Untitled

S42MC, Volume II
908 901 902 903
910 909
913
911 907
904
912 906
905
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)
Checking and Maintenance Schedule,
MAN B&W 2670 MC/MCC Engines
The Checking and Maintenance Schedules indi- Design modifications may necessitate a revision of
cate the intervals at which it is deemed appropri- the instructions, in which case the revised instruc-
ate to inspect the individual components of the tions and changed overhauling intervals, if any, will
engine and to carry out overhauls, if necessary, apply and supersede those originally issued (see
based on the engine condition or a criterion of e.g our Service Letters).
time.
In addition to the checking and overhauling inter-
The stated Regular checks or Service interval vals stated in this schedule, please note that the
are intended primarily as a guide, as differences periodical survey requirements of the classifica-
in the actual service conditions, the quality of the tion society may require additional checks and
fuel oil or lubricating oil, the treatment of cooling reference is made to be carried out. For further
water, etc., will decisively influence the actual information reference is made to the classification
service results, and thus the intervals between society.
necessary overhauling.
The procedures are divided into five categories:
Time-based condition checking marked with a C, under the heading Regular checks or Service
procedures interval, 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 are marked with an O, under the heading Regular checks or
procedures Service interval. Under the heading Refer to (column P), a refer-
ence to additional information is stated.
This procedure number normally refers to one of the above condi-

tion checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.
Time-based overhauling also marked with an O, under the headings Regular checks or
procedures Service interval or Based on observations, are the procedures
where an actual basis for estimation is lacking. It is recommend-
ed, therefore, to carry out these procedures at the overhauling
intervals stated as a basis.
The letters O or C in Based on observations (column B), in-

dicate that special service conditions may make checking or
overhauling necessary beyond the actual standard schedules
indicated.
(continued)
When referring to this page, please quote Maintenance Schedule A90050 Edition 0296 Page 1 of 7
Checking and Maintenance Schedule,
2670 MC/MCC Engines MAN B&W
Initial checking procedures marked with a C, under the heading Check new/overhauled
parts after 500, 1000 and 1500 hours (column H), deal with
initial checks that must be carried out on a new engine, or when
parts have been replaced.
After the three initial checks have been completed, checks need
only be carried out as per heading Regular checks or Service
interval.
When using electronic maintenance planning systems, special

attention should be paid to all initial checking procedures, as
handling of such procedures often can not be done automatically.
Instead such procedures must be handled manually.
Initial adjustment procedures marked with an A, under the heading Check new/overhauled
parts after 500, 1000 and 1500 hours (column H), deal with ini-
tial adjustment that must be carried out on a new engine, or when
parts have been replaced.
After the three initial adjustments have been completed, adjust-

ments need only be carried out as per headings Regular checks
or Service interval.
When using electronic maintenance planning systems, special

attention should be paid to all initial adjustment procedures, as
handling of such procedures often can not be done automatically.
Instead such procedures must be handled manually.
NOTE!
Special attention should be paid to the chain tightener,
which must be adjusted three times (after 500, 1000 and
1500 hours of operation) on a new engine, or when chains
or chain wheels have been replaced.
Page 2 of 7 When referring to this page, please quote Maintenance Schedule A90050 Edition 0296
MAN B&W Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 9001
V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to
Regular Checks Service interval (x 1000 hours of operation)
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks
901 Cylinder Cover

1 Cylinder cover C* O * Check whenever exhaust valve
is removed
Indicator cock O
902 Piston with Rod and Stuffing box

1 Piston C,O O
Inspection through scavenge ports C V
2 Piston rod stuffing box C* O
* Check clearances without
dismantling segments
903 Cylinder Liner and Cylinder Lubrication
1 Cylinder liner O
Inspection through scavenge ports C
Measuring wear inside liner C
2 Cylinder lubricators C A V,M
Accumulators (Only for Alpha Lubricator) C O A
904 Crosshead with connecting rod

1 Crosshead bearing C C C,O V Bearings should only be
opened if bearing material
2 Crosshead C C C,O fragments fall out.
3 Reciprocating parts C C,O
4 Crankpin bearing C C C,O V
5 Connecting rod O
905 Crankshaft and Thrust Bearing

2 Main bearing C C C,O V Bearings should only be
opened if bearing material
3 Thrust bearing C C C,O
fragments fall out.
3 Guide bearing C C C,O
4 Journal bearing C C C,O V
5 Axial vibration damper O
Electronic axial vibration monitor (If applied) C
Mechanical checking C
9001 Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W
7 Tacho pickup C,O M

8 Angle encoder (Only for Alpha Lubricator) C,O M
906 Mechanical Control Gear

1 Chains C C R V New or overhauled chain to be
checked/retightened after 500,
2 Chain tightener C,A C,A A 1500 and 4000 hours
Chain wheels, spray nozzles and guide bars C C R
-3 Camshaft C C C,A
-4 Camshaft bearings C C,O
Camshaft coupling, fitted bolts C
-5 Moment compensator C C C,A
Governor O M
Functional check of overspeed device C M
Functional check of speed-setting system C M
(engine with bridge control system)
907 Starting Air System

-1 Starting air distributor C C A
-2 Starting air valve C,O
908 Exhaust Valve

-1 High-pressure pipe O
-2 Exhaust valve
Conventional hard-faced valve seats O
Nimonic / Dura spindle exhaust valves O See also MAN Diesel service
letter SL01-397.
-3 Exhaust valve actuator O
Actuator safety valve C,A
-4 Exhaust valve roller guide C* C’ C O * Only inspection through
camshaft covers
-5 Exhaust valve cam C* C* O
-7 Exhaust valve special running O
MAN B&W Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 9001

909 Fuel Oil System

Fuel oil water content C
-1 Fuel pump settings A,C V
-2 VIT system (If applied) A V
-3 Fuel pump cam A
-4 Fuel pump C O O
-5 Fuel pump top cover O
-6 Fuel pump barrel assembly R
-7 Fuel pump suction valve C,O
-8 Fuel pump puncture valve C,O
-9 Fuel pump shock absorber C O
-9 Fuel system shock absorber C O
-10 Lifting gear for roller guide C O
11 Fuel valve C,O
* HIP compound type nozzles
Fuel nozzle R* R
only. Other types: 8000 hours
12 Spindle guide R R
13 Nonreturn valve O
* Only inspection through
14 Fuel oil highpressure pipes O
camshaft covers
-15 Fuel pump roller guide C* C* C O
16 Fuel pump special running O
910 Turbocharger System Check p and t

Check at every port inspection
1 Air cooler C O V
2 Nonreturn valve (Not for belt-driven aux.blower ) C O
3 Auxiliary blower O
4 Butterfly valves C O
5 Turbocharger turbine C* C C,O V,M
Turbocharger air filter C O
9001 Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W
Protective grid before turbocharger C R V * Only if separate oil system

Turbocharger lubricating oil water content C* M * Check p
6 Water mist catcher C* C,O
911 Safety Equipment

1 Overpressure indicator valve C O
2 Relief valve C O
3 Scavenge air receiver safety valve C O
Functional test of alarm system for thrust
bearing and slow down /shut down system C C M
Checking and adjustment of pressure gauge C A M
Checking and adjustment of thermometers C A M
Checking and adjustment of thermostats C A M
Checking and adjustment of pressurestats C A M
Checking and adjustment of turning gear switch C A M
912 Assembly of Large Parts

2 Holdingdown and end chock bolts C C
3 Stay bolts C C
Top bracings C C
Diaphragm in crankcase oil outlet C R
System lubricating oil water content C M
System lubricating oil bottom tank O Empty and clean tank
Cooling water quality C A V,M
Crankcase C* * Check for loose nuts and
bearing material fragments
913 General Tools

1 Hydraulic tools C O M
General – Safety Precautions 900-2
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.
SAFETY PRECAUTIONS
X Stopped engine
X Shut off starting air supply – At starting air receiver
X Block the main starting valve
X Shut off starting air distributor/distributing system supply
X Shut off safety air supply – Not ME-engines
X Shut off control air supply
X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
When referring to this page, please quote Safety Precaution A90060 Edition 0002 Page 1 (1)
MAN B&W Diesel A/S
900-2 General - Safety Precautions
MAN B&W Diesel
Safety Equipment - Recommendations 1.
In order to perform maintenance in a safe and

correct way, MAN B&W Diesel A/S recommends
use of the following personal safety gear:
1. • Safety shoes.
• Hearing protection.
• Work gloves.
• Protective head wear, such as a baseball
cap with a hard protective liner.
• Safety goggles.
• Fall arrestor equipment.
A90060-0002C01
Safety shoes, hearing protection, work gloves
and protective head wear should be used when
there is a risk of falling objects, loud noises and
sharp edges or oily surfaces.
2.
Use safety goggles when working with com-
pressed air, grinders, hydraulics and when there
is a risk of getting foreign objects in the eyes.
2. We strongly recommend the use of fall

protection harness and arrestor equipment
when working in places on the engine where
there is a risk of falling or slipping.
3. This is especially needed when mount-

ing eyebolts and hanging tackles inside the
crankcase, and when working on the hydrau-
lic pump station on some ME engines.
A90060-0002C02
3.
A90060-0002C03
Page 2 (2) When referring to this page, please quote Safety Precaution A90060 Edition 0002
Cylinder Cover 101-1
MAN B&W Diesel Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X Stopped engine
X Shut off safety air supply – Not ME engines
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Shut off fuel oil
Data
Ref. Description Value Unit
D01-01 Exhaust valve stud, screwing-in torque 200 Nm

D01-05 Cylinder cover stud, check distance 110±3 mm
D01-06 Cylinder cover, complete 1100 kg
D01-07 Cylinder cover without valves 700 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 25 kg
D01-10 Cylinder cover stud 15 kg
D13-01 Hydraulic pressure, mounting 900 bar
D13-02 Hydraulic pressure, dismantling 800 - 990 bar
When referring to this page, please quote Data D10101 Edition 0075 Page 1 (2)
101-1 Cylinder Cover
Data MAN B&W Diesel
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
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
P90151 130 Lifting chains
P90161 Cylinder Cover - Tools
P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete
P91351 130 9-way distributor block, complete
Page 2 (2) When referring to this page, please quote Data D10101 Edition 0075
Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling
Shut off Oil and Water Supply

2.
1. Check engine blocking.
Check that the engine is stopped and

blocked according to the safety precau-
tions given on the data sheet.
2. Shut off the oil supply.
Close the fuel oil supply for the unit con-

cerned.
3. Shut off the water supply.
M901010254D01
Shut off the water outlet on the main pipe
above the exhaust valve.
Shut off the water supply placed on the ex-

haust side of the main pipe. 3.
Open the drain next to the inlet valve.
Open the venting cock next to the outlet

valve.
M901010255C03
When referring to this page, please quote Procedure M90101 Edition 0258 Page 1 (13)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel
Dismantling of Pipe Connections

4.
4. Disconnect the oil pipes.
Remove the hydraulic high pressure pipe

for the exhaust valve. See Procedure
9081.2
Unscrew the drain pipe for the exhaust

valve.
Remove the fuel oil high pressure pipes.

See Procedure 90914.2.
M90101-0258D04
Disconnect the pipes for return fuel oil from

the fuel valves.
5. Disconnect the water pipes.
5. Unscrew and remove the water outlet

pipes.
6. Exhaust gas compensator.
Remove the protective jacket enclosing the

insulation for the intermediate pipe or com-
pensator. Remove the insulation.
Remove the screws from the flanges be-

tween the intermediate pipe and the ex-
haust receiver.
M90101-0258D05
6.
M90101-0258D06
Page 2 (13) When referring to this page, please quote Procedure M90101 Edition 0258
7. Disconnect the starting air pipe.

7.
Unscrew and remove the control air pipe
for the starting air valve.
Unscrew and remove the air pipe for the

starting valve.
8. Cylinder cover loosening.
Remove the protective caps from the cylin-

der cover nuts.
Loosen and remove the cylinder cover nuts,
M90101-0258D07
see Data.
For use of hydraulic tools, see Procedure

9131.
8.
D13-02
M90101-0258D08
Cylinder Cover Lifting and Landing

9.
9. Cylinder cover lifting.
D01-06
Hook on the engine room crane to the lift-
ing attachment on top of the exhaust valve.
Check that all cylinder cover connections

have been loosened and removed.
Lift away the cylinder cover complete.
10. Cylinder cover landing.

M90101-0258D09
Land the cylinder cover on a couple of

wooden planks.
11. Remove sealing ring.
10. Remove and discard the sealing ring be-

tween the cylinder cover and cylinder liner.
M90101-0258D10
11.
M90101-0258D11
MAN B&W Diesel Overhaul
Overhaul Preparations 1.
1. Dismantle valves and pipes.
Dismantle all valves and pipes from the

cylinder cover. See Procedure 9072.2,
9082.2 and 90911.2. D01-09
Remove all studs on top of the cylinder

cover.
Cooling Water Jacket
M90101-0258O01
2. Remove the cooling water jacket.
Mount four eyebolts and the lifting chains

as shown in the sketch.
2.
Remove the screws which secure the cool-
ing jacket to the cylinder cover.
Lift the cylinder cover free of the cooling D01-07

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

cover, and carefully clean the cooling jacket
and the cylinder cover.
3. Mount the cooling water jacket.

M90101-0258O02
Provide the cylinder cover with new

Orings, well lubricated with oil.
Lift the cylinder cover and guide the jacket/

cover into position, so the marking scratch-
es on the cover and the cooling jacket are
3.
in line (manoeuvre side).
Fit and tighten the screws for the cooling

jacket.
M90101-0258O03
Overhaul MAN B&W Diesel
Reconditioning of Bores
4.
4. Seat reconditioning tools.
The tools for reconditioning of the valve

seats are found on tool panel 901.
5. Fuel valve bore.
The tool consists of a common spindle with

a handle, a guide, a carbon cutter, a seat-
ing face cutter and a grinding mandrel.
Clean the fuel valve bores using the carbon

M90101-0258O04
cutter. If required, recondition the fuel valve

seating with the appropriate cutter.
Grind the seating with the grinding mandrel

and a grinding compound (e.g. Carborun-
5. dum No. 200).
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
1 2 3
M90101-0258O05
6. Exhaust valve bore.

6.
The tool consists of a spindle with a handle
and a grinding disc.
After cleaning the valve bore and seating,

grind the seating with the grinding disc and
a grinding compound (e.g. Carborundum
No. 200).
After the grinding, clean the bore and seat-

ing carefully, and check that the seating is
not damaged.
M901010255O06
7. Starting valve bore.
The tool consists of a guide, a cutter, and a

grinding disc.
Recondition the starting valve bore and 7.

seating in the same way as described for
the fuel valve bore.
When replacing the valves on a cylinder

cover while it is mounted on the engine,
recondition the valve bores/seating as de-
scribed here, however, without removing
the studs.
M901010255O07
8. Indicator safety valve bore.

8.
Clean the bores for safety valve/indicator
cock.
Preparations before Mounting
9. Fitting of studs.
Lubricate the threads with ‘Never Seize’ or

molybdenum disulphide (MoS2) and fit the
valve studs.
Tighten up the studs in accordance with

M901010255O08
the screwingin torque stated on the data

sheet.
Fill up the grooves between the valve studs

and the bores for the valve studs with per-
9. matex to prevent water or oil from entering
the bores during operation of the engine.
10. Mounting of valves.
Install the valves on the cylinder cover, see

D01-01 Procedures 9072.4, 9082.4 and 90911.4.
M90101-0258O09
MAN B&W Diesel Mounting
Landing Preparation
1.
1. Sealing ring.
Check that the liner sealing surface is

clean.
Place a new sealing ring on top of the cyl-

inder liner.
If necessary fit a new ‘klinger’ sealing ring

in the groove of the flange of the intermedi-
ate pipe.
M90101-0258M01
2. Water connections.
Check that the water connections are clean

and provided with new Orings.
Lubricate the Orings with Vaseline and fit 2.

them on the cylinder liner.
M901010255M02
Mounting MAN B&W Diesel
Cylinder Cover Mounting

3.
3. Cylinder cover landing.
D01-06
Carefully wipe the cylinder cover contact
surface facing the cylinder liner.
Lift the cylinder cover by means of the

crane and lower it carefully into position.
During the landing, carefully check that
the cooling water connecting pipes en-
gage correctly with the holes in the cooling
jacket.
M90101-0258M03
4. Cylinder cover stud check distance.
If the cylinder cover studs have been re-

moved and reinstalled, check the distance
the stud is protruding from the cylinder
4. cover.
If necessary, adjust to the distance D0105

by turning the stud.
D0105
M901010254M04
5. Cylinder cover tightening.

5.
Fit and tighten the cylinder cover nuts.
D13-01
For operation of hydraulic jacks, see Proce-
dure 9131.
Fit the protective caps on the cylinder cov-

er studs.
Fitting Pipe Connections
6. Fit the exhaust gas compensator.
M90101-0258M05
Fit the screws in the flanges between the
intermediate pipe and the exhaust receiver,
tight the screws.
Note!
Lubricate the screws with ‘Never Seize’ 6.
or molybdenum disulphide (MoS2) before
fitting.
Fit the insulating jacket around the interme-

diate pipe.
M90101-0258M06
7. Connect the starting air pipe.

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

the starting air valve.
8. Connect the water pipes.
Mount and tighten the water outlet pipes.
9. Connect the oil pipes.

M90101-0258M07
Mount the hydraulic high pressure pipe for

the exhaust valve. See Procedure 9081.4.
Connect the drain pipe for the exhaust

valve.
8.
Connect the fuel oil high pressure pipes.
Connect the pipes for return fuel oil from

the fuel valves.
Check that all the pipe connections are fit-

ted and tightened.
M90101-0258M08
9.
M90101-0258M09
Open Oil and Water Supply

10.
10. Close the drain and open the water sup-
ply.
Close the venting cock next to the outlet

valve.
Close the drain next to the inlet valve.
Slowly open the water supply valve, placed

on the exhaust side of the main pipe.
Vent the unit by releasing air through the

venting cock next to the outlet valve.
When the venting is finished, close the

venting cock. Open the water outlet valve
on the main pipe.
11. Open the oil supply.

M901010255M10
Open the fuel oil supply for the unit con-

cerned.
11.
M901010254M11
Cylinder Cover Panel Plate
P90151-0186
When referring to this page, please quote Plate P90151 Edition 0186 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0186
Item Item Description Item Item Description

No. No.
010 Panel for tools

022 Name plate
046 Grinding tool, exhaust valve seat
058 Milling and grinding tool, fuel valve
seat
060 Milling and grinding wheel, fuel start-
ing valve
071 Dismantling tool, fuel valve
083 Handle, grinding tools
095 Grinding ring, starting valve seat
105 Pin spanner, starting valve
117 Test equipment, combined safety
valve
130 Lifting chains, cylinder cover
Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0186
MAN B&W Diesel A/S
Cylinder Cover - Tools Plate
P90161-0103
Cylinder Cover - Tools
0103
P90161
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0103
Item Item
Item Description Item Description
No. No.
027 Hydraulic jack, complete

039 Support
040 Support
052 O-ring with back-up ring
090 Key, hexagon socket screw
100 Tommy bar
111 Stud setter
206 Hydraulic, tool set, complete
218 Hydraulic, tool set, complete
MAN B&W Diesel A/S
Cylinder Cover - Lifting Tools Plate
MAN B&W P90165-0003
Plate Cylinder Cover - Lifting Tools
P90165-0003 MAN B&W
Item Item
No. No.
017 Lifting tool for cylinder cover

029 Lifting tool for cylinder cover
Piston 102-1
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0056
102-1 Piston
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
D01-05 Cylinder cover studs–check distance 1014±2 mm
D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 280 Nm
D02-03 Piston rod/crown, tightening torque 200 Nm
D02-05 Piston skirt, tightening torque 90 Nm
D02-06 Cooling oil pipe, tightening torque 50 Nm
D02-08 Piston ring new, radial width 14.7 mm
D02-09 Piston ring worn, min. radial width 12.2 mm
D02-10 Groove No.1, max. vertical height 11.7 mm
D02-11 Groove Nos. 2,3 and 4, max. vertical height 8.7 mm
D02-12 Piston top max. permissible burn-away 13 mm
D02-13 Piston ring new, height of ring no 1 10.9 mm
D02-14 Piston rings new, height of ring no 2,3 and 4 7.9 mm
D02-15 Minimum free ring gap ( before dismantling ) 27 mm
D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 2.9 mm
D02-17 Minimum ring gap, ring Nos. 2,3 and 4 ( new ring in new liner ) 2.1 mm
D02-18 Vertical clearance, new parts 0.45-0.5 mm
D02-19 Vertical clearance, worn parts, max. 0.8 mm
D02-20 Piston complete 556 kg
D02-21 Piston crown 121 kg
D02-22 Piston rod 311 kg
D02-23 Piston skirt 28 kg
D02-24 Piston cooling pipe 12 kg
D04-15 Telescopic pipe, tightening torque 40 Nm
MAN B&W Diesel A/S
102-1 Piston
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.

P90251 40 Lifting tool for piston rod foot
75 Template for piston top
87 Distance piece for stuffing box
99 Cover for stuffing box hole
110 Pressure test tool for piston
134 Piston ring expander
158 Guide screw for piston crown
171 Dismantling screw piston skirt
P90261 Guide ring for piston
P90264 Tools for tilted lift
P90265 Support for piston
P90266 16 Lifting tool for piston
P90361 36 Cylinder gauge, complete
P90366 Crossbar for cylinder liner
MAN B&W Diesel A/S
Piston 902-1.1
Checking
0251
Piston S42MC
Checking
902-1.1

Scavenge port inspection
To detect possible leakages from the piston or

cylinder cover, keep the cooling water and cool-
ing oil circulating during the scavenge port in-
spection.
1. Remove the inspection covers on the cam-

shaft side of the cylinder frame.
Note!
The scavenge port inspection can also

be carried out from within the scavenge

air receiver.

1
*
Clean the openings.

Begin the inspection at the cylinder whose
piston is nearest BDC.
2. With the piston in BDC, inspect the piston

crown and the cylinder wall.
Note down the results.

See Volume I, OPERATION, Chapter 707.
3. Turn the engine. While the piston is passing

the scavenge air ports, inspect the piston
rings, the ringlands and the piston skirt.
Check the movability and the tension of the

piston rings, by pressing against them with

a wooden stick.

Note down the results. 1
*

*
+
0$1% :'LHVHO$6
902-1.1 Piston
Checking
4. After turning the piston upwards, past the

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

inder frame. If necessary, replace the gas-
kets.

Piston rings and piston crown

6. Remove the piston from the cylinder and

1
place it on the piston support.
*
See Procedure 902-1.2.
6.
Note!
It is recommended to replace all the pis-

D02-20 ton rings whenever a piston is removed
from the engine.
All the following measurements should be

used as a guideline for the running time of
a set of new piston rings.
Depending on the extent of the wear, the

running time can be increased or de-
creased.
BG902-4.1 72 02
For evaluation of the rings, see Volume I,

OPERATION , Chapter 707.
7. Before dismantling the piston rings, meas-

ure the free ring gap of all the piston rings.
7.
D02-15
BM902-1.1 232 07
0$1% :'LHVHO$6
Piston 902-1.1
Checking
8. Take off the piston rings by means of the 8.

ring expander.
Clean and inspect the rings.
9. Measure and record the radial width of the

rings.
See Volume I, Operation, Chapter 707.
Worn rings must be replaced if the radial

width is less than stated in Data.
10. Piston rings with milled pressure relief

grooves must be replaced if the radial depth
of the grooves has worn down to less than
1 mm.
GN902-1.1 222 14

' 1HZ

'

:RUQ

1
*
10. Min. 1 mm
GN902-1.1 204 09
0$1% :'LHVHO$6
902-1.1 Piston
Checking
11. 11. Clean the ring grooves and check them for
D02-10 burn marks or other deformation.
D02-11
Measure the ring grooves with a caliper
gauge.
Clearance in piston ring grooves:
Max. 2 mm The maximum vertical height in a worn ring

groove must not exceed the value stated in
Data.
The groove is also worn out if there is no

KM902-3.0 47 05
chromium layer.
12. Clean the piston crown and check the burn-

away by means of the template. For maxi-
mum permissible burn-away value, see Da-
12. ta.
D02-12
Check the burn-away on the whole circum-
ference of the piston crown.
13. Before mounting a new piston ring, meas-

ure the piston ring gap.
When measuring, insert the piston ring in

either a new cylinder liner or in the bottom
of a used cylinder (below the ring travel
zone).
For minimum ring gap, see Data.

AM902-3.0 77 04
13.
D02-16
GN902-1.1 222 13
D02-17
0$1% :'LHVHO$6
Piston 902-1.1
Checking
14. Fit the piston rings (alternately right-hand 14.

and left-hand cuts with the ring gaps stag-
gered 180° and with the TOP mark up-
wards).
When mounting the piston rings, use the

ring expander to prevent unintended defor-
mation of the rings.
Do not expand the rings more than neces-

sary. The upper ring (CPR ring) should not
be expanded more than to the milled mark
on the ring expander.
15. Check the vertical clearance between the

new piston ring and the new or recondi-
tioned ring groove with a feeler gauge. See
Data.
GN902-1.1 222 14
Worn ring groove:
Measure the total clearance between the

piston rings and the ring grooves.
The total clearance must not exceed the 15.

value stated in Data.
D02-18
Measurements are to be taken at the top
(E) and bottom (F) between the piston ring
and piston ring groove.
Total clearance = E + F. ( (
D02-19
) )
0D[PP

0
+
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
Dismantling
902-1.2
1. Turn the crosshead down far enough to give

access to the piston rod stuffing box, the
tightening screws for the piston rod, and to
the telescopic pipe.
2. Release the stuffing box by removing the

innermost screws from the stuffing box
flange.
Note!
'R127UHPRYHWKHRXWHUPRVWVFUHZV

IURPWKHIODQJH

3. Remove the four screws and nuts which
0
' tighten the telescopic pipe to the bend.
Disconnect the telescopic pipe from the

bend and fasten the pipe flange to the stuff-
ing box by means of the wing-screw from
the tool panel.
Note!
:KHQDSLVWRQLVGLVPDQWOHGQHYHUWXUQ

WKHHQJLQHZLWKRXWILUVWGLVPDQWOLQJWKH

WHOHVFRSLFSLSHIURPWKHFURVVKHDG

1
*

0
'
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
4. Remove the screws from the piston rod.
5. Mount the two distance pieces on the piston

rod foot to protect the lower scraper ring
and to guide the stuffing box.
6. Turn the crosshead to TDC, while checking

that the stuffing box lands correctly on the
distance pieces.

0
'

0
'
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
7. 7. Dismount the cylinder cover.

8. Piston cleaning ring (PC-ring):
Make a short scratch mark in liner and PC-

ring to ensure the correct mounting.
Remove the PC-ring.
Carefully remove wear ridges at the top of

the cylinder liner.
See Procedure 903-1.
DM902-1.2 251 07
8.
HN902-1.2 237 06
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
9. The top of the piston is now free of the cyl- 9.

inder liner. D02-20
If necessary, remove one or two cylinder
cover studs, using a stud setter.
Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two ‘fixed’ claws of the tool fit into
the lifting groove of the piston.
Fit the third, adjustable, claw of the tool to

the lifting groove and tighten it up against
DM902-1.1 105 06
the stop of the tool.
10. Place the two halves of the support around

one of the openings in the platform.
Lift the piston out of the cylinder and lower 10.

the piston rod foot and stuffing box through
the opening in the platform.
Place the two halves of the support around

the piston rod and secure the two halves
with screws.
11. Place a cover over the opening for the pis-

ton rod stuffing box in the bottom of the cyl-
inder unit.
Clean, measure and recondition the cylin-

der liner.
BG 902-4.1 72 02
11.
BG902-4.1 72 02
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
12. 12. Turn the crosshead down far enough to per-

mit mounting of the protective rubber cover
on the crosshead bearing cap.
The protective rubber cover should remain

in place to protect the crosshead bearing
journal from impurities until the piston is re-
mounted.
Low lifting height
If the space conditions above the engine make

it impossible to remove the piston in the normal
GN902-1.2 204 10
way, the piston can be removed as follows:
13. Remove one or two cylinder cover studs,

using the stud setter.
13. Lift the piston high enough to give ample

room over the cylinder cover studs.
Mount the clamp on the piston rod so that

its distance piece lies true against the pis-
' ton.
DM902-1.2 251 13
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
14. Place the supporting tools on the cylinder

cover studs and lower the piston until the
clamp rests on the tools.
Remove the lifting tool from the piston.
Hook the transverse piece on to the crane

and attach it to the clamp for tilting the pis-
ton.
15. Lift the piston to the maximum crane height.

Run the crane athwartship and, at the same
time, tilt the piston.
Keep the piston rod clear of the cylinder lin-

er and studs while carrying out the tilting.
When space conditions permit, straighten

up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
When the piston is at a suitable height

above the platform cut-out, position the pis-
ton support around the piston rod and
clamp.
Now lower the piston while guiding the sup-

port to the platform cut-out.

After landing the piston and ensuring that it

rests correctly on the support, remove the 0

'
tilting tool.

Note!
2QHQJLQHVZLWKH[WUHPHO\ORZOLIWLQJ
KHLJKWXVHWKHHQJLQHURRPGRXEOHMLE
FUDQHLQVWHDGRIWKHWUDQVYHUVHSLHFH

0
'
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
Overhaul
902-1.3
1. Ease the piston down so that the stuffing

box is below the floor.
2. Assemble the two halves of the piston sup-

port around the piston rod.
'
Land the piston on the support, taking care
that the piston is not resting on the head of
the piston rod bolts.
Dismount the piston rings.


3. Dismount the stuffing box and distance

pieces.


0
%

*
%

*
%
0$1% :'LHVHO$6
Piston 902-1.3
Overhaul
4. Lift the piston with the normal lifting tool. 4.
Lower the piston rod foot near to the plat-

form. Pull the piston rod foot a bit to the
side by hand to tilt the piston. Land the foot
on a wooden block.
Note!
During the lift, follow with the crane to

keep the crane positioned vertically
above the piston crown.
BM902-1.3 236 04
5. Lower the piston crown to the platform and
land it on a wooden block.
6. Remove the lifting tool from the piston

crown. 5.
Attach the lifting bracket to the bottom of

the piston rod foot. Hook the crane on to the
lifting bracket.
7. Lift the piston rod foot clear of the wooden

BM902-1.3 236 05
block.
Note!
'XULQJWKHOLIWIROORZZLWKWKHFUDQHWR 6.
NHHSWKHFUDQHSRVLWLRQHGYHUWLFDOO\
DERYHWKHSLVWRQURGIRRW
Keep lifting until the piston rod is in a verti-

cal position.
BM902-1.3 236 06
7.
BM902-1.3 236 07
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
8. Place the piston in an upright position with

the piston crown resting on wooden blocks.
'
Dismount the locking wire and the inner-
most screws between the rod and the pis-
ton crown. Lift the piston rod away and land
it in a horizontal position on a couple of
wooden blocks.
9. Remove the locking wire and the screws in

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

10. Thoroughly clean and inspect all parts of

the piston.

0
%
If coke deposits are found in the cooling

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

the new sealing rings must be coated with
lubricating oil before the piston is assem-
' bled.

Coat all screws with Molybdenum Disul-

phide (MoS 2).

0
%
Assemble the piston in the reverse order to

disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.
'
Tighten all the screws diagonally to the
torque stated in Data.
'

0
%
0$1% :'LHVHO$6
Piston 902-1.3
Overhaul
11. Lock all the screws with locking wire.
Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
12. Fill the piston and piston rod with lubricat-

ing oil.
Mount the pressure-testing tool around the

base of the piston rod.
Pressure-test the piston at the pressure

stated on the data sheet.

Check the contact surfaces of the piston 0

+
and the sealing rings for tightness.

12.
Check that there are no cracks in the piston
crown.
13. Tilt the piston to an upright position and

land it on the piston support tool. '
Mount the stuffing box.

Mount new piston rings. 2LO

BM902-1.3 236 12
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
Mounting
902-1.4
1. Check the piston rings and piston crown in

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

'
3. Ensure that the stuffing box is correctly po-
sitioned over the distance pieces mounted
on the piston rod foot.
Coat the O-rings of the stuffing box with oil.
4. Remove the protective rubber cover from

the crosshead.

0
%

0
'

1
*
0$1% :'LHVHO$6
Piston 902-1.4
Mounting
5. Remove the cover from the piston rod stuff-

ing box opening in the bottom of the cylin-
der unit.
6. Turn the crosshead to a position 45° from

TDC.
7. Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.
Coat the O-rings of the stuffing box with oil.
Mount the guide ring for piston rings on the

cylinder liner.

Lower the piston into the cylinder liner –

while guiding the piston rod foot through the 1
*
cut-out in the stuffing box flange – until the

piston rings are inside the liner.

0
'

0
%
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
8. Turn the crosshead to TDC while checking

that the guide ring of the crosshead enters
the centre hole in the piston rod.
After turning the piston fully to TDC, un-

screw the adjustable claw of the lifting tool
and pull the lifting tool free of the lifting
groove in the piston
Remove the lifting tool and the guide ring

for piston rings.
9. Turn the crosshead with the piston rod

down far enough to give access to the tel-

escopic pipe stuffing box.

0
%
Loosen the telescopic pipe and land it on
the bend.

Mount and tighten the screws for the tele-
scopic pipe. See Data.
10. Remove the distance pieces for the stuffing

' box.
Mount and tighten the piston rod screws.

See Data.
Lock the screws with locking wire.

the wire is tightened if one of the screws

works loose.


0
'

'

*
%
0$1% :'LHVHO$6
Piston 902-1.4
Mounting
11. Tighten down the piston rod stuffing box by 11.

means of the screws through the inner
holes in the stuffing box flange.
12. If the cylinder cover studs have been re-

moved, mount them with the stud setter.
See Data.
Carefully clean the surfaces around the

base of the mounted studs and refill the
roots properly with Permatex 3.
GN902-1.2 204 02
13. Smear the piston rod with molybdenum di-
sulphide, and turn the crankshaft a couple
of revolutions.
Mount the cylinder cover.

See Procedure 901-1.4. 12.
14. Mount the piston cleaning ring according to

the scratch mark.
If the PC-ring is damaged (broken or

cracked), it must be replaced by a dummy
ring with an over-seize bore, to ensure
proper sealing between cylinder cover and
cylinder liner.
D01-05
BM902-1.4 230 12
14.
HN902-1.4 237 13
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
15. 15. Mount the cylinder cover.

16. Start the engine and keep it running for

about 15 minutes at a number of revolutions
corresponding to very slow.
Then stop the engine and inspect the piston

rod and stuffing box.
GN902-1.2 204 05
0$1% :'LHVHO$6
Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0042
102-2 Piston Rod Stuffing Box
X Stopped engine
X Shut off fuel oil
Data
D02-26 Stuffing box flange, outer screws tightening torque 50 Nm
D02-27 Stuffing box flange, inner screws tightening torque 50 Nm
D02-28 Stuffing box halves, tightening torque 40 Nm
D02-29 Uppermost rings, ring-end clearance 4*6 mm
D02-30 Lowermost rings, ring-end clearance 3*3 mm
D02-31 Vertical clearance, uppermost rings 0,15-0,35 mm
D02-32 Vertical clearance, lowermost rings 0,05-0,20 mm
D02-33 Check length for the six uppermost springs:
D02-34 –F0=0N L0= 525 mm
D02-35 – F 1 = 33 +/– 2 N L1= 590 mm
D02-36 – F 2 = 63 +/– 5 N L2= 650 mm
D02-37 Check length for the four lowermost springs:
D02-38 –F0=0N L0= 370 mm
D02-39 – F 1 = 41 +/– 3 N L1= 506 mm
D02-40 – F 2 = 71 +/– 5 N L2= 606 mm
D02-44 Stuffing box complete 76 kg
D02-45 Stuffing box half 26 kg
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data

P90251 109 Mounting tool for stuffing box spring
P90251 122 Worktable for stuffing box
MAN B&W Diesel A/S
Piston Rod Stuffing Box 902-2.1
Checking
0219 Rod Stuffing Box
Piston S42MC
Checking
902-2.1
1.
1. After the piston rod stuffing box has been
dismantled, check the following clearanc-
es:.
See Procedure 902-2.2. D02-29
Uppermost scraper ring and sealing rings

A
Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D02-29) D02-30
Clearance at ring ends (sealing rings).

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

Total clearance. (D02-30)
B
The ring clearances stated in Data apply to A B
new rings.
As a general guide, it is recommended –

depending on the overhauling intervals and
one’s own experience – to replace sealing D02-29 D02-30
rings and scraper rings when the specified
DM902-2.1 219 01
clearance values D02-29 and D02-30 have

been halved.
2. Check the length of the springs at different

loads. Adjust the loads to achieve the
2.
lengths stated in Data. D02-33
If the loads necessary are outside the limits
stated in Data, the springs must be discard-
ed.
D02-37
HM902-5.0 70 02
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box
Dismantling
Dismantling
902-2.2
1. If, in the period between piston overhauls, it be-

comes necessary to inspect the piston rod
stuffing box, proceed as follows:
1. Turn the crosshead to about 90° from TDC.
Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diametrically opposite in the
GN902-2.2 203 01
stuffing box flange, longitudinally to the en-

gine.
3. Mount the worktable around the piston rod

so that the two remaining screws in the
2. stuffing box flange can be loosened through
the holes.
DM902-5.2 108 02
3.
DM902-5.2 108 03
MAN B&W Diesel A/S
Dismantling
4. Remove the two long dismantling screws 4.

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

holes in the worktable.
Remove the remaining two screws from the

stuffing box.
5. Turn the piston to BDC, thereby withdraw-

ing the stuffing box from the cylinder frame
bottom.
DM902-5.2 108 04
Remove the two long dismantling screws
from the stuffing box and mount them in the
worktable.
6. By means of the four short screws in the

worktable, press the stuffing box out of the 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
DM902-5.2 108 05
6.
DM902-5.2 108 06
MAN B&W Diesel A/S
Overhaul
Overhaul
902-2.3
Outside the engine
Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a

support placed over one of the cut-outs in the
top platform.
Work on the stuffing box is then carried out

from the platform below.
1. Mount two eye bolts in the stuffing box

DG902-5.1 83 01
flange, and hook on two tackles.
Lift the stuffing box a little up the piston rod,

and mount the worktable round the piston
1. rod at a suitable working height.
Land the stuffing box on the worktable, and

remove the tackles and eye bolts.
2. Remove the O-ring of the stuffing box. If the

D02-44 O-ring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.
Remove the nuts from the stuffing box as-

sembling bolts.
DG902-5.1 83 02
2.
DG902-5.1 83 03
MAN B&W Diesel A/S
Overhaul
3. Take out the six bolts, and pull away one 3.

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

and remove it from the worktable.
4. Using a feeler gauge, measure the vertical D02-45

clearance of the rings.
5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.
DG902-5.1 83 04
6. Measure the clearance between the ring
segments to determine whether replace-
ment is necessary.
7.
Dismantle and stack the rings in the same D02-33
order as when fitted in the stuffing box.
Carefully clean all the ring segments.
Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D02-37
7. Check the lengths of the springs.
8. Inspect the surface of the piston rod. If

HM902-5.0 70 02
small longitudinal scratches have occurred

(caused by poorly adapted stuffing box
rings), smooth the piston rod surface care-
fully with a fine grained carborundum stone.
In the case of coarse scratches, it may 8.
prove necessary to machine-grind the sur-
face in a workshop.
9. Clean the halves of the stuffing box hous-

ing.
HC902-5.1 98 07
MAN B&W Diesel A/S
Overhaul
10. 10. Lubricate the piston rod (in the area where
all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).
Assemble all the stuffing box ring units

round the piston rod, on the worktable, in
the following way:
• Place the lowermost scraper ring seg-

ments on the worktable.
• Place the spring round the segments,

and hook the spring ends together.
NB902-3 217 10
Repeat this procedure for the remaining

scraper rings.
11. On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).
Assemble the 8-part sealing ring so that the

two guide pins face upwards, place the
spring round the segments and, hook the
spring ends together.
Assemble the 4-part sealing ring above the

8-part sealing ring. Push the two rings to-
gether in such a manner that the guide pins
in the lower sealing ring engage with the
two holes in the upper sealing ring.
DM902-2.3 219 11
Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
11. 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. Subse-
quently, push the stuffing box half into con-
tact with the piston rod, round the ring units.
MAN B&W Diesel A/S
Overhaul
12. Check the ring clearance again. 12.
Then place the other half of the stuffing box

housing on the worktable, pushing it into D02-28
place round the rings.
Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.
Mount the O-ring in the stuffing box groove.
13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.
DG902-5.1 83 11
Remove the worktable and lower the stuff-
ing box until it rests against the distance
pieces on the piston rod foot.
Remove wire ropes and screws. DG902-5.1 83 12 13.
MAN B&W Diesel A/S
Mounting
Mounting
902-2.4
1. 1. After overhauling, assemble the stuffing

box halves on top of the four screws.
Mount the two long screws from the workta-

ble in the stuffing box.
Turn down the short screws so that the

stuffing box lands on the flange.
2. Turn the piston upwards until the stuffing

box is in place in the cylinder frame.
Note!
DM902-5.2 108 07
Make sure that the two guide pins in the

flange enter the guide holes in the bottom
of the cylinder frame.
2.
3. Mount two screws in the flange through the
holes in the worktable.
DM902-5.2 108 08
3.
DM902-5.2 108 09
MAN B&W Diesel A/S
Mounting
4. Remove the long screws from the stuffing 4.

box and mount them in the worktable.
Remove the worktable from the piston rod.
5. Mount and tighten all the inner and outer

screws for the stuffing box. See Data.
6. Remove the protecting rubber cover from

the piston rod/crosshead.
Smear the piston rod with molybdenum di-

sulphide.
DM902-5.2 108 10
Then turn the crankshaft a couple of revo-
lutions.
Start up the engine and keep it running for

about fifteen minutes at a number of revo- 5.
lutions corresponding to very slow or idle
speed.
Then stop the engine and inspect the piston

rod and stuffing box.
D02-26
DM902-5.2 108 11
D02-27
6.
GN902-2.2 203 01
MAN B&W Diesel A/S
Piston and Piston Rod Panel Plate
P90251-0255
Piston
0255 and Piston Rod Panel
P90251
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0255
Item Item
No. No.
014 Panel for tools

026 Name plate
040 Lifting tool for piston rod
051 Lifting tool for cylinder liner
063 Lifting and tilting screw
075 Template for piston top
087 Distance piece for stuffing box
099 Cover for stuffing box hole
109 Hook for mounting of stuffing box
spring
110 Pressure test
122 Work table for stuffing box
134 Piston ring expander
146 Support for tilting tool
158 Guide screw for piston crown
171 Dismantling screw for piston skrit
MAN B&W Diesel A/S
Piston and Piston Rod - Tools Plate
P90261-0107
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0107

No. No.
019 Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools Plate
P90265-0005
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0005

No. No.
010 Support iron for piston
MAN B&W Diesel A/S
Piston - Lifting Tools Plate
P90266-0004
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0004

No. No.
016 Lifting tool, piston
MAN B&W Diesel A/S
Crosshead Bearing 104-1
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0040
104-1 Crosshead Bearing
X Stopped engine
X Shut off fuel oil
Data
D04-01 Crosshead bearing, top clearance max. 0.45 mm

D04-02 Crosshead bearing, top clearance min. 0.2 mm
D04-03 Oil wedge length, L 10 mm
D04-04 Crosshead bearing cap 84 kg
D04-05 Crosshead bearing shell, upper 12.5 kg
D04-06 Crosshead bearing shell, lower 17.2 kg
D04-07 Crosshead bearing cap with bearing shells 96.5 kg
D04-15 Telescopic pipe, tightening torque 40 Nm
D04-16 Thrust piece, tightening torque 260 Nm
D04-51 Connecting rod 1548 kg
D02-02 Piston rod/crosshead, tightening torque 280 Nm
D13-02 Hydraulic pressure, dismantling 800-990 bar
D02-20 Piston complete 556 kg
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data
The tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indi-
cated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
P90451 47 Wire guide

59 Lifting attachment, connecting rod
60 Lifting tools, crosshead
72 Chain for suspending piston
84 Retaining tool, telescope pipe
96 Bracket for support, crosshead
106 Bracket for support, crosshead
P90461 Connecting rod, hydraulic tools
P91356 Lifting tools, etc.
P91359 Torque spanners
P91368 Working platforms
P91363 Spanners
MAN B&W Diesel A/S
Crosshead Bearing 904-1.1
Checking
Crosshead Bearing
S42MC
0232
Checking
904-1.1
2.
Tin-Aluminium bearings
The top clearance between the journal and a

new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.
The top clearance for a new bearing will nor-

mally be in the range stated in Data. Note that
the figures are to be used for guidance only.
For the top clearance of a specific bearing, see

the measurement in the Adjustment Sheet in
BM904-2.1 76 02
Volume I, OPERATION.
1. Open the crankcase door at the relevant

cylinder.
2. Turn the crankthrow concerned to BDC. 3. D04-01

D04-02
3. Measure the clearance in the crosshead
bearing by inserting a feeler gauge be-
tween the bearing cap and the crosshead
journal at the top of the upper bearing shell,
at both sides and fore and aft. See Data.
4. The difference between the actual clear-

ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
DM904-1.1 232 03
later) must not exceed 0.1 mm. If so, the

crosshead bearing must be disassembled
for inspection.
For evaluation of the bearing shell, see

Chapter 708, ‘Bearings’ in the instruction 5.
book, Volume I, OPERATION.
5. The wear limit for a crosshead bearing shell

is confined to a 50% reduction of the oil
wedge length L.
If the wear limit exceeds the 50% reduction,

(Oil Wedge)
the bearing shell must be replaced by a
new one.
D04-03
DM904-1.1 232 05
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling
Dismantling
904-1.2
1. This procedure has been divided into two dis-

mantling situations, as follows:
• with piston mounted
• with piston removed
With piston mounted:
1. Turn the crankshaft down far enough to give

access to the nuts and screws on the piston
rod.
2. Mount two eye bolts in the top of the crank-

BM904-2.1 76 02
case and suspend two tackles in the

athwartship direction.
Mount the two chains for suspending the

2. piston rod.
3. Loosen and remove the four screws which

tighten the telescopic pipe to the bend.
Suspend the telescopic pipe from the stuff-

ing box using the wing nut (tool).
Caution!
When a piston is dismantled, never turn

the engine without first dismantling the
telescopic pipe from the crosshead.
BM904-1.2 229 02
3.
BG904-2.2 63 05
0$1% :'LHVHO$6
Dismantling
4. Remove the locking wire from the screws, 4.

loosen and remove the screws from the pis-
ton rod foot. Remove the thrust pieces from
both side of the bearing cap.
5. Mount a lifting eye bolt on each side of the

piston rod.
Turn the crosshead to TDC.
Hook the chains to the lifting eye bolts in

the piston rod.
DM904-1.2 232 04
Turn the crosshead downward, and the pis-
ton rod will remain suspended from the two
chains.
With piston removed:

5.
6. Turn to BDC. D02-20
7. Hold the spacer rings around the nuts and
screw the hydraulic jacks on to the studs.
Loosen the crosshead bearing cap nuts.

For operation of the hydraulic jacks, see
Procedure 913.
Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.
DM904-1.4 232 08
7.
D13-02
DM904-1.2 232 07
0$1% :'LHVHO$6
Dismantling
8. 8. Screw two eye bolts into the head of the

connecting rod.
9. Mount two eye bolts in the top of the cross-

head bearing cap.
Hook the two tackles on to the eye bolts

and lift the crosshead bearing cap away
from the crosshead.
Note!
Take care that the studs for the cross-

DM904-1.2 232 08
head bearing cap do not scratch the

crosshead journal.
10. Mount wire guide on the top of the crank-

9. case door frame to prevent damage.
Lift the crosshead bearing cap out of the

engine.
DM904-1.2 232 09
10.
D04-07
DM904-1.2 232 10
0$1% :'LHVHO$6
Dismantling
11. Place the bearing cap on one side on a 11.

couple of wooden planks. D04-07
Remove the thrust pieces for axial guidance

of the connecting rod.
Check the bearing shell, see Procedure

904-1.1.
DM904-1.2 232 11
12. Turn the crosshead to TDC. Ensure that the
connecting piece in the crosshead fits cor-
rectly in the holes of the piston rod. D04-05
Do not remove the chains or lifting eye

bolts. 12.
13. Mount the four supports for guide shoes on

the crosshead guides.
Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.
14. Hook the two tackles on to the eye bolts

screwed into the head of the connecting
rod.
DM904-1.2 232 12
Haul the tackles tight.
13.
DM904-1.2 232 13
0$1% :'LHVHO$6
Dismantling
15. 15. Turn the crankthrow carefully towards BDC

while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.
With the crosshead resting on the supports,

check the lower part of the crosshead jour-
D04-51 nal and the lower bearing shell.
Check the bearing shell, see Procedure

904-1.1.
For further evaluation of journal and bear-

ing shells, see also Volume I, OPERATION,
Chapter 708, ‘Bearings’.
16. In cases where it is necessary to remove

the lower bearing shell, tilt the connecting
rod towards the door in the camshaft side,
using the tackles.
Dismount the lock screws, and lift the bear-

ing shell out of the engine.
DM904-1.2 232 15
16.
D04-06
DM904-1.2 232 16
0$1% :'LHVHO$6
Mounting
Mounting
904-1.4
With the piston mounted/ 1.

With the piston removed:
D04-06
1. Mount and secure the bearing shell in the
bearing housing.
The excess height X is to ensure the cor-

rect tightening-down of the bearing shell
and must not be eliminated.
2. Raise the connecting rod to an upright po-

sition.
DM904-1.4 232 01
Turn to TDC while ‘following’ with the tack-
les, for assembling the crosshead and the
connecting rod.
Take care that the guide shoes do not dam-

age the bearing shell. 2.
3. Remove the tackles from the connecting

rod. Remove the eye bolts from the con-
necting rod.
DM904-1.2 232 15
3.
DM904-1.4 232 03
0$1% :'LHVHO$6
Mounting
4. 4. Remove the supports from the crosshead

guides.
Turn the crank throw to BDC.
If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
5. Lift the bearing cap into the engine. Lower

the bearing cap onto the crosshead and re-
move the tackles. Remove the eye bolts
from the bearing cap.
DM904-1.4 232 04
Note!
Take care that the bearing studs do not

damage the crosshead.
5.
6. Remove wire guide.
D04-07
Tighten all four crosshead bearing cap nuts
simultaneously. See Data.
For operation of hydraulic jacks, see Sec-
tion 913.
Mount the two thrust pieces on both sides

of the bearing cap. See Data.
7. Mount the piston.

DM904-1.4 232 05
6.
D04-16
D13-01
DM904-1.4 232 06
0$1% :'LHVHO$6
Mounting
With the piston mounted: 8.
8. Turn the crosshead upwards until the piston

rod lands on the crosshead. When mount-
ing the piston on the crosshead, make sure
that the piston rod foot is correctly centered
on the crosshead.
9. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and
eye bolts from the top of the crankcase,
from the piston rod and from the crosshead
bearing cap.
DM904-1.4 232 08
10. Mount and tighten the screws on the piston
rod. See Data.
Mount the locking wire on the screws. The

locking wire is to be mounted in such a way 10.
that the wire is tightened if a screw works
loose.
D02-02
After tightening the bearing cap, check the
top clearance once more.
If a new bearing shell has been mounted,

remember to note down the new top clear-
ance in the Adjustment Sheet in Chapter
701, Volume I, OPERATION.
11. Release the telescopic pipe from its sus-

DM904-1.4 232 10
pension, mount and tighten the four screws

which tighten the telescopic pipe to the
bend. See Data.
11.
D04-15
BG904-2.2 63 15
0$1% :'LHVHO$6
Crosshead 104-2
Data
X Stopped engine
X Shut off fuel oil
Lock the turbocharger rotors
Data
D04-07 Crosshead bearing cap with bearing shell 205 kg

D04-08 Cooling oil outlet pipe, tightening torque 260 Nm
D04-09 Inlet pipe, tightening torque 260 Nm
D04-10 Inlet pipe stud, screwing-in torque 150 Nm
D04-11 Guide strip nuts, tightening torque 60 Nm
D04-16 Thrust piece, tightening torque 260 Nm
D04-20 Clearance between thrust piece and crosshead 0.05 .035 mm
D04-21 Crosshead complete 700 kg
D04-22 Guide shoe 60 kg
D04-23 Cooling oil outlet pipe 3.5 kg
D04-50 Connecting rod, without bearing caps 690 kg
D04-57 Guide shoe with crosshead journal 90 kg
D04-59 Telescopic pipe 11 kg
D04-60 Inlet pipe 20 kg
D04-65 Guide shoe journal,tightening torque/angle 100/24 Nm/°
MAN B&W Diesel A/S
104-2 Crosshead
Data

P90451 59 Lifting attachment - connecting rod
P90451 60 Lifting tools - crosshead
P90451 84 Retaining tool telescope pipe
P90464 Crosshead - Hydraulic Tools

P91356 Lifting Tools, etc.
P91359 Torque Spanners
P91366 50 Feeler gauge
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
1. Dismount the main bearing lubricating oil 2.

pipes.
2. Turn the crosshead down far enough to

give access to the nuts on the crosshead
bearing cap.
Mount two eye bolts on the top of the

crankcase in the fore-and-aft direction,
mount two eye bolts in the athwartship di-
rection, and suspend two tackles.
Mount the spacer rings and hydraulic jacks
M904020247D02
for loosening the nuts on the crosshead D1302
bearing studs.
For operation of the hydraulic tools, see

Chapter 913.
4.
Loosen the nuts, remove the hydraulic
jacks and unscrew the nuts.
D0407
3. Turn the crosshead to TDC.
Suspend the telescopic pipe by means of

the tool. Suspend the piston. To suspend
the piston, see Procedure 904-1.
4. Turn to BDC and mount connecting rod lift-

ing tools. Use two tackles to retain the
connecting rod in an upright position.
M904020247D04
Mount two eye bolts and extension screws

in the crosshead bearing cap and hook on
the tackles from the top of the crankcase.
Lift the bearing cap out of the engine.
Remove the piston rod guide ring and the

shim from the crosshead.
Remove both thrust pieces on the cross-

head bearing cap.
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling
5. Dismount the guide pin for the oil inlet

5. bend using the special extractor.
Remove the outlet pipe, dismount the bend

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

head.
Mount the lifting attachments for fixing the

connecting rod, on the head of the con-
necting rod.
D0421
M904020247D05
Fasten tackles to the lifting brackets on the

frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles
tight.
6. Hook the tackles to the top lifting brackets

on to the lifting tool on the crosshead, and
lift the crosshead.
D0450 6. Use the tackles to tilt the connecting rod

towards the exhaust side, while turning the
crankthrow towards the camshaft side.
Transfer the tackles from one lifting attach-

ment to another, as necessary.
When the crankthrow is 90° after BDC,

stop turning.
M904020247D06
By alternate use of the tackles, tilt the con-

necting rod until it rests against a couple of
wooden planks in the bottom of the bed-
plate.
7.
7. Place a thin wooden plank or similar on top
of the crank to protect the crosshead.
Lower the crosshead to a position just

above the main bearing caps.
Remove the guide strips and both guide

plates from the guide shoes.
Mount lifting eye bolts in both guide shoes.

M904020247D07
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
8. Lower the crosshead so that the guide

shoes are just below the cutout in the side 8.
walls of the frame box.
Note!
The clearance between the crank and
the crosshead is very narrow. D0421
9. Hook the tackles on to the eye bolts in the

guide shoes and haul tight.
Remove the locking wire from the screws

on the end of the guide shoe journals.
M904020247D08
Loosen and remove the screws.
10. Separate the guide shoe journal from the

crosshead, using the two dismantling
screws. 9.
M904020247D09
10.
M904020247D10
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling
11. Use the tackles to lift the crosshead mak-

11. ing it possible to remove the guide shoe
from the engine.
If overhaul of the guide shoes is not neces-

sary, let them hang from the tackles inside
the engine.
12. If the guide shoes need to be overhauled,

lift them out of the engine, one at a time,
by means of wire rope and tackles, and
land them on a couple of planks.
Remove the stop screw from the guide

M904020247D11
shoe.
Mount eye bolts in the guide shoe journal

and lift the journal out of the guide shoe.
12. Inspect the surfaces of the journal and the

bearing in the guide shoe.
13. Remove the crosshead from the engine,

using tackles.
Land and protect the crosshead outside

the engine.
D0457
M904020247D12
13.
M904020247D13
MAN B&W Diesel A/S
Crosshead 904-2.4
Mounting
1. Clean the crosshead, remove any protect-

ing layer of grease, and mount the special 1.
lifting tool.
D0421
Lift the crosshead into the engine by
means of wire rope and tackles, and lift it D0457
to make room for the guide shoes.
Lift the guide shoes without the guide

strips into the engine, and place them be-
tween the crosshead guides, hanging from
the tackles.
2. Lower the crosshead to the correct posi-

tion and mount the screws in the ends of
the crosshead.

the wire is tightened if the screw works
loose. See Procedure 913-7.
M904020247M01
2.
D0465
M904020247M02
MAN B&W Diesel A/S
904-2.4 Crosshead
Mounting
3. Use the tackles in the top of the framebox

3. to lift the crosshead into a working position
and mount the guide strips and shims on
the side of the guide shoes.
4. Use the tackles mounted on the lifting

brackets to raise the connecting rod to a
vertical position and hold it there.
Lubricate the crosshead bearing liberally

with clean lubricating oil and carefully lower
the crosshead into place.
M904020247M03
Unhook the wire ropes from the crosshead

lifting tool.
5. Dismount the tackles and connecting rod

lifting tools from the connecting rod.
4. Remove the lifting tool from the crosshead.
Mount the studs for the cooling oil inlet

bend.
D0450
Mount the inlet and outlet pipes.
Tighten the outlet pipe.

M904020247M04
5.
D0408
D0409
D0410
M904020247M05
MAN B&W Diesel A/S
Crosshead 904-2.4
Mounting
6. Lift the crosshead bearing cap into the en-

gine. 6.
Mount and tighten the crosshead bearing

cap.
Remove the eye bolts.
7. Mount the two thrust pads on the sides of

the crosshead. See Data.
Note!
D1301
M904020247M06
Always ensure that clearance exists fore
and aft between the thrust piece and the
crosshead before tightening the thrust
piece.
Mount the distance pipe on the telescopic

pipe bend. 7.
8. Mount the piston. See Procedure 902-2.
Remove the nut from the telescopic pipe

suspending tool. Turn downwards and
tighten the telescopic pipe.
Mount the main bearing oil pipes.

M904020247M07
D0416
D0420
MAN B&W Diesel A/S
Reciprocating Parts 104-3
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
X Shut off fuel oil
Data
D04-25 PF+PA, N max. 0.5 mm

D04-26 PF+PA, O max. 0.7 mm
D04-28 E+G, H+F, N max. 0.45 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.75 mm
D04-34 J+X, L+Y, K+X, M+Y, N max. 0.7 mm
D04-35 J+X, L+Y, K+X, M+Y, N min. 0.4 mm
D04-36 J+X, L+Y, K+X, M+Y, O max. 0.9 mm
D04-39 QF/QA, O max. 0.8 mm
D04-41 ZF/ZA O min. 4 mm
D04-42 TF + TA 0.8 mm
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data
MAN B&W Diesel A/S
Reciprocating Parts 904-3.1
Checking
Reciprocating Parts S42MC 0216
Checking
904-3.1
1.
In order to achieve uniform measuring condi-
tions on board, the ship's trim must be as close
as possible to 0°.
1. Mount a transparent plastic tube along the

length of the bedplate.
Bend each end approx. 250 mm up along

the framebox side. See T.
MA904-5.0 72 01
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
2.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Measurements are to be taken with a ruler. Fore Aft
2. Turn the crankshaft in ASTERN direction to

45° after BDC (the guide shoe must rest
against the crosshead guide).
Check the centering of the piston in the cyl-

inder liner by measuring the clearance (by PA
applying a long feeler gauge from the scav- PF
enge air space) between the piston skirt
and the cylinder liner in the Fore and Aft po-
HN904-3.1 212 02
sitions (PF-PA). 45°

A ste
rn
Make sure that the piston is clear of the cyl-

inder liner in the fore-and-aft direction.
MAN B&W Diesel A/S
904-3.1 Reciprocating Parts
Checking
3. 3. Measure the clearance between the crank-

throw and the connecting rod.
4. Measure the clearance between the thrust

piece and the crosshead (TF and TA or QF
and QA.
Measure the clearance between the cross-

head guides and the guide shoes (E, F, G
and H).
Measure the clearance between the guide

strips and crosshead guides (J, K, L and
M).
The clearance, calculated as J+X, K+Y,

L+Y and M+Y, is adjusted by the insertion
of shims so that it is symmetrical in relation
to the clearance between the piston skirt
and the cylinder liner.
Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
MN904-3.1 215 04
mm per 1000 mm.
BF and BA correspond to the thickness of

the shims and are only to be measured if an
4. adjustment is carried out.
Exhaust Side
Camshaft Side
MN904-3.1 215 05
MAN B&W Diesel A/S
Reciprocating Parts 904-3.1
Checking
5. It is recommended that the measured re- 5. Cyl. 1 2 3 4

sults are noted down so that possible later
PF
changes can be ascertained. Piston/Liner
PA
Shim BF
Thickness
BA
Frame Box E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+X
L+Y
K+X
M+Y
Crosshead QF/TF
Connecting
MN904-3.1 215 06
Rod QA/TA
Crankthrow
ZF
Connecting
Rod ZA
MAN B&W Diesel A/S
Crankpin Bearing 104-4
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
Shut off cooling water
Shut off fuel oil
Data
D04-43 Crankpin bearing clearance, max. 0,45 mm

D04-44 Crankpin bearing clearance, min. 0,2 mm
D04-45 Crankpin bearing cap complete 90 kg
D04-46 Crankpin bearing, upper shell 13 kg
D04-47 Crankpin bearing, lower shell 10 kg
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

P90451 59 Lifting attachment - connecting rod
P90451 84 Retaining tool telescope pipe
P90451 96 Bracket for support, Crosshead
P90451 106 Bracket for support, Crosshead
P90461 Connecting Rod - Hydraulic Tools
P91356 Lifting Tools, Etc.
MAN B&W Diesel A/S
Crankpin Bearing 904-4.1
Checking
Crankpin Bearing
S42MC
0222
Checking
904-4.1
2.
The bottom clearance between the journal and
a new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.
For the bottom clearance of a specific bearing,

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

cylinder.
2. Turn the crank concerned to BDC.
BG904-6.1 74 02
3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
3.
4. The difference between the actual clear-
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
D04-43
GM904-6.1 69 03
For further external inspection of the crank- D04-44

pin bearing, see Chapter 708 ‘Bearings' in
the instruction book, Volume I, OPERA-
TION.
5.
BG904-4.1 219 05
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling
Dismantling
904-4.2
2. 1. Turn the crank to BDC.
2. Mount two eye bolts in the crankcase top

plate in the athwartship direction and sus-
pend two tackles from the eye bolts.
3. Turn the crank to TDC.
Mount eye bolts in each side of the crankpin

bearing cap. Hook the tackles on to the eye
bolts and haul tight.
Loosen the crankpin bearing stud nuts, us-

BG904-6.0 62 03
ing the hydraulic jacks.
For operation of the hydraulic jacks, see

Section 913.
3. Remove the hydraulic jacks and the nuts.
4. Lower the bearing cap while seeing care-

D13-02 fully that the studs do not damage the
crankpin journal.
Land the bearing cap on a couple of planks

placed in the oil pan.
Inspect the bearing shell.

BG904-6.0 62 05
4.
D04-45
DM904-4.2 222 04
0$1% :'LHVHO$6
Dismantling
5. If the bearing shell needs to be replaced, 5.

remove the whole bearing cap from the
crankcase.
Suspend a tackle from the lifting bracket on

the inside camshaft side of the frame box
above the crankcase door opening.
Hook the tackle on to an eye bolt on one

side of the bearing cap.
Mount the wire guide in the top of the D04-45

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

wall, together with a tackle suspended from
the platform bracket, lift the bearing cap out
DM904-4.2 222 05
of the crankcase.
6. Place the bearing cap on one side on a

couple of planks.
Dismount the bearing shell lock screws and 6. D04-47

replace the bearing shell by a new one.
The bearing shells must be replaced in

pairs.
GN904-4.2 203 06
7. Turn to TDC.
Mount the four supports for guide shoes on

Carefully turn the crank down until the 7.

guide shoes rest on the supports.

BG904-6.0 62 09
0$1% :'LHVHO$6
Dismantling
8. 8. Mount a lifting attachment for securing the

connecting rod at the lower end, on one
side.
Hook on the tackle to a beam under the gal-

lery platform and haul tight.
9. Carefully turn the crankshaft downwards,

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
DM904-4.2 222 08
Continue turning the crankshaft until the

bearing surface can be freely inspected.
Inspect the bearing shell surface and the

9. crankpin journal.
10. If it is necessary to replace the bearing

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

rod is hanging freely.
Dismount the bearing shell lock screws.

Carefully lower the bearing shell from the
connecting rod and remove it from the en-
gine.
DM904-4.2 222 09
10.
D04-46
BM904-4.4 219 02
0$1% :'LHVHO$6
Mounting
Mounting
904-4.4
1. Lift the upper bearing shell for the crankpin 1.

concerned into the crankcase.
Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.
D04-46
2. Hook the tackle on to a beam under the gal-
lery platform and on to the lifting attach-
ment on the connecting rod, and haul tight.
Lubricate the upper crankpin bearing shell

and the crankpin journal with plenty of
BM904-4.4 219 02
clean lubricating oil.
Carefully turn the crankshaft upwards,

while following up with the tackle, making
sure that the upper part of the bearing en-
ters the recess in the crankshaft when the 2.
parts turn together.
Remove the tackle and the lifting attach-

ment from the connecting rod.
3. Turn the crosshead to TDC.
Remove the guide shoe support brackets

from the crosshead guides.
DM904-4.4 222 02
3.
BG904-6.0 62 09
0$1% :'LHVHO$6
Mounting
4. 4. Mount two eye bolts in the crankcase top-

plate in the two outer screw holes in the
athwartship direction and suspend two
tackles from the eye bolts..
5. Turn the crankthrow towards the exhaust

side of the engine.
Lift the bearing cap assembly into the

crankcase and land it on a couple of planks
placed in the oil pan.
BG904-6.0 62 03
5.
D04-46
DM904-4.4 222 05
0$1% :'LHVHO$6
Mounting
6. Turn the crankthrow to TDC. 6.
Hook the tackles on to the eye bolts of the

bearing cap and lubricate the bearing shell
with plenty of lubricating oil. D04-45
Lift the bearing cap into position against the
connecting rod.
Caution!
During mounting, take care that the studs

do not damage the crankpin journal, and
check that the guide pins mounted in the
bearing cap enter the holes in the con-
necting rod.
7. Mount the nuts and, by means of spacer

rings and hydraulic jacks, tighten the crank-
pin bearing cap. See Data.
DM904-4.2 222 04
For operation of hydraulic jacks, see Sec-

tion 913.
Remove the tackles, the eye bolts and the

hydraulic tools from the engine.
7.
D13-01
BG904-6.0 62 05
0$1% :'LHVHO$6
Connecting Rod 104-5
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10405
104-5 Data 0041 Connecting Rod
X Stopped engine
Shut off fuel oil
Data
D04-04 Crosshead bearing cap 84 kg

D04-48 Crankpin bearing cap + shell + bearing studs 105 kg
D04-50 Connecting rod, without bearing caps 692 kg
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

P90451 96 Bracket for support of crosshead
P90451 106 Bracket for support of crosshead
P90461 Connecting Rod - Hydraulic Tools
MAN B&W Diesel A/S
Connecting Rod 904-5.2
Dismantling
Connecting Rod
S42MC
0229
Dismantling
904-5.2
1.
1. Suspend the piston and telescopic pipe.
Turn the crank to BDC.
Dismount the nuts from the crosshead

bearing studs.
2. Suspend two tackles from the top lifting

brackets. Mount the wire guide on the door
frame.
DM904-7.0 89 01
Dismount and remove the crosshead bear-
ing cap.
Mount the lifting attachment on the cross-

head end of the connecting rod on the ex- 2.
haust side. D04-04
3. Turn the crank to TDC.
Dismount the crankpin bearing cap.

DM904-1.2 232 10
3.
D04-48
DM904-5.2 229 03
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling
4. 4. Mount the four supports for guide shoes on

Carefully turn the crank down towards the

door opening, camshaft side, until the guide
shoes rest on the supports.

5. Mount the lifting attachments on the cross-

head end of the connecting rod.
DM904-5.2 229 04
Attach tackles to lifting brackets A and D on

the frame box wall and attach the tackle
hooks to the lifting attachments. Haul the
tackles tight.
5.
Mount a lifting attachment on the crankpin
end of the connecting rod, on the exhaust
side.
6. Turn the crankthrow to 45° before BDC,

while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.
Shift tackle D from the lifting attchment on

one side of the connecting rod to the lifting
attachment on the other side of the con-
necting rod.
DM904-5 2229 05
Remove tackle A.
6.
D04-50
DM904-5.2 229 06
0$1% :'LHVHO$6
Connecting Rod 904-5.2
Dismantling
7. Attach a tackle to lifting bracket B on the 7.

frame box wall, and connect the tackle hook
to the lifting attachment on the crankpin end
of the connecting rod.
Attach a tackle to lifting bracket F on the

gallery bracket outside the engine, and con-
nect the tackle hook to the lifting attach-
ment on the connecting rod.
Turn the crank carefully upwards while ‘fol-

lowing’ with the tackles, guiding the con-
necting rod head out of the doorway.
DM904-5.2 229 07
8. Shift tackle D from the lifting attachment on
the crosshead end to the crankpin end of
the connecting rod.
Continue turning upwards till about 30° af- 8.

ter TDC while ‘following’ with the tackles.
9. Attach a tackle to lifting bracket E on the

gallery bracket outside the engine, and at-
tach the tackle hook to the lifting attach-
ment.
Shift the tackle on lifting bracket F to G and

attach the tackle hook to the lifting attach-
ment.
Haul the tackles tight.

DM904-5.2 229 08
Remove the tackle from E.
Disengage the connecting rod from the

crankpin by turning the crank carefully up-
wards while ‘following’ with the tackles. 9.
Lift the connecting rod out of the engine

and land it on the gallery on a couple of
wooden planks.
DM904-5.2 229 09
0$1% :'LHVHO$6
904-5.4 Connecting Rod
Mounting
Mounting
904-5.4
2. 1. Equip the connecting rod with the same lift-

ing attachments as mentioned under dis-
D04-50 mantling.
Check that the crank is in a position about

25° past TDC on the camshaft side.
The connecting rod and the crankshaft

must be placed in line to facilitate mounting.
Apply clean lubricating oil to the crankpin

bearing shell and journal.
Mount the connecting rod and assemble the

parts in the reverse order to dimantling.
M904-5.4 229 01
0$1% :'LHVHO$6
Connecting Rod and Crosshead Panel Plate
P90451-0144
Connecting Rod and Crosshead Panel
0144
P90451
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0144
Item Item
No. No.
011 Tool panel

023 Name plate
047 Wire guide
059 Lifting attchment - connecting rod
060 Lifting tools - crosshead
072 Chain for suspending piston
084 Nut
096 Bracket - support of x-head
106 Bracket - support of x-head
118 Rubber cover for crosshead
120 Rubber cover for crosshead
155 Crowfoot wrench head
MAN B&W Diesel A/S
Connecting Rod - Hydraulic Tools Plate
P90461-0066
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0066

No. No.
028 Hydraulic jack

030 Support
041 Tommy bar
089 Spanner
100 Stud setter
207 Hydraulic toolset, complete
MAN B&W Diesel A/S
Main Bearing 105-2
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D05-01 Main bearing, top clearance max. 0.50 mm

D05-02 Main bearing, top clearance min. 0.25 mm
D05-03 Main bearing cap 149 kg
D05-04 Main bearing shell, upper 12 kg
D05-05 Main bearing shell, lower 13 kg
105-2 Main Bearing
Data MAN B&W Diesel
P90551 76 Lifting tool - main bearing cap

P90551 123 Retaining tool for main bearing shell
P90551 88 Dismantling tool, main bearing shell
P90551 255 Handle for dismantling of mainbearing shell
P90561 Main Bearing - Hydraulic Tools
P90562 Lifting tool for crankshaft
P90572 Main Bearing - Measuring Tools
P91351 22 Hydraulic pump, hand operated
P91351 166 Angle union
P91366 48 Autolog, measuring tool for crankshaft
P91368 Foot gratings
Main Bearing 905-2.1
Checking
Main Bearing
S35MC
0239
Checking
905-2.1
1.
1. If there is too large a difference in the
crankshaft deflection readings (autolog),
check the individual bearings.
2. Remove the lub. oil pipe from the main

bearing cap.
Calibrate the main bearing measuring tool:
MB905-2.0 41 01
See the wooden box for the measuring tool.
3. Insert the measuring tool and check the

clearance between the upper shell and the
journal. 3.
The difference between the actual clear-

later) must not exceed 0.05 mm.
An appreciable increase in clearance may

be an indication of loose staybolts or wear
of the lower shell.
BM905-2.1 239 03
4. If necessary, dismount the bearing cap and

the upper shell. For further inspection of the
bearing, see Procedure 905-2.2.
Inspect the bearing and the journal (see 4.

Volume I, OPERATION, Chapter 708,
‘Bearings’).
BM905-2.1 239 04
0$1% :'LHVHO$6
905-2.2 Main Bearing
Dismantling
Dismantling
905-2.2
In the following, the main bearings are divided

into three categories:
• The main bearings (marked A).
• The thrust shaft end journal bearing

(marked B).
• The axial vibration damper end bearing

BM905-2.2 210 00
(marked C). (The engine is not always

equipped with this bearing).
Check and write down the top clearances be-

fore carrying out any dismantling.
1.
Dismantling of main bearings (A)
1. Disconnect the lubricating oil inlet pipe from

the main bearing cap (if not already done
during checking).
2. Turn the crankthrow so that it points to-

wards the exhaust side of the engine.
Place two spacers on two bearing cap

studs with the slots towards the centre of
the bearing cap.
Screw the two extension studs onto the

same two bearing cap studs (diagonally)
BG905-3.1 71 01
1+3, and subsequently 2+4.
Mount the double hydraulic jacks on the

studs.
2.
Connect the four hydraulic jacks to the
D-6 high-pressure pump by means of the dis-
tributor block and high-pressure hoses.
(For operation of the hydraulic tools, see

Chapter 913).
Then loosen the nuts.
Repeat the sequence until all four nuts are

loose.
Remove the hydraulic tools and unscrew

the nuts.
BG905-3.1 71 02
0$1% :'LHVHO$6
Dismantling
3. Remove the rectangular nut washers from 4.

the bearing cap.
4. Remove the stop screw in the crosshead

guide shoe.
Mount the guide pulley with the lifting wire

rope in the bottom of the guide shoe.
Rig-up two tackles outside the engine.
Mount the outside tackles, one in the lifting

beam on the camshaft side, and one on the
exhaust side.
5. Fasten the lifting tool to the main bearing

cap with wire rope attached to the camshaft
side tackle.
Lift the bearing cap and, by means of the

handle, push the bearing cap free of the
frame and land it on the crank web.
BG905-3.1 71 03
5.
D-4
BM905-2.2 239 05
0$1% :'LHVHO$6
Dismantling
6. 6. Remove the wire rope from the guide pul-

ley, and fasten the two wire ropes from the
lifting tool in the two tackles outside on ei-
ther side, and lift the bearing cap out of the
crankcase.
Remove the guide pulley from the engine.
7. Mount the handle in the upper bearing shell

D-4 and remove the shell from the crankshaft.
Inspect the bearing shell and the journal.

BM905-2.2 239 06
See Volume I, OPERATION Chapter 708,

Bearings).
8. Check that there is clearance between the

journal and the bearing shell in the two ad-
7. jacent main bearings.
D-5
BM905-2.2 210 07
8.
BG905-2.2 216 08
0$1% :'LHVHO$6
Dismantling
9. Remove the screws from the sides of the 9.

crosspiece and screw them into the thread-
ed holes of the upper hydraulic jacks for the
main bearing.
10. Place the crosspiece in the bedplate with

the ends resting on the crossgirders, and
place the hydraulic jacks beneath the crank
webs as shown.
Tighten the screws against the crank webs.
Place a dial gauge to measure the lifting of

the crankshaft.
BG905-3.1 85 09
Connect the hydraulic jacks to the high
pressure pump and raise the pressure until
the crankshaft has lifted maximum 0.2 mm.
10.
11. Dismount the lock screws from the lower
shell.
Place the dismantling tool on the top of the

lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
groove in the bearing shell.
Pull the lower bearing shell round and up

until it lies over the main bearing journal.
Take out the lower shell from the crankcase

in the same way as the upper shell.
BM905-2.2 239 10
Max.0.2 mm
11.
BM905-2.2 239 11
0$1% :'LHVHO$6
Dismantling
Dismantling of journal bearing in the thrust

shaft end (B).
12. Remove the screws of the cover placed

over the thrust bearing. Mount an eye bolt,
shackles and wire rope in the cover. Hook
on a tackle and lift the cover away.
Disconnect the lubricating oil pipe used for

BM905-2.2 210 00
lubricating the bearing.
Turn the crank web for the aftmost cylinder

to TDC.
12. 13. Mount the spacer supports over the two

D-8 nuts and screw the extension studs onto the
two bearing cap studs. Mount the double
hydraulic jacks on the studs.

high-pressure pump by means of the dis-
tributor block and high-pressure hoses.

Chapter 913.
Remove the hydraulic tool and unscrew the

BM905-3.2 117 01
nuts.
13.
D-6
BM905-3.2 117 03
0$1% :'LHVHO$6
Dismantling
14. Mount an eye bolt in the bearing cap and lift 14.
it away. D-3
Remove the upper bearing shell from the
crankshaft.
15. If the crankshaft is turned with the bearing

cap dismounted, use the two stops which
prevent the lower shell from being rolled
out.
BM905-3.2 117 04
16. Set up a dial gauge in such a manner that
a max. lift of 0.20 mm of the shaft can be
measured.
15.
BM905-3.2 117 05
16.
Max. 2/10 mm
BM905-2.2 239 17
0$1% :'LHVHO$6
Dismantling
17. 17. Remove the screws from the sides of the

Max. 2/10 mm
main bearing.
Place the crosspiece in the bedplate with

webs as shown.

the crankshaft has lifted maximum 0.2 mm.
Measure the clearance in the second last

main bearing (positioned fore of the thrust
bearing). Mount a dial gauge on both the
aftmost main bearing and the second last
bearing. Lift until the aftmost bearing is lift-
BM905-2.2 239 19
ed 0.2 mm or the clearance for the second

last bearing is reached.
18. Dismount the lock screws from the lower

shell.
18.
Check that there is at least 0.1 mm clear-
ance in both sides of the bearing.
Note!
The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
relief in the bearing shell.
JM905-2.2 236 24
0$1% :'LHVHO$6
Dismantling
Dismantling of main bearing in the axial vi- 19.

bration damper end (C) D-9
19. Remove the end cover and the top cover
and dismount the lubricating oil pipe.
Turn the crankweb for the foremost cylinder

to TDC.
20. Mount the spacers over the two nuts and

screw the extension studs onto the two
bearing cap studs.
Mount the double hydraulic jacks on the
BM905-3.3 88 01
studs.

high-pressure pump by means of the dis-
tributor block and high-pressure hoses. 20.
Bleed the hydraulic system and raise the

D-6
pressure as indicated in Data.

Chapter 913.
Remove the hydraulic tool and unscrew the

nuts.
21. Mount a shackle over the main bearing cap

BM905-3.3 88 02
and hang up a tackle.
Mount an eye bolt in the top of the bearing

cap, hook on the tackle and lift the bearing
cap out of the crankcase. 21.
D-3
Remove the upper bearing shell from the
crankshaft.
BM905-3.3 88 03
0$1% :'LHVHO$6
Dismantling
23. 22. Inspect the bearing and the journal.
See Volume I, OPERATION Chapter 708,

D-6 Bearings.
23. Check that there is clearance between the

journal and the bearing shell in the two ad-
jacent main bearings.
24. Set up a dial gauge, at the foremost main

bearing, in such a manner that a max. lift
of 0.20 mm of the shaft can be measured.
Remove the screws from the sides of the

main bearing.
Place the crosspiece in the bedplate, with

webs as shown.
BM905-3.3 88 05

24. the crankshaft has lifted maximum 0.2 mm.
BM905-3.3 88 08
0$1% :'LHVHO$6
Dismantling
25. Dismount the lock screws from the lower 25.

shell.
Place the dismantling tool on the top of the

lower bearing shell, making sure that the
flap of the dismantling tool enters the oil
groove in the bearing shell.
Pull the lower bearing shell round and up

until it lies over the main bearing journal.
Take out the lower shell from the crankcase

in the same way as the upper shell.
GN905-2.2 204 12
Note!
Never remove the tools for lifting the

crankshaft before remounting the lower
main bearing shell.
0$1% :'LHVHO$6
Overhaul
Overhaul
905-2.3
1. 1. Clean and inspect the bearing shells. For

2. judging the condition of the bearing, see
Volume I, Chapter 708, ‘Bearings’.
If the bearing shells are damaged, contact

MAN B&W Diesel for advice.
We recommend that the main bearing

shells be replaced in pairs.
If, nevertheless, it is desired only to replace

one shell, it requires a careful evaluation of
the condition of the shell that is to be rein-
GN905-2.3 204 01
stalled. See instruction book, Volume I,

Chapter 708.
For advice on replacing the bearing shells

individually, it is recommended to contact
MAN B&W Diesel A/S or the engine builder.
2. Before remounting:
• Check the bearing support for damage

and burrs. If damage is found, contact
• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and main bearing support.
• Lubricate the bearing journal, the main

bearing support and the back of the
shell.
0$1% :'LHVHO$6
Mounting
Mounting
905-2.4
For all main bearings (A, B and C): 1.
1. Lubricate the lower bearing shell and the

crankshaft journal with plenty of clean lubri-
cating oil.
2. Land the lower bearing shell on the crank-

shaft journal.
Mount the handle on the lower bearing shell

and slide down the lower bearing shell as
far as possible.
BM905-2.2 210 00
Remove the handle.
Using a caliper, check in both sides of the

bearing shell that the bearing shell is
mounted horizontally correct.
2.
3. If necessary, use the bearing shell disman- D-5
tling tool to push the lower bearing shell ful-
ly down under the crankshaft journal.
BM905-2.4 210 02
0$1% :'LHVHO$6
Mounting
4. 4. Check visually that the shell does not pre-

vent the locking screws from being fully
tightened to the bedplate, as this would
cause damage to the screws and shell
when tightening the bearing cap.
See also Volume I, OPERATION, Chapter

708.
5. Lower the crankshaft and remove the

crosspiece and the hydraulic jacks from the
engine.
BM905-2.4 210 02
6. Lubricate the upper bearing shell with plen-

ty of clean lubricating oil. Land the upper
bearing shell on the crankshaft journal.
Make sure that the edge of the upper bear-

6. ing shell does not rest on the tip of the bed-
plate.
If so, press the shell into place.
7. Mount the bearing cap. Make sure that the

guide pin from the bedplate enters the hole
in the bearing cap.
BM905-3.3 88 13
7.
D-4
BG905-3.1 71 16
0$1% :'LHVHO$6
Mounting
For middle main bearing (A) 8.
8. Mount the: D-7

• rectangular washers
• nuts
• extension studs
• spacers
• double hydraulic jacks
Tighten the main bearing cap. See Data.
9. The tightening is done in the following se-

quence:
1) Tighten nuts 1 + 3
2) Tighten nuts 2 + 4
BG905-3.1 85 17
3) Retighten nuts 1 + 3
Remove the hydraulic tools.
10. After tightening the bearing cap, check the 9.


BM905-3.1 71 17
ance in the Adjustment Sheet in Volume I,

OPERATION, Chapter 701.
11. Mount the lubricating oil pipe.

11.
D-10
BG905-2.0 48 05
0$1% :'LHVHO$6
Mounting
12. For main bearing in thrust shaft end (B):

D-7 12. Mount the:
• nuts
• extension studs
• spacers
• hydraulic jacks
BM905-3.2 117 03
Tighten the bearing cap. See Data.
Mount and tighten the nuts of the adjacent

main bearing, see step 9.
13.
D-8 Remove the hydraulic tools.
After tightening the bearing cap, check the


D-11 OPERATION, Chapter 701.
13. Finally, mount the lubricating oil pipe and

the cover over the thrust bearing.
BM905-3.2 117 17
D-10
0$1% :'LHVHO$6
Mounting
For main bearing in axial vibration damper 14.

end (C):
D-7
14. Mount the:
• nuts
• extension studs
• spacers
• hydraulic jacks
Tighten the bearing cap. See Data.
BM905-3.3 88 02
Mount and tighten the nuts of the adjacent
main bearing, see step 9.
Remove the hydraulic tools.

15.
After tightening the bearing cap, check the D-9
top clearance once more. D-11
OPERATION, Chapter 701.
15. Finally, mount the lubricating oil pipe, the

end cover and the cover over the bearing
cap.
D-10
BM905-3.3 88 15
0$1% :'LHVHO$6
Thrust Bearing 105-3
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10503
105-3 Data 0041 Thrust Bearing
X Stopped engine
Shut off fuel oil
Data
D05-06 Thrust bearing segment 24 kg

D05-09 Segment stopper, fore 105 kg
D05-10 Segment stopper, aft 81 kg
D05-29 Segment stopper, tightening torque 450 Nm
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data
P90551 147 Tool for turning out segments

MAN B&W Diesel A/S
Thrust Bearing 905-3.1
Checking
Thrust Bearing
S42MC
0227
Checking
905-3.1

The clearance in the thrust bearing was meas-
ured during testbed trials of the engine and not-
ed down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,

and for an engine in service it must not exceed
2.0 mm.
In service it is only necessary to measure the

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.
1. To measure the wear in the thrust bearing,
DM905-3.4 45 02
it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.

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

has to be pressed against the thrust cam,
to eliminate any gap, i.e. by using a suitable
crowbar on the back of the segment.
If a feeler gauge of 0.1 mm is not able to

enter the groove (the wear is more than 0,9
mm), the thrust bearing must be over-
hauled.
GN905-3.1 224 02
3. Note down the wear for later reference.

KN905-2.2 238 02
0$1% :'LHVHO$6
905-3.2 Thrust Bearing
Dismantling
Dismantling
905-3.2
1. Remove the protective shield, and the lub.

oil pipe for the thrust segments.
D05-09
Loosen and remove the screws from the
D05-10 segment stoppers.
Remove the segment stoppers above the

thrust segments ( AHEAD or ASTERN) that are
to be taken out, and lift the stoppers out of
the chain casing.
2. For turning up the thrust segments, mount

the tools on the chain wheel.
DM905-5.0 67 01
3. Turn up the segments, one at a time, by

turning the engine, and remove the seg-
ment from the chain casing. Inspect the
segment and remount it before turning up
the next segment.
Note!
Never remove more than one segment at

a time.
DM905-3.4 227 02

D05-06
DM905-5.06704
0$1% :'LHVHO$6
Thrust Bearing 905-3.4
Mounting
Mounting
905-3.4
1. Suspend a tackle above the segments 1.

which are to be mounted. Still, it is possible
to lift the segments by hand.
Mount the tool for turning out segments on

the chainwheel.
Land the segment on the journal and re-

move the eye bolt from the segment.
Carefully slide the segment on to the seg-

ment tool. Turn the engine to dismantle the
next segment.
2. After the last segment has been mounted,

turn the segment tool up and dismount it.
DM905-3.4 227 01
2.
DM905-3.4 227 02
0$1% :'LHVHO$6
905-3.4 Thrust Bearing
Mounting
3. Mount the segment stopper.

D05-09
Tighten the screws on the stopper.
D05-10
D05-29 Mount the lub. oil pipe for the thrust seg-
ments and the protective shield.
DM905-3.4 227 03
0$1% :'LHVHO$6
Journal Bearing 105-4
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10504
105-4 Data 0013 Journal Bearing
X Stopped engine
Shut off fuel oil
Data
D05-01 Journal bearing, top clearance, max. 0.50 mm

D05-02 Journal bearing, top clearance, min. 0.25 mm
D05-04 Journal bearing shell, upper 11.6 kg
D05-05 Journal bearing shell, lower 12.3 kg
D05-13 Journal bearing cap 156 kg
D05-16 End cover 68 kg
MAN B&W Diesel A/S
105-4 Journal Bearing
Data

P90551 040 Lifting tool – bearing cap
064 Dismantling tool, bearing shell
076 Mounting tool for bearing shell
088 Lifting tool for bearing shell
P90561 Main Bearing – Hydraulic Tools
P90562 Llifting tool for crankshaft
P91351 Hydraulic pump, pneumatically operated
105 3-way distributor block, complete
MAN B&W Diesel A/S
Journal Bearing 905-4.1
Checking
Journal Bearing
S42MC
0214
Checking
905-4.1
1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-1.1.
2. Write down the journal bearing clearances.
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
0$1% :'LHVHO$6
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2
2. 1. Dismount the screws for the end cover.

D05-36
Mount a ½-ton tackle above the end cover.
Remove the end cover.
2. Disconnect the lubricating oil pipe from the

main pipe.
Remove the protective shield for the thrust

bearing.
Turn the crank throw for the aftmost cylin-

der to TDC.
3. Mount the extension studs, the spacers, the

DM905-4.2 214 02
hydraulic jacks and the nuts on the exten-

sion studs. Loosen the bearing stud nuts,
using the hydraulic jacks

3.
Procedure 913-1.
4. Remove the hydraulic main bearing tools

from the engine
Unscrew and remove the nuts from the

D13-02 bearing studs.
DM905-4.4 214 07
4.
KN905-2.2 238 07
0$1% :'LHVHO$6
Dismantling
5. Remove the rectangular nut washers from 5.

the bearing cap.
Mount the lifting attachment on the journal

bearing cap, and lift the cap out of the en-
gine using the ½-ton tackle above the bear-
ing.
6. Mount the dismantling handle on the upper

shell, and lift the shell out of the engine.
7. Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure until
DM905-4.2 214 05
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the adjacent
bearing.
Dismount the lower bearing shell by lifting

the crankshaft on the aftmost cylinder sec- 6.
tion as shown in Procedure 905-2.
If necessary, the aftmost main bearing cap

nuts can be loosened to attain the required D05-04
clearance.
DM905-4.2 214 06
7.
Min. 0,1 mm
EXH CAM
Min. 60 mm
KN905-2.2 238 28
0$1% :'LHVHO$6
Dismantling
8. 8. Dismount the locking screws.
Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.
Pull the lower bearing shell round and up-

wards until it lies over the bearing journal.
Never use a tackle larger than 0.5 ton.
9. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
dismantling handle.
Note!
M905-4.2 214 08
The clearance between the axial vibration

damper and the journal can be the decisive
factor in judging how much the crankshaft
can be lifted.
9.
D05-05
DM905-4.2 214 06
0$1% :'LHVHO$6
Overhaul
Overhaul
905-4.3
1. Clean and inspect the bearing shells. It is 1 + 2.

recommended that the main bearing shells
be replaced in pairs.
If it is nevertheless desired to replace only

one shell, this requires a careful evaluation
of the condition of the shell that is to be re-
installed.
See Instruction book, Volume I,
Chapter 708.
For advice on replacing individual bearing

shells, it is recommended to contact MAN
B&W Diesel A/S or the engine builder.
2. Before remounting:
• Check the bearing support for damage

and burrs. If damage is found, contact DM905-4.3 214 01
• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and bearing support.
• Lubricate the bearing journal, the bear-

ing support and the back of the shell,
with main engine lubricating oil.
0$1% :'LHVHO$6
Mounting
Mounting
905-4.4
1. 1. Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.
Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and
land it on the crankshaft journal.
2. Position the guide tool for the lower bearing

shell on the bearing support. Remove the
lifting tool from the bearing shell.
Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.
DM905-4.4 214 01
Push the lower bearing shell downwards

while holding the shell back with the dis-
mantling tool.
2. Check that the bearing shell is positioned

with the same distance on both sides.
3. Remove the guide tool when the lower

bearing shell has been mounted.
Mount the locking screws in the bearing

support.
Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from under
the crankshaft.
Wipe the contact surfaces between the up-

DM905-3.2 130 10
per and the lower bearing shells clean with

a non-fluffy piece of cloth.
3.
DM905-4.4 214 02
0$1% :'LHVHO$6
Mounting
4. Land the upper bearing shell on the main 4.

journal in the same way as the lower bear-
ing shell.
Make sure that none of the edges of the up-

per bearing shell are resting on the edge of
the bearing support.
If necessary, place the special tool between

the studs and press the shell into place.
Clean the contact surfaces between the

bearing support and the bearing cap. Make
DM905-3.2 130 11
sure that no oil is left on the contact surfac-
es.
5. Mount the lifting tool on the bearing cap.

Using the lifting tool and the tackles, lift the
bearing cap into the crank casing in reverse 6.
order to dismantling.
See Procedure 905-4, step 5.
6.
Note!
Be sure that the cap lands correctly and

that the guide pin in the assembly sur-
face enters the hole in the bearing cap.
7. Mount the rectangular nut washers, the

KN905-2.4 238 09
nuts, the spacer rings, the hydraulic jacks,

and tighten the nuts. See Data.
For operation of the hydraulic tools,

see Procedure 913-1.
7.
D13-01

0
'
0$1% :'LHVHO$6
Mounting
9. 8.
Note!
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.
9. Remove all tools from the engine.
Note!
KN905-2.4 238 14
Search the crankcase to ensure that

C there are no tools, shackles or rags left
behind.
10.
D05-34 10. Mount the lubricating oil pipe on the bear-

ing cap, and mount the end cover.
KN905-2.4 238 15
0$1% :'LHVHO$6
Axial Vibration Damper 105-5
MAN B&W Diesel Data

X Stopped engine
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off fuel oil
Data
D05-17 Inner screws, tightening torque 250 Nm

D05-21 Outer screws, tightening torque 800 Nm
D05-23 Horizontal screws, tightening torque 230 Nm
D05-24 Horizontal screws, tightening torque/angle 100/17 Nm/°
D05-25 Damper housing, upper part 125 kg
105-5 Axial Vibration Damper
Data MAN B&W Diesel
P90551 111 Lifting tool - AVD

Axial Vibration Damper 905-5.1
Checking
Axial Vibration Damper
S35MC
0226
Checking
905-5.1
1.
For checking the effectiveness of the axial vi-
bration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken

at the same r/min as during the sea trials. (Pref-
erably 90% and 100% of MCR.)
As different equipment can have been mounted

on the specific engines, the checking procedure
describes three different systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, without angle encoder fore
C: Mechanical, with angle encoder fore.
A: Electronic, with Axial Vibration Monitor
A proximeter probe is built on to the lower part

of the damper housing. The probe is connected
to a control unit which displays peak-to-peak
KM905-7.1 35 01
movements and sends signals to the engine

control system.
1. Concerning overhaul and setting of the

electronic device, refer to makers instruc-
tions and Volume I, Operation, Chapter
701.
The peak-to-peak values displayed in mm

are to be compared with the original values
obtained during sea trial and the limits giv-
en in Volume I, Operation, Chapter 701.
If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see
Procedure 905-5.2.
MAN B&W Diesel A/S
905-5.1 Axial Vibration Damper
Checking
1. B: Mechanical, without angle encoder fore
1. Stop the engine.
Unscrew the two plugs from the cover at the

front of the engine.
2. Mount the shaft piece in the end of the

crankshaft, using the handle.
After tightening the shaft, dismount the

handle.
BG905-5.1 223 01B
Screw the measuring arm into the small

threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.
2. Attach a pencil to the arm.
Note!
To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.
BG905-5.1 223 02B
MAN B&W Diesel A/S
Checking
3. Start the engine, and let the speed rise to 3.

the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.) S-2
When measuring, press the measuring arm

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

plate should have a mass of approx. 1-2 kg.
DM905-7.1 74 05
The axial movements (S2) recorded on the
paper must be measured with a slide calli-
per as shown in the sketch.
4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
S1
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.
For a standard measuring tool (L 1 = 38 mm L2

and L 2 = 200 mm), the ratio is 5.3. There- L1 S2
fore, S1 can be calculated as follows:
M90505-0229C10
If a non-standard tool is used, S1 can be

calculated as follows:

Procedure 905-5.2.
MAN B&W Diesel A/S
Checking
1. C: Mechanical, with angle encoder fore
For engines with angle encoder fore, a meas-

uring tool is available for mounting on the angle
encoder housing.
1. Stop the engine.
Dismount the protection shield over the an-

gle encoder. (Not always on engine).
Dismount the cover on the angle encoder

housing.
Apply some Molycote TM on the fore side of

the shaft cam.
2. Mount the axial vibration measuring tool,

using the screws from the cover.
Note!
BG905-5.1 223 01C
To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.
2.
MN905-5.1 214 05
MAN B&W Diesel A/S
Checking
3. Start the engine, and let the speed rise to 3.

the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)
S2
When measuring, pull the measuring arm
against the shaft cam with one hand. With
the other hand, move a sheet/block of pa-
per, clipped onto a solid backing plate,
lightly sidewards against the tip of the pen-
cil.
PULL
To ensure a certain inertia, the backing
plate should have a mass of approx. 1-2 kg.
The axial movements (S2) recorded on the

paper must be measured with a slide calli-
BG905-5.1 223 03
per as shown in the sketch.
4. Before comparing the measured value (S2)

with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in 4.
the tool.
For a standard measuring tool (L 1 = 35 mm

and L 2 = 178 mm), the ratio is 5.1. There-
fore, S1 can be calculated as follows:
If a non-standard tool is used, S1 can be

calculated as follows:

MA905-5.1 212 07

Procedure 905-5.2.
MAN B&W Diesel A/S
905.5.2 Axial Vibration Damper
Dismantling
Dismantling
905.5.2
1. Dismantling of the axial vibration damper is car-

ried out from the crankcase of cyl. No. 1.
1. Turn the engine to 90º after TDC.
Dismount the lubricating oil pipes for the

main bearing and axial vibration damper.
2. Loosen and remove the screws from the

damper housing upper part.
Only the upper part of the housing needs to

be removed, while the lower half remains
mounted on the bedplate.
BG905-7.2 28 01
3. Mount the lifting bracket and a shackle on

the upper part.
2. Dismount the plug screw above the axial vi-

bration damper, on the fore end of the
frame box.
By means of a tackle, mounted below the

foreend platform, and a wire rope, separate
and raise the upper part of the damper
housing to a position in which it is possible
to change the oil seals and springs.
Note!
Before starting work below the suspen-

BG905-7.2 28 02
ded upper part, secure the upper part

with, e.g. a wire rope or another tackle.
3.
D05-25
BG905-5.2 216 03
MAN B&W Diesel A/S
Overhaul
Overhaul
905-5.3
1. Dismantle and remove the springs from the 1.

oil sealing rings.
Remove the oil sealing rings.
Note!
It is recommended to discard both the

springs and the oil sealing rings.
When mounting the new oil sealing rings,

first insert the lower half of the rings in the
HG905-5.2 201 01
lower housing.
Then press the tension springs into the

groove between the oil sealing ring half and
the housing.
2.
2. Mount all the upper halves of the oil sealing
rings in such a way that the clearance at
both the joints on each oil sealing ring is the
same.
Now hook the new tension springs into

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

HG905-5.2 201 02
protrude above the centreline.
MAN B&W Diesel A/S
Mounting
Mounting
905-5.4
1. 1. Release and carefully lower the upper part

of the damper housing.
D05-25 When reaching the oil sealing rings, take

care that the rings enter the sealing ring
grooves correctly.
Before landing the upper part on the lower

part, be sure that the guide pins have en-
tered the guide pin holes.
2. Mount the vertical and horizontal screws.
Tighten the screws. See Data.
Note!
Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.
BG905-5.4 223 01
Mount the lubricating oil pipes.
Mount the plug screw on the fore end of the

frame box.
2. D05-17
D05-21 Note!
After overhaul of the axial vibration

damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
D05-23
BG905-7.2 28 06
MAN B&W Diesel A/S
Tacho Pick-Ups 105-7
Data
SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0002
105-7 Tacho Pick-Ups
X Stopped engine
Shut off fuel oil
Shut off lubricating oil
Data
D-1 Tacho pick-ups for governor

system(Gov. and BMS maker : Lyngso)
– check distance 2.5 mm
When referring to this page, please quote Data D10507 Edition 0S02 Page 1 (2)
MAN B&W Diesel A/S
105-7 Tacho Pick-Ups
Data
Spare Parts
Plate – Item No. Description Qty
Page 2 (2) When referring to this page, please quote Data D10507 Edition 0S02
MAN B&W Diesel A/S
Tacho Pick-Ups 905-7.1
Checking
Tacho Pick-Ups
S46MC-C
0201
Checking
905-7.1

The engine is equipped with below pick-ups:
• Governor system pick-ups
Governor system pick-ups:
1. The tacho pick-ups are placed next to the

turning wheel.
2. Check the distance between the tacho pick-

ups and the turning wheel, see Data.
If necessary, adjust the distance.
If the tacho pick-ups are renewed, note

down the wiring to ensure the correct re-
mounting.
EN905-7.1 201 01

Turning wheel
EN905-7.1 201 02
0$1% :'LHVHO$6
Crankshaft, Thrust Shaft, Main Bearing, Plate
Etc. -Panel P90551-0176
Crankshaft, Thrust Shaft, Main Bearing, Etc. -Panel
0176
P90551
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing,
P90551-0176 Etc. -Panel
Item Item
No. No.
015 Panel for tools

027 Name plate
040 Lifting tool - main bearing cap
052 Stud setter
064 Dismantling tool main bearing shell
076 Mounting tool for thin bearing shell
088 Handle for dismantling main bearing
shell
090 Mounting tool for thin bearing shell
100 Retaining tools for main bearing shell
111 Lifting tool for axial vibration damper
123 Lifting tool for relief valve
135 Tightening template for axial vibration
damper
147 Tool for turn out segments
MAN B&W Diesel A/S
Main Bearing - Hydraulic Tools Plate
P90561-0085
Main Bearing - Hydraulic Tools
0085
P90561
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0085
Item Item
No. No.
021 Hydraulic jack, upper

033 Hydraulic jack, lower
045 Support
057 Distance bolck
069 Spacer ring
070 Extension stud
082 Support
116 Stud setter for main bearing studs
128 Ball handle
200 Hydraulic tool set, complete
MAN B&W Diesel A/S
Crankshaft - Tools Plate
P90562-0128
Crankshaft - Tools
0128
P90562
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0128
Item Item
No. No.
015 Lifting tool for crankshaft
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0003
Main Bearing - Measuring Tools
0003
P90572
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0003
Item Item
No. No.
010 Measuring tool main bearing

clearence
021 Calibration tool
045 Key, hexagon socket screws
057 Wooden box
MAN B&W Diesel A/S
Chains 106-1
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
3” chain
D06-18 Teeth on chain wheel, max. wear 2.5 mm
D06-19 Original length (chain pitch x 10 links) 762 mm
D06-20 10 links measurements + 1% of a tensioned chain = scrapping of chain 769.6 mm
106-1 Chains
Data MAN B&W Diesel
P90651 Chain Drive and Camshaft - Panel
Chains 906-1.1
MAN B&W Diesel Checking
1. The engine is equipped with a set of

chains: 1.
• the drive chains for the camshaft
The set of chains is to be checked and, if

necessary, dismantled and mounted in the
same way.
2. The chains can be accessed from within

the chainwheel frame.
3. Carry out the inspection as follows:
• Make a general inspection for loose

bolts and screws.
• Inspect lube oil pipes for damage, and

check jet nozzles for possible stoppag-
es or deformations.
• Examine the rubber track of the guide-

M906010245C01
ways for cracks or other damage.
• Replace the guideway if bits have start-

ed to be “plucked out” of the rubber
track.
4. Check the teeth of the chain wheels. If ab-

normal wear is found, take a measurement 4.
(See Data).
Measurements are best taken by placing a

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

5. of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.
Draw two rulers on the drawing.
For assessing the wear profile, contact

MAN B&W Diesel.
0 In most cases, scratches caused by the

side plates of the chain will be found on
the sides of the teeth. Such scratches can
generally be considered normal.
Scale 1:1
M906010244C05
10
6. The chains for the camshaft drive are
0 10 matched together to ensure an even load
distribution.
To keep such matching chains in their

pairs, the side plates of the outer link
nearest to the assembled link have been
marked with year, month, day and chain
number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 2C, possible 3rd chain)
No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)
On the same links there is an arrow (–>)

which indicates the mounting direction.
Check the chains for cracks on possibly

defective rollers and side plates.
Check that the chain rollers can run freely

and that the chain links can freely move
on the pin and bushing (that they are not
“seized” between the pin and the bushing).
It is normal, however, that the rollers get

light, circumferential scratches during the
runningin period. These fine scratches are
of no importance and need not be consid-
ered.
It is recommended that each single link is

checked.
Chains 906-1.1
7. Check chain wear by measuring the length

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

See Procedure 9062.3. D0619
Ma
D0620
x.D
06
20
M906010245C07
906-1.2 Chains
It may become necessary to disassemble

1. the chain if, for instance, cracked rollers
or seizures between pin and bushing have
been discovered during the inspection.
Note!
Every time a chain link is disassembled,
a new link must always be fitted as
the link pin pressfit is destroyed when
breaking the chain.
When a new link is fitted in one chain,

the corresponding link in the other chain
must also be renewed.
1. Remove the tension on the chain by loos-

ening the chain tightener.
(See Procedure 9062.3).
M906010245C01
Turn the engine until the slack part of the

chain, with the chain link that is to be dis-
assembled, is in a favourable position for
the work.
2. Mount a wire round the link rollers a short

2. distance from the disassembly point, and
tighten the wire lightly with a tackle.
Protect the link rollers over which the wire

is wrapped.
Note!
If the chain is to be completely removed,

contact MAN B&W Diesel for further in-
formation.
M906010238D02
The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.
Chains 906-1.2
3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter- 3.
nately tightening the screws on the tool.
M906010238D03
906-1.4 Chains
Before assembling the inner and outer

1. links, clean the pins and bushings.
1. Combine the inner chain link with the outer

chain link and mount the compression tool.
Force the loose side plate of the outer

link into place by alternately tightening the
screws on the compression tool.
2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
M906010238M01
Repeat this procedure until the chain has

been assembled.
Remove the tackle and wire and adjust the

chain tension.
(See Data and Procedure 9062.3).
Chain Tightener 106-2
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D06-21 Tightening angle = 10 hexagons 600/10 ° / hex

D06-25 Mechanical or blocked chain tightener, clearance 0,1 mm
106-2 Chain Tightener
Data MAN B&W Diesel
P90651 070 Chain assembling tool

P90651 081 Chain disassembling tool
Chain Tightener 906-2.3
Adjustment
Chain Tightener
S60MC-C
0230
Adjustment
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,
C and D to free the chain tightener bolt. A
B
2. Turn the engine at least one revolution with
the chain slackened on the same side as
the chain tightener wheel.
If the engine is equipped with flyweights,

continue turning until the flyweights are
hanging vertically downwards.
3. Tighten nut B on the chain tightener bolt C

until there is a clearance between the shaft D
HG906-2.3 218 01
and the nut as stated in D06-25.
Then tighten nut B as stated in D06-21

(see Data).
For chain wear, see Procedure 906-1.1. HM906-2.2 95 01 2.
3. B
D06-25
D06-21
HG906-2.3 218 03
0$1% :'LHVHO$6
906-2.3 Chain Tightener
Adjustment
4. 4. Tighten nut C hard against the contact face

of the shaft.
Tighten nut D.
Lock nuts C and D with the tab washer.
5. Tighten nut A.
Lock nuts A and B with the tab washer.
The number of times that retightening can

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

X Stopped engine
Shut off fuel oil
Data
D06-27 Max. permissible change in lead angle 2 °

D06-28 corresponding to 3 mm
106-3 Camshaft
Data MAN B&W Diesel
P90664 Crankshaft - Pin Gauge

P90668 Camshaft - Pin Gauge
P91366 061 Slide caliper
Camshaft 906-3.1
1. Turn the crankthrow for cylinder 1 to TDC.

1.
Turn in the ahead direction to ensure that
the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
Check the TDC of cylinder 1 against the

mark on the turning wheel.
2. Use the check measurement value

stamped on the pin gauges to check the
pin gauges for deformation.
M906030218C01
On some engines the pin gauges can be
checked against punch marks made on the
front cylinder frame.
2.
Check
Che
ck
M90603-0219C02
906-3.1 Camshaft
3. Check the TDC position with the pin gauge

3. on the crankthrow.
Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see D06-27

and D06-28.
4. Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,
if any, in lead angle.
M906030218C03
For max. permissible change, see D06-28.
5. Check and, if necessary, adjust the cylinder

lubricator.
4.
Check the setting of the starting air dis-
tributor.
6. When checking the camshaft position, also

check the running surface of the cams.
As the inspection must include the entire

surface of the cam, the cam should be
turned one complete revolution during the
D06-28 inspection.
M90603-0219C04
The running surface of the cam must be

D06-27 completely smooth and bright.
6.
M90603-0219C06
Camshaft 906-3.1
7. If light scratches are ascertained, remove

them by carefully polishing the cam in the 6.
direction of rotation with a fine carborun-
dum stone. Such light scratches can ap-
pear if the roller guide and the cam are not
correctly aligned.
In the event of heavier scratches or direct

flaking of the material on the running path,
MAN B&W Diesel should be contacted for
further instructions.
M90603-0219C07
906-3.3 Camshaft
Adjustment MAN B&W Diesel
1. If the chains prove to be so heavily worn

1. that the deviation between the measuring
points and the pin gauge has reached the
maximum value D06-28 stated in Data, MAN
B&W Diesel should be contacted for further
instructions.
M90603-0219O01
D06-28
Camshaft Bearings 106-4
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10604
106-4 Data 0027 Camshaft Bearings
X Stopped engine
Shut off fuel oil
Data
D06-31 Screws for bearing cap, tightening torque 150 Nm

D06-33 Clearance between cap/bearing housing 2.7-3.3 mm
D06-34 Bearing shell, max. wear 0.05 mm
D06-37 Camshaft bearing cap 13 kg
MAN B&W Diesel A/S
106-4 Camshaft Bearings
Data

P90862 Jack-hydraulic, complete
MAN B&W Diesel A/S
Camshaft Bearing 906-4.1
Checking
0217
Camshaft Bearing S42MC
Checking
906-4.1
1.
1. As the upper shell of the camshaft bearing
assembly has been dispensed with on this
engine, it is no longer necessary to meas-
ure the top clearance of the camshaft bear-
ing.
Dismount the inspection covers from the

front of the camshaft housing.
Check for wiped-out metal at the bearing

ends, and for fragments of metal in the
camshaft housing.
In the event of any signs of anomalies, the

bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced.
GN906-4.1 203 01
If no anomalies are found during the visual
inspection, dismantling need not be carried
out.
When checking the camshaft bearings, it is

recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 908-5 and 909-3.
MAN B&W Diesel A/S
906-4.2 Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Warning!
Before dismantling any camshaft bear-

ings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
1. Remove the inspection covers on each side

of the bearing from the camshaft housing.
Dismount the lubricating oil connecting pipe

BM906-5.0 47 02
and the plug screws from the baseplate

above the bearing in question.
Lift the roller guide of the exhaust valve hy-

2. draulic pump. See Procedure 908-7.
2. Loosen the bearing cap screws through the

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

BG906-5.0 40 03
D06-37
MAN B&W Diesel A/S
Dismantling
3. Place a hydraulic jack between two pieces 3.

of wood in the camshaft housing under-
neath the camshaft, close to the bearing.
Place a dial gauge on the camshaft, and lift

the camshaft 0.20 mm.
4. Press lightly on the upper edge of the shell

to turn the shell up over the camshaft.
Remove the shell from the camshaft hous-

ing.
BG906-5.0 40 04
BG906-5.0 40 05 4.
MAN B&W Diesel A/S
906-4.3 Camshaft Bearing
Overhaul
Overhaul
906-4.3
1. 1. For assessment of the bearing condition,

see Volume I OPERATION, Chapter 708
‘Bearings’.
Inspect the entire surface of the bearing

journal for seizures.
If seizures are found on the bearing journal

surface (on account of bearing breakdown),
polish the surface with a fine carborundum
stone to re-establish a bright and smooth
surface.
By closely examining the sliding surface of

the bearing shell visually, an impression
can be formed of whether the lubrication of
the bearing surface has been insufficient or
GN906-4.3 203 01
entirely missing. Normally, camshaft bear-

ing damage only occurs due to faulty lubri-
D06-34 cation.
Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.
MAN B&W Diesel A/S
Mounting
Mounting
906-4.4
1. Clean the bearing journal, the bearing sup- 2.

port and the bearing shell.
2. Coat the bearing journal and the bearing

shell with plenty of lubricating oil. Mount the
shell on the camshaft, and turn it into place.
Relieve the hydraulic jack of pressure to

lower the camshaft. Remove the dial gauge,
the pieces of wood and the hydraulic jack
from the camshaft housing.
3. Place the bearing cap on the camshaft and

mount the outermost bearing cap screw.
BG906-5.0 40 07
Note!
Be careful not to scratch the camshaft 3.

surface.
Tighten the outermost screw lightly by hand

until the clearance given in D06-33 is
reached. Then mount and tighten the inner- D06-31
most screw with a torque spanner. See
Data D06-31. This procedure ensures that
the outermost screw will obtain the correct
torque.
Check the torque on the outermost screw D06-33

with a torque spanner.
BG906-5.0 40 08
Check the clearance D06-33 on both sides

of the camshaft. Then mount the lubricating
oil pipe and the plug screws in the base-
plate.
4.
4. Clean the camshaft housing and mount the
inspection covers.
BG906-5.0 40 01
MAN B&W Diesel A/S
Replacement of Cams on Camshaft 106-6
Data
SAFETY PRECAUTIONS
Special Edition
D10606
106-6 Data 0004 Replacement of Cams on Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-47 Exhaust cam screws, tightening torque 360 Nm

D06-49 Fuel cam screws, tightening torque 930 Nm
D06-50 Fuel cam, marking scratch 92 mm
D06-51 Fuel cam, axial movement 135 mm
D06-52 Exhaust cam, marking scratch 73 mm
D06-53 Exhaust cam, axial movement 135 mm
MAN B&W Diesel A/S
106-6 Replacement of Cams on Camshaft
Data
P90951 82 Lifting tool for fuel pump roller guide

MAN B&W Diesel A/S
Replacement of Cams on Camshaft 906-6.2
Dismantling
Replacement of Cams on Camshaft
S42MC
0203
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft

housing.
2. Lift the roller guide from the cam in ques-

tion. See Procedures 908-5 or 909-5.
3. Turn the camshaft so that the marking

scratch can be seen.
4. Extend the marking scratch on the shaft by

D-1. See Data.
XZ906-6.2 201 01
XZ906-6.2 201 02 2.
4.
XZ906-6.2 201 04
D06-50
When referring to this page, please quote Procedure M90606 Edition S203 Page 1 (7)
0$1% :'LHVHO$6
906-6.2 Replacement of Cams on Camshaft
Dismantling
5. 5. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.
6. Connect the snap-on connectors to the hy-

draulic high-pressure pump.
Apply oil pressure to the cam, using the

high-pressure pump.
When oil seeps out along the cam, press

the cam sideways, in the direction towards
the forward end of the engine.
7. The cam should be moved as stated in

XZ906-6.2 201 05
D06-51 to be sure that it gets free of the lin-

er for the roller guide.
8. In case the cam cannot be moved as de-

6. scribed in item 6, MAN B&W should be con-
tacted for further instructions.
XZ906-6.2 201 06
7.
D06-51
XZ906-6.2 201 07
D06-51
Page 2 (7) When referring to this page, please quote Procedure M90606 Edition S203
0$1% :'LHVHO$6
Dismantling
Exhaust Cam 9.
9. Remove the front cover of the camshaft

housing.
10. Lift the roller guide from the cam in ques-

tion. See Procedure 908-5.
11. Extend the marking scratch on the exhaust

cam onto the camshaft by D06-52. See Data.
XZ906-6.2 201 01
XZ906-6.2 201 10 10.
11.
XZ906-6.2 201 11
D06-52
0$1% :'LHVHO$6
Dismantling
12. 12. Remove the plug from the cam and mount
gaskets and snap-on connectors instead.
13. Connect the snap-on connectors to the hy-

draulic high-pressure pump.
Apply oil pressure to the cam, using the

high-pressure pump.
When oil seeps out along the cam, press

the cam sideways, in the direction towards
XZ906-6.2 201 12
the aft end of the engine.
13.
XZ906-6.2 201 13
0$1% :'LHVHO$6
Dismantling
14. The cam should be moved as stated in 14.

D06-53 to be sure that it gets free of the lin-
er for the roller guide.
15. In the event that the cam cannot be moved

as described in item 14, MAN B&W should
be contacted for further instructions.
D06-53
D06-53
XZ906-6.2 201 15
0$1% :'LHVHO$6
Mounting
Mounting
906-6.4
1. Fuel Cam
1. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,

mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
2. Make sure that the marking scratches on

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.
Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the fuel cam lead (see Procedures

909-1 and 909-2) and adjust if necessary.
XZ906-6.4 201 01
Tighten the screws to D06-49 and check

that the gap is still equal at both sides.
Lock the screws with Loctite, type 242

2. (EN243S).
3. Mount the cover on the front of the cam-

shaft housing.
D06-49
XZ906-6.4 201 02
0$1% :'LHVHO$6
Mounting
Exhaust Cam 4.
4. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,
XZ906-6.4 201 04
mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
5. Make sure that the marking scratches on 5.

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.
Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the fuel cam lead (see Procedure

908-7) and adjust if necessary.
Tighten the screws to D06-47 and check

that the gap is still equal at both sides.
XZ906-6.4 201 05
Lock the screws with Loctite, type 242 D06-47

(EN243S).
6. Mount the cover on the front of the cam-

shaft housing.
0$1% :'LHVHO$6
Chain Drive and Camshaft Panel Plate
P90651-0193
Chain Drive and Camshaft Panel
0193
P90651
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft Panel
P90651-0193
Item Item
No. No.
019 Panel for tools

020 Name plate
044 Pin spanner for fuel cams
070 Chain assembling tool
081 Chain opener
MAN B&W Diesel A/S
Crankshaft - Pin Gauge Plate
P90664-0005
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0005

No. No.
021 Pin gauge for crankshaft
MAN B&W Diesel A/S
Camshaft - Pin Gauge Plate
P90668-0005
Camshaft - Pin Gauge
0005
P90668
MAN B&W Diesel A/S
Plate Camshaft - Pin Gauge
P90668-0005
Item Item
No. No.
011 Pin gauge for camshaft
MAN B&W Diesel A/S
Starting Air Distributor 107-1
Data
X Stopped engine
Shut off fuel oil
Stop lubricating oil supply
Data
D07-01 Gear wheel on camshaft, tightening torque 90 Nm

D07-03 Clearance between gear wheel and bushing:Min. Max. 0.9-1.6 mm
D07-04 Clearance with roller in outermost position:Min. Max. 1.0-3.0 mm
D07-05 Clearance with roller in innermost position:Min. Max. 1.0-2.0 mm
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data
MAN B&W Diesel A/S
Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
L42ME/MC
0218
Checking
907-1.1
1.
1. Turn the engine in AHEAD direction to bring
the piston of cylinder No. 1 to TDC.
Check with the pin gauge.
2. Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.
GN906-3.1 203 02
If pin K is not available, use the cylindrical
end of a drill of a suitable size.
3. If the check pin cannot enter the slot, i.e. if

the slot is not aligned with the hole in the
2.
distributor housing, the air distributor must
be adjusted.
S
K S
EN907-1.3 204 02
MAN B&W Diesel A/S
907-1.3 Starting Air Distributor
Adjustment
Adjustment
907-1.3
1. 1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.
Check with the pin gauge.
2. Dismount the end cover of the camshaft

housing, along with the starting air distrib-
utor, from the engine.
GN906-3.1 203 02
Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.
Turn the shaft together with the distributor

2. disc until check pin K enters slot S in the
disc and keep it there.
S 3. Check and, if necessary, adjust clearance

D07-03 between the gear wheel and the
bushing.
K S
EN907-1.3 204 02
3.
GN907-1.3 203 03
D07-03
MAN B&W Diesel A/S
Starting Air Distributor 907-1.3
Adjustment
4. Remove the lower half of the gearwheel 4.

drive cover. Mount the upper half of the
gearwheel drive cover with the complete
starting air distributor after loosening the
gear wheel on the camshaft, and then en-
gage the two gear wheels by turning the
wheel on the camshaft.
Tighten and lock the gear wheel screws on

the camshaft, see Data, D07-01.
Mount the lower half of the gearwheel drive

cover.
5. Remove check pin K from the distributor

housing and mount the gasket and plug
screw. D07-01
6. Check the clearance between the roller and GN907-1.3 203 02
the two interlocking valves with the roller in

its innermost and outermost positions, re-
spectively ( ASTERN and AHEAD).
5.
K
S
GN907-1.3 203 02
6.
D07-05
DL907-1.3 218 06
D07-04
MAN B&W Diesel A/S
Starting Air Valve 107-2
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D07-09 Piston tightening torque 110 Nm

D07-10 Valve tightening torque 25 Nm
D07-12 Starting air valve 12 kg
107-2 Starting Air Valve
Data MAN B&W Diesel
P90151 095 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve
Starting Air Valve 907-2.1
1. When the starting air valve has been over-

hauled, see Procedure 907-2.3, connect a 1.
supply of working air to the control air inlet
at the top of the valve.
Check that the valve opens approx. 15-20

mm.
2. Shut off the air supply
Check that the valve closes fully.
3. Repeat steps 1 and 2 a couple of times.
M907020220C01
2.
M907020220C02
907-2.2 Starting Air Valve
1. Shut off the starting air and control air in-

1. let.
Dismount the control air pipe.
Unscrew the starting valve nuts.
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
M907020220D01
2.
D0712
M907020220D02
1. Remove the top cover fixing screws and re-

move the cover. 1.
Remove and discard the gasket.
2. Remove the split pin and screw off the nut

from the valve spindle.
3. Remove the disc, the piston, the valve

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

end of the valve housing. Remove and dis-
M907020220O01
card the O-ring.
2.
M907020220O02
3.
M907020220O03
When referring to this page, please quote Procedure M90702 Edition 0220 Page 3 (6 )
4. Grind the valve housing seating with the

4. grinding ring after applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle and hous-

ing to match, using the face wrench to ro-
tate the valve spindle.
5. Thoroughly clean all parts before reassem-

bling the valve.
Lubricate all internal parts (sliding surfaces)

with, for instance, Molybdenum Disulphide,
MoS2.
6. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring, the piston and the disc.
M907020220O04
6.
M907020220O03
7. Mount the nut on the valve spindle and

tighten the nut, see Data D07-09. 7.
Mount the split pin.
8. Place a new gasket on the valve housing. D0709

Mount and tighten the top cover.
Replace the O-ring on the valve housing.
9. If the starting air valve is not to be mount-

ed in the engine immediately after the
overhaul, all openings of the valve should
be covered with plastic to prevent dirt from
entering the valve during storage.
M907020220O07
8.
M907020220O01
When referring to this page, please quote Procedure M90702 Edition 0220 Page 5 (6 )
1. Carefully clean the starting valve bore in

1.
the cylinder cover and, if necessary, recon-
dition the seat for the starting valve in the
bore.
If not already done, replace the O-ring on

the overhauled valve and lubricate with
‘Never Seize’ or Molybdenum Disulphide,
MoS2.
For overhaul, see Procedure 907-2.3.
2. Mount the valve in the cylinder cover.

M907020220M01
Mount and tighten the screws as stated in

Data.
Mount the control air pipe and turn on

starting air and control air.
2.
D0710
M907020220M02
High-Pressure Pipe 108-1
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D08-01 High-pressure pipe, tightening torque 20 Nm

D08-02 Distance of high pressure pipe lower edge to pressure flange 19 mm
D08-03 High-pressure pipe 18 kg
108-1 High-Pressure Pipe
Data MAN B&W Diesel
P90851 112 Grinding mandrel for h.p. pipe
High-Pressure Pipe 908-1.2
MAN B&W Dismantling
1. When replacing the hydraulic high-pressure

pipe, the exhaust valve or the hydraulic ac- 1.
tuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.
2. Before dismantling the high-pressure pipe,

stop the camshaft oil pump.
Loosen the screws for the high-pressure

D0803
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.
M908010230D01
2.
M90801-0231D02
908-1.3 High-Pressure Pipe
Overhaul MAN B&W
1. Check the contact surfaces of the pressure

1. pipe for marks and, if necessary, grind the
pipe ends by means of the grinding man-
drel and the guiding tool.
Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and fin-
ish with a fine grinding paste, for example
2. After reconditioning the contact surfaces

of the pipe, measure the distance from
the edge of the thrust bushing to the con-
Carborundum No.200/500
M90801-0231O01
tact surface at both ends of the pipe. This

measurement is to correspond with the
value stated in Data.
3. Mount a new O-ring on both pipe ends.
2.
M90801-0231O02
D08-02
3.
M90801-0231O03
High-Pressure Pipe 908-1.4
MAN B&W Mounting
1. Mount the hydraulic high-pressure pipe as

follows: 1.
Position the high-pressure pipe with the

sealing surfaces flush against the surfaces
of the exhaust valve/ actuator. Take care
not to damage the O-ring. D0803
Mount and lightly tighten the screw by
hand. Ensure that there is a small clearance
(approx. 4-6 mm) between the flanges of
the pipe and the exhaust valve/ actuator.
2. After fitting the pipe correctly in relation to

the exhaust valve and actuator, tighten up
the screws of the pressure flanges diago-
nally, see Data.
3. Check the whole system for tightness.

M908010230M01
2.
D08-01
M90801-0231M02
Exhaust Valve 108-2
MAN B&W Data

X Stopped engine
Shut off fuel oil
Data

D08-04 Safety valve, opening pressure 23 bar
D08-06 Oil cylinder, tightening torque 70 Nm
D08-09 Bottom piece seat, grinding angle 30 °
D08-10 Valve spindle seat, grinding angle 30.3 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1 mm
D08-13 Spindle, max. burn-off 7 mm
D08-14 Spindle, max. grinding 2 mm
D08-15 Spindle stem, measuring area, min. 240 mm
D08-16 Spindle stem, measuring area, max. 300 mm
D08-17 Spindle stem, min. diameter 49.8 mm
D08-18 Bushing max. diameter, top 50.5 mm
D08-19 Bushing max. diameter, bottom 52 mm
D08-20 Oil cylinder max. inside diameter 60.2 mm
D08-21 Piston rings, min. thickness 2.5 mm
D08-22 Damper piston, min. distance 47 mm
D08-23 Damper piston, max. distance 51.2 mm
D08-24 Exhaust valve, complete 351 kg
D08-25 Exhaust valve housing 195 kg
D08-26 Oil cylinder 41 kg
D08-27 Air cylinder 13.5 kg
D08-28 Spindle 40 kg
D08-29 Bottom piece 34 kg
D08-30 Air piston 3 kg
D08-40 Throttle valve, tightening torque 50 Nm
108-2 Exhaust Valve
Data MAN B&W
P90851 065 Lifting tool for exhaust valve

P90851 077 Cone ring for pneumatic piston
P90851 089 Pressure tester for safety valve
P90851 090 Gauge for exhaust valve spindle
P90851 136 Bridge gauge for exhaust valve
P90851 148 Tool for hydraulic piston
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90861 Valve seat and spindle grinder
P90862 Hydraulic jack, complete
Exhaust Valve 908-2.1
MAN B&W Checking
Checks during running:

1.
1. Check of valve spindle rotation
The engine must run when the valve func-

tion and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90° and let it rest on the air piston.
The indicator will now follow the move-

ments of the valve spindle and the air pis-
ton. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the ridge on the
piston.
During engine operation, the spindle must

rotate. The rotation can vary with unit and
engine load. In the event of no rotation, at-
tention should be paid to avoid seat prob-
lems. When check of the valve rotation is
finished, lift the rotation indicator and lock
M908020262C01
it in the top position.
The indicator must not be in constant op-

eration. On ridge On surface
Exhaust valve performance condition

See volume I chapter 706 Performance 2.
Evaluation
2. Check of bottom piece sealings
With the exhaust valve mounted in the cyl-

inder cover, check the cooling water inlet
and outlet to the cylinder cover and ex-
haust valve is open.
Check the tightness of the sealing rings

between the bottom piece and the exhaust
valve housing. If water flows from the small
M908020262C02
bore on the manoeuvring side of the ex-

haust valve, the lowermost sealing ring is
leaking.
If water flows from any of the rings, the

exhaust valve must be dismounted and the
sealing rings replaced.
908-2.1 Exhaust Valve
Checking MAN B&W
Check with stopped engine:

3.
In connection with port stays, at an interval
of e.g. one month, an easy check of all ex-
haust valves is recommended.
3. Check of spindle drop-down time:
Engage all rotation indicators on the ex-

haust valves.
Shut off and release the spring air on the
valve, next to the engineside manoeuvring

stand.
Check the drop down time for all spindles:
• Spindles dropping down within 30 min-

utes: Check and overhaul, See next step
“Check of Air Spring tightness”.
• Spindles dropping down between 30

M908020262C03
minutes and 1 hour: Keep under obser-

vation.
• Spindles dropping down after 1 hour:

OK.
When check of drop down time is finished,

lift the rotation indicators and lock them in
the top position.
Note!
If the air cylinder is fitted with new seal-
ing rings, the time the valve is closed
may be considerably shorter than 15
minutes. The dropdown test should not
be carried out until after a “running-in”
period of 500 hours on valves with new
sealing rings.
MAN B&W Checking
4. Check of Air spring tightness

4.
Connect compressed air to the non return
(A) valve on the air cylinder.
Disconnect and remove the drain oil pipe

from the oil cylinder (C).
Check if air is coming out from:
• Pipe for drain oil (C): If yes, the leakage

comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and over-
haul.
• Remove the air supply to the nonreturn A

valve on the air cylinder and check the
nonreturn valve for tightness.
The checks is for guidance only, minor

leaks is difficult to detect.
D
M90802-0284C04
Dismantling MAN B&W
1. Close off cooling water

1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections
Dismount the highpressure pipe for the hy-

draulic valve actuation.
See Procedure 9081.2
Dismount the return oil pipe from the ex-

haust valve.
M908020263D01
2.
M908020263D02
MAN B&W Dismantling
3. Disconnect pipe connections

3.
Disconnect the cooling water connections
from the exhaust valve and the air pipe for
the air spring.
Remove the plate jacket and insulation

from the intermediate pipe.
Loosen the screws which attach the inter-

mediate pipe to the exhaust valve housing.
Support the intermediate pipe by e.g. a

chain block and remove the screws.
M908020263D03
4. Dismantling of hydraulic nuts.
Remove the protective caps from the ex-

haust valve studs.
4.
Loosen and remove the hydraulic nuts, see D1302
Data. See Procedure 9131.
M908020263D04
Dismantling MAN B&W
5. Lift of exhaust valve

5.
D0824 Check that all connections to the valve are
removed.
Attach the crane to the eye bolt fitted on

top of the valve and start lifting the exhaust
valve. During the lift check the valve goes
clear of all other engine components.
Land the exhaust valve on a wooden plate

on the platform.
Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
ing and sealing surfaces of the bore, if re-
quired. See Procedure 9011.3.
For overhaul of the exhaust valve, see Pro-

cedure 9082.3
M908020263D05
MAN B&W Overhaul
1. Oil cylinder
1.
Place the exhaust valve on a wooden sup- D0826
port on the platform.
Remove the nuts and depending on valve

model the safety strap from the oil cylinder.
Remove the return oil pipe.
Lift away and place the oil cylinder on a

wooden support.
2. Conical locking ring
Relieve the air pressure through the

nonreturn valve from below the piston. Use
a small screwdriver to press the ball into
the nonreturn valve. Cover the nonreturn
valve with a rag to catch the oil drops.
Remove the four screws from the flange

on top of the air piston and dismount the
M908020263O01
flange.
Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring.
2.
M908020262O02
Overhaul MAN B&W
3. Spindle
3.
D0824
Use the oil cylinder as a lifting tool for the
exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
so that the load from the valve housing is
evenly distributed.
Lift the valve housing clear of the valve

spindle. Take care – when the internal
Oring in the air piston and the internal
rings for the sealing arrangement at the
bottom of the air cylinder pass the groove
for the conical ring at the top of the spin-
dle.
4. Bottom piece
Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
M908020263O03
If the bottom piece has become stuck, use

a tin hammer to release it.
Lift the valve housing away and land it on a

couple of wooden planks.
4.
Remove the oil cylinder.
D0829
M908020263O04
MAN B&W Overhaul
5. Air piston and cylinder

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

dismount the air cylinder. D08-27
Remove and discard the Oring on the air

cylinder.
M90802-0284O05
6. Guide bushing
Clean the exhaust valve housing.
Inspect the spindle guide bushing for wear

and measure the top and bottom diam- 6.
eters. See Data. D0818
M908020262O06
D0819
Overhaul MAN B&W
7. Bushing renewal
7.
If it proves necessary to replace the bush-
ing:
Place the valve housing on one side.
Knock out the bushing with a hammer and

a suitable mandrel.
Return the housing to an upright position.
Fit a new bushing.

M908020262O07
Reassemble the spindle stem stuffing box

with new sealing rings.
8. Bottom piece inspection
8. Before cleaning the bottom piece, see Vol-

ume I, supplement 70703
Inspect and evaluate the seating according

to Volume I.
9. Bottom piece measuring
In connection with evaluation of the bottom

piece according to Volume I, wear or the
total amount the seat has been ground, is
measured as described below.
M908020256O09
Use the bottom piece template and a feeler

gauge, take measurements G2 and G3. All
measurements should be taken at four dia-
metrically opposite points on the circumfer-
ence of the bottom piece seating.
9. G3
For maximum wear or grinding, see Data
D0812 D0811 and D0812.
If the seat or the recess G3 is ground, see

Data D08 – 09 for correct grinding angle.
IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN Further
D0809
grinding or reconditioning is not recom-
mended.
D0811
M908020262O09
G2
MAN B&W Overhaul
10. Bottom piece sealing face

10.
If necessary grind the outside seating.
Use carborundum 200 and the special

grinding tool. Turn the special grinding tool
by hand, turning alternately clockwise and
anticlockwise. Grind until a smooth surface
is achieved.
Clean the bottom piece.
11. Bottom piece sealing rings
M908020262O10
Mount new sealing rings on the bottom
piece.
Make sure that the grooves for the sealing

rings are clean.
11.
Mount one O-ring in the upper groove.
Heat the U-seal in 100°C hot water for min-

imum five minutes and then mount it in the
groove immediately.
M908020271O11
Overhaul MAN B&W
12. Bottom piece mounting

12.
exhaust valve housing.
Check the face on the valve housing is

clean.
If fitted, check that the guide pin in the

bottom piece enters the hole in the bottom
of the exhaust valve housing.
Land the exhaust valve housing on the bot-

tom piece. Mount and tighten the retaining
screws for the bottom piece.
13. Spindle inspection
Before cleaning the spindle, see Volume I,

supplement 70703.
Inspect and evaluate the spindle according

M908020263O12
to Volume I.
13.
M908020256O14
MAN B&W Overhaul
14. Spindle burn-off and grinding check

14.
In connection with evaluation of the spindle G1
according to Volume I, burnoff and wear or
the total amount the seat has been ground,
are measured as described below.
The burnoff F1 of the valve spindle is

checked by measuring along the spindle D0814
template from point A to point D and in
point E.
F1
For the maximum allowable burnoff, see
Data D0813. D0810
M908020256O15
The maximum seat grinding, gap G1 is A
measured between the spindle template,
D0813 D E
and the seating of the spindle with a feeler
gauge.
15.
For maximum seat grinding, see Data
D0814.
If necessary to grind the seat, see Data

D0810 for correct grinding angle.
D0816 D0815
15. Spindle stem check

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

D0815 to D0816 measured from the top of
the spindle.
For minimum stem diameter, see data

D0817.
If the exhaust valve spindle needs recon-

ditioning, contact MAN B&W Diesel for
advice.
M908020252O19
Overhaul MAN B&W
16. Spindle transport

16.
When lifting or transporting the exhaust
valve spindle, use the special valve spindle
D0828 lifting tool.
17. Spindle mounting
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.

exhaust valve housing.
M908020255O16
Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
Remove the oil cylinder.

17.
M908020263O17
MAN B&W Overhaul
18. Air cylinder

18.
Dismount the safety valve housing from the
air cylinder or dismount the safety valve
directly from the air cylinder (depending on
engine model.)
Disassemble the air filter and the sealing air

valve.
Clean the air cylinder and blow through all

bores in the air cylinder.
Check the bottom of the air cylinder for

possible coke, remove visible coke depos-
its.
Reassemble the air filter and the sealing air

valve with new sealing rings.
Mount a new Oring in the groove on the

outside of the air cylinder.
M90802-0284O18
Fit a new or overhauled safety valve.

For check of the safety valve see next step.
19. Safety valve
Unscrew the safety valve from the housing 19. D0804

Place the safety valve in the pressure test-
ing device. Connect the testing device with
the high pressure pump by means of a
hose.
Check the opening pressure, see Data.
If the opening pressure is not correct, loos-

en the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated. Tighten the lock nut
and test the opening pressure once more.
M908020262O19
Mount a new gasket and a new Oring on

D0807
the safety valve. Mount the safety valve in
the housing. For tightening torque see Data.
Finally, mount the protective cap.
Overhaul MAN B&W
20. Air cylinder mounting

20.
Lubricate the Orings in the spindle bush-
ing inside the air cylinder.
Carefully land the air cylinder on the ex-

haust valve housing and check correct en-
gaging with the locating pin. Some engines
are not equipped with the locating pin
Note!
Take care not to damage the Orings in
M90802-0284O20
the inside of the air cylinder.
21. Air piston seals
Fill the bottom of the air cylinder to the

21. drain hole with a clean lubricating oil.
22. Air piston seals
Check the teflon guide ring and teflon

Clean oil sealing ring for wear, if it is necessary to
replace the sealing rings on the air piston,
cut them and remove them.
Oil level
Be careful not to damage the edges of
M90802-0284O21
the ring grooves in the piston.
Note!
Before mounting, heat the new teflon
rings in 100°C hot water for at least five
22. minutes. When mounting the teflon rings,
be careful not to damage the running
surfaces.
After mounting, compress the teflon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new Orings in the inside grooves of

the air piston.
M908020252O32
MAN B&W Overhaul
23. Air piston mounting

23.
Fit the conical guide ring for the air piston
on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press

the air piston down in the cylinder
Remove the conical guide ring from the air

cylinder.
Mount the non return valve for spring air.
24. Locking ring
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
Mount the flange on top of the air piston

M90802-0284O22
and, by means of the four screws, tighten

the air piston and the flange together.
On valve models where the bolts are de-

signed for securing, secure the bolts. See
Procedure 9137. 24.
Compressed air
M908020-0284O23
Overhaul MAN B&W
25. Oil cylinder

25.
Unscrew the cover for the throttle valve.
Unscrew and clean the throttle valve. Re-
move and discard the sealing disc. Check
and clean the bore in the top of the oil cyl-
inder.
Place the oil cylinder in a horizontal posi-

tion. Remove the flange and take out the
piston. Inspect the bore in the oil cylinder
for scoring. Measure the cylinder diameter.
If the diameter of the oil cylinder exceeds
Data D0820, send the complete oil cylin-
der to an authorised MAN B&W workshop
for overhaul.
D0820
26. Oil piston
Remove the piston rings from the oil pis-

ton and check them for wear. If the thick-
ness of the rings has worn down to the
M908020262O24
minimum, see Data, discard the rings and

mount new ones. Check that the TOP mark
on the piston rings faces upwards, when
mounting.
26.
Top
D0821
M908020253O42
MAN B&W Overhaul
27. Oil cylinder assembly

27.
Mount the piston and the flange in the oil
cylinder. Tighten and lock the screws.
On some engines the sealing ring between D0840

oil and air cylinder is mounted in an inside
groove in the oil cylinder.
Return the oil cylinder to an upright posi-

tion. Mount a new sealing disc in the bore
for the throttle valve. Screw the throttle
valve into the bore. Mount the cover for the
throttle valve with a new gasket.
28. Oil cylinder mounting
Mount the overhauled oil cylinder on top of

the air cylinder.
Depending on valve model, mount the safe-

ty strap and tighten the nuts. See Data.
M908020262O26
Mount the return oil pipe.
28.
D0806
M908020263O27
Mounting MAN B&W
1. Checks before mounting

1.
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
D0824 the valve is checked and prepared as fol-
lows:
2. Oil level
Check the oil level in the bottom of the air

cylinder. Unscrew and remove the non-
return valve and the safety valve.
fill oil into the non-return valve hole until oil

flows out from the safety valve hole. Refit
the two valves again.
Connect compressed air to the air cylinder

to close the valve.
Lift up the valve with the engine room

G3 crane.
M908020263M01
Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3, to en-
sure that there is a clearance between the
outer parts of the seating faces of valve
housing and spindle.
2.
Carry out the drop down test as described
in procedure 9082.1.
Note!
If the air cylinder is fitted with new seal-
ing rings, the time the valve is closed
may be considerably shorter than 15
minutes. The dropdown test should not
be carried out until after a “running-in”
period of 500 hours on valves with new
sealing rings.
Check the valve is fitted with new sealing

rings in the grooves on the bottom piece.
G3
M90802-0284M02
MAN B&W Mounting
3. Exhaust valve landing

3.
Close the valve with compressed air.
Lubricate the sealing rings with vase-

line and the threads of the studs with
antiseizure paste.
Position the valve in the cylinder cover

bore, guiding it in accordance with the ex-
Compressed Air
haust flanges. Depending on model either
the guide pin on the exhaust side of the ex-
haust valve or the water connection on the
manoeuvre side must fit.
4. Mounting of hydraulic nuts.
Mount and tighten the hydraulic nuts, see

Data. See Procedure 9131.
M908020263M02
Mount the protective caps on the exhaust

valve studs.
4.
D1301
M908020263M03
Mounting MAN B&W
5. Mount the pipe connections

5.
Connect the intermediate pipe to the ex-
haust valve.
Mount and tighten the screws to the ex-

haust valve housing.
Mount the insulation and plate jacket for

the intermediate pipe.
Mount the cooling water connections for

the exhaust valve and the air pipe for the
M908020263M04
air spring.
6. Mount the oil pipe connections
Mount the highpressure pipe for the hy-

draulic valve actuation.
6. See Procedure 9081.2
Mount the return oil pipe to the exhaust

valve.
Check that all pipe connections are prop-

erly tightened.
M908020263M05
MAN B&W Mounting
7. Open cooling water supply

7.
Check that all water connections are
mounted and tightened.
Open the cooling water inlet supply, and

vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 9082.1.
8. Air spring check
The air supply to the exhaust valve must

always be connected and pressurized be-
fore turning on the oil supply to the ex-
haust valve actuator.
M908020263M06
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
8. closed.
Closing of the exhaust valves are eased

if the lubrication oil pumps are stopped
and the actuators are drained at the drain
screws.
M908020256M07
Closed Valve Open Valve
Exhaust Valve Actuator 108-3
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D08-20 Oil cylinder max. inside diameter 60.2 mm

D08-21 Piston rings, min. thickness 2.5 mm
D08-32 Hydraulic actuator, tightening torque 360 Nm
D08-34 Hydraulic actuator, tightening angle 30 °
D08-35 Hydraulic actuator 35 kg
108-3 Exhaust Valve Actuator
Data MAN B&W Diesel
Exhaust Valve Actuator 908-3.1
Checking
0226
Exhaust Valve Actuator S42MC-C
Checking
908-3.1
1.
1. The non-return valve A is built into the oil
inlet pipe to the actuator.
To check the valve, dismantle and clean it

and connect a supply of working air (7 bar)
to the outlet side of the valve (the side fac-
ing the actuator). If the air flow can be felt
at the inlet side of the valve, the valve must
be overhauled.
DM908-3.1 226 01
MAN B&W Diesel A/S
908-3.2 Exhaust Valve Actuator
Dismantling
Dismantling
908-3.2
1. 1. Stop the engine and shut off the oil supply.
Turn the camshaft so that the roller rests on

the circular part of the cam.
Remove the inspection cover of the roller

guide housing to check the position of the
exhaust cam.
Dismount the inlet pipe and the drain pipe

from the exhaust valve.
Dismount the high-pressure pipe.

DM908-3.0 92 02
2. Fit eye screws in the lifting holes of the ac-

tuator housing and hook on a tackle.
2. Unscrew the nuts on the two short studs,

then loosen the nuts on the long studs suc-
D08-35 cessively until the roller guide spring is re-
lieved.
Dismount the nuts and lift the housing care-

fully, leaving the piston on top of the roller
guide.
Remove the spring.
3. Remove the locking plate for the piston.

Turn the piston 90° to release it from the
bayonet joint.
DM908-3.0 92 03
Remove the piston from the roller guide.
4. Overhaul the actuator housing and the pis-

3. ton as required.
See Procedure 908-3.3 .
HM908-3.0 70 03
MAN B&W Diesel A/S
Exhaust Valve Actuator 908-3.3
Overhaul
Overhaul
908-3.3
1. Clean the piston in kerosene and wipe dry 1.

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

wear. If the ring thickness has worn down
to the minimum (see Data) , discard the
rings and mount new ones.
Check that the TOP mark on the piston

rings faces upwards when mounting.
2. Inspect the sliding surfaces of the piston to

ensure that there are no scratch marks or
seizure marks.
3. Clean the oil cylinder and inspect the bores

for deposits.
Check the bore of the oil cylinder for possi-

ble scores and measure it for wear.
HM908-3.0 69 04
If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised work-
shop for reconditioning.
3.
D08-20
DM908-3.0 92 06
MAN B&W Diesel A/S
908-3.4 Exhaust Valve Actuator
Mounting
Mounting
908-3.4
1. 1. Mount the actuator piston in the roller guide

and turn 90° to lock it in the bayonet joint.
Mount the locking plate and tighten as stat-

ed in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
2. Mount the spring on the roller guide. Care-

fully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
Mount the washers and nuts on the two

long studs and tighten alternately until the
KC908-3.0 76 05
actuator housing rests firmly against the

roller guide housing.
Mount the washers and nuts on the two

2. short studs. Tighten all four nuts as stated
in Data.
D08-35
Note!
Use only the tightening angle OR the

D08-32 tightening torque, NOT both.
D08-34
3. Mount the oil inlet pipe and the drain pipe
from the exhaust valve.
Mount the hydraulic high pressure pipe.

DM908-3.0 92 08
3.
DM908-3.0 92 09
MAN B&W Diesel A/S
Exhaust Valve Roller Guide 108-4
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D08-36 Bushing/shaft pin, max. clearance 0,5 mm

D08-38 Roller guide complete 20 kg
108-4 Exhaust Valve Roller Guide
Data MAN B&W Diesel
P90851 053 Lifting tool for roller guide
Exhaust Valve Roller Guide 908-4.1
1. The exhaust valve roller guide can be par-

tially checked while mounted on the engine, 2.
using the following procedure:
Lift the roller guide.

2. Remove the camshaft inspection cover.
Turn the engine to provide the maximum

space between the roller guide and the
cam disc.
Check the movability of the roller by turning
M908040221C02
this by hand to ascertain if the roller moves
freely and without unnecessary resistance
or “hard” points.
Also inspect the surface of the roller

for possible damage marks, seizures or 5.
scratches. Make sure that no traces of
bearing metal exist in the roller guide hous- D0836
ing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
3. A more suitable and reliable method is

to check the roller guide and the bearing
M908040221C05
clearance when the roller guide is dis-

mounted.
For dismantling of the roller guide see Pro-
cedure 908-4.2.
4. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
scratches.
5. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.
6. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance directly on the dial, see Data.
908-4.2 Exhaust Valve Roller Guide
1. Dismantle the hydraulic actuator above the

1. exhaust valve roller guide.
2. Lift the roller guide out of the roller guide

housing by hand. Take care not to damage
the sliding surfaces of the roller guide when
lifting.
M908040221D01
2.
D0838
M908040221D02
Exhaust Valve Roller Guide 908-4.3
1. Inspect and check the exhaust valve roller

guide. 1.
2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
M908040221O01
• seizure marks on the slide surfaces,
have been observed during the checking of

the roller guide.
Note! 3.
For disassembling of the roller guide,
contact an MAN B&W authorized repair
shop.
3. If no irregularities are found, just clean and

lubricate the roller guide before remounting
it in the roller guide bushing.
M908040221O03
908-4.4 Exhaust Valve Roller Guide
1. Clean and lubricate the sliding surfaces of

1. the roller and the roller guide and lower it
carefully into the roller guide bushing by
hand.
D0838
2. Mount the actuator.
M908040221M01
2.
M908040221D01
Exhaust Valve Cam 108-5
Data
X Stopped engine
Shut off fuel oil
Data
D08-39 Check lifting height 10 mm
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
Data
P90851 173 Lifting tool for exhaust valve roller guide

P91351 225 Disc, round-plain, Cu ø11x3 mm
P91366 073 Dial gauge and stand tool
MAN B&W Diesel A/S
Exhaust Valve Cam 908-5.1
1. Turn the crank throw of the cylinder con- 1.

cerned in AHEAD direction until TDC.
Check and write down the angle indicated
on the turning wheel.
2. Remove the high pressure pipe, see proce-

dure 9081.2
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).
Mount a dial gauge (measuring range 0.00

20.00 mm) on the lifting tool for the ex-
haust valve roller guide.
Reset the scale and the pointer.
2.
Press the dial gauge against the face of the
actuator housing until the reading D0839 +
1.00 mm is obtained.
3. Turn the roller guide in AHEAD direction

until lifted to D0839, and the dial gauge
gives the reading 1.00 mm and calculate
the angle A, which is the number of de-
grees the crank throw has turned from TDC
position to the present position.
Continue turning AHEAD until the roller

M908050218C02
guide again is lifted to D0839, and the dial

gauge gives the reading 1.00 mm.
Calculate the angle B, which is the number

of degrees the crank throw has turned from
TDC position to the present position.
Note!
When calculating the angles A and B,
remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees
908-5.1 Exhaust Valve Cam
4. Calculate the lead angle as:

4. 180° – (A° + B°)/2
The lead angle is normally a negative fig-

ure.
The illustration shows the position of the
exhaust cam when the piston of the rel-
evant cylinder is in TDC.
The position of the cam must be correct

within a tolerance of +/0.5°.
See the Adjustment Sheet in Volume I, OP-

ERATION, Chapter 701, for the “lead angle”
of the plant in question.
5. The cam lead angle can be checked visu-

ally by reading directly the scale position of
the exhaust cam over the marking scratch
5. on the camshaft and comparing this angle
with the angle stated in the Adjustment
Sheet.
At the same time, it is recommended to

check the position of the camshaft with the
pin gauge. See Procedure 9063.1
Exhaust Valve Cam 908-5.3
MAN B&W Diesel Adjustment
Normally, adjustment of the exhaust cams

should not be necessary. Before adjust- 1.
ment of any cams, see Volume I, Chapter
706.
1. Remove the inspection cover from the

camshaft housing.
2. Dismount the exhaust valve highpressure

pipe, see procedure 9081.2.
3. Turn the camshaft until there is access to

the oil ducts in the exhaust cam through
the inspection hole.
M908050218O01
If fitted, remove the plugs from the oil
ducts (using, for instance, a screwdriver).
Insert three copper gaskets in each oil

duct. 3.
Mount snapon couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snapon couplings

and the distributor block and between the
distributor block and the hydraulic high
pressure pump.
4. Mount the special spanner on the exhaust

cam disc, ensuring that the two pins enter
the holes in the cam.
M908050218O02
Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snapon couplings.
Raise the hydraulic pressure until oil seeps 4.

out along the camshaft under the cam disc.
Keep the cam pressurised for at least two

to five minutes before turning the cam.
Oil must sweep out with the pump running
during the operation.
Keep the cam pressurised during turning.

M908050218O03
908-5.3 Exhaust Valve Cam
Adjustment MAN B&W Diesel
5. Turn the cam disc, using the fitted spanner,

5. until the desired change of lead is obtained.
Check the change on the cam scale
To increase the lead angle and reduce the

compression pressure:
– turn the cam disc ASTERN.
To reduce lead angle and increase the com-

pression pressure:
– turn the cam disc AHEAD.
6. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the

exhaust cam lead again. See procedure
9085.1.
Write down and file the new results for the

purpose of comparing with future measure-
ments and adjustment.
7. Mount the oil tray on the camshaft housing.

See procedure 9064.4.
8. Mount the high pressure pipe for the exhaust

valve. See procedure 9081.4
9. After any adjustment of the cam position,

pcomp must be recorded and compared with
pcomp at a known engine reference load.
Exhaust Valve Special Running 108-7
Data
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
108-7 Exhaust Valve Special Running
Data
P90851 124 Tool for emergency open exhaust valve

P90851 173 Lifting tool for exhaust valve roller guide
MAN B&W Diesel A/S
Exhaust Valve 908-7
Special Running
Exhaust Valve
S60MC-C
0226
Special Running
908-7
3.
Engine trouble might require that a cylinder be
taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve

locked in either the open or the closed position.
Either way, carry out the following procedure:
1. Lift the relevant fuel pump roller guide.

HN908-7.0 226 03
2. Dismantle the hydraulic high-pressure
pipe.See Procedure 908-1.3.
3. Dismantle the non-return valve on the oil in-

let pipe. Loosen the union nut in the bottom
of the oil pipe and turn the pipe to one side. 4.
Mount the non-return valve on the oil pipe
and blank off the non-return valve with the
plug from tool panel 908.
4. Remove the inspection cover of the cam-

shaft housing. Turn the engine until the ex-
haust roller guide is at TDC.
5. Position the lifting tool on the actuator and

screw the spindle into the top of the actua-
tor piston.
Tighten the lowermost nut on the tool to pull

JN908-4.1 205 02
up the roller guide as far as possible.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position. 5.
6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.
JM908-5.0 55 03
0$1% :'LHVHO$6
908-7 Exhaust Valve
Special Running
7. If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:
7. Turn off the air to the exhaust valve.
Remove the venting plug screw, fitted just

above the ball cock on the air cylinder, to let
the air inside the air cylinder escape.
8. Dismantle the rotation indicator on the oil

cylinder and mount the tool for opening of
the exhaust valve. The tool is found on tool
panel 908.
The tool will keep the piston of the air cyl-

inder in the bottom position and thus keep
the exhaust valve open.
KC908-6.0 18 02
8.
HN908-7.0 226 08
0$1% :'LHVHO$6
Exhaust Valve 908-7
Special Running
After overhaul of the cylinder unit, re-engage 9.

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower

the roller guide on to the exhaust cam. Re-
move the tool.
10. If the engine has been running with the ex-

haust valve open, remove the tool mounted
in the oil cylinder and mount the rotation in-
dicator.
Note!
The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.
Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the for-
mation of a wear groove in the air piston
JM908-5.0 55 06
of the exhaust valve.
Re-connect the air supply to the air cylin-

der.
11.
11. Remove the plug from the non-return valve
and re-connect the oil inlet pipe on the ac-
tuator housing.
12. Mount the hydraulic high-pressure pipe.

13. Engage the fuel pump roller guide.

HN908-7.0 226 11
0$1% :'LHVHO$6
Exhaust Valve Panel Plate
P90851-0172
Exhaust Valve Panel
0172
P90851
MAN B&W Diesel A/S
Plate Exhaust Valve Panel
P90851-0172
Item Item
No. No.
016 Tool panel

028 Name plate
053 Lifting tool, roller guide
065 Lifting tool for exhaust valve
077 Cone ring, pneumatic piston
089 Test equipment, exhaust valve
090 Gauge, exhaust valve spindle
124 Tool, emergency open exhaust valve
136 Bridge gauge, exhaust valve
148 Tool for hydraulic piston
150 Gauge exhaust valve bottom piece
161 Lifting tool for exhaust valve
173 Lifting tool - roller guide - exhaust
valve
185 Grinding ring - exhaust valve bottom
piece
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0041
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0041

No. No.

030 Support
089 Tommy bar
090 Spanner
100 Stud setter
207 Hydraulic tool set, complete
MAN B&W Diesel A/S
Exhaust Valve - Extra Tools Plate
P90863-0016
Exhaust Valve - Extra Tools
0016
P90863
011
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0016
Item Item
No. No.
011 Grinding machine for exhaust valve

spindle seat
MAN B&W Diesel A/S
Fuel Pump Settings 109-1
Data
X Stopped engine
X Shut off fuel oil
Data
D09-01 One shim alters p-max 2.5 bar

D09-05 Nominal shim thickness 0.5 mm
D09-10 Max. number of shims 12
MAN B&W Diesel A/S
109-1 Fuel Pump Settings
Data
P90951 200 Hexagon head screw for topcover
MAN B&W Diesel A/S
Fuel Pump Settings 909-1.3
Adjustment
Before adjustment of the fuel pump is carried 1.

out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:
1. Before Maximum Combustion Pressure

(pmax) is adjusted, loosen the drain oil pipe
from the top cover and dismount the top
cover fixing nuts.
Remove the two screws in the threaded
M909010242O01
holes of the top cover.
2. Screw the two dismantling screws (from

the tool panel) into the theaded holes of
the top cover, thus lifting the top cover to
provide space for inserting or removing
3.
shims.
3. To increase p max, remove shims (advance

injection).
To decrease pmax, insert shims (delay injec-

tion).
One shim will alter p max approximately as

given in Data D09-01.
For nominal shim thickness, see Data D09-

M909010242O03
05.
For maximum inserted number of shims,

see Data D09-10.
Note down the new total shim thickness

(number of shims). 4.
4. Remove the dismantling screws, and press

down the top cover by hand. Mount the
two original screws to protect the threaded
holes. Mount and tighten the nuts for the
top cover, see Procedure 909-5.
Note!
The individual pmax value must not devi-

ate more than 3 bar from the average
value for all cylinders.
M909010242O04
MAN B&W Diesel A/S
909-1.3 Fuel Pump Settings
Adjustment
If the required pmax adjustment cannot be

5. A
attained by inserting or removing shims, it
is possible to carry out the adjustment on
the fuel cam disc. Contact MAN B&W Die-
sel for advice.
MIP adjustment:
5. The Mean Indicated Pressure (pi) for a cer-

tain cylinder is adjusted on the fuel pump
index arm.
A Increase index for higher pi.

M909010242O05
Decrease index for lower pi.
Note!
The mean indicated pressure is one of

6. the most important parameters, in ob-
taining good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the aver-
age value for all cylinders. See Volume I,
Chapter 706.
6. After adjustment of the fuel pumps a set of

observations must be taken, to evaluate
the adjustments, see Volume I.
M909010242O06
MAN B&W Diesel A/S
Fuel Pump Cam 109-3
Data
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
Data
P90651 44 Impact spanner for turning cam

P90951 45 Measuring tool for fuel pump
P91351 154 Conical valve, 0 - 15
P91351 201 Quick coupling, male
P91351 225 Disc, round-plain, Cu ø11x3 mm
MAN B&W Diesel A/S
Fuel Pump Cam 909-3.1
Checking
Fuel Pump Cam
S46MC-C
0228
Checking
909-3.1
1.
Fuel cam lead:
C
The lead C of the fuel cam is defined as the
x2 x1 roller guide
number of mm the plunger is lifted from its bot-
tom position when the main piston is in TDC.
1. To measure the fuel cam lead (top lift):

Dismantle the suction valve and the punc-
ture valve. See Procedures 909-7.2 and fuel cam
909-8.2.
Make sure that the reversing mechanism is

in AHEAD direction. ahead
EN909-3.1 228 00
2. Push down the measuring pin through the
top cover, until it rests against the pump Lowest position Main piston in TDC
plunger. of pump plunger
Turn the engine until the lowest point of the

cam is found, use a calliper to find the 3.
point.
3. Measure the distance x from the top of the

measuring pin to the top cover.
Note down the result as x2.
4. Turn ahead until the main piston of the cyl-

inder concerned is in TDC.
Again measure the distance x from the top

of the measuring tool to the top cover. Note
down the result as x1.
Calculate the fuel cam lead C (top lift) as:
C = x1 – x2 (mm)
JG909-2.1 92 02
5. Note down the result for comparison with

the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.
4.
Remount the suction valve and the punc-
ture valve.
HM906-7.0 56 01
0$1% :'LHVHO$6
909-3.3 Fuel Pump Cam
Adjustment
Adjustment
909-3.3
1. Normally, adjustment of the fuel cam should not

be necessary. Before adjustment of fuel equip-
ment, see Volume I, Chapter 706.
1. Remove the inspection cover from the cam-

shaft housing.
Note!
GN909-3.3 203 01
Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
2. Dismount the puncture valve and the suc-
tion valve from the fuel pump top cover, and
mount the measuring tool.
3. Turn the camshaft until there is access to

the oil ducts in the fuel cam through the in-
spection hole.
If fitted, remove the plugs from the oil ducts

(using, for instance, a screwdriver).
Insert three copper gaskets in each oil duct.
Mount snap-on couplings in the oil ducts,

but do not tighten them.
BM909-1.1 236 03
Fit hoses between the snap-on couplings

and the distributor block and between the
distributor block and the hydraulic high-
pressure pump.
3.
GN909-3.3 204 04
0$1% :'LHVHO$6
Fuel Pump Cam 909-3.3
Adjustment
4. Mount the special spanner on the fuel cam 4.

disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least five

minutes before turning the cam.
GN909-3.3 204 05
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,

until the desired change of lead is obtained.
To increase lead and p max:

– turn the cam disc AHEAD.
To reduce lead and p max:

– turn the cam disc ASTERN.
5. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the

fuel cam lead again.
Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.
6. Mount the inspection cover on the camshaft

housing.
7. Mount a new O-ring on the puncture valve.

Mount the puncture valve and the fuel oil
high pressure pipes.
See Procedure 909-8.4 and 909-14.4.
0$1% :'LHVHO$6
Fuel Pump 109-4
MAN B&W Diesel Data

X Stopped engine
X Shut off fuel oil
Data
D09-18 Pump housing nuts, tightening torque 275 Nm

D09-19 Pump housing nuts, tightening angle 60 °
D09-20 Pump housing 54 kg
109-4 Fuel Pump
Data MAN B&W Diesel
P90951 070 Lifting tool for fuel pump housing
Fuel Pump 909-4.2
Dismantling
Fuel Pump
S46MC-C
0221
Dismantling
909-4.2
2.
Note!

1. Dismantle the fuel pump top cover/plunger

barrel assembly.
2. Remove the fuel oil inlet pipe between the

fuel pump and the fuel oil inlet valve.
Discard the gaskets.
3. Remove the nuts at the base of the fuel

pump.
Mount the lifting tool and lift the fuel pump

housing away.
BM909-4.2 210 02
Note!
Take care not to damage the threads of

the studs. 3.
Land the fuel pump on wooden planks.
D09-20
BM909-4.2 210 03
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
Overhaul
909-4.3
1. 1. Tilt the fuel pump housing into a horizontal

position on the wooden planks.
2. Remove the bottom plate from the fuel

pump housing.
If the bottom plate sticks, loosen it by

screwing two M8x50 mm screws into the
threaded holes of the bottom plate.
3. Dismantle the:
BM909-4.3 210 01
• Fuel oil index arm.
• Regulating guide.
2.
BM909-4.3 210 02
3.
BM909-4.3 210 03
MAN B&W Diesel A/S
Fuel Pump 909-4.3
Overhaul
4. Dismantle and inspect the erosion plugs on 4.

both sides of the fuel pump housing.
If heavily eroded, replace the erosion plugs.
5. Clean all the parts in diesel oil or kerosene.

Blow dry with compressed air.
Warning!
Always use eye protection when working

with compressed air.
6. Mount a new sealing ring in the pointer for

the fuel oil index arm.
Note! BM909-4.3 210 04
Soak the sealing ring in lubricating oil

before mounting. 6.
Depending on engine type, the index point-

er can have a different shape, see the
sketch.
7. Clean all inside surfaces of the fuel pump

housing.
BM909-4.3 210 06
HC909-3.4 121 11
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
9. 8. Lubricate the following with molybdenum di-

sulphide grease (MoS 2):
• All internal surfaces of the fuel pump

housing.
• The sliding surfaces of all the parts of the

regulating system.
• The teeth of the:

– Regulating guide.
– Fuel index arm.
BM909-4.3 210 09
9. Mount the fuel oil index arm.
Adjust the position of the fuel oil index arm

so that the scratch mark on the fuel oil in-
dex arm is aligned with the centre of the
10. fuel pump housing.
Mount the fuel oil index pointer.
10. Mount the regulating guide in the fuel pump

housing, ensuring that the scratch mark on
the regulating guide is aligned with the
scratch mark on the fuel oil index arm.
11. Mount the bottom plate on the fuel pump

housing.
BM909-4.3 210 10
11.
BM909-4.3 210 02
MAN B&W Diesel A/S
Fuel Pump 909-4.4
Mounting
Mounting
909-4.4
1.
Note!
Before mounting the fuel pump housing,

make sure that all sliding faces and
threads are cleaned and lubricated with D09-19
molybdenum disulphide grease (MoS 2). D09-18
D09-20
1. Lower the fuel pump housing on to the

pump base, taking care not to damage the
threads of the studs.
Remove the lifting tool.
Mount and tighten the nuts at the base of

the fuel pump housing. See Data.
Note!
BM909-4.2 210 03
Only use either the tightening angle or

the tightening torque, not both.
2. Mount the fuel oil inlet pipe between the

fuel pump and the fuel inlet valve.
2.
3. Mount the fuel pump top cover/plunger-bar-
rel assembly.
BM909-4.4 210 02
MAN B&W Diesel A/S
Fuel Pump Top Cover 109-5
Data
X Stopped engine
X Shut off fuel oil
Data
D09-23 Top cover studs, screwing-in torque 100 Nm

D09-24 Top cover nuts, tightening torque 90 Nm
D09-25 Pump barrel/top cover, tightening torque 30 Nm
D09-26 Outlet seat, max.grinding diameter 11 mm
D09-27 Top cover 20 kg
D09-28 Plunger/barrel assembly + top cover 38 kg
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data
P90951 Lifting tool for fuel pump

P90951 94 Milling tool for fuel oil pipe seats
P90951 200 Hexagon head screw for topcover
P90951 1 Extraction tool for suctions valve
MAN B&W Diesel A/S
Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
S46MC-C
0222
Dismantling
909-5.2
1.
1. Close the oil inlet valve to the fuel oil pump
and drain the pump.
Dismount t he dr ain oi l pipe from the t op

cover and the ai r pipe connec tion to t he
puncture valve.
Dismount the hi gh pressure pipes.

Dismount the puncture v alve f rom t he t op

cover. See Procedure 909-8.
GN909-5.2 208 01
Dismount the f uel index pointer.
2. Dismount the suction valve by means of the

extractor tool.
3. Remove the top cover fixing nuts, as well as 2.

the two screws in the top co ver.
Loosen the top cover by means of the two

dismantling screws from the t ool panel.
Release the link for the regulating drive and

pull out the toothed rack as far as possible.
GN909-5.2 205 02
3.
GN909-1.3 205 01
0$1% :'LHVHO$6
909-5.2 Fuel Pump Top Cover
Dismantling
4. 4. Mount the lifting tool on t he f uel pump t op

cover. Scre w the c entre s crew of t he tool
into the pump plunger. Ensure that the stop
ring on the cent re screw is loose.
Pull the cent re s crew of the t ool to l ift t he

plunger clear of the bayonet joint in the roll-
er guide and the mil led recess of the r egu-
lating guide.
To do this it may be necessar y to move the

toothed r ack and the centr e scre w of t he
tool in relation to each other .
When the pl unger has been l ifted cl ear of

the rol ler guide and r egulating gui de, l ock
GN909-5.2 208 04
the centr e screw in thi s po sition wit h the

stop ring.
5. Lift the top co ver and barrel with pl unger

5. out of the fuel pump housing as one unit.
Remove the shi ms and t ag them f or rein-
stallation.
D09-28 6. Set u p t he pump unit in a bench vice pro-
vided wit h ‘soft’ j aws. Dismount t he lifting
tool. T ake care that t he pl unger does not
slide out of t he barrel.
Press the pl unger t o the t op of t he barrel

and remove t he barr el/plunger assembly
from the t op cover.
Send t he barr el/plunger assemb ly t o an

MAN B&W authorised w orkshop f or o ver-
haul, or overhaul it on board.
GN909-5.2 205 05
6.
GN909-5.2 205 06
0$1% :'LHVHO$6
Overhaul
Overhaul
909-5.3
1. Remove and discard the sealing rings. 1.

D09-26
Carefully clean and examine the top cover.
Reconditioning of the seatings for the high-

pressure pipes is carried out by milling ac-
cording to the f ollowing procedure:
Fill the oil ducts in the top cover with Vase-

line or heavy grease.
GREASE
During the work the m iller is guided b y the

guide screwed into the thread for the high-
pressure pipe.
Turn the miller by m eans of , e .g. a tap

wrench, whi le t ightening t he guide screw
lightly to provide a s uitable pr essure be-
tween miller and seat .
During the milling, add dr illing oil emulsion

liberally.
GN909-5.3 205 01
For the max. mil ling/grinding di ameter of

the seat, see D ata D09-26.
2. After completing the m illing, blow o ut the

Vaseline/grease from the oi l duct s b y 2.
means of c ompressed air.
Warning!

Clean the top cover with diesel oil, and blow

dry with compressed ai r.
GN909-5.3 205 02
0$1% :'LHVHO$6
Overhaul
3. 3. Mount the sealing rings in the ring grooves.
Sealing between the top cover and the fuel

pump housing is pr ovided by an O-r ing.
Sealing between the top c over and pump

barrel is provided by two back-up rings and
an O-ring in between.
Prepare the bac k-up rings b y twi sting the

rings in the hand, in such a way that the di-
ameter of the rings becomes small er t han
the diameter of the ring groove in which the
rings are t o be m ounted.
GN909-5.3 205 03
‘Screw’ the back-up rings onto the top cov-

er, into the g roove.
4. Finally, insert the O-ring between the back-

D09-25 up rings in the ring groove.
Mount the O -ring which seals between top

cover/fuel pump housing.
4. Mount t he overhauled top co ver on top of

the pump barrel , gui ded b y the gui de pin.
Tighten the screws, see Data D09-25.
GN909-5.2 205 06
0$1% :'LHVHO$6
Mounting
Mounting
909-5.4
1. Mount t he suppli ed m easuring pi n on t he 1.

centre screw of t he lifting tool as sho wn in
the sketch. Loosen the stop ring on the cen-
tre screw.
Place the tool on the pump housi ng and

press do wn the centr e screw unt il the
measuring pin r eaches t he thr ust piece of
the rol ler guide . Loc k the cent re scr ew i n
this position with the st op ring.
Keep the stop ring tightened in this position

until the plunger has been correctly mount-
ed.
GN909-5.4 208 01
Note!
The engine must not be turned until the

mounting of the barrel/plunger assembly
has been completed.
2.
2. Remove the t ool f rom the pump housi ng
and remo ve the measuring pin fr om the
centre screw.
Mount t he tool on t he barrel/plunger and

top-cover assembly.
Tighten the tool to the top c over by means

of the two screws, and attach the plunger to
the centre screw.
The t ool is now f irmly attached to t he as-

sembly, enabling t he corr ect position t o be
obtained during mounting.
Pull t he regulating t oothed r ack out as f ar

as possible.
Pull the plunger as high up in the barr el as

possible.
GN909-5.4 208 02
Carefully lower the assembly into the pump

housing (taking special care not to damage
the O-ring and back-up rings on the barrel).
Adjust t he top cover so t hat t he guide pi n

enters the hole in the pump housing. Lower
the top co ver on t o the pum p housing.
0$1% :'LHVHO$6
Mounting
3. 3. Press the plunger down int o contac t wit h

the thrust piece of the rol ler guide.
If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
and regulating block of the plunger fit prop-
erly in the cutout of t he regulating guide.
Check that the stop ring of the centre screw

is in full contact with the flange of the t ool,
as when measuring.
When the plunger is in place, press the reg-

ulating toothed bar i n, causing the pl unger
GN909-5.4 208 03
foot to interlock with the bayonet joint of the

roller guide.
Check through the inspection cover on the

4. fuel pump base and by pull ing the centr e
screw of the tool , that the plunger is cor-
rectly engaged.
When pul ling on the c entre screw i t must

not be possible to lift the plunger more than
a few mm.
4. Unscrew the centre screw from the plunger

and remove the t ool from the top co ver.
5. Screw the two dismantling screws from the

tool panel into the threaded holes of the top
cover, thus l ifting the t op co ver to pr ovide
GN909-5.4 208 024
space for inserting shims.
6. Insert shi ms betw een the pump housing

and the top cover. (If the barrel assembly is
5. the sam e as t hat dis mounted, inser t the
same n umber of shims as wer e removed).
If a new barrel assembly is mounted, insert
the number of shims specif ied in the test
bed report.
GN909-1.3 205 02
0$1% :'LHVHO$6
Mounting
7. Replace the dismantl ing scr ews wit h the 7.

two screws for mounting the lifting tool, and
press down the t op cover.
Turn t he engine one comp lete r evolution,

and chec k that the top cover does not lift.
If the top cover lifts, the plunger is not cor-
rectly mounted and must be remounted.
D09-23
Mount t he top cover f astening n uts, and D09-24

tighten them diagonal ly.
See Data D09-24.
If any of the fuel pump top cover studs have

come loose, tighten them.
See Data D09-23.
8. Mount t he suction v alve and the punctur e

valve in t he top co ver.
Connect the drain oil pipe t o the top cover

and t he pi pe connecti on to t he punctur e
GN909-1.3 205 03
valve.
Mount t he tw o hi gh-pressure pipes on t he

top cover/fuel valves.
See Procedure 909-14. 9.
Mount the fuel index pointer
Mount the link for the regulating drive.
Open the f uel oil inlet.
For fuel pump settings, see Procedure 909-

1 and Volume I, OPERATION, Chapter 706.
GN909-5.4 208 09
0$1% :'LHVHO$6
Fuel Pump Barrel Assembly 109-6
MAN B&W Data

X Stopped engine
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME engines
Shut off control air supply
Engage turning gear
X Shut off fuel oil
Data
D09-28 Plunger/barrel assembly + top cover 40 kg

D09-29 Barrel assembly 18 kg
D09-30 Plunger 4 kg
109-6 Fuel Pump Barrel Assembly
Data MAN B&W
Fuel Pump Barrel Assembly 909-6.3
Overhaul
Fuel Pump Barrel Assembly
S42MC
0217
Overhaul
909-6.3
1.
1. Remove the top cover with the barrel/plung-
er assembly from the fuel pump housing
and dismantle the barrel/plunger assembly D09-28
from the top cover. See Procedure 909-5.2.
2. Remove and discard the O-rings.
Clean the outside of the barrel.
Note!
BM909-6.3 209 01
It is recommended not to remove the
plunger from the barrel, as this may
cause scratches to the plunger.
2.
For evaluation of pump barrel/plunger see
Volume I, OPERATION, Chapter 706.
D09-29
Overhaul the top cover and mount a new O-
ring and back-up ring on the top cover.
Mount the barrel/plunger on the new/over-
hauled top cover, guided by the guide pin.
BM909-6.3 209 02
3. Mount a new O-ring and back-up ring in the

ring groove on the pump barrel. Make sure
to mount the rings correctly. See the
sketch.
3.
Caution!
Take care that the plunger does not slide

out of the barrel.
If the barrel assembly is not to be mounted

immediately, cover all openings with plastic
to prevent dirt from entering the barrel as-
sembly during storage.
For mounting the fuel pump barrel assem-

bly, see Procedure 909-5.4 (fuel pump top
cover).
BM909-6.3 209 03
MAN B&W Diesel A/S
Fuel Pump Suction Valve 109-7
Data
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data
MAN B&W Diesel A/S
Fuel Pump Suction Valve 909-7.3
Overhaul
Fuel Pump Suction Valve
S35MC
0210
Overhaul
909-7.3
1.
1. Set up the suction valve in a bench vice
with “soft” jaws and press down the spring
by means of the cone to release the valve
spindle from the two-part conical ring.
Clean the parts thoroughly in clean diesel

oil and blow dry with compressed air.
2. Inspect the seat on the valve spindle and

the seat on the valve housing for damage.
If the seats are damaged, a new or recon-

ditioned suction valve must be fitted. (Send
GN909-7.3 205 05
the damaged valve to an authorized MAN
B&W repair shop for reconditioning).
3. After cleaning and inspecting all the parts,

lubricate these with molybdenum disul-
phide (MoS 2) and assemble the suction 2.
valve.
Check the seats for tightness by filling the

inlet hole with diesel oil and waiting 5 min-
utes. No oil may pass through the seats.
4. If the suction valve is not to be mounted on

the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.
GN909-7.3 205 06
3.
GN909-7.3 205 07
0$1% :'LHVHO$6
Fuel Pump Puncture Valve 109-8
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-35 Puncture valve, tightening torque 460 Nm
109-8 Fuel Pump Puncture Valve
Data MAN B&W Diesel
P90951 116 Crowfoot wrench head
P90980 Mounting Tools - Air Piston Seals
Fuel Pump Puncture Valve 909-8.2
1. Note!
1.
been relieved of pressure and that all
oil has been drained off.
Remove the fuel oil high pressure pipes.

2. Disconnect the air pipes from the puncture

valve.
M909080222D01
Unscrew the puncture valve and remove it
from the fuel pump top cover.
2.
M909080222D02
909-8.3 Fuel Pump Puncture Valve
1. Set up the puncture valve in a bench vice

1. with "soft" jaws.
Loosen and remove the two screws and

dismount the cover.
Pull the upper part of the housing clear of

the lower part of the housing.
Remove the spindle and the spring from

the upper part of the housing.
Remove and discard all O-rings and sealing

rings.
Clean all the parts in clean diesel oil.
2. Mount the two O-rings in each ring groove

on the rod of the air piston, and position
the long cone on the rod.
Heat the sealing ring in 100°C hot water for

M909080223O01
minimum 5 minutes.
Place the sealing ring on the cone and, by

means of the pusher, push the sealing ring
on to the O-rings in the lowermost groove.
Remove the pusher and the long cone.
2.
Finally, compress the sealing ring by means
of the compression tool.
3. Repeat step 2 on the uppermost ring

groove on the rod of the air piston with the
short cone.
M909080223O02
Fuel Pump Puncture Valve 909-8.3
4. Mount the O-ring in the ring groove on top

of the piston. Position the cone on the pis- 4.
ton head.
Heat the sealing ring in 100°C hot water for

minimum 5 minutes.
Place the sealing ring on the cone and, us-

ing the pusher, push the sealing ring onto
the O-ring in the groove.
Remove the pusher and the cone.
Finally, compress the sealing ring by means
M909080222O04
of the compression tool.
5. Before assembling the puncture valve, lu-

bricate all parts with molybdenum
disulphide, (MoS2).
5.
Mount new O-rings on the upper and the
lower part of the housing and the cover.
Mount the spring and air piston in the up-

per part of the housing and assemble the
two housing parts and the cover by means
of the two screws.
6. If the puncture valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
M909080223O05
909-8.4 Fuel Pump Puncture Valve
1. Before mounting the puncture valve, check

2. that the bore in the top cover is clean and
check the O-ring on the puncture valve.
D0935
Lubricate the thread on the puncture valve
with molybdenum disulphide grease
(MoS2).
2. Screw in the puncture valve and tighten

with a crowfoot wrench and a torque span-
ner to the specified torque, see Data D09-
35.
M909080222M02
Mount the air pipes for the puncture valve.
3. Mount the fuel oil high pressure pipes, see

Procedure 909-14.4
3.
M909080222M03
Fuel Pump Shock Absorber 109-9
MAN B&W Diesel Data

X Stopped engine
X Shut off fuel oil
Data
D09-39 Shock absorber 12 kg
109-9 Fuel Pump Shock Absorber
Data MAN B&W Diesel
Fuel System Shock Absorber 909-9.1
Checking
Fuel System Shock Absorber
S50MC-C
0212
Checking
909-9.1
1.
1. To ensure satisfactory operation, the func-
tioning of the fuel oil system shock absorb-
er should be checked at regular intervals.
Normally, inspection is necessary only at
the intervals stated in the maintenance pro-
gramme. The checks should be carried out
while the engine is operating.
2. Remove the plug from the end cover of the

shock absorber. Check that air is ‘pulsating’
through the threaded hole.
HM909-4.0 09 01
Short bursts of air should be felt against the
hand, corresponding to the strokes of the
fuel pump.
The air pulses occur when the shock ab- 2.

sorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.
3. To check the ‘tightness’ of the piston, meas-

ure the amount of leakage oil flowing from
the drain pipe below the 3-way valve. Note
down the amounts measured and compare
with earlier measurements.
Increasing amounts indicate a deteriorating

GN909-9.1 212 02
piston sealing. Excessive amounts indicate

that the shock absorber requires overhaul-
ing.
3.
GN909-9.1 212 03
0$1% :'LHVHO$6
909-9.3 Fuel System Shock Absorber
Overhaul
Overhaul
909-9.3
1.
Note !
Before dismantling any part of the fuel oil

system, make sure that the system has
1. Remove the 3-way valve and the drain

pipes. Loosen the screws holding the shock
absorber and remove it from the fuel oil
system.
2. Remove the plug from the end cover of the

GN909-9.3 212 01
shock absorber. Fit a threaded rod between

the piston and the end cover to counteract
the force of the springs. Remove the locking
plates and loosen the screws of the end
2. cover. Remove the end cover and piston.
Discard the gasket.
3. Loosen the nut on the threaded rod to re-

lieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.
4. Clean all parts and polish the sliding sur-

faces of the piston and the shock absorber
housing. Mount a new sealing ring in the
shock absorber housing and a new wear
ring on the piston.
HG909-9.2 201 02
5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
the threaded rod.
4.
Lubricate all sliding surfaces and assemble
the shock absorber. Take care not to dam-
age the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.
6. Mount the end cover. Remove the threaded

rod and insert the plug.
HG909-9.2 201 04
0$1% :'LHVHO$6
Fuel System Shock Absorber 909-9.3
Overhaul
7. Fit a new gasket and mount the shock ab-

sorber. Mount the 3-way valve and the drain
pipes on the fuel oil system.
If an excessive amount of drain oil is still

observed after the overhaul, the shock ab-
sorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
0$1% :'LHVHO$6
Fuel Valve 109-11
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-40 Fuel valve opening pressure 300 - 380 bar

D09-41 Fuel valve tightening torque 20 Nm
D09-42 Inlet seat, max. diameter 10 mm
D09-43 Fuel valve 3 kg
109-11 Fuel Valve
Data MAN B&W Diesel
P90151 071 Dismantling tool for fuel valve
P90951 094 Milling tool for fuel oil pipe seats

P90951 165 Grinding mandrel for valve head
P90961 Fuel Valve - Tools
Fuel Valve 909-11.1
1. Fuel Valve
1.
The fuel valves must be given the utmost at-
tention and care, as the greater part of irregu-
larities that may occur during the running of
the engine can be attributed to defects in these
valves.
If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 9001.
In order to obtain reliable results during test-

ing of the fuel valves, all fuel valves that are
dismantled from the engine must be disas-
sembled, cleaned, inspected and reassembled
before testing. See Procedure 90911.3 and
90912.3.
M909110248C01
Note!
In the event that the slidetype fuel valve is
pressure tested without being cleaned be-
tween the fuel nozzle and the cutoff slide,
the opening pressure value measured might
be considerably lower than specified.
All fuel valves must be functiontested before

being mounted in the cylinder cover.
Pressure testing pump
Use only hydraulic oil (rustpreventing) with a

viscosity of between 7 and 10 cSt at 50°C.
For operation of the pressure testing pump,

see the supplier’s instructions.
Note that the highpressure pump should be

periodically checked in accordance with the
supplier’s instructions.
909-11.1 Fuel Valve
2. Settingup the fuel valve

2.
Place the fuel valve in the test rig and secure it
with the distance pieces and nuts.
Tighten the nuts to the specified torque, see

Data. Fit the oil pipe between the pressure
testing pump and the fuel valve. Fit the drain
pipe.
Pressure testing procedure
The following functions of the fuel valve must

be checked:
M909110248C02
• Flushing and jet control

• Opening pressure
• Sealing test and sliding function
3. • Pressure test, Oring sealing
3. Flushing and jet control
Remove air in the system and check the fuel jet

in the following way.
Slowly increase the oil pressure until straight

jets of oil are ejected from the nozzle holes (no
atomization).
Acceptance criteria:
There is to be a continuous jet of oil through at

least one of the nozzle holes.
Owing to the geometry of the internal part

of the nozzle and because of the height to
which the spindle is lifted during pressure test-
ing is lower than the height it is lifted during
normal engine operation the fuel oil will not
necessarily flow from all of the nozzle holes.
M909110244C04
Cause of fault:
If the jets do not fulfil the above point, the

cause may be:
Dirt in the nozzle holes
The nozzle is not mounted correctly
Fuel Valve 909-11.1
4. Opening pressure
4.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle
holes.
Acceptance criteria: D0940

Check the opening pressure on the pressure
gauge and compare with Data D0940 on the
datasheet.
Note!
Do NOT attempt to carry out an atomization

test on the slide type fuel valvs, as this may
damage the cutoff slide and nozzle.
Cause of fault:
If the opening pressure is higher than specified

in D0940, the cause may be that a wrong type
of spring is used replace the spring.
If the opening pressure is lower than specified

in D0940, the cause may be that the spring
has sagged replace the spring, or add a spe-
cial thin disc.
Note!
Special thin discs are available as spares.
If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated.
M909110248C04
909-11.1 Fuel Valve
5. Sealing test and sliding function

5.
To check the needle valve seat for tightness
and the slide for correct closing.
Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain the
builtup pressure by closing for the oil supply.
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to about

15-30 bar, after which it drops quickly to 0 (the
slide is pressed against the conical seat and
opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when the
fuel valve is full of oil.
M909110248C05
Cause of fault:
If oil flows out of the nozzle holes, the cause is

either:
• Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
• Too quick pressure drop:
the clearances of the movable parts, both of

the spindle guide and of the nonreturn valve,
are too large, or the seats between the thrust
piece/spindle in the spindle guide or thrust
piece/valve slide in the nonreturn valve are
damaged.
Examine and/or replace both the spindle guide

and nonreturn valve. See Procedure 90912.3.
If a quick pressure drop from 15 to 0 bar can-

not be registered:
• The valve slide is sticking; or
• The vent hole in the thrust piece is
blocked.
If so, disassemble and examine the spindle

guide, replace if necessary. See Procedure
90912.3.
Fuel Valve 909-11.1
6. Pressure test, Oring sealing

6.
Max. 10 bar
To ensure that the leak oil (circulation oil) re-
mains in the closed system, build up a working
pressure of about max. 10 bar until oil flows
out of the leak oil outlet.
Close the leak oil outlet with a gasket and plug

screw.
Increase the working pressure to about 100

bar.
The builtup pressure of about 100 bar should

be maintained.
Cause of fault:
If oil leaks out at the union nut, the Oring in- Max. 100 bar
side the fuel valve head is defective, and must
be replaced.
Max. 100 bar

M909110248C07
909-11.1 Fuel Valve
7. Atomization test
7.
Note!
Do NOT attempt to carry out an atomization
test on slide type fuel valves, as this may
damage the cutoff slide and nozzle.
The atomization test may damage the valve

because it makes the needle oscillate, with a
small lift at a very high frequency. The high
pressure drop across the cutoff edge and the
high contact pressure between slide and fuel
M909110244C08
nozzle, in combination with the poor lubricity

of the test oil, increase the risk of seizures be-
tween cutoff slide and nozzle.
All of these conditions involve the risk of sei-

zure between the cutoff slide and the nozzle.
Fuel Valve 909-11.2
1. Close the fuel oil inlet and outlet valves,

and drain the high-pressure pipe and the 1.
fuel valve.
Unscrew the union nut by means of the

hook spanner and take the union nut with
protective hose up along the pipe. Unscrew
the union nipple at both ends of the pipe
(fuel valve and fuel pump).
Remove the high-pressure pipe.
Disconnect the return oil pipe from the fuel

valve.
M909110248D01
Remove the nuts and the tubular spacers.
2. Lift the valve. If the valve is sticking, use

the fuel valve dismantling tool to pull the
fuel valve clear of the top cover. 2.
3. Remove the valve from the engine. If the

valve is not to be overhauled immediately,
the valve should be placed immersed in
diesel oil until overhauling.
M909110248D02
3.
M909110248D03
909-11.3 Fuel Valve
When fuel valves are overhauled, all parts

1.
should be handled carefully and be kept clean.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings
before reassembly.
1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.
M909110248O01
A 2. Remove and discard the O-rings.
Disassemble the fuel valve by screwing

off the two socket head cap screws while
retaining the valve in, for instance, a bench
2. vice provided with “soft” jaws.
Pull the valve head clear of the valve hous-

ing.
Remove the complete spindle guide and

the fuel nozzle from the valve housing.
Remove and discard all the O-rings.

M909110248O02
Fuel Valve 909-11.3
3. Carefully clean and examine all surfaces

of the fuel valve housing and the fuel valve 3.
head. D0942
If necessary, grind the seating surfaces by
means of the grinding mandrels supplied
and a fine-grain abrasive (such as Carbo-
rundum No. 500).
This grinding must only be carried out

manually.
After the grinding, wash the parts in gas oil

and blow clean by means of compressed
air to remove any remains of the grinding
compound.
In the event of more serious damage to the

seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.
M909110248O03
Normally, the milling tool is turned by hand,

but it may be fitted in the chuck of a col-
umn-type drilling machine provided that
the number of revolutions is kept at a mini-
mum (not exceeding approx. 100 r/min). An
ample supply of cutting emulsion must be
used. 4.
Note!
Take care not to exceed the maximum
diameter of the seat, see Data.
4. The complete spindle guide, including the

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
M909110248O04
909-11.3 Fuel Valve
5. Mount a new O-ring on the spindle guide

5. and lubricate it with MoS2.
Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.
Carefully slide the spindle guide down into

the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A cor-
responds to the measurement taken before
the valve is disassembled.
Note!
Make sure that the fuel nozzle and
spindle guide engage correctly with the
guide pin in the fuel valve housing. This
can be ascertained by attempting to turn
the nozzle after mounting. It must not be
possible to turn the nozzle.
M90911-0248O05
Mount a new O-ring in the lowermost

groove of the fuel valve head.
Mount the fuel valve head on the fuel valve

6. housing, and tighten the screws.
Fit the uppermost groove of the valve head

with a new O-ring.
6. When mounting the valve head, make sure

that the guide pin between valve housing
and valve head is intact, and check that the
guide pin between valve housing and valve
head engages correctly so as to prevent
relative turning of the parts.
After overhaul, the fuel valve must be test-

M909110248O06
ed in the test rig.

MoS2
7. If the fuel valve is not to be mounted in
the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.
Fuel Valve 909-11.4
1. Before mounting the fuel valve, thoroughly

1.
clean the valve bore in the cylinder cover
and check the seating in the bore for marks
which, if any, must be eliminated.
(For reconditioning of valve bore in cylinder

cover, see Procedure 901-1.3).
If not already done, mount a new O-ring on

the valve head. Mount a new O-ring in the
groove on the valve housing.
Lubricate the valve with copper grease.
M909110248M01
Mount the valve in position in the cylinder
cover.
2. Mount the tubular spacers and the nuts.

Tighten the nuts as stated in Data.
2.
3. Lubricate the thread on the union nipple of D0941
the fuel oil pipe with a heat resistant anti
seize grease before mounting.
Mount the fuel oil high-pressure pipe and

tighten, using the crow foot wrench and a
torque wrench.
Reconnect the return oil pipe to the fuel

valve.
M909110248M02
Turn on the fuel oil supply.
Note!
All fuel valves must be function-tested
before being mounted in the cylinder
3.
cover, see Procedure 909-11.1.
M909110248M03
Spindle Guide 109-12
MAN B&W Diesel Data

Stopped engine
Shut off starting air supply – At starting air receiver
Block the main starting valve
Engage turning gear
Shut off fuel oil
Data
109-12 Spindle Guide
Data MAN B&W Diesel
P90951 153 Flange for dismantling of non return valve
P90968 Fuel Valve - Inspection Tools
P90966 Fuel Valve Nozzle - Tools

P90974 Fuel Valve Nozzle - Cleaning Tools
Spindle Guide/Non-return Valve 909-12.3
Overhaul
Spindle Guide/Non-return Valve
S35MC
0223
Overhaul
909-12.3
1.
Note!
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
BG909-6.2 66 01
The spindle guide and the non-return
valve have been integrated into one unit.
However, both terms will be used to
describe the part in this procedure.
2.
1. Clean the outside of the spindle guide in pure
gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide should be disassembled
at a time.
Note!
BM909-12.3 223 02
All parts of the spindle guide/non-return

valve, except the springs and the fuel
nozzle are matched parts and may not be
replaced individually.
Place the spindle guide/non-return valve in 3.

a bench vice provided with “soft” jaws, and
use the spindle guide dismantling tool as
shown to remove the non-return valve from
the spindle guide.
2. Place the non-return valve part of the spin-

dle guide in a bench vice provided with
“soft” jaws, and use a brass mandrel and a
hammer to remove the thrust piece from the
valve housing.
3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
BM909-12.3 222 04
MAN B&W Diesel A/S
909-12.3 Spindle Guide/Non-return Valve
Overhaul
4. 4. Clean all the parts of the spindle guide and

the non-return valve in gas oil, and blow
clean with compressed air.
Clean all parts again in kerosene or ‘Elec-

trocleaner’, and blow dry with compressed
air.
5. Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
enlargement magnifying glass and an in-
spection lamp.
BM909-12-3 223 04
During the examination, pay special atten-

tion to the seating surfaces and sliding sur-
faces of the parts.
6. Remove any deposits or very fine scratches

5. by placing the spindle and vent slide in a
lathe, as shown, and polishing it with a very
fine conventional polishing linen ‘grade
360’.
Use also a little oil for the polishing (a

coarser polishing linen must absolutely
not be used).
Note!
The sliding surface of the cut-off slide

may only be polished VERY carefully.
BM909-12.3 223 05
The sliding surface must not be dam-

aged.
6.
MA909-6.2 111 05
MAN B&W Diesel A/S
Overhaul
7. Clean any carbon deposits from the central 7.

bore of the fuel nozzle by means of the spe-
cial brass brush. Clean the spray holes, us-
ing gas oil and the special drills supplied.
Note!
During this operation be very careful not

to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
the fuel nozzle.
Clean the fuel nozzle with kerosene and

wipe dry with a clean cloth.
Then test the spray holes with the test pin.

If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
BM909-12.3 222 07
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
Note!
It is recommended that the fuel nozzle is

changed whenever the spindle guide is
being overhauled.
MAN B&W Diesel A/S
909-12.3 Spindle Guide/Non-return Valve
Overhaul
8. 8. After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat
on spindle/guide. Use an inspection lamp
and an 8-10 times enlargement magnifying
glass.
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
9. Lubricate the sliding surfaces of all parts

with Molybdenum Disulphide (MoS 2).
10. Place the housing of the non-return valve in

a bench vice provided with “soft” jaws.
Insert the non-return valve spindle and the

BM909-12.3 223 08
spring in the housing. Place the thrust

piece at the end of the housing.
Carefully tap the thrust piece into the hous-

ing with a lead hammer.
10.
11. Place the lower part of the spindle guide
housing in a bench vice provided with “soft”
jaws.
Mount the spindle and the spring inside the

BM909-12.3 223 10
housing of the spindle guide using the spin-

dle guide dismantling tool and a hammer.
12. Mount a new O-ring on the spindle guide/

non-return valve.
11.
BM909-12.3 223 11
MAN B&W Diesel A/S
Overhaul
13. Lubricate the sliding surfaces of the nozzle 11.

and the spindle with a little Molybdenum Di-
sulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Use the dismantling tool for the spindle

guide to align the parts.
Place the parts on the plane of a drilling

machine and mount the mounting tool in the
chuck. Make sure that all the parts are per-
fectly aligned.
Press the nozzle on to the spindle guide.
Note!
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
BM909-12.3 223 13
If no mounting tools are available, the nozz-

le can be mounted on the spindle guide us-
ing a short piece of pipe.
Place the pipe around the nozzle, so that

the lower end of the pipe rests on the ‘foot’
of the fuel nozzle. Then press the parts to-
gether the same way as when using the
mounting tools.
14. If the spindle guide is not to be mounted in a

fuel valve immediately after the overhaul, cov-
er all openings of the spindle guide with plas-
tic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
Fuel Oil High-Pressure Pipe 109-14
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-47 Fuel oil high-pressure pipe, tightening torque 40 Nm

D09-52 Fuel oil pipe 8 kg
109-14 Fuel Oil High-Pressure Pipe
Data MAN B&W Diesel
P90951 104 Milling tool for fuel oil pipe

P90951 130 Crowfoot spanner
Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S42MC
0230
Dismantling
909-14.2
2.
High-Pressure Pipe with Double Pipe
1. Close the fuel oil inlet and outlet valves.
2. Unscrew the union nipple from the fuel

valve.
3. Unscrew the union nipple from the fuel

pump.
BM909-14.2 211 02
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.
3.
Note!
It is recommended always to overhaul

the high-pressure pipe before remounting
it on the engine.
The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.
GN909-14.2 210 03
4.
D09-52
BM909-14.2 211 04
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3
1. Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before re-
mounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed

as follows:
1. Lift up the union nut. Remove the spring

ring from the two-part sleeve. Remove the
sleeve.
KB909-7.1 77 01
2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.
2. Note!
The two pipe ends are of different

designs – see sketch.
Turn the upper tightening ring (A) until the

miller presses against the pipe end.
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
KB909-7.1 77 03
During the milling process, add drilling oil

emulsion liberally.
After completing the milling, carefully clean

3. the high-pressure pipe, and blow through
the bore with compressed air.
3. Remove and discard both the internal and

external O-rings. Mount new O-rings.
Mount the two-part sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the high-pressure pipe.
KB909-7.1 77 04
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 909-14.4
Mounting
Mounting
909-14.4
1. Ensure that the fuel valve is fitted with a 3.

new O-ring. Lubricate the thread of the fuel D09-52
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
BM909-14.4 211 03
Screw the union nipples onto the fuel valve
and into the fuel pump top cover, by hand.
Note!
4.
The nipples must be screwed by hand,
as the threads of the union nipples, fuel D09-47
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should

only be done after both of the union nip-
ples have been screwed into position.
4. Use a crowfoot wrench and a torque span-

BM909-14.4 211 04
ner to tighten the union nipple at the fuel

valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque span-

ner to tighten the union nipple at the fuel
pump to the torque stated in Data. 5.
6. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
D09-47
GN909-14.4 210 05
0$1% :'LHVHO$6
Fuel Pump Roller Guide 109-15
MAN B&W Diesel Data

X Stopped engine
X Shut off fuel oil
Data
D09-54 Clearance A 1.0 - 3.3 mm

D09-55 Clearance B 3.0 - 5.3 mm
D09-57 Roller/bushing/shaft pin, max. clearance 0,5 mm
D09-60 Housing for sealing arrangement 35 kg
D09-61 Fuel pump roller guide 35 kg
109-15 Fuel Pump Roller Guide
Data MAN B&W Diesel
P90851 053 Lifting tool for roller guide
Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
S35MC
0227
Checking
909-15.1
2.
Roller guide mounted in engine
The fuel pump roller guide can be partially

checked while mounted on the engine, using
the following procedure:
1. Lift the fuel pump roller guide.

2. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
BM909-15.1 207 03
Turn the roller by hand to check that it can
move freely and without unnecessary re-
sistance or “hard” points.
Also inspect the surface of the roller for 4.

possible damage marks, seizures or
scratches. Make sure that there are no trac-
es of bearing metal left in the roller guide
housing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
3. Lower the roller guide onto the fuel cam

again.
BM909-15.1 207 05
4. Using the telegraph, move the roller guide

to the AHEAD position.
Check that the reversing link is fully tilted

over in AHEAD position.
Carry out the same check in the ASTERN po-

sition.
0$1% :'LHVHO$6
909-15.1 Fuel Pump Roller Guide
Checking
5. Roller guide removed from engine
A more suitable and reliable method is to check

the roller guide and the bearing clearance after
the roller guide has been dismounted:
5. Dismount the roller guide from the engine.

6. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.
7. Turn the roller guide upside down and land

it in a vertical position on a couple of
planks, with the roller hanging freely.
Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clear-
ance permits.
BM909-15.1 207 07
7.
D09-57
BM909-15.1 207 08
0$1% :'LHVHO$6
Dismantling
Dismantling
909-15.2
1.
Note!

1. Dismantle the top cover with the barrel/

plunger assembly.
2. Turn the engine so that the roller guide

rests on the lowermost part of the fuel cam.
Inspect the position of the fuel cam through

the inspection cover opening on the cam-
shaft housing.
GN909-5.2 205 05
2.
BM909-15.1 207 03
0$1% :'LHVHO$6
Dismantling
3. 3. Loosen and remove the nuts on the two

short studs.
Then loosen the nuts on the two long

threaded studs successively until the roller
guide spring is relieved.
Mount the lifting tool on the fuel pump studs

and hook the engine room crane on to the
lifting tool.
Remove the nuts from the two long thread-

ed studs and lift away the fuel pump hous-
ing.
Note!
When lifting the fuel pump housing, take

care not to damage the threads on the
studs.
4. Lift the spring out of the roller guide.

BM909-15.2 207 03
Loosen and remove the screws from the

sealing cap on top of the roller guide inside
the pump base.
4.
BM909-15.2 207 04
0$1% :'LHVHO$6
Dismantling
5. Remove the sealing cap from the roller 5.

guide.
Unscrew the two nuts from the pump base,

and lift away the pump base. D09-62
When lifting, take care that the bushing of
the pump base slides against the neck of
the roller guide without scratching.
6. Mount the roller guide lifting tool as follows:
• Lift the lock plate of the tool up on the

shaft of the tool.
• Position the tool so that its foot rests on

the thrust piece in the bayonet joint of the
roller guide.
• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.
BM909-15.2 207 05
• Lower the lock plate, thereby securing

the foot in the locked position.
Lift the roller guide out of the roller guide

housing, using the crane.
6.
When lifting, take care that the slide surfac-
es of the roller guide do not scrape against
the roller guide bushing.
D09-61
Land the roller guide on wooden planks.
7. Check the roller guide.

BM909-15.2 207 06
0$1% :'LHVHO$6
Overhaul
Overhaul
909-15.3
1. 1. Inspect and check the fuel pump roller

guide.
D09-61 2. It is recommended that the roller guide

should ONLY be dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
• seizure marks on the slide surfaces,
have been observed when checking the

roller guide.
Note!
For disassembling of the roller guide,

contact an MAN B&W authorized repair
BM909-15.1 207 07
shop.
3. If no irregularities are found, just clean and

lubricate the roller guide before remounting
it in the roller guide bushing.
3.
BM909-15.3 207 03
0$1% :'LHVHO$6
Mounting
Mounting
909-15.4
1. Lubricate the roller guide with plenty of 1.

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
During mounting, take care not to scratch

the sliding surfaces of the roller guide. D09-61
Make sure that the pin of the reversing link
fits in the bracket of the reversing shaft.
2. After mounting the roller guide with the re-

versing link, check the clearance between
the roller guide and the guide plate mount-
ed in the roller guide bushing.
Turn the camshaft so that the roller guide is
BM909-15.4 207 01
lifted approx. 20 mm.
The clearance C between the roller guide

and the guide plate must be the same at
both ends +/– 0.1 mm.
2.
The clearances A and B between the
guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.
D09-54
Connect working air to the air cylinder, and

check that the reversing mechanism is
working smoothly.
The clearances A and B must be approx.

the same in both positions. See Data. D09-55
AM909-8.0 50 15
0$1% :'LHVHO$6
Mounting
3. 3. If adjustment is necessary, place the re-

versing arm in ASTERN position and remove
the four cap screws which tighten the flange
for the air cylinder to the roller guide bush-
ing.
Pull out the air cylinder with the flange as

much as possible.
AM909-8.0 50 17A
4. Release the lock nut on the shaft.
5. Turn the shaft to obtain the distance be-

tween the air cylinder flange and the sur-
face of the roller guide bushing. See Data.
4.
Tighten the nut on the shaft.
6. Mount the flange with the air cylinder on the

roller guide bushing and tighten the four
cap screws.
Lock the screws with Loctite (EN243S)

type: 242.
AM909-8.0 50 17B
Repeat the clearance check once more.
5.
AM909-8.0 50 18
6.
AM909-8.0 50 19
0$1% :'LHVHO$6
Mounting
7. Before mounting the pump base on the roll- 7.

er bushing, replace the O-ring between the
sealing bush and the bottom of the pump
base.
8. Mount the pump base on the roller guide

bushing, and tighten the nuts. D09-62
BM909-8.0 54 24
8.
BM909-15.4 207 08
0$1% :'LHVHO$6
Mounting
9. 9. Replace the scraper rings in the sealing

cap as follows:
Loosen and remove the screws and nuts

from the bottom of the cap, remove the re-
taining flange and ring holder with scraper
ring.
10. Replace the axial scraper ring in the bottom

of the cap. Check that the O-ring and scrap-
er ring are mounted correctly. See the
sketch.
11. Remove the scraper ring and O-ring from

the ring holder.
Place the new O-ring in the ring holder.

BM909-15.4 207 09
Before mounting, the new scraper ring must

be heated in 100°C hot water or oil for at
least five minutes.
10.
Note!
When mounting the scraper ring in the

groove, fold the ring without making any
sharp edges, and be careful not to cut
the scraper ring on the edge of the ring
groove when pressing it in.
Check that the O-ring and scraper ring are

AM909-80.0 31 15
mounted correctly. See the sketch.
11.
AM909-8.0 31 16
0$1% :'LHVHO$6
Mounting
12. Assemble the sealing cap, the ring holder 12.

and retaining flange.
Tighten the nuts on the screws.
After tightening, check that the holder can

be moved.
13. Mount a new O-ring in the groove on top of

the roller guide and on the pump base.
14. Mount the sealing cap over the roller guide.
BM909-15.4 207 12
Tighten the sealing cap to the top of the
roller guide.
Tighten the nuts.
Lock the nuts with Loctite type EN243S. 13.
Land the spring on the roller guide inside

the pump base.
BM909-15.4 207 13
14.
BM909-15.2 207 14
0$1% :'LHVHO$6
Mounting
15. 15. Mount the fuel pump housing.

16. Check the movement of the reversing link.

17. Mount the top cover and barrel/plunger as-

sembly.
BM909-15.2 207 03
16.
BM909-15.1 207 05
0$1% :'LHVHO$6
Fuel Pump Special Running 109-16
MAN B&W Diesel Data

X Stopped engine
X Shut off fuel oil
Data
109-16 Fuel Pump Special Running
Data MAN B&W Diesel
P90951 082 Lifting tool for fuel pump roller guide

P90951 116 Crowfoot spanner
Fuel Pump Special Running

S35MC
0212
909-16
Disengagement of fuel pump 2.
Warning!
Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
1. Engine trouble might require a cylinder to

be taken out of action. The engine can con-
tinue operation with the fuel and exhaust
systems of a single cylinder disconnected.
See Volume I, Section 704.
To disconnect the fuel pump of a single cyl-

inder, proceed as follows:
2. Remove the fuel oil high pressure pipes

and the puncture valve from the fuel pump
top cover.
Note!
BM909-16.0 207 02

Screw a plug-screw into the control air pipe 3.

of the puncture valve.
Remove the inspection cover on the cam-

shaft housing. Turn the engine until the fuel
pump roller is at on the circular part of the
cam.
3. Dismount the suction valve by means of the

extractor tool.
AM909-1.1 76 04
0$1% :'LHVHO$6
909-16 Fuel Pump Special Running
4. 4. Mount the lifting tool on the fuel pump top

cover.
Turn the uppermost nut to screw the spindle

of the lifting tool into the fuel pump plunger.
5. Tighten the lowermost nut on the tool to pull

the roller guide upwards as far as possible.
Lock the tool in this position by means of

the lock nut.
6. Turn the engine one full revolution and in-

GN909-16 202 04
spect through the opening in the camshaft

housing to make sure that the roller guide
is clear of the fuel cam.
5. 7. The engine can now operate on the remain-

ing cylinders. See Volume I, Section 704.
GN909-16 202 05
6.
BM909-160 207 06
0$1% :'LHVHO$6
Re-engagement of fuel pump 8.
Warning!
Re-engagement of the fuel pump must

only take place at engine standstill.
8. Remove the cover on the camshaft hous-

ing. Turn the engine until the circular sec-
tion of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in

the reverse order to lifting and remove the
lifting tool.
10. Re-mount the suction valve and the punc-

ture valve. (See Procedure 909-8.4).
Remove the plug screw from the control air

pipe.
BM909-16.0 207 08
Note!
It is recommended always to mount new

or overhauled suction and puncture
valves. 10.
Mount the fuel oil high pressure pipes.

(See Procedure 909-14.4).
BG909-5.0 45 06
0$1% :'LHVHO$6
Fuel Valve and Fuel Pump Panel Plate
P90951-0393
MAN B&W Diesel A/S
Plate Fuel Valve and Fuel Pump Panel
P90951-0393

No. No.
010 Panel for tools

021 Name plate
045 Measuring tool, fuel pump lead
057 Lifting tool, fuel pump
070 Lifting tool, fuel pump housing
082 Lifting tool, fuel pump roller guide
094 Milling tool for seats for fuel oil pipes
104 Milling tool for fuel oil pipe
116 Crowfoot spanner, 41 mm
153 Flange, dismantling of non return
valve
165 Grinding mandrel for fuel valve head
189 Grinding mandrel for holder outside
190 Grinding mandrel for holder inside
200 Dismantling screw
248 Hook spaner, 80/90 mm
297 Extractor for spindle guide
307 Socket wrench
319 SExtractor for suction valve
MAN B&W Diesel A/S
Fuel Valve - T
Valve ools
Tools Plate
MAN B&W Diesel P90961-0071
Plate
Fuel Valve - T
Valve ools
Tools
P90961-0071 MAN B&W Diesel

No. No.
014 High pressure pump

026 Worktable
038 Test rig for fuel oil valve
040 Hose with union
051 Connection piece
Fuel Valve Nozzle - Tools Plate
MAN B&W P90966-0008
When referring to this page, please qoute Plate P90966 Edition 0008 Page 1 (2)
Plate Fuel Valve Nozzle - Tools
P90966-0008 MAN B&W
Item Item Description

No.
011 Tool box
023 Extractor for atomizer
035 Drift for atomiizer
047 Cleaning brush
060 Instruction plate
202 Toolset, complete
Note:
When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2) When referring to this page, please qoute Plate P90966 Edition 0008
Fuel Valve - Inspection Tools Plate
MAN B&W P90968-0001
Plate Fuel Valve - Inspection Tools
P90968-0001 MAN B&W

No.
012 Probe light with magnifier, complete
Fuel Valve Nozzle - Cleaning Tools Plate
MAN B&W P90974-0001
Plate Fuel Valve Nozzle - Cleaning Tools
P90974-0001 MAN B&W

No.
015 Drill*
027 Test mandrel*
039 Pin vice*
206 Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
Mounting Tools - Air Piston Seals Plate
MAN B&W P90980-0001
Plate Mounting Tools - Air Piston Seals
P90980-0001 MAN B&W

No.
018 Cone
020 Pushing tool
031 Compression tool
043 Cone
055 Pushing tool
067 Compression tool
079 Cone
Air Cooler Element 110-1
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D10-04 Air cooler element, complete with covers, up to 1700 kg

D10-06 Reversing chamber 215 kg
D10-07 Water inlet/outlet cover 300 kg
110-1 Air Cooler Element
Data MAN B&W Diesel
P91063 Air Cooler - Tools

P91064 Travelling Trolley
P91066 Air Cooler - Lifting Tools
Air Cooler Element 910-1.1
Checking
Air Cooler Element
S42MC
0231
Checking
910-1.1
1.
1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the instruction book
Volume I, OPERATION, Chapter 706.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
GN910-1.1 207 01
the air side of the cooler.
A decrease in the air temperature drop

across the scavenge air cooler indicates
fouling of the water side of the cooler.
4.
3. If the measurements indicate fouling of the
water side of the air cooler element, the el-
ement must be dismantled and overhauled/
cleaned.
If the measurements indicate fouling of the

air side of the air cooler element, it is rec-
ommended to inspect the air cooler ele-
ment as follows:
4. Remove the inspection cover from the air

cooler.
GN910-1.1 207 04
5. Visually inspect the air cooler element

through the opening.
If the air side of the element is fouled, clean

the element using the spray pipe arrange- 5.
ment fitted above the air cooler element.
GN910-1.1 207 05
MAN B&W Diesel A/S
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2
2. 1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off the
cooling water.
2. Dismount the cooling water inlet and outlet

pipes from the end cover.
Remove and discard the gaskets.
3. Dismantle the screws and pull out the cool-

er element approx. 10 cm, using the dis-
mantling screws.
GN910-1.2 207 01
2.
GN910-1.2 207 02
3.
GN910-1.2 207 03
MAN B&W Diesel A/S
Dismantling
4. Mount the lifting bracket on the front end 4.

cover.
Attach two tackles to the lifting bracket, one

horizontally and one vertically.
Using the vertical tackle, lift the air cooler

element approx. 2-3 mm.
Using the horizontal tackle, pull out the air

cooler element approx. half a metre.
5. Mount the two guide rails on the frame
EN910-1.2 222 04
around the air cooler element.
6. Using the horizontal tackle, pull out the air

cooler element far enough to gain access to
the aft end cover.
5.
Mount two shackles in the upper corners of
the aft end cover.
Mount lifting wire ropes between the two

shackles and the lifting bracket, and hook
the engine room crane on to the lifting wire
ropes.
Remove the two tackles and lift the air cool-

er element away. Land the element on a
couple of wooden planks.
EN910-1.2 222 05
Note!
During the lift, take care not to damage

the air cooler element.
6.
D10-04
EN910-1.2 222 06
MAN B&W Diesel A/S
Overhaul
Overhaul
910-1.3
1. Cleaning the air side:
1. The air side of the cooler is cleaned by in-

jecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.
It is recommended to use one of the follow-

ing cleaning fluids, or a similar product.
• Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
GN910-1.3 207 01
• Product: 80B, produced by

Vecom Int., Maassluis, Holland
2. Do not start cleaning until the engine has

3. been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.
Remove the covers on the scavenge air re-

ceiver to let vapours escape.
3. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pres-
sure must be at least 0.7 bar.
4. Continue the cleaning process for at least

30 minutes. The time required depends on
DG910-5.1 62 01
the frequency with which cleaning is carried

out and on the chemical product used.
5. After cleaning, flush the cooler with clean

water until the water in the sight glasses ap-
pears clean and pure.
6. Inspect the air cooler element by removing

the cover of the scavenge air cooler hous-
ing.
MAN B&W Diesel A/S
Overhaul
Cleaning the water side 2.
1. Dismantle the air cooler element and re-

move it from the engine.
2. Dismantle the front end cover of the air

cooler element. Remove and discard the
gasket.
3. Dismantle the aft end cover of the air cooler

element. Remove and discard the gasket.
4. Clean the water side of the cooler element
GN910-1.3 207 02
(the inside of the tubes) using the cleaning
brush mounted on a drilling machine. Flush D10-07
the tubes with clean fresh water.
In the event of a leaking tube, plug both 3.

ends of the tube using a brass or copper
plug.
In the event of leakages between a tube

and the tube plate, roll the tube using the
tube expander.
5. Clean and check the inside of the front end

and aft end covers. If necessary replace the
corrosion blocks.
Note!
GN910-1.3 207 03
If damaged, the coating inside the covers D10-06

is to be repaired with the original coating
or a similar product.
4.
6. When cleaning is complete, mount new
gaskets and re-mount the front end and aft
end covers of the air cooler element.
7. Re-mount the air cooler element in the

scavenge air cooler housing.
GN910-1.3 207 04
MAN B&W Diesel A/S
Mounting
Mounting
910-1.4
1. 1. Lift the air cooler element and land the aft

end of the element on the guide rails
mounted on the air cooler housing.
Hook a tackle on to the bracket at the front

of the air cooler element.
Remove the lifting wire ropes and shackles.
2. Push the air cooler element inwards ap-

prox. one metre.
Remove the guide rails from the air cooler

housing.
EN910-1.2 222 06
D10-04
3. Clean the frame around the air cooler ele-
ment and the contact surface of the front
end cover.
2.
Apply a thin layer of silicone paste to the
frame around the air cooler element and the
contact surface of the front end cover.
Push the air cooler element fully into the air

cooler housing.
EN910-1.4 222 02
3.
EN910-1.4 222 03
Silicone
MAN B&W Diesel A/S
Mounting
4. Mount and tighten all the screws of the front 4.

end cover.
Remove the tackle and the lifting bracket

from the front end cover.
5. Mount the cooling water inlet and outlet

pipes on the front end cover.
6. Close the drain cocks and open the cooling

water inlet and outlet valves.
Note!
EN910-1.4 222 04
Remember to vent trapped air from the
air cooler element.
GN910-1.2 207 02 5.
6.
GN910-1.4 207 06
MAN B&W Diesel A/S
Non-Return Valve 110-2
MAN B&W Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
When referring to this page, please quote Data D11002Edition 0009 Page 1 (2)
110-2 Non-Return Valve
Data MAN B&W
Non-Return Valve 910-2.3
Overhaul
Non-Return Valve
0211
Overhaul
910-2.3
1.
This procedure includes both the main non-re-
turn valve and the non-return valve for the aux-
iliary blowers.
Both sets of non-return valves are accessed via

the scavenge air receiver.
Note!
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
BM910-2.3 208 01
Main Non-Return Valve
1. The main non-return valve consists of four

valve flaps located inside the scavenge air
cooler housing. 2.
2. Remove the screws holding the valve flap.

Remove the valve from the engine.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
Clean the valve shaft and the slide bearings

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybde-
num disulphide (MoS 2).
After the overhaul, it must be possible to

move the valve flap by the light touch of a
finger.
4. Assemble the valve and re-mount it in the

BM910-2.3 208 02
3.
BM910-2.3 208 03
0$1% :'LHVHO$6
910-2.3 Non-Return Valve
Overhaul
5. Non-Return Valve for Auxiliary Blowers
5. Inside the scavenge air cooler housing, lift

up the valve flap of the valve to be over-
hauled.
6. Remove the screws behind the valve flap.

Remove the valve from the engine.
7. Remove the spring pins from the valve shaft

and knock the valve shaft out of the valve
flap.
BM910-2.3 208 05
Clean the valve shaft, the slide rings and

the slide bearings inside the valve flaps. Lu-
bricate the valve shaft, the slide rings and
the slide bearings with molybdenum disul-
phide (MoS 2).
6.
After the overhaul it must be possible to
move the valve flap by the light touch of a
finger.
8. Assemble the valve and re-mount it in the

BM910-2.3 208 06
7.
BM910-2.3 208 07
0$1% :'LHVHO$6
Auxiliary Blower 110-3
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
D10-09 Weight of blower unit, complete * up to 770 kg

*) Depending on electric motor type and number of
cylinders of engine (size and capacity of auxiliary blower)
D10-12 Electric motor, impeller and motorplate 235 kg
110-3 Auxiliary Blower
Data MAN B&W Diesel
Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
S42MC
0215
Overhaul
910-3.3
2.
1. Depending on the type of overhaul, discon-
nect the cable connections from one or both
blower motors.
The overhaul can be carried out either by

dismantling the complete blower unit or just
dismantling the individual blower wheel
which is to be replaced/overhauled.
2. Complete Blower Unit
Hook a shackle and a tackle to the lifting

bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates.
Remove all screws in the outlet flange of

the blower unit.
D10-09
Remove all screws in the lower inlet flange
of the blower unit.
GN910-3.3 206 02
Remove all screws in the upper inlet flange

of the blower unit.
Lift away the blower unit and land it on

wooden planks for further dismantling/over-
haul.
MAN B&W Diesel A/S
910-3.3 Auxiliary Blower
Overhaul
3. 3. Blower Wheel
Remove the safety guard and the driving

belt.
4. Remove the screws in the blower flange

and lift away the blower flange complete
with blower wheel and bearing housing.
For overhaul of blower wheel and bearings,

see blower manufacturer’s instructions.
GN910-3.3 206 03
5. Electric Motor
The electric motors can be dismantled with-

out removing the blower housing.
4.
Remove the safety guard and the driving
belt.
Hook a shackle and a tackle to the motor.

It may be necessary to remove one or more
of the gallery plates.
Remove all screws in the flange of the mo-

tor.
GN910-3.3 206 04
Lift away the motor and land it on wooden

planks for further dismantling/overhaul.
MAN B&W Diesel A/S
Turbocharger Turbine 110-5
Data
Stopped engine
Shut off safety air supply – Not ME-engines
Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
Data
MAN B&W Diesel A/S
Turbocharger Turbine 910-5.3
MAN B&W Diesel Cleaning
The dry cleaning method employs com-

pressed air to blow dry, solid, granules
through the turbocharger, thus removing
most of the deposits which may have
formed on the nozzle vanes and turbine
blades.
On account of their hardness, nut-shells, or

broken or artificially shaped pieces of acti-
vated charcoal with a size of between 1.0
and max. 1.5 mm are particularly suited as
blasting agents.
Note!
We do not recommend the use of rice or
grain as cleaning materials, as these
may possibly stick in the exhaust gas
boiler.
It is not always possible to remove thick

deposits with this dry cleaning method.
Therefore, in order to prevent the build-up

of thick deposits, the turbine must be
cleaned after every 24 to 50 hours of op-
eration.
Generally, turbocharger cleaning can be

carried out without, or with very little, re-
duction of the engine load.
More detailed information regarding the

amount of granules to be used is stated on
the instruction plate located close to the
turbocharger.
Note!
Regarding water washing of turbo-
charger turbine, see turbine manu-
facturer’s instructions.
See also Volume I, Chapter 706.
910-5.3 Turbocharger Turbine
Cleaning MAN B&W Diesel
Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours

of operation, based on observations.
Amount
TC type
dm3 2. Preferably clean the turbocharger at full
TCA 33 0.5 load. Do not clean below half load.
TCA 44 0.5
3. Close valve A.
TCA 55 1.0
TCA 66 1.5 4. Open valves B and C, to blow out any de-
TCA 77 2.0 posits and/or condensate in the connecting
pipe.
TCA 88 2.5
M910050212O01
TCA 99 3.0 After about two minutes, close valves B

and C.
5. Slowly open valve A to relieve the pressure

in the tank.
6. Fill the tank with the quantity of granules

specified in the table.
A C 7. Close valve A.
8. Open valves B and C, to blow-in the gran-

B ules. After one to two minutes, close valves
B and C.
9. Slowly open valve A to relieve the pressure

in the tank.
M910050211O01
Caution!
1. The drain openings in the gas cas-
ings must remain closed while dry
cleaning the turbine.
2. It is possible that during dry cleaning

of the turbine, some of the blown-in
solid particles or sparks will escape
through the funnel.
Water Mist Catcher 110-6
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-11 Water mist catcher 158 kg
110-6 Water Mist Catcher
Data MAN B&W Diesel
Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
S42MC-C
0217
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the
water mist catcher element from the scav-
enge air cooler housing. If, however, the
water mist catcher element has been fouled
or damaged, it must be dismantled for
cleaning or repair.
2. To dismantle the water mist catcher, dis-

mantle the water mist catcher cover to give
access to the air cooler housing.
3. Loosen the screws which fasten the water

mist element to the cooler frame, through
DG910-5.3 62 01
the small end cover.
4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the
water mist catcher.
3.
Attach a tackle to the eye bolt and tighten
up the tackle.
5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
DG901-5.3 62 02
4.
D10-11
DG901-5.3 62 03
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4
1. 1. Lubricate the two supports on the under-

side of the water mist catcher with plenty of
grease.
D10-11
Apply a thin layer of silicone paste to the
frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.
Note!
Make sure to mount the water mist

catcher correctly. See the sketch.
EN910-6.4 214 01
Air flow 2. Slide the water mist catcher into the scav-
enge air cooler housing.
2. When the water mist catcher is half-way in,

remove the tackle and the eye bolt, and
push the water mist catcher fully into the
3. Tighten the two screws at the front end of

the water mist catcher. Mount the cover.
GN910-6.4 205 02
3.
DG901-5.3 62 02
0$1% :'LHVHO$6
Water Mist Catcher 910-6.4
Mounting
4. Tighten the two screws at the aft end of the 4.

water mist catcher. Clean the water mist
catcher cover and apply a thin layer of sili-
cone paste along the edges of the cover.
Mount the cover.
DG901-5.3 62 01
0$1% :'LHVHO$6
Turbocharger System - Tools
Tools Plate
Plate
Turbocharger System - Tools
Tools

No. No.
014 Pulling tool

026 Lifting eye bolt
Air Cooler - Tools Plate
P91063-0017
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0017

No. No.
015 Guide rail, air cooler fore end

027 Guide rail, air cooler fore end
MAN B&W Diesel A/S
Air Cooler - Lifting Tools Plate
MAN B&W P91066-0001
Plate
Air Cooler - Lifting Tools
P91066-0001 MAN B&W

No. No.
011 Lifting attachment air cooler fore end,

complete
023 Screw
Safety Valve 111-1
MAN B&W Diesel Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D11-01 Opening pressure 200± 5 bar

D11-02 Valve housing, tightening torque 45 Nm
111-1 Safety Valve
Data MAN B&W Diesel

P90151 117 Test equipment for combined safety valve
Safety Valve 911-1.2
Dismantling
0210 Valve
Safety S42MC
Dismantling
911-1.2
1.
When Side-mounted
1. Remove the guard surrounding the safety

valve.
Unscrew the safety valve from the exten-

sion pipe.
2. Dismantle the indicator cock and the inter-

mediate pipe.
BG901-2.5 90 01
BG901-2.5 90 02 2.
When Top-mounted 3.
3. Unscrew the safety valve from the cylinder
cover.
Remove and discard the mild steel disc.

HM911-1.2 205 01
MAN B&W Diesel A/S
911-1.3 Safety Valve
Overhaul (adjustment)
911-1.3
1. 1. If necessary, dismantle the safety valve and

clean all the parts in either gas oil, kero-
sene, 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

in the data, loosen and tighten again to
the torgue stated in the data.
HM911-1.0 27 01
3. Then mount:
• the valve spindle
2. • the spring
• the adjusting screw
• the lock nut
D11-02
D11-02
HM911-1.0 27 02
3.
HM911-1.0 27 03
MAN B&W Diesel A/S
4. To set the safety valve opening pressure: 4.

D11-01
• Set up the safety valve in the testing
device.
• Connect the testing device to the hydrau-

lic pump.
• 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
HM911-1.0 27 04
air bubbles, flows out from the openings
of the safety valve.
• Tighten the adjusting screw of the safety

valve until the correct pressure is indi-
cated (see D-2).
• Tighten the lock nut.
• Test the opening pressure.
• Remove the valve from the testing

device.
MAN B&W Diesel A/S
911-1.4 Safety Valve
Mounting
Mounting
911-1.4
1. When Side-mounted
1. Pierce the bore in the cylinder cover, and

blow it clean.
2. Clean the sealing ring grooves of the indi-

cator cock. Mount the intermediate pipe
and the indicator cock.
3. Mount a new sealing ring and a new or

overhauled safety valve.
DM901-2.4 122 03
When mounting the safety valve, apply

tools only on the hexagon on the safety
valve.
2. Mount the guard surrounding the safety

valve.
BG901-2.5 90 04
3.
BG901-2.5 90 05
MAN B&W Diesel A/S
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.
Mount a new mild steel disc in the bore.
When mounting the safety valve on the cyl-

inder cover, apply tools only on the hexa-
HN911-1.4 205 01
gon on the safety valve.
HN911-1.2 205 01 5.
MAN B&W Diesel A/S
Relief Valve 111-2
MAN B&W Data

X Stopped engine
Engage turning gear
Shut off fuel oil
Data
111-2 Relief Valve
Data MAN B&W
Relief Valve 911-2.1
Checking
60&
Relief Valve
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 dam-

age to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
If one or more plates in the flame arrester

are damaged, the relief valve must be dis-
assembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
XZ911-2.1 209 01
Note!
The complete flame arrester has to be

2.
replaced after a crankcase explosion.
XZ911-2.1 207 03
0$1% :'LHVHO$6
Scavenge Air Receiver Safety Valve 111-3
MAN B&W Diesel Data

X Stopped engine
Shut off fuel oil
Data
111-3 Scavenge Air Receiver Safety Valve
Data MAN B&W Diesel
Scavenge Air Receiver Safety Valve 911-3.1
1. The scavenge air receiver safety valve

2.
is calibrated at the factory and does not
require any adjustment.
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.
Use a piece of cloth to wipe out any dirt

from the Oring packing and close the
valve again. Tighten the counter nut.
M911030001C02
If this operation cannot be performed
smoothly, the safety valve must be
dismantled and cleaned.
911-3.2 Scavenge Air Receiver Safety Valve
1. Dismount the safety valve from the scav-

1. enge air receiver.
2. On some engines, a cover has to be re-

moved in order to gain access to the safety
valve.
M911030001D01
2.
M911030001D02
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.
Pull out the spring.
2. Pull out the valve flap with spindle. If the

Oring seal is damaged remove it without
M911030001O01
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.
2.
M911030001O02
911-3.3 Scavenge Air Receiver Safety Valve
4. If the Oring seal has been removed mount

4. 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.
Tighten the nut until the split pin can be

mounted.
M911030001O04
7. Check the valve according to 9113.1.
5.
M911030001O05
6.
M911030001O01
1. Mount the safety valve on the scavenge air

receiver. 1.
M911030001M01
Holding Down and End Chock Bolts 112-2
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0008
112-2 Holding Down and End Chock Bolts
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Data
D12-01 Tightening pressure for holding down bolts and end chock bolts 900 bar
D12-02 Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
1st check 500 hours
2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequently at intervals of 8000 hours
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data

P91263 24 Hydraulic jack for holding-down bolts, complete
P91263 36 Hydraulic jack for end-chock bolts, complete
P91263 48 Support for holding-down bolt
P91263 50 Support for end-chock bolt
P91263 119 Tommy bar (ball handle)
P91351 10 Hydralic pump, pneumatic operated
P91351 46 Hose with unions (1500mm), complete
MAN B&W Diesel A/S
Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0208
Checking
912-2.1
Note!
The hydraulic jack used for tightening the

holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the

end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking
1. Checking the Bolt Tightening
1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.
If the ‘loosening pressure' is below 80 per

cent of the tightening pressure, the relative
EN912-1.1 205 01
chocks shall always be checked for possi-

ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.
0$1% :'LHVHO$6
Checking
Side Chocks and Side Chock Liners 3.
3. After fitting the liners to an 80 per cent con-

tact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simulta-
neously.
The first time the ship is sailing in a fully-

loaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.
GN912-2.1 203 03
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
The feeler gauge is applied at the 7 points

indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in

the table.
If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking
Holding Down Bolts

Engine Port side Cylinder Starboard side Engine
frame Bolt Bolt frame
No. No. pressure % dev. remarks No. pressure % dev. remarks No. No.
1 1
2 2
1 3 3 1
4 4
1
1 1
2 2
2 3 3 2
4 4
1 2 1
2 2
3 3 3 3
4 4
1 3 1
2 2
4 3 3 4
4 4
1 1
2 2
5 3 3 5
4 4
1 1
2 2
6 3 3 6
4 4
1 1
2 2
7 3 3 7
4 4
1 1
2 2
8 3 3 8
4 4
1 1
2 2
9 3 3 9
4 4
1 1
2 2
10 3 3 10
4 4
1 1
2 2
11 3 3 11
4 4
1 1
2 2
12 3 3 12
4 4
1 1
2 2
13 3 3 13
4 4
1 1
2 2
14 3 3 14
4 4
1 1
0$1% :'LHVHO$6
Checking
Side Chocks and End Chock Bolts

Port side Starboard side
Chock Point Point Chock
Cylinder
No. A B c d e f g No. A B c d e f g No.
1 1
2 1 2
3 2 3
4 3 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
A, B
FORE A, B
A
d
c
A
d
c
e
e
g
B
f
f
g
B
c, d, e, f, g c, d, e, f, g
Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure ation Point Point ation sure Bolt Ch
2) (kp/cm 2 )
No. No. (kp/cm
bar % a b c d e a b c d e % bar
No. No.
1 1
E E
2 2
b c d d c b
a e e a
No. 2 Contact face No. 1 No. 2
AFT
B1
B2
B2
B1
0$1% :'LHVHO$6
Stay Bolts 112-3
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0017
112-3 Stay Bolts
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D12-05 Min. clearance 0.4 mm
MAN B&W Diesel A/S
112-3 Stay Bolts
Data

P91261 59 Hydraulic tools for staybolts, complete
P91351 10 Hydralic pump, pneumatic operated
MAN B&W Diesel A/S
Stay Bolts 912-3.1
MAN B&W Checking
1. Before retightening the stay bolts, remove

1.
the protective caps.
2. Clean the contact faces and fit the hydrau-

lic tools on a pair of stay bolts positioned
opposite each other on the middle of the
engine.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
M912030215C01
2.
D13-01
-ç#
912-3.1 Stay Bolts
Checking MAN B&W
3. If the engine is equipped with split stay-

3.
bolts and one or more staybolts have been
dismantled, make sure that the staybolts
are mounted in such a way that, when the
uppermost staybolt nut is loosened, there
D1205 is a clearance, as stated in Data, between
the contact face of the lowermost nut and
the bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.
4. Start the retightening of the stay bolts and

proceed to tighten the stay bolts in pairs,
working from the middle toward one end of
M912030215C03
the engine and then from the middle again

toward the other end.
5. Maintain the hydraulic pressure at the value

indicated in D13-01, and retighten the stay
4. bolt nuts with a tommy bar. Before relieving
the system of pressure, check with a feeler
gauge that the nuts bear against the con-
tact face.
M912030215C04
5.
D13-01
-10%
-ç#
Stay Bolts 912-3.1
MAN B&W Checking
6. Reconnect the hydraulic tools to the pair of 6.

stay bolts first tightened. Tighten to 10%
below D13-01 and check if the nut is loose.
If the nut is not loose:

Tighten the stay bolts to D13-01.
If the nut is loose:

Tighten all stay bolts once again to D13-01.
7. After completing the retightening proce-

dure, fit the protective caps.
M912030215C06
Crankcase Oil Outlet 912-5.1
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil 1.
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing. E F G D C B A
Note!
If the water content of the main engine
lube oil is rising, this may indicate that
the crankcase oil outlet sealings are frac-
tured.
M912050201C01
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing

remove:
Screws A 2.
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
M912050201C02
Note!
It is strongly recommended to always re-
place the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
912-5.1 Crankcase Oil Outlet
Metal bellow sealing

4.
4. Remove all screws A and grating B.
5. Remount four of the screws A at diametri-

C B cally opposite positions.
D A
6. Remove:
F Screws C
Cover plate D
Screws E.
E
G 7. Lift away metal bellow sealing F and exam-
ine it closely. If any cracks or punctures are
M912050201C04
found in the metal bellow sealing, it must

H be replaced.
Note!
7. It is recommended to always replace the
metal bellow sealing during inspection.
8. Replace gaskets G and H.
9. Mount metal bellow sealing F.
10. Mount:
Screws E
Cover plate D
Screws C.
M912050201C07
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Hydraulic Tools for Large Parts Plate
MAN B&W P91261-0070
Plate Hydraulic Tools for Large Parts
P91261-0070 MAN B&W

No.
035 Support
047 Tommy bar
Hydraulic Tools - Holding-Down and
End Chock Bolts (Epoxy Chocks) Plate
MAN B&W P91263-0058
Hydraulic Tools - Holding-Down and
Plate End Chock Bolts (Epoxy Chocks)
P91263-0058 MAN B&W

No.
024 Hydraulic jack for end-chock bolts
036 Hydraulic jack for holding-down bolt
048 Support for end-chock bolt
050 Support for holding-down bolt
061 Tommy bar
073 Tommy bar
085 Spanner, hex key type
Hydraulic Tools 913-1.1
MAN B&W General Description
A. Snap-on coupling
1.
B. Tool attachment thread
C. Bleed screw
D. Piston
E. Cylinder
F. Sealing rings
G. Spacer ring
H. Tommy bar
M91301-0209M01
I. Nut
J. Stud or bolt
K. Extension stud
L. Lifting tool
S. Clearance
U. Milled recess for feeler gauge L

Studs or bolts provided with threads for attach-
ing hydraulic tools and with circular nuts must
only be loosened and tightened up by means I
of the hydraulic tools supplied.
D
The jack(s) is/are connected, via a distributor
C F
block, to a high-pressure pump, which is set E
to deliver hydraulic oil at the pressure indicated
on the jack and on the data sheet in the rel-
evant section of this instruction book. The stud
or bolt concerned is thereby lengthened relative A F
to the oil pressure applied and the piston area,
G K
and the nut can be loosened or tightened, as
required, with the aid of a tommy bar. B
H
The jacks must never be overloaded or ex- J
posed to blows or impacts. They are marked
M91301-0207M02
with a “Max. lift”, which must not be exceeded. U

1. The hydraulic tools, except those for the I
main bearings, consist of a jack with an
internal thread to suit the tool attachment
thread on the stud or bolt, and a spacer
ring which is to be placed under the jack
and around the nut that is to be loosened
or tightened.
913-1.1 Hydraulic Tools
General Description MAN B&W
2. For the main bearings, the hydraulic tool

3. consists of a double jack with two exten-
sion studs. This jack is designed for the
simultaneous dismantling of both nuts on
one side of the main bearing.
3. The hydraulic jacks are so designed that,

in the event that the “Max. lift” limit is ex-
ceeded, the pressure is relieved at the bot-
tom of the pressure chamber and the oil
will be pressed out into the space between
the stud and the spacer ring.
When the pressure is relieved in this way,

the lowermost sealing ring will in most
cases be damaged. Therefore inspect and,
if necessary, replace this sealing ring.
The oil used must be pure hydraulic oil or

turbine oil (with a viscosity of about SAE
20). Oils such as, for instance, lubricating
oil (system oil) or cylinder lubricating oil
M91301-0209M02
must not be used, as these oils are nor-

mally alkaline and can thus damage the
back-up rings.
The following instructions must be closely

followed to prevent accidents or damage,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.
Warning!
Eye protectors and gloves must be used
when using hydraulic tools.
MAN B&W Loosening of Nut
Single Hydraulic Jack

1.
1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with

molybdenum disulphide grease or with
graphite and oil or similar.
Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot when the nut is to
be loosened.
2. Screw the jack on to the tool attachment

thread of the bolt/stud, until the cylinder
of the jack bears firmly against the spacer
ring.
Connect the hydraulic jack, the distribu-

tor block and the high pressure pump by
means of high pressure hoses.
M91301-0214M05
Unscrew the jack to create a clearance

between the jack and spacer ring. See
sketch.
Loosen the bleed screw in the jack and

fill up the system with oil until oil without 2.
bubbles, flows out of the bleed hole. Then
tighten the bleed screw again.
When loosening nuts on very long bolts

(e.g. staybolts) it is recommended to un-
screw the jack an additional half turn.
The clearance between the jack and spacer

ring ensures dismantling of the jack after
loosening the nut.
After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylin-
der of the jack.
M91301-0214M06
Loosening of Nut MAN B&W
3. Increase the oil pressure to the prescribed

3.
value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.
4. Unscrew the nut with the tommy bar, mak-

ing sure that the nut is not screwed up
against the jack.
M91301-0214M07
4.
M91301-0214M08
MAN B&W Loosening of Nut
5. Relieve the system of pressure, disconnect

5.
the high-pressure pump, and remove the
hydraulic tools.
Note!
Make sure not to exceed the “max lift”
stamped on the jack.
Double Hydraulic Jack
6. Carefully clean the tool attachment threads,

the main bearing studs, the nuts and the
surrounding parts.
Grease the tool attachment threads with

molybdenum disulphide grease or graphite
and oil or similar.
Mount the extension studs on the main

bearing studs.
M91301-0214M09
Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.
6.
7. Press the pistons and the cylinder of both
the hydraulic jacks firmly together.
Mount the two jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.
Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.
M91301-0205M06
Screw the upper nuts on to the threads of

the extension studs until the cylinders of
the jacks bear firmly against each other
and against the spacer ring.
Loosening of Nut MAN B&W
8. The clearance between the pistons and the

8.
cylinder of the top jack is adjusted by un-
screwing the upper nuts 1 turn ª 3 mm.
The clearance between the jack and spacer

ring ensures dismounting of the jack after
loosening the nut.
Connect the hydraulic jacks, the distribu-

tor block and the high pressure pump by
Loosen the bleed screws in both jacks, and

M91301-0205M07
fill up the system with oil until oil, without

bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

9. value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.
10. Unscrew the lower nuts 1½ turns with the

tommy bar, making sure that the nuts are
not screwed up against the extension stud.

the high-pressure pump, and remove the
hydraulic tools.
Note!
M91301-0214M17
Make sure not to exceed the “max lift”

stamped on the jack.
MAN B&W Tightening of Nut
Single Hydraulic Jack

1.
1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.
Clean and lubricate the tool attachment

thread and the thread in the nut with mo-
lybdenum disulphide grease or with graph-
ite and oil or similar.
Fit the round nut on the thread and tighten

it with the tommy bar.
M91301-0211M09
Check with a feeler gauge that the contact
face of the nut bears on the entire circum-
ference.
Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot for the purpose of 2.
tightening the nut.
2. Press the piston and the cylinder of the

jack firmly together.
Screw the hydraulic jack on to the tool at-

tachment thread.
Make sure that the cylinder of the jack

bears firmly against the spacer ring and
that the parts are guided correctly together
Connect the hydraulic jack, the distribu-

tor block and the high-pressure pump by
means of high-pressure hoses.
Loosen the bleed screw in the jack and fill

up the system with oil, until oil without bub-
bles flows out of the bleed hole.
Re-tighten the bleed screw.

M91301-0214M06
Tightening of Nut MAN B&W

3.
value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.
4. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cess at the bottom of the spacer ring that
the nut bears against the contact face.

the pump, and remove the hydraulic jack.
M91301-0214M14
6. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nut as described
under ‘Loosening’, points 2-5, and then
tighten the nut again according to the pro-
cedure under ‘Tightening’, points 2-5.
4.
M91301-0214M15
MAN B&W Tightening of Nut
Double Hydraulic Jack

7.
7. Thoroughly clean the nuts, the threads on
the main bearing studs, the contact faces,
and the surrounding parts.
Clean and lubricate the tool attachment

thread and the threads in the nuts with mo-
lybdenum disulphide grease or with graph-
ite and oil.
Fit the round nuts on the threads and tight-

en them with the tommy bar.
M91301-0205M07
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circum-
ference.
Mount the extension studs on the main

bearing studs. 8.
Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of tightening the
nuts.
8. Press the piston and the cylinder of both

the hydraulic jacks firmly together.
Mount the two jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.
Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.
Screw the upper nuts on to the threads of

the extension studs until the cylinders of
the jacks bear firmly against each other
M91301-0205M08
and against the spacer ring.
Tightening of Nut MAN B&W
9. Connect the hydraulic jacks, the distribu-

9. tor block and the high pressure pump by
Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
M91301-0205M09
spacer ring.
11. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cesses at the bottom of the spacer ring
that the nuts bear against the contact face.
10.
the pump, and remove the hydraulic tools.
13. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nuts as described
under ‘Loosening’, points 7-11, and then
tighten the nuts again according to the pro-
cedure under ‘Tightening’, points 8-12.
M91301-0214M17
11.
M91301-0214M18
MAN B&W Maintenance
1. The hydraulic jacks require no maintenance

1.
except replacement of defective sealing
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.
The piston and cylinder are easily sepa-

rated by taking out the bleed screw and
pressing the parts apart with the help of
compressed air.
Warning!
Make sure that there are no marks or

scratches on the sliding surfaces of the
parts. The presence of metal particles will
damage the sealing rings.
M91301-0214M19
Keep the sliding surfaces and threads coat-

ed with acid-free grease or molybdenum
disulphide grease.
2. The pistons and cylinders of the double

jacks are separated in the same easy way
as described for the single jack. 2.
M91301-0214M20
Maintenance MAN B&W
3. When changing the sealing rings, first

3. mount the back-up ring and then the O-
ring.
Warning!
Note that the back-up ring (1) must be
away from the pressure chamber and the
O-ring (2) close to the pressure chamber.
See the sketch for the correct mounting of

both the upper and the lower sealing rings.
The same principle applies to all the jacks.
4. After fitting the sealing rings, coat the

piston and cylinder with molybdenum di-
sulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
M91301-0214M22
Standard Tightening Torques 913-4
MAN B&W
When tightening screws, studs or nuts for 4. Screwing-in of studs.

which no torque is specified in the instruction
procedure or the related data sheet, the stand- The intention of this procedure is to ensure
ard torques specified in this procedure are to that the studs are screwed right to the bottom
be applied. of the threaded holes.
1. Standard screws and nuts lubricated with Carefully clean off any burrs and loose parti-
a Molybdenum Disulphide (MoS2) based cles from the thread and contact faces, and
lubricant. coat the thread with a lubricant having a parti-
cle size of approx. 0.5 µm, for instance MoS2
Tightening Tightening (molybdenum disulphide) or a non-synthetic
Thread Thread graphite mixed with oil.
torque torque
M8 17 Nm M22 400 Nm
The studs are to be screwed-in applying the
M10 35 Nm M24 460 Nm
torque specified in the instruction procedure
M12 50 Nm M27 610 Nm
in use. If nothing is mentioned in the instruc-
M14 80 Nm M30 950 Nm
tion procedure, Fig. 4 indicates the torque.
M16 135 Nm M33 1200 Nm For thread sizes > M36 the curve indicates a
M18 190 Nm M36 1650 Nm screwing-in torque of 680 Nm.
M20 260 Nm M39 2100 Nm
2. Self-locking nuts.
Screwing-in torque curve
Tightening Tightening
Thread Thread 1000
torque torque
800
M8 20 Nm M22 430 Nm
600
To r q u e (Nm )
M10 40 Nm M24 490 Nm

M12 60 Nm M27 650 Nm 400
M14 90 Nm M30 1000 Nm
M16 150 Nm M33 1250 Nm
M18 210 Nm M36 1700 Nm
200
M20 290 Nm M39 2200 Nm
3. Screws and nuts locked with glue/Loctite.

M913040202C04
100
10 20 40 60 80 100
Tightening Tightening Major diameter of thread (mm)
Thread Thread
torque 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
913-4 Standard Tightening Torques
MAN B&W
5. Screws and nuts locked with

camlock washers.
For correct fitting of washers, see Procedure

913-7.
Tightening Tightening
Thread Thread
torque torque
M8 20 Nm M22 470 Nm
M10 40 Nm M24 550 Nm
M12 70 Nm M27 800 Nm
M14 110 Nm M30 1100 Nm
M16 165 Nm M33 1500 Nm
M18 230 Nm M36 1900 Nm
M20 320 Nm M39 2500 Nm
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 tight-

ening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
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.

7
;

G
Q
D

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. 0

+
0$1% :'LHVHO$6
Torque Spanner 913-5
/0&
Torque Spanner
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mix-
ture of graphite and oil or molybdenum disul-
phide 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 split-
pin hole.
The torque spanner must not be used for tor-

ques 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 span-
ner, and a small click is heard.
When the torque spanner is not in use, the

spring inside should be released by adjusting to
minimum torque.
0$1% :'LHVHO$6
Screws and Nuts 913-7.1
MAN B&W Diesel Locking
Some screwed and bolted connections on the

1.
engine, as well as some movable joints, are se-
cured against untimely loosening by means of
different types of locking devices.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Note!
Make sure only to mount locking devices
on nuts and screws which have been
mounted with locking devices by the en-
M913070207C01
gine manufacturer.
1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers 2.
are to be bent back over one of the flats of
the screw or nut concerned.
2. Used spring washers must be replaced.
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
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
M913070207C02
to the torque value stated on the data

sheet of a procedure.
3.
M913070207C03
913-7.1 Screws and Nuts
Locking MAN B&W Diesel
Locking wire should be fitted after the screws

Fig. 1 Fig. 2 or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Al-
ways fit new wire after tightening-up the units.
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3 Fig. 4 Fig. 1: Insert wire, grasp the upper end of the
wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.
Fig. 2: Twist the wire clockwise until it is just

short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approxi-
Fig. 5 Fig. 6 mately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180°, equal
to half of a complete turn.
M913070207C04
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,

and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it

Fig. 7 min. 3 twists, counterclockwise until tight.
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
Fig. 7-9: Show the preferred ways of mounting
the locking wire on screws with wire holes ori-
ented in different angles.
M913070207C05
Fig. 9
Screws and Nuts 913-7.1
MAN B&W Diesel Locking
Fig. 10: Shows how to route the locking wire

on screws in different planes.
Fig. 11: Wire that passes over the top of a nut

is an acceptable alternative only if it routes
Fig. 10
around the protruding screw thread.
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure. Fig. 11
Fig. 13: Where drilling of locking wire holes has
caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut. Fig. 12
Fig. 14: Locking wire can be mounted to any
other part of the assembly if nothing else is
possible. M913070207C06
Fig. 13
Fig. 14
913-7.1 Screws and Nuts
Locking MAN B&W Diesel
Cam Lock Washers with rising cams on one

Fig. 15 side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam

face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
Fig. 16: Different uses of the cam lock wash-

M913070207C15
ers.
Fig. 17: Don not use the cam lock washers in

conjunction with other loose washers.
Note!
Fig. 16.
Cam lock washers must be installed in
pairs and are not to be substituted by
other typers of washers.
M913070207C16
Fig. 17
M913070207C17
Lubricating Procedures 913-11
Lubricating Procedures
0204
.0&&
913-11
Molybdenum Disulphide (MoS2)
The following procedure is to be followed prior

to the mounting of metal surfaced parts which
are to function as seals.
• Clean the surface with a cleaning fluid

and ensure that the entire surface is
completely free of grease.
• Allow 5 minutes for the cleaning fluid to

evaporate.
• With a clean leathercloth, and using cir-

cular movements, rub a mixture of fine-
grained particles of Molybdenum Disul-
phide (MoS2) and mineral oil (e.g. Moly-
cote G-n Plus, or the like) hard onto the
metal surface.
• Remove any excessive paste and ensure

that the metal surface is only coated with
a thin, uniform, layer of the above mix-
ture.
• Protect the wet paste and cloth from dust

or other foreign particles.
0$1% :'LHVHO$6
Accessories for Hydraulic Tools Plate
MAN B&W P91351-0036
Working Pressure 1500 Bar
Plate Accessories for Hydraulic Tools
P91351-0036 MAN B&W

No.
010 Hydraulic pump, pneumatic operated
022 Hydraulic pump, hand operated
046 Hose with unions (1500mm),
complete
058 Hose with unions (3000mm),
complete
154 Distributor block with shut-off valve
166 Angle union
201 Quick coupling, male
213 Quick coupling, female
225 Disc, round-plain, Cu o11x3mm
237 Bleeder screw
249 Disc, round-plain, Fe o11x9mm
Lifting Tools, Etc. Plate
MAN B&W P91356-0059
Plate Lifting Tools, Etc.
P91356-0059 MAN B&W

No.
020 Forged-bent screw shackle, 10mm
114 Lifting eye bolts, 10mm
210 Chain tackle, 500kg
295 Pull lift, 3000kg
305 Wire rope, 6m
Open Ended Spanners Plate
MAN B&W P91357-0003
Plate
Open Ended Spanners
P91357-0003 MAN B&W

No. No.
013 Open-ended spanner, size 65mm
Open-Ended Slugging Spanners Plate
MAN B&W P91358-0012
Plate Open-Ended Slugging Spanners
P91358-0012 MAN B&W

No.
103 Open-ended slugging spanner, size
55mm
Torque Wrenches Plate
MAN B&W P91359-0002
Item Torque(Nm)
014 10 - 50
038 40 - 200
Item Torque(Nm)
040 100 - 750
Plate Torque Wrenches
P91359-0002 MAN B&W

No.
014 Torque wrench, 10 - 50Nm
026 Adapter for socket wrench, 10 x 12.5
mm
Pliers Plate
MAN B&W P91360-0002
Plate Pliers
P91360-0002 MAN B&W

No.
010 Pliers for retaining ring, size 0.9mm
Combination Spanners Plate
MAN B&W P91361-0052
Plate
Combination Spanners
P91361-0052 MAN B&W

No. No.
&RPELQDWLRQVSDQQHUVVL]HPP
Ring Slugging Spanners Plate
MAN B&W P91362-0064
Plate
Ring Slugging Spanners
P91362-0064 MAN B&W

No. No.
6OXJJLQJVSDQQHUVULQJVLHPP
Spanners
Plate
Plate Spanners

No. No.
016 Tool set, complete, size 10-22 mm

028 Tool set, complete, size 24-46 mm
030 Hex key tool set, complete
041 Adapter for socket wrench, 20->12.5 mm
Open-ended Spanners Plate
MAN B&W P91364-0059
Plate
Open-ended Spanners
P91364-0059 MAN B&W

No. No.
011 Open ring wrench, 14-17mm

023 Open ring wrench, 19-22mm
Instruments Plate
P91366-0066
MAN B&W Diesel A/S
Plate Instruments
P91366-0066

No. No.
012 Indicator, complete

024 Indicator paper
036 Plainmeter, complete
048 Autolog, measuring tool for crankshaft
050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool*)
*) To be suppied by exh. v/v grinding
machine maker
MAN B&W Diesel A/S
Working Platforms Plate
MAN B&W P91368-0007
Plate Working Platforms
P91368-0007 MAN B&W

No.
013 Platform board

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S42MC, Volume II

908 901 902 903

The procedures are divided into five categories:

This procedure number normally refers to one of the above condi-

The letters O or C in Based on observations (column B), in-

When using electronic maintenance planning systems, special

After the three initial adjustments have been completed, adjust-

When using electronic maintenance planning systems, special

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

901 Cylinder Cover

902 Piston with Rod and Stufﬁng box

904 Crosshead with connecting rod

905 Crankshaft and Thrust Bearing

7 Tacho pickup C,O M

906 Mechanical Control Gear

907 Starting Air System

908 Exhaust Valve

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

909 Fuel Oil System

910 Turbocharger System Check p and t

Protective grid before turbocharger C R V * Only if separate oil system

911 Safety Equipment

912 Assembly of Large Parts

913 General Tools

The sketch gives the approximate location of the valves concerned:

Safety Equipment - Recommendations 1.

In order to perform maintenance in a safe and

2. We strongly recommend the use of fall

3. This is especially needed when mount-

SAFETY PRECAUTIONS For detailed sketch, see 900-2

Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 200 Nm

Plate Item No. Description

P90151 046 Grinding tool for exhaust valve seat

P90161 Cylinder Cover - Tools

P91351 010 Hydraulic pump, pneumatically operated

Shut off Oil and Water Supply

Check that the engine is stopped and

2. Shut off the oil supply.

Close the fuel oil supply for the unit con-

3. Shut off the water supply.

Shut off the water supply placed on the ex-

Open the drain next to the inlet valve.

Open the venting cock next to the outlet

Dismantling of Pipe Connections

Remove the hydraulic high pressure pipe

Unscrew the drain pipe for the exhaust

Remove the fuel oil high pressure pipes.

Disconnect the pipes for return fuel oil from

5. Disconnect the water pipes.

5. Unscrew and remove the water outlet

6. Exhaust gas compensator.

Remove the protective jacket enclosing the

Remove the screws from the ﬂanges be-

7. Disconnect the starting air pipe.

Unscrew and remove the air pipe for the

8. Cylinder cover loosening.

Remove the protective caps from the cylin-

Loosen and remove the cylinder cover nuts,

For use of hydraulic tools, see Procedure

Cylinder Cover Lifting and Landing

Check that all cylinder cover connections

Lift away the cylinder cover complete.

10. Cylinder cover landing.