MAN B&W - 6S-50-MC-C-Vol-II-Maintenance-Manual 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
S50MC-C VOLUME II
DS 09091718 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
90023 0027 Instructions for Main Engine
90060 0001 General - Safety Precautions
901 - Cylinder Cover

101-01 0041 Cylinder Cover, Data
901-01 0250 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box

102-01 0065 Piston, Data
902-01 0270 Piston
102-02 0048 Piston Rod Stuffing Box, Data
902-02 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication

103-01 0056 Cylinder Liner, Data
903-01 0253 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0253 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod

104-01 0048 Crosshead Bearing, Data
904-01 0239 Crosshead Bearing
104-02 0050 Crosshead, Data
904-02 0239 Crosshead
104-03 0034 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0042 Crankpin Bearing, Data
904-04 0226 Crankpin Bearing
104-05 0043 Connecting Rod, Data
904-05 0231 Connection Rod
90451 0151 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
MAN B&W Diesel A/S Page 1 (5)

No. Edition Title
90462 0020 Connecting Rod - Tools
905 - Crankshaft, Thrust Bearing and Turning Gear

105-01 0004 Crankshaft Deflection, Data
905-01 0209 Crankshaft Deflection
105-02 0044 Main Bearing, Data
905-02 0241 Main Bearing
105-03 0039 Thrust Bearing, Data
905-03 0224 Thrust Bearing
105-04 0003 Journal Bearing, Data
905-04 0212 Journal Bearing
105-05 0033 Axial Vibration Damper, Data
905-05 0224 Axial Vibration Damper
105-08 0007 Angle Encoder, Data
905-08 0204 Angle Encoder
90551 0227 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0093 Main Bearing - Hydraulic Tools
90562 0125 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90570 0004 Thrust Shaft - Tools
90572 0003 Main Bearing - Measuring Tools
90573 0002 Tuning Wheel - Tools
906 - Control Gear

106-01 0041 Chain, Data
906-01 0236 Chain
106-02 0054 Chain Tightener, Data
906-02 0239 Chain Tightener
106-03 0036 Camshaft, Data
906-03 0214 Camshaft
106-04 0034 Camshaft Bearings, Data
906-04 0216 Camshaft Bearings
106-05 0024 Moment Compensator, Data
906-05 0220 Moment Compensator
106-06 0007 Replacement of Cams on Camshaft, Data
906-06 0203 Replacement of Cams on Camshaft
90651 0173 Chain Drive and Camshaft - Panel
90662 0046 Camshaft - Hydraulic Tools
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
907 - Starting Air System

107-01 0017 Starting Air Distributor, Data
907-01 0216 Starting Air Distributor
107-02 0032 Start Air Valve, Data

No. Edition Title
907-02 0214 Starting Air Valve
908 - Exhaust Valve

108-01 0017 High-Pressure Pipe, Data
908-01 0212 High-Pressure Pipe
108-02 0087 Exhaust Valve, Data
908-02 0256 Exhaust Valve
108-03 0017 Exhaust Valve Actuator, Data
908-03 0218 Exhaust Valve Actuator
108-04 0015 Exhaust Valve Roller Guide, Data
908-04 0210 Exaust Valve Roller Guide
108-05 0002 Exhaust Valve Cam, Data
908-05 0203 Exhaust Valve Cam
108-07 0020 Exhaust Valve - Special Running, Data
90851 0200 Exhaust Valve - Panel
90862 0043 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
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 0205 VIT System
109-03 0044 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0050 Fuel Pump, Data
909-04 0224 Fuel Pump
109-05 0052 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0042 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0034 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0043 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0025 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10911 0047 Fuel Valve, Data
90911 0231 Fuel Valve
10912 0038 Spindle Guide, Data
90912 0222 Spindle Guide
10913 0031 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve

No. Edition Title
10914 0060 Fuel Oil High-Pressure Pipes, Data

90914 0235 Fuel Oil High-Pressure Pipes
10915 0050 Fuel Pump Roller Guide, Data
90915 0226 Fuel Pump Roller Guide
10916 0016 Fuel Pump Spec. Running
90916 0204 Fuel Pump Special Running
90951 0462 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
910 - Turbocharger System

110-01 0032 Air Cooler Element, Data
910-01 0229 Air Cooler Element
110-02 0009 Non-Return Valve in Turbocharger, Data
910-02 0205 Non Return Valve in Tubocharger
910-03 0218 Auxilary Blower
110-03 0019 Auxilary Blower, Data
110-04 0005 Butterfly Valve, Data
910-04 0208 Butterfly Valves
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0018 Water Mist Catcher, Data
910-06 0214 Water Mist Catcher
91061 0071 Turbocharger System - Tools
91063 0017 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0001 Air Cooler - Lifting Tools
911 - Safety Equipment

111-01 0025 Safety Valve, Data
911-01 0211 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 0007 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)

No. Edition Title
112-03 0015 Stay Bolts, Data

912-03 0210 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0073 Hydraulic Tools for Large Parts
91265 0003 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
91268 0001 Hydraulic Tools - End Chock Bolts (Iron 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
91356 0058 Lifting Tools, etc.
91357 0005 Open-Ended Spanners
91358 0013 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0040 Spanners
91366 0066 Instruments
91368 0004 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
901 - Cylinder Cover
101-01 0041 Cylinder Cover, Data

901-01 0250 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Cover 101-1
Data
SAFETY PRECAUTIONS
Special
D10101 Data 0041
101-1 Edition Cylinder
S50ME-C Cover
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
Ref. Description Value Unit
D01-01 Exhaust valve stud, screwing-in torque 680 Nm

D01-02 Starting valve stud, screwing-in torque 150 Nm
D01-03 Fuel valve stud, screwing-in torque 40 Nm
D01-04 Cylinder cover stud, screwing-in torque 500 Nm
D01-05 Cylinder cover stud, check distance 128 - 129 mm
D01-06 Cylinder cover, complete 1700 kg
D01-07 Cylinder cover without valves 1200 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 8 kg
D01-10 Cylinder cover stud 22 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 0041 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, 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
P90151 130 Lifting chains
P90161 Cylinder cover tightening tool
P91351 10 Hydraulic pump, pneumatically 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 0041
MAN B&W Diesel A/S
Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling
1. Set blocking device A on the main starting 1.

valve in the blocked position.
E
Engage turning gear B. C
Close fuel oil inlet valve C. D
A
Close cooling water inlet valve B.
Close cooling water outlet valve E.
Open cooling water drain cocks F and G.
Shut off the air supply for the pneumatic

exhaust valve spring, and vent the system. F
2. Connect a pressure gauge at ‘minimess’ G

point 455.
Check the pressure.
Close valve 420 and open valve 421 on the

M901010250D01
hydraulic block. B
Check that the system is pressure free.
2.
When referring to this page, please quote Procedure M90101 Edition 0250 Page 1 (12)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel
3. Close valve 531 for hydraulic operation of

3. the exhaust valve.
4. Remove the cooling water inlet and outlet

pipes from the exhaust valve and cylinder
cover.
Remove the drain pipe from the intermedi-

ate pipe between the cylinder cover and
the exhaust valve.
Remove the oil supply pipe for the hydrau-

lic damper in the exhaust valve.
M901010250D03
Dismount the fuel oil high-pressure pipes

between fuel valves and fuel pump.
See Procedure 909-14.2.
Dismount the control air pipe from the

4. starting valve.
Remove the starting air pipe.
Disconnect the plug for the electrical ex-

haust valve sensor.
5. Remove the exhaust valve high-pressure

pipe.
Dismount the drain oil pipe from the ex-

haust valve oil cylinder and air cylinder, the
M901010248D04
air pipe for pneumatic closing of the ex-

haust valve, and the pipes for the sealing
air arrangement.
5.
M901010248D05
Page 2 (12) When referring to this page, please quote Procedure M90101 Edition 0250
6. Remove the protective jacket enclosing the

intermediate pipe between the exhaust re- 6.
ceiver and the exhaust valve.
Dismount the screws in the flange between

the intermediate pipe and the exhaust re-
ceiver. The four lowermost screws need not
be dismantled, just loosened.
Remove the protective caps from the cylin-

der cover nuts.
7. Place eight spacer rings, one around each

nut, and screw the eight hydraulic jacks
M901010248D06
onto the studs.
Connect the high-pressure pump to the

jacks by means of the distributor block and
the high-pressure hoses.
7.
Using the vent screws of the hydraulic
jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see

Procedure 913-1.
Loosen the nuts by applying the tommy

bar through the slots in the spacer rings.
Relieve the system of pressure.

M901010250D07
Disconnect the high-pressure hoses from

the jacks.
Remove the hydraulic jacks and spacer

rings, and unscrew the nuts.
8.
8. Hook the engine room crane on to the lift-
ing attachment on top of the exhaust valve.
Lift away the cylinder cover complete, and

land it on a couple of wooden planks.
M901010248D11
9. Remove and discard the sealing ring be-

9. tween cylinder cover and cylinder liner.
M901010248D12
MAN B&W Diesel Overhaul
1. Dismount all valves and pipes on the cylin-

der cover. 1.
See Procedure 907-2.2, 908-2.2 and 909- D0109
11.2.
Dismount all studs on top of the cylinder

cover.
2. 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.
M901010248O01
Remove and discard the O-rings from the
cover, and carefully clean the cooling jacket
and the cylinder cover.
3. Provide the cylinder cover with new O-

rings, well lubricated with oil. 2.
4. Lift the cylinder cover and guide the jacket/ D0107

cover into position, using the guide pin as
a reference (camshaft side).
Mount and tighten the screws for the cool-

ing jacket.
D0108
M901010248O02
3.
4.
M901010248O03
Overhaul MAN B&W Diesel
5. Recondition the valve bores as follows:

5.
Fuel valve bore
6. The tool consists of a common spindle with

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

bon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.
Grind the seating with the grinding mandrel

and a grinding compound (e.g. Carborun-
M901010246O04
dum No. 200).
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
6.
Exhaust valve bore
7. The tool consists of a spindle with 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
M901010246O06
not damaged.
7.
M901010248O07
Starting valve bore

8.
8. The tool consists of a guide, a cutter, and
a grinding disc.
Recondition the starting valve bore and

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

that is mounted on the engine, recondition
the valve bores/seating in the same way as
described here, but without dismounting
the studs.
9. Clean the bores for safety valve/indicator

cock.
M901010248O08
9.
M901010248O09
10. Lubricate the threads with ‘Never Seize' or

10. D0101 Molybdenum Disulphide (MoS2) and mount
the valve studs.
D0103 Tighten up the studs in accordance with

the screwing-in torque stated on the data
sheet.
Fill up the grooves between the valve studs

and the bores for the valve studs with
permatex to prevent water or oil from en-
D0102 tering the bores during operation of the en-
gine.
M901010248O10
Provide the water connection flanges with

new gaskets, and keep the cylinder cover
ready for replacement.
Always fit new or overhauled valves before

a cylinder cover is mounted on the engine.
MAN B&W Diesel Mounting
1. Place a new sealing ring on top of the cyl-

inder liner with the guide tabs in the fore 1.
and aft direction. D0106
This is to ensure that the tabs fit into the
two gas blow-out grooves milled in the cyl-
inder cover guide recess.
2. Lift the cylinder cover by means of the

crane and carefully wipe the contact sur-
face which faces the cylinder liner.
Provide the cooling water connecting pipes
M901010248M01
with new O-rings and lubricate them with
grease or soft soap.
Mount a new sealing ring in the groove of

the flange of the intermediate pipe.
Lower the cover carefully into position. 2.
During the landing, carefully check that the

cooling water connecting pipes engage
correctly with the holes in the cooling
jacket.
3. If cylinder cover studs have been removed

and remounted, check the distance the
stud is protruding from the cylinder cover.
If necessary, adjust the distance D01-05 by

turning the stud.
M901010248M02
3.
D0105
M901010246M03
Mounting MAN B&W Diesel
4. Mount the cover nuts on the studs and

4. screw down.
Place eight spacer rings, one around each

nut, and mount the eight hydraulic jacks on
the studs.
Connect the high-pressure pump to the

jacks by means of the distributor block and
the high-pressure hoses.
Using the vent screws of the hydraulic

jacks, vent the system, and then increase
the pressure as stated in Data.
M901010250D07

Procedure 913-1.
Tighten the nuts by applying the tommy bar

through the slots in the spacer rings.
5.
Relieve the system of pressure.
Finally, remove the hydraulic jacks and

spacer rings from the nuts.
5. Mount the protective caps on the cylinder

cover studs.
Align the intermediate pipe so that the

holes in the flange of the intermediate pipe
are in line with the threaded holes in the
exhaust receiver.
M901010248M04
Mount the screws of the flange between

the intermediate pipe and the exhaust re-
ceiver.
Note!
Lubricate the screws with anti-seize
paste containing Molybdenum Disulphide
(MoS2) before mounting.
Mount the insulating jacket around the in-

termediate pipe.
6. Mount the drain oil pipes and the air pipe

for pneumatic closing of the exhaust valve. 6.
Mount the high-pressure pipe for the hy-

draulic valve gear.
7. Mount the starting air pipe and control air

pipe for the starting valve.
Mount the cooling water inlet and outlet

pipes on the exhaust valve.
M901010248M05
Mount the plug for the electrical sensor for
the exhaust valve.
Mount the drain pipe on the intermediate

pipe between the exhaust valve and the
cylinder cover.
7.
Mount the fuel oil high-pressure pipes for
the fuel valves.
Mount the oil supply pipe for the hydraulic

damper in the exhaust valve.
Connect the outlet pipe from the return oil

pipe on the fuel valves.
Shut the drain valves and open the cooling

water inlet. After venting the cylinder sec-
M901010248M06
tion, shut the vent cocks and open the

cooling water outlet valve.
Open the fuel oil. Open the lubricating oil

and air supplies to the exhaust valve.
Caution!
The air supply to the exhaust valve must
always be connected before starting the
hydraulic oil pumps.
8. Open valve 531 for hydraulic operation of

8. the exhaust valve.
9. Close valve 421 and open valve 420 on the

hydraulic block.
M901010250M07
9.
M901010250M08
Cylinder Cover Panel Plate
P90151-0199
Cylinder Cover Panel
0199
P90151
When referring to this page, please quote Plate P90151 Edition 0199 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0199
Item Item
Item Description Item Description
No. No.
010 Panel for tools

022 Name plate
046 Grinding tool for exhaust valve seat
058 Milling and grinding wheel for fuel
valve seat
060 Milling and grinding wheel for starting
valve seat
071 Dismantling tool for fuel valve seat
083 Handle for cutting and grinding tool
095 Grinding ring for starting valve
105 Grinding handle
117 Pressure tester for safety valve
130 Lifting chains
201 Handle for cutting and grinding tool
Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
Cylinder Cover - Tools Plate
P90161-0105
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0105
Item Item Description Item Item Description

No. No.
027 Hydraulic jack, complete

039 Support
040 Support
052 O-ring with back-up ring
090 Spanner
100 Tommy bar
111 Stud setter
206 Hydraulic tool set, complete
MAN B&W Diesel A/S
902 - Piston with Rod & Stuffing Box
102-01 0065 Piston, Data

902-01 0270 Piston
102-02 0048 Piston Rod Stuffing Box, Data
902-02 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Piston 102-1
Data
SAFETY PRECAUTIONS
Special
D10201 Data 0065
102-1 Edition S50ME-C
Piston
X Stopped engine
X Shut off fuel oil
Data
D01-05 Cylinder cover stud, check distance 128 - 129 mm

D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 430 Nm
D02-03 Piston rod/crown, tightening torque 300 Nm
D02-05 Piston skirt, tightening torque 80 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-07 Piston rod/crosshead, tightening torque + angle 100/30 Nm/°
D02-08 Piston ring new, radial width 17.2 mm
D02-09 Piston ring worn, min. radial width 14.2 mm
D02-10 Groove No.1, max. vertical height 13.2 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 10.2 mm
D02-12 Piston top, max. permissible burn-away 15 mm
D02-13 Piston ring new, height of ring No. 1 12.4 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 9.4 mm
D02-15 Minimum free ring gap (before dismantling) 28 mm
D02-16 Minimum ring gap, ring No. 1 (new ring in new liner) 3.4 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 (new ring in new liner) 2.4 mm
D02-18 Vertical clearance, new parts 0.35-0.4 mm
D02-19 Vertical clearance, worn parts, max. 0.87 mm
D02-20 Piston complete 921 kg
D02-21 Piston crown 200 kg
D02-22 Piston rod 565 kg
D02-23 Piston skirt 57 kg
D02-24 Piston cooling pipe 21 kg
D02-25 Lifting tool, tightening torque 150 Nm
D02-46 CPR ring CL groove, min. depth 1.1 mm
MAN B&W Diesel A/S
102-1 Piston
Data
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
P90264 Tools for tilted lift
P90265 Support for piston
P90266 Lifting tool for piston
P90366 Crossbar for cylinder liner
P90451 118 Rubber cover for crosshead
MAN B&W Diesel A/S
Piston 902-1.1
Checking
Piston
S60MC-C
0270
Checking
902-1.1
1.
Scavenge port inspection
To detect possible leakages from the piston or

cylinder cover, keep the cooling water and cool-
ing oil circulating during the scavenge port in-
spection.
1. The scavenge port inspection is carried out

from the scavenge air receiver. An addition-
al view of the rings is possible through the
cleaning cover on the maneouvring side.
Turn the engine at least ½ a revolution and
HN902-1.1 256 01
start with a unit arriving downwards, just
above the scavenge air ports.
Inspect the piston rod and the lower part of

the cylinder wall. While the piston is pass-
ing downwards, inspect the piston skirt, all 2.
the piston rings, the ringlands and the pis-
ton top.
2. Inspect the rings, one at a time, and note

down the results. See Volume I, Operation,
Chapter 707.
3. Check the movability and the tension of the

piston rings, by pressing against them with
a wooden stick.
HN902-1.1 256 02
3.
HG902-1.1 204 03
MAN B&W Diesel A/S
902-1.1 Piston
Checking
4. 4. Ring grooves:
D02-18 Measure the total clearance between the
piston rings and the ring grooves.
The total clearance must not exceed the

value stated in Data.
Measurements are to be taken at the top

(E) and bottom (F) between the piston ring
D02-19 and piston ring groove.
Total clearance = E + F.
5. Uppermost piston ring:

If possible, measure the depth of the pres-
sure relief grooves with a caliper.
The piston rings must be replaced if the ra-

HM902-1.1 246 15
dial depth of the grooves has worn down to

less than stated in Data D02-46.
Checking of piston rings and piston crown,

in connection with piston overhaul:
5.
Min. 1
D02-46 mm
6. Remove the piston from the cylinder and
place it on the piston support.
Note!
It is recommended to replace all the pis-

GN902-1.2 204 08
ton rings whenever a piston is removed

from the engine.
For evaluation of the rings, see Volume I,

6. Chapter 707.
GN902-1.2 204 08
MAN B&W Diesel A/S
Piston 902-1.1
Checking
7. Before dismantling the piston rings, meas- 7.

ure the free ring gap of all the piston rings.
8. Take off the piston rings by means of the D02-15

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

down the results
See Volume I, Operation, Chapter 707.
BM902-1.1 232 07
GN902-1.1 222 14
8.
9.
D02-08
New
GN902-1.1 204 08
D02-09
Worn
MAN B&W Diesel A/S
902-1.1 Piston
Checking
10. 10. Clean the ring grooves and check them for
burn marks or other deformation.
D02-10 Measure the ring grooves with a caliper

D02-11 gauge, see Data D02-10 and D02-11.
Clearance in piston ring grooves:

The maximum vertical height in a worn ring
groove must not exceed the value stated in
Data.
Max 2 mm
The groove is also worn out if there is no
Max 2 mm chromium layer.
11. Clean the piston crown and check the burn-

away by means of the template. For maxi-
mum permissible burn-away value, see Da-
KM902-3.0 47 05
ta.
Check the burn-away on the whole circum-

ference of the piston crown. Note down the
results for later reference.
11. D02-12
12. Fit the new piston rings (alternately right-
hand and left-hand cuts, with the ring gaps
staggered 180° and with the TOP mark up-
wards), using the ring expander.
AM902-3.0 77 04
When mounting the piston rings, use the

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

sary. The upper ring (CPR-ring) should not
be expanded more than to the milled mark
on the ring expander.
GN902-1.1 222 14
MAN B&W Diesel A/S
Piston 902-1.2
Dismantling
Dismantling
902-1.2
1. Turn the crosshead down far enough to give 1.

access to the piston rod stuffing box and
the screws for the piston rod.
2. Release the stuffing box by removing the

innermost screws from the stuffing box
flange.
Note!
Do NOT remove the outermost screws

from the flange.
MN902-1.2 235 01
3. Remove the screws from the piston rod.
GN902-1.2 204 02 2.
3.
HN902-1.2 237 03
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling
4. 4. Mount the two distance pieces on the piston

rod foot to protect the lower scraper ring
and to guide the stuffing box.
5. Dismount the cylinder cover.

Carefully smooth out any wear ridges at the

top of the cylinder liner.
6. Make a scratch mark in liner and piston

HN902-1.2 256 04
cleaning ring to ensure the correct mount-

ing.
Remove the piston cleaning ring.

5.
Carefully remove any wear ridges at the top
of the cylinder liner.
GN902-1.2 204 05
6.
GN902-1.2 237 06
MAN B&W Diesel A/S
Piston 902-1.2
Dismantling
7. Turn the crosshead towards TDC, while 7.

checking that the stuffing box lands correct-
ly on the distance pieces.
8. Turn to TDC.
The top of the piston is now free of the cyl-

inder liner.
Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two ‘fixed’ claws of the tool fit into
GN902-1.2 204 06
the lifting groove of the piston.
Fit the third, adjustable, claw of the tool to

the lifting groove and tighten it up against
the stop of the tool, see Data D02-25.
8.
Lift the piston out of the cylinder liner.
GN902-1.2 204 07
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling
9. 9. If the lifting height is limited, it can be nec-

essary to guide the piston rod foot in be-
tween the cylinder cover studs.
Note!
Alternatively, with low lifting height,

remove one of the cylinder cover studs
with the stud setter.
10. Lower the piston rod foot and stuffing box

through the opening in the platform.
MN902-1.2 256 09
Place the two halves of the support around

the piston rod and secure the two halves
with screws.
10. 11. Place a cover over the opening for the pis-
ton rod stuffing box in the bottom of the cyl-
inder unit.
D02-20 Clean, measure and recondition the cylin-

der liner.
See Procedure 903-1.
GN902-1.2 204 08
11.
GN902-1.2 204 09
MAN B&W Diesel A/S
Piston 902-1.2
Dismantling
12. Turn the crosshead down far enough to per- 12.

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

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

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

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

room over the cylinder cover studs.
Place the supporting tools on the cylinder

cover studs.
GN902-1.2 243 11
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling
14. 14. Place the collar ring on the supporting tools

and mount the clamp on the collar ring.
Check that the distance pieces have con-
tact with the piston.
Remove the lifting tool from the piston.
Hook the crossbar on to the crane and at-

tach the collar ring to the crossbar.
15. Lift the piston to the maximum crane height.

Run the crane athwartship and, at the same
time, tilt the piston.
Note!
Tilting of the piston must only take place

with the piston rod stuffing box mounted
on the piston rod.
Keep the piston rod clear of the cylinder lin-

GN902-1.2 243 12
er and studs while carrying out the tilting.
When space conditions permit, straighten

up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
15.
When the piston is at a suitable height
above the platform cut-out, position the pis-
ton support around the piston rod and
clamp.
Now lower the piston while guiding the sup-

port to the platform cut-out.
After landing the piston and ensuring that it

rests correctly on the support, remove the
tilting tool.
Note!
On engines with extremely low lifting

height, use the engine room double-jib
crane instead of the transverse piece.
GN902-1.2 243 13
MAN B&W Diesel A/S
Piston 902-1.3
Overhaul
Overhaul
902-1.3
1. Ease the piston down so that the stuffing 1.

D02-20
box is below the floor.
2. Assemble the two halves of the piston sup-

port around the piston rod and land the pis-
ton on the support.
Check and remove the piston rings.

3. Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown.
JM902-1.3 234 01
JM902-1.3 234 02 2.
3.
JM902-1.3 234 03
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul
4. 4. Dismount the locking wire and screw up the

support screws of the piston support to a
position just below the piston skirt.
Remove the piston skirt screws.
D02-23 5. Screw the four screws of the support down-

wards until the skirt rests on the support.
If the skirt will not budge, free it by means

of two dismantling screws.
Lift away the piston crown.

JM902-1.3 234 04
Remove and discard the sealing rings on

the piston rod and on the skirt.
6. Dismount the bolts of the cooling oil pipe

5. flange.
D02-21 Mount the eye bolts and lift out the cooling
oil pipe.
After inspection of the cooling oil pipe, re-

mount the pipe.
JM902-1.3 234 05
6.
D02-24
D02-06
GN902-1.3 204 06
MAN B&W Diesel A/S
Piston 902-1.3
Overhaul
Alternatively, the piston can be dismantled 7.

in the following way:
7. With the piston standing in the piston sup-

port tool, remove the piston rod stuffing
box, see Procedure 902-2.3.
8. Lift the piston with the lifting tool. Land the

piston rod foot on a wooden plank.
Note!
KM902-1.3 240 06
During the lift, follow with the crane to
keep the crane positioned vertically
above the lifting point.
Lower the piston crown to the platform and 8.

land it on a wooden plank, so that it is pos-
sible to remove the lifting tool.
9. Remove the lifting tool from the piston

crown. Attach the lifting bracket to the bot-
tom of the piston rod foot. Hook the crane
GN902-1.3 243 08
on to the lifting bracket.
10. Lift the piston rod foot clear of the wooden

plank.
Keep lifting until the piston rod is in a verti- 9.

cal position.
GN902-1.3 243 09
10.
KM902-1.3 240 09
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul
11. 11. Place the piston in an upright position with

the piston crown resting on wooden blocks.
Dismount the locking wire and the inner-

D02-22 most screws between the rod and the pis-
ton crown. Lift the piston rod away and land
it in a horizontal position on a couple of
wooden planks.
12. Remove the locking wire and the screws in

the skirt and mount two eye bolts in the
holes intended for dismantling screws. Lift
the skirt and land it on a couple of planks.
GN902-1.3 243 11
13. Thoroughly clean and inspect all parts of

the piston.
Regarding check of the piston crown, see
Procedure 902-1.1.
12.
Replace all sealing rings of the piston. All
the new sealing rings must be coated with
lubricating oil before the piston is assem-
bled.
D02-23 Coat all screws with Molybdenum Disul-

phide (MoS 2).
Assemble the piston in the reverse order to

disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.
GN902-1.3 204 11
Tighten all the screws diagonally to the

torque stated in Data.
13.
D02-03
D02-05
GN902-1.3 204 12
MAN B&W Diesel A/S
Piston 902-1.3
Overhaul
14. Lock all the screws with locking wire. 14.
Mount the locking wire in such a way that

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

ing oil.
Mount the pressure-testing tool around the

base of the piston rod.
HM902-1.3 204 13
Pressure-test the piston at the pressure
stated on the data sheet.
Check the contact surfaces of the piston

and the sealing rings for tightness.
15.
Check that there are no cracks in the piston
crown.
For overhaul of the stuffing box, see Proce-

dure 902-2.3. D02-01
Oil
MB902-1.3 204 14
MAN B&W Diesel A/S
902-1.4 Piston
Mounting
Mounting
902-1.4
2. 1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1.
D02-20 Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.
2. Mount the lifting tool on the piston crown.
3. Ensure that the stuffing box is correctly po-

sitioned over the guide pins in the distance
pieces mounted on the piston rod foot.
Coat the O-rings of the stuffing box with oil.
4. Remove the protective rubber cover from

the crosshead.
JM902-1.3 234 01
3.
GN902-1.4 204 03
4.
GN902-1.2 204 10
MAN B&W Diesel A/S
Piston 902-1.4
Mounting
5. Remove the cover from the piston rod stuff- 5.

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

TDC.
Mount the guide ring for piston rings on the

cylinder liner.
7. Lower the piston into the cylinder liner –

while guiding the piston rod foot through the
cut-out in the stuffing box flange – until the
GN902-1.2 204 09
piston rings are inside the liner.
GN902-1.4 204 06 6.
7.
GN902-1.4 204 07
MAN B&W Diesel A/S
902-1.4 Piston
Mounting
8. 8. Turn the crosshead nearly to TDC while

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

and ensuring that the piston rod has full
contact with the crosshead, unscrew the
adjustable claw of the lifting tool and pull
the lifting tool free of the lifting groove in the
piston
Remove the lifting tool and the guide ring

KB902-1.4 225 08
for piston rings.
10. 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
9. correctly centred.
Remove the distance pieces from the piston

rod foot.
GN902-1.4 204 09
10.
KB902-1.4 225 09
MAN B&W Diesel A/S
Piston 902-1.4
Mounting
11. Tighten down the piston rod stuffing box by 11.

means of the screws, through the inner
holes in the stuffing box flange.
12. Mount and tighten the piston rod screws.

Tighten the screws to the specified torque
and lock with locking wire. See Data. Use
either Data D02-02 or Data D02-07.
GN902-1.2 204 02
13. Mount the piston cleaning ring according to
the scratch mark.
If the PC-ring is damaged (broken or

cracked), it must be replaced by another 12.
ring. See Procedure 903-1. D02-02
or
D02-07
HN902-1.4 237 12
13.
HN902-1.4 237 13
MAN B&W Diesel A/S
902-1.4 Piston
Mounting
14. 14. 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 contact and
one half revolution back.
15. Land the cylinder cover on the liner and

check the distance the stud is protruding
from the cylinder cover.
If necessary, adjust the distance D01-05 by

turning the stud.
16. Tighten the cylinder cover and mount the

necessary pipes.
GN902-1.4 204 12
Smear the piston rod with molybdenum di-

sulphide, and turn the crankshaft a couple
15. of revolutions.
Start the engine and keep it running for

about 15 minutes at a number of revolutions
D01-05 corresponding to very slow.
Then stop the engine and inspect the piston

rod and stuffing box.
HN902-1.4 256 15
MAN B&W Diesel A/S
Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS
Special
D10202 Data 0048
102-2 Edition PistonS50ME-C
Rod Stuffing Box
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
D02-33 Check length for the six uppermost springs:
D02-34 – F 0 = 0 N.........…....... L 0 = 639 mm
D02-35 – F 1 = 153 +/– 7 N....... L 1 = 763 mm
D02-36 – F 2 = 163 +/– 10 N..... L 2 = 835 mm
D02-37 Check length for the four lowermost springs:
D02-38 – F 0 = 0 N......….......... L 0 = 496 mm
D02-39 – F 1 = 150 +/– 7 N....... L 1 = 646 mm
D02-40 – F 2 = 200 +/– 10 N..... L 2 = 714 mm
D02-44 Stuffing box complete 63 kg
D02-45 Stuffing box half 19 kg
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data
P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box
P90451 120 Rubber cover for crosshead
MAN B&W Diesel A/S
Piston Rod Stuffing Box 902-2.1
Checking
0221 Rod Stuffing Box
Piston S46MCC
Checking
902-2.1
1.
1. After the piston rod stuffing box has been
dismantled, check the following clearanc-
es:.
See Procedure 902-2.2. D02-29
Uppermost scraper ring and sealing rings

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

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

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

depending on the overhauling intervals and
one’s own experience – to replace sealing D02-29 D02-30
rings and scraper rings when the specified
NB902-2.1 216 01
clearance values D02-29 and D02-30 have

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

loads. Adjust the loads to achieve the
2.
lengths stated in Data. D02-33
If the loads necessary are outside the limits
stated in Data, the springs must be discard-
ed.
It is recommended to renew the springs for

the sealing rings when the rings are re-
newed.
D02-37
HM902-5.0 70 02
0$1% :'LHVHO$6
902-2.2 Piston Rod Stuffing Box
Dismantling
Dismantling
902-2.2
1. In connection with dismantling of the piston,

only the innermost screws in the stuffing box
flange should be removed.
If, in the period between piston overhauls, it be-

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

rod to protect the crosshead bearing from
impurities.
GN902-2.2 203 01
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.
DM902-5.2 108 02
3.
DM902-5.2 108 03
0$1% :'LHVHO$6
Dismantling
4. Remove the two long dismantling screws 4.

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

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

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

ing the stuffing box from the cylinder frame
bottom.
DM902-5.2 108 04
6. Remove the two long dismantling screws
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 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
DM902-5.2 108 05
6.
EN902-2.2 221 06
0$1% :'LHVHO$6
Overhaul
Overhaul
902-2.3
Normally, overhaul of the piston rod stuffing box

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

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

from the platform below.
Overhaul inside the engine is carried out in the

same way as outside the engine.
GM902-5.1 90 01
1. Mount two eye bolts in the stuffing box

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

1. 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.
D02-44 2. Remove the O-ring of the stuffing box. If the
O-ring is intact and is to be used again,
D02-44
move it up the piston rod and secure it in
this position, for example with tape.
Remove the nuts from the stuffing box as-

sembling bolts.
2222041a
2.
2222042a
0$1% :'LHVHO$6
Overhaul
3. Take out the six bolts, and pull away one 3.

stuffing box half.
Mount two eye bolts on the stuffing box half D02-45

and remove it from the worktable.
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.
6. Measure the clearance between the ring
2222043a
segments to determine whether replace-
ment is necessary.
7.
Dismantle and stack the rings in the same D02-33
order as when fitted in the stuffing box.
Carefully clean all the ring segments.
Inspect and assess the surface quality of

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

HM902-5.0 70 02
small longitudinal scratches have occurred

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

ing.
HC902-5.1 98 07
0$1% :'LHVHO$6
Overhaul
10. 10. Lubricate the piston rod (in the area where
all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).
Assemble all the stuffing box ring units

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

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

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

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

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

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

8-part sealing ring. Push the two rings to-
gether in such a manner that the guide pins
in the lower sealing ring engage with the
two holes in the upper sealing ring.
HC902-5.1 98 11
Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
11. Use the stuffing box half on the worktable

to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. Subse-
quently, push the stuffing box half into con-
tact with the piston rod, round the ring units.
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.
0$1% :'LHVHO$6
Overhaul
12. Check the ring clearance again. 12.
Then place the other half of the stuffing box

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

torque specified on the Data Sheet.
Mount the O-ring in the stuffing box groove.
13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.
HC902-5.1 98 12
Remove the worktable and lower the stuff-
ing box until it rests against the distance
pieces on the piston rod foot.
Remove wire ropes and screws. 13.
D02-44
22320313
0$1% :'LHVHO$6
Mounting
Mounting
902-2.4
1. 1. In connection with mounting of the piston,

only the innermost flange screws are to be
mounted and tightened, see data.
After overhauling the stuffing box inside the

engine, assemble the stuffing box halves on
top of the four screws.
Mount the two long screws from the workta-

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

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

22420416
box is in place in the cylinder frame.
2. Note!
Make sure that the two guide pins in the

flange enter the guide holes in the bottom
of the cylinder frame.
3. Mount two screws in the flange through the

holes in the worktable.
DM902-5.2 108 08
3.
DM902-5.2 108 09
0$1% :'LHVHO$6
Mounting
4. Remove the long screws from the stuffing 4.

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

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

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

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

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

rod and stuffing box.
D02-26
DM902-5.2 108 11
D02-27
6.
GN902-2.2 203 01
0$1% :'LHVHO$6
Piston and Piston Rod Panel Plate
P90251-0237
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0237

No. No.
014 Panel for tools

026 Name plate
040 Lifting tool, piston rod foot
051 Lifting tool, cylinder liner
075 Template, piston top
087 Distance piece, stuffing box
099 Cover, stuffing box hole
109 Mounting tool, stuffing box spring
110 Pressure test tool, piston
122 Worktable, stuffing box
134 Expander, piston ring
158 Guide screw, piston crown
160 Guide screw, piston crown
MAN B&W Diesel A/S
Piston and Piston Rod - Tools Plate
P90261-0108
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0108

No. No.
019 Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Extra Tools Plate
P90264-0002
Piston and Piston Rod - Extra Tools
0002
P90264
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Extra Tools
P90264-0002
Item Item
No. No.
015 Lifting collar

027 Support for tilting tool
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools Plate
P90265-0001
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0001

No. No.
010 Support iron for piston
MAN B&W Diesel A/S
Piston - Lifting Tools Plate
P90266-0002
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0002

No. No.
016 Lifting tool for piston
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication
103-01 0056 Cylinder Liner, Data

903-01 0253 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0253 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 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
SAFETY PRECAUTIONS
Special Edition
D10301
103-1 Data 0056 Cylinder
S50ME-C Liner
X Stopped engine
X Shut off fuel oil
Data
D03-01 Lifting tool screws, tightening torque 150 Nm

D03-03 Cylinder diameter, new 500 mm
D03-04 Piston cleaning ring diameter, new 498.3 mm
D03-05 Cylinder liner, complete 1820 kg
D03-06 Cooling jacket 170 kg
D03-16 Piston cleaning ring radial width, new 38.8 mm
D03-17 PC-ring/Liner max. wear deviation 0.5 mm
D03-18 PC-ring replacement criteria:
Liner diameter: 500 mm

Liner wear: Install:
0 – 0.50 mm Standard PC-ring
(new or max. wear of diameter 0.50 mm)
0.50 – 1 mm Oversize PC-ring
> 1 mm Dummy 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
Cylinder Liner
S50MC
0253
Checking
903-1.1
1.
1. Dismount the cylinder cover, piston and
PC-ring.
Clean the cylinder liner and scavenge air

ports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside

micrometer at the positions indicated on the
measuring tool. See Data.
3. Take measurements in the fore-and-aft and

athwartship directions.
4. Check and assess the condition of the cyl-

inder liner according to the description giv-
en in Volume I, Chapter 707.
DM903-2.0 90 01
5. Carefully scratch over any scores or marks

on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3. 2.
6. Check the lubricating points of the cylinder
by pumping cylinder oil to each individual
lubricating point.
Clean any blocked lubricating duct.

GN903-1.1 203 03
4.
GM903-1.1 253 04
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking
7. 7. Piston cleaning (PC) ring:
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 liner,

the PC ring must also be inspected.
When the piston is removed, the PC-ring

must always be taken up before the piston.
GW903-1.1 247 07
8. 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
8. PC ring diameter wear.
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.
Compare the PC ring diameter wear with

the wear of the liner. If wear of the two com-
DM903-1.1 237 08
ponents 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 a
dummy ring according to the table in D03-
18 on the Data sheet.
If it is needed 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 or-
dered.
MAN B&W Diesel A/S
Dismantling
Dismantling
903-1.2
1. Dismount the cylinder cover. 1.

Discard the sealing ring from the top of the

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

possible to remove the wear ridges at the
top of the liner.
Dismount the piston and the PC-ring.
Mount the two lifting screws in the cylinder

liner.
Note! GN903-1.2 224 01
Tighten the lifting screws to the torque

stated in Data.
Check with a 0.05 mm feeler gauge that 2.

there is no clearance between the screws
and the cylinder liner.
This must be done whenever the lifting

tools are mounted on the liner.
2. Disconnect – at the exhaust side of the cyl-

inder – the oil pipes leading from the cylin-
der lubricator to the non-return valves.
Dismount the four cooling water pipes – be-

tween the cooling jacket and cylinder cover
GN903-1.2 224 02
– and clean them carefully.
MAN B&W Diesel A/S
Dismantling
3. 3. Remove the screws of the cooling water in-

let pipe.
4. Attach the crane hook to the lifting cross-

bar.
Hook the chains from the lifting tools on to

the crossbar and lift the cylinder liner with
the cooling jacket out of the cylinder frame.
Note!
Low lifting height in the engine room may

EN903-1.4 205 03
require the removal of one or more cylin-

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

D03-05 stance, a couple of planks.
Clean the cylinder frame internally, taking

special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Discard the O-rings on the cooling water

pipes.
Clean the pipes carefully.

GN903-1.2 224 04
MAN B&W Diesel A/S
Dismantling
5. The lifting screws are also used for trans- 5.

porting the cylinder liner.
D03-05
HN903-1.2 244 05
MAN B&W Diesel A/S
Overhaul
Overhaul
903-1.3
1. 1. Unscrew the nuts on the non-return valves

and remove the valves.
Clean and inspect the non-return valves.
2. Attach two tackles to the crossbar, as

shown.
Mount two lifting eye bolts in the cooling

jacket.
Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
GN903-1.3 224 01
Remove the two lifting screws from the cyl-

inder liner.
Remove the four clamps which fix the cool-

2. ing jacket to the cylinder liner.
3. Lift the cooling jacket away by means of the

tackles, and land it on the wooden planks.
EN903-1.3 237 02
3.
D03-06
EN903-1.3 237 03
MAN B&W Diesel A/S
Overhaul
4. Check and assess the condition of the cyl- 4.

inder liner according to the description giv-
en in Volume I, Chapter 707.
Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
Check in the top of the liner for a wear ridge

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

ing machine to create the groove. For use
of the milling machine, see supplier’s in-
struction.
6. Alternatively, place an old piston ring on the

HN903-1.3 221 04
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.
5.
Check the distance C before grinding to as-
certain that the wear ridge was caused by
the top ring at TDC.
MB903-1.3 231 04
The maximum depth of the groove is calcu-

lated as S max. = D x 0.0045.
Note!
6.
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.
D
R=4-5 mm
C
C
MN903-1.3 229 05
MAN B&W Diesel A/S
Overhaul
7. 7. Replace the two uppermost O-rings on the

cylinder liner.
8. Lower the cooling jacket on to the cylinder

liner.
Note!
Make sure that the scratch marks in the

fuel pump side of the cylinder liner and
cooling jacket coincide.
GN903-1.3 203 04
9. Mount the four clamps in the groove of the

liner, and tighten the screws.
Remove the tackles from the lifting cross-

bar and the cooling jacket lifting eye bolts.
8.
10. Mount the non-return valves for cylinder lu-
brication. Tighten the nuts and connect the
lubricating oil pipes.
D03-06
EN903-1.3 237 08
9.
EN903-1.3 237 09
MAN B&W Diesel A/S
Mounting
Mounting
903-1.4
1. Loosen the water connections on the cool- 1.

ing jacket.
Mount the two lifting screws in the cylinder

liner. See Data D03-01.
Hook the chains from the lifting crossbar on

to the lifting screws, and lift the jacket/liner
assembly.
Mount the lowermost O-ring and apply a lit-

tle lubricating oil on the ring.
D03-01
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.
Coat the joint surfaces with permatex or a

similar liquid sealing compound.
Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connec-
DM903-1.4 237 01
tions on the cooling jacket.
2.
GN903-1.4 224 02
MAN B&W Diesel A/S
Mounting
3. 3. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount and
tighten the screws.
4. Connect and tighten the oil pipes for the

cylinder lubrication.
Vent the cylinder lubricating system until

oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.
When this is in order, check that each indi-

EN903-1.4 205 03
vidual lubricating point functions correctly.
5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil and
mount the piston and the PC ring.
4. See Procedure 902-1.4.
6. Mount the sealing ring and the cylinder cov-

er.
Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.
GM903-1.4 253 04
6.
GN901-1.4 203 01
MAN B&W Diesel A/S
Cylinder Lubricator 103-2
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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
103-2 Cylinder Lubricator
Data MAN B&W Diesel
P90364 Test Equipment for Lubricator
Page 2 (2) When referring to this page, please quote D10302 Edition 0031
Cylinder Lubricators 903-2.1
MAN B&W Diesel Checking
Check of Oil Injection: 1.
With stopped engine and normally when the

system has been disassembled:
1. Activate the prelub.-function on the MOP

control panel, and check that the lubrica-
tors concerned are operating correctly by
watching through the covers for scavenge
port inspection.
Turn the piston concerned to BDC and

check inside the liner with a mirror and a
M903020242C02
powerful light source that all lubrication
points are working properly.
For use of the MOP Panel, see Volume I

Chapter 703.
With running engine:
2. The system is automatically checked.
The Engine Control System will generate an

alarm if faults occur.
Additionally, it is possible to check the

pressure shocks from the injection of the
lubricators on each lubricator pipe by feel-
ing with a hand.
If in doubt, disconnect the pipe at the cyl-

inder liner to observe the oil flow.
903-2.2 Cylinder Lubricators
Dismantling of lubricators:
1.
The engine must be stopped and blocked be-
fore dismounting a lubricator. Stop the cylinder
oil pump station.
Disconnect the electrical plug on the side of

00:00
the lubricator.
ON
OFF
Bourdon Sedeme
CC 1. Mount a pressure gauge at “minimess”

point 565.
565 Check the pressure.
560 Close valve 560. Check that the cylinder lu-

M903020253D01
bricator is pressure free. If pressure is still

present, activate the “prelub” function on
the MOP panel to remove the pressure.
Close the supply valve for cylinder lubricat-

2. ing oil.
Remove the electrical plug for the lubrica-

tor.
2. Unscrew the top cover screws and discon-

nect the cover with pertaining pipes.
Check that the cylinder supply is closed.

Disconnect the cylinder oil supply pipe.
Disconnect the drain pipe.
3. Unscrew the four screws on the side that

M903020253D02
secure the lubricator to the hydraulic cylin-

der unit.
Pull the pipe flange aftwards and pull the

lubricator out and clear of the guide pins.
3.
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
• Dismount the lubricator as described in

M903020253D03
steps 1-3
• Mount a spare lubricator as described

in Procedure 903-2.4.
1. Place the lubricator in a bench vice with 1.

soft “jaws”.
Remove the adjusting screw with bushings.
Discard the O-ring from the adjusting screw.
2. Push down the cylinder block and remove

the four screws from the cylinder block.
3. Pull up the cylinder block.
Remove the springs and actuator piston
M903020246O01
with plungers.
Remove and discard the O-ring from the

cylinder block.
2.
M903020246O02
3.
M903020253O03
4. Screw out the non-return valves and re-

4. move and discard the O-rings.
Clean the valves and check them with

compressed air.
5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass.
6. Fit the non-return valve with new O-rings.
Mount the non-return valves in the cylinder

block.
M903020246O04
5.
M903020253O05
6.
M903020246O06
7. Fit the cylinder block with a new O-ring.

Pre-assemble the cylinder block with the 7.
actuator piston and plungers to ensure cor-
rect guidance of the plungers, before finally
assembling the cylinder block unit.
Mount the spring and press down the ac-

tuator piston with plungers. Mount the spe-
cial screw supplied with the test equipment
for accumulators to keep the spring com-
pressed.
8. Remove the cover from the terminal box,
M903020253O07
and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box.
Carefully unscrew the feedback sensor and

remove and discard the O-ring. 8.
Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.
M903020246O08
9.
M903020246O09
M903020242O08
13. Mount the solenoid valve fitted with new

O-rings. Coat the O-rings with a little 13.
grease to keep the rings in place during
mounting.
14. Mount the cylinder block assembly in the

cylinder housing.
Check that the spring pin engages cor-

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

the housing.
M903020246O13
Remove the special screw.
15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.
16. If the lubricator is not to be mounted on 14.

the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor-
age.
Cover all surfaces with a thin layer of oil.

M903020253O14
15.
M903020246O01
1. Mount new O-rings on the lubricator and

1. on the cover with pipes.
x6
Use a little clean grease to keep the O-
rings in place during mounting.
2. Mount the lubricator and tighten the screws

on the hydraulic cylinder unit.
Tighten the top cover screws in the end of

the lu-bricator to the pipe connection.
Mount the cylinder oil supply pipe.

M903020253M01
Mount the drain pipe.

Open for the cylinder lubrication oil supply.
3. Mount the electrical plug.
2. Open valve 560 for hydraulic oil supply.
Open the valve for cylinder lubricating oil

supply.
When possible, test the prelubrication of

the cylinder on the MOP panel.
M903020253M02
3.
560
M903020253M03
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
No. No.
036 Cylinder gauge, complete
MAN B&W Diesel A/S
Cylinder Liner - Extra Tool Plate
P90362-0002
Cylinder Liner - Extra Tool
0002
P90362
MAN B&W Diesel A/S
Plate Cylinder Liner - Extra Tool
P90362-0002
Item Item
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
904 - Crosshead with Connecting Rod
104-01 0048 Crosshead Bearing, Data

904-01 0239 Crosshead Bearing
104-02 0050 Crosshead, Data
904-02 0239 Crosshead
104-03 0034 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0042 Crankpin Bearing, Data
904-04 0226 Crankpin Bearing
104-05 0043 Connecting Rod, Data
904-05 0231 Connection Rod
90451 0151 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
90462 0020 Connecting Rod - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crosshead Bearing 104-1
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10401
104-1 Data 0048 Crosshead Bearing
X Stopped engine
X Shut off fuel oil
Data

D02-07 Piston rod/crosshead, tightening torque+angle 100/30 Nm/°
D02-20 Piston complete 921 kg
D04-01 Crosshead bearing, top clearance max. 0.55 mm
D04-02 Crosshead bearing, top clearance min. 0.15 mm
D04-03 Oil wedge length, L 10 mm
D04-04 Crosshead bearing cap 160 kg
D04-05 Crosshead bearing shell, upper 13 kg
D04-06 Crosshead bearing shell, lower 28 kg
D04-07 Crosshead bearing cap with bearing shell 173 kg
D04-21 Crosshead complete 1100 kg
D04-51 Connecting rod complete 1400 kg
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data
P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod
P90451 72 Chain for suspending piston
P90451 96 Bracket for support, crosshead
P90463 Crosshead - Hydraulic Tools
P91356 Lifting Tools, Etc.
P91359 Torque Spanners
P91366 58 Feeler gauge
MAN B&W Diesel A/S
Crosshead Bearing 904-1.1
Checking
Crosshead Bearing
S50ME-C
0239
Checking
904-1.1
2.
Tin-Aluminium bearings
The top clearance between the journal and a

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

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

the measurement in the Adjustment Sheet in
GW904-1.1 239 02
Volume I, OPERATION.
1. Open the crankcase door at the relevant

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

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

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

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

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

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

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

mantling situations:
• 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.
GW 904-1.1 239 02
2. Mount two chains in the inner screw holes

in the top of the crankcase, in the athwarth-
ship direction, for suspending the piston
rod.
2. 3. Loosen and remove the locking wire from

the screws on the piston rod foot. Remove
the screws.
HN904-1.2 222 02
3.
HN904-1.2 222 03
0$1% :'LHVHO$6
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:
HN904-1.2 222 04
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.
HN904-1.2 222 05
7.
D13-02
HN904-5.2 217 01
0$1% :'LHVHO$6
Dismantling
8. 8. Mount the lifting attachments on the head

of the connecting rod.
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 cross-

head bearing cap.
Hook the tackles on to the eye bolts, and re-

move the bearing cap from the engine.
JN904-1.2 227 08
Check the upper part of the journal.
9.
JN904-1.2 227 09
10.
D04-07
JN904-1.2 227 10
0$1% :'LHVHO$6
Dismantling
11. Place the bearing cap on one side on a 11. D04-07

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

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

on the frame box wall.
HG904-1.2 238 11
13. Turn the crosshead upwards until the piston
rod lands on the crosshead. Ensure that the
guide ring in the crosshead fits correctly in D04-05
the centre hole of the piston rod.
Do not remove the chains or lifting eye 12.

bolts.
HG904-1.2 238 12
13.
GN904-1.2 203 13
0$1% :'LHVHO$6
Dismantling
14. 14. Turn to TDC and attach the tackle hooks to

the lifting attachments. Haul the tackles
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
HG904-1.2 238 14
is evenly distributed on the four supports.
Haul the tackles tight.
16. Turn the crankthrow carefully towards BDC

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

check the lower part of the crosshead jour-
nal and the lower bearing shell.
Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chap-
ter 708, ‘Bearings’.
JN904-1.2 227 15
16.
17. D04-21
D02-20
JN904-1.2 227 16
0$1% :'LHVHO$6
Dismantling
18. In cases where it is necessary to remove 18.

the lower bearing shell, tilt the connecting
rod towards the doorway on the fuel pump
side, using the tackles.
D04-06
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.
JN904-1.2 227 18
0$1% :'LHVHO$6
Mounting
Mounting
904-1.4
1. With piston mounted/

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

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

sition.
Turn to TDC while ‘following’ with the tack-

JN904-1.4 227 01
les, for assembling the crosshead and the

connecting rod.
Take care that the guide shoes do not dam-

2. age the bearing shell.
D04-21 3. Remove the supports from the crosshead

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.
JN904-1.4 227 02
3.
JN904-1.4 227 03
0$1% :'LHVHO$6
Mounting
4. Lift the bearing cap into the engine. Lower 4. D04-07

the bearing cap onto the crosshead and re-
move the tackles. Remove the lifting attach-
ments 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
JN904-1.4 227 04
simultaneously. See Data.
For operation of hydraulic jacks, see Sec-
tion 913.
6. Mount the piston.

See Procedure 902-1.4. 5.
With piston mounted:

guide ring in the crosshead fits correctly in
D13-01
HN904-5.2 217 01
7.
GN904-1.4 203 07
0$1% :'LHVHO$6
Mounting
8. 8. Unhook the chains from the lifting eye bolts

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

piston rod, and lock with locking wire. See
Data.

GN904-1.2 203 19
the wire is tightened if a screw works loose.

9. D02-02
D02-07
HN904-1.4 222 09
0$1% :'LHVHO$6
Crosshead 104-2
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10402
104-2 Data 0050 Crosshead
X Stopped engine
Shut off fuel oil
Data
D04-04 Crosshead bearing cap 160 kg

D04-08 Cooling oil outlet pipe, tightening torque 50 Nm
D04-12 Guide strip screws, tightening torque 100 Nm
D04-13 Guide plate, tightening torque 135 Nm
D04-15 Telescopic pipe, tightening torque 50 Nm
D04-19 Telescopic pipe, tightening angle 25 °
D04-21 Crosshead complete 1100 kg
D04-22 Guide shoe 159 kg
D04-23 Cooling oil outlet pipe 9 kg
D04-50 Connecting rod, without bearing caps 1020 kg
MAN B&W Diesel A/S
104-2 Crosshead
Data

P90451 60 Lifting tools - crosshead
P90451 72 Chain for suspending piston
P90451 84 Retaining tool telescopic pipe
P90451 214 Torque wrench offset tool
P90462 11 Guide shoe extractor, complete
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
Crosshead
S50ME-C
0239
Dismantling
904-2.2
2.
1. Dismount the piston.
2. Dismount the main bearing lubricating oil

pipes.
3. Dismount 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.
GN904-2.2 203 02
In order to reach the screw in the corner be-
hind the telescopic pipe, use the offset tool
along with a socket wrench.
4. Mount the retaining tool for the telescopic

pipe on the stuffing box housing for the tel- 3.
escopic pipe.
Turn the crosshead to TDC.
Suspend the telescopic pipe by means of

the tool.
Turn the crosshead to gain access to the

nuts on the crosshead bearing studs.
Mount two eye bolts in the top of the crank-

case in the fore-and-aft direction.
GN904-2.2 204 03
Mount the spacer rings and the hydraulic

jacks for loosening the nuts on the cross-
head bearing studs.
For operation of the hydraulic tools, see 4.

Section 913.
D13-02
Loosen the nuts, remove the hydraulic jacks D04-23
and unscrew the nuts.
HN904-2.2 223 04
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling
5. 5. Mount eye bolts in the crosshead bearing

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

the engine.
6. Mount the special lifting tool on the cross-

head.
Mount the lifting attachments for fixing the

connecting rod, on the head of the connect-
ing rod.
HN904-2.2 223 05
Fasten tackles to the lifting brackets on the

frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles
tight.
6.
Attach the flat-plaited wire strap to the en-
gine room crane.
D04-21 Hook the engine room crane on to the lifting

tool on the crosshead, and lift the cross-
head.
7. Using the tackles, tilt the connecting rod to-

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

ment to another as necessary.
GN904-2.2 232 06
When the crankthrow is 90° after BDC, stop

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

necting rod until it rests against a couple of
D04-50 wooden planks in the bottom of the bed-
plate.
HN904-2.2 223 07
0$1% :'LHVHO$6
Crosshead 904-2.2
Dismantling
8. Lower the crosshead to a position just 8.

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.
9. 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 against the
GN904-2.2 232 08
middle of the crosshead. If necessary, use
the guide shoe extractor tool.
10. Pull the “free end” of the crosshead into the

neighbouring cylinder unit. 9.
Mount the guide shoe extractor on the op- D04-22

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

tor, and lift up the guide shoe.
GN904-2.2 232 09
10.
D04-22
GN904-2.2 232 10
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling
11. 11. Pull the crosshead with guide shoe into the
opposite neighbouring cylinder unit.
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.
12. Turn the crosshead 90°.
13. Mount the wire guide tool in the framebox

door opening.
GN904-2.2 232 11
Remove the crosshead from the engine, us-

ing wire rope and tackles.
Protect the crosshead, for instance with

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

the engine.
HN904-2.2 223 11
13.
HN904-2.2 223 12
0$1% :'LHVHO$6
Crosshead 904-2.4
Mounting
Mounting
904-2.4
1. Attach the flat-plaited wire strap to the en- 1.

gine room crane. D04-22 D04-21
Lift the crosshead into the engine, using
wire rope, tackles, and the engine room
crane.
2. Turn the crosshead 90°. Pull the crosshead

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

the crosshead and mount the guide shoe
HN904-2.2 223 11
extractor tool.
Use the guide shoe extractor tool to pull the

crosshead so far through the guide shoe
that the other guide shoe can be lowered.
3.
Follow the movement of the crosshead with
the engine room crane.
4. Lower the other guide shoe.
Use the guide shoe extractor tool to push

the crosshead towards the second guide
shoe.
Remove the extractor tool and adjust the

position of the opposite guide shoe.
GN904-2.4 232 03
4.
GN904-2.4 232 04
0$1% :'LHVHO$6
904-2.4 Crosshead
Mounting
5. 5. Mount the guide plates on the side of the

D04-12
D04-13 guide shoes.
Tighten the screws and lock them with lock-

ing wire.
Using the engine room crane, lift the cross-

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

ing wire.
HN904-2.4 223 05
6. Using the tackles, lift the connecting rod to

a vertical position while turning the crank-
throw to BDC.
6.
7. When the connecting rod is in a vertical po-
D04-50 sition, 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.

HN904-2.4 223 06
7.
EN904-2.4 237 07
0$1% :'LHVHO$6
Crosshead 904-2.4
Mounting
8. Lift the crosshead bearing cap into the en- 8.

gine. D04-04
9. Mount the spacer rings and the hydraulic

jacks for tightening the nuts on the cross-
head bearing studs.

Procedure 913.
Mount the drain oil slotted pipe and the

cooling oil outlet pipe on the guide shoe.
HN904-2.2 223 05
Turn the crankshaft to TDC.
Land the telescopic pipe on the guide shoe.
10. For tightening the bolt in the corner behind

the telescopic pipe, use the offset tool 9.
along with the torque wrench. D13-01 D04-15
D04-19
11. Mount the lubricating oil pipes on the main
bearing caps.
D04-08
12. Mount the piston.
HN904-2.2 223 04
10.
D04-15
D04-19
GN904-2.2 204 03
0$1% :'LHVHO$6
Reciprocating Parts 104-3
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10403
104-3 Data 0034 Reciprocating Parts
X Stopped engine
X Shut off fuel oil
X Lock turbocharger rotors
Data
Acceptance criteria with piston in centre (F-A direction)

D04-25 PF+PA, N max. 0.5 mm
D04-26 PF+PA, O max. 0.7 mm
D04-28 E+G, H+F, N max. 0.5 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.8 mm
D04-53 J, L, K, M, N max. 0.9 mm
D04-54 J, L, K, M, N min. 0.5 mm
D04-55 J, L, K, M, O max. 1.1 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
P90451 226 Alignment tool

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
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10404
104-4 Data 0042 Crankpin Bearing
X Stopped engine
Shut off fuel oil
Data
D04-43 Crankpin bearing clearance, max. 0.6 mm

D04-44 Crankpin bearing clearance, min. 0.2 mm
D04-46 Crankpin bearing, upper shell 17 kg
D04-47 Crankpin bearing, lower shell 13 kg
D04-48 Crankpin bearing cap + shell + bearing studs 150 kg
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

P90461 Connecting Rod - Hydraulic Tools
MAN B&W Diesel A/S
Crankpin Bearing 904-4.1
Checking
Crankpin Bearing
S46MC-C
0226
Checking
904-4.1
2.
The bottom clearance between the journal and
a new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.
For the bottom clearance of a specific bearing,

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

cylinder.
2. Turn the crank concerned to BDC.
GW904-1.1 239 02
3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
3.
4. The difference between the actual clear-
recorded in the Adjustment Sheet (or the
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
GM904-6.1 69 03
D04-43
An average wear rate of 0.01 mm per
10,000 hours is regarded as normal. D04-44
6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in 5.
the instruction book, Volume I, OPERA-
TION.
GN904-4.1 219 05
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling
Dismantling
904-4.2
2. 1. Turn the crank to BDC.
2. 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 crankpin

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.
GW904-2 226 02

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.
Inspect the bearing shell.

D13-02
For evaluation of bearings, see Volume I,
Chapter 708.
GN904-4.2 203 03
4.
D04-48
GW904-4.2 226 04
0$1% :'LHVHO$6
Dismantling
5. If the bearing shell needs to be replaced, 5.

remove the whole bearing cap from the
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.
Using the tackle from the frame box inside D04-48

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

couple of planks.
Inspect the bearing shell.

See Volume I, Chapter 708.
GW904-4.2 226 05
If necessary, dismount the bearing shell

lock screws and replace the bearing shell
by a new one.
6.
Note! D04-47
Normally bearing shells are replaced in
pairs.
GN904-4.2 203 06
If only one of the shells needs replace-

ment, MAN B&W Diesel should be con-
tacted for advice beforehand.
7. Turn to TDC. 7.
Mount the four supports for guide shoes on
Carefully turn the crank down until the

guide shoes rest on the supports.
Adjust the support brackets to the guide

shoes so that the weight of the crosshead
HN904-4.2 217 07
0$1% :'LHVHO$6
Dismantling
8. 8. Mount a lifting attachment for securing the

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

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

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
GW904-4.2 226 08
Continue turning the crankshaft until the

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

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

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

rod is hanging freely.
GW904-4.2 226 09
10.
GW904-4.2 226 10
0$1% :'LHVHO$6
Dismantling
11. Dismount the bearing shell lock screws and 11.

lift out the bearing shell.
D04-46
GN904-4.2 219 11
0$1% :'LHVHO$6
Mounting
Mounting
904-4.4
1. 1. Bearing shells of three mm undersize are

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.
HM904-6.0 61 16
The excess height X is to ensure the cor-

rect tightening-down of the bearing shell,
and must not be eliminated.
2.
2. Lift the upper bearing shell for the crankpin
concerned into the crankcase.
Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.
D04-46
GN904-4.4 219 02
0$1% :'LHVHO$6
Mounting
3. Hook the tackle on to a beam under the gal- 4.

lery platform and on to the lifting attach-
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 the 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.
4. Turn the crosshead to TDC.
Remove the guide shoe support brackets

from the crosshead guides.
GW904-4.4 226 04
5.
HN904-4.4 217 05
0$1% :'LHVHO$6
Mounting
6. 5. Suspend the tackles from the lifting brack-

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.
6. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.
D04-48
Caution!
During mounting, take care that the studs

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

rings and hydraulic jacks, tighten the crank-
GW904-4.4 226 06
pin bearing cap. See Data.
For operation of hydraulic jacks, see Sec-

tion 913.
7. Remove the tackles from the top of the

frame box.
Check the bearing clearance.

GW904-4.4 226 07
D13-01
0$1% :'LHVHO$6
Connecting Rod 104-5
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10405
104-5 Data 0043 Connecting Rod
X Stopped engine
Shut off fuel oil
Data

D04-01 Crosshead bearing, top clearance max. 0.55 mm
D04-02 Crosshead bearing, top clearance min. 0.15 mm
D04-07 Crosshead bearing cap with bearing shell 173 kg
D04-43 Crankpin bearing clearance, max. 0.6 mm
D04-44 Crankpin bearing clearance, min. 0.2 mm
D04-48 Crankpin bearing cap + shell + bearing studs 150 kg
D04-50 Connecting rod, without bearing caps 1020 kg
MAN B&W Diesel A/S
104-5 Connecting Rod
Data
P90461 Connecting Rod - Hydraulic Tools

P90451 96 Bracket for support, Crosshead
P90451 106 Bracket for support, Crosshead
MAN B&W Diesel A/S
Connecting Rod 904-5.2
Dismantling
Connecting Rod
S50ME-C
0231
Dismantling
904-5.2
1.
1. Turn to BDC.
Mount chains for suspending the piston.
Suspend two tackles from the top lifting

brackets. Mount the wire guide on the door
frame.
Measure the clearance in the crosshead

HN904-5.2 230 01
2. Measure the crankpin bearing clearance
fore and aft.
3. Turn the crank to TDC.

2.
Dismount the crankpin bearing cap.
Suspend the piston.

GM904-6.1 69 03
3. A B
C
D04-48
D
HN904-5.2 230 03
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling
4. D04-07 4. Turn the crank to BDC.

A B
Dismount the crosshead bearing cap and
remove the bearing cap from the engine us-
C ing tackles mounted on the gallery outside
the engine. See Procedure 904-1.2.
5. Turn to 25° after TDC and mount two lifting

attachments on the exhaust side of the con-
D
necting rod.
Attach tackles A and C to the upper lifting

attachment and tackle D to the lower lifting
HN904-5.2 230 04
attachment.
6. Mount the four supports for guide shoes on

5. A B Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
C Adjust the support brackets to the guide
D04-50 shoes so that the weight of the crosshead
D
HN904-5.2 230 05
6.
HN904-5.2 230 06
0$1% :'LHVHO$6
Dismantling
7. As soon as the connecting rod is free of the 7. A B

crosshead (approx. 50° after TDC) start E F
loosening tackles A, C and D.
C
When possible attach tackle B to upper lift-
ing attachment on the connecting rod and D04-50
remove tackle C.
If the engine is fitted with a piston cooling D

oil drain pipe on the manoeuvring side, this
has to be taken into account.
8. Mount tackles in E and F, turn slowly to-
GW904-5.2 231 07
wards TDC while loosening tackles C and
D.
As soon as possible attach tackle E to the

upper lifting attachment, move tackle C to
the lower lifting attachment and remove 8. A B
tackle D. E F
Turn a little more and shift tackle B to the C
lower lifting attachment. Attach tackle F to
the upper lifting attachment. Turn to 50° be-
fore TDC.
9. Move tackle E to the lower lifting attach-

ment. D
Tighten tackles B, E and F to lift the con-

necting rod free of the crankshaft. When
the connecting rod is free of the crankshaft,
GW904-5.2 231 08
remove tackle C and turn to TDC.
9. A B
E F
C
D04-50
GW904-5.2 231 09
0$1% :'LHVHO$6
Dismantling
10. 10. Mount a tackle fore or aft of tackle F.
Take the connecting rod out of the crank-

case by pulling it “around the corner”.
E+F F Land the connecting rod on wooden planks.
E
F
HN904-5.2 230 10
0$1% :'LHVHO$6
Mounting
Mounting
904-5.4
1. Mount tackles on the gallery lifting point 1.

and lift the connecting rod into the engine.
Mount the wire guide on the door frame.
E+F F
Caution!
D04-50
Take great care not to damage bearings
and crankpin.
E
F
2. When the connecting rod is in line with the
crankcase door opening, attach tackle B to
HN904-5.2 230 10
the lower lifting point and shift tackle E to
the upper lifting point.
Slowly turn the crankshaft towards the con-

necting rod.
A B
2.
Lubricate the crankpin and bearing liberally.
E F
Carefully move the connecting rod onto the
crankshaft. C
3. Attach tackle C to the lower lifting attach-

ment and move tackle B to the upper lifting
attachment.
D
Turn towards the exhaust side while tight-
ening tackle C, and tighten tackle B when
possible. Attach tackle D to the lower lifting
attachment.
GW904-5.4 231 02
3. A B
E F
C
D
GW904-5.4 231 03
0$1% :'LHVHO$6
Mounting
4. A B
4. Take care not to damage the piston cooling
E F oil drain pipe if fitted.
C Turn the crankshaft slowly downwards while
following with the tackles.
When the crankshaft is turned to approx.

50° after TDC, use tackle C to raise the
D connecting rod. Disconnect tackle B when
practical. Lubricate the crosshead bearing
liberally
5. Turn the crankshaft up until the crosshead

GW904-5.4 231 04
is lifted free of the crosshead support

brackets. Remove the lifting attachments
and tackles C and D.
6. Mount the crankpin bearing cap:

5. A B See Procedure 904-4.4.
D
HN904-5.4 230 05
6. A B
D
HN904-5.4 230 06
0$1% :'LHVHO$6
Mounting
7. A B
7. Turn to BDC.
E F
Lubricate the crosshead and bearing cap.
C
Mount the crosshead bearing cap.
8. Measure the crankpin bearing clearance

fore and aft.
D
guide ring in the crosshead fits correctly in
GW904-5.4 231 07 8.
D04-43
GM904-6.1 69 03
D04-44
9.
GN904-1.4 203 07
0$1% :'LHVHO$6
Mounting
10. 10. Turn down to BDC, tighten the screws in the

D02-02 piston rod, and lock with locking wire.
See Data.

the wire is tightened if a screw works loose.
D04-01
Measure the clearance in the crosshead
D04-02
HN904-5.2 230 01
11. Remove all tools from the engine.
Note!
11.
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
KN905-2.4 238 14
0$1% :'LHVHO$6
Connecting Rod and Crosshead Panel Plate
MAN B&W Diesel P90451-0151
Plate
Connecting Rod and Crosshead Panel
P90451-0151 MAN B&W Diesel

No. No.
011 Panel for tools

023 Name plate
047 Wire guide, main bearing
059 Lifting attachment, connecting rod
060 Lifting tool, crosshead
072 Chain, suspending of piston
084 Retaining tool, telescope pipe
096 Bracket, support of crosshead
106 Bracket, support of crosshead
118 Rubber cover, crosshead
120 Rubber cover with hole, crosshead
214 Offset tool, torque spanner
226 Alignment tool
Connecting Rod - Hydraulic Tools Plate
P90461-0069
Connecting Rod - Hydraulic Tools
0069
P90461
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0069
Item Item
No. No.
028 Jack-hydraulic, complete

030 Support
053 Sealing ring with back-up ring
089 Key, hexagon socket screw
090 Tommy bar
100 Stud setter
207 Hydraulic toolset, complete
MAN B&W Diesel A/S
Connecting Rod - Tools Plate
P90462-0020
Connecting Rod - Tools
0020
P90462
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0020
Item Item
No. No.
011 Guide shoe extractor, complete
MAN B&W Diesel A/S
905 - Crankshaft, Thrust Bearing and Turning Gear
105-01 0004 Crankshaft Deflection, Data

905-01 0209 Crankshaft Deflection
105-02 0044 Main Bearing, Data
905-02 0241 Main Bearing
105-03 0039 Thrust Bearing, Data
905-03 0224 Thrust Bearing
105-04 0003 Journal Bearing, Data
905-04 0212 Journal Bearing
105-05 0033 Axial Vibration Damper, Data
905-05 0224 Axial Vibration Damper
105-08 0007 Angle Encoder, Data
905-08 0204 Angle Encoder
90551 0227 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0093 Main Bearing - Hydraulic Tools
90562 0125 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90570 0004 Thrust Shaft - Tools
90572 0003 Main Bearing - Measuring Tools
90573 0002 Tuning Wheel - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Main Bearing 105-1
Data
SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0004
105-1 Main Bearing
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
105-1 Main Bearing
Data
Spare Parts
Plate – Item No. Description Qty
MAN B&W Diesel A/S
Main Bearing 905-1.1
Checking
Main Bearing
S50MC-C
0209
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. Remove the lub. oil pipe from the main

bearing cap.
Calibrate the main bearing measuring tool:
See the wooden box for the measuring tool.
9. Insert the measuring tool and check the

clearance between the upper shell and the
journal.
Note!
BG905-3.1 71 01
The bearing clearances for a new bear-

ing stated in Data (see Data 105-2) are
for guidance purposes only.
9. 10. The difference between the actual clear-

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.
BM905-2.1 239 03
10.
HN905-2.1 227 03
0$1% :'LHVHO$6
Main Bearing 105-2
Data

Special Data
S50MC-C
0044
105-2 Main Bearing
X Stopped engine
2 x 600 kg
Shut off fuel oil
x2
Data
4 x 1,5 m
Ref. Description Value Unit 1x3m
Top clearance in main
bearing
Max. ..................................... 0.65 mm
Min. ...................................... 0.35 mm
D-1 Main bearing cap 290 kg
D-2 Main bearing shells [NJ

– upper 20 kg
– lower 20 kg
D-3 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar
MAN B&W Diesel A/S
105-2 Main Bearing
Data
Plate
90551
1175465-2
Spare Parts
91210-xxxx 050 Screw 2

91210-xxxx 108 Main bearing, upper shell 1
91210-xxxx 121 Main bearing, lower shell 1
MAN B&W Diesel A/S
Dismantling
Main Bearing
S50MC-C
0241
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

2. fitted to the main, crosshead, and crank-
pin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.
5. Mount the extension studs, the spacers, the

hydraulic jacks and the nuts on the exten-
sion studs. Loosen the main bearing stud
nuts, using the hydraulic jacks.
Procedure 913-1.
6. Remove the hydraulic main bearing tools

from the engine.
GN905-2.2 204 02
Unscrew and remove the nuts from the

main bearing studs.
Remove the rectangular nut washers from

5. the bearing cap.
KN905-2.2 238 07
0$1% :'LHVHO$6
Dismantling
7. Mount the lifting tool on the main bearing 7.

cap.
Mount the pulley on the web-plate over the

main bearing, and mount the wire rope from
the lifting tool in the pulley.
Mount an eye bolt in one of the threaded

holes on the opposite web-plate.
8. Mount the wire guide as shown.
Move the lifting pipes below the platform

outside the relevant cylinder.
GN905-2.2 241 07
Mount tackles in the following positions:
A + B: Two 2-ton chain tackles, below the

platform.
C: One 1-ton chain tackle. 8.
D: One ½-ton chain tackle, in the eye bolt

on the opposite web-plate. A
B
9. Attach the wire rope from the lifting tool to C
tackle A.
Using tackle A, lift the main bearing cap

free of the studs. D
GN905-2.2 241 08
Note!
Owing to space requirements below the

9. P
web-plate, it might be necessary to dis-
mount the eye bolt from the lifting tool.
P
D
A
GN905-2.2 241 09
0$1% :'LHVHO$6
Dismantling
10.
10. Pull the bearing cap clear of the crosshead
guides by using chain tackle D.
D
11. Attach tackle C to the eye bolt in the centre
of the lifting tool.
Dismount the balancing handle from the lift-

A ing tool for main bearing cap.
Tighten tackle C, and release tackles A and

D.
When released, dismount tackle A from the

wire rope, and dismount the wire rope from
GN905-2.2 241 10
the pulley.
12. Lift out the bearing cap, using tackles B and

A.
11.
B A
D
GN905-2.2 241 11
12.
A
B
C
D
GN905-2.2 241 12
0$1% :'LHVHO$6
Dismantling
13.
13. Mount the lifting tool on the upper main
bearing shell, and lift out the shell by hand.
14. If the crankshaft is turned with the bearing

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

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

and compress the jacks.
Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure until
EN905-2.2 206 08
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.

14.
KN905-2.2 238 24
15.
KN905-2.2 238 27
0$1% :'LHVHO$6
Dismantling
16. 16. Check that there is min. 0.1 mm clearance

Min. 0,1 mm between journal and bearing shell, or be-
tween bearing shell and main bearing sup-
port, on both sides of the journal.
Note!
The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
relief in the bearing shell.
EXH CAM
If the clearance is less than 0.1 mm, move

KN905-2.2 238 28
Min. 60 mm
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).
17.
Note!
The lower shell must be lifted out to the

side with the most clearance, which is
normally the camshaft side.
17. If re-positioning of the crosspiece does not

ensure a vertical lift, place a 5-tonne jack
between the side wall and the crank throw,
to correct the journal position in this way.
If it is available, note down the pressure ap-

plied to the jack. This data is used to en-
KN905-2.2 238 25
sure that the crankshaft is in the same

position when the new bearing is installed.
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.
0$1% :'LHVHO$6
Dismantling
18. Dismount the locking screws. 18.
Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.
19. Pull the lower shell around and up until it

lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.
Note!
While pulling out the shell, it is recom-

mended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
KN905-2.2 238 26
19.
JM905-2.2 236 27
0$1% :'LHVHO$6
Dismantling
20. 20. Take the lower shell out of the engine in the
same way as the upper shell, i.e. using the
lifting tool.
EN905-2.2 206 08
0$1% :'LHVHO$6
Overhaul
Overhaul
905-2.3
1. Clean and inspect the bearing shells. It is 1 + 2.

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

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

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

and burrs. If damage is found, contact KN905-2.2 238 25
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. Mounting of bearing shells
1. Lubricate the journal and the bearing sup-

port with clean oil
Using the bearing shell lifting tool, lift the

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

shell on the main bearing support. Remove
the lifting tool from the bearing shell.
GN905-2.4 241 01
Place the lower bearing shell on the journal

and push it down by hand.
To ensure that the shell is correctly mount-

ed, check that the distance from the main
2. bearing support to the shell is equal in both
sides.
3. Mount the locking screws in the bearing

support.
Lower the crankshaft and remove the hy-

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

per and the lower bearing shells clean with
a non-fluffy piece of cloth.
MC905-3.0 118 19
3.
XZS905-13 07
0$1% :'LHVHO$6
Mounting
4. Land the upper bearing shell on the main 4.

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

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

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

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfac-
XZS905-13 09
es.
5. Mount the lifting tool on the bearing cap.
Using the tackles and pulleys, lift the cap 5.

into the crankcase in reverse order to dis-
mantling.
See Procedure 905-2.2, steps 12-9.
Note!
Be sure that the cap lands correctly and

that the spring pin in the assembly sur-
face enters the hole in the bearing cap.
KN905-2.4 238 09
0$1% :'LHVHO$6
Mounting
6. 6. Mount the rectangular nut washers and

screw the round nuts on to the main bearing
studs.
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,

see Procedure 913-1.
7.

Note!

1
0
Before removing the hydraulic jacks,

7. check the top clearance between the
upper bearing shell and the journal.
Note!

behind.
KN 905-1.1 208 09
20
8.
KN905-2.4 238 14
0$1% :'LHVHO$6
Mounting
9. Mount the lubricating oil pipe on the main 9.

bearing cap.
KN905-2.4 238 15
0$1% :'LHVHO$6
Thrust Bearing 105-3
Data

Special Data
S50MC-C
0039
105-3 Thrust Bearing
X Stopped engine
2 x 1 m, 1 x 3 m
Shut off fuel oil
M12
500 kg
Data
D05-07 Segment stopper 37 kg
D05-06 Thrust bearing segment 30 kg
Hydraulic pressure
D13-02 – dismantling 1500-1650 bar
D13-01 – tightening 1500 bar
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data
Plate
90551
1175479-6.0
Spare Parts
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

Special Data
S50MC-C
0003
105-4 Journal Bearing
X Stopped engine
x2
Shut off fuel oil
2x3m
Data
D-1 Min. bearing clearance 0.35 mm
D-2 Max. bearing clearance 0.65 mm
D-3 Main bearing cap 290 kg
D-4 Upper bearing shell 20 kg

[NJ
D-5 Lower bearing shell 20 kg


– tightening 1500 bar
MAN B&W Diesel A/S
105-4 Journal Bearing
Data
Plate
90551
1175465-2
Spare Parts
91210-xxx 108 Screw 2

91210-xxx 121 Main bearing 1
MAN B&W Diesel A/S
Journal Bearing 905-4.1
Checking
0212 Bearing
Journal S50MC-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 905-1.1.
2. Write down the journal bearing clearances.
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
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.
2. Disconnect the lubricating oil pipe from the

main pipe.
Remove the protective shield for the thrust

bearing.
Turn the crank throw for the aftmost cylin-

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

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
Unscrew and remove the nuts from the

bearing studs.
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.
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
and compress the jacks.
Connect the hydraulic jacks to the high- 6.

pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
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.
Place the dismantling tool on top of the low-

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

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

same way as the upper shell, i.e. using the
lifting tool.
KN905-2.2 238 26
9.
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.

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

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

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

and burrs. If damage is found, contact KN905-2.2 238 25
MAN B&W Diesel for advice.
• Make sure that all parts are clean, use

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

ing support and the back of the shell,
with main engine lubricating oil.
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.
Using the bearing shell lifting tool, lift the

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

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

shell and the bearing support with clean oil.
GN905-2.2 224 17
Place the lower bearing shell on the journal

and push it down by hand.
To ensure that the shell is correctly mount-

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

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

support.
Lower the crankshaft and remove the hy-

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

per and the lower bearing shells clean with
a non-fluffy piece of cloth.
3.
XZS905-13 07
MAN B&W Diesel A/S
Mounting
4. Land the upper bearing shell on the main 4.

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

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

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

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfac-
XZS905-13 09
es.
5. Mount the lifting tool on the bearing cap.

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

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

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

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

see Procedure 913-1. 7.
MN913-1 208 11
MAN B&W Diesel A/S
Mounting
8. 8.
Note!
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.

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

Special Data
S50MC-C
0033
105-5 Axial Vibration Damper
X Stopped engine
140 - 760 Nm
Shut off fuel oil 2x1m
1x3m
Data
1 x M12
D05-25 Damper housing,

upper part 280 kg
Hydraulic pressure
D13-02 – dismantling 1500-1650 bar
D13-01 – tightening 1500 bar
D05-22 Screwing-in torque –

outer studs 300 Nm
D05-19 Tightening torque –

nuts on inner studs 500 Nm
D05-18 Screwing-in torque – 150 Nm

inner studs
D05-23 Tightening torque –

horizontal screws 450 Nm 90662
or
D05-24 1. tightening torque 100 Nm
2. tightening angle 25 °
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
Data
Spare Parts
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
Angle Encoder 105-8
Data
SAFETY PRECAUTIONS
Special Edition
MC
D10508
105-8 Data 0007 Angle Encoder
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
105-8 Angle Encoder
Data
MAN B&W Diesel A/S
Angle Encoder 905-8.1
Checking
Angle Encoder
S42MC
0204
Checking
905-8.1

1. Turn the crankthrow for cylinder 1 to TDC.
Check the TDC of cylinder 1 against the

mark on the turning wheel.
2. Check that power is supplied to the inter-
HM906-7.0 56 01
mediate box.
The green indicator should now light.
For adjustment of the angle encoder, see

Procedure 905-8.3.
MN905-8.1 202 03
0$1% :'LHVHO$6
905-8.2 Angle Encoder
Dismantling
Dismantling
905-8.2
1. Remove the inspection cover.
Cut the cable tie which holds the rubber

damper around the coupling, in the end
nearest to the engine, and loosen the cou-
pling.
2. Loosen the three adjusting screws on the

front flange, and remove the angle encoder
and the coupling.
3. Screw out the flange screws and remove

the encoder housing. Take care not to dam-
age the guide pins.
XR905-8.2 204 01

XR905-8.2 204 02

XR905-8.2 204 03
0$1% :'LHVHO$6
Angle Encoder 905-8.3
Adjustment
Adjustment
905-8.3

Check the TDC position with the pin gauge
HM906-7.0 56 01
on the crankthrow, cylinder 1.
Note!
Before using the pin gauge, check the

measurement from tip to tip with the
value stamped on the pin gauge, and/or
the check-marks stamped on the fore
end of the cylinder frame.
2. Loosen the adjusting screws which fasten

the encoder to the housing. Slowly turn the
encoder until the green indicator lights on
BG906-7.0 58 02
the intermediate box.
Tighten the screws to secure the encoder in

the correct position.

MN905-8.3 202 02
0$1% :'LHVHO$6
905-8.4 Angle Encoder
Mounting
Mounting
905-8.4
1. 1. Mount the encoder housing. The two guide

pins indicate the correct positioning of the
housing. Tighten the screws.
2. Mount the angle encoder and the coupling.
Tighten the coupling, and mount new cable

ties around the rubber damper.
Adjust the angle encoder according to Pro-

cedure 905-8.3.
XR905-8.4 204 01
Note!
The adjustment will be easier if mounting

is in the same crank position as disman-
2. tling.
3. Mount the cover.

XR905-8.4 204 02
3.
XR905-8.4 204 03
0$1% :'LHVHO$6
Crankshaft, Thrust Shaft, Main Bearing, Plate
Etc. -Panel P90551-0227
Crankshaft, Thrust Shaft, Main Bearing, Etc. -Panel
0227
P90551
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing,
P90551-0227 Etc. -Panel
Item Item
No. No.
015 Panel for tools

027 Name plate
040 Pulley for wire
076 Lifting tool for main bearing cap
088 Dismantling 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
172 Mounting tool thin bearing shell
184 Lifting tool main bearing shell
MAN B&W Diesel A/S
Main Bearing - Hydraulic Tools Plate
Plate
Main Bearing - Hydraulic Tools

No. No.

045 Jack-hydraulic, support
057 Stud
069 Nut
104 Spanner
130 Ball handle
141 Lifting tool
165 Stud setter
Crankshaft - Tools Plate
P90562-0125
Crankshaft - Tools
0125
P90562
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0125
Item Item
No. No.
015 Support
039 Screw with special head
052 Nut
MAN B&W Diesel A/S
Crankshaft - Measuring Tools
Tools Plate
Plate
Crankshaft - Measuring Tools
Tools

No. No.
016 Measuring tool for axial movement
Thrust Shaft - Tools Plate
P90570-0004
Thrust Shaft - Tools
0004
P90570
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0004
Item Item
No. No.
019 Lifting tool for thrust shaft
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0003
Main Bearing - Measuring Tools
0003
P90572
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0003
Item Item
No. No.
010 Measuring tool main bearing

clearence
021 Calibration tool
045 Key, hexagon socket screws
057 Wooden box
MAN B&W Diesel A/S
Turning Wheel - Tools Plate
Plate
Turning Wheel - Tools

No. No.
027 Support
076 Spanner
090 Tommy bar
906 - Control Gear
106-01 0041 Chain, Data

906-01 0236 Chain
106-02 0054 Chain Tightener, Data
906-02 0239 Chain Tightener
106-03 0036 Camshaft, Data
906-03 0214 Camshaft
106-04 0034 Camshaft Bearings, Data
906-04 0216 Camshaft Bearings
106-05 0024 Moment Compensator, Data
906-05 0220 Moment Compensator
106-06 0007 Replacement of Cams on Camshaft, Data
906-06 0203 Replacement of Cams on Camshaft
90651 0173 Chain Drive and Camshaft - Panel
90662 0046 Camshaft - Hydraulic Tools
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
L60MC-C
D10601
106-1 Data 0041 Chain
X Stopped engine
Shut off fuel oil
Data
D06-10 Teeth on chain wheel, max. wear 3.0 mm

D06-11 Original length (chain pitch x 10 links) 889 mm
D06-12 10 links measurements + 1% of a tensioned chain = scrapping of 897.9 mm
chain
MAN B&W Diesel A/S
106-1 Chain
Data
P90651 70 Chain assembling tool

P90651 81 Chain disassembling tool
MAN B&W Diesel A/S
Chains 906-1.1
Checking
Chains
S50MC-C
0236
Checking
906-1.1
4.
Carry out the inspection as follows:
1. Make a general inspection for loose bolts

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

check jet nozzles for possible stoppages or
deformations.
3. Examine the rubber track of the guideways

for cracks or other damage.
Replace the guideway if bits have started to

be “plucked out” of the rubber track.
4. Check the teeth of the chain wheels. If 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 D06-10.
HN906-1.1 204 04
5. If abnormal wear is observed at the bottom D06-10

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.
For assessing the measurement results, 5.

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.
HN906-1.1203 05
MAN B&W Diesel A/S
906-1.1 Chains
Checking
7. 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.
D06-12
D06-11 Example:
Ma D06-
No. 1 order,
Dx0. D 12
840520 1A
6-016
840520 1B
1-58
(840520 1C, possible 3rd chain)
No. 2 order,
840520 2A
MN906-1.1 226 07
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.
7. Check chain wear by measuring the length

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

MAN B&W Diesel A/S
Chains 906-1.2
Dismantling
Dismantling
906-1.2
It may become necessary to disassemble 1.

the chain if, for instance, cracked rollers or
seizures between pin and bushing have
been discovered during the inspection.
Note!
Every time a chain link is disassembled,

a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.
GN906-1.2 203 01
When a new link is fitted in one chain, the
corresponding link in the other chain
must also be renewed.
1. Remove the tension on the chain by loos- 2.

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. If the engine is equipped with bal-
anceweights, continue the turning until the
balanceweights are hanging vertically
downwards, as shown in the sketch.
2. Mount a wire round the link rollers a short

distance from the disassembly point, and
GN906-1.2 203 02
tighten the wire lightly with a tackle.
Protect the link rollers over which the wire

is wrapped.
3.
Note!
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-
GN906-1.2 203 03
nately tightening the screws on the tool.
MAN B&W Diesel A/S
906-1.4 Chains
Mounting
Mounting
906-1.4
1. Before assembling the inner and outer

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

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

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

the compression tool and lock the pin ends
by riveting.
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).
MAN B&W Diesel A/S
Chain Tightener 106-2
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
Shut off fuel oil
Data
D06-21 Tightening angle = xx hexagons 720/12 ° / hex

D06-23 Reduced tightening angle = xx hexagons 600/10 °
D06-25 Mechanical or blocked chain tightener, clearance 0.1 mm
D06-26 Max.distance 265 mm
D06-66 D max. 165 mm
MAN B&W Diesel A/S
106-2 Chain Tightener
Data
MAN B&W Diesel A/S
Chain Tightener 906-2.3
Adjusting
Chain Tightener
S50MC-C
0239
Adjusting
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,
C and D to free the chain tightener bolt.
2. Turn the engine so that the slack part of the

chains is on the same side as the tightener
wheel.
If balanceweights are mounted, continue

the turning until they are hanging vertically
downwards.
3. With the balanceweights in this position,

tighten nut B on the chain tightener bolt un-
M90602-0239O01
til there is a clearance between the shaft
and the nut as stated in D06-25.
Then tighten nut B as stated in D06-21 (see

Data).
M90602-0239O02 2.
3.
D06-21
D06-25
M90602-0239O03
MAN B&W Diesel A/S
906-2.3 Chain Tightener
Adjusting
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.
6. Measure distance X.
M90602-0239O04
7. If the chain is worn (X > D06-66 mm), re-

peat the procedure from step 1, but tighten
nut B only to the reduced tightening angle,
see Data D06-23.
5. If distance X exceeds the max. distance

A (see Data), find and eliminate the cause of
the abnormal chain elongation, e.g. a de-
fective chain, damaged chain wheels or
bearings, etc. Repeat the procedure from
step 1.
M90602-0239O05
6. X
B
M90602-0239O06
MAN B&W Diesel A/S
Camshaft 106-3
Data
SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10603
106-3 Data 0036 Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-27 Max. permissible change in lead angle 2 °

D06-28 corresponding to 3.5 mm
D06-29 Pin gauge for top dead centre of crankthrow No.1, 697 mm
check measurement
D06-30 Pin gauge for camshaft, check measurement 340 mm
MAN B&W Diesel A/S
106-3 Camshaft
Data
P90664 Crankshaft - Pin Gauge

P90668 Camshaft - Pin Gauge
MAN B&W Diesel A/S
Camshaft 906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1
1.
Turn in the AHEAD direction to ensure that

the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
HM906-7.0 56 01
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 Edition
S50MC-C
D10604
106-4 Data 0034 Camshaft Bearings
X Stopped engine
Shut off fuel oil
Data
D06-31 Screws for bearing cap, tightening torque 125 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 13 kg
D06-65 Bearing shell, minimum thickness 7.35 mm
MAN B&W Diesel A/S
106-4 Camshaft Bearings
Data
Item
Plate Description
No.
P91351 22 Hydraulic pump, hand operated
P90651 152 Hydraulic jack for lift of camshaft
P91366 61 Slide caliper
MAN B&W Diesel A/S
Camshaft Bearing 906-4.1
Checking
Camshaft Bearing
S46MC-C
0216
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 dis-
mantled for closer investigation and, if nec-
essary, 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.
GN906-4.1 203 01
0$1% :'LHVHO$6
906-4.2 Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Warning!
Before dismantling any camshaft bear-

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

shaft housing.
GN906-4.2 203 01
Dismount the lubricating oil connecting pipe

and the plug screws from the baseplate
over the bearing in question.
Lift the roller guide of the exhaust valve hy-

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

holes in the baseplate.
Remove the screws from the bearing cap.
Mount two 10 mm eye bolts in the pertain-

ing threads on top of the bearing cap.
3. Slide the bearing cap carefully towards the

exhaust cam disc.
Turn the bearing cap and pull it out through

GN906-4.2 203 02
the inspection opening.
3.
D06-37
GN906-4.2 203 03
0$1% :'LHVHO$6
Dismantling
4. Place the hydraulic jack in the camshaft 4.

housing underneath the circular part of the
exhaust 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.
GN906-4.2 203 04
GN906-4.2 203 05 5.
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
GN906-4.3 203 01
entirely missing. Normally, camshaft bear-

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

with a micrometer to check the amount of
wear.
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.
3. Place the bearing cap on the camshaft next

to the exhaust cam.
Note!
Be careful not to scratch the exhaust cam

roller surface.
GN906-4.4 203 02
Turn the bearing cap to an upright position
and slide it carefully onto the bearing shell.
Remove the eye bolts and mount the outer- 3.

most bearing cap screw.
4. Tighten the outermost screw lightly until the

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

with a torque spanner.
GN906-4.4 203 03
4.
D06-31
GN906-4.4 203 04
D06-33
0$1% :'LHVHO$6
Mounting
5. 5. Check the clearance D06-33. Then mount

the lubricating oil pipe and the plug screw
in the baseplate.
6. Lower the camshaft into position. Remove

the hydraulic jack from the camshaft hous-
ing.
7. Clean the camshaft housing and mount the

inspection covers.
GN906-4.4 203 05
D06-33
6.
GN906-4.4 203 06
7.
GN906-4.4 203 07
0$1% :'LHVHO$6
Moment Compensator 106-5
Data
X Stopped engine
Shut off starting air distributor/distributing system supply
Shut off safety air supply – Not ME engines
Shut off control air supply
Shut off fuel oil
Data
D06-38 Nominal spring force F= 11800 N

D06-44 Spring length, new L= mm
D06-45 Spring length, nominal L= mm
MAN B&W Diesel A/S
106-5 Moment Compensator
Data
MAN B&W Diesel A/S
Moment Compensator 906-5.1
Checking
If dismantling has been necessary, the fly- (For 4cylinder engines)

weights must be assembled in the correct po-
sition in relation to the engine crankshaft. In- Viewed from Viewed from
correctly mounted flyweights can cause (heavy) AFT FORE
vibrations of the engine.
Note!
The following applies to a clockwise-ro-
tating engine
90 0°
°
Aftmost 2nd Order Moment Compensator
M906050220C01
Turn the crankthrow of cylinder No. 1 in the
AHEAD direction to the position shown in the fig-
ures for 4, 5, 6-cylinder engines, respectively. Cylinder No. 1 Cylinder No. 1
Check that the flyweights point vertically down- (For 5cylinder engines)
wards (max. deviation one-half chainwheel
tooth pitch). Viewed from Viewed from
AFT FORE
Turn the camshaft relative to the crankshaft in
accordance with the ‘valve opening diagram',
and then mount the chain.
Tighten the chain in accordance with the in-

struction. 99
See Procedure 906-2.3. ° 9°

M906050220C02
AHEAD direction to TDC and carry out fine ad-

justment of the camshaft.
Foremost 2nd Order Moment Compensator

Cylinder No. 1 Cylinder No. 1
(For 6cylinder engines)
AHEAD direction to the position shown in the fig-
ures for 4, 5, 6-cylinder engines, respectively. Viewed from Viewed from
AFT FORE
Check that the flyweights point vertically down-
wards (max. deviation one-half chainwheel
tooth pitch) and then mount the chain.
Tighten the chain in accordance with the in-

struction.
See Procedure 906-5.3. 105 15°
°
Note!
M906050220C03
For an anticlockwise-rotating engine,

the degrees mentioned in the respec-
tive figures must be before tdc, not
after tdc. Cylinder No. 1 Cylinder No. 1
MAN B&W Diesel A/S
906-5.2 Moment Compensator
Adjustment
1. When tightening the chain, bring the two

1. flyweights to a vertical downward position.
2. Release the lock washers and loosen nuts

A1, A2 and B2.
3. Tighten nut B1 until the spring is com-

pletely compressed. Then loosen nut B1
until the length of the spring matches the
number of mm indicated on the dataplate
mounted on the spring, (D06-38, D06-44,
D06-45).
M906050220O01
2. A2
B2
A1
M906050220O02
3.
M906050220O03
B1
MAN B&W Diesel A/S
Moment Compensator 906-5.2
Adjustment
4. Tighten nut A1 lightly.

4. A2
Make sure that this does not compress the
spring further.
Tighten nut A2 while holding nut A1 with a

spanner.
Lock both nuts with the lock washer.
5. Tighten nut B1 until the thrust flange of the A1

spring lies hard against the distance tube.
M906050220O04
Tighten nut B2, and lock both nuts with the
lock washer.
5.
B1
B2
M906050220O05
MAN B&W Diesel A/S
Replacement of Cams on Camshaft 106-6
Data
SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10606
106-6 Data 0007 Replacement of Cams on Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-47 Exhaust cam screws, tightening torque 560 Nm

D06-48 Indicator cam screws, tightening torque 50 Nm
D06-49 Fuel cam screws, tightening torque 880 Nm
D06-50 Fuel cam, marking scratch 65 mm
D06-51 Fuel cam, axial movement 145 mm
D06-52 Exhaust cam, marking scratch 55 mm
D06-53 Exhaust cam, axial movement 220 mm
MAN B&W Diesel A/S
106-6 Replacement of Cams on Camshaft
Data
P91351 22 Hydraulic pump, hand operated

P91359 Torque spanners
MAN B&W Diesel A/S
Replacement of Cams on Camshaft 906-6.2
Dismantling
Replacement of Cams on Camshaft
S42MC
0203
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft

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

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

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

D06-50. See Data.
XZ906-6.2 201 01
XZ906-6.2 201 02 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 908-5.
11. Extend the marking scratch on the indicator

drive cam onto the camshaft.
Extend the marking scratch on the exhaust

cam onto the camshaft by D06-52. See Da-
ta.
XZ906-6.2 201 01
XZ906-6.2 201 10 10.
11.
XZ906-6.2 201 11
D06-52
0$1% :'LHVHO$6
Dismantling
12. 12. 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 909-2) and adjust if necessary.
XZ906-6.4 201 01
Tighten the screws to D06-49 and check

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

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

shaft housing.
D06-49
XZ906-6.4 201 02
0$1% :'LHVHO$6
Mounting
Exhaust Cam 4.
4. 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 fuel cam lead (see Procedure

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

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

(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
P90651-0173
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft Panel
P90651-0173

No. No.
019 Panel for tools

020 Name plate
044 Impact spanner, fuel cam
056 Assembling tool, chain
068 Disassembling tool, chain
152 Hydraulic jack, lift of camshaft
MAN B&W Diesel A/S
Camshaft - Hydraulic Tools Plate
P90662-0046
MAN B&W Diesel A/S
Plate Camshaft - Hydraulic Tools
P90662-0046

No. No.
020 Jack - hydraulic, complete

032 Support
044 Tommy bar
093 Spanner
103 Stud setter
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
907 - Starting Air System
107-01 0017 Starting Air Distributor, Data

907-01 0216 Starting Air Distributor
107-02 0032 Start Air Valve, Data
907-02 0214 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
S46MC-C
D10701
107-1 Data 0017 Starting Air Distributor
X Stopped engine
Shut off fuel oil
Shut off lubricating oil
Data
D07-01 Gear wheel on camshaft, tightening torque 90 Nm

D07-03 Clearance between gear wheel and bushing: 0.9 - 1.6 mm
D07-04 Clearance with roller in outermost position: 1.0 - 3.0 mm
D07-05 Clearance with roller in innermost position: 1.0 - 2.0 mm
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data
MAN B&W Diesel A/S
Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
S46MCC
0216
Checking
907-1.1
1.
1. Turn the engine in AHEAD direction to bring
the piston of cylinder No. 1 to TDC.
Check with the pin gauge.
2. Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.
GN906-3.1 203 02
If pin K is not available, use the cylindrical
end of a drill of a suitable size.
3. If the check pin cannot enter the slot, i.e. if

the slot is not aligned with the hole in the
2.
distributor housing, the air distributor must
be adjusted.
S
K S
EN907-1.3 204 02
0$1% :'LHVHO$6
907-1.3 Starting Air Distributor
Adjustment
Adjustment
907-1.3
1. 1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.
Check with the pin gauge.
2. Dismount the end cover of the camshaft

housing, along with the starting air distrib-
utor, from the engine.
GN906-3.1 203 02
Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.
Turn the shaft together with the distributor

2. disc until check pin K enters slot S in the
disc and keep it there.
S 3. Check and, if necessary, adjust clearance

D07-03 between the gear wheel and the
bushing.
K S
EN907-1.3 204 02
3.
GN907-1.3 203 03
D07-03
0$1% :'LHVHO$6
Starting Air Distributor 907-1.3
Adjustment
4. Remove the lower half of the gearwheel 4.

drive cover. Mount the upper half of the
gearwheel drive cover with the complete
starting air distributor after loosening the
gear wheel on the camshaft, and then en-
gage the two gear wheels by turning the
wheel on the camshaft.
Tighten and lock the gear wheel screws on

the camshaft, see Data, D07-01.
Mount the lower half of the gearwheel drive

cover.
5. Remove check pin K from the distributor

housing and mount the gasket and plug
screw. D07-01
6. Check the clearance between the roller and GN907-1.3 203 02
the two interlocking valves with the roller in

its innermost and outermost positions, re-
spectively ( ASTERN and AHEAD).
5.
K
S
GN907-1.3 203 02
6.
D07-01
EN907-1.3 204 06
D07-04
0$1% :'LHVHO$6
Starting Air Valve 107-2
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10702
107-2 Data 0032 Starting Air Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D07-09 Piston tightening torque 180 Nm

D07-10 Valve tightening torque 175±20 Nm
D07-11 Valve tightening angle 50/30 Nm/ °
D07-12 Starting air valve 20 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 907-2.2
Dismantling
Starting Air Valve
S46MC-C
0214
Dismantling
907-2.2
1.
1. Shut off the starting air and control air inlet.
Dismount the control air pipes.
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.
GN907-2.2 203 01 2.
D07-12
GN907-2.2 203 02
0$1% :'LHVHO$6
907-2.3 Starting Air Valve
Overhaul
Overhaul
907-2.3
1. 1. Remove the top cover fixing screws and re-

move the cover.
Remove and discard the gasket.
2. Screw off the valve spindle nut and remove

the valve spindle from the valve housing.
Take out the piston, distance pipe, valve

spring, and the liner.
Remove and discard the O-ring.

EN907-2.3 0212 01
2.
EN907-2.3 0212 02
0$1% :'LHVHO$6
Overhaul
3. Grind the valve housing seating with the 3.

grinding ring after applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle and hous-

ing to match, using the face wrench to ro-
tate the valve spindle.
Carborundum No. 500.
4. Thoroughly clean all parts before reassem-

bling the valve.
Lubricate all internal parts (sliding surfac-

es) with Molybdenum Disulphide, MoS 2
grease.
5. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring and the piston. GN907-2.3 203 03
5.
EN907-2.3 0212 05
0$1% :'LHVHO$6
907-2.3 Starting Air Valve
Overhaul
6. 6. Mount the nut on the valve spindle and

D07-09 tighten the nut, see D07-09.
7. Place a new gasket on the valve housing.
Mount and tighten the top cover.
Replace the O-ring on the valve housing.
8. If the starting air valve is not to be mounted

in the engine immediately after the over-
haul, all openings of the valve should be
covered with plastic to prevent dirt from en-
tering the valve during storage.
EN907-2.3 0212 06
7.
EN907-2.3 0212 07
0$1% :'LHVHO$6
Mounting
Mounting
907-2.4
1. Carefully clean the starting valve bore in 1.

the cylinder cover and, if necessary, recon-
dition the seat for the starting valve in the
bore.
If not already done, replace the O-ring on

the overhauled valve and lubricate with
Neverseize or Molybdenum Disulphide,
MoS 2.
For overhaul, see Procedure 907-2.3.
2. Mount the valve in the cylinder cover.
GN907-2.4 203 01
3. Mount the nuts and tighten-up, according to
data D07-10 or D07-11.
Mount the control air pipes and turn on

starting air and control air. 2.
D07-12
GN907-2.4 203 02
3.
D07-10
or
D07-11
GN907-2.4 203 03
0$1% :'LHVHO$6
908 - Exhaust Valve
108-01 0017 High-Pressure Pipe, Data

908-01 0212 High-Pressure Pipe
108-02 0087 Exhaust Valve, Data
108-03 0017 Exhaust Valve Actuator, Data
908-03 0218 Exhaust Valve Actuator
108-04 0015 Exhaust Valve Roller Guide, Data
908-04 0210 Exaust Valve Roller Guide
108-05 0002 Exhaust Valve Cam, Data
908-05 0203 Exhaust Valve Cam
108-07 0020 Exhaust Valve - Special Running, Data
90851 0200 Exhaust Valve - Panel
90862 0043 Exhaust Valve - Hydraulic Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
High-Pressure Pipe 108-1
Data

Special Data
S50MC-C
0017
108-1 High-Pressure Pipe
X Stopped engine
Engage turning gear
10-120 Nm
Shut off fuel oil
Data
D-1 Weight of high-pressure pipe 34 kg
D-2 Tightening torque –

High-pressure pipe 36 Nm
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data
Spare Parts
MAN B&W Diesel A/S
High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
S50MC-C
0212
Dismantling
908-1.2
1.
1. When replacing the hydraulic high-pressure
pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing sur-
faces.
2. Before dismounting the high-pressure pipe,

stop the camshaft oil pump.
Loosen the screws for the high-pressure

pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator. D-1
3. Remove the screws in both ends of the
high-pressure pipe. Lift the high-pressure
pipe away from the engine.
GN908-1.2 203 01
2.
GN908-1.2 203 02
0$1% :'LHVHO$6
908-1.3 High-Pressure Pipe
Overhaul
Overhaul
908-1.3
1. The two ends of the pipe are identical and

should both be overhauled as follows:
1. Remove the thrust piece from the actuator/

exhaust valve.
Remove and discard the O-rings from the

thrust piece and the thrust flange.
Clean and inspect the conical seats of the

high-pressure pipe and the thrust piece.
Note!
GN908-1.3 203 01
The seats cannot be reconditioned.

If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-part

sleeve.
3. Remove the thrust flange from the pipe

end.
Remove and discard the internal O-rings.

DM908-1.1 61 02
Mount new internal O-rings lubricated with

a little camshaft lubricating oil.
4. Assemble the high-pressure pipe in the re-

3. verse order to disassembling.
DM908-1.1 61 03
0$1% :'LHVHO$6
High-Pressure Pipe 908-1.4
Mounting
Mounting
908-1.4
1. Mount new O-rings, lubricated with a little 1.

camshaft lubricating oil, on the thrust piec-
es and thrust flanges.
Mount the thrust pieces on the actuator/ex-

haust valve.
Mount the high-pressure pipe on the en-

gine.
Note!
When mounting the high-pressure pipe,

take care not to damage the conical
seats of the pipe/thrust pieces.
2. After fitting the pipe to the exhaust valve

and actuator, tighten up the screws of the
pressure flanges diagonally, see Data.
3. Check the system for tightness.

GN908-1.2 203 01
2.
D-2
GN908-1.4 203 02
0$1% :'LHVHO$6
Exhaust Valve 108-2
MAN B&W Diesel Data

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
Shut off fuel oil
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 70 Nm
D08-07 Safety valve, tightening torque 50 - 80 Nm
D08-09 Bottom piece seat, grinding angle 29.9 - 30.0 °
D08-10 Valve spindle seat, grinding angle 30.5 - 30.6 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1.0 mm
D08-13 Spindle, max. burn-off 8.0 mm
D08-14 Spindle, max. grinding 2.0 mm
D08-15 Spindle stem, measuring area, min. 235 mm
D08-16 Spindle stem, measuring area, max. 345 mm
D08-17 Spindle stem, min. diameter 59.8 mm
D08-18 Bushing max. diameter, top 60.6 mm
D08-19 Bushing max. diameter, bottom 62.0 mm
D08-20 Oil cylinder max. inside diameter 71.2 mm
D08-21 Piston rings, min. thickness 2.6 mm
D08-24 Exhaust valve, complete 460 kg
D08-25 Exhaust valve housing 260 kg
D08-26 Oil cylinder 65 kg
D08-27 Air cylinder 20 kg
D08-28 Spindle 45 kg
D08-29 Bottom piece 55 kg
D08-30 Air piston 6 kg
D13-02 Hydraulic pressure, dismantling 1400-1650 bar
108-2 Exhaust Valve
Data MAN B&W Diesel
P90851 065 Lifting tool for exhaust valve

P90851 077 Cone ring for pneumatic piston
P90851 089 Pressure tester for safety valve
P90851 090 Gauge for exhaust valve spindle
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90862 Exhaust Valve - Hydraulic Tools
Exhaust Valve 908-2.1
Checks during running:

1.
1. Check of valve spindle rotation
The engine must run when the valve func-

tion and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90° and let it rest on the air piston.
The indicator will now follow the move-

ments of the valve spindle and the air pis-
ton. During rotation of the valve spindle,
the top position of the indicator will change
M908020252C01
about 6 mm, because of the groove in the
piston.
During engine operation, the spindle must On Surface InGroove

rotate. The rotation can vary with unit and
engine load. In the event of no rotation, at-
tention should be paid to avoid seat prob- 2.
lems. When check of the valve rotation is
finished, lift the rotation indicator and lock
it in the top position.
The indicator must not be in constant op-

eration.
Exhaust valve performance condition

See volume I chapter 706 Performance
Evaluation
M908020256C02
2. Check of sealing oil unit
Check that the injection indicator moves

regularly with the valve opening. Alterna-
tively, unscrew the sealing oil pipe, and
check that oil is coming out (very small
quantity).
Depending on valve model the indicator is

placed either on the manoeuvre side or the
front side
908-2.1 Exhaust Valve
Checking MAN B&W Diesel
3. Check of bottom piece sealings

3.
With the exhaust valve mounted in the cyl-
inder cover, check the cooling water inlet
and outlet to the cylinder cover and ex-
haust valve is open.
Check the tightness of the sealing rings be-

tween the bottom piece and the exhaust
valve housing. IF water flows from the small
bore on the manoeuvring side of the ex-
haust valve, the lowermost sealing ring is
leaking.
M908020254C03
If water flows from the any of the rings, the

exhaust valve must be dismounted and the
sealing rings replaced.
Check with stopped engine:

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

haust valves.
SAFETY AIR Shut off and release the spring air on the
SUPPLY
valve, next to the engine-side manoeuvring

stand.
AIR SUPPLY
EXHAUST VALVE Check the drop down time for all spindles:
• Spindles dropping down within 30 min-

utes: Check and overhaul, See next
step “Check of Air Spring tightness”.
• Spindles dropping down between 30

M908020256C04
minutes and 1 hour: Keep under obser-

vation.
CONTROL AIR
SUPPLY • Spindles dropping down after 1 hour:
OK.
When check of drop down time is finished,

lift the rotation indicators and lock them in
the top position.
5. Check of Air spring tightness

5.
Connect compressed air to the non return
(A) valve on the air cylinder.
Disconnect and remove the drain oil pipe

from the oil cylinder (C).
Disconnect the sealing oil pipe and banjo

coupling from the air cylinder (B).
Check if air is coming out from: B A
• The sealing oil bore (B): Leakage from

spindle stem sealing , change and over-
haul.
• Hole for drain oil (C): If yes, the leakage

comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and over-
haul.
D A
• Remove the air supply to the non-return
valve on the air cylinder and check the
non-return valve for tightness.
The checks is for guidance only, minor

leaks is difficult to detect.
C
D
C
M908020256C05
1. Close off cooling water

1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections
Dismount the high-pressure pipe for the hy-

draulic valve actuation.
See Procedure 908-1.2
Dismount the return oil pipe from the ex-

haust valve.
M908020256D01
2.
M908020256D02
3. Disconnect pipe connections

3.
Disconnect the cooling water connections
from the exhaust valve and the air pipe for
the air spring.
Remove the plate jacket and insulation

from the intermediate pipe.
Loosen the screws which attach the inter-

mediate pipe to the exhaust valve housing.
Support the intermediate pipe by e.g. a

chain block and remove the screws.
M908020256D03
4. Dismantling of hydraulic nuts.
Remove the protective caps from the ex-

haust valve studs.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 913-1.
D1302
M908020256D04
5. Lift of exhaust valve

5.
D0824
Check all connections to the valve are re-
moved.
Attach the crane to the eye bolt fitted on

top of the valve and start lifting the exhaust
valve. During the lift - check the valve goes
clear of all other engine components.
Land the exhaust valve on a wooden plate

on the platform.
Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
ing and sealing surfaces of the bore, if re-
quired.
For overhaul of the exhaust valve, see Pro-

cedure 908-2.3
M908020256D06
1. Oil cylinder
1.
Place the exhaust valve on a wooden sup-
port on the platform.
D0826
Remove the nuts and the safety strap from
the oil cylinder.
Depending on valve model, remove the

sealing oil pipe.
Lift away and place the oil cylinder on a

wooden support.
2. Conical locking ring
Relieve the air pressure through the non-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.
M908020256O01
Remove the four screws from the flange on

top of the air piston and dismount the
flange.
Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring. 2.
M908020256O02
3. Spindle
3.
Use the oil cylinder as a lifting tool for the
exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
so that the load from the valve housing is
D08-24 evenly distributed.
Lift the valve housing clear of the valve

spindle. Take care – when the internal O-
ring in the air piston and the internal rings
for the sealing arrangement at the bottom
of the air cylinder pass the groove for the
conical ring at the top of the spindle.
4. Bottom piece
Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
M908020256O04
If the bottom piece has become stuck, use

a tin hammer to release it.
Lift the valve housing away and land it on a

couple of wooden planks.
4. Remove the oil cylinder.
D08-29
M908020256O05
5. Air piston and cylinder

5.
Dismount the air piston from the air cylin-
D08-30
der.
Dismount the non-return valve from the air

cylinder/valve housing. D08-27
Mount two eye bolts in the air cylinder and
dismount the air cylinder.
Remove and discard the O-ring on the air

cylinder.
M908020256O06
6. Guide bushing
Clean the exhaust valve housing.
Inspect the bushing in the spindle guide for

wear and measure the top and bottom di- 6.
ameters. See Data.
D0818
M908020255O10
D0819
7. Bushing renewal
7.
If it proves necessary to replace the bush-
ing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.
Alternatively, if the extractor tool is avail-

able, mount the extractor tool and pull up
the bushing.
The extractor tool is optional, and can be

ordered as spare part.
When a new bushing is mounted, mount a

new O-ring for sealing between bushing
and exhaust valve housing. Mount and
tighten the screws for the bushing.
8. Bottom piece inspection
Before cleaning the bottom piece, See Vol-

M908020256O08
ume I, supplement 707-03
Inspect and evaluate the seating according

to Volume I.
8.
M908020256O09
9. Bottom piece Measuring

9.
In connection with evaluation of the bottom
piece according to Volume I, wear or the
total amount the seat has been ground, is
measured as described below.
G3
Use the bottom piece template and a feeler D0812
gauge, take measurements G2 and G3. All
measurements should be taken at four dia-
metrically opposite points on the circumfer-
ence of the bottom piece seating.
For maximum wear or grinding, see Data

D08-11 and D08-12.
D0809
If the seat or the recess G3 is ground, see
Data D08 – 09 for correct grinding angle.
IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN Further
grinding or reconditioning is not recom- G2
mended.
M908020255O14
D0811
10. Bottom piece sealing face
If necessary grind the outside seating.
Use carborundum 200 and the special 10.

grinding tool. Turn the special grinding tool
by hand, turning alternately clockwise and
anticlockwise. Grind until a smooth surface
is achieved.
Clean the bottom piece.

M908020255O15
11. Bottom piece sealing rings

11.
Mount new sealing rings on the bottom
piece.
Mount one O-ring in the upper groove.
Make sure that the groove for the U-seal is

clean.
Heat the U-seal in 100°C hot water for

minimum five minutes and then mount it in
the groove immediately.
M908020256O12
12. Bottom piece mounting

exhaust valve housing.
12. Check the face on the valve housing is

clean.
If fitted, check that the guide pin in the

bottom piece enters the hole in the bottom
of the exhaust valve housing.
Land the exhaust valve housing on the bot-

tom piece. Mount and tighten the retaining
screws for the bottom piece.
M908020256O13
13. Spindle inspection

13.
Before cleaning the spindle, See Volume I,
supplement 707-03
Inspect and evaluate the spindle according

to Volume I.
14. Spindle burn-off and grinding check
In connection with evaluation of the spindle

according to Volume I, burn-off and wear or
the total amount the seat has been ground,
are measured as described below.
M908020256O14
The burn-off F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
14.
For the maximum allowable burn-off, see G1
Data D08-13.
The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge. D0814
For maximum seat grinding, see data D08 –

14. F1
If necessary to grind the seat, see Data D0810
M908020256O15
D08-10 for correct grinding angle.

A
D0813 D E
15. Spindle stem check

15.
In connection with evaluation of the spindle
according to Volume I, the spindle stem
wear is measured as described below.
D0816 D0815
Check the spindle stem for wear in the
area D08-15 to D08-16 measured from the
top of the spindle.
D0817
For minimum stem diameter, see data D08
-17.
If the exhaust valve spindle needs recondi-

tioning, contact MAN B&W Diesel for ad-
vice.
16. Spindle transport
When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
M908020252O19
16.
D0828
M908020255O16
17. Spindle bushing sealing-rings

17.
Check the top of the spindle bushing and
the face on the housing is clean.
Fit new o-rings on the spindle bushing as

shown in the sketch.
18. Spindle mounting
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
M908020256O18
exhaust valve housing.
Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
18.
Remove the oil cylinder.
M908020256O19
19. Air cylinder

19.
Clean the air cylinder.
Dismount the safety valve from the air cyl-

inder, use the machined faces to unscrew
the valve.
Unscrew and clean the Banjo coupling for

sealing oil to the spindle stem bushing.
Blow through all bores in the air cylinder.
Check the non-return valve in the Banjo
coupling with compressed air. Clean the
Compressed Air bottom of the air cylinder for possible
coke. Remount the Banjo coupling. Mount
a new O-ring in the groove on the outside
of the air cylinder.
20. Safety valve
Place the safety valve in the pressure test-

ing device. Connect the testing device with
M908020256O20
the high pressure pump by means of a

hose.
Check the opening pressure, see Data.
If the opening pressure is not correct,

20. loosen the lock nut and, using a screw-
driver, adjust the safety valve until the cor-
rect pressure is indicated. Tighten the lock
nut and test the opening pressure once
more.
D08-04 Mount a new gasket and a new O-ring on

the safety valve. Mount the safety valve in
the bore near the bottom of the air cylinder.
When mounting the safety valve in the air
cylinder, use only the machined faces on
the valve housing and tighten, see Data.
Finally, mount the protective cap.

M908020256O21
D08-07
21. Air cylinder mounting

21.
Lubricate the O-rings on the spindle bush-
ing.
Carefully land the air cylinder on the ex-

haust valve housing and check correct en-
gaging with the locating pin. Some engines
are not equipped with the locating pin
Note!
Take care not to damage the O-rings on
the outside of the spindle bushing.
M908020256O22
22. Air piston seals
Check the teflon guide ring and teflon seal-

ing ring for wear, if it is necessary to re- 22.
place the sealing rings on the air piston,
cut them and remove them.
Be careful not to damage the edges of the

ring grooves in the piston.
Note!
Before mounting, heat the new teflon
rings in 100°C hot water for at least five
minutes. When mounting the teflon rings,
M908020252O32
be careful not to damage the running

surfaces.
After mounting, compress the teflon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new O-rings in the inside grooves of

the air piston.
23. Air piston mounting

23.
Fit the conical guide ring for the air piston
on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press

the air piston down in the cylinder
Remove the conical guide ring from the air

cylinder.
Mount the non return valve for spring air
24. Locking ring
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
M908020256O24
Mount the flange on top of the air piston

and, by means of the four screws, tighten
the air piston and the flange together.
On valve models where the bolts are de-

signed for securing, secure the bolts. See
24. Procedure 913-7.
Compressed Air
M908020256O25
25. Oil cylinder

25.
Loosen the screws and remove the lifting
bracket from the oil cylinder to gain access
to the orifice plug.
Remove the sealing oil unit.
Remove and discard the gasket. Unscrew

and clean the orifice plug. Remove and dis-
card the sealing disc. Check and clean the
bore for the orifice plug in the top of the oil
cylinder.
Place the oil cylinder in a horizontal posi-

tion. Remove the flange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylin-
der diameter. If the diameter of the oil cylin- D08-20
der exceeds Data D08-20, either renew the
liner or send the complete oil cylinder to an
authorised MAN B&W workshop for over-
M908020256O26
haul, depending on the valve model.
26. Sealing oil control unit.
Normally overhaul of the sealing oil unit

should not be necessary. Check the unit
according to Procedure 908- 2.1. Before re- 26.
mounting the unit, carefully clean it on the
machined faces. If the unit needs to be
overhauled, send it to an authorised MAN
B&W repair workshop.
M908020255O37
27. Oil piston

27.
Top Remove the piston rings from the oil piston
and check them for wear. If the thickness
of the rings has worn down to the mini-
mum, see Data, discard the rings and
mount new ones. Check that the TOP mark
on the piston rings faces upwards, when
mounting
Check the mesh once more.
D0821 28. Oil cylinder assembly

M908020253O42
Mount the piston and the flange in the oil

cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright posi-

tion. Mount a new sealing disc in the bore
28. for the orifice plug. Screw the orifice plug
into the bore. Place a new gasket on top of
the oil cylinder. Mount the sealing oil unit.
Mount the lifting bracket on the oil cylinder.
Mount the screws and tighten to the torque
stated in Data.
D08-05
M908020256O31
29. Oil cylinder mounting

29.
Mount the overhauled oil cylinder on top
of the air cylinder. Mount the safety strap
and tighten the nuts. See Data. D0806
Mount the sealing oil pipe
M908020256O32
1. Checks before mounting

1.
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
D0824 the valve is checked and prepared as fol-
lows:
Connect compressed air to the air cylinder

to close the valve.
Lift up the valve with the engine room

crane.
Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3, to en-
sure that there is a clearance between the
outer parts of the seating faces of valve
housing and spindle.
Check that the valve stays closed for a

G3 minimum of 5 minutes.
M908020256M01
Carry out the drop down test as described

in procedure 908-2.1.
Check the valve is fitted with new sealing -

rings in the grooves on the bottom piece.
2. 2. Exhaust valve landing
Close the valve with compressed air.
Lubricate the sealing rings with vaseline

and the threads of the studs with anti-sei-
zure paste.
Compressed Air
Position the valve in the cylinder cover
Copper Grease
Vaseline
M908020256M02
bore, guiding it in accordance with the ex-

haust flanges and the guide pin on the ex- 3.
haust side of the exhaust valve.
3. Mounting of hydraulic nuts. D1301

Mount and tighten the hydraulic nuts, see
Data.
Mount the protective caps on the exhaust

valve studs.
M908020256M03
4. Mount the pipe connections
Connect the intermediate pipe to the ex-

haust valve.
Mount and tighten the screws to the ex-

haust valve housing. 4.
Mount the insulation and plate jacket
for the intermediate pipe.
Mount the cooling water connections for

the exhaust valve and the air pipe for the
air spring.
5. Mount the oil pipe connections
Mount the high-pressure pipe for the hy-

M908020256M04
draulic valve actuation.

Mount the return oil pipe to the exhaust
5.
M908020256M05
valve.
6.
Check that all pipe connections are prop-
erly tightened.
6. Open cooling water supply
Check that all water connections are

mounted and tightened.
Open the cooling water inlet supply, and

vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908-2.1.
7. Air spring check

M908020256M06
The air supply to the exhaust valve must al-

ways be connected and pressurized be-
fore turning on the oil supply to the ex-
haust valve actuator.
If the lubricating oil pumps have been

7. started before the exhaust valve pneumatic
springs are pressurize:
Engage the indicators on top of the ex-

haust valves and wait until the exhaust
valves are closed.
Closing of the exhaust valves are eased if

the lubrication oil pumps are stopped and
the actuators are drained at the drain
screws.
M908020256M07
Closed Valve Open Valve
Exhaust Valve Actuator 108-3
Data

Special Data
S50MC-C
0017
108-3 Exhaust Valve Actuator
X Stopped engine
X Shut off fuel oil
10-120 Nm, 140-760 NM
2 x M12
Data
D-2 Weight of hydraulic actuator 70 kg
D-3 Oil cylinder, inside diameter 71.2 mm

max.
D-4 Piston rings, min. thickness 2.6 mm
D-5 Hydraulic actuator

– tightening torque or 300 Nm
– tightening angle 25 °
D-6 Locking plate

– tightening torque 10 Nm
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data
Spare Parts
MAN B&W Diesel A/S
Exhaust Valve Actuator 908-3.1
Checking
Exhaust Valve Actuator
S50MC-C
0218
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- D-1
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.
For a normal system, the oil quantity will be

smaller than the number of litres per hour
DM908-3.0 92 02
stated in Data.
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
correct, 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.
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

from the exhaust valve.
Dismount the high-pressure pipe.

DM908-3.0 92 02
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.
D-2
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.

DM908-3.0 92 03
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.

with a clean piece of cloth. D-4
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.
D-3
DM908-3.0 92 06
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.
Mount the locking plate and tighten as stat-

ed in Data. Lubricate the piston with plenty
D-6 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.
D-2
Note!
Use only the tightening angle OR the

tightening torque, NOT both.
3. Mount the oil inlet pipe and the drain pipe

D-5 from the exhaust valve.
Mount the hydraulic high pressure pipe.

DM908-3.0 92 08
3.
DM908-3.0 92 09
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 108-4
Data

Special Data
S50MC-C
0015
108-4 Exhaust Valve Roller Guide
X Stopped engine
Shut off fuel oil
Data
D-1 Weight of roller guide,

complete 37 kg
D-2 Max. clearance

roller/bushing/shaft pin 0.5 mm
MAN B&W Diesel A/S
108-4 Exhaust Valve Roller Guide
Data
Plate
90851
1175386-1
Spare Parts
MAN B&W Diesel A/S
Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valve Roller Guide
S50MC-C
0210
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.
GN908-4.1 203 01
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 5.

possible damage marks, seizures or
scratches. Make sure that no traces of '
bearing metal exist in the roller guide hous-
ing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
3. A more suitable and reliable method is to

check the roller guide and the bearing
clearance when the roller guide is dis-
mounted.
For dismantling of the roller guide see Pro-
cedure 908-4.2.
4. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
scratches.
GN908-4.3 203 02
5. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.
6. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance D-2 directly on the dial.
0$1% :'LHVHO$6
908-4.1 Exhaust Valve Roller Guide
Checking
7. It is recommended that the roller guide

shold 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 during the checking of

the roller guide.
Note!
For disassembling of the roller guide,

contact an MAN B&W authorized repair
shop.
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 908-4.2
Dismantling
Dismantling
908-4.2
1. Dismantle the hydraulic actuator above the 1.

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.
GN908-4.2 203 01
2.
D-1
GN908-4.2 203 02
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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

D-1 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.
Clean and lubricate the sliding surfaces of

the roller and the roller guide and lower it
carefully into the roller guide bushing.
Remove the lifting tool.
2. Mount the actuator.

GN908-4.2 203 02
0$1% :'LHVHO$6
Exhaust Valve Cam 108-5
Data

Special Data
S50MC-C
0002
108-5 Exhaust Valve Cam
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
Data
Spare Parts
MAN B&W Diesel A/S
Exhaust Valve Cam 908-5.1
Checking
Exhaust Valve Cam
S50MC-C
0203
Checking
908-5.1
For checking the position of the exhaust cam,

turn the engine in AHEAD direction until the roll-
er guide (measured on the activator plunger)
has been lifted 10 mm.
If the cam has been correctly adjusted, the

crankthrow for the cylinder concerned will then
be in a position of A° past its TDC.
To check the lead angle, continue turning in

AHEAD direction until the roller guide has been
lifted 10 mm, corresponding to a turn of B° of
the crankshaft.
The lead angle is then
180° - A° + B°
2
The correct position of the cam must be within

+/-0.5°.
The illustration shows the position of the ex-

haust cam for a 6-cyl. standard engine, when
the piston of the cylinder concerned is in TDC.
See the adjustment sheet in Volume I, OPER-
ATION, Chapter 701, for the “lead angle” of the
plant in question.
The cam lead can be checked visually by read-

ing 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.
0$1% :'LHVHO$6
Exhaust Valve 108-7
Data

Special Data
S50MC-C
0020
108-7 Exhaust Valve
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
108-7 Exhaust Valve
Data
Plate
90851
1175386-1
Spare Parts
MAN B&W Diesel A/S
Exhaust Valve 908-7
Special Running
Exhaust Valve
S50MC-C
0210
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.

GN908-7 203 03
2. Dismantle the hydraulic high-pressure
pipe.See Procedure 908-1.2.
3. Dismantle the connecting sleeve and the oil

inlet pipe. Discard the sealing rings. Blank
off the connection from the main oil pipe 4.
with a plug screw.
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.
GN908-4.1 203 01
Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible.
Tighten the upper nut of the tool against the 5.

lower nut to secure the roller guide in this
position.
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.
GN908-7 203 05
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 air

cylinder and mount the tool for opening of
the exhaust valve.
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.
GN908-7 203 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 air cylinder and mount the rotation in-
dicator.
Re-connect the air supply to the air cylin-

der.
11. Mount the oil inlet pipe and the connecting

sleeve on the actuator housing, after fitting
new sealing rings on the connecting sleeve.
12. Mount the hydraulic high-pressure pipe.

13. Engage the fuel pump roller guide.

GN908-7 203 05
11.
GN908-7 203 11
0$1% :'LHVHO$6
Exhaust Valve - Panel Plate
P90851-0200
MAN B&W Diesel A/S
Plate Exhaust Valve - Panel
P90851-0200

No. No.
016 Panel for tools

028 Name plate
041 Tightening template, actuator
053 Lifting tool , roller guide
065 Lifting tool, exhaust valve
077 Conical ring, pneumatic piston
089 Pressure tester, safety valve
090 Gauge, exhaust valve spindle
124 Tool, emergency opening of exhaust
valve
150 Gauge, exhaust valve bottom piece
161 Lifting tool, exhaust valve spindle
173 Lifting tool, exhaust valve roller guide
185 Grinding ring, exhaust valve bottom
piece
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0043
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0043

No. No.

030 Support
077 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 - Extra Tools Plate
P90863-0016
Exhaust Valve - Extra Tools
0016
P90863
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0016
Item Item
No. No.
011 Grinding machine for exhaust valve

spindle seat
MAN B&W Diesel A/S
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 0205 VIT System
109-03 0044 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0050 Fuel Pump, Data
909-04 0224 Fuel Pump
109-05 0052 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0042 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0034 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0043 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0025 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10911 0047 Fuel Valve, Data
90911 0231 Fuel Valve
10912 0038 Spindle Guide, Data
90912 0222 Spindle Guide
10913 0031 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0060 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0050 Fuel Pump Roller Guide, Data
90915 0226 Fuel Pump Roller Guide
10916 0016 Fuel Pump Spec. Running
90916 0204 Fuel Pump Special Running
MAN B&W Diesel A/S

90951 0462 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
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 909-2.3
Adjustment
VIT System
0205
.0&&
Adjustment
909-2.3
1.
The engine may be equipped with either a me-
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-
ing the pmax of all the cylinders is done by ad-
justing the VIT system in the following way:
Mechanical VIT system
1. The pilot valves have been pre-adjusted to

0.5-5.5 bar control air pressure, corre-
sponding to 0.5-8.0 mm pressing-in of pin
C.
To check a pilot valve already mounted on

the engine, remove the inlet and outlet pipe
connections at A and P, and connect a
pressure gauge at A and a pipe with work-
ing air (pressure 7 bar) at P, on the pilot
HM909-1.3 67 01
valve.
Check that the pressure on the pressure

gauge and the pressing-in of pin C is in ac-
cordance with the curve.
2.
Any necessary adjustment is done by turn-
ing adjusting screw B.
2. Fine adjustment of the p max 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.
XZ909-2.1 203 02
Increase the pmax pressure by moving the

pilot valve toward the lever.
Decrease the p max pressure by moving the

pilot valve away from the lever.
See also Volume I, Chapter 703.
0$1% :'LHVHO$6
909-2.3 VIT System
Adjustment
3. Electronic VIT system
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 p offset value in accord-
ance with the required increase or de-
crease in the p max pressure. One
graduation mark on the p offset scale corre-
sponds to a change in p max 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 p control.
S9148001.WPG
7. To check the adjustment of the I/P convert-

er, operate the panel in the engine control
room to supply various signals I to the I/P
converter.
6.
For operation of the panel, see the panel
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 accord-

ance with the curve, the I/P converter must
P control be adjusted. Remove the hood of the I/P
converter and adjust the I/P converter ac-
cording to the manufacturer’s instructions.
P supply
P control
5
4
3
2
1.5
1
0.5
XZ909-2.3 204 06
0.1 0 I, mA
0 4 8 12 16 20
0$1% :'LHVHO$6
Fuel Pump Cam 109-3
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10903
109-3 Data 0044 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
P90666- Camshaft Coupling - Hydraulic Tools
P91351 10 Hydralic pump, pneumatic operated
P91351 34 Hose with unions (1000mm), complete
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
0$1% :'LHVHO$6
Fuel Pump Cam 909-3.3
Adjustment
4. Mount the special spanner on the fuel cam 4.

disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least five

minutes before turning the cam.
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
D10904 Data 0050
109-4 Edition S50MC-C
Fuel Pump
X Stopped engine
X Shut off fuel oil
Data
D09-18 Pump housing nuts, tightening torque 300 Nm

D09-19 Pump housing nuts, tightening angle 62 °
D09-20 Pump housing 96 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
K90MC-C
0224
Dismantling
909-4.2
1.
1. Close the fuel oil inlet valve.
Open the drain cock, enabling the oil to es-

cape.
Note!

2. Dismantle the fuel pump top cover and con-
MA909-1.1 223 03
nected pipes.
3. Dismantle the barrel/plunger assembly.

4.
4. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel in-
D09-39
let valve.
Remove the fuel oil inlet pipe.
Remove the shock absorber.
Remove the fuel oil outlet pipe.
Discard the gaskets.
5. Remove the drain pipes from the fuel pump

housing.
MA909-4.2 214 04
Remove the control air pipes from the actu-

ator for the VIT index arm.
MAN B&W Diesel A/S
909-4.2 Fuel Pump
Dismantling
6. 6. Loosen the four nuts by means of a slug-

ging spanner. Remove the nuts.
7. Fit the lifting tool using the top cover studs/

nuts, and lift the pump housing away.
Take care not to damage the threads of the

studs.
Land the fuel pump on wooden planks.

MA909-4.2 214 06
7.
D09-20
MA909-4.2 214 07
MAN B&W Diesel A/S
Fuel Pump 909-4.3
Overhaul
Overhaul
909-4.3
1. If the fuel index arm or the VIT index arm 3.

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.
MA909-4.3 214 03
3. Dismantle the actuator and actuator brack-

et.
4. Tilt the fuel pump housing into a horizontal 4.

position on the wooden planks. D09-20
5. Dismantle the screws and the bottom plate
from the fuel pump housing.
If the bottom plate is stuck, loosen it by

screwing two M10x80 mm screws into the
holes of the bottom plate.
MA909-4.3 214 04
5.
D09-21
MA909-4.3 214 05
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
6. 6. Dismantle the:
• Fuel index arm
• Regulating guide
• Sleeve
7. Dismantle the:
• Guide screw
• VIT index arm

MA909-4.3 214 06
• Timing guide
8. Remove the caps from the back of the fuel

pump housing.
7.
Remove the orifice plug from the front side
of the fuel pump housing.
Discard all sealing rings and gaskets.

MA909-4.3 214 07
8.
MA909-4.3 214 08
MAN B&W Diesel A/S
Fuel Pump 909-4.3
Overhaul
9. Dismantle and inspect the plug screws in 9.

both sides of the fuel pump housing.
If eroded, replace the plug screws.
10. Clean all the dismantled parts of the fuel

pump thoroughly in diesel oil or kerosene.
Dry all parts carefully.
Clean all inside surfaces of the fuel pump

housing.
Check that all the bores of the fuel pump

housing are clean.
11. Mount new sealing rings and gaskets.
MA909-4.3 214 09
Mount the caps and the orifice plug.
Mount new sealing rings on the plug screws

and mount the plug screws.
11.
Note!
Lubricate the threads of all the parts with

Molybdenum Disulphide (MoS 2) before
mounting.
12. Mount new sealing rings in the sleeves that

are provided with a pointer scratch.
MA909-4.3 214 11
Note!
Soak the sealing rings in lubricating oil

before mounting.
12.
HC909-3.4 121 11
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
14. Mounting
13. Lubricate the following with molybdenum di-

sulphide (MoS 2):
• all internal surfaces of the fuel pump

housing
• the sliding surfaces of all parts of the

regulating and timing systems.
• the teeth of the:

regulating guide
MA909-4.3 214 14
timing guide
VIT index arm
15. fuel index arm.
14. Mount the VIT index arm and the guide

screw.
Adjust the position of the VIT index arm so

that the scratch mark is aligned with the
centre of the fuel pump housing.
15. Mount the timing guide in the fuel pump

housing.
The timing guide must be mounted in such

a way that the scratch marks on the timing
MA909-4.3 214 15
guide, on the VIT index arm and on the fuel

pump housing are aligned.
16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
16.
sleeve is aligned with the pin hole in the
fuel pump housing.
MA909-4.3 214 16
MAN B&W Diesel A/S
Fuel Pump 909-4.3
Overhaul
17. Mount the fuel index arm. 17.
Adjust the position of the fuel index arm so

that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.
18. Mount the regulating guide in the fuel pump

housing.
The regulating guide must be mounted so

that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.
19. Mount the bottom plate on the fuel pump

housing.
20. Return the fuel pump to a vertical position. MA909-4.3 214 17
Mount the actuator and actuator bracket on

the side of the fuel pump.
18.
MA909-4.3 214 18
19.
MA909-4.3 214 05
MAN B&W Diesel A/S
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
D09-20 are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum di-
sulphide (MoS 2).
2. Mount the lifting tool on the fuel pump top

cover studs. Lift the fuel pump housing on
to the pump base, taking care not to dam-
age the threads of the studs.
Remove the lifting tool.
3. Mount the nuts on the studs and tighten to

the specified torque or angle, see Data.
Note!
Use either the tightening torque or the

tightening angle.
MA909.4.2 214 07
3.
D09-18
or
D09-19
MA909-4.2 214 06
MAN B&W Diesel A/S
Fuel Pump 909-4.4
Mounting
4. Mount the drain oil pipes on the fuel pump 5.

housing.
Connect the control air pipes to the actuator

for the VIT index arm. D09-39
5. Fit new gaskets on the fuel pump inlet pipe.

Mount the pipe between the fuel pump
housing and the fuel oil inlet and outlet
valve.
Mount the shock absorber.
6. Mount the barrel assembly in the fuel pump

housing. See Procedure 909-6.4.
MA909-4.2 214 04
7. Mount the top cover on the fuel pump hous-
ing. See Procedure 909-5.4.
Mount the air pipe for the puncture valve.
8. Close the drain cock and open the fuel oil 8.

inlet valve.
MA909-1.1 223 09
MAN B&W Diesel A/S
Fuel Pump Top Cover 109-5
Data
SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10905
109-5 Data 0052 Fuel Pump Top Cover
X Stopped engine
X Shut off fuel oil
Data
D09-23 Top cover studs, screwing-in torque 100 Nm

D09-24 Top cover nuts, tightening torque 210 Nm
D09-26 Outlet seat, max. grinding diameter 18 mm
D09-27 Top cover 34.1 kg
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data
P90951 69 Lifting tool for fuel pump

P90951 82 Lifting tool for fuel pump roller guide
P90951 94 Milling tool for fuel oil pipe seats
P90951 320 Plunger locking tool
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
0$1% :'LHVHO$6
Fuel Pump Barrel Assembly 109-6
Data
SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10906
109-6 Data 0042 Fuel Pump Barrel Assembly
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-29 Barrel assembly 27.5 kg

D09-30 Plunger 6.2 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
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
Fuel Pump Suction Valve 109-7
Data
SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10907
109-7 Data 0034 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 2 kg
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data
P90951 128 Crowfoot wrench head

P90967 0001 Fuel puncture valve – tools
P90962 0062 Mounting Tools for Fuel Pump Seals
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
0$1% :'LHVHO$6
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
S50MC-C
D10908
109-8 Data 0043 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
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
plastic to prevent dirt from entering the
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
0$1% :'LHVHO$6
Fuel Pump Shock Absorber 109-9
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10909
109-9 Data 0025 Fuel Pump Shock Absorber
X Stopped engine
X Shut off fuel oil
Data
D09-39 Shock absorber 20 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
Fuel Valve 109-11
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10911
109-11 Data 0047 Fuel Valve
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-40 Fuel valve opening pressure 320 - 380 bar

D09-41 Fuel valve tightening torque 25 Nm
D09-42 Inlet seat, max. diameter 18 mm
D09-43 Fuel valve 7.2 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
P90961 14 Fuel valve tester, complete
P90966 Fuel valve nozzle - tools
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
Fuel Valve
S60MC-C
0231
Checking
909-11.1
1.
The fuel valves must be given the utmost atten-
tion and care, as the greater part of irregulari-
ties 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.
GN909-11.1 204 01
In order to obtain reliable results during testing
of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disassem-
bled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3. 2.
Note!
In the event that the slide-type fuel valve is

pressure tested without being cleaned
between the fuel nozzle and the cut-off slide,
the opening pressure value measured might
be considerably lower than specified.
All fuel valves must be function-tested before

being mounted in the cylinder cover.
1. Pressure testing pump
If an air supply of 10 bar is not available,

working air of seven bar can be used. 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.
HM909-6.3 70 01A
2. Spring housing
To ensure that overtightening has not taken

place, check that the locking/indicating pin
has not been bent or broken off.
In the event of overtightening, replace the

spring housing by a new one.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
3. 3. Setting-up the fuel valve
Place the fuel valve in the test rig and se-

cure it with the spring housings and nuts.
Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housings. Mount the oil pipe be-
tween the pressure testing pump and the
fuel valve.
4. Pressure testing procedure
The subsequent items must be followed in

HM909-6.3 70 01B
the sequence stated. Items 5, 7, 8 and 9

are each divided into the following four sub-
items:
A. Objective
4. B. Procedure
C. Acceptance criteria
D. Cause of fault.
Note!
If working air of 10 bar is not available,

pressures down to 7 bar are acceptable
for all the tests.
5. Flushing and jet control
A. Objective:
HM909-6.0 67 00
To remove air in the system and check the

fuel jet.
B. Procedure:
5. The control handle must be in the OPEN po-
sition.
Slowly increase the working pressure until
straight jets of oil are ejected from the noz-
zle holes (no atomization).
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Owing to the geometry of the internal part

of the nozzle – and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
NA909-11.1 215 05
during normal engine operation – the fuel

oil will not necessarily flow from all of the
nozzle holes.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
D. Cause of fault: 6.
If the jets do not fulfil the above point C, the
cause may be:
• Dirt in the nozzle holes.
• The nozzle is not mounted correctly.
6. Atomization test
Note!
MN909-11.1 222 06
Do NOT attempt to carry out an atomiza-
tion test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.
The reason is that the atomization test may

damage the valve because it makes the 7.
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
across the cut-off edge and the high con-
D-3
tact pressure between slide and fuel noz-
zle, in combination with the poor lubricity of
the test oil, increase the risk of seizures be-
tween cut-off slide and nozzle.
All of these conditions involve the risk of

seizure between the cut-off slide and the
nozzle.
7. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Increase the oil pressure until oil is admit-

ted through the nozzle holes.
Check the opening pressure on the pres-
sure gauge.
GN909-11.1 204 06
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
8. D. Cause of fault:
If the opening pressure is higher than spec-
ified in D-3, the cause may be that a wrong
type of spring is used – replace the spring
on the thrust spindle, if necessary, replace
the complete thrust spindle.
If the opening pressure is lower than spec-

ified in D-3, the cause may be that the
spring has sagged – replace the spring, or
add a special thin disc.
Note!
Special thin discs are available as

spares.
If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated from step 4.
8. Sealing test and sliding function
A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
B. Procedure:
The control handle must be in the OPEN po-
sition.
Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
GN909-11.1 204 07
Oil must not flow from the nozzle holes.
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.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
D. Cause of fault:
D.1 Sealing test

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 re-
place 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.
D.2 Sliding function

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!
There will always be an oil flow from the

GN909-11.1 204 07
leak oil outlet when the fuel valve is full of

oil.
If a quick pressure drop from 15 to 0 bar

cannot be registered:
• The valve slide is sticking; or
• the vent hole in the thrust piece is

blocked.
If so, disassemble and examine the spindle

guide, replace if necessary.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
9. 9. Pressure test, O-ring sealings
A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Build up a working pressure of about max.

10 bar until oil flows out of the leak oil out-
let.
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100

bar.
Move the control handle to the CLOSED po-

sition.
The built-up pressure of about 100 bar

should be maintained.
D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
GN909-11.1 204 08
MAN B&W Diesel A/S
Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2
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.
KB901-2.1 104 01
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-

ately, the valve should be placed immersed 2.
in diesel oil until overhauling.
HG909-11.3 201 02
3.
D-2
HG909-11.2 221 03
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
Overhaul
909-11.3
1. When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
A fore reassembly.
MN909-11.3 219 01
1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.
2. 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-

side, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the un-
ion nut with a hook spanner.
Remove the valve from the valve holder.

MN909-11.3 222 02
3.
MN909-11.3 222 03
MAN B&W Diesel A/S
Fuel Valve 909-11.3
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.
GN909-11.3 204 01
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
5. 5. Carefully clean and examine all surfaces of

the:
• Fuel valve housing

D-1 • 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 Carbo-
rundum No. 500).
This grinding must only be carried out man-

ually.
After the grinding, wash the parts in gas oil

and blow clean by means of compressed air
to remove any remains of the grinding com-
pound.
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 exceeding approx. 100 r/min). An am-
ple supply of cutting emulsion must be
used.
Note!
Take care not to exceed the maximum

diameter of the seat, see Data.
GN909-11.3 204 02
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
6. The complete spindle guide, including the 6.

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
Note!
Do not attempt to remove the fuel nozzle
NA909-11.3 215 03
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
7.
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
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

GN909-11.3 204 04
the valve holder, and turn the nozzle until

the spindle guide engages correctly with
the guide pin. Check that distance A corre-
sponds to the measurement taken before
the valve was disassembled.
8.
Note!
Make sure that the fuel nozzle and spin-

dle 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.
MN909-11.3 219 05
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
9. 9. Mount:
• the thrust foot
• the parts of the thrust spindle
• the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost

groove of the fuel valve housing.
Lubricate the thread of the valve head with

molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
10. Make sure that the guide pin between valve

housing and valve head is intact, and press
the valve head down into the valve housing.
See that the guide pin between valve hous-

ing and valve head engages correctly so as
GN909-11.3 204 06
to prevent relative turning of the parts.
10.
GN909-11.3 204 07
MAN B&W Diesel A/S
Fuel Valve 909-11.3
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 tight-
en the union nut with a hook spanner.
After overhaul, the fuel valve must be test-

ed in the test rig.
12. If the fuel valve is not to be mounted in the

engine immediately after the overhaul, cov-
er all openings of the valve with plastic to
prevent dirt from entering the valve during
storage. MN909-11.3 222 09
MAN B&W Diesel A/S
909-11.4 Fuel Valve
Mounting
Mounting
909-11.4
1. 1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover
and check the seating in the bore for marks
D-2 which, if any, must be eliminated.
(For reconditioning of the valve bores in the
cylinder cover, see Procedure 901-1.3).
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS 2).
2. Mount the valve in position in the cylinder

cover.
MA901-2.1 72 03
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
2. great care, as the spring tension in the
housing determines the correct tightening
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.
3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.
Note!
It is recommended to overhaul the fuel oil

HG909-11.4 201 04
high-pressure pipe before mounting.

As a minimum, the distance between the

fuel oil pipe ends and the thrust bushings
3.
must be checked and, if necessary,
adjusted.
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.
KB901-2.1 104 06
MAN B&W Diesel A/S
Spindle Guide 109-12
Data
SAFETY PRECAUTIONS
Special
D10912 Data 0038
109-12 Edition Spindle
S60MC-CGuide
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-12 Spindle Guide
Data
P90966- Fuel Valve Nozzle - Tools

P90968- 12 Probe light with magnifier, complete
MAN B&W Diesel A/S
Spindle Guide 909-12.3
Overhaul
Spindle Guide
S50ME-C
0222
Overhaul
909-12.3
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 8000 hours of operation.
1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.
Note!
GW909-12.3 222 02
The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.
2. Place the spindle guide in a bench vice pro- 4.

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.
3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
Note!
The pulling tool is not standard for all

engines, but may be delivered as an
optional extra.
4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.
Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
GW909-12.3 222 04
and the spindle guide and very carefully

force the fuel nozzle off the spindle guide.
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
5. 5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in kerosene or ‘Elec-

trocleaner’ and wipe dry with a clean piece
of cloth.
Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
magnification magnifying glass and an in-
spection 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 spin-
dle guide respectively in a lathe, as shown,
and polishing with a very fine conventional
polishing linen ‘grade 360’.
GW909-12.3 222 05
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 magnifying
glass.
MA909-6.2 111 05
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 7.

bore of the fuel nozzle by means of the spe-
cial brass brush. Clean the spray holes, us-
ing gas oil and the special drills supplied.
Note!
During this operation be very careful not

to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
the fuel nozzle.
Clean the fuel nozzle with kerosene and

wipe dry with a clean cloth.
Then test the spray holes with the test pin.

If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
GW909-12.3 222 07
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
Note!
It is recommended that the fuel nozzle is

changed whenever the spindle guide is
being overhauled.
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
9. 8. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybde-
num Disulphide (MoS 2), see Procedure
913-11.
9. Assemble the thrust piece, the spindle and

the spindle guide and carefully knock the
parts together using a soft hammer.
10. 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.
MN909-12.3 215 09
10.
GW909-12.3 222 10
MAN B&W Diesel A/S
Overhaul
11. Lubricate the sliding surfaces of the nozzle 11.

and the spindle with a little Molybdenum Di-
sulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Place the parts on the plane of a drilling

machine or hydraulic press and position the
mounting tool over the parts. Make sure
that all the parts are perfectly aligned.
Press the nozzle on to the spindle guide.
Note!
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
If no mounting tools are available, the noz-

zle can be mounted on the spindle guide
GW909-12.3 222 11
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 to-
gether the same way as when using the
mounting tools.
Check that the spindle inside the spindle

guide is able to move freely, by ‘shaking’
the spindle guide.
12. If the spindle guide is not to be mounted in a

fuel valve immediately after the overhaul, cov-
er all openings of the spindle guide with plas-
tic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
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
S50ME-C
D10914
109-14 Data 0060 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 100 Nm

D09-52 Fuel oil pipe 7.3 kg
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data
P90951 104 Milling tool for fuel oil pipe

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
D10915 Data 0050
109-15 Edition Fuel Pump
S50MC-C
Roller Guide
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D09-53 Nut, reversing shaft, tightening torque 80 Nm

D09-54 Clearance A 2.8 - 5.3 mm
D09-55 Clearance B 0.7 - 3.2 mm
D09-56 Clearance C, max. 0.45 mm
D09-57 Roller/bushing/shaft pin, max. clearance 0.5 mm
D09-60 Housing for sealing arrangement 70 kg
D09-61 Fuel pump roller guide 60 kg
D09-62 Pump base 31 kg
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
Data
P90851 173 Lifting tool for exhaust valve 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.
When referring to this page, please quote Procedure 909-15.1 Edition 0226 Page 1 (10)
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
Page 2 (10) When referring to this page, please quote Procedure 909-15.1 Edition 0226
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 Pump Special Running 109-16
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10916
109-16 Data 0016 Fuel Pump Special Running
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
109-16 Fuel Pump Special Running
Data
P90951 82 Lifting tool for fuel pump roller guide

P90951 212 Extraction tool for suction valve
MAN B&W Diesel A/S
S50MC-C Fuel Pump Emergency Running 909-16
Fuel Pump Emergenc y Running

S50MC-C
201
909-16
2.
Disengagement of fuel pump
Warning !
Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
1. Engine trouble might require a cylinder to

be taken out of action. The engine can con-
tinue operation with the fuel and exhaust
GN909-16 201 02
systems of a single cylinder disconnected.
See Volume I, Section 704.
To disconnect the fuel pump of a single cyl-

inder, proceed as follows:
3.
2. Remove the puncture valve from the fuel
pump.
Plug the air supply pipe to the puncture

valve.
Note !

GN909-16 201 03
3. Remove the cover on the camshaft hous-

ing. Turn the engine until the fuel pump roll-
er is at TDC.
4.
4. Mount the lifting tool on the fuel pump top
cover and secure it in position with the two
screws.
Turn the uppermost nut to screw the spindle

of the lifting tool into the fuel pump plunger.
GN909-16 201 04
When referring to this page, please quote Procedure 909-16 Edition 204 Page 1 (2)
MAN B&W Diesel A/S
909-16 Fuel Pump Emergency Running S50MC-C
5. 5. Tighten the lowermost nut on the tool to pull

the roller guide upwards as far as possible.
Tighten the middle nut of the tool against

the lowermost nut to secure the roller guide
in this position.
6. Turn the engine one full revolution and in-

spect through the opening in the camshaft
housing to make sure that the roller guide
is clear of the fuel cam.
7. If necessary, disengage the exhaust valve

GN909-16 201 05
actuator.
The engine can now operate on the remain-

ing cylinders. See Volume I, Section 704.
6.
Re-engagement of fuel pump
Warning !
Re-engagement of the fuel pump must

only take place at engine standstill.
8. Remove the cover on the camshaft hous-

ing. Turn the engine until the circular sec-
tion of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in

GN909-16 201 03
the reverse order to lifting.
10. Remove the lifting tool and re-mount the

puncture valve.
10.
GN909-16 201 10
Page 2 (2) When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
Fuel Valve and Fuel Pump Panel Plate
Plate
Fuel Valve and Fuel Pump Panel

No. No.
010 Panel for tools

021 Name plate
045 Measuring tool, fuel pump lead
057 Lifting tool for fuel pump plunger barrel
069 Lifting tool, fuel pump
070 Lifting tool, fuel pump housing
082 Lifting tool, roller guide
094 Milling tool, fuel oil pipe seats
104 Milling tool, fuel oil pipe
116 Crowfoot spanner
153 Flange, dismantling of non-return valve
165 Grinding mandrel, valve head
177 Grinding mandrel, thrust spindle
189 Grinding mandrel, holder, outside
190 Grinding mandrel, holder, inside
200 Screw, topcover
224 Tool for P. max rack
236 Pin spanner
248 Hook spanner
250 Drift, spindle guide
273 Drift, non-return valve
297 Assembling tool, fuel valve
307 Hook spanner
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 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
910 - Turbocharger System
110-01 0032 Air Cooler Element, Data

910-01 0229 Air Cooler Element
110-02 0009 Non-Return Valve in Turbocharger, Data
910-02 0205 Non Return Valve in Tubocharger
910-03 0218 Auxilary Blower
110-03 0019 Auxilary Blower, Data
110-04 0005 Butterfly Valve, Data
910-04 0208 Butterfly Valves
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0018 Water Mist Catcher, Data
910-06 0214 Water Mist Catcher
91061 0071 Turbocharger System - Tools
91064 0002 Travelling Trolley
91066 0001 Air Cooler - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Air Cooler Element 110-1
Data

Special Data
S50MC-C
0032
110-1 Air Cooler Element
X Stopped engine
Engage turning gear
2 x 2000 kg
Shut off fuel oil
Data
D-1 Air cooler element 1550 kg
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data
Spare Parts
MAN B&W Diesel A/S
Air Cooler Element 910-1.1
Checking
Air Cooler Element
S80MC
0229
Checking
910-1.1
1.
1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see instruction book Vol-
ume I, Chapter 706.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
GN910-1.1 206 01
the air side of the cooler.
A decrease in the air temperature drop

across the scavenge air cooler indicates
fouling of the water side of the cooler.
4.
3. If the measurements indicate fouling, it is
recommended to inspect the air cooler ele-
ments as follows:
4. Remove the front end cover of the air cool-

er.
5. Visually inspect the air cooler element

through the opening.
Clean the element if it is fouled.

GN910-1.1 206 04
If the element needs to be dismantled for

further inspection or replacement, see Pro-
cedure 910-1.2.
5.
GN910-1.1 206 06
MAN B&W Diesel A/S
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2
1. The cooler element normally does not need to

be dismantled for inspection purposes. It is only
in the event that the cooler element has suf-
fered damage that it has to be dismantled and
replaced.
Note!
During dismantling, take care not to dam-

age the cooler element.
1. Close the cooling water inlet and outlet

GN910-1.2 206 01
valves. Open the drain cocks in the aft end

cover to drain off the cooling water.
2. Dismount the cooling water inlet and outlet

pipes from the aft end cover.
2.
3. Release the screws and remove the frame
around the front end cover.
Remove and discard the O-ring.
Remove the sealing plate.

GN910-1.2 206 02
3.
GN910-1.2 206 03
MAN B&W Diesel A/S
Dismantling
4. Mount the first set of guide rails on the 4.

frame around the front end cover.
5. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount, but do not tighten, the lower-
most screws. Mount and tighten the upper-
most screws.
Finally, tighten the lowermost screws and

the thrust nuts on the uppermost screws si-
multaneously. This results in loosening and
lifting the cooler element.
JN910-1.2 213 04
6. Mount the lifting bracket on the aft end cov-
er.
Mount a travelling trolley on the beam

above the aft end cover. 5.
Mount a tackle between the travelling trolley

and the lifting bracket, and use the tackle to
lift the air cooler element approx. 1-2 mm.
GN910-1.2 206 05
6.
GN910-1.2 228 06
MAN B&W Diesel A/S
Dismantling
7. 7. Mount a second tackle on the lifting brack-

et, and use it to pull out the air cooler ele-
ment approx. half a metre.
8. Mount the second set of guide rails on the

frame around the air cooler element.
9. Pull out the air cooler element until the front

end cover of the air cooler element is clear
of the air cooler housing.
Mount a second travelling trolley on the

beam above the air cooler.
GN910-1.2 228 07
Mount a tackle between the second travel-

ling trolley and the lifting holes in the upper
corners of the front end cover of the air
cooler element.
8.
Using the tackles, lift the air cooler element
away and land it on a couple of wooden
planks.
Note!
Depending on the engine layout and

engine room installation, it may be nec-
essary to remove some pipes or floor
plates.
GN910-1.2 228 08
9.
D-2
GN910-1.2 228 09
MAN B&W Diesel A/S
Overhaul
Overhaul
910-1.3
Cleaning the air side: 1.
The air side of the cooler is cleaned by injecting

a chemical fluid through the spray pipe arrange-
ment fitted to the air chamber above the cooler
element.
It is recommended to use one of the following

cleaning fluids, or a similar product.
1) Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
GN910-1.3 206 01
2) Product: 80B, produced by
Vecom Int., Maassluis, Holland
Cleaning should be carried out in the following

sequence:
2.
1. Do not start cleaning until the engine has
been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.
2. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pres-
sure must be at least 0.7 bar.
3. Continue the cleaning process for at least

30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
4. After cleaning, flush the cooler with clean

water until the water appearing in the sight
glasses is clean and pure.
5. Inspect the element either by removing the

cover on top of the cooler or by dismantling
KE910-5.1 61 02
the charging air pipe.
MAN B&W Diesel A/S
Overhaul
6. Cleaning the water side
6. Close the cooling water inlet and outlet

valves. Remove the plug screws from the
front end cover and the aft end cover to
drain off the cooling water.
7. Dismount the cooling water inlet and outlet

pipes from the aft end cover.
8. Screw two eye bolts into the upper flange of

the aft end cover. Mount a lifting wire rope
between the eye bolts.
GN910-1.2 206 01
Mount a travelling trolley on the beam

above the aft end cover.
Mount a tackle between the travelling trolley

7. and the lifting wire rope. Tighten up the
tackle.
GN910-1.2 206 02
8.
GN910-1.3 206 03
MAN B&W Diesel A/S
Overhaul
9. Mount a shackle in each of the two lifting 9.

eyes on the front end cover.
Mount two tackles above the front end of

the air cooler.
Hook the tackles on to the shackles and

tighten up.
10. Remove the screws of the front end and aft

end covers.
Lower both covers and land them on a cou-

ple of wooden planks. Discard the gaskets.
GN910-1.3 206 04
11. Clean the inside of the tubes, using the
cleaning brush mounted on a drilling ma-
chine. In the event of leakages between
cooling tube and tube plate, the tubes are 10.
rolled with the tube expander.
Tools for tube cleaning and the tube ex-

pander are supplied by the air cooler man-
ufacturer.
Clean the front-end and aft-end covers in-

side with a stiff brush and then rinsed with
fresh water.
Replace the anti-corrosion blocks, if neces-

sary.
GN910-1.3 206 05
Note!
D-1 D-3
D
If damaged, the coating inside the covers

is to be repaired with the original coating
or a similar product. 11.
12. When cleaning is complete, mount the cov-

ers in the reverse order to dismantling.
GN910-1.3 206 06
MAN B&W Diesel A/S
Mounting
Mounting
910-1.4
1. 1. Lift the air cooler element and land the front

end of the element on the guide rails
mounted on the aft end of the air cooler
housing.
Remove the tackle from the front end of the

cooler.
2. Push the air cooler element inwards ap-

prox. one metre.
D-2
Remove the guide rails from the aft end of
the air cooler housing.
GN910-1.4 228 01
3. Clean the frame around the air cooler ele-

ment and the contact surface of the aft end
cover.
2. Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the aft end cover.
Push the air cooler element fully into the air

cooler housing.
GN910-1.4 228 02
3.
GN910-1.4 228 03
MAN B&W Diesel A/S
Mounting
4. Mount and tighten all the screws of the aft 4.

end cover.
Remove the tackle and the lifting bracket

from the aft end cover.
5. Remove the guide rails from the front end

cover.
6. Mount the sealing plate, a new O-ring and

the frame around the front end cover.
7. Mount the cooling water inlet and outlet
GN910-1.4 228 04
pipes on the aft end cover.
8. Close the drain cocks, and open the cooling

water inlet and outlet valves.
5.
Note!
Remember to vent trapped air from the

air cooler element.
JN910-1.4 213 04
6.
GN910-1.2 206 03
MAN B&W Diesel A/S
Non-Return Valve 110-2
Data
N
D
X Stopped engine
R
X Block the main starting valve B
X Shut off starting air distributor/distributing system supply I
E
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-2 Non-Return Valve
Data
MAN B&W Diesel A/S
Non-Return Valve 910-2.3
Overhaul
Non-Return Valv e
S50MC-C
205
Overhaul
910-2.3
1.
The non-return valves are accessed from the
scavenge air receiver.
Note!
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
GN910-2.3 205 01
Main Non-Return Valve
1. Inside the scavenge air receiver, lift up the

valve flap of the valve that is to be over- 2.
hauled.
2. Remove the screws behind the valve flap.

Remove the valve from the engine.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
GN910-2.3 205 02
4. For further dismantling, remove the two

screws which hold the clamp and the sup-
port together as an assembly.
Clean the valve shaft and the slide bearings 3.

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybde-
num disulphide (MoS 2).
5. Assemble the valve
After the overhaul, it must be possible to

move the valve flap by the light touch of a
MC910-6.0 26 02
finger.
6. Re-mount the valve in the scavenge air re-

ceiver.
4.
MC910-6.0 26 03
MAN B&W Diesel A/S
Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
0218
60&&
Overhaul
910-3.3
1.
1. When cleaning and inspecting the auxiliary
blower, disengage the cable connections to
the blower motor.
Wire ropes with shackle as well as two tack-

les suspended from mountings on the gal-
lery bracket are to be hooked onto the
blower flange, before removing the screw in
the flange.
2. The end cover complete with blower can

now be pulled free of the suction pipe by
means of the two tackles. D10-12
MC910-8.0 31 01
While pulling out the end cover with the
blower assembly, make sure that the blower
housing disengages from the air pipe with-
out deforming it.
2.
Then inspect and clean the blower wheel as
well as the blower housing.
For overhaul of blower wheel and bearings,

see blower manufacturer’s instructions.
Note!
Exercise care when mounting the elec-

tric motor with blower wheel, as the
blower wheel is to “catch” the guide in the
blower housing.
MC910-8.0 31 02
0$1% :'LHVHO$6
Auxiliary Blower 110-3
Data
SAFETY PRECAUTIONS
Special Edition
110-3
D11003 Data 0019 Auxiliary
S60MCBlower
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-12 Electric motor, impeller and motorplate 556 kg
MAN B&W Diesel A/S
110-3 Auxiliary Blower
Data
MAN B&W Diesel A/S
Butterfly Valves 110-4
Data
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-4 Butterfly Valves
Data
MAN B&W Diesel A/S
Butterfly Valves 910-4.1
Checking
1. It is important that the automatic non-re-

1.
turn valves (butterfly valves) are always
able to function easily and unimpeded.
The movability of the valve flaps should

therefore be checked at suitable intervals. Flow direction
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.
2. To check the valve, remove the cover on

the top of the butterfly valve.
M910040208C01
Reach down through the opening in the top
of the valve and move the valve flaps.
3. If the valve flaps in one of the butterfly

valves cannot be moved by a light touch of
a fingertip, it must be dismantled and over-
hauled. 2.
4. Re-mount the cover on the top of the but-

terfly valve.
M910040208C02
MAN B&W Diesel A/S
Turbocharger Turbine 110-5
Data

Special Data
0005
110-5
.0&& Turbocharger Turbine
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
Data
Spare Parts
MAN B&W Diesel A/S
Turbocharger Turbine 910-5.3
Cleaning
Turbocharger Turbine
0206
.0&&
Cleaning
910-5.3
The dry cleaning method employs compressed

air to blow dry, solid, granules through the tur-
bocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.
On account of their hardness, nut-shells, or

broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.
Note!
We do not recommend the use of rice or

grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.
It is not always possible to remove thick depos-

its with this dry cleaning method.
Therefore, in order to prevent the build-up of

thick deposits, the turbine must be cleaned af-
ter every 24 to 50 hours of operation.
Generally, turbocharger cleaning can be carried

out without, or with very little, reduction of the
engine load.
More detailed information regarding the amount

of granules to be used is stated on the instruc-
tion plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger

turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.
0$1% :'LHVHO$6
910-5.3 Turbocharger Turbine
Cleaning
Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours

of operation, based on observations.
2. Preferably clean the turbocharger at full

load. Do not clean below half load.
3. Close valve A.
4. Open valves B and C, to blow out any de-

posits and/or condensate in the connecting
pipe.
XX706-12 40B
After about two minutes, close valves B and

C.
5. Slowly open valve A to relieve the pressure

in the tank.
6. Fill the tank with the quantity of granules

specified in the table.
7. Close valve A.
8. Open valves B and C, to blow-in the gran-

ules. After one to two minutes, close valves
B and C.
9. Slowly open valve A to relieve the pressure

in the tank.
HM910-5.3 50 02
Caution!
1.The drain openings in the gas casings

must remain closed while dry cleaning
the turbine.
2. It is possible that during dry cleaning

of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.
0$1% :'LHVHO$6
Water Mist Catcher 110-6
Data

Special Data
S50MC-C
0018
110-6 Water Mist Catcher
X Stopped engine
Engage turning gear
Shut off fuel oil
1000 kg
Data
D-1 Water mist catcher 119 kg
MAN B&W Diesel A/S
110-6 Water Mist Catcher
Data
Spare Parts
MAN B&W Diesel A/S
Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
S46MC-C
0214
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the
water mist catcher element from the scav-
enge air cooler housing. If, however, the
water mist catcher element has been fouled
or damaged, it must be dismantled for
cleaning or repair.
2. To dismantle the water mist catcher, dis-

mantle the water mist catcher cover and up-
per cover to give access to the air cooler
housing.
3. Via access through the upper part of the
EN910-6.2 214 02
scavenge air cooler housing, loosen the
four screws which press against the water
mist catcher.
4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the 3.
water mist catcher.
Attach a tackle to the eye bolt and tighten

up the tackle.
5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
EN910-6.2 214 03
4.
GN910-6.2 205 06
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4
1. 1. Lubricate the two supports on the under-

side of the water mist catcher with plenty of
grease.
Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.
Note!
Make sure to mount the water mist

catcher correctly. See the sketch.
EN910-6.4 214 01
Air flow 2. Slide the water mist catcher into the scav-
enge air cooler housing.
2. When the water mist catcher is half-way in,

remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.
3. Via access through the upper part of the

scavenge air cooler housing, tighten the
four screws which press against the water
mist catcher.
GN910-6.4 205 02
3.
EN910-6.4 214 03
0$1% :'LHVHO$6
Water Mist Catcher 910-6.4
Mounting
4. Clean the water mist catcher cover and ap- 4.

ply a thin layer of silicone paste along the
edges of the cover. Mount the cover.
Clean the upper cover and apply a thin lay-

er of silicone paste along the edges of the
cover. Mount the cover.
EN910-6.2 214 02
0$1% :'LHVHO$6
Turbocharger System - Tools
Tools Plate
Plate
Turbocharger System - Tools
Tools

No. No.
014 Pulling tool

026 Lifting eye bolt
Air Cooler - Tools Plate
P91063-0017
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0017

No. No.
015 Guide rail, air cooler fore end

027 Guide rail, air cooler fore end
MAN B&W Diesel A/S
Air Cooler - Tools Plate
P91063-0019
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0019

No. No.
015 Guide rail, rear end

027 Guide rail, rear
Page 2 (2) When referring to this page, please quote Plate Edition
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
911 - Safety Equipment
111-01 0025 Safety Valve, Data

911-01 0211 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
Dismantling
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
2.
M911010211D02
When Top-mounted 3.
3. Unscrew the safety valve from the cylinder

cover.
Remove and discard the mild steel disc.

M911010211D03
MAN B&W Diesel A/S
911-1.3 Safety Valve
Overhaul (adjustment)
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 A/S
Overhaul (adjustment)
4. To set the safety valve opening pressure:

4.
• Set up the safety valve in the testing D1101
device.
• Connect the testing device to the hy-

draulic pump.
• Loosen the lock nut on the safety valve.
• Turn the adjusting screw until the valve

just closes.
• Bleed the valve and hose until oil, with-
M911010211O04
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.
• Test the opening pressure.
• Remove the valve from the testing de-

vice.
MAN B&W Diesel A/S
911-1.4 Safety Valve
Mounting
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
MAN B&W Diesel A/S
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
Mount a new mild steel disc in the bore.
When mounting the safety valve on the cyl-

inder cover, apply tools only on the hexa-
M911010211M04
gon on the safety valve.
5.
M911010211M05
MAN B&W Diesel A/S
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 is

2.
calibrated at the factory and does not re-
quire any adjustment.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
Use a piece of cloth to wipe out any dirt

from the O-ring packing and close the
valve again. Tighten the counter nut.
M911030001C02
If this operation cannot be performed
smoothly, the safety valve must be disman-
tled and cleaned.
911-3.2 Scavenge Air Receiver Safety Valve
1. Dismount the safety valve from the scav-

1. enge air receiver.
M911030001D01
1. Remove the split pin.

1.
Unscrew the nut thereby relieving the
spring tension.
Remove the nut, spring retainer and wash-

ers.
Keep count of the washers.
Pull out the spring.
2. Pull out the valve flap with spindle. If the

O-ring seal is damaged remove it without
M911030001O01
damaging the O-ring groove.
3. Clean the metal surfaces thoroughly.
2.
M911030001O02
911-3.3 Scavenge Air Receiver Safety Valve
4. If the O-ring seal has been removed mount

4. a new one using Locktite type AVX and
Loc-tite activator type T or similar.
5. Push in the valve flap and spindle while

tak-ing care not to damage the O-ring seal.
6. Mount the spring, spring retainer and all the

washers.
Tighten the nut until the split pin can be

mounted.
7. Check the valve according to 911-3.1.

M911030001O04
5.
M911030001O05
6.
M911030001O01
1. Mount the safety valve on the scavenge air

receiver. 1.
M911030001M01
912 - Assembly of Large Parts
112-02 0007 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)
112-03 0015 Stay Bolts, Data
912-03 0210 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0073 Hydraulic Tools for Large Parts
91265 0003 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
91268 0001 Hydraulic Tools - End Chock Bolts (Iron Chocks)
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Holding Down and End Chock Bolts 112-2
Data

.0&
Special Data
112-2
0007 Holding Down and End Chock Bolts
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D-1 Tightening pressure for

holding down bolts and
end chock bolts 1500 bar
D-2 Check holding down bolts

and end chock bolts for cor-
rect tightening after the fol-
lowing service hours:
1st check 500 hours

2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequently at
intervals of 8000 hours
Engine on Epoxy supporting chocks
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data
Spare Parts
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

Special Data
S50MC-C
0015
112-3 Stay Bolts
X Stopped engine
Engage turning gear
Shut off fuel oil 1x3m
2x1m
Data
D-1 Check measurement 148 mm

– mounting 1500 bar

MAN B&W Diesel A/S
112-3 Stay Bolts
Data
Spare Parts
MAN B&W Diesel A/S
Stay Bolts 912-3.1
Checking
Stay Bolts
K98MC
0210
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, D-1. 3.
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 '
thread in the top of the stay bolt, and turn
the stay bolt until D-1 is met.
GN912-3.0 39 09
4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.
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
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
Checking MAN B&W Diesel
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
084 Spanner
106 Stud setter
MAN B&W Diesel A/S
Hydraulic Tools - Holding Down Bolts Plate
(Epoxy Chocks) P91265-0003
Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)
0003
P91265
MAN B&W Diesel A/S
Plate Hydraulic Tools - Holding Down Bolts
P91265-0003 (Epoxy Chocks)
Item Item
No. No.

037 Support
074 Tommy bar
098 Key, hexagon socket screw
MAN B&W Diesel A/S
HydraulicTools - End Chock Bolts Plate
P91268-0001
(Iron Chocks)
MAN B&W Diesel A/S
Plate HydraulicTools - End Chock Bolts
P91268-0001
(Iron Chocks)
No. No.

033 Support
094 Tommy bar
104 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 0058 Lifting Tools, etc.
91358 0013 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0040 Spanners
91366 0066 Instruments
91368 0004 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
P91356-0058
Lifting Tools, Etc.
0058
P91356
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0058
Item Item
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
P91357-0005
Open Ended Spanners
0005
P91357
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0005
Item Item
No. No.
013 Open-ended spanner, size NV65mm

MAN B&W Diesel A/S
Open-Ended Slugging Spanners Plate
P91358-0013
Open-Ended Slugging Spanners
0013
P91358
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0013
Item Item
No. No.
127 Open-ended slugging spanner, size

NV65mm
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
P91360-0003
P91360
Pliers
0003
MAN B&W Diesel A/S
Plate Pliers
P91360-0003
Item Item
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 Spanner Plate
P91362-0064
MAN B&W Diesel A/S
Plate Ring Slugging Spanner
P91362-0064

No. No.
022 Slugging spanners, ring size

NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
NV65mm
NV70mm
NV75mm
NV80mm
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
P91368-0004
Working Platforms
0004
P91368
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0004
Item Item
No. No.
013 Foot grating, 800 x 250 x 40mm
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 (5)

No. Edition Title

90462 0020 Connecting Rod - Tools

905 - Crankshaft, Thrust Bearing and Turning Gear

906 - Control Gear

907 - Starting Air System

MAN B&W Diesel A/S Page 2 (5)

No. Edition Title

907-02 0214 Starting Air Valve

908 - Exhaust Valve

909 - Fuel Oil System

MAN B&W Diesel A/S Page 3 (5)

No. Edition Title

10914 0060 Fuel Oil High-Pressure Pipes, Data

910 - Turbocharger System

911 - Safety Equipment

912 - Assembly of Large Parts

MAN B&W Diesel A/S Page 4 (5)

No. Edition Title

112-03 0015 Stay Bolts, Data

913 - General Tools

MAN B&W Diesel A/S Page 5 (5)

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 0041 Cylinder Cover, Data

MAN B&W Diesel A/S

D01-01 Exhaust valve stud, screwing-in torque 680 Nm

Plate Item No. Description

P90151 46 Grinding tool for exhaust valve seat

1. Set blocking device A on the main starting 1.

Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the air supply for the pneumatic

2. Connect a pressure gauge at ‘minimess’ G

Check the pressure.

Close valve 420 and open valve 421 on the

3. Close valve 531 for hydraulic operation of

4. Remove the cooling water inlet and outlet

Remove the drain pipe from the intermedi-

Remove the oil supply pipe for the hydrau-

Dismount the fuel oil high-pressure pipes

Dismount the control air pipe from the

Remove the starting air pipe.

Disconnect the plug for the electrical ex-

5. Remove the exhaust valve high-pressure

Dismount the drain oil pipe from the ex-

air pipe for pneumatic closing of the ex-

6. Remove the protective jacket enclosing the

Dismount the screws in the flange between

Remove the protective caps from the cylin-

7. Place eight spacer rings, one around each

Connect the high-pressure pump to the