Warning: When Referring To This Page, Please Quote S900 Edition 0001

Warning
S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
When referring to this page, please quote S900 Edition 0001

MAN B&W Diesel A/S
Page 1 (1)
K80MC-C
VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
Table of Contents, Volume II
90050
90060
0289
0002
Checking & Maintenance Schedule

General - Safety Precautions
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
900
Volume II - Maintenance
No.
Edition
Title
900 - Introduction
Table of Contents
90050 0289 Checking & Maintenance Schedule
90060 0002 General - Safety Precautions
901 - Cylinder Cover
101-01 0077 Cylinder Cover, Data
901-01 0260 Cylinder Cover
90151 0208 Cylinder Cover - Panel
90164 0001 Cylinder Cover - Hydraulic Jack Spares
90165 0001 Cylinder Cover - Lifting Tools
902 - Piston with Rod & Stuffing Box
102-01 0090 Piston, Data
902-01 0290 Piston
102-02 0064 Piston Rod Stuffing Box, Data
902-02 0231 Piston Rod Stuffing Box
90251 0258 Piston and Piston Rod - Panel
90261 0102 Piston and Piston Rod - Tools
90264 0006 Piston and Piston Rod - Tilting Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0001 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0075 Cylinder Liner, Data
903-01 0259 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0256 Cylinder Lubricator
90361 0083 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0003 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0069 Crosshead Bearing, Data
904-01 0253 Crosshead Bearing
104-02 0070 Crosshead, Data
904-02 0252 Crosshead
104-03 0044 Reciprocating Parts, Data
904-03 0215 Reciprocating Parts
104-04 0062 Crankpin Bearing, Data
904-04 0233 Crankpin Bearing
104-05 0060 Connecting Rod, Data
904-05 0237 Connection Rod
90451 0155 Connecting Rod and Crosshead - Panel
MAN B&W Diesel A/S
Page 1 (4)
Table of Contents
900
No.
90462
Edition
0018
Title
Connecting Rod - Tools
905 - Crankshaft, Thrust Bearing and Turning Gear

105-02 0086 Main Bearing, Data
905-02 0261 Main Bearing
105-03 0075 Thrust Bearing, Data
905-03 0247 Thrust Bearing
105-04 0050 Journal Bearing, Data
105-05 0061 Axial Vibration Damper, Data
905-05 0230 Axial Vibration Damper
90551 0221 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90562 0123 Crankshaft - Tools
90564 0020 Crankshaft - Measuring Tools
90570 0003 Thrust Shaft - Tools
90571 0001 Main Bearing Shell - Tools
90572 0001 Main Bearing - Measuring Tools
906 - Control Gear
106-01 0051 Chain, Data
906-01 0246 Chain
106-02 0067 Chain Tightener, Data
906-02 0230 Chain Tightener
106-03 0043 Camshaft, Data
906-03 0218 Camshaft
106-04 0045 Camshaft Bearings, Data
906-04 0219 Camshaft Bearings
90651 0203 Chain Drive and Camshaft - Panel
90664 0001 Crankshaft - Pin Gauge
907 - Starting Air System
107-01 0019 Starting Air Distributor, Data
907-01 0219 Starting Air Distributor
107-02 0041 Start Air Valve, Data
907-02 0217 Starting Air Valve
908 - Exhaust Valve
108-01 0037 High-Pressure Pipe, Data
908-01 0226 High-Pressure Pipe
108-02 0094 Exhaust Valve, Data
908-02 0269 Exhaust Valve
108-03 0057 Exhaust Valve Actuator, Data
908-03 0227 Exhaust Valve Actuator
108-04 0041 Exhaust Valve Roller Guide, Data
908-04 0222 Exaust Valve Roller Guide
108-05 0017 Exhaust Valve Cam, Data
MAN B&W Diesel A/S
Page 2 (4)
Table of Contents
900
No.
Edition
908-05
108-07
908-07
90851
90861
90862
90863
90864
0219
0034
0228
0177
0022
0036
0015
0003
Title
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
Exhaust Valve - Panel
Exhaust Valve - Tools
Exhaust Valve - Hydraulic Tools
Exhaust Valve - Extra Tools
Exhaust Valve - Extractor Tool
909 - Fuel Oil System

109-01 0061 Fuel Pump Settings, Data
909-01 0241 Fuel Pump Settings
109-02 0005 VIT System, Data
909-02 0206 VIT System
109-03 0050 Fuel Pump Cam, Data
909-03 0234 Fuel Pump Cam
109-04 0061 Fuel Pump, Data
909-04 0224 Fuel Pump
109-05 0065 Fuel Pump Top Cover, Data
909-05 0234 Fuel Pump Top Cover
109-06 0052 Fuel Pump Barrel Assembly, Data
909-06 0220 Fuel Pump Barrel Assembly
109-07 0040 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0054 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0034 Fuel Pump Shock Absorber, Data
909-09 0216 Fuel System Shock Absorber
10910 0016 Lifting Gear Roller Guide, Data
90910 0218 Lifting Gear for Roller Guide
10911 0065 Fuel Valve, Data
90911 0249 Fuel Valve
10912 0048 Spindle Guide, Data
90912 0228 Spindle Guide
10913 0033 Non-Return Valve in Fuel Valve, Data
90913 0206 Non-Return Valve in Fuel Valve
10914 0080 Fuel Oil High-Pressure Pipes, Data
90914 0255 Fuel Oil High-Pressure Pipes
10915 0062 Fuel Pump Roller Guide, Data
90915 0236 Fuel Pump Roller Guide
90951 0446 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
MAN B&W Diesel A/S
Page 3 (4)
Table of Contents
900
No.
90974
90977
90979
90980
Edition
0001
0001
0001
0001
Title
Fuel Valve Nozzle - Cleaning Tools
Mounting Tools - Pump Barrel Seals
Mounting Tools - Suction Valve Seals
Mounting Tools - Air Piston Seals
910 - Turbocharger System

110-01 0051 Air Cooler Element, Data
910-01 0243 Air Cooler Element
110-02 0009 Non-Return Valve after Air Cooler, Data
910-02 0210 Non Return Valve after Air Cooler
110-03 0031 Auxilary Blower, Data
910-03 0218 Auxilary Blower
110-04 0005 Butterfly Valve, Data
910-04 0205 Butterfly Valves
110-05 0010 Turbocharger Turbine, Data
910-05 0213 Turbocharger Turbine
110-06 0032 Water Mist Catcher, Data
910-06 0222 Water Mist Catcher
91063 0018 Air Cooler - Tools
91064 0001 Travelling Trolley
91066 0002 Air Cooler - Lifting Tools
911 - Safety Equipment
111-01 0026 Safety Valve, Data
911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver Safety Valve, Data
911-03 0001 Scavenge Air Receiver Safety Valve
912 - Assembly of Large Parts
112-02 0015 Holding Down & End Chock Bolts, Data
912-02 0208 Holding Down and End Chock Bolts
112-03 0027 Stay Bolts, Data
912-03 0213 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0075 Hydraulic Tools for Large Parts
91265 0002 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
913 - General Tools
913-01 0211 Hydraulic Tools
913-03 0007 Working Platforms
913-04 0202 Standard Tightening Torques
MAN B&W Diesel A/S
Page 4 (4)
Table of Contents
900
No.
Edition
913-05
913-06
913-07
91311
91351
91356
91357
91359
91360
91361
91362
91363
91364
91366
91368
0205
0205
0207
0204
0034
0051
0006
0003
0005
0052
0060
0040
0059
0066
0011
Title
Torque Spanner
Tightening Gauge
Screws and Nuts
Lubricating
Accessories - Hydraulic Tools
Lifting Tools, etc.
Open-Ended Spanners
Torque Spanners
Pliers
Combination Spanners
Ring Slugging Spanners
Spanners
Open-Ended Spanners
Instruments
Working Platforms
MAN B&W Diesel A/S
Page 5 (4)
MAN B&W Diesel
Checking and Maintenance Schedule,

80-108 MC/MC-C Engines
900-1
The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the
engine and to carry out overhauls, if necessary,
based on the engine condition or on time criteria.
Design modifications may necessitate a revision of

the instructions, in which case the revised instructions and changed overhauling intervals, if any, will
apply and supersede those originally issued (see
e.g our Service Letters).
The stated Normal hours of service should only

be used as a guide, as differences in the actual
service conditions, the quality of the fuel oil or lubricating oil, the treatment of cooling water, etc.
will decisively influence the actual service results,
and thus the intervals between necessary overhauling.
In addition to the checking and overhauling intervals stated in this schedule, please note that the
periodical survey requirements of the classification
society may require additional checks and overhauls to be carried out. For further information
please refer to the classification society.
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 components, and form the basis for estimating whether further overhauling 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
procedures
are those procedures which under the heading Normal hours of

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 condition checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.
Time-based overhauling
procedures
also marked with an O under the headings Normal hours of 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 intervals
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 Schedule A90050 Edition 0289
Page 1 of 6
900-1
Page 2 of 6
Checking and Maintenance Schedule,

80-108 MC/MC-C Engines
MAN B&W Diesel
MAN B&W Diesel
Checking and Maintenance Schedule, 80-108 MC/MC-C Engines
V : See Volume I Operation

A : Adjustment to be carried out
C : Check the condition
M : See makers instructions

O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks
No.
Procedure
902 Piston with Rod and Stuffing box

-1 Piston
Inspection through scavenge ports
-2 Piston rod stuffing box
905
-2
-3
-3
-4
-5
Crankshaft and Thrust Bearing

Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
12
16
24
32
C*
O
O
C,O
C*
903 Cylinder Liner and Cylinder Lubrication

-1 Cylinder liner
Inspection through scavenge ports
Measuring wear inside liner
-2 Cylinder lubricators
Accumulators nitrogen pressure
Crosshead with connecting rod
Crosshead bearing
Crosshead
Reciprocating parts
Crankpin bearing
Connecting rod
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x1000 hours of operation)
Daily Weekly Monthly
901 Cylinder Cover

-1 Cylinder cover
Indicator cock
904
-1
-2
-3
-4
-5
900-1
Remarks
* Check whenever exhaust

valve is removed
V
* Check clearances without
dismantling segments
O
C
C
C
C
A
A
V,M
C,O
C,O
C,O
C,O
O
C
C
C
C
C
C
C
C
C
C
C
C
C,O
C,O
C,O
C,O
O
C
C
Bearings should only be

opened up if bearing material
fragments fall out.
Bearings should only be

opened up if bearing material
fragments fall out.
Page 3 of 6
900-1


Regular Checks
No.
Procedure
-7
-8
Electronic axial vibration monitor

Mechanical checking
Tacho pick-up
Angle encoder
906 Mechanical Control Gear

-1 Chains
-2 Chain tightener
Chain wheels, spray nozzles and guide bars
-3 Camshaft
-4 Camshaft bearings
Camshaft coupling, fitted bolts
-5 Moment compensator
Governor
Functional check of overspeed device
Functional check of speed-setting system
(engine with bridge control system)
907 Starting Air System
-1 Starting air distributor
-2 Starting air valve
908
-1
-2
-3
-4
-5
Exhaust Valve
High-pressure pipe
Exhaust valve
Exhaust valve actuator
Actuator safety valve
Exhaust valve roller guide
Exhaust valve cam
Page 4 of 6
MAN B&W Diesel
P : Refer to

2
12
16
24
32
C,O
C,O
M
M
R
A
R
C,A
C,O
Remarks
C
C
C
C,A
C
C
C
C,A
C
C
O
C
C
C
New or overhauled chain to be

checked/retightened after 500,
1500 and 4000 hours
C,A
M
M
M
C
C
C
C,O
O
O
O
C,A
C*
C*
C*
C*
O
O
* only inspection through

camshaft covers
MAN B&W Diesel


Regular Checks
No.
-7
Procedure
P : Refer to
12
16
24
32
Exhaust valve special running
909 Fuel Oil System

Fuel oil water content
-1 Fuel pump settings
-2 VIT system
-3 Fuel pump cam
-4 Fuel pump
-5 Fuel pump top cover
-6 Fuel pump barrel assembly
-7 Fuel pump suction valve
-8 Fuel pump puncture valve
-9 Fuel pump shock absorber
-9 Fuel system shock absorber
-10 Lifting gear for roller guide
-11 Fuel valve
Fuel nozzle
-12 Spindle guide
-13 Non-return valve
-14 Fuel oil high-pressure pipes
-15 Fuel pump roller guide
-16 Fuel pump special running
910
-1
-2
-3
-4
900-1
Turbocharger System
Air cooler
Non-return valve
Auxiliary blower
Butterfly valves
Remarks
A,C
A
A
O
O
R
C,O
C,O
C
C
C
C,O
R
V
V
O
O
O
R
O
C*
C*
C
C
C
O
O
O
O
O
O
O
* Only inspection through

camshaft covers
Check p and t
Check at every port inspection
Check at every port inspection
Page 5 of 6
900-1


Regular Checks
No.
Procedure
-5
Turbocharger turbine
Turbocharger air filter
Protective grid before turbocharger
Turbocharger lubricating oil water content
Water mist catcher
-6
911
-1
-2
-3
Safety Equipment
Overpressure indicator valve
Relief valve
Scavenge air receiver safety valve
Functional test of alarm system for thrust
bearing and slow down /shut down system
Checking and adjustment of pressure gauge
Checking and adjustment of thermometers
Checking and adjustment of thermostats
Checking and adjustment of pressurestats
Checking and adjustment of turning gear switch
912 Assembly of Large Parts

-2 Holding-down and end chock bolts
-3 Stay bolts
Top bracings
Diaphragm in crankcase oil outlet
System lubricating oil water content
System lubricating oil bottom tank
Cooling water quality
Crankcase
913 General Tools
-1 Hydraulic tools
Page 6 of 6
MAN B&W Diesel
P : Refer to

2
C*
C
12
16
24
32
C
C
C,O
O
R
V,M
C*
C*
V
M
O
O
O
C
C
C
C
C
A
A
A
A
A
C
C
C
C*
* Dry cleaning daily
* Only if separate oil system

* Check p
C,O
C
C
C
Remarks
M
M
M
M
M
M
C
C
* Initial check only
C
C
Empty and clean tank
O
C
V,M
C*
* Check for loose nuts and

bearing material fragments
General Safety Precautions
900-2
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.
SAFETY PRECAUTIONS
X
Stopped engine
Shut off starting air supply At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply Not ME-engines
Shut off control air supply
Shut off air supply to exhaust valve Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
When referring to this page, please quote Safety Precaution A90060 Edition 0001
MAN B&W Diesel A/S
Page 1 (1)

101-01
901-01
90151
90164
90165
0077
0260
0208
0001
0001
Cylinder Cover, Data

Cylinder Cover
Cylinder Cover - Panel
Cylinder Cover - Hydraulic Jack Spares
Cylinder Cover - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
101-1
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Shut off safety air supply Not ME engines
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D01-01
Exhaust valve stud, screwing-in torque
550
Nm
D01-02
Starting valve stud, screwing-in torque
240
Nm
D01-03
Fuel valve stud, screwing-in torque
140
Nm
D01-05
Cylinder cover stud, check distance
196 - 197
mm
D01-06
Cylinder cover, complete
6300
kg
D01-07
Cylinder cover without valves
4600
kg
D01-08
Cooling jacket
120
kg
D01-09
Exhaust valve stud
120
kg
D01-10
Cylinder cover stud
110
kg
D13-01
Hydraulic pressure, mounting
900
bar
D13-02
Hydraulic pressure, dismantling
800 - 990
bar
When referring to this page, please quote Data D10101 Edition 0077
Page 1 (2)
Cylinder Cover
101-1
MAN B&W Diesel
Data
The task-specic tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the rst three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
Description
P90151
46
Grinding tool for exhaust valve seat
P90151
58
Milling and grinding wheel for fuel valve seat
P90151
60
Milling and grinding wheel for starting valve seat
P90151
83
Grinding handle
P90151
105
Grinding handle for starting valve
P90161
Cylinder Cover - Tools
P90165
Cylinder Cover - Lifting Tools
P91351
10
Hydraulic pump, pneumatically operated
P91351
58
Hose with unions (3000 mm), complete
Page 2 (2)
Cylinder Cover
MAN B&W Diesel
Dismantling
Shut off Oil and Water Supply

1.
901-1.2
2.
Check engine blocking.

Check that the engine is stopped and
blocked according to the safety precautions given on the data sheet.
2. Shut off the oil supply.
3. Shut off the water supply.

Close the water outlet above the exhaust
valve.
Close the water outlet on the exhaust side
of the cylinder cover.
M901010260D01
Close the fuel oil supply for the unit concerned.
3.
Shut off the water supply placed on the exhaust side below the exhaust gas receiver.
Open the drain next to the inlet valve.
M901010260D02
Open the venting cock next to the outlet

valve.
When referring to this page, please quote Procedure M90101 Edition 0260
Page 1 (14)
901-1.2
Cylinder Cover
Dismantling
MAN B&W Diesel
Dismantling of Pipe Connections

4.
4. Disconnect the oil pipes.
Remove the hydraulic high pressure pipe
for the exhaust valve. See Procedure
9081.2
Unscrew the drain pipe for the exhaust
valve.
M901010260D04
Remove the fuel oil high pressure pipes.

See Procedure 90914.2.
5.
Disconnect the pipes for return fuel oil from

the fuel valves.
5. Disconnect the water pipes.
Unscrew and remove the water outlet
pipes.
6. Exhaust gas compensator.
Remove the protective jacket enclosing the
insulation for the intermediate pipe or compensator. Remove the insulation.
M901010260D05
Remove the clamp ring from the ange

between the intermediate pipe and the exhaust receiver.
M901010260D06
6.
Page 2 (14)
Cylinder Cover
MAN B&W Diesel
7.
901-1.2
Dismantling
Disconnect the starting air pipe.

7.
Unscrew and remove the control air pipe
for the starting air valve.
Unscrew and remove the air pipe for the
starting valve.
8. Cylinder cover loosening.
Loosen and remove the cylinder cover nuts,

see Data.
For use of hydraulic tools, see Procedure
9131.
M901010260D07
Remove the protective caps from the cylinder cover nuts.
8.
M901010260D08
D1302
Page 3 (14)
901-1.2
Cylinder Cover
Dismantling
MAN B&W Diesel
Cylinder Cover Lifting and Landing

9.
9. Cylinder cover lifting.
D0106
Hook on the engine room crane to the lifting attachment on top of the exhaust valve.
Check that all cylinder cover connections
have been loosened and removed.
Lift away the cylinder cover complete.
10. Cylinder cover landing.
M901010260D09
Land the cylinder cover on a couple of

wooden planks.
M901010260D10
10.
Page 4 (14)
Cylinder Cover
MAN B&W Diesel
901-1.2
Dismantling
11. Remove sealing ring.

11.
M901010260M12
Remove and discard the sealing ring between the cylinder cover and cylinder liner.
Page 5 (14)
901-1.3
Cylinder Cover
Overhaul
MAN B&W Diesel
Overhaul Preparations
1.
1.
D0109
Dismantle valves and pipes.

Dismantle all valves and pipes from the
cylinder cover. See Procedure 9072.2,
9082.2 and 90911.2.
Remove all studs on top of the cylinder
cover.
M901010260O01
Cooling Water Jacket

2. Remove the cooling water jacket.
Mount four eyebolts and the lifting chains
as shown in the sketch.
Remove the four screws which secure the
cooling jacket to the cylinder cover.
2.
Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.
D0107
Remove and discard the Orings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.
M901010260O02
3. Mount the cooling water jacket.
3.
D0108
Provide the cylinder cover with new

Orings, well lubricated with vaseline.
Lift the cylinder cover and guide the jacket/
cover into position, using the guide pin as a
reference (manoeuvre side).
Fit and tighten the screws for the cooling
jacket.
M901010260O03
Silicone
Page 6 (14)
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
Reconditioning of Bores
4.
4. Seat reconditioning tools.
The tools for reconditioning of the valve
seats are found on tool panel 901.
5. Fuel valve bore.
Clean the fuel valve bores using the carbon

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. Carborundum No. 200).
M901010246O04
The tool consists of a common spindle with

a handle, a guide, a carbon cutter, a seating face cutter and a grinding mandrel.
5.
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
M901010260O05
Page 7 (14)
901-1.3
Cylinder Cover
Overhaul
MAN B&W Diesel
6. Exhaust valve bore.

6.
The tool consists of a spindle with a 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).
M901010240O07
After the grinding, clean the bore and seating carefully, and check that the seating is
not damaged.
7.
7.
Starting valve bore.

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.
M901010243O07
When replacing the valves on a cylinder

cover while it is mounted on the engine,
recondition the valve bores/seating as described here, however, without removing
the studs.
Page 8 (14)
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
8. Indicator safety valve bore.

8.
Clean the bores for safety valve/indicator
cock.
Preparations before Mounting
9. Fitting of studs.
Tighten up the studs in accordance with

the screwingin torque stated on the data
sheet.
Fill up the grooves between the valve studs
and the bores for the valve studs with permatex to prevent water or oil from entering
the bores during operation of the engine.
M901010260O08
Lubricate the threads with Never Seize or

molybdenum disulphide (MoS2) and t the
valve studs.
D0101
9.
10. Mounting of valves.
D0103
Install the valves on the cylinder cover, see

Procedures 9072.4, 9082.4 and 90911.4.
M901010260O09
D0102
Page 9 (14)
901-1.4
Cylinder Cover
Mounting
MAN B&W Diesel
Landing Preparation
1.
1.
Sealing ring.
Check that the liner sealing surface is
clean.
Place a new sealing ring on top of the cylinder liner.
M901010260M01
2. Water connections.
Check that the water connections are clean
and provided with new Orings.
Lubricate the Orings with Vaseline and t
them on the cylinder liner.
M901010260M02
2.
Page 10 (14)
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
Cylinder Cover Mounting

3.
3. Cylinder cover landing.
D0106
Carefully wipe the cylinder cover contact
surface facing the cylinder liner, while the
cover is resting on the support.
Lift the cylinder cover by means of the
crane and lower it carefully into position.
During the landing, carefully check that
the cooling water connecting pipes engage correctly with the holes in the cooling
jacket.
4. Cylinder cover stud check distance.
If necessary, adjust to the distance D0105

by turning the stud.
M901010260M03
If the cylinder cover studs have been removed and reinstalled, check the distance
the stud is protruding from the cylinder
cover.
4.
M901010254M04
D0105
Page 11 (14)
Cylinder Cover
901-1.4
Mounting
MAN B&W Diesel
5. Cylinder cover tightening.

5.
Fit and tighten the cylinder cover nuts.
D1301
For operation of hydraulic jacks, see Procedure 9131.

Fit the protective caps on the cylinder cover
studs.
Fitting Pipe Connections
M901010260M05
6. Mount the exhaust gas compensator.
6.
When mounting the clamp connecting the

compensator and the intermediate pipe/exhaust valve it may, in some cases, become
necessary to use the engine room crane.
Clean the anges and the clamp ring carefully and lubricate all contact faces with
Molycote.
M901010246M05
Fit the insulating jacket around the intermediate pipe.
Page 12 (14)
Cylinder Cover
MAN B&W Diesel
7.
901-1.4
Mounting
Connect the starting air pipe.

7.
Connect and tighten the air pipe for the
starting valve.
Connect and tighten the control air pipe for
the starting air valve.
8. Connect the water pipes.

Mount and tighten the water outlet pipes.
Mount the hydraulic high pressure pipe for

the exhaust valve. See Procedure 9081.4.
Connect the drain pipe for the exhaust
valve.
M901010260M07
9. Connect the oil pipes.
8.
Connect the fuel oil high pressure pipes.
M901010260M08
Connect the pipes for return fuel oil from

the fuel valves.
M901010260M09
9.
Page 13 (14)
901-1.4
Cylinder Cover
Mounting
MAN B&W Diesel
Open Oil and Water Supply

10.
10. Close the drain and open the water supply.
Close the venting cock next to the outlet
valve.
Close the drain next to the inlet valve.
Slowly open the water supply valve, placed
below the exhaust gas receiver.
Vent the unit by releasing air through the
venting cock next to the outlet valve.
When the venting is nished, close the
venting cock. Open the two water outlet
valves on the exhaust side of the cylinder
cover.
M901010260M10
11. Open the oil supply.

Open the fuel oil supply for the unit concerned.
M901010260M11
11.
Page 14 (14)
Cylinder Cover Panel
When referring to this page, please quote Plate P90151 Edition 0208
MAN B&W Diesel A/S
Plate
P90151-0208
Page 1 (2)
Plate
P90151-0208
Item
No.
010
022
046
058
060
071
083
095
105
117
129
Page 2 (2)
Cylinder Cover Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Grinding tool, exhaust valve seat
Milling and grinding tool, fuel valve
seat
Milling and grinding wheel, fuel valve
seat
Dismantling tool, fuel valve
Handle, sundry types
Grinding ring, starting valve
Pin spanner, starting valve
Test equipment, combined safety
valve
Extension studs, lifting cylinder cover
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90164-0001
Page 1 (2)
Plate
P90164-0001
Item
No.
011
023
035
047
059
060
072
084
096
118
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Wooden box
Tommy bar
Spanner
Venting screw
Quick coupling male
Disc
O-ring with back-up ring
Stud setter
Disc
Cylinder Cover - Lifting T

ools
Tools
MAN B&W Diesel
Plate
P90165-0001
Page 1 (2)
Plate
P90165-0001
Item
No.
017
Page 2 (2)
Cylinder Cover - Lifting T

ools
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Lifting chains for cylinder cover

102-01
902-01
102-02
902-02
90251
90261
90264
90265
90266
0090
0290
0064
0231
0258
0102
0006
0001
0001
Piston, Data
Piston
Piston Rod Stuffing Box, Data
Piston Rod Stuffing Box
Piston and Piston Rod - Panel
Piston and Piston Rod - Tools
Piston and Piston Rod - Tilting Tools
Piston and Piston Rod - Support Tools
Piston - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
102-1
Piston
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D01-05
D02-01
D02-04
D02-05
D02-06
D02-08
D02-09
D02-10
D02-11
D02-13
D02-14
D02-46
D02-15
D02-16
D02-17
D02-18
D02-19
D02-20
D02-21
D02-22
D02-23
D02-24
D02-25
D02-47
D02-48
D02-49
D13-01
D13-02
Description
Cylinder cover stud, check distance
Test pressure
Piston rod/crown stud, screwing-in torque
Piston skirt, tightening torque
Cooling oil pipe, tightening torque
Piston ring new, radial width
Piston ring worn, min. radial width
Groove No.1, max. vertical height
Groove Nos. 2, 3 and 4, max. vertical height
Piston ring new, height of ring No. 1
Piston rings new, height of ring Nos. 2, 3 and 4
CPR ring CL groove, min. depth
Minimum free ring gap ( before dismantling )
Minimum ring gap, ring No. 1 ( new ring in new liner )
Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner )
Vertical clearance, new parts
Vertical clearance, worn parts, max.
Piston complete
Piston crown
Piston rod
Piston skirt
Piston cooling pipe
Lifting tool, tightening torque
Piston top centre, max. permissible burn-away
Piston top centre diameter
Piston top outer ring area, max. permissible burn-away
MAN B&W Diesel A/S
Value
196 - 197
7
300
380
190
25.2
21.2
18.8
14.8
17.9
13.9
1.8
44
5.6
4.0
0.48
0.97
3300
870
2000
210
55
200
9
375
6
900
800 - 990
Unit
mm
bar
Nm
Nm
Nm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
Nm
mm
mm
mm
bar
bar
Page 1 (2)
102-1
Piston
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
Description
P90251
40
Lifting tool for piston rod foot
P90251
75
Template for piston top
P90251
87
Distance piece for stuffing box
P90251
99
Cover for stuffing box hole
P90251
110
Pressure test tool for piston
P90251
134
Piston ring expander
P90251
158
Guide screw for piston crown
P90251
171
Dismantling screw piston skirt
P90261
Guide ring for piston
P90262
Hydraulic jack for piston rod
P90264
Tools for tilted lift
P90265
Support for piston
P90266
P90366
Cylinder Liner - Lifting Tools
P90451
120
P91351
10
P91351
34
P91351
60
P91351
117
Page 2 (2)
Rubber cover for crosshead
5-way distributor block, complete
MAN B&W Diesel A/S
Piston
MAN B&W Diesel
902-1.1
Checking
Scavenge Port Inspection
1.
To detect possible leakages from the piston

or cylinder cover, keep the cooling water
and cooling oil circulating during the scavenge port inspection.
The scavenge port inspection is carried out
from the scavenge air receiver. An additional view of the rings is possible through the
cleaning cover on the manoeuvring side.
Turn the engine at least a revolution, and
begin with a unit arriving downwards, just
above the scavenge air ports. Inspect the
piston rod and the lower part of the cylinder wall.
While the piston is passing downwards,
inspect the piston skirt, all the piston rings,
the ring lands and the piston top.
M902010280C01
1.
2.
2. Ring inspection:
Inspect the rings, one at a time, and note
down the results. See Volume I, Operation,
Chapter 707.
M902010280C02
3. Ring tension:
Check the tension of the piston rings, by
pressing against them with a wooden stick.
M902010280C03
3.
Page 1 (23)
Piston
902-1.1
Checking
4.
MAN B&W Diesel
4. Ring grooves:
Measure the total clearance between the
piston ring and the ring groove. The total
clearance must not exceed the value stated
in Data.
D0218
D0219
Measure the clearance at the top (E) and

bottom (F) of the piston ring groove.
Total clearance = E + F.
M902010280C04
Max. 2mm
5. Uppermost piston ring:

If possible, measure the depth of the pressure relief grooves with a calliper. The
piston rings must be replaced if the radial
depth of the grooves has worn down to
less than stated in Data D0246.
Checking, in connection with piston
overhaul
5.
D0246
Note!
It is recommended to replace all the piston rings whenever a piston is removed
from the engine.
M902010280C05
6. Piston support:
Remove the piston from the cylinder and
place it on the piston support. See Procedure 9021.2. For evaluation of the rings,
see Volume I, Chapter 707.
M902010280C06
6.
Page 2 (23)
Piston
MAN B&W Diesel
7.
902-1.1
Checking
Free ring gap:

Before dismantling the piston rings, measure the free ring gap of all the piston
rings.
7.
D0215
For dismantling the piston rings, see Procedure 9021.3.
9. Ring grooves:
Clean the ring grooves and check them for
burn marks or other deformation.
Measure the ring grooves with a calliper
gauge, see Data D0210 and D0211.
M902010280C07
8. Radial ring width:

Measure the radial width of the rings. Note
down the results See Volume I, Operation,
Chapter 707.
8.
Clearance in piston ring grooves:
The maximum vertical height in a worn ring
groove must not exceed the value stated
in Data. The groove is also worn out if
there is no chromium layer.
D0208
New
M902010280C08
If the ring grooves are worn out, the piston

crown must be reconditioned, contact MAN
B&W Diesel A/S for advice.
D0209
Worn
9.
D02-10
D02-11
M902010280C09
Max 2mm
Page 3 (23)
Piston
902-1.1
Checking
MAN B&W Diesel
10. Piston top template:

Check that the piston top template is permanently marked with the piston top centre
diameter D0248.
10.
Check that the centre area C has been

marked off, and write the maximum permissible burnaway rate on the template.
See data D0247.
C
R
M902010280C10
D0248
Mark the outer part of the template R for

ring area, and write the maximum permissible burnaway rate for the ring shaped
area. See data D0249.
11. Piston crown top:
Clean the piston crown and check the
burnaway by means of the template.
11.
D0247
D0249
For maximum permissible burn away on the

piston top centre area, see Data D0247.
For the ring shaped area, see Data D0249.
Check the burnaway on the whole circumference of the piston crown top.
If the burnaway exceeds the values given
in Data, contact MAN B&W for advice.
M902010280C11
Note down the results for later reference.
Page 4 (23)
Piston
MAN B&W Diesel
Dismantling
Preparations in the crankcase

1.
902-1.2
1.
Access:
Open the crankcase door to the cylinder
concerned.
M90201280D01
Turn the crosshead down far enough to

give access to the piston rod stufng box
and the piston rod/crosshead connection.
Page 5 (23)
902-1.2
Piston
Dismantling
2.
MAN B&W Diesel
2. Telescopic pipe:
Loosen and remove the screws which tighten the telescopic pipe to the bend. Remove
one screw from the telescopic stufng box
housing and mount the special tool for
suspending the telescopic pipe or use the
thread in the telescopic pipe stufng box
housing.
Turn the crosshead to TDC. Suspend the
telescopic pipe by means of the tool.
Turn the crosshead downward and remove
the distance pipe from the bend.
Note!
M902010280D02
When a piston is dismantled, never turn

the engine without rst dismantling the
telescopic pipe from the crosshead.
Page 6 (23)
Piston
MAN B&W Diesel
902-1.2
Dismantling
3. Stufng box:
Release the stufng box by removing the
innermost screws from the stufng box
ange.
3.
On engine models where the drain pipe is

connected directly to the stufng box:
Disconnect the stufng box drain pipe.
Do NOT remove the outermost screws

from the ange.
4.
D1302
M902010280D04
4. Loosen the piston rodcrosshead connection:

Loosen and remove the hydraulic nuts, see
Data. See Procedure 9131.
M902010280D03
Note!
Page 7 (23)
902-1.2
Piston
Dismantling
5.
MAN B&W Diesel
5. Stufng box distance pieces:

Mount the two distance pieces on the piston rod foot to protect the lower scraper
ring and to guide the stufng box.
Preparations on the cylinder top
6. Cylinder cover:
Remove the cylinder cover. See Procedure
9011.2.
Make a scratch mark in liner and piston cleaning ring to ensure correct
remounting. Remove the piston cleaning
ring.
M902010280D05
Carefully remove any wear ridges at the top

of the cylinder liner. See Procedure 9031.3.
M902010280D06
6.
Page 8 (23)
Piston
MAN B&W Diesel
7.
902-1.2
Dismantling
Piston lifting tool:

Turn the piston to TDC. The top of the piston is now free of the cylinder liner.
7.
D0225
Clean the lifting groove of the piston crown

and mount the lifting tool.
Note!
Limited lifting high:

If the engine is not equipped with long distance pieces, remove one or two cylinder
cover studs, using a stud setter.
M902010280D07
Make sure to mount the lifting tool correctly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.
Page 9 (23)
Piston
902-1.2
Dismantling
MAN B&W Diesel
Piston lift
8.
8. Lift the piston out of the cylinder liner and

guide the piston rod foot through the stuffing box ange.
If the engine is equipped with long distance
pieces for the stufng box, the piston rod
foot can pass between two cylinder cover
studs.
Place the two halves of the support around
one of the openings in the platform. Lower the piston rod foot and stufng box
through the opening in the platform. Secure
the two support halves with screws and
lower the piston on the support. Check the
piston is resting on the piston rod ange.
M902010280D08
D0220
Page 10 (23)
Piston
MAN B&W Diesel
902-1.2
Dismantling
9. Protect the crosshead bearing:

Place a cover over the opening for the piston rod stufng box at the bottom of the
cylinder unit.
9.
Turn the crosshead down far enough to

permit mounting of the protective rubber
cover on the crosshead bearing cap. The
protective rubber cover is found on tool
panel 904.
The covers must remain in place to protect
the crosshead bearing journal from impurities until the piston is remounted.
M902010280D09
Clean, measure and recondition the cylinder liner. See Procedure 9031.
Page 11 (23)
Piston
902-1.3
Overhaul
1.
1.
D0220
MAN B&W Diesel

Piston support:
Place the piston in the support and remove
the piston lifting tool.
Clean the piston top and the piston rings.
Check the free ring gap and the burnoff
on the piston top. See Procedure 9021.1.
Remove the stufng box. See Procedure
9022.3.
M902010280O01
2. Piston ring dismantling:

Take off the piston rings by means of the
ring expanders. If the engine is equipped
with two ring expanders, the short ring expander is for the uppermost ring.
2.
First remove the uppermost ring, then ring

No. two, three and four.
Clean and inspect the rings and the ring
grooves. See Procedure 9021.1.
3. Piston crown dismantling:
Loosen and remove the hydraulic nuts between the rod and the piston crown. See
Data.
M902010280O02
For operation of hydraulic tools, see Procedure 9131.
M902010280O03
3.
Page 12 (23)
Lift the piston crown and skirt clear of the

piston rod.
D0221
+
D0223
D1302
Piston
MAN B&W Diesel
902-1.3
Overhaul
4. Piston rod and cooling pipe:

Remove the screws from the cooling oil
pipe ange.
4.
D0224
Mount the eye bolts and lift out the cooling

oil pipe.
D0206
Clean and inspect the cooling oil pipe and

the piston rod, then remount the cooling oil
pipe, see Data.
Check that the surfaces of the Oring
groove is clean and smooth.
5. Piston crown turning:

Unhook the crane from the piston lifting
tool, and connect the lifting tool and the
crane hook by means of a wire rope. Lift
up the piston crown.
M902010280O04
Mount a new Oring on the piston rod

ange.
D0222
5.
Install a tackle in a suitable place with sufcient space below for the piston crown.
Attach the tackle to the wire rope on the
piston skirt and carefully turn the piston
crown upside down.
Use both cranes if the engine room is
equipped with two cranes.
M902010290O05
Fit two eyebolts in the piston skirt and a

wire rope between the bolts as shown in
the sketch.
Land the piston lifting tool and the piston

crown on a sufcient support of wood
pieces. Loosen the piston lifting tool and
lift the piston crown clear of the tool.
Page 13 (23)
Piston
902-1.3
Overhaul
MAN B&W Diesel
6. Piston crown dismantling and cleaning:

Place the piston crown with skirt on a
wooden support as shown.
6.
D0223
Remove the locking wire and the screws

in the skirt. If necessary, use two dismantling screws to pull the skirt off the piston
crown. Mount two eye bolts in the skirt. Lift
the skirt and land it on a couple of planks.
Discard the sealing ring on the piston skirt.
M902010280O05
Thoroughly clean and inspect all parts of

the crown and skirt. If coke deposits are
found in the cooling spaces of the piston crown, the coke deposits should be
washed out with Carbon Remover or a similar cleaning uid. When all coke deposits
have been dissolved, clean and inspect the
piston crown again.
7.
Note!
Coke deposits reduce the heat transfer
from the piston crown to the cooling
oil. The deposits must be removed as a
routine procedure when a piston is overhauled.
M902010280O06
D0205
If the piston crown is renewed, remove the

piston crown studs using a stud setter.
D0204
7.
Piston crown assembly:

Mount the piston crown studs in a new
or overhauled piston crown, lubricate the
threads on the studs with molybdenum disulphide (MoS2).
Tighten the studs to the specied torque
using a stud setter, see Data D0204.
Mount a new Oring on the piston skirt,
check that the surfaces of the Oring
groove is clean and smooth, coat the ring
with lubricating oil before mounting.
Mount the piston skirt on the piston crown.
Tighten the screws to the specied torque,
see Data D0205. Lock the screws with
locking wire. See Procedure 9137.
Page 14 (23)
Piston
MAN B&W Diesel
902-1.3
Overhaul
8. Piston crown and skirt mounting:

Lubricate the Oring on the piston rod
ange with lubricating oil.
8.
4
6
5
Land the overhauled piston crown and skirt

on the piston rod.
1
3
Mount and tighten the hydraulic nuts on

the piston crown studs.
5
4
3 1
1 3
5
2
2
3
1
4
5
When tightening the hydraulic nuts follow

the tightening sequence. All the nuts must
be tightened twice to full tightening pressure, see Data.
Sealing ring and pressure test
9. Sealing ring test:

Mount the pressuretesting tool on the
piston rod foot. Connect compressed air
to the testing tool and ll the piston to 45
bar. Close the valve on the testing tool and
remove the air connection. The piston must
now hold the pressure for minimum 30
minutes.
D1301
M902010280O07
According to current class rules, the piston

must be pressure tested hydraulically. It is
possible to carry out a test of the sealing
rings with compressed air before lling the
piston with oil. The sealing ring test can
also be carried out when the piston is resting in the support tool.
9.
Spray a little soap water on to the surface

joints between piston rod/crown/skirt and
around the hydraulic nuts to detect leaks.
M902010277O16
Dry off all soap water.
Page 15 (23)
Piston
902-1.3
Overhaul
10. Pressure test:

For this test, the piston must be turned
upside down (see next step to turn a complete piston).
10.
D0201
M902010277O17
oil
Page 16 (23)
MAN B&W Diesel
Fill the piston and piston rod with lubricating oil. Mount the pressuretesting tool
on the piston rod foot. Pressuretest the
piston at the pressure stated on the Data
Sheet. Check the contact surfaces of the
piston and the sealing rings for tightness.
Check that there are no cracks in the piston crown.
Turn the piston upside up and drain out the
piston oil.
Piston
MAN B&W Diesel
902-1.3
Overhaul
11. Piston turning:

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

land it on a wooden block in such a way
that it is possible to remove the lifting tool.
Mount an eyebolt in the side of the lifting
tool, hook on the crane and remove the lifting tool from the piston crown.
Attach the lifting bracket to the bottom of
the piston rod foot. Hook the crane on to
the lifting bracket. Lift the piston rod foot
clear of the wooden block. Keep lifting until
the piston rod is in a vertical position.
Note!
M902010280O10
During the lift, follow with the crane

to keep the crane positioned vertically
above the lifting point. The stufng box
must be removed.
Page 17 (23)
Piston
902-1.3
Overhaul
12. Piston completion:

Fit the new piston rings (alternately
righthand and lefthand cuts, with the ring
gaps staggered 180 and with the TOP
mark upwards), using the ring expander.
12.
A
TOP
B
A
MAN B&W Diesel
When mounting the piston rings, use the

ring expanders to prevent unintended deformation of the rings.
Do not expand the rings more than necessary. The uppermost ring (CPRring) must
be mounted with the short ring expander.
Mount the piston rod stufng box.

M902010280O11
Page 18 (23)
Piston
MAN B&W Diesel
Mounting
Preparation of piston
1.
902-1.4
1.
Check the piston rings and piston crown in

accordance with Procedure 9021.1, if not
already done.
Mount the lifting tool on the piston crown.
See Data D0225.
2. Stufng box position:

Ensure that the stufng box is correctly positioned over the distance pieces mounted
on the piston rod foot. Both the holes for
the ange and the drain hole for the drain
pipe must be positioned correctly.
M902010280M01
D0225
M902010277M02
2.
Page 19 (23)
Piston
902-1.4
Mounting
MAN B&W Diesel
Preparation of cylinder liner
3.
3. Mount the guide ring:

Mount the guide ring in the top of the cylinder liner. The cut outs for the lifting tool
must be turned to foreaft position.
4. Stufng box cover:
Remove the cover from the piston rod
stufng box opening in the bottom of the
cylinder unit.
M902010280M03
Clean the stufng box ange.

5. Crosshead position:
Turn the crosshead to a position 45 from
TDC (crank web pointing towards exhaust
side).
M902010277M05
4.
M902010277M06
5.
Page 20 (23)
45
Piston
MAN B&W Diesel
902-1.4
Mounting
Mounting of piston
6.
D0220
6. Coat the Orings of the stufng box and

the piston rod with oil. Coat the piston
rings and cylinder liner with cylinder lubricating oil.
7.
Protective cover:
Remove the protective rubber cover from
the crosshead.
8. Crosshead alignment:
Turn the crosshead almost to TDC.
If necessary, mount the hydraulic nuts on
the studs and screw down until the nuts
are ush with the top of the studs.
M902010280M06
Lower the piston into the cylinder liner

while guiding the piston rod foot through
the cutout in the stufng box ange until
the piston rings are inside the liner.
7.
Lower the crosshead just enough to enable

removal of the nuts. Turn the crosshead
upwards until the piston rod lands on the
crosshead. When mounting the piston on
the crosshead, make sure that the piston
rod foot does not damage the threads of
the studs. Ensure that the guide ring in the
crosshead ts correctly in the centre hole
of the piston rod.
M902010277D10
Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby
turning the crosshead until the face is parallel to the piston rod foot.
8.
M902010280M08
Unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings.
Page 21 (23)
902-1.4
Piston
Mounting
MAN B&W Diesel
9. Stufng box:
Turn down and land the stufng box on the
stufng box ange. Check that the holes in
the stufng box and stufng box ange are
correctly centered.
9.
Tighten the piston rod stufng box by means

of the screws through the inner holes in the
stufng box ange. For Data, see Procedure
9022.
M902010280M09
On engine models where the drain pipe is

connected directly to the stufng box:
10.
Mount the stufng box drain pipe.

Remove the distance pieces from the piston
rod foot.
D1301
10. Tightening of the piston rodcrosshead

connection:
Mount and tighten the piston rod nuts with
the hydraulic jacks. See Data.
See Procedure 9131.
11. Telescopic pipe:
Place the distance pipe on the bend for the
telescopic pipe.
M902010280M10
Turn up towards TDC until the telescopic

pipe is landed on the distance pipe.
Remove the suspending tool and mount the
screws and tighten the telescopic pipe to the
bend.
For Data, see Procedure 9042.
M902010280M11
11.
Page 22 (23)
Piston
MAN B&W Diesel
902-1.4
Mounting
12. Piston cleaning ring:

Mount the piston cleaning ring in accordance with the scratch mark. If the PCring
is damaged (broken or cracked), it must be
replaced by another ring.
See Procedure 9031.
12.
Mount the cylinder cover studs with the

stud setter. Screw the stud down to contact and half a revolution back.
14. Cylinder cover:
Land the cylinder cover on the liner and
check the distance that the stud is protruding from the cylinder cover. If necessary,
adjust the distance D0105 by turning the
stud.
M902010277M14
13. Cylinder cover studs:

If the cylinder cover studs have been removed, remount them. Carefully clean the
surfaces around the base of the studs and
check the Orings on the studs.
13.
15. Runningin:
Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple
of revolutions.
At the rst opportunity, start the engine
and keep it running for about 15 minutes
at a speed corresponding to Dead Slow
Ahead.
M902010277M15
Tighten the cylinder cover nuts and mount

the necessary pipes.
14.
Then stop the engine and inspect the piston rod and stufng box.
M902010280M14
D0105
Page 23 (23)

MAN B&W Diesel
102-2
Data

Stopped engine
X
X
X
X
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D02-26
Stuffing box flange, outer screws tightening torque
180
Nm
D02-27
Stuffing box flange, inner screws tightening torque
200
Nm
D02-28
Stuffing box halves, tightening torque
80
Nm
D02-29
Uppermost rings, ring-end clearance
4x6
mm
D02-30
Lowermost rings, ring-end clearance
3x3
mm
D02-34
Sealing ring springs new, free length
831
mm
D02-38
Scraper ring springs new, free length
782
mm
D02-44
Stuffing box complete
190
kg
D02-45
Stuffing box half
65
kg
D02-50
Stuffing box halves fitted bolts, tightening torque
80
Nm
Page 1 (2)
102-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90251
109
Mounting tool for stuffing box spring
P90251
122
Worktable for stuffing box
P90451
120
Page 2 (2)

MAN B&W Diesel
902-2.1
Checking
1. After the piston rod stuffing box has been

dismantled, check the following clearances:
See Procedure 902-2.2.
1.
Uppermost scraper ring and sealing rings

Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D02-29)
D0229
B
Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends.
Total clearance. (D02-30)
D0230
A
As a general guide, it is recommended

depending on the overhauling intervals and
ones own experience to replace sealing
rings and scraper rings when the specified
clearance values D02-29 and D02-30 have
been halved.
2. Garter springs:
M902020230C01
The ring clearances stated in Data apply to

new rings.
D0229
2.
D0230
D0234
Generally, it is recommended to renew the

springs when the sealing rings and scraper
rings are renewed.
The springs can be checked as follows:
Place the springs on the table, measure Lo
(free length), and compare with Data. If a
spring is extended more than 8% from the
value given in data, it must be discarded.
M902020227C02
D0238
Page 1 (10)
902-2.2

Dismantling
1.
MAN B&W Diesel
In connection with dismantling of the piston,

only the innermost screws in the stuffing box
flange and the screws for the drain oil pipe
should be removed.
If, in the period between piston overhauls, it
becomes necessary to inspect the piston rod
stuffing box, proceed as follows:
M902020231D01
1. Turn the crosshead to about 90 from TDC.
2.
Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
2. Remove the drain oil pipe and all innermost
screws and all outer screws except for two
screws placed diametrically opposite in the
stuffing box flange, longitudinally to the engine.
M902020231D02
3. Mount the worktable around the piston rod

so that the two remaining screws in the
stuffing box flange can be loosened
through the holes.
M902020230D03
3.
Page 2 (10)

MAN B&W Diesel
902-2.2
Dismantling
4. Remove the two long dismantling screws

from the worktable.
4.
Mount them in the stuffing box through the

holes in the worktable.
Remove the remaining two screws from the
stuffing box.
6. Remove the two long dismantling screws

from the stuffing box and mount them in
the worktable.
5.
M902020229D05
By means of the four short screws in the

worktable, press the stuffing box out of the
flange.
For overhauling the stuffing box, see Procedure 902-2.3.
M902020230D04
5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame
bottom.
M902020230D05
6.
Page 3 (10)
902-2.3

Overhaul
MAN B&W Diesel
Normally, overhaul of the piston rod stuffing

box is carried out by routine methods in connection with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a
support placed over one of the cut-outs in the
top platform.
Work on the stuffing box is then carried out
from the platform below.
M902020230O04
Overhaul inside the engine is carried out in the

same way as outside the engine.
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, and mount the worktable round the
piston rod at a suitable working height.
1.
Land the stuffing box on the worktable,

and remove the tackles and eye bolts.
M902020230O01
D0244
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.
Remove the nuts from the stuffing box assembling bolts.
M902020230O02
2.
Page 4 (10)

MAN B&W Diesel
902-2.3
Overhaul
3. Take out the six bolts, and pull away one

stuffing box half.
3.
Mount two eye bolts on the stuffing box

half and remove it from the worktable.
D0245
4. Using a feeler gauge, measure the vertical

clearance of the rings.
6. Measure the clearance between the ring

segments to determine whether replacement is necessary.
Dismantle and stack the rings in the same
order as when fitted in the stuffing box.
M902020230O03
5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.
7.
D0234
Carefully clean all the ring segments.

Inspect and assess the surface quality of
the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D0238
8. 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 carefully with a fine grained carborundum
stone. In the case of coarse scratches, it
may prove necessary to machine-grind the
surface in a workshop.
M902020227C02
7. Check the lengths of the springs.

8.
M902020230O08
9. Clean the halves of the stuffing box housing.
Page 5 (10)
902-2.3
Overhaul
10.
A
B
C
MAN B&W Diesel
10. Lubricate the piston rod (in the area where

all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS2).
For correct mounting of the sealing and
scraper rings see the sketch. The scraper
ring in groove no. 4 must be without relief
grooves on the underside.
Scraper
ring
A
Scraper
ring
B
Sealing
ring
M902020230O10
No relief
groove
Page 6 (10)
Relief
groove

MAN B&W Diesel
902-2.3
Overhaul
11. Assemble all the stuffing box ring units

round the piston rod, on the worktable, in
the following way:
11.
Place the lowermost scraper ring segments on the worktable.

Place the spring round the segments,
and hook the spring ends together.
On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).
Assemble the 8-part sealing ring so that
the two guide pins face upwards, place the
spring round the segments and, hook the
spring ends together.
M902020229O11
Repeat this procedure for the remaining

scraper rings.
12.
Assemble the 4-part sealing ring above the

8-part sealing ring. Push the two rings together in such a manner that the guide
pins in the lower sealing ring engage with
the two holes in the upper sealing ring.
12. 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. Subsequently, push the stuffing box half into contact with the piston rod, round the ring
units.
M902020230O12
Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
Note!
If the stuffing box is assembled inside
the engine, place two pieces of plywood
of the same thickness as the flange on
the worktable, to ease the assembling.
Page 7 (10)
902-2.3

Overhaul
MAN B&W Diesel
13. Check the ring clearance again.
13.
Then place the other half of the stuffing

box housing on the worktable, pushing it
into place round the rings.
D0228
In the middle holes mount and tighten up

the fitted bolts to the torque specified on
the Data Sheet, See Data D02-50
D0250
14. Mount eye bolts and wire ropes, and lift

the stuffing box a little.
M902020230O13
14.
Mount the O-ring in the stuffing box

groove.
Remove the worktable and lower the stuffing box until it rests against the distance
pieces on the piston rod foot.
D0244
Remove wire ropes and screws.
M902020230O14
Mount and tighten the standard bolts to

specified torque, See Data D02-28
Page 8 (10)

MAN B&W Diesel
902-2.4
Mounting
1. In connection with mounting of the piston,

only the innermost flange screws are to be
mounted and tightened, see data.
1.
After overhauling the stuffing box inside the

engine, assemble the stuffing box halves
on top of the four screws.
Turn down the short screws so that the

stuffing box lands on the flange.
2. Turn the piston upwards until the stuffing
box is in place in the cylinder frame.
M902020230M01
Mount the two long screws from the worktable in the stuffing box.
Note!
Make sure that the two guide pins in the
flange enter the guide holes in the bottom of the cylinder frame.
2.
M902020230M02
3. Mount two screws in the flange through the

holes in the worktable.
M902020230M03
3.
Page 9 (10)
902-2.4

Mountingl
MAN B&W Diesel
4. Remove the long screws from the stuffing

box and mount them in the worktable.
4.
Remove the worktable from the piston rod.

5. Mount the drain oil pipe.
Mount and tighten all the inner and outer
screws for the stuffing box. See Data.
M902020230M04
6. Remove the protecting rubber cover from

the piston rod/crosshead.
Smear the piston rod with molybdenum
disulphide.
Then turn the crankshaft a couple of revolutions.
5.
If possible: Start up the engine and keep it

running for about fifteen minutes at a number of revolutions corresponding to very
slow or idle speed.
M902020231O05
Then stop the engine and inspect the piston rod and stuffing box.
D0226
D0227
M902020231O06
6.
Page 10 (10)
Piston and Piston Rod Panel
MAN B&W Diesel A/S
Plate
P90251-0258
Page 1 (2)
Plate
P90251-0258
Item
No.
014
026
040
063
075
087
099
109
110
122
134
160
Page 2 (2)
Piston and Piston Rod Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Lifting tool for piston rod
Lifting tool for cylinder liner
Template for piston top
Distance piece for stuffing box
Cover for stuffing box hole
Hook for mounting of spring
Pressure tester
Worktable
Piston ring expander
Dismantling screw
MAN B&W Diesel A/S
Piston and Piston Rod - T

ools
Tools
MAN B&W Diesel
Plate
P90261-0102
Page 1 (2)
Plate
P90261-0102
Item
No.
019
Page 2 (2)
Piston and Piston Rod - T

ools
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Guide ring for piston
Piston and Piston Rod - Extra Tools
Plate
P90264-0006

0006
P90264
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90264-0006
Item
No.
015
027
039
Item Description
Item
No.
Item Description
Collar ring for piston

Support for tilting tool
Support for tilting tool
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90265-0001
Page 1 (2)
Plate
P90265-0001
Item
No.
010
Page 2 (2)
Item Description
Item
No.
Item Description
Support iron for piston
MAN B&W Diesel A/S
Plate
P90266-0001

0001
P90266
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90266-0001
Item
No.
016
Item Description
Item
No.
Item Description
Lifting tool for piston
Page 2 (2)
MAN B&W Diesel A/S

103-01
903-01
103-02
903-02
90361
90362
90364
90366
0075
0259
0028
0256
0083
0005
0004
0003
Cylinder Liner, Data

Cylinder Liner
Cylinder Lubricator, Data
Cylinder Lubricator
Cylinder Liner - Tools
Cylinder Liner - Milling Tools
Test Equipment for Lubricators
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Liner
MAN B&W Diesel
103-1
Data

Stopped engine
X
X
X
X
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D03-02
Lifting tool bolts, screwing-in torque
200
Nm
D03-03
Cylinder diameter, new
800
mm
D03-04
Piston cleaning ring diameter, new
798.3
mm
D03-16
Piston cleaning ring radial width, new
15.8
mm
D03-17
PC-ring/Liner max. wear deviation
0.8
mm
D03-05
Cylinder liner, complete
D03-06
Cooling jacket
D03-18
PC-rings replacement criteria:
4700
kg
130
kg
Liner diameter: 800 mm

Liner wear:
Install:
Standard PC-ring
(new or max. diameter wear of 0.80 mm
0.80 mm
0.80
1.6 mm
Oversize PC-ring
>
1.6 mm
No PC-ring
Page 1 (2)
Cylinder Liner
103-1
MAN B&W Diesel
Data
Plate
P90251
Item No.
051
Description
Lifting tool for cylinder liner
P90361
Measuring tool for cylinder liner
P90366
Page 2 (2)
Cylinder Liner
MAN B&W Diesel
903-1.1
Checking
1. Dismount the cylinder cover, the piston

cleaning ring and the piston.
See Procedures 901-1.2 and 902-1.2.
1.
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.
D0303
Take measurements in the fore-and-aft and

athwartship directions.
3. Carefully scratch over any scores or marks

and grind away the wear ridges.
4. Check the lubricating points of the cylinder
by pumping cylinder oil to each lubricating
point with the cylinder lubricator.
Clean any blocked lubricating duct.
M903010259C02
Check and assess the condition of the cylinder liner according to the description
given in Volume I, Chapter 707.
2.
M903010259C04
Mount the piston and cylinder cover.

See Procedures 902-1.4 and 901-1.4.
Page 1 (11)
Cylinder Liner
903-1.1
Checking
MAN B&W Diesel
5. Piston cleaning (PC) ring:
5.
The PC-ring is to be regarded as an integrated part of the liner and it is intended to

follow the service life of the liner.
M903010259C06
During inspection of the piston and the

liner, the PC-ring must also be inspected.
6. Measure the PC-ring radial width B, and

find the most worn place. Compare with
Data D03-16 and calculate the wear of the
PC-ring, multiply the wear by 2 to get the
PC-ring diameter wear.
Measure the liner in the fore-aft and
athwart-ship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner-measuring tool. Compare
the measurements with the diameter of a
new liner as stated in Data. Calculate the
wear of the liner.
7. Compare the PC-ring diameter wear with
the wear of the liner. If wear of the two
components does not deviate more than
D03-17 then reinstall the PC-ring.
If deviation between PC-ring wear and liner
wear is more than D03-17 or if the PC-ring
is broken or cracked, replace the ring with
a new PC-ring, an oversize ring or no ring
according to Table D03-18 on the Data
sheet.
If it is necessary to install an oversize PCring, contact MAN B&W Diesel for advice.
When a new liner is installed, also a new
PC-ring must be installed. When a new
liner is ordered, also a new PC-ring must
be ordered.
Page 2 (11)
Cylinder Liner
MAN B&W Diesel
903-1.2
Dismantling
1. Dismount the cylinder cover.

1.
Discard the sealing ring from the top of the

cylinder liner.
Turn the piston down far enough to make it
possible to remove the wear ridges at the
top of the liner.
Dismount the piston cleaning ring and the
piston.
3. Disconnect the oil pipes leading from the

cylinder lubricator to the cylinder liner.
M903010259D02
2. Screw the two lifting tools on to the cylinder liner. Check with a feeler gauge that
there is no clearance between lifting tool
and cylinder liner. For tightening torque,
see Data.
M903010259D03
3.
Page 3 (11)
903-1.2
Cylinder Liner
Dismantling
MAN B&W Diesel
4. Dismount the four cooling water pipes

between the cooling jacket and cylinder
cover and discard the O-rings from the
pipes and clean them carefully.
4.
Attach the crane to the lifting crossbar.
D0305
Hook the lifting tools on to the crossbar on

both sides of the cylinder liner.
Lift the liner with the cooling jacket out of
the cylinder frame.
Note!
M903010259D04
Low lifting height in the engine room

may require the removal of one or more
cylinder cover studs before dismantling
the cylinder liner.
6.
Land the cylinder liner vertically on, for instance, a couple of planks.
Remove the cooling water pipes and discard the O-rings.
5. Clean the cylinder frame internally, taking
special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
M903010259D06
6. The lifting tools are also used for transporting the cylinder liner.
Page 4 (11)
Cylinder Liner
MAN B&W Diesel
903-1.3
Overhaul
1. Unscrew the non-return valves from the

cylinder liner.
1.
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.
Loosen the screws on the clamps which fix

the cooling jacket to the cylinder liner. Turn
the clamps away from the liner.
M903010259O01
Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
M903010259O02
2.
D0306
Page 5 (11)
903-1.3
Cylinder Liner
Overhaul
3.
MAN B&W Diesel
3. Lower the cooling jacket by means of the

tackles and the crane, and land it on the
wooden planks.
Check that the cooling jacket does not tilt
when it is lowered.
4. Mount the lifting tools in the cylinder liner.
Lift the cylinder liner away from the cooling
jacket.
M903010259O03
Clean the cooling jacket internally.
M903010259O04
4.
Page 6 (11)
Cylinder Liner
903-1.3
Overhaul
MAN B&W Diesel
5. Check and assess the condition of the cylinder liner according to the description
given in Volume I, Chapter 707.
5.
Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
6. It is recommended to use a wear ridge

milling machine to create the groove. For
use of the milling machine, see suppliers
instruction.
C
M903010259O05
Check in the top of the liner for a wear

ridge (where the piston rings reverse direction). If there is any sign of a wear ridge, it
is necessary to create a groove by
grinding.The groove serves to prevent the
build-up of a new wear ridge.
A B
6.
7. Alternatively, place an old piston ring on

the top of the piston and turn to a position
that enables the grinding disc to rest on
the old piston ring while removing the wear
ridge. Use a grinding disc with a round
edge.
The maximum depth of the groove is calculated as Smax = D x 0.0045.

Note!
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.
M903010259O06
Check the distance C before grinding to

ascertain that the wear ridge was caused
by the top ring at TDC.
7.
R=45 mm
M903010259O07
Page 7 (11)
903-1.3
Cylinder Liner
Overhaul
MAN B&W Diesel
8. If necessary, mount a new cylinder liner.

8.
Note!
If a new cylinder liner is mounted, a new
piston cleaning ring must also be
mounted after mounting the piston.
Apply a thin layer of grease on the contact
surface for the cooling jacket on the liner.
Mount the lifting tools on the liner. Lift the
liner a little and mount new O-rings for the
cooling jacket. Then place the liner in the
cooling jacket.
Remove the lifting tools.
M903010259O08
9. Lift the cooling jacket into position marking scratches jacket/cylinder liner must coincide (camshaft side).
M903010259O09
9.
Page 8 (11)
Cylinder Liner
MAN B&W Diesel
903-1.3
Overhaul
10. Turn the clamps until they fit in the groove

of the liner, and tighten the screws.
10.
Remove the tackles and the eye bolts from

the cooling jacket.
M903010259O10
11. Mount the non-return valves for cylinder lubrication.
M903010259O11
11.
Page 9 (11)
Cylinder Liner
903-1.4
Mounting
MAN B&W Diesel
1. Loosen the water connections on the cooling jacket.
1.
Mount the lifting tools on the cylinder liner

and tighten to specified torque. See Data.
D0302
D0305
Hook the chains from the lifting crossbar

on to the lifting tools, and lift the jacket/
liner assembly.
M903010259M01
Mount the lowermost O-rings and apply a

little lubricating oil on the rings.
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.
2.
Mount the cylinder liner in the cylinder
frame. Replace the O-rings on the water
connections and mount the water connections on the cooling jacket.
M903010259M02
Remove the cylinder liner lifting tools.

3. If one or more cylinder cover studs have
been removed during the dismantling of the
cylinder liner, discard the old O-rings and
mount new ones on the cylinder cover
studs.
Mount the studs in the cylinder frame, using the stud setter.
M903010259M03
3.
Page 10 (11)
Cylinder Liner
903-1.4
Mounting
MAN B&W Diesel
4. Screw the pipes from the lubricator on to

the non-return valves, but do not tighten.
4.
When this is in order, tighten the pipes

firmly on the non-return valves and again
pump manually until it is certain that each
individual lubricating point functions correctly.
5. Lubricate the inside of the cylinder liner
with cylinder lubricating oil and mount the
piston. See Procedure 902-1.4.
6. Mount the piston cleaning ring, the sealing
ring and land the cylinder cover on the
liner. See Procedure 901-1.4.
M903010259M04
Vent the cylinder lubricating system by

manually pumping each individual pipe
through until oil, without air bubbles,
comes out from the union pipe/non-return
valve.
6.
Note!
Make sure to mount the piston cleaning
ring correctly, so that the scratch marks
are aligned.
M903010259M06
Tighten the upper water connections on

the cooling jacket as soon as the cylinder
cover is correctly positioned.
Page 11 (11)
103-2
Cylinder Lubricators
Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D03-10
Inlet accumulator, nitrogen pressure,
30
bar
D03-11
Outlet accumulator, nitrogen pressure,
1.5
bar
D03-13
Plug screw, tightening torque,
30
Nm
MAN B&W Diesel A/S
Page 1 (2)
103-2
Data
Plate
P90364
Page 2 (2)
Item No.
Description
Test Equipment for Lubricators
MAN B&W Diesel A/S
MAN B&W Diesel
903-2.1
Checking
Check of Oil Injection:
1.
With stopped engine and normally when the

system has been disassembled:
1. Press the ESC + PRELUB.-button on the
HMI control panel, and check that all lubricators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.
2. If the cylinder cover or the exhaust valve is
removed, check inside the liner that all lubricating points are working properly.
Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
source that all lubrication points are working properly.
With running engine:
3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator.
M903020245C01
Otherwise, remove the covers for scavenge

port inspection.
3.
The LEDs give signal when oil is injected.
Check the pressure shocks from the injection of the lubricators on each lubricator
pipe by feeling with a hand.
M903020245C02
If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow.
Page 1 (13)
903-2.1
Checking
MAN B&W Diesel
Check of Accumulators:
4.
D0311
4. Check of Inlet Accumulator

Checking the inlet accumulator can be
done with running engine.
Close the valve that connects the accumulator to the distributor block.
Mount the special hose on the minimess
coupling and drain all oil out of the accumulator.
M903020256C04
Check the nitrogen pressure.

For use of pressure setting tool, see Step
6. For correct pressure, see Data.
5. Check of Outlet Accumulator
The outlet accumulators are to be dismounted while the nitrogen pressure is
checked.
5.
Dismount the outlet accumulator.

M903020256C05
Check the nitrogen pressure, using the

pressure setting tool.
D0311
M903020245C05
6.
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
shown in the Figure, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor.
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7
litre) is checked, and a 0-10 bar pressure
gauge when the outlet accumulators (0.16
litre) are checked.
Page 2 (13)
MAN B&W Diesel
903-2.1
Checking
7. Before mounting the filling valve on the accumulator, check that the accumulator top
is clean.
Mount the filling valve on the relevant accumulator with the union nut. Check that
valves C and F are closed.
7.
D0313
Loosen the plug screw in the accumulator

using a square drive handle in socket E.
8. If the accumulator needs to be refilled with

nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in
Data.
B
M903020247C07
It is now possible to read the actual nitrogen pressure in the accumulator on the dial
gauge on the filling valve.
Open valve C until the accumulator is filled

to the correct pressure.
Close valve C and tighten the plug screw
with socket E to the torque stated in Data.
Release the pressure in the filling valve at
bleed screw F.
Unscrew the filling valve from the accumulator. Retighten the plug screw to the
torque stated in Data. Remount the accumulator.
Page 3 (13)
903-2.2
Dismantling
MAN B&W Diesel
Dismantling of lubricators:
1.
Both lubricators can be dismounted with running engine, one at a time. If the engine is running when a lubricator is dismounted, it is important to check that the other lubricator is
doubling injection frequency.
M903020256D01
1. Close the supply valve for the lubricator

concerned, using the special tool. The lowermost valve is for lubricator marked A and
the uppermost valve is for lubricator
marked B.
2.
Let the lubricator inject oil until the feedback LED stops flashing. Disconnect the
electrical plug on the topside of the lubricator.
2. Unscrew the screws in the pipe flange of
the lubricator and disconnect the cover
with pertaining pipes.
M903020256D02
3. Unscrew the four screws from the top that

secure the lubricator to the hydraulic block,
and remove the lubricator.
Page 4 (13)
MAN B&W Diesel
903-2.2
Dismantling
Dismantling of accumulators:
4.
4. Inlet Accumulator
Close the valve that connects the accumulator to the distributor block.
Mount the special hose on the minimess
coupling and drain the oil out of the accumulator.
Unscrew the accumulator. If the engine is
running, a new or checked accumulator
should be mounted at once.
Close the supply valve for the accumulator

concerned, using the special tool. The
outer valve is for accumulator marked A
and the inner valve is for accumulator
marked B.
M903020256D04
5. Outlet Accumulator
5.
Let the lubricator inject oil until the feedback LED stops flashing.
M903020256D05
If space conditions permit, unscrew the accumulator; otherwise the lubricator must be
dismounted, see Step 1.
Page 5 (13)
903-2.3
Overhaul
1.
MAN B&W Diesel
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.
M903020247O01
3. Pull up the cylinder block.

Remove the spring and actuator piston
with plungers.
Remove and discard the O-ring from the
cylinder block.
2.
M903020247O02
Remove the cover for the non-return

valves. Take out springs and balls. Remove
and discard the O-rings.
M903020247O03
3.
Page 6 (13)
MAN B&W Diesel
903-2.3
Overhaul
4. Screw out the non-return valves and remove and discard the O-rings.
4.
Clean the valves and check them with

compressed air.
5. Inspect the plungers, actuator piston and
cylinder block for wear, using a magnifying
glass.
Mount the non-return valves in the cylinder

block.
M903020247O04
6. Fit the non-return valve with new O-rings.
M903020247O05
5.
M903020247O06
6.
Page 7 (13)
903-2.3
Overhaul
7.
MAN B&W Diesel
7. Pre-assemble the cylinder blockwith the

actuator piston and plungers to ensure the
correct guidance of the plungers, before finally assembling the cylinder block unit.
Mount the spring and press down the actuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
Fit the cylinder block with a new O-ring.
8. Remove the cover from the terminal box
and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box and the plug for
the solenoid valve.
M903020247O07
Carefully unscrew the feedback sensor and

remove and discard the O-ring.
Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.
M903020247O08
8.
Page 8 (13)
MAN B&W Diesel
9
903-2.3
Overhaul
Turn the lubricator upside down in the vice.
9.
Unscrew the solenoid valve.

Discard the O-rings.
10. Solenoid valve:
Disassemble and clean the valve.
Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
the housing.
M903020247O09
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be replaced by a new one.
Assemble the valve.

10.
See also manufacturers instructions.
11. Before mounting the feedback sensor,
check that the sensor is flush with the sensor housing.
Check with an object with a straight edge

(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.
Mount the terminal box.
M903020244O12
Mount the feedback sensor or a new one,

if necessary, with a new O-ring.
M903020245O10
11.
1
2
3 BN (brown)
BK (black)
4
BU (blue)
5
1
2 Solenoid valve
Feedback sensor
Page 9 (13)
903-2.3
Overhaul
MAN B&W Diesel
12. Connect the wires and mount the cover on

the terminal box.
12.
LED
2
13. Mount the solenoid valve fitted with new

O-rings. Coat the O-rings with a little
grease to keep the rings in place during
mounting.
14. Mount the cylinder block assembly in the
cylinder housing.
Brown+15
Blue OV
M903020242O08
Black FBsignal
Check that the spring pin engages correctly with the cylinder block assembly.
Mount the screws and tighten the block to
the housing.
Remove the M6 x 60 screw with disc.
M903020247O13
13.
M903020247O14
14.
Page 10 (13)
MAN B&W Diesel
903-2.3
Overhaul
15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.
15.
Mount the oil accumulator.

16. 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.
M903020247O01
Cover all surfaces with a thin layer of oil.
16.
Page 11 (13)
903-2.4
Mounting
MAN B&W Diesel
Mounting of Lubricators
1.
1. 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 between the lubricator
and the pipe connection.
2. Open the supply valve and mount the electrical plug. Check the injection of the cylinder oil on the led on the terminal box for
the specific lubricator.
M903020256D02
For checking injection timing, see Procedure 905-8.1.
2.
M903020256M02
Page 12 (13)
MAN B&W Diesel
903-2.4
Mounting
Mounting of Accumulator
3.
3. Mount the accumulator. Remove the drain
hose from the minimess coupling. Open the
valve that connects the accumulator to the
distributor block.
M903020256M03
Check the oil injection.

Page 13 (13)
Cylinder Liner - T
ools
Tools
MAN B&W Diesel
Plate
P90361-0083
Page 1 (2)
Plate
P90361-0083
Item
No.
012
024
048
Page 2 (2)
Cylinder Liner - T
ools
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Measuring rod for cylinder liner, long

Measuring rod for cylinder liner, short
Measuring tool for cylinder liner
MAN B&W Diesel A/S
Plate
P90362-0005
Page 1 (2)
Plate
P90362-0005
Item
No.
Item Description
018
Wear ridge milling machine
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
Test Equipment for Lubricator
Plate
P90364-0004
Page 1 (2)

0004
P90364
MAN B&W Diesel A/S
Plate
P90364-0004
Item
No.
019
020
032
044
056
068
081
103
115
139
152
164
176
211
223
Item Description
Item
No.
Item Description
Tool box
Nameplate
Adaptor
Pressure gauge
Spanner
Pressure gauge
Adaptor
Hose with 2 union
Quick coupling, minimess
Reducing valve
Adaptor
Adaptor
Adaptor
Adaptor
Filling and testing valve
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90366-0003
Page 1 (2)
Plate
P90366-0003
Item
No.
021
Page 2 (2)
Item Description
Item
No.
Item Description
Cross bar for cylinder liner
MAN B&W Diesel A/S

104-01
904-01
104-02
904-02
104-03
904-03
104-04
904-04
104-05
904-05
90451
90462
0069
0253
0070
0252
0044
0215
0062
0233
0060
0237
0155
0018
Crosshead Bearing, Data

Crosshead Bearing
Crosshead, Data
Crosshead
Reciprocating Parts, Data
Reciprocating Parts
Crankpin Bearing, Data
Crankpin Bearing
Connecting Rod, Data
Connection Rod
Connecting Rod and Crosshead - Panel
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crosshead Bearing
MAN B&W Diesel
104-1
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-01
Crosshead bearing, top clearance max.
0,7
mm
D04-02
Crosshead bearing, top clearance min.
0,35
mm
D04-03
Oil wedge length, L
15
mm
D04-04
Crosshead bearing cap
D04-05
900
kg
Crosshead bearing shell, upper
94
kg
D04-06
Crosshead bearing shell, lower
120
kg
D04-07
Crosshead bearing cap with bearing shell
1000
kg
D04-16
Thrust piece, tightening torque
550
Nm
D04-58
Stuffing box, telescopic pipe, tightening torque
340
Nm
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crosshead Bearing
104-1
MAN B&W Diesel
Data
Plate
Item No.
P90451
47
Wire guide
P90451
59
Lifting attachment - connecting rod
P90451
60
Lifting tools - crosshead
P90451
72
Chain for suspending piston
P90451
84
Retaining tool telescope pipe
P90451
96
Bracket for support, Crosshead
P90451
106
P90451
118
P91351
010
P91351
046
P91351
058
P91351
117
P91366
058
Feeler gauge
Page 2 (2)
Description
Crosshead Bearing
MAN B&W Diesel
904-1.1
Checking
White metal bearings

1.
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing
components.
For the top clearance of a new bearing, see the
Data D-1.
2. Turn the crosshead concerned to BDC.

3. Measure the clearance in the crosshead
bearing by inserting a feeler gauge at the
top of the upper bearing shell.
4. The difference between the actual clearance measurements and the measurements
noted in the Adjustment Sheet at the shop
test/sea trial (or the clearance noted for a
new bearing installed later) must not exceed 0.1 mm. If the clearance is too large,
the crosshead must be disassambled for
inspection.
5. The wear limit for a crosshead bearing shell
is confined to a 50% reduction of the oil
wedge length L. This can only be checked
after the crosshead has been disassembled.
2.
D0401
D0402
M904010253C03
1. Open the crankcase door at the relevant

cylinder.
M904010253C02
For the top clearance of a specific bearing, see

the measurement in the Adjustment Sheet in
Volume I, OPERATION.
3.
If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by
a new one.
(Oil Wedge)
L
1/2
M904010253C05
6. For further external inspection of the crosshead bearing, see Chapter 708, Bearings
in the instruction book, Volume I, OPERATION.
D0403
L
Page 1 (8)
904-1.2
Crosshead Bearing
Dismantling
MAN B&W Diesel
This procedure applies to the following two dismantling situations:
1.
with piston mounted (steps 1-11)

with piston removed (steps 3-11)
With piston mounted:
M904010253D01
1. Turn the crosshead down far enough to

give access to the nuts on the piston rod,
the crosshead bearing cap, and the screws
on the telescopic pipe.
2. Mount the two chains for suspending the
piston in the inner screw holes at the top of
the crankcase, in the athwartship direction.
3. Mount two eyebolts in the two outer screw
holes in the top of the frame box in the
athwartship direction.
2.
Remove the thrust pieces for axial guidance of the connecting rod.
Mount the spacer rings and the hydraulic
jacks for loosening the crosshead bearing
cap nuts and the piston rod nuts.
Loosen the nuts.
M904010253D02
For operation of the hydraulic tools, see

Procedure 913.
Remove the hydraulic jacks, and unscrew
the nuts.
Caution!
3.
M904010253D03
Never suspend or remove the piston

without suspending the telescopic pipe.
Page 2 (8)
D1302
Crosshead Bearing
MAN B&W Diesel
904-1.2
Dismantling
4. Mount a lifting eye bolt on each side of the

piston rod foot.
4.
Mount a lifting eye bolt with an extension

screw on each side of the bearing cap.
5. Loosen and remove the screws which secure the telescopic pipe to the bend.
6. Turn the crosshead to TDC.

Hook the ends of the chains to the lifting
eye bolts on the piston rod.
Suspend the telescopic pipe, using the tool
stud.
M904010253D04
Remove one screw from the telescopic

stuffing box housing, and mount the special tool for suspending the telescopic pipe.
5.
Turn the crosshead downward, and the piston rod will remain suspended from the two
chains.
M904010253D05
When turning downwards, remove the distance tube from the bend.
M904010253D06
6.
Page 3 (8)
Crosshead Bearing
904-1.2
Dismantling
7.
MAN B&W Diesel
7. Turn down to BDC.
D0404
D0407
Suspend two tackles from the eyebolts, in

the athwarthship direction.
Hook the tackles on to the eye bolts in the
crosshead bearing cap and raise the cap.
Check the upper bearing shell and the upper part of the journal.
M904010253D07
Mount the wire guide in the top of the door

opening.
8.
If desired, mount a third tackle outside the

engine and lift the bearing cap out of the
engine.
D0405
8. Place the bearing cap on one side on a

couple of wooden planks.
Check the bearing shell, see Procedure
904-1.1.
9. Mount lifting attachments on the head of
the connecting rod.
M904010253D08
Fasten pull lifts to the fixed lifting brackets

on the frame box wall and fix the connecting rod in the vertical position.
M904010253D09
9.
Page 4 (8)
Crosshead Bearing
904-1.2
Dismantling
MAN B&W Diesel
10. Mount the four supports for guide shoes

on the crosshead guides.
10.
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
is evenly distributed on the four supports.
11. Turn the crankthrow carefully towards BDC

while following with the tackles, thus continuously supporting the connecting rod.
M904010253D10
Haul the tackles tight.
Caution!
Take care not to scratch the crosshead
bearing journal or damage the threads of
the crosshead bearing studs.
11.
Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chapter
708, Bearings.
12. In cases where it is necessary to remove
the lower bearing shell, tilt the connecting
rod towards the doorway in the camshaft
side, using the tackles.
M904010253D11
With the crosshead resting on the supports, check the lower part of the crosshead journal and the bearing shell.
12.
Dismount the locking screws, and turn the
bearing shell so far up that an eye bolt can
be mounted.
D0406
M904010253D12
Lift the bearing shell out of the engine.
Page 5 (8)
Crosshead Bearing
904-1.4
Mounting
MAN B&W Diesel
With piston mounted/With piston removed:

1.
1. Mount and secure the bearing shell in the
bearing housing.
The excess height X is to ensure the correct tightening-down of the bearing shell
and must not be eliminated.
D0405
M904010253M01
Raise the connecting rod to an upright position.
2.
Lubricate the bearing shell and the journal

with plenty of lubricating oil.
x
2. Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.
Note!
Take care that the bearing studs do not
damage the crosshead.
3. Remove the supports from the crosshead

guides.
M904010253M02
Remove the tackles and the lifting attachments from the head of the connecting rod.
Turn the crankthrow to BDC.
M904010253M03
3.
Page 6 (8)
Crosshead Bearing
904-1.4
Mounting
MAN B&W Diesel
3. Lift the bearing cap back into the engine.
3.
Lubricate the crosshead bearing journal

with plenty of lubricating oil.
Lower the bearing cap onto the crosshead,
and remove the tackles.
Note!
It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.
M904010253M04
4. Mount the thrust pieces for axial guidance

of the connecting rod.
For tightening torque, see Data.
4.
With the piston mounted:
5. Use a rubber cover to cover the oil inlets/
outlets on top of the crosshead.
D0416
Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby
turning the crosshead until the face is parallel with the piston rod foot.
Lower the crosshead just enough to enable
removal of the nuts and the rubber cover.
If any shims have been removed from the
crosshead, mount them again.
M904010253M05
Mount all hydraulic nuts on the studs,

screw down until the nuts are flush wich
the top of the studs.
5.
Turn the crosshead upwards until the piston rod lands on the crosshead. When
mounting the piston on the crosshead,
make sure that the piston rod foot does
not damage the threads of the studs.
M904010253M06
Ensure that the guide ring in the crosshead

fits correctly in the centre hole of the piston
rod.
Page 7 (8)
Crosshead Bearing
904-1.4
Mounting
MAN B&W Diesel
6. Mount the distance pipe on the telescopic

pipe bend.
6.
Turn up the crosshead until the telescopic

pipe lands on the distance pipe.
Remove the chains and eye bolts from the
top of the frame box, from the piston rod
foot and from the crosshead bearing cap in
the athwartship direction.
M904010253M07
Remove the wire guide from the engine.

Remove the suspending tool stud and
mount the screws in the telescopic stuffing
box housing.
D0416
D0458
Mount the screws and tighten the telescopic pipe, see Data.
7.
7. Turn down to BDC and mount the hydraulic
nuts on the studs. For operation of the hydraulic jacks, see Procedure 913.
D1301
Tighten the nuts on the piston rod foot and

on the crosshead as stated in Data.
With the piston removed:
M904010253M08
8. Mount the piston. See Procedure 902-1.4.
Page 8 (8)
9. Turn down to BDC and tighten all four

crosshead bearing cap nuts simultaneously.
See Data.
For operation of the hydraulic jacks, see
Procedure 913.
Crosshead
MAN B&W Diesel
104-2
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-07
1000
D04-09
Inlet pipe, tightening torque
D04-10
Inlet pipe stud, screwing-in torque
450
Nm
D04-11
Guide strip nuts, tightening torque
400
Nm
D04-14
Crosshead/piston rod stud, screwing-in torque
150
Nm
D04-15
Telescopic pipe, tightening torque
340
Nm
D04-16
550
Nm
D04-17
Cooling oil outlet pipe, tightening angle
D04-18
Inlet pipe, tightening angle
D04-20
Clearance between thrust piece and crosshead
D04-21
Crosshead complete
D04-22
Guide shoe
D04-23
Cooling oil outlet pipe
D04-49
Connecting rod studs , screwing-in torque
D04-51
Connecting rod complete
D04-58
Stuffing box, telescopic pipe, tightening torque
D04-59
100/50
100/20
50
0.35-0.60
kg
Nm/
Nm/
mm
5000
kg
413
kg
30
kg
480
Nm
5650
kg
340
Nm
Telescopic pipe
57
kg
D04-59
Telescopic pipe
57
kg
D04-60
Inlet pipe
57
kg
D04-62
Crosshead without guide shoes
4200
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crosshead
104-2
MAN B&W Diesel
Data
Plate
Item No.
P90451
47
Wire guide
P90451
59
P90451
60
Lifting tools - crosshead
P90451
72
P90451
84
Retaining tool telescope pipe
P90451
96
P90451
106
P90451
118
P90451
131
Drawing tool - bell shaped
P90451
202
Extension (X-Head Cap / Piston Rod)
P91351
010
P91351
046
P91351
058
P91351
117
P91359
P91366
Page 2 (2)
Description
Torque Spanners
058
Feeler gauge
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
1. Dismount the main bearing lubricating oil

pipes.
2.
2. Turn the crosshead to BDC to give access

to the nuts on the crosshead bearing cap.
D1302
Mount the retaining tool for the telescopic

pipe on the stuffing box housing for the
telescopic pipe.
Mount the spacer rings and the hydraulic

jacks for loosening the crosshead bearing
cap nuts.
For operation of the hydraulic tools,
see Procedure 913-1.
M904020252D02
Mount two eye bolts in the athwartship direction, and suspend two tackles.
4.
Loosen the nuts, remove the hydraulic
jacks and unscrew the nuts.
4. Turn to BDC and mount connecting rod lifting tools. Use two tackles to retain the
connecting rod in an upright position.
Mount two eye bolts and extension screws
in the crosshead bearing cap and hook on
the tackles from the top of the crankcase.
M904020252D04
Suspend the telescopic pipe by means of

the tool. Suspend the piston. To suspend
the piston, see Procedure 904-1.
D0407
Lift the bearing cap out of the engine.

Remove the piston rod guide ring and the
shim from the crosshead.
Remove both thrust pieces on the crosshead bearing cap.
Page 1 (9)
Crosshead
904-2.2
Dismantling
MAN B&W Diesel
5. Dismount the four bearing cap studs, using

the stud setter.
5.
D0423
D0460
Dismount the guide pin for the oil inlet

bend using the special extractor.
Mount the eye bolt in one of the threaded
holes in the bend, hook on a tackle and
haul tight.
M904020252D05
Remove the outlet pipe, dismount the bend

for the telescopic pipe and remove the
studs from the crosshead.
6.
Mount the special lifting tool on the crosshead.

6. Attach tackle chains from the two tackles in
the athwartship direction to the wire ropes
on the lifting tool.
M904020252D06
Lift the crosshead free of the connecting

rod.
Page 2 (9)
Crosshead
904-2.2
Dismantling
MAN B&W Diesel
7. Use the tackles to tilt the connecting rod

to-wards the exhaust side, while turning
the crankthrow towards the camshaft side.
7.
D0451
Transfer the tackles from one lifting attachment to another, as necessary.
By alternate use of the tackles, tilt the connecting rod until it is out of the way.
8. Remove the oil pipes from the two adjacent main bearing caps.
9. Remove the guide strips and the stop
screws from the bottom of the guide
shoes.
M904020250D07
Stop turning when the crankthrow is in a

position where there is room in the adjacent cylinder units to pull the guide shoes
through the openings in the side walls just
above the main bearings.
9.
Mount lifting eye bolts in both guide

shoes.There has to be space in the adjacent cylinder units to pull the guide shoes
through the openings in the side walls just
above the main bearings.
It is recommended to tag the guide

strips and shims to avoid mixing them.
10. Lower the crosshead so that the guide

shoes are just below the cutout in the side
walls of the frame box.
M904020250D09
Note!
10.
Note!
M904020250D10
Make sure that the crosshead journal

does not touch the crank.
Page 3 (9)
904-2.2
Crosshead
Dismantling
11.
MAN B&W Diesel
11. Hook the tackles on to the eye bolts in the

guide shoes.
12. Mount two eye bolts in the holes for stop
screws in the guide shoes in the adjacent
cylinder units, and suspend two tackles
from the eye bolts.
M904020252D11
13. Haul the tackles for the guide shoes tight

and, at the same time, pull the guide shoes
sideways until they are free of the crosshead.
Take the guide shoes through the openings
in the side walls by means of the tackles in
the two adjacent cylinders. Lift the guide
shoes to provide space for turning the
crosshead.
M904020250D12
12.
M904020252D13
13.
Page 4 (9)
Crosshead
904-2.2
Dismantling
MAN B&W Diesel

14. Turn the crosshead 90.
14.
15. Mount a tackle outside the engine and, by

means of wire rope and tackle, remove the
crosshead from the engine.
Land and protect the crosshead outside
the engine.
Note!
Take care that the crosshead does not
bump into anything as this will damage
the sliding surfaces of the crosshead.
M904020252D14
Remove the guide shoes from the engine

and tag them.
M904020252D15
15.
D0462
Page 5 (9)
Crosshead
904-2.4
Mounting
MAN B&W Diesel
1. Clean the crosshead and mount the lifting

tool with shackle and wire ropes.
1.
Mount the wire guide tool in the framebox

door opening.
M904020252M01
Suspend two tackles from the top of the

framebox between the guides.
Suspend two tackles from the top lifting
brackets in the framebox and use them in
conjunction with a tackle mounted outside
the engine to carefully lift the crosshead
and ease it into the crankcase.
D0422
D0462
2. Turn the crosshead 90 to enable mounting

of the guide shoes. Check that the oil inlet
and outlet holes are pointing towards the
exhaust side.
2.
3. Attach two tackles to the eye bolts at the
bottom of the guide shoes in the adjacent
cylinders.
Using these tackles and a tackle outside
the engine, carefully lift the guide shoes
into the engine.
Note!
M904020252M02
When handling the crosshead, take great

care that its surfaces are not scratched
or damaged. If necessary, protect the
crosshead with a cloth.
M904020252M03
3.
Page 6 (9)
D0422
Crosshead
MAN B&W Diesel
904-2.4
Mounting
4. Lubricate the sliding surfaces of the guide

shoes and the crosshead with plenty of
clean lubricating oil, and push the guide
shoes into position through the openings in
the side walls.
4.
5. Use the tackles in the top of the framebox

to lift the crosshead into a working position
and mount the guide strips and shims on
the side of the guide shoes.
Remove the tackles and the eye bolts from

the guide shoes.
6. Lift the crosshead to a position above the
connecting rod in the upright position.
M904020252D13
Mount the stop screws in the bottom of the

guide shoes.
5.
Raise the connecting rod to the upright position.
Lubricate the crosshead bearing liberally
with clean lubricating oil and carefully lower
the crosshead into place.
7. Dismount the tackles and connecting rod

lifting tools from the connecting rod.
M904020252M05
Unhook the wire ropes from the crosshead

lifting tool.
D0411
D0421
M904020252M06
6.
Page 7 (9)
904-2.4
Crosshead
Mounting
8.
D0408
D0409
D0410
D0449
D0418
MAN B&W Diesel
8. Turn the connecting rod and crosshead to

BDC.
Remove the lifting tool from the crosshead.
Mount the studs for the cooling oil inlet
bend. Mount the bend and outlet pipe.
See Data.
M904020252M08
Mount the cylindrical dowel with threaded

hole in the bend, and mount the bearing
cap studs.
Mount the piston rod guide ring and the
shim on the crosshead.
9. Lift the crosshead bearing cap into the engine.
9.
D0407
D0416
D0420
Lubricate the crosshead journal with plenty

of clean lubricating oil.
Carefully land the bearing cap on the
crosshead.
Mount the hydraulic nuts.
Mount the thrust pieces on the bearing
cap.
Note!
It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.
M904020252M09
Tighten the screws to the torque stated in

Data.
Page 8 (9)
For correct tightening, see also Procedure

913-5.
Crosshead
904-2.4
Mounting
MAN B&W Diesel

10. Tighten the hydraulic nuts.
10.
For operation of hydraulic tools, see Procedure 913-1.

Remove the hydraulic tools and the eye
bolts from the engine.
Check the clearances between the guide
strips, guide shoes and crosshead guides.
See Procedure 904-3.
Mount the main bearing lubricating oil
pipes.
Mount the piston and the telescopic pipe.
At this point it is recommended to check

the crosshead bearing clearance.
11. Remove all tools from the engine.

Note!
M904020252M10
Note!
D0458
D0459
D1301
11.
M904020250M10
Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.
Page 9 (9)
Reciprocating Parts
MAN B&W Diesel
104-3
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
Acceptance criteria with piston in centre (F-A direction)

D04-25
PF+PA, N max.
0.85
mm
D04-26
PF+PA, O max.
1.35
mm
D04-28
E+G, H+F, N max.
0.60
mm
D04-29
E+G, H+F, N min.
0.20
mm
D04-30
E+G, H+F, O max.
0.90
mm
D04-34
J+X, L+Y, K+X, M+Y, N max.
1.20
mm
D04-35
J+X, L+Y, K+X, M+Y, N min.
0.60
mm
D04-36
J+X, L+Y, K+X, M+Y, O max.
1.40
mm
D04-39
QF/QA, O max.
0.80
mm
D04-41
ZF/ZA O min.
5.0
mm
D04-42
TF + TA
0.80
mm
Page 1 (2)
Reciprocating Parts
104-3
MAN B&W Diesel
Data
Plate
P91366
Page 2 (2)
Item No.
Description
Feeler gauge
Reciprocating Parts
904-3.1
Checking
Reciprocating Parts
S90MC-C
0215
Checking
904-3.1
1.
In order to achieve uniform measuring conditions on board, the ships trim must be as close
as possible to 0.
Bend each end approx. 250 mm up along

the framebox side. See T.
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
MA904-5.0 72 01
1. Mount a transparent plastic tube along the

length of the bedplate.
2.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Fore
Measurements are to be taken with a ruler.
Aft
2. Turn the crankshaft in ASTERN direction to

45 after BDC (the guide shoe must rest
against the crosshead guide).
Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction.
PA
PF
HN904-3.1 212 02
Check the centering of the piston in the cylinder liner by measuring the clearance (by
applying a long feeler gauge from the scavenge air space) between the piston skirt
and the cylinder liner in the Fore and Aft positions (PF-PA).
45
Ast
ern
3.
50
3. Turn in astern direction until the bottom of

the guide shoe is 50 mm in the vertical direction above the top of the cut out in the
web plate.
EXH
G 1-2
10
E 1-2
CAM
F 1-2
HN904-3.1 212 03
H 1-2
0$1% :'LHVHO$6
Page 1 (3)
Reciprocating Parts
904-3.1
Checking
4.
4. Measure the clearance between the crankthrow and the connecting rod.
5. Measure the clearance between the thrust
piece and the crosshead (TF and TA or QF
and QA.
Measure the clearance between the crosshead guides and the guide shoes (E, F, G
and H).
Measure the clearance between the guide
strips and crosshead guides (J, K, L and
M).
The clearance, calculated as J+X, K+Y,
L+Y and M+Y, is adjusted by the insertion
of shims so that it is symmetrical in relation
to the clearance between the piston skirt
and the cylinder liner.
MN904-3.1 215 04
Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.
BF and BA correspond to the thickness of
the shims and are only to be measured if an
adjustment is carried out.
5.
Exhaust Side
MN904-3.1 215 05
Camshaft Side
Page 2 (3)
0$1% :'LHVHO$6
Reciprocating Parts
904-3.1
Checking
6.
6. It is recommended that the measured results are noted down so that possible later
changes can be ascertained.
Cyl.
Piston/Liner
PF
PA
Shim
Thickness
Frame Box
BF
BA
E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+X
L+Y
K+X
MN904-3.1 215 06
M+Y
Crosshead
Connecting
Rod
Crankthrow
Connecting
Rod
0$1% :'LHVHO$6
QF/TF
QA/TA
ZF
ZA
Page 3 (3)
Crankpin Bearing
MAN B&W Diesel
104-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-43
Crankpin bearing clearance, max.
0.8
mm
D04-44
Crankpin bearing clearance, min.
0.4
mm
D04-45
Crankpin bearing cap complete
566
kg
D04-46
Crankpin bearing, upper shell
67
kg
D04-47
Crankpin bearing, lower shell
34
kg
D04-48
Crankpin bearing cap + shell + bearing studs
600
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crankpin Bearing
104-4
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
047
Wire guide
P90451
059
P90451
096
P90451
106
P90461
Connecting Rod - Hydraulic Tools
P90462
Lifting tool for crankshaft shell
P91351
10
Hydraulic pump, pneumatic operated
P91351
46
P91351
60
P91351
105
P91356

Lifting Tools, Etc.
P91366
58
Feeler gauge
P91366
61
Slide caliper
Page 2 (2)
Crankpin Bearing
MAN B&W Diesel
904-4.1
Checking
The bottom clearance between the journal and

a new bearing shell is the result of a summation of the production tolerances of the bearing
assembly components.
2.
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.
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.
4. The difference between the actual clearance 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.
M904040233C02
2. Turn the crank concerned to BDC.
3.
D0443
D0444
An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.
6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.
M904040233C03
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
5.
M904040233C04
D0446
Page 1 (8)
904-4.2
Crankpin Bearing
Dismantling
MAN B&W Diesel
1. Suspend two tackles from the lifting brackets, in the athwartship direction.
1.
Mount the wire guide in the top of the

crankcase door opening.
2. 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.
M904040233D01
Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Procedure 913-1.
2.
Remove the hydraulic jacks and the nuts.

3. Lower the bearing cap while seeing carefully 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.
M904040233D02
D1302
3.
M904040233D03
D0448
Page 2 (8)
Crankpin Bearing
MAN B&W Diesel
904-4.2
Dismantling
4. If the bearing shell needs to be replaced,

remove the whole bearing cap from the
crankcase.
4.
D0448
Suspend a tackle outside the engine above

the crankcase door opening.
Using the tackle from the frame box inside

wall, together with the tackle suspended
outside the engine, lift the bearing cap out
of the crankcase.
5. Place the bearing cap on one side on a
couple of planks.
Dismount the bearing shell lock screws and
replace the bearing shell by a new one.
M904040233D04
Turn the crankthrow to the exhaust side to

give space for lifting out the crankpin bearing cap.
5.
The bearing shells must be replaced in

pairs.
6. Turn to TDC.
Carefully turn the crank to the camshaft

side and down until the guide shoes rest
on the supports.
M904040233D05
Mount the four supports for guide shoes

on the crosshead guides.
M904040233D06
6.
Page 3 (8)
904-4.2
Crankpin Bearing
Dismantling
7.
MAN B&W Diesel
7. Mount a lifting attachment for securing the

connecting rod at the lower end, on the
camshaft side.
Hook the tackle on to the lifting attachment.
M904040233D07
8. 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 separate.
If necessary suspend a second tackle from
the bracket below the doorway.
Continue turning the crankshaft until the
bearing surface can be freely inspected.
8.
Inspect the bearing shell surface and the
crankpin journal.
9. If it is necessary to replace the bearing
shell, proceed as follows:
Turn the crankshaft approx. 80 to a horizontal position.
M904040233D08
Release the tackle so that the connecting

rod is hanging freely.
M904040233D09
9.
Page 4 (8)
Crankpin Bearing
MAN B&W Diesel
904-4.2
Dismantling
10. Mount an eye bolt in the bottom of each

guide shoe.
10.
Suspend two tackles from the eye bolts.

11. Place the lifting tool for the crankpin upper
shell on the crank webs and hook the tackles on to the lifting tool.
12. Dismount the bearing shell lock screws.

Lower the lifting tool with the bearing shell,
using the tackles.
M904040233D10
Mount the tool on the bearing shell in the

connecting rod, using the tackles, and haul
tight.
M904040233D11
11.
M904040233D12
12.
D0446
Page 5 (8)
Crankpin Bearing
904-4.4
Mounting
MAN B&W Diesel
1. If necessary, replace the bearing shells with

new ones. The bearing shells must be replaced in pairs.
1.
Bearing shells of three mm undersize are

available as spares in case of journal rectification.
Coat the bearing shell surfaces and the
journal with clean oil.
M904040231M01
The excess height X is to ensure the correct tightening-down of the bearing shell,
and must not be eliminated.
2. Lift the upper bearing shell for the crankpin
concerned into the crankcase.
Carefully lift the bearing shell into position
in the connecting rod, and mount the lock
screws.
2.
3. Remove the lifting tool, the tackles and the

eye bolts from the guide shoes.
M904040233M02
D0446
M904040233M03
3.
Page 6 (8)
Crankpin Bearing
MAN B&W Diesel
904-4.4
Mounting
4. Hook the tackle on to a beam under the

gallery platform and on to the lifting attachment on the connecting rod, and haul tight.
4.
Carefully turn the crankshaft upwards,

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

Remove the four guide shoe support
brackets from the crosshead guides.
M904040233M04
Remove the tackle and the lifting attachment from the connecting rod.
M904040233D06
5.
Page 7 (8)
904-4.4
Crankpin Bearing
Mounting
MAN B&W Diesel
6. Suspend the tackles from the lifting brackets in the side of the frame box.
6.
Lift the bearing cap assembly into the

crankcase and land it on a couple of
planks placed in the oil pan.
D0448
Remove the wire guide tool from the engine.
M904040233M06
7. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.
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 connecting rod.
7.
Mount the nuts and, by means of spacer

rings and hydraulic jacks, tighten the crankpin bearing cap. See Data.
For operation of hydraulic jacks, see Procedure 913-1.
M904040233M07
Remove the tackles from the side of the

frame box.
Page 8 (8)
D1301
Connecting Rod
MAN B&W Diesel
104-5
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D04-07
D04-16
Value
Unit
1000
kg
550
Nm
D04-48
Crankpin bearing cap + shell + bearing studs
600
kg
D04-49
Connecting rod studs , screwing-in torque
480
Nm
D04-50
Connecting rod, without bearing caps
5000
kg
D04-52
Connecting rod stud
18
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Connectin Rod
104-5
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P90451
72
P90451
96
P90451
106
P90461
Connecting Rod - Hydraulic Tools
P90464
Crosshead - Hydraulic Tools
P91351
10
P91351
46
P91351
58
P91351
117
P91356
P91366
P91368
Page 2 (2)

Lifting Tools, Etc.
58
Feeler gauge
Working Platforms
Connecting Rod
MAN B&W Diesel
904-5.2
Dismantling
1. Suspend the piston rod and dismount the

crosshead bearing cap. See Procedure
904-1.2.
1.
2. Suspend two tackles from the two lifting

brackets at the sides of the frame box.
Mount the wire guide in the top of the
crankcase doorway.
Dismantle the crankpin bearing cap, and

remove it from the engine. See Procedure
904-4.2.
Mount the four support brackets for guide
shoes on the crosshead guides.
M904050237D01
3. Turn the crank to TDC.
D1302
D0407
M904050237D02
2.
M904050237D03
3.
Page 1 (6)
Connecting Rod
904-5.2
Dismantling
MAN B&W Diesel
4. Mount the lifting attachments for fixing the

connecting rod on the head of the connecting rod.
4.
Use the tackles fastened to lifting brackets

A and B on the frame box wall, and attach
the tackle hooks to the mentioned lifting attachments on the connecting rod.
Haul the tackles tight.
M904050237D04
Also mount a lifting attachment in the

crankpin end of the connecting rod, on the
exhaust side.
Carefully turn the crank down towards the
exhaust side, until the crosshead shoes
rest on the supports.
5.
D0450
D0452

5. Turn the crankthrow towards BDC while
following with the tackles, thus continuously supporting the connecting rod.
6. Turn the crankthrow to 90 before BDC.
M904050237D05
Remove the four studs from the connecting

rod.
Page 2 (6)
Shift the hook of the tackle attached to lifting bracket B from the lifting attachment on
the lowermost side of the connecting rod to
the lifting attachment on the uppermost
side.
Connecting Rod
MAN B&W Diesel
904-5.2
Dismantling
7. By means of the tackle from lifting bracket

A, tilt the connecting rod towards the camshaft side until the connecting rod is leaning out of the doorway.
7.
Attach a tackle to lifting bracket C on the

frame box wall and connect the tackle
hook to the lifting attachment at the lower
end of the connecting rod.
8. Attach a tackle to the gallery-mounted lifting bracket E, and hook on to the lifting attachment on the connecting rod.
Shift the tackles from one lifting bracket/attachment to the other, as required.
M904050237D07
Turn the crank carefully upwards while

following with the tackles, guiding the
head of the connecting rod out of the
doorway.
8.
E
A
Remove the floor chequer plate for the pertaining cylinder.

9. Place a plated wire rope round the connecting rod, hook on the engine room
crane and haul tight.
Lift the connecting rod out of the engine

using the engine room crane and the tackles.
M904050237D08
Continue turning upwards till about 30 after TDC, while following with the tackles
and the engine room crane.
9.
E
A
M904050237D09
D0450
Page 3 (6)
Connecting Rod
904-5.4
Mounting
MAN B&W Diesel
1. Equip the connecting rod with the same lifting attachments as mentioned under dismantling.
1.
Turn the crank to a position about 30 past

TDC on the camshaft side.
Apply clean lubricating oil to the crankpin

bearing shell and journal.
M904050237M02
D0450
2. Lift the connecting rod carefully into the

crankcase by alternate use of the engine
room crane and the tackles attached to lifting brackets A and B.
Attach a tackle to bracket E and the upper
2.
E
A
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.
B
4. Turn the crankthrow towards BDC, past
TDC, while following with the tackles.
Lower the engine room crane and remove
the strap around the connecting rod.
M904050237M03
Shift tackle B from the lower end to the upper end of the connecting rod.
3.
E
A
M904050237D08
Page 4 (6)
Connecting Rod
904-5.4
Mounting
MAN B&W Diesel
5. Turn the crankthrow to 90 before BDC,

and use the tackles to raise the connecting
rod to an upright position.
5.
Shift tackle A from the lower end to the top

of the connecting rod.
Remove the tackle at E.
Remove the tackle at C.

Remove the lifting attachment at the lower
6. Screw the studs into the connecting rod.
Using the stud setter and a torque wrench,
tighten the studs to the torque stated in
Data.
M904050237M05
Shift tackle B from the lifting attachment on

one side to the other side of the connecting rod.
6.
Lubricate the crosshead bearing shell and

journal.
7. Turn the crankthrow towards TDC while
following with the tackles, carefully land
the crosshead on the connecting rod.
D0449
D0452
Take care that the studs do not damage

the crosshead bearing journal.
M904050237M06
Note!
M904050237M07
7.
Page 5 (6)
904-5.4
Connecting Rod
Mounting
MAN B&W Diesel
8. When the crank is in TDC, mount the

crankpin bearing cap.
8.
Turn to BDC and mount the crosshead

bearing cap and the piston.
9. Remove the tackles and lifting attachments.
M904050237M08
10. Turn the crosshead to BDC.

Tighten all four crosshead bearing cap nuts
simultaneously. See Data.
For use of hydraulic jacks, see Procedure
913-1.
D0448
Mount the thrust pieces for axial guidance

of the connecting rod, and tighten to the
specified torque. See Data.
M904050237M09
9.
M904050237M10
10.
Page 6 (6)
D1301
D0416

MAN B&W
Plate
P90451-0155
Page 1 (2)
Plate
P90451-0155
Item
No.
011
023
047
059
060
072
084
096
106
118
120
131
143
155
167
180
202
275
287
Page 2 (2)

MAN B&W
Item
No.
Item Description
Item Description
Panel for tools

Name plate
Wire guide
Lifting attachment, connecting rod
Lifting tool, crosshead
Retaining tool, telescope pipe
Bracket, support of crosshead
Bracket, support of crosshead
Rubber cover, crosshead
Rubber cover with hole, crosshead
Drawing tool
Template
Crowfoot spanner
Crowfoot spanner
Template
Screw
Protective screw
Protective screw
Plate
P90462-0018

0018
P90462
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90462-0018
Item
No.
023
Item Description
Item
No.
Item Description
Lifting tool for crankpin shell
Page 2 (2)
MAN B&W Diesel A/S

105-02
905-02
105-03
905-03
105-04
105-05
905-05
90551
90562
90564
90570
90571
90572
0086
0261
0075
0247
0050
0061
0230
0221
0123
0020
0003
0001
0001
Main Bearing, Data

Main Bearing
Thrust Bearing, Data
Thrust Bearing
Journal Bearing, Data
Axial Vibration Damper, Data
Axial Vibration Damper
Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
Crankshaft - Tools
Crankshaft - Measuring Tools
Thrust Shaft - Tools
Main Bearing Shell - Tools
Main Bearing - Measuring Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Bearing
MAN B&W Diesel
105-2
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-01
Main bearing, top clearance max.
0.85
mm
D05-02
Main bearing, top clearance min.
0.60
mm
D05-03
Main bearing cap
1100
kg
D05-04
Main bearing shell, upper
70
kg
D05-05
Main bearing shell, lower
70
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Main Bearing
105-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90551
40
Pulley for wire for main bearing
P90551
64
P90551
76
Lifting tool - main bearing cap
P90551
88
Dismantling tool, main bearing shell
P90551
90
Mounting tool for bearing shell
P90551
123
Retaining tool for main bearing shell
P90551
159
Eye bolt
P90551
160
Wire
P90551
172
Mounting tool, thin bearing shell
P90551
218
Wire guide
P90562
Lifting tool for crankshaft
P90571
P90572
Main Bearing - Measuring Tools
P91351
010
P91351
022
Hydraulic pump, hand operated
P91351
034
P91351
058
P91351
117
P91356
Lifting Tools, Etc.
P91366
058
Feeler gauge
P91366
061
Slide caliper
P91366
073
Dial gauge and stand tool
Page 2 (2)
Main Bearing
MAN B&W Diesel
905-2.1
Checking
General
1.
The condition of the main bearings can be

checked by:
Deection readings
Visual checking
Edge checking and
Crankshaft deection readings

Crankshaft deection readings should be taken
while the ship is aoat (i.e. not while in dry
dock).
As the alignment is inuenced by the engine
temperature as well as the loading conditions,
deection measurements should, for comparison purposes, always be made under nearly
the same temperature and load conditions.
2.
Positive (+)
Place a dial gauge axially in the crank

throw opposite the crankpin, as illustrated
on the sketch. The correct mounting position is marked with punch marks on the
crank throw. See also Chapter 708 in Volume I.
2. Closing of the crank throw (compression

of the gauge) is regarded as negative ()
and opening as positive (+).
3. Set the dial gauge to zero at the B1 side
near BDC. Whilst turning clockwise, take
the readings when the throw passes the
positions:
B1
(near bottom)
(camshaft side)
(top)
(exhaust side)
B2
(near bottom)
Negative ()
M905010208C02
1.
M905020046C01
Measuring of top clearance.
3.
Looking forward
M905010204C03
1/2 (B2+B1) = B
B1
B2
B1
C
T
E
B2
(B1+B2)=B
Page 1 (19)
905-2.1
Main Bearing
Checking
4.
MAN B&W Diesel
4. When taking deection readings for the

three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise,
this pressure may falsify the readings.
For evaluation of the crankshaft deection readings, see Volume I, OPERATION,
Chapter 708.
M905020046C01
If the crankshaft deection (alignment indicator) is approaching the tolerance limits

(see Vol. I, OPERATION), the two adjacent
main bearings must be checked for wear.
See next page for checking of main bearing.
5.
If the bearings are found to be in good

order, please contact MAN B&W Diesel or
the engine manufacturer for checking of the
bedplate alignment.
As reference, use the after seatrial deection table.
M905010208C05
The condition of the bearing can be checked

as follows:
5. Visually look for bearing metal fragments in
the oil pan, and check the lters for metal
fragments.
Such fragments can be from crosshead,
guide shoe or crankpin bearings. If fragments are found, the damaged bearing can
be found by edge checking with a feeler.
General
Bearing damage usually propagates rather
quickly towards the edge of the bearing where,
eventually, it causes chips to be broken off,
which means that loose pieces of white metal
can fall down into the crankcase beneath the
bearing support.
Large, thick pieces will normally be found during a crankcase inspection, and small, thin
pieces can enter the lter. A check of the
bearing edges together with inspection of the
crankcase and the lter normally provides a
good indication of the bearing condition.
Page 2 (19)
Main Bearing
MAN B&W Diesel
905-2.1
Checking
Checking the bearing edges
6.
6. Bearing edges can be checked with a

feeler that is able to follow the bearing
edge against the journal the whole way
round on each side. If white metal is missing at the edge, the tip of the feeler will
enter the hole, thus locating the damage.
In most cases this hole can be seen by the
naked eye as a dark spot when using a
strong ashlight.
7.
Wire-feeler
It is rather easy to make a feeler (see
sketch). The feeler should be made from
a piece of steel wire (e.g. a welding rod)
approx. 0.6 - 1 m long depending on the
engine type, and 2 to 3 mm thick. Approx. 7 to 10 mm of the wire should be
bent to an angle of approx. 65 to form a
feeler tip. Grind the tip smooth to obtain
the shape and dimension shown on the
sketch. Note that the thickness of the white
metal is approx. 1.5 mm, which is why the
tip should be less than 1.2 mm thick, and
bigger than the max. top clearance. At the
other end of the tip, a handle should be
made by bending a hook or similar in the
same direction as the tip.
<1.2 mm
>0.7 mm 7-10 mm
60-70
2-3 mm
500-1000
7.
Hole in
the edge
M905010208C06
The No. 1 and the two aftmost main bearings are more difcult to access on the
whole circumference on each side, but it is
often possible to bend the feeler to suit
the situation and thus reach as far round
as possible.
Wire feeler
The above dimensions of the wire-feeler are guideline values and may depend
on the engine type as well as individual,
personal designs.
M905020252C06
Note!
Page 3 (19)
Main Bearing
905-2.1
Checking
MAN B&W Diesel
8. If there is too large a difference in the

crankshaft deection readings (autolog)
check the clearance in the individual bearings.
8.
M905010208C08
Bearing clearance checks should also be

carried out during time-based overhauls
and surveys.
If there is a suspicion of a damaged bearing, it is recommended to edge check the
bearing, without opening up.
9.
9. Before measuring, check that the feeler
blades are in good condition.
The feeler is inserted along the crank
throw. When the feeler hits the journal, it is
horizontally pushed against the clearance.
Now the feeler blade is pushed max. 20
mm into the gap.
M905010208C09
10 The clearance is measured at both the fore

and the aft part of the bearing.
Note!
The bearing clearances for a new bearing stated in Data (see Data 105-2) are
for guidance purposes only.
20
10.
M905020258C10
D0501
D0502
Page 4 (19)
Main Bearing
MAN B&W Diesel
905-2.1
Checking
11. The difference between the actual clearance measurement and the measurement
recorded in the adjustment sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.
For evaluation of the bearing, see Volume I,
Operation, Chapter 708.
M905020227C03
If the bearing needs to be disassembled for

inspection, see procedure 905-2.2.
Page 5 (19)
Main Bearing
905-2.2
Dismantling
1.
Aftmost main bearing (= Journal bearing)
MAN B&W Diesel
Positioning the crankshaft

1.
Dismantling of main bearing.

The bearings are divided into two categories:
The main bearings
M905020238D01
The aftmost main bearing often referred

to as Journal bearing
(See Procedure 905-4).
2. Before any dismantling, check and write
down the main bearing top clearances and
crankshaft deection readings for the cylinder unit concerned.
Main bearings
Thrust bearing
3. Turn the crank throw to the position shown

on the sketch and in such a way that the
top of the studs is ush with the crank
throw.
2.
Note!
M905020238D02
Be sure that the crosshead for the neighbouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
3.
MANSIDE
M905020238D03
EXHSIDE
Page 6 (19)
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
Oil pipes
4.
4. Disconnect the lubricating oil pipe from the

main pipe.
Note!
Note!
Some engines have temperature sensors
tted to the main, crosshead, and crankpin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.
M905020238D04
On some engines, the oil pipes for the

Axial Vibration Damper (AVD) have to be
removed together with the oil pipe on
main bearing No. 1.
5.
Mounting of tools and tackles

Mount pulley E, pulley F and the special
eye bolt D, as shown on the sketch.
Check with a 0.05 mm feeler gauge that

there is no clearance between the pulley
and the stop screw (guide shoe).
M905020236D05
Pulley F has to be tightened to full surface

contact, i.e. using a spanner. On some engines the stop screw in the guide shoe has
to be removed. Some are provided with a
threaded hole.
Note!
Do not use pulley F if it is not tightened
to full contact.
Page 7 (19)
Main Bearing
905-2.2
Dismantling
6.
6. Mount the wire guide as shown. The wire

guide must be nally positioned when tightening the tackles. Mount the wire guide on
the crosshead guide.
MAN B&W Diesel
Mount tackles in the following positions:

A: a 3 ton chain tackle, in a wire strap
around the beam.
B: a 3 ton chain tackle. (On some engines
a special bracket has to be mounted, before mounting the shackle.)
M90502-0261D06
C: a 3 ton pull lift

D: a 1 ton tackle
C
Loosening the nuts

7.
7.
Before mounting, check the jacks as shown

in Procedure 913-1.
8. Place the spacer rings over the nuts on the

bearing cap. Screw down the extension
studs on the main bearing studs.
M905020253D09
Place three hydraulic jacks on each spacer

ring. Screw down the four upper nuts on
the extension studs. Tighten them rmly.
8.
D13-02
Then turn the upper nuts 3/4 turn backwards to obtain a clearance of about 4.5
mm.
Note!
Be sure to mount the spacer rings and
the hydraulic jacks with the TOP mark
upwards.
D13-02
TOP
9. Connect the hydraulic jacks to the highpressure pump by means of the distributor
block and high-pressure hoses.
TOP
M90502-0261D08
TOP
Page 8 (19)
Bleed the entire hydraulic system and raise

the pressure as indicated in Data. Then
loosen the nuts.
Remove the upper nuts, the hydraulic
jacks, the spacer rings and the extension
studs.
Unscrew the main bearing nuts from the
studs. For operation of the hydraulic jacks,
see Chapter 913.
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
Removal of main bearing cap
10.
10. Mount the main bearing lifting tool on the

main bearing cap.
D05-03
Place one wire rope around pulley E, as

shown, and attach it in tackle A, from outside the engine.
Note!
When tightening up the tackle, be sure
that the wire guides are positioned correctly to protect crosshead guides and
doorframe.
M90502-0261D10
Tighten up tackle A and carefully lift the

main bearing cap clear of the studs.
11.
11. When clear of the studs, pull the other wire
rope around wire guide F, as shown, and
attach it to tackle C, below the door.
F
C
Tighten tackle C and release tackle A, until

the main bearing cap is suspended vertically below pulley F.
Mount the short wire rope across the lifting

tool.
Mount the hook from tackle B (upper in the
crankcase), in the short wire, and tighten it
up.
M905020238D17
12. Remove the wire rope from tackle A and let

it hang freely.
12.
If necessary, pull the main bearing cap free
of the crosshead guides, using tackle D,
from the opposite web plate.
F
C
M905020252D12
Page 9 (19)
Main Bearing
905-2.2
Dismantling
13.
MAN B&W Diesel
13. Release tackle C and at the same time,

tighten tackle B until the bearing cap is
hanging freely below tackle B.
Release and unhook tackles C and D.

14. Attach the hook of tackle A, from outside
the engine, to the short wire rope across
the lifting tool.
By tightening tackle A and releasing tackle
B, lift the bearing cap out of the engine,
and place it on a couple of wooden planks.
M905020254D13
Removal of upper bearing shell

C
14.
B
15. Mount the bearing shell lifting tool on the

upper main bearing shell, pull the wire
around pulley F, as shown, and attach it to
tackle A outside the engine.
Carefully lift the bearing shell, until it is
hanging freely below the guideshoe.
D0503
Lift the bearing shell out of the engine in

the same way as the bearing cap.
M905020261D14
15.
M90502-0261D15
D05-04
Page 10 (19)
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
Removal of upper bearing shell
16.
16. If the crankshaft is turned with the bearing

cap dismounted, use the two stops to prevent the lower shell from being rolled out.
17. Place the crosspiece in the bedplate with
the ends resting on the cross girders, and
position the hydraulic jacks beneath the
crank webs as shown.
Connect the hydraulic jacks to the high

pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.
M905020238D24
Tighten the screws against the crank webs

and compress the jacks.
17.
Note down the pressure for later reference.

18. Check that there is min. 0.1 mm clearance
between journal and bearing shell, or between bearing shell and main bearing support, on both sides of the journal.
The feeler blade must be inserted minimum 60 mm into the gap to pass the
bore relief in the bearing shell.
If the clearance is less than 0.1 mm, move
the crosspiece sideways until clearance is
obtained. Normally, adjustment needs to
be 50-150 mm to the exhaust side (the side
where the clearance is missing).
M905020238D27
Note!
18.
min
0.1 mm
Note!
EXH
CAM
M905020238D28
Min. 60 mm
The lower shell must be lifted out to the

side with the most clearance, which is
normally the manoeuvre side.
Page 11 (19)
905-2.2
Main Bearing
Dismantling
19.
MAN B&W Diesel
19. If re-positioning of the crosspiece does not

ensure a vertical lift, place a 5-tonne jack
between the side wall and the crank throw,
to correct the journal position in this way.
If it is available, note down the pressure
applied to the jack. This data is used to
ensure that the crankshaft is in the same
position when the new bearing is installed.
M905020238D25
Note!
It is recommended that the crankshaft
lifting tool is only removed if it is urgently
necessary and then only after the main
bearing shell has been reinstalled.
20. Dismount the locking screws.

20.
M905020238D26
Place the dismantling tool on top of the

lower bearing shell. Make sure that the
ap on the dismantling tool enters the oil
groove in the bearing shell.
Page 12 (19)
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
21. Pull the lower shell around and up until it

lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.
21.
Note!
22. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.
M905020236D27
While pulling out the shell, it is recommended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
22.
M90502-0261D22
D05-05
Page 13 (19)
905-2.3
Main Bearing
Overhaul
1 + 2.
1.
MAN B&W Diesel

Clean and inspect the bearing shells. It is
recommended that the main bearing shells
be replaced in pairs.
M905020252O01
If it is nevertheless desired to replace only

one shell, this requires a careful evaluation
of the condition of the shell that is to be
reinstalled.
See Instruction book, Volume I,
Chapter 708.
For advice on replacing individual bearing
shells, it is recommended to contact MAN
B&W Diesel A/S or the engine builder.
2. Before remounting:
Check the bearing support for damage
and burrs. If damage is found, contact
MAN B&W Diesel for advice.
Make sure that all parts are clean, use
non-uffy cloth to clean between journal
and main bearing support.
Lubricate the bearing journal, the main
bearing support and the back of the
shell, with main engine lubricating oil.
Page 14 (19)
Main Bearing
MAN B&W Diesel
Mounting
Mounting of bearing shells

1.
905-2.4
1.
Using the bearing shell lifting tool, the

pulleys and tackles, lift the lower bearing
shell into the crankcase and land it on the
crankshaft journal.
Lubricate the journal, the lower bearing

shell and the bearing support with clean
oil.
Place the lower bearing shell on the journal
and push it down by hand.
To ensure that the shell is correctly mounted, check that the distance from the main
bearing support to the shell is equal in
both sides.
M90502-0261M01
2. Position the guide tool for the lower bearing

shell on the main bearing support. Remove
the lifting tool from the bearing shell.
D05-05
2.
3. Remove the guide tool when the lower

bearing shell has been mounted.
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below the crankshaft.
Wipe the contact surfaces between the upper and the lower bearing shells clean with
a non-uffy piece of cloth.
M90502-0261M02
Mount the locking screws in the bearing

support.
M905020252M03
3.
Page 15 (19)
Main Bearing
905-2.4
Mounting
MAN B&W Diesel
4. Land the upper bearing shell on the main

journal in the same way as the lower bearing shell.
4.
D0504
Make sure that none of the edges of the

upper bearing shell are resting on the edge
of the bearing support.
If necessary, place the special tool between the studs and press the shell into
place.
M905020252M04
Clean the contact surfaces between the

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfaces.
5.
B
5. Mount the lifting tool on the bearing cap.

Using the tackles and wire ropes on the
main bearing cap lifting tool, lift the bearing
cap into the crankcase in reverse order to
dismantling.
See Procedure 905-2.2, steps 22-21.
D0503
M905020261D14
Page 16 (19)
Main Bearing
MAN B&W Diesel
Mounting
6. Using the pulleys mounted inside the crank

case, move the bearing cap into position
vertically above the crankshaft bearing
journal in the reverse order to dismantling.
See Procedure 905-2.2, steps 20-17.
7.
905-2.4
6 a.
B
Carefully lower the main bearing cap on to

the upper bearing shell. Keep a hand on
the wire rope while lowering, so that sticking of the bearing cap is immediately felt.
M905020254D13
6 b.
F
C
M905020252M07
7.
M905020238M08
Page 17 (19)
Main Bearing
905-2.4
Mounting
MAN B&W Diesel
8.
8.
Note!
Be sure that the cap lands correctly and
that the spring pin in the assembly surface enters the hole in the bearing cap.
9. Remove the bearing cap lifting tool.
M905020238M09
Screw the nuts on to the main bearing

studs.
Using a tommy bar, tighten the nuts on
both sides of the bearing cap.
Tightening of hydraulic nuts
10. Mount the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts.
See Data and Procedure 905-2.2, step 5
and 6.
9.
After tightening the bearing cap, check the

clearance once more.
M905020238M15
For operation of the hydraulic tools, see

Procedure 913-1.
10.
D13-01
TOP
TOP
M90502-0261M10
TOP
Page 18 (19)
Main Bearing
MAN B&W Diesel
905-2.4
Mounting
11.
11.
Note!
Before removing the hydraulic jacks,
check the top clearance between the upper bearing shell and the journal.
D0501
D0502
12. Remove all tools from the engine.

behind.
13. Mount the lubricating oil pipe on the main
bearing cap,
M905020252M11
Note!
20
M905020238M14
12.
M905020252M13
13.
Page 19 (19)
Thrust Bearing
MAN B&W Diesel
105-3
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D05-06
Thrust bearing segment
D05-07
Value
Unit
90
kg
Segment stopper
440
kg
D05-16
End cover
550
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Thrust Bearing
105-3
MAN B&W Diesel
Data
Plate
P90551
Item No.
100
P90662
Description
Tool for turning out segments
Camshaft - Hydraulic Tools
P91351
010
P91351
046
P91351
058
P91351
105
P91356
P91366
Page 2 (2)
Lifting Tools, Etc.

058
Feeler gauge
Thrust Bearing
MAN B&W Diesel
905-3.1
Checking
The clearance in the thrust bearing was

measured during testbed trials of the engine and noted down in the Adjustment
Sheet which is inserted at the front of Volume I, OPERATION.
1.
In service it is only necessary to measure

the wear of the thrust bearing pads, and to
inspect for white metal particles below the
thrust bearing.
1.
A wear groove of 1 mm is positioned in the

uppermost thrust segment. (The segment
with thermometers)
For measuring the wear, it is necessary to
dismantle the foremost segment stopper.
M905030241C01
For a new engine the clearance is 0.51.0

mm, and for an engine in service it must
not exceed 2.0 mm.
2.
If a feeler gauge of 0.1 mm is not able to

enter the groove (the wear is more than
0.9 mm), the thrust bearing must be overhauled.
3. Note down the wear for later reference.
M905030245C02
2. To measure the wear, the thrust segment

has to be pressed against the thrust cam,
to eliminate any gap, i.e. by using a suitable crowbar on the back of the segment.
M905030245C03
3.
Page 1 (5)
905-3.2
Thrust Bearing
Dismantling
1.
1.
D0516
MAN B&W Diesel
Remove the end cover of the engine.

Remove the lub. oil pipe from the aftmost
main bearing shell.
Remove the lub. oil pipe above the thrust
segments.
Remove the protecting shields from the
thrust collar.
M905030246D01
2. Loosen and remove the nuts from the segment stoppers by using hydraulic tools.
Dismount the stud, if necessary.
3. Mount the special lifting attachment in the
chain drive and suspend a tackle over the
stopper which has to be removed.
2.
M905030247D02
Remove the stoppers above the thrust segment (AHEAD or ASTERN) that are to be taken
out, and lift the stoppers out of the chain
casing.
D1302
3.
M905030247D03
D0507
Page 2 (5)
Thrust Bearing
MAN B&W Diesel
905-3.2
Dismantling
4. Suspend a tackle from the chain tightener

bracket above the segments which are to
be removed.
4.
For turningup the thrust segments, mount

the segment tool on the thrust cam, in the
holes for the protective shields.
Note!
Never remove more than one segment at
a time.
M905030247D04
5. Turn up the segments, one at a time, by

turning the engine, and remove the segment from the chain casing. Inspect the
segment and remount it before turning up
the next segment. See Procedure 9053.4.
5.
M905030246D05
D0506
Page 3 (5)
905-3.4
Thrust Bearing
Mounting
1.
1.
D0506
MAN B&W Diesel

Suspend a tackle from the crossbar above
the segments which are to be mounted.
Mount the segment tool on the chain
wheel.
Land the segment on the journal and remove the eye bolt from the segment.
Carefully slide the segment on to the segment tool.
Turn the engine to dismantle the next segment.
M905030247M01
2. After the last segment has been mounted,

turn the segment tool up and dismount it.
M905030247M02
2.
Page 4 (5)
Thrust Bearing
MAN B&W Diesel
905-3.4
Mounting
3. Mount the segment stoppers.
3.
Mount the hydraulic jacks and tighten the

nuts on the stoppers. See Data.
D0507
Mount the protective shield.

4. Mount the lub. oil pipe for the thrust segments.
5. Mount the end cover.
M905030247M03
Mount the lub. oil pipe for the aftmost main

bearing.
D1301
M905030246M04
4.
Page 5 (5)
Journal Bearing
MAN B&W Diesel
105-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-11
Min. bearing clearance
0.60
mm
D05-12
Max. bearing clearance
0.85
mm
D05-13
Journal bearing cap
1100
kg
D05-14
Upper bearing shell
70
kg
D05-15
Lower bearing shell
70
kg
D05-16
End cover
550
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Journal Bearing
105-4
MAN B&W Diesel
Data
Plate
Item No.
Description
P90551
40
P90551
76
Lifting tool - main bearing cap
P90551
88
Dismantling tool, main bearing shell
P90551
90
Mounting tool for bearing shell
P90551
172
Mounting tool, thin bearing shell
P90561
Main Bearing - Hydraulic Tools
P90570
P90571
P91351
010
P91351
034
P91351
058
P91351
117
P91356
Lifting Tools, Etc.
P91366
058
Feeler gauge
P91366
061
Slide caliper
P91366
073
Page 2 (2)

MAN B&W Diesel
105-5
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-18
Inner studs, screwing-in torque
27020
Nm
D05-22
Outer studs, screwing-in torque
80020
Nm
D05-23
Horizontal screws, tightening torque
215020
Nm
D05-24
Horizontal screws, tightening torque/angle
D05-25
Damper housing, upper part
2025
kg
D13-01
900
bar
D13-02
800 - 990
bar
100/53
Nm/
Page 1 (2)
105-5
MAN B&W Diesel
Data
Plate
Item No.
P90262
Description
Hydraulic jack for piston rod
P90551
111
Lifting attachment
P90551
196
Tightening template A.V.D.
P90564
P91351
046
P91351
058
P91351
105
P91351
117
P91356
Lifting Tools, Etc.
P90662
Page 2 (2)
905-5.1
Checking
For checking the effectiveness of the axial vibration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
1.
The measurement (or reading) should be taken

at the same r/min as during the sea trials.
(Preferably 90% and 100% of MCR.)
As different equipment can have been mounted
on the specific engines, the checking procedure describes three different systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, with angle encoder fore.
A proximeter probe is built on to the lower part

of the damper housing. The probe is connected to a control unit which displays peakto-peak movements and sends signals to the
engine control system.
M905050229C01
A: Electronic, with Axial Vibration Monitor
1. Concerning overhaul and setting of the

electronic device, refer to makers instructions and Volume I, Operation, Chapter
701.
The peak-to-peak values displayed in mm
are to be compared with the original values
obtained during sea trial and the limits
given in Volume I, Operation, Chapter 701.
If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see Procedure 905-5.2.
MAN B&W Diesel A/S
Page 1 (6)
905-5.1

Checking
B: Mechanical, with angle encoder fore
1.
1. Stop the engine.
Unscrew the two plugs from the cover at
the front of the engine.
M905050230C02
2. Mount the shaft piece in the end of the

crankshaft.
Screw the measuring arm into the small
threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.
Attach a pencil to the arm.
Note!
To obtain a correct measurement, the tip
of the pencil should protrude 10 mm
from the end of the arm.
M905050230C03
2.
Page 2 (6)
MAN B&W Diesel A/S
905-5.1

Checking
Start the engine, and let the speed rise to the
number of revolutions at which the measurement is to be taken. (Preferably 90% and
100% of MCR.)
3.
S2
When measuring, press the measuring arm

against the shaft piece with the one hand. With
the other hand, move a sheet/block of paper,
clipped on to a solid backing plate, lightly
downwards against the tip of the pencil.
The axial movements (S2) recorded on the paper must be measured with a slide calliper as
shown in the sketch.
Before comparing the measured value (S2) with
the Normal Service Value (S1), stated in Volume
I, Operation, Chapter 701, it is necessary to
compensate for the ratio in the tool.
M905050229C04
To ensure a certain inertia, the backing plate

should have a mass of approx. 1-2 kg.
4.
S1
For a standard measuring tool (L1 = 38 mm

and L2 = 200 mm), the ratio is 5.3. Therefore,
S1 can be calculated as follows:
L2
If a non-standard tool is used, S1 can be calculated as follows:
S2
M905050229C10
L1
If the peak-to-peak value exceeds the Normal

Service Value, it is necessary to overhaul the
axial vibration damper, see Procedure 905-5.2.
MAN B&W Diesel A/S
Page 3 (6)
905-5.2

Dismantling
1. Dismantling of the axial vibration damper is
carried out from cyl. No. 1.
1.
Disconnect and remove the oil pipes from

the foremost bearing cap and the axial vibration damper housing.
Loosen and remove the No. 1 main bearing
cap. See Procedure 905-2.2.
D1302
Note!
M905050230D01
Before working on top of the main bearing shell, be sure that the open bearing
is well protected, i.e. by use of clean
rags.
Loosen and remove the nuts and screws

from the damper housing upper part.
2.
2. Only the upper part of the housing needs

to be removed, while the lower half remains
mounted on the bedplate.
Mount the lifting tool on the upper part of
the damper.
M905050230D02
Engines with chainbox fore:

Mount a tackle in the bracket above the
axial vibration damper inside the chain box.
3.
Engines without chainbox fore:

Mount a tackle below the fore end platform, and dismount the cover on the lifting
hole above the axial vibration damper.
D0525
3. By means of a tackle and wire rope, separate and raise the upper part of the damper
housing.
Note!
M905050230D03
Before working below the suspended

upper part, secure the upper part e.g. by
mounting two of the vertical screws in
the upper threaded holes.
Page 4 (6)
MAN B&W Diesel A/S
905-5.3
Overhaul
1. Dismantle and remove the springs from the
oil sealing rings.
1.
Remove the oil sealing rings.

Note!
When mounting the new oil sealing rings,

first insert the lower half of the rings in the
lower housing.
Then press the tension springs into the
groove between the oil sealing ring half and
the housing.
2. Mount all the upper halves of the oil sealing rings in such a way that the clearance
at both the joints on each oil sealing ring is
the same.
M905050230O01
It is recommended to discard both the

springs and the oil sealing rings.
2.
Now hook the new tension springs into

place, ensuring that they are centralised in
the grooves of the oil sealing rings.
The lower half of the oil sealing rings will

protrude above the centreline.
M905050229O02
Note!
MAN B&W Diesel A/S
Page 5 (6)
905-5.4

Mounting
1. Remove the screws securing the upper
part of the damper housing.
1.
Release and carefully lower the upper part

of the damper housing.
When reaching the oil sealing rings, take
care that the rings enter the sealing ring
grooves correctly.
M905050230M01
Before landing the upper part on the lower

part, be sure that the guide pins have entered the guide pin holes.
2. If the studs have been removed, re-mount
them at this stage.
For screwing-in torque, see Data.
Remove the lifting tools.
2.
D0518
D0522
Mount the horizontal screws, without tightening.

Mount the nuts on the vertical studs, and
tighten them two by two, using the hydraulic jacks. For operation of the hydraulic
tools, see Procedure 913-1.
Tighten the horizontal screws, see Data.
M905050230M02
D0524
D1301
Mount and tighten the main bearing cap.

Note!
behind.
Mount the lubricating oil pipes for damper

and main bearing.
Engines without chainbox fore:
Mount the cover for the lifting hole above
the axial vibration damper.
Note!
After overhaul of the axial vibration
damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
Page 6 (6)
MAN B&W Diesel A/S
Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
MAN B&W Diesel A/S
Plate
P90551-0221
Page 1 (2)
Plate
P90551-0221
Item
No.
015
027
040
064
076
088
090
100
111
123
159
160
172
196
218
Page 2 (2)
Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Lifting tool for main bearing cap
Dismantling tool for main bearing shell
Mounting tool for thin bearing shell
Tool for turning out segments
Lifting tool for main bearing cap
Retaining tool for relief valve
Eye bolt
Wire
Mounting tool for thin bearing shell
Tightening template A.V.D.
Wire guide for main bearing
MAN B&W Diesel A/S
Crankshaft - Tools
Plate
P90562-0123
Crankshaft - Tools
0123
P90562
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90562-0123
Item
No.
015
Crankshaft - Tools
Item Description
Item
No.
Item Description
Lifting tool for crankshaft
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90564-0020

0020
P90564
Flange on end of crankshaft
Flange on end cover fore
Z
When ordering item 016 or 028, please always state measurement Z
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90564-0020
Item
No.
016
028
041
053
Item Description
Item
No.
Item Description
Measuring instruments, axial vibration

damper
Shaft, measuring instruments axial vibration
Measuring instruments, axial vibration
damper
Handle - sundry types
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90570-0003

0003
P90570
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90570-0003
Item
No.
019
Item Description
Item
No.
Item Description
Lifting tool, thrust shaft
Page 2 (2)
MAN B&W Diesel A/S
Main Bearing Shell - T

ools
Tools
MAN B&W Diesel
Plate
P90571-0001
Page 1 (2)
Plate
P90571-0001
Item
No.
014
Page 2 (2)
Main Bearing Shell - T

ools
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Lifting tool for main bearing shell
Main Bearing - Measuring T

ools
Tools
MAN B&W Diesel
Plate
P90572-0001
Page 1 (2)
Main Bearing - Measuring T

ools
Tools
Plate
P90572-0001
Item
No.
021
033
045
069
070
082
094
104
116
128
141
153
165
177
189
190
200
212
224
236
248
261
273
285
332
344
356
368
381
393
403
415
427
439
440
452
464
476
488
511
523
535
547
559
560
Page 2 (2)
MAN B&W Diesel
Item Description
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Feeler
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
gauge set
gauge set
gauge set
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
tip for feeler
Item
No.
Item Description
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
gauge
906 - Control Gear

106-01
906-01
106-02
906-02
106-03
906-03
106-04
906-04
90651
90664
0051
0246
0067
0230
0043
0218
0045
0219
0203
0001
Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearings, Data
Camshaft Bearings
Chain Drive and Camshaft - Panel
Crankshaft - Pin Gauge
MAN B&W Diesel A/S
MAN B&W Diesel A/S
106-1
Chains
Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D06-18
Teeth on chain wheel, max. wear
D06-19
Original length (chain pitch x 10 links)
D06-20
10 links measurements + 1% of a tensioned chain = scrapping of

chain
MAN B&W Diesel A/S
Value
Unit
mm
1143
mm
1154.4
mm
Page 1 (2)
106-1
Chains
Data
Plate
Item No.
Description
P90651
70
Chain assembling tool
P90651
81
Chain disassembling tool
Page 2 (2)
MAN B&W Diesel A/S
Chains
MAN B&W Diesel
1.
906-1.1
Checking
The engine is equipped with a set of

chains:
1.
the drive chains for the camshaft

The set of chains is to be checked and, if
necessary, dismantled and mounted in the
same way.
2. The chains can be accessed from within
the chainwheel frame.
3. Carry out the inspection as follows:
Make a general inspection for loose
bolts and screws.
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 abnormal wear is found, take a measurement
(See Data).
M90601-0246C01
Inspect lube oil pipes for damage, and

check jet nozzles for possible stoppages or deformations.
4.
Measurements are best taken by placing a

short straightedge over the straight part
of the chain wheel and then measuring the
distance D0618.
M906010245C02
D0618
Page 1 (6)
Chains
906-1.1
Checking
MAN B&W Diesel
5. If abnormal wear is observed at the bottom

of the teeth, make a drawing in scale 1:1 of
the teeth and wear prole.
5.
Draw two rulers on the drawing.

For assessing the wear prole, contact
MAN B&W Diesel.
M906010244C05
Scale 1:1
10
0
10
In most cases, scratches caused by the

side plates of the chain will be found on
the sides of the teeth. Such scratches can
generally be considered normal.
6. The chains for the camshaft drive are
matched together to ensure an even load
distribution.
To keep such matching chains in their
pairs, the side plates of the outer link
nearest to the assembled link have been
marked with year, month, day and chain
number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 2C, 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
defective 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
runningin period. These ne scratches are
of no importance and need not be considered.
It is recommended that each single link is
checked.
Page 2 (6)
Chains
MAN B&W Diesel
7.
906-1.1
Checking
Check chain wear by measuring the length

of 10 chain links. Use two master squares
and a steel measuring tape as shown on
the sketch. Compare the result with the
value given in Data.
7.
If necessary, adjust the chain tightener.

Ma
D0619
D0620
M906010245C07
20
06
x.D
Page 3 (6)
906-1.2
Chains
Dismantling
MAN B&W Diesel
It may become necessary to disassemble

the chain if, for instance, cracked rollers
or seizures between pin and bushing have
been discovered during the inspection.
1.
Note!
Every time a chain link is disassembled,
a new link must always be tted as
the link pin presst is destroyed when
breaking the chain.
When a new link is tted in one chain,
the corresponding link in the other chain
must also be renewed.
M90601-0246C01
1.
2.
Remove the tension on the chain by loosening the chain tightener.

(See Procedure 9062.3).
Turn the engine until the slack part of the
chain, with the chain link that is to be disassembled, 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
is wrapped.
Note!
M906010238D02
If the chain is to be completely removed,

contact MAN B&W Diesel for further information.
Page 4 (6)
The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.
Chains
MAN B&W Diesel
906-1.2
Dismantling
3.
M906010238D03
3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alternately tightening the screws on the tool.
Page 5 (6)
906-1.4
Chains
Mounting
MAN B&W Diesel

Before assembling the inner and outer
links, clean the pins and bushings.
1.
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.
M906010238M01
2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
Page 6 (6)
Repeat this procedure until the chain has

been assembled.
Remove the tackle and wire and adjust the
chain tension.
(See Data and Procedure 9062.3).
Chain Tightener
MAN B&W Diesel
106-2
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D06-21
Tightening angle = 5 hexagons
300
D06-25
Mechanical or blocked chain tightener, clearance
0.1
mm
Page 1 (2)
Chain Tightener
106-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90651
070
P90651
081
Page 2 (2)
Chain Tightener
906-2.3
Adjustment
Chain Tightener
S60MC-C
0230
Adjustment
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,

C and D to free the chain tightener bolt.
A
B
2. Turn the engine at least one revolution with

the chain slackened on the same side as
the chain tightener wheel.
If the engine is equipped with flyweights,
continue turning until the flyweights are
hanging vertically downwards.
Then tighten nut B as stated in D06-21

(see Data).
C
D
HG906-2.3 218 01
3. Tighten nut B on the chain tightener bolt

until there is a clearance between the shaft
and the nut as stated in D06-25.
2.
HM906-2.2 95 01
For chain wear, see Procedure 906-1.1.
3.
D06-25
HG906-2.3 218 03
D06-21
0$1% :'LHVHO$6
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.
HG906-2.3 218 05
The number of times that retightening can

be carried out depends on when the limit for
scrapping the chain has been reached. See
Data page 106-1.
5.
HG906-2.3 218 05
Page 2 (2)
0$1% :'LHVHO$6
Camshaft
MAN B&W Diesel
106-3
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D06-27
Max. permissible change in lead angle
D06-28
corresponding to
Value
Unit
2
5.6
mm
Page 1 (2)
Camshaft
106-3
MAN B&W Diesel
Data
Plate
Item No.
Description
P90664
P90668
Camshaft - Pin Gauge
Page 2 (2)
Camshaft
MAN B&W Diesel
1.
906-3.1
Checking
Turn the crankthrow for cylinder 1 to TDC.
1.
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.
2. Use the check measurement value

stamped on the pin gauges to check the
pin gauges for deformation.
On some engines the pin gauges can be
checked against punch marks made on the
front cylinder frame.
M906030218C01
Check the TDC of cylinder 1 against the

mark on the turning wheel.
2.
Check
M906030218C02
Che
ck
Page 1 (4)
Camshaft
906-3.1
Checking
MAN B&W Diesel
3. Check the TDC position with the pin gauge

on the crankthrow.
3.
Position the camshaft pin gauge in the centre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see D06-27
and D06-28.
M906030218C03
4. Check and, if necessary, adjust the cylinder

lubricator.
Check the setting of the starting air distributor.
5. When checking the camshaft position, also
check the running surface of the cams.
4.
As the inspection must include the entire

surface of the cam, the cam should be
turned one complete revolution during the
inspection.
M906030218C04
The running surface of the cam must be

completely smooth and bright.
D0627
D0628
M906030218C05
5.
Page 2 (4)
Camshaft
MAN B&W Diesel
906-3.1
Checking
6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a ne carborundum stone. Such light scratches can appear if the roller guide and the cam are not
correctly aligned.
6.
M906030218C06
In the event of heavier scratches or direct

aking of the material on the running path,
MAN B&W Diesel should be contacted for
further instructions.
Page 3 (4)
Camshaft
906-3.3
Adjustmentl
1.
M906030218O01
1.
Page 4 (4)
MAN B&W Diesel
If the chains prove to be so heavily worn that

the deviation between the measuring points
and the pin gauge has reached the maximum value D06-27 and D06-28 stated in
Data, MAN B&W Diesel should be contacted
for further instructions.
D0627
D0628
Camshaft Bearings
MAN B&W Diesel
106-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D06-34
Bearing shell, max. wear
0,1
mm
D06-36
Oil pan
130
kg
D06-37
Camshaft bearing cap
150
kg
D06-65
Bearing shell, minimum thickness
6,35
mm
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Camshaft Bearings
106-4
MAN B&W Diesel
Data
Plate
Item No.
P90662
Description
P91351
010
P91351
034
P91351
058
P91351
105
Page 2 (2)
Camshaft Bearing
906-4.1
Checking
Camshaft Bearing
S60MC
0219
Checking
906-4.1
1.
1. As the upper shell of the camshaft bearing

assembly has been dispensed with on this
engine, it is no longer necessary to measure the top clearance of the camshaft bearing.
However, with normal inspection through
the inspection hole in the roller guide housing, we recommend a visual inspection of
the condition of the shell in the bearing cap
from each side.
In the event of any signs of anomalies, the

bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced
HC906-5.0 57 01
Check for wiped-out metal at the bearing

ends, and for fragments of metal in the
camshaft housing.
If no anomalies are found during the visual

inspection, dismantling need not be carried
out.
When checking the camshaft bearings, it is
recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 908-5 and 909-3.
MAN B&W Diesel A/S
Page 1 (5)
906-4.2
Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Caution!
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
HC906-5.0 57 02
1. Dismount the oil outlet pipe from the oil tray.

Mount an eye bolt in the cylinder frame behind the oil tray.
Release the sealing flanges on the roller
guide housing, loosening the screws
mounted in the roller guide housing.
Remove only the screws in the lower half of
the sealing flange.
2.
2. Attach a wire rope to the eye bolt. Place the

wire rope in the lifting fitting of the oil tray,
hook on a tackle and haul tight.
D06-36
Remove the screws securing the oil tray to

the roller guide housing. Ease off the oil
tray, landing it on the platform.
HC906-5.0 57 03
3. Mount lifting fittings on both sides of the

bearing half. Mount grooved pulleys on the
roller guide housing, and hook wire ropes/
tackles on to the lifting fittings/grooved pulleys. Tighten up the tackles.
HG906-4.3 201 03
3.
Page 2 (5)
MAN B&W Diesel A/S
Camshaft Bearing
906-4.2
Dismantling
4.
4. Mount the hydraulic jacks and loosen the

bearing nuts. For use of hydraulic jacks,
see Procedure 913-1.
Remove the hydraulic jacks and dismount
the nuts.
HG906-4.3 201 04
5. Lower the bearing cap and place it on the

platform.
D13-02
5.
HC906-5.0 57 06
D06-37
MAN B&W Diesel A/S
Page 3 (5)
906-4.3
Camshaft Bearing
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.
HC906-5.0 57 07
2. 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
entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication.
2.
MA906-4.3 209 02
Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.
Page 4 (5)
D06-34
D06-65
MAN B&W Diesel A/S
Camshaft Bearing
906-4.4
Mounting
Mounting
906-4.4
1.
1. Clean the bearing journal, the bearing support and the bearing shell.
Mount the bearing shell in the bearing cap,
after coating the shell with oil. Then pull the
bearing cap into place by means of tackles/
wire rope fitted through the grooved pulleys
to the lifting fittings. Check that the guide
pins enter correctly.
Remove the lifting fittings and grooved pulleys from the roller guide housing.
HC906-5.0 57 06
2. Mount and tighten up the nuts by means of

the hydraulic tools.
See Data.
3. Hoist the oil tray into place, positioning it by

means of the guide pins.
D06-37
2.
Then fasten it to the roller guide housing by

tightening up uniformly all round the circumference.
Remove the shackle and eye bolt.
Mount the screws that fasten the sealing
flanges to the roller guide housing. Mount
the oil pipe on the oil tray.
HG906-4.3 201 04
D13-01
3.
HC906-5.0 57 03
D06-36
MAN B&W Diesel A/S
Page 5 (5)
Chain Drive and Camshaft Panel
MAN B&W Diesel A/S
Plate
P90651-0203
Page 1 (2)
Plate
P90651-0203
Item
No.
019
020
044
056
068
070
081
127
139
Page 2 (2)
Chain Drive and Camshaft Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Pin spanner for fuel cam
Pulley for wire
Lifting attachment
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90664-0001
Page 1 (2)
Plate
P90664-0001
Item
No.
021
Page 2 (2)
Item Description
Item
No.
Item Description
Pin gauge for crankshaft
MAN B&W Diesel A/S

107-01
907-01
107-02
907-02
0019
0219
0041
0217
Starting Air Distributor, Data

Starting Air Distributor
Start Air Valve, Data
Starting Air Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
107-1

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
107-1

Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
907-1.1
Checking
K98MC-C
0219
Checking
907-1.1
2.
1. Turn the engine in AHEAD direction to bring

the piston of cylinder No. 1 to TDC. Check
the position with the pin gauge.
3. Check that the guide pin holes in the starting cam coincide or that the guide pins are
mounted and the TDC marking scratch on
the starting cam is positioned vertically in
line with the marking scratch at the valve
slide of cylinder No. 1.
If the scratch marks are out of alignment,
the starting cam must be dismantled.
HN907-1.1 205 02
2. Remove the small end cover of the distributor housing.
3.
4. Remove all the slide valves, see Procedure

907-1.3.
Unlock the centre screw and remove the
screw.
Pull off the starting cam by means of two
dismantling screws.
If the guide pins are bent or broken, remove

the pins and mount new pins.
Remount the starting cam, and the centre
screw.
M90701-0219C03
Check the guide pins.
Note!
The starting cam must always be provided with guide pins.
Mount the slide valve for cylinder No. 1 and
check the alignment once more.
If the scratch marks are out of alignment,
contact MAN B&W Diesel for advice.
MAN B&W Diesel A/S
Page 1 (5)
907-1.3

Overhaul
Overhaul
907-1.3
2.
Difficulties in starting can be caused by the

starting air distributor valve slides sticking
(see Volume I, Chapter 703), so that these are
not activated and pressed against the cam during the starting procedure.
HN907-1.3 205 02
This can be caused by too high humidity in the

main starting air system, which can result in the
formation of rust, and also by dirt, preventing
the slide valves from functioning.
In both cases it is necessary to clean the valve
slides and the liners in the distributor housing
to remove dirt, rust and foreign particles.
3.
Experience will show how often this is necessary to prevent starting difficulties, as differences will be found from plant to plant.
1. Blank off the main starting air and the control air. If this is not possible, lock the main
starting valve in the closed position with a
padlock.
2. Remove all the pipes from the end of the
distributor.
HN907-1.3 205 03
Loosen and remove the screws from the

small and large end covers. Dismount the
end cover which gives access to the slide
valves.
3. Turn the camshaft until the pin of the valve
slide (cam follower) can be pushed clear of
the starting cam.
4.
4. Remove the screws and the cap from the

particular valve slide in question.
HN907-1.3 205 04
Remove the guide screw for the valve slide.
Page 2 (5)
MAN B&W Diesel A/S
907-1.3
Overhaul
5.
5. Remove the complete slide valve (with

spring and the upper liner) from the distributor housing by means of a brass mandrel.
6. Press-in the spring and remove the two part
locking ring.
907-1.3 217 05
7. Remove the upper spring guide, the spring,

the lower spring guide and the upper liner
from the valve slide.
M90701-0219O06
6.
M90701-0219O07
7.
MAN B&W Diesel A/S
Page 3 (5)
907-1.3

Overhaul
8.
8. Clean all the sliding surfaces on the valve

slide. Check the sliding surfaces for wear
and seizures, also check the cam follower
for wear.
Clean the liners and the distributor housing.
Test that the valve slide moves easily in the
liners.
Note!
M90701-0219O08
Polishing of the liners with emery cloth

must not take place as small particles of
the grinding material can stick in the surface of the liner.
10.
Lubricate all parts with Molybdenum Disulphide (MoS2), also the cam follower must
be well lubricated.
9. Place the upper liner, the lower spring
guide, the spring and the upper spring
guide over the valve slide.
10. Press-in the spring and mount the two-part
locking ring.
M90701-0219O10
11. Mount the complete slide valve in the distributor housing. (Check that the pin of the
valve slide goes clear of the starting cam
when mounting).
Lubricate the groove in the starting cam
with Molybdenum Disulphide (MoS2).
M90701-0219O11
11.
Page 4 (5)
MAN B&W Diesel A/S
907-1.3
Overhaul
12.
12. Mount the guide screw for the valve slide.

Mount the cap and the screws on top of the
slide valve.
13. Check that the piston valve slides can be
pushed up and down by hand just overcoming the force of the spring.
M90701-0219O12
14. Finally, mount the two end covers and connect the main starting air and the control
air.
HN907-1.3 205 02
14.
MAN B&W Diesel A/S
Page 5 (5)
107-2
Starting Air Valve

Data
X
Stopped engine

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D07-09
Piston tightening torque
D07-11
Valve tightening angle
60
D07-12
Starting air valve
75
kg
MAN B&W Diesel A/S
140
Nm
Page 1 (2)
107-2
Starting Air Valve

Data
Plate
Item No.
P90151
95
P90151
105
Page 2 (2)
Description
Grinding ring for starting valve
Grinding handle for starting valve
MAN B&W Diesel A/S
Starting Air Valve
907-2.1
Checking
Starting Air Valve
K98MC
0217
Checking
907-2.1
1.
1. When the starting air valve has been overhauled, see Procedure 907-2.3, connect a
supply of working air to the control air inlet
at the top of the valve.
Check that the valve opens approx. 15-20
mm.
2. Shut off the air supply
Check that the valve closes fully.
HM907-2.1 202 01A
3. Repeat steps 1 and 2 a couple of times.
HM907-2.1 202 01B
2.
MAN B&W Diesel A/S
Page 1 (6)
907-2.2
Starting Air Valve

Dismantling
Dismantling
907-2.2
1.
1. Shut off the starting air and control air inlet.

Dismount the control air pipes
Mount two eye bolts in the top cover of the
valve.
Hook a lifting wire on to the eye bolts.
Unscrew the fixing nuts of the starting valve
flange.
HG901-2.2 59 02
2. Lift away the starting valve.
2.
HG907-2.3 201 02
D07-12
Page 2 (6)
MAN B&W Diesel A/S
Starting Air Valve
907-2.3
Overhaul
Overhaul
907-2.3
1.
1. Place the starting air valve horizontally in a

bench vice provided with soft jaws.
Remove and discard the O-ring from the
valve housing.
2. Loosen and remove the screws from the top
cover.
3. Use the face wrench for the spindle as a

back-stop when loosening the two screws
which tighten the piston to the spindle.
Remove the screws and discard the locking
device.
HM907-4.0 39 01
Dismount the top cover.
When unscrewing, the piston will partially

be pressed out of the valve housing due to
the spring force.
HM907-4.0 39 02
2.
HM907-4.0 39 03
3.
MAN B&W Diesel A/S
Page 3 (6)
907-2.3
Starting Air Valve

Overhaul
4.
4. Remove the piston from the top end of the

valve housing.
Take out the spindle from the bottom end of
the valve housing.
Remove the spring from the top end of the
housing.
5. Apply grinding paste, e.g. carborundum No.
200. Grind the valve housing seating with
the grinding ring.
6. When lapping the seatings of the spindle
and valve housing to match, use the face
wrench to rotate the spindle.
HM907-4.0 39 04
As grinding paste, use e.g. carborundum

No. 500.
HM907-4.0 39 05A
5.
MG907-4.0 51 05B
6.
Page 4 (6)
MAN B&W Diesel A/S
Starting Air Valve
907-2.3
Overhaul
7.
7. Thoroughly clean the valve housing and all

the parts in diesel oil or kerosene.
Lubricate all internal parts and sliding surfaces with, e.g., Molybdenum Disulphide,
MoS 2.
Insert the spindle in the valve housing.
Then mount the spring in the housing
around the spindle and, finally, place the
piston on top of the spindle.
8. Fit the discs and the two screws.
When tightening the screws, the piston will
compress the spring.
Lock the screws with locking device.

For correct use of locking device, see Procedure 913-7.
9. Mount and tighten the top cover.
HM907-4.0 39 07
Tighten the screws continuously until the

piston faces tightly against the spindle. Use
the face wrench as a back-stop. See Data.
9.
Fit a new O-ring on the valve housing.

10. Check the starting air valve.
If the valve is not to be mounted in the engine immediately, cover all openings with
plastic to prevent dirt from entering the
valve during storage.
HM907-4.0 39 09
D07-09
MAN B&W Diesel A/S
Page 5 (6)
907-2.4
Starting Air Valve

Mounting
Mounting
907-2.4
1.
1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recondition the seat for the starting valve in the
bore, see Procedure 901-1.3.
If not already done, fit a new O-ring on the
overhauled valve and lubricate with Never
Seize or Molybdenum Disulphide, MoS 2.
For overhaul, see Procedure 907-2.3 .
2. Mount the valve in the cylinder cover.
HG907-2.4 201 01
3. Mount the nuts and tighten-up in at least

three steps, to reach the full tightening angle, see Data.
Mount the control air pipe and turn on starting air and control air.
2.
HG907-2.4 201 02
D07-12
3.
HM901-2.2 114 03
D07-11
Page 6 (6)
MAN B&W Diesel A/S
908 - Exhaust Valve

108-01
908-01
108-02
908-02
108-03
908-03
108-04
908-04
108-05
908-05
108-07
908-07
90851
90861
90862
90863
90864
0037
0226
0094
0269
0057
0227
0041
0222
0017
0219
0034
0228
0177
0022
0036
0015
0003
High-Pressure Pipe, Data

High-Pressure Pipe
Exhaust Valve, Data
Exhaust Valve
Exhaust Valve Actuator, Data
Exhaust Valve Actuator
Exhaust Valve Roller Guide, Data
Exaust Valve Roller Guide
Exhaust Valve Cam, Data
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
Exhaust Valve - Panel
MAN B&W Diesel A/S
MAN B&W Diesel A/S
High-Pressure Pipe
108-1
Data
SAFETY PRECAUTIONS
Special Edition
D10801
S80MC
108-1
Data 0037
High-Pressure Pipe
Stopped engine
Block the starting mechanism
Shut off starting air supply

Engage turning gear
Shut off fuel oil
Shut off lubricating oil

Lock turbocharger rotors
Data
Ref.
D08-01
D08-02
D08-03
Description
High-pressure pipe, tightening torque

Distance of high pressure pipe lower edge to pressure flange
High-pressure pipe
MAN B&W Diesel A/S
Value
Unit
170 Nm
20 mm
100 kg
Page 1 (2)
High-Pressure Pipe
108-1
Data
Plate
P90851
Page 2 (2)
Item No. Description
112
Grinding mandrel for high-pressure pipe
MAN B&W Diesel A/S
High-Pressure Pipe
908-1.2
Dismantling
908-1.2
Disling
908-1.2
Dismantling
1.
1. When replacing the hydraulic high-pressure

pipe, the exhaust valve or the hydraulic actuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.
2. Before dismantling 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.
M908010226D01
D0803
M908010226D02
2.
MAN B&W Diesel A/S
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
1. Check the contact surfaces of the pressure
pipe for marks and, if necessary, grind the
pipe ends by means of the grinding mandrel and the two guiding tools.
1.
M908010226O01
Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and
finish with a fine grinding paste, for example Carborundum No. 500.
Carborundum
2. After reconditioning the contact surfaces of

the pipe, measure the distance from the
edge of the thrust bushing to the contact
surface at both ends of the pipe. This measurement is to correspond with the value
stated in Data.
Check the thrust pads in the exhaust valve
and the actuator for marks on the sealing
surface.
2.
Replace the O-rings on the thrust pads.

If considered necessary, replace the thrust
pads.
M908010226O02
Lift the thrust pad free by, for example, using a screwdriver in the groove of the
thrust pad.
Page 2 (3)
D0802
MAN B&W Diesel A/S
908-1.4
High-Pressure Pipe
Mounting
1. Mount the hydraulic high-pressure pipe as
follows:
1.
After fitting the pipe correctly in relation to

the exhaust valve and actuator, tighten up
the screws of the pressure flanges diagonally, see Data.
2. Check the whole system for tightness.
M908010226M01
Position the high-pressure pipe with the

sealing surfaces of the pipe resting on the
thrust pads of the exhaust valve/actuator.
Take care not to damage the O-rings on
the thrust pads.
D0801
M908010226M02
2.
MAN B&W Diesel A/S
Page 3 (3)
Exhaust Valve
MAN B&W Diesel
108-2
Data

X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D08-04
D08-05
D08-06
D08-07
D08-09
D08-10
D08-11
D08-12
D08-13
D08-14
D08-15
D08-16
D08-17
D08-18
D08-19
D08-20
D08-21
D08-22
D08-23
D08-24
D08-25
D08-26
D08-27
D08-28
D08-29
D08-30
Safety valve, opening pressure

Screws for lifting eye bolt, tightening torque
Oil cylinder, tightening torque
Safety valve, tightening torque
Bottom piece seat, grinding angle
Valve spindle seat, grinding angle
Bottom piece seat, max. grinding
Gap of bottom piece seat
Spindle, max. burn-off
Spindle, max. grinding
Spindle stem, measuring area, min.
Spindle stem, measuring area, max.
Spindle stem, min. diameter
Bushing max. diameter, top
Bushing max. diameter, bottom
Oil cylinder max. inside diameter
Piston rings, min. thickness
Damper piston, min. distance
Damper piston, max. distance
Exhaust valve, complete
Exhaust valve housing
Oil cylinder
Air cylinder
Spindle
Bottom piece
Air piston
D13-01
D13-02

Value
Unit
21
215
215
70 - 100
29.9 - 30.0
30.5 - 30.6
2.3
1.0
11.0
2.0
385
545
95.8
96.7
99.5
112.2
4.2
48,4
51,4
1700
950
230
70
180
220
22
bar
Nm
Nm
Nm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
kg
kg
900
800 - 990
bar
bar
Page 1 (2)
Exhaust Valve
108-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90851
065
Lifting tool for exhaust valve
P90851
077
Cone ring for pneumatic piston
P90851
089
Pressure tester for safety valve
P90851
090
Gauge for exhaust valve spindle
P90851
136
Bridge gauge for exhaust valve
P90851
148
Tool for hydraulic piston
P90851
150
Gauge for exhaust valve bottom piece
P90851
161
Lifting tool for exhaust valve spindle
P90851
185
Grinding ring for exhaust valve bottom piece
P90861
P90862
P91351
010
P91351
046
P91351
060
P91351
117
Page 2 (2)
Exhaust Valve
MAN B&W Diesel
Checking
Checks during running:

1.
908-2.1
1.
Check of valve spindle rotation
The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the groove in the
piston.
During engine operation, the spindle must
rotate. The rotation can vary with unit and
engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is
nished, lift the rotation indicator and lock
it in the top position.
M908020252C01
The engine must run when the valve function and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90 and let it rest on the air piston.
On Surface
InGroove
2.
The indicator must not be in constant operation.
2. Check of sealing oil unit

Check that the injection indicator moves
regularly with the valve opening. Alternatively, unscrew the sealing oil pipe, and
check that oil is coming out (very small
quantity).
M908020256C02
Exhaust valve performance condition

See volume I chapter 706 Performance
Evaluation
Depending on valve model the indicator is

placed either on the manoeuvre side or the
front side
Page 1 (25)
Exhaust Valve
908-2.1
Checking
MAN B&W Diesel
3. Check of bottom piece sealings

3.
With the exhaust valve mounted in the cylinder cover, check the cooling water inlet
and outlet to the cylinder cover and exhaust valve is open.
M908020254C03
Check the tightness of the sealing rings

between the bottom piece and the exhaust
valve housing. IF water ows from the small
bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is
leaking.
If water ows from the any of the rings, the
exhaust valve must be dismounted and the
sealing rings replaced.
Check with stopped engine:
4.
In connection with port stays, at an interval
of e.g. one month, an easy check of all exhaust valves is recommended.
4. Check of spindle dropdown time:
Engage all rotation indicators on the exhaust valves.
SAFETY AIR
SUPPLY
Shut off and release the spring air on the

valve, next to the engineside manoeuvring
stand.
AIR SUPPLY
EXHAUST VALVE
Check the drop down time for all spindles:
Spindles dropping down within 30 min-
M908020256C04
utes: Check and overhaul, See next step

Check of Air Spring tightness.
Spindles dropping down between 30

minutes and 1 hour: Keep under observation.
CONTROL AIR
SUPPLY
Spindles dropping down after 1 hour:

OK.
When check of drop down time is nished,
lift the rotation indicators and lock them in
the top position.
Page 2 (25)
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
5. Check of Air spring tightness

5.
Connect compressed air to the non return
(A) valve on the air cylinder.
Disconnect and remove the drain oil pipe
from the oil cylinder (C).
Disconnect the sealing oil pipe and banjo
coupling from the air cylinder (B).
Check if air is coming out from:
The sealing oil bore (B): Leakage from

spindle stem sealing , change and overhaul.
Hole for drain oil (C): If yes, the leakage
comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and overhaul.
Remove the air supply to the nonreturn

valve on the air cylinder and check the
nonreturn valve for tightness.
The checks is for guidance only, minor
leaks is difcult to detect.
M908020256C05
C
B
Page 3 (25)
908-2.2
Exhaust Valve
Dismantling
1.
MAN B&W Diesel
Close off cooling water
1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections
Dismount the highpressure pipe for the hydraulic valve actuation.
See Procedure 9081.2
M908020256D01
Dismount the return oil pipe from the exhaust valve.
M908020256D02
2.
Page 4 (25)
Exhaust Valve
MAN B&W Diesel
908-2.2
Dismantling
3. Disconnect pipe connections

3.
Disconnect the cooling water connections
from the exhaust valve and the air pipe for
the air spring.
Remove the plate jacket and insulation
from the intermediate pipe.
Support the intermediate pipe by e.g. a

chain block and remove the screws.
4. Dismantling of hydraulic nuts.
Remove the protective caps from the exhaust valve studs.
M908020256D03
Loosen the screws which attach the intermediate pipe to the exhaust valve housing.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 9131.
M908020256D04
D1302
Page 5 (25)
Exhaust Valve
908-2.2
Dismantling
MAN B&W Diesel
5. Lift of exhaust valve

5.
D0824
Check all connections to the valve are removed.

Attach the crane to the eye bolt tted on
top of the valve and start lifting the exhaust
valve. During the lift check the valve goes
clear of all other engine components.
Land the exhaust valve on a wooden plate
on the platform.
Carefully clean the exhaust valve bore in
the cylinder cover and recondition the seating and sealing surfaces of the bore, if required.
M908020256D06
For overhaul of the exhaust valve, see Procedure 9082.3
Page 6 (25)
Exhaust Valve
MAN B&W Diesel
1.
908-2.3
Overhaul
Oil cylinder
1.
Place the exhaust valve on a wooden support on the platform.
D0826
Remove the nuts and the safety strap from

the oil cylinder.
Depending on valve model, remove the sealing oil pipe.
Lift away and place the oil cylinder on a
wooden support.
2. Conical locking ring
Remove the four screws from the ange

on top of the air piston and dismount the
ange.
2.
M908020256O02
Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
M908020256O01
Relieve the air pressure through the

nonreturn valve from below the piston. Use
a small screwdriver to press the ball into
the nonreturn valve. Cover the nonreturn
valve with a rag to catch the oil drops.
Page 7 (25)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
3. Spindle
3.
D08-24
Use the oil cylinder as a lifting tool for the

exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
so that the load from the valve housing is
evenly distributed.
Lift the valve housing clear of the valve
spindle. Take care when the internal
Oring in the air piston and the internal
rings for the sealing arrangement at the
bottom of the air cylinder pass the groove
for the conical ring at the top of the spindle.
4. Bottom piece
M908020256O04
Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
If the bottom piece has become stuck, use
a tin hammer to release it.
Lift the valve housing away and land it on a
couple of wooden planks.
4.
Remove the oil cylinder.
M908020256O05
D08-29
Page 8 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
5. Air piston and cylinder

5.
Dismount the air piston from the air cylinder.
Dismount the nonreturn valve from the air
cylinder/valve housing.
D08-30
D08-27
Mount two eye bolts in the air cylinder and

dismount the air cylinder.
6. Guide bushing
Clean the exhaust valve housing.
Inspect the bushing in the spindle guide for
wear and measure the top and bottom diameters. See Data.
M908020256O06
Remove and discard the Oring on the air

cylinder.
6.
D0818
M908020269O06
D0819
Page 9 (25)
908-2.3
Exhaust Valve
Overhaul
7.
MAN B&W Diesel

Bushing renewal
7.
If it proves necessary to replace the bushing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.
Alternatively, if the extractor tool is available, mount the extractor tool and pull up
the bushing.
The extractor tool is optional, and can be
ordered as spare part.
When a new bushing is mounted, mount
a new Oring for sealing between bushing and exhaust valve housing. Mount and
tighten the screws for the bushing.
M908020269O07
8. Bottom piece inspection

Before cleaning the bottom piece, See Volume I, supplement 70703
Inspect and evaluate the seating according
to Volume I.
M908020256O09
8.
Page 10 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
9. Bottom piece Measuring

9.
In connection with evaluation of the bottom
piece according to Volume I, wear or the
total amount the seat has been ground, is
measured as described below.
G3
D0812
Use the bottom piece template and a feeler

gauge, take measurements G2 and G3. All
measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating.
For maximum wear or grinding, see Data
D0811 and D0812.
D0809
IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN Further
grinding or reconditioning is not recommended.
10. Bottom piece sealing face
If necessary grind the outside seating.
Use carborundum 200 and the special
grinding tool. Turn the special grinding tool
by hand, turning alternately clockwise and
anticlockwise. Grind until a smooth surface
is achieved.
M908020255O14
If the seat or the recess G3 is ground, see

Data D08 09 for correct grinding angle.
G2
D0811
10.
M908020255O15
Clean the bottom piece.
Page 11 (25)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
11. Bottom piece sealing rings

11.
Make sure that the groove for the O-rings
are clean.
Mount the new O-rings on the bottom
piece.
12. Bottom piece mounting
exhaust valve housing.
M908020269O11
Check the face on the valve housing is

clean.
If tted, check that the guide pin in the
bottom piece enters the hole in the bottom
of the exhaust valve housing.
12.
Land the exhaust valve housing on the bottom piece. Mount and tighten the retaining
screws for the bottom piece.
M908020269O12
D0826
+
D0825
Page 12 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
13. Spindle inspection

13.
Before cleaning the spindle, See Volume I,
supplement 70703
Inspect and evaluate the spindle according
to Volume I.
In connection with evaluation of the spindle

according to Volume I, burnoff and wear or
the total amount the seat has been ground,
are measured as described below.
The burnoff F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
M908020256O14
14. Spindle burnoff and grinding check
14.
For the maximum allowable burnoff, see
Data D0813.
G1
The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge.
D0814
For maximum seat grinding, see data D08

14.
M908020256O15
If necessary to grind the seat, see Data

D0810 for correct grinding angle.
F1
D0810
A
D0813
Page 13 (25)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
15. Spindle stem check

15.
In connection with evaluation of the spindle
according to Volume I, the spindle stem
wear is measured as described below.
D0816 D0815
D0817
Check the spindle stem for wear in the

area D0815 to D0816 measured from the
top of the spindle.
For minimum stem diameter, see data D08
17.
If the exhaust valve spindle needs reconditioning, contact MAN B&W Diesel for
advice.
16. Spindle transport
M908020252O19
When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
16.
M908020255O16
D0828
Page 14 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
17. Spindle bushing sealingrings

17.
Check the top of the spindle bushing and
the face on the housing is clean.
Fit new orings on the spindle bushing as
shown in the sketch.
18. Spindle mounting

exhaust valve housing.
Carefully land the exhaust valve housing
with the bottom piece on the exhaust valve
spindle.
M908020269O17
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
18.
M908020256O19
Remove the oil cylinder.
Page 15 (25)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
19. Air cylinder

19.
Clean the air cylinder.
Dismount the safety valve from the air cylinder, use the machined faces to unscrew
the valve.
Unscrew and clean the Banjo coupling for
sealing oil to the spindle stem bushing.
Blow through all bores in the air cylinder.
Check the nonreturn valve in the Banjo
coupling with compressed air. Clean the
bottom of the air cylinder for possible coke.
Remount the Banjo coupling. Mount a new
Oring in the groove on the outside of the
air cylinder.
Compressed Air
20. Safety valve
M908020256O20
Place the safety valve in the pressure testing device. 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, loosen the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated. Tighten the lock nut
and test the opening pressure once more.
20.
D08-04
Mount a new gasket and a new Oring on

the safety valve. Mount the safety valve in
the bore near the bottom of the air cylinder.
When mounting the safety valve in the air
cylinder, use only the machined faces on
the valve housing and tighten, see Data.
M908020256O21
Finally, mount the protective cap.
D08-07
Page 16 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
21. Air cylinder mounting

21.
Lubricate the Orings on the spindle bushing.
Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines
are not equipped with the locating pin
Take care not to damage the Orings on

the outside of the spindle bushing.
22. Air piston seals

Check the teon guide ring and teon sealing ring for wear, if it is necessary to replace the sealing rings on the air piston, cut
them and remove them.
M908020256O22
Note!
22.
Be careful not to damage the edges of the

ring grooves in the piston.
Before mounting, heat the new teon

rings in 100C hot water for at least ve
minutes. When mounting the teon rings,
be careful not to damage the running
surfaces.
M908020252O32
Note!
After mounting, compress the teon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new Orings in the inside grooves of
the air piston.
Page 17 (25)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
23. Air piston mounting

23.
Fit the conical guide ring for the air piston
on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press
the air piston down in the cylinder
Remove the conical guide ring from the air
cylinder.
Mount the non return valve for spring air
24. Locking ring
M908020256O24
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
Mount the ange on top of the air piston
and, by means of the four screws, tighten
the air piston and the ange together.
On valve models where the bolts are designed for securing, secure the bolts. See
Procedure 9137.
M908020256O25
24.
Page 18 (25)
Compressed Air
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
25. Oil cylinder

25.
Loosen the screws and remove the lifting
bracket from the oil cylinder to gain access
to the orice plug.
Remove the sealing oil unit.
Remove and discard the gasket. Unscrew
and clean the orice plug. Remove and discard the sealing disc. Check and clean the
bore for the orice plug in the top of the oil
cylinder.
26. Sealing oil control unit.
26.
M908020255O37
Normally overhaul of the sealing oil unit

should not be necessary. Check the unit
according to Procedure 908 2.1. Before
remounting the unit, carefully clean it on
the machined faces. If the unit needs to be
overhauled, send it to an authorised MAN
B&W repair workshop.
D08-20
M908020256O26
Place the oil cylinder in a horizontal position. Remove the ange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylinder diameter. If the diameter of the oil cylinder exceeds Data D0820, either renew the
liner or send the complete oil cylinder to an
authorised MAN B&W workshop for overhaul, depending on the valve model.
Page 19 (25)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
27. Oil piston

27.
Top
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 and
mount new ones. Check that the TOP mark
on the piston rings faces upwards, when
mounting.
Check the mesh once more.
M908020257O42
D0821
28. Oil piston damper check

Mount the piston on top of the spindle.
Connect compressed air supply to the
space below the air piston, so as to keep
the valve closed, and to keep the air cylinder in close contact with the valve housing.
28.
D0822
D0823
Place the measuring tool on the air cylinder

across the piston.
Check the mesh of the damper piston by
checking the distance from the upper edge
of the crossbar to the top of the damper
piston. See Data.
M908020256O29
If the measurement is outside the value

stated in Data, an adjustment must be
made by changing the disc in the damper
piston
Page 20 (25)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
29. Oil piston damper adjustment

29.
Place the piston in the special tool. Press
out the damper piston and the disc with
the centre screw.
Inspect the spring and the piston.
Assemble the damper piston with the new

disc in the special tool. Place the piston
upside down in the tool and press the disc
into place in the piston.
Check the mesh once more.
M908020256O30
A thicker disk increase the mesh and a

thinner disc decrease the mesh.
30. Oil cylinder assembly

30.
Mount the piston and the ange in the oil
cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright position. Mount a new sealing disc in the bore
for the orice plug. Screw the orice plug
into the bore. Place a new gasket on top of
the oil cylinder. Mount the sealing oil unit.
Mount the lifting bracket on the oil cylinder.
Mount the screws and tighten to the torque
stated in Data.
M908020256O31
D08-05
Page 21 (25)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
31. Oil cylinder mounting

31.
D0806
Mount the overhauled oil cylinder on top of

the air cylinder. Mount the safety strap and
tighten the nuts. See Data.
M908020256O32
Mount the sealing oil pipe
Page 22 (25)
Exhaust Valve
MAN B&W Diesel
1.
908-2.4
Mounting
Checks before mounting

1.
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve is checked and prepared as follows:
D0824
Connect compressed air to the air cylinder

to close the valve.
Lift up the valve with the engine room
crane.
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 spindle.
Carry out the drop down test as described
in procedure 9082.1.
2. Exhaust valve landing

Close the valve with compressed air.
M908020256M01
Check the valve is tted with new sealingrings in the grooves on the bottom piece.
G3
2.
Lubricate the sealing rings with vaseline and the threads of the studs with
antiseizure paste.
Position the valve in the cylinder cover
bore, guiding it in accordance with the exhaust anges and the guide pin on the exhaust side of the exhaust valve.
Compressed Air
Copper Grease
M908020256M02
Vaseline
Page 23 (25)
908-2.4
Exhaust Valve
Mounting
MAN B&W Diesel
3. Mounting of hydraulic nuts.

3.
D1301
Mount and tighten the hydraulic nuts, see

Data.
See Procedure 9131.
Mount the protective caps on the exhaust
valve studs.
4. Mount the pipe connections
M908020256M03
Connect the intermediate pipe to the exhaust valve.
4.
Mount and tighten the screws to the exhaust valve housing.

Mount the insulation and plate jacket
for the intermediate pipe.
Mount the cooling water connections for
the exhaust valve and the air pipe for the
air spring.
5. Mount the oil pipe connections
M908020256M04
Mount the highpressure pipe for the hydraulic valve actuation.

Mount the return oil pipe to the exhaust
valve.
Check that all pipe connections are properly tightened.
M908020256M05
5.
Page 24 (25)
Exhaust Valve
MAN B&W Diesel
908-2.4
Mounting
6. Open cooling water supply

6.
Check that all water connections are
mounted and tightened.
Open the cooling water inlet supply, and
vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring between the bottom piece and the exhaust
valve housing. See Procedure 9082.1.
7.
Air spring check
If the lubricating oil pumps have been

started before the exhaust valve pneumatic
springs are pressurize:
Engage the indicators on top of the exhaust
valves and wait until the exhaust valves are
closed.
M908020256M06
The air supply to the exhaust valve must always be connected and pressurized before
turning on the oil supply to the exhaust
valve actuator.
7.
M908020256M07
Closing of the exhaust valves are eased

if the lubrication oil pumps are stopped
and the actuators are drained at the drain
screws.
Closed Valve
Open Valve
Page 25 (25)

MAN B&W Diesel
108-3
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D08-20
Oil cylinder max. inside diameter
D08-21
Piston rings, min. thickness
D08-32
Hydraulic actuator, tightening torque
D08-33
Locking plate, tightening torque
D08-34
Hydraulic actuator, tightening angle
D08-35
Hydraulic actuator
Value
Unit
112.2
mm
4.2
mm
1450
Nm
50
Nm
100/27
240
Nm/
kg
Page 1 (2)
108-3
MAN B&W Diesel
Data
Plate
P90851
Page 2 (2)
Item No.
041
Description
Tightening template, actuator
908-3.1
Checking
L60MC-C
0227
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 facing 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 hydraulic actuator.
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
normal, any abnormally large leakages
must originate from the hydraulic actuator
from which leak oil quantities cannot be directly registered.
HM908-3.0 70 1/3
The hydraulic actuator is then to be dismantled for checking of the parts.

See Procedure 908-3.2
0$1% :'LHVHO$6
Page 1 (4)
908-3.2
Dismantling
Dismantling
908-3.2
1.
1. Stop the engine and shut off the oil supply.

Turn the camshaft so that the roller rests on
the circular part of the cam.
Remove the inspection cover of the roller
guide housing to check the position of the
exhaust cam.
Dismount the inlet pipe and the drain pipe
from the exhaust valve.
GM908-3.0 78 01
Dismount the high-pressure pipe.

2. Release the mountings for the indicator
drive from the actuator housing.
Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.
2.
D08-35
Unscrew the nuts on the two short studs,
then loosen the nuts on the long studs successively until the roller guide spring is relieved.
Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller
guide.
HG908-3.3 201 02
Remove the spring.

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.
HM908-3.0 70 03
4. Overhaul the actuator housing and the piston as required.

Page 2 (4)
0$1% :'LHVHO$6
908-3.3
Overhaul
Overhaul
908-3.3
1.
1. Clean the piston in kerosene and wipe dry

with a clean piece of cloth.
D08-21
Take off the piston rings and check them for

wear. If the ring thickness has worn down
to the minimum (see Data), discard the
rings and mount new ones.
Check that the TOP mark on the piston
rings faces upwards when mounting.
2. Inspect the sliding surfaces of the piston to
ensure that there are no scratch marks or
seizure marks.
3. Clean the oil cylinder and inspect the bores
for deposits.
If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised workshop for reconditioning.
HM908-3.0 69 04
Check the bore of the oil cylinder for possible scores and measure it for wear.
3.
JM908-3.0 73 05
D08-20
0$1% :'LHVHO$6
Page 3 (4)
908-3.4

Mounting
Mounting
908-3.4
1.
D08-33
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 stated in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
KC908-3.0 76 05
Mount the washers and nuts on the two

long studs and tighten alternately until the
actuator housing rests firmly against the
roller guide housing.
Mount the washers and nuts on the two
short studs. Tighten all four nuts as stated
in Data.
2.
Note!
Use only the tightening angle OR the
tightening torque, NOT both.
D08-32
or
3. Mount the oil inlet pipe and the drain pipe

from the exhaust valve.
D08-34
HG908-3.4 201 02
Mount the hydraulic high pressure pipe.

HG908-3.4 201 03
3.
Page 4 (4)
0$1% :'LHVHO$6
Exhaust Valve Roller Guide

MAN B&W Diesel
108-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D08-36
Bushing/shaft pin, max. clearance
0.5
mm
D08-38
Roller guide complete
110
kg
Page 1 (2)
108-4
MAN B&W Diesel
Data
Plate
P90851
Page 2 (2)
Item No.
053
Description
Lifting tool for roller guide

MAN B&W Diesel
1.
908-4.1
Checking
The exhaust valve roller guide can be partially checked while mounted on the engine,
using the following procedure:
Lift the roller guide. See Procedure 908-7.
2.
2. Remove the camshaft inspection cover.

Turn the engine to provide the maximum
space between the roller guide and the
cam disc.
3. 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.
4. Check the roller guide and the bearing

clearance if the roller guide is dismounted.
For dismantling of the roller guide see Procedure 908-4.2.
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.
M908040222C01
Inspect the surface of the roller for possible damage marks, seizures or scratches.
Make sure that no traces of bearing metal
exist in the roller guide housing.
5.
D0836
6. Place a dial gauge against the roller. Then

lift the roller as much as the clearance permits, which makes it possible to read the
clearance directly on the dial. See Data.
7.
It is recommended that the roller guide

should ONLY be dismantled if:
irregularities when turning the roller,
damage to the roller,
suspect to larger clearance than stated
on the Data sheet,
seizure marks on the slide surfaces,
Note!
For disassembling of the roller guide,
contact an MAN B&W authorized repair
shop.
M908040222C02
have been observed during the checking of

the roller guide.
Page 1 (3)
908-4 .2

Dismantling
1.
1.
MAN B&W Diesel
Dismantle the hydraulic actuator above the

exhaust valve roller guide.
2. Mount the roller guide lifting tool as follows:

Lift the lock ring of the tool up on the
shaft of the tool.
Place the tool in such a manner that
its foot rests on the thrust piece in the
bayonet 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.
M908040222D01
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.
2.
D0838
M908040222D02
90O
Page 2 (3)

MAN B&W Diesel
1.
90?-?.4
Mounting
Mount the lifting tool for the roller guide as

follows:
1.
Lift the lock ring of the tool up on the

shaft of the tool.
D0838
Place the tool in such a manner that

its foot rests on the thrust piece in the
90O
Lower the lock ring, thereby securing

Clean and lubricate the sliding surfaces of
the roller and the roller guide and lower it
carefully into the roller guide bushing.
2. Turn the camshaft so that the roller guide is

lifted approx. 20 mm.
Check that the clearance between the roller
guide and the guide plate is the same at
both sides 0.1 mm.
M908040222D02
Remove the lifting tool.
2.
M908040222M02
3. Mount the actuator.

Page 3 (3)
Exhaust Valve Cam

MAN B&W Diesel
108-5
Data

X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D08-39
Description
Check lifting height
Value
Unit
16
mm
Page 1 (2)
Exhaust Valve Cam
108-5
MAN B&W Diesel
Data
Plate
Item No.
P90661
Description
Impact spanner for turning cam
P90851
173
Lifting tool for exhaust valve roller guide
P91351
010
P91351
034
P91351
058
P91351
154
Conical valve, 0 - 15
P91351
225
Disc, round-plain, Cu 11x3 mm
P91366
073
Page 2 (2)
Exhaust Valve Cam

MAN B&W Diesel
1.
908-5.1
Checking
Turn the crank throw of the cylinder concerned in AHEAD direction until TDC.
Check and write down the angle indicated
on the turning wheel.
1.
2. Remove the high pressure pipe, see procedure 9081.2
Mount a dial gauge (measuring range 0.00

20.00 mm) on the lifting tool for the exhaust valve roller guide.
Reset the scale and the pointer.
Press the dial gauge against the face of the
actuator housing until the reading D0839 +
1.00 mm is obtained.
M90805-0219C01
Mount and tighten the lifting tool for the

exhaust valve roller guide to the actuator
piston (remove the screws for tightening
to the actuator housing and do not lift the
roller guide).
2.
Continue turning AHEAD until the roller

guide again is lifted to D0839, and the dial
gauge gives the reading 1.00 mm.
Calculate the angle B, which is the number
of degrees the crank throw has turned from
TDC position to the present position.
M90805-0219C02
3. Turn the roller guide in AHEAD direction

until lifted to D0839, and the dial gauge
gives the reading 1.00 mm and calculate
the angle A, which is the number of degrees the crank throw has turned from TDC
position to the present position.
Note!
When calculating the angles A and B,
remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees.
Page 1 (4)
908-5.1
Exhaust Valve Cam

Checking
MAN B&W Diesel
4. Calculate the lead angle as:

180 (A + B)/2
4.
The lead angle is normally a negative gure.

The illustration shows the position of the
exhaust cam when the piston of the relevant cylinder is in TDC.
M90805-0219C04
D08-39
5.
The position of the cam must be correct

within a tolerance of +/0.5.
See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the lead angle
of the plant in question.
D08-39
5. The cam lead angle can be checked visually by reading 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.
M90805-0219C05
At the same time, it is recommended to

check the position of the camshaft with the
pin gauge. See Procedure 9063.1
Page 2 (4)
Exhaust Valve Cam

MAN B&W Diesel
Adjustment
Normally, adjustment of the exhaust cams

should not be necessary. Before adjustment of any cams, see Volume I, Chapter
706.
1.
908-5.3
1.
Remove the oil tray from the camshaft

housing. See Procedure 906-4.2.
3. Turn the camshaft until there is access to

the oil duct in the exhaust cam through the
inspection hole.
If tted, remove the plugs from the oil duct
(using, for instance, a screwdriver).
Insert three copper gaskets in each oil
duct.
M90805-0219O01
2. Dismount the exhaust valve highpressure

pipe, see Procedure 9081.2.
3.
Mount snapon couplings in the oil duct,

but do not tighten them.
4. Mount the special spanner on the exhaust

cam disc, ensuring that the two pins enter
the holes in the cam.
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snapon couplings.
Raise the hydraulic pressure until oil seeps
out along the camshaft under the cam disc.
M90805-0219O03
Fit hoses between the snapon couplings

and the distributor block and between the
distributor block and the hydraulic high
pressure pump.
4.
Keep the cam pressurised for at least two

to ve minutes before turning the cam.
Oil must sweep out with the pump running
during the operation.
M90805-0219O04
Keep the cam pressurised during turning.
Page 3 (4)
908-5.3
Exhaust Valve Cam

Adjustment
5.
MAN B&W Diesel
5. Turn the cam disc, using the tted spanner, until the desired change of lead is obtained. Check the change on the cam scale
To increase the lead angle and reduce the
compression pressure:
turn the cam disc ASTERN.
To reduce lead angle and increase the
compression pressure:
turn the cam disc AHEAD.
6. After completing the desired turning of the
cam disc, relieve the hydraulic system of
pressure and dismount the spanner and
the hydraulic equipment.
Wait at least 15 minutes the cam must be
allowed time to settle before mounting
the plugs again in the oil ducts of the cam
disc.
M90805-0219C05
After carrying out adjustment, measure the

exhaust cam lead again. See Procedure
9085.1.
Write down and le the new results for the
purpose of comparing with future measurements and adjustment.
7.
Mount the oil tray on the camshaft housing.

8. Mount the high pressure pipe for the exhaust valve. See Procedure 9081.4
9. After any adjustment of the cam position,
pcomp must be recorded and compared with
pcomp at a known engine reference load.
Page 4 (4)
108-7
Exhaust Valve Special Running

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
108-7
Exhaust Valve Special Running

Data
Plate
Item No.
Description
P90851
124
Tool for emergency open exhaust valve
P90851
173
Lifting tool for exhaust valve roller guide
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve
908-7
Special Running
0228
Exhaust
Valve
S80MC
Special Running
908-7
3.
Warning!
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:
KM908-7.0 223 03
Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
4.
1. Stop the engine.

Stop the lubricating oil pump.
Lift the relevant fuel pump roller guide.
3. Dismantle the non-return valve on the oil inlet pipe. Loosen the union nut in the bottom
of the oil pipe and turn the pipe to one side.
Mount the non-return valve on the oil pipe
and blank off the non-return valve with the
plug from tool panel 908.
HG908-4.1 201 01
2. Dismantle the hydraulic high-pressure pipe

and the connecting sleeve.
5.
4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.
5. Position the lifting tool on the actuator and
screw the spindle into the top of the actuator piston.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position.
JM908-5.0 55 03
Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible.
MAN B&W Diesel A/S
Page 1 (3)
908-7
Exhaust Valve
Special Running
7.
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.
If the cylinder is to operate with the exhaust
valve open, continue the procedure as follows:
7. Shut off the compressed air supply and remove the air pipe connection to the exhaust
valve and plug the pipe. Release the air
from the air spring through the non-return
valve on the side of the air cylinder.
Hint!
KM908-2.1 236 05
Use a small screwdriver to press the ball

into the non-return valve, and cover it
with a rag to catch the oil drops.
8. Dismantle the rotation indicator on the air
cylinder and mount the tool for opening of
the exhaust valve.
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.
KM908-7 228 08
8.
Page 2 (3)
MAN B&W Diesel A/S
Exhaust Valve
908-7
Special Running
9.
After overhaul of the cylinder unit, re-engage

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower
the roller guide on to the exhaust cam. Remove the tool.
10. If the engine has been running with the exhaust valve open, remove the tool mounted
in the air cylinder and mount the rotation indicator.
Note!
Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the formation of a wear groove in the air piston
of the exhaust valve.
Re-connect the air supply to the air cylinder.
JM908-5.0 55 06
The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.
11.
11. Remove the plug from the non-return valve
and re-connect 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.
KM908-7.0 223 11
13. Engage the fuel pump roller guide.

MAN B&W Diesel A/S
Page 3 (3)
Exhaust Valve Panel
Plate
P90851-0177
Exhaust Valve Panel

0177
P90851
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90851-0177
Item
No.
016
028
041
053
065
077
089
090
112
124
136
148
150
161
173
185
Exhaust Valve Panel
Item Description
Item
No.
Item Description
Tool panel
Name plate
Tightening template, actuator
Lifting tool, roller guide
Cone ring, pneumatic piston
Test equipment, exhaust valve
Cauge exhaust valve spindle
Grinding tool - h.p. pipe
Tool, emergency open exhaust valve
Bridge gauge, exhaust valve
Tool for hydraulic piston
Gauge exhaust valve bottom piece
Lifting tool - roller guide - exhaust
valve
Grinding ring - exhaust valve bottom
piece
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90861-0022

0022
P90861
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90861-0022
Item
No.
046
Item Description
Item
No.
Item Description
Grinding machine, complete
Notes:
Page 2 (2)
When ordering spare parts, please refer to the Chris Marine manual
MAN B&W Diesel A/S
Exhaust Valve Hydraulic - Tools
Plate
P90862-0036

0036
P90862
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90862-0036
Item
No.
016
028
041
053
065
077
089
Item Description
Item
No.
Item Description

Hydraulic Jack
Support
Stud setter
Hydraulic tool for exhaust valve, complete
Tommy bar
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90863-0015
Page 1 (2)

0015
P90863
MAN B&W Diesel A/S
Plate
P90863-0015
Item
No.
011
Item Description
Item
No.
Item Description
Worktable
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90864-0003
Page 1 (2)
Plate
P90864-0003
Item
No.
017
Page 2 (2)
Item Description
Item
No.
Item Description
Extractor tool, complete
MAN B&W Diesel A/S

109-01
909-01
109-02
909-02
109-03
909-03
109-04
909-04
109-05
909-05
109-06
909-06
109-07
909-07
109-08
909-08
109-09
909-09
10910
90910
10911
90911
10912
90912
10913
90913
10914
90914
10915
90915
0061
0241
0005
0206
0050
0234
0061
0224
0065
0234
0052
0220
0040
0214
0054
0217
0034
0216
0016
0218
0065
0249
0048
0228
0033
0206
0080
0255
0062
0236
Fuel Pump Settings, Data

Fuel Pump Settings
VIT System, Data
VIT System
Fuel Pump Cam, Data
Fuel Pump Cam
Fuel Pump, Data
Fuel Pump
Fuel Pump Top Cover, Data
Fuel Pump Top Cover
Fuel Pump Barrel Assembly, Data
Fuel Pump Barrel Assembly
Fuel Pump Suction Valve, Data
Fuel Pump Suction Valve
Fuel Pump Puncture Valve, Data
Fuel Pump Puncture Valve
Fuel Pump Shock Absorber, Data
Fuel System Shock Absorber
Lifting Gear Roller Guide, Data
Lifting Gear for Roller Guide
Fuel Valve, Data
Fuel Valve
Spindle Guide, Data
Spindle Guide
Non-Return Valve in Fuel Valve, Data
Non-Return Valve in Fuel Valve
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
MAN B&W Diesel A/S
90951
90961
90966
90967
90968
90974
90977
90979
90980
0446
0069
0008
0001
0001
0001
0001
0001
0001
Fuel Valve and Fuel Pump - Panel

Fuel Valve - Tools
Fuel Valve Nozzle - Tools
Fuel Puncture Valve - Tools
Fuel Valve - Inspection Tools
MAN B&W Diesel A/S
109-1
Fuel Pump Settings

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D09-02
Description
Value
Unit
2.0 - 3.0
bar
Change of one index mark, corresponds to p-max

being altered approx.
MAN B&W Diesel A/S
Page 1 (2)
109-1
Fuel Pump Settings

Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Fuel Pump Settings
909-1.3
Adjustment
Fuel Pump Settings
K98MC-C
0241
Adjustment
909-1.3
1.
Before adjustment of the fuel pump is carried

out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:
2. Loosen lock nut B and then turn adjusting

screw H. The link can be adjusted by approx. 3 index marks.
HN909-1.3 240 01
1. The Maximum Combustion Pressure (pmax)

is adjusted for the individual units at the fuel
pump VIT index arm. For collective adjustments of pmax on all units, see Procedure
909-2.
3. To increase p max, adjust to higher VIT index

(advance injection).
2.
To decrease p max, adjust to lower VIT index

(delay injection).
One index mark will alter pmax approximately as given in Data D09-02.
Note!
4. If the required p max adjustment cannot be

attained by adjustment on the VIT index
arm, it is possible to carry out the adjustment on the fuel cam disc. Contact MAN
B&W Diesel for advice.
HN909-1.3 240 02
The individual p max value must not deviate more than 3 bar from the average
value for all cylinders.
MAN B&W Diesel A/S
Page 1 (2)
909-1.3
Fuel Pump Settings

Adjustment
5.
MIP adjustment:
5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump
index arm.
Increase index for higher p i.
Decrease index for lower p i.
HN909-1.3 240 05
Note!
6.
The mean indicated pressure is one of

the most important parameters in obtaining good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the average value for all cylinders. See Volume I,
Chapter 706.
M90901-0242O06
6. After adjustment of the fuel pumps a set of

observations must be taken, to evaluate the
adjustments see Volume I.
Page 2 (2)
MAN B&W Diesel A/S
109-2
VIT System
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-2
VIT System
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
VIT System
K98MC-C
0206
Adjustment
909-2.3
1.
Before adjustment of any part of the VIT system, see Volume I, Chapter 706. All adjustments should be based on a set of
observations including a set of indicator diagrams taken when the engine is running just
above the breakpoint (90% MCR).
If the fuel quality has changed or if the fuel

pumps are worn, the pmax will change, this
change can be corrected by adjusting the pmax
of all the cylinders with the VIT system, see
Fine adjustment.
M90902-0206O01
The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection
Timing) system.
Normally the VIT system is adjusted to start at

40% engine load and to have break point at
90% of MCR engine output. Look in the test
sheet for actual start- and break point.
2.
Mechanical VIT system

Basic adjustment:
When the basic adjustment is carried out the
engine must be stopped, normally only fine adjustment is necessary.
1. Engage the manual engine control, and adjust the regulating shaft to a fuel pump index corresponding to 90% engine load.
(The fuel index must correspond to 90%
load taken by measurement or from the test
bed sheet).
M90902-0206O02
2. Check that the VIT lever is resting on both

rollers (break point for all cylinders).
MAN B&W Diesel A/S
Page 1 (5)
VIT System
909-2.3
Adjustment
3.
3. If necessary, adjust the lever by loosening

the nut A and turn the clamping arm B, until
lever contact with both rollers and tighten
nut A.
4. Spare pilot valves should be pre-adjusted

to 0.5-5.0 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin
C.
M90602-0238O03
B
A
4.
Adjust the VIT air pressure to 3.0 bar, by

axial displacement of the bracket with the
pilot valve and read the pressure on the
pressure gauge C. See figure 2.
To check a pilot valve already mounted on

the engine, remove the inlet and outlet pipe
connections at A and P, and connect a
pressure gauge at A and a pipe with working air (pressure 7 bar) at P on the pilot
valve.
Pbar
5
4
3
2
1.5
0.5 1
0.1
Pressing
in mm
0 1 2 3 4 5 6 7 8
0.5
Check that the pressure on the pressure

gauge and the pressing-in of pin C is in accordance with the curve.
Any necessary adjustment is done by turning adjusting screw B.
M90902-0206O04
Page 2 (5)
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
5.
Fine adjustment:
5. When the fine adjustment is carried out, the
engine must run at 90% load or just above.
Take a new set of indicator diagrams and
calculate the engine load.
Adjust the VIT air pressure to obtain cylinder p max of 140 bar. The VIT air pressure
must be maximum 5.0 bar.
Increase the pmax pressure by moving the
pilot valve toward the lever.
Decrease the p max pressure by moving the
pilot valve away from the lever.
6. Run the engine at maximum load and check

that p max is 140 bar.
6.
M90902-0206O06
If the maximum combustion pressure deviates more than 3.0 bar from 140 bar, adjust
the pressure by replacement of the lowermost roller.
M90902-0206O05
For adjustment of pmax on a single cylinder,

see procedure 909-1.
MAN B&W Diesel A/S
Page 3 (5)
VIT System
909-2.3
Adjustment
Pmax
adjusted on
lowermost roller
7.
Pbar
Electronic VIT system
Break point
Pmax
adjusted on
uppermost roller
8. The adjustment should be based on a set

of indicator diagrams taken when the engine is running just above the breakpoint.
M90902-0206O07
Pcomp
40
90
100
%Load
9. On the panel in the engine room control

room, change the p offset value in accordance with the required increase or decrease in the p max pressure. One
graduation mark on the p offset scale corresponds to a change in p max of 1 bar.
10. Check the adjustment by taking a new set
of indicator diagrams while the engine is
running just above the breakpoint.
M90902-0206O08
8.
7. The uppermost roller is used to adjust the

VIT start point (40% engine load).
Page 4 (5)
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
11.
11. The I/P converter mounted on the engine

receives a 4-20 mA signal I from the electronic governor system and converts this
into a 0.5-5.0 bar control air pressure
pcontrol .
12. To check the adjustment of the I/P converter, operate the panel in the engine control
room to supply various signals I to the I/P
converter.
For operation of the panel, see the panel
manufacturers instructions.
P control
P supply
On the pressure gauge mounted on the

control air line after the I/P converter check
that the control air pressures from the I/P
converter are in accordance with the curve.
5
4
3
M90902-0206O11
13. If the control air pressure is not in accordance with the curve, the I/P converter must
be adjusted. Remove the hood of the I/P
converter and adjust the I/P converter according to the manufacturers instructions.
P control
1.5
0.5
0.1
2
1
I, mA
0
0
MAN B&W Diesel A/S
12
16
20
Page 5 (5)
109-3
Fuel Pump Cam

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-3
Fuel Pump Cam

Data
Plate
Item No.
Description
P90651
44
Impact spanner for turning cam
P90951
45
Measuring tool for fuel pump
P91351
10
P91351
46
P91351
58
P91351
154
P91351
201
Quick coupling, male
P91351
225
Disc, round-plain, Cu 11x3 mm
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump Cam

MAN B&W Diesel
909-3.1
Checking
Fuel cam lead:

1.
The lead C of the fuel cam is defined as the
number of mm the plunger is lifted from its bottom position when the main piston is in TDC.
C
X2
X1
Roller guide
1. To measure the fuel cam lead (top lift):

Dismantle the puncture valve.
Turn the engine until the lowest point of

the cam is found, use a calliper to nd the
point.
3. Measure the distance x from the top of the
measuring pin to the transverse piece.
M909030233C01
2. Push down the measuring pin through the

top cover, until it rests against the pump
plunger.
Fuel cam
Ahead
Lowest position
of pump plunger
Main piston in TDC
2.
X
Note down the result as x2.

4. Turn ahead until the main piston of the cylinder concerned is in TDC.
Calculate the fuel cam lead C (top lift) as:

C = x1 x2 (mm)
5. Note down the result for comparison with
the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 9093.3.
M909030233C03
Again measure the distance x from the top

of the measuring tool to the transverse
piece. Note down the result as x1.
3.
M909030233C04
Remount the puncture valve.
Page 1 (4)
Fuel Pump Cam
909-3.2
Adjustment
MAN B&W Diesel
Normally, adjustment of the fuel cam should not

be necessary. Before adjustment of fuel equipment, see Volume I, Chapter 706.
1.
1. Remove the inspection cover from the camshaft housing.

Note!
M909030233O01
Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2. Dismount the puncture valve from the fuel

pump top cover, and mount the measuring
tool to check the cam adjustment.
2.
X
3. Turn the camshaft until there is access to

the oil ducts in the fuel cam through the inspection hole.
If tted, remove the plugs from the oil ducts
(using, for instance, a screwdriver).
Insert three copper gaskets in each oil
duct.
M909030233C03
Mount snapon couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snapon couplings
and the distributor block and between
the distributor block and the hydraulic
highpressure pump.
M909030233O03
3.
Page 2 (4)
Fuel Pump Cam

MAN B&W Diesel
909-3.2
Adjustment
4. Mount the special spanner on the fuel cam

disc, ensuring that the two pins enter the
holes in the cam.
4.
For better access to the cam, remove the

oil tray and carry out the adjustment from
the bottom of the cam shaft housing.
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least two
to ve minutes before turning the cam.
M909030233O04
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snapon couplings.
Oil must seep out with the pump running

during the operation to keep the cam pressurised during turning.
Turn the cam disc, using the tted spanner,
until the desired change of lead is obtained.
To increase lead and pmax:
turn the cam disc AHEAD.
To reduce lead and pmax:
turn the cam disc ASTERN.
See Procedure 9091.
5. After completing the desired turning of the
cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes the cam must be
allowed time to settle before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the
fuel cam lead again.
Note down and le the new results for purposes of comparison with future measurements and adjustment.
Page 3 (4)
909-3.2
Fuel Pump Cam

Adjustment
MAN B&W Diesel
6. Mount the inspection cover on the camshaft

housing.
7. Mount the puncture valve.
8. After any adjustment of the cam position,
pmax must be recorded and compared with
pmax at a known engine reference load.
Page 4 (4)
Fuel Pump
MAN B&W Diesel
109-4
Data

X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D09-18
Pump housing nuts, tightening torque
D09-19
Pump housing nuts, tightening angle
D09-20
Pump housing
D09-21
D09-39
Value
Unit
1980
100/50
Nm
Nm/
510
kg
Bottom plate
24
kg
Shock absorber
70
kg
Page 1 (2)
Fuel Pump
109-4
MAN B&W Diesel
Data
Plate
P90951
Page 2 (2)
Item No.
070
Description
Lifting tool for fuel pump housing
Fuel Pump
909-4.2
Dismantling
Fuel Pump
K90MC-C
0224
Dismantling
909-4.2
1.
1. Close the fuel oil inlet valve.

Open the drain cock, enabling the oil to escape.
Note!
2. Dismantle the fuel pump top cover and connected pipes.

3. Dismantle the barrel/plunger assembly.
MA909-1.1 223 03

4.
4. Remove the screws holding the fuel oil inlet

pipe between the fuel pump and the fuel inlet valve.
D09-39
Remove the fuel oil inlet pipe.

Remove the shock absorber.
Remove the fuel oil outlet pipe.
Discard the gaskets.
Remove the control air pipes from the actuator for the VIT index arm.
MA909-4.2 214 04
5. Remove the drain pipes from the fuel pump

housing.
MAN B&W Diesel A/S
Page 1 (9)
909-4.2
Fuel Pump
Dismantling
6.
6. Loosen the four nuts by means of a slugging spanner. Remove the nuts.
7. Fit the lifting tool using the top cover studs/
nuts, and lift the pump housing away.
Take care not to damage the threads of the
studs.
MA909-4.2 214 06
Land the fuel pump on wooden planks.
7.
MA909-4.2 214 07
D09-20
Page 2 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
Overhaul
909-4.3
3.
2. In order to carry out this overhaul, the top

cover and plunger/barrel assembly of the
fuel pump must have been removed, and
the fuel pump must have been dismantled
from the pump base and landed on wooden
planks.
3. Dismantle the actuator and actuator bracket.
MA909-4.3 214 03
1. If the fuel index arm or the VIT index arm

of the fuel pump is moving too tightly, the
regulating and timing systems of the fuel
pump must be overhauled.
4. Tilt the fuel pump housing into a horizontal

position on the wooden planks.
4.
D09-20
5. Dismantle the screws and the bottom plate

from the fuel pump housing.
MA909-4.3 214 04
If the bottom plate is stuck, loosen it by

screwing two M10x80 mm screws into the
holes of the bottom plate.
5.
MA909-4.3 214 05
D09-21
MAN B&W Diesel A/S
Page 3 (9)
909-4.3
Fuel Pump
Overhaul
6.
6. Dismantle the:
Fuel index arm
Regulating guide
Sleeve
7. Dismantle the:
Guide screw
MA909-4.3 214 06
VIT index arm

Timing guide
8. Remove the caps from the back of the fuel
pump housing.
7.
Remove the orifice plug from the front side
of the fuel pump housing.
MA909-4.3 214 07
Discard all sealing rings and gaskets.
MA909-4.3 214 08
8.
Page 4 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
9.
9. Dismantle and inspect the plug screws in

both sides of the fuel pump housing.
If eroded, replace the plug screws.
10. Clean all the dismantled parts of the fuel
pump thoroughly in diesel oil or kerosene.
Dry all parts carefully.
Clean all inside surfaces of the fuel pump
housing.
Check that all the bores of the fuel pump
housing are clean.
Mount the caps and the orifice plug.

Mount new sealing rings on the plug screws
and mount the plug screws.
MA909-4.3 214 09
11. Mount new sealing rings and gaskets.
11.
Note!
Lubricate the threads of all the parts with
Molybdenum Disulphide (MoS 2) before
mounting.
Note!
MA909-4.3 214 11
12. Mount new sealing rings in the sleeves that

are provided with a pointer scratch.
Soak the sealing rings in lubricating oil

before mounting.
HC909-3.4 121 11
12.
MAN B&W Diesel A/S
Page 5 (9)
909-4.3
Fuel Pump
Overhaul
14.
Mounting
13. Lubricate the following with molybdenum disulphide (MoS 2):
all internal surfaces of the fuel pump
housing
the sliding surfaces of all parts of the
regulating and timing systems.
the teeth of the:
MA909-4.3 214 14
regulating guide
timing guide
VIT index arm
15.
fuel index arm.

14. Mount the VIT index arm and the guide
screw.
Adjust the position of the VIT index arm so
that the scratch mark is aligned with the
centre of the fuel pump housing.
15. Mount the timing guide in the fuel pump
housing.
MA909-4.3 214 15
The timing guide must be mounted in such

a way that the scratch marks on the timing
guide, on the VIT index arm and on the fuel
pump housing are aligned.
MA909-4.3 214 16
16.
16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
sleeve is aligned with the pin hole in the
fuel pump housing.
Page 6 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
17.
17. Mount the fuel index arm.

Adjust the position of the fuel index arm so
that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.
18. Mount the regulating guide in the fuel pump
housing.
The regulating guide must be mounted so
that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.
20. Return the fuel pump to a vertical position.

Mount the actuator and actuator bracket on
the side of the fuel pump.
MA909-4.3 214 17
19. Mount the bottom plate on the fuel pump

housing.
MA909-4.3 214 18
18.
MA909-4.3 214 05
19.
MAN B&W Diesel A/S
Page 7 (9)
Fuel Pump
909-4.4
Mounting
Mounting
909-4.4
2.
D09-20
1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum disulphide (MoS 2).
2. Mount the lifting tool on the fuel pump top
cover studs. Lift the fuel pump housing on
to the pump base, taking care not to damage the threads of the studs.
Remove the lifting tool.
3. Mount the nuts on the studs and tighten to
the specified torque or angle, see Data.
Note!
MA909.4.2 214 07
Use either the tightening torque or the

tightening angle.
3.
MA909-4.2 214 06
D09-18
or
D09-19
Page 8 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.4
Mounting
5.
4. Mount the drain oil pipes on the fuel pump

housing.
Connect the control air pipes to the actuator
for the VIT index arm.
D09-39
5. Fit new gaskets on the fuel pump inlet pipe.

Mount the pipe between the fuel pump
housing and the fuel oil inlet and outlet
valve.
Mount the shock absorber.
7. Mount the top cover on the fuel pump housing. See Procedure 909-5.4.
Mount the air pipe for the puncture valve.
MA909-4.2 214 04
6. Mount the barrel assembly in the fuel pump

8.
MA909-1.1 223 09
8. Close the drain cock and open the fuel oil

inlet valve.
MAN B&W Diesel A/S
Page 9 (9)
Fuel Pump Top Cover

MAN B&W Diesel
109-5
Data

X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-23
Top cover studs, screwing-in torque
400
Nm
D09-24
Top cover nuts, tightening torque
460
Nm
D09-26
Outlet seat, max.grinding diameter
26
mm
D09-27
Top cover
100
kg
Page 1 (2)
Fuel Pump Top Cover
109-5
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
069
Lifting tool for fuel pump
P90951
094
Milling tool for fuel oil pipe seats
Page 2 (2)
Fuel Pump Top Cover
909-5.1
Checking
1. Shut off the fuel oil inlet.
1.
Open the drain cock (at the bottom of the

pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.
Note!
Dismount all drain pipes and the pipe connections to the puncture valve.
Dismount the high-pressure pipes between
the top cover and the fuel valves.
M909050234D01

2.
Note!
2. Remove the top cover fixing nuts and

mount the dismantling screws for top cover
in the two threaded holes.
Pull the top cover with suction valve and
puncture valve (if still mounted) free by
tightening the dismantling screws.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
M909050234D02
If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
3.
D0927
3. Lift the top cover carefully off.

For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.
M909050234D03
Discard the gasket.
MAN B&W Diesel A/S
Page 1 (3)
909-5.2
Fuel Pump Top Cover

Dismantling
1. If not already done, dismount the protective
cap and the puncture valve from the top
cover.
1.
2. Mount the top cover in special bracket and

dismantle the suction valve and the lock
washer from the top cover.
3. Fill the oil ducts of the top cover with
vaseline or heavy grease.
M909050234O02
Screw the guide, with the miller, into the

high-pressure pipe thread.
Mill the seat until a smooth surface is
achieved. For maximum seat diameter see
Data.
2.
After completing the milling, use compressed air to blow the vaseline/ grease
out from the oil ducts.
D0926
Clean the top cover with diesel oil/gas oil,

and blow dry with compressed air.
Note!
M9099050234O03
Make sure that all bores and threads inside the top cover are absolutely clean.
4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
M9099050234O04
3.
If necessary, recondition the seats of the

fuel oil high-pressure pipes.
Page 2 (3)
MAN B&W Diesel A/S
909-5.2
Fuel Pump Top Cover

Dismantling
1. Make sure that the inside of the fuel pump
housing and the top of the fuel pump barrel is completely clean.
1.
D0927
2. Mount a new gasket on top of the pump

housing.
Mount the overhauled top cover (with overhauled suction valve and reconditioned
seatings for the high-pressure pipes) on the
pump housing.
Check that the guide pin in the top cover
enters the hole in the pump housing.
Warning!
M909050234M01
Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide
(MoS2). See Procedure 913-11.
3.
D0924
As a safety precaution, and before

mounting the top cover nuts, turn the
engine one revolution.
3. Mount the top cover fixing nuts, and

tighten them diagonally to the torque indicated in Data.
For adjustment of the fuel pump, see Procedure 909-1.1.
4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure
909-8.4.
M909050234M03
When doing this, the top cover must not

move upwards!
4.
Mount the protective cap over the puncture

valve and the two screws in the top cover.
Mount the high-pressure pipes and the
drain screw in the pump housing.
M909050234M04
Mount the drain pipes on the top cover

and the connecting pipe to the puncture
valve. Open the fuel oil inlet.
MAN B&W Diesel A/S
Page 3 (3)

MAN B&W Diesel
109-6
Data

X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D09-29
Barrel assembly
D09-30
Plunger
Value
Unit
120
kg
24
kg
Page 1 (2)
109-6
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
057
Lifting tool for barrel and plunger
P90951
224
Tool for P. max rack
P90962
Page 2 (2)
Fuel Pump Seals - Mounting Tools
909-6.2
Dismantling
K90MC-C
0220
Dismantling
909-6.2
1.
1. Close the fuel oil inlet valve.

Open the fuel pump drain cock, enabling
the oil to escape.
Note!
2. Dismantle the fuel pump top cover.

3. Position the lifting tool for the barrel/plunger
assembly (without measuring pin) in such a
manner that the two distance tubes of the
tool rest on the pump barrel.
MA909-1.1 223 03

2.
Make sure that the two guide pins in the

bottom of the lifting tool enter the holes in
the top of the plunger.
Secure the lifting tool by screwing the two
screws into the pump barrel.
Turn the spindle in this position until the two

guide pins engage with the two holes in the
plunger top.
MA909-3.1 122 03
Loosen the stop ring on the spindle of the

tool and press the spindle down against the
pump plunger.
Tighten the centre screw of the spindle

against the plunger.
NA909-6.2 211 03
3.
MAN B&W Diesel A/S
Page 1 (10)
909-6.2

Dismantling
4.
4. Remove the pump barrel guide screw from

the pump housing.
5. Disconnect the links for the timing drive and
the regulating drive. Dismount the union
and pointer for the timing drive and the regulating drive.
Note the position of the scratch mark on the
lever arm.
Remove the locking plate and the lever
arm.
MA909-3.1 93 05
Mount the extractor tool and connect the

timing toothed rack to the pulling rod by
means of the pin.
5.
6. Turn the nut at the end of the pulling rod,

whereby the timing rack will move outwards.
Continue turning the nut until the pin reaches the outer position of the slot in the tool,
whereby the thread of the fuel pump barrel
goes clear of the timing guide.
Keep the toothed rack in this position during
the overhaul or replacement of the pump
barrel.
MA909-3.1 93 06 AB
There is now a distance between the lifting

tool and the pump housing.
MA909-3.1 93 06 C
6.
Page 2 (10)
MAN B&W Diesel A/S
909-6.2
Dismantling
7.
7. Pull the regulating toothed rack outwards

until the plunger foot has been turned clear
of the bayonet joint in the roller guide.
This can be ascertained by watching the
handles on the spindle of the lifting tool.
These will be parallel with the fore-and-aft
direction of the engine when the plunger
has been turned into position.
Remove the cover of the pump base to
make sure that the plunger is able to go
clear of the bayonet joint.
Lift the spindle so that the plunger foot goes
clear of the bayonet joint.
8. Carefully lift the barrel/plunger assembly

out of the pump housing.
Dismount the tool.
MA909-6.2 213 07
Move the stop ring of the spindle into contact with the upper flange of the tool, and
lock the stop ring in this position by means
of the stop screw.
8.
Press the plunger upwards to the bottom of

the barrel.
Send the barrel/plunger assembly to an
MAN B&W authorized workshop for repair,
or overhaul it on board as described in Procedure 909-6.3.
MA909-6.2 213 08
D09-29
MAN B&W Diesel A/S
Page 3 (10)
909-6.3
Overhaul
Overhaul
909-6.3
1.
1. Place the pump barrel/plunger on a piece of

plywood. Secure the plunger with a couple
of wedges to avoid unwanted movements.
D09-29
Remove and discard the sealing rings from

the barrel.
2. Pull the plunger carefully out of the barrel.
Carefully clean the plunger (for example in
clean kerosene) and dry it with a soft nonfluffy cloth.
MB909-6.3 220 01
Check the plunger for wear or seizure

marks. Also inspect the top of the plunger
for cavitation marks.
3. Clean the bores in the upper end of the
plunger and blow dry with compressed air.
Clean the barrel and dry it with a non-fluffy
cloth.
2.
D09-30
For evaluation of the plunger/barrel condition see Volume I, Chapter 706.

Check the barrel for wear or seizure marks.
Note!
MB909-6.3 220 02
The plunger and the barrel are matched

parts and cannot be replaced individually.
MA909-3.2 122 03
3.
Page 4 (10)
MAN B&W Diesel A/S
909-6.3
Overhaul
4.
4. Before mounting new sealing rings on the

barrel, heat them to 200220C for at least
five minutes.
Note!
200-220 C
5. When mounting the new sealing rings on

the lower end of the pump barrel, the inner
sealing ring must be mounted first.
Mount the guide stick in the barrel and position the big cone on the barrel.
NA909-5.3 214 05
Take care not to exceed the temperature

limits.
Place the spring-loaded sealing ring on the

cone with the spring facing upwards, see
the sketch.
5.
Use the pusher tool to push the sealing ring

into the groove.
After mounting the sealing rings, compress

them by pressing the sizer tool over the
sealing rings.
MA909-6.3 213 05
6. When mounting the sealing ring in the outer

groove, place the spacer tool inside the
cone to obtain the correct distance to the
groove, and repeat the above procedure.
MA909-6.3 213 06
6.
MAN B&W Diesel A/S
Page 5 (10)
909-6.3

Overhaul
7.
7. Mount the guide stick and cone on the top

end of the barrel and mount the uppermost
sealing ring in the same way as above.
Make sure that the spring faces downwards, see the sketch.
8. Lubricate the plunger with molybdenum disulphide (MoS 2).
MB909-3.2 95 06
Carefully slide the plunger into the barrel

and press it to the bottom.
Note!
Do not use force as this will damage the
sliding surfaces of the plunger or barrel
8.
MB909-6.3 220 08
If the barrel assembly is not to be mounted

immediately, all openings must be covered
with plastic to prevent dirt from entering the
barrel assembly during storage.
Page 6 (10)
MAN B&W Diesel A/S
909-6.4
Mounting
Mounting
909-6.4
1.
1. Place the supplied measuring pin which

is of the same length as the plunger on
the spindle of the lifting tool, and fasten it
by tightening the centre screw of the spindle. Loosen the stop ring on the spindle.
Place the tool on the pump housing, and
press the spindle down until the pointed
end of the measuring pin is in contact with
the thrust piece of the roller guide.
Then press the stop ring down until it
reaches the flange of the tool and lock it
there by tightening the screw of the stop
ring against the spindle.
The engine must not be turned until the

mounting of the barrel/plunger assembly
has been completed.
2. Dismount the tool from the pump housing
and remove the measuring pin from the
spindle. Then mount the tool on the barrel/
plunger assembly which is ready for mounting.
MA909-6.4 213 01
The stop ring is to remain tightened in this

position until the plunger has been correctly
mounted.
2.
Secure the tool to the barrel by tightening

the two screws, and attach the plunger to
the spindle of the tool by tightening the centre screw of the spindle. The tool is thus
fixed on the barrel in such a way that its correct positioning is ensured during mounting.
Before mounting the barrel/plunger in the
pump housing, lubricate the thread for the
timing guide and all sealing rings with molybdenum disulphide.
MA909-6.4 213 02
Using the spindle of the tool, pull the plunger as high up in the barrel as possible, at
the same time turning the spindle so as to
position the plunger foot correctly in relation
to the cutout of the regulating guide.
MAN B&W Diesel A/S
Page 7 (10)
909-6.4

Mounting
3.
3. Pull the regulating toothed rack as far out

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer position.
4. Check that the slot in the barrel coincides
with the hole for the guide screw.
Lower the barrel assembly carefully into the
pump housing.
MA909-6.4 213 03
If necessary, turn the regulating guide a little (using the toothed rack) to make the foot
and the regulating block of the plunger fit
properly in the cutout of the regulating
guide.
Lowering the barrel assembly so far down
into the pump housing that the sealing rings
of the barrel are about to enter the bore in
the pump housing.
4.
Then continue pressing down the barrel/

plunger assembly until the barrel assembly
rests on top of the timing guide. There will
be a gap between the tool and the pump
housing.
MA909-6.4 213 04
D09-29
Page 8 (10)
MAN B&W Diesel A/S
909-6.4
Mounting
5.
5. Loosen the nut on the extractor, disconnect

the pulling rod from the timing toothed rack,
and remove the extractor.
Engaging the thread of the fuel pump barrel
with the timing guide is accomplished by
pressing-in the toothed rack. (A pressure of
about 30 kg may be required).
Check that the toothed rack is correctly engaged by pressing-in the rack. When doing
this, the pump barrel shall move downwards.
6. After landing the barrel assembly, press

the plunger down into contact with the
thrust piece of the roller guide.
Check that the stop disc of the spindle is in
full contact with the flange of the tool, as
when measuring.
MA909-6.4 213 05
The top flange of the tool is now resting on

the top of the pump housing.
6.
If necessary, turn the regulating guide a little (using the toothed rack) to make the
plunger foot fit properly in the cutout of the
roller guide. Inspect the position of the
plunger foot through the inspection hole.
When the plunger is in place, press the regulating rod in, thereby turning the plunger
by means of the regulating guide and causing the plunger foot to interlock with the
Check that the plunger is correctly engaged
by pulling at the spindle of the lifting tool.
When doing this, it must not be possible to
lift the spindle.
MA909-6.4 213 06
Mount the inspection hole cover.
MAN B&W Diesel A/S
Page 9 (10)
909-6.4

Mounting
7.
7. Mount the pointer and union for the timing

rack.
Mount the links for the timing drive and the
regulating drive in place in accordance with
the marks.
MA909-6.4 213 07
8. Mount the guide screw for the pump barrel

in the pump housing.
Remove the centre screw from the plunger,
and remove the tool.
8.
9. Mount the fuel pump top cover and the belonging pipes. See Procedure 909-5.4.
10. Close the fuel pump drain cock.
MA909-6.4 213 08
Open the fuel oil inlet valve.
MA909-1.1 223 09
10.
Page 10 (10)
MAN B&W Diesel A/S

MAN B&W Diesel
109-7
Data

X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D09-33
Suction valve, tightening torque
D09-34
Suction valve
Value
Unit
1850
8
Nm
kg
Page 1 (2)
109-7
MAN B&W Diesel
Data
Plate
P90951
P90967
Page 2 (2)
Item No.
130
Description
Crowfoot spanner
909-7.1
Checking
S60MC-C
0214
Checking
909-7.1
1.
1. Using a brass mandrel, check that the valve

slide can slide freely up and down inside
the suction valve.
2. Check the seats for tightness by filling the
inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.
HN909-7.1 207 01
3. If the suction valve is not to be mounted on

the engine immediately after the checking,
cover all openings of the valve with plastic
to prevent dirt from entering the valve during storage.
KB909-3.3 105 08
2.
0$1% :'LHVHO$6
Page 1 (4)
909-7.2

Dismantling
Dismantling
909-7.2
1.
1.
Note!
Before dismantling the top cover, it is
recommended to dismantle the fuel pump
puncture valve, see Procedure 909-8.2.
Dismantle the fuel pump top cover and suction valve assembly from the fuel pump
2. Mount two eye bolts in the bottom of the top

cover and turn it upside down.
GN909-5.2 204 03
3. Mount the top cover in an upside down position in the top cover bracket mounted on
the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover.
2.
Release the suction valve lock washer.
Dismount the suction valve from the top
cover.
GN909-5.3 204 02
Remove and discard the lock washer.
KN909-7.2 213 03
3.
Page 2 (4)
0$1% :'LHVHO$6
909-7.3
Overhaul
Overhaul
909-7.3
1.
1. Set up the suction valve in a bench vice

with soft jaws and, using a brass mandrel
and a hammer, release the spring guide
from the valve thrust piece.
Disassemble the other parts of the suction
valve and clean the parts thoroughly in
clean diesel oil.
2. Inspect the seat of the valve slide and the

seat in the thrust piece for damage. If the
seats are damaged, both the suction valve
and the valve slide must be discarded.
Lapping of the seats must not be attempted.
KB909-3.3 105 05
Remove and discard the sealing ring from

the valve thrust piece.
3. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust
piece.
2.
Note!
Make sure that the sealing ring is
mounted correctly. See the sketch.
KB909-3.3 105 06
Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on
to the groove.
After mounting the sealing ring, compress it

by pressing the sizer tool over the sealing
ring.
3.
4. Clean and overhaul all internal parts, and

lubricate them with molybdenum disulphide
(MoS 2).
5. Re-assemble the suction valve.
XZ909-7.3 204 03
6. Check the suction valve after the overhaul.

0$1% :'LHVHO$6
Page 3 (4)
909-7.4
Mounting
Mounting
909-7.4
1.
D09-33
1. Mount the top cover in an upside down position in the top cover bracket mounted on
the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover.
Lubricate the thread of the suction valve
with copper grease.
Make sure that the bore for the suction
valve in the top cover is absolutely clean.
Fit a new lock washer and mount a new or
overhauled suction valve in the top cover.
Fit the two screws which secure the lock
washer.
Tighten the suction valve with a torque
spanner. See Data.
KN909-7.4 213 01
Lock the suction valve in position by bending up an edge of the lock washer over one
of the flats of the valve.
GN909-5.2 204 03
2.
2. Remove the top cover from the bracket and

mount the top cover in the fuel pump housing. See Procedure 909-5.4.
Page 4 (4)
0$1% :'LHVHO$6

MAN B&W Diesel
109-8
Data

X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D09-35
Puncture valve, tightening torque
D09-36
Puncture valve
Value
Unit
1400
12
Nm
kg
Page 1 (2)
109-8
MAN B&W Diesel
Data
Plate
P90951
Page 2 (2)
Item No.
141
Description
Crowfoot spanner
909-8.2
Dismantling
S60MC-C
0217
Dismantling
909-8.2
2.
1. Shut off the fuel oil inlet.

Open the drain cock at the bottom of the
pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.
Note!
2. Dismantle the control air pipe and the protective cap above the puncture valve.
4. After dismantling it is recommended always

to overhaul the puncture valve.
3.
HN909-8.2 207 03
If the overhaul cannot take place immediately after the dismantling, it is recommended to place the puncture valve immersed in
diesel oil until the overhaul.
HN909-8.2 207 02
3. Unscrew and remove the puncture valve

from the fuel pump top cover.
0$1% :'LHVHO$6
Page 1 (4)
909-8.3

Overhaul
Overhaul
909-8.3
1.
1. Remove and discard the O-rings from the

puncture valve.
Set up the puncture valve in a bench vice
with soft jaws.
Loosen and remove the four screws and
dismount the plug. Use a screw to remove
the air piston from the housing.
Remove and discard the sealing rings from
the air piston.
Disassemble the other parts of the puncture valve, using a brass mandrel and a
hammer. Take care not to damage the valve
seat.
Thoroughly clean all the parts in clean diesel oil.
2. Inspect the conical seats of the valve housing and the valve slide for wear marks or
scratches.
If the seats are damaged, the valve housing
and the valve slide must be discarded.
HN909-8.3 207 01
Lapping of the valve seats must not be attempted.
HG909-8.2 201 02
2.
Page 2 (4)
0$1% :'LHVHO$6
909-8.3
Overhaul
3.
3. When mounting the new sealing rings on

the spindle of the air piston, the inner sealing ring must be mounted first.
Mount the O-ring in the ring groove and position the large cone on the spindle.
Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on
to the O-ring in the groove.
After mounting the sealing ring, compress it
by pressing the sizer' tool, over the sealing
ring.
Mount the outer sealing ring in the groove
using the short cone, and repeating the
above procedure.
Before assembling the puncture valve, lubricate all parts with MOLYKOTE anti-friction SPRAY D321R or molybdenum
disulphide (MoS 2).
GM909-3.3 89 10
4. The new sealing ring is mounted on the

head of the air piston in accordance with
the same procedure as above.
4.
Mount new O-rings on the housing.
GM909-3.3 89 12
5. If the puncture valve is not to be mounted

on the engine immediately after the overhaul, cover all openings of the valve with
valve during storage.
0$1% :'LHVHO$6
Page 3 (4)
909-8.4

Mounting
Mounting
909-8.4
2.
1. Make sure that the bore for the puncture

valve in the fuel pump top cover is absolutely clean.
If this has not already been done, mount
new O-rings on the puncture valve.
Lubricate the thread of the puncture valve
with copper grease.
D09-35
2. Screw the puncture valve into the bore in

the top cover.
Using a crowfoot wrench and a torque
spanner, tighten the puncture valve to the
torque stated in Data.
3. Mount the protective cap and the control air
pipe on top of the puncture valve.
HN909-8.4 207 02
4. If open, close the drain cock on the fuel

pump and open the fuel oil inlet valve.
HN909-8.4 207 03
3.
Page 4 (4)
0$1% :'LHVHO$6
Fuel Pump Shock Absorber

MAN B&W Diesel
109-9
Data

X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D09-37
Nuts, tightening torque
D09-39
Shock absorber
Value
Unit
260
Nm
70
kg
Page 1 (2)
109-9
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description
909-9.1
Checking
K98MC-C
0216
Checking
909-9.1
To ensure satisfactory operation, the functioning of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspection is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is operating.
1. Remove the plug from the end cover of the
shock absorber. Check that air is pulsating
through the threaded hole.
The air pulses occur when the shock absorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.
NA909-9.1 207 01
Short bursts of air should be felt against the

hand, corresponding to the strokes of the
fuel pump.
2. To check the tightness of the piston, measure the amount of leakage oil flowing from
the drain pipe of the shock absorber housing. 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 overhauling.
MAN B&W Diesel A/S
Page 1 (3)
909-9.3

Overhaul
Overhaul
909-9.3
1.
Note!
D09-39

NA909-9.3 211 01
1. Remove the shock absorber drain pipe.

Place a wire strap around the shock absorber and hook on the engine room crane.
Loosen the screws holding the shock absorber and remove it from the fuel pump
housing.
2.
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
of the end cover and remove the end cover
and piston. Discard the gasket.
3. Loosen the nut on the threaded rod to relieve 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.
NA909-9.3 207 02
4. Clean all parts and polish the sliding surfaces 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.
4.
5. Mount the springs and the spring guide between the end cover and the piston, using
the threaded rod.
M90909-0216O04
Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to damage the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.
Page 2 (3)
MAN B&W Diesel A/S
909-9.3
Overhaul
6.
6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking device. Remove the threaded rod and insert
the plug.
If an excessive amount of drain oil is still

observed after the overhaul, the shock absorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
MB909-9.3 215 06
7. Fit a new gasket on the fuel pump housing

and mount the shock absorber. Mount the
shock absorber drain pipe.
D09-37
MAN B&W Diesel A/S
Page 3 (3)
109-10

Data
X
Stopped engine
Shut off star ting air supply At star ting air receiver
Block the main star ting valve
Shut off star ting air distributor/distributing system supply
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-10

Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
Lifting Gear
909-10.1
Checking
Lifting Gear
K90MC-C
0218
Checking
909-10.1
1.
The lifting gear for the fuel pump roller guide is

checked and activated by manually operating
the four-way valve of the lifting gear while the
engine is running or being turned.
Note!
Whereas the roller guide may be lifted
when the engine is running, the roller
guide may only be lowered when the
engine is stopped.
Otherwise, damage may be caused to the
roller guide.
Air inle
t
Thereby compressed air is led to the bearing of the lifting device, causing the shaft,
which functions as piston, to be pressed in
against the roller guide.
The air cylinder is constantly vented
through a bore in the shaft until the shaft is
in the correct position.
KC909-5.0 57 01
1. Lift the knob on the dial of the 4/3 directional control valve, and turn the dial to position
1.
2.
A
2. When the shaft is pressed fully in, its lifting

pin is positioned under the reversing arm of
the roller guide, and the duct (which is connected to the lifting cylinder) is uncovered,
thus activating the air cylinder.
The air cylinder lifts the coupling arm,
which turns the shaft, and the lifting pin on
the shaft thus lifts the roller guide clear of
the arm.
When the roller guide has been successfully lifted, it is no longer possible, with the
hand on the fuel oil high-pressure pipe, to
feel the beat of the oil pressure pulse.
KC909-5.0 57 02
Air inle
t
MAN B&W Diesel A/S
Page 1 (4)
909-10.1
Lifting Gear
Checking
3.
3. When the roller guide has been lifted, the

dial of the 4/3 directional control valve can
be returned to zero position. Lift the knob
to release the dial from position 1.
MB909-5.0 38 05
The roller guide is now locked in a position

free of the fuel cam, and the engine can be
operated on the remaining cylinders, see
Volume I, Chapter 704.
Page 2 (4)
MAN B&W Diesel A/S
Lifting Gear
909-10.1
Checking
4.
Re-engagement of the fuel pump roller guide

4. Stop the engine and engage the turning
gear.
Remove the cover on the camshaft housing
to inspect the position of the fuel cam. Turn
the engine until the circular part of the fuel
cam is facing upwards.
To lower the roller guide again, lift the knob
on the 4/3 directional control valve and turn
the dial to position 2.
Thereby air pressure is led both to the lifting cylinder and to the bearing for the lifting
gear.
At the highest point of the cam the pin of

the shaft clears the reversing arm of the
roller guide, and the air pressure in the
bearing presses the shaft back to its extreme position. Now the roller guide can
pass the pin of the shaft unhindered.
KC909-5.0 57 05
The piston of the lifting cylinder is pressed

back, thereby turning the shaft out of its
locked position and lowering the roller
guide so much that the roller cannot go
clear of the cam.
Air inlet
Return the 4/3 directional control valve to

zero position.
Note!
The engine is able to operate with a roller
guide in the wrong position.
Therefore, to ensure correct timing after
lowering the roller guide, it is recommended to make a START/STOP
manoeuvre.
This will activate the air cylinder for the
reversing mechanism and ensure that the
roller guide is in its correct position.
MAN B&W Diesel A/S
Page 3 (4)
909-10.3
Lifting Gear
Overhaul
Overhaul
909-10.3
1.
1. In the event of leakage at the sealing rings

of the lifting gear (the functioning is not satisfactory), the sealing rings are to be replaced.
Dismount the pipe connections on the bearing. Disconnect the pull rod of the air cylinder from the coupling arm and remove the
coupling arm.
Remove the screws which fasten the flange
and bearing to the roller guide housing.
Dismount the flange, pull the shaft out of
the bearing, and remove the bearing from
the bore of the roller guide housing.
Replace all O-rings A and the piston ring B.
MC909-5.0 48 06
Coat all sliding surfaces and sealing surfaces with molybdenum disulphide (MoS 2).
Place the bearing in the bore of the roller
guide housing, adjusting it in accordance
with the threaded holes.
Carefully press the shaft into the bearing.
2.
Place the flange on the shaft end (adjusted
according to the threaded holes in the bearing), tightening it all up by means of the
screws.
Mount the coupling arm and the pull rod of
the air cylinder. Reconnect the pipes to the
nipples of the bearing.
2. After the overhaul, activate the lifting gear.
In the activated position, check that the adjusting hole in the coupling arm coincides
with the adjusting hole in the flange. If this
is not the case, loosen the lock screw on
the pull rod and adjust the length of the pull
rod until the adjusting holes coincide.
MC909-5.0 48 07
Tighten the lock nut.
Page 4 (4)
MAN B&W Diesel A/S
109-11
Fuel Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
Value
Unit
300 - 380
bar
D09-40
Fuel valve opening pressure
D09-42
Inlet seat, max. diameter
25
mm
D09-43
Fuel valve
16
kg
MAN B&W Diesel A/S
Page 1 (2)
109-11
Fuel Valve
Data
Plate
Item No.
Description
P90151
71
Dismantling tool for fuel valve
P90951
94
P90951
165
Grinding mandrel for valve head
P90951
189
Grinding mandrel for holder - outside
P90951
190
Grinding mandrel for holder - inside
P90951
297
Assembling tool for fuel valve
P90961
14
Page 2 (2)
Fuel Valve tester, complete
MAN B&W Diesel A/S
Fuel Valve
MAN B&W Diesel
909-11.1
Checking
1. Fuel Valve
1.
The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of
the engine can be attributed to defects in these
valves.
If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 9001.
Note!
In the event that the slidetype fuel valve is
pressure tested without being cleaned between the fuel nozzle and the cutoff slide,
the opening pressure value measured might
be considerably lower than specied.
M90911-0249C01
In order to obtain reliable results during testing of the fuel valves, all fuel valves that are
dismantled from the engine must be disassembled, cleaned, inspected and reassembled
before testing. See Procedure 90911.3 and
90912.3.
2.
All fuel valves must be functiontested before

being mounted in the cylinder cover.
Pressure testing pump
Use only hydraulic oil (rustpreventing) with a
viscosity of between 7 and 10 cSt at 50C.
For operation of the pressure testing pump,
see the suppliers instructions.
Note that the highpressure pump should be
periodically checked in accordance with the
suppliers instructions.
To ensure that over tightening has not taken

place, check that the locking/indicating pin has
not been bent or broken off.
In the event of over tightening, replace the
spring housing by a new one.
M909110240C02
2. Spring housing
Page 1 (13)
909-11.1
Fuel Valve
Checking
MAN B&W Diesel
3. Settingup the fuel valve

3.
Place the fuel valve in the test rig and secure it
with the spring housings and nuts.
Tighten the nuts until the top face of the pressure disc is ush with the top face of the
spring housings. Mount the oil pipe between
the pressure testing pump and the fuel valve.
M909110242C03
4.
Pressure testing procedure

The following functions of the fuel valve must
be checked:
Flushing and jet control
Opening pressure
Sealing test and sliding function
Pressure test, Oring sealing
4. Flushing and jet control
Remove air in the system and check the fuel jet
in the following way.
Slowly increase the oil pressure until straight
jets of oil are ejected from the nozzle holes (no
atomization).
M909110240C04
Acceptance criteria:
There is to be a continuous jet of oil through at
least one of the nozzle holes.
Owing to the geometry of the internal part
of the nozzle and because of the height to
which the spindle is lifted during pressure testing is lower than the height it is lifted during
normal engine operation the fuel oil will not
necessarily ow from all of the nozzle holes.
Cause of fault:
If the jets do not full the above point, the
cause may be:
Dirt in the nozzle holes
The nozzle is not mounted correctly
Page 2 (13)
Fuel Valve
MAN B&W Diesel
909-11.1
Checking
5. Opening pressure
5.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle
holes.
D0940
Check the opening pressure on the pressure
gauge and compare with Data D0940 on the
datasheet.
Note!
Do NOT attempt to carry out an atomization
test on the slide type fuel valvs, as this may
damage the cutoff slide and nozzle.
If the opening pressure is higher than specied

in D0940, 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 specied
in D0940, the cause may be that the spring
has sagged replace the spring, or add a special thin disc.
M909110240C05
Cause of fault:
Note!
Special thin discs are available as spares.
If a spring or a disc has been changed, the
pressure testing procedure of the fuel valve
must be repeated.
Page 3 (13)
909-11.1
Fuel Valve
Checking
6.
MAN B&W Diesel
6. Sealing test and sliding function

To check the needle valve seat for tightness
and the slide for correct closing.
Slowly increase the oil pressure to about 50
bar below the opening pressure. Maintain the
builtup pressure by closing for the oil supply.
M909110240C06
Oil must not ow 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 ows out of the leak oil outlet when the
fuel valve is full of oil.
Cause of fault:
If oil ows out of the nozzle holes, the cause is
either:
Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
Too quick pressure drop:
the clearances of the movable parts, both of
the spindle guide and of the nonreturn valve,
are too large, or the seats between the thrust
piece/spindle in the spindle guide or thrust
piece/valve slide in the nonreturn valve are
damaged.
Examine and/or replace both the spindle guide
and nonreturn valve. See Procedure 90912.3.
If a quick pressure drop from 15 to 0 bar cannot be registered:
The valve slide is sticking; or
The vent hole in the thrust piece is
blocked.
If so, disassemble and examine the spindle
guide, replace if necessary. See Procedure
90912.3.
Page 4 (13)
Fuel Valve
MAN B&W Diesel
909-11.1
Checking
7. Pressure test, Oring sealing

7.
Max. 10 bar
To ensure that the leak oil (circulation oil) remains in the closed system, build up a working
pressure of about max. 10 bar until oil ows
out of the leak oil outlet.
Close the leak oil outlet with a gasket and plug
screw.
Max. 100 bar
Increase the working pressure to about 100

bar.
The builtup pressure of about 100 bar should
be maintained.
Max. 100 bar
If oil leaks out at the union nut, the Oring inside the fuel valve head is defective, and must
be replaced.
8. Atomization test
M909110240C07
Cause of fault:
Note!
8.
The atomization test may damage the valve

because it makes the needle oscillate, with a
small lift at a very high frequency. The high
pressure drop across the cutoff edge and the
high contact pressure between slide and fuel
nozzle, in combination with the poor lubricity
of the test oil, increase the risk of seizures between cutoff slide and nozzle.
All of these conditions involve the risk of seizure between the cutoff slide and the nozzle.
M909110240C08
Do NOT attempt to carry out an atomization

test on slide type fuel valves, as this may
damage the cutoff slide and nozzle.
Page 5 (13)
909-11.2
Fuel Valve
Dismantling
1.
1.
MAN B&W Diesel
Close the fuel oil inlet and outlet valves,

and drain the highpressure pipe and the
fuel valve.
Dismantle and remove the fuel oil
highpressure pipe.
Disconnect the return oil pipe from the fuel
valve.
M909110240D01
2. Remove the nuts and the spring housings.

3. Take out the valve. If the valve is sticking,
use the fuel valve dismantling tool to pull
the fuel valve clear of the top cover.
If the valve is not to be overhauled immediately, the valve should be placed immersed
in diesel oil until overhauling.
M909110240D02
2.
3.
M909110239D03
D0943
Page 6 (13)
Fuel Valve
MAN B&W Diesel
909-11.3
Overhaul
When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
1.
Use only clean, nonuffy rags for wiping purposes. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings
before reassembly.
Measure the length A of the protruding part
of the nozzle, and write down the result for
correct reassembling of the valve.
2. Place the valve holder in a machine vice,

mount the fuel valve in the holder and
t the valve with the guide disc from the
grinding tool.
A
M909110240O01
1.
2.
3. Compress the fuel valve and the spring

inside, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the
union nut with a hook spanner.
M909110240O02
Remove the valve from the valve holder.
M909110240O03
3.
Page 7 (13)
909-11.3
Fuel Valve
Overhaul
4.
MAN B&W Diesel
4. Pull the valve head clear of the valve housing.

Remove the:
Non return valve
Thrust spindle parts
Thrust foot
Spindle guide and fuel nozzle
from the valve housing.
M90911-0249O04
Remove and discard all the Orings.
Page 8 (13)
Fuel Valve
MAN B&W Diesel
909-11.3
Overhaul
5. Carefully clean and examine all surfaces of

the:
5.
Fuel valve housing

Fuel valve head
D09-42
Thrust spindle
If necessary, grind the seating surfaces by
means of a negrain abrasive (such as
Carborundum No. 500).
The grinding mandrels supplied are only
purposed for:
The fuel valve housing bottom.
The underside of the fuel valve head.
The top of the non-return valve.
This grinding must only be carried out
manually.
After the grinding, wash the parts in gas oil
and blow clean by means of compressed
air to remove any remains of the grinding
compound.
In the event of more serious damage to the
seating surface for the highpressure pipe
in the valve head, the milling tool can be
used.
Normally, the milling tool is turned by
hand, but it may be tted in the chuck of a
columntype drilling machine provided that
the number of revolutions is kept at a minimum (not exceeding approx. 100 r/min). An
ample supply of cutting emulsion must be
used.
Note!
M90911-0249O05
Take care not to exceed the maximum

diameter of the seat, see Data.
Page 9 (13)
909-11.3
Fuel Valve
Overhaul
6.
MAN B&W Diesel
6. 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.
M909110240O05
Note!
7.
Do not attempt to remove the fuel nozzle

from the spindle guide unless the spindle
guide has been dismantled. Otherwise the
cutoff slide on the spindle may be damaged.
7.
The nonreturn valve should be sent to an

authorised MAN B&W repair shop for overhaul. If this is not possible, the nonreturn
valve may be overhauled on board.
M909110240O06
8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
Note!
Make sure that the fuel nozzle and
spindle guide engage correctly with the
guide pin in the fuel valve housing. This
can be ascertained by attempting to turn
the nozzle after mounting. It must not be
possible to turn the nozzle.
M908020253D05
8.
Carefully slide the spindle guide down into

the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corresponds to the measurement taken before
the valve was disassembled.
Page 10 (13)
Fuel Valve
MAN B&W Diesel
909-11.3
Overhaul
9. Mount:
9.
the thrust foot

the parts of the thrust spindle
the nonreturn valve
in the fuel valve housing.
Mount a new Oring in the uppermost
groove of the fuel valve housing.
Lubricate the thread of the valve head with
molybdenum disulphide (MoS2).
For the correct use of this lubricant, see
Procedure 91311.
10. Make sure that the guide pin between valve

housing and valve head is intact, and press
the valve head down into the valve housing.
See that the guide pin between valve housing and valve head engages correctly so as
to prevent relative turning of the parts.
M90911-0249O09
Fit the valve head with new Orings.
M909110240O09
10.
MoS 2
Page 11 (13)
909-11.4
Fuel Valve
Mounting
11.
MAN B&W Diesel
11. Assemble the valve by means of the union

nut.
Place the valve in the valve holder in a drilling machine.
Compress the fuel valve and the spring
inside. Keep the valve compressed and
tighten the union nut with a hook spanner.
After overhaul, the fuel valve must be tested in the test rig.
M909110240O10
12. If the fuel valve is not to be mounted in

the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve during storage.
Page 12 (13)
Fuel Valve
MAN B&W Diesel
1.
909-11.4
Mounting
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 the valve bores in the
cylinder cover, see Procedure 9011.3).
1.
D0943
If not already done, mount new Orings on

the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2).
MoS 2
Mount the spring housings and the nuts.

Tighten the nuts until the top face of the
pressure disc is ush with the top face
of the spring housing. This must be done
with great care, as the spring tension in the
housing determines the correct tightening
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.
M909110239M01
2. Mount the valve in position in the cylinder

cover.
2.
3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.
It is recommended to overhaul the fuel oil

highpressure pipe before mounting.
As a minimum, the distance between
the fuel oil pipe ends and the thrust
bushings must be checked and, if necessary, adjusted.
M909110245M02
Note!
3.
Mount the overhauled fuel oil highpressure

pipe and the return oil pipe.
Note!
M909110242M03
All fuel valves must be functiontested

before being mounted in the cylinder cover, see Procedure 90911.1.
Page 13 (13)
109-12
Fuel Valve Spindle Guide

Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D09-70
Description
Value
Unit
Nozzel spray hole cleaning tool table
Nozzel
spray hole
Cleaning
drill
Test
pin
Nozzel
spray hole
Cleaning
drill
Test
pin
0.90
0.85
0.94
1.60
1.55
1.65
0.95
0.90
0.99
1.65
1.60
1.70
1.00
0.95
1.04
1.70
1.65
1.74
1.05
1.00
1.09
1.75
1.70
1.80
1.10
1.05
1.14
1.80
1.75
1.85
1.15
1.10
1.20
1.85
1.80
1.89
1.20
1.15
1.24
1.90
1.85
1.94
1.25
1.20
1.30
1.95
1.90
1.99
1.30
1.25
1.34
2.00
1.95
2.05
1.35
1.30
1.39
2.05
2.00
2.09
1.40
1.35
1.44
2.10
2.05
2.14
1.45
1.40
1.49
2.15
2.10
2.19
1.50
1.45
1.54
2.20
2.15
2.24
1.55
1.50
1.59
2.25
2.20
2.29
MAN B&W Diesel A/S
Page 1 (2)
109-12

Data
Plate
P90966
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
909-12.3
Overhaul
Note!
2.
This instruction is only valid for spindle

guides of the slide valve design.
Extreme care and accuracy should be
exercised when carrying out this operation.
Based on service experience it is recommended to replace the complete spindle
guide after 16000 hours of operation.
1. Clean the outside of the spindle guide in
pure gas oil or similar. The individual parts
of the spindle guide are not interchangeable, therefore only one guide is to be disassembled at a time.
The spindle guide, thrust piece and

spindle are matched parts and may not
be re-placed individually.
2. Place the spindle guide in a bench vice
provided with soft jaws, and use the
brass mandrel as shown to disassemble
the spindle guide.
M909120228O02
Note!
4.
3. Mount the pulling tool around the fuel

nozzle on the spindle guide. Turn the nut to
pull the fuel nozzle off the spindle guide.
Note!
The pulling tool is not standard for all
engines, but may be delivered as an optional extra.
4. If no pulling tool is available, the fuel nozzle
can be dismantled from the spindle guide
using two screwdrivers.
M909120228O04
Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
and the spindle guide and very carefully
force the fuel nozzle off the spindle guide.
MAN B&W Diesel A/S
Page 1 (5)
909-12.3

Overhaul
5.
5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in gas oil or
Electrocleaner and wipe dry with a clean
piece of cloth.
Place all the parts on a clean, soft, lint-free
cloth and examine them through an 8-10
times magnification magnifying glass and
an inspection lamp.
M909120228O05
During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts.
6.
6. Remove any deposits or very fine

scratches by placing the spindle, thrust
piece or spindle guide respectively in a
lathe, as shown, and polishing with a very
fine conventional polishing linen grade
360.
Use also a little oil for the polishing (a
coarser polishing linen must absolutely not
be used).
Note!
M909120228O06
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be damaged.
Page 2 (5)
After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the
seat on spindle/guide. Use an inspection
lamp and an 8-10 times enlargement magnifying glass.
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 discarded.
MAN B&W Diesel A/S
909-12.3

Overhaul
8. Read the nominal hole size on the cylindrical part of the nozzle, as shown in the figure. The hole size is given in 1/100 mm.
Depending on the engine model, there can
be one or more different sizes of the holes.
Find the correct drill size and matching test
pin in the table, D09-70, on the data sheet,
via the nominal hole size.
Clean the spray holes, using gas oil and
the special drills supplied.
7.
M909120228O07
7. Clean any carbon deposits from the central

bore of the fuel nozzle by means of the
special brass brush. Clean the fuel nozzle
with gas oil and wipe dry with a clean
cloth.
Note!
During this operation be very careful not
to push the drill too far to avoid scratching the snug-fit surface on the inside of
the fuel nozzle.
8.
1 2
3 4
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
Check the fuel nozzle before mounting on
the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
M909120228O08
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.
XXXXXX
X
XX*XXXXX
9.
Note!
M909120228O09
It is recommended that the fuel nozzle is

changed whenever the spindle guide is
being overhauled or at maximum 8000
running hours.
MAN B&W Diesel A/S
Page 3 (5)
909-12.3

Overhaul
11.
10. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybdenum Disulphide (MoS2), see Procedure 91311.
11. Assemble the thrust piece, the spindle and
the spindle guide and carefully knock the
parts together using a soft hammer.
M909120228O11
12. 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.
M909120228O12
12.
Page 4 (5)
MAN B&W Diesel A/S
909-12.3
Overhaul
13. Lubricate the sliding surfaces of the nozzle
and the spindle with a little Molybdenum
Disulphide (MoS2). See Procedure 913-11.
13.
Mount the nozzle on the spindle guide.

Make sure that the half-circle shaped
groove on the nozzle and the spring pin are
in line.
Spring pin
If nozzle and spindle guide are provided

with scratch marks opposite the spring pin,
they must be in line.
Place the parts on the plane of a drilling
machine or hydraulic press and position
the mounting tool over the parts. Make
sure that all the parts are perfectly aligned.
Press the nozzle on to the spindle guide.
The mounting tools are not standard for

all engines but may be delivered as optional extras.
M909120228O13
Note!
Scratch marks
If no mounting tools are available, the

nozzle can be mounted on the spindle
guide using a short piece of pipe.
Place the pipe around the nozzle, so that
the lower end of the pipe rests on the
foot of the fuel nozzle. Then press the
parts together the same way as when using the mounting tools.
Check that the spindle inside the spindle
guide is able to move freely as in step 10.
14. If the spindle guide is not to be mounted in
a fuel valve immediately after the overhaul,
cover all openings of the spindle guide with
spindle guide during storage.
MAN B&W Diesel A/S
Page 5 (5)
109-13
Non-return Valve for Fuel Valve

Data
Stopped engine
Shut off star ting air supply At star ting air receiver
Block the main star ting valve
Shut off star ting air distributor/distributing system supply
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-13
Non-return Valve for Fuel Valve

Data
Plate
P90951
P90968
Page 2 (2)
153
Flange for dismantling of non return valve

MAN B&W Diesel A/S
Non-return valve
909-13.3
Overhaul
Non-return valve
K98MC-C
0206
Overhaul
909-13.3
1.
Note!
Extreme care and accuracy should be
exercised when carrying out this operation.
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!
Except for the slide valve spring, defective parts cannot be replaced individually
by new ones.
Place the non-return valve as shown in Fig.
1 in a bench vice provided with soft jaws,
and disassemble the non-return valve, using the disassembling tool and a hammer
as shown.
2. Clean all the parts for the spindle guide in
gas oil and wipe them dry with a clean
piece of cloth.
Finally, clean in either gas oil, kerosene or
Electrocleaner', and wipe the parts dry with
a clean piece of cloth.
3. Now place the parts on clean, lint-free rags
and examine with an 8-10 times enlargement magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.

&
0
2.

%
1
3.

&
0
0$1% :'LHVHO$6
Page 1 (2)
909-13.3
Non-return valve
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 AD 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 conventional polishing linen grade 360'.
MC909-6.2 69 04
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
5. Check spring C for the thrust piece for outside 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 enlargement magnifying glass.
NA909-13.3 205 05
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be discarded.
6. Mount the non-return valve as follows:
Lubricate all movable parts with molybdenum disulphide (MoS2).
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.
MC909-6.3 69 06
Press the handle until the housing and

thrust piece meet.
Page 2 (2)
7. If the non-return valve is not to be mounted

in a fuel valve immediately after the overhaul, cover all openings of the non-return
valve with plastic to prevent dirt from entering the valve during storage.
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe

MAN B&W Diesel
109-14
Data

X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-48
Fuel valve end, union nipples, tightening torque
190
Nm
D09-49
Fuel pump end, union nipples, tightening torque
190
Nm
D09-50
Union nuts, tightening torque
55
Nm
D09-52
Fuel oil pipe
20
kg
Page 1 (2)
109-14
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
104
Milling tool for fuel oil pipe
P90951
128
Crowfoot spanner
Page 2 (2)
909-14.2
Dismantling
MAN B&W Diesel

HighPressure Pipe with Double Pipe
2.
1. Close the fuel oil inlet and outlet valves.

2. Unscrew the union nut and the union nipple
from the fuel valve.
3. Unscrew the union nut and the union nipple
from the fuel pump.
Note!
It is recommended always to overhaul
the highpressure pipe before remounting
it on the engine.
M909140254D02
4. Lift the pipe ends clear of the fuel valve/

fuel pump, and remove the highpressure
pipe from the engine.
3.
M909140254D03
The overhaul should preferably take

place immediately after the highpressure
pipe has been dismantled.
4.
M909140254D04
D0952
Page 1 (5)
909-14.3
Overhaul
MAN B&W Diesel

Whenever the fuel oil highpressure system
has been dismantled, it is necessary, before remounting the highpressure pipes,
to carefully inspect the tapered contact
surfaces of the pipe ends, together with
their seats in fuel valves and fuel pump top
cover.
1.
A
If the pipe ends require reconditioning, proceed as follows:
M909140254O01
1. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.
A
Note!
The two pipe ends are of different designs see sketch.
2.
Turn the upper tightening ring (A) until the

miller presses against the pipe end.
Max. grindaway
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.
M909140242O03
During the milling process, add drilling oil

emulsion liberally.
3.
2. On both pipe ends a small groove has been

ground to indicate the maximum allowable
grinding of the pipe ends.
The pipe ends may only be ground until the
ground surface is ush with the bottom of
the groove.
If the pipe ends are still not in order, the
pipe must be discarded.
M90914-0255O03
After completing the milling, carefully clean

the highpressure pipe, and blow through
the bore with compressed air.
Page 2 (5)
3. When the milling is nished:

Lift up the union nut. Remove the spring
ring from the twopart sleeve. Remove the
sleeve.

MAN B&W Diesel
909-14.3
Overhaul
4. Pull off the sleeves and union nuts and remove the sealing rings A, B and C.
Clean all parts carefully.
4.
M90914-0255O04
Page 3 (5)
909-14.3

Overhaul
5.
MAN B&W Diesel
5. Fit the union nuts and bushings with new

seaing rings.
M90914-0255O05
Mount the twopart sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the highpressure pipe.
Page 4 (5)
909-14.4
Mounting
MAN B&W Diesel
1. Ensure that the fuel valve and the fuel

pump end of the highpressure pipe are tted with new Orings. Lubricate the thread
of the fuel valve with a heat resistant
grease.
3.
2. Ensure that the union nuts on both sleeves

on the highpressure pipe is tted. Lubricate the thread on the union nipple with a
heat resistant grease.
D0952
3. Mount the highpressure pipe between the

fuel valve and the fuel pump.
First screw the union nipple onto the fuel
valve to nearly full contact. Then t the
sleeve of the highpressure pipe in the fuel
pump.
M909140254M03
Pull back both sleeves on the highpressure

pipe as far as possisble.
4.
Note!
D09-48
D09-50
Tightening with a crowfoot wrench

should only be done after both of the
union nipples have been screwed into
position.
4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
valve to the torque stated in Data.
M90914-0255M04
The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might
otherwise be damaged.
5.
5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
pump to the torque stated in Data.
Tighten both union nuts to the torque stated in Data.
D09-50
6. If dismantled, remount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
M90914-0255M05
D09-49
When referring to this page, please quote Procedure M90?914Edition 0255
Page 5 (5)

MAN B&W Diesel
109-15
Data

X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-53
Nut, reversing shaft, tightening torque
160
Nm
D09-57
Roller/bushing/shaft pin, max. clearance
0,5
mm
D09-61
Fuel pump roller guide
250
kg
D09-62
Pump base
250
kg
Page 1 (2)
109-15
MAN B&W Diesel
Data
Plate
P90851
Page 2 (2)
Item No.
053
Description
Lifting tool for roller guide

MAN B&W Diesel
Checking
Roller guide mounted in engine

1.
909-15.1
2.
The fuel pump roller guide can be partially

checked while mounted on the engine, using the following procedure:
2. Lift the fuel pump roller guide.

Remove the cover on the camshaft housing
to inspect the fuel pump roller guide.
3. Turn the engine to provide the maximum
space between the roller guide and the
cam disc.
Also inspect the surface of the roller

for possible damage marks, seizures or
scratches. Make sure that there are no
traces 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.
M90915-0236C02
Turn the roller by hand to check that it can

move freely and without unnecessary resistance or hard points.
3.
M90915-0236C03
4. Lower the roller guide onto the fuel cam

again.
Page 1 (10)
909-15.1

Checking
MAN B&W Diesel
Roller guide removed from engine
5.
A more suitable and reliable method is to

check the roller guide and the bearing clearance after the roller guide has been dismounted:
D09-61
5. Dismount the roller guide from the engine.

6. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness.
7.
Turn the roller guide upside down and

land it in a vertical position on a couple
of wooden planks, with the roller hanging
freely.
M90915-0236C07
8. Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clearance permits.
8.
M90915-0236C08
D09-57
Page 2 (10)

MAN B&W Diesel
909-15.2
Dismantling
1.
Note!

1.
Dismantle the top cover and the barrel/

plunger assembly.
2. Dismantle the fuel pump housing.

Note!
M90915-0236D01
When lifting the fuel pump housing, take

care not to damage the threads on the
studs.
M90915-0236D02
2.
Page 3 (10)
909-15.2

Dismantling
3.
MAN B&W Diesel
3. Loosen and remove the locking wire and

the screws from the disc on top of the roller guide inside the pump base.
Remove the sealing cap from the roller
guide/pump base.
M90915-0236D03
Dismantle the lubricating oil pipe and the

drain pipe from the pump base.
4. Remove the cover on the camshaft housing
to inspect the position of the roller guide.
Turn the engine until the roller guide is at
BDC.
M90915-0236C02
4.
Page 4 (10)

MAN B&W Diesel
909-15.2
Dismantling
5. Loosen the nuts on the two threaded studs

successively until the roller guide springs
are relieved.
5.
Remove the nuts, mount two eye bolts in

the pump base and lift it away.
D09-62
When lifting, take care that the bushing of

the pump base slides against the upper
part of the roller guide without scratching.
Remove the springs from the roller guide.
6. Mount the roller guide lifting tool as follows:
Lift the lock plate of the tool up on the
shaft of the tool.

Lower the lock plate, thereby securing
Lift the roller guide out of the roller guide
housing, using the crane.
M90915-0236D05
Position the tool so that its foot rests on

the thrust piece in the bayonet joint of
the roller guide.
6.
When lifting, take care that the slide surfaces of the roller guide do not scrape against
the roller guide bushing.
D09-61
Land the roller guide on wooden planks.

7.
Check the roller guide.

M90915-0236D06
90
Page 5 (10)
909-15.3

Overhaul
1.
1.
MAN B&W Diesel

Inspect and check the fuel pump roller
guide.
2. It is recommended that the roller guide

should ONLY be dismantled if
D09-61
irregularities when turning the roller,

damage to the roller,
larger clearance than stated on the Data
sheet,
seizure marks on the slide surfaces,
M90915-0236C07
have been observed when checking the

roller guide.
Note!
For disassembling of the roller guide,
contact an MAN B&W authorized repair
shop.
3. If no irregularities are found, just clean and
lubricate the roller guide before remounting
it in the roller guide bushing.
M90915-0236O03
3.
Page 6 (10)

MAN B&W Diesel
1.
909-15.4
Mounting
Lubricate the roller guide with plenty of lubricating oil, and mount it in the roller guide
bushing, using the lifting tool.
1.
During mounting, take care not to scratch

the sliding surfaces of the roller guide.
Make sure that the pin of the reversing link
ts in the guide of the reversing shaft.
D09-61
2. After mounting the roller guide with the reversing link, check the clearance between
the roller guide and the guide plate mounted in the roller guide bushing.
90
Turn the camshaft so that the roller guide is

lifted approx. 20 mm.
The clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.
Connect working air to the air cylinder,
and check that the reversing mechanism is
working smoothly.
M90915-0236M01
The clearance C between the roller guide

and the guide plate must be the same at
both ends 0.10 mm.
2.
The clearances A and B must be approx.

the same in both positions.
Note that clearances A and B change position when changing from AHEAD to ASTERN.
A
C
M90915-0236M02
Page 7 (10)
909-15.4
Mounting
MAN B&W Diesel
3. If adjustment is necessary, it must take

place in the ASTERN position.
3.
D09-53
Loosen the nut on the reversing shaft and

carry out the adjustment.
After adjustment, shift to AHEAD position and
check the clearances A and B once more.
Finally, shift again to
ASTERN.
Tighten the nut on the reversing shaft, and

lock the nut with Loctite, see Data.
4. Turn the engine until the roller guide is at
the lowest point of the fuel cam.
5. Mount the new sealing ring in the groove
inside the bushing of the pump base. Make
sure to mount the sealing ring correctly.
See the sketch.
M90915-0236M03
D09-53
M90915-0236M05
5.
Page 8 (10)

MAN B&W Diesel
909-15.4
Mounting
6. Mount the spring and the spring seat discs

over the roller guide.
6.
Mount the pump base over the roller guide

and the springs.
Mount the two special nuts on the threaded studs.
D09-62
Tighten the nuts until the pump base is fastened tightly to the roller guide bushing.
Check the movement of the reversing link.
M90915-0236D05
7.
M90915-0236C03
7.
Page 9 (10)
909-15.4

Mounting
8.
MAN B&W Diesel
8. Mount the lubricating oil pipe and the drain

pipe on the pump base.
Mount the sealing cap, the disc and the
screws on top of the roller guide, over the
sealing bush inside the pump base.
Tighten the screws and lock with locking
wire.
M90915-0236D03
9. Mount the fuel pump housing.

9.
10. Mount the barrel/plunger assembly.

11. Mount the fuel pump top cover.
12. Mount the fuel oil high-pressure pipes.
M90915-0236D02
13. Close the fuel pump drain cock. Open the

fuel oil inlet and outlet valves.
Page 10 (10)
Fuel Valve and Fuel Pump Panel
MAN B&W Diesel A/S
Plate
P90951-0446
Page 1 (2)
Plate
P90951-0446
Item
No.
010
021
045
057
069
070
094
104
128
130
141
153
165
177
189
190
200
224
236
248
250
261
273
297
Page 2 (2)
Fuel Valve and Fuel Pump Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Measuring tool for fuel pump
Lifting tool for fuel pump housing
Milling tool for fuel oil pipe
Crowfoot spanner
Crowfoot spanner
Crowfoot spanner
Flange for dismantling of non-return
valve
Grinding mandrel for valve head
Grinding mandrel for thrust spindle
Grinding mandrel for holder, outside
Grinding mandrel for holder, inside
Screw
Tool for P.max rack
Pin wrench, speciale
Hook spanner
Drift for spindle guide
Drift for puncture valve
Drift for Non-return valve
Assembling tool
MAN B&W Diesel A/S
Fuel Valve - Tools
MAN B&W Diesel A/S
Plate
P90961-0069
Page 1 (2)
Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122
Page 2 (2)
Fuel Valve - Tools
Item Description
Item
No.
Item Description
High-pressure pump
Table
Rig fuel oil valve
High-pressure hose
Connection piece, M42x2
Test rig, complete
Cover
Angle union
Gasket
Plug screw
Hose
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90966-0008
Page 1 (2)
Plate
P90966-0008
Item
No.
011
023
035
047
060
202
Item Description
Item
No.
Item Description
Tool box
Extractor for atomizer
Drift for atomizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When odering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90967-0001
Page 1 (2)
Plate
P90967-0001
Item
No.
Item Description
017
Tool for tightening of puncture valve
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90968-0001
Page 1 (2)
Plate
P90968-0001
Item
No.
Item Description
012
Probe light with magnifier, complete
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90974-0001
Page 1 (2)
Plate
P90974-0001
Item
No.
015
027
039
206

Item Description
Item
No.
Item Description
Drill*
Test mandrel*
Pin vice*
Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90977-0001

0001
P90977
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90977-0001
Item
No.
011
023
035
047
059
060
072
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Spacer ring
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90979-0001

0001
P90979
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90979-0001
Item
No.
012
024
036
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90980-0001

0001
P90980
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90980-0001
Item
No.
018
020
031
043
055
067
079
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Cone
Page 2 (2)
MAN B&W Diesel A/S

110-01
910-01
110-02
910-02
110-03
910-03
110-04
910-04
110-05
910-05
110-06
910-06
91063
91063
91063
91064
91066
0051
0243
0009
0210
0031
0218
0005
0205
0010
0213
0032
0222
0018
0019
0020
0001
0002
Air Cooler Element, Data

Air Cooler Element
Non-Return Valve after Air Cooler, Data
Non Return Valve after Air Cooler
Auxilary Blower, Data
Auxilary Blower
Butterfly Valve, Data
Butterfly Valves
Turbocharger Turbine, Data
Turbocharger Turbine
Water Mist Catcher, Data
Water Mist Catcher
Air Cooler - Tools
Air Cooler - Tools
Air Cooler - Tools
Travelling Trolley
Air Cooler - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
110-1
Air Cooler Element

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
D10-02
Aft end cover
D10-04
D10-05
Value
Unit
260
kg
Air cooler element, complete with covers, up to
2500
kg
Front end cover (waterflow reversing chamber)
260
kg
MAN B&W Diesel A/S
Page 1 (2)
110-1
Air Cooler Element

Data
Plate
Item No.
Description
P91063
Air Cooler - Tools
P91064
Travelling Trolley
P91066
Air Cooler - Lifting Tools
P91356
Lifting Tools, Etc.
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler Element

MAN B&W Diesel
910-1.1
Checking
1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air
across the cooler while the engine is running.
1.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
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.
3. If the measurements indicate fouling of the
water side of the air cooler element, the element must be overhauled/cleaned.
See Procedure 910-1.3 water side.
M910010243C01
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the OPERATION
manual, Volume I, Chapter 706.
2.
If the measurements indicate fouling of the

air side of the air cooler element, it is recommended to inspect the air cooler element as follows:
Unlock and swing open the inspection

hatch at the bottom of the air cooler.
5. Visually inspect the air cooler element
through the openings.
M910010243C02
4. Remove the top inspection cover of the air

cooler.
3.
For further information, see the OPERATION manual, Volume I, Chapter 702
Checks during Standstill Periods.
M910010243C03
If the air side of the element is fouled,

clean the element using the spray pipe arrangement fitted above the air cooler element.
See Procedure 910-1.3 air side.
Page 1 (10)
910-1.2
Air Cooler Element

Dismantling
1.
MAN B&W Diesel
The cooler element normally does not need

to be dismantled for inspection purposes. It
is only in the event that the cooler element
has suffered damage that it has to be dismantled and replaced.
Note!
M910010243C04
During dismantling, take care not to

damage the cooler element.
2.
1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off
the cooling water and dismantle the drain
pipes.
Dismount the screws which fasten the cooling water inlet and outlet flanges to the aft
end cover.
2. Dismount the brackets which control the
longitudinal position of the air cooler element.
M910010243C05
Dismount the sealing flanges around the aft

end cover.
For convenience, the sealing flanges may
be left hanging on the cooling water pipes
during dismantling and mounting of the
cooler element.
3. Dismount the sealing flanges around the
front end cover.
M910010243C06
3.
Page 2 (10)
Air Cooler Element

MAN B&W Diesel
910-1.2
Dismantling
4. Mount the pair of guide rails on the front of

the cooler housing. Mount the lifting
bracket on the front end cover of the
cooler element.
4.
Mount a travelling trolley on the beam

above the front end of the scavenge air
cooler. Attach a tackle between the travelling trolley and the lifting bracket, and haul
tight.
6. Mount a pair of guide rails on the rear end

of the cooler housing.
M910010243D04
5. Mount the guide wheels on the aft end

cover.
M910010243D05
5.
M910010243D06
6.
Page 3 (10)
Air Cooler Element
910-1.2
Dismantling
7. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount, but do not tighten, the lowermost screws. Mount and tighten the uppermost screws.
7.
MAN B&W Diesel
Tighten the lowermost screws and the

thrust nuts on the uppermost screws simultaneously. This results in loosening and lifting the cooler element.
M910010243D07
8. Tighten the tackle until the front end of the

cooler element comes loose.
9. Pull the cooler element out of the cooler
housing by means of a tackle until the
wheels engage with the holes in the guide
rails on the front of the cooler housing.
M910010243D08
8.
M910010243D09
9.
Page 4 (10)
D1003
Air Cooler Element
910-1.3
Overhaul
MAN B&W Diesel

10. Mount a lifting bracket on the aft end
cover.
10.
Fit a tackle to the lifting bracket on the aft

end cover and lift away the cooler element
and land it on a couple of wooden planks.
Note!
M910010243D10
Depending on the engine and the engine

room installation, it may be necessary to
remove some pipes and floor plates.
When referring to this page, please quote M91001 Edition 0243
D1003
Page 5 (10)
910-1.3
Air Cooler Element

Overhaul
MAN B&W Diesel
Cleaning the air side:

1.
The air side of the cooler is cleaned by injecting 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 following
cleaning fluids, or a similar product.
1) Product: ACC 9, produced by
Drew Chemical Corp., New York, USA
2) Product: 80B, produced by
Vecom Int., Maassluis, Holland
M910010243O01
Cleaning should be carried out in the following

sequence:
2.
1. Do not start cleaning until the engine has

been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
2. Follow the detailed cleaning instructions
displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
3. Continue the cleaning process for at least
30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
4. After cleaning, flush the cooler with clean
water until the water appearing in the sight
glasses is clean and pure.
M910010243O02
5. Inspect the element either by removing the

cover on top of the cooler or by dismantling the charging air pipe.
Page 6 (10)
Air Cooler Element

MAN B&W Diesel
910-1.3
Overhaul
Cleaning the water side

6.
6. If necessary, remove the air cooler.
M910010243O06
For overhauling the air cooler, see

manufacturers instruction.
When referring to this page, please quote M91001 Edition 0243
Page 7 (10)
910-1.4
Air Cooler Element

Mounting
MAN B&W Diesel
1. Lift the air cooler element and land the aft

end of the element on the guide rails
mounted on the front end of the air cooler
housing.
1.
Remove the tackle and the lifting bracket

from the aft end of the cooler element.
2. Push the air cooler element fully into the air
cooler housing
M910010243D10
3. Remove the guide rails from the aft end of

the air cooler housing.
Note!
Before pushing the air cooler element
fully in, make sure that the sealing
flanges and a new O-ring are in position,
hanging on the cooling water pipes.
M910010243D05
2.
D1003
M910010243D08
3.
Page 8 (10)
Air Cooler Element

MAN B&W Diesel
910-1.4
Mounting
4. Remove the guide wheels from the aft end

cover.
4.
5. Remove the guide rails and the lifting

bracket from the front end cover.
M910010243M04
6. Mount the sealing plate, a new O-ring and

the frame around the front end cover.
M910010243M05
5.
M910010243C06
6.
Page 9 (10)
910-1.4
Air Cooler Element

Mounting
7.
MAN B&W Diesel
7. Mount the sealing plate, a new O-ring and

the frame around the aft end cover.
Mount and tighten the brackets which control the longitudinal position of the air
cooler element.
M910010243C05
8. Insert new gaskets between the aft end

cover and the flanges of the cooling water
pipes.
8.
Mount and tighten the screws which fasten

the cooling water inlet and outlet pipes to
the aft end cover.
Mount the drain pipes, and open the cooling water inlet and outlet valves.
Note!
M910010243M08
Remember to vent trapped air from the

air cooler element.
Page 10 (10)
110-2
Non-Return Valve
Data
N
D
R
B
I
E

X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-2
Non-Return Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Non-Return Valve
910-2.3
Overhaul
Non-Return Valve
.0&&
0210
Overhaul
910-2.3
1.
1. Access to the non-return valves in the scavenge air receiver takes place after the engine has been stopped through the
inspection openings of the receiver.
Access to the scavenge air receiver

must not be attempted until the air in the
receiver is clean.
MA910-6.0 33 01
Warning!
2. Remove the two outermost and middle nuts

(which fasten the valve assembly to the
housing).
2.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
4. For further dismantling, remove the two
screws which hold the clamp and the support together as an assembly.
MC910-6.0 26 01B
Lift the complete valve assembly out of the

air receiver.
3.
Clean the valve shaft and the slide bearings

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul, it must be possible to

move the valve flap by the light touch of a
finger.
6. Re-mount the valve in the scavenge air receiver.
MC910-6.0 26 02
5. Assemble the valve
MC910-6.0 26 03
4.
0$1% :'LHVHO$6
Page 1 (1)
Auxiliary Blower
MAN B&W Diesel
110-3
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D10-12
Description
Electric motor, impeller and motorplate
Value
705
Unit
kg
Page 1 (2)
Auxiliary Blower
110-3
MAN B&W Diesel
Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting Tools, Etc.
Auxiliary Blower
910-3.3
Overhaul
Auxiliary Blower
60&&
0218
Overhaul
910-3.3
1.
1. When cleaning and inspecting the auxiliary

blower, disengage the cable connections to
the blower motor.
Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the
blower flange, before removing the screw in
the flange.
2. The end cover complete with blower can
now be pulled free of the suction pipe by
means of the two tackles.
MC910-8.0 31 01
While pulling out the end cover with the

blower assembly, make sure that the blower
housing disengages from the air pipe without deforming it.
D10-12
2.
Then inspect and clean the blower wheel as

well as the blower housing.
For overhaul of blower wheel and bearings,
see blower manufacturers instructions.
Exercise care when mounting the electric motor with blower wheel, as the
blower wheel is to catch the guide in the
blower housing.
MC910-8.0 31 02
Note!
0$1% :'LHVHO$6
Page 1 (1)
110-4
Butterfly Valves
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-4
Butterfly Valves
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Butterfly Valves
910-4.1
Checking
Butterfly Valves
60&&
0205
Checking
910-4.1
1.
1. It is important that the automatic non-return

valves (butterfly valves) are always able to
function easily and unimpeded.
The movability of the valve flaps should
therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.
Flow direction
Reach down through the opening in the top

of the valve and move the valve flaps.
3. If the valve flaps in one of the butterfly
valves cannot be moved by a light touch of
a fingertip, it must be dismantled and overhauled.
MN910-4.1 205 01
2. To check the valve, remove the cover on the

top of the butterfly valve.
2.
XZ910-9.0 15 02
4. Re-mount the cover on the top of the butterfly valve.
0$1% :'LHVHO$6
Page 1 (1)
110-5
Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-5
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
MAN B&W Diesel
910-5.3
Cleaning
The dry cleaning method employs compressed

air to blow dry, solid, granules through the turbocharger, 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 2.0 and max.
2.8 mm are particularly suited as blasting
agents. This size of granules is also known as
Marine Grit No. 8.
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 deposits with this dry cleaning method.
Therefore, in order to prevent the build-up of
thick deposits, the turbine must be cleaned after every 24 to 100 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 instruction plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger turbine, see turbine
manufacturers instructions.
See also Volume I, Chapter 706.
Page 1 (2)
910-5.3
Cleaning
MAN B&W Diesel
Cleaning Procedure:
1.
1. Carry out cleaning for every 24 to 100
hours of operation, based on observations.
2. Preferably clean the turbocharger at full

load, but not at TC rpm above those stated
in table 2. Do not clean below half load.
B
3. Close valve A.
M910050211O01
4. Open valves B and C, to blow out any deposits and/or condensate in the connecting
pipe.
After about two minutes, close valves B
and C.
5. Slowly open valve A to relieve the pressure
in the tank.
2.
TC type
TC max.
RPM
MET 33 SD/E/EII/MA
23300
MET 42 SD/E/EII/MA
18800
MET 53 SD/E/EII/MA
14800
MET 60 MA
13300
MET 66 SD/E/EII/MA
11900
MET 71 E/EII/MA
11000
MET 83 SD/E/EII/MA
9400
MET 90 SE/MA
8500
6.
TC type
7. Close valve A.
8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves
B and C.
9. Slowly open valve A to relieve the pressure
in the tank.
Caution!
Amount
Dm3
MET 33 SD/E/EII/MA
0.4
MET 42 SD/E/EII/MA
0.7
MET 53 SD/E/EII/MA
1.6
MET 60 MA
2.1
MET 66 SD/E/EII/MA
2.6
MET 71 E/EII/MA
3.0
MET 83 SD/E/EII/MA
3.5
MET 90 SE/MA
3.5
Page 2 (2)
6. Fill the tank with the quantity of granules

specified in the table.
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.
110-6
Water Mist Catcher

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
D10-11
Description
Water mist catcher
MAN B&W Diesel A/S
Value
Unit
260
kg
Page 1 (2)
110-6
Water Mist Catcher

Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting Tools, Etc.
MAN B&W Diesel A/S
Water Mist Catcher
910-6.2
Dismantling
Water Mist Catcher
K98MC
0222
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the

water mist catcher element from the air
cooler housing. If, however, the water mist
catcher element has been fouled or damaged, it must be dismantled for cleaning or
repair.
2. Dismantle the side covers from the air cooler housing.
4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the
water mist catcher.
NA910-6.2 210 02
3. Loosen the four screws which tighten the

water mist catcher to the air cooler frame.
Attach a tackle to the eye bolt and tighten

up the tackle.
3.
5. Pull the water mist catcher fully out of the

air cooler housing and land it on a couple
of wooden planks.
NA910-6.2 210 03
6. Clean or repair according to manufacturers

instructions.
4.
NA910-6.2 210 04
D10-11
MAN B&W Diesel A/S
Page 1 (2)
910-6.4
Water Mist Catcher

Mounting
Mounting
910-6.4
1.
1. Tilt the water mist catcher to the correct angle and slide it into the scavenge air cooler
housing.
D10-11
Note!
Make sure the water mist catcher is
mounted in the right direction. Check the
air flow indicator on the water mist
catcher.
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 air
cooler housing.
NA910-6.4 210 01
2. Mount the screws which secure the water

mist catcher to the air cooler frame.
NA910-6.4 210 02
2.
3. Clean the side covers and apply a thin layer

of silicone paste along the edges of the
covers. Mount the covers.
NA910-6.2 210 02
3.
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler - Tools
Plate
P91063-0018
Air Cooler - Tools

0018
P91063
Fore end
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91063-0018
Item
No.
015
027
039
Air Cooler - Tools
Item Description
Item
No.
Item Description
Guide rail, fore end - left

Guide rail, fore end - right
Screw
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler - Tools
MAN B&W Diesel A/S
Plate
P91063-0019
Page 1 (2)
Plate
P91063-0019
Item
No.
015
027
Page 2 (2)
Air Cooler - Tools

Item Description
Item
No.
Item Description
Guide rail, rear end

Guide rail, rear
When referring to this page, please quote Plate
Edition
MAN B&W Diesel A/S
Air Cooler - T
ools
Tools
MAN B&W Diesel
Plate
P91063-0020
Page 1 (2)
Air Cooler - T
ools
Tools
Plate
P91063-0020
Item
No.
015
027
039
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Wheel for air cooler, left

Wheel for air cooler, right
Screw
Travelling Trolley
Plate
P91064-0001
Travelling Trolley
0001
P91064
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91064-0001
Item
No.
010
Travelling Trolley
Item Description
Item
No.
Item Description
Travelling trolley
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler - Lifting T

ools
Tools
MAN B&W Diesel
Plate
P91066-0002
Page 1 (2)
Plate
P91066-0002
Item
No.
011
023
Page 2 (2)
Air Cooler - Lifting T

ools
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Lifting attachment air cooler

Screw

111-01
911-01
111-02
911-02
111-03
911-03
0026
0212
0013
0211
0001
0001
Safety Valve, Data

Safety Valve
Relief Valve, Data
Relief Valve
Scavenge Air Receiver Safety Valve, Data
Scavenge Air Receiver Safety Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Safety Valve
MAN B&W Diesel
111-1
Data

Stopped engine
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D11-01
Opening pressure
D11-02
Valve housing, tightening torque
Value
Unit
200 5
bar
45
Nm
Page 1 (2)
Safety Valve
111-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P91351
10
P91351
58
P90151
117
P91359
Page 2 (2)
Test equipment for combined safety valve

Torque Spanners
Safety Valve
MAN B&W Diesel
911-1.2
Dismantling
When Side-mounted
1.
1. Remove the guard surrounding the safety

valve.
Unscrew the safety valve from the extension pipe.
When Top-mounted
3. Unscrew the safety valve from the cylinder
cover.
2.
M911010211D02
Remove and discard the mild steel disc.
M911010211D01
2. Dismantle the indicator cock and the intermediate pipe.
M911010211D03
3.
Page 1 (5)
911-1.3
Safety Valve
Overhaul (Adjustment)
1.
MAN B&W Diesel
1. If necessary, dismantle the safety valve and

clean all the parts in either gas oil, kerosene, 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 the torque stated

M911010211O01
in the data, loosen and tighten again to

the torgue stated in the data.
3. Then mount:
the valve spindle
the spring
the adjusting screw
the lock nut
M911010211O02
2.
M911010211O03
3.
Page 2 (5)
Safety Valve
MAN B&W Diesel
911-1.3
Overhaul (Adjustment)
4. To set the safety valve opening pressure:
4.
Set up the safety valve in the Fuel valve

test rig.
Connect the testing device to the hydraulic pump. Alternatively the hydraulic
hans pump can be used.
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 air bubbles, flows out from the
openings of the safety valve.
Tighten the adjusting screw of the
Tighten the lock nut.

Test the opening pressure.
Remove the valve from the fuel valve
M911010212O04
safety valve until the correct pressure is

indicated (see Data).
test rig.
Page 3 (5)
911-1.4
Safety Valve
Mounting
MAN B&W Diesel
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.
M911010211M01
3. Mount a new sealing ring and a new or

overhauled safety valve.
When mounting the safety valve, apply
tools only on the hexagon on the safety
valve.
Mount the guard surrounding the safety
valve.
M911010211M02
2.
M911010211M03
3.
Page 4 (5)
Safety Valve
MAN B&W Diesel
911-1.4
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
M911010211M04
Mount a new mild steel disc in the bore.
M911010211M05
5.
Page 5 (5)
111-2
Relief Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
111-2
Relief Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Relief Valve
911-2.1
Checking
Relief Valve
60&
0211
Checking
911-2.1
1.
1. During running of the engine, check if there

are any leaks.
If a leak occurs, replace the O-ring inside
the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
If one or more plates in the flame arrester

are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
Note!
XZ911-2.1 209 01
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
The complete flame arrester has to be

replaced after a crankcase explosion.
XZ911-2.1 207 03
2.
0$1% :'LHVHO$6
Page 1 (1)

MAN B&W Diesel
111-3
Data

X
X
X
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
111-3
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
911-3.1
Checking
1. The scavenge air receiver safety valve

is calibrated at the factory and does not
require any adjustment.
2.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
If this operation cannot be performed

smoothly, the safety valve must be
dismantled and cleaned.
M911030001C02
Use a piece of cloth to wipe out any dirt

from the Oring packing and close the
valve again. Tighten the counter nut.
Page 1 (5)
911-3.2

Dismantling
1.
MAN B&W Diesel
1. Dismount the safety valve from the scavenge air receiver.
M911030001D01
2. On some engines, a cover has to be removed in order to gain access to the safety
valve.
M911030001D02
2.
Page 2 (5)

MAN B&W Diesel
911-3.3
Overhaul
1. Remove the split pin.
1.
Unscrew the nut thereby relieving the

spring tension.
Remove the nut, spring retainer and
washers.
Keep count of the washers.
2. Pull out the valve ap with spindle. If the

Oring seal is damaged remove it without
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.
M911030001O01
Pull out the spring.
M911030001O02
2.
Page 3 (5)
911-3.3

Overhaul
4.
MAN B&W Diesel
4. If the Oring seal has been removed mount

a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve ap and spindle while
taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the
washers.
M911030001O04
Tighten the nut until the split pin can be

mounted.
7. Check the valve according to 9113.1.
M911030001O05
5.
M911030001O01
6.
Page 4 (5)

MAN B&W Diesel
911-3.4
Mounting
1.
M911030001M01
1. Mount the safety valve on the scavenge air

receiver.
Page 5 (5)

112-02
912-02
112-03
912-03
912-05
91261
91265
0015
0208
0027
0213
0201
0075
0002
Holding Down & End Chock Bolts, Data

Holding Down and End Chock Bolts
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Holding Down And End Chock Bolts

MAN B&W Diesel
112-2
Data

Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D12-02
Description
Value
Unit
Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
D13-01
1st check
500
hours
2nd check
1000
hours
3rd check
2000
hours
4th check
4000
hours
5th check
8000
hours
Subsequent checks at intervals of
8000
hours
900
bar
Page 1 (2)
112-2
MAN B&W Diesel
Data
Plate
Item No.
P91263
Description
Hydraulic Tools for Holding-Down
Bolts and End Chock Bolts, Epoxy
P91351
010
P91351
058
Page 2 (2)
912-2.1
Checking
.0&
0208
Checking
912-2.1
Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
Page 1 (5)
912-2.1

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 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 to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.
EN912-1.1 205 01
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the tables from successive bolt checks.
If the loosening pressure' is below 80 per
cent of the tightening pressure, the relative
chocks shall always be checked for possible 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 followed.
Page 2 (5)
0$1% :'LHVHO$6
912-2.1
Checking
3.
Side Chocks and Side Chock Liners

3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The first time the ship is sailing in a fullyloaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the liners 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.
GN912-2.1 203 03
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simultaneously.
The feeler gauge is applied at the 7 points

indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have
increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in
the table.
If this procedure does not improve the situation,
the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position
by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Page 3 (5)
912-2.1
Checking
Holding Down Bolts
Engine
frame Bolt
No.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page 4 (5)
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Port side
pressure
% dev.
remarks
Cylinder
No.
1
2
3
Starboard side
pressure
% dev.
remarks
Bolt
No.
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Engine
frame
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0$1% :'LHVHO$6
912-2.1
Checking
Side Chocks and End Chock Bolts
Port side
Point
c d e
Chock
No.
Starboard side
Cylinder
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Chock
d
e
f
Pres-
Port side
c, d, e, f, g
Starboard side
Devi-
Ch Bolt sure ation

2)
No. No. (kp/cm
%
bar
No.
A, B
FORE
c, d, e, f, g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
A, B
Point
c d e
Deviation
Point
Point
a b c d e
a b c d e
Pressure
(kp/cm 2 )
bar
1
2
Bolt Ch
No. No.
1
E
2
b
b
a
Contact face No. 1
No. 2
B1
0$1% :'LHVHO$6
B2
B2
B1
AFT
No. 2
Page 5 (5)
Stay Bolts
MAN B&W Diesel
112-3
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D12-04
Check measurement
0.4
mm
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Stay Bolts
112-3
MAN B&W Diesel
Data
Plate
Item No.
P91261
Description
Large Parts - Tools
P91351
010
P91351
046
P91351
058
P91351
105
Page 2 (2)
Stay Bolts
912-3.1
Checking
Stay Bolts
K90MC-C
0213
Checking
912-3.1
1.
1. Before retightening the stay bolts, remove

the protective caps.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
3. If the engine is equipped with split staybolts
and one or more staybolts have been dismantled, make sure that the staybolts are
mounted in such a way that, when the uppermost staybolt nut is loosened, there is a
clearance, as stated in Data, between the
contact face of the lowermost nut and the
bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.
HM912-3.0 28 01
2. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other on the middle of
the engine.
2.
MB912-3.1 213 02
D13-01
3.
HM912-3.0 28 07
D12-05
MAN B&W Diesel A/S
Page 1 (2)
912-3.1
Stay Bolts
Checking
4.
4. Start the retightening of the stay bolts and

proceed to tighten the stay bolts in pairs,
working from the middle toward one end of
the engine and then from the middle again
toward the other end.
5. Pump up the hydraulic pressure to 10% below the value indicated in D13-01, and
retighten the stay bolt nuts with a tommy
bar if possible. Before relieving the system
of pressure, check with a feeler gauge that
the nuts bear against the contact face.
HM912-3.0 28 03
6. Reconnect the hydraulic tools to the pair of

stay bolts first tightened. Tighten to 10%
below D13-01 and check if the nut is loose.
5.
D13-01
-10%
If the nut is not loose:

Tighten the stay bolts to D13-01.
If the nut is loose:
Tighten all stay bolts once again to D13-01.
MB912-3.1 213 05
7. After completing the retightening procedure, mount the protective caps.
HM912-3.0 28 06
6.
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
912-5.1
Checking
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing.
1.
If the water content of the main engine

lube oil is rising, this may indicate that
the crankcase oil outlet sealings are fractured.
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing
remove:
Screws A
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
M912050201C01
Note!
2.
Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
M912050201C02
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
Page 1 (2)
912-5.1
Checking
MAN B&W Diesel
Metal bellow sealing

4.
4. Remove all screws A and grating B.
C
D
5. Remount four of the screws A at diametrically opposite positions.
B
A
6. Remove:
Screws C
Cover plate D
Screws E.
M912050201C04
7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are
found in the metal bellow sealing, it must
be replaced.
Note!
7.
It is recommended to always replace the

metal bellow sealing during inspection.
8. Replace gaskets G and H.

9. Mount metal bellow sealing F.
M912050201C07
10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Page 2 (2)
Large Parts - Tools
MAN B&W Diesel A/S
Plate
P91261-0075
Page 1 (2)
Plate
P91261-0075
Item
No.
023
035
047
050
060
096
202
Page 2 (2)
Large Parts - Tools
Item Description
Item
No.
Item Description
Hydraulic jack, complete

Support
Tommy bar
Sealing ring with back-up ring
Sealing ring with back-up ring
Spanner
Hydraulic tool set, complete
MAN B&W Diesel A/S
Hydraulic Tools - Holding Down Bolts

(Epoxy Chocks)
Plate
P91265-0002
Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)

0002
P91265
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91265-0002
Item
No.
013
025
037
049
050
062
098
108
Hydraulic Tools - Holding Down Bolts

(Epoxy Chocks)
Item Description
Item
No.
Item Description
Wooden box
Hydraulic jack, complete
Support
Tommy bar
Key, hexagon socket screw
Stud setter
Page 2 (2)
MAN B&W Diesel A/S
913 - General Tools

913-01
913-03
913-04
913-05
913-06
913-07
91311
91351
91356
91357
91359
91360
91361
91362
91363
91364
91366
91368
0211
0007
0202
0205
0205
0207
0204
0034
0051
0006
0003
0005
0052
0060
0040
0059
0066
0011
Hydraulic Tools
Working Platforms
Standard Tightening Torques
Torque Spanner
Tightening Gauge
Screws and Nuts
Lubricating
Accessories - Hydraulic Tools
Lifting Tools, etc.
Open-Ended Spanners
Torque Spanners
Pliers
Spanners
Open-Ended Spanners
Instruments
Working Platforms
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Hydraulic Tools
0211
A. Snap-on coupling
913-1
1.
B. Tool attachment thread

C. Bleed screw
D. Piston
E. Cylinder
F.
Sealing rings
G. Spacer ring
I.
Nut
J.
Stud or bolt
K. Extension stud
S. Clearance
U. Milled recess for feeler gauge
HM913-1.0 10 00
H. Tommy bar
2.
Studs or bolts provided with threads for attaching 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 required, with the aid of a tommy bar.
1. The hydraulic tools, except those for the

main bearings, consist of a jack with an internal 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.
KC913-1.0 17 02
The jacks must never be overloaded or exposed

to blows or impacts. They are marked with a
Max. lift, which must not be exceeded.
2. For the main bearings, an extension stud,

three extra lower hydraulic jacks and a nut
are added to each set. Each part is marked
with a sign showing where to use the specific part.
MAN B&W Diesel A/S
Page 1 (12)
913-1
3.
Hydraulic Tools
3. The hydraulic jacks are so designed that, in

the event that the Max. lift limit is exceeded, 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 cases be damaged. Therefore inspect and, if
necessary, replace this sealing ring.
The oil used must be pure hydraulic oil or
turbine oil (with a viscosity of about SAE
20). Oils such as, for instance, lubricating
oil (system oil) or cylinder lubricating oil
must not be used, as these oils are normally alkaline and can thus damage the backup rings.
MB913-1.0 14 03
The following instructions must be closely

followed to prevent accidents or damage.
After use, the jacks should be cleaned and
kept in the wooden boxes supplied.
Warning!
4.
Eye protectors and gloves must be used

when using hydraulic tools.
Maintenance
KC913-1.0 17 04
4. Disassembling the piston and cylinder is

best carried out by taking out one of the
bleed screws and pressing the parts from
each other by means of compressed air.
Page 2 (12)
After disassembling, check that there are

no damage marks on the sliding surfaces of
the parts. If metal particles are present,
they will damage the sealing rings. Keep
the sliding surfaces and threads coated
with acid-free grease or molybdenum disuplhide. The hydraulic nuts do not require
any maintenance other than replacement of
defective sealing rings. These consist of an
O-ring and a back-up ring, which are positioned in ring grooves in the piston and cylinder.
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Loosening of Nut
Loosening of Nut
913-1
1.
Single Hydraulic Jack

1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar.
Place the spacer ring around the nut in
such a position that the tommy bar can be
applied through the slot when the nut is to
be loosened.
Connect the jack, the distributor block, and

the high-pressure pump by means of highpressure hoses.
HM913-1.1 10 01
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, and check that the parts are guided
correctly together.
2.
Loosen the bleed screw and fill the system

until oil, without bubbles, flows out of the
bleed hole. Then tighten the bleed screw
again.
Adjust the clearance between the piston
and cylinder of the jack (see the sketch and
table) to provide for contraction of the bolt/
stud.
If the clearance is too large, adjustment is
made by loosening the bleed screw and
turning the jack.
The clearance is to have relation to the
"Max. lift" of the jack and has the purpose
of making it possible to dismount the jack
after loosening the nut.
HM913-1.1 10 02
After adjustment, check again that there is

no clearance between the cylinder/spacer
ring/surface.
MAN B&W Diesel A/S
Page 3 (12)
913-1
Hydraulic Tools
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. 90
bar.
4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up
against the jack.
HM913-1.1 10 03
5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
HM913-1.1 10 04
4.
HM913-1.1 10 01
5.
Page 4 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Loosening of Nut
6.
7.
Triple Hydraulic Jack

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.
Using the lifting tool, place the spacer rings

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.
7. Press the pistons and the cylinders of all
the hydraulic jacks firmly together.
KC913-1.1 17 06
Mount the extension studs on the main

bearing studs.
Mount the three jacks (one by one using the

lifting tool) over the extension stud and land
them on the spacer ring.
8.
Make sure that both the cylinders of the

jacks and the spacer ring are guided correctly 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.
8. The clearance between the pistons and the
cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm.
Connect the hydraulic jacks, the distributor

block and the high pressure pump by
means of high pressure hoses.
Loosen the bleed screws in all the jacks,
and fill up the system until oil, without bubbles, flows out of the bleed holes.
KC913-1.1 17 08
The clearance between the jack and spacer

ring has the purpose of making it possible
to dismount the jack after loosening the nut.
Re-tighten the bleed screws.
MAN B&W Diesel A/S
Page 5 (12)
913-1
Hydraulic Tools
Loosening of Nut
9.

value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.
10. Unscrew the lower nuts 1 turns with the
tommy bar, making sure that the nuts are
not screwed up against the extension stud.
KC913-1.1 17 09

the high-pressure pump, and remove the
hydraulic tools.
KC913-1.1 17 11
11.
Page 6 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Tightening of Nut
Tightening of Nut
913-1
1.
Single Hydraulic Jack

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 molybdenum disulphide grease or with graphite
and oil or similar.
Fit the round nut on the thread and tighten
it with the tommy bar.
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
firmly together.
HM913-1.1 10 01
Check with a feeler gauge that the contact

face of the nut bears on the entire circumference.
2.
Screw the hydraulic jack on to the tool attachment thread.

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 bubbles flows out of the bleed hole.
HM913-1.1 10 02
Re-tighten the bleed screw.
MAN B&W Diesel A/S
Page 7 (12)
913-1
Hydraulic Tools
Tightening of Nut
3.

value, and tighten the nut by applying the
tommy bar through the spacer ring slot.
4. While maintaining the pressure, check with
a feeler gauge introduced through the recess at the bottom of the spacer ring that
the nut bears against the contact face.
the pump, and remove the hydraulic jack.
HM913-1.2 10 03
&DXWLRQ
KC913-1.2 17 04
4.
When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nut as described
under Loosening, points 3-4-5, and then
tighten the nut again according to the
procedure under Tightening', points 3-45.
Page 8 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Tightening of Nut
7.
Triple Hydraulic Jack

6. 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 molybdenum disulphide grease or with graphite and oil.
Fit the round nuts on the threads and tighten them with the tommy bar.
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circumference.
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.
KC913-1.2 17 07
Mount the extension studs on the main

bearing studs.
7. Press the piston and the cylinder of all the

hydraulic jacks firmly together.
8.
Mount the three 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 correctly 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.
8. Connect the hydraulic jacks, the distributor
block and the high pressure pump by
means of high pressure hoses.
Re-tighten the bleed screws.
KC913-1.2 17 08
Loosen the bleed screws in all the jacks,

and fill up the system with oil until oil, without bubbles, flows out of the bleed holes.
MAN B&W Diesel A/S
Page 9 (12)
913-1
Hydraulic Tools
Tightening of Nut
10.

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
spacer ring.
10. While maintaining the pressure, check with
a feeler gauge introduced through the recesses at the bottom of the spacer ring that
the nuts bear against the contact face.
KC913-1.2 17 10

the pump, and remove the hydraulic tools.
KC913-1.2 17 11
11.
12. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nuts as described under Loosening', points 9-10-11, and then
tighten the nuts again according to the procedure under Tightening', points 10-11-12.
Page 10 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Maintenance
Maintenance
913-1
1.
1. The hydraulic jacks require no maintenance

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 separated by taking out the bleed screw and pressing the parts apart with the help of
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.
KC913-1.0 17 04
The pistons and cylinders of the lower jack

are separated in the same easy way as described for the upper jack.
MAN B&W Diesel A/S
Page 11 (12)
913-1
Hydraulic Tools
Maintenance
3.
2. When changing the sealing rings, first

mount the back-up ring and then the O-ring.
Note!
Note that the back-up ring (1) must be
away from the pressure chamber and the
O-ring (2) close to the pressure chamber.
See the sketch for the correct mounting of
both the upper and the lower sealing rings.
The same principle applies to all the jacks.
KC913-1.4 17 03
3. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
HM913-1.4 10 02
4.
Page 12 (12)
MAN B&W Diesel A/S
S70MC
Working Platforms
913-3.4
Mounting
WorkingPlatforms
S70MC
0007
Mounting
913-3.4
1.
Before carrying out the checking and overhaul

procedures underlined below in Items 1, 2 and
4, platform boards should be mounted inside
the engine crankcase.
During mounting of the platforms, always use
the harness, lanyard and fall arrester. It is always recommended to clean and wipe off oil
from steps, crankthrow, doorways and assembling surfaces.
1. Checking the crankshaft alignment, using

an Autolog: Turn the engine into a position
where it is possible to place the ladder on
the crankpin bearing stud nuts.
2.
s913-3.4 0007 02
2. Piston rod stuffing box and telescopic pipe:

Put in the standard platform board as a
floor as shown on the sketch. Turn the engine to BDC. Mount the platform board from
the exhaust side of the engine as shown.
s913-3.4 0007 01
The platform boards are placed inside the engine as shown in the following.
MAN B&W Diesel A/S
Page 1 (2)
913-3.4
Working Platforms
S70MC
Mounting
3.
3. The working platform support is mounted

as shown in sketch 3.
s913-3.4 0007 03
4. Main bearing dismantling: Turn the engine

to 80 after TDC. Mount the platform support in a longitudinal direction on the steps
in the bedplate.
4.
5. Mount the longest platform board, with the

ladder attached, on the support and, by
means of a rope, lower the platform support
ladder into place on the crankthrow.
The double platform board can now be
placed on the support and the long platform
board.
Note!
s913-3.4 0007 04
Always remember to remove the platform

boards on completion of each working
procedure or before turning the engine.
s913-3.4 0007 05
5.
Page 2 (2)
MAN B&W Diesel A/S
Standard Tightening Torques
913-4
MAN B&W Diesel

When tightening screws, studs or nuts for
which no torque is specied in the instruction
procedure or the related data sheet, the standard torques specied in this procedure are to
be applied.
1.
4. Screwing-in of studs.
The intention of this procedure is to ensure
that the studs are screwed right to the bottom
of the threaded holes.
Standard screws and nuts lubricated with

a Molybdenum Disulphide (MoS2) based
lubricant.
Thread
M8
M10
M12
M14
M16
M18
M20
Tightening
torque
17 Nm
35 Nm
50 Nm
80 Nm
135 Nm
190 Nm
260 Nm
Thread
M22
M24
M27
M30
M33
M36
M39
Carefully clean off any burrs and loose particles from the thread and contact faces, and
coat the thread with a lubricant having a particle size of approx. 0.5 m, for instance MoS2
(molybdenum disulphide) or a non-synthetic
graphite mixed with oil.
Tightening
torque
400 Nm
460 Nm
610 Nm
950 Nm
1200 Nm
1650 Nm
2100 Nm
The studs are to be screwed-in applying the

torque specied in the instruction procedure
in use. If nothing is mentioned in the instruction procedure, Fig. 4 indicates the torque.
For thread sizes > M36 the curve indicates a
screwing-in torque of 680 Nm.
2. Self-locking nuts.
M22
M24
M27
M30
M33
M36
M39
3. Screws and nuts locked with glue/Loctite.

Thread
M8
M10
M12
M14
M16
M18
M20
Tightening
torque
23 Nm
50 Nm
70 Nm
115 Nm
190 Nm
270 Nm
380 Nm
Thread
M22
M24
M27
M30
M33
M36
M39
Tightening
torque
580 Nm
680 Nm
900 Nm
1350 Nm
1700 Nm
2350 Nm
3000 Nm
Screwing-in torque curve

1000
800
To r q u e (Nm )
M8
M10
M12
M14
M16
M18
M20
Thread
Tightening
torque
430 Nm
490 Nm
650 Nm
1000 Nm
1250 Nm
1700 Nm
2200 Nm
600
400
200
M913040202C04
Thread
Tightening
torque
20 Nm
40 Nm
60 Nm
90 Nm
150 Nm
210 Nm
290 Nm
100
10
20
40
60
Major diameter of thread (mm)
80 100
Page 1 (1)
Torque Spanner
913-5
Torque Spanner
/0&
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient = 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 splitpin hole.
The torque spanner must not be used for torques 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 spanner, and a small click is heard.
When the torque spanner is not in use, the
spring inside should be released by adjusting to
minimum torque.
0$1% :'LHVHO$6
Page 1 (1)
Tightening Gauge
913-6
Tightening Gauge
0205
913-6
Preparations
Before screwing on the nuts, grease the
threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
= 0.10.12 (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 tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:
thread M8 M20 = 50 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. 3045 and 60,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
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.

7
;

G
Q
D

0
+
0$1% :'LHVHO$6
Page 1 (1)
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Some screwed and bolted connections on the

engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.
1.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Make sure only to mount locking devices

on nuts and screws which have been
mounted with locking devices by the engine manufacturer.
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 or nut concerned.
M913070207C01
Note!
2.
2. Used spring washers must be replaced.
To tighten a self-locking nut to a specific

torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data
sheet of a procedure.
M913070207C02
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
M913070207C03
3.
Page 1 (4)
Screws and Nuts
913-7.1
Locking
Fig. 1
MAN B&W Diesel
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. Always fit new wire after tightening-up the units.
Fig. 2
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3
Fig. 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 approximately 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. 6
M913070207C04
Fig. 5
Fig. 4
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,
and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it
min. 3 twists, counterclockwise until tight.
Fig. 7
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
M913070207C05
Fig. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes oriented in different angles.
Page 2 (4)
Fig. 9
Screws and Nuts

MAN B&W Diesel
913-7.1
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. 10
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure.
Fig. 11
Fig. 13: Where drilling of locking wire holes has

caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.
Fig. 12
Fig. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible.
M913070207C06
Fig. 13
Fig. 14
Page 3 (4)
913-7.1
Screws and Nuts

Locking
Fig. 15
MAN B&W Diesel
Cam Lock Washers with rising cams on one

side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam
face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
M913070207C15
Fig. 16: Different uses of the cam lock washers.

Fig. 17: Don not use the cam lock washers in
conjunction with other loose washers.
Fig. 16.
Note!
M913070207C16
Cam lock washers must be installed in

pairs and are not to be substituted by
other typers of washers.
M913070207C17
Fig. 17
Page 4 (4)
Lubricating Procedures
913-11
Lubricating Procedures
.0&&
0204
913-11
Molybdenum Disulphide (MoS2)

The following procedure is to be followed prior
to the mounting of metal surfaced parts which
are to function as seals.
Clean the surface with a cleaning fluid
and ensure that the entire surface is
completely free of grease.
Allow 5 minutes for the cleaning fluid to
evaporate.
With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote 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 mixture.
Protect the wet paste and cloth from dust
or other foreign particles.
0$1% :'LHVHO$6
Page 1 (1)
Accessories for Hydraulic Tools
Plate
P91351-0034

0034
P91351
Working Pressure 1500 Bar
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91351-0034
Item
No.
010
022
034
046
058
060
105
117
129
154
166
201
213
225
237
249
Item Description
Item
No.
Item Description
Hydralic pump, pneumatic operated

Hydralic pump, hand operated
Hose with unions (1000mm), complete
Angle union
Quick coupling, male
Quick coupling, female
Disc, round-plain, Cu 11x3mm
Bleeder screw
Disc, round-plain, Fe 11x9mm
Page 2 (2)
MAN B&W Diesel A/S
Lifting Tools, Etc.
Plate
P91356-0051
Lifting Tools, Etc.

0051
P91356
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91356-0051
Item
No.
018
031
043
055
067
079
092
175
199
222
246
295
305
317
329
330
342
354
378
450
Lifting Tools, Etc.
Item Description
Lifting eye bolts
Lifting eye bolts
Lifting eye bolts
Lifting eye bolts
Lifting eye bolts
Lifting eye bolts
Lifting eye bolts
Chain tackle
Chain tackle
Chain tackle
Wire rope
Forged-bend screw
Forged-bend screw
Forged-bend screw
Forged-bend screw
Forged-bend screw
Forged-bend screw
Forged-bend screw
Forged-bend screw
Pull-lift
Page 2 (2)
Item
No.
Item Description
shackle
shackle
shackle
shackle
shackle
shackle
shackle
shackle
MAN B&W Diesel A/S
Open Ended Spanners
Plate
P91357-0006
Open Ended Spanners

0006
P91357
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91357-0006
Item
No.
013
037
050
074
Open Ended Spanners
Item Description
Open-ended
Open-ended
Open-ended
Open-ended
Page 2 (2)
spanner,
spanner,
spanner,
spanner,
size
size
size
size
Item
No.
Item Description
NV65mm
NV75mm
NV85mm
NV95mm
MAN B&W Diesel A/S
Torque Wrenches
MAN B&W Diesel A/S
Plate
P91359-0003
Page 1 (2)
Plate
P91359-0003
Item
No.
014
026
038
040
051
Page 2 (2)
Torque Wrenches
Item Description
Item
No.
Item Description
Torque wrench, 8 - 400Nm

Adapter for socket wrench, 10 x 12.5
mm
MAN B&W Diesel A/S
Pliers
MAN B&W Diesel
Plate
P91360-0005
Page 1 (2)
Pliers
Plate
P91360-0005
Item
No.
010
021
033
045
069
128
130
141
153
Page 2 (2)
MAN B&W Diesel

Item
No.
Item Description
Item Description
Pliers for retaining ring, size 0.9mm

MAN B&W Diesel
Plate
P91361-0052
Page 1 (2)
Plate
P91361-0052
Item
No.
015
027
039
040
052
064
076
088
090
100
111
123
135
147
159
160
172
184
196
206
218
220
231
Page 2 (2)
MAN B&W Diesel
Item Description
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
Item
No.
Item Description
NV10mm
NV11mm
NV12mm
NV13mm
NV14mm
NV15mm
NV16mm
NV17mm
NV18mm
NV19mm
NV21mm
NV22mm
NV24mm
NV27mm
NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
Plate
P91362-0060

0060
P91362
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91362-0060
Item
No.
022
034
046
058
060
071
083
095
105
117
120
130
142
154
178
180
225
Item Description
Item
No.
Item Description
Slugging spanner, ring size NV30mm

Page 2 (2)
MAN B&W Diesel A/S
Spanners
MAN B&W Diesel
Plate
P91363-0040
Page 1 (2)
Spanners
Plate
P91363-0040
MAN B&W Diesel
Item
No.
Item Description
016
028
030
041
100
150
161
Tool set, complete, size 10-22 mm

Tool set, complete, size 24-46 mm
Hex key tool set, complete
Adapter for socket wrench, 20->12.5 mm
Socket spanner, S=46 mm
Hex key, S=22 mm
Hex key, S=24 mm
Page 2 (2)
Item
No.
Item Description
Open-ended Spanners
Plate
P91364-0059
Page 1 (2)
MAN B&W Diesel A/S
Plate
P91364-0059
Item
No.
011
023
Page 2 (2)
Open-ended Spanners
Item Description
Item
No.
Item Description
Open ring wrench, 14 - 17mm

Open ring wrench, 19 - 22mm
MAN B&W Diesel A/S
Instruments
MAN B&W Diesel A/S
Plate
P91366-0066
Page 1 (2)
Plate
P91366-0066
Item
No.
012
024
036
048
050
061
073
Page 2 (2)
Instruments
Item Description
Item
No.
Item Description
Indicator, complete
Indicator paper
Plainmeter, complete
Autolog, measuring tool for crankshaft
Feeler gauge
Slide caliper
MAN B&W Diesel A/S
Plate
P91368-0011
Working Platforms
Working Platforms
0011
P91368
B
B
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91368-0011
Item
No.
013
025
037
049
062
074
098
204
Working Platforms
Item Description
Item
No.
Item Description
Working platform support

Working platform support
Platform board
Platform board
Platform board
Platform board
Platform board
Working platform, complete
Page 2 (2)
MAN B&W Diesel A/S
Warning
S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
When referring to this page, please quote S900 Edition 0001

MAN B&W Diesel A/S
Page 1 (1)
K80MC-C
VOLUME III
COMPONENTS
DESCRIPTION
900 - Introduction
90001
90002
90003
90004
0040
0001
0001
0001
Table of Contents, Volume III

Cross Section through Engine
Ordering of Insulation
Designations And Symb
Software Licence, Std
90030
0006
Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
900
Volume III - Components Description

No.
Edition
Title
900 - Introduction
Table of Contents
90001 0040 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations And Symb
90004 0001 Software Licence, Std
90030 0006 Description
90101 0180 Cylinder Cover
90103 0003 Indicator Cock - Mounting
90201 0216 Piston and Piston Rod
90205 0117 Piston Rod Stuffing Box
90301 0163 Cylinder Frame
90302 0161 Cylinder Liner and Cooling Jacket
90304 0035 Cylinder Liner - Details
90305 0143 Cylinder Lubricators
90307 0032 Cylinder Lubricator Unit
90308 0010 Cylinder Lubricator - Intermediate Box
90310 0012 Cylinder Frame - Rear Side
90312 0004 Electronic Components - Cylinder Lubrication
90401 0172 Connecting Rod and Crosshead
90403 0012 Lubricating and Cooling Oil Flow
90501 0162 Crankshaft
90502 0052 Arrangement of Fore End
90505 0146 Thrust- and Guide Bearing
90510 0124 Turning Gear
90511 0039 Turning Wheel
90513 0041 Tacho System
906 - Control Gear
90600 0125 Arrangement of Chain Drive and Camshaft
90603 0111 Chain Tightener
90610 0131 Bearing Housing - Mounting
90611 0175 Camshaft and Chain Wheel
90612 0085 Arrangement of Indicator System
90613 0116 Camshaft Bearing
MAN B&W Diesel A/S
Page 1 (3)
Table of Contents
900

No.
90615
90618
90619
90620
90621
90622
90631
90632
90633
90634
Edition
0147
0134
0019
0097
0076
0070
0023
0003
0030
0041
Title
Arrangement of Governor
Regulating Shaft
Load Transmitter
Engine-Side Control Console
Engine-Side Control Console - Details
Arrangement of Layshaft
Chain Drive Guidebars - Upper Part
Chain Drive Guidebars - Lower Part
Chain Drive Lubrication - Upper Part
Chain Drive Lubrication - Lower Part

90702 0069 Main Starting Valve
90703 0129 Starting Air Distributor
90704 0053 Starting Valve
908 - Exhaust Valve
90801 0211 Exhaust Valve - Lower Parts
90803 0045 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0122 Exhaust Valve - Actuator
90806 0104 Exhaust Valve - Pipe System
90810 0089 Arrangement of Cooling Water Pipes
90901 0184 Fuel Pump
90902 0150 Fuel Pump Gear
90903 0040 Fuel Pump Gear - Details
90904 0061 Fuel Pump - Details
90905 0030 Reversing Mechanism
90907 0011 Lifting Device for Fuel Pump
90910 0143 Fuel Valve
90911 0022 Fuel Valve Function
90913 0158 High-Pressure Pipes
90914 0078 Fuel Oil System
90915 0060 Fuel Oil System - Details
90915 0080 Fuel Oil System - Details
90916 0006 Lifting Device for Fuel Pump - Cylinder No. 1
91000 0017 Gas and Air System
91001 0166 Scavenge Air Receiver
91002 0142 Arrangement of Charging Air Pipe
91003 0225 Exhaust Pipes and Receiver
91004 0036 Exhaust Receiver - Details
MAN B&W Diesel A/S
Page 2 (3)
Table of Contents
900

No.
91005
91006
91007
91009
91011
91014
Edition
0140
0029
0018
0020
0026
0029
Title
Air Cooler
Arrangement of Auxiliary Blower
Butterfly Valve
Air Cooler System - Cleaning
Arrangement of Non-Return Valve
Arrangement of Suction Pipe

91101 0037 Safety Valve - Cylinder
91102 0029 Relief Valve
91102 0035 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0099 Arrangement of Safety Cap
91201 0096 Arrangement of Stay Bolts
91203 0005 Frame Box - Details
91205 0201 Frame Box
91206 0097 End Shields
91207 0093 Arrangement of Piston Cooling
91208 0009 Chain Wheel Frame - Upper
91210 0188 Bedplate
91211 0072 Axial Vibration Damper
91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
Page 3 (3)

MAN B&W Diesel
Plate
P90001-0040
Page 1 (2)
Plate
P90001-0040
Item
No.
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Ordering of Insulation
MAN B&W Diesel
Plate
P90002-0001
Page 1 (1)
Designations and Symbols

MAN B&W Diesel
Normal layout
Plate
P90003-0001
Forward (fwd)
Starboard (stbd) side of
Port side of ship
Fore end
1
2
3
4
5
6
7
Manoeuvring side of engine
Aft end
Cyl. nos. always counted

from fore end
Exhaust side of engine
Propeller
Clockwise direction of rotation

defined from aft end of engine
Page 1 (1)
Software License, Standard Conditions

MAN B&W Diesel
Plate
P90004-0001
Standard Conditions of Software Licence

Software supplied by MAN B&W separately or included as a part of any system or embedded in
any device is licensed by MAN B&W Diesel A/S (MAN B&W) subject to the customer's acceptance of the following standard conditions of licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMERS ACCEPTANCE OF THESE
CONDITIONS.
1. Right of Ownership
Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W
against a once-for-all fee. MAN B&W and its software suppliers retain the right of ownership to the
software.
If the engine plant - for which the software is acquired - is transferred to a third party the customer has the right to assign the licence to this third party, provided that the third party agrees to
the terms of this licence agreement and provided that the customer does not retain any copies of
the software.
2. Copyright
The customer must not copy the software or any part thereof. Furthermore the customer is not
allowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software.
3. Support
If required by the customer MAN B&W shall provide technical support for installation and training
in use of the software against separate payment.
4. Updating
The non-exclusive user's licence does not include any updating of the software. If and to the extent MAN B&W updates the programs or develops new versions, such updates or new versions
shall be made available to the customer against separate payment.
5. Warranty & Liability
MAN B&W warrants that the software and data media containing the software are free of defects
in material and workmanship at the time of delivery. If the software and data media are found to
be defective and are returned to MAN B&W within 90 days from the date of delivery, they will be
replaced free of charge.
Except as stated above, MAN B&W disclaims liability for breach of conditions or warranties, either
expressed or implied, with respect to the software and data media, including warranties of suitability and applicability for a particular purpose.
Page 1 (2)
Plate
P90004-0001
Software License, Standard Conditions

MAN B&W Diesel
MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the
form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. MAN B&W shall in no event be liable for
any damages resulting from loss of data, profits or use of equipment, or for any special, incidental
consequential damages arising out of or in connection with the use or performance of the software.
The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&Ws software
suppliers.
6. Law
MAN B&W's tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.
Page 2 (2)
Engine Types 35-98MC/MC-C
Description
A90030-0006

35-98MC
0006
A90030
901 Cylinder Cover

Cylinder Cover
The cylinder cover is made of steel.

On the 70-98MC type engines the cylinder cover is provided with weldedon heat resistant material at the points of fuel oil injection in order to improve the service condition.
Valve bores
The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.
The cover furthermore has bores for the fuel valves, starting valve, starting air inlet, safety valve and indicator cock.
Cooling
A cooling jacket is mounted on the lower part of the cylinder cover,

whereby a cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat,
when the exhaust valve is installed. These two spaces communicate
through a large number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder
liner and passes through water connections to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores,
to the space around the exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe:
On some engine types, an amount of water is also passed directly from
the cylinder cover to the exhaust valve housing through a cooling water
connection.
Tightening
The cylinder cover is tightened against the top of the cylinder liner with
nuts and long studs fitted in the cylinder frame. The nuts are tightened
with hydraulic tools.
Sealing between the cylinder cover and cylinder liner is obtained by
means of a sealing ring of mild steel.
902 Piston with Rod and Stuffing Box

Piston
The piston consists of two main parts:

Piston Crown
Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the
piston skirt is tightened to the piston crown.
When referring to this text, please quote Description A90030 Edition 0006
MAN B&W Diesel A/S, Copenhagen
Page 1 (23)
Description
A90030-0006

The piston crown is provided with one groove all the way around, or with
three smaller grooves for the fitting of lifting tools.
The piston crown is provided with chromium-plated grooves for four piston rings.
Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR).
Piston rings Nos. 2, 3 and 4 have oblique cuts:
piston ring No. 3
has a right-hand cut,
and
piston rings Nos. 2 and 4
have left-hand cuts.
On some engines, the piston rings are provided with Alu-coating to improve the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel
off.
Piston Rod
The piston rod has a through-going bore for the cooling oil pipe, which
is secured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe or on the crosshead and passed through a bore in the piston rod
foot and, through the cooling oil pipe in the piston rod, to the piston
crown.
The oil is passed on, through a number of bores in the thrust part of the
piston crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead
to a discharge spout and to a slotted pipe inside the engine framebox
as well as through a control device for checking the flow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and
nuts. The nuts are tightened with hydraulic tools.
Page 2 (23)
MAN B&W Diesel A/S, Denmark

Stuffing Box
Description
A90030-0006
The bore for the piston rod between the scavenge air space and the
crankcase is fitted with a piston rod stuffing box, which is designed to
prevent the lubricating oil in the crankcase from being drawn up into the
scavenge air space.
The stuffing box also prevents scavenge air (in the scavenge air space)
from leaking into the crankcase.
The stuffing box housing consists of two parts, which are bolted together.
Scraper/sealing rings
The housing is provided with a number of machined ring grooves:

The uppermost groove holds a scraper ring with oblique edges,
which serves to prevent sludge from the scavenge box from being
drawn down to the other rings.
Furthermore, a sealing ring is fitted below the scraper ring (except on
35MC type engines).
The ring grooves in the middle are fitted with sealing rings.
The lowermost ring grooves are fitted with scraper rings which
scrape the lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase
through bores in the stuffing box housing.
Through bores in the housing and a pipe, the stuffing box communicates
with a control funnel on the outside of the engine, which enables the sealing/
scraping performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear
against the piston rod even in worn condition.
903 Cylinder Liner and Cylinder Lubrication

Cylinder Frame
The cylinder section of the engine consists of a cylinder frame with a

bolted-on or integrated camshaft housing. The cylinder section is tightened together with the engine framebox and the bedplate by means of
stay bolts.
Bores and openings
Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod
stuffing boxes.
On the exhaust side of the cylinder frame there are openings which connect the scavenge air space around the cylinder liner with the longitudinal scavenge air receiver of the engine.
Page 3 (23)
Description
A90030-0006

There are also inlet pipes for cooling and lubricating oil. The cylinder
frame is provided with cleaning and inspection covers giving access to
the scavenge air spaces.
Cylinder cover studs
Studs for fastening the cylinder cover are mounted in the cylinder frame.
Cylinder Liner and

Cooling Jacket
The cylinder liner is fitted with a cooling jacket. The cooling water is supplied at the lower part of the cooling jacket.
On slim-type liners, the water continues directly to the upper part of the
cooling jacket, whereas on the bore-cooled type liner, the water first
passes through the cooling bores. From the top of the cooling jackets,
the water flows through water connections to the cooling jacket on the
lower part of the cylinder cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by
the tensioning force from the cylinder cover studs being transmitted via
the cylinder cover.
Scavenge air ports
The part of the cylinder liner which is located in the scavenge air space
of the cylinder frame is provided with a number of scavenge air ports,
which are uncovered by the piston when this is in its bottom position.
The scavenge air ports are bored at an oblique angle to the axis of the
cylinder liner so as to give the scavenge air a rotary movement in the
cylinder.
Cylinder lubrication
In the free part of the cylinder liner, between the cooling jacket and the
cylinder frame, there are a number of bores with non-return valves for
the supply of lubricating oil to the cylinder.
PC-ring
On 80-98MC type engines a piston cleaning (PC) ring is mounted at the

top of the cylinder liner. The purpose of the PC-ring is to prevent the
building-up of deposits on the piston topland and, in turn, prevent the
wiping away of the cylinder lubricating oil. Consequently, the PC-ring
contributes to reducing the wear of liners and rings.
Cylinder
Lubricators
The engine is equipped with mechanically or electronically controlled cylinder lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied.
See also Volume I, OPERATION, Chapter 707.
Page 4 (23)
Description
A90030-0006
904 Crosshead with Connecting Rod

Crosshead
The crosshead is provided with two guide shoes fitted on the crosshead
ends.
The centre part of the crosshead is designed as a bearing journal which
is housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston
rod to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The
lower shell is provided with an overlayer coating.
Piston rod foot
The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the
piston rod and the crosshead.
Lubrication
The crosshead is provided with bores for distributing the oil supplied
through the telescopic pipe, partly as cooling oil for the piston, partly as
lubricating oil for the crosshead bearing and guide shoes and through
a bore in the connecting rod for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder for the purpose of checking the temperature and flow before the
oil is passed on to the lube oil tank.
Guide shoes
The sliding faces of the guide shoes are lined with cast-on bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox
and properly secured against displacement by guide strips fastened to
the guide shoes.
On some engines, the guide shoes are provided with counterweights.
Tightening
The crosshead bearing is held together by studs and nuts. The nuts are
tightened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal
and assembled in the same way as the crosshead bearing.
905 Crankshaft and Turning Gear

Crankshaft
The crankshaft is either of the semi-built type, where the parts are shrunk
together, or it is a one-piece forging.
The main bearings are lubricated via a main lubricating oil pipe that
branches off to the individual bearings, whereas oil for lubricating the
crankpin bearings is supplied from the crossheads through bores in the
connecting rods.
Page 5 (23)
Description
A90030-0006

The crankshaft is provided with a chain wheel for the camshaft drive and
a turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a chain wheel drive for 2nd order and 4th order moment compensators are installed, if required according to vibration calculations.
Marine engines (except geared plants):
At the aftmost end of the engine, a thrust bearing is fitted.
The thrust bearing serves the purpose of transmitting the axial thrust of
the propeller through propeller shaft and intermediate shafts to the ships
hull.
The crankshaft is provided with a thrust collar which transmits the thrust
to a number of segments mounted in a thrust shoe on either side of the
thrust collar.
The thrust shoes rest on surfaces in the thrust bearing housing and are
held in place by means of stoppers or cross bars. The segments have
white metal cast onto the wearing faces against the thrust collar. See
also Volume I, OPERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the
engine. The oil is supplied between the segments through spray pipes
and spray nozzles.
The thrust bearing is provided with alarm, slow-down, and shut-down devices for low lube oil pressure and high segment temperature. See also
Volume I, OPERATION, Chapter 701.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of the guide bearing is to keep the crankshaft in its proper position
in the axial direction.
Axial Vibration
Damper
To counteract heavy axial vibrations, and any resultant adverse forces

and vibrations, the crankshaft is provided with an axial vibration damper.
See also Section 912, Assembly of large parts further on in this text.
The damper consists of a piston and a slit-type housing. The piston is
made as an integrated collar on one of the main bearing journals, and
the housing is mounted on the pertaining main bearing support.
The axial movement is damped as a result of the restrictions incorporated in the bores which interconnect the oil-filled chambers on the two
sides of the piston.
Lubricating oil is supplied to both sides of the piston from the main system.
Page 6 (23)

Turning Gear
Description
A90030-0006
The turning gear is attached to the engine bedplate and is driven by an

electric motor incorporating a disc brake.
Through a planetary gearing, the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually, so as to
engage with the turning wheel of the engine.
The turning gear is provided with a safety arrangement consisting of a
safety lever which must be lifted before the gear wheel of the turning
gear can be made to engage with the turning wheel.
When the safety lever is in its bottom position, it prevents the gear wheel
of the turning gear from engaging with the turning wheel.
Immediately the lever is lifted away from the disengaged position, an
interlock valve inserted in the starting air system of the engine is actuated. This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position.
Warning!
Dismantling
of working
parts:
During any dismantling of working parts of the

engine, the turning gear must be in the engaged
position in order to prevent outside forces from
turning the engine, thus causing injuries to
personnel or damage to the machinery.
See Volume II, MAINTENANCE, DATA pages.
Pressure
testing of
starting
valves:
The turning gear must be in the disengaged

position during pressure testing of starting
valves, as a leaky valve may cause the engine to
rotate, and damage the turning gear.
See Volume I, OPERATION, Chapter 703.
906 Mechanical Control Gear

Chain Drive
The camshaft with cams for operating the fuel pumps, exhaust valves
and indicator drive (option) is driven from the crankshaft through a chain
drive.
The chain drive consists of one or more roller chains running on chain
wheels fitted on the crankshaft and the camshaft. The chain is kept tightened by a chain tightener placed in the chain casing between the crankshaft and the camshaft.
The long free lengths of the chain are guided by rubber-clad guide bars.
Lubricating oil is supplied through spray pipes fitted at the guide bars
and chain wheels.
Page 7 (23)
Description
A90030-0006
Camshaft

The camshaft is made in one or more sections.
If it is made in two or more sections, the sections are assembled by
means of flange couplings.
The camshaft has, for each cylinder:
one cam for operation of the fuel pump
one cam for operation of the exhaust valve
one cam for operation of the indicator drive (option)
The fuel pump and exhaust valve cams are shrunk on to the shaft by
heating, whereas the indicator cams are in two parts, which are assembled with fitted bolts.
The camshaft rotation constantly follows that of the crankshaft.
Bearings
The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. See also Volume I, OPERATION, Chapter 708.
Engine timing
The engine timing is adjusted by forcing lubricating oil in between the

cams, couplings or chain wheel and the shaft, which enables the parts
to be turned in relation to each other. See Volume II, Chapters 906, 908
and 909.
Pin gauges
After the engine has been testrun, the camshaft parts and the cylinder
frame will be provided with pin gauge marks, and the necessary pin
gauges are delivered together with the engine, enabling the camshaft
timing to be checked and readjusted if the parts have been dismantled.
Indicator Valve
Each cylinder is fitted with an indicator valve, which communicates with

the combustion chamber of the cylinder through a bore.
Operating Instructions
When opening the indicator valve, the spindle must be screwed right
back to the stop in order to avoid burns and carbon in the guide.
Note!
For indicator valves of the double-seated design with a spring-loaded
closing face:
In order to prevent overstressing, close the valve lightly before starting the engine, and retighten the valve when the engine has reached
its normal service temperature.
PMI-System
Page 8 (23)
See separate instructions for operating the PMI-system (option).

Moment
Compensators
Description
A90030-0006
On the basis of calculations, the engine may be provided with flyweights

to counteract engine forces and moments.
Caution!
If the chain drives for the compensators have been dismantled, the flyweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly fitted moment compensators may excite heavy vibrations.
1st order moment
Applicable on 4-cylinder engines. The moment compensator is arranged

as adjustable flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in
the main chain drive.
This moment compensator consists of a (new) chain-tightener wheel with
an incorporated flyweight and a flyweight rotating with the crankshaft.
2nd order moment
Applicable on 4-5 and 6-cylinder engines. The moment compensator is

arranged as flyweights built into the main chain drive.
On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.
4th order moment
The moment compensator is arranged as flyweights built into chain

drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.
907 Starting Air System

Starting Air System
The starting air system consists of the manoeuvring system and the starting air components, which comprise:
Main Starting Valve
Starting Valves
The manoeuvring system is of electric/pneumatic design.
Page 9 (23)
Description
A90030-0006
Main Starting
Valve

The main starting valve is interposed in the starting air main pipe.
The main starting valve consists of a large ball valve and, optionally, a
smaller ball valve for slow-turning prior to starting the engine, which is
fitted as a by-pass for the large valve. Both valves are operated by pneumatic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted
for setting the slow-turning speed.
Furthermore, a non-return valve is incorporated to prevent blow-back in
the event of excessive pressure in the starting air line.
The main starting valve is equipped with a blocking device consisting of
a plate which, by means of a handwheel, can be made to block the actuators.
The ball valves and their actuators are, together with the non-return
valve and blocking device, built together to form a unit.
Warning!
During all inspections of the engine, the blocking device of the main
starting valve must be in the BLOCKED position.
The only exception is when the starting valves are being tested for
tightness, in which case the blocking device of the main starting valve
must be in the WORKING position and the shut-off valve for the starting
air distributor must be in the CLOSED position. See Volume I, OPERATION , Chapter 703, Operations after arrival in port.
Starting Air
Distributor
The starting air distributor controls the opening and the closing of the
starting valves.
Starting Valve
The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of
the starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above
the piston of the starting valve is pressurised with control air from the
starting air distributor, the starting valve opens, and starting air now
flows from the starting air pipe to the cylinder.
When the starting period is finished, the chamber above the piston is
vented through the vent pipe of the starting air distributor, and the starting valve will close.
The starting air in the chamber below the piston and the starting air pipe
is vented slowly through small holes in the starting air pipe.
Page 10 (23)
Description
A90030-0006
908 Exhaust Valve

Exhaust Valve
Each cylinder is equipped with an exhaust valve, which is mounted in a

central bore in the cylinder cover. The valve housing is attached with four
studs and nuts to form a gas-tight seal against a seat in the cylinder cover.
Valve housing
The valve housing has an exchangeable bottom piece.

The bore for the valve spindle is provided with an exchangeable spindle
guide liner.
Cooling
The valve housing is water cooled. The cooling water is passed to the
valve housing after it has passed the cylinder cover. The water is discharged from the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which
the cooling water space can be checked and cleaned.
Valve spindle
The part of the spindle stem which travels within the sealing arrangement
of the air cylinder is coated with a wear resistant mixture of metal carbide
and super alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is fitted
which causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:
To enable checking the functioning of the exhaust valve while the engine
is running, a lifting/rotation check rod is mounted on top of the hydraulic
cylinder on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom
positions of the check rod.
Note!
This check rod is only for checking purposes, and must not be permanently activated.
Pistons
At the top of the spindle, two pistons are fitted:
1. Air piston
The piston serves to close the exhaust valve. The piston is locked to
the spindle by a two-piece conical ring.
2. Hydraulic piston
The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrangement, designed to dampen the closing of the valve.
Page 11 (23)
Description
A90030-0006
Caution!
After the exhaust valve has been overhauled, it is important to check
the damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.
Air cylinder
The air cylinder is mounted on top of the valve housing. Air for closing
the exhaust valve is supplied through a non-return valve to the space
below the piston.
A safety valve is mounted in the bottom of the air cylinder. The safety
valve is connected to the drain pipe which leads to the camshaft housing.
Hydraulic cylinder
The hydraulic cylinder is attached with studs and nuts on the air cylinder
on top of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by
the piston in the hydraulic cylinder.
Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerating the oil system is fitted at the top of the cylinder.
When the exhaust valve is closed, the pressure in the hydraulic cylinder
is low. A thrust spring opens the valve, enabling oil and air, if any, to
escape through the throttle.
The oil is led through a duct to the space around the air cylinder and is
drained off through a bore X, together with leakage oil from the piston.
When the exhaust valve is activated, the high oil pressure closes the
valve, and the oil flow stops.
Sealing System
Sealing air (where used):

A sealing air arrangement is fitted around the spindle shaft below the air
cylinder.
The sealing air is supplied from the air cylinder via a sealing air control
unit.
The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the
pneumatic system of the valve gear.
The oil content in the air from the air cylinder improves the service condition of the sealing rings.
The sealing air control unit contains a valve which automatically cuts off
the air flow when the engine is in FINISHED WITH ENGINE status, and
a filter housing.
Page 12 (23)
Description
A90030-0006
Sealing oil (where used):

A sealing oil arrangement is fitted around the spindle shaft below the air
cylinder.
The sealing oil is supplied from a control unit fitted on top of the exhaust
valve hydraulic actuator.
During the exhaust valve lifting period, oil escapes from the hydraulic actuator through the restriction chamber to the control unit which, in turn,
gives a certain amount of oil (dosage oil) to the exhaust valve spindle.
The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the
pneumatic system of the valve gear.
The oil improves the service condition of the sealing rings.
Hydraulic Valve
Actuating Gear
The exhaust valve is actuated by a cam on the camshaft through a hydraulic transmission.
Hydraulic cylinder
The hydraulic cylinder is attached to the camshaft housing by studs and

nuts.
A piston enclosed in the hydraulic cylinder rests on a thrust piece in the
neck of the roller guide and is locked to the roller guide by a bayonet
joint.
The hydraulic cylinder on the camshaft housing is connected to the hydraulic cylinder on the exhaust valve by a high-pressure pipe.
Oil is supplied from the lubricating oil system through a non-return valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained
through a pipe connection.
Puncture Valve
On 4-cylinder reversible engines as well as on 5-cylinder reversible

50MC engines, a puncture valve may be mounted on the exhaust valve
actuator. During starting, this valve prevents the exhaust valve from
opening during the first part of the actuator pistons upward stroke.
This function prevents the starting valve and exhaust valve from being
open at the same time, thus ensuring a safe start.
Page 13 (23)
Description
A90030-0006
909 Fuel Oil System

Fuel Pump
Each engine cylinder is equipped with its own fuel pump, which is mounted on the camshaft housing over the camshaft section corresponding to
the cylinder concerned.
The pump housing is attached to the camshaft housing by studs and
nuts.
The square base of the fuel pump housing is provided with a groove to
receive any leakage oil, which is subsequently drained off through a
drain pipe.
In the base, a bore is provided for at toothed rack, i.e. the regulating
guide, which controls the quantity of fuel oil delivered by the pump.
Furthermore, for the VIT-type fuel pump, another bore is provided above
the bore for the regulating guide. This bore is provided with a rack, i.e.
the timing guide, which controls the engine timing.
At the top, the pump housing is closed by a top cover.
The top cover is provided with a suction valve and a puncture valve.
These two valves are on some engine types combined into one unit.
The pump housing contains the plunger and barrel. The plunger and barrel are matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in
the milled keyway in the regulating guide. At the bottom it has a foot
which rests on a steel disc in the bayonet joint at the roller guide neck.
A clearance of approx. 0.1 mm between the plunger foot and the roller
guide permits turning of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing.
On the outside the regulating guide has a toothed rim to mesh with the
above-mentioned toothed rack at the base of the pump housing. The
toothed rim and toothed rack are marked with lines enabling the parts
to be positioned correctly after disassembly. The toothed rack is linked
together with the regulating gear of the engine through a spring-loaded
connection. Thus, in the event of a sticking pump plunger, the regulating
gear for the remaining fuel pumps will not be blocked.
The pump barrel is provided with oil cut-off holes, which are covered and
uncovered during the travel of the plunger within the barrel. This function, in conjunction with the turning of the plunger effected by the regulating gear, serves to regulate the amount of oil injected into the engine
cylinder.
Two screw plugs are fitted in the pump housing opposite the cut-off holes
of the barrel. The oil jets which are ejected through the cut-off holes at
the end of the delivery stroke will hit the screw plugs, which can be replaced when they are eroded.
Page 14 (23)

Injection timing
Description
A90030-0006
Fuel pumps without VIT (Variable Injection Timing):

The pump barrel is attached to the top cover by means of screws.
The lower part of the barrel is guided in the bore of the pump housing.
Two sets of O-rings and back-up rings are fitted in grooves on the outside of the barrel and the pump cover to seal between pump barrel/pump
cover and housing.
A number of semi-circular shims are inserted between the top cover and
the pump housing. By removing or inserting such shims, the pump barrel
can be slightly lowered or raised in relation to the plunger, and in this
way the initial moment of fuel oil injection into the engine cylinder can
be adjusted, and the maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum
combustion pressure.
VIT-type fuel pumps:
The pump barrel is guided at the top and bottom of the pump housing.
Low friction sealing rings are fitted in grooves in the barrel to seal between barrel and housing. The barrel is provided with a drain bore between the sealing rings at the lower end.
The pump barrel has a threaded lower end which fits into the internal
threads of the timing guide.
The timing guide has a gear rim to mesh with the upper toothed rack at
the base of the pump housing. The gear rim and toothed rack are marked
with lines enabling the parts to be positioned correctly after disassembly.
The toothed rack is linked to a servo-air cylinder which is controlled mechanically or electronically in relation to the engine load. The position of
the upper toothed rack determines the vertical position of the barrel relative to the plunger through the threaded connection.
In this manner the initial moment of fuel oil injection into the cylinder can
be adjusted by a servo-air cylinder.
The pump barrel is prevented from turning by a guide screw mounted in
the pump housing.
Puncture valve
In the top cover of the pump, a puncture valve is fitted. The puncture
valve consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system,
and when STOP is activated, compressed air is supplied to the top of
the piston, causing the piston with pin to be pressed downward and keep
the suction valve in the open position. This will puncture the oil flow to
the fuel valve. As long as the puncture valve is activated, the fuel oil is
returned through bores to the pump housing, and no injection takes
place.
Page 15 (23)
Description
A90030-0006
Fuel Oil Injection
During the suction stroke, the spring-loaded suction valve opens and the
delivery chamber is filled with oil. As soon as the plunger has covered
the cut-off holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until
the cut-off holes are uncovered by the oblique cut-off edges of the plunger, following which the oil is forced through two milled grooves at the side
of the plunger and out through the cut-off holes of the barrel during the
rest of the delivery stroke.
Shock absorber
A shock absorber is installed on each pump housing or in the main fuel

pipe to take up pressure variations.
Fuel Pump
Actuating Gear
The camshaft housing contains the fuel pump and exhaust valve actuating gear for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is
transmitted through the roller guide to the plunger in the barrel of the
pump housing which through the high-pressure pipes is connected
with the fuel valves on the cylinder cover.
Reversible engines:
The roller guide of each fuel pump incorporates an angular displaceable
reversing link.
Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. The link connecting the roller guide and roller is
provided with a reversing arm, and a pivot is mounted at the top end of
the reversing arm. The pivot travels in a reversing guide connected to
an air cylinder. The link is self-locking in either the AHEAD or ASTERN position without the aid of external forces. Each cylinder is reversed individually, and the reversing mechanism is activated by compressed air.
The reversing arrangement may incorporate a damper in order to reduce
the mechanical stresses.
Fuel Oil HighPressure Pipes
All high-pressure pipes in the system are provided with a protective outer
pipe. The space between the pipe and the protective outer pipe communicates, through bores in the union nipples, with a drain bore in the pump
top cover.
Fuel Oil Leakage

Alarm
A fuel oil leakage alarm is required for Unattended Machinery Spaces,

UMS.
35-98MC:
Each fuel pump is, via drain pipes, connected to a common drain tank,
which incorporates a level switch. The drain tank is also equipped with
an overflow pipe, which has a small drain bore below, whereby oil from
small leakages can be drained to the outlet, without actuating the level
switch.
Page 16 (23)
Description
A90030-0006
In the event of pipe fractures or major leakages in the system, the abovementioned bore will not be large enough to allow the increased oil quantity to pass, and the oil level in the drain tank will rise until it reaches the
level of the overflow pipe. The rising oil level will cause the level switch
to set off an alarm.
50-98MC:
Alternatively to the common drain tank, the drain pipes on 50-98MC engines can be connected to a diaphragm valve, which sets off an alarm
and activates the puncture valve in order to stop the fuel oil flow from
the pertaining pump.
On 60-98MC engines, which are provided with pneumatically operated
fuel pump roller guide lifting gear, automatic activation of the lifting gear
by the diaphragm valve can be arranged in order to stop the fuel oil flow
from the pertaining pump.
Fuel Valve
The fuel valve consists of a valve head and a valve housing. Fitted within
the valve housing is a non-return valve and a spindle and spindle guide
with a pressure spring, and a nozzle.
The spindle may be provided with a cut-off slide. When the fuel valve is
fitted in the cylinder cover, the valve parts are tightened together by the
pressure from the securing nuts.
Functioning
The functioning of the fuel valve is as follows:

The electrical fuel oil primary pump circulates preheated oil through the
fuel pump and fuel valve. The fuel oil passes through the fuel valve, leaving through a circulation bore and the return oil pipe on the valve head.
When the pressure at the beginning of the fuel pumps delivery stroke
has reached the predetermined pressure, the circulating bores is closed.
When the pressure has reached the predetermined opening value for the
fuel valve, the spindle will be lifted and oil injected through the nozzle
into the engine cylinder.
On completion of the fuel pumps delivery stroke, the valve spindle is
pressed against its seat and injection now ceases. Then the circulating
bore is uncovered, and oil starts to recirculate through the valve.
910 Turbocharger System

Air System
The engine is supplied with scavenge air from one or more turbochargers, depending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger
and, through a common shaft, the turbine wheel drives the compressor
wheel.
Page 17 (23)
Description
A90030-0006

The compressor draws air from the engine room, through the air filters.
From the compressor outlet, the air passes through the charging air pipe
to the charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.
The air cooler incorporates a water mist catcher, which is designed to
separate condensate from the air.
See also Charging Air Cooler further on in this Section.
When the air has passed the water mist catcher, it is pressed into the
scavenge air receiver through non-return valves. The non-return valves
open by pressure from the turbocharger.
From the scavenge air receiver, the air flows to the cylinder through the
scavenge air ports when the piston is in the bottom position. When the
exhaust valves open, the exhaust gas is pressed into a common exhaust
gas receiver, from where the gas drives the turbine of the turbocharger
with an even and steady pressure
Scavenge Air
Receiver
The scavenge air receiver is a container having a large volume. The receiver is bolted on to the cylinder frame.
Scavenge air is collected in the receiver after the air has passed through
the cooler, the water mist catcher and the non-return valves.
The receiver and the cylinder frame communicate through large openings.
The scavenge air receiver is provided with man-hole covers and a safety
valve.
Auxiliary Blowers
The engine is provided with two or more auxiliary blowers. The suction
sides are connected to the space after the water mist catcher. The discharge sides are connected to the scavenge air receiver. Separate nonreturn valves are installed at the suction side or discharge side of the
auxiliary blowers, in order to prevent reversed air flow.
See also item, Non-return valves, further on.
El. panels for

auxiliary blower
See special instructions supplied by the engine builder.
Running with
auxiliary blowers
During the starting of the engine, and when the engine is running at low
load, the turbocharger is not able to supply enough air for the engine
process. In these cases a pressure switch will automatically start the
auxiliary blowers.
When the auxiliary blowers are operating, they draw air from the engine
room through the turbochargers air filter and compressor side.
Page 18 (23)
Description
A90030-0006
Warning!
If the auxiliary blowers do not start during low-load running (because
of faults, or because the switch for the blowers is not in AUTO position), unburned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box fire.
In order to avoid such a fire:
obtain permission to stop the engine
stop the engine
remove any unburned fuel oil from the top of the pistons
re-establish the supply of scavenge air
start the engine
Note: the switch for the auxiliary blowers should be in
AUTO position during all modes of engine control, i.e.:
remote control
control from engine side control console.
The non-return valves fitted after the water mist catcher are now closed
as a result of partial vacuum and gravitation acting on the valve flaps.
There will be a lack of air supply if the non-return valves do not close.
Non-Return Valves
It is of the utmost importance that the non-return valves of the auxiliary

blowers always function correctly and move easily. This can be checked
either by moving the valves manually in connection with the regular scavenge port inspections, or via locally placed inspection covers.
The non-return valves protect the blowers and engine during:
Start-up of the auxiliary blowers
Running with auxiliary blowers.
Starting the auxiliary blowers:
1. Owing to the relatively high starting current, the blowers start in sequence, with 6-10 seconds in between.
The non-return valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Otherwise, there is a risk that the electric motor will burn out when it starts.
2. If an auxiliary blower fails to start, the non-return valve must be in
the closed position. Otherwise, the operating blower will not be
able to draw fresh air in through the turbocharger and air cooler.
This is due to differences in the air flow resistance.
Page 19 (23)
Description
A90030-0006

Running with auxiliary blowers:
If an auxiliary blower fails during running, the non-return valve must
close to ensure the continued supply of fresh air to the engine. See
Starting the auxiliary blowers, Item 2, above.
Exhaust Gas
Receiver
From the exhaust valves, the exhaust gas is led to the exhaust gas receiver where the pulsatory pressure from the individual exhaust valves
is equalized and led to the turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the seating by flexible supports.
Compensators are inserted between the receiver and the exhaust
valves, and between the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before
the turbocharger.
The exhaust gas receiver and the exhaust pipe are insulated.
Charging Air
Cooler
The charging air cooler insert is of the block type. It is mounted in a

housing which is welded up of steel plates.
The cooler housing is provided with inspection covers.
The cooler is designed with an air reversing chamber which incorporates
a water mist catcher. The water mist catcher is built up of a number of
lamellas which separate the condensation water from the scavenge air
during the passage of the air flow.
The separated water is collected in the bottom of the cooler housing from
which it is removed by a drain system.
Caution!
It is important to check that the drain functions correctly, as otherwise
water droplets may enter the cylinders. See Volume I Operation,
Chapter 706, Cleaning of Turbochargers and Air Coolers.
An alarm device for high water level in the drain system is installed.
911 Safety Equipment

Safety Valves,
Cylinder Cover
Page 20 (23)
Each cylinder cover is provided with a spring-loaded safety valve which

is set to open at a pressure somewhat higher than the maximum firing
pressure in the cylinder.

Relief Valves
Description
A90030-0006
On the exhaust side of the engine a number of spring-loaded relief

valves are fitted, which will open in the event of excessive pressure in
the crankcase/chain casing, for instance as a result of the ignition of oil
mist.
Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by hot air/gas emitted in the event that the
relief valves open.
Regarding how to:

avoid evaporation of the lubricating oil in the crankcase,
detect oil mist in the crankcase using an Oil Mist Detector.
see Volume I, OPERATION, Chapter 704.
Warning!
Do not stand near crankcase doors or relief valves or in corridors
near doors to the engine room casing in the event of an alarm for:
a) oil mist
b) high lube oil temperature
c) no piston cooling oil flow, or
d) scavenge box fire
Alarms b, c and d should be considered as pre-warnings of a possible
increasing oil mist level.
See also our Service Letter SL97-348/ERO.
Note!
If there has been a crankcase explosion, the complete flame arrester
of the relief valves must be replaced.
Safety Valve,
Scavenge Air
Receiver
The scavenge air receiver is fitted with a safety valve which is set to
open should the pressure in the scavenge air receiver exceed a value
somewhat higher than the normal scavenge air pressure of the engine.
In some cases it may be necessary to open the valve manually, see
Volume I, Chapter 704, "Turbocharger Surging".
Page 21 (23)
Description
A90030-0006
Safety Cap in
Starting Air Line

Each starting valve inlet pipe is provided with a safety cap. The safety
cap consists of a bursting disc enclosed by a perforated cylinder and a
perforated cover in order to protect any bystanders, in the event of a
burst.
The cover is provided with a check plate, which shows if the bursting disc
has been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure
in the starting air line, overhaul or replace the starting valve which
caused the burst, and fit a new disc.
If a new disc is not available immediately, turn the cover in relation to
the cylinder, in order to reduce the leakage of starting air. Fit a new
bursting disc and return the cover to the open position at the first opportunity.
912 Assembly of large Parts

Bedplate
The bedplate is made in one or more sections, depending on the number

of cylinders. If there are two or more sections, these are joined together
with fitted bolts. The bedplate consists of two welded, longitudinal girders
and a number of cross girders which support the main bearings. The
main bearings consist of steel shells, lined with bearing metal.
Each main bearing has one or two main bearing caps which are secured
by studs and nuts, designed for tightening with hydraulic tools.
The bedplate is fitted with an axial vibration damper. For the design and
functioning of the axial vibration damper, see Section 905 Crankshaft.
Marine engines (except geared plants):
The aft end of the bedplate incorporates the thrust bearing. See also
Section 905 Crankshaft.
Stationary engines (and geared marine plants):
The bedplate incorporates the guide bearing.
See also Section 905, Crankshaft.
Framebox
A framebox is bolted on to the top of the bedplate. Like the bedplate,

the framebox consists of one or more sections. Together, the bedplate
and the framebox constitute the crankcase of the engine.
The framebox is fitted with steel-plate doors for access to the crossheads and to the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which
the piston cooling oil outlet pipe fitted to the crosshead or guide shoe is
Page 22 (23)
Description
A90030-0006
able to travel. From the slotted pipe the cooling oil is, through an outlet
pipe, led to the oil tray of the bedplate.
Equipment for local checking of the cooling oil temperature and flow, and
for temperature and flow alarms, is installed in conjunction with the outlet
pipe. See also Volume I, OPERATION, Chapter 701.
Staybolts
The bedplate, framebox and the cylinder frame are tightened together to
form one unit by means of staybolts.
Engine Seating
Regarding the engine seating for the specific engine, see the suppliers
special instructions.
Page 23 (23)

90101
90103
0180
0003
Cylinder Cover
Indicator Cock - Mounting
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
Plate
P90101-0180
Page 1 (2)
Cylinder Cover
Plate
P90101-0180
Item
No.
018
031
043
067
080
102
114
126
151
163
175
187
209
210
222
234
246
271
Page 2 (2)
MAN B&W Diesel

Item
No.
Item Description
Item Description
Nut
Washer
Stud
Cylinder cover
O-ring
Cooling jacket
Screw
Gasket
Screw
Protective cap
Nut
Stud for exhaust valve
Nut
Spring house, complete
Stud with guide face for fuel valve
Stud for fuel valve
Pipe for fuel valve
Drain pipe
MAN B&W Diesel A/S
Plate
P90103-0003
Page 1 (2)
Plate
P90103-0003
Item
No.
019
020
032
056
068
081
093
103
127
140
152
164
176
188
223
235
Page 2 (2)
Item Description
Item
No.
Item Description
Indicator cock
Packing
Packing
Disc
Plug screw
Sundry chain
Key ring
Eye screw
Packing
Screw
Nut
Locking plate
Flange
Extension
Screw
Extension
MAN B&W Diesel A/S

90201
90205
0216
0117
Piston and Piston Rod

MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90201-0216
Page 1 (2)
MAN B&W Diesel A/S
Plate
P90201-0216
Item
No.
011
023
035
047
059
060
072
084
096
106
118
143
155
167
179
180
192
202
214
Page 2 (2)
Item Description
Item
No.
Item Description
Screw
Screw
D-ring
D-ring
Piston skirt
Screw
Screw
Locking wire
Piston ring No.1
Piston ring No. 2+4
Piston ring No. 3
Piston crown
Pipe for cooling insert
Disc
Piston rod
Stud
Sealing ring
Disc
Nut
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90205-0117
Page 1 (2)
Plate
P90205-0117
Item
No.
013
025
037
049
074
086
098
121
145
169
170
182
204
228
265
277
300
Page 2 (2)
Item Description
Item
No.
Item Description
O-ring
Scraper ring
Sealing ring
Sealing ring
Nut
Housing stuffing box
Flange
Screw
Fitted bolt
Screw
Scraper ring
Scraper ring
Cylindrical pin
Spring pin
Lamella
Spring
Spring
MAN B&W Diesel A/S

90301
90302
90304
90305
90307
90308
90310
90312
0163
0161
0035
0143
0032
0010
0012
0004
Cylinder Frame
Cylinder Liner and Cooling Jacket
Cylinder Liner - Details
Cylinder Lubricator Unit
Cylinder Lubricator - Intermediate Box
Cylinder Frame - Rear Side
Electronic Components - Cylinder Lubrication
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Frame
MAN B&W Diesel
Plate
P90301-0163
Page 1 (2)
Cylinder Frame
Plate
P90301-0163
Item
No.
135
159
160
172
184
196
206
218
231
255
267
279
292
302
314
338
351
363
387
399
410
422
446
458
471
483
495
517
529
530
542
566
578
591
601
625
637
650
662
674
686
698
721
733
745
757
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Cylinder frame
Distance pipe
Bushing
Stuffing box housing
Screw
Screw
Washer
Cover
Nut
Stud for cylinder cover
O-ring
O-ring
Nut
Distance pipe
Stud
Stud
Distance pipe
Nut
Screw
Distance pipe
Protective pipe
Gasket
Cylinder frame
Gasket
Cover
Stud
Nut
Fittes stud
Stud
Nut
Stud
Fitted stud
Stud
Nut
Stud
Cleaning cover
Gasket
Screw
Rail for sealing
Packing
Stud
Nut
Distance pipe
Distance pipe
Fitted stud
Stud
MAN B&W Diesel A/S
Plate
P90302-0161
Page 1 (2)
Plate
P90302-0161
Item
No.
000
071
083
095
105
117
129
130
142
166
178
191
201
213
225
237
249
262
Page 2 (2)
Item Description
Item
No.
Item Description
O-ring
O-ring
Cooling jacket
Clamp
Screw
Cylinder liner
Cooling water connection
Packing
O-ring
Pipe
Screw
Pipe
Pipe
Spring pin
Plug screw for thermo sensor hole
Gasket
Piston cleaning ring
MAN B&W Diesel A/S
Plate
P90304-0035

0035
P90304
Camshaft side
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90304-0035
Item
No.
023
035
060
072
084
096
Item Description
Item
No.
Item Description
Stud
Nut
Non-return valve
Housing, non-return valve
Non-return valve
Head
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel
Plate
P90305-0143
Page 1 (2)
Plate
P90305-0143
Item
No.
017
029
030
042
066
101
113
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Bracket
Stud
Nut
Washer
Screw
Stud
Nut

MAN B&W Diesel
Plate
P90307-0032
Page 1 (2)
Plate
P90307-0032
Item
No.
018
031
043
055
079
080
092
102
126
138
175
187
199
210
222
258
271
283
295
305
317
329
330
342
354
366
378
391
413
425
449
450
462
486
498
521
533
545
557
569
582
594
604
616
628
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Straight stud coupling

Distributor block
Stud
Nut
Distributor block
Ball valve
Distributor block
Stud
Adjustable elbow coupling
Quick coupling, minimess
O-ring
Gasket
Membrane accumulator
Lubricator, complete
Screw
Straight stud coupling
Adjusting screw
O-ring
Spacer, tubular
Cover
O-ring
Non-return valve
O-ring
Cylinder block
O-ring
Spring
Plunger
Actuator piston
Screw
Screw
Membrane accumulator
Gasket
Cylinder housing
Solenoid valve complete
Screw
O-ring
O-ring
Inductive sensor
Plug
Housing
Cable
Cable gland
Screw
Cable gland
Plug
Intermediate Box
MAN B&W Diesel A/S
Plate
P90308-0010
Page 1 (2)
Plate
P90308-0010
Item
No.
013
037
049
062
Page 2 (2)
Intermediate Box
Item Description
Item
No.
Item Description
Intermediate box, complete

Electric enclosure with cables
Circuitboard assy
Diode
MAN B&W Diesel A/S
Cylinder Frame, Studs on Exhaust Side

MAN B&W Diesel
Plate
P90310-0012
Page 1 (2)
Plate
P90310-0012
Item
No.
014
026
038
054
063
075
Page 2 (2)
Cylinder Frame, Studs on Exhaust Side

MAN B&W Diesel
Item Description
Item
No.
Item Description
Distance pipe
Nut
Stud
Distance pipe
Nut
Stud
Cylinder Lubrication - Electronic Components
MAN B&W Diesel A/S
Plate
P90312-0004
Page 1 (2)
Plate
P90312-0004
Item
No.
015
027
039
040
052
064
076
088
111
159
160
184
196
206
Page 2 (2)
Cylinder Lubrication - Electronic Components
Item Description
Item
No.
Item Description
Name plate
Pilot lamp
Name plate
Selector switch
Terminal
Terminal
Din rail
Terminal
Terminal
HMI panel
Mounting plate
Nut
Screw
Terminal
MAN B&W Diesel A/S

90401
90403
0172
0012
Connecting Rod and Crosshead

Lubricating and Cooling Oil Flow
MAN B&W Diesel A/S
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90401-0172
Page 1 (2)
Plate
P90401-0172
Item
No.
019
020
032
056
068
093
103
127
139
152
164
176
188
223
235
247
260
272
284
296
318
331
343
367
379
392
402
414
426
438
463
475
487
509
510
522
546
558
583
595
617

MAN B&W Diesel
Item
No.
Item Description
Item Description
Screw
Outlet pipe
Guide shoe
Lock washer
Stop screw
Screw
Nut
Thrust piece
Screw
Telescope pipe
Distance tube
Bend
Stud
Plug
Guide pin
Throttle plug
Locking wire
Crosshead
Crosshead bearing shell, complete
Guide strip
Crankpin bearing cap, complete
Guide screw
Crankpin bearing cap
Guide pipe
Nut
Nut
Washer
Stud
Screw
*) Shim
Nut
Crosshead bearing cap
Stud
*) Shim
*) Shim
Stud
Guide pin
Connecting rod
Nut
Stud
Connecting rod, complete
Note:
*) Please state thickness of shim
Page 2 (2)
Lubricating and Cooling Oil Flow

MAN B&W Diesel
Plate
P90403-0012
Page 1 (1)

90501
90502
90505
90510
90511
90513
0162
0052
0146
0124
0039
0041
Crankshaft
Arrangement of Fore End
Thrust- and Guide Bearing
Turning Gear
Turning Wheel
Tacho System
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crankshaft
Plate
P90501-0162
P90501
Crankshaft
0162
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90501-0162
Item
No.
012
024
061
073
097
107
119
120
132
144
156
203
215
227
Crankshaft
Item Description
Item
No.
Item Description
Flange
Screw
Screw
Crankshaft
Guard
Guard
Nut
Packing
Cover
Screw
Locking wire
Fitted bolt
Split pin
Chain wheel
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90502-0052
Page 1 (2)
Plate
P90502-0052
Item
No.
018
024
043
055
Page 2 (2)
Item Description
Item
No.
Item Description
Stud
Nut
Tuning wheel
Disc
MAN B&W Diesel A/S
Thrust and Guide Bearing
Plate
P90505-0146

0146
P90505
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90505-0146
Item
No.
014
026
038
051
063
075
087
109
110
122
134
158
171
195
205
217
229
242
254
266
278
291
301
313
337
350
362
386
408
421
433
445
457
469
494
504
516
541
Item Description
Lubricating oil pipe
Screw
Nut
Stopper
Segment holder
Locking wire
Screw
Segment
Segment
Nut
Screw
Segment holder
Segment holder
Screw
Oil throw ring
Screw
Nut
Scraper ring housing,
Bolt
Screw
Nut
Bolt
Screw
Nut
Page 2 (2)
Item
No.
Item Description
complete
upper
lower
complete
MAN B&W Diesel A/S
Turning Gear
MAN B&W Diesel A/S
Plate
P90510-0124
Page 1 (2)
Plate
P90510-0124
Item
No.
011
023
035
047
059
072
084
096
106
131
143
155
167
192
202
214
226
251
263
299
309
310
322
334
346
358
405
417
429
Page 2 (2)
Turning Gear
Item Description
Item
No.
Item Description
Bracket
Nut
Screw
Spring washer
Cam
Switch
Spring washer
Screw
Lever
3/2-way valve
Screw
Spring washer
Chain
Nut
Distance pipe
Pin
Turning gear
Distance pipe
Screw
Gear wheel
Disengaging divice, complete
Screw
Cam
Spring washer
Shaft
Bush
Spring ring
Eye screw
Circlip
MAN B&W Diesel A/S
Turning Wheel
MAN B&W Diesel A/S
Plate
P90511-0039
Page 1 (2)
Plate
P90511-0039
Item
No.
017
029
030
054
066
078
101
113
125
137
Page 2 (2)
Turning Wheel
Item Description
Item
No.
Item Description
Guide pin
Nut
Nut
Screw
Screw
Dead centre pointer
Fitted bolt
Nut
Turning wheel
Locking wire
MAN B&W Diesel A/S
Tacho System
MAN B&W Diesel
Plate
P90513-0041
Page 1 (2)
Tacho System
Plate
P90513-0041
Item
No.
018
031
043
055
067
080
092
114
126
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Tacho pick-up
Screw
Spring-lock
Nut
Bracket
Screw
Spring-lock
Cylindrical dowel
Nut
906 - Control Gear

90600
90603
90610
90611
90612
90613
90615
90618
90619
90620
90621
90622
90631
90632
90633
90634
0125
0111
0131
0175
0085
0116
0147
0134
0019
0097
0076
0070
0023
0003
0030
0041
Arrangement of Chain Drive and Camshaft

Chain Tightener
Bearing Housing - Mounting
Camshaft and Chain Wheel
Arrangement of Indicator System
Camshaft Bearing
Regulating Shaft
Load Transmitter
Engine-Side Control Console
Engine-Side Control Console - Details
Chain Drive Guidebars - Lower Part
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Arrangement of Chain Drive and Camshaft
MAN B&W Diesel A/S
Plate
P90600-0125
Page 1 (1)
Chain Tightener
Plate
P90603-0111
Chain Tightener
0111
P90603
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90603-0111
Item
No.
017
029
030
042
054
066
078
091
113
125
150
162
174
186
198
208
221
233
245
270
282
294
304
316
328
Chain Tightener
Item Description
Item
No.
Item Description
Chain wheel
Cup point screw
Bushing
Flange bearing
Locking wire
Screw
Screw
Bracket
Shaft
Flange bearing
Distance piece
Distance piece
Screw
Grease nipple
Shaft
Guide nut
Locking plate
Nut
Tightening bolt
Shaft
Guide nut
Retaining ring
Retaining ring
Shaft
Bushing
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90610-0131
Page 1 (2)
Plate
P90610-0131
Item
No.
015
039
052
064
088
111
123
147
159
172
184
196
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Bearing housing
Bearing shell
Nut for hydraulic tightening
Stud
Lock washer
Screw
Guide pin
Guide pin
Shim
Bearing housing
Guide disc
Screw

MAN B&W Diesel
Plate
P90611-0175
Page 1 (2)
Plate
P90611-0175
Item
No.
010
034
058
071
083
095
117
130
154
166
191
213
225
249
250
274
298
321
345
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Camshaft, fore
O-ring
Exhaust cam
Fuel cam
Sealing flange
Coupling
O-ring
Camshaft
Indicator cam
Fitted bolt
Nut, self-locking
O-ring
Fitted bolt
Chain wheel
Camshaft
Guide pin
Disc
Nut
Plug
MAN B&W Diesel A/S
Plate
P90612-0085
Page 1 (2)
Plate
P90612-0085
Item
No.
016
028
041
053
065
077
089
090
100
112
124
136
148
161
173
185
197
207
219
220
232
244
256
268
281
293
303
315
327
555
567
579
580
Page 2 (2)
Item Description
Item
No.
Item Description
Nut
Screw
Washer
Bracket
Screw
Housing
Liner
Spring pin
Roller guide, complete
Circlip
Washer
Screw
Circlip
Roller guide
Liner
Liner
Spring
Key
Screw
Shaft
Needle bearing
Pointed screw
Bracket
Screw
Screw
Handle
Bracket
Washer
Screw
Guide roller
Shaft
Circlip
Washer
MAN B&W Diesel A/S
Camshaft Bearing
Plate
P90613-0116
Camshaft Bearing
0116
P90613
MAN B&W Diesel A/S
Page 1 (2)
Camshaft Bearing
Plate
P90613-0116
Item
No.
023
035
047
059
060
072
084
131
143
155
167
179
192
202
214
226
238
251
263
275
287
Item Description
Item
No.
Item Description
Housing
Guide pin
Screw
Screw
Shield, upper part
Rubber corol
Shield, lower part
Cover
Gasket
Nut
Nut
Screw
Oil pan
Stud
Bearing shell
Pin
Bearing cap
Screw
Flange, complete
Gasket
Cover
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel
Plate
P90615-0147
Page 1 (2)
Plate
P90615-0147
Item
No.
012
036
048
061
073
085
107
119
120
132
156
168
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Electrical governor actuator

Screw
Spring lock
Screw
Nut
Bracket
Pull rod, complete
Fitted bolt
Washer
Nut, self-locking
Terminal
Screw
Regulating Shaft
MAN B&W Diesel A/S
Plate
P90618-0134
Page 1 (2)
Plate
P90618-0134
Item
No.
019
020
032
044
068
081
093
103
115
127
139
140
164
176
188
211
223
260
272
284
296
306
318
331
343
355
367
392
402
414
426
438
451
475
487
499
509
510
522
534
546
571
595
630
642
654
666
678
691
701
Page 2 (2)
Regulating Shaft
Item Description
Item
No.
Item Description
Shaft
Circlip
Pull rod, complete
Fitted bolt
Screw
Lock washer
Arm holder
Pin
Recilient arm, complete
Circlip
Nut
Spring
Screw
Lock washer
Nut
Washer
Fitted bolt
Sleeve coupling, complete
Pin
Self-locking nut
Washer
Moveable arm
Circlip
Pin
Key
Lever
Self-locking nut
Shaft
Shaft
Screw
Spring washer
Sleeve coupling
Nut
Ball bearing
Shim
Bearing housing
Screw
Shaft
Bracket
Bearing housing
Screw
Bracket
Washer
Key
Screw
Lever
Nut
Bracket
Dog point screw
Spring pin
MAN B&W Diesel A/S
Load Transmitter
MAN B&W Diesel
Plate
P90619-0019
Page 1 (2)
Load Transmitter
Plate
P90619-0019
Item
No.
014
026
038
051
075
087
099
109
110
122
134
146
171
183
195
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Clamping arm
Screw
Lock washer
Nut
Fitted bolt
Self-locking nut
Washer
Pull rod, complete
Clamping arm
Screw
Lock washer
Nut
Bracket
Potentiometer
Screw
Plate
P90620-0097
Engine Side Control Console

0097
P90620
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90620-0097
Item
No.
021
033
045
057
069
070
082
094
104
116
128
141
153
165
177
189
190
200
212
224
248
261
273
285
307
319
320
332
368
381
415
427
476
488
511
523
535
547
559
631
643
655
667
680
692
714
726
Item Description
Distance pipe
Screw
Switch 0-110 volt
Spring lock
Name plate
Pressure switch
Screw
Name plate
Name plate
Spring lock
Nut
Stud
Handle
Key
Grease nipple
Nut
Washer
Engine side console
Forked lever
Key
Clamping arm
Screw
Nut
Lock washer
Cover
Screw
Hand wheel
Thrust ring
Locking plate
Nut
Clamping block
Spindle
Ball bearing
Circlip
Screw
Name plate, astern
Name plate, start
Name plate, aahead
Name plate, stop
Screw
Sealing ring
Name plate, remote
Name plate
Thrust ring
Name plate, emergency
Ball bearing
Circlip
Page 2 (2)
Item
No.
738
751
763
775
Item Description
Bearing flange
Shaft
Studs
Ball handle
MAN B&W Diesel A/S
Engine - Side Control Console, Details
Plate
P90621-0076

0076
P90621
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90621-0076
Item
No.
027
039
040
052
076
088
111
123
135
147
159
160
172
196
206
218
231
255
267
279
280
302
314
326
338
351
363
375
387
399
410
422
434
446
458
483
495
505
517
529
542
554
566
578
591
613
637
Item Description
Screw
Self-locking nut
Washer
Fitted bolt
Key
Coupling
Split pin
Bearing
Screw
Angle lever
Circlip
Non-return valve
Nut
Flange bearing
Screw
Manual valve 5/2 way
Screw
Pointer
Screw
Shaft
Circlip
Circlip
Ball bearing
Flange bearing
Clamping arm
Lock washer
Nut
Screw
Nut
Slide shoe
Circlip
Screw
Lock washer
Coupling
Coupling
Non-return valve
Banjo coupling
Coupling
Screw connection
Coupling
Coupling
Coupling
Coupling
Coupling
Coupling
Page 2 (2)
Item
No.
650
Item Description
Coupling
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90622-0070
Page 1 (2)
Plate
P90622-0070
Item
No.
010
022
034
046
058
071
083
095
105
117
129
130
178
191
201
213
225
237
249
250
262
274
286
298
308
321
333
345
357
369
370
Page 2 (2)
Item Description
Item
No.
Item Description
Flange bearing
Washer
Self-locking nut
Lever
Lever
Grease nipple
Fitted bolt
Spindle
Cone
Guide pin
Distance ring
Ball bearing
Lever
Plate
Disc
Nut
Locking plate
Screw
Bushing
Locking arm
Washer
Screw
Spring washer
Screw
Switch
Stop screw
Cam
Impact socket
Impact handwheel
Washer
Self-locking nut
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90631-0023
Page 1 (2)
Plate
P90631-0023
Item
No.
021
045
069
070
094
104
116
128
141
153
165

MAN B&W Diesel
Item Description
Item
No.
Item Description
Chain link, complete

Chain, complete
Outer link
Inner link
Locking wire
Disc
Screw
Beam for guidebar
Guidebar
Screw
Bracket for guidebar
Note:
*
Page 2 (2)
Chain Drive Guide Bars - Lower Parts
MAN B&W Diesel A/S
Plate
P90632-0003
Page 1 (2)
Plate
P90632-0003
Item
No.
015
027
039
052
064
076
111
135
147
160
184
196
218
243
267
Page 2 (2)
Chain Drive Guide Bars - Lower Parts
Item Description
Item
No.
Item Description
Guidebar
Beam f. guidebar
Screw
Disc
Screw
Locking wire
Screw
Beam f. guidebar
Shim
Screw
Screw
Bracket
Screw
Beam f. guidebar
Bracket
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90633-0030
Page 1 (2)
Plate
P90633-0030
Item
No.
010
022
034
058
071
083
095
105
129
142
166
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Lubricating pipe
Spray nozzle
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe

MAN B&W Diesel
Plate
P90634-0041
Page 1 (2)
Plate
P90634-0041
Item
No.
016
028
041
053
065
089
090
100
112
136
148
173
185
219
232
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description

Spray pipe
Spray pipe
Spray pipe
Spray pipe

90702
90703
90704
0069
0129
0053
Main Starting Valve

Starting Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Starting Valve
MAN B&W Diesel A/S
Plate
P90702-0069
Page 1 (2)
Plate
P90702-0069
Item
No.
027
039
052
064
076
088
123
135
147
160
184
196
206
218
231
255
279
280
292
314
326
338
351
363
387
399
410
422
434
458
471
495
505
517
529
530
542
554
566
591
601
625
637
650
674
698
Page 2 (2)
Main Starting Valve
Item Description
Screw
Name plate "Working"
Screw
Washer
Switch
Distance pipe
Spindle
Screw
Plate
Ball valve with actuator*
Nut
Screw
Starting air pipe
Gasket
Intermediate piece
Name plate "Blocked"
Nut
Washer
Hand wheel
Securing plate
Pin
Spring
Screw
Gasket
Gasket
Plug screw
Adjusting screw
Nut
Adapter
Washer
Screw
Screw
Guide
Guide pin
Screw
Distance pipe
Screw
Ball valve with actuator*
Nut
Plug screw
Gasket
Plug screw
Starting air pipe
Non-return valve
Housing
Housing
Item
No.
708
900
912
Item Description
Screw
Repair kit, actuator*
Repair kit, ball valve*
Note:
* When ordering spare parts for this
item, please state manufacturer's Part
No.
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90703-0129
Page 1 (2)
Plate
P90703-0129
Item
No.
010
022
034
046
071
083
105
129
142
166
178
191
213
225
237
250
274
286
298
308
321
333
345
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Starting cam
Lock washer
Screw
Cover
Screw
Cover
Piston valve slide
Liner
Screw
Screw
Washer
Screw
Screw
Housing
Screw
Pin
Screw
Flange
Locking ring
Spring guide
Spring
Spring guide
Liner
Plate
P90704-0053
Starting Valve
Starting Valve
0053
P90704
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90704-0053
Item
No.
016
028
053
065
077
090
100
112
148
161
Starting Valve
Item Description
Item
No.
Item Description
Screw
Piston
Spring
Bushing
Valve housing
Screw
Cover
Locking plate
Sealing ring
Spindle
Page 2 (2)
MAN B&W Diesel A/S
908 - Exhaust Valve

90801
90803
90804
90805
90806
90810
0211
0045
0016
0122
0104
0089
Exhaust Valve - Lower Parts

Exhaust Valve - Upper Parts
Exhaust Valve Upper Parts - Details
Exhaust Valve - Actuator
Exhaust Valve - Pipe System
Arrangement of Cooling Water Pipes
MAN B&W Diesel A/S
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90801-0211
Page 1 (2)
Plate
P90801-0211
Item
No.
013
025
037
050
062
074
086
098
121
145
169
170
182
194
204
228
253
265
277
290
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Cover
Screw
Packing
Packing
Flange
Screw
O-ring
Bottom piece
Valve spindle
Thread insert
Spindle guide lower
Exhaust valve housing
Plug screw
Screw
Sealing ring
O-ring
Packing
Flange
Screw
Sealing ring

MAN B&W Diesel
Plate
P90803-0045
Page 1 (2)
Plate
P90803-0045
Item
No.
014
026
038
063
087
099
110
134
158
205
217
229
242
254
266
291
301
325
337
349
350
362
386
398
408
433
457
469
470
482
494
504
516
528
541
553
565
589
600
612
624
636
661
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Lifting eye bolt

Screw
Lifting attachment
Packing
Orifice plug
Disc
Safety handrail
Piston, air cylinder
O-ring
Locking plate
Sliding bearing
Sealing ring
Oil cylinder
Stud
Nut
Sealing oil pipe
Sealing oil control unit
Disc
Locking plate
Screw
O-ring
Air cylinder
Screw
Disc
Cone
Piston ring
Screw
Pin
Rotation check rod
Steel pipe
Union nut
Screwed connection
Packing ring
Spring
O-ring
Disc
Spring pin
Non-return valve
Piston
Spring
Piston
Disc
Piston, complete
Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel
Plate
P90804-0016
Page 1 (2)
Plate
P90804-0016
Item
No.
021
045
905
Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel
Item Description
Item
No.
Item Description
Gasket
Safty valve, with o-ring
O-ring*
Note:
* Optional extras
Page 2 (2)
Valve Gear
Plate
P90805-0122
Valve Gear
0122
P90805
MAN B&W Diesel A/S
Page 1 (2)
Valve Gear
Plate
P90805-0122
Item
No.
015
027
039
040
052
064
076
088
111
123
135
147
159
160
167
196
206
218
255
267
279
280
292
314
326
338
351
Item Description
Item
No.
Item Description
Nut
Oil cylinder
Stud
Stud
Piston
Roller guide, complete
Thrust disc
Roller guide
Shaft pin for roller
Plug
Circlip
Screw
Bushing
Disc
Bushing for roller guide
Cylinder pin
Screw
Bushing
Piston ring
Disc
Screw
Disc
Spring
Cylinder pin
Roller
Guide block
Guide pin
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90806-0104
Page 1 (2)
Plate
P90806-0104
Item
No.
010
022
046
058
071
083
105
117
129
130
142
154
166
178
191
213
237
262
298
308
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Sealing ring
Sealing disc
Clamp
Nut
Screw
Support
Coupling
Coupling
Thrust bushing
Screw
Cooling water connection
Pipe
Sealing ring
Packing
Hose complete
Drain pipe
Hydraulic pipe, complete
Screw
Plug screw
Packing ring

MAN B&W Diesel
Plate
P90810-0089
Page 1 (2)
Plate
P90810-0089
Item
No.
012
024
036
048
061
073
085
097
119
120
132
156
181
203
215
227
239
240
264
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Steel pipe
Ball valve
Coupling
Steel pipe
Gasket
Freshwater pipe, outlet
Screw
Packing
Screw
Nut
Packing
Freshwater pipe, inlet
Globe valve
Packing
Screw
Sealing ring
Screw
Spring pin
Freshwater pipe, inlet

90901
90902
90903
90904
90905
90907
90910
90911
90913
90914
90915
90915
90916
0184
0150
0040
0061
0030
0011
0143
0022
0158
0078
0060
0080
0006
Fuel Pump
Fuel Pump Gear
Fuel Pump Gear - Details
Fuel Pump - Details
Reversing Mechanism
Lifting Device for Fuel Pump
Fuel Valve
Fuel Valve Function
High-Pressure Pipes
Fuel Oil System
Fuel Oil System - Details
Lifting Device for Fuel Pump - Cylinder No. 1
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Fuel Pump
MAN B&W Diesel A/S
Plate
P90901-0184
Page 1 (2)
Plate
P90901-0184
Item
No.
017
042
054
078
101
113
125
137
149
150
162
174
186
198
221
233
257
269
270
282
294
341
389
390
400
412
436
448
461
473
520
532
544
568
581
603
615
627
639
640
652
664
676
688
711
723
735
747
772
784
Page 2 (2)
Fuel Pump
Item Description
Gasket
Gasket
Plug screw
Pump housing, complete
Timing guide
Sleeve
Regulating guide
Guide pin
Screw
Guide pin
Stud
Gasket
Guide screw
Guide pin
Guide bushing, complete
Guide bushing
Screw
Screw
Top cover
Lock washer
Plug screw
Throttle plug
Nut
Screw
Spring guide
Spring
Suction value, complete
Slide
Thrust piece
Sealing ring
Sealing ring
Pump barrel
Pump barrel, complete
Sealing ring
Plunger
Screw
Lock washer
Cover
Sealing ring
Sealing ring
Puncture valve, complete
Air piston
Gasket
Valve housing
O-ring
Slide
Spring
Spring guide
Throttle plug
Gasket
Item
No.
855
867
879
880
892
902
914
926
Item Description
Screw
Portective cap
Coupling
Pipe
Banjo coupling
Plug screw
Disc
Pipe
MAN B&W Diesel A/S
Fuel Pump Gear
MAN B&W Diesel A/S
Plate
P90902-0150
Page 1 (2)
Plate
P90902-0150
Item
No.
012
024
036
048
061
073
085
097
107
119
120
132
168
181
193
203
215
239
240
252
276
288
311
323
335
360
384
396
406
418
431
467
479
492
502
514
526
551
563
575
587
599
609
610
622
634
646
658
Page 2 (2)
Fuel Pump Gear
Item Description
Item
No.
Item Description
Pin
Shaft
Plug
Circlip
Screw
Fuel pump roller guide, complete
Roller
Bushing
Disc
Shaft
Link f. reversing
Pin
Guide pin
Thrust disc
Roller guide
Plug
Bushing
Nut
Nut
Pump base, complete
Pin
Guide block
Screw
Pin
Bushing
Bushing for roller guide
Disc
Sealing ring
Cap
Sealing ring
Cap
Locking wire
Screw
Gasket
Gasket
Cover
Screw
Seat disc
Spring, internal
Stud
Spring, external
Stud
Seat disc
Seat disc
Pump base
Sealing bush
Retaining ring
Orifice plug
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90903-0040
Page 1 (2)
Plate
P90903-0040
Item
No.
018
031
043
055
067
080
092
102
114
126
138
151
175
187
199
209
210
222
246
258
271
283
295
305
317
329
330
342
354
366
391
401
413
Page 2 (2)
Item Description
Item
No.
Item Description
Screw
Support, complete
Ball lock
Screw
O-ring
Screw
Coupling arm
Screw
Washer
Pull rod head
Nut
Nut
Flange
Shaft
Screw
Collar pin
Split pin
Air cylinder
Locking pin
Securing pin
O-ring
Bearing
Piston ring
O-ring
Screw
Bracket
Stud
Distance piece
Flange suspension
Screw
Disc
Needle bearing
Pin
MAN B&W Diesel A/S
Fuel Pump - Details

MAN B&W Diesel
Plate
P90904-0061
Page 1 (2)
Fuel Pump - Details
Plate
P90904-0061
Item
No.
013
025
037
049
050
062
074
086
108
121
133
157
169
170
182
194
216
228
241
253
265
277
289
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Union
Screw
Bracket
Screw
Actuator
Coupling
Washer
Nut
Guide screw
Toothed bar, regulation
Packing
Union
Pointer
Toothed bar, timing
Nut
Forked lever
Retaining ring
Guide pin
Forked lever
Forked lever
Nut
Adjusting screw
Nut
Reversing Mechanism
Plate
P90905-0030
Reversing Mechanism
0030
P90905
MAN B&W Diesel A/S
Page 1 (2)
Reversing Mechanism
Plate
P90905-0030
Item
No.
019
020
032
044
056
068
093
103
115
127
139
152
164
176
211
223
235
247
259
272
284
296
306
Item Description
Item
No.
Item Description
Shaft
Guide for reversing
Distance pipe
Nut
Guard
Screw
Cover
Screw
Bolt
Flange for air cylinder
Reversing mechanism, complete
Screw
Bush
Air cylinder
Ball valve
Tee-screwed connection
Nut
Packing
Union
Orifice plate
Non-return valve
Nut
Safety valve
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90907-0011
Page 1 (2)
Plate
P90907-0011
Item
No.
021
033
057
069
070
082
094
104
116
141
153
177
189
200
212
224
Page 2 (2)
Item Description
Item
No.
Item Description
4/2 way valve

Screw
Pipe
Coupling
Coupling
Coupling
Coupling
Coupling
Non-return valve
Pressure switch
Screw
Coupling
Pipe
Coupling
Pipe
Hose
MAN B&W Diesel A/S
Plate
P90910-0143
Fuel Valve
P90910
Fuel Valve
0143
016
197
207
028
065
219
089
090
220
100
232
124
244
256
136
268
148
950
281
161
173
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90910-0143
Item
No.
016
028
065
089
090
100
124
136
148
161
173
197
207
219
220
232
244
256
268
281
950
Fuel Valve
Item Description
Item
No.
Item Description
Thrust piece
Cut-off shaft
Spindle guide, complete
Spindle guide
Spring pin
Nozzle
O-ring
Holder
Guide pin
Union nut
O-ring
O-ring
Valve head
Guide pin
Spring
Non-return valve
Disc
Thrust spindle
Spring
Thrust foot
Disc (optional extras)
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve Function
MAN B&W Diesel A/S
Plate
P90911-0022
Page 1 (2)
Plate
P90911-0022
Item
No.
Fuel Valve Function
Item Description
Item
No.
Item Description
Note:
D1 = Predetermined closing value for
non-return valve
D2 = Predetermined opening value for
cut-off spindle
Page 2 (2)
MAN B&W Diesel A/S
High-Pressure Pipes
MAN B&W Diesel A/S
Plate
P90913-0158
Page 1 (2)
Plate
P90913-0158
Item
No.
012
024
036
048
073
085
097
107
120
132
156
181
193
203
215
227
252
264
276
288
323
335
372
High-Pressure Pipes
Item Description
Item
No.
Item Description
Sleeve
Retaining ring
High-pressure pipe
Union nut
Sealing ring
Union nut
Housing
O-ring
Union nut
O-ring
High-pressure pipe, complete
Coupling
Steel pipe
Screw
Flange
Housing
Coupling
Guide pin
High-pressure pipe
High-pressure pipe
Insulation*
Note:
*Pipe end insulation sleeve and tape
can be sold seperatly
Page 2 (2)
MAN B&W Diesel A/S
Fuel Oil System
Plate
P90914-0078
Fuel Oil System

0078
P90914
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90914-0078
Item
No.
018
031
055
067
079
092
102
126
138
187
199
Fuel Oil System
Item Description
Item
No.
Item Description
Pipe
Pipe
Pipe
Coupling
Coupling
Distributor piece
Screw
Pipe
Coupling
Coupling
Gasket
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90915-0060
Page 1 (2)
Plate
P90915-0060
Item
No.
013
025
037
049
050
074
086
098
121
133
145
Page 2 (2)
Item Description
Item
No.
Item Description
By-pass valve, complete

Valve housing
Valve housing
Sealing ring
Spring guide
Screw
Union nut
Nut
Sealing ring
Piston
Spring
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90915-0080
Page 1 (2)
Plate
P90915-0080
Item
No.
013
025
037
049
050
062
074
086
098
108
121
133
157
169
170
194
204
216
228
241
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Nut
Locking plate
Flange
Stud
Spring guide
Disc
Slide
Pressure spring
Piston
Sealing ring
Wearing ring
Packing
Plug screw
Packing ring
Stud
Pressure spring
Packing
Housing
Screw
Shock absorber, complete
Lifting Device for Fuel Pump Cyl. No. 1
MAN B&W Diesel A/S
Plate
P90916-0006
Page 1 (2)
Plate
P90916-0006
Item
No.
020
032
056
068
081
093
103
115
140
152
164
176
Page 2 (2)
Lifting Device for Fuel Pump Cyl. No. 1
Item Description
Item
No.
Item Description
4/2-Way valve
Pipe holder
Screw
Pressure switch
Screw
Coupling
Coupling
Steel pipe
Coupling
Steel pipe
Hose
Copper pipes
MAN B&W Diesel A/S

91000
91001
91002
91003
91004
91005
91006
91007
91009
91011
91014
0017
0166
0142
0225
0036
0140
0029
0018
0020
0026
0029
Gas and Air System

Scavenge Air Receiver
Arrangement of Charging Air Pipe
Exhaust Pipes and Receiver
Exhaust Receiver - Details
Air Cooler
Butterfly Valve
Arrangement of Non-Return Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Gas and Air System
MAN B&W Diesel A/S
Plate
P91000-0017
Page 1 (1)

MAN B&W Diesel
Plate
P91001-0166
Page 1 (2)
Plate
P91001-0166
Item
No.
017
029
030
042
054
066
078
091
101
113
125
137
149
150
162
174
186
198
221
233
257
269
270
282
294
304
316
328
341
353
365
377
389
390
400
412
424
436
448
461
473
485
497
507
519
532
544
556
568
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Scavenge air receiver, aft

Screw
Distance pipe
Air cooler housing sealing
Screw
Support
Spring pin
O-ring
Flange
Screw
Stud
Nut
Washer
Washer
Locking plate
Hinge
Cover
Cross member
Distance piece
O-ring
Screw
Nut
O-ring
Screw
Cover
Distance pipe
Screw
Locking plate
Distance pipe
Screw
Nut
Screw
Cover
Scavenge air receiver, fore
Airflow reversing chamber
Safety catch
Round iron
Stud
Nut
Screw
Distance pipe
O-ring
O-ring
Screw
Cover
Plate
Plate
Stud
Packing

MAN B&W Diesel
Plate
P91002-0142
Page 1 (2)
Plate
P91002-0142
Item
No.
012
024
036
061
085
119
132
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Washer
Nut
Plug screw
Screw
Compensator
Charging air pipe

MAN B&W Diesel
Plate
P91003-0225
Page 1 (2)
Plate
P91003-0225
Item
No.
031
055
067
079
080
092
102
114
138
151
163
175
199
209
234
246
258
271
283
305
317
330
342
354
366
378
391
401
437
449
450
474
486
521
533
545
557
569
MAN B&W Diesel

Item
No.
Item Description
Item Description
Grid, complete
Packing
Compensator
Nut
Screw*
Pipe bend
Nut
Screw*
Wire gauze
Clamp
Pin
Disc
Screw*
Nut
Special nut
Locking device
Locking device
Nut
Screw
Packing
Compensator
Packing
Gas compensator
Nut
Screw*
Gas inlet
Screw*
Nut
Packing
Pipe
Screw*
Packing ring
Plug
O-ring
Stud
Plate
Plate
Wing nut
Note:
* These screws are special screws
for hot joints, they are marked with a
T, and MUST NOT BE USED ELSEWHERE!
Page 2 (2)

MAN B&W
Plate
P91004-0036
Page 1 (2)
Plate
P91004-0036
Item
No.
013
025
037
049
050
062
074
086
098
108
121
133
157
169
182
194
204
216
228
241
265
277
300
312
324
MAN B&W
Item
No.
Item Description
Item Description
Support
Support
Spring pin
Distance pipe
Screw
Supprt
Nut
Distance pipe
Nut
Spring pin
Washer
Screw
Exhaust reciever, aft
Shim
Clamp
Support
Support
Distance pipe
Distance pipe
Spring pin
Exhaust reciever, fore
Support
Support
Spring pin
Clamp
Note:
* These screws are special screws for
hot joints, they are marked with a T
and MUST NOT be used elsewhere !
Page 2 (2)
Air Cooler
MAN B&W Diesel
Plate
P91005-0140
Page 1 (2)
Air Cooler
Plate
P91005-0140
Item
No.
019
020
044
056
068
081
093
103
127
139
140
152
MAN B&W Diesel

Item
No.
Item Description
Item Description
Air cooler insert*

Water mist catcher*
O-ring
Frame for air cooler
Screw
Frame for air cooler
Support
Support
Screw
Stud
Nut
Screw
Note:
* When ordering spare parts for this item,
please state manufacturers part no.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P91006-0029
Page 1 (2)
Plate
P91006-0029
Item
No.
014
026
038
051
075
Page 2 (2)
Item Description
Item
No.
Item Description
Packing
Distance pipe
Screw
Nut
Auxiliary blower
MAN B&W Diesel A/S
Butterfly Valve
MAN B&W Diesel A/S
Plate
P91007-0018
Page 1 (2)
Plate
P91007-0018
Item
No.
021
033
045
057
069
070
082
116
128
Page 2 (2)
Butterfly Valve
Item Description
Item
No.
Item Description
Cover
Packing
Locking wire
Screw
Locking plate
Housing
Screw
Shaft
Flap
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91009-0020
Page 1 (2)
Plate
P91009-0020
Item
No.
010
022
034
046
058
071
083
095
117
129
130
142
154
166
191
201
213
225
237
249
250
262
274
298
321
345
357
370
382
394
404
428
441
453
465
477
489
490
500
512
536
548
561
573
585
597
607
619
620
644
Page 2 (2)
Item Description
Main pipe
Support cleaning
Flow controller
Drain box
Drain pipe
Main pipe
Packing ring
Screw
Nut
Cleaning pipe
Flange
Packing ring
Screw
Steel pipe
Valve
Screw
Drain pipe
Packing ring
Screw
Main pipe
Main pipe
Main pipe
Orifice plate
Valve
Screw
Screw
Nut
Packing ring
Packing ring
Valve
Drain pipe
Drain pipe
Drain pipe
Packing
Stud
Coupling
Guide
Cleaning pipe
Guide
Steel pipe
Coupling
Stud
Stud
Nut
Steel pipe
Cleaning pipe
Coupling
Steel pipe
Cleaning pipe
Cleaning pipe
Item
No.
656
668
Item Description
Packing ring
Screw
MAN B&W Diesel A/S
Arrangement of Non-return Valve

MAN B&W Diesel
Plate
P91011-0026
Page 1 (2)
Plate
P91011-0026
Item
No.
023
035
059
072
084
096
106
131
143
167
180
202
214
238
263
287
299
309
322
334
346
371
395
417
Page 2 (2)
Arrangement of Non-return Valve

MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Distance pipe
Screw
Support
Clamp
Support
Valve flap
Valve mounting plate
Valve mounting plate
Locking wire
Screw
Spring pin
Screw
Shaft
Locking wire
Screw
Support
Clamp
Spring pin
Support
Shaft
Valve flap
Non-return valve, complete
Non-return valve, complete

MAN B&W Diesel
Plate
P91014-0029
Page 1 (2)
Plate
P91014-0029
Item
No.
018
031
043
055
067
079
080
092
114
126
151
163
175
187
209
222
234
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Distance pipe
Screw
Packing
Disc
O-ring
Nut
Suction pipe
Pipe
Plate
Nut
Screw
Disc special
Screw
Suction pipe
Clamp
Nut

91101
91102
91102
91103
91104
0037
0029
0035
0018
0099
Safety Valve - Cylinder

Relief Valve
Relief Valve
Safety Valve - Scavenge Air System
Arrangement of Safety Cap
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Safety V
alve - Cylinder
Valve
MAN B&W Diesel
Plate
P91101-0037
Page 1 (2)
Safety V
alve - Cylinder
Valve
Plate
P91101-0037
Item
No.
010
022
034
046
058
071
083
095
105
117
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Spindle
Spring retainer
Lock nut
Spring
Valve housing
Stop ring
Valve flap
Valve guide
Gasket
Safety valve, complete
Relief Valve
MAN B&W Diesel A/S
Plate
P91102-0029
Page 1 (2)
Plate
P91102-0029
Item
No.
016
028
030
041
Relief Valve
Item Description
Item
No.
Item Description
Relief valve (P.C.D. 530mm) *

Screw*
Packing*
O-ring*
Note:
*When ordering, please state manufacturer of Relief Valve and
P.C.D. xxx mm
Page 2 (2)
MAN B&W Diesel A/S
Relief Valve
MAN B&W Diesel A/S
Plate
P91102-0035
Page 1 (2)
Plate
P91102-0035
Item
No.
016
028
030
041
Relief Valve
Item Description
Item
No.
Item Description
Relief valve (P.C.D. 795mm) *

Screw *
Packing *
O-ring *
Note:
*When ordering, please state manufacturer of Relief Valve and
P.C.D. xxx mm
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P91103-0018
Page 1 (2)
Plate
P91103-0018
Item
No.
011
035
047
059
060
072
096
106
118
131
143
155
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Safety valve, complete

Spindle
Washer
Spring retainer
Castle nut
Split pin
Screw
Nut
Valve flap
Seal
Valve seat
Spring
Plate
P91104-0099

0099
P91104
Only cyl.
No. 1
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91104-0099
Item
No.
017
029
030
042
054
066
078
091
101
125
137
149
150
162
174
186
198
208
233
257
269
270
282
Item Description
Item
No.
Item Description
Fitted bolt
Bursting cap cover
Check plate
Screw
Perforated cylinder
Screw
Washer
Starting air pipe
Packing ring
Screw
Bursting cap protector
Wing nut
Washer
Stud
Bursting disc
Nut
Screw
Nut
Bursting cap complete
Packing ring
Steel pipe
Coupling
Coupling
Page 2 (2)
MAN B&W Diesel A/S

91201
91203
91205
91206
91207
91208
91210
91211
91216
0096
0005
0201
0097
0093
0009
0188
0072
0008
Arrangement of Stay Bolts

Frame Box - Details
Frame Box
End Shields
Arrangement of Piston Cooling
Chain Wheel Frame - Upper
Bedplate
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Arrangment of Stay Bolt
MAN B&W Diesel A/S
Plate
P91201-0096
Page 1 (2)
Plate
P91201-0096
Item
No.
014
026
038
051
063
075
Page 2 (2)
Arrangment of Stay Bolt
Item Description
Item
No.
Item Description
Screw
Screw
Protective cap
Nut
Stay bolt
Neck ring in 2/2
MAN B&W Diesel A/S
Frame Box - Details
MAN B&W Diesel A/S
Plate
P91203-0005
Page 1 (2)
Plate
P91203-0005
Item
No.
015
027
039
040
052
076
088
123
135
147
Page 2 (2)
Frame Box - Details
Item Description
Item
No.
Item Description
Stud
Nut
Distance pipe
Fitted stud
Distance pipe
Distance pipe
Screw
Distance pipe
Distance pipe
Fitted stud
MAN B&W Diesel A/S
Frame Box
MAN B&W Diesel
Plate
P91205-0201
Page 1 (2)
Frame Box
Plate
P91205-0201
Item
No.
016
028
041
077
089
100
112
124
136
148
173
197
207
219
220
244
256
281
293
315
339
340
352
376
388
MAN B&W Diesel
Item Description
Item
No.
Item Description

Screw
Locking wire
Cover
Screw
Locking pin
Spring
Key ring
Frame box door
Packing
Drain pipe
Wing nut
Stud
Spring
Door fastener
Frame box door
Packing
Bush
Washer
Frame box
Flange
Packing
Screw
Cover
Screw
Note:
*
Page 2 (2)
End Shields
MAN B&W Diesel
Plate
P91206-0097
Page 1 (2)
End Shields
Plate
P91206-0097
Item
No.
011
023
035
047
060
096
106
118
131
155
167
179
192
202
214
238
251
263
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Shield, upper
Screw
Gasket
Cover
Screw
Screw
Locking wire
Damper-oil pipe
Screw
Damper-oil pipe
Gasket
Screw
Shield, lower
Screw
Drain pipe
Screw
Screw
Shield, fore
Plate
P91207-0093

0093
P91207
B
B-B
A-A
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91207-0093
Item
No.
017
029
042
054
066
091
101
125
137
149
162
174
198
Item Description
Item
No.
Item Description
Fitted bolt
Nut - special
Screw
Washer
Locking wire
Plate
Fitted bolt
Drain pipe
Drain pipe
Sight glass, complete
Screw
Bracket
Fitted bolt
Page 2 (2)
MAN B&W Diesel A/S
Plate
P91208-0009

0009
P91208
A-A
A
A
C
B B
MAN B&W Diesel A/S
B-B
Page 1 (2)
Plate
P91208-0009
Item
No.
012
024
048
061
085
097
119
120
132
156
168
193
215
239
240
252
276
311
323
347
359
360
372
384
396
418
431
455
467
479
492
502
514
Item Description
Item
No.
Item Description
Nut
Stud
Screw
Screw
Screw
Inspection cover
Chainwheel frame
Screw
Cover
Screw
Pipe
Plug
Cover
Nut
Pipe
Stud
Top guard
Packing ring
Screw
Pipe
Spring pin
Cover
Nut
Disc
Fitted stud
Screw
Pipe
Nut
Pipe
Stud
Inspection cover
Spring
Stud
Page 2 (2)
MAN B&W Diesel A/S
Bedplate
MAN B&W Diesel
Plate
P91210-0188
Page 1 (2)
Bedplate
Plate
P91210-0188
Item
No.
013
025
037
050
062
074
086
098
121
133
145
169
170
194
204
216
241
253
277
290
312
324
336
348
373
397
407
420
432
456
468
493
MAN B&W Diesel
Item Description
Item
No.
Item Description

Screw
Locking wire
Screw
Screw
Locking plate
Grate
Cover
Bedplate
Guide pin
Screw
Screw
Nut
Pipe holder
Screw
Screw
Stud
Nut
Main bearing stud
Main bearing cap
Bearing shell, upper
Bearing shell, lower
Cover
Screw
Cover
Screw
Main bearing, complete
Note:
*
Page 2 (2)
Plate
P91211-0072

0072
P91211
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91211-0072
Item
No.
019
020
081
093
103
115
127
139
140
152
164
223
235
247
259
260
284
296
306
318
Item Description
Item
No.
Item Description
Spring
Spring
Screw
Locking wire
Restriction for damper
Screw
Guide pin
Oil seal in 2/2
Oil seal in 2/2
Nut
Nut
Stud
Stud
Axial vibration damper, complete
Damper, upper part
Special locking
Guide pin
Damper, lower part
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel
HoldingDown Bolts and End Chock Bolts

(Epoxy Chocks)
Plate
P91216-0008
Page 1 (2)
Plate
P91216-0008
Item
No.
016
028
041
053
077
090
100
112
148
161
173
197
207
219
232
244
256
281
Page 2 (2)
HoldingDown Bolts and End Chock Bolts

(Epoxy Chocks)
Item
No.
Item Description
MAN B&W Diesel
Item Description
Screw
Washer
Lock plate
Liner for sidechock, port side
Liner for sidechock, starboard side
Protecting cap
Nut
Distance tube
Spherical washer
Spherical nut
Holding down bolt
Nut
Protecting cap
End chock bolt
Liner for end chock
Spherical washer
Spherical washer
Nut

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Checking & Maintenance Schedule

MAN B&W Diesel A/S

MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear

909 - Fuel Oil System

910 - Turbocharger System

MAN B&W Diesel A/S

MAN B&W Diesel

Checking and Maintenance Schedule,

Design modifications may necessitate a revision of

The stated Normal hours of service should only

The procedures are divided into three categories:

marked under the heading Normal hours of service with a C,

are those procedures which under the heading Normal hours of

Checking and Maintenance Schedule,

MAN B&W Diesel

MAN B&W Diesel

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

902 Piston with Rod and Stuffing box

Crankshaft and Thrust Bearing

903 Cylinder Liner and Cylinder Lubrication

Service interval (x1000 hours of operation)

Daily Weekly Monthly

901 Cylinder Cover

* Check whenever exhaust

Bearings should only be

Bearings should only be

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Electronic axial vibration monitor

906 Mechanical Control Gear

MAN B&W Diesel

Daily Weekly Monthly

Service interval (x1000 hours of operation)

New or overhauled chain to be

* only inspection through

MAN B&W Diesel

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Service interval (x1000 hours of operation)

Daily Weekly Monthly

Exhaust valve special running

909 Fuel Oil System

* Only inspection through

Check at every port inspection

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

912 Assembly of Large Parts

MAN B&W Diesel

Daily Weekly Monthly

Service interval (x1000 hours of operation)

* Dry cleaning daily

* Only if separate oil system

* Initial check only

Empty and clean tank

* Check for loose nuts and