s60mc-c01 PDF

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 Page 1 (1)
MAN B&W Diesel A/S
S60MC-C VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
Table of Contents, Volume II

90023 0027 Instructions for Main Engine
90060 0001 General - Safety Precautions
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Table of Contents 900
Volume II - Maintenance
No. Edition Title
900 - Introduction
Table of Contents
90060 0001 General - Safety Precautions
901 - Cylinder Cover

101-01 0071 Cylinder Cover, Data
901-01 0254 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0110 Cylinder Cover - Tools
90163 0004 Cylinder Cover - Support Tool
90165 0001 Cylinder Cover - Lifting Tools
902 - Piston with Rod & Stuffing Box

102-01 0097 Piston, Data
902-01 0284 Piston
102-02 0060 Piston Rod Stuffing Box, Data
902-02 0229 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0107 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 0005 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication

103-01 0072 Cylinder Liner, Data
903-01 0257 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0249 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod

104-01 0059 Crosshead Bearing, Data
904-01 0249 Crosshead Bearing
104-02 0060 Crosshead, Data
904-02 0248 Crosshead
104-03 0041 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0052 Crankpin Bearing, Data
904-04 0231 Crankpin Bearing
104-05 0051 Connecting Rod, Data
904-05 0228 Connection Rod
MAN B&W Diesel A/S Page 1 (4)

No. Edition Title
90451 0149 Connecting Rod and Crosshead - Panel

90461 0068 Connecting Rod - Hydraulic Tools
90462 0034 Connecting Rod - Tools
90464 0005 Crosshead - Hydraulic Tools
90465 0001 Crosshead - Tools
905 - Crankshaft, Thrust Bearing and Turning Gear

105-01 0006 Crankshaft Deflection, Data
905-01 0208 Crankshaft Deflection
105-02 0052 Main Bearing, Data
905-02 0245 Main Bearing
105-03 0044 Thrust Bearing, Data
905-03 0224 Thrust Bearing
105-04 0017 Journal Bearing, Data
905-04 0216 Journal Bearing
105-05 0037 Axial Vibration Damper, Data
905-05 0224 Axial Vibration Damper
90551 0237 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0133 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90564 0018 Crankshaft - Measuring Tools
90570 0001 Thrust Shaft - Tools
90572 0005 Main Bearing - Measuring Tools
906 - Control Gear

106-01 0042 Chain, Data
906-01 0232 Chain
106-02 0035 Chain Tightener, Data
906-02 0230 Chain Tightener
106-03 0030 Camshaft, Data
906-03 0214 Camshaft
106-04 0029 Camshaft Bearing, Data
906-04 0218 Camshaft Bearings
106-06 0005 Replacement of Cams on Camshaft, Data
906-06 0204 Replacement of Cams on Camshaft
90651 0185 Chain Drive and Camshaft - Panel
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
907 - Starting Air System

107-01 0018 Starting Air Distributor, Data
907-01 0217 Starting Air Distributor
107-02 0034 Start Air Valve, Data

No. Edition Title
907-02 0216 Starting Air Valve
908 - Exhaust Valve

108-01 0031 High-Pressure Pipe, Data
908-01 0226 High-Pressure Pipe
108-02 0059 Exhaust Valve, Data
908-02 0240 Exhaust Valve
108-03 0034 Exhaust Valve Actuator, Data
908-03 0227 Exhaust Valve Actuator
108-04 0031 Exhaust Valve Roller Guide, Data
908-04 0217 Exaust Valve Roller Guide
108-05 0010 Exhaust Valve Cam, Data
908-05 0214 Exhaust Valve Cam
108-07 0031 Exhaust Valve - Special Running, Data
90851 0165 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool
909 - Fuel Oil System

109-01 0055 Fuel Pump Lead, Data
909-01 0240 Fuel Pump Lead
109-02 0004 VIT System, Data
909-02 0207 VIT System
109-03 0047 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0042 Fuel Pump, Data
909-04 0222 Fuel Pump
109-05 0045 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0039 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0029 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0037 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0026 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10910 0018 Lifting Gear Roller Guide, Data
90910 0211 Lifting Gear for Roller Guide
10911 0066 Fuel Valve, Data
90911 0245 Fuel Valve
10912 0048 Spindle Guide, Data

No. Edition Title
90912 0228 Spindle Guide

10913 0031 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0067 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0046 Fuel Pump Roller Guide, Data
90915 0226 Fuel Pump Roller Guide
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
910 - Turbocharger System

91064 0002 Travelling Trolley
91066 0001 Air Cooler - Lifting Tools
911 - Safety Equipment

111-01 0025 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 0009 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)
112-03 0018 Stay Bolts, Data
912-03 0212 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0073 Hydraulic Tools for Large Parts
91266 0001 Hydraulic Tools - End Chock Bolts (Epoxy Chocks)
913 - General Tools

913-01 0215 Hydraulic Tools
913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools

No. Edition Title
91356 0053 Lifting Tools, etc.

91357 0007 Open-Ended Spanners
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0040 Spanners
91366 0066 Instruments
91368 0007 Working Platforms

Instructions for Main Engines
This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel en-
gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-
erence purposes, for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:
1. Name of vessel
2. Engine No. built by
3. Plate No.
4. Part No.
5. Quantity required (and description)
Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

10 off (piston ring)
+ )The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.
To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation “D” refers to the information given on the
data sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct oper-
ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re-
lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on emissions related maintenance of the die-
sel engine, also the additional instructions to that effect set out in the Technical File.
This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.
MAN B&W Diesel A/S

A90023-0027
Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen Telex :16592 manbw dk
Denmark Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
General – Safety Precautions 900-2
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.
SAFETY PRECAUTIONS
X Stopped engine
X Shut off starting air supply – At starting air receiver
X Block the main starting valve
X Shut off starting air distributor/distributing system supply
X Shut off safety air supply – Not ME-engines
X Shut off control air supply
X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
When referring to this page, please quote Safety Precaution A90060 Edition 0001 Page 1 (1)
MAN B&W Diesel A/S
101-01 0071 Cylinder Cover, Data

901-01 0254 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0110 Cylinder Cover - Tools
90163 0004 Cylinder Cover - Support Tool
90165 0001 Cylinder Cover - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Cover 101-1
MAN B&W Diesel Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X Stopped engine
X Shut off safety air supply – Not ME engines
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Shut off fuel oil
Data
Ref. Description Value Unit
D01-01 Exhaust valve stud, screwing-in torque 450 Nm

D01-02 Starting valve stud, screwing-in torque 140 Nm
D01-03 Fuel valve stud, screwing-in torque 140 +/-20 Nm
D01-06 Cylinder cover, complete 2900 kg
D01-07 Cylinder cover without valves 2050 kg
D01-08 Cooling jacket 73 kg
D01-09 Exhaust valve stud 50 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar
When referring to this page, please quote Data D10101 Edition 0071 Page 1 (2)
101-1 Cylinder Cover
Data MAN B&W Diesel
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
P90151 46 Grinding tool for exhaust valve seat

P90151 58 Milling and grinding wheel for fuel valve seat
P90151 60 Milling and grinding wheel for starting valve seat
P90151 83 Grinding handle
P90163 Cylinder Cover - Support Tool

P90161 Cylinder cover tightening tool
P90165 Cylinder Cover - Lifting Tools
P91351 10 Hydraulic pump, pneumatic operated

P91351 34 Hose with unions (1000 mm), complete
P91351 130 9-way distributor block, complete
Page 2 (2) When referring to this page, please quote Data D10101 Edition 0071
Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling
Shut off Oil and Water Supply

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

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

cerned.
3. Shut off the water supply.
M901010254D01
Close the water outlet above the exhaust
valve.
Close the water outlet on the exhaust side

of the cylinder cover. 3.
Shut off the water supply placed on the ex-

haust side below the exhaust gas receiver.
Open the drain next to the inlet valve.

M901010254D02
When referring to this page, please quote Procedure M90101 Edition 0254 Page 1 (14)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel
Open the venting cock next to the outlet

4. valve.
Dismantling of Pipe Connections
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.
M901010254D03
Remove the fuel oil high pressure pipes.

See Procedure 909-14.2.
Disconnect the pipes for return fuel oil from

the fuel valves.
5.
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 com-
pensator. Remove the insulation.
Remove the screws in the flange between

M901010254D04
the intermediate pipe and the exhaust re-

ceiver.
6.
M901010254D05
Page 2 (14) When referring to this page, please quote Procedure M90101 Edition 0254
7. Disconnect the starting air pipe.

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

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

der cover nuts.
Loosen and remove the cylinder cover
M901010254D06
nuts, see Data.
For use of hydraulic tools, see Procedure

913-1.
Cylinder Cover Lifting and Landing 8.
9. Cylinder cover supporting tool.
Fit the cylinder cover supporting tool in the

purposed holes on the uppermost platform.
D1302
M901010254D07
9.
M901010248D08
10. Cylinder cover lifting.

10.
Hook on the engine room crane to the lift-
ing attachment on top of the exhaust valve.
D0106 Check that all cylinder cover connections
have been loosened and removed.
Lift away the cylinder cover complete.
11. Cylinder cover landing.
Land the cylinder cover on the supporting

tool.
If the cylinder cover is to be overhauled it

is recommended instead to land the cylin-
der cover on a couple of wooden planks.
Note!
The cylinder cover supporting tool
should only be used when the ship is in
M901010254D09
port.
11.
M901010254D10
12. Remove sealing ring.

12.
Remove and discard the sealing ring be-
tween the cylinder cover and cylinder liner.
M901010248D12
Overhaul MAN B&W Diesel
Overhaul Preparations
1.
1. Dismantle valves and pipes.
D0109 Dismantle all valves and pipes from the cyl-

inder cover. See Procedure 907-2.2, 908-
2.2 and 909-11.2.
Dismantle the starting air inlet block and

the cooling water outlet block from the ex-
haust side of the cylinder cover.
Remove all studs on top of the cylinder

cover.
M901010254O01
Cooling Water Jacket
2. Remove the cooling water jacket.

2.
Mount four eyebolts and the lifting chains
as shown in the sketch.
D0107 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. If
the cooling jacket sticks, use dismantling
screws to force the jacket/cover apart.
Remove and discard the O-rings from the

D0108
M901010254O02
cover, and carefully clean the cooling jacket

and the cylinder cover.
3. Mount the cooling water jacket.
Provide the cylinder cover with new O-

3.
rings, well lubricated with oil.
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.
M901010254O03
MAN B&W Diesel Overhaul
Reconditioning of Bores
4.
4. Seat reconditioning tools.
The tools for reconditioning of the valve

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

a handle, a guide, a carbon cutter, a seat-
ing face cutter and a grinding mandrel.
Clean the fuel valve bores using the carbon
M901010246O04
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). 5.
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
1 2 3
M901010254O05
6. Exhaust valve bore.

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

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

ing carefully, and check that the seating is
not damaged.
M901010240O07
7. Starting valve bore.
The tool consists of a guide, a cutter, and a

grinding disc.
7. 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, re-
condition the valve bores/seating as de-
scribed here, however, without removing
the studs.
M901010243O07
8. Indicator - safety valve bore.

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

molybdenum disulphide (MoS2) and fit the
valve studs.
Tighten up the studs in accordance with
M901010254O07
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 en- 9. D0101
tering the bores during operation of the en-
gine.
10. Mounting of valves.
Install the valves on the cylinder cover, see

Procedures 907-2.4, 908-2.4 and 909-11.4.
D0102 D0103
M901010254O08
Mounting MAN B&W Diesel
Landing Preparation
1.
1. Sealing ring.
Check that the liner sealing surface is

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

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

in the groove of the flange of the intermedi-
ate pipe.
M901010254M01
2. Water connections.
Check that the water connections are clean

and provided with new O-rings.
2. Lubricate the O-rings with Vaseline and fit

them on the cylinder liner.
M901010254M02
MAN B&W Diesel Mounting
Cylinder Cover Mounting

3.
3. Cylinder cover landing.
D0106
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 re-

moved and reinstalled, check the distance
the stud is protruding from the cylinder
cover.
M901010254M03
If necessary, adjust to the distance D01-05

by turning the stud.
4.
D0105
M901010254M04
5. Cylinder cover tightening.

5.
Fit and tighten the cylinder cover nuts.
For operation of hydraulic jacks, see Proce-

dure 913-1.
Fit the protective caps on the cylinder

D1301 cover studs.
Fitting Pipe Connections
6. Mount the exhaust gas compensator.

M901010254M05
Fit the screws of the flange between the in-

termediate pipe and the exhaust receiver.
Note!
6. Lubricate the screws with ‘Never Seize’

or molybdenum disulphide (MoS2) be-
fore fitting.
Fit the insulating jacket around the interme-

diate pipe.
M901010254M06
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.
M901010254M07
Mount the hydraulic high pressure pipe for
the exhaust valve. See Procedure 908-1.4.
Connect the drain pipe for the exhaust

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

the fuel valves.
M901010254M08
9.
M901010254M09
Open Oil and Water Supply

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

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

next to the cylinder liner cooling water
jacket on the exhaust side.
Vent the unit by releasing air through the

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

venting cock. Open the two water outlet
valves on the exhaust side of the cylinder
cover.
M901010254M10
11. Open the oil supply.
Open the fuel oil supply for the unit con-

cerned.
11.
M901010254M11
Cylinder Cover Panel Plate
MAN B&W Diesel P90151-0205
When referring to this page, please quote Plate P90151 Edition 0205 Page 1 (2)
Plate
Cylinder Cover Panel
P90151-0205 MAN B&W Diesel
Item Item Description Item Item Description

No. No.
010 Panel for tools

022 Name plate
046 Grinding tool, exhaust valve seat
058 Milling and grinding tool, fuel valve seat
060 Milling and grinding wheel, fuel starting
valve
071 Dismantling tool, fuel valve
083 Handle, grinding tools
095 Grinding ring, starting valve seat
105 Pin spanner, starting valve
117 Test equipment, combined safety valve
Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0205
Cylinder Cover - Tools
Tools Plate
Plate
Cylinder Cover - Tools
Tools

No. No.
027 Hydraulic jack for cylinder cover

039 Support
040 Stud setter
052 O-ring with back-up ring
090 Spanner
100 Tommy bar
206 Hydraulic tool set, complete
Cylinder Cover - Support Tool Plate
Plate
Cylinder Cover - Support Tool

No. No.
016 Cylinder cover rack
Cylinder Cover - Lifting Tools
Tools Plate
Plate
Cylinder Cover - Lifting Tools
Tools

No. No.
017 Lifting chains for cylinder cover
102-01 0097 Piston, Data

902-01 0284 Piston
102-02 0060 Piston Rod Stuffing Box, Data
902-02 0229 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0107 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 0005 Piston - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Piston 102-1
MAN B&W Diesel Data

X Stopped engine
X Shut off fuel oil
Lock the turbocharger rotors
Data

D01-05 Cylinder cover stud, check distance 148 - 149 mm
D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 590 Nm
D02-03 Piston rod/crown, tightening torque 580 Nm
D02-05 Piston skirt, tightening torque 190 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-08 Piston ring new, radial width 20.2 mm
D02-09 Piston ring worn, min. radial width 17 mm
D02-10 Groove No.1, max. vertical height 14.7 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 11.7 mm
D02-13 Piston ring new, height of ring No. 1 13.9 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 10.9 mm
D02-15 Minimum free ring gap ( before dismantling ) 30.5 mm
D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 4.1 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 3 mm
D02-18 Vertical clearance, new parts 0.43 mm
D02-19 Vertical clearance, worn parts, max. 0.92 mm
D02-20 Piston complete 1600 kg
D02-21 Piston crown 310 kg
D02-22 Piston rod 1050 kg
D02-23 Piston skirt 95 kg
D02-24 Piston cooling pipe 36 kg
D02-25 Lifting tool, tightening torque 150 Nm
D02-46 CPR ring CL groove, min. depth 1.3 mm
D02-47 Piston top centre, max. permissible burn-away 9 mm
D02-48 Piston top centre diameter 280 mm
D02-49 Piston top outer ring area, max. permissible burn-away 6 mm
102-1 Piston
Data MAN B&W Diesel
P90251 40 Lifting tool for piston rod foot

P90251 75 Template for piston top
P90251 87 Distance piece for stuffing box
P90251 99 Cover for stuffing box hole
P90251 110 Pressure test tool for piston
P90251 134 Piston ring expander
P90251 158 Guide screw for piston crown
P90251 171 Dismantling screw piston skirt
P90261 Guide ring for piston
P90265 Support for piston
P90266 Lifting tool for piston
P90366 Crossbar for cylinder liner
Piston 902-1.1
MAN B&W Diesel Checking
Scavenge Port Inspection

1.
To detect possible leakages from the piston
or cylinder cover, keep the cooling water
and cooling oil circulating during the scav-
enge port inspection.
1. The scavenge port inspection is carried out

from the scavenge air receiver. An addi-
tional view of the rings is possible through
the cleaning cover on the manoeuvring
side.
M902010280C01
Turn the engine at least ½ 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 cylin-
der wall.
While the piston is passing downwards, in- 2.

spect 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.
M902010280C02
3.
M902010280C03
902-1.1 Piston
Checking MAN B&W Diesel
4. Ring grooves:
4. Measure the total clearance between the
D0218 piston ring and the ring groove. The total
clearance must not exceed the value stated
in Data.
D0219 Measure the clearance at the top (E) and
E
bottom (F) of the piston ring groove.
Total clearance = E + F.
F 5. Uppermost piston ring:

If possible, measure the depth of the pres-
sure relief grooves with a calliper. The pis-
ton rings must be replaced if the radial
M902010280C04
Max. 2mm
depth of the grooves has worn down to
less than stated in Data D02-46.
Checking, in connection with piston

overhaul
5.
D0246
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.
Note!
It is recommended to replace all the pis-
ton rings whenever a piston is removed
M902010280C05
from the engine.
6.
M902010283C06
Piston 902-1.1
7. Free ring gap:

Before dismantling the piston rings, mea- 7.
sure the free ring gap of all the piston
rings. D0215
For dismantling the piston rings, see Proce-

dure 902-1.3.
8. Radial ring width:

Measure the radial width of the rings. Note
down the results See Volume I, Operation,
Chapter 707.
9. Ring grooves:
M902010280C07
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.
8.
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.
D0208 New
If the ring grooves are worn out, the piston
crown must be reconditioned, contact MAN
B&W Diesel A/S for advice.
M902010280C08
D0209 Worn
9.
D02-10
D02-11
Max 2mm
M902010280C09
902-1.1 Piston
10. Piston top template:

10.
Check that the piston top template is per-
manently marked with the piston top centre
diameter D02-48.
Check that the centre area C has been

marked off, and write the maximum per-
C missible burn-away rate on the template.
R See data D02-47.
Mark the outer part of the template R for

ring area, and write the maximum permis-
D0248 sible burn-away rate for the ring shaped
area. See data D02-49.
M902010280C10
11. Piston crown top:

Clean the piston crown and check the
burn-away by means of the template.
11. For maximum permissible burn away on the

D0247 piston top centre area, see Data D02-47.
D0249
For the ring shaped area, see Data D02-49.
Check the burn-away on the whole circum-

ference 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.

M902010280C11
Piston 902-1.1
Preparations in the crankcase

1.
1. Access:
Open the crankcase door to the cylinder
concerned.
Turn the crosshead down far enough to

give access to the piston rod stuffing box
and the piston rod/crosshead connection.
2. Stuffing box:
Release the stuffing box by removing the
innermost screws from the stuffing box
flange.
M90201280D01
On engine models where the drain pipe is
connected directly to the stuffing box:
Disconnect the stuffing box drain pipe.

2.
Note!
Do NOT remove the outermost screws
from the flange.
3. Loosen the piston rod-crosshead connec-

tion:
Remove the screws from the piston rod.
M902010280D03
3.
M902010284D04
902-1.1 Piston
4. Stuffing box distance pieces:

4. Mount the two distance pieces on the pis-
ton rod foot to protect the lower scraper
ring and to guide the stuffing box.
Preparations on the cylinder top
5. 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.
M902010280D05
5.
M902010280D06
Piston 902-1.1
6. Piston lifting tool:

Turn the piston to TDC. The top of the pis- 6.
D0225
ton 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 cor-
rectly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.
M902010283D07
Limited lifting high:
If the engine not is equipped with long dis-
tance pieces, remove one or two cylinder
cover studs, using a stud setter.
902-1.1 Piston
Piston lift
7.
7. Lift the piston out of the cylinder liner and
guide the piston rod foot through the stuff-
ing box flange.
If the engine is equipped with long distance

pieces for the stuffing 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 stuffing 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 flange.
D0220
M902010283D08
Piston 902-1.1
8. Protect the crosshead bearing:

8.
Place a cover over the opening for the pis-
ton rod stuffing box in 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 impuri-
ties until the piston is remounted.
Clean, measure and recondition the cylin-

der liner. See Procedure 903-1.
M902010283D09
902-1.1 Piston
1. Piston support:
1.
Place the piston in the support and remove
D0220 the piston lifting tool.
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 stuffing box. See Procedure

902-2.3.
2. Piston ring dismantling:

M902010280O01
Take off the piston rings by means of the

ring expanders. If the engine is equipped
with two ring expanders, the short ring ex-
pander is for the uppermost ring.
2. 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:

Remove the locking wire and the innermost
screws between the rod and the piston
crown.
Lift the piston crown and skirt clear of the

piston rod.
M902010280O02
3.
D0221
+
D0223
M902010284O03
Piston 902-1.1
4. Piston rod and cooling pipe:

Remove the screws from the cooling oil 4.
pipe flange.
Mount the eye bolts and lift out the cooling D0224
oil pipe.
Clean and inspect the cooling oil pipe and D0206

the piston rod, then remount the cooling oil
pipe, see Data.
Check that the surfaces of the O-ring D0222

groove is clean and smooth.
M902010280O04
Mount a new O-ring on the piston rod
flange.
5. Piston crown dismantling and cleaning:

Place the piston crown with skirt on a
wooden support as shown. 5.
Remove the locking wire and the screws in D0223

the skirt. If necessary use two dismantling
screws to pull the skirt out of 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
M902010284O05
crown, they should be washed clean with

Carbon Remover or a similar cleaning fluid.
When all coke deposits have been dis-
solved, clean and inspect the piston crown
again.
Note!
Coke deposits reduce heat transfer from

the piston crown to the cooling oil. The
deposits must be removed as a routine
procedure when a piston is overhauled.
902-1.1 Piston
6. Piston crown assembly:

6. Mount a new O-ring on the piston skirt.
Check that the surfaces of the O-ring
D0205 groove are clean and smooth. Coat the ring
with lubricating oil before mounting.
Mount the piston skirt on the piston crown.

Tighten the screws to specified torque, see
data D02-05. Lock the screws with locking
wire, see Procedure 913-7.
7. Piston crown and skirt mounting:

Mount the guide screw to ensure the cor-
rect positioning of the piston rod in relation
M902010284O06
to the piston crown.
Lubricate the O-ring on the piston rod

flange with lubricating oil.
7. Land the overhauled piston crown and skirt

on the piston rod.
Remove the guide screw.
Mount and tighten the screws between the

piston rod and the piston crown, see Data.
D0203
M902010284O07
Piston 902-1.1
Sealing ring and pressure test

8.
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 filling the
piston with oil. The sealing ring test can
also be carried out when the piston is rest-
ing in the support tool.
8. Sealing ring test:

Mount the pressure-testing tool on the pis-
ton rod foot. Connect compressed air to
the testing tool and fill the piston to 4-5
M902010277O16
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 9.

joints between piston rod/crown/skirt and D0201
around the bolt heads to detect leaks.
Dry off all soap water.
9. Pressure test:
For this test, the piston must be turned up- oil
side down (see next step to turn a com-
plete piston).
Fill the piston and piston rod with lubricat-

ing oil. Mount the pressure-testing tool on
M902010277O17
the piston rod foot. Pressure-test the pis-

ton 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 pis-
ton crown.
Turn the piston upside up and drain out the

piston oil.
902-1.1 Piston
10. Piston turning:

10. 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 lift-
ing 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 stuffing box
must be removed.
M902010283O10
Piston 902-1.1
11. Piston completion:

Fit the new piston rings (alternately right- 11.
hand and left-hand cuts, with the ring gaps A
staggered 180° and with the TOP mark up-
wards), using the ring expander.
B TOP
When mounting the piston rings, use the
ring expanders to prevent unintended de- A
C
formation of the rings.
B
Do not expand the rings more than neces- D
sary. The uppermost ring (CPR-ring) must
be mounted with the short ring expander. C
Mount the piston rod stuffing box.

See Procedure 902-2.3. D
M902010280O11
902-1.1 Piston
Preparation of piston
1.
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. Stuffing box position:

Ensure that the stuffing box is correctly po-
sitioned over the distance pieces mounted
on the piston rod foot. Both the holes for
the flange and the drain hole for the drain
pipe must be positioned correctly.
M902010283M01
2.
M902010277M02
Piston 902-1.1
Preparation of cylinder liner

3.
3. Mount the guide ring:
Mount the guide ring in the top of the cyl-
inder liner. The cut outs for the lifting tool
must be turned to fit the piston lifting tool.
4. Stuffing box cover:

Remove the cover from the piston rod
stuffing box opening in the bottom of the
cylinder unit.
Clean the stuffing box flange.
M902010283M03
5. Crosshead position:
Turn the crosshead to a position 45° from
TDC (crank web pointing towards exhaust
side).
4.
M902010277M05
5.
M902010277M06
45°
902-1.1 Piston
Mounting of piston
6.
D0220 6. Coat the O-rings of the stuffing box and
the piston rod with oil. Coat the piston
rings and cylinder liner with cylinder lubri-
cating oil.
Lower the piston into the cylinder liner –

while guiding the piston rod foot through
the cut-out in the stuffing box flange – until
the piston rings are inside the liner.
7. Protective cover:
M902010283M06
Remove the protective rubber cover from

the crosshead.
8. Crosshead alignment:
Turn the crosshead almost to TDC, while
checking that the guide ring of the cross-
7. head enters the centre hole in the piston
rod.
After turning the crosshead fully to TDC,

and ensuring that the piston rod has full
contact with the crosshead, unscrew the
lifting tool and remove the lifting tool and
the guide ring for piston rings.
M902010283M07
8.
M902010284M08
Piston 902-1.1
9.
9. Stuffing box:
Turn down and land the stuffing box on the
stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
correctly centered.
Tighten the piston rod stuffing box by

means of the screws through the inner
holes in the stuffing box flange. For Data,
see Procedure 902-2.
On engine models where the drain pipe is
M902010280M09
connected directly to the stuffing box:
• Mount the stuffing box drain pipe.
Remove the distance pieces from the pis-

ton rod foot. 10.
10. Tightening of the piston rod-crosshead

D0202
connection: or
Mount and tighten the piston rod screws. D0207
Tighten the screws to the specified torque
and lock with locking wire.
See Data. Use either Data D02-02 or Data
D02-07.
11. Piston cleaning ring:

Mount the piston cleaning ring in accor-
dance with the scratch mark. If the PC-ring
M902010284M10
is damaged (broken or cracked), it must be
11.
M902010277M14
902-1.1 Piston
replaced by another ring.

12. See Procedure 903-1.
12. Cylinder cover studs:

If the cylinder cover studs have been re-
moved, remount them. Carefully clean the
surfaces around the base of the studs and
check the O-rings on the studs.
Mount the cylinder cover studs with the

stud setter. Screw the stud down to con-
tact and half a revolution back.
M902010277M15
13. Cylinder cover:

Land the cylinder cover on the liner and
check the distance that the stud is protrud-
ing from the cylinder cover. If necessary,
adjust the distance D01-05 by turning the
stud.
13.
Tighten the cylinder cover nuts and mount
the necessary pipes.
14. Running-in:
Smear the piston rod with molybdenum
disulphide, and turn the crankshaft a
couple of revolutions.
D0105 At the first opportunity, start the engine
and keep it running for about 15 minutes at
a speed corresponding to “Dead Slow”
M902010280M14
Ahead.
Then stop the engine and inspect the pis-

ton rod and stuffing box.
Piston Rod Stuffing Box 102-2
Data
X Stopped engine
X Shut off fuel oil
Data
D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm
D02-28 Stuffing box halves, tightening torque 80 Nm
D02-29 Uppermost rings, ring-end clearance 4x6 mm
D02-30 Lowermost rings, ring-end clearance 3x3 mm
D02-34 Sealing ring springs new, free length 618 mm
D02-38 Scraper ring springs new, free length 606 mm
D02-44 Stuffing box complete 100 kg
D02-45 Stuffing box half 35 kg
D02-50 Stuffing box halves fitted bolts, tightening torque 25 Nm
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data
P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box
P90451 120 Rubber cover for crosshead
MAN B&W Diesel A/S
Piston Rod Stuffing Box 902-2.1
Checking
1. After the piston rod stuffing box has been 1.

dismantled, check the following clearances: A
Uppermost scraper ring and sealing rings
Clearance at ring ends (scraper ring).

Total clearance (scraper ring). (D02-29) D0229
Clearance at ring ends (sealing rings). B

Total clearance (sealing rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends. D0230

Total clearance. (D02-30)
The ring clearances stated in Data apply to

A B
new rings.
As a general guide, it is recommended –

depending on the overhauling intervals and
D0229 D0230
M902020229C01
one’s 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:
2.
D0234
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 D0238
value given in data, it must be discarded.
M902020227C02
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box
Dismantling
In connection with dismantling of the piston,

1. 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.
M902020229D01
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 en-
2. gine.
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.
M902020229D02
3.
M902020229D03
MAN B&W Diesel A/S
Dismantling
4. Remove the two long dismantling screws

from the worktable. 4.
Mount them in the stuffing box through the

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

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

ing the stuffing box from the cylinder frame
bottom.
6. Remove the two long dismantling screws
M902020229D04
from the stuffing box and mount them in
the worktable.
By means of the four short screws in the

worktable, press the stuffing box out of the
flange. 5.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
M902020229D05
6.
M902020229D06
MAN B&W Diesel A/S
Overhaul
Normally, overhaul of the piston rod stuffing

box is carried out by routine methods in con-
nection with the dismantling (pulling) of the pis-
tons.
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.
M902020229O01
1. Mount two eye bolts in the stuffing box

flange, and hook on two tackles.
Lift the stuffing box a little up the piston

1. 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-rings of the stuffing box. If

D0244 the O-rings are intact and are to be used
again, move them up the piston rod and
secure them in this position, for example
with tape.
Remove the nuts from the stuffing box as-

M902020229O02
sembling bolts.
2.
M902020229O03
MAN B&W Diesel A/S
Overhaul
3. Take out the six bolts, and pull away one

stuffing box half. 3.
Mount two eye bolts on the stuffing box

half and remove it from the worktable. D0245
4. Using a feeler gauge, measure the vertical

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

press all sealing rings and scraper rings
down against the worktable.
M902020229O04
6. Measure the clearance between the ring
segments to determine whether replace-
ment is necessary.
Dismantle and stack the rings in the same 7. D0234

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. D0238

8. Inspect the surface of the piston rod. If

M902020227C02
small longitudinal scratches have occurred

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

ing.
M902020229O08
MAN B&W Diesel A/S
Overhaul
10. 10. Lubricate the piston rod (in the area where
all the ring units in the stuffing box will be
A positioned) with molybdenum disulphide
(MoS2).
B
For correct mounting of the sealing and
scraper rings see the sketch. The scraper
C 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
Relief
M902020229O10
groove
MAN B&W Diesel A/S
Overhaul
11. Assemble all the stuffing box ring units

round the piston rod, on the worktable, in 11.
the following way:
• Place the lowermost scraper ring seg-

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

and hook the spring ends together.
Repeat this procedure for the remaining

scraper rings.
On top of the scraper rings, assemble the
M902020229O11
two sealing ring units (each consisting of a
4-part and an 8-part ring).
Assemble the 8-part sealing ring so that

the two guide pins face upwards, place the
spring round the segments and, hook the 12.
spring ends together.
Assemble the 4-part sealing ring above the

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

(consisting of a 4-part scraper ring and an
8-part sealing ring).
M902020229O12
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. Subse-
quently, push the stuffing box half into con-
tact 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.
MAN B&W Diesel A/S
Overhaul
13. Check the ring clearance again.

13.
Then place the other half of the stuffing
box housing on the worktable, pushing it
into place round the rings.
D0228
In the middle holes mount and tighten up
the fitted bolts to the torque specified on
the Data Sheet, See Data D02-50
D0250 Mount the O-rings in the stuffing box

grooves.
14. Mount eye bolts and wire ropes, and lift

M902020229O13
the stuffing box a little.
Remove the worktable and lower the stuff-

ing box until it rests against the distance
pieces on the piston rod foot.
14.
Remove wire ropes and screws.
Mount and tighten the standard bolts to

specified torque, See Data D02-28
D0244
M902020229O14
MAN B&W Diesel A/S
Mounting
1. In connection with mounting of the piston,

1.
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 work-

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

stuffing box lands on the flange.
M902020229M01
2. Turn the piston upwards until the stuffing
box is in place in the cylinder frame.
Note!
2.
Make sure that the two guide pins in the
flange enter the guide holes in the bot-
tom of the cylinder frame.
3. Mount two screws in the flange through the

holes in the worktable.
M902020229M02
3.
M902020229M03
MAN B&W Diesel A/S
Overhaul
4. Remove the long screws from the stuffing

4. box and mount them itheworktable.
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.
M902020229M04
Smear the piston rod with molybdenum

disulphide.
Then turn the crankshaft a couple of revo-

lutions.
5. If possible: Start up the engine and keep it

running for about fifteen minutes at a num-
ber of revolutions corresponding to very
slow or idle speed.
Then stop the engine and inspect the pis-

ton rod and stuffing box.
M902020229M05
D0226
D0227
6.
M902020229D01
MAN B&W Diesel A/S
Piston and Piston Rod Panel Plate
P90251-0246
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0246

No. No.
014 Panel for tools

026 Name plate
040 Lifting tool for piston rod foot
051 Lifting tool for cylinder liner
075 Template for piston top
087 Distance piece for stuffing box
099 Cover for stuffing box hole
109 Mounting tool for stuffing box spring
110 Pressure test tool for piston
122 Worktable for stuffing box
134 Piston ring expander
158 Guide screw for piston crown
183 Pulling tool for stuffing box
MAN B&W Diesel A/S
Piston and Piston Rod - Tools Plate
P90261-0107
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0107

No. No.
019 Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Tilting Tools Plate
P90264-0012
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tilting Tools
P90264-0012

No. No.
015 Collar ring for piston

027 Support for tilting tool
039 Support for tilting tool
040 Lifting and tilting screw
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools Plate
P90265-0005
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0005

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

No. No.
016 Lifting tool for piston
103-01 0072 Cylinder Liner, Data

903-01 0257 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0249 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Liner 103-1
Data
X Stopped engine
X Shut off fuel oil
Data
D03-01 Lifting tool screws, tightening torque 200 Nm

D03-03 Cylinder diameter, new 600 mm
D03-04 Piston cleaning ring diameter, new 598.7 mm
D03-05 Cylinder liner, complete 3700 kg
D03-06 Cooling jacket 200 kg
D03-16 Piston cleaning ring radial width, new 13.1 mm
D03-17 PC-ring/Liner max. wear deviation 0.6 mm
D03-18 PC-rings replacement criteria:
Liner diameter: 600 mm

Liner wear: Install:
Standard PC-ring
0 – 0.60 mm (new max. diameter wear of 0.60 mm
0.60 – 1.20 mm Oversize PC-ring
> 1.20 mm No PC-ring
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data
P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90362 Cylinder Liner - Extra Tool
P90366 Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S
Cylinder Liner 903-1.1
Checking
1. Dismount the cylinder cover, the piston

cleaning ring and the piston. 1.
See Procedures 901-1.2 and 902-1.2.
Clean the cylinder liner and scavenge air

ports.
2. Position the cylinder liner measuring tool. D0303

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 cyl-

inder liner according to the description
given in Volume I, Chapter 707.
Note!
If the cylinder liner is to be replaced, the
M903010257C02
piston cleaning ring must also be re-

placed.
3. Carefully scratch over any scores or marks

and grind away the wear ridges.
See Procedure 903-1.3. 4.
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.
M903010257C04
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking
5. Piston cleaning (PC) ring:

6.
The PC-ring is to be regarded as an inte-
grated 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
B PC-ring diameter wear.
M903010257C06
Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner-measuring tool. Compare
the measurements with the diameter of a
new liner as stated in Data. Calculate the
wear of the liner.
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 the 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 the table in D03-18 on
the Data sheet.
If it is necessary to install an oversize PC-

ring, 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.
MAN B&W Diesel A/S
Dismantling
1. Dismount the cylinder cover.

See Procedure 901-1.2. 2.
Discard the sealing ring from the top of the

cylinder liner.
Turn the piston down far enough to make it

possible to grind away the wear ridges at
the top of the liner with a hand-grinder.
Dismount the piston cleaning ring and the

piston.
M903010257D02
D0301
2. Screw the two lifting tools on to the cylin-
der liner. Check with a feeler gauge that
there is no clearance between lifting tool
and cylinder liner. For tightening torque,
see Data. 3.
3. Disconnect the oil pipes leading from the

cylinder lubricator to the cylinder liner.
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.
M903010257D03
MAN B&W Diesel A/S
Dismantling
4. Remove the screws of the cooling water in-

4. let pipe.
5. Attach the crane to the lifting crossbar.
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
M903010257D04
may require the removal of one or more

cylinder cover studs before dismantling
the cylinder liner.
5. Land the cylinder liner vertically on, for in-

stance, a couple of planks.
6. Clean the cylinder frame internally, taking

D0305 special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
The lifting tools are also used for transport-

ing the cylinder liner.
M903010257D05
MAN B&W Diesel A/S
Overhaul
1. Remove the non-return valves for the cylin-

der liner lubrication 1.
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
M903010257O01
the clamps away from the liner.
2. Lower the cooling jacket by means of the

tackles and land it on the wooden planks.
3. Mount the lifting tools on the cylinder liner. 2.

See Data.
Lift the cylinder liner away from the cooling

jacket.
Clean the cooling jacket internally.

D0306
M903010257O02
3.
M903010257O03
MAN B&W Diesel A/S
Overhaul
4. Check and assess the condition of the cyl-

4. inder liner according to the description
given in Volume I, Chapter 707.
A B
Carefully scratch over any scores or marks
on the cylinder liner running surface, by
means of a rough grindstone held in the
C hand.
Check in the top of the liner for a wear

ridge (where the piston rings reverse direc-
tion). If there is any sign of a wear ridge, it
is necessary to create a groove by
grinding.The groove serves to prevent the
M903010257O04
build-up of a new wear ridge.
5. It is recommended to use a wear ridge

milling machine to create the groove. For
use of the milling machine, see supplier’s
5. instruction.
6. 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.
M903010256O04
The maximum depth of the groove is cal-

culated as Smax. = D x 0.0045.
Note!
It is of the utmost importance that the
6.
groove is made with a regular rounding
as shown in the sketch.
D
R=4-5 mm
C
C
M903010256O05
MAN B&W Diesel A/S
Overhaul
7. Apply a thin layer of grease on the contact

surface for the cooling jacket on the liner. 7.
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.
8. Lift the cooling jacket into position – mark-

ing scratches jacket/cylinder liner must co-
incide (manoeuvre side).
M903010257O06
8.
M903010257O07
MAN B&W Diesel A/S
Overhaul
9. Turn the clamps until they fit in the groove

9. of the liner, and tighten the screws.
Remove the tackles and the eye bolts from

the cooling jacket.
Mount the non-return valves for the cylin-

der liner lubrication.
M903010257O08
MAN B&W Diesel A/S
Mounting
1. Mount the lifting tools on the cylinder liner

and tighten to the specified torque. 1.
See Data.
Hook the lifting tools on to the crossbar,

and lift the jacket/liner assembly.
Mount the lowermost O-ring and apply a

D0301
little lubricating oil on the ring.
2. Check that the joint surfaces on the cylin-

der frame and cylinder liner are completely
clean.
M903010257M01
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 connec- 2.
tions on the cooling jacket.
3. If one or more cylinder cover studs have

been removed during the dismantling, D0305
mount the studs.
4. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount
and tighten the screws.
M903010257M02
3.
M903010257M04
MAN B&W Diesel A/S
Dismantling
5. Screw the pipes from the lubricator on to

5. the non-return valves, but do not tighten.
Vent the cylinder lubricating system by

pumping all pipes 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 until it is certain that each individual
lubricating point functions correctly.
M903010257M05
6. Lubricate the inside of the cylinder liner

with cylinder lubricating oil and mount the
piston and the piston cleaning ring.
Note!
7.
Make sure to mount the piston cleaning
ring correctly, so that the scratching
marks are aligned.
7. Mount the sealing ring and the cylinder

cover.
Tighten the upper water connections on

the cooling jacket as soon as the cylinder
cover is correctly positioned.
M903010257M06
MAN B&W Diesel A/S
Cylinder Lubricators 103-2
Data
X Stopped engine
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Data
D03-10 Inlet accumulator, nitrogen pressure, 30 bar

D03-11 Outlet accumulator, nitrogen pressure, 1.5 bar
D03-13 Plug screw, tightening torque, 30 Nm
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
Data
P90364 Test Equipment for Lubricators
MAN B&W Diesel A/S
Cylinder Lubricators 903-2.1
Check of Oil Injection:

1.
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 lubri-
cators 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 lu-
bricating 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 work-
ing properly.
M903020245C01
3.
M903020245C02
903-2.1 Cylinder Lubricators
With running engine:

4.
3. Check that all lubricators are operating cor-
Inlet
rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
The LEDs give signal when oil is injected.
Check the pressure shocks from the injec-

tion of the lubricators on each lubricator
pipe by feeling with a hand.
D0311
If in doubt, disconnect the pipe at the cyl-
D0310 inder liner to observe the oil flow.
M903020249C03
Check of Accumulators:
4. Measuring the nitrogen pre-pressure can

only be done with stopped engine and
5. pressure-free lubrication system.
Stop both oil pumps. Close the inlet valve

and open the equalizing valve on the re-
spective lubricator.
The nitrogen pressure in the inlet accumu-

lator (0.7 litre) can be checked without dis-
mounting the accumulator. For use of the
pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), the accumu-
M903020245C05
lator or the lubricator with accumulator

must be dismounted.
For nitrogen pressure in the accumulators,

see Data.
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as 7.
C
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor. A E D0313
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7 F
litre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
B
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean.
M903020247C07
Mount the filling valve on the relevant accu-
mulator with the union nut. Check that
valves C and F are closed.
Loosen the plug screw in the accumulator

using a ½” square drive handle in socket E.
It is now possible to read the actual nitro-

gen 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 accumu-

lator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.
Dismantling of lubricators:
1.
The engine must be stopped and blocked be-
fore dismounting a lubricator. Stop the cylinder
Inlet oil pump station.
1. Close the supply valve for the lubricator

and open the equalizing valve (turn both
handles to a horizontal position). Remove
the upper shield, if installed.
Disconnect the electrical plug on the side

of the lubricator.
M903020249D01
2. Unscrew the six screws in the bottom of

the lubricator and disconnect the cover
with pertaining pipes.
3. Unscrew the four screws on the side that

2.
Inlet
secure the lubricator to the hydraulic block,
and remove the lubricator.
Special running
It is possible to change a lubricator while the

engine is running if a spare lubricator with O-
rings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
• Reduce the engine load to below 40%

of MCR
M903020249D02
• Let the lubricator pump station run
• Dismount the lubricator as described in

steps 1-3
• Mount a spare lubricator as described

in Procedure 903-2.4.
Dismantling of accumulators:
5.
4. The engine must be stopped and blocked
before the accumulator is dismounted.
Inlet
Stop the cylinder oil pump station.
Close the supply valve for the lubricator

and open the equalizing valve.
Note!
When the oil pressure is released, a ni-
M903020249D04
trogen pre-pressure of 25-30 bar will re-
main in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the hy-
draulic block.
1. Place the lubricator in a bench vice with

1. 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.

M903020247O01
Remove the spring and actuator piston

with plungers.
Remove and discard the O-ring from the

cylinder block.
2.
Remove the cover for the non-return
valves. Take out springs and balls. Remove
and discard the O-rings.
M903020247O02
3.
M903020247O03
4. Screw out the non-return valves and re-

move and discard the O-rings. 4.
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.
M903020247O04
5.
M903020247O05
6.
M903020247O06
7. Pre-assemble the cylinder blockwith the

7. actuator piston and plungers to ensure the
correct guidance of the plungers, before fi-
nally assembling the cylinder block unit.
Mount the spring and press down the ac-

tuator 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.

M903020247O07
8. Remove the cover from the terminal box

and disconnect the wires for the feedback 8.
(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.
Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.
9 Turn the lubricator upside down in the vice.
M903020247O08
Unscrew the solenoid valve.
Discard the O-rings.
10. Solenoid valve: 9.
Disassemble and clean the valve.
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be re-
placed 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.

M903020247O09
See also manufacturer’s instructions.
10.
M903020244O12
11. Before mounting the feedback sensor,

11. check that the sensor is flush with the sen-
sor 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.

M903020245O10
1 1
2 2 Solenoid valve 11. Connect the wires and mount the cover on
3 BN (brown) the terminal box.
BK (black)
4
BU (blue) Feedback sensor
5 13. Mount the solenoid valve fitted with new
O-rings. Coat the O-rings with a little
12. grease to keep the rings in place during
LED
mounting.
2
Brown+15
Blue OV
Black FBsignal
M903020242O08
13.
M903020247O13
14. Mount the cylinder block assembly in the

cylinder housing. 14.
Check that the spring pin engages cor-

rectly with the cylinder block assembly.
Mount the screws and tighten the block to

the housing.
Remove the M6 x 60 screw with disc.
15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.
M903020247O14
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 stor- 15.
age.
Cover all surfaces with a thin layer of oil.

M903020247O01
1. Before mounting the accumulator, check

1. Inlet the nitrogen pressure, see Data.
Mount the accumulator.
2. 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 in the bottom of the lu-

bricator to the pipe connection.
M903020249M01
3. Close the equalizing valve and open the

supply valve (handles to be in a vertical po-
sition).
Mount the electrical plug. Check the injec-

2. tion of cylinder oil on the feedback LED on
Inlet the terminal box for the specific lubricator.
M903020249M02
3.
Inlet
M903020249M03
Cylinder Liner - Tools Plate
P90361-0084
Cylinder Liner - Tools
0084
P90361
MAN B&W Diesel A/S
Plate Cylinder Liner - Tools
P90361-0084
Item Item
Item Description Item Description
No. No.
036 Cylinder gauge, complete
MAN B&W Diesel A/S
Cylinder Liner - Milling Tools Plate
P90362-0005
MAN B&W Diesel A/S
Plate Cylinder Liner - Milling Tools
P90362-0005

No. No.
018 Wear ridge milling machine
MAN B&W Diesel A/S
Test Equipment for Lubricator Plate
P90364-0004
Test Equipment for Lubricator
0004
P90364
MAN B&W Diesel A/S
Plate Test Equipment for Lubricator
P90364-0004
Item Item
No. No.
019 Tool box

020 Nameplate
032 Adaptor
044 Pressure gauge
056 Spanner
068 Pressure gauge
081 Adaptor
103 Hose with 2 union
115 Quick coupling, minimess
139 Reducing valve
152 Adaptor
164 Adaptor
176 Adaptor
211 Adaptor
223 Filling and testing valve
MAN B&W Diesel A/S
Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007
Item Item
No. No.
021 Crossbar for cylinder liner
MAN B&W Diesel A/S
104-01 0059 Crosshead Bearing, Data

904-01 0249 Crosshead Bearing
104-02 0060 Crosshead, Data
904-02 0248 Crosshead
104-03 0041 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0052 Crankpin Bearing, Data
904-04 0231 Crankpin Bearing
104-05 0051 Connecting Rod, Data
904-05 0228 Connection Rod
90451 0149 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90462 0034 Connecting Rod - Tools
90464 0005 Crosshead - Hydraulic Tools
90465 0001 Crosshead - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crosshead Bearing 104-1
Data
X Stopped engine
X Shut off fuel oil
Data
D02-02 Piston rod/crosshead, tightening torque 590 Nm

D02-07 Piston rod/crosshead, tightening torque+angle 100/60 Nm/°
D02-20 Piston complete 1483 kg
D04-01 Crosshead bearing, top clearance max. 0.55 mm
D04-02 Crosshead bearing, top clearance min. 0.20 mm
D04-03 Oil wedge length, L 15 mm
D04-04 Crosshead bearing cap 277 kg
D04-06 Crosshead bearing shell, lower 20 kg
D04-07 Crosshead bearing cap with bearing shell 297 kg
D04-21 Crosshead complete 1245 kg
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data
P90451 59 Lifting attachment - connecting rod

P90451 72 Chain for suspending piston
P90451 96 Bracket for support, crosshead
P90451 106 Bracket for support, crosshead
P90464 Crosshead - hydraulic tools
P91356 Lifting tools, etc.
P91366 58 Feeler gauge
MAN B&W Diesel A/S
Crosshead Bearing 904-1.1
Checking
Tin-Aluminium bearings
2.
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.
The top clearance for a new bearing will nor-

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

the measurement in the Adjustment Sheet in
Volume I, OPERATION.
M904010249C02
1. Open the crankcase door at the relevant
cylinder.
2. Turn the crankthrow concerned to BDC.

3.
3. Measure the clearance in the crosshead
bearing by inserting a feeler gauge be- D0401
tween the bearing cap and the crosshead D0402
journal at the top of the upper bearing
shell, at both sides and fore and aft. See
Data.
4. The difference between the actual clear-

ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
M904010249C03
crosshead bearing must be disassembled

for inspection.
For evaluation of the bearing shell, see

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

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

(Oil Wedge)
tion, the bearing shell must be replaced by
a new one.
L
1/2
M904010249C05
D0403
L
MAN B&W Diesel A/S
904-1.1 Crosshead Bearing
Checking
Alternate checking method:

8.
In case the reason for opening the crosshead
bearing is a routine inspection, the following
procedure is sufficient.
6. Perform the clearance measurement shown

in 904-1.1 section 3.
7. Mount the two eyebolts and tackles in the

top of the crankcase in the fore and aft di-
rection. Mount two eyebolts on top of the
guideshoes.
M904010249C08
Turn to BDC, mount the connecting rod lift-

ing attachments on the connecting rod.
Use tackles to hold the connecting rod in
the vertical position.
9. Dismount the crosshead bearing cap hy-

draulic nuts. For operation of the hydraulic
jacks, see Section 913.
8. Mount two eyebolts in the bearing cap and

use two small tackles in the athwartship di-
rection to lift the bearing cap free of the
guidepins and to keep the bearing cap bal-
anced.
9. Use the tackles in the crankcase top to lift

the crosshead and piston high enough to
allow inspection of the lower crosshead
M904010249C09
bearing.
Note!
Ensure that the crosshead is lifted simul-
taneously fore and aft, i.e. by placing
marks on the guide planes using a felt
tipped pen
10. If the lower bearing shows no anomalies

the piston and crosshead is lowered again
and the crosshead bearing cap nuts are
mounted.
11. Recheck the bearing top clearance. Re-

move all tools.
12. If there are any doubt concerning damage

to the upper bearing, the bearing has to be
dismantled and checked according to 904-
1.2
MAN B&W Diesel A/S
Dismantling
This procedure applies to the following two

dismantling situations: 1.
• with piston mounted
• with piston removed
With piston mounted:
1. Turn the crankshaft down far enough to

give access to the nuts and screws on the
piston rod.
2. Mount two chains in the inner screw holes
M904010249D01
in the top of the crankcase, in the
athwarthship direction, for suspending the
piston rod.
3. Loosen and remove the locking wire from

the screws on the piston rod foot. Remove 2.
the screws.
M904010249D02
3.
M904010249D03
MAN B&W Diesel A/S
Dismantling
4. Mount a lifting eye bolt on each side of the

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

the piston rod.
Turn the crosshead downward, and the pis-

ton rod will then remain suspended from
the two chains.
With piston removed:

M904010249D04
6. Turn to BDC.
7. Place the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.
5. Loosen the crosshead bearing cap nuts.

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

rings, and unscrew the nuts.
M904010249D05
7.
D1302
M904010249D07
MAN B&W Diesel A/S
Dismantling
8. Mount the lifting attachments on the head

of the connecting rod. 8.
9. Suspend two tackles from the lifting brack-

ets, in the athwarthship direction.
10. Mount the wire guide at the top of the

crankcase door frame to prevent damage.
Mount two eye bolts in the top of the

crosshead bearing cap.
Hook the tackles on to the eye bolts, and

remove the bearing cap from the engine.
M904010249D08
Check the upper part of the journal.
9.
M904010249D09
10.
D0407
M904010249D10
MAN B&W Diesel A/S
Dismantling
11. Place the bearing cap on one side on a

11. couple of wooden planks.
Check the bearing shell, see Procedure

D0407
904-1.1.
12. Fasten tackles to the fixed lifting brackets

on the frame box wall.
13. Turn the crosshead upwards until the pis-

ton rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.
M904010249D11
Do not remove the chains or lifting eye

bolts.
12.
M904010249D12
13.
M904010249D13
MAN B&W Diesel A/S
Dismantling
14. Turn to TDC and attach the tackle hooks to

the lifting attachments. Haul the tackles 14.
tight.
15. 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.
M904010249D14
Haul the tackles tight.
16. Turn the crankthrow carefully towards BDC

while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod. 15.
17. With the crosshead resting on the sup-

ports, check the lower part of the cross-
head journal and the lower bearing shell.
Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chapter
708, ‘Bearings’.
M904010249D15
16.
17.
D0421
D0220
M904010249D16
MAN B&W Diesel A/S
Dismantling
18. In cases where it is necessary to remove

18. the lower bearing shell, tilt the connecting
rod towards the doorway on the camshaft
D0406 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.

M904010249D18
MAN B&W Diesel A/S
Mounting
With piston mounted/

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

bearing housing.
The excess height X is to ensure the cor-

rect tightening-down of the bearing shell D0406
and must not be eliminated.
2. Raise the connecting rod to an upright po-

sition.
Turn to TDC while ‘following’ with the tack-
M904010249M01
les, for assembling the crosshead and the
connecting rod.
Take care that the guide shoes do not

damage the bearing shell.
2.
3. Remove the supports from the crosshead D0421
guides.
Remove the tackles from the crosshead.
Turn the crank throw to BDC.
If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
M904010249M02
3.
M904010249M03
MAN B&W Diesel A/S
Mounting
4. Lift the bearing cap into the engine. Lower

4. the bearing cap onto the crosshead and re-
D0407 move the tackles. Remove the lifting at-
tachments from the connecting rod and the
wire guide from the door frame.
Note!
Take care that the bearing studs do not
damage the crosshead.
5. Tighten all four crosshead bearing cap nuts

M904010249M04
simultaneously. See Data.

For operation of hydraulic jacks, see Sec-
tion 913.
6. Mount the piston.

5.
With piston mounted:
7. Turn the crosshead upwards until the pis-

ton rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.
D1301
M904010249M05
7.
M904010249D13
MAN B&W Diesel A/S
Mounting
8. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and 8.
eye bolts from the top of the crankcase,
from the piston rod and from the cross-
head bearing cap.
9. Turn down to BDC, tighten the screws in

the piston rod, and lock with locking wire.
See Data.
Mount the locking wire in such a way that

the wire is tightened if a screw works
loose.
See Procedure 913-7.
M904010249D13
9.
D0202
D0207
M904010249M09
MAN B&W Diesel A/S
Crosshead 104-2
Data
X Stopped engine
X Shut off fuel oil
Data
D04-04 Crosshead bearing cap 277 kg

D04-08 Cooling oil outlet pipe, tightening torque 80 Nm
D04-12 Guide strip screws, tightening torque 350 Nm
D04-13 Guide plate, tightening torque 3 x 350 Nm
1 x 80 Nm
D04-15 Telescopic pipe, tightening torque 80 Nm
D04-19 Telescopic pipe, tightening angle 60 °
D04-21 Crosshead complete 1245 kg
D04-22 Guide shoe 325 kg
D04-23 Cooling oil outlet pipe 15 kg
D04-50 Connecting rod, without bearing caps 1820 kg
MAN B&W Diesel A/S
104-2 Crosshead
Data
P90451 47 Wire guide

P90451 59 Lifting attachment – connecting rod
P90451 60 Lifting tools – crosshead
P90451 84 Retaining tool telescope pipe
P90451 214 Torque wrench offset tool
P90462 11 Guide shoe extractor, complete
P90463 Crosshead – hydraulic tools
P91359 40 Torque spanners
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
1. Unbolt the main bearing lubricating oil

pipes. 1.
2. Unbolt the cooling oil outlet pipe from the

guide shoe and the drain oil slotted pipe.
Loosen and remove the screws which se-

cure the telescopic pipe to the guide shoe.
In order to reach the screw in the corner

behind the telescopic pipe, use the offset
tool along with a socket wrench.
3. Mount the retaining tool for the telescopic
M904020248D01
pipe on the stuffing box housing for the
telescopic pipe.
Mount two eye bolts in the top of the

crankcase in the fore-and-aft direction.
2.
Mount two eye bolts in the athwartship di-
rection, and suspend two tackles.
M904020248D02
3.
M904020248D03
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling

4.
Suspend the telescopic pipe by means of
the tool.
Suspend the piston.

To suspend the piston, see Procedure
904-1.2.
5. Turn the crosshead to gain access to the

nuts on the crosshead bearing studs.
Mount the spacer rings and the hydraulic

jacks for loosening the nuts on the cross-
M904020248D04
head bearing studs.
For operation of the hydraulic tools, see

Section 913.
5. Loosen the nuts, remove the hydraulic

jacks and unscrew the nuts.
6. Mount eye bolts in the crosshead bearing

cap and hook the tackles on to the lifting
brackets in the top of the crankcase.
Remove the bearing cap and lift it out of

the engine.
D1302
M904020248D05
6.
D0404
M904020248D06
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
Lifting of the crosshead:

7a.
7a. Mount the special lifting tool on the cross-
head.
Mount the lifting attachments for fixing the

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

frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles D0421
tight.
M904020248D07
Hook the tackles to the top lifting brackets
on to the lifting tool on the crosshead, and
lift the crosshead.
7b. Alternate method.

7b.
If the piston has been removed it is advis-
able to use the engine room crane and the
flat plated wire strap to handle the cross-
head.
This is done by lowering the strap down

through the cylinder and stuffing box and
lifting the crosshead in the crosshead lifting
tool.
This eliminates the need for the tackles

placed in the athwartship direction in the
M904020248D08
crankcase top.
8. Use the tackles to tilt the connecting rod

towards the exhaust side, while turning the
crankthrow towards the camshaft side.
8.
Transfer the tackles from one lifting attach-
ment to another as necessary.
When the crankthrow is 90° after BDC,

stop turning. D0450
By alternate use of the tackles, tilt the con-

necting rod until it rests against a couple of
wooden planks in the bottom of the bed-
plate.
M904020248D09
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling
9. Lower the crosshead to a position just

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

plates from the guide shoes.
Mount lifting eye bolts in both guide shoes.
10. Suspend two tackles from the eye bolts in

the top of the crankcase, in the fore-and-
aft direction, and attach the tackles to the
guide shoes.
Push one of the guide shoes towards the

M904020248D10
middle of the crosshead. If necessary, use

the guide shoe extractor tool.
11. Pull the “free end” of the crosshead into

the neighbouring cylinder unit.
10.
Mount the guide shoe extractor on the op-
D0422 posite guide shoe.
Pull off the guide shoe, remove the extrac-

tor, and lift up the guide shoe.
M904020248D11
11.
D0422
M904020248D12
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
12. Pull the crosshead with guide shoe into the

opposite neighbouring cylinder unit. 12.
Mount the guide shoe extractor tool on the

remaining guide shoe.
Pull off the guide shoe, remove the extrac-

tor tool and lift up the guide shoe.
13. Turn the crosshead 90°.
14. Mount the wire guide tool in the framebox

door opening.
M904020248D13
Remove the crosshead from the engine,
using wire rope and tackles.
Protect the crosshead, for instance with

thick or corrugated paper, and land it out-
side the engine. 13.
If necessary, remove the guide shoes from

the engine.
M904020248D14
14.
M904020248D15
MAN B&W Diesel A/S
904-2.4 Crosshead
Mounting
1. Lift the crosshead into the engine, using

1. wire rope, tackles mounted in the top lifting
brackets inside the engine.
2. Turn the crosshead 90°. Pull the crosshead

to one side under the web plates between
the cylinders.
3. Lower one guide shoe in the other side of

the crosshead and mount the guide shoe
extractor tool.
Use the guide shoe extractor tool to pull

M904020248M01
the crosshead so far through the guide

shoe that the other guide shoe can be low-
ered.
Follow the movement of the crosshead with

the tackles mounted in the engine.
2.
M904020248M02
3.
M904020248M03
MAN B&W Diesel A/S
Crosshead 904-2.4
Mounting
4. Lower the other guide shoe.

4.
Use the guide shoe extractor tool to push
the crosshead towards the second guide D0422
shoe.
Remove the extractor tool and adjust the

position of the opposite guide shoe.
5. Mount the guide plates on the side of the

guide shoes.
Tighten the screws and lock them with

locking wire.
M904020248D12
Remove the eye-bolts from the guide

shoes.
Use the tackles in the fore and aft eyebolts 5.

to lift the crosshead to a working position
and mount the guide strips on the side of
the guide shoes.
Tighten the screws and lock them with

locking wire.
6. Using the tackles, lift the connecting rod to

a vertical position while turning the
crankthrow to BDC.
M904020248M05
D0412
D0413
6.
D0450
M904020248M06
MAN B&W Diesel A/S
904-2.4 Crosshead
Mounting
7. When the connecting rod is in a vertical

7. position, lower the crosshead and land it
on the connecting rod.
Remove the lifting attachments from the

connecting rod head.
Remove the lifting tool from the crosshead.
8. Lift the crosshead bearing cap into the en-

gine.
D0421
9. Mount the spacer rings and the hydraulic
jacks for tightening the nuts on the cross-
M904020248D07
head bearing studs.

Procedure 913.
8. Mount the drain oil slotted pipe and the

cooling oil outlet pipe on the guide shoe.
D0404 Turn the crankshaft to TDC.
Land the telescopic pipe on the guide

shoe.
M904020248D06
9.
D1301
M904020248M09
MAN B&W Diesel A/S
Crosshead 904-2.4
Mounting
10. For tightening the bolt in the corner behind

the telescopic pipe, use the offset tool 10.
along with the torque wrench.
Mount the cooling oil outlet pipe. D0408 D0415

D0419
11. Mount the lubricating oil pipes on the main
bearing caps.
12. Mount the piston.

13. Remove all tools from the engine.
M904020248M10
Note!
Always search the crankcase to ensure
that there are no tools, shackles or rags
left behind.
11.
M904020248M11
12.
M904020248M12
MAN B&W Diesel A/S
Reciprocating Parts 104-3
Data
X Stopped engine
X Shut off fuel oil
Data
D04-25 PF+PA, N max. 0.6 mm

D04-26 PF+PA, O max. 1.1 mm
D04-28 E+G, H+F, N max. 0.55 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.85 mm
D04-34 J+X, L+Y, K+X, M+Y, N max. 0.9 mm
D04-35 J+X, L+Y, K+X, M+Y, N min. 0.5 mm
D04-36 J+X, L+Y, K+X, M+Y, O max. 1.1 mm
D04-41 ZF/ZA O min. 5 mm
N: New and cold engine with staybolts tightened
(less than 100 running hours).
O: Engine in service.
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data
MAN B&W Diesel A/S
Reciprocating Parts 904-3.1
Checking
Reciprocating Parts
S50ME-C
0217
Checking
904-3.1
1.
In order to achieve uniform measuring condi-
tions on board, the ship’s trim must be as close
as possible to 0°.
1. Mount a transparent plastic tube along the

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

the framebox side. See T.
MA904-5.0 72 01
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
3.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Measurements are to be taken with a ruler.
2. Turn the engine in ASTERN direction to 45°

after BDC (the guide shoe must rest against
the crosshead guide).
3. Mount the tool between the guide shoe/

guide strip. For this purpose, use the third
threaded hole from bottom of guide shoe
GN904-3.1 203 03
(this hole is normally used for fastening the

guide strip to the shoe).
By means of the two screws in the middle

of the tool, pull the guide shoes until they
rest lightly against the end face of cross-
head.
Note!
When the tool is mounted, it is not possi-

ble to turn past TDC and BDC.
0$1% :'LHVHO$6
904-3.1 Reciprocating Parts
Checking
4. 4. Check the centering of the piston in the cyl-

FORE AFT
inder liner by measuring the clearance
(from the scavenge air space with a long
feeler gauge) between the piston skirt and
the cylinder liner in the Fore and Aft posi-
tions (PF-PA).
D04-25
D04-25
D04-26 Make sure that the piston is clear of the cyl-

inder liner in the fore-and-aft direction.
PA 5. Measure the clearance between the guide

strips and crosshead guides (J, K, L and
PF
M).
The clearance J, K, L and M is adjusted by

the insertion of shims so that it is symmet-
rical 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.
GN904-3.1 213 04
ZF
ZA
5.
D04-53
D04-54
D04-55
FUEL PUMP
GN904-3.1 203 05
0$1% :'LHVHO$6
Reciprocating Parts 904-3.1
Checking
6. Check the clearance between guide shoe 6.

Exhaust side Fuel pump
and crosshead guide (E, F, G and H) with
a feeler gauge.
7. It is recommended that the measured re-

sults are noted down so that possible later
changes can be ascertained.
D04-28
D04-29
D04-30
GN904-3.1 203 06
7.
GN904-3.1 203 07
0$1% :'LHVHO$6
Crankpin Bearing 104-4
Data
X Stopped engine
Shut off fuel oil
Data
D04-43 Crankpin bearing clearance, max. 0.7 mm

D04-44 Crankpin bearing clearance, min. 0.45 mm
D04-46 Crankpin bearing, upper shell 35 kg
D04-47 Crankpin bearing, lower shell 28 kg
D04-48 Crankpin bearing cap + shell + bearing studs 260 kg
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

P90451 96 Bracket for support, Cross Head
P90461 Connecting Rod - Hydraulic Tools
P90462 59 Lifting tool for crankshaft shell
P91356 Lifting Tools, Etc.
MAN B&W Diesel A/S
Crankpin Bearing 904-4.1
Checking
The bottom clearance between the journal and 2.

a new bearing shell is the result of a summa-
tion 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.
M904040231C02
3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
3.
recorded in the Adjustment Sheet (or the
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2. D0443
D0444
5. The wear limit for the crankpin bearing
shells is based on an evaluation of the
bearing condition at the time of inspection.
M904040231C03
An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.
6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in
the instruction book, Volume I, OPERA- 5.
TION.
M904040231C05
MAN B&W Diesel A/S
904-4.2 Crankpin Bearing
Dismantling
1. Turn the crank to BDC.

2.
2. Suspend two tackles from the lifting brack-
ets, in the athwartship direction.
3. Turn the crank to TDC.
Mount eye bolts in each side of the crank-

pin bearing cap and, using shackles and
wire ropes, hook on the tackles and haul
tight.
Loosen the crankpin bearing stud nuts, us-

ing the hydraulic jacks.
M904040231D02

Procedure 913-1.
Remove the hydraulic jacks and the nuts.

3.
4. Lower the bearing cap while seeing care-
fully that the studs do not damage the
crankpin journal.
Land the bearing cap on a couple of

planks placed in the oil pan.
D1302
Inspect the bearing shell.
For evaluation of bearings, see Volume I,

Chapter 708.
M904040231D03
4.
D0448
M904040231D04
Page 2 (8) When referring to this page, please quote M90404 Edition 0231
MAN B&W Diesel A/S
Dismantling
5. If the bearing shell needs to be replaced,

remove the whole bearing cap from the 5.
crankcase.
Hook the tackle on to an eye bolt on one

side of the bearing cap.
Mount the wire guide in the top of the

crankcase door opening. D0448
Using the tackle from the frame box inside
wall, together with a tackle suspended from
the platform bracket, lift the bearing cap
out of the crankcase.
M904040231D05
6. 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. 6.
Note! D0447
Normally bearing shells are replaced in
pairs.
If only one of the shells needs replace-

ment, MAN B&W Diesel should be con-
tacted for advice beforehand.
7. Turn to TDC.
M904040231D06
Mount the four supports for guide shoes

on the crosshead guides.
Carefully turn the crank down until the

guide shoes rest on the supports. 7.

M904040231D07
MAN B&W Diesel A/S
Dismantling
8. Mount a lifting attachment for securing the

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

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

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
M904040231D08
Continue turning the crankshaft until the

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

crankpin journal.
9.
10. If it is necessary to replace the bearing
shell, proceed as follows:
Turn the crankshaft to HORIZONTAL.
Release the tackle so that the connecting

rod is hanging freely.
M904040231D09
10.
M904040231D10
Page 4 (8) When referring to this page, please quote M90404 Edition 0231
MAN B&W Diesel A/S
Dismantling
11. Mount an eye bolt in the bottom of each

guide shoe. 11.
Suspend two tackles from the eye bolts.
12. Place the lifting tool for the crankpin upper

shell on the crank webs and hook the tack-
les on to the lifting tool.
Mount the tool on the bearing shell in the

connecting rod, using the tackles, and haul
tight.
13. Dismount the bearing shell lock screws.
M904040231D11
Lower the lifting tool with the bearing shell,
using the tackles.
12.
M904040231D12
13.
D0446
M904040231D13
MAN B&W Diesel A/S
Mounting
1. Bearing shells of three mm undersize are

1. available as spares in case of journal recti-
fication. Please contact MAN B&W Diesel
for advice.
Coat the bearing shell surfaces and the

journal with clean oil.
The excess height X is to ensure the cor-

rect tightening-down of the bearing shell,
and must not be eliminated.
2. Lift the upper bearing shell for the crankpin

M904040231M01
concerned into the crankcase.
Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.
2. 3. Remove the lifting tool, the tackles and the

eye bolts from the guide shoes.
D0446
M904040231M02
3.
M904040231M03
MAN B&W Diesel A/S
Mounting
4. Hook the tackle on to a beam under the

gallery platform and on to the lifting attach- 4.
ment 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 t he bearing en-
ters the recess in the crankshaft when the
parts turn together.
Remove the tackle and the lifting attach-

ment from the connecting rod.
M904040231M04
Remove the guide shoe support brackets

from the crosshead guides.
5.
M904040231M05
MAN B&W Diesel A/S
Mounting
6. Suspend the tackles from the lifting brack-

6. ets in the top 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.
7. Hook the tackles on to the wire ropes and

D0448 lift the bearing cap into position against the
connecting rod.
Caution!
During mounting, take care that the
M904040231M06
studs do not damage the crankpin jour-

nal, and check that the guide pins
mounted in the bearing cap enter the
holes in the connecting rod.
7. 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 Sec-

tion 913.
Remove the tackles from the top of the

frame box.
Check the bearing clearance.

M904040231M07
D1301
MAN B&W Diesel A/S
Connecting Rod 104-5
Data
X Stopped engine
Shut off fuel oil
Data
D04-48 Crankpin bearing cap + shell + bearing studs 260 kg

D04-50 Connecting rod, without bearing caps 1850 kg
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

P90461 Connecting Rod - Hydraulic Tools
P91356 Lifting Tools, etc.
MAN B&W Diesel A/S
Connecting Rod 904-5.2
Dismantling
Connecting Rod
S46MC-C
0228
Dismantling
904-5.2
1.
1. Turn the crank to BDC.
Dismount the crosshead bearing stud nuts.

2. Mount two shackles in the top of the crank-

case in the lifting brackets, in the athwart-
ship direction, and suspend two tackles.
3. Turn the crank to TDC.
Dismount the crankpin bearing cap, and re-

move the bearing cap from the engine. D13-02
HN904-5.2 217 01
HN904-5.2 217 02 2.
3.
D13-02
D04-48
GN904-5.2 225 03
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling
4. 4. Mount the four supports for guide shoes on

the crosshead guides.
Carefully turn the crank down towards the

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

5. Mount the lifting attachments for securing

the connecting rod on the head of the con-
HN904-5.2 217 04
necting rod.
Fasten tackles to lifting brackets A and B on

the frame box wall, and attach the tackle
hooks to the mentioned lifting attachments
5. on the connecting rod head.
D04-50 Haul the tackles tight.

A B
Also mount a lifting attachment on the lower
end of the connecting rod, on the exhaust
side.
6. Turn the crankthrow carefully towards BDC

C while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.
The crosshead now rests on the four sup-

ports.
GN904-5.2 225 05
Turn the crankthrow to 90° before BDC.
6.
A B
C
GN904-5.2 225 06
0$1% :'LHVHO$6
Dismantling
7. Shift tackle B from the lifting attachment on 7.

one side of the connecting rod to the lifting
attachment on the other side.
AA
A B
Dismount the lifting attachment on the cam-
shaft side of the connecting rod.
Attach a tackle to lifting bracket C on the

C
frame box wall and connect the tackle hook
to the lifting attachment on the lower end of
the connecting rod.
Mount the wire guide on the door frame.
GN904-5.2 225 07
Turn the crankthrow towards TDC while ‘fol-
lowing’ with the tackles, thus continuously
supporting and guiding the connecting rod
towards the doorway.
8.
8. Attach a tackle to the gallery-mounted lift-
ing bracket E, and hook on to the lifting at-
tachment on the connecting rod. A B E
Shift tackle A from the lifting attachment on

the head of the connecting rod to the lifting
attachment at the bottom of the connecting
rod. C
Turn the crank carefully upwards while ‘fol-

lowing’ with tackles A, B, C and E, guiding
the head of the connecting rod out of the
doorway.
GN904-5.2 225 08
Shift the tackles from one lifting attachment

to the other as necessary.
9. Mount a strap around the connecting rod 9.

and suspend the connecting rod from the
engine room crane. Shift tackle B from the
lifting attachment on the head of the con- A B E
A
necting rod to the lifting attachment at the
bottom of the connecting rod.
Remove tackles A and E.

C
Continue turning upwards till about 30° af-
ter TDC while ‘following’ with the tackles
and the engine room crane.
GN904-5.2 225 09
0$1% :'LHVHO$6
Dismantling
10. 10. Shift the tackle from lifting bracket C to A.
Lift the connecting rod out of the engine,

A B E using the tackles and the engine room
crane.
Remove the tackles, and lift the connecting

rod away by means of the engine room
crane.
C
GN904-5.2 225 10
0$1% :'LHVHO$6
Mounting
Mounting
904-5.4
1. Equip the connecting rod with the same lift- 2.

ing attachments as mentioned under dis-
mantling.
A B E
Turn the crank to a position about 25° past
TDC on the camshaft side.
D04-50
Apply clean lubricating oil to the crankpin
bearing shell and journal. C
2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine
room crane and the tackles attached to lift-
GN904-5.2 225 10
ing brackets A and B.
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. 3.
4. Turn the crankthrow towards BDC, past

A B E
TDC, while ‘following’ with the tackles and
the engine room crane.
Attach tackle B to the upper end of the con-

necting rod.
C
Attach a tackle to bracket E and the upper
end of the connecting rod.
Haul tight and remove the strap around the

GN904-5.4 225 03
connecting rod.
4.
A B E
C
GN904-5.4 225 04
0$1% :'LHVHO$6
Mounting
5. 5. Turn the crankthrow to 90° before BDC.
Shift tackle A from the lower end to the top

A B E of the connecting rod.
Remove the tackle at E.
Shift tackle B from the lifting attachment on

C one side to the other side of the connecting
rod.
Remove the tackle at C and the wire guide

on the door frame.
GN904-5.4 225 05
Remove the lifting attachment at the lower

end of the connecting rod.
6. Turn the crankthrow towards TDC while ‘fol-

6. lowing’ with the tackles.
Caution!
Take care that the studs do not damage

the crosshead bearing shell.
7. When the crank is in TDC, mount the crank-

pin bearing cap.
GN904-5.4 225 06
7.
D13-01
GN904-5.4 225 07
0$1% :'LHVHO$6
Mounting
8. Remove the four supports from the cross- 8.

head guides and the lifting attachments
from the connecting rod.
Turn the crosshead down far enough to fa-

cilitate the tightening of the nuts.
9. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.
GN904-5.4 225 08
HN904-5.2 217 01 9.
D13-01
0$1% :'LHVHO$6
Connecting Rod and Crosshead Panel Plate
P90451-0149
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0149

No. No.
011 Panel for tools

023 Name plate
047 Wire guide, main bearing
059 Lifting attchment, connecting rod
060 Lifting tool, crosshead
072 Chain, suspension of piston
084 Retaining tool, telescope pipe
096 Bracket, support of crosshead
106 Bracket, support of crosshead
118 Rubber cover for crosshead
120 Rubber cover for crosshead
214 Offsett tool, torque spanner
MAN B&W Diesel A/S
Connecting Rod - Hydraulic Tools Plate
P90461-0068
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0068

No. No.
028 Hydraulic jack

030 Support
041 Tommy bar
089 Spanner
100 Stud setter
207 Hydraulic toolset, complete
MAN B&W Diesel A/S
Connecting Rod - Tools Plate
P90462-0034
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0034

No. No.
011 Lifting tool for crankpin shell
MAN B&W Diesel A/S
Crosshead - Hydraulic Tools Plate
P90464-0005
MAN B&W Diesel A/S
Plate Crosshead - Hydraulic Tools
P90464-0005

No. No.
024 Jack-hydrualic, complete

036 Support
048 Tommy bar
085 Key, hexagon socket screw
107 Stud setter
203 Hydraulic toolset, complete
MAN B&W Diesel A/S
Crosshead - Tools Plate
P90465-0001
MAN B&W Diesel A/S
Plate Crosshead - Tools
P90465-0001

No. No.
018 Guide shoe extractor
MAN B&W Diesel A/S
105-01 0006 Crankshaft Deflection, Data

905-01 0208 Crankshaft Deflection
105-02 0052 Main Bearing, Data
905-02 0245 Main Bearing
105-03 0044 Thrust Bearing, Data
905-03 0224 Thrust Bearing
105-04 0017 Journal Bearing, Data
905-04 0216 Journal Bearing
105-05 0037 Axial Vibration Damper, Data
905-05 0224 Axial Vibration Damper
90551 0237 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0133 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90570 0001 Thrust Shaft - Tools
90572 0005 Main Bearing - Measuring Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Main Bearing 105-1
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10501
105-1 Data 0006 Main Bearing
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
MAN B&W Diesel A/S
105-1 Main Bearing
Data
P90572- Main Bearing - Measuring Tools

P91366- 048 Autolog, measuring tool for crankshaft
MAN B&W Diesel A/S
Main Bearing 905-1.1
Checking
0208 Bearing
Main S80MC-C
Checking
905-1.1
1.
General
The condition of the main bearings can be

checked by:
• Deflection readings
• Visual checking
• Edge checking and
• Measuring of top clearance.
HM905-2.0 46 01
Crankshaft deflection readings
Crankshaft deflection readings should be taken

while the ship is afloat (i.e. not while in dry
dock).
2.
As the alignment is influenced by the engine Positive (+)
temperature as well as the loading conditions,
deflection measurements should, for compari-
son 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 Negative ( )
throw. See also Chapter 708 in Volume I.
KN905-1.1 208 02
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 3.
the readings when the throw passes the po-
sitions:
B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
1/2 (B2+B1) = B
XZ905-1.1 204 03
0$1% :'LHVHO$6
905-1.1 Main Bearing
Checking
4. 4. When taking deflection readings for the

three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pres-
sure on the turning wheel teeth. Otherwise,
this pressure may falsify the readings.
For evaluation of the crankshaft deflection

readings, see Volume I, OPERATION,
Chapter 708.
If the crankshaft deflection (alignment indi-

cator) 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 bear-
ing.
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.
HM905-2.0 46 01
As reference, use the “after seatrial” deflec-

tion table.
5. The condition of the bearing can be checked as

follows:
5. Visually look for bearing metal fragments in

the oil pan, and check the filters for metal
fragments.
Such fragments can be from crosshead,

guide shoe or crankpin bearings. If frag-
ments are found, the damaged bearing can
be found by edge checking with a feeler.
General
KN905-1.1 208 05
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 dur-

ing a crankcase inspection, and small, thin
pieces can enter the filter. A check of the bear-
ing edges together with inspection of the crank-
case and the filter normally provides a good
indication of the bearing condition.
0$1% :'LHVHO$6
Checking
Checking the bearing edges 6.
6. Bearing edges can be checked with a “feel-

er” 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
flashlight.
The No. 1 and the two aftmost main bear- Hole in

ings are more difficult to access on the the edge
KN905-1.1 208 06
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.
<1.2 mm
>0.7 mm
7. It is rather easy to make a feeler (see 1 7-10 mm
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 60-70
that the thickness of the white metal is ap-
prox. 1.5 mm, which is why the tip should 2-3 mm
be less than 1.2 mm thick, and bigger than
500-1000
the max. top clearance. At the other end of

the tip, a “handle” should be made by bend-
ing a hook or similar in the same direction
as the tip.
Wire feeler
Note!
The above dimensions of the “wire-

feeler” are guideline values and may
KN905-17.02
depend on the engine type as well as

individual, personal designs.
0$1% :'LHVHO$6
Checking
8. 8. If there is too large a difference in the

crankshaft deflection readings (autolog)
check the clearance in the individual bear-
ings.
Bearing clearance checks should also be

carried out during time-based overhauls
KN905-1.1 208 08
and surveys.
If there is a suspicion of a damaged bear-

ing, it is recommended to edge check the
9. 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 hori-
zontally pushed against the clearance. Now
the feeler blade is pushed max. 20 mm into
the gap.
KN905-1.1 208 09
10. The clearance is measured at both the fore

20
and the aft part of the bearing.
Note!
10.
The bearing clearances for a new bear-
ing stated in Data (see Data 105-2) are
for guidance purposes only.
KN905-1.1 208 10
0$1% :'LHVHO$6
Checking

recorded in the adjustment sheet (or the
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 diassembled for

inspection, see procedure 905-2.2.
HN905-2.1 227 03
0$1% :'LHVHO$6
Main Bearing 105-2
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10502
105-2 Data 0052 Main Bearing
X Stopped engine
Shut off fuel oil
Data
D05-01 Main bearing, top clearance max. 0,75 mm

D05-02 Main bearing, top clearance min. 0,45 mm
D05-03 Main bearing cap 507 kg
D05-04 Main bearing shell, upper 35 kg
D05-05 Main bearing shell, lower 36 kg
MAN B&W Diesel A/S
105-2 Main Bearing
Data
P90551 40 Pulley for wire for main bearing

P90551 76 Lifting tool - main bearing cap
P90551 88 Dismantling tool, main bearing shell
P90551 90 Mounting tool for bearing shell
P90551 184 Lifting tool for main bearing shell
P90561 Main Bearing - Hydraulic Tools
P90562 Lifting tool for crankshaft
P90572 Main Bearing - Measuring Tools
P91351 10 Hydraulic pump, pneumatically operated
P91351 22 Hydraulic pump, hand operated
P91356 Lifting Tools, Etc.
MAN B&W Diesel A/S
Dismantling
Main Bearing
S60MC-C
0245
Dismantling
905-2.2
Positioning the crankshaft 1.

Aftmost main bearing (= Journal bearing)
1. Dismantling of main bearing.
The bearings are divided into two catego-

ries:
• The main bearings
• The aftmost main bearing

often referred to as “Journal bearing”
(See Procedure 905-4).
2. Before any dismantling, check and write

down the main bearing top clearances and
crankshaft deflection readings for the cylin-
KN905-2.2 238 01
der unit concerned.
Main bearings
3. Turn the crank throw to the position shown Thrust bearing

on the sketch and in such a way that the top
of the studs is flush with the crank throw. 2.
Note!
Be sure that the crosshead for the neigh-

bouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
KN905-2.2 238 02
3.
EXH-SIDE MAN-SIDE
KN905-2.2 238 03
0$1% :'LHVHO$6
Dismantling
4.
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.
KN905-2.2 238 04
Note!
Some engines have temperature sensors

fitted to the main, crosshead, and crank-
pin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.
0$1% :'LHVHO$6
Dismantling
Mounting of tools and tackles 1.
1. Mount pulley E on the web plate above the

bearing cap.
2. Pulley E is used to lift the main bearing cap

vertically and free of the bearing studs.
HN905-2.2 245 02
HN905-2.2 227 03 2.
0$1% :'LHVHO$6
Dismantling
3. 3. Mount pulley F in the bottom of the guide

shoe.
On some engines the pulley is mounted in

the bottom of the guide screw, and on some
engines it is necessary to remove the guide
screw before mounting pulley F.
F
4. Pulley F is used in combination with pulley
E, to lift the bearing cap free of the web
plate, the guides and the crankthrow.
5. Mount an eye bolt on the opposite web

plate.
HN905-2.2 227 04
The eye bolt is used in connection with a

pull lift, to keep the main bearing cap clear
of the guides when it is lifted out of the en-
4. gine.
HN905-2.2 227 05
5.
HN905-2.2 227 06
0$1% :'LHVHO$6
Dismantling
6. Mount tackles in the following positions: 6. B A
A. Suspended from a wire strap below the

crane beam. Adjust the suspension (fore-aft
position) to ensure that chains and wire
ropes go free of guides and crosshead.
B. In the lifting bracket in the top of the

crankcase, camshaft side.
D
C. In the lifting bracket below the doorway.
KN905-2.2 238 06
D. In the eye bolt on the web plate opposite
the pulleys. C
Mount the wire guide in the top of the door-

way. 7.
7. Assemble the main bearing hydraulic jacks

on the bearing studs. Connect the hydraulic
pump.
D13-02
Loosen the nuts.
Remove the hydraulic main bearing tools

from the engine.
Unscrew and remove the nuts from the

main bearing studs.

Procedure 913-1.
GN913-1.0 203 22
8. Mount the main bearing lifting tool on the

main bearing cap, and place the wire rope
as shown.
8.
HN905-2.2 227 09
0$1% :'LHVHO$6
Dismantling
9. 9. Attach tackle A to the wire rope and care-

fully lift the main bearing cap clear of the
studs.
10. The lifting tool has one free wire rope.

Place this wire rope around the wheel of
pulley F mounted in the guide shoe. Hook
the wire rope on to the chain of tackle C.
D05-03 11. Tighten tackle C and release tackle A, until

the main bearing cap is suspended vertical-
ly below pulley F.
C
HN905-2.2 22710
10.
C
HN905-2.2 227 11
11.
F
C
D05-03
HN905-2.2 227 12
0$1% :'LHVHO$6
Dismantling
12. Release tackle A from the wire rope of the 12.

lifting tool. Remove the wire rope of the lift-
ing tool from pulley E mounted on the web
plate. F
C
Mount the short wire rope with two shackles
on the main bearing cap lifting tool.
13. Hook the chain of tackle D on to the short

wire rope mounted on the main bearing lift-
ing tool.
Tighten tackle D and release tackle C at the
HN905-2.2 227 13
same time, to get the bearing cap clear of
the guides.
14. Attach the hook from tackle A around the

wire rope of tackle B to keep the wire rope
free from the crosshead and guide plates. 13.
At the same time, release tackle C until the F

main bearing cap is suspended vertically
below tackle B. C
D
HN905-2.2 227 14
14.
KN905-2.2 238 20
0$1% :'LHVHO$6
Dismantling
15.
15. When the main bearing cap is hanging ver-
A
tically below tackle B, remove tackle C and
B
the wire rope around pulley F.
Remove the hook of tackle A from the wire

rope of tackle B.
Attach tackle A to the short wire rope on the

main bearing cap lifting tool.
D Note!
D05-03 Make sure that the wire rope of the main
KN905-2.2 238 21
bearing lifting tool does not scrape

C
against the edges of the guide shoe.
16. Mount the free wire rope in tackle A.

16.
A Now lift the bearing cap out of the engine
B
and place it on a couple of wooden planks.
Removal of upper bearing shell
17. Mount the bearing shell lifting tool on the

upper main bearing shell, and remove the
shell, using pulley F.
Lift the upper bearing shell out of the en-

D gine in the same way as the bearing cap.
KN905-2.2 238 22
17.
D05-04
KN905-2.2 238 23
0$1% :'LHVHO$6
Dismantling
18. If the crankshaft is turned with the bearing 18.

cap dismounted, use the two stops to pre-
vent the lower shell from being rolled out.
19. Place the crosspiece in the bedplate with

the ends resting on the cross girders, and
position the hydraulic jacks beneath the
web plate as shown.
Tighten the screws against the crank webs

and compress the jacks.
Connect the hydraulic jacks to the high-
KN905-2.2 238 24
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. 19.
20. Check that there is min. 0.1 mm clearance

between journal and bearing shell, or be-
tween bearing shell and main bearing sup-
port, on both sides of the journal.
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).
KN905-2.2 238 27
Note!
The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
relief in the bearing shell.
20.
Min. 0,1 mm
Note!
The lower shell must be lifted out to the

side with the most clearance, which is
normally the camshaft side.
EXH CAM
KN905-2.2 238 28
Min. 60 mm
0$1% :'LHVHO$6
Dismantling
21. 21. If repositioning 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 ap-

plied to the jack. This data is used to en-
sure that the crankshaft is in the same
position when the new bearing is installed.
22. Dismount the locking screws.
Place the dismantling tool on top of the low-

KN905-2.2 238 25
er bearing shell. Make sure that the flap on

the dismantling tool enters the oil groove in
the bearing shell.
22. Note!
It is recommended that the crankshaft lift-

ing tool is only removed if it is urgently
necessary and then only after the main
bearing shell has been reinstalled.
KN905-2.2 238 26
0$1% :'LHVHO$6
Dismantling
23. Pull the lower shell around and up until it 23.

lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.
24. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.
Note!
While pulling out the shell, it is recom-

mended to hold a foot or hand on the wire
rope, to tighten it up and to observe
whether the shell is sticking.
JM905-2.2 236 27
24.
D05-05
HN905-2.2 227 19
0$1% :'LHVHO$6
Overhaul
Overhaul
905-2.3
1 + 2. 1. 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 re-
installed.
See Instruction book, Volume I,
Chapter 708.
For advice on replacing individual bearing

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

KN905-2.2 238 25
and burrs. If damage is found, contact

MAN B&W Diesel for advice.
• Make sure that all parts are clean, use

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

bearing support and the back of the
shell, with main engine lubricating oil.
0$1% :'LHVHO$6
Mounting
Mounting
905-2.4
1. Clean and lubricate the journal, the lower 1.

bearing shell and the bearing support with
clean oil.
Place the dismantling tool between the

bearing journal and the bearing support.
Place the guide tool for the lower bearing

shell on the main bearing support.
2. Using the bearing shell lifting tool, the pul-

leys and tackles, lift the lower bearing shell
into the crankcase and land it on the crank-
HN905-2.4 227 01
shaft journal. Remove the lifting tool from
the bearing shell.
Check that the hydraulic pressure to the

crosspiece jacks corresponds to the pres-
sure used when the lower shell was re- 2.
moved, and that the crankshaft is still lifted
max. 0.2 mm.
3. Using the dismantling tool, lower the bear-

ing shell down between journal and sup-
port.
Remove the dismantling tool and push the D05-05

shell entirely down with a piece of wood, for
instance a hammer handle.
To ensure that the shell is correctly mount-

ed, check that the distance from the main
HN905-2.2 227 19
bearing support to the shell is equal in both

sides.
3.
HN905-2.4 227 03
0$1% :'LHVHO$6
Mounting
4. 4. Remove the guide tool when the lower

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

support.
Check with a feeler gauge that there is

clearance around the head of the locking
screws, to ensure correct centering of the
bearing shell.
XZS905-13 07
5. Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from below
the crankshaft.
5.
D05-04 Wipe the contact surfaces between the up-
per and the lower bearing shells clean with
a non-fluffy piece of cloth.
6. Land the upper bearing shell on the main

journal in the same way as the lower bear-
ing shell.
XZS905-13 09
Make sure that none of the edges of the up-

per bearing shell are resting on the edge of
the bearing support.
7. 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
D05-03 sure that no oil is left on the contact surfac-
es.
7. Mount the lifting tool on the bearing cap.

HN905-2.2 227 18
Using the lifting tool and the tackles lift the

bearing cap into the crankcase in the re-
verse order to dismantling.
7. 8. Using the pulleys mounted inside the crank-

case, move the bearing cap into position
vertically above the main bearing upper
shell in the reverse order to dismantling.
KN905-2.2 238 20
0$1% :'LHVHO$6
Mounting
9. Land the bearing cap carefully on the upper 9.

bearing shell, using the bearing cap lifting
tool.
Check that the spring pin in the support en-

ters the hole in the bearing cap.
Take care not to displace the upper bearing

shell.
10. Remove the lifting tool from the bearing

cap.
KN905-2.4 238 09
Screw the nuts on to the main bearing
studs.
Using a tommy bar, tighten in small alter-

nate steps the nuts on both sides of the
bearing cap. 10.
11. Assemble the main bearing hydraulic jacks

on the bearing studs.
KN905-2.4 238 10
10.
GN9913-1.0 203 22
0$1% :'LHVHO$6
Mounting
12. 12. Connect the hydraulic jacks to the high

pressure pump by means of the distributor
block and high-pressure hoses.
D13-01
Bleed the hydraulic system and raise the
pressure as indicated in Data.
Using the hydraulic jacks, fully tighten the

nuts on both sides of the bearing cap.
For tightening pressure, see Data.
For operation of the hydraulic tools,

HN905-2.4 227 11
13. Remove the bearing cap lifting tool.
13. Note!
Before removing the hydraulic jacks,

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

D05-01 there are no tools, shackles or rags left
KN 905-1.1 208 09
20 D05-02 behind.
14.
KN905-2.4 238 14
0$1% :'LHVHO$6
Thrust Bearing 105-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10503
105-3 Data 0044 Thrust Bearing
X Stopped engine
Shut off fuel oil
Data
D05-06 Thrust bearing segment 66 kg

D05-07 Segment stopper 47 kg
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data
P90551 100 Tool for turning out segments

P90563 Segment Stopper - Hydraulic Tools
P91356 Lifting Tools, etc.
MAN B&W Diesel A/S
Thrust Bearing 905-3.1
Checking
Thrust Bearing
S50MC-C
0224
Checking
905-3.1
1.
The clearance in the thrust bearing was meas-
ured during testbed trials of the engine and not-
ed down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,

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

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.
GN905-3.1 224 01
1. To measure the wear in the thrust bearing,
it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).
2. To measure the wear, the thrust segment

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

enter the groove (the wear is more than 0,9
mm), the thrust bearing must be over-
hauled.
GN905-3.1 224 02
3. Note down the wear for later reference.
3.
KN905-2.2 238 02
MAN B&W Diesel A/S
905-3.2 Thrust Bearing
Dismantling
Dismantling
905-3.2
1. 1. Remove the lub. oil pipe from the bearing,

the protective shield, and the lub. oil pipe
for the thrust segments.
2. Loosen and remove the nuts from the seg-

ment stoppers.
Procedure 913-1.
Remove the segment stoppers above the

thrust segments (AHEAD or ASTERN) that are
to be taken out, and lift the stoppers out of
the chain casing.
GN905-3.2 224 01
2.
D05-07
D13-02
GN905-3.2 224 02
MAN B&W Diesel A/S
Dismantling
3. Suspend a tackle from the chain tightener 3.

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

on the protective edge on the chain wheel.
4. Turn up the segments, one at a time, by

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

a time.
GN905-3.2 224 03
4.
D05-06
GN905-3.2 224 04
MAN B&W Diesel A/S
905-3.4 Thrust Bearing
Mounting
Mounting
905-3.4
1. 1. Suspend a tackle above the segments

which are to be mounted. Still, it is possible
to lift the segments by hand.
D13-01
Mount the tool for turning out segments on
the chainwheel.
Land the segment on the journal and re-

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

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

turn the segment tool up and dismount it.
GN905-3.4 224 01
2.
GN905-3.4 224 02
MAN B&W Diesel A/S
Mounting
3. Mount the segment stopper. 5.
Mount the hydraulic jacks and tighten the

nuts on the stopper.
For operating hydraulic jacks,

4. Mount the lub. oil pipe for the thrust seg-

ments, the protective shield and the lub. oil
pipe on the bearing.
GN905-3.2 224 01
MAN B&W Diesel A/S
Journal Bearing 105-4
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10504
105-4 Data 0017 Journal Bearing
X Stopped engine
Shut off fuel oil
Data
D05-11 Min. bearing clearance 0.75 mm

D05-12 Max. bearing clearance 0.45 mm
D05-13 Journal bearing cap 507 kg
D05-14 Upper bearing shell 35 kg
D05-15 Lower bearing shell 36 kg
D05-16 End cover 225 kg
MAN B&W Diesel A/S
105-4 Journal Bearing
Data
P90551 88 Dismantling tool, main bearing shell

P90551 90 Mounting tool for bearing shell
P90551 111 Lifting attachment
P90551 172 Mounting tool, thin bearing shell
P90551 184 Lifting tool for main bearing shell
P90561 Main bearing – hydraulic tools
P90562 Lifting tool for crankshaft
P90572 Main bearing – measuring tools
P91366 61 Slide caliper
MAN B&W Diesel A/S
Journal Bearing 905-4.1
Checking
0216 Bearing
Journal S46MC-C
Checking
905-4.1
1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-2.1.
2. Write down the journal bearing clearances.
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2
2. 1. Dismount the screws for the end cover.
Mount a ½-ton tackle above the end cover.
Remove the end cover.

main pipe.
Remove the protective shield for the thrust

bearing.
Turn the crank throw for the aftmost cylin-

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

GN905-2.2 204 13
hydraulic jacks and the nuts on the exten-

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

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

from the engine

bearing studs.
D13-02
GN905-2.2 204 02
4.
KN905-2.2 238 07
MAN B&W Diesel A/S
Dismantling
5. Remove the rectangular nut washers from 5.

the bearing cap. D05-13
Mount the lifting attachment at the journal
bearing cap, and lift the cap out of the en-
gine by using the ½-ton tackle above the
bearing.
6. Mount the lifting attachment on the upper

shell, and lift the shell out of the engine.
7. Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.
GN905-2.2 224 16
Tighten the screw against the turning wheel
Connect the hydraulic jacks to the high- 6.

D05-14
but max. the clearance in the adjacent
bearing.
GN905-2.2 224 17
7.
GN905-2.2 224 19
MAN B&W Diesel A/S
Dismantling
8. 8. Dismount the locking screws.

the bearing shell.
Pull the lower bearing shell round and up-

wards until it lies over the bearing journal.
Never use a tackle larger than 0.5 ton.

lifting tool.
KN905-2.2 238 26
9.
D05-15
GN905-2.2 224 17
MAN B&W Diesel A/S
Overhaul
Overhaul
905-4.3
1. Clean and inspect the bearing shells. It is 1 + 2.


installed.
Chapter 708.


and burrs. If damage is found, contact KN905-2.2 238 25

and bearing support.
• Lubricate the bearing journal, the bear-

ing support and the back of the shell,
with main engine lubricating oil.
MAN B&W Diesel A/S
Mounting
Mounting
905-4.4
1. 1. Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.
D05-15 Using the bearing shell lifting tool, lift the
lower bearing shell into the crankcase and
land it on the crankshaft journal.
2. Position the guide tool for the lower bearing

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

GN905-2.2 224 17
Place the lower bearing shell on the journal

and push it down by hand.

2. ed, check that the distance from the bear-
ing support to the shell is equal in both
sides.
3. Remove the guide tool when the lower


support.
Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from under
the crankshaft.
MC905-3.0 118 19
Wipe the contact surfaces between the up-

3.
XZS905-13 07
MAN B&W Diesel A/S
Mounting
4. Land the upper bearing shell on the main 4.

ing shell.
D05-14
If necessary, place the special tool between


sure that no oil is left on the contact surfac-
XZS905-13 09
es.

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

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

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

and tighten the nuts. See Data.

see Procedure 913-1. 7.
D13-01
MN913-1 208 11
MAN B&W Diesel A/S
Mounting
8. 8.
D05-11
D05-12 Note!


KN 905-1.1 208 09
20
Note!

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

ing cap, and mount the end cover.
KN905-2.4 238 14
10.
KN905-2.4 238 15
MAN B&W Diesel A/S
Checking
0216 Bearing
Journal S46MC-C
Checking
905-4.1
1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-2.1.
2. Write down the journal bearing clearances.
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
MAN B&W Diesel A/S
Dismantling
Dismantling
905-4.2
2. 1. Dismount the screws for the end cover.
Mount a ½-ton tackle above the end cover.
Remove the end cover.

main pipe.
Remove the protective shield for the thrust

bearing.
Turn the crank throw for the aftmost cylin-

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

GN905-2.2 204 13
hydraulic jacks and the nuts on the exten-

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

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

from the engine

bearing studs.
D13-02
GN905-2.2 204 02
4.
KN905-2.2 238 07
MAN B&W Diesel A/S
Dismantling
5. Remove the rectangular nut washers from 5.

the bearing cap. D05-13
Mount the lifting attachment at the journal
bearing cap, and lift the cap out of the en-
gine by using the ½-ton tackle above the
bearing.
6. Mount the lifting attachment on the upper

shell, and lift the shell out of the engine.
7. Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.
GN905-2.2 224 16
Tighten the screw against the turning wheel
Connect the hydraulic jacks to the high- 6.

D05-14
but max. the clearance in the adjacent
bearing.
GN905-2.2 224 17
7.
GN905-2.2 224 19
MAN B&W Diesel A/S
Dismantling
8. 8. Dismount the locking screws.

the bearing shell.
Pull the lower bearing shell round and up-

wards until it lies over the bearing journal.
Never use a tackle larger than 0.5 ton.

lifting tool.
KN905-2.2 238 26
9.
D05-15
GN905-2.2 224 17
MAN B&W Diesel A/S
Overhaul
Overhaul
905-4.3
1. Clean and inspect the bearing shells. It is 1 + 2.


installed.
Chapter 708.


and burrs. If damage is found, contact KN905-2.2 238 25

and bearing support.
• Lubricate the bearing journal, the bear-

ing support and the back of the shell,
with main engine lubricating oil.
MAN B&W Diesel A/S
Mounting
Mounting
905-4.4
1. 1. Lubricate the journal, the lower bearing

D05-15 Using the bearing shell lifting tool, lift the
lower bearing shell into the crankcase and
land it on the crankshaft journal.
2. Position the guide tool for the lower bearing

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

GN905-2.2 224 17
Place the lower bearing shell on the journal

and push it down by hand.

2. ed, check that the distance from the bear-
ing support to the shell is equal in both
sides.
3. Remove the guide tool when the lower


support.
Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from under
the crankshaft.
MC905-3.0 118 19
Wipe the contact surfaces between the up-

3.
XZS905-13 07
MAN B&W Diesel A/S
Mounting
4. Land the upper bearing shell on the main 4.

ing shell.
D05-14
If necessary, place the special tool between


sure that no oil is left on the contact surfac-
XZS905-13 09
es.

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

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

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

and tighten the nuts. See Data.

see Procedure 913-1. 7.
D13-01
MN913-1 208 11
MAN B&W Diesel A/S
Mounting
8. 8.
D05-11
D05-12 Note!


KN 905-1.1 208 09
20
Note!

9. behind.
10. Mount the lubricating oil pipe on the bear-

ing cap, and mount the end cover.
KN905-2.4 238 14
10.
KN905-2.4 238 15
MAN B&W Diesel A/S
Axial Vibration Damper 105-5
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10505
105-5 Data 0037 Axial Vibration Damper
X Stopped engine
Shut off fuel oil
Data
D05-18 Inner studs, screwing-in torque 100 Nm

D05-19 Nuts on inner studs, tightening torque 460 Nm
D05-22 Outer studs, screwing-in torque 100 Nm
D05-23 Horizontal screws, tightening torque 950 Nm
D05-24 Horizontal screws, tightening torque/angle 100/40 Nm/°
D05-25 Damper housing, upper part 600 kg
D13-01 Hydraulic pressure, mounting 1500 Bar
D13-02 Hydraulic pressure, dismantling 1400-1650 Bar
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
Data
P90551 196 Tightening template A.V.D.

P90564 Crankshaft – measuring tools
P90463 Crosshead – hydraulic tools
P91356- Lifting tools, etc.
P91359- Torque spanners
P91366- 61 Slide caliper
MAN B&W Diesel A/S
Axial Vibration Damper 905-5.1
Checking
Axial Vibration Damper
S46-S50MC-C
0224
Checking
905-5.1
1.
For checking the effectiveness of the axial vi-
bration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken

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

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

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

control system.
1. Concerning overhaul and setting of the

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

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

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

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

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

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

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

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

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

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

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

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

calculated as follows:

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

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

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

housing.
Apply some Molycote TM on the fore side of

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

using the screws from the cover.
Attach a pencil to the arm.

BG905-5.1 223 01C
Note!
To obtain a correct measurement, the tip

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

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

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

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

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

calculated as follows:

MA905-5.1 212 07

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

ried out from the crankcase of cyl. No. 1.
D13-02
1. Turn the engine to 90º after TDC.
Dismount the lubricating oil pipes for the

main bearing and axial vibration damper.
Loosen and remove the nuts from the inner

studs and the hydraulic nuts from the outer
studs. For operation of the hydraulic tools,
GN905-5.2 204 01
Loosen and remove the horizontal screws.
Only the upper part of the housing needs to

be removed, while the lower half remains
mounted on the bedplate.
2.
2. Mount an eyebolt in the centre lifting hole
on the upper part.
Engines with chain box fore:

Mount a tackle in the bracket above the ax-
ial vibration damper inside the chain box.
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. By means of the tackle and wire rope, sep-

GN905-5.2 204 02
arate and raise the upper part of the damp-

er housing to a position in which it is
possible to change the oil seals and
springs.
3.
D05-25 Note!
Before starting the work under the sus-

pended upper part, secure the upper part
with, e.g. a wire rope or another tackle.
GN905-5.2 224 03
MAN B&W Diesel A/S
Overhaul
Overhaul
905-5.3
1. Dismantle and remove the springs from the 1.

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

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

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

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

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

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

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

care that the rings enter the sealing ring
grooves correctly.
D05-25
Before landing the upper part on the lower
part, be sure that the guide pins have en-
tered the guide pin holes.
2. Mount and tighten the vertical nuts. See

Data.
Mount and tighten the hydraulic nuts. For

operation of the hydraulic tools, see Proce-
dure 913-1.
Mount and tighten the horizontal screws.

See Data.
Note!
GN905-5.4 224 01

behind.
2.
Mount the lubricating oil pipes.
D05-18
D05-19 Engines without chainbox fore:
Mount the cover for the lifting hole above
D05-22 the axial vibration damper.
D13-01
Note!
After overhaul of the axial vibration

damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
D05-23
D05-24
GN905-5.4 224 02
MAN B&W Diesel A/S
Crankshaft, Thrust Shaft, Main Bearing, Etc. - Plate
P90551-0237
Panel
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing, Etc. -
P90551-0237
Panel
No. No.
015 Panel for tools

027 Name plate
040 Wire pulley for main bearing
064 Wire pulley for main bearing
076 Lifting tool for main bearing cap
088 Dismanteling tool for main bearing
shell
090 Mounting tool for thin bearing shell
100 Tool for turning out segments
111 Lifting attachment
123 Retaining tool for main bearing shell
135 Lifting tool for relief valve
147 Lifting tool for relief valve
159 Eye bolt
160 Wire
172 Mounting tool for thin bearing shell
184 Lifting tool for main bearing shell
196 Tightening template A.V.D.
MAN B&W Diesel A/S
Main Bearing - Hydraulic Tools Plate
P90561-0064
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0064

No. No.

045 Lifting tool
057 Nut
069 Hydraulic jack, upper
070 Extension stud
082 Supporting block
094 Stud setter
128 Hydraulic jack, lower
141 Hydraulic tool for main bearing,
complete
MAN B&W Diesel A/S
Crankshaft - Tools Plate
Plate
Crankshaft - Tools

No. No.
015 Lifting tool for crankshaft
Turning Wheel - Tools Plate
P90563-0024
MAN B&W Diesel A/S
Plate Turning Wheel - Tools
P90563-0024

No. No.
022 Hydraulic jack

034 Support
046 Tommy bar
083 Spanner
095 Stud setter
201 Hydraulic jack for segment stopper,
complete
MAN B&W Diesel A/S
Crankshaft - Measuring Tools
Tools Plate
Plate
Tools

No. No.
016 Measuring tool for axial movement
Crankshaft - Measuring Tools Plate
P90564-0020
0020
P90564
Flange on end of crankshaft
Flange on end cover fore
When ordering item 016 or 028, please always state measurement “Z”
MAN B&W Diesel A/S
Plate Crankshaft - Measuring Tools
P90564-0020
Item Item
No. No.
016 Measuring instruments, axial vibration

damper
028 Shaft, measuring instruments axial vi-
bration
041 Measuring instruments, axial vibration
damper
053 Handle - sundry types
MAN B&W Diesel A/S
Thrust Shaft - Tools Plate
P90570-0001
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0001

No. No.
019 Lifting tool for thrust shaft
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0005
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0005

No. No.
010 Feeler gauge set

069 Feeler gauge
070 Feeler gauge
082 Feeler gauge
094 Feeler gauge
104 Feeler gauge
116 Feeler gauge
128 Feeler gauge
141 Feeler gauge
153 Feeler gauge
165 Feeler gauge
177 Feeler gauge
189 Feeler gauge
190 Feeler gauge
200 Feeler gauge
212 Feeler gauge
224 Feeler gauge
236 Feeler gauge
248 Feeler gauge
261 Feeler gauge
332 Spare tip for feeler gauge
MAN B&W Diesel A/S
906 - Control Gear
106-01 0042 Chain, Data

906-01 0232 Chain
106-02 0035 Chain Tightener, Data
906-02 0230 Chain Tightener
106-03 0030 Camshaft, Data
906-03 0214 Camshaft
106-04 0029 Camshaft Bearing, Data
906-04 0218 Camshaft Bearings
106-06 0005 Replacement of Cams on Camshaft, Data
906-06 0204 Replacement of Cams on Camshaft
90651 0185 Chain Drive and Camshaft - Panel
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Chain 106-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10601
106-1 Data 0042 Chain
X Stopped engine
Shut off fuel oil
Data
D06-01 1” Chain
D06-02 Teeth on chain wheel, max. wear 0.9 mm
D06-03 Original length (chain pitch x 10 links) 254 mm
D06-04 10 links measurements + 1% of a tensioned chain = scrapping of chain 256.5 mm
D06-13 4” Chain
D06-14 Teeth on chain wheel, max. wear 3.5 mm
D06-15 Original length (chain pitch x 10 links) 1016 mm
D06-16 10 links measurements + 1% of a tensioned chain = scrapping of chain 1026 mm
MAN B&W Diesel A/S
106-1 Chain
Data
P90651 56 Chain assembling tool

P90651 68 Chain disassembling tool
P90651 70 Chain assembling tool
P90651 81 Chain disassembling tool
P91359 Torque spanners
MAN B&W Diesel A/S
Chains 906-1.1
Checking
Chains
S60MC-C
0232
Checking
906-1.1
2.
1. The engine is equipped with two sets of
chains:
• the drive chains for the camshaft
• the drive chain for the cylinder lubricators
Both sets of chains are to be checked and,

if necessary, dismantled and mounted in
the same way.
Note!
There are two sets of dismantling and

mounting tools available, one for each
set of chains.
2. Both sets of chains can be accessed from

within the chainwheel frame.
3. Carry out the inspection as follows:

HG906-2.1 97 02
• Make a general inspection for loose bolts

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

check jet nozzles for possible stoppages 4.
or deformations.
• Examine the rubber track of the guide-

ways 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 ab-

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

short straight-edge over points A and B and
then measuring the distance D-1.
KG906-1.1 202 04
D06-02
D06-14
0$1% :'LHVHO$6
906-1.1 Chains
Checking
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 profile.
For assessing the wear profile, contact

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

side plates of the chain will be found on the
sides of the teeth. Such scratches can gen-
erally 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,
KG906-1.1 203 05
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 de-

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

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

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

checked.
0$1% :'LHVHO$6
Chains 906-1.1
Checking
7. Check chain wear by measuring the length 7.

of 10 chain links. Use two master squares
and a steel measuring tape as shown on
D06-03
the sketch. Compare the result with the val- D06-04
ue given in Data. D06-15
If necessary, adjust the chain tightener. D06-16
See Procedure 906-2.3.S
MMa ax. D
M
axx. .D 06-
D006- 16
65-08
4
HM906-1.1 203 07
0$1% :'LHVHO$6
906-1.2 Chains
Dismantling
Dismantling
906-1.2
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.
Note!
Every time a chain link is disassembled,

a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.
HG906-2.1 97 02
When a new link is fitted in one chain, the

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

ening 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 dis-
assembled, is in a favourable position for
the work.
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

GN906-1.2 203 02
is wrapped.
Note!
3. If the chain is to be completely removed,
contact MAN B&W Diesel for further
information.
The riveting of the pins that are to be

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

chain link, and dismantle the link by alter-
nately tightening the screws on the tool.
GN906-1.2 203 03
0$1% :'LHVHO$6
Chains 906-1.4
Mounting
Mounting
906-1.4
Before assembling the inner and outer 1.

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

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

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

the compression tool and lock the pin ends
by riveting.
GN906-1.4 203 01
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).
0$1% :'LHVHO$6
Chain Tightener 106-2
Data
SAFETY PRECAUTIONS
Special Edition
D10602
106-2 Data 0035 Chain
S60MC-C
Tightener
X Stopped engine
Shut off fuel oil
Data
D06-21 Tightening angle = 5.5 hexagons 330 °/hex

D06-25 Mechanical or blocked chain tightener, clearance 0.1 mm
MAN B&W Diesel A/S
106-2 Chain Tightener
Data
MAN B&W Diesel A/S
Chain Tightener 906-2.3
Adjustment
Chain Tightener
S60MC-C
0230
Adjustment
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,
C and D to free the chain tightener bolt. A
B
2. Turn the engine at least one revolution with
the chain slackened on the same side as
the chain tightener wheel.
If the engine is equipped with flyweights,

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

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

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

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

be carried out depends on when the limit for
C scrapping the chain has been reached. See
Data page 106-1.
D
HG906-2.3 218 05
5.
A
HG906-2.3 218 05
0$1% :'LHVHO$6
Camshaft 106-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10603
106-3 Data 0030 Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-27 Max. permissible change in lead angle 2 °

D06-28 corresponding to 4.5 mm
D06-29 Pin gauge for top dead centre of crankthrow No.1, check measurement 799 mm
D06-30 Pin gauge for camshaft, check measurement 402 mm
MAN B&W Diesel A/S
106-3 Camshaft
Data
P90668 Camshaft – pin gauge
MAN B&W Diesel A/S
Camshaft 906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1
1.
1. Turn the crankthrow 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.
HM906-7.0 56 01
Check the TDC of cylinder 1 against the
mark on the turning wheel.
2. Check the TDC position with the pin gauge 2.

on the crankthrow.
GN906-3.1 203 02
D06-29
MAN B&W Diesel A/S
906-3.1 Camshaft
Checking
3. 3. Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see Data.
4. Check and, if necessary adjust the cylinder

lubricator. See Procedure 903-2.1.
D06-30
Check the setting of the starting air distrib-
utor. See Procedure 907-1.1.
D06-28
5. When checking the camshaft position, also
check the running surface of the cams.
D06-27 As the inspection must include the entire

GN906-3.1 203 03
surface of the cam, the cam should be

turned one complete revolution during the
inspection.
The running surface of the cam must be

5.
completely smooth and bright.
6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a fine carborun-
dum stone. Such light scratches can appear
if the roller guide and the cam are not cor-
rectly aligned.
GN906-3.1 203 05
In the event of heavier scratches or direct

flaking of the material on the running path,
MAN B&W Diesel should be contacted for
further instructions.
6.
GN906-3.1 203 06
MAN B&W Diesel A/S
Camshaft 906-3.3
Adjustment
Adjustment
906-3.3
1. If the chains prove to be so heavily worn 1.

that the deviation between the measuring
points and the pin gauge has reached the
maximum value stated in Procedure 906-
3.1, MAN B&W Diesel should be contacted
for further instructions.
D06-28
D06-27
GN906-3.3 203 01
MAN B&W Diesel A/S
Camshaft Bearings 106-4
Data
SAFETY PRECAUTIONS
Special
D10604 Data 0029
106-4 Edition Camshaft
S60MC-CBearings
X Stopped engine
Shut off fuel oil
Data
D06-31 Screws for bearing cap, tightening torque 210 Nm

D06-33 Clearance between cap/bearing housing 3+/-0.3 mm
D06-34 Bearing shell, max. wear 0.1 mm
D06-37 Camshaft bearing cap 17 kg
MAN B&W Diesel A/S
106-4 Camshaft Bearings
Data
P90651 139 Lifting attachment for camshaft bearing

P90651 152 Hydraulic jack for lift of camshaft
P91359 Torque Spanners
MAN B&W Diesel A/S
Camshaft Bearing 906-4.1
Checking
Camshaft Bearing
S60MC-C
0218
Checking
906-4.1
1.
1. Dismount the inspection covers from the
front of the camshaft housing.
Check for wiped-out metal at the bearing

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

bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced.
If no anomalies are found during the visual

inspection, dismantling need only be car-
ried out in connection with Class surveys.
NA906-4.1 207 01
0$1% :'LHVHO$6
906-4.2 Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Caution!
Before dismantling any camshaft bear-

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

camshaft housing. Remove and discard the
gaskets.
NA906-4.2 207 01
Dismount the plug screws from the base-

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

draulic pump. See Procedure 908-7.
2.
2. Dismount the lubricating oil connecting
pipe.
Using a socket spanner mounted on an ex-

tension, loosen the bearing cap screws
through the outer holes in the baseplate.
3. Through the middle hole in the baseplate,

screw the centre rod of the lifting tool into
the bearing cap.
Use the lock nut on the lifting tool to lift the

bearing cap clear of the camshaft.
NA906-4.2 207 02
3.
D06-37
HN906-4.2 218 03
0$1% :'LHVHO$6
Dismantling
4. Place the hydraulic jack in the camshaft 4.

housing in front of the fuel cam.
Place a dial gauge on the camshaft, and lift

the camshaft 0.30 mm.
5. Press lightly on the upper edge of the shell

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

ing.
HN906-4.2 218 04
5.
HN906-4.2 218 05
0$1% :'LHVHO$6
Overhaul
Overhaul
906-4.3
1. 1. For assessment of the bearing condition,

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

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

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

the bearing shell visually, an impression
can be formed of whether the lubrication of
the bearing surface has been insufficient or
entirely missing. Normally, camshaft bear-
ing damage only occurs due to faulty lubri-
cation.
Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.
HN906-4.3 218 01
D06-34
0$1% :'LHVHO$6
Mounting
Mounting
906-4.4
1. Clean the bearing journal, the bearing sup- 2.

port and the bearing shell.
2. Coat the bearing shell with oil, mount the

shell on the camshaft, and turn it into place.
Using a caliper at both sides of the bearing

shell, check that the bearing is positioned
absolutely horizontally.
3. Lower the camshaft and remove the dial

gauge and the hydraulic jack from the en-
gine.
HN906-4.2 218 05
4. Lower the bearing cap on to the camshaft.
Remove the lifting tool from the bearing
cap.
HN906-4.4 218 03 3.
4.
D06-37
HN906-4.4 218 04
0$1% :'LHVHO$6
Mounting
5. 5. Mount the bearing cap screws.
Tighten both screws lightly.

D06-31
Using a socket spanner mounted on an ex-
tension and a torque wrench, tighten the
screws to the torque stated in Data.
Note!
To ensure that the bearing cap is not

displaced, the tightening must be done
in steps as follows:
NA906-4.2 207 02
1. Tighten the outermost screw

to half the torque stated in Data.
6. 2. Tighten the innermost screw

to half the torque stated in Data.
D06-33 3. Tighten the outermost screw

to the full torque stated in Data.
4. Tighten the innermost screw

to the full torque stated in Data.
6. Check the clearance between the bearing

cap and the bearing housing.
Mount the lubricating oil pipe on the bear-

ing cap.
NA906-4.4 207 06
Mount the plug screws in the baseplate.
7. Clean the camshaft housing and mount the

7. inspection covers, fitted with new gaskets.
NA906-4.4 207 07
0$1% :'LHVHO$6
Replacement of Cams on Camshaft 106-6
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10606
106-6 Data 0005 Replacement of Cams on Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-47 Exhaust cam screws, tightening torque 900 Nm

or 100 Nm
+ 30 °
D06-49 Fuel cam screws, tightening torque 1820 Nm
or 100 Nm
+30 °
D06-50 Fuel cam, marking scratch 115 mm
D06-51 Fuel cam, axial movement 155 mm
D06-52 Exhaust cam, marking scratch 105 mm
D06-53 Exhaust cam, axial movement 190 mm
MAN B&W Diesel A/S
106-6 Replacement of Cams on Camshaft
Data
P90851 173 Lifting tool for exhaust valve roller guide

P91351 22 Hydraulic pump, hand operated
P91351 166 Angle union
MAN B&W Diesel A/S
Replacement of Cams on Camshaft 906-6.2
Dismantling
Replacement of Cams on Camshaft
S60MC-C
0204
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft

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

tion. See Procedure 909-10.
3. Turn the camshaft so that the marking

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

D06-50. See Data.
XZ906-6.2 201 01
HHN909-10.1 205 01 2.
4.
XZ906-6.2 201 04
D06-50
0$1% :'LHVHO$6
906-6.2 Replacement of Cams on Camshaft
Dismantling
5. 5. Remove the plug from the cam and mount

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

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

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

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

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

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

6. scribed in item 6, MAN B&W should be con-
tacted for further instructions.
XZ906-6.2 201 06
7.
D06-51
XZ906-6.2 201 07
D06-51
0$1% :'LHVHO$6
Dismantling
Exhaust Cam 9.
9. Remove the front cover of the camshaft

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

tion. See Procedure 908-7.
11. Extend the marking scratch on the indicator

drive cam onto the camshaft.
Extend the marking scratch on the exhaust
XZ906-6.2 201 01
cam onto the camshaft by D06-52. See Da-
ta.
10.
JM908-5.0 55 03
11.
XZ906-6.2 201 11
D06-52
0$1% :'LHVHO$6
Dismantling
12. 12. Dismantle and remove the indicator drive

cam from the camshaft when fitted.
13. Remove the plug from the cam and mount

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

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

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

the cam sideways, in the direction towards
XZ906-6.2 201 12
the aft end of the engine.
13.
XZ906-6.2 201 13
14.
XZ906-6.2 201 14
0$1% :'LHVHO$6
Dismantling
15. The cam should be moved as stated in 15.

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

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

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

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

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

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

909-1 and 909-3) and adjust if necessary.
XZ906-6.4 201 01
Tighten the screws to D06-49 and check

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

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

shaft housing.
D06-49
XZ906-6.4 201 02
0$1% :'LHVHO$6
Mounting
Exhaust Cam 4.
4. Mount the indicator drive cam and adjust

according to Chapter 706 in the Operation
manual when fitted.
Tighten the self-locking nuts as stated in

D06-48.
5. Before mounting the two-part spare cam,

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

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

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the exhaust cam lead (see Proce-

dure 908-5 and adjust if necessary.
Tighten the screws to D06-47 and check

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

(EN243S).
7. Mount the cover on the front of the cam- 6.

shaft housing.
XZ906-6.4 201 06
D06-47
D06-49
0$1% :'LHVHO$6
Chain Drive and Camshaft - Panel Plate
P90651-0185
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft - Panel
P90651-0185

No. No.
019 Panel for tools

020 Name plate
044 Impact spanner, fuel cam
056 Assembling tool, chain
068 Disassembling tool, chain
070 Assembling tool, chain
081 Disassembling tool, chain
140 Hydraulic jack, lift of camshaft
152 Lifting attachment camshaft bearing
MAN B&W Diesel A/S
Crankshaft - Pin Gauge Plate
P90664-0005
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0005

No. No.
021 Pin gauge for crankshaft
MAN B&W Diesel A/S
Camshaft - Pin Gauge Plate
P90668-0003
MAN B&W Diesel A/S
Plate Camshaft - Pin Gauge
P90668-0003

No. No.
011 Pin gauge
MAN B&W Diesel A/S
107-01 0018 Starting Air Distributor, Data

907-01 0217 Starting Air Distributor
107-02 0034 Start Air Valve, Data
907-02 0216 Starting Air Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Starting Air Distributor 107-1
Data
SAFETY PRECAUTIONS
Special Edition
D10701
107-1 Data 0018 Starting
L60MC-C
Air Distributor
X Stopped engine
Shut off fuel oil
Shut off lubricating oil
Data
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data
MAN B&W Diesel A/S
Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
L60MC-C
0217
Checking
907-1.1
2.
1. Turn the engine to bring the piston of cylin-
der No. 1 to TDC. Check the position with
the pin gauge.
2. Remove the small end cover of the distrib-

utor housing.
3. Check that the TDC marking scratch on the

starting cam is positioned vertically at the
valve slide of cylinder No. 1.
4. If necessary adjust the position of the start-
HN907-1.1 205 02
ing cam by loosening the centre screw and
turning the starting cam until the TDC
marking scratch is positioned vertically at
the valve slide of cylinder No. 1. Then tight-
en the centre screw.
HN907-1.1 205 03 3.
4.
HN907-1.1 205 04
MAN B&W Diesel A/S
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 dur-
ing 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.
HN907-1.3 205 02
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.
3.
Experience will show how often this is neces-
sary to prevent starting difficulties, as differenc-
es will be found from plant to plant.
1. Blank off the main starting air and the con-

trol 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.

HN907-1.3 205 04
MAN B&W Diesel A/S
Overhaul
5. Remove the complete slide valve (with 5.

spring and the upper liner) from the distrib-
utor 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
907-1.3 217 06 6.
7.
MC907-2.2 29 07
MAN B&W Diesel A/S
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!
Polishing of the liners with emery cloth

must not take place as small particles of
907-1.3 217 08
the grinding material can stick in the sur-

face of the liner.
Lubricate all parts with Molybdenum Disul-

10. phide (MoS 2), 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 dis-

tributor housing. (Check that the pin of the
valve slide goes clear of the starting cam
when mounting).
907-1.3 217 10
Lubricate the groove in the starting cam

with Molybdenum Disulphide (MoS 2).
11.
907-1.3 217 11
MAN B&W Diesel A/S
Overhaul
12. Mount the guide screw for the valve slide. 12.
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 overcom-
ing the force of the spring.
14. Finally, mount the two end covers and con-

nect the main starting air and the control
air.
HN907-1.3 205 04
HN907-1.3 205 02 14.
MAN B&W Diesel A/S
Starting Air Valve 107-2
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10702
107-2 Data 0034 Starting Air Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D07-11 Valve tightening angle 60 °

D07-12 Starting air valve 52 kg
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data
P90151 95 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve
MAN B&W Diesel A/S
Starting Air Valve 907-2.1
Checking
Starting Air Valve
L60MC-C
0216
Checking
907-2.1
1.
1. When the starting air valve has been over-
hauled, 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.
HM907-2.1 202 01A
2.
HM907-2.1 202 01B
MAN B&W Diesel A/S
907-2.2 Starting Air Valve
Dismantling
Dismantling
907-2.2
1. 1. Shut off the starting air and control air inlet.
Dismount the control air pipe.
Hook a lifting wire around the starting valve

and attach the crane hook to the wire.
Unscrew the fixing nuts of the starting valve

flange.
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
JN907-2.2 205 01
2.
JN907-2.2 205 02
D07-12
MAN B&W Diesel A/S
Overhaul
Overhaul
907-2.3
1. Place the starting air valve horizontally in a 1.

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.
HM907-4.0 39 01
Remove the screws and discard the locking
device.
When unscrewing, the piston will partially 2.

be pressed out of the valve housing due to
the spring force.
HM907-4.0 39 02
3.
HM907-4.0 39 03
MAN B&W Diesel A/S
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
MAN B&W Diesel A/S
Overhaul
7. Thoroughly clean the valve housing and all 7.

the parts in diesel oil or kerosene.
Lubricate all internal parts and sliding sur-

faces 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.
Lock the screws with locking device.

HM907-4.0 39 07
For correct use of locking device, see Pro-

cedure 913-7.
9. Mount and tighten the top cover.
Fit a new O-ring on the valve housing. 9.
10. Check the starting air valve.

If the valve is not to be mounted in the en-

gine immediately, cover all openings with
plastic to prevent dirt from entering the
valve during storage.
HM907-4.0 39 09
MAN B&W Diesel A/S
Mounting
Mounting
907-2.4
1. 1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recon-
dition 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.
3. Mount the nuts and tighten-up in at least

HG907-2.4 201 01
three steps, to reach the full tightening an-

gle, see Data.
Mount the control air pipe and turn on start-

ing air and control air.
2.
JN907-2.4 205 02
D07-12
3.
D07-11
D07-11
HM901-2.2 114 03
MAN B&W Diesel A/S
908 - Exhaust Valve
108-01 0031 High-Pressure Pipe, Data

908-01 0226 High-Pressure Pipe
108-02 0059 Exhaust Valve, Data
108-03 0034 Exhaust Valve Actuator, Data
908-03 0227 Exhaust Valve Actuator
108-04 0031 Exhaust Valve Roller Guide, Data
908-04 0217 Exaust Valve Roller Guide
108-05 0010 Exhaust Valve Cam, Data
908-05 0214 Exhaust Valve Cam
108-07 0031 Exhaust Valve - Special Running, Data
90851 0165 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool
MAN B&W Diesel A/S

MAN B&W Diesel A/S
High-Pressure Pipe 108-1
Data
SAFETY PRECAUTIONS
Special
D10801 Data 0031
108-1 Edition High-Pressure
S60MC-C Pipe
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D08-01 High-pressure pipe, tightening torque 70 Nm

D08-02 Distance of high-pressure pipe lower edge to pressure flange 16 mm
D08-03 High-pressure pipe 38 kg
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data
P90851 112 Grinding mandrel for high-pressure pipe
MAN B&W Diesel A/S
High-Pressure Pipe 908-1.2
Dismantling
908-1.2
Disling
908-1.2
Dismantling 1.
1. When replacing the hydraulic high-pressure

pipe, the exhaust valve or the hydraulic ac-
tuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.
2. Before dismantling the high-pressure pipe,

stop the camshaft oil pump.
Loosen the screws for the high-pressure

pipe and lift the pipe slightly away from the D0803
actuator to let the oil in the pipe drain
through the drain holes in the actuator.
M908010226D01
2.
M908010226D02
MAN B&W Diesel A/S
908-1.3 High-Pressure Pipe
Overhaul
1. Check the contact surfaces of the pressure

1.
pipe for marks and, if necessary, grind the
pipe ends by means of the grinding man-
drel and the two guiding tools.
Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and
finish with a fine grinding paste, for ex-
ample 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
M908010226O01
surface at both ends of the pipe. This mea-

surement is to correspond with the value
Carborundum stated in Data.
Check the thrust pads in the exhaust valve

and the actuator for marks on the sealing
2. surface.
Replace the O-rings on the thrust pads.
If considered necessary, replace the thrust

pads.
Lift the thrust pad free by, for example, us-

ing a screwdriver in the groove of the
thrust pad.
M908010226O02
D0802
MAN B&W Diesel A/S
High-Pressure Pipe 908-1.4
Mounting
1. Mount the hydraulic high-pressure pipe as

1.
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 diago-
nally, see Data.
M908010226M01
2. Check the whole system for tightness.
See Procedure 908-3.1. D0801
2.
M908010226M02
MAN B&W Diesel A/S
Exhaust Valve 108-2
Data
SAFETY PRECAUTIONS
Special Edition
L60MCC
D10802
108-2 Data 0059 Exhaust Valve
X Stopped engine
Shut off fuel oil
X Lock turbocharger rotors
Data
D08-04 Safety valve, opening pressure 21 bar

D08-05 Screws for lifting eye bolt, tightening torque 50 Nm
D08-06 Oil cylinder, tightening torque 100 Nm
D08-07 Safety valve, tightening torque 50-80 Nm
D08-09 Bottom piece seat, grinding angle 30+0/-0.1 °
D08-10 Valve spindle seat, grinding angle 30.3+0.1/-0 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1 mm
D08-13 Spindle, max. burn-off 9 mm
D08-14 Spindle, max. grinding 2 mm
D08-15 Spindle stem, measuring area, min. 280 mm
D08-16 Spindle stem, measuring area, max. 410 mm
D08-17 Spindle stem, min. diameter 71.8 mm
D08-18 Bushing max. diameter, top 72.6 mm
D08-19 Bushing max. diameter, bottom 74.5 mm
D08-20 Oil cylinder max. inside diameter 85.4 mm
D08-21 Piston rings, min. thickness 3.2 mm
D08-22 Damper piston, min. distance 48.4 mm
D08-23 Damper piston, max. distance 51.4 mm
D08-24 Exhaust valve, complete 710 kg
D08-25 Exhaust valve housing 380 kg
D08-26 Oil cylinder 100 kg
D08-27 Air cylinder 30 kg
D08-28 Spindle 73 kg
D08-29 Bottom piece 100 kg
D08-30 Air piston 9 kg
MAN B&W Diesel A/S
108-2 Exhaust Valve
Data
P90851 65 Lifting tool for exhaust valve

P90851 77 Cone ring for pneumatic piston
P90851 89 Pressure tester for safety valve
P90851 90 Gauge for exhaust valve spindle
P90851 136 Bridge gauge for exhaust valve
P90851 148 Tool for hydraulic piston
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90861 Valve seat and spindle grinder
P90862 Hydraulic jack, complete
MAN B&W Diesel A/S
Exhaust Valve 908-2.1
Checking
Exhaust Valve
L60MC-C 0240
Checking
908-2.1
1.
Checks during running:
Check of valve spindle rotation
1. The engine must run when the valve func-

tion and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90° and let it rest on the air piston. The in-
dicator will now follow the movements of the
valve spindle.
During rotation of the valve spindle, the top

position of the indicator will change about 6
mm, see the sketch.
During engine operation, the spindle must

rotate in the range of 0.5 to 5 rpm. The ro-
NB908-2.1 229 01
tation can vary with unit and engine load. In
the event of no rotation, attention should be
paid to avoid seat problems.
On Surface In Groove
When check of the valve rotation is fin-
ished, lift the rotation indicator and lock it in
the top position. 2.
Note!
The indicator must not be in constant

operation.
Check of bottom piece sealings
2. When the exhaust valve is mounted in the

MN908-2.1 214 02
cylinder cover, and the cooling water inlet to

the cylinder cover and exhaust valve is
open, check the tightness of the sealing
ring between the bottom piece and the cyl-
inder cover by ensuring that water does not 3.
flow from the bore on the top side of the
bottom piece on the manouevring side.
If water does flow from this bore, the ex-
haust valve must be dismounted and the
sealing rings replaced.
Check of sealing oil control unit
3. When the engine is running, check that the

indicator pin is moving regularly in connec-
HH908-2.1 240 03
tion with the valve opening. Alternatively,

unscrew the sealing oil pipe and check that
oil is coming out (only a small quantity).
MAN B&W Diesel A/S
908-2.1 Exhaust Valve
Checking
4. Checks with stopped engine:
Check of air sealings
4. Open the air supply to the air spring of the

exhaust valve.
Engage the rotation indicator and check

that the exhaust valve is closed.
Close the air supply to the exhaust valve,

and vent the system.
5. Disengage the air pipe to the exhaust valve.
The valve should remain closed for at least

15 minutes
6. An additional check with compressed air

can be carried out as follows:
Connect compressed air to the air cylinder

to close the valve.
HH908-2.1 240 04
• After shutting-off the compressed air

Closed valve Open valve supply and releasing the air through the
non-return valve on the side of the air
cylinder, the exhaust valve should open.
5.
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.
• After doing this a couple of times, leave

the valve closed and shut-off the com-
pressed air. The valve should remain
closed for at least 15 minutes.
• If the valve opens within 15 minutes, the

complete exhaust valve should be
replaced by a new one, see Procedure
908-2.2.
GN908-2.2 236 05
For overhaul of the exhaust valve, see

Procedure 908-2.3.
Disengage the rotation indicator.
MAN B&W Diesel A/S
Dismantling
Dismantling
908-2.2
1. Close the cooling water inlet and outlet, and 1.

drain the exhaust valve.
Dismount the high-pressure pipe for the hy-

draulic valve actuation.
Disconnect the cooling water outlet pipe

from the exhaust valve.
Dismount the return oil pipe from the ex-

haust valve.
GN908-2.2 236 01
2. Dismount the air pipe for the pneumatic ex-
haust valve spring.
Remove the screws of the cooling water in-

let flange at the side of the exhaust valve.
2.
3. Remove the plate jacket with insulation
from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the inlet pipe of the exhaust receiver.
GN908-2.1 236 05
3.
GN908-2.2 236 03
MAN B&W Diesel A/S
Dismantling
4. 4. Remove the protective caps from the ex-

haust valve studs, and mount the four hy-
D13-02 draulic jacks.
Connect the high-pressure pump to the

jacks by means of the distributor block and
four high-pressure hoses.
Bleed the hydraulic system and raise the

pressure as stated in Data. Then loosen
and remove the nuts.
HH908-2.2 240 04
5. Attach the crane to the eye bolt fitted on top

of the valve and lift the exhaust valve away.
Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
5. ing and sealing surfaces of the bore, if re-
quired.
D08-24
HH908-2.2 240 05
MAN B&W Diesel A/S
Overhaul
Overhaul
908-2.3
1. Place the exhaust valve on a wooden sup- 1.

port on the platform.
Remove the oil pipe for the spindle sealing

oil.
2. Remove the eight nuts and the safety strap

from the oil cylinder.
Lift away and place the oil cylinder on a

wooden support.
3. Dismount and inspect the O-rings and the
HH908-2.3 240 01
thrust piece of the hydraulic high-pressure
pipe for marks. See Procedure 908-1.
Replace the O-rings and thrust piece, if

necessary.
2.
Check the functioning of the exhaust valve
rotation indicator.
D08-26
HH908-2.3 240 02
3.
HH908-2.3 240 03
MAN B&W Diesel A/S
Overhaul
4. 4. Loosen the screws and remove the lifting

eye from the oil cylinder to gain access to
the orifice plug and the sealing oil control
unit.
Remove the sealing oil unit.
Unscrew and clean the orifice plug.
Check and clean the bore for the orifice

plug in the top of the oil cylinder.
5. 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
HH908-2.3 240 04
clean it on the machined faces.
If the unit needs to be overhauled, send it

to an authorised MAN B&W repair shop.
5.
GN908-2.3 236 05
MAN B&W Diesel A/S
Overhaul
6. Place the oil cylinder in a horizontal posi- 6. D08-20

tion.
Remove and discard the sealing ring.
Remove the flange and take out the piston.
KG908-2.0 115 04
Inspect the bore of the oil cylinder for scor-
ing and check its measurements.
If the diameter of the bore exceeds the val-

ue stated in Data, send the oil cylinder to 7.
an MAN B&W authorized workshop for re-
pair.
7. Relieve the air pressure through the non-re-

turn 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 flange on

top of the air piston, and dismount the
flange.
GN908-2.3 236 07
Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring.
8. Pass lifting straps through the four bores of

8.
the valve housing and 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 seal-
ing arrangement at the bottom of the air cyl-
inder pass the groove for the conical ring at
the top of the spindle.
GN908-2.3 236 08
MAN B&W Diesel A/S
Overhaul
9. 9. Unscrew and remove the lock screws which

retain the bottom piece. Lift the valve hous-
ing approx. 10 mm.
D08-25
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.
Bottom piece:
10. Inspect the seating of the bottom piece

carefully for damage and check with the
bottom piece template.
Note!
Before using the bottom piece template,

D08-29 thoroughly clean the contact faces on the
valve housing w-seat with a steel brush.
GN908-2.3 236 09
All measurements should be taken at four

diametrically opposite points on the
circumference of the bottom piece
seating.
10. Small dent marks in the bottom piece

seating are acceptable and need not be
ground away, provided that the dent
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
exhaust gas receiver.
G3
For further evaluation of the bottom piece
seating, see also Chapter 707 in the
instruction book, Volume I, Operation.
Take measurements G 2 and G3, using a

feeler gauge. Compare the results with the
figures stated in Data D08-11 and D08-12.
IF burn marks are visible on the bottom

piece seating OR G3 does not equal D08-
D08-09
12, THEN the bottom piece seat must be
ground.
G2 IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN the bottom
MB908-2.3 230 12
piece seating must be discarded and re-

placed with a new bottom piece. Further
grinding or reconditioning is not recom-
mended.
MAN B&W Diesel A/S
Overhaul
11. If it is necessary to grind the seating, pro- 11.

ceed as follows:
Before placing the bottom piece on the

grinding machine, turn the grinding head
away from the grinding table.
D08-09
Mount and secure the bottom piece in the
grinding machine. Using a dial gauge,
check that the bottom piece is correctly
centered.
Adjust the grinding head to achieve the cor-
MB908-2.3 230 11
rect grinding angle as stated in Data.
Note!
As the grinding angle is very important 12.

for the correct operation of the exhaust
valve, make absolutely sure that the
D08-09
grinding head is correctly adjusted.
G3
Regarding the use of the grinding machine,
see separate instructions from the grinding
machine manufacturer.
12. During the grinding, use the bottom piece

template frequently to ensure that maxi-
mum grinding is not exceeded.
After grinding, inspect the bottom piece D08-09

seating again, using a feeler gauge and the
bottom piece template, to measure how
much material has been ground away.
MB908-2.3 230 12
Grind the recess so that gap G3 equals

D08-12 as stated on the Data sheet. G2
13. After grinding the inside seating of the bot-
13.
tom piece, grind the outside seating using
carborundum 200 and the special grinding
tool.
Note!
Turn the special grinding tool by hand,

alternately turning clockwise and anti-
clockwise.
MB908-2.3 233 13
Grind until a smooth surface is achieved.

Clean the bottom piece.
MAN B&W Diesel A/S
Overhaul
14. Valve spindle
14. When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
15. Inspect the seating of the valve spindle for

burn marks.
D08-28 Check the burn-off F1 of the valve spindle

NA908-2.3 209 14
by measuring along the spindle template

from point A to point D and in point E and
compare with Data D08-13.
15.
Note!
Before using the spindle template,

thoroughly clean the contact faces on the
valve spindle with a steel brush.
All measurements should be taken at four

diametrically opposite points on the
circumference of the valve spindle. Make
sure that the most burned-off point is
measured.
F-1 Small dent marks in the valve spindle
seating are acceptable and need not be
ground away, provided that the dent
marks do not allow blow-by of exhaust
MA908-2.3 213 12
gas from the combustion chamber to the

A E exhaust gas receiver.
D
For further evaluation of the valve spindle
seating, see also Chapter 707 in the
16. instruction book, Volume I, Operation.
G-1 16. Measure the gap G 1 between the spindle

template and the seating of the spindle.
17. IF burn marks are visible on the seating,

the spindle must be ground.
IF gap G1 exceeds the maximum allowable

value D08-14, see Data, OR the burn-off F 1
exceeds the maximum allowable burn-off
D08-13, the spindle must not be ground. In-
stead the spindle must be reconditioned.
HC908-2.0 117 11
D08-10 Contact MAN B&W Diesel for advice on re-

conditioning.
MAN B&W Diesel A/S
Overhaul
18. Mount and secure the spindle in the grind- 18.

ing machine. Using a dial gauge, check that
the spindle is correctly centered.
Adjust the grinding head to achieve the cor-

rect grinding angle as stated in Data.
Note!
D08-10
As the grinding angle is very important to
the operation of the exhaust valve, make
absolutely sure to adjust the grinding
head correctly.
GM908-2.0 119 14
Regarding the use of the grinding machine,
see separate instructions from the grinding
machine manufacturer.
19.
During grinding, measure gap G 1 frequent-
ly. The max. grinding of the spindle, see
Data, must not be exceeded.
D08-15
If the max. grinding limit is reached, and
burn marks are still visible on the seating of
the spindle, contact MAN B&W Diesel for
advice on reconditioning. D08-16 D08-17
Clean the spindle.
19. Check the spindle stem for wear in the area

D08-15 to D08-16 measured from the top of
the spindle.
If the stem diameter is less than stated in

Data, or the hard facing layer is worn away,
contact MAN B&W Diesel for advice.
JM908-2.0 92 12
MAN B&W Diesel A/S
Overhaul
20. 20. Dismount the air piston from the air cylin-
der, and check the teflon guide ring and te-
flon sealing ring for wear.
Mount two eye bolts in the air cylinder and

dismount the air cylinder.
D08-30
21. Clean the air cylinder and check the run-
ning surface for wear or possible scores.
Blow through the bore for sealing oil, with

D08-27
compressed air.
22. Remove the protective cap from the safety

valve mounted near the bottom of the air
cylinder and dismount the safety valve from
the air cylinder.
GN908-2.3 236 20
Place the safety valve in the pressure test-

ing device.
Connect the testing device with the high-

pressure pump by means of a hose.
21.
Check the opening pressure, see Data.
If the opening pressure is not correct, loos-

en the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated.
Tighten the lock nut and test the opening

pressure once more.
GN908-2.3 236 21
22.
D08-04
NB908-2.3 229 21
MAN B&W Diesel A/S
Overhaul
23. Mount a new gasket and a new O-ring on 23.

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.

D08-07
NB908-2.3 209 22
24. Remove and discard all the O-rings and the
inside sealing ring.
24.
GN908-2.3 236 24
MAN B&W Diesel A/S
Overhaul
25. 25. Inspect the bushing in the spindle guide for

wear and measure the top and bottom di-
ameters. See Data.
26. If it proves necessary to replace the bush-

ing, knock out the bushing with a hammer
and a suitable mandrel.
D08-18
Alternatively, if the extractor tool is availa-
ble, mount the extractor tool and pull up the
bushing.
The extractor tool is optional, and can be

D08-19 ordered as sparepart.
GN908-2.3 236 25
26.
NB908-2.3 229 25A
MAN B&W Diesel A/S
Overhaul
27. Mount the O-rings and sealing ring on the 27.

stuffing box.
Note!
Make sure to mount the sealing ring

correctly, see the sketch.
28. Mount new sealing rings on the bottom

piece. One O-ring in the upper groove and
one U-seal in the lower groove. See the
sketch.
GN908-2.3 236 27
29. Check that the guide pin in the bottom
piece enters the hole in the bottom of the
exhaust valve housing.
28.
Land the exhaust valve housing on the bot-
tom piece.
Mount and tighten the retaining screws for

the bottom piece.
HH908-2.3 240 28
29.
GN908-2.3 236 28
MAN B&W Diesel A/S
Overhaul
30. 30. Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
31. Lubricate the O-rings.
Carefully land the air cylinder on the ex-

haust valve housing and check correct en-
gaging with the locating pin.
GN908-2.3 236 29
Note!
Take care not to damage the O-rings on

the outside of the stuffing box.
31.
D-4
GN908-2.3 236 30
MAN B&W Diesel A/S
Overhaul
32. If it is necessary to replace the sealing 32.

rings on the air piston, cut them and re-
move them.
Be careful not to damage the edges of

the ring grooves in the piston.
Mount the new O-rings in the grooves of the

air piston.
Note!
Before mounting, heat the new teflon
MB908-2.0 90 15
rings in 100°C hot water for at least five
minutes.
When mounting the teflon rings, be

careful not to damage the running
surfaces. 33.
After mounting, compress the teflon rings

by means of the conical ring. This is done
by pressing the air piston through the con-
ical ring.
GN908-2.3 236 32
33. Fill the groove on top of the flange and the

lower part of the air cylinder with clean lu-
bricating oil (approx. 0.5 litre).
34. Fit the conical guide ring for the air piston 34.
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.
Note!
To avoid damage, take great care when

the internal sealing ring in the air piston
passes the groove for the conical locking
ring.
Remove the conical guide ring from the air

cylinder.
NB908-2.3 229 33
MAN B&W Diesel A/S
Overhaul
35. 35. Mount the two part conical locking ring and
apply compressed air below the air piston
through the non-return valve to lift the pis-
ton.
Mount the flange on top of the air piston

and, by means of the four screws, tighten
the air piston and the flange together.
For correct securing, see Procedure 913-7.
36. Remove the piston rings from the oil piston

and check them for wear.
Compressed air
If the thickness of the rings has worn down
GN908-2.3 236 34
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.
36.
37. Mount the piston on top of the spindle and
check the mesh of the damper piston by
checking the height of the damper relative
to the oil cylinder.
Connect compressed air supply to the

space below the air piston, so as to keep
BG908-2.0 99 22
the valve closed, and to keep the air cylin-

D08-21 der in close contact with the valve housing.
Place the measuring tool on the air cylinder

37. across the piston.
GN908-2.3 236 36
MAN B&W Diesel A/S
Overhaul
38. Check the mesh of the damper piston by 38.

checking the distance from the upper edge
of the crossbar to the top of the damper pis- D08-22
ton. See Data. D08-23
If the measurement is outside the value
stated in Data, an adjustment must be
made by changing the disc in the damper
piston as follows:
39. Place the piston in the special tool.
Press out the disc with the centre screw.
If necessary, replace also the spring and

the piston.
GN908-2.3 236 37
40. 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.
39.
Check the mesh once more.
MA908-2.0 103 25
40.
S8211427
MAN B&W Diesel A/S
Overhaul
41. 41. Mount the piston and the flange in the oil
cylinder. Mount the screws and tighten.
Mount a new sealing ring in the inner
groove.
42. Return the oil cylinder to an upright posi-

tion.
Mount a new sealing disc in the bore for the

HG908-2.3 217 34
orifice plug. Screw the orifice plug into the

bore.
Place a new gasket on top of the oil cylin-

der.
42.
Mount the sealing oil control unit.
Mount the lifting bracket on the oil cylinder.
D08-05 Mount the screws and tighten to the torque

stated in Data.
43. Mount a new O-ring on the thrust piece.

Mount the thrust piece in the oil cylinder.
HH908-2.3 240 42
43.
HH908-2.3 240 43
MAN B&W Diesel A/S
Overhaul
44. Mount the overhauled oil cylinder on top of 44.

the air cylinder.
Mount the safety strap and tighten the nuts.

See Data.
45. Mount the sealing oil pipe.
D08-06
HH908-2.3 240 44
45.
HH908-2.3 240 45
MAN B&W Diesel A/S
Mounting
Mounting
908-2.4
1. Check before mounting
Before mounting an overhauled exhaust valve

D08-24 in the engine, it is recommended that the valve
be checked and prepared as follows:
1. Lift up the valve with the engine room crane

(whereby the valve may open).
2. Connect compressed air to the air cylinder

to close the valve:
• Check that a 1.0 mm feeler gauge can be

G3 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.
HH908-2.4 240 01
• After shutting-off the compressed air

supply and releasing the air through the
non-return valve on the control unit, the
2. exhaust valve should open.
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.
• After doing this a couple of times, leave

the valve closed, and shut-off the com-
pressed air.
If the exhaust valve opens within 15 min-

GN908-2.4 236 02
utes, check for air leakages around the air

spring.
Check:
• Air piston sealing (air coming out of drain

oil hole)
• Stem sealing (air coming out along spin-

dle stem in exhaust gas duct)
• Non-return valve for air spring.
MAN B&W Diesel A/S
Mounting
3. 3.
Note!
Before mounting the valve on the engine,

connect 7 bar working air to the air cylin-
der to keep the exhaust valve closed dur-
ing the mounting process.
Mount a new O-ring in the upper groove on Compressed Air

the bottom piece and a U-seal in the lower
groove of bottom piece.
Lubricate the sealing rings with vaseline

and the threads of the studs with anti-sei-
zure paste.
Position the valve in the cylinder cover

bore, guiding it in accordance with the ex- Vaseline
haust flanges and the guide pin on the ex-
haust side of the exhaust valve. Copper Grease
4. Mount the nuts and the hydraulic jacks.

Raise the pressure to the value indicated in
HH908-2.4 240 03
Data and tighten the nuts.
For use of the hydraulic jacks, see also

Procedure 913-1.
Relieve the system of pressure, remove the

4.
hydraulic jacks and high-pressure hoses, D13-01
and fit the protective caps.
HH908-2.2 240 04
MAN B&W Diesel A/S
Mounting
5. 5. Connect the intermediate pipe to the flange

at the exhaust valve, mount and tighten the
screws.
Attach the insulation jacket.
6. Mount the cooling water outlet pipe on the

exhaust valve.
Mount the high-pressure pipe and the re-

turn oil pipe, see Procedure 908-1.4.
Open the lub. oil supply and the cooling wa-

GN908-7.4 236 05
ter supply to the exhaust valve.
Disconnect the compressed air and con-

nect the normal air supply.
6.
Caution!
The air supply to the exhaust valve must

always be connected before turning on
the oil supply to the exhaust valve
actuator.
7. Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908-1.1.
GN908-2.4 236 06
MAN B&W Diesel A/S
Exhaust Valve Actuator 108-3
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10803
108-3 Data 0034 Exhaust Valve Actuator
X Stopped engine
X Shut off fuel oil
Data
D08-20 Oil cylinder max. inside diameter 85.4 mm

D08-21 Piston rings, min. thickness 3.2 mm
D08-32 Hydraulic actuator, tightening torque 500 Nm
D08-33 Locking plate, tightening torque 25 Nm
D08-34 Hydraulic actuator, tightening angle 30 °
D08-35 Hydraulic actuator 90 kg
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data
MAN B&W Diesel A/S
Exhaust Valve Actuator 908-3.1
Checking
Exhaust Valve Actuator
L60MC-C
0227
Checking
908-3.1
1.
1. The non-return valve A is built into the oil
inlet pipe to the actuator.
To check the valve, dismantle and clean it

and connect a supply of working air (7 bar)
to the outlet side of the valve (the side fac-
ing the actuator). If the air flow can be felt
at the inlet side of the valve, the valve must
be overhauled.
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 hy-
draulic 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 di-
rectly registered.
The hydraulic actuator is then to be disman-

tled for checking of the parts.
See Procedure 908-3.2
HM908-3.0 70 1/3
0$1% :'LHVHO$6
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

Dismount the high-pressure pipe.

GM908-3.0 78 01
2. Release the mountings for the indicator

drive from the actuator housing.
2. Fit eye screws in the lifting holes of the ac-

tuator housing and hook on a tackle.
D08-35
Unscrew the nuts on the two short studs,
then loosen the nuts on the long studs suc-
cessively until the roller guide spring is re-
lieved.
Dismount the nuts and lift the housing care-

fully, leaving the piston on top of the roller
guide.
Remove the spring.

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 pis-

ton as required.
HM908-3.0 70 03
0$1% :'LHVHO$6
Exhaust Valve Actuator 908-3.3
Overhaul
Overhaul
908-3.3
1. Clean the piston in kerosene and wipe dry 1.

D08-21
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 possi-

ble scores and measure it for wear.
HM908-3.0 69 04
If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised work-
shop for reconditioning.
3.
D08-20
JM908-3.0 73 05
0$1% :'LHVHO$6
908-3.4 Exhaust Valve Actuator
Mounting
Mounting
908-3.4
1. 1. Mount the actuator piston in the roller guide

and turn 90° to lock it in the bayonet joint.
D08-33
Mount the locking plate and tighten as stat-
ed in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
2. Mount the spring on the roller guide. Care-

fully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
Mount the washers and nuts on the two

long studs and tighten alternately until the
KC908-3.0 76 05
actuator housing rests firmly against the

roller guide housing.
Mount the washers and nuts on the two

2. short studs. Tighten all four nuts as stated
in Data.
Note!
Use only the tightening angle OR the

tightening torque, NOT both.
D08-32
3. Mount the oil inlet pipe and the drain pipe
or
D08-34
Mount the hydraulic high pressure pipe.
HG908-3.4 201 02
3.
HG908-3.4 201 03
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 108-4
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10804
108-4 Data 0031 Exhaust Valve Roller Guide
X Stopped engine
X Shut off fuel oil
Data
D08-36 Bushing/shaft pin, max. clearance 0.5 mm

D08-38 Roller guide complete 45 kg
MAN B&W Diesel A/S
108-4 Exhaust Valve Roller Guide
Data
P90851 53 Lifting tool for roller guide
MAN B&W Diesel A/S
Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valve Roller Guide
L60MC-C
0217
Checking
908-4.1
2.
1. The exhaust valve roller guide can be par-
tially checked while mounted on the engine,
using the following procedure:
Lift the roller guide.

2. Remove the camshaft inspection cover.
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
JN908-4.1 205 02
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.
Also inspect the surface of the roller for 3.

possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide hous-
D08-36
ing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
A more suitable and reliable method is to

check the roller guide and the bearing
clearance when the roller guide is dis-
mounted.
For dismantling of the roller guide, see Pro-
cedure 908-4.2.
3. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
KC908-4.0 57 05
scratches.
4. 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.
5. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance directly on the dial, see Data.
0$1% :'LHVHO$6
908-4.2 Exhaust Valve Roller Guide
Dismantling
Dismantling
908-4.2
1. 1. Dismantle the hydraulic actuator above the

exhaust valve roller guide.
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 bayo-
net 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.
HG908-3.3 201 02
2.
D08-38
HM908-4.0 51 02
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 908-4.3
Overhaul
Overhaul
908-4.3
1. Inspect and check the exhaust valve roller 1.

guide.
2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
• seizure marks on the slide surfaces,
have been observed during the checking of

the roller guide.
Note!
For disassembling of the roller guide,

GM908-4.0 73 05
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.
0$1% :'LHVHO$6
908-4-4 Exhaust Valve Roller Guide
Mounting
Mounting
908-4-4
1. 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 bayo-
net joint of the roller guide.

• Lower the lock ring, thereby securing the

foot in the locked position.
Lubricate the sliding surfaces of the roller

and the roller guide and lower it carefully
into the roller guide bushing.
Remove the lifting tool.
2. When mounting the roller guide, check the

HM908-4.0 51 02
clearance between the roller guide and the

guide plate mounted in the roller guide lin-
er.
2. Turn the camshaft so that the roller guide is

lifted approx. 20 mm. The clearance be-
tween the roller guide and the guide plate
should be the same at both ends +/– 0.1
mm.
3. Mount the actuator.

HM908-4.0 51 10
0$1% :'LHVHO$6
Exhaust Valve Cam 108-5
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10805
108-5 Data 0010 Exhaust Valve Cam
X Stopped engine
X Shut off fuel oil
Data
D08-39 Check lifting height 12 mm
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
Data
MAN B&W Diesel A/S
Exhaust Valve Cam 908-5.1
Checking
Exhaust Valve Cam
S42MC
0214
Checking
908-5.1
1.
1. Turn the crankthrow of the cylinder con-
cerned to TDC. Check and note down the
angle indicated on the turning wheel.
2. Turn in AHEAD direction until the roller guide
HM906-7.0 56 01
(measured on the activator plunger) is lifted
corresponding to D08-39, and calculate the
angle A, which is the number of degrees
the crankthrow has turned from TDC posi-
tion to the present position. For D08-39, 2.
see Data.
Continue turning AHEAD until the roller

guide (measured on the activator plunger)
is lifted to distance D08-39, and calculate
the angle B, which is the number of de-
grees the crankthrow has turned from TDC
position to the present position.
D08-39
17
17 mm
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.
17 mm
HM908-7.0 25 1/1
3. Calculate the lead angle as: D08-39
180° – A° + B°
2
The illustration shows the position of the 4.

exhaust cam when the piston of the rele-
vant cylinder is in TDC.
See the Adjustment Sheet in Volume I, OP-

ERATION, Chapter 701, for the "lead an-
gle" of the plant in question.
4. The cam lead angle can be checked visu-

ally 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.
HM908-7.0 25 1/1
0$1% :'LHVHO$6
Exhaust Valve 108-7
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10807
108-7 Data 0031 Exhaust Valve
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
108-7 Exhaust Valve
Data
P90851 124 Tool for emergency open exhaust valve

P90851 173 Lifting tool for exhaust valve roller guide
MAN B&W Diesel A/S
Exhaust Valve 908-7
Special Running
Exhaust Valve
S60MC-C
0226
Special Running
908-7
3.
Engine trouble might require that a cylinder be
taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve

locked in either the open or the closed position.
Either way, carry out the following procedure:
1. Lift the relevant fuel pump roller guide.

HN908-7.0 226 03
2. Dismantle the hydraulic high-pressure
pipe.See Procedure 908-1.3.
3. Dismantle the non-return valve on the oil in-

let pipe. Loosen the union nut in the bottom
of the oil pipe and turn the pipe to one side. 4.
Mount the non-return valve on the oil pipe
and blank off the non-return valve with the
plug from tool panel 908.
4. Remove the inspection cover of the cam-

shaft housing. Turn the engine until the ex-
haust roller guide is at TDC.
5. Position the lifting tool on the actuator and

screw the spindle into the top of the actua-
tor piston.
Tighten the lowermost nut on the tool to pull

JN908-4.1 205 02
up the roller guide as far as possible.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position. 5.
6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.
JM908-5.0 55 03
0$1% :'LHVHO$6
908-7 Exhaust Valve
Special Running
7. If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:
7. Turn off the air to the exhaust valve.
Remove the venting plug screw, fitted just

above the ball cock on the air cylinder, to let
the air inside the air cylinder escape.
8. Dismantle the rotation indicator on the oil

cylinder and mount the tool for opening of
the exhaust valve. The tool is found on tool
panel 908.
The tool will keep the piston of the air cyl-

inder in the bottom position and thus keep
the exhaust valve open.
KC908-6.0 18 02
8.
HN908-7.0 226 08
0$1% :'LHVHO$6
Exhaust Valve 908-7
Special Running
After overhaul of the cylinder unit, re-engage 9.

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower

the roller guide on to the exhaust cam. Re-
move the tool.
10. If the engine has been running with the ex-

haust valve open, remove the tool mounted
in the oil cylinder and mount the rotation in-
dicator.
Note!
The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.
Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the for-
mation of a wear groove in the air piston
JM908-5.0 55 06
of the exhaust valve.
Re-connect the air supply to the air cylin-

der.
11.
11. Remove the plug from the non-return valve
and re-connect the oil inlet pipe on the ac-
tuator housing.
12. Mount the hydraulic high-pressure pipe.

13. Engage the fuel pump roller guide.

HN908-7.0 226 11
0$1% :'LHVHO$6
Exhaust Valve - Panel Plate
P90851-0165
MAN B&W Diesel A/S
Plate Exhaust Valve - Panel
P90851-0165

No. No.
016 Panel for tools

028 Name plate
053 Lifting tool for roller guide
065 Lifting tool for exhaust valve
077 Cone ring
089 Pressure testing device 0-50 bar
090 Gauge for exhaust valve spindle
100 Stepped drift
112 Grinding tool for high pressure pipe
124 Tool for opening of exhaust valve
136 Bridge gauge for exhaust valve
148 Tool for hydraulic piston
150 Gauge for exhaust valve seat
161 Lifting tool for exhaust valve spindle
173 Lifting tool for exhaust valve roller
guide
185 Grinding ring for exhaust valve seat
MAN B&W Diesel A/S
Exhaust Valve - Tools Plate
P90861-0037
MAN B&W Diesel A/S
Plate Exhaust Valve - Tools
P90861-0037

No. No.
046 Grinding machine, complete*
Note:
* When ordering spare parts, please

refer to the Chris Marine manual
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0041
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0041

No. No.
028 Hydraulic jack, complete

030 Support
089 Tommy bar
090 Spanner
100 Stud setter
MAN B&W Diesel A/S
Exhaust Valve - Extra Tools Plate
P90863-0014
Exhaust Valve - Extra Tools
0014
P90863
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0014
Item Item
No. No.
011 Worktable
MAN B&W Diesel A/S
Exhaust Valve - Extractor Tool Plate
P90864-0003
MAN B&W Diesel A/S
Plate Exhaust Valve - Extractor Tool
P90864-0003

No. No.
017 Extractor tool, complete
MAN B&W Diesel A/S
109-01 0055 Fuel Pump Lead, Data

909-01 0240 Fuel Pump Lead
109-02 0004 VIT System, Data
909-02 0207 VIT System
109-03 0047 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0042 Fuel Pump, Data
909-04 0222 Fuel Pump
109-05 0045 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0039 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0029 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0037 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0026 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10910 0018 Lifting Gear Roller Guide, Data
90910 0211 Lifting Gear for Roller Guide
10911 0066 Fuel Valve, Data
10912 0048 Spindle Guide, Data
90912 0228 Spindle Guide
10913 0031 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0067 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0046 Fuel Pump Roller Guide, Data
90915 0226 Fuel Pump Roller Guide
MAN B&W Diesel A/S

90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
MAN B&W Diesel A/S

Fuel Pump Settings 109-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10901
109-1 Data 0055 Fuel Pump Settings
X Stopped engine
X Shut off fuel oil
Data
D09-02 Change of one index mark corresponds to pmax being altered approx. 3.0 - 4.0 bar
MAN B&W Diesel A/S
109-1 Fuel Pump Settings
Data
MAN B&W Diesel A/S
Fuel Pump Settings 909-1.3
Adjustment
Fuel Pump Settings
S60MC-C
0240
Adjustment
909-1.3
1.
Before adjustment of the fuel pump is carried
out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:
1. The Maximum Combustion Pressure (pmax)

is adjusted for the individual units at the fuel
pump VIT index arm. For collective adjust-
ments of pmax on all units, see Procedure
909-2.
HN909-1.3 240 01
2. Loosen lock nut B and then turn adjusting
screw H. The link can be adjusted by ap-
prox. 3 index marks.
3. To increase p max, adjust to higher VIT index 2.

(advance injection).
To decrease p max, adjust to lower VIT index

(delay injection).
One index mark will alter pmax approximate-

ly as given in Data D09-02.
Note!
The individual pmax value must not devi-

ate more than 3 bar from the average
value for all cylinders.
4. If the required pmax adjustment cannot be

HN909-1.3 240 02
attained by adjustment on the VIT index

arm, it is possible to carry out the adjust-
ment on the fuel cam disc. Contact MAN
B&W Diesel for advice.
0$1% :'LHVHO$6
909-1.3 Fuel Pump Settings
Adjustment
5. MIP adjustment:
5. The Mean Indicated Pressure (pi) for a cer-

tain 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
The mean indicated pressure is one of

the most important parameters in obtain-
ing good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the aver-
age value for all cylinders. See Volume I,
Chapter 706.
0$1% :'LHVHO$6
VIT System 109-2
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10902
109-2 Data 0004 VIT System
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-2 VIT System
Data
MAN B&W Diesel A/S
VIT System 909-2.1
Adjustment
The engine may be equipped with either a me-

1.
chanical 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. Adjust- A
ing the pmax of all the cylinders is done by ad-
justing the VIT system in the following way:
B
Mechanical VIT system
1. The pilot valves have been pre-adjusted to

0.5-5.5 bar control air pressure, corre- C
sponding to 0.5-8.0 mm pressing-in of pin P
C.
Pbar
To check a pilot valve already mounted on
the engine, remove the inlet and outlet pipe 5
connections at A and P, and connect a
4 Curve 2
pressure gauge at A and a pipe with work-
ing air (pressure 7 bar) at P, on the pilot 3
valve. 1.5 2
M909020207C01
0.5 1 Pressing
Check that the pressure on the pressure 0.1 0
gauge and the pressing-in of pin C is in ac- in mm
cordance with the curve. 0 1 2 3 4 5 6 7 8
0.5
Any necessary adjustment is done by turn-
ing adjusting screw B. 2.
2. Fine adjustment of the pmax pressure in the

breakpoint (for all the cylinders) is to be
carried out by axial displacement of the
bracket with the pilot valve.
Release the screw and nut which secure

the bracket with the pilot valve to the larger
bracket through the slotted holes.
Increase the pmax pressure by moving the

pilot valve toward the lever.
Decrease the pmax pressure by moving the

pilot valve away from the lever.
See also Volume I, Chapter 703.

M909020207C02
MAN B&W Diesel A/S
909-2.1 VIT System
Adjustment
Electronic VIT system

3.
3. The adjustment should be based on a set
of indicator diagrams taken when the en-
gine is running just above the breakpoint.
4. On the panel in the engine room control

room, change the poffset value in accordance
with the required increase or decrease in
the pmax pressure. One graduation mark on
the poffset scale corresponds to a change in
pmax of 1 bar.
5. Check the adjustment by taking a new set

of indicator diagrams while the engine is
running just above the breakpoint.
6. The I/P converter mounted on the engine

receives a 4-20 mA signal I from the elec-
tronic control system and converts this into
a 0.5-5.5 bar control air pressure pcontrol.
7. To check the adjustment of the I/P con-

M909020207C03
verter, operate the panel in the engine con-

trol room to supply various signals I to the
I/P converter.
For operation of the panel, see the panel

6. manufacturer’s 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.
8. If the control air pressure is not in accor-

dance with the curve, the I/P converter
Pcontrol must be adjusted. Remove the hood of the
I/P converter and adjust the I/P converter
according to the manufacturer’s instruc-
Psupply tions.
Pcontrol
5
4
3
M909020207C02
2
1.5
1
0.5
0.1 0 I, mA
0 4 8 12 16 20
MAN B&W Diesel A/S
Fuel Pump Cam 109-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10903
109-3 Data 0047 Fuel Pump Cam
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
Data
P90651 44 Impact wrench for turning cam

P90951 45 Measuring tool for fuel pump
P91351 201 Quick coupling, male
P91351 225 Disc, round-plain, Cu ø11x3 mm
MAN B&W Diesel A/S
Fuel Pump Cam 909-3.1
Checking
Fuel Pump Cam
S60MC-C
0229
Checking
909-3.1
1.
Fuel cam lead:
C
The lead C of the fuel cam is defined as the
x2 x1 roller guide
number of mm the plunger is lifted from its bot-
tom position when the main piston is in TDC.
1. To measure the fuel cam lead (top lift):

Dismantle the puncture valve.
See Procedure 909-8.2. fuel cam
Make sure that the reversing mechanism is

in AHEAD direction.
ahead
2. Push down the measuring pin through the
EN909-3.1 228 00
top cover, until it rests against the pump
plunger. Lowest position Main piston in TDC
of pump plunger
Turn the engine until the lowest point of the
cam is found, use a calliper to find the 3.
point.
3. Measure the distance x from the top of the

measuring pin to the transverse piece.
Note down the result as x2.
4. Turn ahead until the main piston of the cyl-

inder concerned is in TDC.
Again measure the distance x from the top

of the measuring tool to the transverse
piece. Note down the result as x1.
Calculate the fuel cam lead C (top lift) as:
C = x1 – x2 (mm)
HN909-3.1 229 03
5. Note down the result for comparison with

the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.
4.
Remount the puncture valve.
HM906-7.0 56 01
0$1% :'LHVHO$6
909-3.3 Fuel Pump Cam
Adjustment
Adjustment
909-3.3
1. Normally, adjustment of the fuel cam should not

be necessary. Before adjustment of fuel equip-
ment, see Volume I, Chapter 706.
1. Remove the inspection cover from the cam-

shaft housing.
Note!
HN909-3.3 207 01
Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
2. Dismount the puncture valve 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 in-
spection hole.
If fitted, remove the plugs from the oil ducts

(using, for instance, a screwdriver).
Insert three copper gaskets in each oil duct.
Mount snap-on couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snap-on couplings

HN909-3.1 229 03
and the distributor block and between the

distributor block and the hydraulic high-
pressure pump.
3.
HN909-3.3 207 04
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Fuel Pump Cam 909-3.3
Adjustment
4. Mount the special spanner on the fuel cam 4.

disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least five

minutes before turning the cam.
HN909-3.3 207 06
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,

until the desired change of lead is obtained.
To increase lead and p max:

– turn the cam disc AHEAD.
To reduce lead and p max:

– turn the cam disc ASTERN.
5. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the

fuel cam lead again.
Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.
6. Mount the inspection cover on the camshaft

housing.
7. Mount the puncture valve.

8. After any adjustment of the cam position,

pmax must be recorded and compared with
pmax at a known engine reference load.
0$1% :'LHVHO$6
Fuel Pump 109-4
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10904
109-4 Data 0042 Fuel Pump
X Stopped engine
X Shut off fuel oil
Data
D09-18 Pump housing nuts, tightening torque 785 Nm

D09-19 Pump housing nuts, tightening angle 60 °
D09-20 Pump housing 200 kg
D09-21 Bottom plate 13 kg
D09-39 Shock absorber 27 kg
MAN B&W Diesel A/S
109-4 Fuel Pump
Data
P90951 70 Lifting tool for fuel pump housing
MAN B&W Diesel A/S
Fuel Pump 909-4.2
Dismantling
Fuel Pump
S60MC-C
0222
Dismantling
909-4.2
3.
Note!

1. Dismantle the fuel pump top cover.

2. Dismantle the barrel/plunger assembly.

GN909-4.2 203 03
3. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel in-
let valve.
Remove the fuel oil inlet pipe. 4.
Discard the gaskets.

D09-20
4. Unscrew the nuts at the base of the fuel
pump.
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.

JG909-8.0 71 02
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul
Overhaul
909-4.3
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.
GN909-4.3 203 03
3. Dismantle the actuator and actuator brack-

et.
4. 4. Dismantle the fuel pump shock absorber.
If necessary, overhaul the fuel pump shock

absorber.
D09-39 See Procedure 909-9.3.
HG909-9.2 201 01
0$1% :'LHVHO$6
Fuel Pump 909-4.3
Overhaul
5. Tilt the fuel pump housing into a horizontal 5.

position on the wooden planks.
6. Dismantle the screws and the bottom plate

from the fuel pump housing.
If the bottom plate is stuck, loosen it by

screwing two M10x70 mm screws into the
holes of the bottom plate.
7. Dismantle the:
• Fuel index arm
HC909-3.4 121 05
• Sleeve
• Regulating guide
6.
D09-21
HC909-3.4 121 06
7.
HC909-3.4 121 07
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul
8. 8. Dismantle the:
• Guide screw
• VIT index arm
• Timing guide
9. Dismantle and inspect the plug screws in

both sides of the fuel pump housing.
If heavily eroded, replace the plug screws.

HC909-3.4 121 08
Replace the sealing rings and mount the

plug screws.
10. Clean all parts thoroughly in diesel oil or

kerosene. Blow dry with compressed air.
9.
11. Mount new sealing rings on the unions.
Note!
Soak the sealing rings in lubricating oil

before mounting
12. Clean all inside surfaces of the fuel pump

housing.
HC909-3.4 121 09
11.
HC909-3.4 121 11
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Fuel Pump 909-4.3
Overhaul
Mounting 14.
13. Lubricate the following with molybdenum di-

sulphide (MoS 2):
• all internal machined surfaces of the fuel

pump housing
• the sliding surfaces of all parts of the

regulating and timing systems.
• the teeth of the:

regulating guide
HC909-3.4 121 14
timing guide
VIT index arm
fuel index arm. 15.
14. Mount the VIT index and the guide screw.
Adjust the position of the VIT index arm so

that the scratch mark is aligned with the
centre of the fuel pump housing.
15. Mount the timing guide in the fuel pump

housing.
The timing guide must be mounted in such

a way that the scratch mark on the timing
guide is aligned with the scratch mark on
HC909-3.4 121 15
the VIT index arm, which must be visible

through the hole in the timing guide.
16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
16.
sleeve is aligned with the pin hole in the
fuel pump housing.
HC909-3.4 121 16
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909-4.3 Fuel Pump
Overhaul
17. 17. Mount the fuel index arm.
Adjust the position of the fuel index arm so

that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.
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
HC909-3.4 121 17
the fuel index arm.
19. Mount the bottom plate on the fuel pump

housing.
18.
HC909-3.4 121 18
19.
HC909-3.4 121 06
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Fuel Pump 909-4.3
Overhaul
20. Mount the fuel pump shock absorber. 20.
21. Mount the actuator and actuator bracket.
HC909-9.2 201 01
21.
GN909-4.3 203 03
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909-4.4 Fuel Pump
Mounting
Mounting
909-4.4
2. 1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum di-
sulphide (MoS 2).
D09-20 See Procedure 913-11.
2. Lower the fuel pump housing on to the

pump base, taking care not to damage the
D09-18 threads of the studs.
or
D09-19 Remove the lifting tool.
Fit and tighten the nuts at the base of the

pump housing. Use either the tightening
torque or the tightening angle. See Data.
3. Mount the fuel oil inlet pipe between the

pump housing and the inlet valve.
4. Mount the barrel assembly in the fuel pump

housing.
5. Mount the top cover on the fuel pump hous-

ing.
6. Mount the puncture valve, see Procedure

909-8.4.
7. Mount the drain oil pipes, and the com-

JG909-8.0 71 02
pressed air pipes.
3.
GN909-4.2 203 03
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Fuel Pump Top Cover 109-5
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10905
109-5 Data 0045 Fuel Pump Top Cover
X Stopped engine
X Shut off fuel oil
Data
D09-23 Top cover studs, screwing-in torque 240 Nm

D09-24 Top cover nuts, tightening torque 300 Nm
D09-26 Outlet seat, max.grinding diameter 26 mm
D09-27 Top cover 52 kg
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data
P90951 69 Lifting tool for fuel pump

P90951 94 Milling tool for fuel oil pipe seats
MAN B&W Diesel A/S
Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
S60MC-C
0223
Dismantling
909-5.2
1.
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 !

GN909-5.2 204 01
Dismount all drain pipes and the pipe con-
nections to the puncture valve.
Dismount the high-pressure pipes between

the top cover and the fuel valves. 2.
Note !
If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
2. Remove the top cover fixing nuts and

mount the dismantling screws for top cover
GN909-5.2 204 02
in the two threaded holes.
Pull the top cover with suction valve and

puncture valve (if still mounted) free by
tightening the dismantling screws.
3.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
D09-27
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.

GN909-5.2 204 03
0$1% :'LHVHO$6
909-5.3 Fuel Pump Top Cover
Overhaul
Overhaul
909-5.3
2. 1. If not already done, dismount the protective

cap and the puncture valve from the top
cover.
2. Dismantle the suction valve and the lock

washer from the top cover.
3. Fill the oil ducts of the top cover with vase-

line or heavy grease.
Screw the guide, with the miller, into the

high-pressure pipe thread.
HM909-3.3 74 03
Mill the seat until a smooth surface is

achieved. For maximum seat diameter see
Data.
3.
After completing the milling, use com-
pressed air to blow the vaseline/ grease out
from the oil ducts.
Clean the top cover with diesel oil/gas oil,

D09-26 and blow dry with compressed air.
Note!
Make sure that all bores and threads

inside the top cover are absolutely clean.
GN909-5.3 204 04
If necessary, recondition the seats of the

fuel oil high-pressure pipes.
4. 4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
HM909-3.3 74 13
0$1% :'LHVHO$6
Fuel Pump Top Cover 909-5.4
Mounting
Mounting
909-5.4
1. Make sure that the inside of the fuel pump 1.

housing and the top of the fuel pump barrel
is completely clean.
D09-27
2. Mount a new gasket on top of the pump
housing.
Lubricate all sliding faces, studs and seal-

ing rings with molybdenum disulphide
(MoS 2). See Procedure 913-11.
Mount the overhauled top cover (with over-

hauled suction valve and reconditioned
GN909-5.2 204 03
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.
3.
D09-24
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!
3. Mount the top cover fixing nuts, and tighten

them diagonally to the torque indicated in
GN909-5.4 204 03
Data.
For adjustment of the fuel pump, see Pro-

cedure 909-1.1.
4. Finally, mount a new or overhauled punc- 4.

ture 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.
GN909-5.4 204 04
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Fuel Pump Barrel Assembly 109-6
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10906
109-6 Data 0039 Fuel Pump Barrel Assembly
X Stopped engine
X Shut off fuel oil
Data
D09-29 Barrel assembly 48 kg

D09-30 Plunger 11 kg
MAN B&W Diesel A/S
109-6 Fuel Pump Barrel Assembly
Data
P90951 57 Lifting tool for fuel pump

P90951 224 Tool for pmax rack
P90962 Fuel pump seals – mounting tools
MAN B&W Diesel A/S
Fuel Pump Barrel Assembly 909-6.2
Dismantling
Fuel Pump Barrel Assembly
S60MC-C
0219
Dismantling
909-6.2
1.
Open the drain cock (at the bottom of the

pump housing), enabling the oil which is left
in the high-pressure pipe and the fuel pump
to escape.
Note!

GN909-5.2 204 01
Dismount the pipe connections to the punc-
ture valve.
Dismount the fuel oil high-pressure pipes. 2.

See Procedure 909-14-2.
2. If the top cover is to be overhauled, dis-

mount the puncture valve.
3. Dismount the fuel pump top cover.

HN909-8.2 207 03
3.
GN909-5.2 204 03
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909-6.2 Fuel Pump Barrel Assembly
Dismantling
4. 4. Position the lifting tool for the barrel/plunger

assembly (without measuring pin) in such a
manner that the two distance tubes of the
tool rest on the pump barrel.
Make sure that the two guide pins in the

bottom of the lifting tool enter the holes in
the top of the plunger.
Secure the lifting tool by screwing the two

screws into the pump barrel.
Loosen the stop ring on the spindle of the

GN909-6.2 204 01
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
5. plunger top.
Tighten the centre screw of the spindle

against the plunger.
5. Remove the pump barrel guide screw from

the pump housing.
MB909-3.1 95 05
6. Disconnect the links for the timing drive and

the regulating drive. Dismount the union
and pointer for the timing drive and the reg-
ulating drive.
6.
Note the position of the scratch mark on the
lever arm.
Remove the locking plate and the lever

arm.
Mount the extractor tool and connect the

timing toothed rack to the pulling rod by
means of the pin.
GN909-6.2 204 03
0$1% :'LHVHO$6
Dismantling
7. Turn the nut at the end of the pulling rod, 7.

whereby the timing rack will move out-
wards.
Continue turning the nut until the pin reach-

es the outer position of the slot in the tool,
whereby the thread of the fuel pump barrel
GN909-6.2 204 04
goes clear of the timing guide.
Keep the toothed rack in this position during

the overhaul or replacement of the pump
barrel.
8.
There is now a distance between the lifting
tool and the pump housing.
8. 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
GN909-6.2 204 05
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 con- 9.

tact with the upper flange of the tool, and
lock the stop ring in this position by means
of the stop screw.
9. Carefully lift the barrel/plunger assembly D09-29

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 Pro-
cedure 909-6.3.
GN909-6.2 204 06
0$1% :'LHVHO$6
Overhaul
Overhaul
909-6.3
1. 1. Clean the outside of the barrel.
Set up the pump barrel/plunger in a bench

vice provided with “soft” jaws.
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 wipe dry with a clean
piece of cloth. Also clean the bores in the
top of the plunger.
MB909-3.2 95 01
Clean the barrel and wipe dry with a clean

piece of cloth.
2. For evaluation of pump barrel/plunger, see

Volume I, OPERATION, Chapter 706.
3. Before mounting new sealing rings on the

barrel, heat them in 100°C hot water for at
least five minutes.
4. 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 po-

D09-30 sition the big cone on the barrel.
MB909-3.2 95 02
Place the spring-loaded sealing ring on the

cone with the spring facing upwards, see
the sketch.
4. Use the pusher tool to push the sealing ring

into the groove.
MB909-3.2 95 04
0$1% :'LHVHO$6
Overhaul
5. When mounting the sealing ring in the outer 5.

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.
6. 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 down-
MB909-3.2 95 05
wards, see the sketch.
7. Lubricate the plunger with molybdenum di-

sulphide (MoS 2).
6.
Carefully slide the plunger into the barrel
and press it to the bottom.
Note!
Do not use force as this will damage the

sliding surfaces of the plunger or barrel
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.
MB909-3.2 95 06
7.
MB909-3.2 95 07
0$1% :'LHVHO$6
Mounting
Mounting
909-6.4
1. 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 spin-
dle. 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
HN909-6.4 207 01
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/
2. plunger assembly which is ready for mount-
ing.
Secure the tool to the barrel by tightening

the two screws, and attach the plunger to
the spindle of the tool by tightening the cen-
tre screw of the spindle. The tool is thus
fixed on the barrel in such a way that its cor-
rect positioning is ensured during mount-
ing.
Before mounting the barrel/plunger in the

pump housing, lubricate the thread for the
timing guide and all sealing rings with mo-
lybdenum disulphide.
Using the spindle of the tool, pull the plung-

er 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.
HN909-6.4 207 02
0$1% :'LHVHO$6
Mounting
3. Pull the regulating toothed rack as far out 3.

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer posi-
tion.
4. Check that the slot in the barrel coincides

with the hole for the guide screw.
Lower the barrel assembly carefully into the
GN909-6.4 204 03
pump housing.
If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
and the regulating block of the plunger fit
properly in the cutout of the regulating 4.
guide.
Lowering the barrel assembly so far down

into the pump housing that the sealing rings D09-29
of the barrel are about to enter the bore in
the pump housing.
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.
GN909-6.4 204 04
0$1% :'LHVHO$6
Mounting
5. 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 en-

gaged by pressing-in the rack. When doing
this, the pump barrel shall move down-
wards.
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
GN909-6.4 204 05
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.
6.
If necessary, turn the regulating guide a lit-
tle (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 reg-

ulating rod in, thereby turning the plunger
by means of the regulating guide and caus-
ing 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.

GN909-6.4 204 06
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Mounting
7. Mount the pointer and union for the timing 7.

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.
GN909-6.4 204 07
Remove the centre screw from the plunger,
and remove the tool.
9. Mount the top cover without mounting the 8.

nuts. Turn the engine one revolution, and
check that the top cover does not move up-
wards. If the top cover does move upwards,
the barrel/plunger assembly has to be re-
moved and re-inserted.
10. Mount the fuel pump top cover, including

the nuts. See Procedure 909-5.4.
GN909-6.4 204 08
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Fuel Pump Suction Valve 109-7
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10907
109-7 Data 0029 Fuel Pump Suction Valve
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Data
D09-33 Suction valve, tightening torque 900 Nm

D09-34 Suction valve 4 kg
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data
P90951 128 Crowfoot wrench head

P90967 Fuel puncture valve – tools
MAN B&W Diesel A/S
Fuel Pump Suction Valve 909-7.1
Checking
Fuel Pump Suction Valve
S60MC-C
0214
Checking
909-7.1
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 dur-
ing storage.
HN909-7.1 207 01
2.
KB909-3.3 105 08
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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 suc-

tion 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 po-

GN909-5.2 204 03
sition in the top cover bracket mounted on

the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
er.
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
3.
KN909-7.2 213 03
0$1% :'LHVHO$6
Fuel Pump Suction Valve 909-7.3
Overhaul
Overhaul
909-7.3
1. Set up the suction valve in a bench vice 1.

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.
KB909-3.3 105 05
Lapping of the seats must not be attempt-
ed.
3. Mount the O-ring in the groove of the seal- 2.

ing ring and position the cone on the thrust
piece.
Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the groove.
Note!
KB909-3.3 105 06
Make sure that the sealing ring is

mounted correctly. See the sketch.
After mounting the sealing ring, compress it 3.

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.

XZ909-7.3 204 03
0$1% :'LHVHO$6
909-7.4 Fuel Pump Suction Valve
Mounting
Mounting
909-7.4
1. 1. Mount the top cover in an upside down po-

sition in the top cover bracket mounted on
the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
D09-33 er.
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 bend-

ing up an edge of the lock washer over one
KN909-7.4 213 01
of the flats of the valve.
2. Remove the top cover from the bracket and

mount the top cover in the fuel pump hous-
2. ing. See Procedure 909-5.4.
GN909-5.2 204 03
0$1% :'LHVHO$6
Fuel Pump Puncture Valve 109-8
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10908
109-8 Data 0037 Fuel Pump Puncture Valve
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D09-35 Puncture valve, tightening torque 890 Nm

D09-36 Puncture valve 5 kg
MAN B&W Diesel A/S
109-8 Fuel Pump Puncture Valve
Data
P90951 128 Crowfoot wrench head
MAN B&W Diesel A/S
Fuel Pump Puncture Valve 909-8.2
Dismantling
Fuel Pump Puncture Valve
S60MC-C
0217
Dismantling
909-8.2
2.
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!

2. Dismantle the control air pipe and the pro-

tective cap above the puncture valve.
3. Unscrew and remove the puncture valve

from the fuel pump top cover.
4. After dismantling it is recommended always

HN909-8.2 207 02
to overhaul the puncture valve.
If the overhaul cannot take place immedi-

ately after the dismantling, it is recommend-
ed to place the puncture valve immersed in
diesel oil until the overhaul. 3.
HN909-8.2 207 03
0$1% :'LHVHO$6
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 punc-

ture valve, using a brass mandrel and a
hammer. Take care not to damage the valve
seat.
Thoroughly clean all the parts in clean die-

sel oil.
2. Inspect the conical seats of the valve hous-

ing 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 at-

HN909-8.3 207 01
tempted.
2.
HG909-8.2 201 02
0$1% :'LHVHO$6
Fuel Pump Puncture Valve 909-8.3
Overhaul
3. When mounting the new sealing rings on 3.

the spindle of the air piston, the inner seal-
ing ring must be mounted first.
Mount the O-ring in the ring groove and po-

sition the large cone on the spindle.
Place the sealing ring on the cone and, us-

ing 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.
GM909-3.3 89 10
Before assembling the puncture valve, lu-

bricate all parts with “MOLYKOTE anti-fric-
tion SPRAY D321R” or molybdenum
disulphide (MoS 2).
4.
Mount new O-rings on the housing.
5. If the puncture valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
valve during storage.
GM909-3.3 89 12
0$1% :'LHVHO$6
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 absolute-
ly 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.
HN909-8.4 207 03
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Fuel Pump Shock Absorber 109-9
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10909
109-9 Data 0026 Fuel Pump Shock Absorber
X Stopped engine
X Shut off fuel oil
Data
D09-39 Shock absorber 27 kg
MAN B&W Diesel A/S
109-9 Fuel Pump Shock Absorber
Data
MAN B&W Diesel A/S
Fuel Pump Shock Absorber 909-9.1
Checking
Fuel Pump Shock Absorber
S60MC-C
0214
Checking
909-9.1
To ensure satisfactory operation, the function-

ing of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspec-
tion is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is oper-
ating.
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
HM909-4.0 09 01
hand, corresponding to the strokes of the
fuel pump.
The air pulses occur when the shock ab-

sorber 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, meas-

ure the amount of leakage oil flowing from
the drain pipe of the shock absorber hous-
ing. 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 overhaul-
ing.
0$1% :'LHVHO$6
909-9.3 Fuel Pump Shock Absorber
Overhaul
Overhaul
909-9.3
1.
Note!

D09-39 has been drained off.
1. Remove the shock absorber drain pipe.

Place a wire strap around the shock ab-
sorber and hook on the engine room crane.
Loosen the screws holding the shock ab-
GN909-9.3 204 01
sorber 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
2. 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 re-

lieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.
4. Clean all parts and polish the sliding sur-

faces of the piston and the shock absorber
housing. Mount a new sealing ring in the
HG909-9.2 201 02
shock absorber housing and a new wear

ring on the piston.
5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
4. the threaded rod.
Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to dam-
age the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.
6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking de-
vice. Remove the threaded rod and insert
the plug.
HG909-9.2 201 04
0$1% :'LHVHO$6
Fuel Pump Shock Absorber 909-9.3
Overhaul
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 ab-
sorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
0$1% :'LHVHO$6
Lifting Gear for Roller Guide 109-10
Data
X Stopped engine
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off fuel oil
Data
When referring to this page, please quote D10910 Edition 0018 Page 1 (2)
MAN B&W Diesel A/S
109-10 Lifting Gear for Roller Guide
Data
P90951 307 Pulling tool bell shaped
MAN B&W Diesel A/S
Lifting Gear 909-10.1
Checking
Lifting Gear
S60MC-C
211
Checking
909-10.1
1.
Caution!
Do not use the lifting tool for the fuel

pump roller guide while the engine is run-
ning.
If a fuel pump is to be put out of action, dis-

connect it in the following manner:
1. Stop the engine and engage the turning

gear.
HN909-10.1 205 01
Remove the inspection cover on the upper
part of the camshaft housing in front of the
fuel cam for the pertaining roller guide.
Turn the engine until the roller is in the high-

est position on the cam (on the circular sec- 2.
tion of the cam).
2. Loosen the lock screw on top of the flange

and the nut on the lifting tool.
Press the shaft against the roller guide.

When the shaft has been pressed fully in,
the guide screw is positioned in line with
the vertical slot of the flange.
HM909-5.0 44 1/2
When referring to this page, please quote Procedure 909-10.1 Edition 211 Page 1 (2)
0$1% :'LHVHO$6
909-10.1 Lifting Gear
Checking
3. 3. Mount a socket spanner, a slide-T handle

and an extension pipe on the shaft, and
turn the shaft anti-clockwise until the guide
screw is in top of the slot, which indicates
that the roller guide is in the lifted position.
4. Lock the shaft in this position by tightening

the lock screw and the nut on the lifting tool.
Check through the inspection cover open-

ing that the roller guide is clear of the fuel
cam. The engine can now operate on the
remaining cylinders, see Volume I, Section
HN909-10.1 211 03
704.
Re-engagement of the fuel pump roller guide
4.
Caution!
Re-engagement of the fuel pump roller

guide must only take place when the
engine is at a standstill.
5. Turn the engine until the circular section of

the pertaining fuel cam is positioned up-
wards, and then lower the roller guide in the
reverse order to lifting.
NB! Remember to loosen the lock screw.

HM909-5.0 44 2/2
6. When the roller guide has been lowered

into the position where the guide screw is
in the lowermost position, tighten the lifting
tool nut against the flange whereby the lift-
6. ing tool will be pulled away from the roller
guide. The guide screw will now be posi-
tioned at the end of the horizontal part of
the slot of the flange.
Tighten the lock screw.

HN909-10.1 205 05
Page 2 (2) When referring to this page, please quote Procedure 909-10.1 Edition 211
0$1% :'LHVHO$6
Fuel Valve 109-11
Data
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-40 Fuel valve opening pressure 300 - 380 bar

D09-42 Inlet seat, max. diameter 25 mm
D09-43 Fuel valve 13 kg
MAN B&W Diesel A/S
109-11 Fuel Valve
Data
P90151 71 Dismantling tool for fuel valve

P90951 94 Milling tool for fuel oil pipe seats
P90951 165 Grinding mandrel for valve head
P90951 297 Assembling tool for fuel valve
P90961 Fuel Valve tester, complete
P90966 Fuel Valve Nozzle - Tools
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
1. Fuel Valve
1.
The fuel valves must be given the utmost at-
tention and care, as the greater part of irregu-
larities that may occur during the running of the
engine can be attributed to defects in these
valves.
If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 900-1.
In order to obtain reliable results during testing

of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disas-
sembled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3.
M909110245C01
Note!
In the event that the slide-type fuel valve is

pressure tested without being cleaned be-
tween the fuel nozzle and the cut-off slide,
the opening pressure value measured might 2.
be considerably lower than specified.
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 50°C.
For operation of the pressure testing pump,

see the supplier's instructions.
Note that the high-pressure pump should be

periodically checked in accordance with the
supplier's instructions.
2. Spring housing
To ensure that over tightening has not taken

place, check that the locking/indicating pin has
M909110240C02
not been bent or broken off.
In the event of over tightening, replace the

spring housing by a new one.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
3. Setting-up the fuel valve

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 pres-

sure disc is flush with the top face of the
spring housings. Mount the oil pipe between
the pressure testing pump and the fuel valve.
o
Pressure testing procedure
The following functions of the fuel valve must

be checked:
M909110242C03
• Flushing and jet control

• Opening pressure
• Sealing test and sliding function
4. • 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:
M909110240C04
There is to be a continuous jet of oil through at

least one of the nozzle holes.
Owing to the geometry of the internal part of

the nozzle - and because of the height to
which the spindle is lifted during pressure test-
ing is lower than the height it is lifted during
normal engine operation - the fuel oil will not
necessarily flow from all of the nozzle holes.
Cause of fault:
If the jets do not fulfil the above point, the

cause may be:
Dirt in the nozzle holes
The nozzle is not mounted correctly
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
5. Opening pressure
5.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle D0940
holes.
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 specified

in D09-40, the cause may be that a wrong type
of spring is used - replace the spring on the
M909110240C05
thrust spindle, if necessary, replace the com-

plete thrust spindle.
If the opening pressure is lower than specified

in D09-40, the cause may be that the spring
has sagged - replace the spring, or add a spe-
cial thin disc.
Note!
Special thin discs are available as spares.
If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
6. Sealing test and sliding function

6.
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.
Oil must not flow from the nozzle holes.

M909110240C06
The pressure drops relatively slowly to about

15 bar, after which it drops quickly to 0 (the
slide is pressed against the conical seat and
opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when the
fuel valve is full of oil.
Cause of fault:
If oil flows out of the nozzle holes, the cause is

either:
• Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
• Too quick pressure drop:
- the clearances of the movable parts, both of

the spindle guide and of the 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.
If a quick pressure drop from 15 to 0 bar can-

not be registered:
• The valve slide is sticking; or
• The vent hole in the thrust piece is
blocked.
If so, disassemble and examine the spindle

guide, replace if necessary. See Procedure
909-12.3.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
7. Pressure test, O-ring sealing

7. Max. 10 bar
To ensure that the leak oil (circulation oil) re-
mains in the closed system, build up a working
pressure of about max. 10 bar until oil flows
out of the leak oil outlet.
Close the leak oil outlet with a gasket and plug

screw.
Max. 100 bar
Increase the working pressure to about 100
bar.
The built-up pressure of about 100 bar should

be maintained.
Cause of fault: Max. 100 bar
If oil leaks out at the union nut, the O-ring in-

side the fuel valve head is defective, and must
be replaced.
M909110240C07
8. Atomization test
Note!
8.
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 be-

cause 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 be-
tween cut-off slide and nozzle.
M909110240C08
All of these conditions involve the risk of sei-

zure between the cut-off slide and the nozzle.
MAN B&W Diesel A/S
909-11.2 Fuel Valve
Dismantling
1. Close the fuel oil inlet and outlet valves,

1. and drain the high-pressure pipe and the
fuel valve.
Dismantle and remove the fuel oil high-

pressure pipe.
Disconnect the return oil pipe from the fuel

valve.
2. Remove the nuts and the spring housings.

M909110240D01
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 immedi-

2. ately, the valve should be placed immersed
in diesel oil until overhauling.
M909110240D02
3.
D0943
M909110239D03
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
When fuel valves are overhauled, all parts

should be handled carefully and be kept clean. 1.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
fore 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. A
M909110240O01
2. Place the valve holder in a machine vice,
mount the fuel valve in the holder and fit
the valve with the guide disc from the
grinding tool.
3. Compress the fuel valve and the spring in- 2.

side, 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.

M909110240O02
3.
M909110240O03
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
4. Pull the valve head clear of the valve hous-

4. ing.
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.

M909110245O04
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
5. Carefully clean and examine all surfaces of

the: 5.
• Fuel valve housing
• Fuel valve head
• Thrust spindle
If necessary, grind the seating surfaces by

means of the grinding mandrels supplied and a
fine-grain abrasive (such as Carborundum No.
500).
This grinding must only be carried out manu-

ally.
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 fitted in the chuck of a column-type
drilling machine provided that the number of
revolutions is kept at a minimum (not exceed-
ing approx. 100 r/min). An ample supply of cut-
ting emulsion must be used.
Note!
Take care not to exceed the maximum dia-
meter of the seat, see Data.
M909110242O05
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
6. The complete spindle guide, including the

6. fuel nozzle, should be sent to an
authorised MAN B&W repair shop for over-
haul. If this is not possible, the spindle
guide may be overhauled on board.
Note!
Do not attempt to remove the fuel nozzle

from the spindle guide unless the spindle
guide has been dismantled. Otherwise the
M909110240O05
cut-off slide on the spindle may be dam-

aged.
7. The non-return valve should be sent to an

authorised MAN B&W repair shop for over-
haul. If this is not possible, the non-return
7.
valve may be overhauled on board.
8. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.
Carefully slide the spindle guide down into

the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corre-
M909110240O06
sponds to the measurement taken before

the valve was disassembled.
Note!
Make sure that the fuel nozzle and

8.
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.
M908020253D05
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
9. Mount:
9.
• 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

M909110242O09
valve housing and valve head is intact, and

press the valve head down into the valve
housing.
See that the guide pin between valve hous-

ing and valve head engages correctly so as
to prevent relative turning of the parts. 10.
M909110240O09
MoS 2
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
11. Assemble the valve by means of the union

11. nut.
Place the valve in the valve holder in a drill-

ing machine.
Compress the fuel valve and the spring in-

side. 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.
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 dur-
ing storage.
M909110240O10
MAN B&W Diesel A/S
Fuel Valve 909-11.4
Mounting
1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover 1.
and check the seating in the bore for
marks which, if any, must be eliminated.
(For reconditioning of the valve bores in the D0943
cylinder cover, see Procedure 901-1.3).
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS2). MoS 2
2. Mount the valve in position in the cylinder

cover.
M909110239M01
Mount the spring housings and the nuts.
Tighten the nuts until the top face of the
pressure disc is flush 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 2.
of the fuel valve to the cylinder cover as O
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.
M909110245M02
As a minimum, the distance between

the fuel oil pipe ends and the thrust
bushings must be checked and, if nec-
essary, adjusted. 3.
Mount the overhauled fuel oil high-pressure

pipe and the return oil pipe.
Note!
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
M909110242M03
MAN B&W Diesel A/S
Fuel Valve Spindle Guide 109-12
Data
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
Engage turning gear
Shut off fuel oil
Data
D09-70 Nozzel spray hole cleaning tool table
Nozzel Cleaning Test Nozzel Cleaning Test

spray hole drill pin spray hole drill pin
0.90 0.85 0.94 1.60 1.55 1.65

0.95 0.90 0.99 1.65 1.60 1.70
1.00 0.95 1.04 1.70 1.65 1.74
1.05 1.00 1.09 1.75 1.70 1.80
1.10 1.05 1.14 1.80 1.75 1.85
1.15 1.10 1.20 1.85 1.80 1.89
1.20 1.15 1.24 1.90 1.85 1.94
1.25 1.20 1.30 1.95 1.90 1.99
1.30 1.25 1.34 2.00 1.95 2.05
1.35 1.30 1.39 2.05 2.00 2.09
1.40 1.35 1.44 2.10 2.05 2.14
1.45 1.40 1.49 2.15 2.10 2.19
1.50 1.45 1.54 2.20 2.15 2.24
1.55 1.50 1.59 2.25 2.20 2.29
MAN B&W Diesel A/S
109-12 Fuel Valve Spindle Guide
Data
P90966 Fuel Valve Nozzle - Tools
MAN B&W Diesel A/S
Fuel Valve Spindle Guide 909-12.3
Overhaul
2.
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 opera-
tion.
Based on service experience it is recom-

mended 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 interchange-
able, therefore only one guide is to be dis-
assembled at a time.
Note!
M909120228O02
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 4.
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 op-
tional 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.
M909120228O04
MAN B&W Diesel A/S
909-12.3 Fuel Valve Spindle Guide
Overhaul
5. Clean all the parts of the spindle guide in

5. 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 atten-

tion to the seating surfaces and sliding sur-
faces 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
M909120228O05
360’.
Use also a little oil for the polishing (a

coarser polishing linen must absolutely not
be used).
6. Note!
The sliding surface of the cut-off slide
may only be polished VERY carefully.
The sliding surface must not be dam-
aged.
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 mag-
nifying glass.
M909120228O06
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
MAN B&W Diesel A/S
Overhaul
7. Clean any carbon deposits from the central

bore of the fuel nozzle by means of the 7.
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 cylindri-

cal part of the nozzle, as shown in the fig-
ure. 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.
M909120228O07
Clean the spray holes, using gas oil and
the special drills supplied.
Note!
8.
During this operation be very careful not
to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
1 2 3 4
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 dis-
carded.
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
M909120228O08
glass). XXXXXX X
XX*XXXXX
Check the fuel nozzle before mounting on
the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
9.
Note!
It is recommended that the fuel nozzle is
changed whenever the spindle guide is
being overhauled or at maximum 8000
running hours.
M909120228O09
MAN B&W Diesel A/S
909-12.3 Fuel Valve Spindle Guide
Overhaul
10. Lubricate the spindle and the thrust piece

11. with the cut-off slide with a little Molybde-
num Disulphide (MoS2), see Procedure 913-
11.
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.
M909120228O11
12.
M909120228O12
MAN B&W Diesel A/S
Overhaul
13. Lubricate the sliding surfaces of the nozzle

and the spindle with a little Molybdenum 13.
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 Spring pin

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. Scratch marks
Note!
M909120228O13
The mounting tools are not standard for

all engines but may be delivered as op-
tional 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 us-
ing 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
spindle guide during storage.
MAN B&W Diesel A/S
Non-return valve 109-13
Data
SAFETY PRECAUTIONS
Special
D10913 Data 0031
109-13 Edition Non-return
S60MC-Cvalve
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-13 Non-return valve
Data
P90951 153 Flange for dismantling of non-return valve

P90968- 12 Probe light with magnifier, complete
MAN B&W Diesel A/S
Non-return valve 909-13.3
Overhaul
Non-return valve
K98MC-C
0206
Overhaul
909-13.3
1.
Note!
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
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, defec-

tive parts cannot be replaced individually

by new ones.

&
Place the non-return valve as shown in Fig. 0
1 in a bench vice provided with “soft” jaws,

A
and disassemble the non-return valve, us- 2.
ing 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 B C D
piece of cloth.

Finally, clean in either gas oil, kerosene or

‘Electrocleaner', and wipe the parts dry with

%
1
a clean piece of cloth.
3. Now place the parts on clean, lint-free rags 3.

and examine with an 8-10 times enlarge-
ment magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.

&
0
0$1% :'LHVHO$6
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 A-
D 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 conven-
tional 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 out-

side 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 enlarge-
ment magnifying glass.
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
NA909-13.3 205 05
6. Mount the non-return valve as follows:
• Lubricate all movable parts with molyb-

denum 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 over-
haul, cover all openings of the non-return
valve with plastic to prevent dirt from enter-
MC909-6.3 69 06
ing the valve during storage.
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 109-14
Data
SAFETY PRECAUTIONS
Special Edition
L70MC-C
D10914
109-14 Data 0067 Fuel Oil High-Pressure Pipe
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-47 Fuel oil high-pressure pipe, tightening torque 190 Nm

D09-50 Union nuts, tightening torque 55 Nm
D09-52 Fuel oil pipe 20 kg
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data
P90951 104 Milling tool for fuel oil pipe

P90951 128 Crowfoot spanner
P90951 130 Crowfoot spanner
MAN B&W Diesel A/S
Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S35MC
0235
Dismantling
909-14.2
2.
High-Pressure Pipe with Double Pipe
1. Close the fuel oil inlet and outlet valves.
2. Unscrew the union nipple from the fuel

valve.
3. Unscrew the union nipple from the fuel

pump.
BM909-14.2 211 02
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.
3.
Note!
It is recommended always to overhaul

the high-pressure pipe before remounting
it on the engine.
The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.
GN909-14.2 210 03
4.
D09-52
BM909-14.2 211 04
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3
1. Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before re-
mounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed

as follows:
1. Lift up the union nut. Remove the spring

ring from the two-part sleeve. Remove the
sleeve.
KB909-7.1 77 01
2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.
2. Note!
The two pipe ends are of different

designs – see sketch.
Turn the upper tightening ring (A) until the

miller presses against the pipe end.
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
KB909-7.1 77 03
During the milling process, add drilling oil

emulsion liberally.
3. On both pipe ends a small groove has been

3. ground to indicate the maximum allowable
grinding of the pipe ends.
Max. grind-away
The pipe ends may only be ground until the
ground surface is flush with the bottom of
the groove.
If the pipe ends are still not in order, the

pipe must be discarded.
After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.
KN909-14.3 223 03
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 909-14.3
Overhaul
4. Remove and discard both the internal and 4.

external O-rings. Mount new O-rings.
Mount the two-part sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the high-pressure pipe.
KB909-7.1 77 04
0$1% :'LHVHO$6
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
Mounting
909-14.4
3. 1. Ensure that the fuel valve is fitted with a

D09-52 new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
BM909-14.4 211 03
Screw the union nipples onto the fuel valve

and into the fuel pump top cover, by hand.
Note!
4.
The nipples must be screwed by hand,
D09-47 as the threads of the union nipples, fuel
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should

only be done after both of the union nip-
ples have been screwed into position.
4. Use a crowfoot wrench and a torque span-

BM909-14.4 211 04
ner to tighten the union nipple at the fuel

valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque span-

ner to tighten the union nipple at the fuel
5. pump 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.
D09-47
GN909-14.4 210 05
0$1% :'LHVHO$6
Fuel Pump Roller Guide 109-15
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10915
109-15 Data 0046 Fuel Pump Roller Guide
X Stopped engine
X Shut off fuel oil
Data
D09-53 Nut, reversing shaft, tightening torque 160 Nm

D09-54 Clearance A 0.6 - 3.1 mm
D09-55 Clearance B 4.3 - 6.0 mm
D09-56 Clearance C 0.3 - 0.8 mm
D09-57 Roller/bushing/shaft pin, max. clearance 0.5 mm
D09-61 Fuel pump roller guide 96 kg
D09-62 Pump base 118 kg
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
Data
P90951 82 Lifting tool for fuel pump roller guide
MAN B&W Diesel A/S
Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
S60MC-C
0226
Checking
909-15.1
3.
Roller guide mounted in engine
1. The fuel pump roller guide can be partially

checked while mounted on the engine, us-
ing the following procedure:
2. Lift the fuel pump roller guide.

3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.
Turn the engine to provide the maximum
HN909-10.1 205 01
space between the roller guide and the cam
disc.
Turn the roller by hand to check that it can

move freely and without unnecessary re-
sistance or “hard” points. 5.
Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no trac-
es of bearing metal left in the roller guide
housing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
4. Lower the roller guide onto the fuel cam

again.
5. Using the telegraph, move the roller guide

to the AHEAD position.
GN909-15.1 203 05
Check that the reversing link is fully tilted

over in AHEAD position.
Carry out the same check in the ASTERN po-

sition.
0$1% :'LHVHO$6
909-15.1 Fuel Pump Roller Guide
Checking
7. 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:
6. Dismount the roller guide from the engine.

7. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.
8. Turn the roller guide upside down and land

it in a vertical position on a couple of
planks, with the roller hanging freely.
Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clear-
ance permits.
MA909-8.0 70 07
8.
D09-57
MA909-8.0 70 06
0$1% :'LHVHO$6
Dismantling
Dismantling
909-15.2
1.
Note!

1. Dismantle the top cover of the fuel pump.

2. Dismantle the fuel pump barrel assembly.

GN909-5.2 204 03
2.
GN909-6.2 204 06
0$1% :'LHVHO$6
Dismantling
3. 3. Dismantle the fuel pump housing, see Pro-

cedure 909-4.2.
Note!
When lifting the fuel pump housing, take

care not to damage the threads on the
studs.
4. Loosen and remove the screws from the

sealing cap 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

GN909-15.2 203 03
drain pipe from the pump base.
5. Remove the cover on the camshaft housing

to inspect the position of the roller guide.
Turn the engine until the roller guide is at
4.
BDC.
HN909-15.2 206 04
5.
HN909-10.1 205 01
0$1% :'LHVHO$6
Dismantling
6. Loosen the nuts on the two threaded studs 6.

successively until the roller guide springs
are relieved.
Remove the nuts, mount two eye bolts in

the pump base and lift it away. D09-62
When lifting, take care that the bushing of
the pump base slides against the neck of
the roller guide without scratching.
Remove the springs from the roller guide.
7. 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.
HN909-15.2 206 06

• Lower the lock plate, thereby securing

the foot in the locked position.
7.
Lift the roller guide out of the roller guide
housing, using the crane.
When lifting, take care that the slide surfac-

es of the roller guide do not scrape against
the roller guide bushing. D09-61
Land the roller guide on wooden planks.
8. Check the roller guide.

GN909-15.2 203 07
0$1% :'LHVHO$6
Overhaul
Overhaul
909-15.3
1. 1. Inspect and check the fuel pump roller

guide.
2. It is recommended that the roller guide

D09-61 should ONLY be dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
• seizure marks on the slide surfaces,
have been observed when checking the

roller guide.
Note!
For disassembling of the roller guide,

MA909-8.0 70 07
contact an MAN B&W authorized repair

shop.
3. If no irregularities are found, just clean and

3. lubricate the roller guide before remounting
it in the roller guide bushing.
HN909-15.3 206 03
0$1% :'LHVHO$6
Mounting
Mounting
909-15.4
1. Lubricate the roller guide with plenty of 1.

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
During mounting, take care not to scratch

the sliding surfaces of the roller guide.
D09-61
Make sure that the pin of the reversing link
fits in the bracket of the reversing shaft.
2. After mounting the roller guide with the re-

versing link, check the clearance between
the roller guide and the guide plate mount-
ed in the roller guide bushing.
Turn the camshaft so that the roller guide is

lifted approx. 20 mm.
The clearance C between the roller guide

and the guide plate must be the same at
both ends +/– 0.1 mm.
HN909-15.4 206 01
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 2.

check that the reversing mechanism is
working smoothly.
The clearances A and B must be approx.

the same in both positions. See Data.
D09-54
D09-56
D09-55
HN909-15.4 206 02
0$1% :'LHVHO$6
Mounting
3. 3. If adjustment is necessary, it must take

place in the ASTERN position.
Remove the cover over the shaft connec-

tion.
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 to the

D09-53 torque stated in Data, and lock the nut with
Loctite type: Screw Lock No. 59.
Mount the cover over the shaft connection.
4. Turn the engine until the roller guide is at

HN909-15.4 206 03
BDC.
5. Mount the springs and the spring seat discs

over the roller guide.
5. Mount the pump base over the roller guide

and the springs.
Mount the two special nuts on the threaded

studs.
Using the special tube-shaped socket

D09-62 wrench, tighten the nuts until the pump
base is fastened tightly to the roller guide
bushing.
HN909-15.2 206 06
0$1% :'LHVHO$6
Mounting
6. Check the movement of the reversing link. 6.

7. Replace the scraper rings in the sealing

cap as follows:
Loosen and remove the screws and nuts

from the bottom of the cap, remove the re-
taining flange and ring holder with scraper
ring.
8. Replace the O-ring in the top of the cap.
Replace the axial scraper ring in the bottom

of the cap. Check that the O-ring and scrap-
GN909-15.1 203 05
er ring are mounted correctly. See the
sketch.
7.
GN909-15.4 203 07
8.
MA909-8.0 70 21
0$1% :'LHVHO$6
Mounting
9. 9. Remove the scraper ring and O-ring from

the ring holder.
Place the new O-ring in the ring holder.
Before mounting, the new scraper ring must

be heated in 100°C hot water or oil for at
least five minutes.
Note!
When mounting the scraper ring in the

groove, fold the ring without making any
AM909-8.0 31 16
sharp edges, and be careful not to cut

the scraper ring on the edge of the ring
groove when pressing it in.
10. Check that the O-ring and scraper ring are

mounted correctly. See the sketch.
10. Assemble the sealing cap, the ring holder

and retaining flange.
Tighten the nuts on the screws.
After tightening, check that the holder can

be moved.
11. Mount the lubricating oil pipe and the drain

pipe on the pump base.
GN909-15.4 203 10
Mount the sealing cap on top of the roller

guide, over the sealing bush inside the
pump base.
11. Tighten the screws and lock with locking

wire.
12. Mount the fuel pump housing.

Mount the barrel assembly.

Mount the top cover.

HN909-15.4 206 11
0$1% :'LHVHO$6
Fuel Valve - Tools Plate
P90961-0069
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0069

No. No.
014 High-pressure pump

026 Table
038 Rig fuel oil valve
040 High-pressure hose
051 Connection piece, M42x2
063 Test rig, complete
075 Cover
087 Angle union
099 Gasket
109 Plug screw
122 Hose
MAN B&W Diesel A/S
Fuel Valve Nozzle - Tools Plate
P90966-0008
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0008

No. No.
011 Tool box

023 Extractor for atomizer
035 Drift for atomizer
047 Cleaning brush
060 Instruction plate
202 Toolset, complete
Note:
When odering new cleaning tool,

please state P/N on fuel nozzle.
MAN B&W Diesel A/S
Fuel Puncture Valve - Tools Plate
P90967-0001
MAN B&W Diesel A/S
Plate Fuel Puncture Valve - Tools
P90967-0001

No. No.
017 Tool for tightening of puncture valve
MAN B&W Diesel A/S
Fuel Valve - Inspection Tools Plate
P90968-0001
MAN B&W Diesel A/S
Plate Fuel Valve - Inspection Tools
P90968-0001

No. No.
012 Probe light with magnifier, complete
MAN B&W Diesel A/S
Fuel Valve Nozzle - Cleaning Tools Plate
P90974-0001
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Cleaning Tools
P90974-0001

No. No.
015 Drill*
027 Test mandrel*
039 Pin vice*
206 Cleaning tool set, complete
Note:
* When ordering new cleaning tool,

please state P/N on fuel nozzle.
MAN B&W Diesel A/S
Mounting Tools - Pump Barrel Seals Plate
P90977-0001
Mounting Tools - Pump Barrel Seals
0001
P90977
MAN B&W Diesel A/S
Plate Mounting Tools - Pump Barrel Seals
P90977-0001
Item Item
No. No.
011 Cone
023 Pushing tool
035 Compression tool
047 Cone
059 Pushing tool
072 Spacer ring
MAN B&W Diesel A/S
Mounting Tools - Suction Valve Seals Plate
P90979-0001
Mounting Tools - Suction Valve Seals
0001
P90979
MAN B&W Diesel A/S
Plate Mounting Tools - Suction Valve Seals
P90979-0001
Item Item
No. No.
012 Cone
024 Pushing tool
MAN B&W Diesel A/S
Mounting Tools - Air Piston Seals Plate
P90980-0001
Mounting Tools - Air Piston Seals
0001
P90980
MAN B&W Diesel A/S
Plate Mounting Tools - Air Piston Seals
P90980-0001
Item Item
No. No.
018 Cone
020 Pushing tool
043 Cone
055 Pushing tool
079 Cone
MAN B&W Diesel A/S
91064 0002 Travelling Trolley

91066 0001 Air Cooler - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Travelling Trolley Plate
P91064-0002
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0002

No. No.
010 Travelling trolley*
Note:
* When ordering this tool, please state

load and track width.
MAN B&W Diesel A/S
Air Cooler - Lifting Tools Plate
P91066-0001
Air Cooler - Lifting Tools
0001
P91066
MAN B&W Diesel A/S
Plate Air Cooler - Lifting Tools
P91066-0001
Item Item
No. No.
011 Lifting attachment air cooler fore end,

complete
023 Screw
MAN B&W Diesel A/S
111-01 0025 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
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Safety Valve 111-1
Data
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D11-01 Opening pressure 200± 5 bar

D11-02 Valve housing, tightening torque 45 Nm
MAN B&W Diesel A/S
111-1 Safety Valve
Data

P90151 117 Test equipment for combined safety valve
MAN B&W Diesel A/S
Safety Valve 911-1.2
When Side-mounted
1.
1. Remove the guard surrounding the safety
valve.
Unscrew the safety valve from the exten-

sion pipe.
2. Dismantle the indicator cock and the inter-

mediate pipe.
M911010211D01
When Top-mounted
3. Unscrew the safety valve from the cylinder

cover.
Remove and discard the mild steel disc.

2.
M911010211D02
3.
M911010211D03
911-1.3 Safety Valve
Overhaul (Adjustment) MAN B&W Diesel
1. If necessary, dismantle the safety valve and

1. clean all the parts in either gas oil, kero-
sene, or ‘electro-cleaner’.
2. Assemble the safety valve in two steps:
• Insert the valve flap and the stop ring in

the valve guide and screw on the valve
housing.
• Tighten the housing to the torque stated

in the data, loosen and tighten again to
the torgue stated in the data.
M911010211O01
3. Then mount:
• the valve spindle
• the spring
2.
• the adjusting screw
• the lock nut

M911010211O02
3.
M911010211O03
MAN B&W Diesel Overhaul (Adjustment)
4. To set the safety valve opening pressure:

4.
• Set up the safety valve in the Fuel valve
test rig.
• Connect the testing device to the hy-

draulic 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, with-

out 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).
• Tighten the lock nut.

M911010212O04
• Test the opening pressure.
• Remove the valve from the fuel valve

test rig.
911-1.4 Safety Valve
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indi-

cator cock. Mount the intermediate pipe
and the indicator cock.
3. Mount a new sealing ring and a new or

overhauled safety valve.
When mounting the safety valve, apply

M911010211M01
tools only on the hexagon on the safety

valve.
Mount the guard surrounding the safety

valve.
2.
M911010211M02
3.
M911010211M03
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
Mount a new mild steel disc in the bore.
When mounting the safety valve on the cyl-

inder cover, apply tools only on the hexa-
M911010211M04
gon on the safety valve.
5.
M911010211M05
Relief Valve 111-2
Data
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
X Shut off fuel oil
Data
MAN B&W Diesel A/S
111-2 Relief Valve
Data
MAN B&W Diesel A/S
Relief Valve 911-2.1
Checking
60&
Relief Valve
0211
Checking
911-2.1
1.
1. During running of the engine, check if there
are any leaks.
If a leak occurs, replace the O-ring inside

the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical dam-

age to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
If one or more plates in the flame arrester

are damaged, the relief valve must be dis-
assembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
XZ911-2.1 209 01
Note!
The complete flame arrester has to be

2.
replaced after a crankcase explosion.
XZ911-2.1 207 03
0$1% :'LHVHO$6
Scavenge Air Receiver Safety Valve 111-3
MAN B&W Diesel Data

X Stopped engine
Shut off safety air supply – Not ME engines
Shut off fuel oil
Data
111-3 Scavenge Air Receiver Safety Valve
Data MAN B&W Diesel
Scavenge Air Receiver Safety Valve 911-3.1
1. The scavenge air receiver safety valve

2.
is calibrated at the factory and does not
require any adjustment.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
Use a piece of cloth to wipe out any dirt

from the Oring packing and close the
valve again. Tighten the counter nut.
M911030001C02
If this operation cannot be performed
smoothly, the safety valve must be
dismantled and cleaned.
911-3.2 Scavenge Air Receiver Safety Valve
1. Dismount the safety valve from the scav-

1. enge air receiver.
2. On some engines, a cover has to be re-

moved in order to gain access to the safety
valve.
M911030001D01
2.
M911030001D02
1. Remove the split pin.

1.
Unscrew the nut thereby relieving the
spring tension.
Remove the nut, spring retainer and

washers.
Keep count of the washers.
Pull out the spring.
2. Pull out the valve ﬂap with spindle. If the

Oring seal is damaged remove it without
M911030001O01
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.
2.
M911030001O02
911-3.3 Scavenge Air Receiver Safety Valve
4. If the Oring seal has been removed mount

4. a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve ﬂap and spindle while

taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the

washers.
Tighten the nut until the split pin can be

mounted.
M911030001O04
7. Check the valve according to 9113.1.
5.
M911030001O05
6.
M911030001O01
1. Mount the safety valve on the scavenge air

receiver. 1.
M911030001M01
112-02 0009 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)
112-03 0018 Stay Bolts, Data
912-03 0212 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0073 Hydraulic Tools for Large Parts
91266 0001 Hydraulic Tools - End Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Holding Down and End Chock Bolts 112-2
Data
SAFETY PRECAUTIONS
Special Edition
D11202
112-2 Data 0009 Holding Down
S60MC-C
and End Chock Bolts
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D12-02 Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
1st check 500 hours
2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequent checks at intervals of 8000 hours
D13-01 Tightening pressure 1500 bar
D13-02 Dismantling pressure 1400-1650 bar
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data
P91263 Hydraulic tools for holding-down bolts

Bolts and end chock bolts, epoxy
MAN B&W Diesel A/S
Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0207
Checking
912-2.1
Note!
The hydraulic jack used for tightening the

holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the

end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking
1. Checking the Bolt Tightening
1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking table, see drawing Nos.
782225-0 and 782226-2, following which
the bolts are tightened to the normal tight-
ening pressure.
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.
If the ‘loosening pressure' is below 80 per

EN912-1.1 205 01
cent of the tightening pressure, the relative

chocks shall always be checked for possi-
ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.
0$1% :'LHVHO$6
Holding Down and End Chock Bolts 912-2.1
Checking
Side Chocks and Side Chock Liners 3.
3. After fitting the liners to an 80 per cent con-

tact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simulta-
neously.
The first time the ship is sailing in a fully-

loaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.
GN912-2.1 203 03
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
The feeler gauge is applied at the 7 points

indicated on drawing No. 782226-2, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated on

drawing No. 782226-2.
If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Stay Bolts 112-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11203
112-3 Data 0018 Stay Bolts
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D12-04 Check measurement 180±3 mm

MAN B&W Diesel A/S
112-3 Stay Bolts
Data

P91261 23 Hydraulic jack, complete
MAN B&W Diesel A/S
Stay Bolts 912-3.1
Checking
Stay Bolts
S60MC-C
0212
Checking
912-3.1
1.
1. This check can be performed during several
periods of stopped engine, but must be per- One Group
formed on complete twin stay bolt groups at One Group
a time, thereby ensuring uniform tension in
the affected bearings.
Note!
The first time this check is performed it

has to be completed in one operation.
NA912-3.1 210 01
The following checks have to be com-
pleted within a 500-hour period.
2. Before retightening the stay bolts, remove

the protective caps. 2.
3. Check for loose staybolt nuts with the tom-

my bar.
If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 01
Loosen and unscrew the nut on the oppo-

site stay bolt.
Check for the correct mounting of the stay

bolt by comparing with the check measure-
ment on the Data Sheet. 3.
D13-02
If the check measurement is not reached,
indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the
D12-04
thread in the top of the stay bolt, and turn
the stay bolt until the check measurement
GN912-3.0 39 09
data is met.
4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.
D13-01
GN912-3.1 202 03
0$1% :'LHVHO$6
912-3.1 Stay Bolts
Checking
5. 5. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
D13-01 stay bolts are tightened in one operation.
6. Maintain the mounting pressure, and

retighten the stay bolt nuts with a tommy
bar. Before relieving the system of pres-
sure, check with a feeler gauge that the
nuts bear against their contact faces.
GN912-3.1 202 02
7. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below the mounting pressure and check
6. whether the nut is loose.
If the nut is not loose:

Tighten the stay bolts concerned to the
mounting pressure.
If the nut is loose:

Tighten all stay bolts once again to the
mounting pressure.
8. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 04
7.
HM912-3.0 28 05
0$1% :'LHVHO$6
Crankcase Oil Outlet 912-5.1
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil 1.
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing. E F G D C B A
Note!
If the water content of the main engine
lube oil is rising, this may indicate that
the crankcase oil outlet sealings are frac-
tured.
M912050201C01
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing

remove:
Screws A 2.
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
M912050201C02
Note!
It is strongly recommended to always re-
place the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
912-5.1 Crankcase Oil Outlet
Metal bellow sealing

4.
4. Remove all screws A and grating B.
5. Remount four of the screws A at diametri-

C B cally opposite positions.
D A
6. Remove:
F Screws C
Cover plate D
Screws E.
E
G 7. Lift away metal bellow sealing F and exam-
ine it closely. If any cracks or punctures are
M912050201C04
found in the metal bellow sealing, it must

H be replaced.
Note!
7. It is recommended to always replace the
metal bellow sealing during inspection.
8. Replace gaskets G and H.
9. Mount metal bellow sealing F.
10. Mount:
Screws E
Cover plate D
Screws C.
M912050201C07
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Large Parts - Tools Plate
P91261-0073
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0073

No. No.

035 Support
047 Tommy bar
050 Sealing ring with back-up ring
060 Sealing ring with back-up ring
084 Spanner
106 Stud setter
MAN B&W Diesel A/S
Hydraulic Tools - End-Chock Bolts Plate
P91266-0001
(Epoxy Chocks)
MAN B&W Diesel A/S
Plate Hydraulic Tools - End-Chock Bolts
P91266-0001
(Epoxy Chocks)
No. No.
019 Wooden box

032 Support
093 Tommy bar
103 Spanner
MAN B&W Diesel A/S
913 - General Tools
913-01 0215 Hydraulic Tools

913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools
91356 0053 Lifting Tools, etc.
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0040 Spanners
91366 0066 Instruments
91368 0007 Working Platforms
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Hydraulic Tools 913-1.1
Description
A. Snap-on coupling
1. A
B. Tool attachment thread C B
C. Bleed screw D
D. Piston E
E. Cylinder
F. Sealing rings
F
G. Spacer ring G S
H. Tommy bar
I. Nut
J. Stud or bolt
M913010215C01
H
K. Extension stud U
I
L. Lifting tool
S. Clearance
J
U. Milled recess for feeler gauge 2.
Studs or bolts provided with threads for at-

taching hydraulic tools and with circular nuts L
must only be loosened and tightened up by
means of the hydraulic tools supplied.
The jack(s) is/are connected, via a distributor I

block, to a high-pressure pump, which is set to
deliver hydraulic oil at the pressure indicated
D
on the jack and on the data sheet in the rel- C F
evant section of this instruction book. The stud E
or bolt concerned is thereby lengthened rela-
tive to the oil pressure applied and the piston
area, and the nut can be loosened or tight-
ened, as required, with the aid of a tommy bar. A F
The jacks must never be overloaded or ex- G K

posed to blows or impacts. They are marked 3. B
with a “Max. lift”, which must not be exceeded. H
J
1. The hydraulic tools, except those for the
M913010215C02
main bearings and the cylinder cover, con- U

sist of a jack with an internal thread to suit
the tool attachment thread on the stud or I
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, the hydraulic tool

consists of a double jack with two exten-
sion studs. This jack is designed for the si-
multaneous dismantling of both nuts on
one side of the main bearing.
MAN B&W Diesel A/S
913-1.1 Hyraulic Tools
Description
3. For the cylinder cover, the hydraulic tool

3. consists of eight individual jacks sus-
pended from a common lifting tool. A
spacer ring is mounted below each jack
using two spring pins.
Operation of the cylinder cover jacks is

identical to the operation of the single hy-
draulic jacks.
4. The hydraulic jacks are so designed that, in

the event that the “Max. lift” limit is ex-
ceeded, the pressure is relieved at the bot-
tom of the pressure chamber and the oil
M913010215C03
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
4. 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 nor-
mally alkaline and can thus damage the
back-up rings.
The following instructions must be closely

followed to prevent accidents or damage,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.
Warning!
Eye protectors and gloves must be used

when using hydraulic tools.
M913010215C04
MAN B&W Diesel A/S
Dismantling
Single Hydraulic Jack

1.
1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with

molybdenum disulphide grease or with
graphite and oil or similar.
Place the spacer ring around the nut in

such a position that the tommy bar can be MoS2
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.
Screw back the jack a number of turns, ac-

cording to the table shown on the sketch,
to produce a clearance between the jack
and the spacer ring.
M913010215D01
The clearance between the jack and spacer

ring ensures dismantling of the jack after
loosening the nut.
When loosening nuts on very long bolts 2.

(e.g. staybolts) it is recommended to un- Max. lift =
screw the jack an additional half turn.
Max. lift 10 mm 25 mm
Connect the hydraulic jack, the distributor Loosening 1 turn 3 turn
block and the high pressure pump by Tightening 1/4 trun 1/4 turn
means of high pressure hoses.
Loosen the bleed screw in the jack and fill

up the system with oil until oil without
bubbles, flows out of the bleed hole. Then
tighten the bleed screw again.
After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylin-
der of the jack.
M913010215D02
MAN B&W Diesel A/S
913-1.2 Hydraulic Tools
Dismantling
3. Increase the oil pressure to the prescribed

3. value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.
4. Unscrew the nut with the tommy bar, mak-

ing sure that the nut is not screwed up
against the jack.
5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
M913010215D03
Note!
Make sure not to exceed the “max lift”

stamped on the jack.
4.
M913010215D04
5.
M913010215D05
MAN B&W Diesel A/S
Dismantling
Double Hydraulic Jack

6.
6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.
Grease the tool attachment threads with

molybdenum disulphide grease or graphite
and oil or similar.
Mount the extension studs on the main

bearing studs.
Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.
Press the pistons and the cylinder of both

the hydraulic jacks firmly together.
Mount the two jacks (one by one using the

M913010215D06
lifting tool) over the extension studs and

land them on the spacer ring.
Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together. 7.
7. Screw the upper nuts on to the threads of

the extension studs until the cylinders of
the jacks bear firmly against each other
and against the spacer ring. MoS2
M913010215D07
MAN B&W Diesel A/S
Dismantling
8. The clearance between the pistons and the

8. cylinder of the top jack is adjusted by un-
Max. lift 10 mm
screwing the upper nuts 1 turn ª 3 mm.
The clearance between the jack and spacer

ring ensures dismounting of the jack after
3 mm loosening the nut.
Connect the hydraulic jacks, the distributor

block and the high pressure pump by
Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
M913010215D08
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

9. value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.
10. Unscrew the lower nuts 1½ turns with the

tommy bar, making sure that the nuts are
not screwed up against the extension stud.

the high-pressure pump, and remove the
hydraulic tools.
M913010215D09
Note!
Make sure not to exceed the “max lift”
stamped on the jack.
MAN B&W Diesel A/S
Overhaul
1. The hydraulic jacks require no maintenance

except replacement of defective sealing 1.
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.
The piston and cylinder are easily sepa-

rated by taking out the bleed screw and
pressing the parts apart with the help of Air
compressed air.
Warning!
Always use protective gloves and eye
protection when working with com-
pressed 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.
M913010215O01
Keep the sliding surfaces and threads

coated with acid-free grease or molybde-
num disulphide grease.
2. The pistons and cylinders of the double

jacks are separated in the same easy way
as described for the single jack. 2.
Air
Air
M913010215O02
MAN B&W Diesel A/S
Overhaul
3. When changing the sealing rings, first

3. 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.
1
2
See the sketch for the correct mounting of
both the upper and the lower sealing rings.
The same principle applies to all the jacks.
2
1 4. After fitting the sealing rings, coat the pis-
ton 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.
M913010215O03
MAN B&W Diesel A/S
Mounting
Single Hydraulic Jack

1.
1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.
Clean and lubricate the tool attachment

thread and the thread in the nut with mo-
lybdenum disulphide grease or with graph-
ite and oil or similar.
Fit the round nut on the thread and tighten MoS2

it with the tommy bar.
Check with a feeler gauge that the contact

face of the nut bears on the entire circum-
ference.
Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot for the purpose of
tightening the nut.
2. Press the piston and the cylinder of the

M913010215D01
jack firmly together.
Screw the hydraulic jack on to the tool at-

tachment thread.
Make sure that the cylinder of the jack 2.

bears firmly against the spacer ring and Max. lift =
that the parts are guided correctly together
Max. lift 10 mm 25 mm
Connect the hydraulic jack, the distributor Loosening 1 turn 3 turn
block and the high-pressure pump by Tightening 1/4 trun 1/4 turn
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.

M913010215D02
MAN B&W Diesel A/S
Mounting

3. value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.
4. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cess at the bottom of the spacer ring that
the nut bears against the contact face.

the pump, and remove the hydraulic jack.
M913010215M03
6. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nut as described un-
der ‘Loosening’, points 6-7-8, and then
tighten the nut again according to the pro-
cedure under ‘Tightening', points 17-18-19.
4.
M913010215M04
MAN B&W Diesel A/S
Mounting
Double Hydraulic Jack 5.
5. Thoroughly clean the nuts, the threads on

the main bearing studs, the contact faces,
and the surrounding parts.
Clean and lubricate the tool attachment

thread and the threads in the nuts with mo-
lybdenum disulphide grease or with graph- MoS2
ite and oil.
Fit the round nuts on the threads and

tighten them with the tommy bar.
M913010215M05
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circum-
ference.
Mount the extension studs on the main 6.

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.
6. Press the piston and the cylinder of both

the hydraulic jacks firmly together.
Mount the two jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.
Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.
Screw the upper nuts on to the threads of

the extension studs until the cylinders of
M913010215D06
the jacks bear firmly against each other

and against the spacer ring.
MAN B&W Diesel A/S
Mounting
7. Connect the hydraulic jacks, the distributor

7. block and the high pressure pump by
Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
M913010215M07
spacer ring.
9. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cesses at the bottom of the spacer ring
that the nuts bear against the contact face.
8.
the pump, and remove the hydraulic tools.
11. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nuts as described un-
der ‘Loosening', points 12-13-14, and then
tighten the nuts again according to the pro-
cedure under ‘Tightening', points 24-25-26.
M913010215M08
9.
M913010215M09
MAN B&W Diesel A/S
Standard Tightening Torques 913-4
Standard Tightening Torques

0201
.0&&
913-4
When tightening screws or nuts for which no

torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a

Molybdenum Disulphide (MoS 2) based lu-
bricant.
Thread Tightening Thread Tightening

torque torque
M8 17 Nm M22 400 Nm
M10 35 Nm M24 460 Nm
M12 50 Nm M27 610 Nm
M14 80 Nm M30 950 Nm
M16 135 Nm M33 1200 Nm
M18 190 Nm M36 1650 Nm
M20 260 Nm M39 2100 Nm
2. Self-locking nuts.

torque torque
M8 20 Nm M22 430 Nm
M10 40 Nm M24 490 Nm
M12 60 Nm M27 650 Nm
M14 90 Nm M30 1000 Nm
M16 150 Nm M33 1250 Nm
M18 210 Nm M36 1700 Nm
M20 290 Nm M39 2200 Nm
3. Screws and nuts locked with glue/Loctite.

torque torque
M8 23 Nm M22 580 Nm
M10 50 Nm M24 680 Nm
M12 70 Nm M27 900 Nm
M14 115 Nm M30 1350 Nm
M16 190 Nm M33 1700 Nm
M18 270 Nm M36 2350 Nm
M20 380 Nm M39 3000 Nm
0$1% :'LHVHO$6
Torque Spanner 913-5
/0&
Torque Spanner
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mix-
ture of graphite and oil or molybdenum disul-
phide with a friction coefficient µ = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are

to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened

to the stated torque and then to the next split-
pin hole.
The torque spanner must not be used for tor-

ques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided

with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,

there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle

appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl

system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the span-
ner, and a small click is heard.
When the torque spanner is not in use, the

spring inside should be released by adjusting to
minimum torque.
0$1% :'LHVHO$6
Tightening Gauge 913-6
Tightening Gauge
0205
913-6
Preparations
Before screwing on the nuts, grease the

threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
µ = 0.1–0.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tight-

ening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:

– thread M8 – M20 = 50 Nm
– thread M22 – M27 = 100 Nm
– thread M30 – M39 = 150 Nm
– thread M42 – M48 = 200 Nm
This is in order to ensure a uniform basis for the

subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge

round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 30°–45° and 60°,

we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,

respectively. Then tighten the nut until the two

marks coincide.

7
;

G
Q
D

When tightening new studs or bolts for the first

time, loosen again and repeat the procedure –

including pre-tightening with a torque spanner,

to allow the parts to settle. 0

+
0$1% :'LHVHO$6
Screws and Nuts 913-7.1
MAN B&W Diesel Locking
Some screwed and bolted connections on the

1.
engine, as well as some movable joints, are se-
cured against untimely loosening by means of
different types of locking devices.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Note!
Make sure only to mount locking devices
on nuts and screws which have been
mounted with locking devices by the en-
M913070207C01
gine manufacturer.
1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers 2.
are to be bent back over one of the flats of
the screw or nut concerned.
2. Used spring washers must be replaced.
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
To tighten a self-locking nut to a specific

torque, first measure the torque required to
turn the nut itself, and then add this torque
M913070207C02
to the torque value stated on the data

sheet of a procedure.
3.
M913070207C03
913-7.1 Screws and Nuts
Locking MAN B&W Diesel
Locking wire should be fitted after the screws

Fig. 1 Fig. 2 or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Al-
ways fit new wire after tightening-up the units.
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3 Fig. 4 Fig. 1: Insert wire, grasp the upper end of the
wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.
Fig. 2: Twist the wire clockwise until it is just

short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approxi-
Fig. 5 Fig. 6 mately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180°, equal
to half of a complete turn.
M913070207C04
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,

and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it

Fig. 7 min. 3 twists, counterclockwise until tight.
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
Fig. 7-9: Show the preferred ways of mounting
the locking wire on screws with wire holes ori-
ented in different angles.
M913070207C05
Fig. 9
Screws and Nuts 913-7.1
MAN B&W Diesel Locking
Fig. 10: Shows how to route the locking wire

on screws in different planes.
Fig. 11: Wire that passes over the top of a nut

is an acceptable alternative only if it routes
Fig. 10
around the protruding screw thread.
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure. Fig. 11
Fig. 13: Where drilling of locking wire holes has
caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut. Fig. 12
Fig. 14: Locking wire can be mounted to any
other part of the assembly if nothing else is
possible. M913070207C06
Fig. 13
Fig. 14
913-7.1 Screws and Nuts
Locking MAN B&W Diesel
Cam Lock Washers with rising cams on one

Fig. 15 side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam

face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
Fig. 16: Different uses of the cam lock wash-

M913070207C15
ers.
Fig. 17: Don not use the cam lock washers in

conjunction with other loose washers.
Note!
Fig. 16.
Cam lock washers must be installed in
pairs and are not to be substituted by
other typers of washers.
M913070207C16
Fig. 17
M913070207C17
Lubricating Procedures 913-11
Lubricating Procedures
0204
.0&&
913-11
Molybdenum Disulphide (MoS2)
The following procedure is to be followed prior

to the mounting of metal surfaced parts which
are to function as seals.
• Clean the surface with a cleaning fluid

and ensure that the entire surface is
completely free of grease.
• Allow 5 minutes for the cleaning fluid to

evaporate.
• With a clean leathercloth, and using cir-

cular movements, rub a mixture of fine-
grained particles of Molybdenum Disul-
phide (MoS2) and mineral oil (e.g. Moly-
cote G-n Plus, or the like) hard onto the
metal surface.
• Remove any excessive paste and ensure

that the metal surface is only coated with
a thin, uniform, layer of the above mix-
ture.
• Protect the wet paste and cloth from dust

or other foreign particles.
0$1% :'LHVHO$6
Accessories for Hydraulic Tools Plate
P91351-0037
MAN B&W Diesel A/S
Plate Accessories for Hydraulic Tools
P91351-0037

No. No.
010 Hydralic pump, pneumatic operated

022 Hydralic pump, hand operated
046 Hose with unions (1500mm), com-
plete
plete
plete
105 2-way distributor block, complete
154 Distributor block with shut-off valve
166 Angle union
201 Quick coupling, male
213 Quick coupling, female
225 Disc, round-plain, Cu o11x3mm
237 Bleeder screw
249 Disc, round-plain, Cu o11x9mm
MAN B&W Diesel A/S
Lifting Tools, Etc. Plate
P91356-0053
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0053

No. No.
020 Forged-bent screw shackle, 10mm

114 Lifting eye bolts, 10mm
210 Chain tackle, 500kg
295 Pull lift, 3000kg
305 Wire rope, 6m
MAN B&W Diesel A/S
Open Ended Spanners Plate
P91357-0007
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0007

No. No.
013 Open-ended spanner, size NV65mm

MAN B&W Diesel A/S
Open-Ended Slugging Spanners Plate
P91358-0014
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0014

No. No.
164 Open-ended slugging spanner, size

NV85mm
MAN B&W Diesel A/S
Torque Wrenches Plate
P91359-0003
MAN B&W Diesel A/S
Plate Torque Wrenches
P91359-0003

No. No.
014 Torque wrench, 8 - 400Nm

026 Adapter for socket wrench, 10 x 12.5
mm
MAN B&W Diesel A/S
Pliers Plate
P91360-0004
MAN B&W Diesel A/S
Plate Pliers
P91360-0004

No. No.
010 Pliers for retaining ring, size 0.9mm

MAN B&W Diesel A/S
Combination Spanners Plate
Plate
Combination Spanners

No. No.
015 Combination spanners, size NV10mm

Ring Slugging Spanners Plate
P91362-0069
MAN B&W Diesel A/S
Plate Ring Slugging Spanners
P91362-0069

No. No.
022 Slugging spanner, ring size NV30mm

MAN B&W Diesel A/S
Spanners Plate
Plate
Spanners

No. No.
016 Tool set, complete, size 10-22 mm

028 Tool set, complete, size 24-46 mm
030 Hex key tool set, complete
041 Adapter for socket wrench, 20->12.5 mm
100 Socket spanner, S=46 mm
150 Hex key, S=22 mm
161 Hex key, S=24 mm
Open-ended Spanners Plate
P91364-0059
MAN B&W Diesel A/S
Plate Open-ended Spanners
P91364-0059

No. No.
011 Open ring wrench, 14 - 17mm

023 Open ring wrench, 19 - 22mm
MAN B&W Diesel A/S
Instruments Plate
P91366-0066
MAN B&W Diesel A/S
Plate Instruments
P91366-0066

No. No.
012 Indicator, complete

024 Indicator paper
036 Plainmeter, complete
048 Autolog, measuring tool for crankshaft
050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool
MAN B&W Diesel A/S
Working Platforms Plate
P91368-0007
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0007

No. No.
013 Platform board
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 Page 1 (1)
MAN B&W Diesel A/S
S60MC-C VOLUME III
COMPONENTS
DESCRIPTION
900 - Introduction
Table of Contents, Volume III

90001 0069 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90030 0009 Description
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Volume III - Components Description
No. Edition Title
900 - Introduction
Table of Contents
90001 0069 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90030 0009 Description

90101 0167 Cylinder Cover
90103 0004 Indicator Cock - Mounting

90201 0220 Piston and Piston Rod
90205 0121 Piston Rod Stuffing Box

90302 0193 Cylinder Liner and Cooling Jacket
90304 0036 Cylinder Liner - Details
90305 0127 Cylinder Lubricators
90307 0035 Cylinder Lubricator Unit
90308 0012 Cylinder Lubricator - Intermediate Box
90309 0026 Cylinder Lubricator System - Details
90312 0004 Electronic Components - Cylinder Lubrication

90401 0171 Connecting Rod and Crosshead
90403 0012 Lubricating and Cooling Oil-Flow

90501 0170 Crankshaft
90502 0057 Arrangement of Fore End
90503 0018 Arrangement of Angle Encoder
90505 0147 Thrust- and Guide Bearing
90510 0123 Turning Gear
90511 0032 Turning Wheel
90512 0002 Turning Gear - Details
906 - Control Gear

90603 0083 Chain Tightener
90605 0071 Lubricator Drive
90610 0106 Bearing Housing - Mounting
90612 0099 Arrangement of Indicator System

No. Edition Title
90613 0118 Camshaft Bearing

90615 0142 Arrangement of Governor
90618 0146 Regulating Shaft
90619 0031 Load Transmitter
90620 0102 Engine-Side Control Console
90621 0087 Engine-Side Control Console - Details
90622 0071 Arrangement of Layshaft
90631 0013 Chain Drive Guidebars - Upper Part
90632 0014 Chain Drive Guidebars - Lower Part
90633 0027 Chain Drive Lubrication - Upper Part
90634 0001 Chain Drive Lubrication - Lower Part

90702 0069 Main Starting Valve
90703 0106 Starting Air Distributor
90704 0055 Starting Valve
908 - Exhaust Valve

90801 0196 Exhaust Valve - Lower Parts
90802 0054 Exhaust Valve - Details
90803 0024 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0119 Exhaust Valve - Actuator
90806 0091 Exhaust Valve - Pipe System
90811 0015 Arrangement of Freshwater Pipes

90901 0195 Fuel Pump
90902 0147 Fuel Pump Gear
90903 0048 Fuel Pump Gear - Details
90904 0055 Fuel Pump - Details
90905 0026 Reversing Mechanism
90911 0022 Fuel Valve Function
90913 0160 High-Pressure Pipes
90914 0096 Fuel Oil System
90915 0060 Fuel Oil System - Details

91000 0017 Gas and Air System
91001 0143 Scavenge Air Receiver
91002 0126 Arrangement of Charging Air Pipe
91003 0206 Exhaust Pipes and Receiver
91004 0067 Exhaust Receiver - Details

No. Edition Title
91005 0130 Air Cooler

91006 0038 Arrangement of Auxiliary Blower
91007 0017 Butterfly Valve
91011 0024 Arrangement of Non-Return Valve
91014 0019 Arrangement of Suction Pipe

91101 0037 Safety Valve - Cylinder
91102 0028 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0088 Arrangement of Safety Cap

91201 0095 Arrangement of Stay Bolts
91204 0027 Frame - Details
91205 0208 Frame Box
91206 0107 End Shields
91207 0092 Arrangement of Piston Cooling
91208 0018 Chain Wheel Frame - Upper
91210 0163 Bedplate
91211 0081 Axial Vibration Damper
91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0002 Top Bracing - Arrangement

Cross Section through Engine Plate
P90001-0069
MAN B&W Diesel A/S
Ordering of Insulation Plate
Designations and Symbols Plate
Normal layout Forward (fwd)
Port side of ship Starboard (stbd) side of
Fore end
1
2
Cyl. nos. always counted
3
4 from fore end
5
6
7
Manoeuvring side of engine Aft end Exhaust side of engine
Propeller
Clockwise direction of rotation

defined from aft end of engine
Software License, Standard Conditions Plate
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 accep-
tance of the following standard conditions of licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S 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 cus-
tomer 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 disas-
semble 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 ex-
tent 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 suit-
ability and applicability for a particular purpose.
Plate
Software License, Standard Conditions
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 li-
cense 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 soft-
ware.
The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&W’s software
suppliers.
6. Law
MAN B&W's tenders and contracts with customers regarding delivery of data and programs, in-
cluding the present licence agreement, shall be interpreted according to Danish Law.
Instructions for Main Engines
This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel en-
gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-
erence purposes, for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:
1. Name of vessel
2. Engine No. built by
3. Plate No.
4. Part No.
5. Quantity required (and description)
Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

10 off (piston ring)
+ )The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.
To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation “D” refers to the information given on the
data sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct oper-
ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re-
lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on emissions related maintenance of the die-
sel engine, also the additional instructions to that effect set out in the Technical File.
This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.
MAN B&W Diesel A/S

A90023-0027
Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen Telex :16592 manbw dk
Denmark Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel
901 Cylinder Cover
Cylinder Cover The cylinder cover is made of steel.
On the 70-98MC type engines the cylinder cover is provided with welded-on
heat resistant material at the points of fuel oil injection in order to improve the
service condition.
Valve bores The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.
The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet, safety valve and indicator cock.
Cooling A cooling jacket is mounted on the lower part of the cylinder cover, whereby a
cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylin-
der 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 connec-
tion.
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 hydrau-
lic 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 pis-
ton skirt is tightened to the piston crown.
When referring to this page, please quote Description A90030 Edition 0009 Page 1 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel
The piston crown is provided with one groove all the way around, or with three
smaller grooves for the fitting of lifting tools.
The piston crown is provided with chromium-plated grooves for four piston
rings.
Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR).
Piston rings Nos. 2, 3 and 4 have oblique cuts:
• piston ring No. 3 has a right-hand cut,
and
• piston rings Nos. 2 and 4 have left-hand cuts.
On some engines, the piston rings are provided with Alu-coating to improve
the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel off.
Piston Rod The piston rod has a through-going bore for the cooling oil pipe, which is se-
cured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe

or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.
The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the flow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.
Page 2 (23) When referring to this page, please quote Description A90030 Edition 0009
MAN B&W Diesel
Stuffing Box The bore for the piston rod between the scavenge air space and the crankcase
is fitted with a piston rod stuffing box, which is designed to prevent the lubri-
cating 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 The housing is provided with a number of machined ring grooves:

rings
• 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/scrap-
ing performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.
903 Cylinder Liner and Cylinder Lubrication
Cylinder Frame The cylinder section of the engine consists of a cylinder frame with a bolted-on
or integrated camshaft housing. The cylinder section is tightened together with
the engine framebox and the bedplate by means of stay bolts. Alternatively as
a complete welded assembly integrating the scavenge air receiver into the cyl-
inder frame.
Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod stuff-
ing 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.
MAN B&W Diesel
There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.
Cylinder cover Studs for fastening the cylinder cover are mounted in the cylinder frame.
studs
Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is supplied
Cooling Jacket at the lower part of the cooling jacket.
On slim-type liners, the water continues directly to the upper part of the cool-
ing 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 cylin-
der 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 cylin-
der cover.
Scavenge air ports The part of the cylinder liner which is located in the scavenge air space of the
cylinder frame is provided with a number of scavenge air ports, which are un
covered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to
give the scavenge air a rotary movement in the cylinder.
Cylinder lubrication In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with non-return valves for the supply of lu-
bricating oil to the cylinder.
PC-ring On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of
the cylinder liner. The purpose of the PC-ring is to prevent the building-up of
deposits on the piston topland and, in turn, prevent the wiping away of the cyl-
inder lubricating oil. Consequently, the PC-ring contributes to reducing the
wear of liners and rings.
Cylinder The engine is equipped with mechanically or electronically controlled cylinder

Lubricators lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the special in-
struction manuals supplied.
See also Volume I, OPERATION, Chapter 707.
MAN B&W Diesel
904 Crosshead with Connecting Rod
Crosshead The crosshead is provided with two guide shoes fitted on the crosshead ends.
The centre part of the crosshead is designed as a bearing journal which is

housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston rod
to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
Piston rod foot The piston rod foot is fastened to the crosshead. To match different engine lay-
outs, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.
Lubrication The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and – through a bore in the con-
necting rod – for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder
for the purpose of checking the temperature and flow before the oil is passed
on to the lube oil tank.
Guide shoes The sliding faces of the guide shoes are lined with cast-on bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.
On some engines, the guide shoes are provided with counterweights.
Tightening The crosshead bearing is held together by studs and nuts. The nuts are tight-
ened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal and as-
sembled 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 to-
gether, 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.
MAN B&W Diesel
The crankshaft is provided with a chain wheel for the camshaft drive and a
turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order and 4th order moment compensators are in-
stalled, 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 ship’s 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 col-
lar.
The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal
cast onto the wearing faces against the thrust collar. See also Volume I, OP
ERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the en

gine. The oil is supplied between the segments through spray pipes and spray
nozzles.
The thrust bearing is provided with alarm, slow-down, and shut-down devices
for low lube oil pressure and high segment temperature. See also Volume I,
OPERATION, Chapter 701.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di
rection.
Axial Vibration To counteract heavy axial vibrations, and any resultant adverse forces and
Damper 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.
MAN B&W Diesel
Turning Gear The turning gear is attached to the engine bedplate and is driven by an electric
motor incorporating a disc brake.
Through a planetary gearing, the motor drives a horizontal shaft equipped with
a gear wheel which can be axially displaced manually, so as to engage with the
turning wheel of the engine.
The turning gear is provided with a safety arrangement consisting of a safety

lever which must be lifted before the gear wheel of the turning gear can be
made to engage with the turning wheel.
When the safety lever is in its bottom position, it prevents the gear wheel of
the turning gear from engaging with the turning wheel.
Immediately the lever is lifted away from the disengaged position, an interlock
valve inserted in the starting air system of the engine is actuated. This interlock
prevents starting air from being supplied to the engine as long as the turning
gear is in the engaged position.
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
Dismantling of
turning the engine, thus causing injuries to per-
working parts:
sonnel or damage to the machinery.
See Volume II, MAINTENANCE, ‘DATA’ pages.
The turning gear must be in the disengaged posi-

tion during pressure testing of starting valves, as
Pressure test- a leaky valve may cause the engine to rotate, and
ing of starting damage the turning gear.
valves:
See Volume I, OPERATION, Chapter 703.
906 Mechanical Control Gear
Chain Drive The camshaft with cams for operating the fuel pumps, exhaust valves and indi-
cator 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. Lubri-
cating oil is supplied through spray pipes fitted at the guide bars and chain
wheels.
MAN B&W Diesel
Camshaft The camshaft is made in one or more sections.
If it is made in two or more sections, the sections are assembled by means of

flange couplings.
The camshaft has, for each cylinder:
• one cam for operation of the fuel pump
• one cam for operation of the exhaust valve
• one cam for operation of the indicator drive (option)
The fuel pump and exhaust valve cams are shrunk on to the shaft by heating,
whereas the indicator cams are in two parts, which are assembled with fitted
bolts.
The camshaft rotation constantly follows that of the crankshaft.
Bearings The camshaft is carried in bearing assemblies which are fitted in the roller
guide housings. See also Volume I, OPERATION, Chapter 708.
Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams,
couplings or chain wheel and the shaft, which enables the parts to be turned in
relation to each other. See Volume II, Chapters 906, 908 and 909.
Pin gauges After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are deliv-
ered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.
Indicator Valve Each cylinder is fitted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.
Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.
Note!
For indicator valves of the double-seated design with a spring-loaded closing

face:
In order to prevent overstressing, close the valve lightly before starting the
engine, and retighten the valve when the engine has reached its normal ser-
vice temperature.
PMI-System See separate instructions for operating the PMI-system (option).
MAN B&W Diesel
Moment On the basis of calculations, the engine may be provided with fly
Compensators weights to counteract engine forces and moments.
Caution!
If the chain drives for the compensators have been dismantled, the
flyweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly fitted moment compensators may excite heavy vibrations.
1st order moment Applicable on 4-cylinder engines. The moment compensator is arranged
as adjustable flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in

the main chain drive.
This moment compensator consists of a (new) chain-tightener wheel

with an incorporated flyweight and a flyweight rotating with the crank
shaft.
2nd order moment Applicable on 4-5 and 6-cylinder engines. The moment compensator is
arranged as flyweights built into the main chain drive.
On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.
4th order moment The moment compensator is arranged as flyweights built into chain
drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.
907 Starting Air System
Starting Air System The starting air system consists of the manoeuvring system and the
starting air components, which comprise:
• Main Starting Valve
• Starting Air Distributor
• Starting Valves
The manoeuvring system is of electric/pneumatic design.

MAN B&W Diesel
Main Starting The main starting valve is interposed in the starting air main pipe.
Valve
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 set-
ting 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, ‘OPERA-
TION after arrival in port’.
Starting Air The starting air distributor controls the opening and the closing of the starting
Distributor valves.
Starting Valve The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled
by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now flows from the starting
air pipe to the cylinder.
When the starting period is finished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.
The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.
MAN B&W Diesel
908 Exhaust Valve
Exhaust Valve Each cylinder is equipped with an exhaust valve, which is mounted in a central
bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gas-tight seal against a seat in the cylinder cover.
Valve housing The valve housing has an exchangeable bottom piece.
The bore for the valve spindle is provided with an exchangeable spindle guide
liner.
Cooling The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from
the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.
Valve spindle The part of the spindle stem which travels within the sealing arrangement of
the air cylinder is coated with a wear resistant mixture of metal carbide and su-
per 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 cylin-
der on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom posi-
tions 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.
MAN B&W Diesel
Note!
After the exhaust valve has been overhauled, it is important to check the
damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.
Air cylinder The air cylinder is mounted on top of the valve housing. Air for closing the ex-
haust valve is supplied through a non-return valve to the space below the pis-
ton.
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 cylin-
der.
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 up-
wards and wearing out the running surfaces and polluting the pneumatic sys-
tem 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 hous-
ing.
MAN B&W Diesel
Sealing oil (where used):
A sealing oil arrangement is fitted around the spindle shaft below the air cylin-
der.
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 cer-
tain amount of oil (dosage oil) to the exhaust valve spindle.
The sealing oil will prevent the exhaust gas and particles from penetrating up-
wards and wearing out the running surfaces and polluting the pneumatic sys-
tem of the valve gear.
The oil improves the service condition of the sealing rings.
Hydraulic Valve The exhaust valve is actuated by a cam on the camshaft through a hydraulic
Actuating Gear transmission.
Hydraulic cylinder The hydraulic cylinder is attached to the camshaft housing by studs and nuts.
A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck
of the roller guide and is locked to the roller guide by a bayonet joint.
The hydraulic cylinder on the camshaft housing is connected to the hydraulic

cylinder on the exhaust valve by a high-pressure pipe.
Oil is supplied from the lubricating oil system through a non-return valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained through
a pipe connection.
Puncture Valve On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC en-
gines, 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 piston’s upward stroke.
This function prevents the starting valve and exhaust valve from being open at
the same time, thus ensuring a safe start.
MAN B&W Diesel
909 Fuel Oil System
Fuel Pump Each engine cylinder is equipped with its own fuel pump, which is mounted on
the camshaft housing over the camshaft section corresponding to the cylinder
concerned.
The pump housing is attached to the camshaft housing by studs and nuts.
The square base of the fuel pump housing is provided with a groove to receive
any leakage oil, which is subsequently drained off through a drain pipe.
In the base, a bore is provided for at toothed rack, i.e. the regulating guide,
which controls the quantity of fuel oil delivered by the pump.
Furthermore, for the VIT-type fuel pump, another bore is provided above the
bore for the regulating guide. This bore is provided with a rack, i.e. the timing
guide, which controls the engine timing.
At the top, the pump housing is closed by a top cover.
The top cover is provided with a suction valve and a puncture valve. These
two valves are on some engine types combined into one unit.
The pump housing contains the plunger and barrel. The plunger and barrel are
matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in the
milled keyway in the regulating guide. At the bottom it has a foot which rests
on a steel disc in the bayonet joint at the roller guide neck. A clearance of
approx. 0.1 mm between the plunger foot and the roller guide permits turning
of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing. On the
outside the regulating guide has a toothed rim to mesh with the above-men-
tioned 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 cor-
rectly after disassembly. The toothed rack is linked together with the regulating
gear of the engine through a spring-loaded connection. Thus, in the event of a
sticking pump plunger, the regulating gear for the remaining fuel pumps will not
be blocked.
The pump barrel is provided with oil cut-off holes, which are covered and un
covered during the travel of the plunger within the barrel. This function, in con
junction with the turning of the plunger effected by the regulating gear, serves
to regulate the amount of oil injected into the engine cylinder.
Two screw plugs are fitted in the pump housing opposite the cut-off holes of
the barrel. The oil jets which are ejected through the cut-off holes at the end of
the delivery stroke will hit the screw plugs, which can be replaced when they
are eroded.
MAN B&W Diesel
Injection timing Fuel pumps without VIT (Variable Injection Timing):
The pump barrel is attached to the top cover by means of screws.
The 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 com-
bustion 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 en-
gine. 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.
MAN B&W Diesel
Fuel Oil Injection During the suction stroke, the spring-loaded suction valve opens and the deliv-
ery 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 com-
mences through the fuel valves. The injection will last until the cut-off holes are
uncovered by the oblique cut-off edges of the plunger, following which the oil
is forced through two milled grooves at the side of the plunger and out through
the cut-off holes of the barrel during the rest of the delivery stroke.
Shock absorber A shock absorber is installed on each pump housing or in the main fuel pipe to
take up pressure variations.
Fuel Pump The camshaft housing contains the fuel pump and exhaust valve actuating gear
Actuating Gear for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is trans-
mitted 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 revers-
ing 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.
Fuel Oil High- All high-pressure pipes in the system are provided with a protective outer pipe.
Pressure Pipes The space between the pipe and the protective outer pipe communicates,
through bores in the union nipples, with a drain bore in the pump top cover.
Fuel Oil Leakage A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS.
Alarm
35-98MC:
Each fuel pump is, via drain pipes, connected to a common drain tank, which
incorporates a level switch. The drain tank is also equipped with an overflow
pipe, which has a small drain bore below, whereby oil from small leakages can
be drained to the outlet, without actuating the level switch.
In the event of pipe fractures or major leakages in the system, the above-men-
tioned bore will not be large enough to allow the increased oil quantity to pass,
and the oil level in the drain tank will rise until it reaches the level of the over
flow pipe. The rising oil level will cause the level switch to set off an alarm.
MAN B&W Diesel
50-98MC:
Alternatively to the common drain tank, the drain pipes on 50-98MC engines
can be connected to a diaphragm valve, which sets off an alarm and activates
the puncture valve in order to stop the fuel oil flow from the pertaining pump.
On 60-98MC engines, which are provided with pneumatically operated fuel

pump roller guide lifting gear, automatic activation of the lifting gear by the dia-
phragm valve can be arranged in order to stop the fuel oil flow from the per-
taining 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 pump’s 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 en-
gine cylinder.
On completion of the fuel pump’s delivery stroke, the valve spindle is pressed
against its seat and injection now ceases. Then the circulating bore is uncov-
ered, 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, de-
pending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger and,
through a common shaft, the turbine wheel drives the compressor wheel.
The compressor draws air from the engine room, through the air filters. From
the compressor outlet, the air passes through the charging air pipe to the
charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.
MAN B&W Diesel
The air cooler incorporates a water mist catcher, which is designed to separate
condensate from the air.
See also ‘Charging Air Cooler’ further on in this Section.
When the air has passed the water mist catcher, it is pressed into the scav
enge air receiver through non-return valves. The non-return valves open by
pressure from the turbocharger.
From the scavenge air receiver, the air flows to the cylinder through the scav-
enge 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 The scavenge air receiver is a container having a large volume. The receiver is
Receiver bolted on to the cylinder frame, or alternatively integrated into the cylinder
frame, if welded. See Chapter 903.
Scavenge air is collected in the receiver after the air has passed through the
cooler, the water mist catcher and the non-return valves.
The receiver and the cylinder frame communicate through large openings.
The scavenge air receiver is provided with man-hole covers and a safety valve.
Auxiliary Blowers The engine is provided with two or more auxiliary blowers. The suction sides
are connected to the space after the water mist catcher. The discharge sides
are connected to the scavenge air receiver. Separate non-return valves are in-
stalled at the suction side or discharge side of the auxiliary blowers, in order to
prevent reversed air flow.
See also item, “Non-return valves”, further on.
El. panels for See special instructions supplied by the engine builder.
auxiliary blower
Running with During the starting of the engine, and when the engine is running at low load,
auxiliary blowers 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 turbocharger’s air filter and compressor side.
MAN B&W Diesel
Warning!
If the auxiliary blowers do not start during low-load running (because of

faults, or because the switch for the blowers is not in “AUTO” position), un-
burned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box fire.
In order to avoid such a fire:
– obtain permission to stop the engine

– stop the engine
– remove any unburned fuel oil from the top of the pistons
– re-establish the supply of scavenge air
– start the engine
Note: the switch for the auxiliary blowers should be in

“AUTO” position during all modes of engine control, i.e.:
– remote control
– control from engine side control console.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbocharger’s air filter and compressor side.
The non-return valves fitted after the water mist catcher are now closed as a
result of partial vacuum and gravitation acting on the valve flaps.
There will be a lack of air supply if the non-return valves do not close.
Non-Return Valves It is of the utmost importance that the non-return valves of the auxiliary blow-
ers always function correctly and move easily. This can be checked either by
moving the valves manually in connection with the regular scavenge port in-
spections, or via locally placed inspection covers.
The non-return valves protect the blowers and engine during:
• Start-up of the auxiliary blowers
• Running with auxiliary blowers.
Starting the auxiliary blowers:
1. Owing to the relatively high starting current, the blowers start in se

quence, with 6-10 seconds in between.
The non-return valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Oth-
erwise, 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.
MAN B&W Diesel
Running with auxiliary blowers:
If an auxiliary blower fails during running, the non-return valve must close to
ensure the continued supply of fresh air to the engine. See ‘Starting the auxil-
iary blowers‘, Item 2, above.
Exhaust Gas From the exhaust valves, the exhaust gas is led to the exhaust gas receiver
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. Com-
pensators are inserted between the receiver and the exhaust valves, and be-
tween the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before the tur-
bocharger.
The exhaust gas receiver and the exhaust pipe are insulated.
Charging Air The charging air cooler insert is of the block type. It is mounted in a housing
Cooler 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 wa-
ter 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 pas-
sage 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, Each cylinder cover is provided with a spring-loaded safety valve which is set
Cylinder Cover to open at a pressure somewhat higher than the maximum firing pressure in
the cylinder.
MAN B&W Diesel
Relief Valves On the exhaust side of the engine a number of spring-loaded relief valves are
fitted, which will open in the event of excessive pressure in the crankcase/
chain casing, for instance as a result of the ignition of oil mist.
Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the
risk of fire caused by hot air/gas emitted in the event that the relief valves
open.
Regarding how to:
• avoid evaporation of the lubricating oil in the crankcase,
• detect oil mist in the crankcase using an ‘Oil Mist Detector’.
see Volume I, OPERATION, Chapter 704.
Warning!
Do not stand near crankcase doors or relief valves – or in corridors near
doors to the engine room casing in the event of an alarm for:
a) 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 in-

creasing 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, The scavenge air receiver is fitted with a safety valve which is set to open
Scavenge Air should the pressure in the scavenge air receiver exceed a value somewhat
Receiver 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".
MAN B&W Diesel
Safety Cap in Each starting valve inlet pipe is provided with a safety cap. The safety cap
Starting Air Line consists of a bursting disc enclosed by a perforated cylinder and a perfo-
rated 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 cylin-
der, 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 fit-
ted 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.
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 func-
tioning of the axial vibration damper, see Section 905 “Crankshaft”.
Marine engines (except geared plants):
The aft end of the bedplate incorporates the thrust bearing. See also Section
905 “Crankshaft”.
Stationary engines (and geared marine plants):
The bedplate incorporates the guide bearing. See also Section 905, “Crank
shaft”.
Framebox A framebox is bolted on to the top of the bedplate. Like the bedplate, the
framebox consists of one or more sections. Together, the bedplate and the
framebox constitute the crankcase of the engine.
The framebox is fitted with steel-plate doors for access to the crossheads and
to the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe fitted to the crosshead or guide shoe is able to
travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to
the oil tray of the bedplate.
MAN B&W Diesel
Equipment for local checking of the cooling oil temperature and flow, and for
temperature and flow alarms, is installed in conjunction with the outlet pipe.
Staybolts The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.
Engine Seating Regarding the engine seating for the specific engine, see the supplier’s special
instructions.
90101 0167 Cylinder Cover

90103 0004 Indicator Cock - Mounting
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Cover Plate
Plate
Cylinder Cover

No. No.
018 Screw
031 Protective cap
043 Nut
055 Stud
067 Cylinder cover
079 Stud
080 Washer
092 Nut
102 Stud
114 Screw
126 O-ring
138 Cooling jacket
151 Gasket
175 Nut
222 Stud
234 Stud
246 Pipe for fuel valve
258 Spring housing, complete
Indicator Cock - Mounting Plate
Plate
Indicator Cock - Mounting

No. No.
019 Indicator cock

020 Gasket
032 Gasket
056 Disc
068 Plug screw
081 Sundry chain
093 Key ring
103 Eye screw
127 Gasket
140 Screw
152 Nut
176 Flange
188 Extension
223 Screw
235 Extension
90201 0220 Piston and Piston Rod

90205 0121 Piston Rod Stuffing Box
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Piston and Piston Rod Plate
P90201-0220
MAN B&W Diesel A/S
Plate Piston and Piston Rod
P90201-0220

No. No.
011 Piston ring no. 1

023 Piston ring no. 2 + 4
035 Piston ring no. 3
047 Piston crown
059 Screw
060 Disc
072 D-ring
084 D-ring
096 Piston skirt
106 Screw
118 Locking wire
131 Screw
143 Screw
167 Cooling pipe
179 Screw
192 Screw
202 Piton
Page 2 (2) When referring to this page, please quote Plate Edition
MAN B&W Diesel A/S
Piston Rod Stuffing Box Plate
P90205-0121
MAN B&W Diesel A/S
Plate Piston Rod Stuffing Box
P90205-0121

No. No.
013 O-ring
025 Top scraper ring
037 Pack sealing ring
049 Cover sealing ring
062 Nut
074 Stuffing box, housing
086 Flange
098 Screw
121 Guide pin
133 Spring pin
157 Lamella for scrapering
170 Stuffing box, housing
182 Fitted bolt
204 Screw
216 Scraper ring
241 Spring
253 Spring
289 Scraper ring
MAN B&W Diesel A/S
90302 0193 Cylinder Liner and Cooling Jacket

90304 0036 Cylinder Liner - Details
90305 0127 Cylinder Lubricators
90307 0035 Cylinder Lubricator Unit
90308 0012 Cylinder Lubricator - Intermediate Box
90309 0026 Cylinder Lubricator System - Details
90312 0004 Electronic Components - Cylinder Lubrication
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Liner and Cooling Jacket Plate
P90302-0193
MAN B&W Diesel A/S
Plate Cylinder Liner and Cooling Jacket
P90302-0193

No. No.
010 Packing
022 Plug screw
034 O-ring
046 O-ring
058 Cooling jacket
071 Clamp
083 Screw
105 Piston cleaning ring
117 Cylinder liner
129 Cooling water connection
130 Packing
142 Pipe
154 Spring pin
166 Plug screw
178 Gasket
201 O-ring
213 Cooling water connection
225 Screw
MAN B&W Diesel A/S
Cylinder Liner - Details Plate
P90304-0036
MAN B&W Diesel A/S
Plate Cylinder Liner - Details
P90304-0036

No. No.
011 Head for non-return valve

023 Housing
035 Non-return valve
059 Non-return valve, complete
MAN B&W Diesel A/S
Cylinder Lubricators Plate
P90305-0127
MAN B&W Diesel A/S
Plate Cylinder Lubricators
P90305-0127

No. No.
017 Screw
030 Screw
054 Guard
066 Bracket
078 Screw
091 Nut
113 Support
137 Steel pipe
149 Straight male stud, complete
MAN B&W Diesel A/S
Cylinder Lubricator Unit Plate
Plate
Cylinder Lubricator Unit

No. No.
018 Ball valve

031 Stud
043 Hydraulic block
055 Nut
067 Plug screw
080 O-ring
092 Intermediate pipe
114 Adjustable elbow coupling
138 Ball valve
151 Stud
175 Lubricator, complete
199 Hydraulic block
209 Gasket
210 Membrane accumulator
234 Screw
258 Adjusting screw
271 O-ring
283 Spacer, tubular
295 Cover
305 O-ring
329 O-ring
330 Cylinder block
342 O-ring
354 Spring
366 Plunger
378 Actuator piston
391 Straight stud coupling
401 Screw
413 Screw
437 Cylinder housing
449 Solenoid valve complete
450 Screw
474 Membrane accumulator
486 Gasket
498 O-ring
508 O-ring
521 Inductive sensor
533 Cable
545 Cable gland, complete
569 Housing
570 Plug
582 Plug
594 Screw
Intermediate Box Plate
P90308-0012
MAN B&W Diesel A/S
Plate Intermediate Box
P90308-0012

No. No.
013 Intermediate box, complete

037 Electric enclosure with cables
049 Circuitboard assy
050 Screw
074 Diode
MAN B&W Diesel A/S
Cylinder Lubrication System - Details Plate
P90309-0026
MAN B&W Diesel A/S
Plate Cylinder Lubrication System - Details
P90309-0026

No. No.
019 Stud
020 Nut
032 Steel pipe
044 Steel pipe
068 Pipe holder
081 Screw
093 Coupling
103 Connection
115 Coupling
139 Pipe holder
152 Coupling
176 Screw
188 Distributor block
211 Sealing ring
223 Distributor block
247 Steel pipe
259 Steel pipe
260 Pipe holder
296 Steel pipe
306 Steel pipe
343 Coupling
367 Screw
MAN B&W Diesel A/S
Cylinder Lubrication - Electronic Components Plate
P90312-0004
MAN B&W Diesel A/S
Plate Cylinder Lubrication - Electronic Components
P90312-0004

No. No.
015 Name plate

027 Pilot lamp
039 Name plate
040 Selector switch
052 Terminal
064 Terminal
076 Din rail
088 Terminal
111 Terminal
159 HMI panel
160 Mounting plate
184 Nut
196 Screw
206 Terminal
MAN B&W Diesel A/S
90401 0171 Connecting Rod and Crosshead

90403 0012 Lubricating and Cooling Oil-Flow
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Connecting Rod and Crosshead Plate
Plate
Connecting Rod and Crosshead

No. No.
019 Plate
020 Screw
044 Screw
068 Crankpin bearing shell, complete
093 Screw
103 Outlet pipe
115 Guide shoe, “Fore”
139 Crosshead bearing cap
140 Crosshead bearing shell, complete
152 Guide pipe
164 Crosshead
188 Connecting rod
211 Screw
223 Crankpin bearing cap
235 Guide pin
247 Screw
260 Screw
272 Shim*
284 Distance piece
296 Bushing
306 Housing for stuffing box
331 Telescope pipe
355 Guide shoe, “Aft”
367 Shim*
379 Shim*
380 Guide strip
414 Guide pin
426 Stud
438 Nut
451 Nut
463 Stud
487 Screw
509 Counterweight
522 Connecting rod, complete
Note:
*When ordering, please state thickness

of shim.
Lubricating and Cooling Oil Flow Plate
90501 0170 Crankshaft

90502 0057 Arrangement of Fore End
90503 0018 Arrangement of Angle Encoder
90505 0147 Thrust- and Guide Bearing
90510 0123 Turning Gear
90511 0032 Turning Wheel
90512 0002 Turning Gear - Details
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crankshaft Plate
P90501-0170
MAN B&W Diesel A/S
Plate Crankshaft
P90501-0170

No. No.
012 Locking wire

024 Screw
036 Flange
061 Crankshaft
073 Packing
085 Cover
097 Screw
107 Locking wire
119 Chain wheel
MAN B&W Diesel A/S
Arrangement of Fore End Plate
P90502-0057
MAN B&W Diesel A/S
Plate Arrangement of Fore End
P90502-0057

No. No.
018 Fitted bolt

031 Nut
043 Locking wire
067 Counterweight
MAN B&W Diesel A/S
Arrangement of Angle Encoder Plate
Plate
Arrangement of Angle Encoder

No. No.
013 Measuring instrument, axial vibration

damper
037 Screw
049 Angle encoder
050 Enclosure, complete
074 Screw
086 Shaft
098 Housing
108 Damping plate
121 Coupling
133 Cable tie
157 Adjustment tool
169 Packing
170 Spring pin
182 Screw
194 Spring lock
204 Shield lower part
216 Packing
228 Shaft
253 Packing
265 Washer
Thrust and Guide Bearing Plate
P90505-0147
MAN B&W Diesel A/S
Plate Thrust and Guide Bearing
P90505-0147

No. No.
014 Nut
026 Stud
038 Stopper segment, fore
051 Spray pipe
063 Segment
075 Segment
099 Lubricating oil pipe
109 Spray pipe
110 Screw
122 Locking wire
146 Screw
158 Nut
183 Oil pipe
195 Spray pipe
205 Stopper segment, fore
217 Stopper segment, aft
229 Segment
242 Stopper segment, aft
254 Spray pipe
278 Oil throw ring, complete
301 Plate
313 Nut
350 Cover
362 Spray pipe
386 Scraper ring housing, upper
398 Screw
408 Spring lock
433 Cylinder pin
445 Scraper ring housing, lower
470 Screw
494 Fitted bolt
516 Nut
528 Screw
553 Screw
565 Gasket
589 Scraper ring housing, complete
600 Fitted bolt
624 Nut
648 Screw
661 Scraper ring, upper
685 Scraper ring, complete
697 Scraper ring, lower
707 Spacer tubular
720 Nut
732 Distance pipe
744 Guard
756 Distance pipe
768 Clamps
793 Guard
MAN B&W Diesel A/S
Turning Gear Plate
P90510-0123
MAN B&W Diesel A/S
Plate Turning Gear
P90510-0123

No. No.
011 Bracket
023 Bush
035 Screw
047 Spring washer
059 Disc
072 Switch
084 Spring washer
096 Screw
106 Lever
131 3/2-way valve
143 Screw
155 Spring washer
167 Chain
214 Cylinder pin
226 Turning gear
251 Distance pipe
263 Screw
299 Gear wheel
309 Disengaging device, complete
310 Screw
322 Disc
334 Spring washer
346 Stud
358 Sleeve special
383 Turning safety device, complete
405 Key ring
417 Eye screw
429 Circlip
MAN B&W Diesel A/S
Turning Wheel Plate
P90511-0032
MAN B&W Diesel A/S
Plate Turning Wheel
P90511-0032

No. No.
017 Guide pin

029 Nut
030 Nut
054 Screw
066 Screw
078 Dead center pointer
101 Fitted bolt
113 Nut
125 Turning wheel
MAN B&W Diesel A/S
Turning Gear - Details Plate
Plate
Turning Gear - Details

No. No.
012 Screw
024 Spring washer
048 3/2-way valve
061 Screw
073 Spring washer
097 Switch 0-110 volts
107 Screw
119 Spring washer
132 Bracket
156 Eye screw
168 Key ring
181 Chain
203 Disc with inicision
215 Stud with groove
227 Circlip
240 Disc with inicision
252 Sleeve
264 Screw
276 Spring washer
311 Lever
323 Bush
906 - Control Gear
90603 0083 Chain Tightener

90605 0071 Lubricator Drive
90610 0106 Bearing Housing - Mounting
90613 0118 Camshaft Bearing
90615 0142 Arrangement of Governor
90618 0146 Regulating Shaft
90619 0031 Load Transmitter
90620 0102 Engine-Side Control Console
90621 0087 Engine-Side Control Console - Details
90622 0071 Arrangement of Layshaft
90631 0013 Chain Drive Guidebars - Upper Part
90632 0014 Chain Drive Guidebars - Lower Part
90633 0027 Chain Drive Lubrication - Upper Part
90634 0001 Chain Drive Lubrication - Lower Part
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Chain Tightener Plate
P90603-0083
MAN B&W Diesel A/S
Plate Chain Tightener
P90603-0083

No. No.
017 Chain wheel

029 Cup point screw
030 Bushing
042 Flange bearing
054 Locking wire
066 Screw
091 Bracket
101 Screw
113 Shaft
125 Flange bearing
150 Distance piece
162 Distance piece
174 Plug screw
198 Shaft
208 Guide nut
221 Lock washer
233 Nut
245 Tightening bolt
270 Shaft
282 Guide nut
294 Circlip
304 Circlip
316 Shaft
328 Bushing
MAN B&W Diesel A/S
Lubricator Drive Plate
Plate
Lubricator Drive

No. No.
018 Chain wheel

031 Flange bearing
043 Screw
055 Locking wire
079 Chain link, complete
080 Screw
092 Chain
102 Outer link
114 Inner link
138 Screw
163 Guide pin
175 Shaft
187 Bracket for guideway
199 Screw
210 Flange bearing
222 Plug
234 Sealing ring
246 Screw
258 Guidebar
271 Nut
295 Circlip
305 Disc
317 Sealing ring
Bearing Housing - Mounting Plate
P90610-0106
MAN B&W Diesel A/S
Plate Bearing Housing - Mounting
P90610-0106

No. No.
015 Screw
027 Bearing cap
040 Guide disc
052 Stud
064 Nut
076 Stud
088 Bearing housing
111 Shim
135 Bearing shell
147 Guide pin
MAN B&W Diesel A/S
Arrangement of Indicator System Plate
Plate
Arrangement of Indicator System

No. No.
028 Roller guide

053 Screw
065 Washer
077 Bracket, complete
089 Bracket, indicator drive
100 Screw
112 Screw
124 Nut
136 Washer
148 Sectional iron
173 Screw
197 Liner
207 Circlip
219 Shaft
220 Needle bearing
244 Guide pulley
256 Round iron
268 Circlip
281 Washer
293 Screw
303 Handle
315 Screw
327 Roller guide
339 Liner
340 Key
352 Housing
364 Screw
388 Spring pin
411 Liner
423 Spring
435 Circlip
Note:
Arrangement of Indicator System Plate
Plate
Arrangement of Indicator System

No. No.
016 PMI system users manual

028 PMI install and start-up
053 PMI software
065 Component storage case
077 Converter box
090 PMI controller box, complete
100 Junction box
124 Handle
136 Pressure transducer
Note:
Camshaft Bearing Plate
P90613-0118
MAN B&W Diesel A/S
Plate Camshaft Bearing
P90613-0118

No. No.
023 Screw
035 Drain pipe
060 Screw
072 Bearing cap
096 Screw
106 Bearing shell
131 Cylinder dowel
143 Plug screw
155 Plug screw
179 Screw
180 Orifice
202 Baseplate
238 Screw
251 Plate
275 Plate
287 Packing
MAN B&W Diesel A/S
Arrangement of Governor Plate
P90615-0142
MAN B&W Diesel A/S
Plate Arrangement of Governor
P90615-0142

No. No.

024 Screw
036 Screw
061 Screw
073 Spring washer
085 Bracket
107 Pull rod, complete
119 Terminal box
120 Fitted bolt
132 Washer
144 Self-locking nut
156 Guide pin
168 Plate
MAN B&W Diesel A/S
Regulating Shaft Plate
P90618-0146
MAN B&W Diesel A/S
Plate Regulating Shaft
P90618-0146

No. No.
019 Sleeve coupling

020 Regulating shaft
032 Regulating shaft
056 Flange bearing, complete
115 Bracket
127 Washer
139 Screw
152 Fitted bolt
176 Pull rod, complete
188 Spring-loaded lever, complete
223 Screw
235 Shaft
247 Lever
259 Nut
260 Spring
284 Spring pin
306 Shaft
318 Circlip
331 Shim
343 Clamping block
355 Washer
367 Screw
MAN B&W Diesel A/S
Load Transmitter Plate
P90619-0031
MAN B&W Diesel A/S
Plate Load Transmitter
P90619-0031

No. No.
014 Tooth belt disc

026 Screw
038 Tooth belt
063 Bracket
075 Screw
087 Tooth belt disc
099 Potentiometer
109 Coupling
110 Coupling
134 Screw
158 Screw
171 Nut
183 Washer
205 Screw
217 Washer
MAN B&W Diesel A/S
Engine Side Control Console Plate
P90620-0102
MAN B&W Diesel A/S
Plate Engine Side Control Console
P90620-0102

No. No.
021 Local manoeuvring console 702 Coupling

045 Name plate 714 Reducing connection, complete
057 Screw 726 Non-return valve
069 Name plate 751 Coupling, complete
070 5/2-way manual valve
082 Screw
094 Name plate
104 Name plate
128 Name plate
165 Name plate
189 Name plate
190 Name plate
212 Coupling
224 Coupling
236 T-coupling, complete
261 Screw
273 Spring lock
285 Pressure switch
307 Bracket
319 Screw
320 Switch 0-110 Volt
332 Screw
344 Pressure switch
368 Coupling
381 Banjo coupling
403 Reducing connection, complete
427 Nut
439 Screw
440 Banjo coupling
476 El-wiring
488 Screw
523 Coupling
547 Stud
559 Key ring
560 Eye screw
572 Sundry chain and link
596 Shaft
606 Stud
618 Bakelite ball
631 Name plate
667 Nut
679 Screw
MAN B&W Diesel A/S
Engine - Side Control Console, Details Plate
P90621-0087
Engine - Side Control Console, Details
0087
P90621
MAN B&W Diesel A/S
Plate Engine - Side Control Console, Details
P90621-0087
Item Item
No. No.
015 Dowel
027 Dowel
039 Lever
052 Impact handwheel
064 Impact socket
076 Washer
088 Nut
123 Screw
135 Bolt
147 Washer
160 Lever
184 Screw
196 Washer
206 Lever
218 Bushing
243 Nut
255 Disc
267 Grease nipple
279 Bushing
292 Roller
302 Screw
326 Switch
338 Screw
351 Spring lock
375 Cone
399 Distance piece
422 Pin
434 Cone
458 Lever
471 Shaft
MAN B&W Diesel A/S
Arrangement of Layshaft Plate
P90622-0071
MAN B&W Diesel A/S
Plate Arrangement of Layshaft
P90622-0071

No. No.
010 Spindle
022 Ball bearing
034 Circlip
058 Hand wheel
071 Thrust ring
095 Handle
105 Stud
129 Spring lock
142 Key
154 Grease nipple
178 Washer
201 Pointer
213 Screw
225 Angle lever
237 Screw
249 Nut
250 Slide shoe
262 Screw
274 Lock washer
298 Circlip
333 Distance pipe
345 Clamping block
357 Ball bearing
370 Split pin
394 Sealing ring
404 Circlip
416 Flange bearing
441 Screw
465 Thrust ring
MAN B&W Diesel A/S
Chain Drive Guidebars - Upper Part Plate
Plate
Chain Drive Guidebars - Upper Part

No. No.
021 Locking wire

033 Screw
057 Beam for guidebar
069 Guidebar
070 Screw
094 Chain
116 Chain, complete
141 Outer link
153 Inner link
Chain Drive Guidebars - Lower Part Plate
Plate
Chain Drive Guidebars - Lower Part

No. No.
111 Screw
123 Locking wire
147 Screw
159 Guidebar
Chain Drive Lubrication - Upper Part Plate
Plate
Chain Drive Lubrication - Upper Part

No. No.
010 Lubricating pipe

022 Spray nozzle
058 Lubrication pipe
Chain Drive Lubrication - Lower Part Plate
P90634-0001
MAN B&W Diesel A/S
Plate Chain Drive Lubrication - Lower Part
P90634-0001

No. No.
016 Spray pipe

041 Spray pipe
053 Spray pipe
077 Spray pipe
089 Spray pipe
090 Connection pipe
112 Spray pipe
124 Spray pipe
MAN B&W Diesel A/S
90702 0069 Main Starting Valve

90703 0106 Starting Air Distributor
90704 0055 Starting Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Main Starting Valve Plate
P90702-0069
MAN B&W Diesel A/S
Plate Main Starting Valve
P90702-0069

No. No.
027 Screw 708 Screw

039 Name plate "Working" 900 Repair kit, actuator*
052 Screw 912 Repair kit, ball valve*
064 Washer
076 Switch Note:
088 Distance pipe
123 Spindle * When ordering spare parts for this
135 Screw item, please state manufacturer's Part
147 Plate No.
160 Ball valve with actuator*
184 Nut
196 Screw
206 Starting air pipe
218 Gasket
231 Intermediate piece
255 Name plate "Blocked"
279 Nut
280 Washer
292 Hand wheel
314 Securing plate
326 Pin
338 Spring
351 Screw
363 Gasket
387 Gasket
399 Plug screw
410 Adjusting screw
422 Nut
434 Adapter
458 Washer
471 Screw
495 Screw
505 Guide
517 Guide pin
529 Screw
530 Distance pipe
542 Screw
554 Ball valve with actuator*
566 Nut
591 Plug screw
601 Gasket
625 Plug screw
674 Housing
698 Housing
MAN B&W Diesel A/S
Starting Air Distributor Plate
P90703-0106
MAN B&W Diesel A/S
Plate Starting Air Distributor
P90703-0106

No. No.
010 Housing
022 Screw
034 Guide screw
046 Disc
058 Starting cam
071 Lock washer
083 Screw
095 Cover
105 Screw
129 Piston valve slide
130 Liner
142 Guide pin
166 Washer
178 Screw
191 Cover
201 Screw
213 Screw
225 Flange
237 Locking ring
249 Spring guide
250 Spring
262 Spring guide
274 Liner
286 Cover
MAN B&W Diesel A/S
Starting Valve Plate
P90704-0055
MAN B&W Diesel A/S
Plate Starting Valve
P90704-0055

No. No.
016 Screw
028 Cover
041 Screw
053 Locking plate
065 Piston
077 Spring
089 Bushing
090 Valve housing
100 Sealing ring
112 Spindle
MAN B&W Diesel A/S
908 - Exhaust Valve
90801 0196 Exhaust Valve - Lower Parts

90802 0054 Exhaust Valve - Details
90803 0024 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0119 Exhaust Valve - Actuator
90806 0091 Exhaust Valve - Pipe System
90811 0015 Arrangement of Freshwater Pipes
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Exhaust Valve - Lower Parts Plate
P90801-0196
MAN B&W Diesel A/S
Plate Exhaust Valve - Lower Parts
P90801-0196

No. No.
013 Sealimg ring

025 Sealing ring
049 Exhaust valve housing
050 Cover
062 Packing
086 Screw
098 Exhaust valve spindle
108 Packing
121 Flange
133 Screw
145 O-ring
157 Bottom piece
170 Screw
182 Sealing ring
194 Spindle guide-lower
216 Flange
241 Thread insert
265 Packing
277 Plug screw
290 Sealing ring
MAN B&W Diesel A/S
Exhaust Valve - Details Plate
P90802-0054
MAN B&W Diesel A/S
Plate Exhaust Valve - Details
P90802-0054

No. No.
019 Sealing oil unit, complete
MAN B&W Diesel A/S
Exhaust Valve - Upper Parts Plate
P90803-0024
MAN B&W Diesel A/S
Plate Exhaust Valve - Upper Parts
P90803-0024

No. No.
014 Pipe
038 Lifting eye bolt
051 Screw
063 Lifting attachment
087 Packing
109 Orifice plug
110 Disc
134 Safty strap
158 Piston
171 Sliding bearing
183 Sealing ring
195 Sealing ring
205 Packing
217 Plug screw
230 Oil cylinder
242 Stud
254 Nut
278 Disc
291 Locking plate
301 Screw
313 O-ring
325 Air cylinder
349 Disc
350 Locking plate
362 Screw
374 Cone
398 Screw
408 Pin
421 Rotation check
433 Steel pipe-straight rod
445 Union nut
457 Screwed connection
469 Packing
470 O-ring
482 Spring
494 Disc
504 Spring pin
553 Pison ring
577 Damper piston
589 Spring
590 Piston
600 Disc
624 Piston, complete
MAN B&W Diesel A/S
Exhaust Valve - Upper Parts, Details
Valve Plate
Plate
Exhaust Valve - Upper Parts, Details
Valve

No. No.
021 Gasket
045 Safty valve, with o-ring
905 O-ring*
Note:
* Optional extras
Valve Gear Plate
P90805-0119
Valve Gear
0119
P90805
MAN B&W Diesel A/S
Plate Valve Gear
P90805-0119
Item Item
No. No.
015 Exhaust roller guide, complete

027 Thrust guide
039 Roller guide
040 Shaft-pin for roller
052 Plug
064 Circlip
076 Screw
088 Bushing
111 Disc
123 Roller
147 Bushing for roller guide
159 Cylindrical pin
160 Screw
172 Bushing
184 Guide block
196 Plug
218 Stud
231 Stud
243 Piston
267 Nut
279 Oil cylinder
292 Piston ring
302 Disc
314 Screw
326 Disc
338 Spring
363 Cylindrical pin
387 Cylindrical pin
MAN B&W Diesel A/S
Exhaust Valve - Pipe System Plate
P90806-0091
MAN B&W Diesel A/S
Plate Exhaust Valve - Pipe System
P90806-0091

No. No.
010 Disc
022 Sealing ring
046 Clamp
058 Nut
071 Screw
083 Support
105 Coupling
117 Drain pipe
129 Coupling
154 Thrust bushing
166 Screw
178 Hydraulic pipe
191 Hose complete
237 Hydraulic pipe, complete
249 Plug screw
250 Packing
MAN B&W Diesel A/S
Arrangement of Freshwater Pipes Plate
P90811-0015
MAN B&W Diesel A/S
Plate Arrangement of Freshwater Pipes
P90811-0015

No. No.
018 Packing
031 Screw
043 Nut
055 Orifice plate
067 Freshwater pipe, outlet
079 Ball valve
102 Support
114 Packing
126 Screw
151 Support
199 Conical valve
210 Screw
234 Main pipe
246 Packing
258 Screw
271 Nut
295 Main pipe
317 Angle valve
329 Coupling
330 Steel pipe
354 Main pipe
MAN B&W Diesel A/S
90901 0195 Fuel Pump

90902 0147 Fuel Pump Gear
90903 0048 Fuel Pump Gear - Details
90904 0055 Fuel Pump - Details
90905 0026 Reversing Mechanism
90911 0022 Fuel Valve Function
90913 0160 High-Pressure Pipes
90914 0096 Fuel Oil System
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Fuel Pump Plate
P90901-0195
Fuel Pump
0195
P90901
MAN B&W Diesel A/S
Plate Fuel Pump
P90901-0195
Item Item
No. No.
029 Packing 640 Throttle plug

042 Packing 652 Packing
054 Plug screw 664 Sealing ring
078 Pump housing, complete 711 Protective cap
091 Timing guide 723 Screw
101 Sleeve 735 Coupling
113 Regulating guide 747 Pipe
125 Guide pin 760 Banjo coupling
137 Screw 772 Plug screw
150 Stud 784 Disc
162 Guide pin 796 Pipe
174 Packing
186 Guide screw
198 Plug screw
208 Throttle plug
233 Guide pin
245 Guide bushing, complete
257 Guide bushing
270 Screw
282 Screw
294 Top cover
304 Lock washer
328 Nut
341 Screw
353 Spring guide
365 Spring
377 Suction valve, complete
389 Slide
390 Valve thrust piece
400 Sealing ring
424 Sealing ring
436 Pump barrel
448 Pump barrel, complete
461 Plunger
485 Screw
497 Lock washer
507 Cover
519 Sealing ring
520 Sealing ring
532 Puncture valve, complete
544 Air piston
556 Packing
568 Valve housing
581 O-ring
593 Slide
603 Spring
615 Spring guide
MAN B&W Diesel A/S
Fuel Pump Gear Plate
P90902-0147
MAN B&W Diesel A/S
Plate Fuel Pump Gear
P90902-0147

No. No.
012 Fuel pump roller guide, complete 705 Sealing bush

024 Shaft-pin for link 717 Guide bushing
036 Plug 729 Cup point screw
048 Circlip
061 Stop screw
073 Roller
085 Bushing
097 Disc
107 Shaft-pin for roller
120 Plug
144 Thrust disc
156 Roller guide
168 Plug
181 Bushing
193 Pin
215 Link for reversing
227 Pin
239 Guide block
240 Guide pin
252 Screw
264 Screw
288 Bushing
323 Pin
347 Nut
359 Bushing for roller guide
360 Sealing ring
372 Cap
396 Screw
418 Scraper ring, axial
431 Scraper ring
443 Flange
455 Holder for scraper ring
467 Locking wire
479 Screw
492 Nut
514 Pump base, complete
526 Packing
538 Cover, transparent
551 Cover
563 Screw
587 Disc
599 Stud
609 Stud
610 Spring
622 Disc
658 Pump base
671 Sealing bush, complete
683 Retaining ring
695 Plug screw
MAN B&W Diesel A/S
Fuel Pump Gear - Details Plate
P90903-0048
MAN B&W Diesel A/S
Plate Fuel Pump Gear - Details
P90903-0048

No. No.
031 Screw
043 Nut
055 Screw
067 Guide screw
079 Flange bearing
080 Spindle
092 Spring pin
102 Sealing ring
114 Catch
MAN B&W Diesel A/S
Fuel Pump - Details Plate
P90904-0055
MAN B&W Diesel A/S
Plate Fuel Pump - Details
P90904-0055

No. No.
013 Shock absorber, complete 419 Circlip

025 Spring guide 420 Pin
037 Bottom flange, complete 432 Forked head
049 Packing 444 Forked head
050 Plug screw 456 Adjusting screw
062 Nut 468 Nut
074 Locking washer
098 Spring, left-hand
108 Spring, right-hand
121 Packing
133 Sealing ring
145 Stud
169 Screw
170 Packing
182 Housing
194 Wearing ring
204 Piston
228 Plug
241 Nut
253 Washer
265 Bracket
277 Screw
289 Actuator
290 Banjo coupling
300 Screw
324 Guide screw
336 Toothed rack for regulation
348 Felt ring
361 Pointer
373 Toothed rack for timing
385 Forked lever
397 Nut
407 Union nut
MAN B&W Diesel A/S
Reversing Mechanism Plate
P90905-0026
Reversing Mechanism
0026
P90905
MAN B&W Diesel A/S
Plate Reversing Mechanism
P90905-0026
Item Item
No. No.
019 Shaft
020 Guide for reversing
032 Distance pipe
044 Nut
056 Guard
068 Screw
093 Cover
103 Screw
115 Bolt
127 Flange for air cylinder
139 Reversing mechanism, complete
152 Screw
164 Bush
176 Air cylinder
211 Screw
235 Ball valve
247 Branch pipe
259 Nut
272 Coupling
284 Orifice plate
306 Nut
318 Safety valve
MAN B&W Diesel A/S
Fuel Valve Plate
P90910-0144
MAN B&W Diesel A/S
Plate Fuel Valve
P90910-0144

No. No.
016 Thrust piece

028 Cut-off shaft
065 Spindle guide, complete
089 Spindle guide
090 Spring pin
100 Nozzle
124 O-ring
136 Holder
148 Guide
161 Union nut
173 O-ring
197 Sealing ring
207 Valve head
219 Guide pin
220 Spring
244 Disc
256 Thrust spindle
268 Spring
281 Thrust foot
950 Disc*
Note:
Note: Optional extras
MAN B&W Diesel A/S
Fuel Valve Function Plate
P90911-0022
MAN B&W Diesel A/S
Plate Fuel Valve Function
P90911-0022

No. No.
Note:
D1 = Predetermined closing value for

non-return valve
D2 = Predetermined opening value for

cut-off spindle
MAN B&W Diesel A/S
High-Pressure Pipes Plate
P90913-0160
MAN B&W Diesel A/S
Plate High-Pressure Pipes
P90913-0160

No. No.
012 Sleeve in 2/2

024 Retaining ring
036 Union nipple
048 Fuel oil pipe
073 O-ring
085 O-ring
097 Housing
107 Union nut
120 Union nipple
132 O-ring
156 Fuel oil pipe, complete
181 Steel pipe
193 Screw
203 Flange
215 Housing
239 Guide pin
240 Fuel oil pipe
276 Coupling
311 Fuel oil pipe, complete
908 Insulation of pipe*
Note:
*Optional extras
MAN B&W Diesel A/S
Fuel Oil System Plate
Plate
Fuel Oil System

No. No.
018 Fuel oil pipe, outlet

067 Distributor piece
079 Screw
092 Coupling
102 Steel pipe
114 Coupling
126 Steel pipe
151 Packing
163 Screw
175 Fuel oil pipe, inlet
187 Ball valve
199 Screw
209 Packing
222 Fuel oil pipe, inlet
234 Screw
246 Nut
Fuel Oil System - Details Plate
P90915-0060
MAN B&W Diesel A/S
Plate Fuel Oil System - Details
P90915-0060

No. No.
013 By-pass valve, complete

025 Valve housing
037 Valve housing
049 Sealing ring
050 Spring guide
074 Screw
086 Union nut
098 Nut
121 Sealing ring
133 Piston
145 Spring
MAN B&W Diesel A/S
Fuel Oil System - Details Plate
P90915-0075
MAN B&W Diesel A/S
Plate Fuel Oil System - Details
P90915-0075

No. No.
013 Drain box, complete

037 Level switch
049 Name plate
050 Screw
062 Gasket
074 Drain box
MAN B&W Diesel A/S
91000 0017 Gas and Air System

91001 0143 Scavenge Air Receiver
91002 0126 Arrangement of Charging Air Pipe
91003 0206 Exhaust Pipes and Receiver
91004 0067 Exhaust Receiver - Details
91005 0130 Air Cooler
91006 0038 Arrangement of Auxiliary Blower
91007 0017 Butterfly Valve
91011 0024 Arrangement of Non-Return Valve
91014 0019 Arrangement of Suction Pipe
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Gas and Air System Plate
P91000-0017
MAN B&W Diesel A/S
Scavenge Air Receiver Plate
P91001-0143
MAN B&W Diesel A/S
Plate Scavenge Air Receiver
P91001-0143

No. No.
017 Plug screw

029 Scavenge air reciever
030 Screw
042 Cover
066 Stud
078 Distance pipe
091 Nut
101 Distance pipe
113 Screw
125 Screw
149 Plug screw
162 O-ring
186 Nut
208 Distance pipe
221 Screw
245 Stud
257 Sectional iron
269 Sectional iron
270 Nut
282 Stud
294 Plate
304 Plate
MAN B&W Diesel A/S
Arrangement of Charging Air Pipe Plate
P91002-0126
MAN B&W Diesel A/S
Plate Arrangement of Charging Air Pipe
P91002-0126

No. No.
012 Nut
024 Compensator
036 Screw
061 Nut
073 Screw
085 Charging air pipe
097 Screw
MAN B&W Diesel A/S
Exhaust Pipes and Receiver Plate
Plate
Exhaust Pipes and Receiver

No. No.
018 Exhaust reciever

031 Screw*
043 Nut
079 Guide pin
080 Screw
092 Nut
114 Split pin
126 Hinge rod
138 Washer
151 Manhole cover
163 Sealing ring
175 Locking plate
187 Distance pipe
199 Screw*
210 Packing
222 Compensator
234 Gas inlet
258 Screw*
271 Distance pipe
283 Wire gauze
305 Screw*
317 Distance pipe
330 Screw*
342 Washer
354 Nut
366 Packing
378 Packing
391 Compensator
401 Screw*
413 Screw*
425 Nut
Note:
* These screws are special screws for hot

joints, they are marked with a "T", and
MUST NOT be used elsewhere!
Exhaust Receiver
Receiver,, Details Plate
Plate
Exhaust Receiver
Receiver,, Details

No. No.
013 Nut
025 Distance pipe
037 Screw
049 Support
062 Support
074 Support
098 Nut
108 Washer
121 Spring pin
145 Clamp
157 Shim
169 Spring plate
170 Screw
194 Adjustment screw
216 Spring pin
228 Support
241 Support
265 Screw
277 Support
Air Cooler Plate
P91005-0130
MAN B&W Diesel A/S
Plate Air Cooler
P91005-0130

No. No.
020 Cooler insert*

032 Plate
044 Steel bar
056 Screw
068 Distance pipe
081 O-ring
093 Screw
103 Distance pipe
115 Frame
127 O-ring
139 Frame
140 Screw
152 Water mist catcher*
164 Cover
176 Nut
188 Locking plate
223 Screw
235 Hinge
247 Support
259 Spring pin
260 Cover
272 O-ring
284 Flange
296 Screw
306 Cross member
318 Washer
331 Stud
343 Air cooler housing
Note:
* When ordering Spare Parts for this

item, please state manufacturers Part
No.
MAN B&W Diesel A/S
Arrangement of Auxiliary Blower Plate
P91006-0038
MAN B&W Diesel A/S
Plate Arrangement of Auxiliary Blower
P91006-0038

No. No.
014 Auxiliary blower*

038 Screw
051 Nut
Note:
* When ordering spare parts for this

item, please state manufacturer’s Part
No.
MAN B&W Diesel A/S
Butterfly Valve Plate
P91007-0017
MAN B&W Diesel A/S
Plate Butterfly Valve
P91007-0017

No. No.
021 Cover
033 Packing
045 Locking wire
057 Screw
069 Locking plate
070 Housing
082 Screw
116 Shaft
128 Flap
MAN B&W Diesel A/S
Arrangement of Non-return Valve Plate
P91011-0024
MAN B&W Diesel A/S
Plate Arrangement of Non-return Valve
P91011-0024

No. No.
011 Locking wire

023 Screw
035 Screw
047 Support
060 Clamp
072 Support
084 Valve flap
118 Spring pin
131 Shaft
MAN B&W Diesel A/S
Arrangement of Suction Pipe Plate
P91014-0019
MAN B&W Diesel A/S
Plate Arrangement of Suction Pipe
P91014-0019

No. No.
018 Steel pipe

031 Pipe coupling
043 Transition pipe
067 Screw
079 Screw
080 Nut
092 Flange
102 O-ring
114 Disc
126 Packing
MAN B&W Diesel A/S
91101 0037 Safety Valve - Cylinder

91103 0018 Safety Valve - Scavenge Air System
91104 0088 Arrangement of Safety Cap
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Safety Valve - Cylinder
Valve Plate
Plate
Safety Valve - Cylinder
Valve

No. No.
010 Spindle
022 Spring retainer
034 Lock nut
046 Spring
058 Valve housing
071 Stop ring
083 Valve flap
095 Valve guide
105 Gasket
117 Safety valve, complete
Relief Valve Plate
P91102-0028
Relief Valve
0028
P91102
P.C.D.
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0028
Item Item
No. No.
016 Relief valve (P.C.D. 465mm)*

028 Screw*
030 Packing*
041 O-ring*
Note:
*When ordering, please state manu-
facturer of Relief Valve and
P.C.D. xxx mm
MAN B&W Diesel A/S
Relief Valve Plate
P91102-0033
Relief Valve
0033
P91102
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0033
Item Item
No. No.
016 Relief valve (P.C.D. 615mm)*

028 Screw*
030 Packing*
041 O-ring*
Note:
*When ordering, please state manu-
facturer of Relief Valve and
P.C.D. xxx mm
MAN B&W Diesel A/S
Safety Valve - Scavenge Air System Plate
Plate
Safety Valve - Scavenge Air System

No. No.
011 Safety valve, complete

035 Spindle
047 Washer
059 Spring retainer
060 Castle nut
072 Split pin
096 Screw
106 Nut
118 Valve flap
131 Seal
143 Valve seat
155 Spring
Arrangement of Safety Cap Plate
Plate
Arrangement of Safety Cap

No. No.
017 Protective guard

029 Screw
042 Bursting cap cover
054 Check plate
066 Screw
078 Perforated cylinder
101 Fitted bolt
125 Screw
149 Wing nut
150 Washer
162 Stud
174 Bursting disc
186 Gasket
198 Block
208 Screw
233 Screw
245 Nut
257 Washer
269 Packing
270 Screw
91201 0095 Arrangement of Stay Bolts

91204 0027 Frame - Details
91205 0208 Frame Box
91206 0107 End Shields
91207 0092 Arrangement of Piston Cooling
91208 0018 Chain Wheel Frame - Upper
91210 0163 Bedplate
91211 0081 Axial Vibration Damper
91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0002 Top Bracing - Arrangement
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Arrangment of Stay Bolt Plate
P91201-0095
MAN B&W Diesel A/S
Plate Arrangment of Stay Bolt
P91201-0095

No. No.
014 Screw
026 Washer
038 Protective cap
063 Nut
087 Stay bolt
109 Guide bushing
110 Guide bushing
134 Assembling of stay bolt
MAN B&W Diesel A/S
Frame - Details Plate
P91204-0027
MAN B&W Diesel A/S
Plate Frame - Details
P91204-0027

No. No.
010 Damper, oil pipe

022 Screw
034 Flange
046 Nut
058 Stud
083 Pipe clamp
095 Screw
105 Locking wire
130 Screw
178 Screw
191 Pipe holder
201 Lubrication oil pipe
249 Screw
262 Lubrcation oil pipe
274 Stud
286 Nut
308 Screw
382 Screw
394 Distance pipe
MAN B&W Diesel A/S
Frame Box Plate
Plate
Frame Box

No. No.
016 Packing, round

028 Drain pipe
041 Cover
053 Screw
065 Cover
077 Frame box
090 Washer
112 Screw
124 Spacer, tubular
136 Nut
148 Screw
161 Screw
173 Cover
185 Nut
197 Door fastener
207 Stud
219 Frame box door
220 Nut
232 Stud
244 Cover
268 Screw
281 Plate
293 Screw
303 Fitted stud
315 Locking pin
327 Spring
339 Key ring
340 Packing, round
364 Packing
376 Frame box door
411 Wing nut
423 Door fastener
435 Spring
447 Stud
460 Cover
472 Screw
484 Cover
End Shields Plate
P91206-0107
End Shields
0107
P91206
MAN B&W Diesel A/S
Plate End Shields
P91206-0107
Item Item
No. No.
011 Screw
023 Flange
035 Packing
047 Packing
059 Cover
060 Plug
084 Plug
106 Screw
118 Shield, upper
143 Shield, lower
167 Screw
180 Gasket
MAN B&W Diesel A/S
Arrangement of Piston Cooling Plate
P91207-0092
Arrangement of Piston Cooling
0092
P91207
C F F
C B
F F
E
B
MAN B&W Diesel A/S
Plate Arrangement of Piston Cooling
P91207-0092
Item Item
No. No.
017 Drain pipe-piston cooling

030 Drain pipe-piston cooling
042 Screw
054 Locking wire
066 Sight glass
091 Screw
101 Drain box
125 Screw
137 Locking plate
150 Screw
162 Distance pipe
186 Flange
198 Screw
208 Packing
MAN B&W Diesel A/S
Chain Wheel Frame - Upper Plate
Plate
Chain Wheel Frame - Upper

No. No.
012 Cover
024 Screw
036 Flange
048 Screw
061 Cover
073 Screw
085 Screw
097 Chainwheel frame
107 Screw
132 Nut
144 Screw
156 Cover
168 Screw
181 Screw
193 Guid pin
203 Cover
215 Top guard
227 Screw
239 Cover
240 Guard
288 Distance pipe
311 Screw
347 Screw
359 Screw
360 Distance pipe
384 Stud
396 Distance pipe
Bedplate Plate
Plate
Bedplate

No. No.
013 Nut
037 Stud
050 Screw
062 Bedplate
086 Main bearing cap
098 Spring pin
108 Main bearing, upper shell
121 Main bearing, lower shell
145 Screw
157 Grate
194 Lock washer
216 Screw
228 Cover plate
Axial Vibration Damper Plate
P91211-0081
MAN B&W Diesel A/S
Plate Axial Vibration Damper
P91211-0081

No. No.
019 Spring
020 Spring
044 Screw
056 Restriction for damper
103 Screw
115 Locking wire
127 Oil seal
139 Oil seal
164 Nut
176 Nut
188 Stud
211 Stud
259 Axial vibration damper, upper part
260 Cylindrical pin
272 Axial vibration damper, lower part
MAN B&W Diesel A/S
Holding-Down Bolts and End-Chock Bolts Plate
P91216-0009
(Epoxy Chocks)
MAN B&W Diesel A/S
Plate Holding-Down Bolts and End-Chock Bolts
P91216-0009
(Epoxy Chocks)
No. No.
028 Screw
041 Washer
053 Locking plate
077 Liner for side chock, port side
089 Liner for side chock, starboard
100 Liner end chock
112 Spherical washer
136 Nut
148 Protective cap
173 Protectice cap
185 Nut
197 Distance pipe
220 Spherical nut
232 Holding-down bolt, M36 x 4
256 Stud for end chock bolt, M60 x 5.5
MAN B&W Diesel A/S
Top Bracing - Arrangement Plate
P91217-0002
MAN B&W Diesel A/S
Plate Top Bracing - Arrangement
P91217-0002

No. No.
011 Screw
023 Friction shim
059 Distance pipe
060 Washer
072 Nut
084 Split pin
106 Plate, short*
118 Plate, medium*
131 Plate, large*
143 Plate
155 Guide pin**
179 Screw
180 Disc spring
192 Distance pipe
202 Washer
214 Nut
238 Plate
251 Friction shim
Note:
* When ordering this spare part,

please state length
** Only to be used during mounting
MAN B&W Diesel A/S

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Warning S900-1

Documents in this Chapter

Table of Contents, Volume II

MAN B&W Diesel A/S

No. Edition Title

901 - Cylinder Cover

902 - Piston with Rod & Stuffing Box

903 - Cylinder Liner and Cylinder Lubrication

904 - Crosshead with Connecting Rod

MAN B&W Diesel A/S Page 1 (4)

No. Edition Title

90451 0149 Connecting Rod and Crosshead - Panel

905 - Crankshaft, Thrust Bearing and Turning Gear

906 - Control Gear

907 - Starting Air System

MAN B&W Diesel A/S Page 2 (4)

No. Edition Title

907-02 0216 Starting Air Valve

908 - Exhaust Valve

909 - Fuel Oil System

MAN B&W Diesel A/S Page 3 (4)

No. Edition Title

90912 0228 Spindle Guide

910 - Turbocharger System

911 - Safety Equipment

912 - Assembly of Large Parts

913 - General Tools

MAN B&W Diesel A/S Page 4 (4)

No. Edition Title

91356 0053 Lifting Tools, etc.

MAN B&W Diesel A/S Page 5 (4)

Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

MAN B&W Diesel A/S

The sketch gives the approximate location of the valves concerned:

Documents in this Chapter

101-01 0071 Cylinder Cover, Data

MAN B&W Diesel A/S

SAFETY PRECAUTIONS For detailed sketch, see 900-2

Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 450 Nm

Plate Item No. Description

P90151 46 Grinding tool for exhaust valve seat

P90163 Cylinder Cover - Support Tool

P91351 10 Hydraulic pump, pneumatic operated

Shut off Oil and Water Supply

Check that the engine is stopped and

2. Shut off the oil supply.

Close the fuel oil supply for the unit con-

3. Shut off the water supply.

Close the water outlet on the exhaust side

Shut off the water supply placed on the ex-

Open the drain next to the inlet valve.

Open the venting cock next to the outlet

Dismantling of Pipe Connections

4. Disconnect the oil pipes.

Remove the hydraulic high pressure pipe

Unscrew the drain pipe for the exhaust

Remove the fuel oil high pressure pipes.

Disconnect the pipes for return fuel oil from

Unscrew and remove the water outlet

6. Exhaust gas compensator.

Remove the protective jacket enclosing the

Remove the screws in the flange between