Instructions Manual S50ME C PDF

Warning S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines’ Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
§94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
When referring to this page, please quote S900 Edition 0001 Page 1 (1)
MAN B&W Diesel A/S
S50ME-C VOLUME II
MAINTENANCE
900 Introduction
Documents in this Chapter
90023 0027 Instructions for Main Engine

Table of Contents, VOLUME II
MAN B&W Diesel A/S

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

101-1 0041 Cylinder Cover, Data
901-1 0231 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
902 Piston with Rod & Stuffing Box

102-1 0065 Piston, Data
902-1 0256 Piston
102-2 0048 Piston Rod Stuffing Box, Data
902-2 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90264 0002 Piston and Piston Rod - Extra Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 Cylinder Liner and Cylinder Lubrication

103-1 0053 Cylinder Liner, Data
903-1 0237 Cylinder Liner
103-2 0015 Cylinder Lubricator, Data
903-2 0226 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Extra Tools
90364 0003 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
904 Crosshead with Connecting Rod

104-1 0048 Crosshead Bearing, Data
904-1 0239 Crosshead Bearing
104-2 0050 Crosshead, Data
904-2 0239 Crosshead
104-3 0034 Reciprocating Parts, Data
904-3 0217 Reciprocating Parts
104-4 0042 Crankpin Bearing, Data
904-4 0226 Crankpin Bearing
104-5 0043 Connecting Rod, Data
904-5 0231 Connection Rod
90451 0133 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
90462 0020 Connecting Rod - Tools
905 Crankshaft, Thrust Bearing and Turning Gear
MAN B&W Diesel A/S Page 1 (4)

No. Edition Title
105-1 0007 Crankshaft Deflection, Data

905-1 0209 Crankshaft Deflection
105-2 0053 Main Bearing, Data
905-2 0246 Main Bearing
105-3 0047 Thrust Bearing, Data
905-3 0233 Thrust Bearing
105-4 0021 Journal Bearing, Data
905-4 0219 Journal Bearing
105-5 0040 Axial Vibration Damper, Data
905-5 0224 Axial Vibration Damper
90551 0239 Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
90561 0079 Main Bearing - Hydraulic Tools
90562 0125 Crankshaft - Tools
90563 0023 Segment Stopper - Hydraulic Tools
90565 0010 Main Bearing - LiftingTools
90570 0005 Thrust Shaft - Tools
90572 0003 Main Bearing - Measuring Tools
906 Mechanical Control Gear

10620 0001 Gear Drive
10621 0001 Hydraulic Pumps
10622 0001 Hydraulic System
10623 0001 Accumulators
10624 0001 Control Valves
10625 0001 Pick-up Arrangement
10628 0001 Special Running
90664 0005 Crankshaft - Pin Gauge
907 Starting Air System

107-2 0032 Start Air Valve, Data
907-2 0214 Starting Air Valve
908 Exhaust Valve

108-1 0032 High-Pressure Pipe, Data
908-1 0217 High-Pressure Pipe
108-2 0065 Exhaust Valve, Data
908-2 0244 Exhaust Valve
108-3 0035 Exhaust Valve Actuator, Data

No. Edition Title
908-3 0228 Exhaust Valve Actuator

90861 0036 Exhaust Valve - Tools
90862 0037 Exhaust Valve - Hydraulic Tools
90863 0009 Exhaust Valve - Extra Tools
909 Fuel Oil System

109-4 0044 Fuel Pump, Data
909-4 0223 Fuel Pump
109-5 0047 Fuel Pump Top Cover, Data
909-5 0224 Fuel Pump Top Cover
109-7 0030 Fuel Pump Suction Valve, Data
909-7 0215 Fuel Pump Suction Valve
10911 0050 Fuel Valve, Data
90911 0235 Fuel Valve
10912 0038 Spindle Guide , Data
90912 0222 Spindle Guide
10913 0031 Non-Return Valve in Fuel Pump, Data
90913 0204 Non-Return Valve in Fuel Pump
10914 0057 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pres Pipes
90951 0434 Fuel Valve and Fuel Pump - Panel
90961 0065 Fuel Valve - Tools
90966 0006 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90981 0001 Mounting Tools - Top Cover Seals
910 Turbocharger System

110-1 0040 Air Cooler Element, Data
910-1 0235 Air Cooler Element
110-2 0008 Non-Return Valve in Turbocharger, Data
910-2 0206 Non Return Valve in Tubocharger
110-3 0018 Auxilary Blower, Data
910-3 0219 Auxilary Blower
110-5 0009 Turbocharger Turbine, Data
910-5 0208 Turbocharger Turbine
110-6 0025 Water Mist Catcher, data
910-6 0221 Water Mist Catcher
91061 0071 Turbocharger System - Tools
91063 0017 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0001 Air Cooler, Lifting Tools
911 Safety Equipment

No. Edition Title
111-1 0024 Safety Valve, Data

911-1 0210 Safety Valve
111-2 0012 Relief Valve, Data
911-2 0211 Relief Valve
912 Assembly of Large Parts

112-2 0007 Holding Down and End Chock Bolts (Epoxy) , Data
912-2 0207 Holding Down and End Chock Bolts (Epoxy)
112-3 0015 Stay Bolts, Data
912-3 0210 Stay Bolts
91261 0064 Large Parts - Tools
913 General Tools

913-1 0210 Hydraulic Tools
913-4 0201 Standard Tightening Torques
913-5 0205 Torque Spanner
913-6 0205 Tightening Gauge
913-7 0206 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools
91356 0058 Lifting Tools, Etc.
91357 0005 Open-Ended Spanners
91358 0013 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0035 Spanners
91366 0064 Instruments
91368 0004 Working Platforms

901 Cylinder Cover
101-1 0041 Cylinder Cover, Data

901-1 0231 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
MAN B&W Diesel A/S

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

D01-02 Starting valve stud, screwing-in torque 150 Nm
D01-03 Fuel valve stud, screwing-in torque 40 Nm
D01-04 Cylinder cover stud, screwing-in torque 500 Nm
D01-05 Cylinder cover stud, check distance 128 - 129 mm
D01-06 Cylinder cover, complete 1700 kg
D01-07 Cylinder cover without valves 1200 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 8 kg
D01-10 Cylinder cover stud 22 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 -1650 bar
When referring to this page, please quote Data D10101 Edition 0041 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
P90151 46 Grinding tool for exhaust valve seat

P90151 58 Milling and grinding wheel for fuel valve seat
P90151 60 Milling and grinding wheel for starting valve seat
P90151 83 Grinding handle
P90151 130 Lifting chains
P90161 Cylinder cover tightening tool
P91351 10 Hydraulic pump, pneumatically operated
P91351 34 Hose with unions (1000 mm), complete
P91351 130 9-way distributor block, complete
Page 2 (2) When referring to this page, please quote Data D10101 Edition 0041
MAN B&W Diesel A/S
Cylinder Cover 901-1.2
Dismantling
Cylinder Cover
S50ME-C
0231
Dismantling
901-1.2
1.
1. Set blocking device A on the main starting
valve in the BLOCKED position.
Engage turning gear B.
Close fuel oil inlet valve C.
Close cooling water inlet valve D.
Close cooling water outlet valve E.
Open cooling water drain cocks F and G.
Shut off the air supply for the pneumatic ex-

haust valve spring, and vent the system.
2. Close valve 420 and open valve 421 on the

hydraulic block.
3. Close valves 531 and 536 for hydraulic op-

eration of the exhaust valve.
GW901-1.2 231 01
2.
GW908-3.2 228 01
3.
GW908-3.2 228 02A
When referring to this page, please quote Procedure M90101 Edition 0231 Page 1 (11)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover
Dismantling
4. 4. Remove the cooling water inlet and outlet

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

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

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

between fuel valves and fuel pump.
GW901-1.2 231 04
See Procedure 909-14.2.
Dismount the control air pipe from the start-

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

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

pipe.
See Procedure 908-1.2 .
Dismount the drain oil pipe from the ex-

haust valve oil cylinder and air cylinder, the
air pipe for pneumatic closing of the ex-
haust valve, and the pipes for the sealing
air arrangement.
GW901-1.2 231 05
6. Remove the protective jacket enclosing the

intermediate pipe between the exhaust re-
ceiver and the exhaust valve.
6.
Dismount the screws in the flange between
the intermediate pipe and the exhaust re-
ceiver. The four lowermost screws need not
be dismantled, just loosened.
Remove the protective caps from the cylin-

der cover nuts.
GW901-1.2 231 06
Page 2 (11) When referring to this page, please quote Procedure M90101 Edition 0231
MAN B&W Diesel A/S
Dismantling
7. Place eight spacer rings, one around each 7.

nut, and screw the eight hydraulic jacks D13-02
onto the studs.
Connect the high-pressure pump to the

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

jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913-1.
GW901-1.2 231 07
Loosen the nuts by applying the tommy bar
through the slots in the spacer rings.
Relieve the system of pressure.

8.
Disconnect the high-pressure hoses from D01-06
the jacks.
Remove the hydraulic jacks and spacer

rings, and unscrew the nuts.
8. 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 a couple of wooden planks.
9. Remove and discard the sealing ring be-

GW901-1.2 231 08
tween cylinder cover and cylinder liner.
9.
GN901-1.2 203 07
MAN B&W Diesel A/S
Overhaul
Overhaul
901-1.3
1. 1. Dismount all valves and pipes on the cylin-

D01-09
der cover.
See Procedure 907-2.2, 908-2.2 and 909-

11.2.
Dismount all studs on top of the cylinder

cover.
2. Remove the four screws which secure the

cooling jacket to the cylinder cover.
Lift the cylinder cover free of the cooling

GN901-1.3 203 01
jacket and land it on a couple of planks.
Remove and discard the O-rings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.
2.
D01-09 3. Provide the cylinder cover with new O-
rings, well lubricated with oil.
4. Lift the cylinder cover and guide the jacket/

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

ing jacket.
D01-08
GN901-1.3 203 02
3.
4.
GN901-1.3 203 03
MAN B&W Diesel A/S
Overhaul
5. Recondition the valve bores as follows: 5.
Fuel valve bore
6. The tool consists of a common spindle with

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

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

and a grinding compound (e.g. Carborun-
GN901-1.3 203 05
dum No. 200).
After the milling/grinding, clean the bore

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

and a grinding disc.
After cleaning the valve bore and seating,

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

ing carefully, and check that the seating is
not damaged.
GN901-1.3 203 06
7.
BG901-3.1 67 04
MAN B&W Diesel A/S
Overhaul
8. Starting valve bore
8. The tool consists of a guide, a cutter, and

a grinding disc.
Recondition the starting valve bore and

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

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

cock.
GW901-1.3 231 08
9.
GN901-1.3 203 09
MAN B&W Diesel A/S
Overhaul
10. Lubricate the threads with ‘Never Seize' or 10.

Molybdenum Disulphide (MoS 2) and mount D01-01
the valve studs.
D01-03
Tighten up the studs in accordance with the
screwing-in torque stated on the data
sheet.
Fill up the grooves between the valve studs

and the bores for the valve studs with per- D01-02
matex to prevent water or oil from entering
the bores during operation of the engine.
GN901-1.3 203 10
Provide the water connection flanges with
new gaskets, and keep the cylinder cover
ready for replacement.
Always fit new or overhauled valves before

a cylinder cover is mounted on the engine.
MAN B&W Diesel A/S
Mounting
Mounting
901-1.4
1. 1. Place a new sealing ring on top of the cyl-

D01-06 inder liner with the guide tabs in the fore
and aft direction.
This is to ensure that the tabs fit into the

two gas blow-out grooves milled in the cyl-
inder cover guide recess.
2. Lift the cylinder cover by means of the

crane and carefully wipe the contact sur-
face which faces the cylinder liner.
Provide the cooling water connecting pipes

with new O-rings and lubricate them with
GN901-1.4 203 01
grease or soft soap.
Mount a new sealing ring in the groove of

the flange of the intermediate pipe.
2.
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.
3. Mount the cover nuts on the studs and

screw down.
Place eight spacer rings, one around each

nut, and mount the eight hydraulic jacks on
the studs.
GN901-1.4 203 02

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

D13-01 jacks, vent the system, and then increase
the pressure as stated in Data.
Procedure 913-1.
Tighten the nuts by applying the tommy bar

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

spacer rings from the nuts.
GW901-1.2 231 07
MAN B&W Diesel A/S
Mounting
4. Mount the protective caps on the cylinder 4.

cover studs.
Align the intermediate pipe so that the

holes in the flange of the intermediate pipe
are in line with the threaded holes in the ex-
haust receiver.
Mount the screws of the flange between the

intermediate pipe and the exhaust receiver.
Note!
GW901-1.4 231 04
Lubricate the screws with anti-seize
paste containing Molybdenum Disulphide
(MoS 2) before mounting.
Mount the insulating jacket around the in-

termediate pipe.
MAN B&W Diesel A/S
Mounting
5. 5. Mount the drain oil pipes and the air pipe for
pneumatic closing of the exhaust valve.
Mount the high-pressure pipe for the hy-

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

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

pipes on the exhaust valve.
GW901-1.4 231 05
Mount the plug for the electrical sensor for

the exhaust valve.
Mount the drain pipe on the intermediate

pipe between the exhaust valve and the cyl-
6. inder cover.
Mount the fuel oil high-pressure pipes for

the fuel valves.
Mount the oil supply pipe for the hydraulic

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

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

water inlet. After venting the cylinder sec-
GW901-1.4 231 06
tion, shut the vent cocks and open the cool-

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

and air supplies to the exhaust valve.
Caution !
The air supply to the exhaust valve must

always be connected before starting the
hydraulic oil pumps.
MAN B&W Diesel A/S
Mounting
7. Open valves 531 and 536 for hydraulic op- 7.

eration of the exhaust valve.

hydraulic block.
GW908-3.4 228 03B

GW908-3.2 228 01 8.
MAN B&W Diesel A/S
Cylinder Cover Panel Plate
P90151-0199
Cylinder Cover Panel
0199
P90151
When referring to this page, please quote Plate P90151 Edition 0199 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0199
Item Item
Item Description Item Description
No. No.
010 Panel for tools

022 Name plate
046 Grinding tool for exhaust valve seat
058 Milling and grinding wheel for fuel
valve seat
060 Milling and grinding wheel for starting
valve seat
071 Dismantling tool for fuel valve seat
083 Handle for cutting and grinding tool
095 Grinding ring for starting valve
105 Grinding handle
117 Pressure tester for safety valve
130 Lifting chains
201 Handle for cutting and grinding tool
Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
Cylinder Cover - Tools Plate
P90161-0105
Cylinder Cover - Tools
0105
P90161
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0105
Item Item
No. No.
027 Hydraulic jack cylinder

039 Support
040 Support
052 O-ring with back-up ring
090 Spanner
100 Tommy bar
111 Stud setter
206 Hydraulic tool set, complete
218 Hydraulic tool set, complete
MAN B&W Diesel A/S
102-1 0065 Piston, Data

902-1 0256 Piston
102-2 0048 Piston Rod Stuffing Box, Data
902-2 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90264 0002 Piston and Piston Rod - Extra Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
MAN B&W Diesel A/S

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

D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 430 Nm
D02-03 Piston rod/crown, tightening torque 300 Nm
D02-05 Piston skirt, tightening torque 80 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-07 Piston rod/crosshead, tightening torque + angle 100/30 Nm/°
D02-08 Piston ring new, radial width 17.2 mm
D02-09 Piston ring worn, min. radial width 14.2 mm
D02-10 Groove No.1, max. vertical height 13.2 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 10.2 mm
D02-12 Piston top, max. permissible burn-away 15 mm
D02-13 Piston ring new, height of ring No. 1 12.4 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 9.4 mm
D02-15 Minimum free ring gap (before dismantling) 28 mm
D02-16 Minimum ring gap, ring No. 1 (new ring in new liner) 3.4 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 (new ring in new liner) 2.4 mm
D02-18 Vertical clearance, new parts 0.35-0.4 mm
D02-19 Vertical clearance, worn parts, max. 0.87 mm
D02-20 Piston complete 921 kg
D02-21 Piston crown 200 kg
D02-22 Piston rod 565 kg
D02-23 Piston skirt 57 kg
D02-24 Piston cooling pipe 21 kg
D02-25 Lifting tool, tightening torque 150 Nm
D02-46 CPR ring CL groove, min. depth 1.1 mm
MAN B&W Diesel A/S
102-1 Piston
Data
P90251 40 Lifting tool for piston rod foot

P90251 75 Template for piston top
P90251 87 Distance piece for stuffing box
P90251 99 Cover for stuffing box hole
P90251 110 Pressure test tool for piston
P90251 134 Piston ring expander
P90251 158 Guide screw for piston crown
P90251 171 Dismantling screw piston skirt
P90261 Guide ring for piston
P90264 Tools for tilted lift
P90265 Support for piston
P90266 Lifting tool for piston
P90366 Crossbar for cylinder liner
P90451 118 Rubber cover for crosshead
MAN B&W Diesel A/S
Piston 902-1.1
Checking
Piston
S50MC-C
0256
Checking
902-1.1
1.
Scavenge port inspection
To detect possible leakages from the piston or

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

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

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

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

piston rings, by pressing against them with
a wooden stick.
HN902-1.1 256 02
3.
HG902-1.1 204 03
0$1% :'LHVHO$6
902-1.1 Piston
Checking
4. 4. Ring grooves:
D02-18 Measure the total clearance between the
piston rings and the ring grooves.
The total clearance must not exceed the

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

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

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

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

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

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

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

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

Chapter 707.

1
*
0$1% :'LHVHO$6
Piston 902-1.1
Checking
7. Before dismantling the piston rings, meas-

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

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

down the results
See Volume I, Operation, Chapter 707.

0
%

1
*

D02-08
1HZ

D02-09
:RUQ

1
*
0$1% :'LHVHO$6
902-1.1 Piston
Checking
10. Clean the ring grooves and check them for
burn marks or other deformation.
D02-10 Measure the ring grooves with a caliper

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

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

away by means of the template. For maxi-

mum permissible burn-away value, see Da-

ta.

0
. Check the burn-away on the whole circum-
ference of the piston crown. Note down the
results for later reference.
D02-12
12. Fit the new piston rings (alternately right-
hand and left-hand cuts, with the ring gaps
staggered 180 and with the TOP mark up-
wards), using the ring expander.

When mounting the piston rings, use the

ring expander to prevent unintended defor-

0
$
mation of the rings.
12. Do not expand the rings more than neces-

sary. The upper ring (CPR-ring) should not
be expanded more than to the milled mark
on the ring expander.
GN902-1.1 222 14
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
Dismantling
902-1.2
1. Turn the crosshead down far enough to give

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

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

from the flange.

3. Remove the screws from the piston rod.

1
0

1
*

1
+
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
4. 4. Mount the two distance pieces on the piston

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

Carefully smooth out any wear ridges at the

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

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

ing.
Remove the piston cleaning ring.

5.
Carefully remove any wear ridges at the top
of the cylinder liner.
GN902-1.2 204 05
6.
GN902-1.2 237 06
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
7. Turn the crosshead towards TDC, while 7.

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

inder liner.
Clean the lifting groove of the piston crown

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

the lifting groove and tighten it up against
the stop of the tool, see Data D02-25.
8.
Lift the piston out of the cylinder liner.
GN902-1.2 204 07
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
9. 9. If the lifting height is limited, it can be nec-

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

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

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

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

der liner.
GN902-1.2 204 08
11.
GN902-1.2 204 09
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
12. Turn the crosshead down far enough to per- 12.

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

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

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

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

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

cover studs.
GN902-1.2 243 11
0$1% :'LHVHO$6
902-1.2 Piston
Dismantling
14. 14. Place the collar ring on the supporting tools

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

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

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

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

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

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

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

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

height, use the engine room double-jib
crane instead of the transverse piece.
GN902-1.2 243 13
0$1% :'LHVHO$6
Piston 902-1.3
Overhaul
Overhaul
902-1.3
1. Ease the piston down so that the stuffing 1.

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

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

3. Dismount the locking wire and the inner-

most screws between the rod and the pis-
ton crown.
JM902-1.3 234 01
JM902-1.3 234 02 2.
3.
JM902-1.3 234 03
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
4. 4. Dismount the locking wire and screw up the

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

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

of two dismantling screws.
Lift away the piston crown.

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

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

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

mount the pipe.
JM902-1.3 234 05
6.
D02-24
D02-06
GN902-1.3 204 06
0$1% :'LHVHO$6
Piston 902-1.3
Overhaul
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 lifting tool. Land the

piston rod foot on a wooden plank.
Note!

During the lift, follow with the crane to

keep the crane positioned vertically

above the lifting point.

0
.
Lower the piston crown to the platform and

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

crown. Attach the lifting bracket to the bot-
tom of the piston rod foot. Hook the crane

on to the lifting bracket.

10. Lift the piston rod foot clear of the wooden

1
*
plank.
Keep lifting until the piston rod is in a verti-

cal position.

1
*

0
.
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
11. 11. Place the piston in an upright position with

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

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

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

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

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

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

torque stated in Data.
13.
D02-03
D02-05
GN902-1.3 204 12
0$1% :'LHVHO$6
Piston 902-1.3
Overhaul
14. Lock all the screws with locking wire. 14.
Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
See Procedure 913-7.
15. Fill the piston and piston rod with lubricat-

ing oil.
Mount the pressure-testing tool around the

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

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

dure 902-2.3. D02-01
Oil
MB902-1.3 204 14
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
Mounting
902-1.4
2. 1. Check the piston rings and piston crown in

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

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

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

the crosshead.
JM902-1.3 234 01
3.
GN902-1.4 204 03
4.
GN902-1.2 204 10
0$1% :'LHVHO$6
Piston 902-1.4
Mounting
5. Remove the cover from the piston rod stuff- 5.

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

TDC.
Mount the guide ring for piston rings on the

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

while guiding the piston rod foot through the
cut-out in the stuffing box flange – until the
GN902-1.2 204 09
piston rings are inside the liner.
GN902-1.4 204 06 6.
7.
GN902-1.4 204 07
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
8. Turn the crosshead nearly to TDC while

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

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

Remove the lifting tool and the guide ring

for piston rings.

10. Turn down and land the stuffing box on the
%
.
stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
9. correctly centred.
Remove the distance pieces from the piston

rod foot.
GN902-1.4 204 09

%
.
0$1% :'LHVHO$6
Piston 902-1.4
Mounting
11. Tighten down the piston rod stuffing box by

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

Tighten the screws to the specified torque
and lock with locking wire. See Data. Use
either Data D02-02 or Data D02-07.

13. Mount the piston cleaning ring according to

the scratch mark.

1
*
If the PC-ring is damaged (broken or

cracked), it must be replaced by another
ring. See Procedure 903-1. D02-02
or
D02-07

1
+

1
+
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
14. 14. If the cylinder cover studs have been re-

moved, remount them.
Carefully clean the surfaces around the

base of the studs and check the O-rings on
the studs.
Mount the cylinder cover studs with the stud

setter. Screw the stud down to contact and
one half revolution back.
15. Land the cylinder cover on the liner and

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

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

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

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

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

rod and stuffing box.
HN902-1.4 256 15
0$1% :'LHVHO$6
Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS
Special
D10202 Data 0048
102-2 Edition PistonS50ME-C
Rod Stuffing Box
X Stopped engine
X Shut off fuel oil
Data
D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm
D02-28 Stuffing box halves, tightening torque 80 Nm
D02-29 Uppermost rings, ring-end clearance 4x6 mm
D02-30 Lowermost rings, ring-end clearance 3x3 mm
D02-33 Check length for the six uppermost springs:
D02-34 – F 0 = 0 N.........…....... L 0 = 639 mm
D02-35 – F 1 = 153 +/– 7 N....... L 1 = 763 mm
D02-36 – F 2 = 163 +/– 10 N..... L 2 = 835 mm
D02-37 Check length for the four lowermost springs:
D02-38 – F 0 = 0 N......….......... L 0 = 496 mm
D02-39 – F 1 = 150 +/– 7 N....... L 1 = 646 mm
D02-40 – F 2 = 200 +/– 10 N..... L 2 = 714 mm
D02-44 Stuffing box complete 63 kg
D02-45 Stuffing box half 19 kg
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data
P90251 109 Mounting tool for stuffing box spring

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

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

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

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

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

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

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

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

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

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

rod to protect the crosshead bearing from
impurities.
GN902-2.2 203 01
2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diametrically opposite in the
stuffing box flange, longitudinally to the en-
2. gine.
3. Mount the worktable around the piston rod

so that the two remaining screws in the
stuffing box flange can be loosened through
the holes.
DM902-5.2 108 02
3.
DM902-5.2 108 03
0$1% :'LHVHO$6
Dismantling
4. Remove the two long dismantling screws 4.

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

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

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

ing the stuffing box from the cylinder frame
bottom.
DM902-5.2 108 04
6. Remove the two long dismantling screws
from the stuffing box and mount them in the
worktable.
By means of the four short screws in the

worktable, press the stuffing box out of the 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
DM902-5.2 108 05
6.
EN902-2.2 221 06
0$1% :'LHVHO$6
Overhaul
Overhaul
902-2.3
Normally, overhaul of the piston rod stuffing box

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

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

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

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

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

1. and mount the worktable round the piston
rod at a suitable working height.
Land the stuffing box on the worktable, and

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

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

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

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

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

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

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

HM902-5.0 70 02
small longitudinal scratches have occurred

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

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

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

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

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

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

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

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

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

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

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

engine, place two pieces of plywood of
the same thickness as the flange on the
worktable, to ease the assembling.
0$1% :'LHVHO$6
Overhaul
12. Check the ring clearance again. 12.
Then place the other half of the stuffing box

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

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

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

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

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

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

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

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

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

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

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

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

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

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

rod and stuffing box.
D02-26
DM902-5.2 108 11
D02-27
6.
GN902-2.2 203 01
0$1% :'LHVHO$6
Piston and Piston Rod Panel Plate
P90251-0237
Piston and Piston Rod Panel
0237
P90251
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0237
Item Item
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 Cover for stuffing box hole
099 Cover for stuffing box hole
109 Hook for mounting of spring
110 Pressure testing device
122 Worktable
134 Piston ring expander
158 Guide screw for piston crown
160 Dismantling screw
MAN B&W Diesel A/S
Piston and Piston Rod - Extra Tools Plate
P90264-0002
Piston and Piston Rod - Extra Tools
0002
P90264
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Extra Tools
P90264-0002
Item Item
No. No.
015 Lifting collar

027 Support for tilting tool
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tool Plate
P90265-0001
Piston and Piston Rod - Support Tool
0001
P90265
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tool
P90265-0001
Item Item
No. No.
010 Support for piston
MAN B&W Diesel A/S
Piston - Lifting Tools Plate
P90266-0002
Piston - Lifting Tools
0002
P90266
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0002
Item Item
No. No.
016 Lifting tool for piston
MAN B&W Diesel A/S
103-1 0053 Cylinder Liner, Data

903-1 0237 Cylinder Liner
103-2 0015 Cylinder Lubricator, Data
903-2 0226 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Extra Tools
90364 0003 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Liner 103-1
Data
SAFETY PRECAUTIONS
Special Data
S50MC-C
0053
103-1 Cylinder Liner
X Stopped engine
X Shut off fuel oil
Data
D03-01 Lifting tool screws, tightening torque 200 Nm

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

Liner wear: Install:
0 – 0.50 mm Standard PC-ring
(new or max. wear of diameter 0.50 mm)
0.50 – 1.0 mm Oversize PC-ring
> 1.0 mm Dummy ring
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data
P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90362 Wear ridge milling machine
P90366 Cylinder liner - Lifting Tools
MAN B&W Diesel A/S
Cylinder Liner 903-1.1
Checking
0237
Cylinder Liner S42MC-C
Checking
903-1.1
1.
1. Dismount the cylinder cover and piston.
Clean the cylinder liner and scavenge air
ports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside

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

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

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

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

GN903-1.1 203 03
4.
EN903-1.1 220 04
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking
8. 7. Piston cleaning (PC) ring:
The PC ring is to be regarded as an inte-

grated part of the liner and it is intended to
follow the service life of the liner.
During inspection of the piston and liner,

the PC ring must also be inspected.
8. Measure the PC ring radial width B, and

find the most worn place. Compare with
data D03-16 and calculate the wear of the
DM903-1.1 237 08
PC 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 D03-
17, then reinstall the PC ring.
If the deviation between PC ring wear and

liner wear is more than D03-17, or if the PC
ring is broken or cracked, replace the ring
with a new PC ring, an oversize ring or a
dummy ring according to the table in D03-
18 on the Data sheet.
If it is needed to install an oversize PC ring,

contact MAN B&W Diesel for advice.
When a new liner is installed, also a new

PC ring must be installed. When a new liner
is ordered, also a new PC ring must be or-
dered.
MAN B&W Diesel A/S
Dismantling
Dismantling
903-1.2
1. Dismount the cylinder cover. 1.

Discard the sealing ring from the top of the

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

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

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

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

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

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

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

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

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

bar.
Hook the chains from the lifting tools on to

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

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

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

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

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

pipes.
Clean the pipes carefully.

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

porting the cylinder liner.
Note!
The cylinder liner is not in balance, even

with the cooling jacket mounted.
To keep the liner in a horizontal position

during transportation, use e.g. a wire
rope connected from the scavenge ports
to the traverse as shown on the sketch.
D03-05
GN903-1.2 224 05
MAN B&W Diesel A/S
Overhaul
Overhaul
903-1.3
1. 1. Unscrew the nuts on the non-return valves

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

shown.
Mount two lifting eye bolts in the cooling

jacket.
Hook the tackles on to the lifting eye bolts

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

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

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

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

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

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

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

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

HN903-1.3 221 04
top of the piston and turn to a position that

enables the grinding disc to rest on the old
piston ring while removing the wear ridge.
Use a grinding disc with a round edge.
5.
Check the distance C before grinding to as-
certain that the wear ridge was caused by
the top ring at TDC.
MB903-1.3 231 04
The maximum depth of the groove is calcu-

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

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

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

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

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

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

ing jacket.
Mount the two lifting screws in the cylinder

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

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

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

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

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

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

cylinder lubrication.
Vent the cylinder lubricating system until

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

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

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

er.
Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.
GN903-1.4 224 04
6.
GN901-1.4 203 01
MAN B&W Diesel A/S
Cylinder Lubricators 103-2
Data
SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0015
103-2 Cylinder Lubricators
X Stopped engine
Shut off cooling water
Shut off fuel oil
Shut off lubrication oil
Data
D-1 Nitrogen pressure

– inlet accumulator 25-30 bar
D-2 Nitrogen pressure

– outlet accumulator 1.5 bar
D-3 Plug screw

– tightening torque 30 Nm
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
Data
Spare Parts
Plate – Item No. Description Qty
90307-xxx 102 O-ring 2

90307-xxx 234 O-ring 1
90307-xxx 246 Feedback sensor (pick-up), complete 1
90307-xxx 557 O-ring 1
90307-xxx 437 O-ring 12
90307-xxx 582 O-ring 1
MAN B&W Diesel A/S
Cylinder Lubricators 903-2.1
Checking
Cylinder Lubricators
S50MC-C
0226
Checking
903-2.1
1.
Check of Oil Injection:
With stopped engine and normally when the

system has been disassembled:
1. Press the PRELUB.-button on the HMI con-

trol panel, and check that all lubricators are
operating correctly by watching the LEDs
on the terminal boxes for each lubricator,
placed next to the lubricators.
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.
NA903-2.1 225 01
With running engine:
3. Check that all lubricators are operating cor-

rectly by watching the LEDs on the terminal
boxes for each lubricator.
2.
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 cylin-

der liner to observe the oil flow.
NA903-2.1 225 02
MAN B&W Diesel A/S
903-2.1 Cylinder Lubricators
Checking
3. Check of Accumulators:
4. Measuring the nitrogen pre-pressure can

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

and open the equalizing valve on the re-
spective lubricator.
D-2
The nitrogen pressure in the inlet accumu-
D-1 lator (0.7 litre) can be checked without dis-
EN903-2.1 219 04
mounting the accumulator. For use of the

pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), the accumu-
5. lator or the lubricator with accumulator
must be dismounted.
For nitrogen pressure in the accumulators,

see Data.
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor.
NA903-2.1 222 05
Mount a 0-60 bar pressure gauge on the fill-

ing valve when the inlet accumulator (0.7 li-
tre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
MAN B&W Diesel A/S
Checking
6. C
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean. A E
Mount the filling valve on the relevant accu- D-3 F
mulator with the union nut. Check that
valves C and F are closed.
Loosen the plug screw in the accumulator

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

gen pressure in the accumulator on the dial
NA903-2.1 222 06
gauge on the filling valve.
8. If the accumulator needs to be refilled with

nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in Da-
ta.
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 accumulator.
MAN B&W Diesel A/S
Dismantling
Dismantling
903-2.2
1. Dismantling of lubricators:
The engine must be stopped and blocked be-

fore dismounting a lubricator. Stop the cylinder
oil pump station.
1. Close the supply valve for the lubricator and

open the equalizing valve (turn both han-
dles to a horizontal position).
Disconnect the electrical plug on the side of

the lubricator.
EN903-2.2 219 01
2. Unscrew the three screws in the bottom of

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

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

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

MCR
EN903-2.2 219 02
• Let the lubricator pump station run
• Dismount the lubricator as described in

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

Procedure 903-2.4.
MAN B&W Diesel A/S
Dismantling
Dismantling of accumulators: 4.
4. The engine must be stopped and blocked

before the accumulator is dismounted.
Stop the cylinder oil pump station.

Close the supply valve for the lubricator and
open the equalizing valve.
Note!
When the oil pressure is released, a

nitrogen pre-pressure of 25-30 bar will
EN903-2.2 219 04
remain in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the
hydraulic block.
MAN B&W Diesel A/S
Overhaul
Overhaul
903-2.3
1. 1. Place the lubricator in a bench vice with

soft “jaws”.
Remove the adjusting screw with bushings.

Unscrew the oil accumulator.
Discard the O-ring from the adjusting

screw.
2. Remove the screws from the cylinder block.
3. Pull up the cylinder block.

EN903-2.3 219 01
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.
EN903-2.3 219 02
3.
EN903-2.3 219 03
MAN B&W Diesel A/S
Overhaul
4. Remove the cover from the terminal box, 4.

and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box.
Carefully, unscrew the feedback sensor and

remove and discard the O-ring.
EN903-2.3 221 04
Clean the housing with diesel oil or kero-
sene and dry with a non-fluffy cloth.
5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass. 5.
Check that the balls from the non-return

valves are in good condition.
Check the seats for the non-return valves.
6. Before mounting the feedback sensor,

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.
EN903-2.3 219 05
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.
6.
Mount the terminal box.
Connect the wires and mount the cover on

the terminal box.
1 1
2 Solenoid valve
EN903-2.3 219 06
2
3 BN (brown)
4 BK (black) Feedback sensor
BU (blue)
5
MAN B&W Diesel A/S
Overhaul
7. 7. Fit the cylinder block with new O-rings.
Assemble the non-return valves in the cyl-

inder block.
Mount the cover with the three inner

screws.
Check with a small screwdriver that the

springs are correctly centered.
8. Fit the cylinder block with a new O-ring.

Pre-assemble the cylinder block with the
EN903-2.3 219 07
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 actu-

8. ator piston with plungers. Mount an M6 x 60
screw with a washer to keep the spring
compressed.
9. Mount the cylinder block assembly in the

cylinder housing.
Mount the screws and tighten the block to

the housing.
Remove the M6 x 60 screw with washer.

EN903-2.3 219 08
9.
EN903-2.3 219 09
MAN B&W Diesel A/S
Overhaul
10. Mount the adjusting screw fitted with a new 10.

O-ring and the distance bushing.
Mount the oil accumulator.
11. If the lubricator is not to be mounted on the

engine immediately after overhauling, cover
all openings with plastic to prevent dirt from
entering the lubricator during storage.
Coat all surfaces with a thin layer of oil.
EN903-2.3 219 01
MAN B&W Diesel A/S
Mounting
Mounting
903-2.4
1. 1. Before mounting the accumulator, check

the nitrogen pressure, see Data.
Mount the accumulator.
2. Mount new O-rings on the hydraulic block

and on the cover with pipes.
Mount the lubricator and tighten the screws

on the hydraulic block.
Tighten the screws in the bottom of the lu-

bricator to the pipe connection.
EN903-2.4 219 01
3. Close the equalizing valve and open the

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

tion of cylinder oil on the feedback LED on
the terminal box for the specific lubricator.
EN903-2.4 219 02
3.
EN903-2.4 219 03
MAN B&W Diesel A/S
Cylinder Liner - Tools Plate
P90361-0084
Cylinder Liner - Tools
0084
P90361
MAN B&W Diesel A/S
Plate Cylinder Liner - Tools
P90361-0084
Item Item
No. No.
036 Cylinder gauge, complete
MAN B&W Diesel A/S
Cylinder Liner - Extra Tool Plate
P90362-0002
Cylinder Liner - Extra Tool
0002
P90362
MAN B&W Diesel A/S
Plate Cylinder Liner - Extra Tool
P90362-0002
Item Item
No. No.
018 Wear ridge milling machine
MAN B&W Diesel A/S
Test Equipment for Lubricator Plate
P90364-0003
Test Equipment for Lubricator
0003
P90364
MAN B&W Diesel A/S
Plate Test Equipment for Lubricator
P90364-0003
Item Item
No. No.
019 Tool box

020 Nameplate
032 Adaptor
044 Adaptor
056 Pressure gauge
068 Spanner
070 Pressure gauge
081 Adaptor
093 Hose with 2 union
103 Quick coupling, minimess
115 Quick coupling, minimess
127 Reducing valve
139 Adaptor
140 Adaptor
152 Filling and testing valve
164 Adaptor
176 Adaptor
188 Adaptor
MAN B&W Diesel A/S
Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007
Item Item
No. No.
021 Crossbar for cylinder liner
MAN B&W Diesel A/S
104-1 0048 Crosshead Bearing, Data

904-1 0239 Crosshead Bearing
104-2 0050 Crosshead, Data
904-2 0239 Crosshead
104-3 0034 Reciprocating Parts, Data
904-3 0217 Reciprocating Parts
104-4 0042 Crankpin Bearing, Data
904-4 0226 Crankpin Bearing
104-5 0043 Connecting Rod, Data
904-5 0231 Connection Rod
90451 0133 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
90462 0020 Connecting Rod - Tools
MAN B&W Diesel A/S

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

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

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

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

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

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

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

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

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

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

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

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

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

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

access to the nuts and screws on the piston
rod.
GW 904-1.1 239 02
2. Mount two chains in the inner screw holes

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

the screws on the piston rod foot. Remove
the screws.
HN904-1.2 222 02
3.
HN904-1.2 222 03
0$1% :'LHVHO$6
Dismantling
4. Mount a lifting eye bolt on each side of the 4.

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

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

ton rod will then remain suspended from
the two chains.
With piston removed:
HN904-1.2 222 04
6. Turn to BDC.
7. Place the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.
5.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.
Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.
HN904-1.2 222 05
7.
D13-02
HN904-5.2 217 01
0$1% :'LHVHO$6
Dismantling
8. 8. Mount the lifting attachments on the head

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

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

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

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

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

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

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

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

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

the lifting attachments. Haul the tackles
tight.
15. Mount the four supports for guide shoes on

the crosshead guides.
Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
Adjust the support brackets to the guide

shoes so that the weight of the crosshead
HG904-1.2 238 14
is evenly distributed on the four supports.
Haul the tackles tight.
16. Turn the crankthrow carefully towards BDC

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

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

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

the lower bearing shell, tilt the connecting
rod towards the doorway on the fuel pump
side, using the tackles.
D04-06
Dismount the locking screws, and turn the

bearing shell so far up that an eye bolt can
be mounted.
Lift the bearing shell out of the engine.
JN904-1.2 227 18
0$1% :'LHVHO$6
Mounting
Mounting
904-1.4
1. With piston mounted/

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

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

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

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

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

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

guides.
Remove the tackles from the crosshead.
Turn the crank throw to BDC.
If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
JN904-1.4 227 02
3.
JN904-1.4 227 03
0$1% :'LHVHO$6
Mounting
4. Lift the bearing cap into the engine. Lower 4. D04-07

the bearing cap onto the crosshead and re-
move the tackles. Remove the lifting attach-
ments from the connecting rod and the wire
guide from the door frame.
Note!
Take care that the bearing studs do not

damage the crosshead.
5. Tighten all four crosshead bearing cap nuts
JN904-1.4 227 04
simultaneously. See Data.
For operation of hydraulic jacks, see Sec-
tion 913.
6. Mount the piston.

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

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

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

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

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

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

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

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

pipes.
3. Dismount the cooling oil outlet pipe from

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

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

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

the tool.
Turn the crosshead to gain access to the

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

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

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

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

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

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

head.
Mount the lifting attachments for fixing the

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

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

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

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

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

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

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

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

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

the top of the crankcase, in the fore-and-aft
direction, and attach the tackles to the
guide shoes.
Push one of the guide shoes against the
GN904-2.2 232 08
middle of the crosshead. If necessary, use
the guide shoe extractor tool.
10. Pull the “free end” of the crosshead into the

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

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

tor, and lift up the guide shoe.
GN904-2.2 232 09
10.
D04-22
GN904-2.2 232 10
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling
11. 11. Pull the crosshead with guide shoe into the
opposite neighbouring cylinder unit.
Mount the guide shoe extractor tool on the

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

a vertical position while turning the crank-
throw to BDC.
6.
7. When the connecting rod is in a vertical po-
D04-50 sition, lower the crosshead and land it on
the connecting rod.
Remove the lifting attachments from the

connecting rod head.
Remove the lifting tool from the crosshead.

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

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

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

Procedure 913.
Mount the drain oil slotted pipe and the

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

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

D04-25 PF+PA, N max. 0.5 mm
D04-26 PF+PA, O max. 0.7 mm
D04-28 E+G, H+F, N max. 0.5 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.8 mm
D04-53 J, L, K, M, N max. 0.9 mm
D04-54 J, L, K, M, N min. 0.5 mm
D04-55 J, L, K, M, O max. 1.1 mm
N: New and cold engine with staybolts tightened
(less than 100 running hours).
O: Engine in service.
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data
P90451 226 Alignment tool

MAN B&W Diesel A/S
Reciprocating Parts 904-3.1
Checking
Reciprocating Parts
S50ME-C
0217
Checking
904-3.1
1.
In order to achieve uniform measuring condi-
tions on board, the ship’s trim must be as close
as possible to 0°.
1. Mount a transparent plastic tube along the

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

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

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

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

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

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

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

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

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

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

the insertion of shims so that it is symmet-
rical in relation to the clearance between
the piston skirt and the cylinder liner.
Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.
GN904-3.1 213 04
ZF
ZA
5.
D04-53
D04-54
D04-55
FUEL PUMP
GN904-3.1 203 05
0$1% :'LHVHO$6
Reciprocating Parts 904-3.1
Checking
6. Check the clearance between guide shoe 6.

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

sults are noted down so that possible later
changes can be ascertained.
D04-28
D04-29
D04-30
GN904-3.1 203 06
7.
GN904-3.1 203 07
0$1% :'LHVHO$6
Crankpin Bearing 104-4
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10404
104-4 Data 0042 Crankpin Bearing
X Stopped engine
Shut off fuel oil
Data
D04-43 Crankpin bearing clearance, max. 0.6 mm

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

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

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

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

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

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

ets, in the athwartship direction.
3. Turn the crank to TDC.
Mount eye bolts in each side of the crankpin

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

ing the hydraulic jacks.
GW904-2 226 02

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

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

placed in the oil pan.
Inspect the bearing shell.

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

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

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

crankcase door opening.
Using the tackle from the frame box inside D04-48

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

couple of planks.
Inspect the bearing shell.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

journal with clean oil.
HM904-6.0 61 16
The excess height X is to ensure the cor-

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

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

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

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

ment from the connecting rod.
4. Turn the crosshead to TDC.
Remove the guide shoe support brackets

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

ets in the top of the frame box.
Lift the bearing cap assembly into the

crankcase and land it on a couple of planks
placed in the oil pan.
6. Hook the tackles on to the wire ropes and

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

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

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

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

frame box.
Check the bearing clearance.

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

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

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

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

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

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

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

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

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

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

5. A B Carefully turn the crank down towards the

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

the wire is tightened if a screw works loose.
D04-01
Measure the clearance in the crosshead
D04-02
HN904-5.2 230 01
11. Remove all tools from the engine.
Note!
11.
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
KN905-2.4 238 14
0$1% :'LHVHO$6
Connecting Rod and Crosshead Panel Plate
P90451-0133
Connecting Rod and Crosshead Panel
0133
P90451
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0133
Item Item
No. No.
011 Panel for tools

023 Name plate
047 Wire guide
059 Lifting attachment
060 Lifting tool for crosshead
072 Chain for suspending of piston
084 Retaining tool for telescope pipe
096 Support crosshead
106 Support crosshead
118 Rubber cover for crosshead
120 Rubber cover w. hole for crosshead
214 Torque wrench offset tool
251 Alignment tool
Notes:
MAN B&W Diesel A/S
Connecting Rod - Hydraulic Tools Plate
P90461-0069
Connecting Rod - Hydraulic Tools
0069
P90461
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0069
Item Item
No. No.
028 Jack-hydraulic, complete

030 Support
053 Sealing ring with back-up ring
089 Key, hexagon socket screw
090 Tommy bar
100 Stud setter
207 Hydraulic toolset, complete
MAN B&W Diesel A/S
Connecting Rod - Tools Plate
P90462-0020
Connecting Rod - Tools
0020
P90462
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0020
Item Item
No. No.
011 Guide shoe extractor, complete
MAN B&W Diesel A/S
105-1 0007 Crankshaft Deflection, Data

905-1 0209 Crankshaft Deflection
105-2 0053 Main Bearing, Data
905-2 0246 Main Bearing
105-3 0047 Thrust Bearing, Data
905-3 0233 Thrust Bearing
105-4 0021 Journal Bearing, Data
905-4 0219 Journal Bearing
105-5 0040 Axial Vibration Damper, Data
905-5 0224 Axial Vibration Damper
90551 0239 Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
90561 0079 Main Bearing - Hydraulic Tools
90562 0125 Crankshaft - Tools
90563 0023 Segment Stopper - Hydraulic Tools
90565 0010 Main Bearing - LiftingTools
90570 0005 Thrust Shaft - Tools
90572 0003 Main Bearing - Measuring Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crankshaft Deflection 105-1
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10501
105-1 Data 0007 Crankshaft Deflection
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
105-1 Crankshaft Deflection
Data
P90572 Main Bearing - Measuring Tools

P91366 48 Autolog, measuring tool for crankshaft
MAN B&W Diesel A/S
Main Bearing 905-1.1
Checking
Main Bearing
S50MC-C
0209
Checking
905-1.1
1.
General
The condition of the main bearings can be

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

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

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

of the gauge) is regarded as negative (–)
and “opening” as positive (+).
3. Set the dial gauge to zero at the B1 side

near BDC. Whilst turning clockwise, take 3.
the readings when the throw passes the po-
sitions:
B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
1/2 (B2+B1) = B
XZ905-1.1 204 03
0$1% :'LHVHO$6
905-1.1 Main Bearing
Checking
4. 4. When taking deflection readings for the

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

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

cator) is approaching the tolerance limits
(see Vol. I, OPERATION), the two adjacent
main bearings must be checked for wear.
See next page for checking of main bear-
ing.
If the bearings are found to be in good

order, please contact MAN B&W Diesel or
the engine manufacturer for checking of the
bedplate alignment.
HM905-2.0 46 01
As reference, use the “after seatrial” deflec-

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

follows:
5. Visually look for bearing metal fragments in

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

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

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

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

er” that is able to follow the bearing edge
against the journal the whole way round on
each side. If white metal is missing at the
edge, the tip of the “feeler” will enter the
hole, thus locating the damage. In most
cases this hole can be seen by the naked
eye as a dark spot when using a strong
flashlight.
The No. 1 and the two aftmost main bear- Hole in

ings are more difficult to access on the the edge
KN905-1.1 208 06
whole circumference on each side, but it is
often possible to bend the “feeler” to suit
the situation and thus reach as far round as
possible.
Wire-feeler 7.
<1.2 mm
>0.7 mm
7. It is rather easy to make a feeler (see 1 7-10 mm
sketch). The “feeler” should be made from
a piece of steel wire (e.g. a welding rod)
approx. 0.6 - 1 m long depending on the
engine type, and 2 to 3 mm thick. Approx.
7 to 10 mm of the wire should be bent to an
angle of approx. 65° to form a “feeler tip”.
Grind the tip smooth to obtain the shape
and dimension shown on the sketch. Note 60-70
that the thickness of the white metal is ap-
prox. 1.5 mm, which is why the tip should 2-3 mm
be less than 1.2 mm thick, and bigger than
500-1000
the max. top clearance. At the other end of

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

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

individual, personal designs.
0$1% :'LHVHO$6
Checking
8. 8. Remove the lub. oil pipe from the main

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

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

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

recorded in the adjustment sheet (or the
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.
For evaluation of the bearing, see Volume

I, Operation, Chapter 708.
If the bearing needs to be diassembled for

inspection, see procedure 905-2.2.
BM905-2.1 239 03
10.
HN905-2.1 227 03
0$1% :'LHVHO$6
Main Bearing 105-2
Data
SAFETY PRECAUTIONS
Special
D10502 Data 0053
105-2 Edition Main
S50ME-C
Bearing
X Stopped engine
Shut off fuel oil
Data
D05-01 Main bearing, top clearance max. 0.65 mm

D05-02 Main bearing, top clearance min. 0.35 mm
D05-03 Main bearing cap 300 kg
D05-04 Main bearing shell, upper 17 kg
D05-05 Main bearing shell, lower 18 kg
MAN B&W Diesel A/S
105-2 Main Bearing
Data

P90551 40 Pulley for wire for main bearing
P90551 76 Lifting tool - main bearing cap
P90551 88 Dismantling tool, main bearing shell
P90551 90 Mounting tool for bearing shell
P90551 123 Retaining tool for main bearing shell
P90551 184 Lifting tool for main bearing shell
P90561 Main Bearing - Hydraulic Tools
P90562 Lifting tool for crankshaft
P91351 22 Hydraulic pump, hand operated
P91351 129 Distributor block
P91366 61 Slide caliper
MAN B&W Diesel A/S
Dismantling
Main Bearing
S50ME-C
0246
Dismantling
905-2.2
Positioning the crankshaft 1.

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

ries:
• The main bearings
• The aftmost main bearing

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

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

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

bouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
KN905-2.2 238 02
3.
EXH-SIDE FUELMAN-SIDE
PUMP SIDE
KN905-2.2 238 03
0$1% :'LHVHO$6
Dismantling
4.
Oil pipes
4. Disconnect the lubricating oil pipe from the

main pipe.
Note!
On some engines, the oil pipes for the

Axial Vibration Damper (AVD) have to be
removed together with the oil pipe on
main bearing No. 1.
KN905-2.2 238 04
Note!
Some engines have temperature sensors

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

hydraulic jacks and the nuts on the exten-
sion studs. Loosen the main bearing stud
nuts, using the hydraulic jacks.
Procedure 913-1.
D13-02 6. Remove the hydraulic main bearing tools

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

main bearing studs.
Remove the rectangular nut washers from

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

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

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

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

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

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

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

free of the studs. D
GW905-2.2 246 08
Note!
Owing to space requirements below the

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

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

D.
D05-03 When released, dismount tackle A from the

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

A.
11.
A
B
C
D
GW905-2.2 246 11
12.
D05-03
A
B
C
D
GW905-2.2 246 12
0$1% :'LHVHO$6
Dismantling
13.
13. Mount the lifting tool on the upper main
bearing shell, and lift out the shell by hand.
14. If the crankshaft is turned with the bearing

cap dismounted, use the two stops to pre- D05-04
vent the lower shell from being rolled out.
15. Place the crosspiece in the bedplate with

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

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

pressure pump, and raise the pressure until
EN905-2.2 206 08
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.
Note down the pressure for later reference.

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

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

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

KN905-2.2 238 28
Min. 60 mm
the crosspiece sideways until clearance is

obtained. Normally, adjustment needs to be
50-150 mm to the exhaust side (the side
where the clearance is missing).
17.
Note!
The lower shell must be lifted out to the

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

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

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

position when the new bearing is installed.
Note!
It is recommended that the crankshaft lift-

ing tool is only removed if it is urgently
necessary and then only after the main
bearing shell has been reinstalled.
0$1% :'LHVHO$6
Dismantling
18. Dismount the locking screws. 18.
Place the dismantling tool on top of the low-

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

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

mended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
KN905-2.2 238 26
19.
JM905-2.2 236 27
0$1% :'LHVHO$6
Dismantling
20. 20. Take the lower shell out of the engine in the
same way as the upper shell, i.e. using the
lifting tool.
D05-05
EN905-2.2 206 08
0$1% :'LHVHO$6
Overhaul
Overhaul
905-2.3
1. Clean and inspect the bearing shells. It is 1 + 2.

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

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

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

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

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

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

port with clean oil
D05-05
Using the bearing shell lifting tool, lift the
lower bearing shell into the crankcase and
land it on the crankshaft journal.
2. Position the guide tool for the lower bearing

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

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

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

support.
Lower the crankshaft and remove the hy-

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

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

journal in the same way as the lower bear-
ing shell. D05-04
Make sure that none of the edges of the up-

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

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

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

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

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

screw the round nuts on to the main bearing
D13-01 studs.
Using the hydraulic jacks, fully tighten the

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

see Procedure 913-1.
7.

Note!

1
0
Before removing the hydraulic jacks,

7. check the top clearance between the
upper bearing shell and the journal.
D05-01
D05-02
8. Mount the lubricating oil pipe on the main
bearing cap.
KN 905-1.1 208 09
20
8.
KN905-2.4 238 15
0$1% :'LHVHO$6
Mounting
9. Remove all tools from the engine. 9.
Note!

behind.
KN905-2.4 238 14
C
0$1% :'LHVHO$6
Thrust Bearing 105-3
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10503
105-3 Data 0047 Thrust Bearing
X Stopped engine
Shut off fuel oil
Data
D05-06 Thrust bearing segment 40 kg

D05-07 Segment stopper 37 kg
D05-32 Segment stopper stud, tightening torque 250 Nm
D13-02 Hydraulic pressure, dismantling 1400-1650 bar
MAN B&W Diesel A/S
105-3 Thrust Bearing
Data
P90551 100 Tool for turning out segments

P90551 111 Lifting attachment
P90563 Segment Stopper, Hydraulic Tools
P91356 Lifting Tools, etc.
MAN B&W Diesel A/S
Thrust Bearing 905-3.1
Checking
Thrust Bearing
S50ME-C
0233
Checking
905-3.1
1.
The clearance in the thrust bearing was meas-
ured during testbed trials of the engine and not-
ed down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,

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

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.
GW905-3.1 233 01
1. To measure the wear in the thrust bearing,
it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).
2. To measure the wear, the thrust segment

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

enter the groove (the wear is more than 0.9
mm), the thrust bearing must be over-
hauled.
GN905-3.1 224 02
3. Note down the wear for later reference.
3.
KN905-2.2 238 02
MAN B&W Diesel A/S
905-3.2 Thrust Bearing
Dismantling
Dismantling
905-3.2
1. 1. Remove the lub. oil pipe from the bearing,

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

ment stoppers.
Procedure 913-1.
Use a stud setter to loosen the segment

stopper studs. Remove the segment stop-
per studs.
GW905-3.2 233 01
Mount an eye bolt in the segment stopper

and use a rope around the horizontal lub.
oil pipe to remove the segment stoppers.
Lift the stoppers out of the chain casing.
2. 3. Mount the tool for turning out the segments

on the edge on the thrust bearing cam.
D13-02
GW905-3.2 233 02
3.
GW905-3.2 233 03
MAN B&W Diesel A/S
Dismantling
4. Turn up the segments, one at a time, by 4. D05-06

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

a time.
GW905-3.2 233 04
MAN B&W Diesel A/S
905-3.4 Thrust Bearing
Mounting
Mounting
905-3.4
1. 1. Suspend a tackle above the segments

which are to be mounted. Still, it is possible
to lift the segments by hand.
D05-06
Mount the tool for turning out segments on
the thrust bearing cam.
Land the segment on the journal and re-

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

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

turn the segment tool up and dismount it.
GW905-3.4 233 01
2.
GW905-3.4 233 02
MAN B&W Diesel A/S
Mounting
3. Mount the segment stopper. 3.

D05-07
Mount the segment stopper studs. D05-32
Mount the hydraulic jacks and tighten the
nuts on the stopper.
For operating hydraulic jacks,

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

ments and the lub. oil pipe on the bearing.
D13-01
GW905-3.4 233 03
GW905-3.4 233 04 4.
MAN B&W Diesel A/S
Journal Bearing 105-4
Data
SAFETY PRECAUTIONS
Special Edition
D10504
105-4 Data 0021 Journal Bearing
X Stopped engine
Shut off fuel oil
Data
D05-11 Min. bearing clearance 0.65 mm

D05-12 Max. bearing clearance 0.35 mm
D05-13 Journal bearing cap 300 kg
D05-14 Upper bearing shell 17 kg
D05-15 Lower bearing shell 18 kg
D05-16 Cover 70 kg
MAN B&W Diesel A/S
105-4 Journal Bearing
Data
P90551 111 Lifting tool – main bearing cap

P90551 88 Dismantling tool, main bearing shell
P90551 90 Mounting tool for bearing shell
P90551 111 Lifting attachment
P90551 172 Mounting tool, thin bearing shell
P90551 184 Lifting tool for main bearing shell
P90561 Main Bearing – hydraulic tools
P90570 Thrust shaft – tools
P91356 Lifting tools, etc.
P91366 61 Slide caliper
P91351 10 Hydraulic pump, pneumatic operated
MAN B&W Diesel A/S
Journal Bearing 905-4.1
Checking
S
0219
Journal Bearing 50ME-C
Checking
905-4.1
1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-1.1.
2. Write down the journal bearing clearances.
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2
1. 1. Remove the screws from the cover placed

D05-16 over the thrust bearing. Mount an eye bolt,
shackles and wire rope on the cover.
Hook a tackle on to the air cooler casing

and lift the cover away.
2. Disconnect the lubricating oil pipe used for

lubricating the bearing.
3. Assemble the hydraulic tightening tools and

mount the lifting tool on the tightening tools,
as shown. Dismount the nuts and remove
GW905-4.2 219 01
the nuts and hydraulic tools.

Procedure 913-1.
2.
GW905-4.2 219 02
3.
D13-02
GN905-2.2 204 02
MAN B&W Diesel A/S
Dismantling
4. Mount the bearing cap lifting tool and con- 4.

nect it to a tackle suspended from the lifting
bracket above the bearing.
5. Use the handle on the lifting tool to ma-

noeuvre the bearing cap out while raising it
with the tackle.
6. Mount the bearing shell lifting tool on the

upper bearing shell, and remove the upper
bearing shell from the engine.
GW905-4.2 219 04 5.
D05-13
GW905-4.2 219 05
6.
D05-14
GW905-4.2 219 06
MAN B&W Diesel A/S
Dismantling
7. 7. Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.
Tighten the screw against the turning

wheel, thus compressing the jack.
Connect the hydraulic jack to the high-pres-

sure pump, and raise the pressure until the
crankshaft has been lifted 0.2-0.5 mm, but
no more than the clearance in the adjacent
bearing.
8. Dismount the locking screws.
Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.
GN905-2.2 224 19
Pull the lower bearing shell around and up-

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

8.
KN905-2.2 238 26
MAN B&W Diesel A/S
Dismantling
9. Take the lower shell out of the engine in the 9.

same way as the upper shell, i.e. using the
lifting tool.
D05-15
GW905-4.2 219 06
MAN B&W Diesel A/S
Overhaul
Overhaul
905-4.3
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:
GW905-4.3 219 01
• Check the bearing support for damage

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

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

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

shell and the bearing support with clean oil.
Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and
land it on the crankshaft journal.
D05-15
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.
GW905-4.2 219 06
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 bear- 2.
ing support to the shell is equal in both
sides.
3. Remove the guide tool when the lower

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

support.
Lower the crankshaft and remove the hy-

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

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

journal in the same way as the lower bear-
ing shell.
D05-14
Make sure that none of the edges of the up-
per bearing shell are resting on the edge of
the bearing support.
If necessary, place the special tool between

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

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

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

that the guide pin in the assembly sur-
face enters the hole in the bearing cap.
7. Mount the nuts, the spacer rings, the hy-

draulic jacks, and tighten the nuts. See Da-
ta.
KN905-2.4 238 09
For operation of the hydraulic tools,

7.
D13-01
GW905-4.2 219 03
MAN B&W Diesel A/S
Mounting
8. 8.
Note!
D05-11
Before removing the hydraulic jacks,
D05-12
check the top clearance between the
upper bearing shell and the journal.
9. Mount the lubricating oil pipe on the bear-

ing cap.
Note!
KN 905-1.1 208 09
there are no tools or rags left behind. 20
10. Mount the journal bearing cover and re-

move all tools from the engine.
GW905-4.4 219 09 9.
10.
D05-16
GW905-4.4 219 10
MAN B&W Diesel A/S
Axial Vibration Damper 105-5
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10505
105-5 Data 0040 Axial Vibration Damper
X Stopped engine
Shut off fuel oil
Data
D05-18 Inner studs, screwing-in torque 150 Nm

D05-19 Nuts on inner studs, tightening torque 500 Nm
D05-22 Outer studs, screwing-in torque 300 Nm
D05-23 Horizontal screws, tightening torque 450 Nm
D05-24 Horizontal screws, tightening torque/angle 100/25 Nm/°
D05-25 Damper housing, upper part 275 kg
MAN B&W Diesel A/S
105-5 Axial Vibration Damper
Data
P90563 Segment stopper, hydraulic tools

MAN B&W Diesel A/S
Axial Vibration Damper 905-5.1
Checking
Axial Vibration Damper
S46-S50MC-C
0224
Checking
905-5.1
1.
For checking the effectiveness of the axial vi-
bration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken

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

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

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

control system.
1. Concerning overhaul and setting of the

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

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

mal Service Value, it is necessary to over-
haul the axial vibration damper, see
Procedure 905-5.2.
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
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
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

and L 2 = 200 mm), the ratio is 5.3. There-
fore, the S1 can be calculated as follows:
DM905-7.1 74 06
If a non-standard tool is used, S1 can be

calculated as follows:

Procedure 905-5.2.
0$1% :'LHVHO$6
Checking
1. C: Mechanical, with angle encoder fore
For engines with angle encoder fore, a meas-

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

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

housing.
Apply some Molycote TM on the fore side of

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

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

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

of the pencil should protrude 10 mm from
2. the end of the arm.
N905-5.1 214 05
0$1% :'LHVHO$6
Checking
3. Start the engine, and let the speed rise to 3.

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

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

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

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

calculated as follows:

MA905-5.1 212 07

Procedure 905-5.2.
0$1% :'LHVHO$6
905.5.2 Axial Vibration Damper
Dismantling
Dismantling
905.5.2
1. Dismantling of the axial vibration damper is car-

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

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

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

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

Mount a tackle in the bracket above the ax-
ial vibration damper inside the chain box.
Engines without chainbox fore:

Mount a tackle below the fore end platform,
and dismount the cover on the lifting hole
above the axial vibration damper.
3. By means of the tackle and wire rope, sep-

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

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

pended upper part, secure the upper part
with, e.g. a wire rope or another tackle.
GN905-5.2 224 03
0$1% :'LHVHO$6
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.
0$1% :'LHVHO$6
Mounting
Mounting
905-5.4
1. 1. Release and carefully lower the upper part

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

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

Data.
Mount and tighten the hydraulic nuts. For

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

See Data.
Note!
GN905-5.4 224 01

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

damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
D05-23
D05-24
GN905-5.4 224 02
0$1% :'LHVHO$6
Crankshaft, Thrust Shaft, Main Bearing, Etc. - Plate
P90551-0239
Panel
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing, Etc. -
P90551-0239
Panel
Item Item Description Item Item Description
No. No.
015 Panel for tools

027 Name plate
040 Pulley for wire
076 Lifting tool for main bearing cap
088 Dismantling tool for main bearing shell
090 Mounting tool for thin bearing shell
100 Tool for turning out segments
111 Lifting attachment
123 Retaining tool for main bearing shell
135 Lifting tool for relief valve
172 Mounting tool thin bearing shell
184 Lifting tool main bearing shell
MAN B&W Diesel A/S
Main Bearing - Hydraulic Tools Plate
P90561-0079
Main Bearing - Hydraulic Tools
0079
P90561
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0079
Item Item
No. No.
010 Wooden box

045 Jack-hydraulic, support
057 Stud
069 Nut, hexagon
130 Ball handle
141 Lifting tools
165 Stud setter
MAN B&W Diesel A/S
Crankshaft - Tools Plate
P90562-0125
Crankshaft - Tools
0125
P90562
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0125
Item Item
No. No.
015 Support
039 Screw with special head
052 Nut
MAN B&W Diesel A/S
Segment Stopper - Hydraulic Tools Plate
P90563-0023
Segment Stopper - Hydraulic Tools
0023
P90563
MAN B&W Diesel A/S
Plate Segment Stopper - Hydraulic Tools
P90563-0023
Item Item
No. No.
022 Hydraulic jack

034 Hydraulic jack - support
046 Tommy bar
071 Hydraulic jack - support
083 Key for hexagon socket screw
105 Stud setter
201 Hydraulic jack for segment stopper,
complete
MAN B&W Diesel A/S
Main Bearing - Tools Plate
P90565-0010
MAN B&W Diesel A/S
Plate Main Bearing - Tools
P90565-0010

No. No.
011 Lifting tool for main bearing cap
MAN B&W Diesel A/S
Thrust Shaft - Tools Plate
P90570-0005
P90570
Thrust
0005 Shaft - Tools
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0005
Item Item
No. No.
019 Lifting tool for thrust shaft
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0003
Main Bearing - Measuring Tools
0003
P90572
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0003
Item Item
No. No.
010 Measuring tool main bearing

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

90664 0005 Crankshaft - Pin Gauge
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Gear Drive 106-20
Data
SAFETY PRECAUTIONS
Special Edition
D10620
106-20 Data 0001 S50ME-C Gear Drive
X Stopped engine
Shut off fuel oil
X Shut down hydraulic power supply
Data
MAN B&W Diesel A/S
106-20 Gear Drive
Data
MAN B&W Diesel A/S
Gear Drive 906-20.1
Checking
Gear Drive
S50ME-C
0201
Checking
906-20.1
1.
1. Remove the two covers on the exhaust side
of the gearbox and the inclined cover on the
fuel pump side.
Carry out a visual inspection of the gear

wheels.
2. Check that there are no signs of abnormal

wear on the contact faces of the gear wheel
teeth.
3. Check that there are no particles of bearing

material on the horizontal surfaces below
the bearings.
906-20 1 201 01
If any signs of abnormal wear or seizure are
observed, contact MAN B&W for advice .
4. Mount the two covers on the exhaust side 2.

of the gearbox and the inclined cover on the
fuel pump side.
906-20 1 201 02
3.
906-20 1 201 03
MAN B&W Diesel A/S
Hydraulic Pumps 106-21
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10621
106-21 Data 0001 Hydraulic Pumps
X Stopped engine
X Shut off fuel oil
Shut off lubricating oil
Data
D06-206 Hydraulic pump 106 kg
MAN B&W Diesel A/S
106-21 Hydraulic Pumps
Data
MAN B&W Diesel A/S
Hydraulic Pumps 906-21.2
Dismantling
Hydraulic Pumps
S50ME-C
0201
Dismantling
906-21.2
1.
Check that startup and booster pumps are
stopped before any part of the hydraulic system
is disassembled.
Note!
Great care must be taken to ensure that

the area around the workplace is clean
before and during any dismantling of the
hydraulic system.
1. Close the suction valve for the relevant
GW906-21.2 201 01
pump.
If mounted, remove the cover.
2. Open valve 315 to release the hydraulic

pressure from the system. 2.
3. Remove the electrical connections to the

solenoid valves.
Remove the electrical connection to the an-

gle encoder .
GW906-23.1 201 02
3.
GW906-21.2 201 03
MAN B&W Diesel A/S
906-21.2 Hydraulic Pumps
Dismantling
4. 4. Unscrew the bolts from the flange on the

suction pipe.
Unscrew the bolts from the discharge pipe

and remove the pipe.
5. Unscrew the servo oil pipes.

GW906-21.2 201 04
5.
GW906-21.2 201 05
MAN B&W Diesel A/S
Dismantling
6. Suspend a tackle above the hydraulic pump 6.

and put a strap around the pump.
Hook the tackle on to the strap and tighten

up.
Note!
The pump must be in balance when it is

lifted.
GW906-21.2 201 06
Unscrew the four screws in the end-flange.
7. Carefully pull out the pump and the internal

drive shaft. See Data.
For overhaul of the pump, send it to an au- 7.

thorized MAN B&W workshop.
The internal drive shaft also functions as an

overload protection. If it is necessary to re-
new the drive shaft, contact MAN B&W Die-
sel for advice.
GW906-21.2 201 07
MAN B&W Diesel A/S
Mounting
Mounting
906-21.4
1.
Note!

D06-206 the area around the workplace is clean
before and during assembly of the
hydraulic system.
1. Mount the intermediate shaft in the gear-

box. Suspend a tackle above the gearbox
and put a strap around the hydraulic pump.
Lift up the pump in position, and carefully

GW906-21.4 201 01
push in the pump, to engage the pump

shaft with the drive shaft.
2. Mount and tighten the bolts in the pump

flange.
2.
3. Mount the bolts in the flange on the suction
pipe.
Mount the discharge pipe and tighten the

bolts.
GW906-21.4 201 02
3.
GW906-21.4 201 03
MAN B&W Diesel A/S
Mounting
4. Mount the servo oil pipes. 4.
5. Mount the electrical connections to the so-

lenoid valves and to the angle encoder.
6. Close valve 315 on the hydraulic block.
GW906-21.4 201 04
GW906-21.4 201 05 5.
6.
GW906-23.1 201 02
MAN B&W Diesel A/S
Mounting
7. 7. Open up the suction valve for the relevant

pump.
If removed, remount the cover.

GW906-21.4 201 07
MAN B&W Diesel A/S
Hydraulic System 106-22
Data
SAFETY PRECAUTIONS
Special Edition
D10622
106-22 Data 0001 S50ME-C Hydraulic System
X Stopped engine
Shut off fuel oil
Data
D06-209 Hydraulic flange tightening torque 50 Nm
MAN B&W Diesel A/S
106-22 Hydraulic System
Data
MAN B&W Diesel A/S
Hydraulic System 906-22.3
Overhaul
Hydraulic System
S50ME-C
0201
Overhaul
906-22.3
1.
Check that startup and booster pumps are
stopped before any part of the hydraulic system
is disassembled.
Note!

hydraulic system.
Hydraulic High-pressure Pipes
906-23.1 201 02
1. Open valve 315 on the hydraulic block next
to the hydraulic high-pressure pumps, to re-
lieve the system of hydraulic pressure.
2. Open valve 431 on the hydraulic block next 2.

to the high-pressure pipe concerned, to the
space between the inner and outer pipes.
3. Unscrew the screws in both flanges on the

pipe concerned.
Pull both flanges clear of the hydraulic

blocks.
906-22.3 001 02
3.
906-22.3 001 03
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul
4. 4. Lift out the hydraulic double pipe.
5. Pull off both flanges.
Remove all sealing rings from the flanges,

discard the rings.
6. Clean the pipes and flanges, check the

sealing surfaces.
Note!

906-22 3 001 04

hydraulic system.
5. Mount new sealing rings, lubricate the rings

with engine lube oil, before mounting the
flanges on the double pipe.
For correct mounting of the sealing rings,

see the sketch.
Push the flanges on to the double pipe.

906-22.3 001 05
6.
906-22.3 001 06
MAN B&W Diesel A/S
Hydraulic System 906-22.3
Overhaul
7. Before remounting the hydraulic high-pres- 7.

sure pipe, check that the faces on the hy-
draulic blocks are clean.
Mount the hydraulic high-pressure pipe.
8. Mount the screws in the flanges and tighten

to the specified torque, see Data.
9. Close valve 431 on the hydraulic block next

the high-pressure pipe concerned.
906-22.3 001 07
906-22.3 001 08 8.
9.
906-22.3 001 02
MAN B&W Diesel A/S
906-22.3 Hydraulic System
Overhaul
10. 10. Close valve 315 on the hydraulic block next

to the hydraulic high-pressure pumps.
906-23.1 201 02
MAN B&W Diesel A/S
Accumulators 106-23
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10623
106-23 Data 0001 Accumulators
X Stopped engine
X Shut off fuel oil
X Shut-down hydr. power supply
Data
D06-201 Accumulator 24 kg
D06-202 N2 Charging pressure 104,3 bar at 20°
D06-203 Accumulator flange tightening torque 60 Nm
D06-204 Pressure Adjustment Table
Accumulator temperature t °C bar
0 97
10 101
20 104
30 108
40 111
50 115
60 119
70 122
80 126
90 129
100 133
Filling pressure must be as stated above
Check pressure within ± 1 bar
MAN B&W Diesel A/S
106-23 Accumulators
Data
P90364 Test Equipment for Alpha-Lubricator

MAN B&W Diesel A/S
Accumulators 906-23.1
Checking
Accumulators
S50ME-C
0201
Checking
906-23.1
1.
Check of Accumulators on Hydraulic Cylin-
der Unit
1. Checking the hydraulic accumulator can be

done with running engine at reduced
speed. See Volume I, Operation.
Close the high pressure inlet valve 420 and

open the high pressure outlet valve 421 to
drain all oil out of the accumulator.
Check the nitrogen pressure
GW908-3.2 228 01
For correct pressure, see Data D06-204.
For use of pressure setting tool, see step 3.
Check of Accumulators on Hydraulic Power

Supply Unit 2.
2. Check of accumulators on accumulator

block can only be performed on a stopped
engine and with stopped start-up and
booster pumps.
Open valve 315 to de-pressurize the hy-

draulic system and drain all oil out of the
accumulators.
Check the nitrogen pressure.

GW906-23.1 201 02
For correct pressure, see Data D06-204.
For use of pressure setting tool, see step 3.
MAN B&W Diesel A/S
906-23.1 Accumulators
Checking
3. Use of Reducing Valve as Pressure Setting

Tool
3. Assemble the reducing valve as shown in

the figure, and mount the reducing valve on
the nitrogen cylinder. If necessary, use a
threaded adaptor.
Before mounting the filling valve on the ac-

cumulator, check that the accumulator top
is clean.
Check that valves A, D and E are closed.
Mount the filling valve on the relevant accu-

mulator with the union nut F.
Open valve D.
It is now possible to read the actual nitro-

GW906-23.1 201 03
gen pressure in the accumulator on the dial

gauge C on the filling valve.
If the accumulator needs to be refilled with

nitrogen, open valve A and adjust the outlet
pressure from valve D on spindle B to 1-2
bar above the pressure stated in the Pres-
sure Adjustment Table.
See Data D06-204.
Keep valve A open until the accumulator is

filled.
Close valve A.
Wait five minutes for the temperature to sta-

bilize.
Check the pressure in the accumulator on

gauge C according to the Pressure Adjust-
ment Table.
See Data D06-204.
Adjust the pressure in the accumulator at

bleed screw E.
Unscrew the union nut F to remove the fill-

ing valve from the accumulator.
MAN B&W Diesel A/S
Accumulators 906-23.2
Dismantling
Dismantling
906-23.2
1.
Note!

hydraulic system.
Dismantling of Accumulators from Hydraulic

Cylinder Unit
1. This can be performed on a running engine

at reduced speed. See Volume I, Operation.
GW908-3.2 228 01
drain all oil out of the accumulator.
2. Dismount the accumulator flange from the 2.

hydraulic cylinder unit.
Dismount the accumulator flange from the

accumulator.
Dismantling of Accumulators from Hydraulic

Power Supply Unit
3. Dismantling of accumulators from the accu-

mulator block can only be performed on a
stopped engine and with stopped start-up
and booster pumps.
GW906-23.2 201 02
Open valve 315 to de-pressurize the hy- D06-201

draulic system and drain all oil out of the
accumulators.
The accumulators on the hydraulic power

supply unit are dismounted in the same way
as on the hydraulic cylinder unit.
MAN B&W Diesel A/S
906-23.4 Accumulators
Mounting
Mounting
906-23.4
1.
Note!

hydraulic system.
Mounting of Accumulators on Hydraulic Cyl-

inder Unit
1. This can be performed on a running engine

GW906-23.2 201 02
at reduced speed. See Volume I, Operation.

D06-201
D06-203 Mount the flange and a new sealing ring on
the accumulator.
2. Mount the accumulator assembly and a

new second sealing ring on the hydraulic
cylinder unit.
2. Close the high pressure outlet valve 421

and open the high pressure inlet valve 420.
Mounting of Accumulators on Hydraulic

Power Supply Unit
3. This can only be performed on a stopped

engine and with stopped start-up and
booster pumps.
GW906-23.1 201 02
The accumulators on the hydraulic power

supply unit are mounted in the same way as
on the hydraulic cylinder unit.
Close valve 315.
MAN B&W Diesel A/S
Control Valves 106-24
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10624
106-24 Data 0001 Control Valves
X Stopped engine
X Shut off fuel oil
Data
D06-207 ELFI Control Valve 21 kg

D06-208 ELVA Control Valve 13 kg
MAN B&W Diesel A/S
106-24 Control Valves
Data
MAN B&W Diesel A/S
Control Valves 906-24.1
Checking
Control Valves
S50ME-C
0201
Checking
906-24.1
1.
1. The function of the Electronic Fuel Injection
valve (ELFI) and the Electronic Exhaust
Valve Activation Valve (ELVA) is continu-
ously checked by the Engine Control Sys-
tem.
Malfunctions will be reported by the system

to the MOP system and to the common
alarm system.
Malfunctioning ELFI and ELVA valves are to

be overhauled by the supplier or by MAN
B&W Diesel.
GW906-24.1 201 01
MAN B&W Diesel A/S
906-24.2 Control Valves
Dismantling
Dismantling
906-24.2
1.
Note!

hydraulic system.
1. Dismantling of the ELFI and ELVA valves

GW908-3.2 228 01
can be performed on a running engine at

reduced speed. See Vol. I.

drain all oil out of the hydraulic cylinder unit.
2.
2. Disconnect the electrical connections.
Dismount the four screws and carefully pull

the ELFI or ELVA valve out past the two
guide pins.
D06-207
D06-208
GW906-24.2 201 01
MAN B&W Diesel A/S
Control Valves 906-24.4
Mounting
Mounting
906-24.4
1.
Note! D06-207
D06-208
hydraulic system.
1. Mount new square section sealing rings in

the control valve.
GW906-23.2 201 01
Mount the control valve on the two guide
pins and tighten the four screws.
Connect the electrical connections.

2.
2. Close the high pressure outlet valve 421
and open the high pressure inlet valve 420. GW908-3.2 228 01
MAN B&W Diesel A/S
Pick-up Arrangement 106-25
Data
SAFETY PRECAUTIONS
Special Edition
D10625
106-25 Data 0001 Pick-up Arrangement
X Stopped engine
Shut off fuel oil
Data
D06-205 Sensor adjustment measurement 3 mm
MAN B&W Diesel A/S
106-25 Pick-up Arrangement
Data
P90655 Feeler gauge
MAN B&W Diesel A/S
Pick-up Arrangement 906-25.1
Checking
Pick-up Arrangement
S50ME-C
0201
Checking
906-25.1
1. The sensors in the Pick-up arrangement

are continuously checked by the system it-
self and will activate an alarm on the main
operating panel if a failure occurs.
Manual checking is to be carried out as de-

scribed in Procedure 906-25.3.
MAN B&W Diesel A/S
906-25.3 Pick-up Arrangement
Adjustment
Adjustment
906-25.3
1. 1. Location of sensors.
MSA
MMB
2. Initial adjustment.
Turn the turning wheel until the highest po-
Q1A MSB
Q2A sition on the marker ring, marked “T”, is po-
sitioned immediately under the sensor.
Adjust the gap to 2 mm. Repeat with the
Q1B
other three sensors.
MMA Q2B
3. Turn the crank throw for cylinder 1 to TDC.
Check the TDC of cylinder 1 against the
“zero” degree mark on the turning wheel.
GW906-25.3 201 01
2.
22 m
m
mm
GW906-25.3 201 02
3.
BG906-7.0 56 01
MAN B&W Diesel A/S
Adjustment
4. Check the TDC position with the pin gauge 4.

on the crank throw.
5. Adjust the MMA sensor tangentially to the

mark on the semi-circle placed according to
Data D06-205.
Turn the engine 135°, i.e. to a position at
BG906-7.0 58 02
which a mark is placed next to each marker
sensor (spaced 45 degrees).
6. Adjust the other three marker sensors to

the same relative position as the first one. 5.
Ahe
ad
45°
45°
GW906-25.3 201 05
45°
D06-205
6.
GW906-25.3 201 06
MAN B&W Diesel A/S
Adjustment
7. 7. The trigger sensors placed opposite the

Q2 Q1
teeth on the trigger ring should be adjusted
as shown in Fig. 7.
Turn to TDC.
AHEAD
Q2 ∆ X Q1 First measure the distance between two
wave tops, to find the value ∆. Place the ad-
justment gauge on the wave tops and mark
the distance “X” from the wave centre line
pitch with a felt tip pen.
∆ = 0.25 x pitch
Draw another line at the distance “∆" from
GW906-25.3 201 07
the “X” line.

Q2 Q1
Felt tipped pen line
Then adjust sensor Q1 so that the back end
just touches the “X” distance line.
8. Then adjust sensor Q2 so that the back end

just touches the “∆” distance line.
8. Final adjustment:
Adjust all sensors until there is a gap of one

mm between sensor head and marker ring
or trigger ring. Use a feeler gauge.
Secure the sensor nuts with Loctite  met-

1m
al glue.
m
GW906-25.3 201 08
MAN B&W Diesel A/S
Adjustment
9. How to replace trigger sensors: 9.
Prepare the sensor cable with sleeves and

markings (BN to be marked 1, BU to be
marked 2 and BK to be marked 3).
3 2 1
The dot on the upper part of the sensor

housing must point towards the Ahead turn-
ing direction. 3 2 1
Turn the engine to the point where the high-

est wave top of the trigger ring is opposite
to the sensor which is to be replaced.
GW906-25.3 201 09
Open the sensor box, check cable colours
and markings. Dismount the old sensor.
The sensor box must not be dismounted or
moved.
10.
10. Mount the new sensor in the sensor box. It
should be mounted with one mm clearance
to the trigger wave top. Secure the sensor
with Loctite  metal glue.
After tightening, check position and clear-

ance.
1m
Mount the sensor cable in accordance with
m
the drawing. BN to terminal 1, BU to termi-
nal 2 and BK to terminal 3.
GW906-25.3 201 08
Turn the engine to see if the sensor light di-

ode flashes; if it does not, stop turning.
Move a piece of steel near the sensor head

and check that the diode light changes.
Test the signal in the service terminal in the

same way.
MAN B&W Diesel A/S
Adjustment
11. 11. How to replace marker sensors

(MMA, MMB, MSA, MSB)
Prepare the sensor cable with sleeves and

markings (BN to be marked 1, BU to be
3 2 1 marked 2 and BK to be marked 3).
Turn the engine to the point where the high-

3 2 1 est point of the marker semi-circle is oppo-
site to the sensor which is to be replaced.
Open the sensor box, check cable colours

and markings. Dismount the old sensor.
GW906-25.3 201 09
The sensor box must not be dismounted or

moved.
12. Mount the new sensor in the sensor box. It

should be mounted with one mm clearance
12. to the trigger wave top. Secure the sensor
with Loctite  metal glue.
After tightening, check position and clear-

ance.
Mount the sensor cable in accordance with

the drawing. BN to terminal 1, BU to termi-
nal 2 and BK to terminal 3.
1m
m
Turn the engine to see if the sensor light di-

ode flashes, if it does not, stop turning.
GW906-25.3 201 18
Move a piece of steel near the sensor head

and check that the diode light changes.
Test the signal in the service terminal in the

same way.
MAN B&W Diesel A/S
Special Running 106-28
Data
SAFETY PRECAUTIONS
Special Edition
D10628
106-28 Data 0001 Special Running
X Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Shut down hydraulic power supply
Data
MAN B&W Diesel A/S
106-28 Special Running
Data
P90364 Test equipment for Alpha-Lubricator
MAN B&W Diesel A/S
Special Running 906-28.3
Special Running
S50ME-C
0201
906-28.3
2.
For all special running conditions, see Volume
I, Chapter 704.
Under conditions where it is necessary to run

the engine with an open exhaust valve, a small
hose must be mounted as follows:
1. Stop the engine.
GW908-3.2 228 01
hydraulic block.
3. Connect the mini-mesh hose to the top

3.
flange on the exhaust valve actuator. Con-
nect the other end of the hose to point 425
on the hydraulic block.
4. Open valve 420 and close valve 421 on the

hydraulic block.
When the special running with open ex-

haust valve is finished, the mini-mesh hose
must be removed.
GW906-28.3 001 03
4.
GW908-3.2 228 01
MAN B&W Diesel A/S
Crankshaft - Pin Gauge Plate
P90664-0005
Crankshaft - Pin Gauge
0005
P90664
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0005
Item Item
No. No.
021 Pin gauge for crankshaft
MAN B&W Diesel A/S
107-2 0032 Start Air Valve, Data

907-2 0214 Starting Air Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Starting Air Valve 107-2
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10702
107-2 Data 0032 Starting Air Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D07-09 Piston tightening torque 180 Nm

D07-10 Valve tightening torque 175±20 Nm
D07-11 Valve tightening angle 50/30 Nm/ °
D07-12 Starting air valve 20 kg
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data
P90151 95 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve
MAN B&W Diesel A/S
Starting Air Valve 907-2.2
Dismantling
Starting Air Valve
S46MC-C
0214
Dismantling
907-2.2
1.
1. Shut off the starting air and control air inlet.
Dismount the control air pipes.
Unscrew the fixing nuts of the starting valve

flange.
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
GN907-2.2 203 01 2.
D07-12
GN907-2.2 203 02
0$1% :'LHVHO$6
907-2.3 Starting Air Valve
Overhaul
Overhaul
907-2.3
1. 1. Remove the top cover fixing screws and re-

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

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

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

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

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

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

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

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

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

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

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

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

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

starting air and control air. 2.
D07-12
GN907-2.4 203 02
3.
D07-10
or
D07-11
GN907-2.4 203 03
0$1% :'LHVHO$6
908 Exhaust Valve
108-1 0032 High-Pressure Pipe, Data

908-1 0217 High-Pressure Pipe
108-2 0065 Exhaust Valve, Data
908-2 0244 Exhaust Valve
108-3 0035 Exhaust Valve Actuator, Data
908-3 0228 Exhaust Valve Actuator
90861 0036 Exhaust Valve - Tools
90863 0009 Exhaust Valve - Extra Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
High-Pressure Pipe 108-1
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10801
108-1 Data 0032 High-Pressure Pipe
X Stopped engine
Shut off fuel oil
Data
D08-01 High-pressure pipe, tightening torque 36 Nm

D08-03 High-pressure pipe 32 kg
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data
MAN B&W Diesel A/S
High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
S50ME-C
0217
Dismantling
908-1.2
1.
1. Stop the engine and shut off the oil supply.
Close valve 420 and open valve 421 on the

hydraulic block for the cylinder concerned.
Note!

hydraulic system.
GW908-3.2 228 01
2. Close the valve 531 for the actuator oil sup-
ply, and valve 536 for damper piston oil sup-
ply.
GW908-3.2 228 02
2.
MAN B&W Diesel A/S
908-1.2 High-Pressure Pipe
Dismantling
3. 3. When replacing the hydraulic high-pressure

pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing sur-
faces.
4. Before dismounting the high-pressure pipe,

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

pipe and lift the pipe slightly away from the
D08-03 actuator to let the oil in the pipe drain
through the drain holes in the actuator.
5. Remove the screws in both ends of the

high-pressure pipe. Lift the high-pressure
pipe away from the engine.
Note!
After removal of the high-pressure pipe,

over the hole in the actuator, to avoid
GW908-1.2 217 01
impurities entering the high-pressure

hydraulic system.
4.
GN908-1.2 203 02
MAN B&W Diesel A/S
Overhaul
Overhaul
908-1.3
The two ends of the pipe are identical and 1.

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

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

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

high-pressure pipe and the thrust piece.
Note!
GN908-1.3 203 01
The seats cannot be reconditioned.
If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-part

sleeve.
3. Remove the thrust flange from the pipe

end.
Remove and discard the internal O-rings.

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

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

verse order to disassembling. 3.
DM908-1.1 61 03
MAN B&W Diesel A/S
908-1.4 High-Pressure Pipe
Mounting
Mounting
908-1.4
1. 1. Mount new O-rings, lubricated with a little

engine lubricating oil, on the thrust pieces
and thrust flanges.
Mount the thrust pieces on the actuator/ex-

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

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

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

and actuator, tighten up the screws of the
pressure flanges diagonally, see Data.
GW908-1.2 217 01
2.
D08-01
GN908-1.4 203 02
MAN B&W Diesel A/S
Mounting
3. Open the valve 531 for actuator oil supply 3.

and open valve 536 for hydraulic damper
oil.
4. Close valve 421, and open valve 420 on the

hydraulic block.
5. Check the system for tightness.

GW908-3.4 228 03B

4.
D-6
GW908-3.2 228 01
MAN B&W Diesel A/S
Exhaust Valve 108-2
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10802
108-2 Data 0065 Exhaust Valve
X Stopped engine
Shut off fuel oil
Data
D08-04 Safety valve, opening pressure 21 bar

D08-06 Oil cylinder, tightening torque 100 Nm
D08-07 Safety valve, tightening torque 50 - 80 Nm
D08-09 Bottom piece seat, grinding angle 29.9 - 30.0 °
D08-10 Valve spindle seat, grinding angle 30.4 - 30.5 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1.0 mm
D08-13 Spindle, max. burn-off 8.0 mm
D08-14 Spindle, max. grinding 2.0 mm
D08-15 Spindle stem, measuring area, min. 335 mm
D08-16 Spindle stem, measuring area, max. 455 mm
D08-17 Spindle stem, min. diameter 59.8 mm
D08-18 Bushing max. diameter, top 60.2 mm
D08-19 Bushing max. diameter, bottom 62.0 mm
D08-20 Oil cylinder max. inside diameter 71.2 mm
D08-21 Piston rings, min. thickness 2.6 mm
D08-24 Exhaust valve, complete 470 kg
D08-25 Exhaust valve housing 255 kg
D08-26 Oil cylinder 62 kg
D08-27 Air cylinder 35 kg
D08-28 Spindle 42 kg
D08-29 Bottom piece 52 kg
MAN B&W Diesel A/S
108-2 Exhaust Valve
Data
P90851 65 Lifting tool for exhaust valve

P90851 89 Pressure tester for safety valve
P90851 90 Gauge for exhaust valve spindle
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90851 281 Cone, for sealing ring
P90861 Valve seat and spindle grinder
P90862 Hydraulic jack, complete
MAN B&W Diesel A/S
Exhaust Valve 908-2.1
Checking
Exhaust Valve
S50ME-C 0244
Checking
908-2.1
1.
1. Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve be checked as follows:
• Lift up the valve with the engine room

crane (which makes the valve open).
• Connect compressed air to the air cylin-

der. The valve should now close.
• Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G 3, to
ensure that there is a clearance between
the outer parts of the seating faces of
valve housing and spindle.
• After shutting-off the compressed air

GW908-2.1 241 01
supply and releasing the vent plug screw
located just above the ball cock on the air
cylinder, the exhaust valve should open.
• After doing this a couple of times, leave

the valve closed and shut-off the com- 2.
pressed air. The valve should remain
closed for at least fifteen minutes.
Check of sealing oil unit
2. Check of the sealing oil unit is carried out

with running engine. Check that the injec-
tion indicator moves regularly with the valve
opening. Alternatively, unscrew the sealing
oil pipe, and check that oil is coming out
GW908-2.1 241 02
(very small quantity).
3. When the exhaust valve is mounted in the

cylinder cover, and the cooling water inlet to
the cylinder cover and exhaust valve is
3.
open, check the tightness of the sealing
ring between the bottom piece and the cyl-
inder cover by ensuring that water does not
flow from the small bore on the top side of
the bottom piece.
If water does flow from one or both of these

bores, the exhaust valve must be dismount-
ed and the sealing rings replaced.
BM908-2.1 235 02
MAN B&W Diesel A/S
908-2.2 Exhaust Valve
Dismantling
Dismantling
908-2.2
1. 1. Close the cooling water inlet and outlet, and

drain the exhaust valve.
Dismount the high-pressure pipe for the hy-

draulic valve actuation.
Disconnect the cooling water outlet pipe

from the exhaust valve.
Disconnect the electrical plug for the valve

position sensor.
GW908-2.2 241 01
Dismount the return oil pipe and oil supply

pipe from the exhaust valve.
2. Dismount the air pipes for pneumatic clos-

ing of the exhaust valve.
2.
Remove the cooling water pipe.
3. Remove the plate jacket with insulation

from the intermediate pipe and remove the
screws which attach the intermediate pipe
to the exhaust valve.
GW908-2.2 241 02
3.
GW908-2.2 241 03
MAN B&W Diesel A/S
Dismantling
4. Remove the protective caps from the ex- 4.

haust valve studs, and mount the four hy-
draulic jacks.

jacks by means of the distributor block and D13-02
high-pressure hoses.
Bleed the hydraulic system and raise the

pressure as stated in Data. Then loosen
and remove the nuts. See Procedure 913-1.
5. Attach the crane to the eye bolt fitted on top

of the valve and lift the exhaust valve away.
Apply compressed air to the air spring, right
GW 908-2.2 241 04
before lifting.
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. 5.
D08-24
Compressed
Compressed Air Air
GW 908-2.2 241 05
MAN B&W Diesel A/S
Overhaul
Overhaul
908-2.3
1. 1. Place the exhaust valve on a wooden sup-

port on the platform. Remove the four nuts
and the safety strap from the oil cylinder.
Remove the oil pipe for the valve spindle oil

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

wooden support.
GW908-2.2 241 01
2.
D08-26
GW908-2.2 241 02
MAN B&W Diesel A/S
Overhaul
3. Mount the support and the hydraulic jack for 3.

the conical nut on the valve spindle.
D13-02
Check that the jack is fully compressed and
tightened to full face contact, unscrew the
jack ½ a revolution.

jack. Bleed the hydraulic system and raise
the pressure as stated in Data. Then loosen
the nut. See Procedure 913-1.
4. Remove the conical nut and the damper

bushing.
GW 908-2.3 241 03
4.
GW 908-2.3 241 04
MAN B&W Diesel A/S
Overhaul
5. 5. Mount two eye bolts in the top of the air cyl-

inder. Lift the air cylinder with damper pis-
ton and air piston.
Land the air cylinder on a wooden support.
6. Remove the retaining ring from the spindle

D08-27 shaft.
GW908-2.3 241 05
6.
GW908-2.3 241 06
MAN B&W Diesel A/S
Overhaul
7. Use the oil cylinder as a lifting tool for the 7.

exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount the four
nuts so that the load from the valve housing
is evenly distributed.
8. Lift the oil cylinder and the valve housing

clear of the exhaust valve spindle.
GW 908-2.3 241 07
8.
D08-26 +
D08-25
GW 908-2.3 241 08
MAN B&W Diesel A/S
Overhaul
9. 9. Land the valve housing on a wooden sup-

port and let the oil cylinder hang in the
crane.
Unscrew the retaining screws for the bot-

tom piece and lift the valve housing 10mm.
If the bottom piece has become stuck, use

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

couple of wooden planks. Remove the oil
cylinder from the valve housing.
10. Inspect the spindle guide bushing in the ex-

haust valve housing for wear and measure
the top and bottom diameters. See Data.
D08-29 11. If it proves necessary to replace the bush-

ing, knock out the bushing with a hammer
and a suitable mandrel. Mount a new bush-
ing. Mount and tighten the screws.
GW908-2.3 241 09
10.
D08-18
D08-19
GN908-2.3 235 25
MAN B&W Diesel A/S
Overhaul
Bottom piece: 12.
12. Inspect the seating of the bottom piece

carefully for damage and check with the
bottom piece template.
G3
Note!
Before using the bottom piece template,

thoroughly clean the contact faces on the
valve housing w-seat with a steel brush.
All measurements should be taken at

four diametrically opposite points on the D08-09
circumference of the bottom piece seat-
ing.
Small dent marks in the bottom piece

seating are acceptable and need not be
ground away, provided that the dent G2
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
MB908-2.3 230 12
exhaust gas receiver.
For further evaluation of the bottom piece

seating, see also Chapter 707 in the
instruction book, Volume I, Operation.
Take measurements G 2 and G 3, using a

feeler gauge. Compare the results with the
figures stated in Data D08-11 and D08-12.
IF burn marks are visible on the bottom

piece seating OR G 3 does not equal D08-
12, THEN the bottom piece seat must be
ground.
IF the template rests on the lower surface

in the groove, i.e. G 2 = 0, THEN the bottom
piece seating must be discarded and re-
placed with a new bottom piece. Further
grinding or reconditioning is not recom-
mended.
MAN B&W Diesel A/S
Overhaul
13. 13. 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
D08-09 away from the grinding table.
Mount and secure the bottom piece in the

grinding machine. Using a dial gauge,
check that the bottom piece is correctly
centered.
MB908-2.3 230 11
Adjust the grinding head to achieve the cor-

rect grinding angle as stated in Data.
Note!
14.
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
D08-12 Regarding the use of the grinding machine,
see separate instructions from the grinding
machine manufacturer.
D-19 14. During the grinding, use the bottom piece

template frequently to ensure that maxi-
mum grinding is not exceeded.
After grinding, inspect the bottom piece

seating again, using a feeler gauge and the
D08-09 bottom piece template, to measure how
much material has been ground away.
MB908-2.3 230 12
D08-11 Grind the recess so that gap G 3 equals

G2 D08-12 as stated on the Data sheet.
15. After grinding the inside seating of the bot-

15. tom piece, grind the outside seating using
carborundum 200 and the special grinding
tool.
Note!
Turn the special grinding tool by hand,

alternately turning clockwise and anti-
clockwise
MB908-2.3 233 13
Grind until a smooth surface is achieved.

Clean the bottom piece.
MAN B&W Diesel A/S
Overhaul
Valve spindle 16.
16. When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
17. Inspect the seating of the valve spindle for

burn marks.
Check the burn-off F1 of the valve spindle DD08-28

by measuring along the spindle template
from point A to point D and in point E.
NA908-2.3 209 14
Note!
Before using the spindle template, thor-

oughly clean the contact faces on the
valve spindle with a steel brush. 17.
All measurements should be taken at

four diametrically opposite points on the
circumference of the valve spindle. Make
sure that the most burned-off point is
measured.
Small dent marks in the valve spindle

seating are acceptable and need not be
ground away, provided that the dent F-1
marks do not allow blow-by of exhaust
gas from the combustion chamber to the
exhaust gas receiver.
MA908-2.3 213 12
For further evaluation of the valve spindle A

seating, see also Chapter 707 in the D E
instruction book, Volume I, Operation.
18.
18. Measure the gap G1 between the spindle
template and the seating of the spindle. G-1
19. 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 D08-10
D08-13, the spindle must not be ground. In-
stead the spindle must be reconditioned.
Contact MAN B&W Diesel for advice on re-

HC908-2.0 117 11
conditioning.
MAN B&W Diesel A/S
Overhaul
20. 20. 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.
D08-10 Note!
As the grinding angle is very important to

the operation of the exhaust valve, make
GM908-2.0 119 14
absolutely sure to adjust the grinding

head correctly.
Regarding the use of the grinding machine,

see separate instructions from the grinding
21. machine manufacturer.
During grinding, measure gap G 1 frequent-

D08-15 ly. The max. grinding of the spindle, see
Data, must not be exceeded.
D08-16
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
D08-17 advice on reconditioning.
Clean the spindle.
21. 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.
GW908-2.3 241 21
MAN B&W Diesel A/S
Overhaul
22. Mount the O-rings and sealing ring on the 22.

spindle stuffing box.
Note!
Make sure to mount the sealing ring cor-

rectly, see the sketch.
23. Mount the oil cylinder as a lifting tool on the

valve housing.
GW908-2.3 241 22
Lift and land the valve housing on the bot-
tom piece. Check that the guide pin in the
bottom piece enters the hole in the bottom
of the exhaust valve housing.
23.
Mount and tighten the retaining screws for
the bottom piece.
24. Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
Mount the guide cone on the exhaust valve

spindle, to protect the sealing rings in the
stuffing box.
Carefully land the exhaust valve housing

GN908-2.3 236 28
with the bottom piece on the exhaust valve

spindle.
Take care not to damage the sealing rings

in the stuffing box. 24.
Remove the oil cylinder from the exhaust

valve.
Remove the guide cone from the exhaust

valve spindle.
GW908-2.3 244 24
MAN B&W Diesel A/S
Overhaul
25. 25. Mount the retaining ring on the spindle.
26. Lift up the damper piston and the air piston

from the air cylinder.
Remove the protective cap from the safety

valve mounted near the bottom of the air
cylinder. Dismount the safety valve from the
air cylinder. Clean the machined surfaces
and the internal bores.
Check the running surface for wear or pos-

GW908-2.3 241 25
sible scores.
27. Place the safety valve in the pressure test-

ing device.
26. 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
pressure is indicated.
Tighten the lock nut and test the opening

pressure once more.
GW908-2.3 241 26
27.
D08-04
NB908-3.2 229 21
MAN B&W Diesel A/S
Overhaul
28. Mount a new gasket and a new O-ring on 28.

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 D08-07

cylinder, use only the machined faces on
the valve housing and tighten, see Data.
Finally, mount the protective cap.
GW908-2.3 241 28
29. Lubricate the O-rings on the spindle stuff-
ing box.
Carefully land the air cylinder on the ex-

haust valve housing and check its correct 29.
engaging with the locating pin.
Note!
Take care not to damage the O-rings on

the outside of the stuffing box.
30. Inspect the air piston sealing rings and

guide ring. If it is necessary to change the
rings, cut them and remove them.
Note!
Before mounting, heat the new teflon

rings in 100°C hot water for at least five
GW908-2.3 241 29
minutes.
When mounting the teflon rings, be care-

ful not to damage the running surfaces.
30.
Compress the teflon ring by hand, using
working gloves.
Mount the new O-ring in the groove of the

air piston.
GW908-2.3 241 30
MAN B&W Diesel A/S
Overhaul
31. 31. Mount new sealing rings on the damper pis-

ton flange.
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).
33. Lubricate the running surface of the air cyl-

inder and the surface for the damper piston
flange.
Lower the air piston over the valve spindle

down into the air cylinder.
GW908-2.3 241 31
Lower the damper piston flange over the

valve spindle down into the upper groove of
the air cylinder.
32.
GN908-2.3 236 32
33.
GW908-2.3 241 33
MAN B&W Diesel A/S
Overhaul
34. Mount the damper bushing and the conical 34.

nut.
35. Mount the support and the hydraulic jack for

the conical nut on the valve spindle.
Check that the jack is fully compressed and

tightened to full face contact, unscrew the
jack ½ a revolution.

jack. Bleed the hydraulic system and raise
the pressure as stated in Data. Then tight-
en the nut. See Procedure 913-1.
Remove the hydraulic jack from the spindle.
GW908-2.3 241 04
35.
D13-01
GW908-2.3 241 03
MAN B&W Diesel A/S
Overhaul
36. 36. Place the oil cylinder in a horizontal posi-

tion with the sealing oil unit pointing up-
wards.
Remove and discard the sealing ring.
Loosen the screws and remove the sealing

oil control unit.
Unscrew and clean the orifice plug.
Check and clean the bore for the orifice

plug in the top of the oil cylinder.
37. Sealing oil control unit:

GW908-2.3 241 36
Normally, overhaul of the sealing oil unit

should not be necessary.
Check the unit according to Procedure 908-

2.1
37.
Before remounting the unit, carefully clean
it on the machined faces. If the unit needs
to be overhauled, send it to an authorized
MAN B&W repair shop.
Mount the orifice plug and the sealing oil

control unit.
38. Remove the flange and take out the piston.
Clean the oil cylinder and inspect the bore

of the oil cylinder for scoring and check its
measurements.
GN908-2.3 236 05
If the diameter of the bore exceeds the val-

ue stated in Data, send the oil cylinder to
an MAN B&W authorized workshop for re-
pair.
38.
D08-20
GW908-2.3 241 38
MAN B&W Diesel A/S
Overhaul
39. Remove the piston rings from the oil piston 39 Top
Top
and check them for wear.
If the thickness of the rings has worn down

to the minimum, see Data, discard the rings
and mount new ones.
Check that the TOP mark on the piston

rings faces upwards, when mounting.
40. Mount the oil piston and the flange in the oil
cylinder and mount a new O-ring in the out- D08-21
side groove.
GW908-2.3 241 39
41. Mount the oil cylinder and the safety strap.
Mount and tighten the four nuts to the spec-

ified torque.
40.
Mount the oil pipe for the valve spindle oil
sealing.
GW908-2.3 241 40
41.
D08-06
GW908-2.3 241 01
MAN B&W Diesel A/S
Mounting
Mounting
908-2.4
1. Check before mounting
Before mounting an overhauled exhaust valve

in the engine, it is recommended that the valve
D08-24 be checked and prepared as follows:
D08-24 1. Lift up the valve with the engine room crane

(whereby the valve may open).
2. Connect compressed air to the air cylinder

to close the valve:
• Check that a 1.0 mm feeler gauge can be

inserted about 15 mm into gap G3, to
ensure that there is a clearance between
the outer parts of the seating faces of
valve housing and spindle.
GW908-2.1 241 01
• After shutting-off the compressed air

supply and releasing the air through the
G3 non-return valve on the air cylinder, the
exhaust valve should open.
2.
Hint!
Use a small screwdriver to press the ball

Compressed Air into the non-return valve, and cover it
with a rag to catch the oil drops.
• After doing this a couple of times, leave

the valve closed, and shut-off the com-
pressed air.
If the exhaust valve opens within 15 min-

utes, check for air leakages around the air
spring.
GW908-2.4 241 02
Connect compressed air to 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)
MAN B&W Diesel A/S
Mounting
3. 3.
Note!
Before mounting the valve on the engine,

connect 7 bar working air to the air cylin-
der to keep the exhaust valve closed dur-
ing the mounting process.
Mount a new O-ring in the upper groove on

the bottom piece and a U-seal in the lower
groove. Compressed Air
Lubricate the sealing rings with vaseline

and the threads of the studs with anti-sei-
zure paste.
Copper Grease
Position the valve in the cylinder cover
bore, guiding it in accordance with the ex-
haust flange.
Vaseline
4. Mount the nuts and the hydraulic jacks.
Raise the pressure to the value stated in
Data and tighten the nuts.
GW908-2.4 241 03
For use of the hydraulic jacks, see also

Procedure 913-1.
Relieve the system of pressure, remove the

hydraulic jacks and high-pressure hoses,
4.
and fit the protective caps. D13-01
GW908-2.2 241 02
MAN B&W Diesel A/S
Mounting
5. 5. Connect the intermediate pipe to the flange

at the exhaust valve, mount and tighten the
screws.
Attach the insulation jacket.
6. Mount the cooling water outlet pipe on the

exhaust valve.
Mount the high-pressure pipe and the re-

turn oil pipe, see Procedure 908-1.4.
Mount the air pipe for the sealing air control

unit.
GW908-2.4 241 05
Connect the electrical plug for the position

sensor.
Open the lub. oil supply and the cooling wa-

ter supply to the exhaust valve.
6.
Disconnect the compressed air and con-
nect the normal air supply.
Caution!
The air supply to the exhaust valve must

always be connected before turning on
the oil supply to the exhaust valve
actuator.
7. Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908-1.1.
GW908-2.4 241 06
MAN B&W Diesel A/S
Exhaust Valve Actuator 108-3
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10803
108-3 Data 0035 Exhaust Valve Actuator
X Stopped engine
X Shut off fuel oil
Data
D08-32 Hydraulic actuator, tightening torque 470 Nm

D08-35 Hydraulic actuator 58 kg
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data
MAN B&W Diesel A/S
Exhaust Valve Actuator 908-3.2
Dismantling
Exhaust Valve Actuator
S50ME-C
0228
Dismantling
908-3.2
1.
1. Stop the engine and shut off the oil supply.

Note!

hydraulic system.
GW908-3.2 228 01
2. Close the valve 531 for the actuator oil sup-
ply, and valve 536 for damper piston oil sup-
ply.
3. Remove the hydraulic high pressure pipe,

see Procedure 908-1.2. 2.
Disconnect the oil pipes from the aft side of

the top flange.
GW908-3.2 228 02
3.
GW908-3.2 228 02B
MAN B&W Diesel A/S
908-3.2 Exhaust Valve Actuator
Dismantling
4. 4. Unscrew the nuts on the top flange of the

actuator.
Mount two eyebolts in the top flange of the

actuator.
5. Lift the actuator unit clear of the actuator

block.
Remove the sealing ring from the bottom

and discard it.
NA908-3.2 214 03
5.
D08-35
NA908-3.2 214 04
MAN B&W Diesel A/S
Overhaul
Overhaul
908-3.3
1. Remove the two screws which retain the 1.

top flange to the cylinder unit.
Lift away the top flange and discard the

sealing ring.
2. Place the actuator on the side. Push out the

upper piston with a brass mandrel.
3. Place the actuator upside down.
Remove the screws from the bottom flange.
GW908-3.3 228 01
Remove the bottom flange and the lower
piston.
Remove and discard the sealing ring.
GW908-3.3 228 02 2.
3.
GW908-3.3 228 03
MAN B&W Diesel A/S
Overhaul
4. 4. Clean all parts and check all running sur-

faces for abnormal wear and scores.
5. Lubricate the cylinder inside with lubricat-

ing oil.
Mount the lower piston in the bottom of the

cylinder.
Mount a new sealing ring.
Mount the bottom flange and tighten the

screws.
GW908-3.3 228 04
6. Lubricate the upper piston on all sliding sur-

faces.
Mount the piston from the top side of the

5. cylinder.
Mount a new sealing ring.
Mount the top flange and tighten the

screws.
GW908-3.3 228 05
6.
GW908-3.3 228 06
MAN B&W Diesel A/S
Mounting
Mounting
908-3.4
1.
Note!

hydraulic system.
D08-35
1. Check the oil hole and the face of the hy-
draulic block and the bottom of the hydrau-
lic actuator to see that they are clean and
free of impurities.
GW908-3.4 228 01
Mount two eye bolts in the top of the actu-
ator assembly and a new sealing ring in the
bottom groove.
Carefully land the actuator assembly on the 2.

hydraulic block.
2. Remove the eye bolts from the top flange.

D08-32
Mount the three nuts, and tighten to the
specified torque. See Data.
3. Mount and tighten the oil pipes for oil sup-

ply and for drains.
Mount the hydraulic high pressure pipe, see

Procedure 908-1.4.
GW908-3.4 228 02
3.
GW908-3.4 228 03A
MAN B&W Diesel A/S
Mounting
4. 4. Open the valve 531 for actuator oil supply

and open valve 536 for hydraulic damper
oil.
5. Close valve 421, and open valve 420 on the

hydraulic block.
GW908-3.4 228 03B
5.
D-6
GW908-3.2 228 01
MAN B&W Diesel A/S
Exhaust Valve - Tools Plate
P90861-0036
Exhaust Valve - Tools
0036
P90861
MAN B&W Diesel A/S
Plate Exhaust Valve - Tools
P90861-0036
Item Item
No. No.
010 *) Support grinding machine, complete
*) When ordering spare parts, please

refer to the Chris Marine manual
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0037
Exhaust Valve - Hydraulic Tools
0037
P90862
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0037
Item Item
No. No.
016 Wooden box

030 Support
077 Tommy bar
100 Stud setter
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0043
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0043

No. No.

030 Support
077 Tommy bar
090 Spanner
100 Stud setter
207 Hydraulic toolset, complete
MAN B&W Diesel A/S
Exhaust Valve - Extra Tools Plate
P90863-0009
Exhaust Valve - Extra Tools
0009
P90863
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0009
Item Item
No. No.
011 Worktable
MAN B&W Diesel A/S
909 Fuel Oil System
109-4 0044 Fuel Pump, Data

909-4 0223 Fuel Pump
109-5 0047 Fuel Pump Top Cover, Data
909-5 0224 Fuel Pump Top Cover
109-7 0030 Fuel Pump Suction Valve, Data
909-7 0215 Fuel Pump Suction Valve
10911 0050 Fuel Valve, Data
10912 0038 Spindle Guide , Data
90912 0222 Spindle Guide
10913 0031 Non-Return Valve in Fuel Pump, Data
90913 0204 Non-Return Valve in Fuel Pump
10914 0057 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pres Pipes
90951 0434 Fuel Valve and Fuel Pump - Panel
90961 0065 Fuel Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90981 0001 Mounting Tools - Top Cover Seals
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Fuel Pump 109-4
Data
SAFETY PRECAUTIONS
Special
D10904 Data 0044
109-4 Edition S50ME-C
Fuel Pump
X Stopped engine
X Shut off fuel oil
Data
D09-18 Pump housing nuts, tightening torque 460 Nm

D09-23 Top cover studs, screwing-in torque 100 Nm
D09-68 Fuel pump complete 146 kg
D09-69 Hydraulic plunger 18 kg
MAN B&W Diesel A/S
109-4 Fuel Pump
Data
P90951 69 Lifting tool for fuel pump

P90951 82 Lifting tool for fuel pump roller guide
MAN B&W Diesel A/S
Fuel Pump 909-4.2
Dismantling
Fuel Pump
S60MC-C
0223
Dismantling
909-4.2
1.
hydraulic block.
2. Close the fuel oil inlet valve.
Remove the fuel oil high pressure pipes,

see Procedure 909-14.2.
GW908-3.2 228 01
Disconnect the electrical sensor connec-
tion.
Remove the fuel oil inlet pipe.
Remove all drain pipes connected to the

2.
fuel pump.
Note!

hydraulic system.
3. Mount the fuel pump lifting tool on top of the

fuel pump.
GW909-4.2 223 02
(At this stage it is practical to loosen the

nuts for the top cover, in connection with
overhaul of the top cover.)
Loosen and remove the four nuts from the

fuel pump foot. Carefully lift the fuel pump 3.
clear of the hydraulic block.
Cover the hole in the hydraulic block, to

keep the hydraulic high pressure system
clean. D09-68
GW909-4.2 223 03
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
Overhaul
909-4.3
1. 1. Place the fuel pump on a wooden plate.
Remove the top cover, see Procedure 909-

5.2.
2. Mount the lifting handle in the top of the hy-

draulic plunger.
Lift up the plunger.

GW909-4.3 223 01
2.
D09-69
GW909-4.3 223 02
MAN B&W Diesel A/S
Fuel Pump 909-4.3
Overhaul
3. Clean the fuel pump housing and the hy- 3.

draulic plunger with kerosene or gas oil.
Place the fuel pump housing on one side.
Remove the two sealing rings from the cy-

lindrical part of the fuel pump and the seal-
ing ring from the bottom. Discard the
sealing rings.
Carefully clean the bottom of the fuel pump.
Inspect the hydraulic cylinder surface and
GW909-4.3 223 03
the hydraulic piston for wear and seizures.
Check the position sensor tip for damage.

The position sensor should only be re-
newed if it is not working properly.
4.
4. Mount new sealing rings in the hydraulic
cylinder.
For correct mounting, see the sketch.
Turn the fuel pump housing to an upright

position and place it on a clean piece of oil
paper.
5. Lubricate the cylinder (lower part) and the

hydraulic piston with proactive oil.
Mount the hydraulic piston.

GW909-4.3 223 04
Note!
All parts of the hydraulic high pressure

system must be kept absolutely clean 5.
and free of impurities.
In this case, pay particular attention to
the hydraulic piston and the lower part of
the pump housing.
MOS
MOS2
2
GW909-4.3 223 05
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul
6. 6. If any of the top cover studs have been re-

newed, tighten the studs with a stud setter
to the specified torque, see Data.
7. Mount the top cover and tighten the top

cover nuts to the specified torque. See Pro-
D09-23 cedure 909-5.4.
8. If the pump is stored before use, cover all

openings with plastic and apply preserva-
tion oil to all machined surfaces to prevent
corrosion.
GW909-4.3 223 06
7.
GW909-4.3 223 07
MAN B&W Diesel A/S
Fuel Pump 909-4.4
Mounting
Mounting
909-4.4
1.
Note!

hydraulic system. D09-68
1. If the fuel pump has been preserved for

storage, remove all preservation and plastic
covers.
Mount the lifting tool in the top of the fuel
GW909-4.4 223 01
pump.
Lift up the fuel pump, and check if the bot-

tom surface is clean and free of impurities.
Mount a new sealing ring if not already 2.

done.
2. Check that the face on the hydraulic block

is completely clean.
3. Land the fuel pump on the hydraulic block.
Mount and tighten the fuel pump housing

nuts to the specified torque. See Data.
GW909-4.4 223 02
3.
D09-18
GW909-4..4 223 03
MAN B&W Diesel A/S
909-4.4 Fuel Pump
Mounting
4. 4. Mount and tighten all drain pipes to the fuel

pump.
Mount the fuel oil inlet pipe.
Mount the fuel oil high pressure pipes, see

Procedure 909-14.4.
Mount the electrical sensor plug.
5. Open valve 420 and close valve 421 on the

hydraulic block.
Open the fuel oil inlet valve.

GW909-4.4 223 04
5.
GW908-3.2 228 01
MAN B&W Diesel A/S
Fuel Pump Top Cover 109-5
Data
SAFETY PRECAUTIONS
Special
D10905 Data 0047
109-5 Edition Fuel Pump
S50ME-C
Top Cover
X Stopped engine
X Shut off fuel oil
Data
D09-23 Top cover studs, screwing-in torque 100 Nm

D09-24 Top cover nuts, tightening torque 210 Nm
D09-26 Outlet seat, max. grinding diameter 18 mm
D09-27 Top cover 55 kg
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data
P90951 69 Lifting tool for fuel pump

P90951 82 Lifting tool for fuel pump roller guide
P90951 94 Milling tool for fuel oil pipe seats
P90951 320 Plunger locking tool
MAN B&W Diesel A/S
Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
S50ME-C
0224
Dismantling
909-5.2
1.
1. Close the fuel oil inlet valve.

hydraulic block.
2. Remove the fuel oil high pressure pipes,

see Procedure 909-14.2.
Remove the return oil pipe.
3. Unscrew the centre plug screw with left-

handed thread and remove the small disc.
GW909-5.2 224 01
Mount the retaining tool for the fuel plunger.
Unscrew the top cover nuts.
GW909-5.2 224 02 2.
3.
GW909-5.2 224 03
MAN B&W Diesel A/S
909-5.2 Fuel Pump Top Cover
Dismantling
4. 4. Mount the fuel pump lifting tool on the top

cover.
Carefully lift up the top cover assembly, and

land it on a wooden support.
D09-27
GW909-5.2 224 04
MAN B&W Diesel A/S
Overhaul
Overhaul
909-5.3
1. Land the top cover assembly on a wooden 1.

support.
D09-27
Unscrew the retaining tool for the fuel

plunger.
Carefully lift the top cover clear of the

plunger.
Remove and discard the sealing rings.
2. Remove the lifting tool and the retaining

tool from the top cover.
GW909-5.3 224 01
Unscrew and remove the suction valve from
the top cover.
3. Carefully clean and examine the top cover. 2.
Reconditioning of the seatings for the high-

pressure pipes is carried out by milling ac-
cording to the following procedure:
Fill the oil ducts in the top cover with Vase-

line or heavy grease.
During the work the miller is guided by the

guide screwed into the thread for the high-
pressure pipe.
GW909-5.3 224 02
Turn the miller by means of, e.g. a tap

wrench, while tightening the guide screw
lightly to provide a suitable pressure be-
tween miller and seat.
During the milling, add drilling oil emulsion 3. D09-26

liberally.
For the max. milling/grinding diameter of

the seat, see Data D09-26.
GW909-5.3 224 03
MAN B&W Diesel A/S
Overhaul
4. 4. After completing the milling, blow out the

Vaseline/grease from the oil ducts by
means of compressed air.
Warning!
Always use eye protection when working

with compressed air.
Clean the top cover with gas oil, and blow

dry with compressed air.
GW909-5.3 224 04
Unscrew the orifice plug for return oil.

Clean the plug and remount it.
5. Place the top cover on one side and clean

the bore for the fuel plunger in clean kero-
5. sene. Inspect the bore and plunger.
For evaluation of the fuel plunger/top cover

assembly, see Volume I, chapter 706.
Mount the suction valve, see Procedure

909-7.4.
The top cover and fuel plunger are matched

parts and must only be renewed as a set.
6. Turn the top cover to an upright position.

Place the retaining tool for the fuel plunger
GW909-5.3 224 05
in the centre hole and mount the lifting tool.
Place the plunger on a plane surface.
Apply a little clean grease to the inner hole

6. in the top cover and a thin layer to the
plunger.
Carefully lower the top cover onto the fuel

plunger, until the top cover rests on the
plunger.
GW909-5.3 224 06
MAN B&W Diesel A/S
Overhaul
7. Screw the retaining tool into the fuel plung- 7.

er, to lock the plunger in position.
Lift the top cover and mount two new seal-

ing rings as shown on the sketch.
GW909-5.3 224 07
MAN B&W Diesel A/S
Mounting
Mounting
909-5.4
1. 1. Mount the lifting tool on the new or over-

D09-27 hauled top cover assembly.
Lift the top cover assembly and apply

grease to the new sealing rings.
Check that the face on the fuel pump hous-

ing and the inside cylindrical part are clean
and free of fuel oil.
2. Carefully land the top cover on the fuel

pump.
GW909-5.4 224 01
Check that the guide pin in the top cover is

entering the hole in the fuel pump housing
for correct positioning.
3. Remove the lifting tool from the top cover.

2.
Unscrew and remove the retaining tool for
the fuel plunger.
Mount and tighten the top cover nuts to the

specified torque. See Data.
GW909-5.4 224 02
3.
D09-24
GW909-5.4 224 03
MAN B&W Diesel A/S
Mounting
4. Mount the small disc in the centre hole. 4.
Mount and tighten the centre plug with the

left-handed thread.
Mount the fuel oil high-pressure pipes, see

Procedure 909-14.4 .
Mount the return oil pipe.

hydraulic block.
GW909-5.4 224 04
Open the fuel oil inlet valve.
GW909-5.4 224 05 5.
MAN B&W Diesel A/S
Fuel Pump Suction Valve 109-7
Data
SAFETY PRECAUTIONS
Special
D10907 Data 0030
109-7 Edition Fuel Pump
S50ME-C
Suction Valve
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-33 Suction valve, tightening torque 250 Nm
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data
MAN B&W Diesel A/S
Fuel Pump Suction Valve 909-7.2
Dismantling
Fuel Pump Suction Valve
S50ME-C
0215
Dismantling
909-7.2
1.
1. Shut off the oil supply to the hydraulic ac-
tuator.

Shut off the fuel oil supply for the fuel pump.
2. Unscrew the union nut for the suction valve,

remove and discard the O-ring.
Pull out the suction valve.
GW908-3.2 228 01
2.
GW909-7.2 215 03
MAN B&W Diesel A/S
909-7.3 Fuel Pump Suction Valve
Overhaul
Overhaul
909-7.3
1. 1. Set up the suction valve in a bench vice

with “soft” jaws and press down the spring
by means of the cone to release the valve
spindle from the two-part conical ring.
Clean the parts thoroughly in clean diesel

oil and carefully dry.
2. Inspect the seat on the valve spindle and

the seat on the valve housing for damage.
If the seats are worn or damaged, a new

suction valve must be fitted.
GW909-7.3 215 01
It is not recommended to recondition the

valve by lapping. Lapping will damage the
seat geometry and lead to very limited run-
ning time for the valve.
2.
3. After cleaning and inspecting all the parts,
lubricate these with molybdenum disul-
phide (MoS 2) and assemble the suction
valve.
Check the seats for tightness by filling the

inlet hole with diesel oil and waiting 5 min-
utes. No oil may pass through the seats.
4. If the suction valve is not to be mounted on

the engine immediately after the overhaul,
cover all openings of the valve with plastic
GW909-7.3 215 02
to prevent dirt from entering the valve dur-

ing storage.
3.
GW909-7.3 215 03
MAN B&W Diesel A/S
Fuel Pump Suction Valve 909-7.4
Mounting
Mounting
909-7.4
1. Check that the face for the suction valve is 1.

clean.
Mount the overhauled or new suction valve.
2. Mount a new O-ring on the union nut.
Lubricate the O-ring and the thread on the

union nut with molybdenum disulphide
(MoS 2) grease.
Mount and tighten the nut to the specified

torque. See Data.
GW909-7.4 215 01
hydraulic block.
Open the fuel oil valve.

GW909-7.4 215 02 2.
D09-33
3.
GW909-5.4 224 05
MAN B&W Diesel A/S
Fuel Valve 109-11
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10911
109-11 Data 0050 Fuel Valve
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-40 Fuel valve opening pressure 330 - 380 bar

D09-41 Fuel valve tightening torque 25 Nm
D09-42 Inlet seat, max. diameter 18 mm
D09-43 Fuel valve 8 kg
MAN B&W Diesel A/S
109-11 Fuel Valve
Data
P90151 71 Dismantling tool for fuel valve

P90951 94 Milling tool for fuel oil pipe seats
P90951 165 Grinding mandrel for valve head
P90951 177 Grinding mandrel for thrust spindle
P90951 189 Grinding mandrel for holder - outside
P90951 190 Grinding mandrel for holder - inside
P90951 248 Hook wrench
P90951 297 Assembling tool for fuel valve
P90961 Fuel valve tester, complete
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
Fuel Valve
S50MEC
0235
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 Schedules. See
Chapter 900-1.
In order to obtain reliable results during testing
of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disassem-
bled, cleaned, inspected and re-assembled
befire testing. See Procedures 909-11.3 and
909-12.3.
GN909-11.1 204 01
Note!
In the event that the slide-type fuel valve

is pressure tested without being cleaned
between the fuel nozzle and the cut-off 2.
slide, the opening pressure value measu-
ered might be considerably lower than D09-41
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 7 bar can be used. Regarding
the operation of the pressure testing pump,
see the supplier’s instructions.
Note!
The high-pressure pump should be peri-

odically checked in accordance with the
supplier’s instructions.
Prescribed oil: Hydraulic oil (rust-prevent-

ing) with a viscosity of between 7 and 10
cSt at 50°C.
Note: use clean oil only.
GN909-11.1 204 02
2. Setting-up the fuel valve
Place the fuel valve in the test rig and se-

cure it with the tubular spacers and nuts.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
3. Tighten the nuts to the torque stated in Da-

ta. Mount the oil pipe between the pressure
testing pump and the fuel valve.
3. Pressure testing procedure

The subsequent items must be followed in
the sequence stated. Items 4, 6, 7 and 8
are each divided into the following four sub-
items:
A. Objective
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.
GN909-11.1 204 03
4. Flushing and jet control

A. Objective:
To remove air in the system and check the
fuel jet.
4.
B. Procedure:
The control handle must be in the OPEN
position. Slowly increase the working pres-
sure until straight jets of oil are ejected from
the nozzle 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
during normal engine operation – the fuel
oil will not necessarily flow from all of the
nozzle holes.
D. Cause of fault:
If the above point C is not fulfilled, the
cause may be:
GW909-11.1 235 04
• Dirt in the nozzle holes.

• The nozzle is not mounted correctly.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
5. Atomization test 5.
Note!
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
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
GW909-11.1 235 05
across the cut-off edge and the high con-
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.
6.
All of these conditions involve the risk of
seizure between the cut-off slide and the D09-40
nozzle.
6. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Increase the oil pressure until oil is admit-

ted through the nozzle holes.
Check the opening pressure on the pres-
sure gauge.
GN909-11.1 204 06
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
7. D. Cause of fault:
If the opening pressure is higher than spec-
ified in D09-40, the cause may be that a
wrong type of spring is used – replace the
spring on the thrust spindle, if necessary,
replace the complete thrust spindle.
If the opening pressure is lower than spec-

ified in D09-40, the cause may be that the
spring has sagged – replace the spring, or
add a special thin disc.
Note!
Special thin discs are available as

spares.
If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated from step 4.
7. Sealing test and sliding function
A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
B. Procedure:
The control handle must be in the OPEN po-
sition.
Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
GN909-11.1 204 07
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to

about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when

the fuel valve is full of oil.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
D. Cause of fault:
D.1 Sealing test

If oil flows out of the nozzle holes, the
cause is either:
• Defective spindle guide at needle seat, or

a sticking spindle. Examine and/or re-
place the spindle guide.
• Too quick pressure drop:

– the clearances of the movable parts,
both of the spindle guide and of the non-
return valve, are too large, or
– the seats between the thrust piece/

spindle in the spindle guide or thrust
piece/valve slide in the non-return valve
are damaged.
Examine and/or replace both the spindle

guide and non-return valve.
D.2 Sliding function

The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
There will always be an oil flow from the

GN909-11.1 204 07
leak oil outlet when the fuel valve is full of

oil.
If a quick pressure drop from 15 to 0 bar

cannot be registered:
• The valve slide is sticking; or
• the vent hole in the thrust piece is

blocked.
If so, disassemble and examine the spindle

guide, replace if necessary.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
8. 8. Pressure test, O-ring sealings
A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Build up a working pressure of about max.

10 bar until oil flows out of the leak oil out-
let.
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100

bar.
Move the control handle to the CLOSED po-

sition.
The built-up pressure of about 100 bar

should be maintained.
D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
GN909-11.1 204 08
MAN B&W Diesel A/S
Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2
1. Close the fuel oil inlet and outlet valves. 1.
Dismantle the high-pressure pipe. See Pro-

cedure 909-14.2.
Disconnect the return oil pipe from the fuel

valve.
2. Remove the nuts and the tubular spacers.
3. Take out the valve. If the valve is sticking,

use the fuel valve dismantling tool to pull
the valve clear of the top cover.
GW909-11.2 235 01
If the valve is not to be overhauled immedi-
ately, the valve should be immersed in die-
sel oil until overhauling.
GN909-11.2 204 02 2.
3.
D09-43
MN909-11.2 206 03
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
Overhaul
909-11.3
1. When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
A fore reassembly.
GW909-11.3 235 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.

GW909-11.3 235 02
3.
MN909-11.3 222 03
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
4. Pull the valve head clear of the valve hous- 4.

ing.
Remove the:
• Non return valve
• Thrust spindle parts
• Thrust foot
• Spindle guide and fuel nozzle
from the valve housing.
Remove and discard all the O-rings.
GW909-11.3 235 04
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
5. 5. Carefully clean and examine all surfaces of

the:
• Fuel valve housing
D09-42 • Fuel valve head
• Thrust spindle
If necessary, grind the seating surfaces by

means of the grinding mandrels supplied
and a fine-grain abrasive (such as Carbo-
rundum No. 500).
This grinding must only be carried out man-

ually.
After the grinding, wash the parts in gas oil

and blow clean by means of compressed air
to remove any remains of the grinding com-
pound.
In the event of more serious damage to the

seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.
Normally, the milling tool is turned by hand,

but it may be fitted in the chuck of a column-
type drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An am-
ple supply of cutting emulsion must be
used.
Note!
Take care not to exceed the maximum

diameter of the seat, see Data.
GN909-11.3 204 02
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
6. The complete spindle guide, including the 6.

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
Note!
Do not attempt to remove the fuel nozzle
GW909-11.3 235 06
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
7.
7. The non-return valve should be sent to an
authorised MAN B&W repair shop for over-
haul. If this is not possible, the non-return
valve may be overhauled on board.
8. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.
Carefully slide the spindle guide down into

GN909-11.3 204 04
the valve holder, and turn the nozzle until it

engages correctly with the guide pin. Check
that distance A corresponds to the meas-
urement taken before the valve was disas-
sembled.
8.
Note!
Make sure that the fuel nozzle engages

correctly with the guide pin in the fuel
valve housing. This can be ascertained
by attempting to turn the nozzle by hand
after mounting. It must not be possible to
turn the nozzle.
GW909-11.3 235 08
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
9. 9. Mount:
• the thrust foot
• the parts of the thrust spindle
• the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost

groove of the fuel valve housing.
Lubricate the thread of the valve head with

molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
10. Make sure that the guide pin between valve

housing and valve head is intact. Press the
valve head down into the valve housing and
check that the guide pin engages correctly
so as to prevent relative turning of the
GW909-11.3 235 09
parts.
10.
GN909-11.3 204 07
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
11. Assemble the valve by means of the union 11.

nut.
Place the valve in the valve holder in a drill-

ing machine.
Compress the fuel valve and the spring in-

side. Keep the valve compressed and tight-
en the union nut with a hook spanner.
After overhaul, the fuel valve must be test-

ed in the test rig.
12. If the fuel valve is not to be mounted in the

engine immediately after the overhaul, cov-
er all openings of the valve with plastic to
prevent dirt from entering the valve during
storage. MN909-11.3 222 09
MAN B&W Diesel A/S
909-11.4 Fuel Valve
Mounting
Mounting
909-11.4
1.
Note!
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover
and check the seating in the bore for marks
which, if any, must be eliminated.
(For reconditioning of valve bore in cylinder
GN909-11.4 204 01
cover, see Procedure 901-1).
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS 2).
2.
2. Mount the valve in position in the cylinder
D09-41 cover.
Mount the tubular spacers and nuts. Tight-

en the nuts as stated in Data.
3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.
Note!
GN909-11.2 204 02
It is recommended to overhaul the fuel oil

pipe before mounting.
3. Mount the overhauled fuel oil pipe. See

Procedure 909-14.4.
Mount and tighten the union nuts.
Reconnect the return oil pipe to the fuel

valve.
Turn on the fuel oil supply.

GW909-11.4 235 03
MAN B&W Diesel A/S
Spindle Guide 109-12
Data
SAFETY PRECAUTIONS
Special
D10912 Data 0038
109-12 Edition Spindle
S60MC-CGuide
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-12 Spindle Guide
Data
P90966- Fuel Valve Nozzle - Tools

P90968- 12 Probe light with magnifier, complete
MAN B&W Diesel A/S
Spindle Guide 909-12.3
Overhaul
Spindle Guide
S50ME-C
0222
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle

guides of the slide valve design.
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
Based on service experience it is recom-

mended to replace the complete spindle
guide after 8000 hours of operation.
1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.
Note!
GW909-12.3 222 02
The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.
2. Place the spindle guide in a bench vice pro- 4.

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.
3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
Note!
The pulling tool is not standard for all

engines, but may be delivered as an
optional extra.
4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.
Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
GW909-12.3 222 04
and the spindle guide and very carefully

force the fuel nozzle off the spindle guide.
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
5. 5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in kerosene or ‘Elec-

trocleaner’ and wipe dry with a clean piece
of cloth.
Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
magnification magnifying glass and an in-
spection lamp.
During the examination, pay special atten-

tion to the seating surfaces and sliding sur-
faces of the parts.
6. Remove any deposits or very fine scratches

by placing the spindle, thrust piece or spin-
dle guide respectively in a lathe, as shown,
and polishing with a very fine conventional
polishing linen ‘grade 360’.
GW909-12.3 222 05
Use also a little oil for the polishing (a

coarser polishing linen must absolutely
not be used).
6.
Note!
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be dam-
aged.
After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat
on spindle/guide. Use an inspection lamp
and an 8-10 times enlargement magnifying
glass.
MA909-6.2 111 05
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
MAN B&W Diesel A/S
Overhaul
7. Clean any carbon deposits from the central 7.

bore of the fuel nozzle by means of the spe-
cial brass brush. Clean the spray holes, us-
ing gas oil and the special drills supplied.
Note!
During this operation be very careful not

to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
the fuel nozzle.
Clean the fuel nozzle with kerosene and

wipe dry with a clean cloth.
Then test the spray holes with the test pin.

If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
GW909-12.3 222 07
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
Note!
It is recommended that the fuel nozzle is

changed whenever the spindle guide is
being overhauled.
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
9. 8. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybde-
num Disulphide (MoS 2), see Procedure
913-11.
9. Assemble the thrust piece, the spindle and

the spindle guide and carefully knock the
parts together using a soft hammer.
10. Shake the spindle guide back and forth.

The spindle with the cut-off slide must be
able to slide freely back and forth inside the
spindle guide, with a ‘clicking’ sound.
MN909-12.3 215 09
10.
GW909-12.3 222 10
MAN B&W Diesel A/S
Overhaul
11. Lubricate the sliding surfaces of the nozzle 11.

and the spindle with a little Molybdenum Di-
sulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Place the parts on the plane of a drilling

machine or hydraulic press and position the
mounting tool over the parts. Make sure
that all the parts are perfectly aligned.
Press the nozzle on to the spindle guide.
Note!
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
If no mounting tools are available, the noz-

zle can be mounted on the spindle guide
GW909-12.3 222 11
using a short piece of pipe.
Place the pipe around the nozzle, so that

the lower end of the pipe rests on the ‘foot’
of the fuel nozzle. Then press the parts to-
gether the same way as when using the
mounting tools.
Check that the spindle inside the spindle

guide is able to move freely, by ‘shaking’
the spindle guide.
12. If the spindle guide is not to be mounted in a

fuel valve immediately after the overhaul, cov-
er all openings of the spindle guide with plas-
tic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
Non-return valve 109-13
Data
SAFETY PRECAUTIONS
Special
D10913 Data 0031
109-13 Edition Non-return
S60MC-Cvalve
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-13 Non-return valve
Data
P90951 153 Flange for dismantling of non-return valve

P90968- 12 Probe light with magnifier, complete
MAN B&W Diesel A/S
Non-return valve 909-13.3
Overhaul
Non-return valve
MC/MC-C
0204
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 &

0
by new ones.
2. A
Place the non-return valve as shown in Fig.
1 in a bench vice provided with “soft” jaws,
and disassemble the non-return valve, us-
ing the disassembling tool and a hammer
as shown. B C D
2. Clean all the parts for the spindle guide in

gas oil and then blow clean.
Finally, clean in either gas oil, kerosene or

‘Electrocleaner', and blow the parts dry with
compressed air as shown in Fig. 2.

3. Now place the parts on clean, lint-free rags

and examine with an 8-10 times enlarge-

&
ment magnifying glass, and an inspection 0
lamp with magnifying glass as shown in Fig.

3. 3.

&
0
0$1% :'LHVHO$6
909-13.3 Non-return valve
Overhaul
4. 4. Examine the slide faces of movable parts

for coating. Vent slide B/housing A will be
too tight if there is a coating. (The letters A-
D refer to the letters/parts in Fig. 2).
Fix vent slide B and, subsequently, housing

A in a lathe as shown in Fig. 4 and remove
the coating by means of very fine conven-
tional polishing linen ‘grade 360'.
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
MC909-6.2 69 04
5. Check spring C for the thrust piece for out-

side wear marks. If defective, it should be
exchanged.
5. Check the seat on thrust piece D/vent slide,

and the seat on vent slide/housing. Use an
inspection lamp and an 8-10 times enlarge-
ment magnifying glass.
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
MC909-6.3 69 05
6. Mount the non-return valve as follows:
• Lubricate all movable parts with molyb-

denum disulphide (MoS2).
6.
• Place the loosely-assembled non-return
valve on the plane of a drilling machine,
with the tool positioned as shown in Fig.
6.
• Make sure that the thrust piece and the

other parts are perfectly aligned and that
the thrust piece is guided in the vent
slide.
• Press the handle until the housing and

thrust piece meet.
7. If the non-return valve is not to be mounted

in a fuel valve immediately after the over-
haul, cover all openings of the non-return
valve with plastic to prevent dirt from enter-
MC909-6.3 69 06
ing the valve during storage.
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 109-14
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10914
109-14 Data 0057 Fuel Oil High-Pressure Pipe
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-47 Fuel oil high-pressure pipe, tightening torque 100 Nm

D09-52 Fuel oil pipe 8 kg
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data
P90951 104 Milling tool for fuel oil pipe

P90951 116 Crowfoot wrench head
MAN B&W Diesel A/S
Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S35MC
0235
Dismantling
909-14.2
2.
High-Pressure Pipe with Double Pipe
1. Close the fuel oil inlet and outlet valves.
2. Unscrew the union nipple from the fuel

valve.
3. Unscrew the union nipple from the fuel

pump.
BM909-14.2 211 02
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.
3.
Note!
It is recommended always to overhaul

the high-pressure pipe before remounting
it on the engine.
The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.
GN909-14.2 210 03
4.
D09-52
BM909-14.2 211 04
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3
1. Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before re-
mounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed

as follows:
1. Lift up the union nut. Remove the spring

ring from the two-part sleeve. Remove the
sleeve.
KB909-7.1 77 01
2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.
2. Note!
The two pipe ends are of different

designs – see sketch.
Turn the upper tightening ring (A) until the

miller presses against the pipe end.
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
KB909-7.1 77 03
During the milling process, add drilling oil

emulsion liberally.
3. On both pipe ends a small groove has been

3. ground to indicate the maximum allowable
grinding of the pipe ends.
Max. grind-away
The pipe ends may only be ground until the
ground surface is flush with the bottom of
the groove.
If the pipe ends are still not in order, the

pipe must be discarded.
After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.
KN909-14.3 223 03
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 909-14.3
Overhaul
4. Remove and discard both the internal and 4.

external O-rings. Mount new O-rings.
Mount the two-part sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the high-pressure pipe.
KB909-7.1 77 04
0$1% :'LHVHO$6
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
Mounting
909-14.4
3. 1. Ensure that the fuel valve is fitted with a

D09-52 new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
BM909-14.4 211 03
Screw the union nipples onto the fuel valve

and into the fuel pump top cover, by hand.
Note!
4.
The nipples must be screwed by hand,
D09-47 as the threads of the union nipples, fuel
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should

only be done after both of the union nip-
ples have been screwed into position.
4. Use a crowfoot wrench and a torque span-

BM909-14.4 211 04
ner to tighten the union nipple at the fuel

valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque span-

ner to tighten the union nipple at the fuel
5. pump to the torque stated in Data.
6. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
D09-47
GN909-14.4 210 05
0$1% :'LHVHO$6
Fuel Valve and Fuel Pump Panel Plate
P90951-0434
MAN B&W Diesel A/S
Plate Fuel Valve and Fuel Pump Panel
P90951-0434

No. No.
010 Panel for tools

021 Name plate
069 Lifting tool for fuel pump barrel
070 Lifting tool for fuel pump housing
082 Lifting tool for fuel pump roller guide
094 Milling tool for fuel oil pipe
104 Milling tool for fuel oil pipe
116 Crowfoot spanner
153 Flange for dismantling of non return
valve
165 Grinding mandrel for fuel valve head
177 Grinding mandrel for holder - outside
189 Grinding mandrel for holder - inside
190 Grinding mandrel
200 Dismantling screw
250 Drift for spindle guide
320 Locking device
332 Cleaning tool for NC valve
MAN B&W Diesel A/S
Fuel Valve - Tools Plate
P90961-0065
Fuel Valve - Tools
0065
P90961
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0065
Item Item
No. No.
014 Test rig, complete

026 High-pressure hose
038 Rig fuel oil valve
051 Table
063 High-pressure pump
099 Gasket
109 Plug screw
110 Angle union
122 Hose
134 Cover, test rig
158 Connection piece, M36x2
183 Nut
195 Stud
MAN B&W Diesel A/S
Fuel Valve Nozzle - Tools Plate
P90966-0006
P90966
Fuel
0006 Valve Nozzle - Tools
For ordering new

cleaning tool;
please state the number
on the fuel nozzle.
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0006
Item Item
No. No.
059 Cleaning toolset for spray holes
MAN B&W Diesel A/S
Fuel Valve Nozzle - Tools Plate
P90966-0007
Fuel Valve Nozzle - Tools
0007
P90966
For ordering new

cleaning tool;
please state the number
on the fuel nozzle.
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0007
Item Item
No. No.
011 Tool box, empty

023 Extractor for fuel nozzle
035 Drift for fuel nozzle
047 Cleaning brush
202 Cleaning tool for fuel valve nozzle,
complete
MAN B&W Diesel A/S
Fuel Valve - Inspection Tools Plate
P90968-0001
Fuel Valve - Inspection Tools
0001
P90968
MAN B&W Diesel A/S
Plate Fuel Valve - Inspection Tools
P90968-0001
Item Item
No. No.
012 Probe light with magnifier, complete
MAN B&W Diesel A/S
Mounting Tools - Top Cover Seals Plate
P90981-0001
MAN B&W Diesel A/S
Plate Mounting Tools - Top Cover Seals
P90981-0001

No. No.
013 Cone
025 Pushing tool
037 Compression tool
049 Spacer ring
MAN B&W Diesel A/S
110-1 0040 Air Cooler Element, Data

910-1 0235 Air Cooler Element
110-2 0008 Non-Return Valve in Turbocharger, Data
910-2 0206 Non Return Valve in Tubocharger
110-3 0018 Auxilary Blower, Data
910-3 0219 Auxilary Blower
110-5 0009 Turbocharger Turbine, Data
910-5 0208 Turbocharger Turbine
110-6 0025 Water Mist Catcher, data
910-6 0221 Water Mist Catcher
91061 0071 Turbocharger System - Tools
91063 0017 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0001 Air Cooler, Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Air Cooler Element 110-1
Data
SAFETY PRECAUTIONS
Special
D11001 Data 0040
110-1 Edition Air Cooler
S50ME-CElement
X Stopped engine
Shut off fuel oil
Data
D10-04 Air cooler element, complete with covers, up to 1550 kg
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data
P91063 Air Cooler - Tools

P91066 Air Cooler - Lifting Tools
MAN B&W Diesel A/S
Air Cooler Element 910-1.1
Checking
Air Cooler Element
S50ME-C
0235
Checking
910-1.1
1.
1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the instruction book
Volume I, OPERATION, Chapter 706.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
GN910-1.1 207 01
the air side of the cooler.
A decrease in the air temperature drop

across the scavenge air cooler indicates
fouling of the water side of the cooler.
4.
3. If the measurements indicate fouling of the
water side of the air cooler element, the el-
ement must be dismantled and overhauled/
cleaned.
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 air

cooler.
GN910-1.1 207 04
5. Visually inspect the air cooler element

through the opening.
If the air side of the element is fouled, clean

the element using the spray pipe arrange- 5.
ment fitted above the air cooler element.
GN910-1.1 207 05
0$1% :'LHVHO$6
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2
2. 1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off the
cooling water.
2. Dismount the cooling water inlet and outlet

pipes from the end cover.
Remove and discard the gaskets.
3. Dismantle the screws and pull out the cool-

er element approx. 10 cm, using the dis-
mantling screws.
GN910-1.2 207 01
2.
GN910-1.2 207 02
3.
GN910-1.2 207 03
0$1% :'LHVHO$6
Dismantling
4. Mount the lifting bracket on the front end 4.

cover. D10-04
Attach two tackles to the lifting bracket, one
horizontally and one vertically.
Using the vertical tackle, lift the air cooler

element approx. 2-3 mm.
Using the horizontal tackle, pull out the air

cooler element approx. half a metre.
5. Mount the two guide rails on the frame
EN910-1.2 222 04
around the air cooler element.
6. Using the horizontal tackle, pull out the air

cooler element far enough to gain access to
the aft end cover.
5.
Mount two shackles in the upper corners of
the aft end cover.
Mount lifting wire ropes between the two

shackles and the lifting bracket, and hook
the engine room crane on to the lifting wire
ropes.
Remove the two tackles and lift the air cool-

er element away. Land the element on a
couple of wooden planks.
EN910-1.2 222 05
Note!
During the lift, take care not to damage

the air cooler element.
6.
D10-04
EN910-1.2 222 06
0$1% :'LHVHO$6
Overhaul
Overhaul
910-1.3
1. Cleaning the air side:
1. The air side of the cooler is cleaned by in-

jecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.
It is recommended to use one of the follow-

ing cleaning fluids, or a similar product.
• Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
GN910-1.3 207 01
• Product: 80B, produced by

Vecom Int., Maassluis, Holland
2. Do not start cleaning until the engine has

3. been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.
Remove the covers on the scavenge air re-

ceiver to let vapours escape.
3. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pres-
sure must be at least 0.7 bar.
4. Continue the cleaning process for at least

30 minutes. The time required depends on
DG910-5.1 62 01
the frequency with which cleaning is carried

out and on the chemical product used.
5. After cleaning, flush the cooler with clean

water until the water in the sight glasses ap-
pears clean and pure.
6. Inspect the air cooler element by removing

the cover of the scavenge air cooler hous-
ing.
0$1% :'LHVHO$6
Overhaul
Cleaning the water side 2.
1. Dismantle the air cooler element and re-

move it from the engine.
2. Dismantle the front end cover of the air

cooler element. Remove and discard the
gasket.
3. Dismantle the aft end cover of the air cooler

element. Remove and discard the gasket.
4. Clean the water side of the cooler element
GN910-1.3 207 02
(the inside of the tubes) using the cleaning
brush mounted on a drilling machine. Flush
the tubes with clean fresh water.
In the event of a leaking tube, plug both 3.

ends of the tube using a brass or copper
plug.
In the event of leakages between a tube

and the tube plate, roll the tube using the
tube expander.
5. Clean and check the inside of the front end

and aft end covers. If necessary replace the
corrosion blocks.
Note!
GN910-1.3 207 03
If damaged, the coating inside the covers

is to be repaired with the original coating
or a similar product.
4.
6. When cleaning is complete, mount new
gaskets and re-mount the front end and aft
end covers of the air cooler element.
7. Re-mount the air cooler element in the

scavenge air cooler housing.
GN910-1.3 207 04
0$1% :'LHVHO$6
Mounting
Mounting
910-1.4
1. 1. Lift the air cooler element and land the aft

end of the element on the guide rails
D10-04 mounted on the air cooler housing.
Hook a tackle on to the bracket at the front

of the air cooler element.
Remove the lifting wire ropes and shackles.
2. Push the air cooler element inwards ap-

prox. one metre.
Remove the guide rails from the air cooler

housing.
EN910-1.2 222 06
3. Clean the frame around the air cooler ele-

ment and the contact surface of the front
end cover.
2.
Apply a thin layer of silicone paste to the
frame around the air cooler element and the
contact surface of the front end cover.
Push the air cooler element fully into the air

cooler housing.
EN910-1.4 222 02
3.
EN910-1.4 222 03
Silicone
0$1% :'LHVHO$6
Mounting
4. Mount and tighten all the screws of the front 4.

end cover.
Remove the tackle and the lifting bracket

from the front end cover.
5. Mount the cooling water inlet and outlet

pipes on the front end cover.
6. Close the drain cocks and open the cooling

water inlet and outlet valves.
Note!
EN910-1.4 222 04
Remember to vent trapped air from the
air cooler element.
GN910-1.2 207 02 5.
6.
GN910-1.4 207 06
0$1% :'LHVHO$6
Non-Return Valve 110-2
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D11002
110-2 Data 0008 Non-Return Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-2 Non-Return Valve
Data
P91361 Combination Wrenches
MAN B&W Diesel A/S
Non-Return Valve 910-2.3
Overhaul
Non-Return Valve
S50MC-C
0206
Overhaul
910-2.3
1.
This procedure includes both the main non-re-
turn valve and the non-return valve for the aux-
iliary blowers.
Both sets of non-return valves are accessed via

the scavenge air receiver.
Note!
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
GN910-2.3 206 01
Main Non-Return Valve
1. Inside the scavenge air cooler housing, lift

up the valve flap of the valve that is to be
overhauled. 2.
2. Remove the screws behind the valve flap.

Remove the valve from the engine.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
Clean the valve shaft and the slide bearings

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybde-
num disulphide (MoS 2).
After the overhaul, it must be possible to

move the valve flap by the light touch of a
finger.
4. Assemble the valve and re-mount it in the

GN910-2.3 203 02
3.
GN910-2.3 203 03
0$1% :'LHVHO$6
910-2.3 Non-Return Valve
Overhaul
5. Non-Return Valve for Auxiliary Blowers
5. Inside the scavenge air cooler housing, lift

up the valve flap of the valve to be over-
hauled.
6. Remove the screws behind the valve flap.

Remove the valve from the engine.
7. Remove the spring pins from the valve shaft

and knock the valve shaft out of the valve
flap.
GN910-2.3 206 05
Clean the valve shaft, the slide rings and

the slide bearings inside the valve flaps. Lu-
bricate the valve shaft, the slide rings and
the slide bearings with molybdenum disul-
phide (MoS 2).
6.
After the overhaul it must be possible to
move the valve flap by the light touch of a
finger.
8. Assemble the valve and re-mount it in the

GN910-2.3 203 06
7.
GN910-2.3 203 07
0$1% :'LHVHO$6
Auxiliary Blower 110-3
Data
SAFETY PRECAUTIONS
Special Edition
D11003
110-3 Data 0018 Auxiliary
S50ME-C Blower
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-09 Weight of blower unit, complete * up to 800 kg

*) Depending on electric motor type and number of
cylinders of engine (size and capacity of auxiliary blower)
MAN B&W Diesel A/S
110-3 Auxiliary Blower
Data

MAN B&W Diesel A/S
Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
S50ME-C
0219
Overhaul
910-3.3
2.
1. Depending on the type of overhaul, discon-
nect the cable connections from one or both
blower motors.
The overhaul can be carried out either by

dismantling the complete blower unit or just
dismantling the individual blower wheel
which is to be replaced/overhauled.
2. Complete Blower Unit
Hook a shackle and a tackle to the lifting

bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates.
Remove all screws in the outlet flange of

the blower unit.
D10-09
Remove all screws in the lower inlet flange
of the blower unit.
GN910-3.3 206 02
Remove all screws in the upper inlet flange

of the blower unit.
Lift away the blower unit and land it on

wooden planks for further dismantling/over-
haul.
0$1% :'LHVHO$6
910-3.3 Auxiliary Blower
Overhaul
3. 3. Blower Wheel
Remove the safety guard and the driving

belt.
4. Remove the screws in the blower flange

and lift away the blower flange complete
with blower wheel and bearing housing.
For overhaul of blower wheel and bearings,

see blower manufacturer’s instructions.
GN910-3.3 206 03
5. Electric Motor
The electric motors can be dismantled with-

out removing the blower housing.
4.
Remove the safety guard and the driving
belt.
Hook a shackle and a tackle to the motor.

It may be necessary to remove one or more
of the gallery plates.
Remove all screws in the flange of the mo-

tor.
GN910-3.3 206 04
Lift away the motor and land it on wooden

planks for further dismantling/overhaul.
0$1% :'LHVHO$6
Turbocharger Turbine 110-5
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D11005
110-5 Data 0009 Turbocharger Turbine
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
Data
MAN B&W Diesel A/S
Turbocharger Turbine 910-5.3
Cleaning
Turbocharger Turbine
0208
60(&
Cleaning
910-5.3
The dry cleaning method employs compressed

air to blow dry, solid, granules through the tur-
bocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.
On account of their hardness, nut-shells, or

broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.
Note!
We do not recommend the use of rice or

grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.
It is not always possible to remove thick depos-

its with this dry cleaning method.
Therefore, in order to prevent the build-up of

thick deposits, the turbine must be cleaned af-
ter every 24 to 50 hours of operation.
Generally, turbocharger cleaning can be carried

out without, or with very little, reduction of the
engine load.
More detailed information regarding the amount

of granules to be used is stated on the instruc-
tion plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger

turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.
0$1% :'LHVHO$6
910-5.3 Turbocharger Turbine
Cleaning
Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours

of operation, based on observations.
2. Preferably clean the turbocharger at full

load. Do not clean below half load.
3. Close valve A.
4. Open valves B and C, to blow out any de-

posits and/or condensate in the connecting
pipe.
HN910-5.3 207 01
After about two minutes, close valves B and

C.
5. Slowly open valve A to relieve the pressure

in the tank.
6. Fill the tank with the quantity of granules

specified in the table.
7. Close valve A.
8. Open valves B and C, to blow-in the gran-

ules. After one to two minutes, close valves
B and C.
9. Slowly open valve A to relieve the pressure

in the tank.
HM910-5.3 50 02
Caution!
1.The drain openings in the gas casings

must remain closed while dry cleaning
the turbine.
2. It is possible that during dry cleaning

of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.
0$1% :'LHVHO$6
Water Mist Catcher 110-6
Data
SAFETY PRECAUTIONS
Special Edition
S50ME-C
D11006
110-6 Data 0025 Water Mist Catcher
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-11 Water mist catcher 119 kg
MAN B&W Diesel A/S
110-6 Water Mist Catcher
Data

MAN B&W Diesel A/S
Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
S50ME-C
0221
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the
water mist catcher element from the scav-
enge air cooler housing. If, however, the
water mist catcher element has been fouled
or damaged, it must be dismantled for
cleaning or repair.
2. To dismantle the water mist catcher, dis-

mantle the water mist catcher cover and up-
per cover to give access to the air cooler
housing.
3. Via access through the upper part of the
EN910-6.2 214 02
scavenge air cooler housing, loosen the
four screws which press against the water
mist catcher.
4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the 3.
water mist catcher.
Attach a tackle to the eye bolt and tighten

up the tackle.
5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
EN910-6.2 214 03
4.
D10-11
GN910-6.2 205 06
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4
1. 1. Lubricate the two supports on the under-

side of the water mist catcher with plenty of
grease.
Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.
Note!
Make sure to mount the water mist

catcher correctly. See the sketch.
EN910-6.4 214 01
Air flow 2. Slide the water mist catcher into the scav-
enge air cooler housing.
2. When the water mist catcher is half-way in,

remove the tackle and the eye bolt, and
push the water mist catcher fully into the
3. Via access through the upper part of the

scavenge air cooler housing, tighten the
four screws which press against the water
mist catcher.
GN910-6.4 205 02
3.
EN910-6.4 214 03
0$1% :'LHVHO$6
Water Mist Catcher 910-6.4
Mounting
4. Clean the water mist catcher cover and ap- 4.

ply a thin layer of silicone paste along the
edges of the cover. Mount the cover.
Clean the upper cover and apply a thin lay-

er of silicone paste along the edges of the
cover. Mount the cover.
EN910-6.2 214 02
0$1% :'LHVHO$6
Turbocharger System - Tools Plate
P91061-0071
Turbocharger System - Tools
0071
P91061
MAN B&W Diesel A/S
Plate Turbocharger System - Tools
P91061-0071
Item Item
No. No.
014 Pulling tool

026 Lifting eye bolt
MAN B&W Diesel A/S
Air Cooler - Tools Plate
P91063-0017
Air Cooler - Tools
0017
P91063
Fore end
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0017
Item Item
No. No.
015 Guide rail, air cooler fore end,left

027 Guide rail, air cooler fore end, right
MAN B&W Diesel A/S
Travelling Trolley Plate
P91064-0002
Travelling Trolley
0002
P91064
When ordering this tool, please state load and track width.
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0002
Item Item
No. No.
010 Travelling trolley
MAN B&W Diesel A/S
Air Cooler - Lifting Tools Plate
P91066-0001
Air Cooler - Lifting Tools
0001
P91066
MAN B&W Diesel A/S
Plate Air Cooler - Lifting Tools
P91066-0001
Item Item
No. No.
011 Lifting attachment air cooler fore end,

complete
023 Screw
MAN B&W Diesel A/S
111-1 0024 Safety Valve, Data

911-1 0210 Safety Valve
111-2 0012 Relief Valve, Data
911-2 0211 Relief Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Safety Valve 111-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11101
111-1 Data 0024 Safety Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D11-01 Opening pressure 200±5 bar

D11-02 Valve housing, tightening torque 45 Nm
MAN B&W Diesel A/S
111-1 Safety Valve
Data
P90151 117 Test equipment for combined safety valve
MAN B&W Diesel A/S
Safety Valve 911-1.2
Dismantling
0210 Valve
Safety S42MC
Dismantling
911-1.2
1.
When Side-mounted
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.
BG901-2.5 90 01
BG901-2.5 90 02 2.
When Top-mounted 3.
3. Unscrew the safety valve from the cylinder
cover.
Remove and discard the mild steel disc.

HM911-1.2 205 01
0$1% :'LHVHO$6
911-1.3 Safety Valve
Overhaul (adjustment)
911-1.3
1. 1. If necessary, dismantle the safety valve and

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.
HM911-1.0 27 01
3. Then mount:
• the valve spindle
2. • the spring
• the adjusting screw
• the lock nut
D11-02
D11-02
HM911-1.0 27 02
3.
HM911-1.0 27 03
0$1% :'LHVHO$6
4. To set the safety valve opening pressure: 4.

D11-01
• Set up the safety valve in the testing
device.
• Connect the testing device to the hydrau-

lic pump.
• Loosen the lock nut on the safety valve.
• Turn the adjusting screw until the valve

just closes.
• Bleed the valve and hose until oil, without
HM911-1.0 27 04
air bubbles, flows out from the openings
of the safety valve.
• Tighten the adjusting screw of the safety

valve until the correct pressure is indi-
cated (see Data).
• Tighten the lock nut.
• Test the opening pressure.
• Remove the valve from the testing

device.
0$1% :'LHVHO$6
911-1.4 Safety Valve
Mounting
Mounting
911-1.4
1. When Side-mounted
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.
DM901-2.4 122 03
When mounting the safety valve, apply

tools only on the hexagon on the safety
valve.
2. Mount the guard surrounding the safety

valve.
BG901-2.5 90 04
3.
BG901-2.5 90 05
0$1% :'LHVHO$6
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-
HN911-1.4 205 01
gon on the safety valve.
HN911-1.2 205 01 5.
0$1% :'LHVHO$6
Relief Valve 111-2
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0012
111-2 Relief Valve
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
111-2 Relief Valve
Data
MAN B&W Diesel A/S
Relief Valve 911-2.1
Checking
60&
Relief Valve
0211
Checking
911-2.1
1.
1. During running of the engine, check if there
are any leaks.
If a leak occurs, replace the O-ring inside

the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical dam-

age to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
If one or more plates in the flame arrester

are damaged, the relief valve must be dis-
assembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
XZ911-2.1 209 01
Note!
The complete flame arrester has to be

2.
replaced after a crankcase explosion.
XZ911-2.1 207 03
0$1% :'LHVHO$6
112-2 0007 Holding Down and End Chock Bolts (Epoxy) , Data
912-2 0207 Holding Down and End Chock Bolts (Epoxy)
112-3 0015 Stay Bolts, Data
912-3 0210 Stay Bolts
91261 0064 Large Parts - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Holding Down and End Chock Bolts 112-2
Data

.0&
Special Data
112-2
0007 Holding Down and End Chock Bolts
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D-1 Tightening pressure for

holding down bolts and
end chock bolts 1500 bar
D-2 Check holding down bolts

and end chock bolts for cor-
rect tightening after the fol-
lowing service hours:
1st check 500 hours

2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequently at
intervals of 8000 hours
Engine on Epoxy supporting chocks
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data
Spare Parts
MAN B&W Diesel A/S
Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0207
Checking
912-2.1
Note!
The hydraulic jack used for tightening the

holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the

end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking
1. Checking the Bolt Tightening
1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking table, see drawing Nos.
782225-0 and 782226-2, following which
the bolts are tightened to the normal tight-
ening pressure.
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.
If the ‘loosening pressure' is below 80 per

EN912-1.1 205 01
cent of the tightening pressure, the relative

chocks shall always be checked for possi-
ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.
0$1% :'LHVHO$6
Holding Down and End Chock Bolts 912-2.1
Checking
Side Chocks and Side Chock Liners 3.
3. After fitting the liners to an 80 per cent con-

tact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simulta-
neously.
The first time the ship is sailing in a fully-

loaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.
GN912-2.1 203 03
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
The feeler gauge is applied at the 7 points

indicated on drawing No. 782226-2, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated on

drawing No. 782226-2.
If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Stay Bolts 112-3
Data

Special Data
S50MC-C
0015
112-3 Stay Bolts
X Stopped engine
Engage turning gear
Shut off fuel oil 1x3m
2x1m
Data
D-1 Check measurement 148 mm
D-2 Hydraulic pressure

– mounting 1500 bar
D-3 Hydraulic pressure

– dismantling 1400-1650 bar
MAN B&W Diesel A/S
112-3 Stay Bolts
Data
Spare Parts
MAN B&W Diesel A/S
Stay Bolts 912-3.1
Checking
Stay Bolts
K98MC
0210
Checking
912-3.1
1.
1. This check can be performed during several
periods of stopped engine, but must be per- One Group
formed on complete twin stay bolt groups at One Group
a time, thereby ensuring uniform tension in
the affected bearings.
Note!
The first time this check is performed it

has to be completed in one operation.
NA912-3.1 210 01
The following checks have to be com-
pleted within a 500-hour period.
2. Before retightening the stay bolts, remove

the protective caps. 2.
3. Check for loose staybolt nuts with the tom-

my bar.
If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 01
Loosen and unscrew the nut on the oppo-

site stay bolt.
Check for the correct mounting of the stay

bolt by comparing with the check measure-
ment on the Data Sheet, D-1. 3.
If the check measurement is not reached,

indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the '
thread in the top of the stay bolt, and turn
the stay bolt until D-1 is met.
GN912-3.0 39 09
4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.
GN912-3.1 202 03
0$1% :'LHVHO$6
912-3.1 Stay Bolts
Checking
5. 5. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
6. Maintain the mounting pressure, and

retighten the stay bolt nuts with a tommy
bar. Before relieving the system of pres-
sure, check with a feeler gauge that the
nuts bear against their contact faces.
GN912-3.1 202 02
7. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below the mounting pressure and check
6. whether the nut is loose.
If the nut is not loose:

Tighten the stay bolts concerned to the
mounting pressure.
If the nut is loose:

Tighten all stay bolts once again to the
mounting pressure.
8. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 04
7.
HM912-3.0 28 05
0$1% :'LHVHO$6
Large Parts - Tools Plate
P91261-0064
Large Parts - Tools
0064
P91261
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0064
Item Item
No. No.
011 Wooden box

023 Hydraulic jack, complete
035 Support
047 Stud setter M52x5
059 O-ring with back-up ring 105/115mm
060 O-ring with back-up ring 85/95mm
072 Disc, round plain
084 Venting screw
096 Tommy bar
MAN B&W Diesel A/S
913 General Tools
913-1 0210 Hydraulic Tools

913-4 0201 Standard Tightening Torques
913-5 0205 Torque Spanner
913-6 0205 Tightening Gauge
913-7 0206 Screws and Nuts
91311 0204 Lubricating
91351 0037 Accessories - Hydraulic Tools
91356 0058 Lifting Tools, Etc.
91358 0013 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0035 Spanners
91366 0064 Instruments
91368 0004 Working Platforms
MAN B&W Diesel A/S

MAN B&W Diesel A/S
+\GUDXOLF7RROV
Hydraulic Tools
S60MC-C
0210
913-1
A. Snap-on coupling
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
L. Lifting tool

S. Clearance

U. Milled recess for feeler gauge

1
*
Studs or bolts provided with threads for attach-

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 and the cylinder cover, con-
sist of a jack with an internal thread to suit
the tool attachment thread on the stud or
bolt, and a spacer ring which is to be placed

under the jack and around the nut that is to

be loosened or tightened.

1
2. For the main bearings, the hydraulic tool *
consists of a double jack with two extension

studs. This jack is designed for the simulta-
neous dismantling of both nuts on one side
of the main bearing.
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3. For the cylinder cover, the hydraulic tool

consists of eight individual jacks suspended
from a common lifting tool. A spacer ring is
mounted below each jack using two spring
pins.
Operation of the cylinder cover jacks is

identical to the operation of the single hy-
draulic jacks.
4. The hydraulic jacks are so designed that, in

the event that the “Max. lift” limit is 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,
1
*
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,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.
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Loosening of Nut
913-1
Single Hydraulic Jack
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.
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Max. lift 10 mm 25 mm
Loosening 1 turn 3 turn
Loosen the bleed screw in the jack and fill
Tightening 1/4 turn 1/4 turn
up the system with oil until oil without bub-
bles, flows out of the bleed hole. Then tight-
en the bleed screw again.
After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylin-
der of the jack.

1
+
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3. Increase the oil pressure to the prescribed

value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.
4. Unscrew the nut with the tommy bar, mak-

ing sure that the nut is not screwed up
against the jack.
5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.

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GN913-1.0 203 22
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FRPSUHVVHGDLU
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Always use protective gloves and eye

protection when working with com-
pressed air.
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Standard Tightening Torques 913-4
Standard Tightening Torques

0201
.0&&
913-4
When tightening screws or nuts for which no

torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a

Molybdenum Disulphide (MoS 2) based lu-
bricant.
Thread Tightening Thread Tightening

torque torque
M8 17 Nm M22 400 Nm
M10 35 Nm M24 460 Nm
M12 50 Nm M27 610 Nm
M14 80 Nm M30 950 Nm
M16 135 Nm M33 1200 Nm
M18 190 Nm M36 1650 Nm
M20 260 Nm M39 2100 Nm
2. Self-locking nuts.

torque torque
M8 20 Nm M22 430 Nm
M10 40 Nm M24 490 Nm
M12 60 Nm M27 650 Nm
M14 90 Nm M30 1000 Nm
M16 150 Nm M33 1250 Nm
M18 210 Nm M36 1700 Nm
M20 290 Nm M39 2200 Nm
3. Screws and nuts locked with glue/Loctite.

torque torque
M8 23 Nm M22 580 Nm
M10 50 Nm M24 680 Nm
M12 70 Nm M27 900 Nm
M14 115 Nm M30 1350 Nm
M16 190 Nm M33 1700 Nm
M18 270 Nm M36 2350 Nm
M20 380 Nm M39 3000 Nm
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Torque Spanner 913-5
/0&
Torque Spanner
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mix-
ture of graphite and oil or molybdenum disul-
phide with a friction coefficient µ = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are

to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened

to the stated torque and then to the next split-
pin hole.
The torque spanner must not be used for tor-

ques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided

with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,

there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle

appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl

system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the span-
ner, and a small click is heard.
When the torque spanner is not in use, the

spring inside should be released by adjusting to
minimum torque.
0$1% :'LHVHO$6
Tightening Gauge 913-6
Tightening Gauge
0205
913-6
Preparations
Before screwing on the nuts, grease the

threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
µ = 0.1–0.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tight-

ening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:

– thread M8 – M20 = 50 Nm
– thread M22 – M27 = 100 Nm
– thread M30 – M39 = 150 Nm
– thread M42 – M48 = 200 Nm
This is in order to ensure a uniform basis for the

subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge

round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 30°–45° and 60°,

we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,

respectively. Then tighten the nut until the two

marks coincide.

7
;

G
Q
D

When tightening new studs or bolts for the first

time, loosen again and repeat the procedure –

including pre-tightening with a torque spanner,

to allow the parts to settle. 0

+
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Screws and Nuts 913-7
Locking
Screws and Nuts
0206
.0&&
Locking
913-7
1
Some screwed and bolted connections on the
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
HM913-7.1 03 01
mounted with locking devices by the
engine manufacturer.
1. Lock washers, tab washers, locking plates,

etc., must always be replaced. The tab-like 2
projections, etc., on the washers are to be
bent back over one of the flats of the screw
or nut concerned.
HM913-7.1 03 02
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. 3
To tighten a self-locking nut to a specific
torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data sheet
HM913-7.1 03 03
of a procedure.
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913-7 Screws and Nuts
Locking
Locking wire should be fitted after the screws

or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. 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 lock-
ing wire. Do not secure more than four units in
a series, unless otherwise specified.
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-
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.
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
HM913-7.2 03 01
Fig. 4: Bend the lower wire around the screw,

and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it

min. 3 twists, counterclockwise until tight.
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes ori-
ented in different angles.
HM913-7.2 03 02
0$1% :'LHVHO$6
Screws and Nuts 913-7
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
around the protruding screw thread.
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure.
Fig. 13: Where drilling of locking wire holes has

caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.
Fig. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible. HM913-7.2 03 03
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Lubricating Procedures 913-11
Lubricating Procedures
0204
.0&&
913-11
Molybdenum Disulphide (MoS2)
The following procedure is to be followed prior

to the mounting of metal surfaced parts which
are to function as seals.
• Clean the surface with a cleaning fluid

and ensure that the entire surface is
completely free of grease.
• Allow 5 minutes for the cleaning fluid to

evaporate.
• With a clean leathercloth, and using cir-

cular movements, rub a mixture of fine-
grained particles of Molybdenum Disul-
phide (MoS2) and mineral oil (e.g. Moly-
cote G-n Plus, or the like) hard onto the
metal surface.
• Remove any excessive paste and ensure

that the metal surface is only coated with
a thin, uniform, layer of the above mix-
ture.
• Protect the wet paste and cloth from dust

or other foreign particles.
0$1% :'LHVHO$6
Accessories for Hydraulic Tools Plate
P91351-0037
Accessories for Hydraulic Tools
0037
P91351
Working Pressure 1500 bar
MAN B&W Diesel A/S
Plate Accessories for Hydraulic Tools
P91351-0037
Item Item
No. No.
010 Hydralic pump, pneumatic operated

022 Hydralic pump, hand operated
046 Hose with unions (1500mm), complete
105 2-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, Cu ø11x9mm
MAN B&W Diesel A/S
Lifting Tools, Etc. Plate
P91356-0058
Lifting Tools, Etc.
0058
P91356
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0058
Item Item
No. No.
020 Forged-bent screw shackle, 10mm

114 Lifting eye bolts, 10mm
210 Chain tackle, 500kg
295 Pull lift, 3000kg
305 Wire rope, 6m
MAN B&W Diesel A/S
Open Ended Spanners Plate
P91357-0005
Open Ended Spanners
0005
P91357
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0005
Item Item
No. No.
013 Open-ended spanner, size NV65mm

MAN B&W Diesel A/S
Open-Ended Slugging Spanners Plate
P91358-0013
Open-Ended Slugging Spanners
0013
P91358
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0013
Item Item
No. No.
127 Open-ended slugging spanner, size

NV65mm
MAN B&W Diesel A/S
Torque Spanners Plate
P91359-0003
Torque Spanners
0003
P91359
MAN B&W Diesel A/S
Plate Torque Spanners
P91359-0003
Item Item
No. No.
014 Torque wrench, 8 - 400Nm

026 Adapter for socket wrench, 10 x 12.5
mm
MAN B&W Diesel A/S
Pliers Plate
P91360-0003
P91360
Pliers
0003
MAN B&W Diesel A/S
Plate Pliers
P91360-0003
Item Item
No. No.
010 Pliers for retaining ring, size 0.9mm

MAN B&W Diesel A/S
Combination Spanners Plate
P91361-0052
Combination Spanners
0052
P91361
MAN B&W Diesel A/S
Plate Combination Spanners
P91361-0052
Item Item
No. No.
015 Combination spanners, size NV10mm

MAN B&W Diesel A/S
Ring Slugging Spanners Plate
P91362-0064
Ring Slugging Spanners
0064
P91362
MAN B&W Diesel A/S
Plate Ring Slugging Spanners
P91362-0064
Item Item
No. No.
022 Slugging spanners, ring size NV30mm

MAN B&W Diesel A/S
Spanners Plate
P91363-0035
P91363
Spanners
0035
MAN B&W Diesel A/S
Plate Spanners
P91363-0035
Item Item
No. No.
016 Tool set, complete size 12.7mm

028 Tool set, complete size 19.05mm
030 Box and Key set size 7-19mm
041 Adapter for socket wrench, size " hole
x 3/4" sq.
100 Socket spanner, sq. drive, size NV
46mm x 3/4" sq.
MAN B&W Diesel A/S
Spanners, Etc. Plate
P91364-0059
Spanners, Etc.
0059
P91364
MAN B&W Diesel A/S
Plate Spanners, Etc.
P91364-0059
Item Item
No. No.
011 Open ring wrench, 14 - 17mm

023 Open ring wrench, 19 - 22mm
MAN B&W Diesel A/S
Instruments Plate
P91366-0064
P91366
Instruments
0064
MAN B&W Diesel A/S
Plate Instruments
P91366-0064
Item Item
No. No.
048 Autolog, measuring tool for crankshaft

058 Feeler gauge
061 Slide caliper
MAN B&W Diesel A/S
Working Platforms Plate
P91368-0004
Working Platforms
0004
P91368
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0004
Item Item
No. No.
013 Foot grating, 800 x 250 x 40mm
MAN B&W Diesel A/S
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
S50ME-C VOLUME III
COMPONENTS
DESCRIPTION
900 Introduction

Table of Contents, VOLUME III
90001 0066 Cross Section through Engine
90030 0001 Description,comp.,Vol.III
MAN B&W Diesel A/S

MAN B&W Diesel A/S
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
Volume III - Components Description
No. Edition Title
900 Introduction
90001 0066 Cross Section through Engine
90030 0001 Description,comp.,Vol.III
901 Cylinder Cover

90101 0157 Cylinder Cover

90201 0204 Piston and Piston Rod
90205 0115 Piston Rod Stuffing Box

90301 0160 Cylinder Frame
90302 0184 Cylinder Liner and Cooling Jacket
90303 0006 Cylinder Frame - Details
90304 0037 Cylinder Liner - Details
90305 0134 Cylinder Lubricators
90307 0005 Cylinder Lubricator - Assy
90308 0012 Cylinder Lubricator - Intermediate Box
90309 0016 Cylinder Lubricator System - Details
90312 0001 Electronic Components - Cylinder Lubrication

90401 0160 Connecting Rod and Crosshead
90403 0008 Lubricating and Cooling Oil Flow

90501 0163 Crankshaft
90502 0050 Arrangement of Fore End
90504 0002 Axial Vibration Monitor
90505 0149 Thrust- and Guide Bearing
90506 0001 Arrangement of Fore End with PTO
90507 0004 Trigger Rings and Pick-ups
90510 0122 Turning Gear
90511 0045 Turning Wheel
90512 0002 Turning Gear - Details
90513 0021 Tacho Equipment

90600 0111 Arrangement of Chain Drive and Camshaft
90612 0086 Arrangement of Indicator System
90635 0001 Hydraulic Cylinder Unit

No. Edition Title
90636 0001 Hydraulic Cylinder Unit - Details

90639 0001 Hydraulic Power Supply - Drive, Details
90644 0001 Hydraulic Supply System, High pressure
90645 0001 Electronic Components - Engine Control System
90646 0001 Electronic Components - Lubrication System

90702 0060 Main Starting Valve
90704 0049 Starting Valve
908 Exhaust Valve

90801 0186 Exhaust Valve - Lower Parts
90802 0044 Exhaust Valve - Details
90803 0015 Exhaust Valve - Upper Parts
90804 0007 Exhaust Valve Upper Parts - Details
90806 0082 Valve Gear - Details
90807 0002 Exhaust Valve Actuator
90810 0079 Arrangement of Cooling Water Pipes
90811 0016 Arrangement of Freshwater Pipes
909 Fuel Oil System

90911 0017 Fuel Valve Function
90914 0080 Fuel Oil System
90915 0068 Fuel Oil System - Details

91000 0016 Turbocharger System
91002 0115 Arrangement of Charging Air Pipe
91003 0186 Exhaust Pipes and Receiver
91004 0052 Exhaust Receiver - Details
91005 0120 Air Cooler
91006 0035 Arrangement of Auxiliary Blower
91008 0006 Sealing Air System - Turbocharger
91009 0021 Air Cooler System - Cleaning
91010 0016 Air Cooler - Frame

91101 0037 Safety Valve - Cylinder
91102 0028 Relief Valve
91103 0015 Safety Valve - Scavenge Air System
91104 0080 Arrangement of Safety Cap

91201 0093 Arrangement of Stay Bolts

No. Edition Title
91204 0022 Frame - Details

91205 0166 Frame Box
91207 0081 Arrangement of Piston Cooling
91210 0167 Bedplate
91211 0065 Axial Vibration Damper
91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

Cross Section Through Engine Plate
P90001-0066
MAN B&W Diesel A/S
Engine Types 35-98MC Description
A90030-0001
S35MC
0001
Engine Types 35-98MC
A90030
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 im-
prove 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, start-
ing 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 sur-
rounding the cylinder cover and, further on, through the cooling bores,
to the space around the exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe:
On some engine types, an amount of water is also passed directly from

the cylinder cover to the exhaust valve housing through a cooling water
connection.
Tightening The cylinder cover is tightened against the top of the cylinder liner with
nuts and long studs fitted in the cylinder frame. The nuts are tightened
with hydraulic tools.
Sealing between the cylinder cover and cylinder liner is obtained by

means of a sealing ring of mild steel.
902 Piston with Rod and Stuffing Box
Piston The piston consists of two main parts:

• Piston Crown
• Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the
piston skirt is tightened to the piston crown.
When referring to this text, please quote Description A90030 Edition 0001 Page 1 (22)
MAN B&W Diesel A/S, Copenhagen
Description Engine Types 35-98MC
A90030-0001
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 pis-
ton 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 im-
prove the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel
off.
Piston Rod The piston rod has a through-going bore for the cooling oil pipe, which
is secured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guide-

shoe 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 tempera-
ture.
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 thick-
ness 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 (22) When referring to this text, please quote Description A90030 Edition 0001
MAN B&W Diesel A/S, Denmark
A90030-0001
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 lubricating oil in the crankcase from being drawn up into the
scavenge air space.
The stuffing box also prevents scavenge air (in the scavenge air space)
from leaking into the crankcase.
The stuffing box housing consists of two parts, which are bolted together.
Scraper/sealing rings The housing is provided with a number of machined ring grooves:
• The uppermost groove holds a scraper ring with oblique edges,
which serves to prevent sludge from the scavenge box from being
drawn down to the other rings.
Furthermore, a sealing ring is fitted below the scraper ring (except on

35MC type engines).
• The ring grooves in the middle are fitted with sealing rings.
• The lowermost ring grooves are fitted with scraper rings which
scrape the lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase
through bores in the stuffing box housing.
Through bores in the housing and a pipe, the stuffing box communicates
with a control funnel on the outside of the engine, which enables the sealing/
scraping performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear
against the piston rod even in worn condition.
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 tight-
ened together with the engine framebox and the bedplate by means of
stay bolts.
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
stuffing boxes.
On the exhaust side of the cylinder frame there are openings which con-
nect the scavenge air space around the cylinder liner with the longitudi-
nal scavenge air receiver of the engine.
A90030-0001
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 Studs for fastening the cylinder cover are mounted in the cylinder frame.
Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is sup-
Cooling Jacket plied at the lower part of the cooling jacket.
On slim-type liners, the water continues directly to the upper part of the
cooling jacket, whereas on the bore-cooled type liner, the water first
passes through the cooling bores. From the top of the cooling jackets,
the water flows through water connections to the cooling jacket on the
lower part of the cylinder cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by
the tensioning force from the cylinder cover studs being transmitted via
the cylinder cover.
Scavenge air ports The part of the cylinder liner which is located in the scavenge air space
of the cylinder frame is provided with a number of scavenge air ports,
which are uncovered by the piston when this is in its bottom position.
The scavenge air ports are bored at an oblique angle to the axis of the
cylinder liner so as to give the scavenge air a rotary movement in the
cylinder.
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 lubricating 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 cylinder 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 cyl-

Lubricators inder lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the spe-

cial instruction manuals supplied.
See also Volume I, OPERATION, Chapter 707.
A90030-0001
Crosshead The crosshead is provided with two guide shoes fitted on the crosshead
ends.
The centre part of the crosshead is designed as a bearing journal which
is housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston
rod to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The
lower shell is provided with an overlayer coating.
Piston rod foot The piston rod foot is fastened to the crosshead. To match different en-
gine layouts, 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 connecting rod – for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cyl-
inder 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
tightened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal
and assembled in the same way as the crosshead bearing.
905 Crankshaft and Turning Gear
Crankshaft The crankshaft is either of the semi-built type, where the parts are shrunk
together, or it is a one-piece forging.
The main bearings are lubricated via a main lubricating oil pipe that
branches off to the individual bearings, whereas oil for lubricating the
crankpin bearings is supplied from the crossheads through bores in the
connecting rods.
A90030-0001
The crankshaft is provided with a chain wheel for the camshaft drive and
a turning wheel. Furthermore, a tuning wheel, a torsional vibration damp-
er and a chain wheel drive for 2nd order and 4th order moment compen-
sators are installed, if required according to vibration calculations.
Marine engines (except geared plants):

At the aftmost end of the engine, a thrust bearing is fitted.
The thrust bearing serves the purpose of transmitting the axial thrust of
the propeller through propeller shaft and intermediate shafts to the 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 collar.
The thrust shoes rest on surfaces in the thrust bearing housing and are
held in place by means of stoppers or cross bars. The segments have
white metal cast onto the wearing faces against the thrust collar. See
also Volume I, OPERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the

engine. The oil is supplied between the segments through spray pipes
and spray nozzles.
The thrust bearing is provided with alarm, slow-down, and shut-down de-
vices 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 pur-
pose of the guide bearing is to keep the crankshaft in its proper position
in the axial direction.
Axial Vibration To counteract heavy axial vibrations, and any resultant adverse forces
Damper and vibrations, the crankshaft is provided with an axial vibration damper.
See also Section 912, “Assembly of large parts” further on in this text.
The damper consists of a ‘piston’ and a slit-type housing. The ‘piston’ is

made as an integrated collar on one of the main bearing journals, and
the housing is mounted on the pertaining main bearing support.
The axial movement is damped as a result of the ‘restrictions’ incorpo-

rated 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 sys-
tem.
A90030-0001
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 equip-

ped 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 actu-
ated. This interlock prevents starting air from being supplied to the en-
gine as long as the turning gear is in the engaged position.
Warning!
During any dismantling of working parts of the

engine, the turning gear must be in the engaged
Dismantling
position in order to prevent outside forces from
of working
turning the engine, thus causing injuries to
parts:
personnel or damage to the machinery.
See Volume II, MAINTENANCE, ‘DATA’ pages.
The turning gear must be in the disengaged

Pressure
position during pressure testing of starting
testing of
valves, as a leaky valve may cause the engine to
starting
rotate, and damage the turning gear.
valves:
See Volume I, OPERATION, Chapter 703.
Chain Drive The camshaft with cams for operating the fuel pumps, exhaust valves
and indicator drive (option) is driven from the crankshaft through a chain
drive.
The chain drive consists of one or more roller chains running on chain
wheels fitted on the crankshaft and the camshaft. The chain is kept tight-
ened by a chain tightener placed in the chain casing between the crank-
shaft and the camshaft.
The long free lengths of the chain are guided by rubber-clad guide bars.
Lubricating oil is supplied through spray pipes fitted at the guide bars
and chain wheels.
A90030-0001
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 assem-
bled 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 roll-
er 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 delivered 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.
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 start-

ing the engine, and retighten the valve when the engine has reached
its normal service temperature.
PMI-System See separate instructions for operating the PMI-system (option).
Moment On the basis of calculations, the engine may be provided with flyweights
Compensators to counteract engine forces and moments.
A90030-0001
Caution!
If the chain drives for the compensators have been dismantled, the fly-
weights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly fitted moment compensators may excite heavy vibrations.
1st order moment Applicable on 4-cylinder engines. The moment compensator is arranged
as adjustable flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in

the main chain drive.
This moment compensator consists of a (new) chain-tightener wheel with
an incorporated flyweight and a flyweight rotating with the crankshaft.
2nd order moment Applicable on 4-5 and 6-cylinder engines. The moment compensator is
arranged as flyweights built into the main chain drive.
On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.
4th order moment The moment compensator is arranged as flyweights built into chain
drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.
Starting Air System The starting air system consists of the manoeuvring system and the start-
ing air components, which comprise:
• Main Starting Valve
• Starting Air Distributor
• Starting Valves
The manoeuvring system is of electric/pneumatic design.

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
A90030-0001
fitted as a by-pass for the large valve. Both valves are operated by pneu-
matic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted

for setting the slow-turning speed.
Furthermore, a non-return valve is incorporated to prevent blow-back in

the event of excessive pressure in the starting air line.
The main starting valve is equipped with a blocking device consisting of

a plate which, by means of a handwheel, can be made to block the ac-
tuators.
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, OPERA-
TION , Chapter 703, ‘Operations after arrival in port’.
Starting Air The starting air distributor controls the opening and the closing of the
Distributor starting valves.
Starting Valve The starting valve (spring-loaded) is fitted on the cylinder cover. It is con-
trolled 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 start-
ing 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.
A90030-0001
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 cov-
er.
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 dis-
charged from the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which
the cooling water space can be checked and cleaned.
Valve spindle The part of the spindle stem which travels within the sealing arrangement
of the air cylinder is coated with a wear resistant mixture of metal carbide
and super alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is fitted
which causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:

To enable checking the functioning of the exhaust valve while the engine
is running, a ‘lifting/rotation check rod’ is mounted on top of the hydraulic
cylinder on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom

positions of the check rod.
Note!
This check rod is only for checking purposes, and must not be perma-
nently 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-
2. Hydraulic piston
The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrange-
ment, designed to dampen the closing of the valve.
A90030-0001
Caution!
After the exhaust valve has been overhauled, it is important to check

the damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.
Air cylinder The air cylinder is mounted on top of the valve housing. Air for closing
the exhaust valve is supplied through a non-return valve to the space
below the piston.
A safety valve is mounted in the bottom of the air cylinder. The safety
valve is connected to the drain pipe which leads to the camshaft housing.
Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder
on top of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by
the piston in the hydraulic cylinder.
Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerat-
ing 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 Air A sealing air arrangement is fitted around the spindle shaft below the air
cylinder.
The sealing air is supplied from the air cylinder via a sealing air control
unit.
The sealing air will prevent the exhaust gas and particles from penetrat-
ing upwards and wearing out the running surfaces and polluting the
pneumatic system of the valve gear.
The oil content in the air from the air cylinder improves the service con-
dition of the sealing rings.
The sealing air control unit contains a valve which automatically cuts off
the air flow when the engine is in FINISHED WITH ENGINE status, and
a filter housing.
A90030-0001
Hydraulic Valve The exhaust valve is actuated by a cam on the camshaft through a hy-
Actuating Gear draulic 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 hy-

draulic cylinder on the exhaust valve by a high-pressure pipe.
Oil is supplied from the lubricating oil system through a non-return valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained
through a pipe connection.
Puncture Valve On 4-cylinder reversible engines as well as on 5-cylinder reversible

50MC engines, a puncture valve may be mounted on the exhaust valve
actuator. During starting, this valve prevents the exhaust valve from
opening during the first part of the actuator 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.
909 Fuel Oil System
Fuel Pump Each engine cylinder is equipped with its own fuel pump, which is mount-
ed 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.
A90030-0001
The pump housing contains the plunger and barrel. The plunger and bar-
rel are matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in

the milled keyway in the regulating guide. At the bottom it has a foot
which rests on a steel disc in the bayonet joint at the roller guide neck.
A clearance of approx. 0.1 mm between the plunger foot and the roller
guide permits turning of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing.
On the outside the regulating guide has a toothed rim to mesh with the
above-mentioned toothed rack at the base of the pump housing. The
toothed rim and toothed rack are marked with lines enabling the parts
to be positioned correctly after disassembly. The toothed rack is linked
together with the regulating gear of the engine through a spring-loaded
connection. Thus, in the event of a sticking pump plunger, the regulating
gear for the remaining fuel pumps will not be blocked.
The pump barrel is provided with oil cut-off holes, which are covered and
uncovered during the travel of the plunger within the barrel. This func-
tion, in conjunction with the turning of the plunger effected by the regu-
lating 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 re-
placed when they are eroded.
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 out-
side of the barrel and the pump cover to seal between pump barrel/pump
cover and housing.
A number of semi-circular shims are inserted between the top cover and
the pump housing. By removing or inserting such shims, the pump barrel
can be slightly lowered or raised in relation to the plunger, and in this
way the initial moment of fuel oil injection into the engine cylinder can
be adjusted, and the maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum
combustion pressure.
VIT-type fuel pumps:

The pump barrel is guided at the top and bottom of the pump housing.
Low friction sealing rings are fitted in grooves in the barrel to seal be-
tween barrel and housing. The barrel is provided with a drain bore be-
tween the sealing rings at the lower end.
A90030-0001
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 me-
chanically or electronically in relation to the engine load. The position of
the upper toothed rack determines the vertical position of the barrel rel-
ative 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 sys-
tem of the engine. In the event of actuation of the shut-down system,
and when STOP is activated, compressed air is supplied to the top of
the piston, causing the piston with pin to be pressed downward and keep
the suction valve in the open position. This will ‘puncture’ the oil flow to
the fuel valve. As long as the puncture valve is activated, the fuel oil is
returned through bores to the pump housing, and no injection takes
place.
Fuel Oil Injection During the suction stroke, the spring-loaded suction valve opens and the
delivery chamber is filled with oil. As soon as the plunger has covered
the cut-off holes during its upward movement in the pump barrel, the in-
jection commences through the fuel valves. The injection will last until
the cut-off holes are uncovered by the oblique cut-off edges of the plung-
er, 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 actu-
Actuating Gear ating gear for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is

transmitted through the roller guide to the plunger in the barrel of the
pump housing which – through the high-pressure pipes – is connected
with the fuel valves on the cylinder cover.
Reversible engines:
The roller guide of each fuel pump incorporates an angular displaceable
reversing link.
A90030-0001
Reversing is achieved by shifting the roller in the fuel pump drive mech-
anism 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 po-
sition without the aid of external forces. Each cylinder is reversed indi-
vidually, 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
Pressure Pipes pipe. The space between the pipe and the protective outer pipe commu-
nicates, 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,
Alarm UMS.
35-98MC:
Each fuel pump is, via drain pipes, connected to a common drain tank,
which incorporates a level switch. The drain tank is also equipped with
an overflow pipe, which has a small drain bore below, whereby oil from
small leakages can be drained to the outlet, without actuating the level
switch.
In the event of pipe fractures or major leakages in the system, the above-
mentioned bore will not be large enough to allow the increased oil quan-
tity to pass, and the oil level in the drain tank will rise until it reaches the
level of the overflow pipe. The rising oil level will cause the level switch
to set off an alarm.
50-98MC:
Alternatively to the common drain tank, the drain pipes on 50-98MC en-
gines can be connected to a diaphragm valve, which sets off an alarm
and activates the puncture valve in order to stop the fuel oil flow from
the pertaining pump.
On 60-98MC engines, which are provided with pneumatically operated

fuel pump roller guide lifting gear, automatic activation of the lifting gear
by the diaphragm valve can be arranged in order to stop the fuel oil flow
from the pertaining pump.
Fuel Valve The fuel valve consists of a valve head and a valve housing. Fitted within
the valve housing is a non-return valve and a spindle and spindle guide
with a pressure spring, and a nozzle.
The spindle may be provided with a cut-off slide. When the fuel valve is
fitted in the cylinder cover, the valve parts are tightened together by the
pressure from the securing nuts.
A90030-0001
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, leav-
ing 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 engine 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 uncovered, and oil starts to recirculate through the valve.
Air System The engine is supplied with scavenge air from one or more turbocharg-
ers, depending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger
and, through a common shaft, the turbine wheel drives the compressor
wheel.
The compressor draws air from the engine room, through the air filters.
From the compressor outlet, the air passes through the charging air pipe
to the charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.
The air cooler incorporates a water mist catcher, which is designed to

separate condensate from the air.
See also ‘Charging Air Cooler’ further on in this Section.
When the air has passed the water mist catcher, it is pressed into the
scavenge air receiver through non-return valves. The non-return valves
open by pressure from the turbocharger.
From the scavenge air receiver, the air flows to the cylinder through the
scavenge air ports when the piston is in the bottom position. When the
exhaust valves open, the exhaust gas is pressed into a common exhaust
gas receiver, from where the gas drives the turbine of the turbocharger
with an even and steady pressure
Scavenge Air The scavenge air receiver is a container having a large volume. The re-
Receiver ceiver is bolted on to the cylinder frame.
A90030-0001
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 open-
ings.
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 dis-
charge sides are connected to the scavenge air receiver. Separate non-
return valves are installed at the suction side or discharge side of the
auxiliary blowers, in order to prevent reversed air flow.
See also item, “Non-return valves”, further on.
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
auxiliary blowers load, the turbocharger is not able to supply enough air for the engine
process. In these cases a pressure switch will automatically start the
auxiliary blowers.
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” posi-
tion), unburned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box fire.
In order to avoid such a fire:

– obtain permission to stop the engine
– stop the engine
– remove any unburned fuel oil from the top of the pistons
– re-establish the supply of scavenge air
– start the engine
Note: the switch for the auxiliary blowers should be in

“AUTO” position during all modes of engine control, i.e.:
– remote control
– control from engine side control console.
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.
A90030-0001
Non-Return Valves It is of the utmost importance that the non-return valves of the auxiliary
blowers always function correctly and move easily. This can be checked
either by moving the valves manually in connection with the regular scav-
enge port inspections, or via locally placed inspection covers.
The non-return valves protect the blowers and engine during:

• Start-up of the auxiliary blowers
• Running with auxiliary blowers.
Starting the auxiliary blowers:

1. Owing to the relatively high starting current, the blowers start in 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.
Running with auxiliary blowers:

If an auxiliary blower fails during running, the non-return valve must
close to ensure the continued supply of fresh air to the engine. See
‘Starting the auxiliary blowers‘, Item 2, above.
Exhaust Gas From the exhaust valves, the exhaust gas is led to the exhaust gas re-
Receiver ceiver where the pulsatory pressure from the individual exhaust valves
is equalized and led to the turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the seating by flexible supports.

Compensators are inserted between the receiver and the exhaust
valves, and between the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before

the turbocharger.
The exhaust gas receiver and the exhaust pipe are insulated.
Charging Air The charging air cooler insert is of the block type. It is mounted in a
Cooler housing which is welded up of steel plates.
The cooler housing is provided with inspection covers.
The cooler is designed with an air reversing chamber which incorporates

a water mist catcher. The water mist catcher is built up of a number of
lamellas which separate the condensation water from the scavenge air
during the passage of the air flow.
A90030-0001
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.
Safety Valves, Each cylinder cover is provided with a spring-loaded safety valve which
Cylinder Cover is set to open at a pressure somewhat higher than the maximum firing
pressure in the cylinder.
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 pre-
vent 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.
A90030-0001
Warning!
Do not stand near crankcase doors or relief valves – or in corridors

near doors to the engine room casing in the event of an alarm for:
a) oil mist
b) high lube oil temperature
c) no piston cooling oil flow, or
d) scavenge box fire
Alarms b, c and d should be considered as pre-warnings of a possible

increasing oil mist level.
See also our Service Letter SL97-348/ERO.
Note!
If there has been a crankcase explosion, the complete flame arrester

of the relief valves must be replaced.
Safety Valve, The scavenge air receiver is fitted with a safety valve which is set to
Scavenge Air open should the pressure in the scavenge air receiver exceed a value
Receiver somewhat higher than the normal scavenge air pressure of the engine.
In some cases it may be necessary to open the valve manually, see

Volume I, Chapter 704, "Turbocharger Surging".
Safety Cap in Each starting valve inlet pipe is provided with a safety cap. The safety
Starting Air Line cap consists of a bursting disc enclosed by a perforated cylinder and a
perforated cover in order to protect any bystanders, in the event of a
burst.
The cover is provided with a check plate, which shows if the bursting disc
has been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure

in the starting air line, overhaul or replace the starting valve which
caused the burst, and fit a new disc.
If a new disc is not available immediately, turn the cover in relation to

the cylinder, in order to reduce the leakage of starting air. Fit a new
bursting disc and return the cover to the open position at the first oppor-
tunity.
A90030-0001
912 Assembly of large Parts
Bedplate The bedplate is made in one or more sections, depending on the number
of cylinders. If there are two or more sections, these are joined together
with fitted bolts. The bedplate consists of two welded, longitudinal girders
and a number of cross girders which support the main bearings. The
main bearings consist of steel shells, lined with bearing metal.
Each main bearing has one or two main bearing caps which are secured
by studs and nuts, designed for tightening with hydraulic tools.
The bedplate is fitted with an axial vibration damper. For the design and
functioning of the axial vibration damper, see Section 905 “Crankshaft”.
Marine engines (except geared plants):

The aft end of the bedplate incorporates the thrust bearing. See also
Section 905 “Crankshaft”.
Stationary engines (and geared marine plants):

The bedplate incorporates the guide bearing.
See also Section 905, “Crankshaft”.
Framebox A framebox is bolted on to the top of the bedplate. Like the bedplate,
the framebox consists of one or more sections. Together, the bedplate
and the framebox constitute the crankcase of the engine.
The framebox is fitted with steel-plate doors for access to the cross-
heads 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.
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.
901 Cylinder Cover
90101 0157 Cylinder Cover
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Cover Plate
P90101-0157
Cylinder Cover
0157
P90101
MAN B&W Diesel A/S
Plate Cylinder Cover
P90101-0157
Item Item
No. No.
018 Screw
031 Protective cap
043 Nut
055 Stud
079 Nut
080 Stud
092 Cylinder cover
102 O-ring
114 Cooling jacket
138 Nut
151 Distance pipe
163 Stud
187 Screw
MAN B&W Diesel A/S
90201 0204 Piston and Piston Rod

90205 0115 Piston Rod Stuffing Box
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Piston and Piston Rod Plate
P90201-0204
MAN B&W Diesel A/S
Plate Piston and Piston Rod
P90201-0204

No. No.
011 Screw
023 Screw
035 Screw
047 Locking wire
059 Screw
060 Screw
084 Piston ring
096 Piston ring
106 Piston ring
118 Piston crown
143 Pipe for cooling
155 Piston rod
167 D-ring
179 D-ring
180 Piston skirt
192 Screw
MAN B&W Diesel A/S
Piston Rod Stuffing Box Plate
P90205-0115
MAN B&W Diesel A/S
Plate Piston Rod Stuffing Box
P90205-0115

No. No.
013 Nut
025 Housing for stuffing box
037 Scraper ring
049 Scraper ring
050 Flange
062 Guide pin
086 Screw
098 Spring pin
121 Lamella
145 O-ring
157 Scraper ring
169 Sealing ring
170 Sealing ring
182 Screw
204 Fitted bolt
216 Housing for stuffing box, complete
241 Spring
253 Spring
MAN B&W Diesel A/S
90301 0160 Cylinder Frame

90302 0184 Cylinder Liner and Cooling Jacket
90303 0006 Cylinder Frame - Details
90304 0037 Cylinder Liner - Details
90305 0134 Cylinder Lubricators
90307 0005 Cylinder Lubricator - Assy
90308 0012 Cylinder Lubricator - Intermediate Box
90309 0016 Cylinder Lubricator System - Details
90312 0001 Electronic Components - Cylinder Lubrication
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Frame Plate
P90301-0160
Cylinder Frame
0160
P90301
MAN B&W Diesel A/S
Plate Cylinder Frame
P90301-0160
Item Item
No. No.
015 Screw
027 Protective cap
039 Nut
040 Stud for cylinder cover
052 O-ring
076 Cylinder frame
111 Screw
123 Cylinder frame
135 Packing
147 Screw
159 Protective tube
160 Sealing ring
172 Packing
196 Nut
206 Stud
218 Cover
231 O-ring
243 Screw
267 Cleaning cover complete
279 Nut
292 Stud
302 Screw
MAN B&W Diesel A/S
Cylinder Liner and Cooling Jacket Plate
P90302-0184
Cylinder Liner and Cooling Jacket
0184
P90302
MAN B&W Diesel A/S
Plate Cylinder Liner and Cooling Jacket
P90302-0184
Item Item
No. No.
010 Cooling jacket

022 Gasket
034 Piston cleaning ring
046 Cylinder liner
058 Packing
071 Plug screw
095 Clamp
105 Screw
117 O-ring
129 O-ring
142 Stud
154 Nut
166 Cooling water connection
178 Packing
201 Sealing ring
225 Screw
MAN B&W Diesel A/S
Cylinder Frame - Details Plate
P90303-0006
Cylinder Frame - Details
0006
P90303
MAN B&W Diesel A/S
Plate Cylinder Frame - Details
P90303-0006
Item Item
No. No.
016 Stud
028 Distance pipe
041 Nut
053 Distance pipe
065 Nut
077 Distance pipe
089 Stud
090 Screw
100 Distance pipe
112 Fitted bolt
124 Distance pipe
148 Intermediate piece
161 Screw
173 Distance pipe
185 Stud
197 Nut
207 Distance pipe
219 Stud
220 Guide pin
232 Stud
244 Distance pipe
256 Nut
268 Screw
281 Distance pipe
MAN B&W Diesel A/S
Cylinder Liner - Details Plate
P90304-0037
MAN B&W Diesel A/S
Plate Cylinder Liner - Details
P90304-0037

No. No.
011 Non-return valve

023 Housing
035 Valve
047 Head
MAN B&W Diesel A/S
Cylinder Lubricators Plate
P90305-0134
MAN B&W Diesel A/S
Plate Cylinder Lubricators
P90305-0134

No. No.
017 Screw
030 Steel pipe
054 Screw
066 Bracket
078 Distance pipe
091 Screw
101 Nut
125 Guard
137 Screw
150 Screw
162 Nut
186 Screw
MAN B&W Diesel A/S
Cylinder Lubricator Assy Plate
P90307-0005
Cylinder Lubricator Assy
0005
P90307
A A
MAN B&W Diesel A/S
Plate Cylinder Lubricator Assy
P90307-0005
Item Item
No. No.
018 Ball valve

031 Stud
043 Nut
055 Hydraulic block
079 Plug screw
092 Intermediate pipe
102 O-ring
126 Membrane accumulator
138 Shim
163 Coupling
187 Hydraulic block
209 Stud
210 Ball valve
234 O-ring
246 Mounting of pick-up, complete
271 Screw
295 Terminal box, complete
305 Screw
329 Membrane accumulator
330 Shim
354 Lubricator
391 Steel ball
401 Spring
413 Screw
437 O-ring
449 Union
462 Adjustment screw
474 Spacer
486 Cover
508 Screw
521 Screw
533 Cover
545 Cylinder block
557 O-ring
570 Spring
582 O-ring
604 Plunger
628 Hydraulic block
641 Actuator piston
665 Screw
677 Solonoid valve, complete
MAN B&W Diesel A/S
Cylinder Lubricator - Intermediate Box Plate
P90308-0012
Cylinder Lubricator - Intermediate Box
0012
P90308
MAN B&W Diesel A/S
Plate Cylinder Lubricator - Intermediate Box
P90308-0012
Item Item
No. No.
013 Electric enclosure, complete

037 Electric enclosure
049 Circuitboard assy
050 Screw
074 Diode
MAN B&W Diesel A/S
Cylinder Lubrication System - Details Plate
P90309-0016
Cylinder Lubrication System - Details
0016
P90309
MAN B&W Diesel A/S
Plate Cylinder Lubrication System - Details
P90309-0016
Item Item
No. No.
019 Steel pipe

020 Pipe holder
032 Screw
044 Steel pipe
056 Pipe holder
068 Coupling
081 Steel pipe
103 Steel pipe
115 Steel pipe
127 Coupling
139 Pipe holder
140 Distributor block
152 Screw
176 Coupling
188 Coupling
211 Steel pipe
223 Steel pipe
MAN B&W Diesel A/S
Electronic components cylinder lubri- Plate
cation P90312-0001
Electronic components cylinder lubrication
0001
P90312
MAN B&W Diesel A/S
Plate Electronic components cylinder lubri-
P90312-0001 cation
Item Item
No. No.
027 Master control unit

039 Circuit board
040 Backup control unit
MAN B&W Diesel A/S
90401 0160 Connecting Rod and Crosshead

90403 0008 Lubricating and Cooling Oil Flow
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Connecting Rod and Crosshead Plate
P90401-0160
Connecting Rod and Crosshead
0160
P90401
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead
P90401-0160
Item Item
No. No.
019 Plate
020 Screw
032 Locking wire
044 Screw
068 Connecting rod bearing, complete
081 Screw
093 Screw
103 Outlet pipe
115 Guide shoe
139 Guide strip
140 Crosshead bearing, lower part
152 Connecting rod
176 Screw
188 Shim
211 Crosshead bearing cap
223 Crosshead bearing, upper part
235 Guide pipe
247 Crosshead
260 Crankpin bearing cap
272 Dowel
284 Screw
306 Distance pipe
318 Bushing
331 Housing for stuffing box
343 Telescope pipe
355 Screw
379 Stud
380 Nut
402 Guide shoe, aft
414 Shim 0,25mm
426 Shim 0,50mm
438 Screw
451 Nut
463 Stud
475 Spring pin
487 Screw
509 Counterwight
510 Spring pin
MAN B&W Diesel A/S
Lubricating and Cooling Oil for Crosshead Plate
Crankpin and Main Bearing P90403-0008
0008
P90403
Lubricating and Cooling Oil for Crosshead Crankpin and Main Bearing
MAN B&W Diesel A/S
90501 0163 Crankshaft

90502 0050 Arrangement of Fore End
90504 0002 Axial Vibration Monitor
90505 0149 Thrust- and Guide Bearing
90506 0001 Arrangement of Fore End with PTO
90507 0004 Trigger Rings and Pick-ups
90510 0122 Turning Gear
90511 0045 Turning Wheel
90512 0002 Turning Gear - Details
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crankshaft Plate
P90501-0163
P90501
Crankshaft
0163
MAN B&W Diesel A/S
Plate Crankshaft
P90501-0163
Item Item
No. No.
012 Crankshaft
036 Intermediate ring
048 Packing ring
061 Cover
073 Screw
097 Nut
107 Stud
119 Gearwheel
MAN B&W Diesel A/S
Arrangement of Fore End Plate
P90502-0050
Arrangement of Fore End
0050
P90502
MAN B&W Diesel A/S
Plate Arrangement of Fore End
P90502-0050
Item Item
No. No.
018 Bolts and nuts, please see manufac-

turer’s manual
043 Counterweight
MAN B&W Diesel A/S
Axial Vibration Monitor Plate
P90504-0002
MAN B&W Diesel A/S
Plate Axial Vibration Monitor
P90504-0002

No. No.
019 Terminal box, complete

020 Steel pipe
032 Pipe holder
044 Screw
068 Elbow
081 Coupling
093 Elbow coupling
115 Bracket
127 Axial vibration monitor
MAN B&W Diesel A/S
Thrust and Guide Bearing Plate
P90505-0149
MAN B&W Diesel A/S
Plate Thrust and Guide Bearing
P90505-0149

No. No.
014 Screw
026 Lubricating oil pipe
038 Nut
063 Screw
075 Spray pipe
099 Segment stopper, fore
109 Segment
110 Segment
134 Oil throw ring, complete
146 Oil throw ring, lower part
158 Oil throw ring, upper part
171 Screw
205 Plug screw
217 Segment
230 Nut
242 Stud
254 Segment stopper, fore
266 Segment stopper, aft
291 Stud
301 Segment stopper, aft
325 Scraper ring housing, complete
337 Scraper ring housing, upper
349 Fitted bolt
350 Nut
362 Scraper ring housing, lower
374 Screw
386 Guide pin
445 Screw
469 Spray pipe
482 Scraper ring, complete
494 Scraper ring, upper
504 Fitted bolt
516 Cap screw
528 Nut
541 Scraper ring, lower
MAN B&W Diesel A/S
Arrangement of Fore End with PTO Plate
P90506-0001
Arrangement of Fore End with PTO
0001
P90506
See Manufacturer’s Manual
MAN B&W Diesel A/S
Plate Arrangement of Fore End with PTO
P90506-0001
Item Item
No. No.
021 Gasket
045 Distance pipe
057 Screw
069 Bracket
MAN B&W Diesel A/S
Trigger Ring and Pick-ups Plate
P90507-0004
MAN B&W Diesel A/S
Plate Trigger Ring and Pick-ups
P90507-0004

No. No.
015 Stud
027 Nut
040 Guide pin
052 Washer
064 Trigger ring
076 TDC ring
111 Stud
123 Distance pipe
135 Nut
147 Distance pipe
159 Stud
160 Screw
MAN B&W Diesel A/S
Turning Gear Plate
P90510-0122
Turning Gear
0122
P90510
MAN B&W Diesel A/S
Plate Turning Gear
P90510-0122
Item Item
No. No.
011 Screw
023 Distance pipe
035 Distance pipe
047 Nut
060 Turning gear
096 Gear wheel
106 Arrangement of disengaging device
131 Guide pin
MAN B&W Diesel A/S
Turning Gear Plate
P90511-0045
MAN B&W Diesel A/S
Plate Turning Gear
P90511-0045

No. No.
017 Screw
029 Fitted bolt
030 Nut, self-locking
054 Turning wheel
078 Pointer for dead center
101 Screw
113 Spring washer
125 Spring pin
MAN B&W Diesel A/S
Turning Gear - Details Plate
P90512-0002
Turning Gear - Details
0002
P90512
MAN B&W Diesel A/S
Plate Turning Gear - Details
P90512-0002
Item Item
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- special
264 Screw
276 Spring washer
311 Lever
323 Bush
MAN B&W Diesel A/S
Tacho Equipment Plate
P90513-0021
MAN B&W Diesel A/S
Plate Tacho Equipment
P90513-0021

No. No.
018 Screw
031 Distance pipe
055 Bracket
067 Washer
079 Screw
092 Bracket
102 Pick-up box*
114 Pick-up box*
126 Sensor*
138 Sensor*
163 Screw
175 Bracket*
187 Bracket*
199 Washer
209 Screw
210 Block
222 Bracket
246 Pull rod
258 Screw
283 Screw
295 Bracket
Note:
* When ordering this item, please

state pick-up name.
MAN B&W Diesel A/S
Tacho Equipment Plate
P90513-0022
MAN B&W Diesel A/S
Plate Tacho Equipment
P90513-0022

No. No.
018 Pick-up box

031 TDC indicator
043 Screw
055 Washer
079 Screw
080 Bracket
102 Dowel
114 Screw
126 Washer
MAN B&W Diesel A/S
90600 0111 Arrangement of Chain Drive and Camshaft

90635 0001 Hydraulic Cylinder Unit
90636 0001 Hydraulic Cylinder Unit - Details
90639 0001 Hydraulic Power Supply - Drive, Details
90644 0001 Hydraulic Supply System, High pressure
90645 0001 Electronic Components - Engine Control System
90646 0001 Electronic Components - Lubrication System
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Arrangement of Chain Drive and Camshaft Plate
P90600-0111
MAN B&W Diesel A/S
Arrangement of Indicator System Plate
P90612-0086
MAN B&W Diesel A/S
Plate Arrangement of Indicator System
P90612-0086

No. No.
016 Gasket
028 Stud
041 Nut, self locking
053 Extension
077 Screw
089 Lock washer
090 Guard
112 Extension
124 Gasket
136 Gasket
148 Connecting piece
161 Indicator valve, complete
173 Screw
185 Locking plate
197 Flange
MAN B&W Diesel A/S
Arrangement of Indicator System Plate
P90612-0087
MAN B&W Diesel A/S
Plate Arrangement of Indicator System
P90612-0087

No. No.
016 Junction box

028 Screw
041 Amplifier
053 Support
065 Screw
077 PMI software
089 PMI system users manual
100 Screw
112 Nut
124 Spring washer
136 Sensor complete
148 Connecting pipe
161 Pressure transducer, complete
185 Storage case
197 Junction box
207 Screw
220 Steel pipe
232 Amplifier
244 Screw
256 Run-out meter, electronic
268 Cable
281 PMI controller box
293 Pressure transducer, complete
MAN B&W Diesel A/S
Hydraulic Cylinder Unit Plate
P90635-0001
MAN B&W Diesel A/S
Plate Hydraulic Cylinder Unit
P90635-0001

No. No.
011 Flange
023 Screw
035 Steel pipe
047 Steel pipe
060 Hydraulic cylinder unit
072 Flange
084 Flange
096 Screw
106 Screw
118 Guide pin
131 Screw
155 Sealing pin
167 Sealing pin
179 Sealing pin
192 Base plate
202 Screw
MAN B&W Diesel A/S
Hydraulic cylinder unit - details. Plate
P90636-0001
Hydraulic cylinder unit - details.
0001
P90636
MAN B&W Diesel A/S
Plate Hydraulic cylinder unit - details.
P90636-0001
Item Item
No. No.
017 Coupling 593 Steel pipe

029 Coupling 603 Coupling
030 Coupling 627 Membrane accumulator
042 Steel pipe 639 Control valve, complete
054 Coupling 640 Steel pipe
066 Ball valve 652 Flange
078 Steel pipe 664 Sealing ring
091 Coupling 676 Screw
113 Coupling 688 Flange
125 Distributor block 711 Screw
149 Stud 723 Sealing ring
150 Nut 735 Valve spindle
162 Steel pipe 747 Sealing ring
174 Steel pipe 759 Valve spindle
198 Thrust piece 760 Stud
208 Retaining ring 772 Nut
221 Spring 784 Valve spindle
233 Valve spindle 796 Spring
257 Control valve, complete 806 Retaining ring
269 Pipe holder 818 Thrust piece
270 Screw
282 Flange
294 Screw
304 Sealing ring
316 Valve spindle
328 Sealing ring
341 Plug valve, complete
365 Valve
377 Sealing ring
389 Sealing ring
390 Coupling
400 Steel pipe
412 Screw
424 Lock washer
473 Top flange, complete
485 Return oil standpipe
497 Sealing ring
507 Coupling
519 Valve
520 Sealing ring
532 Coupling, complete
544 Steel pipe
556 Screw
568 Lock washer
581 Steel pipe
MAN B&W Diesel A/S
Hydraulic Power Supply - Drive, Details Plate
P90639-0001
Hydraulic Power Supply - Drive, Details
0001
P90639
MAN B&W Diesel A/S
Plate Hydraulic Power Supply - Drive, Details
P90639-0001
Item Item
No. No.
013 Coupling
025 Screw
037 Coupling
049 Screw
050 Angle encoder
062 Clamp
074 Hydraulic oil pump
098 Coupling
MAN B&W Diesel A/S
Hydraulic Supply System, High pressure Plate
P90644-0001
MAN B&W Diesel A/S
Plate Hydraulic Supply System, High pressure
P90644-0001

No. No.
010 Screw
058 Nut
071 Sleeve
083 Steel pipe
105 Sealing ring
117 Sealing ring
129 Flange
130 Sleeve divided
142 Retaining ring
166 Flange
178 Screw
191 Sealing ring
213 High pressure pipe
237 Flange
249 Plug screw
262 Flange
286 High pressure pipe, complete
MAN B&W Diesel A/S
Electronic Components - Engine Control System Plate
P90645-0001
MAN B&W Diesel A/S
Plate Electronic Components - Engine Control System
P90645-0001

No. No.
016 Multi purpose controller

028 Printed circuitboard assy
053 Amplifier
065 Amplifier
089 Screw
MAN B&W Diesel A/S
Electronic Components - Lubrication System Plate
P90646-0001
MAN B&W Diesel A/S
Plate Electronic Components - Lubrication System
P90646-0001

No. No.
011 Enclosure. complete

023 Screw
047 U-profile
059 Support
060 Screw
084 Enclosure, complete
096 Screw
106 Nut
118 Clamp
131 Nut
155 Angle profile
167 Screw
180 Enclosure, complete
192 Support
MAN B&W Diesel A/S
90702 0060 Main Starting Valve

90704 0049 Starting Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Main Starting Valve Plate
P90702-0060
Main Starting Valve
0060
P90702
MAN B&W Diesel A/S
Plate Main Starting Valve
P90702-0060
Item Item
No. No.
015 Locking plate

027 Screw
039 Screw
040 Switch
052 Packing ring
064 Screw
111 Spring
123 Nut
135 Air adjustment screw
147 Ball valve with actuator
160 Name plate "Working"
172 Name plate "Blocked"
184 Washer
196 Washer
206 Stud
218 Packing ring
231 Screw
267 Hand wheel
279 Pin
326 Screw
399 Nut
409 Screw
410 Nut
422 Disc
434 Ball valve with actuator
458 Housing
483 Housing
495 Screw
505 Starting air pipe
517 Screw
529 Distance pipe
530 Plate
542 Plug screw
554 Pin
566 Screw
578 Nut
591 Spindle
601 Nut
613 Starting air pipe
625 Plug
637 Packing ring
649 Packing ring
MAN B&W Diesel A/S
Starting Valve Plate
P90704-0049
Starting Valve
0049
P90704
MAN B&W Diesel A/S
Plate Starting Valve
P90704-0049
Item Item
No. No.
016 Screw
028 Cover
041 Packing
053 Valve housing
077 Spring
089 Distance pipe
090 Liner
100 Sealing ring
112 Valve spindle
136 Self-locking nut
161 Piston
MAN B&W Diesel A/S
908 Exhaust Valve
90801 0186 Exhaust Valve - Lower Parts

90802 0044 Exhaust Valve - Details
90803 0015 Exhaust Valve - Upper Parts
90804 0007 Exhaust Valve Upper Parts - Details
90806 0082 Valve Gear - Details
90807 0002 Exhaust Valve Actuator
90810 0079 Arrangement of Cooling Water Pipes
90811 0016 Arrangement of Freshwater Pipes
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Exhaust Valve - Lower Parts Plate
P90801-0186
MAN B&W Diesel A/S
Plate Exhaust Valve - Lower Parts
P90801-0186

No. No.
013 Exhaust valve housing

025 Spindle guide
037 Packing
049 Plug screw
062 Screw
074 Sealing ring
086 Guide pin
098 Cover
108 Packing
145 Screw
157 Flange
169 Screw
170 O-ring
182 Bottom piece
194 Sealing ring
204 Exhaust vave spindle
228 Sealing ring
MAN B&W Diesel A/S
Exhaust Valve - Details Plate
P90802-0044
Exhaust Valve - Details
0044
P90802
MAN B&W Diesel A/S
Plate Exhaust Valve - Details
P90802-0044
Item Item
No. No.
019 Packing
020 Disc
032 Orifice plug
044 Sealing air control unit
056 Screw
068 Coupling
081 Steel pipe
MAN B&W Diesel A/S
Exhaust Valve - Upper Parts Plate
P90803-0015
Exhaust Valve - Upper Parts
0015
P90803
MAN B&W Diesel A/S
Plate Exhaust Valve - Upper Parts
P90803-0015
Item Item
No. No.
014 Plug
026 Coupling
038 Eye bolt
051 Disc
063 Screw
087 Stud
099 Safety handrail
109 Flang
110 Piston, air cylinder
122 Piston
134 Oil cylinder
146 Plug
158 Cone
171 Piston
183 Nut
195 Plug screw
205 Plug
217 Sealing ring
229 Retaining ring
230 Air cylinder, complete
242 Screw
254 Inductive sencor
266 Sealing ring
278 Back-up ring
291 O-ring
313 Sealing ring
325 Plug screw
337 Banjo coupling
350 Packing screw
362 Plug screw
386 Plug
408 Cover
421 Sealing ring
433 Sealing ring
445 Guide ring for piston
470 Pison ring
MAN B&W Diesel A/S
Exhaust Valve, Upper Parts - Details Plate
P90804-0007
MAN B&W Diesel A/S
Plate Exhaust Valve, Upper Parts - Details
P90804-0007

No. No.
021 Gasket
033 Safety valve
MAN B&W Diesel A/S
Valve Gear - Details Plate
P90806-0082
MAN B&W Diesel A/S
Plate Valve Gear - Details
P90806-0082

No. No.
010 Thrust flange

022 Sleeve
034 Screw
046 Segment
058 Steel pipe
071 O-ring
083 Steel pipe
095 Pressure ring
105 Retaining ring
129 Sealing ring
142 Sealing ring
178 Coupling
191 Hydraulic pipe, complete
213 Steel pipe
225 Steel pipe
249 Coupling, complete
250 Steel pipe
262 Steel pipe
274 Support
286 Screw
298 Nut
308 Clamp
321 Flange
333 Screw
357 Packing
369 Sealing ring
MAN B&W Diesel A/S
Exhaust Valve Actuator Plate
P90807-0002
Exhaust Valve Actuator
0002
P90807
MAN B&W Diesel A/S
Plate Exhaust Valve Actuator
P90807-0002
Item Item
No. No.
016 Top piece

028 Coupling
041 Sealing ring
053 Piston
065 Middle piece
077 Sealing ring
089 Piston
090 Bottom piece
112 Screw
124 Screw
136 Hydraulic exhaust actuator, complete
MAN B&W Diesel A/S
Arrangement of Cooling Water Pipes Plate
P90810-0079
MAN B&W Diesel A/S
Plate Arrangement of Cooling Water Pipes
P90810-0079

No. No.
012 Screw
024 Nut
036 Packing
048 Orifice plate
073 Cooling water pipe
097 Packing
107 Screw
132 Pipe (inside valve housing)
156 Packing
168 Screw
181 Screw
193 Packing
239 Plug screw
252 Screw
288 Compensator
323 Butterfly valve
335 Screw
372 Packing
384 Screw
406 Cooling pipe
431 Orifice plate
443 Screw
455 Nut
MAN B&W Diesel A/S
Arrangement of Freshwater Pipes Plate
P90811-0016
MAN B&W Diesel A/S
Plate Arrangement of Freshwater Pipes
P90811-0016

No. No.
018 Screw
031 Nut
043 Packing ring
055 Orifice plate
079 Packing
080 Screw
114 Packing
126 Screw
138 Screw
151 Packing
163 Packing ring
175 Screw
199 Plug screw
222 Screw
234 Compensator
246 Butterfly valve
258 Screw
283 Freshwater pipe
305 Orifice plate
317 Screw
329 Nut
330 Freshwater pipe
342 Blank flange
354 Packing ring
MAN B&W Diesel A/S
909 Fuel Oil System

90911 0017 Fuel Valve Function
90914 0080 Fuel Oil System
90915 0068 Fuel Oil System - Details
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Fuel Valve Plate
P90910-0145
Fuel Valve
0145
P90910
MAN B&W Diesel A/S
Plate Fuel Valve
P90910-0145
Item Item
No. No.
016 Thrust piece

041 Cut-off shaft
053 Spindle guide
065 Nozzle
077 Spindle guide, complete
089 O-ring
090 Holder, complete
100 Guide pin
112 Union nut
124 O-ring
148 O-ring
161 Valve head
173 Guide pin
185 Spring
197 Non-return valve, complete
219 Thrust spindle
220 Spring
232 Spring guide
244 Thrust foot
950 * Disc
* Optional extras
* Optional extras
MAN B&W Diesel A/S
Fuel Valve Function Plate
P90911-0017
MAN B&W Diesel A/S
Fuel Oil System Plate
P90914-0080
MAN B&W Diesel A/S
Plate Fuel Oil System
P90914-0080

No. No.
018 Steel pipe

043 Steel pipe
055 Steel pipe
067 Steel pipe
080 Steel pipe
092 Packing ring
102 Screw
114 Fuel oil inlet
138 Ball valve
151 Fuel oil inlet
175 Screw
187 Nut
MAN B&W Diesel A/S
Fuel Oil System - Details Plate
P90915-0068
MAN B&W Diesel A/S
Plate Fuel Oil System - Details
P90915-0068

No. No.
013 Sealing ring

025 Piston
037 Spring
049 Screw
050 Valve cover
062 Nut
086 Valve housing
098 Valve housing
108 Sealing ring
121 Spring guide
133 By-pass valve
157 Drain box
169 Lever switch
170 Drain box
194 Shock absorber, complete
204 Spring guide
216 Stud
228 Nut
241 Locking plate
253 Packing
265 Housing
277 Spring
289 Sealing ring
290 Piston
300 Wearing ring
312 Packing
324 Screw
348 Flange
361 Stud
373 Spring
MAN B&W Diesel A/S
91000 0016 Turbocharger System

91002 0115 Arrangement of Charging Air Pipe
91003 0186 Exhaust Pipes and Receiver
91004 0052 Exhaust Receiver - Details
91005 0120 Air Cooler
91006 0035 Arrangement of Auxiliary Blower
91008 0006 Sealing Air System - Turbocharger
91009 0021 Air Cooler System - Cleaning
91010 0016 Air Cooler - Frame
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Turbocharger System Plate
P91000-0016
MAN B&W Diesel A/S
Arrangement of Charging Air Pipe Plate
P91002-0115
Arrangement of Charging Air Pipe
0115
P91002
MAN B&W Diesel A/S
Plate Arrangement of Charging Air Pipe
P91002-0115
Item Item
No. No.
012 Cover plate

024 Insulation material
036 Glass fibre cloth
048 Compensator
061 Plug screw
073 Packing
085 Charging air pipe
097 Cover plate
119 Nut
120 Washer
132 Screw
144 Plug screw
156 Screw
MAN B&W Diesel A/S
Exhaust Pipes and Receiver Plate
P91003-0186
Exhaust Pipes and Receiver
0186
P91003
MAN B&W Diesel A/S
Plate Exhaust Pipes and Receiver
P91003-0186
Item Item
No. No.
018 Insulation cover

031 Nut
043 Screw
067 Compensator
079 Packing
080 Blind rivet
092 Insulation material
102 Exhaust receiver
114 Grid
126 Manhole cove, complete
138 Packing
151 Heating shield
163 Wing nut
187 Plug screw
199 Packing
209 Screw
210 Packing
222 Plug screw
234 Plug screw
246 Packing
258 Hinge rod
271 Washer
283 Clamp
295 Distance pipe
305 Screw
329 Wing nut
342 Screw
354 Nut
366 Gas inlet
378 Packing
391 Screw
401 Screw
413 Locking washer
425 Nut
437 Packing
449 Stud
450 Split pin
462 Plug screw
474 Packing
508 Compensator
521 Plate
545 Heating shield
557 Packing
569 Plug screw
MAN B&W Diesel A/S
Exhaust Receiver - Details Plate
P91004-0052
Exhaust Receiver - Details
0052
P91004
MAN B&W Diesel A/S
Plate Exhaust Receiver - Details
P91004-0052
Item Item
No. No.
013 Distance pipe

025 Screw
037 Support
049 Nut
050 Screw
074 Spring pin
086 Spring pin
098 Clamp
108 Support
157 Distance pipe
169 Shim
170 Spring plate
182 Clamp
194 Spring pin
204 Washer
216 Screw
228 Screw
253 Nut
265 Support
277 Screw
MAN B&W Diesel A/S
Air Cooler Plate
P91005-0120
P91005
Air Cooler
0120
MAN B&W Diesel A/S
Plate Air Cooler
P91005-0120
Item Item
No. No.
019 *) Air cooler insert

044 *) Water mist catcher
*) When ordering spare parts for this

item, please state manufacturer's part
No.
MAN B&W Diesel A/S
Arrangement of Auxiliary Blower Plate
P91006-0035
Arrangement of Auxiliary Blower
0035
P91006
A
B
B B-B
A
A-A
MAN B&W Diesel A/S
Plate Arrangement of Auxiliary Blower
P91006-0035
Item Item
No. No.
014* Auxiliary blower

038 Shaft
051 Spring pin
063 Slide bearing
075 Sealing ring
087 Thrust disc
099 Support
109 Valve flap
110 Disc
122 Screw
146 Screw
158 Distance pipe
183 Screw
205 Valve flap
217 Holder
229 Shaft
*) When ordering spare parts, please

state manufacturer's part No.
MAN B&W Diesel A/S
Sealing Air System for Turbocharger Plate
P91008-0006
MAN B&W Diesel A/S
Plate Sealing Air System for Turbocharger
P91008-0006

No. No.
015 Coupling
027 Steel pipe
039 Lubrication oil pipe
052 Packing ring
064 Screw
076 Nut
088 Flange
135 Packing ring
147 Screw
159 Plug screw
172 Plug screw
184 Plug screw
196 Packing
206 Drain pipe
218 Packing
231 Screw
255 Coupling
267 Adaptors
279 Ball valve
280 Coupling
292 Packing ring
302 Screw
314 Nut
338 Drain pipe
MAN B&W Diesel A/S
Air Cooler System - Cleaning Plate
P91009-0021
MAN B&W Diesel A/S
Plate Air Cooler System - Cleaning
P91009-0021

No. No.
010 Packing ring

022 Screw
034 Nipple
046 Ball valve
058 Hose connection
071 Butterfly valve
083 Flange
095 Screw
117 Coupling
129 Coupling
130 Steel pipe
142 Coupling
154 Ball valve
166 Coupling
MAN B&W Diesel A/S
Air Cooler Frame Plate
P91010-0016
MAN B&W Diesel A/S
Plate Air Cooler Frame
P91010-0016

No. No.
016 Plug screw

028 Plug screw
041 Plug screw
053 Packing
065 Cleaning pipe
077 Spray nozzle
089 Stud
090 Nut
100 Plug screw
112 Plate
124 Screw
136 Plate
148 Screw
161 Nut
173 Cover
185 Screw
207 Cover
219 Screw
220 Cover
244 Screw
256 Distance pipe
268 Nut
281 Spring pin
303 Air cooler frame
315 Cover
327 Cover
340 Packing
352 Screw
364 Guard
376 Screw
MAN B&W Diesel A/S
91101 0037 Safety Valve - Cylinder

91102 0028 Relief Valve
91103 0015 Safety Valve - Scavenge Air System
91104 0080 Arrangement of Safety Cap
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Safety Valve - Cylinder Plate
P91101-0037
Safety Valve - Cylinder
0037
P91101
MAN B&W Diesel A/S
Plate Safety Valve - Cylinder
P91101-0037
Item Item
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
MAN B&W Diesel A/S
Relief Valve Plate
P91102-0028
Relief Valve
0028
P91102
P.C.D.
MAN B&W Diesel A/S
Plate Relief Valve
P91102-0028
Item Item
No. No.
016 Relief valve (P.C.D. 465mm)*

028 Screw*
030 Packing*
041 O-ring*
Note:
*When ordering, please state manu-
facturer of Relief Valve and
P.C.D. xxx mm
MAN B&W Diesel A/S
Safety Valve Plate
P91103-0015
Safety Valve
0015
P91103
4.7 Bar abs.
MAN B&W Diesel A/S
Plate Safety Valve
P91103-0015
Item Item
No. No.
011 Spindle
023 Washer
035 Spring retainer
047 Spring
060 Valve flap
072 Screw
084 Nut
096 Split pin
106 Castle nut
131 Seal
143 Valve seat
MAN B&W Diesel A/S
Arrangement of Safety Cap Plate
P91104-0080
Arrangement of Safety Cap
0080
P91104
MAN B&W Diesel A/S
Plate Arrangement of Safety Cap
P91104-0080
Item Item
No. No.
017 Plug screw

029 Gasket
030 Starting air pipe, complete
042 Screw
054 Gasket
066 Nut
078 Bursting cap, complete
091 Screw
101 Check plate
113 Wing nut
125 Screw
137 Washer
150 Bursting cap cover
162 Perforated cylinder
174 Housing
186 Bursting disc
198 Screw
208 Safety cap
MAN B&W Diesel A/S
91201 0093 Arrangement of Stay Bolts

91204 0022 Frame - Details
91205 0166 Frame Box
91207 0081 Arrangement of Piston Cooling
91210 0167 Bedplate
91211 0065 Axial Vibration Damper
91216 0009 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
P91201-0093
Arrangement of Stay Bolts
0093
P91201
MAN B&W Diesel A/S
Plate Arrangement of Stay Bolts
P91201-0093
Item Item
No. No.
014 Stay bolt, complete

026 Screw
038 Protective cap
051 Nut
075 Stay bolt
087 Guide bushing
MAN B&W Diesel A/S
Frame - Details Plate
P91204-0022
MAN B&W Diesel A/S
Plate Frame - Details
P91204-0022

No. No.

034 Damper-oil pipe
046 Damper-oil pipe
071 Bracket
083 Screw
095 Bracket
117 Nut
129 Stud
130 Screw
142 Pipe clamp
154 Screw
166 Screw
191 Pipe holder
213 Screw
225 Damper-oil pipe
286 Distance pipe
298 Stud
308 Nut
MAN B&W Diesel A/S
Frame Box Plate
P91205-0166
MAN B&W Diesel A/S
Plate Frame Box
P91205-0166

No. No.
016 Frame box

028 Sealing ring
041 Face
053 Screw
065 Screw
077 Face
089 Sealing ring
090 Face
100 Locking wire
112 Nut
124 Steel pipe
136 Cover
161 Distance pipe
173 Screw
197 Eye bolt
207 Screw
220 Screw
232 Distance pipe
244 Nut
256 Distance pipe
268 Fitted bolt
281 Stud
293 Spring
303 Wing nut
315 Door fastener
327 Frame box door
MAN B&W Diesel A/S
Arrangement of Piston Cooling Plate
P91207-0081
MAN B&W Diesel A/S
Plate Arrangement of Piston Cooling
P91207-0081

No. No.
017 Screw
029 Locking wire
042 Slotted pipe
054 Screw
078 Washer
091 Drain pipe
113 Sight glass
125 Drain box
149 Bracket
150 Screw
174 Clamp
MAN B&W Diesel A/S
Bedplate Plate
P91210-0167
MAN B&W Diesel A/S
Plate Bedplate
P91210-0167

No. No.
013 Nut
037 Stud
050 Screw
062 Bedplate
086 Main bearing cap
098 Spring pin
108 Main bearing, upper shell
121 Main bearing, lower shell
133 Screw
145 Locking plate
157 Grate
216 Screw
228 Cover plate
MAN B&W Diesel A/S
Axial Vibration Damper Plate
P91211-0065
Axial Vibration Damper
0065
P91211
MAN B&W Diesel A/S
Plate Axial Vibration Damper
P91211-0065
Item Item
No. No.
019 Spring
020 Spring
044 Screw
056 Restriction for damper
103 Screw
127 Oil seal in 2/2
139 Oil seal in 2/2
140 Guide pin
164 Nut
176 Nut
188 Stud
211 Stud
235 Axial vibration damper housing, com-
plete
259 Damper housing, upper part
260 Guide pin
272 Damper housing, lower part
MAN B&W Diesel A/S
Holding-Down Bolts and End-Chock Bolts Plate
P91216-0009
(Epoxy Chocks)
MAN B&W Diesel A/S
Plate Holding-Down Bolts and End-Chock Bolts
P91216-0009
(Epoxy Chocks)
No. No.
028 Screw
041 Washer
053 Locking plate
077 Liner for side chock, port side
089 Liner for side chock, starboard
100 Liner end chock
112 Spherical washer
136 Nut
148 Protective cap
173 Protectice cap
185 Nut
197 Distance pipe
220 Spherical nut
232 Holding-down bolt, M36 x 4
256 Stud for end chock bolt, M60 x 5.5
MAN B&W Diesel A/S

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Warning S900-1

Documents in this Chapter

90023 0027 Instructions for Main Engine

MAN B&W Diesel A/S

Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

MAN B&W Diesel A/S

No. Edition Title

901 Cylinder Cover

902 Piston with Rod & Stuffing Box

903 Cylinder Liner and Cylinder Lubrication

904 Crosshead with Connecting Rod

905 Crankshaft, Thrust Bearing and Turning Gear

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

No. Edition Title

105-1 0007 Crankshaft Deflection, Data

906 Mechanical Control Gear

907 Starting Air System

908 Exhaust Valve

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

No. Edition Title

908-3 0228 Exhaust Valve Actuator

909 Fuel Oil System

910 Turbocharger System

911 Safety Equipment

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

No. Edition Title

111-1 0024 Safety Valve, Data

912 Assembly of Large Parts

913 General Tools

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

Documents in this Chapter

101-1 0041 Cylinder Cover, Data

MAN B&W Diesel A/S

D01-01 Exhaust valve stud, screwing-in torque 680 Nm

Plate Item No. Description

P90151 46 Grinding tool for exhaust valve seat

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve D.

Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the air supply for the pneumatic ex-

2. Close valve 420 and open valve 421 on the

3. Close valves 531 and 536 for hydraulic op-

4. 4. Remove the cooling water inlet and outlet

Remove the drain pipe from the intermedi-

Remove the oil supply pipe for the hydraulic

Dismount the fuel oil high-pressure pipes

See Procedure 909-14.2.

Dismount the control air pipe from the start-

5. Remove the starting air pipe.

Disconnect the plug for the electrical ex-

5. Remove the exhaust valve high-pressure

Dismount the drain oil pipe from the ex-

6. Remove the protective jacket enclosing the

Remove the protective caps from the cylin-

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

Connect the high-pressure pump to the