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 .

26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No.M C.O C.O Crankshaft and Thrust Bearing Main bearing Thrust bearing Guide bearing Journal bearing Axial vibration damper Electronic axial vibration monitor 24 32 B P O O Remarks * Check whenever exhaust valve is removed O C V C* 903 Cylinder Liner and Cylinder Lubrication -1 Cylinder liner Inspection through scavenge ports Measuring wear inside liner -2 Cylinder lubricators Accumulators nitrogen pressure 905 -2 -3 -3 -4 -5 16 C* 902 Piston with Rod and Stuffing box -1 Piston Inspection through scavenge ports -2 Piston rod stuffing box Crosshead with connecting rod Crosshead bearing Crosshead Reciprocating parts Crankpin bearing Connecting rod R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) Daily Weekly Monthly 901 Cylinder Cover -1 Cylinder cover Indicator cock 904 -1 -2 -3 -4 -5 900-1 O * Check clearances without dismantling segments O C C C C A A V. please quote Maintenance Schedule A90050 Edition 0288 Page 3 of 6 .O C. V C When referring to this page. V Bearings should only be opened up if bearing material fragments fall out.MAN B&W Diesel Checking and Maintenance Schedule.O C.O O V C C C C C C C C C C C C C C.O C. Procedure H 2 4 6 8 12 C.O C.O C.O O V C C Bearings should only be opened up if bearing material fragments fall out.

A M M M C C C C C.A C* C* C* C* C O O * only inspection through camshaft covers When referring to this page. Procedure -7 -8 Mechanical checking Tacho pick-up Angle encoder 906 Mechanical Control Gear -1 Chains -2 Chain tightener Chain wheels.A C.O C. 1500 and 4000 hours C. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No. fitted bolts -5 Moment compensator Governor Functional check of overspeed device Functional check of speed-setting system (engine with bridge control system) 907 Starting Air System -1 Starting air distributor -2 Starting air valve 908 Exhaust Valve -1 High-pressure pipe -2 Exhaust valve Conventional hard-faced valve seats Nimonic exhaust valves -3 Exhaust valve actuator Actuator safety valve -4 Exhaust valve roller guide -5 Exhaust valve cam Page 4 of 6 MAN B&W Diesel H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P C.O M M R A R C.O A O O O O C. spray nozzles and guide bars -3 Camshaft -4 Camshaft bearings Camshaft coupling.A C C C C.900-1 Checking and Maintenance Schedule. please quote Maintenance Schedule A90050 Edition 0288 .O V Remarks C C C.A C C C O C C C New or overhauled chain to be checked/retightened after 500.

M Page 5 of 6 .O * Only inspection through camshaft covers V Check ∆p and ∆t Check at every port inspection V. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No. -7 Procedure H R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) Daily Weekly Monthly 2 4 6 8 12 16 24 32 Exhaust valve special running 909 Fuel Oil System Fuel oil water content -1 Fuel pump settings -2 VIT system -3 Fuel pump cam -4 Fuel pump -5 Fuel pump top cover -6 Fuel pump barrel assembly -7 Fuel pump suction valve -8 Fuel pump puncture valve -9 Fuel pump shock absorber -9 Fuel system shock absorber -10 Lifting gear for roller guide -11 Fuel valve Fuel nozzle -12 Spindle guide -13 Non-return valve -14 Fuel oil high-pressure pipes -15 Fuel pump roller guide -16 Fuel pump special running 910 -1 -2 -3 -4 -5 900-1 Turbocharger System Air cooler Non-return valve Auxiliary blower Butterfly valves Turbocharger turbine B P Remarks O C C A.MAN B&W Diesel Checking and Maintenance Schedule.O C C C C. please quote Maintenance Schedule A90050 Edition 0288 C C O O O O O O O C.C A A O O R O C.O C.O R V V O O O R O C* C* C C C C* When referring to this page.

O C C C C C C C C C C* * Check ∆p O O O C C C C Remarks A A A A A M M M M M M C C * Initial check only C C R C M Empty and clean tank O C A V. please quote Maintenance Schedule A90050 Edition 0288 .M * Check for loose nuts and bearing material fragments C* O M When referring to this page. Procedure -6 Turbocharger air filter Protective grid before turbocharger Turbocharger lubricating oil water content Water mist catcher 911 -1 -2 -3 Safety Equipment Overpressure indicator valve Relief valve Scavenge air receiver safety valve Functional test of alarm system for thrust bearing and slow down /shut down system Checking and adjustment of pressure gauge Checking and adjustment of thermometers Checking and adjustment of thermostats Checking and adjustment of pressurestats Checking and adjustment of turning gear switch 912 Assembly of Large Parts -2 Holding-down and end chock bolts -3 Stay bolts Top bracings Diaphragm in crankcase oil outlet System lubricating oil water content System lubricating oil bottom tank Cooling water quality Crankcase 913 General Tools -1 Hydraulic tools Page 6 of 6 MAN B&W Diesel H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 C B O R C C* C* P V M C. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks No.900-1 Checking and Maintenance Schedule.

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

.

Panel Cylinder Cover .Cylinder Cover Documents in this Chapter 101-01 901-01 90151 90161 0031 0223 0189 0101 Cylinder Cover. Data Cylinder Cover Cylinder Cover .901 .Tools MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

50-300 Nm Ref. 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 800–990 bar Hydraulic pressure – tightening 900 bar When referring to this page. Description D-1 Weight of exhaust valve stud D-2 Weight of cyl.Cylinder Cover 101-1 Data SAFETY PRECAUTIONS Special Data S35MC 0031 101-1 Standard Tools: See Section 913 Cylinder Cover X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil Shut off lubricating oil X Lock turbocharger rotors Data 10-120. please quote Data D10101 Edition 0031 MAN B&W Diesel A/S Page 1 (2) .

Page 2 (2) Description Qty When referring to this page.1 90151 Spare Parts Plate – Item No.Cylinder Cover 101-1 Data Plate 1849860-1. please quote Data D10101 Edition 0031 MAN B&W Diesel A/S .

Open drain cock E and vent the system. When referring to this page.2 1. Dismount the drain oil pipe from the exhaust valve to the hydraulic actuator. 1. Vent the manoeuvring system through the ball valve. Open indicator cocks C. Close cooling water inlet and outlet valves D. Shut off the control air and safety air supply G. Engage turning gear B.2 Dismantling Cylinder Cover S35MC 0223 Dismantling 901-1. BM901-1.2 223 02 2.Cylinder Cover 901-1. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 Page 1 (10) . Dismantle the exhaust valve high-pressure pipe. BM901-1. and the sealing air pipe.2.2 223 01 Also shut off the air supply on the pressure reduction unit for the hydraulic/pneumatic exhaust valve. See Procedure 908-1. Close fuel oil inlet valve F. 2. Set blocking device A on the main starting valve in the BLOCKED position. and vent the system.

The four lowermost screws need not be dismantled. Dismount the high-pressure fuel pipes from the fuel pump to the valves.2 223 03 4. BM901-1. Dismount the control air pipe from the starting valve. just loosened. Remove the control air pipe. Remove the protective jacket enclosing the intermediate pipe between the exhaust receiver and the exhaust valve.2 223 04 Remove the protective caps from the cylinder cover nuts.2 Cylinder Cover Dismantling 3. See Procedure 909-14. BM901-1. BM901-1. Dismount the return oil connection from the fuel valves at the fuel pump. 3. Remove the starting air pipe. Dismount the screws in the flange between the intermediate pipe and the exhaust receiver. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 .2 223 05 5.901-1.2. 4. Page 2 (10) When referring to this page. 5. Remove the outlet pipes for cooling water from the exhaust valve and intermediate pipe.

vent the system and increase the pressure as stated in Data. D-2 Finally. see Chapter 913. Place eight spacer rings over the nuts. and unscrew the nuts.2 223 06 Using the vent screws of the hydraulic nuts. When referring to this page. 6. Loosen the nuts by applying the tommy bar through the slots in the spacer rings.2 208 07 Lift away the cylinder cover complete.Cylinder Cover 901-1. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 Page 3 (10) . and land it on a couple of wooden planks. Remove and discard the sealing ring between cylinder cover and cylinder liner.2 Dismantling 6. 7. and screw the eight hydraulic jacks onto the studs. 8. For operation of the hydraulic tools. BM901-1. 7. BM901-1. remove the hydraulic jacks and spacer rings. Hook the engine room crane on to the lifting attachment on top of the exhaust valve. BM901-1. D-8 Connect the high-pressure pump to the jacks by means of the distributor block and the high-pressure hoses.2 223 08 8. Disconnect the high-pressure hoses from the jacks. Relieve the system of pressure.

3. Mount and tighten the screws for the cooling jacket.3 208 01 If the cooling jacket sticks. well lubricated with oil. BM901-1.901-1. using the guide pin as a reference (camshaft side). Dismount all valves and pipes on the cylinder cover. Provide the cylinder cover with new Orings. Lift the cylinder cover and guide the jacket/ cover into position. BM901-1.3 208 03 4.3 208 02 D-3 BM901-1.3 1. D-1 1. 2. Remove the screws which secure the cooling jacket to the cylinder cover. use dismantling screws to force the jacket/cover apart. 4. 2. Remove and discard the O-rings from the cover.3 Cylinder Cover Overhaul Overhaul 901-1. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 . and carefully clean the cooling jacket and the cylinder cover. Page 4 (10) When referring to this page. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. Dismount all studs on top of the cylinder cover.

3 208 05 Clean the fuel valve bores. After the milling/grinding. and check that the seating is not damaged.Cylinder Cover 901-1. BG901-3. grind the seating with the grinding disc and a grinding compound (e.g. Grind the seating with the grinding mandrel and a grinding compound (e.g.1 67 04 7. recondition the fuel valve seating with the appropriate cutter. clean the bore and seating carefully. a carbon cutter. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 Page 5 (10) . Recondition the valve bores as follows: Fuel valve bore 6. 200). The tool consists of a spindle with handle and a grinding disc. After the grinding. 5. Exhaust valve bore 7. GN901-1. using the carbon cutter. Carborundum No. and a grinding mandrel. If required. 200). The tool consists of a common spindle with handle. clean the bore and seating carefully. BM901-1.3 Overhaul 5. When referring to this page. Remove and discard the sealing ring between the cylinder cover and exhaust valve. and of a guide. a seating face cutter. and check that the seating is not damaged. 6.3 203 06 After cleaning the valve bore and seating. Carborundum No.

When replacing valves on a cylinder cover that is mounted on the engine. The tool consists of a guide.3 208 08 9. and a grinding disc. recondition the valve bores/seating in the same way as described here. BM901-1.3 208 09 9. BM901-1. Page 6 (10) When referring to this page.3 Cylinder Cover Overhaul 8.901-1. Recondition the starting valve bore and seating in the same way as described for the fuel valve bore. but without dismounting the studs. Clean the bores for safety valve/indicator cock. Starting valve bore 8. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 . a cutter.

When referring to this page. Tighten up the studs in accordance with the screwing-in torque stated on the data sheet. BM901-1. and keep the cylinder cover ready for replacement. Lubricate the threads with ‘Never Seize' or Molybdenum Disulphide (MoS 2) and mount the valve studs.Cylinder Cover 901-1. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 Page 7 (10) . 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.3 208 10 Provide the water connection flanges with new gaskets.3 Overhaul 10. Always fit new or overhauled valves before a cylinder cover is mounted on the engine.

3. Connect the high-pressure pump to the jacks by means of the distributor block and the high-pressure hoses. BM901-1. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 .4 1. carefully check that the cooling water connecting pipes engage correctly with the holes in the cooling jacket. Lower the cover carefully into position. 2. BM901-1. Mount a new ‘klinger’ sealing ring in the groove of the flange of the intermediate pipe. Relieve the system of pressure.4 Mounting Mounting 901-1.4 208 02 Place a spacer ring around each nut. 3. Lift the cylinder cover by means of the crane and carefully wipe the contact surface which faces the cylinder liner. Tighten the nuts by applying the tommy bar through the slots in the spacer rings. BM901-1. 2. see Chapter 913.4 208 01 Provide the cooling water connecting pipes with new O-rings and lubricate them with vaseline or soft soap. Place a new sealing ring on top of the cylinder liner with the guide tabs in the fore and aft direction. remove the hydraulic jacks and spacer rings from the nuts.2 223 06 Finally. For operation of the hydraulic tools. and mount the hydraulic jacks on the studs. During the landing. D-9 Use the vent screws of the hydraulic nuts to vent the system. Page 8 (10) When referring to this page. This is to ensure that the tabs fit into the two gas blow-out grooves milled in the cylinder cover guide recess. and then increase the pressure as stated in Data.Cylinder Cover 901-1. D-2 1. Mount the cover nuts on the studs and screw down.

Mount the protective caps on the cylinder cover studs. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 Page 9 (10) .4 223 04 Note! 5.4 Mounting 4. 4. Mount the screws of the flange between the intermediate pipe and the exhaust receiver. BM901-1. Mount the insulating jacket around the intermediate pipe. 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. Lubricate the screws with ‘Never Seize’ or Molybdenum Disulphide (MoS 2) before mounting. BM901-1.4 223 05 5.Cylinder Cover 901-1. When referring to this page.

Using a crowfoot wrench and torque spanner. Shut the drain valves and open the cooling water inlet. After venting the cylinder section. Connect the outlet pipe from the return oil pipe on the fuel valves. 6.4 223 07 The air supply to the exhaust valve must always be connected before turning on the camshaft oil supply. Page 10 (10) When referring to this page. This is very important.4. Mount the drain oil pipe and the sealing air pipe. 9. please quote Procedure M90101 Edition 0223 0$1% :'LHVHO$6 .4 223 06 8. shut the vent cocks and open the cooling water outlet valve.4 223 08 8. See Procedure 909-13. Caution ! BM901-1. 7. because otherwise the valve will open more than intended. and the control air pipe for the exhaust valve.4. Mount the cooling water pipes.901-1. BM901-1. Mount the starting air pipe and control air pipe for the starting valve.4 Cylinder Cover Mounting 6. 7. See Procedure 908-1. lubricating oil and air supplies to the alarm system. Open the fuel oil. BM901-1. Mount the high-pressure pipe for the hydraulic valve gear. mount the fuel oil high-pressure pipes.

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) .

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

Tools Plate P90161-0101 When referring to this page.Cylinder Cover . please quote Plate P90161 Edition 0101 Page 1 (2) MAN B&W Diesel A/S .

Plate P90161-0101 Item No.Tools Item Description Item No. 027 039 052 064 088 090 100 206 Page 2 (2) Cylinder Cover . 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 .

Tilting Tools Piston and Piston Rod .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.Tools Piston and Piston Rod . Data Piston Rod Stuffing Box Piston and Piston Rod .Lifting Tools MAN B&W Diesel A/S .Support Tools Piston . Data Piston Piston Rod Stuffing Box.Panel Piston and Piston Rod .902 .

MAN B&W Diesel A/S .

2. please quote Data D10201 Edition 0054 MAN B&W Diesel A/S Page 1 (2) . 1 10.2 mm – groove Nos. permissible burn-away: – standard piston top 11 mm Minimum free ring gap 22 mm Minimum ring gap 2.35 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 837±2 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.Piston 102-1 Data SAFETY PRECAUTIONS Special Data 0054 102-1 Standard Tools: See Section 913 S35MC Piston X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil X Shut off lubrication oil 10–120. new parts 0.5 mm – worn piston ring 10. 3 and 4 8.30-0. Description D-1 Radial width: – new piston ring 12. 50–300 Lock turbocharger rotors 2 x M12 Data Ref.5 mm Vertical clearance.7 mm Max.0 mm Maximum vertical height: – groove No.

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 102-1 Data 1849875-7.

Scavenge port inspection To detect possible leakages from the piston or cylinder cover. With the piston in BDC. Turn the engine. See Volume I.1 201 03 3. While the piston is passing the scavenge air ports. Check the movability and the tension of the piston rings.1 204 01 Note! Clean the openings. the ringlands and the piston skirt. inspect the piston crown and the cylinder wall. Remove the inspection covers on the camshaft side of the cylinder frame. GN902-1.1 1.Piston 902-1. Note down the results. Chapter 707.1 204 02 3. 1. keep the cooling water and cooling oil circulating during the scavenge port inspection. GN902-1. Note down the results.1 Checking Piston S35MC 0249 Checking 902-1. HG902-1. 2. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 1 (19) . by pressing against them with a wooden stick. inspect the piston rings. OPERATION. When referring to this page. Begin the inspection at the cylinder whose piston is nearest BDC. 2. The scavenge port inspection can also be carried out from within the scavenge air receiver.

Before dismantling the piston rings. Note! D-7 It is recommended to replace all the piston rings whenever a piston is removed from the engine.Piston 902-1. GN902-1. After turning the piston upwards.1 204 04 Piston rings and piston crown 6. measure the free ring gap of all the piston rings. If necessary. inspect the piston rod and the lower part of the cylinder wall. Re-mount the inspection covers on the cylinder frame. replace the gaskets. For evaluation of the rings. 5. Note down the results. Page 2 (19) When referring to this page. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . See Procedure 902-1.2. D-4 BM902-1. past the scavenge air ports. Chapter 707. OPERATION . see Volume I. All the following measurements should be used as a guideline for the running time of a set of new piston rings.1 Checking 4.1 72 02 Depending on the extent of the wear. 6. the running time can be increased or decreased. 7. BG902-4. 4.1 232 07 7. Remove the piston from the cylinder and place it on the piston support.

1 204 08 D-1 Worn Min.1 222 14 10. See Volume I. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 3 (19) . Clean and inspect the rings.1 204 09 10. 8. Operation. Worn rings must be replaced if the radial width is less than stated in Data. GN902-1. 9. 9. Measure and record the radial width of the rings. Take off the piston rings by means of the ring expander.Piston 902-1. 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. New GN902-1. 1 mm GN902-1. When referring to this page.1 Checking 8. Chapter 707.

Piston 902-1. 12. Clean the ring grooves and check them for burn marks or other deformation. Clean the piston crown and check the burnaway by means of the template. see Data. 11. 2 mm The maximum vertical height in a worn ring groove must not exceed the value stated in Data.1 Checking 11. Clearance in piston ring grooves: Max. 12. Check the burn-away on the whole circumference of the piston crown. For maximum permissible burn-away value. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S .0 47 05 The groove is also worn out if there is no chromium layer.0 77 04 D-3 Page 4 (19) When referring to this page. AM902-3. D-2 Measure the ring grooves with a caliper gauge. KM902-3.

Check the vertical clearance between the new piston ring and the new or reconditioned ring groove with a feeler gauge. 15. 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).Piston 902-1. use the ring expander to prevent unintended deformation of the rings. 14. Do not expand the rings more than necessary. D-5 14. The upper ring (CPR ring) should not be expanded more than to the milled mark on the ring expander. measure the piston ring gap. When mounting the piston rings.1 Checking 13. see Data. Before mounting a new piston ring. 13. GN902-1.1 222 14 15. GN902-1. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 5 (19) .0 83 06 D-6 When referring to this page. Fit the piston rings (alternately right-hand and left-hand cuts with the ring gaps staggered 180° and with the TOP mark upwards). KC902-3. See Data.1 222 13 For minimum ring gap.

2.2 1.1 105 01 Do NOT remove the outermost screws from the flange. Page 6 (19) When referring to this page. 1. 3.2 Piston Dismantling Dismantling 902-1. Release the stuffing box by removing the innermost screws from the stuffing box flange. and to the telescopic pipe. Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . Remove the screws from the piston rod. BM902-1. GN902-1. Turn the crosshead down far enough to give access to the piston rod stuffing box. Note! DM902-2. the tightening screws for the piston rod.2 249 03 3.902-1.2 204 02 2.

Make a scratch mark in liner and piston cleaning ring to ensure the correct mounting. When a piston is dismantled. 5.Piston 902-1. Dismount the cylinder cover. 4.2.3.2 210 05 Carefully smooth out any wear ridges at the top of the cylinder liner by using a hand grinder. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 7 (19) . DM902-2. When referring to this page. never turn the engine without first dismantling the telescopic pipe from the crosshead.1 105 05 Note! 5. See Procedure 903-1. Remove the four screws and nuts which tighten the telescopic pipe to the bend. Remove the piston cleaning ring. Turn the engine to TDC.2 Dismantling 4. HN902-1. 6.2 237 06 6. BM902-1. 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. See Procedure 901-1.

D-7 If necessary. Page 8 (19) When referring to this page. measure and recondition the cylinder liner. 7. GN902-1. Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit.1 72 02 9. 8.902-1. Lift the piston out of the cylinder and lower the piston rod foot and stuffing box through the opening in the platform.2 Piston Dismantling 7. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . claw of the tool to the lifting groove and tighten it up against the stop of the tool. 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. Place the two halves of the support around the piston rod and secure the two halves with screws. The top of the piston is now free of the cylinder liner.1 72 02 Clean. 8. remove one or two cylinder cover studs. adjustable. using a stud setter.2 204 07 Fit the third. See Procedure 903-1. Place the two halves of the support around one of the openings in the platform. BG 902-4. 9. BG902-4.

The protective rubber cover should remain in place to protect the crosshead bearing journal from impurities until the piston is remounted.2 204 10 Low lifting height Lift the piston high enough to give ample room over the cylinder cover studs. Turn the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap. 10. 11. using the stud setter. GN902-1. If the space conditions above the engine make it impossible to remove the piston in the normal way.2 Dismantling 10.Piston 902-1. BM902-1. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 9 (19) .2 249 11 D-7 When referring to this page. the piston can be removed as follows: 11. Remove one or two cylinder cover studs. Mount the clamp on the piston rod so that its distance piece lies true against the piston.

Keep the piston rod clear of the cylinder liner and studs while carrying out the tilting. remove the tilting tool. Remove the lifting tool from the piston. Run the crane athwartship and. position the piston support around the piston rod and clamp. Page 10 (19) When referring to this page. 13. Lift the piston to the maximum crane height. When the piston is at a suitable height above the platform cut-out.2 249 13 D-7 On engines with extremely low lifting height. Place the supporting tools on the cylinder cover studs and lower the piston until the clamp rests on the tools. When space conditions permit. After landing the piston and ensuring that it rests correctly on the support.Piston 902-1. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . at the same time. Hook the transverse piece on to the crane and attach it to the clamp for tilting the piston.2 249 12 Now lower the piston while guiding the support to the platform cut-out. BM902-1. straighten up the piston and lead it over to the cut-out in the platform for overhauling the piston. Note! BM902-1.2 Dismantling 12. 13. tilt the piston. 12. use the engine room double-jib crane instead of the transverse piece.

3. 2.3 Overhaul Overhaul 902-1. BM902-1. D-7 Land the piston on the support. Ease the piston down so that the stuffing box is below the floor.1 72 02 2. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 11 (19) . See Procedure 902-1. 1. taking care that the piston is not resting on the head of the piston rod bolts. See Procedure 902-2.Piston 902-1. Dismount the stuffing box and distance pieces.2. BG902-5.3 1. Assemble the two halves of the piston support around the piston rod. BG902-4.3 249 01 Dismount the piston rings.1 82 03 3.1. When referring to this page.

5. Note! 6.3 236 05 7. Page 12 (19) When referring to this page. Remove the lifting tool from the piston crown. During the lift. Lift the piston rod foot clear of the wooden block. BM902-1. D-9 Lower the piston rod foot near to the platform. 4.3 236 07 7. 6. 5. Lift the piston with the normal lifting tool. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . BM902-1.Piston 902-1.3 236 06 Keep lifting until the piston rod is in a vertical position. Land the foot on a wooden block. Note! BM902-1. follow with the crane to keep the crane positioned vertically above the piston crown. Lower the piston crown to the platform and land it on a wooden block. Attach the lifting bracket to the bottom of the piston rod foot.3 Overhaul 4. follow with the crane to keep the crane positioned vertically above the piston rod foot. Hook the crane on to the lifting bracket. Pull the piston rod foot a bit to the side by hand to tilt the piston. BM902-1.3 236 04 During the lift.

the piston crown cooling spaces should be washed out with Carbon Remover or a similar cleaning fluid. D-9 Replace all sealing rings of the piston. Regarding check of the piston crown.3 236 09 Coat all screws with Molybdenum Disulphide (MoS 2).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. BM902-1. see Procedure 902-1. D-14 Tighten all the screws diagonally to the torque stated in Data. When all coke deposits have been dissolved. Place the piston in an upright position with the piston crown resting on wooden blocks. Use the guide screw to ensure the correct positioning of the piston rod in relation to the piston crown.3 Overhaul 8. Lift the piston rod away and land it in a horizontal position on a couple of wooden blocks.1. If coke deposits are found in the cooling spaces of the piston crown. BM902-1. D-8 Assemble the piston in the reverse order to disassembly. 8.3 236 10 D-10 When referring to this page. Lift the skirt and land it on a couple of planks. 10. 10.Piston 902-1. Thoroughly clean and inspect all parts of the piston. D-13 Dismount the locking wire and the innermost screws between the rod and the piston crown. BM902-1. All the new sealing rings must be coated with lubricating oil before the piston is assembled. clean and inspect the piston crown again. 9. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 13 (19) .

Tilt the piston to an upright position and land it on the piston support tool. BM902-1.2 52 07 Pressure-test the piston at the pressure stated on the data sheet.4. See Procedure 902-2. Mount the stuffing box and distance pieces. 11. 12. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . Mount the locking wire in such a way that the wire is tightened if one of the screws works loose. HM902-4.3 Overhaul 11. Check the contact surfaces of the piston and the sealing rings for tightness.Piston 902-1. Check that there are no cracks in the piston crown. Fill the piston and piston rod with lubricating oil. Lock all the screws with locking wire.3 236 12 Oil Page 14 (19) When referring to this page. D-15 13. Mount the pressure-testing tool around the base of the piston rod.1. See Procedure 902-1. 12. See Procedure 913-7. Mount new piston rings.

Remove the protective rubber cover from the crosshead.2 204 10 4.4 2. 2.Piston 902-1. BM902-1. BM902-1. When referring to this page. GN902-1. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 15 (19) . Mount the lifting tool on the piston crown.4 249 02 Coat the O-rings of the stuffing box with oil. 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.4 249 03 3. Check the piston rings and piston crown in accordance with Procedure 902-1.4 Mounting Mounting 902-1.1. 1. 4.

5. Turn the crosshead to a position 45° from TDC.2 84 03 6. corresponding to the lifting tool lacking about 30 mm in landing on the guide ring. 7. Coat the O-rings of the stuffing box with oil.902-1. BM902-1.4 Piston Mounting 5. 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.4 249 07 7. GN902-1. Page 16 (19) When referring to this page. DM902-2.2 204 09 Mount the guide ring for piston rings on the cylinder liner. Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit. Coat the piston rings. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . 6. piston rod and cylinder liner with lubricating oil.

Check that the holes in the stuffing box and stuffing box flange are correctly centered. Remove the distance pieces from the piston rod foot.4 Mounting 8. Turn the crosshead to TDC while checking that the guide ring of the crosshead enters the centre hole in the piston rod. See Data.Piston 902-1. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 17 (19) . unscrew the adjustable claw of the lifting tool and pull the lifting tool free of the lifting groove in the piston.2 105 06 D-16 When referring to this page. After turning the piston fully to TDC. 8. BM902-1. 9. BM902-1. 10.4 249 09 Mount and tighten the screws for the telescopic pipe. Turn the crosshead with the piston rod down far enough to give access to the telescopic pipe stuffing box. Turn down and land the stuffing box on the stuffing box flange. 9. Loosen the telescopic pipe and land it on the bend. 10.4 249 08 Remove the lifting tool and the guide ring for piston rings. DM902-2.

mount them with the stud setter.4 230 12 D-17 Page 18 (19) When referring to this page.2 62 08 12. 13. Lock the screws with locking wire.4 Mounting 11. Mount and tighten the piston rod screws. BM902-1. GN902-1. Tighten down the piston rod stuffing box by means of the screws through the inner holes in the stuffing box flange. If the cylinder cover studs have been removed. See Procedure 902-2. See Data. D-18 11. See Procedure 913-7. BG902-2.4.Piston 902-1. Carefully clean the surfaces around the base of the mounted studs and refill the roots properly with Permatex 3. 13. Mount the locking wire in such a way that the wire is tightened if one of the screws works loose.2 204 02 12. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S . See Data.

Start the engine and keep it running for about 15 minutes at a number of revolutions corresponding to very slow.4. and turn the crankshaft a couple of revolutions. to ensure proper sealing between cylinder cover and cylinder liner.4 237 13 If the PC-ring is damaged (broken or cracked). HN902-1. GN902-1. Mount the piston cleaning ring according to the scratch mark. When referring to this page.2 204 05 Then stop the engine and inspect the piston rod and stuffing box. See Procedure 901-1.4 Mounting 14. please quote Procedure M90201 Edition 0249 MAN B&W Diesel A/S Page 19 (19) . 16. 15. 15. 14. Mount the cylinder cover. Smear the piston rod with molybdenum disulphide.Piston 902-1. it must be replaced by a dummy ring with an over-size bore.

.

............... L0 = – F1 = 78 +/– 5 N. radial width – uppermost ring Ring end clearances uppermost ring Min.....Piston Rod Stuffing Box 102-2 Data SAFETY PRECAUTIONS Special Data S35MC 0040 102-2 Standard Tools: See Section 913 Piston Rod Stuffing Box X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil X Shut off lubrication oil Lock turbocharger rotors Data Ref........ L1 = – F2 = 53 +/– 7 N... L0 = – F1 = 59 +/– 4 N. 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............... radial width – middle rings Ring end clearances – middle rings Min. please quote Data D10202 Edition 0040 MAN B&W Diesel A/S Page 1 (2) ... L2 = 374 mm 547 mm 580 mm D-3 D-4 D-5 D-6 D-7 D-8 D-9 Min.. L1 = – F2 = 78 +/– 5 N. L2 = 327 mm 538 mm 606 mm Check length for the eight lowermost springs: – F0 = 0 N..... Description D-1 Stuffing box complete D-2 Check length for the uppermost spring: – F0 = 0 N........

Piston Rod Stuffing Box 102-2 Data 1849875-7. Page 2 (2) Description Qty When referring to this page. please quote Data D10202 Edition 0040 MAN B&W Diesel A/S .1 Plate 90251 Spare Parts Plate – Item No.

Measure the ring end clearances.3. it is recommended – depending on the overhauling intervals and one’s own experience – to replace sealing rings and scraper rings when the specified clearance values have changed by more than 50%. Adjust the loads to achieve the lengths stated in Data. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 Page 1 (9) . If the loads necessary are outside the limits stated in Data. If the radial width of a segment is less than stated in Data. the complete ring must be replaced. BG902-5. see Procedures 902-2.2. D-5 As a general guide. and 902-2. check the rings and springs as follows: 3. when the segments are placed evenly around the piston rod.1 Checking Piston Rod Stuffing Box S35MC 0209 Checking 902-2.Piston Rod Stuffing Box 902-2. D-4 The ring end clearances stated in Data apply to new rings. D-2 BG902-5. Measure the radial width of all the ring segments. D-8 BG902-5.1 74 04 1. 2. i.1 2.0 74 02 D-9 4. 3.e. Check the length of the springs at different loads. the gap between the ends of the segments in a ring. the springs must be discarded.0 74 03 D-3 When referring to this page. D-6 D-7 4. After the piston rod stuffing box has been dismantled and disassembled.

2 109 02 2.2 Piston Rod Stuffing Box Dismantling Dismantling 902-2. Turn the crosshead to about 90° from TDC. 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. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 . Page 2 (9) When referring to this page. BM902-5.2 1. Mount the rubber hose around the piston rod to protect the crosshead bearing from impurities. longitudinally to the engine.2 203 01 2. BM902-5. in the period between piston overhauls. 3.2 109 03 3. GN902-2. proceed as follows: 1. If. it becomes necessary to inspect the piston rod stuffing box.902-2. 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.

see Procedure 902-2.Piston Rod Stuffing Box 902-2. 6. BM902-5.3. When referring to this page. press the stuffing box out of the flange. For overhauling the stuffing box.2 Dismantling 4. Turn the piston to BDC.2 109 06 6. Remove the remaining two screws from the stuffing box. BM902-5.2 109 04 5. Remove the two long screws from the worktable. By means of the four short screws in the worktable. thereby withdrawing the stuffing box from the cylinder frame bottom. BM902-5.2 109 05 5. 4. Mount them in the stuffing box through the holes in the worktable. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 Page 3 (9) .

902-2. Lift the stuffing box a little up the piston rod. move it up the piston rod and secure it in this position. Check the lengths of the springs. overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons. 5. Mount two eye bolts in the stuffing box flange. Pull the stuffing box halves apart and remove them from the worktable. Carefully clean all the ring segments. Page 4 (9) When referring to this page.1 82 03 7.3 1. Outside the engine 1.1. BG902-5. for example with tape.1 82 02 Remove the nuts and screws from the stuffing box. and remove the tackles and screws. replace the rings. If the O-ring is intact and is to be used again. 3. 2. Remove the O-ring of the stuffing box. BG902-5. During such overhauls. the piston rests on a support placed over one of the cut-outs in the top platform. BG902-5. Dismantle and stack the rings in the same order as when fitted in the stuffing box. See Procedure 902-2. Inspect and assess the surface quality of the sealing rings. If their sliding surfaces have scratches or marks. D-1 Land the stuffing box on the worktable. and mount the worktable round the piston rod at a suitable working height. Measure the radial width and the ring end clearances or the ring segments.1 82 01 Work on the stuffing box is then carried out from the platform below. and hook on two tackles. 2. 3. 4. 6.3 Piston Rod Stuffing Box Overhaul Overhaul 902-2. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 .1. Normally. See Procedure 902-2.

BG902-5. assemble the spring ends. in the following way: HC902-5. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings). Place the holders and segments for the lowermost scraper ring on the worktable. on the worktable.Piston Rod Stuffing Box 902-2. When referring to this page. 9. using a similar procedure as described above.1 98 07 8. First assemble the holders with uneven serial number. it may prove necessary to machine-grind the surface in a workshop. 10. smooth the piston rod surface carefully with a fine grained carborundum stone. Secure with the steel pins and place them round the piston rod.1 82 10 On top of the scraper ring. by means of the two hooks. 11. place a 9 mm distance ring and then assemble the next scraper rings. In the case of coarse scratches. place a 7 mm distance ring. 9. 11. Assemble all the stuffing box ring units 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. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 Page 5 (9) .1 82 09 Then assemble the holders with even serial number. Inspect the surface of the piston rod. On top of the scraper rings.3 Overhaul 8. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS 2). Place the three springs round the scraper rings and. BG902-5.

BG902-5. BG902-5. and two springs.1 82 11 Place the lower 4-part sealing ring inside this outer sealing ring so that the two guide pins face upwards. Clean the halves of the stuffing box housing.1 82 13 Push the stuffing box half into contact with the piston rod round the rings. 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. Page 6 (9) When referring to this page. place the holder and two springs. 13. 13. On top of the scraper rings. Place a 7 mm distance ring between the sealing rings and assemble the last sealing unit in the same way. a holder for the springs. Place one stuffing box half on the worktable. 15. and assemble the springs by means of the two hooks. Place the spring round the scraper ring and. When assembling one unit. On top of the sealing section. 12. an outer sealing ring. place 9 mm distance rings. first place the outer sealing ring round the piston rod.1 82 12 Place the 3-part scraper ring on top of the upper sealing unit. Finally. Remove all the distance rings. 14. by means of the two hooks. assemble the spring ends. BG902-5. Each unit consists of a 4-part lower sealing ring with two guide pins. assemble the two sealing ring units. 13. an upper 4-part sealing ring. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 .902-2.3 Piston Rod Stuffing Box Overhaul 12.

and lift the stuffing box a little. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot. pushing it into place round the rings.1 82 14 17. 16. Remove wire ropes and eye bolts. When referring to this page. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 Page 7 (9) . BG902-5. Mount the O-ring in the stuffing box groove.1 82 15 17. Mount eye bolts and wire ropes. Place the other half of the stuffing box housing on the worktable.Piston Rod Stuffing Box 902-2. Mount and tighten up the fitted bolts to the torque specified on the Data Sheet.3 Overhaul 16. BG902-5.

2 109 09 3. BM902-5.902-2. 1. Note! BM902-5. BM902-5. Turn down the short screws so that the stuffing box lands on the flange. After overhauling. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 . Mount the two long screws from the worktable in the stuffing box.2 109 08 2.4 Piston Rod Stuffing Box Mounting Mounting 902-2. 3. assemble the stuffing box halves on top of the two screws. Turn the piston upwards until the stuffing box is in place in the cylinder frame.2 109 07 Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. Mount two screws in the flange through the holes in the worktable.4 1. Page 8 (9) When referring to this page. 2.

2 203 01 6. Remove the long screws from the stuffing box and mount them in the worktable. 6. Then turn the crankshaft a couple of revolutions. GN902-2. 5. See Data. 4. Remove the worktable from the piston rod.2 109 11 Then stop the engine and inspect the piston rod and stuffing box. BM902-5.Piston Rod Stuffing Box 902-2. 5. Start up the engine and keep it running for about fifteen minutes at a number of revolutions corresponding to very slow or idle speed. please quote Procedure M90202 Edition 0209 0$1% :'LHVHO$6 Page 9 (9) . Remove the protecting rubber cover from the piston rod/crosshead. BM902-5. When referring to this page.4 Mounting 4.2 109 10 Smear the piston rod with molybdenum disulphide. Mount and tighten all the inner and outer screws for the stuffing box.

.

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 .

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.Plate P90251-0243 Item No. please quote Plate P90251 Edition 0243 MAN B&W Diesel A/S .

please quote Plate P90261 Edition 0106 MAN B&W Diesel A/S Page 1 (2) .Tools 0106 P90261 When referring to this page.Tools Plate P90261-0106 Piston and Rod .Piston and Rod .

please quote Plate P90261 Edition 0106 MAN B&W Diesel A/S .Tools Item Description Item No. 019 Piston and Rod . Item Description Guide ring for piston Page 2 (2) When referring to this page.Plate P90261-0106 Item No.

please quote Plate P90264 Edition 0004 MAN B&W Diesel A/S Page 1 (2) .Piston and Piston Rod .Extra Tools 0004 P90264 When referring to this page.Extra Tools Plate P90264-0004 Piston and Piston Rod .

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.Plate P90264-0004 Item No. please quote Plate P90264 Edition 0004 MAN B&W Diesel A/S .

Support Tools When referring to this page.Piston and Piston Rod . please quote Plate P90265 Edition 0002 MAN B&W Diesel A/S Plate P90265-0002 Page 1 (2) .

Support Tools Item Description Item No. 010 Page 2 (2) Piston and Piston Rod . Item Description Support for piston When referring to this page. please quote Plate P90265 Edition 0002 MAN B&W Diesel A/S .Plate P90265-0002 Item No.

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

016 Page 2 (2) Piston .Plate P90266-0002 Item No.Lifting Tools Item Description Item No. please quote Plate P90266 Edition 0002 MAN B&W Diesel A/S . Item Description Lifting tool for piston When referring to this page.

Tools Cylinder Liner .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.903 . Data Cylinder Liner Cylinder Lubricator. Data Cylinder Lubricator Cylinder Liner .Lifting Tools MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

8 mm PC-ring/Liner.2 mm Piston cleaning (PC) ring. Description D-1 Cylinder diameter. 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 +/. max.7 mm Dummy ring Lifting tool bolts. screwing-in torque 80 Nm When referring to this page.7 mm Oversize PC-ring > 0. new 27.35 mm) 0.Cylinder Liner 103-1 Data SAFETY PRECAUTIONS Special Data S35MC 0047 103-1 Standard Tools: See Section 913 Cylinder Liner X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.35 – 0. wear deviation 0. please quote Data D10301 Edition 0047 MAN B&W Diesel A/S Page 1 (2) .35 mm Standard PC-ring (new or max. radial width.35 mm PC-rings table: Liner diameter: 350 mm D-8 Liner wear: Install: 0 – 0. wear of diameter 0. new 350 mm D-2 Cylinder liner.

Cylinder Liner 103-1 Data 1849875-7. please quote Data D10301 Edition 0047 MAN B&W Diesel A/S .1 Plate 90251 Spare Parts Plate – Item No. Page 2 (2) Description Qty When referring to this page.

HN903-1. Check and assess the condition of the cylinder liner according to the description given in Volume I. 3.3.0 67 02 Clean any blocked lubricating duct. When referring to this page. 6.1 2. 5. 1. 2. Position the cylinder liner measuring tool. Carefully scratch over any scores or marks on the cylinder liner running surface. D-1 Clean the cylinder liner and scavenge air ports. BM903-1. See Data. See Procedure 901-1. Chapter 707. See Procedure 903-1.1 Checking Cylinder Liner S35MC 0240 Checking 903-1.1 208 02 4. DM903-2.2. and remove the wear ridges.Cylinder Liner 903-1.2. Dismount the cylinder cover and piston. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. See Procedure 902-1. Take measurements in the fore-and-aft and athwartship directions. 3. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S Page 1 (10) .1 235 04 6. Check the lubricating points of the cylinder by pumping cylinder oil to each individual lubricating point.

8. corresponding to measuring point No. contact MAN B&W Diesel for advice. an oversize ring or a dummy ring according to the table in D-7 on the Data sheet. When a new liner is ordered. When a new liner is installed. Measure the liner in the fore-and-aft and athwartship directions at piston skirt TDC position.1 237 08 During inspection of the piston and liner. and find the most worn place. or if the PCring is broken or cracked.903-1. replace the ring with a new PC-ring. If wear of the two components does not deviate more than D-6. the PC-ring must also be inspected. Multiply the wear by 2 to get the PCring diameter wear. then reinstall the PC-ring. Calculate the wear of the liner. If the deviation between PC-ring wear and liner wear is more than D-6. Compare with Data D-5 and calculate the wear of the PCring. Compare the PC-ring diameter wear with the wear of the liner. also a new PC-ring must be installed. 9. 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. 5 on the liner measuring tool. Page 2 (10) When referring to this page. also a new PC-ring must be ordered. If it is necessary to install an oversize PCring.1 Cylinder Liner Checking 8. DM903-1. Compare the measurements with the diameter of a new liner as stated in Data. Measure the PC-ring radial width B. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S .

Discard the sealing ring from the top of the cylinder liner. Mount the two lifting tools on the cylinder liner. See Procedure 903-1. Disconnect – at the distributor block – the oil pipes leading from the cylinder lubricator to the cylinder liner. When referring to this page.2 240 01 Tighten the lifting screws to the torque stated in Data.05 mm feeler gauge that there is no clearance between the screws and the cylinder liner.2 1.3.2.2 240 02 2. 2. Turn the piston down far enough to make it possible to remove the wear ridges at the top of the liner. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S Page 3 (10) . Dismount the cylinder cover. 1. Dismount the piston cleaning ring and the piston. See Procedure 901-1.2 Dismantling Dismantling 903-1. BM903-1. D-8 BM903-1. See Procedure 902-1. Note! Check with a 0.Cylinder Liner 903-1. This must be done whenever the lifting tools are mounted on the liner.2.

Remove the screws of the cooling water inlet pipe. Note! BM903-1. Attach the lifting tools to the crossbar. Page 4 (10) When referring to this page. a couple of planks. Land the cylinder liner vertically on.903-1. BM903-1. for instance. 3. Discard the O-rings on the cooling water pipes. Attach the crane to the lifting crossbar. and lift the cylinder liner with the cooling jacket out of the cylinder frame.2 Cylinder Liner Dismantling 3.2 240 04 Clean the pipes carefully. taking special care with the contact surfaces for the cylinder liner at the top of the cylinder frame. 4.2 208 03 Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner. D-2 Clean the cylinder frame internally. 4. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S .

please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S Page 5 (10) .2 240 05 5.Cylinder Liner 903-1. When referring to this page. The lifting tools are also used for transporting the cylinder liner.2 Dismantling 5. BM903-1.

Mount two lifting eye bolts on the cooling jacket. BM903-1. Remove the two lifting screws from the cylinder liner. Remove the four clamps which fix the cooling jacket to the cylinder liner.3 240 01 2. Lift the cooling jacket away by means of the tackles. 1. BM903-1. Attach two tackles to the crossbar.Cylinder Liner 903-1. Hook the tackles on to the lifting eye bolts on the cooling jacket and haul tight.3 Overhaul Overhaul 903-1. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S .3 240 02 D-3 Page 6 (10) When referring to this page. as shown. and land it on the wooden planks.3 1. 2.

by means of a rough grindstone held in the hand. it is necessary to create a groove by grinding. MB903-1. see supplier’s instruction. = D x 0. 5.The groove serves to prevent the build-up of a new wear ridge.3 Overhaul 3. S R=4-5 mm C MN903-1. 4. Use a grinding disc with a round edge. It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch. The maximum depth of the groove is calculated as S max. It is recommended to use a wear ridge milling machine to create the groove. HN903-1. For use of the milling machine. Chapter 707.Cylinder Liner 903-1. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S Page 7 (10) .3 221 04 4.3 231 04 Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC. 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. If there is any sign of a wear ridge. Check in the top of the liner for a wear ridge (where the piston rings reverse direction). Note! 5.3 229 05 C D When referring to this page. Alternatively. 3.0045. Check and assess the condition of the cylinder liner according to the description given in Volume I. Carefully scratch over any scores or marks on the cylinder liner running surface.

8. 7. Note! BM903-1. 7. Mount the four clamps in the groove of the liner. Remove the tackles from the lifting crossbar and the cooling jacket lifting eye bolts.3 240 07 D-3 BM903-1.3 240 08 8. BM903-1. Page 8 (10) When referring to this page.3 240 06 Make sure that the scratch marks in the camshaft side of the cylinder liner and cooling jacket coincide. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S . Lower the cooling jacket on to the cylinder liner.3 Overhaul 6. Replace the two uppermost O-rings on the cylinder liner.Cylinder Liner 903-1. 6. and tighten the screws.

Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean.4 1. Mount the cylinder liner in the cylinder frame.Cylinder Liner 903-1. 1. see Data. If one or more cylinder cover studs have been removed during the dismantling of the cylinder cover.4 Mounting Mounting 903-1. Mount the lowermost O-ring and apply a little vaseline on the ring. 2. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S Page 9 (10) . Attach the lifting tools to the crossbar. Remove the lifting tools. Replace the O-rings on the water connections and mount the water connections on the cooling jacket. remount the studs using the stud setter.4 240 02 D-4 When referring to this page. and lift the jacket/liner assembly. 3. 2. Mount the two lifting tools on the cylinder liner. BM903-1. Loosen the water connections on the cooling jacket.4 240 01 Coat the joint surfaces with permatex or a similar liquid sealing compound. BM903-1.

BM903-1.2 208 03 When this is in order. Vent the cylinder lubricating system until oil. please quote Procedure M90301 Edition 0240 MAN B&W Diesel A/S . 7.4. Fit a new gasket between the cooling water inlet pipe and the cooling jacket. 4. See Procedure 901-1.4 240 04 Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned. without air bubbles.4.4 Cylinder Liner Mounting 3. Connect and tighten the oil pipes for the cylinder lubrication. 4.903-1. See Procedure 902-1. 6.4 208 01 6. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston and the piston cleaning ring. Check that there is no leakage from the system. comes out from the non-return valves. Mount the sealing ring and the cylinder cover. BM903-1. check that each individual lubricating point functions correctly. Page 10 (10) When referring to this page. BM901-1. 5. Mount and tighten the screws.

please quote Data D10302 Edition 0022 MAN B&W Diesel A/S Page 1 (2) .Cylinder Lubricators 103-2 Data SAFETY PRECAUTIONS Special Data S35MC 0022 103-2 Standard Tools: See Section 913 Cylinder Lubricators X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil Shut off lubrication oil Lock turbocharger rotors Data Ref. Description Value Unit When referring to this page.

Page 2 (2) Description Qty When referring to this page.Cylinder Lubricators 103-2 Data Spare Parts Plate – Item No. please quote Data D10302 Edition 0022 MAN B&W Diesel A/S .

is given in instruction book Volume I. Turn the engine in AHEAD direction until the mark on No. 5. See the sketch. Check that the crankthrow for cylinder No.               0 % 0DUNV            &\O1R     1 * When referring to this page. and recommended oil types. feed rates for runningin and for part load operation. /XEULFDWLRQ3RLQW1R /XEULFDWLRQ3RLQW1R 2. OPERATION.1 Checking Cylinder Lubricators S35MC 0233 Checking 903-2.            0 %  4.    For lubricator number. Each cylinder has four injection points. 1 is positioned between 90° and 112° past BDC. Check that the pumps for all injection points are activated during one revolution of the engine.1  1. please quote Procedure M90302 Edition 0233 0$1% :'LHVHO$6 Page 1 (4) . This indicates that the pump stroke is completed for lubricating point No. The cylinder lubricators are mounted on the manoeuvring side of the engine.Cylinder Lubricators 903-2. 1. Further information concerning other than nominal feed rates. 3. 1 lubricator housing is in line with the mark on the scale at the lead-in shaft. Use the numbers on the turning wheel to determine the exact position of the crankthrows.

See Procedure 903-2. 16 on No. 7. Check that the crankthrow for the aftmost cylinder is positioned between 90° and 112° past BDC. This indicates that the pump stroke is completed for lubricating point No. adjust the lubricators.903-2.              0 % 8. 2 lubricator. 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.1 Cylinder Lubricators Checking  6.3. please quote Procedure M90302 Edition 0233 0$1% :'LHVHO$6 . 0DUNV              1 * Page 2 (4) $IWPRVW &\OLQGHU When referring to this page. If one of the crankthrows is not in the correct position.

3  Note! Any adjustment of lubricator No. Loosen the set screws in the couplings and pull the coupling wheels out of contact with the planet wheels.               0 %  If necessary. Push the coupling wheels in to contact with the planet wheel for lubricator No.3 Adjustment Adjustment 903-2. 2. any adjustment of lubricator No. 1. Therefore. 1 is 101° past BDC for lubricator No. turn the lubricator shaft in AHEAD direction. For adjustment of lubricator No. turn the crankshaft in AHEAD direction until the crankthrow for cylinder No. 2. 1 will alter the setting of lubricator No. 2. Remove the guards over the couplings. 1. 1 and fasten the screws. please quote Procedure M90302 Edition 0233 0$1% :'LHVHO$6 Page 3 (4) . 2. For adjustment of lubricator No. 1. 1 must be followed by a re-adjustment of lubricator No.Cylinder Lubricators 903-2. turn the crankshaft in AHEAD direction until the crankthrow for the aftmost cylinder is 101° past BDC.               1 * When referring to this page. Use the numbers on the turning wheel to determine the exact position of the crankthrows.

Re-engage the coupling wheel and tighten the set screw.               0 %              0 % Page 4 (4) When referring to this page.903-2. please quote Procedure M90302 Edition 0233 0$1% :'LHVHO$6 . See Procedure 903-2. 4. 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.3 Cylinder Lubricators Adjustment  3. Mount the guard over the coupling.1. Re-check the setting.

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

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

Cylinder Liner . please quote Plate P90366 Edition 0005 MAN B&W Diesel A/S Page 1 (2) .Lifting Tools Plate P90366-0005 Cylinder Liner .Lifting Tools 0005 P90366 021 When referring to this page.

021 Cylinder Liner . Item Description Crossbar for cylinder liner Page 2 (2) When referring to this page.Plate P90366-0005 Item No.Lifting Tools Item Description Item No. please quote Plate P90366 Edition 0005 MAN B&W Diesel A/S .

Data Reciprocating Parts Crankpin Bearing.Hydraulic Tools Crosshead . Data Crosshead Reciprocating Parts.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.904 . Data Crankpin Bearing Connecting Rod.Panel Connecting Rod . Data Crosshead Bearing Crosshead.Hydraulic Tools MAN B&W Diesel A/S . Data Connection Rod Connecting Rod and Crosshead .

MAN B&W Diesel A/S .

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.Crosshead Bearing 104-1 Data SAFETY PRECAUTIONS Special Data S35MC 0033 104-1 Standard Tools: See Section 913 Crosshead Bearing X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil X Shut off lubricating oil 50-300 Nm Lock turbocharger rotors 6 x M16 Data Ref. please quote Data D10401 Edition 0033 MAN B&W Diesel A/S Page 1 (2) .15-0. lower 9 kg D-8 Bearing shell. Description D-1 Top clearance for new crosshead bearing: Value Unit 0. 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 2 (2) Description Qty When referring to this page.Crosshead Bearing 104-1 Data Plate 1849859-1 90451 Spare Parts Plate – Item No.

Note that the figures are to be used for guidance only. Volume I. the crosshead bearing must be disassembled for inspection.2. see the measurement in the Adjustment Sheet in Volume I. See Procedure 904-1. 1. OPERATION. When referring to this page. For the top clearance of a specific bearing. BM904-1.05 mm. 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. If so.1 76 02 The top clearance for a new bearing will normally be in the range stated in Data.1 229 03 3. ‘Bearings’ in the instruction book. Turn the crankthrow concerned to BDC. Open the crankcase door at the relevant cylinder. 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. OPERATION. 3. BM904-2. see Chapter 708.1 2.Crosshead Bearing 904-1. 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. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 Page 1 (9) . D-1 4. See Data.1 Checking Crosshead Bearing S35MC 0229 Checking 904-1. 2. For evaluation of the bearing shell.

2. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 . Page 2 (9) When referring to this page. Caution! BM904-1. This procedure has been divided into two dismantling situations. Mount two eye bolts in the top of the crankcase and suspend two tackles in the athwartship direction. Suspend the telescopic pipe from the stuffing box using the wing nut (tool). 3. Turn the crankshaft down far enough to give access to the nuts and screws on the piston rod.2 229 02 When a piston is dismantled.2 63 05 3. BG904-2. Loosen and remove the four screws which tighten the telescopic pipe to the bend.904-1. as follows: • with piston mounted • with piston removed With piston mounted: 1.1 76 02 2.2 1. never turn the engine without first dismantling the telescopic pipe from the crosshead. Mount the two chains for suspending the piston rod.2 Crosshead Bearing Dismantling Dismantling 904-1. BM904-2.

loosen and remove the screws from the piston rod foot. Turn the crosshead downward. Remove the locking wire from the screws. DG904-2. DM904-4. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 Page 3 (9) .Crosshead Bearing 904-1.2 Dismantling 4.0 57 02B D-4 When referring to this page. With piston removed: 5. and unscrew the nuts. 4. Mount a lifting eye bolt on each side of the piston rod.2 229 04 Hook the chains to the lifting eye bolts in the piston rod. 7.3 64 2/3 Remove the hydraulic jacks and the spacer rings. see Procedure 913. Turn to BDC. 6. Hold the spacer rings around the nuts and screw the hydraulic jacks on to the studs. For operation of the hydraulic jacks. and the piston rod will remain suspended from the two chains. Loosen the crosshead bearing cap nuts. Turn the crosshead to TDC. BM904-1. Remove the thrust pieces from both side of the bearing cap. 5. 7.

Hook the two tackles on to the eye bolts and lift the crosshead bearing cap away from the crosshead.0 40 03A 9.Crosshead Bearing 904-1. 10. 10. BM904-4. Screw two eye bolts into the head of the connecting rod. BM904-4. Mount two eye bolts in the top of the crosshead bearing cap. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 .2 Dismantling 8. Note! BG904-2. Lift the crosshead bearing cap out of the engine.0 40 03B D-5 Page 4 (9) When referring to this page.2 63 08 Take care that the studs for the crosshead bearing cap do not scratch the crosshead journal. 8. 9.

GN904-1.2 229 12 Haul the tackles tight. until the guide shoes rest on the supports.1.2 229 13 13. see Procedure 904-1. D-5 12. BM904-1.Crosshead Bearing 904-1. Carefully turn the crank down towards the exhaust side. Mount the four supports for guide shoes on the crosshead guides. Do not remove the chains or lifting eye bolts. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. Ensure that the connecting piece in the crosshead fits correctly in the holes of the piston rod.2 Dismantling 11. Turn the crosshead to TDC. D-8 12. Place the bearing cap on one side on a couple of wooden planks.2 203 11 Check the bearing shell. BM904-1. When referring to this page. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 Page 5 (9) . Hook the two tackles on to the eye bolts screwed into the head of the connecting rod. 11. 13. 14.

16.2 Crosshead Bearing Dismantling 15. using the tackles. thus continuously supporting the connecting rod. ‘Bearings’. In cases where it is necessary to remove the lower bearing shell. For further evaluation of journal and bearing shells. see also Volume I. D-2 With the crosshead resting on the supports. check the lower part of the crosshead journal and the lower bearing shell. tilt the connecting rod towards the door in the camshaft side. OPERATION. Check the bearing shell. and lift the bearing shell out of the engine. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 .1. 15.2 208 14 Dismount the lock screws.2 208 15 D-7 Page 6 (9) When referring to this page. see Procedure 904-1. Chapter 708. 16.904-1. BM904-1. Turn the crankthrow carefully towards BDC while ‘following’ with the tackles. BM904-1.

4 229 01 2. Remove the tackles from the connecting rod. BM904-1.4 1. Take care that the guide shoes do not damage the bearing shell.4 229 03 3. BM904-1. The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated. With the piston mounted/ With the piston removed: D-7 1. Remove the eye bolts from the connecting rod. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 Page 7 (9) . Mount and secure the bearing shell in the bearing housing. Raise the connecting rod to an upright position.Crosshead Bearing 904-1. When referring to this page. for assembling the crosshead and the connecting rod.4 Mounting Mounting 904-1. 2.2 208 14 3. BM904-1. Turn to TDC while ‘following’ with the tackles.

Turn the crank throw to BDC. slowly turn down until it is fully suspended from the chains. 5. Remove the supports from the crosshead guides. BM904-1. Mount the two thrust pieces on both sides of the bearing cap. Mount the piston. Lower the bearing cap onto the crosshead and remove the tackles. 4.4.Crosshead Bearing 904-1. If the piston is mounted.4 229 04 5.0 40 03B 7. For operation of hydraulic jacks. Lift the bearing cap into the engine. See Data. See Data. Remove the eye bolts from the bearing cap. BM904-1. BM904-4. D-5 6.4 229 06 D-10 Page 8 (9) When referring to this page. see Section 913. Note! Take care that the bearing studs do not damage the crosshead. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 . 6.4 Mounting 4. Tighten all four crosshead bearing cap nuts simultaneously. See Procedure 902-1.

Turn the crosshead upwards until the piston rod lands on the crosshead. Release the telescopic pipe from its suspension. 11. OPERATION.2 63 16 If a new bearing shell has been mounted. See Data. Unhook the chains from the lifting eye bolts in the piston rod. D-9 After tightening the bearing cap. BG904-2.2 63 15 D-6 When referring to this page. See Data.4 Mounting 8. With the piston mounted: 8. Mount and tighten the screws on the piston rod. make sure that the piston rod foot is correctly centered on the crosshead. from the piston rod and from the crosshead bearing cap. DG904-1. Mount the locking wire on the screws. When mounting the piston on the crosshead. 10. 11. Remove the chains and eye bolts from the top of the crankcase. The locking wire is to be mounted in such a way that the wire is tightened if a screw works loose. please quote Procedure M90401 Edition 0229 0$1% :'LHVHO$6 Page 9 (9) . See Procedure 913-7.3 64 02A 9. 10. mount and tighten the four screws which tighten the telescopic pipe to the bend.Crosshead Bearing 904-1. check the top clearance once more. remember to note down the new top clearance in the Adjustment Sheet in Chapter 701. BG904-2. Volume I.2.

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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.Crosshead 104-2 Data SAFETY PRECAUTIONS Special Data S35MC 0035 104-2 Standard Tools: See Section 913 Crosshead X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil 50-300 Nm X Shut off lubricating oil 4 x 1. 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. please quote Data D10402 Edition 0035 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.

Note! Remember to dismount the telescopic pipe. mount two eye bolts in the athwartship direction. D-3 Remove the thrust pieces from the bearing cap. Loosen the nuts. 3. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 Page 1 (9) . See Procedure 902-1. and suspend two tackles. Mount two eye bolts in the top of the crankcase in the fore-and-aft direction. When referring to this page. and hook on the tackles.0 40 03 Dismount the bearing cap and lift it out of the engine. Mount eye bolts in the crosshead bearing cap. remove the hydraulic jacks and unscrew the nuts.2 2. D-1 3. BM904-2. Dismount the piston. BM904-4.2.2 231 02 For operation of the hydraulic tools. 2.Crosshead 904-2. see Chapter 913. 1. Mount the spacer rings and hydraulic jacks for loosening the nuts on the crosshead bearing studs.2 Dismantling Crosshead S35MC 0231 Dismantling 904-2. Turn the crosshead down far enough to give access to the nuts on the crosshead bearing cap.

BM904-2. Carefully turn downwards until the guide shoes rest on the supports. 5. Then remove the tackles from the top of the crankcase. 4. remove the hydraulic jacks. D-4 D-1 Mount the spacer rings and hydraulic jacks for loosening the nuts on the crankpin bearing cap studs. BM904-4. 5. 6. 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. 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. and unscrew the nuts. Remove the bearing cap from the engine. Turn the crosshead to TDC. Mount the four support brackets for guide shoes on the crosshead guides. 6.0 40 05 Note! Be careful that the studs do not damage the crankpin journal.2 Dismantling 4. For operation of the hydraulic tools. see Chapter 913. by means of shackles and wire ropes. Mount the special lifting tool on the crosshead.2 231 04 Mount two eye bolts in each side of the crankpin bearing cap and. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 . hook on the tackles and haul tight. Loosen the nuts. Lower the bearing cap.Crosshead 904-2.

by means of the special flat wrapped wire rope. and lift the crosshead a little. See Procedure 904-5. Hook the engine room crane on to the lifting tool on the crosshead. D-5 BM904-4.2 Dismantling 7. Remove the guide strips and the guide screws from the guide shoes.2.0 40 10 D-6 BM904-2. 7. Dismount the connecting rod.0 40 12 9.Crosshead 904-2. 9. When referring to this page. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 Page 3 (9) .2 231 08 8. BM904-4. Remove the four supports from the crosshead guides. 8.

11. Suspend two tackles from the eye bolts at the top of the crankcase in the fore-and-aft direction.2 Crosshead Dismantling 10.904-2. Turn the crank to BDC.0 40 14 Note that the clearance between the crank and the crosshead is very narrow BM904-4. Mount an eye bolt in the top of each guide shoe. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 . Lower the crosshead so that the guide shoes are just below the cut-out in the body plate of the framebox. Place a thin wooden plank or similar on top of the crank to protect the crosshead.2 231 10 12.0 40 15 12. Page 4 (9) When referring to this page. 10. Remove the oil pipes from the two adjacent main bearing caps. 11. BM904-2. Note! BM904-4.

Crosshead 904-2. BM904-2. Note! Take care that the crosshead does not bump into anything as this will damage the sliding surfaces of the crosshead. Turn the crosshead 90°.2 231 13 Use the rubber pieces provided to wrap around the crosshead. and remove the crosshead from the engine. pull the guide shoes sideways until they are free of the crosshead. Remove the guide shoes from the engine. at the same time. Hook the tackles on to the eye bolts in the guide shoes. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 Page 5 (9) . Land and protect the crosshead outside the engine. Attach a tackle to the lifting tool for the crosshead.2 Dismantling 13. 13. Land the guide shoes on top of the main bearings.2 231 14 D-5 D-7 When referring to this page. Haul tight and. 14. 14. BM904-2.

4 Mounting Mounting 904-2.Crosshead 904-2. BM904-2.4 231 02 2. removing any dust or grease. tackles and the engine room crane. Clean the crosshead. 2. and mount the special lifting tool.4 1. Lift the crosshead into the engine by means of wire rope. Turn the crosshead 90°. BM904-2. in the engine on top of the main bearing caps.4 231 01 Hook the tackles on to the eye bolts in the guide shoes and mount the guide shoes on the crosshead. Place the guide shoes. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 . D-7 D-5 1. Page 6 (9) When referring to this page. without the guide strips.

4 231 03 5. When referring to this page. Adjust the support brackets to the guide shoes.4 231 04 4. Mount the connecting rod. Using the engine room crane.4 Mounting 3. lift the crosshead to a working position. Carefully lower the crosshead until the guide shoes rest on the support brackets.Crosshead 904-2. 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. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 Page 7 (9) . 3.4. D-10 BM904-2. See Procedure 904-5. BM904-2.

and the studs for the cooling oil inlet bend. continue turning a little upwards. Remove the eye bolts from the connecting rod and the lifting tool from the crosshead. Turn the connecting rod upwards.4 231 07 D-12 Page 8 (9) When referring to this page. guiding with the tackles until the crosshead is landed in the connecting rod.Crosshead 904-2. and remove the four supports. 7. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 . 7. BM904-2.4 Mounting 6. D-13 D-11 D-8 BM904-2. Remove the tackles. Mount the inlet and outlet pipes. 6.4 231 06 Mount the studs for the cooling oil outlet pipe.

4 231 10 D-2 When referring to this page. 10.0 40 26 Lift the crosshead bearing cap into the engine.Crosshead 904-2. D-9 11. 8. 10. BM904-2. D-1 D-4 Mount and tighten the crankpin bearing cap. 9. See procedure 901-1. and remove the eye bolts.4 Mounting 9. Mount and tighten the crosshead bearing cap. Mount the two thrust pieces on the bearing cap. Remove the eye bolts. Turn to TDC. Turn to BDC. BM904-4. please quote Procedure M90402 Edition 0231 0$1% :'LHVHO$6 Page 9 (9) . Mount the piston. Finally mount the cylinder cover. See procedure 902-2. Lift the crankpin bearing cap into the engine.

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please quote Data D10403 Edition 0025 MAN B&W Diesel A/S Page 1 (2) .10 mm 0. M+D Nmax Nmin Omax 0.Reciprocating Parts 104-3 Data SAFETY PRECAUTIONS Special Data S35MC 0025 104-3 Standard Tools: See Section 913 Reciprocating Parts X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear X Shut off cooling water X Shut off fuel oil X Shut off lubricating oil X Lock turbocharger rotors Data Acceptance criteria with piston in centre (F-A direction) Meas.90 mm E+G H+F Nmax Nmin Omax 0.90 mm TF+TA Omax 0.70 mm J+C.80 mm 0. When referring to this page.70 mm 0.00 mm N: New and cold engine with staybolts tightened (less than 100 running hours). O: Engine in service. L+D. K+C.40 mm 1. points Value PF+PA Nmax Omax 0.40 mm 0.

please quote Data D10403 Edition 0025 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.Reciprocating Parts 104-3 Data Spare Parts Plate – Item No.

G and H) with a feeler gauge. When referring to this page. Fill the tube with water (possibly coloured) until the water level is approx. Trim the ship until the difference between the water level S fore and aft is less than 1. Turn the engine in ASTERN direction to 45° after BDC (the guide shoe must rest against the crosshead guide). MA904-5. Measurements are to be taken with a ruler.1 1. 2.Reciprocating Parts 904-3. F. See T. Bend each end approx.1 Edition 210 MAN B&W Diesel A/S Page 1 (3) . 100 mm from the end of the tube. the ship's trim must be as close as possible to 0°. 2. 250 mm up along the framebox side.0 72 01 1. GN904-3.1 203 06 Check the clearance between guide shoe and crosshead guide (E. In order to achieve uniform measuring conditions on board.5 mm per 1000 mm.1 Checking Reciprocating Parts K90MC 210 Checking 904-3. please quote Procedure 904-3. Mount a transparent plastic tube along the length of the bedplate.

1 Edition 210 MAN B&W Diesel A/S . Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. 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).1 Reciprocating Parts Checking 3. MA904-5.0 72 00 Measure the clearances between the crosshead and the connecting rod (TF–TA). Page 2 (3) When referring to this page.904-3. please quote Procedure 904-3.

L and M). H1-2 The clearance. calculated as J+C. H3-4 Measure the clearance between the guide strips and crosshead guides (J.1 Edition 210 MAN B&W Diesel A/S TF TA Page 3 (3) . 5. please quote Procedure 904-3. Dim G3-4.2 mm per 1000 mm.1 208 04 Parallelism between the guide strip and guide is to be kept within a tolerance of 0. Camshaft side 1 2 3 4 Dim J.1 Reciprocating Parts Checking Exhaust side D C 4. Measure the clearance between the guide shoes and the crosshead (C and D). It is recommended that the measured results are noted down so that possible later changes can be ascertained. NA904-3. K+C. 1 2 3 PF PA E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4 J+C K+C HN904-3. L+D and M+D.K 5. Dim C. 4. 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.D Dim G1-2. Unit mm Piston/Liner Framebox Dim L.1 207 05 L+D M+D Crosshead Connecting Rod When referring to this page.M Cyl.904-3. K.

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Crankpin Bearing 104-4 Data SAFETY PRECAUTIONS Special Data S35MC 0029 104-4 Standard Tools: See Section 913 Crankpin Bearing X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors 2 x 1.50 mm 0. min. Description Value Unit D-1 Clearances in crankpin bearing: max. please quote Data D10404 Edition 0029 MAN B&W Diesel A/S Page 1 (2) . 1 x 3 m Data Ref. 0.5 m.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.

Page 2 (2) Description Qty When referring to this page. please quote Data D10404 Edition 0029 MAN B&W Diesel A/S .Crankpin Bearing 104-4 Data Plate 1849859-1 90451 Spare Parts Plate – Item No.

Crankpin Bearing 904-4. Volume I. 3. BG904-6. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. D-1 BG904-6. See Data for bottom clearance. The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 2. OPERATION. the crankpin bearing must be disassembled for inspection. 3. If so. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection. OPERATION. When referring to this page.1 69 03 5. Turn the crank concerned to BDC. Open the crankcase door at the relevant cylinder.1 74 05 5.05 mm. 2.1 74 02 1. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 Page 1 (7) .1 Checking Crankpin Bearing S35MC 0206 Checking 904-4.2. see Chapter 708 ‘Bearings' in the instruction book. For further external inspection of the crankpin bearing. GM904-6. 4. See Procedure 904-4. For the bottom clearance of a specific bearing. 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. see the measurement in the Adjustment Sheet in Volume I.

Turn the crank to TDC. 1. Remove the hydraulic jacks and the nuts. using the hydraulic jacks.0 62 03 Loosen the crankpin bearing stud nuts.904-4. BG904-6. Mount eye bolts in each side of the crankpin bearing cap. Mount two eye bolts in the crankcase top plate in the athwartship direction and suspend two tackles from the eye bolts. 2. BG904-6. D-2 4. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 . see Section 913. BG904-6.2 Crankpin Bearing Dismantling Dismantling 904-4. Land the bearing cap on a couple of planks placed in the oil pan. Hook the tackles on to the eye bolts and haul tight. For operation of the hydraulic jacks. 4. Turn the crank to BDC.2 2. 3.0 62 05 Inspect the bearing shell. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal. 3.0 62 07 D-6 Page 2 (7) When referring to this page.

If the bearing shell needs to be replaced. remove the whole bearing cap from the crankcase. When referring to this page. together with a tackle suspended from the platform bracket. Place the bearing cap on one side on a couple of planks. Suspend a tackle from the lifting bracket on the inside camshaft side of the frame box above the crankcase door opening. Carefully turn the crank down until the guide shoes rest on the supports. lift the bearing cap out of the crankcase. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 Page 3 (7) . 5.Crankpin Bearing 904-4.2 Dismantling 5. Turn to TDC. BG904-6. 6. Mount the four supports for guide shoes on the crosshead guides. 7. GN904-4.0 62 09 Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. Dismount the bearing shell lock screws and replace the bearing shell by a new one. D-5 7.2 203 06 The bearing shells must be replaced in pairs. BG904-6. Hook the tackle on to an eye bolt on one side of the bearing cap. 6.0 62 08 Mount the wire guide in the top of the crankcase door opening. D-6 Using the tackle from the frame box inside wall.

Inspect the bearing shell surface and the crankpin journal.904-4. Carefully lower the bearing shell from the connecting rod and remove it from the engine. 10. while ‘following’ with the tackle. 9. proceed as follows: Turn the crankshaft to BDC. 10. Carefully turn the crankshaft downwards.0 62 10 9. on one side. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 .0 62 11 Dismount the bearing shell lock screws. Mount a lifting attachment for securing the connecting rod at the lower end. BG904-6. Hook on the tackle to a beam under the gallery platform and haul tight. BM904-4. Release the tackle so that the connecting rod is hanging freely. Continue turning the crankshaft until the bearing surface can be freely inspected. 8.2 206 10 D-4 Page 4 (7) When referring to this page. If it is necessary to replace the bearing shell. BG904-6.2 Crankpin Bearing Dismantling 8. making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to ‘separate’.

0 62 09 3. making sure that the upper part of the bearing enters the recess in the crankshaft when the parts turn together. Carefully lift the bearing shell into position in the connecting rod. and haul tight. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod. BG904-6. while following up with the tackle.4 1.Crankpin Bearing 904-4. When referring to this page. 2. Carefully turn the crankshaft upwards. BM904-4. Remove the tackle and the lifting attachment from the connecting rod. 3. Lift the upper bearing shell for the crankpin concerned into the crankcase. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 Page 5 (7) . Turn the crosshead to TDC. and mount the lock screws.4 Mounting Mounting 904-4. BM904-4.2 206 10 2.4 206 02 Remove the guide shoe support brackets from the crosshead guides. 1. D-4 Lubricate the upper crankpin bearing shell and the crankpin journal with plenty of clean lubricating oil.

Turn the crankthrow towards the exhaust side of the engine.Crankpin Bearing 904-4.4 Mounting 4. 5. 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.. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 . BM904-4. 4.4 206 05 D-6 Page 6 (7) When referring to this page. 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.

4 206 06 7. tighten the crankpin bearing cap. see Section 913. Hook the tackles on to the eye bolts of the bearing cap and lubricate the bearing shell with plenty of lubricating oil. 6. See Data. Mount the nuts and. the eye bolts and the hydraulic tools from the engine. and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod. Turn the crankthrow to TDC. D-6 Lift the bearing cap into position against the connecting rod.4 Mounting 6. please quote Procedure M90404 Edition 0206 0$1% :'LHVHO$6 Page 7 (7) . Remove the tackles. For operation of hydraulic jacks. 7. BM904-4. BG904-6. take care that the studs do not damage the crankpin journal.0 62 05 D-3 When referring to this page.Crankpin Bearing 904-4. by means of spacer rings and hydraulic jacks. Caution! During mounting.

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1 x 3 m Data Ref.Connecting Rod 104-5 Data SAFETY PRECAUTIONS Special Data S35MC 0032 104-5 Standard Tools: See Section 913 Connecting Rod X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X 4 x M16 Shut off lubricating oil Lock turbocharger rotors 4 x 1. 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) .5 m.

Page 2 (2) Description Qty When referring to this page.Connecting Rod 104-5 Data Plate 1849859-1 90451 Spare Parts Plate – Item No. please quote Data D10405 Edition 0032 MAN B&W Diesel A/S .

See Procedure 904-4.Connecting Rod 904-5. BM904-5. Turn the crank towards TDC and land the piston rod foot on the crosshead.2 224 02 4. 1. the piston rod and telescopic pipe have to be suspended and the crosshead bearing cap has to be removed. D-1 2. Remove the suspension chains for the piston. Before dismounting the connecting rod. Dismount the crankpin bearing cap.2. until the guide shoes rest on the supports.2 1. BM904-5.2 224 01 3. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. Mount the four support brackets for the guide shoes on the crosshead guides. BM904-5. When referring to this page.2 222 03 3. Carefully turn the crank down towards the door opening on the camshaft side.2 Dismantling Connecting Rod S35MC 0224 Dismantling 904-5.2. Turn the crank to TDC. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S Page 1 (8) . 2. See Procedure 904-1.

Suspend two tackles outside the engine.2 224 07 AA Page 2 (8) When referring to this page. The weight of the crosshead and the piston is now carried by the four supports. BM904-5. Attach the tackles to the connecting rod as shown in the sketch. Suspend a tackle from the engine room exhaust side and hook it on to the lifting attachment on the connecting rod. 5. 6.2 224 05 Mount the lifting attachment on the exhaust side of the connecting rod. 6. Turn the crank carefully downwards while “following” with the tackles to guide the connecting rod when it separates from the crosshead. Mount two eyebolts in the top end of the connecting rod. BM904-5.2 Dismantling 5. one on each side.2 224 06 7. crankpin end. Remove the relief valve from the exhaust side of the framebox. BM904-5. at the crankpin end. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S . 7.Connecting Rod 904-5.

Unhook the upper tackle from the exhaust side.2 224 10 A When referring to this page. 8. BM904-5.2 224 09 A 10. 9.Connecting Rod 904-5. 10. A When possible. BM904-5.2 Dismantling 8. Lift the connecting rod clear of the crankshaft. Continue turning the crank to a position about 25° after TDC. BM904-5.2 224 08 9. Turn the crank carefully upwards while “following” with the tackles. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S Page 3 (8) . while “following” with the tackles. 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.

please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S . BM904-5. Lift the connecting rod out of the engine using the two tackles.904-5.2 224 11 11.2 Connecting Rod Dismantling 11. Page 4 (8) When referring to this page.

please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S Page 5 (8) . Carefully land the connecting rod on the crankpin journal.Connecting Rod 904-5.4 1. Take care that the end of the connecting rod does not strike or scratch the crankpin journal. Note! 2.4 Mounting Mounting 904-5. 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. 2. When referring to this page. BM904-5. 1. Suspend the connecting rod outside the engine and equip the rod with the same lifting attachments as mentioned under dismantling. past TDC.e BM904-5. 3.4 224 02 4. Turn the crank to a position about 25° past TDC on the camshaft side.4 224 04 4. Turn the crankthrow towards the exhaust side of the engine.4 224 01 Apply clean lubricating oil to the crankpin bearing shell and journal. BM904-5. while ‘following’ with the tackles.

hook the second tackle on to the eye bolt screwed into the exhaust side of the connecting rod top. Turn the crankthrow towards TDC while ‘following’ with the tackles. 7.4 224 07 7.4 224 05 Rise the connecting rod to a more vertical position with the tackle mounted on the exhaust side. When the upper end of the connecting rod has passed through the crankcase door. 6. BM904-5. Unhook the tackle mounted on the camshaft side. Remove the tackle from the lifting attachment at the lower end of the connecting rod. 6. BM904-5. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S .4 Connecting Rod Mounting 5.4 224 06 Take care that the connecting rod does not damage the crosshead journal. 5.904-5. Attach the camshaft side tackle to the camshaft side top of the connecting rod. Page 6 (8) When referring to this page. from the top of the connecting rod. Caution! BM904-5.

4 224 08 10. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S Page 7 (8) . Remove: D-2 BG904-6. Carefully land the crosshead on the connecting rod by turning to TDC.4 Mounting 8. Remove the lifting attachment from the bottom end of the connecting rod.0 62 05 10. and mount and tighten the crankpin bearing cap. When referring to this page.4. BG904-6. 9.0 62 05 9. See Procedure 904-4. • the four supports from the crosshead guides • the eye bolts from the connecting rod. 8. Unhook the tackles from the top of the connecting rod.Connecting Rod 904-5. BG904-5.

Suspend the piston rod. 11. BM904-5. Page 8 (8) When referring to this page. See Procedure 904-1.904-5. Turn the crosshead to BDC. Mount the crosshead bearing cap.4 224 11 12.4 224 12 12.4.4 Connecting Rod Mounting 11. the piston rod and the telescopic pipe as shown in Procedure 904-1. BG904-5.2. please quote Procedure M90405 Edition 0224 MAN B&W Diesel A/S .

please quote Plate P90451 Edition 0129 MAN B&W Diesel A/S Page 1 (2) .Connecting Rod and Crosshead Panel Plate P90451-0129 Connecting Rod and Crosshead Panel 0129 P90451 When referring to this page.

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. 011 023 047 059 060 072 084 096 106 118 120 155 167 Connecting Rod and Crosshead Panel Item Description Item No.Plate P90451-0129 Item No. please quote Plate P90451 Edition 0129 MAN B&W Diesel A/S .

please quote Plate P90461 Edition 0068 MAN B&W Diesel A/S Plate P90461-0068 Page 1 (2) .Hydraulic Tools When referring to this page.Connecting Rod .

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. Item Description When referring to this page. complete Page 2 (2) Item No. please quote Plate P90461 Edition 0068 MAN B&W Diesel A/S .Hydraulic Tools Item No.Plate P90461-0068 Connecting Rod .

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) .

complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Key. please quote Plate P90464 Edition 0005 MAN B&W Diesel A/S . Item Description When referring to this page. hexagon socket screw Stud setter Hydraulic toolset.Hydraulic Tools Item No. Item Description 024 036 048 050 061 085 107 203 Jack-hydrualic. complete Page 2 (2) Item No.Plate P90464-0005 Crosshead .

Measuring Tools MAN B&W Diesel A/S .Tools Crankshaft . etc. Data Axial Vibration Damper Angle Encoder. Data Crankshaft Deflection Main Bearing.Panel Main Bearing . Data Main Bearing Thrust Bearing.Measuring Tools Main Bearing . Data Thrust Bearing Axial Vibration Damper.Crankshaft. Data Angle Encoder 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. .Hydraulic Tools Crankshaft .905 . Thrust Shaft. Main Bearing.

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 X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref. Description Value Unit When referring to this page. please quote Data D10501 Edition 0004 MAN B&W Diesel A/S Page 1 (2) .

Main Bearing 105-1 Data Spare Parts Plate – Item No. please quote Data D10501 Edition 0004 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.

Whilst turning clockwise. HM905-2. 3. the deflection measurements should.e. Set the dial gauge to zero at the B1 side near BDC.0 46 01 As the alignment is influenced by the engine temperature as well as the loading conditions. See also Chapter 708 in Volume I. for comparison. 2. Crankshaft deflection readings should be taken while the ship is afloat (i. not while in dry dock). When referring to this page. “Closing” of the crankthrow (compression of the gauge) is regarded as negative. Place a dial gauge axially in the crankthrow opposite the crankpin. 2.1 1. as illustrated on the sketch. The correct mounting position is marked with punch marks on the crankthrow. always be made under nearly the same temperature and load conditions.1 Checking Crankshaft Deflection S60MC-C 0207 Checking 905-1. 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. please quote Procedure M90501 Edition 0207 0$1% :'LHVHO$6 Page 1 (2) .1 204 03 3.Crankshaft Deflection 905-1.

This pressure may otherwise falsify the readings. OPERATION. When referring to this page. also the alignment of the propeller shaft/ drive shaft must be checked by a jack-up test. For evaluation of the crankshaft deflection readings. OPERATION). please contact MAN B&W Diesel or the engine manufacturer for checking of the bedplate alignment. please quote Procedure M90501 Edition 0207 0$1% :'LHVHO$6 . I.0 46 01 If the crankshaft deflection (alignment indicator) is approaching the tolerance limits (see Vol. If the excessive crankshaft deflection is found at the aftmost cylinder of the engine. 4. the two adjacent main bearings must be checked.1 for checking of main bearing. Chapter 708. be turned a little backwards to ease off the tangential pressure on the turning wheel teeth. See Procedure 905-2. the turning gear should. HM905-2. at each stoppage. When taking deflection readings for the three aftmost cylinders.1 Crankshaft Deflection Checking 4. Page 2 (2) If the bearings are found to be in good order. see Volume I.905-1.

oil pipe [NJ 70 Nm When referring to this page. bearing clearance 0.Main Bearing 105-2 Data SAFETY PRECAUTIONS Special Data S35MC 0035 105-2 Standard Tools: See Section 913 Main Bearing X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water 2 x 1000 kg Shut off fuel oil X Shut off lubricating oil 2 x 1.15 mm D-2 Max.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. Description Value Unit D-1 Min. bearing clearance 0.5 m 1x3m Lock turbocharger rotors Data Ref. please quote Data D10502 Edition 0035 MAN B&W Diesel A/S Page 1 (2) .

please quote Data D10502 Edition 0035 MAN B&W Diesel A/S . upper shell 1 91210-xxx 216 Main bearing. Description Qty 91210-xxx 204 Screw 2 91210-xxx 194 Main bearing. lower shell 1 Page 2 (2) When referring to this page.Main Bearing 105-2 Data Plate 1849873-3 90551 Spare Parts Plate – Item No.

BM905-2. check the individual bearings. If necessary. Chapter 708.1.1 239 04 4. 3. Insert the measuring tool and check the clearance between the upper shell and the journal.2. dismount the bearing cap and the upper shell. Remove the lub. For further inspection of the bearing. see Procedure 905-2. If there is too large a difference in the crankshaft deflection readings (autolog). 2. BM905-2. 1. See Procedure 905-1.1 239 03 An appreciable increase in clearance may be an indication of loose staybolts or wear of the lower shell. 4. MB905-2. OPERATION. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 1 (17) . oil pipe from the main bearing cap. ‘Bearings’). Inspect the bearing and the journal (see Volume I.Main Bearing 905-2. When referring to this page.05 mm.1 Checking Main Bearing S35MC 0239 Checking 905-2. The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.0 41 01 Calibrate the main bearing measuring tool: 3.1 1. See the wooden box for the measuring tool.

Main Bearing 905-2. Page 2 (17) When referring to this page.2 Dismantling Dismantling 905-2. BG905-3.1 71 02 Remove the hydraulic tools and unscrew the nuts. Disconnect the lubricating oil inlet pipe from the main bearing cap (if not already done during checking). BM905-2. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 . Check and write down the top clearances before carrying out any dismantling. Turn the crankthrow so that it points towards the exhaust side of the engine. Mount the double hydraulic jacks on the studs. 1. see Chapter 913). (The engine is not always equipped with this bearing).2 In the following. Place two spacers on two bearing cap studs with the slots towards the centre of the bearing cap. Then loosen the nuts. the main bearings are divided into three categories: • The main bearings (marked A). Dismantling of main bearings (A) 1. (For operation of the hydraulic tools. • The thrust shaft end journal bearing (marked B). 2. Repeat the sequence until all four nuts are loose. and subsequently 2+4.2 210 00 • The axial vibration damper end bearing (marked C).1 71 01 Screw the two extension studs onto the same two bearing cap studs (diagonally) 1+3. D-6 Connect the four hydraulic jacks to the high-pressure pump by means of the distributor block and high-pressure hoses. 2. BG905-3.

Mount the outside tackles. 3. by means of the handle. Mount the guide pulley with the lifting wire rope in the bottom of the guide shoe. Remove the stop screw in the crosshead guide shoe. 4. and one on the exhaust side. Fasten the lifting tool to the main bearing cap with wire rope attached to the camshaft side tackle. 5. BG905-3. Rig-up two tackles outside the engine.2 Dismantling 4. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 3 (17) .2 239 05 D-4 When referring to this page.Main Bearing 905-2. Remove the rectangular nut washers from the bearing cap. 5. push the bearing cap free of the frame and land it on the crank web.1 71 03 Lift the bearing cap and. one in the lifting beam on the camshaft side. BM905-2.

2 239 06 Inspect the bearing shell and the journal. See Volume I. Remove the guide pulley from the engine. 7. Mount the handle in the upper bearing shell and remove the shell from the crankshaft. Page 4 (17) When referring to this page. OPERATION Chapter 708.2 Dismantling 6. and lift the bearing cap out of the crankcase. and fasten the two wire ropes from the lifting tool in the two tackles outside on either side. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 .2 216 08 8. BM905-2. 8. BM905-2.Main Bearing 905-2.2 210 07 D-5 BG905-2. Check that there is clearance between the journal and the bearing shell in the two adjacent main bearings. D-4 7. Bearings). Remove the wire rope from the guide pulley. 6.

1 85 09 Tighten the screws against the crank webs.2 239 11 11.Main Bearing 905-2.2 mm. Dismount the lock screws from the lower shell. Connect the hydraulic jacks to the high pressure pump and raise the pressure until the crankshaft has lifted maximum 0.2 mm BM905-2. Max. 11. 10. making sure that the flap of the dismantling tool enters the oil groove in the bearing shell. BM905-2. 10. Place a dial gauge to measure the lifting of the crankshaft. 9. Place the dismantling tool on the top of the lower bearing shell. Take out the lower shell from the crankcase in the same way as the upper shell. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 5 (17) .2 Dismantling 9. and place the hydraulic jacks beneath the crank webs as shown. When referring to this page.0. 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.2 239 10 Pull the lower bearing shell round and up until it lies over the main bearing journal. BG905-3.

Mount an eye bolt. BM905-3. Turn the crank web for the aftmost cylinder to TDC. BM905-2. Mount the spacer supports over the two nuts and screw the extension studs onto the two bearing cap studs. Remove the screws of the cover placed over the thrust bearing. Then loosen the nuts. 12.2 210 00 Disconnect the lubricating oil pipe used for lubricating the bearing. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 . For operation of the hydraulic tools. see Chapter 913.2 117 03 D-6 Page 6 (17) When referring to this page. Mount the double hydraulic jacks on the studs. Hook on a tackle and lift the cover away. D-8 13.2 117 01 Remove the hydraulic tool and unscrew the nuts. BM905-3. 12. Connect the four hydraulic jacks to the high-pressure pump by means of the distributor block and high-pressure hoses.Main Bearing 905-2. 13. shackles and wire rope in the cover.2 Dismantling Dismantling of journal bearing in the thrust shaft end (B).

14. BM905-3. use the two stops which prevent the lower shell from being rolled out.2 239 17 Max. BM905-3.Main Bearing 905-2. 16. Set up a dial gauge in such a manner that a max. Mount an eye bolt in the bearing cap and lift it away.2 Dismantling 14. D-3 Remove the upper bearing shell from the crankshaft. 2/10 mm When referring to this page.20 mm of the shaft can be measured. BM905-2.2 117 05 15. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 7 (17) .2 117 04 15. 16. lift of 0. If the crankshaft is turned with the bearing cap dismounted.

1 mm clearance in both sides of the bearing. and place the hydraulic jacks beneath the crank webs as shown. Max.2 mm.2 Main Bearing Dismantling 17.905-2. Dismount the lock screws from the lower shell.2 239 19 Measure the clearance in the second last main bearing (positioned fore of the thrust bearing). Check that there is at least 0. 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. BM905-2. Note! JM905-2. Connect the hydraulic jacks to the high pressure pump and raise the pressure until the crankshaft has lifted maximum 0. 18. Place the crosspiece in the bedplate with the ends resting on the crossgirders. Tighten the screws against the crank webs.2 mm or the clearance for the second last bearing is reached. 18. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 .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. Lift until the aftmost bearing is lifted 0. Mount a dial gauge on both the aftmost main bearing and the second last bearing.

When referring to this page. Mount the double hydraulic jacks on the studs. Remove the end cover and the top cover and dismount the lubricating oil pipe.3 88 03 Remove the upper bearing shell from the crankshaft.2 Dismantling 19. Mount a shackle over the main bearing cap and hang up a tackle. BM905-3. Dismantling of main bearing in the axial vibration damper end (C) D-9 19. see Chapter 913. Connect the four hydraulic jacks to the high-pressure pump by means of the distributor block and high-pressure hoses.3 88 01 20. Turn the crankweb for the foremost cylinder to TDC.3 88 02 Remove the hydraulic tool and unscrew the nuts. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 9 (17) . D-3 BM905-3. 21. For operation of the hydraulic tools. 20. hook on the tackle and lift the bearing cap out of the crankcase. BM905-3. Then loosen the nuts. Mount the spacers over the two nuts and screw the extension studs onto the two bearing cap studs. D-6 Bleed the hydraulic system and raise the pressure as indicated in Data. Mount an eye bolt in the top of the bearing cap. 21.Main Bearing 905-2.

Set up a dial gauge. D-6 See Volume I. in such a manner that a max. and place the hydraulic jacks beneath the crank webs as shown. BM905-3. BM905-3. lift of 0. 24. Tighten the screws against the crank webs.20 mm of the shaft can be measured. with the ends resting on the crossgirders. Page 10 (17) When referring to this page.3 88 08 24. 23. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 . OPERATION Chapter 708.Main Bearing 905-2. Inspect the bearing and the journal. Check that there is clearance between the journal and the bearing shell in the two adjacent main bearings. Connect the hydraulic jacks to the high pressure pump and raise the pressure until the crankshaft has lifted maximum 0. 22. Bearings. 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.3 88 05 Place the crosspiece in the bedplate.2 mm. at the foremost main bearing.2 Dismantling 23.

Main Bearing 905-2. Place the dismantling tool on the top of the lower bearing shell. Note! GN905-2.2 Dismantling 25. 25. making sure that the flap of the dismantling tool enters the oil groove in the bearing shell. When referring to this page. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 11 (17) .2 204 12 Take out the lower shell from the crankcase in the same way as the upper shell. Pull the lower bearing shell round and up until it lies over the main bearing journal. Dismount the lock screws from the lower shell. Never remove the tools for lifting the crankshaft before remounting the lower main bearing shell.

contact MAN B&W Diesel for advice. see Volume I. Before remounting: • Check the bearing support for damage and burrs. it requires a careful evaluation of the condition of the shell that is to be reinstalled. Chapter 708. Clean and inspect the bearing shells. For advice on replacing the bearing shells individually. • Make sure that all parts are clean. 2. 2. If. For judging the condition of the bearing.905-2.3 204 01 We recommend that the main bearing shells be replaced in pairs. If damage is found. use non-fluffy cloth to clean between journal and main bearing support. contact MAN B&W Diesel for advice. If the bearing shells are damaged. the main bearing support and the back of the shell. Volume I.3 1. it is desired only to replace one shell. GN905-2. ‘Bearings’. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 . Page 12 (17) When referring to this page. 1. • Lubricate the bearing journal. Chapter 708.3 Main Bearing Overhaul Overhaul 905-2. See instruction book. nevertheless. it is recommended to contact MAN B&W Diesel A/S or the engine builder.

use the bearing shell dismantling tool to push the lower bearing shell fully down under the crankshaft journal. D-5 BM905-2. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 13 (17) . If necessary. 2. B and C): 1. When referring to this page. 2. Land the lower bearing shell on the crankshaft journal. Remove the handle. check in both sides of the bearing shell that the bearing shell is mounted horizontally correct.Main Bearing 905-2. BM905-2.2 210 00 Mount the handle on the lower bearing shell and slide down the lower bearing shell as far as possible.4 210 02 3. Lubricate the lower bearing shell and the crankshaft journal with plenty of clean lubricating oil.4 Mounting Mounting 905-2. For all main bearings (A.4 1. Using a caliper.

as this would cause damage to the screws and shell when tightening the bearing cap. See also Volume I. Chapter 708. If so. Mount the bearing cap. BM905-2. Make sure that the guide pin from the bedplate enters the hole in the bearing cap.4 Main Bearing Mounting 4. 6. 7. BM905-3. 4.1 71 16 D-4 Page 14 (17) When referring to this page. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 . Lubricate the upper bearing shell with plenty of clean lubricating oil. press the shell into place.4 210 02 5. 6. Land the upper bearing shell on the crankshaft journal.3 88 13 7.905-2. Check visually that the shell does not prevent the locking screws from being fully tightened to the bedplate. Lower the crankshaft and remove the crosspiece and the hydraulic jacks from the engine. OPERATION. Make sure that the edge of the upper bearing shell does not rest on the tip of the bedplate. BG905-3.

Main Bearing 905-2. 11.1 85 17 2) Tighten nuts 2 + 4 9. The tightening is done in the following sequence: 1) Tighten nuts 1 + 3 3) Retighten nuts 1 + 3 Remove the hydraulic tools. BM905-3. 9.1 71 17 10. check the top clearance once more. For middle main bearing (A) D-7 8. After tightening the bearing cap. Chapter 701. BG905-3.0 48 05 11. Mount the: • rectangular washers • nuts • extension studs • spacers • double hydraulic jacks Tighten the main bearing cap. If a new bearing shell has been mounted. remember to note down the new top clearance in the Adjustment Sheet in Volume I. D-10 BG905-2. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 15 (17) . OPERATION. Mount the lubricating oil pipe. See Data.4 Mounting 8. When referring to this page.

2 117 17 13. See Data. OPERATION. 13. mount the lubricating oil pipe and the cover over the thrust bearing.4 Mounting 12. For main bearing in thrust shaft end (B): D-7 12. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 .2 117 03 • hydraulic jacks Tighten the bearing cap. Mount and tighten the nuts of the adjacent main bearing. Finally. remember to note down the new top clearance in the Adjustment Sheet in Volume I. BM905-3. D-11 If a new bearing shell has been mounted. see step 9. check the top clearance once more. Mount the: • rectangular washers • nuts • extension studs • spacers BM905-3. After tightening the bearing cap.Main Bearing 905-2. D-8 Remove the hydraulic tools. D-10 Page 16 (17) When referring to this page. Chapter 701.

3 88 02 Tighten the bearing cap. BM905-3.3 88 15 D-10 When referring to this page. Chapter 701. For main bearing in axial vibration damper end (C): D-7 14. 15. check the top clearance once more. After tightening the bearing cap. 15.Main Bearing 905-2.4 Mounting 14. please quote Procedure M90502 Edition 0239 0$1% :'LHVHO$6 Page 17 (17) . D-11 D-9 If a new bearing shell has been mounted. the end cover and the cover over the bearing cap. see step 9. Finally. BM905-3. OPERATION. mount the lubricating oil pipe. See Data. Remove the hydraulic tools. Mount the: • rectangular washers • nuts • extension studs • spacers • hydraulic jacks Mount and tighten the nuts of the adjacent main bearing. remember to note down the new top clearance in the Adjustment Sheet in Volume I.

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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.Thrust Bearing 105-3 Data SAFETY PRECAUTIONS Special Data S35MC 0040 105-3 Standard Tools: See Section 913 Thrust Bearing X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear 140-760 Nm Shut off cooling water Shut off fuel oil X 2 x M10 Shut off lubricating oil Lock turbocharger rotors 2 x 500 kg Data Ref. please quote Data D10503 Edition 0040 MAN B&W Diesel A/S Page 1 (2) .

please quote Data D10503 Edition 0040 MAN B&W Diesel A/S .Thrust Bearing 105-3 Data Plate 1849873-3 90551 Spare Parts Plate – Item No. Page 2 (2) Description Qty When referring to this page.

When referring to this page.9 mm). and for an engine in service it must not exceed 2. To measure the wear.0 mm. see Procedure 905-3.1 224 02 2.1 mm is not able to enter the groove (the wear is more than 0.2. OPERATION.1 226 01 In service it is only necessary to measure the wear of the thrust bearing pads. (The segment with thermometers). A wear groove of 1 mm is positioned in the uppermost thrust segment. 1. to eliminate any gap. For dismantling the segment stopper.0 mm.2 238 02 3. KN905-2. If a feeler gauge of 0. To measure the wear in the thrust bearing. 2. the thrust segment has to be pressed against the thrust cam. GN905-3. BM905-3.1 Checking Thrust Bearing S35MC 0226 Checking 905-3. 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.5-1.e. 3. by using a suitable crowbar on the back of the segment. it is necessary to dismount the foremost segment stopper. the thrust bearing must be overhauled.Thrust Bearing 905-3. and to inspect for white metal below the thrust bearing. Note down the wear for later reference. For a new engine the clearance is 0.1 1. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S Page 1 (5) . i.

2. D05-28 1.2 1. Remove the lub. Screw an eye bolt into the stopper that is to be removed. 2.Thrust Bearing 905-3. The other stopper is to remain fitted. oil pipe from the thrust segments. Remove the cover above the thrust bearing.2 Dismantling Dismantling 905-3. Suspend a tackle above the stopper and hook the tackle on to the eye bolt. BM905-4.0 51 02 D05-07 Page 2 (5) When referring to this page. Loosen and remove the screws from the segment stoppers.0 51 01 Remove the stopper from the engine above the thrust segments ( AHEAD or ASTERN) that are to be taken out. BM905-4. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S .

3.Thrust Bearing 905-3. 4. the weight is no heavier than it is possible to lift the segment by hand. and remove the segment from the chain casing.4. screw the driving pin into the thrust shaft. Inspect the segment and remount it before turning up the next segment. Suspend a tackle from the chain tightener bracket above the segments which are to be removed. Note! D05-06 BG905-5.2 Dismantling 3. When referring to this page. 4. See Procedure 905-3. Nevertheless. by turning the engine.0 76 03 For turning-up the thrust segments. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S Page 3 (5) . Turn up the segments one at a time.0 59 04 Never remove more than one segment at a time. BM905-5.

2. After the last segment has been mounted. 1.0 76 03 Carefully slide the segment on to the driving pin. please quote Procedure M90503 Edition 0226 MAN B&W Diesel A/S . BM905-3. Suspend a tackle above the segments which are to be mounted.4 1. Still. Turn the engine to dismantle the next segment. turn the driving pin up and dismount it. 2. Land the segment on the journal and remove the eye bolt from the segment. see Procedure 905-3.905-3. BM905-5.2. Screw the driving pin into the thrust shaft.4 208 02 D05-06 Page 4 (5) When referring to this page.4 Thrust Bearing Mounting Mounting 905-3. it is possible to lift the segments by hand.

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

.

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. Description Value Unit D05-25 Damper housing.Axial Vibration Damper 105-5 Data SAFETY PRECAUTIONS Special Data S35MC 0032 105-5 Standard Tools: See Section 913 Axial Vibration Damper X Stopped engine X Block the starting mechanism X Shut off starting air supply X 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. please quote Data D10505 Edition 0032 MAN B&W Diesel A/S Page 1 (2) . When referring to this page.

Description Qty 91211-038 127 Spring – middle oil seal 1 91211-038 139 Spring – side oil seals 2 91211-038 272 Oil seal – side oil seals 2 91211-038 284 Oil seal – middle oil seal 1 Page 2 (2) When referring to this page. please quote Data D10505 Edition 0032 MAN B&W Diesel A/S .Axial Vibration Damper 105-5 Data Plate 1849873-3 90551 Spare Parts Plate – Item No.

Axial Vibration Damper 905-5. with angle encoder fore. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 Page 1 (8) . A proximeter probe is built on to the lower part of the damper housing.2. with Axial Vibration Monitor 1. see Procedure 905-5. the checking procedure describes three different systems: A: Electronic. KM905-7. The measurement (or reading) should be taken at the same r/min as during the sea trials. When referring to this page. Concerning overhaul and setting of the electronic device. Mechanical. it is necessary to overhaul the axial vibration damper. (without angle encoder fore) C: Mechanical. Chapter 701. refer to makers instructions and Volume I. with Axial Vibration Monitor B.1 1. 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. The probe is connected to a control unit which displays peak-to-peak movements and sends signals to the engine control system. it is necessary to measure the longitudinal movements of the fore end of the crankshaft during running.1 35 01 A: Electronic. If the peak-to-peak value exceeds the Normal Service Value. Operation. Chapter 701.1 Checking Axial Vibration Damper S35MC 0223 Checking 905-5.) As different equipment may be mounted on the specific engines. Operation. For checking the effectiveness of the axial vibration damper. (Preferably 90% and 100% of MCR.

2. Page 2 (8) When referring to this page. Tighten the lock nut. Stop the engine.905-5. using the handle.1 Axial Vibration Damper Checking 1. Unscrew the two plugs from the cover at the front of the engine.1 223 01B After tightening the shaft. Attach a pencil to the arm. Mount the shaft piece in the end of the crankshaft. BG905-5. so that the arm is perpendicular to the shaft piece. the tip of the pencil should protrude 10 mm from the end of the arm. B: Mechanical (without angle encoder fore). please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 . 2.1 223 02B To obtain a correct measurement. dismount the handle. Note! BG905-5. Screw the measuring arm into the small threaded hole beside the centre hole. 1.

3. press the measuring arm against the shaft piece with the one hand. Operation. S1 can be calculated as follows: DM905-7. stated in Volume I. DM905-7. (Preferably 90% and 100% of MCR.2. 4. Chapter 701. 4.1 Checking 3. 1-2 kg. the ratio is 5. lightly downwards against the tip of the pencil.3. and let the speed rise to the number of revolutions at which the measurement is to be taken. see Procedure 905-5. the backing plate should have a mass of approx.1 74 05 When measuring. S1 can be calculated as follows: If the peak-to-peak value exceeds the Normal Service Value.1 74 06 For a standard measuring tool (L 1 = 38 mm and L 2 = 200 mm). clipped on to a solid backing plate. With the other hand.) S-2 To ensure a certain inertia. it is necessary to overhaul the axial vibration damper. When referring to this page. move a sheet/block of paper. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 Page 3 (8) . Start the engine. The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. Therefore. Before comparing the measured value (S2) with the Normal Service Value (S1). If a non-standard tool is used.Axial Vibration Damper 905-5. it is necessary to compensate for the ratio in the tool.

1 Axial Vibration Damper Checking 1. the tip of the pencil should protrude 10 mm from the end of the arm. (Not always on engine). C: Mechanical. 1.1 223 01C Note! To obtain a correct measurement. using the screws from the cover. 2. with angle encoder fore For engines with angle encoder fore. Stop the engine.1 214 05 2. Apply some Molycote TM on the fore side of the shaft cam. Dismount the protection shield over the angle encoder.905-5. Page 4 (8) When referring to this page. a measuring tool is available for mounting on the angle encoder housing. Mount the axial vibration measuring tool. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 . Dismount the cover on the angle encoder housing. BG905-5. N905-5.

1 212 07 If a non-standard tool is used. 1-2 kg. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 Page 5 (8) .1.Axial Vibration Damper 905-5. the backing plate should have a mass of approx. it is necessary to compensate for the ratio in the tool. Operation. MA905-5. move a sheet/block of paper. S1 can be calculated as follows: When referring to this page. S1 can be calculated as follows: If the peak-to-peak value exceeds the Normal Service Value. 4.1 223 03 To ensure a certain inertia. Chapter 701.) S2 When measuring. and let the speed rise to the number of revolutions at which the measurement is to be taken. stated in Volume I. 4. With the other hand. 3. clipped onto a solid backing plate. BG905-5. pull the measuring arm against the shaft cam with one hand. For a standard measuring tool (L 1 = 35 mm and L 2 = 178 mm). (Preferably 90% and 100% of MCR. see Procedure 905-5. the ratio is 5.1 Checking 3. lightly sidewards against the tip of the pencil. Start the engine. PULL The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. it is necessary to overhaul the axial vibration damper. Before comparing the measured value (S2) with the Normal Service Value (S1). Therefore.2.

g. e. Note! BG905-7. 3. Dismount the lubricating oil pipes for the main bearing and axial vibration damper.2 28 01 Only the upper part of the housing needs to be removed. Dismantling of the axial vibration damper is carried out from the crankcase of cyl.905. 3.5.5. No. 2. By means of tackle and wire rope. 1. while the lower half remains mounted on the bedplate. secure the upper part with. BG905-5. Loosen and remove the screws from the damper housing upper part.2 1. 1. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 . a wire rope or another tackle. Mount the lifting bracket and a shackle on the upper part.2 216 03 D05-25 Page 6 (8) When referring to this page. BG905-7.2 Axial Vibration Damper Dismantling Dismantling 905. separate and raise the upper part of the damper housing to a position in which it is possible to change the oil seals and springs.2 28 02 Before starting work below the suspended upper part. 2. Turn the engine to 90 ž after TDC.

2. Then press the tension springs into the groove between the oil sealing ring half and the housing.3 Overhaul Overhaul 905-5. HG905-5. HG905-5. The lower half of the oil sealing rings will protrude above the centreline. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 Page 7 (8) .2 201 02 Note! When referring to this page. 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.Axial Vibration Damper 905-5.2 201 01 It is recommended to discard both the springs and the oil sealing rings.3 1. Dismantle and remove the springs from the oil sealing rings. Now hook the new tension springs into place. 2. Remove the oil sealing rings. 1. first insert the lower half of the rings in the lower housing. Note! When mounting the new oil sealing rings. ensuring that they are centralised in the grooves of the oil sealing rings.

D05-15 D05-21 After overhaul of the axial vibration damper.4 Axial Vibration Damper Mounting Mounting 905-5. take care that the rings enter the sealing ring grooves correctly. D05-25 When reaching the oil sealing rings. Tighten the screws. Before landing the upper part on the lower part. 2. be sure that the guide pins have entered the guide pin holes. Mount the vertical and horizontal screws.1. Note! BG905-5.2 28 06 D05-23 Page 8 (8) When referring to this page. please quote Procedure M90505 Edition 0223 0$1% :'LHVHO$6 . it is recommended to check the axial vibrations. BG905-7. See Procedure 905-3. Note! 2.4 223 01 Search the crankcase to ensure that there are no tools.4 1. 1.905-5. See Data. Release and carefully lower the upper part of the damper housing. Mount the lubricating oil pipes. shackles or rags left behind.

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 SAFETY PRECAUTIONS Special alle 0006 105-8 medData vinkel encoder Standard Tools: See Section 913 Angle Encoder X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.

please quote Data D10508 Edition 0006 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.Angle Encoder 105-8 Data Spare Parts Plate – Item No.

The green indicator should now light. 2. Turn the crankthrow for cylinder 1 to TDC.1 202 03  When referring to this page. please quote Procedure M90508 Edition 0203 0$1% :'LHVHO$6 Page 1 (4) .0 56 01 Check the TDC of cylinder 1 against the mark on the turning wheel. HM906-7. Check that power is supplied to the intermediate box. For adjustment of the angle encoder.Angle Encoder 905-8. see Procedure 905-8. MN905-8.1  1.1 Checking Angle Encoder S42MC 0203 Checking 905-8.3.

in the end nearest to the engine. 3.2 203 03  Page 2 (4) When referring to this page. please quote Procedure M90508 Edition 0203 0$1% :'LHVHO$6 . Remove the inspection cover. DM905-8. DM905-8.2  1.2 203 01 2. Screw out the flange screws and remove the encoder housing. Loosen the three adjusting screws on the front flange. and remove the angle encoder and the coupling. and loosen the coupling.2 Angle Encoder Dismantling Dismantling 905-8.905-8. Take care not to damage the guide pins. Cut the cable tie which holds the rubber damper around the coupling.2 203 02  DM905-8.

3 Adjustment Adjustment 905-8. Loosen the adjusting screws which fasten the encoder to the housing. check the measurement from tip to tip with the value stamped on the pin gauge.  MN905-8.3  1. Slowly turn the encoder until the green indicator lights on the intermediate box. BG906-7. Check the TDC position with the pin gauge on the crankthrow.0 56 01 Check the TDC of cylinder 1 against the mark on the turning wheel.0 58 02 2. Tighten the screws to secure the encoder in the correct position.3 202 02  When referring to this page. and/or the check-marks stamped on the fore end of the cylinder frame. cylinder 1. Turn the crankthrow for cylinder 1 to TDC. please quote Procedure M90508 Edition 0203 0$1% :'LHVHO$6 Page 3 (4) . Before using the pin gauge. Note! HM906-7.Angle Encoder 905-8.

Mount the encoder housing. 2. Mount the angle encoder and the coupling. DM905-8. 1.905-8. The two guide pins indicate the correct positioning of the housing. Tighten the screws.4 Angle Encoder Mounting Mounting 905-8. Adjust the angle encoder according to Procedure 905-8. and mount a new cable tie around the rubber damper.3. DM905-8. please quote Procedure M90508 Edition 0203 0$1% :'LHVHO$6 . Page 4 (4) When referring to this page.4 1.2 203 02 Mount the cover.2 203 03 Tighten the coupling. The adjustment will be easier if mounting is in the same crank position as dismantling. Note! 2.

Panel Plate P90551-0200 Crankshaft. Etc. Thrust Shaft. Thrust Shaft. please quote Plate P90551 Edition 0200 MAN B&W Diesel A/S Page 1 (2) . Etc.Crankshaft. Panel 0200 P90551 When referring to this page. Main Bearing. Main Bearing.

Etc. Panel Item Description Item No. please quote Plate P90551 Edition 0200 MAN B&W Diesel A/S . Thrust Shaft. 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. Main Bearing. 015 027 052 076 088 100 111 123 135 Crankshaft.Plate P90551-0200 Item No.

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

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

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

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

please quote Plate P90564 Edition 0018 Plate P90564-0018 Page 1 (2) .Measuring T ools Tools MAN B&W Diesel When referring to this page.Crankshaft .

016 Page 2 (2) Crankshaft . please quote Plate P90564 Edition 0018 .Measuring T ools Tools MAN B&W Diesel Item Description Item No.Plate P90564-0018 Item No. Item Description Measuring tool for axial movement When referring to this page.

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

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

Data Camshaft Camshaft Bearing. Data Chain Chain Tightener. Data Camshaft Bearings Replacement of Cams on Camshaft.906 . Data Chain Tightener Camshaft.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.Panel Crankshaft . Data Replacement of Cams on Camshaft Chain Drive and Camshaft .Pin Gauge Camshaft .Pin Gauge MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

Description D-1 Max.5 mm Original length (chain pitch x 10 links) 713.Chain 106-1 Data SAFETY PRECAUTIONS Special Data S35MC 0017 106-1 Standard Tools: See Section 913 Chain X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.8 mm When referring to this page.7 mm 10 links measurements + 1% of a tensioned chain = scrapping of chain 720. please quote Data D10601 Edition 0017 MAN B&W Diesel A/S Page 1 (2) . wear of teeth on chain wheel D-2 D-3 Value Unit 2.

2 90651 Spare Parts Plate – Item No. Page 2 (2) Description Qty When referring to this page.Chain 106-1 Data Plate 1849863-7. please quote Data D10601 Edition 0017 MAN B&W Diesel A/S .

4. Examine the rubber track of the guideways for cracks or other damage. For assessing the measurement results. Measure the geometry of the bottom and note down all available measurements including D-A and D-B on the drawing. Make a general inspection for loose bolts and screws. 5. 2. contact MAN B&W Diesel. please quote Procedure M90601 Edition 0207 0$1% :'LHVHO$6 Page 1 (4) . Such scratches can generally be considered normal.0 37 05 In most cases. make a drawing in scale 1:1 of the teeth and wear profile. 5. KG906-1. and check jet nozzles for possible stoppages or deformations.Chains 906-1. If abnormal wear is observed at the bottom of the teeth. When referring to this page. Carry out the inspection as follows: 1. If abnormal wear is found. Inspect lube oil pipes for damage. take a measurement (see Data). D-B is best found by placing a short straight-edge between the tip of the two teeth.0 33 04 Measurements are best taken by placing a short straight-edge over points A and B and then measuring the distance D-1.1 4. Replace the guideway if bits have started to be “plucked out” of the rubber track. scratches caused by the side plates of the chain will be found on the sides of the teeth. Check the teeth of the chain wheels.1 Checking Chains S35MC 0207 Checking 906-1. KG906-1. 3.

D-2 To keep such matching chains in their pairs. possible 3rd chain) On the same links there is an arrow (–>) which indicates the mounting direction.3. Example: HM906-1. however. See Procedure 906-2.1 Checking 7. the side plates of the outer link nearest to the assembled link have been marked with year. possible 3rd chain) No.0 32 00 D-3 No. 1 order. 6. Check chain wear by measuring the length of 10 chain links and comparing the result with the value given in Data. month. that the rollers get light. 840520 2A 840520 2B (840520 2C. Check the chains for cracks on possibly defective rollers and side plates. adjust the chain tightener. The chains for the camshaft drive are matched together to ensure an even load distribution. It is recommended that each single link is checked. Page 2 (4) When referring to this page. 7. 840520 1A 840520 1B (840520 1C. If necessary. day and chain number. It is normal. circumferential scratches during the running-in period. please quote Procedure M90601 Edition 0207 0$1% :'LHVHO$6 . These fine scratches are of no importance and need not be considered.Chains 906-1. 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). 2 order.

2 203 03 3. If the chain is to be completely removed.2 203 02 2. Note! GN906-1. 1. a new link must always be fitted as the link pin press-fit is destroyed when breaking the chain. 1. The riveting of the pins that are to be pressed out is to be drilled or ground away. 3. contact MAN B&W Diesel for further information. with the chain link that is to be disassembled. Mount a wire round the link rollers a short distance from the disassembly point. and dismantle the link by alternately tightening the screws on the tool. Protect the link rollers over which the wire is wrapped. the corresponding link in the other chain must also be renewed. HN906-1. GN906-1.2 It may become necessary to disassemble the chain if. When referring to this page.3). and tighten the wire lightly with a tackle. Place the chain bursting tool over the outer chain link. Turn the engine until the slack part of the chain. cracked rollers or seizures between pin and bushing have been discovered during the inspection. Note! When a new link is fitted in one chain.2 Dismantling Dismantling 906-1.Chains 906-1. (See Procedure 906-2.2 207 01 Every time a chain link is disassembled. please quote Procedure M90601 Edition 0207 0$1% :'LHVHO$6 Page 3 (4) . for instance.1. 2. is in a favourable position for the work. See Procedure 906-1. Remove the tension on the chain by loosening the chain tightener.

4 1. GN906-1.3). Before assembling the inner and outer links.4 Chains Mounting Mounting 906-1. Remove the tackle and wire and adjust the chain tension. please quote Procedure M90601 Edition 0207 0$1% :'LHVHO$6 . clean the pins and bushings. (See Data and Procedure 906-2. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool. remove the compression tool and lock the pin ends by riveting. Combine the inner chain link with the outer chain link and mount the compression tool. 1. Repeat this procedure until the chain has been assembled. Page 4 (4) When referring to this page. When the link has been assembled.906-1.4 203 01 2.

Chain Tightener 106-2 Data SAFETY PRECAUTIONS Special Data S35MC 0009 106-2 Standard Tools: See Section 913 Chain Tightener X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref. please quote Data D10602 Edition 0009 MAN B&W Diesel A/S Page 1 (2) . 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 2 (2) Description Qty When referring to this page.Chain Tightener 106-2 Data Spare Parts Plate – Item No.

For chain wear. Turn the engine so that the slack part of the chains is on the same side as the tightener wheel.1 81 01 3. see Procedure 906-1. C and D to free the chain tightener bolt. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D-1. please quote Procedure M90602 Edition aa0211 0$1% :'LHVHO$6 Page 1 (2) . When referring to this page.3 Adjusting Chain Tightener S35MC aa0211 Adjusting 906-2. To retighten the chains.1 81 03 3.Chain Tightener 906-2.3 1. 1. 2. ' ' DM906-2. DM906-2.1.2 95 01 2. loosen nuts A. DM906-2. Then tighten nut B as stated in D-2 (see Data). B.

906-2. Page 2 (2) When referring to this page.3 Chain Tightener Adjusting 4. 5. please quote Procedure M90602 Edition aa0211 0$1% :'LHVHO$6 . See Data page 106-1. Tighten nut A. Lock nuts C and D with the tab washer. Lock nuts A and B with the tab washer.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. DM906-2. DM906-2. Tighten nut D. 4.1 81 05 5. Tighten nut C hard against the contact face of the shaft.

please quote Data D10603 Edition 0006 MAN B&W Diesel A/S Page 1 (2) . 1 Check measurement 355 mm Pin gauge for camshaft Check measurement 238 mm Max. permissible change in lead angle corresponding to 2° 2. Description D-1 Pin gauge for top dead centre of crankthrow No.Camshaft 106-3 Data SAFETY PRECAUTIONS Special Data S35MC 0006 106-3 Standard Tools: See Section 913 Camshaft X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.5 mm D-2 D-3 Value Unit D-2 D-1 When referring to this page.

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 .

Turn in the AHEAD direction to ensure that the tension of the chain on the chain drive is correct. HM906-7. please quote Procedure M90603 Edition 0206 0$1% :'LHVHO$6 D-1 Page 1 (3) .Camshaft 906-3.1 Checking Camshaft S35MC 0206 Checking 906-3. BG906-7. If necessary.0 56 01 1. When referring to this page. See Procedure 906-2. Check the TDC position with the pin gauge on the crankthrow. Check the TDC of cylinder 1 against the mark on the turning wheel. 2.3.0 58 02 2. adjust the chain tension. Turn the crankthrow for cylinder 1 to TDC. D-1.1 1.

1 206 03 5.1 203 06 6. BM906-3. 3. adjust the cylinder lubricator. For max. also check the running surface of the cams. the cam should be turned one complete revolution during the inspection. MAN B&W Diesel should be contacted for further instructions. If light scratches are ascertained. The running surface of the cam must be completely smooth and bright.1 206 05 6.1 Checking 3. Such light scratches can appear if the roller guide and the cam are not correctly aligned. When checking the camshaft position. In the event of heavier scratches or direct flaking of the material on the running path. GN906-3. See Procedure 907-1. BM906-3.Camshaft 906-3.1. of necessary. in lead angle. Position the camshaft pin gauge in the centre punch mark. see D-3.1. See Procedure 903-2. Check and. and measure the deviation. D-3 5. As the inspection must include the entire surface of the cam. Check the setting of the starting air distributor. remove them by carefully polishing the cam in the direction of rotation with a fine carborundum stone. Page 2 (3) When referring to this page. permissible change. please quote Procedure M90603 Edition 0206 0$1% :'LHVHO$6 . if any. 4.

Camshaft 906-3.1. When referring to this page. MAN B&W Diesel should be contacted for further instructions.3 1.3 206 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. BM906-3. please quote Procedure M90603 Edition 0206 0$1% :'LHVHO$6 D-3 Page 3 (3) .3 Adjustment Adjustment 906-3.

.

10 mm D-5 Clearance between thrust disc/guide discs 0.7-3.3 mm D-4 Max. wear of bearing shell 0. 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 2.20 mm D-6 Tightening torque – screw for guide discs 20 Nm When referring to this page.Camshaft Bearings 106-4 Data SAFETY PRECAUTIONS Special Data S35MC 0006 106-4 Standard Tools: See Section 913 Camshaft Bearings X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.05-0. 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 2 90613-xxx 143 Camshaft bearing shell 1 Page 2 (2) When referring to this page. please quote Data D10604 Edition 0006 MAN B&W Diesel A/S .

please quote Procedure M90604 Edition 0206 0$1% :'LHVHO$6 Page 1 (5) . and for fragments of metal in the camshaft housing. DM906-5. clearance see Data.Camshaft Bearing 906-4. In the event of any signs of anomalies. the bearing shell must be dismantled for closer investigation and. For max. If no anomalies are found during the visual inspection. Dismount the inspection cover of cylinder No. 3. dismantling need only be carried out in connection with Class surveys.0 51 01 2.1 Checking Camshaft Bearing S35MC 0206 Checking 906-4. See Checking and Maintenance Programme 900-1. if necessary. Dismount the inspection covers from the front of the camshaft housing.0 47 09 D-5 When referring to this page. 1 and use a feeler gauge to check the clearance between the thrust disc and the guide discs.1 1. 2. 1. the bearing shell must be replaced. Check for wiped-out metal at the bearing ends. BM906-5./min.

Remove the screws from the bearing cap.0 47 02 Dismount the lubricating oil connecting pipe and the plug screws from the baseplate above the bearing in question. Page 2 (5) D-1 When referring to this page. Loosen the bearing cap screws through the holes in the baseplate. please quote Procedure M90604 Edition 0206 0$1% :'LHVHO$6 .3. Lift the roller guide of the exhaust valve hydraulic pump. the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts. 2. BG906-5. 2.0 40 03 Remove the bearing cap from the housing. Warning! Before dismantling any camshaft bearings. See Procedure 908-7. Remove the inspection covers on each side of the bearing from the camshaft housing. BM906-5.906-4. 1.2 Camshaft Bearing Dismantling Dismantling 906-4. See Procedure 906-2.2 1.

3. 4. Place a dial gauge on the camshaft.0 40 04 Remove the shell from the camshaft housing. Press lightly on the upper edge of the shell to turn the shell up over the camshaft.Camshaft Bearing 906-4.2 Dismantling 3. Place a hydraulic jack between two pieces of wood in the camshaft housing underneath the camshaft. and lift the camshaft 0. When referring to this page. please quote Procedure M90604 Edition 0206 0$1% :'LHVHO$6 Page 3 (5) .20 mm. BG906-5. close to the bearing.0 40 05 4. BG906-5.

polish the surface with a fine carborundum stone to re-establish a bright and smooth surface. BG906-5. For assessment of the bearing condition. Mount and tighten the screw as stated in Data. an impression can be formed of whether the lubrication of the bearing surface has been insufficient or entirely missing.Camshaft Bearing 906-4. 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. Measure the thickness of the bearing shell with a micrometer to check the amount of wear. Chapter 708 ‘Bearings’.3 Overhaul Overhaul 906-4. Page 4 (5) When referring to this page.0 47 10 Mount new discs. 2. remove the horizontal screw and turn out the discs. If seizures are found on the bearing journal surface (on account of bearing breakdown). If the checking indicates that the guide discs need overhaul/replacement. D-4 2. 1.3 1. D-6 BM906-5. see Volume I OPERATION.0 40 06 By closely examining the sliding surface of the bearing shell visually. Inspect the entire surface of the bearing journal for seizures. please quote Procedure M90604 Edition 0206 0$1% :'LHVHO$6 . Normally. camshaft bearing damage only occurs due to faulty lubrication.

BG906-5. Be careful not to scratch the camshaft surface. Clean the camshaft housing and mount the inspection covers. D-2 Check the torque on the outermost screw with a torque spanner. See Data D2. 2. Remove the dial gauge. 3. Then mount the lubricating oil pipe and the plug screws in the baseplate. This procedure ensures that the outermost screw will obtain the correct torque. Note! BG906-5. Tighten the outermost screw lightly by hand until the clearance given in D-3 is reached. the bearing support and the bearing shell. the pieces of wood and the hydraulic jack from the camshaft housing.Camshaft Bearing 906-4. 3. BG906-5. please quote Procedure M90604 Edition 0206 0$1% :'LHVHO$6 Page 5 (5) .0 40 08 Check the clearance D-3 on both sides of the camshaft.4 Mounting Mounting 906-4. When referring to this page. Place the bearing cap on the camshaft and mount the outermost bearing cap screw. Clean the bearing journal. and turn it into place. D-3 4.4 2.0 40 07 Relieve the hydraulic jack of pressure to lower the camshaft. Then mount and tighten the innermost screw with a torque spanner. 1. Mount the shell on the camshaft.0 40 01 4. Coat the bearing journal and the bearing shell with plenty of lubricating oil.

.

please quote Data D10606 Edition 0002 MAN B&W Diesel A/S Page 1 (2) . 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. 22 mm Shut off cooling water X Shut off fuel oil X Shut off lubricating oil 1x3m 140-760 Nm 750-2000 Nm Lock turbocharger rotors Data Ref. Description Value Unit D-1 Marking scratch.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 X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear 18. 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. 24 mm 17.

please quote Data D10606 Edition 0002 MAN B&W Diesel A/S .Replacement of Cams on Camshaft 106-6 Data Spare Parts Plate – Item No. Description Qty 90301-133 027 O-ring 1 90611-129 010 Screw 4 90611-129 022 Repair cam. exhaust 1 90611-129 213 Cover 2 Page 2 (2) When referring to this page. fuel 1 90611-129 130 Repair cam.

Extend the marking scratch on the shaft by D-4. See Data. 2. BM906-6.0 47 03 D-4 When referring to this page. See procedures 908-7 or 909-16. please quote Procedure M90606 Edition 0202 0$1% :'LHVHO$6 Page 1 (3) . Remove the front cover of the camshaft housing.2 1.0 47 01 3. Turn the camshaft so that the marking scratch can be seen.0 47 02 2. BM906-6.2 Dismantling Replacement of Cams on Camshaft 0202 Dismantling 906-6. 3. 4. 1. Lift the roller guide from the cam in question.Replacement of Cams on Camshaft 906-6. BM906-6.

using the high-pressure pump. 5. please quote Procedure M90606 Edition 0202 0$1% :'LHVHO$6 . 6.906-6. 7. in the direction towards the other cam for the cylinder unit concerned. Remove the plug from the cam and mount three gaskets and a snap-on connector instead. Page 2 (3) When referring to this page. press the cam sideways.0 47 06 D-5 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. 6.0 47 07 7. When oil seeps out along the cam. Connect the snap-on connectors to the hydraulic high-pressure pump. BM906-6. BM906-6.2 Replacement of Cams on Camshaft Dismantling 5. Apply oil pressure to the cam.

Place the two-part spare cam on the shaft. and tighten lightly. the bore and the area on the shaft must be degreased. 4.Replacement of Cams on Camshaft 906-6. 3. BM906-6. Before mounting the two-part spare cam. so that the gap between the two parts is equal at both sides.0 47 09 Extend the marking scratch on the shaft by D-1. please quote Procedure M90606 Edition 0202 0$1% :'LHVHO$6 D-1 D-2 D-3 Page 3 (3) . and check that the gap is still equal.4 Mounting Mounting 906-6. 2. type 242 (EN243S). use the same procedure for moving the cam. mount the four screws. Make sure that the marking scratches on the cam and the camshaft coincide.0 47 08 Tighten the screws to D-6. BM906-6. If it is the fuel cam that is to be changed. D-6 Lock the screws with Loctite.0 47 11 3. 2. When referring to this page. and move the fuel cam at least D-2 mm toward the other cam for the cylinder unit concerned. and that the running surface of the cam is opposite the roller.4 1. 1. BM906-6. Lower the roller guide and mount the cover on the front of the camshaft housing.

.

please quote Plate P90651 Edition 0176 MAN B&W Diesel A/S Plate P90651-0176 Page 1 (2) .Chain Drive and Camshaft Panel When referring to this page.

Item Description Panel for tools Name plate Impact spanner. 019 020 044 056 068 152 Page 2 (2) Chain Drive and Camshaft Panel Item Description Item No. chain Disassembling tool. fuel cam Assembling tool. exhaust cam When referring to this page. chain Impact spanner. please quote Plate P90651 Edition 0176 MAN B&W Diesel A/S .Plate P90651-0176 Item No.

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

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

Camshaft . please quote Plate P90668 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .Pin Gauge Plate P90668-0001 Camshaft .Pin Gauge 0001 P90668 When referring to this page.

Pin Gauge Item Description Item No. please quote Plate P90668 Edition 0001 MAN B&W Diesel A/S . 011 Camshaft . Item Description Pin gauge for camshaft Page 2 (2) When referring to this page.Plate P90668-0001 Item No.

907 . Data Starting Air Distributor Start Air Valve.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 Valve MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

3.Starting Air Distributor MAN B&W Diesel 107-1 Data SAFETY PRECAUTIONS For detailed sketch.9 . see 900-2 Stopped engine X X X X X X Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.0 mm When referring to this page.6 mm D07-04 Clearance with roller in outermost position: 1.0 . please quote Data D10701 Edition 0021 Page 1 (2) . tightening torque D07-03 Value Unit 25 Nm Clearance between gear wheel and bushing: 0.0 .0 mm D07-05 Clearance with roller in innermost position: 1. Description D07-01 Gear wheel on camshaft.1.2.

g. Plate Page 2 (2) Item No.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. P90951 refers to chapter 909. e. Description When referring to this page. please quote Data D10701 Edition 0021 .

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

Check with the pin gauge. Tighten the gear wheel bolts as stated in Data D07-01. from the engine. 1. 2. Turn the engine in AHEAD direction to bring the piston of cylinder 1 to TDC. along with the starting air distributor. Dismount the end cover of the camshaft housing.3 Adjustment MAN B&W Diesel 1. Loosen the bolts on the gear wheel.Starting Air Distributor 907-1. please quote Procedure M90701 Edition 0220 . M907010220O02 D0701 Page 2 (4) When referring to this page. M907010220C01 Turn the coupling together with the distributor disc until check pin K enters slot S in the disc and keep it there. 2.

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

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

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 SAFETY PRECAUTIONS Special Data S35MC 0019 107-2 Standard Tools: See Section 913 Starting Air Valve X Stopped engine X Block the starting mechanism X 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.

Starting Air Valve 107-2 Data Plate 1849860-1. Page 2 (2) Description Qty When referring to this page. please quote Data D10702 Edition 0019 MAN B&W Diesel A/S .1 90151 Spare Parts Plate – Item No.

Repeat steps 1 and 2 a couple of times. 15-20 mm. Shut off the air supply Check that the valve closes fully. connect a supply of working air to the control air inlet at the top of the valve.1 206 01 3. When referring to this page. Check that the valve opens approx.1 Checking Starting Air Valve S35MC 0206 Checking 907-2.1 1. see Procedure 907-2. BM907-2. BM907-2.1 206 02 2. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 Page 1 (6) . When the starting air valve has been overhauled.3. 2.Starting Air Valve 907-2. 1.

2 1. BG901-2. 2. Shut off the starting air and control air inlet. 1. Pull the starting air valve out of the cylinder cover and remove it from the engine. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 .907-2. Unscrew the starting valve screws.2 206 02 D-1 Page 2 (6) When referring to this page. Dismount the control air pipe.2 Starting Air Valve Dismantling Dismantling 907-2.2 77 01 2. BM907-2.

2. Remove and discard the gasket. and the liner from the top end of the valve housing. the piston. Remove the valve spindle from the bottom end of the valve housing. 1.0 49 01 3. Remove the top cover fixing screws and remove the cover. When referring to this page. AM907-4.Starting Air Valve 907-2. Remove and discard the O-ring. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 Page 3 (6) .0 49 02 2. AM907-4. AM907-4.3 Overhaul Overhaul 907-2. the valve spring.0 49 03 3.3 1. Remove the split pin and screw off the nut from the valve spindle. Remove the disc. the distance pipe.

0 49 03 6. Grind the valve housing seating with the grinding ring after applying grinding paste. GN907-2. 4. Carborundum No. using the face wrench to rotate the valve spindle. the piston and the disc.3 Starting Air Valve Overhaul 4. Molybdenum Disulphide. 500.907-2. the spring. Lubricate all internal parts (sliding surfaces) with. Thoroughly clean all parts before reassembling the valve. for instance. the distance pipe. Page 4 (6) When referring to this page. Grind the seatings of the spindle and housing to match. AM907-4. 200. First mount the liner in the valve housing. MoS 2. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 . Carborundum No. 5.3 203 03 6. then the valve spindle.

AM907-4. all openings of the valve should be covered with plastic to prevent dirt from entering the valve during storage. 7.Starting Air Valve 907-2. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 Page 5 (6) . Mount and tighten the top cover. AM907-4.3 Overhaul 7. 8. see D-2. Place a new gasket on the valve housing.0 49 02 9. Mount the nut on the valve spindle and tighten the nut. If the starting air valve is not to be mounted in the engine immediately after the overhaul.0 49 07 D-1 When referring to this page. D-2 Mount the split pin. Replace the O-ring on the valve housing. 8.

If not already done. Mount the valve in the cylinder cover.0 49 08 2. 2. For overhaul. see Procedure 907-2. BG901-2.2 77 03 D-3 Page 6 (6) When referring to this page.4 Mounting Mounting 907-2. please quote Procedure M90702 Edition 0206 0$1% :'LHVHO$6 . if necessary. Mount the control air pipe and turn on starting air and control air.3. recondition the seat for the starting valve in the bore.Starting Air Valve 907-2. MoS 2. 1. AM907-4. replace the O-ring on the overhauled valve and lubricate with ‘Never Seize’ or Molybdenum Disulphide.4 1. See Procedure 901-1. Mount and tighten the screws as stated in Data. Carefully clean the starting valve bore in the cylinder cover and.3.

Data Exhaust Valve Actuator Exhaust Valve Roller Guide.Extra Tools MAN B&W Diesel A/S .Tools Exhaust Valve .Panel Exhaust Valve .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.Special Running. Data Exhaust Valve Cam Exhaust Valve .908 . Data Exhaust Valve Exhaust Valve .Hydraulic Tools Exhaust Valve . Data Exaust Valve Roller Guide Exhaust Valve Cam.

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 X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear 10-120 Nm Shut off cooling water Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref. please quote Data D10801 Edition 0007 MAN B&W Diesel A/S Page 1 (2) . 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 .High-Pressure Pipe 108-1 Data Spare Parts Plate – Item No. Description Qty 90806-xxx 095 O-ring 2 90806-xxx 213 O-ring 2 90806-xxx 249 O-ring 2 Page 2 (2) When referring to this page.

2 203 02 2. When referring to this page.2 Dismantling High-Pressure Pipe S35MC 0207 Dismantling 908-1. When replacing the hydraulic high-pressure pipe. please quote Procedure M90801 Edition 0207 0$1% :'LHVHO$6 Page 1 (3) .2 203 01 3.High-Pressure Pipe 908-1.2 1. exhaust valve or hydraulic actuator. GN908-1. Lift the high-pressure pipe away from the engine. check the high-pressure pipe sealing surfaces. D-1 GN908-1. 1. stop the camshaft oil pump. Remove the screws in both ends of the high-pressure pipe. 2. Before dismounting the high-pressure pipe. 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.

Remove and discard the O-rings from the thrust piece and the thrust flange. Assemble the high-pressure pipe in the reverse order to disassembling.3 1. 2. DM908-1. Clean and inspect the conical seats of the high-pressure pipe and the thrust piece. Page 2 (3) When referring to this page. 2.1 61 03 3.908-1. The two ends of the pipe are identical and should both be overhauled as follows: 1. proceed as follows: Lift the thrust flange upwards. Remove the spring ring from the two-part sleeve. 3.3 High-Pressure Pipe Overhaul Overhaul 908-1. Remove the thrust piece from the actuator/ exhaust valve.1 61 02 Remove and discard the internal O-rings. GN908-1. 4. To change the internal O-ring. Remove the thrust flange from the pipe end. the thrust piece/ high-pressure pipe must be replaced. If a seat is damaged. DM908-1. Mount new internal O-rings lubricated with a little camshaft lubricating oil. please quote Procedure M90801 Edition 0207 0$1% :'LHVHO$6 .3 203 01 Note! The seats cannot be reconditioned.

Check the system for tightness. please quote Procedure M90801 Edition 0207 0$1% :'LHVHO$6 Page 3 (3) .High-Pressure Pipe 908-1.4 1.4 Mounting Mounting 908-1. GN908-1. 3. tighten up the screws of the pressure flanges diagonally.4 203 02 D-2 When referring to this page. lubricated with a little camshaft lubricating oil. Mount the high-pressure pipe on the engine.1. 2. 1. take care not to damage the conical seats of the pipe/thrust pieces. on the thrust pieces and thrust flanges.2 203 01 2. See Procedure 908-3. see Data. After fitting the pipe to the exhaust valve and actuator. Mount new O-rings. Note! When mounting the high-pressure pipe. GN908-1. Mount the thrust pieces on the actuator/exhaust valve.

.

inside diameter max.2 mm D-3 Piston rings.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) . min.Exhaust Valve Actuator 108-3 Data SAFETY PRECAUTIONS Special Data S35MC 0022 108-3 Standard Tools: See Section 913 Exhaust Valve Actuator X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil 140-760 NM Lock turbocharger rotors 2 x M12 Data Ref. thickness 2. Description Value Unit D-1 Weight of hydraulic actuator 30 kg D-2 Oil cylinder. 50.

please quote Data D10803 Edition 0022 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.Exhaust Valve Actuator 108-3 Data Spare Parts Plate – Item No.

On some engines the exhaust valve actuator is equipped with a puncture valve.1 Checking Exhaust Valve Actuator 0209 Checking 908-3. 1.Exhaust Valve Actuator 908-3. 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). it must be overhauled. please quote Procedure M90803 Edition 0209 0$1% :'LHVHO$6 Page 1 (4) .1 207 01 During the starting sequence in ASTERN direction. To check the valve. the exhaust valve will start to open while the cylinder is still being supplied with starting air. If an air flow is felt at the inlet side of the valve. When referring to this page. The non-return valve A is built into the oil inlet pipe to the actuator. Note ! The puncture valve is not standard on all engines. BM908-3.1 1. which will delay opening of the exhaust valve until the starting air sequence has finished.

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

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply

X

Engage turning gear
Shut off cooling water
Shut off fuel oil

X

Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

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

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply

X

Engage turning gear
Shut off cooling water

X

Shut off fuel oil

X

Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data 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

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply

X

Engage turning gear
Shut off cooling water
Shut off fuel oil

X

Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

Value Unit

When referring to this page, please quote Data 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

1

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. Turn the engine until the exhaust roller guide is at TDC.0 53 02 6. When referring to this page. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston. carry out the following procedure: 2. 4.0 206 03 1. See Procedure 908-1. Dismantle the hydraulic high-pressure pipe. If the cylinder is to operate with the exhaust valve closed. No further action is required. GN908-4. 4. Blank off the connection from the main oil pipe with a plug screw. BM908-7. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 Page 1 (3) . Either way. Tighten the lowermost nut on the tool to pull up the roller guide as far as possible. See Procedure 909-10. Dismantle the oil inlet pipe. Remove the inspection cover of the camshaft housing. BG908-5. Lift the relevant fuel pump roller guide. 5. Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position.1 203 01 5. Section 704. This can take place with the exhaust valve locked in either the open or the closed position. Engine trouble might require that a cylinder be taken out of action. See Volume I. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. 3. the air supply must remain connected to the air cylinder of the exhaust valve.2.

If the cylinder is to operate with the exhaust valve open.908-7 Exhaust Valve Special Running 7. BG908-6.0 13 04 8. DM908-6. 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. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 . Page 2 (3) When referring to this page. 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. Turn off the air to the exhaust valve.0 21 02 8. continue the procedure as follows: 7.

BM908-7. Note! The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine. BG908-5.Exhaust Valve 908-7 Special Running 9.0 206 11 11. 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. Mount the hydraulic high-pressure pipe. See Procedure 909-10. See Procedure 908-1. If the engine has been running with the exhaust valve open. Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. 12. remove the tool mounted in the air cylinder and mount the rotation indicator. Engage the fuel pump roller guide. Remove the tool.4. re-engage the exhaust valve gear as follows: 9. please quote Procedure M90807 Edition 0216 0$1% :'LHVHO$6 Page 3 (3) . Remove the plug screw and mount the oil inlet pipe. Re-connect the air supply to the air cylinder. After overhaul of the cylinder unit. 10. 13. When referring to this page.0 53 04 11.

.

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

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

please quote Plate P90861 Edition 0038 MAN B&W Diesel A/S Plate P90861-0038 Page 1 (2) .Tools When referring to this page.Exhaust Valve .

Plate P90861-0038 Item No. 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 . 010 Exhaust Valve . Item Description Support grinding machine* Note: * When ordering spare parts.Tools Item Description Item No.

Hydraulic Tools 0038 P90862 When referring to this page.Exhaust Valve . please quote Plate P90862 Edition 0038 MAN B&W Diesel A/S Page 1 (2) .Hydraulic Tools Plate P90862-0038 Exhaust Valve .

028 030 053 065 089 090 100 207 Exhaust Valve . 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.Hydraulic Tools Item Description Item No.Plate P90862-0038 Item No. please quote Plate P90862 Edition 0038 MAN B&W Diesel A/S . Item Description Hydraulic jack. complete Page 2 (2) When referring to this page.

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

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

Data Fuel System Shock Absorber Fuel Valve. Data Fuel Pump Fuel Pump Top Cover. Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide. Data Fuel Pump Top Cover Fuel Pump Barrel Assembly. Data Fuel Pump Puncture Valve Fuel Pump Shock Absorber. Data Fuel Pump Barrel Assembly Fuel Pump Suction Valve. Runni Fuel Pump Special Running Fuel Valve and Fuel Pump .Panel Fuel Valve .Tools Fuel Valve Nozzle . Data Fuel Valve Spindle Guide. Data Fuel Pump Roller Guide Fuel Pump Spec. Data Fuel Pump Cam Fuel Pump.Tools Fuel Valve .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.909 .Tools MAN B&W Diesel A/S . Data Fuel Pump Suction Valve Fuel Pump Puncture Valve. Data Fuel Pump Lead Fuel Pump Cam. Data Spindle Guide Fuel Oil High-Pressure Pipes.

Cleaning Tools Mounting Tools .90968 90974 90980 0001 0001 0002 Fuel Valve .Inspection Tools Fuel Valve Nozzle .Air Piston Seals MAN B&W Diesel A/S .

number of shims When referring to this page. Page 1 (2) .Fuel Pump Settings 109-1 Data SAFETY PRECAUTIONS Special Edition D10901 S35MC 109-1 Data 0056 Fuel Pump Settings X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.5 mm 12 pcs. D09-01 D09-05 D09-10 Description One shim alters pmax Nominal shim thickness Max. please quote Data D10901 Edition 0056 MAN B&W Diesel A/S Value Unit 2 bar 0.

g. Description 200 Hexagon head screZIRUWRSFRYHU When referring to this page. P90951 refers to chapter 909.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. please quote Data D10901 Edition 0056 MAN B&W Diesel A/S . Plate P90951 Page 2 (2) Item No.

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

909-1. it is possible to carry out the adjustment on the fuel cam disc. in obtaining good engine performance. Increase index for higher p i. Decrease index for lower p i.3 Fuel Pump Settings Adjustment 5. 5. If the required p max adjustment cannot be attained by inserting or removing shims.5 bar from the average value for all cylinders. Chapter 706. The mean indicated pressure should not deviate more than 0. Page 2 (2) When referring to this page. Contact MAN B&W Diesel for advice. Note! The mean indicated pressure is one of the most important parameters.3 239 05. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump index arm. please quote Procedure M90901 Edition 0239 0$1% :'LHVHO$6 . MIP adjustment: EN909-1. See Volume I.

please quote Data D10903 Edition 0046 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page.Fuel Pump Cam 109-3 Data SAFETY PRECAUTIONS 109-3 Special Edition D10903 Data 0046 Fuel S46MCC Pump Cam X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.

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. Plate P90651 P90951 Page 2 (2) Item No.g. please quote Data D10903 Edition 0046 MAN B&W Diesel A/S . e. P90951 refers to chapter 909. Description 44 45 Impact wrench for turning cam Measuring tool for fuel pump When referring to this page.

Calculate the fuel cam lead C (top lift) as: 5. C x2 fuel cam Make sure that the reversing mechanism is in AHEAD direction.2.0 56 01 Remount the suction valve and the puncture valve. Push down the measuring pin through the top cover. Note down the result for comparison with the testbed results and for future reference. 3. until it rests against the pump plunger. HM906-7.Fuel Pump Cam 909-3.2 and 909-8. For adjustment of the fuel cam lead. Note down the result as x1. Lowest position of pump plunger Main piston in TDC 3.1 1. 4. 1. JG909-2. see Procedure 909-3. please quote Procedure M90903 Edition 0228 0$1% :'LHVHO$6 Page 1 (3) . Note down the result as x2. To measure the fuel cam lead (top lift): Dismantle the suction valve and the puncture valve. Turn ahead until the main piston of the cylinder concerned is in TDC. Measure the distance x from the top of the measuring pin to the top cover.3.1 92 02 C = x1 – x2 (mm) 4. Again measure the distance x from the top of the measuring tool to the top cover.1 Checking Fuel Pump Cam S46MC-C 0228 Checking 909-3. Fuel cam lead: The lead C of the fuel cam is defined as the number of mm the plunger is lifted from its bottom position when the main piston is in TDC. See Procedures 909-7. ahead EN909-3. use a calliper to find the point. When referring to this page.1 228 00 2. x1 roller guide Turn the engine until the lowest point of the cam is found.

Chapter 706.3 1. If fitted. make sure that the pump has been relieved of pressure and that all oil has been drained off.3 Fuel Pump Cam Adjustment Adjustment 909-3. remove the plugs from the oil ducts (using.1. Before adjustment of fuel equipment. Page 2 (3) When referring to this page. Dismount the puncture valve and the suction valve from the fuel pump top cover. 2. 1.3 204 04 3. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. Insert three copper gaskets in each oil duct. adjustment of the fuel cam should not be necessary.1 236 03 Mount snap-on couplings in the oil ducts. 3.3 203 01 Note! Before dismantling any part of the fuel pump. Normally. 2. a screwdriver). BM909-1.909-3. and mount the measuring tool. please quote Procedure M90903 Edition 0228 0$1% :'LHVHO$6 . Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulic highpressure pump. GN909-3. see Volume I. GN909-3. for instance. See Procedure 909-3. but do not tighten them. Remove the inspection cover from the camshaft housing.

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

.

D09-18 D09-19 D09-20 Description Pump housing nuts.Fuel Pump 109-4 Data SAFETY PRECAUTIONS Special Edition D10904 S35MC 109-4 Data 0043 Fuel Pump X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref. tightening angle Pump housing When referring to this page. tightening torque Pump housing nuts. please quote Data D10904 Edition 0043 MAN B&W Diesel A/S Value Unit 350 Nm 108 ° 38 kg Page 1 (2) .

please quote Data D10904 Edition 0043 MAN B&W Diesel A/S . e.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. 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.g.

3.Fuel Pump 909-4. BM909-4. 2. Mount the lifting tool and lift the fuel pump housing away. Remove the nuts at the base of the fuel pump. Take care not to damage the threads of the studs.2 2. make sure that the pump has been relieved of pressure and that all oil has been drained off.2. 1. Remove the fuel oil inlet pipe between the fuel pump and the fuel oil inlet valve. See Procedure 909-5. Land the fuel pump on wooden planks. Discard the gaskets.2 Dismantling Fuel Pump S46MC-C 0221 Dismantling 909-4. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 1 (5) . Note! Before dismantling any part of the fuel pump. Note! BM909-4.2 210 03 D09-20 When referring to this page. Dismantle the fuel pump top cover/plunger barrel assembly.2 210 02 3.

please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S .909-4.3 Fuel Pump Overhaul Overhaul 909-4. Page 2 (5) When referring to this page.3 210 01 3.3 210 02 2. BM909-4.3 210 03 3. • Regulating guide. Tilt the fuel pump housing into a horizontal position on the wooden planks. If the bottom plate sticks. Remove the bottom plate from the fuel pump housing. BM909-4.3 1. 2. loosen it by screwing two M8x50 mm screws into the threaded holes of the bottom plate. 1. BM909-4. Dismantle the: • Fuel oil index arm.

Note! BM909-4.3 Overhaul 4. 4.4 121 11 BM909-4. 5. Dismantle and inspect the erosion plugs on both sides of the fuel pump housing. Warning! 6. the index pointer can have a different shape. Blow dry with compressed air. 6. Mount a new sealing ring in the pointer for the fuel oil index arm. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 3 (5) . replace the erosion plugs.3 210 06 7. If heavily eroded. Clean all inside surfaces of the fuel pump housing. see the sketch.Fuel Pump 909-4.3 210 04 Always use eye protection when working with compressed air. Depending on engine type. Clean all the parts in diesel oil or kerosene. HC909-3. Soak the sealing ring in lubricating oil before mounting. When referring to this page.

BM909-4. Mount the fuel oil index arm.3 Fuel Pump Overhaul 9.909-4. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S . • The sliding surfaces of all the parts of the regulating system. – Fuel index arm.3 210 09 • The teeth of the: – Regulating guide. Page 4 (5) When referring to this page. BM909-4. 9. 10.3 210 10 11. Mount the fuel oil index pointer. BM909-4. 10. Mount the bottom plate on the fuel pump housing. 8. ensuring that the scratch mark on the regulating guide is aligned with the scratch mark on the fuel oil index arm.3 210 02 11. 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. Lubricate the following with molybdenum disulphide grease (MoS 2): • All internal surfaces of the fuel pump housing. Mount the regulating guide in the fuel pump housing.

Mount and tighten the nuts at the base of the fuel pump housing. Lower the fuel pump housing on to the pump base. not both. Mount the fuel oil inlet pipe between the fuel pump and the fuel inlet valve. Mount the fuel pump top cover/plunger-barrel assembly. BM909-4. Note! Before mounting the fuel pump housing.4 Mounting Mounting 909-4.4 1.Fuel Pump 909-4. please quote Procedure M90904 Edition 0221 MAN B&W Diesel A/S Page 5 (5) . make sure that all sliding faces and threads are cleaned and lubricated with molybdenum disulphide grease (MoS 2). When referring to this page. D09-19 D09-18 D09-20 See Procedure 913-11. 2. Remove the lifting tool. 1. taking care not to damage the threads of the studs. BM909-4.4 210 02 3. See Data.4.2 210 03 Note! 2. See Procedure 909-5. Only use either the tightening angle or the tightening torque.

.

tightening torque Pump barrel/top cover. D09-23 D09-24 D09-25 D09-26 D09-27 D09-28 Description Top cover studs.Fuel Pump Top Cover 109-5 Data SAFETY PRECAUTIONS Special Edition D10905 S35MC 109-5 Data 0046 Fuel Pump Top Cover X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref. tightening torque Outlet seat. screwing-in torque Top cover nuts. max. 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) .grinding diameter Top cover Plunger/barrel assembly + top cover When referring to this page.

P90951 refers to chapter 909. 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. Plate P90951 P90951 P90951 P90951 Page 2 (2) Item No.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. please quote Data D10905 Edition 0046 MAN B&W Diesel A/S .

1. Remove the top cover fixing nuts. GN909-5. as well as the two screws in the top cover.2 205 02 Release the link for the regulating drive and pull out the toothed rack as far as possible.2 Dismantling Fuel Pump Top Cover S46MC-C 0222 Dismantling 909-5. Loosen the top cover by means of the two dismantling screws from the tool panel. Dismount the drain oil pipe from the top cover and the air pipe connection to the puncture valve. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 1 (7) . 2. 2. GN909-5.3 205 01 3. Dismount the fuel index pointer. Close the oil inlet valve to the fuel oil pump and drain the pump.2 208 01 Dismount the puncture valve from the top cover. When referring to this page. See Procedure 909-8.2 1. 3. Dismount the suction valve by means of the extractor tool.Fuel Pump Top Cover 909-5. Dismount the high pressure pipes. See Procedure 909-14. GN909-1.

2 205 06 6. lock the centre screw in this position with the stop ring. To do this it may be necessary to move the toothed rack and the centre screw of the tool in relation to each other.3. Page 2 (7) When referring to this page.2 208 04 When the plunger has been lifted clear of the roller guide and regulating guide. Remove the shims and tag them for reinstallation. See Procedure 909-6. GN909-5. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 . Lift the top cover and barrel with plunger out of the fuel pump housing as one unit. Dismount the lifting tool. 5. Screw the centre screw of the tool into the pump plunger. Press the plunger to the top of the barrel and remove the barrel/plunger assembly from the top cover. 4. GN909-5. D09-28 6. Set up the pump unit in a bench vice provided with ‘soft’ jaws. Take care that the plunger does not slide out of the barrel. Mount the lifting tool on the fuel pump top cover. or overhaul it on board.2 205 05 Send the barrel/plunger assembly to an MAN B&W authorised workshop for overhaul. 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.Fuel Pump Top Cover 909-5. GN909-5. Ensure that the stop ring on the centre screw is loose. 5.2 Dismantling 4.

1. For the max. Warning! Always use eye protection when working with compressed air. e. 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.3 205 01 During the milling. add drilling oil emulsion liberally. GN909-5.3 1. GN909-5. a tap wrench. Remove and discard the sealing rings.Fuel Pump Top Cover 909-5. 2.g. and blow dry with compressed air. while tightening the guide screw lightly to provide a suitable pressure between miller and seat. Turn the miller by means of. blow out the Vaseline/grease from the oil ducts by means of compressed air.3 205 02 Clean the top cover with diesel oil. see Data D09-26.3 Overhaul Overhaul 909-5. After completing the milling. When referring to this page. GREASE During the work the miller is guided by the guide screwed into the thread for the highpressure pipe. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 3 (7) . milling/grinding diameter of the seat. 2.

insert the O-ring between the backup rings in the ring groove. Mount the O-ring which seals between top cover/fuel pump housing. Tighten the screws. Page 4 (7) When referring to this page. 4. guided by the guide pin.3 Fuel Pump Top Cover Overhaul 3. 3. 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. GN909-5. GN909-5. see Data D09-25. Mount the sealing rings in the ring grooves.909-5. Sealing between the top cover and pump barrel is provided by two back-up rings and an O-ring in between. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 .2 205 06 4. Sealing between the top cover and the fuel pump housing is provided by an O-ring. into the groove. Mount the overhauled top cover on top of the pump barrel.3 205 03 Prepare the back-up rings by twisting the rings in the hand. D09-25 Finally.

2. Carefully lower the assembly into the pump housing (taking special care not to damage the O-ring and back-up rings on the barrel). Mount the tool on the barrel/plunger and top-cover assembly. Mount the supplied measuring pin on the centre screw of the lifting tool as shown in the sketch.4 208 01 Keep the stop ring tightened in this position until the plunger has been correctly mounted. Lower the top cover on to the pump housing. and attach the plunger to 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. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 5 (7) . Note! The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. GN909-5. Pull the regulating toothed rack out as far as possible. Tighten the tool to the top cover by means of the two screws. GN909-5. Remove the tool from the pump housing and remove the measuring pin from the centre screw. Loosen the stop ring on the centre screw.4 Mounting Mounting 909-5. The tool is now firmly attached to the assembly. When referring to this page.4 1.4 208 02 Pull the plunger as high up in the barrel as possible. 2.Fuel Pump Top Cover 909-5. Lock the centre screw in this position with the stop ring. enabling the correct position to be obtained during mounting. Adjust the top cover so that the guide pin enters the hole in the pump housing. 1.

If a new barrel assembly is mounted.4 Fuel Pump Top Cover Mounting 3. (If the barrel assembly is the same as that dismounted. 4.4 208 024 5. GN909-5.909-5. insert the same number of shims as were removed). Insert shims between the pump housing and the top cover. Page 6 (7) When referring to this page. insert the number of shims specified in the test bed report. causing the plunger foot to interlock with the bayonet joint of the roller guide.3 205 02 5. 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. GN909-1. Check through the inspection cover on the fuel pump base and by pulling the centre screw of the tool. If necessary. 6. thus lifting the top cover to provide space for inserting shims. Screw the two dismantling screws from the tool panel into the threaded holes of the top cover. 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. 3. as when measuring. GN909-5. Press the plunger down into contact with the thrust piece of the roller guide. Check that the stop ring of the centre screw is in full contact with the flange of the tool.4 208 03 When the plunger is in place. press the regulating toothed bar in. 4. Unscrew the centre screw from the plunger and remove the tool from the top cover. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 .

Chapter 706.4 208 09 For fuel pump settings. When referring to this page. please quote Procedure M90905 Edition 0222 0$1% :'LHVHO$6 Page 7 (7) . Turn the engine one complete revolution. Mount the fuel index pointer Mount the link for the regulating drive. GN909-1. GN909-5. and check that the top cover does not lift. and press down the top cover. Open the fuel oil inlet. the plunger is not correctly mounted and must be remounted. Mount the top cover fastening nuts. Replace the dismantling screws with the two screws for mounting the lifting tool. Mount the suction valve and the puncture valve in the top cover. and tighten them diagonally. OPERATION. tighten them. 9.Fuel Pump Top Cover 909-5. See Data D09-23. See Data D09-24. 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. If any of the fuel pump top cover studs have come loose. see Procedure 9091 and Volume I. See Procedure 909-14.4 Mounting 7. See Procedure 909-8.3 205 03 8. If the top cover lifts. 7.

.

D09-29 Description Barrel assembly When referring to this page.Fuel Pump Barrel Assembly 109-6 Data SAFETY PRECAUTIONS Special Edition D10906 S35MC 109-6 Data 0040 Fuel Pump Barrel Assembly X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear Shut off cooling water X Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref. please quote Data D10906 Edition 0040 MAN B&W Diesel A/S Value Unit 9 kg Page 1 (2) .

P90951 refers to chapter 909.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. Description When referring to this page.g. Plate Page 2 (2) Item No. e. please quote Data D10906 Edition 0040 MAN B&W Diesel A/S .

Chapter 706. Remove and discard the O-rings. Finally. Note! It is recommended not to remove the plunger from the barrel. position the O-ring in the ring groove.2.3 218 03 3. EN909-6. For evaluation of pump barrel/plunger. When referring to this page. please quote Procedure M90906 Edition 0218 0$1% :'LHVHO$6 Page 1 (1) .4 (fuel pump top cover). ‘Screw’ the back-up ring on to the barrel. See Procedure 909-5.3 205 01 Clean the outside of the barrel. see Volume I. in such a way that the diameter of the ring becomes smaller than the diameter of the barrel.. Remove the top cover with the barrel/plunger assembly from the fuel pump housing. Note! Take care that the plunger does not slide out of the barrel. GN909-6. and dismantle the barrel/plunger assembly from the top cover. 3. D09-29 2. If the barrel assembly is not to be mounted immediately. The sealing ring on the pump barrel consists of an O-ring and a back-up ring. For mounting the fuel pump barrel assembly.3 1.Fuel Pump Barrel Assembly 909-6. The O-ring must be above the back-up ring. Prepare the back-up ring by twisting the ring in the hand. into the groove. as this may cause scratches to the plunger.3 Overhaul Fuel Pump Barrel Assembly S46MC-C 0218 Overhaul 909-6. see Procedure 909-5. OPERATION. 1. 4. cover all openings with plastic to prevent dirt from entering the barrel assembly during storage.

.

Fuel Pump Suction Valve

109-7

Data
SAFETY PRECAUTIONS
Special Edition
D10907
S42MC
109-7
Data 0027

Fuel Pump Suction Valve

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply
Engage turning gear
Shut off cooling water

X

Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

Description

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

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply
Engage turning gear
Shut off cooling water

X

Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref.

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

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply

X

Engage turning gear
Shut off cooling water

X

Shut off fuel oil

X

Shut off lubricating oil
Lock turbocharger rotors

Data

When referring to this page, please quote Data 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

1

90915-xxx 265

Wear ring

1

90915-xxx 277

Sealing ring

1

90915-xxx 289

Gasket

1

90915-xxx 290

Locking plate

1

90915-xxx

Sealing ring

1

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)

.

max. diameter Fuel valve When referring to this page. D09-40 D09-41 D09-42 D09-43 Description Fuel valve opening pressure Fuel valve tightening torque Inlet seat.Fuel Valve 109-11 Data SAFETY PRECAUTIONS Special Edition D10911 109-11 Data 0051 Fuel S35MC Valve X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear Shut off cooling water X Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref.5 bar Nm mm kg Page 1 (2) . please quote Data D10911 Edition 0051 MAN B&W Diesel A/S Value Unit 330-380 20 10 3.

complete When referring to this page. 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. e.g.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. please quote Data D10911 Edition 0051 MAN B&W Diesel A/S . Plate P90151 P90951 P90951 P90951 P90961 Page 2 (2) Item No. P90951 refers to chapter 909.

see the supplier’s instructions. Mount the connecting piece and the oil pipe between the pressure testing pump and the fuel valve.1 Checking Fuel Valve S35MC 0236 Checking 909-11.3 and 909-12. See Procedure 909-11. D09-41 All fuel valves must be function-tested before being mounted in the cylinder cover. 1. Use only hydraulic oil (rust-preventing) with a viscosity of between 7 and 10 cSt at 50°C. For operation of the pressure testing pump. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 1 (11) . 2. Place the fuel valve in the test rig and mount the nuts.1 1.3 101 02 Note that the high-pressure pump should be periodically checked in accordance with the supplier’s instructions. it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. In order to obtain reliable results during testing of the fuel valves. 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. Pressure testing pump If an air supply of 10 bar is not available. cleaned. The fuel valves must be given the utmost attention and care. DM909-6.Fuel Valve 909-11. 2. Tighten the nuts to the torque stated in Data. use a connecting piece with a valve. See Chapter 900-1. all fuel valves that are dismantled from the engine must be disassembled. as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. When referring to this page. If the pressure testing pump has no built-in outlet valve. the opening pressure value measured might be considerably lower than specified.3. working air of seven bar can be used. inspected and re-assembled before testing.1 204 01 If the engine gives normal performance in accordance with diagrams and exhaust temperatures. GN909-11.

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

See Procedure 909-12. BM909-11.1 236 06 D. 5. All of these conditions involve the risk of seizure between the cut-off slide and the nozzle. Opening pressure A. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 3 (11) . Atomization test Note! The reason is that the atomization test may damage the valve because it makes the needle oscillate. D09-40 6.1 Checking 5. The pressure must correspond to the pressure stated in Data D09-40. with a small lift at a very high frequency. Increase the oil pressure until oil is admitted through the nozzle holes.Fuel Valve 909-11. When referring to this page. if necessary. as this may damage the cut-off slide and nozzle. BM909-11. or add a special thin disc. Acceptance criteria: Check the opening pressure on the pressure gauge. the cause may be that a wrong type of spring is used – replace the spring in the spindle guide. If the opening pressure is lower than specified in D09-40. Cause of fault: If the opening pressure is higher than specified in D09-40. Procedure: The control handle is to be in the OPEN position.3. replace the complete spindle guide. in combination with the poor lubricity of the test oil. the cause may be that the spring has sagged – replace the spring. B. 6. C.1 236 05 Do NOT attempt to carry out an atomization test on slide type fuel valves. The high pressure drop across the cut-off edge and the high contact pressure between slide and fuel nozzle. Objective: To check the opening pressure. increase the risk of seizures between cut-off slide and nozzle.

Sealing test and sliding function BM909-11.1 236 07 A.1 Fuel Valve Checking 7. C. the pressure testing procedure of the fuel valve must be repeated from step 3.1 Sealing test If oil flows out of the nozzle holes. Note! Special thin discs are available as spares. Acceptance criteria: Oil must not flow from the nozzle holes.3. Slowly increase the oil pressure to about 50 bar below the opening pressure. 7. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . Repeat the procedure two or three times. See Procedure 909-12. Page 4 (11) When referring to this page. Cause of fault: D. after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). The pressure drops relatively slowly to about 15 bar. Examine and/or replace the spindle guide. D. Maintain the built-up pressure by moving the control handle into the CLOSED position. Objective: To check the needle valve seat for tightness and the slide for correct closing. the cause is either: • Defective spindle guide at needle seat.909-11. Procedure: The control handle must be in the OPEN position. B. Note! Oil flows out of the leak oil outlet when the fuel valve is full of oil. If a spring or a disc has been changed. or a sticking spindle.

3. See Procedure 909-12. Note! There will always be an oil flow from the leak oil outlet when the fuel valve is full of oil.1 Checking • Too quick pressure drop: – the clearances of the movable parts. See Procedure 909-12. after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). If a quick pressure drop from 15 to 0 bar cannot be registered: • The valve slide is sticking. D.3. Examine and/or replace the spindle guide. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 5 (11) . or – the seat between the spindle guide and the fuel valve head is damaged. replace if necessary. When referring to this page. disassemble and examine the spindle guide. or • the vent hole in the vent slide is blocked. inside the spindle guide are too large. If so.Fuel Valve 909-11.2 Sliding function The pressure drops relatively slowly to about 15 bar.

Procedure: The control handle is to be in the OPEN position. Acceptance criteria: Close the leak oil outlet with a gasket and plug screw. 8. Objective: To ensure that the leak oil (circulation oil) remains in the closed system. Move the control handle to the CLOSED position. C. The built-up pressure of about 100 bar should be maintained. Build up a working pressure of about max. Increase the working pressure to about 100 bar. 10 bar until oil flows out of the leak oil outlet. Cause of fault: If oil leaks out at the union nut. Pressure test.1 Fuel Valve Checking 8. BG909-6. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S . B. the O-ring inside the fuel valve head is defective.909-11. Page 6 (11) When referring to this page.3 66 07 D. and must be replaced. O-ring sealings A.

BM909-11. BM909-11. Disconnect the return oil pipe from the fuel valve. When referring to this page. If the valve is sticking. 2. Unscrew the union nut by means of the hook spanner and take the union nut with protective hose up along the pipe. Remove the nuts and the tubular spacers.2 209 02 3. Unscrew the union nipple at both ends of the pipe (fuel valve and fuel pump). 2. If the valve is not to be overhauled immediately. Remove the valve from the engine.2 Dismantling Dismantling 909-11. Close the fuel oil inlet and outlet valves. the valve should be placed immersed in diesel oil until overhauling. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 7 (11) . 1. Lift the valve.2 236 03 3. use the fuel valve dismantling tool to pull the fuel valve clear of the top cover. BG901-2.Fuel Valve 909-11.2 1.1 97 01 Remove the high-pressure pipe. and drain the high-pressure pipe and the fuel valve.

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

wash the parts in gas oil and blow clean by means of compressed air to remove any remains of the grinding compound. the spindle guide may be overhauled on board. This grinding must only be carried out manually. D09-42 If necessary. BM909-11. After the grinding. the milling tool can be used.3 Overhaul 3. An ample supply of cutting emulsion must be used. When referring to this page. see Data. 3. the milling tool is turned by hand. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 9 (11) . Note! Take care not to exceed the maximum diameter of the seat. including the fuel nozzle. Normally. 500).1 66 02 In the event of more serious damage to the seating surface for the high-pressure pipe in the valve head. See Procedure 909-12. Carefully clean and examine all surfaces of the fuel valve housing and the fuel valve head.3 236 04 4.Fuel Valve 909-11. 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. The complete spindle guide. BG909-6.3. 100 r/min). grind the seating surfaces by means of the grinding mandrels supplied and a fine-grain abrasive (such as Carborundum No. should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible. 4.

Mount the fuel valve head on the fuel valve housing. and check that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts. the fuel valve must be tested in the test rig. When mounting the valve head. BG909-6. When referring to this page.1. make sure that the guide pin between valve housing and valve head is intact. 5. It must not be possible to turn the nozzle. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. in the fuel valve housing. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S .3 236 05 Mount a new O-ring in the lowermost groove of the fuel valve head. and turn the nozzle until the spindle guide engages correctly with the guide pin. See Procedure 909-11. Fit the uppermost groove of the valve head with a new O-ring. Carefully slide the spindle guide down into the valve holder. Mount the complete spindle guide. This can be ascertained by attempting to turn the nozzle after mounting. Mount a new O-ring on the spindle guide and lubricate it with MoS 2. Note! Make sure that the fuel nozzle and spindle guide engage correctly with the guide pin in the fuel valve housing. Check that distance A corresponds to the measurement taken before the valve is disassembled.3 Fuel Valve Overhaul 5. BM909-11.909-11.1 66 06 After overhaul. including the fuel nozzle. and tighten the screws. If the fuel valve is not to be mounted in the engine immediately after the overhaul. Page 10 (11) 7. 6. 6.

mount a new O-ring on the valve head. Tighten the nuts as stated in Data.1.1 97 04 Reconnect the return oil pipe to the fuel valve. 1. Note! BM901-2. Mount the valve in position in the cylinder cover. 3. Turn on the fuel oil supply. If not already done. (For reconditioning of valve bore in cylinder cover. see Procedure 909-11. All fuel valves must be function-tested before being mounted in the cylinder cover.4 236 01 Lubricate the valve with copper grease. Before mounting the fuel valve. Mount the tubular spacers and the nuts. 2. BM909-11. must be eliminated. thoroughly clean the valve bore in the cylinder cover and check the seating in the bore for marks which. See Procedure 909-14. BM901-2. if any. Mount a new O-ring in the groove on the valve housing. When referring to this page.Fuel Valve 909-11. please quote Procedure M90911 Edition 0236 MAN B&W Diesel A/S Page 11 (11) .3).1 97 05 3.4. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting.4 1.4 Mounting Mounting 909-11. D09-41 Mount the fuel oil high-pressure pipe and tighten. see Procedure 901-1. 2. using the crow foot wrench and a torque wrench.

.

please quote Data D10912 Edition 0039 MAN B&W Diesel A/S Value Unit Page 1 (2) .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.

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. 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. please quote Data D10912 Edition 0039 MAN B&W Diesel A/S . complete Fuel Valve Nozzle – Tools When referring to this page. P90951 refers to chapter 909.g.

However. therefore only one guide should be disassembled at a time. and use the spindle guide dismantling tool as shown to remove the non-return valve from the spindle guide. 2. both terms will be used to describe the part in this procedure. and use a brass mandrel and a hammer to remove the thrust piece from the valve housing. Place the spindle guide/non-return valve in a bench vice provided with “soft” jaws. BM909-12. 2.3 222 04 3. When referring to this page. Note! The spindle guide and the non-return valve have been integrated into one unit. BG909-6. BM909-12. The individual parts of the spindle guide are not interchangeable.3 Overhaul Spindle Guide/Non-return Valve S35MC 0223 Overhaul 909-12. Place the non-return valve part of the spindle guide in a bench vice provided with “soft” jaws. 1.3 1. Turn the nut to pull the fuel nozzle off the spindle guide.2 66 01 Extreme care and accuracy should be exercised when carrying out this operation. except the springs and the fuel nozzle are matched parts and may not be replaced individually.Spindle Guide/Non-return Valve 909-12. Clean the outside of the spindle guide in pure gas oil or kerosene. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S Page 1 (5) . All parts of the spindle guide/non-return valve.3 223 02 Note! 3. Mount the pulling tool around the fuel nozzle on the spindle guide.

MA909-6. During the examination. lint-free cloth and examine them through an 8-10 times enlargement magnifying glass and an inspection lamp. The sliding surface must not be damaged. 4.909-12. Remove any deposits or very fine scratches by placing the spindle and vent slide in a lathe. BM909-12-3 223 04 5. as shown. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S . and blow clean with compressed air. 5.3 223 05 The sliding surface of the cut-off slide may only be polished VERY carefully. pay special attention to the seating surfaces and sliding surfaces of the parts. Use also a little oil for the polishing (a coarser polishing linen must absolutely not be used). Page 2 (5) When referring to this page.2 111 05 6. Clean all parts again in kerosene or ‘Electrocleaner’. 6. and polishing it with a very fine conventional polishing linen ‘grade 360’. Place all the parts on a clean. Note! BM909-12.3 Spindle Guide/Non-return Valve Overhaul 4. Clean all the parts of the spindle guide and the non-return valve in gas oil. and blow dry with compressed air.

If the test pin is able to enter just one of the holes. Then test the spray holes with the test pin. When referring to this page. using gas oil and the special drills supplied. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. 7.3 Overhaul 7. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S Page 3 (5) . Clean the fuel nozzle with kerosene and wipe dry with a clean cloth. the cut-off slide must be able to move freely inside the nozzle. Note! It is recommended that the fuel nozzle is changed whenever the spindle guide is being overhauled. Check the fuel nozzle before mounting on the spindle guide. 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. BM909-12. the fuel nozzle must be discarded.Spindle Guide/Non-return Valve 909-12. Clean the spray holes.3 222 07 This also applies to nozzles with oval holes (can be ascertained with a magnifying glass).

Page 4 (5) When referring to this page. 12. 9. BM909-12. 8. 11. Place the lower part of the spindle guide housing in a bench vice provided with “soft” jaws.e. BM909-12. After polishing. Place the housing of the non-return valve in a bench vice provided with “soft” jaws.3 223 11 11. the seat on slide valve/spindle. 10. 10.3 223 10 Mount the spindle and the spring inside the housing of the spindle guide using the spindle guide dismantling tool and a hammer.3 223 08 Insert the non-return valve spindle and the spring in the housing. clean the parts again and re-check the seat on thrust piece/spindle. Mount a new O-ring on the spindle guide/ non-return valve. the complete spindle guide must be discarded. If the seats are not in order.3 Spindle Guide/Non-return Valve Overhaul 8. Use an inspection lamp and an 8-10 times enlargement magnifying glass. please quote Procedure M90912 Edition 0223 MAN B&W Diesel A/S . Lubricate the sliding surfaces of all parts with Molybdenum Disulphide (MoS 2). Place the thrust piece at the end of the housing.909-12. See Procedure 913-11. and the seat on spindle/guide. i. if there are pressing-in marks or similar on the seats. Carefully tap the thrust piece into the housing with a lead hammer. BM909-12.

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

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Fuel Oil High-Pressure Pipe 109-14 Data SAFETY PRECAUTIONS Special Edition D10914 S35MC 109-14 Data 0056 Fuel Oil High-Pressure Pipe X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear Shut off cooling water X Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref. 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) . D09-47 D09-52 Description Fuel oil high-pressure pipe.

e.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. Description 116 165 Crowfoot wrench head Grinding mandrel for valve head When referring to this page.g. Plate P90951 P90951 Page 2 (2) Item No. please quote Data D10914 Edition 0056 MAN B&W Diesel A/S . P90951 refers to chapter 909.

Unscrew the union nipple from the fuel valve. 4. See Procedure 909-14.2 211 04 4. Lift the pipe ends clear of the fuel valve/fuel pump. When referring to this page. GN909-14. High-Pressure Pipe with Double Pipe 1.2 Dismantling Fuel Oil High-Pressure Pipe S35MC 0235 Dismantling 909-14. D09-52 BM909-14.2 211 02 2. Close the fuel oil inlet and outlet valves. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 Page 1 (4) .2 2.3. BM909-14.2 210 03 The overhaul should preferably take place immediately after the high-pressure pipe has been dismantled. Unscrew the union nipple from the fuel pump. Note! It is recommended always to overhaul the high-pressure pipe before remounting it on the engine. 3. and remove the high-pressure pipe from the engine. 3.Fuel Oil High-Pressure Pipe 909-14.

3 Fuel Oil High-Pressure Pipe Overhaul Overhaul 909-14.1 77 01 1.3 223 03 After completing the milling. Remove the spring ring from the two-part sleeve.3 1. If the pipe ends are still not in order. 3. carefully clean the high-pressure pipe. 3. KN909-14. Turn the upper tightening ring (A) until the miller presses against the pipe end. a tap wrench while lightly tightening the upper tightening ring (A) to provide a suitable pressure between the miller and the pipe end. Whenever the fuel oil high-pressure system has been dismantled.909-14. grind-away The pipe ends may only be ground until the ground surface is flush with the bottom of the groove. Page 2 (4) When referring to this page.1 77 03 Turn the miller with. Fasten the pipe in a vice with soft jaws. KB909-7. Remove the sleeve. Note! 2. it is necessary. Max. On both pipe ends a small groove has been ground to indicate the maximum allowable grinding of the pipe ends. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 . before remounting the high-pressure pipes. and blow through the bore with compressed air. to carefully inspect the tapered contact surfaces of the pipe ends. add drilling oil emulsion liberally. for instance. proceed as follows: KB909-7. 2. If the pipe ends require reconditioning. During the milling process. the pipe must be discarded. Lift up the union nut. together with their seats in fuel valves and fuel pump top cover. Mount the miller on the pipe end. The two pipe ends are of different designs – see sketch.

4.1 77 04 Mount the two-part sleeve and lock the sleeve with the spring ring. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 Page 3 (4) .3 Overhaul 4. Ensure that all parts are completely clean before mounting the high-pressure pipe. When referring to this page. Remove and discard both the internal and external O-rings. KB909-7.Fuel Oil High-Pressure Pipe 909-14. Mount new O-rings.

4 211 04 4. GN909-14.4 Mounting Mounting 909-14. 5. Ensure that the fuel valve is fitted with a new O-ring. Lubricate the thread on the union nipple with a heat resistant grease. 6. please quote Procedure M90914 Edition 0235 0$1% :'LHVHO$6 . BM909-14. Mount the high-pressure pipe between the fuel valve and the fuel pump.4 210 05 D09-47 Page 4 (4) When referring to this page.4 211 03 3. Lubricate the thread of the fuel valve with a heat resistant grease. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel pump to the torque stated in Data. re-mount the return oil pipe on the fuel valve. BM909-14. as the threads of the union nipples. 5. If dismantled. Note! 4. Open the fuel oil inlet and outlet valves.Fuel Oil High-Pressure Pipe 909-14. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel valve to the torque stated in Data. fuel valve or fuel pump top cover might otherwise be damaged. D09-52 1. by hand. 2. Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position.4 3. D09-47 The nipples must be screwed by hand. Screw the union nipples onto the fuel valve and into the fuel pump top cover. Ensure that the union nipple at the fuel pump end of the high-pressure pipe is fitted with a new O-ring.

please quote Data D10915 Edition 0047 MAN B&W Diesel A/S Value Unit 1.9 .4.Fuel Pump Roller Guide 109-15 Data SAFETY PRECAUTIONS Special Edition D10915 S35MC 109-15 Data 0047 Fuel Pump Roller Guide X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil X Shut off lubricating oil Lock turbocharger rotors Data Ref.5 23 28 mm mm mm kg kg Page 1 (2) .4.8 . clearance Fuel pump roller guide Pump base When referring to this page. max.2 0. D09-54 D09-55 D09-57 D09-61 D09-62 Description Clearance A Clearance B Roller/bushing/shaft pin.1 1.

Description 82 Lifting tool for fuel pump roller guide When referring to this page.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. P90951 refers to chapter 909. Plate P90951 Page 2 (2) Item No. please quote Data D10915 Edition 0047 MAN B&W Diesel A/S .g.

When referring to this page.1 2. Also inspect the surface of the roller for possible damage marks. 4. using the following procedure: 1. 4. move the roller guide to the AHEAD position. Carry out the same check in the ASTERN position. Make sure that there are no traces of bearing metal left in the roller guide housing.Fuel Pump Roller Guide 909-15. seizures or scratches. See Procedure 909-16. 2.1 Checking Fuel Pump Roller Guide S35MC 0227 Checking 909-15. 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. Lift the fuel pump roller guide. See Procedure 909-16. Using the telegraph.1 207 05 3. Check that the reversing link is fully tilted over in AHEAD position. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 1 (12) . Turn the roller by hand to check that it can move freely and without unnecessary resistance or “hard” points. BM909-15. Roller guide mounted in engine The fuel pump roller guide can be partially checked while mounted on the engine. BM909-15. Lower the roller guide onto the fuel cam again. Remove the cover on the camshaft housing to inspect the fuel pump roller guide.1 207 03 Turn the engine to provide the maximum space between the roller guide and the cam disc.

7.2. 7. BM909-15. Check the surface of the roller and the sliding surfaces of the roller guide. Turn the roller guide upside down and land it in a vertical position on a couple of planks. with the roller hanging freely. and measure any ovalness. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . 6.1 Fuel Pump Roller Guide Checking 5.909-15. BM909-15. See Procedure 909-15.1 207 07 Measure the clearance in the slide bearing by placing a dial gauge against the roller and lifting the roller as much as the clearance permits. 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: 5.1 207 08 D09-57 Page 2 (12) When referring to this page. Dismount the roller guide from the engine.

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

BM909-15.2 Fuel Pump Roller Guide Dismantling 3.2 207 03 4. Lift the spring out of the roller guide. take care not to damage the threads on the studs. Loosen and remove the nuts on the two short studs. 3.2 207 04 4. Then loosen the nuts on the two long threaded studs successively until the roller guide spring is relieved. Note! When lifting the fuel pump housing. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . BM909-15.909-15. Loosen and remove the screws from the sealing cap on top of the roller guide inside the pump base. Page 4 (12) When referring to this page. Remove the nuts from the two long threaded studs and lift away the fuel pump housing. Mount the lifting tool on the fuel pump studs and hook the engine room crane on to the lifting tool.

BM909-15.2 207 06 7. Mount the roller guide lifting tool as follows: • Lift the lock plate of the tool up on the shaft of the tool. See Procedure 909-15. When lifting. D09-62 When lifting.2 207 05 • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint. • Lower the lock plate. take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing. • Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide. using the crane. When referring to this page. D09-61 Land the roller guide on wooden planks. BM909-15. Lift the roller guide out of the roller guide housing.1. 6.2 Dismantling 5. and lift away the pump base. Check the roller guide. Unscrew the two nuts from the pump base.Fuel Pump Roller Guide 909-15. 5. 6. thereby securing the foot in the locked position. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 5 (12) . take care that the bushing of the pump base slides against the neck of the roller guide without scratching. Remove the sealing cap from the roller guide.

• damage to the roller.1 207 07 For disassembling of the roller guide.909-15. • larger clearance than stated on the Data sheet. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . just clean and lubricate the roller guide before remounting it in the roller guide bushing. Note! BM909-15. • seizure marks on the slide surfaces. contact an MAN B&W authorized repair shop. Page 6 (12) When referring to this page. 1. It is recommended that the roller guide should ONLY be dismantled if • irregularities when turning the roller.3 1. Inspect and check the fuel pump roller guide. See Procedure 909-15.3 207 03 3. BM909-15.1. If no irregularities are found. 3.3 Fuel Pump Roller Guide Overhaul Overhaul 909-15. have been observed when checking the roller guide. D09-61 2.

See Data. Turn the camshaft so that the roller guide is lifted approx. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 7 (12) . Lubricate the roller guide with plenty of camshaft lubricating oil.4 207 01 2. D09-54 Connect working air to the air cylinder.4 Mounting Mounting 909-15. the same in both positions. check the clearance between the roller guide and the guide plate mounted in the roller guide bushing.1 mm. The clearance C between the roller guide and the guide plate must be the same at both ends +/– 0.0 50 15 D09-55 When referring to this page. 20 mm. D09-61 Make sure that the pin of the reversing link fits in the bracket of the reversing shaft. During mounting. After mounting the roller guide with the reversing link. 2. and mount it in the roller guide bushing. 1. AM909-8.4 1. and check that the reversing mechanism is working smoothly. take care not to scratch the sliding surfaces of the roller guide.Fuel Pump Roller Guide 909-15. 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. BM909-15. The clearances A and B must be approx. using the lifting tool.

0 50 17A Pull out the air cylinder with the flange as much as possible.0 50 18 5. 4. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . AM909-8. AM909-8. AM909-8. If adjustment is necessary. Repeat the clearance check once more. Tighten the nut on the shaft. Page 8 (12) When referring to this page.0 50 19 6. 4. place the reversing arm in ASTERN position and remove the four cap screws which tighten the flange for the air cylinder to the roller guide bushing.4 Fuel Pump Roller Guide Mounting 3.909-15. AM909-8. Release the lock nut on the shaft. 3. See Data. 5. 6. Mount the flange with the air cylinder on the roller guide bushing and tighten the four cap screws.0 50 17B Lock the screws with Loctite (EN243S) type: 242. Turn the shaft to obtain the distance between the air cylinder flange and the surface of the roller guide bushing.

Fuel Pump Roller Guide 909-15. replace the O-ring between the sealing bush and the bottom of the pump base. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 9 (12) .4 Mounting 7. and tighten the nuts.0 54 24 D09-62 BM909-15.4 207 08 8. BM909-8. 8. 7. Mount the pump base on the roller guide bushing. Before mounting the pump base on the roller bushing. When referring to this page.

Before mounting. AM909-80. 9. 11. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 . BM909-15. Replace the axial scraper ring in the bottom of the cap. Page 10 (12) When referring to this page. 10.4 Fuel Pump Roller Guide Mounting 9.0 31 15 Check that the O-ring and scraper ring are mounted correctly. See the sketch. Note! When mounting the scraper ring in the groove. See the sketch. Check that the O-ring and scraper ring are mounted correctly.909-15. AM909-8. and be careful not to cut the scraper ring on the edge of the ring groove when pressing it in. the new scraper ring must be heated in 100°C hot water or oil for at least five minutes. 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.4 207 09 Place the new O-ring in the ring holder. 10.0 31 16 11. fold the ring without making any sharp edges. Remove the scraper ring and O-ring from the ring holder.

Mount the sealing cap over the roller guide. BM909-15.2 207 14 14.4 Mounting 12. the ring holder and retaining flange.4 207 13 Land the spring on the roller guide inside the pump base. When referring to this page. Tighten the nuts on the screws. BM909-15. 13.4 207 12 14.Fuel Pump Roller Guide 909-15. After tightening. Tighten the sealing cap to the top of the roller guide. Mount a new O-ring in the groove on top of the roller guide and on the pump base. BM909-15. Assemble the sealing cap. 12. Lock the nuts with Loctite type EN243S. check that the holder can be moved. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 Page 11 (12) . Tighten the nuts. 13.

Page 12 (12) When referring to this page. Mount the top cover and barrel/plunger assembly. 15. please quote Procedure M90915 Edition 0227 0$1% :'LHVHO$6 .1.909-15. BM909-15.4 Fuel Pump Roller Guide Mounting 15.2 207 03 17. See Procedure 909-15.4. Check the movement of the reversing link.4. Mount the fuel pump housing. 16. BM909-15. See Procedure 909-4. See Procedure 909-5.1 207 05 16.

please quote Data D10916 Edition 0017 MAN B&W Diesel A/S Value Unit Page 1 (2) .Fuel Pump Special Running 109-16 Data SAFETY PRECAUTIONS Special Edition D10916 S35MC 109-16 Data 0017 Fuel Pump Special Running X Stopped engine X Block the starting mechanism X Shut off starting air supply X Engage turning gear Shut off cooling water X Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref. Description When referring to this page.

P90951 refers to chapter 909. e. Description 82 116 212 Lifting tool for fuel pump roller guide Crowfoot wrench head Extraction tool for suctions valve When referring to this page.g. Plate P90951 P90951 P90951 Page 2 (2) Item No.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. please quote Data D10916 Edition 0017 MAN B&W Diesel A/S .

AM909-1. Turn the engine until the fuel pump roller is at on the circular part of the cam. When referring to this page. BM909-16.0 207 02 Note! Screw a plug-screw into the control air pipe of the puncture valve. Remove the fuel oil high pressure pipes and the puncture valve from the fuel pump top cover. make sure that the pump has been relieved of pressure and that all oil has been drained off. proceed as follows: 2. Dismount the suction valve by means of the extractor tool. Engine trouble might require a cylinder to be taken out of action.Fuel Pump Special Running 909-16 Fuel Pump Special Running S35MC 0212 909-16 2. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 Page 1 (3) . 1. Section 704. 3. To disconnect the fuel pump of a single cylinder.1 76 04 3. Remove the inspection cover on the camshaft housing. See Volume I. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. 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. Before dismantling any part of the fuel pump.

7. Tighten the lowermost nut on the tool to pull the roller guide upwards as far as possible. 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. 5. See Volume I. Turn the uppermost nut to screw the spindle of the lifting tool into the fuel pump plunger. GN909-16 202 05 5. The engine can now operate on the remaining cylinders. BM909-160 207 06 6. Mount the lifting tool on the fuel pump top cover. GN909-16 202 04 6. Lock the tool in this position by means of the lock nut. Page 2 (3) When referring to this page. Section 704.909-16 4. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 . Fuel Pump Special Running 4.

10. Remove the cover on the camshaft housing. Turn the engine until the circular section of the fuel cam is positioned upwards.0 45 06 Mount the fuel oil high pressure pipes. Re-mount the suction valve and the puncture valve. When referring to this page. BG909-5. please quote Procedure M90916 Edition 0212 0$1% :'LHVHO$6 Page 3 (3) . 9. (See Procedure 909-14.0 207 08 Remove the plug screw from the control air pipe. Lower the roller guide on to the fuel cam in the reverse order to lifting and remove the lifting tool.Fuel Pump Special Running 909-16 8. BM909-16.4). Re-engagement of fuel pump Warning! Re-engagement of the fuel pump must only take place at engine standstill. Note! It is recommended always to mount new or overhauled suction and puncture valves. (See Procedure 909-8. 8. 10.4).

.

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.outside Grinding mandrel for holder . Item Description When referring to this page.inside Screw Extractor tool for suction valve Page 2 (2) 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 . please quote Plate P90951 Edition 0440 MAN B&W Diesel A/S .

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) .Tools Plate P90961-0037 Fuel Valve .

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

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

Plate P90961-0069 Item No. complete Cover Angle union Gasket Plug screw Hose When referring to this page. M42x2 Test rig. Item Description High-pressure pump Table Rig fuel oil valve High-pressure hose Connection piece.Tools Item Description Item No. 014 026 038 040 051 063 075 087 099 109 122 Page 2 (2) Fuel Valve . please quote Plate P90961 Edition 0069 MAN B&W Diesel A/S .

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

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

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

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

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

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

please quote Plate P90980 Edition 0002 MAN B&W Diesel A/S Plate P90980-0002 Page 1 (2) .Mounting Tools .Air Piston Seals When referring to this page.

Plate P90980-0002 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 .Air Piston Seals Item Description Item No. 018 020 031 043 055 067 Page 2 (2) Mounting Tools .

Data Air Cooler Element Non-Return Valve in Turbocharger.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.Lifting Tools MAN B&W Diesel A/S .910 . Data Water Mist Catcher Air Cooler .Lifting Tools Air Cooler . Data Auxilary Blower Turbocharger Turbine.Tools Travelling Trolley Air Cooler . Data Turbocharger Turbine Water Mist Catcher. Data Non Return Valve in Tubocharger Auxilary Blower.

MAN B&W Diesel A/S .

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 SAFETY PRECAUTIONS Special Data S35MC 0019 110-1 Standard Tools: See Section 913 Air Cooler Element X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear X Shut off cooling water 3 x 2000 kg Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref.

please quote Data D11001 Edition 0019 MAN B&W Diesel A/S . Description Qty See special instructions from air cooler element manufacturer.Air Cooler Element 110-1 Data Spare Parts Plate – Item No. Page 2 (2) When referring to this page.

please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S Page 1 (7) . 4. 1. BM910-1.1 1. the element must be dismantled and overhauled/ cleaned. 3. Chapter 706. For the day-to-day checking of the scavenge air cooler. When referring to this page. Visually inspect the air cooler element through the opening. 2. BM910-1. Remove the top cover of the air cooler. it is recommended to inspect the air cooler element as follows: 5. See Procedure 910-3.1 Checking Air Cooler Element 0215 Checking 910-1. see instruction book Volume I. 4.1 209 01 Compare these measurements with the testbed data. For further evaluation of the measurements.1 209 04 If the measurements indicate fouling of the air side of the air cooler element.Air Cooler Element 910-1. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler. clean the element using the spray pipe arrangement fitted above the air cooler element. See Procedure 910-3. See Procedure 910-2. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. If the measurements indicate fouling of the water side of the air cooler element. measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running.1 209 05 If the air side of the element is fouled. 5. BM910-1.

Close the cooling water inlet and outlet valves. BM910-1. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S .910-1. 1. Dismantle the screws and pull out the cooler element approx.2 209 03 3. 2. Open the drain cocks to drain off the cooling water. Page 2 (7) When referring to this page.2 209 02 2. Remove and discard the gaskets.2 Air Cooler Element Dismantling Dismantling 910-1. Dismount the cooling water inlet and outlet pipes from the front end cover. BM910-1. BM910-1.2 209 01 3. 10 cm using the dismantling screws.2 2.

Air Cooler Element 910-1. Pull out the air cooler element far enough to gain access to the aft end cover. 2-3 mm. Mount the two guide rails on the frame around the air cooler element. Attach a shackle to the lifting tool. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S Page 3 (7) . Pull out the air cooler element approx. Using the tackles lift the air cooler element away. Mount shackles on the lifting brackets on the aft end cover.2 215 06 6. Hook tackles on to the shackles. Mount the lifting tool on the front end cover. lift the air cooler element approx. Using the tackle. BM910-1. Note! BG910-1. take care not to damage the air cooler element.2 215 04 5. 6. BG910-1.2 215 05 During the lift. 5. 4. Land the element on a couple of wooden planks. half a metre. Hook a tackle on to the shackle.2 Dismantling 4. When referring to this page.

or a similar product. Maassluis. The time required depends on the frequency with which cleaning is carried out and on the chemical product used. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S . New York.2. Do not disconnect the compressed air supply to the exhaust valve. To ensure satisfactory spraying of the cleaning fluid.1 62 01 6. Cleaning the air side: 1. BM910-5. flush the cooler with clean water until the water in the sight glasses appears clean and pure.3 1. Holland 2. Remove the covers on the scavenge air receiver to let vapours escape. See Procedure 910-1. Continue the cleaning process for at least 30 minutes. DG910-5. 5. It is recommended to use one of the following cleaning fluids. 4. Page 4 (7) When referring to this page. Do not start cleaning until the engine has been at a standstill for about 30 minutes. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine.910-1. 3. produced by Vecom Int.1 63 02 3. produced by Drew Chemical Corp.3 Air Cooler Element Overhaul Overhaul 910-1.. 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..7 bar. Inspect the air cooler element by removing the cover of the scavenge air cooler housing. USA • Product: 80B. • Product: ACC 9. After cleaning. the circulating pump pressure must be at least 0.

3 207 04 7.4.2. roll the tube using the tube expander. In the event of leakages between a tube and the tube plate. 3. Dismantle the aft end cover of the air cooler element. BG910-1. When cleaning is complete. Clean and check the inside of the front end and aft end covers. In the event of a leaking tube. If necessary replace the corrosion blocks. Dismantle the air cooler element and remove it from the engine. the coating inside the covers is to be repaired with the original coating or a similar product. 6. Re-mount the air cooler element in the scavenge air cooler housing. GN910-1. plug both ends of the tube using a brass or copper plug. If damaged.3 215 02 3. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S Page 5 (7) . 5.2 49 06 Note! 4. Dismantle the front end cover of the air cooler element. Clean the water side of the cooler element (the inside of the tubes) using the cleaning brush mounted on a drilling machine. When referring to this page. 2. Cleaning the water side 1. mount new gaskets or packing paste and re-mount the front end and aft end covers of the air cooler element. See Procedure 910-1.3 Overhaul 2.Air Cooler Element 910-1. Flush the tubes with clean fresh water. BM910-5. 4. See Procedure 910-1.

4 215 03 3.4 215 02 Push the air cooler element fully into the air cooler housing. Clean the frame around the air cooler element and the contact surface of the front end cover. Page 6 (7) When referring to this page. Remove the guide rails from the air cooler housing.4 Air Cooler Element Mounting Mounting 910-1. BM910-1.4 1. Apply a thin layer of silicone paste to the frame around the air cooler element and the contact surface of the front end cover. 2. Push the air cooler element inwards approx. BG910-1. BG910-1. 2. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S . Remove the tackles and shackles from the aftmost lifting brackets. one metre. 1.2 215 06 3.910-1. Lift the air cooler element and land the aft end of the element on the guide rails mounted on the air cooler housing.

When referring to this page. BM910-1. Close the drain cocks and open the cooling water inlet and outlet valves. the shackle and the lifting bracket from the front end cover.4 209 06 6.Air Cooler Element 910-1. please quote Procedure M91001 Edition 0215 MAN B&W Diesel A/S Page 7 (7) . 5. BM910-1. Mount the cooling water inlet and outlet pipes on the front end cover.4 Mounting 4. Remove the tackle. Note! Remember to vent trapped air from the air cooler element.4 212 04 6.2 209 02 5. Mount and tighten all the screws of the front end cover. BG910-1. 4.

.

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 SAFETY PRECAUTIONS Special Data 0004 110-2 Standard Tools: See Section 913 Non-Return Valve X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Ref.

please quote Data D11002 Edition 0004 MAN B&W Diesel A/S . Page 2 (2) Description Qty When referring to this page.Non-Return Valve 110-2 Data Spare Parts Plate – Item No.

Note! Main Non-Return Valve 1.3 208 02 4. please quote Procedure M91002 Edition 0211 0$1% :'LHVHO$6 Page 1 (2) . it must be possible to move the valve flap by the light touch of a finger.3 Overhaul Non-Return Valve 0211 Overhaul 910-2. Lubricate the valve shaft and the slide bearings with molybdenum disulphide (MoS 2). This procedure includes both the main non-return valve and the non-return valve for the auxiliary blowers. 2. After the overhaul. Assemble the valve and re-mount it in the scavenge air cooler housing. Clean the valve shaft and the slide bearings inside the valve flaps. BM910-2. BM910-2. Remove the screws holding the valve flap. Both sets of non-return valves are accessed via the scavenge air receiver. The main non-return valve consists of four valve flaps located inside the scavenge air cooler housing.3 208 01 Access to the scavenge air receiver must not be attempted until the air in the receiver is clean. 2.3 208 03 3. When referring to this page. Remove the valve from the engine. Remove the spring pin from the valve shaft and knock the valve shaft out of the valve flap. 3.3 1. BM910-2.Non-Return Valve 910-2.

Remove the valve from the engine.3 Non-Return Valve Overhaul 5. Clean the valve shaft. the slide rings and the slide bearings inside the valve flaps. 6. please quote Procedure M91002 Edition 0211 0$1% :'LHVHO$6 . Inside the scavenge air cooler housing.3 208 06 8. lift up the valve flap of the valve to be overhauled. the slide rings and the slide bearings with molybdenum disulphide (MoS 2). Remove the screws behind the valve flap. BM910-2. Lubricate the valve shaft.3 208 05 7. Assemble the valve and re-mount it in the scavenge air cooler housing. Page 2 (2) When referring to this page. Remove the spring pins from the valve shaft and knock the valve shaft out of the valve flap.3 208 07 7. After the overhaul it must be possible to move the valve flap by the light touch of a finger. 6. Non-Return Valve for Auxiliary Blowers 5. BM910-2. BM910-2.910-2.

Description D-1 Weight of blower unit. please quote Data D11003 Edition 0012 MAN B&W Diesel A/S Page 1 (2) .Auxiliary Blower 110-3 Data SAFETY PRECAUTIONS Special Data S35NC 0012 110-3 Standard Tools: See Section 913 Auxiliary Blower X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data 1000 kg Ref. 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.

Page 2 (2) Description Qty When referring to this page. please quote Data D11003 Edition 0012 MAN B&W Diesel A/S .Auxiliary Blower 110-3 Data Spare Parts Plate – Item No.

Complete Blower Unit Remove all screws in the outlet flange of the blower unit. Lift away the blower unit and land it on wooden planks for further dismantling/overhaul. Remove all screws in the lower inlet flange of the blower unit.Auxiliary Blower 910-3. It may be necessary to remove one or more of the gallery plates. 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. 1.3 Overhaul Auxiliary Blower S35MC 0214 Overhaul 910-3. Depending on the type of overhaul. D-1 Remove all screws in the upper inlet flange of the blower unit. BM910-3. please quote Procedure M91003 Edition 0214 0$1% :'LHVHO$6 Page 1 (2) . disconnect the cable connections from one or both blower motors.3 2. When referring to this page. 2.3 214 02 Hook a shackle and a tackle to the lifting bracket in the top of the blower unit.

3 Auxiliary Blower Overhaul 3.910-3. as the blower wheel is to “catch” the guide in the blower housing. Page 2 (2) When referring to this page. Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the blower flange. For overhaul of blower wheel and bearings. disengage the cable connections to the blower motor. 4. BM910-3. Blower Wheel and Electric Motor When cleaning and inspecting the auxiliary blower.3 214 03 While pulling out the end cover with the blower assembly. before removing the screws in the flange. Then inspect and clean the blower wheel as well as the blower housing. please quote Procedure M91003 Edition 0214 0$1% :'LHVHO$6 . Note! BM910-3. see blower manufacturer’s instructions. 3. The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. make sure that the blower housing disengages from the air pipe without deforming it. 4.3 214 04 Exercise care when mounting the electric motor with blower wheel.

please quote Data D11005 Edition 0005 MAN B&W Diesel A/S Page 1 (2) .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.Turbocharger Turbine 110-5 Data SAFETY PRECAUTIONS Special Data .

please quote Data D11005 Edition 0005 MAN B&W Diesel A/S .Turbocharger Turbine 110-5 Data Spare Parts Plate – Item No. Page 2 (2) Description Qty When referring to this page.

as these may possibly stick in the exhaust gas boiler. or broken or artificially shaped pieces of activated charcoal with a size of between 1.3 Cleaning Turbocharger Turbine .0 and max. See also Volume I.3 The dry cleaning method employs compressed air to blow dry. turbocharger cleaning can be carried out without.0&& 0206 Cleaning 910-5. When referring to this page. It is not always possible to remove thick deposits with this dry cleaning method. please quote Procedure M91005 Edition 0206 0$1% :'LHVHO$6 Page 1 (2) . in order to prevent the build-up of thick deposits. nut-shells. granules through the turbocharger. On account of their hardness. or with very little. reduction of the engine load. 1.Turbocharger Turbine 910-5. the turbine must be cleaned after every 24 to 50 hours of operation. Therefore. solid. Note! Regarding water washing of turbocharger turbine. see turbine manufacturer’s instructions. Chapter 706.5 mm are particularly suited as blasting agents. More detailed information regarding the amount of granules to be used is stated on the instruction plate located close to the turbocharger. Generally. Note! We do not recommend the use of rice or grain as cleaning materials. thus removing most of the deposits which may have formed on the nozzle vanes and turbine blades.

XX706-12 40B 4. Caution! 1. Close valve A.The drain openings in the gas casings must remain closed while dry cleaning the turbine. Slowly open valve A to relieve the pressure in the tank. Open valves B and C. HM910-5. Close valve A. 5. close valves B and C. 2. It is possible that during dry cleaning of the turbine. After about two minutes.3 50 02 9. Fill the tank with the quantity of granules specified in the table. 3. Carry out cleaning for every 24 to 50 hours of operation. to blow out any deposits and/or condensate in the connecting pipe. Open valves B and C. based on observations.910-5. After one to two minutes.3 Turbocharger Turbine Cleaning Cleaning Procedure: 1. 8. 2. some of the blown-in solid particles or sparks will escape through the funnel. 7. Preferably clean the turbocharger at full load. please quote Procedure M91005 Edition 0206 0$1% :'LHVHO$6 . to blow-in the granules. Page 2 (2) When referring to this page. 6. Do not clean below half load. close valves B and C. Slowly open valve A to relieve the pressure in the tank.

please quote Data D11006 Edition 0011 MAN B&W Diesel A/S Page 1 (2) .Water Mist Catcher 110-6 Data SAFETY PRECAUTIONS Special Data 0011 110-6 Standard Tools: See Section 913 Water Mist Catcher X Stopped engine X Block the starting mechanism X Shut off starting air supply Engage turning gear X Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors 1000 kg Data Ref. Description D-1 Water mist catcher Value Unit 80 kg When referring to this page.

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 110-6 Data Spare Parts Plate – Item No.

2 Dismantling Water Mist Catcher 0211 Dismantling 910-6. During mounting.Water Mist Catcher 910-6.4 75 02 4.4 75 01 Note the position of the water mist catcher. Note! 3. 1. BM910-5. BM910-5. the water mist catcher has been fouled or damaged. To dismantle the water mist catcher.2 2. it must be dismantled for cleaning or repair. 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. Normally it is not necessary to remove the water mist catcher from the scavenge air cooler housing. Note! Take care not to damage the water mist catcher during the lift. 4. If. When referring to this page. Clean the water mist catcher with the same cleaning fluid as used for the scavenge air cooler element. however. please quote Procedure M91006 Edition 0211 0$1% :'LHVHO$6 Page 1 (2) . Land it on a couple of wooden planks. 2. 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. the water mist catcher must be re-mounted in the same position.

Slide the water mist catcher into the scavenge air cooler housing. and push the water mist catcher fully into the scavenge air cooler housing. Also note the markings on the water mist catcher.4 75 03 Make sure to mount the water mist catcher correctly. remove the tackle and the eye bolt. 2. Tighten the screws at the end of the water mist catcher. 2. please quote Procedure M91006 Edition 0211 0$1% :'LHVHO$6 . The screws of the water mist catcher must face the exhaust side of the engine. BM910-5. Note! BM910-5. 1.4 1. Page 2 (2) When referring to this page. When the water mist catcher is half-way in.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.910-6.4 Water Mist Catcher Mounting Mounting 910-6.

Air Cooler . please quote Plate P91063 Edition 0017 MAN B&W Diesel A/S Plate P91063-0017 Page 1 (2) .Tools When referring to this page.

Plate P91063-0017 Item No. Item Description Guide rail. air cooler fore end When referring to this page. air cooler fore end Guide rail.Tools Item Description Item No. 015 027 Page 2 (2) Air Cooler . please quote Plate P91063 Edition 0017 MAN B&W Diesel A/S .

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

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

please quote Plate P91066 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .Lifting Tools 0001 P91066 When referring to this page.Air Cooler .Lifting Tools Plate P91066-0001 Air Cooler .

Plate P91066-0001 Item No. 011 023 Air Cooler . please quote Plate P91066 Edition 0001 MAN B&W Diesel A/S . Item Description Lifting attachment air cooler fore end. complete Screw Page 2 (2) When referring to this page.Lifting Tools Item Description Item No.

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

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

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

MAN B&W Diesel A/S .

see 900-2 Stopped engine X X X X X X X Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D11101 Edition 0026 Value Unit 200± 5 bar 45 Nm Page 1 (2) .Safety Valve MAN B&W Diesel 111-1 Data SAFETY PRECAUTIONS For detailed sketch. Description D11-01 Opening pressure D11-02 Valve housing. tightening torque When referring to this page.

e. Plate Item No. please quote Data D11101 Edition 0026 . P90951 refers to chapter 909. pneumatically operated P91351 58 Hose with unions (3000 mm).g. complete P90151 117 P91359 Page 2 (2) Test equipment for combined safety valve Torque Spanners When referring to this page.Safety Valve 111-1 MAN B&W Diesel Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Description P91351 10 Hydraulic pump.

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

or ‘electro-cleaner’. dismantle the safety valve and clean all the parts in either gas oil. 3. MAN B&W Diesel 1.3 Safety Valve Overhaul (Adjustment) 1. Then mount: • the valve spindle • the spring • the adjusting screw • the lock nut M911010211O02 2. M911010211O03 3. If necessary.911-1. 2. loosen and tighten again to the torgue stated in the data. please quote Procedure M91101 Edition 0212 . Page 2 (5) When referring to this page. kerosene. 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.

• Tighten the adjusting screw of the • Tighten the lock nut. • Bleed the valve and hose until oil. When referring to this page. • Loosen the lock nut on the safety valve.3 Overhaul (Adjustment) 4. flows out from the openings of the safety valve. • Turn the adjusting screw until the valve just closes. • Connect the testing device to the hydraulic pump. Alternatively the hydraulic hans pump can be used. please quote Procedure M91101 Edition 0212 Page 3 (5) .Safety Valve MAN B&W Diesel 911-1. • Test the opening pressure. • Remove the valve from the fuel valve M911010212O04 safety valve until the correct pressure is indicated (see Data). without air bubbles. To set the safety valve opening pressure: 4. test rig. • Set up the safety valve in the Fuel valve test rig.

2. 1. M911010211M01 3.4 Safety Valve Mounting MAN B&W Diesel When Side-mounted 1. Clean the sealing ring grooves of the indicator cock.911-1. apply tools only on the hexagon on the safety valve. When mounting the safety valve. Pierce the bore in the cylinder cover. and blow it clean. Mount the intermediate pipe and the indicator cock. M911010211M03 3. Mount the guard surrounding the safety valve. Page 4 (5) When referring to this page. Mount a new sealing ring and a new or overhauled safety valve. M911010211M02 2. please quote Procedure M91101 Edition 0212 .

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

.

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

P90951 refers to chapter 909. please quote Data D11102 Edition 0013 MAN B&W Diesel A/S . Description When referring to this page. e.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.g. Plate Page 2 (2) Item No.

1. Note! XZ911-2. If work involving risks of mechanical damage to the flame arrester has taken place. The complete flame arrester has to be replaced after a crankcase explosion.1 207 03 2. XZ911-2.1 1. 2. See separate instructions from the valve manufacturer. See separate instructions from the valve manufacturer. a visual inspection of the flame arrester should always be performed before starting the engine. replace the O-ring inside the relief valve.1 209 01 Check on the whole circumference that all the plates in the flame arrester are evenly distributed and that no local openings exist. During running of the engine. the relief valve must be disassembled and the flame arrester replaced. If a leak occurs. If one or more plates in the flame arrester are damaged. When referring to this page.1 Checking Relief Valve 60& 0211 Checking 911-2. please quote Procedure M91102 Edition 0211 0$1% :'LHVHO$6 Page 1 (1) .Relief Valve 911-2. check if there are any leaks.

.

see 900-2 X X X X Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply X Lock the turbocharger rotors Data Ref. Description When referring to this page.Scavenge Air Receiver Safety Valve MAN B&W Diesel 111-3 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11103 Edition 0001 Value Unit Page 1 (2) .

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. P90951 refers to chapter 909.g. Description When referring to this page. e. please quote Data D11103 Edition 0001 . Plate Page 2 (2) Item No.

If this operation cannot be performed smoothly. Tighten the counter nut.Scavenge Air Receiver Safety Valve MAN B&W Diesel 911-3. M911030001C02 Use a piece of cloth to wipe out any dirt from the Oring packing and close the valve again. the safety valve must be dismantled and cleaned. 2. 2. please quote Procedure M91103 Edition 0001 Page 1 (5) . Check the scavenge air receiver safety valve by loosening the counter nut and turn the forced opening screw to open the valve approx. When referring to this page.1 Checking 1. The scavenge air receiver safety valve is calibrated at the factory and does not require any adjustment. 10 millimetres.

2 Scavenge Air Receiver Safety Valve Dismantling 1.911-3. M911030001D02 2. M911030001D01 2. Page 2 (5) When referring to this page. On some engines. please quote Procedure M91103 Edition 0001 . a cover has to be removed in order to gain access to the safety valve. Dismount the safety valve from the scavenge air receiver. MAN B&W Diesel 1.

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

M911030001O05 5. 6. 5. If the Oring seal has been removed mount a new one using Locktite type AVX and Loctite activator type T or similar. Push in the valve flap and spindle while taking care not to damage the Oring seal.3 Scavenge Air Receiver Safety Valve Overhaul 4.911-3. Page 4 (5) When referring to this page. please quote Procedure M91103 Edition 0001 .1. M911030001O04 Tighten the nut until the split pin can be mounted. MAN B&W Diesel 4. Check the valve according to 9113. 7. M911030001O01 6. Mount the spring. spring retainer and all the washers.

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

.

Data Holding Down and End Chock Bolts (Epoxy) Stay Bolts.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 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 .

mounting When referring to this page. see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D12-02 Description Value Unit Check holding down bolts and end chock bolts for correct tightening after the following service hours: D13-01 1st check 500 hours 2nd check 1000 hours 3rd check 2000 hours 4th check 4000 hours 5th check 8000 hours Subsequent checks at intervals of 8000 hours Hydraulic pressure.Holding Down And End Chock Bolts MAN B&W Diesel 112-2 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11202 Edition 0015 900 bar Page 1 (2) .

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

Holding Down and End Chock Bolts 912-2.0& 0208 Checking 912-2. When referring to this page.1 Checking Holding Down and End Chock Bolts . please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 1 (5) . The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool.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.

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

3. These results are used to determine whether refitting or. we recommend that the following procedure is followed: 1. The liners are secured in their correct position by means of hexagon socket set screws with cup point. and the measurements found are to be entered in the relevant table. possibly. Loosen the hexagon screws. all side chocks should be checked to see whether the liners can be knocked further inward. 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. When referring to this page. the liner must be removed. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 3 (5) .Holding Down and End Chock Bolts 912-2. and thus at the same time intervals. Try to knock the liner further inward. The first time the ship is sailing in a fullyloaded condition after the engine has been operating for 1. 2.1 Checking 3. 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. The feeler gauge is applied at the 7 points indicated in the table on page 5. knock the liners a further 3 to 4 mm inwards. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results. replacement of the liners is necessary.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. After fitting the liners to an 80 per cent contact area on both sides of the liners. Side Chocks and Side Chock Liners 3.000 hours. If this procedure does not improve the situation. Measure again at the 7 points indicated in the table. GN912-2.

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

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

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4 mm D13-01 Hydraulic pressure. dismantling 800 .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. mounting 900 bar D13-02 Hydraulic pressure. Description Value Unit D12-04 Check measurement 0.990 bar When referring to this page. please quote Data D11203 Edition 0027 Page 1 (2) .

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

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

Page 2 (2) When referring to this page. HM912-3. Before relieving the system of pressure. After completing the retightening procedure.0 28 03 6. Reconnect the hydraulic tools to the pair of stay bolts first tightened. If the nut is loose: Tighten all stay bolts once again to D-2. 5. Start the retightening of the stay bolts and proceed to tighten the stay bolts in pairs. check with a feeler gauge that the nuts bear against the contact face. HM912-3. 4. and retighten the stay bolt nuts with a tommy bar. Tighten to 10% below D-2 and check if the nut is loose. D13-02 If the nut is not loose: Tighten the stay bolts to D-2. please quote Procedure M91203 Edition 0211 MAN B&W Diesel A/S . working from the middle toward one end of the engine and then from the middle again toward the other end. 5. mount the protective caps.912-3.0 28 04 7.0 28 06 6.1 Stay Bolts Checking 4. HM912-3. Maintain the hydraulic pressure at the value indicated in D-1.

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

Replace gaskets G and H.1 Checking MAN B&W Diesel Metal bellow sealing 4. F M912050201C04 E G H 7. Remove all screws A and grating B. Remount four of the screws A at diametrically opposite positions.Crankcase Oil Outlet 912-5. It is recommended to always replace the metal bellow sealing during inspection. Mount all screws A. Remove the four screws A. 9. If any cracks or punctures are found in the metal bellow sealing. 13. M912050201C07 10. Page 2 (2) When referring to this page. C D 5. B A 6. Mount grating B. 12. Note! 7. please quote Procedure M91205 Edition 0201 . it must be replaced. Remove: Screws C Cover plate D Screws E. 11. 4. 8. Mount: Screws E Cover plate D Screws C. Lift away metal bellow sealing F and examine it closely. Mount metal bellow sealing F.

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

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

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

Plate P91263-0059 Item No. please quote Plate P91263 Edition 0059 MAN B&W Diesel A/S . Item Description Hydraulic jack for end-chock bolt M48 x 5.5 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.Holding-Down and End Chock Bolts (Epoxy Chocks) Item Description Item No. complete When referring to this page.0 Hydraulic jack for holding-down bolt M30 x 3. 024 036 048 050 061 073 085 097 107 119 203 Page 2 (2) Hydraulic Tools .

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 . etc.Hydraulic Tools Lifting Tools.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 .

MAN B&W Diesel A/S .

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

for instance. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . as required. the lowermost sealing ring will in most cases be damaged. lift”. The jack(s) is/are connected. The following instructions must be closely followed to prevent accidents or damage. Therefore inspect and. which must not be exceeded. with the aid of a tommy bar. 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. Oils such as. replace this sealing ring. The stud or bolt concerned is thereby lengthened relative to the oil pressure applied and the piston area.0 15 03 4. When the pressure is relieved in this way. The hydraulic jacks are so designed that. via a distributor block. Warning! Eye protectors and gloves must be used when using hydraulic tools. They are marked with a “Max. as these oils are normally alkaline and can thus damage the backup rings. 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. to a high-pressure pump. lift” limit is exceeded. and after use the jacks should be cleaned and kept in the wooden boxes supplied. BG913-1.913-1 3. in the event that the “Max. and the nut can be loosened or tightened. Hydraulic Tools 3. lubricating oil (system oil) or cylinder lubricating oil must not be used. The oil used must be pure hydraulic oil or turbine oil (with a viscosity of about SAE 20). Page 2 (12) When referring to this page. The jacks must never be overloaded or exposed to blows or impacts. if necessary.

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

Unscrew the nut with the tommy bar. 4. GN913-1 203 08 5. GN913-1 203 06 5. HM913-1. 3. and remove the hydraulic tools. Note! Make sure not to exceed the “max lift” stamped on the jack. making sure that the nut is not screwed up against the jack. disconnect the high-pressure pump. Page 4 (12) When referring to this page.1 10 04 4.913-1 Hydraulic Tools Loosening of Nut 3. Increase the oil pressure to the prescribed value. Relieve the system of pressure. 90 bar. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . the pressure may be increased by approx. If the nut does not come loose.

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

9. BG913-1. the pressure may be increased by approx.1 15 09 Make sure not to exceed the “max lift” stamped on the jack. 8.913-1 Hydraulic Tools Loosening of Nut 8. disconnect the high-pressure pump. making sure that the nuts are not screwed up against the extension stud. Relieve the system of pressure. Note! BG913-1.1 15 11 9. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 . and remove the hydraulic tools. Unscrew the lower nuts 1½ turns with the tommy bar. Page 6 (12) When referring to this page. 90 bar. If the nut does not come loose. Increase the oil pressure to the prescribed value.

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

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

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

disconnect the pump. do not remove the jacks. check with a feeler gauge introduced through the recesses at the bottom of the spacer ring that the nuts bear against the contact face.2 15 11 10. 10. Page 10 (12) When referring to this page. When new studs. Relieve the system of pressure. 9. and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. bolts or nuts are tightened for the first time.913-1 Hydraulic Tools Tightening of Nut 9.2 15 10 12. Increase the oil pressure to the prescribed value. and then tighten the nuts again according to the procedure under ‘Tightening'. While maintaining the pressure. points 9-10-11. and remove the hydraulic tools. BG913-1. BG913-1. 11. point 8. but loosen the nuts as described under ‘Loosening'. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 .

BG913-1.Hydraulic Tools 913-1 Maintenance Maintenance 913-1 1. Warning! Make sure that there are no marks or scratches on the sliding surfaces of the parts. BG913-1. 2. The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of compressed air. The pistons and cylinders of the double jacks are separated in the same easy way as described for the single jack.4 15 01 Always use eye protection when working with compressed air. The presence of metal particles will damage the sealing rings. The hydraulic jacks require no maintenance except replacement of defective sealing rings. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 Page 11 (12) . Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease. 1. When referring to this page.4 15 02 2. each of which consists of an O-ring and a back-up ring fitted in ring grooves in the piston and cylinder.

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.913-1 Hydraulic Tools Maintenance 3. Page 12 (12) When referring to this page. See that the rings do not get stuck between the piston and cylinder. BG913-1. coat the piston and cylinder with molybdenum disulphide grease and press the piston and cylinder together. The same principle applies to all the jacks. 3.4 15 03 4. When changing the sealing rings. After fitting the sealing rings. BG913-1.4 15 04 4. See the sketch for the correct mounting of both the upper and the lower sealing rings. please quote Procedure M91301 Edition 0206 0$1% :'LHVHO$6 .

please quote Procedure M91304 Edition 0201 0$1% :'LHVHO$6 Page 1 (1) . 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 3.0&& 0201 913-4 When tightening screws or nuts for which no torque is specified in the instruction procedure or the related data sheet. 1. Screws and nuts locked with glue/Loctite. Self-locking nuts. Standard screws and nuts lubricated with a Molybdenum Disulphide (MoS 2) based lubricant. the standard torques specified in this procedure are to be applied. Thread Tightening torque Thread Tightening torque M8 23 Nm M22 580 Nm M10 50 Nm M24 680 Nm M12 70 Nm M27 900 Nm M14 115 Nm M30 1350 Nm M16 190 Nm M33 1700 Nm M18 270 Nm M36 2350 Nm M20 380 Nm M39 3000 Nm When referring to this page. Thread Tightening torque Thread Tightening torque M8 17 Nm M22 400 Nm M10 35 Nm M24 460 Nm M12 50 Nm M27 610 Nm M14 80 Nm M30 950 Nm M16 135 Nm M33 1200 Nm M18 190 Nm M36 1650 Nm M20 260 Nm M39 2100 Nm 2.Standard Tightening Torques 913-4 Standard Tightening Torques .

.

and a small click is heard. when the crank handle is turned. When referring to this page. can be set at the required torque on the scale. a small crank handle appears. the nuts are to be tightened and loosened two or three times so that the thread may assume its definite shape. MOLYKOTE paste type G). Rahsol Torque Spanner The handle of the torque spanner is provided with a scale indicating the torques at which the spanner can be set. at which moment a small jerk is felt in the spanner. The nuts should fit easily on the thread. In the case of new nuts and studs. When the ball is pulled. there is a ball on a small arm at the end of the handle.g. the pawl system is released. When the torque spanner is not in use. A spring-loaded slide in the handle is provided with a mark which. The torque spanner must not be used for torques higher than those stamped on it.Torque Spanner 913-5 Torque Spanner /0& 0205 913-5 Before screwing the nuts on.12 (e. 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. When the pre-set torque has been reached. For setting the spanner at the required torque. and it should be checked that they bear on the entire contact face.1-0. the threads and the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient µ = 0. and it must not be damaged by hammering on it or the like. please quote Procedure M91305 Edition 0205 0$1% :'LHVHO$6 Page 1 (1) . The torque spanner works as follows: The above-mentioned spring acts on a pawl system in the handle. the spring inside should be released by adjusting to minimum torque.

.

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

.

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

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

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

Fig. 15 MAN B&W Diesel Cam Lock Washers with rising cams on one side and radial teeth on the other. Fig. M913070207C15 Fig. Note! M913070207C16 Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers. 17: Don not use the cam lock washers in conjunction with other loose washers. 15: The washers are installed in pairs. 16: Different uses of the cam lock washers. 17 Page 4 (4) When referring to this page.913-7. please quote Procedure M91307 Edition 0207 . M913070207C17 Fig.1 Screws and Nuts Locking Fig. Fig. allowing movement only across the face of the cams. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces. The cam lock washer is locked in place. 16. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect og the cams. cam face to cam face.

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

.

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

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 ø11x3mm
Bleeder screw
Disc, round-plain, Fe ø11x9mm

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

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

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

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

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

048 050 061 073 Page 2 (2) Instruments Item Description Item No. 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 . Item Description Autolog.Plate P91366-0065 Item No.

§94.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. Subpart K. In accordance with Chapter I of the Code of Federal Regulations. including.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations. the instructions to that effect included in the Technical File.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions. Part 94. §94. Part 94. please quote S900 Edition 0001 MAN B&W Diesel A/S Page 1 (1) . Subpart C. When referring to this page. but not limited to.

.

S35MC VOLUME III COMPONENTS DESCRIPTION .

.

Introduction Documents in this Chapter 90001 90002 90003 90004 90023 90030 0058 0001 0001 0001 0027 0009 Table of Contents.900 .Standard Conditions Instructions for Main Engine Description MAN B&W Diesel A/S . Volume III Cross Section through Engine Ordering of Insulation Designations and Symbols Software Licence .

MAN B&W Diesel A/S .

Cylinder Cover 90101 0152 Cylinder Cover 90103 0007 Indicator Cock .Cylinder Liner and Cylinder Lubrication 90301 0162 Cylinder Frame 90302 0175 Cylinder Liner and Cooling Jacket 90304 0025 Cylinder Liner .Details 90513 0036 Tacho System 90513 0046 Tacho System 90513 0047 Tacho System 906 . Edition Title 900 .Mounting 902 .Details 904 .Table of Contents 900 Volume III .Piston with Rod & Stuffing Box 90201 0201 Piston and Piston Rod 90205 0122 Piston Rod Stuffing Box 903 .Details 90305 0146 Cylinder Lubricators 90309 0025 Cylinder Lubricator System .Crosshead with Connecting Rod 90401 0145 Connecting Rod and Crosshead 90403 0009 Lubricating and Cooling Oil-Flow 905 .Standard Conditions 90023 0027 Instructions for Main Engine 90030 0009 Description 901 .Components Description No.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) .and Guide Bearing 90510 0113 Turning Gear 90511 0035 Turning Wheel 90512 0001 Turning Gear .Introduction Table of Contents 90001 0058 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations and Symbols 90004 0001 Software Licence . 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.Crankshaft.

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 Pneumatic Components 907 .Details 90915 0078 Fuel Oil System .Cleaning MAN B&W Diesel A/S Page 2 (3) .Details 91005 0113 Air Cooler 91006 0025 Arrangement of Auxiliary Blower 91009 0010 Air Cooler System .Upper Parts 90804 0017 Exhaust Valve Upper Parts .Components Description No.Actuator 90806 0057 Exhaust Valve .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 910 .Details 90915 0077 Fuel Oil System .Exhaust Valve 90801 0184 Exhaust Valve .Lower Parts 90802 0041 Exhaust Valve . 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 .Table of Contents 900 Volume III .Starting Air System 90702 0066 Main Starting Valve 90703 0068 Starting Air Distributor 90704 0050 Starting Valve 908 .Details 90805 0130 Exhaust Valve .Pipe System 90810 0075 Arrangement of Cooling Water Pipes 909 .Details 90803 0032 Exhaust Valve .

Lower 91210 0164 Bedplate 91211 0086 Axial Vibration Damper 91216 0007 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) 91217 0005 Top Bracing .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 .Cylinder 91102 0025 Relief Valve 91103 0018 Safety Valve .Safety Equipment 91101 0037 Safety Valve .Scavenge Air System 91104 0095 Arrangement of Safety Cap 912 .Frame Air Cooler System 911 .Arrangement MAN B&W Diesel A/S Page 3 (3) . 91010 91018 Edition 0028 0003 Title Air Cooler .Upper 91209 0005 Chain Wheel Frame .Table of Contents 900 Volume III .Components Description No.

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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) .

please quote Plate P90001 Edition 0058 . 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.Plate P90001-0058 Item No.

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

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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. nos.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. please quote Plate P90003 Edition 0001 Page 1 (1) .

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When referring to this page. either expressed or implied. MAN B&W disclaims liability for breach of conditions or warranties.for which the software is acquired . Except as stated above. they will be replaced free of charge. 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.Software License. provided that the third party agrees to the terms of this licence agreement and provided that the customer does not retain any copies of the software. 4. including warranties of suitability and applicability for a particular purpose. If the software and data media are found to be defective and are returned to MAN B&W within 90 days from the date of delivery. please quote Plate P90004 Edition 0001 Page 1 (2) . Furthermore the customer is not allowed to make the software available to a third party or to reverse engineer. such updates or new versions shall be made available to the customer against separate payment. Copyright The customer must not copy the software or any part thereof. If the engine plant . If and to the extent MAN B&W updates the programs or develops new versions. 1. 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. decompile or disassemble the software. Updating The non-exclusive user's licence does not include any updating of the software. 5. with respect to the software and data media.is transferred to a third party the customer has the right to assign the licence to this third party. 2. MAN B&W and its software suppliers retain the right of ownership to the software. TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S ACCEPTANCE OF THESE CONDITIONS. 3. Right of Ownership Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W against a once-for-all fee. Standard Conditions MAN B&W Diesel Plate P90004-0001 Standard Conditions of Software Licence Software supplied by MAN B&W separately or included as a part of any system or embedded in any device is licensed by MAN B&W Diesel A/S (“MAN B&W”) subject to the customer's acceptance of the following standard conditions of licence.

regardless of the form of any claim or action. shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. shall be interpreted according to Danish Law. incidental consequential damages arising out of or in connection with the use or performance of the software. 6. or for any special. please quote Plate P90004 Edition 0001 .Plate P90004-0001 Software License. including the present licence agreement. profits or use of equipment. Standard Conditions MAN B&W Diesel MAN B&W's liability for damages to the customer for any cause whatsoever. Law MAN B&W's tenders and contracts with customers regarding delivery of data and programs. The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&W’s software suppliers. MAN B&W shall in no event be liable for any damages resulting from loss of data. Page 2 (2) When referring to this page.

reliability and lifetime of the engine and its components. 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. in whole or in part. When used in texts and illustrations. Engine No. In addition. Name of vessel 2. To ensure optimum efficiency. for instance in correspondence and when ordering spare parts. Consequently. 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. in respect of instructions on emissions related maintenance of the diesel engine. only original spare parts should be used when replacing parts on the engine. 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. Quantity required (and description) Example: M/S Nybo – 7730 B&W – P90201-0036 – 059 10 off (piston ring) + )The Plate No. reproduced. 4. I OPERATION Vol. Part No. 39 66 13 14 . 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. Plate No. 5. Deviations may be found in a specific plant. as the pages are in the process of being updated with new numbers: P90201-0036 or 90201-036. the books can be used for reference purposes. also the additional instructions to that effect set out in the Technical File.Instructions for Main Engines This book forms part of a set of books consisting of three volumes entitled: Vol. 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. MAN B&W Diesel A/S Teglholmsgade 41 DK-2450 Copenhagen Denmark Teleph. it is essential that the engine room personnel are fully acquainted with the contents of this book and. the designation “D” refers to the information given on the data sheets inserted in the respective books. may consist of either of these two sets of digits. III COMPONENTS. be copied. built by 3. and should therefore not. A90023-0027 This book is subject to copyright protection. II MAINTENANCE Vol.:+45 33 85 11 00 Telex :16592 manbw dk Telefax:+45 33 85 10 30 CVR No.

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

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

Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes. The stuffing box housing consists of two parts. which serves to prevent sludge from the scavenge box from being drawn down to the other rings. please quote Description A90030 Edition 0009 Page 3 (23) . • The ring grooves in the middle are fitted with sealing rings. 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. The cylinder section is tightened together with the engine framebox and the bedplate by means of stay bolts.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. The stuffing box also prevents scavenge air (in the scavenge air space) from leaking into the crankcase. • 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. 903 Cylinder Liner and Cylinder Lubrication Cylinder Frame The cylinder section of the engine consists of a cylinder frame with a bolted-on or integrated camshaft housing. Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners. Furthermore. Gaps at the ends of the ring segments ensure that the rings will bear against the piston rod even in worn condition. Scraper/sealing rings The housing is provided with a number of machined ring grooves: • The uppermost groove holds a scraper ring with oblique edges. When referring to this page. a sealing ring is fitted below the scraper ring (except on 35MC type engines). Alternatively as a complete welded assembly integrating the scavenge air receiver into the cylinder frame. which enables the sealing/scraping performance to be checked. which is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space. Through bores in the housing and a pipe. which are bolted together. the stuffing box communicates with a control funnel on the outside of the engine.

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

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

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

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

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. couplings or chain wheel and the shaft. Chapter 708. which communicates with the combustion chamber of the cylinder through a bore. whereas the indicator cams are in two parts. which are assembled with fitted bolts. please quote Description A90030 Edition 0009 . OPERATION. See Volume II. See also Volume I. PMI-System Page 8 (23) See separate instructions for operating the PMI-system (option). Chapters 906. Operating Instructions! When opening the indicator valve. the sections are assembled by means of flange couplings. which enables the parts to be turned in relation to each other. Indicator Valve Each cylinder is fitted with an indicator valve. enabling the camshaft timing to be checked and readjusted if the parts have been dismantled.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. When referring to this page. and the necessary pin gauges are delivered together with the engine. close the valve lightly before starting the engine. The camshaft has. 908 and 909. Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams. Pin gauges After the engine has been testrun. and retighten the valve when the engine has reached its normal service temperature. the camshaft parts and the cylinder frame will be provided with pin gauge marks. Bearings The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. The camshaft rotation constantly follows that of the crankshaft. 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.

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 704. grease. 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. 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. please quote Description A90030 Edition 0009 Page 21 (23) . OPERATION. When referring to this page. etc. In some cases it may be necessary to open the valve manually. c and d should be considered as pre-warnings of a possible increasing oil mist level. Regarding how to: • avoid evaporation of the lubricating oil in the crankcase. the complete flame arrester of the relief valves must be replaced. • detect oil mist in the crankcase using an ‘Oil Mist Detector’. or scavenge box fire Alarms b. Warning! Keep the areas around the relief valves free of oil. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open. see Volume I. "Turbocharger Surging". 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. Note! If there has been a crankcase explosion. See also our Service Letter SL97-348/ERO. Safety Valve. see Volume I. Chapter 704.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Diesel Relief Valves On the exhaust side of the engine a number of spring-loaded relief valves are fitted.

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

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

.

Cylinder Cover Documents in this Chapter 90101 90103 0152 0007 Cylinder Cover Indicator Cock .901 .Mounting MAN B&W Diesel A/S .

MAN B&W Diesel A/S .

please quote Plate P90101 Edition 0152 MAN B&W Diesel A/S Page 1 (2) .Cylinder Cover Plate P90101-0152 Cylinder Cover 0152 P90101 B F-F A G O O A B G G-O-G F F A-O-A B-O-B When referring to this page.

Cylinder Cover Plate P90101-0152 Item No. please quote Plate P90101 Edition 0152 MAN B&W Diesel A/S . 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 P90103 Edition 0007 MAN B&W Diesel A/S Plate P90103-0007 Page 1 (2) .Indicator Cock .Mounting When referring to this page.

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

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

please quote Plate P90305 Edition 0146 Plate P90305-0146 Page 1 (2) .Cylinder Lubricators MAN B&W Diesel When referring to this page.

complete Lever Washer Fitted bolt Spacer.Plate P90305-0146 Cylinder Lubricators MAN B&W Diesel Item No. tubular Pull rod. 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. Page 2 (2) When referring to this page. Item Description Note: * Cam lock washers are to be supplied by MAN B&W Diesel only. please quote Plate P90305 Edition 0146 . stainless* Spring pin Bracket Lubricator Washer Screw Washer Screw Spring-loaded lever. 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. complete Fitted bolt Nut.

Details When referring to this page.Cylinder Lubrication System . please quote Plate P90309 Edition 0025 MAN B&W Diesel A/S Plate P90309-0025 Page 1 (2) .

Plate P90309-0025 Item No. please quote Plate P90309 Edition 0025 MAN B&W Diesel A/S . 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.Details Item Description Item No. 019 020 032 056 068 093 103 127 139 152 164 188 211 223 Page 2 (2) Cylinder Lubrication System .

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 .904 .

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) .

complete Guide pipe Screw(* Shim (* Crosshead bearing shell. 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. lower part Hydraulic nut Connecting rod Hydraulic nut Stud Crankpin bearing cap Connecting rod. please quote Plate P90401 Edition 0145 MAN B&W Diesel A/S . self-locking Nut Outled pipe Screw Lock washer Stop screw Guide shoe Bracket Crosshead bearing cap Guide screw Stud Guide pin Nut.50mm Shim 0. upper part Crosshead Stud Guide pin Crosshead bearing shell. 0.25mm Guide strip Stud Screw Thrust piece Crankpin bearing shell.self-locking Shim.Plate P90401-0145 Item No. Item Description Screw Telescope pipe Nut. complete Notes: Page 2 (2) (* Please state thickness of shim When referring to this page.

please quote Plate P90403 Edition 0009 MAN B&W Diesel A/S Page 1 (1) .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.

.

Crankshaft.and Guide Bearing Turning Gear Turning Wheel Turning Gear .Details Tacho System Tacho System Tacho System MAN B&W Diesel A/S . 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.905 .

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) .

012 024 061 097 107 119 120 Page 2 (2) Crankshaft Item Description Item No.Plate P90501-0150 Item No. please quote Plate P90501 Edition 0150 MAN B&W Diesel A/S . Item Description Crankshaft Chain wheel Self-locking nut Screw Screw Cover Gasket When referring to this page.

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) .

018 031 043 055 067 079 080 092 102 114 126 138 151 Page 2 (2) MAN B&W Diesel Item Description Item No. please quote Plate P90502 Edition 0045 . Item Description Cover Screw Cover Shaft Cover Counterweight Self locking nut Screw Screw Disc Pin Screw Fitted bolt When referring to this page.Arrangement of Fore End Plate P90502-0045 Item No.

please quote Plate P90503 Edition 0016 MAN B&W Diesel A/S Page 1 (2) .Arrangement of Angle Encoder Plate P90503-0016 Arrangement of Angle Encoder 0016 P90503 A-A A A When referring to this page.

Plate P90503-0016 Item No.lower part Packing Screw Spring lock Page 2 (2) When referring to this page. 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. please quote Plate P90503 Edition 0016 MAN B&W Diesel A/S . complete Screw Housing Shaft Screw Damping plate Coupling Cable tie Tool Packing Shaft Spring pin Packing Washer Shield .

please quote Plate P90504 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .Axial Vibration Monitor Plate P90504-0001 Axial Vibration Monitor 0001 P90504 When referring to this page.

Plate P90504-0001 Item No. Item Description Bracket Axial vibration monitor Terminal box. 019 020 032 044 056 068 Axial Vibration Monitor Item Description Item No. 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) .

Item Description Screw Cover Screw Distance pipe Lubricating oil pipe Lubricating oil pipe Segment holder Guide pin Screw Screw Oil throw ring. upper part Scraper ring housing.Plate P90505-0128 Item No. in 2/2 Scraper ring housing. 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. complete Scraper ring housing. please quote Plate P90505 Edition 0128 MAN B&W Diesel A/S . 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.

Plate P90510-0113 Turning Gear Turning Gear 0113 P90510 A A When referring to this page. please quote Plate P90510 Edition 0113 MAN B&W Diesel A/S Page 1 (2) .

please quote Plate P90510 Edition 0113 MAN B&W Diesel A/S . 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. 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.Plate P90510-0113 Item No.

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) .

self-locking Turning wheel Spring pin Screw Washer Dead center pointer Page 2 (2) When referring to this page. Item Description Screw Fitted bolt Nut. please quote Plate P90511 Edition 0035 MAN B&W Diesel A/S .Plate P90511-0035 Item No. 017 029 030 054 078 091 101 125 Turning Wheel Item Description Item No.

please quote Plate P90512 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .Turning Gear .Details 0001 P90512 When referring to this page.Details Plate P90512-0001 Turning Gear .

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 .Plate P90512-0001 Item No.Details Item Description 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 .

Tacho System MAN B&W Diesel When referring to this page. please quote Plate P90513 Edition 0036 Plate P90513-0036 Page 1 (2) .

Item Description Bracket Screw Spring pin Disc When referring to this page.Tacho System Plate P90513-0036 Item No. 018 031 043 055 Page 2 (2) MAN B&W Diesel Item Description Item No. please quote Plate P90513 Edition 0036 .

please quote Plate P90513 Edition 0046 Plate P90513-0046 Page 1 (2) .Tacho System MAN B&W Diesel When referring to this page.

self-locking Nut. self-locking Stud Tacho pick-up Screw When referring to this page. please quote Plate P90513 Edition 0046 . Item Description Bracket Disc Spring pin Washer Nut.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.

please quote Plate P90513 Edition 0047 Plate P90513-0047 Page 1 (2) .Tacho System MAN B&W Diesel When referring to this page.

Tacho System Plate P90513-0047 Item No. Item Description Screw Spring pin Tacho pick-up Screw Dowel Nut. please quote Plate P90513 Edition 0047 . 018 031 055 079 092 114 138 Page 2 (2) MAN B&W Diesel Item Description Item No. self-locking Bracket When referring to this page.

Details Pneumatic Components MAN B&W Diesel A/S .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 .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 .

MAN B&W Diesel A/S .

please quote Plate P90600 Edition 0095 Plate P90600-0095 Page 1 (1) .Arrangement of Chain Drive MAN B&W Diesel When referring to this page.

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please quote Plate P90601 Edition 0100 Page 1 (2) Chain Drive and Guide Bars 0100 P90601 MAN B&W Diesel A/S .Chain Drive and Guide Bars Plate P90601-0100 When referring to this page.

Item Description Distance pipe Bracket Locking wire Screw Screw Banjo coupling Pipe. L= 854 Lub. oil pipe. self-locking Chain Outer link Inner link Chain link. complete Guidebar Tee coupling Spray pipe Bracket Screw Distance pipe Lub. complete Page 2 (2) When referring to this page. oil pipe. 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. please quote Plate P90601 Edition 0100 MAN B&W Diesel A/S . complete Washer Screw Distance pipe Guide pin Stud Screw Washer Nut.Plate P90601-0100 Item No.

Lubrication Plate P90602-0110 Chain Drive . please quote Plate P90602 Edition 0110 MAN B&W Diesel A/S Page 1 (2) .Lubrication 0110 P90602 When referring to this page.Chain Drive .

Item Description pipe pipe pipe pipe pipe When referring to this page. 011 023 035 047 059 Chain Drive .oil Lub.oil Lub.Plate P90602-0110 Item No.Lubrication Item Description Lub.oil Lub.oil Page 2 (2) Item No.oil Lub. please quote Plate P90602 Edition 0110 MAN B&W Diesel A/S .

please quote Plate P90603 Edition 0096 MAN B&W Diesel A/S Page 1 (2) .Chain Tightener Plate P90603-0096 Chain Tightener 0096 P90603 When referring to this page.

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. please quote Plate P90603 Edition 0096 MAN B&W Diesel A/S .oil pipe O-ring Shaft Self-locking nut Banjo coupling Chain wheel Bracket Page 2 (2) When referring to this page. 017 029 030 042 066 078 091 101 113 125 137 149 150 162 174 198 208 221 233 245 257 269 270 294 304 Chain Tightener Item Description Item No.oil pipe Banjo coupling Lub.Plate P90603-0096 Item No.

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) .

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

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) .

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. complete Junction box Handle Pressure transducer Intermediate box Angle encoder When referring to this page. please quote Plate P90612 Edition 0102 . installation PMI system. mounting PMI software Storage case Converter box PMI controller box.Plate P90612-0102 Item No. user’s guide PMI system.

Camshaft Bearing MAN B&W Diesel When referring to this page. please quote Plate P90613 Edition 0136 Plate P90613-0136 Page 1 (2) .

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. please quote Plate P90613 Edition 0136 . 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.Camshaft Bearing Plate P90613-0136 Item No.

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

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

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

please quote Plate P90618 Edition 0139 . 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. Item Description 019 020 032 044 068 081 093 103 115 127 139 164 176 188 211 223 235 247 259 260 272 296 306 318 331 343 355 380 392 402 414 426 438 451 463 475 487 Bearing. Item Description When referring to this page.Plate P90618-0139 Regulating Shaft MAN B&W Diesel Item No. complete Page 2 (2) Item No. complete Screw Clamping arm Nut. complete Nut. self-locking Plate Pull rod.

please quote Plate P90620 Edition 0098 Plate P90620-0098 Page 1 (2) .Engine Side Control Console MAN B&W Diesel When referring to this page.

Item Description Vibration damper Bracket Screw Multiple plug Cable 5/2-way manual valve Clamping arm Pin Screw Screw Guide pin Console Nut. complete Pointer Screw Segment Spring washer Screw 3/2-way manual valve for stop Fitted bolt 3/2-way manual valve for start Nut. please quote Plate P90620 Edition 0098 . self-locking Screw Bushing Electrical box. complete Pressure switch Fitted bolt Clamping arm Screw Shaft Guard Screw Non-return valve Non-return valve When referring to this page. 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.Plate P90620-0098 Item No. self-locking Clamping arm Nut self-locking Shaft Name plate Stop ring Pin Handgrip Lever.

Engine . please quote Plate P90621 Edition 0083 MAN B&W Diesel A/S Plate P90621-0083 Page 1 (2) .Side Control Console. Details When referring to this page.

Side Control Console. self-locking Pull rod. self-locking Screw Nut. complete Bushing Stop ring Guide pin Cone Guide pin Impact handwheel Impact socket Clamping arm Pull rod. Details Item Description Item No. Item Description Nut. please quote Plate P90621 Edition 0083 MAN B&W Diesel A/S . complete Fitted bolt Lever Grease nipple Washer Fitted bolt Fitted bolt Nut. 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 .Plate P90621-0083 Item No. 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 P90648 Edition 0012 Plate P90648-0012 Page 1 (2) .Pneumatic Components MAN B&W Diesel When referring to this page.

pneumatic Screw Straight stud coupling Adjustable straight coupling Straight stud coupling Straight stud coupling Adjustable t-coupling 3/2-way solenoid valve Screw Plate. Item Description Assy of valves 3/2-way valve.Plate P90648-0012 Item No. shaped Washer Adjustable l-coupling 3/2-way valve. please quote Plate P90648 Edition 0012 . shaped Air reciever Non-return valve Screw Plate. 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. 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.

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 .907 .

MAN B&W Diesel A/S .

please quote Plate P90702 Edition 0066 Plate P90702-0066 Page 1 (2) .Main Starting V alve Valve MAN B&W Diesel When referring to this page.

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. please state manufacturer’s Part No. ball valve* Item No. actuator* Repair kit. When referring to this page. Item Description Note: * When ordering spare parts for this item. “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. please quote Plate P90702 Edition 0066 .Main Starting V alve Valve Plate P90702-0066 Item No.

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

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 .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.

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

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

Details Exhaust Valve .Lower Parts Exhaust Valve .Details Exhaust Valve .Actuator Exhaust Valve .Pipe System Arrangement of Cooling Water Pipes MAN B&W Diesel A/S .Upper Parts Exhaust Valve Upper Parts .Exhaust Valve Documents in this Chapter 90801 90802 90803 90804 90805 90806 90810 0184 0041 0032 0017 0130 0057 0075 Exhaust Valve .908 .

MAN B&W Diesel A/S .

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

013 025 049 050 062 074 086 098 108 133 145 157 169 182 194 204 216 228 241 253 Exhaust Valve .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.Plate P90801-0184 Item No. please quote Plate P90801 Edition 0184 MAN B&W Diesel A/S .

Details 0041 P90802 Air inlet. Sealing air.Details Plate P90802-0041 Exhaust Valve . When referring to this page. please quote Plate P90802 Edition 0041 MAN B&W Diesel A/S Page 1 (2) .Exhaust Valve . Control air.

please quote Plate P90802 Edition 0041 MAN B&W Diesel A/S .Plate P90802-0041 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 Page 2 (2) When referring to this page. complete Coupling. 019 020 032 044 056 068 081 093 115 127 139 140 152 164 176 188 211 Exhaust Valve .Details Item Description Item No.

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) .Exhaust Valve .

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. 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. please quote Plate P90803 Edition 0032 MAN B&W Diesel A/S . complete When referring to this page.Plate P90803-0032 Item No.

Upper Parts.Exhaust V alve . Details Valve MAN B&W Diesel When referring to this page. please quote Plate P90804 Edition 0017 Plate P90804-0017 Page 1 (2) .

Item Description Sealing ring Valve housing Packing Safety valve. please quote Plate P90804 Edition 0017 . 021 033 045 069 905 Exhaust V alve .Plate P90804-0017 Item No.Upper Parts. Details Valve MAN B&W Diesel Item Description Item No. with o-ring O-ring* Note: * Optional extras Page 2 (2) When referring to this page.

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. please quote Plate P90805 Edition 0130 MAN B&W Diesel A/S . complete Sealing ring Spring Page 2 (2) When referring to this page.

Details Plate P90806-0057 Valve Gear . please quote Plate P90806 Edition 0057 MAN B&W Diesel A/S Page 1 (2) .Details 0057 P90806 A A When referring to this page.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. 010 022 034 058 071 095 105 129 130 142 166 178 191 213 237 249 262 Valve Gear .Plate P90806-0057 Item No. please quote Plate P90806 Edition 0057 MAN B&W Diesel A/S . complete Page 2 (2) When referring to this page.

please quote Plate P90810 Edition 0075 MAN B&W Diesel A/S Page 1 (2) .Arrangement of Cooling Water Pipes Plate P90810-0075 Arrangement of Cooling Water Pipes 0075 P90810 When referring to this page.

Plate P90810-0075 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. 012 024 036 085 097 107 132 144 156 168 181 193 203 227 239 Arrangement of Cooling Water Pipes Item Description Item No. please quote Plate P90810 Edition 0075 MAN B&W Diesel A/S .

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 MAN B&W Diesel A/S .Details Fuel Oil System .Details Fuel Oil System .909 .

MAN B&W Diesel A/S .

please quote Plate P90901 Edition 0206 Plate P90901-0206 Page 1 (2) .Fuel Pump MAN B&W Diesel When referring to this page.

complete Suction valve. complete Combined puncture valve and suction valve.Fuel Pump Plate P90901-0206 Item No. complete Puncture valve. please quote Plate P90901 Edition 0206 . complete Disc Plug screw When referring to this page. complete 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. 723 747 759 772 806 818 Item Description Pump barrel and top cover.

Fuel Pump Gear MAN B&W Diesel When referring to this page. please quote Plate P90902 Edition 0149 Plate P90902-0149 Page 1 (2) .

Item Description Sealing ring Spring Pump base Bushing for roller guide. 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. 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 Pump Gear Plate P90902-0149 Item No. complete Guide for reversing spindle Shaft Guide spindle Guide spindle Screw Stud Nut Fuel pump roller guide. complete Stud Self-locking nut Sealing ring Sealing bush Sealing ring Screw Stud Nut. complete Bushing Guide pin Guide block Screw Sealing ring Plug screw Stop screw Reversing mechanism. 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.

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

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

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

please quote Plate P90911 Edition 0021 MAN B&W Diesel A/S . 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. Fuel Valve Function Item Description Item No.Plate P90911-0021 Item No.

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) .

Item Description High-pressure pipe. complete High-pressure pipe Page 2 (2) When referring to this page.Plate P90913-0071 Item No. 012 024 036 048 061 073 085 097 107 120 132 High-Pressure Pipes Item Description Item No. please quote Plate P90913 Edition 0071 MAN B&W Diesel A/S . complete Spring pin Sleeve in 2/2 O-ring Union nipple Protective pipe High-pressure pipe Union nipple O-ring High-pressure pipe.

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) .

complete O-ring Union nipple O-ring High-pressure pipe. complete Union nipple Thrust bushing Union nut High-pressure pipe Flexible hose. complete High-pressure pipe Page 2 (2) When referring to this page. Item Description High-pressure pipe. 012 024 036 048 061 073 085 097 107 120 132 High-Pressure Pipes Item Description Item No.Plate P90913-0110 Item No. 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) .

please quote Plate P90914 Edition 0064 . 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.Fuel Oil System Plate P90914-0064 Item No.

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

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

please quote Plate P90915 Edition 0077 . 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.Plate P90915-0077 Item No. complete When referring to this page.

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

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

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 .Cleaning Air Cooler .Details Air Cooler Arrangement of Auxiliary Blower Air Cooler System .Frame Air Cooler System MAN B&W Diesel A/S .910 .

MAN B&W Diesel A/S .

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

.

please quote Plate P91001 Edition 0127 MAN B&W Diesel A/S Page 1 (2) .Scavenge Air Receiver Plate P91001-0127 Scavenge Air Receiver 0127 P91001 When referring to this page.

Plate P91001-0127 Item No. please quote Plate P91001 Edition 0127 MAN B&W Diesel A/S . 017 029 030 042 054 091 101 125 149 150 162 186 198 221 233 245 Scavenge Air Receiver Item Description Item No. 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. Item Description Screw Cover Gasket Screw Distance pipe.

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) .

Page 2 (2) When referring to this page. please quote Plate P91002 Edition 0141 .Plate P91002-0141 Item No. please use Plate P90002. 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 quote Plate P91003 Edition 0220 Plate P91003-0220 Page 1 (2) .Exhaust Pipes and Receiver MAN B&W Diesel When referring to this page.

gas type Plug screw Plug screw End cover Exhaust receiver. please quote Plate 0220 Edition . they are marked with a"T". and MUST NOT BE USED ELSEWHERE! P91003 Page 2 (2) When referring to this page. 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. Plug screw Screw* Nut Plug screw Holder for grid-bolted Screw Screw* Washer Nut Compensator. Item Description Item Description Screw* Washer Nut Compensator.Plate P91003-0220 Item No. tubular Note: * These screws are special screws for hot joints. gas type Stud Grid Screw* Spacer.

please quote Plate P91004 Edition 0081 Plate P91004-0081 Page 1 (2) .Exhaust Pipes and Receiver MAN B&W Diesel When referring to this page.

please quote Plate P91004 Edition 0081 . they are marked with a "T" and MUST NOT be used elsewhere ! Page 2 (2) When referring to this page.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.

please quote Plate P91005 Edition 0113 MAN B&W Diesel A/S Plate P91005-0113 Page 1 (2) .Air Cooler When referring to this page.

please quote Plate P91005 Edition 0113 MAN B&W Diesel A/S . 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. please state manufacturer’s Part No. complete Water mist catcher* Note: * When ordering Spare Parts for this item.Plate P91005-0113 Item No. Page 2 (2) When referring to this page. 019 020 032 044 056 068 081 093 103 115 127 140 176 188 211 223 Air Cooler Item Description Item No.

please quote Plate P91006 Edition 0025 MAN B&W Diesel A/S Page 1 (2) .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 2 (2) When referring to this page. 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.Plate P91006-0025 Item No.

please quote Plate P91009 Edition 0010 MAN B&W Diesel A/S Page 1 (2) .Cleaning of Air Cooler Plate P91009-0010 Cleaning of Air Cooler 0010 P91009 When referring to this page.

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. L= 1500 T-coupling Clamp Adaptor Coupling. complete Steel pipe. L= 650 Steel pipe. L= 3500 Funnel Clamp Nut Support Coupling Coupling Steel pipe. please quote Plate P91009 Edition 0010 MAN B&W Diesel A/S . compl. L= 750 Sight glass Nipple Valve Drain box Coupling.Plate P91009-0010 Item No. Item Description Coupling Coupling. L= 180 Reducing pipe L-coupling Page 2 (2) When referring to this page. complete Steel pipe. L= 270 T-coupling Coupling Valve Reducing pipe L-coupling Steel pipe. L-coupling Steel pipe.

please quote Plate P91010 Edition 0028 Plate P91010-0028 Page 1 (2) .Air Cooler .Frame MAN B&W Diesel When referring to this page.

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.Frame Plate P91010-0028 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 .

Air Cooler System MAN B&W Diesel When referring to this page. please quote Plate P91018 Edition 0003 Plate P91018-0003 Page 1 (2) .

021 033 045 057 069 070 082 094 104 128 141 153 Page 2 (2) MAN B&W Diesel Item Description Item No. please quote Plate P91018 Edition 0003 . 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.Air Cooler System Plate P91018-0003 Item No.

Cylinder Relief Valve Safety Valve .Safety Equipment Documents in this Chapter 91101 91102 91103 91104 0037 0025 0018 0095 Safety Valve .Scavenge Air System Arrangement of Safety Cap MAN B&W Diesel A/S .911 .

MAN B&W Diesel A/S .

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

please quote Plate P91102 Edition 0025 MAN B&W Diesel A/S Plate P91102-0025 Page 1 (2) .Relief Valve When referring to this page.

please quote Plate P91102 Edition 0025 MAN B&W Diesel A/S . Item Description Relief valve (P. xxx mm Page 2 (2) When referring to this page.D.C.Plate P91102-0025 Item No. 302mm) * Screw* Packing* O-ring* Note: *When ordering.C. please state manufacturer of Relief Valve and P. 016 028 030 041 Relief Valve Item Description Item No.D.

please quote Plate P91103 Edition 0018 Plate P91103-0018 Page 1 (2) .Scavenge Air System MAN B&W Diesel When referring to this page.Safety Valve .

011 035 047 059 060 072 096 106 118 131 143 155 Page 2 (2) Safety Valve .Plate P91103-0018 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 .Scavenge Air System MAN B&W Diesel Item Description Item No.

please quote Plate P91104 Edition 0095 Plate P91104-0095 Page 1 (2) .Arrangement of Safety Cap MAN B&W Diesel When referring to this page.

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. please quote Plate P91104 Edition 0095 . 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.Plate P91104-0095 Item No.

Lower Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Top Bracing .912 .Arrangement MAN B&W Diesel A/S .Upper Chain Wheel Frame .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 .

MAN B&W Diesel A/S .

please quote Plate P91201 Edition 0057 MAN B&W Diesel A/S Page 1 (2) .Arrangement of Stay Bolts Plate P91201-0057 Arrangement of Stay Bolts 0057 P91201 When referring to this page.

Item Description Screw Protective cap Nut Stay bolt. please quote Plate P91201 Edition 0057 MAN B&W Diesel A/S . 014 026 038 051 063 075 087 Arrangement of Stay Bolts Item Description Item No. complete Stay bolt Neck ring in 2/2 Screw Page 2 (2) When referring to this page.Plate P91201-0057 Item No.

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) .

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

Plate P91205-0154 Frame Box Frame Box 0154 P91205 Front side B-B B B A A 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) .

L= 100 Distance pipe Nut Fitted bolt Page 2 (2) When referring to this page. L= 150 Union End shield Gasket Screw Screw Distance pipe. please quote Plate P91205 Edition 0154 MAN B&W Diesel A/S .Plate P91205-0154 Item No. L= 75 Distance pipe Distance pipe. 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. 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.

please quote Plate P91207 Edition 0062 MAN B&W Diesel A/S Plate P91207-0062 Page 1 (2) .Arrangement of Piston Cooling When referring to this page.

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. please quote Plate P91207 Edition 0062 MAN B&W Diesel A/S .Plate P91207-0062 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.

Chain Wheel Frame .Upper Plate P91208-0004 When referring to this page.Upper 0004 P91208 MAN B&W Diesel A/S . please quote Plate P91208 Edition 0004 Page 1 (2) Chain Wheel Frame .

Plate P91208-0004 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 . 012 024 048 061 073 085 107 120 144 156 181 193 215 227 240 252 Chain Wheel Frame .Upper Item Description Item No.

please quote Plate P91209 Edition 0005 Page 1 (2) Chain Wheel Frame .Lower Plate P91209-0005 When referring to this page.Lower 0005 P91209 MAN B&W Diesel A/S .Chain Wheel Frame .

018 055 067 079 092 102 151 163 187 199 209 222 234 258 271 Chain Wheel Frame . please quote Plate P91209 Edition 0005 MAN B&W Diesel A/S . 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.Lower Item Description Item No.Plate P91209-0005 Item No.

please quote Plate P91210 Edition 0164 Plate P91210-0164 Page 1 (2) .Bedplate MAN B&W Diesel When referring to this page.

upper shell* Main bearing.Bedplate Plate P91210-0164 Item No. Page 2 (2) When referring to this page. main bearing Gasket Flange Screw 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. lower shell* Screw Spring pin Flange Packing Distance pipe Screw Flange Distance pipe Screw Screw Lubricating oil pipe. Item Description Item Description Lubricating oil pipe. main bearing Pipe holder Screw Grats Stud Lubricating oil pipe. please quote Plate P91210 Edition 0164 . main bearing Nut Baseplate Stud Main bearing cap Main bearing. self-locking Screw Lubricating oil pipe. 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. main bearing Lubricating oil pipe. main bearing Gasket Flange Screw Stud Nut.

please quote Plate P91211 Edition 0086 Page 1 (2) MAN B&W Diesel A/S .Axial Vibration Damper Plate P91211-0086 When referring to this page.

upper part Cylindrical pin Axial vibration damper. 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. lower part Cylidrical dowel When referring to this page.Plate P91211-0086 Item No. please quote Plate P91211 Edition 0086 MAN B&W Diesel A/S . Item Description Spring Spring Oil seal Oil seal Screw Screw Screw Restriction for damper Screw Stud Restriction for damper Axial vibration damper.

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

starboard Liner for side chock. 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.Plate P91216-0007 Item No.0 Spherical washer Spherical washer Nut Protective cap Protective cap Nut Distance pipe Screw Washer Locking plate Liner for side chock. M30 x 3. Item Description Liner Nut Stud for end chock bolt. M48 x 5. port side Spherical washer Spherical nut Holding-down bolt.5 Page 2 (2) When referring to this page. please quote Plate P91216 Edition 0007 MAN B&W Diesel A/S .

Arrangement MAN B&W Diesel When referring to this page. please quote Plate P91217 Edition 0005 Plate P91217-0005 Page 1 (2) .Top Bracing .

short* Friction shim Distance pipe Washer Nut Split pin Screw. please state length Page 2 (2) When referring to this page. please quote Plate P91217 Edition 0005 . Item Description Item Description Screw. large* Plate Guide pin Disc spring Plate Friction shim Note: * When ordering this spare part. long* Plate. 011 023 059 060 072 084 096 106 131 143 155 180 202 214 MAN B&W Diesel Item No.Arrangement Plate P91217-0005 Item No.Top Bracing . short* Plate.