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
K90MC-C VOLUME II
MAINTENANCE
900 - Introduction

Documents in this Chapter

Table of Contents, Volume II

90023 0027 Instructions for Main Engine
90050 0289 Checking & Maintenance Schedule
90060 0002 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
90050 0289 Checking & Maintenance Schedule
90060 0002 General - Safety Precautions

901 - Cylinder Cover

101-01 0036 Cylinder Cover, Data
901-01 0228 Cylinder Cover
90151 0204 Cylinder Cover - Panel
90161 0102 Cylinder Cover - Tools
90164 0001 Cylinder Cover - Hydraulic Jack Spares
90165 0001 Cylinder Cover - Lifting Tools

902 - Piston with Rod & Stuffing Box

102-01 0041 Piston, Data
902-01 0250 Piston
102-02 0035 Piston Rod Stuffing Box, Data
902-02 0210 Piston Rod Stuffing Box
90251 0253 Piston and Piston Rod - Panel
90261 0102 Piston and Piston Rod - Tools
90262 0026 Piston and Piston Rod - HydraulicTools
90263 0007 Piston Crown - Hydraulic Tools
90264 0006 Piston and Piston Rod - Tilting Tools
90265 0003 Piston and Piston Rod - Support Tools
90266 0001 Piston - Lifting Tools

903 - Cylinder Liner and Cylinder Lubrication

103-01 0045 Cylinder Liner, Data
903-01 0238 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0247 Cylinder Lubricator
90361 0083 Cylinder Liner - Tools
90362 0001 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0003 Cylinder Liner - Lifting Tools

904 - Crosshead with Connecting Rod

104-01 0032 Crosshead Bearing, Data
904-01 0236 Crosshead Bearing
104-02 0032 Crosshead, Data
904-02 0235 Crosshead
104-03 0024 Reciprocating Parts, Data
904-03 0214 Reciprocating Parts
104-04 0026 Crankpin Bearing, Data

MAN B&W Diesel A/S Page 1 (5)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

904-04 0212 Crankpin Bearing

104-05 0029 Connecting Rod, Data
904-05 0220 Connection Rod
90451 0102 Connecting Rod and Crosshead - Panel
90461 0062 Connecting Rod - Hydraulic Tools
90462 0032 Connecting Rod - Tools
90462 0033 Connecting Rod - Tools
90464 0003 Crosshead - Hydraulic Tools

905 - Crankshaft, Thrust Bearing and Turning Gear

105-02 0054 Main Bearing, Data
905-02 0248 Main Bearing
105-03 0036 Thrust Bearing, Data
905-03 0220 Thrust Bearing
105-04 0012 Journal Bearing, Data
905-04 0213 Journal Bearing
105-05 0030 Axial Vibration Damper, Data
905-05 0225 Axial Vibration Damper
105-08 0006 Angle Encoder, Data
905-08 0204 Angle Encoder
90551 0225 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0084 Main Bearing - Hydraulic Tools
90562 0129 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90564 0018 Crankshaft - Measuring Tools
90567 0003 Segment Stopper & Vibration Damper - Tools
90570 0002 Thrust Shaft - Tools
90571 0001 Main Bearing Shell - Tools
90572 0001 Main Bearing - Measuring Tools

906 - Control Gear

106-01 0035 Chain, Data
906-01 0228 Chain
106-02 0028 Chain Tightener, Data
906-02 0227 Chain Tightener
106-03 0011 Camshaft, Data
906-03 0210 Camshaft
106-04 0020 Camshaft Bearing, Data
906-04 0214 Camshaft Bearings
90651 0191 Chain Drive and Camshaft - Panel
90661 0063 Chain Drive and Camshaft - Tools
90662 0045 Camshaft - Hydraulic Tools
90664 0001 Crankshaft - Pin Gauge
90666 0001 Camshaft Coupling - Hydraulic Tools

MAN B&W Diesel A/S Page 2 (5)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

907 - Starting Air System

107-01 0015 Starting Air Distributor, Data
907-01 0210 Starting Air Distributor
107-02 0024 Start Air Valve, Data
907-02 0209 Starting Air Valve

908 - Exhaust Valve

108-01 0036 High-Pressure Pipe, Data
908-01 0216 High-Pressure Pipe
108-02 0067 Exhaust Valve, Data
908-02 0250 Exhaust Valve
108-03 0045 Exhaust Valve Actuator, Data
908-03 0235 Exhaust Valve Actuator
108-04 0035 Exhaust Valve Roller Guide, Data
908-04 0219 Exaust Valve Roller Guide
108-05 0012 Exhaust Valve Cam, Data
908-05 0214 Exhaust Valve Cam
108-07 0031 Exhaust Valve - Special Running, Data
908-07 0227 Exhaust Valve
90851 0196 Exhaust Valve - Panel
90861 0022 Exhaust Valve - Tools
90862 0039 Exhaust Valve - Hydraulic Tools
90863 0015 Exhaust Valve - Extra Tools
90864 0002 Exhaust Valve - Extractor Tool
90865 0002 Exhaust Valve Actuator - Tools

909 - Fuel Oil System

109-01 0050 Fuel Pump Lead, Data
909-01 0232 Fuel Pump Lead
109-02 0003 VIT System, Data
909-02 0207 VIT System
109-03 0041 Fuel Pump Cam, Data
909-03 0222 Fuel Pump Cam
109-04 0037 Fuel Pump, Data
909-04 0214 Fuel Pump
109-05 0040 Fuel Pump Top Cover, Data
909-05 0216 Fuel Pump Top Cover
109-06 0034 Fuel Pump Barrel Assembly, Data
909-06 0213 Fuel Pump Barrel Assembly
109-07 0026 Fuel Pump Suction Valve, Data
909-07 0213 Fuel Pump Suction Valve
109-08 0033 Fuel Pump Puncture Valve, Data
909-08 0212 Fuel Pump Puncture Valve
109-09 0022 Fuel Pump Shock Absorber, Data

MAN B&W Diesel A/S Page 3 (5)

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

909-09 0211 Fuel System Shock Absorber

10910 0007 Lifting Gear Roller Guide, Data
90910 0213 Lifting Gear for Roller Guide
10911 0044 Fuel Valve, Data
90911 0227 Fuel Valve
10912 0031 Spindle Guide, Data
90912 0219 Spindle Guide
10913 0027 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0049 Fuel Oil High-Pressure Pipes, Data
90914 0224 Fuel Oil High-Pressure Pipes
10915 0041 Fuel Pump Roller Guide, Data
90915 0222 Fuel Pump Roller Guide
90951 0423 Fuel Valve and Fuel Pump - Panel
90961 0061 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals

910 - Turbocharger System

110-01 0026 Air Cooler Element, Data
910-01 0226 Air Cooler Element
110-02 0003 Non-Return Valve in Turbocharger, Data
910-02 0210 Non Return Valve in Tubocharger
110-03 0008 Auxilary Blower, Data
910-03 0210 Auxilary Blower
110-04 0003 Butterfly Valve, Data
910-04 0205 Butterfly Valves
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0017 Water Mist Catcher, Data
910-06 0210 Water Mist Catcher
91061 0065 Turbocharger System - Tools
91061 0070 Turbocharger System - Tools
91061 0071 Turbocharger System - Tools
91063 0018 Air Cooler - Tools
91063 0019 Air Cooler - Tools
91063 0020 Air Cooler - Tools
91064 0001 Travelling Trolley
91066 0002 Air Cooler - Lifting Tools

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

 Table of Contents 900
Volume II - Maintenance

No. Edition Title

911 - Safety Equipment

111-01 0026 Safety Valve, Data
911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver - Safety Valve, Data
911-03 0001 Scavenge Air Receiver - Safety Valve

912 - Assembly of Large Parts

112-02 0008 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0208 Holding Down and End Chock Bolts (Epoxy)
112-03 0017 Stay Bolts, Data
912-03 0213 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0075 Hydraulic Tools for Large Parts

913 - General Tools

913-01 0211 Hydraulic Tools
113-03 0004 Working Platforms, Data
913-03 0004 Working Platforms
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 0034 Accessories - Hydraulic Tools
91356 0057 Lifting Tools, etc.
91357 0004 Open-Ended Spanners
91358 0009 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0005 Pliers
91361 0052 Combination Spanners
91362 0062 Ring Slugging Spanners
91363 0039 Spanners
91364 0059 Open-Ended Spanners
91366 0066 Instruments
91368 0008 Working Platforms

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

 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
 Checking and Maintenance Schedule,
MAN B&W Diesel 80-108 MC/MC-C Engines 900-1

The Checking and Maintenance Schedules indi- Design modifications may necessitate a revision of
cate the intervals at which it is deemed appropri- the instructions, in which case the revised instruc-
ate to inspect the individual components of the tions and changed overhauling intervals, if any, will
engine and to carry out overhauls, if necessary, apply and supersede those originally issued (see
based on the engine condition or on time criteria. e.g our Service Letters).

The stated Normal hours of service should only In addition to the checking and overhauling inter-
be used as a guide, as differences in the actual vals stated in this schedule, please note that the
service conditions, the quality of the fuel oil or lu- periodical survey requirements of the classification
bricating oil, the treatment of cooling water, etc. society may require additional checks and over-
will decisively influence the actual service results, hauls to be carried out. For further information
and thus the intervals between necessary over- please refer to the classification society.
hauling.

The procedures are divided into three categories:

Condition checking procedures marked under the heading Normal hours of service with a C,
deal with the service condition of a number of engine compo-
nents, and form the basis for estimating whether further overhaul-
ing is necessary. In a number of cases the condition checking
procedures refer to Volume I of the instruction book, in which
more detailed descriptions and working procedures can be found.

Condition-based overhauling are those procedures which under the heading Normal hours of
procedures service are marked with an O, and opposite which, under the
heading Overhaul to be based on procedure No. (column P), a
procedure number is stated.

This procedure number normally refers to one of the above condi-

tion checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.

Time-based overhauling also marked with an O under the headings Normal hours of ser-
procedures vice or Based on observations, are the procedures where an
actual basis for estimation is lacking. It is recommended, there-
fore, to carry out these procedures at the overhauling intervals
stated as a basis.

Where a symbol O or C is indicated in Based on observations

(column B), this is due to the fact that special service conditions
may make checking or overhauling necessary beyond the actual
standard schedules indicated.

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289 Page 1 of 6
 Checking and Maintenance Schedule,
900-1
80-108 MC/MC-C Engines MAN B&W Diesel

Page 2 of 6 When referring to this page, please quote Maintenance Schedule A90050 Edition 0289
MAN B&W Diesel Checking and Maintenance Schedule, 80-108 MC/MC-C Engines 900-1

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts after 500-1500 hours P : Refer to

Regular Checks Service interval (x1000 hours of operation)

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

901 Cylinder Cover

-1 Cylinder cover C* O * Check whenever exhaust
valve is removed
Indicator cock O

902 Piston with Rod and Stuffing box

-1 Piston C,O O
Inspection through scavenge ports C V
-2 Piston rod stuffing box C* O * Check clearances without
dismantling segments
903 Cylinder Liner and Cylinder Lubrication
-1 Cylinder liner O
Inspection through scavenge ports C
Measuring wear inside liner C
-2 Cylinder lubricators C A V,M
Accumulators nitrogen pressure C A

904 Crosshead with connecting rod

-1 Crosshead bearing C C C,O V Bearings should only be
opened up if bearing material
-2 Crosshead C C C,O
fragments fall out.
-3 Reciprocating parts C C,O
-4 Crankpin bearing C C C,O V
-5 Connecting rod O

905 Crankshaft and Thrust Bearing

-2 Main bearing C C C,O V Bearings should only be
opened up if bearing material
-3 Thrust bearing C C C,O fragments fall out.
-3 Guide bearing C C C,O
-4 Journal bearing C C C,O V
-5 Axial vibration damper O

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289 Page 3 of 6
900-1 Checking and Maintenance Schedule, 80-108 MC/MC-C Engines MAN B&W Diesel

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts after 500-1500 hours P : Refer to

Regular Checks Service interval (x1000 hours of operation)

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

Electronic axial vibration monitor C

Mechanical checking C
-7 Tacho pick-up C,O M
-8 Angle encoder C,O M

906 Mechanical Control Gear

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

907 Starting Air System

-1 Starting air distributor C C A
-2 Starting air valve C,O

908 Exhaust Valve

-1 High-pressure pipe O
-2 Exhaust valve O
-3 Exhaust valve actuator O
Actuator safety valve C,A
-4 Exhaust valve roller guide C* C* C O * only inspection through
camshaft covers
-5 Exhaust valve cam C* C* O

Page 4 of 6 When referring to this page, please quote Maintenance Schedule A90050 Edition 0289
MAN B&W Diesel Checking and Maintenance Schedule, 80-108 MC/MC-C Engines 900-1

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts after 500-1500 hours P : Refer to

Regular Checks Service interval (x1000 hours of operation)

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

-7 Exhaust valve special running O

909 Fuel Oil System

Fuel oil water content C
-1 Fuel pump settings A,C V
-2 VIT system A V
-3 Fuel pump cam A
-4 Fuel pump C O O
-5 Fuel pump top cover O
-6 Fuel pump barrel assembly R
-7 Fuel pump suction valve C,O
-8 Fuel pump puncture valve C,O
-9 Fuel pump shock absorber C O
-9 Fuel system shock absorber C O
-10 Lifting gear for roller guide C O
-11 Fuel valve C,O
- Fuel nozzle R
-12 Spindle guide R
-13 Non-return valve O
-14 Fuel oil high-pressure pipes O
-15 Fuel pump roller guide C* C* C O * Only inspection through
-16 Fuel pump special running O camshaft covers

910 Turbocharger System

-1 Air cooler C O V Check ∆p and ∆t
-2 Non-return valve C O Check at every port inspection
-3 Auxiliary blower O
-4 Butterfly valves C O Check at every port inspection

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289 Page 5 of 6
900-1 Checking and Maintenance Schedule, 80-108 MC/MC-C Engines MAN B&W Diesel

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts after 500-1500 hours P : Refer to

Regular Checks Service interval (x1000 hours of operation)

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

-5 Turbocharger turbine C* C C,O V,M * Dry cleaning daily

Turbocharger air filter C O
Protective grid before turbocharger C R V
Turbocharger lubricating oil water content C* M * Only if separate oil system
-6 Water mist catcher C* C,O * Check ∆p

911 Safety Equipment

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

912 Assembly of Large Parts

-2 Holding-down and end chock bolts C C* C * Initial check only
-3 Stay bolts C C
Top bracings C C
Diaphragm in crankcase oil outlet C R
System lubricating oil water content C M Empty and clean tank
System lubricating oil bottom tank O
Cooling water quality C A V,M
Crankcase C* * Check for loose nuts and
bearing material fragments
913 General Tools
-1 Hydraulic tools O M

Page 6 of 6 When referring to this page, please quote Maintenance Schedule A90050 Edition 0289
 General – Safety Precautions 900-2

Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.

SAFETY PRECAUTIONS

X 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 0036 Cylinder Cover, Data

901-01 0228 Cylinder Cover
90151 0204 Cylinder Cover - Panel
90161 0102 Cylinder Cover - Tools
90164 0001 Cylinder Cover - Hydraulic Jack Spares
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 Standard Tools: See Section 913

Special Data
K90MC-C
0036
101-1 Cylinder Cover

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
X Lock turbocharger rotors

Data 50-300 Nm
140-760 Nm
Ref. Description Value Unit

D-1 Weight of exhaust valve stud 200 kg 1x3m

8x1m
D-2 Weight of cyl. cover
complete with valves 9200 kg

D-3 Weight of cooling jacket 200 kg

D-4 Screwing-in torque

– exhaust valve studs 600 Nm

D-5 Screwing-in torque

– starting valve studs 240 Nm

D-6 Screwing-in torque

– fuel valve studs 140 Nm

D-7 Hydraulic pressure

– dismantling 900-990 bar

D-8 Hydraulic pressure

– tightening 900 bar

D-9 Weight of cylinder cover 6500 kg

When referring to this page, please quote Data D10101 Edition 0036 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
Data

Plate
90151

1283702-2

Spare Parts

Plate – Item No. Description Qty

90101-xxxx 114 O-rings 2

90101-xxxx 151 Sealing ring 1
90302-xxxx 267 O-rings 4

Page 2 (2) When referring to this page, please quote Data D10101 Edition 0036
MAN B&W Diesel A/S
 Cylinder Cover 901-1.2
Dismantling
Cylinder Cover
K90MC-C
0228
Dismantling
901-1.2

1.
1. Set blocking device A on the main starting
valve in the BLOCKED position.

Engage turning gear B.

Open indicator cocks C.

Close cooling water inlet and outlet valves

D.

Open cooling water vent and drain cocks E.

As soon as the cylinder cover has been
emptied of water, close the drain cocks
again.

Close fuel oil inlet valve F.

Shut off the control air and safety air supply

G. Vent the manoeuvring system through MA901-1.2 214 01

the ball valve.

Also shut off the air supply on the pressure

reduction unit for the hydraulic/pneumatic
exhaust valve, and vent the system.

Valve H is for checking the water level when

cooling water is drained during replacement
of cylinder cover or piston.

When referring to this page, please quote Procedure M90101 Edition 0228 Page 1 (11)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover
Dismantling

2. 2. Remove the cooling water outlet pipes from

the exhaust valve and cylinder cover.

Remove the screws which fasten the high-

pressure pipe to the oil cylinder on the ex-
haust valve and the hydraulic activator, and
lift the high-pressure pipe away.
See Procedure 908-1.2.

Dismount the drain oil pipe between the ex-

haust valve and the hydraulic activator.

3. Dismount the fuel oil high-pressure pipes

KB901-1.2 220 02

between the fuel pump and the fuel valves.

See Procedure 909-14.2.

Dismount the return oil connection from the

fuel valves at the fuel pump.
3.
Dismount the control air pipe from the start-
ing valve.

Remove the screws in the flange connec-

tion for the starting air pipe.

4. Dismount the air pipes for the sealing air

control unit.
KB901-1.2 220 03

4.
MC901-1.1 131 04

Page 2 (11) When referring to this page, please quote Procedure M90101 Edition 0228
MAN B&W Diesel A/S
 Cylinder Cover 901-1.2
Dismantling

5. Remove the plate cover and the insulating 5.

material from the exhaust receiver and in-
termediate pipe.

Dismount the clamp from the exhaust pipe/

intermediate pipe flanges. On some en-
gines this is a bolted connection.

Remove the protective caps from the cylin-

der cover nuts.

6. Position the cylinder cover tightening tool

over the cylinder cover.

Place the spacer rings over the nuts.

Pull down the hydraulic jacks of the tighten-

ing tool and screw the jacks on to the studs.

Connect the hydraulic hoses to the jacks

KB901-1.2 220 05

and raise the pressure to the level stated in

Data. Loosen the nuts with a tommy bar.

For operation of the hydraulic tools, see

Chapter 913.
6.
Release the pressure.

Remove the hydraulic jacks, the spacer

rings and the nuts.
KB901-1.2 220 06

D-7

When referring to this page, please quote Procedure M90101 Edition 0228 Page 3 (11)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover
Dismantling

7. 7. Hook the engine room crane on to the lifting

attachment on top of the exhaust valve.

Lift away the cylinder cover complete, and

land it on, for instance, a couple of wooden
planks.

8. On the engines with extremely low lifting

height, use the engine room double-jib
crane and two eye bolts.

9. Remove and discard the sealing ring be-

tween cylinder cover and cylinder liner.
KB901-1.2 220 07

8.
MB901-1.2 228 08

8.
KB901-1.2 220 09

Page 4 (11) When referring to this page, please quote Procedure M90101 Edition 0228
MAN B&W Diesel A/S
 Cylinder Cover 901-1.3
Overhaul
Overhaul
901-1.3

1.
1. Dismount all valves and pipes on the cylin-
der cover. See Procedure 907-2.2, 908-2.2
D-1
and 909-11.2.

Dismount all studs on the top of the cylinder

cover.

2. Remove the screws which secure the cool-

ing jacket to the cylinder cover.

Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.

MN901-1.3 216 01
Remove and discard the O-rings from the
cover, and carefully clean the cooling jacket
and the cylinder cover.

Provide the cylinder cover with new O-

rings, well lubricated with oil. 2.

3. Lift the cylinder cover and guide the jacket/

cover into position, using the screw holes
as reference. D-9
Mount and tighten the screws for the cool-
ing jacket.

D-3
MN901-1.3 216 02

3.
MN901-1.3 216 03

When referring to this page, please quote Procedure M90101 Edition 0228 Page 5 (11)
MAN B&W Diesel A/S
901-1.3 Cylinder Cover
Overhaul

4. 4. Recondition the valve bores as follows:

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

MN901-1.3 216 05

and a grinding compound (e.g. Carborun-

dum No. 200).

After the milling/grinding, clean the bore

and seating carefully, and check that the
5.
seating is not damaged.

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
not damaged.
MN901-1.3 216 06

6.
GN901-1.3 203 07

Page 6 (11) When referring to this page, please quote Procedure M90101 Edition 0228
MAN B&W Diesel A/S
 Cylinder Cover 901-1.3
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.

9. Lubricate the threads with ‘Never Seize' or MN901-1.3 216 08

Molybdenum Disulphide (MoS 2) and mount

the valve studs.

Tighten up the studs in accordance with the 8.

screwing-in torque stated on the data
sheet.

Fill up the grooves between the valve studs

and the bores for the valve studs with per-
matex to prevent water or oil from entering
the bores during operation of the engine.
JN901-1.3 207 09

Provide the water connection flanges with

new gaskets, and keep the cylinder cover
ready for replacement.

Always fit new or overhauled valves before 9.

D-4
a cylinder cover is mounted on the engine.

D-6
D-5
MN901-1.3 216 10

When referring to this page, please quote Procedure M90101 Edition 0228 Page 7 (11)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover
Mounting
Mounting
901-1.4

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

inder liner.

2. Lift the cylinder cover by means of the

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

Provide the cooling water connecting pipes

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

Mount a new ‘klinger’ sealing ring in the

groove of the flange of the intermediate
pipe.

Lower the cover carefully into position.

During the landing, carefully check that the

cooling water connecting pipes engage cor-
rectly with the holes in the cooling jacket.
KB901-1.4 220 01

2.

D-2
KB901-1.2 220 07

Page 8 (11) When referring to this page, please quote Procedure M90101 Edition 0228
MAN B&W Diesel A/S
 Cylinder Cover 901-1.4
Mounting

3. Mount all eight nuts on the studs and screw 3.

them down to the cylinder cover.

Place the eight spacer rings over the nuts.

Position the cylinder cover tightening tool

over the cylinder cover.

Pull down the hydraulic jacks of the tighten-

ing tool and screw the jacks on to the studs.

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
Data. Tighten the nuts with a tommy bar.

Release the pressure. Remove the hydrau-

lic jacks and the spacer rings.

4. When mounting the clamp connecting the

compensator and the intermediate pipe/ex-
KB901-1.2 220 06

haust valve it may, in some cases, become

necessary to use the engine room crane. D-8
Mount two shackles to the supports of the
bend.
4.
Fasten the engine room crane to the shack-
les with a wire rope.

Use the engine room crane to bring the

compensator/bend into alignment with the
exhaust valve intermediate pipe.

Mount the lock clamp or the bolts.

MA901-1.2 103 04

When referring to this page, please quote Procedure M90101 Edition 0228 Page 9 (11)
MAN B&W Diesel A/S
901-1.4 Cylinder Cover
Mounting

5. 5. Mount the insulating material and the cover

plate on the intermediate pipe.

Mount the caps on the cylinder cover nuts.

6. Mount the air pipes for the sealing air con-

trol unit on the exhaust valve. Open the air
supply.

Caution!

The air supply to the exhaust valve must

always be connected before starting the
KB901-1.4 220 05

camshaft oil pumps.

This is very important, because other-

wise the valve will open more than
intended.
6.

7. Mount the fuel oil high-pressure pipes be-

tween the fuel pump and the fuel valves.
Check that the pipes fit properly at the
seats and that all parts are clean and pro-
vided with new O-rings.

Lift up the union nuts on the pipes and tight-

en the coupling pieces with the special
spanner head and the torque spanner.
See Procedure 909-14.4.

Lower the union nut and screw it on to the

HM901-1.2 124 05

coupling piece by means of the hook span-

ner.

Connect the outlet pipes for the return oil

7. connection on the fuel valves.

Connect the air hoses and outlet pipes to

the fuel oil alarm system.

Mount the control air pipe for the starting

valve and fasten the starting air pipe.
KB901-1.4 220 07

Page 10 (11) When referring to this page, please quote Procedure M90101 Edition 0228
MAN B&W Diesel A/S
 Cylinder Cover 901-1.4
Mounting

8. Mount the high-pressure pipe for the hy- 8.

draulic valve gear. See Procedure 908-1.4.

Mount the return oil pipe between the ex-

haust valve and the hydraulic actuator.

Mount the cooling water outlet pipes.

9. Shut the drain valves and open the cooling

water inlet.

After venting the cylinder section, shut the

vent cocks and open the cooling water out-
let valve.

Open the fuel oil, lubricating oil and air

KB901-1.4 220 08
valves.

When referring to this page, please quote Procedure M90101 Edition 0228 Page 11 (11)
MAN B&W Diesel A/S
 Cylinder Cover Panel Plate
P90151-0204
Cylinder Cover Panel
0204
P90151

When referring to this page, please quote Plate P90151 Edition 0204 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0204

Item Item
Item Description Item Description
No. No.

010 Panel for tools

022 Name plate
046 Grinding tool
058 Milling and grinding tool for fuel valve
seat
060 Milling and grinding tool for starting
valve seat
071 Dismantling tool for fuel valve
083 Handle
095 Grinding ring for starting valve
105 Grinding handle for starting valve
117 Pressure tester
129 Extension studs for lift of cylinder
cover

Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0204
MAN B&W Diesel A/S
 Cylinder Cover - Tools Plate
P90161-0102

When referring to this page, please quote Plate P90161 Edition 0102 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0102

Item Item Description Item Item Description

No. No.

015 Cylinder cover tightening tool, com-

plete
027 Lifting device
039 Hose with unions
040 Balancing ring assembly, upper
052 Spring balance
064 Balancing ring assembly, lower
076 Heart-shaped thimble
088 Wire lock
111 Jack-hydraulic, complete
123 Jack-hydraulic, support
159 O-ring with back-up ring
160 O-ring with back-up ring
196 Head screw
206 Nut
231 Screw

Page 2 (2) When referring to this page, please quote Plate P90161 Edition 0102
MAN B&W Diesel A/S
 Cylinder Cover - Hydraulic Jack Spares Plate
MAN B&W Diesel P90164-0001

When referring to this page, please quote Plate P90164 Edition 0001 Page 1 (2)
Plate
Cylinder Cover - Hydraulic Jack Spares
P90164-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Wooden box

023 Tommy bar
035 Spanner
047 Venting screw
059 Quick coupling male
060 Disc
072 O-ring with back-up ring
084 O-ring with back-up ring
096 Stud setter
118 Disc

Page 2 (2) When referring to this page, please quote Plate P90164 Edition 0001
 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 0041 Piston, Data

902-01 0250 Piston
102-02 0035 Piston Rod Stuffing Box, Data
902-02 0210 Piston Rod Stuffing Box
90251 0253 Piston and Piston Rod - Panel
90261 0102 Piston and Piston Rod - Tools
90262 0026 Piston and Piston Rod - HydraulicTools
90263 0007 Piston Crown - Hydraulic Tools
90264 0006 Piston and Piston Rod - Tilting Tools
90265 0003 Piston and Piston Rod - Support Tools
90266 0001 Piston - Lifting Tools

MAN B&W Diesel A/S

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

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0041
102-1 Piston

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
50–300, 280–760 Nm
X Shut off lubrication oil
Lock turbocharger rotors
2 x M16

Data
Ref. Description Value Unit

D-1 Radial width:

– new piston ring 28 mm
– worn piston ring 24 mm
D-2 Maximum vertical height:
– groove No. 1 20.3 mm
– groove Nos. 2, 3 and 4 15.8 mm
D-3 Max. permissible burn-away:
– standard piston top 22 mm
D-4 Height new rings:
– piston ring No. 1 19.5 mm
– piston ring Nos. 2, 3 and 4 15 mm
D-5 Minimum ring gap
– piston ring No. 1 6.3 mm
– piston ring Nos. 2, 3 and 4 4.5 mm
D-6 Minimum free ring gap 55 mm
D-7 Vertical clearance, new parts 0.45-0.50 mm
D-8 Piston complete 3800 kg
D-9 Piston crown 1250 kg
D-10 Piston skirt 275 kg
D-11 Piston cooling pipe 65 kg
D-12 Piston rod 2000 kg
D-13 Tightening torque
– cooling oil pipe 190 Nm
D-14 Tightening torque
– Piston skirt 380 Nm
D-15 Tightening torque
– telescopic pipe 590 Nm
D-16 Test pressure 7 bar
D-17 Tightening torque
– stuffing box 180 Nm
D-18 Screwing-in measurement
cylinder cover studs 2.5-3.0 mm
D-19 Hydraulic pressure
– tightening 900 bar
D-20 Hydraulic pressure
– dismantling 800-990 bar
D-21 Piston rod/crown studs,
screwing-in torque 300 Nm

When referring to this page, please quote Data D10201 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
102-1 Piston
Data

Plate
90251

1283725-0

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10201 Edition 0041
MAN B&W Diesel A/S
 Piston 902-1.1
Checking
Piston
K90MC-C
0250
Checking
902-1.1

1.
Scavenge port inspection

To detect possible leakages from the piston or

cylinder cover, keep the cooling water and cool-
ing oil circulating during the scavenge port in-
spection.

1. Remove the inspection covers on the cam-

shaft side of the cylinder frame.

Note!

The scavenge port inspection can also

GN902-1.1 204 01
be carried out from within the scavenge
air receiver.

Clean the openings.

2.
Begin the inspection at the cylinder whose
piston is nearest BDC.

2. With the piston in BDC, inspect the piston

crown and the cylinder wall.

Note down the results.

See Volume I, Operation, Chapter 707.

3. Turn the engine. While the piston is passing

the scavenge air ports, inspect the piston
rings, the ringlands and the piston skirt.

Check the movability and the tension of the

piston rings, by pressing against them with
GN902-1.1 204 02

a wooden stick.

Note down the results.

3.
HG902-1.1 201 03

When referring to this page, please quote Procedure M90201 Edition 0250 Page 1 (21)
MAN B&W Diesel A/S
902-1.1 Piston
Checking

4. 4. After turning the piston upwards, past the

scavenge air ports, inspect the piston rod
and the lower part of the cylinder wall.

Note down the results.

5. Re-mount the inspection covers on the cyl-

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

Piston rings and piston crown

6. Remove the piston from the cylinder and

place it on the piston support.
GN902-1.1 204 04

See Procedure 902-1.2.

Note!
6.
It is recommended to replace all the pis-
ton rings whenever a piston is removed
from the engine.

All the following measurements should be

used as a guideline for the running time of
a set of new piston rings.
D-8
Depending on the extent of the wear, the
running time can be increased or de-
creased. For evaluation of the rings, see
Volume I, Chapter 707.
MN902-1.2 242 08

Page 2 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.1
Checking

7. Before dismantling the piston rings, meas- 7.

ure the free ring gap of all the piston rings.

If the piston ring gap of one of the piston D-6

rings is less than stated in Data, the piston
ring must be replaced.

8. Take off the piston rings by means of the

ring expander.

Clean and inspect the rings.

9. Measure and record the radial width of the

rings.
See Volume I, Operation, Chapter 707.

NA902-1.1 212 07

8.

Top
MB902-2.2 114 01

9.
AM902-3.0 54 02B

D-1 Worn

When referring to this page, please quote Procedure M90201 Edition 0250 Page 3 (21)
MAN B&W Diesel A/S
902-1.1 Piston
Checking

Min. 1 mm 10. Piston rings with milled pressure relief

10. Min. 1 mm grooves must be replaced if the radial depth
of the grooves has worn down to less than
1 mm.

11. Clean the ring grooves and check them for

burn marks or other deformation.
GN902-1.1 204 09

Measure the ring grooves with a caliper

gauge.

Clearance in piston ring grooves:

11.
The maximum vertical height in a worn ring
groove must not exceed the value stated in
Data.
D-2 The groove is also worn out if there is no
chromium layer.

12. Clean the piston crown and check the burn-

away by means of the template. For maxi-
mum permissible burn-away value, see Da-
ta.

Check the burn-away on the whole circum-

Max. 2 mm ference of the piston crown.
KM902-3.0 47 05

12.

D-3
MB902-3.0 94 05

Page 4 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.1
Checking

13. Before mounting a new piston ring, meas- 13.

ure the piston ring gap and the height of the
rings.

When measuring, insert the piston ring in

D-5

JG902-3.0 93 02A
either a new cylinder liner or in the bottom
of a used cylinder (below the ring travel
zone).
D-4
For minimum ring gap, see Data.
14.
For piston ring No. 1, carry out a horizontal

DM902-3.0 64 03B
measurement.
D-5
14. For piston ring Nos. 2, 3 and 4, carry out a
tilted measurement, see the sketch.
D-4
15. Fit the piston rings (alternately right-hand 15.
and left-hand cuts with the ring gaps stag-
gered 180° and with the TOP mark up-
wards), using the ring expander.

When mounting the piston rings, use the

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

Do not expand the rings more than neces-

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

16. Check the vertical clearance between the

new piston ring and the new or recondi-
tioned ring groove with a feeler gauge. See
Data.
KB902-1.2 225 15

16.

D-7
KC902-3.0 83 06

When referring to this page, please quote Procedure M90201 Edition 0250 Page 5 (21)
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling
Dismantling
902-1.2

2. 1. Open the crankcase door to the cylinder

concerned.

2. Loosen and remove the screws which tight-

en the telescopic pipe to the bend.

Remove one screw from the telescopic

stuffing box housing and mount the special
tool for suspending the telescopic pipe or
use the thread in the telescopic pipe stuff-
ing box housing.

Turn the crosshead to TDC.

Suspend the telescopic pipe by means of

the tool.
MA904-2.2 77 05

3. Turn the crosshead downward and remove

the distance tube from the bend.

Note!
3.
When a piston is dismantled, never turn
the engine without first dismantling the
telescopic pipe from the crosshead.
KB902-1.2 225 03

Page 6 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.2
Dismantling

4. Turn the crosshead down far enough to give 4.

access to the piston rod stuffing box and
the piston rod nuts.

5. Release the stuffing box by removing the

innermost screws from the stuffing box
flange.

Note!

Do NOT remove the outermost screws

from the flange.

6. Remove the nuts from the piston rod, using

NA902-1.2 212 01
the hydraulic jacks. See Data.

For operation of the hydraulic jacks,

see Procedure 913-1.

5.
GN902-1.2 204 02

6.

D-20
KB902-1.2 225 06

When referring to this page, please quote Procedure M90201 Edition 0250 Page 7 (21)
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling

7. 7. Mount the two distance pieces on the piston

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

8. Dismount the cylinder cover.

See Procedure 901-1.3.

9. Make a short scratch mark in liner and

scraper ring to ensure the correct mount-
ing.

Remove the scraper ring.

Carefully remove wear ridges at the top of

the cylinder liner.
See Procedure 903-1.3.
NA902-1.2 212 04

9.
KB902-1.2 225 09

Page 8 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.2
Dismantling

10. Turn upwards and check that the stuffing 10.

box lands correctly on the extension studs
on the piston rod.

Turn the piston to TDC.

The top of the piston is now free of the cyl-

inder liner.

MB902-1.2 250 10
In case of low lifting height in the engine
room, it might be necessary to remove one
or two cylinder cover studs, using a stud
setter.

If the engine is equipped with long distance 11.

pieces for the stuffing box, the piston rod
foot can pass between two cylinder cover
studs.

Clean the lifting groove of the piston crown

and mount the lifting tool.
D-8
Note!

Make sure to mount the lifting tool cor-

rectly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.

11. Place the two halves of the support around

one of the openings in the platform.
MB902-1.2 242 08

Lift the piston out of the cylinder and lower

the piston rod foot and stuffing box through
the opening in the platform.
12.
Place the two halves of the support around
the piston rod and secure the two halves
with screws.

12. Place a cover over the opening for the pis-

ton rod stuffing box in the bottom of the cyl-
inder unit.
MC902-2.1 104 09

When referring to this page, please quote Procedure M90201 Edition 0250 Page 9 (21)
MAN B&W Diesel A/S
902-1.2 Piston
Dismantling

13. 13. Turn the crosshead down far enough to per-

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

The protective rubber cover should remain

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

Clean, measure and recondition the cylin-

der liner.
See Procedure 903-2.1.

Low lifting height

14. Place the supporting tool on the cylinder

cover studs.
GM902-2.1 97 09

Remove the clamp from the tilting tool and

place it on the supporting tool by means of
the engine room crane and crossbar.
14.
KB902-1.2 233 14

Page 10 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.2
Dismantling

15. Lift the piston high enough to give ample 15.

room over the tilting tool.

Mount the tilting tool around the piston rod

and lower the piston so that the distance
pieces of the tilting tool are in contact with
the piston.

Fasten the clamp to the tilting tool.

16. Lift the piston to the maximum crane height.

Run the crane athwartship and, at the same
time, tilt the piston.

Keep the piston rod clear of the cylinder lin-

er and studs while carrying out the tilting.

When space conditions permit, straighten

up the piston and lead it over to the cut-out
in the platform for overhauling the piston.

When the piston is at a suitable height

above the platform cut-out, position the pis-
MB902-2.3 114 02

ton support around the piston rod and

clamp.

Now lower the piston while guiding the sup-

port to the platform cut-out. 16.

After landing the piston and ensuring that it

rests correctly on the support, remove the
tilting tool.
D-8

Note!

On engines with extremely low lifting

height, use the engine room double-jib
crane instead of the transverse piece.
KB902-1.2 233 16

When referring to this page, please quote Procedure M90201 Edition 0250 Page 11 (21)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul
Overhaul
902-1.3

1. 1. Ease the piston down so that the stuffing

box is below the floor.

D-8 2. Assemble the two halves of the piston sup-

port around the piston rod.

Remove the piston rings.

See Procedure 902-1.1.

3. Dismount the hydraulic nuts between the

rod and the piston crown. See Data.
HN902-1.3 242 01

2.
HN902-1.3 242 02

3.

D-20
MB902-4.2 117 01

Page 12 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

4. Screw the support screws up to contact 4.

with the piston skirt.

Dismount the locking wires and the screws

of the piston skirt.

Land the piston skirt on the piston support. D-9

5. Lift away the piston crown.
Lift away the piston skirt.

Thoroughly check the cooling spaces of the

piston crown for coke deposits. Any coke
deposits found must be removed, see step
12. D-10
6. Dismount the screws of the cooling oil pipe
flange.
KB902-1.3 233 03

Mount the eye bolts and lift out the cooling

oil pipe.

Clean and inspect, then re-mount the cool-

ing oil pipe.
6.

D-11

D-13
JM902-4.2 89 02

When referring to this page, please quote Procedure M90201 Edition 0250 Page 13 (21)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul

7. Alternatively, the piston can be dismantled

in the following way:

7. With the piston standing in the piston sup-

port tool, remove the piston rod stuffing
box.
See Procedure 902-2.3.

8. Lift the piston with the normal lifting tool.

Lower the piston rod foot until it is close to

the platform. Land the foot on a wooden
block.

Note!

During the lift, follow with the crane to

keep the crane positioned vertically
HN902-1.3 242 07

above the piston crown.

9. Lower the piston crown to the platform and

land it on a wooden block in such a way that
it is possible to remove the lifting tool.
8.
10. Mount an eyebolt in the side of the lifting
tool, hook on the crane and remove the lift-
ing tool from the piston crown.

Attach the lifting bracket to the bottom of

the piston rod foot. Hook the crane on to the
lifting bracket.
HM902-1.3 242 08

10.
HN902-1.3 242 10

Page 14 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

11. Lift the piston rod foot clear of the wooden 11.
block.

Note!

During the lift, follow with the crane to

keep the crane positioned vertically
above the piston rod foot.

Keep lifting until the piston rod is in a verti-

cal position.

HN902-1.3 240 09
12. Place the piston in an upright position with
the piston crown resting on wooden planks.

Dismount the hydraulic nuts. Lift the piston

rod away and land it in a horizontal position
on a couple of wooden planks. 12.

13. 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.
D-20
HN902-1.3 242 12

13.

D-10
MB902-1.3 250 13

When referring to this page, please quote Procedure M90201 Edition 0250 Page 15 (21)
MAN B&W Diesel A/S
902-1.3 Piston
Overhaul

14. 14. Thoroughly clean and inspect all parts of

the piston.

If coke deposits are found in the cooling

spaces of the piston crown, the piston
D-14 crown cooling spaces should be washed
out with Carbon Remover or a similar
cleaning fluid. When all coke deposits have
been dissolved, clean and inspect the pis-
ton crown again.
Regarding check of the piston crown, see
Procedure 902-1.1.
D-19
Replace all sealing rings on the piston. All
the new sealing rings must be coated with
lubricating oil before the piston is assem-
bled.
D-21
Coat all screws with Molybdenum Disul-
phide (MoS 2).

Assemble the piston in the reverse order to

disassembly.
HN902-1.3 242 14

If the piston crown is renewed, the piston

crown studs must be tightened to torque D-
21.

Tighten all the hydraulic nuts to the tighten-

15. ing pressure stated in Data.
For correct tightening sequence, see the
sketch.

15. Lock 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.
HM902-4.2 52 07

Page 16 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.3
Overhaul

16. Fill the piston and piston rod with lubricat- 16.
ing oil. D-16
Mount the pressure-testing tool around the
base of the piston rod.

Pressure-test the piston at the pressure

stated on the data sheet.

Check the contact surfaces of the piston

and the sealing rings for tightness. Oil

Check that there are no cracks in the piston

crown.

17. Drain the piston of oil.

Place the piston in the piston support tool

and mount the piston rod stuffing box.
See Procedure 902-2.3.
MB902-4.0 96 14

When referring to this page, please quote Procedure M90201 Edition 0250 Page 17 (21)
MAN B&W Diesel A/S
902-1.4 Piston
Mounting
Mounting
902-1.4

2. 1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1.
D-8 2. Mount the lifting tool on the piston crown.

3. Remove the cover from the piston rod stuff-

ing box opening in the bottom of the cylin-
der unit.

Clean the topside of the stuffing box flange.

MB902-4.1 117 02

3.
MC902-2.1 104 09

Page 18 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.4
Mounting

4. Remove the protective rubber cover from 4.

the crosshead.

5. Turn the crosshead to a position 45° from

TDC.

6. Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.

Coat the O-rings of the stuffing box with oil.

7. Mount the guide ring for piston rings on the

cylinder liner.

NA902-1.2 217 10
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.
NA902-1.4 212 05 5.

45
°

6.
MB902-1.4 250 06

When referring to this page, please quote Procedure M90201 Edition 0250 Page 19 (21)
MAN B&W Diesel A/S
902-1.4 Piston
Mounting

8. 8. Turn the crosshead nearly to TDC while

checking that the guide ring of the cross-
head enters the centre hole in the piston
rod.

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.

9. 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
KB902-1.4 225 08

correctly centred.

Remove the distance pieces from the piston

rod foot.

9. Mount and tighten the piston rod nuts, us-

ing the hydraulic jacks. See Data.
KB902-1.4 225 09

Page 20 (21) When referring to this page, please quote Procedure M90201 Edition 0250
MAN B&W Diesel A/S
 Piston 902-1.4
Mounting

10. Tighten down the piston rod stuffing box by 10.

means of the screws through the inner
holes in the stuffing box flange. D-17
11. Place the distance tube on the bend for the
telescopic pipe.

Turn up towards TDC until the telescopic

pipe is landed on the distance tube.

GN902-1.2 204 02
Remove the suspending tool and mount the
screws and tighten the telescopic pipe to
the bend. See Data.

12. Mount the cylinder cover studs with the stud 11.
setter, if they have been removed.
See Data.

13. Mount the piston cleaning ring in the liner.

Make sure that the scratch marks on the
scraper ring and on the cylinder liner are
aligned.

Mount the cylinder cover.

See Procedure 901-1.4.

14. Start the engine and keep it running for

about 15 minutes at a number of revolutions
D-15
KB902-1.4 225 11

corresponding to very slow.

Then stop the engine and inspect the piston

rod and stuffing box.
12.

D-18
KB902-1.4 225 12

When referring to this page, please quote Procedure M90201 Edition 0250 Page 21 (21)
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 102-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0035
102-2 Piston Rod Stuffing Box

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubrication oil
Lock turbocharger rotors

Data
Ref. Description Value Unit
D-1 Stuffing box complete 190 kg

D-2 Stuffing box half 60 kg

D-3 Tightening torque for

stuffing box halves 80 Nm

D-4 Tightening torque for

stuffing box flanges 180 Nm

D-5 Tightening torque for

inner screws 180 Nm

D-6 Vertical clearance –

uppermost rings 0.15-0.35 mm

D-7 Vertical clearance –

lowermost rings 0.05-0.20 mm

D-8 Ring-end clearances –

uppermost rings 4 x 6 mm

D-9 Ring-end clearances –

lowermost rings 3 x 3 mm

D-10 Check length for the six

uppermost springs:
– F0 = 0 N................. L0 = 889 mm
– F1 = 173 +/– 7 N....... L1 = 1278 mm
– F2 = 200+/– 10 N..... L2 = 1344 mm

D-11 Check length for the four

lowermost springs:
– F0 = 0 N................. L0 = 839 mm
– F1 = 210+/– 7 N....... L1 = 1219 mm
– F2 = 250 +/– 10 N..... L2 = 1263 mm

When referring to this page, please quote Data D10202 Edition 0035 Page 1 (2)
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data

Plate
90251

1283725-0

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10202 Edition 0035
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.1
Checking
Piston Rod Stuffing Box
0210
Checking
902-2.1

1.
1. After the piston rod stuffing box has been
dismantled, see Procedure 902-2.2, check
the following ring clearances:

Uppermost scraper ring and sealing rings

Vertical clearance between sealing ring

section and groove.

Clearance at ring ends (scraper ring).

Total clearance (scraper ring).

Clearance at ring ends (sealing rings).

Total clearance (sealing rings).

Lowermost scraper rings

Vertical clearance between scraper ring

and groove. GN902-2.1 203 01

Clearance at ring ends.

Total clearance.

The ring clearances stated in Data apply to

new rings.
2. D-10
As a general guide, it is recommended –
depending on the overhauling intervals and
one’s own experience – to replace sealing
rings and scraper rings when the specified
clearance values have changed by more
than 50%.

2. Check the length of the springs at different D-11

loads. Adjust the loads to achieve the
lengths stated in Data.

If the loads necessary are outside the limits

HM902-5.0 70 02

stated in Data, the springs must be discard-

ed.

When referring to this page, please quote Procedure M90202 Edition 0210 Page 1 (9)
0$1% :'LHVHO$6
902-2.2 Piston Rod Stuffing Box
Dismantling
Dismantling
902-2.2

1. If, in the period between piston overhauls, it be-

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

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

Mount the rubber hose around the piston

rod to protect the crosshead bearing from
impurities.

2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diametrically opposite in the
NA902-2.2 210 01

stuffing box flange, longitudinally to the en-

gine.

3. Mount the worktable round the piston rod

so that the two screws can be loosened
2. through the holes.
NA902-2.2 210 02

3.
MB902-5.2 94 03

Page 2 (9) When referring to this page, please quote Procedure M90202 Edition 0210
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.2
Dismantling

4. Remove the two long screws from the 4.

worktable.

Mount them in the stuffing box through the

holes in the worktable.

Remove the remaining two screws from the

stuffing box.

5. Turn the piston to BDC, thereby withdraw-

ing the stuffing box from the cylinder frame
bottom.

Remove the two long dismantling screws

MB902-5.2 94 04
from the stuffing box and mount them in the
worktable.

6. By means of the four short screws in the

worktable, press the stuffing box out of the 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
MB902-5.2 94 05

6.
MB902-5.2 94 06

When referring to this page, please quote Procedure M90202 Edition 0210 Page 3 (9)
0$1% :'LHVHO$6
902-2.3 Piston Rod Stuffing Box
Overhaul
Overhaul
902-2.3

Outside the engine

Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.

During such overhauls, the piston rests on a

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

Work on the stuffing box is then carried out

from the platform below.
NA902-2.3 210 00

1. Mount two eye bolts in the stuffing box

flange, and hook on two tackles.

Lift the stuffing box a little up the piston rod,

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

Land the stuffing box on the worktable, and

remove the tackles and screws.

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

O-ring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.

Remove the nuts from the stuffing box as-

sembling bolts.
NA902-2.3 210 01

2.
NA902-2.3 210 02

Page 4 (9) When referring to this page, please quote Procedure M90202 Edition 0210
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.3
Overhaul

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

stuffing box half.

Mount two eye bolts on the stuffing box half

and remove it from the worktable.

4. Using a feeler gauge, measure the vertical

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.

NA902-2.3 210 03
6. Measure the clearance between the ring
segments to determine whether replace-
ment is necessary.
See Procedure 902-2.1.
7. D-10
Dismantle and stack the rings in the same
order as when fitted in the stuffing box.

Carefully clean all the ring segments.

Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D-11
7. Check the lengths of the springs.
See Procedure 902-2.1.

8. Inspect the surface of the piston rod. If

HM902-5.0 70 02

small longitudinal scratches have occurred

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

9. Clean the halves of the stuffing box hous-

ing.
HC902-5.1 98 07

When referring to this page, please quote Procedure M90202 Edition 0210 Page 5 (9)
0$1% :'LHVHO$6
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
positioned) with molybdenum disulphide
(MoS 2).

Assemble all the stuffing box ring units

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

• Place the lowermost scraper ring seg-

ments on the worktable.

• Place the spring round the segments,

HM902-5.1 70 09

and hook the spring ends together.

Repeat this procedure for the remaining

scraper rings.

11. On top of the scraper rings, assemble the

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

Assemble the 8-part sealing ring so that the

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

Assemble the 4-part sealing ring above the

8-part sealing ring. Push the two rings to-
gether in such a manner that the guide pins
in the lower sealing ring engage with the
two holes in the upper sealing ring.
NA902-2.3 210 11

Finally, assemble the uppermost ring unit

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

11. Use the stuffing box half on the worktable

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

Page 6 (9) When referring to this page, please quote Procedure M90202 Edition 0210
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.3
Overhaul

12. Check the ring clearance again. 12.

Then place the other half of the stuffing box

housing on the worktable, pushing it into
place round the rings.

Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.

Mount the O-ring in the stuffing box groove.

13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.

NA902-2.3 210 12
Remove the worktable and lower the stuff-
ing box until it rests against the distance
pieces on the piston rod foot.

Remove wire ropes and screws. NA902-2.3 210 13 13.

When referring to this page, please quote Procedure M90202 Edition 0210 Page 7 (9)
0$1% :'LHVHO$6
902-2.4 Piston Rod Stuffing Box
Mounting
Mounting
902-2.4

1. 1. After overhauling, assemble the stuffing

box halves on top of the four screws.

Mount the two long screws from the workta-

ble in the stuffing box.

Turn down the short screws so that the

stuffing box lands on the flange.

2. Turn the piston upwards until the stuffing

box is in place in the cylinder frame.

Note!

Make sure that the two guide pins in the

flange enter the guide holes in the bottom
of the cylinder frame.
MB902-5.2 94 06

3. Mount two screws in the flange through the

holes in the worktable.

2.
MB902-5.2 94 08

3.
MB902-5.2 94 09

Page 8 (9) When referring to this page, please quote Procedure M90202 Edition 0210
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.4
Mounting

4. Remove the long screws from the stuffing 4.

box and mount them in the worktable.

Remove the worktable from the piston rod.

5. Mount and tighten all the inner and outer

screws for the stuffing box. See Data.

6. Remove the protecting rubber cover from

the piston rod/crosshead.

Smear the piston rod with molybdenum di-

sulphide.

MB902-5.2 94 10
Then turn the crankshaft a couple of revo-
lutions.

Start up the engine and keep it running for

about fifteen minutes at a number of revo- 5.
lutions corresponding to very slow or idle
speed.

Then stop the engine and inspect the piston

rod and stuffing box.
NA902-2.4 210 05

6.

When referring to this page, please quote Procedure M90202 Edition 0210 Page 9 (9)
0$1% :'LHVHO$6
 Piston and Piston Rod Panel Plate
P90251-0253
Piston and Piston Rod Panel
0253
P90251

When referring to this page, please quote Plate P90251 Edition 0253 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0253

Item Item
Item Description 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
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, set
171 Dismantling screw

Page 2 (2) When referring to this page, please quote Plate P90251 Edition 0253
MAN B&W Diesel A/S
 Piston and Piston Rod - Tools
Tools Plate
MAN B&W Diesel P90261-0102

When referring to this page, please quote Plate P90261 Edition 0102 Page 1 (2)
Plate
Piston and Piston Rod - Tools
Tools
P90261-0102 MAN B&W Diesel

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 0102
 Piston and Piston Rod - Hydraulic Tools Plate
P90262-0026
Piston and Piston Rod - Hydraulic Tools
0026
P90262

When referring to this page, please quote Plate P90262 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Hydraulic Tools
P90262-0026

Item Item
Item Description Item Description
No. No.

014 Wooden box

026 Jack - hydraulic, complete
038 Support
040 Support
051 Sealing ring with back-up ring
063 Sealing ring with back-up ring
075 Tommy bar
087 Key, hexagon socket screw
099 Support
109 Stud setter

Page 2 (2) When referring to this page, please quote Plate P90262 Edition 0026
MAN B&W Diesel A/S
 Piston Crown - Hydraulic Tools Plate
P90263-0007
P90263
Piston
0007 Crown - Hydraulic Tools

When referring to this page, please quote Plate P90263 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston Crown - Hydraulic Tools
P90263-0007

Item Item
Item Description Item Description
No. No.

021 Jack-hydraulic, complete

033 Support
045 Support
057 Sealing ring with back-up ring
069 Sealing ring with back-up ring
070 Tommy bar
082 Key, hexagon scoket screw
104 Stud setter
200 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90263 Edition 0007
MAN B&W Diesel A/S
 Piston and Piston Rod - Extra Tools Plate
P90264-0006
Piston and Piston Rod - Extra Tools
0006
P90264

When referring to this page, please quote Plate P90264 Edition 0006 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Extra Tools
P90264-0006

Item Item
Item Description Item Description
No. No.

015 Collar ring for piston

027 Support for tilting tool
039 Support for tilting tool

Page 2 (2) When referring to this page, please quote Plate P90264 Edition 0006
MAN B&W Diesel A/S
 Piston and Piston Rod - Support Tools Plate
P90265-0003

When referring to this page, please quote Plate P90265 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0003

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 0003
MAN B&W Diesel A/S
 Piston - Lifting Tools Plate
P90266-0001
Piston - Lifting Tools
0001
P90266

When referring to this page, please quote Plate P90266 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0001

Item Item
Item Description Item Description
No. No.

016 Lifting tool for piston

Page 2 (2) When referring to this page, please quote Plate P90266 Edition 0001
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication

Documents in this Chapter

103-01 0045 Cylinder Liner, Data

903-01 0238 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0247 Cylinder Lubricator
90361 0083 Cylinder Liner - Tools
90362 0001 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0003 Cylinder Liner - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Cylinder Liner 103-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

K90MC-C
0045
103-1 Cylinder Liner

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil 140–760 Nm
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Cylinder diameter, new ø 900 mm

D-2 Cylinder liner, complete 580 kg

D-4 Edge distance

– cylinder cover studs 2.5-3 mm

D-5 Cylinder cover stud 120 kg

D-6 Tightening torque

– lifting tool bolts 200 Nm

D-7 Piston cleaning ring

diameter, new 897.8 mm

D-8 Piston cleaning ring 21.1 mm

radial width, new

D-9 PC-ring/Liner
max. wear deviation 0.90 mm

D-10 PC-ring replacement criteria:

Liner wear: Install:

0 - 0.90 mm Standard PC-ring
(new or max. wear of
diameter 0.90 mm)
0.90 - 1.8 mm Oversize PC-ring
> 1.8 mm No PC-ring

When referring to this page, please quote Data D10301 Edition 0045 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data

3ODWH











Spare Parts

Page 2 (2) When referring to this page, please quote Data D10301 Edition 0045
MAN B&W Diesel A/S
 Cylinder Liner 903-1.1
Checking
Cylinder Liner
K90MC-C
0238
Checking
903-1.1


1. Dismount the cylinder cover, the piston
cleaning ring and the piston.
See Procedures 901-1.2 and 902-1.2.

Clean the cylinder liner and scavenge air

ports.

2. Position the cylinder liner measuring tool.

D-1
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 giv-
en in Volume I, Chapter 707.

3. Carefully scratch over any scores or marks

and grind away the wear ridges. 



See Procedure 903-1.3. 










4. Check the lubricating points of the cylinder 
%
0
by pumping cylinder oil to all lubricating
points in the cylinder concerned.

Clean any blocked lubricating duct.















%
0

When referring to this page, please quote Procedure M90301 Edition 0238 Page 1 (10)
0$1% :'LHVHO$6
903-1.1 Cylinder Liner
Checking

8. 5. Piston cleaning (PC) ring:

The PC ring is to be regarded as an inte-

grated part of the liner and it is intended to
D-7 follow the service life of the liner.

During inspection of the piston and 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 D-8 and calculate the wear of the PC
B
MB903-1.1 238 06

ring. Multiply the wear by 2 to get the PC

ring diameter wear.

Measure the liner in the fore-and-aft and

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

Compare the PC ring diameter wear with

the wear of the liner. If wear of the two com-
ponents does not deviate more than D-9,
then reinstall the PC ring.

If the deviation between PC ring wear and

liner wear is more than D-9, or if the PC ring
is broken or cracked, replace the ring with
a new PC ring, an oversize ring or no PC
ring according to the table in D-10 on the
Data sheet.

If it is needed to install an oversize PC ring,

contact MAN B&W Diesel for advice.

When a new liner is installed, also a new

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

Page 2 (10) When referring to this page, please quote Procedure M90301 Edition 0238
0$1% :'LHVHO$6
 Cylinder Liner 903-1.2
Dismantling
Dismantling
903-1.2

1. Dismount the cylinder cover. 

See Procedure 901-1.2.

Discard the sealing ring from the top of the

cylinder liner.

Turn the piston down far enough to make it

possible to 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.

2. Disconnect – at the non-return valves – the

oil pipes leading from the cylinder lubricator
to the non-return valves.

Dismount the four cooling water pipes – be-


tween the cylinder frame and cylinder cover 




– and clean them carefully. 









%
.

















%
0

When referring to this page, please quote Procedure M90301 Edition 0238 Page 3 (10)
0$1% :'LHVHO$6
903-1.2 Cylinder Liner
Dismantling

 3. Attach the crane to the lifting crossbar.

Screw the lifting tools into the cylinder liner.

D-2 Hook the chains from the lifting tools on to
the crossbar.
D-6 Check with a 0.05 mm feeler gauge that
there is no clearance between lifting bolts
and liner. For tightening torque, see Data.

Lift the liner out of the cylinder frame.

Note!

Low lifting height in the engine room may

require the removal of one or more cylin-
der cover studs before dismantling the
cylinder liner.

Land the cylinder liner vertically on, for in-

stance, a couple of planks.







Clean the cylinder frame internally, taking





special care with the contact surfaces for
%
0 the cylinder liner at the top of the cylinder
frame.

Discard the O-rings on the cooling water

pipes.

Clean the pipes carefully.

Page 4 (10) When referring to this page, please quote Procedure M90301 Edition 0238
0$1% :'LHVHO$6
 Cylinder Liner 903-1.2
Dismantling

4. The lifting tools are also used for transport- 

ing the cylinder liner.

5. Remove the lifting tools from the liner.

'















%
0

When referring to this page, please quote Procedure M90301 Edition 0238 Page 5 (10)
0$1% :'LHVHO$6
903-1.3 Cylinder Liner
Overhaul
Overhaul
903-1.3

 1. Land the cylinder liner on, for instance, a

couple of planks. Remove and discard the
O-rings, clean the cylinder liner.

2. Screw off the nuts from the non-return

valves and pull out the valves.














%
0















%
0

Page 6 (10) When referring to this page, please quote Procedure M90301 Edition 0238
0$1% :'LHVHO$6
 Cylinder Liner 903-1.3
Overhaul

3. Check and assess the condition of the cyl- 3.

inder liner according to the description giv-
en in Volume I, Chapter 707.

Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.

Check in the top of the liner for a wear ridge

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

4. It is recommended to use a wear ridge mill-

ing machine to create the groove. For use
of the milling machine, see supplier’s in-
struction.

5. 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. 1
+

Check the distance C before grinding to as- 4.

certain that the wear ridge was caused by
the top ring at TDC.




The maximum depth of the groove is calcu- 



lated as S max. = D x 0.0045. 





%
0

Note!
5.
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.

D
R=4-5 mm
C
C















1
0

When referring to this page, please quote Procedure M90301 Edition 0238 Page 7 (10)
0$1% :'LHVHO$6
903-1.3 Cylinder Liner
Overhaul

 6. If necessary, mount a new cylinder liner.

Note!

If a new cylinder liner is mounted, a new

piston cleaning ring must also be
mounted after mounting the piston.

Apply a thin layer of grease on the contact

surface of the liner.

Mount the lifting tools on the liner. Lift the

liner a little and mount new O-rings for the
cylinder frame.

Lubricate the O-rings with vaseline.

7. Mount the non-return valves for the cylinder

lubricating oil.














%
0
















%
0

Page 8 (10) When referring to this page, please quote Procedure M90301 Edition 0238
0$1% :'LHVHO$6
 Cylinder Liner 903-1.4
Mounting
Mounting
903-1.4

1. Mount the lifting tools on the cylinder liner 

and tighten to specified torque. See Data.

Hook the chains from the lifting tools on to

the crossbar and lift the liner.

Mount the O-rings and apply a little vase-

line on the O-rings.

2. Check that the joint surfaces on the cylinder

'
frame and cylinder liner are completely
clean. '


Mount the cylinder liner in the cylinder 





frame. Replace the O-rings on the water 





connections and mount the water connec- 



%
tion pipes on the cylinder frame. 0

Remove the cylinder liner lifting tools. 

3. If one or more cylinder cover studs have

been removed during the dismantling of the
cylinder cover, discard the old O-rings and
mount new ones on the cylinder cover
studs.

Mount the studs in the cylinder frame, using

the stud setter. See Data.

Note!




The studs should not be fully screwed-in. 





Instead the stud should only be screwed- 




in until the edge on the stud is the 


%
0
distance D-4 above the cylinder frame,
see sketch.


D-4

D-5















%
0

When referring to this page, please quote Procedure M90301 Edition 0238 Page 9 (10)
0$1% :'LHVHO$6
903-1.4 Cylinder Liner
Mounting

 4. Screw the pipes from the lubricator on to

the non-return valves, but do not tighten.

Vent the cylinder lubricating system by

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

When this is in order, tighten the pipes firm-

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




5. Lubricate the inside of the cylinder liner




with cylinder lubricating oil and mount the




piston.

%
0
See Procedure 902-1.4.

 6. Mount the piston cleaning ring, the sealing

ring and the cylinder cover.
See Procedure 901-1.4.

Note!

Make sure to mount the piston cleaning

ring correctly, so that the scratch marks
are aligned.

Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.















%
.

Page 10 (10) When referring to this page, please quote Procedure M90301 Edition 0238
0$1% :'LHVHO$6
 Cylinder Lubricators 103-2
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
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D03-10 Inlet accumulator, nitrogen pressure, 30 bar

D03-11 Outlet accumulator, nitrogen pressure, 1.5 bar
D03-13 Plug screw, tightening torque, 30 Nm

When referring to this page, please quote Data D10302 Edition 0028 Page 1 (2)
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
Data

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

Plate Item No. Description

P90364 Test Equipment for Lubricators

Page 2 (2) When referring to this page, please quote Data D10302 Edition 0028
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.1
Checking

Check of Oil Injection: 1.

With stopped engine and normally when the
system has been disassembled:

1. Press the ESC + PRELUB.-button on the

HMI control panel, and check that all lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.

2. If the cylinder cover or the exhaust valve is

removed, check inside the liner that all lu-
bricating points are working properly.

Otherwise, remove the covers for scavenge

port inspection.

Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
source that all lubrication points are work-
ing properly.
M90302
0245C01

With running engine:

3. Check that all lubricators are operating cor-

rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
3.
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.
M90302
0245C02

When referring to this page, please quote Procedure M90302 Edition 0247 Page 1 (12)
MAN B&W Diesel A/S
903-2.1 Cylinder Lubricators
Checking

Check of Accumulators:
4.
D03
10 1. Check of Inlet Accumulator
Checking the inlet accumulator can be
done with running engine.

Close the valve that connects the accumu-

lator to the distributor block.

Mount the special hose on the minimess

coupling and drain all oil out of the accu-
mulator.

Check the nitrogen pressure.

M90302
0247C04

For use of pressure setting tool, see Step

6. For correct pressure, see Data.

5. Check of Outlet Accumulator

The outlet accumulators are to be dis-
5. mounted while the nitrogen pressure is
checked.
D03
11
Dismount the outlet accumulator.
See Procedure 903-2.2.

Check the nitrogen pressure, using the

pressure setting tool.

6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
shown in the Figure, and mount the reduc-
ing valve on the nitrogen cylinder. If neces-
M90302
0247C05

sary, use a threaded adaptor.

Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7
litre) is checked, and a 0-10 bar pressure
gauge when the outlet accumulators (0.16
6. litre) are checked.
M90302
0245C05

Page 2 (10) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.1
Checking

7. Before mounting the filling valve on the ac-

cumulator, check that the accumulator top 7.
C
is clean.

Mount the filling valve on the relevant accu- A E D03
13

mulator with the union nut. Check that
valves C and F are closed. F
Loosen the plug screw in the accumulator
using a ½” square drive handle in socket E.
B
It is now possible to read the actual nitro-
gen pressure in the accumulator on the dial
gauge on the filling valve.

M90302
0247C07
8. If the accumulator needs to be refilled with
nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in
Data.

Open valve C until the accumulator is filled

to the correct pressure.

Close valve C and tighten the plug screw

with socket E to the torque stated in Data.

Release the pressure in the filling valve at

bleed screw F.

Unscrew the filling valve from the accumu-

lator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.

When referring to this page, please quote Procedure M90302 Edition 0247 Page 3 (12)
MAN B&W Diesel A/S
903-2.2 Cylinder Lubricators
Dismantling

Dismantling of lubricators:
1.
Both lubricators can be dismounted with run-
ning engine, one at a time. If the engine is run-
ning when a lubricator is dismounted, it is im-
portant to check that the other lubricator is
A B doubling injection frequency.

1. Close the supply valve for the lubricator

concerned, using the special tool. The
outer valve is for lubricator marked A and
the inner valve is for lubricator marked B.

Let the lubricator inject oil until the feed-

M90302
0247D01

back LED stops flashing. Disconnect the

electrical plug on the front of the lubricator.

2. Unscrew the screws in the top of the lubri-

cator and disconnect the cover with per-
2. taining pipes.

3. Unscrew the four screws on the front that

secure the lubricator to the hydraulic block,
and remove the lubricator.

Dismantling of accumulators:

4. Inlet Accumulator
Close the valve that connects the accumu-
lator to the distributor block.
Mount the special hose on the minimess
coupling and drain the oil out of the accu-
M90302
0247D02

mulator.
Unscrew the accumulator. If the engine is
running, a new or checked accumulator
should be mounted at once.

4.
M90302
0247D04

Page 4 (12) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.2
Dismantling

5. Outlet Accumulator
5.
Close the supply valve for the accumulator
concerned, using the special tool. The
outer valve is for accumulator marked A
and the inner valve is for accumulator
marked B.
A B
Let the lubricator inject oil until the feed-
back LED stops flashing.

If space conditions permit, unscrew the ac-

cumulator; otherwise the lubricator must be
dismounted, see Step 1.

M90302
0247D05

When referring to this page, please quote Procedure M90302 Edition 0247 Page 5 (12)
MAN B&W Diesel A/S
903-2.3 Cylinder Lubricators
Overhaul

1. Place the lubricator in a bench vice with

1. soft “jaws”.

Remove the adjusting screw with bushings.

Unscrew the oil accumulator.

Discard the O-ring from the adjusting

screw.

2. Remove the screws from the cylinder

block.

3. Pull up the cylinder block.

M90302
0247O01

Remove the spring and actuator piston

with plungers.

Remove and discard the O-ring from the

cylinder block.
2.
Remove the cover for the non-return
valves. Take out springs and balls. Remove
and discard the O-rings.
M90302
0247O02

3.
M90302
0247O03

Page 6 (12) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.3
Overhaul

4. Screw out the non-return valves and re-

move and discard the O-rings. 4.

Clean the valves and check them with

compressed air.

5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass.

6. Fit the non-return valve with new O-rings.

Mount the non-return valves in the cylinder

block.

M90302
0247O04
5.
M90302
0247O05

6.
M90302
0247O06

When referring to this page, please quote Procedure M90302 Edition 0247 Page 7 (12)
MAN B&W Diesel A/S
903-2.3 Cylinder Lubricators
Overhaul

7. Pre-assemble the cylinder blockwith the

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

Mount the spring and press down the ac-

tuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.

Fit the cylinder block with a new O-ring.

M90302
0247O07

Page 8 (12) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.3
Overhaul

8. Remove the cover from the terminal box

and disconnect the wires for the feedback 8.
(pick-up) sensor.

Remove the terminal box and the plug for

the solenoid valve.

Carefully unscrew the feedback sensor and

remove and discard the O-ring.

Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.

9 Turn the lubricator upside down in the vice.

M90302
0247O08
Unscrew the solenoid valve.

Discard the O-rings.

10. Solenoid valve: 9.

Disassemble and clean the valve.

Check the slide for wear. If the slide is

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

Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
the housing.

Assemble the valve.

M90302
0247O09

See also manufacturer’s instructions.

10.
M90302
0244O12

When referring to this page, please quote Procedure M90302 Edition 0247 Page 9 (12)
MAN B&W Diesel A/S
903-2.3 Cylinder Lubricators
Overhaul

11. Before mounting the feedback sensor,

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

Mount the feedback sensor or a new one,

if necessary, with a new O-ring.

Check with an object with a straight edge

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

Mount the terminal box.

M90302
0245O10

1 1
2 2 Solenoid valve 11. Connect the wires and mount the cover on
3 BN (brown) the terminal box.
BK (black)
4
BU (blue) Feedback sensor
5 13. Mount the solenoid valve fitted with new
O-rings. Coat the O-rings with a little
12. grease to keep the rings in place during
LED
mounting.

2

Brown+15

Blue OV

Black FB
signal
M90302
0242O08

13.
M90302
0247O13

Page 10 (12) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.3
Overhaul

14. Mount the cylinder block assembly in the

cylinder housing. 14.

Check that the spring pin engages cor-

rectly with the cylinder block assembly.

Mount the screws and tighten the block to

the housing.

Remove the M6 x 60 screw with disc.

15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.

M90302
0247O14
Mount the oil accumulator.

16. If the lubricator is not to be mounted on

the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor- 15.
age.

Cover all surfaces with a thin layer of oil.

M90302
0247O01

When referring to this page, please quote Procedure M90302 Edition 0247 Page 11 (12)
MAN B&W Diesel A/S
903-2.4 Cylinder Lubricators
Mounting

Mounting of Lubricators
1.
1. Mount new O-rings on the hydraulic
block and on the cover with pipes.

Mount the lubricator and tighten the screws

on the hydraulic block.

Tighten the screws in the top of the lubri-

cator to the pipe connection.

2. Open the supply valve and mount the elec-

trical plug. Check the injection of the cylin-
der oil on the led on the terminal box for
M90302
0247D02

the specific lubricator.

For checking injection timing, see Proce-

dure 905-8.1.

2. Mounting of Accumulator

3. Mount the accumulator. Remove the drain

hose from the minimess coupling. Open the
valve that connects the accumulator to the
A B distributor block.

Check the oil injection.

See Procedure 903-2.1.
M90302
0247M02

3.
M90302
0247M03

Page 12 (12) When referring to this page, please quote Procedure M90302 Edition 0247
MAN B&W Diesel A/S
 Cylinder Liner - Tools
Tools Plate
MAN B&W Diesel P90361-0083

When referring to this page, please quote Plate P90361 Edition 0083 Page 1 (2)
Plate
Cylinder Liner - Tools
Tools
P90361-0083 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

012 Measuring rod for cylinder liner, long

024 Measuring rod for cylinder liner, short
048 Measuring tool for cylinder liner

Page 2 (2) When referring to this page, please quote Plate P90361 Edition 0083
 Cylinder Liner - Extra Tool Plate
P90362-0001
Cylinder Liner - Extra Tool
0001
P90362

When referring to this page, please quote Plate P90362 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Extra Tool
P90362-0001

Item Item
Item Description Item Description
No. No.

018 Wear ridge milling machine

Page 2 (2) When referring to this page, please quote Plate P90362 Edition 0001
MAN B&W Diesel A/S
 Test Equipment for Lubricator Plate
P90364-0004
Test Equipment for Lubricator
0004
P90364

When referring to this page, please quote Plate P90364 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Test Equipment for Lubricator
P90364-0004

Item Item
Item Description Item Description
No. No.

019 Tool box

020 Nameplate
032 Adaptor
044 Pressure gauge
056 Spanner
068 Pressure gauge
081 Adaptor
103 Hose with 2 union
115 Quick coupling, minimess
139 Reducing valve
152 Adaptor
164 Adaptor
176 Adaptor
211 Adaptor
223 Filling and testing valve

Page 2 (2) When referring to this page, please quote Plate P90364 Edition 0004
MAN B&W Diesel A/S
 Cylinder Liner - Lifting Tools Plate
P90366-0003

When referring to this page, please quote Plate P90366 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0003

Item Item Description Item Item Description

No. No.

021 Cross bar for cylinder liner

Page 2 (2) When referring to this page, please quote Plate P90366 Edition 0003
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

Documents in this Chapter

104-01 0032 Crosshead Bearing, Data

904-01 0236 Crosshead Bearing
104-02 0032 Crosshead, Data
904-02 0235 Crosshead
104-03 0024 Reciprocating Parts, Data
904-03 0214 Reciprocating Parts
104-04 0026 Crankpin Bearing, Data
904-04 0212 Crankpin Bearing
104-05 0029 Connecting Rod, Data
904-05 0220 Connection Rod
90451 0102 Connecting Rod and Crosshead - Panel
90461 0062 Connecting Rod - Hydraulic Tools
90462 0032 Connecting Rod - Tools
90462 0033 Connecting Rod - Tools
90464 0003 Crosshead - Hydraulic Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Crosshead Bearing 104-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0032
104-1 Crosshead Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil 2 x 2000 kg, 2 x 5000 kg
X Shut off lubricating oil
50-300 Nm
Lock turbocharger rotors 280-760 Nm

Data
2 x M16, 4 x M30
Ref. Description Value Unit

D-1 Top clearance for new

crosshead bearing: 0.40-0.75 mm
4 x 1.5 m, 1 x 3 m
D-2 Oil wedge length L=18 mm

D-3 Hydraulic pressure

2 x 2000 kg
– tightening 900 bar
2 x 5000 kg
D-4 Hydraulic pressure
– dismantling 900-990 bar

D-5 Crosshead bearing cap

complete 1500 kg

D-6 Bearing shell, lower 175 kg

D-7 Bearing shell, upper 135 kg

D-8 Telescopic pipe 85 kg

D-9 Thrust piece

– tightening torque 550 Nm

D-10 Telescopic pipe

– tightening torque 590 Nm

When referring to this page, please quote Data D10401 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
104-1 Crosshead Bearing
Data

Plate
90451

1283669-8

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10401 Edition 0032
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.1
Checking
Crosshead Bearing
K90MC-C
0236
Checking
904-1.1

2.
White metal bearings

The top clearance between the journal and a

new bearing shell is the result of a summation
of the production tolerances of the bearing
components.

For the top clearance of a new bearing, see the

Data D-1.

For the top clearance of a specific bearing, see

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

BM904-2.1 76 02
1. Open the crankcase door at the relevant
cylinder.

2. Turn the crosshead concerned to BDC.

3.
3. Measure the clearance in the crosshead D-1
bearing by inserting a feeler gauge at the
top of the upper bearing shell.

4. The difference between the actual clear-

ance measurements and the measure-
ments noted in the Adjustment Sheet at the
shop test/sea trial (or the clearance noted
for a new bearing installed later) must not
exceed 0.1 mm. If the clearance is too
large, the crosshead must be disassambled
for inspection.
See Procedure 904-2.2.
KC904-2.1 71 04

5. The wear limit for a crosshead bearing shell

is confined to a 50% reduction of the oil
wedge length L. This can only be checked
after the crosshead has been disassem- 5.
bled.

If the wear limit exceeds the 50% reduction,

the bearing shell must be replaced by a
new one.
(Oil Wedge)
6. For further external inspection of the cross-
head bearing, see Chapter 708, ‘Bearings’
in the instruction book, Volume I, OPERA-
TION.
NB904-1.1 221 05

D-2

When referring to this page, please quote Procedure M90401 Edition 0236 Page 1 (8)
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling
Dismantling
904-1.2

1. This procedure applies to the following two dis-

mantling situations:

• with piston mounted (steps 1-11)

• with piston removed (steps 3-11)

With piston mounted:

1. Turn the crosshead down far enough to give

access to the nuts on the piston rod, the
crosshead bearing cap, and the screws on
the telescopic pipe.
BM904-2.1 76 02

2. Mount the two chains for suspending the

piston in the inner screw holes at the top of
the crankcase, in the athwartship direction.

2. 3. Mount two eyebolts in the two outer screw

holes in the top of the frame box in the
athwartship direction.

Remove the thrust pieces for axial guidance

of the connecting rod.

Mount the spacer rings and the hydraulic

jacks for loosening the crosshead bearing
cap nuts and the piston rod nuts.
Loosen the nuts.

For operation of the hydraulic tools, see

Procedure 913.
MA904-1.2 223 02

Remove the hydraulic jacks, and unscrew

the nuts.

3. Caution!

Never suspend or remove the piston

without suspending the telescopic pipe.

D-3
MA904-1.2 223 03

Page 2 (8) When referring to this page, please quote Procedure M90401 Edition 0236
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.2
Dismantling

4. Mount a lifting eye bolt on each side of the 4.

piston rod foot.

Mount a lifting eye bolt with an extension

screw on each side of the bearing cap.

5. Loosen and remove the screws which se-

cure the telescopic pipe to the bend.

Remove one screw from the telescopic

stuffing box housing, and mount the special
tool for suspending the telescopic pipe.

MB904-1.2 236 04
6. Turn the crosshead to TDC.

Hook the ends of the chains to the lifting

eye bolts on the piston rod.

Suspend the telescopic pipe, using the tool 5.

stud.

Turn the crosshead downward, and the pis-

ton rod will remain suspended from the two
chains.

When turning downwards, remove the dis-

tance tube from the bend.
KC904-2.2 71 05

6.
MA904-1.2 223 06

When referring to this page, please quote Procedure M90401 Edition 0236 Page 3 (8)
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling

7. 7. Turn down to BDC.

D-4
Suspend two tackles from the eyebolts, in
the athwarthship direction.

Hook the tackles on to the eye bolts in the

crosshead bearing cap and raise the cap.

Check the upper bearing shell and the up-

per part of the journal.

Mount the wire guide in the top of the door

opening.
MB904-1.2 236 07

If desired, mount a third tackle outside the

engine and lift the bearing cap out of the
engine.

8. 8. Place the bearing cap on one side on a

couple of wooden planks.

D-7 Check the bearing shell, see Procedure

904-1.1.

9. Mount lifting attachments on the head of

the connecting rod.

Fasten pull lifts to the fixed lifting brackets

MA904-2.26908

on the frame box wall and fix the connecting

rod in the vertical position.

9.
MB904-1.2 236 09

Page 4 (8) When referring to this page, please quote Procedure M90401 Edition 0236
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.2
Dismantling

10. Mount two eyebolts and tackles in the 10.

screwholes in the fore-and-aft direction at
the top of the crankcase.

Mount two eyebolts on the top of the guide

shoes, and lift the crosshead.

Caution!

Take care not to scratch the crosshead

bearing journal or damage the threads of
the crosshead bearing studs.

Check the lower part of the crosshead jour-

nal and the bearing shell.

Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chapter MB904-1.2 236 10

708, ‘Bearings’.

11. In cases where it is necesary to remove the

lower bearing shell, tilt the connecting rod
towards the door in the camshaft side, us- 11.
ing 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.

MB904-1.2 236 11

When referring to this page, please quote Procedure M90401 Edition 0236 Page 5 (8)
0$1% :'LHVHO$6
904-1.4 Crosshead Bearing
Mounting
Mounting
904-1.4

1. With the piston mounted/

With the piston removed:
D-7 1. Mount and secure the bearing shell in the
bearing housing.

To ensure that the shell is correctly mount-

ed, check that the distance X is the same
in both sides.

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell
and must not be removed.
MB904-1.4 236 01

Raise the connecting rod to an upright po-

sition.

Turn to TDC while ‘following’ with the tack-

2. les, for assembling the crosshead and the
connecting rod.

Take care that the guide shoes do not dam-

age the bearing shell.

2. Lower the crosshead into place. Remove

the eyebolts from the guide shoes.

Note!

Take care that the bearing studs do not

damage the crosshead.
MB904-1.4 236 02

Page 6 (8) When referring to this page, please quote Procedure M90401 Edition 0236
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.4
Mounting

3. Lift the bearing cap back into the engine. 3.

Lubricate the crosshead bearing journal

with plenty of lubricating oil.

Lower the bearing cap onto the crosshead,

and remove the tackles.

4. Mount the thrust pieces for axial guidance

of the connecting rod.
For tightening torque, see Data.

With the piston mounted:

MB904-1.2 236 07
5. If any shims have been removed from the
crosshead, mount them again.

Turn the crosshead upwards until the piston

rod lands on the crosshead. When mount- 4.
ing the piston on the crosshead, make sure
that the piston rod foot does not damage
the threads of the studs. Ensure that the
guide ring in the crosshead fits correctly in
the centre hole of the piston rod.

D-14
MA904-1.4 233 05

5.
BM904-1.4 229 06

When referring to this page, please quote Procedure M90401 Edition 0236 Page 7 (8)
0$1% :'LHVHO$6
904-1.4 Crosshead Bearing
Mounting

6. 6. Mount the distance pipe on the telescopic

pipe bend.

Turn up the crosshead until the telescopic

pipe lands on the distance pipe.

Remove the chains and eye bolts from the

top of the frame box, from the piston rod
foot and from the crosshead bearing cap in
the athwartship direction.

Remove the wire guide from the engine.

D-11
MA904-1.4 223 07

Remove the suspending tool stud and

mount the screws in the telescopic stuffing
box housing.

Mount the screws and tighten the telescop-

7. ic pipe, see Data.
D-3
7. Turn down to BDC and mount the hydraulic
nuts on the studs. For operation of the hy-
draulic jacks, see Procedure 913.

Tighten the nuts on the piston rod foot and

on the crosshead as stated in Data.

With the piston removed:

8. Mount the piston. See Procedure 902-1.4.

9. Turn down to BDC and tighten all four

MA904-1.2 223 03

crosshead bearing cap nuts simultaneous-

ly. See Data.

For operation of the hydraulic jacks, see

Procedure 913.

Page 8 (8) When referring to this page, please quote Procedure M90401 Edition 0236
0$1% :'LHVHO$6
 Crosshead 104-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0032
104-2 Crosshead

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water 140-760 Nm
X Shut off fuel oil 50-300 Nm
X Shut off lubricating oil 4x1m
Lock turbocharger rotors 1x3m

2 x M24
Data 4 x M30
2 x M48
Ref. Description Value Unit

D-1 Hydraulic pressure

– dismantling 900-990 bar

D-2 Hydraulic pressure

– tightening 900 bar

D-3 Crosshead bearing cap 1500 kg [NJ

with bearing shell [NJ
[NJ
D-4 Crosshead 6100 kg

D-5 Connecting rod 8500 kg

D-6 Guide shoe 600 kg

D-7 Outlet pipe and bend

for telescopic pipe
– tightening angle 50 °

D-8 Studs on connecting rod

– screwing-in torque 660 Nm

D-9 Nuts on guide strips

– tightening torque 650 Nm

D-10 Thrust piece

– tightening torque 550 Nm

D-11 Studs on crosshead

for oil bend
– screwing-in torque 600 Nm

When referring to this page, please quote Data D10402 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
104-2 Crosshead
Data

Plate
90451

1283669-8

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10402 Edition 0032
MAN B&W Diesel A/S
 Crosshead 904-2.2
Dismantling
Crosshead 0235
Dismantling
904-2.2

2.
1. Dismount the piston and suspend the tele-
scopic pipe.
See Procedure 902-2.

Dismount the main bearing lubricating oil

pipes.

2. Turn the crosshead to BDC to give access

to the nuts on the crosshead bearing cap.

Mount two eye bolts in the top of the crank-

case, in the fore-and-aft direction, and sus-
pend two tackles.

Mount the spacer rings and the hydraulic

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

For operation of the hydraulic tools,

see Procedure 913-1.
MA904-2.2 213 02

Loosen the nuts, remove the hydraulic jacks

and unscrew the nuts. D-1
3. Mount two eye bolts and extension screws
in the crosshead bearing cap and hook on 3.
the tackles.

Lift the bearing cap out of the engine.

Remove the piston rod guide ring and the

shim from the crosshead.

Remove both thrust pieces from the cross-

head bearing cap.
MB904-2.2 235 03

When referring to this page, please quote Procedure M90402 Edition 0235 Page 1 (9)
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling

4. 4. Dismount the four bearing cap studs, using

the stud setter.

Dismount the cylindrical dowel using the

special extractor.

Mount the eye bolt in one of the threaded

holes in the bend, hook on a tackle and
haul tight.

Remove the outlet pipe, dismount the bend

for the telescopic pipe and remove the
studs from the crosshead.
MA904-2.2 213 04

Mount the special lifting tool on the cross-

head.

5. Turn to TDC.
5.
Mount the four guide shoe supports on the
crosshead guides.

6. Remove the crankpin bearing cap and lift

out the connecting rod.
See Procedure 904-5.2.

7. Attach a wire rope to the special lifting tool

on the crosshead and hook on the engine
room crane.

Lift the crosshead free of the supports and

remove the four guide shoe supports.
MA904-2.2 213 05

7.
D-4

D-6
MA904-2.2 213 07

Page 2 (9) When referring to this page, please quote Procedure M90402 Edition 0235
0$1% :'LHVHO$6
 Crosshead 904-2.2
Dismantling

8. Turn the crankthrow to give access for low- 8.

ering the crosshead.

There must also be space in the adjacent

cylinder units to pull the guide shoes
through the openings in the side walls just
above the main bearings.

Remove the guide strips and the stop

screws from the bottom of the guide shoes.

Note!

MB904-2.2 235 08
It is recommended to tag the guide strips
and shim to avoid mixing them.

9. Suspend two tackles from the eye bolts in

the top of the crankcase, in the fore-and-aft 9.
direction.

Mount an eye bolt in the top of each guide

shoe.

Place a thin wooden plank, or similar, on

top of the crank to protect the crosshead.

10. Lower the crosshead so that the guide

shoes are just below the cutout in the side
walls of the frame box.
MA904-2.2 213 09

Note!

Make sure that the crosshead journal

does not touch the crank.
10.
MA904-2.2 213 10

When referring to this page, please quote Procedure M90402 Edition 0235 Page 3 (9)
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling

11. 11. Hook the tackles on to the eye bolts in the

guide shoes.

12. Mount two eye bolts in the holes for stop

screws in the guide shoes in the adjacent
cylinder units, and suspend two tackles
from the eye bolts.

13. Haul the tackles for the guide shoes tight

and, at the same time, pull the guide shoes
sideways until they are free of the cross-
head.

Take the guide shoes through the openings

MA904-2.2 213 11

in the side walls by means of the tackles in

the two adjacent cylinders. Lift the guide
shoes to provide space for turning the
crosshead.
12.
MA904-2.2 213 12

13.
MA904-2.2 213 13

Page 4 (9) When referring to this page, please quote Procedure M90402 Edition 0235
0$1% :'LHVHO$6
 Crosshead 904-2.2
Dismantling

14. Turn the crosshead 90°. 14.

Note!

Take care that the crosshead does not

bump into anything as this will damage
the sliding surfaces of the crosshead.

15. Mount a tackle outside the engine and, by

means of wire rope and tackle, remove the
crosshead from the engine.

MA904-2.2 213 14
To help guide the crosshead out of the door
opening, it is possible to mount an eye bolt
in the end of the crosshead. Do not lift the
entire crosshead in the eye bolt mounted in
the end.
15.
Use a tackle mounted outside the engine to D-4
pull at the eye bolt.

Land and protect the crosshead outside the

engine.

Remove the guide shoes from the engine

and tag them.
MA904-2.2 213 15

When referring to this page, please quote Procedure M90402 Edition 0235 Page 5 (9)
0$1% :'LHVHO$6
904-2.4 Crosshead
Mounting
Mounting
904-2.4

1.
D-4 1. Clean the crosshead and mount the lifting
bracket.

Mount the wire guide tool in the framebox

door opening.

Suspend two tackles from the top of the

frame box between the guides.

Mount a tackle outside the engine. Hook a

wire rope on to the engine room crane.
Lower the wire rope down through the cyl-
inder frame, through the crankcase, and out
MA904-2.2 213 15

of the framebox door opening.

Hook the wire rope and the tackle on to the

lifting bracket mounted on the crosshead,
carefully lift the crosshead and ease it into
2. the crankcase.

2. Turn the crosshead 90° to enable mounting

of the guide shoes. Check that the oil inlet
and outlet holes are pointing towards the
exhaust side.

Note!

When handling the crosshead, take great

care that its surfaces are not scratched
or damaged. If necessary, protect the
crosshead with a cloth.
MA904-2.4 213 02

3. Attach two tackles to the eye bolts at the

bottom of the guide shoes in the adjacent
cylinders.
3.
Using these tackles and a tackle outside
the engine, carefully lift the guide shoes
into the engine.
MA904-2.2 213 12

Page 6 (9) When referring to this page, please quote Procedure M90402 Edition 0235
0$1% :'LHVHO$6
 Crosshead 904-2.4
Mounting

4. Lubricate the sliding surfaces of the guide 4.

shoes and the hole for the crosshead with
plenty of clean lubricating oil, and push the
guide shoes into position through the open-
ings in the side walls.

5. Using the engine room crane, lift the cross-

head to a suitable working position and
mount the guide strips and shims on the
side of the guide shoes. Mount the stop
screws in the bottom of the guide shoes.

Remove the tackles and the eye bolts from

MA904-2.4 213 04
the guide shoes.

Lift the crosshead to TDC position.

Mount the four guide shoe supports on the

crosshead guides. 5.

Adjust the supports for correct contact with

the guide shoes, and carefully land the
crosshead on the supports.

Unhook the wire rope from the crosshead

'
lifting tool.

6. Lift the connecting rod into the engine and

mount the crankpin bearing.
See Procedure 904-5.4.

7. Turn the crosshead free of the guide shoe

MA904-2.4 213 05

supports.

Remove the four supports from the cross-

head guides.
7.
MA904-2.4 213 07

When referring to this page, please quote Procedure M90402 Edition 0235 Page 7 (9)
0$1% :'LHVHO$6
904-2.4 Crosshead
Mounting

8. 8. Tighten the screws to the torque stated in

D-8 Data. Lock the screws with locking wire.
See Procedure 913-7.
D-7 Turn the connecting rod and crosshead to
BDC.

Remove the lifting attachments from the

connecting rod and the lifting tool from the
crosshead.

Mount the studs for the cooling oil inlet

bend. Mount the bend and outlet pipe.
See Data.

Mount the cylindrical dowel with threaded

MB904-2.4 235 08

hole in the bend, and mount the bearing

D-10 D-11 cap studs.

Mount the piston rod guide ring and the

9 shim on the crosshead.

9. Lift the crosshead bearing cap into the en-

gine.

Lubricate the crosshead journal with plenty

of clean lubricating oil.

Carefully land the bearing cap on the cross-

head.

Screw-on the bearing cap nuts.

Mount the two thrust pieces on the cross-

head bearing cap.
MA904-2.2 235 09

Page 8 (9) When referring to this page, please quote Procedure M90402 Edition 0235
0$1% :'LHVHO$6
 Crosshead 904-2.4
Mounting

10. Tighten the bearing cap nuts, using hydrau- 10.

lic tools.

For operation of hydraulic tools, see Proce-

dure 913-1.

Note!

At this point it is recommended to check

the crosshead bearing clearance.
See Procedure 904-1.1.

Remove the hydraulic tools and the eye

bolts from the engine.

Check the clearances between the guide D-2

strips, guide shoes and crosshead guides.
See Procedure 904-3.1. MB904-2.4 235 10

Mount the main bearing lubricating oil

pipes.

Mount the piston and the telescopic pipe.

See Procedure 902-1.4.

When referring to this page, please quote Procedure M90402 Edition 0235 Page 9 (9)
0$1% :'LHVHO$6
 Reciprocating Parts 104-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0024
104-3 Reciprocating Parts

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
X Lock turbocharger rotors

Data

Acceptance criteria with

piston in centre
(F-A direction)
Meas. Value
points

PF+PA Nmax 0.95 mm

Omax 1.45 mm

TF+TA Omax 0.90 mm

E+G Nmax 0.65 mm

H+F Nmin 0.20 mm
Omax 0.95 mm

J+C, Nmax 1.20 mm

K+C, Nmin 0.60 mm
L+D, Omax 1.40 mm
M+D

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 0024 Page 1 (2)
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10403 Edition 0024
MAN B&W Diesel A/S
 Reciprocating Parts 904-3.1
Checking
Reciprocating Parts
K90MC-C
0214
Checking
904-3.1

1.
In order to achieve uniform measuring condi-
tions on board, the ship's trim must be as close
as possible to 0°.

1. Mount a transparent plastic tube along the

length of the bedplate.

Bend each end approx. 250 mm up along

the framebox side. See T.

MA904-5.0 72 01
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
2.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.

Measurements are to be taken with a ruler.

2. Turn the engine in ASTERN direction to 45°

after BDC (the guide shoe must rest against
the crosshead guide).

Check the clearance between guide shoe

and crosshead guide (E, F, G and H) with
a feeler gauge.
GN904-3.1 203 06

When referring to this page, please quote Procedure M90403 Edition 0214 Page 1 (3)
MAN B&W Diesel A/S
904-3.1 Reciprocating Parts
Checking

3. 3. Check the centering of the piston in the cyl-

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).

Make sure that the piston is clear of the cyl-

PA
inder liner in the fore-and-aft direction.
PF
Measure the clearances between the cross-
head and the connecting rod (TF–TA).

TA
TF
NA904-3.1 208 03

Page 2 (3) When referring to this page, please quote Procedure M90403 Edition 0214
MAN B&W Diesel A/S
 Reciprocating Parts 904-3.1
Checking

4. Measure the clearance between the guide 4. Exhaust side

C D Dim C,D
shoes and the crosshead (C and D).

Measure the clearance between the guide

strips and crosshead guides (J, K, L and
M).

The clearance, calculated as J+C, K+C,

L+D and M+D, is adjusted by the insertion
of shims so that it is symmetrical in relation

Dim G1-2, H1-2

to the clearance between the piston skirt

Dim G3-4, H3-4

and the cylinder liner.
Camshaft side
Parallelism between the guide strip and
guide is to be kept within a tolerance of 0.2
mm per 1000 mm.

NA904-3.1 208 04
1 2
5. It is recommended that the measured re- 3 4
sults are noted down so that possible later Dim J,K Dim L,M
changes can be ascertained.

5.
Unit mm Cyl. 1 2 3
PF
Piston/Liner
PA

Framebox E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+C
K+C
L+D
HN904-3.1 207 05

M+D
Crosshead TF
Connecting
Rod TA

When referring to this page, please quote Procedure M90403 Edition 0214 Page 3 (3)
MAN B&W Diesel A/S
 Crankpin Bearing 104-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0026
104-4 Crankpin Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
2 x 5 m – 1800 kg
X Shut off lubricating oil
Lock turbocharger rotors
2 x 1.5 m, 1 x 3 m
Data
Ref. Description Value Unit
4 x 1000 kg, 2 x 2500 kg

D-1 Clearance in crankpin 2 x M24

bearing 0.40-0.75 mm 2 x M30

D-2 Hydraulic pressure:

– dismantling 900-990 bar

D-3 Hydraulic pressure:

– tightening 900 bar

D-4 Crankpin bearing [NJ

– upper shell 87 kg

D-5 Crankpin bearing

– lower shell 65 kg

D-6 Crankpin bearing cap +

shell + bearing studs 900 kg

When referring to this page, please quote Data D10404 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
104-4 Crankpin Bearing
Data

Plate
90451

1283669-8

Spare Parts

Plate – Item No. Description Qty

90401-xxx 272 Crankpin bearing shell, complete 1

Page 2 (2) When referring to this page, please quote Data D10404 Edition 0026
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.1
Checking
Crankpin Bearing
K90MC
0212
Checking
904-4.1

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

For the bottom clearance of a specific bearing,

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

1. Open the crankcase door at the relevant

cylinder.

2. Turn the crank concerned to BDC.

KC904-6.1 70 02
3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
3.
4. The difference between the actual clear-
ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.05 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2.

5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
GM904-6.1 69 03

An average wear rate of 0.01 mm per D-1

10,000 hours is regarded as normal.

6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in 5.
the instruction book, Volume I, OPERA-
TION.
MA904-4.1 212 05

When referring to this page, please quote Procedure M90404 Edition 0212 Page 1 (8)
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling
Dismantling
904-4.2

1. 1. Suspend two tackles from the lifting brack-

ets, in the athwartship direction.

Mount the wire guide in the top of the

crankcase door opening.

2. Turn the crank to TDC.

Mount eye bolts in each side of the crankpin

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

Loosen the crankpin bearing stud nuts, us-

MA904-4.2 212 01

ing the hydraulic jacks.

For operation of the hydraulic jacks, see

Procedure 913-1.

2. Remove the hydraulic jacks and the nuts.

3. Lower the bearing cap while seeing care-

fully that the studs do not damage the
D-2 crankpin journal.

Land the bearing cap on a couple of planks

placed in the oil pan.

Inspect the bearing shell.

MA904-4.2 212 02

3.

D-6
MA904-4.2 212 03

Page 2 (8) When referring to this page, please quote Procedure M90404 Edition 0212
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.2
Dismantling

4. If the bearing shell needs to be replaced, 4.

remove the whole bearing cap from the
crankcase.
D-6
Suspend a tackle outside the engine above
the crankcase door opening.

Turn the crankthrow to the exhaust side to

give space for lifting out the crankpin bear-
ing cap.

Using the tackle from the frame box inside

wall, together with the tackle suspended
outside the engine, lift the bearing cap out
of the crankcase.

5. Place the bearing cap on one side on a

KC904-6.2 70 05
couple of planks.

Dismount the bearing shell lock screws and

replace the bearing shell by a new one.
5.
The bearing shells must be replaced in
pairs.
D-5
6. Turn to TDC.

Mount the four supports for guide shoes on

MC904-6.2 94 07

the crosshead guides.

Carefully turn the crank to the camshaft

side and down until the guide shoes rest on
the supports.
6.
Adjust the support brackets to the guide
shoes so that the weight of the crosshead
is evenly distributed on the four supports.
MA904-4.2 212 06

When referring to this page, please quote Procedure M90404 Edition 0212 Page 3 (8)
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling

7. 7. Mount a lifting attachment for securing the

connecting rod at the lower end, on the
camshaft side.

Hook on the tackle to a beam under the gal-

lery platform and haul tight.

8. Carefully turn the crankshaft downwards,

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
MA904-4.2 212 07

Continue turning the crankshaft until the

bearing surface can be freely inspected.

Inspect the bearing shell surface and the

8. crankpin journal.

9. If it is necessary to replace the bearing

shell, proceed as follows:

Turn the crankshaft to BDC.

Release the tackle so that the connecting

rod is hanging freely.
MA904-4.2 212 08

9.
MA904-4.2 212 09

Page 4 (8) When referring to this page, please quote Procedure M90404 Edition 0212
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.2
Dismantling

10. Mount an eye bolt in the bottom of each 10.

guide shoe.

Suspend two tackles from the eye bolts.

11. Place the lifting tool for the crankpin upper

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

Mount the tool on the bearing shell in the

connecting rod, using the tackles, and haul
tight.

MA904-4.2 212 10
12. Dismount the bearing shell lock screws.

Lower the lifting tool with the bearing shell,

using the tackles.

MA904-4.2 212 11 11.

12.

D-4
MA904-4.2 212 12

When referring to this page, please quote Procedure M90404 Edition 0212 Page 5 (8)
0$1% :'LHVHO$6
904-4.4 Crankpin Bearing
Mounting
Mounting
904-4.4

1. 1. If necessary, replace the bearing shells with

new ones. The bearing shells must be re-
placed in pairs.

Bearing shells of three mm undersize are

available as spares in case of journal recti-
fication.
HM904-6.0 61 16

Coat the bearing shell surfaces and the

journal with clean oil.

2. 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.

Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.

3. Remove the lifting tool, the tackles and the

eye bolts from the guide shoes.

D-4
MA904-4.4 212 02

3.
MA904-4.4 212 03

Page 6 (8) When referring to this page, please quote Procedure M90404 Edition 0212
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.4
Mounting

4. Hook the tackle on to a beam under the gal- 4.

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

Carefully turn the crankshaft upwards,

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

Remove the tackle and the lifting attach-

ment from the connecting rod.

5. Turn the crosshead to TDC.

Remove the four guide shoe support brack-

ets from the crosshead guides.

MA904-4.4 212 04

5.
MA904-4.4 212 05

When referring to this page, please quote Procedure M90404 Edition 0212 Page 7 (8)
0$1% :'LHVHO$6
904-4.4 Crankpin Bearing
Mounting

6. 6. Suspend the tackles from the lifting brack-

ets in the side of the frame box.

Lift the bearing cap assembly into the

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

Remove the wire guide tool from the en-

D-6 gine.

7. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.

Caution!

During mounting, take care that the studs

do not damage the crankpin journal, and
check that the guide pins mounted in the
MA904-4.4 212 06

bearing cap enter the holes in the con-

necting rod.

Mount the nuts and, by means of spacer

7. rings and hydraulic jacks, tighten the crank-
pin bearing cap. See Data.

For operation of hydraulic jacks, see Proce-

dure 913-1.

Remove the tackles from the side of the

frame box.
MA904-4.4 212 07

Page 8 (8) When referring to this page, please quote Procedure M90404 Edition 0212
0$1% :'LHVHO$6
 Connecting Rod 104-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0029
104-5 Connecting Rod

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
140-760 Nm
X Shut off lubricating oil
Lock turbocharger rotors
4 x 1,5 m, 1 x 3 m

Data
Ref. Description Value Unit 3 x 3000 kg
D-1 Hydraulic pressure: 2 x 5000 kg
– dismantling 900-990 bar

D-2 Hydraulic pressure

– mounting 900 bar

D-3 Crankpin bearing cap +

shell + studs 900 kg

D-4 Connecting rod 5875 kg

D-5 Studs on connecting rod

– screwing-in torque 960 Nm

When referring to this page, please quote Data D10405 Edition 0029 Page 1 (2)
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

Plate
90451

1283669-8

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10405 Edition 0029
MAN B&W Diesel A/S
 Connecting Rod 904-5.2
Dismantling
Connecting Rod
K90MC-C
0220
Dismantling
904-5.2

1.
1. Turn the crank to BDC.

Dismount the nuts from the crosshead

bearing studs. See Procedure 904-2.2.

2. Suspend two tackles from the two lifting

brackets at the side of the frame box.

Mount the wire guide in the top of the

crankcase door opening.

3. Turn the crank to TDC.

KC904-6.1 70 02
Mount the four support brackets for the
guide shoes on the crosshead guides.

4. Dismount the crankpin bearing cap, and re-

move the bearing cap from the engine. See
Procedure 904-4.2. 2.

Carefully turn the crank down towards the

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

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.
MA904-4.2 212 01

3.
MA904-4.2 212 06

When referring to this page, please quote Procedure M90405 Edition 0220 Page 1 (6)
0$1% :'LHVHO$6
904-5.2 Connecting Rod
Dismantling

5. 5. Mount the lifting attachments for fixing the

connecting rod on the head of the connect-
ing rod.

Mount the wire guide in the door opening.

A B
Use the tackles fastened to lifting brackets
A and B on the frame box wall, and attach
the tackle hooks to the mentioned lifting at-
tachments on the connecting rod.

Haul the tackles tight.

Also mount a lifting attachment in the

crankpin end of the connecting rod, on the
exhaust side.
MA904-5.2 212 05

Remove the trust pieces for axial guidance

of the connecting rod.

6. Turn the crankthrow towards BDC while

6. “following” with the tackles, thus continu-
ously supporting the connecting rod.

The crosshead now rests on the four sup-

ports.
A B 7. Turn the crankthrow to 90° before BDC.

Remove the four studs from the connecting

rod.

Shift the hook of the tackle attached to lift-

ing bracket B from the lifting attachment on
the lowermost side of the connecting rod to
the lifting attachment on the uppermost
side.
MA904-5.2 212 06

Page 2 (6) When referring to this page, please quote Procedure M90405 Edition 0220
0$1% :'LHVHO$6
 Connecting Rod 904-5.2
Dismantling

8. By means of the tackle from lifting bracket 8.

A, tilt the connecting rod towards the cam-
shaft side until the connecting rod is lean-
A B
ing out of the doorway.

Attach a tackle to lifting bracket C on the

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

Turn the crank carefully upwards while “fol-

lowing” with the tackles, guiding the head of
the connecting rod out of the doorway.

MA904-5.2 212 08
9. Attach a tackle to the gallery-mounted lift-
ing bracket E, and hook on to the lifting at-
tachment on the connecting rod.

Shift the tackles from one lifting bracket/at- 9.

tachment to the other, as required. E

Remove the floor chequer plate for the per- AA

A B
taining cylinder.

10. Place a wire rope round the connecting rod,

hook on the engine room crane and haul C
tight.

Continue turning upwards till about 30° af-

ter TDC, while “following” with the tackles
and the engine room crane.
MA904-5.2 212 09

Lift the connecting rod out of the engine us-

ing the engine room crane and the tackles.

10.
E

A B

D-4
MA904-5.2 212 10

When referring to this page, please quote Procedure M90405 Edition 0220 Page 3 (6)
0$1% :'LHVHO$6
904-5.4 Connecting Rod
Mounting
Mounting
904-5.4

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

ing attachments as mentioned under dis-
mantling.

A Turn the crank to a position about 30° past

B TDC on the camshaft side.

Apply clean lubricating oil to the crankpin

bearing shell and journal.

2. Carefully lift the connecting rod into the

D-4 crankcase by alternate use of the engine
room crane and the tackles attached to lift-
MA904-5.4 212 02

ing brackets A and B.

Attach a tackle to bracket E and the upper

end of the connecting rod.

3. 3. When the end of the connecting rod rests

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

4. Turn the crankthrow towards BDC, past

TDC, while ‘following’ with the tackles. Low-
er the engine room crane and remove the
strap around the connecting rod.

Shift tackle B from the lower end to the up-

per end of the connecting rod.
MA904-5.2 212 10

4.
E

A B

C
MA904-5.2 212 09

Page 4 (6) When referring to this page, please quote Procedure M90405 Edition 0220
0$1% :'LHVHO$6
 Connecting Rod 904-5.4
Mounting

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

Shift tackle A from the lower end to the top

A B
of the connecting rod.

Remove the tackle at E.

Shift tackle B from the lifting attachment on

one side to the other side of the connecting
rod.

Remove the tackle at C and the wire guide

on the door frame.

MA904-5.4 212 05
Remove the lifting attachment at the lower
end of the connecting rod.

6. Screw the studs into the connecting rod.

Using the stud setter and a torque wrench, 6.
tighten the studs to the torque stated in
Data.
A B
Lubricate the crosshead bearing shell and
journal.

7. Turn the crankthrow towards TDC while ‘fol-

lowing’ with the tackles, carefully land the
crosshead on the connecting rod.
D-5
Note!
MA904-5.4 212 06

Take care that the studs do not damage

the crosshead bearing journal.

7.
MA904-5.4 212 07

When referring to this page, please quote Procedure M90405 Edition 0220 Page 5 (6)
0$1% :'LHVHO$6
904-5.4 Connecting Rod
Mounting

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

pin bearing cap.
See Procedure 904-4.4.

9. Remove the tackles and lifting attachments.

Remove the four supports from the cross-

head guides and the lifting attachments
from the connecting rod.

10. Turn the crosshead to BDC.

Tighten all four crosshead bearing cap nuts

MA904-4.4 212 07

simultaneously. See Data.

D-2 For use of hydraulic jacks, see Procedure
913-1.

9.
MA904-4.4 212 05

10.

D-2

D-6
MA904-5.4 212 10

Page 6 (6) When referring to this page, please quote Procedure M90405 Edition 0220
0$1% :'LHVHO$6
 Connecting Rod and Crosshead Panel Plate
P90451-0102
Connecting Rod and Crosshead Panel
0102
P90451

When referring to this page, please quote Plate P90451 Edition 0102 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0102

Item Item
Item Description Item Description
No. No.

011 *) Tool Panel

023 Name plate
047 Guide for wire
059 Lifting tool
060 Tightening gauge
072 Crowfoot spanner
084 Extractor
096 Lifting attachment
106 Bracket for support of crosshead
118 Bracket for support of crosshead
120 Extension
131 Chain for suspension of piston
143 Retaining tool
155 Rubber cover with hole
167 Rubber cover

Notes: 011- 167 *) Tool panel, complete

with tools
*) Optional extras

Page 2 (2) When referring to this page, please quote Plate P90451 Edition 0102
MAN B&W Diesel A/S
 Connecting Rod - Hydraulic Tools Plate
P90461-0062
Connecting Rod - Hydraulic Tools
0062
P90461

When referring to this page, please quote Plate P90461 Edition 0062 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0062

Item Item
Item Description Item Description
No. No.

016 Hydraulic tool

028 O-ring with back-up
041 O-ring with back-up
053 Tommy bar
065 Stud setter
077 Hydraulic jack
089 Spacer ring

Page 2 (2) When referring to this page, please quote Plate P90461 Edition 0062
MAN B&W Diesel A/S
 Connecting Rod - Tools Plate
P90462-0032
Connecting Rod - Tools
0032
P90462

When referring to this page, please quote Plate P90462 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0032

Item Item
Item Description Item Description
No. No.

011 Lifting tool for crankpin shell

Page 2 (2) When referring to this page, please quote Plate P90462 Edition 0032
MAN B&W Diesel A/S
 Connecting Rod - Tools Plate
P90462-0033
Connecting Rod - Tools
0033
P90462

When referring to this page, please quote Plate P90462 Edition 0033 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0033

Item Item
Item Description Item Description
No. No.

011 Lifting attachment, complete

023 Screw

Page 2 (2) When referring to this page, please quote Plate P90462 Edition 0033
MAN B&W Diesel A/S
 Crosshead - Hydraulic T
Crosshead ools
Tools Plate
MAN B&W Diesel P90464-0003

When referring to this page, please quote Plate P90464 Edition 0003 Page 1 (2)
Plate
Crosshead - Hydraulic T
Crosshead ools
Tools
P90464-0003 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

012 Stud setter

024 O-ring with back-up ring
036 O-ring with back-up ring
048 Hydraulic tool for crosshead bearing
bolts, complete
073 Hydraulic jack
085 Spacer ring
097 Tommy bar

Page 2 (2) When referring to this page, please quote Plate P90464 Edition 0003
905 - Crankshaft, Thrust Bearing and Turning Gear

Documents in this Chapter

105-02 0054 Main Bearing, Data

905-02 0248 Main Bearing
105-03 0036 Thrust Bearing, Data
905-03 0220 Thrust Bearing
105-04 0012 Journal Bearing, Data
905-04 0213 Journal Bearing
105-05 0030 Axial Vibration Damper, Data
905-05 0225 Axial Vibration Damper
105-08 0006 Angle Encoder, Data
905-08 0204 Angle Encoder
90551 0225 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0084 Main Bearing - Hydraulic Tools
90562 0129 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90564 0018 Crankshaft - Measuring Tools
90567 0003 Segment Stopper & Vibration Damper - Tools
90570 0002 Thrust Shaft - Tools
90571 0001 Main Bearing Shell - Tools
90572 0001 Main Bearing - Measuring Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Main Bearing 105-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0054
105-2 Main Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
2000 kg
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
x2

Data
12 x 1.0 m
Ref. Description Value Unit 2 x 1.5 m
1 x 3.0 m
D-1 Min. bearing clearance 0.55 mm

D-2 Max. bearing clearance 0.85 mm

D-3 Main bearing cap 1555 kg

[
D-4 Upper bearing shell 94 kg

D-5 Lower bearing shell 101 kg

D-6 Hydraulic pressure [NJ

– dismantling 900-990 bar

D-7 Hydraulic pressure

– tightening 900 bar

[NJ

When referring to this page, please quote Data D10502 Edition 0054 Page 1 (2)
MAN B&W Diesel A/S
105-2 Main Bearing
Data

Plate
90551

1227291-7

Spare Parts

Plate – Item No. Description Qty

91210-xxx 108 Screw 2

91210-xxx 121 Main bearing 1

Page 2 (2) When referring to this page, please quote Data D10502 Edition 0054
MAN B&W Diesel A/S
 Main Bearing 905-2.1
Checking
Main Bearing
K90MC-C
0248

Checking
905-2.1

1.
General

The condition of the main bearings can be

checked by:

• Deflection readings

• Visual checking

• Edge checking and

• Measuring of top clearance.

HM905-2.0 46 01
Crankshaft deflection readings

Crankshaft deflection readings should be taken

while the ship is afloat (i.e. not while in dry
dock).
2.
As the alignment is influenced by the engine “Positive” (+)
temperature as well as the loading conditions,
deflection measurements should, for compari-
son purposes, always be made under nearly
the same temperature and load conditions.

1. Place a dial gauge axially in the crank throw

opposite the crankpin, as illustrated on the
sketch. The correct mounting position is
marked with punch marks on the crank “Negative” ( )
throw. See also Chapter 708 in Volume I.
KN905-1.1 208 02

2. “Closing” of the crank throw (compression

of the gauge) is regarded as negative (–)
and “opening” as positive (+).

3. Set the dial gauge to zero at the B1 side

near BDC. Whilst turning clockwise, take 3.
the readings when the throw passes the po-
sitions:

B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
1/2 (B2+B1) = B
XZ905-1.1 204 03

When referring to this page, please quote Procedure M90502 Edition 0248 Page 1 (19)
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

order, please contact MAN B&W Diesel or
the engine manufacturer for checking of the
bedplate alignment.
HM905-2.0 46 01

As reference, use the “after seatrial” deflec-

tion table.

5. The condition of the bearing can be checked as

follows:

5. Visually look for bearing metal fragments in

the oil pan, and check the filters for metal
fragments.

Such fragments can be from crosshead,

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

General
KN905-1.1 208 05

Bearing damage usually propagates rather

quickly towards the edge of the bearing where,
eventually, it causes chips to be broken off,
which means that loose pieces of white metal
can fall down into the crankcase beneath the
bearing support.

Large, thick pieces will normally be found dur-

ing a crankcase inspection, and small, thin
pieces can enter the filter. A check of the bear-
ing edges together with inspection of the crank-
case and the filter normally provides a good
indication of the bearing condition.

Page 2 (19) When referring to this page, please quote Procedure M90502 Edition 0248
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 0248 Page 3 (19)
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 (19) When referring to this page, please quote Procedure M90502 Edition 0248
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 0248 Page 5 (19)
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 (19) When referring to this page, please quote Procedure M90502 Edition 0248
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

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

Mounting of tools and tackles

FF
5. Mount pulley E, pulley F and the special
eye bolt D, as shown on the sketch.

Pulley E is made in both fore and an aft ver-

sion, to enable mounting on both sides of DD
KN905-2.2 236 05

the web plate.

Pulley F has to be tightened to full surface

E
E
contact, i.e. using a spanner. On some en-
gines the stop screw in the guide shoe has
to be removed. Some are provided with a
threaded hole.

Check with a 0.05 mm feeler gauge that

there is no clearance between the pulley
and the stop screw (guide shoe).

Note!

Do not use pulley F if it is not tightened to

full contact.

When referring to this page, please quote Procedure M90502 Edition 0248 Page 7 (19)
MAN B&W Diesel A/S
 905-2.2 Main Bearing
Dismantling

6. A
A 6. Mount the wire guide as shown. The wire
B guide must be finally positioned when tight-
B ening the tackles . Mount the wire guide on
the crosshead guide.

Mount tackles in the following positions:

A: a 3 ton chain tackle, in a wire strap
around the beam.
B: a 3 ton chain tackle. (On some engines
a special bracket has to be mounted, before
mounting the shackle.)
D
D
C: a 3 ton pull lift
D: a 1 ton tackle
KN905-2.2 238 06

Loosening the nuts

CC
7. Before mounting, check the jacks as shown
in Procedure 913-1.
7.
8. Place the spacer rings over the nuts on the
bearing cap. Screw down the extension
studs on the main bearing studs.

Place three hydraulic jacks on each spacer

ring. Screw down the four upper nuts on the
extension studs. Tighten them firmly.
KN905-2.2 238 07

Then turn the upper nuts 3/4 turn back-

wards to obtain a clearance of about 4.5
mm.

Note!
8.
Be sure to mount the spacer rings and
the hydraulic jacks with the TOP mark
upwards.
TOP

TOP 9. Connect the hydraulic jacks to the high-

pressure pump by means of the distributor
TOP block and high-pressure hoses.

Bleed the entire hydraulic system and raise

the pressure as indicated in Data. Then
loosen the nuts.

Remove the upper nuts, the hydraulic jacks,

the spacer rings and the extension studs.
MB905-3.0 90 03

Unscrew the main bearing nuts from the

studs. For operation of the hydraulic jacks,
see Chapter 913.

Page 8 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

10.
Removal of main bearing cap

10. Mount the main bearing lifting tool on the

main bearing cap.

Place the longest wire rope around pulley

E, as shown, and attach it in tackle A, from
outside the engine.
(The longest wire rope must be approx. 400
mm longer than the other.)

Tighten up tackle A and carefully lift the

main bearing cap clear of the studs.

KN905-2.2 238 16
Note!

When tightening up the tackle, be sure

that the wire guides are positioned cor-
11.
rectly to protect crosshead guides and
doorframe.
F
11. When clear of the studs, pull the shortest C
wire rope around wire guide F, as shown,
and attach it to tackle C, below the door.
A
Tighten tackle C and release tackle A, until
the main bearing cap is suspended vertical-
ly below pulley F.

12. Remove the wire rope from tackle A and let

it hang freely.
KN905-2.2 238 17

Mount the short wire rope across the lifting

tool.

Mount the hook from tackle B (upper in the 12.

crankcase), in the short wire, and tighten it
B
up. F
B
F
If necessary, pull the main bearing cap free
of the crosshead guides, using tackle D, C C
from the opposite web plate. DD

E
E
KN905-2.2 248 12

When referring to this page, please quote Procedure M90502 Edition 0248 Page 9 (19)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

13. BB 13. Release tackle C and at the same time,

tighten tackle B until the bearing cap is
hanging freely below tackle B.

Release and unhook tackles C and D.

14. Attach the hook of tackle A, from outside

the engine, to the short wire rope across
the lifting tool.

By tightening tackle A and releasing tackle

DD
B, lift the bearing cap out of the engine, and
place it on a couple of wooden planks.
KN905-2.2 248 13

Removal of upper bearing shell

CC
15. Mount the bearing shell lifting tool on the
upper main bearing shell, pull the wire
14. around pulley F, as shown, and attach it to
B A tackle A outside the engine.

Carefully lift the bearing shell, until it is

hanging freely below the guideshoe.

Lift the bearing shell out of the engine in the

same way as the bearing cap.

D
KN905-2.2 238 22

15.
HN905-2.2 227 19

Page 10 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

16.
Removal of upper bearing shell

16. If the crankshaft is turned with the bearing

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

17. Place the crosspiece in the bedplate with

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

Tighten the screws against the crank webs

and compress the jacks.

KN905-2.2 238 24
Connect the hydraulic jacks to the high
pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings. 17.

Note down the pressure for later reference.

18. 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.

Note!

The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
KN905-2.2 238 27

relief in the bearing shell.

If the clearance is less than 0.1 mm, move

the crosspiece sideways until clearance is
obtained. Normally, adjustment needs to be
18.
50-150 mm to the exhaust side (the side Min. 0,1 mm
where the clearance is missing).

Note!

The lower shell must be lifted out to the

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

EXH CAM
Min. 60 mm
KN905-2.2 238 28

When referring to this page, please quote Procedure M90502 Edition 0248 Page 11 (19)
MAN B&W Diesel A/S
905-2.2 Main Bearing
Dismantling

19. 19. If re-positioning of the crosspiece does not

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

If it is available, note down the pressure 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.

Note!

It is recommended that the crankshaft lift-

KN905-2.2 238 25

ing tool is only removed if it is urgently

necessary and then only after the main
bearing shell has been reinstalled.

20. 20. Dismount the locking screws.

Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.
KN905-2.2 238 26

Page 12 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling

21. Pull the lower shell around and up until it 21.

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

Note!

While pulling out the shell, it is recom-

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

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

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

JM905-2.2 236 27

22.
HN905-2.2 227 19

When referring to this page, please quote Procedure M90502 Edition 0248 Page 13 (19)
MAN B&W Diesel A/S
905-2.3 Main Bearing
Overhaul
Overhaul
905-2.3

1 + 2. 1. Clean and inspect the bearing shells. It is

recommended that the main bearing shells
be replaced in pairs.

If it is nevertheless desired to replace only

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

For advice on replacing individual bearing

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

2. Before remounting:

• Check the bearing support for damage

KN905-2.2 238 25

and burrs. If damage is found, contact

MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and main bearing support.

• Lubricate the bearing journal, the main

bearing support and the back of the
shell, with main engine lubricating oil.

Page 14 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.4
Mounting
Mounting
905-2.4

Mounting of bearing shells 1.

1. 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-
shaft journal.

2. Position the guide tool for the lower bearing

shell on the main bearing support. Remove
the lifting tool from the bearing shell.

Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.

KN905-2.2 229 26
Place the lower bearing shell on the journal
and push it down by hand.

To ensure that the shell is correctly mount-

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

3. 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 below
the crankshaft.
MC905-3.0 118 19

Wipe the contact surfaces between the up-

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

3.
XZS905-13 07

When referring to this page, please quote Procedure M90502 Edition 0248 Page 15 (19)
MAN B&W Diesel A/S
905-2.4 Main Bearing
Mounting

4. 4. Land the upper bearing shell on the main

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

Make sure that none of the edges of the up-

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

If necessary, place the special tool between

the studs and press the shell into place.

Clean the contact surfaces between the

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

es.

5. Mount the lifting tool on the bearing cap.

Using the tackles and wire ropes on the
5. main bearing cap lifting tool, lift the bearing
B A cap into the crankcase in reverse order to
dismantling.
See Procedure 905-2.2, steps 22-21.

D
KN905-2.2 238 20

Page 16 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.4
Mounting

6. Using the pulleys mounted inside the crank 6 a.

BB
case, move the bearing cap into position
vertically above the crankshaft bearing
journal in the reverse order to dismantling.
See Procedure 905-2.2, steps 20-17.

Note!

Be sure that it is the shortest wire rope

that is pulled around pulley F below the
guideshoe. DD

KN905-2.2 248 6a
7. Carefully lower the main bearing cap on to
the upper bearing shell. Keep a hand on the
wire rope while lowering, so that sticking of CC
the bearing cap is immediately felt.

6 b.

F
F

C
C

AA
KN905-2.2 248 6b

7.
KN905-2.4 238 08

When referring to this page, please quote Procedure M90502 Edition 0248 Page 17 (19)
MAN B&W Diesel A/S
905-2.4 Main Bearing
Mounting

8. 8.

Note!

Be sure that the cap lands correctly and

that the spring pin in the assembly sur-
face enters the hole in the bearing cap.

9. Remove the bearing cap lifting tool.

Screw the nuts on to the main bearing

studs.
KN905-2.4 238 09

Using a tommy bar, tighten the nuts on both

sides of the bearing cap.

Tightening of hydraulic nuts

9.
10. Mount the nuts, the spacer rings, the hy-
draulic jacks, and tighten the nuts.
See Data and Procedure 905-2.2, step 5
and 6.

After tightening the bearing cap, check the

KN905-2.4 238 10

clearance once more.

For operation of the hydraulic tools, see

Procedure 913-1.
10.

TOP

TOP

TOP
MB905-3.0 90 03

Page 18 (19) When referring to this page, please quote Procedure M90502 Edition 0248
MAN B&W Diesel A/S
 Main Bearing 905-2.4
Mounting

11. 11.

Note!

Before removing the hydraulic jacks,

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

12. Remove all tools from the engine.

KN 905-1.1 208 09
20
Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left
behind. 12.

13. Mount the lubricating oil pipe on the main

bearing cap,
KN905-2.4 238 14

13.
KN905-2.4 238 15

When referring to this page, please quote Procedure M90502 Edition 0248 Page 19 (19)
MAN B&W Diesel A/S
 Thrust Bearing 105-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0036
105-3 Thrust Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear M12
M20
Shut off cooling water
Shut off fuel oil
2 x 900 kg
X Shut off lubricating oil
Lock turbocharger rotors 2x1m
1x3m

Data
Ref. Description Value Unit
1000 kg
D-2 Segment stopper 311 kg

D-3 Thrust bearing segment 105 kg

D-4 Hydraulic pressure

– tightening 900 bar

D-5 Hydraulic pressure

– dismantling 900-990 bar

When referring to this page, please quote Data Sheet D10503 Edition 0036 Page 1 (2)
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data

Plate
90551

1227291-7

Spare Parts

Plate – Item No. Description Qty

90505-xxxx 026 Locking wire 1

90505-xxxx 325 Segment without sensor pockets 7
90505-xxxx 301 Segment with sensor pockets 1

Page 2 (2) When referring to this page, please quote Data Sheet D10503 Edition 0036
MAN B&W Diesel A/S
 Thrust Bearing 905-3.1
Checking
Thrust Bearing
K90MC-C
0220
Checking
905-3.1


The clearance in the thrust bearing was meas-
ured during the testbed trials of the engine and
noted down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.

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

and for an engine in service it must not exceed
2.0 mm.
For dismantling the segment stopper, see Pro-
cedure 905-3.2.

1. There is a wear groove of 1 mm in the up-

permost thrust segment. (The segment with
thermometers).

Insert the feeler gauge in this groove on the

foremost side of the thrust collar.

If a feeler gauge of 0.1 mm is not able to NA905-3.1 209 01

enter the wear groove, the thrust bearing

must be overhauled.

When referring to this page, please quote Procedure M90503 Edition 0220 Page 1 (5)
0$1% :'LHVHO$6
905-3.2 Thrust Bearing
Dismantling
Dismantling
905-3.2

 1. Remove the end cover of the engine.

Remove the lub. oil pipe from the aftmost

main bearing shell.

Remove the lub. oil pipe above the thrust

segments.

Remove the protecting shields from the

thrust collar.

2. Loosen and remove the nuts from the seg-

ment stoppers by using hydraulic tools.
NA905-3.2 209 01

Dismount the stud, if necessary.

3. Mount the crossbar in the chain drive and

suspend a tackle over the stopper which
 has to be removed.

Remove the segment stoppers above the

D-5 thrust segments ( AHEAD or ASTERN) that are
to be taken out, and lift the stoppers out of
the chain casing.
JG905-5.0 82 02



D-2
JG905-5.0 82 03

Page 2 (5) When referring to this page, please quote Procedure M90503 Edition 0220
0$1% :'LHVHO$6
 Thrust Bearing 905-3.2
Dismantling

4. Suspend a tackle from the chain tightener 4.

bracket above the segments which are to
be removed.

For turning-up the thrust segments, mount

the segment tool on the chainwheel.

5. Turn up the segments, one at a time, by

turning the engine, and remove the seg-
ment from the chain casing. Inspect the
segment and remount it before turning up
the next segment. See Procedure 905-3.4.

HB905-3.2 220 04
Note!

Never remove more than one segment at

a time.
5.
HB905-3.2 220 05

When referring to this page, please quote Procedure M90503 Edition 0220 Page 3 (5)
0$1% :'LHVHO$6
905-3.4 Thrust Bearing
Mounting
Mounting
905-3.4

1. 1. Suspend a tackle from the crossbar above

the segments which are to be mounted.
D-2
Mount the segment tool on the chainwheel.

Land the segment on the journal and re-

move the eye bolt from the segment.

Carefully slide the segment on to the seg-

ment tool. Turn the engine to dismantle the
next segment. See Procedure 905-3.2.

2. After the last segment has been mounted,

turn the segment tool up and dismount it.
NA905-3.4 209 01

2.
NA905-3.4 209 02

Page 4 (5) When referring to this page, please quote Procedure M90503 Edition 0220
0$1% :'LHVHO$6
 Thrust Bearing 905-3.4
Mounting

3. Mount the segment stoppers. 

Mount the hydraulic jacks and tighten the

nuts on the stoppers. See Data.

Mount the protective shield.

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

ments.

Mount the lub. oil pipe for the aftmost main

bearing.

5. Mount the end cover.

JG905-5.0 82 03


NA905-3.2 209 01

When referring to this page, please quote Procedure M90503 Edition 0220 Page 5 (5)
0$1% :'LHVHO$6
 Journal Bearing 105-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0012
105-4 Journal Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
2000 kg
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
x2

Data
12 x 1.0 m
Ref. Description Value Unit 2 x 1.5 m
1 x 3.0 m
D-1 Min. bearing clearance 0.65 mm

D-2 Max. bearing clearance 0.95 mm

D-3 Main bearing cap 1555 kg

[
D-4 Upper bearing shell 94 kg

D-5 Lower bearing shell 101 kg

D-6 Hydraulic pressure [NJ

– dismantling 900-990 bar

D-7 Hydraulic pressure

– tightening 900 bar

[NJ

When referring to this page, please quote Data D10504 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
105-4 Journal Bearing
Data

Plate
90551

1227291-7

Spare Parts

Plate – Item No. Description Qty

91210-xxx 108 Screw 2

91210-xxx 121 Main bearing 1

Page 2 (2) When referring to this page, please quote Data D10504 Edition 0012
MAN B&W Diesel A/S
 Journal Bearing 905-4.1
Checking
Journal Bearing
K90MC-C
0213
Checking
905-4.1

1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of journal bearing,
check the clearances according to
Procedure 905-1.1

2. Write down the journal bearing clearances.

3. Also check the journal bearing by visually

searching the area underneath the bearing
support.

KN905-2.2 238 01
Main bearings

Thrust bearing

2.
KN905-2.2 238 02

3.
KN905-4.1 202 03

When referring to this page, please quote Procedure M90504 Edition 0213 Page 1 (10)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2

1. Dismantling of journal bearing in the thrust

shaft end.

1. Remove the screws from the cover placed

over the thrust bearing. Mount an eye bolt,
shackles and wire rope on the cover. Hook
on a tackle, and lift the cover away.

2. Disconnect the main bearing lubricating oil

pipe, the horizontal main oil pipe for the
thrust bearing and the vertical thrust bear-
ing pipes.
NA905-2.2 215 24

Mount pulley A on the web-plate as shown.

Turn the crank throw for the aftmost cylin-

der to TDC.

2. 3. Assemble the main bearing hydraulic jacks

on the bearing studs. Connect the hydraulic
A pump.
KB905-4.2 206 02

3.

D-6
KC905-3.0 82 02

Page 2 (10) When referring to this page, please quote Procedure M90504 Edition 0213
MAN B&W Diesel A/S
 Journal Bearing 905-4.2
Dismantling

4. For operation of the hydraulic tools, 4.

see Procedure 913-1.

Remove the hydraulic main bearing tools

from the engine.

Unscrew and remove the nuts from the

bearing studs.

KN905-2.2 238 07
5. Mount the lifting tool on the bearing cap.
Place the wire ropes of the lifting tool as
shown on the sketch. Hook tackles B and
C on to the wire ropes of the lifting tool. 5. B C
B C
Tighten tackle C until the bearing cap is lift-
ed completely clear of the bearing studs.
E
6. Tighten tackle B and release tackle C until
the bearing cap is suspended vertically be-
low tackle B.
KN905-4.2 202 07

6. C
B

E
KN905-4.2 202 08

When referring to this page, please quote Procedure M90504 Edition 0213 Page 3 (10)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling

B
7. 7. Remove the chain of tackle C from the wire
rope of the lifting tool, and remove the wire
E rope of the lifting tool from pulley E.

Using tackle B, lift the bearing cap away

from the engine.

8. Remove the upper bearing shell in the

same way as you remove the bearing cap.

9. Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.
KN905-4.2 202 09

Tighten the screw against the turning wheel

and compress the jacks.

Connect the hydraulic jacks to the high-

8. 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.
KN905-4.2 202 10

9.
KN905-4.2 202 11

Page 4 (10) When referring to this page, please quote Procedure M90504 Edition 0213
MAN B&W Diesel A/S
 Journal Bearing 905-4.2
Dismantling

10. Dismount the locking screws. 10 + 11.

Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.

11. Pull the lower shell around and up until it

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

Note!

While pulling out the shell, it is recom-

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

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

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

12.
KN905-4.2 202 10

When referring to this page, please quote Procedure M90504 Edition 0213 Page 5 (10)
MAN B&W Diesel A/S
905-2.3 Journal Bearing
Overhaul
Overhaul
905-2.3

1 + 2. 1. Clean and inspect the bearing shells. It is

recommended that the main bearing shells
be replaced in pairs.

If it is nevertheless desired to replace only

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

For advice on replacing individual bearing

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

2. Before remounting:

• Check the bearing support for damage

KN905-2.2 238 25

and burrs. If damage is found, contact

MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and bearing support.

• Lubricate the bearing journal, the bear-

ing support and the back of the shell,
with main engine lubricating oil.

Page 6 (10) When referring to this page, please quote Procedure M90504 Edition 0213
MAN B&W Diesel A/S
 Journal Bearing 905-4.4
Mounting
Mounting
905-4.4

1. Using the bearing shell lifting tool, the pul- 1.

leys and tackles, lift the lower bearing shell
into the crankcase and land it on the crank-
shaft journal.

2. Position the guide tool for the lower bearing

shell on the bearing support. Remove the
lifting tool from the bearing shell.

Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.

Place the lower bearing shell on the journal

KN905-4.2 202 10
and push it down by hand.

To ensure that the shell is correctly mount-

ed, check that the distance from the bear-
ing support to the shell is equal in both
sides. 2.

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 below
the crankshaft.

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with
MC905-3.0 118 19

a non-fluffy piece of cloth.

3.
XZS905-13 07

When referring to this page, please quote Procedure M90504 Edition 0213 Page 7 (10)
MAN B&W Diesel A/S
905-4.4 Journal Bearing
Mounting

4. 4. Land the upper bearing shell on the journal

in the same way as the lower bearing shell.

Make sure that none of the edges of the up-

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

If necessary, place the special tool between

the studs and press the shell into place.

Clean the contact surfaces between the

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

5. Mount the lifting tool on the bearing cap.

Using the lifting tool and the tackles, lift the
bearing cap into the crank casing in reverse
5. B C order to dismantling.
See Procedure 905-4, steps 11-9.
E
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.
KN905-4.2 202 08

6.
KN905-2.4 238 09

Page 8 (10) When referring to this page, please quote Procedure M90504 Edition 0213
MAN B&W Diesel A/S
 Journal Bearing 905-4.4
Mounting

7. Remove the bearing cap lifting tool. 7.

Screw the nuts on to the main bearing

studs.

Using a tommy bar, tighten the nuts on both

sides of the bearing cap.

KN905-2.4 238 10
8. Assemble the main bearing hydraulic jacks
on the bearing studs. Connect the hydraulic
pump.

For tightening pressure, see Data.

8.
For operation of the hydraulic tools,
see Procedure 913-1.
D-6
KC905-3.0 82 02

When referring to this page, please quote Procedure M90504 Edition 0213 Page 9 (10)
MAN B&W Diesel A/S
905-4.4 Journal Bearing
Mounting

9. 9.

Note!

Before removing the hydraulic jacks,

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

Remove all tools from the engine.

Note!
KN 905-1.1 208 09

20 Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.

10. 10. Mount the lubricating oil pipes for thrust

bearing and main bearing.

Mount the end cover.

KN905-2.4 238 15

Page 10 (10) When referring to this page, please quote Procedure M90504 Edition 0213
MAN B&W Diesel A/S
 Axial Vibration Damper 105-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0030
105-5 Axial Vibration Damper

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear 140 – 760 Nm
750 – 2000 Nm
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors 2x1m
1x3m

Data
Ref. Description Value Unit 1 x 2000 kg
D-1 Damper housing, upper part 1460 kg

D-2 Hydraulic pressure 900 bar

– tightening

D-3 Hydraulic pressure

– dismantling 900-990 bar

D-4 Screwing-in torque

– outer studs 160+/–20 Nm

D-5 Screwing-in torque

– inner studs 120+/–20 Nm

D-6 Tightening torque

– horizontal screws 1245+/–50 Nm
or tightening angle 28 °

D-7 Clearance at joints

– middle oil seal 8 mm
– side oil seal 6 mm

Calibration of springs:
Spring for the middle oil seal
L0 0 N – Check length 3137 mm
L1 54 +/– 10 N – Check length 4108 mm
L2 80 +/– 16 N – Check length 4574 mm

Spring for the outer oil seal

L0 0 N – Check length 2566 mm
L1 42 +/– 9 N – Check length 3171 mm
L2 75 +/– 15 N – Check length 3669 mm

Limits for axial vibration – K90MC-C

Cyl. 6 7 8 9 10 11 12
S1 mm 1.95 2.28 2.61 2.94 3.26 3.58 3.92
S2 mm 10 12 14 15.5 17 19 20.5

When referring to this page, please quote Data D10505 Edition 0030 Page 1 (2)
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
Data

Plate
90551

1227291-7

Spare Parts

Plate – Item No. Description Qty

91211-xxx 019 Spring – middle oil seal 1

91211-xxx 020 Spring – side oil seals 2
91211-xxx 164 Oil seal – side oil seals 2
91211-xxx 152 Oil seal – middle oil seal 1

Page 2 (2) When referring to this page, please quote Data D10505 Edition 0030
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.1
Checking
Axial Vibration Damper
K98MC-C
0225
Checking
905-5.1

1.
For checking the effectiveness of the axial vi-
bration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.

The measurement (or reading) should be taken

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

As different equipment may be mounted on the

specific engines, the checking procedure de-
scribes three different systems:

A: Electronic, with Axial Vibration Monitor

B. Mechanical, (without angle encoder fore)

C: Mechanical, with angle encoder fore.

A: Electronic, with Axial Vibration Monitor

A proximeter probe is built on to the lower part

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

movements and sends signals to the engine

control system.

1. Concerning overhaul and setting of the

electronic device, refer to makers instruc-
tions and Volume I, Operation, Chapter
701.

The peak-to-peak values displayed in mm

are to be compared with the original values
obtained during sea trial and the limits giv-
en in Volume I, Operation, Chapter 701.

If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see
Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0225 Page 1 (8)
MAN B&W Diesel A/S
905-5.1 Axial Vibration Damper
Checking

1. B: Mechanical (without angle encoder fore)

1. Stop the engine.

Unscrew the two plugs from the cover at the

front of the engine.

2. Mount the shaft piece in the end of the

crankshaft, using the handle.

After tightening the shaft, dismount the

handle.
BG905-5.1 223 01B

Screw the measuring arm into the small

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

2. Attach a pencil to the arm.

Note!

To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.
BG905-5.1 223 02B

Page 2 (8) When referring to this page, please quote Procedure M90505 Edition 0225
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.1
Checking

3. Start the engine, and let the speed rise to 3.

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

When measuring, press the measuring arm

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

To ensure a certain inertia, the backing

plate should have a mass of approx. 1-2 kg.

DM905-7.1 74 05
The axial movements (S2) recorded on the
paper must be measured with a slide calli-
per as shown in the sketch.
4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
S1
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.

For a standard measuring tool (L 1 = 38 mm L2

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

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

calculated as follows:

If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see
Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0225 Page 3 (8)
MAN B&W Diesel A/S
905-5.1 Axial Vibration Damper
Checking

1. C: Mechanical, with angle encoder fore

For engines with angle encoder fore, a meas-

uring tool is available for mounting on the angle
encoder housing.

1. Stop the engine.

Dismount the protection shield over the an-

gle encoder. (Not always on engine).

Dismount the cover on the angle encoder

housing.

Apply some Molycote TM on the fore side of

the shaft cam.

2. Mount the axial vibration measuring tool,

using the screws from the cover.

Note!
BG905-5.1 223 01C

To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.

2.
MN905-5.1 214 05

Page 4 (8) When referring to this page, please quote Procedure M90505 Edition 0225
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.1
Checking

3. Start the engine, and let the speed rise to 3.

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

The axial movements (S2) recorded on the

paper must be measured with a slide calli-

BG905-5.1 223 03
per as shown in the sketch.

4. Before comparing the measured value (S2)

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

For a standard measuring tool (L 1 = 35 mm

and L 2 = 178 mm), the ratio is 5.1. There-
fore, S1 can be calculated as follows:

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

calculated as follows:

If the peak-to-peak value exceeds the Nor-

MA905-5.1 212 07

mal Service Value, it is necessary to over-

haul the axial vibration damper, see
Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0225 Page 5 (8)
MAN B&W Diesel A/S
905.5.2 Axial Vibration Damper
Dismantling
Dismantling
905.5.2

1. Dismantling of the axial vibration damper is car-

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

1. Turn the engine to a position where it is

possible to enter the flyweight housing on
the fore end of the engine

Dismount the lubricating oil pipes for the

main bearing and axial vibration damper.

2. Loosen and remove the horizontal screws

on the upper part of the damper.
NA905-5.2 225 02

On some engines, due to the position of the

flyweight, it is necessary to turn the engine
before loosening the one or the other side
of the axial vibration damper.

2. Loosen and remove the hydraulic nuts from

the studs. For operation of the hydraulic
tools, see Procedure 913-1.

Only the upper part of the housing needs to

be removed, while the lower half remains
mounted on the bedplate.

3. Mount the lifting tool on top of the upper

part.

By means of the tackle and wire rope, sep-

arate and raise the upper part of the damp-
er housing to a position in which it is
NA905-5.2 213 03

possible to change the oil seals and

springs.

Note!
3.
D05-25 Before starting work under the suspen-
ded upper part, secure the upper part
with, e.g. a wire rope or another tackle.
NA905-5.2 213 04

Page 6 (8) When referring to this page, please quote Procedure M90505 Edition 0225
MAN B&W Diesel A/S
 Axial Vibration Damper 905-5.3
Overhaul
Overhaul
905-5.3

1. Dismantle and remove the springs from the 1.

oil sealing rings.

Remove the oil sealing rings.

Note!

It is recommended to discard both the

springs and the oil sealing rings.

When mounting the new oil sealing rings,

first insert the lower half of the rings in the

HG905-5.2 201 01
lower housing.

Then press the tension springs into the

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

Now hook the new tension springs into

place, ensuring that they are centralised in
the grooves of the oil sealing rings.

Note!

The lower half of the oil sealing rings will

HG905-5.2 201 02

protrude above the centreline.

When referring to this page, please quote Procedure M90505 Edition 0225 Page 7 (8)
MAN B&W Diesel A/S
905-5.4 Axial Vibration Damper
Mounting
Mounting
905-5.4

1. 1. Release and carefully lower the upper part

D05-25 of the damper housing.

When reaching the oil sealing rings, take

care that the rings enter the sealing ring
grooves correctly.

Before landing the upper part on the lower

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

2. Mount and tighten the hydraulic nuts. For

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

Mount and tighten the horizontal screws.

See Data.
NA905-5.4 213 01

Note!

Search the crankcase to ensure that

2. there are no tools, shackles or rags left
D05-22 behind.
D13-01
Mount the lubricating oil pipes.

Mount the cover for the lifting hole above

the axial vibration damper.

Note!
D05-24
After overhaul of the axial vibration
damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
NA905-5.4 225 02

Page 8 (8) When referring to this page, please quote Procedure M90505 Edition 0225
MAN B&W Diesel A/S
 Angle Encoder 105-8
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
alle
0006
105-8medData
vinkel encoder Angle Encoder

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10508 Edition 0006 Page 1 (2)
MAN B&W Diesel A/S
105-8 Angle Encoder
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10508 Edition 0006
MAN B&W Diesel A/S
 Angle Encoder 905-8.1
Checking
Angle Encoder
S42MC
0204
Checking
905-8.1


1. Turn the crankthrow for cylinder 1 to TDC.

Check the TDC of cylinder 1 against the

mark on the turning wheel.

2. Check that power is supplied to the inter-

HM906-7.0 56 01
mediate box.

The green indicator should now light.

For adjustment of the angle encoder, see

Procedure 905-8.3. 

MN905-8.1 202 03

When referring to this page, please quote Procedure M90508 Edition 0204 Page 1 (4)
0$1% :'LHVHO$6
905-8.2 Angle Encoder
Dismantling
Dismantling
905-8.2

 1. Remove the inspection cover.

Cut the cable tie which holds the rubber

damper around the coupling, in the end
nearest to the engine, and loosen the cou-
pling.

2. Loosen the three adjusting screws on the

front flange, and remove the angle encoder
and the coupling.

3. Screw out the flange screws and remove

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


XR905-8.2 204 02


XR905-8.2 204 03

Page 2 (4) When referring to this page, please quote Procedure M90508 Edition 0204
0$1% :'LHVHO$6
 Angle Encoder 905-8.3
Adjustment
Adjustment
905-8.3

1. Turn the crankthrow for cylinder 1 to TDC. 

Check the TDC of cylinder 1 against the

mark on the turning wheel.

Check the TDC position with the pin gauge

HM906-7.0 56 01
on the crankthrow, cylinder 1.

Note!

Before using the pin gauge, check the 

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

2. Loosen the adjusting screws which fasten

the encoder to the housing. Slowly turn the
encoder until the green indicator lights on
BG906-7.0 58 02

the intermediate box.

Tighten the screws to secure the encoder in

the correct position.


MN905-8.3 202 02

When referring to this page, please quote Procedure M90508 Edition 0204 Page 3 (4)
0$1% :'LHVHO$6
905-8.4 Angle Encoder
Mounting
Mounting
905-8.4

1. 1. Mount the encoder housing. The two guide

pins indicate the correct positioning of the
housing. Tighten the screws.

2. Mount the angle encoder and the coupling.

Tighten the coupling, and mount new cable

ties around the rubber damper.

Adjust the angle encoder according to Pro-

cedure 905-8.3.
XR905-8.4 204 01

Note!

The adjustment will be easier if mounting

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

3. Mount the cover.

XR905-8.4 204 02

3.
XR905-8.4 204 03

Page 4 (4) When referring to this page, please quote Procedure M90508 Edition 0204
0$1% :'LHVHO$6
 Crankshaft, Thrust Shaft, Panel Plate
P90551-0225
Crankshaft,
0225
P90551 Thrust Shaft, Panel

When referring to this page, please quote Plate P90551 Edition 0225 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Panel
P90551-0225

Item Item
Item Description Item Description
No. No.

015 Panel for tools

027 Name plate
040 Pulley for wire for main bearing
064 Pulley for wire for main bearing
076 Lifting tool for main bearing cap
088 Dismantling tool for main bearing shell
090 Mounting tool for thin bearing shell
100 Tool for turning out segments
111 Lifting attachment
123 Retaining tool for relief valve
135 Lifting tool for relief valve
159 Eye bolt
160 Wire
172 Mounting tool for thin bearing shell
196 Tightening template A.V.D.
218 Wire guide for main bearing

Page 2 (2) When referring to this page, please quote Plate P90551 Edition 0225
MAN B&W Diesel A/S
 Main Bearing - Hydraulic Tools Plate
P90561-0084
P90561
Main
0084 Bearing - Hydraulic Tools

When referring to this page, please quote Plate P90561 Edition 0084 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0084

Item Item
Item Description Item Description
No. No.

021 Hydraulic jack

045 Hydraulic jack, support
057 Extension stud
069 Tommy bar
070 Tommy bar
082 Key for hexagon socket screw
094 O-ring with back-up ring
104 O-ring with back-up ring
153 Nut
165 Stud setter
200 Hydraulic tool, complete

Page 2 (2) When referring to this page, please quote Plate P90561 Edition 0084
MAN B&W Diesel A/S
 Crankshaft - Tools Plate
P90562-0129
Crankshaft
P90562
0129 - Tools

When referring to this page, please quote Plate P90562 Edition 0129 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0129

Item Item
Item Description Item Description
No. No.

015 Lifting tool, crankshaft

Page 2 (2) When referring to this page, please quote Plate P90562 Edition 0129
MAN B&W Diesel A/S
 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
 Crankshaft - Measuring Tools
Tools Plate
MAN B&W Diesel P90564-0018

When referring to this page, please quote Plate P90564 Edition 0018 Page 1 (2)
Plate
Crankshaft - Measuring Tools
Tools
P90564-0018 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Measuring tool for axial movement

Page 2 (2) When referring to this page, please quote Plate P90564 Edition 0018
 Segment Stopper and Vibration Plate
P90567-0003
Dampener - Tools
P90567
Segment
0003 Stopper and Vibration Dampener - Tools

When referring to this page, please quote Plate P90567 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Segment Stopper and Vibration Damp-
P90567-0003 ener - Tools

Item Item
Item Description Item Description
No. No.

012 Crossbar

Page 2 (2) When referring to this page, please quote Plate P90567 Edition 0003
MAN B&W Diesel A/S
 Thrust Shaft - Tools Plate
P90570-0002
Thrust Shaft - Tools
0002
P90570

When referring to this page, please quote Plate P90570 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0002

Item Item
Item Description Item Description
No. No.

019 Lifting tool for thrust shaft

Page 2 (2) When referring to this page, please quote Plate P90570 Edition 0002
MAN B&W Diesel A/S
 Main Bearing Shell - Tools
Tools Plate
MAN B&W Diesel P90571-0001

When referring to this page, please quote Plate P90571 Edition 0001 Page 1 (2)
Plate
Main Bearing Shell - Tools
Tools
P90571-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Lifting tool for main bearing shell

Page 2 (2) When referring to this page, please quote Plate P90571 Edition 0001
 Main Bearing - Measuring Tools
Tools Plate
MAN B&W Diesel P90572-0001

When referring to this page, please quote Plate P90572 Edition 0001 Page 1 (2)
Plate
Main Bearing - Measuring Tools
Tools
P90572-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

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
273 Feeler gauge
285 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
559 Spare tip for feeler gauge
560 Spare tip for feeler gauge

Page 2 (2) When referring to this page, please quote Plate P90572 Edition 0001
906 - Control Gear

Documents in this Chapter

106-01 0035 Chain, Data

906-01 0228 Chain
106-02 0028 Chain Tightener, Data
906-02 0227 Chain Tightener
106-03 0011 Camshaft, Data
906-03 0210 Camshaft
106-04 0020 Camshaft Bearing, Data
906-04 0214 Camshaft Bearings
90651 0191 Chain Drive and Camshaft - Panel
90661 0063 Chain Drive and Camshaft - Tools
90662 0045 Camshaft - Hydraulic Tools
90664 0001 Crankshaft - Pin Gauge
90666 0001 Camshaft Coupling - Hydraulic Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Chain 106-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0035
106-1 Chain

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Max. wear of teeth

on 4.5” chain wheel 4.0 mm

D-2 Original length, 4.5” chain

(chain pitch x 10 links) 1143.0 mm

D-3 Max. length, 4.5” chain

(chain pitch x 10 links) 1154.5 mm

D-7 Max. wear of teeth

on 1” chain wheel 0.9 mm

D-8 Original length, 1” chain

(chain pitch x 10 links) 254.0 mm

D-9 Max. length, 1” chain

(chain pitch x 10 links) 256.5 mm

When referring to this page, please quote Data D10601 Edition 0035 Page 1 (2)
MAN B&W Diesel A/S
106-1 Chain
Data

Plate
90651

1227279-9

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10601 Edition 0035
MAN B&W Diesel A/S
 Chains 906-1.1
Checking
Chains
S80MC
0228
Checking
906-1.1

4.
Carry out the inspection as follows:

1. Make a general inspection for loose bolts

and screws.

2. Inspect lube oil pipes for damage, and

check jet nozzles for possible stoppages or
deformations.

3. Examine the rubber track of the guideways

for cracks or other damage.

Replace the guideway if bits have started to

be “plucked out” of the rubber track.

4. Check the teeth of the chain wheels. If ab-

normal wear is found, take a measurement
(see Data).

Measurements are best taken by placing a

short straight-edge over points A and B and
then measuring the distance D-1.
HN906-1.1 204 04

5. If abnormal wear is observed at the bottom

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.

For assessing the measurement results, 5.

contact MAN B&W Diesel.

In most cases, scratches caused by the

side plates of the chain will be found on the
sides of the teeth. Such scratches can gen-
erally be considered normal.
HN906-1.1203 05

When referring to this page, please quote Procedure M90601 Edition 0228 Page 1 (4)
0$1% :'LHVHO$6
906-1.1 Chains
Checking

7. 6. The chains for the camshaft drive are

matched together to ensure an even load
distribution.

To keep such matching chains in their pairs,

the side plates of the outer link nearest to
the assembled link have been marked with
year, month, day and chain number.

Example:

No. 1 order,
840520 1A
840520 1B
(840520 1C, possible 3rd chain)

No. 2 order,
840520 2A
MN906-1.1 226 07

840520 2B
(840520 2C, possible 3rd chain)

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

which indicates the mounting direction.

Check the chains for cracks on possibly de-

fective rollers and side plates.

Check that the chain rollers can run freely

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

It is normal, however, that the rollers get

light, circumferential scratches during the
running-in period. These fine scratches are
of no importance and need not be consid-
ered.

It is recommended that each single link is

checked.

7. Check chain wear by measuring the length

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

If necessary, adjust the chain tightener.

See Procedure 906-2.3.

Page 2 (4) When referring to this page, please quote Procedure M90601 Edition 0228
0$1% :'LHVHO$6
 Chains 906-1.2
Dismantling
Dismantling
906-1.2

It may become necessary to disassemble 1.

the chain if, for instance, cracked rollers or
seizures between pin and bushing have
been discovered during the inspection.
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.

JN906-2.1 205 01
When a new link is fitted in one chain, the
corresponding link in the other chain
must also be renewed.

1. Remove the tension on the chain by loos-

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 bal-
anceweights, continue the turning until the
balanceweights are hanging vertically
downwards, as shown in the sketch.

2. Mount a wire round the link rollers a short

distance from the disassembly point, and
tighten the wire lightly with a tackle.
GN906-1.2 203 02

Protect the link rollers over which the wire

is wrapped.
3.
Note!

If the chain is to be completely removed,

contact MAN B&W Diesel for further
information.

The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.

3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter-
GN906-1.2 203 03

nately tightening the screws on the tool.

When referring to this page, please quote Procedure M90601 Edition 0228 Page 3 (4)
0$1% :'LHVHO$6
906-1.4 Chains
Mounting
Mounting
906-1.4

1. Before assembling the inner and outer

links, clean the pins and bushings.

1. Combine the inner chain link with the outer

chain link and mount the compression tool.

Force the loose side plate of the outer link

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

2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
GN906-1.4 203 01

Repeat this procedure until the chain has

been assembled.

Remove the tackle and wire and adjust the

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

Page 4 (4) When referring to this page, please quote Procedure M90601 Edition 0228
0$1% :'LHVHO$6
 Chain Tightener 106-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0028
106-2 Chain Tightener

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Clearance 0.1 mm

D-2 Tightening angle for nut B 360 °

When referring to this page, please quote Data D10602 Edition 0028 Page 1 (2)
MAN B&W Diesel A/S
106-2 Chain Tightener
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10602 Edition 0028
MAN B&W Diesel A/S
 Chain Tightener 906-2.3
Adjustment
Chain Tightener
K90MC-C
0227
Adjustment
906-2.3

1.
1. To retighten the chains, loosen nuts A, B,
C and D to free the chain tightener bolt. A
B
2. Turn the engine so that the slack part of the
chains is on the same side as the tightener
wheel.

If the engine is equipped with flyweights,

continue turning until the flyweights are
hanging vertically downwards.

3. Tighten nut B on the chain tightener bolt C

until there is a clearance between the shaft D

HG906-2.3 218 01
and the nut as stated in D-1.

Then tighten nut B as stated in D-2 (see

Data).

For chain wear, see Procedure 906-1.1. HM906-2.3 222 02 2.

3. B

D-1
HG906-2.3 218 03

When referring to this page, please quote Procedure M90602 Edition 0227 Page 1 (2)
MAN B&W Diesel A/S
906-2.3 Chain Tightener
Adjustment

4. 4. Tighten nut C hard against the contact face

of the shaft.

Tighten nut D.

Lock nuts C and D with the tab washer.

5. Tighten nut A.

Lock nuts A and B with the tab washer.

The number of times that retightening can

be carried out depends on when the limit for
C scrapping the chain has been reached. See
Data page 106-1.
D
HG906-2.3 218 05

5.

A
HG906-2.3 218 05

Page 2 (2) When referring to this page, please quote Procedure M90602 Edition 0227
MAN B&W Diesel A/S
 Camshaft 106-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC
0011
106-3 Camshaft

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Pin gauge for top dead centre

of crankthrow No. 1
Check measurement 895 mm

D-2 Pin gauge for camshaft

Check measurement 445 mm

D-3 Max. permissible change in

lead angle 2°
corresponding to 5.8 mm

D-2

D-1

When referring to this page, please quote Data D10603 Edition 0011 Page 1 (2)
MAN B&W Diesel A/S
106-3 Camshaft
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10603 Edition 0011
MAN B&W Diesel A/S
 Camshaft 906-3.1
Checking
Camshaft
K90MC
0210
Checking
906-3.1

1.
1. Turn the crankthrow for cylinder 1 to TDC.

Turn in the AHEAD direction to ensure that

the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
See Procedure 906-2.3.

HM906-7.0 56 01
Check the TDC of cylinder 1 against the
mark on the turning wheel.

2. Check the TDC position with the pin gauge 2.

on the crankthrow, D-1.

BG906-7.0 58 02

D-1

When referring to this page, please quote Procedure M90603 Edition 0210 Page 1 (3)
0$1% :'LHVHO$6
906-3.1 Camshaft
Checking

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

tre punch mark, and measure the deviation,
if any, in lead angle.

For max. permissible change, see D-3.

4. Check and, if necessary, adjust the cylinder

D-2 lubricator.
See Procedure 903-2.1.

Check the setting of the starting air distrib-

utor.
See Procedure 907-1.1.

5. When checking the camshaft position, also

check the running surface of the cams.

As the inspection must include the entire

surface of the cam, the cam should be
turned one complete revolution during the
MA906-3.1 210 03

inspection.
D-3
The running surface of the cam must be
completely smooth and bright.

5. 6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a fine carborun-
dum stone. Such light scratches can appear
if the roller guide and the cam are not cor-
rectly aligned.

In the event of heavier scratches or direct

flaking of the material on the running path,
MAN B&W Diesel should be contacted for
KC906-3.0 07 01

further instructions.

6.
MA906-3.1 210 06

Page 2 (3) When referring to this page, please quote Procedure M90603 Edition 0210
0$1% :'LHVHO$6
 Camshaft 906-3.3
Adjustment
Adjustment
906-3.3

1. If the chains prove to be so heavily worn 1.

that the deviation between the measuring
points and the pin gauge has reached the
maximum value D-3 stated in Data, MAN
B&W Diesel should be contacted for further
instructions.

KB906-7.0 72 04
D-3

When referring to this page, please quote Procedure M90603 Edition 0210 Page 3 (3)
0$1% :'LHVHO$6
 Camshaft Bearings 106-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0020
106-4 Camshaft Bearings

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil M20
X Shut off lubricating oil
Lock turbocharger rotors 1x3m
2x1m

Data
Ref. Description Value Unit

D-1 Weight of oil tray 125 kg

D-2 Hydraulic pressure

– dismantling 900-990 bar

D-3 Hydraulic pressure

– tightening 900 bar 2 x 500 kg

D-4 Weight of bearing cap 160 kg

D-5 Max. wear of bearing shell 0.10 mm

When referring to this page, please quote Data D10604 Edition 0020 Page 1 (2)
MAN B&W Diesel A/S
106-4 Camshaft Bearings
Data

Plate
90651

1283689-0

Spare Parts

Plate – Item No. Description Qty

90301-xxxx 226 Gasket 1

90613-xxxx 238 Bearing shell 1
90613-xxxx 322 Gasket 1
90613-xxxx 226 Gasket 1

Page 2 (2) When referring to this page, please quote Data D10604 Edition 0020
MAN B&W Diesel A/S
 Camshaft Bearing 906-4.1
Checking
Camshaft Bearing
K90MC
0214
Checking
906-4.1

1.
1. As the upper shell of the camshaft bearing
assembly has been dispensed with on this
engine, it is no longer necessary to meas-
ure the top clearance of the camshaft bear-
ing.

However, with normal inspection through

the inspection hole in the roller guide hous-
ing, we recommend a visual inspection of
the condition of the shell in the bearing cap
from each side.

Check for wiped-out metal at the bearing

ends, and for fragments of metal in the
camshaft housing.

In the event of any signs of anomalies, the

HC906-5.0 57 01
bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced

If no anomalies are found during the visual

inspection, dismantling need not be carried
out.

When checking the camshaft bearings, it is

recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 908-5 and 909-3.

When referring to this page, please quote Procedure M90604 Edition 0214 Page 1 (5)
0$1% :'LHVHO$6
906-4.2 Camshaft Bearing
Dismantling
Dismantling
906-4.2

1.
Caution!

Before dismantling any camshaft bear-

ings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.

See Procedure 906-2.3.

1. Dismount the oil outlet pipe from the oil tray.

Mount an eye bolt in the cylinder frame be-
hind the oil tray.
HC906-5.0 57 02

Release the sealing flanges on the roller

guide housing, loosening the screws
mounted in the roller guide housing.

2. Remove only the screws in the lower half of

the sealing flange.

2. Attach a wire rope to the eye bolt. Place the

wire rope in the lifting fitting of the oil tray,
hook on a tackle and haul tight.

Remove the screws securing the oil tray to

D-1 the roller guide housing. Ease off the oil
tray, landing it on the platform.

3. Mount lifting fittings on both sides of the

bearing half. Mount grooved pulleys on the
roller guide housing, and hook wire ropes/
HC906-5.0 57 03

tackles on to the lifting fittings/grooved pul-

leys. Tighten up the tackles.

3.
HG906-4.3 201 03

Page 2 (5) When referring to this page, please quote Procedure M90604 Edition 0214
0$1% :'LHVHO$6
 Camshaft Bearing 906-4.2
Dismantling

4. Mount the hydraulic jacks and loosen the 4.

bearing nuts. For use of hydraulic jacks,
see Procedure 913-1.

Remove the hydraulic jacks and dismount

the nuts.

5. Lower the bearing cap and place it on the

platform.

D-2

HG906-4.3 201 04

5.

D-4
HC906-5.0 57 06

When referring to this page, please quote Procedure M90604 Edition 0214 Page 3 (5)
0$1% :'LHVHO$6
906-4.3 Camshaft Bearing
Overhaul
Overhaul
906-4.3

1. 1. For assessment of the bearing condition,

see Volume I OPERATION, Chapter 708
‘Bearings’.

Inspect the entire surface of the bearing

journal for seizures.

If seizures are found on the bearing journal

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

2. By closely examining the sliding surface of

HC906-5.0 57 07

the bearing shell visually, an impression

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

Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.
MA906-4.3 209 02

D-5

Page 4 (5) When referring to this page, please quote Procedure M90604 Edition 0214
0$1% :'LHVHO$6
 Camshaft Bearing 906-4.4
Mounting
Mounting
906-4.4

1. Clean the bearing journal, the bearing sup- 1.

port and the bearing shell.

Mount the bearing shell in the bearing cap,

after coating the shell with oil. Then pull the
bearing cap into place by means of tackles/
wire rope fitted through the grooved pulleys
to the lifting fittings. Check that the guide
pins enter correctly.

2. Mount and tighten up the nuts by means of

the hydraulic tools.
See Data.

HC906-5.0 57 06
Remove the lifting fittings and grooved pul-
leys from the roller guide housing.
D-4
3. Hoist the oil tray into place, positioning it by
means of the guide pins. 2.

Then fasten it to the roller guide housing by

tightening up uniformly all round the cir-
cumference.

Remove the shackle and eye bolt.

Mount the screws that fasten the sealing

flanges to the roller guide housing. Mount
the oil pipe on the oil tray. D-3
HG906-4.3 201 04

3.
HC906-5.0 57 03

D-1
When referring to this page, please quote Procedure M90604 Edition 0214 Page 5 (5)
0$1% :'LHVHO$6
 Chain Drive and Camshaft Panel Plate
P90651-0191
Chain Drive and Camshaft Panel
0191
P90651

When referring to this page, please quote Plate P90651 Edition 0191 Page 1 (2)
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft Panel
P90651-0191

Item Item
Item Description Item Description
No. No.

019 Panel for tools

020 Name plate
044 Face impact wrench for fuel camshaft
056 Chain assembling tool
068 Chain disassembling tool
070 Chain assembling tool
081 Chain disassembling tool
127 Pulley for wire for camshaft bearing
139 Lifting attachment camshaft bearing

Page 2 (2) When referring to this page, please quote Plate P90651 Edition 0191
MAN B&W Diesel A/S
 Chain Drive and Camshaft - Tools
Tools Plate
MAN B&W Diesel P90661-0063

When referring to this page, please quote Plate P90661 Edition 0063 Page 1 (2)
Plate
Chain Drive and Camshaft - Tools
Tools
P90661-0063 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Pin gauge for camshaft

Page 2 (2) When referring to this page, please quote Plate P90661 Edition 0063
 Camshaft - Hydraulic Tools Plate
P90662-0045
Camshaft - Hydraulic Tools
0045
P90662

When referring to this page, please quote Plate P90662 Edition 0045 Page 1 (2)
MAN B&W Diesel A/S
Plate Camshaft - Hydraulic Tools
P90662-0045

Item Item
Item Description Item Description
No. No.

019 Wooden box

020 Jack - hydaulic, complete
032 Support
044 Tommy bar
056 O-ring with back-up ring
068 O-ring with back-up ring
093 Key, hexagon socket screw
115 Hydraulic jack for camshaft bearing,
complete

Page 2 (2) When referring to this page, please quote Plate P90662 Edition 0045
MAN B&W Diesel A/S
 Crankshaft - Pin Gauge Plate
P90664-0001

When referring to this page, please quote Plate P90664 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0001

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 0001
MAN B&W Diesel A/S
 Camshaft Coupling - Hydraulic Tools
Tools Plate
MAN B&W Diesel P90666-0001

When referring to this page, please quote Plate P90666 Edition 0001 Page 1 (2)
Plate
Camshaft Coupling - Hydraulic Tools
Tools
P90666-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Gasket
022 Coupling
034 Sealing ring
046 Screw
058 Flange
071 Nut
083 Coupling

Page 2 (2) When referring to this page, please quote Plate P90666 Edition 0001
907 - Starting Air System

Documents in this Chapter

107-01 0015 Starting Air Distributor, Data

907-01 0210 Starting Air Distributor
107-02 0024 Start Air Valve, Data
907-02 0209 Starting Air Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Starting Air Distributor 107-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0015
107-1 Starting Air Distributor

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X 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 D10701 Edition 0015 Page 1 (2)
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data

Spare Parts

Plate – Item No. Description Qty

90703-xxxx 095 Piston valve slide 1

Page 2 (2) When referring to this page, please quote Data D10701 Edition 0015
MAN B&W Diesel A/S
 Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
0210
Checking
907-1.1

2.
1. Turn the engine to bring the piston of cylin-
der No. 1 to TDC. Check the position with
the pin gauge.
See Procedure 906-3.1.

2. Remove the small end cover of the distrib-

utor housing.

3. Check that the TDC marking scratch on the

starting cam is positioned vertically at the
valve slide of cylinder No. 1.

4. If necessary adjust the position of the start-

HN907-1.1 205 02
ing cam by loosening the centre screw and
turning the starting cam until the TDC
marking scratch is positioned vertically at
the valve slide of cylinder No. 1. Then tight-
en the centre screw.
HN907-1.1 205 03 3.

4.
HN907-1.1 205 04

When referring to this page, please quote Procedure M90701 Edition 0210 Page 1 (5)
0$1% :'LHVHO$6
907-1.3 Starting Air Distributor
Overhaul
Overhaul
907-1.3

2. Difficulties in starting can be caused by the

starting air distributor valve slides “sticking”
(see Volume I, Chapter 703), so that these are
not activated and pressed against the cam dur-
ing the starting procedure.

This can be caused by too high humidity in the

main starting air system, which can result in the
formation of rust, and also by dirt, preventing
the slide valves from functioning.
HN907-1.3 205 02

In both cases it is necessary to clean the valve

slides and the liners in the distributor housing
to remove dirt, rust and foreign particles.
3.
Experience will show how often this is neces-
sary to prevent starting difficulties, as differenc-
es will be found from plant to plant.

1. Blank off the main starting air and the con-

trol air. If this is not possible, lock the main
starting valve in the closed position with a
padlock.

2. Remove all the pipes from the end of the

distributor.

Loosen and remove the screws from the

small and large end covers. Dismount the
end cover which gives access to the slide
valves.
HN907-1.3 205 03

3. Turn the camshaft until the slot in the start-

ing cam is opposite the pin of the valve
slide.

4. 4. Remove the screws and the cap from the

particular valve slide in question.

Remove the guide screw for the valve slide.

HN907-1.3 205 04

Page 2 (5) When referring to this page, please quote Procedure M90701 Edition 0210
0$1% :'LHVHO$6
 Starting Air Distributor 907-1.3
Overhaul

5. Remove the complete slide valve (with 5.

spring and the upper liner) from the distrib-
utor housing by means of a brass mandrel.

6. Press-in the spring and remove the two part

locking ring.

7. Remove the upper spring guide, the spring,

the lower spring guide and the upper liner
from the valve slide.

HN907-1.3 205 05
MC907-2.2 29 06 6.

7.
MC907-2.2 29 07

When referring to this page, please quote Procedure M90701 Edition 0210 Page 3 (5)
0$1% :'LHVHO$6
907-1.3 Starting Air Distributor
Overhaul

9. 8. Clean all the sliding surfaces on the valve

slide. Lubricate all parts with Molybdenum
Disulphide (MoS 2).

Clean the liners and the distributor housing.

Test that the valve slide moves easily in the
liners.

Note!

Polishing with emery cloth or steel wool

must not take place as this will cause
scratching marks on the sliding surfaces
MC907-2.2 29 09

of the piston valve slide or distributor

housing.

9. Place the upper liner, the lower spring

10. guide, the spring and the upper spring
guide over the valve slide.

10. Press-in the spring and mount the two-part

locking ring.

11. Mount the complete slide valve in the dis-

tributor housing by means of a brass man-
drel. (Check that the slot of the starting cam
is opposite the pin of the valve slide, when
mounting).

Lubricate the groove in the starting cam

with Molybdenum Disulphide (MoS 2).
MC907-2.2 29 10

11.
HN907-1.3 205 11

Page 4 (5) When referring to this page, please quote Procedure M90701 Edition 0210
0$1% :'LHVHO$6
 Starting Air Distributor 907-1.3
Overhaul

12. Mount the guide screw for the valve slide. 12.
Mount the cap and the screws on top of the
slide valve.

13. Finally, mount the two end covers and con-

nect the main starting air and the control
air.

HN907-1.3 205 04
HN907-1.3 205 02 13.

When referring to this page, please quote Procedure M90701 Edition 0210 Page 5 (5)
0$1% :'LHVHO$6
 Starting Air Valve 107-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0024
107-2 Starting Air 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

D-1 Weight of starting air valve 72 kg

D-2 Valve tightening angle 60 °

When referring to this page, please quote Data D10702 Edition 0024 Page 1 (2)
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data

Plate
90151

1283711-7

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10702 Edition 0024
MAN B&W Diesel A/S
 Starting Air Valve 907-2.1
Checking
.0&
Starting Air Valve
0209
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 0209 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.

D-1
HG907-2.3 201 02

Page 2 (6) When referring to this page, please quote Procedure M90702 Edition 0209
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.
D-1
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 0209 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 0209
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

D-3
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 0209 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 alternately,

HG907-2.4 201 01

in at least three steps, to an angle of 40°.

Loosen the nuts again and repeat the pro-

cedure to reach the full tightening angle,
see Data.
2.
Mount the control air pipe and turn on start-
ing air and control air.

D-1
HG907-2.4 201 02

3.

D-2
HM901-2.2 114 03

Page 6 (6) When referring to this page, please quote Procedure M90702 Edition 0209
0$1% :'LHVHO$6
908 - Exhaust Valve

Documents in this Chapter

108-01 0036 High-Pressure Pipe, Data

908-01 0216 High-Pressure Pipe
108-02 0067 Exhaust Valve, Data
908-02 0250 Exhaust Valve
108-03 0045 Exhaust Valve Actuator, Data
908-03 0235 Exhaust Valve Actuator
108-04 0035 Exhaust Valve Roller Guide, Data
908-04 0219 Exaust Valve Roller Guide
108-05 0012 Exhaust Valve Cam, Data
908-05 0214 Exhaust Valve Cam
108-07 0031 Exhaust Valve - Special Running, Data
908-07 0227 Exhaust Valve
90851 0196 Exhaust Valve - Panel
90861 0022 Exhaust Valve - Tools
90862 0039 Exhaust Valve - Hydraulic Tools
90863 0015 Exhaust Valve - Extra Tools
90864 0002 Exhaust Valve - Extractor Tool
90865 0002 Exhaust Valve Actuator - Tools

MAN B&W Diesel A/S

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

SAFETY PRECAUTIONS
Special Edition
K90MC-C
D10801
108-1 Data 0036 High-Pressure Pipe

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
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-01 High-pressure pipe, tightening torque 210 Nm

D08-02 Distance of high-pressure pipe lower edge to pressure flange 24 mm
D08-03 High-pressure pipe 105 kg

When referring to this page, please quote Data D10801 Edition 0036 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 high-pressure pipe

Page 2 (2) When referring to this page, please quote Data D10801 Edition 0036
MAN B&W Diesel A/S
 High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
L60MCC
0216
Dismantling
908-1.2

1.
1. When replacing the hydraulic high-pressure
pipe, the exhaust valve or the hydraulic ac-
tuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.

2. Before dismantling the high-pressure pipe,

stop the camshaft oil pump.

Loosen the screws for the high-pressure

pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator.
D08-03

HM908-1.0 48 01

2.
GM908-1.0 55 02

When referring to this page, please quote Procedure M90801 Edition 0216 Page 1 (3)
0$1% :'LHVHO$6
908-1.3 High-Pressure Pipe
Overhaul
Overhaul
908-1.3

1. 1. Check the contact surfaces of the pressure

pipe for marks and, if necessary, grind the
pipe ends by means of the grinding mandrel
and the two guiding tools.

Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and fin-
ish with a fine grinding paste, for example
HM908-1.0 48 03

Carborundum No. 500.

2. After reconditioning the contact surfaces of

the pipe, measure the distance from the
edge of the thrust bushing to the contact
2.
surface at both ends of the pipe. This meas-
urement is to correspond with the value
stated in Data.

Check the thrust pads in the exhaust valve

and the actuator for marks on the sealing
surface.
HM908-1.0 48 04

Replace the O-rings on the thrust pads.

D08-02
If considered necessary, replace the thrust
pads.

Lift the thrust pad free by, for example, us-

ing a screwdriver in the groove of the thrust
pad.

Page 2 (3) When referring to this page, please quote Procedure M90801 Edition 0216
0$1% :'LHVHO$6
 High-Pressure Pipe 908-1.4
Mounting
Mounting
908-1.4

1. Mount the hydraulic high-pressure pipe as 1.

follows:

Position the high-pressure pipe with the

sealing surfaces of the pipe resting on the
thrust pads of the exhaust valve/actuator.
Take care not to damage the O-rings on the
thrust pads.

After fitting the pipe correctly in relation to

the exhaust valve and actuator, tighten up

HM908-1.0 48 05
the screws of the pressure flanges diago-
nally, see Data. D08-01

2. Check the whole system for tightness.

See Procedure 908-3.1. 2.

HM908-1.0 48 04

When referring to this page, please quote Procedure M90801 Edition 0216 Page 3 (3)
0$1% :'LHVHO$6
 Exhaust Valve 108-2
Data

SAFETY PRECAUTIONS
Special Edition
K90MC-C
D10802
108-2 Data 0067 Exhaust Valve

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
X Shut off lubricating oil
X Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-04 Safety valve, opening pressure 21 bar

D08-05 Screws for lifting eye bolt, tightening torque 340 Nm
D08-06 Oil cylinder, tightening torque 340 Nm
D08-07 Safety valve, tightening torque 70 - 100 Nm
D08-09 Bottom piece seat, grinding angle 29.9 - 30.0 °
D08-10 Valve spindle seat, grinding angle 30.7 - 30.8 °
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 12.0 mm
D08-14 Spindle, max. grinding 2.0 mm
D08-15 Spindle stem, measuring area, min. 435 mm
D08-16 Spindle stem, measuring area, max. 610 mm
D08-17 Spindle stem, min. diameter 107.8 mm
D08-18 Bushing max. diameter, top 108.8 mm
D08-19 Bushing max. diameter, bottom 112.0 mm
D08-20 Oil cylinder max. inside diameter 125.2 mm
D08-21 Piston rings, min. thickness 4.7 mm
D08-22 Damper piston, min. distance 51.6 mm
D08-23 Damper piston, max. distance 52.1 mm
D08-24 Exhaust valve, complete 2400 kg
D08-25 Exhaust valve housing 1285 kg
D08-26 Oil cylinder 325 kg
D08-27 Air cylinder 95 kg
D08-28 Spindle 235 kg
D08-29 Bottom piece 300 kg
D08-30 Air piston 30 kg
D13-01 Hydraulic pressure, mounting 900 bar
D13-02 Hydraulic pressure, dismantling 800 - 990 bar

When referring to this page, please quote Data D10802 Edition 0067 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 77 Cone ring for pneumatic piston
P90851 89 Pressure tester for safety valve
P90851 90 Gauge for exhaust valve spindle
P90851 136 Bridge gauge for exhaust valve
P90851 148 Tool for hydraulic piston
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90861 Valve seat and spindle grinder
P90862 Jack-hydraulic, complete
P91351 10 Hydraulic pump, pneumatic operated
P91351 34 Hose with unions (1000 mm), complete
P91351 60 Hose with unions (5000 mm), complete
P91351 117 5-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10802 Edition 0067
MAN B&W Diesel A/S
 Exhaust Valve 908-2.1
Checking
Exhaust Valve
K90MC-C
0250
Checking
908-2.1

1.
Checks during running:

Check of valve spindle rotation

1. The engine must run when the valve func-

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

During rotation of the valve spindle, the top

position of the indicator will change about 6
mm, see the sketch.

During engine operation, the spindle must

NB908-2.1 229 01
rotate in the range of 0.5 to 5 rpm. The ro-
tation can vary with unit and engine load. In
the event of no rotation, attention should be
paid to avoid seat problems. On Surface In Groove

When check of the valve rotation is fin- 2.

ished, lift the rotation indicator and lock it in
the top position.

Note!

The indicator must not be in constant

operation.

Check of sealing oil unit

2. Check that the injection indicator moves

NA908-2.1 238 02

regularly with the valve opening. Alterna-

tively, unscrew the sealing oil pipe, and
check that oil is coming out (very small
quantity).
3.
Check of bottom piece sealings

3. When the exhaust valve is mounted in the

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 ex-
haust valve housing by ensuring that water
does not flow from the small bore on the
manoeuvring side of the exhaust valve.
NA908-2.1 214 02

If water does flow from the bore, the ex-

haust valve must be dismounted and the
sealing rings replaced.

When referring to this page, please quote Procedure M90802 Edition 0250 Page 1 (24)
MAN B&W Diesel A/S
908-2.1 Exhaust Valve
Checking

4. Checks with stopped engine:

Check of air sealings

4. Mount the adaptor tool on the non-return

valve for air spring.

Connect compressed air to the air cylinder

to close the valve.

5. Engage the rotation indicator:

• After shutting-off the compressed air

supply and releasing the air through the
NB908-2.4 238 02

non-return valve on the control unit, the

exhaust valve should open.

Hint!
5.
Use a small screwdriver to press the ball
into the non-return valve, and cover it
with a rag to catch the oil drops.

• After doing this a couple of times, leave

the valve closed and shut-off the com-
pressed air. The valve should remain
closed for at least 15 minutes.

• If the valve opens within 15 minutes, the

complete exhaust valve should be
replaced by a new one, see Procedure
908-2.2.

For overhaul of the exhaust valve, see

Procedure 908-2.3.

Disengage the rotating indicator.

NA908-2.1 238 05

Closed Valve Open Valve

Page 2 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.2
Dismantling
Dismantling
908-2.2

1. Close the cooling water inlet and outlet, and 1.

drain the exhaust valve.

Dismount the high-pressure pipe for the hy-

draulic valve actuation.
See Procedure 908-1.2.

Disconnect the cooling water outlet pipe

from the exhaust valve.

Dismount the return oil pipe from the ex-

haust valve.

Close the air supply to the exhaust valve.

2. Dismount the air pipe for pneumatic closing

of the exhaust valve.

Mount the adaptor tool on the non-return MB908-2.2 226 01

valve for air spring. The adaptor tool is

found on the tool panel.

3. Connect 7 bar working air to the coupling 2.

assembly, thereby keeping the valve closed
when it is removed from the engine.
NA908-2.2 238 02

3.
NA908-2.4 238 02

When referring to this page, please quote Procedure M90802 Edition 0250 Page 3 (24)
MAN B&W Diesel A/S
908-2.2 Exhaust Valve
Dismantling

4. 4. Remove the plate jacket with insulation

from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the exhaust valve.

5. Remove the protective caps from the ex-

haust valve studs, and mount the four hy-
draulic jacks.

Connect the high-pressure pump to the

jacks by means of the distributor block and
four high-pressure hoses.
MB908-2.2 226 03

Bleed the hydraulic system and raise the

pressure as stated in Data. Then loosen
and remove the nuts.
5. See Procedure 913-1.

D13-02 6. Attach the crane to the eye bolt fitted on top

of the valve and lift the exhaust valve away.

Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
ing and sealing surfaces of the bore, if re-
quired.
See Procedure 901-1.3.

For overhaul of the exhaust valve, see Pro-

cedure 908-2.3.
MB908-2.2 226 04

7.

D08-24
908-2.2 243 06

Page 4 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul
Overhaul
908-2.3

1. Place the exhaust valve on a wooden sup- 1.

port on the platform.

Remove the eight nuts and the safety

strap from the oil cylinder.
Remove the sealing oil pipe. D08-26

Lift away and place the oil cylinder on a

wooden support.

Remove and discard the O-ring from the air

cylinder.

NA908-2.3 238 01
2. Dismount and inspect the O-rings and the
thrust piece of the hydraulic high-pressure
pipe for marks.

Dismantle the thrust piece. Remove and

discard the O-ring. 2.

Check the exhaust valve rotation indicator.

3. Loosen the screws and remove the lifting

bracket from the oil cylinder to gain access
to the orifice plug.
Remove the sealing oil unit.

Remove and discard the gasket.

Unscrew and clean the orifice plug.
Remove and discard the sealing disc.
NA908-2.3 238 02

Check and clean the bore for the orifice

plug in the top of the oil cylinder.

3.
KB908-2.3 242 04

When referring to this page, please quote Procedure M90802 Edition 0250 Page 5 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

4. 4. Sealing oil control unit:

Normally overhaul of the sealing oil unit

should not be necessary.

Check the unit according to Procedure 908-

2.1.

Before remounting the unit, carefully clean

it on the machined faces.
GN908-2.3 236 05

If the unit needs to be overhauled, send it

to an authorised MAN B&W repair work-
shop.

5. Place the oil cylinder in a horizontal posi-

5. D08-20 tion.

Remove the flange and take out the piston.

6. Inspect the bore of the oil cylinder for scor-

ing and check its measurements. See Data.

If the diameter of the bore exceeds the val-

ue stated in Data, send the oil cylinder to
908-2.3 250 05

an MAN B&W authorized workshop for re-

pair.

Page 6 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

7. Relieve the air pressure through the non-re- 7.

turn valve from below the piston. Use a
small screwdriver to press the ball into the
non-return valve. Cover the non-return
valve with a rag to catch the oil drops.

Remove the four screws from the flange on

top of the air piston and dismount the
flange.

Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring.

8. Mount four eye bolts and wire ropes as

shown in the sketch and lift the valve hous-
ing clear of the valve spindle.

GN908-2.3 236 07
Take care – when the internal O-ring in the
air piston and the internal rings for the seal-
ing arrangement at the bottom of the air cyl-
inder pass the groove for the conical ring at 8.
the top of the spindle.

D08-25

D08-28
908-2.3 243 08

When referring to this page, please quote Procedure M90802 Edition 0250 Page 7 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

9. 9. Unscrew and remove the lock screws which

retain the bottom piece. Lift the valve hous-
ing approx. 10 mm.

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.

D08-29
MB908-2.3 243 09

Page 8 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

Bottom piece: 10. D08-12

10. 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 cir-
cumference of the bottom piece seating.

Small dent marks in the bottom piece

seating are acceptable and need not be
ground away, provided that the dent
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
exhaust gas receiver.
MB908-2.3 230 12

For further evaluation of the bottom piece G2 D08-11

seating, see also chapter 707 in the
instruction book, Volume I, Operation.

Take measurements G 2 and G3, using a

feeler gauge. Compare the results with the
figures stated in Data D08-11 and D08-12.

IF burn marks are visible on the bottom

piece seating OR G3 does not equal D08-
12, THEN the bottom piece seat must be
ground.

IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN the bottom
piece seating must be discarded and re-
placed with a new bottom piece. Further
grinding or reconditioning is not recom-
mended.

When referring to this page, please quote Procedure M90802 Edition 0250 Page 9 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

11. 11. If it is necessary to grind the seating, pro-

ceed as follows:

Before placing the bottom piece on the

grinding machine, turn the grinding head
away from the grinding table.
D08-09
Mount and secure the bottom piece in the
grinding machine. Using a dial gauge,
check that the bottom piece is correctly
centered.

Adjust the grinding head to achieve the cor-

MB908-2.3 230 11

rect grinding angle as stated in Data.

Note!

12. As the grinding angle is very important

for the correct operation of the exhaust
valve, make absolutely sure that the
grinding head is correctly adjusted.
G3
Regarding the use of the grinding machine,
see separate instructions from the grinding
machine manufacturer.

12. During the grinding, use the bottom piece

template frequently to ensure that maxi-
mum grinding is not exceeded.

After grinding, inspect the bottom piece

seating again, using a feeler gauge and the
bottom piece template, to measure how
much material has been ground away.
MB908-2.3 230 12

Grind the recess so that gap G3 equals

G2 D08-12 as stated on the Data sheet.

13. After grinding the inside seating of the bot-

13.
tom piece, grind the outside seating using
carborundum 200 and the special grinding
tool.

Note!

Turn the special grinding tool by hand,

alternately turning clockwise and anti-
clockwise.
MB908-2.3 233 13

Grind until a smooth surface is achieved.

Clean the bottom piece.

Page 10 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

Valve spindle 14.

14. When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.

15. Inspect the seating of the valve spindle for

burn marks.

Check the burn-off F1 of the valve spindle D08-28

NA908-2.3 209 14
by measuring along the spindle template
from point A to point D and in point E.

Note! 15.

Before using the spindle template, thor-

oughly clean the contact faces on the
valve spindle with a steel brush.

All measurements should be taken at four

diametrically opposite points on the cir-
cumference of the valve spindle. Make
sure that the most burned-off point is
measured.

Small dent marks in the valve spindle F-1

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
MA908-2.3 213 12

exhaust gas receiver.

A E
For further evaluation of the valve spindle D
seating, see also Chapter 707 in the
instruction book, Volume I, Operation.
16.
16. Measure the gap G 1 between the spindle
template and the seating of the spindle.
G-1
17. IF burn marks are visible on the seating,
the spindle must be ground.

IF gap G1 exceeds the maximum allowable

value D08-14, see Data, OR the burn-off F1
exceeds the maximum allowable burn-off
D08-13, the spindle must not be ground. In-
stead the spindle must be reconditioned.
HC908-2.0 117 11

Contact MAN B&W Diesel for advice on re-

conditioning.

When referring to this page, please quote Procedure M90802 Edition 0250 Page 11 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

18. 18. Mount and secure the spindle in the grind-

ing machine. Using a dial gauge, check that
the spindle is correctly centered.

Adjust the grinding head to achieve the cor-

rect grinding angle as stated in Data.

Note!
D08-10
As the grinding angle is very important to
the operation of the exhaust valve, make
absolutely sure to adjust the grinding
head correctly.
GM908-2.0 119 14

Regarding the use of the grinding machine,

see separate instructions from the grinding
machine manufacturer.
19.
During grinding, measure gap G 1 frequent-
ly. The max. grinding of the spindle, see
D08-15 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
D08-16 D08-17 advice on reconditioning.

Clean the spindle.

19. Check the spindle stem for wear in the area

D08-15 to D08-16, measured from the top
of the spindle.

If the stem diameter is less than stated in

Data, or the hard facing layer is worn away,
contact MAN B&W Diesel for advice.
JM908-2.0 92 12

Page 12 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

20. Dismount the air piston from the air cylin- 20.
der, and check the teflon guide ring and te- D08-30
flon sealing ring for wear.

Dismount the non-return valve from the air

cylinder/valve housing.

Mount two eye bolts in the air cylinder and D08-27

dismount the air cylinder.

Remove and discard the O-ring on the air

cylinder.

Clean the air cylinder and check the run-

ning surface for wear or possible scores.

21. Remove the protective cap from the safety

valve mounted near the bottom of the air
cylinder and dismount the safety valve from 908-2.3 243 20

the air cylinder.

Place the safety valve in the pressure test-

ing device.
21.
Connect the testing device with the high-
pressure pump by means of a hose.

Check the opening pressure, see Data.

If the opening pressure is not correct, loos-

en the lock nut and, using a screwdriver,
adjust the safety valve until the correct D08-04
pressure is indicated.
NB908-2.3 229 21

Tighten the lock nut and test the opening

pressure once more.

22. Unscrew and clean the banjo coupling for

sealing oil to the spindle stem bushing.
22.
Check the non-return valve with com- Air
pressed air.

Blow through all bores in the air cylinder.

Clean the bottom of the air cylinder for pos-

sible coke. Remount the banjo coupling.

Mount a new O-ring in the groove on the

outside of the air cylinder.
908-2.3 243 22

When referring to this page, please quote Procedure M90802 Edition 0250 Page 13 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

23. 23. Mount a new gasket and a new O-ring on

the safety valve.

Mount the safety valve in the bore near the

bottom of the air cylinder.

When mounting the safety valve in the air

cylinder, use only the machined faces on
the valve housing and tighten, see Data.

Finally, mount the protective cap.

D08-07
NB908-2.3 209 22

24. Remove and discard all the O-rings and the

inside sealing ring.

24.
GN908-2.3 236 24

Page 14 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

25. Inspect the bushing in the spindle guide for 25.

wear and measure the top and bottom di-
ameters. See Data.

26. If it proves necessary to replace the bush-

ing, remove the screws and knock out the
bushing with a hammer and a suitable man-
drel.
D08-18
Alternatively, if the extractor tool is availa-
ble, mount the extractor tool and pull up the
bushing.
D08-19
The extractor tool is optional, and can be
ordered as a sparepart.

GN908-2.3 236 25

26.
HM908-2.3 247 26

When referring to this page, please quote Procedure M90802 Edition 0250 Page 15 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

27. 27. Mount a new bushing.

Mount and tighten the screws.

Mount the O-rings and sealing ring on the

stuffing box.

Note!

Make sure to mount the sealing ring cor-

rectly, see the sketch.
HM908-2.3 247 27

28. Mount two new O-rings in the grooves in

the bottom piece.

Land the exhaust valve housing on the bot-

28. tom piece.

29. Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.

Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
908-2.3 243 28

29.
MB908-2.3 233 28

Page 16 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

30. Lubricate the O-rings. 30.

Carefully land the air cylinder on the ex-

haust valve housing.

Note!

Take care not to damage the O-rings on

the outside of the stuffing box.

31. If it is necessary to replace the sealing

rings on the air piston, cut them and re-
move them.

Be careful not to damage the edges of

the ring grooves in the piston.

Mount the new O-rings in the grooves of the

air piston.
MB908-2.3 233 29

Note!

Before mounting, heat the new teflon

rings in 100°C hot water for at least five 31.
minutes.

When mounting the teflon rings, be care-

ful not to damage the running surfaces.

After mounting, compress the teflon rings

by means of the conical ring. This is done
by pressing the air piston through the con-
ical ring.

32. Fill the groove on top of the flange and the

lower part of the air cylinder with clean lu-
bricating oil (approx. 0.5 litre).
MB908-2.0 90 15

32.
GN908-2.3 236 32

When referring to this page, please quote Procedure M90802 Edition 0250 Page 17 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

33. 33. Fit the conical guide ring for the air piston
on the air cylinder.

Lubricate the guide ring and the running

surface of the air cylinder.

Lower the air piston over the valve spindle

down into the air cylinder.

Note!

To avoid damage, take great care when

the internal sealing ring in the air piston
passes the groove for the conical locking
ring.
NB908-2.3 229 33

Remove the conical guide ring from the air

cylinder.

34. Mount the two part conical locking ring and

apply compressed air below the air piston
34. through the non-return valve to lift the pis-
ton.

Mount the flange on top of the air piston

and, by means of the four screws, tighten
the air piston and the flange together.

For correct securing, see Procedure 913-7.

35. Remove the piston rings from the oil piston

and check them for wear.

Compressed air If the thickness of the rings has worn down

to the minimum, see Data, discard the rings
GN908-2.3 236 34

and mount new ones.

Check that the TOP mark on the piston

rings faces upwards, when mounting.

35.
BG908-2.0 99 22

D08-21

Page 18 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

36. Mount the piston on top of the spindle and 36.

check the mesh of the damper piston by
checking the height of the damper relative
to the oil cylinder.

Connect compressed air supply to the

space below the air piston, so as to keep
the valve closed, and to keep the air cylin-
der in close contact with the valve housing.

Place the measuring tool on the air cylinder

across the piston.

37. Check the mesh of the damper piston by

NB908-2.3 226 33
checking the distance from the upper edge
of the crossbar to the top of the damper pis-
ton. See Data.

If the measurement is outside the value

stated in Data, an adjustment must be 37. D08-23
made by changing the disc in the damper
piston as follows: D08-22

38. Place the piston in the special tool.

Press out the disc with the centre screw.

If necessary, replace also the spring and

the piston.
NB908-2.3 226 34

38.
MA908-2.0 103 25

When referring to this page, please quote Procedure M90802 Edition 0250 Page 19 (24)
MAN B&W Diesel A/S
908-2.3 Exhaust Valve
Overhaul

39. 39. Assemble the damper piston with the new

disc in the special tool.

Place the piston upside down in the tool

and press the disc into place in the piston.

Check the mesh once more.

40. Mount the piston and the flange in the oil

cylinder. Mount the screws and tighten.

41. Return the oil cylinder to an upright posi-

tion.
S8211427.WPG

Mount a new sealing disc in the bore for the

orifice plug. Screw the orifice plug into the
bore.

40. Place a new gasket on top of the oil cylin-

der.
Mount the sealing oil unit.

Mount the lifting bracket on the oil cylinder.

Mount the screws and tighten to the torque

stated in Data.
MB908-2.3 245 05

41.

D08-05

D-13
NA908-2.3 248 42

Page 20 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.3
Overhaul

42. Mount a new O-ring on the thrust piece. 42.

Mount the thrust piece in the oil cylinder.

43. Mount the overhauled oil cylinder on top of

the air cylinder.

Mount the safety strap and tighten the nuts.

See Data.

44. Mount the sealing oil pipe.

908-2.3 243 42 43.

D08-06
908-2.3 243 43

44.
NA908-2.3 238 45

When referring to this page, please quote Procedure M90802 Edition 0250 Page 21 (24)
MAN B&W Diesel A/S
908-2.4 Exhaust Valve
Mounting
Mounting
908-2.4

1. Check before mounting

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. Mount the adaptor tool on the non-return

valve for air spring.

Connect compressed air to the air cylinder

to close the valve:

G3 • Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3, to
ensure that there is a clearance between
the outer parts of the seating faces of
908-2.4 243 01

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, the exhaust valve
should open.

Hint!

Use a small screwdriver to press the ball

into the non-return valve, and cover it
with a rag to catch the oil drops.

• After doing this a couple of times, leave

the valve closed, and shut-off the com-
NA908-2.4 238 02

pressed air.
Compressed
air If the exhaust valve opens within 15 min-
utes, check for air leakages around the air
spring.

Check:

• Air piston sealing (air coming out of drain

oil hole)

• Stem sealing (air coming out along spin-

dle stem in exhaust gas duct)

Page 22 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve 908-2.4
Mounting

3. 3.
Note!

Before mounting the valve on the engine,

connect 7 bar working air to the air cylin-
der to keep the exhaust valve closed dur-
ing the mounting process.
Use the special coupling tool.

Mount a new O-ring on the bottom piece

and on the bottom of the exhaust valve Compressed air
housing.

Lubricate the O-rings with vaseline and the

threads of the studs with anti-seizure paste.
Anti seizure
paste
Position the valve in the cylinder cover
bore, guiding it in accordance with the ex-
haust flanges and the guide pin on the ex-
Vaseline
haust side of the exhaust valve.
NA908-2.4 238 03

4. Mount the nuts and the hydraulic jacks.

Raise the pressure to the value indicated in
Data and tighten the nuts.

For use of the hydraulic jacks, see also 4.

Procedure 913-1.
D13-01
Relieve the system of pressure, remove the
hydraulic jacks and high-pressure hoses,
and fit the protective caps.
MB908-2.2 226 04

When referring to this page, please quote Procedure M90802 Edition 0250 Page 23 (24)
MAN B&W Diesel A/S
908-2.4 Exhaust Valve
Mounting

5. 5. Connect the intermediate pipe to the ex-

haust valve.

Mount and tighten the screws.

Attach the insulation jacket.

6. Mount the cooling water outlet pipe on the

exhaust valve.

Mount the high-pressure pipe and the re-

turn oil pipe, see Procedure 908-1.4.

Mount the air pipe for the air spring.

MB908-2.4 226 03

Open the lub. oil supply and the cooling wa-

ter supply to the exhaust valve.

Disconnect the compressed air and con-

nect the normal air supply.
6.

Caution!

The air supply to the exhaust valve must

always be connected before turning on
the oil supply to the exhaust valve actua-
tor.

7. Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908-1.1.
NA908-2.4 238 06

Page 24 (24) When referring to this page, please quote Procedure M90802 Edition 0250
MAN B&W Diesel A/S
 Exhaust Valve Actuator 108-3
Data

SAFETY PRECAUTIONS
Special Edition
K90MC-C
D10803
108-3 Data 0045 Exhaust Valve Actuator

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-20 Oil cylinder max. inside diameter 125.2 mm

D08-21 Piston rings, min. thickness 4.7 mm
D08-32 Hydraulic actuator, tightening torque 2100 Nm
D08-33 Locking plate, tightening torque 90 Nm
D08-34 Hydraulic actuator, tightening angle 100/27 Nm/°
D08-35 Hydraulic actuator 295 kg

When referring to this page, please quote Data D10803 Edition 0045 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

P90865 Exhaust valve actuator – tools

Page 2 (2) When referring to this page, please quote Data D10803 Edition 0045
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.1
Checking
Exhaust Valve Actuator
K90MC-C
0235
Checking
908-3.1

1. A
1. Non-return Valves:
The non-return valves A are built into the oil
inlet pipe to the actuator.

To check the valves, dismantle and clean

them and connect a supply of working air (7
bar) to the outlet side of the valve (the side
facing the actuator). If the air flow can be
felt at the inlet side of a valve, the valve
must be overhauled.

MB908-3.1 235 01

When referring to this page, please quote Procedure M90803 Edition 0235 Page 1 (7)
MAN B&W Diesel A/S
908-3.2 Exhaust Valve Actuator
Dismantling
Dismantling
908-3.2

1. 1. Stop the engine and shut off the oil supply.

Turn the camshaft so that the roller rests on

the circular part of the cam.

Remove the inspection cover of the roller

guide housing to check the position of the
exhaust cam.

Dismount the oil inlet pipes and the drain

pipe from the exhaust valve.

Dismantle the high-pressure pipe and the

MA908-3.2 235 01

sealing disc. Remove and discard the O-

rings on the sealing disc.
See Procedure 908-1.2.

2. Release the mountings for the indicator

3. drive from the actuator housing.

3. Screw the extension stud of the spring com-

pression tool into the top of the actuator
piston, and mount the rest of the spring
compression tool on the actuator housing.

4. Turn the spindle of the spring compression

tool anti-clockwise to compress the actua-
tor spring. For convenience, a pneumatic
impact spanner may be used for turning the
spindle.
MB908-3.2 235 03

4.
MB908-3.2 235 04

Page 2 (7) When referring to this page, please quote Procedure M90803 Edition 0235
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.2
Dismantling

5. Loosen and remove the four nuts on the ac- 5.

tuator housing.

6. Turn the spindle of the spring compression

tool clockwise to release the actuator
spring.

Note!

When releasing the spring, the actuator

housing will move upwards.

MB908-3.2 235 05
Remove the spring compression tool.

7. If the compression tool is not available, un-

screw the two nuts on the short studs.

Release the springs by unscrewing the two 8.

nuts on the long studs.
D08-35
8. Fit eye bolts in the lifting holes of the actu-
ator housing, and hook on tackles and a lift-
ing wire rope.

Using the engine room crane, lift away the

actuator housing.

Remove the spring.

9. Remove the locking plate, and turn the pis-

ton 90° to release it from the bayonet joint.
MB908-3.2 235 08

Remove the piston from the roller guide.

Overhaul the actuator housing and the pis-

ton as required. 9.
See Procedure 908-3.3 .
HM908-3.0 70 03

When referring to this page, please quote Procedure M90803 Edition 0235 Page 3 (7)
MAN B&W Diesel A/S
908-3.3 Exhaust Valve Actuator
Overhaul
Overhaul
908-3.3

1. 1. Clean the piston in kerosene and wipe dry

D08-21
with a clean piece of cloth.

Take off the piston rings and check them for

wear. If the ring thickness has worn down
to the minimum (see Data) , discard the
rings and mount new ones.

Check that the TOP mark on the piston

rings faces upwards when mounting.

2. Inspect the sliding surfaces of the piston to

ensure that there are no scratch-marks or
seizure marks.
HM908-3.0 69 04

Page 4 (7) When referring to this page, please quote Procedure M90803 Edition 0235
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.3
Overhaul

3. Tilt the actuator to a horizontal position. 3.

D08-20
4. Clean the oil cylinder and inspect the bores
for deposits.

Check the bore of the oil cylinder for possi-

ble scores and measure it for wear.
See Data.

5. If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised work-
shop for reconditioning.

MN908-3.3 230 07

When referring to this page, please quote Procedure M90803 Edition 0235 Page 5 (7)
MAN B&W Diesel A/S
908-3.4 Exhaust Valve Actuator
Mounting
Mounting
908-3.4

1. 1. Mount the actuator piston in the roller guide

and turn 90° to lock it in the bayonet joint.

Mount the locking plate and tighten as stat-

ed in Data. Lubricate the piston with plenty
D08-33 of camshaft lubricating oil.

2. Mount the spring on the roller guide. Care-

fully lower the actuator housing on to the
piston, taking care not to damage the piston
rings or the threads of the studs.

3. Screw the extension stud of the spring com-

pression tool into the top of the actuator
KC908-3.0 76 05

piston and mount the rest of the spring

compression tool on the actuator housing.

2.

D08-35
MB908-3.2 235 08

3.
MB908-3.4 235 03

Page 6 (7) When referring to this page, please quote Procedure M90803 Edition 0235
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.4
Mounting

4. Turn the spindle of the spring compression 4.

tool anti-clockwise to compress the actua-
tor spring and to lower the actuator housing
on to the roller guide bushing. For conven-
ience, a pneumatic impact spanner may be
used for turning the spindle.
D08-32
5. Alternatively, if the compression tool is not or
available, screw down the actuator and
compress the springs with two nuts on the D08-34
long studs diagonally.

6. Screw the nuts on to the studs. Tighten the

MB908-3.2 235 05
nuts diagonally to the specification.
See Data.

7. Remove the spring compression tool.

8. Mount the oil inlet pipes and the drain pipe 7.

from the exhaust valve.

Mount the hydraulic high pressure pipe and

the sealing disc fitted with new O-rings.
See Procedure 908-1.4.
MB908-3.2 235 03

8.
MA908-3.2 235 01

When referring to this page, please quote Procedure M90803 Edition 0235 Page 7 (7)
MAN B&W Diesel A/S
 Exhaust Valve Roller Guide 108-4
Data

SAFETY PRECAUTIONS
Special Edition
K90MC-C
D10804
108-4 Data 0035 Exhaust Valve Roller Guide

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-36 Bushing/shaft pin, max. clearance 0.5 mm

D08-38 Roller guide, complete 170 kg

When referring to this page, please quote Data D10804 Edition 0035 Page 1 (2)
MAN B&W Diesel A/S
108-4 Exhaust Valve Roller Guide
Data

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

Plate Item No. Description

P90851 173 Lifting tool for exhaust valve roller guide

Page 2 (2) When referring to this page, please quote Data D10804 Edition 0035
MAN B&W Diesel A/S
 Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valve Roller Guide
K90MC-C
0219
Checking
908-4.1

2.
1. The exhaust valve roller guide can be par-
tially checked while mounted on the engine,
using the following procedure:

Lift the roller guide.

See Procedure 908-7.

2. Remove the camshaft inspection cover.

Turn the engine to provide the maximum

space between the roller guide and the cam
disc.

HG908-4.1 201 01
Check the movability of the roller by turning
this by hand to ascertain if the roller moves
freely and without unnecessary resistance
or “hard” points.

Also inspect the surface of the roller for 3.

possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide hous-
D08-36
ing.

Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.

A more suitable and reliable method is to

check the roller guide and the bearing
clearance when the roller guide is dis-
mounted.
For dismantling of the roller guide, see Pro-
cedure 908-4.2.

3. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
KC908-4.0 57 05

scratches.

4. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.

5. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance directly on the dial.

When referring to this page, please quote Procedure M90804 Edition 0219 Page 1 (4)
MAN B&W Diesel A/S
908-4.2 Exhaust Valve Roller Guide
Dismantling
Dismantling
908-4.2

1. 1. Dismantle the hydraulic actuator above the

exhaust valve roller guide.
See Procedure 908-3.2.

2. Mount the roller guide lifting tool as follows:

• Lift the lock ring of the tool up on the

shaft of the tool.

• Place the tool in such a manner that its

foot rests on the thrust piece in the bayo-
net joint of the roller guide.

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock ring, thereby securing the

foot in the locked position.

Lift the roller guide out of the roller guide

housing, using the crane. Take care not to
damage the sliding surfaces of the roller
guide when lifting.
MA908-3.2 213 02

2.

D08-38
HM908-4.0 51 02

Page 2 (4) When referring to this page, please quote Procedure M90804 Edition 0219
MAN B&W Diesel A/S
 Exhaust Valve Roller Guide 908-4.3
Overhaul
Overhaul
908-4.3

1. Inspect and check the exhaust valve roller 1.

guide.
See Procedure 908-4.1.

2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if

• irregularities when turning the roller,

• damage to the roller,

• larger clearance than stated on the Data

sheet,

• seizure marks on the slide surfaces,

have been observed during the checking of

the roller guide.

Note!

For disassembling of the roller guide,

GM908-4.0 73 05

contact an MAN B&W authorized repair

shop.

3. If no irregularities are found, just clean and

lubricate the roller guide before remounting
it in the roller guide bushing.

When referring to this page, please quote Procedure M90804 Edition 0219 Page 3 (4)
MAN B&W Diesel A/S
908-4.4 Exhaust Valve Roller Guide
Mounting
Mounting
908-4.4

1. 1. Mount the lifting tool for the roller guide as

follows:

• Lift the lock ring of the tool up on the

shaft of the tool.

• Place the tool in such a manner that its

foot rests on the thrust piece in the bayo-
net joint of the roller guide.

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock ring, thereby securing the

foot in the locked position.

Lubricate the sliding surfaces of the roller

and the roller guide, and lower it carefully
into the roller guide bushing.

Remove the lifting tool.

2. When mounting the roller guide, check the

HM908-4.0 51 02

clearance between the roller guide and the

guide plate mounted in the roller guide lin-
er.

2. Turn the camshaft so that the roller guide is

lifted approx. 20 mm. Check that the clear-
ance between the roller guide and the guide
plate should be the same at both sides
±0.1 mm.

3. Mount the actuator.

See Procedure 908-3.4.
HM908-4.0 51 10

Page 4 (4) When referring to this page, please quote Procedure M90804 Edition 0219
MAN B&W Diesel A/S
 Exhaust Valve Cam 108-5
Data

SAFETY PRECAUTIONS
Special
D10805 Data 0012
108-5 Edition Exhaust
S90MC-C
Valve Cam

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D08-39 Check lifting height 17 mm

When referring to this page, please quote Data D10805 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
Data

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

Plate Item No. Description

Page 2 (2) When referring to this page, please quote Data D10805 Edition 0012
MAN B&W Diesel A/S
 Exhaust Valve Cam 908-5.1
Checking
Exhaust Valve Cam
S42MC
0214
Checking
908-5.1

1.
1. Turn the crankthrow of the cylinder con-
cerned to TDC. Check and note down the
angle indicated on the turning wheel.

2. Turn in AHEAD direction until the roller guide

HM906-7.0 56 01
(measured on the activator plunger) is lifted
corresponding to D08-39, and calculate the
angle A, which is the number of degrees
the crankthrow has turned from TDC posi-
tion to the present position. For D08-39, 2.
see Data.

Continue turning AHEAD until the roller

guide (measured on the activator plunger)
is lifted to distance D08-39, and calculate
the angle B, which is the number of de-
grees the crankthrow has turned from TDC
position to the present position.
D08-39
17
17 mm

Note!

When calculating the angles A and B,

remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees.
17 mm
HM908-7.0 25 1/1

3. Calculate the lead angle as: D08-39

180° – A° + B°
2

The illustration shows the position of the 4.

exhaust cam when the piston of the rele-
vant cylinder is in TDC.

See the Adjustment Sheet in Volume I, OP-

ERATION, Chapter 701, for the "lead an-
gle" of the plant in question.

4. The cam lead angle can be checked visu-

ally by reading directly the scale position of
the exhaust cam over the marking scratch
on the camshaft and comparing this angle
with the angle stated in the Adjustment
Sheet.

At the same time, it is recommended to

check the position of the camshaft with the
pin gauge. See Procedure 906-3.1.
HM908-7.0 25 1/1

When referring to this page, please quote Procedure M90805 Edition 0214 Page 1 (1)
0$1% :'LHVHO$6
 Exhaust Valve 108-7
Data

SAFETY PRECAUTIONS
Special Edition
S42MC
D10807
108-7 Data 0031 Exhaust Valve

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10807 Edition 0031 Page 1 (2)
MAN B&W Diesel A/S
108-7 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 124 Tool for emergency open exhaust valve

P90851 173 Lifting tool for exhaust valve roller guide

Page 2 (2) When referring to this page, please quote Data D10807 Edition 0031
MAN B&W Diesel A/S
 Exhaust Valve 908-7
Special Running
Exhaust Valve
K90MC-C
0227
Special Running
908-7

3.
Warning!

Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.

Engine trouble might require that a cylinder be

taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,

MB908-7.0 221 03
Section 704.

This can take place with the exhaust valve

locked in either the open or the closed position.
Either way, carry out the following procedure:
4.
1. Stop the engine.

Stop the lubricating oil pump.

Lift the relevant fuel pump roller guide.

See Procedure 909-10.1.

2. Dismantle the hydraulic high-pressure pipe

and the connecting sleeve.
See Procedure 908-1.2.

3. Dismantle the non-return valves on the oil

HG908-4.1 201 01

inlet pipes. Loosen the union nuts in the

bottom of the oil pipes and turn the pipes
to one side. Mount the non-return valves on
the oil pipes and blank off the non-return
valves with the plugs from tool panel 908.
5.
4. Remove the inspection cover of the cam-
shaft housing. Turn the engine until the ex-
haust roller guide is at TDC.

5. Position the lifting tool on the actuator and

screw the spindle into the top of the actua-
tor piston.

Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible.

Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position.
MN908-7 227 05

When referring to this page, please quote Procedure M90807 Edition 0227 Page 1 (3)
MAN B&W Diesel A/S
908-7 Exhaust Valve
Special Running

7. 6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.

If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:

7. Shut off the compressed air supply and re-

move the air pipe connection to the exhaust
valve.

Release the air from the air spring through

the non-return valve on the side of the air
cylinder.

Hint!

Use a small screwdriver to press the ball

GN908-2.2 236 05

into the non-return valve, and cover it

with a rag to catch the oil drops.

8. Dismantle the rotation indicator on the air

cylinder and mount the tool for opening of
8.
the exhaust valve.

The tool will keep the piston of the air cyl-

inder in the bottom position and thus keep
the exhaust valve open.
908-7 228 08

Page 2 (3) When referring to this page, please quote Procedure M90807 Edition 0227
MAN B&W Diesel A/S
 Exhaust Valve 908-7
Special Running

After overhaul of the cylinder unit, re-engage 9.

the exhaust valve gear as follows:

9. Loosen the nuts of the lifting tool to lower

the roller guide on to the exhaust cam. Re-
move the tool.

10. If the engine has been running with the ex-

haust valve open, remove the tool mounted
in the air cylinder and mount the rotation in-
dicator.

Note!

The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.

Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the for-
mation of a wear groove in the air piston
MN908-7 227 05

of the exhaust valve.

Re-connect the air supply to the air cylin-

der.
11.
11. Remove the plugs from the non-return
valves and re-connect the oil inlet pipe and
the connecting sleeve on the actuator hous-
ing, after fitting new sealing rings on the
connecting sleeve.

12. Mount the hydraulic high-pressure pipe.

See Procedure 908-1.4.

13. Engage the fuel pump roller guide.

See Procedure 909-10.1.
MA908-7.0 211 03

When referring to this page, please quote Procedure M90807 Edition 0227 Page 3 (3)
MAN B&W Diesel A/S
 Exhaust Valve - Panel Plate
P90851-0196

When referring to this page, please quote Plate P90851 Edition 0196 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Panel
P90851-0196

Item Item Description Item Item Description

No. No.

016 Panel for tools

028 Name plate
041 Tightening template, actuator
053 Lifting tool, roller guide
065 Lifting tool, exhaust valve
077 Conical ring, pneumatic piston
089 Pressure tester, safety valve
090 Gauge, exhaust valve spindle
112 Grinding tool, H. P. pipe
124 Tool, emergency opening of exhaust
valve
136 Bridge gauge, exhaust valve
148 Tool, hydraulic piston
150 Gauge, exhaust valve bottom piece
161 Lifting tool, exhaust valve
173 Lifting tool, exhaust valve roller guide
185 Grinding ring, exhaust valve bottom
piece

Page 2 (2) When referring to this page, please quote Plate P90851 Edition 0196
MAN B&W Diesel A/S
 Exhaust Valve - Tools Plate
P90861-0022
Exhaust Valve - Tools
0022
P90861

When referring to this page, please quote Plate P90861 Edition 0022 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Tools
P90861-0022

Item Item
Item Description Item Description
No. No.

046 Grinding machine, complete

Notes: When ordering spare parts, please refer to the Chris Marine manual

Page 2 (2) When referring to this page, please quote Plate P90861 Edition 0022
MAN B&W Diesel A/S
 Exhaust Valve - Hydraulic Tools Plate
P90862-0039
P90862
Exhaust
0039 Valve - Hydraulic Tools

When referring to this page, please quote Plate P90862 Edition 0039 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0039

Item Item
Item Description Item Description
No. No.

028 Hydraulic jack

030 Hydraulic jack - support
053 O-ring with back-up ring
065 O-ring with back-up ring
077 Tommy bar
090 Key for hexagon socket screw
207 Hydraulic jack for exhaust valve, com-
plete

Page 2 (2) When referring to this page, please quote Plate P90862 Edition 0039
MAN B&W Diesel A/S
 Exhaust Valve - Extra Tools Plate
P90863-0015
Exhaust Valve - Extra Tools
0015
P90863

When referring to this page, please quote Plate P90863 Edition 0015 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0015

Item Item
Item Description Item Description
No. No.

011 Worktable

Page 2 (2) When referring to this page, please quote Plate P90863 Edition 0015
MAN B&W Diesel A/S
 Exhaust Valve - Extractor Tool Plate
P90864-0002

When referring to this page, please quote Plate P90864 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Extractor Tool
P90864-0002

Item Item Description Item Item Description

No. No.

017 Rectangular hollow section

029 Studs
030 Nut
042 Screw
054 Nut
066 Hexagon screw
078 Nut
080 Nut
091 Disc
101 Bush
113 Nut
125 Screw
137 Nut
149 Extractor tool, complete

Page 2 (2) When referring to this page, please quote Plate P90864 Edition 0002
MAN B&W Diesel A/S
 Exhaust Valve Actuator - Tools Plate
P90865-0002

When referring to this page, please quote Plate P90865 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve Actuator - Tools
P90865-0002

Item Item Description Item Item Description

No. No.

012 Compression tool for fuel and exhaust

springs, complete

Page 2 (2) When referring to this page, please quote Plate P90865 Edition 0002
MAN B&W Diesel A/S
909 - Fuel Oil System

Documents in this Chapter

109-01 0050 Fuel Pump Lead, Data

909-01 0232 Fuel Pump Lead
109-02 0003 VIT System, Data
909-02 0207 VIT System
109-03 0041 Fuel Pump Cam, Data
909-03 0222 Fuel Pump Cam
109-04 0037 Fuel Pump, Data
909-04 0214 Fuel Pump
109-05 0040 Fuel Pump Top Cover, Data
909-05 0216 Fuel Pump Top Cover
109-06 0034 Fuel Pump Barrel Assembly, Data
909-06 0213 Fuel Pump Barrel Assembly
109-07 0026 Fuel Pump Suction Valve, Data
909-07 0213 Fuel Pump Suction Valve
109-08 0033 Fuel Pump Puncture Valve, Data
909-08 0212 Fuel Pump Puncture Valve
109-09 0022 Fuel Pump Shock Absorber, Data
909-09 0211 Fuel System Shock Absorber
10910 0007 Lifting Gear Roller Guide, Data
90910 0213 Lifting Gear for Roller Guide
10911 0044 Fuel Valve, Data
90911 0227 Fuel Valve
10912 0031 Spindle Guide, Data
90912 0219 Spindle Guide
10913 0027 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
10914 0049 Fuel Oil High-Pressure Pipes, Data
90914 0224 Fuel Oil High-Pressure Pipes
10915 0041 Fuel Pump Roller Guide, Data
90915 0222 Fuel Pump Roller Guide

MAN B&W Diesel A/S

90951 0423 Fuel Valve and Fuel Pump - Panel
90961 0061 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals

MAN B&W Diesel A/S

 Fuel Pump Lead 109-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
109-1 Data
0050 Fuel
K90MC-C
Pump Lead

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Measuring tool constant 80 mm

D-2 Lead change at 1 index mark

on pmax-rack (VIT index) 1 mm

D-3 pmax change at 1 mm change

of lead 2-3 bar

D-4 Index range of pmax-rack 0–14

When referring to this page, please quote Data D10901 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
109-1 Fuel Pump Lead
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10901 Edition 0050
MAN B&W Diesel A/S
 Fuel Pump Lead 909-1.1
Checking
Fuel Pump Lead
S80MC-C
0232
Checking
909-1.1

1.
1. The fuel pump lead a (= the effective lead)
is defined as the distance the top of the fuel xx
pump plunger is lifted above the upper
edge of the upper cut-off holes in the fuel
pump barrel when the piston of the cylinder
concerned is in TDC.
D-1
The measuring tool constant D-1 is calcu-
lated at the point where the fuel pump
plunger passes the upper edge of the upper
cut-off holes at VIT-index 0 (zero).
See Data.

2. Turn the engine in AHEAD direction until the

main piston of the cylinder concerned is ex-
actly at TDC. See Procedure 906-3.1.

Note!

The correct distance x can only be meas- a

a
ured when the fuel pump plunger is in its
delivery stroke.
MA909-1.1 223 01

2.
HM906-7.0 56 01

When referring to this page, please quote Procedure M90901 Edition 0232 Page 1 (4)
0$1% :'LHVHO$6
909-1.1 Fuel Pump Lead
Checking

3. 3. Close the fuel oil inlet valve.

Open the fuel pump drain cock, enabling

the oil to escape.

4. Remove the pin in the forked lever which

connects the actuator and the VIT-index
arm. Pull out the VIT-index arm to index 0
(zero).

5. Dismantle the puncture valve.

See Procedures 909-8.2.
GN909-1.1 227 03

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has been
4. relieved of pressure and that all oil has
been drained off.
MA909-1.1 223 04

5.
EN909-1.1 204 17

Page 2 (4) When referring to this page, please quote Procedure M90901 Edition 0232
0$1% :'LHVHO$6
 Fuel Pump Lead 909-1.1
Checking

6. Mount the measuring tool on top of the fuel 6.

pump top cover.

Push the measuring pin fully down into the

threaded hole in the top of the pump plung-
er.

Measure the distance x from the top of the

measuring pin to the top of the crossbar.

The fuel pump lead is then calculated as:

a = x – D-1.

XZS909-1.1 16 05
If the VIT-index is not “0” when measure-
ments take place, the VIT-index must be in-
corporated into the calculations of the fuel
pump lead:
7.
a = x – D-1 – “VIT-index”. See Data.

Note down the result for future reference.

For adjustment of fuel pump lead, see Pro-

cedure 909-1.3.

7. Remove the measuring tool from the fuel

pump.

Replace the O-rings on the puncture valve

and re-mount the valve in the top cover.
See Procedures 909-8.3 and 909-8.4.
GN909-3.3 203 09

8. Reconnect the VIT-index arm to the forked

lever.

9. Close the fuel pump drain cock. 9.

Open the fuel oil inlet valve.
GN909-1.1 227 09

When referring to this page, please quote Procedure M90901 Edition 0232 Page 3 (4)
0$1% :'LHVHO$6
909-1.3 Fuel Pump Lead
Adjustment
Adjustment
909-1.3

3. 1. Adjustment of the maximum combustion

X
pressure of a single cylinder can be effect-
ed by moving (relatively) the cut-off holes of
the pump barrel in relation to the top of the
pump plunger.

2. If the maximum combustion pressure is to

be increased, corresponding to an increase
of the lead a, increase the index on the
pmax-rack (VIT-index arm), relative to the in-
crease required (advancing the injection
E moment).
F
If the maximum combustion pressure is to
be decreased, corresponding to a reduction
of the lead a, decrease the index on the
pmax-rack (VIT-index arm), relative to the
decrease required (retarding the injection
moment).

3. Adjust the servo air cylinder by displacing

lever F so that the camber height X is even-
MB909-1.2 60 02

ly distributed.

A pre-adjustment is carried out with a con-

trol pressure of 2.75 bar, which corre-
sponds to index 7.0 on the p max-rack in
4. B
accordance with the diagram.

Adjustment of the p max is carried out on the

individual fuel injection pump by displacing
the connecting link E.
H
Loosen lock nut B and then turn adjusting
screw H. The link can be adjusted by ap-
prox. 3 index marks.

After some readings in service, it may be

necessary to make a final adjustment of the
E pmax pressure of the corresponding cylin-
der.

4. If no further adjustment is possible accord-

F ing to the above procedures, the cam disc
MA909-1.3 223 04

has to be adjusted.
See Procedure 909-3.3.

Page 4 (4) When referring to this page, please quote Procedure M90901 Edition 0232
0$1% :'LHVHO$6
 VIT System 109-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
109-2
0003
.0&& VIT System

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 D10902 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
109-2 VIT System
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10902 Edition 0003
MAN B&W Diesel A/S
 VIT System 909-2.1
Adjustment

The engine may be equipped with either a me-

1.
chanical or an electronic VIT (Variable Injection
Timing) system.

If the fuel quality has changed or if the fuel

pumps are worn, the pmax will change. Adjust- A
ing the pmax of all the cylinders is done by ad-
justing the VIT system in the following way:
B
Mechanical VIT system

1. The pilot valves have been pre-adjusted to

0.5-5.5 bar control air pressure, corre- C
sponding to 0.5-8.0 mm pressing-in of pin P
C.
Pbar
To check a pilot valve already mounted on
the engine, remove the inlet and outlet pipe 5
connections at A and P, and connect a
4 Curve 2
pressure gauge at A and a pipe with work-
ing air (pressure 7 bar) at P, on the pilot 3
valve. 1.5 2
M90902
0207C01

0.5 1 Pressing
Check that the pressure on the pressure 0.1 0
gauge and the pressing-in of pin C is in ac- in mm
cordance with the curve. 0 1 2 3 4 5 6 7 8
0.5
Any necessary adjustment is done by turn-
ing adjusting screw B. 2.

2. Fine adjustment of the pmax pressure in the

breakpoint (for all the cylinders) is to be
carried out by axial displacement of the
bracket with the pilot valve.

Release the screw and nut which secure

the bracket with the pilot valve to the larger
bracket through the slotted holes.

Increase the pmax pressure by moving the

pilot valve toward the lever.

Decrease the pmax pressure by moving the

pilot valve away from the lever.

See also Volume I, Chapter 703.

M90902
0207C02

When referring to this page, please quote Procedure M90902 Edition 0207 Page 1 (2)
MAN B&W Diesel A/S
909-2.1 VIT System
Adjustment

Electronic VIT system

3.
3. The adjustment should be based on a set
of indicator diagrams taken when the en-
gine is running just above the breakpoint.

4. On the panel in the engine room control

room, change the poffset value in accordance
with the required increase or decrease in
the pmax pressure. One graduation mark on
the poffset scale corresponds to a change in
pmax of 1 bar.

5. Check the adjustment by taking a new set

of indicator diagrams while the engine is
running just above the breakpoint.

6. The I/P converter mounted on the engine

receives a 4-20 mA signal I from the elec-
tronic control system and converts this into
a 0.5-5.5 bar control air pressure pcontrol.

7. To check the adjustment of the I/P con-

M90902
0207C03

verter, operate the panel in the engine con-

trol room to supply various signals I to the
I/P converter.

For operation of the panel, see the panel

6. manufacturer’s instructions.

On the pressure gauge mounted on the

control air line after the I/P converter check
that the control air pressures from the I/P
converter are in accordance with the curve.

8. If the control air pressure is not in accor-

dance with the curve, the I/P converter
Pcontrol must be adjusted. Remove the hood of the
I/P converter and adjust the I/P converter
according to the manufacturer’s instruc-
Psupply tions.

Pcontrol
5
4
3
M90902
0207C02

2
1.5
1
0.5
0.1 0 I, mA
0 4 8 12 16 20

Page 2 (2) When referring to this page, please quote Procedure M90902 Edition 0207
MAN B&W Diesel A/S
 Fuel Pump Cam 109-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0041
109-3 Fuel Pump Cam

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil 1 x 3 m, 3 x 1 m
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Lead change at 1 index mark

on pmax-rack (VIT index) 1 mm

D-2 pmax change at 1 mm

change of lead 2-3 bar

D-3 Index range of pmax-rack 0-14

When referring to this page, please quote Data D10903 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10903 Edition 0041
MAN B&W Diesel A/S
 Fuel Pump Cam 909-3.1
Checking
Fuel Pump Cam
K80MC-C
0222
Checking
909-3.1

1.
1. The lead c of the fuel cam is defined as the
number of mm the plunger is lifted from its
bottom position when the main piston is in
TDC.

The lead c of the fuel cam disc is measured

with the measuring tool in position a and b.
See the sketch.

2. Close the fuel oil inlet valve. The non-return

valve in the return oil pipe will prevent oil
leaking from the main return oil pipe.

Open the fuel pump drain cock, enabling

the oil to escape.

Pos. a

Pos. b
MA909-3.1 215 01

2.
MA909-1.1 223 03

When referring to this page, please quote Procedure M90903 Edition 0222 Page 1 (6)
0$1% :'LHVHO$6
909-3.1 Fuel Pump Cam
Checking

3. 3. Dismantle the puncture valve. See Proce-

dure 909-8.2.

Note!

Before dismantling any part of the fuel

pump, make sure the pump has been
relieved of pressure and that all oil has
been drained off.

4. Remove the inspection cover in front of the

fuel cam from the camshaft housing.
MA909-1.1 223 05

Make sure that the reversing mechanism is

in AHEAD direction.

5. Turn the engine in AHEAD direction, while

4. noting the position of the cam through the
inspection hole.

Stop turning when the roller is on the lowest

part of the cam, i.e. where the roller guide,
and thus the pump plunger, is in the lowest
position.
MC909-2.0 55 05

5.
MA909-3.1 215 05

Page 2 (6) When referring to this page, please quote Procedure M90903 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Cam 909-3.1
Checking

6. Mount the measuring tool on top of the fuel 6.

pump top cover.

Push the measuring pin fully down into the

threaded hole in the top of the pump plung- x
er.

Measure the distance x from the top of the

measuring pin to the top of the crossbar.
Note down the result as b.

7. Turn AHEAD until the main piston of the cyl-

inder concerned is in TDC.

8. Again measure the distance x from the top

of the measuring tool to the top of the
crossbar. Note down the result as a.
MA909-1.1 223 06

The lead c of the fuel cam is thus =

a – b.

Example:
7.
Reading a = 87,
with main piston in TDC.

Reading b = 70,
with plunger in lowest position.
HM906-7.0 56 01

c = a – b = 87 - 70 = 17

Note down the result for comparison with

the testbed results and for future reference. 10.

For adjustment of fuel cam lead, see Pro-

cedure 909-3.3

9. Mount the cover on the camshaft housing.

10. Mount the puncture valve.

See Procedure 909-8.4.

11. Close the fuel pump drain cock.

Open the fuel oil inlet valve.

MA909-1.1 223 05

When referring to this page, please quote Procedure M90903 Edition 0222 Page 3 (6)
0$1% :'LHVHO$6
909-3.3 Fuel Pump Cam
Adjustment
Adjustment
909-3.3

1. Before adjusting If pmax is to be adjusted by adjusting the fuel

E
cam lead instead of adjusting the pmax rack, it
is recommended to set the pmax rack to its mid-
dle position (index 7 at a control air pressure of
2.75 bar. After the adjustment, chain link E
should be in a middle position) before adjusting
the fuel cam lead. (See Procedure 909-1.3).

D-1 1. Supply a control air pressure of 2.75 bar.

2.75 Operating pressure

D-2 Note down the deviation x between the
present position of the p max rack and its
D-3 middle position.
After adjusting
Maintain the pressure of 2.75 bar, and ad-
just the p max rack to its middle position.

The deviation x must be incorporated into

the calculated change of fuel cam lead:

Example:
Present position (before adjusting link E):
MA909-3.3 215 01

index mark 9 (at 2.75 bar)

2.75 Operating pressure
Middle position (after adjusting link E):
index mark 7 (at 2.75 bar)

Deviation x:
9-7 = +2 index marks

Purpose:
To increase pmax 9 bar.

Data:
As 1 mm change of fuel cam lead corre-
sponds to p max being altered approx. 2-3
bar, the cam lead is to be altered approx.
3 mm.

Calculated change of fuel cam lead:

Change of fuel cam lead + deviation x:
3 + 2 = 5 mm change of fuel cam lead.

The new fuel cam lead is then calculated

as:

The present fuel cam lead + the calculated

change of fuel cam lead.
See Procedure 909-3.1.

Note down the new fuel cam lead.

Page 4 (6) When referring to this page, please quote Procedure M90903 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Cam 909-3.3
Adjustment

2. Make sure that the reversing mechanism is 2.

in AHEAD direction.

Remove the oil tray and inspection cover

from the camshaft housing concerned.
See Procedure 906-4.2.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

MA909-3.3 215 02
3. Dismount the pipe connections and the
puncture valve from the fuel pump top cov-
er, and mount the measuring tool.
3.
Measure the fuel cam lead using the meas-
uring tool. x
See Procedure 909-3.1.

Compare the fuel cam lead with the value

in the Adjustment Sheet, and adjust the fuel
pump cam as necessary.

4. Turn the camshaft until there is access to

the oil ducts in the fuel cam through the in-
spection opening.

Remove the plugs from the oil ducts (using,

MA909-1.1 223 06

for instance, a screw-driver).

Insert three copper gaskets in each oil duct.

Mount snap-on couplings in the oil ducts, 4.

but do not tighten them.

Fit hoses between the snap-on couplings

and the distributor block and between the
distributor block and the hydraulic high-
pressure pump.
MA909-2.0 61 04

When referring to this page, please quote Procedure M90903 Edition 0222 Page 5 (6)
0$1% :'LHVHO$6
909-3.3 Fuel Pump Cam
Adjustment

5. 5. Mount the special spanner on the fuel cam

disc, ensuring that the two pins enter the
holes in the cam.

6. Apply light pressure to the hydraulic system

and, after venting the system, tighten the
snap-on couplings.

Note!

Raise the hydraulic pressure until oil

seeps out along the camshaft under the
cam disc and keep the cam pressurised
for at least 15 minutes.
MA909-2.0 61 05

Turn the cam disc, using the fitted spanner,

until the desired change of lead is read di-
rectly on the measuring tool. (The neces-
6. sary turning of the cam disc is calculated as
described in Procedures 909-1.1 and 909-
3.1).
To increase lead and p max:
– turn the cam disc AHEAD.
To reduce lead and p max:
– turn the cam disc ASTERN.

7. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
MA909-2.0 61 06

After at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.
8.
After carrying out adjustment, measure the
fuel pump lead again.
See Procedure 909-1.1, and re-adjust the
cam if required. Fine adjustment is to be
carried out on chain link E.

Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.

8. Mount the oil tray and inspection cover on

the camshaft housing.
See Procedure 906-4.4.
MA909-3.3 215 08

9. Re-mount the suction valve and the punc-

ture valve. See Procedure 909-8.4.

Page 6 (6) When referring to this page, please quote Procedure M90903 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump 109-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0037
109-4 Fuel Pump

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Shock absorber, complete 90 kg

D-2 Pump housing, complete 750 kg

D-3 Bottom plate 35 kg

D-4 Pump housing nuts

– tightening angle 55 °

D-5 Pump housing nuts

– tightening torque 2100 Nm

When referring to this page, please quote Data D10904 Edition 0037 Page 1 (2)
MAN B&W Diesel A/S
109-4 Fuel Pump
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10904 Edition 0037
MAN B&W Diesel A/S
 Fuel Pump 909-4.2
Dismantling
Fuel Pump
K90MC
0214
Dismantling
909-4.2

1.
1. Close the fuel oil inlet valve.

Open the drain cock, enabling the oil to es-

cape.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

2. Dismantle the fuel pump top cover and con-

MA909-1.1 223 03
nected pipes.
See Procedure 909-5.2.

3. Dismantle the barrel/plunger assembly.

See Procedure 909-6.2.
4.
4. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel in-
D-1
let valve.

Remove the fuel oil inlet pipe.

Remove the shock absorber.

Remove the fuel oil outlet pipe.

Discard the gaskets.

5. Remove the drain pipes from the fuel pump

housing.
MA909-4.2 214 04

Remove the control air pipes from the actu-

ator for the VIT index arm.

When referring to this page, please quote Procedure M90904 Edition 0214 Page 1 (9)
0$1% :'LHVHO$6
909-4.2 Fuel Pump
Dismantling

6. 6. Loosen the four nuts by means of a slug-

ging spanner. Remove the nuts.

7. Fit the lifting tool using the top cover studs/

nuts, and lift the pump housing away.

Take care not to damage the threads of the

studs.

Land the fuel pump on wooden planks.

MA909-4.2 214 06

7.

D-2
MA909-4.2 214 07

Page 2 (9) When referring to this page, please quote Procedure M90904 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump 909-4.3
Overhaul
Overhaul
909-4.3

1. If the fuel index arm or the VIT index arm 3.

of the fuel pump is moving too tightly, the
regulating and timing systems of the fuel
pump must be overhauled.

2. In order to carry out this overhaul, the top

cover and plunger/barrel assembly of the
fuel pump must have been removed, and
the fuel pump must have been dismantled
from the pump base and landed on wooden
planks.
See Procedure 909-4.2.
See Procedure 909-5.2.

MA909-4.3 214 03
See Procedure 909-6.2.

3. Dismantle the actuator and actuator brack-

et.

4. Tilt the fuel pump housing into a horizontal 4.

position on the wooden planks. D-2
5. Dismantle the screws and the bottom plate
from the fuel pump housing.

If the bottom plate is stuck, loosen it by

screwing two M10x80 mm screws into the
holes of the bottom plate.
MA909-4.3 214 04

5.

D-3
MA909-4.3 214 05

When referring to this page, please quote Procedure M90904 Edition 0214 Page 3 (9)
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul

6. 6. Dismantle the:

• Fuel index arm

• Regulating guide

• Sleeve

7. Dismantle the:

• Guide screw

• VIT index arm

MA909-4.3 214 06

• Timing guide

8. Remove the caps from the back of the fuel

pump housing.
7.
Remove the orifice plug from the front side
of the fuel pump housing.

Discard all sealing rings and gaskets.

MA909-4.3 214 07

8.
MA909-4.3 214 08

Page 4 (9) When referring to this page, please quote Procedure M90904 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump 909-4.3
Overhaul

9. Dismantle and inspect the plug screws in 9.

both sides of the fuel pump housing.

If eroded, replace the plug screws.

10. Clean all the dismantled parts of the fuel

pump thoroughly in diesel oil or kerosene.
Dry all parts carefully.

Clean all inside surfaces of the fuel pump

housing.

Check that all the bores of the fuel pump

housing are clean.

11. Mount new sealing rings and gaskets.

MA909-4.3 214 09
Mount the caps and the orifice plug.

Mount new sealing rings on the plug screws

and mount the plug screws.
11.
Note!

Lubricate the threads of all the parts with

Molybdenum Disulphide (MoS 2) before
mounting.

12. Mount new sealing rings in the sleeves that

are provided with a pointer scratch.
MA909-4.3 214 11

Note!

Soak the sealing rings in lubricating oil

before mounting.
12.
HC909-3.4 121 11

When referring to this page, please quote Procedure M90904 Edition 0214 Page 5 (9)
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul

14. Mounting

13. Lubricate the following with molybdenum di-

sulphide (MoS 2):

• all internal surfaces of the fuel pump

housing

• the sliding surfaces of all parts of the

regulating and timing systems.

• the teeth of the:

regulating guide
MA909-4.3 214 14

timing guide
VIT index arm

15. fuel index arm.

14. Mount the VIT index arm and the guide

screw.

Adjust the position of the VIT index arm so

that the scratch mark is aligned with the
centre of the fuel pump housing.

15. Mount the timing guide in the fuel pump

housing.

The timing guide must be mounted in such

a way that the scratch marks on the timing
MA909-4.3 214 15

guide, on the VIT index arm and on the fuel

pump housing are aligned.

16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
16.
sleeve is aligned with the pin hole in the
fuel pump housing.
MA909-4.3 214 16

Page 6 (9) When referring to this page, please quote Procedure M90904 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump 909-4.3
Overhaul

17. Mount the fuel index arm. 17.

Adjust the position of the fuel index arm so

that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.

18. Mount the regulating guide in the fuel pump

housing.

The regulating guide must be mounted so

that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.

19. Mount the bottom plate on the fuel pump

housing.

20. Return the fuel pump to a vertical position. MA909-4.3 214 17

Mount the actuator and actuator bracket on

the side of the fuel pump.

18.
MA909-4.3 214 18

19.

D-3
MA909-4.3 214 05

When referring to this page, please quote Procedure M90904 Edition 0214 Page 7 (9)
0$1% :'LHVHO$6
909-4.4 Fuel Pump
Mounting
Mounting
909-4.4

2. 1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
D-2 are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum di-
sulphide (MoS 2).
See Procedure 913-11.

2. Mount the lifting tool on the fuel pump top

cover studs. Lift the fuel pump housing on
to the pump base, taking care not to dam-
age the threads of the studs.

Remove the lifting tool.

3. Mount the nuts on the studs and tighten to

the specified angle, see Data.
MA909.4.2 214 07

3.

D-4
MA909-4.2 214 06

Page 8 (9) When referring to this page, please quote Procedure M90904 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump 909-4.4
Mounting

4. Mount the drain oil pipes on the fuel pump 5.

housing.

Connect the control air pipes to the actuator

for the VIT index arm. D-1
5. Fit new gaskets on the fuel pump inlet pipe.
Mount the pipe between the fuel pump
housing and the fuel oil inlet and outlet
valve.

Mount the shock absorber.

6. Mount the barrel assembly in the fuel pump

housing. See Procedure 909-6.4.

MA909-4.2 214 04
7. Mount the top cover on the fuel pump hous-
ing. See Procedure 909-5.4.

Mount the air pipe for the puncture valve.

8. Close the drain cock and open the fuel oil 8.

inlet valve.
MA909-1.1 223 09

When referring to this page, please quote Procedure M90904 Edition 0214 Page 9 (9)
0$1% :'LHVHO$6
 Fuel Pump Top Cover 109-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
109-5 Data
0040 Fuel Pump
K90MC-C
Top Cover

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
140-760 Nm
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of top cover 125 kg

D-2 Max. milling/grinding

diameter of seat 26 mm

D-3 Tightening torque –

top cover nuts 500 Nm

When referring to this page, please quote Data D10905 Edition 0040 Page 1 (2)
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10905 Edition 0040
MAN B&W Diesel A/S
 Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
K90MC
0216
Dismantling
909-5.2

1.
1. Shut off the fuel oil inlet.

Open the drain cock (at the bottom of the

pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.

Note !

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

MA909-5.2 216 01
Dismount all drain pipes and the pipe con-
nections to the puncture valve.

Dismount the high-pressure pipes between

the top cover and the fuel valves. 2.
See Procedure 909-14.2.

Note !

If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
See Procedure 909-8.2.

Subsequently, the fuel pump lead can be

measured.
See Procedure 909-1.1.
MA909-5.2 216 02

2. Remove the top cover fixing nuts and

mount the dismantling screws for top cover
in the two threaded holes.
3.
Pull the top cover with suction valve and
puncture valve (if still mounted) free by
tightening the dismantling screws.

When the top cover is loose, remove the D-1

dismantling screws and mount the lifting
tool in the threaded holes instead.

3. Lift the top cover carefully off.

For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.
GN909-5.2 204 03

Discard the gasket.

When referring to this page, please quote Procedure M90905 Edition 0216 Page 1 (3)
0$1% :'LHVHO$6
909-5.3 Fuel Pump Top Cover
Overhaul
Overhaul
909-5.3

2. 1. If not already done, dismount the protective

cap and the puncture valve from the top
cover.
See Procedure 909-8.2.

2. Dismantle the suction valve and the lock

washer from the top cover.
See Procedure 909-7.2.

3. Fill the oil ducts of the top cover with vase-

line or heavy grease.

Screw the guide, with the miller, into the

high-pressure pipe thread.
HM909-3.3 74 03

Mill the seat until a smooth surface is

achieved.

3. After completing the milling, clean the top

cover with diesel oil/gas oil, and dry it care-
fully.

Note!
D-2
Make sure that all bores and threads
inside the top cover are absolutely clean.

If necessary, recondition the seats of the

fuel oil high-pressure pipes.
See Procedure 909-14.
GN909-5.3 204 04

4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
See Procedure 909-7.4.

4.
HM909-3.3 74 13

Page 2 (3) When referring to this page, please quote Procedure M90905 Edition 0216
0$1% :'LHVHO$6
 Fuel Pump Top Cover 909-5.4
Mounting
Mounting
909-5.4

1. Make sure that the inside of the fuel pump 1.

housing and the top of the fuel pump barrel
is completely clean.

2. Mount a new gasket on top of the pump D-1

housing.

Lubricate all sliding faces, studs and seal-

ing rings with “ MOLYKOTE antifriction SPRAY
D32IR” or molybdenum disulphide (MoS 2).
See Procedure 913-11.

Mount the overhauled top cover (with over-

GN909-5.2 204 03
hauled suction valve and reconditioned
seatings for the high-pressure pipes) on the
pump housing.

Check that the guide pin in the top cover

enters the hole in the pump housing. 3.
D-3
Warning !

As a safety precaution, and before

mounting the top cover nuts, turn the
engine one revolution.

When doing this, the top cover must not

move upwards!

3. Mount the top cover fixing nuts, and tighten

them diagonally to the torque indicated in
GN909-5.4 204 03

Data.

Measure the lead of the fuel pump and ad-

just, if necessary. See Procedure 909-1.1.
At the same time, it may prove necessary 4.
to adjust the lead of the cam disc.
See Procedure 909-3.3.

4. Finally, mount a new or overhauled punc-

ture valve on the top cover. See Procedure
909-8.4.

Mount the protective cap over the puncture

valve and the two screws in the top cover.
Mount the high-pressure pipes and close
the drain valve in the bottom of the pump
housing.
MA909-5.4 216 04

Mount the drain pipes on the top cover and

the connecting pipe to the puncture valve.
Open the fuel oil inlet.

When referring to this page, please quote Procedure M90905 Edition 0216 Page 3 (3)
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 109-6
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0034
109-6 Fuel Pump Barrel Assembly

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of barrel assembly 205 kg

D-2 Weight of plunger 40 kg

When referring to this page, please quote Data D10906 Edition 0034 Page 1 (2)
MAN B&W Diesel A/S
109-6 Fuel Pump Barrel Assembly
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10906 Edition 0034
MAN B&W Diesel A/S
 Fuel Pump Barrel Assembly 909-6.2
Dismantling
Fuel Pump Barrel Assembly
K90MC
0213
Dismantling
909-6.2

1.
1. Close the fuel oil inlet valve.

Open the fuel pump drain cock, enabling

the oil to escape.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

MA909-1.1 223 03
2. Dismantle the fuel pump top cover.
See Procedure 909-5.2.

3. Position the lifting tool for the barrel/plunger

assembly (without measuring pin) in such a
manner that the two distance tubes of the 2.
tool rest on the pump barrel.

Make sure that the two guide pins in the

bottom of the lifting tool enter the holes in
the top of the plunger.

Secure the lifting tool by screwing the two

screws into the pump barrel.

Loosen the stop ring on the spindle of the

tool and press the spindle down against the
pump plunger.
MA909-3.1 122 03

Turn the spindle in this position until the two

guide pins engage with the two holes in the
plunger top.

Tighten the centre screw of the spindle 3.

against the plunger.
NA909-6.2 211 03

When referring to this page, please quote Procedure M90906 Edition 0213 Page 1 (10)
0$1% :'LHVHO$6
909-6.2 Fuel Pump Barrel Assembly
Dismantling

4. 4. Remove the pump barrel guide screw from

the pump housing.

5. Disconnect the links for the timing drive and

the regulating drive. Dismount the union
and pointer for the timing drive and the reg-
ulating drive.

Note the position of the scratch mark on the

lever arm.

Remove the locking plate and the lever

arm.

Mount the extractor tool and connect the

MA909-3.1 93 05

timing toothed rack to the pulling rod by

means of the pin.

6. Turn the nut at the end of the pulling rod,

5. whereby the timing rack will move out-
wards.

Continue turning the nut until the pin reach-

es the outer position of the slot in the tool,
whereby the thread of the fuel pump barrel
goes clear of the timing guide.

Keep the toothed rack in this position during

the overhaul or replacement of the pump
barrel.

There is now a distance between the lifting

tool and the pump housing.
MA909-3.1 93 06 AB

6.
MA909-3.1 93 06 C

Page 2 (10) When referring to this page, please quote Procedure M90906 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.2
Dismantling

7. Pull the regulating toothed rack outwards 7.

until the plunger foot has been turned clear
of the bayonet joint in the roller guide.

This can be ascertained by watching the

handles on the spindle of the lifting tool.
These will be parallel with the fore-and-aft
direction of the engine when the plunger
has been turned into position.

Remove the cover of the pump base to

make sure that the plunger is able to go
clear of the bayonet joint.

Lift the spindle so that the plunger foot goes

clear of the bayonet joint.

Move the stop ring of the spindle into con-

tact with the upper flange of the tool, and
lock the stop ring in this position by means
of the stop screw.
MA909-6.2 213 07

8. Carefully lift the barrel/plunger assembly

out of the pump housing.

Dismount the tool.

Press the plunger upwards to the bottom of 8.

the barrel.

Send the barrel/plunger assembly to an

MAN B&W authorized workshop for repair,
or overhaul it on board as described in Pro-
cedure 909-6.3. D-1
MA909-6.2 213 08

When referring to this page, please quote Procedure M90906 Edition 0213 Page 3 (10)
0$1% :'LHVHO$6
909-6.3 Fuel Pump Barrel Assembly
Overhaul
Overhaul
909-6.3

1. 1. Set up the pump barrel/plunger in a bench

vice provided with “soft” jaws.

Remove and discard the sealing rings from

the barrel.
D-1 2. Pull the plunger carefully out of the barrel.

Carefully clean the plunger (for example in

clean kerosene) and dry it with a soft non-
fluffy cloth.

Check the plunger for wear or seizure

marks. Also inspect the top of the plunger
for cavitation marks.
MB909-3.2 95 02

3. Clean the bores in the upper end of the

plunger and blow dry with compressed air.

Clean the barrel and dry it with a non-fluffy

cloth.
2.

D-2 Check the barrel for wear or seizure marks.

Note!

If either the plunger or the barrel shows

signs of wear or seizure marks, both
parts must be replaced, as they are
ground to match and cannot be replaced
individually.
MB909-3.2 95 02

3.
MA909-3.2 122 03

Page 4 (10) When referring to this page, please quote Procedure M90906 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.3
Overhaul

4. Before mounting new sealing rings on the 4.

barrel, heat them to 200–220°C for at least
five minutes.

Note! 200-220 °C
Take care not to exceed the temperature
limits.

5. When mounting the new sealing rings on

the lower end of the pump barrel, the inner
sealing ring must be mounted first.

NA909-5.3 214 05
Mount the guide stick in the barrel and po-
sition the big cone on the barrel.

Place the spring-loaded sealing ring on the

cone with the spring facing upwards, see 5.
the sketch.

Use the pusher tool to push the sealing ring

into the groove.

6. When mounting the sealing ring in the outer

groove, place the spacer tool inside the
cone to obtain the correct distance to the
groove, and repeat the above procedure.

After mounting the sealing rings, compress

them by pressing the “sizer” tool over the
sealing rings.
MA909-6.3 213 05

6.
MA909-6.3 213 06

When referring to this page, please quote Procedure M90906 Edition 0213 Page 5 (10)
0$1% :'LHVHO$6
909-6.3 Fuel Pump Barrel Assembly
Overhaul

7. 7. Mount the guide stick and cone on the top

end of the barrel and mount the uppermost
sealing ring in the same way as above.

Make sure that the spring faces down-

wards, see the sketch.

8. Lubricate the plunger with molybdenum di-

sulphide (MoS 2).

Carefully slide the plunger into the barrel

and press it to the bottom.
MB909-3.2 95 06

Note!

Do not use force as this will damage the

sliding surfaces of the plunger or barrel
8.
If the barrel assembly is not to be mounted
immediately, all openings must be covered
with plastic to prevent dirt from entering the
barrel assembly during storage.
MB909-3.2 95 07

Page 6 (10) When referring to this page, please quote Procedure M90906 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.4
Mounting
Mounting
909-6.4

1. Place the supplied measuring pin – which 1.

is of the same length as the plunger – on
the spindle of the lifting tool, and fasten it
by tightening the centre screw of the spin-
dle. Loosen the stop ring on the spindle.

Place the tool on the pump housing, and

press the spindle down until the pointed
end of the measuring pin is in contact with
the thrust piece of the roller guide.

Then press the stop ring down until it

reaches the flange of the tool and lock it
there by tightening the screw of the stop
ring against the spindle.

The stop ring is to remain tightened in this

position until the plunger has been correctly
mounted.

The engine must not be turned until the

mounting of the barrel/plunger assembly
MA909-6.4 213 01

has been completed.

2. Dismount the tool from the pump housing

and remove the measuring pin from the
spindle. Then mount the tool on the barrel/
plunger assembly which is ready for mount- 2.
ing.

Secure the tool to the barrel by tightening

the two screws, and attach the plunger to
the spindle of the tool by tightening the cen-
tre screw of the spindle. The tool is thus
fixed on the barrel in such a way that its cor-
rect positioning is ensured during mount-
ing.

Before mounting the barrel/plunger in the

pump housing, lubricate the thread for the
timing guide and all sealing rings with mo-
lybdenum disulphide.

Using the spindle of the tool, pull the plung-

er as high up in the barrel as possible, at
the same time turning the spindle so as to
position the plunger foot correctly in relation
to the cutout of the regulating guide.
MA909-6.4 213 02

When referring to this page, please quote Procedure M90906 Edition 0213 Page 7 (10)
0$1% :'LHVHO$6
909-6.4 Fuel Pump Barrel Assembly
Mounting

3. 3. Pull the regulating toothed rack as far out

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer posi-
tion.

4. Check that the slot in the barrel coincides

with the hole for the guide screw.

Lower the barrel assembly carefully into the

pump housing.

If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
MA909-6.4 213 03

and the regulating block of the plunger fit

properly in the cutout of the regulating
guide.

Lowering the barrel assembly so far down

4. into the pump housing that the sealing rings
of the barrel are about to enter the bore in
the pump housing.

Then continue pressing down the barrel/

D-1 plunger assembly until the barrel assembly
rests on top of the timing guide. There will
be a gap between the tool and the pump
housing.
MA909-6.4 213 04

Page 8 (10) When referring to this page, please quote Procedure M90906 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.4
Mounting

5. Loosen the nut on the extractor, disconnect 5.

the pulling rod from the timing toothed rack,
and remove the extractor.

Engaging the thread of the fuel pump barrel

with the timing guide is accomplished by
pressing-in the toothed rack. (A pressure of
about 30 kg may be required).

Check that the toothed rack is correctly en-

gaged by pressing-in the rack. When doing
this, the pump barrel shall move down-
wards.

The top flange of the tool is now resting on

the top of the pump housing.

6. After ‘landing’ the barrel assembly, press

the plunger down into contact with the MA909-6.4 213 05

thrust piece of the roller guide.

Check that the stop disc of the spindle is in

full contact with the flange of the tool, as
when measuring.
6.
If necessary, turn the regulating guide a lit-
tle (using the toothed rack) to make the
plunger foot fit properly in the cutout of the
roller guide. Inspect the position of the
plunger foot through the inspection hole.

When the plunger is in place, press the reg-

ulating rod in, thereby turning the plunger
by means of the regulating guide and caus-
ing the plunger foot to “interlock” with the
bayonet joint of the roller guide.

Check that the plunger is correctly engaged

by pulling at the spindle of the lifting tool.
When doing this, it must not be possible to
lift the spindle.

Mount the inspection hole cover.

MA909-6.4 213 06

When referring to this page, please quote Procedure M90906 Edition 0213 Page 9 (10)
0$1% :'LHVHO$6
909-6.4 Fuel Pump Barrel Assembly
Mounting

7. 7. Mount the pointer and union for the timing

rack.

Mount the links for the timing drive and the

regulating drive in place in accordance with
the marks.

8. Mount the guide screw for the pump barrel

in the pump housing.
MA909-6.4 213 07

Remove the centre screw from the plunger,

and remove the tool.

9. Mount the fuel pump top cover and the be-

8. longing pipes. See Procedure 909-5.4.

10. Close the fuel pump drain cock.

Open the fuel oil inlet valve.

MA909-6.4 213 08

10.
MA909-1.1 223 09

Page 10 (10) When referring to this page, please quote Procedure M90906 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Suction Valve 109-7
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
109-7 Data
0026 Fuel Pump
K90MC-C
Suction Valve

Stopped engine
750-2000 Nm
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

D-1 Tightening torque –

suction valve 1850 Nm

When referring to this page, please quote Data D10907 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10907 Edition 0026
MAN B&W Diesel A/S
 Fuel Pump Suction Valve 909-7.1
Checking
Fuel Pump Suction Valve
S80MC-C
0213
Checking
909-7.1

1.
1. Using a brass mandrel, check that the valve
slide can slide freely up and down inside
the suction valve.

2. Check the seats for tightness by filling the

inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.

3. If the suction valve is not to be mounted on

the engine immediately after the checking,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.

HN909-7.1 207 01

2.
KB909-3.3 105 08

When referring to this page, please quote Procedure M90907 Edition 0213 Page 1 (4)
0$1% :'LHVHO$6
909-7.2 Fuel Pump Suction Valve
Dismantling
Dismantling
909-7.2

1. 1.
Note!

Before dismantling the top cover, it is

recommended to dismantle the fuel pump
puncture valve, see Procedure 909-8.2.

Dismantle the fuel pump top cover and suc-

tion valve assembly from the fuel pump
housing. See Procedure 909-5.2.

2. Mount two eye bolts in the bottom of the top

cover and turn it upside down.

3. Mount the top cover in an upside down po-

GN909-5.2 204 03

sition in the top cover bracket mounted on

the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
er.
2.
Release the suction valve lock washer.

Dismount the suction valve from the top

cover.

Remove and discard the lock washer.

GN909-5.3 204 02

3.
KN909-7.2 213 03

Page 2 (4) When referring to this page, please quote Procedure M90907 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Suction Valve 909-7.3
Overhaul
Overhaul
909-7.3

1. Set up the suction valve in a bench vice 1.

with “soft” jaws and, using a brass mandrel
and a hammer, release the spring guide
from the valve thrust piece.

Disassemble the other parts of the suction

valve and clean the parts thoroughly in
clean diesel oil.

Remove and discard the sealing ring from

the valve thrust piece.

2. Inspect the seat of the valve slide and the

seat in the thrust piece for damage. If the
seats are damaged, both the suction valve
and the valve slide must be discarded.

KB909-3.3 105 05
Lapping of the seats must not be attempt-
ed.

3. Mount the O-ring in the groove of the seal- 2.

ing ring and position the cone on the thrust
piece.

Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the groove.

Note!
KB909-3.3 105 06

Make sure that the sealing ring is

mounted correctly. See the sketch.

After mounting the sealing ring, compress it 3.

by pressing the “sizer” tool over the sealing
ring.

4. Clean and overhaul all internal parts, and

lubricate them with molybdenum disulphide
(MoS 2).

5. Re-assemble the suction valve.

6. Check the suction valve after the overhaul.

See Procedure 909-7.1.
XZ909-7.3 204 03

When referring to this page, please quote Procedure M90907 Edition 0213 Page 3 (4)
0$1% :'LHVHO$6
909-7.4 Fuel Pump Suction Valve
Mounting
Mounting
909-7.4

1. 1. Mount the top cover in an upside down po-

sition in the top cover bracket mounted on
the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
D-1 er.

Lubricate the thread of the suction valve

with copper grease.

Make sure that the bore for the suction

valve in the top cover is absolutely clean.

Fit a new lock washer and mount a new or

overhauled suction valve in the top cover.

Fit the two screws which secure the lock

washer.

Tighten the suction valve with a torque

spanner. See Data.

Lock the suction valve in position by bend-

ing up an edge of the lock washer over one
KN909-7.4 213 01

of the flats of the valve.

2. Remove the top cover from the bracket and

mount the top cover in the fuel pump hous-
2. ing. See Procedure 909-5.4.
GN909-5.2 204 03

Page 4 (4) When referring to this page, please quote Procedure M90907 Edition 0213
0$1% :'LHVHO$6
 Fuel Pump Puncture Valve 109-8
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0033
109-8 Fuel Pump Puncture Valve

Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear 750-2000 Nm
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Puncture valve – weight 12 kg

D-2 Puncture valve – 1400 Nm

tightening torque

When referring to this page, please quote Data D10908 Edition 0033 Page 1 (2)
MAN B&W Diesel A/S
109-8 Fuel Pump Puncture Valve
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10908 Edition 0033
MAN B&W Diesel A/S
 Fuel Pump Puncture Valve 909-8.2
Dismantling
Fuel Pump Puncture Valve
K90MC
0212
Dismantling
909-8.2

2.
1. Shut off the fuel oil inlet.

Open the drain cock at the bottom of the

pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

2. Dismantle the control air pipe and the pro-

tective cap above the puncture valve.

3. Unscrew and remove the puncture valve

from the fuel pump top cover.

4. After dismantling it is recommended always

HN909-8.2 207 02

to overhaul the puncture valve.

If the overhaul cannot take place immedi-

ately after the dismantling, it is recommend-
ed to place the puncture valve immersed in
diesel oil until the overhaul. 3.
HN909-8.2 207 03

When referring to this page, please quote Procedure M90908 Edition 0212 Page 1 (4)
0$1% :'LHVHO$6
909-8.3 Fuel Pump Puncture Valve
Overhaul
Overhaul
909-8.3

1. 1. Remove and discard the O-rings from the

puncture valve.

Set up the puncture valve in a bench vice

with “soft” jaws.

Loosen and remove the four screws and

dismount the plug. Use a screw to remove
the air piston from the housing.

Remove and discard the sealing rings from

the air piston.

Disassemble the other parts of the punc-

ture valve, using a brass mandrel and a
hammer. Take care not to damage the valve
seat.

Thoroughly clean all the parts in clean die-

sel oil.

2. Inspect the conical seats of the valve hous-

ing and the valve slide for wear marks or
scratches.

If the seats are damaged, the valve housing

and the valve slide must be discarded.

Lapping of the valve seats must not be at-

HN909-8.3 207 01

tempted.

2.
HG909-8.2 201 02

Page 2 (4) When referring to this page, please quote Procedure M90908 Edition 0212
0$1% :'LHVHO$6
 Fuel Pump Puncture Valve 909-8.3
Overhaul

3. When mounting the new sealing rings on 3.

the spindle of the air piston, the inner seal-
ing ring must be mounted first.

Mount the O-ring in the ring groove and po-

sition the large cone on the spindle.

Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the O-ring in the groove.

After mounting the sealing ring, compress it

by pressing the ‘sizer' tool, over the sealing
ring.

Mount the outer sealing ring in the groove

using the short cone, and repeating the
above procedure.

4. The new sealing ring is mounted on the

head of the air piston in accordance with
the same procedure as above.
GM909-3.3 89 10

Before assembling the puncture valve, lu-

bricate all parts with “MOLYKOTE anti-fric-
tion SPRAY D321R” or molybdenum
disulphide (MoS 2).
4.
Mount new O-rings on the housing.

5. If the puncture valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
GM909-3.3 89 12

When referring to this page, please quote Procedure M90908 Edition 0212 Page 3 (4)
0$1% :'LHVHO$6
909-8.4 Fuel Pump Puncture Valve
Mounting
Mounting
909-8.4

2. 1. Make sure that the bore for the puncture

valve in the fuel pump top cover is absolute-
ly clean.

If this has not already been done, mount

new O-rings on the puncture valve.

Lubricate the thread of the puncture valve

with copper grease.

D-2 2. Screw the puncture valve into the bore in

the top cover.

Using a crowfoot wrench and a torque

spanner, tighten the puncture valve to the
torque stated in Data.

3. Mount the protective cap and the control air

pipe on top of the puncture valve.

4. If open, close the drain cock on the fuel

pump and open the fuel oil inlet valve.
HN909-8.4 207 02

3.
HN909-8.4 207 03

Page 4 (4) When referring to this page, please quote Procedure M90908 Edition 0212
0$1% :'LHVHO$6
 Fuel Pump Shock Absorber 109-9
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
109-9 Data
0022 Fuel Pump
K90MC-C
Shock Absorber

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
1000 kg
Data

D-1 Shock absorber 90 kg

D-2 Nuts – tightening torque 200 Nm

When referring to this page, please quote Data D10909 Edition 0022 Page 1 (2)
MAN B&W Diesel A/S
109-9 Fuel Pump Shock Absorber
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10909 Edition 0022
MAN B&W Diesel A/S
 Fuel Pump Shock Absorber 909-9.1
Checking
Fuel Pump Shock Absorber
K98MC
0211
Checking
909-9.1

To ensure satisfactory operation, the function-

ing of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspec-
tion is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is oper-
ating.

1. Remove the plug from the end cover of the

shock absorber. Check that air is ‘pulsating’
through the threaded hole.

Short bursts of air should be felt against the

hand, corresponding to the strokes of the
fuel pump.

The air pulses occur when the shock ab-

NA909-9.1 207 01
sorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.

2. To check the ‘tightness’ of the piston, meas-

ure the amount of leakage oil flowing from
the drain pipe of the shock absorber hous-
ing. Note down the amounts measured and
compare with earlier measurements.

Increasing amounts indicate a deteriorating

piston sealing. Excessive amounts indicate
that the shock absorber requires overhaul-
ing.
See Procedure 909-9.3.

When referring to this page, please quote Procedure M90909 Edition 0211 Page 1 (3)
MAN B&W Diesel A/S
909-9.3 Fuel Pump Shock Absorber
Overhaul
Overhaul
909-9.3

1.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
D-1 been relieved of pressure and that all oil
has been drained off.

1. Remove the shock absorber drain pipe.

Place a wire strap around the shock ab-
sorber and hook on the engine room crane.
Loosen the screws holding the shock ab-
sorber and remove it from the fuel pump
NA909-9.3 211 01

housing.

2. Remove the plug from the end cover of the

shock absorber. Fit a threaded rod between
2. the piston and the end cover to counteract
the force of the springs. Loosen the screws
of the end cover and remove the end cover
and piston. Discard the gasket.

3. Loosen the nut on the threaded rod to re-

lieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.

4. Clean all parts and polish the sliding sur-

faces of the piston and the shock absorber
housing. Mount a new sealing ring in the
D-2
NA909-9.3 207 02

shock absorber housing and a new wear

ring on the piston.

5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
4. the threaded rod.

Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to dam-
age the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.

6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking de-
vice. Remove the threaded rod and insert
the plug.
HG909-9.2 201 04

Page 2 (3) When referring to this page, please quote Procedure M90909 Edition 0211
MAN B&W Diesel A/S
 Fuel Pump Shock Absorber 909-9.3
Overhaul

7. Fit a new gasket on the fuel pump housing

and mount the shock absorber. Mount the
shock absorber drain pipe.

If an excessive amount of drain oil is still

observed after the overhaul, the shock ab-
sorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.

When referring to this page, please quote Procedure M90909 Edition 0211 Page 3 (3)
MAN B&W Diesel A/S
 Lifting Gear for Roller Guide 109-10
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
109-10 Data
0007
.0&& Lifting Gear for Roller Guide

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

When referring to this page, please quote Data D10910 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
109-10 Lifting Gear for Roller Guide
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10910 Edition 0007
MAN B&W Diesel A/S
 Lifting Gear 909-10.1
Checking
Lifting Gear
0213
.0&&

Checking
909-10.1

1.
The lifting gear for the fuel pump roller guide is
checked and activated by manually operating
the four-way valve of the lifting gear while the
engine is running or being turned.

1. Lift the knob on the dial of the four-way

valve, and turn the dial to position 1.

Thereby compressed air is led to the bear-

ing of the lifting device, causing the shaft,
which functions as piston, to be pressed in
against the roller guide.

The air cylinder is constantly vented

through a bore in the shaft until the shaft is Air inle
t
in the correct position.

2. When the shaft is pressed fully in, its lifting

pin is positioned under the reversing arm of
the roller guide, and the duct (which is con-
nected to the lifting cylinder) is uncovered,
thus activating the air cylinder.





The air cylinder lifts the coupling arm, 





which turns the shaft, and the lifting pin on 




the shaft thus lifts the roller guide clear of &

.

the arm.
2.

Air inle
t














&
.

When referring to this page, please quote Procedure M90910 Edition 0213 Page 1 (4)
0$1% :'LHVHO$6
909-10.1 Lifting Gear
Checking

3. 3. When the roller guide has been lifted, the

dial of the four-way valve can be returned
to zero position. Lift the knob to release the
dial from position 1.

The roller guide is now locked in a position

free of the fuel cam, and the engine can be
operated on the remaining cylinders, see
Volume I, Chapter 704.
MB909-5.0 38 05

Page 2 (4) When referring to this page, please quote Procedure M90910 Edition 0213
0$1% :'LHVHO$6
 Lifting Gear 909-10.1
Checking

Re-engagement of the fuel pump roller guide 4.

4. To lower the roller guide again, depress the

knob on the four-way valve in zero position.
Keep the knob depressed until the roller
guide has been lowered.

Thereby air pressure is led both to the lift-

ing cylinder and to the bearing for the lifting
gear.

The piston of the lifting cylinder is pressed

back, thereby turning the shaft out of its
‘locked’ position and lowering the roller
guide so much that the roller cannot go
clear of the cam.
Air inlet

When the highest point of the cam thus lifts

the roller guide, the pin of the shaft clears
the reversing arm of the roller guide, and
the air pressure in the bearing presses the
shaft back to its extreme position. Now the

roller guide can pass the pin of the shaft un- 



hindered. 







&
Release the knob of the four-way valve, .

whereby both the bearing and the lifting cyl-

inder are vented.

Note!

The engine is able to operate with a roller

guide in the wrong position.

Therefore, to ensure correct timing after

lowering the roller guide, it is recom-
mended to make a STOP/START
manoeuvre when convenient.

This will activate the air cylinder for the

reversing mechanism and ensure that the
roller guide is in its correct position.

When referring to this page, please quote Procedure M90910 Edition 0213 Page 3 (4)
0$1% :'LHVHO$6
909-10.3 Lifting Gear
Overhaul
Overhaul
909-10.3

1. 1. In the event of leakage at the sealing rings

of the lifting gear (the functioning is not sat-
isfactory), the sealing rings are to be re-
placed.

Dismount the pipe connections on the bear-

ing. Disconnect the pull rod of the air cylin-
der from the coupling arm and remove the
coupling arm.

Remove the screws which fasten the flange

and bearing to the roller guide housing.

Dismount the flange, pull the shaft out of

the bearing, and remove the bearing from
the bore of the roller guide housing.

Replace all O-rings A and the piston ring B.

Coat all sliding surfaces and sealing surfac-

es with molybdenum disulphide (MoS 2).





Place the bearing in the bore of the roller





guide housing, adjusting it in accordance



with the threaded holes.
&
0

Carefully press the shaft into the bearing.

2.
Place the flange on the shaft end (adjusted
according to the threaded holes in the bear-
ing), tightening it all up by means of the
screws.

Mount the coupling arm and the pull rod of

the air cylinder. Reconnect the pipes to the
nipples of the bearing.

2. After the overhaul, activate the lifting gear.

See Procedure 909-10.1.

In the activated position, check that the ad-

justing hole in the coupling arm coincides
with the adjusting hole in the flange. If this
is not the case, loosen the lock screw on
the pull rod and adjust the length of the pull
rod until the adjusting holes coincide.

Tighten the lock nut.














&
0

Page 4 (4) When referring to this page, please quote Procedure M90910 Edition 0213
0$1% :'LHVHO$6
 Fuel Valve 109-11
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0044
109-11 Fuel Valve

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Max. diameter 25 mm

D-2 Weight of fuel valve 15 kg

D-3 Opening pressure 320-380 bar

When referring to this page, please quote Data D10911 Edition 0044 Page 1 (2)
MAN B&W Diesel A/S
109-11 Fuel Valve
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10911 Edition 0044
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking
Fuel Valve
K90MC-C
0227
Checking
909-11.1

1.
The fuel valves must be given the utmost atten-
tion and care, as the greater part of irregulari-
ties that may occur during the running of the
engine can be attributed to defects in these
valves.

If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.

GN909-11.1 204 01
In order to obtain reliable results during testing
of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disassem-
bled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3. 2.

Note!

In the event that the slide-type fuel valve is

pressure tested without being cleaned
between the fuel nozzle and the cut-off slide,
the opening pressure value measured might
be considerably lower than specified.

All fuel valves must be function-tested before

being mounted in the cylinder cover.

1. Pressure testing pump

If an air supply of 10 bar is not available,

working air of seven bar can be used. Use
only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50°C.

For operation of the pressure testing pump,

see the supplier’s instructions.

Note that the high-pressure pump should

be periodically checked in accordance with
the supplier’s instructions.
HM909-6.3 70 01A

2. Spring housing

To ensure that overtightening has not taken

place, check that the locking/indicating pin
has not been bent or broken off.

In the event of overtightening, replace the

spring housing by a new one.

When referring to this page, please quote Procedure M90911 Edition 0227 Page 1 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

3. 3. Setting-up the fuel valve

Place the fuel valve in the test rig and se-

cure it with the spring housings and nuts.
Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housings. Mount the oil pipe be-
tween the pressure testing pump and the
fuel valve.

4. Pressure testing procedure

The subsequent items must be followed in

HM909-6.3 70 01B

the sequence stated. Items 5, 7, 8 and 9

are each divided into the following four sub-
items:

A. Objective
4. B. Procedure
C. Acceptance criteria
D. Cause of fault.

Note!

If working air of 10 bar is not available,

pressures down to 7 bar are acceptable
for all the tests.

5. Flushing and jet control

A. Objective:
HM909-6.0 67 00

To remove air in the system and check the

fuel jet.

B. Procedure:
5. The control handle must be in the OPEN po-
sition.
Slowly increase the working pressure until
straight jets of oil are ejected from the noz-
zle holes (no atomization).

C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.

Owing to the geometry of the internal part

of the nozzle – and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
NA909-11.1 215 05

during normal engine operation – the fuel

oil will not necessarily flow from all of the
nozzle holes.

Page 2 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

D. Cause of fault: 6.
If the jets do not fulfil the above point C, the
cause may be:

• Dirt in the nozzle holes.

• The nozzle is not mounted correctly.

6. Atomization test

Note!

MN909-11.1 222 06
Do NOT attempt to carry out an atomiza-
tion test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.

The reason is that the atomization test may

damage the valve because it makes the 7.
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
across the cut-off edge and the high con-
D-3
tact pressure between slide and fuel noz-
zle, in combination with the poor lubricity of
the test oil, increase the risk of seizures be-
tween cut-off slide and nozzle.

All of these conditions involve the risk of

seizure between the cut-off slide and the
nozzle.

7. Opening pressure

A. Objective:
To check the opening pressure.

B. Procedure:
The control handle is to be in the OPEN po-
sition.

Increase the oil pressure until oil is admit-

ted through the nozzle holes.

C. Acceptance criteria:
Check the opening pressure on the pres-
sure gauge.
MC909-6.4 99 06

When referring to this page, please quote Procedure M90911 Edition 0227 Page 3 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

8. D. Cause of fault:
If the opening pressure is higher than spec-
ified in D-3, the cause may be that a wrong
type of spring is used – replace the spring
on the thrust spindle, if necessary, replace
the complete thrust spindle.

If the opening pressure is lower than spec-

ified in D-3, the cause may be that the
spring has sagged – replace the spring, or
add a special thin disc.

Note!

Special thin discs are available as

spares.

If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated from step 4.

8. Sealing test and sliding function

A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.

B. Procedure:
The control handle must be in the OPEN po-
sition.

Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
NA909-11.1 211 08

C. Acceptance criteria:
Oil must not flow from the nozzle holes.

The pressure drops relatively slowly to

about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).

Note!

Oil flows out of the leak oil outlet when

the fuel valve is full of oil.

Page 4 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

D. Cause of fault:

D.1 Sealing test

If oil flows out of the nozzle holes, the
cause is either:

• Defective spindle guide at needle seat, or

a sticking spindle. Examine and/or re-
place the spindle guide.
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.

D.2 Sliding function

The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).

Note!

There will always be an oil flow from the

NA909-11.1 211 08

leak oil outlet when the fuel valve is full of

oil.

If a quick pressure drop from 15 to 0 bar

cannot be registered:

• The valve slide is sticking; or

• the vent hole in the thrust piece is

blocked.

If so, disassemble and examine the spindle

guide, replace if necessary.
See Procedure 909-12.3.

When referring to this page, please quote Procedure M90911 Edition 0227 Page 5 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

9. 9. Pressure test, O-ring sealings

A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.

B. Procedure:
The control handle is to be in the OPEN po-
sition.

Build up a working pressure of about max.

10 bar until oil flows out of the leak oil out-
let.

C. Acceptance criteria:
Close the leak oil outlet with a gasket and
plug screw.

Increase the working pressure to about 100

bar.

Move the control handle to the CLOSED po-

sition.

The built-up pressure of about 100 bar

should be maintained.

D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
MC909-6.4 99 08

Page 6 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2

1. Close the fuel oil inlet and outlet valves, 1.

and drain the high-pressure pipe and the
fuel valve.

Dismantle and remove the fuel oil high-

pressure pipe.
See Procedure 909-14.2.

Disconnect the return oil pipe from the fuel

valve.

2. Remove the nuts and the spring housings.

KB901-2.1 104 01
3. Take out the valve. If the valve is sticking,
use the fuel valve dismantling tool to pull
the fuel valve clear of the top cover.

If the valve is not to be overhauled immedi-

ately, the valve should be placed immersed 2.
in diesel oil until overhauling.
HG909-11.3 201 02

3.

D-2
HG909-11.2 221 03

When referring to this page, please quote Procedure M90911 Edition 0227 Page 7 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
Overhaul
909-11.3

1. When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.

Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
A fore reassembly.
MN909-11.3 219 01

1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.

2. 2. Place the valve holder in a machine vice,

mount the fuel valve in the holder and fit the
valve with the guide disc from the grinding
tool.

3. Compress the fuel valve and the spring in-

side, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the un-
ion nut with a hook spanner.

Remove the valve from the valve holder.

MN909-11.3 222 02

3.
MN909-11.3 222 03

Page 8 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

Pull the valve head clear of the valve hous-

ing.

Remove the:

• Non return valve

• Thrust spindle parts

• Thrust foot

• Spindle guide and fuel nozzle

from the valve housing.

Remove and discard all the O-rings.

HN909-11.3 223 04

When referring to this page, please quote Procedure M90911 Edition 0227 Page 9 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

4. 4. Carefully clean and examine all surfaces of

the:

• Fuel valve housing

D-1 • Fuel valve head

• Thrust spindle

If necessary, grind the seating surfaces by

means of the grinding mandrels supplied
and a fine-grain abrasive (such as Carbo-
rundum No. 500).

This grinding must only be carried out man-

ually.

After the grinding, wash the parts in gas oil

and blow clean by means of compressed air
to remove any remains of the grinding com-
pound.

In the event of more serious damage to the

seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.

Normally, the milling tool is turned by hand,

but it may be fitted in the chuck of a column-
type drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An am-
ple supply of cutting emulsion must be
used.

Note!

Take care not to exceed the maximum

diameter of the seat, see Data.
HN909-11.3 223 05

Page 10 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

5. The complete spindle guide, including the 5.

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
See Procedure 909-12.3.

Note!

Do not attempt to remove the fuel nozzle

NA909-11.3 215 03
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
6.
6. 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. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.

Carefully slide the spindle guide down into

MC909-6.1 99 04

the valve holder, and turn the nozzle until

the spindle guide engages correctly with
the guide pin. Check that distance A corre-
sponds to the measurement taken before
the valve was disassembled.
7.

Note!

Make sure that the fuel nozzle and spin-

dle guide engage correctly with the guide
pin in the fuel valve housing. This can be
ascertained by attempting to turn the
nozzle after mounting. It must not be
possible to turn the nozzle.
MN909-11.3 219 05

When referring to this page, please quote Procedure M90911 Edition 0227 Page 11 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

8. 8. Mount:

• the thrust foot

• the parts of the thrust spindle

• the non-return valve

in the fuel valve housing.

Mount a new O-ring in the uppermost

groove of the fuel valve housing.

Lubricate the thread of the valve head with

molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.

Fit the valve head with new O-rings.

9. 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
HN909-11.3 223 09

to prevent relative turning of the parts.

9.
MC909-6.1 99 07

Page 12 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

10. Assemble the valve by means of the union 10.

nut.

Place the valve in the valve holder in a drill-

ing machine.

Compress the fuel valve and the spring in-

side. Keep the valve compressed and tight-
en the union nut with a hook spanner.

After overhaul, the fuel valve must be test-

ed in the test rig.
See Procedure 909-11.1.

11. If the fuel valve is not to be mounted in the

engine immediately after the overhaul, cov-
er all openings of the valve with plastic to
prevent dirt from entering the valve during
storage. MN909-11.3 222 09

When referring to this page, please quote Procedure M90911 Edition 0227 Page 13 (14)
MAN B&W Diesel A/S
909-11.4 Fuel Valve
Mounting
Mounting
909-11.4

1. 1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover
and check the seating in the bore for marks
D-2 which, if any, must be eliminated.
(For reconditioning of the valve bores in the
cylinder cover, see Procedure 901-1.3).

If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS 2).

2. Mount the valve in position in the cylinder

cover.
MA901-2.1 72 03

Mount the spring housings and the nuts.

Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housing. This must be done with
2. great care, as the spring tension in the
housing determines the correct tightening
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.

3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.

Note!

It is recommended to overhaul the fuel oil

HG909-11.4 201 04

high-pressure pipe before mounting.

See Procedure 909-14.3.

As a minimum, the distance between the

fuel oil pipe ends and the thrust bushings
3.
must be checked and, if necessary,
adjusted.

Mount the overhauled fuel oil high-pressure

pipe and the return oil pipe.
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.
KB901-2.1 104 06

Page 14 (14) When referring to this page, please quote Procedure M90911 Edition 0227
MAN B&W Diesel A/S
 Spindle Guide 109-12
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K80MC-C
0031
109-12 Spindle Guide

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 D10912 Edition 0031 Page 1 (2)
MAN B&W Diesel A/S
109-12 Spindle Guide
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10912 Edition 0031
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
Overhaul
Spindle Guide
S90MC-C
0219
Overhaul
909-12.3

2.
Note!

This instruction is only valid for spindle

guides of the slide valve design.

Extreme care and accuracy should be

exercised when carrying out this opera-
tion.

Based on service experience it is recom-

mended to replace the complete spindle
guide after 8000 hours of operation.

1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.

Note!
MA909-6.2 111 02

The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.

2. Place the spindle guide in a bench vice pro- 4.

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.

3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.

Note!

The pulling tool is not standard for all

engines, but may be delivered as an
optional extra.

4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.

Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
and the spindle guide and very carefully
MA909-6.2 111 03

force the fuel nozzle off the spindle guide.

When referring to this page, please quote Procedure M90912 Edition 0219 Page 1 (5)
0$1% :'LHVHO$6
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 0219
0$1% :'LHVHO$6
 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 0219 Page 3 (5)
0$1% :'LHVHO$6
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 0219
0$1% :'LHVHO$6
 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. 6SULQJSLQ

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. 6FUDWFKPDUNV

Press the nozzle on to the spindle guide.

MN909-12.3 215 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 0219 Page 5 (5)
0$1% :'LHVHO$6
 Non-return valve 109-13
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0027
109-13 Non-return valve

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

When referring to this page, please quote Data D10913 Edition 0027 Page 1 (2)
MAN B&W Diesel A/S
109-13 Non-return valve
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10913 Edition 0027
MAN B&W Diesel A/S
 Non-return valve 909-13.3
Overhaul
Non-return valve
K98MC-C
0206
Overhaul
909-13.3

1.
Note!

Extreme care and accuracy should be

exercised when carrying out this opera-
tion.

1. Clean the outside of the non-return valve

with pure gas oil. The individual parts are
not interchangeable, therefore only one
guide is to be disassembled at a time.

Note!

Except for the slide valve spring, defec-

tive parts cannot be replaced individually 



by new ones. 








&

Place the non-return valve as shown in Fig. 0

1 in a bench vice provided with “soft” jaws,

A
and disassemble the non-return valve, us- 2.
ing the disassembling tool and a hammer
as shown.

2. Clean all the parts for the spindle guide in

gas oil and wipe them dry with a clean B C D
piece of cloth. 








Finally, clean in either gas oil, kerosene or 




‘Electrocleaner', and wipe the parts dry with 


%
1
a clean piece of cloth.

3. Now place the parts on clean, lint-free rags 3.

and examine with an 8-10 times enlarge-
ment magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.














&
0

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 Standard Tools: See Section 913

Special Data
K90MC-C
0049
109-14 Fuel Oil High-Pressure Pipe

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil 50-300 Nm
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of fuel oil pipe 23 kg

D-2 Tightening torque – 190 Nm

fuel oil high pressure pipe

D-3 Tightening torque – 55 Nm

union nuts

When referring to this page, please quote Data D10914 Edition 0049 Page 1 (2)
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data

Plate
90951

1283727-4

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10914 Edition 0049
MAN B&W Diesel A/S
 Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
K90MC-C
0224
Dismantling
909-14.2

2.
High-Pressure Pipe with Protective Hose

1. Close the fuel oil inlet and outlet valves.

2. Using a hook spanner, unscrew the union

nut at the fuel valve end of the high-pres-
sure pipe.

Pull the union nut and the protective hose

clear of the union nipple.

Unscrew the union nipple from the fuel

valve.

MB909-14.2 224 02
3. Using a hook spanner, unscrew the union
nut at the fuel pump end of the high-pres-
sure pipe.

Pull the union nut and the protective hose 3.

clear of the union nipple.

Unscrew the union nipple from the fuel

pump.

4. Lift the pipe ends clear of the fuel valve/fuel

pump, and remove the high-pressure pipe
from the engine.

Note!

It is recommended always to overhaul

HN909-14.2 209 03

the high-pressure pipe before remounting

it on the engine.
See Procedure 909-14.3.

The overhaul should preferably take

4.
place immediately after the high-pres-
sure pipe has been dismantled.

D-2
MB909-14.2 224 04

When referring to this page, please quote Procedure M90914 Edition 0224 Page 1 (4)
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3

1. 1. Whenever the fuel oil high-pressure system

D-1 has been dismantled, it is necessary, be-
fore remounting the high-pressure pipes, to
carefully inspect the tapered contact surfac-
es of the pipe ends, together with their
seats in fuel valves and fuel pump top cov-
er.

Furthermore, the position of the thrust

bushing on the pipe end must be checked.
If the distance is incorrect, compared with
the measurement stated in Data, it should
be adjusted by screwing the thrust bushing
up or down the pressure pipe.

2. If any of the pipe ends requires recondition-

ing, dismantle the high-pressure pipe as
MB909-14.3 224 01

follows:
D-1 • Lift up the union nut with flexible protec-
tive hose, together with the coupling nut,
on the high-pressure pipe and screw off
2. the thrust bushing.

• Remove the coupling nut and, when the

thrust bushings at both ends of the pipe
have been dismounted, pull the flexible
protective hose with union nuts off the
high-pressure pipe.

3. Shape-up the threads on the pipe ends with

D-2 the nut die.
MC909-7.0 67 02

3.
MC909-7.0 67 04

Page 2 (4) When referring to this page, please quote Procedure M90914 Edition 0224
0$1% :'LHVHO$6
 Fuel Oil High-Pressure Pipe 909-14.3
Overhaul

4. Mount the guide on the pipe end, place the 4.

miller in the guide and lightly screw on the
union nut.

5. Turn the miller with, for instance, a tap

wrench while lightly tightening the union nut
to provide a suitable pressure between mill-
er and pipe end. During the milling, add
drilling oil emulsion liberally.

After completing the milling, carefully clean

the high-pressure pipe with diesel oil and
wipe dry with a clean piece of cloth.

MC909-7.0 67 03
6. When assembling the high-pressure pipe,
screw the thrust bushings so high up on the
thread of the pressure pipe that the dis-
tance between the pipe end and the bottom
edge of the thrust bushing is as stated in 5.
Data.

Replace the O-rings.

Before mounting a high-pressure pipe,

check the centre distances between pipe
ends and seats, and lubricate the threads
of the union nuts with molybdenum disul-
phide (MoS 2).

It is of great importance for the mounting,

and a condition for obtaining tight joints,
GN909-14.3 204 05

that the pipes fit the seats accurately.

For reconditioning of seat in fuel valve, see

Procedure 909-11.3.

For reconditioning of seat in fuel pump top 6.

cover, see Procedure 909-5.3.
HM909-7.0 62 06

When referring to this page, please quote Procedure M90914 Edition 0224 Page 3 (4)
0$1% :'LHVHO$6
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
Mounting
909-14.4

4. 1. Check that the distance between the thrust

bushing and the pipe end is correct at both
ends of the pipe. See Procedure 909-14.3.

2. Ensure that the fuel valve is fitted with a

D-2 new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.

3. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
MB909-14.4 224 04

4. Mount the high-pressure pipe between the

fuel valve and the fuel pump.

Screw the union nipples onto the fuel valve

5. and into the fuel pump top cover, by hand.

Note!

The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nip-
ples have been screwed into position.

5. Use a crowfoot wrench and a torque

MB909-14.4 224 05

D-3 wrench to tighten the union nipple at the

fuel valve to the torque stated in Data.

Screw the union nut onto the union nipple

6. by hand, and tighten lightly with a hook
spanner.

6. Use a crowfoot wrench and a torque

wrench to tighten the union nipple at the
fuel pump to the torque stated in Data.

Screw the union nut onto the union nipple

by hand, and tighten lightly with a hook
spanner.

7. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
HN909-14.4 209 06

D-3

Page 4 (4) When referring to this page, please quote Procedure M90914 Edition 0224
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 109-15
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0041
109-15 Fuel Pump Roller Guide

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
140–760 Nm

Data
2 x M16
Ref. Description Value Unit

D-1 Pump base 385 kg

D-2 Fuel pump roller guide 345 kg

D-3 Max. clearance,

roller/bushing/shaft pin 0.5 mm

D-4 Tightening torque –

nut, reversing shaft 400 Nm

D-5 Clearance C ±0.1 mm

When referring to this page, please quote Data D10915 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10915 Edition 0041
MAN B&W Diesel A/S
 Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
K90MC-C
0222
Checking
909-15.1

3.
Roller guide mounted in engine

1. The fuel pump roller guide can be partially

checked while mounted on the engine, us-
ing the following procedure:

2. Lift the fuel pump roller guide.

See Procedure 909-10.

3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.

Turn the engine to provide the maximum

space between the roller guide and the cam
disc.

Turn the roller by hand to check that it can

move freely and without unnecessary re-
sistance or “hard” points. MB909-15.1 222 03

Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no trac-
es of bearing metal left in the roller guide
housing. 5.

Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.

4. Lower the roller guide onto the fuel cam

again.
See Procedure 909-10.

5. Using the engine telegraph, move the roller

guide to the AHEAD position.

Check that the reversing link is fully tilted

over in AHEAD position, and that there is no
clearance between the reversing link and
the roller guide.

Carry out the same check in the ASTERN po-

sition.
GN909-15.1 203 05

When referring to this page, please quote Procedure M90915 Edition 0222 Page 1 (9)
0$1% :'LHVHO$6
909-15.1 Fuel Pump Roller Guide
Checking

7. Roller guide removed from engine

A more suitable and reliable method is to check

the roller guide and the bearing clearance after
the roller guide has been dismounted:
D-2
6. Dismount the roller guide from the engine.
See Procedure 909-15.2.

7. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.

8. Turn the roller guide upside down and land

it in a vertical position on a couple of wood-
en planks, with the roller hanging freely.

Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clear-
ance permits.
MA909-8.0 70 07

8.

D-3
MA909-8.0 70 06

Page 2 (9) When referring to this page, please quote Procedure M90915 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.2
Dismantling
Dismantling
909-15.2

1.
Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

1. Dismantle the top cover with the barrel/

plunger assembly.
See Procedure 909-6.2.

2. Dismantle the fuel pump housing.

See Procedure 909-4.2.

Note!

When lifting the fuel pump housing, take

care not to damage the threads on the
studs.
MA909-15.2 217 01

2.
MA909-4.2 214 07

When referring to this page, please quote Procedure M90915 Edition 0222 Page 3 (9)
0$1% :'LHVHO$6
909-15.2 Fuel Pump Roller Guide
Dismantling

3. 3. Loosen and remove the locking wire and

the screws from the disc on top of the roller
guide inside the pump base.

Remove the sealing cap from the roller

guide/pump base.

Dismantle the lubricating oil pipe and the

drain pipe from the pump base.

4. Remove the cover on the camshaft housing

to inspect the position of the roller guide.
Turn the engine until the roller guide is at
BDC.
MB909-15.2 222 03

4.
MB909-15.1 222 03

Page 4 (9) When referring to this page, please quote Procedure M90915 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.2
Dismantling

5. Loosen the nuts on the two threaded studs 5.

successively until the roller guide springs
are relieved.

Remove the nuts, mount two eye bolts in

the pump base and lift it away. D-1
When lifting, take care that the bushing of
the pump base slides against the upper
part of the roller guide without scratching.

Remove the springs from the roller guide.

6. Mount the roller guide lifting tool as follows:

• Lift the lock plate of the tool up on the

shaft of the tool.

• Position the tool so that its foot rests on

the thrust piece in the bayonet joint of the
roller guide.
MB909-15.2 222 05

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock plate, thereby securing

the foot in the locked position.
6.
Lift the roller guide out of the roller guide
housing, using the crane.

When lifting, take care that the slide surfac-

es of the roller guide do not scrape against
the roller guide bushing.

Land the roller guide on wooden planks.

D-2
7. Check the roller guide.
See Procedure 909-15.1. 90°
MB909-15.2 222 06

When referring to this page, please quote Procedure M90915 Edition 0222 Page 5 (9)
0$1% :'LHVHO$6
909-15.3 Fuel Pump Roller Guide
Overhaul
Overhaul
909-15.3

1. 1. Inspect and check the fuel pump roller

guide.
See Procedure 909-15.1.

D-2 2. It is recommended that the roller guide

should ONLY be dismantled if

• irregularities when turning the roller,

• damage to the roller,

• larger clearance than stated on the Data

sheet,

• seizure marks on the slide surfaces,

have been observed when checking the

roller guide.

Note!

For disassembling of the roller guide,

MA909-8.0 70 07

contact an MAN B&W authorized repair

shop.

3. If no irregularities are found, just clean and

3. lubricate the roller guide before remounting
it in the roller guide bushing.

D-2
MB909-15.3 222 03

Page 6 (9) When referring to this page, please quote Procedure M90915 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.4
Mounting
Mounting
909-15.4

1. Lubricate the roller guide with plenty of 1.

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.

During mounting, take care not to scratch

the sliding surfaces of the roller guide.
D-2
Make sure that the pin of the reversing link
fits in the guide of the reversing shaft.

2. After mounting the roller guide with the re-

versing link, check the clearance between 90°
the roller guide and the guide plate mount-
ed in the roller guide bushing.

Turn the camshaft so that the roller guide is

lifted approx. 20 mm.

The clearance C between the roller guide

and the guide plate must be the same at
both ends. See Data.
MB909-15.4 222 01

The clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.

Connect working air to the air cylinder, and 2.

check that the reversing mechanism is
working smoothly.

The clearances A and B must be approx. D-5

the same in both positions.

Note that clearances A and B change posi-

tion when changing from AHEAD to ASTERN. C

B C
MB909-15.4 222 02

When referring to this page, please quote Procedure M90915 Edition 0222 Page 7 (9)
0$1% :'LHVHO$6
909-15.4 Fuel Pump Roller Guide
Mounting

3. 3. If adjustment is necessary, it must take

D-4 place in the ASTERN position.

Loosen the nut on the reversing shaft and

carry out the adjustment.

After adjustment, shift to AHEAD position

and check the clearances A and B once
more.

Finally, shift again to ASTERN.

Tighten the nut on the reversing shaft to the

MB909-15.4 222 03

torque stated in Data, and lock the nut with

Loctite type: Screw Lock No. 243.

Mount the cover over the shaft connection.

5. 4. Turn the engine until the roller guide is at

BDC.

5. Mount the new sealing ring in the groove in-

side the bushing of the pump base. Make
sure to mount the sealing ring correctly.
See the sketch.

D-1 6. Mount the springs and the spring seat discs

over the roller guide.

Mount the pump base over the roller guide

and the springs.
NA909-15.4 213 05

Mount the two special nuts on the threaded

studs.

Tighten the nuts until the pump base is fas-

6. tened tightly to the roller guide bushing.

D-1
MB909-15.2 222 05

Page 8 (9) When referring to this page, please quote Procedure M90915 Edition 0222
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.4
Mounting

7. Check the movement of the reversing link. 7.

See Procedure 909-15.1.

8. Mount the lubricating oil pipe and the drain

pipe on the pump base.

Mount the sealing cap, the disc and the

screws on top of the roller guide, over the
sealing bush inside the pump base.

Tighten the screws and lock with locking

wire.

GN909-15.1 203 05
9. Mount the fuel pump housing.
See Procedure 909-4.4.

10. Mount the barrel/plunger assembly.

See Procedure 909-6.4.
8.
11. Mount the fuel pump top cover.
See Procedure 909-5.4.

12. Mount the fuel oil high-pressure pipes.

See Procedure 909-14.4.

13. Close the fuel pump drain cock. Open the

fuel oil inlet and outlet valves.
MB909-15.2 222 03

9.
MA909-4.2 214 07

When referring to this page, please quote Procedure M90915 Edition 0222 Page 9 (9)
0$1% :'LHVHO$6
 Fuel Valve and Fuel Pump Panel Plate
P90951-0423
Fuel
P90951
0423 Valve and Fuel Pump Panel

When referring to this page, please quote Plate P90951 Edition 0423 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve and Fuel Pump Panel
P90951-0423

Item Item
Item Description Item Description
No. No.

010 Panel for tools

021 Name plate
045 Measuring tool
057 Lifting tool for fuel pump
069 Lifting tool for fuel pump
070 Lifting tool for fuel pump housing
094 Milling tool for seats for fuel oil pipe
104 Milling tool for fuel oil pipe
116 Crowfoot wrench head
128 Crowfoot wrench head
130 Crowfoot wrench head
141 Crowfoot wrench head
153 Flange for dismantling of non-return
valve
165 Grinding mandrel for valve head
177 Grinding mandrel for throw spindle
189 Grinding mandrel, outside
190 Grinding mandrel, inside
200 Screw
224 Tool for P.max rack
236 Pin wrench, special
248 Hook wrench
250 Drift for spindle guide
273 Drift for non-return valve
297 Assembling tool
307 Hook wrench

Page 2 (2) When referring to this page, please quote Plate P90951 Edition 0423
MAN B&W Diesel A/S
 Fuel Valve - Tools Plate
P90961-0061
Fuel Valve - Tools
0061
P90961

When referring to this page, please quote Plate P90961 Edition 0061 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0061

Item Item
Item Description Item Description
No. No.

014 Test rig complete

026 Rig fuel oil valve
038 High-pressure pump
051 Table
063 High-pressure pump
087 Spring housing, complete
099 Gasket
109 Plug screw
110 Angle union
122 Hose
134 Test rig, guide
158 Connecting piece, M42x2

Page 2 (2) When referring to this page, please quote Plate P90961 Edition 0061
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 Puncture Valve - Tools Plate
P90967-0001

When referring to this page, please quote Plate P90967 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Puncture Valve - Tools
P90967-0001

Item Item Description Item Item Description

No. No.

017 Tool for tightening of puncture valve

Page 2 (2) When referring to this page, please quote Plate P90967 Edition 0001
MAN B&W Diesel A/S
 Fuel Valve - Inspection Tools Plate
P90968-0001

When referring to this page, please quote Plate P90968 Edition 0001 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 - Pump Barrel Seals Plate
P90977-0001
Mounting Tools - Pump Barrel Seals
0001
P90977

When referring to this page, please quote Plate P90977 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Pump Barrel Seals
P90977-0001

Item Item
Item Description Item Description
No. No.

011 Cone
023 Pushing tool
035 Compression tool
047 Cone
059 Pushing tool
060 Compression tool
072 Spacer ring

Page 2 (2) When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Suction Valve Seals Plate
P90979-0001
Mounting Tools - Suction Valve Seals
0001
P90979

When referring to this page, please quote Plate P90979 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Suction Valve Seals
P90979-0001

Item Item
Item Description Item Description
No. No.

012 Cone
024 Pushing tool
036 Compression tool

Page 2 (2) When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Air Piston Seals Plate
P90980-0001
Mounting Tools - Air Piston Seals
0001
P90980

When referring to this page, please quote Plate P90980 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Air Piston Seals
P90980-0001

Item Item
Item Description Item Description
No. No.

018 Cone
020 Pushing tool
031 Compression tool
043 Cone
055 Pushing tool
067 Compression tool
079 Cone

Page 2 (2) When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S
910 - Turbocharger System

Documents in this Chapter

110-01 0026 Air Cooler Element, Data

910-01 0226 Air Cooler Element
110-02 0003 Non-Return Valve in Turbocharger, Data
910-02 0210 Non Return Valve in Tubocharger
110-03 0008 Auxilary Blower, Data
910-03 0210 Auxilary Blower
110-04 0003 Butterfly Valve, Data
910-04 0205 Butterfly Valves
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0017 Water Mist Catcher, Data
910-06 0210 Water Mist Catcher
91061 0065 Turbocharger System - Tools
91061 0070 Turbocharger System - Tools
91061 0071 Turbocharger System - Tools
91063 0018 Air Cooler - Tools
91063 0019 Air Cooler - Tools
91063 0020 Air Cooler - Tools
91064 0001 Travelling Trolley
91066 0002 Air Cooler - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Air Cooler Element 110-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S80MC-C
0026
110-1 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
2 x 3000 kg
Shut off fuel oil 2 x 1000 kg
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Aft end cover 320 kg

D-2 Air cooler element up to 3100 kg

D-3 Front end cover 280 kg

(waterflow reversing chamber)

When referring to this page, please quote Data D11001 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data

Spare Parts

Plate – Item No. Description Qty

See special instructions from air cooler element manufacturer.

Page 2 (2) When referring to this page, please quote Data D11001 Edition 0026
MAN B&W Diesel A/S
 Air Cooler Element 910-1.1
Checking
Air Cooler Element
0226
60&&

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 
$
1

the air side of the cooler.


A decrease in the air temperature drop
across the scavenge air cooler indicates
fouling of the water side of the cooler.

3. If the measurements indicate fouling of the

water side of the air cooler element, the el-
ement must be overhauled/cleaned.
See Procedure 910-1.3 – water side.

If the measurements indicate fouling of the

air side of the air cooler element, it is rec-
ommended to inspect the air cooler ele-
ment as follows:

4. Remove the inspection cover from the side 




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 910-1.3 – air side.















1
.

When referring to this page, please quote Procedure M91001 Edition 0226 Page 1 (11)
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 to drain off the
cooling water. Dismantle the drain pipes.

2. Dismount the screws which fasten the cool-

KN910-1.2 226 01

ing water inlet and outlet flanges to the aft

end cover.

Dismount the drain cocks from the aft end

cover.
2.
KN910-1.2 226 02

Page 2 (11) When referring to this page, please quote Procedure M91001 Edition 0226
0$1% :'LHVHO$6
 Air Cooler Element 910-1.2
Dismantling

3. Dismount the brackets which control the 3.

longitudinal position of the air cooler ele-
ment.

Dismount the sealing flanges around the aft

end cover.

For convenience, the sealing flanges may

be left hanging on the cooling water pipes
during dismantling and mounting of the
cooler element.

4. Dismount the sealing flanges around the

front end cover.

KN910-1.2 226 03
5. Mount the pair of guide rails on the front of
the cooler housing. Mount the lifting bracket
on the front end cover of the cooler ele-
ment.
4.
Mount a travelling trolley on the beam
above the front end of the scavenge air
cooler. Attach a tackle between the travel-
ling trolley and the lifting bracket, and haul
tight.
KN910-1.2 226 04

5.
KN910-1.2 226 05

When referring to this page, please quote Procedure M91001 Edition 0226 Page 3 (11)
0$1% :'LHVHO$6
910-1.2 Air Cooler Element
Dismantling

6. 6. Mount the guide wheels on the aft end cov-

er.

7. Mount a pair of guide rails on the aft end of

the cooler housing.

8. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount, but do not tighten, the lower-
most screws. Mount and tighten the upper-
most screws.

Tighten the lowermost screws and the

thrust nuts on the uppermost screws simul-
taneously. This results in loosening and lift-
ing the cooler element.
KN910-1.2 226 06

7.
KN910-1.2 226 07

8.
NA910-1.2 214 07

Page 4 (11) When referring to this page, please quote Procedure M91001 Edition 0226
0$1% :'LHVHO$6
 Air Cooler Element 910-1.2
Dismantling

9. Tighten the tackle until the front end of the 9.

cooler element comes loose.

Pull out the cooler element far enough to al-

low a lifting bracket to be mounted on the
aft end cover. Mount the lifting bracket.

10. Pull the cooler element out of the cooler

housing by means of a tackle until the
wheels engage with the holes in the guide
rails on the front of the cooler housing.

11. Fit a tackle to the lifting bracket on the aft

KN910-1.2 226 09
end cover and lift the cooler element away.

Note!

Depending on the engine and the engine 10.

room installation, it may be necessary to
remove some pipes and floor plates.

D-2
KN910-1.2 226 10

11.

D-2
KN910-1.2 226 11

When referring to this page, please quote Procedure M91001 Edition 0226 Page 5 (11)
0$1% :'LHVHO$6
910-1.3 Air Cooler Element
Overhaul
Overhaul
910-1.3

1. Cleaning the air side:

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-
NA910-1.3 214 01

ply to the exhaust valve.

2. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
2. cleaning fluid, the circulating pump pres-
sure must be at least 0.7 bar.

3. Continue the cleaning process for at least

30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.

4. After cleaning, flush the cooler with clean

water until the water appearing in the sight
glasses is clean and pure.

5. Inspect the element either by removing the

cover on top of the cooler or by dismantling
the charging air pipe.
KE910-5.1 61 02

Page 6 (11) When referring to this page, please quote Procedure M91001 Edition 0226
0$1% :'LHVHO$6
 Air Cooler Element 910-1.3
Overhaul

Cleaning the water side 6.

6. Close the cooling water inlet and outlet

valves. Remove the plug screws from the
front end cover and the aft end cover to
drain off the cooling water.

7. Dismount the cooling water inlet and outlet

pipes from the aft end cover.

8. Screw two eye bolts into the upper flange of

the aft end cover. Mount a lifting wire rope
between the eye bolts.

KN910-1.3 226 06
Mount a travelling trolley on the beam
above the aft end cover.

Mount a tackle between the travelling trolley

and the lifting wire rope. Tighten up the 7.
tackle.

Dismount the brackets which control the

longitudinal position of the air cooler ele-
ment.
KN910-1.3 226 07

8.
NA910-1.3 214 08

When referring to this page, please quote Procedure M91001 Edition 0226 Page 7 (11)
0$1% :'LHVHO$6
910-1.3 Air Cooler Element
Overhaul

9. 9. Mount a shackle in each of the two lifting

eyes on the front end cover.

Mount two tackles above the front end of

the air cooler.

Hook the tackles on to the shackles and

tighten up.

10. Remove the screws of the front end and aft

end covers.

Lower both covers and land them on a cou-

ple of wooden planks. Discard the gaskets.
NA910-1.3 214 09

11. Clean the inside of the tubes, using the

cleaning brush mounted on a drilling ma-
chine. In the event of leakages between
10. cooling tube and tube plate, the tubes are
rolled with the tube expander.

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!
D-1 D-3
If damaged, the coating inside the covers
NA910-1.3 214 10

is to be repaired with the original coating

or a similar product.

12. When cleaning is complete, mount the cov-

11. ers in the reverse order to dismantling.
NA910-1.3 214 11

Page 8 (11) When referring to this page, please quote Procedure M91001 Edition 0226
0$1% :'LHVHO$6
 Air Cooler Element 910-1.4
Mounting
Mounting
910-1.4

1. Lift the air cooler element and land the aft 1.

end of the element on the guide rails
mounted on the front end of the air cooler
housing.

Hook a tackle from the travelling trolley on

to the lifting bracket on the front end cover
of the cooler element.

Remove the tackle from the aft end of the D-2

cooler element.

2. Push the air cooler element inwards ap-

prox. one metre.

KN910-1.2 226 11
Remove the lifting bracket from the aft end
cover.

3. Push the air cooler element fully into the air 2.

cooler housing

Remove the guide rails from the aft end of

the air cooler housing.

Note!

Before pushing the air cooler element

fully in, make sure that the sealing
flanges and a new O-ring are in position,
hanging on the cooling water pipes.
KN910-1.2 226 09

3.
KN910-1.2 226 07

When referring to this page, please quote Procedure M91001 Edition 0226 Page 9 (11)
0$1% :'LHVHO$6
910-1.4 Air Cooler Element
Mounting

4. 4. Remove the guide wheels from the aft end

cover.

5. Remove the guide rails and the lifting

bracket from the front end cover.

6. Mount the sealing plate, a new O-ring and

the frame around the front end cover.
KN910-1.2 226 06

5.
KN910-1.2 226 05

6.
KN910-1.2 226 04

Page 10 (11) When referring to this page, please quote Procedure M91001 Edition 0226
0$1% :'LHVHO$6
 Air Cooler Element 910-1.4
Mounting

7. Mount the sealing plate, a new O-ring and 7.

the frame around the aft end cover.

Mount and tighten the brackets which con-

trol the longitudinal position of the air cooler
element.

8. Insert new gaskets between the aft end

cover and the flanges of the cooling water
pipes.

Mount and tighten the screws which fasten

the cooling water inlet and outlet pipes to
the aft end cover.

Mount the drain pipes, and open the cooling

water inlet and outlet valves.

KN910-1.2 226 03
Note!

Remember to vent trapped air from the

air cooler element.
8.
KN910-1.4 226 08

When referring to this page, please quote Procedure M91001 Edition 0226 Page 11 (11)
0$1% :'LHVHO$6
 Non-Return Valve 110-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
110-2 Data
0003
.0&& 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 0003 Page 1 (2)
MAN B&W Diesel A/S
110-2 Non-Return Valve
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11002 Edition 0003
MAN B&W Diesel A/S
 Non-Return Valve 910-2.3
Overhaul
Non-Return Valve
0210
.0&&

Overhaul
910-2.3

1.
1. Access to the non-return valves in the scav-
enge air receiver takes place – after the en-
gine has been stopped – through the
inspection openings of the receiver.

Warning!

Access to the scavenge air receiver

MA910-6.0 33 01
must not be attempted until the air in the
receiver is clean.

2. Remove the two outermost and middle nuts

(which fasten the valve assembly to the 2.
housing).

Lift the complete valve assembly out of the

air receiver.

3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
MC910-6.0 26 01B

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 M91002 Edition 0210 Page 1 (1)
0$1% :'LHVHO$6
 Auxiliary Blower 110-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
110-3
0008
.0&& 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
2 x 2000 kg
Ref. Description Value Unit

D-1 Weight of blower unit,

complete *) up to 1300 kg

*) Depending on electric
motor type and number of
cylinders of engine (size and
capacity of auxiliary blower)

When referring to this page, please quote Data D11003 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
110-3 Auxiliary Blower
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11003 Edition 0008
MAN B&W Diesel A/S
 Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
0210
.0&&

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.

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 0210 Page 1 (1)
0$1% :'LHVHO$6
 Butterfly Valves 110-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special
110-4 Data
0003
.0&& 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 0003 Page 1 (2)
MAN B&W Diesel A/S
110-4 Butterfly Valves
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11004 Edition 0003
MAN B&W Diesel A/S
 Butterfly Valves 910-4.1
Checking
Butterfly Valves
0205
60&&

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. Flow direction

2. To check the valve, remove the cover on the

top of the butterfly valve.

MN910-4.1 205 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 0205 Page 1 (1)
0$1% :'LHVHO$6
 Turbocharger Turbine 110-5
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
0005
110-5
.0&& Turbocharger Turbine

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 0005 Page 1 (2)
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11005 Edition 0005
MAN B&W Diesel A/S
 Turbocharger Turbine 910-5.3
Cleaning
Turbocharger Turbine
0206
.0&&

Cleaning
910-5.3

The dry cleaning method employs compressed

air to blow dry, solid, granules through the tur-
bocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.

On account of their hardness, nut-shells, or

broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.

Note!

We do not recommend the use of rice or

grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.

It is not always possible to remove thick depos-

its with this dry cleaning method.

Therefore, in order to prevent the build-up of

thick deposits, the turbine must be cleaned af-
ter every 24 to 50 hours of operation.

Generally, turbocharger cleaning can be carried

out without, or with very little, reduction of the
engine load.

More detailed information regarding the amount

of granules to be used is stated on the instruc-
tion plate located close to the turbocharger.

Note!

Regarding water washing of turbocharger

turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.

When referring to this page, please quote Procedure M91005 Edition 0206 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.
XX706-12 40B

After about two minutes, close valves B and

C.

5. Slowly open valve A to relieve the pressure

in the tank.

6. Fill the tank with the quantity of granules

specified in the table.

7. Close valve A.

8. Open valves B and C, to blow-in the gran-

ules. After one to two minutes, close valves
B and C.

9. Slowly open valve A to relieve the pressure

in the tank.
HM910-5.3 50 02

Caution!

1.The drain openings in the gas casings

must remain closed while dry cleaning
the turbine.

2. It is possible that during dry cleaning

of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.

Page 2 (2) When referring to this page, please quote Procedure M91005 Edition 0206
0$1% :'LHVHO$6
 Water Mist Catcher 110-6
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

/0&
Special Data
110-6
0017 Water Mist Catcher

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear 2 x M16
X Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
2 x 1000 kg

Data
Ref. Description Value Unit

D-1 Water mist catcher 260 kg

When referring to this page, please quote Data D11006 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
110-6 Water Mist Catcher
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11006 Edition 0017
MAN B&W Diesel A/S
 Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
0210
.0&&

Dismantling
910-6.2

2.
1. Normally it is not necessary to remove the
water mist catcher element from the air
cooler housing. If, however, the water mist
catcher element has been fouled or dam-
aged, it must be dismantled for cleaning or
repair.

2. Dismantle the side covers from the air cool-

er housing.

3. Loosen the four screws which tighten the

water mist catcher to the air cooler frame.

NA910-6.2 210 02
4. Pull the water mist catcher half way out and
screw a lifting eye bolt into the top of the
water mist catcher.

Attach a tackle to the eye bolt and tighten

up the tackle. 3.

5. Pull the water mist catcher fully out of the

air cooler housing and land it on a couple
of wooden planks.

6. Clean or repair according to manufacturer’s

instructions.
NA910-6.2 210 03

4.
NA910-6.2 210 04

When referring to this page, please quote Procedure M91006 Edition 0210 Page 1 (2)
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4

1. 1. Tilt the water mist catcher to the correct an-

gle and slide it into the scavenge air cooler
housing.

Note!

Make sure the water mist catcher is

mounted in the right direction. Check the
air flow indicator on the water mist
catcher.

When the water mist catcher is half-way in,

remove the tackle and the eye bolt, and
push the water mist catcher fully into the air
cooler housing.

2. Mount the screws which secure the water

NA910-6.4 210 01

mist catcher to the air cooler frame.

3. Clean the side covers and apply a thin layer

of silicone paste along the edges of the
covers. Mount the covers.
2.
NA910-6.4 210 02

3.
NA910-6.2 210 02

Page 2 (2) When referring to this page, please quote Procedure M91006 Edition 0210
0$1% :'LHVHO$6
 Turbocharger System - Tools Plate
P91061-0065
Turbocharger System - Tools
0065
P91061

When referring to this page, please quote Plate P91061 Edition 0065 Page 1 (2)
MAN B&W Diesel A/S
Plate Turbocharger System - Tools
P91061-0065

Item Item
Item Description Item Description
No. No.

134 Screw
146 Blank plate (*
171 Blank plate (*
183 Throttle plate (*
195 Throttle plate (*
205 Blank plate (*
217 Eye bolt
229 Pulling tool

*) Exhaust gas system blanking-off

tool. (Only when two or more TC, or
Emergency By-pass, are fitted)

Page 2 (2) When referring to this page, please quote Plate P91061 Edition 0065
MAN B&W Diesel A/S
 Turbocharger System - Tools
Tools Plate
MAN B&W Diesel P91061-0070

When referring to this page, please quote Plate P91061 Edition 0070 Page 1 (2)
Plate
Turbocharger System - Tools
Tools
P91061-0070 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Throttle plate

026 Blank plate
038 Blind plate after turbocharger
040 Throttle plate
051 Blank plate
109 Screw

Page 2 (2) When referring to this page, please quote Plate P91061 Edition 0070
 Turbocharger System - Tools
Tools Plate
MAN B&W Diesel P91061-0071

When referring to this page, please quote Plate P91061 Edition 0071 Page 1 (2)
Plate
Turbocharger System - Tools
Tools
P91061-0071 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Pulling tool

026 Lifting eye bolt

Page 2 (2) When referring to this page, please quote Plate P91061 Edition 0071
 Air Cooler - Tools Plate
P91063-0018
Air Cooler - Tools
0018
P91063

Fore end

When referring to this page, please quote Plate P91063 Edition 0018 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0018

Item Item
Item Description Item Description
No. No.

015 Guide rail, fore end - left

027 Guide rail, fore end - right
039 Screw

Page 2 (2) When referring to this page, please quote Plate P91063 Edition 0018
MAN B&W Diesel A/S
 Air Cooler - Tools Plate
P91063-0019

When referring to this page, please quote Plate P91063 Edition 0019 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
 Air Cooler - Tools
Tools Plate
MAN B&W Diesel P91063-0020

When referring to this page, please quote Plate P91063 Edition 0020 Page 1 (2)
Plate
Air Cooler - Tools
Tools
P91063-0020 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Wheel for air cooler, left

027 Wheel for air cooler, right
039 Screw

Page 2 (2) When referring to this page, please quote Plate P91063 Edition 0020
 Travelling Trolley Plate
P91064-0001
Travelling Trolley
0001
P91064

When referring to this page, please quote Plate P91064 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0001

Item Item
Item Description Item Description
No. No.

010 Travelling trolley

Page 2 (2) When referring to this page, please quote Plate P91064 Edition 0001
MAN B&W Diesel A/S
 Air Cooler - Lifting Tools
Tools Plate
MAN B&W Diesel P91066-0002

When referring to this page, please quote Plate P91066 Edition 0002 Page 1 (2)
Plate
Air Cooler - Lifting Tools
Tools
P91066-0002 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Lifting attachment air cooler

023 Screw

Page 2 (2) When referring to this page, please quote Plate P91066 Edition 0002
911 - Safety Equipment

Documents in this Chapter

111-01 0026 Safety Valve, Data

911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver - Safety Valve, Data
911-03 0001 Scavenge Air Receiver - Safety Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Safety Valve 111-1
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
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

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 0026 Page 1 (2)
111-1 Safety Valve
Data MAN B&W Diesel

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

Plate 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 0026
 Safety Valve 911-1.2
MAN B&W Diesel 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
When Top-mounted

3. Unscrew the safety valve from the cylinder

cover.

Remove and discard the mild steel disc.

2.
M91101
0211D02

3.
M91101
0211D03

When referring to this page, please quote Procedure M91101 Edition 0212 Page 1 (5)
911-1.3 Safety Valve
Overhaul (Adjustment) MAN B&W Diesel

1. If necessary, dismantle the safety valve and

1. clean all the parts in either gas oil, kero-
sene, or ‘electro-cleaner’.

2. Assemble the safety valve in two steps:

• Insert the valve flap and the stop ring in

the valve guide and screw on the valve
housing.

• Tighten the housing to the torque stated

in the data, loosen and tighten again to
the torgue stated in the data.
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 0212
 Safety Valve 911-1.3
MAN B&W Diesel Overhaul (Adjustment)

4. To set the safety valve opening pressure:

4.
• Set up the safety valve in the Fuel valve
test rig.

• Connect the testing device to the hy-

draulic pump. Alternatively the hydraulic
hans pump can be used.

• Loosen the lock nut on the safety valve.

• Turn the adjusting screw until the valve

just closes.

• Bleed the valve and hose until oil, with-

out air bubbles, flows out from the
openings of the safety valve.

• Tighten the adjusting screw of the

safety valve until the correct pressure is
indicated (see Data).

• Tighten the lock nut.

M91101
0212O04

• Test the opening pressure.

• Remove the valve from the fuel valve

test rig.

When referring to this page, please quote Procedure M91101 Edition 0212 Page 3 (5)
911-1.4 Safety Valve
Mounting MAN B&W Diesel

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 0212
 Safety Valve 911-1.4
MAN B&W Diesel 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 0212 Page 5 (5)
 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

2.
is calibrated at the factory and does not
re
quire any adjustment.

2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.

Use a piece of cloth to wipe out any dirt

from the O
ring packing and close the
valve again. Tighten the counter nut.

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.

2. On some engines, a cover has to be re-

moved in order to gain access to the safety
valve.
M91103
0001D01

2.
M91103
0001D02

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.
M91103
0001O04

7. Check the valve according to 911
3.1.

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 0008 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0208 Holding Down and End Chock Bolts (Epoxy)
112-03 0017 Stay Bolts, Data
912-03 0213 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0075 Hydraulic Tools for Large Parts

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Holding Down and End Chock Bolts 112-2
Data

SAFETY PRECAUTIONS
Special Data
S42MC
0008
112-2 Holding Down and End Chock Bolts

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

Data
Ref. Description Value Unit
D12-01 Tightening pressure for holding down bolts and end chock bolts 900 bar
D12-02 Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
1st check 500 hours
2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequently at intervals of 8000 hours

When referring to this page, please quote Data D11202 Edition 0008 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 24 Hydraulic jack for holding-down bolts, complete
P91263 36 Hydraulic jack for end-chock bolts, complete
P91263 48 Support for holding-down bolt
P91263 50 Support for end-chock bolt
P91263 119 Tommy bar (ball handle)
P91351 10 Hydralic pump, pneumatic operated
P91351 34 Hose with unions (1000mm), complete
P91351 58 Hose with unions (3000mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D11202 Edition 0008
MAN B&W Diesel A/S
 Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0208
Checking
912-2.1

Note!

The hydraulic jack used for tightening the

holding down bolts is marked with:

For: Holding down bolts

The larger jack used for tightening the

end chock bolts is marked with:

For: End chock bolts

Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.

When referring to this page, please quote Procedure M91202 Edition 0208 Page 1 (5)
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking

1. Checking the Bolt Tightening

1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.

For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.

The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.

If the ‘loosening pressure' is below 80 per

cent of the tightening pressure, the relative
EN912-1.1 205 01

chocks shall always be checked for possi-

ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.

Checking of Epoxy Supporting Chocks

2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.

The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.

Page 2 (5) When referring to this page, please quote Procedure M91202 Edition 0208
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 in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.

If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:

1. Loosen the hexagon screws.

2. Try to knock the liner further inward.

3. Measure again at the 7 points indicated in

the table.

If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.

The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.

When referring to this page, please quote Procedure M91202 Edition 0208 Page 3 (5)
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking

Holding Down Bolts

Engine Port side Cylinder Starboard side Engine
frame Bolt Bolt frame
No. No. pressure % dev. remarks No. pressure % dev. remarks No. No.
1 1
2 2
1 3 3 1
4 4
1
1 1
2 2
2 3 3 2
4 4
1 2 1
2 2
3 3 3 3
4 4
1 3 1
2 2
4 3 3 4
4 4
1 1
2 2
5 3 3 5
4 4
1 1
2 2
6 3 3 6
4 4
1 1
2 2
7 3 3 7
4 4
1 1
2 2
8 3 3 8
4 4
1 1
2 2
9 3 3 9
4 4
1 1
2 2
10 3 3 10
4 4
1 1
2 2
11 3 3 11
4 4
1 1
2 2
12 3 3 12
4 4
1 1
2 2
13 3 3 13
4 4
1 1
2 2
14 3 3 14
4 4
1 1

Page 4 (5) When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6
 Holding Down and End Chock Bolts 912-2.1
Checking

Side Chocks and End Chock Bolts

Port side Starboard side
Chock Point Point Chock
Cylinder
No. A B c d e f g No. A B c d e f g No.

1 1
2 1 2
3 2 3
4 3 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
A, B
FORE A, B
A
d
c

A
d

c
e

e
g
B

f
f

g
B

c, d, e, f, g c, d, e, f, g

Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure ation Point Point ation sure Bolt Ch
2) (kp/cm 2 )
No. No. (kp/cm
bar % a b c d e a b c d e % bar
No. No.

1 1
E E
2 2
b c d d c b

a e e a

No. 2 Contact face No. 1 No. 2

AFT
B1

B2

B2

B1

When referring to this page, please quote Procedure M91202 Edition 0208 Page 5 (5)
0$1% :'LHVHO$6
 Stay Bolts 112-3
Data

SAFETY PRECAUTIONS
Special Data
S42MC
0017
112-3 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
D12-05 Min. clearance 0.4 mm
D13-01 Hydraulic pressure, mounting 900 bar
D13-02 Hydraulic pressure, dismantling 800-990 bar

When referring to this page, please quote Data D11203 Edition 0017 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

P91261 Hydraulic tools for staybolts, complete
P91351 10 Hydralic pump, pneumatic operated
P91351 34 Hose with unions (1000mm), complete
P91351 58 Hose with unions (3000mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D11203 Edition 0017
MAN B&W Diesel A/S
 Stay Bolts 912-3.1
Checking
Stay Bolts
K90MC-C
0213
Checking
912-3.1

1.
1. Before retightening the stay bolts, remove
the protective caps.

2. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other on the middle of
the engine.

Connect the high-pressure pump by means

HM912-3.0 28 01
of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.

3. If the engine is equipped with split staybolts

and one or more staybolts have been dis-
2.
mantled, make sure that the staybolts are
mounted in such a way that, when the up-
permost staybolt nut is loosened, there is a
clearance, as stated in Data, between the
contact face of the lowermost nut and the
bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.

D13-01
MB912-3.1 213 02

3.

D12-05
HM912-3.0 28 07

When referring to this page, please quote Procedure M91203 Edition 0213 Page 1 (2)
MAN B&W Diesel A/S
912-3.1 Stay Bolts
Checking

4. 4. Start the retightening of the stay bolts and

proceed to tighten the stay bolts in pairs,
working from the middle toward one end of
the engine and then from the middle again
toward the other end.

5. Pump up the hydraulic pressure to 10% be-

low the value indicated in D13-01, and
retighten the stay bolt nuts with a tommy
bar if possible. Before relieving the system
of pressure, check with a feeler gauge that
the nuts bear against the contact face.

6. Reconnect the hydraulic tools to the pair of

HM912-3.0 28 03

stay bolts first tightened. Tighten to 10%

below D13-01 and check if the nut is loose.

If the nut is not loose:

5. Tighten the stay bolts to D13-01.
D13-01
-10% If the nut is loose:
Tighten all stay bolts once again to D13-01.

7. After completing the retightening proce-

dure, mount the protective caps.
MB912-3.1 213 05

6.
HM912-3.0 28 06

Page 2 (2) When referring to this page, please quote Procedure M91203 Edition 0213
MAN B&W Diesel A/S
 Crankcase Oil Outlet 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
P91261-0075

When referring to this page, please quote Plate P91261 Edition 0075 Page 1 (2)
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0075

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
096 Spanner
202 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P91261 Edition 0075
MAN B&W Diesel A/S
913 - General Tools

Documents in this Chapter

913-01 0211 Hydraulic Tools

113-03 0004 Working Platforms, Data
913-03 0004 Working Platforms
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 0034 Accessories - Hydraulic Tools
91356 0057 Lifting Tools, etc.
91357 0004 Open-Ended Spanners
91358 0009 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0005 Pliers
91361 0052 Combination Spanners
91362 0062 Ring Slugging Spanners
91363 0039 Spanners
91364 0059 Open-Ended Spanners
91366 0066 Instruments
91368 0008 Working Platforms

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Hydraulic Tools 913-1

Hydraulic Tools
0211

A. Snap-on coupling
913-1

1.
B. Tool attachment thread
C. Bleed screw
D. Piston
E. Cylinder
F. Sealing rings
G. Spacer ring
H. Tommy bar
I. Nut
J. Stud or bolt

K. Extension stud

HM913-1.0 10 00
S. Clearance
U. Milled recess for feeler gauge

Studs or bolts provided with threads for attach- 2.

ing hydraulic tools and with circular nuts must
only be loosened and tightened up by means of
the hydraulic tools supplied.

The jack(s) is/are connected, via a distributor

block, to a high-pressure pump, which is set to
deliver hydraulic oil at the pressure indicated on
the jack and on the data sheet in the relevant
section of this instruction book. The stud or bolt
concerned is thereby lengthened relative to the
oil pressure applied and the piston area, and
the nut can be loosened or tightened, as re-
quired, with the aid of a tommy bar.

The jacks must never be overloaded or exposed

to blows or impacts. They are marked with a
“Max. lift”, which must not be exceeded.

1. The hydraulic tools, except those for the

main bearings, consist of a jack with an in-
ternal thread to suit the tool attachment
thread on the stud or bolt, and a spacer ring
KC913-1.0 17 02

which is to be placed under the jack and

around the nut that is to be loosened or
tightened.

2. For the main bearings, an extension stud,

three extra lower hydraulic jacks and a nut
are added to each set. Each part is marked
with a sign showing where to use the spe-
cific part.

When referring to this page, please quote Procedure M91301 Edition 0211 Page 1 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools

3. 3. The hydraulic jacks are so designed that, in

the event that the “Max. lift” limit is exceed-
ed, the pressure is relieved at the bottom of
the pressure chamber, and the oil will be
pressed out into the space between the
stud and the spacer ring.

When the pressure is relieved in this way,

the lowermost sealing ring will in most cas-
es 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 normal-
ly alkaline and can thus damage the back-
up rings.

The following instructions must be closely

followed to prevent accidents or damage.
After use, the jacks should be cleaned and
MB913-1.0 14 03

kept in the wooden boxes supplied.

Warning!
4.
Eye protectors and gloves must be used
when using hydraulic tools.

Maintenance

4. Disassembling the piston and cylinder is

best carried out by taking out one of the
bleed screws and pressing the parts from
each other by means of compressed air.

After disassembling, check that there are

no damage marks on the sliding surfaces of
the parts. If metal particles are present,
they will damage the sealing rings. Keep
the sliding surfaces and threads coated
with acid-free grease or molybdenum disu-
plhide. The hydraulic nuts do not require
any maintenance other than replacement of
defective sealing rings. These consist of an
O-ring and a back-up ring, which are posi-
tioned in ring grooves in the piston and cyl-
inder.
KC913-1.0 17 04

Page 2 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
 Hydraulic Tools 913-1
Loosening of Nut
Loosening of Nut
913-1

Single Hydraulic Jack 1.

1. Carefully clean the tool attachment thread,

the nut and the surrounding parts.

Grease the tool attachment thread with mo-

lybdenum disulphide grease or with graph-
ite and oil or similar.

Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot when the nut is to
be loosened.

2. Screw the jack on to the tool attachment

thread of the bolt/stud, until the cylinder of
the jack bears firmly against the spacer
ring, and check that the parts are guided
correctly together. HM913-1.1 10 01

Connect the jack, the distributor block, and

the high-pressure pump by means of high-
pressure hoses.

Loosen the bleed screw and fill the system 2.

until oil, without bubbles, flows out of the
bleed hole. Then tighten the bleed screw
again.

Adjust the clearance between the piston

and cylinder of the jack (see the sketch and
table) to provide for contraction of the bolt/
stud.

If the clearance is too large, adjustment is

made by loosening the bleed screw and
turning the jack.

The clearance is to have relation to the

"Max. lift" of the jack and has the purpose
of making it possible to dismount the jack
after loosening the nut.

After adjustment, check again that there is

no clearance between the cylinder/spacer
ring/surface.
HM913-1.1 10 02

When referring to this page, please quote Procedure M91301 Edition 0211 Page 3 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools
Loosening of Nut

3. 3. Increase the oil pressure to the prescribed

value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.

4. Unscrew the nut with the tommy bar, 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.
HM913-1.1 10 03

4.
HM913-1.1 10 04

5.
HM913-1.1 10 01

Page 4 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
 Hydraulic Tools 913-1
Loosening of Nut

Triple Hydraulic Jack 6.

7.
6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.

Grease the tool attachment threads with

molybdenum disulphide grease or graphite
and oil or similar.

Mount the extension studs on the main

bearing studs.

Using the lifting tool, place the spacer rings

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.
KC913-1.1 17 06

7. Press the pistons and the cylinders of all

the hydraulic jacks firmly together.

Mount the three jacks (one by one using the 8.

lifting tool) over the extension stud and land
them on the spacer ring.

Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.

Screw the upper nuts on to the threads of

the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.

8. The clearance between the pistons and the

cylinder of the top jack is adjusted by un-
screwing the upper nuts 1 turn   3 mm.

The clearance between the jack and spacer

ring has the purpose of making it possible
to dismount the jack after loosening the nut.

Connect the hydraulic jacks, the distributor

block and the high pressure pump by
KC913-1.1 17 08

means of high pressure hoses.

Loosen the bleed screws in all the jacks,

and fill up the system until oil, without bub-
bles, flows out of the bleed holes.

Re-tighten the bleed screws.

When referring to this page, please quote Procedure M91301 Edition 0211 Page 5 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools
Loosening of Nut

9. Increase the oil pressure to the prescribed

9. value. If the nut does not come loose, the
pressure may be increased by approx. 90
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.
KC913-1.1 17 09

11.
KC913-1.1 17 11

Page 6 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
 Hydraulic Tools 913-1
Tightening of Nut
Tightening of Nut
913-1

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 molyb-
denum disulphide grease or with graphite
and oil or similar.

Fit the round nut on the thread and tighten

it with the tommy bar.

Check with a feeler gauge that the contact

face of the nut bears on the entire circum-
ference.

Place the spacer ring around the nut in

such a position that the tommy bar can be HM913-1.1 10 01

applied through the slot for the purpose of

tightening the nut.

2. Press the piston and the cylinder of the jack

firmly together.
2.
Screw the hydraulic jack on to the tool at-
tachment thread.

Make sure that the cylinder of the jack

bears firmly against the spacer ring and
that the parts are guided correctly together.

Connect the hydraulic jack, the distributor

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

Loosen the bleed screw in the jack and fill

up the system with oil, until oil without bub-
bles flows out of the bleed hole.

Re-tighten the bleed screw.

HM913-1.1 10 02

When referring to this page, please quote Procedure M91301 Edition 0211 Page 7 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools
Tightening of Nut

3. 3. Increase the oil pressure to the prescribed

value, and tighten the nut by applying the
tommy bar through the spacer ring slot.

4. While maintaining the pressure, check with

a feeler gauge introduced through the 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.

&DXWLRQ

When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
HM913-1.2 10 03

jacks, but loosen the nut as described

under ‘Loosening’, points 3-4-5, and then
tighten the nut again according to the
procedure under ‘Tightening', points 3-4-
4. 5.
KC913-1.2 17 04

Page 8 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
 Hydraulic Tools 913-1
Tightening of Nut

Triple Hydraulic Jack 7.

6. Thoroughly clean the nuts, the threads on

the main bearing studs, the contact faces,
and the surrounding parts.

Clean and lubricate the tool attachment

thread and the threads in the nuts with mo-
lybdenum disulphide grease or with graph-
ite and oil.

Fit the round nuts on the threads and tight-

en them with the tommy bar.

Check with a feeler gauge that the contact

faces of the nuts bear on the entire circum-
ference.

Mount the extension studs on the main

bearing studs.

Using the lifting tool, place the spacer ring

over the extension studs in such a position
KC913-1.2 17 07

that the tommy bar can be applied through

the slots for the purpose of tightening the
nuts.

7. Press the piston and the cylinder of all the 8.

hydraulic jacks firmly together.

Mount the three jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.

Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.

Screw the upper nuts on to the threads of

the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.

8. Connect the hydraulic jacks, the distributor

block and the high pressure pump by
means of high pressure hoses.

Loosen the bleed screws in all the jacks,

and fill up the system with oil until oil, with-
out bubbles, flows out of the bleed holes.
KC913-1.2 17 08

Re-tighten the bleed screws.

When referring to this page, please quote Procedure M91301 Edition 0211 Page 9 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools
Tightening of Nut

10. 9. Increase the oil pressure to the prescribed

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
spacer ring.

10. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cesses at the bottom of the spacer ring that
the nuts bear against the contact face.

11. Relieve the system of pressure, disconnect

the pump, and remove the hydraulic tools.

12. When new studs, bolts or nuts are tight-

KC913-1.2 17 10

ened for the first time, do not remove the

jacks, but loosen the nuts as described un-
der ‘Loosening', points 9-10-11, and then
tighten the nuts again according to the pro-
11. cedure under ‘Tightening', points 10-11-12.
KC913-1.2 17 11

Page 10 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
 Hydraulic Tools 913-1
Maintenance
Maintenance
913-1

1. The hydraulic jacks require no maintenance 1.

except replacement of defective sealing
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.

The piston and cylinder are easily separat-

ed by taking out the bleed screw and press-
ing the parts apart with the help of
compressed air.

Make sure that there are no marks or

scratches on the sliding surfaces of the
parts. The presence of metal particles will
damage the sealing rings.

The pistons and cylinders of the lower jack

are separated in the same easy way as de-
scribed for the upper jack. KC913-1.0 17 04

When referring to this page, please quote Procedure M91301 Edition 0211 Page 11 (12)
MAN B&W Diesel A/S
913-1 Hydraulic Tools
Maintenance

3. 2. When changing the sealing rings, first

mount the back-up ring and then the O-ring.

Note!

Note that the back-up ring (1) must be

away from the pressure chamber and the
O-ring (2) close to the pressure chamber.

See the sketch for the correct mounting of

both the upper and the lower sealing rings.
The same principle applies to all the jacks.

3. After fitting the sealing rings, coat the pis-

ton and cylinder with molybdenum disul-
phide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
KC913-1.4 17 03

4.
HM913-1.4 10 02

Page 12 (12) When referring to this page, please quote Procedure M91301 Edition 0211
MAN B&W Diesel A/S
K90MC/MC-C Working Platforms 113-3
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
K90MC-C
0004
113-3 Working Platforms

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
x1
Lock turbocharger rotors x1

Data
Ref. Description Value Unit

x6

x2

x2

x1

x1

x2
x1

When referring to this page, please quote Data D11303 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
113-3 Working Platforms K90MC/MC-C
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11303 Edition 0004
MAN B&W Diesel A/S
K90MC/MC-C Working Platforms 913-3.4
Mounting
Working Platforms
K90MC-C
0004
Mounting
913-3.4

1.
Before carrying out the checking and overhaul
procedures underlined below in Items 1, 2 and
4, platform boards should be mounted inside
the engine crankcase.

During mounting of the platforms, always use

the harness, lanyard and fall arrester. It is al-
ways recommended to clean and wipe off oil
from steps, crankthrow, doorways and assem-
bling surfaces.

The platform boards are placed inside the en-

gine as shown in the following.

1. Checking the crankshaft alignment, using

an Autolog: Turn the engine into a position
where it is possible to place the ladder on

MA913-3.1 001 01
the crankpin bearing stud nut.

2. Piston rod stuffing box and telescopic pipe:

Put in the platform board as a floor as
shown on the sketch. Turn the engine to
BDC. Mount the platform board from the ex- 2.
haust side of the engine as shown.
MA913-3.1 001 02

When referring to this page, please quote Procedure M91303 Edition 0004 Page 1 (3)
MAN B&W Diesel A/S
913-3.4 Working Platforms K90MC/MC-C
Mounting

3. 3. Suspend the two boards in the longitudinal

direction on the guide supports and the two
boards with dowel pins on top of these in
the athwartship direction. One of the plat-
form boards can be placed on the steps be-
side the new board, as shown.

4. Main bearing dismantling: Turn the engine

to 80° after TDC. Mount the platform sup-
port in a longitudinal direction on the steps
in the bedplate.

5. Mount the longest platform board, with the

MA913-3.4 001 03

ladder attached, on the support and, by

means of a rope, lower the platform support
ladder into place on the crankthrow.

4.
MA913-3.4 001 04

5.
MA913-3.4 001 05

Page 2 (3) When referring to this page, please quote Procedure M91303 Edition 0004
MAN B&W Diesel A/S
K90MC/MC-C Working Platforms 913-3.4
Mounting

6. The two small platform boards can now be 6.

placed on the support and the long platform
board.

Note!

Always remember to remove the platform

boards on completion of each working
procedure or before turning the engine.

MA913-3.1 001 06

When referring to this page, please quote Procedure M91303 Edition 0004 Page 3 (3)
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
D

When tightening new studs or bolts for the first 



time, loosen again and repeat the procedure – 




including pre-tightening with a torque spanner, 




to allow the parts to settle. 0

+

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
P91351-0034
Accessories for Hydraulic Tools
0034
P91351

Working Pressure 1500 Bar

When referring to this page, please quote Plate P91351 Edition 0034 Page 1 (2)
MAN B&W Diesel A/S
Plate Accessories for Hydraulic Tools
P91351-0034

Item Item
Item Description Item Description
No. No.

010 Hydralic pump, pneumatic operated

022 Hydralic pump, hand operated
034 Hose with unions (1000mm), complete
046 Hose with unions (1500mm), complete
058 Hose with unions (3000mm), complete
060 Hose with unions (5000mm), complete
105 2-way distributor block, complete
117 4-way distributor block, complete
129 6-way distributor block, complete
154 Conical valve, 0 - 15
166 Angle union
201 Quick coupling, male
213 Quick coupling, female
225 Disc, round-plain, Cu ø11x3mm
237 Bleeder screw
249 Disc, round-plain, Fe ø11x9mm

Page 2 (2) When referring to this page, please quote Plate P91351 Edition 0034
MAN B&W Diesel A/S
 Lifting Tools, Etc. Plate
P91356-0057
Lifting Tools, Etc.
0057
P91356

When referring to this page, please quote Plate P91356 Edition 0057 Page 1 (2)
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0057

Item Item
Item Description 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
080 Forged-bent screw shackle, 33mm
092 Forged-bent screw shackle, 42mm
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
175 Lifting eye bolts, 36mm
199 Lifting eye bolts, 48mm
222 Chain tackle, 1000kg
258 Chain tackle, 3000kg
260 Chain tackle, 5000kg
271 Chain tackle, 8000kg
295 Pull lift, 3000kg
305 Wire rope, 6m

Page 2 (2) When referring to this page, please quote Plate P91356 Edition 0057
MAN B&W Diesel A/S
 Open Ended Spanners Plate
P91357-0004
Open Ended Spanners
0004
P91357

When referring to this page, please quote Plate P91357 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0004

Item Item
Item Description 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
074 Open-ended spanner, size NV95mm
098 Open-ended spanner, size NV105mm

Page 2 (2) When referring to this page, please quote Plate P91357 Edition 0004
MAN B&W Diesel A/S
 Open-Ended Slugging Spanners Plate
MAN B&W Diesel P91358-0009

When referring to this page, please quote Plate P91358 Edition 0009 Page 1 (2)
Plate
Open-Ended Slugging Spanners
P91358-0009 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

223 Open-ended slugging spanner, size

NV105mm

Page 2 (2) When referring to this page, please quote Plate P91358 Edition 0009
 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
MAN B&W Diesel P91360-0005

When referring to this page, please quote Plate P91360 Edition 0005 Page 1 (2)
Plate
Pliers
P91360-0005 MAN B&W Diesel

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
069 Pliers for retaining ring, size 3.5mm
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 0005
 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
P91362-0062
Ring Slugging Spanners
0062
P91362

When referring to this page, please quote Plate P91362 Edition 0062 Page 1 (2)
MAN B&W Diesel A/S
Plate Ring Slugging Spanners
P91362-0062

Item Item
Item Description Item Description
No. No.

022 Slugging spanners, ring size NV30mm

034 Slugging spanners, ring size NV32mm
046 Slugging spanners, ring size NV34mm
058 Slugging spanners, ring size NV36mm
060 Slugging spanners, ring size NV41mm
071 Slugging spanners, ring size NV46mm
083 Slugging spanners, ring size NV50mm
095 Slugging spanners, ring size NV55mm
105 Slugging spanners, ring size NV60mm
117 Slugging spanners, ring size NV65mm
130 Slugging spanners, ring size NV75mm
142 Slugging spanners, ring size NV80mm
154 Slugging spanners, ring size NV85mm
178 Slugging spanners, ring size NV95mm
180 Slugging spanners, ring size
NV100mm
191 Slugging spanners, ring size
NV105mm
213 Slugging spanners, ring size
NV115mm
225 Slugging spanners, ring size
NV120mm

Page 2 (2) When referring to this page, please quote Plate P91362 Edition 0062
MAN B&W Diesel A/S
 Spanners Plate
MAN B&W Diesel P91363-0039

When referring to this page, please quote Plate P91363 Edition 0039 Page 1 (2)
Plate
Spanners
P91363-0039 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
053 Adapter for socket wrench, 25->20
100 Socket spanner, S=46 mm
112 Socket spanner, S=50 mm
124 Socket spanner, S=55 mm
150 Hex key, S=22 mm
161 Hex key, S=24 mm
207 Socket wrench, S=33 mm
219 Extension bar, 200 mm

Page 2 (2) When referring to this page, please quote Plate P91363 Edition 0039
 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
P91366-0066

When referring to this page, please quote Plate P91366 Edition 0066 Page 1 (2)
MAN B&W Diesel A/S
Plate Instruments
P91366-0066

Item Item Description Item Item Description

No. No.

012 Indicator, complete

024 Indicator paper
036 Plainmeter, complete
048 Autolog, measuring tool for crankshaft
050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool

Page 2 (2) When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S
 Working Platforms Plate
P91368-0008
P91368
Working
0008 Platforms

A-A

A A

B-B

When referring to this page, please quote Plate P91368 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0008

Item Item
Item Description Item Description
No. No.

013 Working platform support

025 Working platform support
037 Platform board
049 Platform board
050 Platform board
062 Platform board
074 Platform board
086 Ladder
098 Platform board
204 Working platform, complete

Page 2 (2) When referring to this page, please quote Plate P91368 Edition 0008
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
K90MC-C VOLUME III
COMPONENTS
DESCRIPTION
900 - Introduction

Documents in this Chapter

Table of Contents, Volume III

90001 0081 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90023 0027 Instructions for Main Engine
90030 0009 Description

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 0081 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90023 0027 Instructions for Main Engine
90030 0009 Description

901 - Cylinder Cover

90101 0160 Cylinder Cover
90103 0003 Indicator Cock - Mounting

902 - Piston with Rod & Stuffing Box

90201 0224 Piston and Piston Rod
90205 0120 Piston Rod Stuffing Box

903 - Cylinder Liner and Cylinder Lubrication

90301 0197 Cylinder Frame
90302 0170 Cylinder Liner and Cooling Jacket
90304 0021 Cylinder Liner - Details
90305 0143 Cylinder Lubricators
90307 0032 Cylinder Lubricator Unit
90308 0010 Cylinder Lubricator - Intermediate Box
90309 0031 Cylinder Lubricator System - Details
90310 0012 Cylinder Frame - Rear Side
90312 0004 Electronic Components - Cylinder Lubrication

904 - Crosshead with Connecting Rod

90401 0150 Connecting Rod and Crosshead
90403 0010 Lubricating and Cooling Oil-Flow

905 - Crankshaft, Thrust Bearing and Turning Gear

90501 0156 Crankshaft
90502 0065 Arrangement of Fore End
90503 0018 Arrangement of Angle Encoder
90505 0121 Thrust- and Guide Bearing
90510 0130 Turning Gear
90511 0048 Turning Wheel
90512 0002 Turning Gear - Details
90513 0043 Tacho System

906 - Control Gear

90600 0141 Arrangement of Chain Drive and Camshaft
90603 0109 Chain Tightener

MAN B&W Diesel A/S Page 1 (3)

 Table of Contents 900
Volume III - Components Description

No. Edition Title

90610 0117 Bearing Housing - Mounting

90611 0176 Camshaft and Chain Wheel
90612 0085 Arrangement of Indicator System
90613 0119 Camshaft Bearing
90615 0126 Arrangement of Governor
90618 0128 Regulating Shaft
90619 0022 Load Transmitter
90620 0097 Engine-Side Control Console
90621 0076 Engine-Side Control Console - Details
90622 0060 Arrangement of Layshaft
90631 0025 Chain Drive Guidebars - Upper Part
90632 0034 Chain Drive Guidebars - Lower Part
90633 0029 Chain Drive Lubrication - Upper Part
90634 0040 Chain Drive Lubrication - Lower Part

907 - Starting Air System

90702 0069 Main Starting Valve
90703 0111 Starting Air Distributor
90704 0053 Starting Valve
90705 0016 Starting Air Distributor Drive

908 - Exhaust Valve

90801 0199 Exhaust Valve - Lower Parts
90802 0058 Exhaust Valve - Details
90803 0026 Exhaust Valve - Upper Parts
90804 0011 Exhaust Valve Upper Parts - Details
90805 0135 Exhaust Valve - Actuator
90806 0090 Exhaust Valve - Pipe System
90811 0010 Arrangement of Freshwater Pipes

909 - Fuel Oil System

90901 0179 Fuel Pump
90902 0156 Fuel Pump Gear
90903 0045 Fuel Pump Gear - Details
90904 0062 Fuel Pump - Details
90905 0029 Reversing Mechanism
90910 0143 Fuel Valve
90911 0022 Fuel Valve Function
90913 0130 High-Pressure Pipes
90914 0100 Fuel Oil System
90915 0060 Fuel Oil System - Details
90915 0081 Fuel Oil System - Details
90916 0007 Lifting Device for Fuel Pump - Cylinder No. 1

910 - Turbocharger System

MAN B&W Diesel A/S Page 2 (3)

 Table of Contents 900
Volume III - Components Description

No. Edition Title

91000 0017 Gas and Air System

91001 0158 Scavenge Air Receiver
91002 0145 Arrangement of Charging Air Pipe
91003 0226 Exhaust Pipes and Receiver
91004 0083 Exhaust Receiver - Details
91005 0119 Air Cooler
91006 0029 Arrangement of Auxiliary Blower
91007 0018 Butterfly Valve
91009 0047 Air Cooler System - Cleaning
91011 0012 Arrangement of Non-Return Valve
91014 0025 Arrangement of Suction Pipe

911 - Safety Equipment

91101 0037 Safety Valve - Cylinder
91102 0030 Relief Valve
91102 0033 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0094 Arrangement of Safety Cap
91106 0001 Fuel Oil Leakage Monitor

912 - Assembly of Large Parts

91201 0072 Arrangement of Stay Bolts
91203 0018 Frame Box - Details
91205 0205 Frame Box
91206 0097 End Shields
91207 0057 Arrangement of Piston Cooling
91208 0024 Chain Wheel Frame - Upper
91210 0189 Bedplate
91211 0075 Axial Vibration Damper
91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

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

 Cross Section through Engine Plate
MAN B&W Diesel P90001-0081

When referring to this page, please quote Plate P90001 Edition 0081 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

Fore end
1
2
Cyl. nos. always counted
3
4 from fore end
5
6
7

Manoeuvring side of engine Aft end Exhaust side of engine

Propeller

Clockwise direction of rotation

defined from aft end of engine

When referring to this page, please quote Plate P90003 Edition 0001 Page 1 (1)
 Software License, Standard Conditions Plate
MAN B&W Diesel P90004-0001

Standard Conditions of Software Licence

Software supplied by MAN B&W separately or included as a part of any system or embedded in
any device is licensed by MAN B&W Diesel A/S (“MAN B&W”) subject to the customer's accep-
tance of the following standard conditions of licence.

TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S ACCEPTANCE OF THESE
CONDITIONS.

1. Right of Ownership

Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W
against a once-for-all fee. MAN B&W and its software suppliers retain the right of ownership to the
software.

If the engine plant - for which the software is acquired - is transferred to a third party the cus-
tomer has the right to assign the licence to this third party, provided that the third party agrees to
the terms of this licence agreement and provided that the customer does not retain any copies of
the software.

2. Copyright

The customer must not copy the software or any part thereof. Furthermore the customer is not
allowed to make the software available to a third party or to reverse engineer, decompile or disas-
semble the software.

3. Support

If required by the customer MAN B&W shall provide technical support for installation and training
in use of the software against separate payment.

4. Updating

The non-exclusive user's licence does not include any updating of the software. If and to the ex-
tent MAN B&W updates the programs or develops new versions, such updates or new versions
shall be made available to the customer against separate payment.

5. Warranty & Liability

MAN B&W warrants that the software and data media containing the software are free of defects
in material and workmanship at the time of delivery. If the software and data media are found to
be defective and are returned to MAN B&W within 90 days from the date of delivery, they will be
replaced free of charge.

Except as stated above, MAN B&W disclaims liability for breach of conditions or warranties, either
expressed or implied, with respect to the software and data media, including warranties of suit-
ability and applicability for a particular purpose.

When referring to this page, please quote Plate P90004 Edition 0001 Page 1 (2)
Plate
Software License, Standard Conditions
P90004-0001 MAN B&W Diesel

MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the
form of any claim or action, shall not exceed the total licence fee paid by the customer for the li-
cense to use this software under this license agreement. MAN B&W shall in no event be liable for
any damages resulting from loss of data, profits or use of equipment, or for any special, incidental
consequential damages arising out of or in connection with the use or performance of the soft-
ware.

The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&W’s software
suppliers.

6. Law

MAN B&W's tenders and contracts with customers regarding delivery of data and programs, in-
cluding the present licence agreement, shall be interpreted according to Danish Law.

Page 2 (2) When referring to this page, please quote Plate P90004 Edition 0001
 Instructions for Main Engines

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

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

The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel en-
gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-
erence purposes, for instance in correspondence and when ordering spare parts.

It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:

1. Name of vessel
2. Engine No. built by
3. Plate No.
4. Part No.
5. Quantity required (and description)

Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

10 off (piston ring)
+ )The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.

To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.

When used in texts and illustrations, the designation “D” refers to the information given on the
data sheets inserted in the respective books.

Reliable and economical operation of the diesel engines is conditional upon its correct oper-
ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re-
lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on emissions related maintenance of the die-
sel engine, also the additional instructions to that effect set out in the Technical File.

This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.

MAN B&W Diesel A/S

A90023-0027

Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen Telex :16592 manbw dk
Denmark Telefax:+45 33 85 10 30

CVR No. 39 66 13 14
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

901 Cylinder Cover

Cylinder Cover The cylinder cover is made of steel.

On the 70-98MC type engines the cylinder cover is provided with welded-on
heat resistant material at the points of fuel oil injection in order to improve the
service condition.

Valve bores The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.

The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet, safety valve and indicator cock.

Cooling A cooling jacket is mounted on the lower part of the cylinder cover, whereby a
cooling water space is formed.

Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.

The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylin-
der cover and, further on, through the cooling bores, to the space around the
exhaust valve seat.

From here the water is discharged to the main cooling water outlet pipe:

On some engine types, an amount of water is also passed directly from the
cylinder cover to the exhaust valve housing through a cooling water connec-
tion.

Tightening The cylinder cover is tightened against the top of the cylinder liner with nuts
and long studs fitted in the cylinder frame. The nuts are tightened with hydrau-
lic tools.

Sealing between the cylinder cover and cylinder liner is obtained by means of a
sealing ring of mild steel.

902 Piston with Rod and Stuffing Box

Piston The piston consists of two main parts:

• Piston Crown

• Piston Skirt

The piston crown is tightened to the upper end of the piston rod, and the pis-
ton skirt is tightened to the piston crown.

When referring to this page, please quote Description A90030 Edition 0009 Page 1 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

The piston crown is provided with one groove all the way around, or with three
smaller grooves for the fitting of lifting tools.

The piston crown is provided with chromium-plated grooves for four piston
rings.

Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR).

Piston rings Nos. 2, 3 and 4 have oblique cuts:

• piston ring No. 3 has a right-hand cut,

and

• piston rings Nos. 2 and 4 have left-hand cuts.

On some engines, the piston rings are provided with Alu-coating to improve
the running-in stability and to reduce the running-in period.

Handle with care, as impact may cause the coating to crack and peel off.

Stationary Engines:

The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel off.

Piston Rod The piston rod has a through-going bore for the cooling oil pipe, which is se-
cured to the piston rod top.

Cooling oil is supplied through a telescopic pipe connection on the guideshoe

or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.

The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.

From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the flow and temperature.

The piston rod foot rests on a face cut out in the crosshead pin.

A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.

The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.

Page 2 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Stuffing Box The bore for the piston rod between the scavenge air space and the crankcase
is fitted with a piston rod stuffing box, which is designed to prevent the lubri-
cating oil in the crankcase from being drawn up into the scavenge air space.

The stuffing box also prevents scavenge air (in the scavenge air space) from
leaking into the crankcase.

The stuffing box housing consists of two parts, which are bolted together.

Scraper/sealing The housing is provided with a number of machined ring grooves:

rings

• The uppermost groove holds a scraper ring with oblique edges, which
serves to prevent sludge from the scavenge box from being drawn
down to the other rings.

Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC
type engines).

• The ring grooves in the middle are fitted with sealing rings.

• The lowermost ring grooves are fitted with scraper rings which scrape
the lubricating oil off the piston rod.

Oil which is scraped off the piston rod is returned to the crankcase through
bores in the stuffing box housing.

Through bores in the housing and a pipe, the stuffing box communicates with
a control funnel on the outside of the engine, which enables the sealing/scrap-
ing performance to be checked.

Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.

903 Cylinder Liner and Cylinder Lubrication

Cylinder Frame The cylinder section of the engine consists of a cylinder frame with a bolted-on
or integrated camshaft housing. The cylinder section is tightened together with
the engine framebox and the bedplate by means of stay bolts. Alternatively as
a complete welded assembly integrating the scavenge air receiver into the cyl-
inder frame.

Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.

Central bores in the bottom of the cylinder frame enclose the piston rod stuff-
ing boxes.

On the exhaust side of the cylinder frame there are openings which connect
the scavenge air space around the cylinder liner with the longitudinal scavenge
air receiver of the engine.

When referring to this page, please quote Description A90030 Edition 0009 Page 3 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.

Cylinder cover Studs for fastening the cylinder cover are mounted in the cylinder frame.
studs

Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is supplied
Cooling Jacket at the lower part of the cooling jacket.

On slim-type liners, the water continues directly to the upper part of the cool-
ing jacket, whereas on the bore-cooled type liner, the water first passes
through the cooling bores. From the top of the cooling jackets, the water flows
through water connections to the cooling jacket on the lower part of the cylin-
der cover.

Leakage of cooling water is prevented by silicone rubber rings.

The cylinder liner is tightened against the top of the cylinder frame by the
tensioning force from the cylinder cover studs being transmitted via the cylin-
der cover.

Scavenge air ports The part of the cylinder liner which is located in the scavenge air space of the
cylinder frame is provided with a number of scavenge air ports, which are un
covered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to
give the scavenge air a rotary movement in the cylinder.

Cylinder lubrication In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with non-return valves for the supply of lu-
bricating oil to the cylinder.

PC-ring On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of
the cylinder liner. The purpose of the PC-ring is to prevent the building-up of
deposits on the piston topland and, in turn, prevent the wiping away of the cyl-
inder lubricating oil. Consequently, the PC-ring contributes to reducing the
wear of liners and rings.

Cylinder The engine is equipped with mechanically or electronically controlled cylinder

Lubricators lubricators for lubrication of the running surface of liners and rings.

Regarding the cylinder lubricators proper, reference is made to the special in-
struction manuals supplied.

See also Volume I, OPERATION, Chapter 707.

Page 4 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

904 Crosshead with Connecting Rod

Crosshead The crosshead is provided with two guide shoes fitted on the crosshead ends.

The centre part of the crosshead is designed as a bearing journal which is

housed in the crosshead bearing.

The crosshead bearing cap is provided with a cut-out enabling the piston rod
to be assembled with the crosshead journal.

The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
See also Volume I, OPERATION, Chapter 708.

Piston rod foot The piston rod foot is fastened to the crosshead. To match different engine lay-
outs, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.

Lubrication The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and – through a bore in the con-
necting rod – for lubricating the crankpin bearing.

The piston cooling oil outlet is led through a control device for each cylinder
for the purpose of checking the temperature and flow before the oil is passed
on to the lube oil tank.

Guide shoes The sliding faces of the guide shoes are lined with cast-on bearing metal.

The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.

On some engines, the guide shoes are provided with counterweights.

Tightening The crosshead bearing is held together by studs and nuts. The nuts are tight-
ened with hydraulic tools.

The crankpin bearing is fitted with steel shells lined with bearing metal and as-
sembled in the same way as the crosshead bearing.

905 Crankshaft and Turning Gear

Crankshaft The crankshaft is either of the semi-built type, where the parts are shrunk to-
gether, or it is a one-piece forging.

The main bearings are lubricated via a main lubricating oil pipe that branches
off to the individual bearings, whereas oil for lubricating the crankpin bearings
is supplied from the crossheads through bores in the connecting rods.

When referring to this page, please quote Description A90030 Edition 0009 Page 5 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

The crankshaft is provided with a chain wheel for the camshaft drive and a
turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order and 4th order moment compensators are in-
stalled, if required according to vibration calculations.

Marine engines (except geared plants):

At the aftmost end of the engine, a thrust bearing is fitted.

The thrust bearing serves the purpose of transmitting the axial thrust of the
propeller through propeller shaft and intermediate shafts to the ship’s hull.

The crankshaft is provided with a thrust collar which transmits the thrust to a
number of segments mounted in a thrust shoe on either side of the thrust col-
lar.

The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal
cast onto the wearing faces against the thrust collar. See also Volume I, OP
ERATION, Chapter 708.

The thrust bearing is lubricated by the pressure lubrication system of the en

gine. The oil is supplied between the segments through spray pipes and spray
nozzles.

The thrust bearing is provided with alarm, slow-down, and shut-down devices
for low lube oil pressure and high segment temperature. See also Volume I,
OPERATION, Chapter 701.

Stationary engines and geared marine plants:

The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di
rection.

Axial Vibration To counteract heavy axial vibrations, and any resultant adverse forces and
Damper vibrations, the crankshaft is provided with an axial vibration damper. See also
Section 912, “Assembly of large parts” further on in this text.

The damper consists of a ‘piston’ and a slit-type housing. The ‘piston’ is made
as an integrated collar on one of the main bearing journals, and the housing is
mounted on the pertaining main bearing support.

The axial movement is damped as a result of the ‘restrictions’ incorporated in

the bores which interconnect the oil-filled chambers on the two sides of the
‘piston’.

Lubricating oil is supplied to both sides of the ‘piston’ from the main system.

Page 6 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Turning Gear The turning gear is attached to the engine bedplate and is driven by an electric
motor incorporating a disc brake.

Through a planetary gearing, the motor drives a horizontal shaft equipped with
a gear wheel which can be axially displaced manually, so as to engage with the
turning wheel of the engine.

The turning gear is provided with a safety arrangement consisting of a safety

lever which must be lifted before the gear wheel of the turning gear can be
made to engage with the turning wheel.

When the safety lever is in its bottom position, it prevents the gear wheel of
the turning gear from engaging with the turning wheel.

Immediately the lever is lifted away from the disengaged position, an interlock
valve inserted in the starting air system of the engine is actuated. This interlock
prevents starting air from being supplied to the engine as long as the turning
gear is in the engaged position.
See also Volume I, OPERATION, Chapter 703.

Warning!

During any dismantling of working parts of the

engine, the turning gear must be in the engaged
position in order to prevent outside forces from
Dismantling of
turning the engine, thus causing injuries to per-
working parts:
sonnel or damage to the machinery.

See Volume II, MAINTENANCE, ‘DATA’ pages.

The turning gear must be in the disengaged posi-

tion during pressure testing of starting valves, as
Pressure test- a leaky valve may cause the engine to rotate, and
ing of starting damage the turning gear.
valves:
See Volume I, OPERATION, Chapter 703.

906 Mechanical Control Gear

Chain Drive The camshaft with cams for operating the fuel pumps, exhaust valves and indi-
cator drive (option) is driven from the crankshaft through a chain drive.

The chain drive consists of one or more roller chains running on chain wheels
fitted on the crankshaft and the camshaft. The chain is kept tightened by a
chain tightener placed in the chain casing between the crankshaft and the
camshaft.

The long free lengths of the chain are guided by rubber-clad guide bars. Lubri-
cating oil is supplied through spray pipes fitted at the guide bars and chain
wheels.

When referring to this page, please quote Description A90030 Edition 0009 Page 7 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Camshaft The camshaft is made in one or more sections.

If it is made in two or more sections, the sections are assembled by means of

flange couplings.

The camshaft has, for each cylinder:

• one cam for operation of the fuel pump

• one cam for operation of the exhaust valve

• one cam for operation of the indicator drive (option)

The fuel pump and exhaust valve cams are shrunk on to the shaft by heating,
whereas the indicator cams are in two parts, which are assembled with fitted
bolts.

The camshaft rotation constantly follows that of the crankshaft.

Bearings The camshaft is carried in bearing assemblies which are fitted in the roller
guide housings. See also Volume I, OPERATION, Chapter 708.

Engine timing The engine timing is adjusted by forcing lubricating oil in between the cams,
couplings or chain wheel and the shaft, which enables the parts to be turned in
relation to each other. See Volume II, Chapters 906, 908 and 909.

Pin gauges After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are deliv-
ered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.

Indicator Valve Each cylinder is fitted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.

Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.

Note!

For indicator valves of the double-seated design with a spring-loaded closing

face:

In order to prevent overstressing, close the valve lightly before starting the
engine, and retighten the valve when the engine has reached its normal ser-
vice temperature.

PMI-System See separate instructions for operating the PMI-system (option).

Page 8 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Moment On the basis of calculations, the engine may be provided with fly
Compensators weights to counteract engine forces and moments.

Caution!
If the chain drives for the compensators have been dismantled, the
flyweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.

Incorrectly fitted moment compensators may excite heavy vibrations.

1st order moment Applicable on 4-cylinder engines. The moment compensator is arranged
as adjustable flyweights on both ends of the crankshaft.

Alternatively, the 1st order moment compensator can be positioned in

the main chain drive.

This moment compensator consists of a (new) chain-tightener wheel

with an incorporated flyweight and a flyweight rotating with the crank
shaft.

2nd order moment Applicable on 4-5 and 6-cylinder engines. The moment compensator is
arranged as flyweights built into the main chain drive.

On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.

Optionally, an electrically driven compensator can be installed.

4th order moment The moment compensator is arranged as flyweights built into chain
drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.

907 Starting Air System

Starting Air System The starting air system consists of the manoeuvring system and the
starting air components, which comprise:

• Main Starting Valve

• Starting Air Distributor

• Starting Valves

The manoeuvring system is of electric/pneumatic design.

See also Volume I, OPERATION, Chapter 703.

When referring to this page, please quote Description A90030 Edition 0009 Page 9 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Main Starting The main starting valve is interposed in the starting air main pipe.
Valve
The main starting valve consists of a large ball valve and, optionally, a smaller
ball valve for slow-turning prior to starting the engine, which is fitted as a by-
pass for the large valve. Both valves are operated by pneumatic actuators.

If the smaller ball valve is installed, an adjusting screw will be mounted for set-
ting the slow-turning speed.

Furthermore, a non-return valve is incorporated to prevent blow-back in the

event of excessive pressure in the starting air line.

The main starting valve is equipped with a blocking device consisting of a plate
which, by means of a handwheel, can be made to block the actuators.

The ball valves and their actuators are, together with the non-return valve and
blocking device, built together to form a unit.

Warning!
During all inspections of the engine, the blocking device of the main starting
valve must be in the BLOCKED position.

The only exception is when the starting valves are being tested for tightness,
in which case the blocking device of the main starting valve must be in the
WORKING position and the shut-off valve for the starting air distributor must
be in the CLOSED position. See Volume I, operation, Chapter 703, ‘OPERA-
TION after arrival in port’.

Starting Air The starting air distributor controls the opening and the closing of the starting
Distributor valves.

Starting Valve The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled
by control air from the starting air distributor.

When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.

The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now flows from the starting
air pipe to the cylinder.

When the starting period is finished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.

The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.

Page 10 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

908 Exhaust Valve

Exhaust Valve Each cylinder is equipped with an exhaust valve, which is mounted in a central
bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gas-tight seal against a seat in the cylinder cover.

Valve housing The valve housing has an exchangeable bottom piece.

The bore for the valve spindle is provided with an exchangeable spindle guide
liner.

Cooling The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from
the upper part of the valve housing.

On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.

Valve spindle The part of the spindle stem which travels within the sealing arrangement of
the air cylinder is coated with a wear resistant mixture of metal carbide and su-
per alloy, applied by the HVOF process.

On the lower cylindrical part of the valve spindle a vane wheel is fitted which
causes the valve spindle to rotate while the engine is running.

Lifting/rotation check rod:

To enable checking the functioning of the exhaust valve while the engine is
running, a ‘lifting/rotation check rod’ is mounted on top of the hydraulic cylin-
der on the exhaust valve.

Spindle rotation is indicated by regular changes in the top and bottom posi-
tions of the check rod.

Note!
This check rod is only for checking purposes, and must not be permanently
activated.

Pistons

At the top of the spindle, two pistons are fitted:

1. Air piston
The piston serves to close the exhaust valve. The piston is locked to
the spindle by a two-piece conical ring.

2. Hydraulic piston
The piston serves to open the exhaust valve.

The hydraulic piston has two piston rings and a damper arrangement,
designed to dampen the closing of the valve.

When referring to this page, please quote Description A90030 Edition 0009 Page 11 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Note!
After the exhaust valve has been overhauled, it is important to check the
damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.

Air cylinder The air cylinder is mounted on top of the valve housing. Air for closing the ex-
haust valve is supplied through a non-return valve to the space below the pis-
ton.

A safety valve is mounted in the bottom of the air cylinder. The safety valve is
connected to the drain pipe which leads to the camshaft housing.

Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder on
top of the exhaust valve housing.

The exhaust valve is opened by the valve spindle being forced down by the
piston in the hydraulic cylinder.

Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerating the
oil system is fitted at the top of the cylinder.

When the exhaust valve is closed, the pressure in the hydraulic cylinder is low.
A thrust spring opens the valve, enabling oil and air, if any, to escape through
the throttle.

The oil is led through a duct to the space around the air cylinder and is
drained off through a bore X, together with leakage oil from the piston.

When the exhaust valve is activated, the high oil pressure closes the valve, and
the oil flow stops.

Sealing System Sealing air (where used):

A sealing air arrangement is fitted around the spindle shaft below the air cylin-
der.

The sealing air is supplied from the air cylinder via a sealing air control unit.

The sealing air will prevent the exhaust gas and particles from penetrating up-
wards and wearing out the running surfaces and polluting the pneumatic sys-
tem of the valve gear.

The oil content in the air from the air cylinder improves the service condition of
the sealing rings.

The sealing air control unit contains a valve which automatically cuts off the air
flow when the engine is in FINISHED WITH ENGINE status, and a filter hous-
ing.

Page 12 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Sealing oil (where used):

A sealing oil arrangement is fitted around the spindle shaft below the air cylin-
der.

The sealing oil is supplied from a control unit fitted on top of the exhaust valve
hydraulic actuator.

During the exhaust valve lifting period, oil escapes from the hydraulic actuator
through the restriction chamber to the control unit which, in turn, gives a cer-
tain amount of oil (dosage oil) to the exhaust valve spindle.

The sealing oil will prevent the exhaust gas and particles from penetrating up-
wards and wearing out the running surfaces and polluting the pneumatic sys-
tem of the valve gear.

The oil improves the service condition of the sealing rings.

Hydraulic Valve The exhaust valve is actuated by a cam on the camshaft through a hydraulic
Actuating Gear transmission.

Hydraulic cylinder The hydraulic cylinder is attached to the camshaft housing by studs and nuts.

A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck
of the roller guide and is locked to the roller guide by a bayonet joint.

The hydraulic cylinder on the camshaft housing is connected to the hydraulic

cylinder on the exhaust valve by a high-pressure pipe.

Oil is supplied from the lubricating oil system through a non-return valve.

Leakage oil from the hydraulic cylinder on the exhaust valve is drained through
a pipe connection.

Puncture Valve On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC en-
gines, a puncture valve may be mounted on the exhaust valve actuator. During
starting, this valve prevents the exhaust valve from opening during the first part
of the actuator piston’s upward stroke.

This function prevents the starting valve and exhaust valve from being open at
the same time, thus ensuring a safe start.

When referring to this page, please quote Description A90030 Edition 0009 Page 13 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

909 Fuel Oil System

Fuel Pump Each engine cylinder is equipped with its own fuel pump, which is mounted on
the camshaft housing over the camshaft section corresponding to the cylinder
concerned.

The pump housing is attached to the camshaft housing by studs and nuts.

The square base of the fuel pump housing is provided with a groove to receive
any leakage oil, which is subsequently drained off through a drain pipe.

In the base, a bore is provided for at toothed rack, i.e. the regulating guide,
which controls the quantity of fuel oil delivered by the pump.

Furthermore, for the VIT-type fuel pump, another bore is provided above the
bore for the regulating guide. This bore is provided with a rack, i.e. the timing
guide, which controls the engine timing.

At the top, the pump housing is closed by a top cover.

The top cover is provided with a suction valve and a puncture valve. These
two valves are on some engine types combined into one unit.

The pump housing contains the plunger and barrel. The plunger and barrel are
matched parts, and must not be replaced individually.

The pump plunger is provided with a guide block designed to travel in the
milled keyway in the regulating guide. At the bottom it has a foot which rests
on a steel disc in the bayonet joint at the roller guide neck. A clearance of
approx. 0.1 mm between the plunger foot and the roller guide permits turning
of the plunger in the roller guide.

The regulating guide is able to turn in the bottom of the pump housing. On the
outside the regulating guide has a toothed rim to mesh with the above-men-
tioned toothed rack at the base of the pump housing. The toothed rim and
toothed rack are marked with lines enabling the parts to be positioned cor-
rectly after disassembly. The toothed rack is linked together with the regulating
gear of the engine through a spring-loaded connection. Thus, in the event of a
sticking pump plunger, the regulating gear for the remaining fuel pumps will not
be blocked.

The pump barrel is provided with oil cut-off holes, which are covered and un
covered during the travel of the plunger within the barrel. This function, in con
junction with the turning of the plunger effected by the regulating gear, serves
to regulate the amount of oil injected into the engine cylinder.

Two screw plugs are fitted in the pump housing opposite the cut-off holes of
the barrel. The oil jets which are ejected through the cut-off holes at the end of
the delivery stroke will hit the screw plugs, which can be replaced when they
are eroded.

Page 14 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Injection timing Fuel pumps without VIT (Variable Injection Timing):

The pump barrel is attached to the top cover by means of screws.

The lower part of the barrel is guided in the bore of the pump housing. Two
sets of O-rings and back-up rings are fitted in grooves on the outside of the
barrel and the pump cover to seal between pump barrel/pump cover and
housing.

A number of semi-circular shims are inserted between the top cover and the
pump housing. By removing or inserting such shims, the pump barrel can be
slightly lowered or raised in relation to the plunger, and in this way the initial
moment of fuel oil injection into the engine cylinder can be adjusted, and the
maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum com-
bustion pressure.

VIT-type fuel pumps:

The pump barrel is guided at the top and bottom of the pump housing. Low
friction sealing rings are fitted in grooves in the barrel to seal between barrel
and housing. The barrel is provided with a drain bore between the sealing rings
at the lower end.

The pump barrel has a threaded lower end which fits into the internal threads
of the timing guide.

The timing guide has a gear rim to mesh with the upper toothed rack at the
base of the pump housing. The gear rim and toothed rack are marked with
lines enabling the parts to be positioned correctly after disassembly. The
toothed rack is linked to a servo-air cylinder which is controlled mechanically
or electronically in relation to the engine load. The position of the upper
toothed rack determines the vertical position of the barrel relative to the
plunger through the threaded connection.

In this manner the initial moment of fuel oil injection into the cylinder can be
adjusted by a servo-air cylinder.

The pump barrel is prevented from turning by a guide screw mounted in the
pump housing.

Puncture valve In the top cover of the pump, a puncture valve is fitted. The puncture valve
consists of a piston which communicates with the control air system of the en-
gine. In the event of actuation of the shut-down system, and when
STOP is activated, compressed air is supplied to the top of the piston, causing
the piston with pin to be pressed downward and keep the suction valve in the
open position. This will ‘puncture’ the oil flow to the fuel valve. As long as the
puncture valve is activated, the fuel oil is returned through bores to the pump
housing, and no injection takes place.

When referring to this page, please quote Description A90030 Edition 0009 Page 15 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Fuel Oil Injection During the suction stroke, the spring-loaded suction valve opens and the deliv-
ery chamber is filled with oil. As soon as the plunger has covered the cut-off
holes during its upward movement in the pump barrel, the injection com-
mences through the fuel valves. The injection will last until the cut-off holes are
uncovered by the oblique cut-off edges of the plunger, following which the oil
is forced through two milled grooves at the side of the plunger and out through
the cut-off holes of the barrel during the rest of the delivery stroke.

Shock absorber A shock absorber is installed on each pump housing or in the main fuel pipe to
take up pressure variations.

Fuel Pump The camshaft housing contains the fuel pump and exhaust valve actuating gear
Actuating Gear for each cylinder.

The fuel pump is actuated by a cam on the camshaft. The movement is trans-
mitted through the roller guide to the plunger in the barrel of the pump housing
which – through the high-pressure pipes – is connected with the fuel valves on
the cylinder cover.

Reversible engines:

The roller guide of each fuel pump incorporates an angular displaceable revers-
ing link.

Reversing is achieved by shifting the roller in the fuel pump drive mechanism at
each cylinder. The link connecting the roller guide and roller is provided with a
reversing arm, and a pivot is mounted at the top end of the reversing arm. The
pivot travels in a reversing guide connected to an air cylinder. The link is self-
locking in either the ahead or astern position without the aid of external forces.
Each cylinder is reversed individually, and the reversing mechanism is activated
by compressed air.

The reversing arrangement may incorporate a damper in order to reduce the

mechanical stresses.

Fuel Oil High- All high-pressure pipes in the system are provided with a protective outer pipe.
Pressure Pipes The space between the pipe and the protective outer pipe communicates,
through bores in the union nipples, with a drain bore in the pump top cover.

Fuel Oil Leakage A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS.
Alarm
35-98MC:

Each fuel pump is, via drain pipes, connected to a common drain tank, which
incorporates a level switch. The drain tank is also equipped with an overflow
pipe, which has a small drain bore below, whereby oil from small leakages can
be drained to the outlet, without actuating the level switch.

In the event of pipe fractures or major leakages in the system, the above-men-
tioned bore will not be large enough to allow the increased oil quantity to pass,
and the oil level in the drain tank will rise until it reaches the level of the over
flow pipe. The rising oil level will cause the level switch to set off an alarm.

Page 16 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

50-98MC:

Alternatively to the common drain tank, the drain pipes on 50-98MC engines
can be connected to a diaphragm valve, which sets off an alarm and activates
the puncture valve in order to stop the fuel oil flow from the pertaining pump.

On 60-98MC engines, which are provided with pneumatically operated fuel

pump roller guide lifting gear, automatic activation of the lifting gear by the dia-
phragm valve can be arranged in order to stop the fuel oil flow from the per-
taining pump.

Fuel Valve The fuel valve consists of a valve head and a valve housing. Fitted within the
valve housing is a non-return valve and a spindle and spindle guide with a
pressure spring, and a nozzle.

The spindle may be provided with a cut-off slide. When the fuel valve is fitted
in the cylinder cover, the valve parts are tightened together by the pressure
from the securing nuts.

Functioning The functioning of the fuel valve is as follows:

The electrical fuel oil primary pump circulates preheated oil through the fuel
pump and fuel valve. The fuel oil passes through the fuel valve, leaving through
a circulation bore and the return oil pipe on the valve head.

When the pressure at the beginning of the fuel pump’s delivery stroke has
reached the predetermined pressure, the circulating bores is closed.

When the pressure has reached the predetermined opening value for the fuel
valve, the spindle will be lifted and oil injected through the nozzle into the en-
gine cylinder.

On completion of the fuel pump’s delivery stroke, the valve spindle is pressed
against its seat and injection now ceases. Then the circulating bore is uncov-
ered, and oil starts to recirculate through the valve.

910 Turbocharger System

Air System The engine is supplied with scavenge air from one or more turbochargers, de-
pending on the engine type and layout.

The engine exhaust gas drives the turbine wheel of the turbocharger and,
through a common shaft, the turbine wheel drives the compressor wheel.

The compressor draws air from the engine room, through the air filters. From
the compressor outlet, the air passes through the charging air pipe to the
charging air cooler where the air is cooled down.

The charging air pipe, with compensator, is insulated.

When referring to this page, please quote Description A90030 Edition 0009 Page 17 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

The air cooler incorporates a water mist catcher, which is designed to separate
condensate from the air.
See also ‘Charging Air Cooler’ further on in this Section.

When the air has passed the water mist catcher, it is pressed into the scav
enge air receiver through non-return valves. The non-return valves open by
pressure from the turbocharger.

From the scavenge air receiver, the air flows to the cylinder through the scav-
enge air ports when the piston is in the bottom position. When the exhaust
valves open, the exhaust gas is pressed into a common exhaust gas receiver,
from where the gas drives the turbine of the turbocharger with an even and
steady pressure

Scavenge Air The scavenge air receiver is a container having a large volume. The receiver is
Receiver bolted on to the cylinder frame, or alternatively integrated into the cylinder
frame, if welded. See Chapter 903.

Scavenge air is collected in the receiver after the air has passed through the
cooler, the water mist catcher and the non-return valves.

The receiver and the cylinder frame communicate through large openings.

The scavenge air receiver is provided with man-hole covers and a safety valve.

Auxiliary Blowers The engine is provided with two or more auxiliary blowers. The suction sides
are connected to the space after the water mist catcher. The discharge sides
are connected to the scavenge air receiver. Separate non-return valves are in-
stalled at the suction side or discharge side of the auxiliary blowers, in order to
prevent reversed air flow.
See also item, “Non-return valves”, further on.

El. panels for See special instructions supplied by the engine builder.
auxiliary blower

Running with During the starting of the engine, and when the engine is running at low load,
auxiliary blowers the turbocharger is not able to supply enough air for the engine process. In
these cases a pressure switch will automatically start the auxiliary blowers.

When the auxiliary blowers are operating, they draw air from the engine room
through the turbocharger’s air filter and compressor side.

Page 18 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Warning!

If the auxiliary blowers do not start during low-load running (because of

faults, or because the switch for the blowers is not in “AUTO” position), un-
burned fuel oil may accumulate on top of the pistons.

This will involve the risk of a scavenge air box fire.

In order to avoid such a fire:

– obtain permission to stop the engine

– stop the engine
– remove any unburned fuel oil from the top of the pistons
– re-establish the supply of scavenge air
– start the engine

Note: the switch for the auxiliary blowers should be in

“AUTO” position during all modes of engine control, i.e.:
– remote control
– control from engine side control console.

When the auxiliary blowers are operating, they draw air from the engine room
through the turbocharger’s air filter and compressor side.

The non-return valves fitted after the water mist catcher are now closed as a
result of partial vacuum and gravitation acting on the valve flaps.

There will be a lack of air supply if the non-return valves do not close.

Non-Return Valves It is of the utmost importance that the non-return valves of the auxiliary blow-
ers always function correctly and move easily. This can be checked either by
moving the valves manually in connection with the regular scavenge port in-
spections, or via locally placed inspection covers.

The non-return valves protect the blowers and engine during:

• Start-up of the auxiliary blowers

• Running with auxiliary blowers.

Starting the auxiliary blowers:

1. Owing to the relatively high starting current, the blowers start in se

quence, with 6-10 seconds in between.

The non-return valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Oth-
erwise, there is a risk that the electric motor will burn out when it starts.

2. If an auxiliary blower fails to start, the non-return valve must be in the

closed position. Otherwise, the operating blower will not be able to
draw fresh air in through the turbocharger and air cooler. This is due to
differences in the air flow resistance.

When referring to this page, please quote Description A90030 Edition 0009 Page 19 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Running with auxiliary blowers:

If an auxiliary blower fails during running, the non-return valve must close to
ensure the continued supply of fresh air to the engine. See ‘Starting the auxil-
iary blowers‘, Item 2, above.

Exhaust Gas From the exhaust valves, the exhaust gas is led to the exhaust gas receiver
Receiver where the pulsatory pressure from the individual exhaust valves is equalized
and led to the turbocharger at a constant pressure.

The exhaust gas receiver is fastened to the seating by flexible supports. Com-
pensators are inserted between the receiver and the exhaust valves, and be-
tween the receiver and the turbocharger.

Inside the exhaust gas receiver, a protective grating is mounted before the tur-
bocharger.

The exhaust gas receiver and the exhaust pipe are insulated.

Charging Air The charging air cooler insert is of the block type. It is mounted in a housing
Cooler which is welded up of steel plates.

The cooler housing is provided with inspection covers.

The cooler is designed with an air reversing chamber which incorporates a wa-
ter mist catcher. The water mist catcher is built up of a number of lamellas
which separate the condensation water from the scavenge air during the pas-
sage of the air flow.

The separated water is collected in the bottom of the cooler housing from
which it is removed by a drain system.

Caution!
It is important to check that the drain functions correctly, as otherwise water
droplets may enter the cylinders. See Volume I Operation, Chapter 706,
‘Cleaning of Turbochargers and Air Coolers’.

An alarm device for high water level in the drain system is installed.

911 Safety Equipment

Safety Valves, Each cylinder cover is provided with a spring-loaded safety valve which is set
Cylinder Cover to open at a pressure somewhat higher than the maximum firing pressure in
the cylinder.

Page 20 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Relief Valves On the exhaust side of the engine a number of spring-loaded relief valves are
fitted, which will open in the event of excessive pressure in the crankcase/
chain casing, for instance as a result of the ignition of oil mist.

Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the
risk of fire caused by hot air/gas emitted in the event that the relief valves
open.

Regarding how to:

• avoid evaporation of the lubricating oil in the crankcase,

• detect oil mist in the crankcase using an ‘Oil Mist Detector’.

see Volume I, OPERATION, Chapter 704.

Warning!
Do not stand near crankcase doors or relief valves – or in corridors near
doors to the engine room casing in the event of an alarm for:

a) oil mist
b) high lube oil temperature
c) no piston cooling oil flow, or
d) scavenge box fire

Alarms b, c and d should be considered as pre-warnings of a possible in-

creasing oil mist level.

See also our Service Letter SL97-348/ERO.

Note!

If there has been a crankcase explosion, the complete flame arrester of the
relief valves must be replaced.

Safety Valve, The scavenge air receiver is fitted with a safety valve which is set to open
Scavenge Air should the pressure in the scavenge air receiver exceed a value somewhat
Receiver higher than the normal scavenge air pressure of the engine.

In some cases it may be necessary to open the valve manually, see Volume I,
Chapter 704, "Turbocharger Surging".

When referring to this page, please quote Description A90030 Edition 0009 Page 21 (23)
A90030-0009 Engine Types 35-98MC/MC-C
MAN B&W Diesel

Safety Cap in Each starting valve inlet pipe is provided with a safety cap. The safety cap
Starting Air Line consists of a bursting disc enclosed by a perforated cylinder and a perfo-
rated cover in order to protect any bystanders, in the event of a burst.

The cover is provided with a check plate, which shows if the bursting disc has
been damaged.

If the bursting disc of the safety cap is damaged by excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst,
and fit a new disc.

If a new disc is not available immediately, turn the cover in relation to the cylin-
der, in order to reduce the leakage of starting air. Fit a new bursting disc and
return the cover to the open position at the first opportunity.

912 Assembly of large Parts

Bedplate The bedplate is made in one or more sections, depending on the number of
cylinders. If there are two or more sections, these are joined together with fit-
ted bolts. The bedplate consists of two welded, longitudinal girders and a
number of cross girders which support the main bearings. The main bearings
consist of steel shells, lined with bearing metal.
See also Volume I, OPERATION, Chapter 708.

Each main bearing has one or two main bearing caps which are secured by
studs and nuts, designed for tightening with hydraulic tools.

The bedplate is fitted with an axial vibration damper. For the design and func-
tioning of the axial vibration damper, see Section 905 “Crankshaft”.

Marine engines (except geared plants):

The aft end of the bedplate incorporates the thrust bearing. See also Section
905 “Crankshaft”.

Stationary engines (and geared marine plants):

The bedplate incorporates the guide bearing. See also Section 905, “Crank
shaft”.

Framebox A framebox is bolted on to the top of the bedplate. Like the bedplate, the
framebox consists of one or more sections. Together, the bedplate and the
framebox constitute the crankcase of the engine.

The framebox is fitted with steel-plate doors for access to the crossheads and
to the main and crankpin bearings.

For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe fitted to the crosshead or guide shoe is able to
travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to
the oil tray of the bedplate.

Page 22 (23) When referring to this page, please quote Description A90030 Edition 0009
 Engine Types 35-98MC/MC-C A90030-0009
MAN B&W Diesel

Equipment for local checking of the cooling oil temperature and flow, and for
temperature and flow alarms, is installed in conjunction with the outlet pipe.
See also Volume I, OPERATION, Chapter 701.

Staybolts The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.

Engine Seating Regarding the engine seating for the specific engine, see the supplier’s special
instructions.

When referring to this page, please quote Description A90030 Edition 0009 Page 23 (23)
901 - Cylinder Cover

Documents in this Chapter

90101 0160 Cylinder Cover

90103 0003 Indicator Cock - Mounting

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Cylinder Cover Plate
P90101-0160

When referring to this page, please quote Plate P90101 Edition 0160 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover
P90101-0160

Item Item Description Item Item Description

No. No.

018 Screw
031 Cover
043 Nut
055 Stud for exhaust valve
079 Nut
080 Washer
092 Stud for starting valve
102 Cylinder cover
114 O-ring
126 Cooling jacket
138 Screw
151 Gasket
210 Nut
222 Spring housing, complete
234 Stud with guide face for fuel valve
246 Stud for fuel valve
271 Drain pipe

Page 2 (2) When referring to this page, please quote Plate P90101 Edition 0160
MAN B&W Diesel A/S
 Indicator Cock - Mounting Plate
P90103-0003

When referring to this page, please quote Plate P90103 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Indicator Cock - Mounting
P90103-0003

Item Item Description Item Item Description

No. No.

019 Indicator cock

020 Packing
032 Packing
056 Disc
068 Plug screw
081 Sundry chain
093 Key ring
103 Eye screw
127 Packing
140 Screw
152 Nut
164 Locking plate
176 Flange
188 Extension
223 Screw
235 Extension

Page 2 (2) When referring to this page, please quote Plate P90103 Edition 0003
MAN B&W Diesel A/S
902 - Piston with Rod & Stuffing Box

Documents in this Chapter

90201 0224 Piston and Piston Rod

90205 0120 Piston Rod Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Piston and Piston Rod Plate
MAN B&W Diesel P90201-0224

When referring to this page, please quote Plate P90201 Edition 0224 Page 1 (2)
Plate
Piston and Piston Rod
P90201-0224 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Screw
035 Piston ring no. 1
047 Piston ring no. 2
059 Piston ring no. 3
060 Piston ring no. 4
072 Piston crown
084 Cam lock nut
096 Stud
106 Pipe for cooling insert
118 Piston rod
131 D-ring
143 Guide pin
155 D-ring
167 Piston skirt
179 Flange screw
180 Locking wire
192 Cooling insert
202 Screw
214 Intermediate disc
226 Stud
238 Sealing ring
251 Disc
263 Nut for hydraulic tightening

Note:

Page 2 (2) When referring to this page, please quote Plate P90201 Edition 0224
 Piston Rod Stuffing Box Plate
MAN B&W Diesel P90205-0120

When referring to this page, please quote Plate P90205 Edition 0120 Page 1 (2)
Plate
Piston Rod Stuffing Box
P90205-0120 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Stuffing box housing

025 Nut
049 Scraper ring
050 Scraper ring
074 Flange
086 Screw
098 Guide pin
121 O-ring
133 Scraper ring
145 Sealing ring
157 Spring pin
169 Pack sealing ring, complete
170 Sealing pin
182 Tension spring
194 Cover sealing ring, complete
228 Lamella
253 Scraper ring, complete
277 Fitted bolt
290 Screw
300 Tension spring

Page 2 (2) When referring to this page, please quote Plate P90205 Edition 0120
903 - Cylinder Liner and Cylinder Lubrication

Documents in this Chapter

90301 0197 Cylinder Frame

90302 0170 Cylinder Liner and Cooling Jacket
90304 0021 Cylinder Liner - Details
90305 0143 Cylinder Lubricators
90307 0032 Cylinder Lubricator Unit
90308 0010 Cylinder Lubricator - Intermediate Box
90309 0031 Cylinder Lubricator System - Details
90310 0012 Cylinder Frame - Rear Side
90312 0004 Electronic Components - Cylinder Lubrication

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Cylinder Frame Plate
MAN B&W Diesel P90301-0197

When referring to this page, please quote Plate P90301 Edition 0197 Page 1 (2)
Plate
Cylinder Frame
P90301-0197 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Cylinder frame »fore«

040 Stuffing box housing
052 Bushing
064 Flange
076 Screw
088 Screw
123 Screw
135 Wacher
147 Cover
159 Nut
172 Stud for cylinder cover
184 O-ring
206 O-ring
218 Nut
231 Distance pipe
243 Stud
267 Screw
279 Distance pipe
292 Stud
302 Distance pipe
314 Nut
338 Protective pipe
351 Gasket
375 Cylinder frame
399 Stud
409 Nut
422 Gasket
434 Cover
458 Stud
471 Fitted stud
483 Nut
495 Screw
517 Fitted stud
530 Stud
542 Nut
566 Stud
591 Cleaning cover
601 Gasket
625 Screw
637 Rail for sealing
650 Packing-rubber
674 Screw
686 Nut
698 Fitted stud
721 Distance pipe
733 Fitted stud
745 Stud

Page 2 (2) When referring to this page, please quote Plate P90301 Edition 0197
 Cylinder Liner and Cooling Jacket Plate
P90302-0170
Cylinder Liner and Cooling Jacket
0170
P90302

When referring to this page, please quote Plate P90302 Edition 0170 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner and Cooling Jacket
P90302-0170

Item Item
Item Description Item Description
No. No.

071 O-ring
083 O-ring
095 Piston cleaning ring
105 Cooling water connection with drain
129 Cylinder liner
130 Cooling water connection
142 Packing
166 O-ring
178 Pipe
191 Screw
201 Cooling water connection
213 Pipe
225 Spring pin
237 Plug screw for thermo sensor hole
249 Gasket

Page 2 (2) When referring to this page, please quote Plate P90302 Edition 0170
MAN B&W Diesel A/S
 Cylinder Liner - Details Plate
P90304-0021
Cylinder Liner - Details
0021
P90304

A
A A

B B

B B

A A
A

When referring to this page, please quote Plate P90304 Edition 0021 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Details
P90304-0021

Item Item
Item Description Item Description
No. No.

023 Stud
035 Nut
047 Special stud
072 Valve housing
084 Non-return valve
096 Packing
106 Screw
118 Non-return valve
131 Valve housing
143 Thrust piece
167 Non-return valve
180 Thrust piece
192 Stud

Page 2 (2) When referring to this page, please quote Plate P90304 Edition 0021
MAN B&W Diesel A/S
 Cylinder Lubricators Plate
MAN B&W Diesel P90305-0143

When referring to this page, please quote Plate P90305 Edition 0143 Page 1 (2)
Plate
Cylinder Lubricators
P90305-0143 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 Bracket
029 Stud
030 Nut
042 Washer
066 Screw
101 Stud
113 Nut

Page 2 (2) When referring to this page, please quote Plate P90305 Edition 0143
 Cylinder Lubricator Unit Plate
MAN B&W Diesel P90307-0032

When referring to this page, please quote Plate P90307 Edition 0032 Page 1 (2)
Plate
Cylinder Lubricator Unit
P90307-0032 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Straight stud coupling

031 Distributor block
043 Stud
055 Nut
079 Distributor block
080 Ball valve
092 Distributor block
102 Stud
126 Adjustable elbow coupling
138 Quick coupling, minimess
175 O-ring
187 Gasket
199 Membrane accumulator
210 Lubricator, complete
222 Screw
258 Straight stud coupling
271 Adjusting screw
283 O-ring
295 Spacer, tubular
305 Cover
317 O-ring
329 Non-return valve
330 O-ring
342 Cylinder block
354 O-ring
366 Spring
378 Plunger
391 Actuator piston
413 Screw
425 Screw
449 Membrane accumulator
450 Gasket
462 Cylinder housing
486 Solenoid valve complete
498 Screw
521 O-ring
533 O-ring
545 Inductive sensor
557 Plug
569 Housing
582 Cable
594 Cable gland
604 Screw
616 Cable gland
628 Plug

Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0032
 Intermediate Box Plate
P90308-0010

When referring to this page, please quote Plate P90308 Edition 0010 Page 1 (2)
MAN B&W Diesel A/S
Plate Intermediate Box
P90308-0010

Item Item Description Item Item Description

No. No.

013 Intermediate box, complete

037 Electric enclosure with cables
049 Circuitboard assy
062 Diode

Page 2 (2) When referring to this page, please quote Plate P90308 Edition 0010
MAN B&W Diesel A/S
 Cylinder Lubricator System - Details Plate
MAN B&W Diesel P90309-0031

When referring to this page, please quote Plate P90309 Edition 0031 Page 1 (2)
Plate
Cylinder Lubricator System - Details
P90309-0031 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

019 Distributor block, complete

020 Screw
044 Distributor block
068 Coupling
081 Packing
103 Sealing ring
115 Distributor block
127 Screw
140 Couplig
152 Packing
176 Pipe holder
188 Screw
211 Nut
235 Steel pipe
259 Steel pipe
272 Pipe holder
296 Steel pipe
318 Pipe holder
343 Steel pipe
355 Steel pipe
379 Steel pipe
392 Pipe holder
414 Steel pipe
438 Steel pipe
463 Steel pipe
487 Steel pipe
509 Tee-screwed connection
510 Quick coupling, minimess

Page 2 (2) When referring to this page, please quote Plate P90309 Edition 0031
 Cylinder Frame, Studs on Exhaust Side Plate
MAN B&W Diesel P90310-0012

When referring to this page, please quote Plate P90310 Edition 0012 Page 1 (2)
Plate
Cylinder Frame, Studs on Exhaust Side
P90310-0012 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Distance pipe

026 Nut
038 Stud
054 Distance pipe
063 Nut
075 Stud

Page 2 (2) When referring to this page, please quote Plate P90310 Edition 0012
 Cylinder Lubrication - Electronic Components Plate
P90312-0004

When referring to this page, please quote Plate P90312 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Lubrication - Electronic Components
P90312-0004

Item Item Description Item Item Description

No. No.

015 Name plate

027 Pilot lamp
039 Name plate
040 Selector switch
052 Terminal
064 Terminal
076 Din rail
088 Terminal
111 Terminal
159 HMI panel
160 Mounting plate
184 Nut
196 Screw
206 Terminal

Page 2 (2) When referring to this page, please quote Plate P90312 Edition 0004
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

Documents in this Chapter

90401 0150 Connecting Rod and Crosshead

90403 0010 Lubricating and Cooling Oil-Flow

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Connecting Rod and Crosshead Plate
P90401-0150
Connecting Rod and Crosshead
0150
P90401

When referring to this page, please quote Plate P90401 Edition 0150 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead
P90401-0150

Item Item
Item Description Item Description
No. No.

019 Screw
020 Plug
032 Screw
044 Nut
056 Discharge pipe
068 Stud
081 Guide shoe
093 Lock washer
103 Stop screw
115 Screw
127 Locking wire
140 Thrust piece
164 Telescope pipe
176 Distance piece
188 Bracket
211 Plug
223 Guide pin
235 Crosshead
247 Guide strip
260 Crosshead bearing shell, complete
272 Crankpin bearing shell, complete
284 Screw
331 Crankpin bearing cap
343 Guide pipe
355 Nut
367 *) Washer
380 *) Stud
392 *) Shim
402 *) Screw
438 Nut
451 Crosshead bearing cap
463 Self-locking nut
487 Stud
509 Shim 0.75 mm
510 Shim 0.25 mm
522 Connecting rod stud
534 Guide pin
546 Connecting rod
583 Nut
605 Connecting rod stud

*) For engines with shims - please

state thickness of shim.

Page 2 (2) When referring to this page, please quote Plate P90401 Edition 0150
MAN B&W Diesel A/S
 Lubricating and Cooling Oil Flow Plate
MAN B&W Diesel P90403-0010

When referring to this page, please quote Plate P90403 Edition 0010 Page 1 (1)
905 - Crankshaft, Thrust Bearing and Turning Gear

Documents in this Chapter

90501 0156 Crankshaft

90502 0065 Arrangement of Fore End
90503 0018 Arrangement of Angle Encoder
90505 0121 Thrust- and Guide Bearing
90510 0130 Turning Gear
90511 0048 Turning Wheel
90512 0002 Turning Gear - Details
90513 0043 Tacho System

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Crankshaft Plate
P90501-0156
P90501
Crankshaft
0156

When referring to this page, please quote Plate P90501 Edition 0156 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft
P90501-0156

Item Item
Item Description Item Description
No. No.

012 Flange
024 Screw
085 Crankshaft
107 Screw
119 Lock washer
120 Guard
132 Chain wheel
156 Packing
168 Cover
181 Screw
193 Locking wire

Page 2 (2) When referring to this page, please quote Plate P90501 Edition 0156
MAN B&W Diesel A/S
 Arrangement of Fore End Plate
P90502-0065

When referring to this page, please quote Plate P90502 Edition 0065 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Fore End
P90502-0065

Item Item Description Item Item Description

No. No.

018 Fitted bolt

031 Nut
043 Locking wire
067 Counterweight

Page 2 (2) When referring to this page, please quote Plate P90502 Edition 0065
MAN B&W Diesel A/S
 Arrangement of Angle Encoder Plate
MAN B&W Diesel P90503-0018

When referring to this page, please quote Plate P90503 Edition 0018 Page 1 (2)
Plate
Arrangement of Angle Encoder
P90503-0018 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Measuring instrument, axial vibration

damper
037 Screw
049 Angle encoder
050 Enclosure, complete
074 Screw
086 Shaft
098 Housing
108 Damping plate
121 Coupling
133 Cable tie
157 Adjustment tool
169 Packing
170 Spring pin
182 Screw
194 Spring lock
204 Shield lower part
216 Packing
228 Shaft
253 Packing
265 Washer

Page 2 (2) When referring to this page, please quote Plate P90503 Edition 0018
 Thrust- and Guide Bearing Plate
MAN B&W Diesel P90505-0121

When referring to this page, please quote Plate P90505 Edition 0121 Page 1 (2)
Plate
Thrust- and Guide Bearing
P90505-0121 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Lubricating oil pipe

026 Locking wire
038 Screw
051 Screw
063 Lubricating oil pipe
075 Lubricating oil pipe
087 Lubricating oil pipe
099 Lubricating oil pipe
109 Lubricating oil pipe
110 Self-locking nut
122 Screw
146 Spray nozzle
171 Lubricating oil pipe
183 Lubricating oil pipe
195 Lubricating oil pipe
205 Lubricating oil pipe
217 Lubricating oil pipe
230 Segment stopper
242 Screw
254 Support
266 Spray pipe
278 Segment holder
291 Segment holder, complete
301 Segment with sensor pockets
325 Segment
337 Nut
349 Segment stopper
362 Bracket
374 Spray pipe
386 Segment holder, complete
408 Oil throw ring, complete
421 Screw
433 Oil throw ring in 2/2
445 Locking plate
457 Nut
469 Scraper ring housing, complete
470 Scraper ring housing, upper
482 Fitted bolt
494 Screw
504 Nut
516 Scraper ring housing, lower
541 Screw
553 Screw
565 Fitted bolt
577 Screw
589 Scraper ring, upper
590 Nut
600 Scraper ring, complete
612 Scraper ring, lower

Page 2 (2) When referring to this page, please quote Plate P90505 Edition 0121
 Tur ning Gear
urning Plate
MAN B&W Diesel P90510-0130

When referring to this page, please quote Plate P90510 Edition 0130 Page 1 (2)
Plate
Tur ning Gear
urning
P90510-0130 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Screw
023 Distance pipe
047 Distance pipe
059 Screw
072 Nut
084 Distance pipe
096 Guide pin
106 Turning gear
131 Gear wheel
143 Disengaging device

Page 2 (2) When referring to this page, please quote Plate P90510 Edition 0130
 Turning Wheel Plate
P90511-0048

When referring to this page, please quote Plate P90511 Edition 0048 Page 1 (2)
MAN B&W Diesel A/S
Plate Turning Wheel
P90511-0048

Item Item Description Item Item Description

No. No.

017 Dead centre pointer

029 Guide pin
030 Nut
054 Screw
066 Screw
078 Dead centre pointer
101 Turning wheel
113 Nut
125 Fitted bolt

Page 2 (2) When referring to this page, please quote Plate P90511 Edition 0048
MAN B&W Diesel A/S
 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 P90513-0043

A B

When referring to this page, please quote Plate P90513 Edition 0043 Page 1 (2)
Plate
Tacho System
P90513-0043 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Support
031 Screw
043 Locking wire
055 Pick-up box
067 Screw
079 Nut
080 Tacho pick-up
092 Terminal box
102 Screw
114 Terminal box
126 Screw
138 Bracket
151 Screw
163 Washer
175 Nut
187 Plate
199 Bracket
210 Tacho pick-up
222 Bracket
246 Spring lock
258 Screw
283 Cylindrical dowel
295 Nut

Note:

Page 2 (2) When referring to this page, please quote Plate P90513 Edition 0043
906 - Control Gear

Documents in this Chapter

90600 0141 Arrangement of Chain Drive and Camshaft

90603 0109 Chain Tightener
90610 0117 Bearing Housing - Mounting
90611 0176 Camshaft and Chain Wheel
90612 0085 Arrangement of Indicator System
90613 0119 Camshaft Bearing
90615 0126 Arrangement of Governor
90618 0128 Regulating Shaft
90619 0022 Load Transmitter
90620 0097 Engine-Side Control Console
90621 0076 Engine-Side Control Console - Details
90622 0060 Arrangement of Layshaft
90631 0025 Chain Drive Guidebars - Upper Part
90632 0034 Chain Drive Guidebars - Lower Part
90633 0029 Chain Drive Lubrication - Upper Part
90634 0040 Chain Drive Lubrication - Lower Part

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Arrangement of Chain Drive Plate
MAN B&W Diesel P90600-0141

When referring to this page, please quote Plate P90600 Edition 0141 Page 1 (1)
 Chain Tightener Plate
P90603-0109

When referring to this page, please quote Plate P90603 Edition 0109 Page 1 (2)
MAN B&W Diesel A/S
Plate Chain Tightener
P90603-0109

Item Item Description Item Item Description

No. No.

017 Chain wheel

029 Screw
030 Bushing
042 Screw
054 Locking wire
091 Flange bearing
101 Bracket
113 Screw
137 Shaft
149 Flange bearing
162 Screw
174 Shaft
186 Distance piece
198 Guide nut
208 Distance piece
221 Grease nipple
233 Shaft
245 Tightening bolt
257 Nut
269 Locking plate
282 Guide nut
294 Circlip
304 Circlip
316 Shaft
328 Bushing

Page 2 (2) When referring to this page, please quote Plate P90603 Edition 0109
MAN B&W Diesel A/S
 Bearing Housing - Mounting Plate
P90610-0117
P90610
Bearing
0117 Housing - Mounting

When referring to this page, please quote Plate P90610 Edition 0117 Page 1 (2)
MAN B&W Diesel A/S
Plate Bearing Housing - Mounting
P90610-0117

Item Item
Item Description Item Description
No. No.

064 Bearing, upper part

076 Bearing shell in 2/2
088 Bearing, lower part
135 Nut
147 Stud
159 Lock washer
160 Screw
172 Guide screw
184 Guide pin
196 Guide pin
206 Shim
231 Guide bearing, upper part
243 Guide ring
255 Guide bearing, lower part
279 Shim

Page 2 (2) When referring to this page, please quote Plate P90610 Edition 0117
MAN B&W Diesel A/S
 Camshaft and Chain Wheel Plate
MAN B&W Diesel P90611-0176

A
A

When referring to this page, please quote Plate P90611 Edition 0176 Page 1 (2)
Plate
Camshaft and Chain Wheel
P90611-0176 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Camshaft, fore

022 Camshaft
034 O-ring
046 O-ring
058 O-ring
071 Exhaust cam
083 Fuel cam
095 Flange
105 Coupling
130 Indicator cam
142 Fitted bolt
154 Locking washer
166 Locking washer
178 Nut
201 Fitted bolt
225 Disc
237 Nut
249 Locking wire
250 Protective cap
274 Chain wheel
286 Camshaft
298 Guide pin
321 Coupling

Note:

Page 2 (2) When referring to this page, please quote Plate P90611 Edition 0176
 Arrangement of Indicator System Plate
P90612-0085

When referring to this page, please quote Plate P90612 Edition 0085 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Indicator System
P90612-0085

Item Item Description Item Item Description

No. No.

016 Nut
028 Screw
041 Washer
053 Bracket
065 Screw
077 Housing
089 Liner
090 Spring pin
100 Roller guide, complete
112 Circlip
124 Washer
136 Screw
148 Circlip
161 Roller guide
173 Liner
185 Liner
197 Spring
207 Key
219 Screw
220 Shaft
232 Needle bearing
244 Pointed screw
256 Bracket
268 Screw
281 Screw
293 Handle
303 Bracket
315 Washer
327 Screw
555 Guide roller
567 Shaft
579 Circlip
580 Washer

Page 2 (2) When referring to this page, please quote Plate P90612 Edition 0085
MAN B&W Diesel A/S
 Camshaft Bearing Plate
P90613-0119

When referring to this page, please quote Plate P90613 Edition 0119 Page 1 (2)
MAN B&W Diesel A/S
Plate Camshaft Bearing
P90613-0119

Item Item Description Item Item Description

No. No.

011 Roller guide housing

023 Guide pin
035 Screw
060 Camshaft shield, upper
084 Screw
096 Stud
106 Bearing housing, lower part
118 Nut
143 Orifice plug
180 Camshaft shield, lower
192 Oil pan
202 Nut
214 Screw
226 Packing
238 Bearing shell
251 Guide pin
309 Screw
322 Packing
334 Screw
346 Cover
371 Cover
395 Split flange

Page 2 (2) When referring to this page, please quote Plate P90613 Edition 0119
MAN B&W Diesel A/S
 Arrangement of Governor Plate
MAN B&W Diesel P90615-0126

When referring to this page, please quote Plate P90615 Edition 0126 Page 1 (2)
Plate
Arrangement of Governor
P90615-0126 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

012 Screw
024 Spring lock
048 Bracket
073 Terminal box
085 Screw
107 Actuator
120 Screw
132 Spring lock
156 Fitted bolt
168 Washer
181 Self-locking nut

Page 2 (2) When referring to this page, please quote Plate P90615 Edition 0126
 Regulating Shaft Plate
MAN B&W Diesel P90618-0128

When referring to this page, please quote Plate P90618 Edition 0128 Page 1 (2)
Plate
Regulating Shaft
P90618-0128 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

019 Shaft
020 Circlip
032 Pull rod, complete
044 Fitted bolt
068 Screw
081 Lock washer
093 Arm holder
103 Pin
115 Resilient arm, complete
127 Circlip
139 Nut
140 Spring
164 Screw
176 Lock washer
188 Nut
211 Washer
223 Fitted bolt
260 Sleeve coupling, complete
272 Pin
284 Self-locking nut
296 Washer
306 Movable arm
318 Circlip
331 Pin
343 Key
355 Lever
392 Shaft
402 Shaft
414 Screw
426 Spring washer
438 Sleeve coupling
451 Nut
475 Ball bearing
487 Shim
499 Bearing housing
510 Shaft
522 Bracket
534 Bearing housing
546 Screw
571 Bracket
595 Washer
630 Key
642 Screw
654 Lever
666 Nut
678 Bracket
691 Dog point screw
701 Spring pin

Page 2 (2) When referring to this page, please quote Plate P90618 Edition 0018
 Load Transmitter Plate
P90619-0022
Load Transmitter
0022
P90619

When referring to this page, please quote Plate P90619 Edition 0022 Page 1 (2)
MAN B&W Diesel A/S
Plate Load Transmitter
P90619-0022

Item Item
Item Description Item Description
No. No.

014 Clamping arm

026 Fitted bolt
038 Washer
051 Self-locking nut
075 Pull rod, complete
099 Clamping arm
109 Screw
110 Locking plate
122 Nut
134 Potentiometer
146 Screw
158 Bracket
171 Screw
183 Spring washer

Page 2 (2) When referring to this page, please quote Plate P90619 Edition 0022
MAN B&W Diesel A/S
 Engine Side Control Console Plate
P90620-0097
Engine Side Control Console
0097
P90620

When referring to this page, please quote Plate P90620 Edition 0097 Page 1 (2)
MAN B&W Diesel A/S
Plate Engine Side Control Console
P90620-0097

Item Item
Item Description Item Description
No. No.

021 Distance pipe 738 Bearing flange

033 Screw 751 Shaft
045 Switch 0-110 volt 763 Studs
057 Spring lock 775 Ball handle
069 Name plate
070 Pressure switch
082 Screw
094 Name plate
104 Name plate
116 Spring lock
128 Nut
141 Stud
153 Handle
165 Key
177 Grease nipple
189 Nut
190 Washer
200 Engine side console
212 Forked lever
224 Key
248 Clamping arm
261 Screw
273 Nut
285 Lock washer
307 Cover
319 Screw
320 Hand wheel
332 Thrust ring
368 Locking plate
381 Nut
415 Clamping block
427 Spindle
476 Ball bearing
488 Circlip
511 Screw
523 Name plate, astern
535 Name plate, start
547 Name plate, aahead
559 Name plate, stop
631 Screw
643 Sealing ring
655 Name plate, remote
667 Name plate
680 Thrust ring
692 Name plate, emergency
714 Ball bearing
726 Circlip

Page 2 (2) When referring to this page, please quote Plate P90620 Edition 0097
MAN B&W Diesel A/S
 Engine - Side Control Console, Details Plate
P90621-0076
Engine - Side Control Console, Details
0076
P90621

When referring to this page, please quote Plate P90621 Edition 0076 Page 1 (2)
MAN B&W Diesel A/S
Plate Engine - Side Control Console, Details
P90621-0076

Item Item
Item Description Item Description
No. No.

027 Screw 650 Coupling

039 Self-locking nut
040 Washer
052 Fitted bolt
076 Key
088 Coupling
111 Split pin
123 Bearing
135 Screw
147 Angle lever
159 Circlip
160 Non-return valve
172 Nut
196 Flange bearing
206 Screw
218 Manual valve 5/2 way
231 Screw
255 Pointer
267 Screw
279 Shaft
280 Manual valve 3/2 way
302 Circlip
314 Circlip
326 Ball bearing
338 Flange bearing
351 Manual valve 3/2 way
363 Clamping arm
375 Lock washer
387 Nut
399 Screw
410 Nut
422 Slide shoe
434 Circlip
446 Screw
458 Lock washer
483 Coupling
495 Coupling
505 Non-return valve
517 Banjo coupling
529 Coupling
542 Screw connection
554 Coupling
566 Coupling
578 Coupling
591 Coupling
613 Coupling
637 Coupling

Page 2 (2) When referring to this page, please quote Plate P90621 Edition 0076
MAN B&W Diesel A/S
 Arrangement of Layshaft Plate
P90622-0060
Arrangement of Layshaft
0060
P90622

When referring to this page, please quote Plate P90622 Edition 0060 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Layshaft
P90622-0060

Item Item
Item Description Item Description
No. No.

010 Flange bearing

022 Washer
034 Self-locking nut
046 Lever
058 Lever
071 Grease nipple
083 Fitted bolt
095 Spindle
105 Cone
117 Guide pin
129 Distance ring
130 Ball bearing
154 Fitted bolt
178 Lever
191 Plate
201 Disc
213 Nut
225 Locking plate
237 Screw
249 Bushing
250 Locking arm
262 Washer
274 Screw
286 Spring washer
298 Screw
308 Switch
321 Stop screw
333 Cam
345 Impact socket
357 Impact handwheel
369 Washer
370 Self-locking nut

Page 2 (2) When referring to this page, please quote Plate P90622 Edition 0060
MAN B&W Diesel A/S
 Chain Drive Guidebars - Upper Part Plate
MAN B&W Diesel P90631-0025

When referring to this page, please quote Plate P90631 Edition 0025 Page 1 (2)
Plate
Chain Drive Guidebars - Upper Part
P90631-0025 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

021 Chain, complete

033 Outer link
045 Inner link
057 Chain link, complete
070 Locking wire
082 Disc
094 Screw
104 Guidebar
116 Screw
128 Beam for guidebar
141 Screw
153 Bracket for guideway

Page 2 (2) When referring to this page, please quote Plate P90631 Edition 0025
 Chain Drive Guidebars - Lower Part Plate
MAN B&W Diesel P90632-0034

When referring to this page, please quote Plate P90632 Edition 0034 Page 1 (2)
Plate
Chain Drive Guidebars - Lower Part
P90632-0034 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Screw
027 Disc
039 Guidebar
040 Screw
052 Locking wire
064 Beam for guidebar
076 Screw
111 Screw
123 Beam for guidebar
135 Shim
147 Screw
159 Screw
160 Bracket for guideway
172 Beam for guidebar
184 Bracket for guideway

Page 2 (2) When referring to this page, please quote Plate P90632 Edition 0034
 Chain Drive Lubrication - Upper Part Plate
MAN B&W Diesel P90633-0029

When referring to this page, please quote Plate P90633 Edition 0029 Page 1 (2)
Plate
Chain Drive Lubrication - Upper Part
P90633-0029 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Lubricating pipe

022 Spray nozzle
034 Lubricating pipe
058 Lubricating pipe
071 Lubricating pipe
095 Lubricating pipe
105 Lubricating pipe
117 Lubricating pipe
129 Lubricating pipe
130 Lubricating pipe
142 Lubricating pipe
154 Lubricating pipe

Page 2 (2) When referring to this page, please quote Plate P90633 Edition 0029
 Chain Drive Lubrication - Lower Part Plate
MAN B&W Diesel P90634-0040

When referring to this page, please quote Plate P90634 Edition 0040 Page 1 (2)
Plate
Chain Drive Lubrication - Lower Part
P90634-0040 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Lubricating pipe

028 Lubricating pipe
041 Spray pipe
053 Spray pipe
065 Spray pipe
077 Lubricating pipe
089 Lubricating pipe
090 Spray pipe
112 Lubricating pipe
124 Lubricating pipe
136 Lubricating pipe
148 Spray pipe
161 Lubricating pipe
173 Lubricating pipe

Page 2 (2) When referring to this page, please quote Plate P90634 Edition 0040
907 - Starting Air System

Documents in this Chapter

90702 0069 Main Starting Valve

90703 0111 Starting Air Distributor
90704 0053 Starting Valve
90705 0016 Starting Air Distributor Drive

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 Air Distributor Plate
P90703-0111
P90703
Starting Air Distributor
0111

When referring to this page, please quote Plate P90703 Edition 0111 Page 1 (2)
MAN B&W Diesel A/S
Plate Starting Air Distributor
P90703-0111

Item Item
Item Description Item Description
No. No.

010 Housing
022 Screw
034 Guide screw
058 Starting cam
071 Lock washer
083 Screw
095 Cover
105 Screw
129 Piston valve slide
130 Liner
142 Guide pin
166 O-ring
178 O-ring
191 Cover
201 Screw
213 Screw
225 Flange
237 Locking ring
249 Spring guide
250 Spring
262 Spring guide
274 Liner

Page 2 (2) When referring to this page, please quote Plate P90703 Edition 0111
MAN B&W Diesel A/S
 Starting Valve Plate
P90704-0053
Starting Valve
0053
P90704

When referring to this page, please quote Plate P90704 Edition 0053 Page 1 (2)
MAN B&W Diesel A/S
Plate Starting Valve
P90704-0053

Item Item
Item Description Item Description
No. No.

016 Screw
028 Piston
053 Spring
065 Bushing
077 Valve housing
090 Screw
100 Cover
112 Locking plate
148 Sealing ring
161 Spindle

Page 2 (2) When referring to this page, please quote Plate P90704 Edition 0053
MAN B&W Diesel A/S
 Distributor Drive Plate
P90705-0016

When referring to this page, please quote Plate P90705 Edition 0016 Page 1 (2)
MAN B&W Diesel A/S
Plate Distributor Drive
P90705-0016

Item Item Description Item Item Description

No. No.

011 Bearing bracket

023 Pin
035 Screw
047 Sealing ring
059 Disc
072 Locking wire
084 Screw
096 Guide disc in 2/2
106 O-ring
118 Bearing bracket
131 Claw coupling
143 Sleeve
155 Claw coupling
179 Claw coupling, complete

Page 2 (2) When referring to this page, please quote Plate P90705 Edition 0016
MAN B&W Diesel A/S
908 - Exhaust Valve

Documents in this Chapter

90801 0199 Exhaust Valve - Lower Parts

90802 0058 Exhaust Valve - Details
90803 0026 Exhaust Valve - Upper Parts
90804 0011 Exhaust Valve Upper Parts - Details
90805 0135 Exhaust Valve - Actuator
90806 0090 Exhaust Valve - Pipe System
90811 0010 Arrangement of Freshwater Pipes

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Exhaust Valve - Lower Parts Plate
P90801-0199

When referring to this page, please quote Plate P90801 Edition 0199 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Lower Parts
P90801-0199

Item Item Description Item Item Description

No. No.

013 Screw
037 Packing
049 Cover
062 Plug screw
074 Packing
086 Flange
098 Exhaust valve housing, complete
108 Pointed screw
121 O-ring
133 Bottom piece
145 O-ring
169 Valve spindle
182 Sealing ring
194 Screw
204 Spindle guide-lower
228 Plug screw
241 Packing
253 Flange
277 Packing
289 Screw
300 Packing
312 Flange
324 Screw
348 Sealing ring
373 Thread insert

Page 2 (2) When referring to this page, please quote Plate P90801 Edition 0199
MAN B&W Diesel A/S
 Exhaust Valve - Details Plate
P90802-0058

When referring to this page, please quote Plate P90802 Edition 0058 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Details
P90802-0058

Item Item Description Item Item Description

No. No.

020 Sealing oil unit, complete

Page 2 (2) When referring to this page, please quote Plate P90802 Edition 0058
MAN B&W Diesel A/S
 Exhaust Valve - Upper Parts Plate
P90803-0026

When referring to this page, please quote Plate P90803 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Upper Parts
P90803-0026

Item Item Description Item Item Description

No. No.

014 Safety strap

026 Guide bearing
038 Sealing ring
051 Sealing ring
075 Air cylinder
099 Sealing oil pipe
110 Orifice
122 Disc
134 Damper piston
146 Piston
171 Spring
183 Disc *
195 Oil cylinder
229 Piston ring
242 Stud
254 Nut
278 Locking plate
291 Flange
301 Screw
313 Cone
325 Piston
337 Sealing ring
350 Lifting eye bolt
362 Screw
374 Plate
386 Packing
408 Screw
421 Guide pin
433 Guide
445 Rotation check rod
457 Union nut
469 Screwed connection
470 Packing
482 O-ring
494 Spring
504 Disc
516 Spring pin
541 Disc
553 Screw
577 Non return valve

Note:

* When ordering, please state thick-

ness of disc.

Page 2 (2) When referring to this page, please quote Plate P90803 Edition 0026
MAN B&W Diesel A/S
 Exhaust Valve, Upper Parts - Details Plate
P90804-0011

When referring to this page, please quote Plate P90804 Edition 0011 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve, Upper Parts - Details
P90804-0011

Item Item Description Item Item Description

No. No.

021 Packing
033 O-ring
045 Safety valve

Page 2 (2) When referring to this page, please quote Plate P90804 Edition 0011
MAN B&W Diesel A/S
 Valve Gear Plate
P90805-0135

When referring to this page, please quote Plate P90805 Edition 0135 Page 1 (2)
MAN B&W Diesel A/S
Plate Valve Gear
P90805-0135

Item Item Description Item Item Description

No. No.

015 Roller guide, complete

027 Bushing
040 Nut
064 Piston
076 Disc
088 Roller guide
111 Shaft
123 Plug
135 Retaining ring
159 Screw
160 Bushing
172 Disc
196 Guide pin
206 Screw
231 Bushing
255 Oil cylinder
267 Piston ring
279 Disc
280 Screw
302 Spring seat disc
314 Spring
363 Guide pin
375 Roller
387 Guide block
399 Guide pin
410 Stud
422 Stud

Page 2 (2) When referring to this page, please quote Plate P90805 Edition 0135
MAN B&W Diesel A/S
 Exhaust Valve - Pipe System Plate
P90806-0090

When referring to this page, please quote Plate P90806 Edition 0090 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Pipe System
P90806-0090

Item Item Description Item Item Description

No. No.

010 Screw
022 Hose complete
034 Pipe
046 Plug screw
058 Packing
071 Disc
083 Sealing ring
105 Thrust bushing
117 Coupling
129 Hydraulic pipe, complete
130 Drain pipe
142 Coupling
166 Clamp
178 Nut
191 Screw
201 Support

Page 2 (2) When referring to this page, please quote Plate P90806 Edition 0090
MAN B&W Diesel A/S
 Arrangement of Freshwater Pipes Plate
P90811-0010
P90811
Arrangement
0010 of Freshwater Pipes

When referring to this page, please quote Plate P90811 Edition 0010 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Freshwater Pipes
P90811-0010

Item Item
Item Description Item Description
No. No.

018 Screw
043 Orifice plate
055 Butterfly valve
079 Packing
080 Screw
092 Outlet pipe
114 Plug screw
126 Ball valve

Page 2 (2) When referring to this page, please quote Plate P90811 Edition 0010
MAN B&W Diesel A/S
909 - Fuel Oil System

Documents in this Chapter

90901 0179 Fuel Pump

90902 0156 Fuel Pump Gear
90903 0045 Fuel Pump Gear - Details
90904 0062 Fuel Pump - Details
90905 0029 Reversing Mechanism
90910 0143 Fuel Valve
90911 0022 Fuel Valve Function
90913 0130 High-Pressure Pipes
90914 0100 Fuel Oil System
90915 0060 Fuel Oil System - Details
90915 0081 Fuel Oil System - Details
90916 0007 Lifting Device for Fuel Pump - Cylinder No. 1

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Fuel Pump Plate
P90901-0179
Fuel Pump
0179
P90901

When referring to this page, please quote Plate P90901 Edition 0179 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Pump
P90901-0179

Item Item
Item Description Item Description
No. No.

017 Gasket 676 Gasket

029 Bushing 688 Valve housing
030 Connecting pipe 711 O-ring
042 Gasket 723 Slide
054 Plug screw 735 Spring
078 Pump housing, complete 747 Spring guide
091 Bushing 772 Throttle plug
101 Timing guide 784 Gasket
113 Sleeve 855 Screw
125 Regulating guide 867 Protective cap
137 Guide pin 879 Coupling
149 Screw 880 Pipe
162 Stud 892 Banjo coupling
174 Gasket 902 Plug screw
186 Guide screw 914 Disc
198 Guide pin 926 Pipe
208 Guide pin
221 Guide bushing, complete
233 Guide bushing
257 Screw
269 Screw
270 Top cover
282 Lock washer
294 Plug screw
341 Throttle plug
389 Nut
390 Screw
400 Spring guide
412 Spring
436 Suction valve, complete
448 Slide
461 Thrust piece
473 Sealing ring
507 Orifice plate
519 Circlip
520 Sealing ring
532 Pump barrel
544 Pump barrel, complete
556 Plunger
568 Sealing ring
603 Screw
615 Lock washer
627 Cover
639 Sealing ring
640 Sealing ring
652 Puncture valve, complete
664 Air piston

Page 2 (2) When referring to this page, please quote Plate P90901 Edition 0179
MAN B&W Diesel A/S
 Fuel Pump Gear Plate
P90902-0156
Fuel Pump Gear
0156
P90902

When referring to this page, please quote Plate P90902 Edition 0156 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Pump Gear
P90902-0156

Item Item
Item Description Item Description
No. No.

012 Fuel pump roller guide, complete 683 Guide bushing

024 Pin 695 Screw
036 Plug
048 Circlip
061 Screw
073 Roller
085 Bushing
097 Disc
107 Shaft
120 Pin
144 Thrust disc
156 Roller guide
168 Plug
181 Bushing
193 Pin
215 Link for reversing
227 Pin
240 Guide pin
252 Guide block
264 Screw
276 Guide pin
288 Bushing
323 Nut
347 Bushing for roller guide
360 Disc
372 Cap
384 Sealing ring
396 Cap
431 Locking wire
443 Screw
467 Nut
479 Pump base, complete
480 Packing
492 Cover, transparent
502 Flange
514 Screw
538 Disc
551 Stud
563 Stud
575 Spring internal
587 Spring external
599 Disc
609 Disc
622 Sealing bush
634 Circlip
646 Pump base
658 Throttle plug

Page 2 (2) When referring to this page, please quote Plate P90902 Edition 0156
MAN B&W Diesel A/S
 Fuel Pump Gear - Details Plate
P90903-0045
Fuel Pump Gear - Details
0045
P90903

When referring to this page, please quote Plate P90903 Edition 0045 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Pump Gear - Details
P90903-0045

Item Item
Item Description Item Description
No. No.

018 Screw
031 Support, complete
043 Ball lock
055 Screw
067 O-ring
080 Screw
092 Coupling arm
102 Screw
114 Washer
126 Pull rod head
138 Nut
151 Nut
175 Flange
187 Shaft
199 Screw
209 Collar pin
210 Split pin
222 Air cylinder
246 Locking pin
258 Securing pin
271 O-ring
283 Bearing
295 Piston ring
305 O-ring
317 Screw
329 Bracket
330 Stud
342 Distance piece
354 Flange suspension
366 Screw
391 Pin
401 Needle bearing
413 Disc
425 Disc
437 Shaft

Page 2 (2) When referring to this page, please quote Plate P90903 Edition 0045
MAN B&W Diesel A/S
 Fuel Pump - Details Plate
MAN B&W Diesel P90904-0062

When referring to this page, please quote Plate P90904 Edition 0062 Page 1 (2)
Plate
Fuel Pump - Details
P90904-0062 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Union
025 Nut
037 Bracket
049 Screw
050 Washer
062 Actuator
074 Coupling
086 Screw
108 Guide screw
121 Toothed bar, regulation
133 Packing
157 Union
169 Pointer
170 Toothed bar, timing
182 Nut
194 Forked lever
216 Retaining ring
228 Guide pin
241 Forked lever
253 Forked lever
265 Nut
277 Adjusting screw
289 Nut

Page 2 (2) When referring to this page, please quote Plate P90904 Edition 0062
 Reversing Mechanism Plate
P90905-0029
Reversing Mechanism
0029
P90905

When referring to this page, please quote Plate P90905 Edition 0029 Page 1 (2)
MAN B&W Diesel A/S
Plate Reversing Mechanism
P90905-0029

Item Item
Item Description Item Description
No. No.

019 Distance pipe

020 Guard
032 Screw
044 Bolt
068 Guide for reversing
081 Distance pipe
093 Bush
103 Shaft
115 Reversing mechanism, complete
139 Air cylinder
140 Screw
152 Shim
235 Ball valve
247 Branch piece
259 Packing
260 Nut
272 Orifice plate
284 Coupling
296 Non-return valve
306 Nut
318 Safety valve

Page 2 (2) When referring to this page, please quote Plate P90905 Edition 0029
MAN B&W Diesel A/S
 Fuel Valve Plate
P90910-0143
P90910
Fuel Valve
0143

016 197

207

028

065 219

089

090
220

100 232

124
244

256

136

268

148

950

281

161

173

When referring to this page, please quote Plate P90910 Edition 0143 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve
P90910-0143

Item Item
Item Description 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 pin
161 Union nut
173 O-ring
197 O-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 (optional extras)

Page 2 (2) When referring to this page, please quote Plate P90910 Edition 0143
MAN B&W Diesel A/S
 Fuel Valve Function Plate
P90911-0022

When referring to this page, please quote Plate P90911 Edition 0022 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
MAN B&W Diesel P90913-0130

When referring to this page, please quote Plate P90913 Edition 0130 Page 1 (2)
Plate
High-Pressure Pipes
P90913-0130 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

012 High-pressure pipe, complete

024 Union nipple
036 Thrust bushing
048 Union nut
061 High-pressure pipe
073 Hose, complete
097 O-ring
107 Union nipple
119 O-ring
132 High-pressure, complete
144 High-pressure pipe
168 T-coupling
181 Pipe
193 Screw
203 Flange
215 Housing
227 Coupling
239 Guide pin
240 High-pressurepiipe, complete
252 High-pressure pipe

Page 2 (2) When referring to this page, please quote Plate P90913 Edition 0130
 Fuel Oil System Plate
MAN B&W Diesel P90914-0100

When referring to this page, please quote Plate P90914 Edition 0100 Page 1 (2)
Plate
Fuel Oil System
P90914-0100 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Steel pipe

031 Non-return valve
043 Steel pipe
067 Packing
079 Screw
080 Fuel oil pipe, inlet
092 Plug screw
114 Ball valve
126 Packing ring
138 Screw
151 Fuel oil pipe, inlet
163 Screw
175 Nut

Page 2 (2) When referring to this page, please quote Plate P90914 Edition 0100
 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 System - Details Plate
MAN B&W Diesel P90915-0081

When referring to this page, please quote Plate P90915 Edition 0081 Page 1 (2)
Plate
Fuel Oil System - Details
P90915-0081 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Locking wire

025 Nut
037 Flange
049 Stud
050 Spring guide
062 Spring
086 Disc
098 Slide
108 Pressure spring
121 Spring
133 Piston
145 Sealing ring
157 Wearing ring
169 Packing
182 Plug screw
194 Packing ring
204 Stud
216 Packing
228 Housing
241 Packing
253 Plug screw
265 Screw
277 Shock absorber, complete

Page 2 (2) When referring to this page, please quote Plate P90915 Edition 0081
 Lifting Device for Fuel Pump - Cylinder No. 1 Plate
MAN B&W Diesel P90916-0007

C K

A
A: 4-Way 3 position valve
B: 5-Way 2 position valve
C: Air cylinder
K: Pressure switch

When referring to this page, please quote Plate P90916 Edition 0007 Page 1 (2)
 Lifting Device for Fuel Pump - Cylinder No. 1
Plate
P90916-0007 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

020 Straight stud coupling

032 Gauge cock, female/female
056 Adjustable t-coupling
068 4/2-way valve, pneumatic
081 Screw
103 Carrying iron
115 Screw
127 Straight stud coupling
139 Copper pipe
140 Elbow coupling
164 Adjustable elbow coupling
176 T-coupling
188 Straight stud coupling
211 Straight coupling
235 Pressure switch
247 Screw
260 Non-return valve
272 Non-return valve
284 Screw
296 Straight stud coupling
318 Adjustable l-coupling
331 Straight stud coupling
343 Non-return valve
355 Pipe holder
367 Screw
380 Adjustable elbow coupling
392 Banjo coupling
402 Reducing adaptor, male/female
414 Steel pipe
426 Reducing connection
451 Straight stud coupling
463 Adjustable elbow coupling
475 Steel hose
487 Socket plug

Page 2 (2) When referring to this page, please quote Plate P90916 Edition 0007
910 - Turbocharger System

Documents in this Chapter

91000 0017 Gas and Air System

91001 0158 Scavenge Air Receiver
91002 0145 Arrangement of Charging Air Pipe
91003 0226 Exhaust Pipes and Receiver
91004 0083 Exhaust Receiver - Details
91005 0119 Air Cooler
91006 0029 Arrangement of Auxiliary Blower
91007 0018 Butterfly Valve
91009 0047 Air Cooler System - Cleaning
91011 0012 Arrangement of Non-Return Valve
91014 0025 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 P91001-0158

When referring to this page, please quote Plate P91001 Edition 0158 Page 1 (2)
Plate
Scavenge Air Receiver
P91001-0158 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

017 Scavenge air reciever

030 Screw
042 Cover
066 Cross member
078 Screw
091 Support
101 Spring pin
113 O-ring
125 Flange
149 Stud
150 Washer
162 Nut
186 Screw
198 Cover
245 Screw
257 Hinge
270 Screw
282 Nut
294 O-ring
316 Locking plate
328 Cover
341 Sectional iron
353 Sectional iron
365 Nut
377 Stud
424 Screw
436 Cover
461 Screw
473 Distance pipe
485 O-ring
507 O-ring
519 Air cooler housing sealing
520 Washer
532 Distance pipe
544 Screw
568 Plate
581 Plate
593 Stud

Page 2 (2) When referring to this page, please quote Plate P91001 Edition 0158
 Arrangement of Charging Air Pipe Plate
MAN B&W Diesel P91002-0145

When referring to this page, please quote Plate P91002 Edition 0145 Page 1 (2)
Plate
Arrangement of Charging Air Pipe
P91002-0145 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

024 Insulation cloth

036 Insulation material*
048 Screw
061 Insulation cover
085 Insulation cover
107 Packing
119 Plug screw
120 Charging air pipe
144 Packing
156 Plug screw
181 Nut
193 Washer
203 Screw
215 Compensator
227 Screw

Note:

* When ordering insulation material,

please use Plate P90002.

Page 2 (2) When referring to this page, please quote Plate P91002 Edition 0145
 Exhaust Pipes and Receiver Plate
MAN B&W Diesel P91003-0226

When referring to this page, please quote Plate P91003 Edition 0226 Page 1 (2)
Plate
Exhaust Pipes and Receiver
P91003-0226 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

031 Compensator
043 Nut
055 Screw*
079 Exhaust receiver, fore
080 Exhaust receiver, aft
092 Exhaust bend
114 Nut
126 Screw*
151 Clamp
175 Special nut
187 Lock
199 Locking washer
209 Nut
210 Screw
222 Guide pin
234 Clamp
246 Disc
283 Plug screw
295 Packing
317 Screw*
329 Pipe-exhaust valve
342 Insulation material
391 Compensator
401 Nut
413 Screw*
425 Gas inlet
449 Insulation material
474 Compensator
486 Screw*
498 Nut
508 Insulation material
533 Plate
545 Plate
557 Stud
569 Nut
582 Packing
604 Sectional iron, other
616 Sectional iron
628 Stud

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 0226
 Exhaust Pipes and Receiver Plate
MAN B&W Diesel P91004-0083

When referring to this page, please quote Plate P91004 Edition 0083 Page 1 (2)
Plate
Exhaust Pipes and Receiver
P91004-0083 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Support
037 Nut
049 Distance pipe
050 Clamp
062 Distance pipe
074 Clamp
086 Support
098 Spring pin
108 Washer
121 Screw
145 Screw
169 Screw
170 Distance pipe
194 Clamp
204 Spring plate
228 Clamp
241 Spring pin
253 Washer
265 Screw
289 Spring pin
300 Nut
324 Support
336 Support
361 Shim
373 Clamp
385 Spring plate
397 Support
407 Screw
419 Distance pipe
432 Clamp
456 Clamp
468 Shim
481 Clamp
503 Clamp
527 Nut
540 Distance pipe
564 Clamp
576 Clamp
588 Support
611 Spring pin
623 Screw
647 Support
660 Distance pipe
672 Spring pin
684 Screw
706 Clamp

Page 2 (2) When referring to this page, please quote Plate P91004 Edition 0083
 Air Cooler Plate
P91005-0119
Air
P91005
0119Cooler

When referring to this page, please quote Plate P91005 Edition 0119 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler
P91005-0119

Item Item
Item Description Item Description
No. No.

019 Nut
020 Screw
032 Screw
044 Frame
056 O-ring
068 Frame
093 Stud
103 Support
115 Support
127 Screw
139 Cooler insert
140 Water mist catcher

Page 2 (2) When referring to this page, please quote Plate P91005 Edition 0119
MAN B&W Diesel A/S
 Arrangement of Auxiliary Blower Plate
P91006-0029

When referring to this page, please quote Plate P91006 Edition 0029 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Auxiliary Blower
P91006-0029

Item Item Description Item Item Description

No. No.

014 Packing
026 Distance pipe
038 Screw
051 Nut
075 Auxiliary blower

Page 2 (2) When referring to this page, please quote Plate P91006 Edition 0029
MAN B&W Diesel A/S
 Butterfly Valve Plate
P91007-0018

When referring to this page, please quote Plate P91007 Edition 0018 Page 1 (2)
MAN B&W Diesel A/S
Plate Butterfly Valve
P91007-0018

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 0018
MAN B&W Diesel A/S
 Air Cooler System - Cleaning Plate
MAN B&W Diesel P91009-0047

When referring to this page, please quote Plate P91009 Edition 0047 Page 1 (2)
Plate
Air Cooler System - Cleaning
P91009-0047 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

010 Main pipe 668 Ball valve

022 Packing ring 693 Cleaning pipe
034 Screw 703 Straight valve, female/female
046 Nut 715 Plug screw
071 Nut 739 Cleanning pipe
083 Stud 740 Cleanning pipe
095 Packing 752 Cleanning pipe
105 Nut 764 Cleanning pipe
117 Stud 776 Cleanning pipe
130 Cleaning pipe 811 Guide
142 Cleaning pipe 823 Cleanning pipe
154 Cleaning pipe 835 Guide
178 Cleaning pipe 847 Cleanning pipe
191 Cleaning pipe 859 Cleanning pipe
201 Support
213 Main pipe
225 Main pipe
249 Screw
250 Butterfly valve
262 Packing ring
274 Orifice plate
286 Screw
308 Cleaning pipe
321 Packing ring
333 Screw
345 Nut
369 Stud
370 Main pipe
382 Main pipe
404 Orifice plate
416 Packing ring
428 Nut
441 Screw
465 Screw
477 Nut
489 Packing ring
490 Orifice plate
512 Cleaning pipe
524 Drain box
536 Flange
548 Packing ring
561 Screw
573 Nut
597 Screw
607 Packing ring
619 Orifice plate
620 Packing ring
632 Screw
644 Nut

Page 2 (2) When referring to this page, please quote Plate P91009 Edition 0047
 Arrangement of Non-return Valve Plate
P91011-0012
Arrangement of Non-return Valve
0012
P91011

When referring to this page, please quote Plate P91011 Edition 0012 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Non-return Valve
P91011-0012

Item Item
Item Description Item Description
No. No.

023 Screw
035 Lock washer
047 Support
059 Clamp
060 Spring pin
072 Holder
084 Valve flap
096 Screw
106 Distance pipe
131 Mounting plate
155 Screw
167 Shaft
180 Support
192 Clamp
202 Holder
214 Mounting plate
226 Non-return valve, complete
238 Non-return valve, complete

Page 2 (2) When referring to this page, please quote Plate P91011 Edition 0012
MAN B&W Diesel A/S
 Arrangement of Suction Pipe Plate
MAN B&W Diesel P91014-0025

When referring to this page, please quote Plate P91014 Edition 0025 Page 1 (2)
Plate
Arrangement of Suction Pipe
P91014-0025 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Screw
031 Distance pipe
043 Screw
055 Packing
067 Disc
079 O-ring
080 Nut
092 Suction pipe
114 Pipe
126 Plate
151 Nut
163 Screw
175 Disc special
187 Screw
199 Screw
209 Suction pipe

Page 2 (2) When referring to this page, please quote Plate P91014 Edition 0025
911 - Safety Equipment

Documents in this Chapter

91101 0037 Safety Valve - Cylinder

91102 0030 Relief Valve
91102 0033 Relief Valve
91103 0018 Safety Valve - Scavenge Air System
91104 0094 Arrangement of Safety Cap
91106 0001 Fuel Oil Leakage Monitor

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
P91102-0030

When referring to this page, please quote Plate P91102 Edition 0030 Page 1 (2)
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0030

Item Item Description Item 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 0030
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
P91104-0094
Arrangement of Safety Cap
0094
P91104

When referring to this page, please quote Plate P91104 Edition 0094 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Safety Cap
P91104-0094

Item Item
Item Description Item Description
No. No.

017 Gasket
042 Bursting cap
054 Check plate
066 Screw
078 Perforated cylinder
091 Starting air pipe
101 Fitted bolt
125 Screw
137 Protecting guard
149 Wing nut
150 Washer
162 Stud
174 Bursting disc
208 Screw
221 Screw
233 Nut

Page 2 (2) When referring to this page, please quote Plate P91104 Edition 0094
MAN B&W Diesel A/S
 Fuel Oil Leakage Monitor Plate
MAN B&W Diesel P91106-0001

When referring to this page, please quote Plate P91106 Edition 0001 Page 1 (2)
Plate
Fuel Oil Leakage Monitor
P91106-0001 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

018 Disc
031 Diaphragm
043 Rivet
055 Disc
067 Screw
079 Cover
092 Screw
102 Socket plug
114 5/2-way valve

Page 2 (2) When referring to this page, please quote Plate P91106 Edition 0001
912 - Assembly of Large Parts

Documents in this Chapter

91201 0072 Arrangement of Stay Bolts

91203 0018 Frame Box - Details
91205 0205 Frame Box
91206 0097 End Shields
91207 0057 Arrangement of Piston Cooling
91208 0024 Chain Wheel Frame - Upper
91210 0189 Bedplate
91211 0075 Axial Vibration Damper
91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S
 Arrangement of Stay Bolts Plate
P91201-0072
Arrangement of Stay Bolts
0072
P91201

When referring to this page, please quote Plate P91201 Edition 0072 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Stay Bolts
P91201-0072

Item Item
Item Description Item Description
No. No.

014 Stay bolt, complete

026 Screw
051 Protective cap
063 Nut
075 Stay bolt, upper part
099 Assembly nut
110 Stay bolt, lower part

Page 2 (2) When referring to this page, please quote Plate P91201 Edition 0072
MAN B&W Diesel A/S
 Frame Box - Details Plate
MAN B&W Diesel P91203-0018

B E C F F M

M
E C
B

D D
A C C D C
D

A C F F C D DC

A-A B-B C-C

D-D

E-E F-F

K
K

G
G

H H

H H

G-G H-H K-K M-M

When referring to this page, please quote Plate P91203 Edition 0018 Page 1 (2)
Plate
Frame Box - Details
P91203-0018 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

015 Stud
027 Nut
039 Distance pipe
040 Fitted stud
052 Distance pipe
064 Nut
076 Distance pipe
088 Screw
123 Locking wire
135 Screw
147 Fitted stud
159 Distance pipe
160 Distance pipe
172 Distance pipe
184 Fitted stud
196 Screw

Page 2 (2) When referring to this page, please quote Plate P91203 Edition 0018
 Frame Box Plate
MAN B&W Diesel P91205-0205

B
A B

B-B
A

When referring to this page, please quote Plate P91205 Edition 0205 Page 1 (2)
Plate
Frame Box
P91205-0205 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Frame box door

028 Packing
053 Lubricating oil pipe
065 Screw
077 Locking wire
089 Drain pipe
100 Frame box, aft
112 Frame box, fore
136 Frame box door
148 Packing
173 Wing nut
185 Stud
197 Spring
207 Door fastener
220 Locking pin
232 Spring
244 Key ring
256 Washer
281 Cover
293 Screw
315 Screw
327 Cover

Page 2 (2) When referring to this page, please quote Plate P91205 Edition 0205
 End Shields Plate
MAN B&W Diesel P91206-0097

When referring to this page, please quote Plate P91206 Edition 0097 Page 1 (2)
Plate
End Shields
P91206-0097 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

011 Shield, upper

023 Screw
035 Gasket
047 Cover
060 Screw
096 Screw
106 Locking wire
118 Damper-oil pipe
131 Screw
155 Damper-oil pipe
167 Gasket
179 Screw
192 Shield, lower
202 Screw
214 Drain pipe
238 Screw
251 Screw
263 Shield, fore

Page 2 (2) When referring to this page, please quote Plate P91206 Edition 0097
 Arrangement of Piston Cooling Plate
P91207-0057
Arrangement of Piston Cooling
0057
P91207

When referring to this page, please quote Plate P91207 Edition 0057 Page 1 (2)
MAN B&W Diesel A/S
Plate Arrangement of Piston Cooling
P91207-0057

Item Item
Item Description Item Description
No. No.

017 Slotted pipe

029 Sight glass, complete
030 Sight glass
042 Flange
054 Packing
066 Screw
091 Lock washer
101 Nut
113 Fitted bolt
125 Lock washer
137 Fitted bolt
150 Plate
162 Screw
174 Locking plate
186 Bracket
198 Screw
208 Locking plate

Page 2 (2) When referring to this page, please quote Plate P91207 Edition 0057
MAN B&W Diesel A/S
 Chain Wheel Frame - Upper Plate
MAN B&W Diesel P91208-0024

C-C

B B
A

B-B

C C

When referring to this page, please quote Plate P91208 Edition 0024 Page 1 (2)
Plate
Chain Wheel Frame - Upper
P91208-0024 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

012 Handle
024 Screw
036 Inspection cover
061 Nut
073 Stud
085 Screw
097 Inspection cover
119 Screw
120 Screw
132 Chainwheel frame
144 Screw
156 Cover
181 Stud
193 Spacer, tubular
203 Nut
215 Stud
227 Plug
240 Screw
252 Distance pipe
264 Top guard
276 Cover
311 Dowel
323 Cover
335 Cover
359 Packing ring
360 Screw
384 Nut
396 Fitted stud
406 Distance pipe
418 Fitted stud
443 Spacer, tubular
455 Nut
467 Stud
480 Tension spring
492 Stud
514 Cover
526 Screw
538 Nut, self-locking

Page 2 (2) When referring to this page, please quote Plate P91208 Edition 0024
 Bedplate Plate
MAN B&W Diesel P91210-0189

D3
D3
D5-D5 D3-D3 D4-D4
D4
D4

D5

D5

When referring to this page, please quote Plate P91210 Edition 0189 Page 1 (2)
Plate
Bedplate
P91210-0189 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

013 Lubricating pipe

025 Screw
037 Locking wire
050 Screw
062 Screw
074 Locking plate
086 Grate
098 Cover
121 Bedplate, fore
133 Guide pin
145 Screw
169 Screw
170 Nut
194 Pipe holder
204 Screw
216 Lubricating oil pipe
241 Lubricating oil pipe
253 Lubricating oil pipe
277 Screw
290 Stud
312 Lubricating oil pipe
324 Lubricating oil pipe
336 Nut
348 Main bearing stud
373 Main bearing cap
397 Bearing shell, upper
407 Bearing shell, lower
420 Cover
432 Screw
456 Cover
468 Screw
493 Main bearing, complete
515 Bedplate, aft
527 Nut
539 Disc
540 Screw
564 Nut
576 Distance pipe
588 Stud
611 Stud

Page 2 (2) When referring to this page, please quote Plate P91210 Edition 0189
 Axial Vibration Damper Plate
P91211-0075
Axial
P91211
0075 Vibration Damper

When referring to this page, please quote Plate P91211 Edition 0075 Page 1 (2)
MAN B&W Diesel A/S
Plate Axial Vibration Damper
P91211-0075

Item Item
Item Description Item Description
No. No.

019 Spring
020 Spring
081 Screw
093 Lock washer
103 Restriction for damper
115 Restriction for damper
127 Restriction for damper
139 Screw
140 Guide pin
152 Oil seal
164 Oil seal
223 Nut
235 Nut
247 Stud
259 Stud
260 Axial vibration damper, complete
284 Axial vibration damper, upper part
296 Distance pipe
306 Guide pin
318 Axial vibration damper, lower part
331 Distance pipe

Page 2 (2) When referring to this page, please quote Plate P91211 Edition 0075
MAN B&W Diesel A/S
 HoldingDown Bolts and End Chock Bolts Plate
MAN B&W Diesel (Epoxy Chocks) P91216-0008

When referring to this page, please quote Plate P91216 Edition 0008 Page 1 (2)
Plate
HoldingDown Bolts and End Chock Bolts
P91216-0008 (Epoxy Chocks) MAN B&W Diesel

Item Item Description Item Item Description

No. No.

016 Screw
028 Washer
041 Lock plate
053 Liner for sidechock, port side
077 Liner for sidechock, starboard side
090 Protecting cap
100 Nut
112 Distance tube
148 Spherical washer
161 Spherical nut
173 Holding down bolt
197 Nut
207 Protecting cap
219 End chock bolt
232 Liner for end chock
244 Spherical washer
256 Spherical washer
281 Nut

Page 2 (2) When referring to this page, please quote Plate P91216 Edition 0008