Warning

MAN B&W

S900-0002

Warning!
It is important that all MAN 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 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 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 S-Instruction S900

Edition 0002

Page 1 (1)

S50MC

VOLUME II
MAINTENANCE

900 - Introduction
Documents in this Chapter

90023
90050
90060

0027
0288
0002

MAN Diesel A/S

Table of Contents, Volume II
Instructions for Main Engine
Checking & Maintenance Schedule
General - Safety Precautions

MAN 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 0066 Cylinder Cover, Data
901-01 0246 Cylinder Cover
90151 0210 Cylinder Cover - Panel
90161 0106 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0095 Piston, Data
902-01 0285 Piston
102-02 0062 Piston Rod Stuffing Box, Data
902-02 0230 Piston Rod Stuffing Box
90251 0196 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0074 Cylinder Liner, Data
903-01 0252 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0249 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
904 - Crosshead with Connecting Rod
104-01 0061 Crosshead Bearing, Data
904-01 0251 Crosshead Bearing
104-02 0063 Crosshead, Data
904-02 0250 Crosshead
104-03 0043 Reciprocating Parts, Data
904-03 0216 Reciprocating Parts
104-04 0054 Crankpin Bearing, Data
904-04 0232 Crankpin Bearing
104-05 0053 Connecting Rod, Data
904-05 0233 Connection Rod
90451 0139 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90464 0008 Crosshead - Hydraulic Tools
MAN Diesel A/S

Page 1 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

Title

905 - Crankshaft, Thrust Bearing and Turning Gear
90551 0212 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0088 Main Bearing - Hydraulic Tools
90562 0130 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90567 0002 Segment Stopper & Vibration Damper - Tools
90570 0003 Thrust Shaft - Tools
90571 0002 Main Bearing Shell - Tools
906 - Control Gear
106-01 0054 Chain, Data
906-01 0241 Chain
106-02 0059 Chain Tightener, Data
906-02 0231 Chain Tightener
106-03 0039 Camshaft, Data
906-03 0215 Camshaft
106-04 0040 Camshaft Bearings, Data
906-04 0219 Camshaft Bearings
106-08 0002 Camshaft Coupling
906-08 0001 Camshaft Coupling
907 - Starting Air System
107-01 0020 Starting Air Distributor, Data
907-01 0216 Starting Air Distributor
107-02 0042 Start Air Valve, Data
907-02 0214 Starting Air Valve
908 - Exhaust Valve
108-01 0045 High-Pressure Pipe, Data
908-01 0226 High-Pressure Pipe
108-02 0082 Exhaust Valve, Data
908-02 0256 Exhaust Valve
108-03 0052 Exhaust Valve Actuator, Data
908-03 0227 Exhaust Valve Actuator
108-04 0038 Exhaust Valve Roller Guide, Data
908-04 0220 Exaust Valve Roller Guide
108-05 0015 Exhaust Valve Cam, Data
908-05 0216 Exhaust Valve Cam
108-07 0034 Exhaust Valve - Special Running, Data
908-07 0234 Exhaust Valve
90851 0207 Exhaust Valve - Panel
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90863 0016 Exhaust Valve - Extra Tools
MAN Diesel A/S

Page 2 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

Title

909 - Fuel Oil System
109-01 0063 Fuel Pump Settings, Data
909-01 0241 Fuel Pump Settings
109-02 0005 VIT System, Data
909-02 0206 VIT System
109-03 0050 Fuel Pump Cam, Data
909-03 0233 Fuel Pump Cam
109-04 0058 Fuel Pump, Data
909-04 0222 Fuel Pump
109-05 0063 Fuel Pump Top Cover, Data
909-05 0234 Fuel Pump Top Cover
109-06 0050 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0039 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0050 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0032 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10910 0018 Lifting Gear Roller Guide, Data
90910 0209 Lifting Gear for Roller Guide
10911 0068 Fuel Valve, Data
90911 0244 Fuel Valve
10912 0047 Spindle Guide, Data
90912 0222 Spindle Guide
10913 0033 Non-Return Valve in Fuel Valve, Data
90913 0207 Non-Return Valve in Fuel Valve
10914 0074 Fuel Oil High-Pressure Pipes, Data
90914 0234 Fuel Oil High-Pressure Pipes
10915 0058 Fuel Pump Roller Guide, Data
90915 0234 Fuel Pump Roller Guide
90951 0441 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
910 - Turbocharger System
110-01 0047 Air Cooler Element, Data
910-01 0236 Air Cooler Element
110-02 0009 Non-Return Valve after Air Cooler, Data
MAN Diesel A/S

Page 3 (4)

Table of Contents

900

Volume II - Maintenance
No.

Edition

910-02
110-03
910-03
110-04
910-04
110-06
910-06
91061
91064
91065

0214
0024
0220
0005
0206
0031
0219
0067
0002
0001

Title
Non Return Valve after Air Cooler
Auxilary Blower, Data
Auxilary Blower
Butterfly Valve, Data
Butterfly Valves
Water Mist Catcher, Data
Water Mist Catcher
Turbocharger System - Tools
Travelling Trolley
Exhaust Receiver - Tools

911 - Safety Equipment
111-01 0026 Safety Valve, Data
911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver Safety Valve, Data
911-03 0001 Scavenge Air Receiver Safety Valve
912 - Assembly of Large Parts
112-02 0015 Holding Down & End Chock Bolts, Data
912-02 0208 Holding Down and End Chock Bolts
112-03 0028 Stay Bolts, Data
912-03 0216 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91263 0060 Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
913 - General Tools
913-01 0209 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 0038 Accessories - Hydraulic Tools
91356 0058 Lifting Tools, etc.
91357 0005 Open-Ended Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0040 Spanners
91364 0059 Open-Ended Spanners
91366 0066 Instruments

MAN Diesel A/S

Page 4 (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:




Name of vessel
Engine No.
built by
Plate No.
Part No.
Quantity required (and description)

Example:

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

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 Diesel’ instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN Diesel’ 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.
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 Diesel.

MAN Diesel A/S
A90023-0028

Teglholmsgade 41

DK-2450 Copenhagen

Denmark

Teleph. : +45 33 85 11 00
Telefax : +45 33 85 10 30
manbw@dk.manbw.com
www.manbw.com

CVR No. 39 66 13 14

MAN B&W

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  of 6

9001

Page  of 6

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

MAN B&W

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

MAN B&W

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

V : See Volume I “Operation”
A : Adjustment to be carried out
C : Check the condition

M : See maker’s instructions
O : Overhaul to be carried out
H : Check new/overhauled parts after 5001500 hours
Regular Checks

No.

Procedure

901
1

Cylinder Cover
Cylinder cover
Indicator cock

902
1

Piston with Rod and Stuffing box
Piston
Inspection through scavenge ports
Piston rod stuffing box

2
903
1

2

H

Daily

Crosshead with connecting rod
Crosshead bearing
Crosshead
Reciprocating parts
Crankpin bearing
Connecting rod

905
2
3
3
4
5

Crankshaft and Thrust Bearing
Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
Electronic axial vibration monitor
Mechanical checking

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

Service interval (x 1000 hours of operation)

Weekly Monthly

2

4

6

8

12

16

C*

24

32

B

P

C,O

O

C*

O

Remarks

* Check whenever exhaust valve
is removed

O
O

C

Cylinder Liner and Cylinder Lubrication
Cylinder liner
Inspection through scavenge ports
Measuring wear inside liner
Cylinder lubricators
Accumulators nitrogen pressure

904
1
2
3
4
5

9001

V
* Check clearances without
dismantling segments

O
C
C
C
C

A
A

V,M

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

V

C

C
C
C
C

C
C
C
C

C
C
C
C

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

V

C
C

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

V

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

V

C

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

C

Page  of 6

A C* C* C’ C* C O O O * Only inspection through camshaft covers When referring to this page. 1500 and 4000 hours C.O V Remarks New or overhauled chain to be checked/retightened after 500.O A O O O O C. 26-70 MC/MC-C Engines 9001 Page  of 6 H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x 1000 hours of operation) 2 4 C C. Procedure 7 8 Tacho pickup Angle encoder 906 1 2 Mechanical Control Gear Chains Chain tightener Chain wheels.V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 5001500 hours Regular Checks No.O M M R A R C.A C. fitted bolts Moment compensator Governor Functional check of overspeed device Functional check of speed-setting system (engine with bridge control system) -3 -4 -5 907 -1 -2 Starting Air System Starting air distributor Starting air valve 908 -1 -2 Exhaust Valve Hith-pressure pipe Exhaust valve Conventional hard-faced valve seats Nimonic exhaust valves Exhaust valve actuator Actuator safety valve Exhaust valve roller guide Exhaust valve cam Exhaust valve special running -3 -4 -5 -7 MAN B&W Checking and Maintenance Schedule. please quote Maintenance Schedule A90050 Edition 0288 . spray nozzles and guide bars Camshaft Camshaft bearings Camshaft coupling.A C C C O 6 8 12 16 24 32 C C C B P C.O C.A M M M C C C C C.A C C C C.

M V Page  of 6 .O C C C C.O O R * Only inspection through camshaft covers V Check ∆p and ∆t Check at every port inspection V.MAN B&W Checking and Maintenance Schedule. Procedure 909 Fuel Oil System Fuel oil water content Fuel pump settings VIT system Fuel pump cam Fuel pump Fuel pump top cover Fuel pump barrel assembly Fuel pump suction valve Fuel pump puncture valve Fuel pump shock absorber Fuel system shock absorber Lifting gear for roller guide Fuel valve Fuel nozzle Spindle guide Nonreturn valve Fuel oil highpressure pipes Fuel pump roller guide Fuel pump special running -1 -2 -3 -4 -5 -6 -7 -8 -9 -9 -10 11  12 13 14 -15 16 910 1 2 3 4 5 Turbocharger System Air cooler Nonreturn valve Auxiliary blower Butterfly valves Turbocharger turbine Turbocharger air filter Protective grid before turbocharger 9001 H Daily R : Parts to be replaced B : Based on observations P : Refer to Service interval (x 1000 hours of operation) Weekly Monthly 2 4 6 8 12 16 24 32 B P A. 26-70 MC/MC-C Engines V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 5001500 hours Regular Checks No.O C.C A A O O R V V Remarks C C O C. please quote Maintenance Schedule A90050 Edition 0288 C C C O O O O O O O C.O R O O O R O C* C* C C C C* C When referring to this page.

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. 26-70 MC/MC-C Engines 9001 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 Assembly of Large Parts Holdingdown and end chock bolts Stay bolts Top bracings Diaphragm in crankcase oil outlet System lubricating oil water content System lubricating oil bottom tank Cooling water quality Crankcase General Tools Hydraulic tools Page  of 6 H Daily Weekly Monthly R : Parts to be replaced B : Based on observations P : Refer to Service interval (x 1000 hours of operation) 2 4 6 8 12 16 24 32 B C* P M C* C O O O C C C C C A A A A A C C C C * Only if separate oil system * Check ∆p C. Procedure 6 Turbocharger lubricating oil water content Water mist catcher 911 1 2 3 912 2 3 913 1 MAN B&W Checking and Maintenance Schedule.M O M Empty and clean tank * Check for loose nuts and bearing material fragments C* C When referring to this page. please quote Maintenance Schedule A90050 Edition 0288 .O C C C Remarks M M M M M M C C C C R C M O C A V.

the engine must be stopped and blocked according to the safety precautions given on the specific Data Sheet. please quote Safety Precaution A90060 Edition 0001 MAN B&W Diesel A/S Page 1 (1) . 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.General – Safety Precautions 900-2 Before maintenance work is carried out.

.

Data Cylinder Cover Cylinder Cover .Tools .Panel Cylinder Cover .901 .Cylinder Cover Documents in this Chapter 101-01 901-01 90151 90161 0066 0246 0210 0106 MAN Diesel A/S Cylinder Cover.

MAN Diesel A/S .

140 mm D01-06 Cylinder cover. Description Value Unit D01-01 Exhaust valve stud. check distance 139 . complete 1700 kg D01-07 Cylinder cover without valves 1200 kg D01-08 Cooling jacket 55 kg D01-09 Exhaust valve stud 8 kg D01-10 Cylinder cover stud 22 kg D13-01 Hydraulic pressure. dismantling 800 . see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear X Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply X Lock the turbocharger rotors Data Ref. screwing-in torque 140 -160 Nm D01-05 Cylinder cover stud. please quote Data D10101 Edition 0066 MAN B&W Diesel A/S Page 1 (2) .990 bar When referring to this page. screwing-in torque 680 Nm D01-02 Starting valve stud. mounting 900 bar D13-02 Hydraulic pressure.101-1 Cylinder Cover Data SAFETY PRECAUTIONS For detailed sketch. screwing-in torque 175 -195 Nm D01-03 Fuel valve stud.

e. complete P91351 130 9-way distributor block. complete P91351 058 Hose with unions (3000 mm). Description P90151 046 Grinding tool for exhaust valve seat P90151 058 Milling and grinding wheel for fuel valve seat P90151 060 Milling and grinding wheel for starting valve seat P90151 083 Grinding handle P90161 Cylinder Cover .g.Tools P91351 010 Hydraulic pump. please quote Data D10101 Edition 0066 MAN B&W Diesel A/S . complete Page 2 (2) When referring to this page. P90951 refers to chapter 909. Plate Item No. pneumatically operated P91351 046 Hose with unions (1500 mm).101-1 Cylinder Cover 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.

C Close fuel oil inlet valve C.2 Cylinder Cover Dismantling 1. Set blocking device A on the main starting valve in the BLOCKED position. Open cooling water drain cocks G and H. 1. Close cooling water inlet valve D. and vent the system. Vent the manoeuvring system through the ball valve. G M901010246D01 Also shut off the air supply on the reduction unit for the hydraulic/pneumatic exhaust valve. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S B Page 1 (10) . A E Close cooling water outlet valves E and F. D Shut off the control air and safety air supply. F H Engage turning gear B. When referring to this page.901-1.

2 Cylinder Cover Dismantling 2. Dismount the fuel oil high-pressure pipes. Dismount the drain oil pipe between the exhaust valve and the hydraulic actuator. Page 2 (10) When referring to this page. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S . See Procedure 909-14.2. Dismount the clamp from the exhaust pipe/ intermediate pipe flanges. M901010246D03 Remove the protective caps from the cylinder cover nuts. Remove the plate cover and the insulating material from the exhaust receiver and intermediate pipe. 3. 2. Dismount the control air pipe from the starting valve. Dismount the hydraulic high-pressure pipe. 3. M901010246D02 Remove the starting air pipe.2. Remove the screws which fasten the cooling water outlet pipe to the cylinder cover. M901010246D04 4. the air pipe for the pneumatic exhaust valve. Remove the cooling water inlet and outlet pipes from the exhaust valve.901-1. 4. see Procedure 908-1.

one around each nut and screw the eight hydraulic jacks onto the studs. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S Page 3 (10) . Hook the engine room crane on to the lifting attachment on top of the exhaust valve. Place eight spacer rings. Lift away the cylinder cover complete. 7. M901010246D07 7. When referring to this page.Cylinder Cover 901-1. M901010246D06 6. Remove and discard the sealing ring between cylinder cover and cylinder liner. 5. see Chapter 913. and land it on a couple of wooden planks. M901010246D05 6.2 Dismantling 5. Raise the pressure and loosen and remove the nuts. D1302 For operation of the hydraulic tools.

well lubricated with vaseline.901-1. use dismantling screws to force the jacket/cover apart. If the cooling jacket sticks.2 and 909-11.2. Page 4 (10) When referring to this page. M901010246O02 Mount and tighten the screws for the cooling jacket. 4. Remove and discard the O-rings from the cover. D0107 Provide the cylinder cover with new Orings. Unscrew the four screws which secure the cooling jacket to the cylinder cover. 2. D0108 M901010246O03 3.3 Cylinder Cover Overhaul 1. 2. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S . Lift the cylinder cover and guide the jacket/ cover into position. Dismount all studs on the top of the cylinder cover. M901010246O01 Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. Dismount all valves and pipes on the cylinder cover. using the guide pin as reference (manoeuvre side). 3. 908-2. D0109 1.2. and carefully clean the cooling jacket and the cylinder cover. See Procedure 907-2.

3 Overhaul 5. Grind the seating with the grinding mandrel and a grinding compound (e. using the carbon cutter. Recondition the valve bores as follows: 5. 200). When referring to this page. 6. grind the seating with the grinding disc and a grinding compound (e.g. and of a guide.Cylinder Cover 901-1. M901010246O06 After cleaning the valve bore and seating. After the grinding. M901010240O07 7. Carborundum No. recondition the fuel valve seating with the appropriate cutter. a carbon cutter. and check that the seating is not damaged. After the milling/grinding. a seating face cutter.g. and check that the seating is not damaged. If required. M901010246O04 Clean the fuel valve bores. clean the bore and seating carefully. 200). Fuel valve bore 6. 7. Carborundum No. The tool consists of a common spindle with handle. clean the bore and seating carefully. and a grinding mandrel. Exhaust valve bore The tool consists of a spindle with handle and a grinding disc. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S Page 5 (10) .

Clean the bores for safety valve/indicator cock.901-1. The tool consists of a guide. Page 6 (10) When referring to this page. M901010246O08 9. but without dismounting the studs. When replacing valves on a cylinder cover that is mounted on the engine. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S . a cutter. 8. and a grinding disc. recondition the valve bores/seating in the same way as described here. M901010246O09 9.3 Cylinder Cover Overhaul Starting valve bore 8. Recondition the starting valve bore and seating in the same way as described for the fuel valve bore.

1.3 Cylinder Cover Overhaul 10. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S Page 7 (10) . D0102 When referring to this page. Lubricate the threads with ‘Never Seize' or Molybdenum Disulphide (MoS2) and mount the valve studs.901-1. D0103 Fill up the grooves between the valve studs and the bores for the valve studs with permatex to prevent water from entering the bores during operation of the engine. M901010246O10 Always fit new or overhauled valves before a cylinder cover is mounted on the engine. D0101 Tighten up the studs in accordance with the screwing-in torque stated on the data sheet.

Place a new sealing ring on top of the cylinder liner. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S . M901010246M01 Mount a new ‘klinger’ sealing ring in the groove of the flange of the intermediate pipe. Provide the cooling water connecting pipes with new O-rings and lubricate them with grease or soft soap. Lift the cylinder cover by means of the crane and carefully wipe the contact surface which faces the cylinder liner. 2.4 Cylinder Cover Mounting 1. 2. Lower the cover carefully into position. M901010246M02 D0106 Page 8 (10) When referring to this page.901-1. 1. carefully check that the cooling water connecting pipes engage correctly with the holes in the cooling jacket. During the landing.

in some case. D0105 If necessary. Using the vent screws of the hydraulic jacks. 4. M901010246M04 Remove the hydraulic jacks and the spacer rings. When mounting the clamp connecting the compensator and the intermediate pipe/exhaust valve it may. one around each nut. If cylinder cover studs have been removed and remounted. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S Page 9 (10) . and mount the eight hydraulic jacks on the studs. D1301 5. vent the system and the increase the pressure as stated in Data. M901010246M03 Place eight spacer rings. 3. adjust to the distance D01-05 by turning the stud. When referring to this page. M901010246M05 5. Mount all eight nuts on the studs and screw them down to the cylinder cover. Connect the high-pressure pump to the jacks by means of the distributor block and the high-pressure hoses.901-1. see Procedure 913-1. For operation of hydraulic jacks. check the distance the stud is protruding from the cylinder cover. become necessary to use the engine room crane. 4. Clean the flanges and the clamp ring carefully and lubricate all contact faces with Molycote.4 Cylinder Cover Mounting 3.

Mount the return oil pipe and the air pipe for pneumatic closing of the exhaust valve. See Procedure 909-14. Open the fuel oil.4. See Procedure 908-1.4 Cylinder Cover Mounting 6. 6. 7. Page 10 (10) When referring to this page.4. shut the vent cocks and open the cooling water outlet valve. please quote Procedure M90101 Edition 0246 MAN B&W Diesel A/S . M901010246M06 Mount the starting air pipe and control air pipe for the starting valve. Mount the cooling water inlet and outlet pipes on the exhaust valve. 8. Mount the high-pressure pipe for the hydraulic valve gear. Using a crowfoot wrench and torque spanner. 7. Connect the outlet pipe from the return oil pipe on the fuel valves. M901010246M07 Shut the drain valves and open the cooling water inlet.901-1. M901010246M08 This is very important. Mount the insulating jacket around the intermediate pipe. 8. Caution! The air supply to the exhaust valve must always be connected before turning on the oil supply to the exhaust valve actuator. Mount the drain pipe on the intermediate pipe between the exhaust valve and the cylinder cover. After venting the cylinder section. because otherwise the valve will open more than intended. mount the fuel oil high-pressure pipes. lubricating oil and air supplies to the alarm system.

please quote Plate P90151 Edition 0210 MAN B&W Diesel A/S Plate P90151-0210 Page 1 (2) .Cylinder Cover Panel When referring to this page.

Item Description Panel for tools Name plate Grinding tool for exhaust valve seat Milling and grinding wheel for fuel valve Milling and grinding wheel for starting valve Dismantling lever for fuel valve Handle Grinding ring for starting valve Spanner for starting valve Pressure tester for safety valve Lifting chains Handle When referring to this page. 010 022 046 058 060 071 083 095 105 117 130 201 Page 2 (2) Cylinder Cover Panel Item Description Item No. please quote Plate P90151 Edition 0210 MAN B&W Diesel A/S .Plate P90151-0210 Item No.

Tools MAN B&W When referring to this page.Cylinder Cover . please qoute Plate P90161 Edition 0106 Plate P90161-0106 Page 1 (2) .

Tools MAN B&W 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 tool kit.Plate P90161-0106 Item No. please qoute Plate P90161 Edition 0106 . 027 039 052 064 088 090 100 206 Page 2 (2) Cylinder Cover . complete When referring to this page.

Lifting Tools .Piston with Rod & Stuffing Box Documents in this Chapter 102-01 902-01 102-02 902-02 90251 90261 90264 90266 0095 0285 0062 0230 0196 0108 0002 0002 MAN Diesel A/S Piston.Tilting Tools Piston .Panel Piston and Piston Rod .902 . Data Piston Piston Rod Stuffing Box.Tools Piston and Piston Rod . Data Piston Rod Stuffing Box Piston and Piston Rod .

MAN Diesel A/S .

max. max.38 mm D02-19 Vertical clearance. 3 and 4 9. ring Nos. tightening torque 100 Nm When referring to this page. 2.4 mm D02-17 Minimum ring gap. 0. radial width 14. worn parts. tightening torque 300 Nm D02-05 Piston skirt. depth 1. tightening torque 80 Nm D02-06 Cooling oil pipe. 1 ( new ring in new liner ) 3. height of ring Nos. 2. radial width 17.1 mm D02-15 Minimum free ring gap ( before dismantling ) 25 mm D02-16 Minimum ring gap. new parts 0. max. permissible burn-away 15 mm D02-13 Piston ring new. 3 and 4.140 mm 7 bar Piston rod/crosshead. Description D01-05 Cylinder cover stud.87 mm D02-20 Piston complete 900 kg D02-21 Piston crown 210 kg D02-22 Piston rod 550 kg D02-23 Piston skirt 60 kg D02-24 Piston cooling pipe 20 kg D02-25 Lifting tool. check distance D02-01 Test pressure D02-02 Value Unit 139 .Piston MAN B&W Diesel 102-1 Data SAFETY PRECAUTIONS For detailed sketch. min. 2. height of ring No. see 900-2 Stopped engine X X X X X X X X X X X Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.2 mm D02-11 Groove Nos. please quote Data D10201 Edition 0095 100/54 Nm/° Page 1 (2) . min.2 mm D02-12 Piston top.2 mm D02-10 Groove No. tightening torque+angle D02-08 Piston ring new.4 mm D02-14 Piston rings new.2 mm D02-09 Piston ring worn. tightening torque 430 Nm D02-03 Piston rod/crown. 1 12. ring No. 3 and 4 ( new ring in new liner ) 2.4 mm D02-18 Vertical clearance.1. vertical height 13.4 mm D02-46 CPR ring CL groove. max. tightening torque 80 Nm D02-07 Piston rod/crosshead. vertical height 10.

P90951 refers to chapter 909.Tools P90265 Piston and Piston Rod .Piston 102-1 MAN B&W Diesel Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.Support Tools P90266 Piston .Lifting Tools Page 2 (2) When referring to this page. e. please quote Data D10201 Edition 0095 .g. Plate Item No. Description P90251 075 Template for piston top P90251 087 Distance piece for stuffing box P90251 099 Cover for stuffing box hole P90251 110 Pressure test tool for piston P90251 134 Piston ring expander P90251 158 Guide screw for piston crown P90261 Piston and Piston Rod .

please quote Procedure M90201 Edition 0285 Page 1 (22) . one at a time. the ring lands and the piston top. Inspect the piston rod and the lower part of the cylinder wall. Chapter 707. M902010280C03 3. 2. Turn the engine at least ½ a revolution. and begin with a unit arriving downwards. See Volume I. M902010280C02 3. 2.Piston MAN B&W Diesel 902-1. When referring to this page. inspect the piston skirt. by pressing against them with a wooden stick. The scavenge port inspection is carried out from the scavenge air receiver. To detect possible leakages from the piston or cylinder cover. An additional view of the rings is possible through the cleaning cover on the manoeuvring side.1 Checking Scavenge Port Inspection 1. all the piston rings. just above the scavenge air ports. While the piston is passing downwards. keep the cooling water and cooling oil circulating during the scavenge port inspection. Ring tension: Check the tension of the piston rings. and note down the results. Operation. M902010280C01 1. Ring inspection: Inspect the rings.

For evaluation of the rings.1 Checking 4. Total clearance = E + F. MAN B&W Diesel 4. M902010285C06 6. D0218 D0219 Measure the clearance at the top (E) and bottom (F) of the piston ring groove. 2mm 5.2. in connection with piston overhaul 5. Uppermost piston ring: If possible. M902010280C05 Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine. Piston support: Remove the piston from the cylinder and place it on the piston support. see Volume I. Chapter 707. please quote Procedure M90201 Edition 0285 .Piston 902-1. Page 2 (22) When referring to this page. Checking. D0246 6. Ring grooves: Measure the total clearance between the piston ring and the ring groove. E M902010280C04 F Max. The total clearance must not exceed the value stated in Data. measure the depth of the pressure relief grooves with a calliper. The piston rings must be replaced if the radial depth of the grooves has worn down to less than stated in Data D02-46. See Procedure 902-1.

Free ring gap: Before dismantling the piston rings. Operation. Radial ring width: Measure the radial width of the rings.1 Checking 7. contact MAN B&W Diesel A/S for advice.3. see Data D02-10 and D02-11. Clearance in piston ring grooves: The maximum vertical height in a worn ring groove must not exceed the value stated in Data. Note down the results See Volume I. 9. 7. see Procedure 902-1. D0208 New M902010280C08 If the ring grooves are worn out. D0215 For dismantling the piston rings. the piston crown must be reconditioned. please quote Procedure M90201 Edition 0285 Page 3 (22) . Ring grooves: Clean the ring grooves and check them for burn marks or other deformation.Piston MAN B&W Diesel 902-1. measure the free ring gap of all the piston rings. M902010285C07 8. D0209 Worn 9. The groove is also worn out if there is no chromium layer. D02-10 D02-11 M902010280C09 Max 2mm When referring to this page. Chapter 707. Measure the ring grooves with a calliper gauge. 8.

D0212 MAN B&W Diesel 10. please quote Procedure M90201 Edition 0285 . For maximum permissible burn away value. Check the burn-away on the whole circumference of the piston crown top.Piston 902-1. M902010285C10 If the burn-away exceeds the values given in Data. Piston crown top: Clean the piston crown and check the burn-away by means of the template.1 Checking 10. see Data. contact MAN B&W for advice. Page 4 (22) Note down the results for later reference. When referring to this page.

When referring to this page.Piston MAN B&W Diesel 902-1.1 Dismantling Preparations in the crankcase 1. 1. M90201280D01 Turn the crosshead down far enough to give access to the piston rod stuffing box and the piston rod/crosshead connection. Access: Open the crankcase door to the cylinder concerned. please quote Procedure M90201 Edition 0285 Page 5 (22) .

Turn the crosshead to TDC. Suspend the telescopic pipe by means of the tool. Page 6 (22) When referring to this page. Turn the crosshead downward and remove the distance pipe from the bend. Note! M902010280D02 When a piston is dismantled. Telescopic pipe: Loosen and remove the screws which tighten the telescopic pipe to the bend. Remove one screw from the telescopic stuffing box housing and mount the special tool for suspending the telescopic pipe or use the thread in the telescopic pipe stuffing box housing. please quote Procedure M90201 Edition 0285 .902-1. never turn the engine without first dismantling the telescopic pipe from the crosshead.1 Piston Dismantling 2. MAN B&W Diesel 2.

4. Stuffing box: Release the stuffing box by removing the innermost screws from the stuffing box flange. On engine models where the drain pipe is connected directly to the stuffing box: Disconnect the stuffing box drain pipe. Loosen the piston rod-crosshead connection: Remove the screws from the piston rod.1 Dismantling 3.Piston MAN B&W Diesel 902-1. Do NOT remove the outermost screws from the flange. please quote Procedure M90201 Edition 0285 Page 7 (22) . M902010280D03 Note! M902010285D04 4. 3. When referring to this page.

Cylinder cover: Remove the cylinder cover. MAN B&W Diesel 5.3.2. See Procedure 901-1.902-1. Page 8 (22) When referring to this page. please quote Procedure M90201 Edition 0285 . M902010285D06 6. Remove the piston cleaning ring. Preparations on the cylinder top 6. Stuffing box distance pieces: Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box.1 Piston Dismantling 5. See Procedure 903-1. M902010280D05 Carefully remove any wear ridges at the top of the cylinder liner. Make a scratch mark in liner and piston cleaning ring to ensure correct re-mounting.

please quote Procedure M90201 Edition 0285 Page 9 (22) . Piston lifting tool: Turn the piston to TDC. D0225 Clean the lifting groove of the piston crown and mount the lifting tool. When referring to this page. remove one or two cylinder cover studs. 7. Note! Limited lifting high: If the engine not is equipped with long distance pieces.1 Dismantling 7. The top of the piston is now free of the cylinder liner. using a stud setter.Piston MAN B&W Diesel 902-1. M902010285D07 Make sure to mount the lifting tool correctly. so that the claws of the lifting tool enter the lifting grooves of the piston crown.

Piston 902-1.1 Dismantling MAN B&W Diesel Piston lift 8. Check the piston is resting on the piston rod flange. 8. the piston rod foot can pass between two cylinder cover studs. Lift the piston out of the cylinder liner and guide the piston rod foot through the stuffing box flange. please quote Procedure M90201 Edition 0285 . Place the two halves of the support around one of the openings in the platform. If the engine is equipped with long distance pieces for the stuffing box. Lower the piston rod foot and stuffing box through the opening in the platform. M902010285D08 D0220 Page 10 (22) When referring to this page. Secure the two support halves with screws and lower the piston on the support.

The protective rubber cover is found on tool panel 904. Turn the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap. M902010285D09 Clean. measure and recondition the cylinder liner. When referring to this page. please quote Procedure M90201 Edition 0285 Page 11 (22) .Piston MAN B&W Diesel 902-1. Protect the crosshead bearing: 9. Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit. The covers must remain in place to protect the crosshead bearing journal from impurities until the piston is remounted.1 Dismantling 9. See Procedure 903-1.

Remove the stuffing box. 3. three and four. two. Piston support: Place the piston in the support and remove the piston lifting tool. please quote Procedure M90201 Edition 0285 .Piston 902-1. 3.3.1. Piston ring dismantling: Take off the piston rings by means of the ring expanders. the short ring expander is for the uppermost ring. M902010285O02 Lift the piston crown and skirt clear of the piston rod. M902010285O01 2. Piston crown dismantling: Remove the locking wire and the innermost screws between the rod and the piston crown.1. then ring No.1 Overhaul 1. See Procedure 902-1. See Procedure 902-1.2. See Procedure 902-1. Clean and inspect the rings and the ring grooves. D0220 MAN B&W Diesel 1. Check the free ring gap and the burn-off on the piston top. See Procedure 902-2. First remove the uppermost ring. If the engine is equipped with two ring expanders. M902010284O03 D0221 + D0223 Page 12 (22) When referring to this page. Clean the piston top and the piston rings. 2.

D0223 Remove the locking wire and the screws in the skirt. D0224 Mount the eye bolts and lift out the cooling oil pipe. M902010284O05 Discard the sealing ring on the piston skirt. Thoroughly clean and inspect all parts of the crown and skirt. Note! Coke deposits reduce heat transfer from the piston crown to the cooling oil. Piston crown dismantling and cleaning: Place the piston crown with skirt on a wooden support as shown. 5. The deposits must be removed as a routine procedure when a piston is overhauled. 4. see Data. clean and inspect the piston crown again. Piston rod and cooling pipe: Remove the screws from the cooling oil pipe flange. Lift the skirt and land it on a couple of planks. they should be washed clean with Carbon Remover or a similar cleaning fluid. Check that the surfaces of the O-ring groove is clean and smooth.1 Overhaul 4. M902010280O04 Mount a new O-ring on the piston rod flange. If coke deposits are found in the cooling spaces of the piston crown. please quote Procedure M90201 Edition 0285 Page 13 (22) . D0206 Clean and inspect the cooling oil pipe and the piston rod. When all coke deposits have been dissolved. then remount the cooling oil pipe. If necessary use two dismantling screws to pull the skirt out of the piston crown. When referring to this page. D0222 5. Mount two eye bolts in the skirt.Piston MAN B&W Diesel 902-1.

see Data. see Procedure 913-7. Coat the ring with lubricating oil before mounting. Mount and tighten the screws between the piston rod and the piston crown. 6. Piston crown assembly: Mount a new O-ring on the piston skirt. M902010284O06 7. Lock the screws with locking wire. Remove the guide screw. Check that the surfaces of the O-ring groove are clean and smooth. Piston crown and skirt mounting: Mount the guide screw to ensure the correct positioning of the piston rod in relation to the piston crown.Piston 902-1. D0205 Mount the piston skirt on the piston crown.1 Overhaul MAN B&W Diesel 6. Lubricate the O-ring on the piston rod flange with lubricating oil. see data D02-05. 7. please quote Procedure M90201 Edition 0285 . M902010284O07 D0203 Page 14 (22) When referring to this page. Land the overhauled piston crown and skirt on the piston rod. Tighten the screws to specified torque.

1 Overhaul Sealing ring and pressure test 8. 8. Spray a little soap water on to the surface joints between piston rod/crown/skirt and around the bolt heads to detect leaks. Close the valve on the testing tool and remove the air connection. oil Turn the piston upside up and drain out the piston oil. Sealing ring test: Mount the pressure-testing tool on the piston rod foot. the piston must be turned upside down (see next step to turn a complete piston). Mount the pressure-testing tool on the piston rod foot. Check the contact surfaces of the piston and the sealing rings for tightness.Piston MAN B&W Diesel 902-1. the piston must be pressure tested hydraulically. 9. please quote Procedure M90201 Edition 0285 Page 15 (22) . M902010277O16 According to current class rules. The piston must now hold the pressure for minimum 30 minutes. M902010277O17 Fill the piston and piston rod with lubricating oil. Pressure test: For this test. When referring to this page. The sealing ring test can also be carried out when the piston is resting in the support tool. 9. Connect compressed air to the testing tool and fill the piston to 4-5 bar. Pressure-test the piston at the pressure stated on the Data Sheet. D0201 Dry off all soap water. It is possible to carry out a test of the sealing rings with compressed air before filling the piston with oil. Check that there are no cracks in the piston crown.

MAN B&W Diesel 10. Lift the piston rod foot clear of the wooden block. Attach the lifting bracket to the bottom of the piston rod foot. Hook the crane on to the lifting bracket. Keep lifting until the piston rod is in a vertical position.902-1. Piston turning: Lift the piston with the normal lifting tool.1 Piston Overhaul 10. The stuffing box must be removed. Page 16 (22) When referring to this page. Note! M902010283O10 During the lift. Land the foot on a wooden block. Lower the piston crown to the platform and land it on a wooden block in such a way that it is possible to remove the lifting tool. follow with the crane to keep the crane positioned vertically above the lifting point. Lower the piston rod foot until it is close to the platform. please quote Procedure M90201 Edition 0285 .

See Procedure 902-2.Piston MAN B&W Diesel 902-1. using the ring expander. with the ring gaps staggered 180° and with the TOP mark upwards). 11. A B When mounting the piston rings. C M902010285O11 Do not expand the rings more than necessary. please quote Procedure M90201 Edition 0285 Page 17 (22) . Piston completion: Fit the new piston rings (alternately righthand and left-hand cuts. if the engine is equipped with two ring expanders D When referring to this page. The uppermost ring (CPR-ring) must be mounted with the short ring expander. use the ring expanders to prevent unintended deformation of the rings.3.1 Mounting 11. A C D B Mount the piston rod stuffing box.

Check the piston rings and piston crown in accordance with Procedure 902-1. please quote Procedure M90201 Edition 0285 . 1. M902010277M02 2. Both the holes for the flange and the drain hole for the drain pipe must be positioned correctly.902-1. Mount the lifting tool on the piston crown. M902010285M01 2. See Data D02-25.1 Piston Mounting MAN B&W Diesel Preparation of piston 1. Page 18 (22) When referring to this page. if not already done. Stuffing box position: Ensure that the stuffing box is correctly positioned over the distance pieces mounted on the piston rod foot.1.

1 Mounting Preparation of cylinder liner 3. 4. When referring to this page. M902010277M05 4. Crosshead position: Turn the crosshead to a position 45° from TDC (crank web pointing towards exhaust side). The cut outs for the lifting tool must be turned to fit the piston lifting tool. please quote Procedure M90201 Edition 0285 45° Page 19 (22) . M902010277M06 5. Stuffing box cover: Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit. 3.Piston MAN B&W Diesel 902-1. M902010283M03 Clean the stuffing box flange. Mount the guide ring: Mount the guide ring in the top of the cylinder liner. 5.

please quote Procedure M90201 Edition 0285 . Crosshead alignment: Turn the crosshead almost to TDC. 8. M902010284M08 8. while checking that the guide ring of the crosshead enters the centre hole in the piston rod. D0220 6. M902010285M06 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. and ensuring that the piston rod has full contact with the crosshead. 7. unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings.Piston 902-1. Protective cover: Remove the protective rubber cover from the crosshead. M902010285M07 After turning the crosshead fully to TDC.1 Mounting MAN B&W Diesel Mounting of piston 6. Coat the O-rings of the stuffing box and the piston rod with oil. Page 20 (22) When referring to this page. Coat the piston rings and cylinder liner with cylinder lubricating oil. 7.

Check that the holes in the stuffing box and stuffing box flange are correctly centered. Telescopic pipe Place the distance pipe on the bend for the telescopic pipe. Tighten the screws to the specified torque and lock with locking wire. 9. M902010280M11 Remove the suspending tool and mount the screws and tighten the telescopic pipe to the bend. For Data. For data. Tightening of the piston rod-crosshead connection: Mount and tighten the piston rod screws. 10.Piston MAN B&W Diesel 902-1. See Data.1 Mounting 9. D0202 or D0207 Turn up towards TDC until the telescopic pipe is landed on the distance pipe. When referring to this page. Remove the distance pieces from the piston rod foot. Tighten the piston rod stuffing box by means of the screws through the inner holes in the stuffing box flange. 11. please quote Procedure M90201 Edition 0285 Page 21 (22) . M902010280M09 On engine models where the drain pipe is connected directly to the stuffing box: 10. Stuffing box: Turn down and land the stuffing box on the stuffing box flange. M902010285M10 11. Use either Data D02-02 or Data D02-07. see Procedure 902-2. see Procedure 904-2. • Mount the stuffing box drain pipe.

13. Piston cleaning ring: Mount the piston cleaning ring in accordance with the scratch mark.902-1. Running-in: Smear the piston rod with molybdenum disulphide. Then stop the engine and inspect the piston rod and stuffing box. At the first opportunity. Screw the stud down to contact and half a revolution back. 12.4. and turn the crankshaft a couple of revolutions. M902010277M15 15. please quote Procedure M90201 Edition 0285 . Cylinder cover studs: If the cylinder cover studs have been removed. Tighten the cylinder cover nuts and mount the necessary pipes.1 Piston Mounting MAN B&W Diesel 12. If the PC-ring is damaged (broken or cracked). 14. If necessary. start the engine and keep it running for about 15 minutes at a speed corresponding to “Dead Slow” Ahead. M902010280M14 D0105 Page 22 (22) When referring to this page. 14. remount them. See Procedure 903-1. it must be replaced by another ring. Carefully clean the surfaces around the base of the studs and check the O-rings on the studs. M902010285M12 13. adjust the distance D01-05 by turning the stud. Mount the cylinder cover studs with the stud setter. Cylinder cover: Land the cylinder cover on the liner and check the distance that the stud is protruding from the cylinder cover. See Procedure 901-1.

free length 496 mm D02-44 Stuffing box complete 65 kg D02-45 Stuffing box half 20 kg D02-50 Stuffing box halves fitted bolts.102-2 Piston Rod Stuffing Box Data SAFETY PRECAUTIONS For detailed sketch. outer screws tightening torque 80 Nm D02-27 Stuffing box flange. ring-end clearance 3x3 mm D02-34 Sealing ring springs new. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear X Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. inner screws tightening torque 80 Nm D02-28 Stuffing box halves. please quote D10202 Edition 0062 MAN B&W Diesel A/S Page 1 (2) . ring-end clearance 4x6 mm D02-30 Lowermost rings. free length 639 mm D02-38 Scraper ring springs new. Description Value Unit D02-26 Stuffing box flange. tightening torque 25 Nm When referring to this page. tightening torque 80 Nm D02-29 Uppermost rings.

please quote Data D10202 Edition 0062 MAN B&W Diesel A/S . e.102-2 Piston Rod Stuffing Box 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 P90251 109 Mounting tool for stuffing box spring P90251 122 Worktable for stuffing box Page 2 (2) When referring to this page. P90951 refers to chapter 909.g. Plate Item No.

1. 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 D02-29 and D02-30 have been halved. Total clearance (scraper ring). Total clearance. A Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring). check the following clearances: See Procedure 902-2. B D0229 2. If a spring is extended more than 8% from the value given in data. After the piston rod stuffing box has been dismantled.902-2. D0230 D0234 Generally. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S Page 1 (10) .2. it is recommended to renew the springs when the sealing rings and scraper rings are renewed. (D02-30) D0230 A As a general guide. Garter springs: M902020230C01 The ring clearances stated in Data apply to new rings. 2. (D02-29) D0229 B Clearance at ring ends (sealing rings). M902020227C02 D0238 When referring to this page. it must be discarded. (D02-29) Lowermost scraper rings Clearance at ring ends. Total clearance (sealing rings). The springs can be checked as follows: Place the springs on the table.1 Piston Rod Stuffing Box Checking 1. measure Lo (free length). and compare with Data.

Turn the crosshead to about 90° from TDC. in the period between piston overhauls. 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. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S . only the innermost screws in the stuffing box flange and the screws for the drain oil pipe should be removed.2 Piston Rod Stuffing Box Dismantling 1. longitudinally to the engine. In connection with dismantling of the piston. M902020230D03 3. M902020229D01 Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities. 2. proceed as follows: 1. it becomes necessary to inspect the piston rod stuffing box. If. Page 2 (10) When referring to this page. M902020230D02 3.902-2. 2.

Turn the piston to BDC. 4.2 Dismantling 4. 5. thereby withdrawing the stuffing box from the cylinder frame bottom.Piston Rod Stuffing Box 902-2. Mount them in the stuffing box through the holes in the worktable. M902020229D05 By means of the four short screws in the worktable.3. M902020230D04 5. see Procedure 902-2. When referring to this page. press the stuffing box out of the flange. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S Page 3 (10) . For overhauling the stuffing box. M902020230D05 6. 6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. Remove the remaining two screws from the stuffing box. Remove the two long dismantling screws from the worktable.

M902020230O02 2.902-2. Page 4 (10) When referring to this page. Remove the O-ring of the stuffing box. Lift the stuffing box a little up the piston rod. Remove the nuts from the stuffing box assembling bolts. for example with tape. and mount the worktable round the piston rod at a suitable working height. the piston rests on a support placed over one of the cut-outs in the top platform. and hook on two tackles. M902020230O01 D0244 2. If the O-ring is intact and is to be used again. 1. overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons. Land the stuffing box on the worktable. Work on the stuffing box is then carried out from the platform below. 1. During such overhauls. and remove the tackles and eye bolts. Mount two eye bolts in the stuffing box flange. move it up the piston rod and secure it in this position. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S .3 Piston Rod Stuffing Box Overhaul Normally. M902020230O04 Overhaul inside the engine is carried out in the same way as outside the engine.

In the case of coarse scratches. D0238 8. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S Page 5 (10) . D0245 4. 6. When referring to this page. Clean the halves of the stuffing box housing. M902020230O08 9.3 Piston Rod Stuffing Box Overhaul 3. smooth the piston rod surface carefully with a fine grained carborundum stone. replace the rings. Dismantle and stack the rings in the same order as when fitted in the stuffing box. Check the lengths of the springs. 3. 7. Measure the clearance between the ring segments to determine whether replacement is necessary. Using a feeler gauge.902-2.1. measure the vertical clearance of the rings. M902020227C02 7. 8. Take out the six bolts.1. See Procedure 902-2. Inspect and assess the surface quality of the sealing rings. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings). If their sliding surfaces have scratches or marks. Inspect the surface of the piston rod. Mount two eye bolts on the stuffing box half and remove it from the worktable.1. D0234 Carefully clean all the ring segments. and pull away one stuffing box half. See Procedure 902-2. See Procedure 902-2. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. M902020230O03 5. it may prove necessary to machine-grind the surface in a workshop.

4 must be without relief grooves on the underside. Scraper ring A Scraper ring B Sealing ring C M902020230O10 No relief groove Page 6 (10) Relief groove When referring to this page. The scraper ring in groove no. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS2).3 Piston Rod Stuffing Box Overhaul 10. For correct mounting of the sealing and scraper rings see the sketch. A B C 10. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S .902-2.

• Place the spring round the segments. on the worktable. Note! If the stuffing box is assembled inside the engine. place the spring round the segments and. Assemble the 4-part sealing ring above the 8-part sealing ring. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod until the ring units are opposite the corresponding grooves in the stuffing box housing. place two pieces of plywood of the same thickness as the flange on the worktable. in the following way: 11. Push the two rings together in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring. Subsequently. 12. Assemble the 8-part sealing ring so that the two guide pins face upwards. hook the spring ends together. and hook the spring ends together. Assemble all the stuffing box ring units round the piston rod. 12. push the stuffing box half into contact with the piston rod. On top of the scraper rings. round the ring units. • Place the lowermost scraper ring segments on the worktable. to ease the assembling.3 Overhaul 11. M902020229O11 Repeat this procedure for the remaining scraper rings. When referring to this page. assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring).Piston Rod Stuffing Box 902-2. M902020230O12 Finally. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S Page 7 (10) . assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring).

Mount eye bolts and wire ropes. M902020230O13 14.3 Piston Rod Stuffing Box Overhaul 13. M902020230O14 Mount and tighten the standard bolts to specified torque. 13.902-2. Mount the O-ring in the stuffing box groove. Check the ring clearance again. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot. and lift the stuffing box a little. D0244 Remove wire ropes and screws. pushing it into place round the rings. See Data D02-50 D0250 14. D0228 In the middle holes mount and tighten up the fitted bolts to the torque specified on the Data Sheet. See Data D02-28 Page 8 (10) When referring to this page. Then place the other half of the stuffing box housing on the worktable. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S .

please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S Page 9 (10) . Mount two screws in the flange through the holes in the worktable. Turn down the short screws so that the stuffing box lands on the flange.Piston Rod Stuffing Box 902-2. 1. 2. When referring to this page. see data. 2. M902020230M02 3. only the innermost flange screws are to be mounted and tightened. M902020230M01 Mount the two long screws from the worktable in the stuffing box. M902020230M03 3. In connection with mounting of the piston.4 Mounting 1. After overhauling the stuffing box inside the engine. assemble the stuffing box halves on top of the four screws. Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. Turn the piston upwards until the stuffing box is in place in the cylinder frame.

If possible: Start up the engine and keep it running for about fifteen minutes at a number of revolutions corresponding to very slow or idle speed.902-2. Smear the piston rod with molybdenum disulphide. Remove the long screws from the stuffing box and mount them itheworktable.3 Piston Rod Stuffing Box Overhaul 4. M902020230M04 6. Then turn the crankshaft a couple of revolutions. Remove the protecting rubber cover from the piston rod/crosshead. please quote Procedure M90202 Edition 0230 MAN B&W Diesel A/S . See Data. Mount the drain oil pipe. M902020230M05 Then stop the engine and inspect the piston rod and stuffing box. 4. 5. Remove the worktable from the piston rod. Mount and tighten all the inner and outer screws for the stuffing box. Page 10 (10) When referring to this page. 5. D0226 D0227 M902020229D01 6.

please quote Plate P90251 Edition 0196 MAN B&W Diesel A/S Plate P90251-0196 Page 1 (2) .Piston and Piston Rod Panel When referring to this page.

please quote Plate P90251 Edition 0196 MAN B&W Diesel A/S . Item Description When referring to this page.Plate P90251-0196 Piston and Piston Rod Panel Item No. Item Description 014 026 040 051 075 087 099 109 110 122 134 158 160 Tool panel Name plate Lifting tool for piston rod foot Lifting tool for cylinder liner Template for piston top Distance piece Cover for stuffing box hole Mounting tool for stuffing box springs Pressure test tool for piston Worktable for stuffing box Piston ring expander Guide screw for piston crown Screw Page 2 (2) Item No.

please qoute Plate P90261 Edition 0108 Plate P90261-0108 Page 1 (2) .Piston and Piston Rod .Tools MAN B&W When referring to this page.

Tools Plate P90261-0108 Item No. please qoute Plate P90261 Edition 0108 . 019 Page 2 (2) MAN B&W Item Description Guide ring for piston When referring to this page.Piston and Piston Rod .

Piston and Piston Rod .Tilting Tools MAN B&W When referring to this page. please qoute Plate P90264 Edition 0002 Plate P90264-0002 Page 1 (2) .

015 027 Page 2 (2) Piston and Piston Rod .Tilting Tools MAN B&W Item Description Lifting collar Support for tilting tool When referring to this page. please qoute Plate P90264 Edition 0002 .Plate P90264-0002 Item No.

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

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

Data Cylinder Lubricator Cylinder Liner .Cylinder Liner and Cylinder Lubrication Documents in this Chapter 103-01 903-01 103-02 903-02 90361 90362 90364 0074 0252 0028 0249 0084 0002 0004 MAN Diesel A/S Cylinder Liner. Data Cylinder Liner Cylinder Lubricator.Tools Cylinder Liner .Milling Tools Test Equipment for Lubricators .903 .

MAN Diesel A/S .

complete 1600 kg D03-06 Cooling jacket 130 kg D03-16 Piston cleaning ring radial width. please quote Data D10301 Edition 0074 MAN B&W Diesel A/S Page 1 (2) .3 mm D03-05 Cylinder liner. new 38. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear X Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.50 - 1 mm Oversize PC-ring > 1 mm Dummy ring When referring to this page.9 mm D03-17 PC-ring/Liner max.diameter wear of 0. tightening torque 150 Nm D03-03 Cylinder diameter. wear deviation 0.50 mm) 0- 0.50 mm D03-18 PC-rings replacement criteria: Liner diameter 500 mm Liner wear Install : Standard PC-ring (new or max. new 500 mm D03-04 Piston cleaning ring diameter.50 mm 0. Description Value Unit D03-01 Lifting tool screws.103-1 Cylinder Liner Data SAFETY PRECAUTIONS For detailed sketch. new 498.

103-1 Cylinder Liner Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.Tools When referring to this page. P90951 refers to chapter 909. Plate P90251 P90361 Page 2 (2) Item No. 051 Description Lifting tool for cylinder liner Cylinder Liner . please quote Data D10301 Edition 0074 MAN B&W Diesel A/S .g. e.

Check and assess the condition of the cylinder liner according to the description given in Volume I.1 Checking Cylinder Liner S60MC 0252 Checking 903-1. 2. 6. Position the cylinder liner measuring tool. 5.3.Cylinder Liner 903-1.2. Check the lubricating points of the cylinder by pumping cylinder oil to each individual lubricating point. GN903-1. See Procedure 901-1. 1.1 1. HM903-1. Dismount the cylinder cover.1 203 03 Clean any blocked lubricating duct.1 252 04 4. Take measurements in the fore-and-aft and athwartship directions. piston and PC-ring. D03-03 Clean the cylinder liner and scavenge air ports. See Data. See Procedure 903-1. GM903-1. and grind away the wear ridges. Carefully scratch over any scores or marks on the cylinder liner running surface. 2. Chapter 707.1 218 02 3. When referring to this page.2. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. See Procedure 902-1. 4. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S Page 1 (10) .

the PC-ring must always be taken up before the piston. During inspection of the piston and liner. DM903-1. 8. If the deviation between PC ring wear and liner wear is more than D03-17.1 247 07 When the piston is removed. Page 2 (10) When referring to this page. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S . If it is needed to install an oversize PC ring.2. 5 on the liner measuring tool. GW903-1. an oversize ring or a dummy ring according to the table in D0318 on the Data sheet. and find the most worn place. Compare with data D03-16 and calculate the wear of the PC ring. If wear of the two components does not deviate more than D0317. Compare the measurements with the diameter of a new liner as stated in data. Multiply the wear by 2 to get the PC ring diameter wear. When a new liner is ordered. also a new PC ring must be installed.903-1.1 237 08 Measure the liner in the fore-and-aft and athwartship directions at piston skirt TDC position. Measure the PC ring radial width B. also a new PC ring must be ordered. the PC ring must also be inspected. Calculate the wear of the liner. or if the PC ring is broken or cracked. then reinstall the PC ring. replace the ring with a new PC ring. 8.1 Cylinder Liner Checking 7. When a new liner is installed. contact MAN B&W Diesel for advice. 7. corresponding to measuring point No. See Procedure 902-1. Compare the PC ring diameter wear with the wear of the liner. 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.

HM903-1. D03-01 Dismount the piston and the PC-ring. Discard the sealing ring from the top of the cylinder liner.2. See Procedure 901-1. Disconnect the oil pipes leading from the cylinder lubricator to the non-return valves. Note! Tighten the lifting tools to the torque stated in Data. This must be done whenever the lifting tools are mounted on the liner.Cylinder Liner 903-1. 2.2 1. See Procedure 902-1. Dismount the four cooling water pipes – between the cooling jacket and cylinder cover – and clean them carefully. When referring to this page.2 Dismantling Dismantling 903-1. HH903-1. See Procedure 903-1. Check with a 0.05 mm feeler gauge that there is no clearance between the screws and the cylinder liner.2 239 03 2.2 252 01 Mount the two lifting tools in the cylinder liner. Dismount the cylinder cover. 1. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S Page 3 (10) .2. Turn the piston down far enough to make it possible to remove the wear ridges at the top of the liner.3.

Note! The cylinder liner is not in balance. as shown on the sketch. even with the cooling jacket mounted. Dismount the four cooling water pipes between the cooling jacket and the cylinder frame and clean them carefully. HM903-1. 4. D03-05 Hook the chains from the lifting tools on to the crossbar and lift the cylinder liner with the cooling jacket out of the cylinder frame. HM903-1. for instance. Attach the crane hook to the lifting crossbar. a wire rope connected from the scavenge ports to the traverse. 3. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S .2 252 05 To keep the liner in a horizontal position during transportation. Land the cylinder liner vertically on. The lifting screws are also used for transporting the cylinder liner. a couple of planks. paying special attention to the contact surfaces for the cylinder liner at the top of the cylinder frame. Note! Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner. 5.g.2 Dismantling 3. Page 4 (10) When referring to this page. use e. 5.2 252 03 Clean the cylinder frame internally.Cylinder Liner 903-1.

2.3 Overhaul Overhaul 903-1. HM903-1. 2. and land it on the wooden planks. Clean and inspect the non-return valves. Remove the two lifting screws from the cylinder liner. Lift the cooling jacket away by means of the tackles. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S Page 5 (10) .3 1. Remove the four clamps which fix the cooling jacket to the cylinder liner. Mount two lifting eye bolts in the cooling jacket. HM903-1. 3. as shown.3 252 03 D03-06 When referring to this page.3 252 02 3. Unscrew the nuts on the non-return valves and remove the valves. Attach two tackles to the crossbar. 1.3 252 01 Hook the tackles on to the lifting eye bolts on the cooling jacket and haul tight.Cylinder Liner 903-1. HM903-1.

It is recommended to use a wear ridge milling machine to create the groove. Check in the top of the liner for a wear ridge (where the piston rings reverse direction). The maximum depth of the groove is calculated as S max. see supplier’s instruction.Cylinder Liner 903-1. it is necessary to create a groove by grinding. It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch.3 Overhaul 4. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S .3 231 04 Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC. S C R=4-5 mm MN903-1. 5. 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.3 221 04 6. by means of a rough grindstone held in the hand. If there is any sign of a wear ridge. 4. Chapter 707. Alternatively. Use a grinding disc with a round edge. MB903-1. Note! 6.The groove serves to prevent the build-up of a new wear ridge.0045. HN903-1. Carefully scratch over any scores or marks on the cylinder liner running surface. 5. Check and assess the condition of the cylinder liner according to the description given in Volume I. For use of the milling machine.3 229 05 C D Page 6 (10) When referring to this page. = D x 0.

Mount the four clamps in the groove of the liner. When referring to this page.3 252 08 D03-06 HM903-1. Lubricate the O-rings with vaseline. Lower the cooling jacket on to the cylinder liner.3 Overhaul 7. HM903-1. HM903-1. Note! 9. Replace the two uppermost O-rings on the cylinder liner. 7. 8. and tighten the screws.3 252 09 9.Cylinder Liner 903-1. Remove the tackles from the lifting crossbar and the cooling jacket lifting eye bolts.3 252 04 Make sure that the scratch marks in the fuel pump side of the cylinder liner and cooling jacket coincide. 8. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S Page 7 (10) .

3 252 10 10. Mount the non-return valves for cylinder lubrication. Page 8 (10) When referring to this page. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S . HM903-1.3 Cylinder Liner Overhaul 10.903-1. Tighten the nuts and connect the lubricating oil pipes.

4 Mounting Mounting 903-1.4 252 02 3. Loosen the water connections on the cooling jacket. When referring to this page.4 252 01 Mount new O-rings on the four lowermost cooling water pipes. See Data D03-01. 1. and lift the jacket/liner assembly. Mount the lowermost O-rings and apply a little lubricating oil on the rings. 2.4 1. Mount the cylinder liner in the cylinder frame. HM903-1. Coat the joint surfaces with permatex or a similar liquid sealing compound. D03-05 HM903-1. Mount the cooling water pipes in the cylinder frame. Mount the two lifting tools in the cylinder liner. Hook the chains from the lifting tools onto the crossbar. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S Page 9 (10) .Cylinder Liner 903-1. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Replace the O-rings on the uppermost water connections and mount the water connections on the cooling jacket. Remove the lifting tools from the cylinder liner. D03-01 2.

4. Page 10 (10) When referring to this page. GN901-1. See Procedure 902-1. check that each individual lubricating point functions correctly.4.4. See Procedure 901-1. Check that there is no leakage from the system. Mount the sealing ring and the cylinder cover. Connect and tighten the oil pipes for the cylinder lubrication. Lubricate the upper part inside of the cylinder liner with cylinder lubricating oil and mount the piston and the PC ring. without air bubbles. comes out from the non-return valves.4. 7.4 203 01 Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned. please quote Procedure M90301 Edition 0252 MAN B&W Diesel A/S .4 Cylinder Liner Mounting 4. HM903-1.903-1. When this is in order. See Procedure 902-1.4 252 04 5. 7. 6. Vent the cylinder lubricating system until oil. If one or more cylinder cover studs have been removed. mount them again.

1. 30 bar D03-11 Outlet accumulator. nitrogen pressure.103-2 Cylinder Lubricators Data SAFETY PRECAUTIONS For detailed sketch. 30 Nm When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. nitrogen pressure. tightening torque. Description Value Unit D03-10 Inlet accumulator. please quote Data D10302 Edition 0028 MAN B&W Diesel A/S Page 1 (2) .5 bar D03-13 Plug screw.

Plate P90364 Page 2 (2) Item No. Description Test Equipment for Lubricators When referring to this page. please quote Data D10302 Edition 0028 MAN B&W Diesel A/S . P90951 refers to chapter 909. e.103-2 Cylinder Lubricators 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.

M903020245C01 Turn the piston to BDC and check inside the liner with a mirror and a powerful light source that all lubrication points are working properly.Cylinder Lubricators MAN B&W Diesel 903-2. 2. If the cylinder cover or the exhaust valve is removed. remove the covers for scavenge port inspection. When referring to this page. check inside the liner that all lubricating points are working properly. and check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. Otherwise. M903020245C02 3. please quote Procedure M90302 Edition 0249 Page 1 (12) .-button on the HMI control panel. Press the ESC + PRELUB. With stopped engine and normally when the system has been disassembled: 1.1 Checking Check of Oil Injection: 1.

see Step 5.1 Checking MAN B&W Diesel With running engine: 4. Close the inlet valve and open the equalizing valve on the respective lubricator. the accumulator or the lubricator with accumulator must be dismounted. disconnect the pipe at the cylinder liner to observe the oil flow. please quote Procedure M90302 Edition 0249 . M903020245C05 The nitrogen pressure in the inlet accumulator (0. For nitrogen pressure in the accumulators. Inlet The LEDs give signal when oil is injected. Measuring the nitrogen pre-pressure can only be done with stopped engine and pressure-free lubrication system.2. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator.7 litre) can be checked without dismounting the accumulator. M903020249C03 D0311 5. Check the pressure shocks from the injection of the lubricators on each lubricator pipe by feeling with a hand. see Data. To measure the nitrogen pressure in the outlet accumulator (0.16 litre). D0310 If in doubt.Cylinder Lubricators 903-2. See Procedure 903-2. 3. For use of the pressure setting tool. Page 2 (12) When referring to this page. 5. Check of Accumulators: 4. Stop both oil pumps.

If the accumulator needs to be refilled with nitrogen. If necessary. 8. Remount the accumulator. Use of Pressure Setting Tool Assemble the pressure setting tool as shown in Figure 5. Mount the filling valve on the relevant accumulator with the union nut. Release the pressure in the filling valve at bleed screw F.7 litre) is to be checked.16 litre) is to be checked. Check that valves C and F are closed. please quote Procedure M90302 Edition 0249 Page 3 (12) . check that the accumulator top is clean. 7.Cylinder Lubricators Checking 6. 7.1 Loosen the plug screw in the accumulator using a ½” square drive handle in socket E. Open valve C until the accumulator is filled to the correct pressure. Before mounting the filling valve on the accumulator. open valve A and increase the outlet pressure from valve C on spindle B to 1-2 bar above the pressure stated in Data. Retighten the plug screw to the torque stated in Data. use a threaded adaptor. Mount a 0-60 bar pressure gauge on the filling valve when the inlet accumulator (0. Unscrew the filling valve from the accumulator. When referring to this page. and mount the reducing valve on the nitrogen cylinder. C A E D0313 F B M903020247C07 MAN B&W Diesel 903-2. It is now possible to read the actual nitrogen pressure in the accumulator on the dial gauge on the filling valve. and a 0-10 bar pressure gauge when the outlet accumulator (0. Close valve C and tighten the plug screw with socket E to the torque stated in Data.

2 Dismantling MAN B&W Diesel Dismantling of lubricators: 1.4. 2. Stop the cylinder oil pump station. Inlet 1. The engine must be stopped and blocked before dismounting a lubricator. • Reduce the engine load to below 40% of MCR • Let the lubricator pump station run • Dismount the lubricator as described in steps 1-3 • Mount a spare lubricator as described in Procedure 903-2. M903020249D01 Disconnect the electrical plug on the side of the lubricator. Page 4 (12) When referring to this page. please quote Procedure M90302 Edition 0249 . Inlet 3. Special running M903020249D02 It is possible to change a lubricator while the engine is running if a spare lubricator with Orings and the necessary tools is available. Unscrew the four screws on the side that secure the lubricator to the hydraulic block. Unscrew the six screws in the bottom of the lubricator and disconnect the cover with pertaining pipes. Close the supply valve for the lubricator and open the equalizing valve (turn both handles to a horizontal position). 2. if installed. and remove the lubricator. Remove the upper shield. The change should be done in a maximum of 15 minutes.Cylinder Lubricators 903-2.

please quote Procedure M90302 Edition 0249 Page 5 (12) . a nitrogen pre-pressure of 25-30 bar will remain in the accumulator.Cylinder Lubricators MAN B&W Diesel 903-2. Remove the accumulator from the hydraulic block.2 Dismantling Dismantling of accumulators: 5. Inlet Stop the cylinder oil pump station. The engine must be stopped and blocked before the accumulator is dismounted. 4. Close the supply valve for the lubricator and open the equalizing valve. When referring to this page. When the oil pressure is released. M903020249D04 Note! Carefully unscrew the accumulator to release the remaining oil pressure in the system.

Remove and discard the O-rings. Pull up the cylinder block.903-2. Discard the O-ring from the adjusting screw. 2.3 Cylinder Lubricators Overhaul 1. Page 6 (12) When referring to this page. Remove the spring and actuator piston with plungers. MAN B&W Diesel 1. Take out springs and balls. M903020247O01 3. M903020247O03 3. Place the lubricator in a bench vice with soft “jaws”. 2. M903020247O02 Remove the cover for the non-return valves. Remove and discard the O-ring from the cylinder block. Unscrew the oil accumulator. Remove the screws from the cylinder block. please quote Procedure M90302 Edition 0249 . Remove the adjusting screw with bushings.

Inspect the plungers. 5. using a magnifying glass.3 Overhaul 4. When referring to this page. M903020247O04 6. Clean the valves and check them with compressed air. please quote Procedure M90302 Edition 0249 Page 7 (12) . M903020247O05 5. Mount the non-return valves in the cylinder block. actuator piston and cylinder block for wear.Cylinder Lubricators MAN B&W Diesel 903-2. 4. Fit the non-return valve with new O-rings. M903020247O06 6. Screw out the non-return valves and remove and discard the O-rings.

3 Cylinder Lubricators Overhaul 7. before finally assembling the cylinder block unit. M903020247O07 Fit the cylinder block with a new O-ring. MAN B&W Diesel 7. Page 8 (12) When referring to this page. Mount the spring and press down the actuator piston with plungers.903-2. Mount an M6 x 60 screw with a washer to keep the spring compressed. Pre-assemble the cylinder blockwith the actuator piston and plungers to ensure the correct guidance of the plungers. please quote Procedure M90302 Edition 0249 .

9 Turn the lubricator upside down in the vice. Remove the cover from the terminal box and disconnect the wires for the feedback (pick-up) sensor. Check the slide for wear.3 Overhaul 8. When referring to this page. Unscrew the solenoid valve. M903020244O12 10. M903020247O09 Lubricate the slide with oil and check that the slide can move lightly with a good fit in the housing. See also manufacturer’s instructions. If the slide is scratched or scuffed. the valve must be replaced by a new one. Assemble the valve. 8. Disassemble and clean the valve. 10. Discard the O-rings. Solenoid valve: M903020247O08 Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth. please quote Procedure M90302 Edition 0249 Page 9 (12) .Cylinder Lubricators MAN B&W Diesel 903-2. Remove the terminal box and the plug for the solenoid valve. 9. Carefully unscrew the feedback sensor and remove and discard the O-ring.

with a new O-ring. Mount the feedback sensor or a new one. 2 Brown+15 Blue OV M903020242O08 Black FBsignal M903020247O13 13.3 Overhaul MAN B&W Diesel 11. please quote Procedure M90302 Edition 0249 . Before mounting the feedback sensor. 1 2 3 BN (brown) BK (black) 4 BU (blue) 5 1 2 Solenoid valve 11.g. Connect the wires and mount the cover on the terminal box. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder.Cylinder Lubricators 903-2. Page 10 (12) When referring to this page. 11. Mount the solenoid valve fitted with new O-rings. Coat the O-rings with a little grease to keep the rings in place during mounting. if necessary. LED 13. Check with an object with a straight edge (e. check that the sensor is flush with the sensor housing. M903020245O10 Mount the terminal box. Feedback sensor 12.

Cylinder Lubricators MAN B&W Diesel 903-2. Remove the M6 x 60 screw with disc. Mount the adjusting screw fitted with a new O-ring and the distance bushing.3 Overhaul 14. please quote Procedure M90302 Edition 0249 Page 11 (12) . M903020247O01 Cover all surfaces with a thin layer of oil. Mount the cylinder block assembly in the cylinder housing. Check that the spring pin engages correctly with the cylinder block assembly. If the lubricator is not to be mounted on the engine immediately after overhauling. Mount the oil accumulator. 14. 15. When referring to this page. Mount the screws and tighten the block to the housing. cover all openings with plastic to prevent dirt from entering the lubricator during storage. 16. M903020247O14 15.

M903020249M01 Tighten the screws in the bottom of the lubricator to the pipe connection. M903020249M03 Inlet Page 12 (12) When referring to this page.4 Mounting 1. 3. Inlet MAN B&W Diesel 1. Mount new O-rings on the hydraulic block and on the cover with pipes. 2. Mount the lubricator and tighten the screws on the hydraulic block. Before mounting the accumulator.Cylinder Lubricators 903-2. Inlet Mount the electrical plug. Mount the accumulator. M903020249M02 2. Close the equalizing valve and open the supply valve (handles to be in a vertical position). Check the injection of cylinder oil on the feedback LED on the terminal box for the specific lubricator. please quote Procedure M90302 Edition 0249 . see Data. 3. check the nitrogen pressure.

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

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

Milling Tools MAN B&W When referring to this page. please qoute Plate P90362 Edition 0002 Plate P90362-0002 Page 1 (2) .Cylinder Liner .

Plate P90362-0002 Cylinder Liner .Milling Tools MAN B&W Item No. please qoute Plate P90362 Edition 0002 . Item Description 018 Wear ridge milling machine Page 2 (2) When referring to this page.

please qoute Plate P90364 Edition 0004 Plate P90364-0004 Page 1 (2) .Test Equipment for Lubricator MAN B&W When referring to this page.

Plate P90364-0004 Test Equipment for Lubricator MAN B&W Item No. please qoute Plate P90364 Edition 0004 . minimess Quick coupling. complete Page 2 (2) When referring to this page. Item Description 014 026 038 040 051 063 075 087 099 109 122 205 Reducing valve Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor Quick coupling. minimess Special screw Test equipment for accumulators set.

Data Crankpin Bearing Connecting Rod.Hydraulic Tools Crosshead .Crosshead with Connecting Rod Documents in this Chapter 104-01 904-01 104-02 904-02 104-03 904-03 104-04 904-04 104-05 904-05 90451 90461 90464 0061 0251 0063 0250 0043 0216 0054 0232 0053 0233 0139 0068 0008 MAN Diesel A/S Crosshead Bearing. Data Crosshead Reciprocating Parts. Data Connection Rod Connecting Rod and Crosshead . Data Crosshead Bearing Crosshead.904 .Hydraulic Tools . Data Reciprocating Parts Crankpin Bearing.Panel Connecting Rod .

MAN Diesel A/S .

top clearance max. Description Value Unit D04-01 Crosshead bearing. lower 34 kg D04-07 Crosshead bearing cap with bearing shell 325 kg D13-01 Hydraulic pressure.104-1 Crosshead Bearing Data SAFETY PRECAUTIONS For detailed sketch. 0.990 bar When referring to this page. top clearance min. 0. please quote Data D10401 Edition 0061 MAN B&W Diesel A/S Page 1 (2) .15 mm D04-03 Oil wedge length.5 mm D04-02 Crosshead bearing. dismantling 800 . see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. upper 25 kg D04-06 Crosshead bearing shell. L 15 mm D04-04 Crosshead bearing cap 300 kg D04-05 Crosshead bearing shell. mounting 900 bar D13-02 Hydraulic pressure.

Description P90451 47 Wire guide P90451 59 Lifting attachment .g. complete P91356 P91366 Page 2 (2) Lifting Tools. complete P91351 117 5-way distributor block. Plate Item No. pneumatically operated P91351 046 Hose with unions (1500 mm). Crosshead P90451 118 Rubber cover for crosshead P90451 120 Rubber cover for crosshead P90464 Crosshead .104-1 Crosshead Bearing Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Etc. Crosshead P90451 106 Bracket for support. 058 Feeler gauge When referring to this page. e.connecting rod P90451 72 Chain for suspending piston P90451 84 Retaining tool telescope pipe P90451 96 Bracket for support. please quote Data D10401 Edition 0061 MAN B&W Diesel A/S . complete P91351 058 Hose with unions (3000 mm).Hydraulic Tools P91351 010 Hydraulic pump. P90951 refers to chapter 909.

see the measurement in the Adjustment Sheet in Volume I.1 mm. For further external inspection of the crosshead bearing. the crosshead bearing must be disassembled for inspection. See Procedure 904-1. See Data. M904010251C03 4.1 Crosshead Bearing Checking The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing components. 1. M904010251C05 (Oil Wedge) When referring to this page. see Chapter 708. 3.904-1.2. ‘Bearings’ in the instruction book. 6. OPERATION. Open the crankcase door at the relevant cylinder. Volume I. D0401 D0402 5. OPERATION. The wear limit for a crosshead bearing shell is confined to 50% reduction of the oil wedge length (L). Turn the crankthrow concerned to BDC. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S L 1/2 D0403 L Page 1 (10) . Measure the clearance in the crosshead bearing by inserting a feeler gauge between the bearing cap and the crosshead journal. If so. 1. The difference between the actual clearance measurements and the measurements recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0. M904040232C02 2. exactly next to the landing surface for the piston rod foot. 3. For the top clearance of a specific bearing. 2. See Data.

Remove all tools. In case the reason for opening the crosshead bearing is a routine inspection. Mount two eyebolts in the bearing cap and use two small tackles in the athwartship direction to lift the bearing cap free of the guidepins and to keep the bearing cap balanced. Dismount the crosshead bearing cap hydraulic nuts. 10. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S . Use tackles to hold the connecting rod in the vertical position.1 Crosshead Bearing Checking Alternate checking method: 8. Perform the clearance measurement shown in 904-1. 12. i. 9. M904010251C08 7. If there are any doubt concerning damage to the upper bearing. If the lower bearing shows no anomalies the piston and crosshead is lowered again and the crosshead bearing cap nuts are mounted. Recheck the bearing top clearance. see Section 913. the following procedure is sufficient.2 Page 2 (10) When referring to this page. Note! Ensure that the crosshead is lifted simultaneously fore and aft. Turn to BDC. Use the tackles in the crankcase top to lift the crosshead and piston high enough to allow inspection of the lower crosshead bearing. by placing marks on the guide planes using a felt tipped pen. the bearing has to be dismantled and checked according to 9041. Mount two eyebolts on top of the guideshoes. For operation of the hydraulic jacks.904-1. 11.1 section 3. M904010251C09 8. mount the connecting rod lifting attachments on the connecting rod. Mount the two eyebolts and tackles in the top of the crankcase in the fore and aft direction. 6. 9.e.

in the athwartship direction. M904010251D02 For operation of the hydraulic tools. 3. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S Page 3 (10) . see Procedure 913. Remove the screws. Loosen and remove the locking wire from the screws on the piston rod foot. 2. Mount two chains in the inner screw holes at the top of the crankcase. for suspending the piston rod. 3. Remove the hydraulic jacks and unscrew the nuts.Crosshead Bearing 904-1.2 Dismantling This procedure applies to the following two dismantling situations: 1. and the screws on the telescopic pipe. • with piston mounted • with piston removed With piston mounted: 2. the crosshead bearing cap. M904010251D03 D1302 When referring to this page. Loosen the nuts. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts. Turn the crosshead down far enough to give access to the nuts and screws on the piston rod. M904040232C02 1.

Page 4 (10) When referring to this page. Hook the ends of the chains to the lifting eye bolts in the piston rod. Turn the crosshead downward and the piston rod will remain suspended from the two chains.904-1. never turn the engine without first dismantling the telescopic pipe from the crosshead. Caution! M904010251D06 When a piston is dismantled. Loosen the crosshead bearing cap nuts. Mount a lifting eye bolt on each side of the bearing cap and on the piston rod. M904010251D05 8. 5. With piston removed: 7. Remove the hydraulic jacks and the spacer rings and unscrew the nuts. 6. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S . 5.2 Crosshead Bearing Dismantling 4. Turn to BDC. Remove the distance pipe from the bend for the telescopic pipe. see Procedure 913-1. using the tool. Suspend the telescopic pipe. Place the spacer rings around the nuts and screw the hydraulic jacks on to the studs.2. For operation of the hydraulic jacks. 4. Remove one screw from the telescopic stuffing box housing and mount the special tool for suspending the telescopic pipe. Loosen and remove the screws which secure the telescopic pipe to the bend. See Procedure 902-1. Turn the crosshead to TDC. M904010251D04 6.

M904010251D09 Hook the tackles on to the eye bolts in the crosshead bearing cap and remove the cap from the engine.904-1. 10. M904010251D10 10. 11. Mount the lifting attachments on the head of the connecting rod. Check the upper part of the journal. When referring to this page. Suspend two tackles from the lifting brackets in the athwarthship direction. D0407 M904010251D11 11. 9. Mount two eye bolts in the top of the crosshead bearing cap.2 Crosshead Bearing Dismantling 9. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S Page 5 (10) .

please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S .904-1. 12. M904010251D12 13. Place the bearing cap on one side on a couple of wooden planks. 14.2 Crosshead Bearing Dismantling 12. Do not remove the chains or lifting eye bolts. Turn the crosshead upwards until the piston rod lands on the crosshead. Page 6 (10) When referring to this page. M904010251D13 13. D0405 Remove the thrust pieces for axial guidance of the connecting rod. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod. Fasten tackles to the fixed lifting brackets on the frame box wall. M904010251D14 14.

17. 18.2 Crosshead Bearing Dismantling 15. Haul the tackles tight. ‘Bearings’. Turn the crankthrow carefully towards BDC while ‘following’ with the tackles. M904010251D15 Carefully turn the crank down towards the exhaust side. 15. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S Page 7 (10) . With the crosshead resting on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. M904010251D16 D0220 17. Chapter 708. until the guide shoes rest on the supports. Haul the tackles tight. Mount the four supports for guide shoes on the crosshead guides. OPERATION. M904010251D17 D0451 When referring to this page. 16. thus continuously supporting the connecting rod.904-1. check the lower part of the crosshead journal and the lower bearing shell. Regarding checking of journal and bearing shells. Turn to TDC and attach the tackle hooks to the lifting attachments. see Volume I. 16.

M904010251D19 Lift the bearing shell out of the engine. Page 8 (10) When referring to this page.904-1. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S . and turn the bearing shell so far up that an eye bolt can be mounted.2 Crosshead Bearing Dismantling 19. Dismount the locking screws. tilt the connecting rod towards the door in the camshaft side by means of the tackles. In cases where it is necessary to remove the lower bearing shell. D0406 19.

Mount and secure the bearing shell in the bearing housing. M904010251M01 Raise the connecting rod to an upright position. please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S Page 9 (10) . Turn to TDC while ‘following’ with the tackles. 2. The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated. M904010251M03 3. If the piston is mounted. When referring to this page. Note! Take care that the bearing studs do not damage the crosshead. 2. D0451 3.4 Crosshead Bearing Mounting With piston mounted/With piston removed: 1. for assembling the crosshead and the connecting rod. slowly turn down until it is fully suspended from the chains. Remove the tackles from the crosshead. D0406 1.904-1. M904010251M02 Turn the crank throw to BDC. Remove the supports from the crosshead guides.

please quote Procedure M90401 Edition 0251 MAN B&W Diesel A/S . With piston mounted: 5.4. Page 10 (10) When referring to this page. 8.904-1. Remove the chains and eye bolts from the top of the crankcase. Lift the bearing cap into the engine. Tighten all four crosshead bearing cap nuts simultaneously. Check the top clearance in the bearing. 7.4 Crosshead Bearing Mounting 4. Unhook the chains from the lifting eye bolts in the piston rod. For tightening torque. M904010251M04 Mount the thrust pieces for axial guidance of the connecting rod. 4. 6. Remove the lifting attachments from the connecting rod.1. Mount the piston. D0407 5. Turn the crosshead upwards until the piston rod lands on the crosshead. see Procedure 902-1. Lower the bearing cap onto the crosshead and remove the tackles. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod. See Procedure 904-1. For operation of hydraulic jacks. M904010251M07 7. see Data. See Procedure 902-1. from the piston rod and from the crosshead bearing cap. M904010251M05 D0416 D1301 For tigthening of piston rod bolts and mounting of the telescopic pipe. see Section 913. See Data.4.

Description Value Unit D04-07 Crosshead bearing cap with bearing shell 325 kg D04-08 Cooling oil outlet pipe.990 bar When referring to this page. tightening torque 260 Nm D04-09 Inlet pipe. tightening torque 50 Nm D04-16 Thrust piece. tightening torque D04-59 1230 kg 106 kg 13 kg 180 Nm 1220 kg 200 Nm Telescopic pipe 17 kg D04-60 Inlet pipe 14 kg D04-62 Crosshead without guide shoes 1018 kg D13-01 Hydraulic pressure. mounting 900 bar D13-02 Hydraulic pressure. please quote Data D10402 Edition 0063 Page 1 (2) . see 900-2 Stopped engine X X X X X X Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. dismantling 800 . screwing-in torque 120 Nm D04-11 Guide strip nuts. screwing-in torque D04-51 Connecting rod complete D04-58 Stuffing box. tightening torque 460 Nm D04-10 Inlet pipe stud. telescopic pipe.05-0. tightening torque 460 Nm D04-20 Clearance between thrust piece and crosshead 0.Crosshead MAN B&W Diesel 104-2 Data SAFETY PRECAUTIONS For detailed sketch.35 mm D04-21 Crosshead complete D04-22 Guide shoe D04-23 Cooling oil outlet pipe D04-49 Connecting rod studs . tightening torque 100 Nm D04-15 Telescopic pipe.

complete P91351 117 Page 2 (2) 4-way distributor block. e.connecting rod P90451 60 Lifting tools .Hydraulic Tools P91356 Lifting Tools. Etc. Plate Item No. P91366 58 Feeler gauge P91366 61 Slide caliper P91351 10 Hydraulic pump. pneumatic operated P91351 46 Hose with unions (1500 mm).crosshead P90451 72 Chain for suspending piston P90451 84 Retaining tool telescope pipe P90451 118 Rubber cover for crosshead P90451 120 Rubber cover for crosshead P90464 Crosshead . P90951 refers to chapter 909. complete When referring to this page.g. please quote Data D10402 Edition 0063 . Description P90451 47 Wire guide P90451 59 Lifting attachment . complete P91351 58 Hose with unions (3000 mm).Crosshead 104-2 MAN B&W Diesel Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.

4. For operation of the hydraulic tools. M904020250D04 Suspend the telescopic pipe by means of the tool. see Procedure 904-1. D1302 4. Turn the crosshead to TDC. 2. Mount the retaining tool for the telescopic pipe on the stuffing box housing for the telescopic pipe. Remove both thrust pieces on the crosshead bearing cap. Use two tackles to retain the connecting rod in an upright position. Suspend the piston. D0407 3. Turn to BDC and mount connecting rod lifting tools.2 Dismantling 1. Lift the bearing cap out of the engine. Dismount the main bearing lubricating oil pipes. see Procedure 913-1. 2. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts. Mount two eye bolts in the crosshead bearing cap and hook on the tackles from the top of the crankcase. Turn the crosshead to BDC to give access to the nuts on the crosshead bearing cap. remove the hydraulic jacks and unscrew the nuts. and suspend two tackles. Remove the piston rod guide ring and the shim from the crosshead. please quote Procedure M90402 Edition 0250 Page 1 (9) . To suspend the piston. Loosen the nuts.Crosshead MAN B&W Diesel 904-2. M904020250D02 Mount two eye bolts in the athwartship direction. When referring to this page.

Mount the special lifting tool on the crosshead. Lift the crosshead free of the connecting rod. please quote Procedure M90402 Edition 0250 .Crosshead 904-2. using the stud setter. 5. M904020250D06 D0421 Page 2 (9) When referring to this page. 6. Attach tackle chains from the two tackles in the athwartship direction to the lifting tool. M904020250D05 Remove the outlet pipe. D0423 D0460 Dismount the guide pin for the oil inlet bend using the special extractor. Mount the eye bolt in one of the threaded holes in the bend. Dismount the four bearing cap studs. dismount the bend for the telescopic pipe and remove the studs from the crosshead. 6. hook on a tackle and haul tight.2 Dismantling MAN B&W Diesel 5.

8. while turning the crankthrow towards the camshaft side. as necessary. 7. 9. M904020250D07 Stop turning when the crankthrow is in a position where there is room in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings. Remove the oil pipes from the two adjacent main bearing caps.2 Dismantling 7. D0451 Transfer the tackles from one lifting attachment to another. Note! M904020250D10 Make sure that the crosshead journal does not touch the crank. 9. By alternate use of the tackles. Remove the guide strips and the stop screws from the bottom of the guide shoes. M904020250D09 Note! 10. Use the tackles to tilt the connecting rod to-wards the exhaust side. It is recommended to tag the guide strips and shims to avoid mixing them. Lower the crosshead so that the guide shoes are just below the cutout in the side walls of the frame box. Mount lifting eye bolts in both guide shoes. When referring to this page. 10. tilt the connecting rod until it is out of the way.Crosshead MAN B&W Diesel 904-2. please quote Procedure M90402 Edition 0250 Page 3 (9) . There has to be space in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings.

11. at the same time. Haul the tackles for the guide shoes tight and. M904020250D12 12. Lift the guide shoes to provide space for turning the crosshead. Mount two eye bolts in the holes for stop screws in the guide shoes in the adjacent cylinder units. M904020250D13 D0462 Page 4 (9) When referring to this page. 12. Hook the tackles on to the eye bolts in the guide shoes. pull the guide shoes sideways until they are free of the crosshead. 13.2 Crosshead Dismantling MAN B&W Diesel 11. and suspend two tackles from the eye bolts. please quote Procedure M90402 Edition 0250 . M904020250D11 Take the guide shoes through the openings in the side walls by means of the tackles in the two adjacent cylinders. 13.904-2.

When referring to this page. 14. 15.2 Dismantling 14. Take care that the crosshead does not bump into anything as this will damage the sliding surfaces of the crosshead.Crosshead MAN B&W Diesel 904-2. remove the crosshead from the engine. M904020250D14 Note! M904020250D15 15. Remove the guide shoes from the engine and tag them. by means of wire rope and tackle. Mount a tackle outside the engine and. Land and protect the crosshead outside the engine. Turn the crosshead 90°. please quote Procedure M90402 Edition 0250 D0422 Page 5 (9) .

Clean the crosshead and mount the lifting tool.Crosshead 904-2. Turn the crosshead 90° to enable mounting of the guide shoes. M904020250M01 Suspend two tackles from the top of the framebox between the guides. 3. 2. Suspend two tackles from the top lifting brackets in the framebox and use them in conjunction with a tackle mounted outside the engine to carefully lift the crosshead and ease it into the crankcase. Attach two tackles to the eye bolts at the bottom of the guide shoes in the adjacent cylinders. carefully lift the guide shoes into the engine. protect the crosshead with a cloth. If necessary. 3. Using these tackles and a tackle outside the engine. D0421 2. take great care that its surfaces are not scratched or damaged. please quote Procedure M90402 Edition 0250 .4 MAN B&W Diesel Mounting 1. 1. Check that the oil inlet and outlet holes are pointing towards the exhaust side. Note! M904020250M02 When handling the crosshead. M904020250M03 D0422 Page 6 (9) When referring to this page. Mount the wire guide tool in the framebox door opening.

Use the tackles in the top of the framebox to lift the crosshead into a working position and mount the guide strips and shims on the side of the guide shoes. Remove the tackles and the eye bolts from the guide shoes. Dismount the tackles and connecting rod lifting tools from the connecting rod. 4. 6. M904020250M04 Mount the stop screws in the bottom of the guide shoes. 5.Crosshead MAN B&W Diesel 904-2. and push the guide shoes into position through the openings in the side walls. When referring to this page. please quote Procedure M90402 Edition 0250 Page 7 (9) . M904020250M05 7. Lubricate the sliding surfaces of the guide shoes and the crosshead with plenty of clean lubricating oil. D0411 D0421 M904020250M06 6. 5. Lubricate the crosshead bearing liberally with clean lubricating oil and carefully lower the crosshead into place. Lift the crosshead to a position above the connecting rod in the upright position. Raise the connecting rod to the upright position.4 Mounting 4.

Turn the connecting rod and crosshead to BDC. Mount the studs for the cooling oil inlet bend.Crosshead 904-2. MAN B&W Diesel 8. D0407 D1301 M904020250M09 D0416 D0420 Page 8 (9) When referring to this page. Lift the crosshead bearing cap into the engine. Lubricate the crosshead journal with plenty of clean lubricating oil.4 Mounting D0408 D0409 D0410 D0449 8. Mount the two thrust pieces on the sides of the crosshead bearing cap. See Data. Mount the piston rod guide ring and the shim on the crosshead. M904020250M08 Mount the cylindrical dowel with threaded hole in the bend. please quote Procedure M90402 Edition 0250 . D0458 D0459 Mount the hydraulic nuts. Remove the lifting tool from the crosshead. Carefully land the bearing cap on the crosshead. Mount the bend and outlet pipe. and mount the bearing cap studs. 9. Tighten the screws to the torque stated in Data. 9.

shackles or rags left behind. Note! Search the crankcase to ensure that there are no tools. Remove the hydraulic tools and the eye bolts from the engine.Crosshead MAN B&W Diesel 904-2.4 Mounting 10. See Procedure 904-3. See Procedure 904-1. M904020250M10 Check the clearances between the guide strips. Note! At this point it is recommended to check the crosshead bearing clearance. See Procedure 904-1. see Procedure 913-1. 10. guide shoes and crosshead guides. please quote Procedure M90402 Edition 0250 Page 9 (9) . Remove all tools from the engine. For operation of hydraulic tools. Mount the main bearing lubricating oil pipes. When referring to this page. 11. Tighten the hydraulic nuts. Mount the piston and the telescopic pipe.

.

M+Y. L+Y. please quote Data D10403 Edition 0043 MAN B&W Diesel A/S Page 1 (2) . N min. O max. 0. 0. N max. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.8 mm N: New and cold engine with staybolts tightened (less than 100 running hours). When referring to this page. O max. Description Value Unit Acceptance criteria with piston in centre (F-A direction) D04-25 PF+PA. 0. 0.5 mm D04-36 J+X. N max.8 mm D04-41 ZF/ZA O min. H+F. 0. N min. 1. L+Y. K+X. K+X. 4 mm D04-42 TF + TA O max.1 mm D04-39 QF/QA.9 mm D04-35 J+X. M+Y. H+F. N max. K+X. O max. O max. M+Y.5 mm D04-26 PF+PA. H+F.8 mm D04-34 J+X. 0.7 mm D04-28 E+G. O: Engine in service.2 mm D04-30 E+G.104-3 Reciprocating Parts Data SAFETY PRECAUTIONS For detailed sketch.5 mm D04-29 E+G. 0. 0. 0. L+Y.

P90951 refers to chapter 909.g. e. 58 Description Feeler gauge When referring to this page. please quote Data D10403 Edition 0043 MAN B&W Diesel A/S .104-3 Reciprocating Parts Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Plate P91366 Page 2 (2) Item No.

Bend each end approx. 250 mm up along the framebox side.Reciprocating Parts 904-3.5 mm per 1000 mm. Aft 2. 2. In order to achieve uniform measuring conditions on board. MA904-5. Mount a transparent plastic tube along the length of the bedplate.0 72 01 1. Fill the tube with water (possibly coloured) until the water level is approx. Fore Measurements are to be taken with a ruler. PA PF HN904-3. Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. 100 mm from the end of the tube. Trim the ship until the difference between the water level S fore and aft is less than 1. Turn the crankshaft in ASTERN direction to 45° after BDC (the guide shoe must rest against the crosshead guide). See T.1 Checking Reciprocating Parts S42MC 0216 Checking 904-3.1 212 02 Check the centering of the piston in the cylinder liner by measuring the clearance (by applying a long feeler gauge from the scavenge air space) between the piston skirt and the cylinder liner in the Fore and Aft positions (PF-PA).1 1. the ship's trim must be as close as possible to 0°. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S Page 1 (3) . 45° A ste rn When referring to this page.

Reciprocating Parts 904-3. K+Y. The clearance. calculated as J+X. Measure the clearance between the guide strips and crosshead guides (J.1 Checking 3. Exhaust Side MN904-3.2 mm per 1000 mm. Measure the clearance between the crosshead guides and the guide shoes (E. 4. G and H). 4. 3. Measure the clearance between the crankthrow and the connecting rod. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S .1 215 04 Parallelism between the guide strip and guide is to be kept within a tolerance of 0. K. L and M).1 215 05 Camshaft Side Page 2 (3) When referring to this page. L+Y and M+Y. MN904-3. Measure the clearance between the thrust piece and the crosshead (TF and TA or QF and QA. F. 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. BF and BA correspond to the thickness of the shims and are only to be measured if an adjustment is carried out.

It is recommended that the measured results are noted down so that possible later changes can be ascertained. Piston/Liner 1 2 3 4 PF PA Shim Thickness Frame Box BF BA E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4 J+X L+Y K+X MN904-3.1 Checking 5.Reciprocating Parts 904-3.1 215 06 M+Y Crosshead Connecting Rod Crankthrow Connecting Rod When referring to this page. Cyl. please quote Procedure M90403 Edition 0216 MAN B&W Diesel A/S QF/TF QA/TA ZF ZA Page 3 (3) . 5.

.

990 bar When referring to this page. lower shell 15 kg D04-48 Crankpin bearing cap + shell + bearing studs 175 kg D04-51 Connecting rod complete 1220 kg D13-01 Hydraulic pressure. upper shell 20 kg D04-47 Crankpin bearing. dismantling 800 . max. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. 0. min. please quote Data D10404 Edition 0054 MAN B&W Diesel A/S Page 1 (2) .104-4 Crankpin Bearing Data SAFETY PRECAUTIONS For detailed sketch. 0.55 mm D04-44 Crankpin bearing clearance. Description Value Unit D04-43 Crankpin bearing clearance. mounting 900 bar D13-02 Hydraulic pressure.2 mm D04-45 Crankpin bearing cap complete 135 kg D04-46 Crankpin bearing.

complete P91351 105 Page 2 (2) 2-way distributor block. complete P91351 58 Hose with unions (3000 mm). Etc. please quote Data D10404 Edition 0054 MAN B&W Diesel A/S . P91366 58 Feeler gauge P91366 61 Slide caliper P91351 10 Hydraulic pump. Description P90451 47 Wire guide P90451 59 Lifting attachment .connecting rod P91356 Lifting Tools. P90951 refers to chapter 909.g. Plate Item No. complete When referring to this page.104-4 Crankpin Bearing 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. pneumatic operated P91351 46 Hose with unions (1500 mm). e.

5. 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. see Chapter 708 ‘Bearings' in the instruction book.000 hours is regarded as normal. 3. D0443 D0444 An average wear rate of 0. 1. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection. If so. OPERATION. See Data for bottom clearance. see the measurement in the Adjustment Sheet in Volume I.05 mm. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. M904040232C05 D0446 When referring to this page. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S Page 1 (8) . 4. M904040231C03 5. the crankpin bearing must be disassembled for inspection. Open the crankcase door at the relevant cylinder. See Procedure 904-4. For the bottom clearance of a specific bearing. 3. Turn the crank concerned to BDC.2.Crankpin Bearing 904-4. OPERATION. 6.1 Checking The bottom clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing assembly components. M904040232C02 2. Volume I. 2. For further external inspection of the crankpin bearing.01 mm per 10.

M904040232D01 Loosen the crankpin bearing stud nuts. Suspend two tackles from the lifting brackets. M904040232D03 D0448 Page 2 (8) When referring to this page. M904040232D02 D1302 3. in the athwartship direction. Inspect the bearing shell. Mount eye bolts in each side of the crankpin bearing cap and. hook on the tackles and haul tight. Remove the hydraulic jacks and the nuts. 1. Land the bearing cap on a couple of planks placed in the oil pan. using the hydraulic jacks. Mount the wire guide in the top of the crankcase door opening. 2. For operation of the hydraulic jacks. Turn the crank to TDC. see Procedure 913-1. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S . using shackles and wire ropes. 3. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal.904-4. 2.2 Crankpin Bearing Dismantling 1.

lift the bearing cap out of the crankcase. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. If the bearing shell needs to be replaced. 5. Turn to TDC.Crankpin Bearing 904-4. 6. Dismount the bearing shell lock screws and replace the bearing shell by a new one. M904040232D05 Mount the four supports for guide shoes on the crosshead guides. D0448 Suspend a tackle outside the engine above the crankcase door opening. remove the whole bearing cap from the crankcase. M904040232D04 Turn the crankthrow to the exhaust side to give space for lifting out the crankpin bearing cap. M904040232D06 D0451 When referring to this page. 5. The bearing shells must be replaced in pairs.2 Dismantling 4. Carefully turn the crank to the camshaft side and down until the guide shoes rest on the supports. together with the tackle suspended outside the engine. Using the tackle from the frame box inside wall. 4. D0447 6. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S Page 3 (8) . Place the bearing cap on one side on a couple of planks.

9. If it is necessary to replace the bearing shell. Page 4 (8) When referring to this page. proceed as follows: Turn the crankshaft to horizontal position. Continue turning the crankshaft until the bearing surface can be freely inspected. Carefully turn the crankshaft downwards. Mount a lifting attachment for securing the connecting rod at the lower end. while ‘following’ with the tackle. Inspect the bearing shell surface and the crankpin journal. M904040232D07 8. Hook the tackle on to the lifting attachment. If necessary suspend a second tackle from the bracket below the doorway.2 Crankpin Bearing Dismantling 7. M904040232D08 Release the tackle so that the connecting rod is hanging freely. 8. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S . M904040232D09 9. on the camshaft side. making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to ‘separate’.904-4. 7.

Lower the bearing shell and remove it from the crankcase. Dismount the bearing shell lock screws. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S Page 5 (8) . M904040232D10 D0446 When referring to this page. 10.2 Dismantling 10.Crankpin Bearing 904-4.

please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S . Coat the bearing shell surfaces and the journal with clean oil. 2. 1. M904040232M02 D0446 Page 6 (8) When referring to this page.904-4. and must not be eliminated. Bearing shells of three mm undersize are available as spares in case of journal rectification. 2.4 Crankpin Bearing Mounting 1. If necessary. M904040231M01 The excess height X is to ensure the correct tightening-down of the bearing shell. Carefully lift the bearing shell into position in the connecting rod. The bearing shells must be replaced in pairs. Lift the upper bearing shell for the crankpin concerned into the crankcase. replace the bearing shells with new ones. and mount the lock screws.

3. When referring to this page.4 Mounting 3. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S Page 7 (8) . making sure that the upper part of the bearing enters the recess in the crankshaft when the parts turn together. while following up with the tackle. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod. Carefully turn the crankshaft upwards.Crankpin Bearing 904-4. Remove the four guide shoe support brackets from the crosshead guides. M904040232M05 4. and haul tight. 4. Turn the crosshead to TDC. M904040232M04 Remove the tackle and the lifting attachment from the connecting rod.

by means of spacer rings and hydraulic jacks. M904040232M06 6. 6.4 Crankpin Bearing Mounting 5. Caution! During mounting. Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan. See Data. see Procedure 913-1. Remove the wire guide tool from the engine. Hook the tackles on to the wire ropes and lift the bearing cap into position against the connecting rod. Mount the nuts and. Remove the tackles from the side of the frame box. tighten the crankpin bearing cap. please quote Procedure M90404 Edition 0232 MAN B&W Diesel A/S . M904040232M07 D1301 Page 8 (8) When referring to this page. For operation of hydraulic jacks. and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod. D0448 5. take care that the studs do not damage the crankpin journal. Suspend the tackles from the lifting brackets in the side of the frame box.904-4.

tightening torque 460 Nm D04-49 Connecting rod studs . mounting D13-02 Hydraulic pressure. dismantling When referring to this page. screwing-in torque 180 Nm D04-50 Connecting rod. without bearing caps 1160 kg D04-51 Connecting rod complete 1220 kg D04-52 Connecting rod stud 4 kg D13-01 Hydraulic pressure. Description Value Unit D04-07 Crosshead bearing cap with bearing shell 325 kg D04-16 Thrust piece.104-5 Connecting Rod Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10405 Edition 0053 MAN B&W Diesel A/S 900 bar 800 .990 bar Page 1 (2) .

complete P91351 105 2-way distributor block. Plate Item No. Description P90451 47 Wire guide P90451 59 Lifting attachment .connecting rod P90451 60 Lifting tools . Crosshead P90451 118 Rubber cover for crosshead P90451 120 Rubber cover for crosshead P90464 Crosshead . pneumatic operated P91351 46 Hose with unions (1500 mm). please quote Data D10405 Edition 0053 MAN B&W Diesel A/S . complete P91351 117 4-way distributor block. complete Page 2 (2) When referring to this page. P91366 58 Feeler gauge P91366 61 Slide caliper P91351 10 Hydraulic pump.crosshead P90451 72 Chain for suspending piston P90451 84 Retaining tool telescope pipe P90451 96 Bracket for support. P90951 refers to chapter 909.Hydraulic Tools P91356 Lifting Tools. Etc. complete P91351 58 Hose with unions (3000 mm).g.104-5 Connecting Rod 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. Crosshead P90451 106 Bracket for support.

2.2 218 02 2. Mount the wire guide in the top of the crankcase doorway.2.2 218 03 3. 1.Connecting Rod 904-5. Suspend the piston rod and dismount the crosshead bearing cap. Turn the crank to TDC.2 Dismantling Connecting Rod K90MC 0233 Dismantling 904-5.2 1. and remove it from the engine. GM904-5.2 215 02 3. MA904-5. Dismantle the crankpin bearing cap. D13-02 D04-07 MA904-5. please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S Page 1 (6) . Mount the four support brackets for guide shoes on the crosshead guides. When referring to this page. See Procedure 904-1. Suspend two tackles from the two lifting brackets at the sides of the frame box. 2. See Procedure 904-4.

please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S . A B Use the tackles fastened to lifting brackets A and B on the frame box wall. Turn the crankthrow to 90° before BDC. Also mount a lifting attachment in the crankpin end of the connecting rod. thus continuously supporting the connecting rod. 6. and attach the tackle hooks to the mentioned lifting attachments on the connecting rod. MA904-5.2 Dismantling 4. Remove the four studs from the connecting rod. Mount the lifting attachments for fixing the connecting rod on the head of the connecting rod. Page 2 (6) When referring to this page. until the crosshead shoes rest on the supports. Turn the crankthrow towards BDC while “following” with the tackles.2 218 04 Carefully turn the crank down towards the exhaust side. MA904-5.2 218 05 Shift the hook of the tackle attached to lifting bracket B from the lifting attachment on the lowermost side of the connecting rod to the lifting attachment on the uppermost side. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. 4. on the exhaust side.Connecting Rod 904-5. Haul the tackles tight. A B D04-51 D04-52 5. 5.

Connecting Rod 904-5. hook on the engine room crane and haul tight. tilt the connecting rod towards the camshaft side until the connecting rod is leaning out of the doorway. Shift the tackles from one lifting bracket/attachment to the other. A B C Lift the connecting rod out of the engine using the engine room crane and the tackles. while “following” with the tackles and the engine room crane. and hook on to the lifting attachment on the connecting rod. as required. E A B MA904-5. MA904-5. please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S Page 3 (6) . Attach a tackle to the gallery-mounted lifting bracket E.2 218 07 Turn the crank carefully upwards while “following” with the tackles.2 218 08 Continue turning upwards till about 30° after TDC.2 Dismantling 7. MA904-5. A Attach a tackle to lifting bracket C on the frame box wall and connect the tackle hook to the lifting attachment at the lower end of the connecting rod. AA 9. Place a wire rope round the connecting rod. By means of the tackle from lifting bracket A.2 218 09 D04-51 When referring to this page. 9. E Remove the floor chequer plate for the pertaining cylinder. 7. guiding the head of the connecting rod out of the doorway. 8. B C 8.

MA904-5. 3. 1.Connecting Rod 904-5. C MA904-5. 4.2 218 08 C Page 4 (6) When referring to this page. B Apply clean lubricating oil to the crankpin bearing shell and journal. attach a tackle to bracket C and the lower end of the connecting rod. Turn the crankthrow towards BDC. When the end of the connecting rod rests on the crankpin journal. Equip the connecting rod with the same lifting attachments as mentioned under dismantling. Lift the connecting rod carefully into the crankcase by alternate use of the engine room crane and the tackles attached to lifting brackets A and B. Attach a tackle to bracket E and the upper end of the connecting rod. past TDC. 4. E A B 3. Lower the engine room crane and remove the strap around the connecting rod.4 218 02 D04-51 2. E A B MA904-5.2 218 09 Shift tackle B from the lower end to the upper end of the connecting rod.4 2. while ‘following’ with the tackles. please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S .4 Mounting Mounting 904-5. A Turn the crank to a position about 30° past TDC on the camshaft side.

Turn the crankthrow to 90° before BDC. 7. When referring to this page. Turn the crankthrow towards TDC while ‘following’ with the tackles. Using the stud setter and a torque wrench. Remove the lifting attachment at the lower end of the connecting rod. MA904-5. MA904-5. 5. please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S Page 5 (6) . tighten the studs to the torque stated in Data. A B A B Shift tackle A from the lower end to the top of the connecting rod. 6.Connecting Rod 904-5. and use the tackles to raise the connecting rod to an upright position. C Remove the tackle at C. carefully land the crosshead on the connecting rod.4 218 05 Shift tackle B from the lifting attachment on one side to the other side of the connecting rod.4 Mounting 5. Screw the studs into the connecting rod. Lubricate the crosshead bearing shell and journal. Take care that the studs do not damage the crosshead bearing journal. 6.4 218 06 Note! D04-49 MA904-5.4 218 07 7. Remove the tackle at E.

and tighten to the specified torque. 9. When the crank is in TDC. Page 6 (6) D13-01 D04-16 When referring to this page. mount the crankpin bearing cap. See Data. See Data. MA904-5.2 215 01 10. 8. See Procedure 904-1. See Procedure 904-4.4 218 09 9.4. Turn to BDC and mount the crosshead bearing cap and the piston.4. D04-48 Mount the thrust pieces for axial guidance of the connecting rod. Remove the tackles and lifting attachments. For use of hydraulic jacks.4 Connecting Rod Mounting 8. Tighten all four crosshead bearing cap nuts simultaneously. GM904-5. Turn the crosshead to BDC. see Procedure 913-1. MA904-5.904-5. please quote Procedure M90405 Edition 0233 MAN B&W Diesel A/S .4 218 08 10.

Panel MAN B&W When referring to this page.Connecting Rod and Crosshead . please qoute Plate P90451 Edition 0139 Plate P90451-0139 Page 1 (2) .

telescope pipe Bracket.Panel MAN B&W Item Description Panel for tools Name plate Wire guide. crosshead Crowfoot spanner Crowfoot spanner When referring to this page. support of crosshead Rubber cover. support of crosshead Bracket. crosshead Rubber cover with hole. connecting rod Lifting tool. please qoute Plate P90451 Edition 0139 . main bearing Lifting attachment. crosshead Chain. 011 023 047 059 060 072 084 096 106 118 120 155 167 Page 2 (2) Connecting Rod and Crosshead .Plate P90451-0139 Item No. suspension piston Retaining tool.

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

complete Page 2 (2) When referring to this page. 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. please qoute Plate P90461 Edition 0068 .Plate P90461-0068 Connecting Rod .Hydraulic Tools MAN B&W Item No.

please qoute Plate P90464 Edition 0008 Plate P90464-0008 Page 1 (2) .Crosshead .Hydraulic Tools MAN B&W When referring to this page.

Item Description 024 036 048 050 061 085 097 107 203 Hydraulic jack.Hydraulic Tools MAN B&W Item No.Plate P90464-0008 Crosshead . complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Tommy bar Spanner Stud setter Hydraulic tool kit. complete Page 2 (2) When referring to this page. please qoute Plate P90464 Edition 0008 .

. Main Bearing. etc.Measuring Tools Segment Stopper & Vibration Damper .Hydraulic Tools Crankshaft .Tools Crankshaft . Thrust Shaft. Thrust Bearing and Turning Gear Documents in this Chapter 90551 90561 90562 90564 90567 90570 90571 0212 0088 0130 0018 0002 0003 0002 MAN Diesel A/S Crankshaft.Tools .Crankshaft.905 .Panel Main Bearing .Tools Main Bearing Shell .Tools Thrust Shaft .

MAN Diesel A/S .

Thrust Shaft.Crankshaft. Panel When referring to this page. Main Bearing. Etc. please quote Plate P90551 Edition 0212 MAN B&W Diesel A/S Plate P90551-0212 Page 1 (2) .

Etc. 015 027 040 076 100 123 135 184 218 231 Page 2 (2) Crankshaft. Main Bearing. Panel Item Description Item No. Item Description Tool panel Name plate Pulley for wire for main bearing Lifting tool for main bearing cap Tool for turning out segments Retaining tool for main bearing shells Lifting tool for relief valve Lifting tool for main bearing shell Wire for dismantling of mainbearing shell Protective cap When referring to this page. Thrust Shaft.Plate P90551-0212 Item No. please quote Plate P90551 Edition 0212 MAN B&W Diesel A/S .

please qoute Plate P90561 Edition 0088 Plate P90561-0088 Page 1 (2) .Main Bearing .Hydraulic Tools MAN B&W When referring to this page.

complete Page 2 (2) When referring to this page. Item Description 021 033 045 057 069 070 082 094 200 Hydraulic jack.Hydraulic Tools MAN B&W Item No.Plate P90561-0088 Main Bearing . complete Support Tommy bar Tommy bar Spanner O-ring with back-up ring O-ring with back-up ring Stud setter Hydraulic tool set. please qoute Plate P90561 Edition 0088 .

Tools MAN B&W When referring to this page. please qoute Plate P90562 Edition 0130 Plate P90562-0130 Page 1 (2) .Crankshaft .

Tools Plate P90562-0130 Item No. please qoute Plate P90562 Edition 0130 . 015 027 Page 2 (2) MAN B&W Item Description Lifting tool for crankshaft Screw with speciale head When referring to this page.Crankshaft .

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

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

please qoute Plate P90567 Edition 0002 Plate P90567-0002 Page 1 (2) .Tools MAN B&W When referring to this page.Segment Stopper & Vibration Damper .

Tools MAN B&W Item Description Segment stopper and vibration damper .tool When referring to this page. 012 Page 2 (2) Segment Stopper & Vibration Damper .Plate P90567-0002 Item No. please qoute Plate P90567 Edition 0002 .

please qoute Plate P90570 Edition 0003 Plate P90570-0003 Page 1 (2) .Tools MAN B&W When referring to this page.Thrust Shaft .

please qoute Plate P90570 Edition 0003 . 019 Page 2 (2) MAN B&W Item Description Lifting tool. thrust shaft When referring to this page.Thrust Shaft .Tools Plate P90570-0003 Item No.

Tools MAN B&W When referring to this page.Main Bearing Shell . please qoute Plate P90571 Edition 0002 Plate P90571-0002 Page 1 (2) .

Tools Plate P90571-0002 Item No.Main Bearing Shell . please qoute Plate P90571 Edition 0002 . 014 Page 2 (2) MAN B&W Item Description Extractor for guide pin When referring to this page.

Data Chain Chain Tightener. Data Camshaft Camshaft Bearings.Control Gear Documents in this Chapter 106-01 906-01 106-02 906-02 106-03 906-03 106-04 906-04 106-08 906-08 0054 0241 0059 0231 0039 0215 0040 0219 0002 0001 MAN Diesel A/S Chain. Data Camshaft Bearings Camshaft Coupling Camshaft Coupling . Data Chain Tightener Camshaft.906 .

MAN Diesel A/S .

max.9 mm D06-03 Original length (chain pitch x 10 links) 254 mm D06-04 10 links measurements + 1% of a tensioned chain = scrapping of chain 256.5 mm 3 mm 3. wear D06-19 Original length (chain pitch x 10 links) 889 mm D06-20 10 links measurements + 1% of a tensioned chain = scrapping of chain 898 mm When referring to this page.106-1 Chain Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit 1” Chain D06-02 Teeth on chain wheel. please quote Data D10601 Edition 0054 MAN B&W Diesel A/S Page 1 (2) .5" chain D06-18 Teeth on chain wheel. wear 0. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. max.

P90951 refers to chapter 909. e. Description P90651 056 Chain assembling tool P90651 068 Chain disassembling tool P90651 070 Chain assembling tool P90651 081 Chain disassembling tool P91356 Page 2 (2) Lifting Tools. Plate Item No. please quote Data D10601 Edition 0054 MAN B&W Diesel A/S . Etc.106-1 Chain 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. When referring to this page.g.

Carry out the inspection as follows: • Make a general inspection for loose bolts and screws. take a measurement (See Data). if necessary. • Replace the guideway if bits have started to be “plucked out” of the rubber track.1 Chains Checking 1. one for each set of chains. If abnormal wear is found. please quote Procedure M90601 Edition 0241 MAN B&W Diesel A/S Page 1 (5) .906-1. 2. • Inspect lube oil pipes for damage. dismantled and mounted in the same way. • the drive chains for the camshaft • the drive chain for the cylinder lubricators Note! There are two sets of dismantling and mounting tools available. D0602 D0618 B A 4. 4. M906010241C04 • Examine the rubber track of the guideways for cracks or other damage. and check jet nozzles for possible stoppages or deformations. 3. Both sets of chains can be accessed from within the chainwheel frame. Check the teeth of the chain wheels. When referring to this page. Measurements are best taken by placing a short straight-edge over points A and B and then measuring the distance D06-02 or D06-18. The engine is equipped with two sets of chains: 1. M906010238C02 Both sets of chains are to be checked and.

circumferential scratches during the running-in period. For assessing the wear profile. Such scratches can generally be considered normal. Example: No. the side plates of the outer link nearest to the assembled link have been marked with year. however. contact MAN B&W Diesel.1 Chains Checking 5. please quote Procedure M90601 Edition 0241 MAN B&W Diesel A/S . make a drawing in scale 1:1 of the teeth and wear profile. It is normal. Check the chains for cracks on possibly defective rollers and side plates. M906010238C05 In most cases.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). possible 3rd chain) On the same links there is an arrow (–>) which indicates the mounting direction. possible 3rd chain) No. 2 order. To keep such matching chains in their pairs. month. that the rollers get light. If abnormal wear is observed at the bottom of the teeth. scratches caused by the side plates of the chain will be found on the sides of the teeth. Page 2 (5) When referring to this page. These fine scratches are of no importance and need not be considered. 840520 2A 840520 2B (840520 2C. 840520 1A 840520 1B (840520 2C. 5. 6. 1 order. day and chain number. It is recommended that each single link is checked. The chains for the camshaft drive are matched together to ensure an even load distribution.

Check chain wear by measuring the length of 10 chain links. 7. See Procedure 906-2.3. Use two master squares and a steel measuring tape as shown on the sketch. please quote Procedure M90601 Edition 0241 MAN B&W Diesel A/S Page 3 (5) . D0603 D0604 D0619 D0620 M906010241C07 04 06 0 x. Compare the result with the value given in Data.1 Chains Checking 7.906-1. adjust the chain tightener.D 2 Ma . When referring to this page.D06 x Ma If necessary.

is in a favourable position for the work. M906010238D02 2. Mount a wire round the link rollers a short distance from the disassembly point.2 Chains Dismantling 1. contact MAN B&W Diesel for further information. Note! M906010238C02 Every time a chain link is disassembled.906-1. Remove the tension on the chain by loosening the chain tightener. for instance. It may become necessary to disassemble the chain if. please quote Procedure M90601 Edition 0241 MAN B&W Diesel A/S . Page 4 (5) When referring to this page. When a new link is fitted in one chain.1. M906010238D03 3. Place the chain bursting tool over the outer chain link. 1. See Procedure 906-1. and tighten the wire lightly with a tackle. a new link must always be fitted as the link pin press-fit is destroyed when breaking the chain. Turn the engine until the slack part of the chain. The riveting of the pins that are to be pressed out is to be chiselled or ground away. the corresponding link in the other chain must also be renewed. 2. Protect the link rollers over which the wire is wrapped.3). cracked rollers or seizures between pin and bushing have been discovered during the inspection. (See Procedure 906-2. with the chain link that is to be disassembled. Note! If the chain is to be completely removed. and dismantle the link by alternately tightening the screws on the tool. 3.

4 Mounting Before assembling the inner and outer links. When referring to this page.3). Repeat this procedure until the chain has been assembled. 1. clean the pins and bushings. 1. remove the compression tool and lock the pin ends by riveting.Chains 906-1. M906010238M01 2. Combine the inner chain link with the outer chain link and mount the compression tool. (See Data and Procedure 906-2. Remove the tackle and wire and adjust the chain tension. please quote Procedure M90601 Edition 0241 MAN B&W Diesel A/S Page 5 (5) . Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool. When the link has been assembled.

.

see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. clearance When referring to this page. Description D06-21 Tightening angle = 8 hexagons D06-25 Mechanical or blocked chain tightener.106-2 Chain Tightener Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10602 Edition 0059 MAN B&W Diesel A/S Value Unit 480/8 0.1 ° /hex mm Page 1 (2) .

please quote Data D10602 Edition 0059 MAN B&W Diesel A/S . P90951 refers to chapter 909. 58 Description Feeler gauge When referring to this page.g. Plate P91366 Page 2 (2) Item No.106-2 Chain Tightener 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.

HM906-2. Turn the engine so that the slack part of the chains is on the same side as the tightener wheel. Then tighten nut B as stated in D06-21 (see Data).3 222 02 For chain wear. If the engine is equipped with flyweights. please quote Procedure M90602 Edition 0231 0$1% :'LHVHO$6 Page 1 (2) . To retighten the chains.3 Adjustment Chain Tightener S60MC-C 0231 Adjustment 906-2. loosen nuts A. B HG906-2.3 1. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D06-25.Chain Tightener 906-2. 1. A B 2. 3. B. continue turning until the flyweights are hanging vertically downwards. C and D to free the chain tightener bolt.1.3 218 03 D06-25 D06-21 When referring to this page. 2.3 218 01 3. see Procedure 906-1. C D HG906-2.

HG906-2. Lock nuts A and B with the tab washer.3 218 05 D The number of times that retightening can be carried out depends on when the limit for scrapping the chain has been reached. C HG906-2.3 218 05 A Page 2 (2) When referring to this page. 4. See Data page 106-1. 5. Tighten nut C hard against the contact face of the shaft. please quote Procedure M90602 Edition 0231 0$1% :'LHVHO$6 .3 Chain Tightener Adjustment 4. Tighten nut D. Tighten nut A.906-2. Lock nuts C and D with the tab washer. 5.

106-3 Camshaft Data SAFETY PRECAUTIONS For detailed sketch. check measurement 251 mm When referring to this page. check measurement 501 mm D06-30 Pin gauge for camshaft. please quote Data D10603 Edition 0039 MAN B&W Diesel A/S 2 ° Page 1 (2) .5 mm D06-29 Pin gauge for top dead centre of crankthrow No. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. permissible change in lead angle D06-28 corresponding to 3.1. Description Value Unit D06-27 Max.

106-3 Camshaft 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.Pin Gauge Page 2 (2) When referring to this page.Pin Gauge P90668 Camshaft . e. please quote Data D10603 Edition 0039 MAN B&W Diesel A/S . Description P90664 Crankshaft . P90951 refers to chapter 909.g. Plate Item No.

HM906-7. Turn in the AHEAD direction to ensure that the tension of the chain on the chain drive is correct. See Procedure 906-2.3. D06-29. When referring to this page. 2.1 Checking Camshaft S60MC 0215 Checking 906-3. adjust the chain tension. If necessary. BG906-7.0 58 02 2.0 56 01 1. Turn the crankthrow for cylinder 1 to TDC.1 1.Camshaft 906-3. Check the TDC of cylinder 1 against the mark on the turning wheel. Check the TDC position with the pin gauge on the crankthrow. please quote Procedure M90603 Edition 0215 MAN B&W Diesel A/S D06-29 Page 1 (3) .

The running surface of the cam must be completely smooth and bright.Camshaft 906-3. Page 2 (3) When referring to this page.1 Checking 3. in lead angle. When checking the camshaft position. if necessary. If light scratches are ascertained. if any. See Procedure 907-1. adjust the cylinder lubricator. MA906-3. Check the setting of the starting air distributor. Such light scratches can appear if the roller guide and the cam are not correctly aligned. 6. Position the camshaft pin gauge in the centre punch mark. MAN B&W Diesel should be contacted for further instructions. 3. MA906-3.1 210 06 6. also check the running surface of the cams. permissible change.0 07 01 In the event of heavier scratches or direct flaking of the material on the running path. 5. and measure the deviation. remove them by carefully polishing the cam in the direction of rotation with a fine carborundum stone. see D06-27 and D06-28.1 210 03 5. See Procedure 903-2. D06-30 4. the cam should be turned one complete revolution during the inspection. D06-27 D06-28 As the inspection must include the entire surface of the cam.1. Check and. KC906-3. please quote Procedure M90603 Edition 0215 MAN B&W Diesel A/S . For max.1.

3 1.Camshaft 906-3. please quote Procedure M90603 Edition 0215 MAN B&W Diesel A/S D06-27 D06-28 Page 3 (3) . When referring to this page. KB906-7.3 Adjustment Adjustment 906-3. If the chains prove to be so heavily worn that the deviation between the measuring points and the pin gauge has reached the maximum value D06-27 and D06-28 stated in Data.0 72 04 1. MAN B&W Diesel should be contacted for further instructions.

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8 mm D13-01 Hydraulic pressure. dismantling 800 . please quote Data D10604 Edition 0040 MAN B&W Diesel A/S Page 1 (2) . see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.990 bar When referring to this page. mounting 900 bar D13-02 Hydraulic pressure. wear 0. minimum thickness 4.1 mm D06-36 Oil pan 20 kg D06-37 Camshaft bearing cap 54 kg D06-65 Bearing shell. max.106-4 Cylinder Cover Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D06-34 Bearing shell.

complete P91351 105 3-way distributor block. complete P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909. Plate Item No. pneumatically operated P91351 046 Hose with unions (1500 mm).Hydraulic Tools P90651 127 Pulley for wire for camshaft bearing P90651 139 Lifting attachment for camshaft bearing P91351 010 Hydraulic pump. e. please quote Data D10604 Edition 0040 MAN B&W Diesel A/S .g.106-4 Cylinder Cover 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. P90464 Description Crosshead . complete Page 2 (2) When referring to this page.

Camshaft Bearing 906-4. 1. If no anomalies are found during the visual inspection. the bearing shell must be replaced HC906-5. the bearing shell must be dismantled for closer investigation and.1 1. and for fragments of metal in the camshaft housing. we recommend a visual inspection of the condition of the shell in the bearing cap from each side. with normal inspection through the inspection hole in the roller guide housing. it is recommended also to check the condition of the fuel and exhaust cams. it is no longer necessary to measure the top clearance of the camshaft bearing. However. When checking the camshaft bearings. In the event of any signs of anomalies. As the upper shell of the camshaft bearing assembly has been dispensed with on this engine. See Procedures 908-5 and 909-3.0 57 01 Check for wiped-out metal at the bearing ends. if necessary. please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S Page 1 (5) . When referring to this page.1 Checking Camshaft Bearing S60MC 0219 Checking 906-4. dismantling need not be carried out.

please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S . landing it on the platform. Page 2 (5) When referring to this page. Mount lifting fittings on both sides of the bearing half. HC906-5. loosening the screws mounted in the roller guide housing. HG906-4. hook on a tackle and haul tight.2 Camshaft Bearing Dismantling Dismantling 906-4. Release the sealing flanges on the roller guide housing. 2. Place the wire rope in the lifting fitting of the oil tray.3. Dismount the oil outlet pipe from the oil tray. Mount an eye bolt in the cylinder frame behind the oil tray. Ease off the oil tray. Caution! Before dismantling any camshaft bearings. Tighten up the tackles. Mount grooved pulleys on the roller guide housing. See Procedure 906-2. D06-36 Remove the screws securing the oil tray to the roller guide housing. and hook wire ropes/ tackles on to the lifting fittings/grooved pulleys. Remove only the screws in the lower half of the sealing flange. HC906-5.0 57 03 3.2 1.3 201 03 3.0 57 02 1. Attach a wire rope to the eye bolt.906-4. 2. the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts.

Lower the bearing cap and place it on the platform.0 57 06 D06-37 When referring to this page. HG906-4.2 Dismantling 4. Remove the hydraulic jacks and dismount the nuts.Camshaft Bearing 906-4. see Procedure 913-1. 4.3 201 04 5. D13-02 5. HC906-5. For use of hydraulic jacks. Mount the hydraulic jacks and loosen the bearing nuts. please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S Page 3 (5) .

see Volume I OPERATION.3 209 02 Measure the thickness of the bearing shell with a micrometer to check the amount of wear.3 1. HC906-5. 2. an impression can be formed of whether the lubrication of the bearing surface has been insufficient or entirely missing. By closely examining the sliding surface of the bearing shell visually. For assessment of the bearing condition.906-4. Normally. Chapter 708 ‘Bearings’. 1.3 Camshaft Bearing Overhaul Overhaul 906-4. please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S . MA906-4. camshaft bearing damage only occurs due to faulty lubrication. Page 4 (5) D06-34 D06-65 When referring to this page. If seizures are found on the bearing journal surface (on account of bearing breakdown). polish the surface with a fine carborundum stone to re-establish a bright and smooth surface.0 57 07 2. Inspect the entire surface of the bearing journal for seizures.

positioning it by means of the guide pins. Check that the guide pins enter correctly. Mount the bearing shell in the bearing cap. Mount the screws that fasten the sealing flanges to the roller guide housing.0 57 06 2.0 57 03 D06-36 When referring to this page. D06-37 2. Mount the oil pipe on the oil tray. Hoist the oil tray into place. Then pull the bearing cap into place by means of tackles/ wire rope fitted through the grooved pulleys to the lifting fittings. please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S Page 5 (5) . HC906-5. See Data. the bearing support and the bearing shell. 3. 1. Remove the shackle and eye bolt.4 1.3 201 04 D13-01 3. Then fasten it to the roller guide housing by tightening up uniformly all round the circumference. Clean the bearing journal.4 Mounting Mounting 906-4. Remove the lifting fittings and grooved pulleys from the roller guide housing. after coating the shell with oil. HC906-5. HG906-4. Mount and tighten up the nuts by means of the hydraulic tools.Camshaft Bearing 906-4.

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Description Value Unit Camshaft coupling bolts. please quote Data D10608 Edition 0002 MAN B&W Diesel A/S Page 1 (2) . tightening torque D06-67 L 42 MC 130 Nm D06-60 S/K/L 50 MC 300 Nm D06-61 S/K/L 60 MC 460 Nm D06-62 S/L 70 MC 700 Nm D06-63 S/K/L 80 MC 985 Nm D06-64 S/K/L 90 MC 1350 Nm When referring to this page.106-8 Camshaft Coupling Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped 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.

106-8 Camshaft Coupling 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. 152 Description Crowfoot wrench for coupling flange P91356 Lifting Tools. P90951 refers to chapter 909. please quote Data D10608 Edition 0002 MAN B&W Diesel A/S . Etc. e.g. Plate P90651 Item No. P91359 Torque Spanners P91366 Page 2 (2) 58 Feeler gauge When referring to this page.

1 1.1 01 01 The extent of disassembling must be evaluated in each case. Note! KM906-8.Camshaft Coupling 906-8. MAN B&W Diesel should be contacted for further instructions. please quote Procedure M90608 Edition 0001 MAN B&W Diesel A/S Page 1 (2) .05 mm feeler gauge. In order to gain access to the camshaft coupling bolts. Checking of Bolts in Camshaft Couplings 1. 2.1 01 02 If any gap can be measured on the entire circumference of the couplings. When referring to this page.1 Checking Camshaft Coupling S80MC 0001 Checking 906-8. Check the connection between the camshaft coupling flanges with a 0. remove one or all of the following: • top guard • split flange • scraper ring 2. KM906-8.

MAN B&W Diesel must be contacted for further instructions. If the torque needed to move the nut deviates less than 25% from the value in Data. Chapter 913. KM906-8.906-8. Tighten all screws. Mount the top guard. Mount the locking wire that locks the nuts on the camshaft coupling bolts.1 Camshaft Coupling Checking 3. 3. if fitted. please quote Procedure M90608 Edition 0001 MAN B&W Diesel A/S . KM906-8. See Data D06-60 and D06-64.1 01 04 4. Note! 4. If the tightening torque during the recheck deviates more than 25% from the value stated in Data. with liquid gasket and gaskets in the relevant places. Remove the locking wire. scraper ring etc. retighten the nut to the value stated in Data and recheck the tightening torque after 500-1500 hours of running.1 01 03 If the torque needed to move the nut deviates more than 25% from the value stated in Data. from the nuts on the camshaft coupling bolts. the torque is within its limits. Maintenance. Check the tightening torque of the camshaft coupling bolts. See Volume II. When referring to this page. split flange. Page 2 (2) 5.

Data Starting Air Valve .907 .Starting Air System Documents in this Chapter 107-01 907-01 107-02 907-02 0020 0216 0042 0214 MAN Diesel A/S Starting Air Distributor. Data Starting Air Distributor Start Air Valve.

MAN Diesel A/S .

0 mm D07-05 Clearance with roller in innermost position:Min.0 mm When referring to this page. Max.0-2. 1. tightening torque D07-03 Value Unit 90 Nm Clearance between gear wheel and bushing:Min. Description D07-01 Gear wheel on camshaft. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.0-3. 0. Max. 1.6 mm D07-04 Clearance with roller in outermost position:Min.107-1 Starting Air Distributor Data SAFETY PRECAUTIONS For detailed sketch. Max. please quote Data D10701 Edition 0020 MAN B&W Diesel A/S Page 1 (2) .9-1.

P90951 refers to chapter 909. e.g.107-1 Starting Air Distributor 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 D10701 Edition 0020 MAN B&W Diesel A/S . Plate P91366 Page 2 (2) Item No. 058 Description Feeler gauge When referring to this page.

1 203 02 2. If pin K is not available. 1. 1 to TDC.e. please quote Procedure M90701 Edition 0216 0$1% :'LHVHO$6 Page 1 (3) . GN906-3.Starting Air Distributor 907-1. Check with the pin gauge. S S EN907-1. Remove the plug screw and gasket from the side of the distributor housing. the air distributor must be adjusted. 3. Turn the engine in AHEAD direction to bring the piston of cylinder No. i. See Procedure 907-1. and insert check pin K in slot S.3 204 02 K When referring to this page.3. 2. If the check pin cannot enter the slot.1 1.1 Checking Starting Air Distributor S46MCC 0216 Checking 907-1. if the slot is not aligned with the hole in the distributor housing. use the cylindrical end of a drill of a suitable size.

Page 2 (3) D07-03 When referring to this page. Dismount the end cover of the camshaft housing. GN906-3. Turn the engine in AHEAD direction to bring the piston of cylinder 1 to TDC. Check with the pin gauge. and insert check pin K in slot S. Check and. adjust clearance D07-03 between the gear wheel and the bushing.Starting Air Distributor 907-1. EN907-1. from the engine. please quote Procedure M90701 Edition 0216 0$1% :'LHVHO$6 . Turn the shaft together with the distributor disc until check pin K enters slot S in the disc and keep it there. along with the starting air distributor.3 204 02 S GN907-1. Remove the plug screw and gasket from the side of the distributor housing. 1.3 1. if necessary. S K 3. 2.3 Adjustment Adjustment 907-1.1 203 02 2.3 203 03 3.

K GN907-1.3 204 06 D07-01 When referring to this page.Starting Air Distributor 907-1. and then engage the two gear wheels by turning the wheel on the camshaft. Remove the lower half of the gearwheel drive cover. see Data. Check the clearance between the roller and the two interlocking valves with the roller in its innermost and outermost positions. 4. EN907-1. respectively ( ASTERN and AHEAD).3 203 02 6. Mount the upper half of the gearwheel drive cover with the complete starting air distributor after loosening the gear wheel on the camshaft. GN907-1. D07-01 5. D07-01. 5. please quote Procedure M90701 Edition 0216 0$1% :'LHVHO$6 D07-04 Page 3 (3) . Mount the lower half of the gearwheel drive cover. Tighten and lock the gear wheel screws on the camshaft.3 203 02 S 6. Remove check pin K from the distributor housing and mount the gasket and plug screw.3 Adjustment 4.

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see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value Unit D07-09 Piston tightening torque 180 Nm D07-10 Valve tightening torque 175±20 Nm D07-11 Valve tightening angle D07-12 Starting air valve When referring to this page. please quote Data D10702 Edition 0042 MAN B&W Diesel A/S 50/30 24 ° kg Page 1 (2) .107-2 Starting Air Valve Data SAFETY PRECAUTIONS For detailed sketch.

g. please quote Data D10702 Edition 0042 MAN B&W Diesel A/S . e. Plate Item No. P90951 refers to chapter 909. Description P90151 095 Grinding ring for starting valve P90151 105 Grinding handle for starting valve P91359 Page 2 (2) Torque Spanners When referring to this page.107-2 Starting Air 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.

Pull the starting air valve out of the cylinder cover and remove it from the engine.2 203 02 D07-12 When referring to this page.2 1. please quote Procedure M90702 Edition 0214 0$1% :'LHVHO$6 Page 1 (5) . 2. GN907-2. 1.2 Dismantling Starting Air Valve S46MC-C 0214 Dismantling 907-2.2 203 01 2. Unscrew the fixing nuts of the starting valve flange. GN907-2. Shut off the starting air and control air inlet.Starting Air Valve 907-2. Dismount the control air pipes.

Screw off the valve spindle nut and remove the valve spindle from the valve housing. valve spring. EN907-2.3 1. please quote Procedure M90702 Edition 0214 0$1% :'LHVHO$6 . and the liner.3 0212 02 2. 2. Remove and discard the gasket. Remove the top cover fixing screws and remove the cover. Page 2 (5) When referring to this page.907-2. EN907-2. distance pipe. 1.3 0212 01 Remove and discard the O-ring.3 Starting Air Valve Overhaul Overhaul 907-2. Take out the piston.

the spring and the piston. EN907-2. Carborundum No. GN907-2. 500. First mount the liner in the valve housing.3 0212 05 5. When referring to this page. 3. Grind the valve housing seating with the grinding ring after applying grinding paste. the distance pipe. please quote Procedure M90702 Edition 0214 0$1% :'LHVHO$6 Page 3 (5) . 200. Lubricate all internal parts (sliding surfaces) with Molybdenum Disulphide.3 203 03 5. then the valve spindle. MoS 2 grease. using the face wrench to rotate the valve spindle. 4. Thoroughly clean all parts before reassembling the valve. Carborundum No. Grind the seatings of the spindle and housing to match.3 Overhaul 3.Starting Air Valve 907-2.

7.907-2. see D07-09. Mount and tighten the top cover. EN907-2. please quote Procedure M90702 Edition 0214 0$1% :'LHVHO$6 . EN907-2.3 0212 06 8. D07-09 6. If the starting air valve is not to be mounted in the engine immediately after the overhaul.3 0212 07 7.3 Starting Air Valve Overhaul 6. Place a new gasket on the valve housing. Replace the O-ring on the valve housing. all openings of the valve should be covered with plastic to prevent dirt from entering the valve during storage. Page 4 (5) When referring to this page. Mount the nut on the valve spindle and tighten the nut.

if necessary. Carefully clean the starting valve bore in the cylinder cover and. according to data D07-10 or D07-11.4 1.4 203 01 2.4 203 02 D07-12 3. See Procedure 901-1. GN907-2. For overhaul. GN907-2. Mount the nuts and tighten-up. If not already done. GN907-2. 2. replace the O-ring on the overhauled valve and lubricate with Neverseize or Molybdenum Disulphide. see Procedure 907-2. MoS 2. 1. 3.4 Mounting Mounting 907-2. Mount the control air pipes and turn on starting air and control air. recondition the seat for the starting valve in the bore.3.3. please quote Procedure M90702 Edition 0214 0$1% :'LHVHO$6 Page 5 (5) .Starting Air Valve 907-2.4 203 03 D07-10 or D07-11 When referring to this page. Mount the valve in the cylinder cover.

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Data Exhaust Valve Cam Exhaust Valve .Exhaust Valve Documents in this Chapter 108-01 908-01 108-02 908-02 108-03 908-03 108-04 908-04 108-05 908-05 108-07 908-07 90851 90862 90863 90863 0045 0226 0082 0256 0052 0227 0038 0220 0015 0216 0034 0234 0207 0041 0014 0016 MAN Diesel A/S High-Pressure Pipe. Data Exhaust Valve Exhaust Valve Actuator. Data Exhaust Valve Exhaust Valve .908 .Panel Exhaust Valve . Data High-Pressure Pipe Exhaust Valve. Data Exhaust Valve Actuator Exhaust Valve Roller Guide.Special Running.Extra Tools Exhaust Valve . Data Exaust Valve Roller Guide Exhaust Valve Cam.Hydraulic Tools Exhaust Valve .Extra Tools .

MAN Diesel A/S .

please quote Data D10801 Edition 0045 MAN B&W Diesel A/S Page 1 (2) . tightening torque 36 Nm D08-02 Distance of high pressure pipe lower edge to pressure flange 15 mm D08-03 High-pressure pipe 25 kg When referring to this page. Description Value Unit D08-01 High-pressure pipe. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.108-1 High-Pressure Pipe Data SAFETY PRECAUTIONS For detailed sketch.

g. P90951 refers to chapter 909. pipe When referring to this page.p. e.108-1 High-Pressure Pipe 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 D10801 Edition 0045 MAN B&W Diesel A/S . 112 Description Grinding mandrel for h. Plate P90851 Page 2 (2) Item No.

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. 2.2 Disling 908-1. 1. When replacing the hydraulic high-pressure pipe.2 Dismantling 908-1. When referring to this page. recondition the high-pressure pipe sealing surfaces. the exhaust valve or the hydraulic actuator. M908010226D01 D0803 M908010226D02 2. check and. please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S Page 1 (3) . if necessary.High-Pressure Pipe 908-1. stop the camshaft oil pump.2 Dismantling 1. Before dismantling the high-pressure pipe.

if necessary. Check the contact surfaces of the pressure pipe for marks and. 1. Replace the O-rings on the thrust pads. If considered necessary. This measurement is to correspond with the value stated in Data. and finish with a fine grinding paste. Check the thrust pads in the exhaust valve and the actuator for marks on the sealing surface. please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S . Carborundum 2.3 High-Pressure Pipe Overhaul 1. for example Carborundum No.908-1. for example. After reconditioning the contact surfaces of the pipe. replace the thrust pads. 2. 200. Page 2 (3) D0802 When referring to this page. grind the pipe ends by means of the grinding mandrel and the two guiding tools. measure the distance from the edge of the thrust bushing to the contact surface at both ends of the pipe. M908010226O02 Lift the thrust pad free by. 500. M908010226O01 Start grinding with a coarse grinding paste. using a screwdriver in the groove of the thrust pad. for example Carborundum No.

908-1. 2. Check the whole system for tightness. tighten up the screws of the pressure flanges diagonally. After fitting the pipe correctly in relation to the exhaust valve and actuator.4 High-Pressure Pipe Mounting 1. When referring to this page. see Data. Take care not to damage the O-rings on the thrust pads. please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S Page 3 (3) . Mount the hydraulic high-pressure pipe as follows: 1.1. M908010226M01 Position the high-pressure pipe with the sealing surfaces of the pipe resting on the thrust pads of the exhaust valve/actuator. D0801 M908010226M02 2. See Procedure 908-3.

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Description Value Unit D08-04 Safety valve. min. opening pressure 21 bar D08-05 Screws for lifting eye bolt.8 mm D08-18 Bushing max.0 mm D08-14 Spindle. max. tightening torque 50 .6 mm D08-19 Bushing max.9 . 345 mm D08-17 Spindle stem. diameter.2 mm D08-21 Piston rings. diameter. see 900-2 Stopped engine X X X X X X X X X Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil X X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.0 ° D08-10 Valve spindle seat. grinding 2. 235 mm D08-16 Spindle stem.0 mm D08-13 Spindle. top 60. please quote Data D10802 Edition 0082 900 bar 800 . tightening torque 50 Nm D08-06 Oil cylinder.6 mm D08-24 Exhaust valve. inside diameter 71. dismantling When referring to this page.5 ° D08-11 Bottom piece seat. diameter 59. max.0 mm D08-15 Spindle stem. min.80 Nm D08-09 Bottom piece seat. min. complete 460 kg D08-25 Exhaust valve housing 260 kg D08-26 Oil cylinder 65 kg D08-27 Air cylinder 20 kg D08-28 Spindle 45 kg D08-29 Bottom piece 55 kg D08-30 Air piston 6 kg D13-01 Hydraulic pressure.30. max.0 mm D08-20 Oil cylinder max. thickness 2. measuring area.990 bar Page 1 (2) . grinding 2. tightening torque 70 Nm D08-07 Safety valve. grinding angle 30. grinding angle 29. measuring area. max.30. bottom 62.Exhaust Valve MAN B&W Diesel 108-2 Data SAFETY PRECAUTIONS For detailed sketch. mounting D13-02 Hydraulic pressure.3 mm D08-12 Gap of bottom piece seat 1.4 . burn-off 8.

Plate Item No. complete P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909. pneumatically operated P91351 046 Hose with unions (1500 mm). Description P90851 065 Lifting tool for exhaust valve P90851 077 Cone ring for pneumatic piston P90851 089 Pressure tester for safety valve P90851 090 Gauge for exhaust valve spindle P90851 150 Gauge for exhaust valve bottom piece P90851 161 Lifting tool for exhaust valve spindle P90851 185 Grinding ring for exhaust valve bottom piece P91351 010 Hydraulic pump.Exhaust Valve 108-2 MAN B&W Diesel Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.g. e. please quote Data D10802 Edition 0082 . complete P91351 117 5-way distributor block. complete Page 2 (2) When referring to this page.

Check of sealing oil unit Check that the injection indicator moves regularly with the valve opening. The indicator must not be in constant operation. turn it 90° and let it rest on the air piston. In the event of no rotation. 2. Lift the valve spindle rotation indicator. During rotation of the valve spindle. please quote Procedure M90802 Edition 0256 Page 1 (24) . unscrew the sealing oil pipe. M908020256C02 Exhaust valve performance condition See volume I chapter 706 Performance Evaluation Depending on valve model the indicator is placed either on the manoeuvre side or the front side. the spindle must rotate. The rotation can vary with unit and engine load. the top position of the indicator will change about 6 mm. When check of the valve rotation is finished. 908-2. M908020252C01 The engine must run when the valve function and spindle rotation are checked.1 1. Alternatively. lift the rotation indicator and lock it in the top position. When referring to this page. attention should be paid to avoid seat problems. On Surface InGroove 2. and check that oil is coming out (very small quantity). because of the groove in the piston. During engine operation.Exhaust Valve MAN B&W Diesel Checking Checks during running: 1. Check of valve spindle rotation The indicator will now follow the movements of the valve spindle and the air piston.

AIR SUPPLY EXHAUST VALVE Check the drop down time for all spindles: • Spindles dropping down within 30 min- M908020256C04 utes: Check and overhaul. With the exhaust valve mounted in the cylinder cover. at an interval of e. When check of drop down time is finished.1 Checking MAN B&W Diesel 3. Check of spindle dropdown time: Engage all rotation indicators on the exhaust valves. lift the rotation indicators and lock them in the top position. Page 2 (24) When referring to this page. See next step “Check of Air Spring tightness”. the lowermost sealing ring is leaking. one month.Exhaust Valve 908-2. Check with stopped engine: 4. the exhaust valve must be dismounted and the sealing rings replaced.g. next to the engineside manoeuvring stand. If water flows from the any of the rings. M908020254C03 Check the tightness of the sealing rings between the bottom piece and the exhaust valve housing. CONTROL AIR SUPPLY • Spindles dropping down after 1 hour: OK. 4. SAFETY AIR SUPPLY Shut off and release the spring air on the valve. • Spindles dropping down between 30 minutes and 1 hour: Keep under observation. In connection with port stays. please quote Procedure M90802 Edition 0256 . Check of bottom piece sealings 3. IF water flows from the small bore on the manoeuvring side of the exhaust valve. check the cooling water inlet and outlet to the cylinder cover and exhaust valve is open. an easy check of all exhaust valves is recommended.

C M908020256C05 D C B When referring to this page. Disconnect the sealing oil pipe and banjo coupling from the air cylinder (B). • Hole for drain oil (C): If yes. The checks is for guidance only. change and overhaul. Check the safety valve (D). If air still is coming out. the leakage comes from the air piston: change and overhaul. minor leaks is difficult to detect. Connect compressed air to the non return (A) valve on the air cylinder. please quote Procedure M90802 Edition 0256 Page 3 (24) . Check of Air spring tightness 5. Disconnect and remove the drain oil pipe from the oil cylinder (C). B Check if air is coming out from: A • The sealing oil bore (B): Leakage from spindle stem sealing . the leakage comes from the safety valve or the air piston.Exhaust Valve MAN B&W Diesel 908-2. A D • Remove the air supply to the nonreturn valve on the air cylinder and check the nonreturn valve for tightness.1 Checking 5.

MAN B&W Diesel Close off cooling water 1. Dismount the oil pipe connections Dismount the highpressure pipe for the hydraulic valve actuation. Page 4 (24) When referring to this page.2 Exhaust Valve Dismantling 1. M908020256D02 2. 2. and drain the exhaust valve.2 M908020256D01 Dismount the return oil pipe from the exhaust valve. please quote Procedure M90802 Edition 0256 . Close the air supply to the exhaust valve. Close the cooling water inlet and outlet connections. See Procedure 9081.908-2.

Disconnect pipe connections 3. a chain block and remove the screws. 4.Exhaust Valve MAN B&W Diesel 908-2. 4. M908020256D04 D1302 When referring to this page. Loosen and remove the hydraulic nuts. Remove the protective caps from the exhaust valve studs. Support the intermediate pipe by e.2 Dismantling 3. Remove the plate jacket and insulation from the intermediate pipe. M908020256D03 Loosen the screws which attach the intermediate pipe to the exhaust valve housing. Disconnect the cooling water connections from the exhaust valve and the air pipe for the air spring. See Procedure 9131. Dismantling of hydraulic nuts. please quote Procedure M90802 Edition 0256 Page 5 (24) .g. see Data.

See Procedure 9011. During the lift  check the valve goes clear of all other engine components. please quote Procedure M90802 Edition 0256 . D0824 Check all connections to the valve are removed. Lift of exhaust valve 5.3 Page 6 (24) When referring to this page.3. see Procedure 9082.2 Dismantling MAN B&W Diesel 5. if required. Attach the crane to the eye bolt fitted on top of the valve and start lifting the exhaust valve. Land the exhaust valve on a wooden plate on the platform. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seating and sealing surfaces of the bore.Exhaust Valve 908-2. M908020256D06 For overhaul of the exhaust valve.

Conical locking ring Remove the four screws from the flange on top of the air piston and dismount the flange. Depending on valve model. 2. When referring to this page. Place the exhaust valve on a wooden support on the platform. D0826 Remove the nuts and the safety strap from the oil cylinder. Use a small screwdriver to press the ball into the nonreturn valve. please quote Procedure M90802 Edition 0256 Page 7 (24) . 2. and remove the conical locking ring.Exhaust Valve MAN B&W Diesel 1. Cover the nonreturn valve with a rag to catch the oil drops. 908-2. M908020256O01 Relieve the air pressure through the nonreturn valve from below the piston. Lift away and place the oil cylinder on a wooden support. M908020256O02 Loosen the air piston from the conical locking ring by means of a tin hammer. remove the sealing oil pipe.3 Overhaul Oil cylinder 1.

Bottom piece M908020256O04 Unscrew and remove the lock screws which retain the bottom piece. 4. Lift the oil cylinder with the crane. Lift the valve housing away and land it on a couple of wooden planks. Lift the valve housing clear of the valve spindle. use a tin hammer to release it. 4. M908020256O05 D08-29 Page 8 (24) When referring to this page. Take care – when the internal Oring in the air piston and the internal rings for the sealing arrangement at the bottom of the air cylinder pass the groove for the conical ring at the top of the spindle.908-2. D08-24 Use the oil cylinder as a lifting tool for the exhaust valve housing. 10 mm.3 Exhaust Valve Overhaul MAN B&W Diesel 3. Spindle 3. Lift the valve housing approx. and guide it down over the studs for the oil cylinder. Mount four nuts so that the load from the valve housing is evenly distributed. If the bottom piece has become stuck. please quote Procedure M90802 Edition 0256 .

5. 5. Guide bushing M908020256O06 Mount two eye bolts in the air cylinder and dismount the air cylinder. D08-27 Dismount the nonreturn valve from the air cylinder/valve housing. please quote Procedure M90802 Edition 0256 D0819 Page 9 (24) . See Data. Remove and discard the Oring on the air cylinder.3 Overhaul Remove the oil cylinder. Air piston and cylinder D08-30 Dismount the air piston from the air cylinder. 6. 6.Exhaust Valve MAN B&W Diesel 908-2. Inspect the bushing in the spindle guide for wear and measure the top and bottom diameters. Clean the exhaust valve housing. M908020255O10 D0818 When referring to this page.

If it proves necessary to replace the bushing.908-2. remove the screws and knock out the bushing with a hammer and a suitable mandrel. M908020256O08 8. MAN B&W Diesel Bushing renewal 7.3 Exhaust Valve Overhaul 7. Bottom piece inspection Before cleaning the bottom piece. if the extractor tool is available. mount the extractor tool and pull up the bushing. Alternatively. please quote Procedure M90802 Edition 0256 . M908020256O09 8. See Volume I. The extractor tool is optional. Mount and tighten the screws for the bushing. mount a new Oring for sealing between bushing and exhaust valve housing. supplement 70703 Inspect and evaluate the seating according to Volume I. and can be ordered as spare part. Page 10 (24) When referring to this page. When a new bushing is mounted.

M908020255O15 Clean the bottom piece. Use carborundum 200 and the special grinding tool. Bottom piece Measuring 9. Grind until a smooth surface is achieved. turning alternately clockwise and anticlockwise. is measured as described below. wear or the total amount the seat has been ground.3 Overhaul 9. see Data D08 – 09 for correct grinding angle. Turn the special grinding tool by hand.Exhaust Valve MAN B&W Diesel 908-2.e. THEN Further grinding or reconditioning is not recommended. Bottom piece sealing face If necessary grind the outside seating. All measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating. When referring to this page. D0809 IF the template rests on the lower surface in the groove. G2 = 0. i. In connection with evaluation of the bottom piece according to Volume I. M908020255O14 If the seat or the recess G3 is ground. For maximum wear or grinding. G3 D0812 Use the bottom piece template and a feeler gauge. please quote Procedure M90802 Edition 0256 Page 11 (24) . 10. take measurements G2 and G3. see Data D0811 and D0812. G2 D0811 10.

3 Exhaust Valve Overhaul MAN B&W Diesel 11. Mount and tighten the retaining screws for the bottom piece. Mount new sealing rings on the bottom piece. Mount one Oring in the upper groove. please quote Procedure M90802 Edition 0256 . Bottom piece sealing rings 11. 12. check that the guide pin in the bottom piece enters the hole in the bottom of the exhaust valve housing. M908020256O12 Heat the Useal in 100°C hot water for minimum five minutes and then mount it in the groove immediately. If fitted.908-2. Page 12 (24) When referring to this page. Make sure that the groove for the Useal is clean. M908020256O13 Land the exhaust valve housing on the bottom piece. 12. Check the face on the valve housing is clean. Bottom piece mounting Use the oil cylinder as a lifting tool for the exhaust valve housing.

The burnoff F1 of the valve spindle is checked by measuring along the spindle template from point A to point D and in point E. please quote Procedure M90802 Edition 0256 D E Page 13 (24) . and the seating of the spindle with a feeler gauge. gap G1 is measured between the spindle template. Before cleaning the spindle. See Volume I. For the maximum allowable burnoff. M908020256O14 14. In connection with evaluation of the spindle according to Volume I. supplement 70703 Inspect and evaluate the spindle according to Volume I. Spindle burnoff and grinding check 14. F1 D0810 A D0813 When referring to this page. M908020256O15 If necessary to grind the seat. see Data D0810 for correct grinding angle.Exhaust Valve MAN B&W Diesel 908-2. Spindle inspection 13. are measured as described below.3 Overhaul 13. G1 The maximum seat grinding. see Data D0813. D0814 For maximum seat grinding. see data D08 – 14. burnoff and wear or the total amount the seat has been ground.

If the exhaust valve spindle needs reconditioning. D0816 D0815 D0817 Check the spindle stem for wear in the area D0815 to D0816 measured from the top of the spindle. the spindle stem wear is measured as described below. M908020255O16 D0828 Page 14 (24) When referring to this page. 16. use the special valve spindle lifting tool. see data D08 17. 16.3 Overhaul MAN B&W Diesel 15. Spindle stem check 15. For minimum stem diameter.Exhaust Valve 908-2. please quote Procedure M90802 Edition 0256 . In connection with evaluation of the spindle according to Volume I. contact MAN B&W Diesel for advice. Spindle transport M908020252O19 When lifting or transporting the exhaust valve spindle.

When referring to this page. 18. 18. Check the top of the spindle bushing and the face on the housing is clean.Exhaust Valve MAN B&W Diesel 908-2. M908020256O19 Remove the oil cylinder.3 Overhaul 17. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle. Spindle mounting Use the oil cylinder as a lifting tool for the exhaust valve housing. Spindle bushing sealingrings 17. M908020256O18 Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil. please quote Procedure M90802 Edition 0256 Page 15 (24) . Fit new orings on the spindle bushing as shown in the sketch.

using a screwdriver. Dismount the safety valve from the air cylinder. see Data. use only the machined faces on the valve housing and tighten. D08-07 Page 16 (24) When referring to this page.3 Overhaul MAN B&W Diesel 19. Tighten the lock nut and test the opening pressure once more. Connect the testing device with the high pressure pump by means of a hose. Remount the Banjo coupling. Mount a new Oring in the groove on the outside of the air cylinder. Unscrew and clean the Banjo coupling for sealing oil to the spindle stem bushing. Blow through all bores in the air cylinder. Check the opening pressure. Check the nonreturn valve in the Banjo coupling with compressed air. Mount the safety valve in the bore near the bottom of the air cylinder. If the opening pressure is not correct. D08-04 Mount a new gasket and a new Oring on the safety valve. Safety valve M908020256O20 Place the safety valve in the pressure testing device. M908020256O21 Finally. loosen the lock nut and. please quote Procedure M90802 Edition 0256 . Air cylinder 19. adjust the safety valve until the correct pressure is indicated. Compressed Air 20. see Data. When mounting the safety valve in the air cylinder. use the machined faces to unscrew the valve. Clean the air cylinder.Exhaust Valve 908-2. mount the protective cap. 20. Clean the bottom of the air cylinder for possible coke.

if it is necessary to replace the sealing rings on the air piston. please quote Procedure M90802 Edition 0256 Page 17 (24) . Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. This is done by pressing the air piston through the conical ring.3 Overhaul MAN B&W Diesel 21. cut them and remove them. Mount new Orings in the inside grooves of the air piston. M908020256O22 Note! 22. heat the new teflon rings in 100°C hot water for at least five minutes. Lubricate the Orings on the spindle bushing. Be careful not to damage the edges of the ring grooves in the piston. Air cylinder mounting 21. Before mounting.Exhaust Valve 908-2. be careful not to damage the running surfaces. 22. Air piston seals Check the teflon guide ring and teflon sealing ring for wear. When mounting the teflon rings. M908020252O32 Note! After mounting. When referring to this page. compress the teflon rings by means of the conical ring from tool panel 908. Some engines are not equipped with the locating pin Take care not to damage the Orings on the outside of the spindle bushing.

tighten the air piston and the flange together.908-2. please quote Procedure M90802 Edition 0256 . Locking ring M908020256O24 Mount the two part conical locking ring and apply compressed air below the air piston to lift the piston. Page 18 (24) Compressed Air When referring to this page. M908020256O25 24. Lubricate the guide ring and the running surface of the air cylinder. Lower the air piston over the valve spindle down into the air cylinder. See Procedure 9137.3 Exhaust Valve Overhaul MAN B&W Diesel 23. by means of the four screws. Fit the conical guide ring for the air piston on the air cylinder. Air piston mounting 23. Mount the non return valve for spring air 24. On valve models where the bolts are designed for securing. Mount the flange on top of the air piston and. Use a nylon block and a hammer to press the air piston down in the cylinder Remove the conical guide ring from the air cylinder. secure the bolts.

Exhaust Valve MAN B&W Diesel 908-2.1. please quote Procedure M90802 Edition 0256 Page 19 (24) . Check the unit according to Procedure 908 2. Remove the sealing oil unit. Before remounting the unit. 26. Remove and discard the gasket. M908020255O37 Normally overhaul of the sealing oil unit should not be necessary. Unscrew and clean the orifice plug. Sealing oil control unit. Check and clean the bore for the orifice plug in the top of the oil cylinder. D08-20 M908020256O26 Place the oil cylinder in a horizontal position. If the unit needs to be overhauled. depending on the valve model.3 Overhaul 25. Measure the cylinder diameter. When referring to this page. send it to an authorised MAN B&W repair workshop. Loosen the screws and remove the lifting bracket from the oil cylinder to gain access to the orifice plug. If the diameter of the oil cylinder exceeds Data D0820. Remove the flange and take out the piston. carefully clean it on the machined faces. Inspect the inside of the liner in the oil cylinder for scoring. Remove and discard the sealing disc. either renew the liner or send the complete oil cylinder to an authorised MAN B&W workshop for overhaul. 26. Oil cylinder 25.

Place a new gasket on top of the oil cylinder. Mount a new sealing disc in the bore for the orifice plug. Screw the orifice plug into the bore. Return the oil cylinder to an upright position. If the thickness of the rings has worn down to the minimum. please quote Procedure M90802 Edition 0256 . 28. Mount the sealing oil unit.3 Exhaust Valve Overhaul MAN B&W Diesel 27. see Data. Oil cylinder assembly M908020253O42 D0821 Mount the piston and the flange in the oil cylinder. M908020256O31 D08-05 Page 20 (24) When referring to this page. Tighten and lock the screws. Mount the lifting bracket on the oil cylinder. when mounting Check the mesh once more. 28. discard the rings and mount new ones. Top Remove the piston rings from the oil piston and check them for wear.908-2. Check that the TOP mark on the piston rings faces upwards. Oil piston 27. Mount the screws and tighten to the torque stated in Data.

Mount the overhauled oil cylinder on top of the air cylinder. Mount the safety strap and tighten the nuts. please quote Procedure M90802 Edition 0256 Page 21 (24) . When referring to this page.Exhaust Valve MAN B&W Diesel 908-2. D0806 M908020256O32 Mount the sealing oil pipe. See Data. Oil cylinder mounting 29.3 Overhaul 29.

Check that a 1. it is recommended that the valve is checked and prepared as follows: D0824 Connect compressed air to the air cylinder to close the valve.0 mm feeler gauge can be inserted about 15 mm into gap G3. 2. MAN B&W Diesel Checks before mounting Before mounting an overhauled exhaust valve in the engine. 2.Exhaust Valve 908-2. 1. Check the valve is fitted with new sealing rings in the grooves on the bottom piece. Lubricate the sealing rings with vaseline and the threads of the studs with antiseizure paste. Compressed Air Position the valve in the cylinder cover bore. guiding it in accordance with the exhaust flanges and the guide pin on the exhaust side of the exhaust valve. Copper Grease M908020256M02 Vaseline Page 22 (24) When referring to this page. M908020256M01 G3 Check that the valve stays closed for a minimum of 5 minutes. to ensure that there is a clearance between the outer parts of the seating faces of valve housing and spindle. please quote Procedure M90802 Edition 0256 .4 Mounting 1. Exhaust valve landing Close the valve with compressed air. Lift up the valve with the engine room crane.

Mounting of hydraulic nuts. M908020256M04 Mount the highpressure pipe for the hydraulic valve actuation. D1301 Mount the protective caps on the exhaust valve studs. 4.2 M908020256M05 5. see Data. Mount the cooling water connections for the exhaust valve and the air pipe for the air spring. Check that all pipe connections are properly tightened. please quote Procedure M90802 Edition 0256 Page 23 (24) .Exhaust Valve MAN B&W Diesel 908-2. Mount the oil pipe connections Mount the return oil pipe to the exhaustvalve. M908020256M03 Connect the intermediate pipe to the exhaust valve.4 Mounting 3. 5. When referring to this page. Mount and tighten the hydraulic nuts. See Procedure 9131. 3. See Procedure 9081. 4. Mount the pipe connections Mount and tighten the screws to the exhaust valve housing. Mount the insulation and plate jacket for the intermediate pipe.

7.Exhaust Valve 908-2. If the lubricating oil pumps have been started before the exhaust valve pneumatic springs are pressurize: Engage the indicators on top of the exhaust valves and wait until the exhaust valves are closed. Open the cooling water inlet supply. 7. please quote Procedure M90802 Edition 0256 . Closed Valve Page 24 (24) Open Valve When referring to this page.4 Mounting MAN B&W Diesel 6. open the cooling water outlet valve Open the air supply to the exhaust valve.1. Check the tightness of the sealing ring between the bottom piece and the exhaust valve housing. and vent the exhaust valve. Open cooling water supply 6. See Procedure 9082. Air spring check M908020256M06 The air supply to the exhaust valve must always be connected and pressurized before turning on the oil supply to the exhaust valve actuator. Check that all water connections are mounted and tightened. M908020256M07 Closing of the exhaust valves are eased if the lubrication oil pumps are stopped and the actuators are drained at the drain screws.

Description D08-20 Oil cylinder max.2 mm Piston rings. inside diameter D08-21 Value Unit 71. please quote Data D10803 Edition 0052 MAN B&W Diesel A/S 100/25 55 Nm/° kg Page 1 (2) .6 mm D08-32 Hydraulic actuator. min. tightening angle D08-35 Hydraulic actuator When referring to this page. thickness 2. tightening torque 300 Nm D08-33 Locking plate. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. tightening torque 10 Nm D08-34 Hydraulic actuator.108-3 Exhaust Valve Actuator Data SAFETY PRECAUTIONS For detailed sketch.

e. please quote Data D10803 Edition 0052 MAN B&W Diesel A/S . P90951 refers to chapter 909.g. Plate Page 2 (2) Item No.108-3 Exhaust Valve Actuator 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.

1 1. 1. Leakages may also be caused by leaky non-return valves and loose pressure pipe connections. please quote Procedure M90803 Edition 0227 0$1% :'LHVHO$6 Page 1 (4) . 2. any abnormally large leakages must originate from the hydraulic actuator from which leak oil quantities cannot be directly registered. To check the valve. If the pipe connections are tight and the leak oil amount from the exhaust valve is normal. If the air flow can be felt at the inlet side of the valve.Exhaust Valve Actuator 908-3. HM908-3. the valve must be overhauled. The non-return valve A is built into the oil inlet pipe to the actuator. dismantle and clean it and connect a supply of working air (7 bar) to the outlet side of the valve (the side facing the actuator).0 70 1/3 The hydraulic actuator is then to be dismantled for checking of the parts. Leakages in the exhaust valve can be measured – during running of the engine – by collecting the oil from the drain pipe C leading from the exhaust valve to the hydraulic actuator. See Procedure 908-3.2 When referring to this page.1 Checking Exhaust Valve Actuator L60MC-C 0227 Checking 908-3.

2 1. HM908-3. Remove the piston from the roller guide. Fit eye screws in the lifting holes of the actuator housing and hook on a tackle. Remove the locking plate for the piston. 2. please quote Procedure M90803 Edition 0227 0$1% :'LHVHO$6 . GM908-3. Dismount the inlet pipe and the drain pipe from the exhaust valve. Page 2 (4) When referring to this page.0 70 03 4.2 Dismantling Dismantling 908-3. Dismount the nuts and lift the housing carefully. Turn the piston 90° to release it from the bayonet joint. HG908-3. leaving the piston on top of the roller guide. See Procedure 908-1. then loosen the nuts on the long studs successively until the roller guide spring is relieved. 3. 3.3 201 02 Remove the spring.2. See Procedure 908-3. Overhaul the actuator housing and the piston as required. 1. Release the mountings for the indicator drive from the actuator housing. D08-35 Unscrew the nuts on the two short studs.Exhaust Valve Actuator 908-3. Stop the engine and shut off the oil supply.3. 2.0 78 01 Dismount the high-pressure pipe. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the roller guide housing to check the position of the exhaust cam.

3. Inspect the sliding surfaces of the piston to ensure that there are no scratch marks or seizure marks. Clean the piston in kerosene and wipe dry with a clean piece of cloth. please quote Procedure M90803 Edition 0227 0$1% :'LHVHO$6 Page 3 (4) . Clean the oil cylinder and inspect the bores for deposits. JM908-3. 2. D08-21 Take off the piston rings and check them for wear.Exhaust Valve Actuator 908-3. send the oil cylinder to an MAN B&W authorised workshop for reconditioning. discard the rings and mount new ones.0 73 05 D08-20 When referring to this page.0 69 04 Check the bore of the oil cylinder for possible scores and measure it for wear. If the ring thickness has worn down to the minimum (see Data). HM908-3. 1.3 1. Check that the TOP mark on the piston rings faces upwards when mounting.3 Overhaul Overhaul 908-3. 3. If the bore is seized or worn down to the measurement stated in Data.

D08-32 or 3. Page 4 (4) When referring to this page. Tighten all four nuts as stated in Data. taking care not to damage the piston rings. Mount the oil inlet pipe and the drain pipe from the exhaust valve. Mount the spring on the roller guide. See Procedure 908-1.0 76 05 Mount the washers and nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. Lubricate the piston with plenty of camshaft lubricating oil.4 1. Mount the actuator piston in the roller guide and turn 90° to lock it in the bayonet joint. KC908-3. please quote Procedure M90803 Edition 0227 0$1% :'LHVHO$6 .4 201 03 3.4 201 02 Mount the hydraulic high pressure pipe. 2.4 Exhaust Valve Actuator Mounting Mounting 908-3. D08-34 HG908-3. 2.4. HG908-3. D08-33 1. Mount the locking plate and tighten as stated in Data.908-3. NOT both. Carefully lower the actuator housing on to the piston. Note! Use only the tightening angle OR the tightening torque. Mount the washers and nuts on the two short studs.

clearance 0.108-4 Exhaust Valve Roller Guide Data SAFETY PRECAUTIONS For detailed sketch. max.5 mm D08-38 Roller guide complete 30 kg When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear X Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply X Lock the turbocharger rotors Data Ref. please quote Data D10804 Edition 0038 MAN B&W Diesel A/S Page 1 (2) . Description Value Unit D08-36 Bushing/shaft pin.

P90951 refers to chapter 909. Plate P90851 Page 2 (2) Item No. 053 Description Lifting tool for roller guide When referring to this page.108-4 Exhaust Valve Roller Guide 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 D10804 Edition 0038 MAN B&W Diesel A/S . e.g.

6. Place a dial gauge against the roller. See Procedure 908-5. 2. 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. The exhaust valve roller guide can be partially checked while mounted on the engine. using the following procedure: 2. For dismantling of the roller guide see Procedure 908-4.1 Checking 1. Make sure that no traces of bearing metal exist in the roller guide housing. seizures or scratches. M908040220C02 Turn the engine to provide the maximum space between the roller guide and the cam disc. To measure the clearance in the roller guide slide bearing. seizures or scratches. please quote Procedure M90804 Edition 0220 MAN B&W Diesel A/S Page 1 (4) .Exhaust Valve Roller Guide 908-4. Remove the camshaft inspection cover. Also inspect the surface of the roller for possible damage marks. D0836 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. Inspect the surfaces of the roller guide and the roller for damage marks.2. Lift the roller guide. 3. 5. 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. place the roller guide vertically upside down on a couple of planks with the roller hanging freely. 5. A more suitable and reliable method is to check the roller guide and the bearing clearance when the roller guide is dismounted. M908040220C05 4.

• damage to the roller. • seizure marks on the slide surfaces.1 Exhaust Valve Roller Guide Checking 7. • larger clearance than stated on the Data sheet. contact an MAN B&W authorized repair shop. please quote Procedure M90804 Edition 0220 MAN B&W Diesel A/S . Note! For disassembling of the roller guide. It is recommended that the roller guide should ONLY be dismantled if: • irregularities when turning the roller.908-4. Page 2 (4) When referring to this page. have been observed during the checking of the roller guide.

M908040220D01 • Lower the lock ring. Take care not to damage the sliding surfaces of the roller guide when lifting. 2. thereby securing the foot in the locked position. See Procedure 908-3.908-4. 2. • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint.2 Exhaust Valve Roller Guide Dismantling 1. • Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide.2. Lift the roller guide out of the roller guide housing. using the crane. Dismantle the hydraulic actuator above the exhaust valve roller guide. Mount the roller guide lifting tool as follows: • Lift the lock ring of the tool up on the shaft of the tool. 1. D0838 M908040220D02 90 O When referring to this page. please quote Procedure M90804 Edition 0220 MAN B&W Diesel A/S Page 3 (4) .

Clean and lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing. thereby securing the foot in the locked position. • Lift the lock ring of the tool up on the shaft of the tool. When referring to this page. Mount the lifting tool for the roller guide as follows: 1. Mount the actuator. See Procedure 908-3. M908040220D02 Remove the lifting tool. • Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide.4 Exhaust Valve Roller Guide Mounting 1. Page 4 (4) 2.4. D0838 90 O • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint.908-4. • Lower the lock ring. please quote Procedure M90804 Edition 0220 MAN B&W Diesel A/S .

108-5 Exhaust Valve Cam Data SAFETY PRECAUTIONS For detailed sketch. D08-39 Description Check lifting height When referring to this page. please quote Data D10805 Edition 0015 MAN B&W Diesel A/S Value Unit 10 mm Page 1 (2) . see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

complete P91351 154 Conical valve. Cu ø11x3 mm P91366 073 Dial gauge and stand tool Page 2 (2) When referring to this page. 0 . Plate Item No. please quote Data D10805 Edition 0015 MAN B&W Diesel A/S . round-plain.108-5 Exhaust Valve Cam Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.15 P91351 225 Disc.g. e. pneumatically operated P91351 034 Hose with unions (1000 mm). complete P91351 058 Hose with unions (3000 mm). P90951 refers to chapter 909. Description P90651 044 Impact spanner for turning cam P90851 173 Lifting tool for exhaust valve roller guide P91351 010 Hydraulic pump.

00 .00 mm. please quote Procedure M90805 Edition 0216 MAN B&W Diesel A/S Page 1 (4) . and the dial gauge gives the reading 1.00 mm) on the lifting tool for the exhaust valve roller guide. Mount a dial gauge (measuring range 0. Reset the scale and the pointer. Remove the high pressure pipe. Note! When calculating the angles A and B. see procedure 908-1. 2. Turn the crank throw of the cylinder concerned in AHEAD direction until TDC.1 Checking 1. 1. which is the number of degrees the crank throw has turned from TDC position to the present position. which is the number of degrees the crank throw has turned from TDC position to the present position. Check and write down the angle indicated on the turning wheel. Turn the roller guide in AHEAD direction until lifted to D08-39. remember to take into account that the scale on the turning wheel shifts from 360 to 0 (zero) degrees When referring to this page. 2. 3. and the dial gauge gives the reading 1.00 mm and calculate the angle A.20.2 Mount and tighten the lifting tool for the exhaust valve roller guide to the actuator piston (remove the screws for tightening to the actuator housing and do not lift the roller guide). Calculate the angle B. Press the dial gauge against the face of the actuator housing until the reading D08-39 + 1.00 mm is obtained. Continue turning AHEAD until the roller guide again is lifted to D08-39.Exhaust Valve Cam 908-5.

1 Exhaust Valve Cam Checking 4. it is recommended to check the position of the camshaft with the pin gauge. Calculate the lead angle as: 180° – (A° + B°)/2 The lead angle is normally a negative figure. 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. See the Adjustment Sheet in Volume I. The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC.5°. 5. for the “lead angle” of the plant in question. 5. 4. See Procedure 906-3. Chapter 701. The position of the cam must be correct within a tolerance of +/-0. please quote Procedure M90805 Edition 0216 MAN B&W Diesel A/S .1 Page 2 (4) When referring to this page. OPERATION. At the same time.908-5.

Remove the oil tray from the camshaft housing. Apply a light pressure to the hydraulic system and.3 Adjustment Normally. 4. Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulic high pressure pump. for instance. When referring to this page. Insert three copper gaskets in each oil duct. please quote Procedure M90805 Edition 0216 MAN B&W Diesel A/S Page 3 (4) . 1. 3. ensuring that the two pins enter the holes in the cam. Keep the cam pressurised for at least two to five minutes before turning the cam. a screwdriver). Chapter 706. see Volume I. Oil must sweep out with the pump running during the operation. 4. Dismount the exhaust valve high-pressure pipe. after venting the system. M908050216O01 2.Exhaust Valve Cam 908-5. but do not tighten them. see procedure 908-1. tighten the snap-on couplings.2 3. Before adjustment of any cams. Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc. Mount snap-on couplings in the oil ducts. adjustment of the exhaust cams should not be necessary. Turn the camshaft until there is access to the oil ducts in the exhaust cam through the inspection hole.2. See procedure 906-4. Mount the special spanner on the exhaust cam disc. 1. Keep the cam pressurised during turning. remove the plugs from the oil ducts (using. If fitted.

until the desired change of lead is obtained.1. using the fitted spanner. Mount the high pressure pipe for the exhaust valve. See procedure 908-5.4 9. To reduce lead angle and increase the compression pressure: – turn the cam disc AHEAD.3 Exhaust Valve Cam Adjustment 5. Mount the oil tray on the camshaft housing. relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. 5. After any adjustment of the cam position. Page 4 (4) When referring to this page. 7. See procedure 906-4. measure the exhaust cam lead again. Write down and file the new results for the purpose of comparing with future measurements and adjustment. 6. See procedure 908-1. After carrying out adjustment. Check the change on the cam scale To increase the lead angle and reduce the compression pressure: – turn the cam disc ASTERN. 8. pcomp must be recorded and compared with pcomp at a known engine reference load. 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.4.908-5. Turn the cam disc. After completing the desired turning of the cam disc. please quote Procedure M90805 Edition 0216 MAN B&W Diesel A/S .

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

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

Remove the inspection cover of the camshaft housing. please quote Procedure M90807 Edition 0234 MAN B&W Diesel A/S Page 1 (4) .1. Mount the non-return valve on the oil pipe and blank off the non-return valve with the plug from tool panel 908. Turn the engine until the exhaust roller guide is at TDC. carry out the following procedure: 1. See Procedure 908-1.1 Special running Warning! 3. Dismantle the hydraulic high-pressure pipe and the connecting sleeve. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. See Volume I. Dismantle the non-return valve on the oil inlet pipe.Exhaust Valve 908-7. M908070234O03 Disengagement or re-engagement of the fuel pump roller guide or the exhaust valve roller guide must only take place at engine standstill. 3. Section 704. Stop the engine. 4. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one side. M908040220C02 2. 4. When referring to this page.2. See Procedure 909-10. Either way. Lift the relevant fuel pump roller guide. This can take place with the exhaust valve locked in either the open or the closed position. Stop the lubricating oil pump. Engine trouble might require that a cylinder be taken out of action.

Tighten the lowermost nut on the tool to pull up the roller guide as far as possible. please quote Procedure M90807 Edition 0234 MAN B&W Diesel A/S . 5.1 Exhaust Valve Special Running 5. M908070234O07 7. Release the air from the air spring through the non-return valve on the side of the air cylinder. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston. Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position. 7. M908070234O05 If the cylinder is to operate with the exhaust valve open. Shut off the compressed air supply and remove the air pipe connection to the exhaust valve and plug the pipe. If the cylinder is to operate with the exhaust valve closed. Page 2 (4) When referring to this page. the air supply must remain connected to the air cylinder of the exhaust valve.908-7. 6. and cover it with a rag to catch the oil drops. No further action is required. continue the procedure as follows: Hint! Use a small screwdriver to press the ball into the non-return valve.

The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine. please quote Procedure M90807 Edition 0234 MAN B&W Diesel A/S Page 3 (4) . Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. If the engine has been running with the exhaust valve open. 8.Exhaust Valve 908-7. 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. When referring to this page. M908070234O05 Re-connect the air supply to the air cylinder.1 Special running 8. M908070234O08 Note! 9. 10. remove the tool mounted in the air cylinder and mount the rotation indicator. Dismantle the rotation indicator on the air cylinder and mount the tool for opening of the exhaust valve. After overhaul of the cylinder unit. Remove the tool. The tool will keep the piston of the air cylinder in the bottom position and thus keep the exhaust valve open. re-engage the exhaust valve gear as follows: 9.

M908070234O11 13. Engage the fuel pump roller guide. 12. please quote Procedure M90807 Edition 0234 MAN B&W Diesel A/S . Mount the hydraulic high-pressure pipe. 11.4. Remove the plug from the non-return valve and re-connect the oil inlet pipe and the connecting sleeve on the actuator housing.1 Exhaust Valve Special Running 11. See Procedure 909-10.908-7. Page 4 (4) When referring to this page.1. See Procedure 908-1. after fitting new sealing rings on the connecting sleeve.

Panel MAN B&W When referring to this page. please qoute Plate P90851 Edition 0207 Plate P90851-0207 Page 1 (2) .Exhaust Valve .

Item Description 016 028 041 053 065 077 089 090 100 112 Panel for tools Name plate Tightening template for actuator Lifting tool for roller guide Lifting tool for exhaust valve Conical ring for pneumatic piston Pressure tester for safety valve Gauge for exhaust valve spindle Stepped drift for roller guide Grinding mandrel for high-pressure pipe Tool for emergency opening of exhaust valve Gauge for exhaust valve bottom piece Lifting tool for exhaust valve spindle Lifting tool for exhaust valve roller guide Grinding ring. please qoute Plate P90851 Edition 0207 .Panel MAN B&W Item No. exhaust valve bottom piece 124 150 161 173 185 Page 2 (2) When referring to this page.Plate P90851-0207 Exhaust Valve .

Exhaust Valve . please qoute Plate P90862 Edition 0041 Plate P90862-0041 Page 1 (2) .Hydraulic Tools MAN B&W When referring to this page.

Hydraulic Tools MAN B&W Item No. Item Description 028 030 053 065 089 090 100 207 Hydraulic jack. complete Page 2 (2) When referring to this page.Plate P90862-0041 Exhaust Valve . please qoute Plate P90862 Edition 0041 . complete Support O-ring with back-up ring O-ring with back-up ring Tommy bar Spanner Stud setter Hydraulic tool set.

Exhaust Valve . please qoute Plate P90863 Edition 0014 Plate P90863-0014 Page 1 (2) .Extra Tools MAN B&W When referring to this page.

please qoute Plate P90863 Edition 0014 . 011 Page 2 (2) MAN B&W Item Description Worktable When referring to this page.Exhaust Valve .Extra Tools Plate P90863-0014 Item No.

Extra Tools MAN B&W When referring to this page. please qoute Plate P90863 Edition 0016 Plate P90863-0016 Page 1 (2) .Exhaust Valve .

Extra Tools MAN B&W Item Description Grinding machine for exhaust valve spindle seat When referring to this page. 011 Page 2 (2) Exhaust Valve . please qoute Plate P90863 Edition 0016 .Plate P90863-0016 Item No.

Data Fuel Pump Fuel Pump Top Cover. Data Fuel Pump Top Cover Fuel Pump Barrel Assembly. Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide.Fuel Oil System Documents in this Chapter 109-01 909-01 109-02 909-02 109-03 909-03 109-04 909-04 109-05 909-05 109-06 909-06 109-07 909-07 109-08 909-08 109-09 909-09 10910 90910 10911 90911 10912 90912 10913 90913 10914 90914 10915 90915 0063 0241 0005 0206 0050 0233 0058 0222 0063 0234 0050 0219 0039 0214 0050 0217 0032 0214 0018 0209 0068 0244 0047 0222 0033 0207 0074 0234 0058 0234 MAN Diesel A/S Fuel Pump Settings. Data Fuel Pump Puncture Valve Fuel Pump Shock Absorber.909 . Data Fuel Valve Spindle Guide. Data Fuel Pump Suction Valve Fuel Pump Puncture Valve. Data Fuel System Shock Absorber Lifting Gear Roller Guide. Data Spindle Guide Non-Return Valve in Fuel Valve. Data Fuel Pump Barrel Assembly Fuel Pump Suction Valve. Data Fuel Pump Cam Fuel Pump. Data Fuel Pump Settings VIT System. Data Lifting Gear for Roller Guide Fuel Valve. Data Non-Return Valve in Fuel Valve Fuel Oil High-Pressure Pipes. Data Fuel Pump Roller Guide . Data VIT System Fuel Pump Cam.

Panel Fuel Valve .90951 90961 90966 90968 90974 90977 90979 90980 0441 0069 0008 0001 0001 0001 0001 0001 MAN Diesel A/S Fuel Valve and Fuel Pump .Pump Barrel Seals Mounting Tools .Air Piston Seals .Tools Fuel Valve Nozzle .Cleaning Tools Mounting Tools .Inspection Tools Fuel Valve Nozzle .Tools Fuel Valve .Suction Valve Seals Mounting Tools .

see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. When referring to this page. please quote Data D10901 Edition 0063 MAN B&W Diesel A/S Value Unit 3-4 bar Page 1 (2) . D09-02 Description Change of one index mark.109-1 Fuel Pump Settings Data SAFETY PRECAUTIONS For detailed sketch. corresponds to p-max being altered approx.

Plate Page 2 (2) Item No. Description When referring to this page.g. e. please quote Data D10901 Edition 0063 MAN B&W Diesel A/S . P90951 refers to chapter 909.109-1 Fuel Pump Settings Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.

pmax adjustment: 2. If the required p max adjustment cannot be attained by adjustment on the VIT index arm. Loosen lock nut B and then turn adjusting screw H. see Procedure 909-2. To increase p max. 3. Before adjustment of the fuel pump is carried out. The Maximum Combustion Pressure (pmax) is adjusted for the individual units at the fuel pump VIT index arm. Note! 4. To decrease p max. adjust to lower VIT index (delay injection).3 240 01 1. For collective adjustments of pmax on all units. HN909-1. When referring to this page. Contact MAN B&W Diesel for advice.Fuel Pump Settings 909-1. The link can be adjusted by approx. Chapter 706. HN909-1. 3 index marks. also the fuel cam lead should be checked. see Procedure 909-3.3 1. see Volume I.3 240 02 The individual p max value must not deviate more than 3 bar from the average value for all cylinders. it is possible to carry out the adjustment on the fuel cam disc.3 Adjustment Fuel Pump Settings K98MC-C 0241 Adjustment 909-1. 2. adjust to higher VIT index (advance injection). One index mark will alter pmax approximately as given in Data D09-02.1. please quote Procedure M90901 Edition 0241 MAN B&W Diesel A/S Page 1 (2) .

M90901-0242O06 6. Chapter 706. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump index arm. MIP adjustment: 5. See Volume I. to evaluate the adjustments see Volume I. HN909-1.5 bar from the average value for all cylinders. The mean indicated pressure should not deviate more than 0. Decrease index for lower p i.3 Fuel Pump Settings Adjustment 5. Page 2 (2) When referring to this page. The mean indicated pressure is one of the most important parameters in obtaining good engine performance.909-1.3 240 05 Note! 6. After adjustment of the fuel pumps a set of observations must be taken. please quote Procedure M90901 Edition 0241 MAN B&W Diesel A/S . Increase index for higher p i.

109-2 VIT System Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description When referring to this page. please quote Data D10902 Edition 0005 MAN B&W Diesel A/S Value Unit Page 1 (2) .

g.109-2 VIT System Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. P90951 refers to chapter 909. please quote Data D10902 Edition 0005 MAN B&W Diesel A/S . Plate Page 2 (2) Item No. Description When referring to this page. e.

see “Fine adjustment”. (The fuel index must correspond to 90% load taken by measurement or from the test bed sheet).3 Adjustment VIT System K98MC-C 0206 Adjustment 909-2.3 1. please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S Page 1 (5) . Engage the manual engine control. the pmax will change. M90902-0206O01 The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection Timing) system. this change can be corrected by adjusting the pmax of all the cylinders with the VIT system.VIT System 909-2. Look in the test sheet for actual start.and break point. Normally the VIT system is adjusted to start at 40% engine load and to have break point at 90% of MCR engine output. Before adjustment of any part of the VIT system. 1. see Volume I. All adjustments should be based on a set of observations including a set of indicator diagrams taken when the engine is running just above the breakpoint (90% MCR). When referring to this page. If the fuel quality has changed or if the fuel pumps are worn. Chapter 706. Mechanical VIT system Basic adjustment: When the basic adjustment is carried out the engine must be stopped. normally only fine adjustment is necessary. Check that the VIT lever is resting on both rollers (break point for all cylinders). and adjust the regulating shaft to a fuel pump index corresponding to 90% engine load. 2. M90902-0206O02 2.

To check a pilot valve already mounted on the engine.5-8. Pbar 5 4 3 2 1. A M90902-0206O04 B Page 2 (5) P When referring to this page. C 4.1 Pressing in mm 0 1 2 3 4 5 6 7 8 0. Spare pilot valves should be pre-adjusted to 0.0 bar control air pressure. 3. until lever contact with both rollers and tighten nut A.0 bar.0 mm pressing-in of pin C.5 C Check that the pressure on the pressure gauge and the pressing-in of pin C is in accordance with the curve. please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S . adjust the lever by loosening the nut A and turn the clamping arm B.5 1 0. If necessary. corresponding to 0.5-5.VIT System 909-2. M90602-0238O03 B A 4. Adjust the VIT air pressure to 3.5 0.3 Adjustment 3. by axial displacement of the bracket with the pilot valve and read the pressure on the pressure gauge C. remove the inlet and outlet pipe connections at A and P. See figure 2. Any necessary adjustment is done by turning adjusting screw B. and connect a pressure gauge at A and a pipe with working air (pressure 7 bar) at P on the pilot valve.

0 bar from 140 bar. 6. Decrease the p max pressure by moving the pilot valve away from the lever. see procedure 909-1.0 bar.VIT System 909-2. the engine must run at 90% load or just above. 6. M90902-0206O06 If the maximum combustion pressure deviates more than 3. Fine adjustment: 5. Increase the pmax pressure by moving the pilot valve toward the lever. adjust the pressure by replacement of the lowermost roller. Adjust the VIT air pressure to obtain cylinder p max of 140 bar. The VIT air pressure must be maximum 5. please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S Page 3 (5) . When the fine adjustment is carried out. When referring to this page.3 Adjustment 5. Run the engine at maximum load and check that p max is 140 bar. Take a new set of indicator diagrams and calculate the engine load. M90902-0206O05 For adjustment of pmax on a single cylinder.

change the p offset value in accordance with the required increase or decrease in the p max pressure. M90902-0206O08 8. The uppermost roller is used to adjust the VIT start point (40% engine load). The adjustment should be based on a set of indicator diagrams taken when the engine is running just above the breakpoint. On the panel in the engine room control room. please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S . Page 4 (5) When referring to this page.VIT System 909-2. Check the adjustment by taking a new set of indicator diagrams while the engine is running just above the breakpoint. 10. 7. Pbar Electronic VIT system Break point Pmax adjusted on uppermost roller 8. One graduation mark on the p offset scale corresponds to a change in p max of 1 bar. M90902-0206O07 Pcomp 40 90 100 %Load 9.3 Adjustment Pmax adjusted on lowermost roller 7.

The I/P converter mounted on the engine receives a 4-20 mA signal I from the electronic governor system and converts this into a 0. see the panel manufacturer’s instructions. the I/P converter must be adjusted. P control P supply On the pressure gauge mounted on the control air line after the I/P converter check that the control air pressures from the I/P converter are in accordance with the curve. operate the panel in the engine control room to supply various signals I to the I/P converter.5 0. mA 0 0 When referring to this page.VIT System 909-2. please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S 4 8 12 16 20 Page 5 (5) . 12. Remove the hood of the I/P converter and adjust the I/P converter according to the manufacturer’s instructions.5-5. 11. If the control air pressure is not in accordance with the curve.0 bar control air pressure pcontrol .5 0.1 2 1 I. To check the adjustment of the I/P converter.3 Adjustment 11. 5 4 3 M90902-0206O11 13. For operation of the panel. P control 1.

.

Description When referring to this page.109-3 Fuel Pump Cam Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10903 Edition 0050 MAN B&W Diesel A/S Value Unit Page 1 (2) .

complete P91351 154 Conical valve.109-3 Fuel Pump Cam Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number.g. e. complete P91351 58 Hose with unions (3000 mm). 0 . male P91351 225 Disc. Plate Item No. Description P90651 44 Impact spanner for turning cam P90951 45 Measuring tool for fuel pump P91351 10 Hydraulic pump. Cu ø11x3 mm Page 2 (2) When referring to this page.15 P91351 201 Quick coupling. pneumatically operated P91351 46 Hose with unions (1500 mm). P90951 refers to chapter 909. please quote Data D10903 Edition 0050 MAN B&W Diesel A/S . round-plain.

Measure the distance x from the top of the measuring pin to the transverse piece. Again measure the distance x from the top of the measuring tool to the transverse piece. Note down the result for comparison with the testbed results and for future reference. When referring to this page.2. Fuel cam Ahead Lowest position of pump plunger Main piston in TDC 2.3. C X2 X1 Roller guide 1. M909030233C04 Remount the puncture valve. use a calliper to find the point. until it rests against the pump plunger. 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. Push down the measuring pin through the top cover. 5. Calculate the fuel cam lead C (top lift) as: C = x1 – x2 (mm) M909030233C03 4.1 Fuel Pump Cam Checking Fuel cam lead: 1. 2. See Procedure 909-8. Turn ahead until the main piston of the cylinder concerned is in TDC. see Procedure 909-3. M909030233C01 Make sure that the reversing mechanism is in AHEAD direction. Note down the result as x1.909-3. 3. For adjustment of the fuel cam lead. To measure the fuel cam lead (top lift): Dismantle the puncture valve. Turn the engine until the lowest point of the cam is found. please quote Procedure M90903 Edition 0233 MAN B&W Diesel A/S Page 1 (4) . Note down the result as x2. X 3.

please quote Procedure M90903 Edition 0233 MAN B&W Diesel A/S . Chapter 706. 2. Insert three copper gaskets in each oil duct. for instance. see Volume I. 1. a screwdriver). Note! M909030233O01 Before dismantling any part of the fuel pump. Page 2 (4) When referring to this page.909-3. make sure that the pump has been relieved of pressure and that all oil has been drained off. Remove the inspection cover from the camshaft housing.2 Fuel Pump Cam Adjustment Normally. and mount the measuring tool to check the cam adjustment. X 3. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. If fitted. Dismount the puncture valve from the fuel pump top cover. M909030233O03 3. Before adjustment of fuel equipment. but do not tighten them. Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulic highpressure pump. adjustment of the fuel cam should not be necessary. 2. 1. M909030233C03 Mount snap-on couplings in the oil ducts. remove the plugs from the oil ducts (using.

remove the oil tray and carry out the adjustment from the bottom of the cam shaft housing.2 Adjustment 4. please quote Procedure M90903 Edition 0233 MAN B&W Diesel A/S Page 3 (4) . 4. after venting the system. using the fitted spanner. Note down and file the new results for purposes of comparison with future measurements and adjustment. To reduce lead and pmax: – turn the cam disc ASTERN. ensuring that the two pins enter the holes in the cam. See Procedure 909-1. 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. measure the fuel cam lead again. After completing the desired turning of the cam disc. After carrying out adjustment. relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Oil must seep out with the pump running during the operation to keep the cam pressurised during turning. M909030233O04 Apply a light pressure to the hydraulic system and. 5. Mount the special spanner on the fuel cam disc. Turn the cam disc.2 Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc.Fuel Pump Cam 909-3. For better access to the cam. When referring to this page. Keep the cam pressurised for at least two to five minutes before turning the cam. See Procedure 906-4. tighten the snap-on couplings. until the desired change of lead is obtained. To increase lead and pmax: – turn the cam disc AHEAD.

Mount the puncture valve.2 Fuel Pump Cam Adjustment 6. See Procedure 909-8. 7.909-3. 8.4. Page 4 (4) When referring to this page. please quote Procedure M90903 Edition 0233 MAN B&W Diesel A/S . After any adjustment of the cam position. pmax must be recorded and compared with pmax at a known engine reference load. Mount the inspection cover on the camshaft housing.

Description D09-18 Pump housing nuts.109-4 Fuel Pump Data SAFETY PRECAUTIONS For detailed sketch. tightening angle D09-20 Pump housing D09-21 Bottom plate D09-68 Fuel pump complete D09-39 Shock absorber When referring to this page. please quote Data D10904 Edition 0058 MAN B&W Diesel A/S Value Unit 450 150/60 Nm Nm/° 100 kg 5 kg 210 kg 20 kg Page 1 (2) . tightening torque D09-19 Pump housing nuts. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

e.109-4 Fuel Pump 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. 070 Description Lifting tool for fuel pump housing When referring to this page. P90951 refers to chapter 909.g. Plate P90951 Page 2 (2) Item No. please quote Data D10904 Edition 0058 MAN B&W Diesel A/S .

D09-20 4. Unscrew the nuts at the base of the fuel pump. 3. See Procedure 909-6. Note! Before dismantling any part of the fuel pump.2 203 03 1. JG909-8. GN909-4.2 Dismantling Fuel Pump S60MC-C 0222 Dismantling 909-4. 2.2. Dismantle the fuel pump top cover.Fuel Pump 909-4. and lift the pump housing away. Take care not to damage the threads of the studs. Remove the fuel oil inlet pipe. Fit the lifting tool using the top cover studs/ nuts. 4. make sure that the pump has been relieved of pressure and that all oil has been drained off. please quote Procedure M90904 Edition 0222 0$1% :'LHVHO$6 Page 1 (8) . Remove the screws holding the fuel oil inlet pipe between the fuel pump and the fuel inlet valve.0 71 02 Land the fuel pump on wooden planks.2 3. Dismantle the barrel/plunger assembly. See Procedure 909-5. When referring to this page. Discard the gaskets.2.

the top cover and plunger/barrel assembly of the fuel pump must have been removed.3 Fuel Pump Overhaul Overhaul 909-4. See Procedure 909-4.3. Page 2 (8) When referring to this page. Dismantle the actuator and actuator bracket. 4.3 3.2. and the fuel pump must have been dismantled from the pump base and landed on wooden planks. See Procedure 909-9.2. the regulating and timing systems of the fuel pump must be overhauled. Dismantle the fuel pump shock absorber. If the fuel index arm or the VIT index arm of the fuel pump is moving too tightly. GN909-4. In order to carry out this overhaul.3 203 03 2. See Procedure 909-6. See Procedure 909-5. 1. HG909-9. please quote Procedure M90904 Edition 0222 0$1% :'LHVHO$6 .909-4. overhaul the fuel pump shock absorber.2. 4.2 201 01 D09-39 If necessary. 3.

Tilt the fuel pump housing into a horizontal position on the wooden planks. When referring to this page. please quote Procedure M90904 Edition 0222 0$1% :'LHVHO$6 Page 3 (8) . 5.4 121 07 7.4 121 06 D09-21 HC909-3. HC909-3.4 121 05 • Fuel index arm 6. Dismantle the: • Sleeve • Regulating guide HC909-3.3 Overhaul 5. loosen it by screwing two M10x70 mm screws into the holes of the bottom plate.Fuel Pump 909-4. 6. If the bottom plate is stuck. Dismantle the screws and the bottom plate from the fuel pump housing. 7.

909-4.3

Fuel Pump
Overhaul

8.

8. Dismantle the:
• Guide screw
• VIT index arm
• Timing guide
9. Dismantle and inspect the plug screws in
both sides of the fuel pump housing.

HC909-3.4 121 08

If heavily eroded, replace the plug screws.
Replace the sealing rings and mount the
plug screws.
10. Clean all parts thoroughly in diesel oil or
kerosene. Blow dry with compressed air.
9.
11. Mount new sealing rings on the unions.
Note!
Soak the sealing rings in lubricating oil
before mounting

HC909-3.4 121 09

12. Clean all inside surfaces of the fuel pump
housing.

HC909-3.4 121 11

11.

Page 4 (8)

When referring to this page, please quote Procedure M90904 Edition 0222
0$1% :'LHVHO$6

Fuel Pump

909-4.3

Overhaul
14.

Mounting
13. Lubricate the following with molybdenum disulphide (MoS 2):
• all internal machined surfaces of the fuel
pump housing
• the sliding surfaces of all parts of the
regulating and timing systems.

regulating guide
timing guide
VIT index arm

HC909-3.4 121 14

• the teeth of the:

fuel index arm.

15.

14. Mount the VIT index and the guide screw.
Adjust the position of the VIT index arm so
that the scratch mark is aligned with the
centre of the fuel pump housing.

The timing guide must be mounted in such
a way that the scratch mark on the timing
guide is aligned with the scratch mark on
the VIT index arm, which must be visible
through the hole in the timing guide.

16.

HC909-3.4 121 16

16. Mount the sleeve in the fuel pump housing,
ensuring that the notch in the side of the
sleeve is aligned with the pin hole in the
fuel pump housing.

HC909-3.4 121 15

15. Mount the timing guide in the fuel pump
housing.

When referring to this page, please quote Procedure M90904 Edition 0222
0$1% :'LHVHO$6

Page 5 (8)

909-4.3

Fuel Pump
Overhaul

17.

17. Mount the fuel index arm.
Adjust the position of the fuel index arm so
that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.

HC909-3.4 121 17

18. Mount the regulating guide in the fuel pump
housing.
The regulating guide must be mounted so
that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.
19. Mount the bottom plate on the fuel pump
housing.

HC909-3.4 121 18

18.

HC909-3.4 121 06

19.

Page 6 (8)

When referring to this page, please quote Procedure M90904 Edition 0222
0$1% :'LHVHO$6

Fuel Pump

909-4.3

Overhaul
20.

20. Mount the fuel pump shock absorber.

HC909-9.2 201 01

21. Mount the actuator and actuator bracket.

GN909-4.3 203 03

21.

When referring to this page, please quote Procedure M90904 Edition 0222
0$1% :'LHVHO$6

Page 7 (8)

Fuel Pump

909-4.4

Mounting
Mounting
909-4.4

2.

1. Before mounting the fuel pump housing,
make sure that all sliding faces and threads
are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum disulphide (MoS 2).
See Procedure 913-11.

D09-20

D09-18
or
D09-19

2. Lower the fuel pump housing on to the
pump base, taking care not to damage the
threads of the studs.
Remove the lifting tool.
Fit and tighten the nuts at the base of the
pump housing. Use either the tightening
torque or the tightening angle. See Data.
3. Mount the fuel oil inlet pipe between the
pump housing and the inlet valve.
4. Mount the barrel assembly in the fuel pump
housing.
See Procedure 909-6.4.
5. Mount the top cover on the fuel pump housing.
See Procedure 909-5.4.
6. Mount the puncture valve, see Procedure
909-8.4.

JG909-8.0 71 02

7. Mount the drain oil pipes, and the compressed air pipes.

GN909-4.2 203 03

3.

Page 8 (8)

When referring to this page, please quote Procedure M90904 Edition 0222
0$1% :'LHVHO$6

109-5

Fuel Pump Top Cover
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X

Stopped engine

X

Shut off starting air supply – At starting air receiver

X

Block the main starting valve

X

Shut off starting air distributor/distributing system supply

X

Shut off safety air supply – Not ME engines

X

Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X

Engage turning gear
Shut off cooling water

X

Shut off fuel oil

X

Stop lubricating oil supply
Lock the turbocharger rotors

Data
Ref.

Description

Value

Unit

D09-23

Top cover studs, screwing-in torque

130

Nm

D09-24

Top cover nuts, tightening torque

210

Nm

D09-26

Outlet seat, max.grinding diameter

18

mm

D09-27

Top cover

35

kg

When referring to this page, please quote Data D10905 Edition 0063
MAN B&W Diesel A/S

Page 1 (2)

109-5

Fuel Pump Top Cover
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Item No.

Description

P90951

069

Lifting tool for fuel pump

P90951

094

Milling tool for fuel oil pipe seats

Page 2 (2)

When referring to this page, please quote Data D10905 Edition 0063
MAN B&W Diesel A/S

Fuel Pump Top Cover

909-5.1

Checking
1. Shut off the fuel oil inlet.

1.

Open the drain cock (at the bottom of the
pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.
Note!

Dismount all drain pipes and the pipe connections to the puncture valve.
Dismount the high-pressure pipes between
the top cover and the fuel valves.
See Procedure 909-14.2.

M909050234D01

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.

Note!

2. Remove the top cover fixing nuts and
mount the dismantling screws for top cover
in the two threaded holes.
Pull the top cover with suction valve and
puncture valve (if still mounted) free by
tightening the dismantling screws.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.

M909050234D02

If the puncture valve is to be overhauled,
remove the puncture valve from the top
cover at this stage.
See Procedure 909-8.2.

3.

D0927

3. Lift the top cover carefully off.
For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.

M909050234D03

Discard the gasket.

When referring to this page, please quote Procedure M90905 Edition 0234
MAN B&W Diesel A/S

Page 1 (3)

909-5.2

Fuel Pump Top Cover
Dismantling
1. If not already done, dismount the protective
cap and the puncture valve from the top
cover.
See Procedure 909-8.2.

1.

2. Mount the top cover in special bracket and
dismantle the suction valve and the lock
washer from the top cover.
See Procedure 909-7.2.
3. Fill the oil ducts of the top cover with
vaseline or heavy grease.
M909050234O02

Screw the guide, with the miller, into the
high-pressure pipe thread.
Mill the seat until a smooth surface is
achieved. For maximum seat diameter see
Data.

2.
After completing the milling, use compressed air to blow the vaseline/ grease
out from the oil ducts.

D0926

Clean the top cover with diesel oil/gas oil,
and blow dry with compressed air.
Note!

M9099050234O03

Make sure that all bores and threads inside the top cover are absolutely clean.

4. Mount a new lock washer and a new or
overhauled suction valve in the top cover.
See Procedure 909-7.4.

M9099050234O04

3.

If necessary, recondition the seats of the
fuel oil high-pressure pipes.
See Procedure 909-14.3.

Page 2 (3)

When referring to this page, please quote Procedure M90905 Edition 0234
MAN B&W Diesel A/S

909-5.2

Fuel Pump Top Cover
Dismantling
1. Make sure that the inside of the fuel pump
housing and the top of the fuel pump barrel is completely clean.

1.

D0927

2. Mount a new gasket on top of the pump
housing.

Mount the overhauled top cover (with overhauled suction valve and reconditioned
seatings for the high-pressure pipes) on the
pump housing.
Check that the guide pin in the top cover
enters the hole in the pump housing.
Warning!

M909050234M01

Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide
(MoS2). See Procedure 913-11.

3.

D0924

As a safety precaution, and before
mounting the top cover nuts, turn the
engine one revolution.

3. Mount the top cover fixing nuts, and
tighten them diagonally to the torque indicated in Data.
For adjustment of the fuel pump, see Procedure 909-1.1.
4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure
909-8.4.

M909050234M03

When doing this, the top cover must not
move upwards!

4.

Mount the protective cap over the puncture
valve and the two screws in the top cover.
Mount the high-pressure pipes and the
drain screw in the pump housing.

M909050234M04

Mount the drain pipes on the top cover
and the connecting pipe to the puncture
valve. Open the fuel oil inlet.

When referring to this page, please quote Procedure M90905 Edition 0234
MAN B&W Diesel A/S

Page 3 (3)

109-6

Fuel Pump Barrel Assembly
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X

Stopped engine

X

Shut off starting air supply – At starting air receiver

X

Block the main starting valve

X

Shut off starting air distributor/distributing system supply

X

Shut off safety air supply – Not ME engines

X

Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X

Engage turning gear
Shut off cooling water

X

Shut off fuel oil

X

Stop lubricating oil supply
Lock the turbocharger rotors

Data
Ref.

Description

D09-29

Barrel assembly

D09-30

Plunger

When referring to this page, please quote Data D10906 Edition 0050
MAN B&W Diesel A/S

Value

Unit

28

kg

7

kg

Page 1 (2)

109-6

Fuel Pump Barrel Assembly
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Item No.

Description

P90951

057

Lifting tool for barrel and plunger

P90951

224

Tool for P. max rack

P90977

Page 2 (2)

Mounting Tools - Pump Barrel Seals

When referring to this page, please quote Data D10906 Edition 0050
MAN B&W Diesel A/S

Fuel Pump Barrel Assembly

909-6.2

Dismantling
Fuel Pump Barrel Assembly
S60MC-C
0219
Dismantling
909-6.2

1.

1. Shut off the fuel oil inlet.
Open the drain cock (at the bottom of the
pump housing), enabling the oil which is left
in the high-pressure pipe and the fuel pump
to escape.

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.
Dismount the pipe connections to the puncture valve.

GN909-5.2 204 01

Note!

2.

Dismount the fuel oil high-pressure pipes.
See Procedure 909-14-2.
2. If the top cover is to be overhauled, dismount the puncture valve.
See Procedure 909-8.2.

HN909-8.2 207 03

3. Dismount the fuel pump top cover.
See Procedure 909-5.2.

GN909-5.2 204 03

3.

When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6

Page 1 (9)

909-6.2

Fuel Pump Barrel Assembly
Dismantling

4.

4. Position the lifting tool for the barrel/plunger
assembly (without measuring pin) in such a
manner that the two distance tubes of the
tool rest on the pump barrel.
Make sure that the two guide pins in the
bottom of the lifting tool enter the holes in
the top of the plunger.
Secure the lifting tool by screwing the two
screws into the pump barrel.

GN909-6.2 204 01

Loosen the stop ring on the spindle of the
tool and press the spindle down against the
pump plunger.

5.

Turn the spindle in this position until the two
guide pins engage with the two holes in the
plunger top.
Tighten the centre screw of the spindle
against the plunger.

MB909-3.1 95 05

5. Remove the pump barrel guide screw from
the pump housing.
6. Disconnect the links for the timing drive and
the regulating drive. Dismount the union
and pointer for the timing drive and the regulating drive.
6.
Note the position of the scratch mark on the
lever arm.
Remove the locking plate and the lever
arm.

GN909-6.2 204 03

Mount the extractor tool and connect the
timing toothed rack to the pulling rod by
means of the pin.

Page 2 (9)

When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6

Fuel Pump Barrel Assembly 909-6. Carefully lift the barrel/plunger assembly out of the pump housing. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 Page 3 (9) . Turn the nut at the end of the pulling rod.2 Dismantling 7. GN909-6. D09-29 Dismount the tool. whereby the timing rack will move outwards. These will be parallel with the fore-and-aft direction of the engine when the plunger has been turned into position. Keep the toothed rack in this position during the overhaul or replacement of the pump barrel.2 204 04 7.2 204 06 Press the plunger upwards to the bottom of the barrel. Lift the spindle so that the plunger foot goes clear of the bayonet joint. Continue turning the nut until the pin reaches the outer position of the slot in the tool. GN909-6. 9. GN909-6. Move the stop ring of the spindle into contact with the upper flange of the tool. or overhaul it on board as described in Procedure 909-6. and lock the stop ring in this position by means of the stop screw. 8. When referring to this page. There is now a distance between the lifting tool and the pump housing. whereby the thread of the fuel pump barrel goes clear of the timing guide.2 204 05 This can be ascertained by watching the handles on the spindle of the lifting tool. Remove the cover of the pump base to make sure that the plunger is able to go clear of the bayonet joint. Pull the regulating toothed rack outwards until the plunger foot has been turned clear of the bayonet joint in the roller guide. Send the barrel/plunger assembly to an MAN B&W authorized workshop for repair.3. 9. 8.

Before mounting new sealing rings on the barrel. Page 4 (9) When referring to this page. Place the spring-loaded sealing ring on the cone with the spring facing upwards.2 95 04 4. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 . OPERATION.3 Fuel Pump Barrel Assembly Overhaul Overhaul 909-6. 3. MB909-3. For evaluation of pump barrel/plunger. Clean the barrel and wipe dry with a clean piece of cloth. 4. Use the pusher tool to push the sealing ring into the groove.2 95 01 Carefully clean the plunger (for example in clean kerosene) and wipe dry with a clean piece of cloth. the inner sealing ring must be mounted first. MB909-3. see the sketch. heat them in 100°C hot water for at least five minutes. Clean the outside of the barrel. MB909-3. 2. see Volume I.2 95 02 D09-30 Mount the guide stick in the barrel and position the big cone on the barrel. Remove and discard the sealing rings from the barrel. D09-29 Set up the pump barrel/plunger in a bench vice provided with “soft” jaws. When mounting the new sealing rings on the lower end of the pump barrel. 1. 2. Also clean the bores in the top of the plunger. Chapter 706.909-6. Pull the plunger carefully out of the barrel.3 1.

MB909-3. all openings must be covered with plastic to prevent dirt from entering the barrel assembly during storage.Fuel Pump Barrel Assembly 909-6. When referring to this page. 5. place the spacer tool inside the cone to obtain the correct distance to the groove. see the sketch. MB909-3.2 95 06 Do not use force as this will damage the sliding surfaces of the plunger or barrel MB909-3. 7. After mounting the sealing rings. Note! If the barrel assembly is not to be mounted immediately. 6. Carefully slide the plunger into the barrel and press it to the bottom. Lubricate the plunger with molybdenum disulphide (MoS 2).3 Overhaul 5.2 95 05 6.2 95 07 7. When mounting the sealing ring in the outer groove. compress them by pressing the “sizer” tool over the sealing rings. Mount the guide stick and cone on the top end of the barrel and mount the uppermost sealing ring in the same way as above. Make sure that the spring faces downwards. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 Page 5 (9) . and repeat the above procedure.

Place the tool on the pump housing. lubricate the thread for the timing guide and all sealing rings with molybdenum disulphide. Place the supplied measuring pin – which is of the same length as the plunger – on the spindle of the lifting tool. pull the plunger as high up in the barrel as possible. 2.4 207 02 Using the spindle of the tool. and press the spindle down until the pointed end of the measuring pin is in contact with the thrust piece of the roller guide. Secure the tool to the barrel by tightening the two screws. 2. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 . and attach the plunger to the spindle of the tool by tightening the centre screw of the spindle. Page 6 (9) When referring to this page. Loosen the stop ring on the spindle.4 1. at the same time turning the spindle so as to position the plunger foot correctly in relation to the cutout of the regulating guide. Dismount the tool from the pump housing and remove the measuring pin from the spindle. Then mount the tool on the barrel/ plunger assembly which is ready for mounting. 1. HN909-6. and fasten it by tightening the centre screw of the spindle.4 207 01 The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. Then press the stop ring down until it reaches the flange of the tool and lock it there by tightening the screw of the stop ring against the spindle. Before mounting the barrel/plunger in the pump housing. The tool is thus fixed on the barrel in such a way that its correct positioning is ensured during mounting. The stop ring is to remain tightened in this position until the plunger has been correctly mounted.909-6. HN909-6.4 Fuel Pump Barrel Assembly Mounting Mounting 909-6.

4 204 03 4. Pull the regulating toothed rack as far out as possible and check that the extractor tool is mounted correctly on the timing toothed rack when this is in its outer position. There will be a gap between the tool and the pump housing. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 Page 7 (9) . Lower the barrel assembly carefully into the pump housing. Check that the slot in the barrel coincides with the hole for the guide screw.4 204 04 Then continue pressing down the barrel/ plunger assembly until the barrel assembly rests on top of the timing guide. 3. If necessary. GN909-6. When referring to this page. D09-29 GN909-6. 4.Fuel Pump Barrel Assembly 909-6.4 Mounting 3. Lowering the barrel assembly so far down into the pump housing that the sealing rings of the barrel are about to enter the bore in the pump housing. turn the regulating guide a little (using the toothed rack) to make the foot and the regulating block of the plunger fit properly in the cutout of the regulating guide.

Check that the stop disc of the spindle is in full contact with the flange of the tool. press the regulating rod in. press the plunger down into contact with the thrust piece of the roller guide. turn the regulating guide a little (using the toothed rack) to make the plunger foot fit properly in the cutout of the roller guide.4 204 06 Mount the inspection hole cover. GN909-6. 5. When doing this. Page 8 (9) When referring to this page. Inspect the position of the plunger foot through the inspection hole. disconnect the pulling rod from the timing toothed rack. GN909-6. When doing this. Check that the toothed rack is correctly engaged by pressing-in the rack. the pump barrel shall move downwards.909-6.4 204 05 6. When the plunger is in place. The top flange of the tool is now resting on the top of the pump housing. Loosen the nut on the extractor. After ‘landing’ the barrel assembly. thereby turning the plunger by means of the regulating guide and causing the plunger foot to “interlock” with the bayonet joint of the roller guide. Engaging the thread of the fuel pump barrel with the timing guide is accomplished by pressing-in the toothed rack. and remove the extractor. it must not be possible to lift the spindle. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 . as when measuring.4 Fuel Pump Barrel Assembly Mounting 5. (A pressure of about 30 kg may be required). 6. If necessary. Check that the plunger is correctly engaged by pulling at the spindle of the lifting tool.

If the top cover does move upwards. including the nuts. See Procedure 909-5.4 204 08 10. 7. and check that the top cover does not move upwards. Mount the top cover without mounting the nuts. please quote Procedure M90906 Edition 0219 0$1% :'LHVHO$6 Page 9 (9) .4. 8.Fuel Pump Barrel Assembly 909-6. Turn the engine one revolution. Mount the guide screw for the pump barrel in the pump housing. Remove the centre screw from the plunger. and remove the tool. When referring to this page. 8.4 204 07 Mount the links for the timing drive and the regulating drive in place in accordance with the marks. GN909-6. 9. GN909-6. Mount the pointer and union for the timing rack. Mount the fuel pump top cover.4 Mounting 7. the barrel/plunger assembly has to be removed and re-inserted.

.

please quote Data D10907 Edition 0039 MAN B&W Diesel A/S Page 1 (2) .5 kg When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. tightening torque 900 Nm D09-34 Suction valve 2.109-7 Fuel Pump Suction Valve Data SAFETY PRECAUTIONS For detailed sketch. Description Value Unit D09-33 Suction valve.

e.g. 128 Description Crowfoot spanner Mounting Tools .Suction Valve Seals When referring to this page. P90951 refers to chapter 909.109-7 Fuel Pump Suction Valve Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. Plate P90951 P90979 Page 2 (2) Item No. please quote Data D10907 Edition 0039 MAN B&W Diesel A/S .

Fuel Pump Suction Valve 909-7.3 105 08 2. If the suction valve is not to be mounted on the engine immediately after the checking. check that the valve slide can slide freely up and down inside the suction valve.1 207 01 3. 2. please quote Procedure M90907 Edition 0214 0$1% :'LHVHO$6 Page 1 (4) .1 Checking Fuel Pump Suction Valve S60MC-C 0214 Checking 909-7. and wait five minutes. No oil may seep through the seats of the slide/housing. HN909-7.1 1. When referring to this page. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. Check the seats for tightness by filling the inlet hole with diesel oil or gas oil. 1. Using a brass mandrel. KB909-3.

Dismantle the fuel pump top cover and suction valve assembly from the fuel pump housing.909-7.2.2 204 03 3. GN909-5.3 204 02 Remove and discard the lock washer. 1. it is recommended to dismantle the fuel pump puncture valve.2. Release the suction valve lock washer. KN909-7.2 213 03 3. 2. See Procedure 909-5. please quote Procedure M90907 Edition 0214 0$1% :'LHVHO$6 . 2.2 1. Mount two eye bolts in the bottom of the top cover and turn it upside down. Tighten the nuts of the bracket to fix the top cover. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Note! Before dismantling the top cover. Page 2 (4) When referring to this page. Dismount the suction valve from the top cover.2 Fuel Pump Suction Valve Dismantling Dismantling 909-7. GN909-5. see Procedure 909-8.

3. Set up the suction valve in a bench vice with “soft” jaws and. using a brass mandrel and a hammer. 2.3 Overhaul Overhaul 909-7.3 204 03 6. See the sketch.Fuel Pump Suction Valve 909-7. See Procedure 909-7. 3. and lubricate them with molybdenum disulphide (MoS 2). Re-assemble the suction valve.3 105 05 Remove and discard the sealing ring from the valve thrust piece. Lapping of the seats must not be attempted. KB909-3. please quote Procedure M90907 Edition 0214 0$1% :'LHVHO$6 Page 3 (4) . using the pusher tool. Note! Make sure that the sealing ring is mounted correctly. After mounting the sealing ring. 1. 4. push the sealing ring on to the groove. Inspect the seat of the valve slide and the seat in the thrust piece for damage.3 1. KB909-3. 5. XZ909-7. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust piece.1.3 105 06 Place the sealing ring on the cone and. both the suction valve and the valve slide must be discarded. release the spring guide from the valve thrust piece. Clean and overhaul all internal parts. compress it by pressing the “sizer” tool over the sealing ring. 2. Disassemble the other parts of the suction valve and clean the parts thoroughly in clean diesel oil. When referring to this page. Check the suction valve after the overhaul. If the seats are damaged.

Make sure that the bore for the suction valve in the top cover is absolutely clean.4 1. D09-33 1. See Data. 2. Lubricate the thread of the suction valve with copper grease. Remove the top cover from the bracket and mount the top cover in the fuel pump housing.4 213 01 Lock the suction valve in position by bending up an edge of the lock washer over one of the flats of the valve. KN909-7. Page 4 (4) When referring to this page.4 Mounting Mounting 909-7.4. Tighten the nuts of the bracket to fix the top cover. Fit a new lock washer and mount a new or overhauled suction valve in the top cover. please quote Procedure M90907 Edition 0214 0$1% :'LHVHO$6 . Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room.Fuel Pump Suction Valve 909-7. Fit the two screws which secure the lock washer.2 204 03 2. GN909-5. Tighten the suction valve with a torque spanner. See Procedure 909-5.

please quote Data D10908 Edition 0050 MAN B&W Diesel A/S Value Unit 890 Nm Page 1 (2) . tightening torque When referring to this page. D09-35 Description Puncture valve. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.109-8 Fuel Pump Puncture Valve Data SAFETY PRECAUTIONS For detailed sketch.

please quote Data D10908 Edition 0050 MAN B&W Diesel A/S . e. Description P90951 Crowfoot spanner P90980 Mounting Tools .109-8 Fuel Pump Puncture 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.Air Piston Seals Page 2 (2) When referring to this page.g. P90951 refers to chapter 909. Plate Item No.

2 Dismantling Fuel Pump Puncture Valve S60MC-C 0217 Dismantling 909-8. it is recommended to place the puncture valve immersed in diesel oil until the overhaul.Fuel Pump Puncture Valve 909-8. 1. 2. When referring to this page. Unscrew and remove the puncture valve from the fuel pump top cover.2 207 03 If the overhaul cannot take place immediately after the dismantling. Note! Before dismantling any part of the fuel pump. Dismantle the control air pipe and the protective cap above the puncture valve. HN909-8.2 2. HN909-8. After dismantling it is recommended always to overhaul the puncture valve. Open the drain cock at the bottom of the pump housing and drain off any oil left in the fuel oil high-pressure pipe and fuel pump. Shut off the fuel oil inlet. 4. make sure that the pump has been relieved of pressure and that all oil has been drained off.2 207 02 3. please quote Procedure M90908 Edition 0217 0$1% :'LHVHO$6 Page 1 (4) . 3.

HG909-8. Page 2 (4) When referring to this page.2 201 02 2. If the seats are damaged.3 Fuel Pump Puncture Valve Overhaul Overhaul 909-8. Thoroughly clean all the parts in clean diesel oil. Set up the puncture valve in a bench vice with “soft” jaws. Inspect the conical seats of the valve housing and the valve slide for wear marks or scratches. the valve housing and the valve slide must be discarded.3 207 01 Lapping of the valve seats must not be attempted.909-8. Disassemble the other parts of the puncture valve. 1. Loosen and remove the four screws and dismount the plug. 2. Remove and discard the O-rings from the puncture valve. Use a screw to remove the air piston from the housing. Remove and discard the sealing rings from the air piston.3 1. HN909-8. using a brass mandrel and a hammer. Take care not to damage the valve seat. please quote Procedure M90908 Edition 0217 0$1% :'LHVHO$6 .

Fuel Pump Puncture Valve 909-8. 3. lubricate all parts with “MOLYKOTE anti-friction SPRAY D321R” or molybdenum disulphide (MoS 2). When referring to this page. Mount the O-ring in the ring groove and position the large cone on the spindle. the inner sealing ring must be mounted first. 4. GM909-3. Before assembling the puncture valve. If the puncture valve is not to be mounted on the engine immediately after the overhaul.3 89 12 5. over the sealing ring. push the sealing ring on to the O-ring in the groove. and repeating the above procedure.3 Overhaul 3. GM909-3. compress it by pressing the ‘sizer' tool. The new sealing ring is mounted on the head of the air piston in accordance with the same procedure as above.3 89 10 4. After mounting the sealing ring. Place the sealing ring on the cone and. When mounting the new sealing rings on the spindle of the air piston. using the pusher tool. please quote Procedure M90908 Edition 0217 0$1% :'LHVHO$6 Page 3 (4) . Mount new O-rings on the housing. cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. Mount the outer sealing ring in the groove using the short cone.

4 Fuel Pump Puncture Valve Mounting Mounting 909-8. D09-35 2. If this has not already been done. Using a crowfoot wrench and a torque spanner. Lubricate the thread of the puncture valve with copper grease. HN909-8. mount new O-rings on the puncture valve. Screw the puncture valve into the bore in the top cover. please quote Procedure M90908 Edition 0217 0$1% :'LHVHO$6 . Mount the protective cap and the control air pipe on top of the puncture valve. HN909-8.4 207 02 4.4 207 03 3. 1. tighten the puncture valve to the torque stated in Data. 3. Make sure that the bore for the puncture valve in the fuel pump top cover is absolutely clean. Page 4 (4) When referring to this page. close the drain cock on the fuel pump and open the fuel oil inlet valve.4 2.909-8. If open.

D09-39 Description Shock absorber When referring to this page. please quote Data D10909 Edition 0032 MAN B&W Diesel A/S Value Unit 20 kg Page 1 (2) .109-9 Fuel Pump Shock Absorber Data SAFETY PRECAUTIONS For detailed sketch. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

e.109-9 Fuel Pump Shock Absorber 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 D10909 Edition 0032 MAN B&W Diesel A/S .g. P90951 refers to chapter 909. Plate Page 2 (2) Item No. Description When referring to this page.

measure the amount of leakage oil flowing from the drain pipe of the shock absorber housing. See Procedure 909-9. HM909-4. please quote Procedure M90909 Edition 0214 0$1% :'LHVHO$6 Page 1 (3) . inspection is necessary only at the intervals stated in the maintenance programme. 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.3. 2. Remove the plug from the end cover of the shock absorber. Excessive amounts indicate that the shock absorber requires overhauling.1 To ensure satisfactory operation. Normally. The checks should be carried out while the engine is operating. Increasing amounts indicate a deteriorating piston sealing. Note down the amounts measured and compare with earlier measurements. corresponding to the strokes of the fuel pump. Check that air is ‘pulsating’ through the threaded hole. the functioning of the fuel pump shock absorber should be checked at regular intervals. To check the ‘tightness’ of the piston.Fuel Pump Shock Absorber 909-9. Short bursts of air should be felt against the hand.0 09 01 1. When referring to this page.1 Checking Fuel Pump Shock Absorber S60MC-C 0214 Checking 909-9.

Check that the piston slides easily in the shock absorber housing. Fit a threaded rod between the piston and the end cover to counteract the force of the springs. 3.3 1. Mount a new sealing ring in the shock absorber housing and a new wear ring on the piston. Discard the gasket. please quote Procedure M90909 Edition 0214 0$1% :'LHVHO$6 . Loosen the screws of the end cover and remove the end cover and piston. 2.3 Fuel Pump Shock Absorber Overhaul Overhaul 909-9. 2. 5. Loosen the nut on the threaded rod to relieve the springs and remove the threaded rod.909-9. HG909-9. Remove and discard the sealing ring in the shock absorber housing and the wear ring on the piston. Note! D09-39 Before dismantling any part of the fuel pump. Remove the shock absorber drain pipe. HG909-9. Mount the end cover. Take care not to damage the sealing ring or wear ring when mounting the piston.3 204 01 1. Place a wire strap around the shock absorber and hook on the engine room crane. GN909-9. Loosen the screws holding the shock absorber and remove it from the fuel pump housing. using the threaded rod.2 201 02 4. see Data. For tightening the nuts. Page 2 (3) When referring to this page. Lock with the locking device. Remove the plug from the end cover of the shock absorber. make sure that the pump has been relieved of pressure and that all oil has been drained off.2 201 04 6. 4. Mount the springs and the spring guide between the end cover and the piston. Clean all parts and polish the sliding surfaces of the piston and the shock absorber housing. Lubricate all sliding surfaces and assemble the shock absorber. Remove the threaded rod and insert the plug.

Fuel Pump Shock Absorber 909-9. If an excessive amount of drain oil is still observed after the overhaul. Mount the shock absorber drain pipe. please quote Procedure M90909 Edition 0214 0$1% :'LHVHO$6 Page 3 (3) . Fit a new gasket on the fuel pump housing and mount the shock absorber.3 Overhaul 7. the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning. When referring to this page.

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109-10 Lifting Gear for Roller Guide Data SAFETY PRECAUTIONS For detailed sketch. please quote D10910 Edition 0018 MAN B&W Diesel A/S Value Unit Page 1 (2) . see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description When referring to this page.

109-10 Lifting Gear for Roller Guide Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. P90951 refers to chapter 909. please quote Data D10910 Edition 0018 MAN B&W Diesel A/S . e. Plate P90951 Page 2 (2) Item No.g. 307 Description Pulling tool bell shaped When referring to this page.

Stop the engine and engage the turning gear.Lifting Gear for Roller Guide 909-10. please quote Procedure 909-10. 2. Turn the camshaft until the roller is in the highest position on the cam (i.0 59 02 Mount the pulling tool over the lifting device and screw the spindle into the stud. When referring to this page. disconnect it in the following manner: Remove the inspection cover on the upper part of the camshaft housing in front of the fuel cam for the pertaining roller guide.1 1. If a fuel pump is to be put out of action. on the circular section of the fuel cam).0 202 01 1. GG909-10. Warning! Do NOT use the lifting gear for the fuel pump roller guide while the engine is running. 2.e. GM909-5.1 Checking Lifting Gear for Roller Guide K98MC-C 209 Checking 909-10.1 Edition 209 MAN B&W Diesel A/S Page 1 (2) .

Turn the engine until the circular section of the fuel cam is positioned upwards.0 59 03 5.1 Edition 209 MAN B&W Diesel A/S . Re-engagement of the fuel pump roller guide Warining! Re-engagement of the fuel pump roller guide must only take place at engine standstill.e. 3. When the roller guide has been lowered into position and the nut on the spindle is released. Chapter 704. 4. and the engine can be operated on the remaining cylinders. until the sleeve is pressed against the housing.1 Lifting Gear for Roller Guide Checking 3. please quote Procedure 909-10. Page 2 (2) Loosen the spindle nut of the pulling tool to lower the roller guide onto the fuel cam. Lift the roller guide by tightening the spindle nut as much as possible. GM909-5.909-10. The roller guide is now locked in a position free of the fuel cam. remove the pulling tool from the lifting device. see Volume I. i. When referring to this page.

max. Description D09-40 Fuel valve opening pressure D09-42 Inlet seat. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps 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 D10911 Edition 0068 MAN B&W Diesel A/S Value Unit 300 . diameter D09-43 Fuel valve When referring to this page.109-11 Fuel Valve Data SAFETY PRECAUTIONS For detailed sketch.380 bar 18 mm 8 kg Page 1 (2) .

Plate Item No. Description P90151 071 Dismantling tool for fuel valve P90951 094 Milling tool for fuel oil pipe seats P90951 165 Grinding mandrel for valve head P90951 177 Grinding mandrel for thrust spindel P90951 189 Grinding mandrel for holder . please quote Data D10911 Edition 0068 MAN B&W Diesel A/S .outside P90951 190 Grinding mandrel for holder .109-11 Fuel 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.inside P90951 248 Hook spanner P90951 297 Assembling tool for fuel valve P90961 Page 2 (2) Fuel Valve . e.g. P90951 refers to chapter 909.Tools When referring to this page.

For operation of the pressure testing pump. the opening pressure value measured might be considerably lower than specified. replace the spring housing by a new one. check that the locking/indicating pin has not been bent or broken off. See Procedure 909-11. The fuel valves must be given the utmost attention and care. inspected and re-assembled before testing. To ensure that over tightening has not taken place. 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. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 1 (14) . Pressure testing pump Use only hydraulic oil (rust-preventing) with a viscosity of between 7 and 10 cSt at 50°C. See Chapter 900-1. all fuel valves that are dismantled from the engine must be disassembled.3 and 909-12. All fuel valves must be function-tested before being mounted in the cylinder cover. Spring housing When referring to this page. cleaned.Fuel Valve 909-11. In the event of over tightening. see the supplier's instructions.3.1 Checking 1. it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. 2. Note that the high-pressure pump should be periodically checked in accordance with the supplier's instructions. M909110240C02 2. Fuel Valve 1. as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. M909110244C01 In order to obtain reliable results during testing of the fuel valves. If the engine gives normal performance in accordance with diagrams and exhaust temperatures.

1 Fuel Valve Checking 3. Acceptance criteria: M909110244C04 There is to be a continuous jet of oil through at least one of the nozzle holes. Mount the oil pipe between the pressure testing pump and the fuel valve. Pressure testing procedure The following functions of the fuel valve must be checked: • Flushing and jet control • Opening pressure • Sealing test and sliding function • Pressure test.the fuel oil will not necessarily flow from all of the nozzle holes. Place the fuel valve in the test rig and secure it with the spring housings and nuts. Owing to the geometry of the internal part of the nozzle . the cause may be: Dirt in the nozzle holes The nozzle is not mounted correctly Page 2 (14) When referring to this page. Flushing and jet control Remove air in the system and check the fuel jet in the following way. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S .909-11. Cause of fault: If the jets do not fulfil the above point. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housings. M909110242C03 o 4.and because of the height to which the spindle is lifted during pressure testing is lower than the height it is lifted during normal engine operation . Setting-up the fuel valve 3. O-ring sealing 4. Slowly increase the oil pressure until straight jets of oil are ejected from the nozzle holes (no atomization).

If the opening pressure is lower than specified in D09-40. the cause may be that the spring has sagged . the pressure testing procedure of the fuel valve must be repeated. To check the opening pressure. the cause may be that a wrong type of spring is used . M909110244C05 Cause of fault: Note! Special thin discs are available as spares. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 3 (14) .1 Fuel Valve Checking 5. or add a special thin disc.909-11. Note! Do NOT attempt to carry out an atomization test on the slide type fuel valvs. If a spring or a disc has been changed. replace the complete thrust spindle.replace the spring. Opening pressure 5. increase the oil pressure until oil is admitted through the nozzle holes. If the opening pressure is higher than specified in D09-40. When referring to this page. D0940 Acceptance criteria: Check the opening pressure on the pressure gauge and compare with Data D09-40 on the datasheet. if necessary.replace the spring on the thrust spindle. as this may damage the cut-off slide and nozzle.

Page 4 (14) When referring to this page. replace if necessary. If a quick pressure drop from 15 to 0 bar cannot be registered: • The valve slide is sticking.3. • Too quick pressure drop: .3. Examine and/or replace both the spindle guide and non-return valve. Maintain the built-up pressure by closing for the oil supply. Acceptance criteria: M909110240C06 Oil must not flow from the nozzle holes. or If so.1 Fuel Valve Checking 6.the clearances of the movable parts. Cause of fault: If oil flows out of the nozzle holes. See Procedure 909-12. or the seats between the thrust piece/spindle in the spindle guide or thrust piece/valve slide in the non-return valve are damaged. Examine and/or replace the spindle guide.909-11. • The vent hole in the thrust piece is blocked. both of the spindle guide and of the non-return valve. disassemble and examine the spindle guide.3. the cause is either: • Defective spindle guide at needle seat. Sealing test and sliding function To check the needle valve seat for tightness and the slide for correct closing. The pressure drops relatively slowly to about 15 bar.3. after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). See Procedure 909-12. are too large. See Procedure 909-12. Note! Oil flows out of the leak oil outlet when the fuel valve is full of oil. Slowly increase the oil pressure to about 50 bar below the opening pressure. 6. or a sticking spindle. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S . See Procedure 909-13.

Pressure test.1 Fuel Valve Checking 7. 10 bar until oil flows out of the leak oil outlet. and must be replaced. M909110241C07 Max. Increase the working pressure to about 100 bar. Max.909-11. O-ring sealing 7. the O-ring inside the fuel valve head is defective. Close the leak oil outlet with a gasket and plug screw. Max. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 5 (14) . 10 bar To ensure that the leak oil (circulation oil) remains in the closed system. build up a working pressure of about max. 100 bar When referring to this page. 100 bar Cause of fault: If oil leaks out at the union nut. Acceptance criteria: The built-up pressure of about 100 bar should be maintained.

Atomization test 8. The atomization test may damage the valve because it makes the needle oscillate. as this may damage the cut-off slide and nozzle. with a small lift at a very high frequency. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S .909-11.1 Fuel Valve Checking 8. The high pressure drop across the cut-off edge and the high contact pressure between slide and fuel nozzle. Page 6 (14) When referring to this page. All of these conditions involve the risk of seizure between the cut-off slide and the nozzle. in combination with the poor lubricity of the test oil. increase the risk of seizures between cut-off slide and nozzle. Note! M909110244C08 Do NOT attempt to carry out an atomization test on slide type fuel valves.

2. M909110241D03 D0943 When referring to this page. M909110240D02 If the valve is not to be overhauled immediately. If the valve is sticking. Dismantle and remove the fuel oil highpressure pipe. and drain the high-pressure pipe and the fuel valve. Remove the nuts and the spring housings. 3. Disconnect the return oil pipe from the fuel valve. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 7 (14) . 1. 2. the valve should be placed immersed in diesel oil until overhauling. M909110240D01 2. Close the fuel oil inlet and outlet valves. use the fuel valve dismantling tool to pull the fuel valve clear of the top cover.Fuel Valve 909-11. 3. See Procedure 909-14. Take out the valve.2 Dismantling 1.

909-11. 2. A 1. Make sure to remove all liquid or solid impurities. mount the fuel valve in the holder and fit the valve with the guide disc from the grinding tool. 3.3 Fuel Valve Overhaul When fuel valves are overhauled. Place the valve holder in a machine vice. Whenever fuel valves are overhauled. faultless sealing rings before reassembly. and write down the result for correct re-assembling of the valve. to avoid seizures in the union thread. Hold the fuel valve compressed and unscrew the union nut with a hook spanner. non-fluffy rags for wiping purposes. M909110244O01 Use only clean. Page 8 (14) When referring to this page. all sealing rings should be discarded and replaced by new. Measure the length A of the protruding part of the nozzle. M909110240O02 Remove the valve from the valve holder. 2. by means of a drilling machine. M909110240O03 3. Compress the fuel valve and the spring inside. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S . all parts should be handled carefully and be kept clean. 1.

M909110244O04 Remove and discard all the O-rings.3 Overhaul 4. 4. Pull the valve head clear of the valve housing. Remove the: • Non return valve • Thrust spindle parts • Thrust foot • Spindle guide and fuel nozzle from the valve housing. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 9 (14) .Fuel Valve 909-11. When referring to this page.

• Fuel valve housing • Fuel valve head D0942 • Thrust spindle If necessary. the milling tool is turned by hand. In the event of more serious damage to the seating surface for the high-pressure pipe in the valve head.3 Fuel Valve Overhaul 5. 500). the milling tool can be used. After the grinding. Note! M909110244O05 Take care not to exceed the maximum diameter of the seat. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S . Page 10 (14) When referring to this page. 100 r/min). This grinding must only be carried out manually. Carefully clean and examine all surfaces of the: 5. Normally. but it may be fitted in the chuck of a column-type drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. wash the parts in gas oil and blow clean by means of compressed air to remove any remains of the grinding compound. An ample supply of cutting emulsion must be used.909-11. see Data. grind the seating surfaces by means of the grinding mandrels supplied and a fine-grain abrasive (such as Carborundum No.

Mount the complete spindle guide. If this is not possible. the spindle guide may be overhauled on board.3 Fuel Valve Overhaul 6. The complete spindle guide. and turn the nozzle until the spindle guide engages correctly with the guide pin.909-11. This can be ascertained by attempting to turn the nozzle after mounting. 6. See Procedure 909-13. should be sent to an authorised MAN B&W repair shop for overhaul. in the fuel valve housing. Do not attempt to remove the fuel nozzle from the spindle guide unless the spindle guide has been dismantled. The non-return valve should be sent to an authorised MAN B&W repair shop for overhaul. 8. If this is not possible. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S A Page 11 (14) . It must not be possible to turn the nozzle. When referring to this page. M909110244O08 Make sure that the fuel nozzle and spindle guide engage correctly with the guide pin in the fuel valve housing. the non-return valve may be overhauled on board.3. including the fuel nozzle.3. including the fuel nozzle. Otherwise the cut-off slide on the spindle may be damaged. Check that distance A corresponds to the measurement taken before the valve was disassembled. See Procedure 909-12. M909110240O06 Carefully slide the spindle guide down into the valve holder. M909110244O06 Note! 7. Note! 8. 7.

Page 12 (14) MoS 2 When referring to this page. see Procedure 913-11. M909110244O09 10. For the correct use of this lubricant. Mount a new O-ring in the uppermost groove of the fuel valve housing.909-11.3 Fuel Valve Overhaul 9. • the thrust foot • the parts of the thrust spindle • the non-return valve in the fuel valve housing. M909110241O10 10. Make sure that the guide pin between valve housing and valve head is intact. Mount: 9. See that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S . Lubricate the thread of the valve head with molybdenum disulphide (MoS2). Fit the valve head with new O-rings. and press the valve head down into the valve housing.

cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. When referring to this page. 11. the fuel valve must be tested in the test rig. If the fuel valve is not to be mounted in the engine immediately after the overhaul.Fuel Valve 909-11. Place the valve in the valve holder in a drilling machine.3 Overhaul 11. After overhaul. Assemble the valve by means of the union nut. M909110240O10 12.1. Compress the fuel valve and the spring inside. See Procedure 909-11. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S Page 13 (14) . Keep the valve compressed and tighten the union nut with a hook spanner.

1. This must be done with great care. mount new O-rings on the fuel valve. adjusted. 1. as the spring tension in the housing determines the correct tightening of the fuel valve to the cylinder cover as well as the correct compression of the fuel valve. the distance between the fuel oil pipe ends and the thrust bushings must be checked and. O Mount the spring housings and the nuts. see Procedure 909-11. MoS 2 M909110244M01 2.909-11. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housing. See Procedure 909-14. (For reconditioning of the valve bores in the cylinder cover. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting. Page 14 (14) When referring to this page. As a minimum.3. See Procedure 909-14. 3. Mount the overhauled fuel oil high-pressure pipe and the return oil pipe. if any. 2. D0943 If not already done.4. It is recommended to overhaul the fuel oil high-pressure pipe before mounting. please quote Procedure M90911 Edition 0244 MAN B&W Diesel A/S . M909110244M02 Note! 3. Mount the valve in position in the cylinder cover. must be eliminated.4 Fuel Valve Mounting 1. if necessary. see Procedure 901-1. Note! M909110244M03 All fuel valves must be function-tested before being mounted in the cylinder cover. Lubricate the valve with molybdenum Disulphide (MoS2). thoroughly clean the valve bore in the cylinder cover and check the seating in the bore for marks which. Before mounting the fuel valve.3).

see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.109-12 Spindle Guide Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D10912 Edition 0047 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page.

Description P90966 Fuel Valve Nozzle . e. P90951 refers to chapter 909.Inspection Tools P90974 Fuel Valve Nozzle . Plate Item No.Cleaning Tools Page 2 (2) When referring to this page.Tools P90968 Fuel Valve . please quote Data D10912 Edition 0047 MAN B&W Diesel A/S .109-12 Spindle Guide 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.

the fuel nozzle can be dismantled from the spindle guide using two screwdrivers. Note! This instruction is only valid for spindle guides of the slide valve design. therefore only one guide is to be disassembled at a time. Note! The spindle guide. but may be delivered as an optional extra. Turn the nut to pull the fuel nozzle off the spindle guide. GW909-12. Place the spindle guide in a bench vice provided with “soft” jaws. please quote Procedure M90912 Edition 0222 MAN B&W Diesel A/S Page 1 (5) . 3. Mount the pulling tool around the fuel nozzle on the spindle guide.Spindle Guide 909-12. 2. Place the screwdrivers opposite each other in the small gap between the fuel nozzle and the spindle guide and very carefully force the fuel nozzle off the spindle guide.3 222 04 4. The individual parts of the spindle guide are not interchangeable. Based on service experience it is recommended to replace the complete spindle guide after 8000 hours of operation. If no pulling tool is available.3 222 02 1. GW909-12.3 Overhaul Spindle Guide S50ME-C 0222 Overhaul 909-12. Clean the outside of the spindle guide in pure gas oil or kerosene. When referring to this page. Extreme care and accuracy should be exercised when carrying out this operation. Note! The pulling tool is not standard for all engines. thrust piece and spindle are matched parts and may not be replaced individually. and use the brass mandrel as shown to disassemble the spindle guide. 4.3 2.

and the seat on spindle/guide. Page 2 (5) After polishing.909-12. GW909-12. Place all the parts on a clean. Use an inspection lamp and an 8-10 times enlargement magnifying glass. Use also a little oil for the polishing (a coarser polishing linen must absolutely not be used). the seat on slide valve/spindle.2 111 05 The sliding surface of the cut-off slide may only be polished VERY carefully. Note! MA909-6. and polishing with a very fine conventional polishing linen ‘grade 360’. clean the parts again and re-check the seat on thrust piece/spindle. thrust piece or spindle guide respectively in a lathe. Remove any deposits or very fine scratches by placing the spindle. 6. if there are pressing-in marks or similar on the seats. as shown. 5. lint-free cloth and examine them through an 8-10 times magnification magnifying glass and an inspection lamp. pay special attention to the seating surfaces and sliding surfaces of the parts. The sliding surface must not be damaged. the complete spindle guide must be discarded. During the examination. When referring to this page. Clean all the parts of the spindle guide in gas oil and wipe dry with a clean piece of cloth.3 222 05 6.3 Spindle Guide Overhaul 5. If the seats are not in order. please quote Procedure M90912 Edition 0222 MAN B&W Diesel A/S . Clean all parts again in kerosene or ‘Electrocleaner’ and wipe dry with a clean piece of cloth.e. i.

3 222 07 This also applies to nozzles with oval holes (can be ascertained with a magnifying glass). please quote Procedure M90912 Edition 0222 MAN B&W Diesel A/S Page 3 (5) . Note! During this operation be very careful not to push the drill too far to avoid scratching the snug-fit surface on the inside of the fuel nozzle. If the test pin is able to enter just one of the holes.3 Overhaul 7. Clean the fuel nozzle with kerosene and wipe dry with a clean cloth. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. GW909-12. the fuel nozzle must be discarded. 7. Note! It is recommended that the fuel nozzle is changed whenever the spindle guide is being overhauled. using gas oil and the special drills supplied. When referring to this page. the cut-off slide must be able to move freely inside the nozzle. Check the fuel nozzle before mounting on the spindle guide. Clean the spray holes. Then test the spray holes with the test pin.Spindle Guide 909-12.

with a ‘clicking’ sound. The spindle with the cut-off slide must be able to slide freely back and forth inside the spindle guide. MN909-12. see Procedure 913-11. GW909-12. Lubricate the spindle and the thrust piece with the cut-off slide with a little Molybdenum Disulphide (MoS 2). 8.909-12. the spindle and the spindle guide and carefully knock the parts together using a soft hammer. 9. Shake the spindle guide back and forth. Assemble the thrust piece. Page 4 (5) When referring to this page.3 Spindle Guide Overhaul 9.3 222 10 10.3 215 09 10. please quote Procedure M90912 Edition 0222 MAN B&W Diesel A/S .

Press the nozzle on to the spindle guide. the nozzle can be mounted on the spindle guide using a short piece of pipe. If the spindle guide is not to be mounted in a fuel valve immediately after the overhaul. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS 2). so that the lower end of the pipe rests on the ‘foot’ of the fuel nozzle. Then press the parts together the same way as when using the mounting tools. please quote Procedure M90912 Edition 0222 MAN B&W Diesel A/S Page 5 (5) . Note! If no mounting tools are available. See Procedure 913-11. Mount the nozzle on the spindle guide.3 222 11 The mounting tools are not standard for all engines but may be delivered as optional extras. by ‘shaking’ the spindle guide. 12.3 Overhaul 11.Spindle Guide 909-12. Make sure that all the parts are perfectly aligned. 11. cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle guide during storage. Check that the spindle inside the spindle guide is able to move freely. Place the parts on the plane of a drilling machine or hydraulic press and position the mounting tool over the parts. When referring to this page. Place the pipe around the nozzle. GW909-12.

.

109-13 Non-return Valve for Fuel Valve Data SAFETY PRECAUTIONS For detailed sketch. Description When referring to this page. see 900-2 Stopped engine Shut off star ting air supply – At star ting air receiver Block the main star ting valve Shut off star ting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. please quote Data D10913 Edition 0033 MAN B&W Diesel A/S Value Unit Page 1 (2) .

please quote Data D10913 Edition 0033 MAN B&W Diesel A/S .Inspection Tools When referring to this page. Description 153 Flange for dismantling of non return valve Fuel Valve . e. Plate P90951 P90968 Page 2 (2) Item No.g.109-13 Non-return Valve for Fuel 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. P90951 refers to chapter 909.

2. kerosene or ‘Electrocleaner'. and disassemble the non-return valve. 2. and blow the parts dry with compressed air as shown in Fig. clean in either gas oil. Finally. Note! Except for the slide valve spring. Place the non-return valve as shown in Fig. Clean all the parts for the spindle guide in gas oil and then blow clean. using the disassembling tool and a hammer as shown.3 Overhaul Note! 1. When referring to this page. Clean the outside of the non-return valve with pure gas oil.Non-return Valve for Fuel Valve 909-13. M909130207O02 2. lint-free rags and examine with an 8-10 times enlargement magnifying glass. defective parts cannot be replaced individually by new ones. 3. M909130207O03 3. and an inspection lamp with magnifying glass as shown in Fig. 1 in a bench vice provided with “soft” jaws. Now place the parts on clean. please quote Procedure M90913 Edition 0207 MAN B&W Diesel A/S Page 1 (2) . 3. therefore only one guide is to be disassembled at a time. M909130207O01 1. The individual parts are not interchangeable. Extreme care and accuracy should be exercised when carrying out this operation.

(The letters A-D refer to the letters/parts in Fig. and the seat on vent slide/housing. 4 and remove the coating by means of very fine conventional polishing linen ‘grade 360'. When referring to this page. 5.e. Fix vent slide B and. M909130207O05 6. If the seats are not in order.3 Non-return Valve for Fuel Valve Overhaul 4. Page 2 (2) 7. housing A in a lathe as shown in Fig. Examine the slide faces of movable parts for coating. the complete spindle guide must be discarded. • Make sure that the thrust piece and the other parts are perfectly aligned and that the thrust piece is guided in the vent slide. 5. 6. Use an inspection lamp and an 8-10 times enlargement magnifying glass. • Place the loosely-assembled non-return valve on the plane of a drilling machine. i. M909130207O04 Also a little oil should be used (a coarser polishing linen must absolutely not be used). If defective. please quote Procedure M90913 Edition 0207 MAN B&W Diesel A/S . 2). if there are pressing-in marks or similar on the seats. 6. Mount the non-return valve as follows: • Lubricate all movable parts with molybdenum disulphide (MoS2). Check the seat on thrust piece D/vent slide. with the tool positioned as shown in Fig. it should be exchanged. 4. M909130207O06 • Press the handle until the housing and thrust piece meet.909-13. If the non-return valve is not to be mounted in a fuel valve immediately after the overhaul. subsequently. Check spring C for the thrust piece for outside wear marks. cover all openings of the nonreturn valve with plastic to prevent dirt from entering the valve during storage. Vent slide B/housing A will be too tight if there is a coating.

please quote D10914 Edition 0074 MAN B&W Diesel A/S Value Unit 100 Nm 11 mm 8 kg Page 1 (2) . Description D09-47 Fuel oil high-pressure pipe. tightening torque D09-51 Distance from pipe end to thrust bushing lower edge D09-52 Fuel oil pipe When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water X Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.109-14 Fuel Oil High-Pressure Pipe Data SAFETY PRECAUTIONS For detailed sketch.

P90951 refers to chapter 909. Plate Item No.109-14 Fuel Oil High-Pressure Pipe 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 D10914 Edition 0074 MAN B&W Diesel A/S . e.g. Description P90951 104 Milling tool for fuel oil pipe P90951 128 Crowfoot spanner P90951 141 Crowfoot spanner P90951 319 Hook wrench for hose pipe Page 2 (2) When referring to this page.

HN909-14. unscrew the union nut at the fuel pump end of the high-pressure pipe. Unscrew the union nipple from the fuel pump. Pull the union nut and the protective hose clear of the union nipple. 2. Using a hook spanner. 4.2 Dismantling Fuel Oil High-Pressure Pipe S60MC-C 0234 Dismantling 909-14.Fuel Oil High-Pressure Pipe 909-14. HN909-14. Close the fuel oil inlet and outlet valves. 4. unscrew the union nut at the fuel valve end of the high-pressure pipe. HN909-14. It is recommended always to overhaul the high-pressure pipe before remounting it on the engine. and remove the high-pressure pipe from the engine.2 209 04 D09-52 When referring to this page.2 209 03 Note! The overhaul should preferably take place immediately after the high-pressure pipe has been dismantled. High-Pressure Pipe with Protective Hose 1. 3. Lift the pipe ends clear of the fuel valve/fuel pump. Unscrew the union nipple from the fuel valve.2 2. please quote Procedure M90914 Edition 0234 0$1% :'LHVHO$6 Page 1 (4) .3. 3. Using a hook spanner. See Procedure 909-14.2 209 02 Pull the union nut and the protective hose clear of the union nipple.

HM909-7. before remounting the high-pressure pipes.3 Overhaul Overhaul 909-14. If the distance is incorrect. when the thrust bushings at both ends of the pipe have been dismounted. Whenever the fuel oil high-pressure system has been dismantled.3 1. If any of the pipe ends requires reconditioning. the position of the thrust bushing on the pipe end must be checked. compared with the measurement stated in Data. • Lift up the union nut with flexible protective hose. MC909-7. dismantle the high-pressure pipe as follows: D09-51 2.0 67 02 3.0 67 04 3. pull the flexible protective hose with union nuts off the high-pressure pipe. to carefully inspect the tapered contact surfaces of the pipe ends. Furthermore.Fuel Oil High-Pressure Pipe 909-14. • Remove the coupling nut and. D09-51 1. MC909-7. it is necessary. it should be adjusted by screwing the thrust bushing up or down the pressure pipe. Shape-up the threads on the pipe ends with the nut die.0 59 01 2. please quote Procedure M90914 Edition 0234 0$1% :'LHVHO$6 . on the high-pressure pipe and screw off the thrust bushing. together with the coupling nut. together with their seats in fuel valves and fuel pump top cover. Page 2 (4) When referring to this page.

3 Overhaul 4. add drilling oil emulsion liberally. 5. see Procedure 909-11.3. Mount the guide on the pipe end. For reconditioning of seat in fuel pump top cover. HM909-7. For reconditioning of seat in fuel valve. and a condition for obtaining tight joints. screw the thrust bushings so high up on the thread of the pressure pipe that the distance between the pipe end and the bottom edge of the thrust bushing is as stated in Data. for instance.0 62 06 D09-51 When referring to this page. that the pipes fit the seats accurately. 6.0 67 03 After completing the milling. place the miller in the guide and lightly screw on the union nut. It is of great importance for the mounting. When assembling the high-pressure pipe. carefully clean the high-pressure pipe with diesel oil and wipe dry with a clean piece of cloth. Turn the miller with. see Procedure 909-5.3. Replace the O-rings. 6. During the milling. GN909-14. and lubricate the threads of the union nuts with molybdenum disulphide (MoS 2). please quote Procedure M90914 Edition 0234 0$1% :'LHVHO$6 Page 3 (4) . 5.Fuel Oil High-Pressure Pipe 909-14. 4. check the centre distances between pipe ends and seats. MC909-7. a tap wrench while lightly tightening the union nut to provide a suitable pressure between miller and pipe end.3 204 05 Before mounting a high-pressure pipe.

Use a crowfoot wrench and a torque wrench to tighten the union nipple at the fuel valve to the torque stated in Data.4 209 05 The nipples must be screwed by hand. If dismantled. D09-47 When referring to this page. Screw the union nut onto the union nipple by hand. 4. See Procedure 909-14. please quote Procedure M90914 Edition 0234 0$1% :'LHVHO$6 . Lubricate the thread of the fuel valve with a heat resistant grease. and tighten lightly with a hook spanner. re-mount the return oil pipe on the fuel valve.Fuel Oil High-Pressure Pipe 909-14. Open the fuel oil inlet and outlet valves. Check that the distance between the thrust bushing and the pipe end is correct at both ends of the pipe. by hand. 1. Ensure that the union nipple at the fuel pump end of the high-pressure pipe is fitted with a new O-ring. Page 4 (4) 7. Ensure that the fuel valve is fitted with a new O-ring. fuel valve or fuel pump top cover might otherwise be damaged. D09-47 5.3. Screw the union nipples onto the fuel valve and into the fuel pump top cover. Use a crowfoot wrench and a torque wrench to tighten the union nipple at the fuel pump to the torque stated in Data. HN909-14. as the threads of the union nipples. D09-52 HN909-14.4 209 04 3. Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position. 5.4 4. Note! HN909-14.4 209 06 Screw the union nut onto the union nipple by hand. Lubricate the thread on the union nipple with a heat resistant grease. 6. 2. Mount the high-pressure pipe between the fuel valve and the fuel pump. 6.4 Mounting Mounting 909-14. and tighten lightly with a hook spanner.

see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water X Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value Unit D09-53 Nut.109-15 Fuel Pump Roller Guide Data SAFETY PRECAUTIONS For detailed sketch. reversing shaft. tightening torque 80 Nm D09-57 Roller/bushing/shaft pin.5 mm D09-61 Fuel pump roller guide 60 kg D09-62 Pump base 68 kg When referring to this page. max. please quote Data D10915 Edition 0058 MAN B&W Diesel A/S Page 1 (2) . clearance 0.

please quote Data D10915 Edition 0058 MAN B&W Diesel A/S . e.g. Plate P90851 Page 2 (2) Item No. P90951 refers to chapter 909.109-15 Fuel Pump Roller Guide 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. 173 Description Lifting tool for exhaust valve roller guide When referring to this page.

Also inspect the surface of the roller for possible damage marks. Remove the cover on the camshaft housing to inspect the fuel pump roller guide. M909150234C01 Turn the roller by hand to check that it can move freely and without unnecessary resistance or “hard” points. See Procedure 909-10. M909150234C02 4. 5. Lift the fuel pump roller guide. Turn the engine to provide the maximum space between the roller guide and the cam disc. The fuel pump roller guide can be partially checked while mounted on the engine. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S Page 1 (10) . 1. using the following procedure: 2. Lower the roller guide onto the fuel cam again. Make sure that there are no traces of bearing metal left in the roller guide housing.Fuel Pump Roller Guide 909-15. See Procedure 909-10. seizures or scratches.1 Checking Roller guide mounted in engine 3. When referring to this page. 3.

Turn the roller guide upside down and land it in a vertical position on a couple of planks. and measure any ovalness. M909150234C03 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.1 Fuel Pump Roller Guide Checking Roller guide removed from engine 7. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S . See Procedure 909-15. 7. Page 2 (10) When referring to this page.2. A more suitable and reliable method is to check the roller guide and the bearing clearance after the roller guide has been dismounted: 6. 8. with the roller hanging freely. Check the surface of the roller and the sliding surfaces of the roller guide. D0957 M909150234C04 8.909-15. Dismount the roller guide from the engine.

Dismantle the fuel pump barrel assembly. See Procedure 909-6. 1.2. Dismantle the top cover of the fuel pump. make sure that the pump has been relieved of pressure and that all oil has been drained off. M909150234D02 2.2. When referring to this page. See Procedure 909-5. Before dismantling any part of the fuel pump. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S Page 3 (10) .2 Dismantling Note! 1. M909150234D01 2.Fuel Pump Roller Guide 909-15.

see Procedure 909-4. Note! When lifting the fuel pump housing. Dismantle the lubricating oil pipe and the drain pipe from the pump base. Turn the engine until the roller guide is at BDC. take care not to damage the threads on the studs. Dismantle the fuel pump housing. 3. Remove the sealing cap from the roller guide/pump base.2. Remove the cover on the camshaft housing to inspect the position of the roller guide. M909150234D03 4. Page 4 (10) When referring to this page. M909150234C02 5.909-15. Loosen and remove the screws from the sealing cap on top of the roller guide inside the pump base. 5. M909150234D04 4.2 Fuel Pump Roller Guide Dismantling 3. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S .

• Lower the lock plate. When referring to this page. take care that the bushing of the pump base slides against the neck of the roller guide without scratching. M909150234D06 • Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide. Lift the roller guide out of the roller guide housing. 7. 6.2 Fuel Pump Roller Guide Dismantling 6. take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing. D0962 Remove the nuts. 7. Land the roller guide on wooden planks. using the crane. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S Page 5 (10) . Check the roller guide. M909150234D06 8. D0961 When lifting. Remove the springs from the roller guide.909-15. thereby securing the foot in the locked position. • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint.1. Loosen the nuts on the two threaded studs successively until the roller guide springs are relieved. When lifting. Mount the roller guide lifting tool as follows: • Lift the lock plate of the tool up on the shaft of the tool. mount two eye bolts in the pump base and lift it away. See Procedure 909-15.

1. If no irregularities are found. M909150234O01 Note! For disassembling of the roller guide. 2. M909150234O02 2. just clean and lubricate the roller guide before remounting it in the roller guide bushing. 1. See Procedure 909-15. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S . It is recommended that the roller guide should ONLY be dismantled if D0961 • irregularities when turning the roller. • seizure marks on the slide surfaces. 3. • larger clearance than stated on the Data sheet. Page 6 (10) When referring to this page.3 Fuel Pump Roller Guide Overhaul 1. • damage to the roller. contact an MAN B&W authorized repair shop.909-15. Inspect and check the fuel pump roller guide. have been observed when checking the roller guide.

Lubricate the roller guide with plenty of camshaft lubricating oil.Fuel Pump Roller Guide 909-15.2 mm. 1. After mounting the roller guide with the reversing link. 2. Neither A nor B must be less than 0. Make sure that the pin of the reversing link fits in the bracket of the reversing shaft. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S Page 7 (10) . The clearances A and B must be approx. 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. and check that the reversing mechanism is working smoothly. take care not to scratch the sliding surfaces of the roller guide. check the clearance between the roller guide and the guide plate mounted in the roller guide bushing. M909150234M01 The clearance C between the roller guide and the guide plate must be the same at both ends +/– 0.1 mm. 20 mm. During mounting.4 Mounting 1. the same in both positions. and mount it in the roller guide bushing. C A C M909150234M02 B When referring to this page. Turn the camshaft so that the roller guide is lifted approx. Connect working air to the air cylinder. 2. using the lifting tool.

Loosen the nut on the reversing shaft and carry out the adjustment. After adjustment. Remove the cover over the shaft connection. shift again to ASTERN Tighten the nut on the reversing shaft to the torque stated in Data. M909150234M03 4. Page 8 (10) When referring to this page. and lock the nut with Loctite type: Screw Lock No. Mount the pump base over the roller guide and the springs. D0953 Mount the cover over the shaft connection. 5. special nuts on the M909150234D06 Using the special tube-shaped socket wrench. tighten the nuts until the pump base is fastened tightly to the roller guide bushing. it must take place in the ASTERN position.909-15. Finally. If adjustment is necessary. Turn the engine until the roller guide is at BDC. Mount the springs and the spring seat discs over the roller guide.4 Fuel Pump Roller Guide Mounting 3. 3. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S . D0962 Mount the two threaded studs. 243. shift to AHEAD position and check the clearances A and B once more. 5.

1. Replace the axial scraper ring in the bottom of the cap. 7. When referring to this page.Fuel Pump Roller Guide 909-15. Check the movement of the reversing link. remove the retaining flange and ring holder with scraper ring. M909150234C02 Loosen and remove the screws and nuts from the bottom of the cap. See Procedure 909-15. Replace the scraper rings in the sealing cap as follows: 8. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S Page 9 (10) .4 Mounting 6. Check that the O-ring and scraper ring are mounted correctly. M909150234M07 7. See the sketch. 6. M909150234M08 8.

and be careful not to cut the scraper ring on the edge of the ring groove when pressing it in. Mount the sealing cap on top of the roller guide.4. Tighten the nuts on the screws. 11. See Procedure 909-5. 0 M909150234M09 2 Before mounting. Remove the scraper ring and O-ring from the ring holder. Water/Oil 100°C/5 min. Mount the drain pipe on the pump base. M909150234M11 Mount the top cover. After tightening. 12. See Procedure 909-4. over the sealing bush inside the pump base. Check that the O-ring and scraper ring are mounted correctly. Tighten the screws and lock with locking wire. the new scraper ring must be heated in 100°C hot water or oil for at least five minutes. Page 10 (10) When referring to this page. Mount the fuel pump housing.4. 1 Place the new O-ring in the ring holder. See the sketch. 10. Mount a new O-ring in the groove on top of the roller guide.4. 10. Assemble the sealing cap. check that the holder can be moved. See Procedure 909-6. Mount the barrel assembly. fold the ring without making any sharp edges. 9.4 Fuel Pump Roller Guide Mounting 9. Note! When mounting the scraper ring in the groove. please quote Procedure M90915 Edition 0234 MAN B&W Diesel A/S . M909150234M10 11.909-15. the ring holder and retaining flange.

please qoute Plate P90951 Edition 0441 Plate P90951-0441 Page 1 (2) .Fuel valve and Fuel Pump Panel MAN B&W When referring to this page.

inside Screw for topcover Tool for P.Plate P90951-0441 Fuel valve and Fuel Pump Panel MAN B&W Item No.max rack Pin spanner Hook spanner Drift for spindle guide Drift for non return valve Assembly tool for fuel valve Extractor tool for roller guide Hook spanner Crowfoot spanner 069 070 094 104 116 128 130 141 153 165 177 189 190 200 224 236 248 250 273 297 307 319 356 Page 2 (2) When referring to this page. please qoute Plate P90951 Edition 0441 .outside Grinding mandrel for holder . Item Description 010 021 045 057 Panel for tools Name plate Measuring tool for fuel pump Lifting tool for fuel pump plunger barrel Lifting tool for fuel pump Lifting tool for fuel pump housing Milling tool for fuel oil pipe seats Milling tool for fuel oil pipe Crowfoot spanner Crowfoot spanner Crowfoot spanner Crowfoot spanner Flange for dismantling of non return valve Grinding mandrel for valve head Grinding mandrel for thrust spindle Grinding mandrel for holder .

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

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

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

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

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

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

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

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

please qoute Plate P90977 Edition 0001 Plate P90977-0001 Page 1 (2) .Mounting Tools .Fuel Pump Seals MAN B&W When referring to this page.

please qoute Plate P90977 Edition 0001 .Fuel Pump Seals Plate P90977-0001 Item No.Mounting Tools . 011 023 035 047 059 060 072 Page 2 (2) MAN B&W Item Description Cone Pushing tool Compression tool Cone Pushing tool Compression tool Spacer ring When referring to this page.

Suction Valve Seals MAN B&W When referring to this page.Mounting Tools . please quote Plate P90979 Edition 0001 Plate P90979-0001 Page 1 (2) .

Plate P90979-0001 Item No. please quote Plate P90979 Edition 0001 . Item Description Cone Pushing tool Compression tool When referring to this page.Suction Valve Sealsl MAN B&W Item Description Item No. 012 024 036 Page 2 (2) Mounting Tools .

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

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

Data Non Return Valve after Air Cooler Auxilary Blower. Data Water Mist Catcher Turbocharger System .Tools .910 . Data Air Cooler Element Non-Return Valve after Air Cooler. Data Auxilary Blower Butterfly Valve.Tools Travelling Trolley Exhaust Receiver .Turbocharger System Documents in this Chapter 110-01 910-01 110-02 910-02 110-03 910-03 110-04 910-04 110-06 910-06 91061 91064 91065 0047 0236 0009 0214 0024 0220 0005 0206 0031 0219 0067 0002 0001 MAN Diesel A/S Air Cooler Element. Data Butterfly Valves Water Mist Catcher.

MAN Diesel A/S .

see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps X Engage turning gear X Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. up to 3100 kg Front end cover (waterflow reversing chamber) 350 kg When referring to this page.110-1 Air Cooler Element Data SAFETY PRECAUTIONS For detailed sketch. complete with covers. please quote Data D11001 Edition 0047 MAN B&W Diesel A/S Page 1 (2) . Description D10-02 Aft end cover D10-04 D10-05 Value Unit 350 kg Air cooler element.

P90951 refers to chapter 909. please quote Data D11001 Edition 0047 MAN B&W Diesel A/S .110-1 Air Cooler Element 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.Lifting Tools P91356 Lifting Tools.Tools P91064 Travelling Trolley P91066 Air Cooler . Page 2 (2) When referring to this page. e.g. Plate Item No. Etc. Description P91063 Air Cooler .

Visually inspect the air cooler element through the opening. it is recommended to inspect the air cooler element as follows: 4. When referring to this page. 1. For further evaluation of the measurements. If the air side of the element is fouled. Compare these measurements with the testbed data. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler. If the measurements indicate fouling of the air side of the air cooler element. Chapter 706.1 Checking Air Cooler Element S60MC 0236 Checking 910-1.1 1.Air Cooler Element 910-1.3. See Procedure 910-1. Remove the inspection cover from the air cooler. See Procedure 910-3.1 221 01 2. For the day-to-day checking of the scavenge air cooler. 4. See Procedure 910-2. please quote Procedure 910-1. the element must be dismantled and overhauled/ cleaned. If the measurements indicate fouling of the water side of the air cooler element. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. clean the element using the spray pipe arrangement fitted above the air cooler element. GM910-1. GM910-1. 3.1 Edition 0236 MAN B&W Diesel A/S Page 1 (7) . measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running.1 221 04 5. see instruction book Volume I.

Remove and discard the gaskets.2 Edition 0236 MAN B&W Diesel A/S . 1. 2. 2. Dismantling the inlet/outlet end cover: GM910-1. 3. Dismount the cooling water inlet and outlet pipes from the end cover. Then lower the end cover. Suspend a tackle from the lifting bracket on the cooler housing. please quote Procedure 910-1. Fasten the chain hook in the shackle. and lower it in the same way. Close the cooling water inlet and outlet valves.2 Air Cooler Element Dismantling Dismantling 910-1. D10-06 D10-07 GM910-1. Remove the screws from the end cover and lower the cover.2 221 03 3. Mount another shackle at the top of the waterflow reversing chamber.2 221 02 Attach an eye bolt to the top of the inlet/outlet end cover. Fasten a tackle to the lifting bracket on the cooler housing. Attach the chain hook to the shackle and remove the screws from the end cover and from the inlet and outlet valves.910-1. Open the drain cocks to drain off the cooling water. after removing the screws. Page 2 (7) When referring to this page.2 1.2 221 01 Mount a screw shackle at the top of the outer end cover of the cooler housing. Dismantling the waterflow reversing chamber: GM910-1.

2 221 06 During the lift. please quote Procedure 910-1. Lift the air cooler element away. take care not to damage the air cooler element. GM910-1. When referring to this page. checking during this procedure that the aftmost pair of wheels is being centered between the two guide rails. Mount the pair of wheels for the aftmost tube plate. 4.2 221 05 7.2 Dismantling 4.2 221 04 Press the cooler element free. Pull the cooler element halfway out of the cooler housing. 8. 6. and tighten the thrust screws to make the wheels support the cooler element. 5. and tighten the thrust screws to make the wheels support the cooler element. D10-04 GM910-1. Mount two rails. Mount the pair of wheels for the foremost tube plate. Note! 6. When the cooler element has been pulled halfway out.2 221 08 8. mount the support on which the foremost pair of wheels can run.Air Cooler Element 910-1. Pull out the cooler element until it is clear of the cooler housing. on the gallery. using dismantling screws. each with a guide rail on top. GM910-1. GM910-1.2 Edition 0236 MAN B&W Diesel A/S Page 3 (7) . 5.

The time required depends on the frequency with which cleaning is carried out and on the chemical product used. See Procedure 910-1. Continue the cleaning process for at least 30 minutes. or a similar product. DG910-5. produced by Drew Chemical Corp. Remove the covers on the scavenge air receiver to let vapours escape. It is recommended to use one of the following cleaning fluids. • Product: ACC 9.3 1. Page 4 (7) When referring to this page.. After cleaning. To ensure satisfactory spraying of the cleaning fluid.1.3 Air Cooler Element Overhaul Overhaul 910-1. 6. 5. please quote Procedure 910-1.7 bar. 2. USA GM910-1. Maassluis. Cleaning the air side: 1..3 221 01 • Product: 80B. Holland 3. 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. 3. Do not disconnect the compressed air supply to the exhaust valve. flush the cooler with clean water until the water in the sight glasses appears clean and pure. the circulating pump pressure must be at least 0.3 Edition 0236 MAN B&W Diesel A/S . New York.910-1.1 62 01 4. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine. Do not start cleaning until the engine has been at a standstill for about 30 minutes. produced by Vecom Int. Inspect the air cooler element by removing the cover of the scavenge air cooler housing.

When cleaning is complete.2 49 06 Note! When referring to this page. If necessary. 10. If damaged. BM910-5.Air Cooler Element 910-1. Cleaning the water side 7.4. 9. Clean and check the inside of both end covers. Clean the inside of the tubes. mount new gaskets or packing paste and re-mount both end covers of the air cooler element.2.3 Overhaul 8. See Procedure 910-1. Dismantle the inlet/outlet end cover of the air cooler element.3 207 04 12. using the cleaning brush (supplied by the cooler element manufacturer) mounted on a drilling machine.3 Edition 0236 MAN B&W Diesel A/S Page 5 (7) . 8. 10.2. See Procedure 910-1.2. the coating inside the covers is to be repaired with the original coating or a similar product. See Procedure 910-1. replace the corrosion blocks. Dismantle the waterflow reversing end cover of the air cooler element. In the event of leakages between cooling tubes and tube plate.3 215 02 9. BG910-1. It is not necessary to remove the air cooler element from the engine to clean the waterside. please quote Procedure 910-1. GN910-1. See Procedure 910-1. 11. the tubes are rolled with the tube expander (also supplied by the cooler element manufacturer).

4 221 06 3.2 221 06 4. Clean the frame around the air cooler element and the contact surface of the cooler housing. please quote Procedure 910-1.4 Edition 0236 MAN B&W Diesel A/S . Page 6 (7) When referring to this page. Push the air cooler element inwards approx. Push the air cooler element fully into the air cooler housing. 3. Lift the air cooler element and land the aft end of the element on the guide rails mounted on the air cooler housing.4 1. GM910-1. Remove the front and aft end wheels and the guide rails. one metre. Mount a new gasket to seal between cooler element and air cooler housing.910-1. Apply a thin layer of silicone paste to the frame around the air cooler element and the contact surface of the cooler housing. 2.2 221 08 Remove the support from the foremost pair of wheels. GM910-1.4 Air Cooler Element Mounting Mounting 910-1. 1. 2. GM910-1.

4 Edition 0236 MAN B&W Diesel A/S Page 7 (7) .2 221 03 Mount and tighten all the screws of the inlet/outlet cover and the reversing chamber.2 221 02 7.Air Cooler Element 910-1. Remove the tackles and shackles.4 Mounting 5. D10-06 D10-07 Mount the waterflow reversing chamber with a new gasket to which a thin layer of silicone paste has been applied. please quote Procedure 910-1.4 221 07 7. Mount the inspection cover on the cooler housing. Mount the outer end cover on the reversing chamber end with a new gasket to which a thin layer of silicone paste has been applied. Mount and tighten all the screws of the end cover. 6. When referring to this page. 6. Mount the inlet/outlet end cover with a new gasket to which a thin layer of silicone paste has been applied. 5. GM910-1. GM910-1. GM910-1. Note! Remember to vent trapped air from the air cooler element. Mount the cooling water inlet and outlet pipes on the end cover. Close the drain cocks and open the cooling water inlet and outlet valves.

.

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

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

3 Overhaul 0214 Non-Return Valve S80MC Overhaul 910-2. again secure the axle of the valve flap by means of the spring pin.3 Access to the non-return valves in the scavenge air receiver takes place – after the engine has been stopped – through the inspection openings of the receiver. Now the valve flap is free and can be replaced. Replacement of non-return valve assembly: Remove the two outermost screws and the middle screw (which fasten the valve assembly to the housing). remove the two screws which hold the parts together as an assembly. HG910-2.3 212 01 When mounting.Non-Return Valve 910-2. When referring to this page. For further dismantling. please quote Procedure M91002 Edition 0214 MAN B&W Diesel A/S Page 1 (1) . Lift the complete valve assembly out and mount a new assembly instead. Overhaul of non-return valve assembly: Knock out the spring pin which secures the axle of the valve flap and press out the axle. Warning! Access to the scavenge air receiver must not take place until the air in the receiver is clean.

.

D10-09 Description Weight of blower unit. complete * up to Value Unit 700 kg 350 kg *) Depending on electric motor type and number of cylinders of engine (size and capacity of auxiliary blower) D10-12 Electric motor. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps X Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply X Lock the turbocharger rotors Data Ref.110-3 Auxiliary Blower Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11003 Edition 0024 MAN B&W Diesel A/S Page 1 (2) . impeller and motorplate When referring to this page.

When referring to this page.110-3 Auxiliary Blower 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. Etc.g. e. Plate P91356 Page 2 (2) Item No. Description Lifting Tools. please quote Data D11003 Edition 0024 MAN B&W Diesel A/S .

M910030220O01 Attach a wire rope with shackle to the lifting mounting on the blower flange. The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. take out the electric motor and the blower wheel as one whole assembly.910-3. the parts are to be “guided” into place with care. Inspect and clean the blower wheel as well as the blower housing. please quote Procedure M91003 Edition 0220 MAN B&W Diesel A/S Page 1 (1) . making sure that the pipe in the receiver “catches” the guide bosses (A) of the blower housing flange. A B M910030220O03 Attach two wire ropes with shackles to the lifting mountings on the end cover. 3. using the tackle. While pulling out the end cover with the blower assembly. When mounting the end cover with the complete blower. D1012 1. D1009 Caution! Make sure that the air in the receiver is clean before making the access.3 Auxiliary Blower Overhaul When cleaning and inspecting the auxiliary blower. When referring to this page. and pull the electric motor with flange and blower wheel out of the end cover. 4. M910030220O02 Suspend two tackles from the mountings on the gallery bracket above the end cover. 2. 4. make sure that the blower housing disengages from the air pipe without deforming it. Disengage the cable connections to the blower motor. 1. If the whole blower assembly is to be dismounted. Remove the screws in the blower wheel flange. the inspection covers on the scavenge air receiver are first to be removed. and hook on the tackles. and hook-on the tackle suspended from mountings on the gallery bracket. Remove all screws holding the end cover. 3. The gasket (B) constitutes the sealing between blower housing and pipe.

.

110-4 Butterfly Valves Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11004 Edition 0005 MAN B&W Diesel A/S Value Unit Page 1 (2) . Description When referring to this page. see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME-engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.

Plate Page 2 (2) Item No.110-4 Butterfly Valves 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 D11004 Edition 0005 MAN B&W Diesel A/S .g. P90951 refers to chapter 909. e. Description When referring to this page.

The movability of the valve flaps should therefore be checked at suitable intervals.0 15 02 4. When referring to this page. remove the cover on the top of the butterfly valve. It is important that the automatic non-return valves (butterfly valves) are always able to function easily and unimpeded. 2. please quote Procedure 910-4. Access to the butterfly valves is made through the manhole covers of the receiver after the engine has stopped running and it has been ascertained that the air in the receiver is pure.1 Butterfly Valves Checking Butterfly Valves S50MC 206 Checking 910-4.910-4. The valves shall open for the air flow from the valve housing to the auxiliary blowers.0 11 01 Reach down through the opening in the top of the valve and move the valve flaps.1 1. 3. 1. it must be dismantled and overhauled. d ir e c tion HM910-9.1 Edition 206 MAN B&W Diesel A/S Page 1 (1) . To check the valve. If the valve flaps in one of the butterfly valves cannot be moved by a light touch of a fingertip. Flow 2. XZ910-9. Re-mount the cover on the top of the butterfly valve.

.

see 900-2 X Stopped engine X Shut off starting air supply – At starting air receiver X Block the main starting valve X Shut off starting air distributor/distributing system supply X Shut off safety air supply – Not ME engines X Shut off control air supply X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear X Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref.110-6 Water Mist Catcher Data SAFETY PRECAUTIONS For detailed sketch. D-10-11 Description Water mist catcher When referring to this page. please quote Data D11006 Edition 0031 MAN B&W Diesel A/S Value Unit 119 kg Page 1 (2) .

e.g. Plate P91356 Page 2 (2) Item No. P90951 refers to chapter 909.110-6 Water Mist Catcher 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 D11006 Edition 0031 MAN B&W Diesel A/S . Description Lifting tools When referring to this page.

Land it on a couple of wooden planks.2 2. Loosen the screws at both ends of the water mist catcher. please quote Procedure M91006 Edition 0219 0$1% :'LHVHO$6 Page 1 (2) . Take care not to damage the water mist catcher during the lift. the water mist catcher has been fouled or damaged. 2. GM910-6. During mounting. 4.2 213 02 3. D10-11 Hook a tackle on to the eye bolt and lift the water mist catcher away.Water Mist Catcher 910-6. the water mist catcher must be re-mounted in the same position. however. Dismantle the rectangular covers from both the front and aft ends of the scavenge air cooler housing.2 213 04 Note! 5. 1. 4. When referring to this page. Normally it is not necessary to remove the water mist catcher from the scavenge air cooler housing. If. Note! Note the position of the water mist catcher. GM910-6. Pull or push the water mist catcher halfway out and mount an eye bolt in the top of the water mist catcher. Clean the water mist catcher with the same cleaning fluid as used for the scavenge air cooler element. it must be dismantled for cleaning or repair.2 Dismantling Water Mist Catcher S46MC 0219 Dismantling 910-6.

Water Mist Catcher 910-6. Slide the water mist catcher into the scavenge air cooler housing. 3. Page 2 (2) When referring to this page. Tighten the screws at both ends of the water mist catcher. 1. remove the tackle and the eye bolt. Apply a thin layer of silicone paste to the frame of the water mist catcher on the side which will face away from the engine when the water mist catcher is mounted (the side opposite to the screws).4 213 02 D10-11 GM910-6. and push the water mist catcher fully into the scavenge air cooler housing. Apply a thin layer of silicone paste on the frame and mount the rectangular covers on the front and aft ends of the scavenge air cooler housing. Toward Engine 2. please quote Procedure M91006 Edition 0219 0$1% :'LHVHO$6 . Make sure to mount the water mist catcher correctly.4 213 03 3. GM910-6.4 1.4 Mounting Mounting 910-6.4 213 01 Note! 6LOLFRQH 2. When the water mist catcher is half-way in. The screws of the water mist catcher must face the exhaust side of the engine. GM910-6.

Tools MAN B&W When referring to this page. please qoute Plate P91061 Edition 0067 Plate P91061-0067 Page 1 (2) .Turbocharger System .

014 026 Page 2 (2) MAN B&W Item Description Lifting eye bolt Turnbuckle When referring to this page.Tools Plate P91061-0067 Item No.Turbocharger System . please qoute Plate P91061 Edition 0067 .

please qoute Plate P91064 Edition 0002 Plate P91064-0002 Page 1 (2) .Travelling Trolley MAN B&W When referring to this page.

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

please qoute Plate P91065 Edition 0001 Page 1 (2) .Exhaust Receiver .Tools MAN B&W A Plate P91065-0001 A A-A When referring to this page.

Tools Plate P91065-0001 Item No. 016 028 041 053 065 Page 2 (2) MAN B&W Item Description Screw Compensator extender Screw Nut Tool set. complete When referring to this page. please qoute Plate P91065 Edition 0001 .Exhaust Receiver .

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

MAN Diesel A/S .

Safety Valve
MAN B&W Diesel

111-1

Data

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

X
X
X
X
X
X
X

Shut off starting air supply – At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME engines
Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data
Ref.

Description

D11-01

Opening pressure

D11-02

Valve housing, tightening torque

When referring to this page, please quote Data D11101 Edition 0026

Value

Unit

200± 5

bar

45

Nm

Page 1 (2)

Safety Valve

111-1

MAN B&W Diesel

Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Item No.

Description

P91351

10

Hydraulic pump, pneumatically operated

P91351

58

Hose with unions (3000 mm), complete

P90151

117

P91359

Page 2 (2)

Test equipment for combined safety valve
Torque Spanners

When referring to this page, please quote Data D11101 Edition 0026

Safety Valve
MAN B&W Diesel

911-1.2

Dismantling

When Side-mounted

1.

1. Remove the guard surrounding the safety
valve.
Unscrew the safety valve from the extension pipe.

When Top-mounted
3. Unscrew the safety valve from the cylinder
cover.

2.

M911010211D02

Remove and discard the mild steel disc.

M911010211D01

2. Dismantle the indicator cock and the intermediate pipe.

M911010211D03

3.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 1 (5)

911-1.3

Safety Valve
Overhaul (Adjustment)

1.

MAN B&W Diesel

1. If necessary, dismantle the safety valve and
clean all the parts in either gas oil, kerosene, or ‘electro-cleaner’.
2. Assemble the safety valve in two steps:

• Insert the valve flap and the stop ring in
the valve guide and screw on the valve
housing.

• Tighten the housing to the torque stated
M911010211O01

in the data, loosen and tighten again to
the torgue stated in the data.
3. Then mount:

the valve spindle

the spring

the adjusting screw

the lock nut

M911010211O02

2.

M911010211O03

3.

Page 2 (5)

When referring to this page, please quote Procedure M91101 Edition 0212

Safety Valve
MAN B&W Diesel

911-1.3

Overhaul (Adjustment)

4. To set the safety valve opening pressure:

4.

• Set up the safety valve in the Fuel valve
test rig.

• Connect the testing device to the hydraulic pump. Alternatively the hydraulic
hans pump can be used.

• Loosen the lock nut on the safety valve.
• Turn the adjusting screw until the valve
just closes.

• Bleed the valve and hose until oil, without air bubbles, flows out from the
openings of the safety valve.

• Tighten the adjusting screw of the

• Tighten the lock nut.
• Test the opening pressure.
• Remove the valve from the fuel valve

M911010212O04

safety valve until the correct pressure is
indicated (see Data).

test rig.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 3 (5)

911-1.4

Safety Valve
Mounting

MAN B&W Diesel

When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.

M911010211M01

3. Mount a new sealing ring and a new or
overhauled safety valve.
When mounting the safety valve, apply
tools only on the hexagon on the safety
valve.
Mount the guard surrounding the safety
valve.

M911010211M02

2.

M911010211M03

3.

Page 4 (5)

When referring to this page, please quote Procedure M91101 Edition 0212

Safety Valve
MAN B&W Diesel

911-1.4

Mounting

When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.

When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.

M911010211M04

Mount a new mild steel disc in the bore.

M911010211M05

5.

When referring to this page, please quote Procedure M91101 Edition 0212

Page 5 (5)

111-2

Relief Valve
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X

Stopped engine
Shut off starting air supply – At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME-engines
Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water

X

Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data
Ref.

Description

When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S

Value

Unit

Page 1 (2)

111-2

Relief Valve
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Page 2 (2)

Item No.

Description

When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S

Relief Valve

911-2.1

Checking
Relief Valve
60&
0211
Checking
911-2.1

1.

1. During running of the engine, check if there
are any leaks.
If a leak occurs, replace the O-ring inside
the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.

If one or more plates in the flame arrester
are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.

Note!

XZ911-2.1 209 01

Check on the whole circumference that all
the plates in the flame arrester are evenly
distributed and that no local openings exist.

The complete flame arrester has to be
replaced after a crankcase explosion.

XZ911-2.1 207 03

2.

When referring to this page, please quote Procedure M91102 Edition 0211
0$1% :'LHVHO$6

Page 1 (1)

Scavenge Air Receiver Safety Valve
MAN B&W Diesel

111-3

Data

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

Stopped engine
Shut off starting air supply – At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME engines

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, please quote Data D11103 Edition 0001

Value

Unit

Page 1 (2)

Scavenge Air Receiver Safety Valve

111-3

MAN B&W Diesel

Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate

Page 2 (2)

Item No.

Description

When referring to this page, please quote Data D11103 Edition 0001

Scavenge Air Receiver Safety Valve
MAN B&W Diesel

911-3.1

Checking

1. The scavenge air receiver safety valve
is calibrated at the factory and does not
require any adjustment.

2.

2. Check the scavenge air receiver safety
valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.

If this operation cannot be performed
smoothly, the safety valve must be
dismantled and cleaned.

M911030001C02

Use a piece of cloth to wipe out any dirt
from the Oring packing and close the
valve again. Tighten the counter nut.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 1 (5)

911-3.2

Scavenge Air Receiver Safety Valve
Dismantling

1.

MAN B&W Diesel

1. Dismount the safety valve from the scavenge air receiver.

M911030001D01

2. On some engines, a cover has to be removed in order to gain access to the safety
valve.

M911030001D02

2.

Page 2 (5)

When referring to this page, please quote Procedure M91103 Edition 0001

Scavenge Air Receiver Safety Valve
MAN B&W Diesel

911-3.3

Overhaul

1. Remove the split pin.

1.

Unscrew the nut thereby relieving the
spring tension.
Remove the nut, spring retainer and
washers.
Keep count of the washers.

2. Pull out the valve flap with spindle. If the
Oring seal is damaged remove it without
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.

M911030001O01

Pull out the spring.

M911030001O02

2.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 3 (5)

911-3.3

Scavenge Air Receiver Safety Valve
Overhaul

4.

MAN B&W Diesel

4. If the Oring seal has been removed mount
a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve flap and spindle while
taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the
washers.

M911030001O04

Tighten the nut until the split pin can be
mounted.
7. Check the valve according to 9113.1.

M911030001O05

5.

M911030001O01

6.

Page 4 (5)

When referring to this page, please quote Procedure M91103 Edition 0001

Scavenge Air Receiver Safety Valve
MAN B&W Diesel

911-3.4

Mounting
1.

M911030001M01

1. Mount the safety valve on the scavenge air
receiver.

When referring to this page, please quote Procedure M91103 Edition 0001

Page 5 (5)

912 - Assembly of Large Parts
Documents in this Chapter
112-02
912-02
112-03
912-03
912-05
91263

0015
0208
0028
0216
0201
0060

MAN Diesel A/S

Holding Down & End Chock Bolts, Data
Holding Down and End Chock Bolts
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)

MAN Diesel A/S .

D13-01 Description Hydraulic pressure.Holding-down and End Chock Bolts MAN B&W 112-2 Data SAFETY PRECAUTIONS For detailed sketch. please quote Data D11202 Edition 0015 Value 900 Unit bar Page 1 (2) . 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 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 When referring to this page.

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

0& 0208 Checking 912-2.Holding Down and End Chock Bolts 912-2. The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool.1 Checking Holding Down and End Chock Bolts .1 Note! The hydraulic jack used for tightening the holding down bolts is marked with: For: Holding down bolts The larger jack used for tightening the end chock bolts is marked with: For: End chock bolts Hydraulic tightening of holding down bolts and end chock bolts is carried out as detailed in Section 913-1. When referring to this page. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 1 (5) .

Any possible settling of the chocks during the intervals between measurements can thereby be followed. Checking the Bolt Tightening 1. The oil pressure indicated on the pressure gauge when the nut comes loose (‘loosening pressure') is to be noted down in the checking tables. the bolts should be taken out for inspection of threads and contact faces.1 205 01 The condition of the bolted joints. 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. For this purpose. see pages 4 and 5. EN912-1. Page 2 (5) When referring to this page. If the chocks are in position and in order. raise the pressure on the hydraulic tool slowly while constantly attempting to loosen the nut with the tommy bar. following which the bolts are tightened to the normal tightening pressure. If a number of measuring pins have been welded to the tanktop. can be effectively checked by comparing the tables from successive bolt checks. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. the relative chocks shall always be checked for possible defects. Checking of Epoxy Supporting Chocks 2.912-2. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 . If the ‘loosening pressure' is below 80 per cent of the tightening pressure. and thus the general condition of the foundation. 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.

000 hours. please quote Procedure M91202 Edition 0208 0$1% :'LHVHO$6 Page 3 (5) . we recommend that the following procedure is followed: 1. Try to knock the liner further inward. If this procedure does not improve the situation. 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. Side Chocks and Side Chock Liners 3. knock the liners a further 3 to 4 mm inwards. 2. The feeler gauge is applied at the 7 points indicated in the table on page 5. and thus at the same time intervals. GN912-2. The first time the ship is sailing in a fullyloaded condition after the engine has been operating for 1. These results are used to determine whether refitting or.1 203 03 The liners located in way of each main bearing on either side of the engine must be fitted and knocked into position simultaneously. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results. possibly. Loosen the hexagon screws. 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 liners are secured in their correct position by means of hexagon socket set screws with cup point. the liner must be removed. replacement of the liners is necessary. and the measurements found are to be entered in the relevant table. Measure again at the 7 points indicated in the table. all side chocks should be checked to see whether the liners can be knocked further inward. After fitting the liners to an 80 per cent contact area on both sides of the liners.Holding Down and End Chock Bolts 912-2. 3.1 Checking 3. When referring to this page.

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

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

.

see 900-2 X X X X X X Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value Unit D12-03 Check measurement 0. mounting 900 bar D13-02 Hydraulic pressure.4 mm D13-01 Hydraulic pressure. dismantling 800-990 bar When referring to this page. please quote Data D11203 Edition 0028 Page 1 (2) .Stay Bolts MAN B&W 112-3 Data SAFETY PRECAUTIONS For detailed sketch.

please quote Data D11203 Edition 0028 . Plate Item No. P90951 refers to chapter 909. complete P91351 105 3-way distributor block. complete Page 2 (2) When referring to this page. e.Stay Bolts 112-3 MAN B&W Data The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number. complete P91351 058 Hose with unions (3000 mm).g. P91261 Description Large Parts . pneumatically operated P91351 046 Hose with unions (1500 mm).Tools P91351 010 Hydraulic pump.

The following checks have to be completed within a 500-hour period. so that the two stay bolts are tightened in one operation. 2. 1. Connect the highpressure pump by means of the highpressure hoses. 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. 912-3. remove the protective caps. thereby ensuring uniform tension in the affected bearings.Stay Bolts MAN B&W 1. Note! Before retightening the stay bolts.1 Checking This check can be performed during several periods of stopped engine. please quote Procedure M91203 Edition 0216 Page 1 (3) . M912030215C01 The first time this check is performed it has to be completed in one operation. M912030215C02 D1301 When referring to this page. but must be performed on complete twin stay bolt groups at a time.

and retighten the stay bolt nuts with a tommy bar if possible. Retighten the stay bolts in pairs (athwartship).Stay Bolts 912-3. If the engine is equipped with split staybolts and one or more staybolts have been dismantled. check with a feeler gauge that the nuts bear against the contact face. working from fore to aft of the engine. make sure that the staybolts are mounted in such a way that. If the engine is equipped with staybolts in one piece.1 Checking 3. Before relieving the system of pressure. D1203 MAN B&W 3. between the contact face of the lowermost nut and the bedplate. please disregard the above. please quote Procedure M91203 Edition 0216 . there is a clearance. M912030215C05 D1301 Page 2 (3) When referring to this page. M912030216C04 4. 5. when the uppermost staybolt nut is loosened. M912030216C03 4. Pump up the hydraulic pressure to 10% below the value indicated in D1301. as stated in Data. 5.

After completing the retightening procedure. If the nut is loose: 7.Stay Bolts MAN B&W 912-3. mount the protective caps. If the nut is not loose: Tighten the stay bolts to D1301.1 Checking 6. Reconnect the hydraulic tools to the pair of stay bolts first tightened. 6. please quote Procedure M91203 Edition 0216 Page 3 (3) . M912030215C06 Tighten all stay bolts once again to D1301. Tighten to 10% below D1301 and check if the nut is loose. When referring to this page.

.

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

9. 13. Note! 7. Remount four of the screws A at diametrically opposite positions. Remove: Screws C Cover plate D Screws E. Replace gaskets G and H.Crankcase Oil Outlet 912-5. 11. C D 5.1 Checking MAN B&W Diesel Metal bellow sealing 4. 12. Mount metal bellow sealing F. Mount grating B. 4. M912050201C07 10. B A 6. Mount all screws A. It is recommended to always replace the metal bellow sealing during inspection. it must be replaced. Remove the four screws A. 8. Remove all screws A and grating B. Page 2 (2) When referring to this page. F M912050201C04 E G H 7. Mount: Screws E Cover plate D Screws C. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are found in the metal bellow sealing. please quote Procedure M91205 Edition 0201 .

Hydraulic Tools .Holding-Down and End Chock Bolts (Epoxy Chocks) MAN B&W When referring to this page. please qoute Plate P91263 Edition 0060 Plate P91263-0060 Page 1 (2) .

5 Hydraulic jack for holding-down bolt M36 x 4. complete 036 048 050 061 073 085 097 107 119 132 203 Page 2 (2) When referring to this page.Holding-Down and End Chock Bolts (Epoxy Chocks) MAN B&W Item No. please qoute Plate P91263 Edition 0060 .Plate P91263-0060 Hydraulic Tools .0 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 Tommy bar Hydraulic tool set. Item Description 024 Hydraulic jack for end-chock bolt M56 x 5.

General Tools Documents in this Chapter 913-01 913-04 913-05 913-06 913-07 91311 91351 91356 91357 91359 91360 91361 91362 91363 91364 91366 0209 0201 0205 0205 0207 0204 0038 0058 0005 0003 0003 0052 0064 0040 0059 0066 MAN Diesel A/S Hydraulic Tools Standard Tightening Torques Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories . Open-Ended Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments . etc.Hydraulic Tools Lifting Tools.913 .

MAN Diesel A/S .

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Standard Tightening Torques

913-4

Standard Tightening Torques
.0&&
0201
913-4

When tightening screws or nuts for which no
torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a
Molybdenum Disulphide (MoS 2) based lubricant.
Thread

Tightening
torque

Thread

Tightening
torque

M8

17 Nm

M22

400 Nm

M10

35 Nm

M24

460 Nm

M12

50 Nm

M27

610 Nm

M14

80 Nm

M30

950 Nm

M16

135 Nm

M33

1200 Nm

M18

190 Nm

M36

1650 Nm

M20

260 Nm

M39

2100 Nm

2. Self-locking nuts.
Thread

Tightening
torque

Thread

Tightening
torque

M8

20 Nm

M22

430 Nm

M10

40 Nm

M24

490 Nm

M12

60 Nm

M27

650 Nm

M14

90 Nm

M30

1000 Nm

M16

150 Nm

M33

1250 Nm

M18

210 Nm

M36

1700 Nm

M20

290 Nm

M39

2200 Nm

3. Screws and nuts locked with glue/Loctite.
Thread

Tightening
torque

Thread

Tightening
torque

M8

23 Nm

M22

580 Nm

M10

50 Nm

M24

680 Nm

M12

70 Nm

M27

900 Nm

M14

115 Nm

M30

1350 Nm

M16

190 Nm

M33

1700 Nm

M18

270 Nm

M36

2350 Nm

M20

380 Nm

M39

3000 Nm

When referring to this page, please quote Procedure M91304 Edition 0201
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Page 1 (1)

Torque Spanner

913-5

Torque Spanner
/0&
0205
913-5

Before screwing the nuts on, the threads and
the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient µ = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are
to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened
to the stated torque and then to the next splitpin hole.
The torque spanner must not be used for torques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided
with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,
there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle
appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl
system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the spanner, and a small click is heard.
When the torque spanner is not in use, the
spring inside should be released by adjusting to
minimum torque.

When referring to this page, please quote Procedure M91305 Edition 0205
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Page 1 (1)

Tightening Gauge

913-6

Tightening Gauge
0205
913-6

Preparations
Before screwing on the nuts, grease the
threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
µ = 0.1–0.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
See Procedure 913-5.
Apply a pre-tightening torque of:
– thread M8 – M20 = 50 Nm
– thread M22 – M27 = 100 Nm
– thread M30 – M39 = 150 Nm
– thread M42 – M48 = 200 Nm
This is in order to ensure a uniform basis for the
subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge
round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 30°–45° and 60°,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
When tightening new studs or bolts for the first
time, loosen again and repeat the procedure –
including pre-tightening with a torque spanner,
to allow the parts to settle.
See Procedure 913-5.        

7
; 

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0
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When referring to this page, please quote Procedure M91306 Edition 0205
0$1% :'LHVHO$6

Page 1 (1)

Screws and Nuts
MAN B&W Diesel

913-7.1

Locking

Some screwed and bolted connections on the
engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.

1.

When reassembling the engine after overhauls,
it is vital that all such screws and nuts are
again locked correctly.

Make sure only to mount locking devices
on nuts and screws which have been
mounted with locking devices by the engine manufacturer.

1. Lock washers, tab washers, locking
plates, etc., must always be replaced. The
tab-like projections, etc., on the washers
are to be bent back over one of the flats of
the screw or nut concerned.

M913070207C01

Note!

2.

2. Used spring washers must be replaced.

To tighten a self-locking nut to a specific
torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data
sheet of a procedure.

M913070207C02

3. Self-locking nuts may only be used five
times. Therefore, give the nut a centre
punch mark each time it is loosened.

M913070207C03

3.

When referring to this page, please quote Procedure M91307 Edition 0207

Page 1 (4)

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

Fig. 12: Wire that passes over the top of a nut is also an acceptable alternative if the hole is located as shown in the figure. 13: Where drilling of locking wire holes has caused a thin wall section. 13 Fig. please quote Procedure M91307 Edition 0207 Page 3 (4) . 12 Fig.Screws and Nuts MAN B&W Diesel 913-7.1 Locking Fig. Fig. 11 Fig. M913070207C06 Fig. Fig. 10: Shows how to route the locking wire on screws in different planes. 10 Fig. route the wire as shown in the figure. Fig. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread. 14 When referring to this page. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible. to prevent damage to the nut.

The cam lock washer is locked in place. please quote Procedure M91307 Edition 0207 . 17: Don not use the cam lock washers in conjunction with other loose washers. 16.913-7. Fig. 17 Page 4 (4) When referring to this page. 15 MAN B&W Diesel Cam Lock Washers with rising cams on one side and radial teeth on the other. Note! M913070207C16 Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers. 16: Different uses of the cam lock washers. M913070207C15 Fig.1 Screws and Nuts Locking Fig. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect og the cams. cam face to cam face. M913070207C17 Fig. Fig. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces. allowing movement only across the face of the cams. Fig. 15: The washers are installed in pairs.

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

.

Accessories for Hydraulic Tools MAN B&W Plate P91351-0038 Working Pressure 900 Bar When referring to this page. please qoute Plate P91351 Edition 0038 Page 1 (2) .

Cu o11x3mm Bleeder screw Disc. female Disc. Cu o11x9mm 058 060 105 117 130 154 166 201 213 225 237 249 Page 2 (2) When referring to this page. round-plain. please qoute Plate P91351 Edition 0038 . complete Hose with unions (3000mm). complete Distributor block with shut-off valve Angle union Quick coupling. pneumatic operated Hydralic pump.Plate P91351-0038 Accessories for Hydraulic Tools MAN B&W Item No. round-plain. complete 9-way distributor block. male Quick coupling. Item Description 010 022 046 Hydralic pump. complete 2-way distributor block. hand operated Hose with unions (1500mm). complete 4-way distributor block. complete Hose with unions (5000mm).

please qoute Plate P91356 Edition 0058 Plate P91356-0058 Page 1 (2) .Lifting Tools. MAN B&W When referring to this page. Etc.

10mm Forged-bent screw shackle. 1000kg Chain tackle. 3000kg Wire rope. 30mm Lifting eye bolts. 16mm Lifting eye bolts. Plate P91356-0058 Item No. 24mm Forged-bent screw shackle. 20mm Lifting eye bolts. 16mm Forged-bent screw shackle. 10mm Lifting eye bolts. 6m When referring to this page. 020 031 043 055 067 079 114 126 138 140 151 163 210 222 234 258 295 305 Page 2 (2) MAN B&W Item Description Forged-bent screw shackle.Lifting Tools. 24mm Lifting eye bolts. 12mm Lifting eye bolts. please qoute Plate P91356 Edition 0058 . 2000kg Chain tackle. 3000kg Pull lift. 12mm Forged-bent screw shackle. 20mm Forged-bent screw shackle. 30mm Chain tackle. Etc. 500kg Chain tackle.

Open Ended Spanners MAN B&W When referring to this page. please qoute Plate P91357 Edition 0005 Plate P91357-0005 Page 1 (2) .

size 85mm When referring to this page. 013 025 037 050 Page 2 (2) Open Ended Spanners MAN B&W Item Description Open-ended spanner. please qoute Plate P91357 Edition 0005 .Plate P91357-0005 Item No. size 65mm Open-ended spanner. size 75mm Open-ended spanner. size 70mm Open-ended spanner.

Torque Wrenches MAN B&W When referring to this page. please qoute Plate P91359 Edition 0003 Plate P91359-0003 Page 1 (2) .

8 . 750 . 40 . Item Description 014 026 Torque wrench.200Nm Torque wrench.760Nm Torque wrench. 140 .400Nm Adapter for socket wrench. please qoute Plate P91359 Edition 0003 .Torque Wrenches Plate P91359-0003 MAN B&W Item No. 10 x 12.5 mm Torque wrench.2000Nm 038 040 051 Page 2 (2) When referring to this page.

please qoute Plate P91360 Edition 0003 Plate P91360-0003 Page 1 (2) .Pliers MAN B&W When referring to this page.

size 1. size 1. 010 021 033 128 130 141 153 Page 2 (2) MAN B&W Item Description Pliers for retaining ring. please qoute Plate P91360 Edition 0003 .3mm Pliers for retaining ring.2mm When referring to this page.8mm Pliers for retaining ring.3mm Pliers for retaining ring.1mm Pliers for retaining ring.8mm Pliers for retaining ring. size 2. size 1.Pliers Plate P91360-0003 Item No.9mm Pliers for retaining ring. size 0. size 1. size 3.

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

size 10mm Combination spanners. size 11mm Combination spanners. size 12mm Combination spanners.Plate P91361-0052 Item No. size 14mm Combination spanners. size 21mm Combination spanners. size 41mm Combination spanners. 015 027 039 040 052 064 076 088 090 100 111 123 135 147 159 160 172 184 196 206 218 220 231 Page 2 (2) Combination Spanners MAN B&W Item Description Combination spanners. size 13mm Combination spanners. size 22mm Combination spanners. size 50mm Combination spanners. please qoute Plate P91361 Edition 0052 . size 46mm Combination spanners. size 27mm Combination spanners. size 30mm Combination spanners. size 18mm Combination spanners. size 60mm When referring to this page. size 32mm Combination spanners. size 19mm Combination spanners. size 17mm Combination spanners. size 15mm Combination spanners. size 16mm Combination spanners. size 34mm Combination spanners. size 55mm Combination spanners. size 36mm Combination spanners. size 24mm Combination spanners.

please qoute Plate P91362 Edition 0064 Plate P91362-0064 Page 1 (2) .Ring Slugging Spanners MAN B&W When referring to this page.

ring size 70mm Slugging spanners. ring size 65mm Slugging spanners.Plate P91362-0064 Item No. ring size 32mm Slugging spanners. ring size 36mm Slugging spanners. please qoute Plate P91362 Edition 0064 . ring size 60mm Slugging spanners. ring size 41mm Slugging spanners. ring size 34mm Slugging spanners. ring size 30mm Slugging spanners. ring size 50mm Slugging spanners. 022 034 046 058 060 071 083 095 105 117 129 130 142 Page 2 (2) Ring Slugging Spanners MAN B&W Item Description Slugging spanners. ring size 46mm Slugging spanners. ring size 55mm Slugging spanners. ring size 75mm Slugging spanners. ring size 80mm When referring to this page.

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

22 mm Hex key. size 24-46 mm Hex key tool set. size 10-22 mm Tool set. complete. 46 mm Hex key.Spanners Plate P91363-0040 Item No. complete. please qoute Plate P91363 Edition 0040 . 24 mm Note: * Page 2 (2) When referring to this page. complete Socket spanner. 016 028 030 100 150 161 MAN B&W Item Description Tool set.

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

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

please qoute Plate P91366 Edition 0066 Plate P91366-0066 Page 1 (2) .Instruments MAN B&W When referring to this page.

Item Description 012 024 036 048 050 061 073 Indicator. complete Autolog. measuring tool for crankshaft Feeler gauge Slide caliper Dial gauge and stand tool Page 2 (2) When referring to this page.Instruments Plate P91366-0066 MAN B&W Item No. please qoute Plate P91366 Edition 0066 . complete Indicator paper Plainmeter.

Subpart K. the instructions to that effect included in the Technical File.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations. §94. In accordance with Chapter I of the Code of Federal Regulations. please quote S-Instruction S900 Edition 0002 Page 1 (1) . including. Part 94. Subpart C.Warning MAN B&W S900-0002 Warning! It is important that all MAN 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 Diesel A/S maintenance instructions in order to comply with given emissions regulations. but not limited to. Part 94. §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN Diesel A/S instructions. When referring to this page.

.

S50MC VOLUME III COMPONENTS DESCRIPTION .

.

Introduction Documents in this Chapter 90001 90002 90003 90004 90023 90030 0039 0001 0001 0001 0027 0009 MAN Diesel A/S Table of Contents.900 . Std Instructions for Main Engine Description . Volume III Cross Section through Engine Ordering of Insulation Designations and Symbols Software Licence.

MAN Diesel A/S .

Edition Title 900 .Crosshead with Connecting Rod 90401 0170 Connecting Rod and Crosshead 90403 0011 Lubricating and Cooling Oil Flow 905 .Rear Side 90312 0002 Electronic Components . Thrust Bearing and Turning Gear 90501 0164 Crankshaft 90503 0025 Arrangement of Angle Encoder 90504 0014 Axial Vibration Monitor 90505 0117 Thrust.Introduction Table of Contents 90001 0039 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations and Symbols 90004 0001 Software Licence. Std 90023 0027 Instructions for Main Engine 90030 0009 Description 901 .Piston with Rod & Stuffing Box 90201 0204 Piston and Piston Rod 90205 0115 Piston Rod Stuffing Box 903 .Details 90310 0013 Cylinder Frame .Table of Contents 900 Volume III .Cylinder Liner and Cylinder Lubrication 90301 0182 Cylinder Frame 90302 0185 Cylinder Liner and Cooling Jacket 90304 0037 Cylinder Liner .Cylinder Lubrication 904 .Cylinder Lubrication 90312 0004 Electronic Components .and Guide Bearing 90510 0125 Turning Gear 90511 0049 Turning Wheel 90512 0002 Turning Gear .Control Gear 90600 0137 Arrangement of Chain Drive and Camshaft 90603 0073 Chain Tightener MAN Diesel A/S Page 1 (3) .Crankshaft.Cylinder Cover 90101 0175 Cylinder Cover 902 .Components Description No.Details 90305 0134 Cylinder Lubricators 90307 0035 Cylinder Lubricator Unit 90308 0012 Cylinder Lubricator .Details 906 .Intermediate Box 90309 0021 Cylinder Lubricator System .Cylinder Lubrication 90312 0003 Electronic Components .

Details 90915 0074 Fuel Oil System .Actuator 90806 0098 Exhaust Valve .Details 90805 0144 Exhaust Valve . 90611 90612 90613 90618 90619 90632 90634 Edition 0172 0088 0103 0151 0036 0028 0031 Title Camshaft and Chain Wheel Arrangement of Indicator System Camshaft Bearing Regulating Shaft Load Transmitter Chain Drive Guidebars .Pipe System 90810 0090 Arrangement of Cooling Water Pipes 90812 0003 Arrangement of Drain Pipes Freshwater 909 .Lower Parts 90803 0040 Exhaust Valve .Starting Air System 90702 0070 Main Starting Valve 90703 0120 Starting Air Distributor 90704 0059 Starting Valve 908 .Details 910 .Details 90905 0025 Reversing Mechanism 90910 0139 Fuel Valve 90911 0017 Fuel Valve Function 90913 0124 High-Pressure Pipes 90914 0099 Fuel Oil System 90914 0101 Fuel Oil System 90915 0060 Fuel Oil System .Turbocharger System 91000 0012 Gas and Air System 91001 0134 Scavenge Air Receiver 91002 0149 Arrangement of Charging Air Pipe 91003 0235 Exhaust Pipes and Receiver 91004 0069 Exhaust Receiver .Details 90915 0075 Fuel Oil System .Details 91005 0136 Air Cooler 91006 0044 Arrangement of Auxiliary Blower MAN Diesel A/S Page 2 (3) .Components Description No.Exhaust Valve 90801 0206 Exhaust Valve .Table of Contents 900 Volume III .Fuel Oil System 90901 0177 Fuel Pump 90902 0171 Fuel Pump Gear 90903 0021 Fuel Pump Gear .Lower Part Chain Drive Lubrication .Details 90904 0059 Fuel Pump .Upper Parts 90804 0016 Exhaust Valve Upper Parts .Lower Part 907 .

Cleaning Arrangement of Non-Return Valve Arrangement of Non-Return Valve 911 .Safety Equipment 91101 0037 Safety Valve .Assembly of Large Parts 91201 0094 Arrangement of Stay Bolts 91203 0015 Frame Box .Details 91205 0194 Frame Box 91206 0122 End Shields 91207 0101 Arrangement of Piston Cooling 91210 0181 Bedplate 91211 0091 Axial Vibration Damper 91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) MAN Diesel A/S Page 3 (3) .Scavenge Air System 91104 0069 Arrangement of Safety Cap 912 . 91007 91009 91011 91011 Edition 0007 0041 0019 0029 Title Butterfly Valve Air Cooler System .Cylinder 91102 0028 Relief Valve 91103 0016 Safety Valve .Components Description No.Table of Contents 900 Volume III .

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please qoute Plate P90001 Edition 0039 Plate P90001-0039 Page 1 (1) .Cross Section through Engine MAN B&W When referring to this page.

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

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nos.Designations and Symbols MAN B&W Normal layout Plate P90003-0001 Forward (fwd) Starboard (stbd) side of ship Port side of ship Fore end 1 2 3 4 5 6 7 Manoeuvring side of engine Aft end Cyl. always counted from fore end Exhaust side of engine Propeller Clockwise direction of rotation defined from aft end of engine When referring to this page. please qoute Plate P90003 Edition 0001 Page 1 (1) .

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

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

II MAINTENANCE Vol. III COMPONENTS. 39 66 13 14 . only original spare parts should be used when replacing parts on the engine. Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN Diesel’ instructions.com CVR No. reliability and lifetime of the engine and its components. the designation “D” refers to the information given on the data sheets inserted in the respective books. MAN Diesel A/S A90023-0028 Teglholmsgade 41 DK-2450 Copenhagen Denmark Teleph. be copied. for instance in correspondence and when ordering spare parts.com www. and should therefore not. it is essential that the engine room personnel are fully acquainted with the contents of this book and. Part No. built by Plate No. This book is subject to copyright protection. reproduced. Emissions related maintenance of the diesel engine shall be performed as specified in MAN Diesel’ instructions and any additional instructions to that effect included in the Technical File. made public or in any other way made available to a third party without the written consent of this effect from MAN Diesel. In addition. also the additional instructions to that effect set out in the Technical File. in whole or in part. Deviations may be found in a specific plant. 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: Name of vessel Engine No. When used in texts and illustrations. : +45 33 85 11 00 Telefax : +45 33 85 10 30 manbw@dk.manbw. in respect of instructions on emissions related maintenance of the diesel engine. Quantity required (and description) Example: M/S Nybo – 7730 B&W – P90201-0036 – 059 10 off (piston ring) To ensure optimum efficiency. 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. the books can be used for reference purposes. Consequently.Instructions for Main Engines This book forms part of a set of books consisting of three volumes entitled: Vol. I OPERATION Vol.manbw.

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when the exhaust valve is installed. 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. an amount of water is also passed directly from the cylinder cover to the exhaust valve housing through a cooling water connec tion. Cooling A cooling jacket is mounted on the lower part of the cylinder cover. safety valve and indicator cock. further on. When referring to this page. The water is supplied from the cooling jacket surrounding the cylinder liner and passes through water connections to the cooling jacket surrounding the cylin der cover and. On the 7098MC type engines the cylinder cover is provided with weldedon heat resistant material at the points of fuel oil injection in order to improve the service condition. starting air inlet. Valve bores The cover has a central bore for the exhaust valve. Another cooling water space is formed around the exhaust valve seat.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W 901 Cylinder Cover Cylinder Cover The cylinder cover is made of steel. Tightening The cylinder cover is tightened against the top of the cylinder liner with nuts and long studs fitted in the cylinder frame. which is attached by means of four studs and nuts. The cover furthermore has bores for the fuel valves. Sealing between the cylinder cover and cylinder liner is obtained by means of a sealing ring of mild steel. through the cooling bores. The nuts are tightened with hydrau lic tools. and the pis ton skirt is tightened to the piston crown. whereby a cooling water space is formed. From here the water is discharged to the main cooling water outlet pipe: On some engine types. starting valve. These two spaces communicate through a large number of cooling bores in the cover. please quote Description A90030 Edition 0009 Page 1 (23) . to the space around the exhaust valve seat.

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

please quote Description A90030 Edition 0009 Page 3 (23) . which are bolted together. Scraper/sealing rings The housing is provided with a number of machined ring grooves: • The uppermost groove holds a scraper ring with oblique edges. which serves to prevent sludge from the scavenge box from being drawn down to the other rings. The stuffing box also prevents scavenge air (in the scavenge air space) from leaking into the crankcase. which is designed to prevent the lubri cating oil in the crankcase from being drawn up into the scavenge air space. The cylinder section is tightened together with the engine framebox and the bedplate by means of stay bolts. When referring to this page. • The ring grooves in the middle are fitted with sealing rings. Furthermore. 903 Cylinder Liner and Cylinder Lubrication Cylinder Frame The cylinder section of the engine consists of a cylinder frame with a boltedon or integrated camshaft housing. a sealing ring is fitted below the scraper ring (except on 35MC type engines).Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Stuffing Box The bore for the piston rod between the scavenge air space and the crankcase is fitted with a piston rod stuffing box. Through bores in the housing and a pipe. 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. Central bores in the bottom of the cylinder frame enclose the piston rod stuff ing boxes. Oil which is scraped off the piston rod is returned to the crankcase through bores in the stuffing box housing. Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners. which enables the sealing/scrap ing performance to be checked. Alternatively as a complete welded assembly integrating the scavenge air receiver into the cyl inder frame. • The lowermost ring grooves are fitted with scraper rings which scrape the lubricating oil off the piston rod. The stuffing box housing consists of two parts. the stuffing box communicates with a control funnel on the outside of the engine. Gaps at the ends of the ring segments ensure that the rings will bear against the piston rod even in worn condition.

the water first passes through the cooling bores. the water flows through water connections to the cooling jacket on the lower part of the cylin der cover. the PCring contributes to reducing the wear of liners and rings. 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. prevent the wiping away of the cyl inder lubricating oil. OPERATION. The cylinder frame is provided with cleaning and inspection covers giving access to the scavenge air spaces.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W There are also inlet pipes for cooling and lubricating oil. the water continues directly to the upper part of the cool ing jacket. From the top of the cooling jackets. Regarding the cylinder lubricators proper. 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 cylin der cover. which are un covered by the piston when this is in its bottom position. there are a number of bores with nonreturn valves for the supply of lu bricating oil to the cylinder. Chapter 707. Cylinder Liner and The cylinder liner is fitted with a cooling jacket. in turn. The cooling water is supplied Cooling Jacket at the lower part of the cooling jacket. PCring On 8098MC type engines a piston cleaning (PC) ring is mounted at the top of the cylinder liner. Page 4 (23) When referring to this page. reference is made to the special in struction manuals supplied. Cylinder cover studs Studs for fastening the cylinder cover are mounted in the cylinder frame. On slimtype liners. Cylinder lubrication In the free part of the cylinder liner. The purpose of the PCring is to prevent the buildingup of deposits on the piston topland and. Cylinder Lubricators The engine is equipped with mechanically or electronically controlled cylinder lubricators for lubrication of the running surface of liners and rings. Leakage of cooling water is prevented by silicone rubber rings. please quote Description A90030 Edition 0009 . Consequently. between the cooling jacket and the cylinder frame. See also Volume I. 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. whereas on the borecooled type liner.

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

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 col lar. The thrust shoes rest on surfaces in the thrust bearing housing and are held in place by means of stoppers or cross bars. The damper consists of a ‘piston’ and a slittype housing. See also Volume I. See also Section 912. and shutdown devices for low lube oil pressure and high segment temperature. the crankshaft is provided with an axial vibration damper. Stationary engines and geared marine plants: The crankshaft is provided with a collar for the guide bearing. and the housing is mounted on the pertaining main bearing support. The thrust bearing is lubricated by the pressure lubrication system of the en gine. if required according to vibration calculations. Marine engines (except geared plants): At the aftmost end of the engine. See also Volume I.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W The crankshaft is provided with a chain wheel for the camshaft drive and a turning wheel. The axial movement is damped as a result of the ‘restrictions’ incorporated in the bores which interconnect the oilfilled chambers on the two sides of the ‘piston’. OPERATION. The oil is supplied between the segments through spray pipes and spray nozzles. Chapter 701. a tuning wheel. a torsional vibration damper and a chain wheel drive for 2nd order and 4th order moment compensators are in stalled. and any resultant adverse forces and vibrations. The segments have white metal cast onto the wearing faces against the thrust collar. Furthermore. Axial Vibration Damper To counteract heavy axial vibrations. Chapter 708. please quote Description A90030 Edition 0009 . “Assembly of large parts” further on in this text. slowdown. 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. The ‘piston’ is made as an integrated collar on one of the main bearing journals. 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. OPERATION. The thrust bearing is provided with alarm. a thrust bearing is fitted. Page 6 (23) When referring to this page.

thus causing injuries to personnel or damage to the machinery. the turning gear must be in the engaged position in order to prevent outside forces from turning the engine. When the safety lever is in its bottom position. The chain is kept tightened by a chain tightener placed in the chain casing between the crankshaft and the camshaft. an interlock valve inserted in the starting air system of the engine is actuated. Pressure testing of starting valves: The turning gear must be in the disengaged position during pressure testing of starting valves. Chapter 703. Through a planetary gearing. OPERATION. so as to engage with the turning wheel of the engine. and damage the turning gear. Chapter 703. Lubri cating oil is supplied through spray pipes fitted at the guide bars and chain wheels. The long free lengths of the chain are guided by rubberclad guide bars. MAINTENANCE. ‘DATA’ pages. Immediately the lever is lifted away from the disengaged position. OPERATION. When referring to this page. please quote Description A90030 Edition 0009 Page 7 (23) . as a leaky valve may cause the engine to rotate. See Volume II. See Volume I. 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. it prevents the gear wheel of the turning gear from engaging with the turning wheel. The chain drive consists of one or more roller chains running on chain wheels fitted on the crankshaft and the camshaft. the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually. 906 Mechanical Control Gear Chain Drive The camshaft with cams for operating the fuel pumps. Warning! Dismantling of working parts: During any dismantling of working parts of the engine. exhaust valves and indi cator drive (option) is driven from the crankshaft through a chain drive. This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W 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 camshaft has. Bearings The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. 908 and 909. which communicates with the combustion chamber of the cylinder through a bore. the sections are assembled by means of flange couplings. the spindle must be screwed right back to the stop in order to avoid burns and carbon in the guide.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Camshaft The camshaft is made in one or more sections. which are assembled with fitted bolts. OPERATION. close the valve lightly before starting the engine. See also Volume I. When referring to this page. Chapter 708. which enables the parts to be turned in relation to each other. couplings or chain wheel and the shaft. 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. and the necessary pin gauges are deliv ered together with the engine. Note! For indicator valves of the doubleseated design with a springloaded closing face: In order to prevent overstressing. Pin gauges After the engine has been testrun. If it is made in two or more sections. Operating Instructions! When opening the indicator valve. 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. please quote Description A90030 Edition 0009 . Chapters 906. The camshaft rotation constantly follows that of the crankshaft. PMISystem Page 8 (23) See separate instructions for operating the PMIsystem (option). whereas the indicator cams are in two parts. See Volume II. and retighten the valve when the engine has reached its normal service temperature. Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams. the camshaft parts and the cylinder frame will be provided with pin gauge marks.

and each chain casing is fitted with a relief valve. 907 Starting Air System Starting Air System The starting air system consists of the manoeuvring system and the starting air components. Incorrectly fitted moment compensators may excite heavy vibrations. Chapter 703.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Moment Compensators On the basis of calculations. Optionally. 4th order moment The moment compensator is arranged as flyweights built into chain drives on both ends of the camshaft. OPERATION. Each chain drive is equipped with a springloaded chain tightener. 2nd order moment Applicable on 45 and 6cylinder engines. the flyweights must be positioned correctly in relation to the crankshaft. Alternatively. Volume II. The moment compensator is arranged as flyweights built into the main chain drive. which comprise: • Main Starting Valve • Starting Air Distributor • Starting Valves The manoeuvring system is of electric/pneumatic design. 1st order moment Applicable on 4cylinder engines. an electrically driven compensator can be installed. the 1st order moment compensator can be positioned in the main chain drive. the engine may be provided with fly weights to counteract engine forces and moments. See also Volume I. When referring to this page. On some engines. The moment compensator is arranged as adjustable flyweights on both ends of the crankshaft. flyweights are built into a second chain drive. This chain drive is equipped with a springloaded chain tightener. which on some engines is equipped with a hydraulic damper. Caution! If the chain drives for the compensators have been dismantled. MAINTENANCE. which is driven from the opposite end of the crankshaft. This moment compensator consists of a (new) chaintightener wheel with an incorporated flyweight and a flyweight rotating with the crank shaft. See the instruction book. please quote Description A90030 Edition 0009 Page 9 (23) .

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

designed to dampen the closing of the valve. applied by the HVOF process. 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 su per alloy. Pistons: At the top of the spindle. please quote Description A90030 Edition 0009 Page 11 (23) . The cooling water is passed to the valve housing after it has passed the cylinder cover. a ‘lifting/rotation check rod’ is mounted on top of the hydraulic cylin der on the exhaust valve. The hydraulic piston has two piston rings and a damper arrangement.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W 908 Exhaust Valve Exhaust Valve Each cylinder is equipped with an exhaust valve. two pistons are fitted: 1. which is mounted in a central bore in the cylinder cover. 2. 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. The valve housing is attached with four studs and nuts to form a gastight seal against a seat in the cylinder cover. and must not be permanently activated. Hydraulic piston The piston serves to open the exhaust valve. On the front of the valve housing there is a cleaning cover through which the cooling water space can be checked and cleaned. Spindle rotation is indicated by regular changes in the top and bottom posi tions of the check rod. Cooling The valve housing is water cooled. Valve housing The valve housing has an exchangeable bottom piece. The water is discharged from the upper part of the valve housing. Note! This check rod is only for checking purposes. Air piston The piston serves to close the exhaust valve. The piston is locked to the spindle by a twopiece conical ring. Lifting/rotation check rod: To enable checking the functioning of the exhaust valve while the engine is running. For small bore engine types (26-70MC/MC-C) the damper arrangement is of self-adjusting type. When referring to this page. The bore for the valve spindle is provided with an exchangeable spindle guide liner.

Procedure 908. a combined throttle/valve designed for deaerating the oil system is fitted at the top of the cylinder. The exhaust valve is opened by the valve spindle being forced down by the piston in the hydraulic cylinder. Air cylinder The air cylinder is mounted on top of the valve housing. it is important to check the damper after the exhaust valve has been overhauled. Page 12 (23) When referring to this page. The sealing air will prevent the exhaust gas and particles from penetrating up wards and wearing out the running surfaces and polluting the pneumatic sys tem of the valve gear. to escape through the throttle. The oil is led through a duct to the space around the air cylinder and is drained off through a bore X. if any. The sealing air is supplied from the air cylinder via a sealing air control unit. MAINTENANCE. Throttle/valve: On some engine types. When the exhaust valve is activated.A90030-0009 Engine Types 35-98MC/MC-C MAN B&W Note! For damper arrangements of non-self-adjusting type. The safety valve is connected to the drain pipe which leads to the camshaft housing. enabling oil and air. Air for closing the ex haust valve is supplied through a nonreturn valve to the space below the pis ton. A thrust spring opens the valve. The oil content in the air from the air cylinder improves the service condition of the sealing rings. the pressure in the hydraulic cylinder is low. and the oil flow stops. Sealing System Sealing air (where used): A sealing air arrangement is fitted around the spindle shaft below the air cylin der. The sealing air control unit contains a valve which automatically cuts off the air flow when the engine is in FINISHED WITH ENGINE status. together with leakage oil from the piston. to avoid knocking. When the exhaust valve is closed. Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder on top of the exhaust valve housing. the high oil pressure closes the valve. A safety valve is mounted in the bottom of the air cylinder. and a filter hous ing. See Volume II. please quote Description A90030 Edition 0009 .

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

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

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

The fuel pump is actuated by a cam on the camshaft. the injection com mences through the fuel valves. The link is self locking in either the ahead or astern position without the aid of external forces. The link connecting the roller guide and roller is provided with a reversing arm. through bores in the union nipples. and the reversing mechanism is activated by compressed air. Reversible engines: The roller guide of each fuel pump incorporates an angular displaceable revers ing link. Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. connected to a common drain tank. Fuel Oil High Pressure Pipes All highpressure pipes in the system are provided with a protective outer pipe. The pivot travels in a reversing guide connected to an air cylinder. UMS. As soon as the plunger has covered the cutoff holes during its upward movement in the pump barrel. The reversing arrangement may incorporate a damper in order to reduce the mechanical stresses. and the oil level in the drain tank will rise until it reaches the level of the over flow pipe. via drain pipes. and a pivot is mounted at the top end of the reversing arm. 3598MC: Each fuel pump is. The movement is trans mitted through the roller guide to the plunger in the barrel of the pump housing which – through the highpressure pipes – is connected with the fuel valves on the cylinder cover. which incorporates a level switch. The injection will last until the cutoff holes are uncovered by the oblique cutoff edges of the plunger. The space between the pipe and the protective outer pipe communicates. Fuel Oil Leakage Alarm A fuel oil leakage alarm is required for Unattended Machinery Spaces. with a drain bore in the pump top cover. The drain tank is also equipped with an overflow pipe. please quote Description A90030 Edition 0009 . Each cylinder is reversed individually. Fuel Pump Actuating Gear The camshaft housing contains the fuel pump and exhaust valve actuating gear for each cylinder. Page 16 (23) When referring to this page. following which the oil is forced through two milled grooves at the side of the plunger and out through the cutoff holes of the barrel during the rest of the delivery stroke. whereby oil from small leakages can be drained to the outlet. the abovemen tioned bore will not be large enough to allow the increased oil quantity to pass.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Fuel Oil Injection During the suction stroke. In the event of pipe fractures or major leakages in the system. Shock absorber A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations. the springloaded suction valve opens and the deliv ery chamber is filled with oil. The rising oil level will cause the level switch to set off an alarm. without actuating the level switch. which has a small drain bore below.

When the fuel valve is fitted in the cylinder cover. through a common shaft. is insulated. and oil starts to recirculate through the valve. Fuel Valve The fuel valve consists of a valve head and a valve housing. On 6098MC engines. the valve spindle is pressed against its seat and injection now ceases. When referring to this page. which sets off an alarm and activates the puncture valve in order to stop the fuel oil flow from the pertaining pump. Fitted within the valve housing is a nonreturn valve and a spindle and spindle guide with a pressure spring.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W 5098MC: Alternatively to the common drain tank. the air passes through the charging air pipe to the charging air cooler where the air is cooled down. Then the circulating bore is uncov ered. the turbine wheel drives the compressor wheel. 910 Turbocharger System Air System The engine is supplied with scavenge air from one or more turbochargers. the valve parts are tightened together by the pressure from the securing nuts. On completion of the fuel pump’s delivery stroke. The charging air pipe. automatic activation of the lifting gear by the dia phragm valve can be arranged in order to stop the fuel oil flow from the per taining pump. When the pressure has reached the predetermined opening value for the fuel valve. From the compressor outlet. leaving through a circulation bore and the return oil pipe on the valve head. which are provided with pneumatically operated fuel pump roller guide lifting gear. the spindle will be lifted and oil injected through the nozzle into the en gine cylinder. the circulating bores is closed. The engine exhaust gas drives the turbine wheel of the turbocharger and. When the pressure at the beginning of the fuel pump’s delivery stroke has reached the predetermined pressure. The compressor draws air from the engine room. through the air filters. The fuel oil passes through the fuel valve. de pending on the engine type and layout. The spindle may be provided with a cutoff slide. please quote Description A90030 Edition 0009 Page 17 (23) . and a nozzle. the drain pipes on 5098MC engines can be connected to a diaphragm valve. with compensator. 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.

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

The nonreturn valves fitted after the water mist catcher are now closed as a result of partial vacuum and gravitation acting on the valve flaps. or because the switch for the blowers is not in “AUTO” position). NonReturn Valves It is of the utmost importance that the nonreturn valves of the auxiliary blow ers always function correctly and move easily. If an auxiliary blower fails to start. The nonreturn valve of the blower that has not yet started must be in the closed position to prevent the blower from rotating backwards.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Warning! If the auxiliary blowers do not start during lowload running (because of faults. they draw air from the engine room through the turbocharger’s air filter and compressor side. Oth erwise. The nonreturn valves protect the blowers and engine during: • Startup of the auxiliary blowers • Running with auxiliary blowers. i. or via locally placed inspection covers. Owing to the relatively high starting current. the operating blower will not be able to draw fresh air in through the turbocharger and air cooler. with 610 seconds in between. When the auxiliary blowers are operating. Starting the auxiliary blowers: 1.e. 2. the blowers start in se quence. There will be a lack of air supply if the nonreturn valves do not close. This will involve the risk of a scavenge air box fire. unburned fuel oil may accumulate on top of the pistons. the nonreturn valve must be in the closed position. there is a risk that the electric motor will burn out when it starts. please quote Description A90030 Edition 0009 Page 19 (23) . 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 reestablish 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. When referring to this page. Otherwise. This can be checked either by moving the valves manually in connection with the regular scavenge port in spections. This is due to differences in the air flow resistance.: – remote control – control from engine side control console.

Caution! It is important to check that the drain functions correctly. Inside the exhaust gas receiver. When referring to this page. The cooler is designed with an air reversing chamber which incorporates a wa ter mist catcher. ‘Cleaning of Turbochargers and Air Coolers’. The separated water is collected in the bottom of the cooler housing from which it is removed by a drain system. An alarm device for high water level in the drain system is installed. Com pensators are inserted between the receiver and the exhaust valves. The water mist catcher is built up of a number of lamellas which separate the condensation water from the scavenge air during the pas sage of the air flow. please quote Description A90030 Edition 0009 . Chapter 706.Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Running with auxiliary blowers: If an auxiliary blower fails during running. 911 Safety Equipment Safety Valves. See Volume I Operation. Item 2. Exhaust Gas Receiver From the exhaust valves. It is mounted in a housing which is welded up of steel plates. The exhaust gas receiver is fastened to the seating by flexible supports. and be tween the receiver and the turbocharger. Cylinder Cover Page 20 (23) Each cylinder cover is provided with a springloaded safety valve which is set to open at a pressure somewhat higher than the maximum firing pressure in the cylinder. The exhaust gas receiver and the exhaust pipe are insulated. the nonreturn valve must close to ensure the continued supply of fresh air to the engine. Charging Air Cooler The charging air cooler insert is of the block type. above. as otherwise water droplets may enter the cylinders. See ‘Starting the auxil iary blowers‘. the exhaust gas is led to the exhaust gas receiver where the pulsatory pressure from the individual exhaust valves is equalized and led to the turbocharger at a constant pressure. a protective grating is mounted before the tur bocharger. The cooler housing is provided with inspection covers.

OPERATION. • detect oil mist in the crankcase using an ‘Oil Mist Detector’. please quote Description A90030 Edition 0009 Page 21 (23) .Engine Types 35-98MC/MC-C A90030-0009 MAN B&W Relief Valves On the exhaust side of the engine a number of springloaded relief valves are fitted. »Turbocharger Surging«. Warning! Keep the areas around the relief valves free of oil. which will open in the event of excessive pressure in the crankcase/ chain casing. Scavenge Air Receiver The scavenge air receiver is fitted with a safety valve which is set to open should the pressure in the scavenge air receiver exceed a value somewhat higher than the normal scavenge air pressure of the engine. see Volume I. see Volume I. etc. c and d should be considered as prewarnings of a possible increasing oil mist level. Chapter 704. or d) scavenge box fire Alarms b. grease. the complete flame arrester of the relief valves must be replaced. Regarding how to: • avoid evaporation of the lubricating oil in the crankcase. Safety Valve. See also our Service Letter SL97348/ERO. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open. Warning! Do not stand near crankcase doors or relief valves – or in corridors near doors to the engine room casing in the event of an alarm for: a) oil mist b) high lube oil temperature c) no piston cooling oil flow. In some cases it may be necessary to open the valve manually. When referring to this page. for instance as a result of the ignition of oil mist. Note! If there has been a crankcase explosion. Chapter 704.

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

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

.

Cylinder Cover Documents in this Chapter 90101 0175 MAN Diesel A/S Cylinder Cover .901 .

MAN Diesel A/S .

please qoute Plate P90101 Edition 0175 Page 1 (2) MAN B&W .Cylinder Cover Plate P90101-0175 When referring to this page.

018 031 043 055 067 079 080 092 102 114 138 151 163 175 187 209 Page 2 (2) MAN B&W Item Description Screw Protective cap Nut Stud Nut Stud Cylinder cover O-ring Cooling jacket Screw Nut Spring house complete Stud Stud Pipe for fuel valve Guide pin When referring to this page.Cylinder Cover Plate P90101-0175 Item No. please qoute Plate P90101 Edition 0175 .

902 .Piston with Rod & Stuffing Box Documents in this Chapter 90201 90205 0204 0115 MAN Diesel A/S Piston and Piston Rod Piston Rod Stuffing Box .

MAN Diesel A/S .

please qoute Plate P90201 Edition 0204 Page 1 (2) .Piston and Piston Rod MAN B&W Plate P90201-0204 A A When referring to this page.

011 023 035 047 059 060 084 096 106 118 143 155 167 179 180 192 Page 2 (2) MAN B&W Item Description Screw Screw Screw Locking wire Screw Screw Piston ring Piston ring Piston ring Piston crown Pipe for cooling Piston rod D-ring D-ring Piston skirt Screw When referring to this page. please qoute Plate P90201 Edition 0204 .Piston and Piston Rod Plate P90201-0204 Item No.

please qoute Plate P90205 Edition 0115 B Page 1 (2) .Piston Rod Stuffing Box Plate P90205-0115 MAN B&W A A B When referring to this page.

Plate P90205-0115 Item No. complete Spring Spring When referring to this page. please qoute Plate P90205 Edition 0115 . 013 025 037 049 050 062 086 098 121 145 157 169 170 182 204 216 241 253 Page 2 (2) Piston Rod Stuffing Box MAN B&W Item Description Nut Housing for stuffing box Scraper ring Scraper ring Flange Guide pin Screw Spring pin Lamella O-ring Scraper ring Sealing ring Sealing ring Screw Fitted bolt Housing for stuffing box.

Details Cylinder Lubricators Cylinder Lubricator Unit Cylinder Lubricator .Cylinder Lubrication Electronic Components .Rear Side Electronic Components .Details Cylinder Frame .Cylinder Lubrication .903 .Cylinder Lubrication Electronic Components .Intermediate Box Cylinder Lubricator System .Cylinder Liner and Cylinder Lubrication Documents in this Chapter 90301 90302 90304 90305 90307 90308 90309 90310 90312 90312 90312 0182 0185 0037 0134 0035 0012 0021 0013 0002 0003 0004 MAN Diesel A/S Cylinder Frame Cylinder Liner and Cooling Jacket Cylinder Liner .

MAN Diesel A/S .

please qoute Plate P90301 Edition 0182 Page 1 (2) MAN B&W .Cylinder Frame Plate P90301-0182 When referring to this page.

015 027 039 040 052 076 088 123 135 147 196 206 218 255 267 279 280 302 314 326 338 363 387 399 409 422 446 458 471 483 495 505 517 529 542 554 566 578 591 601 613 625 637 Page 2 (2) MAN B&W Item Description Screw Protective cap Nut Stud Sealing ring Nut O-ring Nut Stud Distance pipe Cylinder frame Distance pipe Screw Screw Protective tube Gasket Stud Nut Distance Pipe Bushing Stuffing box housing Screw Screw Fitted stud Fitted stud Fitted stud Fitted stud Screw Screw Screw Fitted stud Stud Nut Stud Screw Screw Rail for sealing Packing Stud Distance pipe Self-locking nut Cleaning cover Sealing ring When referring to this page. please qoute Plate P90301 Edition 0182 .Cylinder Frame Plate P90301-0182 Item No.

please qoute Plate P90302 Edition 0185 Plate P90302-0185 Page 1 (2) .Cylinder Liner and Cooling Jacket MAN B&W When referring to this page.

010 022 034 046 058 071 095 154 178 191 201 213 237 249 Page 2 (2) Cylinder Liner and Cooling Jacket MAN B&W Item Description O-ring Cooling water connection Screw Gasket Clamp Screw Pipe Cylinder liner Pipe Cooling jacket Gasket Piston cleaning ring O-ring O-ring When referring to this page. please qoute Plate P90302 Edition 0185 .Plate P90302-0185 Item No.

please qoute Plate P90304 Edition 0037 Plate P90304-0037 Page 1 (2) .Cylinder Liner .Details MAN B&W When referring to this page.

please qoute Plate P90304 Edition 0037 . complete Head Valve Housing Page 2 (2) When referring to this page.Details MAN B&W Item No.Plate P90304-0037 Cylinder Liner . Item Description 011 023 035 047 Non-return valve.

Cylinder Lubricators MAN B&W When referring to this page. please qoute Plate P90305 Edition 0134 Plate P90305-0134 Page 1 (2) .

Cylinder Lubricators Plate P90305-0134 Item No. please qoute Plate P90305 Edition 0134 . 017 030 054 066 078 091 101 125 137 150 162 186 Page 2 (2) MAN B&W Item Description Screw Steel pipe Screw Bracket Distance pipe Screw Nut Guard Screw Screw Nut Screw When referring to this page.

please qoute Plate P90307 Edition 0035 Plate P90307-0035 Page 1 (2) .Cylinder Lubricator Unit MAN B&W When referring to this page.

complete Housing Plug Plug Screw Note: * Page 2 (2) When referring to this page.Plate P90307-0035 Item No. please qoute Plate P90307 Edition 0035 . tubular Cover O-ring Non-return valve O-ring Cylinder block O-ring Spring Plunger Actuator piston Straight stud coupling Screw Screw Cylinder housing Solenoid valve complete Screw Membrane accumulator Gasket O-ring O-ring Inductive sensor Cable Cable gland. 018 031 043 055 067 080 092 114 138 151 175 199 209 210 234 258 271 283 295 305 317 329 330 342 354 366 378 391 401 413 437 449 450 474 486 498 508 521 533 545 569 570 582 594 Cylinder Lubricator Unit MAN B&W Item Description Ball valve Stud Hydraulic block Nut Plug screw O-ring Intermediate pipe Adjustable elbow coupling Ball valve Stud Lubricator. complete Hydraulic block Gasket Membrane accumulator Screw Adjusting screw O-ring Spacer.

please qoute Plate P90308 Edition 0012 Page 1 (2) .Intermediate Box MAN B&W A Plate P90308-0012 A A-A When referring to this page.

013 037 049 050 074 Page 2 (2) MAN B&W Item Description Intermediate box. please qoute Plate P90308 Edition 0012 . complete Electric enclosure with cables Circuitboard assy Screw Diode When referring to this page.Intermediate Box Plate P90308-0012 Item No.

Details MAN B&W When referring to this page.Cylinder Lubricator System . please qoute Plate P90309 Edition 0021 Plate P90309-0021 Page 1 (2) .

Cylinder Lubricator System . 019 020 032 044 056 068 081 093 103 127 139 152 176 188 211 223 235 Page 2 (2) MAN B&W Item Description Screw Pipe holder Coupling Stud Nut Pipe holder Steel pipe Pipe holder Steel pipe Coupling Connection Steel pipe Distributor block Screw Steel pipe Steel pipe Steel pipe When referring to this page.Details Plate P90309-0021 Item No. please qoute Plate P90309 Edition 0021 .

Cylinder Frame . please qoute Plate P90310 Edition 0013 B-B Page 1 (2) . Cyl. 1 A A B B A-A When referring to this page.Rear Side Plate P90310-0013 MAN B&W Aft C.C.

014 026 038 063 075 087 Page 2 (2) MAN B&W Item Description Nut Distance pipe Stud Nut Distance pipe Stud When referring to this page.Cylinder Frame .Rear Side Plate P90310-0013 Item No. please qoute Plate P90310 Edition 0013 .

please qoute Plate P90312 Edition 0002 Plate P90312-0002 Page 1 (2) .Cylinder Lubrication Electronic Components MAN B&W When referring to this page.

please qoute Plate P90312 Edition 0002 . 027 039 040 052 Page 2 (2) MAN B&W Item Description Enclosure.Cylinder Lubrication Electronic Components Plate P90312-0002 Item No. complete Master control unit Circuit board Backup control unit When referring to this page.

Electronic Components MAN B&W When referring to this page. please quote Plate P90312 Edition 0003 Plate P90312-0003 Page 1 (2) .Cylinder Lubrication .

Plate P90312-0003 Item No.Electronic Components MAN B&W Item Description Item No. 015 027 039 052 064 076 088 111 123 135 147 166 184 206 Page 2 (2) Cylinder Lubrication . please quote Plate P90312 Edition 0003 . Item Description Electronic enclosure. complete Screw Nut Bracket Screw Nut Distance pipe Terminal Terminal Terminal Rail Electronic enclosure Terminal Terminal When referring to this page.

Cylinder Lubrication Electronic Components MAN B&W When referring to this page. please qoute Plate P90312 Edition 0004 Plate P90312-0004 Page 1 (2) .

please qoute Plate P90312 Edition 0004 . 015 027 039 040 052 064 076 088 111 159 160 184 196 206 Page 2 (2) MAN B&W Item Description Name plate Pilot lamp Name plate Selector switch Terminal Terminal Din rail Terminal Terminal HMI panel Mounting plate Nut Screw Terminal When referring to this page.Cylinder Lubrication Electronic Components Plate P90312-0004 Item No.

904 .Crosshead with Connecting Rod Documents in this Chapter 90401 90403 0170 0011 MAN Diesel A/S Connecting Rod and Crosshead Lubricating and Cooling Oil Flow .

MAN Diesel A/S .

please qoute Plate P90401 Edition 0170 Plate P90401-0170 Page 1 (2) .Connecting Rod and Crosshead MAN B&W When referring to this page.

complete Shims * Plug Note: *When ordering. please state thickness of shim. Page 2 (2) When referring to this page. complete Guide screw Crankpin bearing cap Screw Shim* Nut Crosshead bearing cap Self-locking nut Stud Guide pipe Shims* Nut Stud Guide pin Connecting rod Stud Connecting rod.Plate P90401-0170 Item No. please qoute Plate P90401 Edition 0170 . complete Guide strip Screw Thrust piece Crankpin bearing shell. 019 044 056 081 093 103 115 139 140 152 164 176 188 223 247 260 296 306 331 343 355 367 380 392 402 414 426 451 463 487 499 509 510 522 534 546 571 595 Connecting Rod and Crosshead MAN B&W Item Description Screw Nut Screw Outlet pipe Guide shoe Lock washer Stop screw Telescope pipe Distance pipe Bracket Stud Plug Spring pin Throttle plug Crosshead Crosshead bearing shell.

Lubricating and Cooling Oil Flow MAN B&W Diesel When referring to this page. please quote Plate P90403 Edition 0011 Plate P90403-0011 Page 1 (1) .

.

Thrust Bearing and Turning Gear Documents in this Chapter 90501 90503 90504 90505 90510 90511 90512 0164 0025 0014 0117 0125 0049 0002 MAN Diesel A/S Crankshaft Arrangement of Angle Encoder Axial Vibration Monitor Thrust.and Guide Bearing Turning Gear Turning Wheel Turning Gear .Details .Crankshaft.905 .

MAN Diesel A/S .

please qoute Plate P90501 Edition 0164 Plate P90501-0164 Page 1 (2) .Crankshaft MAN B&W When referring to this page.

please qoute Plate P90501 Edition 0164 .Crankshaft Plate P90501-0164 Item No. 012 024 048 061 073 085 097 107 Page 2 (2) MAN B&W Item Description Screw Crankshaft Guard Guard Chain wheel Packing ring Cover Screw When referring to this page.

please qoute Plate P90503 Edition 0025 Plate P90503-0025 Page 1 (2) .Arrangement of Angle Encoder MAN B&W When referring to this page.

Arrangement of Angle Encoder Plate P90503-0025 Item No. 013 025 037 050 062 074 086 098 108 121 133 145 157 170 182 194 204 253 Page 2 (2) MAN B&W Item Description Screw Angle encoder Packing Intermediate box Screw Screw Shaft Housing Coupling Washer Packing Screw Spring lock Shaft Shield. lower part Packing Guide pin Adjustment tool When referring to this page. please qoute Plate P90503 Edition 0025 .

please qoute Plate P90504 Edition 0014 Page 1 (2) .Axial Vibration Monitor Plate P90504-0014 MAN B&W D D C C A A-A A C-C B B-B B When referring to this page.

please qoute Plate P90504 Edition 0014 . 019 020 044 056 081 093 115 139 140 Page 2 (2) MAN B&W Item Description Steel pipe Coupling Bracket Axial vibration monitor Screw Locking wire Male stud complete Pipe holder Screw When referring to this page.Axial Vibration Monitor Plate P90504-0014 Item No.

Thrust. please qoute Plate P90505 Edition 0117 Plate P90505-0117 Page 1 (2) .and Guide Bearing MAN B&W When referring to this page.

and Guide Bearing MAN B&W Item Description Locking wire Screw Lubricating oil pipe Stopper Thrust shoe. upper part Screw Guide pin Scraper ring housing.Plate P90505-0117 Item No. complete When referring to this page. complete Screw Oil throw ring in 2/2 Self-locking nut Lubricating oil pipe Nut Self-locking nut Lubricating oil pipe Segment Segment with sensor pockets Scraper ring housing. please qoute Plate P90505 Edition 0117 . complete Scraper ring housing. complete Screw Fitted bolt Guide screw Scraper ring in 2/2 Nut Scraper ring. 014 026 038 051 063 075 087 099 110 122 146 158 171 183 195 205 217 229 230 242 254 266 291 301 313 325 337 349 362 374 386 398 408 421 433 445 Page 2 (2) Thrust. lower part Nut Screw Screw Lubricating oil pipe Thrust shoe Spray pipe Screw Pipe holder Thrust shoe. complete Spray pipe Oil throw ring.

please qoute Plate P90510 Edition 0125 Plate P90510-0125 Page 1 (2) .Turning Gear MAN B&W When referring to this page.

please qoute Plate P90510 Edition 0125 . 011 023 035 047 059 072 084 096 106 131 143 155 167 192 202 214 226 238 251 263 299 309 310 322 334 346 358 405 417 429 Page 2 (2) MAN B&W Item Description Bracket Bush Screw Spring lock Disc Switch Spring lock Screw Lever 3/2-way valve Screw Spring lock Chain Nut Distance pipe Pin Turning gear Distance pipe Distance pipe Screw Gear wheel Disengaging divice. complete Screw Disc Spring lock Stud Sleeve Key ring Eye screw Circlip When referring to this page.Turning Gear Plate P90510-0125 Item No.

please qoute Plate P90511 Edition 0049 Page 1 (2) MAN B&W .Turning Wheel Plate P90511-0049 When referring to this page.

017 029 030 054 066 078 101 113 125 Page 2 (2) MAN B&W Item Description Guide pin Nut Nut Screw Screw Dead centre pointer Turning wheel Nut Fitted bolt When referring to this page. please qoute Plate P90511 Edition 0049 .Turning Wheel Plate P90511-0049 Item No.

please qoute Plate P90512 Edition 0002 Plate P90512-0002 Page 1 (2) .Turning Gear .Details MAN B&W When referring to this page.

Turning Gear .Details Plate P90512-0002 Item No. please qoute Plate P90512 Edition 0002 . 012 024 048 061 073 097 107 119 132 156 168 181 203 215 227 240 252 264 276 311 323 Page 2 (2) MAN B&W 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 Disc with inicision Stud with groove Circlip Disc with inicision Sleeve Screw Spring washer Lever Bush When referring to this page.

906 .Lower Part .Control Gear Documents in this Chapter 90600 90603 90611 90612 90613 90618 90619 90632 90634 0137 0073 0172 0088 0103 0151 0036 0028 0031 MAN Diesel A/S Arrangement of Chain Drive and Camshaft Chain Tightener Camshaft and Chain Wheel Arrangement of Indicator System Camshaft Bearing Regulating Shaft Load Transmitter Chain Drive Guidebars .Lower Part Chain Drive Lubrication .

MAN Diesel A/S .

Arrangement of Chain Drive and Camshaft MAN B&W When referring to this page. please qoute Plate P90600 Edition 0137 Plate P90600-0137 Page 1 (1) .

.

Chain Tightener Plate P90603-0073 When referring to this page. please qoute Plate P90603 Edition 0073 Page 1 (2) MAN B&W .

please qoute Plate P90603 Edition 0073 . 017 029 042 054 066 078 113 137 149 150 186 208 233 245 270 304 316 328 341 353 365 377 389 Page 2 (2) MAN B&W Item Description Locking wire Screw Flange bearing Bracket Shaft Flange Screw Chain wheel Cup point screw Bearing bush Screw Distance piece Shaft Tightening bolt Shaft Nut Lock washer Guide nut Circlip Guide nut Circlip Bushing Shaft When referring to this page.Chain Tightener Plate P90603-0073 Item No.

Camshaft and Chain Wheel Plate P90611-0172 MAN B&W A A Z Z When referring to this page. please qoute Plate P90611 Edition 0172 Page 1 (2) .

please qoute Plate P90611 Edition 0172 .Camshaft and Chain Wheel Plate P90611-0172 Item No. 010 022 046 058 071 083 095 105 117 142 166 178 191 201 213 225 237 249 250 274 286 298 321 Page 2 (2) MAN B&W Item Description Camshaft Nut Fitted bolt Coupling flange Camshaft Exhaust cam Fuel cam Indicator cam Coupling flange O-ring Chain wheel Camshaft Indicator cam Nut Indicator cam Screw Protective cap Chain wheel Thrust disc Gear wheel Flange screw Locking wire Disc When referring to this page.

Arrangement of Indicator System MAN B&W Plate P90612-0088 A B C A B C When referring to this page. please qoute Plate P90612 Edition 0088 Page 1 (2) .

please qoute Plate P90612 Edition 0088 . 016 028 041 053 077 089 100 124 136 148 161 173 185 197 207 219 220 232 244 268 281 293 303 315 327 339 340 352 364 Page 2 (2) MAN B&W Item Description Spring pin Liner Spring Packing Packing Connecting piece Circlip Stud Self-locking nut Extension Packing Flange Screw Indicator valve Screw Washer Extension Liner Circlip Handle Screw Roller guide Liner Cup point screw Key Screw Housing Needle bearing Shaft When referring to this page.Arrangement of Indicator System Plate P90612-0088 Item No.

please qoute Plate P90613 Edition 0103 Plate P90613-0103 Page 1 (2) .Camshaft Bearing MAN B&W When referring to this page.

complete Nut Gasket Cover Screw Gasket Cover Screw Washer Oil pan Screw Cover Screw Rubber cord Oil pan When referring to this page. 011 023 035 047 059 060 096 106 131 143 155 167 180 192 202 214 238 251 263 275 287 309 310 322 334 346 371 383 405 417 430 Page 2 (2) MAN B&W Item Description Screw End cover "Fore" Gasket Gasket Rubber cord Nut Bolt for camshaft bearing Housing Bearing shell in 2/2 Guide screw Bearing cap Cover Fitted bolt Screw Screw Screw End cover "Aft".Camshaft Bearing Plate P90613-0103 Item No. please qoute Plate P90613 Edition 0103 .

please qoute Plate P90618 Edition 0151 Plate P90618-0151 Page 1 (2) .Regulating Shaft MAN B&W When referring to this page.

complete Resilient arm. complete Screw Arm holder Pin Circlip Nut Spring Washer Fitted bolt Circlip Pin Self-locking nut Movable arm Shim Shaft Screw Washer Screw Bracket Bearing housing Ball bearing Spring pin Bracket Nut Washer Fitted bolt Screw Key Nut Lever Self-locking nut Guide pin Bearing housing When referring to this page. please qoute Plate P90618 Edition 0151 . 019 020 032 044 056 068 093 103 127 139 140 164 176 211 223 235 247 259 272 284 296 306 331 343 355 367 380 392 402 414 438 451 463 475 487 499 509 522 546 558 583 595 605 629 Page 2 (2) MAN B&W Item Description Sleeve coupling. complete Screw Spring washer Sleeve coupling Nut Key Regulating shaft Regulating shaft Circlip Pin Pull rod.Regulating Shaft Plate P90618-0151 Item No.

please qoute Plate P90619 Edition 0036 Plate P90619-0036 Page 1 (2) .Load Transmitter MAN B&W When referring to this page.

014 038 051 063 087 109 110 122 134 146 171 195 205 229 230 242 266 278 291 313 325 349 362 374 386 408 421 Page 2 (2) MAN B&W Item Description Screw Cover Washer Self-locking nut Screw Nut Pull rod Ball joint Fork head Screw Nut Space tubular Screw Screw Disc Clamping arm Shim Pipe clamp Potentiometer Self-locking nut Screw Washer Bracket Washer Nut Self-locking nut Washer When referring to this page.Load Transmitter Plate P90619-0036 Item No. please qoute Plate P90619 Edition 0036 .

please qoute Plate P90632 Edition 0028 Plate P90632-0028 Page 1 (2) .Chain Drive Guidebars .Lower Part MAN B&W When referring to this page.

Lower Part MAN B&W Item Description Locking wire Disc Screw Guidebar Screw Beam for guidebar Screw Screw Beam for guidebar Bracket for guideway Bracket for guideway Screw Guidebar Screw Beam for guidebar Screw Bracket for guideway Beam for guidebar Guidebar Screw When referring to this page. please qoute Plate P90632 Edition 0028 . 015 027 039 040 052 064 076 088 111 123 135 159 160 172 184 206 218 231 243 255 Page 2 (2) Chain Drive Guidebars .Plate P90632-0028 Item No.

please qoute Plate P90634 Edition 0031 Plate P90634-0031 Page 1 (2) .Lower Part MAN B&W When referring to this page.Chain Drive Lubrication .

Lower Part Plate P90634-0031 Item No. 016 041 065 077 090 100 124 136 148 173 185 207 220 244 268 281 Page 2 (2) MAN B&W Item Description Spray pipe Lubricating pipe Spray pipe Lubricating pipe Spray pipe Spray pipe Spray pipe Spray pipe Lubricating pipe Lubricating pipe Lubricating pipe Spray pipe Spray pipe Spray pipe Lubricating pipe Lubricating pipe When referring to this page. please qoute Plate P90634 Edition 0031 .Chain Drive Lubrication .

907 .Starting Air System Documents in this Chapter 90702 90703 90704 0070 0120 0059 MAN Diesel A/S Main Starting Valve Starting Air Distributor Starting Valve .

MAN Diesel A/S .

Main Starting Valve MAN B&W When referring to this page. please qoute Plate P90702 Edition 0070 Plate P90702-0070 Page 1 (2) .

"slow turning" Repair kit. low Ball valve with actuator* Screw Packing ring Disc Housing Screw Screw Stud Starting air pipe Housing Non-return valve Nut Adjusting screw. slow turning* Repair kit. please qoute Plate P90702 Edition 0070 .Main Starting Valve Plate P90702-0070 Item No. slow turning* Repair kit. slow turning* When referring to this page. slave actuator. 015 027 039 052 064 076 111 123 135 147 159 172 184 196 206 231 243 267 279 280 292 302 326 338 351 363 375 387 399 409 410 422 434 446 458 471 483 495 505 517 529 530 542 900 924 936 948 Page 2 (2) MAN B&W Item Description Screw Switch Distance pipe Screw Plate Ball valve with actuator* Plug screw Packing ring Packing ring Plug screw Intermediate piece Nut Washer Handwheel Locking plate Spring Spindle Nut Screw Nut Starting air pipe Packing ring Screw Washer Guide pin Sundry chain Split pin Key ring Screw Nut. slave ball valve. main ball valve. main actuator. slow turning* Repair kit.

please qoute Plate P90703 Edition 0120 Plate P90703-0120 Page 1 (2) .Starting Air Distributor MAN B&W When referring to this page.

please qoute Plate P90703 Edition 0120 . Page 2 (2) When referring to this page.Starting Air Distributor Plate P90703-0120 Item No. 010 022 034 046 058 083 095 105 117 129 130 154 166 191 201 225 237 249 262 274 286 298 308 333 345 357 370 382 394 404 416 428 441 490 500 MAN B&W Item Description Screw Packing Screw Name plate Bracket Fitted bolt Self-locking nut Air cylinder Spring pin Screw 3/2-way valve Stud Nut Guide pin Guide pin Gear wheel Lock washer Nut Bushing Spring pin Key Screw Bracket Distributor housing* Shaft Sealing ring Reversing disc* Sealing ring Distributor disc Piston ring Cover Fitted bolt Washer Adaptor Coupling Note: * When ordering spare parts. please state number of cylinders.

please qoute Plate P90704 Edition 0059 Plate P90704-0059 Page 1 (2) .Starting Valve MAN B&W When referring to this page.

Starting Valve Plate P90704-0059 Item No. please qoute Plate P90704 Edition 0059 . 016 028 041 053 077 089 090 100 112 124 136 Page 2 (2) MAN B&W Item Description Screw Cover Gasket Self-locking nut Piston Spring Distance pipe Liner Valve housing Sealing ring Valve spindle When referring to this page.

908 .Actuator Exhaust Valve .Exhaust Valve Documents in this Chapter 90801 90803 90804 90805 90806 90810 90812 0206 0040 0016 0144 0098 0090 0003 MAN Diesel A/S Exhaust Valve .Upper Parts Exhaust Valve Upper Parts .Lower Parts Exhaust Valve .Pipe System Arrangement of Cooling Water Pipes Arrangement of Drain Pipes Freshwater .Details Exhaust Valve .

MAN Diesel A/S .

Lower Parts Plate P90801-0206 MAN B&W A A B B When referring to this page.Exhaust Valve . please qoute Plate P90801 Edition 0206 Page 1 (2) .

Lower Parts Plate P90801-0206 Item No. 013 025 037 062 074 098 108 121 133 157 194 204 228 241 253 265 277 289 300 324 336 Page 2 (2) MAN B&W Item Description Packing Covers Screw Packing Flange Screw O-ring Bottom piece Sealing ring Valve spindle Valve housing Spindle guide lower Packing Plug screw Spring pin Screw Sealing ring Sealing ring Tread insert Packing Plug screw When referring to this page.Exhaust Valve . please qoute Plate P90801 Edition 0206 .

Exhaust Valve .Upper Parts Plate P90803-0040 MAN B&W B B B A A B C A A C D E D E When referring to this page. please qoute Plate P90803 Edition 0040 Page 1 (2) .

Exhaust Valve . complete Flange Sliding bearing Sealing ring Oil control unit Screw Pin Steel pipe Union nut Adapter Packing ring O-ring Spring Disc Spring pin Rotation check rod Non-return valve Locking wire Screw Conical ring 2/2 Piston Slide Piston Spring Disc Piston. complete Piston ring When referring to this page. air cylinder Sealing ring Coupling Disc Locking plate Screw Screw Packing Oil cylinder Plug Stud Nut Non-return valve Plug Plug Sealing ring Air cylinder.Upper Parts Plate P90803-0040 Item No. please qoute Plate P90803 Edition 0040 . 014 026 038 063 087 099 110 134 158 183 205 217 229 230 242 254 266 278 291 301 313 325 337 349 362 374 386 408 421 433 445 457 469 470 482 494 504 516 528 541 553 565 577 590 600 612 624 636 648 661 Page 2 (2) MAN B&W Item Description Lifting eye bolt Plate Coupling Steel pipe Orifice plug Disc Safety handrail Piston.

Details MAN B&W When referring to this page.Exhaust Valve . please qoute Plate P90804 Edition 0016 Plate P90804-0016 Page 1 (2) .Upper Parts.

021 045 905 MAN B&W Item Description Gasket Safty valve.Upper Parts. please qoute Plate P90804 Edition 0016 . Details Plate P90804-0016 Item No. with o-ring O-ring* Note: * Optional extras Page 2 (2) When referring to this page.Exhaust Valve .

Actuator MAN B&W When referring to this page.Exhaust Valve . please qoute Plate P90805 Edition 0144 Plate P90805-0144 Page 1 (2) .

Actuator Plate P90805-0144 Item No. please qoute Plate P90805 Edition 0144 .Exhaust Valve . complete Thrust disc Roller guide Shaftpin for roller Plug Screw Bushing Disc Bushing for roller guide Cylindrical pin Screw Bushing Piston ring Disc Screw Disc Spring Cylindrical pin Roller Guide block When referring to this page. 015 027 039 040 052 064 076 088 111 123 147 159 160 184 196 206 218 255 267 279 280 292 314 326 338 Page 2 (2) MAN B&W Item Description Nut Oil cylinder Stud Stud Piston Roller guide.

please qoute Plate P90806 Edition 0098 Page 1 (2) .Pipe System Plate P90806-0098 MAN B&W C A C A B D B D When referring to this page.Exhaust Valve .

Plate P90806-0098 Item No. please qoute Plate P90806 Edition 0098 . 010 022 046 058 071 083 105 117 129 130 154 178 201 225 249 250 262 274 286 308 321 Page 2 (2) Exhaust Valve .Pipe System MAN B&W Item Description Sealing ring Disc Clamp Nut Screw Support Thrust bushing Screw Pipe Hose. complete Coupling Drain pipe Coupling Hydraulic pipe. complete Packing Flange Sealing ring Screw Cooling water connection Packing Plug screw When referring to this page.

please qoute Plate P90810 Edition 0090 Plate P90810-0090 Page 1 (2) .Arrangement of Cooling Water Pipes MAN B&W When referring to this page.

012 024 048 061 073 085 097 107 119 120 132 144 156 181 193 203 215 239 240 252 264 276 288 323 Page 2 (2) MAN B&W Item Description Screw Butterfly valve Plug Outlet pipe Screw Packing Nut Compensator Orifice plate Outlet pipe Nut Packing Packing Ball valve Screw Screw Outlet pipe Outlet pipe Screw Packing Inlet pipe Screw Screw Packing When referring to this page. please qoute Plate P90810 Edition 0090 .Arrangement of Cooling Water Pipes Plate P90810-0090 Item No.

please qoute Plate P90812 Edition 0003 Plate P90812-0003 Page 1 (2) .Arrangement of Drain Water Pipes MAN B&W When referring to this page.

013 025 037 Page 2 (2) MAN B&W Item Description Straight valve Drain pipe Drain pipe When referring to this page.Arrangement of Drain Water Pipes Plate P90812-0003 Item No. please qoute Plate P90812 Edition 0003 .

Fuel Oil System Documents in this Chapter 90901 90902 90903 90904 90905 90910 90911 90913 90914 90914 90915 90915 90915 0177 0171 0021 0059 0025 0139 0017 0124 0099 0101 0060 0074 0075 MAN Diesel A/S Fuel Pump Fuel Pump Gear Fuel Pump Gear .Details Fuel Oil System .Details Fuel Pump .Details .909 .Details Reversing Mechanism Fuel Valve Fuel Valve Function High-Pressure Pipes Fuel Oil System Fuel Oil System Fuel Oil System .Details Fuel Oil System .

MAN Diesel A/S .

Fuel Pump MAN B&W When referring to this page. please qoute Plate P90901 Edition 0177 Plate P90901-0177 Page 1 (2) .

complete Plunger Sealing ring Screw Lock washer Cover Sealing ring Sealing ring Puncture valve. 784 867 879 880 892 902 914 926 Item Description Gasket Protective cap Coupling Pipe Banjo coupling Plug screw Disc Pipe When referring to this page. complete Slide Thrust piece Sealing ring Sealing ring Pump barrel Pump barrel. complete Guide bushing Screw Screw Top cover Lock washer Plug screw Orifice plate Nut Screw Spring guide Spring Suction valve.Fuel Pump Plate P90901-0177 Item No. complete Timing guide Sleeve Regulating guide Guide pin Screw Stud Gasket Guide screw Guide pin Guide pin Guide bushing. please qoute Plate P90901 Edition 0177 . complete Air piston Gasket Valve housing O-ring Slide Spring Spring guide Throttle plug Item No. 017 030 042 054 078 101 113 125 137 149 162 174 186 198 208 221 233 257 269 270 282 294 341 389 390 400 412 436 448 461 473 520 532 544 556 568 603 615 627 639 640 652 664 676 688 711 723 735 747 772 Page 2 (2) MAN B&W Item Description Gasket Cylindrical pin Gasket Plug screw Pump housing.

Fuel Pump Gear Plate P90902-0171 When referring to this page. please qoute Plate P90902 Edition 0171 Page 1 (2) MAN B&W .

717 730 742 766 791 Item Description Screw Screw Screw Locking wire Plug When referring to this page.Fuel Pump Gear Plate P90902-0171 Item No. please qoute Plate P90902 Edition 0171 . 012 024 036 048 061 073 085 097 107 119 120 144 156 181 193 215 227 240 252 264 276 288 311 323 347 359 360 372 384 396 418 431 443 455 467 479 492 514 526 538 551 563 587 599 609 622 646 671 683 695 Page 2 (2) MAN B&W Item Description Fuel pump roller guide Shaft Needle bearing Pin Screw Roller Bushing Dics Shaft Plug Dowel pin Plate Roller Guide Bushing Pin Link for reversing Pin Pin Guide block Screw Pin Bushing roller guide Screw Name plate Nut Bushing roller guide Sealing ring Cap Self locking nut Screw Scraper ring Scraper ring Retaining flange Holder for scraper ring Locking wire Screw Nut Pump base Packing Cover Packing Screw Spring seat disk Stud Stud Spring Spring seat disk Flange Screw Sealing bush Item No.

please qoute Plate P90903 Edition 0021 Plate P90903-0021 Page 1 (2) .Details MAN B&W When referring to this page.Fuel Pump Gear .

Fuel Pump Gear . 018 031 043 055 067 079 080 092 114 126 138 151 Page 2 (2) MAN B&W Item Description Lifting tool Sealing ring Spring Nut Locking plate Crosspiece Bolt Guide pin Screw Screw Guide plate Guide pin When referring to this page. please qoute Plate P90903 Edition 0021 .Details Plate P90903-0021 Item No.

please qoute Plate P90904 Edition 0059 Plate P90904-0059 Page 1 (2) .Details MAN B&W When referring to this page.Fuel Pump .

please qoute Plate P90904 Edition 0059 . regulation Packing Union Pointer Toothed bar.Fuel Pump . 013 025 037 049 050 062 074 086 108 121 133 157 169 170 182 194 216 228 241 253 265 277 Page 2 (2) MAN B&W Item Description Plug Nut Washer Bracket Screw Actuator Coupling Screw Guide screw Toothed bar. timing Nut Forked lever Retaining ring Shaft Forked lever Forked lever Adjusting screw Nut When referring to this page.Details Plate P90904-0059 Item No.

please qoute Plate P90905 Edition 0025 Plate P90905-0025 Page 1 (2) .Reversing Mechanism MAN B&W When referring to this page.

please qoute Plate P90905 Edition 0025 . complete Screw Bush Air cylinder Screw Union Reducing socket Ball valve Union When referring to this page.Plate P90905-0025 Item No. 019 020 032 044 056 068 093 103 115 127 139 152 164 176 211 223 235 247 259 Page 2 (2) Reversing Mechanism MAN B&W Item Description Shaft Guide for reversing Distance pipe Self-locking nut Guard Screw Cover Screw Bolt Flange for air cylinder Reversing mechanism.

please qoute Plate P90910 Edition 0139 Plate P90910-0139 Page 1 (2) .Fuel Valve MAN B&W When referring to this page.

016 041 053 065 077 089 090 100 112 124 148 161 173 185 197 219 220 232 244 950 MAN B&W Item Description Thrust piece Cut-off shaft Spindle guide Fuel nozzle Spindle guide O-ring Holder. fuel nozzle Guide pin Union O-ring O-ring Head Guide pin Spring Non-return valve Thrust spindle Spring Spring guide Foot Disc* Note: * Optional extras Page 2 (2) When referring to this page. please qoute Plate P90910 Edition 0139 .Fuel Valve Plate P90910-0139 Item No.

Fuel Valve Function MAN B&W When referring to this page. please qoute Plate P90911 Edition 0017 Plate P90911-0017 Page 1 (1) .

.

High-Pressure Pipes MAN B&W When referring to this page. please qoute Plate P90913 Edition 0124 Plate P90913-0124 Page 1 (2) .

012 024 036 048 061 073 097 107 119 132 156 181 193 203 215 227 239 240 252 264 Page 2 (2) MAN B&W Item Description High-pressure pipe. L=400 Housing Flange Screw Elbow coupling Tee-coupling Guide pin Screw Flange When referring to this page.High-Pressure Pipes Plate P90913-0124 Item No. complete O-ring Union nipple O-ring High-pressure pipe. complete High-pressure pipe Pipe. complete Union nipple Thrust bushing Union nut High-pressure pipe Flexible hose. please qoute Plate P90913 Edition 0124 .

please qoute Plate P90914 Edition 0099 Page 1 (2) MAN B&W .Fuel Oil System Plate P90914-0099 When referring to this page.

outlet Non-return valve Fuel oil pipe. inlet Packing ring Screw Nut When referring to this page. 018 031 043 067 079 080 092 102 126 138 151 163 Page 2 (2) MAN B&W Item Description Fuel oil pipe.Fuel Oil System Plate P90914-0099 Item No. inlet Plug screw Ball valve Fuel oil pipe. please qoute Plate P90914 Edition 0099 . outlet Packing Screw Fuel oil pipe.

Fuel Oil System Plate P90914-0101 When referring to this page. please qoute Plate P90914 Edition 0101 Page 1 (2) MAN B&W .

please qoute Plate P90914 Edition 0101 . 018 043 055 067 080 092 114 126 151 Page 2 (2) MAN B&W Item Description Fuel oil pipe Stud. complete Distributor piece Screw Screw Drain pipe Steel pipe Coupling Steel pipe When referring to this page.Fuel Oil System Plate P90914-0101 Item No.

please qoute Plate P90915 Edition 0060 Plate P90915-0060 Page 1 (2) .Details MAN B&W When referring to this page.Fuel Oil System .

please qoute Plate P90915 Edition 0060 .Fuel Oil System . 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) MAN B&W Item Description By-pass valve.Details Plate P90915-0060 Item No.

Fuel Oil System .Details MAN B&W When referring to this page. please qoute Plate P90915 Edition 0074 Plate P90915-0074 Page 1 (2) .

Plate P90915-0074 Item No. please qoute Plate P90915 Edition 0074 .Details MAN B&W Item Description Shock absorber. 013 037 049 050 062 074 086 098 108 121 133 145 157 169 170 182 Page 2 (2) Fuel Oil System . complete Spring guide Stud Nut Lock washer Packing Sealing ring Wearing ring Packing Screw Spring Flange Stud Spring Piston Housing When referring to this page.

Fuel Oil System . please qoute Plate P90915 Edition 0075 Plate P90915-0075 Page 1 (2) .Details MAN B&W When referring to this page.

please qoute Plate P90915 Edition 0075 .Fuel Oil System . 013 037 049 050 062 074 Page 2 (2) MAN B&W Item Description Drain box. complete Level switch Name plate Screw Gasket Drain box When referring to this page.Details Plate P90915-0075 Item No.

Details Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Air Cooler System .Cleaning Arrangement of Non-Return Valve Arrangement of Non-Return Valve .Turbocharger System Documents in this Chapter 91000 91001 91002 91003 91004 91005 91006 91007 91009 91011 91011 0012 0134 0149 0235 0069 0136 0044 0007 0041 0019 0029 MAN Diesel A/S Gas and Air System Scavenge Air Receiver Arrangement of Charging Air Pipe Exhaust Pipes and Receiver Exhaust Receiver .910 .

MAN Diesel A/S .

please qoute Plate P91000 Edition 0012 Plate P91000-0012 Page 1 (1) .Gas and Air System MAN B&W When referring to this page.

.

please qoute Plate P91001 Edition 0134 Page 1 (2) .Scavenge Air Receiver Plate P91001-0134 MAN B&W A A When referring to this page.

Scavenge Air Receiver Plate P91001-0134 Item No. please qoute Plate P91001 Edition 0134 . 017 029 030 042 066 091 101 137 150 162 186 198 Page 2 (2) MAN B&W Item Description Cover Packing Screw Cover Screw Screw Nut Scavenge air reciever Screw Packing Distance pipe Screw When referring to this page.

please quote Plate P91002 Edition 0149 Plate P91002-0149 Page 1 (2) .Arrangement of Charging Air Pipe MAN B&W When referring to this page.

Arrangement of Charging Air Pipe Plate P91002-0149 Item No. please quote Plate P91002 Edition 0149 . Item Description Compensator Plug screw Packing Charging air pipe Flange Nut Washer Screw Plug screw Screw When referring to this page. 012 024 036 048 061 085 097 107 119 120 Page 2 (2) MAN B&W Item Description Item No.

Exhaust Pipes and Receiver MAN B&W When referring to this page. please quote Plate P91003 Edition 0235 Plate P91003-0235 Page 1 (2) .

Plate P91003-0235 Item No. Item Description Wing nut Steel bar Steel bar Stud Packing Screw Nut Screw Packing Plug screw Packing Exhaust receiver Wire gauze Grid Clamp with lock. complete Compensator Special nut Guide pin Clamp Disc Screw Nut Locking plate Locking device Support Compensator Spring pin Screw Pipe-exhaust valve Screw Nut Screw Screw Nut Washer When referring to this page. please quote Plate P91003 Edition 0235 . 018 031 043 055 067 079 080 092 102 138 151 163 187 199 209 210 222 234 246 258 271 283 295 305 317 329 342 366 378 391 401 425 437 449 450 Page 2 (2) Exhaust Pipes and Receiver MAN B&W Item Description Item No.

please qoute Plate P91004 Edition 0069 Plate P91004-0069 Page 1 (2) .Exhaust Receiver .Details MAN B&W When referring to this page.

please qoute Plate P91004 Edition 0069 .Exhaust Receiver .Details Plate P91004-0069 Item No. 013 025 037 049 050 062 074 086 108 121 133 157 169 182 194 204 216 228 253 277 289 300 312 324 336 348 373 385 420 432 444 456 Page 2 (2) MAN B&W Item Description Nut Clamp Support Nut Washer Nut Distance pipe Screw Screw Distance pipe Spring pin Spring pin Screw Nut Distance pipe Shim Nut Clamp Screw Spring pin Washer Screw Nut Distance pipe Screw Support Clamp Support Nut Washer Spring pin Screw When referring to this page.

Air Cooler MAN B&W When referring to this page. please qoute Plate P91005 Edition 0136 Plate P91005-0136 Page 1 (2) .

Page 2 (2) When referring to this page. please state manufacturer's Part No. please qoute Plate P91005 Edition 0136 .Air Cooler Plate P91005-0136 Item No. 019 020 032 044 056 068 081 093 103 115 140 152 164 176 211 223 247 259 260 284 296 306 331 343 355 367 380 392 MAN B&W Item Description Cooler insert Steel bar Sealing plate O-ring Air cooler housing Screw Screw Support Spring pin Cover Cross member Stud Washer Nut Screw Steel bar Locking plate Hinge O-ring Distance pipe Steel bar Sealing plate Screw Distance pipe Cover Screw Water mist catcher Cover Note: * When ordering Spare Parts for this item.

please qoute Plate P91006 Edition 0044 Plate P91006-0044 Page 1 (2) .Arrangement of Auxiliary Blower MAN B&W When referring to this page.

Arrangement of Auxiliary Blower Plate P91006-0044 Item No. please qoute Plate P91006 Edition 0044 . 014 026 038 051 Page 2 (2) MAN B&W Item Description Screw Nut O-ring Auxiliaru blower When referring to this page.

please qoute Plate P91007 Edition 0007 Page 1 (2) MAN B&W .Butterfly Valve Plate P91007-0007 When referring to this page.

Butterfly Valve Plate P91007-0007 Item No. please qoute Plate P91007 Edition 0007 . 021 033 045 057 070 082 094 116 128 Page 2 (2) MAN B&W Item Description Nut Locking plate Locking device Pin Valve housing Screw Spring lock Shaft Valve flap When referring to this page.

please qoute Plate P91009 Edition 0041 Page 1 (2) .Air Cooler System .Cleaning Plate P91009-0041 MAN B&W A A B B A-A When referring to this page.

010 022 046 071 083 095 105 117 130 154 166 178 201 213 225 249 250 262 274 298 308 333 345 357 370 382 394 416 441 453 465 489 490 500 512 536 561 585 607 619 620 644 656 Page 2 (2) MAN B&W Item Description Cleaning pipe Cleaning pipe Cleaning pipe Nut Stud Stud Nut Packing Main pipe-cleaning Guide-cleaning pipe Cleaning pipe Guide-cleaning pipe Packing Screw Nut Flange Packing Screw Nut Packing Stud Support Straight valv Straight male stud Packing Screw Nut Main pipe-cleaning Screw Nut Packing Butterfly valv Screw Nut Main pipe-cleaning Main pipe cleaning Straight valv Main pipe-cleaning Main pipe-cleaning Drain box.Cleaning Plate P91009-0041 Item No. complete Main pipe-cleaning Orifice plate Screw When referring to this page.Air Cooler System . please qoute Plate P91009 Edition 0041 .

please qoute Plate P91011 Edition 0019 Plate P91011-0019 Page 1 (2) .Arrangement of Non-Return Valve MAN B&W When referring to this page.

023 035 047 059 072 096 106 118 143 Page 2 (2) MAN B&W Item Description Shaft Screw Lock washer Support Screw Clamp Spring pin Support Valve flap When referring to this page.Arrangement of Non-Return Valve Plate P91011-0019 Item No. please qoute Plate P91011 Edition 0019 .

please qoute Plate P91011 Edition 0029 Plate P91011-0029 Page 1 (2) .Arrangement of Non-Return Valve MAN B&W When referring to this page.

please qoute Plate P91011 Edition 0029 . 011 023 035 047 060 072 084 106 131 155 167 179 180 192 202 214 226 238 251 263 275 287 299 309 310 322 334 346 358 371 383 Page 2 (2) Arrangement of Non-Return Valve MAN B&W Item Description Suction pipe Clamp Locking plate Nut Screw Screw Locking plate Nut Disc special Body for non-return valve Screw Screw Lock washer Support Clamp Spring pin Valve flap Screw Locking plate Washer Mounting fixture Spring pin Screw Nut Locking plate Washer Support Screw Suction pipe Screw Shaft When referring to this page.Plate P91011-0029 Item No.

Safety Equipment Documents in this Chapter 91101 91102 91103 91104 0037 0028 0016 0069 MAN Diesel A/S Safety Valve .Cylinder Relief Valve Safety Valve .Scavenge Air System Arrangement of Safety Cap .911 .

MAN Diesel A/S .

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

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

When referring to this page.Relief Valve MAN B&W Plate P91102-0028 P. please qoute Plate P91102 Edition 0028 Page 1 (2) .C.D.

C. xxx mm Page 2 (2) When referring to this page.D. 465mm)* Screw* Packing* O-ring* Note: *When ordering. please state manufacturer of Relief Valve and P. please qoute Plate P91102 Edition 0028 . 016 028 030 041 MAN B&W Item Description Relief valve (P.D.C.Relief Valve Plate P91102-0028 Item No.

85 Bar abs. When referring to this page. please qoute Plate P91103 Edition 0016 Page 1 (2) .Scavenge Air System MAN B&W Plate P91103-0016 3.Safety Valve .

011 023 035 047 060 072 084 096 106 131 143 Page 2 (2) MAN B&W Item Description Spindle Washer Spring retainer Spring Valve flap Screw Nut Split pin Castle nut Seal Valve seat When referring to this page. please qoute Plate P91103 Edition 0016 .Safety Valve .Scavenge Air System Plate P91103-0016 Item No.

please qoute Plate P91104 Edition 0069 Plate P91104-0069 Page 1 (2) .Arrangement of Safety Cap MAN B&W When referring to this page.

please qoute Plate P91104 Edition 0069 . 017 029 030 042 054 066 078 091 101 125 137 149 150 162 174 221 233 257 270 Page 2 (2) MAN B&W Item Description Gasket Bursting cap Check plate Screw Perforated cylinder Starting air pipe Screw Nut Screw Screw Protective guard Wing nut Washer Stud Bursting disc Nut Screw Washer Bursting cap. complete When referring to this page.Arrangement of Safety Cap Plate P91104-0069 Item No.

Assembly of Large Parts Documents in this Chapter 91201 91203 91205 91206 91207 91210 91211 91216 0094 0015 0194 0122 0101 0181 0091 0008 MAN Diesel A/S Arrangement of Stay Bolts Frame Box .Details Frame Box End Shields Arrangement of Piston Cooling Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) .912 .

MAN Diesel A/S .

please qoute Plate P91201 Edition 0094 Plate P91201-0094 Page 1 (2) .Arrangment of Stay Bolt MAN B&W When referring to this page.

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

please qoute Plate P91203 Edition 0015 Page 1 (2) .Details Plate P91203-0015 MAN B&W A B A C D C D B A-A B-B C-C D-D When referring to this page.Frame Box .

015 027 040 052 076 088 111 Page 2 (2) MAN B&W Item Description Distance pipe Screw Nut Disc Distance pipe Distance pipe Fitted stud When referring to this page. please qoute Plate P91203 Edition 0015 .Details Plate P91203-0015 Item No.Frame Box .

Frame Box Plate P91205-0194 MAN B&W Front side Fore end A A Rear side When referring to this page. please qoute Plate P91205 Edition 0194 Aft end Page 1 (2) .

please qoute Plate P91205 Edition 0194 .Frame Box Plate P91205-0194 Item No. 016 028 053 065 077 089 100 124 136 148 173 185 197 219 220 244 256 281 293 303 315 339 340 364 388 423 447 460 472 496 506 518 543 567 579 Page 2 (2) MAN B&W Item Description Frame box door Sealing material Wing nut Door fastener Spring Stud Drain pipe Flange Packing Screw Packing Frame door-rear Screw Stud Nut Stud Nut Screw Cleaning cover Packing Washer Screw Cover Frame box Cover Bushing Cover Screw Cover Locking pin Spring Key ring Cover Flange Screw When referring to this page.

please qoute Plate P91206 Edition 0122 Plate P91206-0122 Page 1 (2) .End Shields MAN B&W When referring to this page.

End Shields Plate P91206-0122 Item No. 023 035 047 059 072 084 096 106 131 143 167 179 180 202 226 238 251 275 Page 2 (2) MAN B&W Item Description Screw Plug Plug Screw Nut Stud Cover Gasket Packing Cover Cover Packing Gasket Shield-upper Stud Nut Shield-lower Screw When referring to this page. please qoute Plate P91206 Edition 0122 .

Arrangement of Piston Cooling Plate P91207-0101 MAN B&W B-B B B D A D A A-A When referring to this page. please qoute Plate P91207 Edition 0101 Page 1 (2) .

017 029 030 054 066 078 101 113 137 150 174 186 198 208 233 245 Page 2 (2) Arrangement of Piston Cooling MAN B&W Item Description Locking plate Fitted bolt Nut Bracket Locking plate Screw Plate Screw Drain pipe-piston cooling Sight glass. please qoute Plate P91207 Edition 0101 .Plate P91207-0101 Item No. complete Sight glass Flange Packing Screw Fitted bolts Screw When referring to this page.

please qoute Plate P91210 Edition 0181 Plate P91210-0181 Page 1 (2) .Bedplate MAN B&W When referring to this page.

complete Bearing shell.Bedplate Plate P91210-0181 Item No. please state thickness Page 2 (2) When referring to this page. please qoute Plate P91210 Edition 0181 . 025 049 050 062 074 086 121 133 145 157 169 170 182 194 204 228 241 253 265 277 290 300 324 336 348 361 373 385 397 407 456 468 481 493 503 540 MAN B&W Item Description Lubricating oil pipe Locking wire Screw Shim* Nut Main bearing stud Main bearing cap Screw Main bearing shell. lower Screw Cover plate Pipe holder Lock washer Screw Lubricating oil pipe Screw Lubricating oil pipe Self-locking nut Lubricating oil pipe Locating pin Screw Lock washer Grate Lubricating oil pipe Screw Cover Lubricating oil pipe Lubricating oil pipe Stud Cover Screw Bedplate Note: When ordering. upper Shim* Screw Bearing shell.

Axial Vibration Damper MAN B&W When referring to this page. please qoute Plate P91211 Edition 0091 Plate P91211-0091 Page 1 (2) .

Plate P91211-0091 Item No. complete Damper. please qoute Plate P91211 Edition 0091 . 019 020 032 044 056 068 081 093 103 115 127 139 140 152 164 176 188 211 223 235 247 259 272 284 296 306 Page 2 (2) Axial Vibration Damper MAN B&W Item Description Lubricating oil pipe Lubricating oil pipe Screw Spring Spring Lubricating oil pipe Locking wire Screw Restriction for damper Restriction for damper Restriction for damper Screw Locking wire Guide pin Oil seal in 2/2 Oil seal in 2/2 Restriction for damper Locking wire Nut Nut Stud Stud Axial vibration damper. upper part Guide pin Damper. lower part When referring to this page.

HoldingDown Bolts and End Chock Bolts (Epoxy Chocks) MAN B&W When referring to this page. please qoute Plate P91216 Edition 0008 Plate P91216-0008 Page 1 (2) .

016 028 041 053 077 090 100 112 148 161 173 197 207 219 232 244 256 281 Page 2 (2) HoldingDown Bolts and End Chock Bolts (Epoxy Chocks) MAN B&W Item Description Screw Washer Lock plate Liner for sidechock. starboard side Protecting cap Nut Distance tube Spherical washer Spherical nut Holding down bolt Nut Protecting cap End chock bolt Liner for end chock Spherical washer Spherical washer Nut When referring to this page.Plate P91216-0008 Item No. port side Liner for sidechock. please qoute Plate P91216 Edition 0008 .