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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)

S35MC

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 0031 Cylinder Cover, Data
901-01 0223 Cylinder Cover
90151 0189 Cylinder Cover - Panel
90161 0101 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0054 Piston, Data
902-01 0249 Piston
102-02 0040 Piston Rod Stuffing Box, Data
902-02 0209 Piston Rod Stuffing Box
90251 0243 Piston and Piston Rod - Panel
90261 0106 Piston and Piston Rod - Tools
90264 0004 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 0047 Cylinder Liner, Data
903-01 0240 Cylinder Liner
103-02 0022 Cylinder Lubricator, Data
903-02 0233 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90366 0005 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0033 Crosshead Bearing, Data
904-01 0229 Crosshead Bearing
104-02 0035 Crosshead, Data
904-02 0231 Crosshead
104-03 0025 Reciprocating Parts, Data
904-03 0210 Reciprocating Parts
104-04 0029 Crankpin Bearing, Data
904-04 0206 Crankpin Bearing
104-05 0032 Connecting Rod, Data
904-05 0224 Connection Rod
90451 0129 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


105-01 0004 Crankshaft Deflection, Data
905-01 0207 Crankshaft Deflection
105-02 0035 Main Bearing, Data
905-02 0239 Main Bearing
105-03 0040 Thrust Bearing, Data
905-03 0226 Thrust Bearing
105-05 0032 Axial Vibration Damper, Data
905-05 0223 Axial Vibration Damper
105-08 0006 Angle Encoder, Data
905-08 0203 Angle Encoder
90551 0200 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0087 Main Bearing - Hydraulic Tools
90562 0124 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90572 0003 Main Bearing - Measuring Tools
906 - Control Gear
106-01 0017 Chain, Data
906-01 0207 Chain
106-02 0009 Chain Tightener, Data
906-02 0211 Chain Tightener
106-03 0006 Camshaft, Data
906-03 0206 Camshaft
106-04 0006 Camshaft Bearing, Data
906-04 0206 Camshaft Bearings
106-06 0002 Replacement of Cams on Camshaft, Data
906-06 0202 Replacement of Cams on Camshaft
90651 0176 Chain Drive and Camshaft - Panel
90664 0003 Crankshaft - Pin Gauge
90668 0001 Camshaft - Pin Gauge
907 - Starting Air System
107-01 0021 Starting Air Distributor, Data
907-01 0220 Starting Air Distributor
107-02 0019 Start Air Valve, Data
907-02 0206 Starting Air Valve
908 - Exhaust Valve
108-01 0007 High-Pressure Pipe, Data
908-01 0207 High-Pressure Pipe
108-03 0022 Exhaust Valve Actuator, Data
908-03 0209 Exhaust Valve Actuator
108-04 0027 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

0215
0006
0210
0018
0216
0206
0038
0038
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 0056 Fuel Pump Lead, Data
909-01 0239 Fuel Pump Lead
109-03 0046 Fuel Pump Cam, Data
909-03 0228 Fuel Pump Cam
109-04 0043 Fuel Pump, Data
909-04 0221 Fuel Pump
109-05 0046 Fuel Pump Top Cover, Data
909-05 0222 Fuel Pump Top Cover
109-06 0040 Fuel Pump Barrel Assembly, Data
909-06 0218 Fuel Pump Barrel Assembly
109-07 0027 Fuel Pump Suction Valve, Data
909-07 0210 Fuel Pump Suction Valve
109-08 0038 Fuel Pump Puncture Valve, Data
909-08 0216 Fuel Pump Puncture Valve
109-09 0011 Fuel Pump Shock Absorber, Data
909-09 0208 Fuel System Shock Absorber
10911 0051 Fuel Valve, Data
90911 0236 Fuel Valve
10912 0039 Spindle Guide, Data
90912 0223 Spindle Guide
10914 0056 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0047 Fuel Pump Roller Guide, Data
90915 0227 Fuel Pump Roller Guide
10916 0017 Fuel Pump Spec. Runni
90916 0212 Fuel Pump Special Running
90951 0440 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 0002 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 0019 Air Cooler Element, Data
910-01 0215 Air Cooler Element
110-02 0004 Non-Return Valve in Turbocharger, Data
910-02 0211 Non Return Valve in Tubocharger
110-03 0012 Auxilary Blower, Data
910-03 0214 Auxilary Blower
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0011 Water Mist Catcher, Data
910-06 0211 Water Mist Catcher
91063 0017 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0001 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

MAN B&W Diesel

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

V : See Volume I Operation


A : Adjustment to be carried out
C : Check the condition

M : See makers instructions


O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks

No.

Procedure

12

C,O

Crankshaft and Thrust Bearing


Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
Electronic axial vibration monitor

24

32

O
O

Remarks

* Check whenever exhaust


valve is removed

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

* Check clearances without


dismantling segments

O
C
C
C
C

A
A

V,M

C,O
C,O
C,O
C,O
O

C
C
C
C

C
C
C
C

C
C
C
C

C,O
C,O
C,O
C,O
O

C
C

Bearings should only be


opened up if bearing material
fragments fall out.

Bearings should only be


opened up if bearing material
fragments fall out.

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

Page 3 of 6

900-1

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

V : See Volume I Operation


A : Adjustment to be carried out
C : Check the condition

M : See makers instructions


O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks

No.

Procedure

-7
-8

Mechanical checking
Tacho pick-up
Angle encoder

906 Mechanical Control Gear


-1 Chains
-2 Chain tightener
Chain wheels, spray nozzles and guide bars
-3 Camshaft
-4 Camshaft bearings
Camshaft coupling, fitted bolts
-5 Moment compensator
Governor
Functional check of overspeed device
Functional check of speed-setting system
(engine with bridge control system)
907 Starting Air System
-1 Starting air distributor
-2 Starting air valve
908 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

Daily Weekly Monthly

R : Parts to be replaced
B : Based on observations
P : Refer to

Service interval (x1000 hours of operation)


2

12

16

24

32

C,O
C,O

M
M

R
A
R
C,A
C,O

Remarks

C
C,A
C
C

C
C,A
C

C
O

C
C
C

New or overhauled chain to be


checked/retightened after 500,
1500 and 4000 hours

C,A
M
M
M

C
C

C
C,O

O
O
O
O
C,A
C*
C*

C*
C*

O
O

* only inspection through


camshaft covers

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

MAN B&W Diesel

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

V : See Volume I Operation


A : Adjustment to be carried out
C : Check the condition

M : See makers instructions


O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks

No.

-7

Procedure

R : Parts to be replaced
B : Based on observations
P : Refer to

Service interval (x1000 hours of operation)

Daily Weekly Monthly

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

Remarks

A,C
A
A
O
O
R

C,O
C,O
C
C
C
C,O
R

V
V

O
O
O

R
O
C*

C*

C
C
C
C*

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

O
O
O

O
O
O
O
C,O

* Only inspection through


camshaft covers

Check p and t
Check at every port inspection

V,M
Page 5 of 6

900-1

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

V : See Volume I Operation


A : Adjustment to be carried out
C : Check the condition

M : See makers instructions


O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks

No.

Procedure

-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

Daily Weekly Monthly

R : Parts to be replaced
B : Based on observations
P : Refer to

Service interval (x1000 hours of operation)


2

12

16

24

32

O
R

C
C*
C*

V
M

C,O

C
C
C
C

C
C
C
C
C

C*

* Check p

O
O
O

C
C
C

Remarks

A
A
A
A
A

M
M
M
M
M
M

C
C

* Initial check only

C
C

M
Empty and clean tank

O
C

V,M
* Check for loose nuts and
bearing material fragments

C*

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

General Safety Precautions

900-2

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

SAFETY PRECAUTIONS
X

Stopped engine

Shut off starting air supply At starting air receiver

Block the main starting valve

Shut off starting air distributor/distributing system supply

Shut off safety air supply Not ME-engines

Shut off control air supply

Shut off air supply to exhaust valve Only with stopped lubriating oil pumps

Engage turning gear

Shut off cooling water

Shut off fuel oil

Stop lubricating oil supply

Lock the turbocharger rotors

The sketch gives the approximate location of the valves concerned:

When referring to this page, please quote Safety Precaution A90060 Edition 0001
MAN B&W Diesel A/S

Page 1 (1)

901 - Cylinder Cover


Documents in this Chapter
101-01
901-01
90151
90161

0031
0223
0189
0101

Cylinder Cover, Data


Cylinder Cover
Cylinder Cover - Panel
Cylinder Cover - Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover

101-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0031
101-1

Standard Tools: See Section 913

Cylinder Cover

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil


Shut off lubricating oil

Lock turbocharger rotors

Data
10-120, 50-300 Nm
Ref.

Description

D-1

Weight of exhaust valve stud

D-2

Weight of cyl. cover


complete with valves

D-3

Weight of cooling jacket

D-4

Screwing-in torque
exhaust valve studs

200 Nm

Tightening torque
starting valve screws

25 Nm

D-5

D-6

D-8

D-9

Value Unit

3 kg

1 x 3 m, 8 x 1 m

600 kg

28 kg

Screwing-in torque
fuel valve studs

140 Nm

Hydraulic pressure
dismantling

800990 bar

Hydraulic pressure
tightening

900 bar

When referring to this page, please quote Data D10101 Edition 0031
MAN B&W Diesel A/S

Page 1 (2)

Cylinder Cover

101-1

Data

Plate

1849860-1.1

90151

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10101 Edition 0031
MAN B&W Diesel A/S

Cylinder Cover

901-1.2

Dismantling
Cylinder Cover
S35MC
0223
Dismantling
901-1.2

1.

1. Set blocking device A on the main starting


valve in the BLOCKED position.
Engage turning gear B.
Open indicator cocks C.
Close cooling water inlet and outlet valves
D.
Open drain cock E and vent the system.
Close fuel oil inlet valve F.
Shut off the control air and safety air supply
G. Vent the manoeuvring system through
the ball valve.

2. Dismantle the exhaust valve high-pressure


pipe. See Procedure 908-1.2.

BM901-1.2 223 01

Also shut off the air supply on the pressure


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

Dismount the drain oil pipe from the exhaust valve to the hydraulic actuator, and
the sealing air pipe.

BM901-1.2 223 02

2.

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Page 1 (10)

901-1.2

Cylinder Cover
Dismantling

3.

3. Dismount the high-pressure fuel pipes from


the fuel pump to the valves.
See Procedure 909-14.2.
Dismount the return oil connection from the
fuel valves at the fuel pump.
Dismount the control air pipe from the starting valve.
Remove the starting air pipe.

BM901-1.2 223 03

4. Remove the outlet pipes for cooling water


from the exhaust valve and intermediate
pipe.
Remove the control air pipe.
4.

5. Remove the protective jacket enclosing the


intermediate pipe between the exhaust receiver and the exhaust valve.
Dismount the screws in the flange between
the intermediate pipe and the exhaust receiver. The four lowermost screws need not
be dismantled, just loosened.

BM901-1.2 223 04

Remove the protective caps from the cylinder cover nuts.

BM901-1.2 223 05

5.

Page 2 (10)

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Cylinder Cover

901-1.2

Dismantling
6.

6. Place eight spacer rings over the nuts, and


screw the eight hydraulic jacks onto the
studs.

D-8

Connect the high-pressure pump to the


jacks by means of the distributor block and
the high-pressure hoses.

Loosen the nuts by applying the tommy bar


through the slots in the spacer rings.

BM901-1.2 223 06

Using the vent screws of the hydraulic nuts,


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

Relieve the system of pressure.


7.
Disconnect the high-pressure hoses from
the jacks.

D-2

Finally, remove the hydraulic jacks and


spacer rings, and unscrew the nuts.
7. Hook the engine room crane on to the lifting
attachment on top of the exhaust valve.

8. Remove and discard the sealing ring between cylinder cover and cylinder liner.

BM901-1.2 208 07

Lift away the cylinder cover complete, and


land it on a couple of wooden planks.

BM901-1.2 223 08

8.

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Page 3 (10)

901-1.3

Cylinder Cover
Overhaul
Overhaul
901-1.3

1.

D-1

1. Dismount all valves and pipes on the cylinder cover.


Dismount all studs on top of the cylinder
cover.
2. Remove the screws which secure the cooling jacket to the cylinder cover.
Lift the cylinder cover free of the cooling
jacket and land it on a couple of planks.

BM901-1.3 208 01

If the cooling jacket sticks, use dismantling


screws to force the jacket/cover apart.
3. Remove and discard the O-rings from the
cover, and carefully clean the cooling jacket
and the cylinder cover.
2.
4. Provide the cylinder cover with new Orings, well lubricated with oil.
Lift the cylinder cover and guide the jacket/
cover into position, using the guide pin as
a reference (camshaft side).
Mount and tighten the screws for the cooling jacket.

BM901-1.3 208 02

D-3

BM901-1.3 208 03

4.

Page 4 (10)

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Cylinder Cover

901-1.3

Overhaul
5.

5. Recondition the valve bores as follows:


Fuel valve bore
6. The tool consists of a common spindle with
handle, and of a guide, a carbon cutter, a
seating face cutter, and a grinding mandrel.

Grind the seating with the grinding mandrel


and a grinding compound (e.g. Carborundum No. 200).
After the milling/grinding, clean the bore
and seating carefully, and check that the
seating is not damaged.

BM901-1.3 208 05

Clean the fuel valve bores, using the carbon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.

6.

Exhaust valve bore


7. Remove and discard the sealing ring between the cylinder cover and exhaust valve.
The tool consists of a spindle with handle
and a grinding disc.

After the grinding, clean the bore and seating carefully, and check that the seating is
not damaged.

GN901-1.3 203 06

After cleaning the valve bore and seating,


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

BG901-3.1 67 04

7.

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Page 5 (10)

901-1.3

Cylinder Cover
Overhaul

8.

Starting valve bore


8. The tool consists of a guide, a cutter, and
a grinding disc.
Recondition the starting valve bore and
seating in the same way as described for
the fuel valve bore.
When replacing valves on a cylinder cover
that is mounted on the engine, recondition
the valve bores/seating in the same way as
described here, but without dismounting the
studs.

BM901-1.3 208 08

9. Clean the bores for safety valve/indicator


cock.

BM901-1.3 208 09

9.

Page 6 (10)

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Cylinder Cover

901-1.3

Overhaul

10. Lubricate the threads with Never Seize' or


Molybdenum Disulphide (MoS 2) and mount
the valve studs.
Tighten up the studs in accordance with the
screwing-in torque stated on the data
sheet.

10.

D-4
D-5
D-6

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.

Always fit new or overhauled valves before


a cylinder cover is mounted on the engine.

BM901-1.3 208 10

Provide the water connection flanges with


new gaskets, and keep the cylinder cover
ready for replacement.

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Page 7 (10)

Cylinder Cover

901-1.4

Mounting
Mounting
901-1.4

1.

D-2

1. Place a new sealing ring on top of the cylinder liner with the guide tabs in the fore
and aft direction.
This is to ensure that the tabs fit into the
two gas blow-out grooves milled in the cylinder cover guide recess.
2. Lift the cylinder cover by means of the
crane and carefully wipe the contact surface which faces the cylinder liner.

BM901-1.4 208 01

Provide the cooling water connecting pipes


with new O-rings and lubricate them with
vaseline or soft soap.
Mount a new klinger sealing ring in the
groove of the flange of the intermediate
pipe.

2.

Lower the cover carefully into position.


During the landing, carefully check that the
cooling water connecting pipes engage correctly with the holes in the cooling jacket.
3. Mount the cover nuts on the studs and
screw down.

BM901-1.4 208 02

Place a spacer ring around each nut, and


mount the hydraulic jacks on the studs.
Connect the high-pressure pump to the
jacks by means of the distributor block and
the high-pressure hoses.
3.

D-9

Use the vent screws of the hydraulic nuts to


vent the system, and then increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Chapter 913.
Tighten the nuts by applying the tommy bar
through the slots in the spacer rings.
Relieve the system of pressure.

BM901-1.2 223 06

Finally, remove the hydraulic jacks and


spacer rings from the nuts.

Page 8 (10)

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Cylinder Cover

901-1.4

Mounting
4.

4. Mount the protective caps on the cylinder


cover studs.
Align the intermediate pipe so that the
holes in the flange of the intermediate pipe
are in line with the threaded holes in the exhaust valve.
Mount the screws of the flange between the
intermediate pipe and the exhaust receiver.

Lubricate the screws with Never Seize


or Molybdenum Disulphide (MoS 2) before
mounting.

BM901-1.4 223 04

Note!

5.

BM901-1.4 223 05

5. Mount the insulating jacket around the intermediate pipe.

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

Page 9 (10)

901-1.4

Cylinder Cover
Mounting

6.

6. Mount the cooling water pipes, and the control air pipe for the exhaust valve.
7. Mount the starting air pipe and control air
pipe for the starting valve.
Using a crowfoot wrench and torque spanner, mount the fuel oil high-pressure pipes.
See Procedure 909-13.4.
Connect the outlet pipe from the return oil
pipe on the fuel valves.

BM901-1.4 223 06

8. Mount the high-pressure pipe for the hydraulic valve gear.


See Procedure 908-1.4.

7.

Mount the drain oil pipe and the sealing air


pipe.
9. Shut the drain valves and open the cooling
water inlet. After venting the cylinder section, shut the vent cocks and open the cooling water outlet valve.
Open the fuel oil, lubricating oil and air supplies to the alarm system.
Caution !

BM901-1.4 223 07

The air supply to the exhaust valve must


always be connected before turning on
the camshaft oil supply.

BM901-1.4 223 08

8.

This is very important, because otherwise the valve will open more than
intended.

Page 10 (10)

When referring to this page, please quote Procedure M90101 Edition 0223
0$1% :'LHVHO$6

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)

Plate
P90151-0189
Item
No.
010
022
046
058
060
071
083
095
105
117

Cylinder Cover Panel

Item Description

Item
No.

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, please quote Plate P90151 Edition 0189
MAN B&W Diesel A/S

Cylinder Cover - Tools

Plate
P90161-0101

When referring to this page, please quote Plate P90161 Edition 0101

Page 1 (2)

MAN B&W Diesel A/S

Plate
P90161-0101
Item
No.
027
039
052
064
088
090
100
206

Page 2 (2)

Cylinder Cover - Tools

Item Description

Item
No.

Item Description

Hydraulic jack cylinder cover


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

When referring to this page, please quote Plate P90161 Edition 0101
MAN B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


Documents in this Chapter
102-01
902-01
102-02
902-02
90251
90261
90264
90265
90266

0054
0249
0040
0209
0243
0106
0004
0002
0002

Piston, Data
Piston
Piston Rod Stuffing Box, Data
Piston Rod Stuffing Box
Piston and Piston Rod - Panel
Piston and Piston Rod - Tools
Piston and Piston Rod - Tilting Tools
Piston and Piston Rod - Support Tools
Piston - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Piston

102-1

Data
SAFETY PRECAUTIONS
Special Data
0054
102-1

Standard Tools: See Section 913

S35MC
Piston

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubrication oil

10120, 50300

Lock turbocharger rotors


2 x M12

Data
Ref.

Description

D-1

Radial width:
new piston ring
12.5 mm
worn piston ring
10.0 mm
Maximum vertical height:
groove No. 1
10.2 mm
groove Nos. 2, 3 and 4
8.7 mm
Max. permissible burn-away:
standard piston top
11 mm
Minimum free ring gap
22 mm
Minimum ring gap
2.5 mm
Vertical clearance, new parts 0.30-0.35 mm
Piston complete
325 kg
Piston crown
80 kg
Piston skirt
12 kg
Tightening torque
piston skirt
50 Nm
Tightening torque
cooling pipe
50 Nm
Piston rod
190 kg
Tightening torque
piston crown/rod
150 Nm
Test pressure
7 bar
Tightening torque
telescopic pipe
40 Nm
Check distance
cylinder cover studs
8372 mm
Tightening torque
piston/crosshead
210 Nm

D-2

D-3
D-4
D-5
D-6
D-7
D-8
D-9
D-10
D-12
D-13
D-14
D-15
D-16
D-17
D-18

Value Unit

When referring to this page, please quote Data D10201 Edition 0054
MAN B&W Diesel A/S

Page 1 (2)

Piston

102-1

Data

1849875-7.1

Plate
90251

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10201 Edition 0054
MAN B&W Diesel A/S

Piston

902-1.1

Checking
Piston
S35MC
0249
Checking
902-1.1

1.

Scavenge port inspection


To detect possible leakages from the piston or
cylinder cover, keep the cooling water and cooling oil circulating during the scavenge port inspection.
1. Remove the inspection covers on the camshaft side of the cylinder frame.

The scavenge port inspection can also


be carried out from within the scavenge
air receiver.

GN902-1.1 204 01

Note!

Clean the openings.

2.

Begin the inspection at the cylinder whose


piston is nearest BDC.
2. With the piston in BDC, inspect the piston
crown and the cylinder wall.
Note down the results.
See Volume I, OPERATION, Chapter 707.

Check the movability and the tension of the


piston rings, by pressing against them with
a wooden stick.
Note down the results.

GN902-1.1 204 02

3. Turn the engine. While the piston is passing


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

HG902-1.1 201 03

3.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 1 (19)

Piston

902-1.1

Checking
4.

4. After turning the piston upwards, past the


scavenge air ports, inspect the piston rod
and the lower part of the cylinder wall.
Note down the results.
5. Re-mount the inspection covers on the cylinder frame. If necessary, replace the gaskets.

GN902-1.1 204 04

Piston rings and piston crown


6. Remove the piston from the cylinder and
place it on the piston support.
See Procedure 902-1.2.
6.
Note!

D-7

It is recommended to replace all the piston rings whenever a piston is removed


from the engine.
All the following measurements should be
used as a guideline for the running time of
a set of new piston rings.

BG902-4.1 72 02

Depending on the extent of the wear, the


running time can be increased or decreased.
For evaluation of the rings, see Volume I,
OPERATION , Chapter 707.
7. Before dismantling the piston rings, measure the free ring gap of all the piston rings.

D-4

BM902-1.1 232 07

7.

Page 2 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.1

Checking
8.

8. Take off the piston rings by means of the


ring expander.
Clean and inspect the rings.
9. Measure and record the radial width of the
rings.
See Volume I, Operation, Chapter 707.
Worn rings must be replaced if the radial
width is less than stated in Data.

GN902-1.1 222 14

10. Piston rings with milled pressure relief


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

9.

New

GN902-1.1 204 08

D-1

Worn

Min. 1 mm

GN902-1.1 204 09

10.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 3 (19)

Piston

902-1.1

Checking
11.

11. Clean the ring grooves and check them for


burn marks or other deformation.

D-2

Measure the ring grooves with a caliper


gauge.
Clearance in piston ring grooves:
Max. 2 mm

The maximum vertical height in a worn ring


groove must not exceed the value stated in
Data.

KM902-3.0 47 05

The groove is also worn out if there is no


chromium layer.
12. Clean the piston crown and check the burnaway by means of the template. For maximum permissible burn-away value, see Data.

12.

Check the burn-away on the whole circumference of the piston crown.

AM902-3.0 77 04

D-3

Page 4 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.1

Checking
13.

13. Before mounting a new piston ring, measure the piston ring gap.
When measuring, insert the piston ring in
either a new cylinder liner or in the bottom
of a used cylinder (below the ring travel
zone).

D-5

14. Fit the piston rings (alternately right-hand


and left-hand cuts with the ring gaps staggered 180 and with the TOP mark upwards).
When mounting the piston rings, use the
ring expander to prevent unintended deformation of the rings.

GN902-1.1 222 13

For minimum ring gap, see Data.

14.

Do not expand the rings more than necessary. The upper ring (CPR ring) should not
be expanded more than to the milled mark
on the ring expander.

GN902-1.1 222 14

15. Check the vertical clearance between the


new piston ring and the new or reconditioned ring groove with a feeler gauge. See
Data.

15.

KC902-3.0 83 06

D-6

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 5 (19)

902-1.2

Piston
Dismantling
Dismantling
902-1.2

1.

1. Turn the crosshead down far enough to give


access to the piston rod stuffing box, the
tightening screws for the piston rod, and to
the telescopic pipe.
2. Release the stuffing box by removing the
innermost screws from the stuffing box
flange.
Note!

DM902-2.1 105 01

Do NOT remove the outermost screws


from the flange.
3. Remove the screws from the piston rod.
Mount the two distance pieces on the piston
rod foot to protect the lower scraper ring
and to guide the stuffing box.

GN902-1.2 204 02

2.

BM902-1.2 249 03

3.

Page 6 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.2

Dismantling
4.

4. Remove the four screws and nuts which


tighten the telescopic pipe to the bend.
Disconnect the telescopic pipe from the
bend and fasten the pipe flange to the stuffing box by means of the wing-screw from
the tool panel.
Turn the engine to TDC.

When a piston is dismantled, never turn


the engine without first dismantling the
telescopic pipe from the crosshead.

DM902-2.1 105 05

Note!

5. Dismount the cylinder cover.


See Procedure 901-1.2.

5.

6. Make a scratch mark in liner and piston


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

BM902-1.2 210 05

Carefully smooth out any wear ridges at the


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

HN902-1.2 237 06

6.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 7 (19)

902-1.2

Piston
Dismantling

7.

7. The top of the piston is now free of the cylinder liner.

D-7

If necessary, remove one or two cylinder


cover studs, using a stud setter.
Clean the lifting groove of the piston crown
and mount the lifting tool in such a manner
that the two fixed claws of the tool fit into
the lifting groove of the piston.

GN902-1.2 204 07

Fit the third, adjustable, claw of the tool to


the lifting groove and tighten it up against
the stop of the tool.
8. Place the two halves of the support around
one of the openings in the platform.
8.

Lift the piston out of the cylinder and lower


the piston rod foot and stuffing box through
the opening in the platform.
Place the two halves of the support around
the piston rod and secure the two halves
with screws.
9. Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit.

BG 902-4.1 72 02

Clean, measure and recondition the cylinder liner.


See Procedure 903-1.

BG902-4.1 72 02

9.

Page 8 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.2

Dismantling
10.

10. Turn the crosshead down far enough to permit mounting of the protective rubber cover
on the crosshead bearing cap.
The protective rubber cover should remain
in place to protect the crosshead bearing
journal from impurities until the piston is remounted.

If the space conditions above the engine make


it impossible to remove the piston in the normal
way, the piston can be removed as follows:
11. Remove one or two cylinder cover studs,
using the stud setter.

GN902-1.2 204 10

Low lifting height

Lift the piston high enough to give ample


room over the cylinder cover studs.

11.

Mount the clamp on the piston rod so that


its distance piece lies true against the piston.

BM902-1.2 249 11

D-7

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 9 (19)

Piston

902-1.2

Dismantling
12.

12. Place the supporting tools on the cylinder


cover studs and lower the piston until the
clamp rests on the tools.
Remove the lifting tool from the piston.
Hook the transverse piece on to the crane
and attach it to the clamp for tilting the piston.
13. Lift the piston to the maximum crane height.
Run the crane athwartship and, at the same
time, tilt the piston.
Keep the piston rod clear of the cylinder liner and studs while carrying out the tilting.
When space conditions permit, straighten
up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
When the piston is at a suitable height
above the platform cut-out, position the piston support around the piston rod and
clamp.

BM902-1.2 249 12

Now lower the piston while guiding the support to the platform cut-out.
After landing the piston and ensuring that it
rests correctly on the support, remove the
tilting tool.
13.
Note!

BM902-1.2 249 13

D-7

On engines with extremely low lifting


height, use the engine room double-jib
crane instead of the transverse piece.

Page 10 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.3

Overhaul
Overhaul
902-1.3

1.

1. Ease the piston down so that the stuffing


box is below the floor.
2. Assemble the two halves of the piston support around the piston rod.

D-7

Land the piston on the support, taking care


that the piston is not resting on the head of
the piston rod bolts.

3. Dismount the stuffing box and distance


pieces.
See Procedure 902-2.2.

BM902-1.3 249 01

Dismount the piston rings.


See Procedure 902-1.1.

BG902-4.1 72 02

2.

BG902-5.1 82 03

3.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 11 (19)

Piston

902-1.3

Overhaul
4.

4. Lift the piston with the normal lifting tool.

D-9

Lower the piston rod foot near to the platform. Pull the piston rod foot a bit to the
side by hand to tilt the piston. Land the foot
on a wooden block.
Note!

BM902-1.3 236 04

During the lift, follow with the crane to


keep the crane positioned vertically
above the piston crown.
5. Lower the piston crown to the platform and
land it on a wooden block.

5.

6. Remove the lifting tool from the piston


crown.
Attach the lifting bracket to the bottom of
the piston rod foot. Hook the crane on to the
lifting bracket.

BM902-1.3 236 05

7. Lift the piston rod foot clear of the wooden


block.
Note!
6.

During the lift, follow with the crane to


keep the crane positioned vertically
above the piston rod foot.

BM902-1.3 236 06

Keep lifting until the piston rod is in a vertical position.

BM902-1.3 236 07

7.

Page 12 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.3

Overhaul
8.

8. Place the piston in an upright position with


the piston crown resting on wooden blocks.

D-13

Dismount the locking wire and the innermost screws between the rod and the piston crown. Lift the piston rod away and land
it in a horizontal position on a couple of
wooden blocks.

10. Thoroughly clean and inspect all parts of


the piston.

BM902-1.3 236 08

9. Remove the locking wire and the screws in


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

If coke deposits are found in the cooling


spaces of the piston crown, the piston
crown cooling spaces should be washed
out with Carbon Remover or a similar
cleaning fluid. When all coke deposits have
been dissolved, clean and inspect the piston crown again.
Regarding check of the piston crown, see
Procedure 902-1.1.

9.

D-9

Replace all sealing rings of the piston. All


the new sealing rings must be coated with
lubricating oil before the piston is assembled.
BM902-1.3 236 09

Coat all screws with Molybdenum Disulphide (MoS 2).

D-8

Assemble the piston in the reverse order to


disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.

10.

D-14

Tighten all the screws diagonally to the


torque stated in Data.

BM902-1.3 236 10

D-10

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 13 (19)

Piston

902-1.3

Overhaul
11.

11. Lock all the screws with locking wire.


Mount the locking wire in such a way that
the wire is tightened if one of the screws
works loose.
See Procedure 913-7.
12. Fill the piston and piston rod with lubricating oil.
Mount the pressure-testing tool around the
base of the piston rod.

HM902-4.2 52 07

Pressure-test the piston at the pressure


stated on the data sheet.
Check the contact surfaces of the piston
and the sealing rings for tightness.
12.

Check that there are no cracks in the piston


crown.

D-15

13. Tilt the piston to an upright position and


land it on the piston support tool.
Mount the stuffing box and distance pieces.
See Procedure 902-2.4.
Mount new piston rings.
See Procedure 902-1.1.

BM902-1.3 236 12

Oil

Page 14 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.4

Mounting
Mounting
902-1.4

2.

1. Check the piston rings and piston crown in


accordance with Procedure 902-1.1.
2. Mount the lifting tool on the piston crown.

D-7

3. Ensure that the stuffing box is correctly positioned over the guide pins in the distance
pieces mounted on the piston rod foot.

4. Remove the protective rubber cover from


the crosshead.

BM902-1.4 249 02

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

BM902-1.4 249 03

3.

GN902-1.2 204 10

4.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 15 (19)

902-1.4

Piston
Mounting

5.

5. Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit.
6. Turn the crosshead to a position 45 from
TDC.
7. Coat the piston rings, piston rod and cylinder liner with lubricating oil.
Coat the O-rings of the stuffing box with oil.

GN902-1.2 204 09

Mount the guide ring for piston rings on the


cylinder liner.

DM902-2.2 84 03

6.

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, corresponding to the lifting tool lacking about 30
mm in landing on the guide ring.

BM902-1.4 249 07

7.

Page 16 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.4

Mounting
8.

8. Turn the crosshead to TDC while checking


that the guide ring of the crosshead enters
the centre hole in the piston rod.
After turning the piston fully to TDC, unscrew the adjustable claw of the lifting tool
and pull the lifting tool free of the lifting
groove in the piston.

9. Turn down and land the stuffing box on the


stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
correctly centered.

BM902-1.4 249 08

Remove the lifting tool and the guide ring


for piston rings.

Remove the distance pieces from the piston


rod foot.

9.

10. Turn the crosshead with the piston rod


down far enough to give access to the telescopic pipe stuffing box.
Loosen the telescopic pipe and land it on
the bend.

BM902-1.4 249 09

Mount and tighten the screws for the telescopic pipe. See Data.

10.

DM902-2.2 105 06

D-16

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 17 (19)

Piston

902-1.4

Mounting
11.

D-18

11. Mount and tighten the piston rod screws.


See Data.
Lock the screws with locking wire.
Mount the locking wire in such a way that
the wire is tightened if one of the screws
works loose.
See Procedure 913-7.

BG902-2.2 62 08

12. Tighten down the piston rod stuffing box by


means of the screws through the inner
holes in the stuffing box flange.
See Procedure 902-2.4.
13. If the cylinder cover studs have been removed, mount them with the stud setter.
See Data.
Carefully clean the surfaces around the
base of the mounted studs and refill the
roots properly with Permatex 3.

GN902-1.2 204 02

12.

13.

BM902-1.4 230 12

D-17

Page 18 (19)

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Piston

902-1.4

Mounting
14.

14. Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple
of revolutions.
Mount the piston cleaning ring according to
the scratch mark.

15. Mount the cylinder cover.


See Procedure 901-1.4.
16. Start the engine and keep it running for
about 15 minutes at a number of revolutions
corresponding to very slow.

HN902-1.4 237 13

If the PC-ring is damaged (broken or


cracked), it must be replaced by a dummy
ring with an over-size bore, to ensure proper sealing between cylinder cover and cylinder liner.

15.

GN902-1.2 204 05

Then stop the engine and inspect the piston


rod and stuffing box.

When referring to this page, please quote Procedure M90201 Edition 0249
MAN B&W Diesel A/S

Page 19 (19)

Piston Rod Stuffing Box

102-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0040
102-2

Standard Tools: See Section 913

Piston Rod Stuffing Box

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubrication oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Stuffing box complete

D-2

Check length for the


uppermost spring:
F0 = 0 N................. L0 =
F1 = 59 +/ 4 N....... L1 =
F2 = 78 +/ 5 N....... L2 =

327 mm
538 mm
606 mm

Check length for the eight


lowermost springs:
F0 = 0 N................. L0 =
F1 = 78 +/ 5 N....... L1 =
F2 = 53 +/ 7 N....... L2 =

374 mm
547 mm
580 mm

D-3

D-4

D-5

D-6

D-7

D-8

D-9

Min. radial width


uppermost ring
Ring end clearances
uppermost ring
Min. radial width
middle rings
Ring end clearances
middle rings
Min. radial width
lowermost rings
Ring-end clearances
lowermost rings

Value Unit

40 kg

17 mm

3 x 3 mm

12 mm

4 x 5 mm

11 mm

3 x 6 mm

When referring to this page, please quote Data D10202 Edition 0040
MAN B&W Diesel A/S

Page 1 (2)

Piston Rod Stuffing Box

102-2

Data

1849875-7.1

Plate
90251

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10202 Edition 0040
MAN B&W Diesel A/S

Piston Rod Stuffing Box

902-2.1

Checking
Piston Rod Stuffing Box
S35MC
0209
Checking
902-2.1

2.

2. Measure the radial width of all the ring segments. If the radial width of a segment is
less than stated in Data, the complete ring
must be replaced.
3. Measure the ring end clearances, i.e. the
gap between the ends of the segments in a
ring, when the segments are placed evenly
around the piston rod.

BG902-5.1 74 04

1. After the piston rod stuffing box has been


dismantled and disassembled, see Procedures 902-2.2, and 902-2.3, check the rings
and springs as follows:

3.

D-4

The ring end clearances stated in Data apply to new rings.

D-5

As a general guide, it is recommended


depending on the overhauling intervals and
ones own experience to replace sealing
rings and scraper rings when the specified
clearance values have changed by more
than 50%.

D-6
D-7

4. Check the length of the springs at different


loads. Adjust the loads to achieve the
lengths stated in Data.
If the loads necessary are outside the limits
stated in Data, the springs must be discarded.

D-8

BG902-5.0 74 02

D-9

4.

D-2
BG902-5.0 74 03

D-3

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Page 1 (9)

902-2.2

Piston Rod Stuffing Box


Dismantling
Dismantling
902-2.2

1.

If, in the period between piston overhauls, it becomes necessary to inspect the piston rod
stuffing box, proceed as follows:
1. Turn the crosshead to about 90 from TDC.
Mount the rubber hose around the piston
rod to protect the crosshead bearing from
impurities.

GN902-2.2 203 01

2. Remove the drain oil pipe and all innermost


screws and all outer screws except for two
screws placed diametrically opposite in the
stuffing box flange, longitudinally to the engine.

BM902-5.2 109 02

2.

3. Mount the worktable round the piston rod


so that the two remaining screws in the
stuffing box flange can be loosened through
the holes in the worktable.

BM902-5.2 109 03

3.

Page 2 (9)

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Piston Rod Stuffing Box

902-2.2

Dismantling
4.

4. Remove the two long screws from the


worktable.
Mount them in the stuffing box through the
holes in the worktable.
Remove the remaining two screws from the
stuffing box.

Remove the two long dismantling screws


from the stuffing box and mount them in the
worktable.

BM902-5.2 109 04

5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame
bottom.

6. By means of the four short screws in the


worktable, press the stuffing box out of the
flange.
For overhauling the stuffing box, see Procedure 902-2.3.

BM902-5.2 109 05

5.

BM902-5.2 109 06

6.

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Page 3 (9)

902-2.3

Piston Rod Stuffing Box


Overhaul
Overhaul
902-2.3

1.

Outside the engine


1. Normally, overhaul of the piston rod stuffing
box is carried out by routine methods in
connection with the dismantling (pulling) of
the pistons.
During such overhauls, the piston rests on
a support placed over one of the cut-outs in
the top platform.

BG902-5.1 82 01

Work on the stuffing box is then carried out


from the platform below.
2. Mount two eye bolts in the stuffing box
flange, and hook on two tackles.
Lift the stuffing box a little up the piston rod,
and mount the worktable round the piston
rod at a suitable working height.

2.

D-1

Land the stuffing box on the worktable, and


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

BG902-5.1 82 02

Remove the nuts and screws from the stuffing box. Pull the stuffing box halves apart
and remove them from the worktable.
4. Dismantle and stack the rings in the same
order as when fitted in the stuffing box.
3.

Carefully clean all the ring segments.


5. Inspect and assess the surface quality of
the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
6. Measure the radial width and the ring end
clearances or the ring segments.
See Procedure 902-2.1.

BG902-5.1 82 03

7. Check the lengths of the springs.


See Procedure 902-2.1.

Page 4 (9)

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Piston Rod Stuffing Box

902-2.3

Overhaul
8.

9. Lubricate the piston rod (in the area where


all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).
Assemble all the stuffing box ring units
round the piston rod, on the worktable, in
the following way:

HC902-5.1 98 07

8. Inspect the surface of the piston rod. If


small longitudinal scratches have occurred
(caused by poorly adapted stuffing box
rings), smooth the piston rod surface carefully with a fine grained carborundum stone.
In the case of coarse scratches, it may
prove necessary to machine-grind the surface in a workshop.

9.

10. Place the holders and segments for the


lowermost scraper ring on the worktable.
First assemble the holders with uneven serial number.
Secure with the steel pins and place them
round the piston rod.

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
with uneven serial number.
Place the three springs round the scraper
rings and, by means of the two hooks, assemble the spring ends.

BG902-5.1 82 09

Then assemble the holders with even serial


number.

11.

11. On top of the scraper rings, place a 9 mm


distance ring and then assemble the next
scraper rings, using a similar procedure as
described above.

BG902-5.1 82 10

On top of the scraper ring, place a 7 mm


distance ring.

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Page 5 (9)

902-2.3

Piston Rod Stuffing Box


Overhaul

12.

12. On top of the scraper rings, assemble the


two sealing ring units.
Each unit consists of a 4-part lower sealing
ring with two guide pins, an upper 4-part
sealing ring, an outer sealing ring, a holder
for the springs, and two springs.
When assembling one unit, first place the
outer sealing ring round the piston rod.

BG902-5.1 82 11

Place the lower 4-part sealing ring inside


this outer sealing ring so that the two guide
pins face upwards, 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.
Finally, place the holder and two springs,
and assemble the springs by means of the
two hooks.
13.

Place a 7 mm distance ring between the


sealing rings and assemble the last sealing
unit in the same way.
13. On top of the sealing section, place 9 mm
distance rings.

BG902-5.1 82 12

Place the 3-part scraper ring on top of the


upper sealing unit.
Place the spring round the scraper ring
and, by means of the two hooks, assemble
the spring ends.
13.

14. Clean the halves of the stuffing box housing.


15. Place one stuffing box half on the worktable.
Remove all the distance rings.

BG902-5.1 82 13

Push the stuffing box half into contact with


the piston rod round the rings.

Page 6 (9)

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Piston Rod Stuffing Box

902-2.3

Overhaul
16.

16. Place the other half of the stuffing box


housing on the worktable, pushing it into
place round the rings.
Mount and tighten up the fitted bolts to the
torque specified on the Data Sheet.
Mount the O-ring in the stuffing box groove.

Remove the worktable and lower the stuffing box until it rests against the distance
pieces on the piston rod foot.
Remove wire ropes and eye bolts.

BG902-5.1 82 14

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

BG902-5.1 82 15

17.

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Page 7 (9)

902-2.4

Piston Rod Stuffing Box


Mounting
Mounting
902-2.4

1.

1. After overhauling, assemble the stuffing


box halves on top of the two screws.
Mount the two long screws from the worktable in the stuffing box.
Turn down the short screws so that the
stuffing box lands on the flange.
2. Turn the piston upwards until the stuffing
box is in place in the cylinder frame.
Note!

BM902-5.2 109 07

Make sure that the two guide pins in the


flange enter the guide holes in the bottom
of the cylinder frame.
3. Mount two screws in the flange through the
holes in the worktable.

BM902-5.2 109 08

2.

BM902-5.2 109 09

3.

Page 8 (9)

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Piston Rod Stuffing Box

902-2.4

Mounting
4.

4. Remove the long screws from the stuffing


box and mount them in the worktable.
Remove the worktable from the piston rod.
5. Mount and tighten all the inner and outer
screws for the stuffing box. See Data.
6. Remove the protecting rubber cover from
the piston rod/crosshead.

Then turn the crankshaft a couple of revolutions.

BM902-5.2 109 10

Smear the piston rod with molybdenum disulphide.

Start up the engine and keep it running for


about fifteen minutes at a number of revolutions corresponding to very slow or idle
speed.

5.

BM902-5.2 109 11

Then stop the engine and inspect the piston


rod and stuffing box.

GN902-2.2 203 01

6.

When referring to this page, please quote Procedure M90202 Edition 0209
0$1% :'LHVHO$6

Page 9 (9)

Piston and Piston Rod Panel

Plate
P90251-0243

When referring to this page, please quote Plate P90251 Edition 0243

Page 1 (2)

Piston and Piston Rod Panel


0243
P90251

MAN B&W Diesel A/S

Plate
P90251-0243
Item
No.
014
026
040
051
075
087
099
109
110
122
134
158
171
195

Piston and Piston Rod Panel

Item Description

Item
No.

Item Description

Panel for tools


Name plate
Lifting tool for piston rod foot
Lifting tool for cylinder liner
Template for piston top
Distance piece for stuffing box
Cover
Hook for mounting of spring
Pressure tester
Work table
Piston ring expander
Guide screw for piston crown
Dismantling screw piston skirt
Distance piece stuffing box

Page 2 (2)

When referring to this page, please quote Plate P90251 Edition 0243
MAN B&W Diesel A/S

Piston and Rod - Tools

Plate
P90261-0106

Piston and Rod - Tools


0106
P90261

When referring to this page, please quote Plate P90261 Edition 0106
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90261-0106
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 0106
MAN B&W Diesel A/S

Piston and Piston Rod - Extra Tools

Plate
P90264-0004

Piston and Piston Rod - Extra Tools


0004
P90264

When referring to this page, please quote Plate P90264 Edition 0004
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90264-0004
Item
No.
015
027

Piston and Piston Rod - Extra Tools

Item Description

Item
No.

Item Description

Collar ring for piston


Support for tilting tool

Page 2 (2)

When referring to this page, please quote Plate P90264 Edition 0004
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

0047
0240
0022
0233
0084
0005

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 Liner

103-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0047
103-1

Standard Tools: See Section 913

Cylinder Liner

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Cylinder diameter, new

350 mm

D-2

Cylinder liner, complete

630 kg

D-3

Cooling jacket

D-4

Check distance
cylinder cover studs

D-5

D-6

D-7

Value Unit

60 kg

837 +/- 2 mm

Piston cleaning (PC) ring,


radial width, new

27.8 mm

PC-ring/Liner,
max. wear deviation

0.35 mm

PC-rings table:
Liner diameter: 350 mm

D-8

Liner wear:

Install:

0 0.35 mm

Standard PC-ring
(new or max. wear of
diameter 0.35 mm)

0.35 0.7 mm

Oversize PC-ring

> 0.7 mm

Dummy ring

Lifting tool bolts, screwing-in


torque

80 Nm

When referring to this page, please quote Data D10301 Edition 0047
MAN B&W Diesel A/S

Page 1 (2)

Cylinder Liner

103-1

Data

1849875-7.1

Plate
90251

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10301 Edition 0047
MAN B&W Diesel A/S

Cylinder Liner

903-1.1

Checking
Cylinder Liner
S35MC
0240
Checking
903-1.1

2.

1. Dismount the cylinder cover and piston.


See Procedure 901-1.2.
See Procedure 902-1.2.

D-1

Clean the cylinder liner and scavenge air


ports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside
micrometer at the positions indicated on the
measuring tool. See Data.
3. Take measurements in the fore-and-aft and
athwartship directions.

5. Carefully scratch over any scores or marks


on the cylinder liner running surface, and
remove the wear ridges. See Procedure
903-1.3.

BM903-1.1 208 02

4. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.

3.

6. Check the lubricating points of the cylinder


by pumping cylinder oil to each individual
lubricating point.

DM903-2.0 67 02

Clean any blocked lubricating duct.

HN903-1.1 235 04

6.

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Page 1 (10)

903-1.1

Cylinder Liner
Checking

8.

7. Piston cleaning (PC) ring:


The PC-ring is to be regarded as an integrated part of the liner and it is intended to
follow the service life of the liner.

DM903-1.1 237 08

During inspection of the piston and liner,


the PC-ring must also be inspected.
8. Measure the PC-ring radial width B, and
find the most worn place. Compare with
Data D-5 and calculate the wear of the PCring. Multiply the wear by 2 to get the PCring diameter wear.
Measure the liner in the fore-and-aft and
athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner measuring tool. Compare
the measurements with the diameter of a
new liner as stated in Data. Calculate the
wear of the liner.
9. Compare the PC-ring diameter wear with
the wear of the liner. If wear of the two components does not deviate more than D-6,
then reinstall the PC-ring.
If the deviation between PC-ring wear and
liner wear is more than D-6, or if the PCring is broken or cracked, replace the ring
with a new PC-ring, an oversize ring or a
dummy ring according to the table in D-7 on
the Data sheet.
If it is necessary to install an oversize PCring, contact MAN B&W Diesel for advice.
When a new liner is installed, also a new
PC-ring must be installed. When a new liner
is ordered, also a new PC-ring must be ordered.

Page 2 (10)

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Cylinder Liner

903-1.2

Dismantling
Dismantling
903-1.2

1.

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 remove the wear ridges at the
top of the liner.
See Procedure 903-1.3.
Dismount the piston cleaning ring and the
piston.
See Procedure 902-1.2.
Mount the two lifting tools on the cylinder
liner.
Note!

Check with a 0.05 mm feeler gauge that


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

D-8
BM903-1.2 240 01

Tighten the lifting screws to the torque


stated in Data.

2.

This must be done whenever the lifting


tools are mounted on the liner.

BM903-1.2 240 02

2. Disconnect at the distributor block the


oil pipes leading from the cylinder lubricator
to the cylinder liner.

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Page 3 (10)

903-1.2

Cylinder Liner
Dismantling

3.

3. Remove the screws of the cooling water inlet pipe.


4. Attach the crane to the lifting crossbar.
Attach the lifting tools to the crossbar, and
lift the cylinder liner with the cooling jacket
out of the cylinder frame.
Note!

BM903-1.2 208 03

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.

4.

D-2

Clean the cylinder frame internally, taking


special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Discard the O-rings on the cooling water
pipes.

BM903-1.2 240 04

Clean the pipes carefully.

Page 4 (10)

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Cylinder Liner

903-1.2

Dismantling
5.

BM903-1.2 240 05

5. The lifting tools are also used for transporting the cylinder liner.

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Page 5 (10)

Cylinder Liner

903-1.3

Overhaul
Overhaul
903-1.3

1.

1. Attach two tackles to the crossbar, as


shown.
Mount two lifting eye bolts on the cooling
jacket.
Hook the tackles on to the lifting eye bolts
on the cooling jacket and haul tight.
Remove the two lifting screws from the cylinder liner.
Remove the four clamps which fix the cooling jacket to the cylinder liner.

BM903-1.3 240 01

2. Lift the cooling jacket away by means of the


tackles, and land it on the wooden planks.

2.

BM903-1.3 240 02

D-3

Page 6 (10)

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Cylinder Liner

903-1.3

Overhaul
3.

3. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.
Carefully scratch over any scores or marks
on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
Check in the top of the liner for a wear ridge
(where the piston rings reverse direction). If
there is any sign of a wear ridge, it is necessary to create a groove by grinding.The
groove serves to prevent the build-up of a
new wear ridge.

5. Alternatively, place an old piston ring on the


top of the piston and turn to a position that
enables the grinding disc to rest on the old
piston ring while removing the wear ridge.
Use a grinding disc with a round edge.

HN903-1.3 221 04

4. It is recommended to use a wear ridge milling machine to create the groove. For use
of the milling machine, see suppliers instruction.

4.

The maximum depth of the groove is calculated as S max. = D x 0.0045.

MB903-1.3 231 04

Check the distance C before grinding to ascertain that the wear ridge was caused by
the top ring at TDC.

Note!

5.

It is of the utmost importance that the


groove is made with a regular rounding
as shown in the sketch.
S

R=4-5 mm

MN903-1.3 229 05

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Page 7 (10)

Cylinder Liner

903-1.3

Overhaul
6.

6. Replace the two uppermost O-rings on the


cylinder liner.
7. Lower the cooling jacket on to the cylinder
liner.
Note!

BM903-1.3 240 06

Make sure that the scratch marks in the


camshaft side of the cylinder liner and
cooling jacket coincide.
8. Mount the four clamps in the groove of the
liner, and tighten the screws.
Remove the tackles from the lifting crossbar and the cooling jacket lifting eye bolts.
7.

BM903-1.3 240 07

D-3

BM903-1.3 240 08

8.

Page 8 (10)

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Cylinder Liner

903-1.4

Mounting
Mounting
903-1.4

1.

1. Loosen the water connections on the cooling jacket.


Mount the two lifting tools on the cylinder
liner.
Attach the lifting tools to the crossbar, and
lift the jacket/liner assembly.
Mount the lowermost O-ring and apply a little vaseline on the ring.
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.

Mount the cylinder liner in the cylinder


frame. Replace the O-rings on the water
connections and mount the water connections on the cooling jacket.
Remove the lifting tools.

BM903-1.4 240 01

Coat the joint surfaces with permatex or a


similar liquid sealing compound.

3. If one or more cylinder cover studs have


been removed during the dismantling of the
cylinder cover, remount the studs using the
stud setter, see Data.

2.

BM903-1.4 240 02

D-4

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Page 9 (10)

903-1.4

Cylinder Liner
Mounting

3.

4. Fit a new gasket between the cooling water


inlet pipe and the cooling jacket. Mount and
tighten the screws.
5. Connect and tighten the oil pipes for the
cylinder lubrication.
Vent the cylinder lubricating system until
oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.

BM903-1.2 208 03

When this is in order, check that each individual lubricating point functions correctly.

4.

6. Lubricate the inside of the cylinder liner


with cylinder lubricating oil and mount the
piston and the piston cleaning ring.
See Procedure 902-1.4.
7. Mount the sealing ring and the cylinder cover.
See Procedure 901-1.4.

BM903-1.4 240 04

Tighten the upper water connections on the


cooling jacket as soon as the cylinder cover
is correctly positioned.

BM901-1.4 208 01

6.

Page 10 (10)

When referring to this page, please quote Procedure M90301 Edition 0240
MAN B&W Diesel A/S

Cylinder Lubricators

103-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0022
103-2

Standard Tools: See Section 913

Cylinder Lubricators

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil
Shut off lubrication oil
Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D10302 Edition 0022
MAN B&W Diesel A/S

Page 1 (2)

Cylinder Lubricators

103-2

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10302 Edition 0022
MAN B&W Diesel A/S

Cylinder Lubricators

903-2.1

Checking
Cylinder Lubricators
S35MC
0233
Checking
903-2.1



1. Further information concerning other than


nominal feed rates, feed rates for runningin and for part load operation, and recommended oil types, is given in instruction
book Volume I, OPERATION.

/XEULFDWLRQ3RLQW1R

/XEULFDWLRQ3RLQW1R

2. The cylinder lubricators are mounted on the


manoeuvring side of the engine.




For lubricator number. See the sketch.


3. Each cylinder has four injection points.
Check that the pumps for all injection points
are activated during one revolution of the
engine.












0
%



4. Turn the engine in AHEAD direction until the


mark on No. 1 lubricator housing is in line
with the mark on the scale at the lead-in
shaft. This indicates that the pump stroke is
completed for lubricating point No. 1.
5. Check that the crankthrow for cylinder No.
1 is positioned between 90 and 112 past
BDC.
Use the numbers on the turning wheel to
determine the exact position of the crankthrows.















0
%

0DUNV














&\O1R





1
*

When referring to this page, please quote Procedure M90302 Edition 0233
0$1% :'LHVHO$6

Page 1 (4)

903-2.1

Cylinder Lubricators
Checking



6. Turn the engine further in AHEAD direction


until the mark on the second lubricator
housing is in line with the mark on the scale
at the lead-in shaft. This indicates that the
pump stroke is completed for lubricating
point No. 16 on No. 2 lubricator.
7. Check that the crankthrow for the aftmost
cylinder is positioned between 90 and
112 past BDC.














0
%

8. If one of the crankthrows is not in the correct position, adjust the lubricators.
See Procedure 903-2.3.
0DUNV















1
*

Page 2 (4)

$IWPRVW
&\OLQGHU

When referring to this page, please quote Procedure M90302 Edition 0233
0$1% :'LHVHO$6

Cylinder Lubricators

903-2.3

Adjustment
Adjustment
903-2.3


Note!
Any adjustment of lubricator No. 1 will
alter the setting of lubricator No. 2.
Therefore, any adjustment of lubricator
No. 1 must be followed by a re-adjustment of lubricator No. 2.
1. Remove the guards over the couplings.
Loosen the set screws in the couplings and
pull the coupling wheels out of contact with
the planet wheels.
2. For adjustment of lubricator No. 1, turn the
crankshaft in AHEAD direction until the
crankthrow for cylinder No. 1 is 101 past
BDC for lubricator No. 1.















0
%



If necessary, turn the lubricator shaft in


AHEAD direction.
Push the coupling wheels in to contact with
the planet wheel for lubricator No. 1 and
fasten the screws.
For adjustment of lubricator No. 2, turn the
crankshaft in AHEAD direction until the
crankthrow for the aftmost cylinder is 101
past BDC.
Use the numbers on the turning wheel to
determine the exact position of the crankthrows.














1
*

When referring to this page, please quote Procedure M90302 Edition 0233
0$1% :'LHVHO$6

Page 3 (4)

903-2.3

Cylinder Lubricators
Adjustment



3. 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.
4. Re-engage the coupling wheel and tighten
the set screw.
Re-check the setting.
See Procedure 903-2.1.
Mount the guard over the coupling.















0
%















0
%

Page 4 (4)

When referring to this page, please quote Procedure M90302 Edition 0233
0$1% :'LHVHO$6

Cylinder Liner - Tools

Plate
P90361-0084

Cylinder Liner - Tools


0084
P90361

When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90361-0084
Item
No.
036

Cylinder Liner - Tools

Item Description

Item
No.

Item Description

Cylinder gauge, complete

Page 2 (2)

When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S

Cylinder Liner - Lifting Tools

Plate
P90366-0005

Cylinder Liner - Lifting Tools


0005
P90366

021

When referring to this page, please quote Plate P90366 Edition 0005
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90366-0005
Item
No.
021

Cylinder Liner - Lifting Tools

Item Description

Item
No.

Item Description

Crossbar for cylinder liner

Page 2 (2)

When referring to this page, please quote Plate P90366 Edition 0005
MAN B&W Diesel A/S

904 - 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

0033
0229
0035
0231
0025
0210
0029
0206
0032
0224
0129
0068
0005

Crosshead Bearing, Data


Crosshead Bearing
Crosshead, Data
Crosshead
Reciprocating Parts, Data
Reciprocating Parts
Crankpin Bearing, Data
Crankpin Bearing
Connecting Rod, Data
Connection Rod
Connecting Rod and Crosshead - Panel
Connecting Rod - Hydraulic Tools
Crosshead - Hydraulic Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crosshead Bearing

104-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0033
104-1

Standard Tools: See Section 913

Crosshead Bearing

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubricating oil

50-300 Nm

Lock turbocharger rotors


6 x M16

Data
Ref.

Description

D-1

Top clearance for new


crosshead bearing:

Value Unit

0.15-0.40 mm

D-2

Connecting rod

370 kg

D-3

Hydraulic pressure
tightening

900 bar

Hydraulic pressure
dismantling

800-990 bar

D-4

4 x 1.5 m, 1 x 3 m

D-5

Crosshead bearing cap

44 kg

D-6

Telescopic pipe
tightening torque

40 Nm

D-7

Bearing shell, lower

9 kg

D-8

Bearing shell, upper

7 kg

D-9

Piston rod
tightening torque

210 Nm

D-10 Thrust piece


tightening torque

60 Nm

2 x 1000 kg

When referring to this page, please quote Data D10401 Edition 0033
MAN B&W Diesel A/S

Page 1 (2)

Crosshead Bearing

104-1

Data

Plate

1849859-1

90451

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10401 Edition 0033
MAN B&W Diesel A/S

Crosshead Bearing

904-1.1

Checking
Crosshead Bearing
S35MC
0229
Checking
904-1.1

2.

Tin-Aluminium bearings
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.

For the top clearance of a specific bearing, see


the measurement in the Adjustment Sheet in
Volume I, OPERATION.
1. Open the crankcase door at the relevant
cylinder.

BM904-2.1 76 02

The top clearance for a new bearing will normally be in the range stated in Data. Note that
the figures are to be used for guidance only.

3.

2. Turn the crankthrow concerned to BDC.

D-1

4. The difference between the actual clearance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.05 mm. If so, the
crosshead bearing must be disassembled
for inspection.
See Procedure 904-1.2.
For evaluation of the bearing shell, see
Chapter 708, Bearings in the instruction
book, Volume I, OPERATION.

BM904-1.1 229 03

3. 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.
See Data.

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Page 1 (9)

904-1.2

Crosshead Bearing
Dismantling
Dismantling
904-1.2

1.

This procedure has been divided into two dismantling situations, as follows:
with piston mounted
with piston removed
With piston mounted:
1. Turn the crankshaft down far enough to give
access to the nuts and screws on the piston
rod.

BM904-2.1 76 02

2. Mount two eye bolts in the top of the crankcase and suspend two tackles in the
athwartship direction.

2.

Mount the two chains for suspending the


piston rod.
3. Loosen and remove the four screws which
tighten the telescopic pipe to the bend.
Suspend the telescopic pipe from the stuffing box using the wing nut (tool).
Caution!

BM904-1.2 229 02

When a piston is dismantled, never turn


the engine without first dismantling the
telescopic pipe from the crosshead.

BG904-2.2 63 05

3.

Page 2 (9)

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Crosshead Bearing

904-1.2

Dismantling
4.

4. Remove the locking wire from the screws,


loosen and remove the screws from the piston rod foot. Remove the thrust pieces from
both side of the bearing cap.
5. Mount a lifting eye bolt on each side of the
piston rod.
Turn the crosshead to TDC.

Turn the crosshead downward, and the piston rod will remain suspended from the two
chains.

BM904-1.2 229 04

Hook the chains to the lifting eye bolts in


the piston rod.

With piston removed:


5.
6. Turn to BDC.
7. Hold the spacer rings around the nuts and
screw the hydraulic jacks on to the studs.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.

DG904-2.3 64 2/3

Remove the hydraulic jacks and the spacer


rings, and unscrew the nuts.

7.

DM904-4.0 57 02B

D-4

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Page 3 (9)

Crosshead Bearing

904-1.2

Dismantling
8.

8. Screw two eye bolts into the head of the


connecting rod.
9. Mount two eye bolts in the top of the crosshead bearing cap.
Hook the two tackles on to the eye bolts
and lift the crosshead bearing cap away
from the crosshead.
Note!

BG904-2.2 63 08

Take care that the studs for the crosshead bearing cap do not scratch the
crosshead journal.
10. Lift the crosshead bearing cap out of the
engine.

BM904-4.0 40 03A

9.

10.

BM904-4.0 40 03B

D-5

Page 4 (9)

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Crosshead Bearing

904-1.2

Dismantling
11.

11. Place the bearing cap on one side on a


couple of wooden planks.

D-5

12. Turn the crosshead to TDC. Ensure that the


connecting piece in the crosshead fits correctly in the holes of the piston rod.
Do not remove the chains or lifting eye
bolts.

GN904-1.2 203 11

Check the bearing shell, see Procedure


904-1.1.

13. Mount the four supports for guide shoes on


the crosshead guides.

D-8
12.

Carefully turn the crank down towards the


exhaust side, until the guide shoes rest on
the supports.
Adjust the support brackets to the guide
shoes so that the weight of the crosshead
is evenly distributed on the four supports.
14. Hook the two tackles on to the eye bolts
screwed into the head of the connecting
rod.

BM904-1.2 229 12

Haul the tackles tight.

BM904-1.2 229 13

13.

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Page 5 (9)

904-1.2

Crosshead Bearing
Dismantling

15.

15. Turn the crankthrow carefully towards BDC


while following with the tackles, thus continuously supporting the connecting rod.

D-2

With the crosshead resting on the supports,


check the lower part of the crosshead journal and the lower bearing shell.
Check the bearing shell, see Procedure
904-1.1.
For further evaluation of journal and bearing shells, see also Volume I, OPERATION,
Chapter 708, Bearings.
16. In cases where it is necessary to remove
the lower bearing shell, tilt the connecting
rod towards the door in the camshaft side,
using the tackles.

BM904-1.2 208 14

Dismount the lock screws, and lift the bearing shell out of the engine.

16.

BM904-1.2 208 15

D-7

Page 6 (9)

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Crosshead Bearing

904-1.4

Mounting
Mounting
904-1.4

1.

With the piston mounted/


With the piston removed:

D-7

1. Mount and secure the bearing shell in the


bearing housing.
The excess height X is to ensure the correct tightening-down of the bearing shell
and must not be eliminated.

Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.

BM904-1.4 229 01

2. Raise the connecting rod to an upright position.

Take care that the guide shoes do not damage the bearing shell.

2.

BM904-1.2 208 14

3. Remove the tackles from the connecting


rod. Remove the eye bolts from the connecting rod.

BM904-1.4 229 03

3.

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Page 7 (9)

Crosshead Bearing

904-1.4

Mounting
4.

4. Remove the supports from the crosshead


guides.
Turn the crank throw to BDC.
If the piston is mounted, slowly turn down
until it is fully suspended from the chains.

BM904-1.4 229 04

5. Lift the bearing cap into the engine. Lower


the bearing cap onto the crosshead and remove the tackles. Remove the eye bolts
from the bearing cap.
Note!
Take care that the bearing studs do not
damage the crosshead.
5.

D-5

6. Tighten all four crosshead bearing cap nuts


simultaneously. See Data.
For operation of hydraulic jacks, see Section 913.
Mount the two thrust pieces on both sides
of the bearing cap. See Data.

BM904-4.0 40 03B

7. Mount the piston.


See Procedure 902-1.4.

6.

BM904-1.4 229 06

D-10

Page 8 (9)

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Crosshead Bearing

904-1.4

Mounting
8.

With the piston mounted:


8. Turn the crosshead upwards until the piston
rod lands on the crosshead. When mounting the piston on the crosshead, make sure
that the piston rod foot is correctly centered
on the crosshead.

10. Mount and tighten the screws on the piston


rod. See Data.

DG904-1.3 64 02A

9. Unhook the chains from the lifting eye bolts


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

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.
See Procedure 913-7.2.

10.

D-9

After tightening the bearing cap, check the


top clearance once more.

11. Release the telescopic pipe from its suspension, mount and tighten the four screws
which tighten the telescopic pipe to the
bend. See Data.

BG904-2.2 63 16

If a new bearing shell has been mounted,


remember to note down the new top clearance in the Adjustment Sheet in Chapter
701, Volume I, OPERATION.

11.

BG904-2.2 63 15

D-6

When referring to this page, please quote Procedure M90401 Edition 0229
0$1% :'LHVHO$6

Page 9 (9)

Crosshead

104-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0035
104-2

Standard Tools: See Section 913

Crosshead

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

50-300 Nm

Shut off lubricating oil

4 x 1.5 m
1x3m

Lock turbocharger rotors

Data
Ref.

Description

D-1

Hydraulic pressure
dismantling

800-990 bar

Hydraulic pressure
tightening

900 bar

D-2

Value Unit

D-3

Crosshead bearing cap

44 kg

D-4

Crankpin bearing cap

41 kg

D-5

Crosshead complete

290 kg

D-6

Connecting rod

370 kg

D-7

Guide shoe

D-8

Outlet pipe
tightening torque

135 Nm

Thrust piece
tightening torque

60 Nm

D-9

[NJ

35 kg

D-10 Nuts on guide strips


tightening torque

60 Nm

D-11 Telescopic pipe


tightening torque

40 Nm

D-12 Inlet bend stud


screwing-in torque

150 Nm

D-13 Inlet bend


tightening torque
or

260 Nm
45

When referring to this page, please quote Data D10402 Edition 0035
MAN B&W Diesel A/S

Page 1 (2)

Crosshead

104-2

Data

Plate

1849859-1

90451

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10402 Edition 0035
MAN B&W Diesel A/S

Crosshead

904-2.2

Dismantling
Crosshead
S35MC
0231
Dismantling
904-2.2

2.

1. Dismount the piston.


See Procedure 902-1.2.
Note!
Remember to dismount the telescopic
pipe.
2. Turn the crosshead down far enough to give
access to the nuts on the crosshead bearing cap.
Mount two eye bolts in the top of the crankcase in the fore-and-aft direction, mount
two eye bolts in the athwartship direction,
and suspend two tackles.
Mount the spacer rings and hydraulic jacks
for loosening the nuts on the crosshead
bearing studs.

Loosen the nuts, remove the hydraulic jacks


and unscrew the nuts.

BM904-2.2 231 02

For operation of the hydraulic tools, see


Chapter 913.

D-1

3.

D-3

Remove the thrust pieces from the bearing


cap.
3. Mount eye bolts in the crosshead bearing
cap, and hook on the tackles.

BM904-4.0 40 03

Dismount the bearing cap and lift it out of


the engine.

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Page 1 (9)

Crosshead

904-2.2

Dismantling
4.

4. Dismount the bend for the telescopic pipe


and remove the studs and guide pin from
the crosshead.
Dismount the cooling oil outlet pipe and remove the studs from the crosshead.
Mount the special lifting tool on the crosshead.
5. Turn the crosshead to TDC.

BM904-2.2 231 04

Mount two eye bolts in each side of the


crankpin bearing cap and, by means of
shackles and wire ropes, hook on the tackles and haul tight.

5.

D-4
D-1

Mount the spacer rings and hydraulic jacks


for loosening the nuts on the crankpin bearing cap studs.
For operation of the hydraulic tools, see
Chapter 913.
Loosen the nuts, remove the hydraulic
jacks, and unscrew the nuts.
Lower the bearing cap.

BM904-4.0 40 05

Note!
Be careful that the studs do not damage
the crankpin journal.

6.

Remove the bearing cap from the engine.


Then remove the tackles from the top of the
crankcase.
6. Mount the four support brackets for guide
shoes on the crosshead guides.
Carefully turn downwards until the guide
shoes rest on the supports.

BM904-4.0 40 06

Adjust the support brackets to the guide


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

Page 2 (9)

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Crosshead

904-2.2

Dismantling
7.

7. Dismount the connecting rod.


See Procedure 904-5.2.
8. Remove the guide strips and the guide
screws from the guide shoes.
9. Hook the engine room crane on to the lifting
tool on the crosshead, by means of the special flat wrapped wire rope, and lift the
crosshead a little.
Remove the four supports from the crosshead guides.
BM904-4.0 40 10

D-6

BM904-2.2 231 08

8.

D-5

BM904-4.0 40 12

9.

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Page 3 (9)

904-2.2

Crosshead
Dismantling

10.

10. Suspend two tackles from the eye bolts at


the top of the crankcase in the fore-and-aft
direction.
Mount an eye bolt in the top of each guide
shoe.
11. Turn the crank to BDC.
Remove the oil pipes from the two adjacent
main bearing caps.

BM904-2.2 231 10

12. Place a thin wooden plank or similar on top


of the crank to protect the crosshead.
Lower the crosshead so that the guide
shoes are just below the cut-out in the body
plate of the framebox.
11.
Note!

BM904-4.0 40 14

Note that the clearance between the


crank and the crosshead is very narrow

BM904-4.0 40 15

12.

Page 4 (9)

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Crosshead

904-2.2

Dismantling
13.

13. Hook the tackles on to the eye bolts in the


guide shoes.
Haul tight and, at the same time, pull the
guide shoes sideways until they are free of
the crosshead.
Land the guide shoes on top of the main
bearings.
14. Turn the crosshead 90.
Note!
Take care that the crosshead does not
bump into anything as this will damage
the sliding surfaces of the crosshead.

Attach a tackle to the lifting tool for the


crosshead, and remove the crosshead from
the engine.

BM904-2.2 231 13

Use the rubber pieces provided to wrap


around the crosshead.

Land and protect the crosshead outside the


engine.

14.

Remove the guide shoes from the engine.

BM904-2.2 231 14

D-5

D-7

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Page 5 (9)

Crosshead

904-2.4

Mounting
Mounting
904-2.4

1.

D-7
D-5

1. Place the guide shoes, without the guide


strips, in the engine on top of the main
bearing caps.
Clean the crosshead, removing any dust or
grease, and mount the special lifting tool.
Lift the crosshead into the engine by means
of wire rope, tackles and the engine room
crane.
2. Turn the crosshead 90.

BM904-2.4 231 01

Hook the tackles on to the eye bolts in the


guide shoes and mount the guide shoes on
the crosshead.

BM904-2.4 231 02

2.

Page 6 (9)

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Crosshead

904-2.4

Mounting
3.

3. Using the engine room crane, lift the crosshead to a working position, and mount the
guide strips on the side of the guide shoes.
4. Lift the crosshead and mount the four support brackets on the crosshead guides.
Carefully lower the crosshead until the
guide shoes rest on the support brackets.
Adjust the support brackets to the guide
shoes.

D-10

BM904-2.4 231 03

5. Mount the connecting rod.


See Procedure 904-5.4.

BM904-2.4 231 04

4.

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Page 7 (9)

Crosshead

904-2.4

Mounting
6.

6. Turn the connecting rod upwards, guiding


with the tackles until the crosshead is landed in the connecting rod.
Remove the tackles, continue turning a little
upwards, and remove the four supports.
7. Remove the eye bolts from the connecting
rod and the lifting tool from the crosshead.

BM904-2.4 231 06

Mount the studs for the cooling oil outlet


pipe, and the studs for the cooling oil inlet
bend. Mount the inlet and outlet pipes.

7.

D-13
D-11
D-8

BM904-2.4 231 07

D-12

Page 8 (9)

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Crosshead

904-2.4

Mounting
9.

8. Turn to TDC.
Lift the crankpin bearing cap into the engine.

D-1
D-4

Mount and tighten the crankpin bearing


cap, and remove the eye bolts.
9. Turn to BDC.

Mount and tighten the crosshead bearing


cap. Remove the eye bolts.
Mount the two thrust pieces on the bearing
cap.

BM904-4.0 40 26

Lift the crosshead bearing cap into the engine.

10.

10. Mount the piston.


See procedure 902-2.

D-9

11. Finally mount the cylinder cover.


See procedure 901-1.

BM904-2.4 231 10

D-2

When referring to this page, please quote Procedure M90402 Edition 0231
0$1% :'LHVHO$6

Page 9 (9)

Reciprocating Parts

104-3

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0025
104-3

Standard Tools: See Section 913

Reciprocating Parts

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubricating oil

Lock turbocharger rotors

Data
Acceptance criteria with
piston in centre
(F-A direction)
Meas.
points

Value

PF+PA Nmax
Omax

0.70 mm
0.90 mm

TF+TA Omax

0.90 mm

E+G
H+F

Nmax
Nmin
Omax

0.40 mm
0.10 mm
0.70 mm

J+C,
K+C,
L+D,
M+D

Nmax
Nmin
Omax

0.80 mm
0.40 mm
1.00 mm

N: New and cold engine


with staybolts tightened
(less than 100 running
hours).
O: Engine in service.

When referring to this page, please quote Data D10403 Edition 0025
MAN B&W Diesel A/S

Page 1 (2)

Reciprocating Parts

104-3

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10403 Edition 0025
MAN B&W Diesel A/S

Reciprocating Parts

904-3.1

Checking
Reciprocating Parts
K90MC
210
Checking
904-3.1

1.

In order to achieve uniform measuring conditions on board, the ship's trim must be as close
as possible to 0.

Bend each end approx. 250 mm up along


the framebox side. See T.
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.

MA904-5.0 72 01

1. Mount a transparent plastic tube along the


length of the bedplate.

2.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Measurements are to be taken with a ruler.
2. Turn the engine in ASTERN direction to 45
after BDC (the guide shoe must rest against
the crosshead guide).

GN904-3.1 203 06

Check the clearance between guide shoe


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

When referring to this page, please quote Procedure 904-3.1 Edition 210
MAN B&W Diesel A/S

Page 1 (3)

904-3.1

Reciprocating Parts
Checking

3.

3. Check the centering of the piston in the cylinder liner by measuring the clearance
(from the scavenge air space with a long
feeler gauge) between the piston skirt and
the cylinder liner in the Fore and Aft positions (PF-PA).
Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction.

MA904-5.0 72 00

Measure the clearances between the crosshead and the connecting rod (TFTA).

Page 2 (3)

When referring to this page, please quote Procedure 904-3.1 Edition 210
MAN B&W Diesel A/S

904-3.1

Reciprocating Parts
Checking
Exhaust side
D
C

4.

4. Measure the clearance between the guide


shoes and the crosshead (C and D).

Dim C,D

Dim G1-2, H1-2

The clearance, calculated as J+C, K+C,


L+D and M+D, 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.

5. It is recommended that the measured results are noted down so that possible later
changes can be ascertained.

NA904-3.1 208 04

Parallelism between the guide strip and


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

Dim G3-4, H3-4

Measure the clearance between the guide


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

Camshaft side

Dim J,K

5.

Unit mm
Piston/Liner
Framebox

Dim L,M

Cyl.

PF
PA
E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+C
K+C

HN904-3.1 207 05

L+D
M+D
Crosshead
Connecting
Rod

When referring to this page, please quote Procedure 904-3.1 Edition 210
MAN B&W Diesel A/S

TF
TA

Page 3 (3)

Crankpin Bearing

104-4

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0029
104-4

Standard Tools: See Section 913

Crankpin Bearing

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors
2 x 1.5 m, 1 x 3 m

Data
Ref.

Description

Value Unit

D-1

Clearances in crankpin
bearing:
max.
min.

0.50 mm
0.15 mm

D-2

D-3

D-4

D-5

D-6

Hydraulic pressure
dismantling

800-990 bar

Hydraulic pressure
mounting

900 bar

Crankpin bearing
upper shell

6 kg

Crankpin bearing
lower shell

5 kg

Crankpin bearing cap +


shell + bearing studs

2 x 1000 kg

55 kg

When referring to this page, please quote Data D10404 Edition 0029
MAN B&W Diesel A/S

Page 1 (2)

Crankpin Bearing

104-4

Data

Plate

1849859-1

90451

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10404 Edition 0029
MAN B&W Diesel A/S

Crankpin Bearing

904-4.1

Checking
Crankpin Bearing
S35MC
0206
Checking
904-4.1

2.

The bottom clearance between the journal and


a new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.
For the bottom clearance of a specific bearing,
see the measurement in the Adjustment Sheet
in Volume I, OPERATION.

2. Turn the crank concerned to BDC.


3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.

BG904-6.1 74 02

1. Open the crankcase door at the relevant


cylinder.

3.

4. The difference between the actual clearance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.05 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2.

For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.

GM904-6.1 69 03

5. The wear limit for the crankpin bearing


shells is based on an evaluation of the
bearing condition at the time of inspection.

D-1

BG904-6.1 74 05

5.

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Page 1 (7)

904-4.2

Crankpin Bearing
Dismantling
Dismantling
904-4.2

2.

1. Turn the crank to BDC.


2. Mount two eye bolts in the crankcase top
plate in the athwartship direction and suspend two tackles from the eye bolts.
3. Turn the crank to TDC.
Mount eye bolts in each side of the crankpin
bearing cap. Hook the tackles on to the eye
bolts and haul tight.

BG904-6.0 62 03

Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Section 913.
Remove the hydraulic jacks and the nuts.

3.

D-2

4. Lower the bearing cap while seeing carefully that the studs do not damage the
crankpin journal.
Land the bearing cap on a couple of planks
placed in the oil pan.

BG904-6.0 62 05

Inspect the bearing shell.

4.

BG904-6.0 62 07

D-6

Page 2 (7)

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Crankpin Bearing

904-4.2

Dismantling
5.

5. If the bearing shell needs to be replaced,


remove the whole bearing cap from the
crankcase.
Suspend a tackle from the lifting bracket on
the inside camshaft side of the frame box
above the crankcase door opening.
Hook the tackle on to an eye bolt on one
side of the bearing cap.

D-6

Using the tackle from the frame box inside


wall, together with a tackle suspended from
the platform bracket, lift the bearing cap out
of the crankcase.
6. Place the bearing cap on one side on a
couple of planks.

BG904-6.0 62 08

Mount the wire guide in the top of the


crankcase door opening.

6.

Dismount the bearing shell lock screws and


replace the bearing shell by a new one.

D-5

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

GN904-4.2 203 06

The bearing shells must be replaced in


pairs.

7.

Carefully turn the crank down until the


guide shoes rest on the supports.

BG904-6.0 62 09

Adjust the support brackets to the guide


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

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Page 3 (7)

904-4.2

Crankpin Bearing
Dismantling

8.

8. Mount a lifting attachment for securing the


connecting rod at the lower end, on one
side.
Hook on the tackle to a beam under the gallery platform and haul tight.

BG904-6.0 62 10

9. Carefully turn the crankshaft downwards,


while following with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to separate.
Continue turning the crankshaft until the
bearing surface can be freely inspected.
Inspect the bearing shell surface and the
crankpin journal.

9.

10. If it is necessary to replace the bearing


shell, proceed as follows:
Turn the crankshaft to BDC.
Release the tackle so that the connecting
rod is hanging freely.

BG904-6.0 62 11

Dismount the bearing shell lock screws.


Carefully lower the bearing shell from the
connecting rod and remove it from the engine.

10.

BM904-4.2 206 10

D-4

Page 4 (7)

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Crankpin Bearing

904-4.4

Mounting
Mounting
904-4.4

1.

1. Lift the upper bearing shell for the crankpin


concerned into the crankcase.
Carefully lift the bearing shell into position
in the connecting rod, and mount the lock
screws.

D-4

Lubricate the upper crankpin bearing shell


and the crankpin journal with plenty of
clean lubricating oil.
Carefully turn the crankshaft upwards,
while following up with the tackle, making
sure that the upper part of the bearing enters the recess in the crankshaft when the
parts turn together.

BM904-4.2 206 10

2. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod, and haul tight.

2.

Remove the tackle and the lifting attachment from the connecting rod.
3. Turn the crosshead to TDC.

BM904-4.4 206 02

Remove the guide shoe support brackets


from the crosshead guides.

BG904-6.0 62 09

3.

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Page 5 (7)

Crankpin Bearing

904-4.4

Mounting
4.

4. 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..
5. Turn the crankthrow towards the exhaust
side of the engine.

BG904-6.0 62 03

Lift the bearing cap assembly into the


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

5.

BM904-4.4 206 05

D-6

Page 6 (7)

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Crankpin Bearing

904-4.4

Mounting
6.

6. Turn the crankthrow to TDC.


Hook the tackles on to the eye bolts of the
bearing cap and lubricate the bearing shell
with plenty of lubricating oil.

D-6

Lift the bearing cap into position against the


connecting rod.
Caution!
During mounting, take care that the studs
do not damage the crankpin journal, and
check that the guide pins mounted in the
bearing cap enter the holes in the connecting rod.

For operation of hydraulic jacks, see Section 913.


Remove the tackles, the eye bolts and the
hydraulic tools from the engine.

BM904-4.4 206 06

7. Mount the nuts and, by means of spacer


rings and hydraulic jacks, tighten the crankpin bearing cap. See Data.

7.

BG904-6.0 62 05

D-3

When referring to this page, please quote Procedure M90404 Edition 0206
0$1% :'LHVHO$6

Page 7 (7)

Connecting Rod

104-5

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0032
104-5

Standard Tools: See Section 913

Connecting Rod

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

4 x M16

Shut off lubricating oil


Lock turbocharger rotors

4 x 1,5 m, 1 x 3 m

Data
Ref.

Description

D-1

Hydraulic pressure
dismantling

800-990 bar

Hydraulic pressure
tightening

900 bar

Connecting rod

365 kg

D-2

D-4

Value Unit

When referring to this page, please quote Data D10405 Edition 0032
MAN B&W Diesel A/S

3 x 1000 kg

Page 1 (2)

Connecting Rod

104-5

Data

Plate

1849859-1

90451

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10405 Edition 0032
MAN B&W Diesel A/S

Connecting Rod

904-5.2

Dismantling
Connecting Rod
S35MC
0224
Dismantling
904-5.2

1.

1. Before dismounting the connecting rod, the


piston rod and telescopic pipe have to be
suspended and the crosshead bearing cap
has to be removed.
See Procedure 904-1.2.

D-1

2. Turn the crank towards TDC and land the


piston rod foot on the crosshead. Remove
the suspension chains for the piston.

Mount the four support brackets for the


guide shoes on the crosshead guides.
Carefully turn the crank down towards the
door opening on the camshaft side, until the
guide shoes rest on the supports.

BM904-5.2 224 01

3. Turn the crank to TDC.

2.
Adjust the support brackets to the guide
shoes so that the weight of the crosshead
is evenly distributed on the four supports.

BM904-5.2 224 02

4. Dismount the crankpin bearing cap.


See Procedure 904-4.2.

BM904-5.2 222 03

3.

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Page 1 (8)

Connecting Rod

904-5.2

Dismantling
5.

5. Remove the relief valve from the exhaust


side of the framebox.
Mount two eyebolts in the top end of the
connecting rod.
Suspend two tackles outside the engine,
one on each side.
Attach the tackles to the connecting rod as
shown in the sketch.

BM904-5.2 224 05

Mount the lifting attachment on the exhaust


side of the connecting rod, at the crankpin
end.
6. Turn the crank carefully downwards while
following with the tackles to guide the connecting rod when it separates from the
crosshead.

6.

The weight of the crosshead and the piston


is now carried by the four supports.

BM904-5.2 224 06

7. Suspend a tackle from the engine room exhaust side and hook it on to the lifting attachment on the connecting rod, crankpin
end.

7.

BM904-5.2 224 07

AA

Page 2 (8)

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Connecting Rod

904-5.2

Dismantling
8.

8. Turn the crank carefully upwards while following with the tackles.

When possible, move the tackle from the


camshaft side to the exhaust side of the
connecting rod and guide the upper part of
the connecting rod towards and as far out
of the door opening as possible.

10. Continue turning the crank to a position


about 25 after TDC, while following with
the tackles.
Lift the connecting rod clear of the crankshaft.

BM904-5.2 224 08

9. Unhook the upper tackle from the exhaust


side.

9.

BM904-5.2 224 09

10.

BM904-5.2 224 10

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Page 3 (8)

904-5.2

Connecting Rod
Dismantling

11. Lift the connecting rod out of the engine using the two tackles.

BM904-5.2 224 11

11.

Page 4 (8)

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Connecting Rod

904-5.4

Mounting
Mounting
904-5.4

1.

1. Suspend the connecting rod outside the engine and equip the rod with the same lifting
attachments as mentioned under dismantling.
Turn the crank to a position about 25 past
TDC on the camshaft side.

2. Carefully lift the connecting rod into the


crankcase by alternate use of the two tackles attached to the lifting bracket mounted
on the connecting rod and the eyebolt.

BM904-5.4 224 01

Apply clean lubricating oil to the crankpin


bearing shell and journal.

Note!
2.

Take care that the end of the connecting


rod does not strike or scratch the crankpin journal.
3. Carefully land the connecting rod on the
crankpin journal.

BM904-5.4 224 02

4. Turn the crankthrow towards the exhaust


side of the engine, past TDC, while following with the tackles.e

BM904-5.4 224 04

4.

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Page 5 (8)

904-5.4

Connecting Rod
Mounting

5.

5. When the upper end of the connecting rod


has passed through the crankcase door,
hook the second tackle on to the eye bolt
screwed into the exhaust side of the connecting rod top.
6. Unhook the tackle mounted on the camshaft side, from the top of the connecting
rod.

BM904-5.4 224 05

Rise the connecting rod to a more vertical


position with the tackle mounted on the exhaust side.
7. Attach the camshaft side tackle to the camshaft side top of the connecting rod.

6.

Remove the tackle from the lifting attachment at the lower end of the connecting
rod.
Turn the crankthrow towards TDC while following with the tackles.
Caution!

BM904-5.4 224 06

Take care that the connecting rod does


not damage the crosshead journal.

BM904-5.4 224 07

7.

Page 6 (8)

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Connecting Rod

904-5.4

Mounting
8.

8. Carefully land the crosshead on the connecting rod by turning to TDC.


Remove the lifting attachment from the bottom end of the connecting rod.
9. Unhook the tackles from the top of the connecting rod, and mount and tighten the
crankpin bearing cap.
See Procedure 904-4.4.

the four supports from the


crosshead guides
the eye bolts from the connecting rod.

BG904-5.4 224 08

10. Remove:

D-2

BG904-6.0 62 05

9.

BG904-6.0 62 05

10.

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Page 7 (8)

904-5.4

Connecting Rod
Mounting

11.

11. Suspend the piston rod.


See Procedure 904-1.2.
Turn the crosshead to BDC.

BG904-5.4 224 11

12. Mount the crosshead bearing cap, the piston rod and the telescopic pipe as shown in
Procedure 904-1.4.

BM904-5.4 224 12

12.

Page 8 (8)

When referring to this page, please quote Procedure M90405 Edition 0224
MAN B&W Diesel A/S

Connecting Rod and Crosshead Panel

Plate
P90451-0129

Connecting Rod and Crosshead Panel


0129
P90451

When referring to this page, please quote Plate P90451 Edition 0129
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90451-0129
Item
No.
011
023
047
059
060
072
084
096
106
118
120
155
167

Connecting Rod and Crosshead Panel

Item Description

Item
No.

Item Description

Panel for tools


Name plate
Wire guide
Lifting tool
Lifting attachment
Chain for suspension piston
Wing nut
Support for crosshead
Support for crosshead
Rubber cover for crosshead
Rubber cover for crosshead
Crowfoot spanner
Crowfoot spanner

Notes:

Page 2 (2)

When referring to this page, please quote Plate P90451 Edition 0129
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
105-01
905-01
105-02
905-02
105-03
905-03
105-05
905-05
105-08
905-08
90551
90561
90562
90564
90572

0004
0207
0035
0239
0040
0226
0032
0223
0006
0203
0200
0087
0124
0018
0003

Crankshaft Deflection, Data


Crankshaft Deflection
Main Bearing, Data
Main Bearing
Thrust Bearing, Data
Thrust Bearing
Axial Vibration Damper, Data
Axial Vibration Damper
Angle Encoder, Data
Angle Encoder
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

105-1

Data
SAFETY PRECAUTIONS
Special Data
S50MC-C
0004
105-1

Standard Tools: See Section 913

Main Bearing

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D10501 Edition 0004
MAN B&W Diesel A/S

Page 1 (2)

Main Bearing

105-1

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10501 Edition 0004
MAN B&W Diesel A/S

Crankshaft Deflection

905-1.1

Checking
Crankshaft Deflection
S60MC-C
0207
Checking
905-1.1

1.

Crankshaft deflection readings should be taken


while the ship is afloat (i.e. not while in dry
dock).

1. Place a dial gauge axially in the crankthrow


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

HM905-2.0 46 01

As the alignment is influenced by the engine


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

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

XZ905-1.1 204 02

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

XZ905-1.1 204 03

3.

When referring to this page, please quote Procedure M90501 Edition 0207
0$1% :'LHVHO$6

Page 1 (2)

905-1.1

Crankshaft Deflection
Checking

4.

4. When taking deflection readings for the


three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pressure on the turning wheel teeth. This pressure may otherwise falsify the readings.
For evaluation of the crankshaft deflection
readings, see Volume I, OPERATION,
Chapter 708.

HM905-2.0 46 01

If the crankshaft deflection (alignment indicator) is approaching the tolerance limits


(see Vol. I, OPERATION), the two adjacent
main bearings must be checked.
See Procedure 905-2.1 for checking of
main bearing.

Page 2 (2)

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.
If the excessive crankshaft deflection is
found at the aftmost cylinder of the engine,
also the alignment of the propeller shaft/
drive shaft must be checked by a jack-up
test.

When referring to this page, please quote Procedure M90501 Edition 0207
0$1% :'LHVHO$6

Main Bearing

105-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0035
105-2

Standard Tools: See Section 913

Main Bearing

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
2 x 1000 kg

Shut off fuel oil


X

Shut off lubricating oil


2 x 1,5 m
1x3m

Lock turbocharger rotors

Data
Ref.

Description

Value Unit

D-1

Min. bearing clearance

0.15 mm

D-2

Max. bearing clearance

0.40 mm

D-3

Foremost and aftmost


main bearing cap

81 kg

D-4

Middle main bearing cap

77 kg

D-5

Main bearing shell

D-6

Hydraulic pressure
dismantling

800-990 bar

Hydraulic pressure
tightening

900 bar

D-7

[0

6 kg

D-8

Top cover aft

78 kg

D-9

End cover fore

83 kg

D-10 Tightening torque


lub. oil pipe

[NJ

70 Nm

When referring to this page, please quote Data D10502 Edition 0035
MAN B&W Diesel A/S

Page 1 (2)

Main Bearing

105-2

Data

Plate

1849873-3

90551

Spare Parts
Plate Item No.

Description

Qty

91210-xxx 204

Screw

91210-xxx 194

Main bearing, upper shell

91210-xxx 216

Main bearing, lower shell

Page 2 (2)

When referring to this page, please quote Data D10502 Edition 0035
MAN B&W Diesel A/S

Main Bearing

905-2.1

Checking
Main Bearing
S35MC
0239
Checking
905-2.1

1.

1. If there is too large a difference in the


crankshaft deflection readings (autolog),
check the individual bearings.
See Procedure 905-1.1.
2. Remove the lub. oil pipe from the main
bearing cap.

See the wooden box for the measuring tool.


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

MB905-2.0 41 01

Calibrate the main bearing measuring tool:

3.

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 0.05 mm.

4. If necessary, dismount the bearing cap and


the upper shell. For further inspection of the
bearing, see Procedure 905-2.2.

BM905-2.1 239 03

An appreciable increase in clearance may


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

Inspect the bearing and the journal (see


Volume I, OPERATION, Chapter 708,
Bearings).

BM905-2.1 239 04

4.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 1 (17)

Main Bearing

905-2.2

Dismantling
Dismantling
905-2.2

In the following, the main bearings are divided


into three categories:
The main bearings (marked A).
The thrust shaft end journal bearing
(marked B).
BM905-2.2 210 00

The axial vibration damper end bearing


(marked C). (The engine is not always
equipped with this bearing).
Check and write down the top clearances before carrying out any dismantling.

1.

Dismantling of main bearings (A)


1. Disconnect the lubricating oil inlet pipe from
the main bearing cap (if not already done
during checking).
2. Turn the crankthrow so that it points towards the exhaust side of the engine.
Place two spacers on two bearing cap
studs with the slots towards the centre of
the bearing cap.

BG905-3.1 71 01

Screw the two extension studs onto the


same two bearing cap studs (diagonally)
1+3, and subsequently 2+4.
Mount the double hydraulic jacks on the
studs.
2.

D-6

Connect the four hydraulic jacks to the


high-pressure pump by means of the distributor block and high-pressure hoses.
(For operation of the hydraulic tools, see
Chapter 913).
Then loosen the nuts.
Repeat the sequence until all four nuts are
loose.

BG905-3.1 71 02

Remove the hydraulic tools and unscrew


the nuts.

Page 2 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.2

Dismantling
4.

3. Remove the rectangular nut washers from


the bearing cap.
4. Remove the stop screw in the crosshead
guide shoe.
Mount the guide pulley with the lifting wire
rope in the bottom of the guide shoe.
Rig-up two tackles outside the engine.
Mount the outside tackles, one in the lifting
beam on the camshaft side, and one on the
exhaust side.
5. Fasten the lifting tool to the main bearing
cap with wire rope attached to the camshaft
side tackle.

BG905-3.1 71 03

Lift the bearing cap and, by means of the


handle, push the bearing cap free of the
frame and land it on the crank web.

5.

BM905-2.2 239 05

D-4

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 3 (17)

Main Bearing

905-2.2

Dismantling
6.

6. Remove the wire rope from the guide pulley, and fasten the two wire ropes from the
lifting tool in the two tackles outside on either side, and lift the bearing cap out of the
crankcase.
Remove the guide pulley from the engine.

D-4

7. Mount the handle in the upper bearing shell


and remove the shell from the crankshaft.

BM905-2.2 239 06

Inspect the bearing shell and the journal.


See Volume I, OPERATION Chapter 708,
Bearings).
8. Check that there is clearance between the
journal and the bearing shell in the two adjacent main bearings.

7.

BM905-2.2 210 07

D-5

BG905-2.2 216 08

8.

Page 4 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.2

Dismantling
9.

9. 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.
10. Place the crosspiece in the bedplate with
the ends resting on the crossgirders, and
place the hydraulic jacks beneath the crank
webs as shown.

Place a dial gauge to measure the lifting of


the crankshaft.
Connect the hydraulic jacks to the high
pressure pump and raise the pressure until
the crankshaft has lifted maximum 0.2 mm.

BG905-3.1 85 09

Tighten the screws against the crank webs.

10.
11. Dismount the lock screws from the lower
shell.
Place the dismantling tool on the top of the
lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
groove in the bearing shell.

Take out the lower shell from the crankcase


in the same way as the upper shell.

BM905-2.2 239 10

Pull the lower bearing shell round and up


until it lies over the main bearing journal.

Max.0.2 mm

BM905-2.2 239 11

11.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 5 (17)

Main Bearing

905-2.2

Dismantling

Dismantling of journal bearing in the thrust


shaft end (B).
12. Remove the screws of the cover placed
over the thrust bearing. Mount an eye bolt,
shackles and wire rope in the cover. Hook
on a tackle and lift the cover away.
BM905-2.2 210 00

Disconnect the lubricating oil pipe used for


lubricating the bearing.
Turn the crank web for the aftmost cylinder
to TDC.
12.

D-8

13. Mount the spacer supports over the two


nuts and screw the extension studs onto the
two bearing cap studs. Mount the double
hydraulic jacks on the studs.
Connect the four hydraulic jacks to the
high-pressure pump by means of the distributor block and high-pressure hoses.
For operation of the hydraulic tools, see
Chapter 913.
Then loosen the nuts.

BM905-3.2 117 01

Remove the hydraulic tool and unscrew the


nuts.

13.

BM905-3.2 117 03

D-6

Page 6 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.2

Dismantling
14.

14. Mount an eye bolt in the bearing cap and lift


it away.

D-3

Remove the upper bearing shell from the


crankshaft.

16. Set up a dial gauge in such a manner that


a max. lift of 0.20 mm of the shaft can be
measured.

BM905-3.2 117 04

15. If the crankshaft is turned with the bearing


cap dismounted, use the two stops which
prevent the lower shell from being rolled
out.

BM905-3.2 117 05

15.

16.

BM905-2.2 239 17

Max. 2/10 mm

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 7 (17)

905-2.2

Main Bearing
Dismantling

17.
Max. 2/10 mm

17. 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.
Place the crosspiece in the bedplate with
the ends resting on the crossgirders, and
place the hydraulic jacks beneath the crank
webs as shown.
Tighten the screws against the crank webs.
Connect the hydraulic jacks to the high
pressure pump and raise the pressure until
the crankshaft has lifted maximum 0.2 mm.

BM905-2.2 239 19

Measure the clearance in the second last


main bearing (positioned fore of the thrust
bearing). Mount a dial gauge on both the
aftmost main bearing and the second last
bearing. Lift until the aftmost bearing is lifted 0.2 mm or the clearance for the second
last bearing is reached.
18. Dismount the lock screws from the lower
shell.
18.
Check that there is at least 0.1 mm clearance in both sides of the bearing.
Note!

JM905-2.2 236 24

The feeler blade must be inserted minimum 60 mm into the gap to pass the bore
relief in the bearing shell.

Page 8 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.2

Dismantling
19.

Dismantling of main bearing in the axial vibration damper end (C)

D-9

19. Remove the end cover and the top cover


and dismount the lubricating oil pipe.
Turn the crankweb for the foremost cylinder
to TDC.

Mount the double hydraulic jacks on the


studs.
Connect the four hydraulic jacks to the
high-pressure pump by means of the distributor block and high-pressure hoses.

BM905-3.3 88 01

20. Mount the spacers over the two nuts and


screw the extension studs onto the two
bearing cap studs.

20.

D-6

Bleed the hydraulic system and raise the


pressure as indicated in Data.
Then loosen the nuts.
For operation of the hydraulic tools, see
Chapter 913.

21. Mount a shackle over the main bearing cap


and hang up a tackle.
Mount an eye bolt in the top of the bearing
cap, hook on the tackle and lift the bearing
cap out of the crankcase.

BM905-3.3 88 02

Remove the hydraulic tool and unscrew the


nuts.

21.

D-3

BM905-3.3 88 03

Remove the upper bearing shell from the


crankshaft.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 9 (17)

Main Bearing

905-2.2

Dismantling
23.

22. Inspect the bearing and the journal.

D-6

See Volume I, OPERATION Chapter 708,


Bearings.
23. Check that there is clearance between the
journal and the bearing shell in the two adjacent main bearings.
24. Set up a dial gauge, at the foremost main
bearing, in such a manner that a max. lift
of 0.20 mm of the shaft can be measured.
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.

BM905-3.3 88 05

Place the crosspiece in the bedplate, with


the ends resting on the crossgirders, and
place the hydraulic jacks beneath the crank
webs as shown.
Tighten the screws against the crank webs.

BM905-3.3 88 08

24.

Connect the hydraulic jacks to the high


pressure pump and raise the pressure until
the crankshaft has lifted maximum 0.2 mm.

Page 10 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.2

Dismantling
25.

25. Dismount the lock screws from the lower


shell.
Place the dismantling tool on the top of the
lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
groove in the bearing shell.
Pull the lower bearing shell round and up
until it lies over the main bearing journal.

Note!

GN905-2.2 204 12

Take out the lower shell from the crankcase


in the same way as the upper shell.

Never remove the tools for lifting the


crankshaft before remounting the lower
main bearing shell.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 11 (17)

905-2.3

Main Bearing
Overhaul
Overhaul
905-2.3

1.
2.

1. Clean and inspect the bearing shells. For


judging the condition of the bearing, see
Volume I, Chapter 708, Bearings.
If the bearing shells are damaged, contact
MAN B&W Diesel for advice.

GN905-2.3 204 01

We recommend that the main bearing


shells be replaced in pairs.
If, nevertheless, it is desired only to replace
one shell, it requires a careful evaluation of
the condition of the shell that is to be reinstalled. See instruction book, Volume I,
Chapter 708.
For advice on replacing the bearing shells
individually, it is recommended to contact
MAN B&W Diesel A/S or the engine builder.
2. Before remounting:
Check the bearing support for damage
and burrs. If damage is found, contact
MAN B&W Diesel for advice.
Make sure that all parts are clean, use
non-fluffy cloth to clean between journal
and main bearing support.
Lubricate the bearing journal, the main
bearing support and the back of the
shell.

Page 12 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.4

Mounting
Mounting
905-2.4

1.

For all main bearings (A, B and C):


1. Lubricate the lower bearing shell and the
crankshaft journal with plenty of clean lubricating oil.
2. Land the lower bearing shell on the crankshaft journal.

Remove the handle.


Using a caliper, check in both sides of the
bearing shell that the bearing shell is
mounted horizontally correct.

BM905-2.2 210 00

Mount the handle on the lower bearing shell


and slide down the lower bearing shell as
far as possible.

2.

D-5

BM905-2.4 210 02

3. If necessary, use the bearing shell dismantling tool to push the lower bearing shell fully down under the crankshaft journal.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 13 (17)

905-2.4

Main Bearing
Mounting

4.

4. Check visually that the shell does not prevent the locking screws from being fully
tightened to the bedplate, as this would
cause damage to the screws and shell
when tightening the bearing cap.
See also Volume I, OPERATION, Chapter
708.

BM905-2.4 210 02

5. Lower the crankshaft and remove the


crosspiece and the hydraulic jacks from the
engine.
6. Lubricate the upper bearing shell with plenty of clean lubricating oil. Land the upper
bearing shell on the crankshaft journal.
Make sure that the edge of the upper bearing shell does not rest on the tip of the bedplate.

6.

If so, press the shell into place.

BM905-3.3 88 13

7. Mount the bearing cap. Make sure that the


guide pin from the bedplate enters the hole
in the bearing cap.

7.

BG905-3.1 71 16

D-4

Page 14 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.4

Mounting
8.

For middle main bearing (A)

D-7

8. Mount the:
rectangular washers
nuts
extension studs
spacers
double hydraulic jacks
Tighten the main bearing cap. See Data.
9. The tightening is done in the following sequence:
1) Tighten nuts 1 + 3

3) Retighten nuts 1 + 3
Remove the hydraulic tools.

BG905-3.1 85 17

2) Tighten nuts 2 + 4

9.

If a new bearing shell has been mounted,


remember to note down the new top clearance in the Adjustment Sheet in Volume I,
OPERATION, Chapter 701.
11. Mount the lubricating oil pipe.

BM905-3.1 71 17

10. After tightening the bearing cap, check the


top clearance once more.

D-10

BG905-2.0 48 05

11.

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 15 (17)

Main Bearing

905-2.4

Mounting
12.

For main bearing in thrust shaft end (B):

D-7

12. Mount the:


rectangular washers
nuts
extension studs
spacers

BM905-3.2 117 03

hydraulic jacks
Tighten the bearing cap. See Data.
Mount and tighten the nuts of the adjacent
main bearing, see step 9.
13.

D-8

Remove the hydraulic tools.


After tightening the bearing cap, check the
top clearance once more.

D-11

If a new bearing shell has been mounted,


remember to note down the new top clearance in the Adjustment Sheet in Volume I,
OPERATION, Chapter 701.

BM905-3.2 117 17

13. Finally, mount the lubricating oil pipe and


the cover over the thrust bearing.

D-10

Page 16 (17)

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Main Bearing

905-2.4

Mounting
14.

For main bearing in axial vibration damper


end (C):

D-7

14. Mount the:


rectangular washers
nuts
extension studs
spacers
hydraulic jacks

Mount and tighten the nuts of the adjacent


main bearing, see step 9.
Remove the hydraulic tools.

BM905-3.3 88 02

Tighten the bearing cap. See Data.

15.

After tightening the bearing cap, check the


top clearance once more.

D-11

D-9

If a new bearing shell has been mounted,


remember to note down the new top clearance in the Adjustment Sheet in Volume I,
OPERATION, Chapter 701.
15. Finally, mount the lubricating oil pipe, the
end cover and the cover over the bearing
cap.

BM905-3.3 88 15

D-10

When referring to this page, please quote Procedure M90502 Edition 0239
0$1% :'LHVHO$6

Page 17 (17)

Thrust Bearing

105-3

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0040
105-3

Standard Tools: See Section 913

Thrust Bearing

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


140-760 Nm

Shut off cooling water


Shut off fuel oil
X

2 x M10

Shut off lubricating oil


Lock turbocharger rotors

2 x 500 kg

Data
Ref.

Description

Value Unit

D05-28 Cover

78 kg

D05-07 Stopper

44 kg

D05-06 Thrust bearing segment

13 kg

D05-29 Tightening torque


stopper

500 kg

650 Nm

When referring to this page, please quote Data D10503 Edition 0040
MAN B&W Diesel A/S

Page 1 (2)

Thrust Bearing

105-3

Data

Plate

1849873-3

90551

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10503 Edition 0040
MAN B&W Diesel A/S

Thrust Bearing

905-3.1

Checking
Thrust Bearing
S35MC
0226
Checking
905-3.1

1.

The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,
and for an engine in service it must not exceed
2.0 mm.

1. To measure the wear in the thrust bearing,


it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.

BM905-3.1 226 01

In service it is only necessary to measure the


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

2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).

If a feeler gauge of 0.1 mm is not able to


enter the groove (the wear is more than 0,9
mm), the thrust bearing must be overhauled.
3. Note down the wear for later reference.

GN905-3.1 224 02

2. To measure the wear, the thrust segment


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

KN905-2.2 238 02

3.

When referring to this page, please quote Procedure M90503 Edition 0226
MAN B&W Diesel A/S

Page 1 (5)

Thrust Bearing

905-3.2

Dismantling
Dismantling
905-3.2

1.

D05-28

1. Remove the cover above the thrust bearing.


Remove the lub. oil pipe from the thrust
segments.
2. Loosen and remove the screws from the
segment stoppers.
Screw an eye bolt into the stopper that is to
be removed.
Suspend a tackle above the stopper and
hook the tackle on to the eye bolt.

BM905-4.0 51 01

Remove the stopper from the engine above


the thrust segments ( AHEAD or ASTERN) that
are to be taken out. The other stopper is to
remain fitted.

2.

BM905-4.0 51 02

D05-07

Page 2 (5)

When referring to this page, please quote Procedure M90503 Edition 0226
MAN B&W Diesel A/S

Thrust Bearing

905-3.2

Dismantling
3.

3. Suspend a tackle from the chain tightener


bracket above the segments which are to
be removed. Nevertheless, the weight is no
heavier than it is possible to lift the segment
by hand.

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


turning the engine, and remove the segment from the chain casing. Inspect the
segment and remount it before turning up
the next segment. See Procedure 905-3.4.

BM905-5.0 76 03

For turning-up the thrust segments, screw


the driving pin into the thrust shaft.

4.

Note!

D05-06

BG905-5.0 59 04

Never remove more than one segment at


a time.

When referring to this page, please quote Procedure M90503 Edition 0226
MAN B&W Diesel A/S

Page 3 (5)

905-3.4

Thrust Bearing
Mounting
Mounting
905-3.4

1.

1. Suspend a tackle above the segments


which are to be mounted. Still, it is possible
to lift the segments by hand.
Screw the driving pin into the thrust shaft.
2. Land the segment on the journal and remove the eye bolt from the segment.

BM905-5.0 76 03

Carefully slide the segment on to the driving pin. Turn the engine to dismantle the
next segment, see Procedure 905-3.2.
After the last segment has been mounted,
turn the driving pin up and dismount it.
2.

BM905-3.4 208 02

D05-06

Page 4 (5)

When referring to this page, please quote Procedure M90503 Edition 0226
MAN B&W Diesel A/S

Thrust Bearing

905-3.4

Mounting
3.

3. Mount the segment stopper.


Mount and tighten the screws which fasten
the segment stopper. See Data.

D05-07
D05-29

Note!
Use only the tightening angle or the
tightening torque, not both.
4. Mount the lub. oil pipe.

BM905-4.0 51 02

Mount the cover above the thrust bearing.

D05-28

BM905-3.4 208 04

4.

When referring to this page, please quote Procedure M90503 Edition 0226
MAN B&W Diesel A/S

Page 5 (5)

Axial Vibration Damper

105-5

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0032
105-5

Standard Tools: See Section 913

Axial Vibration Damper

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

40-200 Nm +
140-760 Nm

Shut off cooling water


Shut off fuel oil
X

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

D05-25 Damper housing, upper part

61 kg

D05-17 Tightening torque


vertical screws (inner)

50 Nm

D05-21 Tightening torque


vertical screws (outer)

400 Nm

D05-23 Tightening torque


horizontal screws

120 Nm

Other tightening torques according to procedure


913-04.

When referring to this page, please quote Data D10505 Edition 0032
MAN B&W Diesel A/S

Page 1 (2)

Axial Vibration Damper

105-5

Data

Plate

1849873-3

90551

Spare Parts
Plate Item No.

Description

Qty

91211-038 127

Spring middle oil seal

91211-038 139

Spring side oil seals

91211-038 272

Oil seal side oil seals

91211-038 284

Oil seal middle oil seal

Page 2 (2)

When referring to this page, please quote Data D10505 Edition 0032
MAN B&W Diesel A/S

Axial Vibration Damper

905-5.1

Checking
Axial Vibration Damper
S35MC
0223
Checking
905-5.1

1.

For checking the effectiveness of the axial vibration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken
at the same r/min as during the sea trials. (Preferably 90% and 100% of MCR.)
As different equipment may be mounted on the
specific engines, the checking procedure describes three different systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, (without angle encoder fore)
C: Mechanical, with angle encoder fore.

A proximeter probe is built on to the lower part


of the damper housing. The probe is connected
to a control unit which displays peak-to-peak
movements and sends signals to the engine
control system.

KM905-7.1 35 01

A: Electronic, with Axial Vibration Monitor

1. Concerning overhaul and setting of the


electronic device, refer to makers instructions and Volume I, Operation, Chapter
701.
The peak-to-peak values displayed in mm
are to be compared with the original values
obtained during sea trial and the limits given in Volume I, Operation, Chapter 701.
If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Page 1 (8)

905-5.1

Axial Vibration Damper


Checking

1.

B: Mechanical (without angle encoder fore).


1. Stop the engine.
Unscrew the two plugs from the cover at the
front of the engine.
2. Mount the shaft piece in the end of the
crankshaft, using the handle.

BG905-5.1 223 01B

After tightening the shaft, dismount the


handle.
Screw the measuring arm into the small
threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.
2.

Attach a pencil to the arm.


Note!

BG905-5.1 223 02B

To obtain a correct measurement, the tip


of the pencil should protrude 10 mm from
the end of the arm.

Page 2 (8)

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Axial Vibration Damper

905-5.1

Checking
3.

3. Start the engine, and let the speed rise to


the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)

S-2

To ensure a certain inertia, the backing


plate should have a mass of approx. 1-2 kg.
The axial movements (S2) recorded on the
paper must be measured with a slide calliper as shown in the sketch.

DM905-7.1 74 05

When measuring, press the measuring arm


against the shaft piece with the one hand.
With the other hand, move a sheet/block of
paper, clipped on to a solid backing plate,
lightly downwards against the tip of the
pencil.

4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.

If a non-standard tool is used, S1 can be


calculated as follows:

DM905-7.1 74 06

For a standard measuring tool (L 1 = 38 mm


and L 2 = 200 mm), the ratio is 5.3. Therefore, S1 can be calculated as follows:

If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Page 3 (8)

905-5.1

Axial Vibration Damper


Checking

1.

C: Mechanical, with angle encoder fore


For engines with angle encoder fore, a measuring tool is available for mounting on the angle
encoder housing.
1. Stop the engine.
Dismount the protection shield over the angle encoder. (Not always on engine).
Dismount the cover on the angle encoder
housing.
Apply some Molycote TM on the fore side of
the shaft cam.
2. Mount the axial vibration measuring tool,
using the screws from the cover.

BG905-5.1 223 01C

Note!
To obtain a correct measurement, the tip
of the pencil should protrude 10 mm from
the end of the arm.

N905-5.1 214 05

2.

Page 4 (8)

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Axial Vibration Damper

905-5.1

Checking
3.

3. Start the engine, and let the speed rise to


the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)

S2

When measuring, pull the measuring arm


against the shaft cam with one hand. With
the other hand, move a sheet/block of paper, clipped onto a solid backing plate,
lightly sidewards against the tip of the pencil.
PULL

The axial movements (S2) recorded on the


paper must be measured with a slide calliper as shown in the sketch.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.

BG905-5.1 223 03

To ensure a certain inertia, the backing


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

4.

For a standard measuring tool (L 1 = 35 mm


and L 2 = 178 mm), the ratio is 5.1. Therefore, S1 can be calculated as follows:

If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.

MA905-5.1 212 07

If a non-standard tool is used, S1 can be


calculated as follows:

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Page 5 (8)

905.5.2

Axial Vibration Damper


Dismantling
Dismantling
905.5.2

1.

Dismantling of the axial vibration damper is carried out from the crankcase of cyl. No. 1.
1. Turn the engine to 90  after TDC.
Dismount the lubricating oil pipes for the
main bearing and axial vibration damper.
2. Loosen and remove the screws from the
damper housing upper part.

BG905-7.2 28 01

Only the upper part of the housing needs to


be removed, while the lower half remains
mounted on the bedplate.
3. Mount the lifting bracket and a shackle on
the upper part.
By means of tackle and wire rope, separate
and raise the upper part of the damper
housing to a position in which it is possible
to change the oil seals and springs.

2.

Note!

BG905-7.2 28 02

Before starting work below the suspended upper part, secure the upper part
with, e.g. a wire rope or another tackle.

3.

BG905-5.2 216 03

D05-25

Page 6 (8)

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Axial Vibration Damper

905-5.3

Overhaul
Overhaul
905-5.3

1.

1. Dismantle and remove the springs from the


oil sealing rings.
Remove the oil sealing rings.

Note!

When mounting the new oil sealing rings,


first insert the lower half of the rings in the
lower housing.
Then press the tension springs into the
groove between the oil sealing ring half and
the housing.

HG905-5.2 201 01

It is recommended to discard both the


springs and the oil sealing rings.

2.

2. Mount all the upper halves of the oil sealing


rings in such a way that the clearance at
both the joints on each oil sealing ring is the
same.
Now hook the new tension springs into
place, ensuring that they are centralised in
the grooves of the oil sealing rings.

The lower half of the oil sealing rings will


protrude above the centreline.

HG905-5.2 201 02

Note!

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Page 7 (8)

905-5.4

Axial Vibration Damper


Mounting
Mounting
905-5.4

1.

1. Release and carefully lower the upper part


of the damper housing.

D05-25

When reaching the oil sealing rings, take


care that the rings enter the sealing ring
grooves correctly.
Before landing the upper part on the lower
part, be sure that the guide pins have entered the guide pin holes.
2. Mount the vertical and horizontal screws.
Tighten the screws. See Data.
Note!

BG905-5.4 223 01

Search the crankcase to ensure that


there are no tools, shackles or rags left
behind.
Mount the lubricating oil pipes.

Note!
2.

D05-15
D05-21

After overhaul of the axial vibration


damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.

BG905-7.2 28 06

D05-23

Page 8 (8)

When referring to this page, please quote Procedure M90505 Edition 0223
0$1% :'LHVHO$6

Angle Encoder

105-8

Data
SAFETY PRECAUTIONS
Special
alle
0006
105-8
medData
vinkel encoder

Standard Tools: See Section 913

Angle Encoder

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D10508 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Angle Encoder

105-8

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10508 Edition 0006
MAN B&W Diesel A/S

Angle Encoder

905-8.1

Checking
Angle Encoder
S42MC
0203
Checking
905-8.1



1. Turn the crankthrow for cylinder 1 to TDC.

2. Check that power is supplied to the intermediate box.


The green indicator should now light.

HM906-7.0 56 01

Check the TDC of cylinder 1 against the


mark on the turning wheel.

For adjustment of the angle encoder, see


Procedure 905-8.3.

MN905-8.1 202 03



When referring to this page, please quote Procedure M90508 Edition 0203
0$1% :'LHVHO$6

Page 1 (4)

905-8.2

Angle Encoder
Dismantling
Dismantling
905-8.2



1. Remove the inspection cover.


Cut the cable tie which holds the rubber
damper around the coupling, in the end
nearest to the engine, and loosen the coupling.

DM905-8.2 203 01

2. Loosen the three adjusting screws on the


front flange, and remove the angle encoder
and the coupling.
3. Screw out the flange screws and remove
the encoder housing. Take care not to damage the guide pins.

DM905-8.2 203 02



DM905-8.2 203 03



Page 2 (4)

When referring to this page, please quote Procedure M90508 Edition 0203
0$1% :'LHVHO$6

Angle Encoder

905-8.3

Adjustment
Adjustment
905-8.3



1. Turn the crankthrow for cylinder 1 to TDC.

Check the TDC position with the pin gauge


on the crankthrow, cylinder 1.
Note!

HM906-7.0 56 01

Check the TDC of cylinder 1 against the


mark on the turning wheel.

Before using the pin gauge, check the


measurement from tip to tip with the
value stamped on the pin gauge, and/or
the check-marks stamped on the fore
end of the cylinder frame.

Tighten the screws to secure the encoder in


the correct position.

BG906-7.0 58 02

2. Loosen the adjusting screws which fasten


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



MN905-8.3 202 02



When referring to this page, please quote Procedure M90508 Edition 0203
0$1% :'LHVHO$6

Page 3 (4)

905-8.4

Angle Encoder
Mounting
Mounting
905-8.4

1.

1. Mount the encoder housing. The two guide


pins indicate the correct positioning of the
housing. Tighten the screws.
2. Mount the angle encoder and the coupling.

DM905-8.2 203 03

Tighten the coupling, and mount a new cable tie around the rubber damper.
Adjust the angle encoder according to Procedure 905-8.3.
Note!
2.
The adjustment will be easier if mounting
is in the same crank position as dismantling.

DM905-8.2 203 02

Mount the cover.

Page 4 (4)

When referring to this page, please quote Procedure M90508 Edition 0203
0$1% :'LHVHO$6

Crankshaft, Thrust Shaft, Main Bearing,


Etc. Panel

Plate
P90551-0200

Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel


0200
P90551

When referring to this page, please quote Plate P90551 Edition 0200
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90551-0200
Item
No.
015
027
052
076
088
100
111
123
135

Crankshaft, Thrust Shaft, Main Bearing,


Etc. Panel
Item Description

Item
No.

Item Description

Panel for tools


Name plate
Handle for bearing shells
Lifting tool for main bearing cap
Dismantling tool main bearing shell
Tool for turning out segments
Lifting tool for damper
Retaining tools for main bearing shells
Lifting tool for relief valve

Notes:

Page 2 (2)

When referring to this page, please quote Plate P90551 Edition 0200
MAN B&W Diesel A/S

Main Bearing - 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)

Plate
P90561-0087
Item
No.
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, upper, complete


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

When referring to this page, please quote Plate P90561 Edition 0087
MAN B&W Diesel A/S

Crankshaft - Tools

Plate
P90562-0124

Crankshaft - Tools
0124
P90562

When referring to this page, please quote Plate P90562 Edition 0124
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90562-0124
Item
No.
015
027
039

Crankshaft - Tools

Item Description

Item
No.

Item Description

Support
Screw with special head
Nut

Page 2 (2)

When referring to this page, please quote Plate P90562 Edition 0124
MAN B&W Diesel A/S

Crankshaft - Measuring T
ools
Tools
MAN B&W Diesel

When referring to this page, please quote Plate P90564 Edition 0018

Plate
P90564-0018

Page 1 (2)

Plate
P90564-0018
Item
No.
016

Page 2 (2)

Crankshaft - Measuring T
ools
Tools
MAN B&W Diesel

Item Description

Item
No.

Item Description

Measuring tool for axial movement

When referring to this page, please quote Plate P90564 Edition 0018

Main Bearing - Measuring Tools

Plate
P90572-0003

Main Bearing - Measuring Tools


0003
P90572

When referring to this page, please quote Plate P90572 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90572-0003
Item
No.
010
021
045
057

Main Bearing - Measuring Tools

Item Description

Item
No.

Item Description

Measuring tool main bearing


clearence
Calibration tool
Key, hexagon socket screws
Wooden box

Page 2 (2)

When referring to this page, please quote Plate P90572 Edition 0003
MAN B&W Diesel A/S

906 - 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

0017
0207
0009
0211
0006
0206
0006
0206
0002
0202
0176
0003
0001

Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearing, Data
Camshaft Bearings
Replacement of Cams on Camshaft, Data
Replacement of Cams on Camshaft
Chain Drive and Camshaft - Panel
Crankshaft - Pin Gauge
Camshaft - Pin Gauge

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Chain

106-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0017
106-1

Standard Tools: See Section 913

Chain

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Max. wear of teeth


on chain wheel

D-2

D-3

Value Unit

2.5 mm

Original length
(chain pitch x 10 links)

713.7 mm

10 links measurements
+ 1% of a tensioned chain
= scrapping of chain

720.8 mm

When referring to this page, please quote Data D10601 Edition 0017
MAN B&W Diesel A/S

Page 1 (2)

Chain

106-1

Data

Plate

1849863-7.2

90651

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10601 Edition 0017
MAN B&W Diesel A/S

Chains

906-1.1

Checking
Chains
S35MC
0207
Checking
906-1.1

4.

Carry out the inspection as follows:


1. Make a general inspection for loose bolts
and screws.
2. Inspect lube oil pipes for damage, and
check jet nozzles for possible stoppages or
deformations.
3. Examine the rubber track of the guideways
for cracks or other damage.
Replace the guideway if bits have started to
be plucked out of the rubber track.
4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement
(see Data).

5. If abnormal wear is observed at the bottom


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

KG906-1.0 33 04

Measurements are best taken by placing a


short straight-edge over points A and B and
then measuring the distance D-1.

Measure the geometry of the bottom and


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

5.

For assessing the measurement results,


contact MAN B&W Diesel.

KG906-1.0 37 05

In most cases, scratches caused by the


side plates of the chain will be found on the
sides of the teeth. Such scratches can generally be considered normal.

When referring to this page, please quote Procedure M90601 Edition 0207
0$1% :'LHVHO$6

Page 1 (4)

Chains

906-1.1

Checking
7.

6. The chains for the camshaft drive are


matched together to ensure an even load
distribution.

D-2

To keep such matching chains in their pairs,


the side plates of the outer link nearest to
the assembled link have been marked with
year, month, day and chain number.
Example:

HM906-1.0 32 00

D-3
No. 1 order,
840520 1A
840520 1B
(840520 1C, possible 3rd chain)
No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)
On the same links there is an arrow (>)
which indicates the mounting direction.
Check the chains for cracks on possibly defective rollers and side plates.
Check that the chain rollers can run freely
and that the chain links can freely move on
the pin and bushing (that they are not
seized between the pin and the bushing).
It is normal, however, that the rollers get
light, circumferential scratches during the
running-in period. These fine scratches are
of no importance and need not be considered.
It is recommended that each single link is
checked.
7. Check chain wear by measuring the length
of 10 chain links and comparing the result
with the value given in Data.
If necessary, adjust the chain tightener.
See Procedure 906-2.3.

Page 2 (4)

When referring to this page, please quote Procedure M90601 Edition 0207
0$1% :'LHVHO$6

Chains

906-1.2

Dismantling
Dismantling
906-1.2

It may become necessary to disassemble


the chain if, for instance, cracked rollers or
seizures between pin and bushing have
been discovered during the inspection.
See Procedure 906-1.1.

1.

Note!

When a new link is fitted in one chain, the


corresponding link in the other chain
must also be renewed.

HN906-1.2 207 01

Every time a chain link is disassembled,


a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.

1. Remove the tension on the chain by loosening the chain tightener.


(See Procedure 906-2.3).

2.

Turn the engine until the slack part of the


chain, with the chain link that is to be disassembled, is in a favourable position for
the work.

Protect the link rollers over which the wire


is wrapped.
Note!

GN906-1.2 203 02

2. Mount a wire round the link rollers a short


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

3.

If the chain is to be completely removed,


contact MAN B&W Diesel for further
information.
The riveting of the pins that are to be
pressed out is to be drilled or ground away.

GN906-1.2 203 03

3. Place the chain bursting tool over the outer


chain link, and dismantle the link by alternately tightening the screws on the tool.

When referring to this page, please quote Procedure M90601 Edition 0207
0$1% :'LHVHO$6

Page 3 (4)

906-1.4

Chains
Mounting
Mounting
906-1.4

1.

Before assembling the inner and outer


links, clean the pins and bushings.
1. Combine the inner chain link with the outer
chain link and mount the compression tool.
Force the loose side plate of the outer link
into place by alternately tightening the
screws on the compression tool.

GN906-1.4 203 01

2. When the link has been assembled, remove


the compression tool and lock the pin ends
by riveting.
Repeat this procedure until the chain has
been assembled.
Remove the tackle and wire and adjust the
chain tension.
(See Data and Procedure 906-2.3).

Page 4 (4)

When referring to this page, please quote Procedure M90601 Edition 0207
0$1% :'LHVHO$6

Chain Tightener

106-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0009
106-2

Standard Tools: See Section 913

Chain Tightener

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Clearance

D-2

Tightening angle
(= 12 hexagons)

Value Unit

0.1 mm
2 x 360

When referring to this page, please quote Data D10602 Edition 0009
MAN B&W Diesel A/S

Page 1 (2)

Chain Tightener

106-2

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10602 Edition 0009
MAN B&W Diesel A/S

Chain Tightener

906-2.3

Adjusting
Chain Tightener
S35MC
aa0211
Adjusting
906-2.3

1.

1. To retighten the chains, loosen nuts A, B,


C and D to free the chain tightener bolt.
2. Turn the engine so that the slack part of the
chains is on the same side as the tightener
wheel.

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


Data).
For chain wear, see Procedure 906-1.1.

DM906-2.1 81 01

3. Tighten nut B on the chain tightener bolt


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

DM906-2.2 95 01

2.

'

'

DM906-2.1 81 03

3.

When referring to this page, please quote Procedure M90602 Edition aa0211
0$1% :'LHVHO$6

Page 1 (2)

906-2.3

Chain Tightener
Adjusting

4.

4. Tighten nut C hard against the contact face


of the shaft.
Tighten nut D.
Lock nuts C and D with the tab washer.
5. Tighten nut A.
Lock nuts A and B with the tab washer.

DM906-2.1 81 04

The number of times that retightening can


be carried out depends on when the limit for
scrapping the chain has been reached. See
Data page 106-1.

DM906-2.1 81 05

5.

Page 2 (2)

When referring to this page, please quote Procedure M90602 Edition aa0211
0$1% :'LHVHO$6

Camshaft

106-3

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0006
106-3

Standard Tools: See Section 913

Camshaft

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Pin gauge for top dead centre


of crankthrow No. 1
Check measurement

355 mm

Pin gauge for camshaft


Check measurement

238 mm

Max. permissible change in


lead angle
corresponding to

2
2.5 mm

D-2

D-3

Value Unit

D-2

D-1

When referring to this page, please quote Data D10603 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Camshaft

106-3

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10603 Edition 0006
MAN B&W Diesel A/S

Camshaft

906-3.1

Checking
Camshaft
S35MC
0206
Checking
906-3.1

1.

Turn in the AHEAD direction to ensure that


the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
See Procedure 906-2.3.
Check the TDC of cylinder 1 against the
mark on the turning wheel.

HM906-7.0 56 01

1. Turn the crankthrow for cylinder 1 to TDC.

2. Check the TDC position with the pin gauge


on the crankthrow, D-1.

BG906-7.0 58 02

2.

When referring to this page, please quote Procedure M90603 Edition 0206
0$1% :'LHVHO$6

D-1

Page 1 (3)

Camshaft

906-3.1

Checking
3.

3. Position the camshaft pin gauge in the centre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see D-3.
4. Check and, of necessary, adjust the cylinder lubricator.
See Procedure 903-2.1.
Check the setting of the starting air distributor.
See Procedure 907-1.1.

BM906-3.1 206 03

5. When checking the camshaft position, also


check the running surface of the cams.

D-3
5.

As the inspection must include the entire


surface of the cam, the cam should be
turned one complete revolution during the
inspection.
The running surface of the cam must be
completely smooth and bright.

BM906-3.1 206 05

6. If light scratches are ascertained, remove


them by carefully polishing the cam in the
direction of rotation with a fine carborundum stone. 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,
MAN B&W Diesel should be contacted for
further instructions.

GN906-3.1 203 06

6.

Page 2 (3)

When referring to this page, please quote Procedure M90603 Edition 0206
0$1% :'LHVHO$6

Camshaft

906-3.3

Adjustment
Adjustment
906-3.3

1.

BM906-3.3 206 01

1. 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 Procedure 9063.1, MAN B&W Diesel should be contacted
for further instructions.

When referring to this page, please quote Procedure M90603 Edition 0206
0$1% :'LHVHO$6

D-3

Page 3 (3)

Camshaft Bearings

106-4

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0006
106-4

Standard Tools: See Section 913

Camshaft Bearings

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Weight of bearing cap

4 kg

D-2

Tightening torque
screws for bearing cap

50 Nm

D-3

Clearance between cap/


bearing housing

Value Unit

2.7-3.3 mm

D-4

Max. wear of bearing shell

0.10 mm

D-5

Clearance between thrust


disc/guide discs

0.05-0.20 mm

D-6

Tightening torque
screw for guide discs

20 Nm

When referring to this page, please quote Data D10604 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Camshaft Bearings

106-4

Data

Spare Parts
Plate Item No.

Description

Qty

90613-xxx 096

Guide disc

90613-xxx 143

Camshaft bearing shell

Page 2 (2)

When referring to this page, please quote Data D10604 Edition 0006
MAN B&W Diesel A/S

Camshaft Bearing

906-4.1

Checking
Camshaft Bearing
S35MC
0206
Checking
906-4.1

1.

1. Dismount the inspection covers from the


front of the camshaft housing.
Check for wiped-out metal at the bearing
ends, and for fragments of metal in the
camshaft housing.
In the event of any signs of anomalies, the
bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced.

3. If no anomalies are found during the visual


inspection, dismantling need only be carried out in connection with Class surveys.
See Checking and Maintenance Programme 900-1.

DM906-5.0 51 01

2. Dismount the inspection cover of cylinder


No. 1 and use a feeler gauge to check the
clearance between the thrust disc and the
guide discs. For max./min. clearance see
Data.

2.

BM906-5.0 47 09

D-5

When referring to this page, please quote Procedure M90604 Edition 0206
0$1% :'LHVHO$6

Page 1 (5)

906-4.2

Camshaft Bearing
Dismantling
Dismantling
906-4.2

1.
Warning!
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
See Procedure 906-2.3.
1. Remove the inspection covers on each side
of the bearing from the camshaft housing.
BM906-5.0 47 02

Dismount the lubricating oil connecting pipe


and the plug screws from the baseplate
above the bearing in question.
Lift the roller guide of the exhaust valve hydraulic pump. See Procedure 908-7.

2.

2. Loosen the bearing cap screws through the


holes in the baseplate.
Remove the screws from the bearing cap.

BG906-5.0 40 03

Remove the bearing cap from the housing.

Page 2 (5)

D-1

When referring to this page, please quote Procedure M90604 Edition 0206
0$1% :'LHVHO$6

Camshaft Bearing

906-4.2

Dismantling
3.

3. Place a hydraulic jack between two pieces


of wood in the camshaft housing underneath the camshaft, close to the bearing.
Place a dial gauge on the camshaft, and lift
the camshaft 0.20 mm.
4. Press lightly on the upper edge of the shell
to turn the shell up over the camshaft.

BG906-5.0 40 04

Remove the shell from the camshaft housing.

BG906-5.0 40 05

4.

When referring to this page, please quote Procedure M90604 Edition 0206
0$1% :'LHVHO$6

Page 3 (5)

Camshaft Bearing

906-4.3

Overhaul
Overhaul
906-4.3

1.

1. For assessment of the bearing condition,


see Volume I OPERATION, Chapter 708
Bearings.
Inspect the entire surface of the bearing
journal for seizures.
If seizures are found on the bearing journal
surface (on account of bearing breakdown),
polish the surface with a fine carborundum
stone to re-establish a bright and smooth
surface.

BG906-5.0 40 06

By closely examining the sliding surface of


the bearing shell visually, an impression
can be formed of whether the lubrication of
the bearing surface has been insufficient or
entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication.
Measure the thickness of the bearing shell
with a micrometer to check the amount of
wear.

D-4

2. If the checking indicates that the guide


discs need overhaul/replacement, remove
the horizontal screw and turn out the discs.

2.

Note!
Turning of the engine must not take
place until all camshaft bearing shells are
in place and the hydraulic jack has been
removed from underneath the camshaft.

D-6

BM906-5.0 47 10

Mount new discs. Mount and tighten the


screw as stated in Data.

Page 4 (5)

When referring to this page, please quote Procedure M90604 Edition 0206
0$1% :'LHVHO$6

Camshaft Bearing

906-4.4

Mounting
Mounting
906-4.4

2.

1. Clean the bearing journal, the bearing support and the bearing shell.
2. Coat the bearing journal and the bearing
shell with plenty of lubricating oil. Mount the
shell on the camshaft, and turn it into place.

3. Place the bearing cap on the camshaft and


mount the outermost bearing cap screw.
Note!

BG906-5.0 40 07

Relieve the hydraulic jack of pressure to


lower the camshaft. Remove the dial gauge,
the pieces of wood and the hydraulic jack
from the camshaft housing.

Be careful not to scratch the camshaft


surface.

3.

Tighten the outermost screw lightly by hand


until the clearance given in D-3 is reached.
Then mount and tighten the innermost
screw with a torque spanner. See Data D2. This procedure ensures that the outermost screw will obtain the correct torque.

D-2

Check the torque on the outermost screw


with a torque spanner.
BG906-5.0 40 08

Check the clearance D-3 on both sides of


the camshaft. Then mount the lubricating
oil pipe and the plug screws in the baseplate.

D-3

4. Clean the camshaft housing and mount the


inspection covers.

BG906-5.0 40 01

4.

When referring to this page, please quote Procedure M90604 Edition 0206
0$1% :'LHVHO$6

Page 5 (5)

Replacement of Cams on Camshaft

106-6

Data
SAFETY PRECAUTIONS
Special Data
0002
106-6

Standard Tools: See Section 913

Replacement of Cams on Camshaft

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear

18, 24 mm

17, 22 mm

Shut off cooling water


X

Shut off fuel oil

Shut off lubricating oil

1x3m
140-760 Nm
750-2000 Nm

Lock turbocharger rotors

Data
Ref.

Description

Value Unit

D-1

Marking scratch, fuel cam

60 mm

D-2

Fuel cam axial movement

114 mm

D-3

Tightening torque for screws


in fuel cam

120 Nm

D-4

Marking scratch, exhaust cam

60 mm

D-5

Exhaust cam axial movement

100 mm

D-6

Tightening torque for screws


in exhaust cam

120 Nm

When referring to this page, please quote Data D10606 Edition 0002
MAN B&W Diesel A/S

Page 1 (2)

Replacement of Cams on Camshaft

106-6

Data

Spare Parts
Plate Item No.

Description

Qty

90301-133 027

O-ring

90611-129 010

Screw

90611-129 022

Repair cam, fuel

90611-129 130

Repair cam, exhaust

90611-129 213

Cover

Page 2 (2)

When referring to this page, please quote Data D10606 Edition 0002
MAN B&W Diesel A/S

Replacement of Cams on Camshaft

906-6.2

Dismantling
Replacement of Cams on Camshaft
0202
Dismantling
906-6.2

1.

1. Remove the front cover of the camshaft


housing.
2. Lift the roller guide from the cam in question. See procedures 908-7 or 909-16.

4. Extend the marking scratch on the shaft by


D-4. See Data.

BM906-6.0 47 01

3. Turn the camshaft so that the marking


scratch can be seen.

BM906-6.0 47 02

2.

3.

BM906-6.0 47 03

D-4

When referring to this page, please quote Procedure M90606 Edition 0202
0$1% :'LHVHO$6

Page 1 (3)

906-6.2

Replacement of Cams on Camshaft


Dismantling

5.

5. Remove the plug from the cam and mount


three gaskets and a snap-on connector instead.
6. Connect the snap-on connectors to the hydraulic high-pressure pump.
7. Apply oil pressure to the cam, using the
high-pressure pump.
When oil seeps out along the cam, press
the cam sideways, in the direction towards
the other cam for the cylinder unit concerned.

BM906-6.0 47 05

The cam should be moved as stated in D-5


to be sure that it gets free of the liner for the
roller guide.

6.

BM906-6.0 47 06

D-5

BM906-6.0 47 07

7.

Page 2 (3)

When referring to this page, please quote Procedure M90606 Edition 0202
0$1% :'LHVHO$6

Replacement of Cams on Camshaft

906-6.4

Mounting
Mounting
906-6.4

1.

1. Before mounting the two-part spare cam,


the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,
mount the four screws, and tighten lightly,
so that the gap between the two parts is
equal at both sides.
2. Make sure that the marking scratches on
the cam and the camshaft coincide, and
that the running surface of the cam is opposite the roller.
BM906-6.0 47 08

Tighten the screws to D-6, and check that


the gap is still equal.

D-6

Lock the screws with Loctite, type 242


(EN243S).

2.

3. Lower the roller guide and mount the cover


on the front of the camshaft housing.
4. If it is the fuel cam that is to be changed,
use the same procedure for moving the
cam.

BM906-6.0 47 09

Extend the marking scratch on the shaft by


D-1, and move the fuel cam at least D-2
mm toward the other cam for the cylinder
unit concerned.

BM906-6.0 47 11

3.

When referring to this page, please quote Procedure M90606 Edition 0202
0$1% :'LHVHO$6

D-1

D-2 D-3
Page 3 (3)

Chain Drive and Camshaft Panel

When referring to this page, please quote Plate P90651 Edition 0176
MAN B&W Diesel A/S

Plate
P90651-0176

Page 1 (2)

Plate
P90651-0176
Item
No.
019
020
044
056
068
152

Page 2 (2)

Chain Drive and Camshaft Panel

Item Description

Item
No.

Item Description

Panel for tools


Name plate
Impact spanner, fuel cam
Assembling tool, chain
Disassembling tool, chain
Impact spanner, exhaust cam

When referring to this page, please quote Plate P90651 Edition 0176
MAN B&W Diesel A/S

Crankshaft - Pin Gauge

Plate
P90664-0003

Crankshaft - Pin Gauge


0003
P90664

When referring to this page, please quote Plate P90664 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90664-0003
Item
No.
010

Crankshaft - Pin Gauge

Item Description

Item
No.

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

Camshaft - Pin Gauge

Plate
P90668-0001

Camshaft - Pin Gauge


0001
P90668

When referring to this page, please quote Plate P90668 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90668-0001
Item
No.
011

Camshaft - Pin Gauge

Item Description

Item
No.

Item Description

Pin gauge for camshaft

Page 2 (2)

When referring to this page, please quote Plate P90668 Edition 0001
MAN B&W Diesel A/S

907 - Starting Air System


Documents in this Chapter
107-01
907-01
107-02
907-02

0021
0220
0019
0206

Starting Air Distributor, Data


Starting Air Distributor
Start Air Valve, Data
Starting Air Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Starting Air Distributor


MAN B&W Diesel

107-1

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

Engage turning gear


Shut off cooling water
Shut off fuel oil

Stop lubricating oil supply


Lock the turbocharger rotors

Data
Ref.

Description

D07-01

Gear wheel on camshaft, tightening torque

D07-03

Value

Unit
25

Nm

Clearance between gear wheel and bushing:

0.9 - 1.6

mm

D07-04

Clearance with roller in outermost position:

1.0 - 3.0

mm

D07-05

Clearance with roller in innermost position:

1.0 - 2.0

mm

When referring to this page, please quote Data D10701 Edition 0021

Page 1 (2)

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, e.g. P90951 refers to chapter 909.
Plate

Page 2 (2)

Item No.

Description

When referring to this page, please quote Data D10701 Edition 0021

Starting Air Distributor


MAN B&W Diesel

907-1.1

Checking

1. Turn the engine in AHEAD direction to bring


the piston of cylinder No. 1 to TDC.

1.

Check with the pin gauge.


2. Remove the plug screw and gasket from
the side of the distributor housing, and insert check pin K in slot S.

3. If the check pin cannot enter the slot, i.e. if


the slot is not aligned with the hole in the
distributor housing, the air distributor must
be adjusted.
See Procedure 907-1.3.

M907010220C01

If pin K is not available, use the cylindrical


end of a drill of a suitable size.

2.

M907010220C02

When referring to this page, please quote Procedure M90701 Edition 0220

Page 1 (4)

Starting Air Distributor

907-1.3

Adjustment

MAN B&W Diesel

1. Turn the engine in AHEAD direction to bring


the piston of cylinder 1 to TDC.

1.

Check with the pin gauge.


2. Dismount the end cover of the camshaft
housing, along with the starting air distributor, from the engine.
Loosen the bolts on the gear wheel.

M907010220C01

Turn the coupling together with the distributor disc until check pin K enters slot S
in the disc and keep it there.
Tighten the gear wheel bolts as stated in
Data D07-01.

2.

M907010220O02

D0701

Page 2 (4)

When referring to this page, please quote Procedure M90701 Edition 0220

Starting Air Distributor


MAN B&W Diesel

907-1.3

Adjustment

3. Check the clearance D07-03 between the


coupling wheel and the bushing.
If clearance does not correspond with D0703, please contact MAN B&W Diesel for
advice.

3.

4. Remove check pin K from the distributor


housing and mount the gasket and plug
screw.

M907010220O03

Mount the covers on the camshaft housing.

D0703

4.

M907010220O04

When referring to this page, please quote Procedure M90701 Edition 0220

Page 3 (4)

907-1.3

Starting Air Distributor


Adjustment

MAN B&W Diesel

5. Check the clearance between the roller and


the two interlocking valves with the roller in
its innermost and outermost positions, respectively (ASTERN and AHEAD).

5.

M907010220O05

D0704

Page 4 (4)

D0705

When referring to this page, please quote Procedure M90701 Edition 0220

Starting Air Valve

107-2

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0019
107-2

Standard Tools: See Section 913

Starting Air Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply


10-120 Nm

Engage turning gear


Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

Value Unit

D-1

Weight of starting air valve

D-2

Tightening-up torque

58 Nm

D-3

Valve tightening torque

25 Nm

7 kg

When referring to this page, please quote Data D10702 Edition 0019
MAN B&W Diesel A/S

Page 1 (2)

Starting Air Valve

107-2

Data

Plate

1849860-1.1

90151

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10702 Edition 0019
MAN B&W Diesel A/S

Starting Air Valve

907-2.1

Checking
Starting Air Valve
S35MC
0206
Checking
907-2.1

1.

1. When the starting air valve has been overhauled, see Procedure 907-2.3, connect a
supply of working air to the control air inlet
at the top of the valve.
Check that the valve opens approx. 15-20
mm.
2. Shut off the air supply
Check that the valve closes fully.

BM907-2.1 206 01

3. Repeat steps 1 and 2 a couple of times.

BM907-2.1 206 02

2.

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

Page 1 (6)

907-2.2

Starting Air Valve


Dismantling
Dismantling
907-2.2

1.

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


Dismount the control air pipe.
Unscrew the starting valve screws.

BG901-2.2 77 01

2. Pull the starting air valve out of the cylinder


cover and remove it from the engine.

2.

BM907-2.2 206 02

D-1

Page 2 (6)

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

Starting Air Valve

907-2.3

Overhaul
Overhaul
907-2.3

1.

1. Remove the top cover fixing screws and remove the cover.
Remove and discard the gasket.
2. Remove the split pin and screw off the nut
from the valve spindle.

Remove the valve spindle from the bottom


end of the valve housing. Remove and discard the O-ring.

AM907-4.0 49 01

3. Remove the disc, the piston, the valve


spring, the distance pipe, and the liner from
the top end of the valve housing.

AM907-4.0 49 02

2.

AM907-4.0 49 03

3.

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

Page 3 (6)

907-2.3

Starting Air Valve


Overhaul

4.

4. Grind the valve housing seating with the


grinding ring after applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle and housing to match, using the face wrench to rotate the valve spindle.
Carborundum No. 500.
5. Thoroughly clean all parts before reassembling the valve.
Lubricate all internal parts (sliding surfaces) with, for instance, Molybdenum Disulphide, MoS 2.

GN907-2.3 203 03

6. First mount the liner in the valve housing,


then the valve spindle, the distance pipe,
the spring, the piston and the disc.

AM907-4.0 49 03

6.

Page 4 (6)

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

Starting Air Valve

907-2.3

Overhaul
7.

7. Mount the nut on the valve spindle and


tighten the nut, see D-2.

D-2

Mount the split pin.


8. Place a new gasket on the valve housing.
Mount and tighten the top cover.
Replace the O-ring on the valve housing.

AM907-4.0 49 02

9. If the starting air valve is not to be mounted


in the engine immediately after the overhaul, all openings of the valve should be
covered with plastic to prevent dirt from entering the valve during storage.

8.

AM907-4.0 49 07

D-1

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

Page 5 (6)

Starting Air Valve

907-2.4

Mounting
Mounting
907-2.4

1.

1. Carefully clean the starting valve bore in


the cylinder cover and, if necessary, recondition the seat for the starting valve in the
bore.
See Procedure 901-1.3.
If not already done, replace the O-ring on
the overhauled valve and lubricate with
Never Seize or Molybdenum Disulphide,
MoS 2.
For overhaul, see Procedure 907-2.3.

AM907-4.0 49 08

2. Mount the valve in the cylinder cover.


Mount and tighten the screws as stated in
Data.
Mount the control air pipe and turn on starting air and control air.

2.

BG901-2.2 77 03

D-3

Page 6 (6)

When referring to this page, please quote Procedure M90702 Edition 0206
0$1% :'LHVHO$6

908 - Exhaust Valve


Documents in this Chapter
108-01
908-01
108-03
908-03
108-04
908-04
108-05
908-05
108-07
908-07
90851
90861
90862
90863

0007
0207
0022
0209
0027
0215
0006
0210
0018
0216
0206
0038
0038
0007

High-Pressure Pipe, Data


High-Pressure Pipe
Exhaust Valve Actuator, Data
Exhaust Valve Actuator
Exhaust Valve Roller Guide, Data
Exaust Valve Roller Guide
Exhaust Valve Cam, Data
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
Exhaust Valve - Panel
Exhaust Valve - Tools
Exhaust Valve - Hydraulic Tools
Exhaust Valve - Extra Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

High-Pressure Pipe

108-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0007
108-1

Standard Tools: See Section 913

High-Pressure Pipe

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
10-120 Nm

Shut off cooling water


Shut off fuel oil
X

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

D-1

Weight of high-pressure pipe

11 kg

D-2

Tightening torque
High-pressure pipe

30 Nm

When referring to this page, please quote Data D10801 Edition 0007
MAN B&W Diesel A/S

Page 1 (2)

High-Pressure Pipe

108-1

Data

Spare Parts
Plate Item No.

Description

Qty

90806-xxx 095

O-ring

90806-xxx 213

O-ring

90806-xxx 249

O-ring

Page 2 (2)

When referring to this page, please quote Data D10801 Edition 0007
MAN B&W Diesel A/S

High-Pressure Pipe

908-1.2

Dismantling
High-Pressure Pipe
S35MC
0207
Dismantling
908-1.2

1.

1. When replacing the hydraulic high-pressure


pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing surfaces.
2. Before dismounting the high-pressure pipe,
stop the camshaft oil pump.
Loosen the screws for the high-pressure
pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator.

D-1

GN908-1.2 203 01

3. Remove the screws in both ends of the


high-pressure pipe. Lift the high-pressure
pipe away from the engine.

GN908-1.2 203 02

2.

When referring to this page, please quote Procedure M90801 Edition 0207
0$1% :'LHVHO$6

Page 1 (3)

908-1.3

High-Pressure Pipe
Overhaul
Overhaul
908-1.3

1.

The two ends of the pipe are identical and


should both be overhauled as follows:
1. Remove the thrust piece from the actuator/
exhaust valve.
Remove and discard the O-rings from the
thrust piece and the thrust flange.
Clean and inspect the conical seats of the
high-pressure pipe and the thrust piece.

GN908-1.3 203 01

Note!
The seats cannot be reconditioned.
If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-part
sleeve.
3. Remove the thrust flange from the pipe
end.

DM908-1.1 61 02

Remove and discard the internal O-rings.


Mount new internal O-rings lubricated with
a little camshaft lubricating oil.
4. Assemble the high-pressure pipe in the reverse order to disassembling.

DM908-1.1 61 03

3.

Page 2 (3)

When referring to this page, please quote Procedure M90801 Edition 0207
0$1% :'LHVHO$6

High-Pressure Pipe

908-1.4

Mounting
Mounting
908-1.4

1.

1. Mount new O-rings, lubricated with a little


camshaft lubricating oil, on the thrust pieces and thrust flanges.
Mount the thrust pieces on the actuator/exhaust valve.
Mount the high-pressure pipe on the engine.
Note!
When mounting the high-pressure pipe,
take care not to damage the conical
seats of the pipe/thrust pieces.

3. Check the system for tightness.


See Procedure 908-3.1.

GN908-1.2 203 01

2. After fitting the pipe to the exhaust valve


and actuator, tighten up the screws of the
pressure flanges diagonally, see Data.

2.

GN908-1.4 203 02

D-2

When referring to this page, please quote Procedure M90801 Edition 0207
0$1% :'LHVHO$6

Page 3 (3)

Exhaust Valve Actuator

108-3

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0022
108-3

Standard Tools: See Section 913

Exhaust Valve Actuator

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil

140-760 NM

Lock turbocharger rotors


2 x M12

Data
Ref.

Description

Value Unit

D-1

Weight of hydraulic actuator

30 kg

D-2

Oil cylinder, inside diameter


max.

50.2 mm

D-3

Piston rings, min. thickness

2.0 mm

D-4

Actuator tightening torque


or tightening angle

350 Nm
46

When referring to this page, please quote Data D10803 Edition 0022
MAN B&W Diesel A/S

Page 1 (2)

Exhaust Valve Actuator

108-3

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10803 Edition 0022
MAN B&W Diesel A/S

Exhaust Valve Actuator

908-3.1

Checking
Exhaust Valve Actuator
0209
Checking
908-3.1

1.

1. The non-return valve A is built into the oil


inlet pipe to the actuator.
To check the valve, 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). If an air flow is felt at the
inlet side of the valve, it must be overhauled.

On some engines the exhaust valve actuator is equipped with a puncture valve, which
will delay opening of the exhaust valve until
the starting air sequence has finished.

BM908-3.1 207 01

During the starting sequence in ASTERN direction, the exhaust valve will start to open
while the cylinder is still being supplied with
starting air.

Note !
The puncture valve is not standard on all
engines.

When referring to this page, please quote Procedure M90803 Edition 0209
0$1% :'LHVHO$6

Page 1 (4)

908-3.2

Exhaust Valve Actuator


Dismantling
Dismantling
908-3.2

1.

1. Stop the engine and shut off the oil supply.


Turn the camshaft so that the roller rests on
the circular part of the cam.
Remove the inspection cover of the camshaft housing to inspect the position of the
exhaust cam.
Dismount the oil inlet pipe from the exhaust
valve actuator.

BG908-4.0 52 01

Dismount the screws of the high-pressure


pipe flange, and lift away the high-pressure
pipe. See Data.
See Procedure 908-1.
2. Fit eye bolts in the lifting holes of the actuator housing and hook on a tackle.

2.

D-1

Unscrew the nuts on the two short studs,


then loosen the nuts on the long studs successively until the tension of the roller guide
spring is relieved.
Dismount the nuts and lift the housing carefully up, leaving the piston on the top of the
roller guide.
Remove the spring.

BG908-4.0 52 12

3. Remove the locking plate for the piston.


Turn the piston 90 to free it from the bayonet joint.
Remove the piston from the roller guide.

BG908-3.0 71 03

3.

Page 2 (4)

When referring to this page, please quote Procedure M90803 Edition 0209
0$1% :'LHVHO$6

Exhaust Valve Actuator

908-3.3

Overhaul
Overhaul
908-3.3

1.

1. Clean the piston in kerosene and blow dry


with compressed air.

TOP

Take off the piston rings and check them for


wear. If the ring thickness has worn down
to the minimum, see Data, discard the rings
and mount new ones.
Check that the TOP mark on the piston
rings faces upwards when mounting.
Inspect the sliding surfaces of the piston for
scratching or seizure marks.

D-3

2. Clean the oil cylinder and inspect the bores


for deposits.
Check the bore of the oil cylinder for possible scores and measure it for wear.

BG908-3.0 71 04

If the bore is seized or has worn up to the


maximum diameter, see Data, send the oil
cylinder to an MAN B&W authorised workshop for reconditioning.

2.

BG908-3.0 71 05

D-2

When referring to this page, please quote Procedure M90803 Edition 0209
0$1% :'LHVHO$6

Page 3 (4)

908-3.4

Exhaust Valve Actuator


Mounting
Mounting
908-3.4

1.

1. Mount the actuator piston in the roller guide


and turn 90 to lock it in the bayonet joint.
Mount the locking plate and tighten, see
Data. Lubricate the piston with plenty of
camshaft lubricating oil.
2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.

BM908-3.4 207 01

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.
Mount the washers and nuts on the two
short studs. Tighten all four nuts as stated
in Data.

2.

D-1

3. Mount the oil inlet pipe on the exhaust valve


actuator.

D-4

Mount the hydraulic high pressure pipe.


See Procedure 908-1.

BG908-4.0 52 12

D-5

BM908-3.4 207 03

3.

Page 4 (4)

When referring to this page, please quote Procedure M90803 Edition 0209
0$1% :'LHVHO$6

Exhaust Valve Roller Guide

108-4

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0027
108-4

Standard Tools: See Section 913

Exhaust Valve Roller Guide

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

D-1

Weight of roller guide,


complete

9 kg

Max. clearance
roller/bushing/shaft pin

0.5 mm

D-2

Value Unit

When referring to this page, please quote Data D10804 Edition 0027
MAN B&W Diesel A/S

Page 1 (2)

Exhaust Valve Roller Guide

108-4

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10804 Edition 0027
MAN B&W Diesel A/S

Exhaust Valve Roller Guide

908-4.1

Checking
Exhaust Valve Roller Guide
S35MC
0215
Checking
908-4.1

2.

1. The exhaust valve roller guide can be partially checked while mounted on the engine,
using the following procedure:
Lift the roller guide.
See Procedure 908-5.
2. Remove the camshaft inspection cover.

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.

GN908-4.1 203 01

Turn the engine to provide the maximum


space between the roller guide and the cam
disc.

5.

Also inspect the surface of the roller for


possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide housing.

D-2

Check the clearance in the slide bearing by


lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
3. A more suitable and reliable method is to
check the roller guide and the bearing
clearance when the roller guide is dismounted.
For dismantling of the roller guide see Procedure 908-4.2.

5. To measure the clearance in the roller


guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.

BG908-4.0 52 04

4. Inspect the surfaces of the roller guide and


the roller for damage marks, seizures or
scratches.

6. Place a dial gauge against the roller. Then


lift the roller as much as the clearance permits, which makes it possible to read the
clearance D-2 directly on the dial.

When referring to this page, please quote Procedure M90804 Edition 0215
MAN B&W Diesel A/S

Page 1 (4)

908-4.2

Exhaust Valve Roller Guide


Dismantling
Dismantling
908-4.2

1.

1. Dismantle the hydraulic actuator above the


exhaust valve roller guide.
See Procedure 908-3.2.

BG908-4.0 52 12

2. Lift the roller guide out of the roller guide


housing by hand. Take care not to damage
the sliding surfaces of the roller guide when
lifting.

2.

BM908-4.2 215 02

D-1

Page 2 (4)

When referring to this page, please quote Procedure M90804 Edition 0215
MAN B&W Diesel A/S

Exhaust Valve Roller Guide

908-4.3

Overhaul
Overhaul
908-4.3

1. Inspect and check the exhaust valve roller


guide.
See Procedure 909-15.1.

1.

2. It is recommended that the roller guide


should ONLY be overhauled/dismantled if

D-1

irregularities when turning the roller,


damage to the roller,
larger clearance than stated on the Data
sheet,
seizure marks on the slide surfaces,
have been observed during the checking of
the roller guide.

For disassembling of the roller guide,


contact an MAN B&W authorized repair
shop.

BM908-4.3 215 01

Note!

3. If no irregularities are found, just clean and


lubricate the roller guide before remounting
it in the roller guide bushing.

3.

BM908-4.3 215 03

D-1

When referring to this page, please quote Procedure M90804 Edition 0215
MAN B&W Diesel A/S

Page 3 (4)

908-4-4

Exhaust Valve Roller Guide


Mounting
Mounting
908-4-4

1.

1. Clean and lubricate the sliding surfaces of


the roller and the roller guide and lower it
carefully into the roller guide bushing by
hand.

GN908-4.2 215 01

D-1

2. Mount the actuator.


See Procedure 908-3.4.

BG908-4.0 52 12

2.

Page 4 (4)

When referring to this page, please quote Procedure M90804 Edition 0215
MAN B&W Diesel A/S

Exhaust Valve Cam

108-5

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0006
108-5

Standard Tools: See Section 913

Exhaust Valve Cam

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D10805 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Exhaust Valve Cam

108-5

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D10805 Edition 0006
MAN B&W Diesel A/S

Exhaust Valve Cam

908-5.1

Checking
Exhaust Valve Cam
S35MC
0210
Checking
908-5.1

1.

2. Turn in AHEAD direction until the roller guide


(measured on the activator plunger) is lifted
10.0 mm, and calculate the angle A, which
is the number of degrees the crankthrow
has turned from TDC position to the
present position.

HM906-7.0 56 01

1. Turn the crankthrow of the cylinder concerned to TDC. Check and note down the
angle indicated on the turning wheel.

2.

Continue turning AHEAD until the roller


guide (measured on the activator plunger)
is lifted 10.0 mm, and calculate the angle
B, which is the number of degrees the
crankthrow has turned from TDC position to
the present position.
17

Note!

3. Calculate the lead angle as:


180 A + B
2

HM908-7.0 25 1/1

When calculating the angles A and B,


remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees.

The illustration shows the position of the


exhaust cam when the piston of the relevant cylinder is in TDC.

4.

See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the "lead angle" of the plant in question.
4. 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.

HM908-7.0 25 1/1

At the same time, it is recommended to


check the position of the camshaft with the
pin gauge. See Procedure 906-3.1.

When referring to this page, please quote Procedure M90805 Edition 0210
0$1% :'LHVHO$6

Page 1 (1)

Exhaust Valve

108-7

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0018
108-7

Standard Tools: See Section 913

Exhaust Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water
Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D10807 Edition 0018
MAN B&W Diesel A/S

Page 1 (2)

Exhaust Valve

108-7

Data

Plate

1849864-9

90851

Spare Parts
Plate Item No.

Description

Qty

90301-xxx 027

O-ring

Page 2 (2)

When referring to this page, please quote Data D10807 Edition 0018
MAN B&W Diesel A/S

Exhaust Valve

908-7

Special Running
Exhaust Valve
S35MC
0216
Special Running
908-7

3.

Engine trouble might require that a cylinder be


taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve
locked in either the open or the closed position.
Either way, carry out the following procedure:

2. Dismantle the hydraulic high-pressure pipe.


See Procedure 908-1.2.
3. Dismantle the oil inlet pipe. Blank off the
connection from the main oil pipe with a
plug screw.

BM908-7.0 206 03

1. Lift the relevant fuel pump roller guide.


See Procedure 909-10.

4.

4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.

Tighten the lowermost nut on the tool to pull


up the roller guide as far as possible.

GN908-4.1 203 01

5. Position the lifting tool on the actuator and


screw the spindle into the top of the actuator piston.

Tighten the upper nut of the tool against the


lower nut to secure the roller guide in this
position.

5.

BG908-5.0 53 02

6. If the cylinder is to operate with the exhaust


valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.

When referring to this page, please quote Procedure M90807 Edition 0216
0$1% :'LHVHO$6

Page 1 (3)

908-7

Exhaust Valve
Special Running

7.

If the cylinder is to operate with the exhaust


valve open, continue the procedure as follows:
7. Turn off the air to the exhaust valve.
Remove the air pipe and the non-return
valve on the aftmost side of the air cylinder
to let the air inside the air cylinder escape.

DM908-6.0 21 02

8. Dismantle the rotation indicator on the air


cylinder and mount the tool for opening of
the exhaust valve.
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.

BG908-6.0 13 04

8.

Page 2 (3)

When referring to this page, please quote Procedure M90807 Edition 0216
0$1% :'LHVHO$6

Exhaust Valve

908-7

Special Running
9.

After overhaul of the cylinder unit, re-engage


the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower
the roller guide on to the exhaust cam. Remove the tool.
10. If the engine has been running with the exhaust valve open, remove the tool mounted
in the air cylinder and mount the rotation indicator.
Note!
The rotation indicator should only be left
in the engaged position for short periods
of time during operation of the engine.
Leaving the rotation indicator in the
engaged position continuously might
damage the exhaust valve due to the formation of a wear groove in the air piston
of the exhaust valve.
Re-connect the air supply to the air cylinder.

12. Mount the hydraulic high-pressure pipe.


See Procedure 908-1.4.
13. Engage the fuel pump roller guide.
See Procedure 909-10.

BG908-5.0 53 04

11. Remove the plug screw and mount the oil


inlet pipe.

BM908-7.0 206 11

11.

When referring to this page, please quote Procedure M90807 Edition 0216
0$1% :'LHVHO$6

Page 3 (3)

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)

Plate
P90851-0206
Item
No.
016
028
077
089
090
124
150
173
185
219

Page 2 (2)

Exhaust Valve - Panel

Item Description

Item
No.

Item Description

Panel for tools


Name plate
Conical ring, pneumatic piston
Pressure tester, safety valve
Gauge, exhaust valve spindle
Tool, emergency opening of exhaust
valve
Gauge, exhaust valve bottom piece
Lifting tool, exhaust valve roller guide
Grinding ring, exhaust valve bottom
piece
Eye bolts

When referring to this page, please quote Plate P90851 Edition 0206
MAN B&W Diesel A/S

Exhaust Valve - Tools

When referring to this page, please quote Plate P90861 Edition 0038
MAN B&W Diesel A/S

Plate
P90861-0038

Page 1 (2)

Plate
P90861-0038
Item
No.
010

Exhaust Valve - Tools

Item Description

Item
No.

Item Description

Support grinding machine*


Note:
* When ordering spare parts, please
refer to the Chris Marine manual

Page 2 (2)

When referring to this page, please quote Plate P90861 Edition 0038
MAN B&W Diesel A/S

Exhaust Valve - Hydraulic Tools

Plate
P90862-0038

Exhaust Valve - Hydraulic Tools


0038
P90862

When referring to this page, please quote Plate P90862 Edition 0038
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90862-0038
Item
No.
028
030
053
065
089
090
100
207

Exhaust Valve - Hydraulic Tools

Item Description

Item
No.

Item Description

Hydraulic jack, complete


Support
O-ring with back-up ring
O-ring with back-up ring
Ball handle
Key, hexagon socket screws
Stud setter
Hydraulic tool-set, complete

Page 2 (2)

When referring to this page, please quote Plate P90862 Edition 0038
MAN B&W Diesel A/S

Exhaust Valve - Extra Tools

Plate
P90863-0007

When referring to this page, please quote Plate P90863 Edition 0007

Page 1 (2)

Exhaust Valve - Extra Tools


0007
P90863

MAN B&W Diesel A/S

Plate
P90863-0007
Item
No.
011

Exhaust Valve - Extra Tools

Item Description

Item
No.

Item Description

Worktable

Page 2 (2)

When referring to this page, please quote Plate P90863 Edition 0007
MAN B&W Diesel A/S

909 - 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

0056
0239
0046
0228
0043
0221
0046
0222
0040
0218
0027
0210
0038
0216
0011
0208
0051
0236
0039
0223
0056
0235
0047
0227
0017
0212
0440
0037
0069
0008

Fuel Pump Lead, Data


Fuel Pump Lead
Fuel Pump Cam, Data
Fuel Pump Cam
Fuel Pump, Data
Fuel Pump
Fuel Pump Top Cover, Data
Fuel Pump Top Cover
Fuel Pump Barrel Assembly, Data
Fuel Pump Barrel Assembly
Fuel Pump Suction Valve, Data
Fuel Pump Suction Valve
Fuel Pump Puncture Valve, Data
Fuel Pump Puncture Valve
Fuel Pump Shock Absorber, Data
Fuel System Shock Absorber
Fuel Valve, Data
Fuel Valve
Spindle Guide, Data
Spindle Guide
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
Fuel Pump Spec. Runni
Fuel Pump Special Running
Fuel Valve and Fuel Pump - Panel
Fuel Valve - Tools
Fuel Valve - Tools
Fuel Valve Nozzle - Tools

MAN B&W Diesel A/S

90968
90974
90980

0001
0001
0002

Fuel Valve - Inspection Tools


Fuel Valve Nozzle - Cleaning Tools
Mounting Tools - Air Piston Seals

MAN B&W Diesel A/S

Fuel Pump Settings

109-1

Data
SAFETY PRECAUTIONS
Special Edition
D10901
S35MC
109-1
Data 0056

Fuel Pump Settings

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

D09-01
D09-05
D09-10

Description

One shim alters pmax


Nominal shim thickness
Max. number of shims

When referring to this page, please quote Data D10901 Edition 0056
MAN B&W Diesel A/S

Value Unit

2 bar
0.5 mm
12 pcs.

Page 1 (2)

Fuel Pump Settings

109-1

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

P90951

Page 2 (2)

Item No. Description

200

Hexagon head screZIRUWRSFRYHU

When referring to this page, please quote Data D10901 Edition 0056
MAN B&W Diesel A/S

Fuel Pump Settings

909-1.3

Adjustment
Fuel Pump Settings
S46MC-C
0239
Adjustment
909-1.3

1.

Before adjustment of the fuel pump is carried


out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:

Remove the two screws in the threaded


holes of the top cover.
2. Screw the two dismantling screws (from the
tool panel) into the theaded holes of the top
cover, thus lifting the top cover to provide
space for inserting or removing shims.

EN909-1.3 239 01

1. Before Maximum Combustion Pressure


(p max) is adjusted, loosen the drain oil pipe
from the top cover and dismount the top
cover fixing nuts.

3.

To decrease p max, insert shims (delay injection).


One shim will alter p max approximately as
given in Data D09-01.

GN909-1.3 205 02

3. To increase p max, remove shims (advance


injection).

For nominal shim thickness, see Data D0905.

4.

For maximum inserted number of shims,


see Data D09-10.
Note down the new total shim thickness
(number of shims).

Note!
The individual p max value must not deviate more than 3 bar from the average
value for all cylinders.

GN909-1.3 205 03

4. Remove the dismantling screws, and press


down the top cover by hand. Mount the two
original screws to protect the threaded
holes. Mount and tighten the nuts for the
top cover, see Procedure 909-5.

When referring to this page, please quote Procedure M90901 Edition 0239
0$1% :'LHVHO$6

Page 1 (2)

909-1.3

Fuel Pump Settings


Adjustment

5.

If the required p max adjustment cannot be


attained by inserting or removing shims, it
is possible to carry out the adjustment on
the fuel cam disc. Contact MAN B&W Diesel for advice.
MIP adjustment:

EN909-1.3 239 05.

5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump
index arm.
Increase index for higher p i.
Decrease index for lower p i.

Note!
The mean indicated pressure is one of
the most important parameters, in obtaining good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the average value for all cylinders. See Volume I,
Chapter 706.

Page 2 (2)

When referring to this page, please quote Procedure M90901 Edition 0239
0$1% :'LHVHO$6

Fuel Pump Cam

109-3

Data
SAFETY PRECAUTIONS
109-3
Special Edition
D10903
Data 0046

Fuel
S46MCC
Pump Cam

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

Description

When referring to this page, please quote Data D10903 Edition 0046
MAN B&W Diesel A/S

Value Unit

Page 1 (2)

Fuel Pump Cam

109-3

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

P90651
P90951

Page 2 (2)

Item No. Description

44
45

Impact wrench for turning cam


Measuring tool for fuel pump

When referring to this page, please quote Data D10903 Edition 0046
MAN B&W Diesel A/S

Fuel Pump Cam

909-3.1

Checking
Fuel Pump Cam
S46MC-C
0228
Checking
909-3.1

1.

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.
1. To measure the fuel cam lead (top lift):
Dismantle the suction valve and the puncture valve. See Procedures 909-7.2 and
909-8.2.

x2

fuel cam

Make sure that the reversing mechanism is


in AHEAD direction.

ahead
EN909-3.1 228 00

2. Push down the measuring pin through the


top cover, until it rests against the pump
plunger.

x1 roller guide

Turn the engine until the lowest point of the


cam is found, use a calliper to find the
point.

Lowest position
of pump plunger

Main piston in TDC

3.

3. Measure the distance x from the top of the


measuring pin to the top cover.
Note down the result as x2.
4. Turn ahead until the main piston of the cylinder concerned is in TDC.
Again measure the distance x from the top
of the measuring tool to the top cover. Note
down the result as x1.
Calculate the fuel cam lead C (top lift) as:

5. Note down the result for comparison with


the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.

JG909-2.1 92 02

C = x1 x2 (mm)

4.

HM906-7.0 56 01

Remount the suction valve and the puncture valve.

When referring to this page, please quote Procedure M90903 Edition 0228
0$1% :'LHVHO$6

Page 1 (3)

909-3.3

Fuel Pump Cam


Adjustment
Adjustment
909-3.3

1.

Normally, adjustment of the fuel cam should not


be necessary. Before adjustment of fuel equipment, see Volume I, Chapter 706.
1. Remove the inspection cover from the camshaft housing.

GN909-3.3 203 01

Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.

2. Dismount the puncture valve and the suction valve from the fuel pump top cover, and
mount the measuring tool.
See Procedure 909-3.1.
3. Turn the camshaft until there is access to
the oil ducts in the fuel cam through the inspection hole.
If fitted, remove the plugs from the oil ducts
(using, for instance, a screwdriver).
Insert three copper gaskets in each oil duct.

BM909-1.1 236 03

Mount snap-on couplings in the oil ducts,


but do not tighten them.
Fit hoses between the snap-on couplings
and the distributor block and between the
distributor block and the hydraulic highpressure pump.

GN909-3.3 204 04

3.

Page 2 (3)

When referring to this page, please quote Procedure M90903 Edition 0228
0$1% :'LHVHO$6

Fuel Pump Cam

909-3.3

Adjustment
4.

4. Mount the special spanner on the fuel cam


disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snap-on couplings.

Keep the cam pressurised for at least five


minutes before turning the cam.
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,
until the desired change of lead is obtained.

GN909-3.3 204 05

Raise the hydraulic pressure until oil seeps


out along the camshaft under the cam disc.

To increase lead and p max:


turn the cam disc AHEAD.
To reduce lead and p max:
turn the cam disc ASTERN.
See Procedure 909-1.
5. After completing the desired turning of the
cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes the cam must be
allowed time to settle before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the
fuel cam lead again.
Note down and file the new results for purposes of comparison with future measurements and adjustment.
6. Mount the inspection cover on the camshaft
housing.
7. Mount a new O-ring on the puncture valve.
Mount the puncture valve and the fuel oil
high pressure pipes.
See Procedure 909-8.4 and 909-14.4.

When referring to this page, please quote Procedure M90903 Edition 0228
0$1% :'LHVHO$6

Page 3 (3)

Fuel Pump

109-4

Data
SAFETY PRECAUTIONS
Special Edition
D10904
S35MC
109-4
Data 0043

Fuel Pump

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

D09-18
D09-19
D09-20

Description

Pump housing nuts, tightening torque


Pump housing nuts, tightening angle
Pump housing

When referring to this page, please quote Data D10904 Edition 0043
MAN B&W Diesel A/S

Value Unit

350 Nm
108
38 kg

Page 1 (2)

Fuel Pump

109-4

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

P90951

Page 2 (2)

Item No. Description

70

Lifting tool for fuel pump housing

When referring to this page, please quote Data D10904 Edition 0043
MAN B&W Diesel A/S

Fuel Pump

909-4.2

Dismantling
Fuel Pump
S46MC-C
0221
Dismantling
909-4.2

2.
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
1. Dismantle the fuel pump top cover/plunger
barrel assembly.
See Procedure 909-5.2.
2. Remove the fuel oil inlet pipe between the
fuel pump and the fuel oil inlet valve.
Discard the gaskets.

Mount the lifting tool and lift the fuel pump


housing away.
Note!

BM909-4.2 210 02

3. Remove the nuts at the base of the fuel


pump.

Take care not to damage the threads of


the studs.

3.

Land the fuel pump on wooden planks.

BM909-4.2 210 03

D09-20

When referring to this page, please quote Procedure M90904 Edition 0221
MAN B&W Diesel A/S

Page 1 (5)

909-4.3

Fuel Pump
Overhaul
Overhaul
909-4.3

1.

1. Tilt the fuel pump housing into a horizontal


position on the wooden planks.
2. Remove the bottom plate from the fuel
pump housing.
If the bottom plate sticks, loosen it by
screwing two M8x50 mm screws into the
threaded holes of the bottom plate.

BM909-4.3 210 01

3. Dismantle the:
Fuel oil index arm.
Regulating guide.

BM909-4.3 210 02

2.

BM909-4.3 210 03

3.

Page 2 (5)

When referring to this page, please quote Procedure M90904 Edition 0221
MAN B&W Diesel A/S

Fuel Pump

909-4.3

Overhaul
4.

4. Dismantle and inspect the erosion plugs on


both sides of the fuel pump housing.
If heavily eroded, replace the erosion plugs.
5. Clean all the parts in diesel oil or kerosene.
Blow dry with compressed air.
Warning!

6. Mount a new sealing ring in the pointer for


the fuel oil index arm.
Note!

BM909-4.3 210 04

Always use eye protection when working


with compressed air.

Soak the sealing ring in lubricating oil


before mounting.

6.

Depending on engine type, the index pointer can have a different shape, see the
sketch.

HC909-3.4 121 11

BM909-4.3 210 06

7. Clean all inside surfaces of the fuel pump


housing.

When referring to this page, please quote Procedure M90904 Edition 0221
MAN B&W Diesel A/S

Page 3 (5)

909-4.3

Fuel Pump
Overhaul

9.

8. Lubricate the following with molybdenum disulphide grease (MoS 2):


All internal surfaces of the fuel pump
housing.
The sliding surfaces of all the parts of the
regulating system.

BM909-4.3 210 09

The teeth of the:


Regulating guide.
Fuel index arm.
9. Mount the fuel oil index arm.

10.

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.
Mount the fuel oil index pointer.
10. Mount the regulating guide in the fuel pump
housing, ensuring that the scratch mark on
the regulating guide is aligned with the
scratch mark on the fuel oil index arm.

BM909-4.3 210 10

11. Mount the bottom plate on the fuel pump


housing.

BM909-4.3 210 02

11.

Page 4 (5)

When referring to this page, please quote Procedure M90904 Edition 0221
MAN B&W Diesel A/S

Fuel Pump

909-4.4

Mounting
Mounting
909-4.4

1.
Note!
Before mounting the fuel pump housing,
make sure that all sliding faces and
threads are cleaned and lubricated with
molybdenum disulphide grease (MoS 2).

D09-19
D09-18
D09-20

See Procedure 913-11.


1. Lower the fuel pump housing on to the
pump base, taking care not to damage the
threads of the studs.
Remove the lifting tool.
Mount and tighten the nuts at the base of
the fuel pump housing. See Data.

Only use either the tightening angle or


the tightening torque, not both.
2. Mount the fuel oil inlet pipe between the
fuel pump and the fuel inlet valve.

BM909-4.2 210 03

Note!

2.

BM909-4.4 210 02

3. Mount the fuel pump top cover/plunger-barrel assembly.


See Procedure 909-5.4.

When referring to this page, please quote Procedure M90904 Edition 0221
MAN B&W Diesel A/S

Page 5 (5)

Fuel Pump Top Cover

109-5

Data
SAFETY PRECAUTIONS
Special Edition
D10905
S35MC
109-5
Data 0046

Fuel Pump Top Cover

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

D09-23
D09-24
D09-25
D09-26
D09-27
D09-28

Description

Top cover studs, screwing-in torque


Top cover nuts, tightening torque
Pump barrel/top cover, tightening torque
Outlet seat, max.grinding diameter
Top cover
Plunger/barrel assembly + top cover

When referring to this page, please quote Data D10905 Edition 0046
MAN B&W Diesel A/S

Value Unit

40
30
15
10
11
20

Nm
Nm
Nm
mm
kg
kg

Page 1 (2)

Fuel Pump Top Cover

109-5

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

P90951
P90951
P90951
P90951

Page 2 (2)

Item No. Description

69
94
200
212

Lifting tool for fuel pump


Milling tool for fuel oil pipe seats
Hexagon head screZIRUWRSFRYHU
Extraction tool for suctions valve

When referring to this page, please quote Data D10905 Edition 0046
MAN B&W Diesel A/S

Fuel Pump Top Cover

909-5.2

Dismantling
Fuel Pump Top Cover
S46MC-C
0222
Dismantling
909-5.2

1.

1. Close the oil inlet valve to the fuel oil pump


and drain the pump.
Dismount the drain oil pipe from the top
cover and the air pipe connection to the
puncture valve.
Dismount the high pressure pipes.
See Procedure 909-14.

Dismount the fuel index pointer.


2. Dismount the suction valve by means of the
extractor tool.

GN909-5.2 208 01

Dismount the puncture valve from the top


cover. See Procedure 909-8.

2.

3. Remove the top cover fixing nuts, as well as


the two screws in the top cover.
Loosen the top cover by means of the two
dismantling screws from the tool panel.

GN909-5.2 205 02

Release the link for the regulating drive and


pull out the toothed rack as far as possible.

GN909-1.3 205 01

3.

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Page 1 (7)

Fuel Pump Top Cover

909-5.2

Dismantling
4.

4. Mount the lifting tool on the fuel pump top


cover. Screw the centre screw of the tool
into the pump plunger. Ensure that the stop
ring on the centre screw is loose.
Pull the centre screw of the tool to lift the
plunger clear of the bayonet joint in the roller guide and the milled recess of the regulating guide.
To do this it may be necessary to move the
toothed rack and the centre screw of the
tool in relation to each other.

GN909-5.2 208 04

When the plunger has been lifted clear of


the roller guide and regulating guide, lock
the centre screw in this position with the
stop ring.
5. Lift the top cover and barrel with plunger
out of the fuel pump housing as one unit.
Remove the shims and tag them for reinstallation.

5.

D09-28

6. Set up the pump unit in a bench vice provided with soft jaws. Dismount the lifting
tool. Take care that the plunger does not
slide out of the barrel.
Press the plunger to the top of the barrel
and remove the barrel/plunger assembly
from the top cover.

GN909-5.2 205 05

Send the barrel/plunger assembly to an


MAN B&W authorised workshop for overhaul, or overhaul it on board.
See Procedure 909-6.3.

GN909-5.2 205 06

6.

Page 2 (7)

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Fuel Pump Top Cover

909-5.3

Overhaul
Overhaul
909-5.3

1.

1. Remove and discard the sealing rings.

D09-26

Carefully clean and examine the top cover.


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.

GREASE

During the work the miller is guided by the


guide screwed into the thread for the highpressure pipe.
Turn the miller by means of, e.g. a tap
wrench, while tightening the guide screw
lightly to provide a suitable pressure between miller and seat.

For the max. milling/grinding diameter of


the seat, see Data D09-26.

GN909-5.3 205 01

During the milling, add drilling oil emulsion


liberally.

2. After completing the milling, blow out the


Vaseline/grease from the oil ducts by
means of compressed air.

2.

Warning!
Always use eye protection when working
with compressed air.

GN909-5.3 205 02

Clean the top cover with diesel oil, and blow


dry with compressed air.

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Page 3 (7)

909-5.3

Fuel Pump Top Cover


Overhaul

3.

3. Mount the sealing rings in the ring grooves.


Sealing between the top cover and the fuel
pump housing is provided by an O-ring.
Sealing between the top cover and pump
barrel is provided by two back-up rings and
an O-ring in between.

GN909-5.3 205 03

Prepare the back-up rings by twisting the


rings in the hand, 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.
Screw the back-up rings onto the top cover, into the groove.
4.

D09-25

Finally, insert the O-ring between the backup rings in the ring groove.
Mount the O-ring which seals between top
cover/fuel pump housing.

GN909-5.2 205 06

4. Mount the overhauled top cover on top of


the pump barrel, guided by the guide pin.
Tighten the screws, see Data D09-25.

Page 4 (7)

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Fuel Pump Top Cover

909-5.4

Mounting
Mounting
909-5.4

1.

1. Mount the supplied measuring pin on the


centre screw of the lifting tool as shown in
the sketch. Loosen the stop ring on the centre screw.
Place the tool on the pump housing and
press down the centre screw until the
measuring pin reaches the thrust piece of
the roller guide. Lock the centre screw in
this position with the stop ring.

Note!
The engine must not be turned until the
mounting of the barrel/plunger assembly
has been completed.

GN909-5.4 208 01

Keep the stop ring tightened in this position


until the plunger has been correctly mounted.

2.
2. Remove the tool from the pump housing
and remove the measuring pin from the
centre screw.
Mount the tool on the barrel/plunger and
top-cover assembly.
Tighten the tool to the top cover by means
of the two screws, and attach the plunger to
the centre screw.
The tool is now firmly attached to the assembly, enabling the correct position to be
obtained during mounting.
Pull the regulating toothed rack out as far
as possible.

Carefully lower the assembly into the pump


housing (taking special care not to damage
the O-ring and back-up rings on the barrel).

GN909-5.4 208 02

Pull the plunger as high up in the barrel as


possible.

Adjust the top cover so that the guide pin


enters the hole in the pump housing. Lower
the top cover on to the pump housing.

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Page 5 (7)

909-5.4

Fuel Pump Top Cover


Mounting

3.

3. Press the plunger down into contact with


the thrust piece of the roller guide.
If necessary, 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.
Check that the stop ring of the centre screw
is in full contact with the flange of the tool,
as when measuring.

GN909-5.4 208 03

When the plunger is in place, press the regulating toothed bar in, causing the plunger
foot to interlock with the bayonet joint of the
roller guide.

4.

Check through the inspection cover on the


fuel pump base and by pulling the centre
screw of the tool, that the plunger is correctly engaged.
When pulling on the centre screw it must
not be possible to lift the plunger more than
a few mm.
4. Unscrew the centre screw from the plunger
and remove the tool from the top cover.

GN909-5.4 208 024

5. Screw the two dismantling screws from the


tool panel into the threaded holes of the top
cover, thus lifting the top cover to provide
space for inserting shims.

GN909-1.3 205 02

5.

6. Insert shims between the pump housing


and the top cover. (If the barrel assembly is
the same as that dismounted, insert the
same number of shims as were removed).
If a new barrel assembly is mounted, insert
the number of shims specified in the test
bed report.

Page 6 (7)

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Fuel Pump Top Cover

909-5.4

Mounting
7.

7. Replace the dismantling screws with the


two screws for mounting the lifting tool, and
press down the top cover.
Turn the engine one complete revolution,
and check that the top cover does not lift.
If the top cover lifts, the plunger is not correctly mounted and must be remounted.
Mount the top cover fastening nuts, and
tighten them diagonally.
See Data D09-24.
If any of the fuel pump top cover studs have
come loose, tighten them.
See Data D09-23.

Connect the drain oil pipe to the top cover


and the pipe connection to the puncture
valve.
Mount the two high-pressure pipes on the
top cover/fuel valves.
See Procedure 909-14.

GN909-1.3 205 03

8. Mount the suction valve and the puncture


valve in the top cover.
See Procedure 909-8.

9.

Mount the fuel index pointer


Mount the link for the regulating drive.
Open the fuel oil inlet.

GN909-5.4 208 09

For fuel pump settings, see Procedure 9091 and Volume I, OPERATION, Chapter 706.

When referring to this page, please quote Procedure M90905 Edition 0222
0$1% :'LHVHO$6

Page 7 (7)

Fuel Pump Barrel Assembly

109-6

Data
SAFETY PRECAUTIONS
Special Edition
D10906
S35MC
109-6
Data 0040

Fuel Pump Barrel Assembly

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

D09-29

Description

Barrel assembly

When referring to this page, please quote Data D10906 Edition 0040
MAN B&W Diesel A/S

Value Unit

9 kg

Page 1 (2)

Fuel Pump Barrel Assembly

109-6

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

Page 2 (2)

Item No. Description

When referring to this page, please quote Data D10906 Edition 0040
MAN B&W Diesel A/S

Fuel Pump Barrel Assembly

909-6.3

Overhaul
Fuel Pump Barrel Assembly
S46MC-C
0218
Overhaul
909-6.3

1.

1. Remove the top cover with the barrel/plunger assembly from the fuel pump housing,
and dismantle the barrel/plunger assembly
from the top cover. See Procedure 909-5.2.

D09-29

2. Remove and discard the O-rings.

Note!
It is recommended not to remove the
plunger from the barrel, as this may
cause scratches to the plunger.

GN909-6.3 205 01

Clean the outside of the barrel.

3.

For evaluation of pump barrel/plunger, see


Volume I, OPERATION, Chapter 706.

Prepare the back-up ring by twisting the


ring in the hand, in such a way that the diameter of the ring becomes smaller than
the diameter of the barrel.
Screw the back-up ring on to the barrel,
into the groove.

EN909-6.3 218 03

3. The sealing ring on the pump barrel consists of an O-ring and a back-up ring..

Finally, position the O-ring in the ring


groove.
The O-ring must be above the back-up ring.
Note!
Take care that the plunger does not slide
out of the barrel.
4. If the barrel assembly is not to be mounted
immediately, cover all openings with plastic
to prevent dirt from entering the barrel assembly during storage.
For mounting the fuel pump barrel assembly, see Procedure 909-5.4 (fuel pump top
cover).

When referring to this page, please quote Procedure M90906 Edition 0218
0$1% :'LHVHO$6

Page 1 (1)

Fuel Pump Suction Valve

109-7

Data
SAFETY PRECAUTIONS
Special Edition
D10907
S42MC
109-7
Data 0027

Fuel Pump Suction Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

When referring to this page, please quote Data D10907 Edition 0027
MAN B&W Diesel A/S

Value Unit

Page 1 (2)

Fuel Pump Suction Valve

109-7

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

Page 2 (2)

Item No. Description

When referring to this page, please quote Data D10907 Edition 0027
MAN B&W Diesel A/S

Fuel Pump Suction Valve

909-7.3

Overhaul
Fuel Pump Suction Valve
S35MC
0210
Overhaul
909-7.3

1.

1. Set up the suction valve in a bench vice


with soft jaws and press down the spring
by means of the cone to release the valve
spindle from the two-part conical ring.
Clean the parts thoroughly in clean diesel
oil and blow dry with compressed air.

If the seats are damaged, a new or reconditioned suction valve must be fitted. (Send
the damaged valve to an authorized MAN
B&W repair shop for reconditioning).
3. After cleaning and inspecting all the parts,
lubricate these with molybdenum disulphide (MoS 2) and assemble the suction
valve.

GN909-7.3 205 05

2. Inspect the seat on the valve spindle and


the seat on the valve housing for damage.

2.

Check the seats for tightness by filling the


inlet hole with diesel oil and waiting 5 minutes. No oil may pass through the seats.

GN909-7.3 205 06

4. If the suction valve is not to be mounted on


the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve during storage.

GN909-7.3 205 07

3.

When referring to this page, please quote Procedure M90907 Edition 0210
0$1% :'LHVHO$6

Page 1 (1)

Fuel Pump Puncture Valve

109-8

Data
SAFETY PRECAUTIONS
Special Edition
D10908
S35MC
109-8
Data 0038

Fuel Pump Puncture Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

D09-35

Description

Puncture valve, tightening torque

When referring to this page, please quote Data D10908 Edition 0038
MAN B&W Diesel A/S

Value Unit

250 Nm

Page 1 (2)

Fuel Pump Puncture Valve

109-8

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

P90951

Page 2 (2)

Item No. Description

128

Crowfoot wrench head

When referring to this page, please quote Data D10908 Edition 0038
MAN B&W Diesel A/S

Fuel Pump Puncture Valve

909-8.2

Dismantling
Fuel Pump Puncture Valve
S46MC-C
0216
Dismantling
909-8.2

2.

1.
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

2. Disconnect the air pipes from the puncture


valve.
Unscrew the puncture valve and remove it
from the fuel pump top cover.

AM909-14.2 210 04

Remove the fuel oil high pressure pipes.


See Procedure 909-14.2.

EN909-8.2 216 02

2.

When referring to this page, please quote Procedure M90908 Edition 0216
0$1% :'LHVHO$6

Page 1 (4)

909-8.3

Fuel Pump Puncture Valve


Overhaul
Overhaul
909-8.3

1.

1. Remove and discard the O-ring from the


puncture valve housing.
Set up the puncture valve in a bench vice
with "soft" jaws.
Loosen and remove the two screws and dismount the plug.
Insert an M6 screw in the air piston, and remove the air piston from the housing.
Remove and discard the sealing rings from
the air piston.

BG909-3.3 80 07

Disassemble the other parts of the puncture valve and discard the O-rings from the
plug and the flexible connection. Clean all
the parts thoroughly in clean diesel oil.
Check all seats in the valve housing and on
the valve slide, and recondition, if necessary.

2.

Remove the fuel pump suction valve, see


Procedure 909-7.

JG909-3.3 130 09

2.

Note!
Do not use a mandrel to disassemble the
flexible connection.
Use the tubular dismantling tool from the
tool panel.

3.
3. Mount the two O-rings in the ring groove on
the rod of the air piston, and position the
large cone on the rod.
Place the sealing ring on the cone and, by
means of the pusher, push the sealing ring
on to the O-rings in the groove. Remove the
pusher and the large cone.

BG909-3.3 80 08

Finally, compress the sealing ring by means


of the sizer tool.

Page 2 (4)

When referring to this page, please quote Procedure M90908 Edition 0216
0$1% :'LHVHO$6

Fuel Pump Puncture Valve

909-8.3

Overhaul
4.

4. Mount the O-ring in the ring groove on top


of the piston. Position the cone on the piston head.
Place the sealing ring on the cone and, using the pusher, push the sealing ring onto
the O-ring in the groove.
Remove the pusher and the cone.
Finally, compress the sealing ring by means
of the "sizer" tool.
5. Before assembling the puncture valve, lubricate all parts with molybdenum disulphide, (MoS 2).
Mount new O-rings on the the housing and
the plug.

Mount the spring and air piston in the upper


housing and assemble the two housings by
means of the plug and the two screws.

BG909-3.3 80 09

Mount a new O-ring on the flexible connection and place it in the lower housing.

6. If the puncture valve is not to be mounted


on the engine immediately after the overhaul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.

BG909-3.3 80 11

5.

When referring to this page, please quote Procedure M90908 Edition 0216
0$1% :'LHVHO$6

Page 3 (4)

Fuel Pump Puncture Valve

909-8.4

Mounting
Mounting
909-8.4

2.

D09-35

1. Before mounting the puncture valve, check


that the bore in the top cover is clean and
check the O-ring on the puncture valve.
Lubricate the thread on the puncture valve
with molybdenum disulphide
grease
(MoS 2).

EN909-8.4 216 02

2. Screw in the puncture valve and tighten


with a crowfoot wrench and a torque spanner to the specified torque, see data D0935.
Mount the air pipes for the puncture valve.
3. Mount the fuel oil high pressure pipes, see
Procedure 909-14.4

BM909-14.4 211 03

3.

Page 4 (4)

When referring to this page, please quote Procedure M90908 Edition 0216
0$1% :'LHVHO$6

Fuel System Shock Absorber

109-9

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0011
109-9

Standard Tools: See Section 913

Fuel System Shock Absorber

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data

When referring to this page, please quote Data D10909 Edition 0011
MAN B&W Diesel A/S

Page 1 (2)

Fuel System Shock Absorber

109-9

Data

Spare Parts
Plate Item No.

Description

Qty

90915-xxx 241

Gasket

90915-xxx 265

Wear ring

90915-xxx 277

Sealing ring

90915-xxx 289

Gasket

90915-xxx 290

Locking plate

90915-xxx

Sealing ring

Page 2 (2)

When referring to this page, please quote Data D10909 Edition 0011
MAN B&W Diesel A/S

Fuel System Shock Absorber

909-9.1

Checking
Fuel System Shock Absorber
S35MC
0208
Checking
909-9.1

1.

2. Remove the plug from the end cover of the


shock absorber. Check that air is pulsating
through the threaded hole.
Short bursts of air should be felt against the
hand, corresponding to the strokes of the
fuel pump.

HM909-4.0 09 01

1. To ensure satisfactory operation, the functioning of the fuel oil system shock absorber should be checked at regular intervals.
Normally, inspection is necessary only at
the intervals stated in the maintenance programme. The checks should be carried out
while the engine is operating.

2.

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.

Increasing amounts indicate a deteriorating


piston sealing. Excessive amounts indicate
that the shock absorber requires overhauling.
See Procedure 909-9.3.

BG909-9.1 208 02

3. To check the tightness of the piston, measure the amount of leakage oil flowing from
the drain pipe of the shock absorber housing. Note down the amounts measured and
compare with earlier measurements.

BG909-9.1 208 03

3.

When referring to this page, please quote Procedure M90909 Edition 0208
0$1% :'LHVHO$6

Page 1 (3)

909-9.3

Fuel System Shock Absorber


Overhaul
Overhaul
909-9.3

1.
Note !
Before dismantling any part of the fuel oil
system, make sure that the system has
been relieved of pressure and that all oil
has been drained off.
1. Remove the shock absorber drain pipe.
Loosen the screws holding the shock absorber and remove it from the fuel oil system.

BG909-9.3 208 01

2. Remove the plug from the end cover of the


shock absorber. Fit an M10 threaded rod
between the piston and the end cover to
counteract the force of the springs. Remove
the locking plates and loosen the screws of
the end cover. Remove the end cover and
piston. Discard the gasket.
2.
3. Loosen the nut on the threaded rod to relieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.
4. Clean all parts and polish the sliding surfaces of the piston and the shock absorber
housing. Mount a new sealing ring in the
shock absorber housing and a new wear
ring on the piston.

HG909-9.2 201 02

5. Mount the springs and the spring guide between the end cover and the piston, using
the threaded rod.

4.

Lubricate all sliding surfaces and assemble


the shock absorber. Take care not to damage the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.

HG909-9.2 201 04

6. Mount the end cover. Remove the threaded


rod and insert the plug.

Page 2 (3)

When referring to this page, please quote Procedure M90909 Edition 0208
0$1% :'LHVHO$6

Fuel System Shock Absorber

909-9.3

Overhaul

7. Fit a new gasket and mount the shock absorber. Mount the shock absorber drain
pipe.
If an excessive amount of drain oil is still
observed after the overhaul, the shock 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 0208
0$1% :'LHVHO$6

Page 3 (3)

Fuel Valve

109-11

Data
SAFETY PRECAUTIONS
Special Edition
D10911
109-11
Data 0051

Fuel
S35MC
Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

D09-40
D09-41
D09-42
D09-43

Description

Fuel valve opening pressure


Fuel valve tightening torque
Inlet seat, max. diameter
Fuel valve

When referring to this page, please quote Data D10911 Edition 0051
MAN B&W Diesel A/S

Value Unit

330-380
20
10
3.5

bar
Nm
mm
kg

Page 1 (2)

Fuel Valve

109-11

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

P90151
P90951
P90951
P90951
P90961

Page 2 (2)

Item No. Description

71
94
104
165

Dismantling tool for fuel valve


Milling tool for fuel oil pipe seats
Milling tool for fuel oil pipe
Grinding mandrel for valve head
Fuel valve tester, complete

When referring to this page, please quote Data D10911 Edition 0051
MAN B&W Diesel A/S

Fuel Valve

909-11.1

Checking
Fuel Valve
S35MC
0236
Checking
909-11.1

1.

The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the
engine can be attributed to defects in these
valves.

In order to obtain reliable results during testing


of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and re-assembled
before testing.
See Procedure 909-11.3 and 909-12.3.

GN909-11.1 204 01

If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.

2.

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,
the opening pressure value measured might
be considerably lower than specified.

D09-41

All fuel valves must be function-tested before


being mounted in the cylinder cover.
1. Pressure testing pump
If an air supply of 10 bar is not available,
working air of seven bar can be used. Use
only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50C.

For operation of the pressure testing pump,


see the suppliers instructions.

2. Place the fuel valve in the test rig and


mount the nuts. Tighten the nuts to the
torque stated in Data. Mount the connecting
piece and the oil pipe between the pressure
testing pump and the fuel valve.
If the pressure testing pump has no built-in
outlet valve, use a connecting piece with a
valve.

DM909-6.3 101 02

Note that the high-pressure pump should


be periodically checked in accordance with
the suppliers instructions.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 1 (11)

909-11.1

Fuel Valve
Checking

3.

3. Pressure testing procedure


The subsequent items must be followed in
the sequence stated. Items 4, 6, 7 and 8
are each divided into the following four subitems:
A.
B.
C.
D.

Objective
Procedure
Acceptance criteria
Cause of fault.

4. Flushing and jet control


A. Objective:
To remove air in the system and check the
fuel jet.

BM909-11.1 236 04

B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the working pressure until
straight jets of oil are ejected from the nozzle holes (no atomization).
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Owing to the geometry of the internal part
of the nozzle and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
during normal engine operation the fuel
oil will not necessarily flow from all of the
nozzle holes.
D. Cause of fault:
If the jets do not fulfil the above point C, the
cause may be:

Page 2 (11)

Dirt in the nozzle holes.

The nozzle is not mounted correctly.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Fuel Valve

909-11.1

Checking
5.

5. Atomization test
Note!

The reason is that the atomization test may


damage the valve because it makes the
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
across the cut-off edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures between cut-off slide and nozzle.

BM909-11.1 236 05

Do NOT attempt to carry out an atomization test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.

6.
All of these conditions involve the risk of
seizure between the cut-off slide and the
nozzle.

D09-40

6. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN position.
Increase the oil pressure until oil is admitted through the nozzle holes.
C. Acceptance criteria:
Check the opening pressure on the pressure gauge. The pressure must correspond
to the pressure stated in Data D09-40.

If the opening pressure is lower than specified in D09-40, the cause may be that the
spring has sagged replace the spring, or
add a special thin disc.
See Procedure 909-12.3.

BM909-11.1 236 06

D. Cause of fault:
If the opening pressure is higher than specified in D09-40, the cause may be that a
wrong type of spring is used replace the
spring in the spindle guide, if necessary, replace the complete spindle guide.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 3 (11)

909-11.1

Fuel Valve
Checking

7.
Note!
Special thin discs are available as
spares.
If a spring or a disc has been changed, the
pressure testing procedure of the fuel valve
must be repeated from step 3.
7. Sealing test and sliding function

BM909-11.1 236 07

A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the oil pressure to about 50
bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
C. Acceptance criteria:
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when
the fuel valve is full of oil.
D. Cause of fault:
D.1 Sealing test
If oil flows out of the nozzle holes, the
cause is either:
Defective spindle guide at needle seat, or
a sticking spindle. Examine and/or replace the spindle guide.
See Procedure 909-12.3.

Page 4 (11)

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Fuel Valve

909-11.1

Checking

Too quick pressure drop:


the clearances of the movable parts,
inside the spindle guide are too large, or
the seat between the spindle guide and
the fuel valve head is damaged.
Examine and/or replace the spindle guide.
See Procedure 909-12.3.
D.2 Sliding function
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
There will always be an oil flow from the
leak oil outlet when the fuel valve is full of
oil.
If a quick pressure drop from 15 to 0 bar
cannot be registered:
The valve slide is sticking; or
the vent hole in the vent slide is blocked.
If so, disassemble and examine the spindle
guide, replace if necessary.
See Procedure 909-12.3.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 5 (11)

909-11.1

Fuel Valve
Checking

8.

8. Pressure test, O-ring sealings


A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN position.
Build up a working pressure of about max.
10 bar until oil flows out of the leak oil outlet.
C. Acceptance criteria:
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100
bar.
Move the control handle to the CLOSED position.
The built-up pressure of about 100 bar
should be maintained.

BG909-6.3 66 07

D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.

Page 6 (11)

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Fuel Valve

909-11.2

Dismantling
Dismantling
909-11.2

1.

1. Close the fuel oil inlet and outlet valves,


and drain the high-pressure pipe and the
fuel valve.
Unscrew the union nut by means of the
hook spanner and take the union nut with
protective hose up along the pipe. Unscrew
the union nipple at both ends of the pipe
(fuel valve and fuel pump).

Disconnect the return oil pipe from the fuel


valve.
Remove the nuts and the tubular spacers.

BG901-2.1 97 01

Remove the high-pressure pipe.

2. Lift the valve. If the valve is sticking, use the


fuel valve dismantling tool to pull the fuel
valve clear of the top cover.

2.

BM909-11.2 209 02

3. Remove the valve from the engine. If the


valve is not to be overhauled immediately,
the valve should be placed immersed in
diesel oil until overhauling.

BM909-11.2 236 03

3.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 7 (11)

Fuel Valve

909-11.3

Overhaul
Overhaul
909-11.3

1.

When fuel valves are overhauled, all parts


should be handled carefully and be kept clean.

BM909-11.3 236 01

Use only clean, non-fluffy rags for wiping purposes. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings before reassembly.
1. Measure the length A of the protruding part
of the nozzle, and write down the result for
correct re-assembling of the valve.

2.

2. Remove and discard the O-rings.


Disassemble the fuel valve by screwing off
the two socket head cap screws while retaining the valve in, for instance, a bench
vice provided with soft jaws.
Pull the valve head clear of the valve housing.
Remove the complete spindle guide and
the fuel nozzle from the valve housing.

BM909-11.3 236 02

Remove and discard all the O-rings.

Page 8 (11)

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Fuel Valve

909-11.3

Overhaul
3.

3. Carefully clean and examine all surfaces of


the fuel valve housing and the fuel valve
head.

D09-42

If necessary, grind the seating surfaces by


means of the grinding mandrels supplied
and a fine-grain abrasive (such as Carborundum No. 500).
This grinding must only be carried out manually.
After the grinding, wash the parts in gas oil
and blow clean by means of compressed air
to remove any remains of the grinding compound.

Normally, the milling tool is turned by hand,


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. 100 r/min). An ample supply of cutting emulsion must be
used.

BG909-6.1 66 02

In the event of more serious damage to the


seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.

4.

Note!
Take care not to exceed the maximum
diameter of the seat, see Data.

BM909-11.3 236 04

4. The complete spindle guide, including the


fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
See Procedure 909-12.3.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 9 (11)

909-11.3

Fuel Valve
Overhaul

5.

5. Mount a new O-ring on the spindle guide


and lubricate it with MoS 2.
Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
Carefully slide the spindle guide down into
the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corresponds to the measurement taken before
the valve is disassembled.
Note!
Make sure that the fuel nozzle and spindle guide engage correctly with the guide
pin in the fuel valve housing. This can be
ascertained by attempting to turn the
nozzle after mounting. It must not be
possible to turn the nozzle.

BM909-11.3 236 05

Mount a new O-ring in the lowermost


groove of the fuel valve head.
Mount the fuel valve head on the fuel valve
housing, and tighten the screws.
Fit the uppermost groove of the valve head
with a new O-ring.
6.

6. When mounting the valve head, make sure


that the guide pin between valve housing
and valve head is intact, and check that the
guide pin between valve housing and valve
head engages correctly so as to prevent
relative turning of the parts.

BG909-6.1 66 06

After overhaul, the fuel valve must be tested in the test rig.
See Procedure 909-11.1.

Page 10 (11)

7. If the fuel valve is not to be mounted in the


engine immediately after the overhaul, cover all openings of the valve with plastic to
prevent dirt from entering the valve during
storage.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Fuel Valve

909-11.4

Mounting
Mounting
909-11.4

1.

1. Before mounting the fuel valve, thoroughly


clean the valve bore in the cylinder cover
and check the seating in the bore for marks
which, if any, must be eliminated.
(For reconditioning of valve bore in cylinder
cover, see Procedure 901-1.3).
If not already done, mount a new O-ring on
the valve head. Mount a new O-ring in the
groove on the valve housing.

Mount the valve in position in the cylinder


cover.
2. Mount the tubular spacers and the nuts.
Tighten the nuts as stated in Data.

BM909-11.4 236 01

Lubricate the valve with copper grease.

2.
3. Lubricate the thread on the union nipple of
the fuel oil pipe with a heat resistant anti
seize grease before mounting.

D09-41

Mount the fuel oil high-pressure pipe and


tighten, using the crow foot wrench and a
torque wrench.
See Procedure 909-14.4.

Turn on the fuel oil supply.


Note!

BM901-2.1 97 04

Reconnect the return oil pipe to the fuel


valve.

All fuel valves must be function-tested


before being mounted in the cylinder
cover, see Procedure 909-11.1.

BM901-2.1 97 05

3.

When referring to this page, please quote Procedure M90911 Edition 0236
MAN B&W Diesel A/S

Page 11 (11)

Spindle Guide

109-12

Data
SAFETY PRECAUTIONS
Special Edition
D10912
S35MC
109-12
Data 0039

Spindle Guide

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

Data
Ref.

Description

When referring to this page, please quote Data D10912 Edition 0039
MAN B&W Diesel A/S

Value Unit

Page 1 (2)

Spindle Guide

109-12

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

P90951
P90951
P90968
P90966

Page 2 (2)

Item No. Description

153
297

Flange for dismantling of non return valve


Assembling tool for fuel valve
Probe light with magnifier, complete
Fuel Valve Nozzle Tools

When referring to this page, please quote Data D10912 Edition 0039
MAN B&W Diesel A/S

Spindle Guide/Non-return Valve

909-12.3

Overhaul
Spindle Guide/Non-return Valve
S35MC
0223
Overhaul
909-12.3

1.
Note!

The spindle guide and the non-return


valve have been integrated into one unit.
However, both terms will be used to
describe the part in this procedure.

BG909-6.2 66 01

Extreme care and accuracy should be


exercised when carrying out this operation.

2.
1. Clean the outside of the spindle guide in pure
gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, therefore only one guide should be disassembled
at a time.

All parts of the spindle guide/non-return


valve, except the springs and the fuel
nozzle are matched parts and may not be
replaced individually.

BM909-12.3 223 02

Note!

3.

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.
2. Place the non-return valve part of the spindle guide in a bench vice provided with
soft jaws, and use a brass mandrel and a
hammer to remove the thrust piece from the
valve housing.

BM909-12.3 222 04

3. Mount the pulling tool around the fuel nozzle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.

When referring to this page, please quote Procedure M90912 Edition 0223
MAN B&W Diesel A/S

Page 1 (5)

909-12.3

Spindle Guide/Non-return Valve


Overhaul

4.

4. Clean all the parts of the spindle guide and


the non-return valve in gas oil, and blow
clean with compressed air.
Clean all parts again in kerosene or Electrocleaner, and blow dry with compressed
air.

BM909-12-3 223 04

5. Place all the parts on a clean, lint-free cloth


and examine them through an 8-10 times
enlargement magnifying glass and an inspection lamp.
During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts.

5.

6. Remove any deposits or very fine scratches


by placing the spindle and vent slide in a
lathe, as shown, and polishing it with a very
fine conventional polishing linen grade
360.
Use also a little oil for the polishing (a
coarser polishing linen must absolutely
not be used).
Note!

BM909-12.3 223 05

The sliding surface of the cut-off slide


may only be polished VERY carefully.
The sliding surface must not be damaged.

MA909-6.2 111 05

6.

Page 2 (5)

When referring to this page, please quote Procedure M90912 Edition 0223
MAN B&W Diesel A/S

Spindle Guide/Non-return Valve

909-12.3

Overhaul
7.

7. Clean any carbon deposits from the central


bore of the fuel nozzle by means of the special brass brush. Clean the spray holes, using gas oil and the special drills supplied.
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.
Clean the fuel nozzle with kerosene and
wipe dry with a clean cloth.
Then test the spray holes with the test pin.
If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.

Check the fuel nozzle before mounting on


the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.

BM909-12.3 222 07

This also applies to nozzles with oval holes


(can be ascertained with a magnifying
glass).

Note!
It is recommended that the fuel nozzle is
changed whenever the spindle guide is
being overhauled.

When referring to this page, please quote Procedure M90912 Edition 0223
MAN B&W Diesel A/S

Page 3 (5)

909-12.3

Spindle Guide/Non-return Valve


Overhaul

8.

8. After polishing, clean the parts again and


re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat
on spindle/guide. Use an inspection lamp
and an 8-10 times enlargement magnifying
glass.
If the seats are not in order, i.e. if there are
pressing-in marks or similar on the seats,
the complete spindle guide must be discarded.
9. Lubricate the sliding surfaces of all parts
with Molybdenum Disulphide (MoS 2).
See Procedure 913-11.
10. Place the housing of the non-return valve in
a bench vice provided with soft jaws.

BM909-12.3 223 08

Insert the non-return valve spindle and the


spring in the housing. Place the thrust
piece at the end of the housing.

10.

Carefully tap the thrust piece into the housing with a lead hammer.
11. Place the lower part of the spindle guide
housing in a bench vice provided with soft
jaws.

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.
12. Mount a new O-ring on the spindle guide/
non-return valve.

BM909-12.3 223 11

11.

Page 4 (5)

When referring to this page, please quote Procedure M90912 Edition 0223
MAN B&W Diesel A/S

Spindle Guide/Non-return Valve

909-12.3

Overhaul
11.

13. Lubricate the sliding surfaces of the nozzle


and the spindle with a little Molybdenum Disulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Use the dismantling tool for the spindle
guide to align the parts.
Place the parts on the plane of a drilling
machine and mount the mounting tool in the
chuck. Make sure that all the parts are perfectly aligned.
Press the nozzle on to the spindle guide.
Note!

If no mounting tools are available, the nozzle can be mounted on the spindle guide using a short piece of pipe.

BM909-12.3 223 13

The mounting tools are not standard for


all engines but may be delivered as
optional extras.

Place the pipe around the nozzle, so that


the lower end of the pipe rests on the foot
of the fuel nozzle. Then press the parts together the same way as when using the
mounting tools.
14. If the spindle guide is not to be mounted in a
fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle
guide during storage.

When referring to this page, please quote Procedure M90912 Edition 0223
MAN B&W Diesel A/S

Page 5 (5)

Fuel Oil High-Pressure Pipe

109-14

Data
SAFETY PRECAUTIONS
Special Edition
D10914
S35MC
109-14
Data 0056

Fuel Oil High-Pressure Pipe

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

D09-47
D09-52

Description

Fuel oil high-pressure pipe, tightening torque


Fuel oil pipe

When referring to this page, please quote Data D10914 Edition 0056
MAN B&W Diesel A/S

Value Unit

25 Nm
3 kg

Page 1 (2)

Fuel Oil High-Pressure Pipe

109-14

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

P90951
P90951

Page 2 (2)

Item No. Description

116
165

Crowfoot wrench head


Grinding mandrel for valve head

When referring to this page, please quote Data D10914 Edition 0056
MAN B&W Diesel A/S

Fuel Oil High-Pressure Pipe

909-14.2

Dismantling
Fuel Oil High-Pressure Pipe
S35MC
0235
Dismantling
909-14.2

2.

High-Pressure Pipe with Double Pipe


1. Close the fuel oil inlet and outlet valves.

3. Unscrew the union nipple from the fuel


pump.
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.

BM909-14.2 211 02

2. Unscrew the union nipple from the fuel


valve.

3.
Note!
It is recommended always to overhaul
the high-pressure pipe before remounting
it on the engine.
See Procedure 909-14.3.

GN909-14.2 210 03

The overhaul should preferably take


place immediately after the high-pressure pipe has been dismantled.

D09-52

BM909-14.2 211 04

4.

When referring to this page, please quote Procedure M90914 Edition 0235
0$1% :'LHVHO$6

Page 1 (4)

909-14.3

Fuel Oil High-Pressure Pipe


Overhaul
Overhaul
909-14.3

1.

Whenever the fuel oil high-pressure system has


been dismantled, it is necessary, before remounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed
as follows:

KB909-7.1 77 01

1. Lift up the union nut. Remove the spring


ring from the two-part sleeve. Remove the
sleeve.
2. Fasten the pipe in a vice with soft jaws.
Mount the miller on the pipe end.
Note!

2.

The two pipe ends are of different


designs see sketch.
Turn the upper tightening ring (A) until the
miller presses against the pipe end.

KB909-7.1 77 03

Turn the miller with, for instance, a tap


wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
During the milling process, add drilling oil
emulsion liberally.
3. On both pipe ends a small groove has been
ground to indicate the maximum allowable
grinding of the pipe ends.

3.
Max. grind-away

The pipe ends may only be ground until the


ground surface is flush with the bottom of
the groove.
If the pipe ends are still not in order, the
pipe must be discarded.

KN909-14.3 223 03

After completing the milling, carefully clean


the high-pressure pipe, and blow through
the bore with compressed air.

Page 2 (4)

When referring to this page, please quote Procedure M90914 Edition 0235
0$1% :'LHVHO$6

Fuel Oil High-Pressure Pipe

909-14.3

Overhaul
4.

4. Remove and discard both the internal and


external O-rings. Mount new O-rings.

KB909-7.1 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.

When referring to this page, please quote Procedure M90914 Edition 0235
0$1% :'LHVHO$6

Page 3 (4)

Fuel Oil High-Pressure Pipe

909-14.4

Mounting
Mounting
909-14.4

3.

D09-52

1. Ensure that the fuel valve is fitted with a


new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel
pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.

BM909-14.4 211 03

3. Mount the high-pressure pipe between the


fuel valve and the fuel pump.
Screw the union nipples onto the fuel valve
and into the fuel pump top cover, by hand.
Note!
4.

D09-47

The nipples must be screwed by hand,


as the threads of the union nipples, fuel
valve or fuel pump top cover might otherwise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nipples have been screwed into position.

BM909-14.4 211 04

4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
pump to the torque stated in Data.

5.

6. If dismantled, re-mount the return oil pipe


on the fuel valve. Open the fuel oil inlet and
outlet valves.

GN909-14.4 210 05

D09-47

Page 4 (4)

When referring to this page, please quote Procedure M90914 Edition 0235
0$1% :'LHVHO$6

Fuel Pump Roller Guide

109-15

Data
SAFETY PRECAUTIONS
Special Edition
D10915
S35MC
109-15
Data 0047

Fuel Pump Roller Guide

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil

Shut off lubricating oil


Lock turbocharger rotors

Data
Ref.

D09-54
D09-55
D09-57
D09-61
D09-62

Description

Clearance A
Clearance B
Roller/bushing/shaft pin, max. clearance
Fuel pump roller guide
Pump base

When referring to this page, please quote Data D10915 Edition 0047
MAN B&W Diesel A/S

Value Unit

1.8 - 4.1
1.9 - 4.2
0.5
23
28

mm
mm
mm
kg
kg

Page 1 (2)

Fuel Pump Roller Guide

109-15

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

P90951

Page 2 (2)

Item No. Description

82

Lifting tool for fuel pump roller guide

When referring to this page, please quote Data D10915 Edition 0047
MAN B&W Diesel A/S

Fuel Pump Roller Guide

909-15.1

Checking
Fuel Pump Roller Guide
S35MC
0227
Checking
909-15.1

2.

Roller guide mounted in engine


The fuel pump roller guide can be partially
checked while mounted on the engine, using
the following procedure:
1. Lift the fuel pump roller guide.
See Procedure 909-16.
2. Remove the cover on the camshaft housing
to inspect the fuel pump roller guide.

Turn the roller by hand to check that it can


move freely and without unnecessary resistance or hard points.

BM909-15.1 207 03

Turn the engine to provide the maximum


space between the roller guide and the cam
disc.

Also inspect the surface of the roller for


possible damage marks, seizures or
scratches. Make sure that there are no traces of bearing metal left in the roller guide
housing.

4.

Check the clearance in the slide bearing by


lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.

4. Using the telegraph, move the roller guide


to the AHEAD position.
Check that the reversing link is fully tilted
over in AHEAD position.

BM909-15.1 207 05

3. Lower the roller guide onto the fuel cam


again.
See Procedure 909-16.

Carry out the same check in the ASTERN position.

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 1 (12)

909-15.1

Fuel Pump Roller Guide


Checking

5.

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. Dismount the roller guide from the engine.
See Procedure 909-15.2.
6. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness.
7. Turn the roller guide upside down and land
it in a vertical position on a couple of
planks, with the roller hanging freely.

BM909-15.1 207 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.

7.

BM909-15.1 207 08

D09-57

Page 2 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Roller Guide

909-15.2

Dismantling
Dismantling
909-15.2

1.
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
1. Dismantle the top cover with the barrel/
plunger assembly.
See Procedure 909-5.2.
2. Turn the engine so that the roller guide
rests on the lowermost part of the fuel cam.

GN909-5.2 205 05

Inspect the position of the fuel cam through


the inspection cover opening on the camshaft housing.

BM909-15.1 207 03

2.

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 3 (12)

909-15.2

Fuel Pump Roller Guide


Dismantling

3.

3. Loosen and remove the nuts on the two


short studs.
Then loosen the nuts on the two long
threaded studs successively until the roller
guide spring is relieved.
Mount the lifting tool on the fuel pump studs
and hook the engine room crane on to the
lifting tool.
Remove the nuts from the two long threaded studs and lift away the fuel pump housing.
Note!
When lifting the fuel pump housing, take
care not to damage the threads on the
studs.

BM909-15.2 207 03

4. Lift the spring out of the roller guide.


Loosen and remove the screws from the
sealing cap on top of the roller guide inside
the pump base.

BM909-15.2 207 04

4.

Page 4 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Roller Guide

909-15.2

Dismantling
5.

5. Remove the sealing cap from the roller


guide.
Unscrew the two nuts from the pump base,
and lift away the pump base.

D09-62

When lifting, take care that the bushing of


the pump base slides against the neck of
the roller guide without scratching.
6. Mount the roller guide lifting tool as follows:
Lift the lock plate of the tool up on the
shaft of the tool.
Position the tool so that its foot rests on
the thrust piece in the bayonet joint of the
roller guide.

Lower the lock plate, thereby securing


the foot in the locked position.
Lift the roller guide out of the roller guide
housing, using the crane.

BM909-15.2 207 05

Turn the tool 90 so as to allow the foot to


engage properly in the bayonet joint.

6.

When lifting, take care that the slide surfaces of the roller guide do not scrape against
the roller guide bushing.

D09-61

Land the roller guide on wooden planks.

BM909-15.2 207 06

7. Check the roller guide.


See Procedure 909-15.1.

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 5 (12)

909-15.3

Fuel Pump Roller Guide


Overhaul
Overhaul
909-15.3

1.

1. Inspect and check the fuel pump roller


guide.
See Procedure 909-15.1.

D09-61

2. It is recommended that the roller guide


should ONLY be dismantled if
irregularities when turning the roller,
damage to the roller,
larger clearance than stated on the Data
sheet,
seizure marks on the slide surfaces,
have been observed when checking the
roller guide.
Note!

BM909-15.1 207 07

For disassembling of the roller guide,


contact an MAN B&W authorized repair
shop.
3. If no irregularities are found, just clean and
lubricate the roller guide before remounting
it in the roller guide bushing.

BM909-15.3 207 03

3.

Page 6 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Roller Guide

909-15.4

Mounting
Mounting
909-15.4

1.

1. Lubricate the roller guide with plenty of


camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
During mounting, take care not to scratch
the sliding surfaces of the roller guide.

D09-61

Make sure that the pin of the reversing link


fits in the bracket of the reversing shaft.

Turn the camshaft so that the roller guide is


lifted approx. 20 mm.
The clearance C between the roller guide
and the guide plate must be the same at
both ends +/ 0.1 mm.

BM909-15.4 207 01

2. After mounting the roller guide with the reversing link, check the clearance between
the roller guide and the guide plate mounted in the roller guide bushing.

2.
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.

D09-54

Connect working air to the air cylinder, and


check that the reversing mechanism is
working smoothly.
The clearances A and B must be approx.
the same in both positions. See Data.
AM909-8.0 50 15

D09-55

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 7 (12)

909-15.4

Fuel Pump Roller Guide


Mounting

3.

3. If adjustment is necessary, 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.

AM909-8.0 50 17A

Pull out the air cylinder with the flange as


much as possible.
4. Release the lock nut on the shaft.

4.

5. Turn the shaft to obtain the distance between the air cylinder flange and the surface of the roller guide bushing. See Data.
Tighten the nut on the shaft.
6. Mount the flange with the air cylinder on the
roller guide bushing and tighten the four
cap screws.

AM909-8.0 50 17B

Lock the screws with Loctite (EN243S)


type: 242.
Repeat the clearance check once more.

AM909-8.0 50 18

5.

AM909-8.0 50 19

6.

Page 8 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Roller Guide

909-15.4

Mounting
7.

7. Before mounting the pump base on the roller bushing, replace the O-ring between the
sealing bush and the bottom of the pump
base.
8. Mount the pump base on the roller guide
bushing, and tighten the nuts.

BM909-8.0 54 24

D09-62

BM909-15.4 207 08

8.

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 9 (12)

909-15.4

Fuel Pump Roller Guide


Mounting

9.

9. Replace the scraper rings in the sealing


cap as follows:
Loosen and remove the screws and nuts
from the bottom of the cap, remove the retaining flange and ring holder with scraper
ring.
10. Replace the axial scraper ring in the bottom
of the cap. Check that the O-ring and scraper ring are mounted correctly. See the
sketch.
11. Remove the scraper ring and O-ring from
the ring holder.

BM909-15.4 207 09

Place the new O-ring in the ring holder.


Before mounting, the new scraper ring must
be heated in 100C hot water or oil for at
least five minutes.
10.
Note!
When mounting the scraper ring in the
groove, fold the ring without making any
sharp edges, and be careful not to cut
the scraper ring on the edge of the ring
groove when pressing it in.

AM909-80.0 31 15

Check that the O-ring and scraper ring are


mounted correctly. See the sketch.

AM909-8.0 31 16

11.

Page 10 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Roller Guide

909-15.4

Mounting
12.

12. Assemble the sealing cap, the ring holder


and retaining flange.
Tighten the nuts on the screws.
After tightening, check that the holder can
be moved.
13. Mount a new O-ring in the groove on top of
the roller guide and on the pump base.

Tighten the sealing cap to the top of the


roller guide.
Tighten the nuts.

BM909-15.4 207 12

14. Mount the sealing cap over the roller guide.

Lock the nuts with Loctite type EN243S.

13.

BM909-15.4 207 13

Land the spring on the roller guide inside


the pump base.

BM909-15.2 207 14

14.

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Page 11 (12)

909-15.4

Fuel Pump Roller Guide


Mounting

15.

15. Mount the fuel pump housing.


See Procedure 909-4.4.
16. Check the movement of the reversing link.
See Procedure 909-15.1.

BM909-15.2 207 03

17. Mount the top cover and barrel/plunger assembly.


See Procedure 909-5.4.

BM909-15.1 207 05

16.

Page 12 (12)

When referring to this page, please quote Procedure M90915 Edition 0227
0$1% :'LHVHO$6

Fuel Pump Special Running

109-16

Data
SAFETY PRECAUTIONS
Special Edition
D10916
S35MC
109-16
Data 0017

Fuel Pump Special Running

Stopped engine

Block the starting mechanism

Shut off starting air supply

Engage turning gear


Shut off cooling water

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

When referring to this page, please quote Data D10916 Edition 0017
MAN B&W Diesel A/S

Value Unit

Page 1 (2)

Fuel Pump Special Running

109-16

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

P90951
P90951
P90951

Page 2 (2)

Item No. Description

82
116
212

Lifting tool for fuel pump roller guide


Crowfoot wrench head
Extraction tool for suctions valve

When referring to this page, please quote Data D10916 Edition 0017
MAN B&W Diesel A/S

Fuel Pump Special Running

909-16

Fuel Pump Special Running


S35MC
0212
909-16

2.

Disengagement of fuel pump


Warning!
Disengagement or re-engagement of the
fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
1. Engine trouble might require a cylinder to
be taken out of action. The engine can continue operation with the fuel and exhaust
systems of a single cylinder disconnected.
See Volume I, Section 704.
To disconnect the fuel pump of a single cylinder, proceed as follows:
2. Remove the fuel oil high pressure pipes
and the puncture valve from the fuel pump
top cover.

Before dismantling any part of the fuel


pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

BM909-16.0 207 02

Note!

Screw a plug-screw into the control air pipe


of the puncture valve.

3.

Remove the inspection cover on the camshaft housing. Turn the engine until the fuel
pump roller is at on the circular part of the
cam.

AM909-1.1 76 04

3. Dismount the suction valve by means of the


extractor tool.

When referring to this page, please quote Procedure M90916 Edition 0212
0$1% :'LHVHO$6

Page 1 (3)

909-16

4.

Fuel Pump Special Running

4. Mount the lifting tool on the fuel pump top


cover.
Turn the uppermost nut to screw the spindle
of the lifting tool into the fuel pump plunger.
5. Tighten the lowermost nut on the tool to pull
the roller guide upwards as far as possible.
Lock the tool in this position by means of
the lock nut.

GN909-16 202 04

6. 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.
7. The engine can now operate on the remaining cylinders. See Volume I, Section 704.

GN909-16 202 05

5.

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

909-16

8.

Re-engagement of fuel pump


Warning!
Re-engagement of the fuel pump must
only take place at engine standstill.
8. Remove the cover on the camshaft housing. Turn the engine until the circular section of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in
the reverse order to lifting and remove the
lifting tool.
10. Re-mount the suction valve and the puncture valve. (See Procedure 909-8.4).

Note!
It is recommended always to mount new
or overhauled suction and puncture
valves.

BM909-16.0 207 08

Remove the plug screw from the control air


pipe.

10.

BG909-5.0 45 06

Mount the fuel oil high pressure pipes.


(See Procedure 909-14.4).

When referring to this page, please quote Procedure M90916 Edition 0212
0$1% :'LHVHO$6

Page 3 (3)

Fuel Valve and Fuel Pump Panel

When referring to this page, please quote Plate P90951 Edition 0440
MAN B&W Diesel A/S

Plate
P90951-0440

Page 1 (2)

Plate
P90951-0440

Fuel Valve and Fuel Pump Panel

Item
No.

Item Description

010
021
045
057
069
082
094
104
116
128
165
177
189
190
200
212

Panel for tools


Name plate
Measuring tool for fuel pump lead
Lifting tool for fuel pump
Lifting tool
Lifting tool for roller guide
Milling tool for seat fuel oil pipe
Milling tool for fuel oil pipe
Crowfoot spanner
Crowfoot spanner
Grinding mandrel for valve head
Grinding mandrel for throw spindle
Grinding mandrel for holder - outside
Grinding mandrel for holder - inside
Screw
Extractor tool for suction valve

Page 2 (2)

Item
No.

Item Description

When referring to this page, please quote Plate P90951 Edition 0440
MAN B&W Diesel A/S

Fuel Valve - Tools

Plate
P90961-0037

Fuel Valve - Tools


0037
P90961

When referring to this page, please quote Plate P90961 Edition 0037
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90961-0037
Item
No.
014
026
038
051
063

Fuel Valve - Tools

Item Description

Item
No.

Item Description

Connection piece
Test rig
High-pressure hose
Table
High-pressure pump

Page 2 (2)

When referring to this page, please quote Plate P90961 Edition 0037
MAN B&W Diesel A/S

Fuel Valve - Tools

When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S

Plate
P90961-0069

Page 1 (2)

Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122

Page 2 (2)

Fuel Valve - Tools

Item Description

Item
No.

Item Description

High-pressure pump
Table
Rig fuel oil valve
High-pressure hose
Connection piece, M42x2
Test rig, complete
Cover
Angle union
Gasket
Plug screw
Hose

When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S

Fuel Valve Nozzle - Tools

When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S

Plate
P90966-0008

Page 1 (2)

Plate
P90966-0008
Item
No.
011
023
035
047
060
202

Fuel Valve Nozzle - Tools

Item Description

Item
No.

Item Description

Tool box
Extractor for atomizer
Drift for atomizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When odering new cleaning tool,
please state P/N on fuel nozzle.

Page 2 (2)

When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S

Fuel Valve - Inspection Tools

When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S

Plate
P90968-0001

Page 1 (2)

Plate
P90968-0001

Fuel Valve - Inspection Tools

Item
No.

Item Description

012

Probe light with magnifier, complete

Page 2 (2)

Item
No.

Item Description

When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S

Fuel Valve Nozzle - 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)

Plate
P90974-0001
Item
No.
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,
please state P/N on fuel nozzle.

Page 2 (2)

When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S

Mounting Tools - Air Piston Seals

When referring to this page, please quote Plate P90980 Edition 0002
MAN B&W Diesel A/S

Plate
P90980-0002

Page 1 (2)

Plate
P90980-0002
Item
No.
018
020
031
043
055
067

Page 2 (2)

Mounting Tools - Air Piston Seals

Item Description

Item
No.

Item Description

Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool

When referring to this page, please quote Plate P90980 Edition 0002
MAN B&W Diesel A/S

910 - 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

0019
0215
0004
0211
0012
0214
0005
0206
0011
0211
0017
0002
0001
0010

Air Cooler Element, Data


Air Cooler Element
Non-Return Valve in Turbocharger, Data
Non Return Valve in Tubocharger
Auxilary Blower, Data
Auxilary Blower
Turbocharger Turbine, Data
Turbocharger Turbine
Water Mist Catcher, Data
Water Mist Catcher
Air Cooler - Tools
Travelling Trolley
Air Cooler - Lifting Tools
Air Cooler - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Air Cooler Element

110-1

Data
SAFETY PRECAUTIONS
Special Data
S35MC
0019
110-1

Standard Tools: See Section 913

Air Cooler Element

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear

Shut off cooling water

3 x 2000 kg

Shut off fuel oil


Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

D-1

Air cooler element

Value Unit

1210 kg

When referring to this page, please quote Data D11001 Edition 0019
MAN B&W Diesel A/S

Page 1 (2)

Air Cooler Element

110-1

Data

Spare Parts
Plate Item No.

Description

Qty

See special instructions from air cooler element manufacturer.

Page 2 (2)

When referring to this page, please quote Data D11001 Edition 0019
MAN B&W Diesel A/S

Air Cooler Element

910-1.1

Checking
Air Cooler Element
0215
Checking
910-1.1

1.

1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air
across the cooler while the engine is running.

2. An increase in the air pressure drop across


the scavenge air cooler indicates fouling of
the air side of the cooler.
A decrease in the air temperature drop
across the scavenge air cooler indicates
fouling of the water side of the cooler.

BM910-1.1 209 01

Compare these measurements with the


testbed data. For further evaluation of the
measurements, see instruction book Volume I, Chapter 706.

4.

3. If the measurements indicate fouling of the


water side of the air cooler element, the element must be dismantled and overhauled/
cleaned.
See Procedure 910-2.
See Procedure 910-3.

4. Remove the top cover of the air cooler.


5. Visually inspect the air cooler element
through the opening.

BM910-1.1 209 04

If the measurements indicate fouling of the


air side of the air cooler element, it is recommended to inspect the air cooler element as follows:

5.

BM910-1.1 209 05

If the air side of the element is fouled, clean


the element using the spray pipe arrangement fitted above the air cooler element.
See Procedure 910-3.

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Page 1 (7)

910-1.2

Air Cooler Element


Dismantling
Dismantling
910-1.2

2.

1. Close the cooling water inlet and outlet


valves. Open the drain cocks to drain off the
cooling water.
2. Dismount the cooling water inlet and outlet
pipes from the front end cover.
Remove and discard the gaskets.

BM910-1.2 209 01

3. Dismantle the screws and pull out the cooler element approx. 10 cm using the dismantling screws.

BM910-1.2 209 02

2.

BM910-1.2 209 03

3.

Page 2 (7)

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Air Cooler Element

910-1.2

Dismantling
4.

4. Mount the lifting tool on the front end cover.


Attach a shackle to the lifting tool. Hook a
tackle on to the shackle.
Using the tackle, lift the air cooler element
approx. 2-3 mm.
Pull out the air cooler element approx. half
a metre.

6. Pull out the air cooler element far enough


to gain access to the aft end cover.

BG910-1.2 215 04

5. Mount the two guide rails on the frame


around the air cooler element.

Mount shackles on the lifting brackets on


the aft end cover. Hook tackles on to the
shackles.

5.

Using the tackles lift the air cooler element


away. Land the element on a couple of
wooden planks.
Note!

BG910-1.2 215 05

During the lift, take care not to damage


the air cooler element.

BM910-1.2 215 06

6.

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Page 3 (7)

910-1.3

Air Cooler Element


Overhaul
Overhaul
910-1.3

1.

Cleaning the air side:


1. The air side of the cooler is cleaned by injecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.
It is recommended to use one of the following cleaning fluids, or a similar product.
Product: ACC 9, produced by
Drew Chemical Corp., New York, USA
Product: 80B, produced by
Vecom Int., Maassluis, Holland
2. Do not start cleaning until the engine has
been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
Remove the covers on the scavenge air receiver to let vapours escape.

BM910-5.1 63 02

3. Follow the detailed cleaning instructions


displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
3.

4. Continue the cleaning process for at least


30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
5. After cleaning, flush the cooler with clean
water until the water in the sight glasses appears clean and pure.

DG910-5.1 62 01

6. Inspect the air cooler element by removing


the cover of the scavenge air cooler housing.
See Procedure 910-1.2.

Page 4 (7)

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Air Cooler Element

910-1.3

Overhaul
2.

Cleaning the water side


1. Dismantle the air cooler element and remove it from the engine.
See Procedure 910-1.2.
2. Dismantle the front end cover of the air
cooler element.

4. Clean the water side of the cooler element


(the inside of the tubes) using the cleaning
brush mounted on a drilling machine. Flush
the tubes with clean fresh water.

BG910-1.3 215 02

3. Dismantle the aft end cover of the air cooler


element.

In the event of a leaking tube, plug both


ends of the tube using a brass or copper
plug.

3.

In the event of leakages between a tube


and the tube plate, roll the tube using the
tube expander.
5. Clean and check the inside of the front end
and aft end covers. If necessary replace the
corrosion blocks.

If damaged, the coating inside the covers


is to be repaired with the original coating
or a similar product.

BM910-5.2 49 06

Note!

4.

6. When cleaning is complete, mount new


gaskets or packing paste and re-mount the
front end and aft end covers of the air cooler element.

GN910-1.3 207 04

7. Re-mount the air cooler element in the


scavenge air cooler housing.
See Procedure 910-1.4.

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Page 5 (7)

910-1.4

Air Cooler Element


Mounting
Mounting
910-1.4

1.

1. Lift the air cooler element and land the aft


end of the element on the guide rails
mounted on the air cooler housing.
Remove the tackles and shackles from the
aftmost lifting brackets.
2. Push the air cooler element inwards approx. one metre.
Remove the guide rails from the air cooler
housing.

BM910-1.2 215 06

3. Clean the frame around the air cooler element and the contact surface of the front
end cover.

2.

Apply a thin layer of silicone paste to the


frame around the air cooler element and the
contact surface of the front end cover.

BG910-1.4 215 02

Push the air cooler element fully into the air


cooler housing.

BG910-1.4 215 03

3.

Page 6 (7)

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Air Cooler Element

910-1.4

Mounting
4.

4. Mount and tighten all the screws of the front


end cover.
Remove the tackle, the shackle and the lifting bracket from the front end cover.
5. Mount the cooling water inlet and outlet
pipes on the front end cover.

Note!
Remember to vent trapped air from the
air cooler element.

BG910-1.4 212 04

6. Close the drain cocks and open the cooling


water inlet and outlet valves.

BM910-1.2 209 02

5.

BM910-1.4 209 06

6.

When referring to this page, please quote Procedure M91001 Edition 0215
MAN B&W Diesel A/S

Page 7 (7)

Non-Return Valve

110-2

Data
SAFETY PRECAUTIONS
Special Data
0004
110-2

Standard Tools: See Section 913

Non-Return Valve

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D11002 Edition 0004
MAN B&W Diesel A/S

Page 1 (2)

Non-Return Valve

110-2

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D11002 Edition 0004
MAN B&W Diesel A/S

Non-Return Valve

910-2.3

Overhaul
Non-Return Valve
0211
Overhaul
910-2.3

1.

This procedure includes both the main non-return valve and the non-return valve for the auxiliary blowers.
Both sets of non-return valves are accessed via
the scavenge air receiver.
Note!

Main Non-Return Valve


1. The main non-return valve consists of four
valve flaps located inside the scavenge air
cooler housing.

BM910-2.3 208 01

Access to the scavenge air receiver must


not be attempted until the air in the
receiver is clean.

2.

2. Remove the screws holding the valve flap.


Remove the valve from the engine.
3. Remove the spring pin from the valve shaft
and knock the valve shaft out of the valve
flap.
Clean the valve shaft and the slide bearings
inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul, it must be possible to
move the valve flap by the light touch of a
finger.

BM910-2.3 208 02

4. Assemble the valve and re-mount it in the


scavenge air cooler housing.

BM910-2.3 208 03

3.

When referring to this page, please quote Procedure M91002 Edition 0211
0$1% :'LHVHO$6

Page 1 (2)

910-2.3

Non-Return Valve
Overhaul

5.

Non-Return Valve for Auxiliary Blowers


5. Inside the scavenge air cooler housing, lift
up the valve flap of the valve to be overhauled.
6. Remove the screws behind the valve flap.
Remove the valve from the engine.

BM910-2.3 208 05

7. Remove the spring pins from the valve shaft


and knock the valve shaft out of the valve
flap.

6.

Clean the valve shaft, the slide rings and


the slide bearings inside the valve flaps. Lubricate the valve shaft, the slide rings and
the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul it must be possible to
move the valve flap by the light touch of a
finger.

BM910-2.3 208 06

8. Assemble the valve and re-mount it in the


scavenge air cooler housing.

BM910-2.3 208 07

7.

Page 2 (2)

When referring to this page, please quote Procedure M91002 Edition 0211
0$1% :'LHVHO$6

Auxiliary Blower

110-3

Data
SAFETY PRECAUTIONS
Special Data
S35NC
0012
110-3

Standard Tools: See Section 913

Auxiliary Blower

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data

1000 kg

Ref.

Description

D-1

Weight of blower unit,


complete *)

Value Unit

up till 750 kg

*) Depending on electric
motor type and number of cylinders of engine (size and
capacity of auxiliary blower)

When referring to this page, please quote Data D11003 Edition 0012
MAN B&W Diesel A/S

Page 1 (2)

Auxiliary Blower

110-3

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D11003 Edition 0012
MAN B&W Diesel A/S

Auxiliary Blower

910-3.3

Overhaul
Auxiliary Blower
S35MC
0214
Overhaul
910-3.3

2.

1. Depending on the type of overhaul, disconnect the cable connections from one or both
blower motors.
The overhaul can be carried out either by
dismantling the complete blower unit or just
dismantling the individual blower wheel
which is to be replaced/overhauled.
2. Complete Blower Unit

Remove all screws in the outlet flange of


the blower unit.
Remove all screws in the lower inlet flange
of the blower unit.

BM910-3.3 214 02

Hook a shackle and a tackle to the lifting


bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates.

D-1

Remove all screws in the upper inlet flange


of the blower unit.
Lift away the blower unit and land it on
wooden planks for further dismantling/overhaul.

When referring to this page, please quote Procedure M91003 Edition 0214
0$1% :'LHVHO$6

Page 1 (2)

910-3.3

Auxiliary Blower
Overhaul

3.

3. Blower Wheel and Electric Motor


When cleaning and inspecting the auxiliary
blower, disengage the cable connections to
the blower motor.
Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the
blower flange, before removing the screws
in the flange.
4. The end cover complete with blower can
now be pulled free of the suction pipe by
means of the two tackles.

BM910-3.3 214 03

While pulling out the end cover with the


blower assembly, make sure that the blower
housing disengages from the air pipe without deforming it.
4.

Then inspect and clean the blower wheel as


well as the blower housing.
For overhaul of blower wheel and bearings,
see blower manufacturers instructions.

Note!

BM910-3.3 214 04

Exercise care when mounting the electric motor with blower wheel, as the
blower wheel is to catch the guide in the
blower housing.

Page 2 (2)

When referring to this page, please quote Procedure M91003 Edition 0214
0$1% :'LHVHO$6

Turbocharger Turbine

110-5

Data
SAFETY PRECAUTIONS
Special Data
.0&&
0005
110-5

Standard Tools: See Section 913

Turbocharger Turbine

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

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data D11005 Edition 0005
MAN B&W Diesel A/S

Page 1 (2)

Turbocharger Turbine

110-5

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D11005 Edition 0005
MAN B&W Diesel A/S

Turbocharger Turbine

910-5.3

Cleaning
Turbocharger Turbine
.0&&
0206
Cleaning
910-5.3

The dry cleaning method employs compressed


air to blow dry, solid, granules through the turbocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.
On account of their hardness, nut-shells, or
broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.
Note!
We do not recommend the use of rice or
grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.
It is not always possible to remove thick deposits with this dry cleaning method.
Therefore, in order to prevent the build-up of
thick deposits, the turbine must be cleaned after every 24 to 50 hours of operation.
Generally, turbocharger cleaning can be carried
out without, or with very little, reduction of the
engine load.
More detailed information regarding the amount
of granules to be used is stated on the instruction plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger
turbine, see turbine manufacturers
instructions.
See also Volume I, Chapter 706.

When referring to this page, please quote Procedure M91005 Edition 0206
0$1% :'LHVHO$6

Page 1 (2)

910-5.3

Turbocharger Turbine
Cleaning

Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours
of operation, based on observations.
2. Preferably clean the turbocharger at full
load. Do not clean below half load.
3. Close valve A.

XX706-12 40B

4. Open valves B and C, to blow out any deposits and/or condensate in the connecting
pipe.
After about two minutes, close valves B and
C.
5. Slowly open valve A to relieve the pressure
in the tank.
6. Fill the tank with the quantity of granules
specified in the table.
7. Close valve A.
8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves
B and C.

HM910-5.3 50 02

9. Slowly open valve A to relieve the pressure


in the tank.

Caution!
1.The drain openings in the gas casings
must remain closed while dry cleaning
the turbine.
2. It is possible that during dry cleaning
of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.

Page 2 (2)

When referring to this page, please quote Procedure M91005 Edition 0206
0$1% :'LHVHO$6

Water Mist Catcher

110-6

Data
SAFETY PRECAUTIONS
Special Data
0011
110-6

Standard Tools: See Section 913

Water Mist Catcher

Stopped engine

Block the starting mechanism

Shut off starting air supply


Engage turning gear

Shut off cooling water


Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

1000 kg

Data
Ref.

Description

D-1

Water mist catcher

Value Unit

80 kg

When referring to this page, please quote Data D11006 Edition 0011
MAN B&W Diesel A/S

Page 1 (2)

Water Mist Catcher

110-6

Data

Spare Parts
Plate Item No.

Page 2 (2)

Description

Qty

When referring to this page, please quote Data D11006 Edition 0011
MAN B&W Diesel A/S

Water Mist Catcher

910-6.2

Dismantling
Water Mist Catcher
0211
Dismantling
910-6.2

2.

1. Normally it is not necessary to remove the


water mist catcher from the scavenge air
cooler housing. If, however, the water mist
catcher has been fouled or damaged, it
must be dismantled for cleaning or repair.
2. To dismantle the water mist catcher, 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. Pull or push in the water mist catcher halfway out and mount an eye bolt in the top of
the water mist catcher.
Hook a tackle on to the eye bolt and lift the
water mist catcher away. Land it on a couple of wooden planks.

BM910-5.4 75 01

Note the position of the water mist


catcher. During mounting, the water mist
catcher must be re-mounted in the same
position.

4.

Note!
Take care not to damage the water mist
catcher during the lift.

BM910-5.4 75 02

4. Clean the water mist catcher with the same


cleaning fluid as used for the scavenge air
cooler element.

When referring to this page, please quote Procedure M91006 Edition 0211
0$1% :'LHVHO$6

Page 1 (2)

910-6.4

Water Mist Catcher


Mounting
Mounting
910-6.4

1.

1. Slide the water mist catcher into the scavenge air cooler housing.
Note!

BM910-5.4 75 03

Make sure to mount the water mist


catcher correctly. The screws of the
water mist catcher must face the exhaust
side of the engine.
Also note the markings on the water mist
catcher.
When the water mist catcher is half-way in,
remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.
2.
2. Tighten the screws at the end of the water
mist catcher.

BM910-5.4 75 04

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.

Page 2 (2)

When referring to this page, please quote Procedure M91006 Edition 0211
0$1% :'LHVHO$6

Air Cooler - Tools

When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S

Plate
P91063-0017

Page 1 (2)

Plate
P91063-0017
Item
No.
015
027

Page 2 (2)

Air Cooler - Tools


Item Description

Item
No.

Item Description

Guide rail, air cooler fore end


Guide rail, air cooler fore end

When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S

Travelling Trolley

When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S

Plate
P91064-0002

Page 1 (2)

Plate
P91064-0002
Item
No.
010

Travelling Trolley
Item Description

Item
No.

Item Description

Travelling trolley*
Note:
* When ordering this tool, please state
load and track width.

Page 2 (2)

When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S

Air Cooler - Lifting Tools

Plate
P91066-0001

Air Cooler - Lifting Tools


0001
P91066

When referring to this page, please quote Plate P91066 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91066-0001
Item
No.
011
023

Air Cooler - Lifting Tools

Item Description

Item
No.

Item Description

Lifting attachment air cooler fore end,


complete
Screw

Page 2 (2)

When referring to this page, please quote Plate P91066 Edition 0001
MAN B&W Diesel A/S

Air Cooler - Lifting Tools

When referring to this page, please quote Plate P91066 Edition 0010
MAN B&W Diesel A/S

Plate
P91066-0010

Page 1 (2)

Plate
P91066-0010
Item
No.
011
023
035
047

Page 2 (2)

Air Cooler - Lifting Tools

Item Description

Item
No.

Item Description

Crame beam
Screw
Distance pipe
Nut

When referring to this page, please quote Plate P91066 Edition 0010
MAN B&W Diesel A/S

911 - 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


Safety Valve
Relief Valve, Data
Relief Valve
Scavenge Air Receiver - Safety Valve, Data
Scavenge Air Receiver - Safety Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Safety Valve
MAN B&W Diesel

111-1

Data

SAFETY PRECAUTIONS For detailed sketch, 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.

Description

D11-01

Opening pressure

D11-02

Valve housing, tightening torque

When referring to this page, please quote Data D11101 Edition 0026

Value

Unit

200 5

bar

45

Nm

Page 1 (2)

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, e.g. P90951 refers to chapter 909.
Plate

Item No.

Description

P91351

10

Hydraulic pump, pneumatically operated

P91351

58

Hose with unions (3000 mm), complete

P90151

117

P91359

Page 2 (2)

Test equipment for combined safety valve


Torque Spanners

When referring to this page, please quote Data D11101 Edition 0026

Safety Valve
MAN B&W Diesel

911-1.2

Dismantling

When Side-mounted

1.

1. Remove the guard surrounding the safety


valve.
Unscrew the safety valve from the extension pipe.

When Top-mounted
3. Unscrew the safety valve from the cylinder
cover.

2.

M911010211D02

Remove and discard the mild steel disc.

M911010211D01

2. Dismantle the indicator cock and the intermediate pipe.

M911010211D03

3.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 1 (5)

911-1.3

Safety Valve
Overhaul (Adjustment)

1.

MAN B&W Diesel

1. If necessary, dismantle the safety valve and


clean all the parts in either gas oil, kerosene, or electro-cleaner.
2. Assemble the safety valve in two steps:

Insert the valve flap and the stop ring in


the valve guide and screw on the valve
housing.

Tighten the housing to the torque stated


M911010211O01

in the data, loosen and tighten again to


the torgue stated in the data.
3. Then mount:

the valve spindle

the spring

the adjusting screw

the lock nut

M911010211O02

2.

M911010211O03

3.

Page 2 (5)

When referring to this page, please quote Procedure M91101 Edition 0212

Safety Valve
MAN B&W Diesel

911-1.3

Overhaul (Adjustment)

4. To set the safety valve opening pressure:

4.

Set up the safety valve in the Fuel valve


test rig.

Connect the testing device to the hydraulic pump. Alternatively the hydraulic
hans pump can be used.

Loosen the lock nut on the safety valve.


Turn the adjusting screw until the valve
just closes.

Bleed the valve and hose until oil, without air bubbles, flows out from the
openings of the safety valve.

Tighten the adjusting screw of the

Tighten the lock nut.


Test the opening pressure.
Remove the valve from the fuel valve

M911010212O04

safety valve until the correct pressure is


indicated (see Data).

test rig.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 3 (5)

911-1.4

Safety Valve
Mounting

MAN B&W Diesel

When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.

M911010211M01

3. Mount a new sealing ring and a new or


overhauled safety valve.
When mounting the safety valve, apply
tools only on the hexagon on the safety
valve.
Mount the guard surrounding the safety
valve.

M911010211M02

2.

M911010211M03

3.

Page 4 (5)

When referring to this page, please quote Procedure M91101 Edition 0212

Safety Valve
MAN B&W Diesel

911-1.4

Mounting

When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.

When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.

M911010211M04

Mount a new mild steel disc in the bore.

M911010211M05

5.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 5 (5)

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

Shut off fuel oil


Stop lubricating oil supply
Lock the turbocharger rotors

Data
Ref.

Description

When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S

Value

Unit

Page 1 (2)

111-2

Relief Valve
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Page 2 (2)

Item No.

Description

When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S

Relief Valve

911-2.1

Checking
Relief Valve
60&
0211
Checking
911-2.1

1.

1. During running of the engine, check if there


are any leaks.
If a leak occurs, replace the O-ring inside
the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.

If one or more plates in the flame arrester


are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.

Note!

XZ911-2.1 209 01

Check on the whole circumference that all


the plates in the flame arrester are evenly
distributed and that no local openings exist.

The complete flame arrester has to be


replaced after a crankcase explosion.

XZ911-2.1 207 03

2.

When referring to this page, please quote Procedure M91102 Edition 0211
0$1% :'LHVHO$6

Page 1 (1)

Scavenge Air Receiver Safety Valve


MAN B&W Diesel

111-3

Data

SAFETY PRECAUTIONS For detailed sketch, 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

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

When referring to this page, please quote Data D11103 Edition 0001

Value

Unit

Page 1 (2)

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, e.g. P90951 refers to chapter 909.
Plate

Page 2 (2)

Item No.

Description

When referring to this page, please quote Data D11103 Edition 0001

Scavenge Air Receiver Safety Valve


MAN B&W Diesel

911-3.1

Checking

1. The scavenge air receiver safety valve


is calibrated at the factory and does not
require any adjustment.

2.

2. Check the scavenge air receiver safety


valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.

If this operation cannot be performed


smoothly, the safety valve must be
dismantled and cleaned.

M911030001C02

Use a piece of cloth to wipe out any dirt


from the Oring packing and close the
valve again. Tighten the counter nut.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 1 (5)

911-3.2

Scavenge Air Receiver Safety Valve


Dismantling

1.

MAN B&W Diesel

1. Dismount the safety valve from the scavenge air receiver.

M911030001D01

2. On some engines, a cover has to be removed in order to gain access to the safety
valve.

M911030001D02

2.

Page 2 (5)

When referring to this page, please quote Procedure M91103 Edition 0001

Scavenge Air Receiver Safety Valve


MAN B&W Diesel

911-3.3

Overhaul

1. Remove the split pin.

1.

Unscrew the nut thereby relieving the


spring tension.
Remove the nut, spring retainer and
washers.
Keep count of the washers.

2. Pull out the valve ap with spindle. If the


Oring seal is damaged remove it without
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.

M911030001O01

Pull out the spring.

M911030001O02

2.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 3 (5)

911-3.3

Scavenge Air Receiver Safety Valve


Overhaul

4.

MAN B&W Diesel

4. If the Oring seal has been removed mount


a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve ap and spindle while
taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the
washers.

M911030001O04

Tighten the nut until the split pin can be


mounted.
7. Check the valve according to 9113.1.

M911030001O05

5.

M911030001O01

6.

Page 4 (5)

When referring to this page, please quote Procedure M91103 Edition 0001

Scavenge Air Receiver Safety Valve


MAN B&W Diesel

911-3.4

Mounting
1.

M911030001M01

1. Mount the safety valve on the scavenge air


receiver.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 5 (5)

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, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Holding Down And End Chock Bolts


MAN B&W Diesel

112-2

Data

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.
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, mounting

When referring to this page, please quote Data D11202 Edition 0015

900

bar

Page 1 (2)

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, e.g. P90951 refers to chapter 909.
Plate

Item No.

P91263

Description
Hydraulic Tools for Holding-Down
Bolts and End Chock Bolts, Epoxy

P91351

010

Hydraulic pump, pneumatically operated

P91351

058

Hose with unions (3000 mm), complete

Page 2 (2)

When referring to this page, please quote Data D11202 Edition 0015

Holding Down and End Chock Bolts

912-2.1

Checking
Holding Down and End Chock Bolts
.0&
0208
Checking
912-2.1

Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.

When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6

Page 1 (5)

912-2.1

Holding Down and End Chock Bolts


Checking

1.

Checking the Bolt Tightening


1. The holding down bolts and end chock bolts
must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the
hydraulic tool slowly while constantly attempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pressure gauge when the nut comes loose
(loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.

EN912-1.1 205 01

The condition of the bolted joints, and thus


the general condition of the foundation, can
be effectively checked by comparing the tables from successive bolt checks.
If the loosening pressure' is below 80 per
cent of the tightening pressure, the relative
chocks shall always be checked for possible defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been
welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins
and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be followed.

Page 2 (5)

When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6

Holding Down and End Chock Bolts

912-2.1

Checking
3.

Side Chocks and Side Chock Liners


3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.

The first time the ship is sailing in a fullyloaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the liners can be knocked further inward.
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.

GN912-2.1 203 03

The liners located in way of each main


bearing on either side of the engine must
be fitted and knocked into position simultaneously.

The feeler gauge is applied at the 7 points


indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have
increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in
the table.
If this procedure does not improve the situation,
the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position
by means of hexagon socket set screws with
cup point.

When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6

Page 3 (5)

Holding Down and End Chock Bolts

912-2.1

Checking
Holding Down Bolts
Engine
frame Bolt
No.
No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Page 4 (5)

1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1

Port side
pressure

% dev.

remarks

Cylinder
No.

1
2
3

Starboard side
pressure

% dev.

remarks

Bolt
No.

1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1

Engine
frame
No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6

Holding Down and End Chock Bolts

912-2.1

Checking
Side Chocks and End Chock Bolts

Port side
Point
c d e

Chock
No.

Starboard side

Cylinder
No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Chock

d
e
f

Pres-

Port side

c, d, e, f, g

Starboard side

Devi-

Ch Bolt sure ation


2)
No. No. (kp/cm
%
bar

No.

A, B

FORE

c, d, e, f, g

1
2
3
4
5
6
7
8
9
10
11
12
13
14

1
2
3

A, B

Point
c d e

Deviation

Point

Point

a b c d e

a b c d e

Pressure

(kp/cm 2 )

bar

1
2

Bolt Ch
No. No.

1
E
2
b

b
a

Contact face No. 1

No. 2

B1

When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6

B2

B2

B1

AFT

No. 2

Page 5 (5)

Stay Bolts
MAN B&W Diesel

112-3

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

Data
Ref.

Description

Value

Unit

D12-04

Check measurement

0.4

mm

D13-01

Hydraulic pressure, mounting

900

bar

D13-02

Hydraulic pressure, dismantling

800 - 990

bar

When referring to this page, please quote Data D11203 Edition 0027

Page 1 (2)

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, e.g. P90951 refers to chapter 909.
Plate

Item No.

P91261

Description
Large Parts - Tools

P91351

010

Hydraulic pump, pneumatically operated

P91351

046

Hose with unions (1500 mm), complete

P91351

058

Hose with unions (3000 mm), complete

P91351

105

3-way distributor block, complete

Page 2 (2)

When referring to this page, please quote Data D11203 Edition 0027

Stay Bolts

912-3.1

Checking
0211 Bolts
Stay

S42MC

Checking
912-3.1

1.

1. Before retightening the stay bolts, remove


the protective caps.

Connect the high-pressure pump by means


of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
3. If the engine is equipped with split staybolts
and one or more staybolts have been dismantled, make sure that the staybolts are
mounted in such a way that, when the uppermost staybolt nut is loosened, there is a
clearance, as stated in Data, between the
contact face of the lowermost nut and the
bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.

HM912-3.0 28 01

2. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other on the middle of
the engine.

2.

HM912-3.0 28 02

D13-01

3.

HM912-3.0 28 07

D12-05

When referring to this page, please quote Procedure M91203 Edition 0211
MAN B&W Diesel A/S

Page 1 (2)

912-3.1

Stay Bolts
Checking

4.

4. Start the retightening of the stay bolts and


proceed to tighten the stay bolts in pairs,
working from the middle toward one end of
the engine and then from the middle again
toward the other end.
5. Maintain the hydraulic pressure at the value
indicated in D-1, and retighten the stay bolt
nuts with a tommy bar. Before relieving the
system of pressure, check with a feeler
gauge that the nuts bear against the contact face.

HM912-3.0 28 03

6. Reconnect the hydraulic tools to the pair of


stay bolts first tightened. Tighten to 10%
below D-2 and check if the nut is loose.

5.

D13-02

If the nut is not loose:


Tighten the stay bolts to D-2.
If the nut is loose:
Tighten all stay bolts once again to D-2.

HM912-3.0 28 04

7. After completing the retightening procedure, mount the protective caps.

HM912-3.0 28 06

6.

Page 2 (2)

When referring to this page, please quote Procedure M91203 Edition 0211
MAN B&W Diesel A/S

Crankcase Oil Outlet


MAN B&W Diesel

912-5.1

Checking

The crankcase oil outlets guide the lubricating


oil from the crankcase to the lubricating oil
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing.

1.

If the water content of the main engine


lube oil is rising, this may indicate that
the crankcase oil outlet sealings are fractured.
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing
remove:
Screws A
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.

M912050201C01

Note!

2.

Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.

M912050201C02

2. Lift away the rubber sealing diaphragms G


and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.

3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.

When referring to this page, please quote Procedure M91205 Edition 0201

Page 1 (2)

Crankcase Oil Outlet

912-5.1

Checking

MAN B&W Diesel

Metal bellow sealing


4.
4. Remove all screws A and grating B.

C
D

5. Remount four of the screws A at diametrically opposite positions.

B
A

6. Remove:
Screws C
Cover plate D
Screws E.

M912050201C04

7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are
found in the metal bellow sealing, it must
be replaced.
Note!

7.

It is recommended to always replace the


metal bellow sealing during inspection.

8. Replace gaskets G and H.


9. Mount metal bellow sealing F.

M912050201C07

10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.

Page 2 (2)

When referring to this page, please quote Procedure M91205 Edition 0201

Large Parts - Tools

Plate
P91261-0072

Large Parts - Tools


0072
P91261

When referring to this page, please quote Plate P91261 Edition 0072
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91261-0072
Item
No.
023
035
047
059
060
084
096
202

Large Parts - Tools

Item Description

Item
No.

Item Description

Hydraulic jack, complete


Support
Tommy bar
O-ring with back-up ring
O-ring with back-up ring
Tommy bar
Key, hexagon socket screw
Hydraulic tool set, complete

Page 2 (2)

When referring to this page, please quote Plate P91261 Edition 0072
MAN B&W Diesel A/S

Hydraulic Tools - Holding-Down and


End Chock Bolts (Epoxy Chocks)

When referring to this page, please quote Plate P91263 Edition 0059
MAN B&W Diesel A/S

Plate
P91263-0059

Page 1 (2)

Plate
P91263-0059
Item
No.
024
036
048
050
061
073
085
097
107
119
203

Page 2 (2)

Hydraulic Tools - Holding-Down and


End Chock Bolts (Epoxy Chocks)
Item Description

Item
No.

Item Description

Hydraulic jack for end-chock bolt M48


x 5.0
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, complete

When referring to this page, please quote Plate P91263 Edition 0059
MAN B&W Diesel A/S

913 - 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 - Hydraulic Tools
Lifting Tools, etc.
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

MAN B&W Diesel A/S

Hydraulic Tools

913-1

Hydraulic Tools
0206
913-1

1.

A. Snap-on coupling
B. Tool attachment thread
C. Bleed screw
D. Piston
E. Cylinder
F. Sealing rings
G. Spacer ring
H. Tommy bar
I. Nut
J. Stud or bolt

L. Lifting tool
S. Clearance

BG913-1.0 15 01

K. Extension stud

U. Milled recess for feeler gauge


2.
Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts must
only be loosened and tightened up by means of
the hydraulic tools supplied.
1. The hydraulic tools, except those for the
main bearings, consist of a jack with an internal thread to suit the tool attachment
thread on the stud or bolt, and a spacer ring
which is to be placed under the jack and
around the nut that is to be loosened or
tightened.

BG913-1.0 15 02

2. For the main bearings, the hydraulic tool


consists of a double jack with two extension
studs. This jack is designed for the simultaneous dismantling of both nuts on one side
of the main bearing.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 1 (12)

913-1

3.

Hydraulic Tools

3. The jack(s) is/are connected, via a distributor block, to a high-pressure pump, which
is set to deliver hydraulic oil at the pressure
indicated on the jack and on the data sheet
in the relevant section of this instruction
book. The stud or bolt concerned is thereby
lengthened relative to the oil pressure applied and the piston area, and the nut can
be loosened or tightened, as required, with
the aid of a tommy bar.
The jacks must never be overloaded or exposed to blows or impacts. They are
marked with a Max. lift, which must not be
exceeded.

BG913-1.0 15 03

4. The hydraulic jacks are so designed that, in


the event that the Max. lift limit is exceeded, the pressure is relieved at the bottom of
the pressure chamber and the oil will be
pressed out into the space between the
stud and the spacer ring.
When the pressure is relieved in this way,
the lowermost sealing ring will in most cases be damaged. Therefore inspect and, if
necessary, replace this sealing ring.
The oil used must be pure hydraulic oil or
turbine oil (with a viscosity of about SAE
20). Oils such as, for instance, lubricating
oil (system oil) or cylinder lubricating oil
must not be used, as these oils are normally alkaline and can thus damage the backup rings.
The following instructions must be closely
followed to prevent accidents or damage,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.

Warning!
Eye protectors and gloves must be used
when using hydraulic tools.

Page 2 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Hydraulic Tools

913-1

Loosening of Nut
Loosening of Nut
913-1

1.

Single Hydraulic Jack


1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar.
Place the spacer ring around the nut in
such a position that the tommy bar can be
applied through the slot when the nut is to
be loosened.
2. Screw the jack on to the tool attachment
thread of the bolt/stud, until the cylinder of
the jack bears firmly against the spacer
ring.

Unscrew the jack to create a clearance between the jack and spacer ring. See sketch.

BG913-1.1 15 01

Connect the hydraulic jack, the distributor


block and the high pressure pump by
means of high pressure hoses.

Loosen the bleed screw in the jack and fill


up the system with oil until oil without bubbles, flows out of the bleed hole. Then tighten the bleed screw again.

2.

When loosening nuts on very long bolts


(e.g. staybolts) it is recommended to unscrew the jack an additional half turn.
The clearance between the jack and spacer
ring ensures dismantling of the jack after
loosening the nut.

BG913-1.1 15 02

After adjustment, check that the parts are


guided correctly together and that there is
no clearance between the piston and cylinder of the jack.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 3 (12)

913-1

Hydraulic Tools
Loosening of Nut

3.

3. Increase the oil pressure to the prescribed


value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.
4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up
against the jack.

GN913-1 203 06

5. Relieve the system of pressure, disconnect


the high-pressure pump, and remove the
hydraulic tools.
Note!
Make sure not to exceed the max lift
stamped on the jack.

HM913-1.1 10 04

4.

GN913-1 203 08

5.

Page 4 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Hydraulic Tools

913-1

Loosening of Nut
6.

Double Hydraulic Jack


6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.
Grease the tool attachment threads with
molybdenum disulphide grease or graphite
and oil or similar.
Mount the extension studs on the main
bearing studs.
Using the lifting tool, place the spacer ring
over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.

Mount the two jacks (one by one using the


lifting tool) over the extension studs and
land them on the spacer ring.

BG913-1.1 15 06

Press the pistons and the cylinder of both


the hydraulic jacks firmly together.

Make sure that both the cylinders of the


jacks and the spacer ring are guided correctly together.

7.

Screw the upper nuts on to the threads of


the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.
7. The clearance between the pistons and the
cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm.
The clearance between the jack and spacer
ring ensures dismounting of the jack after
loosening the nut.

Loosen the bleed screws in both jacks, and


fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

BG913-1.1 15 08

Connect the hydraulic jacks, the distributor


block and the high pressure pump by
means of high pressure hoses.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 5 (12)

913-1

Hydraulic Tools
Loosening of Nut

8.

8. Increase the oil pressure to the prescribed


value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.
Unscrew the lower nuts 1 turns with the
tommy bar, making sure that the nuts are
not screwed up against the extension stud.
9. Relieve the system of pressure, disconnect
the high-pressure pump, and remove the
hydraulic tools.

Note!

BG913-1.1 15 09

Make sure not to exceed the max lift


stamped on the jack.

BG913-1.1 15 11

9.

Page 6 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Hydraulic Tools

913-1

Tightening of Nut
Tightening of Nut
913-1

1.

Single Hydraulic Jack


1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.
Clean and lubricate the tool attachment
thread and the thread in the nut with molybdenum disulphide grease or with graphite
and oil or similar.
Fit the round nut on the thread and tighten
it with the tommy bar.
Check with a feeler gauge that the contact
face of the nut bears on the entire circumference.

2. Press the piston and the cylinder of the jack


firmly together.
Screw the hydraulic jack on to the tool attachment thread.

BG913-1.2 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.

2.
Make sure that the cylinder of the jack
bears firmly against the spacer ring and
that the parts are guided correctly together
Connect the hydraulic jack, the distributor
block and the high-pressure pump by
means of high-pressure hoses.
Loosen the bleed screw in the jack and fill
up the system with oil, until oil without bubbles flows out of the bleed hole.

BG913-1.2 15 02

Re-tighten the bleed screw.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 7 (12)

913-1

Hydraulic Tools
Tightening of Nut

3.

3. Increase the oil pressure to the prescribed


value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.
4. While maintaining the pressure, check with
a feeler gauge introduced through the recess at the bottom of the spacer ring that
the nut bears against the contact face.
5. Relieve the system of pressure, disconnect
the pump, and remove the hydraulic jack.

GN913-1 203 17

6. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nut as described under Loosening, points 6-7-8, and then
tighten the nut again according to the procedure under Tightening', points 3-4-5.

GN913-1 203 18

4.

Page 8 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Hydraulic Tools

913-1

Tightening of Nut
7.

Double Hydraulic Jack


7. Thoroughly clean the nuts, the threads on
the main bearing studs, the contact faces,
and the surrounding parts.
Clean and lubricate the tool attachment
thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil.
Fit the round nuts on the threads and tighten them with the tommy bar.
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circumference.

Using the lifting tool, place the spacer ring


over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of tightening the
nuts.

BG913-1.2 15 07

Mount the extension studs on the main


bearing studs.

8.

8. Press the piston and the cylinder of both


the hydraulic jacks firmly together.
Mount the two jacks (one by one using the
lifting tool) over the extension studs and
land them on the spacer ring.
Make sure that both the cylinders of the
jacks and the spacer ring are guided correctly together.
Screw the upper nuts on to the threads of
the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.

Loosen the bleed screws in both jacks, and


fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

BG913-1.2 15 08

Connect the hydraulic jacks, the distributor


block and the high pressure pump by
means of high pressure hoses.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 9 (12)

913-1

Hydraulic Tools
Tightening of Nut

9.

9. Increase the oil pressure to the prescribed


value, and tighten the nuts by means of the
tommy bar applied through the slots of the
spacer ring.
10. While maintaining the pressure, check with
a feeler gauge introduced through the recesses at the bottom of the spacer ring that
the nuts bear against the contact face.
11. Relieve the system of pressure, disconnect
the pump, and remove the hydraulic tools.

BG913-1.2 15 10

12. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nuts as described under Loosening', point 8, and then tighten
the nuts again according to the procedure
under Tightening', points 9-10-11.

BG913-1.2 15 11

10.

Page 10 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Hydraulic Tools

913-1

Maintenance
Maintenance
913-1

1.

1. The hydraulic jacks require no maintenance


except replacement of defective sealing
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.
The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of
compressed air.
Warning!

Make sure that there are no marks or


scratches on the sliding surfaces of the
parts. The presence of metal particles will
damage the sealing rings.

BG913-1.4 15 01

Always use eye protection when working


with compressed air.

Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease.

2.

BG913-1.4 15 02

2. The pistons and cylinders of the double


jacks are separated in the same easy way
as described for the single jack.

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

Page 11 (12)

913-1

Hydraulic Tools
Maintenance

3.

3. When changing the sealing rings, first


mount the back-up ring and then the O-ring.
Warning!
Note that the back-up ring (1) must be
away from the pressure chamber and the
O-ring (2) close to the pressure chamber.
See the sketch for the correct mounting of
both the upper and the lower sealing rings.
The same principle applies to all the jacks.

BG913-1.4 15 03

4. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.

BG913-1.4 15 04

4.

Page 12 (12)

When referring to this page, please quote Procedure M91301 Edition 0206
0$1% :'LHVHO$6

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, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a
Molybdenum Disulphide (MoS 2) based lubricant.
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. Self-locking nuts.
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. Screws and nuts locked with glue/Loctite.


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, please quote Procedure M91304 Edition 0201
0$1% :'LHVHO$6

Page 1 (1)

Torque Spanner

913-5

Torque Spanner
/0&
0205
913-5

Before screwing the nuts on, the threads and


the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are
to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened
to the stated torque and then to the next splitpin hole.
The torque spanner must not be used for torques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided
with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,
there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle
appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl
system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the spanner, and a small click is heard.
When the torque spanner is not in use, the
spring inside should be released by adjusting to
minimum torque.

When referring to this page, please quote Procedure M91305 Edition 0205
0$1% :'LHVHO$6

Page 1 (1)

Tightening Gauge

913-6

Tightening Gauge
0205
913-6

Preparations
Before screwing on the nuts, grease the
threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
= 0.10.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
See Procedure 913-5.
Apply a pre-tightening torque of:
thread M8 M20 = 50 Nm
thread M22 M27 = 100 Nm
thread M30 M39 = 150 Nm
thread M42 M48 = 200 Nm
This is in order to ensure a uniform basis for the
subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge
round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 3045 and 60,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
When tightening new studs or bolts for the first
time, loosen again and repeat the procedure
including pre-tightening with a torque spanner,
to allow the parts to settle.
See Procedure 913-5.









7
;

G
Q
D














0
+

When referring to this page, please quote Procedure M91306 Edition 0205
0$1% :'LHVHO$6

Page 1 (1)

Screws and Nuts


MAN B&W Diesel

913-7.1

Locking

Some screwed and bolted connections on the


engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.

1.

When reassembling the engine after overhauls,


it is vital that all such screws and nuts are
again locked correctly.

Make sure only to mount locking devices


on nuts and screws which have been
mounted with locking devices by the engine manufacturer.

1. Lock washers, tab washers, locking


plates, etc., must always be replaced. The
tab-like projections, etc., on the washers
are to be bent back over one of the flats of
the screw or nut concerned.

M913070207C01

Note!

2.

2. Used spring washers must be replaced.

To tighten a self-locking nut to a specific


torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data
sheet of a procedure.

M913070207C02

3. Self-locking nuts may only be used five


times. Therefore, give the nut a centre
punch mark each time it is loosened.

M913070207C03

3.

When referring to this page, please quote Procedure M91307 Edition 0207

Page 1 (4)

Screws and Nuts

913-7.1

Locking

Fig. 1

MAN B&W Diesel

Locking wire should be fitted after the screws


or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Always fit new wire after tightening-up the units.

Fig. 2

Any tendency of the screws or nuts to loosen


will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.

Fig. 3

Fig. 1: Insert wire, grasp the upper end of the


wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.
Fig. 2: Twist the wire clockwise until it is just
short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approximately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180, equal
to half of a complete turn.

Fig. 6

M913070207C04

Fig. 5

Fig. 4

Fig. 3: Insert the uppermost wire in the second


screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,
and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it
min. 3 twists, counterclockwise until tight.

Fig. 7

Fig. 6: During the final twisting motion, bend


the wire along the screw head. Cut off excess
wire.

Fig. 8

M913070207C05

Fig. 7-9: Show the preferred ways of mounting


the locking wire on screws with wire holes oriented in different angles.

Page 2 (4)

Fig. 9

When referring to this page, please quote Procedure M91307 Edition 0207

Screws and Nuts


MAN B&W Diesel

913-7.1

Locking

Fig. 10: Shows how to route the locking wire


on screws in different planes.
Fig. 11: Wire that passes over the top of a nut
is an acceptable alternative only if it routes
around the protruding screw thread.

Fig. 10

Fig. 12: Wire that passes over the top of a nut


is also an acceptable alternative if the hole is
located as shown in the figure.

Fig. 11

Fig. 13: Where drilling of locking wire holes has


caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.

Fig. 12

Fig. 14: Locking wire can be mounted to any


other part of the assembly if nothing else is
possible.

M913070207C06

Fig. 13

Fig. 14

When referring to this page, please quote Procedure M91307 Edition 0207

Page 3 (4)

913-7.1

Screws and Nuts


Locking

Fig. 15

MAN B&W Diesel

Cam Lock Washers with rising cams on one


side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam
face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.

M913070207C15

Fig. 16: Different uses of the cam lock washers.


Fig. 17: Don not use the cam lock washers in
conjunction with other loose washers.

Fig. 16.

Note!

M913070207C16

Cam lock washers must be installed in


pairs and are not to be substituted by
other typers of washers.

M913070207C17

Fig. 17

Page 4 (4)

When referring to this page, please quote Procedure M91307 Edition 0207

Lubricating Procedures

913-11

Lubricating Procedures
.0&&
0204
913-11

Molybdenum Disulphide (MoS2)


The following procedure is to be followed prior
to the mounting of metal surfaced parts which
are to function as seals.
Clean the surface with a cleaning fluid
and ensure that the entire surface is
completely free of grease.
Allow 5 minutes for the cleaning fluid to
evaporate.
With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote G-n Plus, or the like) hard onto the
metal surface.
Remove any excessive paste and ensure
that the metal surface is only coated with
a thin, uniform, layer of the above mixture.
Protect the wet paste and cloth from dust
or other foreign particles.

When referring to this page, please quote Procedure M91311 Edition 0204
0$1% :'LHVHO$6

Page 1 (1)

Accessories for Hydraulic Tools

Plate
P91351-0033

Accessories for Hydraulic Tools


0033
P91351

Working Pressure 900 Bar

When referring to this page, please quote Plate P91351 Edition 0033
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91351-0033
Item
No.
010
046
058
105
117
130
166
201
213
225
237
249

Accessories for Hydraulic Tools

Item Description

Item
No.

Item Description

Hydraulic pump, pneumatic operated


Hose with unions (1500mm), complete
Hose with unions (3000mm), complete
2-way distributor block, complete
4-way distributor block, complete
9-way distributor block, complete
Angle union
Quick coupling, male
Quick coupling, female
Disc, round-plain, Cu 11x3mm
Bleeder screw
Disc, round-plain, Fe 11x9mm

Page 2 (2)

When referring to this page, please quote Plate P91351 Edition 0033
MAN B&W Diesel A/S

Lifting Tools, Etc.

Plate
P91356-0052

Lifting Tools, Etc.


0052
P91356

When referring to this page, please quote Plate P91356 Edition 0052
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91356-0052
Item
No.
018
020
031
055
114
126
138
140
222
283
305

Lifting Tools, Etc.

Item Description

Item
No.

Item Description

Forged-bent screw shackle, 8mm


Forged-bent screw shackle, 10mm
Forged-bent screw shackle, 12mm
Forged-bent screw shackle, 20mm
Lifting eye bolts, 10mm
Lifting eye bolts, 12mm
Lifting eye bolts, 16mm
Lifting eye bolts, 20mm
Chain tackle, 1000kg
Pull lift, 750kg
Wire rope, 3m

Page 2 (2)

When referring to this page, please quote Plate P91356 Edition 0052
MAN B&W Diesel A/S

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

Page 1 (2)

Plate
P91357-0003
Item
No.
013

Open Ended Spanners

Item Description

Item
No.

Item Description

Open-ended spanner, size NV65mm

Page 2 (2)

When referring to this page, please quote Plate P91357 Edition 0003
MAN B&W Diesel A/S

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)

Plate
P91358-0002
Item
No.
020
081

Open-Ended Slugging Spanners

Item Description

Item
No.

Item Description

Open-ended slugging spanner, size


NV30mm
Open-ended slugging spanner, size
NV46mm

Page 2 (2)

When referring to this page, please quote Plate P91358 Edition 0002
MAN B&W Diesel A/S

Torque Spanners

Plate
P91359-0002

Torque Spanners
0002
P91359

When referring to this page, please quote Plate P91359 Edition 0002
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91359-0002
Item
No.
014
026
038
040

Torque Spanners

Item Description

Item
No.

Item Description

Torque wrench, 8 - 400Nm


Adapter for socket wrench, 10 x 12.5
mm
Torque wrench, 40 - 200Nm
Torque wrench, 140 - 760Nm

Page 2 (2)

When referring to this page, please quote Plate P91359 Edition 0002
MAN B&W Diesel A/S

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)

Plate
P91360-0002

Pliers

Item
No.
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,
ring,
ring,
ring,
ring,

size
size
size
size
size
size
size

Item
No.

Item Description

0.9mm
1.3mm
1.8mm
0.9mm
1.1mm
1.8mm
2.3mm

When referring to this page, please quote Plate P91360 Edition 0002
MAN B&W Diesel A/S

Combination Spanners
MAN B&W Diesel

When referring to this page, please quote Plate P91361 Edition 0052

Plate
P91361-0052

Page 1 (2)

Combination Spanners

Plate
P91361-0052
Item
No.
015
027
039
040
052
064
076
088
090
100
111
123
135
147
159
160
172
184
196
206
218
220
231

Page 2 (2)

MAN B&W Diesel

Item Description
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination

spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,

size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size

Item
No.

Item Description

NV10mm
NV11mm
NV12mm
NV13mm
NV14mm
NV15mm
NV16mm
NV17mm
NV18mm
NV19mm
NV21mm
NV22mm
NV24mm
NV27mm
NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm

When referring to this page, please quote Plate P91361 Edition 0052

Ring Slugging Spanners

Plate
P91362-0059

Ring Slugging Spanners


0059
P91362

When referring to this page, please quote Plate P91362 Edition 0059
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91362-0059
Item
No.
010
022
034
046
058
071
083
095
105
117

Ring Slugging Spanners

Item Description

Item
No.

Item Description

Slugging spanners, ring size NV30mm


Slugging spanners, ring size NV32mm
Slugging spanners, ring size NV34mm
Slugging spanners, ring size NV36mm
Slugging spanners, ring size NV41mm
Slugging spanners, ring size NV46mm
Slugging spanners, ring size NV50mm
Slugging spanners, ring size NV55mm
Slugging spanners, ring size NV60mm
Slugging spanners, ring size NV65mm

Page 2 (2)

When referring to this page, please quote Plate P91362 Edition 0059
MAN B&W Diesel A/S

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.

Item Description

016
028
030
041
100
150
161

Tool set, complete, size 10-22 mm


Tool set, complete, size 24-46 mm
Hex key tool set, complete
Adapter for socket wrench, 20->12.5 mm
Socket spanner, S=46 mm
Hex key, S=22 mm
Hex key, S=24 mm

Page 2 (2)

Item
No.

Item Description

When referring to this page, 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

Plate
P91364-0059
Item
No.
011
023

Page 2 (2)

Open-ended Spanners
Item Description

Item
No.

Item Description

Open ring wrench, 14 - 17mm


Open ring wrench, 19 - 22mm

When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S

Instruments

When referring to this page, please quote Plate P91366 Edition 0065
MAN B&W Diesel A/S

Plate
P91366-0065

Page 1 (2)

Plate
P91366-0065
Item
No.
048
050
061
073

Page 2 (2)

Instruments

Item Description

Item
No.

Item Description

Autolog, measuring tool for crankshaft


Feeler gauge
Slide caliper
Dial gauge and stand tool

When referring to this page, please quote Plate P91366 Edition 0065
MAN B&W Diesel A/S

Warning

S900-1

0001
S900-1

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

When referring to this page, please quote S900 Edition 0001


MAN B&W Diesel A/S

Page 1 (1)

S35MC

VOLUME III
COMPONENTS
DESCRIPTION

900 - Introduction
Documents in this Chapter

90001
90002
90003
90004
90023
90030

0058
0001
0001
0001
0027
0009

Table of Contents, Volume III


Cross Section through Engine
Ordering of Insulation
Designations and Symbols
Software Licence - Standard Conditions
Instructions for Main Engine
Description

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Table of Contents

900

Volume III - Components Description


No.

Edition

Title

900 - Introduction
Table of Contents
90001 0058 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90023 0027 Instructions for Main Engine
90030 0009 Description
901 - Cylinder Cover
90101 0152 Cylinder Cover
90103 0007 Indicator Cock - Mounting
902 - Piston with Rod & Stuffing Box
90201 0201 Piston and Piston Rod
90205 0122 Piston Rod Stuffing Box
903 - Cylinder Liner and Cylinder Lubrication
90301 0162 Cylinder Frame
90302 0175 Cylinder Liner and Cooling Jacket
90304 0025 Cylinder Liner - Details
90305 0146 Cylinder Lubricators
90309 0025 Cylinder Lubricator System - Details
904 - Crosshead with Connecting Rod
90401 0145 Connecting Rod and Crosshead
90403 0009 Lubricating and Cooling Oil-Flow
905 - Crankshaft, Thrust Bearing and Turning Gear
90501 0150 Crankshaft
90502 0045 Arrangement of Fore End
90503 0016 Arrangement of Angle Encoder
90504 0001 Axial Vibration Monitor
90505 0128 Thrust- and Guide Bearing
90510 0113 Turning Gear
90511 0035 Turning Wheel
90512 0001 Turning Gear - Details
90513 0036 Tacho System
90513 0046 Tacho System
90513 0047 Tacho System
906 - Control Gear
90600 0095 Arrangement of Chain Drive and Camshaft
90601 0100 Chain Drive and Guide Bars
90602 0110 Chain Drive - Lubrication
MAN B&W Diesel A/S

Page 1 (3)

Table of Contents

900

Volume III - Components Description


No.
90603
90611
90612
90613
90615
90618
90620
90621
90648

Edition
0096
0170
0102
0136
0138
0139
0098
0083
0012

Title
Chain Tightener
Camshaft and Chain Wheel
Arrangement of Indicator System
Camshaft Bearing
Arrangement of Governor
Regulating Shaft
Engine-Side Control Console
Engine-Side Control Console - Details
Pneumatic Components

907 - Starting Air System


90702 0066 Main Starting Valve
90703 0068 Starting Air Distributor
90704 0050 Starting Valve
908 - Exhaust Valve
90801 0184 Exhaust Valve - Lower Parts
90802 0041 Exhaust Valve - Details
90803 0032 Exhaust Valve - Upper Parts
90804 0017 Exhaust Valve Upper Parts - Details
90805 0130 Exhaust Valve - Actuator
90806 0057 Exhaust Valve - Pipe System
90810 0075 Arrangement of Cooling Water Pipes
909 - Fuel Oil System
90901 0206 Fuel Pump
90902 0149 Fuel Pump Gear
90910 0152 Fuel Valve
90911 0021 Fuel Valve Function
90913 0071 High-Pressure Pipes
90913 0110 High-Pressure Pipes
90914 0064 Fuel Oil System
90915 0076 Fuel Oil System - Details
90915 0077 Fuel Oil System - Details
90915 0078 Fuel Oil System - Details
910 - Turbocharger System
91000 0016 Gas and Air System
91001 0127 Scavenge Air Receiver
91002 0141 Arrangement of Charging Air Pipe
91003 0220 Exhaust Pipes and Receiver
91004 0081 Exhaust Receiver - Details
91005 0113 Air Cooler
91006 0025 Arrangement of Auxiliary Blower
91009 0010 Air Cooler System - Cleaning
MAN B&W Diesel A/S

Page 2 (3)

Table of Contents

900

Volume III - Components Description


No.
91010
91018

Edition
0028
0003

Title
Air Cooler - Frame
Air Cooler System

911 - Safety Equipment


91101 0037 Safety Valve - Cylinder
91102 0025 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0095 Arrangement of Safety Cap
912 - Assembly of Large Parts
91201 0057 Arrangement of Stay Bolts
91201 0094 Arrangement of Stay Bolts
91205 0154 Frame Box
91207 0062 Arrangement of Piston Cooling
91208 0004 Chain Wheel Frame - Upper
91209 0005 Chain Wheel Frame - Lower
91210 0164 Bedplate
91211 0086 Axial Vibration Damper
91216 0007 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0005 Top Bracing - Arrangement

MAN B&W Diesel A/S

Page 3 (3)

Cross Section through Engine


MAN B&W Diesel

When referring to this page, please quote Plate P90001 Edition 0058

Plate
P90001-0058

Page 1 (2)

Plate
P90001-0058
Item
No.

Cross Section through Engine


MAN B&W Diesel

Item Description

Item
No.

Item Description

Note:
* For Guidance Only

Page 2 (2)

When referring to this page, please quote Plate P90001 Edition 0058

Ordering of Insulation
MAN B&W Diesel

When referring to this page, please quote Plate P90002 Edition 0001

Plate
P90002-0001

Page 1 (1)

Designations and Symbols


MAN B&W Diesel

Normal layout

Plate
P90003-0001

Forward (fwd)

Starboard (stbd) side of

Port side of ship

Fore end
1
2
3
4
5
6
7

Manoeuvring side of engine

Aft end

Cyl. nos. always counted


from fore end

Exhaust side of engine

Propeller

Clockwise direction of rotation


defined from aft end of engine

When referring to this page, please quote Plate P90003 Edition 0001

Page 1 (1)

Software License, Standard Conditions


MAN B&W Diesel

Plate
P90004-0001

Standard Conditions of Software Licence


Software supplied by MAN B&W separately or included as a part of any system or embedded in
any device is licensed by MAN B&W Diesel A/S (MAN B&W) subject to the customer's acceptance of the following standard conditions of licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMERS ACCEPTANCE OF THESE
CONDITIONS.
1. Right of Ownership
Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W
against a once-for-all fee. MAN B&W and its software suppliers retain the right of ownership to the
software.
If the engine plant - for which the software is acquired - is transferred to a third party the customer has the right to assign the licence to this third party, provided that the third party agrees to
the terms of this licence agreement and provided that the customer does not retain any copies of
the software.
2. Copyright
The customer must not copy the software or any part thereof. Furthermore the customer is not
allowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software.
3. Support
If required by the customer MAN B&W shall provide technical support for installation and training
in use of the software against separate payment.
4. Updating
The non-exclusive user's licence does not include any updating of the software. If and to the extent MAN B&W updates the programs or develops new versions, such updates or new versions
shall be made available to the customer against separate payment.
5. Warranty & Liability
MAN B&W warrants that the software and data media containing the software are free of defects
in material and workmanship at the time of delivery. If the software and data media are found to
be defective and are returned to MAN B&W within 90 days from the date of delivery, they will be
replaced free of charge.
Except as stated above, MAN B&W disclaims liability for breach of conditions or warranties, either
expressed or implied, with respect to the software and data media, including warranties of suitability and applicability for a particular purpose.

When referring to this page, please quote Plate P90004 Edition 0001

Page 1 (2)

Plate
P90004-0001

Software License, Standard Conditions


MAN B&W Diesel

MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the
form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. MAN B&W shall in no event be liable for
any damages resulting from loss of data, profits or use of equipment, or for any special, incidental
consequential damages arising out of or in connection with the use or performance of the software.
The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&Ws software
suppliers.
6. Law
MAN B&W's tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.

Page 2 (2)

When referring to this page, please quote Plate P90004 Edition 0001

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

Engine Types 35-98MC/MC-C

A90030-0009

MAN B&W Diesel


901 Cylinder Cover
Cylinder Cover

The cylinder cover is made of steel.


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.

Valve bores

The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.
The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet, safety valve and indicator cock.

Cooling

A cooling jacket is mounted on the lower part of the cylinder cover, whereby a
cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores, to the space around the
exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe:
On some engine types, an amount of water is also passed directly from the
cylinder cover to the exhaust valve housing through a cooling water connection.

Tightening

The cylinder cover is tightened against the top of the cylinder liner with nuts
and long studs fitted in the cylinder frame. The nuts are tightened with hydraulic tools.
Sealing between the cylinder cover and cylinder liner is obtained by means of a
sealing ring of mild steel.

902 Piston with Rod and Stuffing Box


Piston

The piston consists of two main parts:


Piston Crown
Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the piston skirt is tightened to the piston crown.

When referring to this page, please quote Description A90030 Edition 0009

Page 1 (23)

Engine Types 35-98MC/MC-C

A90030-0009

MAN B&W Diesel


The piston crown is provided with one groove all the way around, or with three
smaller grooves for the fitting of lifting tools.
The piston crown is provided with chromium-plated grooves for four piston
rings.
Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR).
Piston rings Nos. 2, 3 and 4 have oblique cuts:
piston ring No. 3 has a right-hand cut,
and
piston rings Nos. 2 and 4 have left-hand cuts.
On some engines, the piston rings are provided with Alu-coating to improve
the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel off.

Piston Rod

The piston rod has a through-going bore for the cooling oil pipe, which is secured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe
or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.
The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the flow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.

Page 2 (23)

When referring to this page, please quote Description A90030 Edition 0009

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 is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space.
The stuffing box also prevents scavenge air (in the scavenge air space) from
leaking into the crankcase.
The stuffing box housing consists of two parts, which are bolted together.

Scraper/sealing
rings

The housing is provided with a number of machined ring grooves:

The uppermost groove holds a scraper ring with oblique edges, which
serves to prevent sludge from the scavenge box from being drawn
down to the other rings.
Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC
type engines).
The ring grooves in the middle are fitted with sealing rings.
The lowermost ring grooves are fitted with scraper rings which scrape
the lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase through
bores in the stuffing box housing.
Through bores in the housing and a pipe, the stuffing box communicates with
a control funnel on the outside of the engine, which enables the sealing/scraping performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.

903 Cylinder Liner and Cylinder Lubrication


Cylinder Frame

The cylinder section of the engine consists of a cylinder frame with a bolted-on
or integrated camshaft housing. The cylinder section is tightened together with
the engine framebox and the bedplate by means of stay bolts. Alternatively as
a complete welded assembly integrating the scavenge air receiver into the cylinder frame.

Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes.
On the exhaust side of the cylinder frame there are openings which connect
the scavenge air space around the cylinder liner with the longitudinal scavenge
air receiver of the engine.

When referring to this page, please quote Description A90030 Edition 0009

Page 3 (23)

A90030-0009

Engine Types 35-98MC/MC-C


MAN B&W Diesel
There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.

Cylinder cover
studs

Studs for fastening the cylinder cover are mounted in the cylinder frame.

Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is supplied
Cooling Jacket
at the lower part of the cooling jacket.
On slim-type liners, the water continues directly to the upper part of the cooling jacket, whereas on the bore-cooled type liner, the water first passes
through the cooling bores. From the top of the cooling jackets, the water flows
through water connections to the cooling jacket on the lower part of the cylinder cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by the
tensioning force from the cylinder cover studs being transmitted via the cylinder cover.
Scavenge air ports

The part of the cylinder liner which is located in the scavenge air space of the
cylinder frame is provided with a number of scavenge air ports, which are un
covered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to
give the scavenge air a rotary movement in the cylinder.

Cylinder lubrication

In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with non-return valves for the supply of lubricating oil to the cylinder.

PC-ring

On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of
the cylinder liner. The purpose of the PC-ring is to prevent the building-up of
deposits on the piston topland and, in turn, prevent the wiping away of the cylinder lubricating oil. Consequently, the PC-ring contributes to reducing the
wear of liners and rings.

Cylinder
Lubricators

The engine is equipped with mechanically or electronically controlled cylinder


lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied.
See also Volume I, OPERATION, Chapter 707.

Page 4 (23)

When referring to this page, please quote Description A90030 Edition 0009

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.
The centre part of the crosshead is designed as a bearing journal which is
housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston rod
to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
See also Volume I, OPERATION, Chapter 708.

Piston rod foot

The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.

Lubrication

The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and through a bore in the connecting rod for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder
for the purpose of checking the temperature and flow before the oil is passed
on to the lube oil tank.

Guide shoes

The sliding faces of the guide shoes are lined with cast-on bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.
On some engines, the guide shoes are provided with counterweights.

Tightening

The crosshead bearing is held together by studs and nuts. The nuts are tightened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal and assembled in the same way as the crosshead bearing.

905 Crankshaft and Turning Gear


Crankshaft

The crankshaft is either of the semi-built type, where the parts are shrunk together, or it is a one-piece forging.
The main bearings are lubricated via a main lubricating oil pipe that branches
off to the individual bearings, whereas oil for lubricating the crankpin bearings
is supplied from the crossheads through bores in the connecting rods.

When referring to this page, please quote Description A90030 Edition 0009

Page 5 (23)

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. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order and 4th order moment compensators are installed, if required according to vibration calculations.
Marine engines (except geared plants):
At the aftmost end of the engine, a thrust bearing is fitted.
The thrust bearing serves the purpose of transmitting the axial thrust of the
propeller through propeller shaft and intermediate shafts to the ships hull.
The crankshaft is provided with a thrust collar which transmits the thrust to a
number of segments mounted in a thrust shoe on either side of the thrust collar.
The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal
cast onto the wearing faces against the thrust collar. See also Volume I, OP
ERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the en
gine. The oil is supplied between the segments through spray pipes and spray
nozzles.
The thrust bearing is provided with alarm, slow-down, and shut-down devices
for low lube oil pressure and high segment temperature. See also Volume I,
OPERATION, Chapter 701.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di
rection.

Axial Vibration
Damper

To counteract heavy axial vibrations, and any resultant adverse forces and
vibrations, the crankshaft is provided with an axial vibration damper. See also
Section 912, Assembly of large parts further on in this text.
The damper consists of a piston and a slit-type housing. The piston is made
as an integrated collar on one of the main bearing journals, and the housing is
mounted on the pertaining main bearing support.
The axial movement is damped as a result of the restrictions incorporated in
the bores which interconnect the oil-filled chambers on the two sides of the
piston.
Lubricating oil is supplied to both sides of the piston from the main system.

Page 6 (23)

When referring to this page, please quote Description A90030 Edition 0009

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.
Through a planetary gearing, the motor drives a horizontal shaft equipped with
a gear wheel which can be axially displaced manually, so as to engage with the
turning wheel of the engine.
The turning gear is provided with a safety arrangement consisting of a safety
lever which must be lifted before the gear wheel of the turning gear can be
made to engage with the turning wheel.
When the safety lever is in its bottom position, it prevents the gear wheel of
the turning gear from engaging with the turning wheel.
Immediately the lever is lifted away from the disengaged position, an interlock
valve inserted in the starting air system of the engine is actuated. This interlock
prevents starting air from being supplied to the engine as long as the turning
gear is in the engaged position.
See also Volume I, OPERATION, Chapter 703.

Warning!

Dismantling of
working parts:

During any dismantling of working parts of the


engine, the turning gear must be in the engaged
position in order to prevent outside forces from
turning the engine, thus causing injuries to personnel or damage to the machinery.
See Volume II, MAINTENANCE, DATA pages.

Pressure testing of starting


valves:

The turning gear must be in the disengaged position during pressure testing of starting valves, as
a leaky valve may cause the engine to rotate, and
damage the turning gear.
See Volume I, OPERATION, Chapter 703.

906 Mechanical Control Gear


Chain Drive

The camshaft with cams for operating the fuel pumps, exhaust valves and indicator drive (option) is driven from the crankshaft through a chain drive.
The chain drive consists of one or more roller chains running on chain wheels
fitted on the crankshaft and the camshaft. The chain is kept tightened by a
chain tightener placed in the chain casing between the crankshaft and the
camshaft.
The long free lengths of the chain are guided by rubber-clad guide bars. Lubricating oil is supplied through spray pipes fitted at the guide bars and chain
wheels.

When referring to this page, please quote Description A90030 Edition 0009

Page 7 (23)

A90030-0009

Engine Types 35-98MC/MC-C


MAN B&W Diesel

Camshaft

The camshaft is made in one or more sections.


If it is made in two or more sections, the sections are assembled by means of
flange couplings.
The camshaft has, for each cylinder:
one cam for operation of the fuel pump
one cam for operation of the exhaust valve
one cam for operation of the indicator drive (option)
The fuel pump and exhaust valve cams are shrunk on to the shaft by heating,
whereas the indicator cams are in two parts, which are assembled with fitted
bolts.
The camshaft rotation constantly follows that of the crankshaft.

Bearings

The camshaft is carried in bearing assemblies which are fitted in the roller
guide housings. See also Volume I, OPERATION, Chapter 708.

Engine timing

The engine timing is adjusted by forcing lubricating oil in between the cams,
couplings or chain wheel and the shaft, which enables the parts to be turned in
relation to each other. See Volume II, Chapters 906, 908 and 909.

Pin gauges

After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are delivered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.

Indicator Valve

Each cylinder is fitted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.
Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.
Note!
For indicator valves of the double-seated design with a spring-loaded closing
face:
In order to prevent overstressing, close the valve lightly before starting the
engine, and retighten the valve when the engine has reached its normal service temperature.

PMI-System

Page 8 (23)

See separate instructions for operating the PMI-system (option).

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Moment
Compensators

On the basis of calculations, the engine may be provided with fly


weights to counteract engine forces and moments.
Caution!
If the chain drives for the compensators have been dismantled, the
flyweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly fitted moment compensators may excite heavy vibrations.

1st order moment

Applicable on 4-cylinder engines. The moment compensator is arranged


as adjustable flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in
the main chain drive.
This moment compensator consists of a (new) chain-tightener wheel
with an incorporated flyweight and a flyweight rotating with the crank
shaft.

2nd order moment

Applicable on 4-5 and 6-cylinder engines. The moment compensator is


arranged as flyweights built into the main chain drive.
On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.

4th order moment

The moment compensator is arranged as flyweights built into chain


drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.

907 Starting Air System


Starting Air System

The starting air system consists of the manoeuvring system and the
starting air components, which comprise:
Main Starting Valve
Starting Air Distributor
Starting Valves
The manoeuvring system is of electric/pneumatic design.
See also Volume I, OPERATION, Chapter 703.

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Page 9 (23)

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.
The main starting valve consists of a large ball valve and, optionally, a smaller
ball valve for slow-turning prior to starting the engine, which is fitted as a bypass for the large valve. Both valves are operated by pneumatic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted for setting the slow-turning speed.
Furthermore, a non-return valve is incorporated to prevent blow-back in the
event of excessive pressure in the starting air line.
The main starting valve is equipped with a blocking device consisting of a plate
which, by means of a handwheel, can be made to block the actuators.
The ball valves and their actuators are, together with the non-return valve and
blocking device, built together to form a unit.

Warning!
During all inspections of the engine, the blocking device of the main starting
valve must be in the BLOCKED position.
The only exception is when the starting valves are being tested for tightness,
in which case the blocking device of the main starting valve must be in the
WORKING position and the shut-off valve for the starting air distributor must
be in the CLOSED position. See Volume I, operation, Chapter 703, OPERATION after arrival in port.

Starting Air
Distributor

The starting air distributor controls the opening and the closing of the starting
valves.

Starting Valve

The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled


by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now flows from the starting
air pipe to the cylinder.
When the starting period is finished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.
The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.

Page 10 (23)

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908 Exhaust Valve
Exhaust Valve

Each cylinder is equipped with an exhaust valve, which is mounted in a central


bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gas-tight seal against a seat in the cylinder cover.

Valve housing

The valve housing has an exchangeable bottom piece.


The bore for the valve spindle is provided with an exchangeable spindle guide
liner.

Cooling

The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from
the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.

Valve spindle

The part of the spindle stem which travels within the sealing arrangement of
the air cylinder is coated with a wear resistant mixture of metal carbide and super alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is fitted which
causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:
To enable checking the functioning of the exhaust valve while the engine is
running, a lifting/rotation check rod is mounted on top of the hydraulic cylinder on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod.
Note!
This check rod is only for checking purposes, and must not be permanently
activated.

Pistons
At the top of the spindle, two pistons are fitted:
1.

Air piston
The piston serves to close the exhaust valve. The piston is locked to
the spindle by a two-piece conical ring.

2.

Hydraulic piston
The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrangement,
designed to dampen the closing of the valve.

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Page 11 (23)

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Engine Types 35-98MC/MC-C


MAN B&W Diesel
Note!
After the exhaust valve has been overhauled, it is important to check the
damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.

Air cylinder

The air cylinder is mounted on top of the valve housing. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston.
A safety valve is mounted in the bottom of the air cylinder. The safety valve is
connected to the drain pipe which leads to the camshaft housing.

Hydraulic cylinder

The hydraulic cylinder is attached with studs and nuts on the air cylinder on
top of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by the
piston in the hydraulic cylinder.
Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerating the
oil system is fitted at the top of the cylinder.
When the exhaust valve is closed, the pressure in the hydraulic cylinder is low.
A thrust spring opens the valve, enabling oil and air, if any, to escape through
the throttle.
The oil is led through a duct to the space around the air cylinder and is
drained off through a bore X, together with leakage oil from the piston.
When the exhaust valve is activated, the high oil pressure closes the valve, and
the oil flow stops.

Sealing System

Sealing air (where used):


A sealing air arrangement is fitted around the spindle shaft below the air cylinder.
The sealing air is supplied from the air cylinder via a sealing air control unit.
The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear.
The oil content in the air from the air cylinder improves the service condition of
the sealing rings.
The sealing air control unit contains a valve which automatically cuts off the air
flow when the engine is in FINISHED WITH ENGINE status, and a filter housing.

Page 12 (23)

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Sealing oil (where used):
A sealing oil arrangement is fitted around the spindle shaft below the air cylinder.
The sealing oil is supplied from a control unit fitted on top of the exhaust valve
hydraulic actuator.
During the exhaust valve lifting period, oil escapes from the hydraulic actuator
through the restriction chamber to the control unit which, in turn, gives a certain amount of oil (dosage oil) to the exhaust valve spindle.
The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear.
The oil improves the service condition of the sealing rings.
Hydraulic Valve
Actuating Gear

The exhaust valve is actuated by a cam on the camshaft through a hydraulic


transmission.

Hydraulic cylinder

The hydraulic cylinder is attached to the camshaft housing by studs and nuts.
A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck
of the roller guide and is locked to the roller guide by a bayonet joint.
The hydraulic cylinder on the camshaft housing is connected to the hydraulic
cylinder on the exhaust valve by a high-pressure pipe.
Oil is supplied from the lubricating oil system through a non-return valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained through
a pipe connection.

Puncture Valve

On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines, a puncture valve may be mounted on the exhaust valve actuator. During
starting, this valve prevents the exhaust valve from opening during the first part
of the actuator pistons upward stroke.
This function prevents the starting valve and exhaust valve from being open at
the same time, thus ensuring a safe start.

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Page 13 (23)

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 is mounted on
the camshaft housing over the camshaft section corresponding to the cylinder
concerned.
The pump housing is attached to the camshaft housing by studs and nuts.
The square base of the fuel pump housing is provided with a groove to receive
any leakage oil, which is subsequently drained off through a drain pipe.
In the base, a bore is provided for at toothed rack, i.e. the regulating guide,
which controls the quantity of fuel oil delivered by the pump.
Furthermore, for the VIT-type fuel pump, another bore is provided above the
bore for the regulating guide. This bore is provided with a rack, i.e. the timing
guide, which controls the engine timing.
At the top, the pump housing is closed by a top cover.
The top cover is provided with a suction valve and a puncture valve. These
two valves are on some engine types combined into one unit.
The pump housing contains the plunger and barrel. The plunger and barrel are
matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in the
milled keyway in the regulating guide. At the bottom it has a foot which rests
on a steel disc in the bayonet joint at the roller guide neck. A clearance of
approx. 0.1 mm between the plunger foot and the roller guide permits turning
of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing. On the
outside the regulating guide has a toothed rim to mesh with the above-mentioned toothed rack at the base of the pump housing. The toothed rim and
toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked together with the regulating
gear of the engine through a spring-loaded connection. Thus, in the event of a
sticking pump plunger, the regulating gear for the remaining fuel pumps will not
be blocked.
The pump barrel is provided with oil cut-off holes, which are covered and un
covered during the travel of the plunger within the barrel. This function, in con
junction with the turning of the plunger effected by the regulating gear, serves
to regulate the amount of oil injected into the engine cylinder.
Two screw plugs are fitted in the pump housing opposite the cut-off holes of
the barrel. The oil jets which are ejected through the cut-off holes at the end of
the delivery stroke will hit the screw plugs, which can be replaced when they
are eroded.

Page 14 (23)

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Injection timing

Fuel pumps without VIT (Variable Injection Timing):


The pump barrel is attached to the top cover by means of screws.
The lower part of the barrel is guided in the bore of the pump housing. Two
sets of O-rings and back-up rings are fitted in grooves on the outside of the
barrel and the pump cover to seal between pump barrel/pump cover and
housing.
A number of semi-circular shims are inserted between the top cover and the
pump housing. By removing or inserting such shims, the pump barrel can be
slightly lowered or raised in relation to the plunger, and in this way the initial
moment of fuel oil injection into the engine cylinder can be adjusted, and the
maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum combustion pressure.
VIT-type fuel pumps:
The pump barrel is guided at the top and bottom of the pump housing. Low
friction sealing rings are fitted in grooves in the barrel to seal between barrel
and housing. The barrel is provided with a drain bore between the sealing rings
at the lower end.
The pump barrel has a threaded lower end which fits into the internal threads
of the timing guide.
The timing guide has a gear rim to mesh with the upper toothed rack at the
base of the pump housing. The gear rim and toothed rack are marked with
lines enabling the parts to be positioned correctly after disassembly. The
toothed rack is linked to a servo-air cylinder which is controlled mechanically
or electronically in relation to the engine load. The position of the upper
toothed rack determines the vertical position of the barrel relative to the
plunger through the threaded connection.
In this manner the initial moment of fuel oil injection into the cylinder can be
adjusted by a servo-air cylinder.
The pump barrel is prevented from turning by a guide screw mounted in the
pump housing.

Puncture valve

In the top cover of the pump, a puncture valve is fitted. The puncture valve
consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system, and when
STOP is activated, compressed air is supplied to the top of the piston, causing
the piston with pin to be pressed downward and keep the suction valve in the
open position. This will puncture the oil flow to the fuel valve. As long as the
puncture valve is activated, the fuel oil is returned through bores to the pump
housing, and no injection takes place.

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Page 15 (23)

Engine Types 35-98MC/MC-C

A90030-0009

MAN B&W Diesel


Fuel Oil Injection

During the suction stroke, the spring-loaded suction valve opens and the delivery chamber is filled with oil. As soon as the plunger has covered the cut-off
holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until the cut-off holes are
uncovered by the oblique cut-off edges of the plunger, following which the oil
is forced through two milled grooves at the side of the plunger and out through
the cut-off holes of the barrel during the rest of the delivery stroke.

Shock absorber

A shock absorber is installed on each pump housing or in the main fuel pipe to
take up pressure variations.

Fuel Pump
Actuating Gear

The camshaft housing contains the fuel pump and exhaust valve actuating gear
for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is transmitted through the roller guide to the plunger in the barrel of the pump housing
which through the high-pressure pipes is connected with the fuel valves on
the cylinder cover.
Reversible engines:
The roller guide of each fuel pump incorporates an angular displaceable reversing link.
Reversing is achieved by shifting the roller in the fuel pump drive mechanism at
each cylinder. The link connecting the roller guide and roller is provided with a
reversing arm, and a pivot is mounted at the top end of the reversing arm. The
pivot travels in a reversing guide connected to an air cylinder. The link is selflocking in either the ahead or astern position without the aid of external forces.
Each cylinder is reversed individually, and the reversing mechanism is activated
by compressed air.
The reversing arrangement may incorporate a damper in order to reduce the
mechanical stresses.

Fuel Oil HighPressure Pipes

All high-pressure pipes in the system are provided with a protective outer pipe.
The space between the pipe and the protective outer pipe communicates,
through bores in the union nipples, with a drain bore in the pump top cover.

Fuel Oil Leakage


Alarm

A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS.
35-98MC:
Each fuel pump is, via drain pipes, connected to a common drain tank, which
incorporates a level switch. The drain tank is also equipped with an overflow
pipe, which has a small drain bore below, whereby oil from small leakages can
be drained to the outlet, without actuating the level switch.
In the event of pipe fractures or major leakages in the system, the above-mentioned bore will not be large enough to allow the increased oil quantity to pass,
and the oil level in the drain tank will rise until it reaches the level of the over
flow pipe. The rising oil level will cause the level switch to set off an alarm.

Page 16 (23)

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MAN B&W Diesel


50-98MC:
Alternatively to the common drain tank, the drain pipes on 50-98MC engines
can be connected to a diaphragm valve, which sets off an alarm and activates
the puncture valve in order to stop the fuel oil flow from the pertaining pump.
On 60-98MC engines, which are provided with pneumatically operated fuel
pump roller guide lifting gear, automatic activation of the lifting gear by the diaphragm valve can be arranged in order to stop the fuel oil flow from the pertaining pump.
Fuel Valve

The fuel valve consists of a valve head and a valve housing. Fitted within the
valve housing is a non-return valve and a spindle and spindle guide with a
pressure spring, and a nozzle.
The spindle may be provided with a cut-off slide. When the fuel valve is fitted
in the cylinder cover, the valve parts are tightened together by the pressure
from the securing nuts.

Functioning

The functioning of the fuel valve is as follows:


The electrical fuel oil primary pump circulates preheated oil through the fuel
pump and fuel valve. The fuel oil passes through the fuel valve, leaving through
a circulation bore and the return oil pipe on the valve head.
When the pressure at the beginning of the fuel pumps delivery stroke has
reached the predetermined pressure, the circulating bores is closed.
When the pressure has reached the predetermined opening value for the fuel
valve, the spindle will be lifted and oil injected through the nozzle into the engine cylinder.
On completion of the fuel pumps delivery stroke, the valve spindle is pressed
against its seat and injection now ceases. Then the circulating bore is uncovered, and oil starts to recirculate through the valve.

910 Turbocharger System


Air System

The engine is supplied with scavenge air from one or more turbochargers, depending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger and,
through a common shaft, the turbine wheel drives the compressor wheel.
The compressor draws air from the engine room, through the air filters. From
the compressor outlet, the air passes through the charging air pipe to the
charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.

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Page 17 (23)

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Engine Types 35-98MC/MC-C


MAN B&W Diesel
The air cooler incorporates a water mist catcher, which is designed to separate
condensate from the air.
See also Charging Air Cooler further on in this Section.
When the air has passed the water mist catcher, it is pressed into the scav
enge air receiver through non-return valves. The non-return valves open by
pressure from the turbocharger.
From the scavenge air receiver, the air flows to the cylinder through the scavenge air ports when the piston is in the bottom position. When the exhaust
valves open, the exhaust gas is pressed into a common exhaust gas receiver,
from where the gas drives the turbine of the turbocharger with an even and
steady pressure

Scavenge Air
Receiver

The scavenge air receiver is a container having a large volume. The receiver is
bolted on to the cylinder frame, or alternatively integrated into the cylinder
frame, if welded. See Chapter 903.
Scavenge air is collected in the receiver after the air has passed through the
cooler, the water mist catcher and the non-return valves.
The receiver and the cylinder frame communicate through large openings.
The scavenge air receiver is provided with man-hole covers and a safety valve.

Auxiliary Blowers

The engine is provided with two or more auxiliary blowers. The suction sides
are connected to the space after the water mist catcher. The discharge sides
are connected to the scavenge air receiver. Separate non-return valves are installed at the suction side or discharge side of the auxiliary blowers, in order to
prevent reversed air flow.
See also item, Non-return valves, further on.

El. panels for


auxiliary blower

See special instructions supplied by the engine builder.

Running with
auxiliary blowers

During the starting of the engine, and when the engine is running at low load,
the turbocharger is not able to supply enough air for the engine process. In
these cases a pressure switch will automatically start the auxiliary blowers.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air filter and compressor side.

Page 18 (23)

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MAN B&W Diesel


Warning!
If the auxiliary blowers do not start during low-load running (because of
faults, or because the switch for the blowers is not in AUTO position), unburned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box fire.
In order to avoid such a fire:

obtain permission to stop the engine


stop the engine
remove any unburned fuel oil from the top of the pistons
re-establish the supply of scavenge air
start the engine

Note: the switch for the auxiliary blowers should be in


AUTO position during all modes of engine control, i.e.:
remote control
control from engine side control console.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air filter and compressor side.
The non-return valves fitted after the water mist catcher are now closed as a
result of partial vacuum and gravitation acting on the valve flaps.
There will be a lack of air supply if the non-return valves do not close.
Non-Return Valves

It is of the utmost importance that the non-return valves of the auxiliary blowers always function correctly and move easily. This can be checked either by
moving the valves manually in connection with the regular scavenge port inspections, or via locally placed inspection covers.
The non-return valves protect the blowers and engine during:
Start-up of the auxiliary blowers
Running with auxiliary blowers.
Starting the auxiliary blowers:
1.

Owing to the relatively high starting current, the blowers start in se


quence, with 6-10 seconds in between.
The non-return valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Otherwise, there is a risk that the electric motor will burn out when it starts.

2.

If an auxiliary blower fails to start, the non-return valve must be in the


closed position. Otherwise, the operating blower will not be able to
draw fresh air in through the turbocharger and air cooler. This is due to
differences in the air flow resistance.

When referring to this page, please quote Description A90030 Edition 0009

Page 19 (23)

Engine Types 35-98MC/MC-C

A90030-0009

MAN B&W Diesel


Running with auxiliary blowers:
If an auxiliary blower fails during running, the non-return valve must close to
ensure the continued supply of fresh air to the engine. See Starting the auxiliary blowers, Item 2, above.
Exhaust Gas
Receiver

From the exhaust valves, the exhaust gas is led to the exhaust gas receiver
where the pulsatory pressure from the individual exhaust valves is equalized
and led to the turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the seating by flexible supports. Compensators are inserted between the receiver and the exhaust valves, and between the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before the turbocharger.
The exhaust gas receiver and the exhaust pipe are insulated.

Charging Air
Cooler

The charging air cooler insert is of the block type. It is mounted in a housing
which is welded up of steel plates.
The cooler housing is provided with inspection covers.
The cooler is designed with an air reversing chamber which incorporates a water mist catcher. The water mist catcher is built up of a number of lamellas
which separate the condensation water from the scavenge air during the passage of the air flow.
The separated water is collected in the bottom of the cooler housing from
which it is removed by a drain system.
Caution!
It is important to check that the drain functions correctly, as otherwise water
droplets may enter the cylinders. See Volume I Operation, Chapter 706,
Cleaning of Turbochargers and Air Coolers.
An alarm device for high water level in the drain system is installed.

911 Safety Equipment


Safety Valves,
Cylinder Cover

Page 20 (23)

Each cylinder cover is provided with a spring-loaded safety valve which is set
to open at a pressure somewhat higher than the maximum firing pressure in
the cylinder.

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Relief Valves

On the exhaust side of the engine a number of spring-loaded relief valves are
fitted, which will open in the event of excessive pressure in the crankcase/
chain casing, for instance as a result of the ignition of oil mist.
Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the
risk of fire caused by hot air/gas emitted in the event that the relief valves
open.
Regarding how to:
avoid evaporation of the lubricating oil in the crankcase,
detect oil mist in the crankcase using an Oil Mist Detector.
see Volume I, OPERATION, Chapter 704.
Warning!
Do not stand near crankcase doors or relief valves or in corridors near
doors to the engine room casing in the event of an alarm for:
a)
b)
c)
d)

oil mist
high lube oil temperature
no piston cooling oil flow, or
scavenge box fire

Alarms b, c and d should be considered as pre-warnings of a possible increasing oil mist level.
See also our Service Letter SL97-348/ERO.

Note!
If there has been a crankcase explosion, the complete flame arrester of the
relief valves must be replaced.

Safety Valve,
Scavenge Air
Receiver

The scavenge air receiver is fitted with a safety valve which is set to open
should the pressure in the scavenge air receiver exceed a value somewhat
higher than the normal scavenge air pressure of the engine.
In some cases it may be necessary to open the valve manually, see Volume I,
Chapter 704, "Turbocharger Surging".

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Page 21 (23)

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Safety Cap in
Starting Air Line

Each starting valve inlet pipe is provided with a safety cap. The safety cap
consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders, in the event of a burst.
The cover is provided with a check plate, which shows if the bursting disc has
been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst,
and fit a new disc.
If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Fit a new bursting disc and
return the cover to the open position at the first opportunity.

912 Assembly of large Parts


Bedplate

The bedplate is made in one or more sections, depending on the number of


cylinders. If there are two or more sections, these are joined together with fitted bolts. The bedplate consists of two welded, longitudinal girders and a
number of cross girders which support the main bearings. The main bearings
consist of steel shells, lined with bearing metal.
See also Volume I, OPERATION, Chapter 708.
Each main bearing has one or two main bearing caps which are secured by
studs and nuts, designed for tightening with hydraulic tools.
The bedplate is fitted with an axial vibration damper. For the design and functioning of the axial vibration damper, see Section 905 Crankshaft.
Marine engines (except geared plants):
The aft end of the bedplate incorporates the thrust bearing. See also Section
905 Crankshaft.
Stationary engines (and geared marine plants):
The bedplate incorporates the guide bearing. See also Section 905, Crank
shaft.

Framebox

A framebox is bolted on to the top of the bedplate. Like the bedplate, the
framebox consists of one or more sections. Together, the bedplate and the
framebox constitute the crankcase of the engine.
The framebox is fitted with steel-plate doors for access to the crossheads and
to the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe fitted to the crosshead or guide shoe is able to
travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to
the oil tray of the bedplate.

Page 22 (23)

When referring to this page, please quote Description A90030 Edition 0009

Engine Types 35-98MC/MC-C

A90030-0009

MAN B&W Diesel


Equipment for local checking of the cooling oil temperature and flow, and for
temperature and flow alarms, is installed in conjunction with the outlet pipe.
See also Volume I, OPERATION, Chapter 701.
Staybolts

The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.

Engine Seating

Regarding the engine seating for the specific engine, see the suppliers special
instructions.

When referring to this page, please quote Description A90030 Edition 0009

Page 23 (23)

901 - Cylinder Cover


Documents in this Chapter
90101
90103

0152
0007

Cylinder Cover
Indicator Cock - Mounting

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover

Plate
P90101-0152

Cylinder Cover
0152
P90101

B
F-F
A
G
O
O

B
G
G-O-G
F

A-O-A

B-O-B

When referring to this page, please quote Plate P90101 Edition 0152
MAN B&W Diesel A/S

Page 1 (2)

Cylinder Cover

Plate
P90101-0152
Item
No.
018
031
043
055
067
079
080
102
114
126
138

Item Description

Item
No.

Item Description

Nut
Stud
Cylinder cover
Screw
O-ring
Cooling jacket
Screw
Nut
Distance pipe
Stud
Cylindrical pin

Page 2 (2)

When referring to this page, please quote Plate P90101 Edition 0152
MAN B&W Diesel A/S

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)

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.

Item Description

Connecting piece
Extension
Gasket
Gasket
Indicator cock
Screw
Locking plate
Flange
Guard
Screw
Lock washer
Stud
Nut, self-locking

When referring to this page, please quote Plate P90103 Edition 0007
MAN B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


Documents in this Chapter
90201
90205

0201
0122

Piston and Piston Rod


Piston Rod Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Piston and Piston Rod

Plate
P90201-0201

When referring to this page, please quote Plate P90201 Edition 0201

Page 1 (2)

MAN B&W Diesel A/S

Plate
P90201-0201
Item
No.
011
023
035
047
060
072
084
106
118
131
155
167
179

Page 2 (2)

Piston and Piston Rod

Item Description

Item
No.

Item Description

Screw
Screw
Locking wire
Piston skirt
Piston ring No. 1
Piston ring No. 2 and 4
Piston ring No. 3
Piston crown
Cooling oil pipe
Piston rod
D-ring
Screw
Screw

When referring to this page, please quote Plate P90201 Edition 0201
MAN B&W Diesel A/S

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)

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.

Item Description

O-ring
Nut, self-locking
Screw
Top scraper ring
Spring
Cover sealing ring
Spring pin
Pack sealing ring
Sealing ring, complete
Sealing ring
Spring
Holder
Lamella
Scraper ring
Spring
Top scraper ring, complete
Holder
Pin
Holder
Scraper ring, complete
Stuffing box housing in 2/2
Stuffing box housing, complete
Fitted bolt
Flange
Guide pin

When referring to this page, please quote Plate P90205 Edition 0122
MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


Documents in this Chapter
90301
90302
90304
90305
90309

0162
0175
0025
0146
0025

Cylinder Frame
Cylinder Liner and Cooling Jacket
Cylinder Liner - Details
Cylinder Lubricators
Cylinder Lubricator System - Details

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Frame

When referring to this page, please quote Plate P90301 Edition 0162
MAN B&W Diesel A/S

Plate
P90301-0162

Page 1 (2)

Plate
P90301-0162
Item
No.
015
027
039
040
052
064
076
088
111
135
159
160
184
196
218
231
243
255
279
280
292
302
326
338
351
363
387
399
409
410
422
446
458
471
483
495
505
529
530

Page 2 (2)

Cylinder Frame

Item Description

Item
No.

Item Description

Cover
O-ring
Screw
Stud
Nut
Pipe bend
Cover
O-ring
Screw
Cleaning cover, complete
Stud
Nut
Cylinder frame
Stud
Screw
Nut
Protective cap
Stud for cylinder cover
Nut
Distance pipe
Fitted bolt
Screw
Screw
Cover
Screw
Cover
Guide pin
Stud
Distance pipe
Nut
Screw
Bushing
Housing-stuffing box
Stud
O-ring
Stud
Distance piece
Screw
Distance tube

When referring to this page, please quote Plate P90301 Edition 0162
MAN B&W Diesel A/S

Cylinder Liner and Cooling Jacket

When referring to this page, please quote Plate P90302 Edition 0175
MAN B&W Diesel A/S

Plate
P90302-0175

Page 1 (2)

Plate
P90302-0175
Item
No.
010
022
034
046
058
071
095
105
117
129
130
142
154
166
178

Page 2 (2)

Cylinder Liner and Cooling Jacket

Item Description

Item
No.

Item Description

Cooling jacket
Clamp
Screw
Cylinder liner
Packing
Plug screw
O-ring
O-ring
Cooling water connection
Cooling water connection
Packing
Screw
Sealing ring
Gasket
Piston cleaning ring

When referring to this page, please quote Plate P90302 Edition 0175
MAN B&W Diesel A/S

Cylinder Liner - Details

Plate
P90304-0025

Cylinder Liner - Details


0025
P90304

A A

When referring to this page, please quote Plate P90304 Edition 0025
MAN B&W Diesel A/S

Page 1 (2)

Cylinder Liner - Details

Plate
P90304-0025
Item
No.
011
023
035
059

Item Description

Item
No.

Item Description

Head, non-return valve


Non-return valve
Housing, non-return valve
Non-return valve, complete

Page 2 (2)

When referring to this page, please quote Plate P90304 Edition 0025
MAN B&W Diesel A/S

Cylinder Lubricators
MAN B&W Diesel

When referring to this page, please quote Plate P90305 Edition 0146

Plate
P90305-0146

Page 1 (2)

Plate
P90305-0146

Cylinder Lubricators
MAN B&W Diesel

Item
No.

Item Description

017
029
030
042
054
066
078
091
137
149
150
162
174
198
208
221
233
245
257
269
270
282
294
304
316
328
341
353
365
377
389
390
400
424
436

Guard
Lubricator
Key
Coupling
Screw
Cam lock washer, stainless*
Spring pin
Bracket
Lubricator
Washer
Screw
Washer
Screw
Spring-loaded lever, complete
Lever
Washer
Fitted bolt
Spacer, tubular
Pull rod, complete
Fitted bolt
Nut, self-locking
Screw
Locking plate
Clamping arm
Spring pin
Spring pin
Spring
Eye bolt
Locking plate
Nut
Nut
Clamping arm
Screw
Nut
Fitted bolt

Item
No.

Item Description

Note:
* Cam lock washers are to be supplied by MAN B&W Diesel only.

Page 2 (2)

When referring to this page, please quote Plate P90305 Edition 0146

Cylinder Lubrication System - Details

When referring to this page, please quote Plate P90309 Edition 0025
MAN B&W Diesel A/S

Plate
P90309-0025

Page 1 (2)

Plate
P90309-0025
Item
No.
019
020
032
056
068
093
103
127
139
152
164
188
211
223

Page 2 (2)

Cylinder Lubrication System - Details

Item Description

Item
No.

Item Description

Steel pipe
Banjo coupling
Steel pipe
Banjo coupling
Straight screw
Screw
Distributor block
Pipe holder
Screw
Coupling
Steel pipe
Steel pipe
Steel pipe
Coupling

When referring to this page, please quote Plate P90309 Edition 0025
MAN B&W Diesel A/S

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)

Plate
P90401-0145
Item
No.
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.

Item Description

Screw
Telescope pipe
Nut, self-locking
Nut
Outled pipe
Screw
Lock washer
Stop screw
Guide shoe
Bracket
Crosshead bearing cap
Guide screw
Stud
Guide pin
Nut- self-locking
Shim, 0,50mm
Shim 0,25mm
Guide strip
Stud
Screw
Thrust piece
Crankpin bearing shell, complete
Guide pipe
Screw(*
Shim (*
Crosshead bearing shell, upper part
Crosshead
Stud
Guide pin
Crosshead bearing shell, lower part
Hydraulic nut
Connecting rod
Hydraulic nut
Stud
Crankpin bearing cap
Connecting rod, complete

Notes:

Page 2 (2)

(* Please state thickness of shim


When referring to this page, please quote Plate P90401 Edition 0145
MAN B&W Diesel A/S

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)

905 - Crankshaft, Thrust Bearing and Turning Gear


Documents in this Chapter
90501
90502
90503
90504
90505
90510
90511
90512
90513
90513
90513

0150
0045
0016
0001
0128
0113
0035
0001
0036
0046
0047

Crankshaft
Arrangement of Fore End
Arrangement of Angle Encoder
Axial Vibration Monitor
Thrust- and Guide Bearing
Turning Gear
Turning Wheel
Turning Gear - Details
Tacho System
Tacho System
Tacho System

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crankshaft

When referring to this page, please quote Plate P90501 Edition 0150
MAN B&W Diesel A/S

Plate
P90501-0150

Page 1 (2)

Plate
P90501-0150
Item
No.
012
024
061
097
107
119
120

Page 2 (2)

Crankshaft

Item Description

Item
No.

Item Description

Crankshaft
Chain wheel
Self-locking nut
Screw
Screw
Cover
Gasket

When referring to this page, please quote Plate P90501 Edition 0150
MAN B&W Diesel A/S

Arrangement of Fore End


MAN B&W Diesel

When referring to this page, please quote Plate P90502 Edition 0045

Plate
P90502-0045

Page 1 (2)

Arrangement of Fore End

Plate
P90502-0045
Item
No.
018
031
043
055
067
079
080
092
102
114
126
138
151

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Cover
Screw
Cover
Shaft
Cover
Counterweight
Self locking nut
Screw
Screw
Disc
Pin
Screw
Fitted bolt

When referring to this page, please quote Plate P90502 Edition 0045

Arrangement of Angle Encoder

Plate
P90503-0016

Arrangement of Angle Encoder


0016
P90503

A-A

When referring to this page, please quote Plate P90503 Edition 0016
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90503-0016
Item
No.
013
049
086
098
108
133
145
157
170
182
204
228
253
265
289
290
300
312

Arrangement of Angle Encoder

Item Description

Item
No.

Item Description

Measuring tool for axial movement,


complete
Screw
Housing
Shaft
Screw
Damping plate
Coupling
Cable tie
Tool
Packing
Shaft
Spring pin
Packing
Washer
Shield - lower part
Packing
Screw
Spring lock

Page 2 (2)

When referring to this page, please quote Plate P90503 Edition 0016
MAN B&W Diesel A/S

Axial Vibration Monitor

Plate
P90504-0001

Axial Vibration Monitor


0001
P90504

When referring to this page, please quote Plate P90504 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90504-0001
Item
No.
019
020
032
044
056
068

Axial Vibration Monitor

Item Description

Item
No.

Item Description

Bracket
Axial vibration monitor
Terminal box, complete
Screw
Pipe holder
Cable gland

Page 2 (2)

When referring to this page, please quote Plate P90504 Edition 0001
MAN B&W Diesel A/S

Thrust and Guide Bearing

When referring to this page, please quote Plate P90505 Edition 0128
MAN B&W Diesel A/S

Plate
P90505-0128

Page 1 (2)

Plate
P90505-0128
Item
No.
014
026
038
051
063
075
099
109
110
122
134
146
158
183
195
217
229
230
254
266
278
291
301
313
325
349
350
362
374

Page 2 (2)

Thrust and Guide Bearing

Item Description

Item
No.

Item Description

Screw
Cover
Screw
Distance pipe
Lubricating oil pipe
Lubricating oil pipe
Segment holder
Guide pin
Screw
Screw
Oil throw ring, in 2/2
Scraper ring housing, complete
Scraper ring housing, upper part
Scraper ring housing, lower part
Screw
Segment stopper
Segment with sensor pockets
Segment
Screw
Cover
Lubricating oil pipe
Screw
Distance pipe
Spring pin
Spring
Distance pipe
Screw
Self-locking nut
Lubricating oil pipe

When referring to this page, please quote Plate P90505 Edition 0128
MAN B&W Diesel A/S

Plate
P90510-0113

Turning Gear
Turning Gear
0113
P90510

When referring to this page, please quote Plate P90510 Edition 0113
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90510-0113
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

Turning Gear

Item Description

Item
No.

Item Description

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

Page 2 (2)

When referring to this page, please quote Plate P90510 Edition 0113
MAN B&W Diesel A/S

Turning Wheel

Plate
P90511-0035

Turning Wheel
0035
P90511

When referring to this page, please quote Plate P90511 Edition 0035
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90511-0035
Item
No.
017
029
030
054
078
091
101
125

Turning Wheel

Item Description

Item
No.

Item Description

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

Page 2 (2)

When referring to this page, please quote Plate P90511 Edition 0035
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

Tacho System
MAN B&W Diesel

When referring to this page, please quote Plate P90513 Edition 0046

Plate
P90513-0046

Page 1 (2)

Tacho System

Plate
P90513-0046
Item
No.
018
031
043
067
079
080
092
114
126

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Bracket
Disc
Spring pin
Washer
Nut, self-locking
Nut, self-locking
Stud
Tacho pick-up
Screw

When referring to this page, please quote Plate P90513 Edition 0046

Tacho System
MAN B&W Diesel

When referring to this page, please quote Plate P90513 Edition 0047

Plate
P90513-0047

Page 1 (2)

Tacho System

Plate
P90513-0047
Item
No.
018
031
055
079
092
114
138

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Screw
Spring pin
Tacho pick-up
Screw
Dowel
Nut, self-locking
Bracket

When referring to this page, please quote Plate P90513 Edition 0047

906 - Control Gear


Documents in this Chapter
90600
90601
90602
90603
90611
90612
90613
90615
90618
90620
90621
90648

0095
0100
0110
0096
0170
0102
0136
0138
0139
0098
0083
0012

Arrangement of Chain Drive and Camshaft


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

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangement of Chain Drive


MAN B&W Diesel

When referring to this page, please quote Plate P90600 Edition 0095

Plate
P90600-0095

Page 1 (1)

Chain Drive and Guide Bars

Plate
P90601-0100

When referring to this page, please quote Plate P90601 Edition 0100

Page 1 (2)

Chain Drive and Guide Bars


0100
P90601

MAN B&W Diesel A/S

Plate
P90601-0100
Item
No.
016
028
041
053
077
089
090
100
112
124
136
148
161
173
197
207
219
220
232
244
256
268
281
293
303
315
327

Chain Drive and Guide Bars

Item Description

Item
No.

Item Description

Distance pipe
Bracket
Locking wire
Screw
Screw
Banjo coupling
Pipe, L= 854
Lub. oil pipe, complete
Guidebar
Tee coupling
Spray pipe
Bracket
Screw
Distance pipe
Lub. oil pipe, complete
Washer
Screw
Distance pipe
Guide pin
Stud
Screw
Washer
Nut, self-locking
Chain
Outer link
Inner link
Chain link, complete

Page 2 (2)

When referring to this page, please quote Plate P90601 Edition 0100
MAN B&W Diesel A/S

Chain Drive - Lubrication

Plate
P90602-0110

Chain Drive - Lubrication


0110
P90602

When referring to this page, please quote Plate P90602 Edition 0110
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90602-0110
Item
No.
011
023
035
047
059

Chain Drive - Lubrication

Item Description
Lub.oil
Lub.oil
Lub.oil
Lub.oil
Lub.oil

Page 2 (2)

Item
No.

Item Description

pipe
pipe
pipe
pipe
pipe

When referring to this page, please quote Plate P90602 Edition 0110
MAN B&W Diesel A/S

Chain Tightener

Plate
P90603-0096

Chain Tightener
0096
P90603

When referring to this page, please quote Plate P90603 Edition 0096
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90603-0096
Item
No.
017
029
030
042
066
078
091
101
113
125
137
149
150
162
174
198
208
221
233
245
257
269
270
294
304

Chain Tightener

Item Description

Item
No.

Item Description

Distance piece
Shaft
Cover
Screw
Locking wire
Guide nut
Shaft
Cover
Screw
Guide nut
Lock washer
Nut
Tightening bolt
Shaft
Cover
Bushing
Lub.oil pipe
Banjo coupling
Lub.oil pipe
O-ring
Shaft
Self-locking nut
Banjo coupling
Chain wheel
Bracket

Page 2 (2)

When referring to this page, please quote Plate P90603 Edition 0096
MAN B&W Diesel A/S

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)

Camshaft and Chain Wheel

Plate
P90611-0170
Item
No.
010
022
046
058
095
117
129
130
142
154
178
191
201
213

MAN B&W Diesel


Item
No.

Item Description

Item Description

Repair cam - fuel, complete*


Screw*
Thrust disc
Chain wheel
Protective cap
Exhaust cam
Fuel cam
Camshaft
Screw*
Repair cam - exhaust, complete*
Washer
Screw
Locking wire
Gear wheel
Note:
* Optional extras

Page 2 (2)

When referring to this page, please quote Plate P90611 Edition 0170

Arrangement of Indicator System


MAN B&W Diesel

When referring to this page, please quote Plate P90612 Edition 0102

Plate
P90612-0102

Page 1 (2)

Plate
P90612-0102
Item
No.
016
028
041
053
065
077
090
100
124
136
161
185

Page 2 (2)

Arrangement of Indicator System


MAN B&W Diesel

Item Description

Item
No.

Item Description

PMI system, users guide


PMI system, installation
PMI system, mounting
PMI software
Storage case
Converter box
PMI controller box, complete
Junction box
Handle
Pressure transducer
Intermediate box
Angle encoder

When referring to this page, please quote Plate P90612 Edition 0102

Camshaft Bearing
MAN B&W Diesel

When referring to this page, please quote Plate P90613 Edition 0136

Plate
P90613-0136

Page 1 (2)

Camshaft Bearing

Plate
P90613-0136
Item
No.
011
023
035
047
060
072
096
118
131
155
167
179
192
202

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Connecting pipe
Gasket
O-ring
Bushing
Screw
Bearing cap
Guide disc
Guide pin
Screw
Plug screw
Bearing cap
Screw
Bearing shell
Screw

When referring to this page, please quote Plate P90613 Edition 0136

Arrangement of Governor

Plate
P90615-0138

Arrangement of Governor
0138
P90615

Clockwise

Counterclockwise

When referring to this page, please quote Plate P90615 Edition 0138
MAN B&W Diesel A/S

Air inlet

Page 1 (2)

Plate
P90615-0138
Item
No.
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.

Item Description

Governor
Screw
Screw
Coupling
Key
Shaft
Bracket
Bevel gear wheel
Nut
Split pin
Screw
Locking wire, L= 300
Washer
Spray pipe
Spray pipe
Union
Union
Guide pin
Screw
Bushing
Thrust washer
Key
Bevel gear wheel
Pipe, L= 600
Pipe, L= 700
Union
Union
Booster
Pipe, L= 600

Page 2 (2)

When referring to this page, please quote Plate P90615 Edition 0138
MAN B&W Diesel A/S

Regulating Shaft
MAN B&W Diesel

When referring to this page, please quote Plate P90618 Edition 0139

Plate
P90618-0139

Page 1 (2)

Plate
P90618-0139

Regulating Shaft
MAN B&W Diesel

Item
No.

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, complete
Nut, self-locking
Plate
Pull rod, 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, complete

Page 2 (2)

Item
No.

Item Description

When referring to this page, please quote Plate P90618 Edition 0139

Engine Side Control Console


MAN B&W Diesel

When referring to this page, please quote Plate P90620 Edition 0098

Plate
P90620-0098

Page 1 (2)

Plate
P90620-0098
Item
No.
021
033
045
057
069
070
082
094
104
116
141
153
165
177
189
200
212
224
236
248
261
273
285
307
319
320
332
344
356
368
381
403
415
427
439
440
452
464
476
511
523
535

Page 2 (2)

Engine Side Control Console


MAN B&W Diesel

Item Description

Item
No.

Item Description

Vibration damper
Bracket
Screw
Multiple plug
Cable
5/2-way manual valve
Clamping arm
Pin
Screw
Screw
Guide pin
Console
Nut, self-locking
Screw
Bushing
Electrical box, complete
Pointer
Screw
Segment
Spring washer
Screw
3/2-way manual valve for stop
Fitted bolt
3/2-way manual valve for start
Nut, self-locking
Clamping arm
Nut self-locking
Shaft
Name plate
Stop ring
Pin
Handgrip
Lever, complete
Pressure switch
Fitted bolt
Clamping arm
Screw
Shaft
Guard
Screw
Non-return valve
Non-return valve

When referring to this page, please quote Plate P90620 Edition 0098

Engine - Side Control Console, Details

When referring to this page, please quote Plate P90621 Edition 0083
MAN B&W Diesel A/S

Plate
P90621-0083

Page 1 (2)

Plate
P90621-0083
Item
No.
015
027
039
040
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

Page 2 (2)

Engine - Side Control Console, Details

Item Description

Item
No.

Item Description

Nut, self-locking
Screw
Nut, self-locking
Pull rod, complete
Bushing
Stop ring
Guide pin
Cone
Guide pin
Impact handwheel
Impact socket
Clamping arm
Pull rod, complete
Fitted bolt
Lever
Grease nipple
Washer
Fitted bolt
Fitted bolt
Nut, self-locking
Screw
Guide pin
Clamping arm
Bushing
Lever
Switch
Screw
Lock washer
Cone
Lever
Washer
Screw

When referring to this page, please quote Plate P90621 Edition 0083
MAN B&W Diesel A/S

Pneumatic Components
MAN B&W Diesel

When referring to this page, please quote Plate P90648 Edition 0012

Plate
P90648-0012

Page 1 (2)

Plate
P90648-0012
Item
No.
012
036
048
061
073
085
097
107
119
120
144
168
181
203
227
239
240
252
264
276
288
297
307
311
323
335
372
384
396

Page 2 (2)

Pneumatic Components
MAN B&W Diesel

Item Description

Item
No.

Item Description

Assy of valves
3/2-way valve, pneumatic
Screw
Straight stud coupling
Adjustable straight coupling
Straight stud coupling
Straight stud coupling
Adjustable t-coupling
3/2-way solenoid valve
Screw
Plate, shaped
Air reciever
Non-return valve
Screw
Plate, shaped
Washer
Adjustable l-coupling
3/2-way valve, pneumatic
Screw
Cross coupling
3/2-way solenoid valve
Straight stud coupling
Screw
Adjustable elbow coupling
Non-return valve
Adjustable elbow coupling
Pressure switch
Screw
T-coupling

When referring to this page, please quote Plate P90648 Edition 0012

907 - Starting Air System


Documents in this Chapter
90702
90703
90704

0066
0068
0050

Main Starting Valve


Starting Air Distributor
Starting Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Main Starting V
alve
Valve
MAN B&W Diesel

When referring to this page, please quote Plate P90702 Edition 0066

Plate
P90702-0066

Page 1 (2)

Main Starting V
alve
Valve

Plate
P90702-0066
Item
No.
015
027
039
040
052
064
076
088
111
135
147
159
172
184
196
206
218
231
243
255
267
280
292
302
314
338
351
363
375
387
399
409
410
434
446
458
471
483
495
517
529
530
542
566
578
900
912

Page 2 (2)

MAN B&W Diesel

Item Description
Screw
Name plate, working
Screw
Switch
Distance pipe
Spindle
Screw
Plate
Ball valve with actuator*
Intermediate piece
Plug screw
Plug screw
Name plate blocked
Nut
Washer
Hand wheel
Securing plate
Pin
Spring
Gasket
Gasket
Screw
Split pin
Key ring
Chain
Screw
Screw
Screw
Nut
Nut
Nut
Air adjustment screw
Screw
Non-return valve
Housing
Gasket
Screw
Starting air pipe
Screw
Split pin
Ball valve with actuator*
Housing
Nut
Screw
Starting air pipe
Repair kit, actuator*
Repair kit, ball valve*

Item
No.

Item Description
Note:
* When ordering spare parts for this item,
please state manufacturers Part No.

When referring to this page, please quote Plate P90702 Edition 0066

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)

Plate
P90703-0068
Item
No.
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.

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, please quote Plate P90703 Edition 0068
MAN B&W Diesel A/S

Starting Valve

When referring to this page, please quote Plate P90704 Edition 0050
MAN B&W Diesel A/S

Plate
P90704-0050

Page 1 (2)

Plate
P90704-0050
Item
No.
016
028
041
053
065
077
089
100
112
124
136
148
161

Page 2 (2)

Starting Valve

Item Description

Item
No.

Item Description

Cover
Gasket
Castle nut
Piston
Bushing
Spring
Washer
Bushing
Valve housing
Screw
O-Ring
Split
Valve spindle

When referring to this page, please quote Plate P90704 Edition 0050
MAN B&W Diesel A/S

908 - Exhaust Valve


Documents in this Chapter
90801
90802
90803
90804
90805
90806
90810

0184
0041
0032
0017
0130
0057
0075

Exhaust Valve - Lower Parts


Exhaust Valve - Details
Exhaust Valve - Upper Parts
Exhaust Valve Upper Parts - Details
Exhaust Valve - Actuator
Exhaust Valve - Pipe System
Arrangement of Cooling Water Pipes

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Exhaust Valve - Lower Parts

Plate
P90801-0184

Exhaust Valve - Lower Parts


0184
P90801

When referring to this page, please quote Plate P90801 Edition 0184
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90801-0184
Item
No.
013
025
049
050
062
074
086
098
108
133
145
157
169
182
194
204
216
228
241
253

Exhaust Valve - Lower Parts

Item Description

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, please quote Plate P90801 Edition 0184
MAN B&W Diesel A/S

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

Valve Gear - Details

Plate
P90806-0057

Valve Gear - Details


0057
P90806

When referring to this page, please quote Plate P90806 Edition 0057
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90806-0057
Item
No.
010
022
034
058
071
095
105
129
130
142
166
178
191
213
237
249
262

Valve Gear - Details

Item Description

Item
No.

Item Description

Thrust flange
Spring ring
Sleeve in 2/2
Pipe
Screw
Sealing ring
Intermediate piece
Pipe
Reducing stand pipe
Tee coupling
Coupling
Pipe
Coupling
Sealing ring
Pipe
O-ring
Hydraulic pipe, complete

Page 2 (2)

When referring to this page, please quote Plate P90806 Edition 0057
MAN B&W Diesel A/S

Arrangement of Cooling Water Pipes

Plate
P90810-0075

Arrangement of Cooling Water Pipes


0075
P90810

When referring to this page, please quote Plate P90810 Edition 0075
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90810-0075
Item
No.
012
024
036
085
097
107
132
144
156
168
181
193
203
227
239

Arrangement of Cooling Water Pipes

Item Description

Item
No.

Item Description

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

Page 2 (2)

When referring to this page, please quote Plate P90810 Edition 0075
MAN B&W Diesel A/S

909 - Fuel Oil System


Documents in this Chapter
90901
90902
90910
90911
90913
90913
90914
90915
90915
90915

0206
0149
0152
0021
0071
0110
0064
0076
0077
0078

Fuel Pump
Fuel Pump Gear
Fuel Valve
Fuel Valve Function
High-Pressure Pipes
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
MAN B&W Diesel

When referring to this page, please quote Plate P90901 Edition 0206

Plate
P90901-0206

Page 1 (2)

Fuel Pump

Plate
P90901-0206
Item
No.
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

Page 2 (2)

MAN B&W Diesel

Item Description
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
Sealing ring
Back-up ring
Plunger
Flange
Screw
Toothed bar
Top cover
Guide pin
Sealing ring
Back-up ring
Sealing ring
Pump barrel
Felt ring
Restriction plug
Screw
Screw
Sealing ring
Sealing ring
Spring
Housing
Sealing ring
Screw
Cover
Air piston
Sealing ring
Housing
Sealing ring
Conical ring in 2/2
Cone
Spring
Spindle
Housing
Pump barrel, complete

Item
No.
723
747
759
772
806
818

Item Description
Pump barrel and top cover, complete
Puncture valve, complete
Suction valve, complete
Combined puncture valve and suction
valve, complete
Disc
Plug screw

When referring to this page, please quote Plate P90901 Edition 0206

Fuel Pump Gear


MAN B&W Diesel

When referring to this page, please quote Plate P90902 Edition 0149

Plate
P90902-0149

Page 1 (2)

Fuel Pump Gear

Plate
P90902-0149
Item
No.
012
024
036
048
073
085
097
107
119
120
132
156
168
181
193
203
215
239
240
252
264
276
288
311
323
335
347
360
372
384
396
406
418
443
455
467
479
480
492
502
526
538
551
563
575
587
599
609
610

Page 2 (2)

MAN B&W Diesel


Item
No.

Item Description
Sealing ring
Spring
Pump base
Bushing for roller guide, complete
Bushing
Guide pin
Guide block
Screw
Sealing ring
Plug screw
Stop screw
Reversing mechanism, complete
Guide for reversing spindle
Shaft
Guide spindle
Guide spindle
Screw
Stud
Nut
Fuel pump roller guide, complete
Thrust piece
Roller guide
Link for reversing
Guide pin
Baseplate
Shaft pin
Bearing bushing
Roller
Screw
Screw
Air cylinder
Locking plate
Flange for air cylinder
Fuel oil sealing, complete
Stud
Self-locking nut
Sealing ring
Sealing bush
Sealing ring
Screw
Stud
Nut, low
Bushing
Pin
Screw
Cap
Flange
Screw
Cover

634
646
658
671
683

Item Description
Scraper ring, axial
Screw
Flange
Holder for scraper ring
Scraper ring

When referring to this page, please quote Plate P90902 Edition 0149

Fuel Valve
MAN B&W Diesel

When referring to this page, please quote Plate P90910 Edition 0152

Plate
P90910-0152

Page 1 (2)

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.

Item Description

Fuel valve, 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, complete
Disc*
Note:
* Optional extras

Page 2 (2)

When referring to this page, please quote Plate P90910 Edition 0152

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)

Plate
P90911-0021
Item
No.

Fuel Valve Function

Item Description

Item
No.

Item Description

Note:
D1 = Predetermined closing value for
non-return valve
D2 = Predetermined opening value for
cut-off spindle

Page 2 (2)

When referring to this page, please quote Plate P90911 Edition 0021
MAN B&W Diesel A/S

High-Pressure Pipes

Plate
P90913-0071

High-Pressure Pipes
0071
P90913

When referring to this page, please quote Plate P90913 Edition 0071
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90913-0071
Item
No.
012
024
036
048
061
073
085
097
107
120
132

High-Pressure Pipes

Item Description

Item
No.

Item Description

High-pressure pipe, complete


Spring pin
Sleeve in 2/2
O-ring
Union nipple
Protective pipe
High-pressure pipe
Union nipple
O-ring
High-pressure pipe, complete
High-pressure pipe

Page 2 (2)

When referring to this page, please quote Plate P90913 Edition 0071
MAN B&W Diesel A/S

High-Pressure Pipes

Plate
P90913-0110

High-Pressure Pipes
0110
P90913

When referring to this page, please quote Plate P90913 Edition 0110
MAN B&W Diesel A/S

Page 1 (2)

Plate
P90913-0110
Item
No.
012
024
036
048
061
073
085
097
107
120
132

High-Pressure Pipes

Item Description

Item
No.

Item Description

High-pressure pipe, complete


Union nipple
Thrust bushing
Union nut
High-pressure pipe
Flexible hose, complete
O-ring
Union nipple
O-ring
High-pressure pipe, complete
High-pressure pipe

Page 2 (2)

When referring to this page, please quote Plate P90913 Edition 0110
MAN B&W Diesel A/S

Fuel Oil System


MAN B&W Diesel

When referring to this page, please quote Plate P90914 Edition 0064

Plate
P90914-0064

Page 1 (2)

Fuel Oil System

Plate
P90914-0064
Item
No.
018
031
055
067
079
092
114
126
138
163
175
187
209
210
222
246
258
271
295
317
329

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Steel pipe
Steel pipe
Steel pipe
Steel pipe
Fuel oil return pipe
Fuel oil return pipe
Copper pipe
Non-return valve
Copper pipe
Steel pipe
Flange
Flange
Packing ring
Screw
Ball valve
Ball valve
Screw
Packing ring
Steel pipe
Steel pipe
Non-return valve

When referring to this page, please quote Plate P90914 Edition 0064

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)

Fuel Oil System - Details

Plate
P90915-0076
Item
No.
013

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Drain box, complete

When referring to this page, please quote Plate P90915 Edition 0076

Fuel Oil System - Details


MAN B&W Diesel

When referring to this page, please quote Plate P90915 Edition 0077

Plate
P90915-0077

Page 1 (2)

Plate
P90915-0077
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 - Details


MAN B&W Diesel

Item Description

Item
No.

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, complete

When referring to this page, please quote Plate P90915 Edition 0077

Fuel Oil System - Details


MAN B&W Diesel

When referring to this page, please quote Plate P90915 Edition 0078

Plate
P90915-0078

Page 1 (2)

Plate
P90915-0078
Item
No.
013
025
037
049
050
074
086
098
121
133
145

Page 2 (2)

Fuel Oil System - Details


MAN B&W Diesel

Item Description

Item
No.

Item Description

By-pass valve, complete


Valve housing
Valve housing
Sealing ring
Spring guide
Screw
Union nut
Nut
Sealing ring
Piston
Spring

When referring to this page, please quote Plate P90915 Edition 0078

910 - Turbocharger System


Documents in this Chapter
91000
91001
91002
91003
91004
91005
91006
91009
91010
91018

0016
0127
0141
0220
0081
0113
0025
0010
0028
0003

Gas and Air System


Scavenge Air Receiver
Arrangement of Charging Air Pipe
Exhaust Pipes and Receiver
Exhaust Receiver - Details
Air Cooler
Arrangement of Auxiliary Blower
Air Cooler System - Cleaning
Air Cooler - Frame
Air Cooler System

MAN B&W Diesel A/S

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)

Scavenge Air Receiver

Plate
P91001-0127

Scavenge Air Receiver


0127
P91001

When referring to this page, please quote Plate P91001 Edition 0127
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91001-0127
Item
No.
017
029
030
042
054
091
101
125
149
150
162
186
198
221
233
245

Scavenge Air Receiver

Item Description

Item
No.

Item Description

Screw
Cover
Gasket
Screw
Distance pipe, L=040
Scavenge air receiver
O-ring
Gasket
Support
Screw
Nut
Plug screw
Plug screw
Screw
Guard
Screw

Page 2 (2)

When referring to this page, please quote Plate P91001 Edition 0127
MAN B&W Diesel A/S

Arrangement of Charging Air Pipe


MAN B&W Diesel

When referring to this page, please quote Plate P91002 Edition 0141

Plate
P91002-0141

Page 1 (2)

Plate
P91002-0141
Item
No.
012
024
036
048
061
073
085
097

Arrangement of Charging Air Pipe


MAN B&W Diesel
Item
No.

Item Description

Item Description

Insulation cover*
Screw
Nut
Plug screw
Charging air pipe
Screw
Compensator, gas type
Plug screw
Note:
* When ordering insulation material,
please use Plate P90002.

Page 2 (2)

When referring to this page, please quote Plate P91002 Edition 0141

Exhaust Pipes and Receiver


MAN B&W Diesel

When referring to this page, please quote Plate P91003 Edition 0220

Plate
P91003-0220

Page 1 (2)

Plate
P91003-0220
Item
No.
018
031
043
055
080
102
163
175
209
246
258
283
295
305
330
342
354
366
378
391
401
413

Exhaust Pipes and Receiver


MAN B&W Diesel
Item
No.

Item Description

Item Description

Screw*
Washer
Nut
Compensator, gas type
Plug screw
Plug screw
End cover
Exhaust receiver,
Plug screw
Screw*
Nut
Plug screw
Holder for grid-bolted
Screw
Screw*
Washer
Nut
Compensator, gas type
Stud
Grid
Screw*
Spacer, tubular
Note:
* These screws are special screws for
hot joints, they are marked with a"T", and
MUST NOT BE USED ELSEWHERE!

P91003

Page 2 (2)

When referring to this page, please quote Plate 0220

Edition

Exhaust Pipes and Receiver


MAN B&W Diesel

When referring to this page, please quote Plate P91004 Edition 0081

Plate
P91004-0081

Page 1 (2)

Exhaust Pipes and Receiver

Plate
P91004-0081
Item
No.
013
025
037
050
074
086
098
108
121
145
157
169
170
182
204
216
241
277

MAN B&W Diesel


Item
No.

Item Description

Item Description

Screw*
Distance pipe
Screw
Spring pin
Nut
Support
Nut
Nut
Clamp
Spring plate
Shim
Support
Locking plate
Screw
Spring pin
Screw
Washer
Support
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 0081

Air Cooler

When referring to this page, please quote Plate P91005 Edition 0113
MAN B&W Diesel A/S

Plate
P91005-0113

Page 1 (2)

Plate
P91005-0113
Item
No.
019
020
032
044
056
068
081
093
103
115
127
140
176
188
211
223

Air Cooler

Item Description

Item
No.

Item Description

Reversing chamber
Lock washer
Screw
Nut
Locking plate
Anti corrosion block
Support iron
Gasket
Cover
Screw
Screw
Cooler block*
End cover
Plug screw
End cover, complete
Water mist catcher*
Note:
* When ordering Spare Parts for this
item, please state manufacturers
Part No.

Page 2 (2)

When referring to this page, please quote Plate P91005 Edition 0113
MAN B&W Diesel A/S

Arrangement of Auxiliary Blower

Plate
P91006-0025

Arrangement of Auxiliary Blower


0025
P91006

When referring to this page, please quote Plate P91006 Edition 0025
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91006-0025
Item
No.
014
026
038
051
063
075
109
110
134
158*)
183
195
217
230
254

Arrangement of Auxiliary Blower

Item Description

Item
No.

Item Description

Valve flap
Support
Sealing ring
Slide bearing
Shaft
Valve flap
Spring pin
Shaft
Support
Auxiliary blower
Distance pipe, L=35
Screw
Screw
Screw
Screw

*) When ordering spare parts, please


state manufacturer's part No.

Page 2 (2)

When referring to this page, please quote Plate P91006 Edition 0025
MAN B&W Diesel A/S

Cleaning of Air Cooler

Plate
P91009-0010

Cleaning of Air Cooler


0010
P91009

When referring to this page, please quote Plate P91009 Edition 0010
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91009-0010
Item
No.
010
022
034
046
058
071
083
095
105
129
130
142
154
166
178
191
201
213
225
249
250
262
274
286
298
308
321
333
357
370
394

Cleaning of Air Cooler

Item Description

Item
No.

Item Description

Coupling
Coupling, complete
Steel pipe, L= 650
Steel pipe, L= 1500
T-coupling
Clamp
Adaptor
Coupling, compl.
L-coupling
Steel pipe, L= 3500
Funnel
Clamp
Nut
Support
Coupling
Coupling
Steel pipe, L= 270
T-coupling
Coupling
Valve
Reducing pipe
L-coupling
Steel pipe, L= 750
Sight glass
Nipple
Valve
Drain box
Coupling, complete
Steel pipe, L= 180
Reducing pipe
L-coupling

Page 2 (2)

When referring to this page, please quote Plate P91009 Edition 0010
MAN B&W Diesel A/S

Air Cooler - Frame


MAN B&W Diesel

When referring to this page, please quote Plate P91010 Edition 0028

Plate
P91010-0028

Page 1 (2)

Air Cooler - Frame

Plate
P91010-0028
Item
No.
016
028
053
065
077
089
090
112
124
148
161
173
185
197
219
220
256
268
281
293
303
315
339
352
376
388
411

MAN B&W Diesel

Item Description

Item
No.

Item Description

Distance pipe
Screw
Screw
Cover
Gasket
Plug screw
Air cooler
Screw
Distance pipe
Screw
Nut
O-ring
Cover
Screw
Plug screw
Spring pin
Packing
Cleaning pipe
Screw
Spray nozzle
Cap screw
Screw
Cover
Packing
Plate
Screw
Washer
Note:
*

Page 2 (2)

When referring to this page, please quote Plate P91010 Edition 0028

Air Cooler System


MAN B&W Diesel

When referring to this page, please quote Plate P91018 Edition 0003

Plate
P91018-0003

Page 1 (2)

Air Cooler System

Plate
P91018-0003
Item
No.
021
033
045
057
069
070
082
094
104
128
141
153

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Packing
Screw
Cooling water pipe
Cooling water pipe
Plug screw
Plug screw
Butterfly valve
Screw
Flange
Coupling
Ball valve
Nipple

When referring to this page, please quote Plate P91018 Edition 0003

911 - Safety Equipment


Documents in this Chapter
91101
91102
91103
91104

0037
0025
0018
0095

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

Safety V
alve - Cylinder
Valve
MAN B&W Diesel

When referring to this page, please quote Plate P91101 Edition 0037

Plate
P91101-0037

Page 1 (2)

Safety V
alve - Cylinder
Valve

Plate
P91101-0037
Item
No.
010
022
034
046
058
071
083
095
105
117

Page 2 (2)

MAN B&W Diesel

Item Description

Item
No.

Item Description

Spindle
Spring retainer
Lock nut
Spring
Valve housing
Stop ring
Valve flap
Valve guide
Gasket
Safety valve, complete

When referring to this page, please quote Plate P91101 Edition 0037

Relief Valve

When referring to this page, please quote Plate P91102 Edition 0025
MAN B&W Diesel A/S

Plate
P91102-0025

Page 1 (2)

Plate
P91102-0025
Item
No.
016
028
030
041

Relief Valve

Item Description

Item
No.

Item Description

Relief valve (P.C.D. 302mm) *


Screw*
Packing*
O-ring*
Note:
*When ordering, please state manufacturer of Relief Valve and
P.C.D. xxx mm

Page 2 (2)

When referring to this page, please quote Plate P91102 Edition 0025
MAN B&W Diesel A/S

Safety Valve - Scavenge Air System


MAN B&W Diesel

When referring to this page, please quote Plate P91103 Edition 0018

Plate
P91103-0018

Page 1 (2)

Plate
P91103-0018
Item
No.
011
035
047
059
060
072
096
106
118
131
143
155

Page 2 (2)

Safety Valve - Scavenge Air System


MAN B&W Diesel

Item Description

Item
No.

Item Description

Safety valve, complete


Spindle
Washer
Spring retainer
Castle nut
Split pin
Screw
Nut
Valve flap
Seal
Valve seat
Spring

When referring to this page, please quote Plate P91103 Edition 0018

Arrangement of Safety Cap


MAN B&W Diesel

When referring to this page, please quote Plate P91104 Edition 0095

Plate
P91104-0095

Page 1 (2)

Plate
P91104-0095
Item
No.
017
029
054
066
078
091
137
149
150
162
174
186
198
208
221

Page 2 (2)

Arrangement of Safety Cap


MAN B&W Diesel

Item Description

Item
No.

Item Description

Starting air pipe


Starting air pipe
Bursting cap, complete
Protective guard
Gasket
Screw
Fit bolt
Check plate
Wing nut
Screw
Washer
Bursting cap cover
Perforated cylinder
Housing
Bursting disc

When referring to this page, please quote Plate P91104 Edition 0095

912 - Assembly of Large Parts


Documents in this Chapter
91201
91201
91205
91207
91208
91209
91210
91211
91216
91217

0057
0094
0154
0062
0004
0005
0164
0086
0007
0005

Arrangement of Stay Bolts


Arrangement of Stay Bolts
Frame Box
Arrangement of Piston Cooling
Chain Wheel Frame - Upper
Chain Wheel Frame - Lower
Bedplate
Axial Vibration Damper
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
Top Bracing - Arrangement

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangement of Stay Bolts

Plate
P91201-0057

Arrangement of Stay Bolts


0057
P91201

When referring to this page, please quote Plate P91201 Edition 0057
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91201-0057
Item
No.
014
026
038
051
063
075
087

Arrangement of Stay Bolts

Item Description

Item
No.

Item Description

Screw
Protective cap
Nut
Stay bolt, complete
Stay bolt
Neck ring in 2/2
Screw

Page 2 (2)

When referring to this page, please quote Plate P91201 Edition 0057
MAN B&W Diesel A/S

Arrangement of Stay Bolts

When referring to this page, please quote Plate P91201 Edition 0094
MAN B&W Diesel A/S

Plate
P91201-0094

Page 1 (2)

Plate
P91201-0094
Item
No.
014
026
038
051
063
087

Page 2 (2)

Arrangement of Stay Bolts

Item Description

Item
No.

Item Description

Screw
Protective cap
Nut
Stay bolt assembly
Guide bushing
Stay bolt, complete

When referring to this page, please quote Plate P91201 Edition 0094
MAN B&W Diesel A/S

Plate
P91205-0154

Frame Box
Frame Box
0154
P91205

Front side

B-B

Fore end

A-A
C

Rear side
C

C-C

When referring to this page, please quote Plate P91205 Edition 0154
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91205-0154
Item
No.
016
028
041
053
065
077
089
100
112
124
136
148
161
173
185
244
256
268
293
303
315
327
339
340
352
364
376
388

Frame Box

Item Description

Item
No.

Item Description

Frame
Frame door
O-ring
Spring
Door fastener
Wing nut
Stud
Flange
Gasket
Screw
Plug screw
Cleaning cover
Screw
Washer
Gasket
Banjo coupling
Pipe, L= 150
Union
End shield
Gasket
Screw
Screw
Distance pipe, L= 75
Distance pipe
Distance pipe, L= 100
Distance pipe
Nut
Fitted bolt

Page 2 (2)

When referring to this page, please quote Plate P91205 Edition 0154
MAN B&W Diesel A/S

Arrangement of Piston Cooling

When referring to this page, please quote Plate P91207 Edition 0062
MAN B&W Diesel A/S

Plate
P91207-0062

Page 1 (2)

Plate
P91207-0062
Item
No.
017
029
030
042
054
066
078
091
113
125
137
149
150
162
174
198

Page 2 (2)

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

When referring to this page, please quote Plate P91207 Edition 0062
MAN B&W Diesel A/S

Chain Wheel Frame - Upper

Plate
P91208-0004

When referring to this page, please quote Plate P91208 Edition 0004

Page 1 (2)

Chain Wheel Frame - Upper


0004
P91208

MAN B&W Diesel A/S

Plate
P91208-0004
Item
No.
012
024
048
061
073
085
107
120
144
156
181
193
215
227
240
252

Chain Wheel Frame - Upper

Item Description

Item
No.

Item Description

Screw
Guide pin
Screw
Cover
Gasket
Screw
Screw
Chain casing
Cover
Spring pin
Cover
Gasket
Stud
Nut
Screw
Cover

Page 2 (2)

When referring to this page, please quote Plate P91208 Edition 0004
MAN B&W Diesel A/S

Chain Wheel Frame - Lower

Plate
P91209-0005

When referring to this page, please quote Plate P91209 Edition 0005

Page 1 (2)

Chain Wheel Frame - Lower


0005
P91209

MAN B&W Diesel A/S

Plate
P91209-0005
Item
No.
018
055
067
079
092
102
151
163
187
199
209
222
234
258
271

Chain Wheel Frame - Lower

Item Description

Item
No.

Item Description

Cover
Cover
Gasket
Screw
Cover
Gasket
Stud
Nut
Flange
Screw
Gasket
Cover
Gasket
Flange
Gasket

Page 2 (2)

When referring to this page, please quote Plate P91209 Edition 0005
MAN B&W Diesel A/S

Bedplate
MAN B&W Diesel

When referring to this page, please quote Plate P91210 Edition 0164

Plate
P91210-0164

Page 1 (2)

Bedplate

Plate
P91210-0164
Item
No.
013
025
037
049
050
062
074
086
108
121
133
145
157
169
170
182
204
216
228
241
253
265
277
289
300
312
324
348
361
385
397
419
420
432
456
468
481
493
503
515
539
540
552

MAN B&W Diesel


Item
No.

Item Description

Item Description

Lubricating oil pipe, main bearing


Gasket
Flange
Screw
Stud
Nut, self-locking
Screw
Lubricating oil pipe, main bearing
Nut
Baseplate
Stud
Main bearing cap
Main bearing, upper shell*
Main bearing, lower shell*
Screw
Spring pin
Flange
Packing
Distance pipe
Screw
Flange
Distance pipe
Screw
Screw
Lubricating oil pipe, main bearing
Gasket
Flange
Screw
Lubricating oil pipe, main bearing
Lubricating oil pipe, main bearing
Pipe holder
Screw
Grats
Stud
Lubricating oil pipe, main bearing
Baseplate
Main bearing cap
Cover
Gasket
Bedplate
Gasket
Cover
Plain plug
Note:
To be ordered as a complete part only.

Page 2 (2)

When referring to this page, please quote Plate P91210 Edition 0164

Axial Vibration Damper

Plate
P91211-0086

When referring to this page, please quote Plate P91211 Edition 0086

Page 1 (2)

MAN B&W Diesel A/S

Plate
P91211-0086
Item
No.
019
020
032
044
056
068
081
093
115
127
139
164
176
188
211

Page 2 (2)

Axial Vibration Damper

Item Description

Item
No.

Item Description

Spring
Spring
Oil seal
Oil seal
Screw
Screw
Screw
Restriction for damper
Screw
Stud
Restriction for damper
Axial vibration damper, upper part
Cylindrical pin
Axial vibration damper, lower part
Cylidrical dowel

When referring to this page, please quote Plate P91211 Edition 0086
MAN B&W Diesel A/S

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, please quote Plate P91216 Edition 0007
MAN B&W Diesel A/S

Page 1 (2)

Plate
P91216-0007
Item
No.
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.

Item Description

Liner
Nut
Stud for end chock bolt, M48 x 5.0
Spherical washer
Spherical washer
Nut
Protective cap
Protective cap
Nut
Distance pipe
Screw
Washer
Locking plate
Liner for side chock, starboard
Liner for side chock, port side
Spherical washer
Spherical nut
Holding-down bolt, M30 x 3.5

Page 2 (2)

When referring to this page, please quote Plate P91216 Edition 0007
MAN B&W Diesel A/S

Top Bracing - Arrangement


MAN B&W Diesel

When referring to this page, please quote Plate P91217 Edition 0005

Plate
P91217-0005

Page 1 (2)

Top Bracing - Arrangement

Plate
P91217-0005
Item
No.
011
023
059
060
072
084
096
106
131
143
155
180
202
214

MAN B&W Diesel


Item
No.

Item Description

Item Description

Screw, short*
Friction shim
Distance pipe
Washer
Nut
Split pin
Screw, long*
Plate, short*
Plate, large*
Plate
Guide pin
Disc spring
Plate
Friction shim
Note:
* When ordering this spare part, please
state length

Page 2 (2)

When referring to this page, please quote Plate P91217 Edition 0005