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Warning

S900-1

0001 S900-1

Warning! It is important that all MAN B&W Diesel A/S engines are operated within the given specifications and performance tolerances specified in the engines Technical Files and are maintained according to the MAN B&W Diesel A/S maintenance instructions in order to comply with given emissions regulations. In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, 94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote S900 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

K80MC-C

VOLUME II MAINTENANCE

900 - Introduction
Documents in this Chapter
Table of Contents, Volume II 90050 90060 0289 0002 Checking & Maintenance Schedule General - Safety Precautions

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Table of Contents
Volume II - Maintenance No. Edition Title

900

900 - Introduction Table of Contents 90050 0289 Checking & Maintenance Schedule 90060 0002 General - Safety Precautions 901 - Cylinder Cover 101-01 0077 Cylinder Cover, Data 901-01 0260 Cylinder Cover 90151 0208 Cylinder Cover - Panel 90164 0001 Cylinder Cover - Hydraulic Jack Spares 90165 0001 Cylinder Cover - Lifting Tools 902 - Piston with Rod & Stuffing Box 102-01 0090 Piston, Data 902-01 0290 Piston 102-02 0064 Piston Rod Stuffing Box, Data 902-02 0231 Piston Rod Stuffing Box 90251 0258 Piston and Piston Rod - Panel 90261 0102 Piston and Piston Rod - Tools 90264 0006 Piston and Piston Rod - Tilting Tools 90265 0001 Piston and Piston Rod - Support Tools 90266 0001 Piston - Lifting Tools 903 - Cylinder Liner and Cylinder Lubrication 103-01 0075 Cylinder Liner, Data 903-01 0259 Cylinder Liner 103-02 0028 Cylinder Lubricator, Data 903-02 0256 Cylinder Lubricator 90361 0083 Cylinder Liner - Tools 90362 0005 Cylinder Liner - Milling Tools 90364 0004 Test Equipment for Lubricators 90366 0003 Cylinder Liner - Lifting Tools 904 - Crosshead with Connecting Rod 104-01 0069 Crosshead Bearing, Data 904-01 0253 Crosshead Bearing 104-02 0070 Crosshead, Data 904-02 0252 Crosshead 104-03 0044 Reciprocating Parts, Data 904-03 0215 Reciprocating Parts 104-04 0062 Crankpin Bearing, Data 904-04 0233 Crankpin Bearing 104-05 0060 Connecting Rod, Data 904-05 0237 Connection Rod 90451 0155 Connecting Rod and Crosshead - Panel
MAN B&W Diesel A/S Page 1 (4)

Table of Contents
Volume II - Maintenance No. 90462 Edition 0018 Title Connecting Rod - Tools

900

905 - Crankshaft, Thrust Bearing and Turning Gear 105-02 0086 Main Bearing, Data 905-02 0261 Main Bearing 105-03 0075 Thrust Bearing, Data 905-03 0247 Thrust Bearing 105-04 0050 Journal Bearing, Data 105-05 0061 Axial Vibration Damper, Data 905-05 0230 Axial Vibration Damper 90551 0221 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel 90562 0123 Crankshaft - Tools 90564 0020 Crankshaft - Measuring Tools 90570 0003 Thrust Shaft - Tools 90571 0001 Main Bearing Shell - Tools 90572 0001 Main Bearing - Measuring Tools 906 - Control Gear 106-01 0051 Chain, Data 906-01 0246 Chain 106-02 0067 Chain Tightener, Data 906-02 0230 Chain Tightener 106-03 0043 Camshaft, Data 906-03 0218 Camshaft 106-04 0045 Camshaft Bearings, Data 906-04 0219 Camshaft Bearings 90651 0203 Chain Drive and Camshaft - Panel 90664 0001 Crankshaft - Pin Gauge 907 - Starting Air System 107-01 0019 Starting Air Distributor, Data 907-01 0219 Starting Air Distributor 107-02 0041 Start Air Valve, Data 907-02 0217 Starting Air Valve 908 - Exhaust Valve 108-01 0037 High-Pressure Pipe, Data 908-01 0226 High-Pressure Pipe 108-02 0094 Exhaust Valve, Data 908-02 0269 Exhaust Valve 108-03 0057 Exhaust Valve Actuator, Data 908-03 0227 Exhaust Valve Actuator 108-04 0041 Exhaust Valve Roller Guide, Data 908-04 0222 Exaust Valve Roller Guide 108-05 0017 Exhaust Valve Cam, Data
MAN B&W Diesel A/S Page 2 (4)

Table of Contents
Volume II - Maintenance No. Edition 0219 0034 0228 0177 0022 0036 0015 0003 Title Exhaust Valve Cam Exhaust Valve - Special Running, Data Exhaust Valve Exhaust Valve - Panel Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools Exhaust Valve - Extra Tools Exhaust Valve - Extractor Tool

900

908-05 108-07 908-07 90851 90861 90862 90863 90864

909 - Fuel Oil System 109-01 0061 Fuel Pump Settings, Data 909-01 0241 Fuel Pump Settings 109-02 0005 VIT System, Data 909-02 0206 VIT System 109-03 0050 Fuel Pump Cam, Data 909-03 0234 Fuel Pump Cam 109-04 0061 Fuel Pump, Data 909-04 0224 Fuel Pump 109-05 0065 Fuel Pump Top Cover, Data 909-05 0234 Fuel Pump Top Cover 109-06 0052 Fuel Pump Barrel Assembly, Data 909-06 0220 Fuel Pump Barrel Assembly 109-07 0040 Fuel Pump Suction Valve, Data 909-07 0214 Fuel Pump Suction Valve 109-08 0054 Fuel Pump Puncture Valve, Data 909-08 0217 Fuel Pump Puncture Valve 109-09 0034 Fuel Pump Shock Absorber, Data 909-09 0216 Fuel System Shock Absorber 10910 0016 Lifting Gear Roller Guide, Data 90910 0218 Lifting Gear for Roller Guide 10911 0065 Fuel Valve, Data 90911 0249 Fuel Valve 10912 0048 Spindle Guide, Data 90912 0228 Spindle Guide 10913 0033 Non-Return Valve in Fuel Valve, Data 90913 0206 Non-Return Valve in Fuel Valve 10914 0080 Fuel Oil High-Pressure Pipes, Data 90914 0255 Fuel Oil High-Pressure Pipes 10915 0062 Fuel Pump Roller Guide, Data 90915 0236 Fuel Pump Roller Guide 90951 0446 Fuel Valve and Fuel Pump - Panel 90961 0069 Fuel Valve - Tools 90966 0008 Fuel Valve Nozzle - Tools 90967 0001 Fuel Puncture Valve - Tools 90968 0001 Fuel Valve - Inspection Tools
MAN B&W Diesel A/S Page 3 (4)

Table of Contents
Volume II - Maintenance No. 90974 90977 90979 90980 Edition 0001 0001 0001 0001 Title Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals

900

910 - Turbocharger System 110-01 0051 Air Cooler Element, Data 910-01 0243 Air Cooler Element 110-02 0009 Non-Return Valve after Air Cooler, Data 910-02 0210 Non Return Valve after Air Cooler 110-03 0031 Auxilary Blower, Data 910-03 0218 Auxilary Blower 110-04 0005 Butterfly Valve, Data 910-04 0205 Butterfly Valves 110-05 0010 Turbocharger Turbine, Data 910-05 0213 Turbocharger Turbine 110-06 0032 Water Mist Catcher, Data 910-06 0222 Water Mist Catcher 91063 0018 Air Cooler - Tools 91063 0019 Air Cooler - Tools 91063 0020 Air Cooler - Tools 91064 0001 Travelling Trolley 91066 0002 Air Cooler - Lifting Tools 911 - Safety Equipment 111-01 0026 Safety Valve, Data 911-01 0212 Safety Valve 111-02 0013 Relief Valve, Data 911-02 0211 Relief Valve 111-03 0001 Scavenge Air Receiver Safety Valve, Data 911-03 0001 Scavenge Air Receiver Safety Valve 912 - Assembly of Large Parts 112-02 0015 Holding Down & End Chock Bolts, Data 912-02 0208 Holding Down and End Chock Bolts 112-03 0027 Stay Bolts, Data 912-03 0213 Stay Bolts 912-05 0201 Crankcase Oil Outlet 91261 0075 Hydraulic Tools for Large Parts 91265 0002 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks) 913 - General Tools 913-01 0211 Hydraulic Tools 913-03 0007 Working Platforms 913-04 0202 Standard Tightening Torques
MAN B&W Diesel A/S Page 4 (4)

Table of Contents
Volume II - Maintenance No. Edition 0205 0205 0207 0204 0034 0051 0006 0003 0005 0052 0060 0040 0059 0066 0011 Title Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories - Hydraulic Tools Lifting Tools, etc. Open-Ended Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms

900

913-05 913-06 913-07 91311 91351 91356 91357 91359 91360 91361 91362 91363 91364 91366 91368

MAN B&W Diesel A/S

Page 5 (4)

MAN B&W Diesel

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

900-1

The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the engine and to carry out overhauls, if necessary, based on the engine condition or on time criteria. The stated Normal hours of service should only be used as a guide, as differences in the actual service conditions, the quality of the fuel oil or lubricating oil, the treatment of cooling water, etc. will decisively influence the actual service results, and thus the intervals between necessary overhauling.

Design modifications may necessitate a revision of the instructions, in which case the revised instructions and changed overhauling intervals, if any, will apply and supersede those originally issued (see e.g our Service Letters). In addition to the checking and overhauling intervals stated in this schedule, please note that the periodical survey requirements of the classification society may require additional checks and overhauls to be carried out. For further information please refer to the classification society.

The procedures are divided into three categories: Condition checking procedures marked under the heading Normal hours of service with a C, deal with the service condition of a number of engine components, and form the basis for estimating whether further overhauling is necessary. In a number of cases the condition checking procedures refer to Volume I of the instruction book, in which more detailed descriptions and working procedures can be found. are those procedures which under the heading Normal hours of service are marked with an O, and opposite which, under the heading Overhaul to be based on procedure No. (column P), a procedure number is stated. This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul. For this reason, the intervals stated are for guidance only. Time-based overhauling procedures also marked with an O under the headings Normal hours of service or Based on observations, are the procedures where an actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling intervals stated as a basis. Where a symbol O or C is indicated in Based on observations (column B), this is due to the fact that special service conditions may make checking or overhauling necessary beyond the actual standard schedules indicated.

Condition-based overhauling procedures

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

Page 1 of 6

900-1

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

MAN B&W Diesel

Page 2 of 6

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

MAN B&W Diesel


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

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines


M : See makers instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours
Regular Checks Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P Remarks

900-1
R : Parts to be replaced B : Based on observations P : Refer to

No.

Procedure

Daily Weekly Monthly

901 Cylinder Cover -1 Cylinder cover Indicator cock 902 Piston with Rod and Stuffing box -1 Piston Inspection through scavenge ports -2 Piston rod stuffing box 903 Cylinder Liner and Cylinder Lubrication -1 Cylinder liner Inspection through scavenge ports Measuring wear inside liner -2 Cylinder lubricators Accumulators nitrogen pressure 904 -1 -2 -3 -4 -5 905 -2 -3 -3 -4 -5 Crosshead with connecting rod Crosshead bearing Crosshead Reciprocating parts Crankpin bearing Connecting rod Crankshaft and Thrust Bearing Main bearing Thrust bearing Guide bearing Journal bearing Axial vibration damper

C*

O O

* Check whenever exhaust valve is removed

C,O C C*

O V O
* Check clearances without dismantling segments

O C C C C A A V,M

C C C

C C C C

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

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

C C C C

C C C C

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

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

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

Page 3 of 6

900-1
V : See Volume I Operation A : Adjustment to be carried out C : Check the condition

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines


M : See makers instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours
Regular Checks Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P

MAN B&W Diesel


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

No.

Procedure

Daily Weekly Monthly

Remarks

-7 -8

Electronic axial vibration monitor Mechanical checking Tacho pick-up Angle encoder

C C C,O C,O M M

906 Mechanical Control Gear -1 Chains -2 Chain tightener Chain wheels, spray nozzles and guide bars -3 Camshaft -4 Camshaft bearings Camshaft coupling, fitted bolts -5 Moment compensator Governor Functional check of overspeed device Functional check of speed-setting system (engine with bridge control system) 907 Starting Air System -1 Starting air distributor -2 Starting air valve 908 -1 -2 -3 -4 -5 Exhaust Valve High-pressure pipe Exhaust valve Exhaust valve actuator Actuator safety valve Exhaust valve roller guide Exhaust valve cam

C C,A C C

C C,A C C C C C O C C

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

New or overhauled chain to be checked/retightened after 500, 1500 and 4000 hours

M M M

C C,O

O O O C,A C* C* C* C* C O O
* only inspection through camshaft covers

Page 4 of 6

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

MAN B&W Diesel


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

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines


M : See makers instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours
Regular Checks Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P Remarks

900-1
R : Parts to be replaced B : Based on observations P : Refer to

No.

Procedure

Daily Weekly Monthly

-7

Exhaust valve special running

909 Fuel Oil System Fuel oil water content -1 Fuel pump settings -2 VIT system -3 Fuel pump cam -4 Fuel pump -5 Fuel pump top cover -6 Fuel pump barrel assembly -7 Fuel pump suction valve -8 Fuel pump puncture valve -9 Fuel pump shock absorber -9 Fuel system shock absorber -10 Lifting gear for roller guide -11 Fuel valve Fuel nozzle -12 Spindle guide -13 Non-return valve -14 Fuel oil high-pressure pipes -15 Fuel pump roller guide -16 Fuel pump special running 910 -1 -2 -3 -4 Turbocharger System Air cooler Non-return valve Auxiliary blower Butterfly valves

C A,C A A O O R V V

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

O O O

O O O

* Only inspection through camshaft covers

C C C

O O O O

Check p and t Check at every port inspection

Check at every port inspection

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

Page 5 of 6

900-1
V : See Volume I Operation A : Adjustment to be carried out C : Check the condition

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines


M : See makers instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours
Regular Checks Service interval (x1000 hours of operation) 2 4 6 8 12 16 24 32 B P

MAN B&W Diesel


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

No.

Procedure

Daily Weekly Monthly

Remarks * Dry cleaning daily

-5

-6 911 -1 -2 -3

Turbocharger turbine Turbocharger air filter Protective grid before turbocharger Turbocharger lubricating oil water content Water mist catcher Safety Equipment Overpressure indicator valve Relief valve Scavenge air receiver safety valve Functional test of alarm system for thrust bearing and slow down /shut down system Checking and adjustment of pressure gauge Checking and adjustment of thermometers Checking and adjustment of thermostats Checking and adjustment of pressurestats Checking and adjustment of turning gear switch

C* C C* C*

C C

C,O O R C,O

V,M V M

* Only if separate oil system * Check p

C C C C C C C C C C

O O O M M M M M M

A A A A A

912 Assembly of Large Parts -2 Holding-down and end chock bolts -3 Stay bolts Top bracings Diaphragm in crankcase oil outlet System lubricating oil water content System lubricating oil bottom tank Cooling water quality Crankcase 913 General Tools -1 Hydraulic tools Page 6 of 6

C C C C

C* C

C C C O R M A C* V,M

* Initial check only

Empty and clean tank

* Check for loose nuts and bearing material fragments

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

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 X X X X X X X X X X X

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

The sketch gives the approximate location of the valves concerned:

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

Page 1 (1)

901 - Cylinder Cover


Documents in this Chapter
101-01 901-01 90151 90164 90165 0077 0260 0208 0001 0001 Cylinder Cover, Data Cylinder Cover Cylinder Cover - Panel Cylinder Cover - Hydraulic Jack Spares Cylinder Cover - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover
MAN B&W Diesel Data

101-1

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D01-01 D01-02 D01-03 D01-05 D01-06 D01-07 D01-08 D01-09 D01-10 D13-01 D13-02 Description Exhaust valve stud, screwing-in torque Starting valve stud, screwing-in torque Fuel valve stud, screwing-in torque Cylinder cover stud, check distance Cylinder cover, complete Cylinder cover without valves Cooling jacket Exhaust valve stud Cylinder cover stud Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 550 240 140 196 - 197 6300 4600 120 120 110 900 800 - 990 Unit Nm Nm Nm mm kg kg kg kg kg bar bar

When referring to this page, please quote Data D10101 Edition 0077

Page 1 (2)

101-1

Cylinder Cover
Data MAN B&W Diesel

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

Plate P90151 P90151 P90151 P90151 P90151 P90161 P90165 P91351 P91351

Item No. 46 58 60 83 105

Description Grinding tool for exhaust valve seat Milling and grinding wheel for fuel valve seat Milling and grinding wheel for starting valve seat Grinding handle Grinding handle for starting valve Cylinder Cover - Tools Cylinder Cover - Lifting Tools

10 58

Hydraulic pump, pneumatically operated Hose with unions (3000 mm), complete

Page 2 (2)

When referring to this page, please quote Data D10101 Edition 0077

Cylinder Cover
MAN B&W Diesel
Shut off Oil and Water Supply 1. Check engine blocking. Check that the engine is stopped and blocked according to the safety precautions given on the data sheet. 2. Shut off the oil supply. Close the fuel oil supply for the unit concerned.
M90101 0260D01

901-1.2

Dismantling

2.

3. Shut off the water supply. Close the water outlet above the exhaust valve. Close the water outlet on the exhaust side of the cylinder cover. Shut off the water supply placed on the exhaust side below the exhaust gas receiver. Open the drain next to the inlet valve. Open the venting cock next to the outlet valve.

3.

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260D02

Page 1 (14)

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 908 1.2 Unscrew the drain pipe for the exhaust valve. Remove the fuel oil high pressure pipes. See Procedure 909 14.2.
M90101 0260D04

Disconnect the pipes for return fuel oil from the fuel valves. 5. Disconnect the water pipes. Unscrew and remove the water outlet pipes. 6. Exhaust gas compensator. Remove the protective jacket enclosing the insulation for the intermediate pipe or compensator. Remove the insulation. Remove the clamp ring from the ange between the intermediate pipe and the exhaust receiver.

5.

Page 2 (14)

M90101 0260D06

M90101 0260D05

6.

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
MAN B&W Diesel
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 cylinder cover nuts.
M90101 0260D07

901-1.2

Dismantling

Loosen and remove the cylinder cover nuts, see Data. For use of hydraulic tools, see Procedure 913 1.

8.

D13 02

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260D08

Page 3 (14)

901-1.2

Cylinder Cover
Dismantling MAN B&W Diesel

Cylinder Cover Lifting and Landing 9. 9. Cylinder cover lifting.

D01 06

Hook on the engine room crane to the lifting 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. Land the cylinder cover on a couple of wooden planks.

Page 4 (14)

M90101 0260D10

M90101 0260D09

10.

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
MAN B&W Diesel
11. Remove sealing ring. 11. Remove and discard the sealing ring between the cylinder cover and cylinder liner.

901-1.2

Dismantling

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260M12

Page 5 (14)

901-1.3

Cylinder Cover
Overhaul
Overhaul Preparations

MAN B&W Diesel

1. 1. Dismantle valves and pipes. Dismantle all valves and pipes from the cylinder cover. See Procedure 907 2.2, 908 2.2 and 909 11.2. Remove all studs on top of the cylinder cover. Cooling Water Jacket
M90101 0260O01

D01 09

2. Remove the cooling water jacket. Mount four eyebolts and the lifting chains as shown in the sketch. Remove the four screws which secure the cooling jacket to the cylinder cover. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks.

2.

D01 07

Remove and discard the O rings from the cover, and carefully clean the cooling jacket and the cylinder cover. 3. Mount the cooling water jacket.

M90101 0260O02

D01 08

Provide the cylinder cover with new O rings, well lubricated with vaseline. Lift the cylinder cover and guide the jacket/ cover into position, using the guide pin as a reference (manoeuvre side). Fit and tighten the screws for the cooling jacket.

3.

Silicone

Page 6 (14)

M90101 0260O03

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
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 seating face cutter and a grinding mandrel.
M90101 0246O04

901-1.3

Overhaul

Clean the fuel valve bores using the carbon 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. Carborundum No. 200). After the milling/grinding, clean the bore and seating carefully, and check that the seating is not damaged.

5.

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260O05

Page 7 (14)

901-1.3

Cylinder Cover
Overhaul
6. Exhaust valve bore.

MAN B&W Diesel

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 seating carefully, and check that the seating is not damaged.
M90101 0240O07

7.

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

7.

Page 8 (14)

M90101 0243O07

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
MAN B&W Diesel
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 t the valve studs.
M90101 0260O08

901-1.3

Overhaul

Tighten up the studs in accordance with the screwing in torque stated on the data sheet. Fill up the grooves between the valve studs and the bores for the valve studs with permatex to prevent water or oil from entering the bores during operation of the engine. 10. Mounting of valves. Install the valves on the cylinder cover, see Procedures 907 2.4, 908 2.4 and 909 11.4.

9.

D01 01

D01 03 D01 02

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260O09

Page 9 (14)

901-1.4

Cylinder Cover
Mounting
Landing Preparation

MAN B&W Diesel

1. 1. Sealing ring. Check that the liner sealing surface is clean. Place a new sealing ring on top of the cylinder liner. 2. Water connections. Check that the water connections are clean and provided with new O rings. Lubricate the O rings with Vaseline and t them on the cylinder liner.

Page 10 (14)

M90101 0260M02

M90101 0260M01

2.

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
MAN B&W Diesel
Cylinder Cover Mounting 3. 3. Cylinder cover landing.

901-1.4

Mounting

D01 06
Carefully wipe the cylinder cover contact surface facing the cylinder liner, while the cover is resting on the support. 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 engage correctly with the holes in the cooling jacket. 4. Cylinder cover stud check distance.

If the cylinder cover studs have been removed and reinstalled, check the distance the stud is protruding from the cylinder cover. If necessary, adjust to the distance D01 05 by turning the stud.
M90101 0260M03

4.

D01 05

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0254M04

Page 11 (14)

901-1.4

Cylinder Cover
Mounting MAN B&W Diesel

5. Cylinder cover tightening. 5. Fit and tighten the cylinder cover nuts.

D13 01

For operation of hydraulic jacks, see Procedure 913 1. Fit the protective caps on the cylinder cover studs. Fitting Pipe Connections 6. Mount the exhaust gas compensator.

M90101 0260M05

When mounting the clamp connecting the compensator and the intermediate pipe/exhaust valve it may, in some cases, become necessary to use the engine room crane. Clean the anges and the clamp ring carefully and lubricate all contact faces with Molycote. Fit the insulating jacket around the intermediate pipe.

6.

Page 12 (14)

M90101 0246M05

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover
MAN B&W Diesel
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. Mount the hydraulic high pressure pipe for the exhaust valve. See Procedure 908 1.4. Connect the drain pipe for the exhaust valve. Connect the fuel oil high pressure pipes. See Procedure 909 14.4. Connect the pipes for return fuel oil from the fuel valves.
M90101 0260M07

901-1.4

Mounting

8.

When referring to this page, please quote Procedure M90101 Edition 0260

M90101 0260M09

M90101 0260M08

9.

Page 13 (14)

901-1.4

Cylinder Cover
Mounting
Open Oil and Water Supply

MAN B&W Diesel

10. 10. Close the drain and open the water supply. Close the venting cock next to the outlet valve. Close the drain next to the inlet valve. Slowly open the water supply valve, placed below the exhaust gas receiver. Vent the unit by releasing air through the venting cock next to the outlet valve. When the venting is nished, close the venting cock. Open the two water outlet valves on the exhaust side of the cylinder cover. 11. Open the oil supply.
M90101 0260M10

Open the fuel oil supply for the unit concerned.

11.

Page 14 (14)

M90101 0260M11

When referring to this page, please quote Procedure M90101 Edition 0260

Cylinder Cover Panel

Plate P90151-0208

When referring to this page, please quote Plate P90151 Edition 0208
MAN B&W Diesel A/S

Page 1 (2)

Plate P90151-0208 Item No.


010 022 046 058 060 071 083 095 105 117 129

Cylinder Cover Panel


Item No.

Item Description
Panel for tools Name plate Grinding tool, exhaust valve seat Milling and grinding tool, fuel valve seat Milling and grinding wheel, fuel valve seat Dismantling tool, fuel valve Handle, sundry types Grinding ring, starting valve Pin spanner, starting valve Test equipment, combined safety valve Extension studs, lifting cylinder cover

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90151 Edition 0208
MAN B&W Diesel A/S

Cylinder Cover - Hydraulic Jack Spares


MAN B&W Diesel

Plate P90164-0001

When referring to this page, please quote Plate P90164 Edition 0001

Page 1 (2)

Plate P90164-0001 Item No.


011 023 035 047 059 060 072 084 096 118

Cylinder Cover - Hydraulic Jack Spares


MAN B&W Diesel Item No.

Item Description
Wooden box Tommy bar Spanner Venting screw Quick coupling male Disc O-ring with back-up ring O-ring with back-up ring Stud setter Disc

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90164 Edition 0001

Cylinder Cover - Lifting T ools Tools


MAN B&W Diesel

Plate P90165-0001

When referring to this page, please quote Plate P90165 Edition 0001

Page 1 (2)

Plate P90165-0001 Item No.


017

Cylinder Cover - Lifting T ools Tools


MAN B&W Diesel Item No.

Item Description
Lifting chains for cylinder cover

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90165 Edition 0001

902 - Piston with Rod & Stuffing Box


Documents in this Chapter
102-01 902-01 102-02 902-02 90251 90261 90264 90265 90266 0090 0290 0064 0231 0258 0102 0006 0001 0001 Piston, Data Piston Piston Rod Stuffing Box, Data Piston Rod Stuffing Box Piston and Piston Rod - Panel Piston and Piston Rod - Tools Piston and Piston Rod - Tilting Tools Piston and Piston Rod - Support Tools Piston - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

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

102-1

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

Data
Ref. D01-05 D02-01 D02-04 D02-05 D02-06 D02-08 D02-09 D02-10 D02-11 D02-13 D02-14 D02-46 D02-15 D02-16 D02-17 D02-18 D02-19 D02-20 D02-21 D02-22 D02-23 D02-24 D02-25 D02-47 D02-48 D02-49 D13-01 D13-02 Description Cylinder cover stud, check distance Test pressure Piston rod/crown stud, screwing-in torque Piston skirt, tightening torque Cooling oil pipe, tightening torque Piston ring new, radial width Piston ring worn, min. radial width Groove No.1, max. vertical height Groove Nos. 2, 3 and 4, max. vertical height Piston ring new, height of ring No. 1 Piston rings new, height of ring Nos. 2, 3 and 4 CPR ring CL groove, min. depth Minimum free ring gap ( before dismantling ) Minimum ring gap, ring No. 1 ( new ring in new liner ) Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) Vertical clearance, new parts Vertical clearance, worn parts, max. Piston complete Piston crown Piston rod Piston skirt Piston cooling pipe Lifting tool, tightening torque Piston top centre, max. permissible burn-away Piston top centre diameter Piston top outer ring area, max. permissible burn-away Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 196 - 197 7 300 380 190 25.2 21.2 18.8 14.8 17.9 13.9 1.8 44 5.6 4.0 0.48 0.97 3300 870 2000 210 55 200 9 375 6 900 800 - 990 Unit mm bar Nm Nm Nm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg Nm mm mm mm bar bar
Page 1 (2)

When referring to this page, please quote Data D10201 Edition 0090 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.
Plate P90251 P90251 P90251 P90251 P90251 P90251 P90251 P90251 P90261 P90262 P90264 P90265 P90266 P90366 P90451 P91351 P91351 P91351 P91351 120 10 34 60 117 Item No. 40 75 87 99 110 134 158 171 Lifting tool for piston rod foot Template for piston top Distance piece for stuffing box Cover for stuffing box hole Pressure test tool for piston Piston ring expander Guide screw for piston crown Dismantling screw piston skirt Guide ring for piston Hydraulic jack for piston rod Tools for tilted lift Support for piston Piston - Lifting Tools Cylinder Liner - Lifting Tools Rubber cover for crosshead Hydraulic pump, pneumatically operated Hose with unions (1000 mm), complete Hose with unions (5000 mm), complete 5-way distributor block, complete Description

Page 2 (2)

When referring to this page, please quote Data D10201 Edition 0090 MAN B&W Diesel A/S

Piston
MAN B&W Diesel
Scavenge Port Inspection To detect possible leakages from the piston or cylinder cover, keep the cooling water and cooling oil circulating during the scavenge port inspection. 1. The scavenge port inspection is carried out from the scavenge air receiver. An additional view of the rings is possible through the cleaning cover on the manoeuvring side. Turn the engine at least a revolution, and begin with a unit arriving downwards, just above the scavenge air ports. Inspect the piston rod and the lower part of the cylinder wall. While the piston is passing downwards, inspect the piston skirt, all the piston rings, the ring lands and the piston top. 2. Ring inspection: Inspect the rings, one at a time, and note down the results. See Volume I, Operation, Chapter 707. 3. Ring tension: Check the tension of the piston rings, by pressing against them with a wooden stick.
M90201 0280C02

902-1.1

Checking

1.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280C03

M90201 0280C01

2.

3.

Page 1 (23)

902-1.1

Piston
Checking MAN B&W Diesel

4.

D02 18

4. Ring grooves: Measure the total clearance between the piston ring and the ring groove. The total clearance must not exceed the value stated in Data.
E

D02 19

Measure the clearance at the top (E) and bottom (F) of the piston ring groove. Total clearance = E + F. 5. Uppermost piston ring: If possible, measure the depth of the pressure relief grooves with a calliper. The piston rings must be replaced if the radial depth of the grooves has worn down to less than stated in Data D02 46. Checking, in connection with piston overhaul

M90201 0280C04

Max. 2mm

5.

D02 46

Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine. 6. Piston support: Remove the piston from the cylinder and place it on the piston support. See Procedure 902 1.2. For evaluation of the rings, see Volume I, Chapter 707.

Page 2 (23)

M90201 0280C06

M90201 0280C05

6.

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
7.

902-1.1

Checking

Free ring gap: Before dismantling the piston rings, measure the free ring gap of all the piston rings. For dismantling the piston rings, see Procedure 902 1.3.

7.

D02 15

8. Radial ring width: Measure the radial width of the rings. Note down the results See Volume I, Operation, Chapter 707.
M90201 0280C07

9. Ring grooves: Clean the ring grooves and check them for burn marks or other deformation. Measure the ring grooves with a calliper gauge, see Data D02 10 and D02 11. Clearance in piston ring grooves: The maximum vertical height in a worn ring groove must not exceed the value stated in Data. The groove is also worn out if there is no chromium layer. If the ring grooves are worn out, the piston crown must be reconditioned, contact MAN B&W Diesel A/S for advice.

8.

D02 08

New

M90201 0280C08

D02 09

Worn

9.

D02-10 D02-11

Max 2mm

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280C09

Page 3 (23)

902-1.1

Piston
Checking MAN B&W Diesel

10.

10. Piston top template: Check that the piston top template is permanently marked with the piston top centre diameter D02 48. Check that the centre area C has been marked off, and write the maximum permissible burn away rate on the template. See data D02 47. Mark the outer part of the template R for ring area, and write the maximum permissible burn away rate for the ring shaped area. See data D02 49. 11. Piston crown top: Clean the piston crown and check the burn away by means of the template.

C R

D02 48
M90201 0280C10

11.

D02 47 D02 49

For maximum permissible burn away on the piston top centre area, see Data D02 47. For the ring shaped area, see Data D02 49. Check the burn away on the whole circumference of the piston crown top. If the burn away exceeds the values given in Data, contact MAN B&W for advice. Note down the results for later reference.

Page 4 (23)

M90201 0280C11

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
Preparations in the crankcase 1. Access: Open the crankcase door to the cylinder concerned. Turn the crosshead down far enough to give access to the piston rod stufng box and the piston rod/crosshead connection.

902-1.2

Dismantling
1.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 280D01

Page 5 (23)

902-1.2

Piston
Dismantling MAN B&W Diesel

2.

2. Telescopic pipe: Loosen and remove the screws which tighten the telescopic pipe to the bend. Remove one screw from the telescopic stufng box housing and mount the special tool for suspending the telescopic pipe or use the thread in the telescopic pipe stufng box housing. Turn the crosshead to TDC. Suspend the telescopic pipe by means of the tool. Turn the crosshead downward and remove the distance pipe from the bend. Note! When a piston is dismantled, never turn the engine without rst dismantling the telescopic pipe from the crosshead.

Page 6 (23)

M90201 0280D02

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel Dismantling
3.

902-1.2

3. Stufng box: Release the stufng box by removing the innermost screws from the stufng box ange. On engine models where the drain pipe is connected directly to the stufng box: Disconnect the stufng box drain pipe. Note! Do NOT remove the outermost screws from the ange.

4. Loosen the piston rod crosshead connection: Loosen and remove the hydraulic nuts, see Data. See Procedure 913 1.

M90201 0280D03

4.

D13 02

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280D04

Page 7 (23)

902-1.2

Piston
Dismantling MAN B&W Diesel

5.

5. Stufng box distance pieces: Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stufng box. Preparations on the cylinder top 6. Cylinder cover: Remove the cylinder cover. See Procedure 901 1.2. Make a scratch mark in liner and piston cleaning ring to ensure correct re mounting. Remove the piston cleaning ring. Carefully remove any wear ridges at the top of the cylinder liner. See Procedure 903 1.3.

Page 8 (23)

M90201 0280D06

M90201 0280D05

6.

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
7.

902-1.2

Dismantling
7.

Piston lifting tool: Turn the piston to TDC. The top of the piston is now free of the cylinder liner. Clean the lifting groove of the piston crown and mount the lifting tool. Note! Make sure to mount the lifting tool correctly, so that the claws of the lifting tool enter the lifting grooves of the piston crown. Limited lifting high: If the engine is not equipped with long distance pieces, remove one or two cylinder cover studs, using a stud setter.

D02 25

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280D07

Page 9 (23)

902-1.2

Piston
Dismantling MAN B&W Diesel

8.

Piston lift 8. Lift the piston out of the cylinder liner and guide the piston rod foot through the stuffing box ange. If the engine is equipped with long distance pieces for the stufng box, the piston rod foot can pass between two cylinder cover studs. Place the two halves of the support around one of the openings in the platform. Lower the piston rod foot and stufng box through the opening in the platform. Secure the two support halves with screws and lower the piston on the support. Check the piston is resting on the piston rod ange.

D02 20

Page 10 (23)

M90201 0280D08

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel Dismantling
9.

902-1.2

9. Protect the crosshead bearing: Place a cover over the opening for the piston rod stufng box at the bottom of the cylinder unit. Turn the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap. The protective rubber cover is found on tool panel 904. The covers must remain in place to protect the crosshead bearing journal from impurities until the piston is remounted. Clean, measure and recondition the cylinder liner. See Procedure 903 1.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280D09

Page 11 (23)

902-1.3

Piston
Overhaul MAN B&W Diesel
Piston support: Place the piston in the support and remove the piston lifting tool. See Procedure 902 1.2. Clean the piston top and the piston rings. Check the free ring gap and the burn off on the piston top. See Procedure 902 1.1. Remove the stufng box. See Procedure 902 2.3. 2. Piston ring dismantling: Take off the piston rings by means of the ring expanders. If the engine is equipped with two ring expanders, the short ring expander is for the uppermost ring. First remove the uppermost ring, then ring No. two, three and four. Clean and inspect the rings and the ring grooves. See Procedure 902 1.1. 3. Piston crown dismantling: Loosen and remove the hydraulic nuts between the rod and the piston crown. See Data. For operation of hydraulic tools, see Procedure 913 1. Lift the piston crown and skirt clear of the piston rod.

1.

1.

D02 20

M90201 0280O02

M90201 0280O01

2.

3.

D02 21 + D02 23

M90201 0280O03

D13 02
When referring to this page, please quote Procedure M90201 Edition 0290

Page 12 (23)

Piston
MAN B&W Diesel
4. Piston rod and cooling pipe: Remove the screws from the cooling oil pipe ange. Mount the eye bolts and lift out the cooling oil pipe. Clean and inspect the cooling oil pipe and the piston rod, then remount the cooling oil pipe, see Data. Check that the surfaces of the O ring groove is clean and smooth. Mount a new O ring on the piston rod ange. 5. Piston crown turning: Unhook the crane from the piston lifting tool, and connect the lifting tool and the crane hook by means of a wire rope. Lift up the piston crown. Fit two eyebolts in the piston skirt and a wire rope between the bolts as shown in the sketch. Install a tackle in a suitable place with sufcient space below for the piston crown. Attach the tackle to the wire rope on the piston skirt and carefully turn the piston crown upside down. Use both cranes if the engine room is equipped with two cranes. Land the piston lifting tool and the piston crown on a sufcient support of wood pieces. Loosen the piston lifting tool and lift the piston crown clear of the tool.
M90201 0280O04

902-1.3

Overhaul
4.

D02 24 D02 06

D02 22

5.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0290O05

Page 13 (23)

902-1.3

Piston
Overhaul MAN B&W Diesel

6.

6. Piston crown dismantling and cleaning: Place the piston crown with skirt on a wooden support as shown.

D02 23

Remove the locking wire and the screws in the skirt. If necessary, use two dismantling screws to pull the skirt off the piston crown. Mount two eye bolts in the skirt. Lift the skirt and land it on a couple of planks. Discard the sealing ring on the piston skirt. Thoroughly clean and inspect all parts of the crown and skirt. If coke deposits are found in the cooling spaces of the piston crown, the coke deposits should be washed out with Carbon Remover or a similar cleaning uid. When all coke deposits have been dissolved, clean and inspect the piston crown again. Note!

M90201 0280O05

7.

D02 05

Coke deposits reduce the heat transfer from the piston crown to the cooling oil. The deposits must be removed as a routine procedure when a piston is overhauled. If the piston crown is renewed, remove the piston crown studs using a stud setter. 7. Piston crown assembly: Mount the piston crown studs in a new or overhauled piston crown, lubricate the threads on the studs with molybdenum disulphide (MoS2). Tighten the studs to the specied torque using a stud setter, see Data D02 04. Mount a new O ring on the piston skirt, check that the surfaces of the O ring groove is clean and smooth, coat the ring with lubricating oil before mounting. Mount the piston skirt on the piston crown. Tighten the screws to the specied torque, see Data D02 05. Lock the screws with locking wire. See Procedure 913 7.

Page 14 (23)

M90201 0280O06

D02 04

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
8. Piston crown and skirt mounting: Lubricate the O ring on the piston rod ange with lubricating oil. Land the overhauled piston crown and skirt on the piston rod. Mount and tighten the hydraulic nuts on the piston crown studs. When tightening the hydraulic nuts follow the tightening sequence. All the nuts must be tightened twice to full tightening pressure, see Data. Sealing ring and pressure test According to current class rules, the piston must be pressure tested hydraulically. It is possible to carry out a test of the sealing rings with compressed air before lling the piston with oil. The sealing ring test can also be carried out when the piston is resting in the support tool. 9. Sealing ring test: Mount the pressure testing tool on the piston rod foot. Connect compressed air to the testing tool and ll the piston to 4 5 bar. Close the valve on the testing tool and remove the air connection. The piston must now hold the pressure for minimum 30 minutes. Spray a little soap water on to the surface joints between piston rod/crown/skirt and around the hydraulic nuts to detect leaks. Dry off all soap water.
M90201 0277O16

902-1.3

Overhaul

8.
6 5 4 6 5 4 2 1 3 2 3 1 4 5 2 2 3 1 5 6 4

1 3 6

D13 01

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280O07

9.

Page 15 (23)

902-1.3

Piston
Overhaul MAN B&W Diesel

10.

D02 01

10. Pressure test: For this test, the piston must be turned upside down (see next step to turn a complete piston). Fill the piston and piston rod with lubricating oil. Mount the pressure testing tool on the piston rod foot. Pressure test the piston at the pressure stated on the Data Sheet. Check the contact surfaces of the piston and the sealing rings for tightness. Check that there are no cracks in the piston crown. Turn the piston upside up and drain out the piston oil.

oil

Page 16 (23)

M90201 0277O17

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel Overhaul
11.

902-1.3

11. Piston turning: Lift the piston with the normal lifting tool. Lower the piston rod foot until it is close to the platform. Land the foot on a wooden block. Lower the piston crown to the platform and land it on a wooden block in such a way that it is possible to remove the lifting tool. Mount an eyebolt in the side of the lifting tool, hook on the crane and remove the lifting tool from the piston crown. Attach the lifting bracket to the bottom of the piston rod foot. Hook the crane on to the lifting bracket. Lift the piston rod foot clear of the wooden block. Keep lifting until the piston rod is in a vertical position. Note! During the lift, follow with the crane to keep the crane positioned vertically above the lifting point. The stufng box must be removed.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280O10

Page 17 (23)

902-1.3

Piston
Overhaul MAN B&W Diesel

12.
A

12. Piston completion: Fit the new piston rings (alternately right hand and left hand cuts, with the ring gaps staggered 180 and with the TOP mark upwards), using the ring expander.
TOP

B A B D C C

When mounting the piston rings, use the ring expanders to prevent unintended deformation of the rings. Do not expand the rings more than necessary. The uppermost ring (CPR ring) must be mounted with the short ring expander. Mount the piston rod stufng box. See Procedure 902 2.3.

Page 18 (23)

M90201 0280O11

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
Preparation of piston 1. Check the piston rings and piston crown in accordance with Procedure 902 1.1, if not already done. Mount the lifting tool on the piston crown. See Data D02 25. 2. Stufng box position: Ensure that the stufng box is correctly positioned over the distance pieces mounted on the piston rod foot. Both the holes for the ange and the drain hole for the drain pipe must be positioned correctly.

902-1.4

Mounting
1.

D02 25

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0277M02

M90201 0280M01

2.

Page 19 (23)

902-1.4

Piston
Mounting MAN B&W Diesel

3.

Preparation of cylinder liner 3. Mount the guide ring: Mount the guide ring in the top of the cylinder liner. The cut outs for the lifting tool must be turned to fore aft position. 4. Stufng box cover: Remove the cover from the piston rod stufng box opening in the bottom of the cylinder unit. Clean the stufng box ange.

M90201 0280M03

5. Crosshead position: Turn the crosshead to a position 45 from TDC (crank web pointing towards exhaust side).

4.

M90201 0277M06

M90201 0277M05

5.

45

Page 20 (23)

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel
Mounting of piston 6. 6. Coat the O rings of the stufng box and the piston rod with oil. Coat the piston rings and cylinder liner with cylinder lubricating oil. Lower the piston into the cylinder liner while guiding the piston rod foot through the cut out in the stufng box ange until the piston rings are inside the liner. 7. Protective cover: Remove the protective rubber cover from the crosshead.

902-1.4

Mounting

D02 20

8. Crosshead alignment: Turn the crosshead almost to TDC. If necessary, mount the hydraulic nuts on the studs and screw down until the nuts are ush with the top of the studs. Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby turning the crosshead until the face is parallel to the piston rod foot. Lower the crosshead just enough to enable removal of the nuts. Turn the crosshead upwards until the piston rod lands on the crosshead. When mounting the piston on the crosshead, make sure that the piston rod foot does not damage the threads of the studs. Ensure that the guide ring in the crosshead ts correctly in the centre hole of the piston rod. Unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings.

When referring to this page, please quote Procedure M90201 Edition 0290

M90201 0280M08

M90201 0277D10

M90201 0280M06

7.

8.

Page 21 (23)

902-1.4

Piston
Mounting MAN B&W Diesel

9.

9. Stufng box: Turn down and land the stufng box on the stufng box ange. Check that the holes in the stufng box and stufng box ange are correctly centered. Tighten the piston rod stufng box by means of the screws through the inner holes in the stufng box ange. For Data, see Procedure 902 2. On engine models where the drain pipe is connected directly to the stufng box:

M90201 0280M09

Mount the stufng box drain pipe. Remove the distance pieces from the piston rod foot.

10.

D13 01

10. Tightening of the piston rod crosshead connection: Mount and tighten the piston rod nuts with the hydraulic jacks. See Data. See Procedure 913 1. 11. Telescopic pipe: Place the distance pipe on the bend for the telescopic pipe. Turn up towards TDC until the telescopic pipe is landed on the distance pipe.

M90201 0280M10

Remove the suspending tool and mount the screws and tighten the telescopic pipe to the bend. For Data, see Procedure 904 2.

11.

Page 22 (23)

M90201 0280M11

When referring to this page, please quote Procedure M90201 Edition 0290

Piston
MAN B&W Diesel Mounting

902-1.4

12. Piston cleaning ring: Mount the piston cleaning ring in accordance with the scratch mark. If the PC ring is damaged (broken or cracked), it must be replaced by another ring. See Procedure 903 1. 13. Cylinder cover studs: If the cylinder cover studs have been removed, remount them. Carefully clean the surfaces around the base of the studs and check the O rings on the studs.

12.

14. Cylinder cover: Land the cylinder cover on the liner and check the distance that the stud is protruding from the cylinder cover. If necessary, adjust the distance D01 05 by turning the stud. Tighten the cylinder cover nuts and mount the necessary pipes. See Procedure 901 1.4. 15. Running in: Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple of revolutions. At the rst opportunity, start the engine and keep it running for about 15 minutes at a speed corresponding to Dead Slow Ahead. Then stop the engine and inspect the piston rod and stufng box.

M90201 0277M15

M90201 0277M14

Mount the cylinder cover studs with the stud setter. Screw the stud down to contact and half a revolution back.

13.

14.

D01 05
M90201 0280M14

When referring to this page, please quote Procedure M90201 Edition 0290

Page 23 (23)

Piston Rod Stuffing Box


MAN B&W Diesel Data

102-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X X X X X X Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D02-26 D02-27 D02-28 D02-29 D02-30 D02-34 D02-38 D02-44 D02-45 D02-50 Description Stuffing box flange, outer screws tightening torque Stuffing box flange, inner screws tightening torque Stuffing box halves, tightening torque Uppermost rings, ring-end clearance Lowermost rings, ring-end clearance Sealing ring springs new, free length Scraper ring springs new, free length Stuffing box complete Stuffing box half Stuffing box halves fitted bolts, tightening torque Value 180 200 80 4x6 3x3 831 782 190 65 80 Unit Nm Nm Nm mm mm mm mm kg kg Nm

When referring to this page, please quote Data D10202 Edition 0064

Page 1 (2)

102-2

Piston Rod Stuffing Box


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 P90251 P90251 P90451 Item No. 109 122 120 Description Mounting tool for stuffing box spring Worktable for stuffing box Rubber cover for crosshead

Page 2 (2)

When referring to this page, please quote Data D10202 Edition 0064

Piston Rod Stuffing Box


MAN B&W Diesel Checking
1.

902-2.1

1. After the piston rod stuffing box has been dismantled, check the following clearances: See Procedure 902-2.2. Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring). Total clearance (scraper ring). (D02-29) Clearance at ring ends (sealing rings). Total clearance (sealing rings). (D02-29) Lowermost scraper rings Clearance at ring ends. Total clearance. (D02-30) The ring clearances stated in Data apply to new rings. As a general guide, it is recommended depending on the overhauling intervals and ones own experience to replace sealing rings and scraper rings when the specified clearance values D02-29 and D02-30 have been halved. 2. Garter springs: Generally, it is recommended to renew the springs when the sealing rings and scraper rings are renewed. The springs can be checked as follows: Place the springs on the table, measure Lo (free length), and compare with Data. If a spring is extended more than 8% from the value given in data, it must be discarded.

D02 29 B

D02 30 A B

M90202 0230C01

D02 29

D02 30

2.

D02 34

D02 38

When referring to this page, please quote Procedure M90202 Edition 0231

M90202 0227C02

Page 1 (10)

902-2.2

Piston Rod Stuffing Box


Dismantling MAN B&W Diesel

1.

In connection with dismantling of the piston, only the innermost screws in the stuffing box flange and the screws for the drain oil pipe should be removed. If, in the period between piston overhauls, it becomes necessary to inspect the piston rod stuffing box, proceed as follows: 1. Turn the crosshead to about 90 from TDC. Mount the rubber 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 stuffing box flange, longitudinally to the engine. 3. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes.

Page 2 (10)

M90202 0230D03

M90202 0231D02

M90202 0231D01

2.

3.

When referring to this page, please quote Procedure M90202 Edition 0231

Piston Rod Stuffing Box


MAN B&W Diesel Dismantling
4.

902-2.2

4. Remove the two long dismantling screws from the worktable. Mount them in the stuffing box through the holes in the worktable. Remove the remaining two screws from the stuffing box. 5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame bottom.

By means of the four short screws in the worktable, press the stuffing box out of the flange. For overhauling the stuffing box, see Procedure 902-2.3.

When referring to this page, please quote Procedure M90202 Edition 0231

M90202 0230D05

M90202 0229D05

M90202 0230D04

6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable.

5.

6.

Page 3 (10)

902-2.3

Piston Rod Stuffing Box


Overhaul MAN B&W Diesel

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. Overhaul inside the engine is carried out in the same way as outside the engine. 1. Mount two eye bolts in the stuffing box flange, and hook on two tackles. Lift the stuffing box a little up the piston rod, and mount the worktable round the piston rod at a suitable working height. 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 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 assembling bolts.

M90202 0230O04

1.

D02 44

Page 4 (10)

M90202 0230O02

M90202 0230O01

2.

When referring to this page, please quote Procedure M90202 Edition 0231

Piston Rod Stuffing Box


MAN B&W Diesel Overhaul
3.

902-2.3

3. Take out the six bolts, and pull away one 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 clearance of the rings. See Procedure 902-2.1. 5. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. 6. Measure the clearance between the ring segments to determine whether replacement is necessary. See Procedure 902-2.1. Dismantle and stack the rings in the same 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. 7. Check the lengths of the springs. See Procedure 902-2.1. 8. Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface carefully with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to machine-grind the surface in a workshop. 9. Clean the halves of the stuffing box housing.

D02 45

M90202 0230O03

7.

D02 34

D02 38

When referring to this page, please quote Procedure M90202 Edition 0231

M90202 0230O08

M90202 0227C02

8.

Page 5 (10)

902-2.3

Piston Rod Stuffing Box


Overhaul MAN B&W Diesel

10.

A B C

10. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS2). For correct mounting of the sealing and scraper rings see the sketch. The scraper ring in groove no. 4 must be without relief grooves on the underside.

Scraper ring

A Scraper ring

B Sealing ring

C No relief groove
M90202 0230O10

Relief groove

Page 6 (10)

When referring to this page, please quote Procedure M90202 Edition 0231

Piston Rod Stuffing Box


MAN B&W Diesel Overhaul
11.

902-2.3

11. Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way: Place the lowermost scraper ring segments on the worktable. Place the spring round the segments, and hook the spring ends together. Repeat this procedure for the remaining scraper rings.

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 together in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring. Finally, assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring). 12. 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. Subsequently, push the stuffing box half into contact with the piston rod, round the ring units. Note! If the stuffing box is assembled inside the engine, place two pieces of plywood of the same thickness as the flange on the worktable, to ease the assembling.

When referring to this page, please quote Procedure M90202 Edition 0231

M90202 0230O12

M90202 0229O11

On top of the scraper rings, assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring).

12.

Page 7 (10)

902-2.3

Piston Rod Stuffing Box


Overhaul MAN B&W Diesel

13.

13. Check the ring clearance again. Then place the other half of the stuffing box housing on the worktable, pushing it into place round the rings.

D02 28

In the middle holes mount and tighten up the fitted bolts to the torque specified on the Data Sheet, See Data D02-50

D02 50
M90202 0230O13

Mount the O-ring in the stuffing box groove. 14. Mount eye bolts and wire ropes, and lift the stuffing box a little. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot.

14.

D02 44

Remove wire ropes and screws. Mount and tighten the standard bolts to specified torque, See Data D02-28

Page 8 (10)

M90202 0230O14

When referring to this page, please quote Procedure M90202 Edition 0231

Piston Rod Stuffing Box


MAN B&W Diesel Mounting

902-2.4

1. In connection with mounting of the piston, only the innermost flange screws are to be mounted and tightened, see data. After overhauling the stuffing box inside the engine, assemble the stuffing box halves on top of the four screws. Mount the two long screws from the worktable in the stuffing box. Turn down the short screws so that the stuffing box lands on the flange. 2. Turn the piston upwards until the stuffing box is in place in the cylinder frame. Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. 3. Mount two screws in the flange through the holes in the worktable.

1.

When referring to this page, please quote Procedure M90202 Edition 0231

M90202 0230M03

M90202 0230M02

M90202 0230M01

2.

3.

Page 9 (10)

902-2.4

Piston Rod Stuffing Box


Mountingl MAN B&W Diesel

4.

4. Remove the long screws from the stuffing box and mount them in the worktable. Remove the worktable from the piston rod. 5. Mount the drain oil pipe. 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.

M90202 0230M04

Smear the piston rod with molybdenum disulphide. Then turn the crankshaft a couple of revolutions. If possible: Start up the engine and keep it running for about fifteen minutes at a number of revolutions corresponding to very slow or idle speed. Then stop the engine and inspect the piston rod and stuffing box.

5.

M90202 0231O05

D02 26 D02 27

6.

Page 10 (10)

M90202 0231O06

When referring to this page, please quote Procedure M90202 Edition 0231

Piston and Piston Rod Panel

Plate P90251-0258

When referring to this page, please quote Plate P90251 Edition 0258
MAN B&W Diesel A/S

Page 1 (2)

Plate P90251-0258 Item No.


014 026 040 063 075 087 099 109 110 122 134 160

Piston and Piston Rod Panel


Item No.

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

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90251 Edition 0258
MAN B&W Diesel A/S

Piston and Piston Rod - T ools Tools


MAN B&W Diesel

Plate P90261-0102

When referring to this page, please quote Plate P90261 Edition 0102

Page 1 (2)

Plate P90261-0102 Item No.


019

Piston and Piston Rod - T ools Tools


MAN B&W Diesel Item No.

Item Description
Guide ring for piston

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90261 Edition 0102

Piston and Piston Rod - Extra Tools


Piston and Piston Rod - Extra Tools 0006 P90264

Plate P90264-0006

When referring to this page, please quote Plate P90264 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Plate P90264-0006 Item No.


015 027 039

Piston and Piston Rod - Extra Tools


Item No.

Item Description
Collar ring for piston Support for tilting tool Support for tilting tool

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90264 Edition 0006
MAN B&W Diesel A/S

Piston and Piston Rod - Support Tools

Plate P90265-0001

When referring to this page, please quote Plate P90265 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90265-0001 Item No.


010

Piston and Piston Rod - Support Tools


Item No.

Item Description
Support iron for piston

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90265 Edition 0001
MAN B&W Diesel A/S

Piston - Lifting Tools


Piston - Lifting Tools 0001 P90266

Plate P90266-0001

When referring to this page, please quote Plate P90266 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90266-0001 Item No.


016

Piston - Lifting Tools


Item No.

Item Description
Lifting tool for piston

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90266 Edition 0001
MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


Documents in this Chapter
103-01 903-01 103-02 903-02 90361 90362 90364 90366 0075 0259 0028 0256 0083 0005 0004 0003 Cylinder Liner, Data Cylinder Liner Cylinder Lubricator, Data Cylinder Lubricator Cylinder Liner - Tools Cylinder Liner - Milling Tools Test Equipment for Lubricators Cylinder Liner - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Liner
MAN B&W Diesel Data

103-1

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X X X X X X Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D03-02 D03-03 D03-04 D03-16 D03-17 D03-05 D03-06 D03-18 Description Lifting tool bolts, screwing-in torque Cylinder diameter, new Piston cleaning ring diameter, new Piston cleaning ring radial width, new PC-ring/Liner max. wear deviation Cylinder liner, complete Cooling jacket PC-rings replacement criteria: Value 200 800 798.3 15.8 0.8 4700 130 Unit Nm mm mm mm mm kg kg

Liner diameter: 800 mm Liner wear: 0 0.80 mm 1.6 mm 1.6 mm Install: Standard PC-ring (new or max. diameter wear of 0.80 mm Oversize PC-ring No PC-ring

0.80 >

When referring to this page, please quote Data D10301 Edition 0075

Page 1 (2)

103-1

Cylinder Liner
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 P90251 P90361 P90366 Item No. 051 Lifting tool for cylinder liner Measuring tool for cylinder liner Cylinder Liner - Lifting Tools Description

Page 2 (2)

When referring to this page, please quote Data D10301 Edition 0075

Cylinder Liner
MAN B&W Diesel
1. Dismount the cylinder cover, the piston cleaning ring and the piston. See Procedures 901-1.2 and 902-1.2. Clean the cylinder liner and scavenge air ports. 2. Position the cylinder liner measuring tool. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. Take measurements in the fore-and-aft and athwartship directions. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707. 3. Carefully scratch over any scores or marks and grind away the wear ridges. See Procedure 903-1.3. 4. Check the lubricating points of the cylinder by pumping cylinder oil to each lubricating point with the cylinder lubricator. Clean any blocked lubricating duct. Mount the piston and cylinder cover. See Procedures 902-1.4 and 901-1.4.

903-1.1

Checking
1.

D03 03

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259C04

M90301 0259C02

2.

Page 1 (11)

903-1.1

Cylinder Liner
Checking MAN B&W Diesel

5.

5. Piston cleaning (PC) ring: The PC-ring is to be regarded as an integrated part of the liner and it is intended to follow the service life of the liner. During inspection of the piston and the liner, the PC-ring must also be inspected. 6. Measure the PC-ring radial width B, and find the most worn place. Compare with Data D03-16 and calculate the wear of the PC-ring, multiply the wear by 2 to get the PC-ring diameter wear. Measure the liner in the fore-aft and athwart-ship directions at piston skirt TDC position, corresponding to measuring point No. 5 on the liner-measuring tool. Compare the measurements with the diameter of a new liner as stated in Data. Calculate the wear of the liner. 7. Compare the PC-ring diameter wear with the wear of the liner. If wear of the two components does not deviate more than D03-17 then reinstall the PC-ring. If deviation between PC-ring wear and liner wear is more than D03-17 or if the PC-ring is broken or cracked, replace the ring with a new PC-ring, an oversize ring or no ring according to Table D03-18 on the Data sheet. If it is necessary to install an oversize PCring, contact MAN B&W Diesel for advice. When a new liner is installed, also a new PC-ring must be installed. When a new liner is ordered, also a new PC-ring must be ordered.

Page 2 (11)

M90301 0259C06

When referring to this page, please quote Procedure M90301 Edition 0259

Cylinder Liner
MAN B&W Diesel
1. Dismount the cylinder cover. See Procedure 901-1.2. Discard the sealing ring from the top of the cylinder liner. Turn the piston down far enough to make it possible to remove the wear ridges at the top of the liner. See Procedure 903-1.3. Dismount the piston cleaning ring and the piston. See Procedure 902-1.2. 2. Screw the two lifting tools on to the cylinder liner. Check with a feeler gauge that there is no clearance between lifting tool and cylinder liner. For tightening torque, see Data. 3. Disconnect the oil pipes leading from the cylinder lubricator to the cylinder liner.

903-1.2

Dismantling
1.

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259D03

M90301 0259D02

3.

Page 3 (11)

903-1.2

Cylinder Liner
Dismantling MAN B&W Diesel

4.

4. Dismount the four cooling water pipes between the cooling jacket and cylinder cover and discard the O-rings from the pipes and clean them carefully. Attach the crane to the lifting crossbar.

D03 05

Hook the lifting tools on to the crossbar on both sides of the cylinder liner. Lift the liner with the cooling jacket out of the cylinder frame. Note! Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner. Land the cylinder liner vertically on, for instance, a couple of planks. Remove the cooling water pipes and discard the O-rings. 5. Clean the cylinder frame internally, taking special care with the contact surfaces for the cylinder liner at the top of the cylinder frame. 6. The lifting tools are also used for transporting the cylinder liner.

Page 4 (11)

M90301 0259D06

M90301 0259D04

6.

When referring to this page, please quote Procedure M90301 Edition 0259

Cylinder Liner
MAN B&W Diesel
1. Unscrew the non-return valves from the cylinder liner. Clean and inspect the non-return valves. 2. Attach two tackles to the crossbar, as shown. Mount two lifting eye bolts in the cooling jacket. Hook the tackles on to the lifting eye bolts on the cooling jacket and haul tight. Loosen the screws on the clamps which fix the cooling jacket to the cylinder liner. Turn the clamps away from the liner.
M90301 0259O01

903-1.3

Overhaul
1.

2.

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259O02

D03 06

Page 5 (11)

903-1.3

Cylinder Liner
Overhaul MAN B&W Diesel

3.

3. Lower the cooling jacket by means of the tackles and the crane, and land it on the wooden planks. Check that the cooling jacket does not tilt when it is lowered. 4. Mount the lifting tools in the cylinder liner. Lift the cylinder liner away from the cooling jacket. Clean the cooling jacket internally.

Page 6 (11)

M90301 0259O04

M90301 0259O03

4.

When referring to this page, please quote Procedure M90301 Edition 0259

Cylinder Liner
MAN B&W Diesel Overhaul
5.

903-1.3

5. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707. Carefully scratch over any scores or marks on the cylinder liner running surface, by means of a rough grindstone held in the hand. Check in the top of the liner for a wear ridge (where the piston rings reverse direction). If there is any sign of a wear ridge, it is necessary to create a groove by grinding.The groove serves to prevent the build-up of a new wear ridge. 6. It is recommended to use a wear ridge milling machine to create the groove. For use of the milling machine, see suppliers instruction. 7. Alternatively, place an old piston ring on the top of the piston and turn to a position that enables the grinding disc to rest on the old piston ring while removing the wear ridge. Use a grinding disc with a round edge. Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC. The maximum depth of the groove is calculated as Smax = D x 0.0045. Note! It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch.

A B

C
M90301 0259O05

6.

M90301 0259O06

7.

S D
R=4 5 mm

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259O07

Page 7 (11)

903-1.3

Cylinder Liner
Overhaul MAN B&W Diesel

8. If necessary, mount a new cylinder liner. 8. Note! If a new cylinder liner is mounted, a new piston cleaning ring must also be mounted after mounting the piston. Apply a thin layer of grease on the contact surface for the cooling jacket on the liner. Mount the lifting tools on the liner. Lift the liner a little and mount new O-rings for the cooling jacket. Then place the liner in the cooling jacket. Remove the lifting tools. 9. Lift the cooling jacket into position marking scratches jacket/cylinder liner must coincide (camshaft side).
M90301 0259O08

9.

Page 8 (11)

M90301 0259O09

When referring to this page, please quote Procedure M90301 Edition 0259

Cylinder Liner
MAN B&W Diesel Overhaul
10.

903-1.3

10. Turn the clamps until they fit in the groove of the liner, and tighten the screws. Remove the tackles and the eye bolts from the cooling jacket. 11. Mount the non-return valves for cylinder lubrication.

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259O11

M90301 0259O10

11.

Page 9 (11)

903-1.4

Cylinder Liner
Mounting MAN B&W Diesel

1.

1. Loosen the water connections on the cooling jacket. Mount the lifting tools on the cylinder liner and tighten to specified torque. See Data.

D03 02 D03 05

Hook the chains from the lifting crossbar on to the lifting tools, and lift the jacket/ liner assembly. Mount the lowermost O-rings and apply a little lubricating oil on the rings.

M90301 0259M01

2. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Coat the joint surfaces with permatex or a similar liquid sealing compound. Mount the cylinder liner in the cylinder frame. Replace the O-rings on the water connections and mount the water connections on the cooling jacket. Remove the cylinder liner lifting tools. 3. If one or more cylinder cover studs have been removed during the dismantling of the cylinder liner, discard the old O-rings and mount new ones on the cylinder cover studs. Mount the studs in the cylinder frame, using the stud setter.

2.

Page 10 (11)

M90301 0259M03

M90301 0259M02

3.

When referring to this page, please quote Procedure M90301 Edition 0259

Cylinder Liner
MAN B&W Diesel Mounting
4.

903-1.4

4. Screw the pipes from the lubricator on to the non-return valves, but do not tighten. Vent the cylinder lubricating system by manually pumping each individual pipe through until oil, without air bubbles, comes out from the union pipe/non-return valve. When this is in order, tighten the pipes firmly on the non-return valves and again pump manually until it is certain that each individual lubricating point functions correctly. 5. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston. See Procedure 902-1.4. 6. Mount the piston cleaning ring, the sealing ring and land the cylinder cover on the liner. See Procedure 901-1.4. Note! Make sure to mount the piston cleaning ring correctly, so that the scratch marks are aligned. Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned.

When referring to this page, please quote Procedure M90301 Edition 0259

M90301 0259M06

M90301 0259M04

6.

Page 11 (11)

Cylinder Lubricators
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X X X X X X X X

103-2

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

Data
Ref. Description Value Unit

D03-10 D03-11 D03-13

Inlet accumulator, nitrogen pressure, Outlet accumulator, nitrogen pressure, Plug screw, tightening torque,

30 1.5 30

bar bar Nm

When referring to this page, please quote Data D10302 Edition 0028 MAN B&W Diesel A/S

Page 1 (2)

103-2

Cylinder Lubricators
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90364 Item No. Test Equipment for Lubricators Description

Page 2 (2)

When referring to this page, please quote Data D10302 Edition 0028 MAN B&W Diesel A/S

Cylinder Lubricators
MAN B&W Diesel
Check of Oil Injection: With stopped engine and normally when the system has been disassembled: 1. Press the ESC + PRELUB.-button on the HMI control panel, and check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. 2. If the cylinder cover or the exhaust valve is removed, check inside the liner that all lubricating points are working properly. Otherwise, remove the covers for scavenge port inspection. Turn the piston to BDC and check inside the liner with a mirror and a powerful light source that all lubrication points are working properly. With running engine: 3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. The LEDs give signal when oil is injected. Check the pressure shocks from the injection of the lubricators on each lubricator pipe by feeling with a hand. If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow.

903-2.1

Checking
1.

When referring to this page, please quote Procedure M90302 Edition 0256

M90302 0245C02

M90302 0245C01

3.

Page 1 (13)

903-2.1

Cylinder Lubricators
Checking
Check of Accumulators:

MAN B&W Diesel

4.

D03 11

4. Check of Inlet Accumulator Checking the inlet accumulator can be done with running engine. Close the valve that connects the accumulator to the distributor block. Mount the special hose on the minimess coupling and drain all oil out of the accumulator.

M90302 0256C04

Check the nitrogen pressure. For use of pressure setting tool, see Step 6. For correct pressure, see Data. 5. Check of Outlet Accumulator The outlet accumulators are to be dismounted while the nitrogen pressure is checked. Dismount the outlet accumulator. See Procedure 903-2.2. Check the nitrogen pressure, using the pressure setting tool. 6. Use of Pressure Setting Tool Assemble the pressure setting tool as shown in the Figure, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor. Mount a 0-60 bar pressure gauge on the filling valve when the inlet accumulator (0.7 litre) is checked, and a 0-10 bar pressure gauge when the outlet accumulators (0.16 litre) are checked.

5.

M90302 0256C05

D03 11

6.

Page 2 (13)

M90302 0245C05

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel Checking
7.

903-2.1

7. Before mounting the filling valve on the accumulator, check that the accumulator top is clean. Mount the filling valve on the relevant accumulator with the union nut. Check that valves C and F are closed. Loosen the plug screw in the accumulator using a square drive handle in socket E. It is now possible to read the actual nitrogen pressure in the accumulator on the dial gauge on the filling valve. 8. If the accumulator needs to be refilled with nitrogen, open valve A and increase the outlet pressure from valve C on spindle B to 1-2 bar above the pressure stated in Data. Open valve C until the accumulator is filled to the correct pressure. Close valve C and tighten the plug screw with socket E to the torque stated in Data. Release the pressure in the filling valve at bleed screw F. Unscrew the filling valve from the accumulator. Retighten the plug screw to the torque stated in Data. Remount the accumulator.

C E
D03 13

B
M90302 0247C07

When referring to this page, please quote Procedure M90302 Edition 0256

Page 3 (13)

903-2.2

Cylinder Lubricators
Dismantling
Dismantling of lubricators:

MAN B&W Diesel

1.

Both lubricators can be dismounted with running engine, one at a time. If the engine is running when a lubricator is dismounted, it is important to check that the other lubricator is doubling injection frequency. 1. Close the supply valve for the lubricator concerned, using the special tool. The lowermost valve is for lubricator marked A and the uppermost valve is for lubricator marked B.

M90302 0256D01

Let the lubricator inject oil until the feedback LED stops flashing. Disconnect the electrical plug on the topside of the lubricator. 2. Unscrew the screws in the pipe flange of the lubricator and disconnect the cover with pertaining pipes. 3. Unscrew the four screws from the top that secure the lubricator to the hydraulic block, and remove the lubricator.

2.

Page 4 (13)

M90302 0256D02

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel
Dismantling of accumulators: 4. 4. Inlet Accumulator Close the valve that connects the accumulator to the distributor block. Mount the special hose on the minimess coupling and drain the oil out of the accumulator. Unscrew the accumulator. If the engine is running, a new or checked accumulator should be mounted at once. 5. Outlet Accumulator Close the supply valve for the accumulator concerned, using the special tool. The outer valve is for accumulator marked A and the inner valve is for accumulator marked B. Let the lubricator inject oil until the feedback LED stops flashing. If space conditions permit, unscrew the accumulator; otherwise the lubricator must be dismounted, see Step 1.
M90302 0256D04

903-2.2

Dismantling

5.

When referring to this page, please quote Procedure M90302 Edition 0256

M90302 0256D05

Page 5 (13)

903-2.3

Cylinder Lubricators
Overhaul MAN B&W Diesel

1.

1. Place the lubricator in a bench vice with soft jaws. Remove the adjusting screw with bushings. Unscrew the oil accumulator. Discard the O-ring from the adjusting screw. 2. Remove the screws from the cylinder block. 3. Pull up the cylinder block.

M90302 0247O01

Remove the spring and actuator piston with plungers. Remove and discard the O-ring from the cylinder block. Remove the cover for the non-return valves. Take out springs and balls. Remove and discard the O-rings.

2.

Page 6 (13)

M90302 0247O03

M90302 0247O02

3.

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel
4. Screw out the non-return valves and remove and discard the O-rings. Clean the valves and check them with compressed air. 5. Inspect the plungers, actuator piston and cylinder block for wear, using a magnifying glass. 6. Fit the non-return valve with new O-rings. Mount the non-return valves in the cylinder block.

903-2.3

Overhaul
4.

When referring to this page, please quote Procedure M90302 Edition 0256

M90302 0247O06

M90302 0247O05

M90302 0247O04

5.

6.

Page 7 (13)

903-2.3

Cylinder Lubricators
Overhaul MAN B&W Diesel

7.

7. Pre-assemble the cylinder blockwith the actuator piston and plungers to ensure the correct guidance of the plungers, before finally assembling the cylinder block unit. Mount the spring and press down the actuator piston with plungers. Mount an M6 x 60 screw with a washer to keep the spring compressed. Fit the cylinder block with a new O-ring. 8. Remove the cover from the terminal box and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box and the plug for the solenoid valve. Carefully unscrew the feedback sensor and remove and discard the O-ring.

M90302 0247O07

Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.

8.

Page 8 (13)

M90302 0247O08

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel
9

903-2.3

Overhaul
9.

Turn the lubricator upside down in the vice. Unscrew the solenoid valve. Discard the O-rings.

10. Solenoid valve: Disassemble and clean the valve. Check the slide for wear. If the slide is scratched or scuffed, the valve must be replaced by a new one. Lubricate the slide with oil and check that the slide can move lightly with a good fit in the housing. Assemble the valve. 10. See also manufacturers instructions. 11. Before mounting the feedback sensor, check that the sensor is flush with the sensor housing. Mount the feedback sensor or a new one, if necessary, with a new O-ring. Check with an object with a straight edge (e.g. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder. Mount the terminal box.
M90302 0247O09 M90302 0245O10 M90302 0244O12

11.

1 2 3 BN (brown) BK (black) 4 BU (blue) 5

1 2 Solenoid valve

Feedback sensor

When referring to this page, please quote Procedure M90302 Edition 0256

Page 9 (13)

903-2.3

Cylinder Lubricators
Overhaul MAN B&W Diesel

12.
LED

12. Connect the wires and mount the cover on the terminal box. 13. Mount the solenoid valve fitted with new O-rings. Coat the O-rings with a little grease to keep the rings in place during mounting. 14. Mount the cylinder block assembly in the cylinder housing.
Black FB signal

Brown+15 Blue OV

Check that the spring pin engages correctly with the cylinder block assembly. Mount the screws and tighten the block to the housing. Remove the M6 x 60 screw with disc.

Page 10 (13)

M90302 0247O14

M90302 0247O13

M90302 0242O08

13.

14.

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel
15. Mount the adjusting screw fitted with a new O-ring and the distance bushing. Mount the oil accumulator. 16. If the lubricator is not to be mounted on the engine immediately after overhauling, cover all openings with plastic to prevent dirt from entering the lubricator during storage. Cover all surfaces with a thin layer of oil.
M90302 0247O01

903-2.3

Overhaul
15.

16.

When referring to this page, please quote Procedure M90302 Edition 0256

Page 11 (13)

903-2.4

Cylinder Lubricators
Mounting
Mounting of Lubricators

MAN B&W Diesel

1. 1. Mount new O-rings on the hydraulic block and on the cover with pipes. Mount the lubricator and tighten the screws on the hydraulic block. Tighten the screws between the lubricator and the pipe connection. 2. Open the supply valve and mount the electrical plug. Check the injection of the cylinder oil on the led on the terminal box for the specific lubricator. For checking injection timing, see Procedure 905-8.1.

M90302 0256D02

2.

Page 12 (13)

M90302 0256M02

When referring to this page, please quote Procedure M90302 Edition 0256

Cylinder Lubricators
MAN B&W Diesel
Mounting of Accumulator 3. 3. Mount the accumulator. Remove the drain hose from the minimess coupling. Open the valve that connects the accumulator to the distributor block. Check the oil injection. See Procedure 903-2.1.

903-2.4

Mounting

When referring to this page, please quote Procedure M90302 Edition 0256

M90302 0256M03

Page 13 (13)

Cylinder Liner - T ools Tools


MAN B&W Diesel

Plate P90361-0083

When referring to this page, please quote Plate P90361 Edition 0083

Page 1 (2)

Plate P90361-0083 Item No.


012 024 048

Cylinder Liner - T ools Tools


MAN B&W Diesel Item No.

Item Description
Measuring rod for cylinder liner, long Measuring rod for cylinder liner, short Measuring tool for cylinder liner

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90361 Edition 0083

Cylinder Liner - Milling Tools

Plate P90362-0005

When referring to this page, please quote Plate P90362 Edition 0005
MAN B&W Diesel A/S

Page 1 (2)

Plate P90362-0005 Item No.


018

Cylinder Liner - Milling Tools


Item Description Item No. Item Description

Wear ridge milling machine

Page 2 (2)

When referring to this page, please quote Plate P90362 Edition 0005
MAN B&W Diesel A/S

Test Equipment for Lubricator


Test Equipment for Lubricator 0004 P90364

Plate P90364-0004

When referring to this page, please quote Plate P90364 Edition 0004
MAN B&W Diesel A/S

Page 1 (2)

Plate P90364-0004 Item No.


019 020 032 044 056 068 081 103 115 139 152 164 176 211 223

Test Equipment for Lubricator


Item No.

Item Description
Tool box Nameplate Adaptor Pressure gauge Spanner Pressure gauge Adaptor Hose with 2 union Quick coupling, minimess Reducing valve Adaptor Adaptor Adaptor Adaptor Filling and testing valve

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90364 Edition 0004
MAN B&W Diesel A/S

Cylinder Liner - Lifting Tools

Plate P90366-0003

When referring to this page, please quote Plate P90366 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P90366-0003 Item No.


021

Cylinder Liner - Lifting Tools


Item No.

Item Description
Cross bar for cylinder liner

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90366 Edition 0003
MAN B&W Diesel A/S

904 - Crosshead with Connecting Rod


Documents in this Chapter
104-01 904-01 104-02 904-02 104-03 904-03 104-04 904-04 104-05 904-05 90451 90462 0069 0253 0070 0252 0044 0215 0062 0233 0060 0237 0155 0018 Crosshead Bearing, Data Crosshead Bearing Crosshead, Data Crosshead Reciprocating Parts, Data Reciprocating Parts Crankpin Bearing, Data Crankpin Bearing Connecting Rod, Data Connection Rod Connecting Rod and Crosshead - Panel Connecting Rod - Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crosshead Bearing
MAN B&W Diesel Data

104-1

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D04-01 D04-02 D04-03 D04-04 D04-05 D04-06 D04-07 D04-16 D04-58 D13-01 D13-02 Description Crosshead bearing, top clearance max. Crosshead bearing, top clearance min. Oil wedge length, L Crosshead bearing cap Crosshead bearing shell, upper Crosshead bearing shell, lower Crosshead bearing cap with bearing shell Thrust piece, tightening torque Stufng box, telescopic pipe, tightening torque Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 0,7 0,35 15 900 94 120 1000 550 340 900 800 - 990 Unit mm mm mm kg kg kg kg Nm Nm bar bar

When referring to this page, please quote Data D10401 Edition 0069

Page 1 (2)

104-1

Crosshead Bearing
Data MAN B&W Diesel

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

Plate P90451 P90451 P90451 P90451 P90451 P90451 P90451 P90451 P91351 P91351 P91351 P91351 P91366

Item No. 47 59 60 72 84 96 106 118 010 046 058 117 058 Wire guide

Description

Lifting attachment - connecting rod Lifting tools - crosshead Chain for suspending piston Retaining tool telescope pipe Bracket for support, Crosshead Bracket for support, Crosshead Rubber cover for crosshead Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Feeler gauge

Page 2 (2)

When referring to this page, please quote Data D10401 Edition 0069

Crosshead Bearing
MAN B&W Diesel
White metal bearings 1. The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing components. For the top clearance of a new bearing, see the Data D-1. For the top clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume I, OPERATION. 1. Open the crankcase door at the relevant cylinder. 2. Turn the crosshead concerned to BDC. 3. Measure the clearance in the crosshead bearing by inserting a feeler gauge at the top of the upper bearing shell. 4. The difference between the actual clearance measurements and the measurements noted in the Adjustment Sheet at the shop test/sea trial (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If the clearance is too large, the crosshead must be disassambled for inspection. See Procedure 904-2.2. 5. The wear limit for a crosshead bearing shell is confined to a 50% reduction of the oil wedge length L. This can only be checked after the crosshead has been disassembled. If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by a new one. 6. For further external inspection of the crosshead bearing, see Chapter 708, Bearings in the instruction book, Volume I, OPERATION.
M90401 0253C02

904-1.1

Checking

2.

D04 01 D04 02

M90401 0253C03

3.

(Oil Wedge) L 1/2


M90401 0253C05

D04 03 L

When referring to this page, please quote Procedure M90401 Edition 0253

Page 1 (8)

904-1.2

Crosshead Bearing
Dismantling MAN B&W Diesel

1.

This procedure applies to the following two dismantling situations: with piston mounted (steps 1-11) with piston removed (steps 3-11) With piston mounted: 1. Turn the crosshead down far enough to give access to the nuts on the piston rod, the crosshead bearing cap, and the screws on the telescopic pipe.

M90401 0253D01

2. Mount the two chains for suspending the piston in the inner screw holes at the top of the crankcase, in the athwartship direction. 3. Mount two eyebolts in the two outer screw holes in the top of the frame box in the athwartship direction. Remove the thrust pieces for axial guidance of the connecting rod. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts and the piston rod nuts. Loosen the nuts.

2.

M90401 0253D02

For operation of the hydraulic tools, see Procedure 913. Remove the hydraulic jacks, and unscrew the nuts. Caution! Never suspend or remove the piston without suspending the telescopic pipe.

3.

M90401 0253D03

D13 02

Page 2 (8)

When referring to this page, please quote Procedure M90401 Edition 0253

Crosshead Bearing
MAN B&W Diesel Dismantling
4.

904-1.2

4. Mount a lifting eye bolt on each side of the piston rod foot. Mount a lifting eye bolt with an extension screw on each side of the bearing cap. 5. Loosen and remove the screws which secure the telescopic pipe to the bend. Remove one screw from the telescopic stuffing box housing, and mount the special tool for suspending the telescopic pipe.

Hook the ends of the chains to the lifting eye bolts on the piston rod. Suspend the telescopic pipe, using the tool stud. Turn the crosshead downward, and the piston rod will remain suspended from the two chains. When turning downwards, remove the distance tube from the bend.

When referring to this page, please quote Procedure M90401 Edition 0253

M90401 0253D06

M90401 0253D05

M90401 0253D04

6. Turn the crosshead to TDC.

5.

6.

Page 3 (8)

904-1.2

Crosshead Bearing
Dismantling MAN B&W Diesel

7.

D04 04 D04 07

7. Turn down to BDC. Suspend two tackles from the eyebolts, in the athwarthship direction. Hook the tackles on to the eye bolts in the crosshead bearing cap and raise the cap. Check the upper bearing shell and the upper part of the journal. Mount the wire guide in the top of the door opening.

M90401 0253D07

If desired, mount a third tackle outside the engine and lift the bearing cap out of the engine. 8. Place the bearing cap on one side on a couple of wooden planks. Check the bearing shell, see Procedure 904-1.1. 9. Mount lifting attachments on the head of the connecting rod. Fasten pull lifts to the fixed lifting brackets on the frame box wall and fix the connecting rod in the vertical position.

8.

D04 05

Page 4 (8)

M90401 0253D09

M90401 0253D08

9.

When referring to this page, please quote Procedure M90401 Edition 0253

Crosshead Bearing
MAN B&W Diesel Dismantling
10.

904-1.2

10. 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. Haul the tackles tight.

Caution! Take care not to scratch the crosshead bearing journal or damage the threads of the crosshead bearing studs. 11.

With the crosshead resting on the supports, check the lower part of the crosshead journal and the bearing shell. Regarding checking of journal and bearing shells, see Volume I, OPERATION, Chapter 708, Bearings. 12. In cases where it is necessary to remove the lower bearing shell, tilt the connecting rod towards the doorway in the camshaft side, using the tackles. Dismount the locking screws, and turn the bearing shell so far up that an eye bolt can be mounted. Lift the bearing shell out of the engine.

M90401 0253D11

M90401 0253D10

11. Turn the crankthrow carefully towards BDC while following with the tackles, thus continuously supporting the connecting rod.

12.

D04 06

When referring to this page, please quote Procedure M90401 Edition 0253

M90401 0253D12

Page 5 (8)

904-1.4

Crosshead Bearing
Mounting MAN B&W Diesel

With piston mounted/With piston removed: 1. 1. Mount and secure the bearing shell in the bearing housing.

D04 05

The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated. Raise the connecting rod to an upright position. Lubricate the bearing shell and the journal with plenty of lubricating oil.

M90401 0253M01

x
2. Turn to TDC while following with the tackles, for assembling the crosshead and the connecting rod. Note! Take care that the bearing studs do not damage the crosshead.

2.

3. Remove the supports from the crosshead guides. Remove the tackles and the lifting attachments from the head of the connecting rod.
M90401 0253M02

Turn the crankthrow to BDC.

3.

Page 6 (8)

M90401 0253M03

When referring to this page, please quote Procedure M90401 Edition 0253

Crosshead Bearing
MAN B&W Diesel Mounting
3.

904-1.4

3. Lift the bearing cap back into the engine. Lubricate the crosshead bearing journal with plenty of lubricating oil. Lower the bearing cap onto the crosshead, and remove the tackles. 4. Mount the thrust pieces for axial guidance of the connecting rod. For tightening torque, see Data. Note! It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.

With the piston mounted: 5. Use a rubber cover to cover the oil inlets/ outlets on top of the crosshead. Mount all hydraulic nuts on the studs, screw down until the nuts are flush wich the top of the studs. Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby turning the crosshead until the face is parallel with the piston rod foot. Lower the crosshead just enough to enable removal of the nuts and the rubber cover. If any shims have been removed from the crosshead, mount them again. Turn the crosshead upwards until the piston rod lands on the crosshead. When mounting the piston on the crosshead, make sure that the piston rod foot does not damage the threads of the studs. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod.
M90401 0253M06

M90401 0253M04

4.

D04 16

When referring to this page, please quote Procedure M90401 Edition 0253

M90401 0253M05

5.

Page 7 (8)

904-1.4

Crosshead Bearing
Mounting MAN B&W Diesel

6.

6. Mount the distance pipe on the telescopic pipe bend. Turn up the crosshead until the telescopic pipe lands on the distance pipe. Remove the chains and eye bolts from the top of the frame box, from the piston rod foot and from the crosshead bearing cap in the athwartship direction. Remove the wire guide from the engine.

M90401 0253M07

D04 16 D04 58

Remove the suspending tool stud and mount the screws in the telescopic stuffing box housing. Mount the screws and tighten the telescopic pipe, see Data. 7. Turn down to BDC and mount the hydraulic nuts on the studs. For operation of the hydraulic jacks, see Procedure 913. Tighten the nuts on the piston rod foot and on the crosshead as stated in Data. With the piston removed: 8. Mount the piston. See Procedure 902-1.4.

7.

D13 01

M90401 0253M08

9. Turn down to BDC and tighten all four crosshead bearing cap nuts simultaneously. See Data. For operation of the hydraulic jacks, see Procedure 913.

Page 8 (8)

When referring to this page, please quote Procedure M90401 Edition 0253

Crosshead
MAN B&W Diesel Data

104-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D04-07 D04-09 D04-10 D04-11 D04-14 D04-15 D04-16 D04-17 D04-18 D04-20 D04-21 D04-22 D04-23 D04-49 D04-51 D04-58 D04-59 D04-59 D04-60 D04-62 D13-01 D13-02 Description Crosshead bearing cap with bearing shell Inlet pipe, tightening torque Inlet pipe stud, screwing-in torque Guide strip nuts, tightening torque Crosshead/piston rod stud, screwing-in torque Telescopic pipe, tightening torque Thrust piece, tightening torque Cooling oil outlet pipe, tightening angle Inlet pipe, tightening angle Clearance between thrust piece and crosshead Crosshead complete Guide shoe Cooling oil outlet pipe Connecting rod studs , screwing-in torque Connecting rod complete Stufng box, telescopic pipe, tightening torque Telescopic pipe Telescopic pipe Inlet pipe Crosshead without guide shoes Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 1000 100/50 450 400 150 340 550 100/20 50 0.35-0.60 5000 413 30 480 5650 340 57 57 57 4200 900 800 - 990 Unit kg Nm/ Nm Nm Nm Nm Nm Nm/ mm kg kg kg Nm kg Nm kg kg kg kg bar bar

When referring to this page, please quote Data D10402 Edition 0070

Page 1 (2)

104-2

Crosshead
Data MAN B&W Diesel

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

Plate P90451 P90451 P90451 P90451 P90451 P90451 P90451 P90451 P90451 P90451 P91351 P91351 P91351 P91351 P91359 P91366

Item No. 47 59 60 72 84 96 106 118 131 202 010 046 058 117 058 Wire guide

Description

Lifting attachment - connecting rod Lifting tools - crosshead Chain for suspending piston Retaining tool telescope pipe Bracket for support, Crosshead Bracket for support, Crosshead Rubber cover for crosshead Drawing tool - bell shaped Extension (X-Head Cap / Piston Rod) Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Torque Spanners Feeler gauge

Page 2 (2)

When referring to this page, please quote Data D10402 Edition 0070

Crosshead
MAN B&W Diesel Dismantling
2.

904-2.2

1. Dismount the main bearing lubricating oil pipes. 2. Turn the crosshead to BDC to give access to the nuts on the crosshead bearing cap. Mount the retaining tool for the telescopic pipe on the stuffing box housing for the telescopic pipe. Mount two eye bolts in the athwartship direction, and suspend two tackles. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts. For operation of the hydraulic tools, see Procedure 913-1. Loosen the nuts, remove the hydraulic jacks and unscrew the nuts. 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 lifting tools. Use two tackles to retain the connecting rod in an upright position. 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 crosshead bearing cap.

D13 02

M90402 0252D04

M90402 0252D02

4.

D04 07

When referring to this page, please quote Procedure M90402 Edition 0252

Page 1 (9)

904-2.2

Crosshead
Dismantling MAN B&W Diesel

5.

5. Dismount the four bearing cap studs, using the stud setter.

D04 23 D04 60

Dismount the guide pin for the oil inlet bend using the special extractor. Mount the eye bolt in one of the threaded holes in the bend, hook on a tackle and haul tight. Remove the outlet pipe, dismount the bend for the telescopic pipe and remove the studs from the crosshead.

M90402 0252D05

Mount the special lifting tool on the crosshead. 6. Attach tackle chains from the two tackles in the athwartship direction to the wire ropes on the lifting tool. Lift the crosshead free of the connecting rod.

6.

Page 2 (9)

M90402 0252D06

When referring to this page, please quote Procedure M90402 Edition 00252

Crosshead
MAN B&W Diesel Dismantling
7.

904-2.2

7. Use the tackles to tilt the connecting rod to-wards the exhaust side, while turning the crankthrow towards the camshaft side. Transfer the tackles from one lifting attachment to another, as necessary. Stop turning when the crankthrow is in a position where there is room in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings.

D04 51

8. Remove the oil pipes from the two adjacent main bearing caps. 9. Remove the guide strips and the stop screws from the bottom of the guide shoes. Mount lifting eye bolts in both guide shoes.There has to be space in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings. Note!

10. Lower the crosshead so that the guide shoes are just below the cutout in the side walls of the frame box. Note! Make sure that the crosshead journal does not touch the crank.

When referring to this page, please quote Procedure M90402 Edition 0252

M90402 0250D10

M90402 0250D09

It is recommended to tag the guide strips and shims to avoid mixing them.

M90402 0250D07

By alternate use of the tackles, tilt the connecting rod until it is out of the way.

9.

10.

Page 3 (9)

904-2.2

Crosshead
Dismantling MAN B&W Diesel

11.

11. Hook the tackles on to the eye bolts in the guide shoes. 12. Mount two eye bolts in the holes for stop screws in the guide shoes in the adjacent cylinder units, and suspend two tackles from the eye bolts. 13. Haul the tackles for the guide shoes tight and, at the same time, pull the guide shoes sideways until they are free of the crosshead. Take the guide shoes through the openings in the side walls by means of the tackles in the two adjacent cylinders. Lift the guide shoes to provide space for turning the crosshead.

Page 4 (9)

M90402 0252D13

M90402 0250D12

M90402 0252D11

12.

13.

When referring to this page, please quote Procedure M90402 Edition 00252

Crosshead
MAN B&W Diesel
14. Turn the crosshead 90. 15. Mount a tackle outside the engine and, by means of wire rope and tackle, remove the crosshead from the engine. Land and protect the crosshead outside the engine. Remove the guide shoes from the engine and tag them. Note! Take care that the crosshead does not bump into anything as this will damage the sliding surfaces of the crosshead.

904-2.2

Dismantling
14.

M90402 0252D15

M90402 0252D14

15.

D04 62

When referring to this page, please quote Procedure M90402 Edition 0252

Page 5 (9)

904-2.4

Crosshead
Mounting MAN B&W Diesel

1.

1. Clean the crosshead and mount the lifting tool with shackle and wire ropes. Mount the wire guide tool in the framebox door opening. Suspend two tackles from the top of the framebox between the guides. Suspend two tackles from the top lifting brackets in the framebox and use them in conjunction with a tackle mounted outside the engine to carefully lift the crosshead and ease it into the crankcase.

M90402 0252M01

D04 22 D04 62

2. Turn the crosshead 90 to enable mounting of the guide shoes. Check that the oil inlet and outlet holes are pointing towards the exhaust side. 3. Attach two tackles to the eye bolts at the bottom of the guide shoes in the adjacent cylinders. Using these tackles and a tackle outside the engine, carefully lift the guide shoes into the engine. Note! When handling the crosshead, take great care that its surfaces are not scratched or damaged. If necessary, protect the crosshead with a cloth.

2.

M90402 0252M03

M90402 0252M02

3.

D04 22
When referring to this page, please quote Procedure M90402 Edition 0252

Page 6 (9)

Crosshead
MAN B&W Diesel Mounting
4.

904-2.4

4. Lubricate the sliding surfaces of the guide shoes and the crosshead with plenty of clean lubricating oil, and push the guide shoes into position through the openings in the side walls. 5. Use the tackles in the top of the framebox to lift the crosshead into a working position and mount the guide strips and shims on the side of the guide shoes. Mount the stop screws in the bottom of the guide shoes. Remove the tackles and the eye bolts from the guide shoes. 6. Lift the crosshead to a position above the connecting rod in the upright position. Raise the connecting rod to the upright position. Lubricate the crosshead bearing liberally with clean lubricating oil and carefully lower the crosshead into place. Unhook the wire ropes from the crosshead lifting tool. 7. Dismount the tackles and connecting rod lifting tools from the connecting rod.

M90402 0252M05

M90402 0252D13

5.

D04 11 D04 21

6.

When referring to this page, please quote Procedure M90402 Edition 0252

M90402 0252M06

Page 7 (9)

904-2.4

Crosshead
Mounting MAN B&W Diesel

8.

D04 D04 D04 D04 D04

08 09 10 49 18

8. Turn the connecting rod and crosshead to BDC. Remove the lifting tool from the crosshead. Mount the studs for the cooling oil inlet bend. Mount the bend and outlet pipe. See Data. Mount the cylindrical dowel with threaded hole in the bend, and mount the bearing cap studs.

M90402 0252M08

Mount the piston rod guide ring and the shim on the crosshead. 9. Lift the crosshead bearing cap into the engine. Lubricate the crosshead journal with plenty of clean lubricating oil. Carefully land the bearing cap on the crosshead. Mount the hydraulic nuts. Mount the thrust pieces on the bearing cap. Note! It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.

9.

D04 07 D04 16 D04 20

Tighten the screws to the torque stated in Data.


M90402 0252M09

For correct tightening, see also Procedure 913-5.

Page 8 (9)

When referring to this page, please quote Procedure M90402 Edition 0252

Crosshead
MAN B&W Diesel
10. Tighten the hydraulic nuts. For operation of hydraulic tools, see Procedure 913-1. Remove the hydraulic tools and the eye bolts from the engine. Check the clearances between the guide strips, guide shoes and crosshead guides. See Procedure 904-3. Mount the main bearing lubricating oil pipes. Mount the piston and the telescopic pipe. See Procedure 904-1. Note! At this point it is recommended to check the crosshead bearing clearance. See Procedure 904-1.

904-2.4

Mounting
10.

M90402 0252M10

D04 58 D04 59

D13 01

11. Remove all tools from the engine. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind.

11.

When referring to this page, please quote Procedure M90402 Edition 0252

M90402 0250M10

Page 9 (9)

Reciprocating Parts
MAN B&W Diesel Data

104-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X X Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil X Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Acceptance criteria with piston in centre (F-A direction) D04-25 D04-26 D04-28 D04-29 D04-30 D04-34 D04-35 D04-36 D04-39 D04-41 D04-42 PF+PA, N max. PF+PA, O max. E+G, H+F, N max. E+G, H+F, N min. E+G, H+F, O max. J+X, L+Y, K+X, M+Y, N max. J+X, L+Y, K+X, M+Y, N min. J+X, L+Y, K+X, M+Y, O max. QF/QA, O max. ZF/ZA O min. TF + TA 0.85 1.35 0.60 0.20 0.90 1.20 0.60 1.40 0.80 5.0 0.80 mm mm mm mm mm mm mm mm mm mm mm Value Unit

When referring to this page, please quote Data D10403 Edition 0044

Page 1 (2)

104-3

Reciprocating Parts
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 P91366 Item No. Feeler gauge Description

Page 2 (2)

When referring to this page, please quote Data D10403 Edition 0044

Reciprocating Parts
Checking
Reciprocating Parts S90MC-C 0215 Checking 904-3.1

904-3.1

In order to achieve uniform measuring conditions on board, the ships 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. Fill the tube with water (possibly coloured) until the water level is approx. 100 mm from the end of the tube. Trim the ship until the difference between the water level S fore and aft is less than 1.5 mm per 1000 mm. Measurements are to be taken with a ruler. 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 cylinder liner by measuring the clearance (by applying a long feeler gauge from the scavenge air space) between the piston skirt and the cylinder liner in the Fore and Aft positions (PF-PA). Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. 3. Turn in astern direction until the bottom of the guide shoe is 50 mm in the vertical direction above the top of the cut out in the web plate.

1.

MA904-5.0 72 01

2.

Fore

Aft

PA PF
HN904-3.1 212 02

45

Ast

ern

3.
50

EXH

CAM

E 1-2

G 1-2 10

F 1-2 H 1-2

When referring to this page, please quote Procedure M90403 Edition 0215 0$1 % : 'LHVHO $6

HN904-3.1 212 03

Page 1 (3)

904-3.1

Reciprocating Parts
Checking

4.

4. Measure the clearance between the crankthrow and the connecting rod. 5. Measure the clearance between the thrust piece and the crosshead ( TF and TA or QF and QA . Measure the clearance between the crosshead 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 mm per 1000 mm. BF and BA correspond to the thickness of the shims and are only to be measured if an adjustment is carried out.
Exhaust Side

MN904-3.1 215 04

5.

Camshaft Side

Page 2 (3)

MN904-3.1 215 05

When referring to this page, please quote Procedure M90403 Edition 0215 0$1 % : 'LHVHO $6

Reciprocating Parts
Checking
6.
Piston/Liner Shim Thickness Frame Box

904-3.1

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

Cyl. PF PA BF BA 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 Connecting Rod Crankthrow Connecting Rod

QF/TF QA/TA ZF ZA

When referring to this page, please quote Procedure M90403 Edition 0215 0$1 % : 'LHVHO $6

MN904-3.1 215 06

Page 3 (3)

Crankpin Bearing
MAN B&W Diesel Data

104-4

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D04-43 D04-44 D04-45 D04-46 D04-47 D04-48 D13-01 D13-02 Description Crankpin bearing clearance, max. Crankpin bearing clearance, min. Crankpin bearing cap complete Crankpin bearing, upper shell Crankpin bearing, lower shell Crankpin bearing cap + shell + bearing studs Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 0.8 0.4 566 67 34 600 900 800 - 990 Unit mm mm kg kg kg kg bar bar

When referring to this page, please quote Data D10404 Edition 0062

Page 1 (2)

104-4

Crankpin Bearing
Data MAN B&W Diesel

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

Plate P90451 P90451 P90451 P90451 P90461 P90462 P91351 P91351 P91351 P91351 P91356 P91366 P91366

Item No. 047 059 096 106 Wire guide

Description

Lifting attachment - connecting rod Bracket for support, Crosshead Bracket for support, Crosshead Connecting Rod - Hydraulic Tools Lifting tool for crankshaft shell

10 46 60 105 58 61

Hydraulic pump, pneumatic operated Hose with unions (1500 mm), complete Hose with unions (5000 mm), complete 3-way distributor block, complete Lifting Tools, Etc. Feeler gauge Slide caliper

Page 2 (2)

When referring to this page, please quote Data D10404 Edition 0062

Crankpin Bearing
MAN B&W Diesel Checking
2.

904-4.1

The bottom clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing assembly components. For the bottom clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume I, OPERATION. 1. Open the crankcase door at the relevant cylinder. 2. Turn the crank concerned to BDC. 3. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. See Data for bottom clearance. 4. The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If so, the crankpin bearing must be disassembled for inspection. See Procedure 904-4.2. 5. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection. An average wear rate of 0.01 mm per 10,000 hours is regarded as normal. 6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in the instruction book, Volume I, OPERATION.

M90404 0233C02

3.

D04 43 D04 44
M90404 0233C03

5.

D04 46

When referring to this page, please quote Procedure M90404 Edition 0233

M90404 0233C04

Page 1 (8)

904-4.2

Crankpin Bearing
Dismantling MAN B&W Diesel

1.

1. Suspend two tackles from the lifting brackets, in the athwartship direction. Mount the wire guide in the top of the crankcase door opening. 2. Turn the crank to TDC. Mount eye bolts in each side of the crankpin bearing cap and, using shackles and wire ropes, hook on the tackles and haul tight.

M90404 0233D01

Loosen the crankpin bearing stud nuts, using the hydraulic jacks. For operation of the hydraulic jacks, see Procedure 913-1. 2. Remove the hydraulic jacks and the nuts. 3. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal. Land the bearing cap on a couple of planks placed in the oil pan.

D13 02
M90404 0233D02

Inspect the bearing shell.

3.

D04 48

Page 2 (8)

M90404 0233D03

When referring to this page, please quote Procedure M90404 Edition 0233

Crankpin Bearing
MAN B&W Diesel Dismantling
4.

904-4.2

4. If the bearing shell needs to be replaced, remove the whole bearing cap from the crankcase. Suspend a tackle outside the engine above the crankcase door opening. Turn the crankthrow to the exhaust side to give space for lifting out the crankpin bearing cap. Using the tackle from the frame box inside wall, together with the tackle suspended outside the engine, lift the bearing cap out of the crankcase. 5. Place the bearing cap on one side on a couple of planks. Dismount the bearing shell lock screws and replace the bearing shell by a new one. The bearing shells must be replaced in pairs. 6. Turn to TDC. Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank to the camshaft side and down 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.

D04 48

When referring to this page, please quote Procedure M90404 Edition 0233

M90404 0233D06

M90404 0233D05

M90404 0233D04

5.

6.

Page 3 (8)

904-4.2

Crankpin Bearing
Dismantling MAN B&W Diesel

7.

7. Mount a lifting attachment for securing the connecting rod at the lower end, on the camshaft side. Hook the tackle on to the lifting attachment. 8. Carefully turn the crankshaft downwards, while following with the tackle, making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to separate.

M90404 0233D07

If necessary suspend a second tackle from the bracket below the doorway. Continue turning the crankshaft until the bearing surface can be freely inspected. Inspect the bearing shell surface and the crankpin journal. 9. If it is necessary to replace the bearing shell, proceed as follows: Turn the crankshaft approx. 80 to a horizontal position. Release the tackle so that the connecting rod is hanging freely.

8.

Page 4 (8)

M90404 0233D09

M90404 0233D08

9.

When referring to this page, please quote Procedure M90404 Edition 0233

Crankpin Bearing
MAN B&W Diesel Dismantling
10.

904-4.2

10. Mount an eye bolt in the bottom of each guide shoe. Suspend two tackles from the eye bolts. 11. Place the lifting tool for the crankpin upper shell on the crank webs and hook the tackles on to the lifting tool. Mount the tool on the bearing shell in the connecting rod, using the tackles, and haul tight.

Lower the lifting tool with the bearing shell, using the tackles.

M90404 0233D11

M90404 0233D10

12. Dismount the bearing shell lock screws.

11.

12.

When referring to this page, please quote Procedure M90404 Edition 0233

M90404 0233D12

D04 46

Page 5 (8)

904-4.4

Crankpin Bearing
Mounting MAN B&W Diesel

1.

1. If necessary, replace the bearing shells with new ones. The bearing shells must be replaced in pairs. Bearing shells of three mm undersize are available as spares in case of journal rectification. Coat the bearing shell surfaces and the journal with clean oil. The excess height X is to ensure the correct tightening-down of the bearing shell, and must not be eliminated. 2. Lift the upper bearing shell for the crankpin concerned into the crankcase. Carefully lift the bearing shell into position in the connecting rod, and mount the lock screws. 3. Remove the lifting tool, the tackles and the eye bolts from the guide shoes.

M90404 0231M01

2.

M90404 0233M02

D04 46

3.

Page 6 (8)

M90404 0233M03

When referring to this page, please quote Procedure M90404 Edition 0233

Crankpin Bearing
MAN B&W Diesel Mounting
4.

904-4.4

4. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod, and haul tight. Carefully turn the crankshaft upwards, while following up with the tackle, making sure that the upper part of the bearing enters the recess in the crankshaft when the parts turn together. Remove the tackle and the lifting attachment from the connecting rod. 5. Turn the crosshead to TDC. Remove the four guide shoe support brackets from the crosshead guides.

When referring to this page, please quote Procedure M90404 Edition 0233

M90404 0233D06

M90404 0233M04

5.

Page 7 (8)

904-4.4

Crankpin Bearing
Mounting MAN B&W Diesel

6.

6. Suspend the tackles from the lifting brackets in the side of the frame box. Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan.

D04 48
Remove the wire guide tool from the engine. 7. Hook the tackles on to the wire ropes and lift the bearing cap into position against the connecting rod.
M90404 0233M06

Caution! During mounting, take care that the studs do not damage the crankpin journal, and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod. Mount the nuts and, by means of spacer rings and hydraulic jacks, tighten the crankpin bearing cap. See Data. For operation of hydraulic jacks, see Procedure 913-1. Remove the tackles from the side of the frame box.

7.

M90404 0233M07

D13 01

Page 8 (8)

When referring to this page, please quote Procedure M90404 Edition 0233

Connecting Rod
MAN B&W Diesel Data

104-5

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D04-07 D04-16 D04-48 D04-49 D04-50 D04-52 D13-01 D13-02 Description Crosshead bearing cap with bearing shell Thrust piece, tightening torque Crankpin bearing cap + shell + bearing studs Connecting rod studs , screwing-in torque Connecting rod, without bearing caps Connecting rod stud Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 1000 550 600 480 5000 18 900 800 - 990 Unit kg Nm kg Nm kg kg bar bar

When referring to this page, please quote Data D10405 Edition 0060

Page 1 (2)

104-5

Connectin Rod
Data MAN B&W Diesel

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

Plate P90451 P90451 P90451 P90451 P90451 P90461 P90464 P91351 P91351 P91351 P91351 P91356 P91366 P91368

Item No. 47 59 72 96 106 Wire guide

Description Lifting attachment - connecting rod Chain for suspending piston Bracket for support, Crosshead Bracket for support, Crosshead Connecting Rod - Hydraulic Tools Crosshead - Hydraulic Tools

10 46 58 117 58

Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Lifting Tools, Etc. Feeler gauge Working Platforms

Page 2 (2)

When referring to this page, please quote Data D10405 Edition 0060

Connecting Rod
MAN B&W Diesel Dismantling
1.

904-5.2

1. Suspend the piston rod and dismount the crosshead bearing cap. See Procedure 904-1.2. 2. Suspend two tackles from the two lifting brackets at the sides of the frame box. Mount the wire guide in the top of the crankcase doorway. 3. Turn the crank to TDC. Dismantle the crankpin bearing cap, and remove it from the engine. See Procedure 904-4.2. Mount the four support brackets for guide shoes on the crosshead guides.

M90405 0237D01

D13 02 D04 07

2.

When referring to this page, please quote Procedure M90405 Edition 0237

M90405 0237D03

M90405 0237D02

3.

Page 1 (6)

904-5.2

Connecting Rod
Dismantling MAN B&W Diesel

4.

4. Mount the lifting attachments for fixing the connecting rod on the head of the connecting rod.

Use the tackles fastened to lifting brackets A and B on the frame box wall, and attach the tackle hooks to the mentioned lifting attachments on the connecting rod. Haul the tackles tight. Also mount a lifting attachment in the crankpin end of the connecting rod, on the exhaust side. Carefully turn the crank down towards the exhaust side, until the crosshead 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. 5. Turn the crankthrow towards BDC while following with the tackles, thus continuously supporting the connecting rod. 6. Turn the crankthrow to 90 before BDC. Remove the four studs from the connecting rod.

M90405 0237D04

5.

D04 50 D04 52

M90405 0237D05

Shift the hook of the tackle attached to lifting bracket B from the lifting attachment on the lowermost side of the connecting rod to the lifting attachment on the uppermost side.

Page 2 (6)

When referring to this page, please quote Procedure M90405 Edition 0237

Connecting Rod
MAN B&W Diesel Dismantling
7.

904-5.2

7. By means of the tackle from lifting bracket A, tilt the connecting rod towards the camshaft side until the connecting rod is leaning out of the doorway. Attach a tackle to lifting bracket C on the frame box wall and connect the tackle hook to the lifting attachment at the lower end of the connecting rod. Turn the crank carefully upwards while following with the tackles, guiding the head of the connecting rod out of the doorway. 8. Attach a tackle to the gallery-mounted lifting bracket E, and hook on to the lifting attachment on the connecting rod. Shift the tackles from one lifting bracket/attachment to the other, as required. Remove the floor chequer plate for the pertaining cylinder. 9. Place a plated wire rope round the connecting rod, hook on the engine room crane and haul tight. Continue turning upwards till about 30 after TDC, while following with the tackles and the engine room crane. Lift the connecting rod out of the engine using the engine room crane and the tackles.

M90405 0237D07

8.

E A B

M90405 0237D08

9.

E A B

D04 50

When referring to this page, please quote Procedure M90405 Edition 0237

M90405 0237D09

Page 3 (6)

904-5.4

Connecting Rod
Mounting MAN B&W Diesel

1.

1. Equip the connecting rod with the same lifting attachments as mentioned under dismantling.

Turn the crank to a position about 30 past TDC on the camshaft side. Apply clean lubricating oil to the crankpin bearing shell and journal. 2. Lift the connecting rod carefully into the crankcase by alternate use of the engine room crane and the tackles attached to lifting brackets A and B. Attach a tackle to bracket E and the upper end of the connecting rod. 3. When the end of the connecting rod rests on the crankpin journal, attach a tackle to bracket C and the lower end of the connec-ting rod. 4. Turn the crankthrow towards BDC, past TDC, while following with the tackles. Lower the engine room crane and remove the strap around the connecting rod.

D04 50
M90405 0237M02

2.

E A B

C
Shift tackle B from the lower end to the upper end of the connecting rod.
M90405 0237M03

3.

E A B

Page 4 (6)

M90405 0237D08

When referring to this page, please quote Procedure M90405 Edition 0237

Connecting Rod
MAN B&W Diesel Mounting
5.

904-5.4

5. Turn the crankthrow to 90 before BDC, and use the tackles to raise the connecting rod to an upright position. Shift tackle A from the lower end to the top of the connecting rod. Remove the tackle at E. Shift tackle B from the lifting attachment on one side to the other side of the connecting rod. Remove the tackle at C. Remove the lifting attachment at the lower end of the connecting rod. 6. Screw the studs into the connecting rod. Using the stud setter and a torque wrench, tighten the studs to the torque stated in Data. Lubricate the crosshead bearing shell and journal. 7. Turn the crankthrow towards TDC while following with the tackles, carefully land the crosshead on the connecting rod. Note! Take care that the studs do not damage the crosshead bearing journal.

M90405 0237M05

6.

D04 49 D04 52
M90405 0237M06

7.

When referring to this page, please quote Procedure M90405 Edition 0237

M90405 0237M07

Page 5 (6)

904-5.4

Connecting Rod
Mounting MAN B&W Diesel

8.

8. When the crank is in TDC, mount the crankpin bearing cap. See Procedure 904-4.4. Turn to BDC and mount the crosshead bearing cap and the piston. See Procedure 904-1.4. 9. Remove the tackles and lifting attachments. 10. Turn the crosshead to BDC. Tighten all four crosshead bearing cap nuts simultaneously. See Data. For use of hydraulic jacks, see Procedure 913-1. Mount the thrust pieces for axial guidance of the connecting rod, and tighten to the specified torque. See Data.

M90405 0237M08

D04 48

9.

M90405 0237M10

M90405 0237M09

10.

D13 01 D04 16

Page 6 (6)

When referring to this page, please quote Procedure M90405 Edition 0237

Connecting Rod and Crosshead - Panel MAN B&W

Plate P90451-0155

When referring to this page, please quote Plate P90451 Edition 0155

Page 1 (2)

Plate P90451-0155 Item No.


011 023 047 059 060 072 084 096 106 118 120 131 143 155 167 180 202 275 287

Connecting Rod and Crosshead - Panel MAN B&W


Item Description Item No. Item Description

Panel for tools Name plate Wire guide Lifting attachment, connecting rod Lifting tool, crosshead Chain for suspending piston Retaining tool, telescope pipe Bracket, support of crosshead Bracket, support of crosshead Rubber cover, crosshead Rubber cover with hole, crosshead Drawing tool Template Crowfoot spanner Crowfoot spanner Template Screw Protective screw Protective screw

Page 2 (2)

When referring to this page, please quote Plate P90451 Edition 0155

Connecting Rod - Tools


Connecting Rod - Tools 0018 P90462

Plate P90462-0018

When referring to this page, please quote Plate P90462 Edition 0018
MAN B&W Diesel A/S

Page 1 (2)

Plate P90462-0018 Item No.


023

Connecting Rod - Tools


Item No.

Item Description
Lifting tool for crankpin shell

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90462 Edition 0018
MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear


Documents in this Chapter
105-02 905-02 105-03 905-03 105-04 105-05 905-05 90551 90562 90564 90570 90571 90572 0086 0261 0075 0247 0050 0061 0230 0221 0123 0020 0003 0001 0001 Main Bearing, Data Main Bearing Thrust Bearing, Data Thrust Bearing Journal Bearing, Data Axial Vibration Damper, Data Axial Vibration Damper Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel Crankshaft - Tools Crankshaft - Measuring Tools Thrust Shaft - Tools Main Bearing Shell - Tools Main Bearing - Measuring Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Main Bearing
MAN B&W Diesel Data

105-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D05-01 D05-02 D05-03 D05-04 D05-05 D13-01 D13-02 Description Main bearing, top clearance max. Main bearing, top clearance min. Main bearing cap Main bearing shell, upper Main bearing shell, lower Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 0.85 0.60 1100 70 70 900 800 - 990 Unit mm mm kg kg kg bar bar

When referring to this page, please quote Data D10502 Edition 0086

Page 1 (2)

105-2

Main Bearing
Data MAN B&W Diesel

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

Plate P90551 P90551 P90551 P90551 P90551 P90551 P90551 P90551 P90551 P90551 P90562 P90571 P90572 P91351 P91351 P91351 P91351 P91351 P91356 P91366 P91366 P91366

Item No. 40 64 76 88 90 123 159 160 172 218 Pulley for wire for main bearing Pulley for wire for main bearing Lifting tool - main bearing cap

Description

Dismantling tool, main bearing shell Mounting tool for bearing shell Retaining tool for main bearing shell Eye bolt Wire Mounting tool, thin bearing shell Wire guide Lifting tool for crankshaft Main Bearing Shell - Tools Main Bearing - Measuring Tools

010 022 034 058 117 058 061 073

Hydraulic pump, pneumatically operated Hydraulic pump, hand operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Lifting Tools, Etc. Feeler gauge Slide caliper Dial gauge and stand tool

Page 2 (2)

When referring to this page, please quote Data D10502 Edition 0086

Main Bearing
MAN B&W Diesel
General The condition of the main bearings can be checked by: Deection readings Visual checking Edge checking and Measuring of top clearance.
M90502 0046C01

905-2.1

Checking
1.

Crankshaft deection readings Crankshaft deection readings should be taken while the ship is aoat (i.e. not while in dry dock). As the alignment is inuenced by the engine temperature as well as the loading conditions, deection measurements should, for comparison purposes, always be made under nearly the same temperature and load conditions. 1. Place a dial gauge axially in the crank throw opposite the crankpin, as illustrated on the sketch. The correct mounting position is marked with punch marks on the crank throw. See also Chapter 708 in Volume I.

2.
Positive (+)

Negative ( )
M90501 0208C02

2. Closing of the crank throw (compression of the gauge) is regarded as negative () and opening as positive (+). 3. Set the dial gauge to zero at the B1 side near BDC. Whilst turning clockwise, take the readings when the throw passes the positions: B1 C T E B2 (near bottom) (camshaft side)

3.

(top) (exhaust side) (near bottom)


M90501 0204C03

Looking forward B1 B B2 B1 C T E B2 (B1+B2)=B

1/2 (B2+B1) = B

When referring to this page, please quote Procedure M90502 Edition 0261

Page 1 (19)

905-2.1

Main Bearing
Checking MAN B&W Diesel

4.

4. When taking deection readings for the three aftmost cylinders, the turning gear should, at each stoppage, be turned a little backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise, this pressure may falsify the readings. For evaluation of the crankshaft deection readings, see Volume I, OPERATION, Chapter 708. If the crankshaft deection (alignment indicator) is approaching the tolerance limits (see Vol. I, OPERATION), the two adjacent main bearings must be checked for wear. See next page for checking of main bearing. If the bearings are found to be in good order, please contact MAN B&W Diesel or the engine manufacturer for checking of the bedplate alignment. As reference, use the after seatrial deection table. The condition of the bearing can be checked as follows: 5. Visually look for bearing metal fragments in the oil pan, and check the lters for metal fragments. Such fragments can be from crosshead, guide shoe or crankpin bearings. If fragments are found, the damaged bearing can be found by edge checking with a feeler. General Bearing damage usually propagates rather quickly towards the edge of the bearing where, eventually, it causes chips to be broken off, which means that loose pieces of white metal can fall down into the crankcase beneath the bearing support. Large, thick pieces will normally be found during a crankcase inspection, and small, thin pieces can enter the lter. A check of the bearing edges together with inspection of the crankcase and the lter normally provides a good indication of the bearing condition.

M90502 0046C01

5.

Page 2 (19)

M90501 0208C05

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
Checking the bearing edges 6. Bearing edges can be checked with a feeler that is able to follow the bearing edge against the journal the whole way round on each side. If white metal is missing at the edge, the tip of the feeler will enter the hole, thus locating the damage. In most cases this hole can be seen by the naked eye as a dark spot when using a strong ashlight. The No. 1 and the two aftmost main bearings are more difcult to access on the whole circumference on each side, but it is often possible to bend the feeler to suit the situation and thus reach as far round as possible. Wire-feeler 7. It is rather easy to make a feeler (see sketch). The feeler should be made from a piece of steel wire (e.g. a welding rod) approx. 0.6 - 1 m long depending on the engine type, and 2 to 3 mm thick. Approx. 7 to 10 mm of the wire should be bent to an angle of approx. 65 to form a feeler tip. Grind the tip smooth to obtain the shape and dimension shown on the sketch. Note that the thickness of the white metal is approx. 1.5 mm, which is why the tip should be less than 1.2 mm thick, and bigger than the max. top clearance. At the other end of the tip, a handle should be made by bending a hook or similar in the same direction as the tip. Note!
M90502 0252C06

905-2.1

Checking
6.

M90501 0208C06

Hole in the edge

7.
1 <1.2 mm >0.7 mm 7-10 mm

60-70 2-3 mm

500-1000

Wire feeler

The above dimensions of the wire-feeler are guideline values and may depend on the engine type as well as individual, personal designs.

When referring to this page, please quote Procedure M90502 Edition 0261

Page 3 (19)

905-2.1

Main Bearing
Checking MAN B&W Diesel

8.

8. If there is too large a difference in the crankshaft deection readings (autolog) check the clearance in the individual bearings. Bearing clearance checks should also be carried out during time-based overhauls and surveys. If there is a suspicion of a damaged bearing, it is recommended to edge check the bearing, without opening up. 9. Before measuring, check that the feeler blades are in good condition. The feeler is inserted along the crank throw. When the feeler hits the journal, it is horizontally pushed against the clearance. Now the feeler blade is pushed max. 20 mm into the gap. 10 The clearance is measured at both the fore and the aft part of the bearing.

M90501 0208C09

M90501 0208C08

9.

20

Note! The bearing clearances for a new bearing stated in Data (see Data 105-2) are for guidance purposes only.

10.

D05 01 D05 02

Page 4 (19)

M90502 0258C10

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel Checking

905-2.1

11. The difference between the actual clearance measurement and the measurement recorded in the adjustment sheet (or the clearance noted for a new bearing installed later) must not exceed 0.10 mm. If it does, see Volume I, Operation, Chapter 708. For evaluation of the bearing, see Volume I, Operation, Chapter 708. If the bearing needs to be disassembled for inspection, see procedure 905-2.2.
M90502 0227C03

When referring to this page, please quote Procedure M90502 Edition 0261

Page 5 (19)

905-2.2

Main Bearing
Dismantling MAN B&W Diesel

1.

Aftmost main bearing (= Journal bearing)

Positioning the crankshaft 1. Dismantling of main bearing. The bearings are divided into two categories: The main bearings The aftmost main bearing often referred to as Journal bearing (See Procedure 905-4).

M90502 0238D01

Main bearings Thrust bearing

2. Before any dismantling, check and write down the main bearing top clearances and crankshaft deection readings for the cylinder unit concerned. 3. Turn the crank throw to the position shown on the sketch and in such a way that the top of the studs is ush with the crank throw. Note! Be sure that the crosshead for the neighbouring cylinder is in a higher position than for the cylinder you are working on, otherwise it will be impossible to lift the cap.

2.

M90502 0238D02

3.

EXH SIDE

MAN SIDE

Page 6 (19)

M90502 0238D03

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
Oil pipes 4. Disconnect the lubricating oil pipe from the main pipe. Note! On some engines, the oil pipes for the Axial Vibration Damper (AVD) have to be removed together with the oil pipe on main bearing No. 1.

905-2.2

Dismantling
4.

Note! Some engines have temperature sensors tted to the main, crosshead, and crankpin bearings. These sensors must be carefully handled to avoid damaging the equipment.

Mounting of tools and tackles Mount pulley E, pulley F and the special eye bolt D, as shown on the sketch. Pulley F has to be tightened to full surface contact, i.e. using a spanner. On some engines the stop screw in the guide shoe has to be removed. Some are provided with a threaded hole. Check with a 0.05 mm feeler gauge that there is no clearance between the pulley and the stop screw (guide shoe). Note! Do not use pulley F if it is not tightened to full contact.

M90502 0238D04

5.

M90502 0236D05

When referring to this page, please quote Procedure M90502 Edition 0261

Page 7 (19)

905-2.2

Main Bearing
Dismantling MAN B&W Diesel

6.

6. Mount the wire guide as shown. The wire guide must be nally positioned when tightening the tackles. Mount the wire guide on the crosshead guide. Mount tackles in the following positions: A: a 3 ton chain tackle, in a wire strap around the beam. B: a 3 ton chain tackle. (On some engines a special bracket has to be mounted, before mounting the shackle.) C: a 3 ton pull lift D: a 1 ton tackle

D
M90502-0261D06

Loosening the nuts 7. Before mounting, check the jacks as shown in Procedure 913-1.

7.

8. Place the spacer rings over the nuts on the bearing cap. Screw down the extension studs on the main bearing studs. Place three hydraulic jacks on each spacer ring. Screw down the four upper nuts on the extension studs. Tighten them rmly. Then turn the upper nuts 3/4 turn backwards to obtain a clearance of about 4.5 mm. Note! Be sure to mount the spacer rings and the hydraulic jacks with the TOP mark upwards.

M90502 0253D09

D13-02

8.

D13-02
TO P TO P TO P

9. Connect the hydraulic jacks to the highpressure pump by means of the distributor block and high-pressure hoses. Bleed the entire hydraulic system and raise the pressure as indicated in Data. Then loosen the nuts. Remove the upper nuts, the hydraulic jacks, the spacer rings and the extension studs. Unscrew the main bearing nuts from the studs. For operation of the hydraulic jacks, see Chapter 913.

Page 8 (19)

M90502-0261D08

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
Removal of main bearing cap 10. 10. Mount the main bearing lifting tool on the main bearing cap. Place one wire rope around pulley E, as shown, and attach it in tackle A, from outside the engine. Tighten up tackle A and carefully lift the main bearing cap clear of the studs. Note! When tightening up the tackle, be sure that the wire guides are positioned correctly to protect crosshead guides and doorframe. 11. When clear of the studs, pull the other wire rope around wire guide F, as shown, and attach it to tackle C, below the door. Tighten tackle C and release tackle A, until the main bearing cap is suspended vertically below pulley F. 12. Remove the wire rope from tackle A and let it hang freely.
M90502 0238D17

905-2.2

Dismantling
P

D05-03
E P

M90502-0261D10

11.

F C A

Mount the short wire rope across the lifting tool. Mount the hook from tackle B (upper in the crankcase), in the short wire, and tighten it up. If necessary, pull the main bearing cap free of the crosshead guides, using tackle D, from the opposite web plate.

12.

F C

D E

When referring to this page, please quote Procedure M90502 Edition 0261

M90502 0252D12

Page 9 (19)

905-2.2

Main Bearing
Dismantling MAN B&W Diesel

13.

13. Release tackle C and at the same time, tighten tackle B until the bearing cap is hanging freely below tackle B. Release and unhook tackles C and D. 14. Attach the hook of tackle A, from outside the engine, to the short wire rope across the lifting tool. By tightening tackle A and releasing tackle B, lift the bearing cap out of the engine, and place it on a couple of wooden planks. Removal of upper bearing shell
C

D
M90502 0254D13

14.
B A

15. Mount the bearing shell lifting tool on the upper main bearing shell, pull the wire around pulley F, as shown, and attach it to tackle A outside the engine. Carefully lift the bearing shell, until it is hanging freely below the guideshoe.

D05 03

Lift the bearing shell out of the engine in the same way as the bearing cap.

D
M90502 0261D14

15.

D05-04

Page 10 (19)

M90502-0261D15

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
Removal of upper bearing shell 16. If the crankshaft is turned with the bearing cap dismounted, use the two stops to prevent the lower shell from being rolled out. 17. Place the crosspiece in the bedplate with the ends resting on the cross girders, and position the hydraulic jacks beneath the crank webs as shown. Tighten the screws against the crank webs and compress the jacks. Connect the hydraulic jacks to the high pressure pump, and raise the pressure until the crankshaft has been lifted 0.2-0.5 mm, but max. the clearance in the two adjacent bearings. Note down the pressure for later reference. 18. Check that there is min. 0.1 mm clearance between journal and bearing shell, or between bearing shell and main bearing support, on both sides of the journal. Note! The feeler blade must be inserted minimum 60 mm into the gap to pass the bore relief in the bearing shell. If the clearance is less than 0.1 mm, move the crosspiece sideways until clearance is obtained. Normally, adjustment needs to be 50-150 mm to the exhaust side (the side where the clearance is missing). Note! The lower shell must be lifted out to the side with the most clearance, which is normally the manoeuvre side.
M90502 0238D24

905-2.2

Dismantling
16.

17.

M90502 0238D27

18.

min 0.1 mm

Min. 60 mm

EXH

CAM

When referring to this page, please quote Procedure M90502 Edition 0261

M90502 0238D28

Page 11 (19)

905-2.2

Main Bearing
Dismantling MAN B&W Diesel

19.

19. If re-positioning of the crosspiece does not ensure a vertical lift, place a 5-tonne jack between the side wall and the crank throw, to correct the journal position in this way. If it is available, note down the pressure applied to the jack. This data is used to ensure that the crankshaft is in the same position when the new bearing is installed. Note!

M90502 0238D25

It is recommended that the crankshaft lifting tool is only removed if it is urgently necessary and then only after the main bearing shell has been reinstalled.

20. Dismount the locking screws. 20. Place the dismantling tool on top of the lower bearing shell. Make sure that the ap on the dismantling tool enters the oil groove in the bearing shell.

Page 12 (19)

M90502 0238D26

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel Dismantling
21.

905-2.2

21. Pull the lower shell around and up until it lies over the main bearing journal. Never use a tackle larger than 0.5 tonne. Note! While pulling out the shell, it is recommended to hold a foot or hand on the wire rope, to tighten it up and to observe whether the shell is sticking.

M90502 0236D27

22. Take the lower shell out of the engine in the same way as the upper shell, i.e. using the lifting tool.

22.

D05-05

When referring to this page, please quote Procedure M90502 Edition 0261

M90502-0261D22

Page 13 (19)

905-2.3

Main Bearing
Overhaul MAN B&W Diesel
Clean and inspect the bearing shells. It is 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 reinstalled. 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 MAN B&W Diesel for advice. Make sure that all parts are clean, use non-uffy cloth to clean between journal and main bearing support. Lubricate the bearing journal, the main bearing support and the back of the shell, with main engine lubricating oil.

1 + 2.

1.

Page 14 (19)

M90502 0252O01

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
Mounting of bearing shells 1. Using the bearing shell lifting tool, the pulleys and tackles, lift the lower bearing shell into the crankcase and land it on the crankshaft journal.

905-2.4

Mounting
1.

2. Position the guide tool for the lower bearing shell on the main bearing support. Remove the lifting tool from the bearing shell. Lubricate the journal, the lower bearing shell and the bearing support with clean oil. Place the lower bearing shell on the journal and push it down by hand. To ensure that the shell is correctly mounted, check that the distance from the main bearing support to the shell is equal in 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 hydraulic jacks and the crosspiece from below the crankshaft. Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-uffy piece of cloth.

When referring to this page, please quote Procedure M90502 Edition 0261

M90502 0252M03

M90502-0261M02

M90502-0261M01

D05-05

2.

3.

Page 15 (19)

905-2.4

Main Bearing
Mounting MAN B&W Diesel

4.

4. Land the upper bearing shell on the main journal in the same way as the lower bearing shell.

D05 04

Make sure that none of the edges of the upper 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 sure that no oil is left on the contact surfaces. 5. Mount the lifting tool on the bearing cap. Using the tackles and wire ropes on the main bearing cap lifting tool, lift the bearing cap into the crankcase in reverse order to dismantling. See Procedure 905-2.2, steps 22-21.

M90502 0252M04

5.
B A

D05 03

D
M90502 0261D14

Page 16 (19)

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel Mounting
6 a.
B

905-2.4

6. Using the pulleys mounted inside the crank case, move the bearing cap into position vertically above the crankshaft bearing journal in the reverse order to dismantling. See Procedure 905-2.2, steps 20-17. 7. Carefully lower the main bearing cap on to the upper bearing shell. Keep a hand on the wire rope while lowering, so that sticking of the bearing cap is immediately felt.

D
M90502 0254D13

6 b.

F C A

M90502 0252M07

7.

When referring to this page, please quote Procedure M90502 Edition 0261

M90502 0238M08

Page 17 (19)

905-2.4

Main Bearing
Mounting
8. Note! Be sure that the cap lands correctly and that the spring pin in the assembly surface enters the hole in the bearing cap.

MAN B&W Diesel

8.

9. Remove the bearing cap lifting tool. Screw the nuts on to the main bearing studs.
M90502 0238M09

Using a tommy bar, tighten the nuts on both sides of the bearing cap. Tightening of hydraulic nuts 10. Mount the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts. See Data and Procedure 905-2.2, step 5 and 6. After tightening the bearing cap, check the clearance once more. For operation of the hydraulic tools, see Procedure 913-1.

9.

M90502 0238M15

10.

D13-01
TO P TO P TO P

Page 18 (19)

M90502-0261M10

When referring to this page, please quote Procedure M90502 Edition 0261

Main Bearing
MAN B&W Diesel
11. Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal. 12. Remove all tools from the engine. Note!
M90502 0252M11

905-2.4

Mounting
11.

D05 01 D05 02

Search the crankcase to ensure that there are no tools, shackles or rags left behind. 13. Mount the lubricating oil pipe on the main bearing cap,

20

12.

M90502 0238M14

13.

When referring to this page, please quote Procedure M90502 Edition 0261

M90502 0252M13

Page 19 (19)

Thrust Bearing
MAN B&W Diesel Data

105-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D05-06 D05-07 D05-16 D13-01 D13-02 Thrust bearing segment Segment stopper End cover Hydraulic pressure, mounting Hydraulic pressure, dismantling Description Value 90 440 550 900 800 - 990 Unit kg kg kg bar bar

When referring to this page, please quote Data D10503 Edition 0075

Page 1 (2)

105-3

Thrust Bearing
Data MAN B&W Diesel

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

Plate P90551 P90662 P91351 P91351 P91351 P91351 P91356 P91366

Item No. 100 010 046 058 105 058 Tool for turning out segments Camshaft - Hydraulic Tools

Description

Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete Lifting Tools, Etc. Feeler gauge

Page 2 (2)

When referring to this page, please quote Data D10503 Edition 0075

Thrust Bearing
MAN B&W Diesel Checking

905-3.1

The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the Adjustment Sheet which is inserted at the front of Volume I, OPERATION. For a new engine the clearance is 0.5 1.0 mm, and for an engine in service it must not exceed 2.0 mm. In service it is only necessary to measure the wear of the thrust bearing pads, and to inspect for white metal particles below the thrust bearing. 1. A wear groove of 1 mm is positioned in the uppermost thrust segment. (The segment with thermometers) For measuring the wear, it is necessary to dismantle the foremost segment stopper. See Procedure 905 3.2. 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 overhauled. 3. Note down the wear for later reference.

1.

When referring to this page, please quote Procedure M90503 Edition 0247

M90503 0245C03

M90503 0245C02

M90503 0241C01

2.

3.

Page 1 (5)

905-3.2

Thrust Bearing
Dismantling
1.

MAN B&W Diesel

1.

Remove the end cover of the engine. Remove the lub. oil pipe from the aftmost main bearing shell. Remove the lub. oil pipe above the thrust segments. Remove the protecting shields from the thrust collar.

D05 16

2. Loosen and remove the nuts from the segment stoppers by using hydraulic tools.
M90503 0246D01

Dismount the stud, if necessary. 3. Mount the special lifting attachment in the chain drive and suspend a tackle over the stopper which has to be removed. Remove the stoppers above the thrust segment (AHEAD or ASTERN) that are to be taken out, and lift the stoppers out of the chain casing.

2.

M90503 0247D02

D13 02

3.

D05 07

Page 2 (5)

M90503 0247D03

When referring to this page, please quote Procedure M90503 Edition 0247

Thrust Bearing
MAN B&W Diesel Dismantling

905-3.2

4. Suspend a tackle from the chain tightener bracket above the segments which are to be removed. For turning up the thrust segments, mount the segment tool on the thrust cam, in the holes for the protective shields. 5. Turn up the segments, one at a time, by turning the engine, and remove the segment from the chain casing. Inspect the segment and remount it before turning up the next segment. See Procedure 905 3.4. Note! Never remove more than one segment at a time.

4.

M90503 0247D04

5.

D05 06

When referring to this page, please quote Procedure M90503 Edition 0247

M90503 0246D05

Page 3 (5)

905-3.4

Thrust Bearing
Mounting
1.

MAN B&W Diesel


Suspend a tackle from the crossbar above the segments which are to be mounted. Mount the segment tool on the chain wheel. Land the segment on the journal and remove the eye bolt from the segment. Carefully slide the segment on to the segment tool. Turn the engine to dismantle the next segment. See Procedure 905 3.2.

1.

D05 06

2. After the last segment has been mounted, turn the segment tool up and dismount it.

Page 4 (5)

M90503 0247M02

M90503 0247M01

2.

When referring to this page, please quote Procedure M90503 Edition 0247

Thrust Bearing
MAN B&W Diesel
3. Mount the segment stoppers. Mount the hydraulic jacks and tighten the nuts on the stoppers. See Data. Mount the protective shield. 4. Mount the lub. oil pipe for the thrust segments. Mount the lub. oil pipe for the aftmost main bearing. 5. Mount the end cover.
M90503 0247M03

905-3.4

Mounting

3.

D05 07

D13 01

4.

When referring to this page, please quote Procedure M90503 Edition 0247

M90503 0246M04

Page 5 (5)

Journal Bearing
MAN B&W Diesel Data

105-4

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D05-11 D05-12 D05-13 D05-14 D05-15 D05-16 D13-01 D13-02 Min. bearing clearance Max. bearing clearance Journal bearing cap Upper bearing shell Lower bearing shell End cover Hydraulic pressure, mounting Hydraulic pressure, dismantling Description Value 0.60 0.85 1100 70 70 550 900 800 - 990 Unit mm mm kg kg kg kg bar bar

When referring to this page, please quote Data D10504 Edition 0050

Page 1 (2)

105-4

Journal Bearing
Data MAN B&W Diesel

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

Plate P90551 P90551 P90551 P90551 P90551 P90561 P90570 P90571 P91351 P91351 P91351 P91351 P91356 P91366 P91366 P91366

Item No. 40 76 88 90 172 Pulley for wire for main bearing Lifting tool - main bearing cap

Description

Dismantling tool, main bearing shell Mounting tool for bearing shell Mounting tool, thin bearing shell Main Bearing - Hydraulic Tools Thrust Shaft - Tools Main Bearing Shell - Tools

010 034 058 117 058 061 073

Hydraulic pump, pneumatically operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Lifting Tools, Etc. Feeler gauge Slide caliper Dial gauge and stand tool

Page 2 (2)

When referring to this page, please quote Data D10504 Edition 0050

Axial Vibration Damper


MAN B&W Diesel Data

105-5

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D05-18 D05-22 D05-23 D05-24 D05-25 D13-01 D13-02 Description Inner studs, screwing-in torque Outer studs, screwing-in torque Horizontal screws, tightening torque Horizontal screws, tightening torque/angle Damper housing, upper part Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 27020 80020 215020 100/53 2025 900 800 - 990 Unit Nm Nm Nm Nm/ kg bar bar

When referring to this page, please quote Data D10505 Edition 0061

Page 1 (2)

105-5

Axial Vibration Damper


Data MAN B&W Diesel

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

Plate P90262 P90551 P90551 P90564 P91351 P91351 P91351 P91351 P91356 P90662

Item No. Hydraulic jack for piston rod 111 196 046 058 105 117 Lifting attachment Tightening template A.V.D. Crankshaft - Measuring Tools

Description

Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete 5-way distributor block, complete Lifting Tools, Etc. Camshaft - Hydraulic Tools

Page 2 (2)

When referring to this page, please quote Data D10505 Edition 0061

Axial Vibration Damper


Checking
For checking the effectiveness of the axial vibration damper, it is necessary to measure the longitudinal movements of the fore end of the crankshaft during running. The measurement (or reading) should be taken at the same r/min as during the sea trials. (Preferably 90% and 100% of MCR.) As different equipment can have been mounted on the specific engines, the checking procedure describes three different systems: A: Electronic, with Axial Vibration Monitor B. Mechanical, with angle encoder fore.

905-5.1

1.

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 peakto-peak movements and sends signals to the engine control system. 1. Concerning overhaul and setting of the electronic device, refer to makers instructions and Volume I, Operation, Chapter 701. The peak-to-peak values displayed in mm are to be compared with the original values obtained during sea trial and the limits given in Volume I, Operation, Chapter 701. If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

M90505 0229C01

Page 1 (6)

905-5.1

Axial Vibration Damper


Checking
B: Mechanical, with angle encoder fore

1. 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. 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. Attach a pencil to the arm. Note! 2. To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.

Page 2 (6)

M90505 0230C03

M90505 0230C02

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

Axial Vibration Damper


Checking
Start the engine, and let the speed rise to the number of revolutions at which the measurement is to be taken. (Preferably 90% and 100% of MCR.) 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. The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. Before comparing the measured value (S2) with the Normal Service Value (S1), stated in Volume I, Operation, Chapter 701 , it is necessary to compensate for the ratio in the tool. For a standard measuring tool (L1 = 38 mm and L2 = 200 mm), the ratio is 5.3. Therefore, S1 can be calculated as follows:
M90505 0229C04

905-5.1

3.

S2

4.

S1

L2 L1
If a non-standard tool is used, S1 can be calculated as follows:

S2

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

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

M90505 0229C10

Page 3 (6)

905-5.2

Axial Vibration Damper


Dismantling
1. Dismantling of the axial vibration damper is carried out from cyl. No. 1. Disconnect and remove the oil pipes from the foremost bearing cap and the axial vibration damper housing. Loosen and remove the No. 1 main bearing cap. See Procedure 905-2.2. Note! Before working on top of the main bearing shell, be sure that the open bearing is well protected, i.e. by use of clean rags.

1.

D13 02
M90505 0230D01

2.

Loosen and remove the nuts and screws from the damper housing upper part. 2. Only the upper part of the housing needs to be removed, while the lower half remains mounted on the bedplate. Mount the lifting tool on the upper part of the damper. Engines with chainbox fore: Mount a tackle in the bracket above the axial vibration damper inside the chain box.

M90505 0230D02

Engines without chainbox fore: Mount a tackle below the fore end platform, and dismount the cover on the lifting hole above the axial vibration damper.

3.

D05 25

3. By means of a tackle and wire rope, separate and raise the upper part of the damper housing. Note! Before working below the suspended upper part, secure the upper part e.g. by mounting two of the vertical screws in the upper threaded holes.

Page 4 (6)

M90505 0230D03

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

Axial Vibration Damper


Overhaul
1. Dismantle and remove the springs from the 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 lower housing. Then press the tension springs into the groove between the oil sealing ring half and the housing. 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 protrude above the centreline.

905-5.3

1.

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

M90505 0229O02

M90505 0230O01

2.

Page 5 (6)

905-5.4

Axial Vibration Damper


Mounting
1. Remove the screws securing the upper part of the damper housing. Release and carefully lower the upper part of the damper housing. When reaching the oil sealing rings, take care that the rings enter the sealing ring grooves correctly. Before landing the upper part on the lower part, be sure that the guide pins have entered the guide pin holes.

1.

M90505 0230M01

2. If the studs have been removed, re-mount them at this stage. For screwing-in torque, see Data. Remove the lifting tools.

2.

D05 18 D05 22

Mount the horizontal screws, without tightening. Mount the nuts on the vertical studs, and tighten them two by two, using the hydraulic jacks. For operation of the hydraulic tools, see Procedure 913-1. Tighten the horizontal screws, see Data.

D05 24
M90505 0230M02

D13 01

Mount and tighten the main bearing cap. See Procedure 905-2.4. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind.

Mount the lubricating oil pipes for damper and main bearing. Engines without chainbox fore: Mount the cover for the lifting hole above the axial vibration damper. Note! After overhaul of the axial vibration damper, it is recommended to check the axial vibrations. See Procedure 905-3.1.

Page 6 (6)

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel

Plate P90551-0221

When referring to this page, please quote Plate P90551 Edition 0221
MAN B&W Diesel A/S

Page 1 (2)

Plate P90551-0221 Item No.


015 027 040 064 076 088 090 100 111 123 159 160 172 196 218

Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel


Item No.

Item Description
Panel for tools Name plate Pulley for wire for main bearing Pulley for wire for main bearing Lifting tool for main bearing cap Dismantling tool for main bearing shell Mounting tool for thin bearing shell Tool for turning out segments Lifting tool for main bearing cap Retaining tool for relief valve Eye bolt Wire Mounting tool for thin bearing shell Tightening template A.V.D. Wire guide for main bearing

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90551 Edition 0221
MAN B&W Diesel A/S

Crankshaft - Tools
Crankshaft - Tools 0123 P90562

Plate P90562-0123

When referring to this page, please quote Plate P90562 Edition 0123
MAN B&W Diesel A/S

Page 1 (2)

Plate P90562-0123 Item No.


015

Crankshaft - Tools
Item No.

Item Description
Lifting tool for crankshaft

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90562 Edition 0123
MAN B&W Diesel A/S

Crankshaft - Measuring Tools


Crankshaft - Measuring Tools 0020 P90564

Plate P90564-0020

Flange on end of crankshaft

Flange on end cover fore

Z
When ordering item 016 or 028, please always state measurement Z

When referring to this page, please quote Plate P90564 Edition 0020
MAN B&W Diesel A/S

Page 1 (2)

Plate P90564-0020 Item No.


016 028 041 053

Crankshaft - Measuring Tools


Item No.

Item Description
Measuring instruments, axial vibration damper Shaft, measuring instruments axial vibration Measuring instruments, axial vibration damper Handle - sundry types

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90564 Edition 0020
MAN B&W Diesel A/S

Thrust Shaft - Tools


Thrust Shaft - Tools 0003 P90570

Plate P90570-0003

When referring to this page, please quote Plate P90570 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P90570-0003 Item No.


019

Thrust Shaft - Tools


Item No.

Item Description
Lifting tool, thrust shaft

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90570 Edition 0003
MAN B&W Diesel A/S

Main Bearing Shell - T ools Tools


MAN B&W Diesel

Plate P90571-0001

When referring to this page, please quote Plate P90571 Edition 0001

Page 1 (2)

Plate P90571-0001 Item No.


014

Main Bearing Shell - T ools Tools


MAN B&W Diesel Item No.

Item Description
Lifting tool for main bearing shell

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90571 Edition 0001

Main Bearing - Measuring T ools Tools


MAN B&W Diesel

Plate P90572-0001

When referring to this page, please quote Plate P90572 Edition 0001

Page 1 (2)

Plate P90572-0001 Item No.


021 033 045 069 070 082 094 104 116 128 141 153 165 177 189 190 200 212 224 236 248 261 273 285 332 344 356 368 381 393 403 415 427 439 440 452 464 476 488 511 523 535 547 559 560 Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

Main Bearing - Measuring T ools Tools


MAN B&W Diesel Item No.

Item Description
gauge set gauge set gauge set gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler

Item Description

gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge

Page 2 (2)

When referring to this page, please quote Plate P90572 Edition 0001

906 - Control Gear


Documents in this Chapter
106-01 906-01 106-02 906-02 106-03 906-03 106-04 906-04 90651 90664 0051 0246 0067 0230 0043 0218 0045 0219 0203 0001 Chain, Data Chain Chain Tightener, Data Chain Tightener Camshaft, Data Camshaft Camshaft Bearings, Data Camshaft Bearings Chain Drive and Camshaft - Panel Crankshaft - Pin Gauge

MAN B&W Diesel A/S

MAN B&W Diesel A/S

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

106-1

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

Stop lubricating oil supply Lock the turbocharger rotors

Data
Ref. Description Value Unit

D06-18 D06-19 D06-20

Teeth on chain wheel, max. wear Original length (chain pitch x 10 links) 10 links measurements + 1% of a tensioned chain = scrapping of chain

4 1143 1154.4

mm mm mm

When referring to this page, please quote Data D10601 Edition 0051 MAN B&W Diesel A/S

Page 1 (2)

106-1

Chains
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90651 P90651 Item No. 70 81 Chain assembling tool Chain disassembling tool Description

Page 2 (2)

When referring to this page, please quote Data D10601 Edition 0051 MAN B&W Diesel A/S

Chains
MAN B&W Diesel
1. The engine is equipped with a set of chains: 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 stoppages or deformations. Examine the rubber track of the guideways for cracks or other damage. Replace the guideway if bits have started to be plucked out of the rubber track. 4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement (See Data). Measurements are best taken by placing a short straight edge over the straight part of the chain wheel and then measuring the distance D06 18.

906-1.1

Checking

1.

M90601-0246C01

4.

D06 18
M90601 0245C02

When referring to this page, please quote Procedure M90601 Edition 0246

Page 1 (6)

906-1.1

Chains
Checking MAN B&W Diesel

5.

5. If abnormal wear is observed at the bottom of the teeth, make a drawing in scale 1:1 of the teeth and wear prole. Draw two rulers on the drawing. For assessing the wear prole, contact MAN B&W Diesel.

M90601 0244C05

10 0 10

Scale 1:1

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. 6. The chains for the camshaft drive are 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 running in period. These ne scratches are of no importance and need not be considered. It is recommended that each single link is checked.

Page 2 (6)

When referring to this page, please quote Procedure M90601 Edition 0246

Chains
MAN B&W Diesel
7.

906-1.1

Checking
7.

Check chain wear by measuring the length of 10 chain links. Use two master squares 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 906 2.3.

D06 19 D06 20

Ma x.D 20 06

When referring to this page, please quote Procedure M90601 Edition 0246

M90601 0245C07

Page 3 (6)

906-1.2

Chains
Dismantling MAN B&W Diesel

1.

It may become necessary to disassemble the chain if, for instance, cracked rollers or seizures between pin and bushing have been discovered during the inspection. See Procedure 906 1.1. Note! Every time a chain link is disassembled, a new link must always be tted as the link pin press t is destroyed when breaking the chain. When a new link is tted in one chain, the corresponding link in the other chain must also be renewed.

1.

Remove the tension on the chain by loosening the chain tightener. (See Procedure 906 2.3). Turn the engine until the slack part of the chain, with the chain link that is to be disassembled, is in a favourable position for the work.

M90601-0246C01

2.

2. Mount a wire round the link rollers a short 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 information.

M90601 0238D02

The riveting of the pins that are to be pressed out is to be chiselled or ground away.

Page 4 (6)

When referring to this page, please quote Procedure M90601 Edition 0246

Chains
MAN B&W Diesel Dismantling

906-1.2

3. Place the chain bursting tool over the outer chain link, and dismantle the link by alternately tightening the screws on the tool.

3.

When referring to this page, please quote Procedure M90601 Edition 0246

M90601 0238D03

Page 5 (6)

906-1.4

Chains
Mounting MAN B&W Diesel
Before assembling the inner and outer links, clean the pins and bushings. 1. Combine the inner chain link with the outer chain link and mount the compression tool. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool. 2. When the link has been assembled, remove the compression tool and lock the pin ends by riveting.

1.

M90601 0238M01

Repeat this procedure until the chain has been assembled. Remove the tackle and wire and adjust the chain tension. (See Data and Procedure 906 2.3).

Page 6 (6)

When referring to this page, please quote Procedure M90601 Edition 0246

Chain Tightener
MAN B&W Diesel Data

106-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D06-21 D06-25 Description Tightening angle = 5 hexagons Mechanical or blocked chain tightener, clearance Value 300 0.1 mm Unit

When referring to this page, please quote Data D10602 Edition 0067

Page 1 (2)

106-2

Chain Tightener
Data MAN B&W Diesel

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

Plate P90651 P90651

Item No. 070 081 Chain assembling tool Chain disassembling tool

Description

Page 2 (2)

When referring to this page, please quote Data D10602 Edition 0067

Chain Tightener
Adjustment
Chain Tightener S60MC-C 0230 Adjustment 906-2.3

906-2.3

1. To retighten the chains, loosen nuts A, B, C and D to free the chain tightener bolt. 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 until there is a clearance between the shaft 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.

1. A B

C
HG906-2.3 218 01

2.

HM906-2.2 95 01

3.

D06-25 D06-21

When referring to this page, please quote Procedure M90602 Edition 0230 0$1 % : 'LHVHO $6

HG906-2.3 218 03

Page 1 (2)

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 scrapping the chain has been reached. See Data page 106-1.

C D

HG906-2.3 218 05

5. A

Page 2 (2)

HG906-2.3 218 05

When referring to this page, please quote Procedure M90602 Edition 0230 0$1 % : 'LHVHO $6

Camshaft
MAN B&W Diesel Data

106-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D06-27 D06-28 Description Max. permissible change in lead angle corresponding to Value 2 5.6 mm Unit

When referring to this page, please quote Data D10603 Edition 0043

Page 1 (2)

106-3

Camshaft
Data MAN B&W Diesel

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

Plate P90664 P90668

Item No. Crankshaft - Pin Gauge Camshaft - Pin Gauge

Description

Page 2 (2)

When referring to this page, please quote Data D10603 Edition 0043

Camshaft
MAN B&W Diesel
1.

906-3.1

Checking
1.

Turn the crank throw for cylinder 1 to TDC. Turn in the ahead direction to ensure that the tension of the chain on the chain drive is correct. If necessary, adjust the chain tension. See Procedure 906-2.3. Check the TDC of cylinder 1 against the mark on the turning wheel.

On some engines the pin gauges can be checked against punch marks made on the front cylinder frame.

M90603 0218C01

2. Use the check measurement value stamped on the pin gauges to check the pin gauges for deformation.

2.

Check

Che ck
M90603 0218C02

When referring to this page, please quote Procedure M90603 Edition 0218

Page 1 (4)

906-3.1

Camshaft
Checking MAN B&W Diesel

3.

3. Check the TDC position with the pin gauge on the crank throw. Position the camshaft pin gauge in the centre punch mark, and measure the deviation, if any, in lead angle. For max. permissible change, see D06-27 and D06-28. 4. Check and, if necessary, adjust the cylinder lubricator. See Procedure 903-2.1.

M90603 0218C03

Check the setting of the starting air distributor. See Procedure 907-1.1. 4. 5. 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 inspection. The running surface of the cam must be completely smooth and bright.

M90603 0218C04

D06 27 D06 28
5.

Page 2 (4)

M90603 0218C05

When referring to this page, please quote Procedure M90603 Edition 0218

Camshaft
MAN B&W Diesel Checking
6.

906-3.1

6. If light scratches are ascertained, remove them by carefully polishing the cam in the direction of rotation with a ne carborundum stone. Such light scratches can appear if the roller guide and the cam are not correctly aligned. In the event of heavier scratches or direct aking of the material on the running path, MAN B&W Diesel should be contacted for further instructions.

When referring to this page, please quote Procedure M90603 Edition 0218

M90603 0218C06

Page 3 (4)

906-3.3

Camshaft
Adjustmentl
1.

MAN B&W Diesel

1.

If the chains prove to be so heavily worn that the deviation between the measuring points and the pin gauge has reached the maximum value D06-27 and D06-28 stated in Data, MAN B&W Diesel should be contacted for further instructions.

M90603 0218O01

D06 27 D06 28

Page 4 (4)

When referring to this page, please quote Procedure M90603 Edition 0218

Camshaft Bearings
MAN B&W Diesel Data

106-4

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D06-34 D06-36 D06-37 D06-65 D13-01 D13-02 Bearing shell, max. wear Oil pan Camshaft bearing cap Bearing shell, minimum thickness Hydraulic pressure, mounting Hydraulic pressure, dismantling Description Value 0,1 130 150 6,35 900 800 - 990 Unit mm kg kg mm bar bar

When referring to this page, please quote Data D10604 Edition 0045

Page 1 (2)

106-4

Camshaft Bearings
Data MAN B&W Diesel

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

Plate P90662 P91351 P91351 P91351 P91351

Item No. Camshaft - Hydraulic Tools 010 034 058 105

Description

Hydraulic pump, pneumatically operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete

Page 2 (2)

When referring to this page, please quote Data D10604 Edition 0045

Camshaft Bearing
Checking
Camshaft Bearing S60MC 0219 Checking 906-4.1

906-4.1

1. As the upper shell of the camshaft bearing assembly has been dispensed with on this engine, it is no longer necessary to measure the top clearance of the camshaft bearing. However, with normal inspection through the inspection hole in the roller guide housing, we recommend a visual inspection of the condition of the shell in the bearing cap from each side. Check for wiped-out metal at the bearing ends, and for fragments of metal in the camshaft housing.
HC906-5.0 57 01

1.

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 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.

When referring to this page, please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S

Page 1 (5)

906-4.2

Camshaft Bearing
Dismantling
Dismantling 906-4.2

1. Caution! Before dismantling any camshaft bearings, the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts.

See Procedure 906-2.3.


1. Dismount the oil outlet pipe from the oil tray. Mount an eye bolt in the cylinder frame behind the oil tray.
HC906-5.0 57 02

Release the sealing flanges on the roller guide housing, loosening the screws mounted in the roller guide housing. 2. Remove only the screws in the lower half of the sealing flange. 2. Attach a wire rope to the eye bolt. Place the wire rope in the lifting fitting of the oil tray, hook on a tackle and haul tight. Remove the screws securing the oil tray to the roller guide housing. Ease off the oil tray, landing it on the platform. 3. Mount lifting fittings on both sides of the bearing half. Mount grooved pulleys on the roller guide housing, and hook wire ropes/ tackles on to the lifting fittings/grooved pulleys. Tighten up the tackles.

D06-36

HC906-5.0 57 03

3.

HG906-4.3 201 03

Page 2 (5)

When referring to this page, please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S

Camshaft Bearing
Dismantling
4.

906-4.2

4. Mount the hydraulic jacks and loosen the bearing nuts. For use of hydraulic jacks, see Procedure 913-1. Remove the hydraulic jacks and dismount the nuts. 5. Lower the bearing cap and place it on the platform.

HG906-4.3 201 04

D13-02

5.

D06-37
HC906-5.0 57 06

When referring to this page, please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S

Page 3 (5)

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

HC906-5.0 57 07

2.

MA906-4.3 209 02

D06-34 D06-65

Page 4 (5)

When referring to this page, please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S

Camshaft Bearing
Mounting
Mounting 906-4.4

906-4.4

1. Clean the bearing journal, the bearing support and the bearing shell. Mount the bearing shell in the bearing cap, after coating the shell with oil. Then pull the bearing cap into place by means of tackles/ wire rope fitted through the grooved pulleys to the lifting fittings. Check that the guide pins enter correctly. 2. Mount and tighten up the nuts by means of the hydraulic tools. See Data. Remove the lifting fittings and grooved pulleys from the roller guide housing. 3. Hoist the oil tray into place, positioning it by means of the guide pins. Then fasten it to the roller guide housing by tightening up uniformly all round the circumference. Remove the shackle and eye bolt. Mount the screws that fasten the sealing flanges to the roller guide housing. Mount the oil pipe on the oil tray.
HC906-5.0 57 06

1.

D06-37
2.

D13-01
HG906-4.3 201 04

3.

D06-36
HC906-5.0 57 03

When referring to this page, please quote Procedure M90604 Edition 0219 MAN B&W Diesel A/S

Page 5 (5)

Chain Drive and Camshaft Panel

Plate P90651-0203

When referring to this page, please quote Plate P90651 Edition 0203
MAN B&W Diesel A/S

Page 1 (2)

Plate P90651-0203 Item No.


019 020 044 056 068 070 081 127 139

Chain Drive and Camshaft Panel


Item No.

Item Description
Panel for tools Name plate Pin spanner for fuel cam Chain assembling tool Chain disassembling tool Chain assembling tool Chain disassembling tool Pulley for wire Lifting attachment

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90651 Edition 0203
MAN B&W Diesel A/S

Crankshaft - Pin Gauge

Plate P90664-0001

When referring to this page, please quote Plate P90664 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90664-0001 Item No.


021

Crankshaft - Pin Gauge


Item No.

Item Description
Pin gauge for crankshaft

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90664 Edition 0001
MAN B&W Diesel A/S

907 - Starting Air System


Documents in this Chapter
107-01 907-01 107-02 907-02 0019 0219 0041 0217 Starting Air Distributor, Data Starting Air Distributor Start Air Valve, Data Starting Air Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Starting Air Distributor


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

107-1

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10701 Edition 0019 MAN B&W Diesel A/S

Page 1 (2)

107-1

Starting Air Distributor


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D10701 Edition 0019 MAN B&W Diesel A/S

Starting Air Distributor


Checking
Starting Air Distributor K98MC-C 0219 Checking 907-1.1

907-1.1

1. Turn the engine in AHEAD direction to bring the piston of cylinder No. 1 to TDC. Check the position with the pin gauge. See Procedure 906-3.1. 2. Remove the small end cover of the distributor housing. 3. Check that the guide pin holes in the starting cam coincide or that the guide pins are mounted and the TDC marking scratch on the starting cam is positioned vertically in line with the marking scratch at the valve slide of cylinder No. 1. If the scratch marks are out of alignment, the starting cam must be dismantled. 4. Remove all the slide valves, see Procedure 907-1.3. Unlock the centre screw and remove the screw. Pull off the starting cam by means of two dismantling screws. Check the guide pins. If the guide pins are bent or broken, remove the pins and mount new pins. Remount the starting cam, and the centre screw. Note! The starting cam must always be provided with guide pins. Mount the slide valve for cylinder No. 1 and check the alignment once more. If the scratch marks are out of alignment, contact MAN B&W Diesel for advice.

2.

HN907-1.1 205 02

3.

When referring to this page, please quote Procedure M90701 Edition 0219 MAN B&W Diesel A/S

M90701-0219C03

Page 1 (5)

907-1.3

Starting Air Distributor


Overhaul
Overhaul 907-1.3

2.

Difficulties in starting can be caused by the starting air distributor valve slides sticking (see Volume I, Chapter 703), so that these are not activated and pressed against the cam during the starting procedure. This can be caused by too high humidity in the main starting air system, which can result in the formation of rust, and also by dirt, preventing the slide valves from functioning. In both cases it is necessary to clean the valve slides and the liners in the distributor housing to remove dirt, rust and foreign particles.

HN907-1.3 205 02

3.

Experience will show how often this is necessary to prevent starting difficulties, as differences will be found from plant to plant. 1. Blank off the main starting air and the control air. If this is not possible, lock the main starting valve in the closed position with a padlock. 2. Remove all the pipes from the end of the distributor. Loosen and remove the screws from the small and large end covers. Dismount the end cover which gives access to the slide valves.

HN907-1.3 205 03

3. Turn the camshaft until the pin of the valve slide (cam follower) can be pushed clear of the starting cam. 4. 4. Remove the screws and the cap from the particular valve slide in question. Remove the guide screw for the valve slide.

Page 2 (5)

HN907-1.3 205 04

When referring to this page, please quote Procedure M90701 Edition 0219 MAN B&W Diesel A/S

Starting Air Distributor


Overhaul
5.

907-1.3

5. Remove the complete slide valve (with spring and the upper liner) from the distributor housing by means of a brass mandrel. 6. Press-in the spring and remove the two part locking ring. 7. Remove the upper spring guide, the spring, the lower spring guide and the upper liner from the valve slide.

907-1.3 217 05

6.

M90701-0219O06

7.

When referring to this page, please quote Procedure M90701 Edition 0219 MAN B&W Diesel A/S

M90701-0219O07

Page 3 (5)

907-1.3

Starting Air Distributor


Overhaul

8.

8. Clean all the sliding surfaces on the valve slide. Check the sliding surfaces for wear and seizures, also check the cam follower for wear. Clean the liners and the distributor housing. Test that the valve slide moves easily in the liners. Note!

M90701-0219O08

Polishing of the liners with emery cloth must not take place as small particles of the grinding material can stick in the surface of the liner. Lubricate all parts with Molybdenum Disulphide (MoS2), also the cam follower must be well lubricated. 9. Place the upper liner, the lower spring guide, the spring and the upper spring guide over the valve slide. 10. Press-in the spring and mount the two-part locking ring. 11. Mount the complete slide valve in the distributor housing. (Check that the pin of the valve slide goes clear of the starting cam when mounting). Lubricate the groove in the starting cam with Molybdenum Disulphide (MoS2). 11.

10.

Page 4 (5)

M90701-0219O11

M90701-0219O10

When referring to this page, please quote Procedure M90701 Edition 0219 MAN B&W Diesel A/S

Starting Air Distributor


Overhaul
12.

907-1.3

12. Mount the guide screw for the valve slide. Mount the cap and the screws on top of the slide valve. 13. Check that the piston valve slides can be pushed up and down by hand just overcoming the force of the spring. 14. Finally, mount the two end covers and connect the main starting air and the control air.
M90701-0219O12

14.

When referring to this page, please quote Procedure M90701 Edition 0219 MAN B&W Diesel A/S

HN907-1.3 205 02

Page 5 (5)

Starting Air Valve


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

107-2

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

Data
Ref. Description Value Unit

D07-09 D07-11 D07-12

Piston tightening torque Valve tightening angle Starting air valve

140 60 75

Nm kg

When referring to this page, please quote Data D10702 Edition 0041 MAN B&W Diesel A/S

Page 1 (2)

107-2

Starting Air Valve


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90151 P90151 Item No. 95 105 Grinding ring for starting valve Grinding handle for starting valve Description

Page 2 (2)

When referring to this page, please quote Data D10702 Edition 0041 MAN B&W Diesel A/S

Starting Air Valve


Checking
Starting Air Valve K98MC 0217 Checking 907-2.1

907-2.1

1. When the starting air valve has been overhauled, see Procedure 907-2.3, connect a supply of working air to the control air inlet at the top of the valve. Check that the valve opens approx. 15-20 mm. 2. Shut off the air supply Check that the valve closes fully. 3. Repeat steps 1 and 2 a couple of times.

1.

HM907-2.1 202 01A

2.

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

HM907-2.1 202 01B

Page 1 (6)

907-2.2

Starting Air Valve


Dismantling
Dismantling 907-2.2

1.

1. Shut off the starting air and control air inlet. Dismount the control air pipes Mount two eye bolts in the top cover of the valve. Hook a lifting wire on to the eye bolts. Unscrew the fixing nuts of the starting valve flange. 2. Lift away the starting valve.

HG901-2.2 59 02

2.

D07-12

HG907-2.3 201 02

Page 2 (6)

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

Starting Air Valve


Overhaul
Overhaul 907-2.3

907-2.3

1. Place the starting air valve horizontally in a bench vice provided with soft jaws. Remove and discard the O-ring from the valve housing. 2. Loosen and remove the screws from the top cover. Dismount the top cover. 3. Use the face wrench for the spindle as a back-stop when loosening the two screws which tighten the piston to the spindle. Remove the screws and discard the locking device. When unscrewing, the piston will partially be pressed out of the valve housing due to the spring force.

1.

HM907-4.0 39 01

2.

HM907-4.0 39 02

3.

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

HM907-4.0 39 03

Page 3 (6)

907-2.3

Starting Air Valve


Overhaul

4.

4. Remove the piston from the top end of the valve housing. Take out the spindle from the bottom end of the valve housing. Remove the spring from the top end of the housing. 5. Apply grinding paste, e.g. carborundum No. 200. Grind the valve housing seating with the grinding ring. 6. When lapping the seatings of the spindle and valve housing to match, use the face wrench to rotate the spindle. As grinding paste, use e.g. carborundum No. 500.

HM907-4.0 39 04

5.

HM907-4.0 39 05A

6.

MG907-4.0 51 05B

Page 4 (6)

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

Starting Air Valve


Overhaul
7.

907-2.3

7. Thoroughly clean the valve housing and all the parts in diesel oil or kerosene. Lubricate all internal parts and sliding surfaces with, e.g., Molybdenum Disulphide, MoS 2. Insert the spindle in the valve housing. Then mount the spring in the housing around the spindle and, finally, place the piston on top of the spindle. 8. Fit the discs and the two screws. When tightening the screws, the piston will compress the spring. Tighten the screws continuously until the piston faces tightly against the spindle. Use the face wrench as a back-stop. See Data.
HM907-4.0 39 07

Lock the screws with locking device. For correct use of locking device, see Procedure 913-7. 9. Mount and tighten the top cover. Fit a new O-ring on the valve housing. 10. Check the starting air valve. See Procedure 907-2.1. If the valve is not to be mounted in the engine immediately, cover all openings with plastic to prevent dirt from entering the valve during storage.

9.

D07-09

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

HM907-4.0 39 09

Page 5 (6)

907-2.4

Starting Air Valve


Mounting
Mounting 907-2.4

1.

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

HG907-2.4 201 01

3. Mount the nuts and tighten-up in at least three steps, to reach the full tightening angle, see Data. Mount the control air pipe and turn on starting air and control air. 2.

D07-12

HG907-2.4 201 02

3.

D07-11

HM901-2.2 114 03

Page 6 (6)

When referring to this page, please quote Procedure M90702 Edition 0217 MAN B&W Diesel A/S

908 - Exhaust Valve


Documents in this Chapter
108-01 908-01 108-02 908-02 108-03 908-03 108-04 908-04 108-05 908-05 108-07 908-07 90851 90861 90862 90863 90864 0037 0226 0094 0269 0057 0227 0041 0222 0017 0219 0034 0228 0177 0022 0036 0015 0003 High-Pressure Pipe, Data High-Pressure Pipe Exhaust Valve, Data Exhaust Valve Exhaust Valve Actuator, Data Exhaust Valve Actuator Exhaust Valve Roller Guide, Data Exaust Valve Roller Guide Exhaust Valve Cam, Data Exhaust Valve Cam Exhaust Valve - Special Running, Data Exhaust Valve Exhaust Valve - Panel Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools Exhaust Valve - Extra Tools Exhaust Valve - Extractor Tool

MAN B&W Diesel A/S

MAN B&W Diesel A/S

High-Pressure Pipe
Data SAFETY PRECAUTIONS
Special Edition D10801 S80MC 108-1 Data 0037 High-Pressure Pipe

108-1

X X X

Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil

Shut off lubricating oil Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-01 D08-02 D08-03

High-pressure pipe, tightening torque Distance of high pressure pipe lower edge to pressure flange High-pressure pipe

170 Nm 20 mm 100 kg

When referring to this page, please quote Data D10801 Edition 0037 MAN B&W Diesel A/S

Page 1 (2)

108-1

High-Pressure Pipe
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

P90851

112

Grinding mandrel for high-pressure pipe

Page 2 (2)

When referring to this page, please quote Data D10801 Edition 0037 MAN B&W Diesel A/S

High-Pressure Pipe
Dismantling
908-1.2 Disling 908-1.2 Dismantling

908-1.2

1.

1. When replacing the hydraulic high-pressure pipe, the exhaust valve or the hydraulic actuator, 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 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.

D08 03

When referring to this page, please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S

M90801 0226D02

M90801 0226D01

2.

Page 1 (3)

908-1.3

High-Pressure Pipe
Overhaul
1. Check the contact surfaces of the pressure pipe for marks and, if necessary, grind the pipe ends by means of the grinding mandrel and the two guiding tools. Start grinding with a coarse grinding paste, for example Carborundum No. 200, and finish with a fine grinding paste, for example Carborundum No. 500. 2. After reconditioning the contact surfaces of the pipe, measure the distance from the edge of the thrust bushing to the contact surface at both ends of the pipe. This measurement is to correspond with the value stated in Data. Check the thrust pads in the exhaust valve and the actuator for marks on the sealing surface. Replace the O-rings on the thrust pads. If considered necessary, replace the thrust pads. Lift the thrust pad free by, for example, using a screwdriver in the groove of the thrust pad.

1.

M90801 0226O01

Carborundum

2.

M90801 0226O02

D08 02

Page 2 (3)

When referring to this page, please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S

High-Pressure Pipe
Mounting
1. Mount the hydraulic high-pressure pipe as follows: Position the high-pressure pipe with the sealing surfaces of the pipe resting on the thrust pads of the exhaust valve/actuator. Take care not to damage the O-rings on the thrust pads. After fitting the pipe correctly in relation to the exhaust valve and actuator, tighten up the screws of the pressure flanges diagonally, see Data. 2. Check the whole system for tightness. See Procedure 908-3.1.

908-1.4

1.

M90801 0226M01

D08 01

2.

When referring to this page, please quote Procedure M90801 Edition 0226 MAN B&W Diesel A/S

M90801 0226M02

Page 3 (3)

Exhaust Valve
MAN B&W Diesel Data

108-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D08-04 D08-05 D08-06 D08-07 D08-09 D08-10 D08-11 D08-12 D08-13 D08-14 D08-15 D08-16 D08-17 D08-18 D08-19 D08-20 D08-21 D08-22 D08-23 D08-24 D08-25 D08-26 D08-27 D08-28 D08-29 D08-30 D13-01 D13-02 Description Safety valve, opening pressure Screws for lifting eye bolt, tightening torque Oil cylinder, tightening torque Safety valve, tightening torque Bottom piece seat, grinding angle Valve spindle seat, grinding angle Bottom piece seat, max. grinding Gap of bottom piece seat Spindle, max. burn-off Spindle, max. grinding Spindle stem, measuring area, min. Spindle stem, measuring area, max. Spindle stem, min. diameter Bushing max. diameter, top Bushing max. diameter, bottom Oil cylinder max. inside diameter Piston rings, min. thickness Damper piston, min. distance Damper piston, max. distance Exhaust valve, complete Exhaust valve housing Oil cylinder Air cylinder Spindle Bottom piece Air piston Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 21 215 215 70 - 100 29.9 - 30.0 30.5 - 30.6 2.3 1.0 11.0 2.0 385 545 95.8 96.7 99.5 112.2 4.2 48,4 51,4 1700 950 230 70 180 220 22 900 800 - 990 Unit bar Nm Nm Nm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg kg kg bar bar

When referring to this page, please quote Data D10802 Edition 0094

Page 1 (2)

108-2

Exhaust Valve
Data MAN B&W Diesel

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

Plate P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90861 P90862 P91351 P91351 P91351 P91351

Item No. 065 077 089 090 136 148 150 161 185 Lifting tool for exhaust valve Cone ring for pneumatic piston Pressure tester for safety valve Gauge for exhaust valve spindle Bridge gauge for exhaust valve Tool for hydraulic piston

Description

Gauge for exhaust valve bottom piece Lifting tool for exhaust valve spindle Grinding ring for exhaust valve bottom piece Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools

010 046 060 117

Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (5000 mm), complete 5-way distributor block, complete

Page 2 (2)

When referring to this page, please quote Data D10802 Edition 0094

Exhaust Valve
MAN B&W Diesel
Checks during running: 1. Check of valve spindle rotation The engine must run when the valve function 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 movements of the valve spindle and the air piston. During rotation of the valve spindle, the top position of the indicator will change about 6 mm, because of the groove in the piston. During engine operation, the spindle must rotate. The rotation can vary with unit and engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is nished, lift the rotation indicator and lock it in the top position. The indicator must not be in constant operation. Exhaust valve performance condition See volume I chapter 706 Performance Evaluation
M90802 0256C02

908-2.1

Checking

1.

M90802 0252C01

On Surface

InGroove

2.

2. Check of sealing oil unit Check that the injection indicator moves regularly with the valve opening. Alternatively, unscrew the sealing oil pipe, and check that oil is coming out (very small quantity). Depending on valve model the indicator is placed either on the manoeuvre side or the front side

When referring to this page, please quote Procedure M90802 Edition 0269

Page 1 (25)

908-2.1

Exhaust Valve
Checking MAN B&W Diesel

3. Check of bottom piece sealings 3. With the exhaust valve mounted in the cylinder cover, check the cooling water inlet and outlet to the cylinder cover and exhaust valve is open. Check the tightness of the sealing rings between the bottom piece and the exhaust valve housing. IF water ows from the small bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is leaking.
M90802 0254C03

If water ows from the any of the rings, the exhaust valve must be dismounted and the sealing rings replaced. Check with stopped engine:

4. In connection with port stays, at an interval of e.g. one month, an easy check of all exhaust valves is recommended. 4. Check of spindle drop down time: Engage all rotation indicators on the exhaust valves.
SAFETY AIR SUPPLY

Shut off and release the spring air on the valve, next to the engine side manoeuvring stand.

AIR SUPPLY EXHAUST VALVE

Check the drop down time for all spindles:

Spindles dropping down within 30 minutes: Check and overhaul, See next step Check of Air Spring tightness.
M90802 0256C04

Spindles dropping down between 30


minutes and 1 hour: Keep under observation.
CONTROL AIR SUPPLY

Spindles dropping down after 1 hour:


OK. When check of drop down time is nished, lift the rotation indicators and lock them in the top position.

Page 2 (25)

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
5. Check of Air spring tightness 5. 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). Disconnect the sealing oil pipe and banjo coupling from the air cylinder (B). Check if air is coming out from: The sealing oil bore (B): Leakage from spindle stem sealing , change and overhaul. Hole 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 overhaul. Remove the air supply to the non return valve on the air cylinder and check the non return valve for tightness. The checks is for guidance only, minor leaks is difcult to detect.

908-2.1

Checking

C D

M90802 0256C05

C B

When referring to this page, please quote Procedure M90802 Edition 0269

Page 3 (25)

908-2.2

Exhaust Valve
Dismantling
1. Close off cooling water 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 high pressure pipe for the hydraulic valve actuation. See Procedure 908 1.2 Dismount the return oil pipe from the exhaust valve.

MAN B&W Diesel

1.

Page 4 (25)

M90802 0256D02

M90802 0256D01

2.

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
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 intermediate pipe to the exhaust valve housing. Support the intermediate pipe by e.g. a chain block and remove the screws. 4. Dismantling of hydraulic nuts. Remove the protective caps from the exhaust valve studs. Loosen and remove the hydraulic nuts, see Data. See Procedure 913 1.

908-2.2

Dismantling

M90802 0256D03

4.

D13 02

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0256D04

Page 5 (25)

908-2.2

Exhaust Valve
Dismantling
5. Lift of exhaust valve

MAN B&W Diesel

5.

D08 24

Check all connections to the valve are removed. Attach the crane to the eye bolt tted 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 seating and sealing surfaces of the bore, if required. See Procedure 901 1.3. For overhaul of the exhaust valve, see Procedure 908 2.3

Page 6 (25)

M90802 0256D06

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
1. Oil cylinder 1. Place the exhaust valve on a wooden support on the platform. Remove the nuts and the safety strap from the oil cylinder. Depending on valve model, remove the sealing oil pipe. Lift away and place the oil cylinder on a wooden support. 2. Conical locking ring Relieve the air pressure through the non return valve from below the piston. Use a small screwdriver to press the ball into the non return valve. Cover the non return valve with a rag to catch the oil drops. Remove the four screws from the ange on top of the air piston and dismount the ange. Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
M90802 0256O01

908-2.3

Overhaul

D08 26

2.

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0256O02

Page 7 (25)

908-2.3

Exhaust Valve
Overhaul
3. Spindle

MAN B&W Diesel

3. 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 O ring in the air piston and the internal rings for the sealing arrangement at the bottom of the air cylinder pass the groove for the conical ring at the top of the spindle. 4. Bottom piece Unscrew and remove the lock screws which retain the bottom piece. Lift the valve housing approx. 10 mm.
M90802 0256O04

D08-24

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. Remove the oil cylinder.

4.

D08-29

Page 8 (25)

M90802 0256O05

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
5. Air piston and cylinder 5. Dismount the air piston from the air cylinder. Dismount the non return valve from the air cylinder/valve housing. Mount two eye bolts in the air cylinder and dismount the air cylinder. Remove and discard the O ring on the air cylinder. 6. Guide bushing Clean the exhaust valve housing. Inspect the bushing in the spindle guide for wear and measure the top and bottom diameters. See Data.
M90802 0256O06

908-2.3

Overhaul

D08-30

D08-27

6.

D08 18

D08 19

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0269O06

Page 9 (25)

908-2.3

Exhaust Valve
Overhaul
7. Bushing renewal If it proves necessary to replace the bushing, remove the screws and knock out the bushing with a hammer and a suitable mandrel. Alternatively, if the extractor tool is available, mount the extractor tool and pull up the bushing. The extractor tool is optional, and can be ordered as spare part. When a new bushing is mounted, mount a new O ring for sealing between bushing and exhaust valve housing. Mount and tighten the screws for the bushing. 8. Bottom piece inspection Before cleaning the bottom piece, See Volume I, supplement 707 03 Inspect and evaluate the seating according to Volume I.

MAN B&W Diesel

7.

Page 10 (25)

M90802 0256O09

M90802 0269O07

8.

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
9. Bottom piece Measuring 9. 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. Use the bottom piece template and a feeler gauge, take measurements G2 and G3. All measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating. For maximum wear or grinding, see Data D08 11 and D08 12. 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 grinding or reconditioning is not recommended. 10. Bottom piece sealing face 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.

908-2.3

Overhaul

G3 D08 12

D08 09

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0255O15

M90802 0255O14

G2 D08 11

10.

Page 11 (25)

908-2.3

Exhaust Valve
Overhaul MAN B&W Diesel

11. Bottom piece sealing rings 11. Make sure that the groove for the O-rings are clean. Mount the new O-rings on the bottom piece. 12. Bottom piece mounting Use the oil cylinder as a lifting tool for the exhaust valve housing.
M90802 0269O11

Check the face on the valve housing is clean. If tted, 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 bottom piece. Mount and tighten the retaining screws for the bottom piece.

12.

D08 26 + D08 25

Page 12 (25)

M90802 0269O12

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
13. Spindle inspection 13. Before cleaning the spindle, See Volume I, supplement 707 03 Inspect and evaluate the spindle according to Volume I. 14. Spindle burn off and grinding check In connection with evaluation of the spindle according to Volume I, burn off and wear or the total amount the seat has been ground, are measured as described below. The burn off F1 of the valve spindle is checked by measuring along the spindle template from point A to point D and in point E. For the maximum allowable burn off, see Data D08 13. The maximum seat grinding, gap G1 is measured between the spindle template, and the seating of the spindle with a feeler gauge. For maximum seat grinding, see data D08 14.
M90802 0256O15

908-2.3

Overhaul

M90802 0256O14

14.

G1

D08 14 F1 D08 10 A D08 13 D E

If necessary to grind the seat, see Data D08 10 for correct grinding angle.

When referring to this page, please quote Procedure M90802 Edition 0269

Page 13 (25)

908-2.3

Exhaust Valve
Overhaul
15. Spindle stem check

MAN B&W Diesel

15. In connection with evaluation of the spindle according to Volume I, the spindle stem wear is measured as described below.

D08 16 D08 15 D08 17

Check the spindle stem for wear in the area D08 15 to D08 16 measured from the top of the spindle. For minimum stem diameter, see data D08 17. If the exhaust valve spindle needs reconditioning, contact MAN B&W Diesel for advice. 16. Spindle transport When lifting or transporting the exhaust valve spindle, use the special valve spindle lifting tool.

16.

M90802 0252O19

D08 28

Page 14 (25)

M90802 0255O16

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
17. Spindle bushing sealing rings 17. Check the top of the spindle bushing and the face on the housing is clean. Fit new o rings on the spindle bushing as shown in the sketch. 18. Spindle mounting Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil.
M90802 0269O17

908-2.3

Overhaul

Use the oil cylinder as a lifting tool for the exhaust valve housing. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle. Remove the oil cylinder.

18.

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0256O19

Page 15 (25)

908-2.3

Exhaust Valve
Overhaul
19. Air cylinder

MAN B&W Diesel

19. Clean the air cylinder. Dismount the safety valve from the air cylinder, use the machined faces to unscrew the valve. Unscrew and clean the Banjo coupling for sealing oil to the spindle stem bushing. Blow through all bores in the air cylinder. Check the non return valve in the Banjo coupling with compressed air. Clean the bottom of the air cylinder for possible coke. Remount the Banjo coupling. Mount a new O ring in the groove on the outside of the air cylinder. 20. Safety valve Place the safety valve in the pressure testing 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, loosen 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. Mount a new gasket and a new O ring on the safety valve. Mount the safety valve in the bore near the bottom of the air cylinder. When mounting the safety valve in the air cylinder, use only the machined faces on the valve housing and tighten, see Data. Finally, mount the protective cap.

Compressed Air

M90802 0256O20

20.

D08-04

M90802 0256O21

D08-07

Page 16 (25)

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
21. Air cylinder mounting 21. Lubricate the O rings on the spindle bushing. Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines are not equipped with the locating pin Note! Take care not to damage the O rings on the outside of the spindle bushing.

908-2.3

Overhaul

22. Air piston seals Check the teon guide ring and teon sealing ring for wear, if it is necessary to replace the sealing rings on the air piston, cut them and remove them. Be careful not to damage the edges of the ring grooves in the piston.

Note! Before mounting, heat the new teon rings in 100C hot water for at least ve minutes. When mounting the teon rings, be careful not to damage the running surfaces.

After mounting, compress the teon 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 O rings in the inside grooves of the air piston.

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0252O32

M90802 0256O22

22.

Page 17 (25)

908-2.3

Exhaust Valve
Overhaul
23. Air piston mounting

MAN B&W Diesel

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.
M90802 0256O24

Mount the ange on top of the air piston and, by means of the four screws, tighten the air piston and the ange together. On valve models where the bolts are designed for securing, secure the bolts. See Procedure 913 7.

24.

Page 18 (25)

M90802 0256O25

Compressed Air

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
25. Oil cylinder 25. Loosen the screws and remove the lifting bracket from the oil cylinder to gain access to the orice plug. Remove the sealing oil unit. Remove and discard the gasket. Unscrew and clean the orice plug. Remove and discard the sealing disc. Check and clean the bore for the orice plug in the top of the oil cylinder. Place the oil cylinder in a horizontal position. Remove the ange and take out the piston. Inspect the inside of the liner in the oil cylinder for scoring. Measure the cylinder diameter. If the diameter of the oil cylinder exceeds Data D08 20, either renew the liner or send the complete oil cylinder to an authorised MAN B&W workshop for overhaul, depending on the valve model. 26. Sealing oil control unit. Normally overhaul of the sealing oil unit should not be necessary. Check the unit according to Procedure 908 2.1. Before remounting the unit, carefully clean it on the machined faces. If the unit needs to be overhauled, send it to an authorised MAN B&W repair workshop.

908-2.3

Overhaul

D08-20

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0255O37

M90802 0256O26

26.

Page 19 (25)

908-2.3

Exhaust Valve
Overhaul
27. Oil piston

MAN B&W Diesel

27.
Top

Remove the piston rings from the oil piston and check them for wear. If the thickness of the rings 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. Check the mesh once more.

D08 21
M90802 0257O42

28. Oil piston damper check Mount the piston on top of the spindle. Connect compressed air supply to the space below the air piston, so as to keep the valve closed, and to keep the air cylinder in close contact with the valve housing.

28.

D08 22 D08 23

Place the measuring tool on the air cylinder across the piston. Check the mesh of the damper piston by checking the distance from the upper edge of the crossbar to the top of the damper piston. See Data. If the measurement is outside the value stated in Data, an adjustment must be made by changing the disc in the damper piston

Page 20 (25)

M90802 0256O29

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
29. Oil piston damper adjustment 29. Place the piston in the special tool. Press out the damper piston and the disc with the centre screw. Inspect the spring and the piston. A thicker disk increase the mesh and a thinner disc decrease the mesh. Assemble the damper piston with the new disc in the special tool. Place the piston upside down in the tool and press the disc into place in the piston. Check the mesh once more. 30. Oil cylinder assembly 30. Mount the piston and the ange in the oil cylinder. Tighten and lock the screws. Return the oil cylinder to an upright position. Mount a new sealing disc in the bore for the orice plug. Screw the orice plug into the bore. Place a new gasket on top of the oil cylinder. Mount the sealing oil unit. Mount the lifting bracket on the oil cylinder. Mount the screws and tighten to the torque stated in Data.

908-2.3

Overhaul

M90802 0256O30

D08-05

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0256O31

Page 21 (25)

908-2.3

Exhaust Valve
Overhaul
31. Oil cylinder mounting

MAN B&W Diesel

31. Mount the overhauled oil cylinder on top of the air cylinder. Mount the safety strap and tighten the nuts. See Data. Mount the sealing oil pipe

D08 06

Page 22 (25)

M90802 0256O32

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
1. Checks before mounting 1. Before mounting an overhauled exhaust valve in the engine, it is recommended that the valve is checked and prepared as follows: Connect compressed air to the air cylinder to close the valve. Lift up the valve with the engine room crane. Check that a 1.0 mm feeler gauge can be inserted about 15 mm into gap G3, to ensure that there is a clearance between the outer parts of the seating faces of valve housing and spindle. Carry out the drop down test as described in procedure 908 2.1. Check the valve is tted with new sealingrings in the grooves on the bottom piece. 2. Exhaust valve landing Close the valve with compressed air. Lubricate the sealing rings with vaseline and the threads of the studs with anti seizure paste. Position the valve in the cylinder cover bore, guiding it in accordance with the exhaust anges and the guide pin on the exhaust side of the exhaust valve.
M90802 0256M01

908-2.4

Mounting

D08 24

G3

2.

Compressed Air

Copper Grease Vaseline

When referring to this page, please quote Procedure M90802 Edition 0269

M90802 0256M02

Page 23 (25)

908-2.4

Exhaust Valve
Mounting MAN B&W Diesel

3. Mounting of hydraulic nuts. 3. Mount and tighten the hydraulic nuts, see Data. See Procedure 913 1. Mount the protective caps on the exhaust valve studs. 4. Mount the pipe connections Connect the intermediate pipe to the exhaust valve.
M90802 0256M03

D13 01

Mount and tighten the screws to the exhaust 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 air spring. 5. Mount the oil pipe connections Mount the high pressure pipe for the hydraulic valve actuation. See Procedure 908 1.2

4.

M90802 0256M04

Mount the return oil pipe to the exhaust valve. Check that all pipe connections are properly tightened.

5.

Page 24 (25)

M90802 0256M05

When referring to this page, please quote Procedure M90802 Edition 0269

Exhaust Valve
MAN B&W Diesel
6. Open cooling water supply 6. 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 between the bottom piece and the exhaust valve housing. See Procedure 908 2.1. 7. Air spring check The air supply to the exhaust valve must always be connected and pressurized before turning on the oil supply to the exhaust valve actuator. If the lubricating oil pumps have been started before the exhaust valve pneumatic springs are pressurize: Engage the indicators on top of the exhaust valves and wait until the exhaust valves are closed. Closing of the exhaust valves are eased if the lubrication oil pumps are stopped and the actuators are drained at the drain screws.
M90802 0256M06

908-2.4

Mounting

7.

M90802 0256M07

Closed Valve

Open Valve

When referring to this page, please quote Procedure M90802 Edition 0269

Page 25 (25)

Exhaust Valve Actuator


MAN B&W Diesel Data

108-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D08-20 D08-21 D08-32 D08-33 D08-34 D08-35 Description Oil cylinder max. inside diameter Piston rings, min. thickness Hydraulic actuator, tightening torque Locking plate, tightening torque Hydraulic actuator, tightening angle Hydraulic actuator Value 112.2 4.2 1450 50 100/27 240 Unit mm mm Nm Nm Nm/ kg

When referring to this page, please quote Data D10803 Edition 0057

Page 1 (2)

108-3

Exhaust Valve Actuator


Data MAN B&W Diesel

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

Plate P90851

Item No. 041 Tightening template, actuator

Description

Page 2 (2)

When referring to this page, please quote Data D10803 Edition 0057

Exhaust Valve Actuator


Checking
Exhaust Valve Actuator L60MC-C 0227 Checking 908-3.1

908-3.1

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 facing the actuator). If the air flow can be felt at the inlet side of the valve, the valve must be overhauled. 2. Leakages in the exhaust valve can be measured during running of the engine by collecting the oil from the drain pipe C leading from the exhaust valve to the hydraulic actuator. Leakages may also be caused by leaky non-return valves and loose pressure pipe connections. If the pipe connections are tight and the leak oil amount from the exhaust valve is normal, any abnormally large leakages must originate from the hydraulic actuator from which leak oil quantities cannot be directly registered. The hydraulic actuator is then to be dismantled for checking of the parts. See Procedure 908-3.2

1.

When referring to this page, please quote Procedure M90803 Edition 0227 0$1 % : 'LHVHO $6

HM908-3.0 70 1/3

Page 1 (4)

908-3.2

Exhaust Valve Actuator


Dismantling
Dismantling 908-3.2

1.

1. Stop the engine and shut off the oil supply. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the 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. See Procedure 908-1.2. 2. Release the mountings for the indicator drive from the actuator housing.

GM908-3.0 78 01

2.

Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.

D08-35
Unscrew the nuts on the two short studs, then loosen the nuts on the long studs successively until the roller guide spring is relieved. Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller guide. Remove the spring.
HG908-3.3 201 02

3. Remove the locking plate for the piston. Turn the piston 90 to release it from the bayonet joint. 3. Remove the piston from the roller guide. 4. Overhaul the actuator housing and the piston as required. See Procedure 908-3.3 .

Page 2 (4)

HM908-3.0 70 03

When referring to this page, please quote Procedure M90803 Edition 0227 0$1 % : 'LHVHO $6

Exhaust Valve Actuator


Overhaul
Overhaul 908-3.3

908-3.3

1. Clean the piston in kerosene and wipe dry with a clean piece of cloth. 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 possible scores and measure it for wear. If the bore is seized or worn down to the measurement stated in Data, send the oil cylinder to an MAN B&W authorised workshop for reconditioning.
HM908-3.0 69 04

1.

D08-21

3.

D08-20

When referring to this page, please quote Procedure M90803 Edition 0227 0$1 % : 'LHVHO $6

JM908-3.0 73 05

Page 3 (4)

908-3.4

Exhaust Valve Actuator


Mounting
Mounting 908-3.4

1.

D08-33

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 stated in Data. Lubricate the piston with plenty of camshaft lubricating oil. 2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the piston, taking care not to damage the piston rings. Mount the washers and nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. Mount the washers and nuts on the two short studs. Tighten all four nuts as stated in Data. Note! Use only the tightening angle OR the tightening torque, NOT both.

KC908-3.0 76 05

2.

D08-32 or D08-34
HG908-3.4 201 02

3. Mount the oil inlet pipe and the drain pipe from the exhaust valve. Mount the hydraulic high pressure pipe. See Procedure 908-1.4.

3.

Page 4 (4)

HG908-3.4 201 03

When referring to this page, please quote Procedure M90803 Edition 0227 0$1 % : 'LHVHO $6

Exhaust Valve Roller Guide


MAN B&W Diesel Data

108-4

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D08-36 D08-38 Description Bushing/shaft pin, max. clearance Roller guide complete Value 0.5 110 Unit mm kg

When referring to this page, please quote Data D10804 Edition 0041

Page 1 (2)

108-4

Exhaust Valve Roller Guide


Data MAN B&W Diesel

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

Plate P90851

Item No. 053 Lifting tool for roller guide

Description

Page 2 (2)

When referring to this page, please quote Data D10804 Edition 0041

Exhaust Valve Roller Guide


MAN B&W Diesel
1.

908-4.1

Checking
2.

The exhaust valve roller guide can be partially checked while mounted on the engine, using the following procedure: Lift the roller guide. See Procedure 908-7.

2. Remove the camshaft inspection cover. Turn the engine to provide the maximum space between the roller guide and the cam disc. 3. Check the movability of the roller by turning this by hand to ascertain if the roller moves freely and without unnecessary resistance or hard points. Inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that no traces of bearing metal exist in the roller guide housing. 4. Check the roller guide and the bearing clearance if the roller guide is dismounted. For dismantling of the roller guide see Procedure 908-4.2. 5. To measure the clearance in the roller guide slide bearing, place the roller guide vertically upside down on a couple of planks with the roller hanging freely. 6. Place a dial gauge against the roller. Then lift the roller as much as the clearance permits, which makes it possible to read the clearance directly on the dial. See Data. 7. It is recommended that the roller guide should ONLY be dismantled if: irregularities when turning the roller, damage to the roller, suspect to larger clearance than stated on the Data sheet, seizure marks on the slide surfaces, have been observed during the checking of the roller guide.

M90804 0222C01

5.

D08 36

For disassembling of the roller guide, contact an MAN B&W authorized repair shop.

When referring to this page, please quote Procedure M90804 Edition 0222

M90804 0222C02

Note!

Page 1 (3)

908-4 .2

Exhaust Valve Roller Guide


Dismantling
1.

MAN B&W Diesel

1.

Dismantle the hydraulic actuator above the exhaust valve roller guide. See Procedure 908-3.2.

2. Mount the roller guide lifting tool as follows: Lift the lock ring of the tool up on the shaft of the tool. Place the tool in such a manner 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. Lower the lock ring, thereby securing the foot in the locked position. Lift the roller guide out of the roller guide housing, using the crane. Take care not to damage the sliding surfaces of the roller guide when lifting.

M90804 0222D01

2.

D08 38

90O

Page 2 (3)

M90804 0222D02

When referring to this page, please quote Procedure M90804 Edition 0222

Exhaust Valve Roller Guide


MAN B&W Diesel
1.

90?-?.4

Mounting
1.

Mount the lifting tool for the roller guide as follows: Lift the lock ring of the tool up on the shaft of the tool. Place the tool in such a manner 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. Lower the lock ring, thereby securing the foot in the locked position. Clean and lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing. Remove the lifting tool.

D08 38

90O

2. Turn the camshaft so that the roller guide is lifted approx. 20 mm. Check that the clearance between the roller guide and the guide plate is the same at both sides 0.1 mm. 3. Mount the actuator. See Procedure 908-3.4.

When referring to this page, please quote Procedure M90804 Edition 0222

M90804 0222M02

M90804 0222D02

2.

Page 3 (3)

Exhaust Valve Cam


MAN B&W Diesel Data

108-5

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D08-39 Check lifting height Description Value 16 Unit mm

When referring to this page, please quote Data D10805 Edition 0017

Page 1 (2)

108-5

Exhaust Valve Cam


Data MAN B&W Diesel

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

Plate P90661 P90851 P91351 P91351 P91351 P91351 P91351 P91366

Item No. Impact spanner for turning cam 173 010 034 058 154 225 073

Description

Lifting tool for exhaust valve roller guide Hydraulic pump, pneumatically operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete Conical valve, 0 - 15 Disc, round-plain, Cu 11x3 mm Dial gauge and stand tool

Page 2 (2)

When referring to this page, please quote Data D10805 Edition 0017

Exhaust Valve Cam


MAN B&W Diesel
1.

908-5.1

Checking
1.

Turn the crank throw of the cylinder concerned in AHEAD direction until TDC. Check and write down the angle indicated on the turning wheel.

2. Remove the high pressure pipe, see procedure 908 1.2 Mount and tighten the lifting tool for the exhaust valve roller guide to the actuator piston (remove the screws for tightening to the actuator housing and do not lift the roller guide). Mount a dial gauge (measuring range 0.00 20.00 mm) on the lifting tool for the exhaust valve roller guide. Reset the scale and the pointer. Press the dial gauge against the face of the actuator housing until the reading D08 39 + 1.00 mm is obtained. 3. Turn the roller guide in AHEAD direction until lifted to D08 39, and the dial gauge gives the reading 1.00 mm and calculate the angle A, which is the number of degrees the crank throw has turned from TDC position to the present position. Continue turning AHEAD until the roller guide again is lifted to D08 39, 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.
M90805-0219C01

2.

When referring to this page, please quote Procedure M90805 Edition 0219

M90805-0219C02

Page 1 (4)

908-5.1

Exhaust Valve Cam


Checking MAN B&W Diesel

4.

4. Calculate the lead angle as: 180 (A + B)/2 The lead angle is normally a negative gure. The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC.

D08-39

The position of the cam must be correct within a tolerance of +/ 0.5. See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the lead angle of the plant in question.

M90805-0219C04

D08-39

5.

5. The cam lead angle can be checked visually by reading directly the scale position of the exhaust cam over the marking scratch on the camshaft and comparing this angle with the angle stated in the Adjustment Sheet. At the same time, it is recommended to check the position of the camshaft with the pin gauge. See Procedure 906 3.1

Page 2 (4)

M90805-0219C05

When referring to this page, please quote Procedure M90805 Edition 0219

Exhaust Valve Cam


MAN B&W Diesel Adjustment
1.

908-5.3

Normally, adjustment of the exhaust cams should not be necessary. Before adjustment of any cams, see Volume I, Chapter 706. 1. Remove the oil tray from the camshaft housing. See Procedure 906-4.2.

2. Dismount the exhaust valve high pressure pipe, see Procedure 908 1.2. 3. Turn the camshaft until there is access to the oil duct in the exhaust cam through the inspection hole. If tted, remove the plugs from the oil duct (using, for instance, a screwdriver). Insert three copper gaskets in each oil duct. Mount snap on couplings in the oil duct, but do not tighten them. Fit hoses between the snap on 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. Apply a light pressure to the hydraulic system 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 two to ve minutes before turning the cam. Oil must sweep out with the pump running during the operation. Keep the cam pressurised during turning.

When referring to this page, please quote Procedure M90805 Edition 0219

M90805-0219O04

M90805-0219O03

M90805-0219O01

3.

4.

Page 3 (4)

908-5.3

Exhaust Valve Cam


Adjustment MAN B&W Diesel

5.

5. Turn the cam disc, using the tted spanner, 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 compression 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.

M90805-0219C05

After carrying out adjustment, measure the exhaust cam lead again. See Procedure 908 5.1. Write down and le the new results for the purpose of comparing with future measurements and adjustment. 7. Mount the oil tray on the camshaft housing. See Procedure 906-4.4.

8. Mount the high pressure pipe for the exhaust valve. See Procedure 908 1.4 9. After any adjustment of the cam position, pcomp must be recorded and compared with pcomp at a known engine reference load.

Page 4 (4)

When referring to this page, please quote Procedure M90805 Edition 0219

Exhaust Valve Special Running


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

108-7

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

Stop lubricating oil supply Lock the turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10807 Edition 0034 MAN B&W Diesel A/S

Page 1 (2)

108-7

Exhaust Valve Special Running


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90851 P90851 Item No. 124 173 Description Tool for emergency open exhaust valve Lifting tool for exhaust valve roller guide

Page 2 (2)

When referring to this page, please quote Data D10807 Edition 0034 MAN B&W Diesel A/S

Exhaust Valve
Special Running
0228 Exhaust Valve Special Running 908-7 S80MC

908-7

3. Warning! Disengagement or re-engagement of the fuel pump roller guide or the exhaust valve roller guide must only take place at engine standstill. 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. Stop the engine. Stop the lubricating oil pump. Lift the relevant fuel pump roller guide. See Procedure 909-10.1. 2. Dismantle the hydraulic high-pressure pipe and the connecting sleeve. See Procedure 908-1.2. 3. Dismantle the non-return valve on the oil inlet pipe. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one side. 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 camshaft housing. Turn the engine until the exhaust roller guide is at TDC. 5. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston. Tighten the lowermost nut on the tool to pull 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.

KM908-7.0 223 03

4.

HG908-4.1 201 01

5.

When referring to this page, please quote Procedure M90807 Edition 0228 MAN B&W Diesel A/S

JM908-5.0 55 03

Page 1 (3)

908-7

Exhaust Valve
Special Running

7.

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. If the cylinder is to operate with the exhaust valve open, continue the procedure as follows: 7. Shut off the compressed air supply and remove the air pipe connection to the exhaust valve and plug the pipe. Release the air from the air spring through the non-return valve on the side of the air cylinder. Hint! Use a small screwdriver to press the ball into the non-return valve, and cover it with a rag to catch the oil drops. 8. Dismantle the rotation indicator on the air cylinder and mount the tool for opening of the exhaust valve.

KM908-2.1 236 05

8.

The tool will keep the piston of the air cylinder in the bottom position and thus keep the exhaust valve open.

KM908-7 228 08

Page 2 (3)

When referring to this page, please quote Procedure M90807 Edition 0228 MAN B&W Diesel A/S

Exhaust Valve
Special Running
9.

908-7

After overhaul of the cylinder unit, re-engage the exhaust valve gear as follows: 9. Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. Remove the tool. 10. If the engine has been running with the exhaust valve open, remove the tool mounted in the air cylinder and mount the rotation indicator. Note! The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine. Leaving the rotation indicator in the engaged position continuously might damage the exhaust valve due to the formation of a wear groove in the air piston of the exhaust valve. Re-connect the air supply to the air cylinder. 11. Remove the plug from the non-return valve and re-connect the oil inlet pipe and the connecting sleeve on the actuator housing, after fitting new sealing rings on the connecting sleeve. 12. Mount the hydraulic high-pressure pipe. See Procedure 908-1.4. 13. Engage the fuel pump roller guide. See Procedure 909-10.1.

JM908-5.0 55 06

11.

When referring to this page, please quote Procedure M90807 Edition 0228 MAN B&W Diesel A/S

KM908-7.0 223 11

Page 3 (3)

Exhaust Valve Panel


Exhaust Valve Panel 0177 P90851

Plate P90851-0177

When referring to this page, please quote Plate P90851 Edition 0177
MAN B&W Diesel A/S

Page 1 (2)

Plate P90851-0177 Item No.


016 028 041 053 065 077 089 090 112 124 136 148 150 161 173 185

Exhaust Valve Panel


Item No.

Item Description
Tool panel Name plate Tightening template, actuator Lifting tool, roller guide Lifting tool for exhaust valve Cone ring, pneumatic piston Test equipment, exhaust valve Cauge exhaust valve spindle Grinding tool - h.p. pipe Tool, emergency open exhaust valve Bridge gauge, exhaust valve Tool for hydraulic piston Gauge exhaust valve bottom piece Lifting tool for exhaust valve Lifting tool - roller guide - exhaust valve Grinding ring - exhaust valve bottom piece

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90851 Edition 0177
MAN B&W Diesel A/S

Exhaust Valve - Tools


Exhaust Valve - Tools 0022 P90861

Plate P90861-0022

When referring to this page, please quote Plate P90861 Edition 0022
MAN B&W Diesel A/S

Page 1 (2)

Plate P90861-0022 Item No.


046

Exhaust Valve - Tools


Item No.

Item Description
Grinding machine, complete

Item Description

Notes:

When ordering spare parts, please refer to the Chris Marine manual When referring to this page, please quote Plate P90861 Edition 0022
MAN B&W Diesel A/S

Page 2 (2)

Exhaust Valve Hydraulic - Tools


Exhaust Valve Hydraulic - Tools 0036 P90862

Plate P90862-0036

When referring to this page, please quote Plate P90862 Edition 0036
MAN B&W Diesel A/S

Page 1 (2)

Plate P90862-0036 Item No.


016 028 041 053 065 077 089

Exhaust Valve Hydraulic - Tools


Item No.

Item Description
O-ring with back-up ring O-ring with back-up ring Hydraulic Jack Support Stud setter Hydraulic tool for exhaust valve, complete Tommy bar

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90862 Edition 0036
MAN B&W Diesel A/S

Exhaust Valve - Extra Tools


Exhaust Valve - Extra Tools 0015 P90863

Plate P90863-0015

When referring to this page, please quote Plate P90863 Edition 0015
MAN B&W Diesel A/S

Page 1 (2)

Plate P90863-0015 Item No.


011

Exhaust Valve - Extra Tools


Item No.

Item Description
Worktable

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90863 Edition 0015
MAN B&W Diesel A/S

Exhaust Valve - Extractor Tool

Plate P90864-0003

When referring to this page, please quote Plate P90864 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P90864-0003 Item No.


017

Exhaust Valve - Extractor Tool


Item No.

Item Description
Extractor tool, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90864 Edition 0003
MAN B&W Diesel A/S

909 - Fuel Oil System


Documents in this Chapter
109-01 909-01 109-02 909-02 109-03 909-03 109-04 909-04 109-05 909-05 109-06 909-06 109-07 909-07 109-08 909-08 109-09 909-09 10910 90910 10911 90911 10912 90912 10913 90913 10914 90914 10915 90915 0061 0241 0005 0206 0050 0234 0061 0224 0065 0234 0052 0220 0040 0214 0054 0217 0034 0216 0016 0218 0065 0249 0048 0228 0033 0206 0080 0255 0062 0236 Fuel Pump Settings, Data Fuel Pump Settings VIT System, Data VIT System Fuel Pump Cam, Data Fuel Pump Cam Fuel Pump, Data Fuel Pump Fuel Pump Top Cover, Data Fuel Pump Top Cover Fuel Pump Barrel Assembly, Data Fuel Pump Barrel Assembly Fuel Pump Suction Valve, Data Fuel Pump Suction Valve Fuel Pump Puncture Valve, Data Fuel Pump Puncture Valve Fuel Pump Shock Absorber, Data Fuel System Shock Absorber Lifting Gear Roller Guide, Data Lifting Gear for Roller Guide Fuel Valve, Data Fuel Valve Spindle Guide, Data Spindle Guide Non-Return Valve in Fuel Valve, Data Non-Return Valve in Fuel Valve Fuel Oil High-Pressure Pipes, Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide, Data Fuel Pump Roller Guide

MAN B&W Diesel A/S

90951 90961 90966 90967 90968 90974 90977 90979 90980

0446 0069 0008 0001 0001 0001 0001 0001 0001

Fuel Valve and Fuel Pump - Panel Fuel Valve - Tools Fuel Valve Nozzle - Tools Fuel Puncture Valve - Tools Fuel Valve - Inspection Tools Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals

MAN B&W Diesel A/S

Fuel Pump Settings


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

109-1

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

Data
Ref. Description Value Unit

D09-02

Change of one index mark, corresponds to p-max being altered approx. 2.0 - 3.0 bar

When referring to this page, please quote Data D10901 Edition 0061 MAN B&W Diesel A/S

Page 1 (2)

109-1

Fuel Pump Settings


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D10901 Edition 0061 MAN B&W Diesel A/S

Fuel Pump Settings


Adjustment
Fuel Pump Settings K98MC-C 0241 Adjustment 909-1.3

909-1.3

Before adjustment of the fuel pump is carried out, see Volume I, Chapter 706, also the fuel cam lead should be checked, see Procedure 909-3.1. pmax adjustment: 1. The Maximum Combustion Pressure (pmax) is adjusted for the individual units at the fuel pump VIT index arm. For collective adjustments of pmax on all units, see Procedure 909-2. 2. Loosen lock nut B and then turn adjusting screw H. The link can be adjusted by approx. 3 index marks. 3. To increase p max, adjust to higher VIT index (advance injection). To decrease p max, adjust to lower VIT index (delay injection). One index mark will alter pmax approximately as given in Data D09-02. Note! The individual p max value must not deviate more than 3 bar from the average value for all cylinders. 4. If the required p max adjustment cannot be attained by adjustment on the VIT index arm, it is possible to carry out the adjustment on the fuel cam disc. Contact MAN B&W Diesel for advice.
HN909-1.3 240 01

1.

2.

When referring to this page, please quote Procedure M90901 Edition 0241 MAN B&W Diesel A/S

HN909-1.3 240 02

Page 1 (2)

909-1.3

Fuel Pump Settings


Adjustment

5.

MIP adjustment: 5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump index arm. Increase index for higher p i. Decrease index for lower p i. Note!

HN909-1.3 240 05

6.

The mean indicated pressure is one of the most important parameters in obtaining good engine performance. The mean indicated pressure should not deviate more than 0.5 bar from the average value for all cylinders. See Volume I, Chapter 706. 6. After adjustment of the fuel pumps a set of observations must be taken, to evaluate the adjustments see Volume I.

Page 2 (2)

M90901-0242O06

When referring to this page, please quote Procedure M90901 Edition 0241 MAN B&W Diesel A/S

VIT System
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X X X X X X X

109-2

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10902 Edition 0005 MAN B&W Diesel A/S

Page 1 (2)

109-2

VIT System
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D10902 Edition 0005 MAN B&W Diesel A/S

VIT System
Adjustment
VIT System K98MC-C 0206 Adjustment 909-2.3

909-2.3

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

1.

M90902-0206O01

2.

When referring to this page, please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S

Page 1 (5)

909-2.3

VIT System
Adjustment

3.

3. If necessary, adjust the lever by loosening the nut A and turn the clamping arm B, until lever contact with both rollers and tighten nut A. Adjust the VIT air pressure to 3.0 bar, by axial displacement of the bracket with the pilot valve and read the pressure on the pressure gauge C. See figure 2. 4. Spare pilot valves should be pre-adjusted to 0.5-5.0 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin C. To check a pilot valve already mounted on the engine, remove the inlet and outlet pipe connections at A and P, and connect a pressure gauge at A and a pipe with working air (pressure 7 bar) at P on the pilot valve. Check that the pressure on the pressure gauge and the pressing-in of pin C is in accordance with the curve. Any necessary adjustment is done by turning adjusting screw B.

C B
M90602-0238O03

5 4 3 2 1.5 0.5 1 0.1

4.

Pbar

Pressing in mm 0 1 2 3 4 5 6 7 8 0.5

A B

M90902-0206O04

Page 2 (5)

When referring to this page, please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S

VIT System
Adjustment
5.

909-2.3

Fine adjustment: 5. When the fine adjustment is carried out, the engine must run at 90% load or just above. Take a new set of indicator diagrams and calculate the engine load. Adjust the VIT air pressure to obtain cylinder p max of 140 bar. The VIT air pressure must be maximum 5.0 bar. Increase the pmax pressure by moving the pilot valve toward the lever. Decrease the p max pressure by moving the pilot valve away from the lever. For adjustment of pmax on a single cylinder, see procedure 909-1. 6. Run the engine at maximum load and check that p max is 140 bar. If the maximum combustion pressure deviates more than 3.0 bar from 140 bar, adjust the pressure by replacement of the lowermost roller.
M90902-0206O05

6.

When referring to this page, please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S

M90902-0206O06

Page 3 (5)

909-2.3

VIT System
Adjustment

7.
Pbar Break point Pmax adjusted on uppermost roller

Pmax adjusted on lowermost roller

7. The uppermost roller is used to adjust the VIT start point (40% engine load). Electronic VIT system 8. The adjustment should be based on a set of indicator diagrams taken when the engine is running just above the breakpoint.

Pcomp
M90902-0206O07

40

90

100

%Load

9. On the panel in the engine room control room, change the p offset value in accordance with the required increase or decrease in the p max pressure. One graduation mark on the p offset scale corresponds to a change in p max of 1 bar. 10. Check the adjustment by taking a new set of indicator diagrams while the engine is running just above the breakpoint.

8.

Page 4 (5)

M90902-0206O08

When referring to this page, please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S

VIT System
Adjustment
11.

909-2.3

11. The I/P converter mounted on the engine receives a 4-20 mA signal I from the electronic governor system and converts this into a 0.5-5.0 bar control air pressure pcontrol . 12. To check the adjustment of the I/P converter, operate the panel in the engine control room to supply various signals I to the I/P converter. For operation of the panel, see the panel manufacturers instructions. On the pressure gauge mounted on the control air line after the I/P converter check that the control air pressures from the I/P converter are in accordance with the curve. 13. If the control air pressure is not in accordance with the curve, the I/P converter must be adjusted. Remove the hood of the I/P converter and adjust the I/P converter according to the manufacturers instructions.

P control

P supply

P control

5 4 3

M90902-0206O11

1.5 0.5 0.1

2 1 0 0 4 8 12 16 20 I, mA

When referring to this page, please quote Procedure M90902 Edition 0206 MAN B&W Diesel A/S

Page 5 (5)

Fuel Pump Cam


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

109-3

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10903 Edition 0050 MAN B&W Diesel A/S

Page 1 (2)

109-3

Fuel Pump Cam


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90651 P90951 P91351 P91351 P91351 P91351 P91351 P91351 Item No. 44 45 10 46 58 154 201 225 Impact spanner for turning cam Measuring tool for fuel pump Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete Conical valve, 0 - 15 Quick coupling, male Disc, round-plain, Cu 11x3 mm Description

Page 2 (2)

When referring to this page, please quote Data D10903 Edition 0050 MAN B&W Diesel A/S

Fuel Pump Cam


MAN B&W Diesel
Fuel cam lead: 1. The lead C of the fuel cam is defined as the number of mm the plunger is lifted from its bottom position when the main piston is in TDC. 1. To measure the fuel cam lead (top lift): Dismantle the puncture valve. See Procedure 909 8.2. 2. Push down the measuring pin through the top cover, until it rests against the pump plunger. Turn the engine until the lowe s t point of the cam is found, use a calliper to nd the point. 3. Measure the distance x from the top of the measuring pin to the transverse piece. Note down the result as x2. 4. Turn ahead until the main piston of the cylinder concerned is in TDC. Again measure the distance x from the top of the mea s uring tool to the tran s ver s e piece. Note down the result as x1.
M90903 0233C03

909-3.1

Checking

C X2 X1
Roller guide

Fuel cam

M90903 0233C01

Ahead

Lowest position of pump plunger

Main piston in TDC

2.
X

Calculate the fuel cam lead C (top lift) as: C = x1 x2 (mm) 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. Remount the puncture valve.

3.

When referring to this page, please quote Procedure M90903 Edition 0234

M90903 0233C04

Page 1 (4)

909-3.2

Fuel Pump Cam


Adjustment MAN B&W Diesel

1.

Normally, adjustment of the fuel cam should not be necessary. Before adjustment of fuel equipment, see Volume I, Chapter 706. 1. Remove the inspection cover from the camshaft housing. Note! Before dismantling any part of the fuel pump, make s ure that the pump ha s been relieved of pressure and that all oil has been drained off.

M90903 0233O01

2. Dismount the puncture valve from the fuel pump top cover, and mount the measuring tool to check the cam adjustment. 3. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. If tted, remove the plugs from the oil ducts (using, for instance, a screwdriver). In s ert three copper ga s ket s in each oil duct. Mount snap on couplings in the oil ducts, but do not tighten them.

2.
X

M90903 0233C03

Fit hoses between the snap on couplings and the di s tributor block and between the di s tributor block and the hydraulic high pressure pump.

3.

Page 2 (4)

M90903 0233O03

When referring to this page, please quote Procedure M90903 Edition 0234

Fuel Pump Cam


MAN B&W Diesel Adjustment

909-3.2

4. Mount the special spanner on the fuel cam disc, ensuring that the two pins enter the holes in the cam. For better access to the cam, remove the oil tray and carry out the adjustment from the bottom of the cam shaft housing. See Procedure 906 4.2 Apply a light pressure to the hydraulic system and, after venting the system, tighten the snap on couplings.

4.

Keep the cam pressurised for at least two to ve minutes before turning the cam. Oil must seep out with the pump running during the operation to keep the cam pressurised during turning. Turn the cam disc, using the tted spanner, until the desired change of lead is obtained. To increase lead and pmax: turn the cam disc AHEAD. To reduce lead and pmax: turn the cam disc ASTERN. See Procedure 909 1. 5. After completing the desired turning of the cam disc, relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Wait at least 15 minutes the cam must be allowed time to settle before mounting the plugs again in the oil ducts of the cam disc. After carrying out adjustment, measure the fuel cam lead again. Note down and le the new results for purposes of comparison with future measurements and adjustment.

When referring to this page, please quote Procedure M90903 Edition 0234

M90903 0233O04

Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc.

Page 3 (4)

909-3.2

Fuel Pump Cam


Adjustment MAN B&W Diesel

6. Mount the inspection cover on the camshaft housing. 7. Mount the puncture valve. See Procedure 909 8.4. 8. After any adju s tment of the cam po s ition, pmax must be recorded and compared with pmax at a known engine reference load.

Page 4 (4)

When referring to this page, please quote Procedure M90903 Edition 0234

Fuel Pump
MAN B&W Diesel Data

109-4

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-18 D09-19 D09-20 D09-21 D09-39 Description Pump housing nuts, tightening torque Pump housing nuts, tightening angle Pump housing Bottom plate Shock absorber Value 1980 100/50 510 24 70 Unit Nm Nm/ kg kg kg

When referring to this page, please quote Data D10904 Edition 0061

Page 1 (2)

109-4

Fuel Pump
Data MAN B&W Diesel

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

Plate P90951

Item No. 070 Lifting tool for fuel pump housing

Description

Page 2 (2)

When referring to this page, please quote Data D10904 Edition 0061

Fuel Pump
Dismantling
Fuel Pump K90MC-C 0224 Dismantling 909-4.2

909-4.2

1. Close the fuel oil inlet valve. Open the drain cock, enabling the oil to escape. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismantle the fuel pump top cover and connected pipes. See Procedure 909-5.2. 3. Dismantle the barrel/plunger assembly. See Procedure 909-6.2. 4. Remove the screws holding the fuel oil inlet pipe between the fuel pump and the fuel inlet valve. Remove the fuel oil inlet pipe. Remove the shock absorber. Remove the fuel oil outlet pipe. Discard the gaskets. 5. Remove the drain pipes from the fuel pump housing. Remove the control air pipes from the actuator for the VIT index arm.
MA909-4.2 214 04

1.

MA909-1.1 223 03

4.

D09-39

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

Page 1 (9)

909-4.2

Fuel Pump
Dismantling

6.

6. Loosen the four nuts by means of a slugging spanner. Remove the nuts. 7. Fit the lifting tool using the top cover studs/ nuts, and lift the pump housing away. Take care not to damage the threads of the studs. Land the fuel pump on wooden planks.

MA909-4.2 214 06

7.

D09-20

MA909-4.2 214 07

Page 2 (9)

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

Fuel Pump
Overhaul
Overhaul 909-4.3

909-4.3

1. If the fuel index arm or the VIT index arm of the fuel pump is moving too tightly, the regulating and timing systems of the fuel pump must be overhauled. 2. In order to carry out this overhaul, the top cover and plunger/barrel assembly of the fuel pump must have been removed, and the fuel pump must have been dismantled from the pump base and landed on wooden planks. See Procedure 909-4.2. See Procedure 909-5.2. See Procedure 909-6.2. 3. Dismantle the actuator and actuator bracket. 4. Tilt the fuel pump housing into a horizontal position on the wooden planks. 5. Dismantle the screws and the bottom plate from the fuel pump housing. If the bottom plate is stuck, loosen it by screwing two M10x80 mm screws into the holes of the bottom plate.

3.

MA909-4.3 214 03

4.

D09-20

MA909-4.3 214 04

5.

D09-21

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

MA909-4.3 214 05

Page 3 (9)

909-4.3

Fuel Pump
Overhaul

6.

6. Dismantle the: Fuel index arm Regulating guide Sleeve 7. Dismantle the: Guide screw VIT index arm

MA909-4.3 214 06

Timing guide 8. Remove the caps from the back of the fuel pump housing. 7. Remove the orifice plug from the front side of the fuel pump housing. Discard all sealing rings and gaskets.

MA909-4.3 214 07

8.

MA909-4.3 214 08

Page 4 (9)

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

Fuel Pump
Overhaul
9.

909-4.3

9. Dismantle and inspect the plug screws in both sides of the fuel pump housing. If eroded, replace the plug screws. 10. Clean all the dismantled parts of the fuel pump thoroughly in diesel oil or kerosene. Dry all parts carefully. Clean all inside surfaces of the fuel pump housing. Check that all the bores of the fuel pump housing are clean. 11. Mount new sealing rings and gaskets. Mount the caps and the orifice plug. Mount new sealing rings on the plug screws and mount the plug screws. Note! Lubricate the threads of all the parts with Molybdenum Disulphide (MoS 2) before mounting. 12. Mount new sealing rings in the sleeves that are provided with a pointer scratch. Note! Soak the sealing rings in lubricating oil before mounting.
MA909-4.3 214 11 MA909-4.3 214 09

11.

12.

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

HC909-3.4 121 11

Page 5 (9)

909-4.3

Fuel Pump
Overhaul

14.

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

MA909-4.3 214 14

regulating guide timing guide VIT index arm 15. fuel index arm. 14. Mount the VIT index arm and the guide screw. Adjust the position of the VIT index arm so that the scratch mark is aligned with the centre of the fuel pump housing. 15. Mount the timing guide in the fuel pump housing. The timing guide must be mounted in such a way that the scratch marks on the timing guide, on the VIT index arm and on the fuel pump housing are aligned. 16. Mount the sleeve in the fuel pump housing, ensuring that the notch in the side of the sleeve is aligned with the pin hole in the fuel pump housing.

MA909-4.3 214 15

16.

MA909-4.3 214 16

Page 6 (9)

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

Fuel Pump
Overhaul
17.

909-4.3

17. Mount the fuel index arm. Adjust the position of the fuel index arm so that the scratch mark on the fuel index arm is aligned with the centre of the fuel pump housing. 18. Mount the regulating guide in the fuel pump housing. The regulating guide must be mounted so that the scratch mark on the regulating guide is aligned with the scratch mark on the fuel index arm. 19. Mount the bottom plate on the fuel pump housing. 20. Return the fuel pump to a vertical position. Mount the actuator and actuator bracket on the side of the fuel pump.
MA909-4.3 214 17

18.

MA909-4.3 214 18

19.

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

MA909-4.3 214 05

Page 7 (9)

909-4.4

Fuel Pump
Mounting
Mounting 909-4.4

2.

D09-20

1. Before mounting the fuel pump housing, make sure that all sliding faces and threads are cleaned and lubricated with MOLYKOTE antifriction spray D321R or molybdenum disulphide (MoS 2). See Procedure 913-11. 2. Mount the lifting tool on the fuel pump top cover studs. Lift the fuel pump housing on to the pump base, taking care not to damage the threads of the studs. Remove the lifting tool. 3. Mount the nuts on the studs and tighten to the specified torque or angle, see Data. Note! Use either the tightening torque or the tightening angle.

MA909.4.2 214 07

3.

D09-18 or D09-19

MA909-4.2 214 06

Page 8 (9)

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

Fuel Pump
Mounting
5.

909-4.4

4. Mount the drain oil pipes on the fuel pump housing. Connect the control air pipes to the actuator for the VIT index arm. 5. Fit new gaskets on the fuel pump inlet pipe. Mount the pipe between the fuel pump housing and the fuel oil inlet and outlet valve. Mount the shock absorber. 6. Mount the barrel assembly in the fuel pump housing. See Procedure 909-6.4. 7. Mount the top cover on the fuel pump housing. See Procedure 909-5.4. Mount the air pipe for the puncture valve. 8. Close the drain cock and open the fuel oil inlet valve.
MA909-4.2 214 04

D09-39

8.

When referring to this page, please quote Procedure M90904 Edition 0224 MAN B&W Diesel A/S

MA909-1.1 223 09

Page 9 (9)

Fuel Pump Top Cover


MAN B&W Diesel Data

109-5

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-23 D09-24 D09-26 D09-27 Description Top cover studs, screwing-in torque Top cover nuts, tightening torque Outlet seat, max.grinding diameter Top cover Value 400 460 26 100 Unit Nm Nm mm kg

When referring to this page, please quote Data D10905 Edition 0065

Page 1 (2)

109-5

Fuel Pump Top Cover


Data MAN B&W Diesel

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

Plate P90951 P90951

Item No. 069 094 Lifting tool for fuel pump Milling tool for fuel oil pipe seats

Description

Page 2 (2)

When referring to this page, please quote Data D10905 Edition 0065

Fuel Pump Top Cover


Checking
1. Shut off the fuel oil inlet. Open the drain cock (at the bottom of the pump housing), and drain off any oil left in the high-pressure pipe and the fuel pump. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Dismount all drain pipes and the pipe connections to the puncture valve. Dismount the high-pressure pipes between the top cover and the fuel valves. See Procedure 909-14.2. Note! If the puncture valve is to be overhauled, remove the puncture valve from the top cover at this stage. See Procedure 909-8.2.
M90905 0234D01

909-5.1

1.

2.

Pull the top cover with suction valve and puncture valve (if still mounted) free by tightening the dismantling screws. When the top cover is loose, remove the dismantling screws and mount the lifting tool in the threaded holes instead. 3. Lift the top cover carefully off. For overhaul of top cover, puncture valve and suction valve, see Procedures 909-5.3, 909-7.3, 909-8.3. Discard the gasket.

M90905 0234D02

2. Remove the top cover fixing nuts and mount the dismantling screws for top cover in the two threaded holes.

3.

D09 27

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

M90905 0234D03

Page 1 (3)

909-5.2

Fuel Pump Top Cover


Dismantling
1. If not already done, dismount the protective cap and the puncture valve from the top cover. See Procedure 909-8.2. 2. Mount the top cover in special bracket and dismantle the suction valve and the lock washer from the top cover. See Procedure 909-7.2. 3. Fill the oil ducts of the top cover with vaseline or heavy grease.

1.

M90905 0234O02

Screw the guide, with the miller, into the high-pressure pipe thread. Mill the seat until a smooth surface is achieved. For maximum seat diameter see Data. After completing the milling, use compressed air to blow the vaseline/ grease out from the oil ducts.

2.

D09 26

Clean the top cover with diesel oil/gas oil, and blow dry with compressed air. Note! Make sure that all bores and threads inside the top cover are absolutely clean.

M909905 0234O03

If necessary, recondition the seats of the fuel oil high-pressure pipes. See Procedure 909-14.3. 4. Mount a new lock washer and a new or overhauled suction valve in the top cover. See Procedure 909-7.4.

3.

Page 2 (3)

M909905 0234O04

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

Fuel Pump Top Cover


Dismantling
1. Make sure that the inside of the fuel pump housing and the top of the fuel pump barrel is completely clean. 2. Mount a new gasket on top of the pump housing. Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide (MoS2). See Procedure 913-11. Mount the overhauled top cover (with overhauled suction valve and reconditioned seatings for the high-pressure pipes) on the pump housing. Check that the guide pin in the top cover enters the hole in the pump housing. Warning! As a safety precaution, and before mounting the top cover nuts, turn the engine one revolution. When doing this, the top cover must not move upwards!

909-5.2

1.

D09 27

M90905 0234M01

3.

D09 24

For adjustment of the fuel pump, see Procedure 909-1.1. 4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure 909-8.4. Mount the protective cap over the puncture valve and the two screws in the top cover. Mount the high-pressure pipes and the drain screw in the pump housing. Mount the drain pipes on the top cover and the connecting pipe to the puncture valve. Open the fuel oil inlet.

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

M90905 0234M04

M90905 0234M03

3. Mount the top cover fixing nuts, and tighten them diagonally to the torque indicated in Data.

4.

Page 3 (3)

Fuel Pump Barrel Assembly


MAN B&W Diesel Data

109-6

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-29 D09-30 Barrel assembly Plunger Description Value 120 24 Unit kg kg

When referring to this page, please quote Data D10906 Edition 0052

Page 1 (2)

109-6

Fuel Pump Barrel Assembly


Data MAN B&W Diesel

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

Plate P90951 P90951 P90962

Item No. 057 224 Lifting tool for barrel and plunger Tool for P. max rack

Description

Fuel Pump Seals - Mounting Tools

Page 2 (2)

When referring to this page, please quote Data D10906 Edition 0052

Fuel Pump Barrel Assembly


Dismantling
Fuel Pump Barrel Assembly K90MC-C 0220 Dismantling 909-6.2

909-6.2

1. Close the fuel oil inlet valve. Open the fuel pump drain cock, enabling the oil to escape. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismantle the fuel pump top cover. See Procedure 909-5.2. 3. Position the lifting tool for the barrel/plunger assembly (without measuring pin) in such a manner that the two distance tubes of the tool rest on the pump barrel. Make sure that the two guide pins in the bottom of the lifting tool enter the holes in the top of the plunger. Secure the lifting tool by screwing the two screws into the pump barrel. Loosen the stop ring on the spindle of the tool and press the spindle down against the pump plunger. Turn the spindle in this position until the two guide pins engage with the two holes in the plunger top. Tighten the centre screw of the spindle against the plunger.
MA909-3.1 122 03 MA909-1.1 223 03

1.

2.

3.

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

NA909-6.2 211 03

Page 1 (10)

909-6.2

Fuel Pump Barrel Assembly


Dismantling

4.

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

MA909-3.1 93 05

Mount the extractor tool and connect the timing toothed rack to the pulling rod by means of the pin. 6. Turn the nut at the end of the pulling rod, whereby the timing rack will move outwards. Continue turning the nut until the pin reaches the outer position of the slot in the tool, whereby the thread of the fuel pump barrel goes clear of the timing guide. Keep the toothed rack in this position during the overhaul or replacement of the pump barrel. There is now a distance between the lifting tool and the pump housing.

5.

MA909-3.1 93 06 AB

6.

MA909-3.1 93 06 C

Page 2 (10)

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Fuel Pump Barrel Assembly


Dismantling
7.

909-6.2

7. Pull the regulating toothed rack outwards until the plunger foot has been turned clear of the bayonet joint in the roller guide. This can be ascertained by watching the handles on the spindle of the lifting tool. These will be parallel with the fore-and-aft direction of the engine when the plunger has been turned into position. Remove the cover of the pump base to make sure that the plunger is able to go clear of the bayonet joint. Lift the spindle so that the plunger foot goes clear of the bayonet joint. Move the stop ring of the spindle into contact with the upper flange of the tool, and lock the stop ring in this position by means of the stop screw. 8. Carefully lift the barrel/plunger assembly out of the pump housing. Dismount the tool. Press the plunger upwards to the bottom of the barrel. Send the barrel/plunger assembly to an MAN B&W authorized workshop for repair, or overhaul it on board as described in Procedure 909-6.3.
MA909-6.2 213 07

8.

D09-29

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

MA909-6.2 213 08

Page 3 (10)

909-6.3

Fuel Pump Barrel Assembly


Overhaul
Overhaul 909-6.3

1.

1. Place the pump barrel/plunger on a piece of plywood. Secure the plunger with a couple of wedges to avoid unwanted movements.

D09-29

Remove and discard the sealing rings from the barrel. 2. Pull the plunger carefully out of the barrel. Carefully clean the plunger (for example in clean kerosene) and dry it with a soft nonfluffy cloth. Check the plunger for wear or seizure marks. Also inspect the top of the plunger for cavitation marks. 3. Clean the bores in the upper end of the plunger and blow dry with compressed air.

MB909-6.3 220 01

2.

Clean the barrel and dry it with a non-fluffy cloth.

D09-30

For evaluation of the plunger/barrel condition see Volume I, Chapter 706. Check the barrel for wear or seizure marks. Note! The plunger and the barrel are matched parts and cannot be replaced individually.

MB909-6.3 220 02

3.

MA909-3.2 122 03

Page 4 (10)

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Fuel Pump Barrel Assembly


Overhaul
4.

909-6.3

4. Before mounting new sealing rings on the barrel, heat them to 200220C for at least five minutes. Note! Take care not to exceed the temperature limits. 5. When mounting the new sealing rings on the lower end of the pump barrel, the inner sealing ring must be mounted first. Mount the guide stick in the barrel and position the big cone on the barrel. Place the spring-loaded sealing ring on the cone with the spring facing upwards, see the sketch. Use the pusher tool to push the sealing ring into the groove. 6. When mounting the sealing ring in the outer groove, place the spacer tool inside the cone to obtain the correct distance to the groove, and repeat the above procedure. After mounting the sealing rings, compress them by pressing the sizer tool over the sealing rings.

200-220 C

NA909-5.3 214 05

5.

MA909-6.3 213 05

6.

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

MA909-6.3 213 06

Page 5 (10)

909-6.3

Fuel Pump Barrel Assembly


Overhaul

7.

7. Mount the guide stick and cone on the top end of the barrel and mount the uppermost sealing ring in the same way as above. Make sure that the spring faces downwards, see the sketch. 8. Lubricate the plunger with molybdenum disulphide (MoS 2). Carefully slide the plunger into the barrel and press it to the bottom.

MB909-3.2 95 06

Note! Do not use force as this will damage the sliding surfaces of the plunger or barrel 8. If the barrel assembly is not to be mounted immediately, all openings must be covered with plastic to prevent dirt from entering the barrel assembly during storage.

MB909-6.3 220 08

Page 6 (10)

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Fuel Pump Barrel Assembly


Mounting
Mounting 909-6.4

909-6.4

1. Place the supplied measuring pin which is of the same length as the plunger on the spindle of the lifting tool, and fasten it by tightening the centre screw of the spindle. Loosen the stop ring on the spindle. Place the tool on the pump housing, and press the spindle down until the pointed end of the measuring pin is in contact with the thrust piece of the roller guide. Then press the stop ring down until it reaches the flange of the tool and lock it there by tightening the screw of the stop ring against the spindle. The stop ring is to remain tightened in this position until the plunger has been correctly mounted. The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. 2. Dismount the tool from the pump housing and remove the measuring pin from the spindle. Then mount the tool on the barrel/ plunger assembly which is ready for mounting. Secure the tool to the barrel by tightening the two screws, and attach the plunger to the spindle of the tool by tightening the centre screw of the spindle. The tool is thus fixed on the barrel in such a way that its correct positioning is ensured during mounting. Before mounting the barrel/plunger in the pump housing, lubricate the thread for the timing guide and all sealing rings with molybdenum disulphide. Using the spindle of the tool, pull the plunger as high up in the barrel as possible, at the same time turning the spindle so as to position the plunger foot correctly in relation to the cutout of the regulating guide.
MA909-6.4 213 02

1.

MA909-6.4 213 01

2.

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Page 7 (10)

909-6.4

Fuel Pump Barrel Assembly


Mounting

3.

3. Pull the regulating toothed rack as far out as possible and check that the extractor tool is mounted correctly on the timing toothed rack when this is in its outer position. 4. Check that the slot in the barrel coincides with the hole for the guide screw. Lower the barrel assembly carefully into the pump housing. If necessary, turn the regulating guide a little (using the toothed rack) to make the foot and the regulating block of the plunger fit properly in the cutout of the regulating guide. Lowering the barrel assembly so far down into the pump housing that the sealing rings of the barrel are about to enter the bore in the pump housing.

MA909-6.4 213 03

4.

D09-29

Then continue pressing down the barrel/ plunger assembly until the barrel assembly rests on top of the timing guide. There will be a gap between the tool and the pump housing.

MA909-6.4 213 04

Page 8 (10)

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Fuel Pump Barrel Assembly


Mounting
5.

909-6.4

5. Loosen the nut on the extractor, disconnect the pulling rod from the timing toothed rack, and remove the extractor. Engaging the thread of the fuel pump barrel with the timing guide is accomplished by pressing-in the toothed rack. (A pressure of about 30 kg may be required). Check that the toothed rack is correctly engaged by pressing-in the rack. When doing this, the pump barrel shall move downwards. The top flange of the tool is now resting on the top of the pump housing. 6. After landing the barrel assembly, press the plunger down into contact with the thrust piece of the roller guide. Check that the stop disc of the spindle is in full contact with the flange of the tool, as when measuring. If necessary, turn the regulating guide a little (using the toothed rack) to make the plunger foot fit properly in the cutout of the roller guide. Inspect the position of the plunger foot through the inspection hole. When the plunger is in place, press the regulating rod in, thereby turning the plunger by means of the regulating guide and causing the plunger foot to interlock with the bayonet joint of the roller guide. Check that the plunger is correctly engaged by pulling at the spindle of the lifting tool. When doing this, it must not be possible to lift the spindle. Mount the inspection hole cover.

MA909-6.4 213 05

6.

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

MA909-6.4 213 06

Page 9 (10)

909-6.4

Fuel Pump Barrel Assembly


Mounting

7.

7. Mount the pointer and union for the timing rack. Mount the links for the timing drive and the regulating drive in place in accordance with the marks. 8. Mount the guide screw for the pump barrel in the pump housing. Remove the centre screw from the plunger, and remove the tool.

MA909-6.4 213 07

8.

9. Mount the fuel pump top cover and the belonging pipes. See Procedure 909-5.4. 10. Close the fuel pump drain cock. Open the fuel oil inlet valve.

MA909-6.4 213 08

10.

MA909-1.1 223 09

Page 10 (10)

When referring to this page, please quote Procedure M90906 Edition 0220 MAN B&W Diesel A/S

Fuel Pump Suction Valve


MAN B&W Diesel Data

109-7

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

X X

Data Ref. D09-33 D09-34 Description Suction valve, tightening torque Suction valve Value 1850 8 Unit Nm kg

When referring to this page, please quote Data D10907 Edition 0040

Page 1 (2)

109-7

Fuel Pump Suction Valve


Data MAN B&W Diesel

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

Plate P90951 P90967

Item No. 130 Crowfoot spanner Fuel Puncture Valve - Tools

Description

Page 2 (2)

When referring to this page, please quote Data D10907 Edition 0040

Fuel Pump Suction Valve


Checking
Fuel Pump Suction Valve S60MC-C 0214 Checking 909-7.1

909-7.1

1. Using a brass mandrel, check that the valve slide can slide freely up and down inside the suction valve. 2. Check the seats for tightness by filling the inlet hole with diesel oil or gas oil, and wait five minutes. No oil may seep through the seats of the slide/housing. 3. If the suction valve is not to be mounted on the engine immediately after the checking, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.

1.

HN909-7.1 207 01

2.

When referring to this page, please quote Procedure M90907 Edition 0214 0$1 % : 'LHVHO $6

KB909-3.3 105 08

Page 1 (4)

909-7.2

Fuel Pump Suction Valve


Dismantling
Dismantling 909-7.2

1.

1.

Note! Before dismantling the top cover, it is recommended to dismantle the fuel pump puncture valve, see Procedure 909-8.2. Dismantle the fuel pump top cover and suction valve assembly from the fuel pump housing. See Procedure 909-5.2.

2. Mount two eye bolts in the bottom of the top cover and turn it upside down. 3. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. 2. Release the suction valve lock washer. Dismount the suction valve from the top cover. Remove and discard the lock washer.
GN909-5.3 204 02 GN909-5.2 204 03

3.

Page 2 (4)

KN909-7.2 213 03

When referring to this page, please quote Procedure M90907 Edition 0214 0$1 % : 'LHVHO $6

Fuel Pump Suction Valve


Overhaul
Overhaul 909-7.3

909-7.3

1. Set up the suction valve in a bench vice with soft jaws and, using a brass mandrel and a hammer, release the spring guide from the valve thrust piece. Disassemble the other parts of the suction valve and clean the parts thoroughly in clean diesel oil. Remove and discard the sealing ring from the valve thrust piece. 2. Inspect the seat of the valve slide and the seat in the thrust piece for damage. If the seats are damaged, both the suction valve and the valve slide must be discarded. Lapping of the seats must not be attempted. 3. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust piece. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the groove. Note! Make sure that the sealing ring is mounted correctly. See the sketch. After mounting the sealing ring, compress it by pressing the sizer tool over the sealing ring. 4. Clean and overhaul all internal parts, and lubricate them with molybdenum disulphide (MoS 2). 5. Re-assemble the suction valve. 6. Check the suction valve after the overhaul. See Procedure 909-7.1.

1.

KB909-3.3 105 05

2.

KB909-3.3 105 06

3.

When referring to this page, please quote Procedure M90907 Edition 0214 0$1 % : 'LHVHO $6

XZ909-7.3 204 03

Page 3 (4)

909-7.4

Fuel Pump Suction Valve


Mounting
Mounting 909-7.4

1.

D09-33

1. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. Lubricate the thread of the suction valve with copper grease. Make sure that the bore for the suction valve in the top cover is absolutely clean. Fit a new lock washer and mount a new or overhauled suction valve in the top cover. Fit the two screws which secure the lock washer. Tighten the suction valve with a torque spanner. See Data. Lock the suction valve in position by bending up an edge of the lock washer over one of the flats of the valve. 2. Remove the top cover from the bracket and mount the top cover in the fuel pump housing. See Procedure 909-5.4.

KN909-7.4 213 01

2.

Page 4 (4)

GN909-5.2 204 03

When referring to this page, please quote Procedure M90907 Edition 0214 0$1 % : 'LHVHO $6

Fuel Pump Puncture Valve


MAN B&W Diesel Data

109-8

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-35 D09-36 Description Puncture valve, tightening torque Puncture valve Value 1400 12 Unit Nm kg

When referring to this page, please quote Data D10908 Edition 0054

Page 1 (2)

109-8

Fuel Pump Puncture Valve


Data MAN B&W Diesel

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

Plate P90951

Item No. 141 Crowfoot spanner

Description

Page 2 (2)

When referring to this page, please quote Data D10908 Edition 0054

Fuel Pump Puncture Valve


Dismantling
Fuel Pump Puncture Valve S60MC-C 0217 Dismantling 909-8.2

909-8.2

1. Shut off the fuel oil inlet. Open the drain cock at the bottom of the pump housing and drain off any oil left in the fuel oil high-pressure pipe and fuel pump. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismantle the control air pipe and the protective cap above the puncture valve. 3. Unscrew and remove the puncture valve from the fuel pump top cover.
HN909-8.2 207 02

2.

4. After dismantling it is recommended always to overhaul the puncture valve. If the overhaul cannot take place immediately after the dismantling, it is recommended to place the puncture valve immersed in diesel oil until the overhaul.

3.

When referring to this page, please quote Procedure M90908 Edition 0217 0$1 % : 'LHVHO $6

HN909-8.2 207 03

Page 1 (4)

909-8.3

Fuel Pump Puncture Valve


Overhaul
Overhaul 909-8.3

1.

1. Remove and discard the O-rings from the puncture valve. Set up the puncture valve in a bench vice with soft jaws. Loosen and remove the four screws and dismount the plug. Use a screw to remove the air piston from the housing. Remove and discard the sealing rings from the air piston. Disassemble the other parts of the puncture valve, using a brass mandrel and a hammer. Take care not to damage the valve seat. Thoroughly clean all the parts in clean diesel oil. 2. Inspect the conical seats of the valve housing and the valve slide for wear marks or scratches. If the seats are damaged, the valve housing and the valve slide must be discarded. Lapping of the valve seats must not be attempted.

HN909-8.3 207 01

2.

Page 2 (4)

HG909-8.2 201 02

When referring to this page, please quote Procedure M90908 Edition 0217 0$1 % : 'LHVHO $6

Fuel Pump Puncture Valve


Overhaul
3.

909-8.3

3. When mounting the new sealing rings on the spindle of the air piston, the inner sealing ring must be mounted first. Mount the O-ring in the ring groove and position the large cone on the spindle. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the O-ring in the groove. After mounting the sealing ring, compress it by pressing the sizer' tool, over the sealing ring. Mount the outer sealing ring in the groove using the short cone, and repeating the above procedure. 4. The new sealing ring is mounted on the head of the air piston in accordance with the same procedure as above. Before assembling the puncture valve, lubricate all parts with MOLYKOTE anti-friction SPRAY D321R or molybdenum disulphide (MoS 2). Mount new O-rings on the housing. 5. If the puncture valve is not to be mounted on the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.
GM909-3.3 89 10

4.

When referring to this page, please quote Procedure M90908 Edition 0217 0$1 % : 'LHVHO $6

GM909-3.3 89 12

Page 3 (4)

909-8.4

Fuel Pump Puncture Valve


Mounting
Mounting 909-8.4

2.

1. Make sure that the bore for the puncture valve in the fuel pump top cover is absolutely clean. If this has not already been done, mount new O-rings on the puncture valve. Lubricate the thread of the puncture valve with copper grease.

D09-35

2. Screw the puncture valve into the bore in the top cover. Using a crowfoot wrench and a torque spanner, tighten the puncture valve to the torque stated in Data. 3. Mount the protective cap and the control air pipe on top of the puncture valve. 4. If open, close the drain cock on the fuel pump and open the fuel oil inlet valve.

HN909-8.4 207 02

3.

Page 4 (4)

HN909-8.4 207 03

When referring to this page, please quote Procedure M90908 Edition 0217 0$1 % : 'LHVHO $6

Fuel Pump Shock Absorber


MAN B&W Diesel Data

109-9

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-37 D09-39 Nuts, tightening torque Shock absorber Description Value 260 70 Unit Nm kg

When referring to this page, please quote Data D10909 Edition 0034

Page 1 (2)

109-9

Fuel Pump Shock Absorber


Data MAN B&W Diesel

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

Plate

Item No.

Description

Page 2 (2)

When referring to this page, please quote Data D10909 Edition 0034

Fuel Pump Shock Absorber


Checking
Fuel Pump Shock Absorber K98MC-C 0216 Checking 909-9.1

909-9.1

To ensure satisfactory operation, the functioning of the fuel pump shock absorber should be checked at regular intervals. Normally, inspection is necessary only at the intervals stated in the maintenance programme. The checks should be carried out while the engine is operating. 1. Remove the plug from the end cover of the shock absorber. Check that air is pulsating through the threaded hole. Short bursts of air should be felt against the hand, corresponding to the strokes of the fuel pump.
NA909-9.1 207 01

The air pulses occur when the shock absorber piston is working and the air below the piston is being compressed and forced out through the threaded hole. 2. To check the tightness of the piston, measure the amount of leakage oil flowing from the drain pipe of the shock absorber housing. Note down the amounts measured and compare with earlier measurements. Increasing amounts indicate a deteriorating piston sealing. Excessive amounts indicate that the shock absorber requires overhauling. See Procedure 909-9.3.

When referring to this page, please quote Procedure M90909 Edition 0216 MAN B&W Diesel A/S

Page 1 (3)

909-9.3

Fuel Pump Shock Absorber


Overhaul
Overhaul 909-9.3

1. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1. Remove the shock absorber drain pipe. Place a wire strap around the shock absorber and hook on the engine room crane. Loosen the screws holding the shock absorber and remove it from the fuel pump housing. 2. Remove the plug from the end cover of the shock absorber. Fit a threaded rod between the piston and the end cover to counteract the force of the springs. Loosen the screws of the end cover and remove the end cover and piston. Discard the gasket. 3. Loosen the nut on the threaded rod to relieve the springs and remove the threaded rod. Remove and discard the sealing ring in the shock absorber housing and the wear ring on the piston. 4. Clean all parts and polish the sliding surfaces of the piston and the shock absorber housing. Mount a new sealing ring in the shock absorber housing and a new wear ring on the piston. 5. Mount the springs and the spring guide between the end cover and the piston, using the threaded rod. Lubricate all sliding surfaces and assemble the shock absorber. Take care not to damage the sealing ring or wear ring when mounting the piston. Check that the piston slides easily in the shock absorber housing.

D09-39

NA909-9.3 211 01

2.

NA909-9.3 207 02

4.

Page 2 (3)

M90909-0216O04

When referring to this page, please quote Procedure M90909 Edition 0216 MAN B&W Diesel A/S

Fuel Pump Shock Absorber


Overhaul
6.

909-9.3

6. Mount the end cover. For tightening the nuts, see Data. Lock with the locking device. Remove the threaded rod and insert the plug. 7. Fit a new gasket on the fuel pump housing and mount the shock absorber. Mount the shock absorber drain pipe. If an excessive amount of drain oil is still observed after the overhaul, the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning.

MB909-9.3 215 06

D09-37

When referring to this page, please quote Procedure M90909 Edition 0216 MAN B&W Diesel A/S

Page 3 (3)

Lifting Gear for Roller Guide


Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X X X X X X X X
Stopped engine Shut off star ting air supply At star ting air receiver Block the main star ting valve Shut off star ting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil

109-10

Stop lubricating oil supply Lock the turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10910 Edition 0016 MAN B&W Diesel A/S

Page 1 (2)

109-10

Lifting Gear for Roller Guide


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D10910 Edition 0016 MAN B&W Diesel A/S

Lifting Gear
Checking
Lifting Gear K90MC-C 0218 Checking 909-10.1

909-10.1

The lifting gear for the fuel pump roller guide is checked and activated by manually operating the four-way valve of the lifting gear while the engine is running or being turned. Note! Whereas the roller guide may be lifted when the engine is running, the roller guide may only be lowered when the engine is stopped. Otherwise, damage may be caused to the roller guide. 1. Lift the knob on the dial of the 4/3 directional control valve, and turn the dial to position 1. Thereby compressed air is led to the bearing of the lifting device, causing the shaft, which functions as piston, to be pressed in against the roller guide. The air cylinder is constantly vented through a bore in the shaft until the shaft is in the correct position. 2. When the shaft is pressed fully in, its lifting pin is positioned under the reversing arm of the roller guide, and the duct (which is connected to the lifting cylinder) is uncovered, thus activating the air cylinder. The air cylinder lifts the coupling arm, which turns the shaft, and the lifting pin on the shaft thus lifts the roller guide clear of the arm. When the roller guide has been successfully lifted, it is no longer possible, with the hand on the fuel oil high-pressure pipe, to feel the beat of the oil pressure pulse.

1.

Air inle t

KC909-5.0 57 01

2. A

Air inle t

When referring to this page, please quote Procedure M90910 Edition 0218 MAN B&W Diesel A/S

KC909-5.0 57 02

Page 1 (4)

909-10.1

Lifting Gear
Checking

3.

3. When the roller guide has been lifted, the dial of the 4/3 directional control valve can be returned to zero position. Lift the knob to release the dial from position 1. The roller guide is now locked in a position free of the fuel cam, and the engine can be operated on the remaining cylinders, see Volume I, Chapter 704.

MB909-5.0 38 05

Page 2 (4)

When referring to this page, please quote Procedure M90910 Edition 0218 MAN B&W Diesel A/S

Lifting Gear
Checking
4.

909-10.1

Re-engagement of the fuel pump roller guide 4. Stop the engine and engage the turning gear. Remove the cover on the camshaft housing to inspect the position of the fuel cam. Turn the engine until the circular part of the fuel cam is facing upwards. To lower the roller guide again, lift the knob on the 4/3 directional control valve and turn the dial to position 2. Thereby air pressure is led both to the lifting cylinder and to the bearing for the lifting gear. The piston of the lifting cylinder is pressed back, thereby turning the shaft out of its locked position and lowering the roller guide so much that the roller cannot go clear of the cam. At the highest point of the cam the pin of the shaft clears the reversing arm of the roller guide, and the air pressure in the bearing presses the shaft back to its extreme position. Now the roller guide can pass the pin of the shaft unhindered. Return the 4/3 directional control valve to zero position.

Air inlet

Note! The engine is able to operate with a roller guide in the wrong position. Therefore, to ensure correct timing after lowering the roller guide, it is recommended to make a START/STOP manoeuvre. This will activate the air cylinder for the reversing mechanism and ensure that the roller guide is in its correct position.

When referring to this page, please quote Procedure M90910 Edition 0218 MAN B&W Diesel A/S

KC909-5.0 57 05

Page 3 (4)

909-10.3

Lifting Gear
Overhaul
Overhaul 909-10.3

1.

1. In the event of leakage at the sealing rings of the lifting gear (the functioning is not satisfactory), the sealing rings are to be replaced. Dismount the pipe connections on the bearing. Disconnect the pull rod of the air cylinder from the coupling arm and remove the coupling arm. Remove the screws which fasten the flange and bearing to the roller guide housing. Dismount the flange, pull the shaft out of the bearing, and remove the bearing from the bore of the roller guide housing. Replace all O-rings A and the piston ring B. Coat all sliding surfaces and sealing surfaces with molybdenum disulphide (MoS 2).

MC909-5.0 48 06

Place the bearing in the bore of the roller guide housing, adjusting it in accordance with the threaded holes. Carefully press the shaft into the bearing. 2. Place the flange on the shaft end (adjusted according to the threaded holes in the bearing), tightening it all up by means of the screws. Mount the coupling arm and the pull rod of the air cylinder. Reconnect the pipes to the nipples of the bearing. 2. After the overhaul, activate the lifting gear. See Procedure 909-10.1. In the activated position, check that the adjusting hole in the coupling arm coincides with the adjusting hole in the flange. If this is not the case, loosen the lock screw on the pull rod and adjust the length of the pull rod until the adjusting holes coincide. Tighten the lock nut.

MC909-5.0 48 07

Page 4 (4)

When referring to this page, please quote Procedure M90910 Edition 0218 MAN B&W Diesel A/S

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

109-11

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

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

Data
Ref. Description Value Unit

D09-40 D09-42 D09-43

Fuel valve opening pressure Inlet seat, max. diameter Fuel valve

300 - 380 25 16

bar mm kg

When referring to this page, please quote Data D10911 Edition 0065 MAN B&W Diesel A/S

Page 1 (2)

109-11

Fuel Valve
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90151 P90951 P90951 P90951 P90951 P90951 P90961 Item No. 71 94 165 189 190 297 14 Dismantling tool for fuel valve Milling tool for fuel oil pipe seats Grinding mandrel for valve head Grinding mandrel for holder - outside Grinding mandrel for holder - inside Assembling tool for fuel valve Fuel Valve tester, complete Description

Page 2 (2)

When referring to this page, please quote Data D10911 Edition 0065 MAN B&W Diesel A/S

Fuel Valve
MAN B&W Diesel
1. Fuel Valve 1. The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. See Chapter 900 1. In order to obtain reliable results during testing of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and re assembled before testing. See Procedure 909 11.3 and 909 12.3.
M90911-0249C01

909-11.1

Checking

Note! In the event that the slide type fuel valve is pressure tested without being cleaned between the fuel nozzle and the cut off slide, the opening pressure value measured might be considerably lower than specied. All fuel valves must be function tested before being mounted in the cylinder cover. Pressure testing pump Use only hydraulic oil (rust preventing) with a viscosity of between 7 and 10 cSt at 50C. For operation of the pressure testing pump, see the suppliers instructions. Note that the high pressure pump should be periodically checked in accordance with the suppliers instructions. 2. Spring housing To ensure that over tightening has not taken place, check that the locking/indicating pin has not been bent or broken off. In the event of over tightening, replace the spring housing by a new one.

2.

When referring to this page, please quote Procedure M90911 Edition 0249

M90911 0240C02

Page 1 (13)

909-11.1

Fuel Valve
Checking
3. Setting up the fuel valve

MAN B&W Diesel

3. Place the fuel valve in the test rig and secure it with the spring housings and nuts. Tighten the nuts until the top face of the pressure disc is ush with the top face of the spring housings. Mount the oil pipe between the pressure testing pump and the fuel valve.

Pressure testing procedure The following functions of the fuel valve must be checked: Flushing and jet control Opening pressure Sealing test and sliding function Pressure test, O ring sealing 4. 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:

M90911 0240C04

M90911 0242C03

4.

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 testing is lower than the height it is lifted during normal engine operation the fuel oil will not necessarily ow from all of the nozzle holes. Cause of fault: If the jets do not full the above point, the cause may be: Dirt in the nozzle holes The nozzle is not mounted correctly

Page 2 (13)

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel
5. Opening pressure 5. To check the opening pressure, increase the oil pressure until oil is admitted through the nozzle holes. Acceptance criteria: Check the opening pressure on the pressure gauge and compare with Data D09 40 on the datasheet. Note! Do NOT attempt to carry out an atomization test on the slide type fuel valvs, as this may damage the cut off slide and nozzle. Cause of fault: If the opening pressure is higher than specied in D09 40, the cause may be that a wrong type of spring is used replace the spring on the thrust spindle, if necessary, replace the complete thrust spindle. If the opening pressure is lower than specied in D09 40, the cause may be that the spring has sagged replace the spring, or add a special 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.

909-11.1

Checking

D09 40

When referring to this page, please quote Procedure M90911 Edition 0249

M90911 0240C05

Page 3 (13)

909-11.1

Fuel Valve
Checking MAN B&W Diesel

6.

6. Sealing test and sliding function 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 built up pressure by closing for the oil supply. Acceptance criteria: Oil must not ow from the nozzle holes.

M90911 0240C06

The pressure drops relatively slowly to about 15 bar, after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). Note! Oil ows out of the leak oil outlet when the fuel valve is full of oil. Cause of fault: If oil ows out of the nozzle holes, the cause is either: Defective spindle guide at needle seat, or a sticking spindle. Examine and/or replace the spindle guide. See Procedure 909 12.3. Too quick pressure drop: the clearances of the movable parts, both of the spindle guide and of the non return valve, are too large, or the seats between the thrust piece/spindle in the spindle guide or thrust piece/valve slide in the non return valve are damaged. Examine and/or replace both the spindle guide and non return valve. See Procedure 909 12.3. See Procedure 909 13.3. If a quick pressure drop from 15 to 0 bar cannot 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 909 12.3.

Page 4 (13)

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel
7. Pressure test, O ring sealing 7. To ensure that the leak oil (circulation oil) remains in the closed system, build up a working pressure of about max. 10 bar until oil ows 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. Acceptance criteria: The built up pressure of about 100 bar should be maintained. Cause of fault: If oil leaks out at the union nut, the O ring inside the fuel valve head is defective, and must be replaced. 8. Atomization test
Max. 100 bar Max. 100 bar Max. 10 bar

909-11.1

Checking

Note! Do NOT attempt to carry out an atomization test on slide type fuel valves, as this may damage the cut off 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 cut off edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of the test oil, increase the risk of seizures between cut off slide and nozzle. All of these conditions involve the risk of seizure between the cut off slide and the nozzle. 8.

When referring to this page, please quote Procedure M90911 Edition 0249

M90911 0240C08

M90911 0240C07

Page 5 (13)

909-11.2

Fuel Valve
Dismantling
1.

MAN B&W Diesel

1.

Close the fuel oil inlet and outlet valves, and drain the high pressure pipe and the fuel valve. Dismantle and remove the fuel oil high pressure pipe. See Procedure 909 14.2. Disconnect the return oil pipe from the fuel valve.

2. Remove the nuts and the spring housings.


M90911 0240D01

3. Take out the valve. If the valve is sticking, use the fuel valve dismantling tool to pull the fuel valve clear of the top cover. If the valve is not to be overhauled immediately, the valve should be placed immersed in diesel oil until overhauling.

2.

M90911 0240D02

3.

D09 43

Page 6 (13)

M90911 0239D03

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel Overhaul

909-11.3

When fuel valves are overhauled, all parts should be handled carefully and be kept clean. Use only clean, non uffy rags for wiping purposes. Make sure to remove all liquid or solid impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded and replaced by new, faultless sealing rings before reassembly. 1. Measure the length A of the protruding part of the nozzle, and write down the result for correct re assembling of the valve.
M90911 0240O01

1.

2. Place the valve holder in a machine vice, mount the fuel valve in the holder and t the valve with the guide disc from the grinding tool. 3. Compress the fuel valve and the spring inside, by means of a drilling machine, to avoid seizures in the union thread. Hold the fuel valve compressed and unscrew the union nut with a hook spanner. Remove the valve from the valve holder.

2.

M90911 0240O02

3.

When referring to this page, please quote Procedure M90911 Edition 0249

M90911 0240O03

Page 7 (13)

909-11.3

Fuel Valve
Overhaul MAN B&W Diesel

4.

4. Pull the valve head clear of the valve housing. Remove the: Non return valve Thrust spindle parts Thrust foot Spindle guide and fuel nozzle from the valve housing. Remove and discard all the O rings.

Page 8 (13)

M90911-0249O04

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel Overhaul

909-11.3

5. Carefully clean and examine all surfaces of the: Fuel valve housing Fuel valve head Thrust spindle If necessary, grind the seating surfaces by means of a ne grain abrasive (such as Carborundum No. 500). The grinding mandrels supplied are only purposed for: The fuel valve housing bottom. The underside of the fuel valve head. The top of the non-return valve. 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. Normally, the milling tool is turned by hand, but it may be tted in the chuck of a column type drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. 100 r/min). An ample supply of cutting emulsion must be used. Note! Take care not to exceed the maximum diameter of the seat, see Data.

5.

D09-42

When referring to this page, please quote Procedure M90911 Edition 0249

M90911-0249O05

Page 9 (13)

909-11.3

Fuel Valve
Overhaul MAN B&W Diesel

6.

6. The complete spindle guide, including the fuel nozzle, should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the spindle guide may be overhauled on board. See Procedure 909 12.3.

Note! Do not attempt to remove the fuel nozzle from the spindle guide unless the spindle guide has been dismantled. Otherwise the cut off slide on the spindle may be damaged. 7. The non return valve should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the non return valve may be overhauled on board. See Procedure 909 13.3. 8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing. Carefully slide the spindle guide down into the valve holder, and turn the nozzle until the spindle guide engages correctly with the guide pin. Check that distance A corresponds to the measurement taken before the valve was 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.

Page 10 (13)

M90802 0253D05

M90911 0240O06

M90911 0240O05

7.

8.

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel
9. Mount: the thrust foot the parts of the thrust spindle the non return valve in the fuel valve housing. Mount a new O ring in the uppermost groove of the fuel valve housing. Lubricate the thread of the valve head with molybdenum disulphide (MoS2). For the correct use of this lubricant, see Procedure 913 11. Fit the valve head with new O rings. 10. Make sure that the guide pin between valve housing and valve head is intact, and press the valve head down into the valve housing. See that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts.

909-11.3

Overhaul

9.

M90911 0240O09

M90911-0249O09

10.

MoS 2

When referring to this page, please quote Procedure M90911 Edition 0249

Page 11 (13)

909-11.4

Fuel Valve
Mounting MAN B&W Diesel

11.

11. Assemble the valve by means of the union nut. Place the valve in the valve holder in a drilling machine. Compress the fuel valve and the spring inside. Keep the valve compressed and tighten the union nut with a hook spanner. After overhaul, the fuel valve must be tested in the test rig. See Procedure 909 11.1. 12. If the fuel valve is not to be mounted in the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.

Page 12 (13)

M90911 0240O10

When referring to this page, please quote Procedure M90911 Edition 0249

Fuel Valve
MAN B&W Diesel
1.

909-11.4

Mounting

Before mounting the fuel valve, thoroughly clean the valve bore in the cylinder cover and check the seating in the bore for marks which, if any, must be eliminated. (For reconditioning of the valve bores in the cylinder cover, see Procedure 901 1.3). If not already done, mount new O rings on the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2).

1.

D09 43

MoS 2

2. Mount the valve in position in the cylinder cover. Mount the spring housings and the nuts. Tighten the nuts until the top face of the pressure disc is ush with the top face of the spring housing. This must be done with great care, as the spring tension in the housing determines the correct tightening of the fuel valve to the cylinder cover as well as the correct compression of the fuel valve. 3. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting. Note! It is recommended to overhaul the fuel oil high pressure pipe before mounting. See Procedure 909 14.3. As a minimum, the distance between the fuel oil pipe ends and the thrust bushings must be checked and, if necessary, adjusted. Mount the overhauled fuel oil high pressure pipe and the return oil pipe. See Procedure 909 14.4.
M90911 0239M01

2.

Note! All fuel valves must be function tested before being mounted in the cylinder cover, see Procedure 909 11.1.
M90911 0242M03

When referring to this page, please quote Procedure M90911 Edition 0249

M90911 0245M02

3.

Page 13 (13)

Fuel Valve Spindle Guide


Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

109-12

Data
Ref. D09-70 Description Nozzel spray hole cleaning tool table Value Unit

Nozzel spray hole

Cleaning drill

Test pin

Nozzel spray hole

Cleaning drill

Test pin

0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55

0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50

0.94 0.99 1.04 1.09 1.14 1.20 1.24 1.30 1.34 1.39 1.44 1.49 1.54 1.59

1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25

1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.65 1.70 1.74 1.80 1.85 1.89 1.94 1.99 2.05 2.09 2.14 2.19 2.24 2.29

When referring to this page, please quote Data D10912 Edition 0048 MAN B&W Diesel A/S

Page 1 (2)

109-12

Fuel Valve Spindle Guide


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90966 Item No. Fuel Valve Nozzle - Tools Description

Page 2 (2)

When referring to this page, please quote Data D10912 Edition 0048 MAN B&W Diesel A/S

Fuel Valve Spindle Guide


Overhaul

909-12.3

Note! This instruction is only valid for spindle guides of the slide valve design. Extreme care and accuracy should be exercised when carrying out this operation. Based on service experience it is recommended to replace the complete spindle guide after 16000 hours of operation. 1. Clean the outside of the spindle guide in pure gas oil or similar. The individual parts of the spindle guide are not interchangeable, therefore only one guide is to be disassembled at a time. Note! The spindle guide, thrust piece and spindle are matched parts and may not be re-placed individually. 2. Place the spindle guide in a bench vice provided with soft jaws, and use the brass mandrel as shown to disassemble the spindle guide. 3. Mount the pulling tool around the fuel nozzle on the spindle guide. Turn the nut to pull the fuel nozzle off the spindle guide. Note! The pulling tool is not standard for all engines, but may be delivered as an optional extra. 4. If no pulling tool is available, the fuel nozzle can be dismantled from the spindle guide using two screwdrivers. Place the screwdrivers opposite each other in the small gap between the fuel nozzle and the spindle guide and very carefully force the fuel nozzle off the spindle guide.

2.

When referring to this page, please quote Procedure M90912 Edition 0228 MAN B&W Diesel A/S

M90912 0228O04

M90912 0228O02

4.

Page 1 (5)

909-12.3

Fuel Valve Spindle Guide


Overhaul
5. Clean all the parts of the spindle guide in gas oil and wipe dry with a clean piece of cloth. Clean all parts again in gas oil or Electrocleaner and wipe dry with a clean piece of cloth. Place all the parts on a clean, soft, lint-free cloth and examine them through an 8-10 times magnification magnifying glass and an inspection lamp. During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts. 6. Remove any deposits or very fine scratches by placing the spindle, thrust piece or spindle guide respectively in a lathe, as shown, and polishing 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. The sliding surface must not be damaged. After polishing, clean the parts again and re-check the seat on thrust piece/spindle, the seat on slide valve/spindle, and the seat on spindle/guide. Use an inspection lamp and an 8-10 times enlargement magnifying glass. If the seats are not in order, i.e. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded.

5.

Page 2 (5)

M90912 0228O06

M90912 0228O05

6.

When referring to this page, please quote Procedure M90912 Edition 0228 MAN B&W Diesel A/S

Fuel Valve Spindle Guide


Overhaul
7. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. Clean the fuel nozzle with gas oil and wipe dry with a clean cloth. 8. Read the nominal hole size on the cylindrical part of the nozzle, as shown in the figure. The hole size is given in 1/100 mm. Depending on the engine model, there can be one or more different sizes of the holes. Find the correct drill size and matching test pin in the table, D09-70, on the data sheet, via the nominal hole size. Clean the spray holes, using gas oil and the special drills supplied. Note! During this operation be very careful not to push the drill too far to avoid scratching the snug-fit surface on the inside of the fuel nozzle. 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). 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 or at maximum 8000 running hours. 8.
1 2 3 4

909-12.3

7.

M90912 0228O08

M90912 0228O07

XXXXXX

X X X*XXX XX

9.

When referring to this page, please quote Procedure M90912 Edition 0228 MAN B&W Diesel A/S

M90912 0228O09

Page 3 (5)

909-12.3

Fuel Valve Spindle Guide


Overhaul
10. Lubricate the spindle and the thrust piece with the cut-off slide with a little Molybdenum Disulphide (MoS2), see Procedure 91311. 11. Assemble the thrust piece, the spindle and the spindle guide and carefully knock the parts together using a soft hammer. 12. Shake the spindle guide back and forth. The spindle with the cut-off slide must be able to slide freely back and forth inside the spindle guide, with a clicking sound.

11.

Page 4 (5)

M90912 0228O12

M90912 0228O11

12.

When referring to this page, please quote Procedure M90912 Edition 0228 MAN B&W Diesel A/S

Fuel Valve Spindle Guide


Overhaul
13. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS2). See Procedure 913-11. Mount the nozzle on the spindle guide. Make sure that the half-circle shaped groove on the nozzle and the spring pin are in line. If nozzle and spindle guide are provided with scratch marks opposite the spring pin, they must be in line. Place the parts on the plane of a drilling machine or hydraulic press and position the mounting tool over the parts. Make sure that all the parts are perfectly 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. If no mounting tools are available, the nozzle can be mounted on the spindle guide using 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 together the same way as when using the mounting tools. Check that the spindle inside the spindle guide is able to move freely as in step 10. 14. If the spindle guide is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle guide during storage.

909-12.3

13.

Spring pin

Scratch marks

When referring to this page, please quote Procedure M90912 Edition 0228 MAN B&W Diesel A/S

M90912 0228O13

Page 5 (5)

Non-return Valve for Fuel Valve


Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
Stopped engine Shut off star ting air supply At star ting air receiver Block the main star ting valve Shut off star ting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

109-13

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10913 Edition 0033 MAN B&W Diesel A/S

Page 1 (2)

109-13

Non-return Valve for Fuel Valve


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

P90951 P90968

153

Flange for dismantling of non return valve Fuel Valve - Inspection Tools

Page 2 (2)

When referring to this page, please quote Data D10913 Edition 0033 MAN B&W Diesel A/S

Non-return valve
Overhaul
Non-return valve K98MC-C 0206 Overhaul 909-13.3

909-13.3

1. Note! Extreme care and accuracy should be exercised when carrying out this operation. 1. Clean the outside of the non-return valve with pure gas oil. The individual parts are not interchangeable, therefore only one guide is to be disassembled at a time. Note! Except for the slide valve spring, defective parts cannot be replaced individually by new ones. Place the non-return valve as shown in Fig. 1 in a bench vice provided with soft jaws, and disassemble the non-return valve, using the disassembling tool and a hammer as shown. 2. Clean all the parts for the spindle guide in gas oil and wipe them dry with a clean piece of cloth. Finally, clean in either gas oil, kerosene or Electrocleaner', and wipe the parts dry with a clean piece of cloth. 3. Now place the parts on clean, lint-free rags and examine with an 8-10 times enlargement magnifying glass, and an inspection lamp with magnifying glass as shown in Fig. 3.

     

     & 0

2.

B
             % 1

3.

           & 0

When referring to this page, please quote Procedure M90913 Edition 0206 0$1 % : 'LHVHO $6

Page 1 (2)

909-13.3

Non-return valve
Overhaul

4.

4. Examine the slide faces of movable parts for coating. Vent slide B/housing A will be too tight if there is a coating. (The letters AD refer to the letters/parts in Fig. 2). Fix vent slide B and, subsequently, housing A in a lathe as shown in Fig. 4 and remove the coating by means of very fine conventional polishing linen grade 360'. Also a little oil should be used (a coarser polishing linen must absolutely not be used).

MC909-6.2 69 04

5. Check spring C for the thrust piece for outside wear marks. If defective, it should be exchanged. 5. Check the seat on thrust piece D/vent slide, and the seat on vent slide/housing. Use an inspection lamp and an 8-10 times enlargement magnifying glass. If the seats are not in order, i.e. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded. 6. Mount the non-return valve as follows: Lubricate all movable parts with molybdenum disulphide (MoS2). 6. Place the loosely-assembled non-return valve on the plane of a drilling machine, with the tool positioned as shown in Fig. 6. Make sure that the thrust piece and the other parts are perfectly aligned and that the thrust piece is guided in the vent slide. Press the handle until the housing and thrust piece meet. 7. If the non-return valve is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the non-return valve with plastic to prevent dirt from entering the valve during storage.

Page 2 (2)

MC909-6.3 69 06

NA909-13.3 205 05

When referring to this page, please quote Procedure M90913 Edition 0206 0$1 % : 'LHVHO $6

Fuel Oil High-Pressure Pipe


MAN B&W Diesel Data

109-14

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-48 D09-49 D09-50 D09-52 Description Fuel valve end, union nipples, tightening torque Fuel pump end, union nipples, tightening torque Union nuts, tightening torque Fuel oil pipe Value 190 190 55 20 Unit Nm Nm Nm kg

When referring to this page, please quote Data D10914 Edition 0080

Page 1 (2)

109-14

Fuel Oil High-Pressure Pipe


Data MAN B&W Diesel

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

Plate P90951 P90951

Item No. 104 128 Milling tool for fuel oil pipe Crowfoot spanner

Description

Page 2 (2)

When referring to this page, please quote Data D10914 Edition 0080

Fuel Oil High-Pressure Pipe


MAN B&W Diesel
High Pressure Pipe with Double Pipe 1. Close the fuel oil inlet and outlet valves. 2. Unscrew the union nut and the union nipple from the fuel valve. 3. Unscrew the union nut and the union nipple from the fuel pump. 4. Lift the pipe ends clear of the fuel valve/ fuel pump, and remove the high pressure pipe from the engine. Note! It is recommended always to overhaul the high pressure pipe before remounting it on the engine. See Procedure 909 14.3. The overhaul should preferably take place immediately after the high pressure pipe has been dismantled.
M90914 0254D02

909-14.2

Dismantling
2.

3.

M90914 0254D03

4.

D09 52

When referring to this page, please quote Procedure M90914 Edition 0255

M90914 0254D04

Page 1 (5)

909-14.3

Fuel Oil High-Pressure Pipe


Overhaul MAN B&W Diesel
Whenever the fuel oil high pressure system has been dismantled, it is necessary, before remounting the high pressure pipes, to carefully inspect the tapered contact surfaces of the pipe ends, together with their seats in fuel valves and fuel pump top cover. If the pipe ends require reconditioning, proceed as follows: 1. Fasten the pipe in a vice with soft jaws. Mount the miller on the pipe end.

1.
A

M90914 0254O01

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.
Max. grind away

2.

Turn the miller with, for instance, a tap wrench while lightly tightening the upper tightening ring (A) to provide a suitable pressure between the miller and the pipe end. During the milling process, add drilling oil emulsion liberally.
M90914 0242O03

2. On both pipe ends a small groove has been ground to indicate the maximum allowable grinding of the pipe ends. The pipe ends may only be ground until the ground surface is ush with the bottom of the groove. If the pipe ends are still not in order, the pipe must be discarded. After completing the milling, carefully clean the high pressure pipe, and blow through the bore with compressed air. 3. When the milling is nished: Lift up the union nut. Remove the spring ring from the two part sleeve. Remove the sleeve.

3.

Page 2 (5)

M90914-0255O03

When referring to this page, please quote Procedure M90914 Edition 0255

Fuel Oil High-Pressure Pipe


MAN B&W Diesel Overhaul
4.

909-14.3

4. Pull off the sleeves and union nuts and remove the sealing rings A, B and C. Clean all parts carefully.

When referring to this page, please quote Procedure M90914 Edition 0255

M90914-0255O04

Page 3 (5)

909-14.3

Fuel Oil High-Pressure Pipe


Overhaul MAN B&W Diesel

5.

5. Fit the union nuts and bushings with new seaing 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.

Page 4 (5)

M90914-0255O05

When referring to this page, please quote Procedure M90914 Edition 0255

Fuel Oil High-Pressure Pipe


MAN B&W Diesel Mounting
3.

909-14.4

1. Ensure that the fuel valve and the fuel pump end of the high pressure pipe are tted with new O rings. Lubricate the thread of the fuel valve with a heat resistant grease. 2. Ensure that the union nuts on both sleeves on the high pressure pipe is tted. Lubricate the thread on the union nipple with a heat resistant grease. Pull back both sleeves on the high pressure pipe as far as possisble. 3. Mount the high pressure pipe between the fuel valve and the fuel pump. First screw the union nipple onto the fuel valve to nearly full contact. Then t the sleeve of the high pressure pipe in the fuel pump. Note! The nipples must be screwed by hand, as the threads of the union nipples, fuel valve or fuel pump top cover might otherwise be damaged. Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position. 4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel valve to the torque stated in Data. 5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel pump to the torque stated in Data. Tighten both union nuts to the torque stated in Data. 6. If dismantled, re mount the return oil pipe on the fuel valve. Open the fuel oil inlet and outlet valves.

D09 52

M90914 0254M03

4.

D09-48 D09-50

M90914-0255M04

5.

D09-50 D09-49

When referring to this page, please quote Procedure M90?914Edition 0255

M90914-0255M05

Page 5 (5)

Fuel Pump Roller Guide


MAN B&W Diesel Data

109-15

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D09-53 D09-57 D09-61 D09-62 Description Nut, reversing shaft, tightening torque Roller/bushing/shaft pin, max. clearance Fuel pump roller guide Pump base Value 160 0,5 250 250 Unit Nm mm kg kg

When referring to this page, please quote Data D10915 Edition 0062

Page 1 (2)

109-15

Fuel Pump Roller Guide


Data MAN B&W Diesel

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

Plate P90851

Item No. 053 Lifting tool for roller guide

Description

Page 2 (2)

When referring to this page, please quote Data D10915 Edition 0062

Fuel Pump Roller Guide


MAN B&W Diesel
Roller guide mounted in engine 1. The fuel pump roller guide can be partially checked while mounted on the engine, using the following procedure:

909-15.1

Checking
2.

2. Lift the fuel pump roller guide. See Procedure 909-10. Remove the cover on the camshaft housing to inspect the fuel pump roller guide. 3. Turn the engine to provide the maximum space between the roller guide and the cam disc. Turn the roller by hand to check that it can move freely and without unnecessary resistance or hard points. Also inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that there are no traces of bearing metal left in the roller guide housing. Check the clearance in the slide bearing by lifting the roller relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller. 4. Lower the roller guide onto the fuel cam again. See Procedure 909-10.

When referring to this page, please quote Procedure M90915 Edition 0236

M90915-0236C03

M90915-0236C02

3.

Page 1 (10)

909-15.1

Fuel Pump Roller Guide


Checking MAN B&W Diesel

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:

D09-61

5. Dismount the roller guide from the engine. See Procedure 909-15.2. 6. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness. 7. Turn the roller guide upside down and land it in a vertical position on a couple of wooden planks, with the roller hanging freely.

M90915-0236C07

8. Measure the clearance in the slide bearing by placing a dial gauge against the roller and lifting the roller as much as the clearance permits.

8.

D09-57

Page 2 (10)

M90915-0236C08

When referring to this page, please quote Procedure M90915 Edition 0236

Fuel Pump Roller Guide


MAN B&W Diesel Dismantling
1. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1. Dismantle the top cover and the barrel/ plunger assembly. See Procedure 909-5.2. See Procedure 909-6.2.

909-15.2

2. Dismantle the fuel pump housing. See Procedure 909-4.2. Note! When lifting the fuel pump housing, take care not to damage the threads on the studs.
M90915-0236D01

2.

When referring to this page, please quote Procedure M90915 Edition 0236

M90915-0236D02

Page 3 (10)

909-15.2

Fuel Pump Roller Guide


Dismantling MAN B&W Diesel

3.

3. Loosen and remove the locking wire and the screws from the disc on top of the roller guide inside the pump base. Remove the sealing cap from the roller guide/pump base. Dismantle the lubricating oil pipe and the drain pipe from the pump base. 4. Remove the cover on the camshaft housing to inspect the position of the roller guide. Turn the engine until the roller guide is at BDC.

Page 4 (10)

M90915-0236C02

M90915-0236D03

4.

When referring to this page, please quote Procedure M90915 Edition 0236

Fuel Pump Roller Guide


MAN B&W Diesel Dismantling
5.

909-15.2

5. Loosen the nuts on the two threaded studs successively until the roller guide springs are relieved. Remove the nuts, mount two eye bolts in the pump base and lift it away. When lifting, take care that the bushing of the pump base slides against the upper part of the roller guide without scratching. Remove the springs from the roller guide. 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.

D09-62

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. When lifting, take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing. Land the roller guide on wooden planks. 7. Check the roller guide. See Procedure 909-15.1.

M90915-0236D05

Turn the tool 90 so as to allow the foot to engage properly in the bayonet joint.

6.

D09-61

90

When referring to this page, please quote Procedure M90915 Edition 0236

M90915-0236D06

Page 5 (10)

909-15.3

Fuel Pump Roller Guide


Overhaul
1.

MAN B&W Diesel


Inspect and check the fuel pump roller guide. See Procedure 909-15.1.

1.

2. It is recommended that the roller guide should ONLY be dismantled if

D09-61

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 shop. 3. If no irregularities are found, just clean and lubricate the roller guide before remounting it in the roller guide bushing.

Page 6 (10)

M90915-0236O03

M90915-0236C07

3.

When referring to this page, please quote Procedure M90915 Edition 0236

Fuel Pump Roller Guide


MAN B&W Diesel
1.

909-15.4

Mounting

Lubricate the roller guide with plenty of 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. Make sure that the pin of the reversing link ts in the guide of the reversing shaft.

1.

D09-61

2. After mounting the roller guide with the reversing link, check the clearance between the roller guide and the guide plate mounted in the roller guide bushing. Turn the camshaft so that the roller guide is lifted approx. 20 mm. The clearance C between the roller guide and the guide plate must be the same at both ends 0.10 mm. The clearances A and B between the guideway and the pin of the reversing link (arm) must be checked in the AHEAD and ASTERN positions. 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. Note that clearances A and B change position when changing from AHEAD to ASTERN.
M90915-0236M01

90

2.

A B C

When referring to this page, please quote Procedure M90915 Edition 0236

M90915-0236M02

Page 7 (10)

909-15.4

Fuel Pump Roller Guide


Mounting MAN B&W Diesel

3.

3. If adjustment is necessary, it must take place in the ASTERN position.

D09-53

Loosen the nut on the reversing shaft and carry out the adjustment. After adjustment, shift to AHEAD position and check the clearances A and B once more. Finally, shift again to
ASTERN.

Tighten the nut on the reversing shaft, and lock the nut with Loctite, see Data. 4. Turn the engine until the roller guide is at the lowest point of the fuel cam.

D09-53

5. Mount the new sealing ring in the groove inside the bushing of the pump base. Make sure to mount the sealing ring correctly. See the sketch.

Page 8 (10)

M90915-0236M05

M90915-0236M03

5.

When referring to this page, please quote Procedure M90915 Edition 0236

Fuel Pump Roller Guide


MAN B&W Diesel Mounting
6.

909-15.4

6. Mount the spring and the spring seat discs over the roller guide. Mount the pump base over the roller guide and the springs. Mount the two special nuts on the threaded studs. Tighten the nuts until the pump base is fastened tightly to the roller guide bushing. 7. Check the movement of the reversing link. See Procedure 909-15.1.

D09-62

When referring to this page, please quote Procedure M90915 Edition 0236

M90915-0236C03

M90915-0236D05

7.

Page 9 (10)

909-15.4

Fuel Pump Roller Guide


Mounting MAN B&W Diesel

8.

8. Mount the lubricating oil pipe and the drain pipe on the pump base. Mount the sealing cap, the disc and the screws on top of the roller guide, over the sealing bush inside the pump base. Tighten the screws and lock with locking wire. 9. Mount the fuel pump housing. See Procedure 909-4.4.

M90915-0236D03

10. Mount the barrel/plunger assembly. See Procedure 909-6.4. 11. Mount the fuel pump top cover. See Procedure 909-5.4. 12. Mount the fuel oil high-pressure pipes. See Procedure 909-14.4. 13. Close the fuel pump drain cock. Open the fuel oil inlet and outlet valves.

9.

Page 10 (10)

M90915-0236D02

When referring to this page, please quote Procedure M90915 Edition 0236

Fuel Valve and Fuel Pump Panel

Plate P90951-0446

When referring to this page, please quote Plate P90951 Edition 0446
MAN B&W Diesel A/S

Page 1 (2)

Plate P90951-0446 Item No.


010 021 045 057 069 070 094 104 128 130 141 153 165 177 189 190 200 224 236 248 250 261 273 297

Fuel Valve and Fuel Pump Panel


Item No.

Item Description
Panel for tools Name plate Measuring tool for fuel pump Lifting tool for fuel pump Lifting tool for fuel pump Lifting tool for fuel pump housing Milling tool for fuel oil pipe seats Milling tool for fuel oil pipe Crowfoot spanner Crowfoot spanner Crowfoot spanner Flange for dismantling of non-return valve Grinding mandrel for valve head Grinding mandrel for thrust spindle Grinding mandrel for holder, outside Grinding mandrel for holder, inside Screw Tool for P.max rack Pin wrench, speciale Hook spanner Drift for spindle guide Drift for puncture valve Drift for Non-return valve Assembling tool

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90951 Edition 0446
MAN B&W Diesel A/S

Fuel Valve - Tools

Plate P90961-0069

When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S

Page 1 (2)

Plate P90961-0069 Item No.


014 026 038 040 051 063 075 087 099 109 122

Fuel Valve - Tools


Item No.

Item Description
High-pressure pump Table Rig fuel oil valve High-pressure hose Connection piece, M42x2 Test rig, complete Cover Angle union Gasket Plug screw Hose

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S

Fuel Valve Nozzle - Tools

Plate P90966-0008

When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S

Page 1 (2)

Plate P90966-0008 Item No.


011 023 035 047 060 202

Fuel Valve Nozzle - Tools


Item No.

Item Description
Tool box Extractor for atomizer Drift for atomizer Cleaning brush Instruction plate Toolset, complete Note: When odering new cleaning tool, please state P/N on fuel nozzle.

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S

Fuel Puncture Valve - Tools

Plate P90967-0001

When referring to this page, please quote Plate P90967 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90967-0001 Item No.


017

Fuel Puncture Valve - Tools


Item Description Item No. Item Description

Tool for tightening of puncture valve

Page 2 (2)

When referring to this page, please quote Plate P90967 Edition 0001
MAN B&W Diesel A/S

Fuel Valve - Inspection Tools

Plate P90968-0001

When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90968-0001 Item No.


012

Fuel Valve - Inspection Tools


Item Description Item No. Item Description

Probe light with magnifier, complete

Page 2 (2)

When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S

Fuel Valve Nozzle - Cleaning Tools

Plate P90974-0001

When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90974-0001 Item No.


015 027 039 206

Fuel Valve Nozzle - Cleaning Tools


Item Description Item No. Item Description

Drill* Test mandrel* Pin vice* Cleaning tool set, complete Note: * When ordering new cleaning tool, please state P/N on fuel nozzle.

Page 2 (2)

When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S

Mounting Tools - Pump Barrel Seals


Mounting Tools - Pump Barrel Seals 0001 P90977

Plate P90977-0001

When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90977-0001 Item No.


011 023 035 047 059 060 072

Mounting Tools - Pump Barrel Seals


Item No.

Item Description
Cone Pushing tool Compression tool Cone Pushing tool Compression tool Spacer ring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S

Mounting Tools - Suction Valve Seals


Mounting Tools - Suction Valve Seals 0001 P90979

Plate P90979-0001

When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90979-0001 Item No.


012 024 036

Mounting Tools - Suction Valve Seals


Item No.

Item Description
Cone Pushing tool Compression tool

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S

Mounting Tools - Air Piston Seals


Mounting Tools - Air Piston Seals 0001 P90980

Plate P90980-0001

When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P90980-0001 Item No.


018 020 031 043 055 067 079

Mounting Tools - Air Piston Seals


Item No.

Item Description
Cone Pushing tool Compression tool Cone Pushing tool Compression tool Cone

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S

910 - Turbocharger System


Documents in this Chapter
110-01 910-01 110-02 910-02 110-03 910-03 110-04 910-04 110-05 910-05 110-06 910-06 91063 91063 91063 91064 91066 0051 0243 0009 0210 0031 0218 0005 0205 0010 0213 0032 0222 0018 0019 0020 0001 0002 Air Cooler Element, Data Air Cooler Element Non-Return Valve after Air Cooler, Data Non Return Valve after Air Cooler Auxilary Blower, Data Auxilary Blower Butterfly Valve, Data Butterfly Valves Turbocharger Turbine, Data Turbocharger Turbine Water Mist Catcher, Data Water Mist Catcher Air Cooler - Tools Air Cooler - Tools Air Cooler - Tools Travelling Trolley Air Cooler - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Air Cooler Element


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

110-1

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

Data
Ref. Description Value Unit

D10-02 D10-04 D10-05

Aft end cover Air cooler element, complete with covers, up to Front end cover (waterflow reversing chamber)

260 2500 260

kg kg kg

When referring to this page, please quote Data D11001 Edition 0051 MAN B&W Diesel A/S

Page 1 (2)

110-1

Air Cooler Element


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P91063 P91064 P91066 P91356 Item No. Air Cooler - Tools Travelling Trolley Air Cooler - Lifting Tools Lifting Tools, Etc. Description

Page 2 (2)

When referring to this page, please quote Data D11001 Edition 0051 MAN B&W Diesel A/S

Air Cooler Element


MAN B&W Diesel Checking
1.

910-1.1

1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running. Compare these measurements with the testbed data. For further evaluation of the measurements, see the OPERATION manual, Volume I, Chapter 706. 2. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. 3. If the measurements indicate fouling of the water side of the air cooler element, the element must be overhauled/cleaned. See Procedure 910-1.3 water side. If the measurements indicate fouling of the air side of the air cooler element, it is recommended to inspect the air cooler element as follows: 4. Remove the top inspection cover of the air cooler. Unlock and swing open the inspection hatch at the bottom of the air cooler. 5. Visually inspect the air cooler element through the openings. For further information, see the OPERATION manual, Volume I, Chapter 702 Checks during Standstill Periods. If the air side of the element is fouled, clean the element using the spray pipe arrangement fitted above the air cooler element. See Procedure 910-1.3 air side.

When referring to this page, please quote Procedure M91001 Edition 0243

M91001 0243C03

M91001 0243C02

M91001 0243C01

2.

3.

Page 1 (10)

910-1.2

Air Cooler Element


Dismantling MAN B&W Diesel

1.

The cooler element normally does not need to be dismantled for inspection purposes. It is only in the event that the cooler element has suffered damage that it has to be dismantled and replaced. Note! During dismantling, take care not to damage the cooler element.

M91001 0243C04

1. Close the cooling water inlet and outlet valves. Open the drain cocks to drain off the cooling water and dismantle the drain pipes. Dismount the screws which fasten the cooling water inlet and outlet flanges to the aft end cover. 2. Dismount the brackets which control the longitudinal position of the air cooler element. Dismount the sealing flanges around the aft end cover. For convenience, the sealing flanges may be left hanging on the cooling water pipes during dismantling and mounting of the cooler element. 3. Dismount the sealing flanges around the front end cover.

2.

Page 2 (10)

M91001 0243C06

M91001 0243C05

3.

When referring to this page, please quote Procedure M91001 Edition 0243

Air Cooler Element


MAN B&W Diesel Dismantling
4.

910-1.2

4. Mount the pair of guide rails on the front of the cooler housing. Mount the lifting bracket on the front end cover of the cooler element. Mount a travelling trolley on the beam above the front end of the scavenge air cooler. Attach a tackle between the travelling trolley and the lifting bracket, and haul tight. 5. Mount the guide wheels on the aft end cover. 6. Mount a pair of guide rails on the rear end of the cooler housing.

When referring to this page, please quote Procedure M91001 Edition 0243

M91001 0243D06

M91001 0243D05

M91001 0243D04

5.

6.

Page 3 (10)

910-1.2

Air Cooler Element


Dismantling MAN B&W Diesel

7.

7. When mounting the guide rails, hold them up against the wheels of the cooler element and mount, but do not tighten, the lowermost screws. Mount and tighten the uppermost screws. Tighten the lowermost screws and the thrust nuts on the uppermost screws simultaneously. This results in loosening and lifting the cooler element. 8. Tighten the tackle until the front end of the cooler element comes loose.

M91001 0243D07

9. Pull the cooler element out of the cooler housing by means of a tackle until the wheels engage with the holes in the guide rails on the front of the cooler housing.

8.

M91001 0243D08

9.

Page 4 (10)

M91001 0243D09

D10 03

When referring to this page, please quote Procedure M91001 Edition 0243

Air Cooler Element


MAN B&W Diesel
10. Mount a lifting bracket on the aft end cover. Fit a tackle to the lifting bracket on the aft end cover and lift away the cooler element and land it on a couple of wooden planks. Note! Depending on the engine and the engine room installation, it may be necessary to remove some pipes and floor plates.
M91001 0243D10

910-1.3

Overhaul
10.

D10 03

When referring to this page, please quote M91001 Edition 0243

Page 5 (10)

910-1.3

Air Cooler Element


Overhaul
Cleaning the air side:

MAN B&W Diesel

1. The air side of the cooler is cleaned by injecting a chemical fluid through the spray pipe arrangement fitted to the air chamber above the cooler element. It is recommended to use one of the following cleaning fluids, or a similar product. 1) Product: ACC 9, produced by Drew Chemical Corp., New York, USA 2) Product: 80B, produced by Vecom Int., Maassluis, Holland Cleaning should be carried out in the following sequence: 1. Do not start cleaning until the engine has been at a standstill for about 30 minutes. Do not disconnect the compressed air supply to the exhaust valve. 2. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the cleaning fluid, the circulating pump pressure must be at least 0.7 bar. 3. Continue the cleaning process for at least 30 minutes. The time required depends on the frequency with which cleaning is carried out and on the chemical product used. 4. After cleaning, flush the cooler with clean water until the water appearing in the sight glasses is clean and pure. 5. Inspect the element either by removing the cover on top of the cooler or by dismantling the charging air pipe.

Page 6 (10)

M91001 0243O02

M91001 0243O01

2.

When referring to this page, please quote Procedure M91001 Edition 0243

Air Cooler Element


MAN B&W Diesel
Cleaning the water side 6. 6. If necessary, remove the air cooler. See Procedure 910-1.2. For overhauling the air cooler, see manufacturers instruction.

910-1.3

Overhaul

When referring to this page, please quote M91001 Edition 0243

M91001 0243O06

Page 7 (10)

910-1.4

Air Cooler Element


Mounting MAN B&W Diesel

1.

1. Lift the air cooler element and land the aft end of the element on the guide rails mounted on the front end of the air cooler housing. Remove the tackle and the lifting bracket from the aft end of the cooler element. 2. Push the air cooler element fully into the air cooler housing 3. Remove the guide rails from the aft end of the air cooler housing.

M91001 0243D10

D10 03

Note! Before pushing the air cooler element fully in, make sure that the sealing flanges and a new O-ring are in position, hanging on the cooling water pipes.

2.

Page 8 (10)

M91001 0243D08

M91001 0243D05

3.

When referring to this page, please quote Procedure M91001 Edition 0243

Air Cooler Element


MAN B&W Diesel Mounting
4.

910-1.4

4. Remove the guide wheels from the aft end cover. 5. Remove the guide rails and the lifting bracket from the front end cover. 6. Mount the sealing plate, a new O-ring and the frame around the front end cover.

When referring to this page, please quote Procedure M91001 Edition 0243

M91001 0243C06

M91001 0243M05

M91001 0243M04

5.

6.

Page 9 (10)

910-1.4

Air Cooler Element


Mounting MAN B&W Diesel

7.

7. Mount the sealing plate, a new O-ring and the frame around the aft end cover. Mount and tighten the brackets which control the longitudinal position of the air cooler element. 8. Insert new gaskets between the aft end cover and the flanges of the cooling water pipes. Mount and tighten the screws which fasten the cooling water inlet and outlet pipes to the aft end cover. Mount the drain pipes, and open the cooling water inlet and outlet valves. Note! Remember to vent trapped air from the air cooler element.

Page 10 (10)

M91001 0243M08

M91001 0243C05

8.

When referring to this page, please quote Procedure M91001 Edition 0243

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

110-2

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

N D R B I E

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11002 Edition 0009 MAN B&W Diesel A/S

Page 1 (2)

110-2

Non-Return Valve
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D11002 Edition 0009 MAN B&W Diesel A/S

Non-Return Valve
Overhaul
Non-Return Valve .0&& 0210 Overhaul 910-2.3

910-2.3

1. Access to the non-return valves in the scavenge air receiver takes place after the engine has been stopped through the inspection openings of the receiver. Warning!
MA910-6.0 33 01

1.

Access to the scavenge air receiver must not be attempted until the air in the receiver is clean. 2. Remove the two outermost and middle nuts (which fasten the valve assembly to the housing). Lift the complete valve assembly out of the air receiver. 3. Remove the spring pin from the valve shaft and knock the valve shaft out of the valve flap. 4. For further dismantling, remove the two screws which hold the clamp and the support together as an assembly. Clean the valve shaft and the slide bearings inside the valve flaps. Lubricate the valve shaft and the slide bearings with molybdenum disulphide (MoS 2). 5. Assemble the valve After the overhaul, it must be possible to move the valve flap by the light touch of a finger. 6. Re-mount the valve in the scavenge air receiver.

2.

MC910-6.0 26 01B

3.

MC910-6.0 26 02

4.

When referring to this page, please quote Procedure M91002 Edition 0210 0$1 % : 'LHVHO $6

MC910-6.0 26 03

Page 1 (1)

Auxiliary Blower
MAN B&W Diesel Data

110-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


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

Data Ref. D10-12 Description Electric motor, impeller and motorplate Value 705 Unit kg

When referring to this page, please quote Data D11003 Edition 0031

Page 1 (2)

110-3

Auxiliary Blower
Data MAN B&W Diesel

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

Plate P91356

Item No. Lifting Tools, Etc.

Description

Page 2 (2)

When referring to this page, please quote Data D11003 Edition 0031

Auxiliary Blower
Overhaul
Auxiliary Blower 60&& 0218 Overhaul 910-3.3

910-3.3

1. When cleaning and inspecting the auxiliary blower, disengage the cable connections to the blower motor. Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the blower flange, before removing the screw in the flange. 2. The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. While pulling out the end cover with the blower assembly, make sure that the blower housing disengages from the air pipe without deforming it. Then inspect and clean the blower wheel as well as the blower housing. For overhaul of blower wheel and bearings, see blower manufacturers instructions. Note! Exercise care when mounting the electric motor with blower wheel, as the blower wheel is to catch the guide in the blower housing.
MC910-8.0 31 01

1.

D10-12

2.

When referring to this page, please quote Procedure M91003 Edition 0218 0$1 % : 'LHVHO $6

MC910-8.0 31 02

Page 1 (1)

Butterfly Valves
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X X X X X X X

110-4

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11004 Edition 0005 MAN B&W Diesel A/S

Page 1 (2)

110-4

Butterfly Valves
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D11004 Edition 0005 MAN B&W Diesel A/S

Butterfly Valves
Checking
Butterfly Valves 60&& 0205 Checking 910-4.1

910-4.1

1. It is important that the automatic non-return valves (butterfly valves) are always able to function easily and unimpeded. The movability of the valve flaps should therefore be checked at suitable intervals. The valves shall open for the air flow from the scavenge air cooler housings to the auxiliary blowers. 2. To check the valve, remove the cover on the top of the butterfly valve. Reach down through the opening in the top of the valve and move the valve flaps. 3. If the valve flaps in one of the butterfly valves cannot be moved by a light touch of a fingertip, it must be dismantled and overhauled. 4. Re-mount the cover on the top of the butterfly valve.
MN910-4.1 205 01

1.

Flow direction

2.

When referring to this page, please quote Procedure M91004 Edition 0205 0$1 % : 'LHVHO $6

XZ910-9.0 15 02

Page 1 (1)

Turbocharger Turbine
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

110-5

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11005 Edition 0010 MAN B&W Diesel A/S

Page 1 (2)

110-5

Turbocharger Turbine
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

When referring to this page, please quote Data D11005 Edition 0010 MAN B&W Diesel A/S

Turbocharger Turbine
MAN B&W Diesel Cleaning

910-5.3

The dry cleaning method employs compressed air to blow dry, solid, granules through the turbocharger, thus removing most of the deposits which may have formed on the nozzle vanes and turbine blades. On account of their hardness, nut-shells, or broken or artificially shaped pieces of activated charcoal with a size of between 2.0 and max. 2.8 mm are particularly suited as blasting agents. This size of granules is also known as Marine Grit No. 8. 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 100 hours of operation. Generally, turbocharger cleaning can be carried out without, or with very little, reduction of the engine load. More detailed information regarding the amount of granules to be used is stated on the instruction plate located close to the turbocharger. Note! Regarding water washing of turbocharger turbine, see turbine manufacturers instructions. See also Volume I, Chapter 706.

When referring to this page, please quote Procedure M91005 Edition 0213

Page 1 (2)

910-5.3

Turbocharger Turbine
Cleaning
Cleaning Procedure:

MAN B&W Diesel

1. 1. Carry out cleaning for every 24 to 100 hours of operation, based on observations.

A B

2. Preferably clean the turbocharger at full load, but not at TC rpm above those stated in table 2. Do not clean below half load. 3. Close valve A. 4. Open valves B and C, to blow out any deposits and/or condensate in the connecting pipe. After about two minutes, close valves B and C. 5. Slowly open valve A to relieve the pressure in the tank. TC max. RPM 23300 18800 14800 13300 11900 11000 9400 8500 7. Close valve A. 8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves B and C. 9. Slowly open valve A to relieve the pressure in the tank. 6. Fill the tank with the quantity of granules specified in the table.

M91005 0211O01

2. TC type MET 33 SD/E/EII/MA MET 42 SD/E/EII/MA MET 53 SD/E/EII/MA MET 60 MA MET 66 SD/E/EII/MA MET 71 E/EII/MA MET 83 SD/E/EII/MA MET 90 SE/MA 6. TC type MET 33 SD/E/EII/MA MET 42 SD/E/EII/MA MET 53 SD/E/EII/MA MET 60 MA MET 66 SD/E/EII/MA MET 71 E/EII/MA MET 83 SD/E/EII/MA MET 90 SE/MA Amount Dm3 0.4 0.7 1.6 2.1 2.6 3.0 3.5 3.5

Caution! 1.The drain openings in the gas casings must remain closed while dry cleaning the turbine. 2. It is possible that during dry cleaning of the turbine, some of the blown-in solid particles or sparks will escape through the funnel.

Page 2 (2)

When referring to this page, please quote Procedure M91005 Edition 0213

Water Mist Catcher


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

110-6

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

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

Data
Ref. Description Value Unit

D10-11

Water mist catcher

260

kg

When referring to this page, please quote Data D11006 Edition 0032 MAN B&W Diesel A/S

Page 1 (2)

110-6

Water Mist Catcher


Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P91356 Item No. Lifting Tools, Etc. Description

Page 2 (2)

When referring to this page, please quote Data D11006 Edition 0032 MAN B&W Diesel A/S

Water Mist Catcher


Dismantling
Water Mist Catcher K98MC 0222 Dismantling 910-6.2

910-6.2

1. Normally it is not necessary to remove the water mist catcher element from the air cooler housing. If, however, the water mist catcher element has been fouled or damaged, it must be dismantled for cleaning or repair. 2. Dismantle the side covers from the air cooler housing. 3. Loosen the four screws which tighten the water mist catcher to the air cooler frame. 4. Pull the water mist catcher half way out and screw a lifting eye bolt into the top of the water mist catcher. Attach a tackle to the eye bolt and tighten up the tackle. 5. Pull the water mist catcher fully out of the air cooler housing and land it on a couple of wooden planks. 6. Clean or repair according to manufacturers instructions.
NA910-6.2 210 02

2.

3.

NA910-6.2 210 03

4.

D10-11

When referring to this page, please quote Procedure M91006 Edition 0222 MAN B&W Diesel A/S

NA910-6.2 210 04

Page 1 (2)

910-6.4

Water Mist Catcher


Mounting
Mounting 910-6.4

1.

1. Tilt the water mist catcher to the correct angle and slide it into the scavenge air cooler housing. Note! Make sure the water mist catcher is mounted in the right direction. Check the air flow indicator on the water mist catcher. When the water mist catcher is half-way in, remove the tackle and the eye bolt, and push the water mist catcher fully into the air cooler housing.

D10-11

NA910-6.4 210 01

2. Mount the screws which secure the water mist catcher to the air cooler frame. 3. Clean the side covers and apply a thin layer of silicone paste along the edges of the covers. Mount the covers.

2.

NA910-6.4 210 02

3.

NA910-6.2 210 02

Page 2 (2)

When referring to this page, please quote Procedure M91006 Edition 0222 MAN B&W Diesel A/S

Air Cooler - Tools


Air Cooler - Tools 0018 P91063

Plate P91063-0018

Fore end

When referring to this page, please quote Plate P91063 Edition 0018
MAN B&W Diesel A/S

Page 1 (2)

Plate P91063-0018 Item No.


015 027 039

Air Cooler - Tools


Item No.

Item Description
Guide rail, fore end - left Guide rail, fore end - right Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91063 Edition 0018
MAN B&W Diesel A/S

Air Cooler - Tools

Plate P91063-0019

When referring to this page, please quote Plate P91063 Edition 0019
MAN B&W Diesel A/S

Page 1 (2)

Plate P91063-0019 Item No.


015 027

Air Cooler - Tools


Item Description Item No. Item Description

Guide rail, rear end Guide rail, rear

Page 2 (2)

When referring to this page, please quote Plate

Edition
MAN B&W Diesel A/S

Air Cooler - T ools Tools


MAN B&W Diesel

Plate P91063-0020

When referring to this page, please quote Plate P91063 Edition 0020

Page 1 (2)

Plate P91063-0020 Item No.


015 027 039

Air Cooler - T ools Tools


MAN B&W Diesel Item No.

Item Description
Wheel for air cooler, left Wheel for air cooler, right Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91063 Edition 0020

Travelling Trolley
Travelling Trolley 0001 P91064

Plate P91064-0001

When referring to this page, please quote Plate P91064 Edition 0001
MAN B&W Diesel A/S

Page 1 (2)

Plate P91064-0001 Item No.


010

Travelling Trolley
Item No.

Item Description
Travelling trolley

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91064 Edition 0001
MAN B&W Diesel A/S

Air Cooler - Lifting T ools Tools


MAN B&W Diesel

Plate P91066-0002

When referring to this page, please quote Plate P91066 Edition 0002

Page 1 (2)

Plate P91066-0002 Item No.


011 023

Air Cooler - Lifting T ools Tools


MAN B&W Diesel Item No.

Item Description
Lifting attachment air cooler Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91066 Edition 0002

911 - Safety Equipment


Documents in this Chapter
111-01 911-01 111-02 911-02 111-03 911-03 0026 0212 0013 0211 0001 0001 Safety Valve, Data Safety Valve Relief Valve, Data Relief Valve Scavenge Air Receiver Safety Valve, Data Scavenge Air Receiver Safety Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Safety Valve
MAN B&W Diesel Data

111-1

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X X Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D11-01 D11-02 Opening pressure Valve housing, tightening torque Description Value 200 5 45 Unit bar Nm

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

Page 1 (2)

111-1

Safety Valve
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 P91351 P91351 P90151 P91359 Item No. 10 58 117 Description Hydraulic pump, pneumatically operated Hose with unions (3000 mm), complete Test equipment for combined safety valve Torque Spanners

Page 2 (2)

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

Safety Valve
MAN B&W Diesel
When Side-mounted 1. Remove the guard surrounding the safety valve. Unscrew the safety valve from the extension pipe. 2. Dismantle the indicator cock and the intermediate pipe.

911-1.2

Dismantling
1.

When Top-mounted 3. Unscrew the safety valve from the cylinder cover. Remove and discard the mild steel disc.

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

M91101 0211D03

M91101 0211D02

M91101 0211D01

2.

3.

Page 1 (5)

911-1.3

Safety Valve
Overhaul (Adjustment) MAN B&W Diesel

1.

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

Insert the valve flap and the stop ring in


the valve guide and screw on the valve housing.

Tighten the housing to the torque stated


in the data, loosen and tighten again to the torgue stated in the data.
M91101 0211O01

3. Then mount:

the valve spindle the spring the adjusting screw the lock nut

2.

Page 2 (5)

M91101 0211O03

M91101 0211O02

3.

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

Safety Valve
MAN B&W Diesel Overhaul (Adjustment)

911-1.3

4. To set the safety valve opening pressure:

4.

Set up the safety valve in the Fuel valve


test rig.

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

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

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

Tighten the adjusting screw of the


safety valve until the correct pressure is indicated (see Data).
M91101 0212O04

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

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

Page 3 (5)

911-1.4

Safety Valve
Mounting
When Side-mounted

MAN B&W Diesel

1. 1. Pierce the bore in the cylinder cover, and blow it clean. 2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe and the indicator cock. 3. Mount a new sealing ring and a new or overhauled safety valve. When mounting the safety valve, apply tools only on the hexagon on the safety valve. Mount the guard surrounding the safety valve.

Page 4 (5)

M91101 0211M03

M91101 0211M02

M91101 0211M01

2.

3.

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

Safety Valve
MAN B&W Diesel
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 cylinder cover, apply tools only on the hexagon on the safety valve.

911-1.4

Mounting

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

M91101 0211M05

M91101 0211M04

5.

Page 5 (5)

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

111-2

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

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

Data
Ref. Description Value Unit

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

Page 1 (2)

111-2

Relief Valve
Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description

Page 2 (2)

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

Relief Valve
Checking
Relief Valve 60& 0211 Checking 911-2.1

911-2.1

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

1.

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

XZ911-2.1 209 01

2.

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

XZ911-2.1 207 03

Page 1 (1)

Scavenge Air Receiver Safety Valve


MAN B&W Diesel Data

111-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply X Data Ref. Description Value Unit Lock the turbocharger rotors

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

Page 1 (2)

111-3

Scavenge Air Receiver Safety Valve


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

Page 2 (2)

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

Scavenge Air Receiver Safety Valve


MAN B&W Diesel
1. The scavenge air receiver safety valve is calibrated at the factory and does not re quire 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 O ring packing and close the valve again. Tighten the counter nut. If this operation cannot be performed smoothly, the safety valve must be disman tled and cleaned.
M91103 0001C02

911-3.1

Checking
2.

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

Page 1 (5)

911-3.2

Scavenge Air Receiver Safety Valve


Dismantling MAN B&W Diesel

1.

1. Dismount the safety valve from the scavenge air receiver. 2. On some engines, a cover has to be removed in order to gain access to the safety valve.

Page 2 (5)

M91103 0001D02

M91103 0001D01

2.

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

Scavenge Air Receiver Safety Valve


MAN B&W Diesel
1. Remove the split pin. Unscrew the nut thereby relieving the spring tension. Remove the nut, spring retainer and wash ers. Keep count of the washers. Pull out the spring. 2. Pull out the valve ap with spindle. If the O ring seal is damaged remove it without damaging the O ring groove. 3. Clean the metal surfaces thoroughly.

911-3.3

Overhaul
1.

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

M91103 0001O02

M91103 0001O01

2.

Page 3 (5)

911-3.3

Scavenge Air Receiver Safety Valve


Overhaul MAN B&W Diesel

4.

4. If the O ring seal has been removed mount a new one using Locktite type AVX and Loc tite activator type T or similar. 5. Push in the valve ap and spindle while tak ing care not to damage the O ring seal. 6. Mount the spring, spring retainer and all the washers. Tighten the nut until the split pin can be mounted.

M91103 0001O04

7. Check the valve according to 911 3.1.

5.

M91103 0001O05

6.

Page 4 (5)

M91103 0001O01

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

Scavenge Air Receiver Safety Valve


MAN B&W Diesel Mounting
1.

911-3.4

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

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

M91103 0001M01

Page 5 (5)

912 - Assembly of Large Parts


Documents in this Chapter
112-02 912-02 112-03 912-03 912-05 91261 91265 0015 0208 0027 0213 0201 0075 0002 Holding Down & End Chock Bolts, Data Holding Down and End Chock Bolts Stay Bolts, Data Stay Bolts Crankcase Oil Outlet Hydraulic Tools for Large Parts Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Holding Down And End Chock Bolts


MAN B&W Diesel Data

112-2

SAFETY PRECAUTIONS For detailed sketch, see 900-2


Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D12-02 Description Check holding down bolts and end chock bolts for correct tightening after the following service hours: 1st check 2nd check 3rd check 4th check 5th check Subsequent checks at intervals of D13-01 Hydraulic pressure, mounting 500 1000 2000 4000 8000 8000 900 hours hours hours hours hours hours bar Value Unit

When referring to this page, please quote Data D11202 Edition 0015

Page 1 (2)

112-2

Holding Down and End Chock Bolts


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 P91263 P91351 P91351 010 058 Item No. Description Hydraulic Tools for Holding-Down Bolts and End Chock Bolts, Epoxy Hydraulic pump, pneumatically operated Hose with unions (3000 mm), complete

Page 2 (2)

When referring to this page, please quote Data D11202 Edition 0015

Holding Down and End Chock Bolts


Checking
Holding Down and End Chock Bolts .0& 0208 Checking 912-2.1

912-2.1

Note! The hydraulic jack used for tightening the holding down bolts is marked with: For: Holding down bolts The larger jack used for tightening the end chock bolts is marked with: For: End chock bolts Hydraulic tightening of holding down bolts and end chock bolts is carried out as detailed in Section 913-1. The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool.

When referring to this page, please quote Procedure M91202 Edition 0208 0$1 % : 'LHVHO $6

Page 1 (5)

912-2.1

Holding Down and End Chock Bolts


Checking

1.

Checking the Bolt Tightening 1. The holding down bolts and end chock bolts must be checked for correct tightness at the intervals indicated on the Data sheet. For this purpose, raise the pressure on the hydraulic tool slowly while constantly attempting to loosen the nut with the tommy bar. The oil pressure indicated on the pressure gauge when the nut comes loose (loosening pressure') is to be noted down in the checking tables, see pages 4 and 5, following which the bolts are tightened to the normal tightening pressure. The condition of the bolted joints, and thus the general condition of the foundation, can be effectively checked by comparing the tables from successive bolt checks. If the loosening pressure' is below 80 per cent of the tightening pressure, the relative chocks shall always be checked for possible defects. If the chocks are in position and in order, the bolts should be taken out for inspection of threads and contact faces. Checking of Epoxy Supporting Chocks 2. If a number of measuring pins have been welded to the tanktop, the heights of the epoxy supporting chocks are to be checked immediately after finishing the checking of the loosening pressures of the holding down bolts and the retightening of these. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. Any possible settling of the chocks during the intervals between measurements can thereby be followed.

Page 2 (5)

EN912-1.1 205 01

When referring to this page, please quote Procedure M91202 Edition 0208 0$1 % : 'LHVHO $6

Holding Down and End Chock Bolts


Checking
3.

912-2.1

Side Chocks and Side Chock Liners 3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock the liners a further 3 to 4 mm inwards. The liners located in way of each main bearing on either side of the engine must be fitted and knocked into position simultaneously. The first time the ship is sailing in a fullyloaded condition after the engine has been operating for 1,000 hours, all side chocks should be checked to see whether the liners can be knocked further inward. The fit of the side chock liners should be checked with a feeler gauge each time the loosening pressure of the holding down bolts is checked, and thus at the same time intervals. The feeler gauge is applied at the 7 points indicated in the table on page 5, and the measurements found are to be entered in the relevant table. These results are used to determine whether refitting or, possibly, replacement of the liners is necessary. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed: 1. Loosen the hexagon screws. 2. Try to knock the liner further inward. 3. Measure again at the 7 points indicated in the table. If this procedure does not improve the situation, the liner must be removed, and it must be checked that the actual contact area is more than 80 per cent of the possible contact surface areas on both sides of the liner. The liners are secured in their correct position by means of hexagon socket set screws with cup point.

When referring to this page, please quote Procedure M91202 Edition 0208 0$1 % : 'LHVHO $6

GN912-2.1 203 03

Page 3 (5)

912-2.1

Holding Down and End Chock Bolts


Checking Holding Down Bolts

Engine frame Bolt No. No.

Port side
pressure % dev. remarks

Cylinder No.

Starboard side
pressure % dev. remarks

Bolt No.

Engine frame No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1

1 2 3

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Page 4 (5)

When referring to this page, please quote Procedure M91202 Edition 0208 0$1 % : 'LHVHO $6

Holding Down and End Chock Bolts


Checking Side Chocks and End Chock Bolts

912-2.1

Port side
Chock No.

Starboard side
f g
Cylinder No.

Point c d e

Point c d e

Chock

No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14
A

1 2 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14
A, B

A, B
c

FORE
d

c, d, e, f, g

c, d, e, f, g

Port side
Ch Bolt 2) No. No. (kp/cm bar
Pressure

Starboard side
Point Point a b c d e
Deviation

Deviation

a b c d e

(kp/cm 2 )

Pressure

bar

Bolt Ch No. No.

1 2
b a c d e d e c b a

1 E 2

No. 2

Contact face No. 1

No. 2

AFT

When referring to this page, please quote Procedure M91202 Edition 0208 0$1 % : 'LHVHO $6

B1

B2

B2

B1
Page 5 (5)

Stay Bolts
MAN B&W Diesel Data

112-3

SAFETY PRECAUTIONS For detailed sketch, see 900-2


X X X X X X
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D12-04 D13-01 D13-02 Check measurement Hydraulic pressure, mounting Hydraulic pressure, dismantling Description Value 0.4 900 800 - 990 Unit mm bar bar

When referring to this page, please quote Data D11203 Edition 0027

Page 1 (2)

112-3

Stay Bolts
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 P91261 P91351 P91351 P91351 P91351 010 046 058 105 Item No. Large Parts - Tools Hydraulic pump, pneumatically operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete Description

Page 2 (2)

When referring to this page, please quote Data D11203 Edition 0027

Stay Bolts
Checking
Stay Bolts K90MC-C 0213 Checking 912-3.1

912-3.1

1. Before retightening the stay bolts, remove the protective caps. 2. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other on the middle of the engine.
HM912-3.0 28 01

1.

Connect the high-pressure pump by means of the high-pressure hoses, so that the two stay bolts are tightened in one operation. 3. If the engine is equipped with split staybolts and one or more staybolts have been dismantled, make sure that the staybolts are mounted in such a way that, when the uppermost staybolt nut is loosened, there is a clearance, as stated in Data, between the contact face of the lowermost nut and the bedplate. If the engine is equipped with staybolts in one piece, please disregard the above.

2.

D13-01

MB912-3.1 213 02

3.

D12-05

When referring to this page, please quote Procedure M91203 Edition 0213 MAN B&W Diesel A/S

HM912-3.0 28 07

Page 1 (2)

912-3.1

Stay Bolts
Checking

4.

4. Start the retightening of the stay bolts and proceed to tighten the stay bolts in pairs, working from the middle toward one end of the engine and then from the middle again toward the other end. 5. Pump up the hydraulic pressure to 10% below the value indicated in D13-01, and retighten the stay bolt nuts with a tommy bar if possible. Before relieving the system of pressure, check with a feeler gauge that the nuts bear against the contact face.

HM912-3.0 28 03

6. Reconnect the hydraulic tools to the pair of stay bolts first tightened. Tighten to 10% below 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 procedure, mount the protective caps.

5.

D13-01 -10%

MB912-3.1 213 05

6.

HM912-3.0 28 06

Page 2 (2)

When referring to this page, please quote Procedure M91203 Edition 0213 MAN B&W Diesel A/S

Crankcase Oil Outlet


MAN B&W Diesel Checking
1.

912-5.1

The crankcase oil outlets guide the lubricating oil from the crankcase to the lubricating oil bottom tank. The sealings of the crankcase oil outlets must be checked at regular intervals, for example during dockings. The crankcase oil outlets may be equipped with either rubber diaphragm sealing or metal bellow sealing. Note! If the water content of the main engine lube oil is rising, this may indicate that the crankcase oil outlet sealings are fractured. Rubber diaphragm sealing 1. To access the rubber diaphragm sealing remove: Screws A Grating B Screws C Cover plate D Screws E Steel ring F. 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. Note! It is strongly recommended to always replace the diaphragms during inspection. If unavailable, new diaphragms may be made from three layers of 2 mm thick oil and temperature resistant rubber. 3. Mount: Rubber sealing diaphragms G Steel ring F Screws E Cover plate D Screws C Grating B Screws A. Note! Remember to fit new locking plates at screws A.

When referring to this page, please quote Procedure M91205 Edition 0201

M91205 0201C02

M91205 0201C01

2.

Page 1 (2)

912-5.1

Crankcase Oil Outlet


Checking
Metal bellow sealing

MAN B&W Diesel

4. 4. Remove all screws A and grating B.

C D F E
M91205 0201C04

B A

5. Remount four of the screws A at diametrically opposite positions. 6. Remove: Screws C Cover plate D Screws E.

7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are found in the metal bellow sealing, it must be replaced. Note!

7.

It is recommended to always replace the metal bellow sealing during inspection.

8. Replace gaskets G and H. 9. Mount metal bellow sealing F. 10. Mount: Screws E Cover plate D Screws C.
M91205 0201C07

11. Remove the four screws A. 12. Mount grating B. 13. Mount all screws A.

Page 2 (2)

When referring to this page, please quote Procedure M91205 Edition 0201

Large Parts - Tools

Plate P91261-0075

When referring to this page, please quote Plate P91261 Edition 0075
MAN B&W Diesel A/S

Page 1 (2)

Plate P91261-0075 Item No.


023 035 047 050 060 096 202

Large Parts - Tools


Item No.

Item Description
Hydraulic jack, complete Support Tommy bar Sealing ring with back-up ring Sealing ring with back-up ring Spanner Hydraulic tool set, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91261 Edition 0075
MAN B&W Diesel A/S

Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)


Hydraulic Tools - Holding Down Bolts (Epoxy Chocks) 0002 P91265

Plate P91265-0002

When referring to this page, please quote Plate P91265 Edition 0002
MAN B&W Diesel A/S

Page 1 (2)

Plate P91265-0002 Item No.


013 025 037 049 050 062 098 108

Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)


Item Description Item No. Item Description

Wooden box Hydraulic jack, complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Key, hexagon socket screw Stud setter

Page 2 (2)

When referring to this page, please quote Plate P91265 Edition 0002
MAN B&W Diesel A/S

913 - General Tools


Documents in this Chapter
913-01 913-03 913-04 913-05 913-06 913-07 91311 91351 91356 91357 91359 91360 91361 91362 91363 91364 91366 91368 0211 0007 0202 0205 0205 0207 0204 0034 0051 0006 0003 0005 0052 0060 0040 0059 0066 0011 Hydraulic Tools Working Platforms Standard Tightening Torques Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories - Hydraulic Tools Lifting Tools, etc. Open-Ended Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Hydraulic Tools

913-1

Hydraulic Tools 0211

A. Snap-on coupling
913-1

1.

B. Tool attachment thread C. Bleed screw D. Piston E. Cylinder F. Sealing rings

G. Spacer ring H. Tommy bar I. J. Nut Stud or bolt


HM913-1.0 10 00

K. Extension stud S. Clearance U. Milled recess for feeler gauge Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts must only be loosened and tightened up by means of the hydraulic tools supplied. The jack(s) is/are connected, via a distributor block, to a high-pressure pump, which is set to deliver hydraulic oil at the pressure indicated on the jack and on the data sheet in the relevant section of this instruction book. The stud or bolt concerned is thereby lengthened relative to the oil pressure applied and the piston area, and the nut can be loosened or tightened, as required, with the aid of a tommy bar. The jacks must never be overloaded or exposed to blows or impacts. They are marked with a Max. lift, which must not be exceeded. 1. The hydraulic tools, except those for the main bearings, consist of a jack with an internal thread to suit the tool attachment thread on the stud or bolt, and a spacer ring which is to be placed under the jack and around the nut that is to be loosened or tightened. 2. For the main bearings, an extension stud, three extra lower hydraulic jacks and a nut are added to each set. Each part is marked with a sign showing where to use the specific part.

2.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

KC913-1.0 17 02

Page 1 (12)

913-1

Hydraulic Tools

3.

3. The hydraulic jacks are so designed that, in the event that the Max. lift limit is exceeded, the pressure is relieved at the bottom of the pressure chamber, and the oil will be pressed out into the space between the stud and the spacer ring. When the pressure is relieved in this way, the lowermost sealing ring will in most cases be damaged. Therefore inspect and, if necessary, replace this sealing ring. The oil used must be pure hydraulic oil or turbine oil (with a viscosity of about SAE 20). Oils such as, for instance, lubricating oil (system oil) or cylinder lubricating oil must not be used, as these oils are normally alkaline and can thus damage the backup rings. The following instructions must be closely followed to prevent accidents or damage. After use, the jacks should be cleaned and kept in the wooden boxes supplied. Warning!

MB913-1.0 14 03

4.

Eye protectors and gloves must be used when using hydraulic tools. Maintenance 4. Disassembling the piston and cylinder is best carried out by taking out one of the bleed screws and pressing the parts from each other by means of compressed air. After disassembling, check that there are no damage marks on the sliding surfaces of the parts. If metal particles are present, they will damage the sealing rings. Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disuplhide. The hydraulic nuts do not require any maintenance other than replacement of defective sealing rings. These consist of an O-ring and a back-up ring, which are positioned in ring grooves in the piston and cylinder.

Page 2 (12)

KC913-1.0 17 04

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Hydraulic Tools
Loosening of Nut
Loosening of Nut 913-1

913-1

Single Hydraulic Jack 1. Carefully clean the tool attachment thread, the nut and the surrounding parts. Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar. Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot when the nut is to be loosened. 2. Screw the jack on to the tool attachment thread of the bolt/stud, until the cylinder of the jack bears firmly against the spacer ring, and check that the parts are guided correctly together. Connect the jack, the distributor block, and the high-pressure pump by means of highpressure hoses. Loosen the bleed screw and fill the system until oil, without bubbles, flows out of the bleed hole. Then tighten the bleed screw again. Adjust the clearance between the piston and cylinder of the jack (see the sketch and table) to provide for contraction of the bolt/ stud. If the clearance is too large, adjustment is made by loosening the bleed screw and turning the jack. The clearance is to have relation to the "Max. lift" of the jack and has the purpose of making it possible to dismount the jack after loosening the nut. After adjustment, check again that there is no clearance between the cylinder/spacer ring/surface.
HM913-1.1 10 01

1.

2.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

HM913-1.1 10 02

Page 3 (12)

913-1

Hydraulic Tools
Loosening of Nut

3.

3. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 90 bar. 4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up against the jack. 5. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.

HM913-1.1 10 03

4.

HM913-1.1 10 04

5.

Page 4 (12)

HM913-1.1 10 01

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Hydraulic Tools
Loosening of Nut
6. 7.

913-1

Triple Hydraulic Jack 6. Carefully clean the tool attachment threads, the main bearing studs, the nuts and the surrounding parts. Grease the tool attachment threads with molybdenum disulphide grease or graphite and oil or similar. Mount the extension studs on the main bearing studs. Using the lifting tool, place the spacer rings 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. 7. Press the pistons and the cylinders of all the hydraulic jacks firmly together. Mount the three jacks (one by one using the lifting tool) over the extension stud and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring. 8. The clearance between the pistons and the cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm. The clearance between the jack and spacer ring has the purpose of making it possible to dismount the jack after loosening the nut. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in all the jacks, and fill up the system until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws.

KC913-1.1 17 06

8.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

KC913-1.1 17 08

Page 5 (12)

913-1

Hydraulic Tools
Loosening of Nut
9. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 90 bar. 10. Unscrew the lower nuts 1 turns with the tommy bar, making sure that the nuts are not screwed up against the extension stud. 11. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.

9.

KC913-1.1 17 09

11.

Page 6 (12)

KC913-1.1 17 11

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Hydraulic Tools
Tightening of Nut
Tightening of Nut 913-1

913-1

Single Hydraulic Jack 1. Thoroughly clean the nut, the thread, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the thread in the nut with molybdenum disulphide grease or with graphite and oil or similar. Fit the round nut on the thread and tighten it with the tommy bar. Check with a feeler gauge that the contact face of the nut bears on the entire circumference. Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot for the purpose of tightening the nut. 2. Press the piston and the cylinder of the jack firmly together. Screw the hydraulic jack on to the tool attachment thread. Make sure that the cylinder of the jack bears firmly against the spacer ring and that the parts are guided correctly together. Connect the hydraulic jack, the distributor block and the high-pressure pump by means of high-pressure hoses. Loosen the bleed screw in the jack and fill up the system with oil, until oil without bubbles flows out of the bleed hole. Re-tighten the bleed screw.

1.

HM913-1.1 10 01

2.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

HM913-1.1 10 02

Page 7 (12)

913-1

Hydraulic Tools
Tightening of Nut

3.

3. Increase the oil pressure to the prescribed value, and tighten the nut by applying the tommy bar through the spacer ring slot. 4. While maintaining the pressure, check with a feeler gauge introduced through the recess at the bottom of the spacer ring that the nut bears against the contact face. 5. Relieve the system of pressure, disconnect the pump, and remove the hydraulic jack.

&DXWLRQ
When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nut as described under Loosening, points 3-4-5, and then tighten the nut again according to the procedure under Tightening', points 3-45.

HM913-1.2 10 03

4.

Page 8 (12)

KC913-1.2 17 04

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Hydraulic Tools
Tightening of Nut
7.

913-1

Triple Hydraulic Jack 6. Thoroughly clean the nuts, the threads on the main bearing studs, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil. Fit the round nuts on the threads and tighten them with the tommy bar. Check with a feeler gauge that the contact faces of the nuts bear on the entire circumference. Mount the extension studs on the main bearing studs. Using the lifting tool, place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of tightening the nuts. 7. Press the piston and the cylinder of all the hydraulic jacks firmly together. Mount the three jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring. 8. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in all the jacks, and fill up the system with oil until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws.
KC913-1.2 17 08

KC913-1.2 17 07

8.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Page 9 (12)

913-1

Hydraulic Tools
Tightening of Nut

10.

9. Increase the oil pressure to the prescribed value, and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. 10. While maintaining the pressure, check with a feeler gauge introduced through the recesses at the bottom of the spacer ring that the nuts bear against the contact face. 11. Relieve the system of pressure, disconnect the pump, and remove the hydraulic tools. 12. When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nuts as described under Loosening', points 9-10-11, and then tighten the nuts again according to the procedure under Tightening', points 10-11-12.

KC913-1.2 17 10

11.

Page 10 (12)

KC913-1.2 17 11

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

Hydraulic Tools
Maintenance
Maintenance 913-1

913-1

1. The hydraulic jacks require no maintenance except replacement of defective sealing rings, each of which consists of an O-ring and a back-up ring fitted in ring grooves in the piston and cylinder. The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of compressed air. 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. The pistons and cylinders of the lower jack are separated in the same easy way as described for the upper jack.

1.

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

KC913-1.0 17 04

Page 11 (12)

913-1

Hydraulic Tools
Maintenance

3.

2. When changing the sealing rings, first mount the back-up ring and then the O-ring. Note! 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. 3. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and cylinder together. See that the rings do not get stuck between the piston and cylinder.

KC913-1.4 17 03

4.

Page 12 (12)

HM913-1.4 10 02

When referring to this page, please quote Procedure M91301 Edition 0211 MAN B&W Diesel A/S

S70MC

Working Platforms
Mounting

913-3.4

WorkingPlatforms S70MC 0007 Mounting 913-3.4

Before carrying out the checking and overhaul procedures underlined below in Items 1, 2 and 4, platform boards should be mounted inside the engine crankcase. During mounting of the platforms, always use the harness, lanyard and fall arrester. It is always recommended to clean and wipe off oil from steps, crankthrow, doorways and assembling surfaces. The platform boards are placed inside the engine as shown in the following. 1. Checking the crankshaft alignment, using an Autolog: Turn the engine into a position where it is possible to place the ladder on the crankpin bearing stud nuts. 2. Piston rod stuffing box and telescopic pipe: Put in the standard platform board as a floor as shown on the sketch. Turn the engine to BDC. Mount the platform board from the exhaust side of the engine as shown.

1.

s913-3.4 0007 01

2.

When referring to this page, please quote Procedure M91303 Edition 0007 MAN B&W Diesel A/S

s913-3.4 0007 02

Page 1 (2)

913-3.4

Working Platforms
Mounting

S70MC

3.

3. The working platform support is mounted as shown in sketch 3. 4. Main bearing dismantling: Turn the engine to 80 after TDC. Mount the platform support in a longitudinal direction on the steps in the bedplate. 5. Mount the longest platform board, with the ladder attached, on the support and, by means of a rope, lower the platform support ladder into place on the crankthrow. The double platform board can now be placed on the support and the long platform board.

s913-3.4 0007 03

4.

Note! Always remember to remove the platform boards on completion of each working procedure or before turning the engine.

s913-3.4 0007 04

5.

s913-3.4 0007 05

Page 2 (2)

When referring to this page, please quote Procedure M91303 Edition 0007 MAN B&W Diesel A/S

Standard Tightening Torques


MAN B&W Diesel
When tightening screws, studs or nuts for which no torque is specied in the instruction procedure or the related data sheet, the standard torques specied in this procedure are to be applied. 1. Standard screws and nuts lubricated with a Molybdenum Disulphide (MoS2) based lubricant.
Thread M8 M10 M12 M14 M16 M18 M20 Tightening torque 17 Nm 35 Nm 50 Nm 80 Nm 135 Nm 190 Nm 260 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 400 Nm 460 Nm 610 Nm 950 Nm 1200 Nm 1650 Nm 2100 Nm

913-4

4. Screwing-in of studs. The intention of this procedure is to ensure that the studs are screwed right to the bottom of the threaded holes. Carefully clean off any burrs and loose particles from the thread and contact faces, and coat the thread with a lubricant having a particle size of approx. 0.5 m, for instance MoS2 (molybdenum disulphide) or a non-synthetic graphite mixed with oil. The studs are to be screwed-in applying the torque specied in the instruction procedure in use. If nothing is mentioned in the instruction procedure, Fig. 4 indicates the torque. For thread sizes > M36 the curve indicates a screwing-in torque of 680 Nm.

2. Self-locking nuts.
Thread M8 M10 M12 M14 M16 M18 M20 Tightening torque 20 Nm 40 Nm 60 Nm 90 Nm 150 Nm 210 Nm 290 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 430 Nm 490 Nm 650 Nm 1000 Nm 1250 Nm 1700 Nm 2200 Nm
Screwing-in torque curve 1000 800

To r q u e (Nm )
M91304 0202C04

600 400

200

3. Screws and nuts locked with glue/Loctite.


Thread M8 M10 M12 M14 M16 M18 M20 Tightening torque 23 Nm 50 Nm 70 Nm 115 Nm 190 Nm 270 Nm 380 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 580 Nm 680 Nm 900 Nm 1350 Nm 1700 Nm 2350 Nm 3000 Nm

100 10

20 40 60 Major diameter of thread (mm)

80 100

When referring to this page, please quote Procedure M91304 Edition 0202

Page 1 (1)

Torque Spanner
Torque Spanner /0& 0205 913-5

913-5

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

When referring to this page, please quote Procedure M91305 Edition 0205 0$1 % : 'LHVHO $6

Page 1 (1)

Tightening Gauge

913-6

Tightening Gauge 0205 913-6

Preparations Before screwing on the nuts, grease the threads and the contact faces with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient. = 0.10.12 (e.g. MOLYKOTE paste type G) The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face. Pre-tightening with a torque spanner Before tightening the nuts according to a tightening gauge or tightening angle, they must be pre-tightened with a torque spanner. See Procedure 913-5. Apply a pre-tightening torque of: thread M8 M20 = 50 Nm thread M22 M27 = 100 Nm thread M30 M39 = 150 Nm thread M42 M48 = 200 Nm This is in order to ensure a uniform basis for the subsequent tightening with gauge or tightening angle. Tightening with a tightening gauge After pre-tightening, place the tightening gauge round the nut, and mark off with chalk on the nut at slot A on the tightening gauge, and make another chalk mark on the contact face at slot B. Then tighten the nut until the two chalk marks coincide. Tightening without a tightening gauge For tightening angles of e.g. 3045 and 60, we usually do not deliver a tightening gauge. Therefore, after pre-tightening, mark the angle on a corner of the nut and on the contact face, respectively. Then tighten the nut until the two marks coincide. When tightening new studs or bolts for the first time, loosen again and repeat the procedure including pre-tightening with a torque spanner, to allow the parts to settle. See Procedure 913-5.

        7 ; G Q D            0 +

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

Page 1 (1)

Screws and Nuts


MAN B&W Diesel Locking
1.

913-7.1

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

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

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

M91307 0207C03

M91307 0207C02

M91307 0207C01

2.

3.

Page 1 (4)

913-7.1

Screws and Nuts


Locking MAN B&W Diesel

Fig. 1

Fig. 2

Locking wire should be fitted after the screws or nuts have been tightened to the correct torque. Do not overtighten or loosen the units to get a correct alignment of the wire holes. Always fit new wire after tightening-up the units. 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 approximately 7-10 twists per 25 mm. One twist is a twist of the wires through an arc of 180, equal to half of a complete turn. Fig. 3: Insert the uppermost wire in the second screw, and pull it tight. Fig. 4: Bend the lower wire around the screw, and under the end protruding from the screw. Fig. 5: Keeping the wire under tension, twist it min. 3 twists, counterclockwise until tight. Fig. 6: During the final twisting motion, bend the wire along the screw head. Cut off excess wire. Fig. 7-9: Show the preferred ways of mounting the locking wire on screws with wire holes oriented in different angles.

Fig. 5
M91307 0207C04

Fig. 6

Fig. 7

Fig. 8

M91307 0207C05

Fig. 9

Page 2 (4)

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

Screws and Nuts


MAN B&W Diesel
Fig. 10: Shows how to route the locking wire on screws in different planes. Fig. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread. Fig. 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. 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. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible.

913-7.1

Locking

Fig. 10

Fig. 11

Fig. 12

Fig. 13
M91307 0207C06

Fig. 14

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

Page 3 (4)

913-7.1

Screws and Nuts


Locking MAN B&W Diesel

Fig. 15

Cam Lock Washers with rising cams on one side and radial teeth on the other. Fig. 15: The washers are installed in pairs, cam face to cam face. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces. The cam lock washer is locked in place, allowing movement only across the face of the cams. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect og the cams. Fig. 16: Different uses of the cam lock washers. Fig. 17: Don not use the cam lock washers in conjunction with other loose washers. Note! Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers.

M91307 0207C15

Fig. 16.

M91307 0207C16

Fig. 17

M91307 0207C17

Page 4 (4)

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

Lubricating Procedures

913-11

Lubricating Procedures .0&& 0204 913-11

Molybdenum Disulphide (MoS2) The following procedure is to be followed prior to the mounting of metal surfaced parts which are to function as seals. Clean the surface with a cleaning fluid and ensure that the entire surface is completely free of grease. Allow 5 minutes for the cleaning fluid to evaporate. With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote G-n Plus, or the like) hard onto the metal surface. Remove any excessive paste and ensure that the metal surface is only coated with a thin, uniform, layer of the above mixture. Protect the wet paste and cloth from dust or other foreign particles.

When referring to this page, please quote Procedure M91311 Edition 0204 0$1 % : 'LHVHO $6

Page 1 (1)

Accessories for Hydraulic Tools


Accessories for Hydraulic Tools 0034 P91351

Plate P91351-0034

Working Pressure 1500 Bar

When referring to this page, please quote Plate P91351 Edition 0034
MAN B&W Diesel A/S

Page 1 (2)

Plate P91351-0034 Item No.


010 022 034 046 058 060 105 117 129 154 166 201 213 225 237 249

Accessories for Hydraulic Tools


Item No.

Item Description
Hydralic pump, pneumatic operated Hydralic pump, hand operated Hose with unions (1000mm), complete Hose with unions (1500mm), complete Hose with unions (3000mm), complete Hose with unions (5000mm), complete 2-way distributor block, complete 4-way distributor block, complete 6-way distributor block, complete Conical valve, 0 - 15 Angle union Quick coupling, male Quick coupling, female Disc, round-plain, Cu 11x3mm Bleeder screw Disc, round-plain, Fe 11x9mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91351 Edition 0034
MAN B&W Diesel A/S

Lifting Tools, Etc.


Lifting Tools, Etc. 0051 P91356

Plate P91356-0051

When referring to this page, please quote Plate P91356 Edition 0051
MAN B&W Diesel A/S

Page 1 (2)

Plate P91356-0051 Item No.


018 031 043 055 067 079 092 175 199 222 246 295 305 317 329 330 342 354 378 450

Lifting Tools, Etc.


Item No.

Item Description
Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Chain tackle Chain tackle Chain tackle Wire rope Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Pull-lift

Item Description

shackle shackle shackle shackle shackle shackle shackle shackle

Page 2 (2)

When referring to this page, please quote Plate P91356 Edition 0051
MAN B&W Diesel A/S

Open Ended Spanners


Open Ended Spanners 0006 P91357

Plate P91357-0006

When referring to this page, please quote Plate P91357 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Plate P91357-0006 Item No.


013 037 050 074

Open Ended Spanners


Item No.

Item Description
Open-ended Open-ended Open-ended Open-ended spanner, spanner, spanner, spanner, size size size size NV65mm NV75mm NV85mm NV95mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91357 Edition 0006
MAN B&W Diesel A/S

Torque Wrenches

Plate P91359-0003

When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P91359-0003 Item No.


014 026 038 040 051

Torque Wrenches
Item Description Item No. Item Description

Torque wrench, 8 - 400Nm Adapter for socket wrench, 10 x 12.5 mm Torque wrench, 40 - 200Nm Torque wrench, 140 - 760Nm Torque wrench, 750 - 2000Nm

Page 2 (2)

When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S

Pliers
MAN B&W Diesel

Plate P91360-0005

When referring to this page, please quote Plate P91360 Edition 0005

Page 1 (2)

Plate P91360-0005 Item No.


010 021 033 045 069 128 130 141 153

Pliers
MAN B&W Diesel Item No.

Item Description
Pliers for retaining ring, size 0.9mm Pliers for retaining ring, size 1.3mm Pliers for retaining ring, size 1.8mm Pliers for retaining ring, size 2.3mm Pliers for retaining ring, size 3.5mm Pliers for retaining ring, size 1.1mm Pliers for retaining ring, size 1.8mm Pliers for retaining ring, size 2.3mm Pliers for retaining ring, size 3.2mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91360 Edition 0005

Combination Spanners
MAN B&W Diesel

Plate P91361-0052

When referring to this page, please quote Plate P91361 Edition 0052

Page 1 (2)

Plate P91361-0052 Item No.


015 027 039 040 052 064 076 088 090 100 111 123 135 147 159 160 172 184 196 206 218 220 231

Combination Spanners
MAN B&W Diesel Item No.

Item Description
Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, size size size size size size size size size size size size size size size size size size size size size size size NV10mm NV11mm NV12mm NV13mm NV14mm NV15mm NV16mm NV17mm NV18mm NV19mm NV21mm NV22mm NV24mm NV27mm NV30mm NV32mm NV34mm NV36mm NV41mm NV46mm NV50mm NV55mm NV60mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91361 Edition 0052

Ring Slugging Spanners


Ring Slugging Spanners 0060 P91362

Plate P91362-0060

When referring to this page, please quote Plate P91362 Edition 0060
MAN B&W Diesel A/S

Page 1 (2)

Plate P91362-0060 Item No.


022 034 046 058 060 071 083 095 105 117 120 130 142 154 178 180 225

Ring Slugging Spanners


Item No.

Item Description
Slugging spanner, ring size NV30mm Slugging spanner, ring size NV32mm Slugging spanner, ring size NV34mm Slugging spanner, ring size NV36mm Slugging spanner, ring size NV41mm Slugging spanner, ring size NV46mm Slugging spanner, ring size NV50mm Slugging spanner, ring size NV55mm Slugging spanner, ring size NV60mm Slugging spanner, ring size NV65mm Slugging spanner, ring size NV70mm Slugging spanner, ring size NV75mm Slugging spanner, ring size NV80mm Slugging spanner, ring size NV85mm Slugging spanner, ring size NV95mm Slugging spanner, ring size NV100mm Slugging spanner, ring size NV120mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91362 Edition 0060
MAN B&W Diesel A/S

Spanners
MAN B&W Diesel

Plate P91363-0040

When referring to this page, please quote Plate P91363 Edition 0040

Page 1 (2)

Plate P91363-0040 Item No.


016 028 030 041 100 150 161

Spanners
MAN B&W Diesel Item No.

Item Description
Tool set, complete, size 10-22 mm Tool set, complete, size 24-46 mm Hex key tool set, complete Adapter for socket wrench, 20->12.5 mm Socket spanner, S=46 mm Hex key, S=22 mm Hex key, S=24 mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91363 Edition 0040

Open-ended Spanners

Plate P91364-0059

When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S

Page 1 (2)

Plate P91364-0059 Item No.


011 023

Open-ended Spanners
Item Description Item No. Item Description

Open ring wrench, 14 - 17mm Open ring wrench, 19 - 22mm

Page 2 (2)

When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S

Instruments

Plate P91366-0066

When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S

Page 1 (2)

Plate P91366-0066 Item No.


012 024 036 048 050 061 073

Instruments
Item Description Item No. Item Description

Indicator, complete Indicator paper Plainmeter, complete Autolog, measuring tool for crankshaft Feeler gauge Slide caliper Dial gauge and stand tool

Page 2 (2)

When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S

Working Platforms
Working Platforms 0011 P91368

Plate P91368-0011

B B

When referring to this page, please quote Plate P91368 Edition 0011
MAN B&W Diesel A/S

Page 1 (2)

Plate P91368-0011 Item No.


013 025 037 049 062 074 098 204

Working Platforms
Item No.

Item Description
Working platform support Working platform support Platform board Platform board Platform board Platform board Platform board Working platform, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91368 Edition 0011
MAN B&W Diesel A/S

Warning

S900-1

0001 S900-1

Warning! It is important that all MAN B&W Diesel A/S engines are operated within the given specifications and performance tolerances specified in the engines Technical Files and are maintained according to the MAN B&W Diesel A/S maintenance instructions in order to comply with given emissions regulations. In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, 94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote S900 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

K80MC-C

VOLUME III COMPONENTS DESCRIPTION

900 - Introduction
Documents in this Chapter
Table of Contents, Volume III Cross Section through Engine Ordering of Insulation Designations And Symb Software Licence, Std Description

90001 90002 90003 90004 90030

0040 0001 0001 0001 0006

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Table of Contents
Volume III - Components Description No. Edition Title

900

900 - Introduction Table of Contents 90001 0040 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations And Symb 90004 0001 Software Licence, Std 90030 0006 Description 901 - Cylinder Cover 90101 0180 Cylinder Cover 90103 0003 Indicator Cock - Mounting 902 - Piston with Rod & Stuffing Box 90201 0216 Piston and Piston Rod 90205 0117 Piston Rod Stuffing Box 903 - Cylinder Liner and Cylinder Lubrication 90301 0163 Cylinder Frame 90302 0161 Cylinder Liner and Cooling Jacket 90304 0035 Cylinder Liner - Details 90305 0143 Cylinder Lubricators 90307 0032 Cylinder Lubricator Unit 90308 0010 Cylinder Lubricator - Intermediate Box 90310 0012 Cylinder Frame - Rear Side 90312 0004 Electronic Components - Cylinder Lubrication 904 - Crosshead with Connecting Rod 90401 0172 Connecting Rod and Crosshead 90403 0012 Lubricating and Cooling Oil Flow 905 - Crankshaft, Thrust Bearing and Turning Gear 90501 0162 Crankshaft 90502 0052 Arrangement of Fore End 90505 0146 Thrust- and Guide Bearing 90510 0124 Turning Gear 90511 0039 Turning Wheel 90513 0041 Tacho System 906 - Control Gear 90600 0125 Arrangement of Chain Drive and Camshaft 90603 0111 Chain Tightener 90610 0131 Bearing Housing - Mounting 90611 0175 Camshaft and Chain Wheel 90612 0085 Arrangement of Indicator System 90613 0116 Camshaft Bearing
MAN B&W Diesel A/S Page 1 (3)

Table of Contents
Volume III - Components Description No. 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634 Edition 0147 0134 0019 0097 0076 0070 0023 0003 0030 0041 Title Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part

900

907 - Starting Air System 90702 0069 Main Starting Valve 90703 0129 Starting Air Distributor 90704 0053 Starting Valve 908 - Exhaust Valve 90801 0211 Exhaust Valve - Lower Parts 90803 0045 Exhaust Valve - Upper Parts 90804 0016 Exhaust Valve Upper Parts - Details 90805 0122 Exhaust Valve - Actuator 90806 0104 Exhaust Valve - Pipe System 90810 0089 Arrangement of Cooling Water Pipes 909 - Fuel Oil System 90901 0184 Fuel Pump 90902 0150 Fuel Pump Gear 90903 0040 Fuel Pump Gear - Details 90904 0061 Fuel Pump - Details 90905 0030 Reversing Mechanism 90907 0011 Lifting Device for Fuel Pump 90910 0143 Fuel Valve 90911 0022 Fuel Valve Function 90913 0158 High-Pressure Pipes 90914 0078 Fuel Oil System 90915 0060 Fuel Oil System - Details 90915 0080 Fuel Oil System - Details 90916 0006 Lifting Device for Fuel Pump - Cylinder No. 1 910 - Turbocharger System 91000 0017 Gas and Air System 91001 0166 Scavenge Air Receiver 91002 0142 Arrangement of Charging Air Pipe 91003 0225 Exhaust Pipes and Receiver 91004 0036 Exhaust Receiver - Details
MAN B&W Diesel A/S Page 2 (3)

Table of Contents
Volume III - Components Description No. 91005 91006 91007 91009 91011 91014 Edition 0140 0029 0018 0020 0026 0029 Title Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Air Cooler System - Cleaning Arrangement of Non-Return Valve Arrangement of Suction Pipe

900

911 - Safety Equipment 91101 0037 Safety Valve - Cylinder 91102 0029 Relief Valve 91102 0035 Relief Valve 91103 0018 Safety Valve - Scavenge Air System 91104 0099 Arrangement of Safety Cap 912 - Assembly of Large Parts 91201 0096 Arrangement of Stay Bolts 91203 0005 Frame Box - Details 91205 0201 Frame Box 91206 0097 End Shields 91207 0093 Arrangement of Piston Cooling 91208 0009 Chain Wheel Frame - Upper 91210 0188 Bedplate 91211 0072 Axial Vibration Damper 91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

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Cross Section through Engine


MAN B&W Diesel

Plate P90001-0040

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Page 1 (2)

Plate P90001-0040 Item No.

Cross Section through Engine


MAN B&W Diesel Item No.

Item Description

Item Description

Page 2 (2)

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Ordering of Insulation
MAN B&W Diesel

Plate P90002-0001

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Designations and Symbols


MAN B&W Diesel

Plate P90003-0001

Normal layout

Forward (fwd)

Port side of ship

Starboard (stbd) side of

Fore end
1 2 3 4 5 6 7

Cyl. nos. always counted from fore end

Manoeuvring side of engine

Aft end

Exhaust side of engine

Propeller

Clockwise direction of rotation defined from aft end of engine

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Software License, Standard Conditions


MAN B&W Diesel

Plate P90004-0001

Standard Conditions of Software Licence


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

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Plate P90004-0001

Software License, Standard Conditions


MAN B&W Diesel

MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. MAN B&W shall in no event be liable for any damages resulting from loss of data, profits or use of equipment, or for any special, incidental consequential damages arising out of or in connection with the use or performance of the software. The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&Ws software suppliers. 6. Law MAN B&W's tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.

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Engine Types 35-98MC/MC-C


Engine Types 35-98MC/MC-C 35-98MC 0006 A90030

Description A90030-0006

901 Cylinder Cover


Cylinder Cover
The cylinder cover is made of steel. On the 70-98MC type engines the cylinder cover is provided with weldedon heat resistant material at the points of fuel oil injection in order to improve the service condition.

Valve bores

The cover has a central bore for the exhaust valve, which is attached by means of four studs and nuts. The cover furthermore has bores for the fuel valves, starting valve, starting air inlet, safety valve and indicator cock.

Cooling

A cooling jacket is mounted on the lower part of the cylinder cover, whereby a cooling water space is formed. Another cooling water space is formed around the exhaust valve seat, when the exhaust valve is installed. These two spaces communicate through a large number of cooling bores in the cover. The water is supplied from the cooling jacket surrounding the cylinder liner and passes through water connections to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores, to the space around the exhaust valve seat. From here the water is discharged to the main cooling water outlet pipe: On some engine types, an amount of water is also passed directly from the cylinder cover to the exhaust valve housing through a cooling water connection.

Tightening

The cylinder cover is tightened against the top of the cylinder liner with nuts and long studs fitted in the cylinder frame. The nuts are tightened with hydraulic tools. Sealing between the cylinder cover and cylinder liner is obtained by means of a sealing ring of mild steel.

902 Piston with Rod and Stuffing Box


Piston
The piston consists of two main parts: Piston Crown Piston Skirt The piston crown is tightened to the upper end of the piston rod, and the piston skirt is tightened to the piston crown.

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Page 1 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C


The piston crown is provided with one groove all the way around, or with three smaller grooves for the fitting of lifting tools. The piston crown is provided with chromium-plated grooves for four piston rings. Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR). Piston rings Nos. 2, 3 and 4 have oblique cuts: piston ring No. 3 has a right-hand cut, and piston rings Nos. 2 and 4 have left-hand cuts. On some engines, the piston rings are provided with Alu-coating to improve the running-in stability and to reduce the running-in period. Handle with care, as impact may cause the coating to crack and peel off. Stationary Engines: The CPR ring may have been coated with PM14 on the external surface. Handle with care, as impacts may cause the coating to crack and peel off.

Piston Rod

The piston rod has a through-going bore for the cooling oil pipe, which is secured to the piston rod top. Cooling oil is supplied through a telescopic pipe connection on the guideshoe or on the crosshead and passed through a bore in the piston rod foot and, through the cooling oil pipe in the piston rod, to the piston crown. The oil is passed on, through a number of bores in the thrust part of the piston crown, to the space around the cooling oil pipe in the piston rod. From the bore in the piston rod foot, the oil is led through the crosshead to a discharge spout and to a slotted pipe inside the engine framebox as well as through a control device for checking the flow and temperature. The piston rod foot rests on a face cut out in the crosshead pin. A shim is inserted between the piston rod and the crosshead. The thickness of the shim is predetermined to match the actual engine layout. The piston rod is fastened to the crosshead pin with screws or studs and nuts. The nuts are tightened with hydraulic tools.

Page 2 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C


Stuffing Box

Description A90030-0006

The bore for the piston rod between the scavenge air space and the crankcase is fitted with a piston rod stuffing box, which is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space. The stuffing box also prevents scavenge air (in the scavenge air space) from leaking into the crankcase. The stuffing box housing consists of two parts, which are bolted together.

Scraper/sealing rings

The housing is provided with a number of machined ring grooves: The uppermost groove holds a scraper ring with oblique edges, which serves to prevent sludge from the scavenge box from being drawn down to the other rings. Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC type engines). The ring grooves in the middle are fitted with sealing rings. The lowermost ring grooves are fitted with scraper rings which scrape the lubricating oil off the piston rod. Oil which is scraped off the piston rod is returned to the crankcase through bores in the stuffing box housing. Through bores in the housing and a pipe, the stuffing box communicates with a control funnel on the outside of the engine, which enables the sealing/ scraping performance to be checked. Gaps at the ends of the ring segments ensure that the rings will bear against the piston rod even in worn condition.

903 Cylinder Liner and Cylinder Lubrication


Cylinder Frame
The cylinder section of the engine consists of a cylinder frame with a bolted-on or integrated camshaft housing. The cylinder section is tightened together with the engine framebox and the bedplate by means of stay bolts. Central bores at the top of the cylinder frame enclose the cylinder liners. Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes. On the exhaust side of the cylinder frame there are openings which connect the scavenge air space around the cylinder liner with the longitudinal scavenge air receiver of the engine.

Bores and openings

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Page 3 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C


There are also inlet pipes for cooling and lubricating oil. The cylinder frame is provided with cleaning and inspection covers giving access to the scavenge air spaces.

Cylinder cover studs Cylinder Liner and Cooling Jacket

Studs for fastening the cylinder cover are mounted in the cylinder frame. The cylinder liner is fitted with a cooling jacket. The cooling water is supplied at the lower part of the cooling jacket. On slim-type liners, the water continues directly to the upper part of the cooling jacket, whereas on the bore-cooled type liner, the water first passes through the cooling bores. From the top of the cooling jackets, the water flows through water connections to the cooling jacket on the lower part of the cylinder cover. Leakage of cooling water is prevented by silicone rubber rings. The cylinder liner is tightened against the top of the cylinder frame by the tensioning force from the cylinder cover studs being transmitted via the cylinder cover.

Scavenge air ports

The part of the cylinder liner which is located in the scavenge air space of the cylinder frame is provided with a number of scavenge air ports, which are uncovered by the piston when this is in its bottom position. The scavenge air ports are bored at an oblique angle to the axis of the cylinder liner so as to give the scavenge air a rotary movement in the cylinder. In the free part of the cylinder liner, between the cooling jacket and the cylinder frame, there are a number of bores with non-return valves for the supply of lubricating oil to the cylinder. On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of the cylinder liner. The purpose of the PC-ring is to prevent the building-up of deposits on the piston topland and, in turn, prevent the wiping away of the cylinder lubricating oil. Consequently, the PC-ring contributes to reducing the wear of liners and rings. The engine is equipped with mechanically or electronically controlled cylinder lubricators for lubrication of the running surface of liners and rings. Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied. See also Volume I, OPERATION, Chapter 707.

Cylinder lubrication

PC-ring

Cylinder Lubricators

Page 4 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C

Description A90030-0006

904 Crosshead with Connecting Rod


Crosshead
The crosshead is provided with two guide shoes fitted on the crosshead ends. The centre part of the crosshead is designed as a bearing journal which is housed in the crosshead bearing. The crosshead bearing cap is provided with a cut-out enabling the piston rod to be assembled with the crosshead journal. The crosshead is equipped with steel shells lined with bearing metal. The lower shell is provided with an overlayer coating. See also Volume I, OPERATION, Chapter 708.

Piston rod foot

The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the piston rod and the crosshead. The crosshead is provided with bores for distributing the oil supplied through the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil for the crosshead bearing and guide shoes and through a bore in the connecting rod for lubricating the crankpin bearing. The piston cooling oil outlet is led through a control device for each cylinder for the purpose of checking the temperature and flow before the oil is passed on to the lube oil tank.

Lubrication

Guide shoes

The sliding faces of the guide shoes are lined with cast-on bearing metal. The guide shoes are guided by crosshead guides in the engine framebox and properly secured against displacement by guide strips fastened to the guide shoes. On some engines, the guide shoes are provided with counterweights.

Tightening

The crosshead bearing is held together by studs and nuts. The nuts are tightened with hydraulic tools. The crankpin bearing is fitted with steel shells lined with bearing metal and assembled in the same way as the crosshead bearing.

905 Crankshaft and Turning Gear


Crankshaft
The crankshaft is either of the semi-built type, where the parts are shrunk together, or it is a one-piece forging. The main bearings are lubricated via a main lubricating oil pipe that branches off to the individual bearings, whereas oil for lubricating the crankpin bearings is supplied from the crossheads through bores in the connecting rods.

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Page 5 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C


The crankshaft is provided with a chain wheel for the camshaft drive and a turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a chain wheel drive for 2nd order and 4th order moment compensators are installed, if required according to vibration calculations. Marine engines (except geared plants): At the aftmost end of the engine, a thrust bearing is fitted. The thrust bearing serves the purpose of transmitting the axial thrust of the propeller through propeller shaft and intermediate shafts to the ships hull. The crankshaft is provided with a thrust collar which transmits the thrust to a number of segments mounted in a thrust shoe on either side of the thrust collar. The thrust shoes rest on surfaces in the thrust bearing housing and are held in place by means of stoppers or cross bars. The segments have white metal cast onto the wearing faces against the thrust collar. See also Volume I, OPERATION, Chapter 708. The thrust bearing is lubricated by the pressure lubrication system of the engine. The oil is supplied between the segments through spray pipes and spray nozzles. The thrust bearing is provided with alarm, slow-down, and shut-down devices for low lube oil pressure and high segment temperature. See also Volume I, OPERATION, Chapter 701. Stationary engines and geared marine plants: The crankshaft is provided with a collar for the guide bearing. The purpose of the guide bearing is to keep the crankshaft in its proper position in the axial direction.

Axial Vibration Damper

To counteract heavy axial vibrations, and any resultant adverse forces and vibrations, the crankshaft is provided with an axial vibration damper. See also Section 912, Assembly of large parts further on in this text. The damper consists of a piston and a slit-type housing. The piston is made as an integrated collar on one of the main bearing journals, and the housing is mounted on the pertaining main bearing support. The axial movement is damped as a result of the restrictions incorporated in the bores which interconnect the oil-filled chambers on the two sides of the piston. Lubricating oil is supplied to both sides of the piston from the main system.

Page 6 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C


Turning Gear

Description A90030-0006

The turning gear is attached to the engine bedplate and is driven by an electric motor incorporating a disc brake. Through a planetary gearing, the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually, so as to engage with the turning wheel of the engine. The turning gear is provided with a safety arrangement consisting of a safety lever which must be lifted before the gear wheel of the turning gear can be made to engage with the turning wheel. When the safety lever is in its bottom position, it prevents the gear wheel of the turning gear from engaging with the turning wheel. Immediately the lever is lifted away from the disengaged position, an interlock valve inserted in the starting air system of the engine is actuated. This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position. See also Volume I, OPERATION, Chapter 703.

Warning! During any dismantling of working parts of the engine, the turning gear must be in the engaged position in order to prevent outside forces from turning the engine, thus causing injuries to personnel or damage to the machinery. See Volume II, MAINTENANCE, DATA pages. The turning gear must be in the disengaged position during pressure testing of starting valves, as a leaky valve may cause the engine to rotate, and damage the turning gear. See Volume I, OPERATION, Chapter 703.

Dismantling of working parts:

Pressure testing of starting valves:

906 Mechanical Control Gear


Chain Drive
The camshaft with cams for operating the fuel pumps, exhaust valves and indicator drive (option) is driven from the crankshaft through a chain drive. The chain drive consists of one or more roller chains running on chain wheels fitted on the crankshaft and the camshaft. The chain is kept tightened by a chain tightener placed in the chain casing between the crankshaft and the camshaft. The long free lengths of the chain are guided by rubber-clad guide bars. Lubricating oil is supplied through spray pipes fitted at the guide bars and chain wheels.

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Page 7 (23)

Description A90030-0006 Camshaft

Engine Types 35-98MC/MC-C


The camshaft is made in one or more sections. If it is made in two or more sections, the sections are assembled by means of flange couplings. The camshaft has, for each cylinder: one cam for operation of the fuel pump one cam for operation of the exhaust valve one cam for operation of the indicator drive (option) The fuel pump and exhaust valve cams are shrunk on to the shaft by heating, whereas the indicator cams are in two parts, which are assembled with fitted bolts. The camshaft rotation constantly follows that of the crankshaft.

Bearings Engine timing

The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. See also Volume I, OPERATION, Chapter 708. The engine timing is adjusted by forcing lubricating oil in between the cams, couplings or chain wheel and the shaft, which enables the parts to be turned in relation to each other. See Volume II, Chapters 906, 908 and 909. After the engine has been testrun, the camshaft parts and the cylinder frame will be provided with pin gauge marks, and the necessary pin gauges are delivered together with the engine, enabling the camshaft timing to be checked and readjusted if the parts have been dismantled. Each cylinder is fitted with an indicator valve, which communicates with the combustion chamber of the cylinder through a bore. Operating Instructions When opening the indicator valve, the spindle must be screwed right back to the stop in order to avoid burns and carbon in the guide.

Pin gauges

Indicator Valve

Note! For indicator valves of the double-seated design with a spring-loaded closing face: In order to prevent overstressing, close the valve lightly before starting the engine, and retighten the valve when the engine has reached its normal service temperature.

PMI-System

See separate instructions for operating the PMI-system (option).

Page 8 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C


Moment Compensators

Description A90030-0006

On the basis of calculations, the engine may be provided with flyweights to counteract engine forces and moments.

Caution! If the chain drives for the compensators have been dismantled, the flyweights must be positioned correctly in relation to the crankshaft. See the instruction book, Volume II, MAINTENANCE. Incorrectly fitted moment compensators may excite heavy vibrations.

1st order moment

Applicable on 4-cylinder engines. The moment compensator is arranged as adjustable flyweights on both ends of the crankshaft. Alternatively, the 1st order moment compensator can be positioned in the main chain drive. This moment compensator consists of a (new) chain-tightener wheel with an incorporated flyweight and a flyweight rotating with the crankshaft.

2nd order moment

Applicable on 4-5 and 6-cylinder engines. The moment compensator is arranged as flyweights built into the main chain drive. On some engines, flyweights are built into a second chain drive, which is driven from the opposite end of the crankshaft. This chain drive is equipped with a spring-loaded chain tightener, which on some engines is equipped with a hydraulic damper. Optionally, an electrically driven compensator can be installed.

4th order moment

The moment compensator is arranged as flyweights built into chain drives on both ends of the camshaft. Each chain drive is equipped with a spring-loaded chain tightener, and each chain casing is fitted with a relief valve.

907 Starting Air System


Starting Air System
The starting air system consists of the manoeuvring system and the starting air components, which comprise: Main Starting Valve Starting Air Distributor Starting Valves The manoeuvring system is of electric/pneumatic design. See also Volume I, OPERATION, Chapter 703.

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Page 9 (23)

Description A90030-0006 Main Starting Valve

Engine Types 35-98MC/MC-C


The main starting valve is interposed in the starting air main pipe. The main starting valve consists of a large ball valve and, optionally, a smaller ball valve for slow-turning prior to starting the engine, which is fitted as a by-pass for the large valve. Both valves are operated by pneumatic actuators. If the smaller ball valve is installed, an adjusting screw will be mounted for setting the slow-turning speed. Furthermore, a non-return valve is incorporated to prevent blow-back in the event of excessive pressure in the starting air line. The main starting valve is equipped with a blocking device consisting of a plate which, by means of a handwheel, can be made to block the actuators. The ball valves and their actuators are, together with the non-return valve and blocking device, built together to form a unit. Warning! During all inspections of the engine, the blocking device of the main starting valve must be in the BLOCKED position. The only exception is when the starting valves are being tested for tightness, in which case the blocking device of the main starting valve must be in the WORKING position and the shut-off valve for the starting air distributor must be in the CLOSED position. See Volume I, OPERATION , Chapter 703, Operations after arrival in port.

Starting Air Distributor Starting Valve

The starting air distributor controls the opening and the closing of the starting valves. The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled by control air from the starting air distributor. When the main starting valve is open, the chamber below the piston of the starting valve is pressurised through the starting air pipe. The starting valve is kept closed by the spring. When the chamber above the piston of the starting valve is pressurised with control air from the starting air distributor, the starting valve opens, and starting air now flows from the starting air pipe to the cylinder. When the starting period is finished, the chamber above the piston is vented through the vent pipe of the starting air distributor, and the starting valve will close. The starting air in the chamber below the piston and the starting air pipe is vented slowly through small holes in the starting air pipe.

Page 10 (23)

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Engine Types 35-98MC/MC-C 908 Exhaust Valve


Exhaust Valve

Description A90030-0006

Each cylinder is equipped with an exhaust valve, which is mounted in a central bore in the cylinder cover. The valve housing is attached with four studs and nuts to form a gas-tight seal against a seat in the cylinder cover. The valve housing has an exchangeable bottom piece. The bore for the valve spindle is provided with an exchangeable spindle guide liner.

Valve housing

Cooling

The valve housing is water cooled. The cooling water is passed to the valve housing after it has passed the cylinder cover. The water is discharged from the upper part of the valve housing. On the front of the valve housing there is a cleaning cover through which the cooling water space can be checked and cleaned.

Valve spindle

The part of the spindle stem which travels within the sealing arrangement of the air cylinder is coated with a wear resistant mixture of metal carbide and super alloy, applied by the HVOF process. On the lower cylindrical part of the valve spindle a vane wheel is fitted which causes the valve spindle to rotate while the engine is running. Lifting/rotation check rod: To enable checking the functioning of the exhaust valve while the engine is running, a lifting/rotation check rod is mounted on top of the hydraulic cylinder on the exhaust valve. Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod. Note! This check rod is only for checking purposes, and must not be permanently activated. Pistons At the top of the spindle, two pistons are fitted: 1. Air piston The piston serves to close the exhaust valve. The piston is locked to the spindle by a two-piece conical ring. 2. Hydraulic piston The piston serves to open the exhaust valve. The hydraulic piston has two piston rings and a damper arrangement, designed to dampen the closing of the valve.

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Page 11 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C

Caution! After the exhaust valve has been overhauled, it is important to check the damper, to avoid knocking. See Volume II, MAINTENANCE, Procedure 908.

Air cylinder

The air cylinder is mounted on top of the valve housing. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston. A safety valve is mounted in the bottom of the air cylinder. The safety valve is connected to the drain pipe which leads to the camshaft housing.

Hydraulic cylinder

The hydraulic cylinder is attached with studs and nuts on the air cylinder on top of the exhaust valve housing. The exhaust valve is opened by the valve spindle being forced down by the piston in the hydraulic cylinder. Throttle/valve: On some engine types, a combined throttle/valve designed for deaerating the oil system is fitted at the top of the cylinder. When the exhaust valve is closed, the pressure in the hydraulic cylinder is low. A thrust spring opens the valve, enabling oil and air, if any, to escape through the throttle. The oil is led through a duct to the space around the air cylinder and is drained off through a bore X , together with leakage oil from the piston. When the exhaust valve is activated, the high oil pressure closes the valve, and the oil flow stops.

Sealing System

Sealing air (where used): A sealing air arrangement is fitted around the spindle shaft below the air cylinder. The sealing air is supplied from the air cylinder via a sealing air control unit. The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil content in the air from the air cylinder improves the service condition of the sealing rings. The sealing air control unit contains a valve which automatically cuts off the air flow when the engine is in FINISHED WITH ENGINE status, and a filter housing.

Page 12 (23)

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Engine Types 35-98MC/MC-C


Sealing oil (where used):

Description A90030-0006

A sealing oil arrangement is fitted around the spindle shaft below the air cylinder. The sealing oil is supplied from a control unit fitted on top of the exhaust valve hydraulic actuator. During the exhaust valve lifting period, oil escapes from the hydraulic actuator through the restriction chamber to the control unit which, in turn, gives a certain amount of oil (dosage oil) to the exhaust valve spindle. The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil improves the service condition of the sealing rings.

Hydraulic Valve Actuating Gear Hydraulic cylinder

The exhaust valve is actuated by a cam on the camshaft through a hydraulic transmission. The hydraulic cylinder is attached to the camshaft housing by studs and nuts. A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck of the roller guide and is locked to the roller guide by a bayonet joint. The hydraulic cylinder on the camshaft housing is connected to the hydraulic cylinder on the exhaust valve by a high-pressure pipe. Oil is supplied from the lubricating oil system through a non-return valve. Leakage oil from the hydraulic cylinder on the exhaust valve is drained through a pipe connection.

Puncture Valve

On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines, a puncture valve may be mounted on the exhaust valve actuator. During starting, this valve prevents the exhaust valve from opening during the first part of the actuator pistons upward stroke. This function prevents the starting valve and exhaust valve from being open at the same time, thus ensuring a safe start.

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Page 13 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C

909 Fuel Oil System


Fuel Pump
Each engine cylinder is equipped with its own fuel pump, which is mounted on the camshaft housing over the camshaft section corresponding to the cylinder concerned. The pump housing is attached to the camshaft housing by studs and nuts. The square base of the fuel pump housing is provided with a groove to receive any leakage oil, which is subsequently drained off through a drain pipe. In the base, a bore is provided for at toothed rack, i.e. the regulating guide, which controls the quantity of fuel oil delivered by the pump. Furthermore, for the VIT-type fuel pump, another bore is provided above the bore for the regulating guide. This bore is provided with a rack, i.e. the timing guide, which controls the engine timing. At the top, the pump housing is closed by a top cover. The top cover is provided with a suction valve and a puncture valve. These two valves are on some engine types combined into one unit. The pump housing contains the plunger and barrel. The plunger and barrel are matched parts, and must not be replaced individually. The pump plunger is provided with a guide block designed to travel in the milled keyway in the regulating guide. At the bottom it has a foot which rests on a steel disc in the bayonet joint at the roller guide neck. A clearance of approx. 0.1 mm between the plunger foot and the roller guide permits turning of the plunger in the roller guide. The regulating guide is able to turn in the bottom of the pump housing. On the outside the regulating guide has a toothed rim to mesh with the above-mentioned toothed rack at the base of the pump housing. The toothed rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked together with the regulating gear of the engine through a spring-loaded connection. Thus, in the event of a sticking pump plunger, the regulating gear for the remaining fuel pumps will not be blocked. The pump barrel is provided with oil cut-off holes, which are covered and uncovered during the travel of the plunger within the barrel. This function, in conjunction with the turning of the plunger effected by the regulating gear, serves to regulate the amount of oil injected into the engine cylinder. Two screw plugs are fitted in the pump housing opposite the cut-off holes of the barrel. The oil jets which are ejected through the cut-off holes at the end of the delivery stroke will hit the screw plugs, which can be replaced when they are eroded.

Page 14 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C


Injection timing
Fuel pumps without VIT (Variable Injection Timing):

Description A90030-0006

The pump barrel is attached to the top cover by means of screws. The lower part of the barrel is guided in the bore of the pump housing. Two sets of O-rings and back-up rings are fitted in grooves on the outside of the barrel and the pump cover to seal between pump barrel/pump cover and housing. A number of semi-circular shims are inserted between the top cover and the pump housing. By removing or inserting such shims, the pump barrel can be slightly lowered or raised in relation to the plunger, and in this way the initial moment of fuel oil injection into the engine cylinder can be adjusted, and the maximum combustion pressure thus changed. Refer to Volume II, Chapter 909, regarding adjustment of the maximum combustion pressure. VIT-type fuel pumps: The pump barrel is guided at the top and bottom of the pump housing. Low friction sealing rings are fitted in grooves in the barrel to seal between barrel and housing. The barrel is provided with a drain bore between the sealing rings at the lower end. The pump barrel has a threaded lower end which fits into the internal threads of the timing guide. The timing guide has a gear rim to mesh with the upper toothed rack at the base of the pump housing. The gear rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked to a servo-air cylinder which is controlled mechanically or electronically in relation to the engine load. The position of the upper toothed rack determines the vertical position of the barrel relative to the plunger through the threaded connection. In this manner the initial moment of fuel oil injection into the cylinder can be adjusted by a servo-air cylinder. The pump barrel is prevented from turning by a guide screw mounted in the pump housing.

Puncture valve

In the top cover of the pump, a puncture valve is fitted. The puncture valve consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system, and when STOP is activated, compressed air is supplied to the top of the piston, causing the piston with pin to be pressed downward and keep the suction valve in the open position. This will puncture the oil flow to the fuel valve. As long as the puncture valve is activated, the fuel oil is returned through bores to the pump housing, and no injection takes place.

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

Page 15 (23)

Description A90030-0006 Fuel Oil Injection

Engine Types 35-98MC/MC-C


During the suction stroke, the spring-loaded suction valve opens and the delivery chamber is filled with oil. As soon as the plunger has covered the cut-off holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until the cut-off holes are uncovered by the oblique cut-off edges of the plunger, following which the oil is forced through two milled grooves at the side of the plunger and out through the cut-off holes of the barrel during the rest of the delivery stroke. A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations. The camshaft housing contains the fuel pump and exhaust valve actuating gear for each cylinder. The fuel pump is actuated by a cam on the camshaft. The movement is transmitted through the roller guide to the plunger in the barrel of the pump housing which through the high-pressure pipes is connected with the fuel valves on the cylinder cover. Reversible engines: The roller guide of each fuel pump incorporates an angular displaceable reversing link. Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. The link connecting the roller guide and roller is provided with a reversing arm, and a pivot is mounted at the top end of the reversing arm. The pivot travels in a reversing guide connected to an air cylinder. The link is self-locking in either the AHEAD or ASTERN position without the aid of external forces. Each cylinder is reversed individually, and the reversing mechanism is activated by compressed air. The reversing arrangement may incorporate a damper in order to reduce the mechanical stresses.

Shock absorber

Fuel Pump Actuating Gear

Fuel Oil HighPressure Pipes

All high-pressure pipes in the system are provided with a protective outer pipe. The space between the pipe and the protective outer pipe communicates, through bores in the union nipples, with a drain bore in the pump top cover. A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS. 35-98MC: Each fuel pump is, via drain pipes, connected to a common drain tank, which incorporates a level switch. The drain tank is also equipped with an overflow pipe, which has a small drain bore below, whereby oil from small leakages can be drained to the outlet, without actuating the level switch.

Fuel Oil Leakage Alarm

Page 16 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C

Description A90030-0006

In the event of pipe fractures or major leakages in the system, the abovementioned bore will not be large enough to allow the increased oil quantity to pass, and the oil level in the drain tank will rise until it reaches the level of the overflow pipe. The rising oil level will cause the level switch to set off an alarm. 50-98MC: Alternatively to the common drain tank, the drain pipes on 50-98MC engines can be connected to a diaphragm valve, which sets off an alarm and activates the puncture valve in order to stop the fuel oil flow from the pertaining pump. On 60-98MC engines, which are provided with pneumatically operated fuel pump roller guide lifting gear, automatic activation of the lifting gear by the diaphragm valve can be arranged in order to stop the fuel oil flow from the pertaining pump.

Fuel Valve

The fuel valve consists of a valve head and a valve housing. Fitted within the valve housing is a non-return valve and a spindle and spindle guide with a pressure spring, and a nozzle. The spindle may be provided with a cut-off slide. When the fuel valve is fitted in the cylinder cover, the valve parts are tightened together by the pressure from the securing nuts.

Functioning

The functioning of the fuel valve is as follows: The electrical fuel oil primary pump circulates preheated oil through the fuel pump and fuel valve. The fuel oil passes through the fuel valve, leaving through a circulation bore and the return oil pipe on the valve head. When the pressure at the beginning of the fuel pumps delivery stroke has reached the predetermined pressure, the circulating bores is closed. When the pressure has reached the predetermined opening value for the fuel valve, the spindle will be lifted and oil injected through the nozzle into the engine cylinder. On completion of the fuel pumps delivery stroke, the valve spindle is pressed against its seat and injection now ceases. Then the circulating bore is uncovered, and oil starts to recirculate through the valve.

910 Turbocharger System


Air System
The engine is supplied with scavenge air from one or more turbochargers, depending on the engine type and layout. The engine exhaust gas drives the turbine wheel of the turbocharger and, through a common shaft, the turbine wheel drives the compressor wheel.

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

Page 17 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C


The compressor draws air from the engine room, through the air filters. From the compressor outlet, the air passes through the charging air pipe to the charging air cooler where the air is cooled down. The charging air pipe, with compensator, is insulated. The air cooler incorporates a water mist catcher, which is designed to separate condensate from the air. See also Charging Air Cooler further on in this Section. When the air has passed the water mist catcher, it is pressed into the scavenge air receiver through non-return valves. The non-return valves open by pressure from the turbocharger. From the scavenge air receiver, the air flows to the cylinder through the scavenge air ports when the piston is in the bottom position. When the exhaust valves open, the exhaust gas is pressed into a common exhaust gas receiver, from where the gas drives the turbine of the turbocharger with an even and steady pressure

Scavenge Air Receiver

The scavenge air receiver is a container having a large volume. The receiver is bolted on to the cylinder frame. Scavenge air is collected in the receiver after the air has passed through the cooler, the water mist catcher and the non-return valves. The receiver and the cylinder frame communicate through large openings. The scavenge air receiver is provided with man-hole covers and a safety valve.

Auxiliary Blowers

The engine is provided with two or more auxiliary blowers. The suction sides are connected to the space after the water mist catcher. The discharge sides are connected to the scavenge air receiver. Separate nonreturn valves are installed at the suction side or discharge side of the auxiliary blowers, in order to prevent reversed air flow. See also item, Non-return valves, further on. See special instructions supplied by the engine builder.

El. panels for auxiliary blower Running with auxiliary blowers

During the starting of the engine, and when the engine is running at low load, the turbocharger is not able to supply enough air for the engine process. In these cases a pressure switch will automatically start the auxiliary blowers. When the auxiliary blowers are operating, they draw air from the engine room through the turbochargers air filter and compressor side.

Page 18 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C

Description A90030-0006

Warning! If the auxiliary blowers do not start during low-load running (because of faults, or because the switch for the blowers is not in AUTO position), unburned fuel oil may accumulate on top of the pistons. This will involve the risk of a scavenge air box fire. In order to avoid such a fire: obtain permission to stop the engine stop the engine remove any unburned fuel oil from the top of the pistons re-establish the supply of scavenge air start the engine Note: the switch for the auxiliary blowers should be in AUTO position during all modes of engine control, i.e.: remote control control from engine side control console. The non-return valves fitted after the water mist catcher are now closed as a result of partial vacuum and gravitation acting on the valve flaps. There will be a lack of air supply if the non-return valves do not close.

Non-Return Valves

It is of the utmost importance that the non-return valves of the auxiliary blowers always function correctly and move easily. This can be checked either by moving the valves manually in connection with the regular scavenge port inspections, or via locally placed inspection covers. The non-return valves protect the blowers and engine during: Start-up of the auxiliary blowers Running with auxiliary blowers. Starting the auxiliary blowers: 1. Owing to the relatively high starting current, the blowers start in sequence, with 6-10 seconds in between. The non-return valve of the blower that has not yet started must be in the closed position to prevent the blower from rotating backwards. Otherwise, there is a risk that the electric motor will burn out when it starts. 2. If an auxiliary blower fails to start, the non-return valve must be in the closed position. Otherwise, the operating blower will not be able to draw fresh air in through the turbocharger and air cooler. This is due to differences in the air flow resistance.

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

Page 19 (23)

Description A90030-0006

Engine Types 35-98MC/MC-C


Running with auxiliary blowers: If an auxiliary blower fails during running, the non-return valve must close to ensure the continued supply of fresh air to the engine. See Starting the auxiliary blowers, Item 2, above.

Exhaust Gas Receiver

From the exhaust valves, the exhaust gas is led to the exhaust gas receiver where the pulsatory pressure from the individual exhaust valves is equalized and led to the turbocharger at a constant pressure. The exhaust gas receiver is fastened to the seating by flexible supports. Compensators are inserted between the receiver and the exhaust valves, and between the receiver and the turbocharger. Inside the exhaust gas receiver, a protective grating is mounted before the turbocharger. The exhaust gas receiver and the exhaust pipe are insulated.

Charging Air Cooler

The charging air cooler insert is of the block type. It is mounted in a housing which is welded up of steel plates. The cooler housing is provided with inspection covers. The cooler is designed with an air reversing chamber which incorporates a water mist catcher. The water mist catcher is built up of a number of lamellas which separate the condensation water from the scavenge air during the passage of the air flow. The separated water is collected in the bottom of the cooler housing from which it is removed by a drain system.

Caution! It is important to check that the drain functions correctly, as otherwise water droplets may enter the cylinders. See Volume I Operation, Chapter 706, Cleaning of Turbochargers and Air Coolers.

An alarm device for high water level in the drain system is installed.

911 Safety Equipment


Safety Valves, Cylinder Cover
Each cylinder cover is provided with a spring-loaded safety valve which is set to open at a pressure somewhat higher than the maximum firing pressure in the cylinder.

Page 20 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C


Relief Valves

Description A90030-0006

On the exhaust side of the engine a number of spring-loaded relief valves are fitted, which will open in the event of excessive pressure in the crankcase/chain casing, for instance as a result of the ignition of oil mist. Warning! Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open.

Regarding how to: avoid evaporation of the lubricating oil in the crankcase, detect oil mist in the crankcase using an Oil Mist Detector. see Volume I, OPERATION, Chapter 704. Warning! Do not stand near crankcase doors or relief valves or in corridors near doors to the engine room casing in the event of an alarm for: a) oil mist b) high lube oil temperature c) no piston cooling oil flow, or d) scavenge box fire Alarms b, c and d should be considered as pre-warnings of a possible increasing oil mist level. See also our Service Letter SL97-348/ERO.

Note! If there has been a crankcase explosion, the complete flame arrester of the relief valves must be replaced.

Safety Valve, Scavenge Air Receiver

The scavenge air receiver is fitted with a safety valve which is set to open should the pressure in the scavenge air receiver exceed a value somewhat higher than the normal scavenge air pressure of the engine. In some cases it may be necessary to open the valve manually, see Volume I, Chapter 704, "Turbocharger Surging".

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

Page 21 (23)

Description A90030-0006 Safety Cap in Starting Air Line

Engine Types 35-98MC/MC-C


Each starting valve inlet pipe is provided with a safety cap. The safety cap consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders, in the event of a burst. The cover is provided with a check plate, which shows if the bursting disc has been damaged. If the bursting disc of the safety cap is damaged by excessive pressure in the starting air line, overhaul or replace the starting valve which caused the burst, and fit a new disc. If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Fit a new bursting disc and return the cover to the open position at the first opportunity.

912 Assembly of large Parts


Bedplate
The bedplate is made in one or more sections, depending on the number of cylinders. If there are two or more sections, these are joined together with fitted bolts. The bedplate consists of two welded, longitudinal girders and a number of cross girders which support the main bearings. The main bearings consist of steel shells, lined with bearing metal. See also Volume I, OPERATION, Chapter 708. Each main bearing has one or two main bearing caps which are secured by studs and nuts, designed for tightening with hydraulic tools. The bedplate is fitted with an axial vibration damper. For the design and functioning of the axial vibration damper, see Section 905 Crankshaft. Marine engines (except geared plants): The aft end of the bedplate incorporates the thrust bearing. See also Section 905 Crankshaft. Stationary engines (and geared marine plants): The bedplate incorporates the guide bearing. See also Section 905, Crankshaft.

Framebox

A framebox is bolted on to the top of the bedplate. Like the bedplate, the framebox consists of one or more sections. Together, the bedplate and the framebox constitute the crankcase of the engine. The framebox is fitted with steel-plate doors for access to the crossheads and to the main and crankpin bearings. For each cylinder, the framebox is equipped with a slotted pipe in which the piston cooling oil outlet pipe fitted to the crosshead or guide shoe is

Page 22 (23)

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C

Description A90030-0006

able to travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to the oil tray of the bedplate. Equipment for local checking of the cooling oil temperature and flow, and for temperature and flow alarms, is installed in conjunction with the outlet pipe. See also Volume I, OPERATION, Chapter 701.

Staybolts

The bedplate, framebox and the cylinder frame are tightened together to form one unit by means of staybolts. Regarding the engine seating for the specific engine, see the suppliers special instructions.

Engine Seating

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

Page 23 (23)

901 - Cylinder Cover


Documents in this Chapter
90101 90103 0180 0003 Cylinder Cover Indicator Cock - Mounting

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover
MAN B&W Diesel

Plate P90101-0180

When referring to this page, please quote Plate P90101 Edition 0180

Page 1 (2)

Plate P90101-0180 Item No.


018 031 043 067 080 102 114 126 151 163 175 187 209 210 222 234 246 271

Cylinder Cover
MAN B&W Diesel Item No.

Item Description
Nut Washer Stud Cylinder cover O-ring Cooling jacket Screw Gasket Screw Protective cap Nut Stud for exhaust valve Nut Spring house, complete Stud with guide face for fuel valve Stud for fuel valve Pipe for fuel valve Drain pipe

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90101 Edition 0180

Indicator Cock - Mounting

Plate P90103-0003

When referring to this page, please quote Plate P90103 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P90103-0003 Item No.


019 020 032 056 068 081 093 103 127 140 152 164 176 188 223 235

Indicator Cock - Mounting


Item No.

Item Description
Indicator cock Packing Packing Disc Plug screw Sundry chain Key ring Eye screw Packing Screw Nut Locking plate Flange Extension Screw Extension

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90103 Edition 0003
MAN B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


Documents in this Chapter
90201 90205 0216 0117 Piston and Piston Rod Piston Rod Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Piston and Piston Rod

Plate P90201-0216

When referring to this page, please quote Plate P90201 Edition 0216
MAN B&W Diesel A/S

Page 1 (2)

Plate P90201-0216 Item No.


011 023 035 047 059 060 072 084 096 106 118 143 155 167 179 180 192 202 214

Piston and Piston Rod


Item No.

Item Description
Screw Screw D-ring D-ring Piston skirt Screw Screw Locking wire Piston ring No.1 Piston ring No. 2+4 Piston ring No. 3 Piston crown Pipe for cooling insert Disc Piston rod Stud Sealing ring Disc Nut

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90201 Edition 0216
MAN B&W Diesel A/S

Piston Rod Stuffing Box

Plate P90205-0117

When referring to this page, please quote Plate P90205 Edition 0117
MAN B&W Diesel A/S

Page 1 (2)

Plate P90205-0117 Item No.


013 025 037 049 074 086 098 121 145 169 170 182 204 228 265 277 300

Piston Rod Stuffing Box


Item No.

Item Description
O-ring Scraper ring Sealing ring Sealing ring Nut Housing stuffing box Flange Screw Fitted bolt Screw Scraper ring Scraper ring Cylindrical pin Spring pin Lamella Spring Spring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90205 Edition 0117
MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


Documents in this Chapter
90301 90302 90304 90305 90307 90308 90310 90312 0163 0161 0035 0143 0032 0010 0012 0004 Cylinder Frame Cylinder Liner and Cooling Jacket Cylinder Liner - Details Cylinder Lubricators Cylinder Lubricator Unit Cylinder Lubricator - Intermediate Box Cylinder Frame - Rear Side Electronic Components - Cylinder Lubrication

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Frame
MAN B&W Diesel

Plate P90301-0163

When referring to this page, please quote Plate P90301 Edition 0163

Page 1 (2)

Plate P90301-0163 Item No.


135 159 160 172 184 196 206 218 231 255 267 279 292 302 314 338 351 363 387 399 410 422 446 458 471 483 495 517 529 530 542 566 578 591 601 625 637 650 662 674 686 698 721 733 745 757

Cylinder Frame
MAN B&W Diesel Item No.

Item Description
Cylinder frame Distance pipe Bushing Stuffing box housing Screw Screw Washer Cover Nut Stud for cylinder cover O-ring O-ring Nut Distance pipe Stud Stud Distance pipe Nut Screw Distance pipe Protective pipe Gasket Cylinder frame Gasket Cover Stud Nut Fittes stud Stud Nut Stud Fitted stud Stud Nut Stud Cleaning cover Gasket Screw Rail for sealing Packing Stud Nut Distance pipe Distance pipe Fitted stud Stud

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90301 Edition 0163

Cylinder Liner and Cooling Jacket

Plate P90302-0161

When referring to this page, please quote Plate P90302 Edition 0161
MAN B&W Diesel A/S

Page 1 (2)

Plate P90302-0161 Item No.


000 071 083 095 105 117 129 130 142 166 178 191 201 213 225 237 249 262

Cylinder Liner and Cooling Jacket


Item No.

Item Description

Item Description

O-ring O-ring Cooling jacket Clamp Screw Cylinder liner Cooling water connection Packing O-ring Pipe Screw Pipe Pipe Spring pin Plug screw for thermo sensor hole Gasket Piston cleaning ring

Page 2 (2)

When referring to this page, please quote Plate P90302 Edition 0161
MAN B&W Diesel A/S

Cylinder Liner - Details


Cylinder Liner - Details 0035 P90304

Plate P90304-0035

Camshaft side

When referring to this page, please quote Plate P90304 Edition 0035
MAN B&W Diesel A/S

Page 1 (2)

Plate P90304-0035 Item No.


023 035 060 072 084 096

Cylinder Liner - Details


Item No.

Item Description
Stud Nut Non-return valve Housing, non-return valve Non-return valve Head

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90304 Edition 0035
MAN B&W Diesel A/S

Cylinder Lubricators
MAN B&W Diesel

Plate P90305-0143

When referring to this page, please quote Plate P90305 Edition 0143

Page 1 (2)

Plate P90305-0143 Item No.


017 029 030 042 066 101 113 Bracket Stud Nut Washer Screw Stud Nut

Cylinder Lubricators
MAN B&W Diesel Item No.

Item Description

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90305 Edition 0143

Cylinder Lubricator Unit


MAN B&W Diesel

Plate P90307-0032

When referring to this page, please quote Plate P90307 Edition 0032

Page 1 (2)

Plate P90307-0032 Item No.


018 031 043 055 079 080 092 102 126 138 175 187 199 210 222 258 271 283 295 305 317 329 330 342 354 366 378 391 413 425 449 450 462 486 498 521 533 545 557 569 582 594 604 616 628

Cylinder Lubricator Unit


MAN B&W Diesel Item No.

Item Description
Straight stud coupling Distributor block Stud Nut Distributor block Ball valve Distributor block Stud Adjustable elbow coupling Quick coupling, minimess O-ring Gasket Membrane accumulator Lubricator, complete Screw Straight stud coupling Adjusting screw O-ring Spacer, tubular Cover O-ring Non-return valve O-ring Cylinder block O-ring Spring Plunger Actuator piston Screw Screw Membrane accumulator Gasket Cylinder housing Solenoid valve complete Screw O-ring O-ring Inductive sensor Plug Housing Cable Cable gland Screw Cable gland Plug

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90307 Edition 0032

Intermediate Box

Plate P90308-0010

When referring to this page, please quote Plate P90308 Edition 0010
MAN B&W Diesel A/S

Page 1 (2)

Plate P90308-0010 Item No.


013 037 049 062

Intermediate Box
Item No.

Item Description
Intermediate box, complete Electric enclosure with cables Circuitboard assy Diode

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90308 Edition 0010
MAN B&W Diesel A/S

Cylinder Frame, Studs on Exhaust Side


MAN B&W Diesel

Plate P90310-0012

When referring to this page, please quote Plate P90310 Edition 0012

Page 1 (2)

Plate P90310-0012 Item No.


014 026 038 054 063 075

Cylinder Frame, Studs on Exhaust Side


MAN B&W Diesel Item No.

Item Description
Distance pipe Nut Stud Distance pipe Nut Stud

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90310 Edition 0012

Cylinder Lubrication - Electronic Components

Plate P90312-0004

When referring to this page, please quote Plate P90312 Edition 0004
MAN B&W Diesel A/S

Page 1 (2)

Plate P90312-0004 Item No.


015 027 039 040 052 064 076 088 111 159 160 184 196 206

Cylinder Lubrication - Electronic Components


Item No.

Item Description
Name plate Pilot lamp Name plate Selector switch Terminal Terminal Din rail Terminal Terminal HMI panel Mounting plate Nut Screw Terminal

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90312 Edition 0004
MAN B&W Diesel A/S

904 - Crosshead with Connecting Rod


Documents in this Chapter
90401 90403 0172 0012 Connecting Rod and Crosshead Lubricating and Cooling Oil Flow

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Connecting Rod and Crosshead


MAN B&W Diesel

Plate P90401-0172

When referring to this page, please quote Plate P90401 Edition 0172

Page 1 (2)

Plate P90401-0172 Item No.


019 020 032 056 068 093 103 127 139 152 164 176 188 223 235 247 260 272 284 296 318 331 343 367 379 392 402 414 426 438 463 475 487 509 510 522 546 558 583 595 617

Connecting Rod and Crosshead


MAN B&W Diesel Item No.

Item Description
Screw Outlet pipe Guide shoe Lock washer Stop screw Screw Nut Thrust piece Screw Telescope pipe Distance tube Bend Stud Plug Guide pin Throttle plug Locking wire Crosshead Crosshead bearing shell, complete Guide strip Crankpin bearing cap, complete Guide screw Crankpin bearing cap Guide pipe Nut Nut Washer Stud Screw *) Shim Nut Crosshead bearing cap Stud *) Shim *) Shim Stud Guide pin Connecting rod Nut Stud Connecting rod, complete Note: *) Please state thickness of shim

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90401 Edition 0172

Lubricating and Cooling Oil Flow


MAN B&W Diesel

Plate P90403-0012

When referring to this page, please quote Plate P90403 Edition 0012

Page 1 (1)

905 - Crankshaft, Thrust Bearing and Turning Gear


Documents in this Chapter
90501 90502 90505 90510 90511 90513 0162 0052 0146 0124 0039 0041 Crankshaft Arrangement of Fore End Thrust- and Guide Bearing Turning Gear Turning Wheel Tacho System

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crankshaft
P90501 Crankshaft 0162

Plate P90501-0162

When referring to this page, please quote Plate P90501 Edition 0162
MAN B&W Diesel A/S

Page 1 (2)

Plate P90501-0162 Item No.


012 024 061 073 097 107 119 120 132 144 156 203 215 227

Crankshaft
Item No.

Item Description
Flange Screw Screw Crankshaft Guard Guard Nut Packing Cover Screw Locking wire Fitted bolt Split pin Chain wheel

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90501 Edition 0162
MAN B&W Diesel A/S

Arrangement of Fore End

Plate P90502-0052

When referring to this page, please quote Plate P90502 Edition 0052
MAN B&W Diesel A/S

Page 1 (2)

Plate P90502-0052 Item No.


018 024 043 055

Arrangement of Fore End


Item No.

Item Description
Stud Nut Tuning wheel Disc

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90502 Edition 0052
MAN B&W Diesel A/S

Thrust and Guide Bearing


Thrust and Guide Bearing 0146 P90505

Plate P90505-0146

When referring to this page, please quote Plate P90505 Edition 0146
MAN B&W Diesel A/S

Page 1 (2)

Plate P90505-0146 Item No.


014 026 038 051 063 075 087 109 110 122 134 158 171 195 205 217 229 242 254 266 278 291 301 313 337 350 362 386 408 421 433 445 457 469 494 504 516 541

Thrust and Guide Bearing


Item No.

Item Description
Lubricating oil pipe Screw Nut Lubricating oil pipe Lubricating oil pipe Stopper Segment holder Locking wire Screw Segment Segment Lubricating oil pipe Nut Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Screw Lubricating oil pipe Lubricating oil pipe Segment holder Segment holder Lubricating oil pipe Screw Lubricating oil pipe Oil throw ring Screw Nut Scraper ring housing, Scraper ring housing, Bolt Screw Scraper ring housing, Nut Scraper ring housing, Bolt Screw Nut

Item Description

complete upper

lower complete

Page 2 (2)

When referring to this page, please quote Plate P90505 Edition 0146
MAN B&W Diesel A/S

Turning Gear

Plate P90510-0124

When referring to this page, please quote Plate P90510 Edition 0124
MAN B&W Diesel A/S

Page 1 (2)

Plate P90510-0124 Item No.


011 023 035 047 059 072 084 096 106 131 143 155 167 192 202 214 226 251 263 299 309 310 322 334 346 358 405 417 429

Turning Gear
Item No.

Item Description
Bracket Nut Screw Spring washer Cam Switch Spring washer Screw Lever 3/2-way valve Screw Spring washer Chain Nut Distance pipe Pin Turning gear Distance pipe Screw Gear wheel Disengaging divice, complete Screw Cam Spring washer Shaft Bush Spring ring Eye screw Circlip

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90510 Edition 0124
MAN B&W Diesel A/S

Turning Wheel

Plate P90511-0039

When referring to this page, please quote Plate P90511 Edition 0039
MAN B&W Diesel A/S

Page 1 (2)

Plate P90511-0039 Item No.


017 029 030 054 066 078 101 113 125 137

Turning Wheel
Item No.

Item Description
Guide pin Nut Nut Screw Screw Dead centre pointer Fitted bolt Nut Turning wheel Locking wire

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90511 Edition 0039
MAN B&W Diesel A/S

Tacho System
MAN B&W Diesel

Plate P90513-0041

When referring to this page, please quote Plate P90513 Edition 0041

Page 1 (2)

Plate P90513-0041 Item No.


018 031 043 055 067 080 092 114 126

Tacho System
MAN B&W Diesel Item No.

Item Description
Tacho pick-up Screw Spring-lock Nut Bracket Screw Spring-lock Cylindrical dowel Nut

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90513 Edition 0041

906 - Control Gear


Documents in this Chapter
90600 90603 90610 90611 90612 90613 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634 0125 0111 0131 0175 0085 0116 0147 0134 0019 0097 0076 0070 0023 0003 0030 0041 Arrangement of Chain Drive and Camshaft Chain Tightener Bearing Housing - Mounting Camshaft and Chain Wheel Arrangement of Indicator System Camshaft Bearing Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangement of Chain Drive and Camshaft

Plate P90600-0125

When referring to this page, please quote Plate P90600 Edition 0125
MAN B&W Diesel A/S

Page 1 (1)

Chain Tightener
Chain Tightener 0111 P90603

Plate P90603-0111

When referring to this page, please quote Plate P90603 Edition 0111
MAN B&W Diesel A/S

Page 1 (2)

Plate P90603-0111 Item No.


017 029 030 042 054 066 078 091 113 125 150 162 174 186 198 208 221 233 245 270 282 294 304 316 328

Chain Tightener
Item No.

Item Description
Chain wheel Cup point screw Bushing Flange bearing Locking wire Screw Screw Bracket Shaft Flange bearing Distance piece Distance piece Screw Grease nipple Shaft Guide nut Locking plate Nut Tightening bolt Shaft Guide nut Retaining ring Retaining ring Shaft Bushing

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90603 Edition 0111
MAN B&W Diesel A/S

Bearing Housing - Mounting


MAN B&W Diesel

Plate P90610-0131

When referring to this page, please quote Plate P90610 Edition 0131

Page 1 (2)

Plate P90610-0131 Item No.


015 039 052 064 088 111 123 147 159 172 184 196

Bearing Housing - Mounting


MAN B&W Diesel Item No.

Item Description
Bearing housing Bearing shell Nut for hydraulic tightening Stud Lock washer Screw Guide pin Guide pin Shim Bearing housing Guide disc Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90610 Edition 0131

Camshaft and Chain Wheel


MAN B&W Diesel

Plate P90611-0175

When referring to this page, please quote Plate P90611 Edition 0175

Page 1 (2)

Plate P90611-0175 Item No.


010 034 058 071 083 095 117 130 154 166 191 213 225 249 250 274 298 321 345

Camshaft and Chain Wheel


MAN B&W Diesel Item No.

Item Description
Camshaft, fore O-ring Exhaust cam Fuel cam Sealing flange Coupling O-ring Camshaft Indicator cam Fitted bolt Nut, self-locking O-ring Fitted bolt Chain wheel Camshaft Guide pin Disc Nut Plug

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90611 Edition 0175

Arrangement of Indicator System

Plate P90612-0085

When referring to this page, please quote Plate P90612 Edition 0085
MAN B&W Diesel A/S

Page 1 (2)

Plate P90612-0085 Item No.


016 028 041 053 065 077 089 090 100 112 124 136 148 161 173 185 197 207 219 220 232 244 256 268 281 293 303 315 327 555 567 579 580

Arrangement of Indicator System


Item No.

Item Description
Nut Screw Washer Bracket Screw Housing Liner Spring pin Roller guide, complete Circlip Washer Screw Circlip Roller guide Liner Liner Spring Key Screw Shaft Needle bearing Pointed screw Bracket Screw Screw Handle Bracket Washer Screw Guide roller Shaft Circlip Washer

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90612 Edition 0085
MAN B&W Diesel A/S

Camshaft Bearing
Camshaft Bearing 0116 P90613

Plate P90613-0116

When referring to this page, please quote Plate P90613 Edition 0116
MAN B&W Diesel A/S

Page 1 (2)

Plate P90613-0116 Item No.


023 035 047 059 060 072 084 131 143 155 167 179 192 202 214 226 238 251 263 275 287

Camshaft Bearing
Item No.

Item Description
Housing Guide pin Screw Screw Shield, upper part Rubber corol Shield, lower part Cover Gasket Nut Nut Screw Oil pan Stud Bearing shell Pin Bearing cap Screw Flange, complete Gasket Cover

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90613 Edition 0116
MAN B&W Diesel A/S

Arrangement of Governor
MAN B&W Diesel

Plate P90615-0147

When referring to this page, please quote Plate P90615 Edition 0147

Page 1 (2)

Plate P90615-0147 Item No.


012 036 048 061 073 085 107 119 120 132 156 168

Arrangement of Governor
MAN B&W Diesel Item No.

Item Description
Electrical governor actuator Screw Spring lock Screw Nut Bracket Pull rod, complete Fitted bolt Washer Nut, self-locking Terminal Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90615 Edition 0147

Regulating Shaft

Plate P90618-0134

When referring to this page, please quote Plate P90618 Edition 0134
MAN B&W Diesel A/S

Page 1 (2)

Plate P90618-0134 Item No.


019 020 032 044 068 081 093 103 115 127 139 140 164 176 188 211 223 260 272 284 296 306 318 331 343 355 367 392 402 414 426 438 451 475 487 499 509 510 522 534 546 571 595 630 642 654 666 678 691 701

Regulating Shaft
Item No.

Item Description
Shaft Circlip Pull rod, complete Fitted bolt Screw Lock washer Arm holder Pin Recilient arm, complete Circlip Nut Spring Screw Lock washer Nut Washer Fitted bolt Sleeve coupling, complete Pin Self-locking nut Washer Moveable arm Circlip Pin Key Lever Self-locking nut Shaft Shaft Screw Spring washer Sleeve coupling Nut Ball bearing Shim Bearing housing Screw Shaft Bracket Bearing housing Screw Bracket Washer Key Screw Lever Nut Bracket Dog point screw Spring pin

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90618 Edition 0134
MAN B&W Diesel A/S

Load Transmitter
MAN B&W Diesel

Plate P90619-0019

When referring to this page, please quote Plate P90619 Edition 0019

Page 1 (2)

Plate P90619-0019 Item No.


014 026 038 051 075 087 099 109 110 122 134 146 171 183 195

Load Transmitter
MAN B&W Diesel Item No.

Item Description
Clamping arm Screw Lock washer Nut Fitted bolt Self-locking nut Washer Pull rod, complete Clamping arm Screw Lock washer Nut Bracket Potentiometer Screw

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90619 Edition 0019

Engine Side Control Console


Engine Side Control Console 0097 P90620

Plate P90620-0097

When referring to this page, please quote Plate P90620 Edition 0097
MAN B&W Diesel A/S

Page 1 (2)

Plate P90620-0097 Item No.


021 033 045 057 069 070 082 094 104 116 128 141 153 165 177 189 190 200 212 224 248 261 273 285 307 319 320 332 368 381 415 427 476 488 511 523 535 547 559 631 643 655 667 680 692 714 726

Engine Side Control Console


Item No.
738 751 763 775

Item Description
Distance pipe Screw Switch 0-110 volt Spring lock Name plate Pressure switch Screw Name plate Name plate Spring lock Nut Stud Handle Key Grease nipple Nut Washer Engine side console Forked lever Key Clamping arm Screw Nut Lock washer Cover Screw Hand wheel Thrust ring Locking plate Nut Clamping block Spindle Ball bearing Circlip Screw Name plate, astern Name plate, start Name plate, aahead Name plate, stop Screw Sealing ring Name plate, remote Name plate Thrust ring Name plate, emergency Ball bearing Circlip

Item Description
Bearing flange Shaft Studs Ball handle

Page 2 (2)

When referring to this page, please quote Plate P90620 Edition 0097
MAN B&W Diesel A/S

Engine - Side Control Console, Details


Engine - Side Control Console, Details 0076 P90621

Plate P90621-0076

When referring to this page, please quote Plate P90621 Edition 0076
MAN B&W Diesel A/S

Page 1 (2)

Plate P90621-0076 Item No.


027 039 040 052 076 088 111 123 135 147 159 160 172 196 206 218 231 255 267 279 280 302 314 326 338 351 363 375 387 399 410 422 434 446 458 483 495 505 517 529 542 554 566 578 591 613 637

Engine - Side Control Console, Details


Item No.
650 Coupling

Item Description
Screw Self-locking nut Washer Fitted bolt Key Coupling Split pin Bearing Screw Angle lever Circlip Non-return valve Nut Flange bearing Screw Manual valve 5/2 way Screw Pointer Screw Shaft Manual valve 3/2 way Circlip Circlip Ball bearing Flange bearing Manual valve 3/2 way Clamping arm Lock washer Nut Screw Nut Slide shoe Circlip Screw Lock washer Coupling Coupling Non-return valve Banjo coupling Coupling Screw connection Coupling Coupling Coupling Coupling Coupling Coupling

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90621 Edition 0076
MAN B&W Diesel A/S

Arrangement of Layshaft

Plate P90622-0070

When referring to this page, please quote Plate P90622 Edition 0070
MAN B&W Diesel A/S

Page 1 (2)

Plate P90622-0070 Item No.


010 022 034 046 058 071 083 095 105 117 129 130 178 191 201 213 225 237 249 250 262 274 286 298 308 321 333 345 357 369 370

Arrangement of Layshaft
Item No.

Item Description
Flange bearing Washer Self-locking nut Lever Lever Grease nipple Fitted bolt Spindle Cone Guide pin Distance ring Ball bearing Lever Plate Disc Nut Locking plate Screw Bushing Locking arm Washer Screw Spring washer Screw Switch Stop screw Cam Impact socket Impact handwheel Washer Self-locking nut

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90622 Edition 0070
MAN B&W Diesel A/S

Chain Drive Guidebars - Upper Part


MAN B&W Diesel

Plate P90631-0023

When referring to this page, please quote Plate P90631 Edition 0023

Page 1 (2)

Plate P90631-0023 Item No.


021 045 069 070 094 104 116 128 141 153 165

Chain Drive Guidebars - Upper Part


MAN B&W Diesel Item No.

Item Description
Chain link, complete Chain, complete Outer link Inner link Locking wire Disc Screw Beam for guidebar Guidebar Screw Bracket for guidebar Note: *

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90631 Edition 0023

Chain Drive Guide Bars - Lower Parts

Plate P90632-0003

When referring to this page, please quote Plate P90632 Edition 0003
MAN B&W Diesel A/S

Page 1 (2)

Plate P90632-0003 Item No.


015 027 039 052 064 076 111 135 147 160 184 196 218 243 267

Chain Drive Guide Bars - Lower Parts


Item No.

Item Description
Guidebar Beam f. guidebar Screw Disc Screw Locking wire Screw Beam f. guidebar Shim Screw Screw Bracket Screw Beam f. guidebar Bracket

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90632 Edition 0003
MAN B&W Diesel A/S

Chain Drive Lubrication - Upper Part


MAN B&W Diesel

Plate P90633-0030

When referring to this page, please quote Plate P90633 Edition 0030

Page 1 (2)

Plate P90633-0030 Item No.


010 022 034 058 071 083 095 105 129 142 166

Chain Drive Lubrication - Upper Part


MAN B&W Diesel Item No.

Item Description
Lubricating pipe Spray nozzle Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90633 Edition 0030

Chain Drive Lubrication - Lower Part


MAN B&W Diesel

Plate P90634-0041

When referring to this page, please quote Plate P90634 Edition 0041

Page 1 (2)

Plate P90634-0041 Item No.


016 028 041 053 065 089 090 100 112 136 148 173 185 219 232

Chain Drive Lubrication - Lower Part


MAN B&W Diesel Item No.

Item Description
Lubricating oil pipe Lubricating oil pipe Spray pipe Spray pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Spray pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Spray pipe Lubricating oil pipe

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90634 Edition 0041

907 - Starting Air System


Documents in this Chapter
90702 90703 90704 0069 0129 0053 Main Starting Valve Starting Air Distributor Starting Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Main Starting Valve

Plate P90702-0069

When referring to this page, please quote Plate P90702 Edition 0069
MAN B&W Diesel A/S

Page 1 (2)

Plate P90702-0069 Item No.


027 039 052 064 076 088 123 135 147 160 184 196 206 218 231 255 279 280 292 314 326 338 351 363 387 399 410 422 434 458 471 495 505 517 529 530 542 554 566 591 601 625 637 650 674 698

Main Starting Valve


Item No.
708 900 912

Item Description
Screw Name plate "Working" Screw Washer Switch Distance pipe Spindle Screw Plate Ball valve with actuator* Nut Screw Starting air pipe Gasket Intermediate piece Name plate "Blocked" Nut Washer Hand wheel Securing plate Pin Spring Screw Gasket Gasket Plug screw Adjusting screw Nut Adapter Washer Screw Screw Guide Guide pin Screw Distance pipe Screw Ball valve with actuator* Nut Plug screw Gasket Plug screw Starting air pipe Non-return valve Housing Housing

Item Description
Screw Repair kit, actuator* Repair kit, ball valve* Note: * When ordering spare parts for this item, please state manufacturer's Part No.

Page 2 (2)

When referring to this page, please quote Plate P90702 Edition 0069
MAN B&W Diesel A/S

Starting Air Distributor


MAN B&W Diesel

Plate P90703-0129

When referring to this page, please quote Plate P90703 Edition 0129

Page 1 (2)

Plate P90703-0129 Item No.


010 022 034 046 071 083 105 129 142 166 178 191 213 225 237 250 274 286 298 308 321 333 345

Starting Air Distributor


MAN B&W Diesel Item No.

Item Description
Starting cam Lock washer Screw Cover Screw Cover Piston valve slide Liner Screw Screw Washer Screw Screw Housing Screw Pin Screw Flange Locking ring Spring guide Spring Spring guide Liner

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90703 Edition 0129

Starting Valve
Starting Valve 0053 P90704

Plate P90704-0053

When referring to this page, please quote Plate P90704 Edition 0053
MAN B&W Diesel A/S

Page 1 (2)

Plate P90704-0053 Item No.


016 028 053 065 077 090 100 112 148 161

Starting Valve
Item No.

Item Description
Screw Piston Spring Bushing Valve housing Screw Cover Locking plate Sealing ring Spindle

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90704 Edition 0053
MAN B&W Diesel A/S

908 - Exhaust Valve


Documents in this Chapter
90801 90803 90804 90805 90806 90810 0211 0045 0016 0122 0104 0089 Exhaust Valve - Lower Parts Exhaust Valve - Upper Parts Exhaust Valve Upper Parts - Details Exhaust Valve - Actuator Exhaust Valve - Pipe System Arrangement of Cooling Water Pipes

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Exhaust Valve - Lower Parts


MAN B&W Diesel

Plate P90801-0211

When referring to this page, please quote Plate P90801 Edition 0211

Page 1 (2)

Plate P90801-0211 Item No.


013 025 037 050 062 074 086 098 121 145 169 170 182 194 204 228 253 265 277 290

Exhaust Valve - Lower Parts


MAN B&W Diesel Item No.

Item Description
Cover Screw Packing Packing Flange Screw O-ring Bottom piece Valve spindle Thread insert Spindle guide lower Exhaust valve housing Plug screw Screw Sealing ring O-ring Packing Flange Screw Sealing ring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90801 Edition 0211

Exhaust Valve - Upper Parts


MAN B&W Diesel

Plate P90803-0045

When referring to this page, please quote Plate P90803 Edition 0045

Page 1 (2)

Plate P90803-0045 Item No.


014 026 038 063 087 099 110 134 158 205 217 229 242 254 266 291 301 325 337 349 350 362 386 398 408 433 457 469 470 482 494 504 516 528 541 553 565 589 600 612 624 636 661

Exhaust Valve - Upper Parts


MAN B&W Diesel Item No.

Item Description
Lifting eye bolt Screw Lifting attachment Packing Orifice plug Disc Safety handrail Piston, air cylinder O-ring Locking plate Sliding bearing Sealing ring Oil cylinder Stud Nut Sealing oil pipe Sealing oil control unit Disc Locking plate Screw O-ring Air cylinder Screw Disc Cone Piston ring Screw Pin Rotation check rod Steel pipe Union nut Screwed connection Packing ring Spring O-ring Disc Spring pin Non-return valve Piston Spring Piston Disc Piston, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90803 Edition 0045

Exhaust V alve - Upper Parts, Details Valve


MAN B&W Diesel

Plate P90804-0016

When referring to this page, please quote Plate P90804 Edition 0016

Page 1 (2)

Plate P90804-0016 Item No.


021 045 905

Exhaust V alve - Upper Parts, Details Valve


MAN B&W Diesel Item No.

Item Description
Gasket Safty valve, with o-ring O-ring* Note: * Optional extras

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90804 Edition 0016

Valve Gear
Valve Gear 0122 P90805

Plate P90805-0122

When referring to this page, please quote Plate P90805 Edition 0122
MAN B&W Diesel A/S

Page 1 (2)

Plate P90805-0122 Item No.


015 027 039 040 052 064 076 088 111 123 135 147 159 160 167 196 206 218 255 267 279 280 292 314 326 338 351

Valve Gear
Item No.

Item Description
Nut Oil cylinder Stud Stud Piston Roller guide, complete Thrust disc Roller guide Shaft pin for roller Plug Circlip Screw Bushing Disc Bushing for roller guide Cylinder pin Screw Bushing Piston ring Disc Screw Disc Spring Cylinder pin Roller Guide block Guide pin

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90805 Edition 0122
MAN B&W Diesel A/S

Exhaust Valve - Pipe System


MAN B&W Diesel

Plate P90806-0104

When referring to this page, please quote Plate P90806 Edition 0104

Page 1 (2)

Plate P90806-0104 Item No.


010 022 046 058 071 083 105 117 129 130 142 154 166 178 191 213 237 262 298 308

Exhaust Valve - Pipe System


MAN B&W Diesel Item No.

Item Description
Sealing ring Sealing disc Clamp Nut Screw Support Coupling Coupling Thrust bushing Screw Cooling water connection Pipe Sealing ring Packing Hose complete Drain pipe Hydraulic pipe, complete Screw Plug screw Packing ring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90806 Edition 0104

Arrangement of Cooling Water Pipes


MAN B&W Diesel

Plate P90810-0089

When referring to this page, please quote Plate P90810 Edition 0089

Page 1 (2)

Plate P90810-0089 Item No.


012 024 036 048 061 073 085 097 119 120 132 156 181 203 215 227 239 240 264

Arrangement of Cooling Water Pipes


MAN B&W Diesel Item No.

Item Description
Steel pipe Ball valve Coupling Steel pipe Gasket Freshwater pipe, outlet Screw Packing Screw Nut Packing Freshwater pipe, inlet Globe valve Packing Screw Sealing ring Screw Spring pin Freshwater pipe, inlet

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90810 Edition 0089

909 - Fuel Oil System


Documents in this Chapter
90901 90902 90903 90904 90905 90907 90910 90911 90913 90914 90915 90915 90916 0184 0150 0040 0061 0030 0011 0143 0022 0158 0078 0060 0080 0006 Fuel Pump Fuel Pump Gear Fuel Pump Gear - Details Fuel Pump - Details Reversing Mechanism Lifting Device for Fuel Pump Fuel Valve Fuel Valve Function High-Pressure Pipes Fuel Oil System Fuel Oil System - Details Fuel Oil System - Details Lifting Device for Fuel Pump - Cylinder No. 1

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Fuel Pump

Plate P90901-0184

When referring to this page, please quote Plate P90901 Edition 0184
MAN B&W Diesel A/S

Page 1 (2)

Plate P90901-0184 Item No.


017 042 054 078 101 113 125 137 149 150 162 174 186 198 221 233 257 269 270 282 294 341 389 390 400 412 436 448 461 473 520 532 544 568 581 603 615 627 639 640 652 664 676 688 711 723 735 747 772 784

Fuel Pump
Item No.
855 867 879 880 892 902 914 926

Item Description
Gasket Gasket Plug screw Pump housing, complete Timing guide Sleeve Regulating guide Guide pin Screw Guide pin Stud Gasket Guide screw Guide pin Guide bushing, complete Guide bushing Screw Screw Top cover Lock washer Plug screw Throttle plug Nut Screw Spring guide Spring Suction value, complete Slide Thrust piece Sealing ring Sealing ring Pump barrel Pump barrel, complete Sealing ring Plunger Screw Lock washer Cover Sealing ring Sealing ring Puncture valve, complete Air piston Gasket Valve housing O-ring Slide Spring Spring guide Throttle plug Gasket

Item Description
Screw Portective cap Coupling Pipe Banjo coupling Plug screw Disc Pipe

Page 2 (2)

When referring to this page, please quote Plate P90901 Edition 0184
MAN B&W Diesel A/S

Fuel Pump Gear

Plate P90902-0150

When referring to this page, please quote Plate P90902 Edition 0150
MAN B&W Diesel A/S

Page 1 (2)

Plate P90902-0150 Item No.


012 024 036 048 061 073 085 097 107 119 120 132 168 181 193 203 215 239 240 252 276 288 311 323 335 360 384 396 406 418 431 467 479 492 502 514 526 551 563 575 587 599 609 610 622 634 646 658

Fuel Pump Gear


Item No.

Item Description
Pin Shaft Plug Circlip Screw Fuel pump roller guide, complete Roller Bushing Disc Shaft Link f. reversing Pin Guide pin Thrust disc Roller guide Plug Bushing Nut Nut Pump base, complete Pin Guide block Screw Pin Bushing Bushing for roller guide Disc Sealing ring Cap Sealing ring Cap Locking wire Screw Gasket Gasket Cover Screw Seat disc Spring, internal Stud Spring, external Stud Seat disc Seat disc Pump base Sealing bush Retaining ring Orifice plug

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90902 Edition 0150
MAN B&W Diesel A/S

Fuel Pump Gear - Details

Plate P90903-0040

When referring to this page, please quote Plate P90903 Edition 0040
MAN B&W Diesel A/S

Page 1 (2)

Plate P90903-0040 Item No.


018 031 043 055 067 080 092 102 114 126 138 151 175 187 199 209 210 222 246 258 271 283 295 305 317 329 330 342 354 366 391 401 413

Fuel Pump Gear - Details


Item No.

Item Description
Screw Support, complete Ball lock Screw O-ring Screw Coupling arm Screw Washer Pull rod head Nut Nut Flange Shaft Screw Collar pin Split pin Air cylinder Locking pin Securing pin O-ring Bearing Piston ring O-ring Screw Bracket Stud Distance piece Flange suspension Screw Disc Needle bearing Pin

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90903 Edition 0040
MAN B&W Diesel A/S

Fuel Pump - Details


MAN B&W Diesel

Plate P90904-0061

When referring to this page, please quote Plate P90904 Edition 0061

Page 1 (2)

Plate P90904-0061 Item No.


013 025 037 049 050 062 074 086 108 121 133 157 169 170 182 194 216 228 241 253 265 277 289

Fuel Pump - Details


MAN B&W Diesel Item No.

Item Description
Union Screw Bracket Screw Actuator Coupling Washer Nut Guide screw Toothed bar, regulation Packing Union Pointer Toothed bar, timing Nut Forked lever Retaining ring Guide pin Forked lever Forked lever Nut Adjusting screw Nut

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90904 Edition 0061

Reversing Mechanism
Reversing Mechanism 0030 P90905

Plate P90905-0030

When referring to this page, please quote Plate P90905 Edition 0030
MAN B&W Diesel A/S

Page 1 (2)

Plate P90905-0030 Item No.


019 020 032 044 056 068 093 103 115 127 139 152 164 176 211 223 235 247 259 272 284 296 306

Reversing Mechanism
Item No.

Item Description
Shaft Guide for reversing Distance pipe Nut Guard Screw Cover Screw Bolt Flange for air cylinder Reversing mechanism, complete Screw Bush Air cylinder Ball valve Tee-screwed connection Nut Packing Union Orifice plate Non-return valve Nut Safety valve

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90905 Edition 0030
MAN B&W Diesel A/S

Lifting Device for Fuel Pump

Plate P90907-0011

When referring to this page, please quote Plate P90907 Edition 0011
MAN B&W Diesel A/S

Page 1 (2)

Plate P90907-0011 Item No.


021 033 057 069 070 082 094 104 116 141 153 177 189 200 212 224

Lifting Device for Fuel Pump


Item No.

Item Description
4/2 way valve Screw Pipe Coupling Coupling Coupling Coupling Coupling Non-return valve Pressure switch Screw Coupling Pipe Coupling Pipe Hose

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90907 Edition 0011
MAN B&W Diesel A/S

Fuel Valve
P90910 Fuel Valve 0143

Plate P90910-0143

016

197 207

028

065 089

219

090 220

100 124

232

244

256

136

268

148 950

281

161

173

When referring to this page, please quote Plate P90910 Edition 0143
MAN B&W Diesel A/S

Page 1 (2)

Plate P90910-0143 Item No.


016 028 065 089 090 100 124 136 148 161 173 197 207 219 220 232 244 256 268 281 950

Fuel Valve
Item No.

Item Description
Thrust piece Cut-off shaft Spindle guide, complete Spindle guide Spring pin Nozzle O-ring Holder Guide pin Union nut O-ring O-ring Valve head Guide pin Spring Non-return valve Disc Thrust spindle Spring Thrust foot Disc (optional extras)

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90910 Edition 0143
MAN B&W Diesel A/S

Fuel Valve Function

Plate P90911-0022

When referring to this page, please quote Plate P90911 Edition 0022
MAN B&W Diesel A/S

Page 1 (2)

Plate P90911-0022 Item No.

Fuel Valve Function


Item No.

Item Description

Item Description

Note: D1 = Predetermined closing value for non-return valve D2 = Predetermined opening value for cut-off spindle

Page 2 (2)

When referring to this page, please quote Plate P90911 Edition 0022
MAN B&W Diesel A/S

High-Pressure Pipes

Plate P90913-0158

When referring to this page, please quote Plate P90913 Edition 0158
MAN B&W Diesel A/S

Page 1 (2)

Plate P90913-0158 Item No.


012 024 036 048 073 085 097 107 120 132 156 181 193 203 215 227 252 264 276 288 323 335 372

High-Pressure Pipes
Item No.

Item Description
Sleeve Retaining ring High-pressure pipe Union nut Sealing ring Union nut Housing O-ring Union nut O-ring High-pressure pipe, complete Coupling Steel pipe Screw Flange Housing Coupling Guide pin High-pressure pipe, complete High-pressure pipe High-pressure pipe, complete High-pressure pipe Insulation* Note: *Pipe end insulation sleeve and tape can be sold seperatly

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90913 Edition 0158
MAN B&W Diesel A/S

Fuel Oil System


Fuel Oil System 0078 P90914

Plate P90914-0078

When referring to this page, please quote Plate P90914 Edition 0078
MAN B&W Diesel A/S

Page 1 (2)

Plate P90914-0078 Item No.


018 031 055 067 079 092 102 126 138 187 199

Fuel Oil System


Item No.

Item Description
Pipe Pipe Pipe Coupling Coupling Distributor piece Screw Pipe Coupling Coupling Gasket

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90914 Edition 0078
MAN B&W Diesel A/S

Fuel Oil System - Details

Plate P90915-0060

When referring to this page, please quote Plate P90915 Edition 0060
MAN B&W Diesel A/S

Page 1 (2)

Plate P90915-0060 Item No.


013 025 037 049 050 074 086 098 121 133 145

Fuel Oil System - Details


Item No.

Item Description
By-pass valve, complete Valve housing Valve housing Sealing ring Spring guide Screw Union nut Nut Sealing ring Piston Spring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90915 Edition 0060
MAN B&W Diesel A/S

Fuel Oil System - Details


MAN B&W Diesel

Plate P90915-0080

When referring to this page, please quote Plate P90915 Edition 0080

Page 1 (2)

Plate P90915-0080 Item No.


013 025 037 049 050 062 074 086 098 108 121 133 157 169 170 194 204 216 228 241

Fuel Oil System - Details


MAN B&W Diesel Item No.

Item Description
Nut Locking plate Flange Stud Spring guide Disc Slide Pressure spring Piston Sealing ring Wearing ring Packing Plug screw Packing ring Stud Pressure spring Packing Housing Screw Shock absorber, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90915 Edition 0080

Lifting Device for Fuel Pump Cyl. No. 1

Plate P90916-0006

When referring to this page, please quote Plate P90916 Edition 0006
MAN B&W Diesel A/S

Page 1 (2)

Plate P90916-0006 Item No.


020 032 056 068 081 093 103 115 140 152 164 176

Lifting Device for Fuel Pump Cyl. No. 1


Item No.

Item Description
4/2-Way valve Pipe holder Screw Pressure switch Screw Coupling Coupling Steel pipe Coupling Steel pipe Hose Copper pipes

Item Description

Page 2 (2)

When referring to this page, please quote Plate P90916 Edition 0006
MAN B&W Diesel A/S

910 - Turbocharger System


Documents in this Chapter
91000 91001 91002 91003 91004 91005 91006 91007 91009 91011 91014 0017 0166 0142 0225 0036 0140 0029 0018 0020 0026 0029 Gas and Air System Scavenge Air Receiver Arrangement of Charging Air Pipe Exhaust Pipes and Receiver Exhaust Receiver - Details Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Air Cooler System - Cleaning Arrangement of Non-Return Valve Arrangement of Suction Pipe

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Gas and Air System

Plate P91000-0017

When referring to this page, please quote Plate P91000 Edition 0017
MAN B&W Diesel A/S

Page 1 (1)

Scavenge Air Receiver


MAN B&W Diesel

Plate P91001-0166

When referring to this page, please quote Plate P91001 Edition 0166

Page 1 (2)

Plate P91001-0166 Item No.


017 029 030 042 054 066 078 091 101 113 125 137 149 150 162 174 186 198 221 233 257 269 270 282 294 304 316 328 341 353 365 377 389 390 400 412 424 436 448 461 473 485 497 507 519 532 544 556 568

Scavenge Air Receiver


MAN B&W Diesel Item No.

Item Description
Scavenge air receiver, aft Screw Distance pipe Air cooler housing sealing Screw Support Spring pin O-ring Flange Screw Stud Nut Washer Washer Locking plate Hinge Cover Cross member Distance piece O-ring Screw Nut O-ring Screw Cover Distance pipe Screw Locking plate Distance pipe Screw Nut Screw Cover Scavenge air receiver, fore Airflow reversing chamber Safety catch Round iron Stud Nut Screw Distance pipe O-ring O-ring Screw Cover Plate Plate Stud Packing

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91001 Edition 0166

Arrangement of Charging Air Pipe


MAN B&W Diesel

Plate P91002-0142

When referring to this page, please quote Plate P91002 Edition 0142

Page 1 (2)

Plate P91002-0142 Item No.


012 024 036 061 085 119 132

Arrangement of Charging Air Pipe


MAN B&W Diesel Item No.

Item Description
Screw Washer Nut Plug screw Screw Compensator Charging air pipe

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91002 Edition 0142

Exhaust Pipes and Receiver


MAN B&W Diesel

Plate P91003-0225

When referring to this page, please quote Plate P91003 Edition 0225

Page 1 (2)

Plate P91003-0225 Item No.


031 055 067 079 080 092 102 114 138 151 163 175 199 209 234 246 258 271 283 305 317 330 342 354 366 378 391 401 437 449 450 474 486 521 533 545 557 569

Exhaust Pipes and Receiver


MAN B&W Diesel Item No.

Item Description
Grid, complete Packing Compensator Nut Screw* Pipe bend Nut Screw* Wire gauze Clamp Pin Disc Screw* Nut Special nut Locking device Locking device Nut Screw Packing Compensator Packing Gas compensator Nut Screw* Gas inlet Screw* Nut Packing Pipe Screw* Packing ring Plug O-ring Stud Plate Plate Wing nut Note: * These screws are special screws for hot joints, they are marked with a T, and MUST NOT BE USED ELSEWHERE!

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91003 Edition 0225

Exhaust Receiver - Details MAN B&W

Plate P91004-0036

When referring to this page, please quote Plate P91004 Edition 0036

Page 1 (2)

Plate P91004-0036 Item No.


013 025 037 049 050 062 074 086 098 108 121 133 157 169 182 194 204 216 228 241 265 277 300 312 324

Exhaust Receiver - Details MAN B&W


Item Description Item No. Item Description

Support Support Spring pin Distance pipe Screw Supprt Nut Distance pipe Nut Spring pin Washer Screw Exhaust reciever, aft Shim Clamp Support Support Distance pipe Distance pipe Spring pin Exhaust reciever, fore Support Support Spring pin Clamp Note: * These screws are special screws for hot joints, they are marked with a T and MUST NOT be used elsewhere !

Page 2 (2)

When referring to this page, please quote Plate P91004 Edition 0036

Air Cooler
MAN B&W Diesel

Plate P91005-0140

When referring to this page, please quote Plate P91005 Edition 0140

Page 1 (2)

Plate P91005-0140 Item No.


019 020 044 056 068 081 093 103 127 139 140 152

Air Cooler
MAN B&W Diesel Item No.

Item Description
Air cooler insert* Water mist catcher* O-ring Frame for air cooler Screw Frame for air cooler Support Support Screw Stud Nut Screw Note: * When ordering spare parts for this item, please state manufacturers part no.

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91005 Edition 0140

Arrangement of Auxiliary Blower

Plate P91006-0029

When referring to this page, please quote Plate P91006 Edition 0029
MAN B&W Diesel A/S

Page 1 (2)

Plate P91006-0029 Item No.


014 026 038 051 075

Arrangement of Auxiliary Blower


Item No.

Item Description
Packing Distance pipe Screw Nut Auxiliary blower

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91006 Edition 0029
MAN B&W Diesel A/S

Butterfly Valve

Plate P91007-0018

When referring to this page, please quote Plate P91007 Edition 0018
MAN B&W Diesel A/S

Page 1 (2)

Plate P91007-0018 Item No.


021 033 045 057 069 070 082 116 128

Butterfly Valve
Item No.

Item Description
Cover Packing Locking wire Screw Locking plate Housing Screw Shaft Flap

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91007 Edition 0018
MAN B&W Diesel A/S

Air Cooler System - Cleaning

Plate P91009-0020

When referring to this page, please quote Plate P91009 Edition 0020
MAN B&W Diesel A/S

Page 1 (2)

Plate P91009-0020 Item No.


010 022 034 046 058 071 083 095 117 129 130 142 154 166 191 201 213 225 237 249 250 262 274 298 321 345 357 370 382 394 404 428 441 453 465 477 489 490 500 512 536 548 561 573 585 597 607 619 620 644

Air Cooler System - Cleaning


Item No.
656 668

Item Description
Main pipe Support cleaning Flow controller Drain box Drain pipe Main pipe Packing ring Screw Nut Cleaning pipe Flange Packing ring Screw Steel pipe Valve Screw Drain pipe Packing ring Screw Main pipe Main pipe Main pipe Orifice plate Valve Screw Screw Nut Packing ring Packing ring Valve Drain pipe Drain pipe Drain pipe Packing Stud Coupling Guide Cleaning pipe Guide Steel pipe Coupling Stud Stud Nut Steel pipe Cleaning pipe Coupling Steel pipe Cleaning pipe Cleaning pipe

Item Description
Packing ring Screw

Page 2 (2)

When referring to this page, please quote Plate P91009 Edition 0020
MAN B&W Diesel A/S

Arrangement of Non-return Valve


MAN B&W Diesel

Plate P91011-0026

When referring to this page, please quote Plate P91011 Edition 0026

Page 1 (2)

Plate P91011-0026 Item No.


023 035 059 072 084 096 106 131 143 167 180 202 214 238 263 287 299 309 322 334 346 371 395 417

Arrangement of Non-return Valve


MAN B&W Diesel Item No.

Item Description
Screw Distance pipe Screw Support Clamp Support Valve flap Valve mounting plate Valve mounting plate Locking wire Screw Spring pin Screw Shaft Locking wire Screw Support Clamp Spring pin Support Shaft Valve flap Non-return valve, complete Non-return valve, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91011 Edition 0026

Arrangement of Suction Pipe


MAN B&W Diesel

Plate P91014-0029

When referring to this page, please quote Plate P91014 Edition 0029

Page 1 (2)

Plate P91014-0029 Item No.


018 031 043 055 067 079 080 092 114 126 151 163 175 187 209 222 234

Arrangement of Suction Pipe


MAN B&W Diesel Item No.

Item Description
Screw Distance pipe Screw Packing Disc O-ring Nut Suction pipe Pipe Plate Nut Screw Disc special Screw Suction pipe Clamp Nut

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91014 Edition 0029

911 - Safety Equipment


Documents in this Chapter
91101 91102 91102 91103 91104 0037 0029 0035 0018 0099 Safety Valve - Cylinder Relief Valve Relief Valve Safety Valve - Scavenge Air System Arrangement of Safety Cap

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Safety V alve - Cylinder Valve


MAN B&W Diesel

Plate P91101-0037

When referring to this page, please quote Plate P91101 Edition 0037

Page 1 (2)

Plate P91101-0037 Item No.


010 022 034 046 058 071 083 095 105 117

Safety V alve - Cylinder Valve


MAN B&W Diesel Item No.

Item Description
Spindle Spring retainer Lock nut Spring Valve housing Stop ring Valve flap Valve guide Gasket Safety valve, complete

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91101 Edition 0037

Relief Valve

Plate P91102-0029

When referring to this page, please quote Plate P91102 Edition 0029
MAN B&W Diesel A/S

Page 1 (2)

Plate P91102-0029 Item No.


016 028 030 041

Relief Valve
Item No.

Item Description
Relief valve (P.C.D. 530mm) * Screw* Packing* O-ring* Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91102 Edition 0029
MAN B&W Diesel A/S

Relief Valve

Plate P91102-0035

When referring to this page, please quote Plate P91102 Edition 0035
MAN B&W Diesel A/S

Page 1 (2)

Plate P91102-0035 Item No.


016 028 030 041

Relief Valve
Item No.

Item Description
Relief valve (P.C.D. 795mm) * Screw * Packing * O-ring * Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91102 Edition 0035
MAN B&W Diesel A/S

Safety Valve - Scavenge Air System


MAN B&W Diesel

Plate P91103-0018

When referring to this page, please quote Plate P91103 Edition 0018

Page 1 (2)

Plate P91103-0018 Item No.


011 035 047 059 060 072 096 106 118 131 143 155

Safety Valve - Scavenge Air System


MAN B&W Diesel Item No.

Item Description
Safety valve, complete Spindle Washer Spring retainer Castle nut Split pin Screw Nut Valve flap Seal Valve seat Spring

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91103 Edition 0018

Arrangement of Safety Cap


Arrangement of Safety Cap 0099 P91104

Plate P91104-0099

Only cyl. No. 1

When referring to this page, please quote Plate P91104 Edition 0099
MAN B&W Diesel A/S

Page 1 (2)

Plate P91104-0099 Item No.


017 029 030 042 054 066 078 091 101 125 137 149 150 162 174 186 198 208 233 257 269 270 282

Arrangement of Safety Cap


Item No.

Item Description
Fitted bolt Bursting cap cover Check plate Screw Perforated cylinder Screw Washer Starting air pipe Packing ring Screw Bursting cap protector Wing nut Washer Stud Bursting disc Nut Screw Nut Bursting cap complete Packing ring Steel pipe Coupling Coupling

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91104 Edition 0099
MAN B&W Diesel A/S

912 - Assembly of Large Parts


Documents in this Chapter
91201 91203 91205 91206 91207 91208 91210 91211 91216 0096 0005 0201 0097 0093 0009 0188 0072 0008 Arrangement of Stay Bolts Frame Box - Details Frame Box End Shields Arrangement of Piston Cooling Chain Wheel Frame - Upper Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangment of Stay Bolt

Plate P91201-0096

When referring to this page, please quote Plate P91201 Edition 0096
MAN B&W Diesel A/S

Page 1 (2)

Plate P91201-0096 Item No.


014 026 038 051 063 075

Arrangment of Stay Bolt


Item No.

Item Description
Screw Screw Protective cap Nut Stay bolt Neck ring in 2/2

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91201 Edition 0096
MAN B&W Diesel A/S

Frame Box - Details

Plate P91203-0005

When referring to this page, please quote Plate P91203 Edition 0005
MAN B&W Diesel A/S

Page 1 (2)

Plate P91203-0005 Item No.


015 027 039 040 052 076 088 123 135 147

Frame Box - Details


Item No.

Item Description
Stud Nut Distance pipe Fitted stud Distance pipe Distance pipe Screw Distance pipe Distance pipe Fitted stud

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91203 Edition 0005
MAN B&W Diesel A/S

Frame Box
MAN B&W Diesel

Plate P91205-0201

When referring to this page, please quote Plate P91205 Edition 0201

Page 1 (2)

Plate P91205-0201 Item No.


016 028 041 077 089 100 112 124 136 148 173 197 207 219 220 244 256 281 293 315 339 340 352 376 388

Frame Box
MAN B&W Diesel Item No.

Item Description
Lubricating oil pipe Screw Locking wire Cover Screw Locking pin Spring Key ring Frame box door Packing Drain pipe Wing nut Stud Spring Door fastener Frame box door Packing Bush Washer Frame box Flange Packing Screw Cover Screw Note: *

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91205 Edition 0201

End Shields
MAN B&W Diesel

Plate P91206-0097

When referring to this page, please quote Plate P91206 Edition 0097

Page 1 (2)

Plate P91206-0097 Item No.


011 023 035 047 060 096 106 118 131 155 167 179 192 202 214 238 251 263

End Shields
MAN B&W Diesel Item No.

Item Description
Shield, upper Screw Gasket Cover Screw Screw Locking wire Damper-oil pipe Screw Damper-oil pipe Gasket Screw Shield, lower Screw Drain pipe Screw Screw Shield, fore

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91206 Edition 0097

Arrangement of Piston Cooling


Arrangement of Piston Cooling 0093 P91207

Plate P91207-0093

B B-B

A-A

When referring to this page, please quote Plate P91207 Edition 0093
MAN B&W Diesel A/S

Page 1 (2)

Plate P91207-0093 Item No.


017 029 042 054 066 091 101 125 137 149 162 174 198

Arrangement of Piston Cooling


Item No.

Item Description
Fitted bolt Nut - special Screw Washer Locking wire Plate Fitted bolt Drain pipe Drain pipe Sight glass, complete Screw Bracket Fitted bolt

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91207 Edition 0093
MAN B&W Diesel A/S

Chain Wheel Frame - Upper


Chain Wheel Frame - Upper 0009 P91208

Plate P91208-0009

A-A A A C

B B

B-B

When referring to this page, please quote Plate P91208 Edition 0009
MAN B&W Diesel A/S

Page 1 (2)

Plate P91208-0009 Item No.


012 024 048 061 085 097 119 120 132 156 168 193 215 239 240 252 276 311 323 347 359 360 372 384 396 418 431 455 467 479 492 502 514

Chain Wheel Frame - Upper


Item No.

Item Description
Nut Stud Screw Screw Screw Inspection cover Chainwheel frame Screw Cover Screw Pipe Plug Cover Nut Pipe Stud Top guard Packing ring Screw Pipe Spring pin Cover Nut Disc Fitted stud Screw Pipe Nut Pipe Stud Inspection cover Spring Stud

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91208 Edition 0009
MAN B&W Diesel A/S

Bedplate
MAN B&W Diesel

Plate P91210-0188

When referring to this page, please quote Plate P91210 Edition 0188

Page 1 (2)

Plate P91210-0188 Item No.


013 025 037 050 062 074 086 098 121 133 145 169 170 194 204 216 241 253 277 290 312 324 336 348 373 397 407 420 432 456 468 493

Bedplate
MAN B&W Diesel Item No.

Item Description
Lubricating oil pipe Screw Locking wire Screw Screw Locking plate Grate Cover Bedplate Guide pin Screw Screw Nut Pipe holder Screw Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Screw Stud Lubricating oil pipe Lubricating oil pipe Nut Main bearing stud Main bearing cap Bearing shell, upper Bearing shell, lower Cover Screw Cover Screw Main bearing, complete Note: *

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91210 Edition 0188

Axial Vibration Damper


Axial Vibration Damper 0072 P91211

Plate P91211-0072

When referring to this page, please quote Plate P91211 Edition 0072
MAN B&W Diesel A/S

Page 1 (2)

Plate P91211-0072 Item No.


019 020 081 093 103 115 127 139 140 152 164 223 235 247 259 260 284 296 306 318

Axial Vibration Damper


Item No.

Item Description
Spring Spring Screw Locking wire Restriction for damper Restriction for damper Restriction for damper Screw Guide pin Oil seal in 2/2 Oil seal in 2/2 Nut Nut Stud Stud Axial vibration damper, complete Damper, upper part Special locking Guide pin Damper, lower part

Item Description

Page 2 (2)

When referring to this page, please quote Plate P91211 Edition 0072
MAN B&W Diesel A/S

MAN B&W Diesel

HoldingDown Bolts and End Chock Bolts (Epoxy Chocks)

Plate P91216-0008

When referring to this page, please quote Plate P91216 Edition 0008

Page 1 (2)

Plate P91216-0008 Item No.


016 028 041 053 077 090 100 112 148 161 173 197 207 219 232 244 256 281

HoldingDown Bolts and End Chock Bolts (Epoxy Chocks)


Item Description Item No.

MAN B&W Diesel

Item Description

Screw Washer Lock plate Liner for sidechock, port side Liner for sidechock, starboard side Protecting cap Nut Distance tube Spherical washer Spherical nut Holding down bolt Nut Protecting cap End chock bolt Liner for end chock Spherical washer Spherical washer Nut

Page 2 (2)

When referring to this page, please quote Plate P91216 Edition 0008