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)

L35MC

VOLUME II
MAINTENANCE

900 - Introduction
Documents in this Chapter

90023
90050
90060

0027
0288
0002

Table of Contents, Volume II
Instructions for Main Engine
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
90023 0027 Instructions for Main Engine
90050 0288 Checking & Maintenance Schedule
90060 0002 General - Safety Precautions
901 - Cylinder Cover
101-01 0072 Cylinder Cover, Data
901-01 0255 Cylinder Cover
90151 0189 Cylinder Cover - Panel
90161 0107 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0100 Piston, Data
902-01 0288 Piston
102-02 0068 Piston Rod Stuffing Box, Data
902-02 0232 Piston Rod Stuffing Box
90251 0259 Piston and Piston Rod - Panel
90261 0103 Piston and Piston Rod - Tools
90264 0011 Piston and Piston Rod - Tilting Tools
90265 0002 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0077 Cylinder Liner, Data
903-01 0261 Cylinder Liner
103-02 0032 Cylinder Lubricator, Data
903-02 0255 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90366 0010 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0065 Crosshead Bearing, Data
904-01 0255 Crosshead Bearing
104-02 0067 Crosshead, Data
904-02 0254 Crosshead
104-03 0046 Reciprocating Parts, Data
904-03 0216 Reciprocating Parts
104-04 0059 Crankpin Bearing, Data
904-04 0235 Crankpin Bearing
104-05 0057 Connecting Rod, Data
904-05 0238 Connection Rod
90451 0143 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90464 0005 Crosshead - Hydraulic Tools
MAN B&W Diesel A/S

Page 1 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

Title

905 - Crankshaft, Thrust Bearing and Turning Gear
105-02 0083 Main Bearing, Data
905-02 0259 Main Bearing
105-03 0073 Thrust Bearing, Data
905-03 0226 Thrust Bearing
105-04 0048 Journal Bearing, Data
905-04 0232 Journal Bearing
105-05 0059 Axial Vibration Damper, Data
905-05 0226 Axial Vibration Damper
90551 0198 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0087 Main Bearing - Hydraulic Tools
90562 0124 Crankshaft - Tools
90564 0020 Crankshaft - Measuring Tools
90572 0003 Main Bearing - Measuring Tools
906 - Control Gear
106-01 0055 Chain, Data
906-01 0243 Chain
106-02 0064 Chain Tightener, Data
906-02 0228 Chain Tightener
106-03 0040 Camshaft, Data
906-03 0217 Camshaft
106-04 0042 Camshaft Bearing, Data
906-04 0225 Camshaft Bearings
106-06 0009 Replacement of Cams on Camshaft, Data
906-06 0203 Replacement of Cams on Camshaft
90651 0181 Chain Drive and Camshaft - Panel
90664 0003 Crankshaft - Pin Gauge
90668 0006 Camshaft - Pin Gauge
907 - Starting Air System
107-01 0021 Starting Air Distributor, Data
907-01 0220 Starting Air Distributor
107-02 0044 Start Air Valve, Data
907-02 0213 Starting Air Valve
908 - Exhaust Valve
108-01 0049 High-Pressure Pipe, Data
908-01 0230 High-Pressure Pipe
108-02 0091 Exhaust Valve, Data
908-02 0268 Exhaust Valve
108-03 0055 Exhaust Valve Actuator, Data
908-03 0245 Exhaust Valve Actuator
108-04 0039 Exhaust Valve Roller Guide, Data
MAN B&W Diesel A/S

Page 2 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

908-04
108-05
908-05
108-07
908-07
90851
90861
90862
90863

0221
0016
0217
0034
0216
0206
0033
0042
0007

Title
Exaust Valve Roller Guide
Exhaust Valve Cam, Data
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
Exhaust Valve - Panel
Exhaust Valve - Tools
Exhaust Valve - Hydraulic Tools
Exhaust Valve - Extra Tools

909 - Fuel Oil System
109-01 0062 Fuel Pump Lead, Data
909-01 0239 Fuel Pump Lead
109-03 0051 Fuel Pump Cam, Data
909-03 0228 Fuel Pump Cam
109-04 0059 Fuel Pump, Data
909-04 0221 Fuel Pump
109-05 0064 Fuel Pump Top Cover, Data
909-05 0222 Fuel Pump Top Cover
109-06 0051 Fuel Pump Barrel Assembly, Data
909-06 0218 Fuel Pump Barrel Assembly
109-07 0038 Fuel Pump Suction Valve, Data
909-07 0210 Fuel Pump Suction Valve
109-08 0053 Fuel Pump Puncture Valve, Data
909-08 0222 Fuel Pump Puncture Valve
109-09 0033 Fuel Pump Shock Absorber, Data
909-09 0212 Fuel System Shock Absorber
10911 0070 Fuel Valve, Data
90911 0236 Fuel Valve
10912 0049 Spindle Guide, Data
90912 0223 Spindle Guide
10914 0077 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0059 Fuel Pump Roller Guide, Data
90915 0227 Fuel Pump Roller Guide
10916 0018 Fuel Pump Spec. Runni
90916 0212 Fuel Pump Special Running
90951 0453 Fuel Valve and Fuel Pump - Panel
90961 0037 Fuel Valve - Tools
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90980 0001 Mounting Tools - Air Piston Seals

MAN B&W Diesel A/S

Page 3 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

Title

910 - Turbocharger System
110-01 0057 Air Cooler Element, Data
910-01 0244 Air Cooler Element
110-02 0009 Non-Return Valve in Turbocharger, Data
910-02 0211 Non Return Valve in Tubocharger
110-03 0028 Auxilary Blower, Data
910-03 0221 Auxilary Blower
110-05 0010 Turbocharger Turbine, Data
910-05 0211 Turbocharger Turbine
110-06 0036 Water Mist Catcher, Data
910-06 0224 Water Mist Catcher
91063 0021 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0003 Air Cooler - Lifting Tools
91066 0010 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 and End Chock Bolts (Epoxy), Data
912-02 0208 Holding Down and End Chock Bolts (Epoxy)
112-03 0027 Stay Bolts, Data
912-03 0211 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0072 Hydraulic Tools for Large Parts
91263 0059 Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
913 - General Tools
913-01 0206 Hydraulic Tools
913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0033 Accessories - Hydraulic Tools
91356 0052 Lifting Tools, etc.
91357 0003 Open-Ended Spanners
91358 0002 Open Ended Slugging Spanners
MAN B&W Diesel A/S

Page 4 (4)

Table of Contents

900

Volume II - Maintenance
No.
91359
91360
91361
91362
91363
91364
91366

Edition
0002
0002
0052
0059
0040
0059
0065

Title
Torque Spanners
Pliers
Combination Spanners
Ring Slugging Spanners
Spanners
Open-Ended Spanners
Instruments

MAN B&W Diesel A/S

Page 5 (4)

Instructions for Main Engines
This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes, for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:
1. Name of vessel
2. Engine No.
built by
3. Plate No.
4. Part No.
5. Quantity required (and description)
Example:

M/S Nybo – 7730 B&W – P90201-0036 – 059
10 off (piston ring)

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

To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation “D” refers to the information given on the
data sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.

A90023-0027

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

MAN B&W Diesel A/S
Teglholmsgade 41
DK-2450 Copenhagen
Denmark

Teleph.:+45 33 85 11 00
Telex :16592 manbw dk
Telefax:+45 33 85 10 30

CVR No. 39 66 13 14

MAN B&W Diesel

Checking and Maintenance Schedule,
26-70 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 0288

Page 1 of 6

900-1

Page 2 of 6

Checking and Maintenance Schedule,
26-70 MC/MC-C Engines

MAN B&W Diesel

When referring to this page, please quote Maintenance Schedule A90050 Edition 0288

O O V C C Bearings should only be opened up if bearing material fragments fall out.O C.O C. V C When referring to this page.O Crankshaft and Thrust Bearing Main bearing Thrust bearing Guide bearing Journal bearing Axial vibration damper Electronic axial vibration monitor 24 32 B P O O Remarks * Check whenever exhaust valve is removed O C V C* 903 Cylinder Liner and Cylinder Lubrication -1 Cylinder liner Inspection through scavenge ports Measuring wear inside liner -2 Cylinder lubricators Accumulators nitrogen pressure 905 -2 -3 -3 -4 -5 16 C* 902 Piston with Rod and Stuffing box -1 Piston Inspection through scavenge ports -2 Piston rod stuffing box 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 O * Check clearances without dismantling segments O C C C C A A V. please quote Maintenance Schedule A90050 Edition 0288 Page 3 of 6 .O C.O O V C C C C C C C C C C C C C C.M C. Procedure H 2 4 6 8 12 C.O C.O C. V Bearings should only be opened up if bearing material fragments fall out. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No.MAN B&W Diesel Checking and Maintenance Schedule.O C.

A C* C* C* C* C O O * only inspection through camshaft covers When referring to this page.O C. Procedure -7 -8 Mechanical checking Tacho pick-up Angle encoder 906 Mechanical Control Gear -1 Chains -2 Chain tightener Chain wheels.900-1 Checking and Maintenance Schedule.A M M M C C C C C.A C. 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 Exhaust Valve -1 High-pressure pipe -2 Exhaust valve Conventional hard-faced valve seats Nimonic exhaust valves -3 Exhaust valve actuator Actuator safety valve -4 Exhaust valve roller guide -5 Exhaust valve cam Page 4 of 6 MAN B&W Diesel H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P C.O A O O O O C. spray nozzles and guide bars -3 Camshaft -4 Camshaft bearings Camshaft coupling.O V Remarks C C C.A C C C O C C C New or overhauled chain to be checked/retightened after 500. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No.A C C C C. 1500 and 4000 hours C.O M M R A R C. please quote Maintenance Schedule A90050 Edition 0288 .

M Page 5 of 6 . -7 Procedure H R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) Daily Weekly Monthly 2 4 6 8 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 -5 900-1 Turbocharger System Air cooler Non-return valve Auxiliary blower Butterfly valves Turbocharger turbine B P Remarks O C C A.O * Only inspection through camshaft covers V Check ∆p and ∆t Check at every port inspection V. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No.O C.O R V V O O O R O C* C* C C C C* When referring to this page.C A A O O R O C.MAN B&W Diesel Checking and Maintenance Schedule.O C C C C. please quote Maintenance Schedule A90050 Edition 0288 C C O O O O O O O C.

900-1 Checking and Maintenance Schedule.M * Check for loose nuts and bearing material fragments C* O M When referring to this page. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No. please quote Maintenance Schedule A90050 Edition 0288 . Procedure -6 Turbocharger air filter Protective grid before turbocharger Turbocharger lubricating oil water content Water mist catcher 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 H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 C B O R C C* C* P V M C.O C C C C C C C C C C* * Check ∆p O O O C C C C Remarks A A A A A M M M M M M C C * Initial check only C C R C M Empty and clean tank O C A V.

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

.

Cylinder Cover Documents in this Chapter 101-01 901-01 90151 90161 0072 0255 0189 0107 Cylinder Cover. Data Cylinder Cover Cylinder Cover .901 .Panel Cylinder Cover .Tools MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

see 900-2 X X X X X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Cylinder Cover MAN B&W Diesel 101-1 Data SAFETY PRECAUTIONS For detailed sketch.91 mm 900 bar 800 . mounting D13-02 Hydraulic pressure. please quote Data D10101 Edition 0072 200 Nm 90 .990 bar Page 1 (2) . complete 510 kg D01-07 Cylinder cover without valves 300 kg D01-08 Cooling jacket 15 kg D01-09 Exhaust valve stud 3 kg D01-10 Cylinder cover stud 6 kg D13-01 Hydraulic pressure. screwing-in torque D01-05 Cylinder cover stud. Description Value Unit D01-01 Exhaust valve stud. dismantling When referring to this page. check distance D01-06 Cylinder cover.

e. Plate Item No.Tools P91351 010 Hydraulic pump. please quote Data D10101 Edition 0072 . pneumatically operated P91351 034 Hose with unions (1000 mm).Cylinder Cover 101-1 MAN B&W Diesel 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. Description P90151 046 Grinding tool for exhaust valve seat P90151 058 Milling and grinding wheel for fuel valve seat P90151 060 Milling and grinding wheel for starting valve seat P90151 083 Grinding handle P90161 Cylinder Cover . complete Page 2 (2) When referring to this page. P90951 refers to chapter 909. complete P91351 130 9-way distributor block. complete P91351 058 Hose with unions (3000 mm).g.

M901010254D01 Close the fuel oil supply for the unit concerned. please quote Procedure M90101 Edition 0255 Page 1 (13) . Check that the engine is stopped and blocked according to the safety precautions given on the data sheet. Open the drain next to the inlet valve. Shut off the water supply. 2. When referring to this page. 901-1. Shut off the water supply placed on the exhaust side below the exhaust gas receiver. M901010255C03 Open the venting cock next to the outlet valve.2 2. 3. Shut off the water outlet above the exhaust valve. 3.Cylinder Cover MAN B&W Diesel Dismantling Shut off Oil and Water Supply 1. Shut off the oil supply. Check engine blocking.

4. 5. Disconnect the oil pipes.901-1. M901010255D04 Remove the fuel oil high pressure pipes.2. Exhaust gas compensator.2 Cylinder Cover Dismantling MAN B&W Diesel Dismantling of Pipe Connections 4. 5. Disconnect the water pipes. Page 2 (13) When referring to this page. 6. See Procedure 90914. M901010255D05 Remove the clamp ring on the flanges between the intermediate pipe and the exhaust receiver. Remove the hydraulic high pressure pipe for the exhaust valve. please quote Procedure M90101 Edition 0255 . See Procedure 9081. Remove the protective jacket enclosing the insulation for the intermediate pipe or compensator. Disconnect the pipes for return fuel oil from the fuel valves. Remove the insulation. M901010255D06 6.2 Unscrew the drain pipe for the exhaust valve. Unscrew and remove the water outlet pipes.

Cylinder Cover MAN B&W Diesel 7. Cylinder cover loosening. M901010255D08 D1302 When referring to this page. see Procedure 9131. 7. please quote Procedure M90101 Edition 0255 Page 3 (13) . For use of hydraulic tools. 8. M901010255D07 Remove the protective caps from the cylinder cover nuts. 8.2 Dismantling Disconnect the starting air pipe. Unscrew and remove the air pipe for the starting valve. see Data. Loosen and remove the cylinder cover nuts. Unscrew and remove the control air pipe for the starting air valve. 901-1.

Hook on the engine room crane to the lifting attachment on top of the exhaust valve. D0106 9.2 Cylinder Cover Dismantling MAN B&W Diesel Cylinder Cover Lifting and Landing 9. 11. Lift away the cylinder cover complete. Remove and discard the sealing ring between the cylinder cover and cylinder liner. Land the cylinder cover on a couple of wooden planks. Check that all cylinder cover connections have been loosened and removed. Remove sealing ring. please quote Procedure M90101 Edition 0255 . Cylinder cover landing. M901010255D09 10. M901010255D11 11. M901010255D10 10. Page 4 (13) When referring to this page.901-1. Cylinder cover lifting.

3 1. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. Remove the screws which secure the cooling jacket to the cylinder cover. M901010255O03 Fit and tighten the screws for the cooling jacket.2. using the guide pin as a reference (manoeuvre side). Mount the cooling water jacket. Lift the cylinder cover and guide the jacket/ cover into position. D0108 M901010255O02 Provide the cylinder cover with new Orings. 3. 2.2. please quote Procedure M90101 Edition 0255 Page 5 (13) . 901-1. Dismantle valves and pipes.2 and 90911. Dismantle all valves and pipes from the cylinder cover. M901010255O01 Cooling Water Jacket 2. 9082. and carefully clean the cooling jacket and the cylinder cover. Remove the cooling water jacket. 3. D0109 Remove all studs on top of the cylinder cover. See Procedure 9072.Cylinder Cover MAN B&W Diesel Overhaul Overhaul Preparations 1. D0107 Remove and discard the Orings from the cover. well lubricated with oil. When referring to this page. Mount four eyebolts and the lifting chains as shown in the sketch.

The tool consists of a common spindle with a handle. recondition the fuel valve seating with the appropriate cutter. After the milling/grinding.Cylinder Cover 901-1. 5. clean the bore and seating carefully. please quote Procedure M90101 Edition 0255 . If required. 200). 5.g. a carbon cutter.3 Overhaul MAN B&W Diesel Reconditioning of Bores 4. Fuel valve bore. 2 3 M901010255O05 1 Page 6 (13) When referring to this page. Carborundum No. 4. and check that the seating is not damaged. a seating face cutter and a grinding mandrel. The tools for reconditioning of the valve seats are found on tool panel 901. Seat reconditioning tools. a guide. Grind the seating with the grinding mandrel and a grinding compound (e. M901010255O04 Clean the fuel valve bores using the carbon cutter.

Starting valve bore.Cylinder Cover MAN B&W Diesel 901-1. Recondition the starting valve bore and seating in the same way as described for the fuel valve bore. a cutter. however. After cleaning the valve bore and seating. The tool consists of a spindle with a handle and a grinding disc. grind the seating with the grinding disc and a grinding compound (e. 7. clean the bore and seating carefully. When referring to this page.g. 6. 7. and a grinding disc. 200). The tool consists of a guide. and check that the seating is not damaged. Carborundum No. M901010255O06 After the grinding. please quote Procedure M90101 Edition 0255 Page 7 (13) . recondition the valve bores/seating as described here.3 Overhaul 6. M901010255O07 When replacing the valves on a cylinder cover while it is mounted on the engine. Exhaust valve bore. without removing the studs.

4. 10. 9. Install the valves on the cylinder cover. Clean the bores for safety valve/indicator cock. Indicator  safety valve bore.4.4 and 90911. 8. Lubricate the threads with ‘Never Seize’ or molybdenum disulphide (MoS2) and fit the valve studs. M901010255O09 D0101 Page 8 (13) When referring to this page. 9082. Preparations before Mounting 9. M901010255O08 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.3 Cylinder Cover Overhaul MAN B&W Diesel 8.901-1. please quote Procedure M90101 Edition 0255 . Fitting of studs. see Procedures 9072. Mounting of valves.

please quote Procedure M90101 Edition 0255 Page 9 (13) . Check that the liner sealing surface is clean. 1. Place a new sealing ring on top of the cylinder liner. When referring to this page. Water connections. 2. M901010255M02 Lubricate the Orings with Vaseline and fit them on the cylinder liner. 2. M901010255M01 If necessary fit a new ‘klinger’ sealing ring in the groove of the flange of the intermediate pipe. Sealing ring. Check that the water connections are clean and provided with new Orings.4 Mounting Landing Preparation 1.Cylinder Cover MAN B&W Diesel 901-1.

D0106 Carefully wipe the cylinder cover contact surface facing the cylinder liner. 3.4 Cylinder Cover Mounting MAN B&W Diesel Cylinder Cover Mounting 3.901-1. while the cover is resting on the support. 4. adjust to the distance D0105 by turning the stud. Cylinder cover stud  check distance. Cylinder cover landing. check the distance the stud is protruding from the cylinder cover. carefully check that the cooling water connecting pipes engage correctly with the holes in the cooling jacket. M901010254M04 D0105 If necessary. please quote Procedure M90101 Edition 0255 . During the landing. Page 10 (13) When referring to this page. 4. M901010255M03 Lift the cylinder cover by means of the crane and lower it carefully into position. If the cylinder cover studs have been removed and reinstalled.

When referring to this page. Fit the exhaust gas compensator. M901010255M06 Fit the insulating jacket around the intermediate pipe. M901010255M05 6. see Procedure 9131. tight the screws. Note! Lubricate the flange edges with ‘Never Seize’ or molybdenum disulphide (MoS2) before fitting. D1301 Fitting Pipe Connections Fit the pipe clamp on the flanges between the intermediate pipe and the exhaust receiver. Fit and tighten the cylinder cover nuts. For operation of hydraulic jacks. Cylinder cover tightening. 6. 5.4 Mounting 5.Cylinder Cover MAN B&W Diesel 901-1. please quote Procedure M90101 Edition 0255 Page 11 (13) . Fit the protective caps on the cylinder cover studs.

8. Connect the oil pipes. See Procedure 9081. M901010255M07 9. M901010255M08 Connect the pipes for return fuel oil from the fuel valves.901-1. Connect and tighten the air pipe for the starting valve. Connect the fuel oil high pressure pipes. Connect and tighten the control air pipe for the starting air valve. 7. See Procedure 90914. Connect the drain pipe for the exhaust valve. Connect the water pipes. M901010255M09 9. Mount and tighten the water outlet pipes.4. 8. Page 12 (13) When referring to this page. Mount the hydraulic high pressure pipe for the exhaust valve. MAN B&W Diesel Connect the starting air pipe.4. please quote Procedure M90101 Edition 0255 .4 Cylinder Cover Mounting 7.

Vent the unit by releasing air through the venting cock next to the outlet valve.4 Mounting Open Oil and Water Supply 10. When the venting is finished. Close the drain next to the inlet valve. placed next to the cylinder liner cooling water jacket on the exhaust side. Close the venting cock next to the outlet valve. M901010255M10 11. When referring to this page. Open the water outlet valve on the exhaust side of the cylinder cover. 10. Open the oil supply. Close the drain and open the water supply. please quote Procedure M90101 Edition 0255 Page 13 (13) . Slowly open the water supply valve. Open the fuel oil supply for the unit concerned. M901010254M11 11.Cylinder Cover MAN B&W Diesel 901-1. close the venting cock.

.

Cylinder Cover Panel Plate P90151-0189 Cylinder Cover Panel 0189 P90151 When referring to this page. please quote Plate P90151 Edition 0189 MAN B&W Diesel A/S Page 1 (2) .

please quote Plate P90151 Edition 0189 MAN B&W Diesel A/S . Item Description Panel for tools Name plate Grinding tool for exhaust valve seat Cutting and grinding tool for fuel valve seat Cutting and grinding tool for starting valve seat Dismantling tool for fuel valve seat Grinding handle Grinding ring for starting valve Grinding handle Pressure tester for safety valve Notes: Page 2 (2) When referring to this page. 010 022 046 058 060 071 083 095 105 117 Cylinder Cover Panel Item Description Item No.Plate P90151-0189 Item No.

Cylinder Cover . please quote Plate P90161 Edition 0107 Page 1 (2) MAN B&W Diesel A/S .Tools Plate P90161-0107 When referring to this page.

complete When referring to this page. 027 039 052 064 088 090 100 206 Page 2 (2) Cylinder Cover .Tools Item Description Item No. Item Description Hydraulic jack for cylinder cover Support O-ring with back-up ring O-ring with back-up ring Tommy bar Spanner Stud setter Hydraulic toolset.Plate P90161-0107 Item No. please quote Plate P90161 Edition 0107 MAN B&W Diesel A/S .

Panel Piston and Piston Rod .902 .Support Tools Piston .Tilting Tools Piston and Piston Rod .Tools Piston and Piston Rod . Data Piston Piston Rod Stuffing Box.Lifting Tools MAN B&W Diesel A/S .Piston with Rod & Stuffing Box Documents in this Chapter 102-01 902-01 102-02 902-02 90251 90261 90264 90265 90266 0100 0288 0068 0232 0259 0103 0011 0002 0002 Piston. Data Piston Rod Stuffing Box Piston and Piston Rod .

MAN B&W Diesel A/S .

tightening torque+angle D02-08 Piston ring new. ring No. 0.5 mm D02-17 Minimum ring gap. max. radial width 10 mm D02-10 Groove No. 2.82 mm D02-20 Piston complete 280 kg D02-21 Piston crown 60 kg D02-22 Piston rod 160 kg D02-23 Piston skirt 16 kg D02-24 Piston cooling pipe 7 kg D02-25 Lifting tool. tightening torque 30 Nm D02-46 CPR ring CL groove. 2. vertical height 10.7 mm D02-12 Piston top. worn parts. 1 9.1. vertical height 8. permissible burn-away 11 mm D02-13 Piston ring new.2 mm D02-11 Groove Nos. tightening torque 210 Nm D02-03 Piston rod/crown.9 mm D02-15 Minimum free ring gap ( before dismantling ) 22 mm D02-16 Minimum ring gap.Piston MAN B&W Diesel 102-1 Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 Stopped engine X X X X X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.91 mm 7 bar Piston rod/crosshead. 2. tightening torque 50 Nm D02-07 Piston rod/crosshead. ring Nos. min. new parts 0. 3 and 4 ( new ring in new liner ) 2. tightening torque 50 Nm D02-06 Cooling oil pipe. radial width D02-09 100/30 Nm/° 12. height of ring Nos. max.32 mm D02-19 Vertical clearance.4 mm D02-14 Piston rings new. please quote Data D10201 Edition 0100 Page 1 (2) . 3 and 4. Description D01-05 Cylinder cover stud.8 mm When referring to this page. height of ring No. min. max. check distance D02-01 Test pressure D02-02 Value Unit 90 . tightening torque 150 Nm D02-05 Piston skirt. 1 ( new ring in new liner ) 3. max.5 mm D02-18 Vertical clearance. 3 and 4 7. depth 0.5 mm Piston ring worn.

Lifting Tools Page 2 (2) When referring to this page. e. please quote Data D10201 Edition 0100 .Piston 102-1 MAN B&W Diesel 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. Plate Item No.Support Tools P90266 Piston .Tools P90265 Piston and Piston Rod . Description P90251 040 Lifting tool for piston rod foot P90251 075 Template for piston top P90251 087 Distance piece for stuffing box P90251 099 Cover for stuffing box hole P90251 110 Pressure test tool for piston P90251 134 Piston ring expander P90251 158 Guide screw for piston crown P90251 171 Dismantling screw piston skirt P90261 Piston and Piston Rod .g. P90951 refers to chapter 909.

Chapter 707. and note down the results. keep the cooling water and cooling oil circulating during the scavenge port inspection. Turn the engine at least ½ a revolution. the ring lands and the piston top. 2. just above the scavenge air ports. one at a time. See Volume I. The scavenge port inspection is carried out from the scavenge air receiver. Inspect the piston rod and the lower part of the cylinder wall. Ring tension: Check the tension of the piston rings.1 Checking Scavenge Port Inspection 1. M902010280C02 3.Piston MAN B&W Diesel 902-1. by pressing against them with a wooden stick. Operation. M902010280C01 1. While the piston is passing downwards. Ring inspection: Inspect the rings. inspect the piston skirt. and begin with a unit arriving downwards. all the piston rings. An additional view of the rings is possible through the cleaning cover on the manoeuvring side. please quote Procedure M90201 Edition 0288 Page 1 (22) . When referring to this page. To detect possible leakages from the piston or cylinder cover. 2. M902010280C03 3.

2mm 5. measure the depth of the pressure relief grooves with a calliper.2. Uppermost piston ring: If possible. The piston rings must be replaced if the radial depth of the grooves has worn down to less than stated in Data D02-46. Checking.Piston 902-1. please quote Procedure M90201 Edition 0288 . D0246 6. in connection with piston overhaul 5. Chapter 707.1 Checking 4. For evaluation of the rings. The total clearance must not exceed the value stated in Data. M902010285C06 6. Piston support: Remove the piston from the cylinder and place it on the piston support. see Volume I. D0218 D0219 Measure the clearance at the top (E) and bottom (F) of the piston ring groove. See Procedure 902-1. MAN B&W Diesel 4. Total clearance = E + F. M902010280C05 Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine. Ring grooves: Measure the total clearance between the piston ring and the ring groove. E M902010280C04 F Max. Page 2 (22) When referring to this page.

7.3. Free ring gap: Before dismantling the piston rings. Measure the ring grooves with a calliper gauge. D02-10 D02-11 M902010280C09 Max 2mm When referring to this page. Ring grooves: Clean the ring grooves and check them for burn marks or other deformation. see Data D02-10 and D02-11. 9.1 Checking 7. 8. Radial ring width: Measure the radial width of the rings. please quote Procedure M90201 Edition 0288 Page 3 (22) . Note down the results See Volume I. D0209 Worn 9. D0208 New M902010280C08 If the ring grooves are worn out. contact MAN B&W Diesel A/S for advice. Operation. see Procedure 902-1. 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.Piston MAN B&W Diesel 902-1. D0215 For dismantling the piston rings. measure the free ring gap of all the piston rings. the piston crown must be reconditioned. M902010285C07 8. Chapter 707.

M902010285C10 If the burn-away exceeds the values given in Data. please quote Procedure M90201 Edition 0288 . Piston crown top: Clean the piston crown and check the burn-away by means of the template. D0212 MAN B&W Diesel 10.1 Checking 10. For maximum permissible burn away value.Piston 902-1. see Data. Page 4 (22) Note down the results for later reference. contact MAN B&W for advice. When referring to this page. Check the burn-away on the whole circumference of the piston crown top.

please quote Procedure M90201 Edition 0288 Page 5 (22) . 1.Piston MAN B&W Diesel 902-1.1 Dismantling Preparations in the crankcase 1. When referring to this page. M90201280D01 Turn the crosshead down far enough to give access to the piston rod stuffing box and the piston rod/crosshead connection. Access: Open the crankcase door to the cylinder concerned.

Remove one screw from the telescopic stuffing box housing and mount the special tool for suspending the telescopic pipe or use the thread in the telescopic pipe stuffing box housing.902-1. Note! M902010288D02 When a piston is dismantled.1 Piston Dismantling 2. Suspend the telescopic pipe by means of the tool. MAN B&W Diesel 2. Turn the crosshead to TDC. Telescopic pipe: Loosen and remove the screws which tighten the telescopic pipe to the bend. Page 6 (22) When referring to this page. please quote Procedure M90201 Edition 0288 . Turn the crosshead downward and remove the distance pipe from the bend. never turn the engine without first dismantling the telescopic pipe from the crosshead.

Do NOT remove the outermost screws from the flange. When referring to this page. 3. On engine models where the drain pipe is connected directly to the stuffing box: Disconnect the stuffing box drain pipe. Loosen the piston rod-crosshead connection: Remove the screws from the piston rod.1 Dismantling 3. Stuffing box: Release the stuffing box by removing the innermost screws from the stuffing box flange. please quote Procedure M90201 Edition 0288 Page 7 (22) .Piston MAN B&W Diesel 902-1. M902010280D03 Note! M902010288D05 4. 4.

Stuffing box distance pieces: Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box.1 Piston Dismantling 5. M902010288D06 5. MAN B&W Diesel Page 8 (22) When referring to this page.902-1. please quote Procedure M90201 Edition 0288 .

When referring to this page. remove one or two cylinder cover studs.Piston MAN B&W Diesel 902-1. See Procedure 901-1. Limited lifting high: If the engine not is equipped with long distance pieces.2. Note! Make sure to mount the lifting tool correctly. please quote Procedure M90201 Edition 0288 Page 9 (22) .1 Dismantling Preparations on the cylinder top 7. using a stud setter. The top of the piston is now free of the cylinder liner. Piston lifting tool: Turn the piston to TDC. 7. Cylinder cover: Remove the cylinder cover. D0225 6. M902010285D07 Clean the lifting groove of the piston crown and mount the lifting tool. so that the claws of the lifting tool enter the lifting grooves of the piston crown.

Lift the piston out of the cylinder liner and guide the piston rod foot through the stuffing box flange. M902010285D08 D0220 Page 10 (22) When referring to this page. Secure the two support halves with screws and lower the piston on the support. Check the piston is resting on the piston rod flange. Lower the piston rod foot and stuffing box through the opening in the platform. 8.1 Dismantling MAN B&W Diesel Piston lift 8. the piston rod foot can pass between two cylinder cover studs. If the engine is equipped with long distance pieces for the stuffing box.Piston 902-1. please quote Procedure M90201 Edition 0288 . Place the two halves of the support around one of the openings in the platform.

please quote Procedure M90201 Edition 0288 Page 11 (22) . See Procedure 903-1. measure and recondition the cylinder liner. The protective rubber cover is found on tool panel 904. Turn the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap.Piston MAN B&W Diesel 902-1. When referring to this page. M902010283D09 Clean.1 Dismantling 9. The covers must remain in place to protect the crosshead bearing journal from impurities until the piston is remounted. Protect the crosshead bearing: Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit. 9.

See Procedure 902-1. Clean and inspect the rings and the ring grooves. Piston ring dismantling: Take off the piston rings by means of the ring expanders. two. See Procedure 902-1. Remove the stuffing box.Piston 902-1.1. First remove the uppermost ring. M902010285O02 Lift the piston crown and skirt clear of the piston rod.1. Piston support: Place the piston in the support and remove the piston lifting tool. D0220 MAN B&W Diesel 1.2. 3. If the engine is equipped with two ring expanders. please quote Procedure M90201 Edition 0288 . Clean the piston top and the piston rings.1 Overhaul 1.3. See Procedure 902-1. See Procedure 902-2. M902010284O03 D0221 + D0223 Page 12 (22) When referring to this page. M902010285O01 2. the short ring expander is for the uppermost ring. Piston crown dismantling: Remove the locking wire and the innermost screws between the rod and the piston crown. 2. three and four. then ring No. Check the free ring gap and the burn-off on the piston top. 3.

Piston crown dismantling and cleaning: Place the piston crown with skirt on a wooden support as shown. Land the piston lifting tool and the piston crown on a sufficient support of wood pieces.Piston MAN B&W Diesel 902-1. Lift up the piston crown. Check that the surfaces of the O-ring groove is clean and smooth. D0224 Mount the eye bolts and lift out the cooling oil pipe. If necessary use two dismantling screws to pull the skirt out of the piston crown. 4. M902010284O05 Remove the locking wire and the screws in the skirt. please quote Procedure M90201 Edition 0288 Page 13 (22) . 6. Loosen the piston lifting tool and lift the piston crown clear of the tool. Attach the tackle to the wire rope on the piston crown and carefully turn the piston crown upside down.1 Overhaul 4. Use both cranes if the engine room is equipped with two cranes. 5. Crown turning: Unhook the crane from the piston lifting tool. M902010280O04 Mount a new O-ring on the piston rod flange. D0223 Discard the sealing ring on the piston skirt. D0222 5. see Data. 6. M902010286O05 Fit two eyebolts in the piston skirt and a wire rope between the bolts as shown in the sketch. and connect the lifting tool and the crane hook by means of a wire rope. Mount two eye bolts in the skirt. Piston rod and cooling pipe: Remove the screws from the cooling oil pipe flange. then remount the cooling oil pipe. D0206 Clean and inspect the cooling oil pipe and the piston rod. Install a tackle in a suitable place with sufficient space below for the piston crown. When referring to this page. Lift the skirt and land it on a couple of planks.

Lock the screws with locking wire. Coat the ring with lubricating oil before mounting. D0205 Mount the piston skirt on the piston crown. Check that the surfaces of the O-ring groove are clean and smooth. Piston crown and skirt mounting: Mount the guide screw to ensure the correct positioning of the piston rod in relation to the piston crown. see Procedure 913-7. please quote Procedure M90201 Edition 0288 . see data D02-05. M902010284O07 D0203 Page 14 (22) When referring to this page. 8. Piston crown assembly: Mount a new O-ring on the piston skirt. Remove the guide screw. Tighten the screws to specified torque. M902010284O06 8. Land the overhauled piston crown and skirt on the piston rod.Piston 902-1. 7. Lubricate the O-ring on the piston rod flange with lubricating oil. Mount and tighten the screws between the piston rod and the piston crown.1 Overhaul MAN B&W Diesel 7. see Data.

M902010288O10 10. Mount the pressure-testing tool on the piston rod foot. Turn the piston upside up and drain out the piston oil. The sealing ring test can also be carried out when the piston is resting in the support tool. The piston must now hold the pressure for minimum 30 minutes. 9. Check the contact surfaces of the piston and the sealing rings for tightness. the piston must be turned upside down (see next step to turn a complete piston). 10. It is possible to carry out a test of the sealing rings with compressed air before filling the piston with oil.Piston MAN B&W Diesel 902-1. Close the valve on the testing tool and remove the air connection. Check that there are no cracks in the piston crown. the piston must be pressure tested hydraulically. When referring to this page. D0201 Dry off all soap water. Fill the piston and piston rod with lubricating oil.1 Overhaul Sealing ring and pressure test 9. Pressure test: For this test. please quote Procedure M90201 Edition 0288 Page 15 (22) . M902010288O09 According to current class rules. Pressure-test the piston at the pressure stated on the Data Sheet. Sealing ring test: Mount the pressure-testing tool on the piston rod foot. Spray a little soap water on to the surface joints between piston rod/crown/skirt and around the bolt heads to detect leaks. Connect compressed air to the testing tool and fill the piston to 4-5 bar.

Piston turning: Lift the piston with the normal lifting tool. follow with the crane to keep the crane positioned vertically above the lifting point. 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.902-1. Attach the lifting bracket to the bottom of the piston rod foot. The stuffing box must be removed. Lower the piston rod foot until it is close to the platform. Page 16 (22) When referring to this page.1 Piston Overhaul 11. Note! M902010283O10 During the lift. please quote Procedure M90201 Edition 0288 . MAN B&W Diesel 11. Lift the piston rod foot clear of the wooden block. Hook the crane on to the lifting bracket. Keep lifting until the piston rod is in a vertical position. Land the foot on a wooden block.

See Procedure 902-2. 12.1 Overhaul 12.3. with the ring gaps staggered 180° and with the TOP mark upwards). if the engine is equipped with two ring expanders D When referring to this page. please quote Procedure M90201 Edition 0288 Page 17 (22) . A C D B Mount the piston rod stuffing box.Piston MAN B&W Diesel 902-1. Piston completion: Fit the new piston rings (alternately righthand and left-hand cuts. A B When mounting the piston rings. The uppermost ring (CPR-ring) must be mounted with the short ring expander. C M902010285O11 Do not expand the rings more than necessary. using the ring expander. use the ring expanders to prevent unintended deformation of the rings.

Check the piston rings and piston crown in accordance with Procedure 902-1. See Data D02-25. if not already done.1. Stuffing box position: Ensure that the stuffing box is correctly positioned over the distance pieces mounted on the piston rod foot. M902010285M01 2.1 Piston Mounting MAN B&W Diesel Preparation of piston 1. Both the holes for the flange and the drain hole for the drain pipe must be positioned correctly. M902010288M02 2. please quote Procedure M90201 Edition 0288 . Page 18 (22) When referring to this page.902-1. 1. Mount the lifting tool on the piston crown.

5. When referring to this page. The cut outs for the lifting tool must be turned to fit the piston lifting tool.Piston MAN B&W Diesel 902-1. Crosshead position: Turn the crosshead to a position 45° from TDC (crank web pointing towards exhaust side). Stuffing box cover: Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit. M902010288M03 Clean the stuffing box flange. 3.1 Mounting Preparation of cylinder liner 3. M902010277M05 4. 4. M902010277M06 5. Mount the guide ring: Mount the guide ring in the top of the cylinder liner. please quote Procedure M90201 Edition 0288 45° Page 19 (22) .

unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings. Coat the O-rings of the stuffing box and the piston rod with oil. D0220 6. while checking that the guide ring of the crosshead enters the centre hole in the piston rod. Crosshead alignment: Turn the crosshead almost to TDC. Page 20 (22) When referring to this page. M902010284M08 8.Piston 902-1. M902010283M07 After turning the crosshead fully to TDC. 8. 7. 7. Protective cover: Remove the protective rubber cover from the crosshead. Coat the piston rings and cylinder liner with cylinder lubricating oil. and ensuring that the piston rod has full contact with the crosshead. please quote Procedure M90201 Edition 0288 . M902010288M06 Lower the piston into the cylinder liner – while guiding the piston rod foot through the cut-out in the stuffing box flange – until the piston rings are inside the liner.1 Mounting MAN B&W Diesel Mounting of piston 6.

M902010280M09 On engine models where the drain pipe is connected directly to the stuffing box: 10. Stuffing box: Turn down and land the stuffing box on the stuffing box flange. see Procedure 904-2.Piston MAN B&W Diesel 902-1. see Procedure 902-2. When referring to this page. 9.1 Mounting 9. M902010288M11 Remove the suspending tool and mount the screws and tighten the telescopic pipe to the bend. Remove the distance pieces from the piston rod foot. 10. D0202 or D0207 Turn up towards TDC until the telescopic pipe is landed on the distance pipe. M902010288M10 11. please quote Procedure M90201 Edition 0288 Page 21 (22) . Check that the holes in the stuffing box and stuffing box flange are correctly centered. 11. • Mount the stuffing box drain pipe. See Data. Tighten the piston rod stuffing box by means of the screws through the inner holes in the stuffing box flange. Tightening of the piston rod-crosshead connection: Mount and tighten the piston rod screws. Telescopic pipe Place the distance pipe on the bend for the telescopic pipe. For data. Use either Data D02-02 or Data D02-07. For Data. Tighten the screws to the specified torque and lock with locking wire.

When referring to this page. Carefully clean the surfaces around the base of the studs and check the O-rings on the studs.4. Then stop the engine and inspect the piston rod and stuffing box. Mount the cylinder cover studs with the stud setter. Tighten the cylinder cover nuts and mount the necessary pipes. adjust the distance D01-05 by turning the stud. M902010288M12 13. Screw the stud down to contact and half a revolution back. please quote Procedure M90201 Edition 0288 . 14. remount them.1 Piston Mounting MAN B&W Diesel 12. and turn the crankshaft a couple of revolutions. M902010280M14 D0105 Page 22 (22) At the first opportunity. start the engine and keep it running for about 15 minutes at a speed corresponding to “Dead Slow” Ahead. Running-in: Smear the piston rod with molybdenum disulphide. 12. See Procedure 901-1. If necessary.902-1. Cylinder cover: Land the cylinder cover on the liner and check the distance that the stud is protruding from the cylinder cover. 13. Cylinder cover studs: If the cylinder cover studs have been removed.

D02-26 Description Stuffing box flange. outer screws tightening torque D02-27 80 Unit Nm Stuffing box flange.Piston Rod Stuffing Box MAN B&W Diesel 102-2 Data SAFETY PRECAUTIONS For detailed sketch. free length 374 mm D02-57 Springs for ring C. free length 327 mm D02-56 Springs for ring B. please quote Data D10202 Edition 0068 Value Page 1 (2) . inner screws tightening torque 80 Nm D02-28 Stuffing box halves. see 900-2 X X X X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. free length 293 mm D02-58 Springs for ring D. tightening torque 17 Nm D02-44 Stuffing box complete 35 kg D02-45 Stuffing box half 11 kg D02-51 Ring-end clearance A 3x3 mm D02-52 Ring-end clearance B 4x5 mm D02-53 Ring-end clearance C 3x3 mm D02-54 Ring-end clearance D 3x6 mm D02-55 Springs for ring A. free length 374 mm When referring to this page.

Plate Item No. please quote Data D10202 Edition 0068 . Description P90251 109 Mounting tool for stuffing box spring P90251 122 Worktable for stuffing box P90251 195 Distance piece stuffing box assembling Page 2 (2) When referring to this page.g. e.Piston Rod Stuffing Box 102-2 MAN B&W Diesel 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. P90951 refers to chapter 909.

Piston Rod Stuffing Box MAN B&W Diesel 1. Total clearance (sealing rings) D0252. A B Uppermost scraper ring and sealing rings C Clearance at ring ends (scraper ring) A. 902-2. Generally. Garter springs: M902020232C01 The ring clearances stated in Data apply to new rings. it is recommended to renew the springs when the sealing rings and scraper rings are renewed. Total clearance D0253. D Clearance at ring ends (sealing rings) B. it is recommended – depending on the overhauling intervals and one’s own experience – to replace sealing rings and scraper rings when the specified clearance values have been halved. it must be discarded. When referring to this page. 2. L M902020232C02 The springs can be checked as follows: Place the springs on the table. C As a general guide. and compare with Data.2. B x3 Clearance at lowermost lamella ring ends D. If a spring is extended more than 8% from the value given in data.1 Checking After the piston rod stuffing box has been dismantled. A Lowermost lamella scraper rings Clearance at uppermost lamella ring ends C. Total clearance (scraper ring) D0251. x4 D x3 x3 2. please quote Procedure M90202 Edition 0232 D0255 D0256 D0257 D0258 Page 1 (11) . 1. measure Lo (free length). Total clearance D02-54. check the following clearances: See Procedure 9022.

Page 2 (11 ) When referring to this page. Remove the drain oil pipe and all innermost screws and all outer screws except for two screws placed diamentrically opposite in the stuffing box flange. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes. remove only the innermost screws in the stuffing box flange. M902020232D03 3. If. M902020229D01 Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities. in the period between piston overhauls. 2. Turn the crosshead to about 90° from TDC.902-2. MAN B&W Diesel When dismantling the piston. longitudinally to the engine.2 Piston Rod Stuffing Box Dismantling 1. please quote Procedure M90202 Edition 0232 . M902020232D02 2. 3. it becomes necessary to inspect the piston rod stuffing box. proceed as follows: 1.

see Procedure 9022. Remove the two long dismantling screws from the worktable. 6. 4. thereby withdrawing the stuffing box from the cylinder frame bottom.Piston Rod Stuffing Box MAN B&W Diesel 902-2. For overhauling the stuffing box. 5. Remove the remaining two screws from the stuffing box. Mount them in the stuffing box through the holes in the worktable. When referring to this page. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. please quote Procedure M90202 Edition 0232 Page 3 (11) . M902020232D04 5.2 Dismantling 4.3. M902020232D06 6. press the stuffing box out of the flange. Turn the piston to BDC. M902020232D05 By means of the short screws in the worktable.

D0244 Land the stuffing box on the worktable. and remove the tackles. If the Oring is intact and is to be used again. and mount the worktable round the piston rod at a suitable working height. the piston rests on a support placed over one of the cutouts in the top platform.902-2. and hook on two tackles. Page 4 (11 ) When referring to this page.3 Piston Rod Stuffing Box Overhaul MAN B&W Diesel Normally. During such overhauls. 1. Lift the stuffing box a little up the piston rod. move it up the piston rod and secure it in this position. Mount two eye bolts in the stuffing box flange. 1. Remove the Oring of the stuffing box. for example with tape. M902020232O02 2. M902020232O01 Overhaul inside the engine is carried out in the same way as outside the engine. Work on the stuffing box is then carried out from the platform below. please quote Procedure M90202 Edition 0232 . M902020232O03 2. Remove the nuts from the stuffing box assembling bolts. overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons.

7. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings). replace the rings. Take out the four bolts. Dismantle and stack the rings in the same order as when fitted in the stuffing box. M902020232O04 5. D0255 D0256 D0257 D0258 M902020232O05 8. In the case of coarse scratches. If their sliding surfaces have scratches or marks. it may prove necessary to machinegrind the surface in a workshop. Check the lengths of the springs. please quote Procedure M90202 Edition 0232 Page 5 (11) . Remove the springs one at a time and measure the clearance between the ring segments to determine whether replacement is necessary. 6. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. When referring to this page. Inspect the surface of the piston rod. and pull away one stuffing box half and remove it from the work table. Carefully clean all the ring segments. smooth the piston rod surface carefully with a fine grained carborundum stone. See Procedure 9022. M902020232C02 L 8. D0245 4.3 Overhaul 3. 7.Piston Rod Stuffing Box MAN B&W Diesel 902-2.1. See Procedure 9022. 3.1. Inspect and assess the surface quality of the sealing rings.

M902020232O09 Then assemble the holders as shown in Fig. A. B. 1 1 MAN B&W Diesel 9.Piston Rod Stuffing Box 902-2. First assemble the holders as shown in Fig. Page 6 (11 ) When referring to this page. A B Place the holders and segments for the lowermost scraper ring on the worktable. 1 2 10. 10.3 Overhaul 9. by means of the two hooks. Secure them with the steel pins and place them round the piston rod. assemble the spring ends. please quote Procedure M90202 Edition 0232 . Secure with the steel pins and place them round the piston rod in such a way that the scraper rings fit together with the holders as shown in Fig. A. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS2). Assemble all the stuffing box ring units round the piston rod in the following way: Place the distance ring marked »1« on the work table. Place the three springs round the scraper rings and. M902020232O10 Cross your arms before tightening the springs.

first place the outer sealing ring round the piston rod. 4 distance ring between the sealing rings and assemble the last sealing unit in the same way. please quote Procedure M90202 Edition 0232 Page 7 (11) . 3 On top of the scraper ring. 3 distance ring. On top of the scraper rings. an outer sealing ring. Finally. place the holder and two springs.3 Overhaul 11. and assemble the springs by means of the two hooks. When assembling one unit. a holder for the springs. M902020232O12 4 3 2 1 When referring to this page. 11. 2 M902020232O11 12. 3 2 Each unit consists of a 4-part lower sealing ring with two guide pins. Place the lower 4-part sealing ring inside this outer sealing ring so that the two guide pins face upwards. 12. 2 distance ring and then assemble the next scraper rings. Place No. assemble the two sealing ring units.Piston Rod Stuffing Box MAN B&W Diesel 902-2. then place the upper 4part sealing ring in such a way that the two guide pins in the lower sealing ring engage with the two holes in the upper sealing ring. place No. On top of the scraper rings. place No. and two springs. using the two hooks as described above. an upper 4-part sealing ring.

Place one stuffing box half on the worktable. by means of the two hooks. place No.902-2. 14. On top of the sealing section. 5 distance rings. please quote Procedure M90202 Edition 0232 . Check that all scraper and sealing rings and distance rings are pressed down against the work table. Place the spring round the scraper ring and. Clean the halves of the stuffing box housing. assemble the spring ends. MAN B&W Diesel Place the 3-part scraper ring on top of the upper sealing unit. 13. Remove all the distance rings. 15.3 Piston Rod Stuffing Box Overhaul 13. Page 8 (11 ) When referring to this page. 5 4 3 2 M902020232O13 1 14. M902020232O14 Push the stuffing box half into contact with the piston rod round the rings.

M902020232O17 17. Place the other half of the stuffing box housing on the worktable. Mount eye bolts and wire ropes. 16. Mount the O-ring in the stuffing box groove.3 Overhaul 16. and lift the stuffing box a little. please quote Procedure M90202 Edition 0232 Page 9 (11) .Piston Rod Stuffing Box MAN B&W Diesel 902-2. When referring to this page. M902020232O16 17. pushing it into place round the rings. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot. Remove wire ropes and eye bolts. D0228 Mount and tighten up the fitted bolts to the torque specified on the Data Sheet.

M902020232M03 3. Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. only the innermost flange screws are to be mounted and tightened. see data. please quote Procedure M90202 Edition 0232 . Turn the piston upwards until the stuffing box is in place in the cylinder frame. Mount two screws in the flange through the holes in the worktable. After overhauling the stuffing box inside the engine.4 Piston Rod Stuffing Box Mounting 1. M902020232M02 3. 1. MAN B&W Diesel In connection with mounting of the piston. 2. Mount the two long screws from the worktable in the stuffing box. Page 10 (11 ) When referring to this page.902-2. 2. assemble the stuffing box halves on top of the two screws. M902020232M01 Turn down the short screws so that the stuffing box lands on the flange.

Remove the long screws from the stuffing box and mount them in the worktable. 4. Mount the drain oil pipe. Then turn the crankshaft a couple of revolutions. Remove the worktable from the piston rod. 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. Smear the piston rod with molybdenum disulphide. D0226 D0227 M902020229D01 6. M902020232M04 6.4 Mounting 4.Piston Rod Stuffing Box MAN B&W Diesel 902-2. please quote Procedure M90202 Edition 0232 Page 11 (11) . 5. M902020232M05 Then stop the engine and inspect the piston rod and stuffing box. When referring to this page. See Data. Remove the protecting rubber cover from the piston rod/crosshead. 5. Mount and tighten all the inner and outer screws for the stuffing box.

.

Piston and Piston Rod Panel Plate P90251-0259 Piston and Piston Rod Panel 0259 P90251 When referring to this page. please quote Plate P90251 Edition 0259 MAN B&W Diesel A/S Page 1 (2) .

Plate
P90251-0259
Item
No.
014
026
040
075
087
099
109
110
122
134
158
171

Piston and Piston Rod Panel

Item Description

Item
No.

Item Description

Panel for tools
Name plate
Lifting tool for piston rod
Template for piston top
Distance piece for stuffing box
Cover
Hook for mounting of spring
Pressure tester
Worktable
Piston ring expander
Guide screw for piston crown
Dismantling screw

Page 2 (2)

When referring to this page, please quote Plate P90251 Edition 0259
MAN B&W Diesel A/S

Piston and Rod - Tools

Plate
P90261-0103

Piston and Rod - Tools
0103
P90261

When referring to this page, please quote Plate P90261 Edition 0103
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90261-0103
Item
No.
019

Piston and Rod - Tools

Item Description

Item
No.

Item Description

Guide ring for piston

Page 2 (2)

When referring to this page, please quote Plate P90261 Edition 0103
MAN B&W Diesel A/S

Piston and Piston Rod - TiltingTools

Plate
P90264-0011

Piston and Piston Rod - TiltingTools
0011
P90264

When referring to this page, please quote Plate P90264 Edition 0011
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90264-0011
Item
No.
015
027
039

Piston and Piston Rod - TiltingTools

Item Description

Item
No.

Item Description

Collar ring for piston
Support for tilting tool
Crossbar for cylinder liner

Page 2 (2)

When referring to this page, please quote Plate P90264 Edition 0011
MAN B&W Diesel A/S

Piston and Piston Rod - Support Tools

When referring to this page, please quote Plate P90265 Edition 0002
MAN B&W Diesel A/S

Plate
P90265-0002

Page 1 (2)

Plate
P90265-0002
Item
No.
010

Page 2 (2)

Piston and Piston Rod - Support Tools

Item Description

Item
No.

Item Description

Support for piston

When referring to this page, please quote Plate P90265 Edition 0002
MAN B&W Diesel A/S

Piston - Lifting Tools

When referring to this page, please quote Plate P90266 Edition 0002
MAN B&W Diesel A/S

Plate
P90266-0002

Page 1 (2)

Plate
P90266-0002
Item
No.
016

Page 2 (2)

Piston - Lifting Tools
Item Description

Item
No.

Item Description

Lifting tool for piston

When referring to this page, please quote Plate P90266 Edition 0002
MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication
Documents in this Chapter
103-01
903-01
103-02
903-02
90361
90366

0077
0261
0032
0255
0084
0010

Cylinder Liner, Data
Cylinder Liner
Cylinder Lubricator, Data
Cylinder Lubricator
Cylinder Liner - Tools
Cylinder Liner - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover
MAN B&W Diesel

103-1

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2
Stopped engine

X
X
X
X
X
X
X
X
X
X
X

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

Data
Ref.

Description

Value

Unit

D03-03

Cylinder diameter, new

350

mm

D03-05

Cylinder liner, complete

380

kg

D03-06

Cooling jacket

40

kg

When referring to this page, please quote Data D10301 Edition 0077

Page 1 (2)

Cylinder Cover

103-1

MAN B&W Diesel

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

P90361

Measuring tool for cylinder liner

P90366

Cylinder Liner - Lifting Tools

Page 2 (2)

When referring to this page, please quote Data D10301 Edition 0077

Cyliner Liner
MAN B&W Diesel

903-1.1

Checking

1. Dismount the cylinder cover and piston.
See Procedure 901-1.2.
See Procedure 902-1.2.

1.

Clean the cylinder liner and scavenge air
ports.

D0303

2. Position the cylinder liner measuring tool.

3. Take measurements in the fore-and-aft and
athwartship directions.
4. Check and assess the condition of the cylinder liner according to the description
given in Volume I, Chapter 707.

M903010256C01

Measure the cylinder liner with an inside
micrometer at the positions indicated on
the measuring tool. See Data.

2.
5. Carefully scratch over any scores or marks
on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3.
6. Check the lubricating points of the cylinder
by pumping cylinder oil to all lubricating
points.

Mount the piston and the cylinder cover.
See Procedures 901-1.4 and 902-1.4.

M903010261C02

Clean any blocked lubricating duct.

M903010256C02

3.

When referring to this page, please quote Procedure M90301 Edition 0261

Page 1 (9)

903-1.2

Cyliner Liner
Dismantling

1.

MAN B&W Diesel

1. Dismount the cylinder cover.
See Procedure 901-1.2.
Discard the sealing ring from the top of the
cylinder liner.
Turn the piston down far enough to make it
possible to grind away the wear ridges at
the top of the liner.
See Procedure 903-1.3.

M903010261D01

Dismount the piston.
See Procedure 902-1.2.

Mount the two screws in the cooling jacket.
2. Disconnect – at the non-return valves – the
oil pipes leading from the cylinder lubricator
to the non-return valves.

M903010261D02

2.

Mount the lifting tool on the cylinder liner.

Page 2 (9)

When referring to this page, please quote Procedure M90301 Edition 0261

Cyliner Liner

903-1.2

Dismantling

MAN B&W Diesel

3. Attach the crane to the lifting crossbar, and
lift the liner out of the cylinder frame.

3.

Note!
Low lifting height in the engine room
may require the removal of one or more
cylinder cover studs before dismantling
the cylinder liner.

Land the cylinder liner vertically on, for instance, a couple of planks.

D0305

Clean the cylinder frame internally, taking
special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.

Clean the pipes carefully.

M903010261D03

4. Discard the O-rings on the cooling water
pipes.

M903010261D04

4.

When referring to this page, please quote Procedure M90301 Edition 0261

Page 3 (9)

Cyliner Liner 903-1. 1. M903010261O01 Remove the lifting tool from the cylinder liner D0306 M903010261O02 2. Page 4 (9) When referring to this page. Lift away the cooling jacket and land it on wooden planks.3 Overhaul MAN B&W Diesel 1. Remove the clamps which fix the cooling jacket to the cylinder liner. please quote Procedure M90301 Edition 0261 . 2.

4. It is recommended to use a wear ridge milling machine to create the groove. Carefully scratch over any scores or marks on the cylinder liner running surface. Chapter 707. Alternatively. C M903010261O03 Check in the top of the liner for a wear ridge (where the piston rings reverse direction). A B 4. For use of the milling machine. by means of a rough grindstone held in the hand. it is necessary to create a groove by grinding. The maximum depth of the groove is calculated as Smax. = D x 0. 5. Note! It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch.0045. The groove serves to prevent the build-up of a new wear ridge. 5. Check and assess the condition of the cylinder liner according to the description given in Volume I. see supplier’s instruction. Use a grinding disc with a round edge. S C R=4-5 mm M903010256O05 C D When referring to this page. If there is any sign of a wear ridge.3 Overhaul MAN B&W Diesel 3.Journal Bearing 903-1. M903010256O04 Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC. 3. please quote Procedure M90301 Edition 0261 Page 5 (9) . 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.

903-1. Page 6 (9) When referring to this page. please quote Procedure M90301 Edition 0261 .3 Cyliner Liner Overhaul 6. M903010261O06 7. MAN B&W Diesel 6. Replace the two uppermost O-rings on the cylinder liner. Unscrew the nuts on the non-return valves and remove the valves. Clean and inspect the non-return valves. Remount the valves. M903010261O07 7.

3 Overhaul MAN B&W Diesel 8. Lower the cooling jacket on to the cylinder liner.Journal Bearing 903-1. Note! Make sure that the scratch marks in the camshaft side of the cylinder liner and cooling jacket coincide. please quote Procedure M90301 Edition 0261 Page 7 (9) . M903010261O08 9. and tighten the screws. Lubricate the O-rings with vaseline. M903010261O09 9. When referring to this page. 8. Mount the four clamps in the groove of the liner.

Note! M903010261M01 Make sure that the scratch marks of the cylinder liner and frame coincide. Mount the cylinder liner in the cylinder frame. 2. Mount the lowermost O-rings and apply a little vaseline on the rings. If one or more cylinder cover studs have been removed during the dismantling of the cylinder cover.4 Page 8 (9) When referring to this page.4 Mounting MAN B&W Diesel 1. please quote Procedure M90301 Edition 0261 . Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. see Procedure 901-1. 1. Coat the joint surfaces with permatex or a similar liquid sealing compound. remount the studs using the stud setter. Loosen the water connections on the cooling jacket.Cyliner Liner 903-1. Mount the cooling water pipes with new O-rings. D0305 M903010261M02 2.

4. but do not tighten.4. See Procedure 901-1. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston. Remove the cylinder liner lifting tool. tighten the pipes firmly on the non-return valves and again pump manually until it is certain that each individual lubricating point functions correctly. 3. Screw the pipes from the lubricator on to the non-return valves.Cyliner Liner MAN B&W Diesel 903-1.4. When referring to this page. Vent the cylinder lubricating system by pumping all pipes through until oil. See Procedure 902-1. M903010261M03 When this is in order. M903010256M05 5. 5.4 Mounting 3. comes out from the union pipe/non-return valve. 4. Mount the sealing ring and the cylinder cover. M903010261M04 Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned. please quote Procedure M90301 Edition 0261 Page 9 (9) . without air bubbles.

.

please quote Data D10302 Edition 0032 Page 1 (2) . Description Value Unit D03-22 minimum crankthrow angle 118 ° D03-23 maximum crankthrow angle 140 ° D03-24 optimum crankthrow angle 129 ° When referring to this page. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Cylinder Lubricators MAN B&W Diesel 103-2 Data SAFETY PRECAUTIONS For detailed sketch.

Description When referring to this page. please quote Data D10302 Edition 0032 .g. e.Cylinder Lubricators 103-2 MAN B&W Diesel 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. P90951 refers to chapter 909. Plate Page 2 (2) Item No.

Check that the crankthrow for cylinder No. feed rates for running-in and for part load operation. Turn the engine in the ahead direction until the mark on the first lubricator housing is in line with the mark on the scale at the leadin shaft. M903020255C02 Use the numbers on the turning wheel to determine the exact position of the crankthrows. 1 Page 1 (3) . 4. OPERATION. Marks Seen from fore M903020255C03 D0322 D0323 When referring to this page. and recommended oil types. Check that the pumps of all injection points are activated during one revolution of the engine. The cylinder lubricator is mounted on the camshaft side of the scavenge air cooler housing. 1 Each cylinder has four injection points. 1. Further information concerning other than nominal feed rates. This indicates that the pump stroke is completed for lubricating point No. is given in instruction book Volume I. please quote Procedure M90302 Edition 0255 Cyl.1 Checking 1. 3. 3. No. 1 is positioned between D03-22 and D0323 past BDC.Cylinder Lubricators MAN B&W Diesel 903-2. Lubrication point no. 4. 1. M903020255C01 2.

1.Cylinder Lubricators 903-2. For adjustment of the lubricator. M903020255O01 Use the indications on the turning wheel to determine the exact position of the crankthrows. M903020255O02 D0324 Page 2 (3) XXX XXX XXX XXX When referring to this page. 2. Loosen the set screws in the couplings and pull the coupling wheels out of contact with the planet wheels. Seen from fore 2. turn the crankshaft in ahead direction until the crankthrow for cylinder No. 1. Remove the guards over the couplings. 1 is D03-24 past BDC for cylinder No.3 Adjustment MAN B&W Diesel 1. please quote Procedure M90302 Edition 0255 .

please quote Procedure M90302 Edition 0255 Page 3 (3) . 4.3 Adjustment 3. Re-check the setting. M903020255O03 Mount the guard over the coupling. 3.1.Cylinder Lubricators MAN B&W Diesel 903-2. See Procedure 903-2. Turn the pump shaft slowly in ahead direction until the mark on the scale at the leadin shaft is in line with the mark on the lubricator housing. When referring to this page. Re-engage the coupling wheel and tighten the set screw. Marks M903020255O04 4.

.

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

please quote Plate P90361 Edition 0084 MAN B&W Diesel A/S . Item Description Cylinder gauge. complete Page 2 (2) When referring to this page.Tools Item Description Item No.Plate P90361-0084 Item No. 036 Cylinder Liner .

Cylinder Liner .Lifting Tools 0010 P90366 When referring to this page. please quote Plate P90366 Edition 0010 MAN B&W Diesel A/S Page 1 (2) .Lifting Tools Plate P90366-0010 Cylinder Liner .

Plate P90366-0010 Item No. Item Description Crossbar for cylinder liner Page 2 (2) When referring to this page. 021 Cylinder Liner . please quote Plate P90366 Edition 0010 MAN B&W Diesel A/S .Lifting Tools Item Description Item No.

Data Crosshead Reciprocating Parts.Panel Connecting Rod . Data Crosshead Bearing Crosshead.Crosshead with Connecting Rod Documents in this Chapter 104-01 904-01 104-02 904-02 104-03 904-03 104-04 904-04 104-05 904-05 90451 90461 90464 0065 0255 0067 0254 0046 0216 0059 0235 0057 0238 0143 0068 0005 Crosshead Bearing. Data Connection Rod Connecting Rod and Crosshead . Data Crankpin Bearing Connecting Rod.Hydraulic Tools Crosshead . Data Reciprocating Parts Crankpin Bearing.904 .Hydraulic Tools MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

top clearance max. tightening torque 210 Nm D02-20 Piston complete 280 kg D04-01 Crosshead bearing. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.1 mm D04-03 Oil wedge length. 0. top clearance min. tightening torque 40 Nm D04-16 Thrust piece. Description Value Unit D02-02 Piston rod/crosshead. upper 7 kg D04-06 Crosshead bearing shell. L 10 mm D04-04 Crosshead bearing cap 52 kg D04-05 Crosshead bearing shell. lower 9 kg D04-07 Crosshead bearing cap with bearing shell 60 kg D04-15 Telescopic pipe.Crosshead Bearing MAN B&W Diesel 104-1 Data SAFETY PRECAUTIONS For detailed sketch.990 bar When referring to this page. dismantling 800 . please quote Data D10401 Edition 0065 Page 1 (2) . mounting 900 bar D13-02 Hydraulic pressure. tightening torque 60 Nm D04-51 Connecting rod complete 415 kg D04-66 Crosshead with piston and guide shoes 700 kg D13-01 Hydraulic pressure. 0.4 mm D04-02 Crosshead bearing.

pneumatically operated P91351 046 Hose with unions (1500 mm). Crosshead P90464 Crosshead . Description P90451 59 Lifting attachment . complete P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909. complete P91356 Lifting Tools.g. Plate Item No.connecting rod P90451 72 Chain for suspending piston P90451 84 Retaining tool telescope pipe P90451 96 Bracket for support.Hydraulic Tools P91351 010 Hydraulic pump. Crosshead P90451 106 Bracket for support. complete P91351 117 5-way distributor block.Crosshead Bearing 104-1 MAN B&W Diesel 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. please quote Data D10401 Edition 0065 . Etc. P91359 Torque Spanners P91366 Page 2 (2) 058 Feeler gauge When referring to this page. e.

See Data. The wear limit for a crosshead bearing shell is confined to a 50% reduction of the oil wedge length L. Volume I. OPERATION.Crosshead Bearing MAN B&W Diesel 904-1.1 Checking Tin-Aluminium bearings 2. OPERATION. 5. (Oil Wedge) If the wear limit exceeds the 50% reduction. M904010255C03 L 1/2 D0403 L When referring to this page. 1. the crosshead bearing must be disassembled for inspection. M904010255C01 The top clearance for a new bearing will normally be in the range stated in Data. the bearing shell must be replaced by a new one. D0401 D0402 5. M904010255C02 4. For the top clearance of a specific bearing.2. Open the crankcase door at the relevant cylinder. 3. ‘Bearings’ in the instruction book. 3. Turn the crankthrow concerned to BDC.1 mm. For evaluation of the bearing shell. See Procedure 904-1. please quote Procedure M90401 Edition 0255 Page 1 (10) . Measure the clearance in the crosshead bearing by inserting a feeler gauge between the bearing cap and the crosshead journal at the top of the upper bearing shell. 2. see Chapter 708. at both sides and fore and aft. see the measurement in the Adjustment Sheet in Volume I. The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing assembly components. 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. Note that the figures are to be used for guidance only. If so.

2. M904010255C04 7. For operation of the hydraulic jacks. Use the tackles in the crankcase top to lift the crosshead and piston high enough to allow inspection of the lower crosshead bearing. Recheck the bearing top clearance. the following procedure is sufficient. 9. mount the connecting rod lifting attachments on the connecting rod. Turn to BDC.1 Crosshead Bearing Checking MAN B&W Diesel Alternate checking method: 8. Mount the two eyebolts and tackles in the top of the crankcase in the fore and aft direction. In case the reason for opening the crosshead bearing is a routine inspection. see Section 913. Dismount the crosshead bearing cap hydraulic nuts. Use tackles to hold the connecting rod in the vertical position. Note! Ensure that the crosshead is lifted simultaneously fore and aft. Page 2 (10) When referring to this page. If the lower bearing shows no anomalies the piston and crosshead is lowered again and the crosshead bearing cap nuts are mounted. Remove all tools. please quote Procedure M90401 Edition 0255 . 6. Perform the clearance measurement shown in 904-1. the bearing has to be dismantled and checked according to 9041.1 section 3. Mount two eyebolts on top of the guideshoes. i. D0466 9. M904010255C05 8.904-1. by placing marks on the guide planes using a felt tipped pen 10. 12. If there are any doubt concerning damage to the upper bearing.e. 11. Mount two eyebolts in the bearing cap and use two small tackles in the athwartship direction to lift the bearing cap free of the guidepins and to keep the bearing cap balanced.

Turn the crankshaft down far enough to give access to the nuts and screws on the piston rod. never turn the engine without first dismantling the telescopic pipe from the crosshead. M904010255C01 1. Suspend the telescopic pipe from the stuffing box using the wing nut (tool). please quote Procedure M90401 Edition 0255 Page 3 (10) . Caution! M904010255D02 When a piston is dismantled. Loosen and remove the four screws which tighten the telescopic pipe to the bend. M904010255D03 3. Mount two eye bolts in the top of the crankcase and suspend two tackles in the athwartship direction. • with piston mounted • with piston removed With piston mounted: 2. Mount the two chains for suspending the piston rod.2 Dismantling MAN B&W Diesel This procedure has been divided into two dismantling situations. 3. 2.Crosshead Bearing 904-1. as follows: 1. When referring to this page.

Loosen the crosshead bearing cap nuts. please quote Procedure M90401 Edition 0255 . Hold the spacer rings around the nuts and screw the hydraulic jacks on to the studs. 6. With piston removed: 5. 4. Mount a lifting eye bolt on each side of the piston rod. and unscrew the nuts. Turn to BDC. Turn the crosshead to TDC. Remove the locking wire from the screws. M904010255D04 Turn the crosshead downward. Page 4 (10) D1302 When referring to this page.2 Crosshead Bearing Dismantling MAN B&W Diesel 4. loosen and remove the screws from the piston rod foot. For operation of the hydraulic jacks. M904010255D05 Remove the hydraulic jacks and the spacer rings. Hook the chains to the lifting eye bolts in the piston rod. 5.904-1. and the piston rod will remain suspended from the two chains. D0220 7. see Procedure 913. M904010255D06 7. Remove the thrust pieces from both side of the bearing cap.

9.Crosshead Bearing 904-1. M904010255D08 Lift the crosshead bearing cap out of the engine. 9. 8. M904010255D09 D0407 When referring to this page. please quote Procedure M90401 Edition 0255 Page 5 (10) .2 Dismantling MAN B&W Diesel 8. Take care that the studs for the crosshead bearing cap do not scratch the crosshead journal. Mount wire guide on the top of the crankcase door frame to prevent damage. 10. M904010255D07 Note! 10. Hook the two tackles on to the eye bolts and lift the crosshead bearing cap away from the crosshead. Mount two eye bolts in the top of the crosshead bearing cap. Mount the connecting rod lifting attachment tool on the head of the connecting rod.

M904010255D10 12. Turn the crosshead to TDC. 12. D0407 Remove the thrust pieces for axial guidance of the connecting rod. 14. Hook the two tackles on to the eye bolts screwed into the head of the connecting rod.1. see Procedure 904-1. Ensure that the connecting piece in the crosshead fits correctly in the holes of the piston rod. Place the bearing cap on one side on a couple of wooden planks. Do not remove the chains or lifting eye bolts. Check the bearing shell. Carefully turn the crank down towards the exhaust side.2 Dismantling MAN B&W Diesel 11. please quote Procedure M90401 Edition 0255 . until the guide shoes rest on the supports. 13. Mount the four supports for guide shoes on the crosshead guides. 11. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. M904010251D16 D0220 Page 6 (10) When referring to this page.Crosshead Bearing 904-1. M904010255D11 Haul the tackles tight. D0405 13.

1. With the crosshead resting on the supports. Turn the crankthrow carefully towards BDC while ‘following’ with the tackles. For further evaluation of journal and bearing shells. and lift the bearing shell out of the engine. In cases where it is necessary to remove the lower bearing shell. ‘Bearings’. OPERATION. D0451 Check the bearing shell. please quote Procedure M90401 Edition 0255 Page 7 (10) . 16. 15. Chapter 708. M904010255D16 D0406 When referring to this page. tilt the connecting rod towards the door in the camshaft side. 16. check the lower part of the crosshead journal and the lower bearing shell. see Procedure 904-1. M904010255D15 Dismount the lock screws. thus continuously supporting the connecting rod. using the tackles.2 Dismantling 15. see also Volume I.Crosshead Bearing MAN B&W Diesel 904-1.

for assembling the crosshead and the connecting rod. Remove the lifting attachment tool from the connecting rod. Raise the connecting rod to an upright position.904-1. Remove the tackles from the connecting rod.4 Crosshead Bearing Mounting MAN B&W Diesel With the piston mounted/ With the piston removed: 1. Mount and secure the bearing shell in the bearing housing. Page 8 (10) When referring to this page. please quote Procedure M90401 Edition 0255 . 2. Take care that the guide shoes do not damage the bearing shell. D0406 M904010255M01 X X The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated. Turn to TDC while ‘following’ with the tackles. M904010255M03 3. 1. M904010255M02 3. 2.

Note! Take care that the bearing studs do not damage the crosshead. See Data. D0407 Mount the two thrust pieces on both sides of the bearing cap. M904010255M05 7. please quote Procedure M90401 Edition 0255 Page 9 (10) . Turn the crank throw to BDC. If the piston is mounted. see Section 913.Crosshead Bearing 904-1. Tighten all four crosshead bearing cap nuts simultaneously. For operation of hydraulic jacks. See Procedure 902-1. 4. Remove the eye bolts from the bearing cap. Lift the bearing cap into the engine. slowly turn down until it is fully suspended from the chains. See Data.4. 5.4 Mounting MAN B&W Diesel 4. 6. Remove wire guide. Mount the piston. D0416 M904010255M06 D1301 When referring to this page. M904010251M03 5. 6. Lower the bearing cap onto the crosshead and remove the tackles. Remove the supports from the crosshead guides.

Volume I. mount and tighten the four screws which tighten the telescopic pipe to the bend. OPERATION. See Procedure 913-7. D0202 After tightening the bearing cap.904-1. M904010255M08 11. Mount the locking wire on the screws. The locking wire is to be mounted in such a way that the wire is tightened if a screw works loose. 8. See Data. Release the telescopic pipe from its suspension.2. remember to note down the new top clearance in the Adjustment Sheet in Chapter 701.4 Crosshead Bearing Mounting MAN B&W Diesel With the piston mounted: 8. M904010255M07 9. Turn the crosshead upwards until the piston rod lands on the crosshead. check the top clearance once more. 10. please quote Procedure M90401 Edition 0255 . See Data. 11. Remove the chains and eye bolts from the top of the crankcase. 10. If a new bearing shell has been mounted. from the piston rod and from the crosshead bearing cap. Unhook the chains from the lifting eye bolts in the piston rod. When mounting the piston on the crosshead. Mount and tighten the screws on the piston rod. M904010255M09 D0415 Page 10 (10) When referring to this page. make sure that the piston rod foot is correctly centered on the crosshead.

tightening torque 135 Nm D04-09 Inlet pipe. tightening torque 40 Nm D04-16 Thrust piece.30 mm 360 kg 35 kg 415 kg Cooling oil outlet pipe 2 kg D04-59 Telescopic pipe 5 kg D04-60 Inlet pipe 5 kg D04-62 Crosshead without guide shoes 285 kg D13-01 Hydraulic pressure. screwing-in torque 150 Nm D04-11 Guide strip nuts.Crosshead MAN B&W Diesel 104-2 Data SAFETY PRECAUTIONS For detailed sketch. tightening angle D04-18 Inlet pipe. tightening torque 60 Nm D04-17 Cooling oil outlet pipe. dismantling 800 . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. tightening angle D04-20 Clearance between thrust piece and crosshead D04-21 Crosshead complete D04-22 Guide shoe D04-51 Connecting rod complete D04-23 135 ° 45 ° 0. tightening torque 60 Nm D04-15 Telescopic pipe. Description D04-07 Crosshead bearing cap with bearing shell D04-08 Value Unit 60 kg Cooling oil outlet pipe. mounting 900 bar D13-02 Hydraulic pressure. tightening torque 260 Nm D04-10 Inlet pipe stud.990 bar When referring to this page. please quote Data D10402 Edition 0067 Page 1 (2) .15-0.

g. P91359 Torque Spanners P91366 Page 2 (2) 058 Feeler gauge When referring to this page. e. pneumatically operated P91351 046 Hose with unions (1500 mm). Etc. Plate Item No. please quote Data D10402 Edition 0067 . Description P90451 47 Wire guide P90451 59 Lifting attachment . P90951 refers to chapter 909.Crosshead 104-2 MAN B&W Diesel 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. complete P91356 Lifting Tools.crosshead P90451 72 Chain for suspending piston P90451 84 Retaining tool telescope pipe P90464 Crosshead . complete P91351 105 3-way distributor block.Hydraulic Tools P91351 010 Hydraulic pump.connecting rod P90451 60 Lifting tools . complete P91351 058 Hose with unions (3000 mm).

Mount two eye bolts in the crosshead bearing cap and hook on the tackles from the top of the crankcase. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts. 3. and suspend two tackles. When referring to this page. please quote Procedure M90402 Edition 0254 Page 1 (10) . Suspend the piston. Dismount the main bearing lubricating oil pipes. Lift the bearing cap out of the engine. Mount the retaining tool for the telescopic pipe on the stuffing box housing for the telescopic pipe. Remove the piston rod guide ring and the shim from the crosshead. Remove both thrust pieces on the crosshead bearing cap. 2. Turn the crosshead to TDC. D0407 Loosen the nuts. see Procedure 904-1. see Procedure 913-1.Crosshead MAN B&W Diesel 904-2. 4. M904020247D02 Mount two eye bolts in the athwartship direction. To suspend the piston.2 Dismantling 1. For operation of the hydraulic tools. 2. Turn the crosshead to BDC to give access to the nuts on the crosshead bearing cap. remove the hydraulic jacks and unscrew the nuts. Use two tackles to retain the connecting rod in an upright position. M904020247D04 Suspend the telescopic pipe by means of the tool. Turn to BDC and mount connecting rod lifting tools. D1302 4.

Page 2 (10) When referring to this page. 5. M904020254D06 Lift the crosshead free of the connecting rod. Mount the special lifting tool on the crosshead. Haul the tackles tight.Crosshead 904-2. dismount the bend for the telescopic pipe and remove the studs from the crosshead. 6. please quote Procedure M90402 Edition 0254 . Attach tackle chains from the two tackles in the athwartship direction to the lifting tool. D0421 Hook the tackles to the top lifting brackets onto the lifting tool on the crosshead and lift the crosshead.2 Dismantling MAN B&W Diesel 5. Remove the outlet pipe. 6. Dismount the guidepin for the oil inlet bend using the special extractor. Fasten tackles to the lifting brackets on the frame box wall and attach the tackle hooks to the lifting attachments. M904020254D05 Mount the lifting attachments for fixing the connecting rod on the head of the connecting rod.

It is recommended to tag the guide strips and shims to avoid mixing them. as necessary. 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. When referring to this page. 8. 9. Lower the crosshead so that the guide shoes are just below the cutout in the side walls of the frame box. 9. M904020250D09 Note! 10. Mount lifting eye bolts in both guide shoes. Use the tackles to tilt the connecting rod to-wards the exhaust side. while turning the crankthrow towards the camshaft side.2 Dismantling 7. tilt the connecting rod until it is out of the way. Note! M904020250D10 Make sure that the crosshead journal does not touch the crank. 10. D0451 Transfer the tackles from one lifting attachment to another. 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. please quote Procedure M90402 Edition 0254 Page 3 (10) . 7.Crosshead MAN B&W Diesel 904-2. Remove the oil pipes from the two adjacent main bearing caps. By alternate use of the tackles. Remove the guide strips and the stop screws from the bottom of the guide shoes.

M904020254D13 D0462 D0422 Page 4 (10) When referring to this page. 13. at the same time. Hook the tackles on to the eye bolts in the guide shoes. M904020250D12 12. M904020250D11 Take the guide shoes through the openings in the side walls by means of the tackles in the two adjacent cylinders. and suspend two tackles from the eye bolts. Mount two eye bolts in the holes for stop screws in the guide shoes in the adjacent cylinder units. Haul the tackles for the guide shoes tight and. 11.904-2. pull the guide shoes sideways until they are free of the crosshead. 13. Lift the guide shoes to provide space for turning the crosshead. please quote Procedure M90402 Edition 0254 .2 Crosshead Dismantling MAN B&W Diesel 11. 12.

please quote Procedure M90402 Edition 0254 D0422 Page 5 (10) . remove the crosshead from the engine.2 Dismantling 14. M904020250D14 Note! M904020250D15 15. When referring to this page.Crosshead MAN B&W Diesel 904-2. Remove the guide shoes from the engine and tag them. by means of wire rope and tackle. 15. Land and protect the crosshead outside the engine. 14. Take care that the crosshead does not bump into anything as this will damage the sliding surfaces of the crosshead. Mount a tackle outside the engine and. Turn the crosshead 90°.

carefully lift the guide shoes into the engine. Turn the crosshead 90° to enable mounting of the guide shoes. Attach two tackles to the eye bolts at the bottom of the guide shoes in the adjacent cylinders. D0421 2. M904020250M01 Suspend two tackles from the top of the framebox between the guides.4 MAN B&W Diesel Mounting 1. take great care that its surfaces are not scratched or damaged. Note! M904020250M02 When handling the crosshead. If necessary. Check that the oil inlet and outlet holes are pointing towards the exhaust side. Mount the wire guide tool in the framebox door opening. M904020250M03 D0422 Page 6 (10) When referring to this page. 2. 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. protect the crosshead with a cloth. Clean the crosshead and mount the lifting tool. Using these tackles and a tackle outside the engine. 3. 1. please quote Procedure M90402 Edition 0254 .Crosshead 904-2. 3.

M904020250M04 Mount the stop screws in the bottom of the guide shoes. 4. M904020250M05 7. When referring to this page. 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. Lubricate the crosshead bearing liberally with clean lubricating oil and carefully lower the crosshead into place. 5. Raise the connecting rod to the upright position.Crosshead MAN B&W Diesel 904-2. Dismount the tackles and connecting rod lifting tools from the connecting rod. 5. please quote Procedure M90402 Edition 0254 Page 7 (10) . Remove the tackles and the eye bolts from the guide shoes. 6. D0411 D0421 M904020254M06 6. Lubricate the sliding surfaces of the guide shoes and the crosshead with plenty of clean lubricating oil. Lift the crosshead to a position above the connecting rod in the upright position. and push the guide shoes into position through the openings in the side walls.4 Mounting 4.

Remove the lifting tool from the crosshead. Mount the piston rod guide ring and the shim on the crosshead. Turn the connecting rod and crosshead to BDC. please quote Procedure M90402 Edition 0254 . 8. Mount the studs for the cooling oil inlet bend. M904020247M05 Mount the inlet and outlet pipes. When referring to this page. D0408 D0409 D0410 Dismount the tackles and connecting rod lifting tools from the connecting rod. Mount the bend and outlet pipe. See Data. Page 8 (10) Tighten the outlet pipe.4 MAN B&W Diesel Mounting 8.Crosshead 904-2.

See Data. Lift the crosshead bearing cap into the engine.4 Mounting 9. M904020247M06 Note! D1301 10. Always ensure that clearance exists fore and aft between the thrust piece and the crosshead before tightening the thrust piece. D04-15. 10. 11. Remoce the eye bolts.Crosshead MAN B&W Diesel 904-2. Mount and tighten the crosshead bearing cap. 9. M904020247M07 Remove the nut from the telescopic pipe suspending tool. Mount the two thrust pads on the sides of the crosshead. When referring to this page. Mount the distance pipe on the telescopic pipe bend. please quote Procedure M90402 Edition 0254 D0416 D0420 Page 9 (10) . Turn downwards and tighten the telescopic pipe. Mount the piston. See Procedure 902-2.

Remove the hydraulic tools and the eye bolts from the engine. M904020250M10 Mount the main bearing lubricating oil pipes. Page 10 (10) When referring to this page. See Procedure 904-1. shackles or rags left behind. For operation of hydraulic tools. See Procedure 904-1.904-2. guide shoes and crosshead guides.4 Crosshead MAN B&W Diesel Mounting 12. Remove all tools from the engine. see Procedure 913-1. Note! At this point it is recommended to check the crosshead bearing clearance. Check the clearances between the guide strips. please quote Procedure M90402 Edition 0254 . 13. 12. Tighten the hydraulic nuts. Note! Search the crankcase to ensure that there are no tools. Mount the piston and the telescopic pipe. See Procedure 904-3.

0. N min.40 mm D04-29 E+G. 0. O max.70 mm D04-26 PF+PA. 1. M+Y. K+X.40 mm D04-36 J+X. 0. O max. L+Y. 0. 0.Reciprocating Parts MAN B&W Diesel 104-3 Data SAFETY PRECAUTIONS For detailed sketch. M+Y. L+Y. O max. N max. L+Y.00 mm D04-39 QF/QA. 4. M+Y. O: Engine in service.80 mm D04-41 ZF/ZA O min. 0.70 mm D04-34 J+X. K+X.80 mm D04-35 J+X.00 mm D04-42 TF + TA.80 mm N: New and cold engine with staybolts tightened (less than 100 running hours). H+F. O max. N max. K+X. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. O max. N min. Description Value Unit D04-25 PF+PA. 0. H+F. please quote Data D10403 Edition 0046 Page 1 (2) . H+F.10 mm D04-30 E+G.90 mm D04-28 E+G. 0. When referring to this page. 0. N max.

g. 058 Description Feeler gauge When referring to this page. e. P90951 refers to chapter 909. please quote Data D10403 Edition 0046 .Reciprocating Parts 104-3 MAN B&W Diesel 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. Plate P91366 Page 2 (2) Item No.

250 mm up along the framebox side.1 Checking Reciprocating Parts S42MC 0216 Checking 904-3. Fill the tube with water (possibly coloured) until the water level is approx. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S Page 1 (3) . Turn the crankshaft in ASTERN direction to 45° after BDC (the guide shoe must rest against the crosshead guide). 45° A ste rn When referring to this page. 100 mm from the end of the tube.0 72 01 1. Aft 2. Trim the ship until the difference between the water level S fore and aft is less than 1. In order to achieve uniform measuring conditions on board.5 mm per 1000 mm. PA PF HN904-3. Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. See T. Bend each end approx.1 1. MA904-5. the ship's trim must be as close as possible to 0°. Fore Measurements are to be taken with a ruler.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). Mount a transparent plastic tube along the length of the bedplate. 2.Reciprocating Parts 904-3.

K. MN904-3. Measure the clearance between the thrust piece and the crosshead (TF and TA or QF and QA. G and H). 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.2 mm per 1000 mm.1 215 05 Camshaft Side Page 2 (3) When referring to this page. Measure the clearance between the guide strips and crosshead guides (J. L and M). F. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S . calculated as J+X.Reciprocating Parts 904-3.1 Checking 3. 3. 4. Measure the clearance between the crosshead guides and the guide shoes (E.1 215 04 Parallelism between the guide strip and guide is to be kept within a tolerance of 0. The clearance. L+Y and M+Y. BF and BA correspond to the thickness of the shims and are only to be measured if an adjustment is carried out. Measure the clearance between the crankthrow and the connecting rod. 4. K+Y. Exhaust Side MN904-3.

Cyl. It is recommended that the measured results are noted down so that possible later changes can be ascertained.1 Checking 5. Piston/Liner 1 2 3 4 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 When referring to this page.Reciprocating Parts 904-3. 5. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S QF/TF QA/TA ZF ZA Page 3 (3) .

.

Crankpin Bearing MAN B&W Diesel 104-4 Data SAFETY PRECAUTIONS For detailed sketch. 0. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10404 Edition 0059 Page 1 (2) . min. upper shell 6 kg D04-47 Crankpin bearing.990 bar When referring to this page.45 mm D04-44 Crankpin bearing clearance. dismantling 800 . max. lower shell 4 kg D04-48 Crankpin bearing cap + shell + bearing studs 55 kg D13-01 Hydraulic pressure. Description Value Unit D04-43 Crankpin bearing clearance. mounting 900 bar D13-02 Hydraulic pressure.15 mm D04-46 Crankpin bearing. 0.

e. pneumatically operated P91351 046 Hose with unions (1500 mm). Plate Item No.Crankpin Bearing 104-4 MAN B&W Diesel 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. complete P91351 105 3-way distributor block.connecting rod P90451 96 Bracket for support.Hydraulic Tools P91351 010 Hydraulic pump. Crosshead P90451 106 Bracket for support.g. complete P91366 061 Slide caliper Page 2 (2) When referring to this page. Description P90451 47 Wire guide P90451 59 Lifting attachment . Crosshead P90461 Connecting Rod . P90951 refers to chapter 909. complete P91351 058 Hose with unions (3000 mm). please quote Data D10404 Edition 0059 .

D0443 D0444 C M904040235C03 5. See Data for bottom clearance. see the measurement in the Adjustment Sheet in Volume I. 5. M904040235C01 2. When referring to this page. the crankpin bearing must be disassembled for inspection. OPERATION. 3. OPERATION. see Chapter 708 ‘Bearings' in the instruction book.2. please quote Procedure M90404 Edition 0235 Page 1 (7) . Volume I. See Procedure 904-4. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection. If so. M904040235C02 For further external inspection of the crankpin bearing. 4.Crankpin Bearing MAN B&W Diesel 904-4. 2. 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. For the bottom clearance of a specific bearing. 3. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. Open the crankcase door at the relevant cylinder. Turn the crank concerned to BDC.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. 1.1 mm.

3. Turn the crank to BDC. using the hydraulic jacks. 2. M904040235D02 Inspect the bearing shell. Mount eye bolts in each side of the crankpin bearing cap. M904040235D01 Loosen the crankpin bearing stud nuts.904-4. Remove the hydraulic jacks and the nuts. Turn the crank to TDC. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal. Hook the tackles on to the eye bolts and haul tight. D1302 4. For operation of the hydraulic jacks. M904040235D03 D0448 Page 2 (7) When referring to this page. please quote Procedure M90404 Edition 0235 . 3. Mount two eye bolts in the crankcase top plate in the athwartship direction and suspend two tackles from the eye bolts. 2. Land the bearing cap on a couple of planks placed in the oil pan. 4. see Section 913.2 Crankpin Bearing Dismantling MAN B&W Diesel 1.

Carefully turn the crank down until the guide shoes rest on the supports. Suspend a tackle from the lifting bracket on the inside camshaft side of the frame box above the crankcase door opening. D0447 Dismount the bearing shell lock screws and replace the bearing shell by a new one. Place the bearing cap on one side on a couple of planks. Using the tackle from the frame box inside wall. 6. 5. together with a tackle suspended from the platform bracket. remove the whole bearing cap from the crankcase. M904040235D05 7. Mount the four supports for guide shoes on the crosshead guides. D0448 Hook the tackle on to an eye bolt on one side of the bearing cap. M904040235D04 Mount the wire guide in the top of the crankcase door opening. M904040235D06 Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. 7. When referring to this page. 6. If the bearing shell needs to be replaced. The bearing shells must be replaced in pairs. Turn to TDC.2 Dismantling 5. lift the bearing cap out of the crankcase. please quote Procedure M90404 Edition 0235 Page 3 (7) .Crankpin Bearing MAN B&W Diesel 904-4.

Carefully turn the crankshaft downwards. Continue turning the crankshaft until the bearing surface can be freely inspected. Inspect the bearing shell surface and the crankpin journal. making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to ‘separate’. Release the tackle so that the connecting rod is hanging freely.2 Crankpin Bearing Dismantling MAN B&W Diesel 8. 8. If it is necessary to replace the bearing shell.904-4. Carefully lower the bearing shell from the connecting rod and remove it from the engine. proceed as follows: Turn the crankshaft to BDC. 10. 10. M904040235D07 9. M904040235D09 D0446 Page 4 (7) When referring to this page. 9. Hook on the tackle to a beam under the gallery platform and haul tight. while ‘following’ with the tackle. on one side. M904040235D08 Dismount the bearing shell lock screws. please quote Procedure M90404 Edition 0235 . Mount a lifting attachment for securing the connecting rod at the lower end.

2. Lift the upper bearing shell for the crankpin concerned into the crankcase. M904040235M02 Remove the guide shoe support brackets from the crosshead guides. making sure that the upper part of the bearing enters the recess in the crankshaft when the parts turn together. and mount the lock screws. Carefully turn the crankshaft upwards. Carefully lift the bearing shell into position in the connecting rod. When referring to this page. please quote Procedure M90404 Edition 0235 Page 5 (7) . M904040235D06 3. M904040235D09 2. Remove the tackle and the lifting attachment from the connecting rod. 1. while following up with the tackle. 3. and haul tight. D0446 Lubricate the upper crankpin bearing shell and the crankpin journal with plenty of clean lubricating oil.4 Mounting 1. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod.Crankpin Bearing MAN B&W Diesel 904-4. Turn the crosshead to TDC.

Mount two eye bolts in the crankcase topplate in the two outer screw holes in the athwartship direction and suspend two tackles from the eye bolts.. M904040235M05 D0448 Page 6 (7) When referring to this page. 5. M904040235D01 Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan. 5.4 Crankpin Bearing Mounting MAN B&W Diesel 4. Turn the crankthrow towards the exhaust side of the engine. 4. please quote Procedure M90404 Edition 0235 .904-4.

the eye bolts and the hydraulic tools from the engine.4 Mounting MAN B&W Diesel 6. 6. For operation of hydraulic jacks. D1301 M904040235M07 Remove the tackles. D0448 Lift the bearing cap into position against the connecting rod. See Data.Crankpin Bearing 904-4. by means of spacer rings and hydraulic jacks. Mount the nuts and. take care that the studs do not damage the crankpin journal. see Section 913. Hook the tackles on to the eye bolts of the bearing cap and lubricate the bearing shell with plenty of lubricating oil. When referring to this page. tighten the crankpin bearing cap. Turn the crankthrow to TDC. 7. During mounting. please quote Procedure M90404 Edition 0235 Page 7 (7) . M904040235D03 Caution! 7. and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod.

.

990 bar When referring to this page. see 900-2 X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. dismantling 800 . mounting 900 bar D13-02 Hydraulic pressure. please quote Data D10405 Edition 0057 Page 1 (2) .Connecting Rod MAN B&W Diesel 104-5 Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D04-50 Connecting rod. without bearing caps 305 kg D13-01 Hydraulic pressure.

When referring to this page. e. complete P91356 Page 2 (2) Lifting Tools. pneumatically operated P91351 046 Hose with unions (1500 mm).Connecting Rod 104-5 MAN B&W Diesel 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. Etc. P90451 47 Wire guide P90451 59 Lifting attachment . complete P91351 105 3-way distributor block. please quote Data D10405 Edition 0057 . Plate Item No. Crosshead P90451 106 Bracket for support. Crosshead P90461 Description Connecting Rod .g.Hydraulic Tools P91351 010 Hydraulic pump. P90951 refers to chapter 909. complete P91351 058 Hose with unions (3000 mm).connecting rod P90451 96 Bracket for support.

Mount the support brackets for the guide shoes on the crosshead guides. 2. and suspend two tackles. 904-5. D1302 2. Dismount the nuts from the crosshead bearing studs. M904050238D03 3.2 Dismantling Turn the crank to BDC. Dismount the crankpin bearing cap.Connecting Rod MAN B&W Diesel 1. until the crosshead shoes rest on the supports. Mount two eye bolts in the top of the crankcase in the athwartship direction. Adjust the support brackets to the guide shoes so that the weight of the crosshead is distributed evenly on the four supports M904050238D01 3. Carefully turn the crank down towards the door opening. 1. When referring to this page. camshaft side. See Procedure 904-4.2.2. please quote Procedure M90405 Edition 0238 Page 1 (7) . M904050238D02 4. Turn the crank to TDC. See Procedure 904-1.

2 Connecting Rod Dismantling 5. M904050238D04 6. Turn the crank carefully downwards while “following” with the tackles to guide the connecting rod when this separates from the crosshead. at the crankpin end. The weight of the crosshead. hook on the tackles. MAN B&W Diesel 5. Mount the lifting attachment on the exhaust side of the connecting rod. together with the piston and crosshead bearing cap.904-5. please quote Procedure M90405 Edition 0238 . Page 2 (7) When referring to this page. Mount an eye bolt in each side of the connecting rod at the crosshead end. M904050238D05 6. and haul tight. is now carried by the four supports.

7. on the exhaust side.2 Dismantling Open the crankcase door on the exhaust side of the engine. please quote Procedure M90405 Edition 0238 Page 3 (7) . M904050238D07 8. Suspend a tackle from the platform bracket and hook it on to the eye bolt in the connecting rod. M904050238D06 9.Connecting Rod MAN B&W Diesel 7. crosshead end. 8. When possible. Remove the tackle from the connecting rod. change the lifting point from the camshaft side to the exhaust side of the connecting rod and guide the upper part of the connecting rod towards and out of the door opening as far as possible. When referring to this page. Turn the crank carefully upwards while “following” with the tackle from the topplate and the one on the exhaust side. crankpin end. M904050238D08 9. 904-5.

if possible. M904050238D10 11. Lift the connecting rod out of the engine using the two tackles and. 10. M904050238D09 D0450 11. Page 4 (7) When referring to this page.904-5. please quote Procedure M90405 Edition 0238 . hook on the tackle and haul tight. while “following” with the two tackles. using the engine room crane. Place a wire rope round the connecting rod. Continue turning the crank to a position about 25° after TDC.2 Connecting Rod Dismantling MAN B&W Diesel 10.

Connecting Rod MAN B&W Diesel 1. 3. 2. 904-5. When referring to this page. hook the second tackle on to the eye bolt screwed into the camshaft side of the connecting rod. Turn the crank to a position about 25° past TDC on the camshaft side. M904050238M01 2. past TDC. D0450 3. Apply clean lubricating oil to the crankpin bearing shell and journal. 4. while ‘following’ with the tackle and the engine room crane. M904050238M02 4. M904050238M03 Haul tight and remove the strap around the connecting rod. Note! Take care that the end of the connecting rod does not scratch the crankpin journal. please quote Procedure M90405 Edition 0238 Page 5 (7) . Carefully land the connecting rod on the crankpin journal. When the upper end of the connecting rod has passed the crankcase door. Carefully lift the connecting rod into the crankcase by alternate use of the engine room crane and the tackle attached to the lifting bracket mounted on the connecting rod.4 Mounting Equip the connecting rod with the same lifting attachments as mentioned under dismantling. Turn the crankthrow towards the exhaust side of the engine.

Page 6 (7) When referring to this page. Turn the crankthrow towards TDC while ‘following’ with the tackles.4. M904050238M04 Caution! Take care that the studs do not damage the crosshead bearing shell. M904050238M04 6. Remove the tackle from the lifting attachment at the lower end of the connecting rod 7. See Procedure 904-4. D1301 M904050238M05 7. 5.Connecting Rod 904-5. Hook the third tackle on to the eye bolt screwed into the exhaust side of the connecting rod. When the crank is in TDC.4 Mounting MAN B&W Diesel 5. please quote Procedure M90405 Edition 0238 . 6. mount and tighten the crankpin bearing cap. Turn the crankthrow to 90° before BDC.

• the four supports from the crosshead guides • the eye bolts and the lifting attachment from the connecting rod • the eye bolts from the top of the crankcase.4 Mounting 8. Remove: 8. D1301 M904050238M08 9. M904050238M07 9. See Data. please quote Procedure M90405 Edition 0238 Page 7 (7) . When referring to this page. Tighten all four crosshead bearing cap nuts simultaneously.Connecting Rod MAN B&W Diesel 904-5.

.

Connecting Rod and Crosshead Panel

Plate
P90451-0143

Connecting Rod and Crosshead Panel
0143
P90451

When referring to this page, please quote Plate P90451 Edition 0143
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90451-0143
Item
No.
011
023
047
059
060
072
084
096
106
118
120
155
167
238

Connecting Rod and Crosshead Panel

Item Description

Item
No.

Item Description

Panel for tools
Name plate
Wire guide
Lifting attachment for connecting rod
Lifting tool for crosshead
Chain for suspending piston
Retaining tool for telescope pipe
Support for crosshead
Support for crosshead
Rubber cover for crosshead
Rubber cover for crosshead
Crowfoot wrench
Crowfoot wrench
Dismantling screw for crosshead

Page 2 (2)

When referring to this page, please quote Plate P90451 Edition 0143
MAN B&W Diesel A/S

Connecting Rod - Hydraulic Tools

When referring to this page, please quote Plate P90461 Edition 0068
MAN B&W Diesel A/S

Plate
P90461-0068

Page 1 (2)

Plate
P90461-0068

Connecting Rod - Hydraulic Tools

Item
No.

Item Description

028
030
041
053
065
089
100
207

Hydraulic jack
Support
Tommy bar
O-ring with back-up ring
O-ring with back-up ring
Spanner
Stud setter
Hydraulic toolset, complete

Page 2 (2)

Item
No.

Item Description

When referring to this page, please quote Plate P90461 Edition 0068
MAN B&W Diesel A/S

Crosshead - Hydraulic Tools

When referring to this page, please quote Plate P90464 Edition 0005
MAN B&W Diesel A/S

Plate
P90464-0005

Page 1 (2)

Plate
P90464-0005

Crosshead - Hydraulic Tools

Item
No.

Item Description

024
036
048
050
061
085
107
203

Jack-hydrualic, complete
Support
Tommy bar
O-ring with back-up ring
O-ring with back-up ring
Key, hexagon socket screw
Stud setter
Hydraulic toolset, complete

Page 2 (2)

Item
No.

Item Description

When referring to this page, please quote Plate P90464 Edition 0005
MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear
Documents in this Chapter
105-02
905-02
105-03
905-03
105-04
905-04
105-05
905-05
90551
90561
90562
90564
90572

0083
0259
0073
0226
0048
0232
0059
0226
0198
0087
0124
0020
0003

Main Bearing, Data
Main Bearing
Thrust Bearing, Data
Thrust Bearing
Journal Bearing, Data
Journal Bearing
Axial Vibration Damper, Data
Axial Vibration Damper
Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
Main Bearing - Hydraulic Tools
Crankshaft - Tools
Crankshaft - Measuring 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

SAFETY PRECAUTIONS For detailed sketch, see 900-2
X
X
X
X
X
X
X

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

Data
Ref.

Description

Value

Unit

D05-01

Main bearing, top clearance max.

0.45

mm

D05-02

Main bearing, top clearance min.

0.15

mm

D05-03

Main bearing cap

D05-04

88

kg

Main bearing shell, upper

5

kg

D05-05

Main bearing shell, lower

5

kg

D13-01

Hydraulic pressure, mounting

D13-02

Hydraulic pressure, dismantling

When referring to this page, please quote Data D10502 Edition 0083

900

bar

800 - 990

bar

Page 1 (2)

Main Bearing

105-2

MAN B&W Diesel

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.

P90464

Description
Crosshead - Hydraulic Tools

P90551

52

Handle, dismantling of main bearing shell

P90551

88

Dismantling tool, main bearing shell

P90561

Main Bearing - Hydraulic Tools

P90562

Lifting tool for crankshaft

P90572

Main Bearing - Measuring Tools

P91351

010

Hydraulic pump, pneumatically operated

P91351

022

Hydraulic pump, hand operated

P91351

046

Hose with unions (1500 mm), complete

P91351

058

Hose with unions (3000 mm), complete

P91351

105

3-way distributor block, complete

P91356
P91366

Page 2 (2)

Lifting Tools, etc.
073

Dial gauge and stand tool

When referring to this page, please quote Data D10502 Edition 0083

Main Bearing
MAN B&W Diesel

905-2.1

Checking

General

1.

The condition of the main bearings can be
checked by:
• Deflection readings
• Visual checking
• Edge checking and

Crankshaft deflection readings
Crankshaft deflection readings should be taken
while the ship is afloat (i.e. not while in dry
dock).
As the alignment is influenced by the engine
temperature as well as the loading conditions,
deflection 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:

“Negative” ()
M905010208C02

1.

M905020046C01

• Measuring of top clearance.

3.

B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
B = 1/2 (B2+B1)

T

C

E

M905010204C03

Looking forward
B1

When referring to this page, please quote Procedure M90502 Edition 0259

B

B2

B1
C
T
E
B2
½ (B1+B2)=B

Page 1 (15)

905-2.1

Main Bearing
Checking

4.

MAN B&W Diesel

4. When taking deflection readings for the
three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise,
this pressure may falsify the readings.

M905020046C01

For evaluation of the crankshaft deflection
readings, see Volume I, OPERATION, Chapter 708.

5.

If the crankshaft deflection (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.
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” deflection 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 filters 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 filter. A check of the
bearing edges together with inspection of the
crankcase and the filter normally provides a
good indication of the bearing condition.

Page 2 (15)

When referring to this page, please quote Procedure M90502 Edition 0259

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 flashlight.

7.

Wirefeeler
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

1

60-70
2-3 mm

500-1000

7.

Hole in
the edge

M905010208C06

The No. 1 and the two aftmost main bearings are more difficult 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
“wirefeeler” are guideline values and
may depend on the engine type as well
as individual, personal designs.

M905020252C06

Note!

When referring to this page, please quote Procedure M90502 Edition 0259

Page 3 (15)

905-2.1

Main Bearing
Checking

8.

MAN B&W Diesel

8. Remove the lub. oil pipe from the main
bearing cap.
Calibrate the main bearing measuring tool:
See the wooden box for the measuring
tool.

M905020259C08

9. Insert the measuring tool and check the
clearance between the upper shell and the
journal.

10.

An appreciable increase in clearance may
be an indication of loose staybolts or wear
of the lower shell.
10. If there is too large a difference in the
crankshaft deflection readings (autolog)
check the clearance in the individual bearings.

M905010208C08

Bearing clearance checks should also be
carried out during timebased overhauls,
surveys and during crankcase inspections.

Page 4 (15)

If there is a suspicion of a damaged bearing, it is recommended to edge check the
bearing, without opening up.

When referring to this page, please quote Procedure M90502 Edition 0259

Main Bearing
MAN B&W Diesel

905-2.1

Checking

11. Before measuring, check that the feeler
blades are in good condition.

12.

The feeler is inserted along the crank
throw. When the feeler hits the journal,
gently attempt to enter the feeler gauge
into the bearing. Do not use force.
Measure until a Go/No go difference of
0.05 mm has been found, e.g. Go = 0.75
mm / No go = 0.8 mm.

Note!
The bearing clearances for a new bearing stated in Data (see Data 1052) are
for guidance purposes only.

M905020227C03

Check the feeler blades after measuring.

12. 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.
If the bearing needs to be disassembled for
inspection, see Procedure 9052.2.

When referring to this page, please quote Procedure M90502 Edition 0259

Page 5 (15)

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 9054).
2. Before any dismantling, check and write
down the main bearing top clearances and
crankshaft deflection 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 flush 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 (15)

When referring to this page, please quote Procedure M90502 Edition 0259

5. Connect the four hydraulic jacks to the high-pressure pump by means of the distributor block and high-pressure hoses. D1302 (For operation of the hydraulic tools. Turn the crankthrow so that it points towards the exhaust side of the engine. 4. see Chapter 913). 3 1 Then loosen the nuts. When referring to this page. please quote Procedure M90502 Edition 0259 Page 7 (15) . and subsequently 2+4.Main Bearing MAN B&W Diesel 905-2. Screw the two extension studs onto the same two bearing cap studs (diagonally) 1+3. M905020259D04 Place two spacers on two bearing cap studs with the slots towards the centre of the bearing cap. 2 Repeat the sequence until all four nuts are loose. Disconnect the lubricating oil inlet pipe from the main bearing cap (if not already done during checking). Mount the double hydraulic jacks on the studs.2 Dismantling Dismantling of main bearings (A) 4. 5. 4 M905020259D05 Remove the hydraulic tools and unscrew the nuts.

Mount the outside tackles. M905020259D08 D0503 Page 8 (15) When referring to this page. 8. Mount the guide pulley with the lifting wire rope in the bottom of the guide shoe. Remove the rectangular nut washers from the bearing cap. Rig-up two tackles outside the engine. MAN B&W Diesel 6. one in the lifting beam on the camshaft side. please quote Procedure M90502 Edition 0259 . push the bearing cap free of the frame and land it on the crank web.905-2. 8. and one on the exhaust side. M905020259D07 Lift the bearing cap and. Fasten the lifting tool to the main bearing cap with wire rope attached to the camshaft side tackle. by means of the handle. 7.2 Main Bearing Dismantling 7. Remove the stop screw in the crosshead guide shoe.

D0504 M905020259D11 11. Mount the handle in the upper bearing shell and remove the shell from the crankshaft. When referring to this page. 10. D0503 10. OPERATION Chapter 708.Main Bearing MAN B&W Diesel 905-2. See Volume I. Remove the wire rope from the guide pulley. Bearings). 9. Check that there is clearance between the journal and the bearing shell in the two adjacent main bearings. and lift the bearing cap out of the crankcase.2 Dismantling 9. Remove the guide pulley from the engine. M905020259D10 11. please quote Procedure M90502 Edition 0259 Page 9 (15) . and fasten the two wire ropes from the lifting tool in the two tackles outside on either side. M905020259D09 Inspect the bearing shell and the journal.

Take out the lower shell from the crankcase in the same way as the upper shell.2 mm. Max. Tighten the screws against the crank webs. please quote Procedure M90502 Edition 0259 . 14. 13. 13.2 Dismantling MAN B&W Diesel 12. Place the crosspiece in the bedplate with the ends resting on the crossgirders. making sure that the flap of the dismantling tool enters the oil groove in the bearing shell. 12.Main Bearing 905-2. Remove the screws from the sides of the crosspiece and screw them into the threaded holes of the upper hydraulic jacks for the main bearing. M905020259D13 Pull the lower bearing shell round and up until it lies over the main bearing journal. Place the dismantling tool on the top of the lower bearing shell. M905020259D12 Place a dial gauge to measure the lifting of the crankshaft. and place the hydraulic jacks beneath the crank webs as shown. Page 10 (15) D0505 When referring to this page.0. Dismount the lock screws from the lower shell.2 mm M905020259D14 14. Connect the hydraulic jacks to the high pressure pump and raise the pressure until the crankshaft has lifted maximum 0.

Chapter 708. • Lubricate the bearing journal. If. See instruction book. If the bearing shells are damaged. 1. When referring to this page. Volume I. 905-2. If damage is found. contact MAN B&W Diesel for advice. M905020259O01 We recommend that the main bearing shells be replaced in pairs. Before remounting: • Check the bearing support for damage and burrs. see Volume I. please quote Procedure M90502 Edition 0259 Page 11 (15) . it is recommended to contact MAN B&W Diesel A/S or the engine builder. use non-fluffy cloth to clean between journal and main bearing support. the main bearing support and the back of the shell. it requires a careful evaluation of the condition of the shell that is to be reinstalled. it is desired only to replace one shell. 2. For advice on replacing the bearing shells individually. Chapter 708.Main Bearing MAN B&W Diesel 1. ‘Bearings’. For judging the condition of the bearing. • Make sure that all parts are clean. contact MAN B&W Diesel for advice.3 Overhaul Clean and inspect the bearing shells. nevertheless.

MAN B&W Diesel Lubricate the lower bearing shell and the crankshaft journal with plenty of clean lubricating oil. check in both sides of the bearing shell that the bearing shell is mounted horizontally correct. Land the lower bearing shell on the crankshaft journal.Main Bearing 905-2. use the bearing shell dismantling tool to push the lower bearing shell fully down under the crankshaft journal.4 Mounting 1. please quote Procedure M90502 Edition 0259 . Mount the handle on the lower bearing shell and slide down the lower bearing shell as far as possible. If necessary. 1. 2. 3. M905020259M02 D0505 Page 12 (15) When referring to this page. Using a caliper. M905020255M01 Remove the handle. 2.

Lubricate the upper bearing shell with plenty of clean lubricating oil. M905020259M07 D0503 When referring to this page.4 Mounting 4. Land the upper bearing shell on the crankshaft journal. Mount the bearing cap. Make sure that the edge of the upper bearing shell does not rest on the tip of the bedplate. OPERATION. Check visually that the shell does not prevent the locking screws from being fully tightened to the bedplate. 6. 6. If so. as this would cause damage to the screws and shell when tightening the bearing cap. press the shell into place. D0504 M905020259M06 7.Main Bearing MAN B&W Diesel 905-2. Make sure that the guide pin from the bedplate enters the hole in the bearing cap. 4. See also Volume I. M905020259M04 5. 7. Lower the crankshaft and remove the crosspiece and the hydraulic jacks from the engine. please quote Procedure M90502 Edition 0259 Page 13 (15) . Chapter 708.

4 Mounting MAN B&W Diesel 8. M905020259M09 1 4 If a new bearing shell has been mounted. remember to note down the new top clearance in the Adjustment Sheet in Volume I. OPERATION. please quote Procedure M90502 Edition 0259 . • rectangular washers D1301 • nuts • extension studs 2 3 1 • spacers • double hydraulic jacks 4 M905020259M08 Tighten the main bearing cap. Page 14 (15) When referring to this page. Mount the lubricating oil pipe.Main Bearing 905-2. 9. The tightening is done in the following sequence: 1) Tighten nuts 1 + 3 9. See Data. After tightening the bearing cap. Chapter 701. Mount the: 8. 2) Tighten nuts 2 + 4 3) Retighten nuts 1 + 3 Remove the hydraulic tools. 11. M905020259M11 11. 2 3 10. check the top clearance once more.

Note! M905020238M14 Search the crankcase to ensure that there are no tools. Remove all tools from the engine.4 Mounting 12. please quote Procedure M90502 Edition 0259 C Page 15 (15) . 12. shackles or rags left behind. When referring to this page.Main Bearing MAN B&W Diesel 905-2.

.

650 Nm When referring to this page. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. top cover 85 kg D05-29 Segment stopper. please quote Data D10503 Edition 0073 Page 1 (2) .Thrust Bearing MAN B&W Diesel 105-3 Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D05-06 Thrust bearing segment 11 kg D05-07 Segment stopper 44 kg D05-28 Thrust bearing. tightening torque.

g. P90951 refers to chapter 909. Plate P90551 Item No. e. 058 Feeler gauge When referring to this page. please quote Data D10503 Edition 0073 . 100 P91356 P91366 Page 2 (2) Description Tool for turning out segments Lifting Tools.Thrust Bearing 105-3 MAN B&W Diesel 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. Etc.

OPERATION. 3.1 1.1 mm is not able to enter the groove (the wear is more than 0. 2.Thrust Bearing 905-3.0 mm. For dismantling the segment stopper. When referring to this page.2 238 02 3. see Procedure 905-3.9 mm). the thrust segment has to be pressed against the thrust cam. If a feeler gauge of 0. the thrust bearing must be overhauled.e. KN905-2.1 224 02 2. (The segment with thermometers). and to inspect for white metal below the thrust bearing.0 mm. A wear groove of 1 mm is positioned in the uppermost thrust segment. To measure the wear. 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. it is necessary to dismount the foremost segment stopper. For a new engine the clearance is 0. Note down the wear for later reference.2.5-1. BM905-3. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S Page 1 (5) . i.1 Checking Thrust Bearing S35MC 0226 Checking 905-3. by using a suitable crowbar on the back of the segment.1 226 01 In service it is only necessary to measure the wear of the thrust bearing pads. and for an engine in service it must not exceed 2. GN905-3. To measure the wear in the thrust bearing. to eliminate any gap. 1.

The other stopper is to remain fitted.2 1. BM905-4. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S .0 51 02 D05-07 Page 2 (5) When referring to this page. oil pipe from the thrust segments. Screw an eye bolt into the stopper that is to be removed. 2. BM905-4.2 Dismantling Dismantling 905-3. Suspend a tackle above the stopper and hook the tackle on to the eye bolt. D05-28 1. Remove the lub.0 51 01 Remove the stopper from the engine above the thrust segments ( AHEAD or ASTERN) that are to be taken out. Loosen and remove the screws from the segment stoppers. 2. Remove the cover above the thrust bearing.Thrust Bearing 905-3.

Inspect the segment and remount it before turning up the next segment. the weight is no heavier than it is possible to lift the segment by hand.0 76 03 For turning-up the thrust segments. 4. by turning the engine. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S Page 3 (5) .Thrust Bearing 905-3. Turn up the segments one at a time. Suspend a tackle from the chain tightener bracket above the segments which are to be removed. and remove the segment from the chain casing. screw the driving pin into the thrust shaft.0 59 04 Never remove more than one segment at a time. Nevertheless. 3. When referring to this page. 4. See Procedure 905-3.4.2 Dismantling 3. BM905-5. Note! D05-06 BG905-5.

After the last segment has been mounted.2. it is possible to lift the segments by hand. BM905-3. see Procedure 905-3. Suspend a tackle above the segments which are to be mounted. 2. Turn the engine to dismantle the next segment. Land the segment on the journal and remove the eye bolt from the segment.0 76 03 Carefully slide the segment on to the driving pin. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S .4 208 02 D05-06 Page 4 (5) When referring to this page.4 Thrust Bearing Mounting Mounting 905-3. Screw the driving pin into the thrust shaft.4 1. 1. Still.905-3. 2. BM905-5. turn the driving pin up and dismount it.

4 Mounting 3. D05-07 D05-29 Note! Use only the tightening angle or the tightening torque. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S Page 5 (5) . Mount the lub.Thrust Bearing 905-3. Mount and tighten the screws which fasten the segment stopper.4 208 04 4. D05-28 BM905-3. oil pipe.0 51 02 Mount the cover above the thrust bearing. 3. Mount the segment stopper. See Data. BM905-4. 4. When referring to this page. not both.

.

Description Value Unit D05-11 Min. bearing clearance 0. bearing clearance 0. mounting 900 bar D13-02 Hydraulic pressure. please quote Data D10504 Edition 0048 Page 1 (2) . top cover 85 kg D13-01 Hydraulic pressure.20 mm D05-12 Max.990 bar When referring to this page. see 900-2 X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Journal Bearing MAN B&W Diesel 105-4 Data SAFETY PRECAUTIONS For detailed sketch. dismantling 800 .50 mm D05-13 Journal bearing cap 93 kg D05-14 Upper bearing shell 5 kg D05-15 Lower bearing shell 5 kg D05-28 Thrust bearing.

dismantling of main bearing shell P90551 88 Dismantling tool. complete P91351 105 3-way distributor block.Hydraulic Tools P90562 Lifting tool for crankshaft P90572 Main Bearing . pneumatically operated P91351 022 Hydraulic pump. e. please quote Data D10504 Edition 0048 . main bearing shell P90551 111 Lifting attachment P90561 Main Bearing . Plate Item No.g. Description P90551 52 Handle. complete P91356 P91366 Page 2 (2) Lifting Tools. 073 Dial gauge and stand tool When referring to this page.Measuring Tools P91351 010 Hydraulic pump. hand operated P91351 046 Hose with unions (1500 mm).Journal Bearing 105-4 MAN B&W Diesel 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. complete P91351 058 Hose with unions (3000 mm). Etc. P90951 refers to chapter 909.

check the clearances according to Procedure 9052. Also check the journal bearing by visually searching the area underneath the bearing support.Journal Bearing MAN B&W Diesel 1. See Procedure 9054. 905-4. Main bearings Thrust bearing M905020238D02 2. Write down the journal bearing clearances. M905040225C03 3. 2. please quote Procedure M90504 Edition 0232 Page 1 (9) .2. Aftmost main bearing (= Journal bearing) Journal bearing clearance can only be measured with the thrust bearing cover removed. When referring to this page.1 Checking Before any dismantling of journal bearing.1 1. M905040225C01 3.

shackles and wire rope on the cover. and lift the cover away. 6.Journal Bearing 905-4. 1. M905040232D05 5. M905040232D06 D1302 Page 2 (9) When referring to this page. Mount an eye bolt.2 Dismantling MAN B&W Diesel Dismantling of journal bearing in the thrust shaft end. D0528 Remove the screws from the cover placed over the thrust bearing. Assemble the main bearing hydraulic jacks on the bearing studs. M905040232D04 3. Disconnect the lubricating oil pipe used for lubricating the bearing. Connect the hydraulic pump. please quote Procedure M90504 Edition 0232 . 2. Hook on a tackle. 4.

Mount the bearing shell lifting tool and lift the bearing shell away. lift away the journal bearing cap. M905020238D02 5. please quote Procedure M90504 Edition 0232 Page 3 (9) . 4. Remove the hydraulic main bearing tools from the engine. 5. Mount the lifting tool on the journal bearing cap. M905040232D07 D0513 6. By use of the tackle mounted below the platform. M905040226D03 D0514 When referring to this page.2 Dismantling 4. Unscrew and remove the nuts from the bearing studs. For operation of the hydraulic tools. above the journal bearing. see Procedure 9131.Journal Bearing MAN B&W Diesel 905-4. 6.

Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell. 8. Place the dismantling tool on top of the lower bearing shell. Never use a tackle larger than 0. 7.2 Journal Bearing Dismantling 7.905-4. Note! While pulling out the shell. Mount a dial gauge to measure the lift of the crankshaft. M905040225D08 10. please quote Procedure M90504 Edition 0232 . by using the lifting tool. Tighten the screw against the turning wheel and compress the jacks. to tighten it up and to observe whether the shell is sticking. and raise the pressure until the crankshaft has been lifted 0. Connect the hydraulic jacks to the highpressure pump. M905040226D03 D0514 Page 4 (9) When referring to this page. Dismount the locking screws.5 mm M905040232D08 8. it is recommended to hold a foot or hand on the wire rope.20. 9.5 tonne. 9. Pull the lower shell around and up until it lies over the bearing journal. Take the lower shell out of the engine in the same way as the upper shell. MAN B&W Diesel Place the crosspiece under the turning wheel as shown.

Journal Bearing MAN B&W Diesel 1. it is recommended to contact MAN B&W Diesel A/S or the engine builder. Before remounting: M905040232O01 See Instruction book. When referring to this page. use nonfluffy cloth to clean between journal and bearing support. If damage is found. with main engine lubricating oil. • Make sure that all parts are clean. 2. please quote Procedure M90504 Edition 0232 Page 5 (9) . Volume I. + 2. • Check the bearing support for damage and burrs. this requires a careful evaluation of the condition of the shell that is to be reinstalled. Chapter 708. If it is nevertheless desired to replace only one shell. • Lubricate the bearing journal. 905-4.3 Overhaul Clean and inspect the bearing shells. 1. It is recommended that the main bearing shells be replaced in pairs. contact MAN B&W Diesel for advice. For advice on replacing individual bearing shells. the bearing support and the back of the shell.

please quote Procedure M90504 Edition 0232 . 1. M905040232M02 Wipe the contact surfaces between the upper and the lower bearing shells clean with a nonfluffy piece of cloth. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below the turning wheel. Lubricate the journal. Page 6 (9) When referring to this page. check that the distance from the bearing support to the shell is equal in both sides. 2.4 Journal Bearing Mounting 1. Push the shell down by hand. lift the lower bearing shell to above the crankshaft journal. M905040232M03 3. Place the lower bearing shell on the journal and remove the lifting tool from the bearing shell. M905020255M01 2.905-4. Mount the locking screws in the bearing support. the lower bearing shell and the bearing support with clean oil. 3. MAN B&W Diesel Using the bearing shell lifting tool and tackles. To ensure that the shell is correctly mounted.

lift the bearing cap back in reverse order to dismantling. Mount the lifting tool on the bearing cap. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. M905040232M04 If necessary.4 Mounting 4. M905040232M05 D0513 M905020238M09 6. 5. Land the upper bearing shell on the journal in the same way as the lower bearing shell. place the special tool between the studs and press the shell into place. Make sure that no oil is left on the contact surfaces.Journal Bearing MAN B&W Diesel 905-4. Using the tackles and wire ropes on the main bearing cap lifting tool. please quote Procedure M90504 Edition 0232 Page 7 (9) . 4. 5. When referring to this page. Note! Be sure that the cap lands correctly and that the guide pin in the assembly surface enters the hole in the bearing cap. 6.

M905040232M08 D1301 Page 8 (9) When referring to this page. Assemble the main bearing hydraulic jacks on the bearing studs. 7. please quote Procedure M90504 Edition 0232 . tighten the nuts on both sides of the bearing cap. M905020238M15 For tightening pressure.4 Mounting 7. Connect the hydraulic pump. For operation of the hydraulic tools. see Data. 8.Journal Bearing 905-4. Using a tommy bar. see Procedure 9131. 8. Screw the nuts on to the main bearing studs. MAN B&W Diesel Remove the bearing cap lifting tool.

Before removing the hydraulic jacks. Mount the lubricating oil pipe on the bearing cap. Note! 10. check the top clearance between the upper bearing shell and the journal.Journal Bearing MAN B&W Diesel 9. and mount the thrust bearing cover. please quote Procedure M90504 Edition 0232 Page 9 (9) . shackles or rags left behind. M905040232M09 Search the crankcase to ensure that there are no tools. M905040232M10 D0528 When referring to this page.4 Mounting Note! 9. 905-4. Remove all tools from the engine. D0511 D0512 10.

.

tightening torque 50 Nm D05-21 Outer screws. Description Value Unit D05-17 Inner screws.Axial Vibration Damper MAN B&W Diesel 105-5 Data SAFETY PRECAUTIONS For detailed sketch. tightening torque 400 Nm D05-23 Horizontal screws. upper part 65 kg When referring to this page. tightening torque 120 Nm D05-25 Damper housing. please quote Data D10505 Edition 0059 Page 1 (2) . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

e. 111 Description Lifting attachment P90564 Crankshaft .Axial Vibration Damper 105-5 MAN B&W Diesel 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. please quote Data D10505 Edition 0059 . P91359 Torque Spanners Page 2 (2) When referring to this page. P90951 refers to chapter 909. Etc.g.Measuring Tools P91356 Lifting Tools. Plate P90551 Item No.

without angle encoder fore C: Mechanical. KM905-7. The probe is connected to a control unit which displays peak-to-peak movements and sends signals to the engine control system. Chapter 701. the checking procedure describes three different systems: A: Electronic.2. with Axial Vibration Monitor B. For checking the effectiveness of the axial vibration damper. Chapter 701. it is necessary to measure the longitudinal movements of the fore end of the crankshaft during running. Operation. Concerning overhaul and setting of the electronic device.1 Checking Axial Vibration Damper S35MC 0226 Checking 905-5. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S Page 1 (8) . it is necessary to overhaul the axial vibration damper.1 1. A proximeter probe is built on to the lower part of the damper housing. with Axial Vibration Monitor 1. refer to makers instructions and Volume I. see Procedure 905-5. Operation.1 35 01 A: Electronic.) As different equipment can have been mounted on the specific engines. If the peak-to-peak value exceeds the Normal Service Value. 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. (Preferably 90% and 100% of MCR. When referring to this page. with angle encoder fore.Axial Vibration Damper 905-5. The measurement (or reading) should be taken at the same r/min as during the sea trials. Mechanical.

Attach a pencil to the arm. Note! BG905-5. Screw the measuring arm into the small threaded hole beside the centre hole. Unscrew the two plugs from the cover at the front of the engine. using the handle. the tip of the pencil should protrude 10 mm from the end of the arm. so that the arm is perpendicular to the shaft piece. Stop the engine. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S .1 Axial Vibration Damper Checking 1.1 223 02B To obtain a correct measurement. 2. 2. dismount the handle. Tighten the lock nut.1 223 01B After tightening the shaft.905-5. without angle encoder fore 1. B: Mechanical. Page 2 (8) When referring to this page. BG905-5. Mount the shaft piece in the end of the crankshaft.

it is necessary to compensate for the ratio in the tool. When referring to this page. stated in Volume I. Chapter 701. Start the engine. Before comparing the measured value (S2) with the Normal Service Value (S1). DM905-7. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S Page 3 (8) . it is necessary to overhaul the axial vibration damper. and let the speed rise to the number of revolutions at which the measurement is to be taken. 4.3. 3.2.) S-2 To ensure a certain inertia. The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. 1-2 kg. S1 can be calculated as follows: L2 If the peak-to-peak value exceeds the Normal Service Value.1 Checking 3.1 74 05 When measuring. the backing plate should have a mass of approx.Axial Vibration Damper 905-5. 4. Therefore. the ratio is 5. (Preferably 90% and 100% of MCR. Operation. lightly downwards against the tip of the pencil. S1 can be calculated as follows: L1 S2 M90505-0229C10 If a non-standard tool is used. press the measuring arm against the shaft piece with the one hand. move a sheet/block of paper. S1 For a standard measuring tool (L 1 = 38 mm and L 2 = 200 mm). see Procedure 905-5. With the other hand. clipped on to a solid backing plate.

BG905-5. 1. Dismount the cover on the angle encoder housing.1 214 05 2.905-5.1 Axial Vibration Damper Checking 1. using the screws from the cover. a measuring tool is available for mounting on the angle encoder housing. C: Mechanical. Dismount the protection shield over the angle encoder. with angle encoder fore For engines with angle encoder fore. 2. Stop the engine. the tip of the pencil should protrude 10 mm from the end of the arm. MN905-5.1 223 01C Note! To obtain a correct measurement. Page 4 (8) When referring to this page. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S . Apply some Molycote TM on the fore side of the shaft cam. Mount the axial vibration measuring tool. (Not always on engine).

S1 can be calculated as follows: When referring to this page. With the other hand. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S Page 5 (8) . and let the speed rise to the number of revolutions at which the measurement is to be taken. see Procedure 905-5. the ratio is 5.1 212 07 If a non-standard tool is used. stated in Volume I. PULL The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. clipped onto a solid backing plate. BG905-5.2. S1 can be calculated as follows: If the peak-to-peak value exceeds the Normal Service Value.1 Checking 3. pull the measuring arm against the shaft cam with one hand. the backing plate should have a mass of approx. lightly sidewards against the tip of the pencil. it is necessary to compensate for the ratio in the tool. Before comparing the measured value (S2) with the Normal Service Value (S1). MA905-5. it is necessary to overhaul the axial vibration damper. 3. Chapter 701. move a sheet/block of paper.1 223 03 To ensure a certain inertia. Start the engine. Therefore. For a standard measuring tool (L 1 = 35 mm and L 2 = 178 mm). (Preferably 90% and 100% of MCR.) S2 When measuring. 1-2 kg.1. 4.Axial Vibration Damper 905-5. 4. Operation.

2 216 03 D05-25 Page 6 (8) When referring to this page. 3.5.2 1. No. 1. By means of a tackle. Mount the lifting bracket and a shackle on the upper part. Note! BG905-7. mounted below the foreend platform. Dismantling of the axial vibration damper is carried out from the crankcase of cyl.g. while the lower half remains mounted on the bedplate.5. 2. Dismount the plug screw above the axial vibration damper.905. on the fore end of the frame box. Dismount the lubricating oil pipes for the main bearing and axial vibration damper. 3. e. a wire rope or another tackle. BG905-5. and a wire rope. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S . 2. secure the upper part with. Loosen and remove the screws from the damper housing upper part. separate and raise the upper part of the damper housing to a position in which it is possible to change the oil seals and springs.2 28 02 Before starting work below the suspended upper part.2 Axial Vibration Damper Dismantling Dismantling 905.2 28 01 Only the upper part of the housing needs to be removed. Turn the engine to 90º after TDC. BG905-7. 1.

Note! When mounting the new oil sealing rings. The lower half of the oil sealing rings will protrude above the centreline.2 201 01 It is recommended to discard both the springs and the oil sealing rings. 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. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S Page 7 (8) . Remove the oil sealing rings.3 Overhaul Overhaul 905-5. Now hook the new tension springs into place. Then press the tension springs into the groove between the oil sealing ring half and the housing. 2. ensuring that they are centralised in the grooves of the oil sealing rings. 1.2 201 02 Note! When referring to this page.Axial Vibration Damper 905-5. Dismantle and remove the springs from the oil sealing rings. first insert the lower half of the rings in the lower housing. 2. HG905-5. HG905-5.3 1.

Mount the vertical and horizontal screws. See Data.905-5. Mount the plug screw on the fore end of the frame box. shackles or rags left behind. please quote Procedure M90505 Edition 0226 MAN B&W Diesel A/S . BG905-7. Before landing the upper part on the lower part. D05-25 When reaching the oil sealing rings. it is recommended to check the axial vibrations.2 28 06 D05-23 Page 8 (8) When referring to this page. 2. take care that the rings enter the sealing ring grooves correctly. See Procedure 905-3. Note! BG905-5.4 1. 1. Tighten the screws. Mount the lubricating oil pipes.4 Axial Vibration Damper Mounting Mounting 905-5. be sure that the guide pins have entered the guide pin holes. 2. Release and carefully lower the upper part of the damper housing.1. D05-17 D05-21 Note! After overhaul of the axial vibration damper.4 223 01 Search the crankcase to ensure that there are no tools.

Main Bearing. Main Bearing. Etc.. Thrust Shaft. please quote Plate P90551 Edition 0198 MAN B&W Diesel A/S Page 1 (2) . Panel 0198 P90551 When referring to this page.Crankshaft. Thrust Shaft. Panel Plate P90551-0198 Crankshaft.. Etc.

. Thrust Shaft. Panel Item Description Item No.Plate P90551-0198 Item No. Main Bearing. 015 027 052 076 088 090 100 111 123 135 Crankshaft. Item Description Panel for tools Name plate Handle for dimantling of main bearing shell Lifting tool for main bearing cap Dismantling tool for main bearing shell Mounting tool for thin bearing shell Tool for turning out segment Lifting tool for axial damper Retaining tool for main bearing shell Lifting tool for relief valve Page 2 (2) When referring to this page. please quote Plate P90551 Edition 0198 MAN B&W Diesel A/S . Etc.

Hydraulic Tools When referring to this page. please quote Plate P90561 Edition 0087 MAN B&W Diesel A/S Plate P90561-0087 Page 1 (2) .Main Bearing .

complete When referring to this page. lower. complete Hydraulic jack. upper.Plate P90561-0087 Item No. complete Support Extension stud Tommy bar Spanner Stud setter O-ring with back-up ring O-ring with back-up ring Hydraulic toolset. please quote Plate P90561 Edition 0087 MAN B&W Diesel A/S . 021 033 045 057 069 070 082 094 104 200 Page 2 (2) Main Bearing .Hydraulic Tools Item Description Item No. Item Description Hydraulic jack.

please quote Plate P90562 Edition 0124 MAN B&W Diesel A/S Page 1 (2) .Tools 0124 P90562 When referring to this page.Crankshaft .Tools Plate P90562-0124 Crankshaft .

015 027 039 Crankshaft . please quote Plate P90562 Edition 0124 MAN B&W Diesel A/S .Plate P90562-0124 Item No. Item Description Support Screw with special head Nut Page 2 (2) When referring to this page.Tools Item Description Item No.

Measuring Tools 0020 P90564 Flange on end of crankshaft Flange on end cover fore Z When ordering item 016 or 028.Crankshaft .Measuring Tools Plate P90564-0020 Crankshaft . please quote Plate P90564 Edition 0020 MAN B&W Diesel A/S Page 1 (2) . please always state measurement “Z” When referring to this page.

Plate P90564-0020 Item No. axial vibration damper Handle .sundry types Page 2 (2) When referring to this page. measuring instruments axial vibration Measuring instruments. Item Description Measuring instruments. axial vibration damper Shaft.Measuring Tools Item Description Item No. 016 028 041 053 Crankshaft . please quote Plate P90564 Edition 0020 MAN B&W Diesel A/S .

Measuring Tools 0003 P90572 When referring to this page.Measuring Tools Plate P90572-0003 Main Bearing .Main Bearing . please quote Plate P90572 Edition 0003 MAN B&W Diesel A/S Page 1 (2) .

Item Description Measuring tool main bearing clearence Calibration tool Key. please quote Plate P90572 Edition 0003 MAN B&W Diesel A/S .Plate P90572-0003 Item No. 010 021 045 057 Main Bearing . hexagon socket screws Wooden box Page 2 (2) When referring to this page.Measuring Tools Item Description Item No.

Control Gear Documents in this Chapter 106-01 906-01 106-02 906-02 106-03 906-03 106-04 906-04 106-06 906-06 90651 90664 90668 0055 0243 0064 0228 0040 0217 0042 0225 0009 0203 0181 0003 0006 Chain. Data Chain Tightener Camshaft.Panel Crankshaft . Data Camshaft Bearings Replacement of Cams on Camshaft.Pin Gauge Camshaft . Data Replacement of Cams on Camshaft Chain Drive and Camshaft .906 . Data Camshaft Camshaft Bearing. Data Chain Chain Tightener.Pin Gauge MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Description Value Unit 3” chain D06-18 Teeth on chain wheel.5 mm When referring to this page.Chains MAN B&W Diesel 106-1 Data SAFETY PRECAUTIONS For detailed sketch. wear 2. please quote Data D10601 Edition 0055 Page 1 (2) .5 mm D06-19 Original length (chain pitch x 10 links) 762 mm D06-20 10 links measurements + 1% of a tensioned chain = scrapping of chain 769. max. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

Chains 106-1 MAN B&W Diesel 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.Panel When referring to this page. P90951 refers to chapter 909. Plate P90651 Page 2 (2) Item No. please quote Data D10601 Edition 0055 . Description Chain Drive and Camshaft .g.

The engine is equipped with a drive chain for the camshaft. if necessary. • Examine the rubber track of the guideways for cracks or other damage. When referring to this page. take a measurement (See Data). The chain can be accessed from within the chainwheel frame. 4. dismantled and mounted in the same way. please quote Procedure M90601 Edition 0243 D0618 A Page 1 (5) . The chain is to be checked and. and check jet nozzles for possible stoppages or deformations. Carry out the inspection as follows: 4. B M906010243C02 Measurements are best taken by placing a short straight-edge over points A and B and then measuring the distance D06-18. M906010243C01 3. Check the teeth of the chain wheels. • Make a general inspection for loose bolts and screws.Chains MAN B&W Diesel 906-1. • Replace the guideway if bits have started to be “plucked out” of the rubber track. • Inspect lube oil pipes for damage. If abnormal wear is found. 2.1 Checking 1. 1.

month. possible 3rd chain) No. It is recommended that each single link is checked. 1 order. make a drawing in scale 1:1 of the teeth and wear profile. however. The chains for the camshaft drive are matched together to ensure an even load distribution. For assessing the wear profile. contact MAN B&W Diesel. possible 3rd chain) On the same links there is an arrow (–>) which indicates the mounting direction.906-1. These fine scratches are of no importance and need not be considered. MAN B&W Diesel 5. M906010238C05 In most cases. 840520 2A 840520 2B (840520 2C. 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). 840520 1A 840520 1B (840520 2C. Such scratches can generally be considered normal. circumferential scratches during the running-in period. scratches caused by the side plates of the chain will be found on the sides of the teeth. Check the chains for cracks on possibly defective rollers and side plates. the side plates of the outer link nearest to the assembled link have been marked with year. day and chain number. It is normal. If abnormal wear is observed at the bottom of the teeth. Page 2 (5) When referring to this page.1 Chains Checking 5. 6. please quote Procedure M90601 Edition 0243 . To keep such matching chains in their pairs. Example: No. that the rollers get light. 2 order.

3.D D0619 D0620 When referring to this page. Use two master squares and a steel measuring tape as shown on the sketch.Chains MAN B&W Diesel 906-1.1 Checking 7. 7. Check chain wear by measuring the length of 10 chain links. adjust the chain tightener. If necessary. See Procedure 906-2. Compare the result with the value given in Data. please quote Procedure M90601 Edition 0243 Page 3 (5) . Ma M906010243C07 20 06 x.

M906010238D03 3. (See Procedure 906-2. Remove the tension on the chain by loosening the chain tightener. Page 4 (5) When referring to this page. Note! M906010243C01 Every time a chain link is disassembled. is in a favourable position for the work.906-1.3). Place the chain bursting tool over the outer chain link. and tighten the wire lightly with a tackle. 1. Turn the engine until the slack part of the chain.1. When a new link is fitted in one chain. 3. for instance. See Procedure 906-1. a new link must always be fitted as the link pin press-fit is destroyed when breaking the chain. 2. M906010238D02 2. and dismantle the link by alternately tightening the screws on the tool. with the chain link that is to be disassembled. please quote Procedure M90601 Edition 0243 .2 Chains Dismantling 1. cracked rollers or seizures between pin and bushing have been discovered during the inspection. MAN B&W Diesel It may become necessary to disassemble the chain if. Protect the link rollers over which the wire is wrapped. contact MAN B&W Diesel for further information. The riveting of the pins that are to be pressed out is to be chiselled or ground away. Note! If the chain is to be completely removed. the corresponding link in the other chain must also be renewed. Mount a wire round the link rollers a short distance from the disassembly point.

clean the pins and bushings. When referring to this page. M906010238M01 2. When the link has been assembled. remove the compression tool and lock the pin ends by riveting. Remove the tackle and wire and adjust the chain tension. Repeat this procedure until the chain has been assembled.Chains MAN B&W Diesel 906-1. Combine the inner chain link with the outer chain link and mount the compression tool. 1.4 Mounting Before assembling the inner and outer links. (See Data and Procedure 906-2. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool.3). please quote Procedure M90601 Edition 0243 Page 5 (5) . 1.

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1 mm When referring to this page. Description Value Unit D06-21 Tightening angle = 12 hexagons 720 ° D06-25 Mechanical or blocked chain tightener. clearance 0. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Chain Tightener MAN B&W Diesel 106-2 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10602 Edition 0064 Page 1 (2) .

Plate P91366 Page 2 (2) Item No.Chain Tightener 106-2 MAN B&W Diesel 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. 058 Description Feeler gauge When referring to this page. please quote Data D10602 Edition 0064 .g. P90951 refers to chapter 909. e.

1. continue turning until the flyweights are hanging vertically downwards. see Procedure 906-1.Chain Tightener 906-2.1. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D06-25. C and D to free the chain tightener bolt. 2. A B 2.3 218 03 D06-21 When referring to this page. loosen nuts A.2 95 01 For chain wear.3 218 01 3. To retighten the chains. If the engine is equipped with flyweights.3 1. C D HG906-2. B. Turn the engine so that the slack part of the chains is on the same side as the tightener wheel. HM906-2. Then tighten nut B as stated in D06-21 (see Data).3 Adjustment Chain Tightener S42MC 0228 Adjustment 906-2. please quote Procedure M90602 Edition 0228 MAN B&W Diesel A/S Page 1 (2) . B D06-25 HG906-2. 3.

Tighten nut C hard against the contact face of the shaft. 4.3 218 05 A Page 2 (2) When referring to this page. Lock nuts C and D with the tab washer. 5.906-2. Tighten nut A. 5. HG906-2. See Data page 106-1. Lock nuts A and B with the tab washer.3 Chain Tightener Adjustment 4. Tighten nut D.3 218 05 D The number of times that retightening can be carried out depends on when the limit for scrapping the chain has been reached. please quote Procedure M90602 Edition 0228 MAN B&W Diesel A/S . C HG906-2.

check measurement When referring to this page.1 Pin gauge for camshaft.2 355 238 ° mm mm mm Page 1 (2) . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. permissible change in lead angle corresponding to Pin gauge for top dead centre of crankthrow No. D06-27 D06-28 D06-29 D06-30 Description Max.Camshaft MAN B&W Diesel 106-3 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10603 Edition 0040 Value Unit 2 2.

please quote Data D10603 Edition 0040 .Camshaft 106-3 MAN B&W Diesel 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. Plate Item No.Pin Gauge Page 2 (2) When referring to this page. P90951 refers to chapter 909. e.g.Pin Gauge P90668 Camshaft . Description P90664 Crankshaft .

adjust the chain tension.1 Checking Camshaft K98MC 0227 Checking 906-3.1 1. M90603-0217C02 2.Camshaft 906-3. When referring to this page. Turn the crankthrow for cylinder 1 to TDC.0 56 01 1. If necessary. Check the TDC position with the pin gauge on the crankthrow. See Procedure 906-2. 2.3. please quote Procedure M90603 Edition 0227 MAN B&W Diesel A/S Page 1 (3) . Check the TDC of cylinder 1 against the mark on the turning wheel. D06-29. HM906-7. Turn in the AHEAD direction to ensure that the tension of the chain on the chain drive is correct.

D06-30 NA906-3. remove them by carefully polishing the cam in the direction of rotation with a fine carborundum stone.1. in lead angle. adjust the cylinder lubricator. Such light scratches can appear if the roller guide and the cam are not correctly aligned. In the event of heavier scratches or direct flaking of the material on the running path. 4. Check the setting of the starting air distributor. and measure the deviation. If light scratches are ascertained. See Procedure 907-1. see D06-27 and D06-28.1 and 903-2.1 207 05 6.Camshaft 906-3. also check the running surface of the cams. MAN B&W Diesel should be contacted for further instructions.1 Checking 3. As the inspection must include the entire surface of the cam. Page 2 (3) When referring to this page. See Procedure 903-2. When checking the camshaft position. if necessary. 5. Position the camshaft pin gauge in the centre punch mark. please quote Procedure M90603 Edition 0227 MAN B&W Diesel A/S .1 207 03 D06-27 D06-28 5. 3. if any.3. permissible change. GN906-3. For max.1 203 06 6. NA906-3. Check and. the cam should be turned one complete revolution during the inspection. The running surface of the cam must be completely smooth and bright.

MAN B&W Diesel should be contacted for further instructions.Camshaft 906-3. When referring to this page.3 Adjustment Adjustment 906-3. 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 stated in Data.3 207 01 1.3 1. NA906-3. please quote Procedure M90603 Edition 0227 MAN B&W Diesel A/S D06-27 D06-28 Page 3 (3) .

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Description Value Unit D06-31 Screws for bearing cap. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. tightening torque 50 Nm D06-33 Clearance between cap/bearing housing 3±0.34 kg mm Page 1 (2) . minimum thickness When referring to this page.3 mm D06-34 Bearing shell. max.Camshaft Bearings MAN B&W Diesel 106-4 Data SAFETY PRECAUTIONS For detailed sketch. wear 0.1 mm D06-37 Camshaft bearing cap D06-65 Bearing shell. please quote Data D10604 Edition 0042 4 5.

P91359 P91366 Page 2 (2) Description Torque Spanners 073 Dial gauge and stand tool When referring to this page.Camshaft Bearings 106-4 MAN B&W Diesel 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. Plate Item No. please quote Data D10604 Edition 0042 . P90951 refers to chapter 909.g.

it is no longer necessary to measure the top clearance of the camshaft bearing. 906-4. In the event of any signs of anomalies. it is recommended also to check the condition of the fuel and exhaust cams. please quote Procedure M90604 Edition 0225 Page 1 (5) .Camshaft Bearing MAN B&W Diesel 1. If no anomalies are found during the visual inspection.1 Checking As the upper shell of the camshaft bearing assembly has been dispensed with on this engine. if necessary. 1. Dismount the inspection covers from the front of the camshaft housing. See Procedures 9085 and 9093. the bearing shell must be dismantled for closer investigation and. M906040225C01 Check for wipedout metal at the bearing ends. and for fragments of metal in the camshaft housing. dismantling need not be carried out. When checking the camshaft bearings. the bearing shell must be replaced. When referring to this page.

Remove the bearing cap from the housing. M906040225D02 D0637 Page 2 (5) When referring to this page.2 Camshaft Bearing Dismantling MAN B&W Diesel Warning! 1. 2. See Procedure 9062. Before dismantling any camshaft bearings. 1. M906040225D01 Dismount the lubricating oil connecting pipe and the plug screws from the baseplate above the bearing in question. Loosen the bearing cap screws through the holes in the baseplate.3. 2. please quote Procedure M90604 Edition 0225 . the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts. Remove the screws from the bearing cap.906-4. Lift the roller guide of the exhaust valve actuator. See Procedure 9087. Remove the inspection covers on each side of the bearing from the camshaft housing.

2 Dismantling 3. Press lightly on the upper edge of the shell to turn the shell up over the camshaft. 4. M906040225D04 4. Max. 20/100 mm Place a dial gauge on the camshaft. please quote Procedure M90604 Edition 0225 Page 3 (5) . Place a hydraulic jack between two pieces of wood in the camshaft housing underneath the camshaft. M906040225D03 Remove the shell from the camshaft housing.Camshaft Bearing MAN B&W Diesel 906-4. 3.20 mm. close to the bearing. and lift the camshaft 0. When referring to this page.

Measure the thickness of the bearing shell with a micrometer to check the amount of wear. Normally. polish the surface with a fine carborundum stone to reestablish a bright and smooth surface. 1. M906040225O01 Inspect the entire surface of the bearing journal for seizures. see Volume I OPERATION.3 Camshaft Bearing Overhaul 1. camshaft bearing damage only occurs due to faulty lubrication. D0634 D0665 If seizures are found on the bearing journal surface (on account of bearing breakdown). 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. Chapter 708 ‘Bearings’. MAN B&W Diesel For assessment of the bearing condition. please quote Procedure M90604 Edition 0225 .906-4. Page 4 (5) When referring to this page.

Remove the dial gauge. please quote Procedure M90604 Edition 0225 Page 5 (5) . D0633 M906040225M02 Check the torque on the outermost screw with a torque spanner. 2. See Procedure 908-7. M906040225M03 5. Then mount the lubricating oil pipe and the plug screws in the baseplate. Check the clearance D0633 on both sides of the camshaft. Clean the camshaft housing and mount the inspection covers. When referring to this page. D0631 3. Place the bearing cap on the camshaft and mount the outermost bearing cap screw. the pieces of wood and the hydraulic jack from the camshaft housing. Tighten the outermost screw lightly by hand until the clearance given in D0633 is reached. 2. Note! Be careful not to scratch the camshaft surface. This procedure ensures that the outermost screw will obtain the correct torque. M906040225M01 Relieve the hydraulic jack of pressure to lower the camshaft. 4.Camshaft Bearing MAN B&W Diesel 1. Lower the exhaust valve actuator roller guide. See Data D0631. Mount the shell on the camshaft. Coat the bearing journal and the bearing shell with plenty of lubricating oil. 906-4. Then mount and tighten the innermost screw with a torque spanner. the bearing support and the bearing shell. 1.4 Mounting Clean the bearing journal. 3. and turn it into place.

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Description Value Unit D06-47 Exhaust cam screws.Replacement of Cams on Camshaft MAN B&W Diesel 106-6 Data SAFETY PRECAUTIONS For detailed sketch. tightening torque 120 Nm D06-49 Fuel Cam screws. tightening torque 120 Nm D06-50 Fuel cam. axial movement 70 mm D06-52 Exhaust cam. marking scratch 40 mm D06-51 Fuel cam. axial movement 95 mm When referring to this page. please quote Data D10606 Edition 0009 Page 1 (2) . marking scratch 40 mm D06-53 Exhaust cam. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

complete P91351 058 Hose with unions (3000 mm). Plate Item No. Cu ø11x3 mm P91351 237 Bleeder screw P91351 249 Disc. round-plain. Cu ø11x9 mm P91359 P91366 Page 2 (2) Torque Spanners 073 Dial gauge and stand tool When referring to this page. male P91351 213 Quick coupling. round-plain. please quote Data D10606 Edition 0009 . complete P91351 166 Angle union P91351 201 Quick coupling. Description P90851 173 Lifting tool for exhaust valve roller guide P90951 082 Lifting tool for fuel pump roller guide P91351 022 Hydraulic pump. e. female P91351 225 Disc.Replacement of cams on Camshaft 106-6 MAN B&W Diesel 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. P90951 refers to chapter 909.g. complete P91351 105 3-way distributor block. hand operated P91351 046 Hose with unions (1500 mm).

XZ906-6.2 1. See Procedures 908-5 or 909-5.Replacement of Cams on Camshaft 906-6. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 D06-50 Page 1 (7) . Lift the roller guide from the cam in question.2 201 02 2. See Data. Turn the camshaft so that the marking scratch can be seen.2 201 04 4.2 Dismantling Replacement of Cams on Camshaft S42MC 0203 Dismantling 906-6. 3. When referring to this page.2 201 01 4. Extend the marking scratch on the shaft by D06-50. Remove the front cover of the camshaft housing. 2. XZ906-6. Fuel Cam 1. XZ906-6.

2 201 05 7. in the direction towards the forward end of the engine. When oil seeps out along the cam. XZ906-6.Replacement of Cams on Camshaft 906-6. using the high-pressure pump. press the cam sideways. The cam should be moved as stated in D06-51 to be sure that it gets free of the liner for the roller guide. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 . XZ906-6. 5. 7. Apply oil pressure to the cam. 8. XZ906-6. Connect the snap-on connectors to the hydraulic high-pressure pump.2 201 07 D06-51 Page 2 (7) D06-51 When referring to this page. In case the cam cannot be moved as described in item 6. MAN B&W should be contacted for further instructions.2 Dismantling 5.2 201 06 6. Remove the plug from the cam and mount gaskets and snap-on connectors instead. 6.

Extend the marking scratch on the indicator drive cam onto the camshaft. Exhaust Cam 9. XZ906-6. See Data. Remove the front cover of the camshaft housing. See Procedure 908-5. Extend the marking scratch on the exhaust cam onto the camshaft by D06-52. Lift the roller guide from the cam in question. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 D06-52 Page 3 (7) . 10. XZ906-6. When referring to this page. XZ906-6.2 201 11 11.2 201 01 11.Replacement of Cams on Camshaft 906-6.2 201 10 10.2 Dismantling 9.

2 201 14 14. press the cam sideways. XZ906-6. in the direction towards the aft end of the engine.2 Replacement of Cams on Camshaft Dismantling 12. Apply oil pressure to the cam.2 201 13 13. 12. Connect the snap-on connectors to the hydraulic high-pressure pump. XZ906-6. XZ906-6. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 . using the high-pressure pump. Remove the plug from the cam and mount gaskets and snap-on connectors instead.2 201 12 When oil seeps out along the cam. 13. 14. Page 4 (7) When referring to this page.906-6. Dismantle and remove the indicator drive cam from the camshaft when fitted.

2 201 15 D06-53 When referring to this page. 16. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 D06-53 Page 5 (7) . In the event that the cam cannot be moved as described in item 14. MAN B&W should be contacted for further instructions. 15.2 Dismantling 15. XZ906-6.Replacement of Cams on Camshaft 906-6. The cam should be moved as stated in D06-53 to be sure that it gets free of the liner for the roller guide.

4 Replacement of Cams on Camshaft Mounting Mounting 906-6. Make sure that the marking scratches on the cam and the camshaft coincide. Lock the screws with Loctite. so that the gap between the two parts is equal at both sides. 3. Fuel Cam 1. Tighten the screws just hard enough to avoid that the cam slips when the roller guide is lowered onto the cam. the bore and the area on the shaft must be degreased.906-6. mount the four screws. Place the two-part spare cam on the shaft.4 201 01 Measure the fuel cam lead (see Procedures 909-1 and 909-2) and adjust if necessary. and that the running surface of the cam is opposite the roller. XZ906-6. Tighten the screws to D06-49 and check that the gap is still equal at both sides. and tighten slightly. Mount the cover on the front of the camshaft housing. type 242 (EN243S). 2. 2. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 . XZ906-6. Before mounting the two-part spare cam.4 1.4 201 02 D06-49 Page 6 (7) When referring to this page.

4 201 04 5. so that the gap between the two parts is equal at both sides. the bore and the area on the shaft must be degreased. please quote Procedure M90606 Edition 0203 0$1% :'LHVHO$6 Page 7 (7) . Place the two-part spare cam on the shaft. Make sure that the marking scratches on the cam and the camshaft coincide. Mount the cover on the front of the camshaft housing. Lock the screws with Loctite. and tighten slightly. Exhaust Cam 4. Mount the indicator drive cam and adjust according to Chapter 706 in the Operation manual when fitted. 6.4 201 05 Measure the fuel cam lead (see Procedure 908-7) and adjust if necessary. XZ906-6. and that the running surface of the cam is opposite the roller. XZ906-6. 5. Tighten the screws to D06-47 and check that the gap is still equal at both sides.4 201 06 6. mount the four screws. Tighten the self-locking nuts as stated in D06-48.Replacement of Cams on Camshaft 906-6. XZ906-6.4 Mounting 4. Before mounting the two-part spare cam. Tighten the screws just hard enough to avoid that the cam slips when the roller guide is lowered onto the cam. D06-47 D06-49 When referring to this page. 7. type 242 (EN243S).

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please quote Plate P90651 Edition 0181 MAN B&W Diesel A/S Page 1 (2) .Chain Drive and Camshaft Panel Plate P90651-0181 Chain Drive and Camshaft Panel 0181 P90651 When referring to this page.

please quote Plate P90651 Edition 0181 MAN B&W Diesel A/S .coupling Page 2 (2) When referring to this page. 019 020 044 056 068 140 Chain Drive and Camshaft Panel Item Description Item No.Plate P90651-0181 Item No. fuel cam Chain assembling tool Chain disassembling tool Hydraulic tool . Item Description Tool panel Name plate Face impact wrench.

please quote Plate P90664 Edition 0003 MAN B&W Diesel A/S Page 1 (2) .Pin Gauge Plate P90664-0003 Crankshaft .Pin Gauge 0003 P90664 When referring to this page.Crankshaft .

Plate P90664-0003 Item No. 010 Crankshaft . Item Description Pin gauge for crankshaft Page 2 (2) When referring to this page. please quote Plate P90664 Edition 0003 MAN B&W Diesel A/S .Pin Gauge Item Description Item No.

Camshaft .Pin Gauge Plate P90668-0006 Camshaft . please quote Plate P90668 Edition 0006 MAN B&W Diesel A/S Page 1 (2) .Pin Gauge 0006 P90668 When referring to this page.

please quote Plate P90668 Edition 0006 MAN B&W Diesel A/S .Plate P90668-0006 Item No. 011 Camshaft .Pin Gauge Item Description Item No. Item Description Pin gauge for camshaft Page 2 (2) When referring to this page.

Starting Air System Documents in this Chapter 107-01 907-01 107-02 907-02 0021 0220 0044 0213 Starting Air Distributor. Data Starting Air Distributor Start Air Valve. Data Starting Air Valve MAN B&W Diesel A/S .907 .

MAN B&W Diesel A/S .

tightening torque D07-03 Value Unit 25 Nm Clearance between gear wheel and bushing: 0.6 mm D07-04 Clearance with roller in outermost position: 1.Starting Air Distributor MAN B&W Diesel 107-1 Data SAFETY PRECAUTIONS For detailed sketch. Description D07-01 Gear wheel on camshaft.9 . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.0 .1.0 mm D07-05 Clearance with roller in innermost position: 1.3.2.0 mm When referring to this page.0 . please quote Data D10701 Edition 0021 Page 1 (2) .

Description When referring to this page.Starting Air Distributor 107-1 MAN B&W Diesel 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. Plate Page 2 (2) Item No. P90951 refers to chapter 909.g. please quote Data D10701 Edition 0021 . e.

3. i. 1. if the slot is not aligned with the hole in the distributor housing. Remove the plug screw and gasket from the side of the distributor housing. 1 to TDC. If the check pin cannot enter the slot. 2. S M907010220C02 K When referring to this page. See Procedure 907-1. the air distributor must be adjusted.e.Starting Air Distributor MAN B&W Diesel 907-1.3. Turn the engine in AHEAD direction to bring the piston of cylinder No. M907010220C01 If pin K is not available. use the cylindrical end of a drill of a suitable size. please quote Procedure M90701 Edition 0220 S Page 1 (4) . Check with the pin gauge. 2.1 Checking 1. and insert check pin K in slot S.

1. Tighten the gear wheel bolts as stated in Data D07-01.Starting Air Distributor 907-1. 2. Dismount the end cover of the camshaft housing. from the engine. along with the starting air distributor. Loosen the bolts on the gear wheel. M907010220O02 D0701 Page 2 (4) When referring to this page. Check with the pin gauge. 2.3 Adjustment MAN B&W Diesel 1. Turn the engine in AHEAD direction to bring the piston of cylinder 1 to TDC. M907010220C01 Turn the coupling together with the distributor disc until check pin K enters slot S in the disc and keep it there. please quote Procedure M90701 Edition 0220 .

3.3 Adjustment 3. If clearance does not correspond with D0703. Remove check pin K from the distributor housing and mount the gasket and plug screw.Starting Air Distributor MAN B&W Diesel 907-1. Check the clearance D07-03 between the coupling wheel and the bushing. M907010220O04 K When referring to this page. D0703 4. please contact MAN B&W Diesel for advice. please quote Procedure M90701 Edition 0220 S Page 3 (4) . M907010220O03 Mount the covers on the camshaft housing. 4.

please quote Procedure M90701 Edition 0220 .3 Starting Air Distributor Adjustment MAN B&W Diesel 5. M907010220O05 D0704 Page 4 (4) D0705 When referring to this page. respectively (ASTERN and AHEAD). Check the clearance between the roller and the two interlocking valves with the roller in its innermost and outermost positions.907-1. 5.

Description Value Unit D07-09 Piston tightening torque 58 Nm D07-10 Valve tightening torque 25 Nm D07-12 Starting air valve 7 kg When referring to this page. please quote Data D10702 Edition 0044 Page 1 (2) . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Starting Air Valve MAN B&W Diesel 107-2 Data SAFETY PRECAUTIONS For detailed sketch.

Plate Item No. Description P90151 095 Grinding ring for starting valve P90151 105 Grinding handle for starting valve Page 2 (2) When referring to this page.Starting Air Valve 107-2 MAN B&W Diesel 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. please quote Data D10702 Edition 0044 . P90951 refers to chapter 909. e.g.

1 206 02 2. please quote Procedure M90702 Edition 0213 MAN B&W Diesel A/S Page 1 (5) . see Procedure 907-2. Check that the valve opens fully. Shut off the air supply Check that the valve closes fully.3. connect a supply of working air to the control air inlet at the top of the valve. 2.1 206 01 3. When the starting air valve has been overhauled.Starting Air Valve 907-2. Repeat steps 1 and 2 a couple of times.1 1. BM907-2. 1. When referring to this page.1 Checking Starting Air Valve S42MC 0213 Checking 907-2. BM907-2.

1. 2.2 Starting Air Valve Dismantling Dismantling 907-2. BM907-2.2 1.907-2. BG901-2. please quote Procedure M90702 Edition 0213 MAN B&W Diesel A/S . Pull the starting air valve out of the cylinder cover and remove it from the engine. Unscrew the starting valve screws.2 206 02 D07-12 Page 2 (5) When referring to this page. Dismount the control air pipe. Shut off the starting air and control air inlet.2 77 01 2.

BG907-2. please quote Procedure M90702 Edition 0213 MAN B&W Diesel A/S Page 3 (5) . and the liner from the top end of the valve housing. 1. 2. BG907-2.3 1. When referring to this page.3 208 01 Remove the valve spindle from the bottom end of the valve housing. Remove the split pin and screw off the nut from the valve spindle. Remove the disc. Remove and discard the gasket. Remove the top cover fixing screws and remove the cover.3 208 02 2. the distance pipe. the piston. Remove and discard the O-ring. the valve spring.3 Overhaul Overhaul 907-2.Starting Air Valve 907-2.

3 208 04 If the starting air valve is not to be mounted in the engine immediately after the overhaul. 3. Mount and tighten the top cover.3 208 03 First mount the liner in the valve housing. Mount the nut on the valve spindle and tighten the nut. Lubricate all internal parts (sliding surfaces) with. 200. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. Thoroughly clean all parts before reassembling the valve.3 Starting Air Valve Overhaul 3. BG907-2. then the valve spindle. Carborundum No. 4. the distance pipe. the spring. MoS 2. Page 4 (5) When referring to this page. see D07-09. for instance. 4. the piston and the disc. Mount the split pin.907-2. please quote Procedure M90702 Edition 0213 MAN B&W Diesel A/S . BG907-2. Carborundum No. Replace the O-ring on the valve housing. Place a new gasket on the valve housing. Molybdenum Disulphide. Grind the seatings of the spindle and housing to match. Grind the valve housing seating with the grinding ring after applying grinding paste. using the face wrench to rotate the valve spindle. 500.

2 77 03 D07-10 When referring to this page.0 49 08 2. AM907-4. See Procedure 901-1. Mount the valve in the cylinder cover. 1. Mount and tighten the screws as stated in Data. If not already done. if necessary.4 Mounting Mounting 907-2. For overhaul. BG901-2.3.Starting Air Valve 907-2. see Procedure 907-2. Carefully clean the starting valve bore in the cylinder cover and. recondition the seat for the starting valve in the bore.3. replace the O-ring on the overhauled valve and lubricate with ‘Never Seize’ or Molybdenum Disulphide. 2. MoS 2. please quote Procedure M90702 Edition 0213 MAN B&W Diesel A/S Page 5 (5) . Mount the control air pipe and turn on starting air and control air.4 1.

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Panel Exhaust Valve . Data Exaust Valve Roller Guide Exhaust Valve Cam. Data Exhaust Valve Exhaust Valve .908 . Data Exhaust Valve Actuator Exhaust Valve Roller Guide.Exhaust Valve Documents in this Chapter 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 0049 0230 0091 0268 0055 0245 0039 0221 0016 0217 0034 0216 0206 0033 0042 0007 High-Pressure Pipe.Special Running.Tools Exhaust Valve . Data High-Pressure Pipe Exhaust Valve.Extra Tools MAN B&W Diesel A/S .Hydraulic Tools Exhaust Valve . Data Exhaust Valve Cam Exhaust Valve . Data Exhaust Valve Exhaust Valve Actuator.

MAN B&W Diesel A/S .

tightening torque 30 Nm D08-03 High-pressure pipe 12 kg When referring to this page. please quote Data D10801 Edition 0049 Page 1 (2) .High-Pressure Pipe MAN B&W Diesel 108-1 Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value Unit D08-01 High-pressure pipe.

Plate Page 2 (2) Item No.g. please quote Data D10801 Edition 00049 . P90951 refers to chapter 909. Description When referring to this page. e.High-Pressure Pipe 108-1 MAN B&W Diesel 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.

Lift the high-pressure pipe away from the engine. exhaust valve or hydraulic actuator. When referring to this page. M908010227D04 2. 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. check the high-pressure pipe sealing surfaces. D0803 M908010230D01 3. 2.2 1. please quote Procedure M90801 Edition 0230 Page 1 (3) . When replacing the hydraulic high-pressure pipe. Remove the screws in both ends of the high-pressure pipe.High-Pressure Pipe MAN B&W Diesel Dismantling Double Pipe: 1. 908-1.

Remove the spring ring from the two-part sleeve. Remove the thrust flange from the pipe end. MAN B&W Diesel The two ends of the pipe are identical and should both be overhauled as follows: 1. Remove and discard the O-rings from the thrust piece and the thrust flange. M908010227O02 Remove and discard the internal O-rings. M908010227O01 Note! 2. M908010227O03 3. proceed as follows: Lift the thrust flange upwards. please quote Procedure M90801 Edition 0230 . Remove the thrust piece from the actuator/ exhaust valve. Page 2 (3) When referring to this page. Clean and inspect the conical seats of the high-pressure pipe and the thrust piece. The seats cannot be reconditioned.908-1.3 High-Pressure Pipe Overhaul 1. Assemble the high-pressure pipe in the reverse order to disassembling. Mount new internal O-rings lubricated with a little camshaft lubricating oil. the thrust piece/ high-pressure pipe must be replaced. To change the internal O-ring. 4. If a seat is damaged. 2. 3.

After fitting the pipe correctly in relation to the exhaust valve and actuator. When referring to this page. D0803 Mount and lightly tighten the screw by hand. 4-6 mm) between the flanges of the pipe and the exhaust valve/actuator.4 Mounting Mount the hydraulic high-pressure pipe as follows: 1. see Data.High-Pressure Pipe MAN B&W Diesel 1. please quote Procedure M90801 Edition 0230 Page 3 (3) . 908-1. Position the high-pressure pipe with the sealing surfaces flush against the surfaces of the exhaust valve/actuator. M908010230M01 2. Ensure that there is a small clearance (approx. Take care not to damage the O-rings. D08-01 M90801-0230M02 2. tighten up the screws of the pressure flanges diagonally.

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thickness Exhaust valve. tightening torque Safety valve.30. min.0 145 205 29. Spindle stem.5 32. complete Exhaust valve housing Oil cylinder Air cylinder Spindle Bottom piece Air piston Throttle valve.5 200 120 26 12 16 15 2 50 bar Nm Nm ° ° mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg kg kg Nm 900 800 . Spindle stem. dismantling When referring to this page. grinding Spindle stem. burn-off Spindle. max. max. bottom Oil cylinder max. diameter Bushing max. max.3 . opening pressure Oil cylinder.0 2. inside diameter Piston rings. grinding Gap of bottom piece seat Spindle.5 5.9 .3 0.Exhaust Valve MAN B&W Diesel 108-2 Data SAFETY PRECAUTIONS For detailed sketch. grinding angle Bottom piece seat. max. tightening torque Bottom piece seat.990 bar bar Page 1 (2) .8 30. top Bushing max. please quote Data D10802 Edition 0091 Value Unit 21 110 50 .4 2.30. measuring area.80 29. see 900-2 X X X X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. grinding angle Valve spindle seat. tightening torque D13-01 D13-02 Hydraulic pressure. min. diameter. min. measuring area.0 30.0 36. Description D08-04 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 D08-24 D08-25 D08-26 D08-27 D08-28 D08-29 D08-30 D08-40 Safety valve. mounting Hydraulic pressure. diameter.1 1.

e. Description P90851 077 Cone ring for pneumatic piston P90851 089 Pressure tester for safety valve P90851 090 Gauge for exhaust valve spindle P90851 150 Gauge for exhaust valve bottom piece P90851 185 Grinding ring for exhaust valve bottom piece P90851 219 Eye bolts P90862 Page 2 (2) Exhaust Valve . P90951 refers to chapter 909.g.Exhaust Valve 108-2 MAN B&W Diesel 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. please quote Data D10802 Edition 0091 .Hydraulic Tools When referring to this page. Plate Item No.

M908020262C02 Exhaust valve performance condition.1 1. Lift the valve spindle rotation indicator. IF water flows from the small bore on the manoeuvring side of the exhaust valve. 2. please quote Procedure M90802 Edition 0268 Page 1 (22) . On Ridge On Surface 2. the spindle must rotate. the lowermost sealing ring is leaking. the exhaust valve must be dismounted and the sealing rings replaced. See volume I chapter 706 Performance Evaluation. turn it 90° and let it rest on the air piston. check that the cooling water inlet and outlet to the cylinder cover and exhaust valve are open. lift the rotation indicator and lock it in the top position.Exhaust Valve MAN B&W Diesel Checking Checks during running 1. the top position of the indicator will change about 6 mm. Check the tightness of the sealing rings between the bottom piece and the exhaust valve housing. The indicator must not be in constant operation. Check of valve spindle rotation: The indicator will now follow the movements of the valve spindle and the air piston. M908020268C01 The engine must run when the valve function and spindle rotation are checked. The rotation can vary with unit and engine load. 908-2. During rotation of the valve spindle. Check of bottom piece sealings: With the exhaust valve mounted in the cylinder cover. because of the ridge on the piston. When check of the valve rotation is finished. When referring to this page. In the event of no rotation. If water flows from the any of the rings. attention should be paid to avoid seat problems. During engine operation.

SAFETY AIR SUPPLY AIR SUPPLY EXHAUST VALVE Shut off and release the spring air on the valve next to the engine-side manoeuvring stand. 3. The dropdown test should not be carried out until after a ‘‘runningin’’ period of 500 hours on valves with new sealing rings. • Spindles dropping down between 30 minutes and 1 hour: Keep under observation.g. Check of spindle drop-down time: Engage all rotation indicators on the exhaust valves. When check of drop down time is finished. one month. CONTROL AIR SUPPLY • Spindles dropping down after 1 hour: OK.1 Checking MAN B&W Diesel Check with stopped engine 3. See next step “Check of Air Spring tightness”. In connection with port stays. Check the drop down time for all spindles: M908020268C03 • Spindles dropping down within 30 minutes: Check and overhaul. lift the rotation indicators and lock them in the top position. at an interval of e. the time the valve concerned is closed may be considerably shorter than 15 minutes. Note! If an air cylinder is fitted with new sealing rings. Page 2 (22) When referring to this page. please quote Procedure M90802 Edition 0268 . an easy check of all exhaust valves is recommended.Exhaust Valve 908-2.

Check of air spring tightness: 4. the leakage comes from the air piston: change and overhaul. • Remove the air supply to the non-return valve on the air cylinder and check the non-return valve for tightness. C Open the ball-valve (B). If air is coming out: change and overhaul.Exhaust Valve MAN B&W Diesel 908-2. minor leaks are difficult to detect. The checks are for guidance only. please quote Procedure M90802 Edition 0268 B Page 3 (22) . M90802-0268C04 • Check the safety valve (D). • Hole for drain oil (C): If yes. Connect compressed air to the non return valve (A) on the air cylinder. D Check if air is coming out from: • The air bore (B): Leakage from spindle stem sealing: change and overhaul. A When referring to this page.1 Checking 4. Disconnect and remove the drain oil pipe from the oil cylinder (C).

2 M90802-0268D01 Dismount the return oil pipe from the exhaust valve. please quote Procedure M90802 Edition 0268 . 2.2 Exhaust Valve Dismantling 1. Page 4 (22) When referring to this page. Dismount the oil pipe connections: Dismount the high-pressure pipe for the hydraulic valve actuation. MAN B&W Diesel Close off cooling water: Close the cooling water inlet and outlet connections. 1. and drain the exhaust valve.908-2. M90802-0268D02 2. Close the air supply to the exhaust valve. See Procedure 908-1.

see Data.g. M90802-0268D03 Loosen the screws which attach the intermediate pipe to the exhaust valve housing. 4.Exhaust Valve MAN B&W Diesel 908-2. please quote Procedure M90802 Edition 0268 Page 5 (22) . Disconnect the air pipes for the air spring and the sealing air arrangement. Disconnect pipe connections: 3. 4. When referring to this page. Remove the plate jacket and insulation from the intermediate pipe.2 Dismantling 3. M908020268D04 For use of hydraulic tools. See Procedure 913-1. Dismantling of nuts: Remove the protective caps from the exhaust valve studs. Disconnect the cooling water connections from the exhaust valve. D1302 Loosen and remove the nuts hydraulically. Support the intermediate pipe by e. a chain block and remove the screws.

3.3. Land the exhaust valve on a wooden plate on the platform. See Procedure 901-1. see Procedure 908-2. Attach the crane to the eye bolt fitted on top of the valve and start lifting the exhaust valve.908-2.2 Exhaust Valve Dismantling MAN B&W Diesel 5. D0824 Check all connections to the valve are removed. Lift of exhaust valve: 5. if required. please quote Procedure M90802 Edition 0268 . Page 6 (22) When referring to this page. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seating and sealing surfaces of the bore. During the lift . M908020268D05 For overhaul of the exhaust valve.check that the valve goes clear of all other engine components.

D0826 Remove the nuts from the oil cylinder. Lift away and place the oil cylinder on a wooden support. When referring to this page.3 Overhaul Oil cylinder: 1. Sealing air control unit: M908020268O01 Loosen the union nuts. Unscrew and remove the sealing air control unit. M908020268O02 2. 2. 908-2.Exhaust Valve MAN B&W Diesel 1. please quote Procedure M90802 Edition 0268 Page 7 (22) . Place the exhaust valve on a wooden support on the platform.

please quote Procedure M90802 Edition 0268 . Use a small screwdriver to press the ball into the non-return valve. 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. Page 8 (22) D0828 When referring to this page. Lift the oil cylinder with the crane. Mount four nuts so that the load from the valve housing is evenly distributed. M908020268O03 Loosen the air piston from the conical locking ring by means of a tin hammer.3 Overhaul MAN B&W Diesel 3.Exhaust Valve 908-2. D0824 Use the oil cylinder as a lifting tool for the exhaust valve housing. Relieve the air pressure through the nonreturn valve from below the piston. Cover the non-return valve with a rag to catch the oil drops. and remove the conical locking ring. M908020268O04 Lift the valve housing clear of the valve spindle. Conical locking ring: 3. 4. Remove the four screws from the flange on top of the air piston and dismount the flange. and guide it down over the studs for the oil cylinder. Spindle: 4.

Lift the valve housing away and land it on a couple of wooden planks. Remove and discard the O-ring on the air cylinder. use a tin hammer to release it. D0829 D08-30 M90802-0268O06 D08-27 When referring to this page. Unscrew and remove the lock screws which retain the bottom piece. 6. Lift the valve housing approx. 10 mm.3 Overhaul 5.Exhaust Valve MAN B&W Diesel 908-2. D0825 If the bottom piece has become stuck. please quote Procedure M90802 Edition 0268 Page 9 (22) . Air piston and cylinder: Dismount the air piston from the air cylinder. Mount two long screws in the air cylinder and dismount the air cylinder. M908020268O05 Dismount the non-return valve from the air cylinder/valve housing. Remove the oil cylinder. 6. Bottom piece: 5.

M908020256O09 9. Fit a new bushing. M908020262O07 Inspect and evaluate the seating according to Volume I. See Volume I. Page 10 (22) When referring to this page. supplement 707-03. Bottom piece inspection: Before cleaning the bottom piece. 7. See Data. 8. Bushing renewal: M908020262O06 If it proves necessary to replace the bushing: Place the valve housing on one side. D0818 MAN B&W Diesel Guide bushing: Clean the exhaust valve housing. 9.3 Overhaul 7. Inspect the bushing in the spindle guide for wear and measure the top and bottom diameters. please quote Procedure M90802 Edition 0268 .Exhaust Valve 908-2. 8. Return the housing to an upright position. D0819 Knock out the bushing with a hammer and a suitable mandrel.

D0809 G2 11.3 Overhaul 10. THEN Further grinding or reconditioning is not recommended. G2 = 0. If the seat or the recess G3 is ground. 12. Bottom piece measuring: G3 10. Bottom piece sealing rings: 12. D0812 Use the bottom piece template and a feeler gauge. grind the outside seating.e. wear or the total amount the seat has been ground is measured as described below. Bottom piece sealing face: Use carborundum 200 and the special grinding tool. M908020262O11 Mount new sealing rings on the bottom piece. All measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating. turning alternately clockwise and anticlockwise. take measurements G2 and G3. please quote Procedure M90802 Edition 0268 Page 11 (22) . In connection with evaluation of the bottom piece according to Volume I. When referring to this page. Make sure that the grooves for the sealing rings are clean. Grind until a smooth surface is achieved. i. see Data D08 – 09 for correct grinding angle. Clean the bottom piece. 11.Exhaust Valve MAN B&W Diesel 908-2. D0811 M908020262O09 For maximum wear or grinding. see Data D08-11 and D08-12. IF the template rests on the lower surface in the groove. Turn the special grinding tool by hand. M908020262O10 If necessary.

Check the face on the valve housing is clean. Mount and tighten the retaining screws for the bottom piece. check that the guide pin in the bottom piece enters the hole in the bottom of the exhaust valve housing.3 Exhaust Valve Overhaul 13. 14.908-2. Inspect and evaluate the spindle according to Volume I. Bottom piece mounting: Use the oil cylinder as a lifting tool for the exhaust valve housing. If fitted. M908020256O14 14. supplement 707-03. Spindle inspection: M90802-0268O13 Before cleaning the spindle. please quote Procedure M90802 Edition 0268 . Page 12 (22) When referring to this page. Land the exhaust valve housing on the bottom piece. MAN B&W Diesel 13. See Volume I.

burn-off and wear or the total amount the seat has been ground are measured as described below.3 Overhaul 15. 16. and the seating of the spindle with a feeler gauge. Spindle burn-off and grinding check: 15. see Data D08-10 for correct grinding angle. gap G1 is measured between the spindle template. please quote Procedure M90802 Edition 0268 Page 13 (22) . If the exhaust valve spindle needs reconditioning. For maximum seat grinding. the spindle stem wear is measured as described below. M90802-0268O14 For minimum stem diameter. When referring to this page. The burn-off F1 of the valve spindle is checked by measuring along the spindle template from point A to point D and in point E. see Data D08 –14. D08-15 16. G1 In connection with evaluation of the spindle according to Volume I. D0814 D0810 A D0813 D E D08-16 If necessary to grind the seat. see Data D08-13. Check the spindle stem for wear in the area D08-15 to D08-16 measured from the top of the spindle.Exhaust Valve MAN B&W Diesel 908-2. Spindle stem check: D08-17 In connection with evaluation of the spindle according to Volume I. F1 M908020256O15 For the maximum allowable burn-off. see Data D08 -17. contact MAN B&W Diesel for advice. The maximum seat grinding.

discard the sealing rings. Remove the oil cylinder. M908020268O16 For check of the safety valve see next step. see the sketch. Check the bottom of the air cylinder for possible coke. Air cylinder: Dismount the safety valve housing from the air cylinder.908-2. 18. please quote Procedure M90802 Edition 0268 . Use the oil cylinder as a lifting tool for the exhaust valve housing. MAN B&W Diesel 17. M908020268O15 Disassemble the stuffing box for the spindle stem. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle. Clean the air cylinder and blow through all bores in the air cylinder. 18. remove visible coke deposits. Page 14 (22) When referring to this page. Fit a new or overhauled safety valve with housing. Reassemble the spindle stem stuffing box with new sealing rings.3 Exhaust Valve Overhaul 17. Mount a new O-ring in the groove on the outside of the air cylinder. Spindle mounting: Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil.

adjust the safety valve until the correct pressure is indicated. see Data. please quote Procedure M90802 Edition 0268 Page 15 (22) . mount the protective cap. For tightening torque see Data. If the opening pressure is not correct. M908020268O18 Lubricate the O-rings in the spindle bushing inside the air cylinder. When referring to this page.3 Overhaul 19. Finally. Mount a new gasket and a new O-ring on the safety valve. 20. Air cylinder mounting: Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Safety valve: 19. Some engines are not equipped with the locating pin Note! Take care not to damage the O-rings in the inside the air cylinder. D0804 Unscrew the safety valve from the housing Place the safety valve in the pressure testing device. Tighten the lock nut and test the opening pressure once more. Connect the testing device with the high pressure pump by means of a hose. loosen the lock nut and. Mount the safety valve in the housing.Exhaust Valve MAN B&W Diesel 908-2. M908020268O17 Check the opening pressure. D0807 20. using a screwdriver.

When mounting the teflon rings. Before mounting. 5 min Check the teflon guide ring and teflon sealing ring for wear. 22. if it is necessary to replace the sealing rings on the air piston. cut them and remove them. Use a nylon block and a hammer to press the air piston down in the cylinder M90802-0268O19 Remove the conical guide ring from the air cylinder.3 Overhaul MAN B&W Diesel 21. Mount new O-rings in the inside grooves of the air piston. compress the teflon rings by means of the conical ring from tool panel 908. Lubricate the guide ring and the running surface of the air cylinder. Air piston seals: 21. be careful not to damage the running surfaces. please quote Procedure M90802 Edition 0268 . heat the new teflon rings in 100°C hot water for at least five minutes. When referring to this page. After mounting. Lower the air piston over the valve spindle down into the air cylinder. This is done by pressing the air piston through the conical ring. Air piston mounting: Fit the conical guide ring for the air piston on the air cylinder. Page 16 (22) Mount a new O-ring on the air cylinder. Be careful not to damage the edges of the ring grooves in the piston. 100°C M908020267O29 Note! 22.Exhaust Valve 908-2. Mount the non return valve for spring air.

Mount the two part conical locking ring and apply compressed air below the air piston to lift the piston.3 Overhaul 23. Oil cylinder: Unscrew the cover for the throttle valve. Place the oil cylinder in a horizontal position. send the complete oil cylinder to an authorised MAN B&W workshop for overhaul. Remove the flange and take out the piston. Measure the cylinder diameter. by means of the four screws. Unscrew and clean the throttle valve. M908020268O20 On valve models where the bolts are designed for securing. M90802-0268O21 D08-20 When referring to this page. 24. Mount the flange on top of the air piston and.Exhaust Valve MAN B&W Diesel 908-2. Check and clean the bore in the top of the oil cylinder. Remove and discard the sealing disc. See Procedure 913-7. 24. secure the bolts. please quote Procedure M90802 Edition 0268 Page 17 (22) . Inspect the bore in the oil cylinder for scoring. tighten the air piston and the flange together. If the diameter of the oil cylinder exceeds Data D08-20. Locking ring: 23.

discard the rings and mount new ones. Screw the throttle valve into the bore.3 Overhaul MAN B&W Diesel 25. Return the oil cylinder to an upright position. Mount a new sealing disc in the bore for the throttle valve. Check that the TOP mark on the piston rings faces upwards. M90802-0268O22 D08-40 Page 18 (22) When referring to this page. 26. please quote Procedure M90802 Edition 0268 . 26.Exhaust Valve 908-2. If the thickness of the rings has worn down to the minimum. when mounting. Tighten and lock the screws. Oil piston: 25. Oil cylinder assembly: M908020253O42 D0821 Mount the piston and the flange in the oil cylinder. see Data. Mount the cover for the throttle valve with a new gasket. Top Remove the piston rings from the oil piston and check them for wear.

When referring to this page. D0806 Mount and tighten the nuts. and tighten the cover. Clean and check the filter plug screw. replace them. Oil cylinder mounting: 27. Loosen and remove the screws and cover the sealing air valve spindle in the control unit.Exhaust Valve MAN B&W Diesel 908-2. If necessary. Mount the sealing air control unit on the exhaust valve. M908020268O23 Clean the housing and check all bores are clean. Mount the overhauled oil cylinder on top of the air cylinder. Sealing air control unit: Remove the filter plug screw from the sealing air control unit. Re-fit the valve spindle and spring. Remove the valve spindle and check the sealing rings and the spring. re-fit the filter plug screw. See Data. and replace the O-ring. please quote Procedure M90802 Edition 0268 Page 19 (22) . 28. M90802-0268O24 28.3 Overhaul 27. Tighten the union nuts.

the time the valve is closed may be considerably shorter than 15 minutes. Page 20 (22) When referring to this page. M90802-0268M01 Carry out the drop down test as described in procedure 908-2. Depending on model either the guide pin on the exhaust side of the exhaust valve or the water connection on the manoeuvring side must fit. guiding it in accordance with the exhaust flanges.1. 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. Exhaust valve landing: Close the valve with compressed air. 2.Exhaust Valve 908-2. Note! 2. Check the valve is fitted with new sealingrings in the grooves on the bottom piece. The dropdown test should not be carried out until after a ‘‘running-in’’ period of 500 hours on valves with new sealing rings. please quote Procedure M90802 Edition 0268 . D08-24 If the air cylinder is fitted with new sealing rings. Lift up the valve with the engine room crane. it is recommended that the valve is checked and prepared as follows: D08-24 Connect compressed air to the air cylinder to close the valve. Lubricate the sealing rings with Vaseline and the threads of the studs with anti-seizure paste. M90802-0268M02 Position the valve in the cylinder cover bore. MAN B&W Diesel Checks before mounting: Before mounting an overhauled exhaust valve in the engine.4 Mounting 1. Check that a 1.

see Data. Mount and tighten the screws to the exhaust valve housing. Fit the air pipes for the air spring and for the sealing air arrangement. Mount the return oil pipe to the exhaust valve. please quote Procedure M90802 Edition 0268 Page 21 (22) . M90802-0268M03 4. See Procedure 908-1. Connect the intermediate pipe to the exhaust valve. Mounting of nuts: 3. Mount the cooling water connections for the exhaust valve. Mount the protective caps on the exhaust valve studs.Exhaust Valve MAN B&W Diesel 908-2. Mount the high-pressure pipe for the hydraulic valve actuation. D13-01 For use of hydraulic tools. M90802-0268M05 Check that all pipe connections are properly tightened. 5. Mount the oil pipe connections: When referring to this page.4 Mounting 3. Mount the pipe connections: 4. M90802-0268M04 5. See Procedure 913-1.2. Mount the insulation and plate jacket for the intermediate pipe. Mount and tighten the nuts hydraulically.

Exhaust Valve 908-2. 7. If the lubricating oil pumps have been started before the exhaust valve pneumatic springs are pressurise: Engage the indicators on top of the exhaust valves and wait until the exhaust valves are closed. M90802-0268M07 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 Page 22 (22) Open Valve When referring to this page.4 Mounting MAN B&W Diesel 6. 7. Open cooling water supply: 6. Open the cooling water inlet supply. and vent the exhaust valve. Check that all water connections are mounted and tightened. Air spring check: M90802-0268M06 The air supply to the exhaust valve must always be connected and pressurised before turning on the oil supply to the exhaust valve actuator. open the cooling water outlet valve Open the air supply to the exhaust valve. See Procedure 908-2. Check the tightness of the sealing ring between the bottom piece and the exhaust valve housing. please quote Procedure M90802 Edition 0268 .1.

please quote Data D10803 Edition 0055 Page 1 (2) . tightening torque 350 Nm D08-34 Hydraulic actuator.Exhaust Valve Actuator MAN B&W Diesel 108-3 Data SAFETY PRECAUTIONS For detailed sketch. thickness 1. min. Description D08-20 Oil cylinder max.1 mm Piston rings. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. inside diameter D08-21 Value Unit 36. tightening angle 46 ° D08-35 Hydraulic actuator 32 kg When referring to this page.5 mm D08-32 Hydraulic actuator.

please quote Data D10803 Edition 0055 . e. Description When referring to this page. Plate Page 2 (2) Item No.g. P90951 refers to chapter 909.Exhaust Valve Actuator 108-3 MAN B&W Diesel 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.

it must be overhauled. If an air flow is felt at the inlet side of the valve. 908-3. please quote Procedure M90803 Edition 0245 Page 1 (4) .Exhaust Valve Actuator MAN B&W Diesel 1. 1.1 Checking The nonreturn valve A is built into the oil inlet pipe to the actuator. A M908030245C01 To check the valve. When referring to this page. disconnect and clean it and connect a supply of working air (7 bar) to the outlet side of the valve (the side facing the actuator).

MAN B&W Diesel Stop the engine and shut off the oil supply. M908030245D02 3. Remove the piston from the roller guide. 2. Remove the locking plate for the piston. 90 M908030245D03 3.Exhaust Valve Actuator 908-3. 2. M908030245D01 Dismount the screws of the highpressure pipe flange. please quote Procedure M90803 Edition 0245 . See Procedure 9081. leaving the piston on the top of the roller guide. Remove the spring. Fit eye bolts in the threaded holes of the actuator housing and hook on a tackle. Dismount the oil inlet pipe from the exhaust valve actuator. 1. D0835 Unscrew the nuts on the two short studs. and lift away the highpressure pipe. Turn the piston 90° to free it from the bayonet joint. See Data. Dismount the nuts and lift the housing carefully up. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the camshaft housing to inspect the position of the exhaust cam. Page 2 (4) When referring to this page. then loosen the nuts on the long studs successively until the tension of the roller guide spring is relieved.2 Dismantling 1.

Inspect the sliding surfaces of the piston for scratching or seizure marks. If the ring thickness has worn down to the minimum.Exhaust Valve Actuator MAN B&W Diesel 1. 1. see Data. please quote Procedure M90803 Edition 0245 Page 3 (4) . 2. Top D0821 Take off the piston rings and check them for wear. 2. M908030245O02 D0820 When referring to this page. If the bore is seized or has worn up to the maximum diameter. Check that the TOP mark on the piston rings faces upwards when mounting.3 Overhaul Clean the piston in kerosene and dry with nonfluffy rags. see Data. send the oil cylinder to an MAN B&W authorised workshop for reconditioning. Clean the oil cylinder and inspect the bores for deposits. 908-3. discard the rings and mount new ones. M908030245O01 Check the bore of the oil cylinder for possible scores and measure it for wear.

1. Tighten all four nuts as stated in Data. Carefully lower the actuator housing on to the piston. Mount the oil inlet pipe on the exhaust valve actuator. Mount the locking plate and tighten. please quote Procedure M90803 Edition 0245 .Exhaust Valve Actuator 908-3. Mount the hydraulic high pressure pipe. Page 4 (4) When referring to this page. 3. M908030245M01 Mount the washers and the nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. 90 MAN B&W Diesel Mount the actuator piston in the roller guide and turn 90° to lock it in the bayonet joint.4 Mounting 1. see Procedure 9134. See Procedure 9081. Mount the spring on the roller guide. M908030245M03 3. Lubricate the piston with plenty of lubricating oil. Do NOT use both. 2. taking care not to damage the piston rings. Mount the washers and nuts on the two short studs. Note! M90803-0245M02 D08-35 D09-32 or D08-34 Either use tightening torque or tightening angle. 2.

5 9 mm kg Page 1 (2) . see 900-2 X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description D08-36 Bushing/shaft pin. please quote Data D10804 Edition 0039 Value Unit 0. max. clearance D08-38 Roller guide complete When referring to this page.Exhaust Valve Roller Guide MAN B&W Diesel 108-4 Data SAFETY PRECAUTIONS For detailed sketch.

e. 073 Description Dial gauge and stand tool When referring to this page. please quote Data D10804 Edition 0039 . P90951 refers to chapter 909.g. Plate P91366 Page 2 (2) Item No.Exhaust Valve Roller Guide 108-4 MAN B&W Diesel 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.

4. Then lift the roller as much as the clearance permits. For dismantling of the roller guide see Procedure 908-4. 6. M908040221C05 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. place the roller guide vertically upside down on a couple of planks with the roller hanging freely. When referring to this page. Make sure that no traces of bearing metal exist in the roller guide housing. 5. 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. using the following procedure: 2.1 Checking The exhaust valve roller guide can be partially checked while mounted on the engine. seizures or scratches. M908040221C02 Turn the engine to provide the maximum space between the roller guide and the cam disc.Exhaust Valve Roller Guide MAN B&W Diesel 1. Remove the camshaft inspection cover. 2. seizures or scratches. To measure the clearance in the roller guide slide bearing. 908-4.2. Also inspect the surface of the roller for possible damage marks. Lift the roller guide. D0836 3. Inspect the surfaces of the roller guide and the roller for damage marks. See Procedure 908-5. Place a dial gauge against the roller. which makes it possible to read the clearance directly on the dial. please quote Procedure M90804 Edition 0221 Page 1 (4) . see Data. A more suitable and reliable method is to check the roller guide and the bearing clearance when the roller guide is dismounted. 5.

M908040221D01 2. Lift the roller guide out of the roller guide housing by hand.2.2 Exhaust Valve Roller Guide Dismantling 1. M908040221D02 D0838 Page 2 (4) When referring to this page. please quote Procedure M90804 Edition 0221 . See Procedure 908-3. MAN B&W Diesel Dismantle the hydraulic actuator above the exhaust valve roller guide. Take care not to damage the sliding surfaces of the roller guide when lifting. 2.908-4. 1.

contact an MAN B&W authorized repair shop. 1. just clean and lubricate the roller guide before remounting it in the roller guide bushing. It is recommended that the roller guide should ONLY be overhauled/dismantled if • irregularities when turning the roller.3 Overhaul Inspect and check the exhaust valve roller guide. 908-4. When referring to this page. For disassembling of the roller guide. have been observed during the checking of the roller guide. See Procedure 908-4. If no irregularities are found.1. • seizure marks on the slide surfaces. 2.Exhaust Valve Roller Guide MAN B&W Diesel 1. • damage to the roller. 3. M908040221O03 3. Note! M908040221O01 • larger clearance than stated on the Data sheet. please quote Procedure M90804 Edition 0221 Page 3 (4) .

please quote Procedure M90804 Edition 0221 . 1.4 Exhaust Valve Roller Guide Mounting 1. M908040221D01 2. Page 4 (4) When referring to this page. See Procedure 908-3.4. M908040221M01 2.908-4. Mount the actuator. D0838 MAN B&W Diesel Clean and lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing by hand.

D08-39 Description Check lifting height When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.108-5 Exhaust Valve Cam Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10805 Edition 0016 MAN B&W Diesel A/S Value Unit 10 mm Page 1 (2) .

complete P91351 166 Angle union P91351 225 Disc. pneumatically operated P91351 058 Hose with unions (3000 mm). Plate Item No. e. Description P90851 173 Lifting tool for exhaust valve roller guide P91351 010 Hydraulic pump. Cu ø11x3 mm P91366 073 Dial gauge and stand tool Page 2 (2) When referring to this page. P90951 refers to chapter 909.108-5 Exhaust Valve Cam Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. please quote Data D10805 Edition 0016 MAN B&W Diesel A/S . round-plain.g.

which is the number of degrees the crank throw has turned from TDC position to the present position.00 mm is obtained. Continue turning AHEAD until the roller guide again is lifted to D08-39. and the dial gauge gives the reading 1. 2. Mount a dial gauge (measuring range 0. Turn the roller guide in AHEAD direction until lifted to D08-39. which is the number of degrees the crank throw has turned from TDC position to the present position. remember to take into account that the scale on the turning wheel shifts from 360 to 0 (zero) degrees.00 mm and calculate the angle A. Note! When calculating the angles A and B.00 mm. 1. Reset the scale and the pointer.Exhaust Valve Cam 908-5.1 Checking 1. Remove the high pressure pipe.00 mm) on the lifting tool for the exhaust valve roller guide. M908050217C02 3. Press the dial gauge against the face of the actuator housing until the reading D08-39 + 1. Turn the crank throw of the cylinder concerned in AHEAD direction until TDC. When referring to this page. see procedure 908-1. Check and write down the angle indicated on the turning wheel. please quote Procedure M90805 Edition 0217 MAN B&W Diesel A/S Page 1 (4) . 2.00 . Calculate the angle B. and the dial gauge gives the reading 1.2 Mount and tighten the lifting tool for the exhaust valve roller guide to the actuator piston (remove the screws for tightening to the actuator housing and do not lift the roller guide).20.

please quote Procedure M90805 Edition 0217 MAN B&W Diesel A/S . The position of the cam must be correct within a tolerance of +/-0. 5. See the Adjustment Sheet in Volume I.1 Page 2 (4) When referring to this page. The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC. 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. Calculate the lead angle as: 180° – (A° + B°)/2 The lead angle is normally a negative figure.1 Exhaust Valve Cam Checking 4. Chapter 701. for the “lead angle” of the plant in question. OPERATION.5°. it is recommended to check the position of the camshaft with the pin gauge. At the same time.908-5. See Procedure 906-3. 4.

2. M908050217O01 2. 1. Turn the camshaft until there is access to the oil duct in the exhaust cam through the inspection hole. Remove the inspection cover from the camshaft housing. Chapter 706. Before adjustment of any cams. M908050217O03 4. Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc. 1. ensuring that the two pins enter the holes in the cam. Insert three copper gaskets in the oil duct. When referring to this page. for instance.3 Adjustment Normally. If fitted. 4. see procedure 908-1. but do not tighten it. Fit a hose between the snap-on coupling and the hydraulic high pressure pump. a screwdriver). M908050217O04 Keep the cam pressurised during turning.Exhaust Valve Cam 908-5. 3. remove the plug from the oil duct (using. adjustment of the exhaust cams should not be necessary. Apply a light pressure to the hydraulic system and. Keep the cam pressurised for at least two to five minutes before turning the cam. Mount one snap-on couplings in the oil duct. please quote Procedure M90805 Edition 0217 MAN B&W Diesel A/S Page 3 (4) . see Volume I. after venting the system. tighten the snap-on couplings. Dismount the exhaust valve high-pressure pipe. Oil must sweep out with the pump running during the operation. 3. Mount the special spanner on the exhaust cam disc.

Turn the cam disc. pcomp must be recorded and compared with pcomp at a known engine reference load. See procedure 908-5. relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Mount the inspection cover on the camshaft housing. After completing the desired turning of the cam disc.908-5. After any adjustment of the cam position. Check the change on the cam scale To increase the lead angle and reduce the compression pressure: – turn the cam disc ASTERN.3 Exhaust Valve Cam Adjustment 5. After carrying out adjustment. until the desired change of lead is obtained. Write down and file the new results for the purpose of comparing with future measurements and adjustment. To reduce lead angle and increase the compression pressure: – turn the cam disc AHEAD.4 9. 5. measure the exhaust cam lead again. using the fitted spanner. Mount the high pressure pipe for the exhaust valve.1. 6. Page 4 (4) When referring to this page. 7. Wait at least 15 minutes – the cam must be allowed time to “settle” – before mounting the plug again in the oil duct of the cam disc. please quote Procedure M90805 Edition 0217 MAN B&W Diesel A/S . See procedure 908-1. 8.

108-7 Exhaust Valve Special Running Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10807 Edition 0034 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page.

P90951 refers to chapter 909. please quote Data D10807 Edition 0034 MAN B&W Diesel A/S .108-7 Exhaust Valve Special Running Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. e.g. Plate Item No. Description P90851 124 Tool for emergency open exhaust valve P90851 173 Lifting tool for exhaust valve roller guide Page 2 (2) When referring to this page.

0 206 03 1. If the cylinder is to operate with the exhaust valve closed. 4. Section 704.Exhaust Valve 908-7 Special Running Exhaust Valve S35MC 0216 Special Running 908-7 3. GN908-4. 3. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston.2.1 203 01 5. the air supply must remain connected to the air cylinder of the exhaust valve. When referring to this page. 5. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 Page 1 (3) . This can take place with the exhaust valve locked in either the open or the closed position. Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position. No further action is required. Dismantle the oil inlet pipe. 4. Dismantle the hydraulic high-pressure pipe. See Procedure 909-10. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. Tighten the lowermost nut on the tool to pull up the roller guide as far as possible. carry out the following procedure: 2. Turn the engine until the exhaust roller guide is at TDC. See Volume I. Remove the inspection cover of the camshaft housing. See Procedure 908-1. Either way. BM908-7. Engine trouble might require that a cylinder be taken out of action.0 53 02 6. BG908-5. Lift the relevant fuel pump roller guide. Blank off the connection from the main oil pipe with a plug screw.

Remove the air pipe and the non-return valve on the aftmost side of the air cylinder to let the air inside the air cylinder escape. BG908-6.0 21 02 8. DM908-6. The tool will keep the piston of the air cylinder in the bottom position and thus keep the exhaust valve open. If the cylinder is to operate with the exhaust valve open. continue the procedure as follows: 7. Dismantle the rotation indicator on the air cylinder and mount the tool for opening of the exhaust valve. Page 2 (3) When referring to this page. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 .0 13 04 8. Turn off the air to the exhaust valve.908-7 Exhaust Valve Special Running 7.

10.0 53 04 11. Mount the hydraulic high-pressure pipe.Exhaust Valve 908-7 Special Running 9. See Procedure 908-1. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 Page 3 (3) . BM908-7. Remove the tool. BG908-5.0 206 11 11. Re-connect the air supply to the air cylinder.4. Note! The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine. 12. remove the tool mounted in the air cylinder and mount the rotation indicator. Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. See Procedure 909-10. If the engine has been running with the exhaust valve open. 13. When referring to this page. After overhaul of the cylinder unit. re-engage the exhaust valve gear as follows: 9. Remove the plug screw and mount the oil inlet pipe. Engage the fuel pump roller guide. 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.

.

Panel When referring to this page. please quote Plate P90851 Edition 0206 MAN B&W Diesel A/S Plate P90851-0206 Page 1 (2) .Exhaust Valve .

Panel Item Description Item No. 016 028 077 089 090 124 150 173 185 219 Page 2 (2) Exhaust Valve . exhaust valve roller guide Grinding ring. pneumatic piston Pressure tester. please quote Plate P90851 Edition 0206 MAN B&W Diesel A/S .Plate P90851-0206 Item No. exhaust valve bottom piece Lifting tool. emergency opening of exhaust valve Gauge. exhaust valve spindle Tool. safety valve Gauge. Item Description Panel for tools Name plate Conical ring. exhaust valve bottom piece Eye bolts When referring to this page.

Exhaust Valve .Tools 0033 P90861 When referring to this page.Tools Plate P90861-0033 Exhaust Valve . please quote Plate P90861 Edition 0033 MAN B&W Diesel A/S Page 1 (2) .

please refer to the Chris Marine manual When referring to this page. complete Notes: Page 2 (2) When ordering spare parts.Tools Item Description Item No.Plate P90861-0033 Item No. 046 Exhaust Valve . please quote Plate P90861 Edition 0033 MAN B&W Diesel A/S . Item Description Grinding machine.

please quote Plate P90862 Edition 0042 MAN B&W Diesel A/S Page 1 (2) .Exhaust Valve .Hydraulic Tools Plate P90862-0042 Exhaust Valve .Hydraulic Tools 0042 P90862 When referring to this page.

Plate P90862-0042 Item No. please quote Plate P90862 Edition 0042 MAN B&W Diesel A/S . Item Description Jack-hydraulic. complete Support O-ring with back-up ring O-ring with back-up ring Tommy bar Key. hexagon socket screw Hydraulic toolset. 028 030 053 065 089 090 207 Exhaust Valve . complete Page 2 (2) When referring to this page.Hydraulic Tools Item Description Item No.

Extra Tools Plate P90863-0007 When referring to this page.Extra Tools 0007 P90863 MAN B&W Diesel A/S . please quote Plate P90863 Edition 0007 Page 1 (2) Exhaust Valve .Exhaust Valve .

please quote Plate P90863 Edition 0007 MAN B&W Diesel A/S . 011 Exhaust Valve .Extra Tools Item Description Item No. Item Description Worktable Page 2 (2) When referring to this page.Plate P90863-0007 Item No.

Data Fuel Pump Top Cover Fuel Pump Barrel Assembly.909 .Tools Fuel Valve Nozzle .Fuel Oil System Documents in this Chapter 109-01 909-01 109-03 909-03 109-04 909-04 109-05 909-05 109-06 909-06 109-07 909-07 109-08 909-08 109-09 909-09 10911 90911 10912 90912 10914 90914 10915 90915 10916 90916 90951 90961 90961 90966 0062 0239 0051 0228 0059 0221 0064 0222 0051 0218 0038 0210 0053 0222 0033 0212 0070 0236 0049 0223 0077 0235 0059 0227 0018 0212 0453 0037 0069 0008 Fuel Pump Lead. Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide. Data Spindle Guide Fuel Oil High-Pressure Pipes. Data Fuel Pump Barrel Assembly Fuel Pump Suction Valve.Tools Fuel Valve . Data Fuel Pump Roller Guide Fuel Pump Spec. Data Fuel Pump Fuel Pump Top Cover. Runni Fuel Pump Special Running Fuel Valve and Fuel Pump . Data Fuel System Shock Absorber Fuel Valve. Data Fuel Valve Spindle Guide. Data Fuel Pump Suction Valve Fuel Pump Puncture Valve. Data Fuel Pump Cam Fuel Pump.Tools MAN B&W Diesel A/S . Data Fuel Pump Puncture Valve Fuel Pump Shock Absorber. Data Fuel Pump Lead Fuel Pump Cam.Panel Fuel Valve .

Cleaning Tools Mounting Tools .Inspection Tools Fuel Valve Nozzle .Air Piston Seals MAN B&W Diesel A/S .90968 90974 90980 0001 0001 0001 Fuel Valve .

109-1 Fuel Pump Settings Data SAFETY PRECAUTIONS For detailed sketch.5 mm D09-10 Max. Description Value Unit D09-01 One shim alters p-max 2. number of shims 12 When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10901 Edition 0062 MAN B&W Diesel A/S Page 1 (2) .5 bar D09-05 Nominal shim thickness 0.

109-1 Fuel Pump Settings Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. 200 Description Hexagon head screw for topcover When referring to this page. Plate P90951 Page 2 (2) Item No. e. P90951 refers to chapter 909.g. please quote Data D10901 Edition 0062 MAN B&W Diesel A/S .

insert shims (delay injection). loosen the drain oil pipe from the top cover and dismount the top cover fixing nuts. Mount the two original screws to protect the threaded holes. thus lifting the top cover to provide space for inserting or removing shims. When referring to this page.Fuel Pump Settings 909-1. Note down the new total shim thickness (number of shims). One shim will alter p max approximately as given in Data D09-01. For maximum inserted number of shims.3 1. Chapter 706. remove shims (advance injection). see Data D09-10. Before adjustment of the fuel pump is carried out.3 205 02 3. see Data D0905.1. To decrease p max. Note! The individual p max value must not deviate more than 3 bar from the average value for all cylinders. see Procedure 909-5. 3.3 Adjustment Fuel Pump Settings S46MC-C 0239 Adjustment 909-1. see Procedure 909-3. Mount and tighten the nuts for the top cover. GN909-1.3 239 01 1. GN909-1. To increase p max. see Volume I. 2.3 205 03 4. For nominal shim thickness. Before Maximum Combustion Pressure (p max) is adjusted. Screw the two dismantling screws (from the tool panel) into the theaded holes of the top cover. please quote Procedure M90901 Edition 0239 0$1% :'LHVHO$6 Page 1 (2) . pmax adjustment: Remove the two screws in the threaded holes of the top cover. and press down the top cover by hand. 4. also the fuel cam lead should be checked. EN909-1. Remove the dismantling screws.

If the required p max adjustment cannot be attained by inserting or removing shims. please quote Procedure M90901 Edition 0239 0$1% :'LHVHO$6 .3 239 05. 5. MIP adjustment: EN909-1. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump index arm.3 Fuel Pump Settings Adjustment 5.909-1. See Volume I. The mean indicated pressure should not deviate more than 0. Note! The mean indicated pressure is one of the most important parameters. in obtaining good engine performance.5 bar from the average value for all cylinders. it is possible to carry out the adjustment on the fuel cam disc. Contact MAN B&W Diesel for advice. Chapter 706. Page 2 (2) When referring to this page. Increase index for higher p i. Decrease index for lower p i.

see 900-2 X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Fuel Pump Cam MAN B&W Diesel 109-3 Data SAFETY PRECAUTIONS For detailed sketch. Description When referring to this page. please quote Data D10903 Edition 0051 Value Unit Page 1 (2) .

complete P91351 201 Quick coupling. male P91351 225 Disc.Fuel Pump Cam 109-3 MAN B&W Diesel 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.g. Plate Item No. pneumatically operated P91351 058 Hose with unions (3000 mm). Description P90651 044 Impact spanner for turning cam P90951 045 Measuring tool for fuel pump P91351 010 Hydraulic pump. Cu ø11x3 mm Page 2 (2) When referring to this page. P90951 refers to chapter 909. e. round-plain. please quote Data D10903 Edition 0051 .

until it rests against the pump plunger. please quote Procedure M90903 Edition 0228 0$1% :'LHVHO$6 Page 1 (3) .2. Turn ahead until the main piston of the cylinder concerned is in TDC. HM906-7.0 56 01 Remount the suction valve and the puncture valve. Note down the result as x1. see Procedure 909-3. To measure the fuel cam lead (top lift): Dismantle the suction valve and the puncture valve. Calculate the fuel cam lead C (top lift) as: 5. use a calliper to find the point. 3.1 1. ahead EN909-3.Fuel Pump Cam 909-3.1 228 00 2. Push down the measuring pin through the top cover.3. For adjustment of the fuel cam lead. Measure the distance x from the top of the measuring pin to the top cover.1 92 02 C = x1 – x2 (mm) 4.2 and 909-8. 1. Again measure the distance x from the top of the measuring tool to the top cover. When referring to this page. 4. Note down the result as x2. Lowest position of pump plunger Main piston in TDC 3. C x2 fuel cam Make sure that the reversing mechanism is in AHEAD direction.1 Checking Fuel Pump Cam S46MC-C 0228 Checking 909-3. Fuel cam lead: 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. Note down the result for comparison with the testbed results and for future reference. JG909-2. See Procedures 909-7. x1 roller guide Turn the engine until the lowest point of the cam is found.

2. Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulic highpressure pump.1 236 03 Mount snap-on couplings in the oil ducts. GN909-3. Chapter 706. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. a screwdriver).3 1. Dismount the puncture valve and the suction valve from the fuel pump top cover. 3. but do not tighten them. 2. see Volume I. and mount the measuring tool. adjustment of the fuel cam should not be necessary. Before adjustment of fuel equipment.3 204 04 3. 1.909-3. Normally.3 203 01 Note! Before dismantling any part of the fuel pump. for instance. make sure that the pump has been relieved of pressure and that all oil has been drained off. If fitted. GN909-3. See Procedure 909-3.3 Fuel Pump Cam Adjustment Adjustment 909-3. BM909-1. Page 2 (3) When referring to this page.1. Insert three copper gaskets in each oil duct. Remove the inspection cover from the camshaft housing. please quote Procedure M90903 Edition 0228 0$1% :'LHVHO$6 . remove the plugs from the oil ducts (using.

3 Adjustment 4.4 and 909-14. ensuring that the two pins enter the holes in the cam. Turn the cam disc.4. relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Mount a new O-ring on the puncture valve. after venting the system. 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. until the desired change of lead is obtained.3 204 05 Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc.Fuel Pump Cam 909-3. 5. After completing the desired turning of the cam disc. Mount the puncture valve and the fuel oil high pressure pipes. GN909-3. Keep the cam pressurised during turning. See Procedure 909-1. measure the fuel cam lead again. using the fitted spanner. To reduce lead and p max: – turn the cam disc ASTERN. Note down and file the new results for purposes of comparison with future measurements and adjustment. Keep the cam pressurised for at least five minutes before turning the cam. Mount the inspection cover on the camshaft housing. please quote Procedure M90903 Edition 0228 0$1% :'LHVHO$6 Page 3 (3) . When referring to this page. To increase lead and p max: – turn the cam disc AHEAD. 4. See Procedure 909-8. Mount the special spanner on the fuel cam disc. 7. 6. tighten the snap-on couplings. Apply a light pressure to the hydraulic system and. After carrying out adjustment.

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Fuel Pump MAN B&W Diesel 109-4 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10904 Edition 0059 Page 1 (2) . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. tightening torque 350 Nm D09-19 Pump housing nuts. Description Value Unit D09-18 Pump housing nuts. tightening angle 108 ° D09-20 Pump housing 38 kg D09-68 Fuel pump complete 58 kg When referring to this page.

Fuel Pump 109-4 MAN B&W Diesel 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. P90951 refers to chapter 909. please quote Data D10904 Edition 0059 .g. Plate P90951 Page 2 (2) Item No. 070 Description Lifting tool for fuel pump housing When referring to this page. e.

2.2 210 02 3. 1. Remove the fuel oil inlet pipe between the fuel pump and the fuel oil inlet valve. Take care not to damage the threads of the studs. make sure that the pump has been relieved of pressure and that all oil has been drained off.2 2. Note! Before dismantling any part of the fuel pump. Land the fuel pump on wooden planks. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 1 (5) . Remove the nuts at the base of the fuel pump.2 Dismantling Fuel Pump S46MC-C 0221 Dismantling 909-4. Dismantle the fuel pump top cover/plunger barrel assembly.Fuel Pump 909-4. Note! BM909-4. See Procedure 909-5. Discard the gaskets. 2. 3.2 210 03 D09-20 When referring to this page. BM909-4. Mount the lifting tool and lift the fuel pump housing away.

3 1.909-4. BM909-4. If the bottom plate sticks. • Regulating guide. loosen it by screwing two M8x50 mm screws into the threaded holes of the bottom plate. Page 2 (5) When referring to this page. BM909-4. Dismantle the: • Fuel oil index arm.3 210 03 3.3 Fuel Pump Overhaul Overhaul 909-4. BM909-4. Tilt the fuel pump housing into a horizontal position on the wooden planks.3 210 01 3. Remove the bottom plate from the fuel pump housing. 2. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S . 1.3 210 02 2.

3 210 04 Always use eye protection when working with compressed air. Warning! 6. 4. Mount a new sealing ring in the pointer for the fuel oil index arm. 5.Fuel Pump 909-4. Depending on engine type. When referring to this page. Soak the sealing ring in lubricating oil before mounting. Clean all inside surfaces of the fuel pump housing. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 3 (5) . Note! BM909-4. the index pointer can have a different shape. 6.4 121 11 BM909-4. Blow dry with compressed air. see the sketch. Clean all the parts in diesel oil or kerosene.3 Overhaul 4. replace the erosion plugs. Dismantle and inspect the erosion plugs on both sides of the fuel pump housing. If heavily eroded.3 210 06 7. HC909-3.

3 Fuel Pump Overhaul 9. Mount the regulating guide in the fuel pump housing. Mount the fuel oil index arm. BM909-4.909-4. 9. Mount the fuel oil index pointer. Mount the bottom plate on the fuel pump housing.3 210 09 • The teeth of the: – Regulating guide.3 210 10 11. ensuring that the scratch mark on the regulating guide is aligned with the scratch mark on the fuel oil index arm. – Fuel index arm. Page 4 (5) When referring to this page. 8. 10.3 210 02 11. • The sliding surfaces of all the parts of the regulating system. Adjust the position of the fuel oil index arm so that the scratch mark on the fuel oil index arm is aligned with the centre of the fuel pump housing. BM909-4. 10. Lubricate the following with molybdenum disulphide grease (MoS 2): • All internal surfaces of the fuel pump housing. BM909-4. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S .

make sure that all sliding faces and threads are cleaned and lubricated with molybdenum disulphide grease (MoS 2). Mount and tighten the nuts at the base of the fuel pump housing. 1. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 5 (5) . taking care not to damage the threads of the studs. not both. Lower the fuel pump housing on to the pump base. See Procedure 909-5. See Data. When referring to this page.4 Mounting Mounting 909-4. Note! Before mounting the fuel pump housing. BM909-4. BM909-4.Fuel Pump 909-4.4 210 02 3.4 1.2 210 03 Note! 2. D09-19 D09-18 D09-20 See Procedure 913-11. Mount the fuel oil inlet pipe between the fuel pump and the fuel inlet valve. Mount the fuel pump top cover/plunger-barrel assembly.4. Only use either the tightening angle or the tightening torque. Remove the lifting tool. 2.

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please quote Data D10905 Edition 0064 Page 1 (2) . max. tightening torque 15 Nm D09-26 Outlet seat. tightening torque 30 Nm D09-25 Pump barrel/top cover.grinding diameter 10 mm D09-27 Top cover 12 kg D09-28 Plunger/barrel assembly + top cover 20 kg When referring to this page. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. screwing-in torque 40 Nm D09-24 Top cover nuts. Description Value Unit D09-23 Top cover studs.Fuel Pump Top Cover MAN B&W Diesel 109-5 Data SAFETY PRECAUTIONS For detailed sketch.

Description P90951 069 Lifting tool for fuel pump P90951 094 Milling tool for fuel oil pipe seats P90951 200 Hexagon head screw for topcover P90951 212 Extraction tool for suctions valve Page 2 (2) When referring to this page. please quote Data D10905 Edition 0064 . e. Plate Item No. P90951 refers to chapter 909.g.Fuel Pump Top Cover 109-5 MAN B&W Diesel 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.

GN909-5.Fuel Pump Top Cover 909-5. Remove the top cover fixing nuts. GN909-5. GN909-1. Dismount the suction valve by means of the extractor tool. 2.3 205 01 3. as well as the two screws in the top cover. 2.2 208 01 Dismount the puncture valve from the top cover. When referring to this page. Close the oil inlet valve to the fuel oil pump and drain the pump. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 1 (7) . See Procedure 909-8. Loosen the top cover by means of the two dismantling screws from the tool panel.2 Dismantling Fuel Pump Top Cover S46MC-C 0222 Dismantling 909-5. See Procedure 909-14.2 205 02 Release the link for the regulating drive and pull out the toothed rack as far as possible. Dismount the drain oil pipe from the top cover and the air pipe connection to the puncture valve. Dismount the fuel index pointer. 3. 1.2 1. Dismount the high pressure pipes.

Fuel Pump Top Cover 909-5. D09-28 6. Mount the lifting tool on the fuel pump top cover. Ensure that the stop ring on the centre screw is loose. To do this it may be necessary to move the toothed rack and the centre screw of the tool in relation to each other. Dismount the lifting tool.2 Dismantling 4. Page 2 (7) When referring to this page. Take care that the plunger does not slide out of the barrel. GN909-5. 5.2 205 05 Send the barrel/plunger assembly to an MAN B&W authorised workshop for overhaul. Screw the centre screw of the tool into the pump plunger. GN909-5.3. 5.2 208 04 When the plunger has been lifted clear of the roller guide and regulating guide. Pull the centre screw of the tool to lift the plunger clear of the bayonet joint in the roller guide and the milled recess of the regulating guide. lock the centre screw in this position with the stop ring. Lift the top cover and barrel with plunger out of the fuel pump housing as one unit. or overhaul it on board.2 205 06 6. Set up the pump unit in a bench vice provided with ‘soft’ jaws. See Procedure 909-6. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 . Remove the shims and tag them for reinstallation. Press the plunger to the top of the barrel and remove the barrel/plunger assembly from the top cover. GN909-5. 4.

GN909-5. Turn the miller by means of. GN909-5. see Data D09-26. Reconditioning of the seatings for the highpressure pipes is carried out by milling according to the following procedure: Fill the oil ducts in the top cover with Vaseline or heavy grease.3 205 02 Clean the top cover with diesel oil. while tightening the guide screw lightly to provide a suitable pressure between miller and seat. For the max. e.g.3 205 01 During the milling.3 Overhaul Overhaul 909-5. a tap wrench. add drilling oil emulsion liberally. When referring to this page. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 3 (7) . 2.Fuel Pump Top Cover 909-5. blow out the Vaseline/grease from the oil ducts by means of compressed air. milling/grinding diameter of the seat.3 1. After completing the milling. 2. GREASE During the work the miller is guided by the guide screwed into the thread for the highpressure pipe. Remove and discard the sealing rings. D09-26 Carefully clean and examine the top cover. Warning! Always use eye protection when working with compressed air. 1. and blow dry with compressed air.

‘Screw’ the back-up rings onto the top cover. guided by the guide pin. in such a way that the diameter of the rings becomes smaller than the diameter of the ring groove in which the rings are to be mounted. Mount the O-ring which seals between top cover/fuel pump housing. Page 4 (7) When referring to this page. insert the O-ring between the backup rings in the ring groove. D09-25 Finally. 3. Mount the overhauled top cover on top of the pump barrel. 4. Sealing between the top cover and pump barrel is provided by two back-up rings and an O-ring in between. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 .3 Fuel Pump Top Cover Overhaul 3. see Data D09-25. into the groove. Tighten the screws.3 205 03 Prepare the back-up rings by twisting the rings in the hand. Sealing between the top cover and the fuel pump housing is provided by an O-ring.909-5. GN909-5.2 205 06 4. Mount the sealing rings in the ring grooves. GN909-5.

4 208 02 Pull the plunger as high up in the barrel as possible. Place the tool on the pump housing and press down the centre screw until the measuring pin reaches the thrust piece of the roller guide.4 208 01 Keep the stop ring tightened in this position until the plunger has been correctly mounted.4 Mounting Mounting 909-5. Remove the tool from the pump housing and remove the measuring pin from the centre screw.4 1. and attach the plunger to the centre screw.Fuel Pump Top Cover 909-5. Carefully lower the assembly into the pump housing (taking special care not to damage the O-ring and back-up rings on the barrel). Note! The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. GN909-5. GN909-5. The tool is now firmly attached to the assembly. 2. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 5 (7) . Mount the supplied measuring pin on the centre screw of the lifting tool as shown in the sketch. Mount the tool on the barrel/plunger and top-cover assembly. Adjust the top cover so that the guide pin enters the hole in the pump housing. Tighten the tool to the top cover by means of the two screws. Lock the centre screw in this position with the stop ring. Loosen the stop ring on the centre screw. enabling the correct position to be obtained during mounting. When referring to this page. 1. 2. Lower the top cover on to the pump housing. Pull the regulating toothed rack out as far as possible.

4 Fuel Pump Top Cover Mounting 3. Screw the two dismantling screws from the tool panel into the threaded holes of the top cover. GN909-5. Unscrew the centre screw from the plunger and remove the tool from the top cover. Check that the stop ring of the centre screw is in full contact with the flange of the tool. turn the regulating guide a little (using the toothed rack) to make the foot and regulating block of the plunger fit properly in the cutout of the regulating guide.909-5. 3. When pulling on the centre screw it must not be possible to lift the plunger more than a few mm. press the regulating toothed bar in. as when measuring.4 208 03 When the plunger is in place. Check through the inspection cover on the fuel pump base and by pulling the centre screw of the tool.4 208 024 5.3 205 02 5. 4. 6. If a new barrel assembly is mounted. insert the same number of shims as were removed). insert the number of shims specified in the test bed report. causing the plunger foot to interlock with the bayonet joint of the roller guide. GN909-1. that the plunger is correctly engaged. Page 6 (7) When referring to this page. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 . thus lifting the top cover to provide space for inserting shims. Insert shims between the pump housing and the top cover. 4. Press the plunger down into contact with the thrust piece of the roller guide. GN909-5. (If the barrel assembly is the same as that dismounted. If necessary.

tighten them. and check that the top cover does not lift.3 205 03 8. the plunger is not correctly mounted and must be remounted. Chapter 706. Mount the suction valve and the puncture valve in the top cover. See Data D09-24. and press down the top cover.Fuel Pump Top Cover 909-5.4 Mounting 7. Connect the drain oil pipe to the top cover and the pipe connection to the puncture valve. Replace the dismantling screws with the two screws for mounting the lifting tool. Mount the two high-pressure pipes on the top cover/fuel valves. When referring to this page. See Data D09-23. GN909-5. GN909-1. If the top cover lifts. See Procedure 909-8. If any of the fuel pump top cover studs have come loose. 7. See Procedure 909-14. OPERATION. Mount the fuel index pointer Mount the link for the regulating drive. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 7 (7) . Turn the engine one complete revolution. and tighten them diagonally. see Procedure 9091 and Volume I. Open the fuel oil inlet. 9. Mount the top cover fastening nuts.4 208 09 For fuel pump settings.

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D09-29 Description Barrel assembly When referring to this page. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Fuel Pump Barrel Assembly MAN B&W Diesel 109-6 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10906 Edition 0051 Value Unit 8 kg Page 1 (2) .

P90951 refers to chapter 909. e. Description When referring to this page. Plate Page 2 (2) Item No. please quote Data D10901 Edition 0000 .Fuel Pump Barrel Assembly 109-6 MAN B&W Diesel 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.g.

‘Screw’ the back-up ring on to the barrel.Fuel Pump Barrel Assembly 909-6. Chapter 706. cover all openings with plastic to prevent dirt from entering the barrel assembly during storage. 1. See Procedure 909-5. see Volume I.3 205 01 Clean the outside of the barrel.3 1. Finally. EN909-6. For evaluation of pump barrel/plunger. 4. please quote Procedure M90906 Edition 0218 0$1% :'LHVHO$6 Page 1 (1) .3 Overhaul Fuel Pump Barrel Assembly S46MC-C 0218 Overhaul 909-6. When referring to this page. Note! Take care that the plunger does not slide out of the barrel. see Procedure 909-5. OPERATION. and dismantle the barrel/plunger assembly from the top cover.2.3 218 03 3. 3. GN909-6. Remove the top cover with the barrel/plunger assembly from the fuel pump housing. in such a way that the diameter of the ring becomes smaller than the diameter of the barrel. The sealing ring on the pump barrel consists of an O-ring and a back-up ring. position the O-ring in the ring groove. into the groove. D09-29 2. For mounting the fuel pump barrel assembly. as this may cause scratches to the plunger. Remove and discard the O-rings.. Prepare the back-up ring by twisting the ring in the hand. If the barrel assembly is not to be mounted immediately. Note! It is recommended not to remove the plunger from the barrel. The O-ring must be above the back-up ring.4 (fuel pump top cover).

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Description When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.109-7 Fuel Pump Suction Valve Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10907 Edition 0038 MAN B&W Diesel A/S Value Unit Page 1 (2) .

please quote Data D10907 Edition 0038 MAN B&W Diesel A/S . P90951 refers to chapter 909.109-7 Fuel Pump Suction Valve Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.g. e. Plate P90951 Page 2 (2) Item No. 212 Description Extraction tool for suctions valve When referring to this page.

3 Overhaul Fuel Pump Suction Valve S35MC 0210 Overhaul 909-7. please quote Procedure M90907 Edition 0210 0$1% :'LHVHO$6 Page 1 (1) . If the seats are damaged. 1. 3. After cleaning and inspecting all the parts.3 205 07 3. If the suction valve is not to be mounted on the engine immediately after the overhaul. GN909-7. Check the seats for tightness by filling the inlet hole with diesel oil and waiting 5 minutes.3 205 05 2. Set up the suction valve in a bench vice with “soft” jaws and press down the spring by means of the cone to release the valve spindle from the two-part conical ring. a new or reconditioned suction valve must be fitted.3 205 06 4. 2. Clean the parts thoroughly in clean diesel oil and blow dry with compressed air.Fuel Pump Suction Valve 909-7. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. (Send the damaged valve to an authorized MAN B&W repair shop for reconditioning). GN909-7. GN909-7. When referring to this page.3 1. lubricate these with molybdenum disulphide (MoS 2) and assemble the suction valve. Inspect the seat on the valve spindle and the seat on the valve housing for damage. No oil may pass through the seats.

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please quote Data D10908 Edition 0053 Value Unit 250 Nm Page 1 (2) . tightening torque When referring to this page. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D09-35 Description Puncture valve.Fuel Pump Puncture Valve MAN B&W Diesel 109-8 Data SAFETY PRECAUTIONS For detailed sketch.

128 Description Crowfoot spanner When referring to this page. please quote Data D10908 Edition 0053 . e.Fuel Pump Puncture Valve 109-8 MAN B&W Diesel 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.g. Plate P90951 Page 2 (2) Item No. P90951 refers to chapter 909.

Unscrew the puncture valve and remove it from the fuel pump top cover. When referring to this page. Disconnect the air pipes from the puncture valve.2 Dismantling 1. M909080222D01 Remove the fuel oil high pressure pipes. 2. M909080222D02 2. Note! Before dismantling any part of the fuel pump.Fuel Pump Puncture Valve 909-8. please quote Procedure M90908 Edition 0222 MAN B&W Diesel A/S Page 1 (4) . make sure that the pump has been relieved of pressure and that all oil has been drained off. 2.2. See Procedure 909-14.

Loosen and remove the two screws and dismount the cover. Repeat step 2 on the lowermost ring groove on the rod of the air piston. 2. 1. When referring to this page. Mount the two O-rings in the uppermost ring groove on the rod of the air piston. 2. Remove the pusher and the large cone. Page 2 (4) 3. compress the sealing ring by means of the compression tool. by means of the pusher. and position the large cone on the rod. Set up the puncture valve in a bench vice with "soft" jaws. push the sealing ring on to the O-rings in the groove. Clean all the parts in clean diesel oil. M909080222O01 Remove the spindle and the spring from the upper part of the housing. Remove and discard all O-rings and sealing rings. Pull the upper part of the housing clear of the lower part of the housing. M909080222O02 Finally. please quote Procedure M90908 Edition 0222 MAN B&W Diesel A/S .909-8. Place the sealing ring on the cone and. Heat the sealing ring in 100°C hot water for minimum 5 minutes.3 Fuel Pump Puncture Valve Overhaul 1.

please quote Procedure M90908 Edition 0222 MAN B&W Diesel A/S Page 3 (4) .Fuel Pump Puncture Valve 909-8.3 Overhaul 4. 5. Before assembling the puncture valve. M909080222O05 Mount the spring and air piston in the upper part of the housing and assemble the two housing parts and the cover by means of the two screws. Position the cone on the piston head. 4. lubricate all parts with molybdenum disulphide. M909080222O04 Remove the pusher and the cone. (MoS2). Mount the O-ring in the ring groove on top of the piston. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. If the puncture valve is not to be mounted on the engine immediately after the overhaul. Mount new O-rings on the upper and the lower part of the housing and the cover. push the sealing ring onto the O-ring in the groove. Heat the sealing ring in 100°C hot water for minimum 5 minutes. Finally. using the pusher. 6. When referring to this page. Place the sealing ring on the cone and. 5. compress the sealing ring by means of the compression tool.

please quote Procedure M90908 Edition 0222 MAN B&W Diesel A/S . Mount the fuel oil high pressure pipes. Mount the air pipes for the puncture valve.909-8. D0935 Lubricate the thread on the puncture valve with molybdenum disulphide grease (MoS2). Before mounting the puncture valve. Screw in the puncture valve and tighten with a crowfoot wrench and a torque spanner to the specified torque. M909080222M02 2. 3. see Data D0935.4 M909080222M03 3.4 Fuel Pump Puncture Valve Mounting 1. 2. check that the bore in the top cover is clean and check the O-ring on the puncture valve. see Procedure 909-14. Page 4 (4) When referring to this page.

see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D09-39 Description Shock absorber When referring to this page.Fuel Pump Shock Absorber MAN B&W Diesel 109-9 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10909 Edition 0033 Value Unit 12 kg Page 1 (2) .

please quote Data D10909 Edition 0033 . e. Plate Page 2 (2) Item No. Description When referring to this page.g. P90951 refers to chapter 909.Fuel Pump Shock Absorber 109-9 MAN B&W Diesel 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.

GN909-9. Note down the amounts measured and compare with earlier measurements. The checks should be carried out while the engine is operating.1 Checking Fuel System Shock Absorber S50MC-C 0212 Checking 909-9. When referring to this page. measure the amount of leakage oil flowing from the drain pipe below the 3-way valve. Check that air is ‘pulsating’ through the threaded hole. corresponding to the strokes of the fuel pump. please quote Procedure M90909 Edition 0212 0$1% :'LHVHO$6 Page 1 (3) . See Procedure 909-9.1 1.1 212 02 3. Remove the plug from the end cover of the shock absorber. Increasing amounts indicate a deteriorating piston sealing. HM909-4.3. 2.0 09 01 1. inspection is necessary only at the intervals stated in the maintenance programme. Excessive amounts indicate that the shock absorber requires overhauling. To check the ‘tightness’ of the piston.1 212 03 3. Short bursts of air should be felt against the hand.Fuel System Shock Absorber 909-9. the functioning of the fuel oil system shock absorber should be checked at regular intervals. Normally. To ensure satisfactory operation. 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. GN909-9. 2.

Lubricate all sliding surfaces and assemble the shock absorber. Remove and discard the sealing ring in the shock absorber housing and the wear ring on the piston. Remove the locking plates and loosen the screws of the end cover. HG909-9. 2. GN909-9. Remove the threaded rod and insert the plug. Page 2 (3) When referring to this page. Mount the springs and the spring guide between the end cover and the piston. HG909-9. Loosen the screws holding the shock absorber and remove it from the fuel oil system.3 Fuel System Shock Absorber Overhaul Overhaul 909-9. make sure that the system has been relieved of pressure and that all oil has been drained off. Clean all parts and polish the sliding surfaces of the piston and the shock absorber housing. Take care not to damage the sealing ring or wear ring when mounting the piston. 4. Mount a new sealing ring in the shock absorber housing and a new wear ring on the piston. 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. Remove the end cover and piston. 5. please quote Procedure M90909 Edition 0212 0$1% :'LHVHO$6 .3 1. 2. Remove the 3-way valve and the drain pipes. Loosen the nut on the threaded rod to relieve the springs and remove the threaded rod. Mount the end cover.2 201 04 6. Note ! Before dismantling any part of the fuel oil system.2 201 02 4.3 212 01 1. using the threaded rod. Check that the piston slides easily in the shock absorber housing.909-9. Discard the gasket. 3.

Fit a new gasket and mount the shock absorber.Fuel System Shock Absorber 909-9.3 Overhaul 7. the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning. When referring to this page. please quote Procedure M90909 Edition 0212 0$1% :'LHVHO$6 Page 3 (3) . If an excessive amount of drain oil is still observed after the overhaul. Mount the 3-way valve and the drain pipes on the fuel oil system.

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please quote Data D10911 Edition 0070 3 kg Page 1 (2) .Fuel Valve MAN B&W Diesel 109-11 Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D09-40 Fuel valve opening pressure 300 . max. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.380 bar D09-41 Fuel valve tightening torque 20 Nm D09-42 Inlet seat. diameter 10 mm D09-43 Fuel valve When referring to this page.

Plate Item No.g.Fuel Valve 109-11 MAN B&W Diesel 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.Tools When referring to this page. P90951 refers to chapter 909. please quote Data D10911 Edition 0070 . e. Description P90151 071 Dismantling tool for fuel valve P90951 094 Milling tool for fuel oil pipe seats P90951 165 Grinding mandrel for valve head P90961 Page 2 (2) Fuel Valve .

see the supplier’s instructions. D09-41 All fuel valves must be function-tested before being mounted in the cylinder cover. the opening pressure value measured might be considerably lower than specified. inspected and re-assembled before testing. Note! In the event that the slide-type fuel valve is pressure tested without being cleaned between the fuel nozzle and the cut-off slide. as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. cleaned. 2. working air of seven bar can be used. For operation of the pressure testing pump.3 101 02 Note that the high-pressure pump should be periodically checked in accordance with the supplier’s instructions.3. In order to obtain reliable results during testing of the fuel valves.3 and 909-12. Use only hydraulic oil (rust-preventing) with a viscosity of between 7 and 10 cSt at 50°C.1 204 01 If the engine gives normal performance in accordance with diagrams and exhaust temperatures. DM909-6. When referring to this page. use a connecting piece with a valve. 2. See Chapter 900-1. GN909-11.Fuel Valve 909-11. it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. all fuel valves that are dismantled from the engine must be disassembled. Pressure testing pump If an air supply of 10 bar is not available. 1. If the pressure testing pump has no built-in outlet valve. Place the fuel valve in the test rig and mount the nuts. The fuel valves must be given the utmost attention and care.1 1. Tighten the nuts to the torque stated in Data. See Procedure 909-11. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 1 (11) .1 Checking Fuel Valve S35MC 0236 Checking 909-11. Mount the connecting piece and the oil pipe between the pressure testing pump and the fuel valve.

4. 6. B. D. Owing to the geometry of the internal part of the nozzle – and because the height to which the spindle is lifted during pressure testing is lower than the height it is lifted during normal engine operation – the fuel oil will not necessarily flow from all of the nozzle holes. Pressure testing procedure The subsequent items must be followed in the sequence stated. BM909-11. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . • The nozzle is not mounted correctly. Procedure: The control handle must be in the OPEN position. When referring to this page. C. Objective Procedure Acceptance criteria Cause of fault. Acceptance criteria: There is to be a continuous jet of oil through at least one of the nozzle holes. the cause may be: Page 2 (11) • Dirt in the nozzle holes. 7 and 8 are each divided into the following four subitems: A. Slowly increase the working pressure until straight jets of oil are ejected from the nozzle holes (no atomization). D. Objective: To remove air in the system and check the fuel jet. C. Cause of fault: If the jets do not fulfil the above point C.909-11. 3. Flushing and jet control A. Items 4.1 236 04 B.1 Fuel Valve Checking 3.

B. with a small lift at a very high frequency. Cause of fault: If the opening pressure is higher than specified in D09-40. Atomization test Note! The reason is that the atomization test may damage the valve because it makes the needle oscillate. The high pressure drop across the cut-off edge and the high contact pressure between slide and fuel nozzle. replace the complete spindle guide. if necessary. 6. BM909-11. D09-40 6. as this may damage the cut-off slide and nozzle. the cause may be that a wrong type of spring is used – replace the spring in the spindle guide. C. Opening pressure A. or add a special thin disc. The pressure must correspond to the pressure stated in Data D09-40. the cause may be that the spring has sagged – replace the spring. 5. BM909-11. in combination with the poor lubricity of the test oil. When referring to this page.1 236 06 D. Procedure: The control handle is to be in the OPEN position. Objective: To check the opening pressure.1 Checking 5. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 3 (11) .1 236 05 Do NOT attempt to carry out an atomization test on slide type fuel valves. increase the risk of seizures between cut-off slide and nozzle. Acceptance criteria: Check the opening pressure on the pressure gauge. If the opening pressure is lower than specified in D09-40.Fuel Valve 909-11.3. All of these conditions involve the risk of seizure between the cut-off slide and the nozzle. Increase the oil pressure until oil is admitted through the nozzle holes. See Procedure 909-12.

See Procedure 909-12.3.1 236 07 A. B. Note! Oil flows out of the leak oil outlet when the fuel valve is full of oil. after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). The pressure drops relatively slowly to about 15 bar. 7. Examine and/or replace the spindle guide. Page 4 (11) When referring to this page. the pressure testing procedure of the fuel valve must be repeated from step 3. Cause of fault: D.1 Sealing test If oil flows out of the nozzle holes. Note! Special thin discs are available as spares. Acceptance criteria: Oil must not flow from the nozzle holes. C. Objective: To check the needle valve seat for tightness and the slide for correct closing. D.1 Fuel Valve Checking 7. Repeat the procedure two or three times. the cause is either: • Defective spindle guide at needle seat. or a sticking spindle. Sealing test and sliding function BM909-11. Maintain the built-up pressure by moving the control handle into the CLOSED position. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S .909-11. Procedure: The control handle must be in the OPEN position. If a spring or a disc has been changed. Slowly increase the oil pressure to about 50 bar below the opening pressure.

or – the seat between the spindle guide and the fuel valve head is damaged.3. When referring to this page. replace if necessary.2 Sliding function The pressure drops relatively slowly to about 15 bar. Examine and/or replace the spindle guide.Fuel Valve 909-11. See Procedure 909-12.1 Checking • Too quick pressure drop: – the clearances of the movable parts. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 5 (11) . after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). See Procedure 909-12. inside the spindle guide are too large. disassemble and examine the spindle guide. or • the vent hole in the vent slide is blocked. If so. D. If a quick pressure drop from 15 to 0 bar cannot be registered: • The valve slide is sticking.3. Note! There will always be an oil flow from the leak oil outlet when the fuel valve is full of oil.

Pressure test. Cause of fault: If oil leaks out at the union nut. Page 6 (11) When referring to this page. BG909-6. 10 bar until oil flows out of the leak oil outlet. Move the control handle to the CLOSED position. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . C.1 Fuel Valve Checking 8. O-ring sealings A. the O-ring inside the fuel valve head is defective. 8.909-11. and must be replaced. Increase the working pressure to about 100 bar. Acceptance criteria: Close the leak oil outlet with a gasket and plug screw. Procedure: The control handle is to be in the OPEN position. Objective: To ensure that the leak oil (circulation oil) remains in the closed system. The built-up pressure of about 100 bar should be maintained. B. Build up a working pressure of about max.3 66 07 D.

2. the valve should be placed immersed in diesel oil until overhauling.Fuel Valve 909-11. BM909-11.2 236 03 3. Close the fuel oil inlet and outlet valves. BM909-11.2 209 02 3. Remove the nuts and the tubular spacers. Lift the valve. 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.1 97 01 Remove the high-pressure pipe. and drain the high-pressure pipe and the fuel valve. Unscrew the union nipple at both ends of the pipe (fuel valve and fuel pump). 2.2 Dismantling Dismantling 909-11. BG901-2. If the valve is sticking. Unscrew the union nut by means of the hook spanner and take the union nut with protective hose up along the pipe. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 7 (11) . Disconnect the return oil pipe from the fuel valve. 1.2 1. Remove the valve from the engine. When referring to this page.

and write down the result for correct re-assembling of the valve.3 236 01 A Use only clean. Pull the valve head clear of the valve housing. Remove the complete spindle guide and the fuel nozzle from the valve housing. BM909-11. Disassemble the fuel valve by screwing off the two socket head cap screws while retaining the valve in. Measure the length A of the protruding part of the nozzle. for instance. BM909-11. 1. all sealing rings should be discarded and replaced by new. 2. a bench vice provided with “soft” jaws.3 1. non-fluffy rags for wiping purposes. all parts should be handled carefully and be kept clean. 2. Whenever fuel valves are overhauled. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . When fuel valves are overhauled.Fuel Valve 909-11.3 236 02 Remove and discard all the O-rings. Remove and discard the O-rings. Make sure to remove all liquid or solid impurities. Page 8 (11) When referring to this page. faultless sealing rings before reassembly.3 Overhaul Overhaul 909-11.

500). but it may be fitted in the chuck of a columntype drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. An ample supply of cutting emulsion must be used. BM909-11.3 Overhaul 3. If this is not possible. 3.Fuel Valve 909-11. 100 r/min). please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 9 (11) . including the fuel nozzle. Carefully clean and examine all surfaces of the fuel valve housing and the fuel valve head.3. BG909-6. see Data. Normally. wash the parts in gas oil and blow clean by means of compressed air to remove any remains of the grinding compound. This grinding must only be carried out manually. D09-42 If necessary. Note! Take care not to exceed the maximum diameter of the seat.3 236 04 4. should be sent to an authorised MAN B&W repair shop for overhaul. the milling tool can be used. When referring to this page. See Procedure 909-12. The complete spindle guide. the milling tool is turned by hand. 4. grind the seating surfaces by means of the grinding mandrels supplied and a fine-grain abrasive (such as Carborundum No. the spindle guide may be overhauled on board.1 66 02 In the event of more serious damage to the seating surface for the high-pressure pipe in the valve head. After the grinding.

1. Carefully slide the spindle guide down into the valve holder. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . Check that distance A corresponds to the measurement taken before the valve is disassembled. BM909-11. 5. 6. Mount a new O-ring on the spindle guide and lubricate it with MoS 2. It must not be possible to turn the nozzle. When mounting the valve head. and tighten the screws. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. and turn the nozzle until the spindle guide engages correctly with the guide pin. If the fuel valve is not to be mounted in the engine immediately after the overhaul. Mount the fuel valve head on the fuel valve housing.1 66 06 After overhaul. See Procedure 909-11. the fuel valve must be tested in the test rig. and check that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts. including the fuel nozzle.3 Fuel Valve Overhaul 5. Mount the complete spindle guide. When referring to this page. Note! Make sure that the fuel nozzle and spindle guide engage correctly with the guide pin in the fuel valve housing. Page 10 (11) 7. in the fuel valve housing.909-11. make sure that the guide pin between valve housing and valve head is intact. BG909-6. This can be ascertained by attempting to turn the nozzle after mounting.3 236 05 Mount a new O-ring in the lowermost groove of the fuel valve head. 6. Fit the uppermost groove of the valve head with a new O-ring.

D09-41 Mount the fuel oil high-pressure pipe and tighten. Turn on the fuel oil supply. 2. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting.1 97 05 3. 1.4 Mounting Mounting 909-11. thoroughly clean the valve bore in the cylinder cover and check the seating in the bore for marks which. Mount a new O-ring in the groove on the valve housing. BM901-2. BM909-11. 3. Note! BM901-2. All fuel valves must be function-tested before being mounted in the cylinder cover. Tighten the nuts as stated in Data.1. using the crow foot wrench and a torque wrench.3). mount a new O-ring on the valve head. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 11 (11) . If not already done. Mount the valve in position in the cylinder cover. must be eliminated. See Procedure 909-14. if any. (For reconditioning of valve bore in cylinder cover.1 97 04 Reconnect the return oil pipe to the fuel valve. Mount the tubular spacers and the nuts. When referring to this page.Fuel Valve 909-11.4.4 1. 2. see Procedure 901-1.4 236 01 Lubricate the valve with copper grease. Before mounting the fuel valve. see Procedure 909-11.

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please quote Data D10912 Edition 0049 Value Unit Page 1 (2) . Description When referring to this page.Spindle Guide MAN B&W Diesel 109-12 Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

Cleaning Tools Page 2 (2) When referring to this page. e.g.Spindle Guide 109-12 MAN B&W Diesel 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. P90951 refers to chapter 909. 153 Description Flange for dismantling of non return valve P90968 Fuel Valve .Tools P90974 Fuel Valve Nozzle . please quote Data D10912 Edition 0049 . Plate P90951 Item No.Inspection Tools P90966 Fuel Valve Nozzle .

and use a brass mandrel and a hammer to remove the thrust piece from the valve housing. both terms will be used to describe the part in this procedure.2 66 01 Extreme care and accuracy should be exercised when carrying out this operation. The individual parts of the spindle guide are not interchangeable.3 222 04 3. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S Page 1 (5) .3 223 02 Note! 3.3 Overhaul Spindle Guide/Non-return Valve S35MC 0223 Overhaul 909-12. 1. Place the non-return valve part of the spindle guide in a bench vice provided with “soft” jaws. except the springs and the fuel nozzle are matched parts and may not be replaced individually. All parts of the spindle guide/non-return valve.Spindle Guide/Non-return Valve 909-12. BM909-12. BM909-12. However. Clean the outside of the spindle guide in pure gas oil or kerosene. 2. Place the spindle guide/non-return valve in a bench vice provided with “soft” jaws. and use the spindle guide dismantling tool as shown to remove the non-return valve from the spindle guide. Mount the pulling tool around the fuel nozzle on the spindle guide. therefore only one guide should be disassembled at a time. BG909-6. Turn the nut to pull the fuel nozzle off the spindle guide. Note! The spindle guide and the non-return valve have been integrated into one unit.3 1. When referring to this page. 2.

Clean all the parts of the spindle guide and the non-return valve in gas oil. and blow clean with compressed air. The sliding surface must not be damaged.2 111 05 6. and polishing it with a very fine conventional polishing linen ‘grade 360’. lint-free cloth and examine them through an 8-10 times enlargement magnifying glass and an inspection lamp. Page 2 (5) When referring to this page. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S . 4.3 223 05 The sliding surface of the cut-off slide may only be polished VERY carefully. pay special attention to the seating surfaces and sliding surfaces of the parts.3 Spindle Guide/Non-return Valve Overhaul 4. 6. Place all the parts on a clean. Remove any deposits or very fine scratches by placing the spindle and vent slide in a lathe. During the examination. as shown. MA909-6. Use also a little oil for the polishing (a coarser polishing linen must absolutely not be used).909-12. BM909-12-3 223 04 5. and blow dry with compressed air. Note! BM909-12. Clean all parts again in kerosene or ‘Electrocleaner’. 5.

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. the cut-off slide must be able to move freely inside the nozzle. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. If the test pin is able to enter just one of the holes. using gas oil and the special drills supplied.Spindle Guide/Non-return Valve 909-12. 7. When referring to this page.3 222 07 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. Clean the spray holes. the fuel nozzle must be discarded. Note! It is recommended that the fuel nozzle is changed whenever the spindle guide is being overhauled. BM909-12. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S Page 3 (5) . Then test the spray holes with the test pin. Clean the fuel nozzle with kerosene and wipe dry with a clean cloth.3 Overhaul 7.

clean the parts again and re-check the seat on thrust piece/spindle. the seat on slide valve/spindle. 10. 10. 8. Lubricate the sliding surfaces of all parts with Molybdenum Disulphide (MoS 2). See Procedure 913-11. BM909-12.e. 9. Place the thrust piece at the end of the housing. BM909-12. Place the lower part of the spindle guide housing in a bench vice provided with “soft” jaws. and the seat on spindle/guide.3 Spindle Guide/Non-return Valve Overhaul 8. After polishing. 11.3 223 08 Insert the non-return valve spindle and the spring in the housing.909-12. 12. Page 4 (5) When referring to this page. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S . i. Place the housing of the non-return valve in a bench vice provided with “soft” jaws.3 223 11 11. if there are pressing-in marks or similar on the seats. BM909-12.3 223 10 Mount the spindle and the spring inside the housing of the spindle guide using the spindle guide dismantling tool and a hammer. Carefully tap the thrust piece into the housing with a lead hammer. the complete spindle guide must be discarded. Use an inspection lamp and an 8-10 times enlargement magnifying glass. Mount a new O-ring on the spindle guide/ non-return valve. If the seats are not in order.

Press the nozzle on to the spindle guide. BM909-12. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS 2). cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle guide during storage. Then press the parts together the same way as when using the mounting tools. the nozzle can be mounted on the spindle guide using a short piece of pipe. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S Page 5 (5) . Use the dismantling tool for the spindle guide to align the parts.Spindle Guide/Non-return Valve 909-12. See Procedure 913-11. Make sure that all the parts are perfectly aligned. 14. Place the parts on the plane of a drilling machine and mount the mounting tool in the chuck. so that the lower end of the pipe rests on the ‘foot’ of the fuel nozzle.3 223 13 The mounting tools are not standard for all engines but may be delivered as optional extras. Note! If no mounting tools are available. When referring to this page. Place the pipe around the nozzle. If the spindle guide is not to be mounted in a fuel valve immediately after the overhaul. Mount the nozzle on the spindle guide. 13.3 Overhaul 11.

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see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description D09-47 Fuel oil high-pressure pipe. tightening torque D09-52 Fuel oil pipe When referring to this page. please quote Data D10914 Edition 0077 Value Unit 25 Nm 4 kg Page 1 (2) .Fuel Oil High-Pressure Pipe MAN B&W Diesel 109-14 Data SAFETY PRECAUTIONS For detailed sketch.

P90951 refers to chapter 909. please quote Data D10914 Edition 0077 . Description P90951 104 Milling tool for fuel oil pipe P90951 116 Crowfoot spanner Page 2 (2) When referring to this page. e. Plate Item No.Fuel Oil High-Pressure Pipe 109-14 MAN B&W Diesel 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.g.

2 210 03 The overhaul should preferably take place immediately after the high-pressure pipe has been dismantled.Fuel Oil High-Pressure Pipe 909-14. See Procedure 909-14. 3.3. and remove the high-pressure pipe from the engine. D09-52 BM909-14. Close the fuel oil inlet and outlet valves. GN909-14. BM909-14. 4. Lift the pipe ends clear of the fuel valve/fuel pump. When referring to this page. Unscrew the union nipple from the fuel pump. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 Page 1 (4) . Unscrew the union nipple from the fuel valve.2 2. High-Pressure Pipe with Double Pipe 1.2 211 02 2. 3. Note! It is recommended always to overhaul the high-pressure pipe before remounting it on the engine.2 Dismantling Fuel Oil High-Pressure Pipe S35MC 0235 Dismantling 909-14.2 211 04 4.

Remove the spring ring from the two-part sleeve. together with their seats in fuel valves and fuel pump top cover. 3. Fasten the pipe in a vice with soft jaws. and blow through the bore with compressed air. Lift up the union nut. KN909-14. Remove the sleeve. Whenever the fuel oil high-pressure system has been dismantled. a tap wrench while lightly tightening the upper tightening ring (A) to provide a suitable pressure between the miller and the pipe end. to carefully inspect the tapered contact surfaces of the pipe ends. If the pipe ends require reconditioning. proceed as follows: KB909-7. Turn the upper tightening ring (A) until the miller presses against the pipe end. 2. Page 2 (4) When referring to this page.3 Fuel Oil High-Pressure Pipe Overhaul Overhaul 909-14. KB909-7. On both pipe ends a small groove has been ground to indicate the maximum allowable grinding of the pipe ends. Max. add drilling oil emulsion liberally. the pipe must be discarded.1 77 03 Turn the miller with.3 1. Mount the miller on the pipe end. During the milling process. If the pipe ends are still not in order. Note! 2. it is necessary. carefully clean the high-pressure pipe. 3. grind-away The pipe ends may only be ground until the ground surface is flush with the bottom of the groove.909-14. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 .1 77 01 1.3 223 03 After completing the milling. for instance. before remounting the high-pressure pipes. The two pipe ends are of different designs – see sketch.

3 Overhaul 4. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 Page 3 (4) .Fuel Oil High-Pressure Pipe 909-14. KB909-7. 4. When referring to this page.1 77 04 Mount the two-part sleeve and lock the sleeve with the spring ring. Ensure that all parts are completely clean before mounting the high-pressure pipe. Mount new O-rings. Remove and discard both the internal and external O-rings.

If dismantled.Fuel Oil High-Pressure Pipe 909-14. Screw the union nipples onto the fuel valve and into the fuel pump top cover. D09-52 1. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel pump to the torque stated in Data. 5. fuel valve or fuel pump top cover might otherwise be damaged. 2.4 210 05 D09-47 Page 4 (4) When referring to this page. 5. by hand. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel valve to the torque stated in Data.4 Mounting Mounting 909-14. re-mount the return oil pipe on the fuel valve.4 211 03 3. Lubricate the thread on the union nipple with a heat resistant grease. Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position. Lubricate the thread of the fuel valve with a heat resistant grease. Note! 4. as the threads of the union nipples. Ensure that the fuel valve is fitted with a new O-ring. GN909-14. 6.4 211 04 4. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 . Mount the high-pressure pipe between the fuel valve and the fuel pump.4 3. BM909-14. Open the fuel oil inlet and outlet valves. D09-47 The nipples must be screwed by hand. Ensure that the union nipple at the fuel pump end of the high-pressure pipe is fitted with a new O-ring. BM909-14.

4 .Fuel Pump Roller Guide MAN B&W Diesel 109-15 Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D09-54 Clearance A 1.6 mm D09-55 Clearance B 0.5 mm D09-61 Fuel pump roller guide 16 kg D09-62 Pump base 28 kg When referring to this page.4.3. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.1 mm D09-57 Roller/bushing/shaft pin. clearance 0. max. please quote Data D10915 Edition 0059 Page 1 (2) .9 .

g. fuel pump When referring to this page.Fuel Pump Roller Guide 109-15 MAN B&W Diesel 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. 069 Description Lifting tool. please quote Data D10915 Edition 0059 . e. Plate P90951 Page 2 (2) Item No. P90951 refers to chapter 909.

Using the telegraph. 4. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 1 (12) .1 2. Check that the reversing link is fully tilted over in AHEAD position. See Procedure 909-16.1 Checking Fuel Pump Roller Guide S35MC 0227 Checking 909-15. When referring to this page. using the following procedure: 1. Also inspect the surface of the roller for possible damage marks. Roller guide mounted in engine The fuel pump roller guide can be partially checked while mounted on the engine. Carry out the same check in the ASTERN position. 2. Lower the roller guide onto the fuel cam again. 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.1 207 03 Turn the engine to provide the maximum space between the roller guide and the cam disc. Remove the cover on the camshaft housing to inspect the fuel pump roller guide. See Procedure 909-16. BM909-15. Make sure that there are no traces of bearing metal left in the roller guide housing. Turn the roller by hand to check that it can move freely and without unnecessary resistance or “hard” points. seizures or scratches. move the roller guide to the AHEAD position. BM909-15.1 207 05 3. 4. Lift the fuel pump roller guide.Fuel Pump Roller Guide 909-15.

1 207 07 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. Check the surface of the roller and the sliding surfaces of the roller guide.2. Turn the roller guide upside down and land it in a vertical position on a couple of planks. Roller guide removed from engine A more suitable and reliable method is to check the roller guide and the bearing clearance after the roller guide has been dismounted: 5. BM909-15. 6. Dismount the roller guide from the engine. and measure any ovalness. 7. 7.909-15. See Procedure 909-15. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . with the roller hanging freely.1 Fuel Pump Roller Guide Checking 5.1 207 08 D09-57 Page 2 (12) When referring to this page. BM909-15.

When referring to this page. See Procedure 909-5.2. make sure that the pump has been relieved of pressure and that all oil has been drained off. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 3 (12) .2 205 05 Inspect the position of the fuel cam through the inspection cover opening on the camshaft housing.2 1.1 207 03 2. Turn the engine so that the roller guide rests on the lowermost part of the fuel cam. Dismantle the top cover with the barrel/ plunger assembly. 2. 1. BM909-15. GN909-5.Fuel Pump Roller Guide 909-15.2 Dismantling Dismantling 909-15. Note! Before dismantling any part of the fuel pump.

Loosen and remove the nuts on the two short studs.2 207 04 4. Remove the nuts from the two long threaded studs and lift away the fuel pump housing. Then loosen the nuts on the two long threaded studs successively until the roller guide spring is relieved. take care not to damage the threads on the studs. Page 4 (12) When referring to this page. BM909-15.2 207 03 4. Note! When lifting the fuel pump housing. Lift the spring out of the roller guide. BM909-15. 3. Mount the lifting tool on the fuel pump studs and hook the engine room crane on to the lifting tool. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . Loosen and remove the screws from the sealing cap on top of the roller guide inside the pump base.2 Fuel Pump Roller Guide Dismantling 3.909-15.

2 207 05 • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint.2 207 06 7. 5. take care that the bushing of the pump base slides against the neck of the roller guide without scratching.1. using the crane. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 5 (12) .2 Dismantling 5. 6. When lifting. BM909-15. Lift the roller guide out of the roller guide housing. • Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide. Unscrew the two nuts from the pump base. BM909-15. Check the roller guide. Remove the sealing cap from the roller guide. take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing. Mount the roller guide lifting tool as follows: • Lift the lock plate of the tool up on the shaft of the tool.Fuel Pump Roller Guide 909-15. and lift away the pump base. D09-62 When lifting. • Lower the lock plate. D09-61 Land the roller guide on wooden planks. See Procedure 909-15. 6. thereby securing the foot in the locked position. When referring to this page.

1.3 1.3 Fuel Pump Roller Guide Overhaul Overhaul 909-15. It is recommended that the roller guide should ONLY be dismantled if • irregularities when turning the roller. BM909-15. Page 6 (12) When referring to this page. • seizure marks on the slide surfaces. Inspect and check the fuel pump roller guide. Note! BM909-15. just clean and lubricate the roller guide before remounting it in the roller guide bushing.1 207 07 For disassembling of the roller guide. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . 3.3 207 03 3. D09-61 2.909-15. • damage to the roller. have been observed when checking the roller guide.1. • larger clearance than stated on the Data sheet. See Procedure 909-15. If no irregularities are found. contact an MAN B&W authorized repair shop.

AM909-8.4 Mounting Mounting 909-15. Turn the camshaft so that the roller guide is lifted approx. and check that the reversing mechanism is working smoothly. The clearance C between the roller guide and the guide plate must be the same at both ends +/– 0.Fuel Pump Roller Guide 909-15. 1. check the clearance between the roller guide and the guide plate mounted in the roller guide bushing. take care not to scratch the sliding surfaces of the roller guide. D09-54 Connect working air to the air cylinder.1 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. Lubricate the roller guide with plenty of camshaft lubricating oil. D09-61 Make sure that the pin of the reversing link fits in the bracket of the reversing shaft. 2. and mount it in the roller guide bushing.4 1. After mounting the roller guide with the reversing link.0 50 15 D09-55 When referring to this page. the same in both positions. The clearances A and B must be approx. using the lifting tool. See Data.4 207 01 2. BM909-15. During mounting. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 7 (12) . 20 mm.

4 Fuel Pump Roller Guide Mounting 3. Release the lock nut on the shaft. See Data. AM909-8. AM909-8.0 50 18 5. If adjustment is necessary. Turn the shaft to obtain the distance between the air cylinder flange and the surface of the roller guide bushing. AM909-8. 3. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 .909-15. Mount the flange with the air cylinder on the roller guide bushing and tighten the four cap screws.0 50 19 6.0 50 17A Pull out the air cylinder with the flange as much as possible. 4. place the reversing arm in ASTERN position and remove the four cap screws which tighten the flange for the air cylinder to the roller guide bushing. AM909-8. Tighten the nut on the shaft. 6. 5. Repeat the clearance check once more. 4.0 50 17B Lock the screws with Loctite (EN243S) type: 242. Page 8 (12) When referring to this page.

When referring to this page.Fuel Pump Roller Guide 909-15.0 54 24 D09-62 BM909-15. 7. Before mounting the pump base on the roller bushing. Mount the pump base on the roller guide bushing. and tighten the nuts. 8.4 Mounting 7. replace the O-ring between the sealing bush and the bottom of the pump base.4 207 08 8. BM909-8. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 9 (12) .

9. See the sketch. BM909-15. Page 10 (12) When referring to this page. Replace the scraper rings in the sealing cap as follows: Loosen and remove the screws and nuts from the bottom of the cap. 10. AM909-80. 11. and be careful not to cut the scraper ring on the edge of the ring groove when pressing it in. 10. See the sketch.4 Fuel Pump Roller Guide Mounting 9. Remove the scraper ring and O-ring from the ring holder. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . remove the retaining flange and ring holder with scraper ring. Before mounting. Check that the O-ring and scraper ring are mounted correctly. fold the ring without making any sharp edges. AM909-8. Note! When mounting the scraper ring in the groove. Replace the axial scraper ring in the bottom of the cap.0 31 16 11. the new scraper ring must be heated in 100°C hot water or oil for at least five minutes.909-15.0 31 15 Check that the O-ring and scraper ring are mounted correctly.4 207 09 Place the new O-ring in the ring holder.

13.4 207 12 14. When referring to this page. BM909-15. Tighten the nuts. Mount a new O-ring in the groove on top of the roller guide and on the pump base. 13. check that the holder can be moved. Mount the sealing cap over the roller guide.4 207 13 Land the spring on the roller guide inside the pump base. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 11 (12) . After tightening. Tighten the sealing cap to the top of the roller guide. 12. BM909-15.2 207 14 14. Tighten the nuts on the screws.4 Mounting 12. Lock the nuts with Loctite type EN243S. Assemble the sealing cap. the ring holder and retaining flange.Fuel Pump Roller Guide 909-15. BM909-15.

4. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . Check the movement of the reversing link.1 207 05 16.909-15. See Procedure 909-4. See Procedure 909-15. BM909-15. Mount the fuel pump housing. Page 12 (12) When referring to this page. BM909-15. See Procedure 909-5.1.2 207 03 17. 15.4 Fuel Pump Roller Guide Mounting 15. 16. Mount the top cover and barrel/plunger assembly.4.

please quote Data D10916 Edition 0018 Value Unit Page 1 (2) .Fuel Pump Special Running MAN B&W Diesel 109-16 Data SAFETY PRECAUTIONS For detailed sketch. Description When referring to this page. see 900-2 X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

Description P90951 082 Lifting tool for fuel pump roller guide P90951 128 Crowfoot spanner P90951 212 Extraction tool for suctions valve Page 2 (2) When referring to this page. e. Plate Item No. please quote Data D10916 Edition 0018 .Fuel Pump Special Running 109-16 MAN B&W Diesel 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. P90951 refers to chapter 909.g.

Turn the engine until the fuel pump roller is at on the circular part of the cam. When referring to this page. BM909-16. Engine trouble might require a cylinder to be taken out of action. proceed as follows: 2. Disengagement of fuel pump Warning! Disengagement or re-engagement of the fuel pump roller guide or the exhaust valve roller guide must only take place at engine standstill. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. Remove the fuel oil high pressure pipes and the puncture valve from the fuel pump top cover.1 76 04 3. 1. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 Page 1 (3) .0 207 02 Note! Screw a plug-screw into the control air pipe of the puncture valve. Dismount the suction valve by means of the extractor tool. Remove the inspection cover on the camshaft housing. 3. See Volume I. To disconnect the fuel pump of a single cylinder. make sure that the pump has been relieved of pressure and that all oil has been drained off. Section 704. AM909-1.Fuel Pump Special Running 909-16 Fuel Pump Special Running S35MC 0212 909-16 2. Before dismantling any part of the fuel pump.

Turn the uppermost nut to screw the spindle of the lifting tool into the fuel pump plunger. GN909-16 202 04 6. GN909-16 202 05 5. See Volume I. Section 704. 5. Lock the tool in this position by means of the lock nut. 7. Turn the engine one full revolution and inspect through the opening in the camshaft housing to make sure that the roller guide is clear of the fuel cam. BM909-160 207 06 6. Page 2 (3) When referring to this page. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 . Fuel Pump Special Running 4. Mount the lifting tool on the fuel pump top cover.909-16 4. Tighten the lowermost nut on the tool to pull the roller guide upwards as far as possible. The engine can now operate on the remaining cylinders.

10.0 207 08 Remove the plug screw from the control air pipe. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 Page 3 (3) . BM909-16.0 45 06 Mount the fuel oil high pressure pipes. BG909-5. (See Procedure 909-8. Lower the roller guide on to the fuel cam in the reverse order to lifting and remove the lifting tool.4). Note! It is recommended always to mount new or overhauled suction and puncture valves.4). Remove the cover on the camshaft housing. Re-mount the suction valve and the puncture valve.Fuel Pump Special Running 909-16 8. 9. Turn the engine until the circular section of the fuel cam is positioned upwards. When referring to this page. (See Procedure 909-14. 8. Re-engagement of fuel pump Warning! Re-engagement of the fuel pump must only take place at engine standstill. 10.

.

please quote Plate P90951 Edition 0453 MAN B&W Diesel A/S Plate P90951-0453 Page 1 (2) .Fuel Valve and Fuel Pump Panel When referring to this page.

holder . holder .inside Screw. 010 021 045 057 069 082 094 104 116 128 153 165 177 189 190 200 212 319 Page 2 (2) Fuel Valve and Fuel Pump Panel Item Description Item No. dismantling of non return valve Grinding mandrel. suctions valve Hook spanner When referring to this page. fuel pump Lifting tool. topcover Extractor tool. Item Description Panel for tools Name plate Measuring tool for fuel pump lead Lifting tool.outside Grinding mandrel. fuel oil pipe Crowfoot spanner Crowfoot spanner Flange. please quote Plate P90951 Edition 0453 MAN B&W Diesel A/S . fuel oil pipe seats Milling tool. valve head Grinding mandrel.Plate P90951-0453 Item No. fuel pump Lifting tool. thrust spindle Grinding mandrel. fuel pump roller guide Milling tool.

Tools 0037 P90961 When referring to this page. please quote Plate P90961 Edition 0037 MAN B&W Diesel A/S Page 1 (2) .Fuel Valve .Tools Plate P90961-0037 Fuel Valve .

please quote Plate P90961 Edition 0037 MAN B&W Diesel A/S . 014 026 038 051 063 Fuel Valve . Item Description Connection piece Test rig High-pressure hose Table High-pressure pump Page 2 (2) When referring to this page.Plate P90961-0037 Item No.Tools Item Description Item No.

please quote Plate P90961 Edition 0069 MAN B&W Diesel A/S Plate P90961-0069 Page 1 (2) .Fuel Valve .Tools When referring to this page.

please quote Plate P90961 Edition 0069 MAN B&W Diesel A/S . 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 When referring to this page. 014 026 038 040 051 063 075 087 099 109 122 Page 2 (2) Fuel Valve .Tools Item Description Item No.Plate P90961-0069 Item No.

Tools When referring to this page.Fuel Valve Nozzle . please quote Plate P90966 Edition 0008 MAN B&W Diesel A/S Plate P90966-0008 Page 1 (2) .

Tools Item Description Item No. please state P/N on fuel nozzle. Item Description Tool box Extractor for atomizer Drift for atomizer Cleaning brush Instruction plate Toolset. please quote Plate P90966 Edition 0008 MAN B&W Diesel A/S .Plate P90966-0008 Item No. Page 2 (2) When referring to this page. complete Note: When odering new cleaning tool. 011 023 035 047 060 202 Fuel Valve Nozzle .

Inspection Tools When referring to this page.Fuel Valve . please quote Plate P90968 Edition 0001 MAN B&W Diesel A/S Plate P90968-0001 Page 1 (2) .

Item Description When referring to this page.Plate P90968-0001 Fuel Valve . please quote Plate P90968 Edition 0001 MAN B&W Diesel A/S . complete Page 2 (2) Item No. Item Description 012 Probe light with magnifier.Inspection Tools Item No.

Cleaning Tools When referring to this page. please quote Plate P90974 Edition 0001 MAN B&W Diesel A/S Plate P90974-0001 Page 1 (2) .Fuel Valve Nozzle .

Plate P90974-0001 Item No. please state P/N on fuel nozzle. 015 027 039 206 Fuel Valve Nozzle .Cleaning Tools Item Description Item No. Item Description Drill* Test mandrel* Pin vice* Cleaning tool set. complete Note: * When ordering new cleaning tool. Page 2 (2) When referring to this page. please quote Plate P90974 Edition 0001 MAN B&W Diesel A/S .

Air Piston Seals 0001 P90980 When referring to this page. please quote Plate P90980 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .Air Piston Seals Plate P90980-0001 Mounting Tools .Mounting Tools .

018 020 031 043 055 067 079 Item Description Item No. please quote Plate P90980 Edition 0001 MAN B&W Diesel A/S .Mounting Tools .Air Piston Seals Plate P90980-0001 Item No. Item Description Cone Pushing tool Compression tool Cone Pushing tool Compression tool Cone Page 2 (2) When referring to this page.

Data Air Cooler Element Non-Return Valve in Turbocharger. Data Turbocharger Turbine Water Mist Catcher. Data Water Mist Catcher Air Cooler .Lifting Tools MAN B&W Diesel A/S . Data Non Return Valve in Tubocharger Auxilary Blower.910 .Lifting Tools Air Cooler .Tools Travelling Trolley Air Cooler . Data Auxilary Blower Turbocharger Turbine.Turbocharger System Documents in this Chapter 110-01 910-01 110-02 910-02 110-03 910-03 110-05 910-05 110-06 910-06 91063 91064 91066 91066 0057 0244 0009 0211 0028 0221 0010 0211 0036 0224 0021 0002 0003 0010 Air Cooler Element.

MAN B&W Diesel A/S .

complete with covers. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description D10-02 Aft end cover D10-04 Air cooler element.Air Cooler Element MAN B&W Diesel 110-1 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11001 Edition 0057 Value Unit 75 kg 1100 kg 120 kg Page 1 (2) . up to D10-05 Front end cover When referring to this page.

P90951 refers to chapter 909. please quote Data D11001 Edition 0057 . Plate Item No. Etc.Air Cooler Element 110-1 MAN B&W Diesel 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.g.Tools P91064 Travelling Trolley P91066 Air Cooler . Page 2 (2) When referring to this page.Lifting Tools P91356 Lifting Tools. e. Description P91063 Air Cooler .

Chapter 706. 4. For the day-to-day checking of the scavenge air cooler. See Procedure 910-3. See Procedure 910-2. M910010244C01 Compare these measurements with the testbed data. See Procedure 910-3. it is recommended to inspect the air cooler element as follows: When referring to this page. 2. please quote Procedure M91001 Edition 0244 Page 1 (7) . measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running. clean the element using the spray pipe arrangement fitted above the air cooler element.1 Checking 1. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler.Air Cooler Element MAN B&W Diesel 910-1. M910010244C02 If the measurements indicate fouling of the air side of the air cooler element. If the measurements indicate fouling of the water side of the air cooler element. the element must be dismantled and overhauled/ cleaned. 3. 5. M910010244C03 If the air side of the element is fouled. see instruction book Volume I. 1. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. Visually inspect the air cooler element through the opening. Remove the top cover of the air cooler. 2. For further evaluation of the measurements. 3.

Dismount the cooling water inlet and outlet pipes from the front end cover. M910010244D01 3. Page 2 (7) When referring to this page. 2. Close the cooling water inlet and outlet valves.2 Air Cooler Element Dismantling 1. M910010244D02 2. please quote Procedure M91001 Edition 0244 . 10 cm using the dismantling screws. Remove and discard the gaskets. Open the drain cocks to drain off the cooling water. M910010244D03 3.910-1. Dismantle the screws and pull out the cooler element approx. MAN B&W Diesel 1.

lift the air cooler element approx. 4. Using the tackles lift the air cooler element away. M910010244D06 D1004 When referring to this page. take care not to damage the air cooler element.Air Cooler Element 910-1. Using the tackle. half a metre. Mount the two guide rails on the frame around the air cooler element. Attach a shackle to the lifting tool. 2-3 mm. Mount shackles on the lifting brackets on the aft end cover. 6. Pull out the air cooler element far enough to gain access to the aft end cover.2 Dismantling MAN B&W Diesel 4. 5. Note! M910010244D05 During the lift. M910010244D04 Pull out the air cooler element approx. please quote Procedure M91001 Edition 0244 Page 3 (7) . Land the element on a couple of wooden planks. 6. Mount the lifting tool on the front end cover. Hook a tackle on to the shackle. 5. Hook tackles on to the shackles.

When referring to this page. Do not disconnect the compressed air supply to the exhaust valve. or a similar product. Continue the cleaning process for at least 30 minutes.3 Air Cooler Element Overhaul MAN B&W Diesel Cleaning the air side: 1. produced by Drew Chemical Corp. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine. Do not start cleaning until the engine has been at a standstill for about 30 minutes. produced by Vecom Int.910-1. please quote Procedure M91001 Edition 0244 . M910010244O02 5. After cleaning. USA • Product: 80B. See Procedure 910-1. 1. To ensure satisfactory spraying of the cleaning fluid. Inspect the air cooler element by removing the cover of the scavenge air cooler housing. 2. 4. flush the cooler with clean water until the water in the sight glasses appears clean and pure. Holland M910010244O01 2. 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.7 bar. Maassluis. the circulating pump pressure must be at least 0. The time required depends on the frequency with which cleaning is carried out and on the chemical product used. • Product: ACC 9. New York.. Page 4 (7) 6. It is recommended to use one of the following cleaning fluids. 3. Remove the covers on the scavenge air receiver to let vapours escape.2..

Note! If damaged. When referring to this page. roll the tube using the tube expander. M910010244O03 3. 6.3 Overhaul MAN B&W Diesel Cleaning the water side 2. See Procedure 910-1. M910010244O04 Tools for tube cleaning and the tube expander are supplied by the air cooler manufacturer. See Procedure 910-1. 3. D1002 In the event of leakages between a tube and the tube plate. M910010244O05 7. 1. plug both ends of the tube using a brass or copper plug. please quote Procedure M91001 Edition 0244 Page 5 (7) .4. 4. In the event of a leaking tube. Re-mount the air cooler element in the scavenge air cooler housing. If necessary replace the corrosion blocks. Dismantle the aft end cover of the air cooler element. Flush the tubes with clean fresh water. Dismantle the front end cover of the air cooler element. Dismantle the air cooler element and remove it from the engine. mount new gaskets or packing paste and re-mount the front end and aft end covers of the air cooler element. When cleaning is complete. Clean the water side of the cooler element (the inside of the tubes) using the cleaning brush mounted on a drilling machine. Clean and check the inside of the front end and aft end covers.Air Cooler Element 910-1. 4. 5. the coating inside the covers is to be repaired with the original coating or a similar product.2. D1005 2.

Push the air cooler element inwards approx. M910010244D06 Remove the guide rails from the air cooler housing.Air Cooler Element 910-1. Remove the tackles and shackles from the aftmost lifting brackets. D1004 MAN B&W Diesel 1. Apply a thin layer of silicone paste to the frame around the air cooler element and the contact surface of the front end cover. 3.4 Mounting 1. 2. Lift the air cooler element and land the aft end of the element on the guide rails mounted on the air cooler housing. one metre. Clean the frame around the air cooler element and the contact surface of the front end cover. M910010244M03 3. M910010244M02 Push the air cooler element fully into the air cooler housing. 2. please quote Procedure M91001 Edition 0244 . Page 6 (7) When referring to this page.

Close the drain cocks and open the cooling water inlet and outlet valves. 4. Mount and tighten all the screws of the front end cover. Remember to vent trapped air from the air cooler element. 6. When referring to this page. Mount the cooling water inlet and outlet pipes on the front end cover. M910010244M04 Note! M910010244D02 5. M910010244M06 6. please quote Procedure M91001 Edition 0244 Page 7 (7) .Air Cooler Element 910-1. the shackle and the lifting bracket from the front end cover. 5.4 Mounting MAN B&W Diesel 4. Remove the tackle.

.

please quote Data D11002 Edition 0009 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page.110-2 Non-Return Valve Data N D R B I E SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

110-2 Non-Return Valve Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Plate Page 2 (2) Item No. Description When referring to this page. e. P90951 refers to chapter 909.g. please quote Data D11002 Edition 0009 MAN B&W Diesel A/S .

BM910-2. 2. 2. When referring to this page. Remove the screws holding the valve flap.3 208 03 3. Lubricate the valve shaft and the slide bearings with molybdenum disulphide (MoS 2). please quote Procedure M91002 Edition 0211 0$1% :'LHVHO$6 Page 1 (2) . Both sets of non-return valves are accessed via the scavenge air receiver. The main non-return valve consists of four valve flaps located inside the scavenge air cooler housing. Note! Main Non-Return Valve 1. This procedure includes both the main non-return valve and the non-return valve for the auxiliary blowers. 3. After the overhaul. Remove the spring pin from the valve shaft and knock the valve shaft out of the valve flap.Non-Return Valve 910-2. Remove the valve from the engine. Clean the valve shaft and the slide bearings inside the valve flaps.3 1.3 208 01 Access to the scavenge air receiver must not be attempted until the air in the receiver is clean. it must be possible to move the valve flap by the light touch of a finger.3 208 02 4. Assemble the valve and re-mount it in the scavenge air cooler housing. BM910-2.3 Overhaul Non-Return Valve 0211 Overhaul 910-2. BM910-2.

Remove the valve from the engine. Inside the scavenge air cooler housing. please quote Procedure M91002 Edition 0211 0$1% :'LHVHO$6 .3 208 07 7. BM910-2. BM910-2. After the overhaul it must be possible to move the valve flap by the light touch of a finger. Remove the screws behind the valve flap. BM910-2. the slide rings and the slide bearings with molybdenum disulphide (MoS 2).910-2. Remove the spring pins from the valve shaft and knock the valve shaft out of the valve flap. lift up the valve flap of the valve to be overhauled.3 Non-Return Valve Overhaul 5. Clean the valve shaft. Page 2 (2) When referring to this page. the slide rings and the slide bearings inside the valve flaps. 6. Lubricate the valve shaft. Non-Return Valve for Auxiliary Blowers 5. 6. Assemble the valve and re-mount it in the scavenge air cooler housing.3 208 06 8.3 208 05 7.

D10-09 Description Weight of blower unit.Auxiliary Blower MAN B&W Diesel 110-3 Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D11003 Edition 0028 Value Unit 600 kg Page 1 (2) . complete * up to When referring to this page.

Auxiliary Blower 110-3 MAN B&W Diesel 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. Plate P91356 Page 2 (2) Item No. P90951 refers to chapter 909. When referring to this page. please quote Data D11003 Edition 0028 .g. e. Description Lifting Tools. Etc.

Remove all screws in the upper inlet flange of the blower unit. It may be necessary to remove one or more of the gallery plates. Depending on the type of overhaul. Remove all screws in the outlet flange of the blower unit.3 Overhaul 1.Auxiliary Blower MAN B&W Diesel 910-3. Complete Blower Unit D1009 Remove all screws in the lower inlet flange of the blower unit. disconnect the cable connections from one or both blower motors. please quote Procedure M91003 Edition 0221 Page 1 (2) . When referring to this page. 2. Hook a shackle and a tackle to the lifting bracket in the top of the blower unit. The overhaul can be carried out either by dismantling the complete blower unit or just dismantling the individual blower wheel which is to be replaced/overhauled. M910030221O01 2. Lift away the blower unit and land it on wooden planks for further dismantling/overhaul.

MAN B&W Diesel 3. Then inspect and clean the blower wheel as well as the blower housing. please quote Procedure M91003 Edition 0221 . 4. as the blower wheel is to “catch” the guide in the blower housing. M910030221O03 Note! Page 2 (2) Exercise care when mounting the electric motor with blower wheel. When referring to this page. For overhaul of blower wheel and bearings. While pulling out the end cover with the blower assembly.3 Auxiliary Blower Overhaul 3. disengage the cable connections to the blower motor. The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. before removing the screws in the flange. make sure that the blower housing disengages from the air pipe without deforming it. 4. see blower manufacturer’s instructions. M910030221O02 Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the blower flange. Blower Wheel and Electric Motor When cleaning and inspecting the auxiliary blower.910-3.

please quote Data D11005 Edition 0010 MAN B&W Diesel A/S Value Unit Page 1 (2) . see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description When referring to this page.110-5 Turbocharger Turbine Data SAFETY PRECAUTIONS For detailed sketch.

Plate Page 2 (2) Item No. please quote Data D11005 Edition 0010 MAN B&W Diesel A/S . e.110-5 Turbocharger Turbine Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.g. Description When referring to this page. P90951 refers to chapter 909.

please quote Procedure M91005 Edition 00211 MAN B&W Diesel A/S Page 1 (2) . the turbine must be cleaned after every 24 to 50 hours of operation. On account of their hardness.0 and max. in order to prevent the build-up of thick deposits. Generally.5 mm are particularly suited as blasting agents.1 Cleaning The dry cleaning method employs compressed air to blow dry. solid.Turbocharger Turbine 910-5. When referring to this page. see turbine manufacturer’s instructions. as these may possibly stick in the exhaust gas boiler. turbocharger cleaning can be carried out without. nut-shells. Therefore. Chapter 706. It is not always possible to remove thick deposits with this dry cleaning method. Note! Regarding water washing of turbocharger turbine. thus removing most of the deposits which may have formed on the nozzle vanes and turbine blades. or broken or artificially shaped pieces of activated charcoal with a size of between 1. See also Volume I. 1. reduction of the engine load. Note! We do not recommend the use of rice or grain as cleaning materials. or with very little. More detailed information regarding the amount of granules to be used is stated on the instruction plate located close to the turbocharger. granules through the turbocharger.

9. please quote Procedure M91005 Edition 0211 MAN B&W Diesel A/S .The drain openings in the gas casings must remain closed while dry cleaning the turbine. Open valves B and C.3 Turbocharger Turbine Cleaning Cleaning Procedure: 1. Fill the tank with the quantity of granules specified in the table. B 3.6 2.0 3. Preferably clean the turbocharger at full load. close valves B and C.6 3.910-5. to blow out any deposits and/or condensate in the connecting pipe. 1. 8. When referring to this page.5 1. some of the blown-in solid particles or sparks will escape through the funnel. Close valve A.0 1. to blow-in the granules. 5. 2.5 3. based on observations.0 3. Close valve A. Caution! 1. Carry out cleaning for every 24 to 50 hours of operation. It is possible that during dry cleaning of the turbine. A C 2.0 1. 7. Slowly open valve A to relieve the pressure in the tank.5 1.5 2. After one to two minutes. Open valves B and C.5 2. After about two minutes.6 2.0 2. close valves B and C. M910050211O01 4. Do not clean below half load. 2.5 6. M910050211O02 TC type NA34 NA40 NA48 NA57 NA70 NA83 VTR354/TPL77 VTR454/TPL80 VTR564 VTR714/TPL85 MET53SD/E MET66SD/E MET71SD/E MET83SD/E Page 2 (2) Amount dm3 0. Slowly open valve A to relieve the pressure in the tank.

see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear X Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D10-11 Description Water mist catcher When referring to this page. please quote Data D11006 Edition 0036 Value Unit 65 kg Page 1 (2) .Water Mist Catcher MAN B&W Diesel 110-6 Data SAFETY PRECAUTIONS For detailed sketch.

Etc. When referring to this page. P90951 refers to chapter 909.g. e.Water Mist Catcher 110-6 MAN B&W Diesel 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. Description Lifting Tools. Plate P91356 Page 2 (2) Item No. please quote Data D11006 Edition 0036 .

2. Note! Take care not to damage the water mist catcher during the lift. 2. Land it on a couple of wooden planks. the water mist catcher must be re-mounted in the same position. the water mist catcher has been fouled or damaged. M910060224D02 D1011 When referring to this page.Water Mist Catcher MAN B&W Diesel 910-6. During mounting. Hook a tackle on to the eye bolt and lift the water mist catcher away. If. M910060224D01 Note the position of the water mist catcher. 4. dismantle the rectangular cover from the aft end of the scavenge air cooler housing. Loosen the screws at the end of the water mist catcher. Note! 3. To dismantle the water mist catcher. it must be dismantled for cleaning or repair. please quote Procedure M91006 Edition 0224 Page 1 (2) . Clean the water mist catcher with the same cleaning fluid as used for the scavenge air cooler element. however.2 Dismantling 1. Normally it is not necessary to remove the water mist catcher from the scavenge air cooler housing. 4. Pull or push in the water mist catcher halfway out and mount an eye bolt in the top of the water mist catcher.

please quote Procedure M91006 Edition 0224 . The screws of the water mist catcher must face the exhaust side of the engine. Also note the markings on the water mist catcher. Tighten the screws at the end of the water mist catcher. 2. remove the tackle and the eye bolt.4 Water Mist Catcher Mounting MAN B&W Diesel 1. 2.910-6. M910060224M02 Apply a thin layer of silicone paste on the frame and mount the rectangular covers on the aft end of the scavenge air cooler housing. 1. and push the water mist catcher fully into the scavenge air cooler housing. Note! D1011 M910060224M01 Air flow Make sure to mount the water mist catcher correctly. Page 2 (2) When referring to this page. Slide the water mist catcher into the scavenge air cooler housing. When the water mist catcher is half-way in.

please quote Plate P91063 Edition 0021 MAN B&W Diesel A/S Page 1 (2) .Air Cooler .Tools 0021 P91063 Fore end When referring to this page.Tools Plate P91063-0021 Air Cooler .

015 027 Air Cooler .Plate P91063-0021 Item No. please quote Plate P91063 Edition 0021 MAN B&W Diesel A/S .Tools Item Description Item No. Item Description Guide rail for air cooler fore end Guide rail for air cooler fore end Page 2 (2) When referring to this page.

please quote Plate P91064 Edition 0002 MAN B&W Diesel A/S Plate P91064-0002 Page 1 (2) .Travelling Trolley When referring to this page.

please state load and track width.Plate P91064-0002 Item No. Item Description Travelling trolley* Note: * When ordering this tool. 010 Travelling Trolley Item Description Item No. please quote Plate P91064 Edition 0002 MAN B&W Diesel A/S . Page 2 (2) When referring to this page.

Air Cooler . please quote Plate P91066 Edition 0003 MAN B&W Diesel A/S Page 1 (2) .Lifting Tools 0003 P91066 When referring to this page.Lifting Tools Plate P91066-0003 Air Cooler .

011 047 Air Cooler . Item Description Lifting attachment air cooler fore end. please quote Plate P91066 Edition 0003 MAN B&W Diesel A/S .Plate P91066-0003 Item No. complete Screw Page 2 (2) When referring to this page.Lifting Tools Item Description Item No.

please quote Plate P91066 Edition 0010 MAN B&W Diesel A/S Plate P91066-0010 Page 1 (2) .Air Cooler .Lifting Tools When referring to this page.

011 023 035 047 Page 2 (2) Air Cooler . please quote Plate P91066 Edition 0010 MAN B&W Diesel A/S .Plate P91066-0010 Item No.Lifting Tools Item Description Item No. Item Description Crame beam Screw Distance pipe Nut When referring to this page.

Data Safety Valve Relief Valve.Safety Valve MAN B&W Diesel A/S .Safety Valve. Data Relief Valve Scavenge Air Receiver .Safety Equipment Documents in this Chapter 111-01 911-01 111-02 911-02 111-03 911-03 0026 0212 0013 0211 0001 0001 Safety Valve. Data Scavenge Air Receiver .911 .

MAN B&W Diesel A/S .

see 900-2 Stopped engine X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.Safety Valve MAN B&W Diesel 111-1 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11101 Edition 0026 Value Unit 200± 5 bar 45 Nm Page 1 (2) . tightening torque When referring to this page. Description D11-01 Opening pressure D11-02 Valve housing.

Plate Item No. please quote Data D11101 Edition 0026 .g.Safety Valve 111-1 MAN B&W Diesel 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. Description P91351 10 Hydraulic pump. pneumatically operated P91351 58 Hose with unions (3000 mm). P90951 refers to chapter 909. e. complete P90151 117 P91359 Page 2 (2) Test equipment for combined safety valve Torque Spanners When referring to this page.

2.2 Dismantling When Side-mounted 1. Unscrew the safety valve from the cylinder cover. When referring to this page. Remove the guard surrounding the safety valve. When Top-mounted 3. Unscrew the safety valve from the extension pipe. M911010211D03 3. M911010211D02 Remove and discard the mild steel disc. M911010211D01 2.Safety Valve MAN B&W Diesel 911-1. Dismantle the indicator cock and the intermediate pipe. please quote Procedure M91101 Edition 0212 Page 1 (5) . 1.

please quote Procedure M91101 Edition 0212 . M911010211O03 3.3 Safety Valve Overhaul (Adjustment) 1.911-1. or ‘electro-cleaner’. dismantle the safety valve and clean all the parts in either gas oil. Then mount: • the valve spindle • the spring • the adjusting screw • the lock nut M911010211O02 2. 3. 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. kerosene. If necessary. Page 2 (5) When referring to this page. MAN B&W Diesel 1. 2. • Tighten the housing to the torque stated M911010211O01 in the data. loosen and tighten again to the torgue stated in the data.

please quote Procedure M91101 Edition 0212 Page 3 (5) . • Tighten the adjusting screw of the • Tighten the lock nut. test rig. Alternatively the hydraulic hans pump can be used. flows out from the openings of the safety valve. • Bleed the valve and hose until oil. To set the safety valve opening pressure: 4. • Test the opening pressure. • Connect the testing device to the hydraulic pump. • Remove the valve from the fuel valve M911010212O04 safety valve until the correct pressure is indicated (see Data). without air bubbles. • Set up the safety valve in the Fuel valve test rig. • Loosen the lock nut on the safety valve.Safety Valve MAN B&W Diesel 911-1.3 Overhaul (Adjustment) 4. • Turn the adjusting screw until the valve just closes. When referring to this page.

M911010211M03 3. 1. 2.4 Safety Valve Mounting MAN B&W Diesel When Side-mounted 1. M911010211M02 2. and blow it clean. When mounting the safety valve. Pierce the bore in the cylinder cover. Page 4 (5) When referring to this page.911-1. Mount a new sealing ring and a new or overhauled safety valve. Mount the intermediate pipe and the indicator cock. Clean the sealing ring grooves of the indicator cock. Mount the guard surrounding the safety valve. apply tools only on the hexagon on the safety valve. please quote Procedure M91101 Edition 0212 . M911010211M01 3.

Pierce the bore in the cylinder cover.4 Mounting When Top-mounted 4. 5. and blow it clean. Mount a new or overhauled safety valve. When referring to this page. please quote Procedure M91101 Edition 0212 Page 5 (5) . apply tools only on the hexagon on the safety valve. When mounting the safety valve on the cylinder cover. M911010211M04 Mount a new mild steel disc in the bore.Safety Valve MAN B&W Diesel 911-1. Clean the thread and the sealing surface. 4. M911010211M05 5.

.

please quote Data D11102 Edition 0013 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page.111-2 Relief Valve Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

e. please quote Data D11102 Edition 0013 MAN B&W Diesel A/S . P90951 refers to chapter 909.111-2 Relief Valve Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Description When referring to this page. Plate Page 2 (2) Item No.g.

please quote Procedure M91102 Edition 0211 0$1% :'LHVHO$6 Page 1 (1) . See separate instructions from the valve manufacturer. The complete flame arrester has to be replaced after a crankcase explosion. If work involving risks of mechanical damage to the flame arrester has taken place.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. During running of the engine. check if there are any leaks. When referring to this page.Relief Valve 911-2. If one or more plates in the flame arrester are damaged.1 1. If a leak occurs. the relief valve must be disassembled and the flame arrester replaced. See separate instructions from the valve manufacturer. Note! XZ911-2. a visual inspection of the flame arrester should always be performed before starting the engine. 2.1 Checking Relief Valve 60& 0211 Checking 911-2.1 207 03 2. 1. replace the O-ring inside the relief valve. XZ911-2.

.

see 900-2 X X X 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 X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply X Lock the turbocharger rotors Data Ref.Scavenge Air Receiver Safety Valve MAN B&W Diesel 111-3 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11103 Edition 0001 Value Unit Page 1 (2) . Description When referring to this page.

Plate Page 2 (2) Item No.Scavenge Air Receiver Safety Valve 111-3 MAN B&W Diesel 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.g. please quote Data D11103 Edition 0001 . e. P90951 refers to chapter 909. Description When referring to this page.

The scavenge air receiver safety valve is calibrated at the factory and does not require any adjustment. Check the scavenge air receiver safety valve by loosening the counter nut and turn the forced opening screw to open the valve approx. 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. When referring to this page. If this operation cannot be performed smoothly.1 Checking 1. please quote Procedure M91103 Edition 0001 Page 1 (5) . 2.Scavenge Air Receiver Safety Valve MAN B&W Diesel 911-3. 2. 10 millimetres.

a cover has to be removed in order to gain access to the safety valve.2 Scavenge Air Receiver Safety Valve Dismantling 1. please quote Procedure M91103 Edition 0001 .911-3. M911030001D01 2. Page 2 (5) When referring to this page. Dismount the safety valve from the scavenge air receiver. On some engines. M911030001D02 2. MAN B&W Diesel 1.

When referring to this page.Scavenge Air Receiver Safety Valve MAN B&W Diesel 911-3. M911030001O01 Pull out the spring. Unscrew the nut thereby relieving the spring tension. Keep count of the washers. 2. please quote Procedure M91103 Edition 0001 Page 3 (5) . Clean the metal surfaces thoroughly.3 Overhaul 1. Pull out the valve flap with spindle. 3. 1. Remove the split pin. M911030001O02 2. spring retainer and washers. Remove the nut. If the Oring seal is damaged remove it without damaging the Oring groove.

911-3. Check the valve according to 9113.3 Scavenge Air Receiver Safety Valve Overhaul 4. If the Oring seal has been removed mount a new one using Locktite type AVX and Loctite activator type T or similar. spring retainer and all the washers. M911030001O01 6. M911030001O05 5. MAN B&W Diesel 4. 6. Push in the valve flap and spindle while taking care not to damage the Oring seal. 5. Page 4 (5) When referring to this page. M911030001O04 Tighten the nut until the split pin can be mounted. 7.1. please quote Procedure M91103 Edition 0001 . Mount the spring.

When referring to this page.4 Mounting 1.Scavenge Air Receiver Safety Valve MAN B&W Diesel 911-3. M911030001M01 1. Mount the safety valve on the scavenge air receiver. please quote Procedure M91103 Edition 0001 Page 5 (5) .

.

Holding-Down and End Chock Bolts (Epoxy Chocks) MAN B&W Diesel A/S . Data Stay Bolts Crankcase Oil Outlet Hydraulic Tools for Large Parts Hydraulic Tools .912 .Assembly of Large Parts Documents in this Chapter 112-02 912-02 112-03 912-03 912-05 91261 91263 0015 0208 0027 0211 0201 0072 0059 Holding Down and End Chock Bolts (Epoxy). Data Holding Down and End Chock Bolts (Epoxy) Stay Bolts.

MAN B&W Diesel A/S .

mounting When referring to this page. please quote Data D11202 Edition 0015 900 bar Page 1 (2) . see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors 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 Hydraulic pressure.Holding Down And End Chock Bolts MAN B&W Diesel 112-2 Data SAFETY PRECAUTIONS For detailed sketch.

g. Epoxy P91351 010 Hydraulic pump. P91263 Description Hydraulic Tools for Holding-Down Bolts and End Chock Bolts. complete Page 2 (2) When referring to this page. pneumatically operated P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909. please quote Data D11202 Edition 0015 .Holding Down and End Chock Bolts 112-2 MAN B&W Diesel 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. Plate Item No. e.

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. When referring to this page.1 Checking Holding Down and End Chock Bolts .Holding Down and End Chock Bolts 912-2. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 1 (5) . The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool.

please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 . following which the bolts are tightened to the normal tightening pressure. 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.1 Holding Down and End Chock Bolts Checking 1. can be effectively checked by comparing the tables from successive bolt checks. EN912-1. see pages 4 and 5. Checking of Epoxy Supporting Chocks 2. The oil pressure indicated on the pressure gauge when the nut comes loose (‘loosening pressure') is to be noted down in the checking tables. raise the pressure on the hydraulic tool slowly while constantly attempting to loosen the nut with the tommy bar. If the ‘loosening pressure' is below 80 per cent of the tightening pressure. Page 2 (5) When referring to this page.912-2. and thus the general condition of the foundation. Any possible settling of the chocks during the intervals between measurements can thereby be followed. For this purpose.1 205 01 The condition of the bolted joints. Checking the Bolt Tightening 1. the bolts should be taken out for inspection of threads and contact faces. If the chocks are in position and in order. The holding down bolts and end chock bolts must be checked for correct tightness at the intervals indicated on the Data sheet. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. the relative chocks shall always be checked for possible defects.

the liner must be removed. After fitting the liners to an 80 per cent contact area on both sides of the liners. If this procedure does not improve the situation. knock the liners a further 3 to 4 mm inwards. 2. and thus at the same time intervals.Holding Down and End Chock Bolts 912-2. GN912-2. replacement of the liners is necessary. Loosen the hexagon screws. The feeler gauge is applied at the 7 points indicated in the table on page 5. we recommend that the following procedure is followed: 1. Measure again at the 7 points indicated in the table. 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. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 3 (5) .000 hours. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results. The first time the ship is sailing in a fullyloaded condition after the engine has been operating for 1. Side Chocks and Side Chock Liners 3. Try to knock the liner further inward. The liners are secured in their correct position by means of hexagon socket set screws with cup point. 3. and the measurements found are to be entered in the relevant table. These results are used to determine whether refitting or.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. possibly. When referring to this page. 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. all side chocks should be checked to see whether the liners can be knocked further inward.1 Checking 3.

remarks Bolt No.1 Checking Holding Down Bolts Engine frame Bolt No. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 When referring to this page. 1 2 3 Starboard side pressure % dev. 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. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 .Holding Down and End Chock Bolts 912-2. remarks Cylinder 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.

A Starboard side B f g Cylinder No. f. e. No. f. 2 Page 5 (5) . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B Chock f d e f B c g g c B f Pres- A e Port side c. B d A FORE c. 2 B1 When referring to this page. 1 E 2 b c a d d e e c b a Contact face No. e. No.Holding Down and End Chock Bolts 912-2. d. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 B2 B2 B1 AFT No. g Starboard side Devi- Ch Bolt sure ation 2) No. A. B E A 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. (kp/cm % bar No.1 Checking Side Chocks and End Chock Bolts Port side Point c d e Chock No. 1 No. d. g g 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 A.

.

dismantling 800 . see 900-2 Stopped engine X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.4 mm D13-01 Hydraulic pressure.Stay Bolts MAN B&W Diesel 112-3 Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D12-04 Check measurement 0. please quote Data D11203 Edition 0027 Page 1 (2) .990 bar When referring to this page. mounting 900 bar D13-02 Hydraulic pressure.

complete Page 2 (2) When referring to this page. complete P91351 105 3-way distributor block. complete P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909.g. P91261 Description Large Parts . please quote Data D11203 Edition 0027 . pneumatically operated P91351 046 Hose with unions (1500 mm). Plate Item No.Stay Bolts 112-3 MAN B&W Diesel 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.Tools P91351 010 Hydraulic pump. e.

so that the two stay bolts are tightened in one operation. when the uppermost staybolt nut is loosened.Stay Bolts 912-3. remove the protective caps. please disregard the above. HM912-3. make sure that the staybolts are mounted in such a way that. 2. as stated in Data. If the engine is equipped with split staybolts and one or more staybolts have been dismantled.1 1. 3.0 28 01 2. Connect the high-pressure pump by means of the high-pressure hoses. between the contact face of the lowermost nut and the bedplate.0 28 07 D12-05 When referring to this page. HM912-3. If the engine is equipped with staybolts in one piece. please quote Procedure M91203 Edition 0211 MAN B&W Diesel A/S Page 1 (2) . 1. there is a clearance. HM912-3.1 Checking 0211 Bolts Stay S42MC Checking 912-3.0 28 02 D13-01 3. 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. Before retightening the stay bolts.

D13-02 If the nut is not loose: Tighten the stay bolts to D-2. please quote Procedure M91203 Edition 0211 MAN B&W Diesel A/S . Tighten to 10% below D-2 and check if the nut is loose. HM912-3.0 28 04 7. HM912-3. HM912-3. Reconnect the hydraulic tools to the pair of stay bolts first tightened. working from the middle toward one end of the engine and then from the middle again toward the other end.912-3. If the nut is loose: Tighten all stay bolts once again to D-2. check with a feeler gauge that the nuts bear against the contact face.1 Stay Bolts Checking 4. 5. 4. After completing the retightening procedure. Page 2 (2) When referring to this page.0 28 06 6. mount the protective caps.0 28 03 6. and retighten the stay bolt nuts with a tommy bar. Before relieving the system of pressure. Maintain the hydraulic pressure at the value indicated in D-1. Start the retightening of the stay bolts and proceed to tighten the stay bolts in pairs. 5.

In case of any rips or tears in the diaphragms. new diaphragms may be made from three layers of 2 mm thick oil and temperature resistant rubber. When referring to this page. 1. E F G D C B A If the water content of the main engine lube oil is rising.1 Checking The crankcase oil outlets guide the lubricating oil from the crankcase to the lubricating oil bottom tank. M912050201C02 2. please quote Procedure M91205 Edition 0201 Page 1 (2) .Crankcase Oil Outlet MAN B&W Diesel 912-5. Mount: Rubber sealing diaphragms G Steel ring F Screws E Cover plate D Screws C Grating B Screws A. To access the rubber diaphragm sealing remove: Screws A Grating B Screws C Cover plate D Screws E Steel ring F. Note! Remember to fit new locking plates at screws A. they must be replaced. 3. M912050201C01 Note! 2. If unavailable. The crankcase oil outlets may be equipped with either rubber diaphragm sealing or metal bellow sealing. The sealings of the crankcase oil outlets must be checked at regular intervals. Lift away the rubber sealing diaphragms G and examine each diaphragm closely. for example during dockings. Note! It is strongly recommended to always replace the diaphragms during inspection. Rubber diaphragm sealing 1. this may indicate that the crankcase oil outlet sealings are fractured.

F M912050201C04 E G H 7. please quote Procedure M91205 Edition 0201 . it must be replaced. If any cracks or punctures are found in the metal bellow sealing. Remove all screws A and grating B. 4. 12. 8. 13. Replace gaskets G and H. Mount metal bellow sealing F. 11. Remove: Screws C Cover plate D Screws E. Mount all screws A. Remount four of the screws A at diametrically opposite positions. Remove the four screws A. B A 6. Note! 7.Crankcase Oil Outlet 912-5. Lift away metal bellow sealing F and examine it closely. Page 2 (2) When referring to this page. 9.1 Checking MAN B&W Diesel Metal bellow sealing 4. Mount grating B. It is recommended to always replace the metal bellow sealing during inspection. Mount: Screws E Cover plate D Screws C. M912050201C07 10. C D 5.

Tools Plate P91261-0072 Large Parts .Large Parts . please quote Plate P91261 Edition 0072 MAN B&W Diesel A/S Page 1 (2) .Tools 0072 P91261 When referring to this page.

Item Description Hydraulic jack. 023 035 047 059 060 084 096 202 Large Parts .Plate P91261-0072 Item No. complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Tommy bar Key. please quote Plate P91261 Edition 0072 MAN B&W Diesel A/S . hexagon socket screw Hydraulic tool set.Tools Item Description Item No. complete Page 2 (2) When referring to this page.

Holding-Down and End Chock Bolts (Epoxy Chocks) When referring to this page.Hydraulic Tools . please quote Plate P91263 Edition 0059 MAN B&W Diesel A/S Plate P91263-0059 Page 1 (2) .

Plate P91263-0059 Item No. complete When referring to this page.Holding-Down and End Chock Bolts (Epoxy Chocks) Item Description Item No. please quote Plate P91263 Edition 0059 MAN B&W Diesel A/S . 024 036 048 050 061 073 085 097 107 119 203 Page 2 (2) Hydraulic Tools .0 Hydraulic jack for holding-down bolt M30 x 3.5 Support for end-chock bolt Support for holding-down bolt Tommy bar Spanner O-ring with back-up ring O-ring with back-up ring O-ring with back-up ring O-ring with back-up ring Hydraulic tool set. Item Description Hydraulic jack for end-chock bolt M48 x 5.

etc.General Tools Documents in this Chapter 913-01 913-04 913-05 913-06 913-07 91311 91351 91356 91357 91358 91359 91360 91361 91362 91363 91364 91366 0206 0201 0205 0205 0207 0204 0033 0052 0003 0002 0002 0002 0052 0059 0040 0059 0065 Hydraulic Tools Standard Tightening Torques Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories .913 . Open-Ended Spanners Open Ended Slugging Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments MAN B&W Diesel A/S .Hydraulic Tools Lifting Tools.

MAN B&W Diesel A/S .

1. Extension stud U.0 15 02 2. Nut J. 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. the hydraulic tool consists of a double jack with two extension studs. Lifting tool S. A. Spacer ring H. Sealing rings G. Bleed screw D. This jack is designed for the simultaneous dismantling of both nuts on one side of the main bearing. 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 hydraulic tools. Piston E. Milled recess for feeler gauge 2.Hydraulic Tools 913-1 Hydraulic Tools 0206 913-1 1. For the main bearings. Stud or bolt L. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 1 (12) . Snap-on coupling B. Cylinder F. When referring to this page. Tommy bar I. Clearance BG913-1. BG913-1.0 15 01 K. and a spacer ring which is to be placed under the jack and around the nut that is to be loosened or tightened. Tool attachment thread C.

if necessary. which must not be exceeded. Hydraulic Tools 3. The stud or bolt concerned is thereby lengthened relative to the oil pressure applied and the piston area. and after use the jacks should be cleaned and kept in the wooden boxes supplied. replace this sealing ring. The hydraulic jacks are so designed that. Warning! Eye protectors and gloves must be used when using hydraulic tools. BG913-1. Therefore inspect and. 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. Oils such as.0 15 03 4. The jack(s) is/are connected. When the pressure is relieved in this way. Page 2 (12) When referring to this page. via a distributor block. in the event that the “Max. as these oils are normally alkaline and can thus damage the backup rings. the lowermost sealing ring will in most cases be damaged.913-1 3. The following instructions must be closely followed to prevent accidents or damage. 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. lift”. to a high-pressure pump. as required. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . with the aid of a tommy bar. lift” limit is exceeded. and the nut can be loosened or tightened. The oil used must be pure hydraulic oil or turbine oil (with a viscosity of about SAE 20). for instance. lubricating oil (system oil) or cylinder lubricating oil must not be used. The jacks must never be overloaded or exposed to blows or impacts. They are marked with a “Max.

When referring to this page. until the cylinder of the jack bears firmly against the spacer ring. Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar. flows out of the bleed hole. BG913-1. Screw the jack on to the tool attachment thread of the bolt/stud. check that the parts are guided correctly together and that there is no clearance between the piston and cylinder of the jack. See sketch. 2. 2. Unscrew the jack to create a clearance between the jack and spacer ring.1 15 02 After adjustment. When loosening nuts on very long bolts (e. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 3 (12) . Single Hydraulic Jack 1.1 15 01 Connect the hydraulic jack. Loosen the bleed screw in the jack and fill up the system with oil until oil without bubbles. Then tighten the bleed screw again.g. The clearance between the jack and spacer ring ensures dismantling of the jack after loosening the nut. Carefully clean the tool attachment thread. the nut and the surrounding parts. staybolts) it is recommended to unscrew the jack an additional half turn. BG913-1. the distributor block and the high pressure pump by means of high pressure hoses. 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.Hydraulic Tools 913-1 Loosening of Nut Loosening of Nut 913-1 1.

Increase the oil pressure to the prescribed value.913-1 Hydraulic Tools Loosening of Nut 3. and remove the hydraulic tools. Relieve the system of pressure. Note! Make sure not to exceed the “max lift” stamped on the jack. Page 4 (12) When referring to this page. Unscrew the nut with the tommy bar. 3. GN913-1 203 08 5. the pressure may be increased by approx. GN913-1 203 06 5.1 10 04 4. HM913-1. If the nut does not come loose. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . 90 bar. 4. making sure that the nut is not screwed up against the jack. disconnect the high-pressure pump.

Mount the extension studs on the main bearing studs. BG913-1. and fill up the system with oil until oil. the nuts and the surrounding parts. Re-tighten the bleed screws. without bubbles.1 15 06 Press the pistons and the cylinder of both the hydraulic jacks firmly together.Hydraulic Tools 913-1 Loosening of Nut 6. flows out of the bleed holes. Grease the tool attachment threads with molybdenum disulphide grease or graphite and oil or similar. 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. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. The clearance between the pistons and the cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn   3 mm. 7. the distributor block and the high pressure pump by means of high pressure hoses. the main bearing studs. Carefully clean the tool attachment threads. BG913-1. 7. Loosen the bleed screws in both jacks. When referring to this page. The clearance between the jack and spacer ring ensures dismounting of the jack after loosening the nut. Using the lifting tool. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 5 (12) . place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of loosening the nuts. Double Hydraulic Jack 6. Mount the two jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring.1 15 08 Connect the hydraulic jacks.

1 15 09 Make sure not to exceed the “max lift” stamped on the jack. If the nut does not come loose.1 15 11 9. Note! BG913-1. 90 bar. and remove the hydraulic tools. 9. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 .913-1 Hydraulic Tools Loosening of Nut 8. BG913-1. Page 6 (12) When referring to this page. Unscrew the lower nuts 1½ turns with the tommy bar. making sure that the nuts are not screwed up against the extension stud. 8. Relieve the system of pressure. the pressure may be increased by approx. disconnect the high-pressure pump. Increase the oil pressure to the prescribed value.

please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 7 (12) . Single Hydraulic Jack 1. Thoroughly clean the nut. Check with a feeler gauge that the contact face of the nut bears on the entire circumference. BG913-1. Press the piston and the cylinder of the jack firmly together.2 15 01 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. until oil without bubbles flows out of the bleed hole. the contact faces. and the surrounding parts. Fit the round nut on the thread and tighten it with the tommy bar. 2. Clean and lubricate the tool attachment thread and the thread in the nut with molybdenum disulphide grease or with graphite and oil or similar. BG913-1. the thread. 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. When referring to this page.2 15 02 Re-tighten the bleed screw. 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. 2.Hydraulic Tools 913-1 Tightening of Nut Tightening of Nut 913-1 1.

and tighten the nut by means of the tommy bar applied through the slot of the spacer ring. While maintaining the pressure. GN913-1 203 17 6. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . GN913-1 203 18 4. do not remove the jacks. points 6-7-8. Page 8 (12) When referring to this page. check with a feeler gauge introduced through the recess at the bottom of the spacer ring that the nut bears against the contact face.913-1 Hydraulic Tools Tightening of Nut 3. Relieve the system of pressure. and then tighten the nut again according to the procedure under ‘Tightening'. points 3-4-5. bolts or nuts are tightened for the first time. disconnect the pump. and remove the hydraulic jack. When new studs. 5. Increase the oil pressure to the prescribed value. 4. but loosen the nut as described under ‘Loosening’. 3.

and fill up the system with oil until oil. the contact faces. Loosen the bleed screws in both jacks. Clean and lubricate the tool attachment thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil. without bubbles. 8. 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. the distributor block and the high pressure pump by means of high pressure hoses. Press the piston and the cylinder of both the hydraulic jacks firmly together. Mount the two jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring.2 15 08 Connect the hydraulic jacks. Using the lifting tool.Hydraulic Tools 913-1 Tightening of Nut 7. BG913-1. the threads on the main bearing studs. Double Hydraulic Jack 7. Check with a feeler gauge that the contact faces of the nuts bear on the entire circumference. flows out of the bleed holes. and the surrounding parts. Fit the round nuts on the threads and tighten them with the tommy bar. BG913-1. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. When referring to this page. 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. Re-tighten the bleed screws. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 9 (12) . 8. Thoroughly clean the nuts.2 15 07 Mount the extension studs on the main bearing studs.

and then tighten the nuts again according to the procedure under ‘Tightening'. disconnect the pump. point 8. and remove the hydraulic tools. bolts or nuts are tightened for the first time. Relieve the system of pressure. 10. BG913-1.2 15 11 10. points 9-10-11. When new studs. but loosen the nuts as described under ‘Loosening'. 11. While maintaining the pressure. and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. check with a feeler gauge introduced through the recesses at the bottom of the spacer ring that the nuts bear against the contact face.913-1 Hydraulic Tools Tightening of Nut 9.2 15 10 12. BG913-1. Page 10 (12) When referring to this page. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . Increase the oil pressure to the prescribed value. 9. do not remove the jacks.

The hydraulic jacks require no maintenance except replacement of defective sealing rings. The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of compressed air. BG913-1. The presence of metal particles will damage the sealing rings. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 11 (12) . Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease. Warning! Make sure that there are no marks or scratches on the sliding surfaces of the parts. The pistons and cylinders of the double jacks are separated in the same easy way as described for the single jack. each of which consists of an O-ring and a back-up ring fitted in ring grooves in the piston and cylinder. 1. BG913-1.4 15 02 2. When referring to this page. 2.Hydraulic Tools 913-1 Maintenance Maintenance 913-1 1.4 15 01 Always use eye protection when working with compressed air.

4 15 03 4. BG913-1. See the sketch for the correct mounting of both the upper and the lower sealing rings. The same principle applies to all the jacks. When changing the sealing rings. BG913-1. Warning! Note that the back-up ring (1) must be away from the pressure chamber and the O-ring (2) close to the pressure chamber. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . Page 12 (12) When referring to this page.4 15 04 4.913-1 Hydraulic Tools Maintenance 3. 3. first mount the back-up ring and then the O-ring. 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. After fitting the sealing rings.

Thread Tightening torque Thread Tightening torque M8 20 Nm M22 430 Nm M10 40 Nm M24 490 Nm M12 60 Nm M27 650 Nm M14 90 Nm M30 1000 Nm M16 150 Nm M33 1250 Nm M18 210 Nm M36 1700 Nm M20 290 Nm M39 2200 Nm 3. 1.Standard Tightening Torques 913-4 Standard Tightening Torques .0&& 0201 913-4 When tightening screws or nuts for which no torque is specified in the instruction procedure or the related data sheet. Standard screws and nuts lubricated with a Molybdenum Disulphide (MoS 2) based lubricant. Thread Tightening torque Thread Tightening torque M8 23 Nm M22 580 Nm M10 50 Nm M24 680 Nm M12 70 Nm M27 900 Nm M14 115 Nm M30 1350 Nm M16 190 Nm M33 1700 Nm M18 270 Nm M36 2350 Nm M20 380 Nm M39 3000 Nm When referring to this page. Thread Tightening torque Thread Tightening torque M8 17 Nm M22 400 Nm M10 35 Nm M24 460 Nm M12 50 Nm M27 610 Nm M14 80 Nm M30 950 Nm M16 135 Nm M33 1200 Nm M18 190 Nm M36 1650 Nm M20 260 Nm M39 2100 Nm 2. Screws and nuts locked with glue/Loctite. Self-locking nuts. please quote Procedure M91304 Edition 0201 0$1% :'LHVHO$6 Page 1 (1) . the standard torques specified in this procedure are to be applied.

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can be set at the required torque on the scale. A spring-loaded slide in the handle is provided with a mark which. When the ball is pulled. and it must not be damaged by hammering on it or the like. When the torque spanner is not in use. thus obviating the risk of loose nuts. when the crank handle is turned. and a small click is heard.1-0. please quote Procedure M91305 Edition 0205 0$1% :'LHVHO$6 Page 1 (1) .g. the nuts are to be tightened and loosened two or three times so that the thread may assume its definite shape. Rahsol Torque Spanner The handle of the torque spanner is provided with a scale indicating the torques at which the spanner can be set. MOLYKOTE paste type G). The torque spanner must not be used for torques higher than those stamped on it. there is a ball on a small arm at the end of the handle. For setting the spanner at the required torque. at which moment a small jerk is felt in the spanner. Nuts secured with a split pin are to be tightened to the stated torque and then to the next splitpin hole. In the case of new nuts and studs. The torque spanner works as follows: The above-mentioned spring acts on a pawl system in the handle. a small crank handle appears. the pawl system is released. the spring inside should be released by adjusting to minimum torque. When referring to this page. and it should be checked that they bear on the entire contact face.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 µ = 0.12 (e. The nuts should fit easily on the thread. When the pre-set torque has been reached.

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Pre-tightening with a torque spanner Before tightening the nuts according to a tightening gauge or tightening angle. Then tighten the nut until the two marks coincide. MOLYKOTE paste type G) The nuts should fit easily on the thread. and mark off with chalk on the nut at slot A on the tightening gauge. When tightening new studs or bolts for the first time.g.12 (e. to allow the parts to settle. please quote Procedure M91306 Edition 0205 0$1% :'LHVHO$6 Page 1 (1) . respectively. grease the threads and the contact faces with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient. Therefore. mark the angle on a corner of the nut and on the contact face.Tightening Gauge 913-6 Tightening Gauge 0205 913-6 Preparations Before screwing on the nuts. µ = 0. place the tightening gauge round the nut.g. Then tighten the nut until the two chalk marks coincide. after pre-tightening.  G Q D               0 + When referring to this page. See Procedure 913-5.         7 . Apply a pre-tightening torque of: – thread M8 – M20 = 50 Nm – thread M22 – M27 = 100 Nm – thread M30 – M39 = 150 Nm – thread M42 – M48 = 200 Nm This is in order to ensure a uniform basis for the subsequent tightening with gauge or tightening angle. we usually do not deliver a tightening gauge. Tightening without a tightening gauge For tightening angles of e. and make another chalk mark on the contact face at slot B. 30°–45° and 60°.1–0. they must be pre-tightened with a torque spanner. See Procedure 913-5. and it should be checked that they bear on the entire contact face. loosen again and repeat the procedure – including pre-tightening with a torque spanner. Tightening with a tightening gauge After pre-tightening.

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When reassembling the engine after overhauls. Lock washers...Screws and Nuts MAN B&W Diesel 913-7. M913070207C03 3. etc. 1. The tab-like projections. it is vital that all such screws and nuts are again locked correctly. tab washers. on the washers are to be bent back over one of the flats of the screw or nut concerned. and then add this torque to the torque value stated on the data sheet of a procedure. Therefore. locking plates.1 Locking Some screwed and bolted connections on the engine. are secured against untimely loosening by means of different types of locking devices. Self-locking nuts may only be used five times. as well as some movable joints. M913070207C01 Note! 2. must always be replaced. etc. To tighten a self-locking nut to a specific torque. 1. 2. Make sure only to mount locking devices on nuts and screws which have been mounted with locking devices by the engine manufacturer. first measure the torque required to turn the nut itself. When referring to this page. Used spring washers must be replaced. M913070207C02 3. give the nut a centre punch mark each time it is loosened. please quote Procedure M91307 Edition 0207 Page 1 (4) .

be sure that the wire is tight around the head. and under the end protruding from the screw. When the wire is tight. Do not overtighten or loosen the units to get a correct alignment of the wire holes. Fig. 3 Fig. Do not secure more than four units in a series. 7 Fig. Page 2 (4) Fig. 6: During the final twisting motion. 2: Twist the wire clockwise until it is just short of the hole in the second screw. Always fit new wire after tightening-up the units. 1: Insert wire. bend the wire along the screw head. 3: Insert the uppermost wire in the second screw. Fig. 6 M913070207C04 Fig. Fig. Fig. 4 Fig. then under the other end of the wire. One twist is a twist of the wires through an arc of 180°. the wire shall have approximately 7-10 twists per 25 mm. twist it min. Fig. Cut off excess wire. 9 When referring to this page. 4: Bend the lower wire around the screw. Keeping the wire under tension. equal to half of a complete turn. twist it until tight. Fig. Fig. Fig.Screws and Nuts 913-7. please quote Procedure M91307 Edition 0207 . 3 twists. 2 Any tendency of the screws or nuts to loosen will be counteracted by a tightening of the locking wire. counterclockwise until tight. and pull it tight. grasp the upper end of the wire and bend it around the head of the screw.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. 8 M913070207C05 Fig. 5 Fig. 5: Keeping the wire under tension. 7-9: Show the preferred ways of mounting the locking wire on screws with wire holes oriented in different angles. unless otherwise specified.

to prevent damage to the nut. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread. 10 Fig. Fig. Fig. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible. route the wire as shown in the figure. 13 Fig. Fig. 11 Fig. 14 When referring to this page. 12 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. 13: Where drilling of locking wire holes has caused a thin wall section.Screws and Nuts MAN B&W Diesel 913-7. M913070207C06 Fig. please quote Procedure M91307 Edition 0207 Page 3 (4) . 10: Shows how to route the locking wire on screws in different planes.1 Locking Fig. Fig.

Fig. The cam lock washer is locked in place. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect og the cams. 15: The washers are installed in pairs. please quote Procedure M91307 Edition 0207 . M913070207C17 Fig. 17: Don not use the cam lock washers in conjunction with other loose washers.913-7.1 Screws and Nuts Locking Fig. 16: Different uses of the cam lock washers. Fig. 16. M913070207C15 Fig. Fig. cam face to cam face. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces. 17 Page 4 (4) When referring to this page. allowing movement only across the face of the cams. Note! M913070207C16 Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers. 15 MAN B&W Diesel Cam Lock Washers with rising cams on one side and radial teeth on the other.

• Protect the wet paste and cloth from dust or other foreign particles. • Allow 5 minutes for the cleaning fluid to evaporate.Lubricating Procedures 913-11 Lubricating Procedures . uniform. rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e. • Remove any excessive paste and ensure that the metal surface is only coated with a thin. Molycote G-n Plus. or the like) hard onto the metal surface. layer of the above mixture.g. • With a clean leathercloth. When referring to this page. and using circular movements. • Clean the surface with a cleaning fluid and ensure that the entire surface is completely free of grease.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. please quote Procedure M91311 Edition 0204 0$1% :'LHVHO$6 Page 1 (1) .

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please quote Plate P91351 Edition 0033 MAN B&W Diesel A/S Page 1 (2) .Accessories for Hydraulic Tools Plate P91351-0033 Accessories for Hydraulic Tools 0033 P91351 Working Pressure 900 Bar When referring to this page.

round-plain. Item Description Hydraulic pump. female Disc. Cu ø11x3mm Bleeder screw Disc. Fe ø11x9mm Page 2 (2) When referring to this page. male Quick coupling. complete Angle union Quick coupling. complete 2-way distributor block. complete Hose with unions (3000mm). 010 046 058 105 117 130 166 201 213 225 237 249 Accessories for Hydraulic Tools Item Description Item No. pneumatic operated Hose with unions (1500mm). complete 4-way distributor block. complete 9-way distributor block. please quote Plate P91351 Edition 0033 MAN B&W Diesel A/S .Plate P91351-0033 Item No. round-plain.

Etc. 0052 P91356 When referring to this page. please quote Plate P91356 Edition 0052 MAN B&W Diesel A/S Page 1 (2) .Lifting Tools. Plate P91356-0052 Lifting Tools. Etc.

16mm Lifting eye bolts. 018 020 031 055 114 126 138 140 222 283 305 Lifting Tools. 3m Page 2 (2) When referring to this page.Plate P91356-0052 Item No. 20mm Lifting eye bolts. 10mm Lifting eye bolts. Etc. 8mm Forged-bent screw shackle. Item Description Forged-bent screw shackle. 1000kg Pull lift. 10mm Forged-bent screw shackle. 20mm Chain tackle. please quote Plate P91356 Edition 0052 MAN B&W Diesel A/S . 750kg Wire rope. 12mm Forged-bent screw shackle. 12mm Lifting eye bolts. Item Description Item No.

please quote Plate P91357 Edition 0003 MAN B&W Diesel A/S Page 1 (2) .Open Ended Spanners Plate P91357-0003 Open Ended Spanners 0003 P91357 When referring to this page.

please quote Plate P91357 Edition 0003 MAN B&W Diesel A/S . 013 Open Ended Spanners Item Description Item No.Plate P91357-0003 Item No. size NV65mm Page 2 (2) When referring to this page. Item Description Open-ended spanner.

Open-Ended Slugging Spanners Plate P91358-0002 Open-Ended Slugging Spanners 0002 P91358 When referring to this page. please quote Plate P91358 Edition 0002 MAN B&W Diesel A/S Page 1 (2) .

size NV46mm Page 2 (2) When referring to this page. Item Description Open-ended slugging spanner. please quote Plate P91358 Edition 0002 MAN B&W Diesel A/S . 020 081 Open-Ended Slugging Spanners Item Description Item No.Plate P91358-0002 Item No. size NV30mm Open-ended slugging spanner.

please quote Plate P91359 Edition 0002 MAN B&W Diesel A/S Page 1 (2) .Torque Spanners Plate P91359-0002 Torque Spanners 0002 P91359 When referring to this page.

8 .5 mm Torque wrench. 014 026 038 040 Torque Spanners Item Description Item No. Item Description Torque wrench. 10 x 12. 140 .400Nm Adapter for socket wrench. 40 .200Nm Torque wrench.760Nm Page 2 (2) When referring to this page. please quote Plate P91359 Edition 0002 MAN B&W Diesel A/S .Plate P91359-0002 Item No.

Pliers Plate P91360-0002 P91360 Pliers 0002 When referring to this page. please quote Plate P91360 Edition 0002 MAN B&W Diesel A/S Page 1 (2) .

3mm 1. 010 021 033 116 128 130 141 Item Description Pliers Pliers Pliers Pliers Pliers Pliers Pliers Page 2 (2) for for for for for for for retaining retaining retaining retaining retaining retaining retaining ring. ring. ring.Plate P91360-0002 Pliers Item No.1mm 1. ring.9mm 1.3mm When referring to this page.8mm 2. please quote Plate P91360 Edition 0002 MAN B&W Diesel A/S . Item Description 0.8mm 0. size size size size size size size Item No.9mm 1. ring. ring. ring.

please quote Plate P91361 Edition 0052 Plate P91361-0052 Page 1 (2) .Combination Spanners MAN B&W Diesel When referring to this page.

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. spanners. spanners. spanners. spanners. spanners. spanners. spanners. 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.Combination Spanners Plate P91361-0052 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 When referring to this page. spanners. spanners. spanners. spanners. spanners. spanners. spanners. please quote Plate P91361 Edition 0052 . spanners. spanners.

please quote Plate P91362 Edition 0059 MAN B&W Diesel A/S Page 1 (2) .Ring Slugging Spanners Plate P91362-0059 Ring Slugging Spanners 0059 P91362 When referring to this page.

ring size NV46mm Slugging spanners. ring size NV55mm Slugging spanners. ring size NV50mm Slugging spanners. ring size NV41mm Slugging spanners. ring size NV32mm Slugging spanners. ring size NV65mm Page 2 (2) When referring to this page. ring size NV30mm Slugging spanners. ring size NV34mm Slugging spanners. Item Description Slugging spanners. 010 022 034 046 058 071 083 095 105 117 Ring Slugging Spanners Item Description Item No. ring size NV60mm Slugging spanners. please quote Plate P91362 Edition 0059 MAN B&W Diesel A/S .Plate P91362-0059 Item No. ring size NV36mm Slugging spanners.

Spanners MAN B&W Diesel When referring to this page. please quote Plate P91363 Edition 0040 Plate P91363-0040 Page 1 (2) .

Spanners Plate P91363-0040 MAN B&W Diesel Item No.5 mm Socket spanner. size 10-22 mm Tool set. complete Adapter for socket wrench. complete. complete. S=22 mm Hex key. S=46 mm Hex key. Item Description When referring to this page. size 24-46 mm Hex key tool set. Item Description 016 028 030 041 100 150 161 Tool set. S=24 mm Page 2 (2) Item No. 20->12. please quote Plate P91363 Edition 0040 .

Open-ended Spanners Plate P91364-0059 When referring to this page. please quote Plate P91364 Edition 0059 Page 1 (2) MAN B&W Diesel A/S .

Item Description Open ring wrench. please quote Plate P91364 Edition 0059 MAN B&W Diesel A/S . 19 .22mm When referring to this page.Plate P91364-0059 Item No. 14 . 011 023 Page 2 (2) Open-ended Spanners Item Description Item No.17mm Open ring wrench.

Instruments When referring to this page. please quote Plate P91366 Edition 0065 MAN B&W Diesel A/S Plate P91366-0065 Page 1 (2) .

please quote Plate P91366 Edition 0065 MAN B&W Diesel A/S . Item Description Autolog. measuring tool for crankshaft Feeler gauge Slide caliper Dial gauge and stand tool When referring to this page. 048 050 061 073 Page 2 (2) Instruments Item Description Item No.Plate P91366-0065 Item No.

When referring to this page. Subpart K. but not limited to. please quote S900 Edition 0001 MAN B&W Diesel A/S Page 1 (1) .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.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions. §94. the instructions to that effect included in the Technical File. Subpart C. In accordance with Chapter I of the Code of Federal Regulations. Part 94. including. §94. Part 94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations.

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L35MC VOLUME III COMPONENTS DESCRIPTION .

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Standard Conditions Instructions for Main Engine Description MAN B&W Diesel A/S .900 .Introduction Documents in this Chapter 90001 90002 90003 90004 90023 90030 0029 0001 0001 0001 0027 0009 Table of Contents. Volume III Cross Section through Engine Ordering of Insulation Designations and Symbols Software Licence .

MAN B&W Diesel A/S .

Standard Conditions 90023 0027 Instructions for Main Engine 90030 0009 Description 901 .Details 904 .Control Gear 90600 0068 Arrangement of Chain Drive and Camshaft 90601 0105 Chain Drive and Guide Bars 90602 0124 Chain Drive . Edition Title 900 .Cylinder Liner and Cylinder Lubrication 90301 0188 Cylinder Frame 90302 0192 Cylinder Liner and Cooling Jacket 90304 0025 Cylinder Liner .Mounting 902 .Crosshead with Connecting Rod 90401 0145 Connecting Rod and Crosshead 90403 0009 Lubricating and Cooling Oil-Flow 905 .Components Description No.Cylinder Cover 90101 0138 Cylinder Cover 90103 0007 Indicator Cock .Lubrication 90603 0059 Chain Tightener 90605 0076 Lubricator Drive 90611 0170 Camshaft and Chain Wheel 90613 0117 Camshaft Bearing 90615 0138 Arrangement of Governor 90618 0139 Regulating Shaft MAN B&W Diesel A/S Page 1 (2) . Thrust Bearing and Turning Gear 90501 0179 Crankshaft 90502 0076 Arrangement of Fore End 90505 0170 Thrust.Details 90513 0036 Tacho System 906 .Crankshaft.Piston with Rod & Stuffing Box 90201 0217 Piston and Piston Rod 90205 0122 Piston Rod Stuffing Box 903 .Table of Contents 900 Volume III .and Guide Bearing 90510 0120 Turning Gear 90511 0040 Turning Wheel 90512 0001 Turning Gear .Introduction Table of Contents 90001 0029 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations and Symbols 90004 0001 Software Licence .

Lower Parts 90802 0041 Exhaust Valve .Details 910 .Pipe System 90810 0092 Arrangement of Cooling Water Pipes 909 .Upper Parts 90804 0017 Exhaust Valve Upper Parts .Starting Air System 90702 0046 Main Starting Valve 90703 0068 Starting Air Distributor 90704 0050 Starting Valve 908 .Cylinder 91102 0024 Relief Valve 91103 0017 Safety Valve . 90620 90621 Edition 0107 0085 Title Engine-Side Control Console Engine-Side Control Console .Details 90915 0078 Fuel Oil System .Actuator 90806 0080 Exhaust Valve .Details 90915 0077 Fuel Oil System .Fuel Oil System 90901 0207 Fuel Pump 90902 0138 Fuel Pump Gear 90910 0152 Fuel Valve 90911 0021 Fuel Valve Function 90913 0096 High-Pressure Pipes 90914 0105 Fuel Oil System 90915 0076 Fuel Oil System .Details 90805 0130 Exhaust Valve .Turbocharger System 91000 0016 Gas and Air System 91001 0125 Scavenge Air Receiver 91002 0127 Arrangement of Charging Air Pipe 91003 0197 Exhaust Pipes and Receiver 91004 0049 Exhaust Receiver .Details 91005 0132 Air Cooler 91006 0030 Arrangement of Auxiliary Blower 91009 0036 Air Cooler System .Cleaning 91010 0026 Air Cooler .Table of Contents 900 Volume III .Safety Equipment 91101 0037 Safety Valve .Components Description No.Details 907 .Exhaust Valve 90801 0184 Exhaust Valve .Frame 91018 0006 Air Cooler System 911 .Scavenge Air System 91104 0108 Arrangement of Safety Cap MAN B&W Diesel A/S Page 2 (2) .Details 90803 0032 Exhaust Valve .

Table of Contents 900 Volume III .Arrangement MAN B&W Diesel A/S Page 3 (2) .Lower 91210 0186 Bedplate 91211 0036 Axial Vibration Damper 91216 0007 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) 91217 0004 Top Bracing .Components Description No. Edition Title 912 .Assembly of Large Parts 91201 0094 Arrangement of Stay Bolts 91205 0159 Frame Box 91207 0054 Arrangement of Piston Cooling 91208 0019 Chain Wheel Frame .Upper 91209 0007 Chain Wheel Frame .

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Cross Section through Engine When referring to this page. please quote Plate P90001 Edition 0029 MAN B&W Diesel A/S Plate P90001-0029 Page 1 (1) .

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Ordering of Insulation MAN B&W Diesel When referring to this page. please quote Plate P90002 Edition 0001 Plate P90002-0001 Page 1 (1) .

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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 When referring to this page. please quote Plate P90003 Edition 0001 Page 1 (1) .

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Furthermore the customer is not allowed to make the software available to a third party or to reverse engineer. When referring to this page. please quote Plate P90004 Edition 0001 Page 1 (2) . 1. MAN B&W and its software suppliers retain the right of ownership to the software.is transferred to a third party the customer has the right to assign the licence to this third party. 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. 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. 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. 3. 5. 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. Updating The non-exclusive user's licence does not include any updating of the software. with respect to the software and data media. MAN B&W disclaims liability for breach of conditions or warranties. Except as stated above. such updates or new versions shall be made available to the customer against separate payment. 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. 4. including warranties of suitability and applicability for a particular purpose. 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.Software License. they will be replaced free of charge. TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S ACCEPTANCE OF THESE CONDITIONS. Copyright The customer must not copy the software or any part thereof.for which the software is acquired . If and to the extent MAN B&W updates the programs or develops new versions. 2. If the engine plant . decompile or disassemble the software. either expressed or implied.

including the present licence agreement. Page 2 (2) When referring to this page. The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&W’s software suppliers. Law MAN B&W's tenders and contracts with customers regarding delivery of data and programs. 6. MAN B&W shall in no event be liable for any damages resulting from loss of data. or for any special.Plate P90004-0001 Software License. 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. shall be interpreted according to Danish Law. please quote Plate P90004 Edition 0001 . profits or use of equipment. incidental consequential damages arising out of or in connection with the use or performance of the software. Standard Conditions MAN B&W Diesel MAN B&W's liability for damages to the customer for any cause whatsoever.

In addition. I OPERATION Vol. reliability and lifetime of the engine and its components. be copied. Plate No. may consist of either of these two sets of digits. Quantity required (and description) Example: M/S Nybo – 7730 B&W – P90201-0036 – 059 10 off (piston ring) + )The Plate No. To ensure optimum efficiency. the books can be used for reference purposes. Consequently. 39 66 13 14 . Engine No. in respect of instructions on emissions related maintenance of the diesel engine. A90023-0027 This book is subject to copyright protection. Name of vessel 2. it is essential that the engine room personnel are fully acquainted with the contents of this book and. built by 3. and should therefore not. It is essential that the following data is stated in spare parts orders as it is used by us to ensure the supply of the correct parts for the individual engines: 1. When used in texts and illustrations. as the pages are in the process of being updated with new numbers: P90201-0036 or 90201-036. II MAINTENANCE Vol. Part No. Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S’ instructions and any additional instructions to that effect included in the Technical File. the designation “D” refers to the information given on the data sheets inserted in the respective books.Instructions for Main Engines This book forms part of a set of books consisting of three volumes entitled: Vol. Deviations may be found in a specific plant. reproduced. also the additional instructions to that effect set out in the Technical File.:+45 33 85 11 00 Telex :16592 manbw dk Telefax:+45 33 85 10 30 CVR No. DESCRIPTIONS The purpose of these books is to provide general guidance on operation and maintenance and to describe the constructional features of a standard version of an MAN B&W main diesel engine. made public or in any other way made available to a third party without the written consent of this effect from MAN B&W Diesel A/S. 5. III COMPONENTS. for instance in correspondence and when ordering spare parts. MAN B&W Diesel A/S Teglholmsgade 41 DK-2450 Copenhagen Denmark Teleph. only original spare parts should be used when replacing parts on the engine. in whole or in part. 4.

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further on. to the space around the exhaust valve seat. Cooling A cooling jacket is mounted on the lower part of the cylinder cover. whereby a cooling water space is formed. When referring to this page. please quote Description A90030 Edition 0009 Page 1 (23) . when the exhaust valve is installed. Valve bores The cover has a central bore for the exhaust valve. 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. On the 70-98MC type engines the cylinder cover is provided with welded-on heat resistant material at the points of fuel oil injection in order to improve the service condition. From here the water is discharged to the main cooling water outlet pipe: On some engine types. Tightening The cylinder cover is tightened against the top of the cylinder liner with nuts and long studs fitted in the cylinder frame. an amount of water is also passed directly from the cylinder cover to the exhaust valve housing through a cooling water connection.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel 901 Cylinder Cover Cylinder Cover The cylinder cover is made of steel. starting air inlet. Sealing between the cylinder cover and cylinder liner is obtained by means of a sealing ring of mild steel. through the cooling bores. These two spaces communicate through a large number of cooling bores in the cover. and the piston skirt is tightened to the piston crown. safety valve and indicator cock. starting valve. which is attached by means of four studs and nuts. Another cooling water space is formed around the exhaust valve seat. The cover furthermore has bores for the fuel valves. 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. The nuts are tightened with hydraulic tools.

Piston Rod The piston rod has a through-going bore for the cooling oil pipe. Handle with care. or with three smaller grooves for the fitting of lifting tools. Stationary Engines: The CPR ring may have been coated with PM14 on the external surface. 3 has a right-hand cut. From the bore in the piston rod foot. The piston crown is provided with chromium-plated grooves for four piston rings. 2. Page 2 (23) When referring to this page. Piston rings Nos. 3 and 4 have oblique cuts: • piston ring No. through a number of bores in the thrust part of the piston crown. On some engines. the piston rings are provided with Alu-coating to improve the running-in stability and to reduce the running-in period. The piston rod is fastened to the crosshead pin with screws or studs and nuts. The nuts are tightened with hydraulic tools. as impact may cause the coating to crack and peel off. 2 and 4 have left-hand cuts. The piston rod foot rests on a face cut out in the crosshead pin. 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. please quote Description A90030 Edition 0009 . and • piston rings Nos. as impacts may cause the coating to crack and peel off. The oil is passed on. Handle with care. A shim is inserted between the piston rod and the crosshead. 1 is a Controlled-Pressure Relief ring (CPR). which is secured to the piston rod top. The thickness of the shim is predetermined to match the actual engine layout. to the piston crown. Piston ring No. 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. to the space around the cooling oil pipe in the piston rod.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel The piston crown is provided with one groove all the way around.

The stuffing box also prevents scavenge air (in the scavenge air space) from leaking into the crankcase. a sealing ring is fitted below the scraper ring (except on 35MC type engines). The cylinder section is tightened together with the engine framebox and the bedplate by means of stay bolts. Oil which is scraped off the piston rod is returned to the crankcase through bores in the stuffing box housing. Gaps at the ends of the ring segments ensure that the rings will bear against the piston rod even in worn condition. Alternatively as a complete welded assembly integrating the scavenge air receiver into the cylinder frame.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Stuffing Box The bore for the piston rod between the scavenge air space and the crankcase is fitted with a piston rod stuffing box. which are bolted together. When referring to this page. Scraper/sealing rings The housing is provided with a number of machined ring grooves: • The uppermost groove holds a scraper ring with oblique edges. • The ring grooves in the middle are fitted with sealing rings. please quote Description A90030 Edition 0009 Page 3 (23) . the stuffing box communicates with a control funnel on the outside of the engine. 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. Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners. • The lowermost ring grooves are fitted with scraper rings which scrape the lubricating oil off the piston rod. which enables the sealing/scraping performance to be checked. Furthermore. Through bores in the housing and a pipe. Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes. which is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space. 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. which serves to prevent sludge from the scavenge box from being drawn down to the other rings. The stuffing box housing consists of two parts.

Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is supplied Cooling Jacket at the lower part of the cooling jacket. 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. the PC-ring contributes to reducing the wear of liners and rings. prevent the wiping away of the cylinder lubricating oil. Page 4 (23) When referring to this page. the water flows through water connections to the cooling jacket on the lower part of the cylinder cover. which are un covered by the piston when this is in its bottom position. in turn. The purpose of the PC-ring is to prevent the building-up of deposits on the piston topland and. reference is made to the special instruction manuals supplied.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel There are also inlet pipes for cooling and lubricating oil. On slim-type liners. 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. the water continues directly to the upper part of the cooling jacket. From the top of the cooling jackets. OPERATION. Leakage of cooling water is prevented by silicone rubber rings. Cylinder Lubricators The engine is equipped with mechanically or electronically controlled cylinder lubricators for lubrication of the running surface of liners and rings. The cylinder frame is provided with cleaning and inspection covers giving access to the scavenge air spaces. there are a number of bores with non-return valves for the supply of lubricating oil to the cylinder. See also Volume I. the water first passes through the cooling bores. Cylinder lubrication In the free part of the cylinder liner. Chapter 707. whereas on the bore-cooled type liner. please quote Description A90030 Edition 0009 . PC-ring On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of the cylinder liner. 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. between the cooling jacket and the cylinder frame. Cylinder cover studs Studs for fastening the cylinder cover are mounted in the cylinder frame. Consequently. Regarding the cylinder lubricators proper.

905 Crankshaft and Turning Gear Crankshaft The crankshaft is either of the semi-built type. where the parts are shrunk together. Tightening The crosshead bearing is held together by studs and nuts. please quote Description A90030 Edition 0009 Page 5 (23) . When referring to this page. On some engines. OPERATION. 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. To match different engine layouts. The lower shell is provided with an overlayer coating. The crankpin bearing is fitted with steel shells lined with bearing metal and assembled in the same way as the crosshead bearing. whereas oil for lubricating the crankpin bearings is supplied from the crossheads through bores in the connecting rods. The nuts are tightened with hydraulic tools. Guide shoes The sliding faces of the guide shoes are lined with cast-on bearing metal. or it is a one-piece forging. Lubrication The crosshead is provided with bores for distributing the oil supplied through the telescopic pipe. 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. Piston rod foot The piston rod foot is fastened to the crosshead. partly as cooling oil for the piston. See also Volume I. The crosshead is equipped with steel shells lined with bearing metal. The centre part of the crosshead is designed as a bearing journal which is housed in the crosshead bearing. a shim of predetermined thickness is inserted between the piston rod and the crosshead. partly as lubricating oil for the crosshead bearing and guide shoes and – through a bore in the connecting rod – for lubricating the crankpin bearing.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel 904 Crosshead with Connecting Rod Crosshead The crosshead is provided with two guide shoes fitted on the crosshead ends. Chapter 708. the guide shoes are provided with counterweights. The main bearings are lubricated via a main lubricating oil pipe that branches off to the individual bearings. The crosshead bearing cap is provided with a cut-out enabling the piston rod to be assembled with the crosshead journal.

The oil is supplied between the segments through spray pipes and spray nozzles. and any resultant adverse forces and vibrations. The segments have white metal cast onto the wearing faces against the thrust collar. a tuning wheel. See also Volume I. the crankshaft is provided with an axial vibration damper. The thrust shoes rest on surfaces in the thrust bearing housing and are held in place by means of stoppers or cross bars. Lubricating oil is supplied to both sides of the ‘piston’ from the main system. Page 6 (23) When referring to this page. The thrust bearing serves the purpose of transmitting the axial thrust of the propeller through propeller shaft and intermediate shafts to the ship’s hull. Marine engines (except geared plants): At the aftmost end of the engine. and the housing is mounted on the pertaining main bearing support. Stationary engines and geared marine plants: The crankshaft is provided with a collar for the guide bearing. See also Volume I. a thrust bearing is fitted. The purpose of the guide bearing is to keep the crankshaft in its proper position in the axial di rection. The thrust bearing is lubricated by the pressure lubrication system of the en gine. Chapter 701. slow-down. if required according to vibration calculations. Axial Vibration Damper To counteract heavy axial vibrations. OP ERATION. 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.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel The crankshaft is provided with a chain wheel for the camshaft drive and a turning wheel. please quote Description A90030 Edition 0009 . and shut-down devices for low lube oil pressure and high segment temperature. “Assembly of large parts” further on in this text. 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’. The thrust bearing is provided with alarm. The ‘piston’ is made as an integrated collar on one of the main bearing journals. Chapter 708. See also Section 912. a torsional vibration damper and a chain wheel drive for 2nd order and 4th order moment compensators are installed. The damper consists of a ‘piston’ and a slit-type housing. Furthermore. OPERATION.

This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position. The long free lengths of the chain are guided by rubber-clad guide bars. See Volume II. OPERATION. please quote Description A90030 Edition 0009 Page 7 (23) . Pressure testing of starting valves: The turning gear must be in the disengaged position during pressure testing of starting valves. the turning gear must be in the engaged position in order to prevent outside forces from turning the engine. so as to engage with the turning wheel of the engine. and damage the turning gear. Chapter 703. exhaust valves and indicator drive (option) is driven from the crankshaft through a chain drive. as a leaky valve may cause the engine to rotate. 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.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Turning Gear The turning gear is attached to the engine bedplate and is driven by an electric motor incorporating a disc brake. When referring to this page. Chapter 703. an interlock valve inserted in the starting air system of the engine is actuated. it prevents the gear wheel of the turning gear from engaging with the turning wheel. See also Volume I. The chain is kept tightened by a chain tightener placed in the chain casing between the crankshaft and the camshaft. ‘DATA’ pages. thus causing injuries to personnel or damage to the machinery. the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually. Lubricating oil is supplied through spray pipes fitted at the guide bars and chain wheels. Through a planetary gearing. OPERATION. The chain drive consists of one or more roller chains running on chain wheels fitted on the crankshaft and the camshaft. Warning! Dismantling of working parts: During any dismantling of working parts of the engine. When the safety lever is in its bottom position. 906 Mechanical Control Gear Chain Drive The camshaft with cams for operating the fuel pumps. See Volume I. Immediately the lever is lifted away from the disengaged position. MAINTENANCE.

whereas the indicator cams are in two parts. which communicates with the combustion chamber of the cylinder through a bore. Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams. the camshaft parts and the cylinder frame will be provided with pin gauge marks. which are assembled with fitted bolts. See also Volume I. please quote Description A90030 Edition 0009 . The camshaft rotation constantly follows that of the crankshaft. 908 and 909. the spindle must be screwed right back to the stop in order to avoid burns and carbon in the guide. and the necessary pin gauges are delivered together with the engine. Note! For indicator valves of the double-seated design with a spring-loaded closing face: In order to prevent overstressing. Chapter 708.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel Camshaft The camshaft is made in one or more sections. Pin gauges After the engine has been testrun. the sections are assembled by means of flange couplings. Indicator Valve Each cylinder is fitted with an indicator valve. and retighten the valve when the engine has reached its normal service temperature. See Volume II. If it is made in two or more sections. Operating Instructions! When opening the indicator valve. When referring to this page. The camshaft has. which enables the parts to be turned in relation to each other. couplings or chain wheel and the shaft. OPERATION. Chapters 906. enabling the camshaft timing to be checked and readjusted if the parts have been dismantled. close the valve lightly before starting the engine. 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. Bearings The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. PMI-System Page 8 (23) See separate instructions for operating the PMI-system (option).

Chapter 703. which comprise: • Main Starting Valve • Starting Air Distributor • Starting Valves The manoeuvring system is of electric/pneumatic design. 907 Starting Air System Starting Air System The starting air system consists of the manoeuvring system and the starting air components. Optionally. 1st order moment Applicable on 4-cylinder engines. the 1st order moment compensator can be positioned in the main chain drive. Alternatively. 2nd order moment Applicable on 4-5 and 6-cylinder engines. which is driven from the opposite end of the crankshaft. Each chain drive is equipped with a spring-loaded chain tightener. On some engines. The moment compensator is arranged as flyweights built into the main chain drive. and each chain casing is fitted with a relief valve. Caution! If the chain drives for the compensators have been dismantled. MAINTENANCE. an electrically driven compensator can be installed. This moment compensator consists of a (new) chain-tightener wheel with an incorporated flyweight and a flyweight rotating with the crank shaft. This chain drive is equipped with a spring-loaded chain tightener. 4th order moment The moment compensator is arranged as flyweights built into chain drives on both ends of the camshaft. OPERATION.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Moment Compensators On the basis of calculations. See also Volume I. See the instruction book. which on some engines is equipped with a hydraulic damper. please quote Description A90030 Edition 0009 Page 9 (23) . the engine may be provided with fly weights to counteract engine forces and moments. Incorrectly fitted moment compensators may excite heavy vibrations. flyweights are built into a second chain drive. Volume II. the flyweights must be positioned correctly in relation to the crankshaft. When referring to this page. The moment compensator is arranged as adjustable flyweights on both ends of the crankshaft.

Warning! During all inspections of the engine. the chamber above the piston is vented through the vent pipe of the starting air distributor. The main starting valve is equipped with a blocking device consisting of a plate which. built together to form a unit. Starting Air Distributor The starting air distributor controls the opening and the closing of the starting valves. Chapter 703. optionally. operation. When the starting period is finished. a smaller ball valve for slow-turning prior to starting the engine. please quote Description A90030 Edition 0009 . the chamber below the piston of the starting valve is pressurised through the starting air pipe. The main starting valve consists of a large ball valve and. which is fitted as a bypass for the large valve. When the main starting valve is open. Furthermore. an adjusting screw will be mounted for setting the slow-turning speed. When the chamber above the piston of the starting valve is pressurised with control air from the starting air distributor. the blocking device of the main starting valve must be in the BLOCKED position. can be made to block the actuators. The only exception is when the starting valves are being tested for tightness. Page 10 (23) When referring to this page. the starting valve opens. 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.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel Main Starting Valve The main starting valve is interposed in the starting air main pipe. It is controlled by control air from the starting air distributor. Starting Valve The starting valve (spring-loaded) is fitted on the cylinder cover. ‘OPERATION after arrival in port’. See Volume I. a non-return valve is incorporated to prevent blow-back in the event of excessive pressure in the starting air line. The ball valves and their actuators are. and the starting valve will close. Both valves are operated by pneumatic actuators. together with the non-return valve and blocking device. 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. by means of a handwheel. If the smaller ball valve is installed. and starting air now flows from the starting air pipe to the cylinder. The starting valve is kept closed by the spring.

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. Air piston The piston serves to close the exhaust valve. 2. which is mounted in a central bore in the cylinder cover. On the front of the valve housing there is a cleaning cover through which the cooling water space can be checked and cleaned. Note! This check rod is only for checking purposes. Pistons At the top of the spindle. The bore for the valve spindle is provided with an exchangeable spindle guide liner. The hydraulic piston has two piston rings and a damper arrangement.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel 908 Exhaust Valve Exhaust Valve Each cylinder is equipped with an exhaust valve. a ‘lifting/rotation check rod’ is mounted on top of the hydraulic cylinder on the exhaust valve. Hydraulic piston The piston serves to open the exhaust valve. Valve housing The valve housing has an exchangeable bottom piece. applied by the HVOF process. When referring to this page. two pistons are fitted: 1. 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. and must not be permanently activated. designed to dampen the closing of the valve. The water is discharged from the upper part of the valve housing. please quote Description A90030 Edition 0009 Page 11 (23) . The cooling water is passed to the valve housing after it has passed the cylinder cover. The piston is locked to the spindle by a two-piece conical ring. Cooling The valve housing is water cooled. The valve housing is attached with four studs and nuts to form a gas-tight seal against a seat in the cylinder cover. Lifting/rotation check rod: To enable checking the functioning of the exhaust valve while the engine is running. Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod.

Air cylinder The air cylinder is mounted on top of the valve housing. and a filter housing. Page 12 (23) When referring to this page. See Volume II. Sealing System Sealing air (where used): A sealing air arrangement is fitted around the spindle shaft below the air cylinder. MAINTENANCE. When the exhaust valve is activated. it is important to check the damper. 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. enabling oil and air.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel Note! After the exhaust valve has been overhauled. Procedure 908. please quote Description A90030 Edition 0009 . Throttle/valve: On some engine types. Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder on top of the exhaust valve housing. the pressure in the hydraulic cylinder is low. if any. When the exhaust valve is closed. The sealing air is supplied from the air cylinder via a sealing air control unit. 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. and the oil flow stops. to avoid knocking. to escape through the throttle. The exhaust valve is opened by the valve spindle being forced down by the piston in the hydraulic cylinder. A thrust spring opens the valve. The sealing air control unit contains a valve which automatically cuts off the air flow when the engine is in FINISHED WITH ENGINE status. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston. the high oil pressure closes the valve. a combined throttle/valve designed for deaerating the oil system is fitted at the top of the cylinder. together with leakage oil from the piston. The oil is led through a duct to the space around the air cylinder and is drained off through a bore X.

During the exhaust valve lifting period. oil escapes from the hydraulic actuator through the restriction chamber to the control unit which. in turn. The sealing oil is supplied from a control unit fitted on top of the exhaust valve hydraulic actuator. The hydraulic cylinder on the camshaft housing is connected to the hydraulic cylinder on the exhaust valve by a high-pressure pipe. Leakage oil from the hydraulic cylinder on the exhaust valve is drained through a pipe connection. 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. When referring to this page. thus ensuring a safe start. Oil is supplied from the lubricating oil system through a non-return valve. The oil improves the service condition of the sealing rings. this valve prevents the exhaust valve from opening during the first part of the actuator piston’s upward stroke. Hydraulic cylinder The hydraulic cylinder is attached to the camshaft housing by studs and nuts. This function prevents the starting valve and exhaust valve from being open at the same time. a puncture valve may be mounted on the exhaust valve actuator.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Sealing oil (where used): A sealing oil arrangement is fitted around the spindle shaft below the air cylinder. please quote Description A90030 Edition 0009 Page 13 (23) . During starting. 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. Puncture Valve On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines. Hydraulic Valve Actuating Gear The exhaust valve is actuated by a cam on the camshaft through a hydraulic transmission.

A clearance of approx. 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.e. in con junction with the turning of the plunger effected by the regulating gear. The pump barrel is provided with oil cut-off holes. The plunger and barrel are matched parts. in the event of a sticking pump plunger. which can be replaced when they are eroded. Page 14 (23) When referring to this page. which is mounted on the camshaft housing over the camshaft section corresponding to the cylinder concerned. The toothed rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. This bore is provided with a rack. the regulating gear for the remaining fuel pumps will not be blocked. which are covered and un covered during the travel of the plunger within the barrel. At the bottom it has a foot which rests on a steel disc in the bayonet joint at the roller guide neck. The oil jets which are ejected through the cut-off holes at the end of the delivery stroke will hit the screw plugs. which is subsequently drained off through a drain pipe.e. Furthermore. another bore is provided above the bore for the regulating guide.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel 909 Fuel Oil System Fuel Pump Each engine cylinder is equipped with its own fuel pump. which controls the engine timing. These two valves are on some engine types combined into one unit. At the top. a bore is provided for at toothed rack. This function. for the VIT-type fuel pump. serves to regulate the amount of oil injected into the engine cylinder. The toothed rack is linked together with the regulating gear of the engine through a spring-loaded connection. The regulating guide is able to turn in the bottom of the pump housing. The top cover is provided with a suction valve and a puncture valve. The square base of the fuel pump housing is provided with a groove to receive any leakage oil. In the base. and must not be replaced individually. i. i. the pump housing is closed by a top cover. The pump plunger is provided with a guide block designed to travel in the milled keyway in the regulating guide. 0. The pump housing is attached to the camshaft housing by studs and nuts. the regulating guide. please quote Description A90030 Edition 0009 . Thus. Two screw plugs are fitted in the pump housing opposite the cut-off holes of the barrel. the timing guide.1 mm between the plunger foot and the roller guide permits turning of the plunger in the roller guide. The pump housing contains the plunger and barrel. which controls the quantity of fuel oil delivered by the pump.

the pump barrel can be slightly lowered or raised in relation to the plunger. By removing or inserting such shims. The puncture valve consists of a piston which communicates with the control air system of the engine. VIT-type fuel pumps: The pump barrel is guided at the top and bottom of the pump housing.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Injection timing Fuel pumps without VIT (Variable Injection Timing): The pump barrel is attached to the top cover by means of screws. 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. and when STOP is activated. A number of semi-circular shims are inserted between the top cover and the pump housing. The toothed rack is linked to a servo-air cylinder which is controlled mechanically or electronically in relation to the engine load. When referring to this page. causing the piston with pin to be pressed downward and keep the suction valve in the open position. and no injection takes place. Refer to Volume II. The barrel is provided with a drain bore between the sealing rings at the lower end. the fuel oil is returned through bores to the pump housing. In the event of actuation of the shut-down system. The position of the upper toothed rack determines the vertical position of the barrel relative to the plunger through the threaded connection. regarding adjustment of the maximum combustion pressure. and the maximum combustion pressure thus changed. In this manner the initial moment of fuel oil injection into the cylinder can be adjusted by a servo-air cylinder. compressed air is supplied to the top of the piston. Puncture valve In the top cover of the pump. The pump barrel has a threaded lower end which fits into the internal threads of the timing guide. a puncture valve is fitted. Chapter 909. This will ‘puncture’ the oil flow to the fuel valve. As long as the puncture valve is activated. The gear rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The timing guide has a gear rim to mesh with the upper toothed rack at the base of the pump housing. The lower part of the barrel is guided in the bore of the pump housing. and in this way the initial moment of fuel oil injection into the engine cylinder can be adjusted. Low friction sealing rings are fitted in grooves in the barrel to seal between barrel and housing. please quote Description A90030 Edition 0009 Page 15 (23) . The pump barrel is prevented from turning by a guide screw mounted in the pump housing.

The space between the pipe and the protective outer pipe communicates. Reversible engines: The roller guide of each fuel pump incorporates an angular displaceable reversing link. Shock absorber A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations. As soon as the plunger has covered the cut-off holes during its upward movement in the pump barrel. The fuel pump is actuated by a cam on the camshaft. Fuel Oil HighPressure Pipes All high-pressure pipes in the system are provided with a protective outer pipe. Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. In the event of pipe fractures or major leakages in the system. without actuating the level switch. Fuel Pump Actuating Gear The camshaft housing contains the fuel pump and exhaust valve actuating gear for each cylinder. which has a small drain bore below. Each cylinder is reversed individually. The drain tank is also equipped with an overflow pipe. the injection commences through the fuel valves. and the reversing mechanism is activated by compressed air. via drain pipes. 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. please quote Description A90030 Edition 0009 . UMS. Page 16 (23) When referring to this page. the spring-loaded suction valve opens and the delivery chamber is filled with oil. and a pivot is mounted at the top end of the reversing arm. 35-98MC: Each fuel pump is. 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. The rising oil level will cause the level switch to set off an alarm. whereby oil from small leakages can be drained to the outlet.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Fuel Oil Injection During the suction stroke. The injection will last until the cut-off holes are uncovered by the oblique cut-off edges of the plunger. The reversing arrangement may incorporate a damper in order to reduce the mechanical stresses. which incorporates a level switch. connected to a common drain tank. with a drain bore in the pump top cover. through bores in the union nipples. The pivot travels in a reversing guide connected to an air cylinder. Fuel Oil Leakage Alarm A fuel oil leakage alarm is required for Unattended Machinery Spaces. and the oil level in the drain tank will rise until it reaches the level of the over flow pipe. The link connecting the roller guide and roller is provided with a reversing arm. the above-mentioned bore will not be large enough to allow the increased oil quantity to pass. The link is selflocking in either the ahead or astern position without the aid of external forces.

the spindle will be lifted and oil injected through the nozzle into the engine cylinder. 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 engine exhaust gas drives the turbine wheel of the turbocharger and. Fuel Valve The fuel valve consists of a valve head and a valve housing. the circulating bores is closed. which sets off an alarm and activates the puncture valve in order to stop the fuel oil flow from the pertaining pump. On completion of the fuel pump’s delivery stroke. The compressor draws air from the engine room. When referring to this page. leaving through a circulation bore and the return oil pipe on the valve head. through a common shaft. On 60-98MC engines. please quote Description A90030 Edition 0009 Page 17 (23) . depending on the engine type and layout. When the pressure at the beginning of the fuel pump’s delivery stroke has reached the predetermined pressure. and a nozzle. which are provided with pneumatically operated fuel pump roller guide lifting gear. Fitted within the valve housing is a non-return valve and a spindle and spindle guide with a pressure spring. and oil starts to recirculate through the valve. with compensator. through the air filters. From the compressor outlet. The spindle may be provided with a cut-off slide. the air passes through the charging air pipe to the charging air cooler where the air is cooled down. the valve parts are tightened together by the pressure from the securing nuts. When the pressure has reached the predetermined opening value for the fuel valve. the valve spindle is pressed against its seat and injection now ceases. 910 Turbocharger System Air System The engine is supplied with scavenge air from one or more turbochargers. the turbine wheel drives the compressor wheel.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel 50-98MC: Alternatively to the common drain tank. 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. The charging air pipe. the drain pipes on 50-98MC engines can be connected to a diaphragm valve. Then the circulating bore is uncovered. When the fuel valve is fitted in the cylinder cover. The fuel oil passes through the fuel valve. is insulated.

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. Scavenge air is collected in the receiver after the air has passed through the cooler. “Non-return valves”. please quote Description A90030 Edition 0009 . When the auxiliary blowers are operating. and when the engine is running at low load. panels for auxiliary blower See special instructions supplied by the engine builder. further on. it is pressed into the scav enge air receiver through non-return valves. Separate non-return valves are installed at the suction side or discharge side of the auxiliary blowers. See also item. in order to prevent reversed air flow. if welded. The non-return valves open by pressure from the turbocharger. When the air has passed the water mist catcher. The receiver is bolted on to the cylinder frame. Running with auxiliary blowers During the starting of the engine. they draw air from the engine room through the turbocharger’s air filter and compressor side. the turbocharger is not able to supply enough air for the engine process. El. In these cases a pressure switch will automatically start the auxiliary blowers. See Chapter 903. From the scavenge air receiver. The discharge sides are connected to the scavenge air receiver. Page 18 (23) When referring to this page. or alternatively integrated into the cylinder frame. the exhaust gas is pressed into a common exhaust gas receiver. the air flows to the cylinder through the scavenge air ports when the piston is in the bottom position. The scavenge air receiver is provided with man-hole covers and a safety valve.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Diesel The air cooler incorporates a water mist catcher. the water mist catcher and the non-return valves. See also ‘Charging Air Cooler’ further on in this Section. The suction sides are connected to the space after the water mist catcher. which is designed to separate condensate from the air. The receiver and the cylinder frame communicate through large openings. When the exhaust valves open. Auxiliary Blowers The engine is provided with two or more auxiliary blowers.

there is a risk that the electric motor will burn out when it starts. i. 2. 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. please quote Description A90030 Edition 0009 Page 19 (23) . 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 is due to differences in the air flow resistance. When the auxiliary blowers are operating. If an auxiliary blower fails to start. Otherwise. There will be a lack of air supply if the non-return valves do not close. or because the switch for the blowers is not in “AUTO” position). This can be checked either by moving the valves manually in connection with the regular scavenge port inspections.: – remote control – control from engine side control console. the operating blower will not be able to draw fresh air in through the turbocharger and air cooler. the non-return valve must be in the closed position.e. The non-return valves protect the blowers and engine during: • Start-up of the auxiliary blowers • Running with auxiliary blowers. Otherwise.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Warning! If the auxiliary blowers do not start during low-load running (because of faults. When referring to this page. unburned fuel oil may accumulate on top of the pistons. or via locally placed inspection covers. with 6-10 seconds in between. the blowers start in se quence. they draw air from the engine room through the turbocharger’s air filter and compressor side. 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. Starting the auxiliary blowers: 1. 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. Owing to the relatively high starting current. This will involve the risk of a scavenge air box fire.

Inside the exhaust gas receiver. Item 2. The cooler is designed with an air reversing chamber which incorporates a water mist catcher. Caution! It is important to check that the drain functions correctly. The cooler housing is provided with inspection covers. please quote Description A90030 Edition 0009 . When referring to this page. See ‘Starting the auxiliary blowers‘. 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 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. See Volume I Operation. ‘Cleaning of Turbochargers and Air Coolers’. 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. The separated water is collected in the bottom of the cooler housing from which it is removed by a drain system. a protective grating is mounted before the turbocharger. as otherwise water droplets may enter the cylinders. and between the receiver and the turbocharger. It is mounted in a housing which is welded up of steel plates. the non-return valve must close to ensure the continued supply of fresh air to the engine. Chapter 706. Charging Air Cooler The charging air cooler insert is of the block type. The exhaust gas receiver and the exhaust pipe are insulated.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Running with auxiliary blowers: If an auxiliary blower fails during running. Compensators are inserted between the receiver and the exhaust valves. An alarm device for high water level in the drain system is installed. 911 Safety Equipment Safety Valves. Exhaust Gas Receiver From the exhaust valves. above. The exhaust gas receiver is fastened to the seating by flexible supports.

please quote Description A90030 Edition 0009 Page 21 (23) . Chapter 704. Safety Valve. which will open in the event of excessive pressure in the crankcase/ chain casing. the complete flame arrester of the relief valves must be replaced. • detect oil mist in the crankcase using an ‘Oil Mist Detector’.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Relief Valves On the exhaust side of the engine a number of spring-loaded relief valves are fitted. OPERATION. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open. for instance as a result of the ignition of oil mist. Regarding how to: • avoid evaporation of the lubricating oil in the crankcase. 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) b) c) d) oil mist high lube oil temperature no piston cooling oil flow. Warning! Keep the areas around the relief valves free of oil. grease. see Volume I. Note! If there has been a crankcase explosion. or scavenge box fire Alarms b. When referring to this page. c and d should be considered as pre-warnings of a possible increasing oil mist level. etc. See also our Service Letter SL97-348/ERO. In some cases it may be necessary to open the valve manually. "Turbocharger Surging". 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. see Volume I.

“Crank shaft”. The framebox is fitted with steel-plate doors for access to the crossheads and to the main and crankpin bearings. See also Volume I. designed for tightening with hydraulic tools.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Safety Cap in Starting Air Line Each starting valve inlet pipe is provided with a safety cap. Together. through an outlet pipe. Like the bedplate. lined with bearing metal. Each main bearing has one or two main bearing caps which are secured by studs and nuts. and fit a new disc. Marine engines (except geared plants): The aft end of the bedplate incorporates the thrust bearing. If a new disc is not available immediately. turn the cover in relation to the cylinder. Chapter 708. 912 Assembly of large Parts Bedplate The bedplate is made in one or more sections. in order to reduce the leakage of starting air. The cover is provided with a check plate. From the slotted pipe the cooling oil is. The safety cap consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders. which shows if the bursting disc has been damaged. Fit a new bursting disc and return the cover to the open position at the first opportunity. If the bursting disc of the safety cap is damaged by excessive pressure in the starting air line. see Section 905 “Crankshaft”. these are joined together with fitted bolts. the framebox consists of one or more sections. please quote Description A90030 Edition 0009 . led to the oil tray of the bedplate. The main bearings consist of steel shells. Stationary engines (and geared marine plants): The bedplate incorporates the guide bearing. For the design and functioning of the axial vibration damper. Framebox A framebox is bolted on to the top of the bedplate. OPERATION. overhaul or replace the starting valve which caused the burst. If there are two or more sections. longitudinal girders and a number of cross girders which support the main bearings. in the event of a burst. See also Section 905 “Crankshaft”. the bedplate and the framebox constitute the crankcase of the engine. depending on the number of cylinders. The bedplate is fitted with an axial vibration damper. the framebox is equipped with a slotted pipe in which the piston cooling oil outlet pipe fitted to the crosshead or guide shoe is able to travel. For each cylinder. The bedplate consists of two welded. See also Section 905. Page 22 (23) When referring to this page.

and for temperature and flow alarms. OPERATION. Chapter 701. When referring to this page. please quote Description A90030 Edition 0009 Page 23 (23) . is installed in conjunction with the outlet pipe.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Equipment for local checking of the cooling oil temperature and flow. framebox and the cylinder frame are tightened together to form one unit by means of staybolts. see the supplier’s special instructions. Engine Seating Regarding the engine seating for the specific engine. See also Volume I. Staybolts The bedplate.

.

Cylinder Cover Documents in this Chapter 90101 90103 0138 0007 Cylinder Cover Indicator Cock .901 .Mounting MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Plate P90101-0138 Cylinder Cover Cylinder Cover 0138 P90101 G-O-G F F-F G F O C B B G O A A-O-A C A B-O-B C-O-C When referring to this page. please quote Plate P90101 Edition 0138 MAN B&W Diesel A/S Page 1 (2) .

031 043 055 067 079 092 102 126 138 163 187 199 209 Cylinder Cover Item Description Item No. please quote Plate P90101 Edition 0138 MAN B&W Diesel A/S .Plate P90101-0138 Item No. Item Description Nut Distance pipe Stud Cylinder cover Screw O-ring Cooling jacket Screw Cooling water connection Sealing ring Nut Stud Pin Page 2 (2) When referring to this page.

Indicator Cock .Mounting When referring to this page. please quote Plate P90103 Edition 0007 MAN B&W Diesel A/S Plate P90103-0007 Page 1 (2) .

self-locking When referring to this page. please quote Plate P90103 Edition 0007 MAN B&W Diesel A/S . Item Description Connecting piece Extension Gasket Gasket Indicator cock Screw Locking plate Flange Guard Screw Lock washer Stud Nut.Plate P90103-0007 Item No. 019 032 056 068 081 093 103 115 139 140 152 176 188 Page 2 (2) Indicator Cock .Mounting Item Description Item No.

902 .Piston with Rod & Stuffing Box Documents in this Chapter 90201 90205 0217 0122 Piston and Piston Rod Piston Rod Stuffing Box MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

please quote Plate P90201 Edition 0217 Plate P90201-0217 Page 1 (2) .Piston and Piston Rod MAN B&W Diesel When referring to this page.

Item Description Screw Screw Locking wire Piston skirt Piston ring no. please quote Plate P90201 Edition 0217 .Piston and Piston Rod Plate P90201-0217 Item No. 2 + 4 Piston ring no. 011 023 035 047 072 084 096 106 118 131 143 155 167 179 Page 2 (2) MAN B&W Diesel Item Description Item No. 1 Piston ring no. 3 Piston crown Cooling oil pipe Piston rod D-ring D-ring Screw Screw When referring to this page.

Piston Rod Stuffing Box When referring to this page. please quote Plate P90205 Edition 0122 MAN B&W Diesel A/S Plate P90205-0122 Page 1 (2) .

complete Fitted bolt Flange Guide pin When referring to this page. complete Holder Pin Holder Scraper ring. Item Description O-ring Nut. complete Stuffing box housing in 2/2 Stuffing box housing. self-locking Screw Top scraper ring Spring Cover sealing ring Spring pin Pack sealing ring Sealing ring.Plate P90205-0122 Item No. 013 025 050 074 086 098 108 121 133 145 157 169 170 182 194 204 216 228 241 253 277 289 290 312 324 Page 2 (2) Piston Rod Stuffing Box Item Description Item No. complete Sealing ring Spring Holder Lamella Scraper ring Spring Top scraper ring. please quote Plate P90205 Edition 0122 MAN B&W Diesel A/S .

Cylinder Liner and Cylinder Lubrication Documents in this Chapter 90301 90302 90304 0188 0192 0025 Cylinder Frame Cylinder Liner and Cooling Jacket Cylinder Liner .903 .Details MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

please quote Plate P90301 Edition 0188 Plate P90301-0188 Page 1 (2) .Cylinder Frame MAN B&W Diesel When referring to this page.

Item Description Cover O-ring Screw Stud Nut Pipe bend Cleaning cover.Cylinder Frame Plate P90301-0188 Item No. housing Stud O-ring Stud Distance pipe Screw Distance tube Flange Packing Screw Note: * Page 2 (2) When referring to this page. please quote Plate P90301 Edition 0188 . 015 027 039 040 052 064 076 088 111 123 135 147 159 160 172 184 196 206 218 231 243 255 267 279 280 292 302 314 326 351 363 375 387 399 409 410 422 434 446 458 471 483 MAN B&W Diesel Item Description Item No. complete Sealing ring Stud Nut Cylinder frame Stud Screw Nut Protective cap Stud Nut Fitted bolt Screw Distance pipe Screw Cover Screw Cover Dowel Stud Distance piece Nut Screw Protective tube Sealing ring Bushing Stuffing box.

please quote Plate P90302 Edition 0192 MAN B&W Diesel A/S Plate P90302-0192 Page 1 (2) .Cylinder Liner and Cooling Jacket When referring to this page.

Plate P90302-0192 Item No. 010 022 034 046 058 071 083 095 105 129 130 142 166 178 Page 2 (2) Cylinder Liner and Cooling Jacket Item Description Item No. please quote Plate P90302 Edition 0192 MAN B&W Diesel A/S . Item Description Cooling jacket Clamp Screw Cylinder liner Packing Plug screw Packing O-ring O-ring Cooling water connection Packing Screw Stud Nut When referring to this page.

please quote Plate P90304 Edition 0025 MAN B&W Diesel A/S Page 1 (2) .Details Plate P90304-0025 Cylinder Liner .Details 0025 P90304 A A A A When referring to this page.Cylinder Liner .

011 023 035 059 Item Description Item No. Item Description Head. please quote Plate P90304 Edition 0025 MAN B&W Diesel A/S . non-return valve Non-return valve.Cylinder Liner . non-return valve Non-return valve Housing. complete Page 2 (2) When referring to this page.Details Plate P90304-0025 Item No.

904 .Crosshead with Connecting Rod Documents in this Chapter 90401 90403 0145 0009 Connecting Rod and Crosshead Lubricating and Cooling Oil-Flow MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Connecting Rod and Crosshead Plate P90401-0145 Connecting Rod and Crosshead 0145 P90401 When referring to this page. please quote Plate P90401 Edition 0145 MAN B&W Diesel A/S Page 1 (2) .

0. self-locking Nut Outled pipe Screw Lock washer Stop screw Guide shoe Bracket Crosshead bearing cap Guide screw Stud Guide pin Nut. 019 020 032 044 056 068 081 093 103 127 139 140 152 164 211 223 235 247 259 296 306 318 331 343 355 379 380 392 402 414 426 438 451 463 475 487 Connecting Rod and Crosshead Item Description Item No.25mm Guide strip Stud Screw Thrust piece Crankpin bearing shell. Item Description Screw Telescope pipe Nut. complete Notes: Page 2 (2) (* Please state thickness of shim When referring to this page. complete Guide pipe Screw(* Shim (* Crosshead bearing shell. please quote Plate P90401 Edition 0145 MAN B&W Diesel A/S .Plate P90401-0145 Item No. upper part Crosshead Stud Guide pin Crosshead bearing shell.50mm Shim 0. lower part Hydraulic nut Connecting rod Hydraulic nut Stud Crankpin bearing cap Connecting rod.self-locking Shim.

Lubricating and Cooling Oil for Crosshead Crankpin and Main Bearing Plate P90403-0009 0009 P90403 Lubricating and Cooling Oil for Crosshead Crankpin and Main Bearing When referring to this page. please quote Plate P90403 Edition 0009 MAN B&W Diesel A/S Page 1 (1) .

.

Thrust Bearing and Turning Gear Documents in this Chapter 90501 90502 90505 90510 90511 90512 90513 0179 0076 0170 0120 0040 0001 0036 Crankshaft Arrangement of Fore End Thrust.and Guide Bearing Turning Gear Turning Wheel Turning Gear .Crankshaft.905 .Details Tacho System MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Crankshaft MAN B&W Diesel When referring to this page. please quote Plate P90501 Edition 0179 Plate P90501-0179 Page 1 (2) .

please quote Plate P90501 Edition 0179 . 012 024 061 097 MAN B&W Diesel Item Description Item No. Item Description Crankshaft Chain wheel Nut Screw Note: * Page 2 (2) When referring to this page.Crankshaft Plate P90501-0179 Item No.

Arrangement of Fore End MAN B&W Diesel When referring to this page. please quote Plate P90502 Edition 0076 Plate P90502-0076 Page 1 (2) .

Item Description Screw Nut Screw End cover. please quote Plate P90502 Edition 0076 .Plate P90502-0076 Item No. lower part Screw Cover Packing Cover. 018 031 043 055 079 080 092 102 114 138 151 163 199 Page 2 (2) Arrangement of Fore End MAN B&W Diesel Item Description Item No. complete Packing Plug Plug Cover Lower end cover. complete When referring to this page.

please quote Plate P90505 Edition 0170 Plate P90505-0170 Page 1 (2) .Thrust and Guide Bearing MAN B&W Diesel When referring to this page.

upper part Nut Scraper ring housing. complete Scraper ring housing. Item Description Item Description Screw Cover Screw Flange Lubricating oil pipe Nut Segment holder Fitted bolt Screw Screw Oil throw ring. please quote Plate P90505 Edition 0170 . complete Scraper ring housing.Plate P90505-0170 Item No. 014 026 038 051 063 075 099 109 110 122 134 146 158 171 183 217 230 242 254 266 278 291 337 349 350 362 374 386 Page 2 (2) Thrust and Guide Bearing MAN B&W Diesel Item No. lower part Screw Screw Screw Nut Segment stopper Segment Segment Cover Lubricating oil pipe Screw Pipe holder Spring pin Spring When referring to this page.

Plate
P90510-0120

Turning Gear
Turning Gear
0120
P90510

A

B

A

B

A

When referring to this page, please quote Plate P90510 Edition 0120
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90510-0120
Item
No.
011
023
035
047
059
072
084
096
106
118
143
155
167
179
180
192
202
226
238
251
263
275
287
299
310

Turning Gear

Item Description

Item
No.

Item Description

Turning gear
Screw
Distance pipe, L= 45
Nut
Washer
Gear wheel
Disenganging spindle
Stop screw
Stop ring
Bushing
Nut
Guide pin
Flange
Stop screw
Flange
Screw
Screw
Key
Screw
Handle
Washer
Hand wheel
Disc
Bushing
Stud

Page 2 (2)

When referring to this page, please quote Plate P90510 Edition 0120
MAN B&W Diesel A/S

Turning Wheel

Plate
P90511-0040

Turning Wheel
0040
P90511

When referring to this page, please quote Plate P90511 Edition 0040
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90511-0040
Item
No.
017
029
030
054
078
091
101
125

Turning Wheel

Item Description

Item
No.

Item Description

Spring pin
Screw
Washer
Dead center pointer
Screw
Fitted bolt
Nut, self-locking
Turning wheel

Page 2 (2)

When referring to this page, please quote Plate P90511 Edition 0040
MAN B&W Diesel A/S

Turning Gear - Details

Plate
P90512-0001

Turning Gear - Details
0001
P90512

When referring to this page, please quote Plate P90512 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90512-0001
Item
No.
012
024
048
061
073
097
107
119
132
156
168
181
203
215
227
240
252
264
276
311
323

Turning Gear - Details

Item Description

Item
No.

Item Description

Screw
Spring washer
3/2-way valve
Screw
Spring washer
Switch 0-110 volts
Screw
Spring washer
Bracket
Eye screw
Key ring
Chain
Cam
Stud with groove
Circlip
Cam
Bush
Screw
Spring washer
Lever
Bush

Page 2 (2)

When referring to this page, please quote Plate P90512 Edition 0001
MAN B&W Diesel A/S

Tacho System
MAN B&W Diesel

When referring to this page, please quote Plate P90513 Edition 0036

Plate
P90513-0036

Page 1 (2)

Tacho System

Plate
P90513-0036
Item
No.
018
031
043
055

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Bracket
Screw
Spring pin
Disc

When referring to this page, please quote Plate P90513 Edition 0036

906 - Control Gear
Documents in this Chapter
90600
90601
90602
90603
90605
90611
90613
90615
90618
90620
90621

0068
0105
0124
0059
0076
0170
0117
0138
0139
0107
0085

Arrangement of Chain Drive and Camshaft
Chain Drive and Guide Bars
Chain Drive - Lubrication
Chain Tightener
Lubricator Drive
Camshaft and Chain Wheel
Camshaft Bearing
Arrangement of Governor
Regulating Shaft
Engine-Side Control Console
Engine-Side Control Console - Details

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangement of Chain Drive Camshaft

Plate
P90600-0068

Arrangement of Chain Drive Camshaft
0068
P90600

When referring to this page, please quote Plate P90600 Edition 0068
MAN B&W Diesel A/S

Page 1 (1)

Chain Drive and Guide Bars
MAN B&W Diesel

When referring to this page, please quote Plate P90601 Edition 0105

Plate
P90601-0105

Page 1 (2)

Chain Drive and Guide Bars

Plate
P90601-0105
Item
No.
016
028
053
065
112
124
136
148
161
173
185
219
220
232

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Locking wire
Screw
Distance pipe
Guidebar
Bracket
Distance pipe
Guide pin
Stud
Screw
Washer
Nut
Outer link
Inner link
Chain link, complete

When referring to this page, please quote Plate P90601 Edition 0105

Chain Drive - Lubrication
MAN B&W Diesel

When referring to this page, please quote Plate P90602 Edition 0124

Plate
P90602-0124

Page 1 (2)

Chain Drive - Lubrication

Plate
P90602-0124
Item
No.
011
035
047

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Lubricating oil pipe
Lubricating oil pipe
Lubricating oil pipe

When referring to this page, please quote Plate P90602 Edition 0124

Chain Tightener MAN B&W Diesel When referring to this page. please quote Plate P90603 Edition 0059 Plate P90603-0059 Page 1 (2) .

Chain Tightener Plate P90603-0059 Item No. please quote Plate P90603 Edition 0059 . Item Description Distance piece Shaft Cover Screw Locking wire Guide nut Shaft Cover Screw Guide nut Lock washer Nut Tightening bolt Shaft Cover Bushing Lubricating pipe Screw Self-locking nut Screw Spray pipe Shaft Self-locking nut Flange Chain wheel Bracket When referring to this page. 017 029 030 042 066 078 091 101 113 125 137 149 150 162 174 198 208 221 233 245 269 270 282 294 316 328 Page 2 (2) MAN B&W Diesel Item Description Item No.

Lubricator Drive Plate P90605-0076 Lubricator Drive 0076 P90605 When referring to this page. please quote Plate P90605 Edition 0076 MAN B&W Diesel A/S Page 1 (2) .

Plate P90605-0076 Item No.lubricator. please quote Plate P90605 Edition 0076 MAN B&W Diesel A/S . 031 043 055 067 079 080 092 102 114 126 151 Lubricator Drive Item Description Item No. complete Page 2 (2) When referring to this page. Item Description Self-locking nut Gear wheel Key Ball bearing Circlip Hosuing Key Shaft Guide pin Screw Shaft .

Camshaft and Chain Wheel MAN B&W Diesel When referring to this page. please quote Plate P90611 Edition 0170 Plate P90611-0170 Page 1 (2) .

exhaust. 010 022 046 058 095 117 129 130 142 154 178 191 201 213 MAN B&W Diesel Item No.Camshaft and Chain Wheel Plate P90611-0170 Item No. complete* Screw* Thrust disc Chain wheel Protective cap Exhaust cam Fuel cam Camshaft Screw* Repair cam . please quote Plate P90611 Edition 0170 . Item Description Item Description Repair cam .fuel. complete* Washer Screw Locking wire Gear wheel Note: * Optional extras Page 2 (2) When referring to this page.

please quote Plate P90613 Edition 0117 MAN B&W Diesel A/S Plate P90613-0117 Page 1 (2) .Camshaft Bearing When referring to this page.

011 023 035 047 059 060 072 096 106 118 131 143 155 Page 2 (2) Camshaft Bearing Item Description Item No. Item Description Connecting pipe Gasket O-ring Screw Bearing cap Guide pin Screw Guide disc Plug screw Bearing cap Screw Bearing shell Screw When referring to this page.Plate P90613-0117 Item No. please quote Plate P90613 Edition 0117 MAN B&W Diesel A/S .

please quote Plate P90615 Edition 0138 MAN B&W Diesel A/S Air inlet Page 1 (2) .Arrangement of Governor Plate P90615-0138 Arrangement of Governor 0138 P90615 A A Clockwise A Counterclockwise When referring to this page.

012 024 036 048 061 073 097 107 119 120 132 144 156 181 193 215 227 240 252 276 288 311 323 347 359 360 372 384 396 Arrangement of Governor Item Description Item No. L= 600 Pipe. L= 300 Washer Spray pipe Spray pipe Union Union Guide pin Screw Bushing Thrust washer Key Bevel gear wheel Pipe. L= 600 Page 2 (2) When referring to this page. Item Description Governor Screw Screw Coupling Key Shaft Bracket Bevel gear wheel Nut Split pin Screw Locking wire. please quote Plate P90615 Edition 0138 MAN B&W Diesel A/S .Plate P90615-0138 Item No. L= 700 Union Union Booster Pipe.

Regulating Shaft MAN B&W Diesel When referring to this page. please quote Plate P90618 Edition 0139 Plate P90618-0139 Page 1 (2) .

please quote Plate P90618 Edition 0139 . complete Page 2 (2) Item No. self-locking Plate Pull rod. complete Nut. Item Description 019 020 032 044 068 081 093 103 115 127 139 164 176 188 211 223 235 247 259 260 272 296 306 318 331 343 355 380 392 402 414 426 438 451 463 475 487 Bearing. Item Description When referring to this page.Plate P90618-0139 Regulating Shaft MAN B&W Diesel Item No. complete Screw Clamping arm Nut. self-locking Pin Screw Locking wire Switch 0-100 volts Bearing Screw Washer Distance pipe Nut Locking plate Eye bolt Spring Pin Regulating shaft Bushing Screw Nut Holder Screw Spring washer Lever Screw Guide pin Fitted bolt Pin Locking plate Screw Clamping arm Fitted bolt Spring-loaded lever.

Engine-Side Control Console MAN B&W Diesel When referring to this page. please quote Plate P90620 Edition 0107 Plate P90620-0107 Page 1 (2) .

self-locking Clamping arm Nut.Plate P90620-0107 Item No. 021 033 045 069 070 116 128 141 153 165 177 189 190 200 212 224 236 248 261 273 285 307 319 320 332 356 368 381 393 403 415 427 439 452 476 511 523 535 Page 2 (2) Engine-Side Control Console MAN B&W Diesel Item No. self-locking Name plate Stop ring Pin Pin Handle grip Lever Pressure switch Fitted bolt Screw Shaft Guard Screw Non-return valve When referring to this page. Item Description Item Description Vibrations damper Bracket Screw Multiple plug Cable Screw 5/2-way valve for remote locale console Guide pin Console Bushing Screw Screw Nut. please quote Plate P90620 Edition 0107 . self-locking Control box Pointer Screw Segment Spring washer Screw Stop valve Fitted bolt Start valve Nut.

Details Plate P90621-0085 Engine . Details 0085 P90621 When referring to this page.Side Control Console.Side Control Console.Engine . please quote Plate P90621 Edition 0085 MAN B&W Diesel A/S Page 1 (2) .

self-locking Pull rod. complete Fitted bolt Lever Grease nipple Washer Fitted bolt Fitted bolt Nut. self-locking Screw Guide pin Clamping arm Bushing Lever Switch. Item Description Nut. 015 027 039 040 052 064 076 088 111 123 135 147 160 172 184 196 206 218 243 255 267 279 280 292 302 326 338 351 363 375 387 399 409 422 446 458 471 483 495 Engine . self-locking Screw Nut. complete Bushing Stop ring Guide pin Cone Guide pin Impact hand wheel Impact socket Clamping arm Pull rod. 110 volt Screw Lock washer Spindle Lever Washer Screw Clamping arm Shaft Clamping arm Screw Nut.Plate P90621-0085 Item No. Details Item Description Item No.Side Control Console. self-locking Pin Page 2 (2) When referring to this page. complete Pull rod. please quote Plate P90621 Edition 0085 MAN B&W Diesel A/S .

Starting Air System Documents in this Chapter 90702 90703 90704 0046 0068 0050 Main Starting Valve Starting Air Distributor Starting Valve MAN B&W Diesel A/S .907 .

MAN B&W Diesel A/S .

Main Starting Valve Plate P90702-0046 Main Starting Valve 0046 P90702 When referring to this page. please quote Plate P90702 Edition 0046 MAN B&W Diesel A/S Page 1 (2) .

015 027 039 040 052 064 076 088 111 135 147 159 160 172 184 196 206 231 243 255 267 279 280 292 302 314 326 351 363 375 399 409 530 547 Main Starting Valve Item Description Item No.Plate P90702-0046 Item No. Item Description Name plate "Working" Screw Name plate "Blocked" Handwheel Screw Switch Spindle Securing plate Spring Distance pipe Base plate Screw Housing for non-return valve Housing for non-return valve Nut Non-return valve Gasket Gasket Nut Washer Spring ring Split pin Nut Plug screw Screw Screw Split pin Chain Screw Screw Ball valve with actuator Stud Upstream seat Downstream seat Page 2 (2) When referring to this page. please quote Plate P90702 Edition 0046 MAN B&W Diesel A/S .

Starting Air Distributor Plate P90703-0068 Starting P90703 0068 Air Distributor When referring to this page. please quote Plate P90703 Edition 0068 MAN B&W Diesel A/S Page 1 (2) .

Item Description Spring pin Screw Gasket Screw 3/2-way valve Stud Nut Guide pin Screw Bracket Name plate Air cylinder Fitted bolt Self-locking nut Flexible coupling Lock washer Nut Key Spring pin Bushing Distributor housing *) Shaft Reversing disc *) Sealing ring Distributor disc Screw Fitted bolt Washer Bracket Sealing ring Piston ring Cover *) Please state number of cylinders Page 2 (2) When referring to this page. 010 022 034 046 058 083 095 105 117 129 130 154 166 178 201 213 225 237 249 250 262 274 286 298 308 333 345 357 369 370 394 404 Starting Air Distributor Item Description Item No.Plate P90703-0068 Item No. please quote Plate P90703 Edition 0068 MAN B&W Diesel A/S .

please quote Plate P90704 Edition 0050 MAN B&W Diesel A/S Plate P90704-0050 Page 1 (2) .Starting Valve When referring to this page.

Item Description Cover Gasket Castle nut Piston Bushing Spring Washer Bushing Valve housing Screw O-Ring Split Valve spindle When referring to this page. 016 028 041 053 065 077 089 100 112 124 136 148 161 Page 2 (2) Starting Valve Item Description Item No. please quote Plate P90704 Edition 0050 MAN B&W Diesel A/S .Plate P90704-0050 Item No.

908 .Pipe System Arrangement of Cooling Water Pipes MAN B&W Diesel A/S .Actuator Exhaust Valve .Details Exhaust Valve .Details Exhaust Valve .Exhaust Valve Documents in this Chapter 90801 90802 90803 90804 90805 90806 90810 0184 0041 0032 0017 0130 0080 0092 Exhaust Valve .Upper Parts Exhaust Valve Upper Parts .Lower Parts Exhaust Valve .

MAN B&W Diesel A/S .

please quote Plate P90801 Edition 0184 MAN B&W Diesel A/S Page 1 (2) .Lower Parts 0184 P90801 When referring to this page.Exhaust Valve .Lower Parts Plate P90801-0184 Exhaust Valve .

013 025 049 050 062 074 086 098 108 133 145 157 169 182 194 204 216 228 241 253 Exhaust Valve . please quote Plate P90801 Edition 0184 MAN B&W Diesel A/S .Lower Parts Item Description Item No.Plate P90801-0184 Item No. Item Description Spring pin Sealing ring Valve housing Spring pin Screw Bottom piece O-ring Sealing ring Valve spindle Spindle guide Cover Packing Screw Water connection Packing Screw Sealing ring Flange Packing Screw Page 2 (2) When referring to this page.

Exhaust Valve - Details

Plate
P90802-0041

Exhaust Valve - Details
0041
P90802

Air inlet.
Control air.

Sealing air.

When referring to this page, please quote Plate P90802 Edition 0041
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90802-0041
Item
No.
019
020
032
044
056
068
081
093
115
127
139
140
152
164
176
188
211

Exhaust Valve - Details

Item Description

Item
No.

Item Description

Sealing air control unit
Elbow coupling
Coupling
Pipe
Throttle valve
Restrictor screw
Screw
Cover
Sealing ring
Spring
Valve spindle
O-ring
O-ring
Valve housing
Packing
Filter housing, complete
Coupling, complete

Page 2 (2)

When referring to this page, please quote Plate P90802 Edition 0041
MAN B&W Diesel A/S

Exhaust Valve - Upper Parts

When referring to this page, please quote Plate P90803 Edition 0032
MAN B&W Diesel A/S

Plate
P90803-0032

Page 1 (2)

Plate
P90803-0032
Item
No.
014
038
051
063
087
099
110
122
134
146
158
171
183
195
217
229
230
242
254
266
278
291
301
325
337
349
350
362
374
386
398
421
433
445
469
482
494
504
541
553
565
589
590

Page 2 (2)

Exhaust Valve - Upper Parts

Item Description

Item
No.

Item Description

Oil cylinder
Sealing ring
Air cylinder
Non-return valve
Sealing ring
Sealing ring
Screw
Spring washer
Disc
Guide ring
Sealing ring
Conical ring in 2/2
Piston
O-ring
Eye bolt
Flange
Union nut
Packing
Spacer ring
Throttle valve
Disc
Stud
Nut
Screw
Guide pin
Steel pipe
Union nut
Adapter
Packing ring
O-ring
Rotation check rod
Spring
Disc
Guide pin
Piston
Actuator piston
Spring
Disc
Piston ring
Disc
Screw
Screw
Actuator piston, complete

When referring to this page, please quote Plate P90803 Edition 0032
MAN B&W Diesel A/S

Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel

When referring to this page, please quote Plate P90804 Edition 0017

Plate
P90804-0017

Page 1 (2)

Plate
P90804-0017
Item
No.
021
033
045
069
905

Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel

Item Description

Item
No.

Item Description

Sealing ring
Valve housing
Packing
Safety valve, with o-ring
O-ring*
Note:
* Optional extras

Page 2 (2)

When referring to this page, please quote Plate P90804 Edition 0017

Valve Gear

Plate
P90805-0130

Valve Gear
0130
P90805

When referring to this page, please quote Plate P90805 Edition 0130
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90805-0130
Item
No.
015
027
039
040
052
064
088
111
123
135
147
160
172
184
196
206
218
243
255
267
279
280
302

Valve Gear

Item Description

Item
No.

Item Description

Oil cylinder
Nut
Stud
Stud
Thrust piece
Roller guide
Screw
Key
Bushing
Roller guide housing
Guide pin
Plug
Piston ring
Piston
Disc
Locking plate
Screw
Shaft pin for roller
Stop screw
Roller
Roller guide, complete
Sealing ring
Spring

Page 2 (2)

When referring to this page, please quote Plate P90805 Edition 0130
MAN B&W Diesel A/S

Exhaust Valve - Pipe System

When referring to this page, please quote Plate P90806 Edition 0080
MAN B&W Diesel A/S

Plate
P90806-0080

Page 1 (2)

Plate
P90806-0080
Item
No.
010
022
034
058
071
095
105
129
130
154
166
178
201
213
225
249
250
274
286
308

Exhaust Valve - Pipe System

Item Description

Item
No.

Item Description

Thrust flange
Spring ring
Sleeve in 2/2
Intermediate piece
Screw*
High pressure pipe
Screw
O-ring
Intermediate piece
Steel pipe
Reducing stand pipe
Coupling
Coupling
Steel pipe
Coupling
Sealing ring
Sealing ring
Steel pipe
Drain pipe, complete
High pressure pipe, complete
Note:
* These screws are special screws
for hot joints, they are marked with a
“T” and MUST NOT be used elsewhere !

Page 2 (2)

When referring to this page, please quote Plate P90806 Edition 0080
MAN B&W Diesel A/S

Arrangement of Cooling Water Pipes
MAN B&W Diesel

When referring to this page, please quote Plate P90810 Edition 0092

Plate
P90810-0092

Page 1 (2)

Arrangement of Cooling Water Pipes

Plate
P90810-0092
Item
No.
012
024
036
085
097
107
132
144
156
168
181
193
227
239

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Flange
Screw
Butterfly valve
Cooling pipe
Packing
Screw
Packing
Screw
Nut
Compensator
Orifice plate
Cooling pipe
Packing
Screw

When referring to this page, please quote Plate P90810 Edition 0092

909 - Fuel Oil System
Documents in this Chapter
90901
90902
90910
90911
90913
90914
90915
90915
90915

0207
0138
0152
0021
0096
0105
0076
0077
0078

Fuel Pump
Fuel Pump Gear
Fuel Valve
Fuel Valve Function
High-Pressure Pipes
Fuel Oil System
Fuel Oil System - Details
Fuel Oil System - Details
Fuel Oil System - Details

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Fuel Pump

When referring to this page, please quote Plate P90901 Edition 0207
MAN B&W Diesel A/S

Plate
P90901-0207

Page 1 (2)

Plate
P90901-0207

Fuel Pump

Item
No.

Item Description

017
029
030
042
054
066
091
113
125
149
150
162
174
198
208
221
233
245
257
270
282
294
316
328
341
353
365
377
390
424
436
461
485
497
507
519
520
544
556
568
593
615
627
639
640
652
664
676
711
723

Stud
Nut
Steel ball
Plug screw
Plug
Gasket
Guide pin
Plug screw
Gasket
Shim
Fuel pump housing
Guide bushing
Regulating guide
Plug screw
Gasket
Screw
O-ring
Back-up ring
Plunger
Flange
Screw
Toothed bar
Top cover
Guide pin
O-ring
Back-up ring
O-ring
Pump barrel
Felt ring
Restriction plug
Screw
Screw
O-ring
O-ring
Spring
Housing
O-ring
Screw
Cover
Air piston
O-ring
Housing
O-ring
Conical ring in 2/2
Cone
Spring
Spindle
Housing
Pump barrel, complete
Pump barrel and top cover, complete

Page 2 (2)

Item
No.
747
759
772
806
818

Item Description
Puncture valve, complete
Suction valve, complete
Comb.puncture valve and suction valve,
complete
Disc
Plug screw

When referring to this page, please quote Plate P90901 Edition 0207
MAN B&W Diesel A/S

please quote Plate P90902 Edition 0138 Plate P90902-0138 Page 1 (2) .Fuel Pump Gear MAN B&W Diesel When referring to this page.

012 024 036 048 061 073 085 097 107 119 120 132 156 168 181 193 203 215 239 240 252 264 276 288 311 323 335 347 359 360 372 384 396 406 418 431 443 455 467 479 480 492 502 526 538 551 563 Page 2 (2) Fuel Pump Gear MAN B&W Diesel Item No.Plate P90902-0138 Item No. complete Stud Nut Sealing ring Sealing bush Sealing ring Screw Stud Nut Bushing Pin 575 587 599 609 610 622 646 658 671 683 Item Description Screw Cap Flange Screw Cover Screw Holder Scraper ring Scraper ring Flange When referring to this page. complete Guide pin Bushing Guide pin Guide block Screw Sealing ring Plug screw Stop screw Reversing mechanism. Item Description Sealing ring Spring Pump base Bushing for roller guide. please quote Plate P90902 Edition 0138 . complete Thrust piece Roller guide Link for reversing Guide pin Baseplate Shaft pin Bushing Shaft pin Roller Screw Screw Nut Tab washer Flange Air cylinder Fuel oil sealing. complete Guide Shaft Guide spindle Guide spindle Screw Stud Nut Roller guide.

please quote Plate P90910 Edition 0152 Plate P90910-0152 Page 1 (2) .Fuel Valve MAN B&W Diesel When referring to this page.

complete Disc* Note: * Optional extras Page 2 (2) When referring to this page. Item Description Fuel valve. please quote Plate P90910 Edition 0152 .Fuel Valve Plate P90910-0152 Item No. 004 016 028 053 065 077 089 100 112 124 136 148 161 173 185 197 207 219 220 232 950 MAN B&W Diesel Item Description Item No. complete Guide pin Guide pin Spindle guide Nozzle Holder Sealing ring Screw Sealing ring Valve head Sealing ring Spring Housing Thrust piece Vent slide Sealing ring Spring Disc Cut-off shaft Spindle guide.

Fuel Valve Function When referring to this page. please quote Plate P90911 Edition 0021 MAN B&W Diesel A/S Plate P90911-0021 Page 1 (2) .

Fuel Valve Function Item Description Item No. please quote Plate P90911 Edition 0021 MAN B&W Diesel A/S .Plate P90911-0021 Item No. Item Description Note: D1 = Predetermined closing value for non-return valve D2 = Predetermined opening value for cut-off spindle Page 2 (2) When referring to this page.

High-Pressure Pipes Plate P90913-0096 High-Pressure Pipes 0096 P90913 When referring to this page. please quote Plate P90913 Edition 0096 MAN B&W Diesel A/S Page 1 (2) .

complete Spring pin Sleeve O-ring Union nipple Protective pipe High-pressure pipe Union nipple O-ring High-pressure pipe. 012 024 036 048 061 073 085 097 107 120 132 High-Pressure Pipes Item Description Item No. complete High-pressure pipe Page 2 (2) When referring to this page.Plate P90913-0096 Item No. please quote Plate P90913 Edition 0096 MAN B&W Diesel A/S . Item Description High-pressure pipe.

Fuel Oil System MAN B&W Diesel When referring to this page. please quote Plate P90914 Edition 0105 Plate P90914-0105 Page 1 (2) .

inlet Non-return valve Note: * Page 2 (2) When referring to this page. return Fuel oil pipe. Item Description Steel pipe Steel pipe Coupling Steel pipe Fuel oil pipe. return Non-return valve Copper pipe Non-return valve Copper pipe Fuel oil pipe. 018 031 043 055 079 092 102 114 126 138 163 209 246 258 271 295 317 329 MAN B&W Diesel Item Description Item No. inlet Ball valve Ball valve Screw Packing ring Steel pipe Lubrication oil pipe.Fuel Oil System Plate P90914-0105 Item No. please quote Plate P90914 Edition 0105 .

Fuel Oil System .Details MAN B&W Diesel When referring to this page. please quote Plate P90915 Edition 0076 Plate P90915-0076 Page 1 (2) .

013 Page 2 (2) MAN B&W Diesel Item Description Item No. complete When referring to this page.Fuel Oil System . please quote Plate P90915 Edition 0076 .Details Plate P90915-0076 Item No. Item Description Drain box.

Details MAN B&W Diesel When referring to this page.Fuel Oil System . please quote Plate P90915 Edition 0077 Plate P90915-0077 Page 1 (2) .

Details MAN B&W Diesel Item Description Item No. 013 025 037 049 050 062 074 086 098 108 121 133 145 157 169 170 182 204 Page 2 (2) Fuel Oil System . Item Description Plug screw Gasket Spring guide Stud Nut Lock washer Packing Sealing ring Wearing ring Packing Screw Spring Flange Stud Spring Piston Housing Shock absorber.Plate P90915-0077 Item No. please quote Plate P90915 Edition 0077 . complete When referring to this page.

Details MAN B&W Diesel When referring to this page.Fuel Oil System . please quote Plate P90915 Edition 0078 Plate P90915-0078 Page 1 (2) .

Details MAN B&W Diesel Item Description Item No. 013 025 037 049 050 074 086 098 121 133 145 Page 2 (2) Fuel Oil System . Item Description By-pass valve. please quote Plate P90915 Edition 0078 .Plate P90915-0078 Item No. complete Valve housing Valve housing Sealing ring Spring guide Screw Union nut Nut Sealing ring Piston Spring When referring to this page.

Turbocharger System Documents in this Chapter 91000 91001 91002 91003 91004 91005 91006 91009 91010 91018 0016 0125 0127 0197 0049 0132 0030 0036 0026 0006 Gas and Air System Scavenge Air Receiver Arrangement of Charging Air Pipe Exhaust Pipes and Receiver Exhaust Receiver .Cleaning Air Cooler .Frame Air Cooler System MAN B&W Diesel A/S .Details Air Cooler Arrangement of Auxiliary Blower Air Cooler System .910 .

MAN B&W Diesel A/S .

Gas and Air System When referring to this page. please quote Plate P91000 Edition 0016 MAN B&W Diesel A/S Plate P91000-0016 Page 1 (1) .

.

please quote Plate P91001 Edition 0125 MAN B&W Diesel A/S Page 1 (2) .Scavenge Air Receiver Plate P91001-0125 Scavenge Air Receiver 0125 P91001 When referring to this page.

Item Description Screw Guard Screw Cover Gasket Distance piece Screw Scavenge air receiver Screw O-ring Support Screw Nut Plug screw Plug screw Page 2 (2) When referring to this page.Plate P91001-0125 Item No. please quote Plate P91001 Edition 0125 MAN B&W Diesel A/S . 017 029 030 042 054 078 091 113 149 150 221 233 245 269 270 Scavenge Air Receiver Item Description Item No.

Arrangement of Charging Air Pipe When referring to this page. please quote Plate P91002 Edition 0127 MAN B&W Diesel A/S Plate P91002-0127 Page 1 (2) .

please quote Plate P91002 Edition 0127 MAN B&W Diesel A/S . Item Description Cover plate Insulation material Glass fibre cloth Compensator Plug screw Gasket Charging air pipe Cover plate Nut Washer Screw Plug screw Screw When referring to this page.Plate P91002-0127 Item No. 012 024 036 048 073 085 097 119 132 144 156 181 203 Page 2 (2) Arrangement of Charging Air Pipe Item Description Item No.

Exhaust Pipes and Receiver When referring to this page. please quote Plate P91003 Edition 0197 MAN B&W Diesel A/S Plate P91003-0197 Page 1 (2) .

Plate P91003-0197 Item No. please quote Plate P91003 Edition 0197 MAN B&W Diesel A/S . 018 031 055 079 092 114 138 151 163 175 187 199 209 222 234 246 271 283 295 305 317 330 342 354 366 378 391 401 413 425 437 449 462 474 486 521 533 Exhaust Pipes and Receiver Item Description Item No. Item Description Cover Insulation material Gasket Gasket Plug screw Wire gauze Washer Screw* Plug screw Gasket Screw Exhaust receiver Screw* Compensator Nut Screw* Nut Locking plate End cover Gasket Plug screw Gasket Screw* Clamp Compensator Insulation material Cover Heating shield Screw* Distance pipe Junk ring Screw* Cover Insulation material Gasket Screw 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) When referring to this page.

please quote Plate P91004 Edition 0049 Plate P91004-0049 Page 1 (2) .Exhaust Receiver. Details MAN B&W Diesel When referring to this page.

Details Plate P91004-0049 Item No. they are marked with a “T” and MUST NOT be used elsewhere ! Page 2 (2) When referring to this page. Item Description Item Description Screw* Distance pipe Screw Distance pipe Spring pin Nut Support Nut Nut Clamp Spring pin Spring plate Shim Support Lock washer Screw Clamp Spring pin Screw Screw Washer Screw Note: * These screws are special screws for hot joints. please quote Plate P91004 Edition 0049 . 013 025 037 049 050 074 086 098 108 121 133 145 157 169 170 182 194 204 216 228 241 253 MAN B&W Diesel Item No.Exhaust Receiver.

Air Cooler When referring to this page. please quote Plate P91005 Edition 0132 MAN B&W Diesel A/S Plate P91005-0132 Page 1 (2) .

please quote Plate P91005 Edition 0132 MAN B&W Diesel A/S .Plate P91005-0132 Item No. Page 2 (2) When referring to this page. 019 020 Air Cooler Item Description Item No. please state manufacturers Part No. Item Description Cooler insert* Water mist catcher* Note: * When ordering Spare Parts for this item.

Arrangement of Auxiliary Blower When referring to this page. please quote Plate P91006 Edition 0030 MAN B&W Diesel A/S Plate P91006-0030 Page 1 (2) .

Plate P91006-0030 Item No. please quote Plate P91006 Edition 0030 MAN B&W Diesel A/S . Page 2 (2) When referring to this page. please state manufacturer’s Part No. 014 026 038 051 063 087 099 109 122 134 146 158 171 183 195 Arrangement of Auxiliary Blower Item Description Item No. Item Description Valve flap Slide bearing Sealing ring Support Shaft Support Shaft Valve flap Auxiliary blower* Distance pipe Screw Spring pin Screw Screw Screw Note: * When ordering spare parts for this item.

Air Cooler System . please quote Plate P91009 Edition 0036 MAN B&W Diesel A/S Plate P91009-0036 Page 1 (2) .Cleaning When referring to this page.

Item Description Screw Cleaning pipe Spray nozzle Gasket When referring to this page.Cleaning Item Description Item No. please quote Plate P91009 Edition 0036 MAN B&W Diesel A/S . 010 034 046 058 Page 2 (2) Air Cooler System .Plate P91009-0036 Item No.

Air Cooler Frame MAN B&W Diesel When referring to this page. please quote Plate P91010 Edition 0026 Plate P91010-0026 Page 1 (2) .

Air Cooler Frame Plate P91010-0026 Item No. Item Description Screw Cover Gasket Plug screw Air cooler Screw Distance piece Plug screw Plug screw Plug screw Stud Nut Cover Screw Gasket When referring to this page. please quote Plate P91010 Edition 0026 . 016 028 041 053 065 089 090 112 136 148 173 185 207 219 220 Page 2 (2) MAN B&W Diesel Item Description Item No.

please quote Plate P91018 Edition 0006 Plate P91018-0006 Page 1 (2) .Air Cooler System MAN B&W Diesel When referring to this page.

021 033 045 057 069 070 082 094 104 116 128 141 153 Page 2 (2) MAN B&W Diesel Item Description Item No. please quote Plate P91018 Edition 0006 .Air Cooler System Plate P91018-0006 Item No. Item Description Screw Packing Cooling water pipe Cooling water pipe Plug screw Plug screw Butterfly valve Screw Flange Nut Stud Ball valve Nipple When referring to this page.

911 .Safety Equipment Documents in this Chapter 91101 91102 91103 91104 0037 0024 0017 0108 Safety Valve .Cylinder Relief Valve Safety Valve .Scavenge Air System Arrangement of Safety Cap MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Cylinder Valve MAN B&W Diesel When referring to this page.Safety V alve . please quote Plate P91101 Edition 0037 Plate P91101-0037 Page 1 (2) .

please quote Plate P91101 Edition 0037 . 010 022 034 046 058 071 083 095 105 117 Page 2 (2) MAN B&W Diesel Item Description Item No.Safety V alve . Item Description Spindle Spring retainer Lock nut Spring Valve housing Stop ring Valve flap Valve guide Gasket Safety valve. complete When referring to this page.Cylinder Valve Plate P91101-0037 Item No.

please quote Plate P91102 Edition 0024 MAN B&W Diesel A/S Plate P91102-0024 Page 1 (2) .Relief Valve When referring to this page.

Plate P91102-0024 Item No. please quote Plate P91102 Edition 0024 MAN B&W Diesel A/S .D.C. Item Description Relief valve (P. xxx mm Page 2 (2) When referring to this page.C. please state manufacturer of Relief Valve and P.D. 016 028 030 041 Relief Valve Item Description Item No. 255mm) * Screw* Packing* O-ring* Note: *When ordering.

Scavenge Air System Plate P91103-0017 Safety Valve.Safety Valve. Scavenge Air System 0017 P91103 4. When referring to this page. please quote Plate P91103 Edition 0017 MAN B&W Diesel A/S Page 1 (2) .1 Bar abs.

Plate P91103-0017 Item No. 011 023 035 047 060 072 084 096 106 131 143 Safety Valve. Item Description Stud Washer Spring retainer Spring Valve flap Screw Nut Split pin Castle nut Sealing ring Valve seat Page 2 (2) When referring to this page. Scavenge Air System Item Description Item No. please quote Plate P91103 Edition 0017 MAN B&W Diesel A/S .

Arrangement of Safety Cap MAN B&W Diesel When referring to this page. please quote Plate P91104 Edition 0108 Plate P91104-0108 Page 1 (2) .

Plate P91104-0108 Item No. Item Description Starting air pipe Starting air pipe Stud Bursting cap. please quote Plate P91104 Edition 0108 . complete Safety cap Packing Screw Fitted bolt Plate Wing nut Screw Washer Cover Perforated cylinder Housing Disc Note: * Page 2 (2) When referring to this page. 017 029 030 054 066 078 091 137 149 150 162 174 186 198 208 221 Arrangement of Safety Cap MAN B&W Diesel Item Description Item No.

Arrangement MAN B&W Diesel A/S .Lower Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Top Bracing .912 .Assembly of Large Parts Documents in this Chapter 91201 91205 91207 91208 91209 91210 91211 91216 91217 0094 0159 0054 0019 0007 0186 0036 0007 0004 Arrangement of Stay Bolts Frame Box Arrangement of Piston Cooling Chain Wheel Frame .Upper Chain Wheel Frame .

MAN B&W Diesel A/S .

please quote Plate P91201 Edition 0094 MAN B&W Diesel A/S Plate P91201-0094 Page 1 (2) .Arrangement of Stay Bolts When referring to this page.

Plate P91201-0094 Item No. complete When referring to this page. Item Description Screw Protective cap Nut Stay bolt assembly Guide bushing Stay bolt. please quote Plate P91201 Edition 0094 MAN B&W Diesel A/S . 014 026 038 051 063 087 Page 2 (2) Arrangement of Stay Bolts Item Description Item No.

please quote Plate P91205 Edition 0159 MAN B&W Diesel A/S Page 1 (2) .Plate P91205-0159 Frame Box Frame Box 0159 P91205 B-B Front side B B A A Fore end A-A Rear side When referring to this page.

Item Description Frame Frame door O-ring Spring Door fastener Wing nut Stud Flange Gasket Screw Plug screw Gasket Drain pipe Banjo coupling Pipe Union End shield Gasket Screw Screw Nut Distance pipe Distance pipe Fitted bolt Screw Page 2 (2) When referring to this page. please quote Plate P91205 Edition 0159 MAN B&W Diesel A/S .Plate P91205-0159 Item No. 016 028 041 053 065 077 089 100 112 124 136 173 197 219 220 232 244 256 268 293 303 315 327 339 340 Frame Box Item Description Item No.

Arrangement of Piston Cooling Plate P91207-0054 Arrangement of Piston Cooling 0054 P91207 P P When referring to this page. please quote Plate P91207 Edition 0054 MAN B&W Diesel A/S Page 1 (2) .

Plate P91207-0054 Item No. please quote Plate P91207 Edition 0054 MAN B&W Diesel A/S . 017 029 030 042 054 066 078 091 113 125 137 149 150 162 174 198 Arrangement of Piston Cooling Item Description Item No. Item Description Slotted pipe Screw Locking plate Down pipe Lock washer Clamp Locking plate Nut Union nut Packing Sight glass Flange Stop screw Rubber packing Packing Bracket Page 2 (2) When referring to this page.

please quote Plate P91208 Edition 0019 Plate P91208-0019 Page 1 (2) .Chain Wheel Frame .Upper MAN B&W Diesel When referring to this page.

please quote Plate P91208 Edition 0019 . Item Description Screw Guide pin Screw Cover Gasket Screw Screw Chain casing Cover Spring pin Cover Gasket Stud Nut Cover When referring to this page.Upper Plate P91208-0019 Item No. 012 024 048 061 073 085 107 120 144 156 181 193 215 227 252 Page 2 (2) MAN B&W Diesel Item Description Item No.Chain Wheel Frame .

Lower MAN B&W Diesel When referring to this page. please quote Plate P91209 Edition 0007 Plate P91209-0007 Page 1 (2) .Chain Wheel Frame .

please quote Plate P91209 Edition 0007 .Lower MAN B&W Diesel Item Description Item No. Item Description Cover Screw Cover Gasket Cover Gasket Cover Screw Gasket Cover Gasket When referring to this page.Plate P91209-0007 Item No. 018 031 043 055 079 080 102 114 126 151 163 Page 2 (2) Chain Wheel Frame .

please quote Plate P91210 Edition 0186 Plate P91210-0186 Page 1 (2) .Bedplate MAN B&W Diesel When referring to this page.

main bearing Screw Main bearing shell. 013 025 037 050 062 074 086 108 121 133 157 169 182 194 216 228 253 265 277 290 300 324 336 348 373 385 Page 2 (2) MAN B&W Diesel Item No. Item Description Item Description Bedplate Screw Grate Main bearing cap Stud Baseplate Nut Screw Flange Packing Spring pin Screw Stud Nut Pipe holder Screw Lubricating oil pipe. please quote Plate P91210 Edition 0186 .Bedplate Plate P91210-0186 Item No. lower Screw Lubricating oil pipe Lubricating oil pipe Baseplate Main bearing cap When referring to this page. main bearing Lubricating oil pipe. upper Main bearing shell.

please quote Plate P91211 Edition 0036 Page 1 (2) MAN B&W Diesel A/S .Axial Vibration Damper Plate P91211-0036 When referring to this page.

019 020 032 044 056 081 093 103 115 127 139 152 164 176 188 211 223 235 247 259 260 272 284 306 318 331 343 355 367 379 380 392 402 Page 2 (2) Axial Vibration Damper Item Description Item No. lower part Oil seal Oil seal Clamp Bracket Self-locking nut Screw Pipe holder Screw Screw Screw Guide pin Axial vibration damper.oil pipe Spring Spring Stud Screw Restriction for damper Restriction for damper Restriction for damper Restriction for damper Damper. Item Description Gasket Flange Lub. pipe Screw Self-locking nut Screw Pipe holder Lub.Plate P91211-0036 Item No. complete When referring to this page. please quote Plate P91211 Edition 0036 MAN B&W Diesel A/S .oil pipe Lub. upper part Screw Guide pin Damper.

please quote Plate P91216 Edition 0007 MAN B&W Diesel A/S Page 1 (2) .Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Plate P91216-0007 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) 0007 P91216 When referring to this page.

5 Page 2 (2) When referring to this page. port side Spherical washer Spherical nut Holding-down bolt. 016 028 041 065 077 089 090 112 124 136 148 161 173 197 207 220 232 244 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Item Description Item No. M30 x 3. please quote Plate P91216 Edition 0007 MAN B&W Diesel A/S . Item Description Liner Nut Stud for end chock bolt.Plate P91216-0007 Item No. starboard Liner for side chock.0 Spherical washer Spherical washer Nut Protective cap Protective cap Nut Distance pipe Screw Washer Locking plate Liner for side chock. M48 x 5.

please quote Plate P91217 Edition 0004 Plate P91217-0004 Page 1 (2) .Arrangement MAN B&W Diesel When referring to this page.Top Bracing .

Top Bracing . please quote Plate P91217 Edition 0004 . 011 023 059 060 072 084 106 131 143 155 179 180 202 214 MAN B&W Diesel Item Description Item No. please state length Page 2 (2) When referring to this page. short* Plate. large* Plate Guide pin Screw Disc spring Plate Friction shim Note: * When ordering this spare part. Item Description Screw Friction shim Distance pipe Washer Nut Split pin Plate.Arrangement Plate P91217-0004 Item No.