34 65 EN554L65

36 EN554L36 70 EN554L70

41 EN554L41 75 EN554L75

46 EN554L46 80 EN554L80

50 EN554L50

Open-ended impact spanner

Size MAN B&W Standard No. Size MAN B&W Standard No.

65 EN553E65
 Spanners Plate 91363-32

Spanners
S26MC
32
91363

MAN B&W MAN B&W

Standard No. Standard No.
Designation Small set Large set
Complete EN563H 1 EN563H 2
Ratchet EN563B 12,5 EN563B 20,0
Slide T-handle EN506A 12,5 EN506A 20,0
Universal joint EN506P 12,5 EN506P 20,0
Extension EN506F 12,5125 EN506F 20,0200
Extension EN506F 12,5250 EN506F 20,0400
Socket EN506L 10 EN506L 24
Socket EN506L 12 EN506L 27
Socket EN506L 13 EN506L 30
Socket EN506L 16 EN506L 32
Socket EN506L 17 EN506L 34
Socket EN506L 18 EN506L 36
Socket EN506L 19 EN506L 41
Socket EN506L 21
Socket EN506L 22
Socket for internal hexagon EN506G 5 EN506G 14
Socket for internal hexagon EN506G 6 EN506G 17
Socket for internal hexagon EN506G 7 EN506G 19
Socket for internal hexagon EN506G 8
Socket for internal hexagon EN506G 10
Socket for internal hexagon EN506G 12
Box EN563G 1 EN563G 2

MAN B&W
Item
Standard No.
Socket spanner - Size 46mm EN506L46

Reducing socket - 20/12,5 mm 028

Socket wrench set for internal hexagon

MAN B&W MAN B&W
Size Size
Standard No. Standard No.
Small set Large set
Complete EN549E 1 Complete EN549G 1
1,5 mm EN549A 1,5 7 mm EN549A 7
2 mm EN549A 2 12 mm EN549A 12
2,5 mm EN549A 2,5 14 mm EN549A 14
3 mm EN549A 3 17 mm EN549A 17
4 mm EN549A 4 19 mm EN549A 19
5 mm EN549A 5
6 mm EN549A 6
8 mm EN549A 8
10 mm EN549A 10

When referring to this page, please quote Plate 91363-32 Page 1 (1)
MAN B&W Diesel A/S
 Spanners, Etc. Plate 91364-55

Spanners, Etc.
55
91364

Size

When referring to this page, please quote Plate 91364 Edition 55

MAN B&W Diesel A/S
Plate 91364-55 Spanners, Etc.

Item Item
Part Description Part Description
No. No.

011 Double open spanner, 14/17 mm

023 Double open spanner, 19/22 mm
035 Torque spanner, 8-40 Nm
047 Torque spanner, 40-200 Nm
059 Torque spanner, 140-760 Nm
060 Reduring socket, 12.5 x 10
072 Pliers for circlip, size 0.9 mm
084 Pliers for circlip, size 1.3 mm
096 Pliers for circlip, size 1.8 mm
118 Pliers for circlip, size 0.9 mm
131 Pliers for circlip, size 1.1 mm
143 Pliers for circlip, size 1.8 mm
155 Pliers for circlip, size 2.3 mm
 Instruments Plate 91366-60

Instruments
60
91366

When referring to this page, please quote Plate 91366 Edition 60

MAN B&W Diesel A/S
Plate 91366-60 Instruments

Item Item
Part Description Part Description
No. No.

012 Indicator, complete

024 Crankshaft measuring tool (Autolog),
complete
036 Indicator paper
048 Planimeter, complete
061 Feeler gauge
073 Slide caliper