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
 VOLUME II
S60ME-C 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 0064 Cylinder Cover, Data
901-01 0243 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0110 Cylinder Cover - Tools
90163 0004 Cylinder Cover - Support Tool
90165 0001 Cylinder Cover - Lifting Tools

902 - Piston with Rod & Stuffing Box

102-01 0082 Piston, Data
902-01 0279 Piston
102-02 0060 Piston Rod Stuffing Box, Data
902-02 0229 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 0005 Piston - Lifting Tools

903 - Cylinder Liner and Cylinder Lubrication

103-01 0072 Cylinder Liner, Data
903-01 0257 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0251 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90366 0007 Cylinder Liner - Lifting Tools

904 - Crosshead with Connecting Rod

104-01 0059 Crosshead Bearing, Data
904-01 0249 Crosshead Bearing
104-02 0060 Crosshead, Data
904-02 0248 Crosshead
104-03 0041 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0052 Crankpin Bearing, Data
904-04 0231 Crankpin Bearing
104-05 0051 Connecting Rod, Data
904-05 0228 Connection Rod
90451 0149 Connecting Rod and Crosshead - Panel

MAN B&W Diesel A/S Page 1 (4)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

90461 0068 Connecting Rod - Hydraulic Tools

90462 0034 Connecting Rod - Tools
90464 0005 Crosshead - Hydraulic Tools
90465 0001 Crosshead - Tools

905 - Crankshaft, Thrust Bearing and Turning Gear

105-02 0073 Main Bearing, Data
905-02 0247 Main Bearing
105-03 0064 Thrust Bearing, Data
905-03 0242 Thrust Bearing
105-04 0037 Journal Bearing, Data
905-04 0227 Journal Bearing
105-05 0052 Axial Vibration Damper, Data
905-05 0231 Axial Vibration Damper
90551 0229 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0133 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90570 0001 Thrust Shaft - Tools
90572 0005 Main Bearing - Measuring Tools

906 - Control Gear

106-01 0053 Chain, Data
906-01 0239 Chain
106-02 0057 Chain Tightener, Data
906-02 0240 Chain Tightener
10620 0002 Gear Drive, Data
90620 0202 Gear Drive
10621 0006 Hydraulic Pumps, Data
90621 0208 Hydraulic Pumps
10622 0005 Hydraulic System, Data
90622 0206 Hydraulic System
10623 0004 Accumulators, Data
90623 0207 Accumulators
10624 0004 Control Valves, Data
90624 0206 Control Valves
10626 0001 Angle Encoder, Data
90626 0201 Angle Encoder
10628 0003 Special running, Data
90628 0204 Special running
90664 0005 Crankshaft - Pin Gauge
90671 0001 Hydraulic Tools - Chain Tightener
90674 0001 Test Equipment for Accumulators

907 - Starting Air System

MAN B&W Diesel A/S Page 2 (4)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

107-02 0040 Start Air Valve, Data

907-02 0215 Starting Air Valve

908 - Exhaust Valve

108-01 0043 High-Pressure Pipe, Data
908-01 0225 High-Pressure Pipe
108-02 0081 Exhaust Valve, Data
908-02 0255 Exhaust Valve
108-03 0050 Exhaust Valve Actuator, Data
908-03 0240 Exhaust Valve Actuator
90851 0211 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90862 0044 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool

909 - Fuel Oil System

10911 0066 Fuel Valve, Data
90911 0241 Fuel Valve
10912 0047 Spindle Guide, Data
90912 0224 Spindle Guide
10913 0033 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0071 Fuel Oil High-Pressure Pipes, Data
90914 0245 Fuel Oil High-Pressure Pipes
10920 0003 Fuel Oil Pressure Booster, Data
90920 0203 Fuel Oil Pressure Booster, Data
10921 0003 Fuel Oil Pressure Booster - Top Cover, Data
90921 0203 Fuel Oil Pressure Booster - Top Cover, Data
10922 0003 Fuel Oil Pressure Booster - Suction Valve, Data
90922 0203 Fuel Oil Pressure Booster - Suction Valve, Data
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90981 0001 Mounting Tools - Top Cover Seals

910 - Turbocharger System

110-01 0039 Air Cooler Element, Data
910-01 0234 Air Cooler Element
110-02 0007 Non-Return Valve in Turbocharger, Data
910-02 0215 Non Return Valve in Tubocharger
110-03 0017 Auxilary Blower, Data
910-03 0218 Auxilary Blower

MAN B&W Diesel A/S Page 3 (4)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

110-04 0004 Butterfly Valve, Data

910-04 0207 Butterfly Valves
110-05 0008 Turbocharger Turbine, Data
910-05 0207 Turbocharger Turbine
110-06 0024 Water Mist Catcher, Data
910-06 0219 Water Mist Catcher
91063 0017 Air Cooler - Tools
91063 0019 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0005 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 0009 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)
112-03 0018 Stay Bolts, Data
912-03 0212 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0073 Hydraulic Tools for Large Parts
91266 0001 Hydraulic Tools - End Chock Bolts (Epoxy Chocks)

913 - General Tools

913-01 0215 Hydraulic Tools
913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools
91356 0053 Lifting Tools, etc.
91357 0007 Open-Ended Spanners
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0040 Spanners
91364 0059 Open-Ended Spanners

MAN B&W Diesel A/S Page 4 (4)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

91366 0065 Instruments

91366 0067 Instruments
91368 0007 Working Platforms

MAN B&W Diesel A/S Page 5 (4)

 Instructions for Main Engines

This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS

The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel 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

Documents in this Chapter

101-01 0064 Cylinder Cover, Data

901-01 0243 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0110 Cylinder Cover - Tools
90163 0004 Cylinder Cover - Support Tool
90165 0001 Cylinder Cover - Lifting Tools

MAN B&W Diesel A/S

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

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

Data

Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 450 Nm

D01-02 Starting valve stud, screwing-in torque 140 Nm
D01-03 Fuel valve stud, screwing-in torque 140 Nm
D01-05 Cylinder cover stud, check distance 148 - 149 mm
D01-06 Cylinder cover, complete 2650 kg
D01-07 Cylinder cover without valves 1800 kg
D01-08 Cooling jacket 70 kg
D01-09 Exhaust valve stud 50 kg
D01-10 Cylinder cover stud 80 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 0064 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

P90161 Cylinder cover tightening tool

P90165 Cylinder Cover - Lifting Tools

P91351 10 Hydraulic pump, pneumatically operated

P91351 34 Hose with unions (1000 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 130 9-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10101 Edition 0064
MAN B&W Diesel A/S
 Cylinder Cover 901-1.2
Dismantling

1. Set blocking device A on the main starting 1. E

valve in the blocked position.

Engage turning gear B.

C
Close fuel oil inlet valve C. A F
D
G
Close cooling water inlet valve D.

Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

M90101
0243D01
Shut off the air supply for the pneumatic
exhaust valve spring, and vent the system.

2. Connect a pressure gauge at “minimess” B

point 455. Check the pressure.

Close valve 420 and open valve 421 on the 2.

00:00
hydraulic block for the cylinder concerned. ON

OFF

Check that the system is pressure free. Bourdon Sedeme

CC

Note!
Always ensure that the area around the
workplace is clean before any disman-
tling of the hydraulic system.

3. Close the valve 531 for the actuator oil

M90101
0243D02

supply.

3.
M90101
0243D03

When referring to this page, please quote Procedure M90101 Edition 0243 Page 1 (11)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover
Dismantling

4. Remove the cooling water outlet pipe from

4.
the exhaust valve.

Remove the screws which fasten the cool-

ing water outlet pipe to the block on the
cylinder cover.

Dismount the fuel oil high-pressure pipes.

See Procedure 909-14.2.

Dismount the control air pipe from the

starting valve.
M90101
0240D04

Remove the screws which fasten the start-

ing air inlet pipe to the block on the cylin-
der cover.

5. Unbolt the hydraulic high-pressure pipe,

see Procedure 908-1.2.
5.
Remove the oil supply pipe for the hydrau-
lic damper in the exhaust valve.

Dismount the drain oil pipe between the

exhaust valve and the hydraulic activator,
the air pipe for the pneumatic exhaust
valve, and the pipes for the sealing air ar-
rangement.

Disconnect the plug for the electrical ex-

haust valve sensor.
M90101
0240D05

6. Remove the protective jacket enclosing the

intermediate pipe between the exhaust re-
ceiver and the exhaust valve.

Loosen the screws in the flange between

6. the intermediate pipe and the exhaust re-
ceiver. The four lowermost screws need not
be removed, just loosened.

Remove the protective caps from the cylin-

der cover nuts.
M90101
0240D06

Page 2 (11) When referring to this page, please quote Procedure M90101 Edition 0243
MAN B&W Diesel A/S
 Cylinder Cover 901-1.2
Dismantling

7. Place eight spacer rings, one around each 7.

nut, and screw the eight hydraulic jacks
onto the studs.
D13
02
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 increase the
pressure as stated in Data.

For operation of the hydraulic tools, see

M90101
0243D05
Chapter 913.

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

8.
it on a couple of wooden planks.

9. Remove and discard the sealing ring be-

tween cylinder cover and cylinder liner. D01
06
M90101
0243D06

9.
M90101
0240D12

When referring to this page, please quote Procedure M90101 Edition 0243 Page 3 (11)
MAN B&W Diesel A/S
901-1.3 Cylinder Cover
Overhaul

1. Dismount all valves and pipes on the cylin-

1. der cover. See Procedure 907-2.2, 908-2.2
and 909-11.2.
D01
09
Remove the starting air inlet block and the
cooling water outlet block from the exhaust
side of the cylinder cover.

Unscrew all studs on top of the cylinder

cover.

2. Remove the four screws which secure the

cooling jacket to the cylinder cover.
M90101
0240O01

Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.

If the cooling jacket sticks, use dismantling

screws to force the jacket/cover apart.
2.
Remove and discard the O-rings from the
cover, and carefully clean the cooling jacket
D01
07 and the cylinder cover.

3. Provide the cylinder cover with new O-

rings, well lubricated with oil.

Lift the cylinder cover and guide the jacket/

D01-08 cover into position, using the guide pin as
a reference (camshaft side).

Mount and tighten the screws for the cool-

M90101
0240O02

ing jacket.

3.
M90101
0240O03

Page 4 (11) When referring to this page, please quote Procedure M90101 Edition 0243
MAN B&W Diesel A/S
 Cylinder Cover 901-1.3
Overhaul

4. Recondition the valve bores as follows:

4.
Fuel valve bore

5. The tool consists of a common spindle with

handle, and of 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.

M90101
0240O05
Carborundum No. 200).

After milling/grinding, clean the bore and

seating carefully, and check that the seat-
ing is not damaged.
5.
Exhaust valve bore

6. 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
M90101
0240O06

not damaged.

6.
M90101
0240O07

When referring to this page, please quote Procedure M90101 Edition 0243 Page 5 (11)
MAN B&W Diesel A/S
901-1.3 Cylinder Cover
Overhaul

Starting valve bore

7.
7. 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.

8. Clean the bores for safety valve/indicator

cock.
M90101
0243O07

8.
D01
09
M90101
0240O01

Page 6 (11) When referring to this page, please quote Procedure M90101 Edition 0243
MAN B&W Diesel A/S
 Cylinder Cover 901-1.3
Overhaul

9. Lubricate the threads with ‘Never Seize' or

Molybdenum Disulphide (MoS2) and mount 9. D01
01
the valve studs.

Tighten the studs in accordance with the

screwing-in torque stated on the data
sheet.
D01
03
Fill up the grooves between the valve studs D01
02
and the bores for the valve studs with
permatex to prevent water or oil from en-
tering the bores during operation of the en-
gine.

M90101
0243O09
Always fit new or overhauled valves before
mounting a cylinder cover on the engine.

10. Clean the starting air inlet block and the

cooling water outlet block.
10.
Mount the blocks and new packings on the
cylinder cover.
M90101
0243O10

When referring to this page, please quote Procedure M90101 Edition 0243 Page 7 (11)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover
Mounting

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

1. inder liner.

2. Lift the cylinder cover by means of the

crane and carefully wipe the contact sur-
face which faces the cylinder liner.

Fit the cooling water connecting pipes with

new O-rings and lubricate them with grease
D01
06 or soft soap.

Mount a new ‘klinger’ sealing ring in the

groove of the flange of the intermediate
M90101
0240M01

pipe.

Lower the cover carefully into position.

During the landing, carefully check that the

cooling water connecting pipes engage
2. correctly with the holes in the cooling
jacket.

3. If any of the cylinder covers studs have

been removed, check the distance they
protrude from the cylinder cover.

If necessary, adjust the distance D01-05 by

turning the studs.
M90101
0240M03

3.

D01
05
M90101
0240M04

Page 8 (11) When referring to this page, please quote Procedure M90101 Edition 0243
MAN B&W Diesel A/S
 Cylinder Cover 901-1.4
Mounting

4. Mount all eight nuts on the studs and

screw them down to the cylinder cover. 4.

Place eight spacer rings, one around each

D13
01
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

M90101
0243M04
the pressure as stated in Data.

For operation of hydraulic jacks, see Proce-

dure 913-1.

Connect the hydraulic hoses to the jacks

and raise the pressure to the level stated in 5.
Data. Tighten the nuts with a tommy bar.

Release the pressure. Remove the hydrau-

lic jacks and the spacer rings.

5. Fit 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 holes in the flange on
the exhaust receiver.
M90101
0240M06

Mount the screws of the flange between

the intermediate pipe and the exhaust re-
ceiver.
Note!
Lubricate the screws with ‘Never Seize’
or Molybdenum Disulphide (MoS2) before
mounting.

6. Fit the insulating jacket around the interme-

diate pipe.

When referring to this page, please quote Procedure M90101 Edition 0243 Page 9 (11)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover
Mounting

7. Mount the supply and return oil pipes, the

7. sealing air pipe and the air pipe for pneu-
matic closing of the exhaust valve.

Mount oil supply pipe for the hydraulic

damper in the exhaust valve

Mount the high-pressure pipe for the hy-

draulic valve gear.
See Procedure 908-1.4.

Mount the plug for the electrical sensor for

the exhaust valve.
M90101
0240M07

8. Mount the control air pipe for the starting

valve. Mount the screws which fasten the
starting air inlet pipe to the block on the
cylinder cover.

8. Mount the cooling water outlet pipe on the

exhaust valve. Mount the screws which
fasten the cooling water outlet pipe to the
block on the cylinder cover.

Using a crowfoot wrench and torque span-

ner, mount the fuel oil high-pressure pipes.
See Procedure 909-14.4.

9. Connect the outlet pipe from the return oil

pipe on the fuel valves.

Shut the drain valves and open the cooling

M90101
0240M08

water inlet. After venting the cylinder sec-

tion, shut the vent cocks and open the
cooling water outlet valve.

Open fuel oil, lubricating oil and air sup-

plies to the alarm system.

Caution!
Always connect the air supply to the ex-
haust valve before turning on the oil
supply to the exhaust valve actuator.

Page 10 (11) When referring to this page, please quote Procedure M90101 Edition 0243
MAN B&W Diesel A/S
 Cylinder Cover 901-1.4
Mounting

10. Open valve 531 for hydraulic operation of

the exhaust valve. 10.

11. Close valve 421 and open valve 420 on the

hydraulic block.

M90101
0243M10
11.
M90101
0243M11

When referring to this page, please quote Procedure M90101 Edition 0243 Page 11 (11)
MAN B&W Diesel A/S
 Cylinder Cover Panel Plate
MAN B&W Diesel P90151-0205

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

Item Item Description Item Item Description

No. No.

010 Panel for tools

022 Name plate
046 Grinding tool, exhaust valve seat
058 Milling and grinding tool, fuel valve seat
060 Milling and grinding wheel, fuel starting
valve
071 Dismantling tool, fuel valve
083 Handle, grinding tools
095 Grinding ring, starting valve seat
105 Pin spanner, starting valve
117 Test equipment, combined safety valve

Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0205
 Cylinder Cover - Tools
Tools Plate
MAN B&W Diesel P90161-0110

When referring to this page, please quote Plate P90161 Edition 0110 Page 1 (2)
Plate
Cylinder Cover - Tools
Tools
P90161-0110 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

027 Hydraulic jack for cylinder cover

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

Page 2 (2) When referring to this page, please quote Plate P90161 Edition 0110
 Cylinder Cover - Support Tool Plate
MAN B&W Diesel P90163-0004

When referring to this page, please quote Plate P90163 Edition 0004 Page 1 (2)
Plate
Cylinder Cover - Support Tool
P90163-0004 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Cylinder cover rack

Page 2 (2) When referring to this page, please quote Plate P90163 Edition 0004
 Cylinder Cover - Lifting Tools
Tools Plate
MAN B&W Diesel P90165-0001

When referring to this page, please quote Plate P90165 Edition 0001 Page 1 (2)
Plate
Cylinder Cover - Lifting Tools
Tools
P90165-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 Lifting chains for cylinder cover

Page 2 (2) When referring to this page, please quote Plate P90165 Edition 0001
902 - Piston with Rod & Stuffing Box

Documents in this Chapter

102-01 0082 Piston, Data

902-01 0279 Piston
102-02 0060 Piston Rod Stuffing Box, Data
902-02 0229 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 0005 Piston - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Piston 102-1
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D01-05 Cylinder cover stud, check distance 148 - 149 mm
D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 590 Nm
D02-03 Piston rod/crown, tightening torque 580 Nm
D02-05 Piston skirt, tightening torque 190 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-08 Piston ring new, radial width 20.2 mm
D02-09 Piston ring worn, min. radial width 17.2 mm
D02-10 Groove No.1, max. vertical height 14.75 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 11.75 mm
D02-13 Piston ring new, height of ring No. 1 13.9 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 10.9 mm
D02-15 Minimum free ring gap ( before dismantling ) 30 mm
D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 4.1 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 3.0 mm
D02-18 Vertical clearance, new parts 0.43 mm
D02-19 Vertical clearance, worn parts, max. 0.92 mm
D02-20 Piston complete 1600 kg
D02-21 Piston crown 320 kg
D02-22 Piston rod 1100 kg
D02-23 Piston skirt 100 kg
D02-24 Piston cooling pipe 40 kg
D02-25 Lifting tool, tightening torque 150 Nm
D02-46 CPR ring CL groove, min. depth 1.3 mm
D02-47 Piston top centre, max. permissible burn-away 9 mm
D02-48 Piston top centre diameter 280 mm
D02-49 Piston top outer ring area, max. permissible burn-away 6 mm

When referring to this page, please quote Data D10201 Edition 0082 Page 1 (2)
MAN B&W Diesel A/S
102-1 Piston
Data

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

Plate Item No. Description

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
P90251 183 Pulling tool for stuffing box

P90261 Guide ring for piston

P90265 Support for piston
P90266 Piston - Lifting Tools

Page 2 (2) When referring to this page, please quote Data D10201 Edition 0082
MAN B&W Diesel A/S
 Piston 902-1.1
Checking

Scavenge port inspection 1.

To detect possible leakages from the piston or
cylinder cover, keep the cooling water and
cooling oil circulating during the scavenge port
inspection.

1. The scavenge port inspection is carried out

from the scavenge air receiver.

An additional view of the rings is possible

through the cleaning cover on the
manoeuvring side.

M90201
0277C01
Turn the engine at least ½ a revolution and
start with a unit arriving downwards, just
above the scavenge air ports. Inspect the
piston rod and the lower part of the cylin-
der wall.
2.
While the piston is passing downwards, in-
spect the piston skirt, all the piston rings,
the ringlands and the piston 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.
M90201
0277C02

3.
M90201
0277C03

When referring to this page, please quote Procedure M90201Edition 0279 Page 1 (20)
MAN B&W Diesel A/S
902-1.1 Piston
Checking

4. Ring grooves:
4. Measure the total clearance between the
piston rings and the ring grooves. The total
D02
18
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
and piston ring groove.
D02-19
Total clearance = E + F.

5. Uppermost piston ring:

If possible, measure the depth of the pres-
M90201
0277C04

sure relief grooves with a caliper.

The piston rings must be replaced if the ra-

dial depth of the grooves has worn down
to less than stated in Data D02-46.
5.
D02
46 Checking of piston rings and piston crown,
in connection with piston overhaul:

6. Remove the piston from the cylinder and

place it on the piston support.
See Procedure 902-1.2.

Note!
It is recommended to replace all the pis-
ton rings whenever a piston is removed
from the engine.
M90201
0277C05

For evaluation of the rings, see Volume I,

Chapter 707.

6.

D02
20
M90201
0279C06

Page 2 (20) When referring to this page, please quote Procedure M90201Edition
 Piston 902-1.1
Checking

7.
7. Before dismantling the piston rings, mea-
sure the free ring gap of all the piston
rings. D02
15
8. Take off the piston rings by means of the
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.

M90201
0279C07
8.
A A

B B Top

C C

D D
M90201
0277C08

9.

D02
08 New
M90201
0277C09

D02
09 Worn

When referring to this page, please quote Procedure M90201Edition 0279 Page 3 (20)
MAN B&W Diesel A/S
902-1.1 Piston
Checking

10. Clean the ring grooves and check them for

10. 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

Max 2 mm groove must not exceed the value stated in
Data.

11. Check the piston template is permanently

marked with the piston top centre diameter
M90201
0277C10

D02-48.

If not already done, mark the centre area C

and write the maximum permissible burn-
away rate on the template, see Data D02-
11. 47.

Mark the outer part of the template R for

ring area and write the maximum permis-
sible brun-away rate for the ring shaped
area, see Data D02-49

R C

D02
48
S902
0026C01

Page 4 (20) When referring to this page, please quote Procedure M90201Edition
 Piston 902-1.1
Checking

12. Clean the piston crown and check the

burn-away by means of the template. 12.

For the piston top centre area maximum

D02
49 D02
47
permissible burn-away, see Data D02-47.
For the ring shaped area, see Data D02-49.

Check the burn-away on the whole circum-

ference of the piston crown.

If the burn-away exeeds the values given in

data, contact MAN B&W for advice.

Note down the results for later reference.

13. 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), by using the ring expander.

When mounting the piston rings, use the

ring expander to prevent unintended defor-
mation of the rings.
S902
0026C02

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.
13. Top

A
B

A C

B D

C
D
M90201
0277C12

When referring to this page, please quote Procedure M90201Edition 0279 Page 5 (20)
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling

1. Turn the crosshead down far enough to

1. give 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.
M90201
0277D01

3. Remove the screws from the piston rod.

2.
M90201
0277D02

3.
M90201
0279D03

Page 6 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.2
Dismantling

4. Mount the two distance pieces on the pis-

ton rod foot to protect the lower scraper 4.
ring and to guide the stuffing box.

5. Dismount the cylinder cover.

See Procedure 901-1.2.

Carefully smooth out any wear ridges at

the top of the cylinder liner.
See Procedure 903-1.3.

6. Make a scratch mark in liner and piston

cleaning ring to ensure the correct mount-
ing.

M90201
0279D04
Remove the piston cleaning ring.

Carefully remove any wear ridges at the

top of the cylinder liner.
See Procedure 903-1.3. 5.
M90201
0279D05

6.
M90201
0279D06

When referring to this page, please quote Procedure M90201Edition 0279 Page 7 (20)
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling

7. Turn the crosshead to TDC, while checking

7. that the stuffing box lands correctly on the
distance pieces.

8. Turn to TDC.

The top of the piston is now free of the

cylinder liner.

Note!
If necessary, remove one or two cylinder
cover studs, using a stud setter.
M90201
0279D07

Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two ‘fixed’ claws of the tool fit into
the lifting groove of the piston.
8.
Fit the third, adjustable, claw of the tool to
the lifting groove and tighten it up against
the stop of the tool. See Data.

9. Lift the piston out of the cylinder liner.

D02
25 If the lifting height is limited, it can be nec-

essary to guide the piston rod foot in be-
D02
20 tween the cylinder cover studs.
M90201
0279D08

9.
M90201
0279D09

Page 8 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.2
Dismantling

10. Lower the piston rod foot and stuffing box

through the opening in the platform. 10.

Place the two halves of the support around

the piston rod and secure the two halves
with screws.

11. Place a cover over the opening for the pis- D02
20
ton rod stuffing box in the bottom of the
cylinder unit.

Clean, measure and recondition the cylin-

der liner.
See Procedure 903-1.

M90201
0279C06
12. Turn the crosshead down far enough to
permit mounting of the protective rubber
cover on the crosshead bearing cap.

The protective rubber cover should remain 11.

in place to protect the crosshead bearing
journal from impurities until the piston is re-
mounted.
M90201
0279D11

12.
M90201
0279D12

When referring to this page, please quote Procedure M90201Edition 0279 Page 9 (20)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul

1. Ease the piston down so that the stuffing

1. box is below the floor.

2. Assemble the two halves of the piston sup-

port around the piston rod and land the
piston on the support.

Check and remove the piston rings.

See Procedure 902-1.1.

3. Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown.
M90201
0279O01

2.

D02
20
M90201
0279C06

3.
M90201
0279O03

Page 10 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

4. Dismount the locking wire and screw up

the support screws of the piston support to 4.
a position just below the piston skirt.

Remove the piston skirt screws.

5. Screw the four screws of the support

downwards until the skirt rests on the sup- D02
23
port.

If the skirt will not budge, free it by means

of two dismantling screws.

Lift away the piston crown.

M90201
0279O04
Remove and discard the sealing rings on
the piston rod and on the skirt.

6. Dismount the bolts of the cooling oil pipe

flange. 5.

Mount the eye bolts and lift out the cooling

oil pipe.

After inspection of the cooling oil pipe, re- D02
21

mount the pipe.
M90201
0279O05

6.

D02
24

D02
06
M90201
0279O06

When referring to this page, please quote Procedure M90201Edition 0279 Page 11 (20)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul

Alternatively, the piston can be dismantled in

7. 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.

D02
20 8. Lift the piston with the lifting tool. Land the
piston rod foot on a wooden plank.

Note!
During the lift, follow with the crane to
keep the crane positioned vertically
M90201
0279C06

above the lifting point.

Lower the piston crown to the platform and

land it on a wooden plank, so that it is
possible to remove the lifting tool.
8.
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
on to the lifting bracket.
M90201
0278O05

9.
M90201
0278O06

Page 12 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

10. Lift the piston rod foot clear of the wooden

plank. 10.

Keep lifting until the piston rod is in a verti-

cal position.

11. Place the piston in an upright position with

the piston crown resting on wooden
blocks.

Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown. Lift the piston rod away and
land it in a horizontal position on a couple

M90201
0279O10
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. 11.

D02
22
M90201
0279O11

12.

D02
23
M90201
0279O12

When referring to this page, please quote Procedure M90201Edition 0279 Page 13 (20)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul

13. Thoroughly clean and inspect all parts of

13. the piston.
Regarding check of the piston crown, see
Procedure 902-1.1.
D02
03
Replace all sealing rings of the piston. All
the new sealing rings must be coated with
D02
05 lubricating oil before the piston is as-
sembled.

Coat all screws with Molybdenum

Disulphide (MoS2).

Assemble the piston in the reverse order to

M90201
0279O13

disassembly. Use the guide screw to en-

sure the correct positioning of the piston
rod in relation to the piston crown.

Tighten all the screws diagonally to the

14. torque stated in Data.

14. Lock all the screws with locking wire.

Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
See Procedure 913-7.
M90201
0279O14

Page 14 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

Sealing ring and Pressure test:

15.
According to current class rules, the piston
must be pressure tested hydraulically. It is
possible to carry out a test of the sealing
rings with compressed air before filling the
piston with oil. The sealing ring test can
also be carried out when the piston is rest-
ing in the support tool.

Sealing ring test:

15. Mount the pressure-testing tool on the pis-

M90201
0279O19
ton rod foot.

Connect compressed air to the testing tool

and fill the piston to 4-5 bar.

Close the valve on the testing tool and re-

move the air connection, the piston must 16.
now hold the pressure for minimum 30
D02
01
minutes.

Spray a little soap water on to the surface

joints between piston rod/crow/skirt and
around hydraulic nuts to detect leaks.

Dry off all soap water.

Pressure test:

For this test, the piston must be turned upside

M90201
0279O20

down.

16. Fill the piston and piston rod with lubricat-

ing oil.

Mount the pressure-testing tool on the pis-

ton rod foot.

Pressure-test the piston at the pressure

stated on the Data Sheet.

Check the contact surfaces of the piston

and the sealing rings for tightness.

Check that there are no cracks in the pis-

ton crown.

17. Drain the piston oil.

Place the piston in the piston support tool

and mount the piston rod stuffing box. See
Procedure 902-2.3.

When referring to this page, please quote Procedure M90201Edition 0279 Page 15 (20)
MAN B&W Diesel A/S
902-1.4 Piston
Mounting

1. Check the piston rings and piston crown in

2. accordance with Procedure 902-1.1.

Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.

2. Mount the lifting tool on the piston crown.

D02
20
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

M90201
0279M01

oil.

4. Remove the protective rubber cover from

the crosshead.

3.
M90201
0279M02

4.
M90201
0279D12

Page 16 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.4
Mounting

5. Remove the cover from the piston rod

stuffing box opening in the bottom of the 5.
cylinder 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 piston rings are inside the liner.

M90201
0279D11
6.
M90201
0279M06

7.
M90201
0279M07

When referring to this page, please quote Procedure M90201Edition 0279 Page 17 (20)
MAN B&W Diesel A/S
902-1.4 Piston
Mounting

8. Turn the crosshead nearly to TDC while

8. 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

for piston rings.
M90201
0278M08

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
correctly centred.
9.
Remove the distance pieces from the pis-
ton rod foot.
M90201
0279M09

10.
M90201
0279M10

Page 18 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston 902-1.4
Mounting

11. Tighten down the piston rod stuffing box

by means of the screws, through the inner 11.
holes in the stuffing box flange. If neces-
sary use the special pulling tool from
toolpanel 902.
See Procedure 902-2.

12. Mount and tighten the piston rod screws.

Tighten the screws to the specified torque
and lock with locking wire. See Data.

13. Mount the piston cleaning ring according to

the scratch mark.

M90201
0279M11
If the PC-ring is damaged (broken or
cracked), see Procedure 903-1 for replace-
ment.

12.

D02
02
M90201
0279M12

13.
M90201
0279M13

When referring to this page, please quote Procedure M90201Edition 0279 Page 19 (20)
MAN B&W Diesel A/S
902-1.4 Piston
Mounting

14. If the cylinder cover studs have been re-

14. 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. See Data.

Screw the stud down to obtain contact,

and then half a revolution back.
M90201
0279M14

15. Land the cylinder cover on the liner and

check the distance the stud is protruding
from the cylinder cover.

If necessary, adjust to the distance D01-05

by turning the stud.
15.
16. Smear the piston rod with molybdenum
disulphide, and turn the crankshaft a
D01
05 couple of revolutions.

Tighten the cylinder cover and mount the

necessary pipes.
See Procedure 901-1.4.

Start the engine and keep it running for

about 15 minutes at a number of revolu-
tions corresponding to very slow.
M90201
0279M15

Then stop the engine and inspect the pis-

ton rod and stuffing box.

Page 20 (20) When referring to this page, please quote Procedure M90201Edition 0279
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm
D02-28 Stuffing box halves, tightening torque 80 Nm
D02-29 Uppermost rings, ring-end clearance 4x6 mm
D02-30 Lowermost rings, ring-end clearance 3x3 mm
D02-34 Sealing ring springs new, free length 618 mm
D02-38 Scraper ring springs new, free length 606 mm
D02-44 Stuffing box complete 100 kg
D02-45 Stuffing box half 35 kg
D02-50 Stuffing box halves fitted bolts, tightening torque 25 Nm

When referring to this page, please quote Data D10202 Edition 0060 Page 1 (2)
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data

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

Plate Item No. Description

P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box
P90451 120 Rubber cover for crosshead

Page 2 (2) When referring to this page, please quote Data D10202 Edition 0060
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.1
Checking

1. After the piston rod stuffing box has been 1.

dismantled, check the following clearances: A
See Procedure 902-2.2.

Uppermost scraper ring and sealing rings

Clearance at ring ends (scraper ring).

Total clearance (scraper ring). (D02-29) D02
29

Clearance at ring ends (sealing rings). B

Total clearance (sealing rings). (D02-29)

Lowermost scraper rings

Clearance at ring ends. D02
30

Total clearance. (D02-30)

The ring clearances stated in Data apply to

A B
new rings.

As a general guide, it is recommended –

depending on the overhauling intervals and
D02
29 D02
30
M90202
0229C01

one’s own experience – to replace sealing

rings and scraper rings when the specified
clearance values D02-29 and D02-30 have
been halved.

2. Garter springs:
2.
D02
34
Generally, it is recommended to renew the
springs when the sealing rings and scraper
rings are renewed.

The springs can be checked as follows:

Place the springs on the table, measure Lo
(free length), and compare with Data. If a
spring is extended more than 8% from the D02
38
value given in data, it must be discarded.
M90202
0227C02

When referring to this page, please quote Procedure M90202 Edition 0229 Page 1 (10)
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box
Dismantling

In connection with dismantling of the piston,

1. only the innermost screws in the stuffing box
flange and the screws for the drain oil pipe
should be removed.

If, in the period between piston overhauls, it

becomes necessary to inspect the piston rod
stuffing box, proceed as follows:

1. Turn the crosshead to about 90° from TDC.

Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
M90202
0229D01

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.
M90202
0229D02

3.
M90202
0229D03

Page 2 (10) When referring to this page, please quote Procedure M90202 Edition 0229
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.2
Dismantling

4. Remove the two long dismantling screws

from the worktable. 4.

Mount them in the stuffing box through the

holes in the worktable.

Remove the remaining two screws from the

stuffing box.

5. Turn the piston to BDC, thereby withdraw-

ing the stuffing box from the cylinder frame
bottom.

6. Remove the two long dismantling screws

M90202
0229D04
from the stuffing box and mount them in
the worktable.

By means of the four short screws in the

worktable, press the stuffing box out of the
flange. 5.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
M90202
0229D05

6.
M90202
0229D06

When referring to this page, please quote Procedure M90202 Edition 0229 Page 3 (10)
MAN B&W Diesel A/S
902-2.3 Piston Rod Stuffing Box
Overhaul

Normally, overhaul of the piston rod stuffing

box is carried out by routine methods in con-
nection with the dismantling (pulling) of the pis-
tons.

During such overhauls, the piston rests on a

support placed over one of the cut-outs in the
top platform.

Work on the stuffing box is then carried out

from the platform below.

Overhaul inside the engine is carried out in the

same way as outside the engine.
M90202
0229O01

1. Mount two eye bolts in the stuffing box

flange, and hook on two tackles.

Lift the stuffing box a little up the piston

1. rod, and mount the worktable round the
piston rod at a suitable working height.

Land the stuffing box on the worktable,

and remove the tackles and eye bolts.

2. Remove the O-rings of the stuffing box. If

D02
44 the O-rings are intact and are to be used
again, move them up the piston rod and
secure them in this position, for example
with tape.

Remove the nuts from the stuffing box as-

M90202
0229O02

sembling bolts.

2.
M90202
0229O03

Page 4 (10) When referring to this page, please quote Procedure M90202 Edition 0229
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.3
Overhaul

3. Take out the six bolts, and pull away one

stuffing box half. 3.

Mount two eye bolts on the stuffing box

half and remove it from the worktable. D02
45

4. Using a feeler gauge, measure the vertical

clearance of the rings.
See Procedure 902-2.1.

5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.

M90202
0229O04
6. Measure the clearance between the ring
segments to determine whether replace-
ment is necessary.
See Procedure 902-2.1.

Dismantle and stack the rings in the same 7. D02
34

order as when fitted in the stuffing box.

Carefully clean all the ring segments.

Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.

7. Check the lengths of the springs. D02
38

See Procedure 902-2.1.

8. Inspect the surface of the piston rod. If

M90202
0227C02

small longitudinal scratches have occurred

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

9. Clean the halves of the stuffing box hous-

ing.
M90202
0229O08

When referring to this page, please quote Procedure M90202 Edition 0229 Page 5 (10)
MAN B&W Diesel A/S
902-2.3 Piston Rod Stuffing Box
Overhaul

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

Scraper
ring

A
Scraper
ring

B
Sealing
ring

C
No relief
groove

Relief
M90202
0229O10

groove

Page 6 (10) When referring to this page, please quote Procedure M90202 Edition 0229
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.3
Overhaul

11. Assemble all the stuffing box ring units

round the piston rod, on the worktable, in 11.
the following way:

• Place the lowermost scraper ring seg-

ments on the worktable.

• Place the spring round the segments,

and hook the spring ends together.

Repeat this procedure for the remaining

scraper rings.

On top of the scraper rings, assemble the

M90202
0229O11
two sealing ring units (each consisting of a
4-part and an 8-part ring).

Assemble the 8-part sealing ring so that

the two guide pins face upwards, place the
spring round the segments and, hook the 12.
spring ends together.

Assemble the 4-part sealing ring above the

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

Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
M90202
0229O12

12. Use the stuffing box half on the worktable

to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. Subse-
quently, push the stuffing box half into con-
tact with the piston rod, round the ring
units.

Note!
If the stuffing box is assembled inside
the engine, place two pieces of plywood
of the same thickness as the flange on
the worktable, to ease the assembling.

When referring to this page, please quote Procedure M90202 Edition 0229 Page 7 (10)
MAN B&W Diesel A/S
902-2.3 Piston Rod Stuffing Box
Overhaul

13. Check the ring clearance again.

13.
Then place the other half of the stuffing
box housing on the worktable, pushing it
into place round the rings.
D02
28
In the middle holes mount and tighten up
the fitted bolts to the torque specified on
the Data Sheet, See Data D02-50

D02
50 Mount the O-rings in the stuffing box

grooves.

14. Mount eye bolts and wire ropes, and lift

M90202
0229O13

the stuffing box a little.

Remove the worktable and lower the stuff-

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

Mount and tighten the standard bolts to

specified torque, See Data D02-28
D02
44
M90202
0229O14

Page 8 (10) When referring to this page, please quote Procedure M90202 Edition 0229
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.4
Mounting

1. In connection with mounting of the piston,

1.
only the innermost flange screws are to be
mounted and tightened, see data.

After overhauling the stuffing box inside the

engine, assemble the stuffing box halves
on top of the four screws.

Mount the two long screws from the work-

table in the stuffing box.

Turn down the short screws so that the

stuffing box lands on the flange.

M90202
0229M01
2. Turn the piston upwards until the stuffing
box is in place in the cylinder frame.

Note!
2.
Make sure that the two guide pins in the
flange enter the guide holes in the bot-
tom of the cylinder frame.

3. Mount two screws in the flange through the

holes in the worktable.
M90202
0229M02

3.
M90202
0229M03

When referring to this page, please quote Procedure M90202 Edition 0229 Page 9 (10)
MAN B&W Diesel A/S
902-2.3 Piston Rod Stuffing Box
Overhaul

4. Remove the long screws from the stuffing

4. box and mount them itheworktable.

Remove the worktable from the piston rod.

5. Mount the drain oil pipe.

Mount and tighten all the inner and outer

screws for the stuffing box. See Data.

6. Remove the protecting rubber cover from

the piston rod/crosshead.
M90202
0229M04

Smear the piston rod with molybdenum

disulphide.

Then turn the crankshaft a couple of revo-

lutions.

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

running for about fifteen minutes at a num-
ber of revolutions corresponding to very
slow or idle speed.

Then stop the engine and inspect the pis-

ton rod and stuffing box.
M90202
0229M05

D02
26
D02
27

6.
M90202
0229D01

Page 10 (10) When referring to this page, please quote Procedure M90202 Edition 0229
MAN B&W Diesel A/S
 Piston and Piston Rod Panel Plate
P90251-0246

When referring to this page, please quote Plate P90251 Edition 0246 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0246

Item Item Description Item Item Description

No. No.

014 Panel for tools

026 Name plate
040 Lifting tool for piston rod foot
051 Lifting tool for cylinder liner
075 Template for piston top
087 Distance piece for stuffing box
099 Cover for stuffing box hole
109 Mounting tool for stuffing box spring
110 Pressure test tool for piston
122 Worktable for stuffing box
134 Piston ring expander
158 Guide screw for piston crown
183 Pulling tool for stuffing box

Page 2 (2) When referring to this page, please quote Plate P90251 Edition 0246
MAN B&W Diesel A/S
 Piston and Piston Rod - Tools Plate
P90261-0108

When referring to this page, please quote Plate P90261 Edition 0108 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0108

Item Item Description Item Item Description

No. No.

019 Guide ring for piston

Page 2 (2) When referring to this page, please quote Plate P90261 Edition 0108
MAN B&W Diesel A/S
 Piston and Piston Rod - Tilting Tools Plate
P90264-0012

When referring to this page, please quote Plate P90264 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tilting Tools
P90264-0012

Item Item Description Item Item Description

No. No.

015 Collar ring for piston

027 Support for tilting tool
039 Support for tilting tool
040 Lifting and tilting screw

Page 2 (2) When referring to this page, please quote Plate P90264 Edition 0012
MAN B&W Diesel A/S
 Piston and Piston Rod - Support Tools Plate
P90265-0005

When referring to this page, please quote Plate P90265 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0005

Item Item Description Item Item Description

No. No.

010 Support iron for piston

Page 2 (2) When referring to this page, please quote Plate P90265 Edition 0005
MAN B&W Diesel A/S
 Piston - Lifting Tools Plate
MAN B&W Diesel P90266-0005

When referring to this page, please quote Plate P90266 Edition 0005 Page 1 (2)
Plate
Piston - Lifting Tools
P90266-0005 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Lifting tool for piston

Page 2 (2) When referring to this page, please quote Plate P90266 Edition 0005
903 - Cylinder Liner and Cylinder Lubrication

Documents in this Chapter

103-01 0072 Cylinder Liner, Data

903-01 0257 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0251 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
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 For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D03-01 Lifting tool screws, tightening torque 200 Nm

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

Liner diameter: 600 mm

Liner wear: Install:
Standard PC-ring
0 – 0.60 mm (new max. diameter wear of 0.60 mm
0.60 – 1.20 mm Oversize PC-ring
> 1.20 mm No PC-ring

When referring to this page, please quote Data D10301 Edition 0072 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data

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

Plate Item No. Description

P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90362 Cylinder Liner - Extra Tool
P90366 Cylinder Liner - Lifting Tools

Page 2 (2) When referring to this page, please quote Data D10301 Edition 0072
MAN B&W Diesel A/S
 Cylinder Liner 903-1.1
Checking

1. Dismount the cylinder cover, the piston

cleaning ring and the piston. 1.
See Procedures 901-1.2 and 902-1.2.

Clean the cylinder liner and scavenge air

ports.

2. Position the cylinder liner measuring tool. D03
03

Measure the cylinder liner with an inside
micrometer at the positions indicated on
the measuring tool.

Take measurements in the fore-and-aft and

athwartship directions.

Check and assess the condition of the cyl-

inder liner according to the description
given in Volume I, Chapter 707.

Note!
If the cylinder liner is to be replaced, the
M90301
0257C02

piston cleaning ring must also be re-

placed.

3. Carefully scratch over any scores or marks

and grind away the wear ridges.
See Procedure 903-1.3. 4.

4. Check the lubricating points of the cylinder

by pumping cylinder oil to each lubricating
point with the cylinder lubricator.

Clean any blocked lubricating duct.

Mount the piston and cylinder cover.

See Procedures 902-1.4 and 901-1.4.
M90301
0257C04

When referring to this page, please quote Procedure M90301 Edition 0257 Page 1 (10)
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking

5. Piston cleaning (PC) ring:

6.
The PC-ring is to be regarded as an inte-
grated part of the liner and it is intended to
follow the service life of the liner.

During inspection of the piston and the

liner, the PC-ring must also be inspected.

6. Measure the PC-ring radial width B, and

find the most worn place. Compare with
Data D03-16 and calculate the wear of the
PC-ring, multiply the wear by 2 to get the
B PC-ring diameter wear.
M90301
0257C06

Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner-measuring tool. Compare
the measurements with the diameter of a
new liner as stated in Data. Calculate the
wear of the liner.

7. Compare the PC-ring diameter wear with

the wear of the liner. If wear of the two
components does not deviate more than
D03-17 then reinstall the PC-ring.

If the deviation between PC-ring wear and

liner wear is more than D03-17 or if the
PC-ring is broken or cracked, replace the
ring with a new PC-ring, an oversize ring or
no ring according to the table in D03-18 on
the Data sheet.

If it is necessary to install an oversize PC-

ring, contact MAN B&W Diesel for advice.

When a new liner is installed, also a new

PC-ring must be installed. When a new
liner is ordered, also a new PC-ring must
be ordered.

Page 2 (10) When referring to this page, please quote Procedure M90301 Edition 0257
MAN B&W Diesel A/S
 Cylinder Liner 903-1.2
Dismantling

1. Dismount the cylinder cover.

See Procedure 901-1.2. 2.

Discard the sealing ring from the top of the

cylinder liner.

Turn the piston down far enough to make it

possible to grind away the wear ridges at
the top of the liner with a hand-grinder.
See Procedure 903-1.3.

Dismount the piston cleaning ring and the

piston.
See Procedure 902-1.2.

M90301
0257D02
D03
01
2. Screw the two lifting tools on to the cylin-
der liner. Check with a feeler gauge that
there is no clearance between lifting tool
and cylinder liner. For tightening torque,
see Data. 3.

3. Disconnect the oil pipes leading from the

cylinder lubricator to the cylinder liner.

Dismount the four cooling water pipes –

between the cooling jacket and cylinder
cover and discard the O-rings from the
pipes – and clean them carefully.
M90301
0257D03

When referring to this page, please quote Procedure M90301 Edition 0257 Page 3 (10)
MAN B&W Diesel A/S
903-1.2 Cylinder Liner
Dismantling

4. Remove the screws of the cooling water in-

4. let pipe.

5. Attach the crane to the lifting crossbar.

Hook the lifting tools on to the crossbar on

both sides of the cylinder liner.

Lift the liner with the cooling jacket out of

the cylinder frame.

Note!
Low lifting height in the engine room
M90301
0257D04

may require the removal of one or more

cylinder cover studs before dismantling
the cylinder liner.

5. Land the cylinder liner vertically on, for in-

stance, a couple of planks.

6. Clean the cylinder frame internally, taking

D03
05 special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.

The lifting tools are also used for transport-

ing the cylinder liner.
M90301
0257D05

Page 4 (10) When referring to this page, please quote Procedure M90301 Edition 0257
MAN B&W Diesel A/S
 Cylinder Liner 903-1.3
Overhaul

1. Remove the non-return valves for the cylin-

der liner lubrication 1.

Attach two tackles to the crossbar, as

shown.

Mount two lifting eye bolts in the cooling

jacket.

Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.

Loosen the screws on the clamps which fix

the cooling jacket to the cylinder liner. Turn

M90301
0257O01
the clamps away from the liner.

2. Lower the cooling jacket by means of the

tackles and land it on the wooden planks.

3. Mount the lifting tools on the cylinder liner. 2.

See Data.

Lift the cylinder liner away from the cooling

jacket.

Clean the cooling jacket internally.

D03
06
M90301
0257O02

3.
M90301
0257O03

When referring to this page, please quote Procedure M90301 Edition 0257 Page 5 (10)
MAN B&W Diesel A/S
903-1.3 Cylinder Liner
Overhaul

4. Check and assess the condition of the cyl-

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

Check in the top of the liner for a wear

ridge (where the piston rings reverse direc-
tion). If there is any sign of a wear ridge, it
is necessary to create a groove by
grinding.The groove serves to prevent the
M90301
0257O04

build-up of a new wear ridge.

5. It is recommended to use a wear ridge

milling machine to create the groove. For
use of the milling machine, see supplier’s
5. instruction.

6. Alternatively, place an old piston ring on

the top of the piston and turn to a position
that enables the grinding disc to rest on
the old piston ring while removing the wear
ridge. Use a grinding disc with a round
edge.

Check the distance C before grinding to

ascertain that the wear ridge was caused
by the top ring at TDC.
M90301
0256O04

The maximum depth of the groove is cal-

culated as Smax. = D x 0.0045.

Note!
It is of the utmost importance that the
6.
groove is made with a regular rounding
as shown in the sketch.

D
R=4-5 mm
C
C
M90301
0256O05

Page 6 (10) When referring to this page, please quote Procedure M90301 Edition 0257
MAN B&W Diesel A/S
 Cylinder Liner 903-1.3
Overhaul

7. Apply a thin layer of grease on the contact

surface for the cooling jacket on the liner. 7.

Mount the lifting tools on the liner. Lift the

liner a little and mount new O-rings for the
cooling jacket. Then place the liner in the
cooling jacket.

Remove the lifting tools.

8. Lift the cooling jacket into position – mark-

ing scratches jacket/cylinder liner must co-
incide (manoeuvre side).

M90301
0257O06
8.
M90301
0257O07

When referring to this page, please quote Procedure M90301 Edition 0257 Page 7 (10)
MAN B&W Diesel A/S
903-1.3 Cylinder Liner
Overhaul

9. Turn the clamps until they fit in the groove

9. of the liner, and tighten the screws.

Remove the tackles and the eye bolts from

the cooling jacket.

Mount the non-return valves for the cylin-

der liner lubrication.
M90301
0257O08

Page 8 (10) When referring to this page, please quote Procedure M90301 Edition 0257
MAN B&W Diesel A/S
 Cylinder Liner 903-1.4
Mounting

1. Mount the lifting tools on the cylinder liner

and tighten to the specified torque. 1.
See Data.

Hook the lifting tools on to the crossbar,

and lift the jacket/liner assembly.

Mount the lowermost O-ring and apply a

D03
01
little lubricating oil on the ring.

2. Check that the joint surfaces on the cylin-

der frame and cylinder liner are completely
clean.

M90301
0257M01
Coat the joint surfaces with permatex or a
similar liquid sealing compound.

Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connec- 2.
tions on the cooling jacket.

3. If one or more cylinder cover studs have

been removed during the dismantling, D03
05
mount the studs.
See Procedure 902-1.4.

4. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount
and tighten the screws.
M90301
0257M02

3.
M90301
0257M04

When referring to this page, please quote Procedure M90301 Edition 0257 Page 9 (10)
MAN B&W Diesel A/S
903-1.2 Cylinder Liner
Dismantling

5. Screw the pipes from the lubricator on to

5. the non-return valves, but do not tighten.

Vent the cylinder lubricating system by

pumping all pipes through until oil, without
air bubbles, comes out from the union
pipe/non-return valve.

When this is in order, tighten the pipes

firmly on the non-return valves and again
pump until it is certain that each individual
lubricating point functions correctly.

6. Lubricate the inside of the cylinder liner

M90301
0257M05

with cylinder lubricating oil and mount the

piston and the piston cleaning ring.
See Procedure 902-1.4.

Note!
7.
Make sure to mount the piston cleaning
ring correctly, so that the scratching
marks are aligned.

7. Mount the sealing ring and the cylinder

cover.
See Procedure 901-1.4.

Tighten the upper water connections on

the cooling jacket as soon as the cylinder
cover is correctly positioned.
M90301
0257M06

Page 10 (10) When referring to this page, please quote Procedure M90301 Edition 0257
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 starting air supply – At starting air receiver
X Block the main starting valve
X Shut off starting air distributor/distributing system supply
X Shut off safety air supply – Not ME engines
X Shut off control air supply
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10302 Edition 0031 Page 1 (2)
103-2 Cylinder Lubricator
Data MAN B&W Diesel

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

Plate Item No. Description

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 all lubricators
are operating correctly by watching the
Lubricator
LEDs on the intermediate boxes next to
each lubricator.

For use of the MOP Panel, see Volume I

Chapter 703.

M90302
0244C01
2. If the cylinder cover or the exhaust valve is
removed, check inside the liner that all lu-
bricating points are working properly.

Otherwise, remove the covers for scavenge 2.

port inspection.

Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
source that all lubrication points are work-
ing properly.

With running engine:

3. Check that all lubricators are operating cor-

rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
M90302
0242C02

The LEDs give signal when oil is injected.

Check the pressure shocks from the injec-

tion of the lubricators on each lubricator
pipe by feeling with a hand.

If in doubt, disconnect the pipe at the cyl-

inder liner to observe the oil flow.

When referring to this page, please quote Procedure M90302 Edition 0251 Page 1 (8)
903-2.2 Cylinder Lubricators
Dismantling MAN B&W Diesel

Dismantling of lubricators:
1.
The engine must be stopped and blocked be-
fore dismounting a lubricator. Stop the cylinder
00:00 oil pump station.

ON Disconnect the electrical plug on the side of

OFF the lubricator.
Bourdon Sedeme

CC 1. Mount a pressure gauge at “minimess”

point 565.

Check the pressure.

M90302
0243D01

Close valve 560. Check that the cylinder lu-

560 bricator is pressure free. If pressure is still
present, activate the “prelub” function on
the Mop panel to remove the pressure.

2. Close the supply valve for cylinder lubricat-

ing oil.

2. Unscrew the four screws in the aft side of

the lubricator and disconnect the cover
with pertaining pipes.

3. Unscrew the four screws on the side that

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.
M90302
0243D02

Special running

It is possible to change a lubricator while the

engine is running if a spare lubricator with O-
3. 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

steps 1-3

• Mount a spare lubricator as described

in Procedure 903-2.4.
M90302
0243D03

Page 2 (8) When referring to this page, please quote Procedure M90302 Edition 0251
 Cylinder Lubricators 903-2.3
MAN B&W Diesel Overhaul

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, spring dics and

M90302
0251O01
actuator piston with plungers.

Remove and discard the O-ring from the

cylinder block.

2.
M90302
0251O02

3.
M90302
0251O03

When referring to this page, please quote Procedure M90302 Edition 0251 Page 3 (8)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W Diesel

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.
M90302
0242O04

5.
M90302
0251O05

6.
M90302
0242O09

Page 4 (8) When referring to this page, please quote Procedure M90302 Edition 0251
 Cylinder Lubricators 903-2.3
MAN B&W Diesel Overhaul

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 springs and spring dics and

press down the actuator piston with plung-
ers. Mount the special screw, supplied with
the test equipment for accumulators to
keep the spring compressed.

8. Remove the cover from the terminal box,

M90302
0251O07
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.

9. Turn the lubricator upside down in the vice.

Unscrew the solenoid valve.

Discard the O-rings

M90302
0251O08

9.
M90302
0251O09

When referring to this page, please quote Procedure M90302 Edition 0251 Page 5 (8)
903-2.3 Cylinder Lubricators
Overhaul MAN B&W Diesel

10. Before mounting the feedback sensor,

10. check that the sensor is flush with the sen-
sor housing.

Mount the feedback sensor or a new one,

if necessary, with a new O-ring.

Check with an object with a straight edge

(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.

11. Mount the terminal box.

1 1 Solenoid
2 2 valve
M90302
0242O07

Connect the wires and mount the cover on

3 BN (brown) the terminal box.
BK (black) Feedback
4
BU (blue) sensor
5 Solenoid Valve:

11. 12. Disassemble and clean the valve.

LED
Check the slide for wear. If the slide is

2
scratched or scuffed, the valve must be re-
placed by a new one.

Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
Brown+15 the housing.
Blue OV

Black FB
signal
Assemble the valve.
M90302
0242O08

12.
M90302
0244O12

Page 6 (8) When referring to this page, please quote Procedure M90302 Edition 0251
 Cylinder Lubricators 903-2.3
MAN B&W Diesel Overhaul

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.

M90302
0251O09
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.

M90302
0251O14

15.
M90302
0251O01

When referring to this page, please quote Procedure M90302 Edition 0251 Page 7 (8)
903-2.4 Cylinder Lubricators
Mounting MAN B&W Diesel

1. Mount new O-rings on the lubricator and

1. on the cover with pipes.

2. Mount the lubricator and tighten the screws

on the hydraulic cylinder unit.

Tighten the screws in the aft end of the lu-

bricator to the pipe connection.

Mount the cylinder oil supply pipe.

3. Mount the electrical plug. Check the injec-

tion of cylinder oil on the feedback LED on
the terminal box for the specific lubricator.
M90302
0242M01

Open valve 560 for hydraulic oil supply.

Open the valve for cylinder lubricating oil

supply.
2.
M90302
0243M02

3.
M90302
0243M03

560

Page 8 (8) When referring to this page, please quote Procedure M90302 Edition 0251
 Cylinder Liner - Tools Plate
P90361-0084
Cylinder Liner - Tools
0084
P90361

When referring to this page, please quote Plate P90361 Edition 0084 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Tools
P90361-0084

Item Item
Item Description Item Description
No. No.

036 Cylinder gauge, complete

Page 2 (2) When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S
 Cylinder Liner - Milling Tools Plate
P90362-0005

When referring to this page, please quote Plate P90362 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Milling Tools
P90362-0005

Item Item Description Item Item Description

No. No.

018 Wear ridge milling machine

Page 2 (2) When referring to this page, please quote Plate P90362 Edition 0005
MAN B&W Diesel A/S
 Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366

When referring to this page, please quote Plate P90366 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007

Item Item
Item Description Item Description
No. No.

021 Crossbar for cylinder liner

Page 2 (2) When referring to this page, please quote Plate P90366 Edition 0007
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

Documents in this Chapter

104-01 0059 Crosshead Bearing, Data

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

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Crosshead Bearing 104-1
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D02-02 Piston rod/crosshead, tightening torque 590 Nm

D02-07 Piston rod/crosshead, tightening torque+angle 100/60 Nm/°
D02-20 Piston complete 1483 kg
D04-01 Crosshead bearing, top clearance max. 0.55 mm
D04-02 Crosshead bearing, top clearance min. 0.20 mm
D04-03 Oil wedge length, L 15 mm
D04-04 Crosshead bearing cap 277 kg
D04-06 Crosshead bearing shell, lower 20 kg
D04-07 Crosshead bearing cap with bearing shell 297 kg
D04-21 Crosshead complete 1245 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10401 Edition 0059 Page 1 (2)
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data

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

Plate Item No. Description

P90451 59 Lifting attachment - connecting rod

P90451 72 Chain for suspending piston
P90451 96 Bracket for support, crosshead
P90451 106 Bracket for support, crosshead
P90464 Crosshead - hydraulic tools
P91356 Lifting tools, etc.
P91366 58 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10401 Edition 0059
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.1
Checking

Tin-Aluminium bearings
2.
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.

The top clearance for a new bearing will nor-

mally be in the range stated in Data. Note that
the figures are to be used for guidance only.

For the top clearance of a specific bearing, see

the measurement in the Adjustment Sheet in
Volume I, OPERATION.

M90401
0249C02
1. Open the crankcase door at the relevant
cylinder.

2. Turn the crankthrow concerned to BDC.

3.
3. Measure the clearance in the crosshead
bearing by inserting a feeler gauge be- D04
01
tween the bearing cap and the crosshead D04
02
journal at the top of the upper bearing
shell, at both sides and fore and aft. See
Data.

4. The difference between the actual clear-

ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
M90401
0249C03

crosshead bearing must be disassembled

for inspection.
See Procedure 904-1.2.

For evaluation of the bearing shell, see

Chapter 708, ‘Bearings’ in the instruction 5.
book, Volume I, OPERATION.

5. The wear limit for a crosshead bearing shell

is confined to a 50% reduction of the oil
wedge length L.

If the wear limit exceeds the 50% reduc-

(Oil Wedge)
tion, the bearing shell must be replaced by
a new one.
L
1/2
M90401
0249C05

D04
03
L

When referring to this page, please quote Procedure M90401 Edition 0249 Page 1 (11)
MAN B&W Diesel A/S
904-1.1 Crosshead Bearing
Checking

Alternate checking method:

8.
In case the reason for opening the crosshead
bearing is a routine inspection, the following
procedure is sufficient.

6. Perform the clearance measurement shown

in 904-1.1 section 3.

7. Mount the two eyebolts and tackles in the

top of the crankcase in the fore and aft di-
rection. Mount two eyebolts on top of the
guideshoes.
M90401
0249C08

Turn to BDC, mount the connecting rod lift-

ing attachments on the connecting rod.
Use tackles to hold the connecting rod in
the vertical position.

9. Dismount the crosshead bearing cap hy-

draulic nuts. For operation of the hydraulic
jacks, see Section 913.

8. Mount two eyebolts in the bearing cap and

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

9. Use the tackles in the crankcase top to lift

the crosshead and piston high enough to
allow inspection of the lower crosshead
M90401
0249C09

bearing.

Note!
Ensure that the crosshead is lifted simul-
taneously fore and aft, i.e. by placing
marks on the guide planes using a felt
tipped pen

10. If the lower bearing shows no anomalies

the piston and crosshead is lowered again
and the crosshead bearing cap nuts are
mounted.

11. Recheck the bearing top clearance. Re-

move all tools.

12. If there are any doubt concerning damage

to the upper bearing, the bearing has to be
dismantled and checked according to 904-
1.2

Page 2 (11) When referring to this page, please quote Procedure M90401 Edition 0249
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.2
Dismantling

This procedure applies to the following two

dismantling situations: 1.

• with piston mounted

• with piston removed

With piston mounted:

1. Turn the crankshaft down far enough to

give access to the nuts and screws on the
piston rod.

2. Mount two chains in the inner screw holes

M90401
0249D01
in the top of the crankcase, in the
athwarthship direction, for suspending the
piston rod.

3. Loosen and remove the locking wire from

the screws on the piston rod foot. Remove 2.
the screws.
M90401
0249D02

3.
M90401
0249D03

When referring to this page, please quote Procedure M90401 Edition 0249 Page 3 (11)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing
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:

M90401
0249D04

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.
M90401
0249D05

7.

D13
02
M90401
0249D07

Page 4 (11) When referring to this page, please quote Procedure M90401 Edition 0249
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.2
Dismantling

8. Mount the lifting attachments on the head

of the connecting rod. 8.

9. Suspend two tackles from the lifting brack-

ets, in the athwarthship direction.

10. Mount the wire guide at the top of the

crankcase door frame to prevent damage.

Mount two eye bolts in the top of the

crosshead bearing cap.

Hook the tackles on to the eye bolts, and

remove the bearing cap from the engine.

M90401
0249D08
Check the upper part of the journal.

9.
M90401
0249D09

10.
D04
07
M90401
0249D10

When referring to this page, please quote Procedure M90401 Edition 0249 Page 5 (11)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing
Dismantling

11. Place the bearing cap on one side on a

11. couple of wooden planks.

Check the bearing shell, see Procedure

D04
07
904-1.1.

12. Fasten tackles to the fixed lifting brackets

on the frame box wall.

13. Turn the crosshead upwards until the pis-

ton rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.
M90401
0249D11

Do not remove the chains or lifting eye

bolts.

12.
M90401
0249D12

13.
M90401
0249D13

Page 6 (11) When referring to this page, please quote Procedure M90401 Edition 0249
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.2
Dismantling

14. Turn to TDC and attach the tackle hooks to

the lifting attachments. Haul the tackles 14.
tight.

15. Mount the four supports for guide shoes

on the crosshead guides.

Carefully turn the crank down towards the

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

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.

M90401
0249D14
Haul the tackles tight.

16. Turn the crankthrow carefully towards BDC

while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod. 15.

17. With the crosshead resting on the sup-

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

Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chapter
708, ‘Bearings’.
M90401
0249D15

16.
17.
D04
21
D02
20
M90401
0249D16

When referring to this page, please quote Procedure M90401 Edition 0249 Page 7 (11)
MAN B&W Diesel A/S
904-1.2 Crosshead Bearing
Dismantling

18. In cases where it is necessary to remove

18. the lower bearing shell, tilt the connecting
rod towards the doorway on the camshaft
D04
06 side, using the tackles.

Dismount the locking screws, and turn the

bearing shell so far up that an eye bolt can
be mounted.

Lift the bearing shell out of the engine.

M90401
0249D18

Page 8 (11) When referring to this page, please quote Procedure M90401 Edition 0249
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.4
Mounting

With piston mounted/

With piston removed: 1.

1. Mount and secure the bearing shell in the

bearing housing.

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell D04
06
and must not be eliminated.

2. Raise the connecting rod to an upright po-

sition.

Turn to TDC while ‘following’ with the tack-

M90401
0249M01
les, for assembling the crosshead and the
connecting rod.

Take care that the guide shoes do not

damage the bearing shell.
2.
3. Remove the supports from the crosshead D04
21
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.
M90401
0249M02

3.
M90401
0249M03

When referring to this page, please quote Procedure M90401 Edition 0249 Page 9 (11)
MAN B&W Diesel A/S
904-1.4 Crosshead Bearing
Mounting

4. Lift the bearing cap into the engine. Lower

4. the bearing cap onto the crosshead and re-
D04
07 move the tackles. Remove the lifting at-
tachments from the connecting rod and the
wire guide from the door frame.

Note!
Take care that the bearing studs do not
damage the crosshead.

5. Tighten all four crosshead bearing cap nuts

M90401
0249M04

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:

7. Turn the crosshead upwards until the pis-

ton rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.

D13
01
M90401
0249M05

7.
M90401
0249D13

Page 10 (11) When referring to this page, please quote Procedure M90401 Edition 0249
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.4
Mounting

8. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and 8.
eye bolts from the top of the crankcase,
from the piston rod and from the cross-
head bearing cap.

9. Turn down to BDC, tighten the screws in

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

Mount the locking wire in such a way that

the wire is tightened if a screw works
loose.
See Procedure 913-7.

M90401
0249D13
9.
D02
02
D02
07
M90401
0249M09

When referring to this page, please quote Procedure M90401 Edition 0249 Page 11 (11)
MAN B&W Diesel A/S
 Crosshead 104-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D04-04 Crosshead bearing cap 277 kg

D04-08 Cooling oil outlet pipe, tightening torque 80 Nm
D04-12 Guide strip screws, tightening torque 350 Nm
D04-13 Guide plate, tightening torque 3 x 350 Nm
1 x 80 Nm
D04-15 Telescopic pipe, tightening torque 80 Nm
D04-19 Telescopic pipe, tightening angle 60 °
D04-21 Crosshead complete 1245 kg
D04-22 Guide shoe 325 kg
D04-23 Cooling oil outlet pipe 15 kg
D04-50 Connecting rod, without bearing caps 1820 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10402 Edition 0060 Page 1 (2)
MAN B&W Diesel A/S
104-2 Crosshead
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

P90451 47 Wire guide

P90451 59 Lifting attachment – connecting rod
P90451 60 Lifting tools – crosshead
P90451 84 Retaining tool telescope pipe
P90451 118 Rubber cover for crosshead
P90451 120 Rubber cover for crosshead
P90451 214 Torque wrench offset tool
P90462 11 Guide shoe extractor, complete
P90463 Crosshead – hydraulic tools
P91351 10 Hydraulic pump, pneumatic operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 117 5-way distributor block, complete
P91356 Lifting tools, etc.
P91359 40 Torque spanners

Page 2 (2) When referring to this page, please quote Data D10402 Edition 0060
MAN B&W Diesel A/S
 Crosshead 904-2.2
Dismantling

1. Unbolt the main bearing lubricating oil

pipes. 1.

2. Unbolt the cooling oil outlet pipe from the

guide shoe and the drain oil slotted pipe.

Loosen and remove the screws which se-

cure the telescopic pipe to the guide shoe.

In order to reach the screw in the corner

behind the telescopic pipe, use the offset
tool along with a socket wrench.

3. Mount the retaining tool for the telescopic

M90402
0248D01
pipe on the stuffing box housing for the
telescopic pipe.

Mount two eye bolts in the top of the

crankcase in the fore-and-aft direction.
2.
Mount two eye bolts in the athwartship di-
rection, and suspend two tackles.
M90402
0248D02

3.
M90402
0248D03

When referring to this page, please quote Procedure M90402 Edition 0248 Page 1 (9)
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling

4. Turn the crosshead to TDC.

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

Suspend the piston.

To suspend the piston, see Procedure
904-1.2.

5. Turn the crosshead to gain access to the

nuts on the crosshead bearing studs.

Mount the spacer rings and the hydraulic

jacks for loosening the nuts on the cross-
M90402
0248D04

head bearing studs.

For operation of the hydraulic tools, see

Section 913.

5. Loosen the nuts, remove the hydraulic

jacks and unscrew the nuts.

6. Mount eye bolts in the crosshead bearing

cap and hook the tackles on to the lifting
brackets in the top of the crankcase.

Remove the bearing cap and lift it out of

the engine.

D13
02
M90402
0248D05

6.

D04
04
M90402
0248D06

Page 2 (9) When referring to this page, please quote Procedure M90402 Edition 0248
MAN B&W Diesel A/S
 Crosshead 904-2.2
Dismantling

Lifting of the crosshead:

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

Mount the lifting attachments for fixing the

connecting rod, on the head of the con-
necting rod.

Fasten tackles to the lifting brackets on the

frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles D04
21
tight.

M90402
0248D07
Hook the tackles to the top lifting brackets
on to the lifting tool on the crosshead, and
lift the crosshead.

7b. Alternate method.

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

This is done by lowering the strap down

through the cylinder and stuffing box and
lifting the crosshead in the crosshead lifting
tool.

This eliminates the need for the tackles

placed in the athwartship direction in the
M90402
0248D08

crankcase top.

8. Use the tackles to tilt the connecting rod

towards the exhaust side, while turning the
crankthrow towards the camshaft side.
8.
Transfer the tackles from one lifting attach-
ment to another as necessary.

When the crankthrow is 90° after BDC,

stop turning. D04
50

By alternate use of the tackles, tilt the con-

necting rod until it rests against a couple of
wooden planks in the bottom of the bed-
plate.
M90402
0248D09

When referring to this page, please quote Procedure M90402 Edition 0248 Page 3 (9)
MAN B&W Diesel A/S
904-2.2 Crosshead
Dismantling

9. Lower the crosshead to a position just

9. above the main bearing caps.

Remove the guide strips and both guide

plates from the guide shoes.

Mount lifting eye bolts in both guide shoes.

10. Suspend two tackles from the eye bolts in

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

Push one of the guide shoes towards the

M90402
0248D10

middle of the crosshead. If necessary, use

the guide shoe extractor tool.

11. Pull the “free end” of the crosshead into

the neighbouring cylinder unit.
10.
Mount the guide shoe extractor on the op-
D04
22 posite guide shoe.

Pull off the guide shoe, remove the extrac-

tor, and lift up the guide shoe.
M90402
0248D11

11.

D04
22
M90402
0248D12

Page 4 (9) When referring to this page, please quote Procedure M90402 Edition 0248
MAN B&W Diesel A/S
 Crosshead 904-2.2
Dismantling

12. Pull the crosshead with guide shoe into the

opposite neighbouring cylinder unit. 12.

Mount the guide shoe extractor tool on the

remaining guide shoe.

Pull off the guide shoe, remove the extrac-

tor tool and lift up the guide shoe.

13. Turn the crosshead 90°.

14. Mount the wire guide tool in the framebox

door opening.

M90402
0248D13
Remove the crosshead from the engine,
using wire rope and tackles.

Protect the crosshead, for instance with

thick or corrugated paper, and land it out-
side the engine. 13.

If necessary, remove the guide shoes from

the engine.
M90402
0248D14

14.
M90402
0248D15

When referring to this page, please quote Procedure M90402 Edition 0248 Page 5 (9)
MAN B&W Diesel A/S
904-2.4 Crosshead
Mounting

1. Lift the crosshead into the engine, using

1. wire rope, tackles mounted in the top lifting
brackets inside the engine.

2. Turn the crosshead 90°. Pull the crosshead

to one side under the web plates between
the cylinders.

3. Lower one guide shoe in the other side of

the crosshead and mount the guide shoe
extractor tool.

Use the guide shoe extractor tool to pull

the crosshead so far through the guide
M90402
0248M01

shoe that the other guide shoe can be low-

ered.

Follow the movement of the crosshead with

the tackles mounted in the engine.
2.
M90402
0248M02

3.
M90402
0248M03

Page 6 (9) When referring to this page, please quote Procedure M90402 Edition 0248
MAN B&W Diesel A/S
 Crosshead 904-2.4
Mounting

4. Lower the other guide shoe.

4.
Use the guide shoe extractor tool to push
the crosshead towards the second guide D04
22
shoe.

Remove the extractor tool and adjust the

position of the opposite guide shoe.

5. Mount the guide plates on the side of the

guide shoes.

Tighten the screws and lock them with

locking wire.

M90402
0248D12
See Procedure 913-7.

Remove the eye-bolts from the guide

shoes.

Use the tackles in the fore and aft eyebolts 5.

to lift the crosshead to a working position
and mount the guide strips on the side of
the guide shoes.

Tighten the screws and lock them with

locking wire.
See Procedure 913-7.

6. Using the tackles, lift the connecting rod to

a vertical position while turning the
crankthrow to BDC.
M90402
0248M05

D04
12
D04
13

6.

D04
50
M90402
0248M06

When referring to this page, please quote Procedure M90402 Edition 0248 Page 7 (9)
MAN B&W Diesel A/S
904-2.4 Crosshead
Mounting

7. When the connecting rod is in a vertical

7. position, lower the crosshead and land it
on the connecting rod.

Remove the lifting attachments from the

connecting rod head.

Remove the lifting tool from the crosshead.

8. Lift the crosshead bearing cap into the en-

gine.
D04
21
9. Mount the spacer rings and the hydraulic
jacks for tightening the nuts on the cross-
M90402
0248D07

head bearing studs.

For operation of the hydraulic tools, see

Procedure 913.

8. Mount the drain oil slotted pipe and the

cooling oil outlet pipe on the guide shoe.

D04
04 Turn the crankshaft to TDC.

Land the telescopic pipe on the guide

shoe.
M90402
0248D06

9.

D13
01
M90402
0248M09

Page 8 (9) When referring to this page, please quote Procedure M90402 Edition 0248
MAN B&W Diesel A/S
 Crosshead 904-2.4
Mounting

10. For tightening the bolt in the corner behind

the telescopic pipe, use the offset tool 10.
along with the torque wrench.

Mount the cooling oil outlet pipe. D04
08 D04
15

D04
19
11. Mount the lubricating oil pipes on the main
bearing caps.

12. Mount the piston.

See Procedure 902-1.4.

13. Remove all tools from the engine.

M90402
0248M10
Note!
Always search the crankcase to ensure
that there are no tools, shackles or rags
left behind.
11.
M90402
0248M11

12.
M90402
0248M12

When referring to this page, please quote Procedure M90402 Edition 0248 Page 9 (9)
MAN B&W Diesel A/S
 Reciprocating Parts 104-3
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D04-25 PF+PA, N max. 0.6 mm

D04-26 PF+PA, O max. 1.1 mm
D04-28 E+G, H+F, N max. 0.55 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.85 mm
D04-34 J+X, L+Y, K+X, M+Y, N max. 0.9 mm
D04-35 J+X, L+Y, K+X, M+Y, N min. 0.5 mm
D04-36 J+X, L+Y, K+X, M+Y, O max. 1.1 mm
D04-41 ZF/ZA O min. 5 mm
N: New and cold engine with staybolts tightened
(less than 100 running hours).
O: Engine in service.

When referring to this page, please quote Data D10403 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data

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

Plate Item No. Description

P91366 58 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10403 Edition 0041
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.

When referring to this page, please quote Procedure M90403 Edition 0217 Page 1 (3)
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

Page 2 (3) When referring to this page, please quote Procedure M90403 Edition 0217
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

When referring to this page, please quote Procedure M90403 Edition 0217 Page 3 (3)
0$1% :'LHVHO$6
 Crankpin Bearing 104-4
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D04-43 Crankpin bearing clearance, max. 0.7 mm

D04-44 Crankpin bearing clearance, min. 0.45 mm
D04-46 Crankpin bearing, upper shell 35 kg
D04-47 Crankpin bearing, lower shell 28 kg
D04-48 Crankpin bearing cap + shell + bearing studs 260 kg

When referring to this page, please quote Data D10404 Edition 0052 Page 1 (2)
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

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

Plate Item No. Description

P90451 59 Lifting attachment - connecting rod

P90451 96 Bracket for support, Cross Head
P90451 106 Bracket for support, Cross Head
P90461 Connecting Rod - Hydraulic Tools
P90462 59 Lifting tool for crankshaft shell
P91351 10 Hydraulic pump, pneumatic operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91356 Lifting Tools, Etc.
P91366 58 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10404 Edition 0052
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.1
Checking

The bottom clearance between the journal and 2.

a new bearing shell is the result of a summa-
tion of the production tolerances of the bearing
assembly components.

For the bottom clearance of a specific bearing,

see the measurement in the Adjustment Sheet
in Volume I, OPERATION.

1. Open the crankcase door at the relevant

cylinder.

2. Turn the crank concerned to BDC.

M90404
0231C02
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-
ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2. D04
43
D04
44
5. The wear limit for the crankpin bearing
shells is based on an evaluation of the
bearing condition at the time of inspection.
M90404
0231C03

An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.

6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in
the instruction book, Volume I, OPERA- 5.
TION.
M90404
0231C05

When referring to this page, please quote Procedure M90404 Edition 0231 Page 1 (8)
MAN B&W Diesel A/S
904-4.2 Crankpin Bearing
Dismantling

1. Turn the crank to BDC.

2.
2. Suspend two tackles from the lifting brack-
ets, in the athwartship direction.

3. Turn the crank to TDC.

Mount eye bolts in each side of the crank-

pin bearing cap and, using shackles and
wire ropes, hook on the tackles and haul
tight.

Loosen the crankpin bearing stud nuts, us-

ing the hydraulic jacks.
M90404
0231D02

For operation of the hydraulic jacks, see

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.
D13
02
Inspect the bearing shell.

For evaluation of bearings, see Volume I,

Chapter 708.
M90404
0231D03

4.

D04
48
M90404
0231D04

Page 2 (8) When referring to this page, please quote M90404 Edition 0231
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.2
Dismantling

5. If the bearing shell needs to be replaced,

remove the whole bearing cap from the 5.
crankcase.

Hook the tackle on to an eye bolt on one

side of the bearing cap.

Mount the wire guide in the top of the

crankcase door opening. D04
48
Using the tackle from the frame box inside
wall, together with a tackle suspended from
the platform bracket, lift the bearing cap
out of the crankcase.

M90404
0231D05
6. Place the bearing cap on one side on a
couple of planks.

Dismount the bearing shell lock screws and

replace the bearing shell by a new one. 6.

Note! D04
47
Normally bearing shells are replaced in
pairs.

If only one of the shells needs replace-

ment, MAN B&W Diesel should be con-
tacted for advice beforehand.

7. Turn to TDC.
M90404
0231D06

Mount the four supports for guide shoes

on the crosshead guides.

Carefully turn the crank down until the

guide shoes rest on the supports. 7.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.
M90404
0231D07

When referring to this page, please quote Procedure M90404 Edition 0231 Page 3 (8)
MAN B&W Diesel A/S
904-4.2 Crankpin Bearing
Dismantling

8. Mount a lifting attachment for securing the

8. connecting rod at the lower end, on one
side.

Hook on the tackle to a beam under the

gallery platform and haul tight.

9. Carefully turn the crankshaft downwards,

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
M90404
0231D08

Continue turning the crankshaft until the

bearing surface can be freely inspected.

Inspect the bearing shell surface and the

crankpin journal.
9.
10. If it is necessary to replace the bearing
shell, proceed as follows:

Turn the crankshaft to HORIZONTAL.

Release the tackle so that the connecting

rod is hanging freely.
M90404
0231D09

10.
M90404
0231D10

Page 4 (8) When referring to this page, please quote M90404 Edition 0231
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.2
Dismantling

11. Mount an eye bolt in the bottom of each

guide shoe. 11.

Suspend two tackles from the eye bolts.

12. Place the lifting tool for the crankpin upper

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

Mount the tool on the bearing shell in the

connecting rod, using the tackles, and haul
tight.

13. Dismount the bearing shell lock screws.

M90404
0231D11
Lower the lifting tool with the bearing shell,
using the tackles.

12.
M90404
0231D12

13.

D04
46
M90404
0231D13

When referring to this page, please quote Procedure M90404 Edition 0231 Page 5 (8)
MAN B&W Diesel A/S
904-4.4 Crankpin Bearing
Mounting

1. Bearing shells of three mm undersize are

1. available as spares in case of journal recti-
fication. Please contact MAN B&W Diesel
for advice.

Coat the bearing shell surfaces and the

journal with clean oil.

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell,
and must not be eliminated.

2. Lift the upper bearing shell for the crankpin

concerned into the crankcase.
M90404
0231M01

Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.

2. 3. Remove the lifting tool, the tackles and the

eye bolts from the guide shoes.

D04
46
M90404
0231M02

3.
M90404
0231M03

Page 6 (8) When referring to this page, please quote Procedure M90404 Edition 0231
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.4
Mounting

4. Hook the tackle on to a beam under the

gallery platform and on to the lifting attach- 4.
ment on the connecting rod, and haul tight.

Carefully turn the crankshaft upwards,

while following up with the tackle, making
sure that the upper part of t he bearing en-
ters the recess in the crankshaft when the
parts turn together.

Remove the tackle and the lifting attach-

ment from the connecting rod.

5. Turn the crosshead to TDC.

M90404
0231M04
Remove the guide shoe support brackets
from the crosshead guides.

5.
M90404
0231M05

When referring to this page, please quote Procedure M90404 Edition 0231 Page 7 (8)
MAN B&W Diesel A/S
904-4.4 Crankpin Bearing
Mounting

6. Suspend the tackles from the lifting brack-

6. ets in the top of the frame box.

Lift the bearing cap assembly into the

crankcase and land it on a couple of
planks placed in the oil pan.

7. Hook the tackles on to the wire ropes and

D04
48 lift the bearing cap into position against the
connecting rod.

Caution!
During mounting, take care that the
M90404
0231M06

studs do not damage the crankpin jour-

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

7. Mount the nuts and, by means of spacer

rings and hydraulic jacks, tighten the
crankpin bearing cap. See Data.

For operation of hydraulic jacks, see Sec-

tion 913.

Remove the tackles from the top of the

frame box.

Check the bearing clearance.

See Procedure 904-4.1.
M90404
0231M07

D13
01

Page 8 (8) When referring to this page, please quote Procedure M90404 Edition 0231
MAN B&W Diesel A/S
 Connecting Rod 104-5
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D04-48 Crankpin bearing cap + shell + bearing studs 260 kg

D04-50 Connecting rod, without bearing caps 1850 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10405 Edition 0051 Page 1 (2)
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

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

Plate Item No. Description

P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod
P90451 96 Bracket for support, Cross Head
P90451 106 Bracket for support, Cross Head
P90461 Connecting Rod - Hydraulic Tools
P91351 10 Hydraulic pump, pneumatic operated
P91351 46 Hose with unions (1500 mm), complete
P91351 60 Hose with unions (5000 mm), complete
P91351 105 3-way distributor block, complete
P91356 Lifting Tools, etc.

Page 2 (2) When referring to this page, please quote Data D10405 Edition 0051
MAN B&W Diesel A/S
 Connecting Rod 904-5.2
Dismantling
Connecting Rod
S46MC-C
0228
Dismantling
904-5.2

1.
1. Turn the crank to BDC.

Dismount the crosshead bearing stud nuts.

See Procedure 904-1.2.

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

case in the lifting brackets, in the athwart-
ship direction, and suspend two tackles.

3. Turn the crank to TDC.

Dismount the crankpin bearing cap, and re-

move the bearing cap from the engine. D13-02

HN904-5.2 217 01
See Procedure 904-4.2.

HN904-5.2 217 02 2.

3.
D13-02

D04-48
GN904-5.2 225 03

When referring to this page, please quote Procedure M90405 Edition 0228 Page 1 (7)
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling

4. 4. Mount the four supports for guide shoes on

the crosshead guides.

Carefully turn the crank down towards the

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

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.

5. Mount the lifting attachments for securing

the connecting rod on the head of the con-
HN904-5.2 217 04

necting rod.

Fasten tackles to lifting brackets A and B on

the frame box wall, and attach the tackle
hooks to the mentioned lifting attachments
5. on the connecting rod head.

D04-50 Haul the tackles tight.

A B
Also mount a lifting attachment on the lower
end of the connecting rod, on the exhaust
side.

6. Turn the crankthrow carefully towards BDC

C while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.

The crosshead now rests on the four sup-

ports.
GN904-5.2 225 05

Turn the crankthrow to 90° before BDC.

6.

A B

C
GN904-5.2 225 06

Page 2 (7) When referring to this page, please quote Procedure M90405 Edition 0228
0$1% :'LHVHO$6
 Connecting Rod 904-5.2
Dismantling

7. Shift tackle B from the lifting attachment on 7.

one side of the connecting rod to the lifting
attachment on the other side.
AA
A B
Dismount the lifting attachment on the cam-
shaft side of the connecting rod.

Attach a tackle to lifting bracket C on the

C
frame box wall and connect the tackle hook
to the lifting attachment on the lower end of
the connecting rod.

Mount the wire guide on the door frame.

GN904-5.2 225 07
Turn the crankthrow towards TDC while ‘fol-
lowing’ with the tackles, thus continuously
supporting and guiding the connecting rod
towards the doorway.
8.
8. Attach a tackle to the gallery-mounted lift-
ing bracket E, and hook on to the lifting at-
tachment on the connecting rod. A B E

Shift tackle A from the lifting attachment on

the head of the connecting rod to the lifting
attachment at the bottom of the connecting
rod. C

Turn the crank carefully upwards while ‘fol-

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

Shift the tackles from one lifting attachment

to the other as necessary.

9. Mount a strap around the connecting rod 9.

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

Remove tackles A and E.

C
Continue turning upwards till about 30° af-
ter TDC while ‘following’ with the tackles
and the engine room crane.
GN904-5.2 225 09

When referring to this page, please quote Procedure M90405 Edition 0228 Page 3 (7)
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling

10. 10. Shift the tackle from lifting bracket C to A.

Lift the connecting rod out of the engine,

A B E using the tackles and the engine room
crane.

Remove the tackles, and lift the connecting

rod away by means of the engine room
crane.
C
GN904-5.2 225 10

Page 4 (7) When referring to this page, please quote Procedure M90405 Edition 0228
0$1% :'LHVHO$6
 Connecting Rod 904-5.4
Mounting
Mounting
904-5.4

1. Equip the connecting rod with the same lift- 2.

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

2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine
room crane and the tackles attached to lift-

GN904-5.2 225 10
ing brackets A and B.

3. When the end of the connecting rod rests

on the crankpin journal, attach a tackle to
bracket C and the lower end of the connec-
ting rod. 3.

4. Turn the crankthrow towards BDC, past

A B E
TDC, while ‘following’ with the tackles and
the engine room crane.

Attach tackle B to the upper end of the con-

necting rod.
C
Attach a tackle to bracket E and the upper
end of the connecting rod.

Haul tight and remove the strap around the

GN904-5.4 225 03

connecting rod.

4.

A B E

C
GN904-5.4 225 04

When referring to this page, please quote Procedure M90405 Edition 0228 Page 5 (7)
0$1% :'LHVHO$6
904-5.4 Connecting Rod
Mounting

5. 5. Turn the crankthrow to 90° before BDC.

Shift tackle A from the lower end to the top

A B E of the connecting rod.

Remove the tackle at E.

Shift tackle B from the lifting attachment on

C one side to the other side of the connecting
rod.

Remove the tackle at C and the wire guide

on the door frame.
GN904-5.4 225 05

Remove the lifting attachment at the lower

end of the connecting rod.

6. Turn the crankthrow towards TDC while ‘fol-

6. lowing’ with the tackles.

Caution!

Take care that the studs do not damage

the crosshead bearing shell.

7. When the crank is in TDC, mount the crank-

pin bearing cap.
See Procedure 904-4.4.
GN904-5.4 225 06

7.

D13-01
GN904-5.4 225 07

Page 6 (7) When referring to this page, please quote Procedure M90405 Edition 0228
0$1% :'LHVHO$6
 Connecting Rod 904-5.4
Mounting

8. Remove the four supports from the cross- 8.

head guides and the lifting attachments
from the connecting rod.

Turn the crosshead down far enough to fa-

cilitate the tightening of the nuts.

9. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.

GN904-5.4 225 08
HN904-5.2 217 01 9.

D13-01

When referring to this page, please quote Procedure M90405 Edition 0228 Page 7 (7)
0$1% :'LHVHO$6
 Connecting Rod and Crosshead Panel Plate
P90451-0149

When referring to this page, please quote Plate P90451 Edition 0149 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0149

Item Item Description Item Item Description

No. No.

011 Panel for tools

023 Name plate
047 Wire guide, main bearing
059 Lifting attchment, connecting rod
060 Lifting tool, crosshead
072 Chain, suspension of piston
084 Retaining tool, telescope pipe
096 Bracket, support of crosshead
106 Bracket, support of crosshead
118 Rubber cover for crosshead
120 Rubber cover for crosshead
214 Offsett tool, torque spanner

Page 2 (2) When referring to this page, please quote Plate P90451 Edition 0149
MAN B&W Diesel A/S
 Connecting Rod - Hydraulic Tools Plate
P90461-0068

When referring to this page, please quote Plate P90461 Edition 0068 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0068

Item Item Description Item Item Description

No. No.

028 Hydraulic jack

030 Support
041 Tommy bar
053 O-ring with back-up ring
065 O-ring with back-up ring
089 Spanner
100 Stud setter
207 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90461 Edition 0068
MAN B&W Diesel A/S
 Connecting Rod - Tools Plate
P90462-0034

When referring to this page, please quote Plate P90462 Edition 0034 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0034

Item Item Description Item Item Description

No. No.

011 Lifting tool for crankpin shell

Page 2 (2) When referring to this page, please quote Plate P90462 Edition 0034
MAN B&W Diesel A/S
 Crosshead - Hydraulic Tools Plate
P90464-0005

When referring to this page, please quote Plate P90464 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Crosshead - Hydraulic Tools
P90464-0005

Item Item Description Item Item Description

No. No.

024 Jack-hydrualic, complete

036 Support
048 Tommy bar
050 O-ring with back-up ring
061 O-ring with back-up ring
085 Key, hexagon socket screw
107 Stud setter
203 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90464 Edition 0005
MAN B&W Diesel A/S
 Crosshead - Tools Plate
P90465-0001

When referring to this page, please quote Plate P90465 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Crosshead - Tools
P90465-0001

Item Item Description Item Item Description

No. No.

018 Guide shoe extractor

Page 2 (2) When referring to this page, please quote Plate P90465 Edition 0001
MAN B&W Diesel A/S
905 - Crankshaft, Thrust Bearing and Turning Gear

Documents in this Chapter

105-02 0073 Main Bearing, Data

905-02 0247 Main Bearing
105-03 0064 Thrust Bearing, Data
905-03 0242 Thrust Bearing
105-04 0037 Journal Bearing, Data
905-04 0227 Journal Bearing
105-05 0052 Axial Vibration Damper, Data
905-05 0231 Axial Vibration Damper
90551 0229 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0133 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90570 0001 Thrust Shaft - Tools
90572 0005 Main Bearing - Measuring Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Main Bearing 105-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D05-01 Main bearing, top clearance max. 0,75 mm

D05-02 Main bearing, top clearance min. 0,45 mm
D05-03 Main bearing cap 510 kg
D05-04 Main bearing shell, upper 35 kg
D05-05 Main bearing shell, lower 36 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10502 Edition 0073 Page 1 (2)
MAN B&W Diesel A/S
105-2 Main Bearing
Data

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

Plate Item No. Description

P90551 40 Pulley for wire for main bearing

P90551 76 Lifting tool - main bearing cap
P90551 88 Dismantling tool, main bearing shell
P90551 90 Mounting tool for bearing shell
P90551 184 Lifting tool for main bearing shell
P90551 220 Wire guide
P90561 Main Bearing - Hydraulic Tools
P90562 Lifting tool for crankshaft
P90572 Main Bearing - Measuring Tools
P91351 10 Hydraulic pump, pneumatic operated
P91351 22 Hydraulic pump, hand operated
P91351 117 5-way distributor block, complete
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91356 Lifting Tools, Etc.
P91366 48 Autolog, measuring tool for crankshaft

Page 2 (2) When referring to this page, please quote Data D10502 Edition 0073
MAN B&W Diesel A/S
 Main Bearing 905-2.1
Checking
Main Bearing
S60MC-C
0247
Checking
905-2.1

1.
General

The condition of the main bearings (and the jour-

nal bearing) 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

When referring to this page, please quote Procedure M90502 Edition 0247 Page 1 (21)
MAN B&W Diesel A/S
905-2.1 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 or-

der 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.

Page 2 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.1
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.

When referring to this page, please quote Procedure M90502 Edition 0247 Page 3 (21)
MAN B&W Diesel A/S
905-2.1 Main Bearing
Checking

8. 8. If there is too large a difference in the

crankshaft deflection readings (autolog)
check the clearance in the individual bear-
ings.

Bearing clearance checks should also be

carried out during time-based overhauls
KN905-1.1 208 08

and surveys.

If there is a suspicion of a damaged bear-

ing, it is recommended to edge check the
9. bearing, without opening up.

9. Before measuring, check that the feeler

blades are in good condition.

The feeler is inserted along the crank throw.

When the feeler hits the journal, it is hori-
zontally pushed against the clearance. Now
the feeler blade is pushed max. 20 mm into
the gap.
KN905-1.1 208 09

10. The clearance is measured at both the fore

20
and the aft part of the bearing.

Note!
10.
The bearing clearances for a new bear-
ing stated in Data ( see Data 105-2) are
for guidance purposes only.
KN905-1.1 208 10

Page 4 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.1
Checking

11. The difference between the actual clear-

ance measurement and the measurement
recorded in the adjustment sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.

For evaluation of the bearing, see Volume

I, Operation, Chapter 708.

If the bearing needs to be disassembled for

inspection, see procedure 905-2.2.

HN905-2.1 227 03

When referring to this page, please quote Procedure M90502 Edition 0247 Page 5 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling
Dismantling
905-2.2

1. Positioning the crankshaft

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

Thrust bearing 3. Turn the crank throw to the position shown

on the sketch and in such a way that the top
2. of the studs is flush with the crank throw.

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

Page 6 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

4.
Oil pipes

4. Disconnect the lubricating oil pipe from the

main pipe.

Note!

On some engines, the oil pipes for the

Axial Vibration Damper (AVD) have to be
removed together with the oil pipe on
main bearing No. 1.

KN905-2.2 238 04
Note!

Some engines have temperature sensors

fitted to the main, crosshead, and crank-
pin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.

When referring to this page, please quote Procedure M90502 Edition 0247 Page 7 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

1. Mounting of tools and tackles

1. Mount pulley E on the web plate above the

bearing cap.

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

vertically and free of the bearing studs.
HN905-2.2 245 02

2.
HN905-2.2 227 03

Page 8 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

3. Mount pulley F in the bottom of the guide 3.

shoe.

On some engines the pulley is mounted in

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

5. Mount an eye bolt on the opposite web

plate.

HN905-2.2 227 04
The eye bolt is used in connection with a
pull lift, to keep the main bearing cap clear
of the guides when it is lifted out of the en-
gine. HN905-2.2 227 05 4.

5.
HN905-2.2 227 06

When referring to this page, please quote Procedure M90502 Edition 0247 Page 9 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

6. B A 6. Mount tackles in the following positions:

A. Suspended from a wire strap below the

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

B. In the lifting bracket in the top of the

crankcase, camshaft side.
D
C. In the lifting bracket below the doorway.
KN905-2.2 238 06

D. In the eye bolt on the web plate opposite

C
the pulleys.

Mount the wire guide in the top of the door-

7. way.

7. Assemble the main bearing hydraulic jacks

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

Remove the hydraulic main bearing tools

from the engine.

Unscrew and remove the nuts from the

main bearing studs.

For operation of the hydraulic tools, see

Procedure 913-1.
GN913-1.0 203 22

8. Mount the main bearing lifting tool on the

main bearing cap, and place the wire rope
as shown.

8.
HN905-2.2 227 09

Page 10 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

9. Attach tackle A to the wire rope and care- 9.

fully lift the main bearing cap clear of the
studs.

10. The lifting tool has one free wire rope.

Place this wire rope around the wheel of
pulley F mounted in the guide shoe. Hook
the wire rope on to the chain of tackle C.

11. Tighten tackle C and release tackle A, until D05-03

the main bearing cap is suspended vertical-
ly below pulley F.

HN905-2.2 22710 10.

C
HN905-2.2 227 11

11.

F
C

D05-03
HN905-2.2 227 12

When referring to this page, please quote Procedure M90502 Edition 0247 Page 11 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

12. 12. Release tackle A from the wire rope of the

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

13. Hook the chain of tackle D on to the short

wire rope mounted on the main bearing lift-
ing tool.

Tighten tackle D and release tackle C at the

HN905-2.2 227 13

same time, to get the bearing cap clear of

the guides.

14. Attach the hook from tackle A around the

wire rope of tackle B to keep the wire rope
13. free from the crosshead and guide plates.

F At the same time, release tackle C until the

main bearing cap is suspended vertically
C below tackle B.

D
HN905-2.2 227 14

14.
KN905-2.2 238 20

Page 12 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

15.
15. When the main bearing cap is hanging ver-
tically below tackle B, remove tackle C and A
B
the wire rope around pulley F.

Remove the hook of tackle A from the wire

rope of tackle B.

Attach tackle A to the short wire rope on the

main bearing cap lifting tool.

Note! D

Make sure that the wire rope of the main D05-03

KN905-2.2 238 21
bearing lifting tool does not scrape
against the edges of the guide shoe. C

16. Mount the free wire rope in tackle A.

16.
Now lift the bearing cap out of the engine A
B
and place it on a couple of wooden planks.

Removal of upper bearing shell

17. Mount the bearing shell lifting tool on the

upper main bearing shell, and remove the
shell, using pulley F.

Lift the upper bearing shell out of the en-

gine in the same way as the bearing cap. D
KN905-2.2 238 22

17.

D05-04
KN905-2.2 238 23

When referring to this page, please quote Procedure M90502 Edition 0247 Page 13 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

18. 18. If the crankshaft is turned with the bearing

cap dismounted, use the two stops to pre-
vent the lower shell from being rolled out.

19. Place the crosspiece in the bedplate with

the ends resting on the cross girders, and
position the hydraulic jacks beneath the
web plate as shown.

Tighten the screws against the crank webs

and compress the jacks.

Connect the hydraulic jacks to the high-

KN905-2.2 238 24

pressure pump, and raise the pressure until

the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.

19. Note down the pressure for later reference.

20. Check that there is min. 0.1 mm clearance

between journal and bearing shell, or be-
tween bearing shell and main bearing sup-
port, on both sides of the journal.

If the clearance is less than 0.1 mm, move

the crosspiece sideways until clearance is
obtained. Normally, adjustment needs to be
50-150 mm to the exhaust side (the side
where the clearance is missing).
KN905-2.2 238 27

Note!

The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
relief in the bearing shell.
20.
Min. 0,1 mm

Note!

The lower shell must be lifted out to the

side with the most clearance, which is
normally the camshaft side.

EXH CAM
KN905-2.2 238 28
Min. 60 mm

Page 14 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

21. If repositioning of the crosspiece does not 21.

ensure a vertical lift, place a 5-tonne jack
between the side wall and the crank throw,
to correct the journal position in this way.

If it is available, note down the pressure ap-

plied to the jack. This data is used to en-
sure that the crankshaft is in the same
position when the new bearing is installed.

22. Dismount the locking screws.

Place the dismantling tool on top of the low-

KN905-2.2 238 25
er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.

Note! 22.

It is recommended that the crankshaft lift-

ing tool is only removed if it is urgently
necessary and then only after the main
bearing shell has been reinstalled.
KN905-2.2 238 26

When referring to this page, please quote Procedure M90502 Edition 0247 Page 15 (21)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

23. 23. Pull the lower shell around and up until it

lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.

24. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.

Note!

While pulling out the shell, it is recom-

mended to hold a foot or hand on the wire
rope, to tighten it up and to observe
whether the shell is sticking.
JM905-2.2 236 27

24.

D05-05
HN905-2.2 227 19

Page 16 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.3
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.

When referring to this page, please quote Procedure M90502 Edition 0247 Page 17 (21)
MAN B&W Diesel A/S
905-2.4 Main Bearing
Mounting
Mounting
905-2.4

1. 1. Clean and lubricate the journal, the lower

bearing shell and the bearing support with
clean oil.

Place the dismantling tool between the

bearing journal and the bearing support.

Place the guide tool for the lower bearing

shell on the main bearing support.

2. Using the bearing shell lifting tool, the pul-

leys and tackles, lift the lower bearing shell
into the crankcase and land it on the crank-
HN905-2.4 227 01

shaft journal. Remove the lifting tool from

the bearing shell.

Check that the hydraulic pressure to the

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

3. Using the dismantling tool, lower the bear-

ing shell down between journal and sup-
port.

D05-05 Remove the dismantling tool and push the

shell entirely down with a piece of wood, for
instance a hammer handle.

To ensure that the shell is correctly mount-

ed, check that the distance from the main
HN905-2.2 227 19

bearing support to the shell is equal in both

sides.

3.
HN905-2.4 227 03

Page 18 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.4
Mounting

4. Remove the guide tool when the lower 4.

bearing shell has been mounted.

Mount the locking screws in the bearing

support.

Check with a feeler gauge that there is

clearance around the head of the locking
screws, to ensure correct centering of the
bearing shell.

XZS905-13 07
5. Lower the crankshaft and remove the hy-
draulic jacks and the crosspiece from below
the crankshaft.
5.
Wipe the contact surfaces between the up- D05-04
per and the lower bearing shells clean with
a non-fluffy piece of cloth.

6. Land the upper bearing shell on the main

journal in the same way as the lower bear-
ing shell.
XZS905-13 09

Make sure that none of the edges of the up-

per bearing shell are resting on the edge of
the bearing support.

If necessary, place the special tool between 7.

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- D05-03
es.

7. Mount the lifting tool on the bearing cap.

HN905-2.2 227 18

Using the lifting tool and the tackles lift the

bearing cap into the crankcase in the re-
verse order to dismantling.
See Procedure 905-2.2.

8. Using the pulleys mounted inside the crank- 8.

case, move the bearing cap into position
vertically above the main bearing upper
shell in the reverse order to dismantling.
See Procedure 905-2.2.
KN905-2.2 238 20

When referring to this page, please quote Procedure M90502 Edition 0247 Page 19 (21)
MAN B&W Diesel A/S
905-2.4 Main Bearing
Mounting

9. 9. Land the bearing cap carefully on the upper

bearing shell, using the bearing cap lifting
tool .

Check that the spring pin in the support en-

ters the hole in the bearing cap.

Take care not to displace the upper bearing

shell.

10. Remove the lifting tool from the bearing

cap.
KN905-2.4 238 09

Screw the nuts on to the main bearing

studs.

Using a tommy bar, tighten in small alter-

nate steps the nuts on both sides of the
10. bearing cap.

11. Assemble the main bearing hydraulic jacks

on the bearing studs.
KN905-2.4 238 10

11.
GN9913-1.0 203 22

Page 20 (21) When referring to this page, please quote Procedure M90502 Edition 0247
MAN B&W Diesel A/S
 Main Bearing 905-2.4
Mounting

12. Connect the hydraulic jacks to the high 12.

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

Using the hydraulic jacks, fully tighten the

nuts on both sides of the bearing cap.

For tightening pressure, see Data.

For operation of the hydraulic tools,

HN905-2.4 227 11
see Procedure 913-1.

13. Remove the bearing cap lifting tool.

Note! 13.
Before removing the hydraulic jacks,
check the top clearance between the
upper bearing shell and the journal.

14. Remove all the tools from the engine.

Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left D05-01
KN 905-1.1 208 09

behind. 20 D05-02

14.
KN905-2.4 238 14

When referring to this page, please quote Procedure M90502 Edition 0247 Page 21 (21)
MAN B&W Diesel A/S
 Thrust Bearings 105-3
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D05-06 Thrust bearing segment 66 kg

D05-07 Segment stopper 47 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10503 Edition 0064 Page 1 (2)
MAN B&W Diesel A/S
105-3 Thrust Bearings
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

P90551 100 Tool for turning out segments

P90563 Segment Stopper - Hydraulic Tools
P91351 10 Hydraulic pump, pneumatic operated
P91351 34 Hose with unions (1000 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D10503 Edition 0064
MAN B&W Diesel A/S
 Thrust Bearings 905-3.1
Checking

The clearance in the thrust bearing was mea-

sured during testbed trials of the engine and 1.
noted down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.

For a new engine the clearance is 0.5-1.0 mm,

and for an engine in service it must not exceed
2.0 mm.

In service it is only necessary to measure the

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.

1. To measure the wear in the thrust bearing,

M90503
0242C01
it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.

A wear groove of 1 mm is positioned in the 2.

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 suit-
able 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.
M90503
0224C02

Note down the wear for later reference.

3.
M90502
0238D02

When referring to this page, please quote Procedure M90503Edition 0242 Page 1 (5)
MAN B&W Diesel A/S
905-3.2 Thrust Bearings
Dismantling

1. Remove the end cover of the engine.

1.
Remove the lub. oil pipe from the thrust
segments.

If necessary, remove the lub. oil pipe for

the aftmost main bearing shell.

2. Remove the protective shields from the

thrust collar.

Loosen and remove the nuts from the seg-

ment stoppers.
For operation of the hydraulic jacks, see
M90503
0242D01

Procedure 913-1.

Screw an eye bolt into the stoppers that

are to be removed.

2. Suspend a tackle above each stopper and

hook the tackle on to the eye bolt.

Remove the stoppers from the chain drive

above the thrust segments (AHEAD or
ASTERN) that are to be taken out.

D05
07
D13
01
D13
02
M90503
0242D02

Page 2 (5) When referring to this page, please quote Procedure M90503Edition 0242
MAN B&W Diesel A/S
 Thrust Bearings 905-3.2
Dismantling

3. Suspend a tackle from the chain tightener

bracket above the segments which are to 1.
be removed.

For turning-up the thrust segments, mount

the segment tool on the thrust collar.

4. Turn up the segments by turning the en-

gine, and remove them from the chain cas-
ing.

M90503
0242D03
2.
M90503
0242D04

When referring to this page, please quote Procedure M90503Edition 0242 Page 3 (5)
MAN B&W Diesel A/S
905-3.4 Thrust Bearings
Mounting

1. Suspend a tackle from the crossbar above

1. the segments which are to be mounted.
D05
06
Mount the segment tool on the thrust col-
lar.

Land the segment on the journal and re-

move the eye bolt from the segment.

Turn the shaft a little. Land the next seg-

ment. Repeat this process until all seg-
ments have been mounted.
M90503
0242M01

2. After the last segment has been mounted,

turn the segment tool up and dismount it.

2.
M90503
0242M02

3.

Page 4 (5) When referring to this page, please quote Procedure M90503Edition 0242
MAN B&W Diesel A/S
 Thrust Bearings 905-3 .4
Mounting

3. Mount the protective shields for the thrust

collar. 5.

4. Mount the segment stoppers.

Mount the hydraulic jacks and tighten the

nuts on the stoppers. See data.

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

ments.

If dismantled, mount the lub. oil pipe for

the aftmost main bearing.

M90503
0242M05
6. Mount the end cover.

When referring to this page, please quote Procedure M90503Edition 0242 Page 5 (5)
MAN B&W Diesel A/S
 Journal Bearing 105-4
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D05-11 Min. bearing clearance 0.45 mm

D05-12 Max. bearing clearance 0.75 mm
D05-13 Journal bearing cap 510 kg
D05-14 Upper bearing shell 35 kg
D05-15 Lower bearing shell 36 kg
D05-16 End cover 225 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10504 Edition 0037 Page 1 (2)
MAN B&W Diesel A/S
105-4 Journal Bearing
Data

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

Plate Item No. Description

P90551 088 Dismantling tool, main bearing shell

P90551 090 Mounting tool for bearing shell
P90551 111 Lifting attachment
P90551 172 Mounting tool, thin bearing shell
P90561 Main Bearing - Hydraulic Tools
P90562 Crankshaft - Tools
P91351 010 Hydraulic pump, pneumatically operated
P91351 046 Hose with unions (1500 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91356 Lifting Tools, Etc.
P91366 058 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10504 Edition 0037
MAN B&W Diesel A/S
 Journal Bearing 905-4.1
Checking

1. Check the journal bearing in the same way Aftmost main bearing (= Journal bearing)
1.
as the remaining main bearings, see Proce-
dure 905-2.1.

2. Write down the journal bearing clearances.

3. Also check the journal bearing by visually

searching the area underneath the bearing
support for bearing material.

M90502
0238D01
Main bearings

Thrust bearing

2.
M90502
0238D02

3.
M90504
0226C03

When referring to this page, please quote Procedure M90504 Edition 0227 Page 1 (9)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling

1. Dismount the screws for the end cover.

2.
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 horizontal position. Remove other
M90504
0227D02

piping if necessary.

3. Mount the extension studs, the spacers,

the hydraulic jacks and the nuts on the ex-
tension studs. Loosen the bearing stud
3. nuts, using the hydraulic jacks

For operation of the hydraulic tools, see

Procedure 913-1.

4. Remove the hydraulic main bearing tools

from the engine

Unscrew and remove the nuts from the

bearing studs.

D13
02
M90504
0227D03

4.
M90504
0227D04

Page 2 (9) When referring to this page, please quote Procedure M90504 Edition 0227
MAN B&W Diesel A/S
 Journal Bearing 905-4.2
Dismantling

Note! 5.
As piping may vary, the amount of pip-
ing necessary to be removed may also
vary.
D05
13
5. Mount the lifting attachment on the journal
bearing cap, and lift the cap out of the en-
gine using the ½-ton tackle.

Use a pull lift mounted on the opposite

webplate to guide the vertical lift.

6. Mount a tackle on the lifting beam on the

M90504
0227D05
exhaust side engine gallery.

Lift the journal bearing cap out through the

cut-out in the engine wall in the exhaust
side.
6.
7. Mount the lifting attachment on the upper
shell, and lift the shell out of the engine.
M90504
0227D06

7.

D05
14
M90504
0227D07

When referring to this page, please quote Procedure M90504 Edition 0227 Page 3 (9)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling

8. Place the crosspiece under the turning

8. wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.

Tighten the screw against the turning wheel

and compress the jacks.

Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the adjacent
bearing.

9. Dismount the locking screws.

M90504
0227D08

Place the dismantling tool on top of the

lower bearing shell. Make sure that the flap
on the dismantling tool enters the oil
groove in the bearing shell.
9.
Pull the lower bearing shell round and up-
wards until it lies over the bearing journal.
Never use a tackle larger than ½-ton.
M90502
0238D26

Page 4 (9) When referring to this page, please quote Procedure M90504 Edition 0227
MAN B&W Diesel A/S
 Journal Bearing 905-4.2
Dismantling

10. Take the lower shell out of the engine in

the same way as the upper shell, i.e. using 10.
the lifting tool.

D05
15

M90504
0227D10

When referring to this page, please quote Procedure M90504 Edition 0227 Page 5 (9)
MAN B&W Diesel A/S
905-4.3 Journal Bearing
Overhaul

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
reinstalled.
See Instruction book, Volume I,
Chapter 708.

For advice on replacing individual bearing

shells, it is recommended to contact MAN
B&W Diesel A/S or the engine builder.
M90502
0252O01

2. Before remounting:

• Check the bearing support for damage

and burrs. If damage is found, contact
MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-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.

Page 6 (9) When referring to this page, please quote Procedure M90504 Edition 0227
MAN B&W Diesel A/S
 Journal Bearing 905-4.4
Mounting

1. Lubricate the journal, the lower bearing

shell and the bearing support with clean 1.
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 bear-

ing shell on the bearing support. Remove D05
15
the lifting tool from the bearing shell.

Lubricate the journal, the lower bearing

shell and the bearing support with clean

M90504
0227D10
oil.

Place the lower bearing shell on the journal

and push it down by hand.

To ensure that the shell is correctly 2.

mounted, check that the distance from the
bearing support to the shell is equal in
both sides.

3. Remove the guide tool when the lower

bearing shell has been mounted.

Mount the locking screws in the bearing

support.

Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from un-
M90504
0227M02

der the crankshaft.

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with
a non-fluffy piece of cloth.
3.
M90504
0227M03

When referring to this page, please quote Procedure M90504 Edition 0227 Page 7 (9)
MAN B&W Diesel A/S
905-4.4 Journal Bearing
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

upper bearing shell are resting on the edge
of the bearing support.

If necessary, place the special tool between

the studs and press the shell into place.

Clean the contact surfaces between the

bearing support and the bearing cap. Make
M90504
0227M04

sure that no oil is left on the contact sur-

faces.

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 re-
6. verse order to dismantling.
See Procedure 905-4, steps 5 and 6.

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 nuts, the spacer rings, the hy-

draulic jacks, and tighten the nuts.
See Data.
M90502
0255M05

For operation of the hydraulic tools,

see Procedure 913-1.

7.
M91301
0215D09

Page 8 (9) When referring to this page, please quote Procedure M90504 Edition 0227
MAN B&W Diesel A/S
 Journal Bearing 905-4.4
Mounting

8.
Note! 8.
Before removing the hydraulic jacks,
check the top clearance between the
upper bearing shell and the journal.
D05
11
D05
12
9. Remove all tools from the engine.

Note!
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.

M90504
0227M08
20
10. Mount all disassembled piping, and mount
the end cover.

9.
M90502
0238M14

10.
M90502
0252M13

When referring to this page, please quote Procedure M90504 Edition 0227 Page 9 (9)
MAN B&W Diesel A/S
 Axial Vibration Damper 105-5
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D05-18 Inner studs, screwing-in torque 100 Nm

D05-19 Nuts on inner studs, tightening torque 460 Nm
D05-22 Outer studs, screwing-in torque 100 Nm
D05-23 Horizontal screws, tightening torque 950 Nm
D05-24 Horizontal screws, tightening torque/angle 100/40 Nm/°
D05-25 Damper housing, upper part 600 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10505 Edition 0052 Page 1 (2)
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
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

P90464 Crosshead - Hydraulic Tools

P90551 111 Lifting attachment
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91356 Lifting Tools, Etc.
P91359 Torque Spanners
P91366 61 Slide calliper

Page 2 (2) When referring to this page, please quote Data D10505 Edition 0052
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.1
MAN B&W Diesel Checking

For checking the effectiveness of the axial vi-

bration damper, it is necessary to measure the 1.
longitudinal movements of the fore end of the
crankshaft during running.

The measurement (or reading) should be taken

at the same r/min as during the sea trials.
(Preferably 90% and 100% of MCR.)

As different equipment can have been mounted

on the specific engines, the checking proce-
dure describes three different systems:

A: Electronic, with Axial Vibration Monitor

B. 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 con-
M90505
0229C01

nected to a control unit which displays peak-

to-peak 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
given 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 Proce-
dure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0231 Page 1 (6)
905-5.1 Axial Vibration Damper
Checking MAN B&W Diesel

B: Mechanical, with angle encoder fore

1.
1. Stop the engine.

Unscrew the two plugs from the cover at

the front of the engine.

2. Mount the shaft piece in the end of the

crankshaft.

Screw the measuring arm into the small

threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.
M90505
0231C01

Attach a pencil to the arm.

Note!
2. To obtain a correct measurement, the tip
of the pencil should protrude 10 mm
from the end of the arm.
M90505
0231C02

Page 2 (6) When referring to this page, please quote Procedure M90505 Edition 0231
 Axial Vibration Damper 905-5.1
MAN B&W Diesel Checking

Start the engine, and let the speed rise to the

number of revolutions at which the measure- 3.
ment is to be taken. (Preferably 90% and
100% of MCR.)

When measuring, press the measuring arm

against the shaft piece with the one hand. With
S2
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.

M90505
0231C03
The axial movements (S2) recorded on the pa-
per must be measured with a slide calliper as
shown in the sketch.

Before comparing the measured value (S2) with

the Normal Service Value (S1), stated in Volume 4.
I, Operation, Chapter 701, it is necessary to S1
compensate for the ratio in the tool.

For a standard measuring tool (L1 = 38 mm

and L2 = 200 mm), the ratio is 5.3. Therefore,
S1 can be calculated as follows:
S2 L2
S1 = L1 S2
5.3

If a non-standard tool is used, S1 can be cal-

culated as follows:
M90505
0229C10

L1
S1 = S2 x
L2
If the peak-to-peak value exceeds the Normal
Service Value, it is necessary to overhaul the
axial vibration damper, see Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0231 Page 3 (6)
905-5.2 Axial Vibration Damper
Dismantling MAN B&W Diesel

Dismantling of the axial vibration damper is

1. carried out from the crankcase of cyl. No. 1.

1. Turn the engine to 90º after TDC.

D13
02
Unfasten 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,
see Procedure 913-1.

Loosen and remove the horizontal screws.

M90505
0229D01

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
axial vibration damper inside the chain box.

Engines without chainbox fore:

Mount a tackle below the fore end plat-
form, and remove the cover on the lifting
hole above the axial vibration damper.

3. By means of the tackle and wire rope,

M90505
0229D02

separate and raise the upper part of the

damper housing to a position at which it is
possible to change the oil seals and
springs.

3.
Warning!
Before starting the work under the sus-
pended upper part, secure the upper
D05
25
part with, e.g. a wire rope or another
tackle.
M90505
0229D03

Page 4 (6) When referring to this page, please quote Procedure M90505 Edition 0231
 Axial Vibration Damper 905-5.3
MAN B&W Diesel Overhaul

1. Dismantle and remove the springs from the

oil sealing rings. 1.

Remove the oil sealing rings.

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

When mounting the new oil sealing rings,

first insert the lower half of the rings in the
lower housing.

M90505
0229O01
Then press the tension springs into the
groove between the oil sealing ring half and
the housing.

2. Mount all the upper halves of the oil seal- 2.

ing 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 centered in
the grooves of the oil sealing rings.

Note!
The lower half of the oil sealing rings will
protrude above the centreline.
M90505
0229O02

When referring to this page, please quote Procedure M90505 Edition 0231 Page 5 (6)
905-5.4 Axial Vibration Damper
Mounting MAN B&W Diesel

1. Release and carefully lower the upper part

1. of the damper housing.

When reaching the oil sealing rings, take

care that the rings enter the sealing ring
D05
25 grooves correctly.

Before landing the upper part on the lower

part, be sure that the guide pins have en-
tered the guide pin holes.

2. Mount and tighten the vertical nuts. See

Data.
M90505
0229M01

Mount and tighten the hydraulic nuts. For

operation of the hydraulic tools, see Proce-
dure 913-1.

Mount and tighten the horizontal screws.

2. See Data.
D05
18
Note!
D05
19
Search the crankcase to ensure that
D05
22 there are no tools, shackles or rags left
behind.

D13
01
Mount the lubricating oil pipes.

D05
23 Engines without chainbox fore:

Mount the cover for the lifting hole above
D05
24 the axial vibration damper.
M90505
0229M02

Note!
After overhaul of the axial vibration
damper, it is recommended to check the
axial vibration. See Procedure 905-3.1.

Page 6 (6) When referring to this page, please quote Procedure M90505 Edition 0231
 Crankshaft, Thrust Shaft, Main Bearing, Etc. - Plate
P90551-0229
Panel

When referring to this page, please quote Plate P90551 Edition 0229 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing, Etc. -
P90551-0229
Panel
Item Item Description Item Item Description
No. No.

015 Panel for tools

027 Name plate
040 Wire pulley, main bearing
064 Wire pulley, main bearing
076 Lifting tool, main bearing cap
088 Dismantling tool, main bearing shell
090 Mounting tool, thin bearing shell
100 Tool, turning out segments
111 Lifting attachment
123 Retaining tool, main bearing shell
135 Lifting tool, relief valve
147 Lifting tool, relief valve
159 Eye bolt
160 Wire
172 Mounting tool, thin bearing shell
184 Lifting tool, main bearing shell
196 Tightening template, axial vibration
damper

Page 2 (2) When referring to this page, please quote Plate P90551 Edition 0229
MAN B&W Diesel A/S
 Main Bearing - Hydraulic Tools Plate
P90561-0064

When referring to this page, please quote Plate P90561 Edition 0064 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0064

Item Item Description Item Item Description

No. No.

021 O-ring with back-up ring

033 O-ring with back-up ring
045 Lifting tool
057 Nut
069 Hydraulic jack, upper
070 Extension stud
082 Supporting block
094 Stud setter
104 O-ring with back-up ring
116 O-ring with back-up ring
128 Hydraulic jack, lower
141 Hydraulic tool for main bearing,
complete

Page 2 (2) When referring to this page, please quote Plate P90561 Edition 0064
MAN B&W Diesel A/S
 Crankshaft - Tools Plate
MAN B&W Diesel P90562-0133

When referring to this page, please quote Plate P90562 Edition 0133 Page 1 (2)
Plate
Crankshaft - Tools
P90562-0133 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Lifting tool for crankshaft

Page 2 (2) When referring to this page, please quote Plate P90562 Edition 0133
 Turning Wheel - Tools Plate
P90563-0024

When referring to this page, please quote Plate P90563 Edition 0024 Page 1 (2)
MAN B&W Diesel A/S
Plate Turning Wheel - Tools
P90563-0024

Item Item Description Item Item Description

No. No.

022 Hydraulic jack

034 Support
046 Tommy bar
058 O-ring with back-up ring
060 O-ring with back-up ring
083 Spanner
095 Stud setter
201 Hydraulic jack for segment stopper,
complete

Page 2 (2) When referring to this page, please quote Plate P90563 Edition 0024
MAN B&W Diesel A/S
 Thrust Shaft - Tools Plate
P90570-0001

When referring to this page, please quote Plate P90570 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0001

Item Item Description Item Item Description

No. No.

019 Lifting tool for thrust shaft

Page 2 (2) When referring to this page, please quote Plate P90570 Edition 0001
MAN B&W Diesel A/S
 Main Bearing - Measuring Tools Plate
P90572-0005

When referring to this page, please quote Plate P90572 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0005

Item Item Description Item Item Description

No. No.

010 Feeler gauge set

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

Page 2 (2) When referring to this page, please quote Plate P90572 Edition 0005
MAN B&W Diesel A/S
906 - Control Gear

Documents in this Chapter

106-01 0053 Chain, Data

906-01 0239 Chain
106-02 0057 Chain Tightener, Data
906-02 0240 Chain Tightener
10620 0002 Gear Drive, Data
90620 0202 Gear Drive
10621 0006 Hydraulic Pumps, Data
90621 0208 Hydraulic Pumps
10622 0005 Hydraulic System, Data
90622 0206 Hydraulic System
10623 0004 Accumulators, Data
90623 0207 Accumulators
10624 0004 Control Valves, Data
90624 0206 Control Valves
10626 0001 Angle Encoder, Data
90626 0201 Angle Encoder
10628 0003 Special running, Data
90628 0204 Special running
90664 0005 Crankshaft - Pin Gauge
90671 0001 Hydraulic Tools - Chain Tightener
90674 0001 Test Equipment for Accumulators

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Chain 106-1
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D06-13 4” Chain
D06-18 Teeth on chain wheel, max. wear 3.5 mm
D06-19 Original length (chain pitch x 10 links) 1016 mm
D06-20 10 links measurements + 1% of a tensioned chain = scrapping of chain 1026 mm

When referring to this page, please quote Data D10601 Edition 0053 Page 1 (2)
MAN B&W Diesel A/S
106-1 Chain
Data

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

Plate Item No. Description

P90651 56 Chain assembling tool

P90651 68 Chain disassembling tool

Page 2 (2) When referring to this page, please quote Data D10601 Edition 0053
MAN B&W Diesel A/S
 Chain 906-1.1
Checking

Carry out the inspection as follows:

1.
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).
B
Measurements are best taken by placing a
short straight-edge over points A and B
and then measuring the distance D06-18.

5. If abnormal wear is observed at the bottom A

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.
D06
18
M90601
0239C04

For assessing the measurement results,

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
generally be considered normal.

2.
M90601
0239C05

When referring to this page, please quote Procedure M90601 Edition 0239 Page 1 (4)
MAN B&W Diesel A/S
906-1.1 Chain
Checking

6. The chains for the camshaft drive are

7. matched together to ensure an even load
distribution.

To keep such matching chains in their

D06
19 pairs, the side plates of the outer link near-
D06
20 est to the assembled link have been
marked with year, month, day and chain
number.
Ma
x. D

Example:
06-
18

No. 1 order,
840520 1A
M90601
0239C07

840520 1B
(840520 1C, possible 3rd chain)

No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)

On the same links there is an arrow (–>)

which indicates the mounting direction.

Check the chains for cracks on possibly

defective rollers and side plates.

Check that the chain rollers can run freely

and that the chain links can freely move on
the pin and bushing (that they are not
“seized” between the pin and the bushing).

It is normal, however, that the rollers get

light, circumferential scratches during the
running-in period. These 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
values given in Data.

If necessary, adjust the chain tightener.

See Procedure 906-2.3.

Page 2 (4) When referring to this page, please quote Procedure M90601 Edition 0239
MAN B&W Diesel A/S
 Chain 906-1.2
Dismantling

It may become necessary to disassemble

the chain if, for instance, cracked rollers or 1.
seizures between pin and bushing have
been discovered during the inspection.
See Procedure 906-1.1.

Note!
Every time a chain link is disassembled,
a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.

When a new link is fitted in one chain,

M90602
0239D01
the corresponding link in the other chain
must also be renewed.

1. Remove the tension on the chain by loos-

ening the chain tightener. 2.
(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
balanceweights, 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
M90601
0239D02

tighten the wire lightly with a tackle.

Protect the link rollers over which the wire

is wrapped.

Note! 3.
If the chain is to be completely removed,
contact MAN B&W Diesel for further in-
formation.

The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.

3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter-
nately tightening the screws on the tool.
M90601
0239D03

When referring to this page, please quote Procedure M90601 Edition 0239 Page 3 (4)
MAN B&W Diesel A/S
906-1.4 Chain
Mounting

Before assembling the inner and outer

1. links, clean the pins and bushings.

1. Combine the inner chain link with the outer

chain link and mount the compression tool.

Force the loose side plate of the outer link

into place by alternately tightening the
screws on the compression tool.

2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
M90601
0239M01

Repeat this procedure until the chain has

been assembled.

Remove the tackle and wire and adjust the

chain tension.
(See Data and Procedure 906-2.3).

Page 4 (4) When referring to this page, please quote Procedure M90601 Edition 0239
MAN B&W Diesel A/S
 Chain Tightener 106-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D13-01 Hydraulic pressure, mounting 1500 bar

D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10602 Edition 0057 Page 1 (2)
MAN B&W Diesel A/S
106-2 Chain Tightener
Data

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

Plate Item No. Description

P91268 Hydraulic Tools - End-Chock Bolts

(Iron Chocks)
P91351 10 Hydraulic pump, pneumatically operated
P91351 22 Hydraulic pump, hand operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10602 Edition 0057
MAN B&W Diesel A/S
 Chain Tightener 906-2.3
Adjustment

1. Turn the engine in the AHEAD direction.

1.
2. Mount the tightening tool studs B in the
threaded holes in the tightener wheel shaft. C
This is done through the opening in the
supports on the guide bar C.

3. Loosen the hydraulic nut A on the fore side

of the chain tightener wheel.
For operation of the hydraulic tools, see
Procedure 913-1.
A
4. Mount the chain tightener tool hydraulic
jacks on the studs C and tighten both si-

M90602
0240O01
B
multaneously to the value stated in Data
D13-01.

Use the hand operated hydraulic pump for

this operation.
2.
5. Tighten the hydraulic nut A to the value
stated in data D13-01. Use the hydraulic
pump for this operation.

6. Loosen the hydraulic chain tightener tools

and remove the tools from the engine.
M90602
238O02

4. C

A
M90602
0238O04

When referring to this page, please quote Procedure M90602Edition 0240 Page 1 (1)
MAN B&W Diesel A/S
 Gear Drive 106-20
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10620 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
106-20 Gear Drive
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

P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D10620 Edition 0002
MAN B&W Diesel A/S
 Gear Drive 906-20.1
Checking
Gear Drive
S70ME-C
0202
Checking
906-20.1

1.
1. Remove the cover on the manoeuvring side
of the chain drive.

Carry out a visual inspection of the gear

wheels.

2. Check that there are no signs of abnormal

wear on the contact faces of the gear wheel
teeth.

3. Check that there are no particles of bearing

material on the horizontal surfaces below
the bearings.

JW906-20.1 202 01
JW906-20.1 202 02 2.

3.
JW906-20.1 202 03

When referring to this page, please quote Procedure M90620 Edition 0202 Page 1 (2)
MAN B&W Diesel A/S
906-20.1 Gear Drive
Checking

4. 4. Mount the cover on the manoeuvring side

of the chain drive.
JW906-20.1 202 04

Page 2 (2) When referring to this page, please quote Procedure M90620 Edition 0202
MAN B&W Diesel A/S
 Hydraulic Pumps 106-21
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D06-206 Hydraulic pump 102 kg

D06-210 Internal drive shaft 78 kg
D06-214 Shear Nut tightening torque 150 Nm

When referring to this page, please quote Data D10621 Edition 0006 Page 1 (2)
MAN B&W Diesel A/S
106-21 Hydraulic Pumps
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

P91356 Lifting Tools, Etc.

P91359 Torque Spanners
P91366 Instruments

Page 2 (2) When referring to this page, please quote Data D10621 Edition 0006
MAN B&W Diesel A/S
 Hydraulic Pumps 906-21.2
MAN B&W Diesel Dismantling

Check that startup and booster pumps are

stopped before any part of the hydraulic sys- 1.
tem is disassembled.

Note!
Always ensure that the area around the
workplace is clean before and during
any dismantling of the hydraulic system.

1. Open the covers at the hydraulic pumps.

2. Mount a pressure gauge on the “minimess”

M90621
0211D01
coupling No. 339. Check the pressure.

Open valve 315 to release the hydraulic

pressure from the system.

Check on the pressure gauge that the sys-

tem is pressure free. 2.

3. Loosen the screws on the flange on the

low pressure pipe leading to the pump in
question. Move the sliding flange to close 00:00

off the pipe and tighten the flange again. ON

OFF

Bourdon Sedeme

CC
M90621
0208D03

3.
M90621
0211D03

When referring to this page, please quote Procedure M90621 Edition 0211 Page 1 (8)
906-21.2 Hydraulic Pumps
Dismantling MAN B&W Diesel

4. Remove the electrical connections to the

4. solenoid valves.

5. Unscrew the bolts from the flange on the

suction pipe.

Unscrew the bolts from the discharge pipe

and remove the pipe.

6. Unscrew the servo oil pipes.

M90621
0207D04

5.
M90621
0207D05

6.
M90621
0207D06

Page 2 (8) When referring to this page, please quote Procedure M90621 Edition 0211
 Hydraulic Pumps 906-21.2
MAN B&W Diesel Dismantling

7. Suspend a tackle above the hydraulic

pump and put a strap around the pump. 7.

Hook the tackle on to the strap and tighten

up. D06
206

Note!
The pump must be in balance when it is
lifted.

Unscrew the four nuts from the studs in the

end-flange.

M90621
0207D07
8. Carefully pull out the pump and the internal
drive shaft. See Data.

For overhaul of the pump, send it to an au-

thorized MAN B&W workshop. 8.

The internal drive shaft also functions as an

overload protection. If it is necessary to re-
new the drive shaft, contact MAN B&W
Diesel for advice.

D06
206
M90621
0208D08

When referring to this page, please quote Procedure M90621 Edition 0211 Page 3 (8)
906-21.3 Hydraulic Pumps
Overhaul MAN B&W Diesel

When the internal drive shaft has been over-

1. loaded it must be taken out for overhaul.

1. Dismantle the hydraulic pump.

Remove the broken end of the internal

drive shaft.

Note!
Take care to catch all loose bits and
other parts.
M90621
0208O01

2. Screw an appropriate screw into the thread

in the end of the internal drive shaft and
pull it out.

3. Inspect the internal drive shaft parts and

2. renew as necessary.
M90621
0208O02

3.
M90621
0208O03

D06
214

Page 4 (8) When referring to this page, please quote Procedure M90621 Edition 0211
 Hydraulic Pumps 906-21.3
MAN B&W Diesel Overhaul

4. Mount the internal drive shaft and the hy-

draulic pump. 4.

D06
206

M90621
0208O04

When referring to this page, please quote Procedure M90621 Edition 0211 Page 5 (8)
906-21.4 Hydraulic Pumps
Mounting MAN B&W Diesel

1. Note!
Always ensure that the area around the
workplace is clean before and during as-
D06
206 sembly of the hydraulic system.

1. Mount the intermediate shaft in the gear-

box. Suspend a tackle above the gearbox
and put a strap around the hydraulic pump.

Lift up the pump in position, and carefully

push in the pump, to engage the pump
shaft with the drive shaft.
M90621
0208O04

2. Mount and tighten the nuts on the pump

flange.

3. Mount the bolts in the flange on the suc-

tion pipe.
2.
Mount the discharge pipe and tighten the
bolts.
M90621
0207M02

3.
M90621
0207M03

Page 6 (8) When referring to this page, please quote Procedure M90621 Edition 0211
 Hydraulic Pumps 906-21.4
MAN B&W Diesel Mounting

4. Mount the servo oil pipes.

4.
5. Mount the electrical connections to the so-
lenoid valves and to the angle encoder.

6. Loosen the screws on the flange on the

low pressure pipe leading to the pump in
question. Move the sliding flange to open
the pipe and tighten the flange again.

M90621
0207M04
5.
M90621
0207M05

6.
M90621
0211D03

When referring to this page, please quote Procedure M90621 Edition 0211 Page 7 (8)
906-21.4 Hydraulic Pumps
Mounting MAN B&W Diesel

7. Close valve 315 on the hydraulic block.

7.
8. Close the cover.
M90621
0208M06

8.
M90621
0211M08

Page 8 (8) When referring to this page, please quote Procedure M90621 Edition 0211
 Hydraulic System 106-22
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D06-209 Hydraulic flange tightening torque 190 Nm

When referring to this page, please quote Data D10622 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
106-22 Hydraulic System
Data

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

Plate Item No. Description

P90951 332 Cleaning tool for NC valve

356 Flange extractor tool
P1359 Torque Spanners

Page 2 (2) When referring to this page, please quote Data D10622 Edition 0005
MAN B&W Diesel A/S
 Hydraulic System 906-22.1
Checking

Procedure for test of double-walled pipe

and alarm sensors for flow and pressure. 2.

1. Check that flow alarm and pressure alarm

are normal.

2. Open valve number 333 on the accumula-

tor block.

3. Start one start-up pump.

4. Wait until flow alarm is activated - normally

after approx. one minute.

M90622
0206C02
5. Start the second start-up pump. 333

6. Wait until pressure alarm is activated and

the flow alarm is gone.

7. During pressure build-up, check double-

walled pipe for leaks.

8. Stop pumps and observe pressure drop to

supply pressure (approx. 2 bar).

9. Check that pressure alarm is gone.

10. Start one start-up pump.

11. Wait until flow alarm is activated.

12. Stop pumps. Wait until pressure is low, and

close valve number 333.

13. Wait until flow alarm is gone - time may be

up to one hour.

When referring to this page, please quote Procedure M90622 Edition 0206 Page 1 (11)
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul

Check that the hydraulic power pumps are

1. stopped before any part of the hydraulic sys-
tem is disassembled.
315

Note!
Always ensure that the area around the
workplace is clean before and during
any dismantling of the hydraulic system.

Hydraulic High-Pressure Pipes

00:00
M90622
0206O01

ON

OFF 340 1. Mount a pressure gauge on the “minimess”

Bourdon Sedeme coupling 340. Check the pressure.
CC

Open valve 315 on the hydraulic block next

to the hydraulic high-pressure pumps, to
2. relieve the system of hydraulic pressure.
Check on the pressure gauge that the sys-
tem is pressure-free.

2. Open valve 431 on the hydraulic block next

to the high-pressure pipe concerned, to the
space between the inner and outer pipes.

3. Unscrew the screws in both flanges on the

pipe concerned.

Mount the dismantling tool in one side and

pull one flange clear of the hydraulic block
M90622
0206O02

by means of the two screws.

431

3.
M90622
0206O03

Page 2 (11) When referring to this page, please quote Procedure M90622 Edition 0206
MAN B&W Diesel A/S
 Hydraulic System 906-22.3
Overhaul

4. Lift out the hydraulic double pipe.

4.
5. Pull off both flanges.

6. Remove all sealing rings from the flanges,

discard the rings.

Clean the pipes and flanges, check the

sealing surfaces.

Note!
Always ensure that the area around the

M90622
0206O04
workplace is clean before and during as-
sembly of the hydraulic system.

Mount new sealing rings, lubricate the rings

with engine lube oil, before mounting the 5.
flanges on the double pipe.

For correct mounting of the sealing rings,

see the sketch.

Push the flanges on to the double pipe.

M90622
0206O05

6.
M90622
0206O06

When referring to this page, please quote Procedure M90622 Edition 0206 Page 3 (11)
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul

7. Before remounting the hydraulic high-pres-

7. sure pipe, check that the faces on the hy-
draulic blocks are clean.

Mount the hydraulic high-pressure pipe.

8. Mount the screws in the flanges and tighten

to the specified torque, see Data.

9. Close valve 431 on the hydraulic block next

the high-pressure pipe concerned.
M90622
0206O07

8.
M90622
0206O08

9.
M90622
0206O02

431

Page 4 (11) When referring to this page, please quote Procedure M90622 Edition 0206
MAN B&W Diesel A/S
 Hydraulic System 906-22.3
Overhaul

10. Close valve 315 on the hydraulic block next

to the hydraulic high-pressure pumps. 10.
315
After renewing sealing rings on the high-
pressure pipes between the HCU, it is rec-
ommended to pressure test the pipes, see
Procedure 906-22.1.

M90622
0206O10

When referring to this page, please quote Procedure M90622 Edition 0206 Page 5 (11)
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul

11. Flushing of hydraulic high-pressure system

If large components in the hydraulic high-pressure system have been renewed, or if a major
overhaul has been carried out on the system, it is recommended to flush the system or parts of
the system.

The valve numbers in the system are shown in the figure on the last page in this procedure.

Before flushing, remove the FIVA control valve from the hydraulic cylinder unit (HCU) concerned.
See Procedure 906-24.2.

Mount the cleaning tools, for correct tools see data.

11.
M90622
0206O11

Page 6 (11) When referring to this page, please quote Procedure M90622 Edition 0206
MAN B&W Diesel A/S
 Hydraulic System 906-22.3
Overhaul

12. Flushing of high-pressure line

Start the electrically driven pumps and increase the pressure to normal working pressure,
175 - 210 bar.

Check the system for leaks.

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Closed Open Closed Closed

FIVA Tool

Valve/filter pos. No. 14 15 16 17 18

Open/closed pos. Closed Closed Closed Closed Closed

Start with the HCU nearest the accumulator block and pump station, if more than one HCU is
flushed. Open valve 420, then open and close valve 421 several times. Wait for the pressure to
build up to normal before repeating. Repeat the procedure for each relevant cylinder.

13. Flushing of bores inside distributor blocks (“Fuel Injection” side)

When repeating the procedure, it is important to ensure that the pressure does not fall below
120 bar.

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Closed Open Closed Open

ELFI Tool FIVA Tool

Valve/filter pos. No. 14 15 16 17 18
Open/closed pos. Closed Closed Closed Closed Closed

Start with the cylinder nearest the accumulator block. Open valves 420 and 14, then open and
close valve 18 several times. Repeat the procedure for each cylinder concerned.

When referring to this page, please quote Procedure M90622 Edition 0206 Page 7 (11)
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul

14. Flushing of bores inside distributor blocks (“Valve Activation” side)

When repeating the procedure, it is important to ensure that the pressure does not fall below
120 bar.

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Closed Open Closed Open

FIVA Tool
Valve/filter pos. No. 14 15 16 17 18
Open/closed pos. Closed Closed Closed Closed Closed

Start with the cylinder closest to the accumulator block. Open valves 420 and 14, then open and
close valve 17 several times. Repeat the procedure for each relevant cylinder.

15. Flushing of fuel oil pressure booster actuator side (“Fuel Injection” side)

When repeating the procedure, it is important to ensure that the pressure does not fall below
120 bar.

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Closed Open Closed Open

FIVA Tool
Valve/filter pos. No. 14 15 16 17 18

Open/closed pos. Closed Closed Closed Closed Closed

The fuel oil system must be running normally at operating pressure.

Start with the cylinder closest to the accumulator block.

Open valves 14 and 16, then carefully open valve 420, and check that the fuel oil pressure
booster pump moves slowly upwards to the end position.

Close valve 420 and open valve 14. Open valve 18 and see that the fuel pump moves back to
the start position.

Repeat 2-3 times. Carry out the procedure for each relevant cylinder.

Note! Due to the high pressure in the system, some valves may be difficult to operate.

Release the pressure by opening valve 17 or 18. The pressure can be observed by mounting a
pressure gauge at the relevant “minimess” valve. To avoid too much fuel oil on top of the piston,
the fuel oil pressure booster pump may only be activated 2-3 times.

Page 8 (11) When referring to this page, please quote Procedure M90622 Edition 0206
MAN B&W Diesel A/S
 Hydraulic System 906-22.3
Overhaul

16. Flushing of exhaust actuator (“Valve Activation” side)

When repeating the procedure, it is important to ensure that the pressure does not fall below
120 bar.

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Closed Open Closed Open

FIVA Tool
Valve/filter pos. No. 14 15 16 17 18
Open/closed pos. Closed Closed Closed Closed Closed

Air must be supplied to the exhaust valve air spring and oil supplied to the exhaust valve
damper and exhaust actuator.

Open valves 14 and 15, then carefully open valve 420, and the exhaust valve actuator will move
slowly upwards to the end position.

Close valve 14 and open valve 17, and the exhaust actuator will move back to the start position.
Repeat several times. Carry out the procedure for each relevant cylinder.

Release the pressure by opening valve 17 or 18. The pressure can be observed by mounting a
pressure gauge at the relevant “minimess” valves.

Check the cleanliness of the oil, e.g. at sample point “minimess” valve 425.

Flushing of the high-pressure hydraulic system is considered as finished at this stage.

17. Dismantling of temporary flushing components

Valve/filter pos. No. 405/406 420 421 430 431 531

Open/closed pos. Closed Closed Open Open Closed Open

FIVA Tool
Valve/filter pos. No. 14 15 16 17 18
Open/closed pos. Open Open Open Open Open

Close valve 420 and then open valves 421, 405, 8, 9, 10, 11, 12 and 13. To be carried out on all
cylinders.

When referring to this page, please quote Procedure M90622 Edition 0206 Page 9 (11)
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul

Remove the cleaning tools and mount the ELFI and ELVA valves on the relevant cylinders.
See procedure 906-24.4.

M90622
0206O11

18. Basic position of valves during normal running of the Engine

Valve/filter pos. No. 101 103 105 106 109 115

Open/closed pos. Open Open Blocked In use Open Closed

Valve/filter pos. No. 230 285 405/406 420 421 430 431 531
Open/closed pos. Open Open Closed Open Closed Open Closed Open

Valve/filter pos. No. 14 15 16 17 18

Open/closed pos. Replaced by FIVA valve

Valve 430 normally open. To be used for detection of leaks.

Valve 431 normally closed.

Oil samples should be taken in order to record the contamination level. These should be taken
at suitable intervals, e.g. at start-up and after the oil has circulated in the system for some min-
utes. The samples should be taken at a position where the oil flow is turbulent.

A flushing of 4 – 6 hrs. is considered as sufficient, depending on the system cleanliness.

Page 10 (11) When referring to this page, please quote Procedure M90622 Edition 0206
MAN B&W Diesel A/S
 M90622
0206O1a3

FIVE I & II
19. Venting

14-15-16-17-18
Cleaning tool

MAN B&W Diesel A/S

Fuel oil pressure booster pump
Hydraulic Exhaust actuator
420
430 14-15-16-17-18 FIVAI valves
431 Cleaning tool
421 420
Distributor block Distributor block
430
431
421

15
Cleaning tool
CCU
15
Cyl.. 1 Cyl.. 2 Cyl.. n - 1 Cyl.. n
17
18 Drain valve to decrease
14 Accumulator block the pressure to zero
Overhaul

Low pressure system and Exhaust 215

Blank flange 315
105 Redundancy filter
16 5361
Piston cooling Main lube 230
Hydraulic System

Mini-mess
See Ms908 and Ms909 + bearings pump 103
107

When referring to this page, please quote Procedure M90622 Edition 0206
remove the “minimess” hose. The system has now been vented.

101
285
120
See drawing No. 3061153-5; Appendix 9

Return to sump
Engine driven EL. driven
*

hydraulic pumps hydraulic pumps

115
109 Back flushing Return to sump
From sump
to sludge tank
Return to sump
106 Self-Cleaning filter

No. Of pumps acording to actuel engine types

*
To vent the system, connect a “minimess” hose between 425 and 550 at each HCU concerned.

Start the start-up pumps and let the pumps run for approximately 10 min. Stop the pumps and

Page 11 (11)
906-22.3
 Accumulators 106-23
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data
Ref. Description Value Unit
D06-201 Accumulator 24/55 kg
D06-202 N2 Charging pressure 104.3 bar at
20°
D06-203 Accumulator flange tightening torque 60 Nm
D06-204 Pressure Adjustment Table
Accumulator temperature t °C bar
0 97,2
10 100,7
20 104,3
30 107,9
40 111,4
50 115
60 118,5
70 122,1
80 125,7
90 129,2
100 132,8
Filling pressure must be as stated above
Check pressure within ± 5 bar.
D06-216 assembly off-set 4-liter accumulator 9 mm

D06-217 assembly off-set 10-liter accumulator 10 mm

When referring to this page, please quote Data D10623 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
106-23 Accumulators
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

P90364 Test Equipment for Alpha Lubricator

P90653 Tools for Accumulator
P91356 Lifting Tools, etc.
P91359 Torque Spanners
P91366 Instruments

Page 2 (2) When referring to this page, please quote Data D10623 Edition 0004
MAN B&W Diesel A/S
 Accumulators 906-23.1
Checking

Check of Accumulators on Hydraulic

1.
Cylinder Unit 00:00

ON

1. Check of the hydraulic accumulator can be OFF

Bourdon Sedeme

done with running engine at reduced CC

speed. See Volume I, Operation.

Connect a pressure gauge at “minimess”

point 455. Check the pressure.

Close the high pressure inlet valve 420 and

open the high pressure outlet valve 421 to
drain all oil out of the accumulator.

M90101
0243D02
Check that the system is pressure free.

Check the nitrogen pressure.

For correct pressure, see Data D06-204.

2.
For use of pressure setting tool, see step 3.

Check of Accumulators on Hydraulic Power

Supply Unit
00:00
2. Check of accumulators on the accumulator
block can only be performed on a stopped ON

engine and with stopped start-up and OFF

booster pumps.
Bourdon Sedeme

CC
Connect a pressure gauge at “minimess”
M90623
0207C02

point 340. Check the pressure.

Open valve 315 to de-pressurise the hy-

draulic system and drain all oil out of the
accumulators.

Check that the system is pressure free.

Check the nitrogen pressure.

For correct pressure, see Data D06-204.

For use of pressure setting tool, see step 3.

When referring to this page, please quote Procedure M90623 Edition 0207 Page 1 (6)
MAN B&W Diesel A/S
906-23.1 Accumulators
Checking

Use of Reducing Valve as Pressure Setting

3. C 00:00
Tool

3. Assemble the reducing valve as shown in

ON

OFF

Bourdon Sedeme the figure, and mount the reducing valve on

CC
the nitrogen cylinder. If necessary, use a
threaded adaptor.
A
Before mounting the filling hose on the ac-
cumulator, check that the accumulator top
is clean.
D
Check that valves A and D are closed.
M90623
0206C03

B E
Mount the filling hose on the relevant accu-
D06
202 mulator with the union nut E.
D06
204
It is now possible to read the actual nitro-
gen pressure in the accumulator on the
digital gauge C on the filling valve.

If the accumulator needs to be refilled with

nitrogen, open valve A and adjust the out-
let pressure on spindle B to 1-2 bar above
the pressure stated in the Pressure Adjust-
ment Table. See Data D06-204.

Keep valve A open until the accumulator is

filled.

Close valve A.

Wait five minutes for the temperature to

stabilise.

Check the pressure in the accumulator on

gauge C according to the Pressure Adjust-
ment Table. See Data D06-204.

Adjust the pressure in the accumulator at

bleed screw D.

Unscrew the union nut E to remove the fil-

ling valve from the accumulator.

Page 2 (6) When referring to this page, please quote Procedure M90623 Edition 0207
MAN B&W Diesel A/S
 Accumulators 906-23.2
Dismantling

Note!
1.
Great care must be taken to ensure that 00:00

the area around the workplace is clean ON

before and during any dismantling of the

OFF

Bourdon Sedeme

hydraulic system. CC

Dismantling of Accumulators from Hydraulic

Cylinder Unit

1. This can be performed on a running engine

at reduced speed. See Volume I, Opera-
tion.

M90101
0243D02
Connect a pressure gauge at “minimess”
point 455. Check the pressure.

Close the high pressure inlet valve 420 and

open the high pressure outlet valve 421 to 2.
drain all oil out of the accumulator.

Check that the system is pressure free.

2. Dismount the accumulator flange from the

hydraulic cylinder unit.

Dismount the accumulator flange from the

accumulator.

Dismantling of Accumulators from Hydraulic D06
201

Power Supply Unit
M90623
0207D02

3. Dismantling of accumulators from the accu-

mulator block can only be performed on a
stopped engine and with stopped start-up
and booster pumps.

Open valve 315 to de-pressurise the hy-

draulic system and drain all oil out of the
accumulators.

The accumulators on the hydraulic power

supply unit are dismounted in the same
way as on the hydraulic cylinder unit.

When referring to this page, please quote Procedure M90623 Edition 0207 Page 3 (6)
MAN B&W Diesel A/S
906-23.3 Accumulators
Overhaul

1. Remove the accumulator with the accumu-

3. lator flange. See Procedure 906-23.2.

2. Use the pressure adjustment tool to drain

the accumulator of nitrogen gas.
See Procedure 906-23.1.

3. Unscrew the “minimess” valve on the accu-

mulator.

Mount the accumulator in the bottom half

of the accumulator tool. Make sure that the
guides on the tool fit into the slots on the
accumulator.
M90623
0206O03

4. Mount the upper half of the accumulator

tool and screw the dowel pin with lifting
eye into the accumulator top. Make sure
that the guides on the tool fit into the slots
4. on the accumulator.

Unscrew the upper half of the accumulator.

Use a piece of pipe in the holes at the end

of the wings of the accumulator tool to
provide leverage.

If the upper half binds, it may be loosened

by tapping a few times with a hammer on
the wings of the accumulator tool.

5. Remove the defective diaphragm “A”

M90623-0206O04

5.

A
M90623
0206O05

Page 4 (6) When referring to this page, please quote Procedure M90623 Edition 0207
MAN B&W Diesel A/S
 Accumulators 906-23.3
Overhaul

6. Clean both accumulator halves throroughly,

especially the threads, and make sure that 7.
the parts are dry afterwards.

7. Assemble the two accumulator halves with-

out fitting the diaphragm. Tighten until the
halves are in contact.

Mark the relative position of the accumula-

tor halves.

8. Disassemble the accumulator and install

the new diaphragm and anti-extrusion ring.

M90623
0206O07
Note!
Check that the new diaphragm is made
of the same material as the old one.

Do not lubricate the diaphragm lip lodg- 8.

ing.

9. Lubricate the upper part of the diaphragm

lip and the accumulator threads with
molyb-denum disulphide grease.

10. Assemble the accumulator. Tighten until the

marks made in section 7 are off-set ac-
cording to D06-216.

11. Mount the “minimess” valve, by using a

new O-ring.
M90623
0206O08

Fill the accumulator with nitrogen gas as

described in Procedure 906-23.1

Use soapy water to check the accumulator

for any leakages. 10.

Mount the accumulator.

D06
216
M90623
0206O10

When referring to this page, please quote Procedure M90623 Edition 0207 Page 5 (6)
MAN B&W Diesel A/S
906-23.4 Accumulators
Mounting

1. Note!
Great care must be taken to ensure that
the area around the workplace is clean
before and during assembly of the hy-
draulic system.

Mounting of Accumulators on Hydraulic

Cylinder Unit

1. This can be performed on a running engine

D06
201 at reduced speed. See Volume I, Opera-
D06
203
M90623
0207M01

tion.

Mount the flange and a new sealing ring on

the accumulator.

Mount the accumulator assembly and a

2. new second sealing ring on the hydraulic
cylinder unit.

2. Close the high pressure outlet valve 421

and open the high pressure inlet valve 420.

Mounting of Accumulators on Hydraulic

Power Supply Unit

3. This can only be performed on a stopped

engine and with stopped start-up and
booster pumps.
M90623
0207M02

The accumulators on the hydraulic power

supply unit are mounted in the same way
as on the hydraulic cylinder unit.

Close valve 315.

Page 6 (6) When referring to this page, please quote Procedure M90623 Edition 0207
MAN B&W Diesel A/S
 Control Valves 106-24
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D06-215 FIVA Control Valve 35 kg

When referring to this page, please quote Data D10624 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
106-24 Control Valves
Data

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

Plate Item No. Description

P91356 Lifting Tools, Etc

Page 2 (2) When referring to this page, please quote Data D10624 Edition 0004
MAN B&W Diesel A/S
 Control Valves 906-24.1
Checking

1. The function of the Fuel Injection and the

Valve Activation Valve (FIVA) is continuously 1.
checked by the Engine Control System.

Malfunctions will be reported by the system

to the MOP system and to the common
alarm system.

Malfunctioning FIVA valves are to be over-

hauled by the supplier or by MAN B&W
Diesel.

M90624
0205C01

When referring to this page, please quote Procedure M90624 Edition 0206 Page 1 (3)
MAN B&W Diesel A/S
906-24.2 Control Valves
Dismantling

1. Note!
Great care must be taken to ensure that
the area around the workplace is clean
before and during any dismantling of the
hydraulic system.

1. Dismantling of the FIVA valve can be per-

formed on a running engine at reduced
speed. See Vol. I.

Mount a pressure gauge at “minimess”

420
point No. 455. Check the pressure.
M90628
0204C01

00:00 421
ON

OFF
455 Close the high pressure inlet valve 420 and
Bourdon Sedeme open the high pressure outlet valve 421 to
CC

drain all oil out of the hydraulic cylinder

unit.
2.
Check that the hydraulic cylinder unit is
pressure free.

2. Disconnect the electrical connections.

Dismount the eight screws and carefully

pull the FIVA valve out past the two guide
pins.
M90624
0205D02

Page 2 (3) When referring to this page, please quote Procedure M90624 Edition 0206
MAN B&W Diesel A/S
 Control Valves 906-24.4
Mounting

Note! 1.
Great care must be taken to ensure that
the area around the workplace is clean
before and during any dismantling of the
hydraulic system.

1. Mount new square section sealing rings in

the control valve.

Mount the control valve on the two guide

pins and tighten the four screws.

M90624
0205M01
Note!
To prevent an unwanted 130% injection
the following must be observed. After re-
placement of a FIVA valve, the drain
valve #421 must be closed and the sup- 2.
ply valve #420 opened before the electri-
cal connections are connected.

2. Close the high pressure outlet valve 421

and open the high pressure inlet valve 420.

3. Connect the electrical connections

420
M90803
0239M05

421

3.
M90624
0205M03

When referring to this page, please quote Procedure M90624 Edition 0206 Page 3 (3)
MAN B&W Diesel A/S
 Angle Encoder 106-26
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D06-218 Angle Encoder cover 20/42 kg

D06-219 Angle Encoder bracket 47 kg

When referring to this page, please quote Data D10626 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
106-26 Angle Encoder
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

P91356 Lifting Tools, Etc.

P91366 61 Slide caliper

Page 2 (2) When referring to this page, please quote Data D10626 Edition 0001
MAN B&W Diesel A/S
 Angle Encoder 906-26.1
MAN B&W Diesel Checking

1. Check that power is supplied to the Tacho 1.

Signal Amplifier box.
Turn the crankthrow for cylinder 1 towards
TDC. The LED indicator on TSA-A lights
up when TDC is reached.

2. Check the TDC of cylinder 1 against the

mark on the turning wheel.

3. Turn the engine a further 45 degrees in the

engines rotational direction. The LED on
TSA-B should now turn on.

M9026
0201C01
2.
M90626
0201C02

When referring to this page, please quote Procedure M90626 Edition 0201 Page 1 (6)
906-26.2 Angle Encoder
Dismantling MAN B&W Diesel

1. Use a tackle to lift off the angle encoder

1. cover where applicable.

2. Tag the electical plugs "Inner encoder" and

"Outer encoder" before disconnecting
them.

Loosen the screws as shown and pull the

outer encoder off.

3. Loosen the locking washer and use a

hook wrench to unscrew the locking nut on
the bearing adapter sleeve. The locking nut
should be unscrewed so far that the nut
M90626
0201D01

covers the thread on the end of the sleeve.

D06
218 Slide a piece of pipe onto the axle. Tap the
end of the pipe with a mallet to loosen the
bearing adapter sleeve.
2.
Unscrew the locking nut and remove the
locking washer.
M90626
0201D02

3.
M90626
0201D03

Page 2 (6) When referring to this page, please quote Procedure M90626 Edition 0201
 Angle Encoder 906-26.2
MAN B&W Diesel Dismantling

4. Unscrew the outer screws on the flange

and remove the compesator. 4.

5. The inner encoder and compensator is dis-

mantled in the same way as the outer en-
coder and compensator.

6. If it is necessary the mounting bracket can

be dismantled.

Use a tackle and lifting strap to secure the

bracket.

Unscrew the screws in the base plate and

M90626
0201D04
remove the bracket.

Note!
Due to the need for realignment the
mounting bracket should only be dis-
5.
mounted when it is absolutely
necessesary.
M90626
0201D05

6.

D06
219
M90626
0201D06

When referring to this page, please quote Procedure M90626 Edition 0201 Page 3 (6)
906-26.3 Angle Encoder
Adjustment MAN B&W Diesel

1. Use a tackle to lift off the angle encoder

1. cover where applicable.

2. Turn the crankthrow for cylinder 1 to TDC.

3. Check the TDC position with the pin gauge

on the cranckthrow.

Note!
Before using the pin gauge, check the
measurement from tip to tip with the
value stamped on the pin gauge, and/or
M9026
0201C01

the check-marks stamped on the fore

end of the cylinder frame.

4. Loosen the clamping ring on the inner en-

2. coder.

5. Use a mandrel or a drill to turn the encoder

hollow shaft until the indicator light turns
on.

If the indicator light allready is on , turn un-

til it goes off and then back until it turns on
again. Tighten the clamping ring.

6. Turn the engine 45 degrees in the engines

rotational direction and repeat the proce-
dure in section 4 and 5 on the outer angle
M90603
0217C02

encoder.

Note!
When adjusting the outer angle encoder
5. a CLOCKWISE turning engine must be
turned 45 degrees in the CLOCKWISE
direction and an ANTICLOCKWISE turn-
ing engine must be turned 45 degrees in
the ANTICLOCKWISE direction.

7. Mount the angle encoder cover where ap-

plicable.

This concludes the mechanical adjustment

of the angle encoders.
M90626
0201O05

If the software settings need to be adjusted

please contact MAN B&W Diesel A/S

Page 4 (6) When referring to this page, please quote Procedure M90626 Edition 0201
 Angle Encoder 906-26.4
MAN B&W Diesel Mounting

1. Mount the mounting bracket. Use a Slide

caliper to ensure a maximum deviation 1.
from "X" of ± 0.1 mm around the center
shaft.

2. Loosely assemble the bearing sleeve, lock-

ing washer, locking nut and compensator.
Slide the assembly onto the axel and
mount the screws.
X
Tighten the locking nut to surface contact,
then tighten a further 60° using a hook
wrench.

M90626
0201M01
3. Perform a basic adjustment of the angle
encoder by turning the hollow shaft to a
position where the dot; in case of a clock-
wise turning engine or the two dots in case
of a counter clockwise turning engine, are
in line with the arrow. 2.
M90626
0201M02

3.
M90626
0201M03

When referring to this page, please quote Procedure M90626 Edition 0201 Page 5 (6)
906-26.4 Angle Encoder
Mounting MAN B&W Diesel

4. Mount the inner encoder on the shaft.

5.
Adjust the encoder according to M906-26.3

5. Mount the outer compensator with bearing

in the same way as shown in section 2.

6. Perform a basic adjustment on the outer

encoder as shown in section 3 and mount
the encoder on the shaft.

7. Adjust the encoder according to M906-26.3

8. Use a tackle to lift and mount the angle en-

M90626
0201D04

coder cover where applicable

6.
M90626
0201D02

Page 6 (6) When referring to this page, please quote Procedure M90626 Edition 0201
 Special Running 106-28
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10628 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
106-28 Special Running
Data

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

Plate Item No. Description

P90851 124 Tool for emergency open exhaust valve

P91366 Instruments

Page 2 (2) When referring to this page, please quote Data D10628 Edition 0003
MAN B&W Diesel A/S
 Special Running 906-28.3
MAN B&W Diesel Overhaul

For all special running conditions, see Volume

I, Chapter 704. 1.

Under conditions where it is necessary to run

the engine with an open exhaust valve, an ex-
haust emergency opening tool must be
mounted as follows.

1. Stop the engine.

Mount a pressure gauge at “minimess”

point No. 455. Check the pressure.
420
Close valve 420 and open valve 421 on the

M90628
0204C01
hydraulic block for the cylinder concerned. 00:00 421
ON

OFF
455
Check that the hydraulic cylinder unit is Bourdon Sedeme

CC

pressure free.

2. Shut off the oil damper oil supply by clos- 2.

ing valve 531 on the hydraulic cylinder unit.

3. Shut off and disconnect the exhaust valve

air supply.

Use a mandrel to puncture the non-return

valve. Cover the valve with a cloth to pro-
tect against oil spray. 531

4. Check on the MOP panel that the exhaust

valve spindle has moved to the open posi-
tion.
M90628
0204C02

3.
M90628
0204C03

When referring to this page, please quote Procedure M90628 Edition 0204 Page 1 (3)
906-28.3 Special Running
Overhaul MAN B&W Diesel

5. Remove the plug screw and mount the tool

5. for emergency opening of exhaust valve.

6. Open the oil damper oil supply by opening

valve 531 on the hydraulic block.

7. Reconnect the exhaust valve air supply.

Return to normal:

When the special running with open exhaust

valve is finished, the engine must be brought
back to normal operation condition.
M90628
0204C05

8. Stop the engine.

Mount a pressure gauge at “minimess”

point No. 455. Check that the hydraulic cyl-
inder unit is pressureless.
7.
Check that valve 531 is closed.

Air
M90628
0204C07

8.
M90628
0204C08

00:00

ON

OFF
455
Bourdon Sedeme

CC

Page 2 (3) When referring to this page, please quote Procedure M90628 Edition 0204
 Special Running 906-28.3
MAN B&W Diesel Overhaul

9. Shut off and disconnect the exhaust valve

air supply. 9.

Use a mandrel to puncture the non-return

valve. Cover the valve with a cloth to pro-
tect against oil spray.

10. Check that the exhaust valve spindle has

moved to the open position.

11. Remove the tool for emergency opening of

exhaust valve and remount the plug screw.

12. Open the oil damper oil supply by opening

M90628
0204C03
valve 531 on the hydraulic block.

13. Reconnect the exhaust valve air supply.

14. Close valve 421 and open valve 420 on the

hydraulic block for the cylinder concerned.
12.

531
M90628
0204C12

When referring to this page, please quote Procedure M90628 Edition 0204 Page 3 (3)
 Crankshaft - Pin Gauge Plate
P90664-0005

When referring to this page, please quote Plate P90664 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0005

Item Item Description Item Item Description

No. No.

021 Pin gauge for crankshaft

Page 2 (2) When referring to this page, please quote Plate P90664 Edition 0005
MAN B&W Diesel A/S
 Hydraulic Tools - Chain Tightener Plate
P90671-0001

When referring to this page, please quote Plate P90671 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Hydraulic Tools - Chain Tightener
P90671-0001

Item Item Description Item Item Description

No. No.

020 Hydralic jack, complete

055 Sealing ring with back-up ring
080 Spanner
209 Stud
258 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P90671 Edition 0001
MAN B&W Diesel A/S
 Test Equipment for Accumulators Plate
MAN B&W Diesel P90674-0001

When referring to this page, please quote Plate P90674 Edition 0001 Page 1 (2)
Plate
Test Equipment for Accumulators
P90674-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Reducing valve

026 Adaptor
038 Adaptor
040 Adaptor
051 Adaptor
063 Adaptor
075 Adaptor
087 Adaptor
099 Quick coupling, Minimess
109 Quick coupling, Minimess
122 Special screw
205 Test equipment for accumulators set,
complete

Page 2 (2) When referring to this page, please quote Plate P90674 Edition 0001
907 - Starting Air System

Documents in this Chapter

107-02 0040 Start Air Valve, Data

907-02 0215 Starting Air Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Starting Air Valve 107-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D07-11 Valve tightening angle 60 °

D07-12 Starting air valve 36 kg

When referring to this page, please quote Data D10702 Edition 0040 Page 1 (2)
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data

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

Plate Item No. Description

P90151 95 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve

Page 2 (2) When referring to this page, please quote Data D10702 Edition 0040
MAN B&W Diesel A/S
 Starting Air Valve 907-2.1
Checking
Starting Air Valve
0215
/0&&

Checking
907-2.1

1.
1. When the starting air valve has been over-
hauled, see Procedure 907-2.3, connect a
supply of working air to the control air inlet
at the top of the valve.

Check that the valve opens approx. 15-20

mm.

2. Shut off the air supply

Check that the valve closes fully.

3. Repeat steps 1 and 2 a couple of times.

HM907-2.1 202 01A

2.
HM907-2.1 202 01B

When referring to this page, please quote Procedure M90702 Edition 0215 Page 1 (6)
0$1% :'LHVHO$6
907-2.2 Starting Air Valve
Dismantling
Dismantling
907-2.2

1. 1. Shut off the starting air and control air inlet.

Dismount the control air pipes

Mount two eye bolts in the top cover of the

valve.

Hook a lifting wire on to the eye bolts.

Unscrew the fixing nuts of the starting valve

flange.

2. Lift away the starting valve.

HG901-2.2 59 02

2.

D07-12
HG907-2.3 201 02

Page 2 (6) When referring to this page, please quote Procedure M90702 Edition 0215
0$1% :'LHVHO$6
 Starting Air Valve 907-2.3
Overhaul
Overhaul
907-2.3

1. Place the starting air valve horizontally in a 1.

bench vice provided with “soft” jaws.

Remove and discard the O-ring from the

valve housing.

2. Loosen and remove the screws from the top

cover.

Dismount the top cover.

3. Use the face wrench for the spindle as a

back-stop when loosening the two screws
which tighten the piston to the spindle.

HM907-4.0 39 01
Remove the screws and discard the locking
device.

When unscrewing, the piston will partially 2.

be pressed out of the valve housing due to
the spring force.
HM907-4.0 39 02

3.
HM907-4.0 39 03

When referring to this page, please quote Procedure M90702 Edition 0215 Page 3 (6)
0$1% :'LHVHO$6
907-2.3 Starting Air Valve
Overhaul

4. 4. Remove the piston from the top end of the

valve housing.

Take out the spindle from the bottom end of

the valve housing.

Remove the spring from the top end of the

housing.

5. Apply grinding paste, e.g. carborundum No.

200. Grind the valve housing seating with
the grinding ring.

6. When lapping the seatings of the spindle

and valve housing to match, use the face
wrench to rotate the spindle.

As grinding paste, use e.g. carborundum

No. 500.
HM907-4.0 39 04

5.
HM907-4.0 39 05A

6.
MG907-4.0 51 05B

Page 4 (6) When referring to this page, please quote Procedure M90702 Edition 0215
0$1% :'LHVHO$6
 Starting Air Valve 907-2.3
Overhaul

7. Thoroughly clean the valve housing and all 7.

the parts in diesel oil or kerosene.

Lubricate all internal parts and sliding sur-

faces with, e.g., Molybdenum Disulphide,
MoS 2.

Insert the spindle in the valve housing.

Then mount the spring in the housing
around the spindle and, finally, place the
piston on top of the spindle.

8. Fit the discs and the two screws.

When tightening the screws, the piston will

compress the spring.

Tighten the screws continuously until the

piston faces tightly against the spindle. Use
the face wrench as a back-stop.

Lock the screws with locking device.

HM907-4.0 39 07

For correct use of locking device, see Pro-

cedure 913-7.

9. Mount and tighten the top cover.

Fit a new O-ring on the valve housing. 9.

10. Check the starting air valve.

See Procedure 907-2.1.

If the valve is not to be mounted in the en-

gine immediately, cover all openings with
plastic to prevent dirt from entering the
valve during storage.
HM907-4.0 39 09

When referring to this page, please quote Procedure M90702 Edition 0215 Page 5 (6)
0$1% :'LHVHO$6
907-2.4 Starting Air Valve
Mounting
Mounting
907-2.4

1. 1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recon-
dition the seat for the starting valve in the
bore, see Procedure 901-1.3.

If not already done, fit a new O-ring on the

overhauled valve and lubricate with ‘Never
Seize’ or Molybdenum Disulphide, MoS 2.
For overhaul, see Procedure 907-2.3.

2. Mount the valve in the cylinder cover.

3. Mount the nuts and tighten-up in at least

three steps, to reach the full tightening an-
HG907-2.4 201 01

gle, see Data.

Mount the control air pipe and turn on start-

ing air and control air.
2.

D07-12
HG907-2.4 201 02

3.

D07-11
HM901-2.2 114 03

Page 6 (6) When referring to this page, please quote Procedure M90702 Edition 0215
0$1% :'LHVHO$6
908 - Exhaust Valve

Documents in this Chapter

108-01 0043 High-Pressure Pipe, Data

908-01 0225 High-Pressure Pipe
108-02 0081 Exhaust Valve, Data
908-02 0255 Exhaust Valve
108-03 0050 Exhaust Valve Actuator, Data
908-03 0240 Exhaust Valve Actuator
90851 0211 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90862 0044 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 High-Pressure Pipe 108-1
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D08-01 High-pressure pipe, tightening torque 53 Nm

D08-03 High-pressure pipe 50 kg

When referring to this page, please quote Data D10801 Edition 0043 Page 1 (2)
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data

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

Plate Item No. Description

P90851 112 Grinding mandrel for h.p. pipe

Page 2 (2) When referring to this page, please quote Data D10801 Edition 0043
MAN B&W Diesel A/S
 High-Pressure Pipe 908-1.2
Dismantling

1. Stop the engine and shut off the oil supply. 1. 00:00

Connect a pressure gauge at “minimess” ON

OFF

point 455. Check the pressure. Bourdon Sedeme

CC

Close valve 420 and open valve 421 on the

hydraulic block for the cylinder concerned.

Check that the system is pressure free.

Note!
Great care must be taken to ensure that
the area around the workplace is clean

M90101
0243D02
before and during any dismantling of the
hydraulic system.

2. Close the valve 531 for the actuator oil

2.
supply.
M90101
0243D03

When referring to this page, please quote Procedure M90801 Edition 0225 Page 1 (6)
MAN B&W Diesel A/S
908-1.2 High-Pressure Pipe
Dismantling

3. When replacing the hydraulic high-pressure

3. pipe, the exhaust valve or the hydraulic ac-
tuator, check the high-pressure pipe sealing
surfaces.

Loosen the screws for the high-pressure

pipe and lift the pipe slightly away from the
D08
03
actuator to let the oil in the pipe drain
through the drain holes in the actuator.

4. Remove the screws in both ends of the

high-pressure pipe. Lift the high-pressure
pipe away from the engine.
M90801
0224D03

4.
M90801
0224D04

Page 2 (6) When referring to this page, please quote Procedure M90801 Edition 0225
MAN B&W Diesel A/S
 High-Pressure Pipe 908-1.3
Overhaul

The two ends of the pipe are identical and

should both be overhauled as follows: 1.

1. Remove the thrust piece from the actuator

and exhaust valve.

Remove and discard the O-rings from the

thrust piece and the thrust flange.

2. Pull the thrust flange clear of the pipe end.

Remove the spring ring.

Push in the sleeve and remove the two-

M90801
0224O01
part conical locking ring.

Pull the sleeve off the pipe.

3. Remove the screws and the two-part disc

from the thrust flange. 2.

Pull the thrust flange off the pipe.

Remove and discard the O-ring.

M90801
0224O02

3.
M90801
0224O03

When referring to this page, please quote Procedure M90801 Edition 0225 Page 3 (6)
MAN B&W Diesel A/S
908-1.3 High-Pressure Pipe
Overhaul

4. Clean and inspect the contact surfaces of

4. the high-pressure pipe and the thrust
piece.

If necessary, grind the contact surfaces by

means of the grinding mandrel.

Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and
finish with a fine grinding paste, for ex-
ample Carborundum No. 500.

After the grinding, clean the high-pressure

pipe and the thrust piece.
M90801
0224O04

Corborundum No. 200/500

5. Mount a new O-ring on the flexible hose.

Mount the thrust flange and the sleeve.

5. 6. Mount the two-part conical locking ring

and the spring ring.
M90801
0224O05

6.
M90801
0224O06

Page 4 (6) When referring to this page, please quote Procedure M90801 Edition 0225
MAN B&W Diesel A/S
 High-Pressure Pipe 908-1.4
Mounting

1. If not already done, mount new O-rings, lu-

bricated with a little lubricating oil, on the 1.
thrust flanges.

Mount the high-pressure pipe on the en-

gine.

Note!
When mounting the high-pressure pipe, D08
03
take care not to damage the sealing sur-
faces of the pipe/thrust pieces.

2. After fitting the pipe to the exhaust valve

and actuator, mount and tighten the screws
by hand.

Finally, tighten the screws diagonally to the

torque stated in Data, using a torque span-
ner.

For correct use of the torque spanner, see

Procedure 913-5.
M90801
0224M01

2.
M90801
0224M02

D08
01

When referring to this page, please quote Procedure M90801 Edition 0225 Page 5 (6)
MAN B&W Diesel A/S
908-1.4 High-Pressure Pipe
Mounting

3. Open the valve 531 for actuator oil supply.

3.
4. Close valve 421, and open valve 420 on
the hydraulic block.
M90101
0243M10

4.
M90101
0243M11

Page 6 (6) When referring to this page, please quote Procedure M90801 Edition 0225
MAN B&W Diesel A/S
 Exhaust Valve 108-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D08-04 Safety valve, opening pressure 21 bar

D08-06 Oil cylinder, tightening torque 230 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 30.4 - 30.5 °
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 9.0 mm
D08-14 Spindle, max. grinding 2.0 mm
D08-15 Spindle stem, measuring area, min. 470 mm
D08-16 Spindle stem, measuring area, max. 600 mm
D08-17 Spindle stem, min. diameter 71.8 mm
D08-18 Bushing max. diameter, top 72.6 mm
D08-19 Bushing max. diameter, bottom 74.5 mm
D08-20 Oil cylinder max. inside diameter 85.4 mm
D08-21 Piston rings, min. thickness 3.2 mm
D08-24 Exhaust valve, complete 800 kg
D08-25 Exhaust valve housing 450 kg
D08-26 Oil cylinder 110 kg
D08-27 Air cylinder 65 kg
D08-28 Spindle 75 kg
D08-29 Bottom piece 100 kg
D08-45 Damper piston 12 kg
D08-46 Damper flange 8 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10802 Edition 0081 Page 1 (2)
MAN B&W Diesel A/S
108-2 Exhaust Valve
Data

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

Plate Item No. Description

P90851 65 Lifting tool for exhaust valve

P90851 89 Pressure tester for safety valve
P90851 90 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
P90851 293 Pliers for retaining ring
P90861 Valve seat and spindle grinder
P90862 Jack-hydraulic, complete
P91351 10 Hydraulic pump, pneumatically operated
P91351 34 Hose with unions (1000 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 117 5-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10802 Edition 0081
MAN B&W Diesel A/S
 Exhaust Valve 908-2.1
Checking

1. Before mounting an overhauled exhaust

1.
valve in the engine, it is recommended that
the valve be checked as follows:

• Lift up the valve with the engine room

crane (which makes the valve open).

• Connect compressed air to the air cylin-

der. The valve should now close.

• Check that a 1.0 mm feeler gauge can

be inserted about 15 mm into gap G 3,
to ensure that there is a clearance be-

M90802
0255C01
tween the outer parts of the seating
faces of valve housing and spindle.
See Procedure 908-2.3.

• After shutting-off the compressed air

supply and releasing the vent plug
screw located just above the ball cock 2.
on the air cylinder, the exhaust valve
should open.

• After doing this a couple of times, leave

the valve closed and shut-off the com-
pressed air. The valve should remain
closed for at least fifteen minutes.

Check of sealing oil unit

2. Check of the sealing oil unit is carried out

M90802
0255C02

with running engine. Check that the injec-

tion indicator moves regularly with the
valve opening. Alternatively, unscrew the
sealing oil pipe, and check that oil is com-
ing out (very small quantity).

3. When the exhaust valve is mounted in the 3.

cylinder cover, and the cooling water inlet
to the cylinder cover and exhaust valve is
open, check the tightness of the sealing
ring between the bottom piece and the cyl-
inder cover by ensuring that water does
not flow from the small bore on the top
side of the bottom piece.

If water does flow from one or both of

these bores, the exhaust valve must be
dismounted and the sealing rings replaced.
M90802
0255C03

When referring to this page, please quote Procedure M90802 Edition 0255 Page 1 (23)
MAN B&W Diesel A/S
908-2.2 Exhaust Valve
Dismantling

1. Close the cooling water inlet and outlet,

1. and drain the exhaust valve.

Dismount the high-pressure pipe for the

hydraulic valve actuation.
See Procedure 908-1.2.

Disconnect the cooling water outlet pipe

from the exhaust valve.

Disconnect the electrical plug for the valve

position sensor.

Dismount the return oil pipe and oil supply

M90802
0255D01

pipe from the exhaust valve.

2. Dismount the air pipes for pneumatic clos-

ing of the exhaust valve.

2. 3. Remove the plate jacket with insulation

from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the exhaust valve.
M90802
0255D02

3.
M90802
0255D03

Page 2 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.2
Dismantling

4. Remove the protective caps from the ex-

haust valve studs, and mount the four hy- 4.
draulic jacks.

Connect the high-pressure pump to the

jacks by means of the distributor block and
high-pressure hoses.
D13
02
Bleed the hydraulic system and raise the
pressure as stated in Data. Then loosen
and remove the nuts. See Procedure 913-
1.

5. Attach the crane to the eye bolt fitted on

M90802
0255D04
top of the valve and lift the exhaust valve
away. Apply compressed air to the air
spring, right before lifting.

Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat- 5.
ing and sealing surfaces of the bore, if re-
quired. See Procedure 901-1.3.
D08
24

Compressed
Air
M90802
0255D05

When referring to this page, please quote Procedure M90802 Edition 0255 Page 3 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

1. Place the exhaust valve on a wooden sup-

1. port on the platform. Remove the four nuts
and the safety strap from the oil cylinder.

Remove the oil pipe for the valve spindle

oil sealing.

2. Lift away and place the oil cylinder on a

wooden support.
M90802
0255O01

2.

D08
26
M90802
0255O02

Page 4 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

3. Mount the support and the hydraulic jack

for the conical nut on the valve spindle. 3.

Check that the jack is fully compressed

and tightened to full face contact, unscrew
the jack ½ a revolution. D13
02

Connect the high-pressure pump to the

jack. Bleed the hydraulic system and raise
the pressure as stated in Data. Then loosen
the nut. See Procedure 913-1.

4. Remove the conical nut and the damper

bushing.

M90802
0255O03
4.
M90802
0255O04

When referring to this page, please quote Procedure M90802 Edition 0255 Page 5 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

5. Mount two eye bolts in the top of the air

5. cylinder. Lift the air cylinder with damper
piston and air piston.

Land the air cylinder on a wooden support.

6. Remove the retaining ring from the spindle

shaft. Using the special pliers from tool
panel 908.

D08
27
M90802
0255O05

6.
M90802
0257O06

Page 6 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

7. Use the oil cylinder as a lifting tool for the

exhaust valve housing. Lift the oil cylinder 7.
with the crane, and guide it down over the
studs for the oil cylinder. Mount the four
nuts so that the load from the valve hous-
ing is evenly distributed.

8. Lift the oil cylinder and the valve housing

clear of the exhaust valve spindle.

M90802
0255O07

8.

D08
26 +
D0825
M90802
0255O08

When referring to this page, please quote Procedure M90802 Edition 0255 Page 7 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

9. Land the valve housing on a wooden sup-

9. port and let the oil cylinder hang in the
crane.

Unscrew the retaining screws for the bot-

tom piece and lift the valve housing 10mm.

If the bottom piece has become stuck, use

a tin hammer to release it.

Lift the valve housing away and land it on a

couple of wooden planks. Remove the oil
cylinder from the valve housing.

10. Inspect the spindle guide bushing in the

exhaust valve housing for wear and mea-
sure the top and bottom diameters. See
Data.
D08
29
11. If it proves necessary to replace the bush-
ing, knock out the bushing with a hammer
and a suitable mandrel. Mount a new bush-
ing. Mount and tighten the screws.
M90802
0255O09

10.

D08
18
M90802
0255O10

D08
19

Page 8 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

Bottom piece:
12.
12. Inspect the seating of the bottom piece
carefully for damage and check with the
bottom piece template. G3
Note!
Before using the bottom piece template,
thoroughly clean the contact faces on
the valve housing w-seat with a steel
brush.

All measurements should be taken at

four diametrically opposite points on the
circumference of the bottom piece seat- D08
09
ing.

Small dent marks in the bottom piece

seating are acceptable and need not be
ground away, provided that the dent
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
G2
M90802
0255O12

exhaust gas receiver.

For further evaluation of the bottom

piece seating, see also Chapter 707 in
the instruction book, Volume I, Opera-
tion.

Take measurements G 2 and G 3, using a

feeler gauge. Compare the results with the
figures stated in Data D08-11 and D08-12.

IF burn marks are visible on the bottom

piece seating OR G 3 does not equal D08-
12, THEN the bottom piece seat must be
ground.

IF the template rests on the lower surface

in the groove, i.e. G 2 = 0, THEN the bot-
tom piece seating must be discarded and
replaced with a new bottom piece. Further
grinding or reconditioning is not recom-
mended.

When referring to this page, please quote Procedure M90802 Edition 0255 Page 9 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

13. If it is necessary to grind the seating, pro-

13. ceed as follows:

Before placing the bottom piece on the

grinding machine, turn the grinding head
away from the grinding table.
D08
09
Mount and secure the bottom piece in the
grinding machine. Using a dial gauge,
check that the bottom piece is correctly
centered.

Adjust the grinding head to achieve the

correct grinding angle as stated in Data.
M90802
0255O13

Note!
As the grinding angle is very important
for the correct operation of the exhaust
14. valve, make absolutely sure that the
grinding head is correctly adjusted.

Regarding the use of the grinding machine,

G3 see separate instructions from the grinding
machine manufacturer.
D08
12
14. During the grinding, use the bottom piece
template frequently to ensure that maxi-
mum grinding is not exceeded.

After grinding, inspect the bottom piece

seating again, using a feeler gauge and the
D08
09 bottom piece template, to measure how
much material has been ground away.

Grind the recess so that gap G 3 equals

15. D08-12 as stated on the Data sheet.

G2
M90802
0255O14

D08
11

Page 10 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

15. After grinding the inside seating of the bot-

tom piece, grind the outside seating using 15.
carborundum 200 and the special grinding
tool.

Note!
Turn the special grinding tool by hand,
alternately turning clockwise and anti-
clockwise

Grind until a smooth surface is achieved.

Clean the bottom piece.

M90802
0255O15
Valve spindle

16. When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
16.
17. Inspect the seating of the valve spindle for
burn marks.
D08
28
Check the burn-off F1 of the valve spindle
by measuring along the spindle template
from point A to point D and in point E.

Note!
Before using the spindle template, thor-
oughly clean the contact faces on the
valve spindle with a steel brush.
M90802
0255O16

All measurements should be taken at

four diametrically opposite points on the
circumference of the valve spindle. Make
sure that the most burned-off point is
measured. 17.
Small dent marks in the valve soindle
seating are acceptable and need not be
grund away, provided that the dent
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
exhaust gas receiver.

For further evaluation of the valve spindle

seating, see also Chapter 707 in the in- F
1
struction book, Volume 1, Operation.
M90802
0255O17

A E
D

When referring to this page, please quote Procedure M90802 Edition 0255 Page 11 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

18. Measure the gap G1 between the spindle

18. template and the seating of the spindle.

19. IF burn marks are visible on the seating,

G1
the spindle must be ground.

IF gap G1 exceeds the maximum allowable

value D08-14, see Data, OR the burn-off F1
exceeds the maximum allowable burn-off
D08-13, the spindle must not be ground.
D08
14 Instead the spindle must be reconditioned.

Contact MAN B&W Diesel for advice on re-

conditioning.
M90802
0255O18

20. Mount and secure the spindle in the grind-

ing machine. Using a dial gauge, check
that the spindle is correctly centered.

20. Adjust the grinding head to achieve the

correct grinding angle as stated in Data.

Note!
As the grinding angle is very important
to the operation of the exhaust valve,
make absolutely sure to adjust the grind-
D08
10 ing head correctly.

Regarding the use of the grinding machine,

see separate instructions from the grinding
M90802
0255O20

machine manufacturer.

During grinding, measure gap G 1 fre-

quently. The max. grinding of the spindle,
see Data, must not be exceeded.

If the max. grinding limit is reached, and

burn marks are still visible on the seating of
the spindle, contact MAN B&W Diesel for
advice on reconditioning.

Clean the spindle.

Page 12 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

21. Check the spindle stem for wear in the

area D08-15 to D08-16 measured from the 21.
top of the spindle.

If the stem diameter is less than stated in

Data, or the hard facing layer is worn away, D08
15
contact MAN B&W Diesel for advice. D08
16
22. Mount the O-rings and sealing ring on the
spindle stuffing box.

Note! D08
17
Make sure to mount the sealing ring cor-
rectly, see the sketch

M90802
0255O21

22.
M90802
0255O22

When referring to this page, please quote Procedure M90802 Edition 0255 Page 13 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

23. Mount the oil cylinder as a lifting tool on

23. the valve housing.

Lift and land the valve housing on the bot-

tom piece. Check that the guide pin in the
bottom piece enters the hole in the bottom
of the exhaust valve housing.

Mount and tighten the retaining screws for

the bottom piece.

24. Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
M90802
0255O23

Mount the guide cone on the exhaust valve

spindle, to protect the sealing rings in the
stuffing box.

Carefully land the exhaust valve housing

24. with the bottom piece on the exhaust valve
spindle.

Take care not to damage the sealing rings

in the stuffing box.

Remove the oil cylinder from the exhaust

valve.

Remove the guide cone from the exhaust

valve spindle.

25. Mount the retaining ring on the spindle, us-

M90802
0255O24

ing the special pliers from tool panel 908.

25.
M90802
0257O06

Page 14 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

26. Lift up the damper piston and the air piston

from the air cylinder. 26.

Remove the protective cap from the safety D08
46

valve mounted near the bottom of the air
cylinder. Dismount the safety valve from the
air cylinder. Clean the machined surfaces
and the internal bores.

Check the running surface for wear or pos-

sible scores.

27. Place the safety valve in the pressure test-

ing device.

M90802
0255O26
Connect the testing device with the high
pressure pump by means of a hose. Check
the opening pressure, see Data.

If the opening pressure is not correct, 27.

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.

28. Mount a new gasket and a new O-ring on

the safety valve. D08
04

Mount the safety valve in the bore near the

bottom of the air cylinder.
M90802
0255O27

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. 28.

D08
07
M90802
0255O28

When referring to this page, please quote Procedure M90802 Edition 0255 Page 15 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

29. Lubricate the O-rings on the spindle stuff-

29. ing box.

Carefully land the air cylinder on the ex-

haust valve housing and check its correct
engaging with the locating pin.

Note!
Take care not to damage the O-rings on
the outside of the stuffing box

30. Inspect the air piston sealing rings and

M90802
0255O29

guide ring. If it is necessary to change the

rings, cut them and remove them.

Note!

30. Before mounting, heat the new teflon

rings in 100° hot water for at least five
minutes.

When mounting the teflon rings, be care-

ful not to damage the running surfaces.

Compress the teflon ring by hand, using

working gloves.

Mount the new O-ring in the groove of the

air piston.
M90802
0255O30

31. Mount new sealing rings on the damper

piston flange.

31.
M90802
0255O31

Page 16 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

32. Fill the groove on top of the flange and the

lower part of the air cylinder with clean lu- 32.
bricating oil (approx. 0.5 litre).

33. Lubricate the running surface of the air cyl- Clean oil
inder and the surface for the damper piston
flange.

Lower the air piston over the valve spindle

down into the air cylinder.

Lower the damper piston flange over the

valve spindle down into the upper groove
of the air cylinder.

M90802
0255O32
33.
M90802
0255O33

When referring to this page, please quote Procedure M90802 Edition 0255 Page 17 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

34. Mount the damper bushing and the conical

34. nut.

35. Mount the support and the hydraulic jack

for the conical nut on the valve spindle.

Check that the jack is fully compressed

and tightened to full face contact, unscrew
the jack ½ a revolution.

Connect the high-pressure pump to the

jack. Bleed the hydraulic system and raise
the pressure as stated in Data. Then
tighten the nut. See Procedure 913-1.

Remove the hydraulic jack from the

spindle.
M90802
0255O04

35.

D13
01
M90802
0255O35

Page 18 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

36. Place the oil cylinder in a horizontal posi-

tion with the sealing oil unit pointing up- 36.
wards.

Remove and discard the sealing ring.

Loosen the screws and remove the sealing

oil control unit.

Unscrew and clean the orifice plug.

Check and clean the bore for the orifice

plug in the top of the oil cylinder.

M90802
0255O36
37. Sealing oil control unit:

Normally, overhaul of the sealing oil unit

should not be necessary.

Check the unit according to Procedure 37.

908-2.1

Before remounting the unit, carefully clean

it on the machined faces. If the unit needs
to be overhauled, send it to an authorized
MAN B&W repair shop.

Mount the orifice plug and the sealing oil

control unit.

38. Remove the flange and take out the piston.

M90802
0255O37

Clean the oil cylinder and inspect the bore

of the oil cylinder for scoring and check its
measurements.

If the diameter of the bore exceeds the

value stated in Data, send the oil cylinder 38.
to an MAN B&W authorized workshop for
repair.

D08
20
M90802
0255O38

When referring to this page, please quote Procedure M90802 Edition 0255 Page 19 (23)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

39. Remove the piston rings from the oil piston

39. and check them for wear.

Top If the thickness of the rings has worn down

to the minimum, see Data, discard the
rings and mount new ones.

Check that the TOP mark on the piston

rings faces upwards, when mounting.

40. Mount the oil piston and the flange in the

oil cylinder and mount a new O-ring in the
D08
21 outside groove.
M90802
0255O39

41. Mount the oil cylinder and the safety strap.

Mount and tighten the four nuts to the

specified torque.

40. Mount the oil pipe for the valve spindle oil
sealing.
M90802
0255O40

41.

D08
06
M90802
0255O41

Page 20 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.4
Mounting

Check before mounting

1.
Before mounting an overhauled exhaust valve
in the engine, it is recommended that the valve
be checked and prepared as follows:
D08
24
1. Lift up the valve with the engine room
crane (whereby the valve may open).

2. Connect compressed air to the air cylinder

to close the valve:

• Check that a 1.0 mm feeler gauge can

be inserted about 15 mm into gap G3,

M90802
0255M01
to ensure that there is a clearance be-
tween the outer parts of the seating
faces of valve housing and spindle.
See Procedure 908-2.3.

• After shutting-off the compressed air 2.

supply and releasing the air through the
non-return valve on the air cylinder, the
exhaust valve should open.
Compressed
Air
Hint!
Use a small screwdriver to press the ball
into the non-return valve, and cover it
with a rag to catch the oil drops.

• After doing this a couple of times, leave

the valve closed, and shut-off the com-
M90802
0255M02

pressed air.

If the exhaust valve opens within 15 min-

utes, check for air leakages around the air
spring.

Connect compressed air to the air spring.

Check:

• Air piston sealing (air coming out of

drain oil hole)

• Stem sealing (air coming out along

spindle stem in exhaust gas duct)

When referring to this page, please quote Procedure M90802 Edition 0255 Page 21 (23)
MAN B&W Diesel A/S
908-2.4 Exhaust Valve
Mounting

3.
3.
Note!
Before mounting the valve on the engine,
connect 7 bar working air to the air cyl-
inder to keep the exhaust valve closed
during the mounting process.

Mount a new O-ring in the upper groove on

the bottom piece and a U-seal in the lower
groove.
Compressed
Air Lubricate the sealing rings with vaseline
and the threads of the studs with anti-sei-
zure paste.
Copper
Grease
Position the valve in the cylinder cover
bore, guiding it in accordance with the ex-
Vaseline haust flange.

4. Mount the nuts and the hydraulic jacks.

Raise the pressure to the value stated in
Data and tighten the nuts.
M90802
0255M03

For use of the hydraulic jacks, see also

Procedure 913-1.

Relieve the system of pressure, remove the

4. hydraulic jacks and high-pressure hoses,
and fit the protective caps.

D13
01
M90802
0255M04

Page 22 (23) When referring to this page, please quote Procedure M90802 Edition 0255
MAN B&W Diesel A/S
 Exhaust Valve 908-2.4
Mounting

5. Connect the intermediate pipe to the flange

at the exhaust valve, mount and tighten the 5.
screws.

Attach the insulation jacket.

6. Mount the cooling water outlet pipe on the

exhaust valve.

Mount the high-pressure pipe and the re-

turn oil pipe, see Procedure 908-1.4.

Mount the air pipe for the sealing air con-

trol unit.

M90802
0255M05
Connect the electrical plug for the position
sensor.

Open the lub. oil supply and the cooling

water supply to the exhaust valve. 6.

Disconnect the compressed air and con-

nect the normal air supply.

Caution!
The air supply to the exhaust valve must
always be connected before turning on
the oil supply to the exhaust valve ac-
tuator.

7. Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908-1.1.
M90802
0255M06

When referring to this page, please quote Procedure M90802 Edition 0255 Page 23 (23)
MAN B&W Diesel A/S
 Exhaust Valve Actuator 108-3
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D08-35 Hydraulic actuator 90 kg

D08-47 Top flange 25 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10803 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data

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

Plate Item No. Description

P90862 Exhaust Valve - Hydraulic Tools

P91351 10 Hydraulic pump, pneumatically operated
P91351 34 Hose with unions (1000 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10803 Edition 0050
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.2
Dismantling

1. Stop the engine and shut off the oil supply.

1.
00:00
Mount a pressure gauge at “minimess” ON

point No. 455. Check the pressure. OFF

Bourdon Sedeme

CC

Close valve 420 and open valve 421 on the

hydraulic block for the cylinder concerned.

Check that the hydraulic cylinder unit is

pressure free.

Note!
Great care must be taken to ensure that

M90101
0243D02
the area around the workplace is clean
before and during any dismantling of the
hydraulic system.

2. Close valve 531 for the actuator oil supply. 2.

3. Remove the hydraulic high pressure pipe,

see Procedure 908-1.2.

Disconnect the oil pipe from the aft side of

the top flange.
M90101
0243D03

3.
M90803
0240D03

When referring to this page, please quote Procedure M90803 Edition 0240 Page 1 (7)
MAN B&W Diesel A/S
908-3.2 Exhaust Valve Actuator
Dismantling

4. Loosen the nuts, two at a time, diagonally.

4.
Mount the spacer rings and the hydraulic
jacks over the nuts. Pump up the hydraulic
jacks to the dismantling pressure, as speci-
fied in Data. Loosen and remove the nuts.

For use of hydraulic tools, see also Proce-

dure 913-1.

5. Mount two eyebolts in the top flange of the

actuator.

6. Lift the actuator unit clear of the actuator

M90803
0240D04

block.

Remove the sealing rings from the bottom

and discard them.

6.

D08
35
M90803
0240D06

Page 2 (7) When referring to this page, please quote Procedure M90803 Edition 0240
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.3
Overhaul

1. Remove the two screws which retain the

top flange to the cylinder unit. 1.

Lift away the top flange and discard the

sealing rings.
D08
47
2. Place the actuator on the side. Push out
the upper piston with a brass mandrel.

M90803
0240O01

2.
M90803
0240O02

When referring to this page, please quote Procedure M90803 Edition 0240 Page 3 (7)
MAN B&W Diesel A/S
908-3.3 Exhaust Valve Actuator
Overhaul

3. Place the actuator upside down.

3.
Remove the retaining ring from the bottom
flange of the oil cylinder.

Remove and discard the sealing ring.

4. Clean all parts and check all running sur-

faces for abnormal wear and scores.

5. Lubricate the cylinder inside with lubricat-

ing oil.

Mount the lower piston in the bottom of

M90803
0240O03

the cylinder.

Mount the retaining ring.

Mount a new sealing ring.

4.
M90803
0240O04

5.
M90803
0240O05

Page 4 (7) When referring to this page, please quote Procedure M90803 Edition 0240
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.3
Overhaul

6. Lubricate the upper piston on all sliding

surfaces. 6.

Mount the piston from the top side of the

cylinder.

Mount new sealing rings.

Mount the top flange and tighten the

screws.

M90803
0240O06

When referring to this page, please quote Procedure M90803 Edition 0240 Page 5 (7)
MAN B&W Diesel A/S
908-3.4 Exhaust Valve Actuator
Mounting

1. Note!
Great care must be taken to ensure that
the area around the workplace is clean
before and during assembly of the hy-
draulic system.
D08
35
1. Check the oil hole and the face of the hy-
draulic block and the bottom of the hy-
draulic actuator to see that they are clean
and free of impurities.
M90803
0240M01

Mount two eye bolts in the top of the ac-

tuator assembly and a new sealing ring in
the bottom groove.

Mount a new sealing ring on the hydraulic

block.
2.
Carefully land the actuator assembly on the
hydraulic block.

2. Remove the eye bolts from the top flange.

Tighten two nuts at a time diagonally.

Screw the nuts on to the studs. Mount the

spacer rings and the hydraulic jacks over
the nuts. Pump up the jacks to the tighten-
ing pressure, as specified in Data. Tighten
the nuts, and remove the hydraulic jacks
M90803
0240M02

and the spacer rings.

For use of hydraulic tools, see also Proce-

dure 913-1.

3. 3. Mount and tighten the oil pipe for oil sup-

ply.

Mount the hydraulic high pressure pipe,

see Procedure 908-1.4.
M90803
0240M03

Page 6 (7) When referring to this page, please quote Procedure M90803 Edition 0240
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.4
Mounting

4. Open valve 531 for actuator oil supply.

4.
5. Close valve 421, and open valve 420 on
the hydraulic block.

M90101
0243M10

5.
M90101
0243M11

When referring to this page, please quote Procedure M90803 Edition 0240 Page 7 (7)
MAN B&W Diesel A/S
 Exhaust Valve - Panel Plate
MAN B&W Diesel P90851-0211

When referring to this page, please quote Plate P90851 Edition 0211 Page 1 (2)
Plate
Exhaust Valve - Panel
P90851-0211 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Panel for tools

028 Name plate
065 Lifting tool for exhaust valve
089 Test equipment for exhaust valve
090 Gauge for exhaust valve spindle
112 Grinding tool for H.P. pipe
124 Tool for emergency opening of exhaust
valve
150 Gauge for exhaust valve bottom piece
161 Lifting tool for exhaust valve
185 Grinding ring for exhaust valve bottom
piece
281 Cone for mounting of sealing ring
293 Pliers for retaining ring

Page 2 (2) When referring to this page, please quote Plate P90851 Edition 0211
 Exhaust Valve - Tools Plate
P90861-0037

When referring to this page, please quote Plate P90861 Edition 0037 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Tools
P90861-0037

Item Item Description Item Item Description

No. No.

046 Grinding machine, complete*

Note:

* When ordering spare parts, please

refer to the Chris Marine manual

Page 2 (2) When referring to this page, please quote Plate P90861 Edition 0037
MAN B&W Diesel A/S
 Exhaust Valve - Hydraulic Tools Plate
P90862-0041

When referring to this page, please quote Plate P90862 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0041

Item Item Description Item Item Description

No. No.

028 Hydraulic jack, complete

030 Support
053 O-ring with back-up ring
065 O-ring with back-up ring
089 Tommy bar
090 Spanner
100 Stud setter
207 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P90862 Edition 0041
MAN B&W Diesel A/S
 Exhaust Valve - Hydraulic Tools Plate
P90862-0044

When referring to this page, please quote Plate P90862 Edition 0044 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0044

Item Item Description Item Item Description

No. No.

028 Jack-hydraulic, complete

030 Support
053 Sealing ring with back-up ring
065 Sealing ring with back-up ring
077 Tommy bar
090 Spanner
100 Stud setter
124 Jack-hydraulic, complete
136 Support
150 Sealing ring with back-up ring
161 Sealing ring with back-up ring
173 Tommy bar
207 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90862 Edition 0044
MAN B&W Diesel A/S
 Exhaust Valve - Extra Tools Plate
P90863-0014
Exhaust Valve - Extra Tools
0014
P90863

When referring to this page, please quote Plate P90863 Edition 0014 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0014

Item Item
Item Description Item Description
No. No.

011 Worktable

Page 2 (2) When referring to this page, please quote Plate P90863 Edition 0014
MAN B&W Diesel A/S
 Exhaust Valve - Extractor Tool Plate
P90864-0003

When referring to this page, please quote Plate P90864 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Extractor Tool
P90864-0003

Item Item Description Item Item Description

No. No.

017 Extractor tool, complete

Page 2 (2) When referring to this page, please quote Plate P90864 Edition 0003
MAN B&W Diesel A/S
909 - Fuel Oil System

Documents in this Chapter

10911 0066 Fuel Valve, Data

90911 0241 Fuel Valve
10912 0047 Spindle Guide, Data
90912 0224 Spindle Guide
10913 0033 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0071 Fuel Oil High-Pressure Pipes, Data
90914 0245 Fuel Oil High-Pressure Pipes
10920 0003 Fuel Oil Pressure Booster, Data
90920 0203 Fuel Oil Pressure Booster, Data
10921 0003 Fuel Oil Pressure Booster - Top Cover, Data
90921 0203 Fuel Oil Pressure Booster - Top Cover, Data
10922 0003 Fuel Oil Pressure Booster - Suction Valve, Data
90922 0203 Fuel Oil Pressure Booster - Suction Valve, Data
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90981 0001 Mounting Tools - Top Cover Seals

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Fuel Valve 109-11
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D09-40 Fuel valve opening pressure 300 - 380 bar

D09-42 Inlet seat, max. diameter 25 mm
D09-43 Fuel valve 13 kg

When referring to this page, please quote Data D10911 Edition 0066 Page 1 (2)
MAN B&W Diesel A/S
109-11 Fuel Valve
Data

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

Plate Item No. Description

P90151 71 Dismantling tool for fuel valve

P90951 94 Milling tool for fuel oil pipe seats
P90951 165 Grinding mandrel for valve head
P90951 297 Assembling tool for fuel valve
P90961 Fuel Valve tester, complete
P90966 Fuel Valve Nozzle - Tools

Page 2 (2) When referring to this page, please quote Data D10911 Edition 0066
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

1. Fuel Valve
1.
The fuel valves must be given the utmost at-
tention and care, as the greater part of irregu-
larities that may occur during the running of the
engine can be attributed to defects in these
valves.

If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 900-1.

In order to obtain reliable results during testing

of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disas-
sembled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3.
M90911
0241C01

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 mea-
sured might be considerably lower than 2.
specified.

All fuel valves must be function-tested before

being mounted in the cylinder cover.

Pressure testing pump

Use only hydraulic oil (rust-preventing) with a

viscosity of between 7 and 10 cSt at 50°C.

For operation of the pressure testing pump,

see the supplier's instructions.

Note that the high-pressure pump should be

periodically checked in accordance with the
supplier's instructions.

2. Spring housing

To ensure that over tightening has not taken

M90911
0240C02

place, check that the locking/indicating pin has

not been bent or broken off.

In the event of over tightening, replace the

spring housing by a new one.
When referring to this page, please quote Procedure M90911 Edition 0241 Page 1 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

3. Setting-up the fuel valve

3.
Place the fuel valve in the test rig and secure it
with the spring housings and nuts.

Tighten the nuts until the top face of the pres-

sure disc is flush with the top face of the
spring housings. Mount the oil pipe between
the pressure testing pump and the fuel valve.

Pressure testing procedure

The following functions of the fuel valve must

be checked:
M90911
0240C03

• Flushing and jet control

• Opening pressure
• Sealing test and sliding function
4. • Pressure test, O-ring sealing

4. Flushing and jet control

Remove air in the system and check the fuel

jet in the following way.

Slowly increase the oil pressure until straight

jets of oil are ejected from the nozzle holes (no
atomization).

Acceptance criteria:
M90911
0240C04

There is to be a continuous jet of oil through at

least one of the nozzle holes.

Owing to the geometry of the internal part of

the nozzle - and because of the height to
which the spindle is lifted during pressure test-
ing is lower than the height it is lifted during
normal engine operation - the fuel oil will not
necessarily flow from all of the nozzle holes.

Cause of fault:

If the jets do not fulfil the above point, the

cause may be:

Dirt in the nozzle holes

The nozzle is not mounted correctly

Page 2 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

5. Opening pressure
5.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle D09
40
holes.

Acceptance criteria:

Check the opening pressure on the pressure

gauge and compare with Data D09-40 on the
datasheet.

Note!

Do NOT attempt to carry out an atomization

test on the slide type fuel valvs, as this may
damage the cut-off slide and nozzle.

Cause of fault:

If the opening pressure is higher than specified

in D09-40, the cause may be that a wrong type
of spring is used - replace the spring on the
M90911
0240C05

thrust spindle, if necessary, replace the com-

plete thrust spindle.

If the opening pressure is lower than specified

in D09-40, the cause may be that the spring
has sagged - replace the spring, or add a spe-
cial thin disc.

Note!

Special thin discs are available as spares.

If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated.

When referring to this page, please quote Procedure M90911 Edition 0241 Page 3 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

6. Sealing test and sliding function

6.
To check the needle valve seat for tightness
and the slide for correct closing.

Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain the
built-up pressure by closing for the oil supply.

Acceptance criteria:

Oil must not flow from the nozzle holes.

M90911
0240C06

The pressure drops relatively slowly to about

15 bar, after which it drops quickly to 0 (the
slide is pressed against the conical seat and
opens for circulation oil).

Note!
Oil flows out of the leak oil outlet when the
fuel valve is full of oil.

Cause of fault:

If oil flows out of the nozzle holes, the cause is

either:
• Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
See Procedure 909-12.3.
• Too quick pressure drop:

- the clearances of the movable parts, both of

the spindle guide and of the non-return valve,
are too large, or the seats between the thrust
piece/spindle in the spindle guide or thrust
piece/valve slide in the non-return valve are
damaged.

Examine and/or replace both the spindle guide

and non-return valve. See Procedure 909-12.3.
See Procedure 909-13.3.

If a quick pressure drop from 15 to 0 bar can-

not be registered:
• The valve slide is sticking; or
• The vent hole in the thrust piece is
blocked.

If so, disassemble and examine the spindle

guide, replace if necessary. See Procedure
909-12.3.

Page 4 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

7. Pressure test, O-ring sealing

7. Max. 10 bar
To ensure that the leak oil (circulation oil) re-
mains in the closed system, build up a working
pressure of about max. 10 bar until oil flows
out of the leak oil outlet.

Close the leak oil outlet with a gasket and plug

screw.

Increase the working pressure to about 100

bar.

Acceptance criteria:

The built-up pressure of about 100 bar should

be maintained.

Cause of fault: Max. 100 bar

If oil leaks out at the union nut, the O-ring in-

side the fuel valve head is defective, and must
be replaced.

Max. 100 bar

M90911
0241C07

When referring to this page, please quote Procedure M90911 Edition 0241 Page 5 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

8. Atomization test
8.

Note!
Do NOT attempt to carry out an atomi-
zation test on slide type fuel valves, as
this may damage the cut-off slide and
nozzle.

The atomization test may damage the valve be-

cause it makes the needle oscillate, with a
small lift at a very high frequency. The high
pressure drop across the cut-off edge and the
M90911
0240C08

high contact pressure between slide and fuel

nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures be-
tween cut-off slide and nozzle.

All of these conditions involve the risk of sei-

zure between the cut-off slide and the nozzle.

Page 6 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.2
Dismantling

1. Close the fuel oil inlet and outlet valves,

1.
and drain the high-pressure pipe and the
fuel valve.

Dismantle and remove the fuel oil high-

pressure pipe.
See Procedure 909-14.2.

Disconnect the return oil pipe from the fuel

valve.

2. Remove the nuts and the spring housings.

M90911
0240D01
3. Take out the valve. If the valve is sticking,
use the fuel valve dismantling tool to pull
the fuel valve clear of the top cover.

If the valve is not to be overhauled immedi-

ately, the valve should be placed immersed
in diesel oil until overhauling. 2.
M90911
0240D02

3.

D09
43
M90911
0241D03

When referring to this page, please quote Procedure M90911 Edition 0241 Page 7 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

When fuel valves are overhauled, all parts

1. should be handled carefully and be kept clean.

Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
fore reassembly.

1. Measure the length A of the protruding part

of the nozzle, and write down the result for
A correct re-assembling of the valve.
M90911
0240O01

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.

2. 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
union nut with a hook spanner.

Remove the valve from the valve holder.

M90911
0240O02

3.
M90911
0240O03

Page 8 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

4. Pull the valve head clear of the valve hous-

ing. 4.

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.

M90911
0240O04

When referring to this page, please quote Procedure M90911 Edition 0241 Page 9 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

5. Carefully clean and examine all surfaces of

5. the:
D09
42
• Fuel valve housing

• Fuel valve head

• Thrust spindle

If necessary, grind the seating surfaces by

means of the grinding mandrels supplied
and a fine-grain abrasive (such as
Carborundum No. 500).

This grinding must only be carried out

manually.

After the grinding, wash the parts in gas oil

and blow clean by means of compressed
air to remove any remains of the grinding
compound.

In the event of more serious damage to the

seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.

Normally, the milling tool is turned by hand,

but it may be fitted in the chuck of a col-
umn-type drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An
ample supply of cutting emulsion must be
used.

Note!
Take care not to exceed the maximum
diameter of the seat, see Data.
M90911
0239O04

Page 10 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

6. The complete spindle guide, including the

fuel nozzle, should be sent to an 6.
authorised MAN B&W repair shop for over-
haul. If this is not possible, the spindle
guide may be overhauled on board.
See Procedure 909-12.3.

Note!
Do not attempt to remove the fuel nozzle
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.

M90911
0240O05
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.
See Procedure 909-13.3. 7.

8. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.

Carefully slide the spindle guide down into

the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corre-
sponds to the measurement taken before
the valve was disassembled.
M90911
0240O06

Note!
Make sure that the fuel nozzle and
spindle guide engage correctly with the
guide pin in the fuel valve housing. This
can be ascertained by attempting to turn
8.
the nozzle after mounting. It must not be
possible to turn the nozzle.
M90802
0253D05

When referring to this page, please quote Procedure M90911 Edition 0241 Page 11 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

9. Mount:
9.
• the thrust foot

• the parts of the thrust spindle

• the non-return valve

in the fuel valve housing.

Mount a new O-ring in the uppermost

groove of the fuel valve housing.

Lubricate the thread of the valve head with

M90911
0240O08

molybdenum disulphide (MoS2).

For the correct use of this lubricant, see
Procedure 913-11.

Fit the valve head with new O-rings.

10.
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
to prevent relative turning of the parts.
M90911
0241O10

MoS 2

Page 12 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

11. Assemble the valve by means of the union

nut. 11.

Place the valve in the valve holder in a drill-

ing machine.

Compress the fuel valve and the spring in-

side. Keep the valve compressed and
tighten the union nut with a hook spanner.

After overhaul, the fuel valve must be

tested in the test rig.
See Procedure 909-11.1.

12. If the fuel valve is not to be mounted in the

engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage. M90911
0240O10

When referring to this page, please quote Procedure M90911 Edition 0241 Page 13 (14)
MAN B&W Diesel A/S
909-11.4 Fuel Valve
Mounting

1. Before mounting the fuel valve, thoroughly

1. clean the valve bore in the cylinder cover
and check the seating in the bore for
marks which, if any, must be eliminated.
D09
43 (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-
MoS 2 lybdenum Disulphide (MoS2).

2. Mount the valve in position in the cylinder

cover.
M90911
0239M01

Mount the spring housings and the nuts.

Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housing. This must be done with
great care, as the spring tension in the
2. housing determines the correct tightening
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.

3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.

Note!
It is recommended to overhaul the fuel
oil high-pressure pipe before mounting.
M90911
0240M02

See Procedure 909-14.3.

As a minimum, the distance between the

fuel oil pipe ends and the thrust bush-
ings must be checked and, if necessary,
3. adjusted.

Mount the overhauled fuel oil high-pressure

pipe and the return oil pipe.
See Procedure 909-14.4.

Note!
All fuel valves must be function-tested
before being mounted in the cylinder
cover, see Procedure 909-11.1.
M90911
0240M03

Page 14 (14) When referring to this page, please quote Procedure M90911 Edition 0241
MAN B&W Diesel A/S
 Spindle Guide 109-12
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10912 Edition 0047 Page 1 (2)
MAN B&W Diesel A/S
109-12 Spindle Guide
Data

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

Plate Item No. Description

P90966 Fuel Valve Nozzle - Tools

P90968 Fuel Valve - Inspection Tools
P90974 Fuel Valve Nozzle - Cleaning Tools

Page 2 (2) When referring to this page, please quote Data D10912 Edition 0047
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
Overhaul
Spindle Guide
S60MC-C
0224
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.

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!

The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.
MA909-6.2 111 02

2. Place the spindle guide in a bench vice pro-

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.
4.
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
and the spindle guide and very carefully
force the fuel nozzle off the spindle guide.
MA909-6.2 111 03

When referring to this page, please quote Procedure M90912 Edition 0224 Page 1 (5)
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’.
MA909-6.2 111 04

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.

Page 2 (5) When referring to this page, please quote Procedure M90912 Edition 0224
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
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).
MN909-12.3 213 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.

When referring to this page, please quote Procedure M90912 Edition 0224 Page 3 (5)
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.
MN909-12.3 215 10

Page 4 (5) When referring to this page, please quote Procedure M90912 Edition 0224
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
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.

Make sure that the half-circle shaped

groove on the nozzle and the spring pin are
in line. Spring pin

If nozzle and spindle guide are provided

with scratch marks opposite the spring pin,
they must be in line.

Place the parts on the plane of a drilling

machine or hydraulic press and position the
mounting tool over the parts. Make sure
that all the parts are perfectly aligned.
Scratch marks
Press the nozzle on to the spindle guide.
HN909-12.3 221 11

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
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 as in step 10.

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.

When referring to this page, please quote Procedure M90912 Edition 0224 Page 5 (5)
MAN B&W Diesel A/S
 Non-return Valve for Fuel Valve 109-13
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10913 Edition 0033 Page 1 (2)
MAN B&W Diesel A/S
109-13 Non-return Valve for Fuel Valve
Data

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

Plate Item No. Description

P90951 153 Flange for dismantling of non return valve

P90968 Fuel Valve - Inspection Tools

Page 2 (2) When referring to this page, please quote Data D10913 Edition 0033
MAN B&W Diesel A/S
 Non-return valve 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 


%

a clean piece of cloth. 1

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

When referring to this page, please quote Procedure M90913 Edition 0206 Page 1 (2)
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.

Page 2 (2) When referring to this page, please quote Procedure M90913 Edition 0206
0$1% :'LHVHO$6
 Fuel Oil High-Pressure Pipe 109-14
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D09-47 Fuel oil high-pressure pipe, tightening torque 300 Nm

D09-50 Union nuts, tightening torque 55 Nm
D09-52 Fuel oil pipe 20 kg

When referring to this page, please quote D10914 Edition 0071 Page 1 (2)
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data

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

Plate Item No. Description

P90951 104 Milling tool for fuel oil pipe

P90951 116 Crowfoot wrench head

Page 2 (2) When referring to this page, please quote Data D10914 Edition 0071
MAN B&W Diesel A/S
 Fuel Oil High-Pressure Pipe 909-14.2
Dismantling

High-Pressure Pipe with Double Pipe 2.

1. Close the fuel oil inlet and outlet valves.

2. Unscrew the union nut at the fuel valve end

of the high-pressure pipe.

Pull the union nut clear of the union nipple.

Unscrew the union nipple from the fuel

valve.

3. Unscrew the union nut at the fuel oil pres-

M90914
0245D02
sure booster end of the high-pressure pipe.

Pull the union nut clear of the union nipple.

Unscrew the union nipple from the fuel

pump. 3.

4. Lift the pipe ends clear of the fuel valve/

fuel pump, and remove the high-pressure
pipe from the engine.

Note!
It is recommended always to overhaul
the high-pressure pipe before remount-
ing it on the engine.
See Procedure 909-14.3.
M90914
0245D03

The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.

4.

D09
52
M90914
0245D04

When referring to this page, please quote Procedure M90914 Edition 0245 Page 1 (4)
MAN B&W Diesel A/S
909-14.3 Heading
Overhaul

Whenever the fuel oil high-pressure system has

1.
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 oil pressure booster top cover.

If the pipe ends require reconditioning, proceed

as follows:

1. If not already done, unscrew the union nuts

from the union nipples.
M90914
0242O01

2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.

Note!

The two pipe ends are of different de-

2. signs – see sketch.
A
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.

During the milling process, add drilling oil

A emulsion liberally.
M90914
0242O02

3. On both pipe ends a small groove has

been ground to indicate the maximum al-
lowable grinding of the pipe ends.

3. The pipe ends may only be ground until the

ground surface is flush with the bottom of
Max. grind
away 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.
M90914
0242O03

Page 2 (4) When referring to this page, please quote Procedure M90914 Edition 0245
MAN B&W Diesel A/S
 Heading 909-14.3
Overhaul

4. Lift up the union nuts and the union 4.

nipples.

Remove the spring rings from the two-part

sleeves. Remove the sleeves.

5. Remove the union nipple and union nut

from the pipe ends. Clean all parts and re-
place the O-rings. Remount the union
nipple and union nut on both pipe ends.

6. Mount the two-part sleeves and lock the

sleeves with the spring rings.

M90914
0242O04
Screw the union nuts losely (approx. 2
revolutions) on to the union nipples.

5.
M90914
0242O05

6.
M90914
0242O06

When referring to this page, please quote Procedure M90914 Edition 0245 Page 3 (4)
MAN B&W Diesel A/S
909-14.4 Fuel Oil High-Pressure Pipe
Mounting

1. Check that the sealing surfaces on both

4.
pipe ends are in order without scratches or
pressing-in marks.

2. Ensure that the fuel valve is fitted with a

new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.

3. Ensure that the union nipple at the fuel oil

D09
52 pressure booster 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.
M90914
0245M04

4. Mount the high-pressure pipe between the

fuel valve and the fuel oil pressure booster.
Screw the union nipples onto the fuel valve
and into the fuel oil pressure booster top
cover, by hand.
5.
Note!
D09
50
The nipples must be screwed by hand,
as the threads of the union nipples, fuel
valve or fuel oil pressure booster top
cover might otherwise be damaged.
Tightening with a crowfoot wrench
should only be done after both of the
union nipples have been screwed into
position.

5. If not already done, screw the union nut

M90914
0245M05

D09
47 loosely (approx. 2 revolutions) on to the

union nipple screwed into the fuel valve.

Using a crowfoot wrench and torque

wrench, tighten the union nipple, then the
6. union nut, to the torques stated in data.
D09
47
6. Repeat step 5 on the union nipple screwed
into the fuel oil pressure booster.
D09
50
If dismantled, re-mount the return oil pipe
on the fuel valve. Open the fuel oil inlet
and outlet valves.
M90914
0245M06

Page 4 (4) When referring to this page, please quote Procedure M90914 Edition 0245
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster 109-20
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D09-81 Booster complete 260 kg

D09-82 Booster housing 110 kg
D09-83 Hydraulic plunger 25 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10920 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
109-20 Fuel Oil Pressure Booster
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

P90862 Exhaust Valve - Hydraulic Tools

P90951 70 Lifting tool for fuel pump housing
P90951 368 Lifting tool for hydraulic plunger
P91351 10 Hydraulic pump, pneumatically operated
P91351 34 Hose with unions (1000 mm), complete
P91351 60 Hose with unions (5000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10920 Edition 0003
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster 909-20.2
Dismantling

1. Mount a pressure gauge at “minimess”

point No. 455. Check the pressure. 1.

Close valve 420 and open valve 421 on the 00:00

hydraulic block. Check that the hydraulic ON

cylinder unit is pressure free.

OFF

Bourdon Sedeme

CC

2. Close the fuel oil inlet valve.

Open the fuel oil drain.

Remove the fuel oil high pressure pipes,

see Procedure 909-14.2.

M90920
0203D01
Disconnect the electrical sensor connec-
tion.

Remove the fuel oil inlet pipe.

Remove all drain pipes connected to the 2.

fuel oil pressure booster.

Note!

Great care must be taken to ensure that

the area around the workplace is clean
before and during any dismantling of the
hydraulic system.

3. Loosen the nuts, two at a time, diagonally.

M90920
0203D02

Mount the spacer rings and the hydraulic

jacks over the nuts. Pump up the hydraulic
jacks to the dismantling pressure, as speci-
fied in Data. Loosen and remove the nuts.

For use of hydraulic tools, see also Proce-

3.
dure 913-1

D13
02
M90921
0203D03

When referring to this page, please quote Procedure M90920 Edition 0203 Page 1 (7)
MAN B&W Diesel A/S
909-20.2 Fuel Oil Pressure Booster
Dismantling

4. Mount the lifting tool on top of the fuel oil

4. pressure booster.
D09
81
See Procedure 909-21.2.

Carefully lift the fuel oil pressure booster

clear of the hydraulic block and the fuel oil
pressure booster studs.

Cover the hole in the hydraulic block, to

keep the hydraulic high pressure system
clean.

5. Land the fuel oil pressure booster on a

M90920
0203D04

wooden support and take care not to dam-

age the drain oil bushing.

5.
M90920
0203D05

Page 2 (7) When referring to this page, please quote Procedure M90920 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster 909-20.3
Overhaul

1. Place the fuel oil pressure booster on a

wooden support. 1.

Remove the booster top cover, see Proce-

dure 909-21.2.

2. Mount the lifting tool in the top of the hy-

draulic plunger.

Lift up the plunger.

3. Unscrew the flange for the throttle valve.

Screw out the throttle valve, clean the valve
in gas oil and blow through with com-

M90920
0203D06
pressed air.

2.
D09
83
M90920
0201O02

3.
M90920
0203O03

When referring to this page, please quote Procedure M90920 Edition 0203 Page 3 (7)
MAN B&W Diesel A/S
909-20.3 Fuel Oil Pressure Booster
Overhaul

4. Clean the booster housing and the hydrau-

4. lic plunger with kerosene or gas oil.
D09
82
Place the booster housing on one side.

Remove the two sealing rings from the cy-

lindrical part of the booster housing and
the sealing ring from the bottom. Discard
the sealing rings.

Carefully clean the bottom of the booster

housing.

Inspect the hydraulic cylinder surface and

M90920
0201O04

the hydraulic piston for wear and seizures.

Check the position sensor tip for damage.

The position sensor should only be re-
newed if it is not working properly.
5.
Pull out the drain oil bushing and discard
the two sealing rings. Clean the hole and
the bushing.

Mount the bushing with new sealing rings.

5. Mount new sealing rings in the hydraulic

cylinder.

For correct mounting, see the sketch.

Turn the booster housing to an upright po-

M90920
0201O05

sition and place it on a clean piece of oil

paper.

6. Lubricate the cylinder (lower part) and the

hydraulic piston with proactive oil.
6.
Mount the hydraulic piston.
MOS 2
Note!

All parts of the hydraulic high pressure

system must be kept absolutely clean
and free of impurities.

In this case, pay particular attention to

the hydraulic piston and the lower part
of the booster housing.
M90920
0201O06

Mount the throttle valve and the flange.

Page 4 (7) When referring to this page, please quote Procedure M90920 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster 909-20.3
Overhaul

7. Mount the booster top cover and tighten

the top cover screws. See Procedure 909- 7.
21.4.

8. If the booster is stored before use, cover

all openings with plastic and apply preser-
vation oil to all machined surfaces to pre-
vent corrosion.

M90920
0201O07

When referring to this page, please quote Procedure M90920 Edition 0203 Page 5 (7)
MAN B&W Diesel A/S
909-20.4 Fuel Oil Pressure Booster
Mounting

Note!
1.
D09
81 Great care must be taken to ensure that
the area around the workplace is clean
before and during assembly of the hy-
draulic system.

1. If the fuel oil pressure booster has been

preserved for storage, remove all preserva-
tion and plastic covers.

Mount the lifting tool in the top of the fuel

oil pressure booster.
M90920
0203M01

Lift up the fuel oil pressure booster, and

check if the bottom surface is clean and
free of impurities.

2. Mount new sealing rings if not already

done.

2. Check that the face on the hydraulic block

is completely clean.

3. Land the fuel oil pressure booster on the

hydraulic block.

Remove the lifting tool.

M90920
0203M02

3.
M90920
0203M03

Page 6 (7) When referring to this page, please quote Procedure M90920 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster 909-20.4
Mounting

4. Tighten two nuts at a time diagonally.

4.
Screw the hydraulic nuts on to the studs.
Mount the spacer rings and the hydraulic
jacks over the nuts. Pump up the jacks to D13
01
the tightning pressure, as specified in Data.
Tighten the nuts and remove the hydraulic
jacks and the spacer rings.

For operation of hydraulic tools, see Proce-

dure 913-1.

5. Mount and tighten all drain pipes to the

fuel oil pressure booster.

M90921
0203M04
Mount the fuel oil inlet pipe.

Mount the fuel oil high pressure pipes, see

Procedure 909-14.4.
5.
Close the fuel oil drain valve.

Mount the electrical sensor plug.

6. Open valve 420 and close valve 421 on the

hydraulic block.

Open the fuel oil inlet valve.

M90920
0203M05

6.
M90922
0203M03

When referring to this page, please quote Procedure M90920 Edition 0203 Page 7 (7)
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Top Cover 109-21
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D09-86 Fuel outlet seat, max.grinding diameter 26 mm

D09-87 Booster top cover 120 kg
D09-88 Fuel plunger 12 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 - 1650 bar

When referring to this page, please quote Data D10921 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
109-21 Fuel Oil Pressure Booster Top Cover
Data

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

Plate Item No. Description

P90862 Exhaust Valve - Hydraulic Tools

P90951 70 Lifting tool for fuel pump housing
P90951 320 Plunger locking tool
P91351 10 Hydraulic pump, pneumatically operated
P91351 34 Hose with unions (1000 mm), complete
P91351 60 Hose with unions (5000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10921 Edition 0003
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Top Cover 909-21.2
Dismantling

1. Close the fuel oil inlet valve. 1.

Mount a pressure gauge at “minimess”

point No. 455. Check the pressure.
00:00
Close valve 420 and open valve 421 on the
ON

hydraulic block. OFF

Bourdon Sedeme

CC

Check that the hydraulic cylinder unit is

pressure free.

2. Remove the fuel oil high pressure pipes,

see Procedure 909-14.2.

M90922
0203D01
Drain the fuel oil pressure booster for oil.

Remove the drain oil pipe from the top

cover.
2.
3. Loosen the hydraulic nuts, two at a time,
diagonally.

Mount the spacer rings and the hydraulic

jacks over the nuts. Pump up the hydraulic
jacks to the dismantling pressure, as speci-
fied in Data. Loosen and remove the nuts.

For operation of the hydraulic tools, see

Procedure 913-1.
M90921
0203D02

3.

D13
02
M90921
0203D03

When referring to this page, please quote Procedure M90921 Edition 0203 Page 1 (7)
MAN B&W Diesel A/S
909-21.2 Fuel Oil Pressure Booster Top Cover
Dismantling

4. Unscrew the centre plug screw with

4. lefthanded thread and remove the small
disc.

Mount the retaining tool for the fuel

plunger.

Remove the two Allen screws.

5. Remove the two hexagon head screws and

mount the lifting tool in the holes.

6. Carefully lift up the top cover assembly,

M90921
0201D04

and land it on a wooden support.

5.
M90921
0201D05

6.

D09
87
M90921
0201D06

Page 2 (7) When referring to this page, please quote Procedure M90921 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Top Cover 909-21.3
Overhaul

1. Land the top cover assembly on a wooden

support. 1.

Unscrew the retaining tool for the fuel

plunger. D09
87

Carefully lift the booster top cover clear of

the plunger.

Remove and discard the sealing rings.

2. Remove the lifting tool and the retaining

tool from the top cover.

M90921
0201O01
Unscrew and remove the suction valve D09-88
from the top cover.

See Procedure 909-22.2.

3. Carefully clean and examine the top cover. 2.

Reconditioning of the seatings for the high-

pressure pipes is carried out by milling ac-
cording to the following procedure:

Fill the oil ducts in the top cover with

Vaseline or heavy grease.

During the work the miller is guided by the

guide screwed into the thread for the high-
pressure pipe.
M90921
0201O02

Turn the miller by means of, e.g. a tap

wrench, while tightening the guide screw
lightly to provide a suitable pressure be-
tween miller and seat.

During the milling, add drilling oil emulsion 3. D09
86

liberally.

For the max. milling/grinding diameter of

the seat, see Data D09-86.
M90921
0201O03

When referring to this page, please quote Procedure M90921 Edition 0203 Page 3 (7)
MAN B&W Diesel A/S
909-21.3 Fuel Oil Pressure Booster Top Cover
Overhaul

4. After completing the milling, blow out the

4. Vaseline/grease from the oil ducts by
means of compressed air.

Warning!

Always use eye protection when working

with compressed air.

Clean the top cover with gas oil, and blow

dry with compressed air.

Unscrew the orifice plug for return oil.

M90921
0201O04

Clean the plug and remount it.

5. Place the top cover on one side and clean

the bore for the fuel plunger in clean kero-
sene. Inspect the bore and plunger.
5.
For evaluation of the fuel plunger/top cover
assembly, see Volume I, chapter 706.

Mount the suction valve, see Procedure

909-22.4.

The top cover and fuel plunger are

matched parts and must only be renewed
as a set.

6. Turn the top cover to an upright position.

Place the retaining tool for the fuel plunger
M90921
0201O05

in the centre hole and mount the lifting

tool.

Place the plunger on a plane surface.

6. Apply a little clean grease to the inner hole
in the top cover and a thin layer to the
plunger.

Carefully lower the top cover onto the fuel

plunger, until the top cover rests on the
plunger.
M90921
0201O06

Page 4 (7) When referring to this page, please quote Procedure M90921 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Top Cover 909-21.3
Overhaul

7. Screw the retaining tool into the fuel

plunger, to lock the plunger in position. 7.

Lift the top cover and mount two new seal-

ing rings as shown on the sketch.

M90921
0201O07

When referring to this page, please quote Procedure M90921 Edition 0203 Page 5 (7)
MAN B&W Diesel A/S
909-21.4 Fuel Oil Pressure Booster Top Cover
Mounting

1. Mount the lifting tool on the new or over-

1. hauled top cover assembly.

Lift the top cover assembly and apply

D09
87 grease to the new sealing rings.

Check that the face on the fuel oil pressure

booster housing and the inside cylindrical
part are clean and free of fuel oil.

2. Carefully land the top cover on the fuel oil

pressure booster.

Check that the guide pin in the top cover is

M90921
0201M01

entering the hole in the fuel oil pressure

booster housing for correct positioning.

3. Remove the lifting tool from the top cover.

2. Unscrew and remove the retaining tool for

the fuel plunger.
M90921
0201M02

3.
M90921
0201M03

Page 6 (7) When referring to this page, please quote Procedure M90921 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Top Cover 909-21.4
Mounting

4. Tighten two nut at a time diagonally.

4.
Screw the nuts on to the studs. Mount the
spacer rings and the hydraulic jacks over
the nuts. Pump up the jacks to the tighten- D13
01
ing pressure, as specified in Data. Tighten
the nuts, and remove the hydraulic jacks
and the spacer rings.

For use of hydraulic tools, see also Proce-

dure 913-1.

5. Mount the small disc in the centre hole.

M90921
0203M04
Mount and tighten the centre plug with the
left-handed thread.

Mount the fuel oil high-pressure pipes, see

Procedure 909-14.4.
5.
Mount the return oil pipe.

6. Close valve 421 and open valve 420 on the

hydraulic block.

Close the oil drain.

Open the fuel oil inlet valve.

M90921
0203M05

6.
M90921
0203M06

When referring to this page, please quote Procedure M90921 Edition 0203 Page 7 (7)
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Suction Valve 109-22
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D09-89 Fuel suction valve, tightening torque 250 Nm

When referring to this page, please quote Data D10922 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
109-22 Fuel Oil Pressure Booster Suction Valve
Data

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

Plate Item No. Description

Page 2 (2) When referring to this page, please quote Data D10922 Edition 0003
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Suction Valve 909-22.2
Dismantling

1. Shut off the oil supply to the hydraulic ac-

tuator. 1.

Mount a pressure gauge at “minimess”

point No. 455.
00:00
Close valve 420 and open valve 421 on the ON

hydraulic block for the cylinder concerned. OFF

Bourdon Sedeme

CC

Check that the hydraulic cylinder unit is

pressure free.

Shut off the fuel oil supply for the fuel oil
pressure booster.

M90922
0203D01
2. Unscrew the union nut for the suction
valve, remove and discard the O-ring.

Pull out the suction valve.

2.
M90922
0201D02

When referring to this page, please quote Procedure M90922 Edition 0203 Page 1 (3)
MAN B&W Diesel A/S
909-22.3 Fuel Oil Pressure Booster Suction Valve
Overhaul

1. Set up the fuel suction valve in a bench

1. vice with “soft” jaws and press down the
spring by means of the cone to release the
valve spindle from the two-part conical
ring.

Clean the parts thoroughly in clean diesel

oil and carefully dry.

2. Inspect the seat on the valve spindle and

the seat on the valve housing for damage.

If the seats are worn or damaged, a new

suction valve must be fitted.
M90922
0203O01

It is not recommended to recondition the

valve by lapping. Lapping will damage the
seat geometry and lead to very limited run-
ning time for the valve.
2.
3. After cleaning and inspecting all the parts,
lubricate these with molybdenum disul-
phide (MoS 2) and assemble the suction
valve.

Check the seats for tightness by filling the

inlet hole with diesel oil and waiting 5 min-
utes. No oil may pass through the seats.

4. If the suction valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
M90922
0203O02

plastic to prevent dirt from entering the

valve dur-ing storage.

3.

5 Min

Gas Oil
M90922
0203O03

Page 2 (3) When referring to this page, please quote Procedure M90922 Edition 0203
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Suction Valve 909-22.4
Mounting

1. Check that the face for the suction valve is

clean. 1.

Mount the overhauled or new suction valve.

2. Mount a new O-ring on the union nut.

Lubricate the O-ring and the thread on the

union nut with molybdenum disulphide
(MoS2) grease.

Mount and tighten the nut to the specified

torque. See Data.

M90922
0201M01
3. Close valve 421 and open valve 420 on the
hydraulic block.

Open the fuel oil valve.

2.

D09
89
M90922
0201M02

3.
M90922
0201M03

420
421

When referring to this page, please quote Procedure M90922 Edition 0203 Page 3 (3)
MAN B&W Diesel A/S
 Fuel Valve - Tools Plate
P90961-0069

When referring to this page, please quote Plate P90961 Edition 0069 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0069

Item Item Description Item Item Description

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

Page 2 (2) When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S
 Fuel Valve Nozzle - Tools Plate
P90966-0008

When referring to this page, please quote Plate P90966 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0008

Item Item Description Item Item Description

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.

Page 2 (2) When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S
 Fuel Valve - Inspection Tools Plate
P90968-0001

When referring to this page, please quote Plate P90968 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Inspection Tools
P90968-0001

Item Item Description Item Item Description

No. No.

012 Probe light with magnifier, complete

Page 2 (2) When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S
 Fuel Valve Nozzle - Cleaning Tools Plate
P90974-0001

When referring to this page, please quote Plate P90974 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Cleaning Tools
P90974-0001

Item Item Description Item Item Description

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.

Page 2 (2) When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Top Cover Seals Plate
P90981-0001

When referring to this page, please quote Plate P90981 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Top Cover Seals
P90981-0001

Item Item Description Item Item Description

No. No.

013 Cone
025 Pushing tool
037 Compression tool
049 Spacer ring

Page 2 (2) When referring to this page, please quote Plate P90981 Edition 0001
MAN B&W Diesel A/S
910 - Turbocharger System

Documents in this Chapter

110-01 0039 Air Cooler Element, Data

910-01 0234 Air Cooler Element
110-02 0007 Non-Return Valve in Turbocharger, Data
910-02 0215 Non Return Valve in Tubocharger
110-03 0017 Auxilary Blower, Data
910-03 0218 Auxilary Blower
110-04 0004 Butterfly Valve, Data
910-04 0207 Butterfly Valves
110-05 0008 Turbocharger Turbine, Data
910-05 0207 Turbocharger Turbine
110-06 0024 Water Mist Catcher, Data
910-06 0219 Water Mist Catcher
91063 0017 Air Cooler - Tools
91063 0019 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0005 Air Cooler - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Air Cooler Element 110-1
Data

SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11001
110-1 Data 0039 Air Cooler Element

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D10-02 Aft end cover 300 kg

D10-04 Air cooler element, complete with covers, up to 3500 kg
D10-05 Front end cover (waterflow reversing chamber) 300 kg

When referring to this page, please quote Data D11001 Edition 0039 Page 1 (2)
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data

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

Plate Item No. Description

Travelling trolley
P91066 Air Cooler - Lifting tools
Guide rail air cooler, fore end
Guide rail air cooler, rear end
P91356 Lifting tools, etc.

Page 2 (2) When referring to this page, please quote Data D11001 Edition 0039
MAN B&W Diesel A/S
 Air Cooler Element 910-1.1
Checking
Air Cooler Element
S60M-CC
0234
Checking
910-1.1


1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.

Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the OPERATION man-
ual, Volume I, Chapter 706.

2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of 

the air side of the cooler. 











A decrease in the air temperature drop 




across the scavenge air cooler indicates

1
-

fouling of the water side of the cooler.


3. If the measurements indicate fouling of the
water side of the air cooler element, the el-
ement must be dismantled and overhauled/
cleaned.
See Procedure 910-2.
See Procedure 910-3.

If the measurements indicate fouling of the

air side of the air cooler element, it is rec-
ommended to inspect the air cooler ele-
ment as follows:

4. Remove the top inspection cover of the air 





cooler. 









Unlock and swing open the inspection


1
-

hatch at the bottom of the air cooler.


5. Visually inspect the air cooler element
through the openings.

For further information, see the OPERA-

TION manual, Volume I, Chapter 702
“Checks during Standstill Periods”.

If the air side of the element is fouled, clean

the element using the spray pipe arrange-
ment fitted above the air cooler element.
See Procedure 910-3.















1
-

When referring to this page, please quote Procedure M91001 Edition 0234 Page 1 (9)
0$1% :'LHVHO$6
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

valves. Open the drain cocks on the water
JN910-1.2 213 01

inlet/outlet cover to drain off the cooling wa-

ter.

2. Dismount the cooling water inlet and outlet

2. pipes from the water inlet/outlet cover.

3. Release the screws and remove the frame

around the reversing chamber.

Remove and discard the O-ring.

Remove the sealing plate.

JN910-1.2 213 02

3.
JN910-1.2 213 03

Page 2 (9) When referring to this page, please quote Procedure M91001 Edition 0234
0$1% :'LHVHO$6
 Air Cooler Element 910-1.2
Dismantling

4. Mount the first set of guide rails on the 4.

frame around the reversing chamber.

5. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount the lowermost screws. Mount
and tighten the uppermost screws.

Tighten the thrust nuts on the uppermost

screws simultaneously. This results in loos-
ening and lifting the cooler element.

6. Mount the lifting bracket on the water inlet/

outlet cover.

Mount two travelling trolleys on the beam

above the water inlet/outlet cover.

Mount a tackle between the travelling trolley JN910-1.2 213 04

nearest to the air cooling housing and the

lifting bracket, and use the tackle to lift the
air cooler element approx. 1-2 mm.
5.
JN910-1.2 213 05

6.
JN910-1.2 213 06

When referring to this page, please quote Procedure M91001 Edition 0234 Page 3 (9)
0$1% :'LHVHO$6
910-1.2 Air Cooler Element
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.

Shift the lifting tackle between the two trav-

elling trolleys to avoid damaging pipes,
valves, etc.

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

wheels on the reversing chamber interlock
with the recess in the guide rails.
JN910-1.2 213 07

8.
JN910-1.2 213 08

9.
D10-04
JN910-1.2 213 09

Page 4 (9) When referring to this page, please quote Procedure M91001 Edition 0234
0$1% :'LHVHO$6
 Air Cooler Element 910-1.3
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

2) Product: 80B, produced by

Vecom Int., Maassluis, Holland

Cleaning should be carried out in the following

sequence:

1. Do not start cleaning until the engine has

been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.
JN910-1.3 213 01

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- 2.
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 as described in Proce-

dure 910-1.1.
KE910-5.1 61 02

When referring to this page, please quote Procedure M91001 Edition 0234 Page 5 (9)
0$1% :'LHVHO$6
910-1.3 Air Cooler Element
Overhaul

6. Cleaning the water side

6. Close the cooling water inlet and outlet

valves. Open the drain cocks on the water
inlet/outlet cover to drain off the cooling wa-
ter.

7. Dismount the cooling water inlet and outlet

pipes from the water inlet/outlet cover.

8. Screw two eye bolts into the upper flange of

the water inlet/outlet cover. Mount a lifting
wire rope between the eye bolts.
JN910-1.2 213 01

Mount a travelling trolley on the beam

above the water inlet/outlet cover.

Mount a tackle between the travelling trolley

7. and the lifting wire rope. Tighten up the
tackle.
JN910-1.2 213 02

8.
JN910-1.3 213 08

Page 6 (9) When referring to this page, please quote Procedure M91001 Edition 0234
0$1% :'LHVHO$6
 Air Cooler Element 910-1.3
Overhaul

9. Mount a shackle in each of the two lifting 9.

eyes on the reversing chamber.

Mount two tackles above the reversing

chamber.

Hook the tackles on to the shackles and

tighten up.

10. Remove the screws of the water inlet/outlet

cover and the reversing chamber.

Lower both covers and land them on a cou-

ple of wooden planks. Discard the gaskets.

JN910-1.3 213 09
11. Clean the inside of the tubes, using the
cleaning brush (delivered by the cooler el-
ement manufacturer) mounted on a drilling
machine. In the event of leakages between 10. D10-02
cooling tube and tube plate, the tubes are D10-05
rolled with the tube expande (also delivered
by the cooler element manufacturer).

Clean the front-end and aft-end covers in-

side with a stiff brush and then rinse with
fresh water.

Replace the anti-corrosion blocks, if neces-

sary.

Note!
JN910-1.3 213 10

If damaged, the coating inside the covers

D-1
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.
JN910-1.3 213 11

When referring to this page, please quote Procedure M91001 Edition 0234 Page 7 (9)
0$1% :'LHVHO$6
910-1.4 Air Cooler Element
Mounting
Mounting
910-1.4

1. 1. Push the air cooler element inwards ap-

prox. one metre.

Remove the guide rails from the water inlet/

outlet cover end of the air cooler housing.

2. Clean the frame around the air cooler ele-

ment and the contact surface of the water
inlet/outlet cover.

Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the water inlet/outlet cov-
er.

Push the air cooler element fully into the air

cooler housing.
JN910-1.4 213 01

Shift the lifting tackles bsetween the two

travelling trolleys to avoid damaging pipes,
valves etc.
2.
JN910-1.4 213 02

Page 8 (9) When referring to this page, please quote Procedure M91001 Edition 0234
0$1% :'LHVHO$6
 Air Cooler Element 910-1.4
Mounting

3. Mount and tighten all the screws of the wa- 3.

ter inlet/outlet cover.

Remove the tackle and the lifting bracket

from the water inlet/outlet cover.

4. Remove the guide rails from the reversing

chamber end of the air cooler housing.

5. Mount the sealing plate, a new O-ring and

the frame around the reversing chamber.

6. Mount the cooling water inlet and outlet

pipes on the water inlet/outlet cover.

JN910-1.4 213 03
7. Close the drain cocks, and open the cooling
water inlet and outlet valves.

4.
Note!

Remember to vent trapped air from the

air cooler element.
JN910-1.4 213 04

When referring to this page, please quote Procedure M91001 Edition 0234 Page 9 (9)
0$1% :'LHVHO$6
 Non-Return Valve 110-2
Data

SAFETY PRECAUTIONS
Special Edition
S60MCC
D11002
110-2 Data 0007 Non-Return Valve

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11002 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
110-2 Non-Return Valve
Data

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

Plate Item No. Description

P91361 Combination wrenches

Page 2 (2) When referring to this page, please quote Data D11002 Edition 0007
MAN B&W Diesel A/S
 Non-Return Valve 910-2.3
Overhaul
Non-Return Valve
S60MC-C
0215
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.

HN910-2.3 215 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.
HN910-2.3 215 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

When referring to this page, please quote Procedure 910-2.3 Edition 0215 Page 1 (1)
0$1% :'LHVHO$6
 Auxiliary Blower 110-3
Data

SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11003
110-3 Data 0017 Auxiliary Blower

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D10-12 Electric motor, impeller and motorplate 610 kg

When referring to this page, please quote Data D11003 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
110-3 Auxiliary Blower
Data

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

Plate Item No. Description

P91356 Lifting tools, etc.

P91361 Combination wrenches

Page 2 (2) When referring to this page, please quote Data D11003 Edition 0017
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

When referring to this page, please quote Procedure M91003 Edition 0218 Page 1 (1)
0$1% :'LHVHO$6
 Butterfly Valves 110-4
Data

SAFETY PRECAUTIONS
Special Edition
S46MC-C
D11004
110-4 Data 0004 Butterfly Valves

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11004 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
110-4 Butterfly Valves
Data

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

Plate Item No. Description

P91361 Combination Wrenches

Page 2 (2) When referring to this page, please quote Data D11004 Edition 0004
MAN B&W Diesel A/S
 Butterfly Valves 910-4.1
Checking
Butterfly Valves
S60MC-C
0207
Checking
910-4.1

1.
1. It is important that the automatic non-return
valves (butterfly valves) are always able to
function easily and unimpeded.

The movability of the valve flaps should

therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.

2. To check the valve, remove the cover on the

top of the butterfly valve.

GN910-4.1 203 01
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
2.
a fingertip, it must be dismantled and over-
hauled.

4. Re-mount the cover on the top of the but-

terfly valve.
XZ910-9.0 15 02

When referring to this page, please quote Procedure M91004 Edition 0207 Page 1 (1)
0$1% :'LHVHO$6
 Turbocharger Turbine 110-5
Data

SAFETY PRECAUTIONS
Special Edition
D11005
110-5 Data 0008 Turbocharger
L60MCCTurbine

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

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11005 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
Data

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

Plate Item No. Description

Page 2 (2) When referring to this page, please quote Data D11005 Edition 0008
MAN B&W Diesel A/S
 Turbocharger Turbine 910-5.3
Cleaning
Turbocharger Turbine
0207
/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.

When referring to this page, please quote Procedure M91005 Edition 0207 Page 1 (2)
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.
HN910-5.3 207 01

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.

Page 2 (2) When referring to this page, please quote Procedure M91005 Edition 0207
0$1% :'LHVHO$6
 Water Mist Catcher 110-6
Data

SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11006
110-6 Data 0024 Water Mist Catcher

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
X Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D10-11 Water mist catcher 180 kg

When referring to this page, please quote Data D11006 Edition 0024 Page 1 (2)
MAN B&W Diesel A/S
110-6 Water Mist Catcher
Data

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

Plate Item No. Description

P91356 Lifting tools, etc.

Page 2 (2) When referring to this page, please quote Data D11006 Edition 0024
MAN B&W Diesel A/S
 Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
S46MC
0219
Dismantling
910-6.2

2.
1. Normally it is not necessary to remove the
water mist catcher from the scavenge air
cooler housing. If, however, the water mist
catcher has been fouled or damaged, it
must be dismantled for cleaning or repair.

2. Dismantle the rectangular covers from both

the front and aft ends of the scavenge air
cooler housing.

3. Loosen the screws at both ends of the wa-

ter mist catcher.

GM910-6.2 213 02
Note!

Note the position of the water mist

catcher. During mounting, the water mist
catcher must be re-mounted in the same 4.
position.

4. Pull or push the water mist catcher halfway

out and mount an eye bolt in the top of the
water mist catcher. D10-11
Hook a tackle on to the eye bolt and lift the
water mist catcher away. Land it on a cou-
ple of wooden planks.

Note!
GM910-6.2 213 04

Take care not to damage the water mist

catcher during the lift.

5. Clean the water mist catcher with the same

cleaning fluid as used for the scavenge air
cooler element.

When referring to this page, please quote Procedure M91006 Edition 0219 Page 1 (2)
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4

1. 1. Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face away from the engine when
the water mist catcher is mounted (the side
opposite to the screws).
Toward
Engine 2. Slide the water mist catcher into the scav-
enge air cooler housing.

Note!

Make sure to mount the water mist

catcher correctly. The screws of the
GM910-6.4 213 01

water mist catcher must face the exhaust

side of the engine.
6LOLFRQH

When the water mist catcher is half-way in,

2. remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.

3. Tighten the screws at both ends of the wa-

ter mist catcher.

Apply a thin layer of silicone paste on the

D10-11 frame and mount the rectangular covers on
the front and aft ends of the scavenge air
cooler housing.
GM910-6.4 213 02

3.
GM910-6.4 213 03

Page 2 (2) When referring to this page, please quote Procedure M91006 Edition 0219
0$1% :'LHVHO$6
 Air Cooler - Tools Plate
P91063-0017

When referring to this page, please quote Plate P91063 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0017

Item Item Description Item Item Description

No. No.

015 Guide rail, air cooler fore end

027 Guide rail, air cooler fore end

Page 2 (2) When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S
 Air Cooler - Tools Plate
P91063-0019

When referring to this page, please quote Plate P91063 Edition 0019 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0019

Item Item Description Item Item Description

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

When referring to this page, please quote Plate P91064 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0002

Item Item Description Item Item Description

No. No.

010 Travelling trolley*

Note:

* When ordering this tool, please state

load and track width.

Page 2 (2) When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S
 Air Cooler - Lifting Tools Plate
P91066-0005

When referring to this page, please quote Plate P91066 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler - Lifting Tools
P91066-0005

Item Item Description Item Item Description

No. No.

011 Lifting attachment air cooler fore

end, complete
047 Screw

Page 2 (2) When referring to this page, please quote Plate P91066 Edition 0005
MAN B&W Diesel A/S
911 - Safety Equipment

Documents in this Chapter

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
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

D11-01 Opening pressure 200± 5 bar

D11-02 Valve housing, tightening torque 45 Nm

When referring to this page, please quote Data D11101 Edition 0025 Page 1 (2)
MAN B&W Diesel A/S
111-1 Safety Valve
Data

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

Plate Item No. Description

P91351 10 Hydraulic pump, pneumatically operated

P91351 58 Hose with unions (3000 mm), complete
P90151 117 Test equipment for combined safety valve
P91359 Torque Spanners

Page 2 (2) When referring to this page, please quote Data D11101 Edition 0025
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.

M91101
0211D01
2.
M91101
0211D02

When Top-mounted 3.

3. Unscrew the safety valve from the cylinder

cover.

Remove and discard the mild steel disc.

M91101
0211D03

When referring to this page, please quote Procedure M91101 Edition 0211 Page 1 (5)
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.
M91101
0211O01

3. Then mount:

• the valve spindle

• the spring
2.
• the adjusting screw

• the lock nut

M91101
0211O02

3.
M91101
0211O03

Page 2 (5) When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
 Safety Valve 911-1.3
Overhaul (adjustment)

4. To set the safety valve opening pressure:

4.
• Set up the safety valve in the testing D11
01
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-

M91101
0211O04
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.

When referring to this page, please quote Procedure M91101 Edition 0211 Page 3 (5)
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

M91101
0211M01

tools only on the hexagon on the safety

valve.

Mount the guard surrounding the safety

valve.

2.
M91101
0211M02

3.
M91101
0211M03

Page 4 (5) When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
 Safety Valve 911-1.4
Mounting

When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.

Clean the thread and the sealing surface.

5. Mount a new or overhauled safety valve.

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-

M91101
0211M04
gon on the safety valve.

5.
M91101
0211M05

When referring to this page, please quote Procedure M91101 Edition 0211 Page 5 (5)
MAN B&W Diesel A/S
 Relief Valve 111-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

When referring to this page, please quote Data D11102 Edition 0013 Page 1 (2)
MAN B&W Diesel A/S
111-2 Relief Valve
Data

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

Plate Item No. Description

Page 2 (2) When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S
 Relief Valve 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

When referring to this page, please quote Procedure M91102 Edition 0211 Page 1 (1)
0$1% :'LHVHO$6
 Scavenge Air Receiver Safety Valve 111-3
MAN B&W Diesel Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

When referring to this page, please quote Data D11103 Edition 0001 Page 1 (2)
111-3 Scavenge Air Receiver Safety Valve
Data MAN B&W Diesel

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

Plate Item No. Description

Page 2 (2) When referring to this page, please quote Data D11103 Edition 0001
 Scavenge Air Receiver Safety Valve 911-3.1
MAN B&W Diesel Checking

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.

M91103
0001C02
If this operation cannot be performed
smoothly, the safety valve must be disman-
tled and cleaned.

When referring to this page, please quote Procedure M91103 Edition 0001 Page 1 (5)
911-3.2 Scavenge Air Receiver Safety Valve
Dismantling MAN B&W Diesel

1. Dismount the safety valve from the scav-

1. enge air receiver.
M91103
0001D01

Page 2 (5) When referring to this page, please quote Procedure M91103 Edition 0001
 Scavenge Air Receiver Safety Valve 911-3.3
MAN B&W Diesel Overhaul

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

M91103
0001O01
damaging the O-ring groove.

3. Clean the metal surfaces thoroughly.

2.
M91103
0001O02

When referring to this page, please quote Procedure M91103 Edition 0001 Page 3 (5)
911-3.3 Scavenge Air Receiver Safety Valve
Overhaul MAN B&W Diesel

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.

M91103
0001O04

5.
M91103
0001O05

6.
M91103
0001O01

Page 4 (5) When referring to this page, please quote Procedure M91103 Edition 0001
 Scavenge Air Receiver Safety Valve 911-3.4
MAN B&W Diesel Mounting

1. Mount the safety valve on the scavenge air

receiver. 1.

M91103
0001M01

When referring to this page, please quote Procedure M91103 Edition 0001 Page 5 (5)
912 - Assembly of Large Parts

Documents in this Chapter

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

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Holding Down and End Chock Bolts 112-2
Data

SAFETY PRECAUTIONS
Special Edition
D11202
112-2 Data 0009 Holding Down
S60MC-C
and End Chock Bolts

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

Data
Ref. Description Value Unit

D12-02 Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
1st check 500 hours
2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequent checks at intervals of 8000 hours
D13-01 Tightening pressure 1500 bar
D13-02 Dismantling pressure 1400-1650 bar

When referring to this page, please quote Data D11202 Edition 0009 Page 1 (2)
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
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

P91263 Hydraulic tools for holding-down bolts

Bolts and end chock bolts, epoxy
P91351 10 Hydraulic pump, pneumatically operated

Page 2 (2) When referring to this page, please quote Data D11202 Edition 0009
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.

When referring to this page, please quote Procedure M91202 Edition 0207 Page 1 (3)
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.

Page 2 (3) When referring to this page, please quote Procedure M91202 Edition 0207
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.

When referring to this page, please quote Procedure M91202 Edition 0207 Page 3 (3)
0$1% :'LHVHO$6
 Stay Bolts 112-3
Data

SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11203
112-3 Data 0018 Stay Bolts

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D12-04 Check measurement 180±3 mm

D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D11203 Edition 0018 Page 1 (2)
MAN B&W Diesel A/S
112-3 Stay Bolts
Data

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

Plate Item No. Description

P91351 10 Hydraulic pump, pneumatically operated

P91351 34 Hose with unions (1000 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91261 23 Hydraulic jack, complete

Page 2 (2) When referring to this page, please quote Data D11203 Edition 0018
MAN B&W Diesel A/S
 Stay Bolts 912-3.1
Checking
Stay Bolts
S60MC-C
0212
Checking
912-3.1

1.
1. This check can be performed during several
periods of stopped engine, but must be per- One Group
formed on complete twin stay bolt groups at One Group
a time, thereby ensuring uniform tension in
the affected bearings.

Note!

The first time this check is performed it

has to be completed in one operation.

NA912-3.1 210 01
The following checks have to be com-
pleted within a 500-hour period.

2. Before retightening the stay bolts, remove

the protective caps. 2.

3. Check for loose staybolt nuts with the tom-

my bar.

If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 01

Loosen and unscrew the nut on the oppo-

site stay bolt.

Check for the correct mounting of the stay

bolt by comparing with the check measure-
ment on the Data Sheet. 3.
D13-02
If the check measurement is not reached,
indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the
D12-04
thread in the top of the stay bolt, and turn
the stay bolt until the check measurement
GN912-3.0 39 09

data is met.

4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.

D13-01
GN912-3.1 202 03

When referring to this page, please quote Procedure M91203 Edition 0212 Page 1 (2)
0$1% :'LHVHO$6
912-3.1 Stay Bolts
Checking

5. 5. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other.

Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
D13-01 stay bolts are tightened in one operation.

6. Maintain the mounting pressure, and

retighten the stay bolt nuts with a tommy
bar. Before relieving the system of pres-
sure, check with a feeler gauge that the
nuts bear against their contact faces.
GN912-3.1 202 02

7. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below the mounting pressure and check
6. whether the nut is loose.

If the nut is not loose:

Tighten the stay bolts concerned to the
mounting pressure.

If the nut is loose:

Tighten all stay bolts once again to the
mounting pressure.

8. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 04

7.
HM912-3.0 28 05

Page 2 (2) When referring to this page, please quote Procedure M91203 Edition 0212
0$1% :'LHVHO$6
 Crankcase Oil Outlet 912-5.1
MAN B&W Diesel Checking

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.

M91205
0201C01
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.
M91205
0201C02

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.

When referring to this page, please quote Procedure M91205 Edition 0201 Page 1 (2)
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
M91205
0201C04

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.
M91205
0201C07

11. Remove the four screws A.

12. Mount grating B.

13. Mount all screws A.

Page 2 (2) When referring to this page, please quote Procedure M91205 Edition 0201
 Large Parts - Tools Plate
P91261-0073

When referring to this page, please quote Plate P91261 Edition 0073 Page 1 (2)
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0073

Item Item Description Item Item Description

No. No.

023 Hydraulic jack, complete

035 Support
047 Tommy bar
050 Sealing ring with back-up ring
060 Sealing ring with back-up ring
084 Spanner
106 Stud setter
202 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P91261 Edition 0073
MAN B&W Diesel A/S
 Hydraulic Tools - End-Chock Bolts Plate
P91266-0001
(Epoxy Chocks)

When referring to this page, please quote Plate P91266 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Hydraulic Tools - End-Chock Bolts
P91266-0001
(Epoxy Chocks)
Item Item Description Item Item Description
No. No.

019 Wooden box

020 Hydraulic jack, complete
032 Support
056 O-ring with back-up ring
068 O-ring with back-up ring
093 Tommy bar
103 Spanner

Page 2 (2) When referring to this page, please quote Plate P91266 Edition 0001
MAN B&W Diesel A/S
913 - General Tools

Documents in this Chapter

913-01 0215 Hydraulic Tools

913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools
91356 0053 Lifting Tools, etc.
91357 0007 Open-Ended Spanners
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0040 Spanners
91364 0059 Open-Ended Spanners
91366 0065 Instruments
91366 0067 Instruments
91368 0007 Working Platforms

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Hydraulic Tools 913-1.1
Description

A. Snap-on coupling
1. A
B. Tool attachment thread C B
C. Bleed screw D
D. Piston E
E. Cylinder
F. Sealing rings
F
G. Spacer ring G S
H. Tommy bar
I. Nut
J. Stud or bolt

M91301
0215C01
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
M91301
0215C02

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.

When referring to this page, please quote Procedure M91301 Edition 0215 Page 1 (12)
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
M91301
0215C03

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.
M91301
0215C04

Page 2 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.2
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.
M91301
0215D01

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.
M91301
0215D02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 3 (12)
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.
M91301
0215D03

Note!

Make sure not to exceed the “max lift”

stamped on the jack.

4.
M91301
0215D04

5.
M91301
0215D05

Page 4 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.2
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

M91301
0215D06

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
M91301
0215D07

When referring to this page, please quote Procedure M91301 Edition 0215 Page 5 (12)
MAN B&W Diesel A/S
913-1.2 Hydraulic Tools
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
means of high pressure hoses.

Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
M91301
0215D08

bubbles, flows out of the bleed holes.

Re-tighten the bleed screws.

9. Increase the oil pressure to the prescribed

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.

11. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
M91301
0215D09

Note!
Make sure not to exceed the “max lift”
stamped on the jack.

Page 6 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.3
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.
M91301
0215O01

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
M91301
0215O02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 7 (12)
MAN B&W Diesel A/S
913-1.3 Hydraulic Tools
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.
M91301
0215O03

Page 8 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.4
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

M91301
0215D01

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.

M91301
0215D02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 9 (12)
MAN B&W Diesel A/S
913-1.4 Hydraulic Tools
Mounting

3. Increase the oil pressure to the prescribed

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.

5. Relieve the system of pressure, disconnect

the pump, and remove the hydraulic jack.
M91301
0215M03

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.
M91301
0215M04

Page 10 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.4
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.

M91301
0215M05
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
M91301
0215D06

the jacks bear firmly against each other

and against the spacer ring.

When referring to this page, please quote Procedure M91301 Edition 0215 Page 11 (12)
MAN B&W Diesel A/S
913-1.4 Hydraulic Tools
Mounting

7. Connect the hydraulic jacks, the distributor

7. block and the high pressure pump by
means of high pressure hoses.

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.

8. Increase the oil pressure to the prescribed

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
M91301
0215M07

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.
10. Relieve the system of pressure, disconnect
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.
M91301
0215M08

9.
M91301
0215M09

Page 12 (12) When referring to this page, please quote Procedure M91301 Edition 0215
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.

Thread Tightening Thread Tightening

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.

Thread Tightening Thread Tightening

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

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

When referring to this page, please quote Procedure M91305 Edition 0205 Page 1 (1)
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.
See Procedure 913-5.

Apply a pre-tightening torque of:

– thread M8 – M20 = 50 Nm
– thread M22 – M27 = 100 Nm
– thread M30 – M39 = 150 Nm
– thread M42 – M48 = 200 Nm

This is in order to ensure a uniform basis for the

subsequent tightening with gauge or tightening
angle.

Tightening with a tightening gauge

After pre-tightening, place the tightening gauge

round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.

Tightening without a tightening gauge

For tightening angles of e.g. 30°–45° and 60°,

we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,


respectively. Then tighten the nut until the two 





marks coincide.



7
;

G
Q

When tightening new studs or bolts for the first

D





time, loosen again and repeat the procedure –







including pre-tightening with a torque spanner,






to allow the parts to settle.


0
+

See Procedure 913-5.

When referring to this page, please quote Procedure M91306 Edition 0205 Page 1 (1)
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-

M91307
0207C01
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
M91307
0207C02

to the torque value stated on the data

sheet of a procedure.

3.
M91307
0207C03

When referring to this page, please quote Procedure M91307 Edition 0207 Page 1 (4)
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.
M91307
0207C04

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.
M91307
0207C05

Fig. 9

Page 2 (4) When referring to this page, please quote Procedure M91307 Edition 0207
 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. M91307
0207C06
Fig. 13

Fig. 14

When referring to this page, please quote Procedure M91307 Edition 0207 Page 3 (4)
913-7.1 Screws and Nuts
Locking MAN B&W Diesel

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-

M91307
0207C15

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.
M91307
0207C16

Fig. 17
M91307
0207C17

Page 4 (4) When referring to this page, please quote Procedure M91307 Edition 0207
 Lubricating Procedures 913-11

Lubricating Procedures
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.

When referring to this page, please quote Procedure M91311 Edition 0204 Page 1 (1)
0$1% :'LHVHO$6
 Accessories for Hydraulic Tools Plate
P91351-0037

When referring to this page, please quote Plate P91351 Edition 0037 Page 1 (2)
MAN B&W Diesel A/S
Plate Accessories for Hydraulic Tools
P91351-0037

Item Item Description Item Item Description

No. No.

010 Hydralic pump, pneumatic operated

022 Hydralic pump, hand operated
046 Hose with unions (1500mm), com-
plete
058 Hose with unions (3000mm), com-
plete
060 Hose with unions (5000mm), com-
plete
105 2-way distributor block, complete
117 4-way distributor block, complete
130 9-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

Page 2 (2) When referring to this page, please quote Plate P91351 Edition 0037
MAN B&W Diesel A/S
 Lifting Tools, Etc. Plate
P91356-0053

When referring to this page, please quote Plate P91356 Edition 0053 Page 1 (2)
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0053

Item Item Description Item Item Description

No. No.

020 Forged-bent screw shackle, 10mm

031 Forged-bent screw shackle, 12mm
043 Forged-bent screw shackle, 16mm
055 Forged-bent screw shackle, 20mm
067 Forged-bent screw shackle, 24mm
079 Forged-bent screw shackle, 30mm
114 Lifting eye bolts, 10mm
126 Lifting eye bolts, 12mm
138 Lifting eye bolts, 16mm
140 Lifting eye bolts, 20mm
151 Lifting eye bolts, 24mm
163 Lifting eye bolts, 30mm
210 Chain tackle, 500kg
222 Chain tackle, 1000kg
234 Chain tackle, 2000kg
260 Chain tackle, 5000kg
295 Pull lift, 3000kg
305 Wire rope, 6m

Page 2 (2) When referring to this page, please quote Plate P91356 Edition 0053
MAN B&W Diesel A/S
 Open Ended Spanners Plate
P91357-0007

When referring to this page, please quote Plate P91357 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0007

Item Item Description Item Item Description

No. No.

013 Open-ended spanner, size NV65mm

037 Open-ended spanner, size NV75mm
049 Open-ended spanner, size NV80mm
050 Open-ended spanner, size NV85mm
062 Open-ended spanner, size NV90mm

Page 2 (2) When referring to this page, please quote Plate P91357 Edition 0007
MAN B&W Diesel A/S
 Open-Ended Slugging Spanners Plate
P91358-0014

When referring to this page, please quote Plate P91358 Edition 0014 Page 1 (2)
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0014

Item Item Description Item Item Description

No. No.

164 Open-ended slugging spanner, size

NV85mm

Page 2 (2) When referring to this page, please quote Plate P91358 Edition 0014
MAN B&W Diesel A/S
 Torque Wrenches Plate
P91359-0003

When referring to this page, please quote Plate P91359 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Torque Wrenches
P91359-0003

Item Item Description Item Item Description

No. No.

014 Torque wrench, 8 - 400Nm

026 Adapter for socket wrench, 10 x 12.5
mm
038 Torque wrench, 40 - 200Nm
040 Torque wrench, 140 - 760Nm
051 Torque wrench, 750 - 2000Nm

Page 2 (2) When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S
 Pliers Plate
P91360-0004

When referring to this page, please quote Plate P91360 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Pliers
P91360-0004

Item Item Description Item Item Description

No. No.

010 Pliers for retaining ring, size 0.9mm

021 Pliers for retaining ring, size 1.3mm
033 Pliers for retaining ring, size 1.8mm
045 Pliers for retaining ring, size 2.3mm
057 Pliers for retaining ring, size 3.2mm
128 Pliers for retaining ring, size 1.1mm
130 Pliers for retaining ring, size 1.8mm
141 Pliers for retaining ring, size 2.3mm
153 Pliers for retaining ring, size 3.2mm

Page 2 (2) When referring to this page, please quote Plate P91360 Edition 0004
MAN B&W Diesel A/S
 Combination Spanners Plate
MAN B&W Diesel P91361-0052

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

Item Item Description Item Item Description

No. No.

015 Combination spanners, size NV10mm

027 Combination spanners, size NV11mm
039 Combination spanners, size NV12mm
040 Combination spanners, size NV13mm
052 Combination spanners, size NV14mm
064 Combination spanners, size NV15mm
076 Combination spanners, size NV16mm
088 Combination spanners, size NV17mm
090 Combination spanners, size NV18mm
100 Combination spanners, size NV19mm
111 Combination spanners, size NV21mm
123 Combination spanners, size NV22mm
135 Combination spanners, size NV24mm
147 Combination spanners, size NV27mm
159 Combination spanners, size NV30mm
160 Combination spanners, size NV32mm
172 Combination spanners, size NV34mm
184 Combination spanners, size NV36mm
196 Combination spanners, size NV41mm
206 Combination spanners, size NV46mm
218 Combination spanners, size NV50mm
220 Combination spanners, size NV55mm
231 Combination spanners, size NV60mm

Page 2 (2) When referring to this page, please quote Plate P91361 Edition 0052
 Ring Slugging Spanners Plate
P91362-0069

When referring to this page, please quote Plate P91362 Edition 0069 Page 1 (2)
MAN B&W Diesel A/S
Plate Ring Slugging Spanners
P91362-0069

Item Item Description Item Item Description

No. No.

022 Slugging spanner, ring size NV30mm

034 Slugging spanner, ring size NV32mm
046 Slugging spanner, ring size NV34mm
058 Slugging spanner, ring size NV36mm
060 Slugging spanner, ring size NV41mm
071 Slugging spanner, ring size NV46mm
083 Slugging spanner, ring size NV50mm
095 Slugging spanner, ring size NV55mm
105 Slugging spanner, ring size NV60mm
117 Slugging spanner, ring size NV65mm
120 Slugging spanner, ring size NV70mm
130 Slugging spanner, ring size NV75mm
142 Slugging spanner, ring size NV80mm
154 Slugging spanner, ring size NV85mm
166 Slugging spanner, ring size NV90mm
178 Slugging spanner, ring size NV95mm

Page 2 (2) When referring to this page, please quote Plate P91362 Edition 0069
MAN B&W Diesel A/S
 Spanners Plate
MAN B&W Diesel P91363-0040

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

Item Item Description Item Item Description

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

Page 2 (2) When referring to this page, please quote Plate P91363 Edition 0040
 Open-ended Spanners Plate
P91364-0059

When referring to this page, please quote Plate P91364 Edition 0059 Page 1 (2)
MAN B&W Diesel A/S
Plate Open-ended Spanners
P91364-0059

Item Item Description Item Item Description

No. No.

011 Open ring wrench, 14 - 17mm

023 Open ring wrench, 19 - 22mm

Page 2 (2) When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S
 Instruments Plate
P91366-0065

When referring to this page, please quote Plate P91366 Edition 0065 Page 1 (2)
MAN B&W Diesel A/S
Plate Instruments
P91366-0065

Item Item Description Item Item Description

No. No.

048 Autolog, measuring tool for crankshaft

050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool

Page 2 (2) When referring to this page, please quote Plate P91366 Edition 0065
MAN B&W Diesel A/S
 Instruments Plate
P91366-0067

When referring to this page, please quote Plate P91366 Edition 0067 Page 1 (2)
MAN B&W Diesel A/S
Plate Instruments
P91366-0067

Item Item Description Item Item Description

No. No.

012 Pressure gauge

Page 2 (2) When referring to this page, please quote Plate P91366 Edition 0067
MAN B&W Diesel A/S
 Working Platforms Plate
P91368-0007

When referring to this page, please quote Plate P91368 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0007

Item Item Description Item Item Description

No. No.

013 Platform board

Page 2 (2) When referring to this page, please quote Plate P91368 Edition 0007
MAN B&W Diesel A/S
 Warning S900-1

0001
S900-1

Warning!

It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines’ Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
§94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.

When referring to this page, please quote S900 Edition 0001 Page 1 (1)
MAN B&W Diesel A/S
 VOLUME III
S60ME-C COMPONENTS
DESCRIPTION
900 - Introduction

Documents in this Chapter

Table of Contents, Volume III

90001 0076 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90023 0027 Instructions for Main Engine

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Table of Contents 900
Volume III - Components Description

No. Edition Title

900 - Introduction
Table of Contents
90001 0076 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90023 0027 Instructions for Main Engine

901 - Cylinder Cover

90101 0167 Cylinder Cover
90103 0004 Indicator Cock - Mounting

902 - Piston with Rod & Stuffing Box

90201 0220 Piston and Piston Rod
90205 0121 Piston Rod Stuffing Box

903 - Cylinder Liner and Cylinder Lubrication

90301 0176 Cylinder Frame
90302 0196 Cylinder Liner and Cooling Jacket
90303 0013 Cylinder Frame - Details
90304 0036 Cylinder Liner - Details
90307 0025 Cylinder Lubricator Unit
90309 0026 Cylinder Lubricator System - Details

904 - Crosshead with Connecting Rod

90401 0139 Connecting Rod and Crosshead
90403 0012 Lubricating and Cooling Oil-Flow

905 - Crankshaft, Thrust Bearing and Turning Gear

90503 0023 Arrangement of Angle Encoder
90504 0010 Axial Vibration Monitor
90505 0166 Thrust- and Guide Bearing
90507 0007 Trigger Ring System
90510 0129 Turning Gear
90511 0052 Turning Wheel
90512 0002 Turning Gear - Details
90513 0034 Tacho System

906 - Control Gear

90600 0133 Arrangement of Chain Drive and Camshaft
90603 0120 Chain Tightener
90612 0092 Arrangement of Indicator System
90632 0025 Chain Drive Guidebars - Lower Part
90634 0027 Chain Drive Lubrication - Lower Part
90635 0009 Hydraulic Cylinder Unit
90636 0011 Hydraulic Cylinder Unit - Details

MAN B&W Diesel A/S Page 1 (3)

 Table of Contents 900
Volume III - Components Description

No. Edition Title

90638 0013 Hydraulic Power Supply - Drive

90639 0014 Hydraulic Power Supply - Drive, Details
90641 0012 Hydraulic Power Supply - Accumulator
90643 0008 Hydraulic Supply System, Low Pressure
90644 0012 Hydraulic Supply System, High Pressure
90645 0012 Electronic Components - Engine Control System
90646 0008 Electronic Components - Lubrication System
90647 0005 Engine Control Room - Components
90648 0004 Pneumatic Components

907 - Starting Air System

90702 0069 Main Starting Valve
90704 0055 Starting Valve

908 - Exhaust Valve

90801 0205 Exhaust Valve - Lower Parts
90802 0059 Exhaust Valve - Details
90803 0038 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0142 Exhaust Valve - Actuator
90806 0097 Exhaust Valve - Pipe System
90811 0015 Arrangement of Freshwater Pipes

909 - Fuel Oil System

90910 0144 Fuel Valve
90911 0022 Fuel Valve Function
90913 0166 High-Pressure Pipes
90914 0095 Fuel Oil System
90915 0060 Fuel Oil System - Details
90917 0004 Fuel Oil Pressure Booster

910 - Turbocharger System

91000 0017 Gas and Air System
91001 0167 Scavenge Air Receiver
91002 0126 Arrangement of Charging Air Pipe
91003 0200 Exhaust Pipes and Receiver
91004 0064 Exhaust Receiver - Details
91005 0127 Air Cooler
91006 0041 Arrangement of Auxiliary Blower
91007 0017 Butterfly Valve
91009 0032 Air Cooler System - Cleaning
91011 0024 Arrangement of Non-Return Valve
91012 0026 Arrangement of Floor Plates - Scavenge Air Receiver
91014 0022 Arrangement of Suction Pipe

MAN B&W Diesel A/S Page 2 (3)

 Table of Contents 900
Volume III - Components Description

No. Edition Title

911 - Safety Equipment

91101 0037 Safety Valve - Cylinder
91102 0028 Relief Valve
91102 0033 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0100 Arrangement of Safety Cap
91107 0002 Manual Shutdown Valve, F.

912 - Assembly of Large Parts

91201 0095 Arrangement of Stay Bolts
91204 0027 Frame - Details
91205 0188 Frame Box
91206 0118 End Shields
91207 0092 Arrangement of Piston Cooling
91210 0163 Bedplate
91211 0081 Axial Vibration Damper
91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0002 Top Bracing - Arrangement

MAN B&W Diesel A/S Page 3 (3)

 Cross Section through Engine Plate
MAN B&W Diesel P90001-0076

When referring to this page, please quote Plate P90001 Edition 0076 Page 1 (1)
 Ordering of Insulation Plate
MAN B&W Diesel P90002-0001

When referring to this page, please quote Plate P90002 Edition 0001 Page 1 (1)
 Designations and Symbols Plate
MAN B&W Diesel P90003-0001

Normal layout Forward (fwd.)

Port side of ship Starboard (stbd) side of ship

Fore end
1
2
Cyl. nos. always counted
3
4 from fore end
5
6
7

Manoevring side of engine Aft end Exhaust side of engine

Propeller

Clockwise direction of rotation

defined from aft end of engine

When referring to this page, please quote Plate P90003 Edition 0001 Page 1 (1)
 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
901 - Cylinder Cover

Documents in this Chapter

90101 0167 Cylinder Cover

90103 0004 Indicator Cock - Mounting

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Cylinder Cover Plate
MAN B&W Diesel P90101-0167

When referring to this page, please quote Plate P90101 Edition 0167 Page 1 (2)
Plate
Cylinder Cover
P90101-0167 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Screw
031 Protective cap
043 Nut
055 Stud
067 Cylinder cover
079 Stud
080 Washer
092 Nut
102 Stud
114 Screw
126 O-ring
138 Cooling jacket
151 Gasket
175 Nut
222 Stud
234 Stud
246 Pipe for fuel valve
258 Spring housing, complete

Page 2 (2) When referring to this page, please quote Plate P90101 Edition 0167
 Indicator Cock - Mounting Plate
MAN B&W Diesel P90103-0004

When referring to this page, please quote Plate P90103 Edition 0004 Page 1 (2)
Plate
Indicator Cock - Mounting
P90103-0004 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

019 Indicator cock

020 Gasket
032 Gasket
056 Disc
068 Plug screw
081 Sundry chain
093 Key ring
103 Eye screw
127 Gasket
140 Screw
152 Nut
176 Flange
188 Extension
223 Screw
235 Extension

Page 2 (2) When referring to this page, please quote Plate P90103 Edition 0004
902 - Piston with Rod & Stuffing Box

Documents in this Chapter

90201 0220 Piston and Piston Rod

90205 0121 Piston Rod Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Piston and Piston Rod Plate
P90201-0220

When referring to this page, please quote Plate P90201 Edition 0220 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod
P90201-0220

Item Item Description Item Item Description

No. No.

011 Piston ring no. 1

023 Piston ring no. 2 + 4
035 Piston ring no. 3
047 Piston crown
059 Screw
060 Disc
072 D-ring
084 D-ring
096 Piston skirt
106 Screw
118 Locking wire
131 Screw
143 Screw
167 Cooling pipe
179 Screw
192 Screw
202 Piton

Page 2 (2) When referring to this page, please quote Plate Edition
MAN B&W Diesel A/S
 Piston Rod Stuffing Box Plate
P90205-0121

When referring to this page, please quote Plate P90205 Edition 0121 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston Rod Stuffing Box
P90205-0121

Item Item Description Item Item Description

No. No.

013 O-ring
025 Top scraper ring
037 Pack sealing ring
049 Cover sealing ring
062 Nut
074 Stuffing box, housing
086 Flange
098 Screw
121 Guide pin
133 Spring pin
157 Lamella for scrapering
170 Stuffing box, housing
182 Fitted bolt
204 Screw
216 Scraper ring
241 Spring
253 Spring
289 Scraper ring

Page 2 (2) When referring to this page, please quote Plate P90205 Edition 0121
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication

Documents in this Chapter

90301 0176 Cylinder Frame

90302 0196 Cylinder Liner and Cooling Jacket
90303 0013 Cylinder Frame - Details
90304 0036 Cylinder Liner - Details
90307 0025 Cylinder Lubricator Unit
90309 0026 Cylinder Lubricator System - Details

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Cylinder Frame Plate
MAN B&W Diesel P90301-0176

When referring to this page, please quote Plate P90301 Edition 0176 Page 1 (2)
Plate
Cylinder Frame
P90301-0176 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Protective cap

027 Screw
039 Washer
040 Nut
064 Headless screw
076 Cleaning cover, complete
088 Packing
111 Screw
135 Protective tube
147 O-ring
159 Packing
160 Screw
184 Screw
196 Rail
206 Packing
231 Screw
243 Nut
255 Distance pipe
267 Stud
279 Distance pipe
292 Stud
302 Sealing ring
326 Distance pipe

Page 2 (2) When referring to this page, please quote Plate P90301 Edition 0176
 Cylinder Liner and Cooling Jacket Plate
MAN B&W Diesel P90302-0196

When referring to this page, please quote Plate P90302 Edition 0196 Page 1 (2)
Plate
Cylinder Liner and Cooling Jacket
P90302-0196 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Packing
022 Plug screw
034 O-ring
046 O-ring
058 Cooling jacket
071 Clamp
083 Screw
105 Piston cleaning ring
117 Cylinder liner
129 Cooling water connection
130 Packing
142 Pipe
154 Spring pin
166 Plug screw
178 Gasket
201 O-ring
213 Cooling water connection
225 Screw

Page 2 (2) When referring to this page, please quote Plate P90302 Edition 0196
 Cylinder Frame - Details Plate
MAN B&W Diesel P90303-0013

When referring to this page, please quote Plate P90303 Edition 0013 Page 1 (2)
Plate
Cylinder Frame - Details
P90303-0013 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Cylinder frame, fore

028 Cylinder frame, aft
065 Nut
077 Stud
090 Screw

Page 2 (2) When referring to this page, please quote Plate P90303 Edition 0013
 Cylinder Liner - Details Plate
P90304-0036

When referring to this page, please quote Plate P90304 Edition 0036 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Details
P90304-0036

Item Item Description Item Item Description

No. No.

011 Head for non-return valve

023 Housing
035 Non-return valve
059 Non-return valve, complete

Page 2 (2) When referring to this page, please quote Plate P90304 Edition 0036
MAN B&W Diesel A/S
 Cylinder Lubricator Unit Plate
MAN B&W Diesel P90307-0025

When referring to this page, please quote Plate P90307 Edition 0025 Page 1 (2)
Plate
Cylinder Lubricator Unit
P90307-0025 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Spring
031 Spring
043 Disc
055 Screw
067 Coupling
079 Distance pipe
080 O-ring
092 Adjusting screw
114 Plunger
126 Actuator piston
138 Disc
151 Cover
163 Screw
187 Plug screw
199 Sealing ring
209 Cylinder housing
210 O-ring
222 O-ring
234 Non-return valve
246 O-ring
271 Screw
283 Inductive sensor
295 O-ring
305 O-ring
329 Plug
330 Screw
342 Plug
354 Screw
366 Housing
378 Sealing ring
391 Sealing ring
401 Cylinder block
425 Solenoid valve, complete
437 Cable
449 Cable
450 Cable
462 Plug screw

Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0025
 Cylinder Lubrication System - Details Plate
P90309-0026

When referring to this page, please quote Plate P90309 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Lubrication System - Details
P90309-0026

Item Item Description Item Item Description

No. No.

019 Stud
020 Nut
032 Steel pipe
044 Steel pipe
068 Pipe holder
081 Screw
093 Coupling
103 Connection
115 Coupling
139 Pipe holder
152 Coupling
176 Screw
188 Distributor block
211 Sealing ring
223 Distributor block
247 Steel pipe
259 Steel pipe
260 Pipe holder
296 Steel pipe
306 Steel pipe
343 Coupling
367 Screw

Page 2 (2) When referring to this page, please quote Plate P90309 Edition 0026
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

Documents in this Chapter

90401 0139 Connecting Rod and Crosshead

90403 0012 Lubricating and Cooling Oil-Flow

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Connecting Rod and Crosshead Plate
P90401-0139

When referring to this page, please quote Plate P90401 Edition 0139 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead
P90401-0139

Item Item Description Item Item Description

No. No.

019 Plate
020 Screw
044 Screw
068 Crankpin bearing shell, complete
081 Screw
093 Screw
103 Outlet pipe
115 Guide shoe, “Fore”
139 Guide strip
140 Crosshead bearing shell, lower part
152 Connecting rod
176 Screw
188 Shim*
211 Crosshead bearing cap
235 Guide pipe
247 Crosshead
260 Crankpin bearing cap
272 Guide pin
284 Screw
306 Distance piece
318 Bushing
331 Housing for stuffing box
343 Telescope pipe
355 Guide pin
379 Stud
380 Nut
402 Guide shoe, “Aft”
414 Shim*
426 Shim*
451 Nut
463 Stud
487 Screw
509 Counterweight
558 Connecting rod, complete

Note:

*When ordering, please state thick-

ness of shim.

Page 2 (2) When referring to this page, please quote Plate P90401 Edition 0139
MAN B&W Diesel A/S
 Lubricating and Cooling Oil Flow Plate
MAN B&W Diesel P90403-0012

When referring to this page, please quote Plate P90403 Edition 0012 Page 1 (1)
905 - Crankshaft, Thrust Bearing and Turning Gear

Documents in this Chapter

90503 0023 Arrangement of Angle Encoder

90504 0010 Axial Vibration Monitor
90505 0166 Thrust- and Guide Bearing
90507 0007 Trigger Ring System
90510 0129 Turning Gear
90511 0052 Turning Wheel
90512 0002 Turning Gear - Details
90513 0034 Tacho System

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Arrangement of Angle Encoder Plate
MAN B&W Diesel P90503-0023

When referring to this page, please quote Plate P90503 Edition 0023 Page 1 (2)
Plate
Arrangement of Angle Encoder
P90503-0023 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Amplifier
025 Screw
049 Washer
050 Screw
062 Bracket
074 Tapered dowel
086 Sleeve
108 Nut
121 Screw
133 Distance pipe
145 Screw
169 Cover
170 Washer
182 Screw
194 Plug screw
204 Plug screw
228 Washer
241 Screw
253 Screw
265 Washer
277 Bearing, complete
289 Bearing, complete
290 Flange
300 Angle encoder
312 Cover
336 Screw
348 Locking wire
361 Cover
373 Flange shaft

Page 2 (2) When referring to this page, please quote Plate P90503 Edition 0023
 Axial Vibration Monitor Plate
P90504-0010
Axial Vibration Monitor
0010
P90504

B
A

A
C

When referring to this page, please quote Plate P90504 Edition 0010 Page 1 (2)
MAN B&W Diesel A/S
Plate Axial Vibration Monitor
P90504-0010

Item Item
Item Description Item Description
No. No.

019 Coupling
032 Pipe holder
044 Screw
068 Steel pipe
093 Coupling
115 Bracket
127 Screw
139 Washer
152 Axial vibration monitor, complete

Page 2 (2) When referring to this page, please quote Plate P90504 Edition 0010
MAN B&W Diesel A/S
 Thrust and Guide Bearing Plate
MAN B&W Diesel P90505-0166

When referring to this page, please quote Plate P90505 Edition 0166 Page 1 (2)
Plate
Thrust and Guide Bearing
P90505-0166 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Spray pipe 624 Scraper ring housing, upper

026 Nut 636 Screw
038 Stud 648 Scraper ring, complete
051 Stopper segment, fore 661 Scraper ring housing, complete
063 Segment
075 Spray pipe
087 Segment
109 Spray pipe
110 Screw
122 Locking wire
146 Nut, self-locking
158 Distance piece
171 Guard
183 Lubricating oil pipe
195 Distance piece
205 Clamp
217 Lubricating oil pipe
229 Nut, self-locking
242 Guard
254 Screw
266 Stopper segment, fore
278 Stopper segment, aft
301 Screw
313 Spray pipe
325 Stopper segment, aft
337 Segment
349 Spray pipe
350 Nut, self-locking
362 Oil throw ring
386 Spray pipe
398 Cover
408 Screw
421 Spring lock
433 Guide pin
445 Scraper ring housing, lower
457 Fitted bolt
469 Nut, self-locking
482 Screw
494 Lubricating oil pipe
504 Fitted bolt
516 Nut
528 Screw
541 Spacer tubular
553 Screw
565 Scraper ring upper
577 Scraper ring lower
590 Screw
600 Screw
612 Gasket

Page 2 (2) When referring to this page, please quote Plate P90505 Edition 0166
 Trigger Ring System Plate
P90507-0007

When referring to this page, please quote Plate P90507 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Trigger Ring System
P90507-0007

Item Item Description Item Item Description

No. No.

015 TDC indicator

027 TDC indicator
040 TDC indicator
052 Screw

Page 2 (2) When referring to this page, please quote Plate P90507 Edition 0007
MAN B&W Diesel A/S
 Tur ning Gear
urning Plate
MAN B&W Diesel P90510-0129

When referring to this page, please quote Plate P90510 Edition 0129 Page 1 (2)
Plate
Tur ning Gear
urning
P90510-0129 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Screw
023 Distance pipe
047 Turning gear
060 Guide pin
084 Gear wheel
096 Disengaging device

Page 2 (2) When referring to this page, please quote Plate P90510 Edition 0129
 Tur ning Wheel
urning Plate
MAN B&W Diesel P90511-0052

When referring to this page, please quote Plate P90511 Edition 0052 Page 1 (2)
Plate
Tur ning Wheel
urning
P90511-0052 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 Screw
029 Screw
030 Tapered dowel
054 Nut
078 Dead centre pointer, bracket
091 Dead centre pointer, pointer
113 Nut
125 Fitted bolt
149 Turning wheel

Page 2 (2) When referring to this page, please quote Plate P90511 Edition 0052
 Turning Gear - Details Plate
MAN B&W Diesel P90512-0002

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

Item Item Description Item Item Description

No. No.

012 Screw
024 Spring washer
048 3/2-way valve
061 Screw
073 Spring washer
097 Switch 0-110 volts
107 Screw
119 Spring washer
132 Bracket
156 Eye screw
168 Key ring
181 Chain
203 Disc with inicision
215 Stud with groove
227 Circlip
240 Disc with inicision
252 Sleeve
264 Screw
276 Spring washer
311 Lever
323 Bush

Page 2 (2) When referring to this page, please quote Plate P90512 Edition 0002
 Tacho System Plate
MAN B&W Diesel P90513-0034

When referring to this page, please quote Plate P90513 Edition 0034 Page 1 (2)
Plate
Tacho System
P90513-0034 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Bracket
031 Pull rod
043 Block
055 Bracket
067 Screw
079 Screw
080 Wasker
092 Screw
114 Screw
126 Washer
151 Support
163 Nut
175 Spring lock
187 Screw
199 Bracket
209 Bracket
210 Pick-up box
222 Screw
234 Sensor
258 Tacho pick-up
271 Distance pipe
283 Screw
305 Distance pipe
317 Screw

Page 2 (2) When referring to this page, please quote Plate P90513 Edition 0034
906 - Control Gear

Documents in this Chapter

90600 0133 Arrangement of Chain Drive and Camshaft

90603 0120 Chain Tightener
90612 0092 Arrangement of Indicator System
90632 0025 Chain Drive Guidebars - Lower Part
90634 0027 Chain Drive Lubrication - Lower Part
90635 0009 Hydraulic Cylinder Unit
90636 0011 Hydraulic Cylinder Unit - Details
90638 0013 Hydraulic Power Supply - Drive
90639 0014 Hydraulic Power Supply - Drive, Details
90641 0012 Hydraulic Power Supply - Accumulator
90643 0008 Hydraulic Supply System, Low Pressure
90644 0012 Hydraulic Supply System, High Pressure
90645 0012 Electronic Components - Engine Control System
90646 0008 Electronic Components - Lubrication System
90647 0005 Engine Control Room - Components
90648 0004 Pneumatic Components

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Arrangement of Chain Drive Plate
P90600-0133

When referring to this page, please quote Plate P90600 Edition 0133 Page 1 (1)
MAN B&W Diesel A/S
 Chain Tightener Plate
P90603-0120

When referring to this page, please quote Plate P90603 Edition 0120 Page 1 (2)
MAN B&W Diesel A/S
Plate Chain Tightener
P90603-0120

Item Item Description Item Item Description

No. No.

017 Bushing
029 Screw
030 Locking wire
042 Plate
054 Nut
066 Chain wheel
078 Stud
091 Shaft
101 Bushing
113 Screw

Page 2 (2) When referring to this page, please quote Plate P90603 Edition 0120
MAN B&W Diesel A/S
 Arrangement of Indicator System Plate
P90612-0092

When referring to this page, please quote Plate P90612 Edition 0092 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Indicator System
P90612-0092

Item Item Description Item Item Description

No. No.

016 PMI system users manual

028 PMI software
041 Storage case
053 PMI install and start-up manual
065 Converter box
077 PMI controller box, complete
089 Junction box
090 Handle
100 Pressure transducer, complete

Page 2 (2) When referring to this page, please quote Plate P90612 Edition 0092
MAN B&W Diesel A/S
 Chain Drive Guide Bars - Lower Parts Plate
MAN B&W Diesel P90632-0025

When referring to this page, please quote Plate P90632 Edition 0025 Page 1 (2)
Plate
Chain Drive Guide Bars - Lower Parts
P90632-0025 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Stud
027 Nut
039 Screw
040 Cover
064 Chain, complete
076 Screw
088 Locking wire
111 Screw
123 Steel bar
135 Nut
147 Guidebar
159 Beam for guidebar
160 Screw
172 Outer link
184 Inner link
196 Chain link, complete

Page 2 (2) When referring to this page, please quote Plate P90632 Edition 0025
 Chain Drive Lubrication - Lower Part Plate
P90634-0027

When referring to this page, please quote Plate P90634 Edition 0027 Page 1 (2)
MAN B&W Diesel A/S
Plate Chain Drive Lubrication - Lower Part
P90634-0027

Item Item Description Item Item Description

No. No.

016 Nut
028 Support
041 Lubricating pipe
053 Screw
065 Nut
077 Nut
089 Screw
100 Screw
112 Locking wire
124 Screw
136 Clamp
148 Screw
161 Support
173 Screw
185 Spray pipe
197 Screw
207 Spray pipe
220 Spray pipe
244 Pipe holder
256 Flange
281 Lubricating pipe
293 Screw

Page 2 (2) When referring to this page, please quote Plate P90634 Edition 0027
MAN B&W Diesel A/S
 Hydraulic Cylinder Unit Plate
MAN B&W Diesel P90635-0009

When referring to this page, please quote Plate P90635 Edition 0009 Page 1 (2)
Plate
Hydraulic Cylinder Unit
P90635-0009 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Bracket, aft

023 Bracket, fore
035 Stud
047 Distance pipe
059 Nut
072 Guide pin
084 Screw
096 Flange
106 Sealing ring
118 Sealing ring
131 Base plate, fore
143 Base plate, aft*
155 Screw
167 Cover
179 Packing
192 Coupling
202 Steel pipe
214 Screw
226 Pipe holder
238 Stud
251 Hydraulic jack, support
263 Hydraulic nut
275 Packing
287 Cover
299 Screw
310 Screw*
322 Cover*
334 Packing*
358 Bushing*
371 Sealing ring*
383 Pipe*
405 Guide pin
417 Sealing ring
429 Sealing ring
430 Screw
442 Flange
454 High pressure pipe, outer
466 High pressure pipe, inner
478 Sealing ring
491 Sealing ring

Note:

* Not installed on engines with 4-5 cylin-

ders

Page 2 (2) When referring to this page, please quote Plate P90635 Edition 0009
 Hydraulic Cylinder Unit - Details Plate
MAN B&W Diesel P90636-0011

When referring to this page, please quote Plate P90636 Edition 0011 Page 1 (2)
Plate Hydraulic Cylinder Unit - Details
P90636-0011 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 Nut 593 Plug screw

029 Stud 603 Steel pipe
042 Coupling
054 Membrane accumulator, complete
066 Membrane accumulator, complete
078 Sealing ring
091 Flange
101 Steel pipe
113 Coupling
125 Steel pipe
137 Steel pipe
149 Screw
150 Screw
162 Screw
174 Sealing ring
186 Flange
198 Screw
208 Distributor block
233 Screw
245 Return oil standpipe
257 Plug screw
269 Sealing ring
270 Guide pin
282 Sealing ring
294 Sealing ring
304 Sealing ring
316 Sealing ring
328 Sealing ring
341 Sealing ring
353 Multi-way valve
377 Steel pipe
389 Coupling
390 Ball valve
400 Screw
412 Screw
424 Ball valve
436 Guide pin
448 Multi-way valve
461 Lock washer
473 Screw
497 Stud
507 Packing ring
519 Sealing ring
520 Plate
532 Screw
544 Lever switch
556 Screw
568 Plate
581 Screw

Page 2 (2) When referring to this page, please quote Plate P90636 Edition 0011
 Hydraulic Power Supply - Drive Plate
MAN B&W Diesel P90638-0013

When referring to this page, please quote Plate P90638 Edition 0013 Page 1 (2)
Plate
Hydraulic Power Supply - Drive
P90638-0013 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Drive shaft, complete 604 Spray pipe

031 Connecting flange 616 Sectional iron, angle
043 Screw 641 Cover
055 Stud 689 Flange
079 Screw 690 Screw
080 Bearing 700 Screw
092 Gearwheel, drive shaft 712 Plate
102 Screw 724 Screw
114 Cover 736 Bearing for interm. shaft
126 Screw 807 Drive shaft
138 Intermediate wheel 819 Bushing
151 Cover 820 Shear nut
163 Stud 832 Disc
175 Wing nut 844 Drive shaft
187 Screw 856 Hexagon socket screws
199 Cover
209 Screw Note:
210 Flange
222 Packing ring *
234 Flange
246 Spray pipe
258 Sectional iron, angle
271 Plug screw
283 Nut, self-locking
295 Locking wire
305 Screw
317 Bearing f. interm. shaft
329 Screw
330 Cover
342 Sectional iron, angle
354 Screw
366 Locking wire
378 Sectional iron, angle
391 Plug screw
401 Gearbox
413 Bearing for interm. shaft
425 Intermediate shaft
437 Plug screw
449 Spray pipe
450 Spray pipe
462 Clamp
474 Clamp
508 Screw
521 Spacer, tubular
533 Screw
545 Cover
570 Spray pipe
582 Screw
594 Nut, self-locking

Page 2 (2) When referring to this page, please quote Plate P90638 Edition 0013
 Hydraulic Power Supply - Drive, Details Plate
MAN B&W Diesel P90639-0014

When referring to this page, please quote Plate P90639 Edition 0014 Page 1 (2)
Plate
Hydraulic Power Supply - Drive, Details
P90639-0014 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Adapter, straight, male/male

025 Hydraulic oil pump
037 Packing, rectangular
049 Flange, rectangular
050 Screw
108 Adapter, straight, male/male
133 Gasket
157 Oil filter*
194 Flange
204 Screw
241 Screw
289 Pressure transducer
290 Valve, needle
300 Name plate
312 Locking wire
324 Straight stud coupling
336 Extension socket
361 Name plate
373 Name plate

Note:

* Please specify manufacture, type and

part no.

Page 2 (2) When referring to this page, please quote Plate P90639 Edition 0014
 Hydraulic Power Supply - Accumulator Plate
P90641-0012

When referring to this page, please quote Plate P90641 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
Plate Hydraulic Power Supply - Accumulator
P90641-0012

Item Item Description Item Item Description

No. No.

014 Cover
026 Cover
038 Cover
051 Screw
075 Membrane accumulator
099 Cartridge valve
109 Cartridge valve
110 Cartridge valve
134 Pressure transducer
146 Plug Screw
183 Cartridge valve
195 Seal ring
205 Flange
229 Reducing socket
230 Gasket
242 Cartridge valve
254 Screw
278 Screw
301 Cover
313 Accumulator block
325 Plug screw
337 Non-return valve
349 Orifice plug
350 Seal ring
433 Coupling
445 Ball valve
457 Non-return valve
469 Shim
470 Flange
504 Level switch
516 Screw
541 Screw

Page 2 (2) When referring to this page, please quote Plate P90641 Edition 0012
MAN B&W Diesel A/S
 Hydraulic Supply System, Low pressure Plate
MAN B&W Diesel P90643-0008

When referring to this page, please quote Plate P90643 Edition 0008 Page 1 (2)
Plate
Hydraulic Supply System, Low pressure
P90643-0008 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Nut
027 Clamps
039 Screw
040 Packing ring
052 Main pipe, cooling oil
064 Screw
076 Packing ring
088 Main pipe, cooling oil
111 Lubricating oil pipe
123 Support
147 Butterfly valve
159 Screw
160 Lubricating oil pipe
172 Screw
184 Nut
196 Packing ring
206 Lubricating oil pipe
218 Steel pipe
231 Coupling
255 Main pipe, cooling oil
267 Butterfly valve
279 Screw
280 Nut
292 Packing ring
302 Lubricating oil pipe
314 Screw
326 Packing ring
338 Screw
351 Lubricating oil pipe
363 Screw
375 Support
387 Reducing valve
399 Lubricating oil pipe, complete
409 Lubricating oil pipe, complete
410 Packing ring
422 Screw
434 Nut
458 Screw
471 Coupling
483 Screw
495 Screw
505 Packing ring
517 Screw
529 Packing ring
530 Packing ring
542 Screw
554 Nut
566 Flange
578 Lubricating oil pipe, complete

Page 2 (2) When referring to this page, please quote Plate P90643 Edition 0008
 Hydraulic Supply System - High Pressure Plate
MAN B&W Diesel P90644-0012

When referring to this page, please quote Plate P90644 Edition 0012 Page 1 (2)
Plate
Hydraulic Supply System - High Pressure
P90644-0012 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Sealing ring

022 Sealing ring
034 Screw
046 Screw
058 High pressure pipe
071 High pressure pipe
083 Screw
095 Bracket, complete
105 Screw
129 Screw
130 Connection piece
142 Flange
154 Sealing ring
166 Sealing ring
191 Screw
201 Connection piece

Page 2 (2) When referring to this page, please quote Plate P90644 Edition 0012
 Engine Control System - Plate
P90645-0012
Electronic Components

When referring to this page, please quote Plate P90645 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
Plate Engine Control System -
P90645-0012
Electronic Components
Item Item Description Item Item Description
No. No.

016 Multi purpose controller

028 Amplifier
041 Printed circuitboard assy
065 Amplifier
077 Amplifier
090 Amplifier

Page 2 (2) When referring to this page, please quote Plate P90645 Edition 0012
MAN B&W Diesel A/S
 Engine Control System - Plate
P90646-0008
Wiring and Enclosures

When referring to this page, please quote Plate P90646 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
Plate Engine Control System -
P90646-0008
Wiring and Enclosures
Item Item Description Item Item Description
No. No.

023 Engine control system

047 Engine control system
060 Enclosure, complete
072 Screw
084 Nut
096 Engine control system
118 Engine control system
143 Enclosure, complete
155 Engine control system
179 Engine control system
192 Enclosure, complete*
202 Connector, kit*
214 Screw*
226 Nut*

Note:

* Applies to all ACU, CCU and ECU’s,

when ordering please specify no. of
cylinders.

Page 2 (2) When referring to this page, please quote Plate P90646 Edition 0008
MAN B&W Diesel A/S
 Engine Control Room - Components Plate
MAN B&W Diesel P90647-0005

When referring to this page, please quote Plate P90647 Edition 0005 Page 1 (2)
Plate
Engine Control Room - Components
P90647-0005 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 HMI panel

029 Trackball
030 Keyboard
042 Keyboard and CD drive
066 Enclosure, complete
091 Multi purpose controller
101 Printer circuitboard assy
113 Connector - PCB, kit
125 Flat screen monitor
137 PC hardware*
150 PC hardware
162 Regulating handle
186 Printer
198 Ethernet hub*
208 Cable*
233 PC hardware
304 Battery for multi purpose controller
328 Fuse cartridge, 10.0A slow blow
341 Fuse cartridge, 3.15A slow blow
353 Fuse cartridge, 2.0A slow blow
365 Fuse cartridge, 6.3A slow blow
377 Fuse cartridge, 12.5A slow blow
389 Fuse cartridge set, complete

Note:

*Only for CoCoS

Page 2 (2) When referring to this page, please quote Plate P90647 Edition 0005
 Pneumatic Components Plate
P90648-0004

When referring to this page, please quote Plate P90648 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Pneumatic Components
P90648-0004

Item Item Description Item Item Description

No. No.

024 Control air pipe

036 Ball valve
048 Coupling
061 Pressure transducer
073 Screw
085 Pressure transducer
097 Distributor block
107 Coupling
119 Copper pipe
120 Reducing connection
132 Coupling
144 Reducing connection
156 Coupling
168 Reducing connection
181 Coupling
193 Ball valve
203 Screw
227 Distributor block
239 Plate for pneumatics
240 Silencer
252 Reducing adaptors
264 Ball valve
276 Screw
288 Coupling
311 Copper pipe
323 Reducing adaptors
335 Reducing connection
359 Local control box
360 Air reciever
372 Copper pipe
384 Plate with pneumatics, complete

Page 2 (2) When referring to this page, please quote Plate P90648 Edition 0004
MAN B&W Diesel A/S
907 - Starting Air System

Documents in this Chapter

90702 0069 Main Starting Valve

90704 0055 Starting Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Main Starting Valve Plate
P90702-0069

When referring to this page, please quote Plate P90702 Edition 0069 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Starting Valve
P90702-0069

Item Item Description Item Item Description

No. No.

027 Screw 708 Screw

039 Name plate "Working" 900 Repair kit, actuator*
052 Screw 912 Repair kit, ball valve*
064 Washer
076 Switch Note:
088 Distance pipe
123 Spindle * When ordering spare parts for this
135 Screw item, please state manufacturer's Part
147 Plate No.
160 Ball valve with actuator*
184 Nut
196 Screw
206 Starting air pipe
218 Gasket
231 Intermediate piece
255 Name plate "Blocked"
279 Nut
280 Washer
292 Hand wheel
314 Securing plate
326 Pin
338 Spring
351 Screw
363 Gasket
387 Gasket
399 Plug screw
410 Adjusting screw
422 Nut
434 Adapter
458 Washer
471 Screw
495 Screw
505 Guide
517 Guide pin
529 Screw
530 Distance pipe
542 Screw
554 Ball valve with actuator*
566 Nut
591 Plug screw
601 Gasket
625 Plug screw
637 Starting air pipe
650 Non-return valve
674 Housing
698 Housing

Page 2 (2) When referring to this page, please quote Plate P90702 Edition 0069
MAN B&W Diesel A/S
 Starting Valve Plate
P90704-0055

When referring to this page, please quote Plate P90704 Edition 0055 Page 1 (2)
MAN B&W Diesel A/S
Plate Starting Valve
P90704-0055

Item Item Description Item Item Description

No. No.

016 Screw
028 Cover
041 Screw
053 Locking plate
065 Piston
077 Spring
089 Bushing
090 Valve housing
100 Sealing ring
112 Spindle

Page 2 (2) When referring to this page, please quote Plate P90704 Edition 0055
MAN B&W Diesel A/S
908 - Exhaust Valve

Documents in this Chapter

90801 0205 Exhaust Valve - Lower Parts

90802 0059 Exhaust Valve - Details
90803 0038 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0142 Exhaust Valve - Actuator
90806 0097 Exhaust Valve - Pipe System
90811 0015 Arrangement of Freshwater Pipes

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Exhaust Valve - Lower Parts Plate
P90801-0205

When referring to this page, please quote Plate P90801 Edition 0205 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Lower Parts
P90801-0205

Item Item Description Item Item Description

No. No.

013 Sealing ring

025 Sealing ring
037 Spindle guide
049 Exhaust valve spindle
050 Guide pin
062 Packing
074 Plug screw
098 Packing
108 Flange
121 Screw
133 Screw
145 Guide pin
157 O-ring
169 Bottom piece
170 O-ring
204 Screw
228 Exhaust valve housing
241 Thread insert
253 Plug screw
265 Packing
277 Packing
289 Plug screw
300 Packing
312 Cover

Page 2 (2) When referring to this page, please quote Plate P90801 Edition 0205
MAN B&W Diesel A/S
 Exhaust Valve - Details Plate
P90802-0059

When referring to this page, please quote Plate P90802 Edition 0059 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Details
P90802-0059

Item Item Description Item Item Description

No. No.

019 Sealing oil control unit

020 Screw
032 Coupling
044 Oil pipe
068 Packing
081 Plate
093 Packing
115 Sealing ring
127 Orifice plug

Page 2 (2) When referring to this page, please quote Plate P90802 Edition 0059
MAN B&W Diesel A/S
 Exhaust Valve - Upper Parts Plate
MAN B&W Diesel P90803-0038

When referring to this page, please quote Plate P90803 Edition 0038 Page 1 (2)
Plate
Exhaust Valve - Upper Parts
P90803-0038 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Safety handrail

038 Oil cylinder, housing
051 Screw
063 Inductive sensor
075 Sealing ring
087 Plug screw
099 Orifice plug
109 Coupling
110 Coupling
122 Air cylinder, housing
134 Plug screw
146 Non-return valve
158 Plug screw
171 Lifting eye bolt
183 Nut
195 Plug screw
205 Plug screw
217 Sealing ring
229 Orifice plug
230 Plug screw
242 Orifice plug
254 Cover
266 Sealing ring
278 Disc
291 Screw
301 Sealing ring
313 Plug screw
325 Non-return valve
350 Piston ring
362 Piston
374 Slide
386 Piston
398 Spring
408 Disc
421 Cone
433 Actuator piston
445 O-ring
457 Back-up ring
469 Flange
470 Sealing ring
482 Guide ring
494 Air cylinder piston
504 Sealing ring
516 Retaining ring
528 Stud
553 Piston, complete

Page 2 (2) When referring to this page, please quote Plate P90803 Edition 0038
 Exhaust Valve - Upper Parts, Details
Valve Plate
MAN B&W Diesel P90804-0016

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

Item Item Description Item Item Description

No. No.

021 Gasket
045 Safty valve, with o-ring
905 O-ring*

Note:

* Optional extras

Page 2 (2) When referring to this page, please quote Plate P90804 Edition 0016
 Exhaust Valve - Actuator Plate
MAN B&W Diesel P90805-0142

When referring to this page, please quote Plate P90805 Edition 0142 Page 1 (2)
Plate
Exhaust Valve - Actuator
P90805-0142 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Top piece

027 Plug
039 Sealing ring
040 Actuator piston
052 Actuator cylinder
064 Actuator piston
111 Screw
123 Plug
135 Sealing ring
147 Retaining ring

Page 2 (2) When referring to this page, please quote Plate P90805 Edition 0142
 Exhaust Valve - Pipe System Plate
MAN B&W Diesel P90806-0097

When referring to this page, please quote Plate P90806 Edition 0097 Page 1 (2)
Plate
Exhaust Valve - Pipe System
P90806-0097 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Hydraulic pipe

022 Sealing ring
046 Disc
058 Sealing ring
071 Screw
083 Disc
095 Screw
105 Thrust flange
117 Sealing ring
129 Cone
130 Cone
142 Retaining ring
154 Hydraulic pipe, complete
178 Steel pipe
191 Non-return valve
201 Steel pipe
213 Coupling
225 Nut
237 Screw
249 Support
250 Coupling
262 Steel pipe
274 Steel pipe
286 Coupling
308 Clamp

Page 2 (2) When referring to this page, please quote Plate P90806 Edition 0097
 Arrangement of Freshwater Pipes Plate
P90811-0015

When referring to this page, please quote Plate P90811 Edition 0015 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Freshwater Pipes
P90811-0015

Item Item Description Item Item Description

No. No.

018 Packing
031 Screw
043 Nut
055 Orifice plate
067 Freshwater pipe, outlet
079 Ball valve
080 Freshwater pipe, outlet
102 Support
114 Packing
126 Screw
138 Freshwater pipe, outlet
151 Support
175 Freshwater pipe, outlet
199 Conical valve
210 Screw
234 Main pipe
246 Packing
258 Screw
271 Nut
295 Main pipe
317 Angle valve
329 Coupling
330 Steel pipe
354 Main pipe

Page 2 (2) When referring to this page, please quote Plate P90811 Edition 0015
MAN B&W Diesel A/S
909 - Fuel Oil System

Documents in this Chapter

90910 0144 Fuel Valve

90911 0022 Fuel Valve Function
90913 0166 High-Pressure Pipes
90914 0095 Fuel Oil System
90915 0060 Fuel Oil System - Details
90917 0004 Fuel Oil Pressure Booster

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Fuel Valve Plate
P90910-0144

When referring to this page, please quote Plate P90910 Edition 0144 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve
P90910-0144

Item Item Description Item Item Description

No. No.

016 Thrust piece

028 Cut-off shaft
065 Spindle guide, complete
089 Spindle guide
090 Spring pin
100 Nozzle
124 O-ring
136 Holder
148 Guide
161 Union nut
173 O-ring
197 Sealing ring
207 Valve head
219 Guide pin
220 Spring
232 Non-return valve
244 Disc
256 Thrust spindle
268 Spring
281 Thrust foot
950 Disc*

Note:

Note: Optional extras

Page 2 (2) When referring to this page, please quote Plate P90910 Edition 0144
MAN B&W Diesel A/S
 Fuel Valve Function Plate
P90911-0022

When referring to this page, please quote Plate P90911 Edition 0022 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve Function
P90911-0022

Item Item Description Item Item Description

No. No.

Note:

D1 = Predetermined closing value for

non-return valve

D2 = Predetermined opening value for

cut-off spindle

Page 2 (2) When referring to this page, please quote Plate P90911 Edition 0022
MAN B&W Diesel A/S
 High-Pressure Pipes Plate
P90913-0166

When referring to this page, please quote Plate P90913 Edition 0166 Page 1 (2)
MAN B&W Diesel A/S
Plate High-Pressure Pipes
P90913-0166

Item Item Description Item Item Description

No. No.

012 Insulation of high-pressure pipe, left

side
024 Insulation of high-pressure pipe, right
side
036 High-pressure pipe, left side
048 High-pressure pipe, right side
061 Union nut
073 Housing for sealing rings
085 Sealing ring
097 Sealing ring
107 Sleeve
119 Retaining ring
120 Union nipple
132 O-ring
156 High-pressure pipe, left side, com-
plete
168 High-pressure pipe, right side, com-
plete
181 Union nipple

Page 2 (2) When referring to this page, please quote Plate P90913 Edition 0166
MAN B&W Diesel A/S
 Fuel Oil System Plate
MAN B&W Diesel P90914-0095

When referring to this page, please quote Plate P90914 Edition 0095 Page 1 (2)
Plate
Fuel Oil System
P90914-0095 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Coupling
031 Steel pipe
055 Steel pipe
079 Coupling
080 Distributor piece
092 Coupling
102 Steel pipe
114 Screw

Page 2 (2) When referring to this page, please quote Plate P90914 Edition 0095
 Fuel Oil System - Details Plate
P90915-0060

When referring to this page, please quote Plate P90915 Edition 0060 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Oil System - Details
P90915-0060

Item Item Description Item Item Description

No. No.

013 By-pass valve, complete

025 Valve housing
037 Valve housing
049 Sealing ring
050 Spring guide
074 Screw
086 Union nut
098 Nut
121 Sealing ring
133 Piston
145 Spring

Page 2 (2) When referring to this page, please quote Plate P90915 Edition 0060
MAN B&W Diesel A/S
 Fuel Oil Pressure Booster Plate
P90917-0004

When referring to this page, please quote Plate P90917 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Oil Pressure Booster
P90917-0004

Item Item Description Item Item Description

No. No.

014 Plug screw

026 Disc
038 Top cover, complete
051 Guide pin
063 Sealing ring
075 Retaining ring
087 Sealing ring
099 Hydraulic plunger
109 Booster housing
110 Screw
122 Inductive sensor
134 Sealing ring
146 Sealing ring
158 Sealing ring
171 Sealing ring
183 Bushing
195 Screw
205 Screw
217 Cover
230 Disc
242 Throttle valve
254 Flange
278 Sealing ring
291 Screw
337 Spindle
349 Housing
350 Spring
362 Cone
374 Conical ring
386 Sealing ring
398 Union nut
421 Suction valve, complete

Page 2 (2) When referring to this page, please quote Plate P90917 Edition 0004
MAN B&W Diesel A/S
910 - Turbocharger System

Documents in this Chapter

91000 0017 Gas and Air System

91001 0167 Scavenge Air Receiver
91002 0126 Arrangement of Charging Air Pipe
91003 0200 Exhaust Pipes and Receiver
91004 0064 Exhaust Receiver - Details
91005 0127 Air Cooler
91006 0041 Arrangement of Auxiliary Blower
91007 0017 Butterfly Valve
91009 0032 Air Cooler System - Cleaning
91011 0024 Arrangement of Non-Return Valve
91012 0026 Arrangement of Floor Plates - Scavenge Air Receiver
91014 0022 Arrangement of Suction Pipe

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Gas and Air System Plate
P91000-0017

When referring to this page, please quote Plate P91000 Edition 0017 Page 1 (1)
MAN B&W Diesel A/S
 Scavenge Air Receiver Plate
MAN B&W Diesel P91001-0167

When referring to this page, please quote Plate P91001 Edition 0167 Page 1 (2)
Plate
Scavenge Air Receiver
P91001-0167 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

029 Scavenge air receiver

030 Screw
042 Cover
066 Stud
078 Distance pipe
091 Nut
101 Distance pipe
113 Screw
125 Screw
137 Screw
149 Plug screw
150 Screw
162 O-ring
186 Nut
245 Stud
257 Safety catch
269 Sectional iron
270 Nut
282 Stud
294 Plate
304 Plate

Page 2 (2) When referring to this page, please quote Plate P91001 Edition 0167
 Arrangement of Charging Air Pipe Plate
P91002-0126

When referring to this page, please quote Plate P91002 Edition 0126 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Charging Air Pipe
P91002-0126

Item Item Description Item Item Description

No. No.

012 Nut
024 Compensator
036 Screw
061 Nut
073 Screw
085 Charging air pipe
097 Screw

Page 2 (2) When referring to this page, please quote Plate P91002 Edition 0126
MAN B&W Diesel A/S
 Exhaust Pipes and Receiver Plate
P91003-0200

When referring to this page, please quote Plate P91003 Edition 0200 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Pipes and Receiver
P91003-0200

Item Item Description Item Item Description

No. No.

018 Exhaust reciever, complete

031 Screw
043 Nut
055 Guide pin
067 Screw*
079 Nut
092 Screw*
102 Distance pipe
114 Wire gauze
138 Sealing ring
151 Compensator
175 Screw*
199 Distance pipe
209 Sealing ring
210 Cover
222 Locking plate
234 Distance pipe
246 Screw*
271 Sealing ring
283 Compensator
295 Screw*
305 Washer
317 Nut
329 Sealing ring
330 Washer
342 Split pin
354 Hinge rod
366 Screw*
378 Screw*
391 Nut

Note:

* These screws are special screws

for hot joints, they are marked with a
“T”, and MUST NOT be used else-
where!

Page 2 (2) When referring to this page, please quote Plate P91003 Edition 0200
MAN B&W Diesel A/S
 Exhaust Receiver
Receiver,, Details Plate
MAN B&W Diesel P91004-0064

When referring to this page, please quote Plate P91004 Edition 0064 Page 1 (2)
Plate
Exhaust Receiver
Receiver,, Details
P91004-0064 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Nut
025 Washer
037 Spring pin
049 Shim
050 Spring plate
062 Clamp
074 Distance pipe
086 Screw
098 Nut
108 Support
121 Screw
145 Support
169 Shim
170 Support
194 Spring pin
216 Screw

Page 2 (2) When referring to this page, please quote Plate P91004 Edition 0064
 Air Cooler Plate
P91005-0127

When referring to this page, please quote Plate P91005 Edition 0127 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler
P91005-0127

Item Item Description Item Item Description

No. No.

019 Frame for air cooler

032 O-ring
044 Frame for air cooler
056 Screw
081 Inspection cover, complete
093 O-ring
115 Cooler insert
139 O-ring
152 Air cooler housing
164 Cover
188 Water mist catcher
223 Screw
235 Distance pipe
259 Distance pipe
260 Screw
272 Plate
284 Sealing plate
306 Nut
318 Washer
331 Locking plate
343 Hinge
355 Cover
379 Cross member
380 Stud
392 Screw
402 Support
414 Spring pin
426 Flange
438 Screw

Page 2 (2) When referring to this page, please quote Plate P91005 Edition 0127
MAN B&W Diesel A/S
 Arrangement of Auxiliary Blower Plate
P91006-0041

When referring to this page, please quote Plate P91006 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Auxiliary Blower
P91006-0041

Item Item Description Item Item Description

No. No.

014 Auxiliary blower*

038 Nut
051 Screw

Note:

When ordering Spare Parts for this

item, please state manufacturer’s Part
No.

Page 2 (2) When referring to this page, please quote Plate P91006 Edition 0041
MAN B&W Diesel A/S
 Butterfly Valve Plate
P91007-0017

When referring to this page, please quote Plate P91007 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
Plate Butterfly Valve
P91007-0017

Item Item Description Item Item Description

No. No.

021 Cover
033 Packing
045 Locking wire
057 Screw
069 Locking plate
070 Housing
082 Screw
116 Shaft
128 Flap

Page 2 (2) When referring to this page, please quote Plate P91007 Edition 0017
MAN B&W Diesel A/S
 Air Cooler System - Cleaning Plate
P91009-0032

When referring to this page, please quote Plate P91009 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler System - Cleaning
P91009-0032

Item Item Description Item Item Description

No. No.

010 Valve
034 Main pipe
046 Cleaning pipe
058 Nut
071 Stud
083 Stud
095 Nut
105 Packing
129 Guide
130 Cleaning pipe
142 Guide
166 Stud
178 Packing

Page 2 (2) When referring to this page, please quote Plate P91009 Edition 0032
MAN B&W Diesel A/S
 Arrangement of Non-return Valve Plate
P91011-0024

When referring to this page, please quote Plate P91011 Edition 0024 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Non-return Valve
P91011-0024

Item Item Description Item Item Description

No. No.

011 Locking wire

023 Screw
035 Screw
047 Support
060 Clamp
072 Support
084 Valve flap
118 Spring pin
131 Shaft

Page 2 (2) When referring to this page, please quote Plate P91011 Edition 0024
MAN B&W Diesel A/S
 Arrangement of Floor Plates - Plate
P91012-0026
Scavenge Air Receiver

When referring to this page, please quote Plate P91012 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Floor Plates -
P91012-0026
Scavenge Air Receiver
Item Item Description Item Item Description
No. No.

017 Screw
029 Locking wire
030 Plate
042 Distance pipe
066 Nut
078 Chequer plate
091 Steel bar
101 Chequer plate
125 Steel bar
137 Expanded metal
149 Plate
150 Expanded metal
186 Chequer plate
198 Steel bar
221 Chequer plate
233 Steel bar
245 Chequer plate
257 Steel bar
282 Chequer plate
294 Steel bar
304 Chequer plate
316 Screw

Page 2 (2) When referring to this page, please quote Plate P91012 Edition 0026
MAN B&W Diesel A/S
 Arrangement of Suction Pipe Plate
P91014-0022

When referring to this page, please quote Plate P91014 Edition 0022 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Suction Pipe
P91014-0022

Item Item Description Item Item Description

No. No.

018 Screw
043 Screw
067 Nut
079 Flange
080 O-ring
092 Disc
102 Packing

Page 2 (2) When referring to this page, please quote Plate P91014 Edition 0022
MAN B&W Diesel A/S
911 - Safety Equipment

Documents in this Chapter

91101 0037 Safety Valve - Cylinder

91102 0028 Relief Valve
91102 0033 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0100 Arrangement of Safety Cap
91107 0002 Manual Shutdown Valve, F.

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Safety Valve - Cylinder
Valve Plate
MAN B&W Diesel P91101-0037

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

Item Item Description Item Item Description

No. No.

010 Spindle
022 Spring retainer
034 Lock nut
046 Spring
058 Valve housing
071 Stop ring
083 Valve flap
095 Valve guide
105 Gasket
117 Safety valve, complete

Page 2 (2) When referring to this page, please quote Plate P91101 Edition 0037
 Relief Valve Plate
P91102-0028
Relief Valve
0028
P91102

P.C.D.

When referring to this page, please quote Plate P91102 Edition 0028 Page 1 (2)
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0028

Item Item
Item Description Item Description
No. No.

016 Relief valve (P.C.D. 465mm)*

028 Screw*
030 Packing*
041 O-ring*

Note:
*When ordering, please state manu-
facturer of Relief Valve and
P.C.D. xxx mm

Page 2 (2) When referring to this page, please quote Plate P91102 Edition 0028
MAN B&W Diesel A/S
 Relief Valve Plate
P91102-0033
Relief Valve
0033
P91102

When referring to this page, please quote Plate P91102 Edition 0033 Page 1 (2)
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0033

Item Item
Item Description Item Description
No. No.

016 Relief valve (P.C.D. 615mm)*

028 Screw*
030 Packing*
041 O-ring*

Note:
*When ordering, please state manu-
facturer of Relief Valve and
P.C.D. xxx mm

Page 2 (2) When referring to this page, please quote Plate P91102 Edition 0033
MAN B&W Diesel A/S
 Safety Valve - Scavenge Air System Plate
MAN B&W Diesel P91103-0018

When referring to this page, please quote Plate P91103 Edition 0018 Page 1 (2)
Plate
Safety Valve - Scavenge Air System
P91103-0018 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Safety valve, complete

035 Spindle
047 Washer
059 Spring retainer
060 Castle nut
072 Split pin
096 Screw
106 Nut
118 Valve flap
131 Seal
143 Valve seat
155 Spring

Page 2 (2) When referring to this page, please quote Plate P91103 Edition 0018
 Arrangement of Safety Cap Plate
P91104-0100

When referring to this page, please quote Plate P91104 Edition 0100 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Safety Cap
P91104-0100

Item Item Description Item Item Description

No. No.

017 Bursting cap, complete

029 Screw
030 Bursting disc
042 Packing
066 Block for starting air inlet
078 Packing
091 Screw
113 Bursting cap protector
125 Washer
137 Screw
150 Screw
162 Starting air pipe
186 Fitted bolt
198 Bursting cap cover
208 Check plate
221 Screw
245 Stud
257 Washer
269 Wing nut
282 Perforated cylinder

Page 2 (2) When referring to this page, please quote Plate P91104 Edition 0100
MAN B&W Diesel A/S
 Manual Shutdown Valve - Fuel Oil System Plate
MAN B&W Diesel P91107-0002

When referring to this page, please quote Plate P91107 Edition 0002 Page 1 (2)
Plate
Manual Shutdown Valve - Fuel Oil System
P91107-0002 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Coupling
025 Steel pipe
037 Ball valve with actuator
049 3/2-way valve

Page 2 (2) When referring to this page, please quote Plate P91107 Edition 0002
912 - Assembly of Large Parts

Documents in this Chapter

91201 0095 Arrangement of Stay Bolts

91204 0027 Frame - Details
91205 0188 Frame Box
91206 0118 End Shields
91207 0092 Arrangement of Piston Cooling
91210 0163 Bedplate
91211 0081 Axial Vibration Damper
91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0002 Top Bracing - Arrangement

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Arrangment of Stay Bolt Plate
P91201-0095

When referring to this page, please quote Plate P91201 Edition 0095 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangment of Stay Bolt
P91201-0095

Item Item Description Item Item Description

No. No.

014 Screw
026 Washer
038 Protective cap
063 Nut
087 Stay bolt
109 Guide bushing
110 Guide bushing
134 Assembling of stay bolt

Page 2 (2) When referring to this page, please quote Plate P91201 Edition 0095
MAN B&W Diesel A/S
 Frame - Details Plate
P91204-0027

When referring to this page, please quote Plate P91204 Edition 0027 Page 1 (2)
MAN B&W Diesel A/S
Plate Frame - Details
P91204-0027

Item Item Description Item Item Description

No. No.

010 Damper, oil pipe

022 Screw
034 Flange
046 Nut
058 Stud
071 Damper, oil pipe
083 Pipe clamp
095 Screw
105 Locking wire
117 Damper, oil pipe
130 Screw
142 Damper, oil pipe
154 Damper, oil pipe
178 Screw
191 Pipe holder
201 Lubrication oil pipe
225 Lubrication oil pipe
249 Screw
250 Lubrication oil pipe
262 Lubrcation oil pipe
274 Stud
286 Nut
308 Screw
333 Lubrication oil pipe
357 Lubrication oil pipe
370 Lubrication oil pipe
382 Screw
394 Distance pipe

Page 2 (2) When referring to this page, please quote Plate P91204 Edition 0027
MAN B&W Diesel A/S
 Frame Box Plate
P91205-0188

When referring to this page, please quote Plate P91205 Edition 0188 Page 1 (2)
MAN B&W Diesel A/S
Plate Frame Box
P91205-0188

Item Item Description Item Item Description

No. No.

016 Nut
028 Drain pipe
041 Frame box
053 Cover
065 Screw
077 Cover
090 Screw
100 Distance pipe
112 Nut
136 Washer
148 Screw
161 Plate
185 Stud
207 Nut
219 Screw
220 Packing
232 Frame box door
244 Screw
268 Door fastener
281 Stud
303 Packing
315 Frame box door
327 Wing nut
339 Door fastener
340 Stud
352 Spring
364 Locking pin
376 Spring
388 Key ring
411 Screw
423 Cover
447 Screw

Page 2 (2) When referring to this page, please quote Plate P91205 Edition 0188
MAN B&W Diesel A/S
 End Shields Plate
P91206-0118

When referring to this page, please quote Plate P91206 Edition 0118 Page 1 (2)
MAN B&W Diesel A/S
Plate End Shields
P91206-0118

Item Item Description Item Item Description

No. No.

011 Screw
023 Shield, upper
035 Screw
047 Screw
059 Washer
060 Cover
084 Shield, lower
106 Packing

Page 2 (2) When referring to this page, please quote Plate P91206 Edition 0118
MAN B&W Diesel A/S
 Arrangement of Piston Cooling Plate
P91207-0092
Arrangement of Piston Cooling
0092
P91207

C F F

C B

F F

E
B

When referring to this page, please quote Plate P91207 Edition 0092 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Piston Cooling
P91207-0092

Item Item
Item Description Item Description
No. No.

017 Drain pipe-piston cooling

030 Drain pipe-piston cooling
042 Screw
054 Locking wire
066 Sight glass
091 Screw
101 Drain box
125 Screw
137 Locking plate
150 Screw
162 Distance pipe
186 Flange
198 Screw
208 Packing

Page 2 (2) When referring to this page, please quote Plate P91207 Edition 0092
MAN B&W Diesel A/S
 Bedplate Plate
MAN B&W Diesel P91210-0163

When referring to this page, please quote Plate P91210 Edition 0163 Page 1 (2)
Plate
Bedplate
P91210-0163 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Nut
037 Stud
050 Screw
062 Bedplate
086 Main bearing cap
098 Spring pin
108 Main bearing, upper shell
121 Main bearing, lower shell
145 Screw
157 Grate
194 Lock washer
216 Screw
228 Cover plate

Page 2 (2) When referring to this page, please quote Plate P91210 Edition 0163
 Axial Vibration Damper Plate
P91211-0081

When referring to this page, please quote Plate P91211 Edition 0081 Page 1 (2)
MAN B&W Diesel A/S
Plate Axial Vibration Damper
P91211-0081

Item Item Description Item Item Description

No. No.

019 Spring
020 Spring
044 Screw
056 Restriction for damper
081 Restriction for damper
093 Restriction for damper
103 Screw
115 Locking wire
127 Oil seal
139 Oil seal
164 Nut
176 Nut
188 Stud
211 Stud
259 Axial vibration damper, upper part
260 Cylindrical pin
272 Axial vibration damper, lower part
296 Restriction for damper

Page 2 (2) When referring to this page, please quote Plate P91211 Edition 0081
MAN B&W Diesel A/S
 Holding-Down Bolts and End-Chock Bolts Plate
P91216-0009
(Epoxy Chocks)

When referring to this page, please quote Plate P91216 Edition 0009 Page 1 (2)
MAN B&W Diesel A/S
Plate Holding-Down Bolts and End-Chock Bolts
P91216-0009
(Epoxy Chocks)
Item Item Description Item Item Description
No. No.

028 Screw
041 Washer
053 Locking plate
077 Liner for side chock, port side
089 Liner for side chock, starboard
100 Liner end chock
112 Spherical washer
124 Spherical washer
136 Nut
148 Protective cap
173 Protectice cap
185 Nut
197 Distance pipe
219 Spherical washer
220 Spherical nut
232 Holding-down bolt, M36 x 4
256 Stud for end chock bolt, M60 x 5.5

Page 2 (2) When referring to this page, please quote Plate P91216 Edition 0009
MAN B&W Diesel A/S
 Top Bracing - Arrangement Plate
P91217-0002

When referring to this page, please quote Plate P91217 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Top Bracing - Arrangement
P91217-0002

Item Item Description Item Item Description

No. No.

011 Screw
023 Friction shim
059 Distance pipe
060 Washer
072 Nut
084 Split pin
106 Plate, short*
118 Plate, medium*
131 Plate, large*
143 Plate
155 Guide pin**
179 Screw
180 Disc spring
192 Distance pipe
202 Washer
214 Nut
238 Plate
251 Friction shim

Note:

* When ordering this spare part,

please state length

** Only to be used during mounting

Page 2 (2) When referring to this page, please quote Plate P91217 Edition 0002
MAN B&W Diesel A/S