2 Mantenance

Warning S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines’ Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
§94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
When referring to this page, please quote S900 Edition 0001 Page 1 (1)
MAN B&W Diesel A/S
S60MC-C VOLUME II
PS 09088198 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
90023 0027 Instructions for Main Engine
901 Cylinder Cover

101-1 0051 Cylinder Cover, Data
901-1 0232 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0101 Cylinder Cover - Tools
90165 0001 Cylinder Cover - Lifting Tools
902 Piston with Rod & Stuffing Box

102-1 0063 Piston, Data
902-1 0270 Piston
102-2 0047 Piston Rod Stuffing Box, Data
902-2 0221 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0107 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 Cylinder Liner and Cylinder Lubrication

103-1 0052 Cylinder Liner, Data
903-1 0244 Cylinder Liner
103-2 0023 Cylinder Lubricator, Data
903-2 0234 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90366 0007 Cylinder Liner - Lifting Tools
904 Crosshead with Connecting Rod

104-1 0046 Crosshead Bearing, Data
904-1 0237 Crosshead Bearing
104-2 0048 Crosshead, Data
904-2 0238 Crosshead
104-3 0033 Reciprocating Parts, Data
904-3 0212 Reciprocating Parts
104-4 0041 Crankpin Bearing, Data
904-4 0225 Crankpin Bearing
104-5 0042 Connecting Rod, Data
904-5 0230 Connection Rod
90451 0149 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90462 0034 Connecting Rod - Tools
90464 0005 Crosshead - Hydraulic Tools
MAN B&W Diesel A/S Page 1 (4)

No. Edition Title
90465 0001 Crosshead - Tools
905 Crankshaft, Thrust Bearing and Turning Gear

105-1 0006 Crankshaft Deflection, Data
905-1 0208 Crankshaft Deflection
105-2 0052 Main Bearing, Data
905-2 0245 Main Bearing
105-3 0044 Thrust Bearing, Data
905-3 0224 Thrust Bearing
105-4 0017 Journal Bearing, Data
905-4 0216 Journal Bearing
105-5 0037 Axial Vibration Damper, Data
905-5 0224 Axial Vibration Damper
105-8 0007 Angle Encoder, Data
905-8 0204 Angle Encoder
90551 0237 Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0127 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90570 0001 Thrust Shaft - Tools
90572 0005 Main Bearing - Measuring Tools
906 Mechanical Control Gear

106-1 0042 Chain, Data
906-1 0232 Chain
106-2 0037 Chain Tightener, Data
906-2 0230 Chain Tightener
106-3 0030 Camshaft, Data
906-3 0214 Camshaft
106-4 0029 Camshaft Bearings, Data
906-4 0218 Camshaft Bearings
106-5 0010 Moment Compensator, Data
906-5 0211 Moment Compensator
106-6 0005 Replacement of Cams On Camshaft, Data
906-6 0204 Replacement of Cams on Camshaft
90651 0185 Chain Drive and Camshaft - Panel
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
907 Starting Air System

107-1 0018 Starting Air Distributor, Data
907-1 0217 Starting Air Distributor
107-2 0034 Start Air Valve, Data
907-2 0216 Starting Air Valve

No. Edition Title
908 Exhaust Valve

108-1 0031 High-Pressure Pipe, Data
908-1 0216 High-Pressure Pipe
108-2 0059 Exhaust Valve, Data
908-2 0240 Exhaust Valve
108-3 0034 Exhaust Valve Actuator, Data
908-3 0227 Exhaust Valve Actuator
108-4 0031 Exhaust Valve Roller Guide, Data
908-4 0217 Exaust Valve Roller Guide
108-5 0010 Exhaust Valve Cam, Data
908-5 0214 Exhaust Valve Cam
108-7 0031 Exhaust Valve - Special Running, Data
90851 0165 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool
909 Fuel Oil System

90951 0432 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0007 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
910 Turbocharger System

110-1 0039 Air Cooler Element, Data
910-1 0234 Air Cooler Element
110-2 0007 Non-Return Valve in Turbocharger, Data
910-2 0215 Non Return Valve in Tubocharger
910-3 0218 Auxilary Blower
110-3 0017 Auxilary Blower, Data
110-4 0004 Butterfly Valve, Data
910-4 0207 Butterfly Valves
110-5 0008 Turbocharger Turbine, Data
910-5 0207 Turbocharger Turbine
110-6 0024 Water Mist Catcher, data
910-6 0219 Water Mist Catcher
91063 0017 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0005 Air Cooler, Lifting Tools

No. Edition Title
911 Safety Equipment

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 0009 Holding Down and End Chock Bolts (Epoxy) , Data
912-2 0207 Holding Down and End Chock Bolts (Epoxy)
112-3 0018 Stay Bolts, Data
912-3 0212 Stay Bolts
91261 0073 Large Parts - Tools
91266 0001 HydraulicTools - End Chock Bolts (IEpoxy Chocks)
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 0053 Lifting Tools, Etc.
91357 0007 Open-Ended Spanners
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0035 Spanners
91366 0065 Instruments
91368 0007 Working Platforms

Cross Section through Engine Plate 90001-54
S60MC-C
CHECKING AND MAINTENANCE PROGRAMME 900-1
and list of working procedures Edition 207
Page 1 (7)
The Checking and Maintenance Programme B. Condition-based overhauling

indicates the intervals at which it is deemed procedures
appropriate to inspect the individual compo- are those procedures which under the
nents of the engine and to carry out over- heading `Normal hours of service' are mar-
hauls, if necessary, based on the engine ked by O, and opposite which, under the he-
condition or on time criteria. ading Òverhaul to be based on procedure
No.', a procedure number is stated.
The procedures contained in the instruction
book are arranged in a logical order, and the This procedure number normally refers to
following Checking and Maintenance Pro- one of the above condition checking proce-
gramme can be used as a table of contents. dures which form the basis of the overhaul.
For this reason, the intervals stated are for
The stated `Normal hours of service' are only guidance only.
to be used as a guidance, as difference in
the actual service conditions, the quality of Where several procedures are to be carried
the fuel oil, lubricating oil, treatment of cool - out on the same estimation basis, and these
ing water, etc. will decisively influence th e belong together with regard to the work, this
actual service results, and thus the intervals is stated under the heading `Related proce-
between necessary overhauling. dure'.
Design modifications may necessitate a revi- C. Time-based overhauling procedures,
sion of the instructions, and in that case the
revised instructions and changed overhau- also marked by O under the headings `Nor-
ling intervals, if any, will apply and supersede mal hours of service' or `Based on observa-
those originally issued (see e.g our Service tions', are the procedures where an actual
Letters). basis for estimation is lacking. It is recom-
mended, therefore, to carry out these proce-
The procedures are divided into three cate- dures at the overhauling intervals stated as a
gories: basis.
A. Condition checking procedures, Where a symbol O or C is indicated under

the heading `Based on observations', this is
marked under the heading `Normal hours of
due to the fact that special service conditions
service' by C, deal with the service condition may make checking or overhauling neces-
of a number of engine components, and form sary beyond the actual programme.
the basis for estimating whether further over-
hauling is necessary. In a number of cases
the condition checking procedures refer to
Volume I, OPERATION, in which more detai-
led descriptions and working procedures can
be found.
Where a procedure number is stated under

the heading `Related procedure', it will be
appropriate to carry out this procedure at the
same time.
CHECK ING AND M AINTENANCE Norm a lhou rs
PRO G RAM M E ofs ervice 900-1
*) : See Vol. IOpera tion Edition 20 7
** ) : See m a k er´s ins tru ctions
*** ) : See s pecia lnotes Pa g e 2 (7)
S60MC-C C : Check the condition
O : Overha u lto be ca rried ou t
A : Adju s tm ent to be ca rried ou t
No. PROCEDU RE
901 CYLINDER COVER
-1 Cylinder cover
-1.2 Dismantling
-1.3 Overhaul O
-1.4 Mounting
902 PISTON WITH ROD AND STUFFING BOX
-1 Piston 901-1
-1.1 Checking *) C C
-1.2 Dismantling 901-1
-1.3 Overhaul *** ) O O
-1.4 Mounting
-2 Stuffing box
-2.1 Checking C
-2.3 Overhaul O
-2.4 Mounting
903 CYLINDER LINER AND LUBRICATION
-1 Cylinder liner 901-1

-1.1 Checking *** ) C C 902-1
-1.2 Dismantling
-1.3 Overhaul O O
-1.4 Mounting
-2 Cylinder lubricators
-2.1 Checking * ( ** ) C
-2.3 Adjustment A
904 CROSSHEAD WITH CONNECTING ROD
-1 Crosshead bearings 904-4

-1.1 Checking C 905-2
-1.2 Dismantling C O
-1.4 Mounting
-2 Crosshead
-2.2 Dismantling O
-2.4 Mounting
-3 Reciprocating parts
-3.1 Checking O
No. PROCEDU RE
-4 Crankpin bearings 904-1

-4.1 Checking C C 905-2
-4.2 Dismantling
-4.4 Mounting
-5 Connecting rod
-5.2 Dismantling O 904-1
-5.4 Mounting
905 CRANKSHAFT, THRUST BEARING

AND TURNING GEAR
-1 Deflection of Crankshaft
-2 Main bearings 904-1

-2.1 Checking 905-1 C C 904-4
-2.2 Dismantling C C
-2.4 Mounting A
-3 Thrust bearings
-3.1 Checking C C
-3.2 Dismantling C
-3.4 Mounting
-5 Axial vibration damper

-5.1 Checking C
-5.2 Dismantling
-5.3 Overhaul O
-5.4 Mounting
906 MECHANICAL CONTROL GEAR
-1 Chains
-1.2 Dismantling
-1.4 Mounting
-2 Chain tightener
-2.3 Adjustment A
-3 Camshaft
-3.1 Checking C C C
-3.3 Adjustment A
No. PROCEDU RE
-4 Camshaft bearings
-4.1 Checking C
-4.2 Dismantling
-4.3 Overhaul O
-4.4 Mounting
907 STARTING AIR SYSTEM
-1 Starting air distributor

-1.1 Checking C C
-1.3 Overhaul O
-2 Starting air valve

-2.1 Checking C
-2.2 Dismantling
-2.3 Overhaul O
-2.4 Mounting
908 EXHAUST VALVE
-1 High-pressure pipe
-1.2 Dismantling
-1.3 Overhaul O
-1.4 Mounting
-2 Exhaust valve
-2.1 Checking C
-2.2 Dismantling
-2.3 Overhaul ! Nimonic valve spindle C*) O
! valve spindle with hard facing O
*) When new exhaust valve is fitted
-2.4 Mounting
-3 Exhaust valve actuator

-3.1 Checking
-3.2 Dismantling
-3.3 Overhaul O
-3.4 Mounting
-4 Exhaust valve roller guide

-4.2 Dismantling
-4.3 Overhaul O
-4.4 Mounting
No. PROCEDU RE
-5 Exhaust valve cam

-5.1 Checking C
-7 Exhaust valve emergency running C
909 FUEL OIL SYSTEM
-1 Fuel pump lead

-1.1 Checking *) C
-1.3 Adjustment A
-2 VIT system
-2.3 Adjustment A
-3 Fuel pump cam

-3.3 Adjustment 909-1 A
-4 Fuel pump
-4.2 Dismantling
-4.3 Overhaul O
-4.4 Mounting
-5 Fuel pump top cover

-5.2 Dismantling
-5.3 Overhaul O
-5.4 Mounting
-6 Fuel pump barrel assembly

-6.2 Dismantling
-6.3 Overhaul O
-6.4 Mounting
-7 Fuel pump suction valve

-7.1 Checking C
-7.2 Dismantling
-7.3 Overhaul O 909-5
-7.4 Mounting
-8 Fuel pump puncture valve

-8.2 Dismantling
-8.3 Overhaul C O 909-5
-8.4 Mounting
-9 Fuel pump shock absorber

-9.1 Checking C
-9.3 Overhaul O
No. PROCEDU RE
-10 Lifting gear

-10.1 Checking C C
-11 Fuel valve

-11.1 Checking C C
-11.2 Dismantling
-11.3 Overhaul O
-11.4 Mounting
-12 Spindle guide

-12.3 Overhaul O
-13 Fuel valve non-return valve

-13.3 Overhaul O
-14 Fuel oil high-pressure pipe

-14.2 Dismantling
-14.3 Overhaul O 909-5
-14.4 Mounting
-15 Fuel pump roller guide

-15.1 Checking C
-15.2 Dismantling
-15.3 Overhaul O
-15.4 Mounting
910 TURBOCHARGER SYSTEM
-1 Air cooler element *)

-1.1 Checking
-1.2 Dismantling
-1.3 Overhaul O O
-1.4 Mounting
-2 Non-return valve
-2.3 Overhaul C O
-3 Auxiliary blower
-3.3 Overhaul O
-5 Turbocharger turbine
-5.3 Cleaning ** ) O
-6 Watermist catcher
-6.4 Mounting
No. PROCEDU RE
911 SAFETY EQUIPMENT
-1 Safety valve
-1.2 Dismantling
-1.3 Overhaul C O
-1.4 Mounting
-2 Relief valve
-2.1 Checking C O
912 ASSEMBLY OF LARGE PARTS
-1 Holding down bolts and end chock bolts,

cast iron
-1.1 Checking C C
-2 Holding down bolts and end chock bolts,

epoxy
-2.1 Checking C C
-3 Stay bolts
-3.1 Checking C C
913 GENERAL TOOLS
-1 Hydraulic tools
-5 Torque spanner
-6 Tightening gauge
-7 Screws and nuts ! locking
-11 Lubricating procedures
SPECIAL NOTES
Piston overhaul ! Section 902:

8000 h piston rings only
16000 h piston complete
Cylinder liner ! Section 903:

1000 + 2000 h inspection through
scavenge ports
8000 h measuring inside liner
901 Cylinder Cover
101-1 0051 Cylinder Cover, Data

901-1 0232 Cylinder Cover
90151 0205 Cylinder Cover - Panel
90161 0101 Cylinder Cover - Tools
90165 0001 Cylinder Cover - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Cover 101-1
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
X Lock the turbocharger rotors
Data
Ref. Description Value Unit
D01-01 Exhaust valve stud, screwing-in torque 450 Nm

D01-02 Starting valve stud, screwing-in torque 140 Nm
D01-03 Fuel valve stud, screwing-in torque 140 +/-20 Nm
D01-06 Cylinder cover, complete 2900 kg
D01-07 Cylinder cover without valves 2050 kg
D01-08 Cooling jacket 73 kg
D01-09 Exhaust valve stud 50 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar
When referring to this page, please quote Data D10101 Edition 0051 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
P90151 46 Grinding tool for exhaust valve seat

P90151 58 Milling and grinding wheel for fuel valve seat
P90151 60 Milling and grinding wheel for starting valve seat
P90151 83 Grinding handle
P90161 Cylinder cover tightening tool
P90165 Cylinder Cover - Lifting Tools
P91351 10 Hydraulic pump, pneumatic operated
P91351 34 Hose with unions (1000 mm), complete
P91351 130 9-way distributor block, complete
Page 2 (2) When referring to this page, please quote Data D10101 Edition 0051
MAN B&W Diesel A/S
Cylinder Cover 901-1.2
Dismantling
Cylinder Cover
L60MC-C
0232
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 valves E and F.
Open cooling water drain cocks G and H.
Shut off the control air and safety air supply.

Vent the manoeuvring system through the
ball valve.
Also shut off the air supply on the pressure

reduction unit for the hydraulic/pneumatic
exhaust valve, and vent the system.
HN901-1.2 206 01
When referring to this page, please quote Procedure M90101 Edition 0232 Page 1 (10)
MAN B&W Diesel A/S
901-1.2 Cylinder Cover
Dismantling
2. 2. Remove the cooling water outlet pipe from

the exhaust valve.
Remove the screws which fasten the cool-

ing water outlet pipe to the block on the cyl-
inder cover.
Dismount the fuel oil high-pressure pipes.

See Procedure 909-14.2.
Dismount the control air pipe from the start-

ing valve.
HN901-1.2 206 02
Remove the screws which fasten the start-

ing air inlet pipe to the block on the cylinder
cover.
3. Dismount the hydraulic high-pressure pipe,

3. see Procedure 908-1.2.
Dismount the drain oil pipe between the ex-

haust valve and the hydraulic activator, the
air pipe for the pneumatic exhaust valve,
and the pipes for the sealing air arrange-
ment.
4. Remove the protective jacket enclosing the

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

the intermediate pipe and the exhaust re-
HN901-1.2 206 03
ceiver. The four lowermost screws need not

be dismantled, just loosened.
Remove the protective caps from the cylin-

4. der cover nuts.
HN901-1.2 206 04
Page 2 (10) When referring to this page, please quote Procedure M90101 Edition 0232
MAN B&W Diesel A/S
Dismantling
5. Place eight spacer rings, one around each 5. D13-02

nut, and screw the eight hydraulic jacks
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
HH901-1.2 0232 05
Chapter 913.
6. Hook the engine room crane on to the lifting

attachment on top of the exhaust valve.
Lift away the cylinder cover complete, and 6.

land it on a couple of wooden planks.
D01-06
7. Remove and discard the sealing ring be-
tween cylinder cover and cylinder liner.
HN901-1.2 206 06
7.
JN901-1.2 207 07
MAN B&W Diesel A/S
Overhaul
Overhaul
901-1.3
1. D01-09 1. Dismount all valves and pipes on the cylin-

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

cooling water outlet block from the exhaust
side of the cylinder cover.
Dismount all studs on top of the cylinder

cover.
2. Remove the four screws which secure the

cooling jacket to the cylinder cover.
HN901-1.3 206 01
Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.
If the cooling jacket sticks, use dismantling

2. screws to force the jacket/cover apart.
Remove and discard the O-rings from the

D01-07
cover, and carefully clean the cooling jacket
and the cylinder cover.
3. Provide the cylinder cover with new O-

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

D01-08 cover into position, using the guide pin as
a reference (camshaft side).
Mount and tighten the screws for the cool-

HN901-1.3 206 02
ing jacket.
3.
HN901-1.3 206 04
MAN B&W Diesel A/S
Overhaul
4. Recondition the valve bores as follows: 4.
Fuel valve bore
5. The tool consists of a common spindle with

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

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

and a grinding compound (e.g. Carborun-
HN901-1.3 206 05
dum No. 200).
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged. 5.
Exhaust valve bore
6. The tool consists of a spindle with handle

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

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

ing carefully, and check that the seating is
not damaged.
GN901-1.3 203 06
6.
GI901-3.1 98 05
MAN B&W Diesel A/S
Overhaul
7. Starting valve bore
7. The tool consists of a guide, a cutter, and

a grinding disc.
Recondition the starting valve bore and

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

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

cock.
HN901-1.3 2036 08
8.
HN901-1.3 206 09
MAN B&W Diesel A/S
Overhaul
9. Lubricate the threads with ‘Never Seize' or 9.

Molybdenum Disulphide (MoS 2) and mount D01-01
the valve studs.
Tighten up the studs in accordance with the

screwing-in torque stated on the data
sheet.
D01-03
Fill up the grooves between the valve studs D01-02
and the bores for the valve studs with per-
matex to prevent water or oil from entering
the bores during operation of the engine.
Provide the water connection flanges with

new gaskets, and keep the cylinder cover
ready for replacement.
HN901-1.3 206 10
Always fit new or overhauled valves before
a cylinder cover is mounted on the engine.
10. Clean the starting air inlet block and the

cooling water outlet block.
10.
Mount the blocks and new packings on the
cylinder cover.
HN901-1.3 206 10
MAN B&W Diesel A/S
Mounting
Mounting
901-1.4
1. 1. Place a new sealing ring on top of the cyl-

inder liner.
D01-06 2. Lift the cylinder cover by means of the

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

with new O-rings and lubricate them with
grease or soft soap.
Mount a new ‘klinger’ sealing ring in the

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

cooling water connecting pipes engage cor-
rectly with the holes in the cooling jacket.
HN901-1.4 206 01
2.
HN901-1.4 206 02
MAN B&W Diesel A/S
Mounting
3. Mount all eight nuts on the studs and screw 3.

them down to the cylinder cover.
Place eight spacer rings, one around each

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

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

jacks, vent the system, and then increase D13-01
the pressure as stated in Data.
For operation of hydraulic jacks, see Proce-

dure 913-1.
Connect the hydraulic hoses to the jacks HH901-1.2 0232 05
and raise the pressure to the level stated in

Data. Tighten the nuts with a tommy bar.
Release the pressure. Remove the hydrau- 4.

lic jacks and the spacer rings.
4. Mount the protective caps on the cylinder

cover studs.
Align the intermediate pipe so that the

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

intermediate pipe and the exhaust receiver.
Note!
HN901-1.4 206 04
Lubricate the screws with ‘Never Seize’

or Molybdenum Disulphide (MoS 2) before
mounting.
MAN B&W Diesel A/S
Mounting
5. 5. Mount the insulating jacket around the in-

termediate pipe.
6. Mount the return oil pipe, the sealing air

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

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

valve. Mount the screws which fasten the
HN901-1.4 206 05
starting air inlet pipe to the block on the cyl-

inder cover.
Mount the cooling water outlet pipe on the

exhaust valve. Mount the screws which fas-
6. ten the cooling water outlet pipe to the
block on the cylinder cover.
Using a crowfoot wrench and torque span-

ner, mount the fuel oil high-pressure pipes.
8. 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-
tion, shut the vent cocks and open the cool-
ing water outlet valve.
HN901-1.4 206 06
Open fuel oil, lubricating oil and air supplies

to the alarm system.
7. Caution !
The air supply to the exhaust valve must

always be connected before turning on
the oil supply to the exhaust valve actua-
tor.
This is very important, because other-

wise the valve will open more than
intended.
HN901-1.4 206 07
MAN B&W Diesel A/S
Cylinder Cover Panel Plate
P90151-0205
P90151
Cylinder Cover Panel
0205
When referring to this page, please quote Plate P90151 Edition 0205 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0205
Item Item
Item Description Item Description
No. No.
010 Panel for tools

022 Name plate
046 Grinding tool for exhast valve seat
058 Milling and grinding wheel for fuel
valve
060 Milling and grinding wheel for starting
valve
071 Dismantling lever for fuel valve
083 Handle
095 Grinding ring for starting valve
105 Pin wrench for starting valve
117 Test equipment for combined safety
valve
Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0205
MAN B&W Diesel A/S
Cylinder Cover - Tools Plate
P90161-0101
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0101
Item Item Description Item Item Description

No. No.
027 Hydraulic jack cylinder cover

039 Support
052 O-ring with back-up ring
088 Tommy bar
090 Spanner
100 Stud setter
206 Hydraulic toolset, complete
MAN B&W Diesel A/S
Cylinder Cover - Lifting Tools Plate
P90165-0001
Cylinder Cover - Lifting Tools
0001
P90165
MAN B&W Diesel A/S
Plate Cylinder Cover - Lifting Tools
P90165-0001
Item Item
No. No.
017 Lifting chains for cylinder cover
MAN B&W Diesel A/S
902 Piston with Rod & Stuffing Box
102-1 0063 Piston, Data

902-1 0270 Piston
102-2 0047 Piston Rod Stuffing Box, Data
902-2 0221 Piston Rod Stuffing Box
90251 0246 Piston and Piston Rod - Panel
90261 0107 Piston and Piston Rod - Tools
90264 0012 Piston and Piston Rod - Tilting Tools
90265 0005 Piston and Piston Rod - Support Tools
90266 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 0063
102-1 Edition S60MC-C
Piston
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
D01-05 Cylinder cover stud, check distance 124+0/-1 mm

D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 590 Nm
D02-03 Piston rod/crown, tightening torque 500 Nm
D02-05 Piston skirt, tightening torque 190 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-07 Piston rod/crosshead, tightening torque + angle 100/60 Nm/°
D02-08 Piston ring new, radial width 20.2 mm
D02-09 Piston ring worn, min. radial width 17 mm
D02-10 Groove No.1, max. vertical height 14.7 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 11.7 mm
D02-12 Piston top, max. permissible burn-away 16 mm
D02-13 Piston ring new, height of ring No. 1 13.9 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 10.9 mm
D02-15 Minimum free ring gap (before dismantling) 30.5 mm
D02-16 Minimum ring gap, ring No. 1 (new ring in new liner) 4.1 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 (new ring in new liner) 3 mm
D02-18 Vertical clearance, new parts 0.43 mm
D02-19 Vertical clearance, worn parts, max. 0.92 mm
D02-20 Piston complete 1483 kg
D02-21 Piston crown 351 kg
D02-22 Piston rod 974 kg
D02-23 Piston skirt 93 kg
D02-24 Piston cooling pipe 36 kg
D02-25 Lifting tool, tightening torque 150 Nm
D02-46 CPR ring CL groove, min. depth 1.3 mm
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
MAN B&W Diesel A/S
Piston 902-1.1
Checking
Piston
S60MC-C
0270
Checking
902-1.1
1.
Scavenge port inspection
To detect possible leakages from the piston or

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Carefully smooth out any wear ridges at the

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

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

ing.
Remove the piston cleaning ring.

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

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

inder liner.
Clean the lifting groove of the piston crown

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3. Dismount the locking wire and the inner-

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

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

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

of two dismantling screws.
Lift away the piston crown.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ing oil.
Mount the pressure-testing tool around the

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

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

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

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

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

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

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

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

TDC.
Mount the guide ring for piston rings on the

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

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

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

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

KB902-1.4 225 08
for piston rings.
10. Turn down and land the stuffing box on the

stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
9. correctly centred.
Remove the distance pieces from the piston

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

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

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

cracked), it must be replaced by another 12.
ring. See Procedure 903-1. D02-02
or
D02-07
HN902-1.4 237 12
13.
HN902-1.4 237 13
MAN B&W Diesel A/S
902-1.4 Piston
Mounting
14. 14. If the cylinder cover studs have been re-

moved, remount them.
Carefully clean the surfaces around the

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

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

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

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

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

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

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

rod and stuffing box.
HN902-1.4 256 15
MAN B&W Diesel A/S
Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10202
102-2 Data 0047 Piston 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 6 mm
D02-30 Lowermost rings, ring-end clearance 3 mm
D02-33 Check length for the six uppermost springs:
D02-34 – F 0 = 0 N.........…....... L 0 = 618 mm
D02-35 – F 1 = 153 +/– 7 N....... L 1 = 902 mm
D02-36 – F 2 = 163 +/– 10 N..... L 2 = 983 mm
D02-37 Check length for the four lowermost springs:
D02-38 – F 0 = 0 N......….......... L 0 = 606 mm
D02-39 – F 1 = 150 +/– 7 N....... L 1 = 780 mm
D02-40 – F 2 = 200 +/– 10 N..... L 2 = 844 mm
D02-44 Stuffing box complete 110 kg
D02-45 Stuffing box half 35 kg
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
Data
P90251 109 Mounting tool for stuffing box spring

P90251 110 Pressure test tool for piston
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
P90251-0246
Piston
P90251
0246 and Piston Rod Panel
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0246
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 Distance piece for stuffing box
099 Cover for stuffing box hole
109 Mounting tool for stuffing box spring
110 Pressure test tool for piston
122 Worktable for stuffing box
134 Piston ring expander
158 Guide screw for piston crown
183 Pulling tool for stuffing box
MAN B&W Diesel A/S
Piston and Piston Rod - Tools Plate
P90261-0107
Piston and Piston Rod - Tools
0107
P90261
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0107
Item Item
No. No.
019 Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Tilting Tools Plate
P90264-0012
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tilting Tools
P90264-0012

No. No.
015 Collar ring for piston

027 Support for tilting tool
039 Support for tilting tool
040 Lifting and tilting screw
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools Plate
P90265-0005
Piston and Piston Rod - Support Tools
0005
P90265
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0005
Item Item
No. No.
010 Support iron 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
903 Cylinder Liner and Cylinder Lubrication
103-1 0052 Cylinder Liner, Data

903-1 0244 Cylinder Liner
103-2 0023 Cylinder Lubricator, Data
903-2 0234 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0005 Cylinder Liner - Milling Tools
90366 0007 Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Cylinder Liner 103-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10301
103-1 Data 0052 Cylinder Liner
X Stopped engine
X Shut off fuel oil
Data
D03-01 Lifting tool screws, tightening torque 150 Nm

D03-03 Cylinder diameter, new 600 mm
D03-04 Piston cleaning ring diameter, new 598.6 mm
D03-05 Cylinder liner, complete 3356 kg
D03-06 Cooling jacket 286 kg
D03-16 Piston cleaning ring radial width, new 46.2 mm
D03-17 PC-ring/Liner max. wear deviation 0.6 mm
D03-18 PC-ring replacement criteria:
Liner diameter: 600 mm

Liner wear: Install:
0 – 0.60 mm Standard PC-ring
(new or max. wear of diameter 0.60 mm)
0.60 – 1.2 mm Oversize PC-ring
> 1.2 mm Dummy ring
When referring to this page, please quote Data D10301 Edition D10301 Edition 0052 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data
P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90362 Cylinder liner – extra tool
P90366 Cylinder liner – lifting tools
Page 2 (2) When referring to this page, please quote Data D10301 Edition D10301 Edition 0052
MAN B&W Diesel A/S
Cylinder Liner 903-1.1
Checking
Cylinder Liner
S60MC-C
0244
Checking
903-1.1

1. Dismount the cylinder cover, piston and
PC-ring.
Clean the cylinder liner and scavenge air

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

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

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

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

5. Carefully scratch over any scores or marks

on the cylinder liner running surface, and

0
'
grind away the wear ridges. See Procedure

903-1.3.

6. Check the lubricating points of the cylinder
by pumping cylinder oil to each individual
lubricating point.
Clean any blocked lubricating duct.

1
*

1
(
0$1% :'LHVHO$6
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.
0$1% :'LHVHO$6
Dismantling
Dismantling
903-1.2
1. Dismount the cylinder cover. 1.

Discard the sealing ring from the top of the

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

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

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

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

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

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

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

tween the cooling jacket and cylinder cover
GN903-1.2 224 02
– and clean them carefully.
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
Dismantling
5. The lifting screws are also used for trans- 5.

porting the cylinder liner.
D03-05
HN903-1.2 244 05
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
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

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. 1
+
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.

The maximum depth of the groove is calcu-

lated as S max. = D x 0.0045.

%
0
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

1
0
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
Cylinder Lubricators 103-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X Stopped engine
X Shut off starting air supply – At starting air receiver
X Block the main starting valve
X Shut off starting air distributor/distributing system supply
X Shut off safety air supply – Not ME-engines
X Shut off control air supply
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
D03-10 Inlet accumulator, nitrogen pressure, 30 bar

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

1.
With stopped engine and normally when the
system has been disassembled:
1. Press the ESC + PRELUB.-button on the
HMI control panel, and check that all lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.
2. If the cylinder cover or the exhaust valve is
removed, check inside the liner that all lu-
bricating points are working properly.
Otherwise, remove the covers for scavenge
port inspection.
Turn the piston to BDC and check inside
the liner with a mirror and a powerful light
source that all lubrication points are work-
ing properly.
M90302-0245C01
3.
M90302-0245C02
903-2.1 Cylinder Lubricators
Checking MAN B&W Diesel
With running engine:

4.
Inlet 3. Check that all lubricators are operating cor-
rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
The LEDs give signal when oil is injected.
Check the pressure shocks from the injec-
tion of the lubricators on each lubricator
pipe by feeling with a hand.
D03-11
If in doubt, disconnect the pipe at the cyl-
D03-10 inder liner to observe the oil flow.
M90302-0249C03
Check of Accumulators:
4. Measuring the nitrogen pre-pressure can
only be done with stopped engine and
5. pressure-free lubrication system.
Stop both oil pumps. Close the inlet valve
and open the equalizing valve on the re-
spective lubricator.
The nitrogen pressure in the inlet accumu-
lator (0.7 litre) can be checked without dis-
mounting the accumulator. For use of the
pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the
outlet accumulator (0.16 litre), the accumu-
M90302-0245C05
lator or the lubricator with accumulator

must be dismounted.
For nitrogen pressure in the accumulators,
see Data.
MAN B&W Diesel Checking
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as 7. C
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor. A E D03-13
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7 F
litre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
B
7. Before mounting the filling valve on the ac-
cumulator, check that the accumulator top
is clean.
M90302-0247C07
Mount the filling valve on the relevant accu-
mulator with the union nut. Check that
valves C and F are closed.
Loosen the plug screw in the accumulator
using a ½” square drive handle in socket E.
It is now possible to read the actual nitro-
gen pressure in the accumulator on the dial
gauge on the filling valve.
8. If the accumulator needs to be refilled with
nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in
Data.
Open valve C until the accumulator is filled
to the correct pressure.
Close valve C and tighten the plug screw
with socket E to the torque stated in Data.
Release the pressure in the filling valve at
bleed screw F.
Unscrew the filling valve from the accumu-
lator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.
Dismantling MAN B&W Diesel
Dismantling of lubricators:
1.
The engine must be stopped and blocked be-
fore dismounting a lubricator. Stop the cylinder
Inlet oil pump station.
1. Close the supply valve for the lubricator
and open the equalizing valve (turn both
handles to a horizontal position). Remove
the upper shield, if installed.
Disconnect the electrical plug on the side
of the lubricator.
M90302-0249D01
2. Unscrew the six screws in the bottom of

the lubricator and disconnect the cover
with pertaining pipes.
3. Unscrew the four screws on the side that
2. Inlet
secure the lubricator to the hydraulic block,
and remove the lubricator.
Special running
It is possible to change a lubricator while the
engine is running if a spare lubricator with O-
rings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
• Reduce the engine load to below 40%
of MCR
M90302-0249D02
• 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 Dismantling
Dismantling of accumulators:
5.
4. The engine must be stopped and blocked
before the accumulator is dismounted.
Inlet
Stop the cylinder oil pump station.
Close the supply valve for the lubricator
and open the equalizing valve.
Note!
When the oil pressure is released, a ni-
trogen pre-pressure of 25-30 bar will re-
M90302-0249D04
main in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the hy-
draulic block.
Overhaul MAN B&W Diesel
1. Place the lubricator in a bench vice with

1. soft “jaws”.
Remove the adjusting screw with bushings.
Unscrew the oil accumulator.
Discard the O-ring from the adjusting
screw.
2. Remove the screws from the cylinder
block.
3. Pull up the cylinder block.
M90302-0247O01
Remove the spring and actuator piston

with plungers.
Remove and discard the O-ring from the
cylinder block.
2.
Remove the cover for the non-return
valves. Take out springs and balls. Remove
and discard the O-rings.
M90302-0247O02
3.
M90302-0247O03
MAN B&W Diesel Overhaul
4. Screw out the non-return valves and re-

move and discard the O-rings. 4.
Clean the valves and check them with
compressed air.
5. Inspect the plungers, actuator piston and
cylinder block for wear, using a magnifying
glass.
6. Fit the non-return valve with new O-rings.
Mount the non-return valves in the cylinder
block.
M90302-0247O04
5.
M90302-0247O05
6.
M90302-0247O06
7. Pre-assemble the cylinder blockwith the

7. actuator piston and plungers to ensure the
correct guidance of the plungers, before fi-
nally assembling the cylinder block unit.
Mount the spring and press down the ac-
tuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
Fit the cylinder block with a new O-ring.
M90302-0247O07
8. Remove the cover from the terminal box

and disconnect the wires for the feedback 8.
(pick-up) sensor.
Remove the terminal box and the plug for
the solenoid valve.
Carefully unscrew the feedback sensor and
remove and discard the O-ring.
Clean the housing with diesel oil or kero-
sene and dry with a non-fluffy cloth.
9 Turn the lubricator upside down in the vice.
M90302-0247O08
Unscrew the solenoid valve.
Discard the O-rings.
10. Solenoid valve: 9.
Disassemble and clean the valve.
Check the slide for wear. If the slide is
scratched or scuffed, the valve must be re-
placed by a new one.
Lubricate the slide with oil and check that
the slide can move lightly with a good fit in
the housing.
Assemble the valve.
M90302-0247O09
See also manufacturer’s instructions.
10.
M90302-0244O12
11. Before mounting the feedback sensor,

11. check that the sensor is flush with the sen-
sor housing.
Mount the feedback sensor or a new one,
if necessary, with a new O-ring.
Check with an object with a straight edge
(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.
Mount the terminal box.
M90302-0245O10
1 1
2 2 Solenoid valve 11. Connect the wires and mount the cover on
3 BN (brown) the terminal box.
BK (black)
4 Feedback sensor
5
BU (blue)
13. Mount the solenoid valve fitted with new
O-rings. Coat the O-rings with a little
12. grease to keep the rings in place during
LED
mounting.
-2
Brown+15
Blue OV
Black FB-signal
M90302-0242O08
13.
M90302-0247O13
14. Mount the cylinder block assembly in the

cylinder housing. 14.
Check that the spring pin engages cor-
rectly with the cylinder block assembly.
Mount the screws and tighten the block to
the housing.
Remove the M6 x 60 screw with disc.
15. Mount the adjusting screw fitted with a
new O-ring and the distance bushing.
M90302-0247O14
Mount the oil accumulator.
16. If the lubricator is not to be mounted on
the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor- 15.
age.
Cover all surfaces with a thin layer of oil.
M90302-0247O01
Mounting MAN B&W Diesel
1. Before mounting the accumulator, check

1. Inlet the nitrogen pressure, see Data.
Mount the accumulator.
2. Mount new O-rings on the hydraulic block
and on the cover with pipes.
Mount the lubricator and tighten the screws
on the hydraulic block.
Tighten the screws in the bottom of the lu-
bricator to the pipe connection.
M90302-0249M01
3. Close the equalizing valve and open the

supply valve (handles to be in a vertical po-
sition).
Mount the electrical plug. Check the injec-
2. tion of cylinder oil on the feedback LED on
Inlet the terminal box for the specific lubricator.
M90302-0249M02
3.
Inlet
M90302-0249M03
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
P90362-0005
Cylinder Liner - Extra Tool
0005
P90362
MAN B&W Diesel A/S
Plate Cylinder Liner - Extra Tool
P90362-0005
Item Item
No. No.
018 Wear ridge milling machine
MAN B&W Diesel A/S
Test Equipment for Lubricator Plate
MAN B&W P90364-0004
When referring to this page, please qoute Plate P90364 Edition 0004 Page 1 (2)
Plate Test Equipment for Lubricator
P90364-0004 MAN B&W
Item Item Description

No.
014 Reducing valve
026 Adaptor
038 Adaptor
040 Adaptor
051 Adaptor
063 Adaptor
075 Adaptor
087 Adaptor
099 Quick coupling, minimess
109 Quick coupling, minimess
122 Special screw
205 Test equipment for accumulators set,
complete
Page 2 (2) When referring to this page, please qoute Plate P90364 Edition 0004
Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007
Item Item
No. No.
021 Crossbar for cylinder liner
MAN B&W Diesel A/S
904 Crosshead with Connecting Rod
104-1 0046 Crosshead Bearing, Data

904-1 0237 Crosshead Bearing
104-2 0048 Crosshead, Data
904-2 0238 Crosshead
104-3 0033 Reciprocating Parts, Data
904-3 0212 Reciprocating Parts
104-4 0041 Crankpin Bearing, Data
904-4 0225 Crankpin Bearing
104-5 0042 Connecting Rod, Data
904-5 0230 Connection Rod
90451 0149 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90462 0034 Connecting Rod - Tools
90464 0005 Crosshead - Hydraulic Tools
90465 0001 Crosshead - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Crosshead Bearing 104-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MCC
D10401
104-1 Data 0046 Crosshead Bearing
X Stopped engine
X Shut off fuel oil
Data

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

P90451 72 Chain for suspending piston
P90451 96 Bracket for support, crosshead
P90464 Crosshead - hydraulic tools
P91356 Lifting tools, etc.
P91366 58 Feeler gauge
MAN B&W Diesel A/S
Crosshead Bearing 904-1.1
Checking
Crosshead Bearing
S60MCC
0237
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
BM904-2.1 76 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.
HN904-1.2 237 01
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
DM904-1.2 232 10
0$1% :'LHVHO$6
Dismantling
11. Place the bearing cap on one side on a 11.

couple of wooden planks.
12. Fasten tackles to the fixed lifting brackets

on the frame box wall.
13. Turn the crosshead upwards until the piston

rod lands on the crosshead. Ensure that the
guide ring in the crosshead fits correctly in
GN904-1.2 203 11
the centre hole of the piston rod.
Do not remove the chains or lifting eye

bolts.
12.
MN904-1.2 237 17
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
HN904-1.2 237 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 camshaft
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:

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
S60MC-C
D10402
104-2 Data 0048 Crosshead
X Stopped engine
X Shut off fuel oil
Data
D04-04 Crosshead bearing cap 277 kg

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

P90451 59 Lifting attachment – connecting rod
P90451 60 Lifting tools – crosshead
P90451 84 Retaining tool telescope pipe
P90451 214 Torque wrench offset tool
P90462 11 Guide shoe extractor, complete
P90463 Crosshead – hydraulic tools
P91359 40 Torque spanners
MAN B&W Diesel A/S
Crosshead 904-2.2
Dismantling
Crosshead
S60MC-C
0238
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. D04-23
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
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
D04-04 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.
HN904-2.2 223 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
wooden planks in the bottom of the bed-
plate.
D04-50
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 a lifting eye bolt in one of the guide

shoes, and hook on a tackle.
Squeeze in a plank between the guide

shoes.
9. Suspend two tackles from the eye bolts in

the top of the crankcase in the fore-and-aft
HN904-2.2 223 08
direction.
Mount an eye bolt in the top of each guide

shoe.
9.
Mount the guide shoe extractor tool on the D04-22
guide shoe.
Hook the tackles on to the eye bolts in the

guide shoes, haul tight and, at the same
time, using the guide shoe extractor tool,
pull the crosshead towards the extractor
tool until it is free of the opposite guide
shoe.
Follow the movement of the crosshead with

the engine room crane.
HN904-2.2 223 09
Lift up the free guide shoe.
10. Using the guide shoe extractor tool, push

the crosshead away from the remaining
guide shoe, until the crosshead is free of 10.
the guide shoe.

Dismount the guide shoe extractor tool.
Lift up the guide shoe.

HN904-2.2 223 10
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling
11. 11. Turn the crosshead 90°.
12. Mount the wire guide tool in the framebox

door opening.
By means of wire rope and tackles, remove

the crosshead from the engine.
Protect the crosshead, for instance with

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
12.
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°.
3. Lower one guide shoe and mount the guide

shoe extractor tool.
Use the guide shoe extractor tool to pull the
HN904-2.2 223 11
crosshead so far through the guide shoe
that the other guide shoe can be lowered.

3.
4. Lower the other guide shoe.
Use the guide shoe extractor tool to push

the crosshead towards the second guide
shoe.

HN904-2.4 223 03
4.
HN904-2.4 223 04
0$1% :'LHVHO$6
904-2.4 Crosshead
Mounting
5. 5. Mount the guide plates on the side of the

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
D04-12 See Procedure 913-7.

D04-13 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-
sition, lower the crosshead and land it on
D04-50 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.
HN904-2.2 223 06
0$1% :'LHVHO$6
Crosshead 904-2.4
Mounting
8. Lift the crosshead bearing cap into the en- 8.

D04-04
gine.
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.
D04-15
D13-01 D04-19
11. Mount the lubricating oil pipes on the main
bearing caps.
D04-23
12. Mount the piston.
HN904-2.2 223 04
10.
D04-08
GN904-2.2 204 03
0$1% :'LHVHO$6
Reciprocating Parts 104-3
Data
SAFETY PRECAUTIONS
Special Edition
L/S60MC-C
D10403
104-3 Data 0033 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. 0.6 mm

D04-26 PF+PA, O max. 1.1 mm
D04-28 E+G, H+F, N max. 0.55 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.85 mm
D04-34 J+C, L+D, K+C, M+D, N max. 0.9 mm
D04-35 J+C, L+D, K+C, M+D, N min. 0.5 mm
D04-36 J+C, L+D, K+C, M+D, O max. 1.1 mm
D04-41 ZF/ZA O min. 5 mm
MAN B&W Diesel A/S
104-3 Reciprocating Parts
Data
MAN B&W Diesel A/S
Reciprocating Parts 904-3.1
Checking
Reciprocating Parts
S60MC-C
0212
Checking
904-3.1
1.
In order to achieve uniform measuring condi-
tions on board, the ship’s trim must be as close
as possible to 0°.
1. Mount a transparent plastic tube along the

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

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

45° after BDC (the guide shoe must rest
against the crosshead guide).
Check the centering of the piston in the cyl-

inder liner by measuring the clearance (by PA
applying a long feeler gauge from the scav- PF
enge air space) between the piston skirt
and the cylinder liner in the Fore and Aft po-
HN904-3.1 212 02
sitions (PF-PA). 45°

Ast
ern
Make sure that the piston is clear of the cyl-

inder liner in the fore-and-aft direction.
3. Turn in astern direction until the bottom of 3.

the guide shoe is 50 mm in the vertical di-
rection above the top of the cut out in the
50
web plate.
EXH CAM
E 1-2 G 1-2
10
F 1-2
H 1-2
HN904-3.1 212 03
0$1% :'LHVHO$6
904-3.1 Reciprocating Parts
Checking
4. 4. Measure the clearance between the crank-

throw and the connecting rod.
5. Measure the clearance between the stop

plate and the crosshead (C and D).
Measure the clearance between the cross-

head guides and the guide shoes (E, F, G
and H).
Measure the clearance between the guide

strips and crosshead guides (J, K, L and
M).
The clearance, calculated as J+C, K+C,

L+D and M+D, is adjusted by the insertion
of shims so that it is symmetrical in relation
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
ZA mm per 1000 mm.
HN904-3.1 212 04
ZF
5.
Exhaust side
F1-2 F3-4
E1-2 E3-4
D
G3-4, H3-4
C Camshaft side
G1-2, H1-2
1 2 3 4
J,K L,M
F J F
H H
L
J,K+C
K
M
HN904-3.1 212 05
G G
E E
L,M+D
0$1% :'LHVHO$6
Reciprocating Parts 904-3.1
Checking
6. It is recommended that the measured re- 6.

Unit mm
Unit mm Cyl.
Cyl. 1 2 3
sults are noted down so that possible later
changes can be ascertained. PF
Piston/Liner
Piston/Liner
PA
Framebox
Framebox E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+C
K+C
L+D
HN904-3.1 207 05
M+D
Crosshead
Crankthrow ZF
TF
Connecting
Connecting rod TA
Rod ZA
0$1% :'LHVHO$6
Crankpin Bearing 104-4
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10404
104-4 Data 0041 Crankpin Bearing
X Stopped engine
Shut off fuel oil
Data
D04-43 Crankpin bearing clearance, max. 0.7 mm

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

P90451 96 Bracket for support, Cross Head
P90451 106 Bracket for support, Cross Head
P90461 Connecting Rod – Hydraulic Tools
P90462 59 Lifting tool for crankshaft shell
P91356 Lifting Tools, Etc.
MAN B&W Diesel A/S
Crankpin Bearing 904-4.1
Checking
Crankpin Bearing
S60MC-C
0225
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.
NB904-4.1 221 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.
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 D04-43
bearing condition at the time of inspection.
D04-44
GM904-6.1 69 03
An average wear rate of 0.01 mm per

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

pin bearing, see Chapter 708 ‘Bearings' in 5.
the instruction book, Volume I, OPERA-
TION.
HN904-4.1 217 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.
HN904-4.2 217 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
HN904-4.2 217 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.
Dismount the bearing shell lock screws and

replace the bearing shell by a new one.
HN904-4.2 217 05
Note!
Normally bearing shells are replaced in

pairs. 6.
D04-47
If only one of the shells needs replace-
ment, MAN B&W Diesel should be con-
tacted for advice beforehand.
GN904-4.2 203 06
7. Turn to TDC.
Mount the four supports for guide shoes on

7.
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’.
HN904-4.2 217 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.
HN904-4.2 217 09
10.
HN904-4.2 217 10
0$1% :'LHVHO$6
Dismantling
11. Mount an eye bolt in the bottom of each 11.

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

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

connecting rod, using the tackles, and haul
tight.
HN904-4.2 217 11
13. Dismount the bearing shell lock screws.
Lower the lifting tool with the bearing shell,

using the tackles.
HN904-4.2 217 12 12.
13.
D04-46
HN904-4.2 217 13
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.
3. Remove the lifting tool, the tackles and the

eye bolts from the guide shoes.
D04-46
HN904-4.4 217 02
3.
HN904-4.4 217 03
0$1% :'LHVHO$6
Mounting
4. Hook the tackle on to a beam under the gal- 4.

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

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

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

from the crosshead guides.
HN904-4.4 217 04
5.
HN904-4.4 217 05
0$1% :'LHVHO$6
Mounting
6. 6. 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.
7. 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-
HN904-4.4 217 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.

HN904-4.4 217 07
D13-01
0$1% :'LHVHO$6
Connecting Rod 104-5
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10405
104-5 Data 0042 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. 0.2 mm
D04-07 Crosshead bearing cap with bearing shell 297 kg
D04-43 Crankpin bearing clearance, max. 0.7 mm
D04-44 Crankpin bearing clearance, min. 0.45 mm
D04-48 Crankpin bearing cap + shell + bearing studs 260 kg
D04-50 Connecting rod, without bearing caps 1820 kg
MAN B&W Diesel A/S
104-5 Connecting Rod
Data

P90451 72 Chain for suspending piston
P90461 Connecting rod – hydraulic tools
P91351 10 Hydraulic pump, pneumatically operated
P91357 Open-ended spanners
P91359 Torque spanners
MAN B&W Diesel A/S
Connecting Rod 904-5.2
Dismantling
Connecting Rod
S60MC-C
0230
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-
HN904-5.2 230 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,
HN904-5.2 230 08
remove tackle C and turn to TDC.
9. A B
E F
C
D04-50
HN904-5.2 230 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.
2. A B
Lubricate the crankpin and bearing liberally.
Carefully move the connecting rod onto the E F
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.
HN904-5.2 230 02
3. A B
E F
C
D
HN904-5.2 230 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

HN904-5.4 230 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. Turn to BDC. 7. A B
E F
Lubricate the crosshead and bearing cap.
C
Mount the crosshead bearing cap.
8. Measure the crankpin bearing clearance

fore and aft.
D
HN904-5.4 230 04 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.
Measure the clearance in the crosshead

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
P90451-0149
Connecting Rod and Crosshead Panel
0149
P90451
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0149
Item Item
No. No.
011 Panel for tools

023 Name plate
047 Wire guide
059 Lifting attachment - connecting rod
060 Lifting tools - crosshead
072 Chain for suspending piston
084 Retaining tool for telescope pipe
096 Bracket for support of crosshead
106 Bracket for support of crosshead
118 Rubber cover for crosshead
120 Rubber cover for crosshead
214 Torque wrench offset tool
MAN B&W Diesel A/S
Connecting Rod - Hydraulic Tools Plate
P90461-0068
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0068

No. No.
028 Hydraulic jack

030 Support
041 Tommy bar
089 Spanner
100 Stud setter
MAN B&W Diesel A/S
Connecting Rod - Tools Plate
P90462-0034
Connecting Rod - Tools
0034
P90462
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0034
Item Item
No. No.
011 Lifting tool for crankpin shell
MAN B&W Diesel A/S
Crosshead - Hydraulic Tools Plate
P90464-0005
MAN B&W Diesel A/S
Plate Crosshead - Hydraulic Tools
P90464-0005

No. No.
024 Jack-hydrualic, complete

036 Support
048 Tommy bar
085 Key, hexagon socket screw
107 Stud setter
MAN B&W Diesel A/S
Crosshead - Tools Plate
P90465-0001
Crosshead - Tools
0001
P90465
MAN B&W Diesel A/S
Plate Crosshead - Tools
P90465-0001
Item Item
No. No.
018 Guide shoe extractor
MAN B&W Diesel A/S
905 Crankshaft, Thrust Bearing and Turning Gear
105-1 0006 Crankshaft Deflection, Data

905-1 0208 Crankshaft Deflection
105-2 0052 Main Bearing, Data
905-2 0245 Main Bearing
105-3 0044 Thrust Bearing, Data
905-3 0224 Thrust Bearing
105-4 0017 Journal Bearing, Data
905-4 0216 Journal Bearing
105-5 0037 Axial Vibration Damper, Data
905-5 0224 Axial Vibration Damper
105-8 0007 Angle Encoder, Data
905-8 0204 Angle Encoder
90551 0237 Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel
90561 0064 Main Bearing - Hydraulic Tools
90562 0127 Crankshaft - Tools
90563 0024 Segment Stopper - Hydraulic Tools
90570 0001 Thrust Shaft - Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Main Bearing 105-1
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10501
105-1 Data 0006 Main Bearing
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
105-1 Main Bearing
Data
P90572- Main Bearing - Measuring Tools

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

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

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

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

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

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

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

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

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

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

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

follows:
5. Visually look for bearing metal fragments in

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

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

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

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

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

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

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

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

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

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

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

ing, it is recommended to edge check the
9. bearing, without opening up.
9. Before measuring, check that the feeler

blades are in good condition.
The feeler is inserted along the crank throw.

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

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

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

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

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

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

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

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

ries:
• The main bearings
• The aftmost main bearing

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

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

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

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

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

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

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

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

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

shoe.
On some engines the pulley is mounted in

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

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

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

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

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

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

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

from the engine.
Unscrew and remove the nuts from the

main bearing studs.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

and compress the jacks.
Connect the hydraulic jacks to the high-
KN905-2.2 238 24
pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.
Note down the pressure for later reference. 19.
20. Check that there is min. 0.1 mm clearance

between journal and bearing shell, or be-
tween bearing shell and main bearing sup-
port, on both sides of the journal.
If the clearance is less than 0.1 mm, move

the crosspiece sideways until clearance is
obtained. Normally, adjustment needs to be
50-150 mm to the exhaust side (the side
where the clearance is missing).
KN905-2.2 238 27
Note!
The feeler blade must be inserted mini-

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

side with the most clearance, which is
normally the camshaft side.
EXH CAM
KN905-2.2 238 28
Min. 60 mm
0$1% :'LHVHO$6
Dismantling
21. 21. If repositioning of the crosspiece does not

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

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

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

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

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

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

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

mended to hold a foot or hand on the wire
rope, to tighten it up and to observe
whether the shell is sticking.
JM905-2.2 236 27
24.
D05-05
HN905-2.2 227 19
0$1% :'LHVHO$6
Overhaul
Overhaul
905-2.3
1 + 2. 1. Clean and inspect the bearing shells. It is

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

support.
Check with a feeler gauge that there is

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

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

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

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

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

bearing support and the bearing cap. Make
D05-03 sure that no oil is left on the contact surfac-
es.
7. Mount the lifting tool on the bearing cap.

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

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

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

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

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

shell.
10. Remove the lifting tool from the bearing

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

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

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

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

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

HN905-2.4 227 11
see Procedure 913-1.
13. Remove the bearing cap lifting tool.
13. Note!
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.
14. Remove all the tools from the engine.
Note!

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

nuts on the stopper.
For operating hydraulic jacks,

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

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

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

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

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-1.1.
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
0$1% :'LHVHO$6
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2
2. 1. Dismount the screws for the end cover.
Mount a ½-ton tackle above the end cover.
Remove the end cover.
2. Disconnect the lubricating oil pipe from the

main pipe.
Remove the protective shield for the thrust

bearing.
Turn the crank throw for the aftmost cylin-

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

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

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

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

from the engine
Unscrew and remove the nuts from the

bearing studs.
D13-02
GN905-2.2 204 02
4.
KN905-2.2 238 07
0$1% :'LHVHO$6
Dismantling
5. Remove the rectangular nut washers from 5.

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

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

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

pressure pump, and raise the pressure until
D05-14
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the adjacent
bearing.
GN905-2.2 224 17
7.
GN905-2.2 224 19
0$1% :'LHVHO$6
Dismantling
8. 8. Dismount the locking screws.
Place the dismantling tool on top of the low-

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

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

same way as the upper shell, i.e. using the
lifting tool.
KN905-2.2 238 26
9.
D05-15
GN905-2.2 224 17
0$1% :'LHVHO$6
Overhaul
Overhaul
905-4.3
1. Clean and inspect the bearing shells. It is 1 + 2.

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

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

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

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

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

ing support and the back of the shell,
with main engine lubricating oil.
0$1% :'LHVHO$6
Mounting
Mounting
905-4.4
1. 1. Lubricate the journal, the lower bearing

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

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

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

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

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

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

support.
Lower the crankshaft and remove the hy-

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

per and the lower bearing shells clean with
a non-fluffy piece of cloth.
3.
XZS905-13 07
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.
D05-14
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
bearing cap into the crank casing in reverse 6.
order to dismantling.
See Procedure 905-4, step 5.
6.
Note!
Be sure that the cap lands correctly and

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

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

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

see Procedure 913-1. 7.
D13-01

1
0
0$1% :'LHVHO$6
Mounting
8. 8.
D05-11
D05-12 Note!
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.
9. Remove all tools from the engine.

KN 905-1.1 208 09
20
Note!

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

ing cap, and mount the end cover.
KN905-2.4 238 14
10.
KN905-2.4 238 15
0$1% :'LHVHO$6
Axial Vibration Damper 105-5
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10505
105-5 Data 0037 Axial Vibration Damper
X Stopped engine
Shut off fuel oil
Data
D05-18 Inner studs, screwing-in torque 100 Nm

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

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

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

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

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

control system.
1. Concerning overhaul and setting of the

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

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

mal Service Value, it is necessary to over-
haul the axial vibration damper, see
Procedure 905-5.2.
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
Angle Encoder 105-8
Data
SAFETY PRECAUTIONS
Special Edition
MC
D10508
105-8 Data 0007 Angle Encoder
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
105-8 Angle Encoder
Data
MAN B&W Diesel A/S
Angle Encoder 905-8.1
Checking
Angle Encoder
S42MC
0204
Checking
905-8.1

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

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

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

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

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

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

XR905-8.2 204 02

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

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

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

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

the correct position.

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

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

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

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

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

XR905-8.4 204 02
3.
XR905-8.4 204 03
0$1% :'LHVHO$6
Crankshaft, Thrust Shaft, Main Bearing, Etc. - Plate
P90551-0237
Panel
MAN B&W Diesel A/S
Plate Crankshaft, Thrust Shaft, Main Bearing, Etc. -
P90551-0237
Panel
No. No.
015 Panel for tools

027 Name plate
040 Wire pulley for main bearing
064 Wire pulley for main bearing
076 Lifting tool for main bearing cap
088 Dismanteling tool for main bearing
shell
090 Mounting tool for thin bearing shell
100 Tool for turning out segments
111 Lifting attachment
123 Retaining tool for main bearing shell
135 Lifting tool for relief valve
147 Lifting tool for relief valve
159 Eye bolt
160 Wire
172 Mounting tool for thin bearing shell
184 Lifting tool for main bearing shell
196 Tightening template A.V.D.
MAN B&W Diesel A/S
Main Bearing - Tools Plate
P90561-0064
Main Bearing - Tools
0064
P90561
MAN B&W Diesel A/S
Plate Main Bearing - Tools
P90561-0064
Item Item
No. No.
021 O-ring with back-up ring, 95/105 mm

045 Lifting tool
057 Nut
069 Hydraulic jack, upper
070 Extension stud
082 Supporting block
094 Stud setter
128 Hydraulic jack, lower
141 Hydraulic tool for main bearing, com-
plete
MAN B&W Diesel A/S
Crankshaft - Tools Plate
P90562-0127
Crankshaft - Tools
0127
P90562
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0127
Item Item
No. No.
015 Support
MAN B&W Diesel A/S
Segment Stopper - Hydraulic Tools Plate
P90563-0024
Segment Stopper - Hydraulic Tools
0024
P90563
MAN B&W Diesel A/S
Plate Segment Stopper - Hydraulic Tools
P90563-0024
Item Item
No. No.
022 Hydraulic jack

034 Hydraulic jack - support
046 Tommy bar
083 Key for hexagon socket screw
095 Stud setter
201 Hydraulic jack for segment stopper,
complete
MAN B&W Diesel A/S
Thrust Shaft - Tools Plate
P90570-0001
Thrust Shaft - Tools
0001
P90570
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0001
Item Item
No. No.
019 Lifting tool for thrust shaft
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0005
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0005

No. No.
010 Feeler gauge set

069 Feeler gauge
070 Feeler gauge
082 Feeler gauge
094 Feeler gauge
104 Feeler gauge
116 Feeler gauge
128 Feeler gauge
141 Feeler gauge
153 Feeler gauge
165 Feeler gauge
177 Feeler gauge
189 Feeler gauge
190 Feeler gauge
200 Feeler gauge
212 Feeler gauge
224 Feeler gauge
236 Feeler gauge
248 Feeler gauge
261 Feeler gauge
332 Spare tip for feeler gauge
Page 2 (2) When referring to this page, please quote Plate Edition
MAN B&W Diesel A/S
Main Bearing - Measuring Tools Plate
P90572-0008
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0008

No. No.

094 Feeler gauge
104 Feeler gauge
116 Feeler gauge
128 Feeler gauge
141 Feeler gauge
153 Feeler gauge
165 Feeler gauge
MAN B&W Diesel A/S
906 Mechanical Control Gear
106-1 0042 Chain, Data

906-1 0232 Chain
106-2 0037 Chain Tightener, Data
906-2 0230 Chain Tightener
106-3 0030 Camshaft, Data
906-3 0214 Camshaft
106-4 0029 Camshaft Bearings, Data
906-4 0218 Camshaft Bearings
106-5 0010 Moment Compensator, Data
906-5 0211 Moment Compensator
106-6 0005 Replacement of Cams On Camshaft, Data
906-6 0204 Replacement of Cams on Camshaft
90651 0185 Chain Drive and Camshaft - Panel
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
MAN B&W Diesel A/S

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

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

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

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

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

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

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

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

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

to be “plucked out” of the rubber track.
4. Check the teeth of the chain wheels. If ab-

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

short straight-edge over points A and B and
then measuring the distance D-1.
KG906-1.1 202 04
D06-02
D06-14
0$1% :'LHVHO$6
906-1.1 Chains
Checking
5. 5. If abnormal wear is observed at the bottom

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

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

side plates of the chain will be found on the
sides of the teeth. Such scratches can gen-
erally be considered normal.
6. The chains for the camshaft drive are

matched together to ensure an even load
distribution.
To keep such matching chains in their pairs,

the side plates of the outer link nearest to
the assembled link have been marked with
year, month, day and chain number.
Example:
No. 1 order,
KG906-1.1 203 05
840520 1A
840520 1B
(840520 2C, possible 3rd chain)
No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)
On the same links there is an arrow (–>)

which indicates the mounting direction.
Check the chains for cracks on possibly de-

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

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

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

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

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

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

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

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

ening the chain tightener.
(See Procedure 906-2.3).
Turn the engine until the slack part of the

chain, with the chain link that is to be dis-
assembled, is in a favourable position for
the work.
2. Mount a wire round the link rollers a short

distance from the disassembly point, and
tighten the wire lightly with a tackle.
Protect the link rollers over which the wire

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

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

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

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

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

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

the compression tool and lock the pin ends
by riveting.
GN906-1.4 203 01
Repeat this procedure until the chain has
been assembled.
Remove the tackle and wire and adjust the

chain tension.
(See Data and Procedure 906-2.3).
0$1% :'LHVHO$6
Chain Tightener 106-2
Data
SAFETY PRECAUTIONS
Special Edition
D10602
106-2 Data 0037 Chain
S60MC-C
Tightener
X Stopped engine
Shut off fuel oil
Data
D06-21 Tightening angle = 9.0 hexagons 540 °/hex

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

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

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

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

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

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

D06-28 corresponding to 4.5 mm
D06-29 Pin gauge for top dead centre of crankthrow No.1, check measurement 799 mm
D06-30 Pin gauge for camshaft, check measurement 402 mm
MAN B&W Diesel A/S
106-3 Camshaft
Data
P90668 Camshaft – pin gauge
MAN B&W Diesel A/S
Camshaft 906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1
1.
Turn in the AHEAD direction to ensure that

the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
HM906-7.0 56 01
2. Check the TDC position with the pin gauge 2.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

port and the bearing shell.
2. Coat the bearing shell with oil, mount the

shell on the camshaft, and turn it into place.
Using a caliper at both sides of the bearing

shell, check that the bearing is positioned
absolutely horizontally.
3. Lower the camshaft and remove the dial

gauge and the hydraulic jack from the en-
gine.
HN906-4.2 218 05
4. Lower the bearing cap on to the camshaft.
Remove the lifting tool from the bearing
cap.
HN906-4.4 218 03 3.
4.
D06-37
HN906-4.4 218 04
0$1% :'LHVHO$6
Mounting
5. 5. Mount the bearing cap screws.
Tighten both screws lightly.

D06-31
Using a socket spanner mounted on an ex-
tension and a torque wrench, tighten the
screws to the torque stated in Data.
Note!
To ensure that the bearing cap is not

displaced, the tightening must be done
in steps as follows:
NA906-4.2 207 02
1. Tighten the outermost screw

to half the torque stated in Data.
6. 2. Tighten the innermost screw

to half the torque stated in Data.
D06-33 3. Tighten the outermost screw

to the full torque stated in Data.
4. Tighten the innermost screw

to the full torque stated in Data.
6. Check the clearance between the bearing

cap and the bearing housing.
Mount the lubricating oil pipe on the bear-

ing cap.
NA906-4.4 207 06
Mount the plug screws in the baseplate.
7. Clean the camshaft housing and mount the

7. inspection covers, fitted with new gaskets.
NA906-4.4 207 07
0$1% :'LHVHO$6
Replacement of Cams on Camshaft 106-6
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10606
106-6 Data 0005 Replacement of Cams on Camshaft
X Stopped engine
X Shut off fuel oil
Data
D06-47 Exhaust cam screws, tightening torque 900 Nm

or 100 Nm
+ 30 °
D06-49 Fuel cam screws, tightening torque 1820 Nm
or 100 Nm
+30 °
D06-50 Fuel cam, marking scratch 115 mm
D06-51 Fuel cam, axial movement 155 mm
D06-52 Exhaust cam, marking scratch 105 mm
D06-53 Exhaust cam, axial movement 190 mm
MAN B&W Diesel A/S
106-6 Replacement of Cams on Camshaft
Data
P90851 173 Lifting tool for exhaust valve roller guide

P91351 22 Hydraulic pump, hand operated
P91351 166 Angle union
P91359 Torque Spanners
MAN B&W Diesel A/S
Replacement of Cams on Camshaft 906-6.2
Dismantling
Replacement of Cams on Camshaft
S60MC-C
0204
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft

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

tion. See Procedure 909-10.
3. Turn the camshaft so that the marking

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

D06-50. See Data.
XZ906-6.2 201 01
HHN909-10.1 205 01 2.
4.
XZ906-6.2 201 04
D06-50
0$1% :'LHVHO$6
906-6.2 Replacement of Cams on Camshaft
Dismantling
5. 5. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.
6. Connect the snap-on connectors to the hy-

draulic high-pressure pump.
Apply oil pressure to the cam, using the

high-pressure pump.
When oil seeps out along the cam, press

the cam sideways, in the direction towards
the forward end of the engine.
7. The cam should be moved as stated in

XZ906-6.2 201 05
D06-51 to be sure that it gets free of the lin-

er for the roller guide.
8. In case the cam cannot be moved as de-

6. scribed in item 6, MAN B&W should be con-
tacted for further instructions.
XZ906-6.2 201 06
7.
D06-51
XZ906-6.2 201 07
D06-51
0$1% :'LHVHO$6
Dismantling
Exhaust Cam 9.
9. Remove the front cover of the camshaft

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

tion. See Procedure 908-7.
11. Extend the marking scratch on the indicator

drive cam onto the camshaft.
Extend the marking scratch on the exhaust
XZ906-6.2 201 01
cam onto the camshaft by D06-52. See Da-
ta.
10.
JM908-5.0 55 03
11.
XZ906-6.2 201 11
D06-52
0$1% :'LHVHO$6
Dismantling
12. 12. Dismantle and remove the indicator drive

cam from the camshaft when fitted.
13. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.
14. Connect the snap-on connectors to the hy-

draulic high-pressure pump.
Apply oil pressure to the cam, using the

high-pressure pump.
When oil seeps out along the cam, press

the cam sideways, in the direction towards
XZ906-6.2 201 12
the aft end of the engine.
13.
XZ906-6.2 201 13
14.
XZ906-6.2 201 14
0$1% :'LHVHO$6
Dismantling
15. The cam should be moved as stated in 15.

D06-53 to be sure that it gets free of the lin-
er for the roller guide.
16. In the event that the cam cannot be moved

as described in item 14, MAN B&W should
be contacted for further instructions.
D06-53
D06-53
XZ906-6.2 201 15
0$1% :'LHVHO$6
Mounting
Mounting
906-6.4
1. Fuel Cam
1. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,

mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
2. Make sure that the marking scratches on

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.
Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the fuel cam lead (see Procedures

909-1 and 909-3) and adjust if necessary.
XZ906-6.4 201 01
Tighten the screws to D06-49 and check

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

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

shaft housing.
D06-49
XZ906-6.4 201 02
0$1% :'LHVHO$6
Mounting
Exhaust Cam 4.
4. Mount the indicator drive cam and adjust

according to Chapter 706 in the Operation
manual when fitted.
Tighten the self-locking nuts as stated in

D06-48.
5. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,
XZ906-6.4 201 04
mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
6. Make sure that the marking scratches on 5.

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.
Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.
Measure the exhaust cam lead (see Proce-

dure 908-5 and adjust if necessary.
Tighten the screws to D06-47 and check

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

(EN243S).
7. Mount the cover on the front of the cam- 6.

shaft housing.
XZ906-6.4 201 06
D06-47
D06-49
0$1% :'LHVHO$6
Chain Drive and Camshaft Panel Plate
P90651-0185
P90651
Chain
0185 Drive and Camshaft Panel
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft Panel
P90651-0185
Item Item
No. No.
019 Panel for tools

020 Name plate
044 Face impact wrench for fuel cam
056 Chain assembling tool
068 Chain disassembling tool
070 Chain assembling tool
081 Chain disassembling tool
140 Hydraulic jack
152 Lifting attachment camshaft bearing
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
Camshaft - Pin Gauge Plate
P90668-0003
Camshaft - Pin Gauge
0003
P90668
MAN B&W Diesel A/S
Plate Camshaft - Pin Gauge
P90668-0003
Item Item
No. No.
011 Pin gauge for camshaft
MAN B&W Diesel A/S
907 Starting Air System
107-1 0018 Starting Air Distributor, Data

907-1 0217 Starting Air Distributor
107-2 0034 Start Air Valve, Data
907-2 0216 Starting Air Valve
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Starting Air Distributor 107-1
Data
SAFETY PRECAUTIONS
Special Edition
D10701
107-1 Data 0018 Starting
L60MC-C
Air Distributor
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
107-1 Starting Air Distributor
Data
MAN B&W Diesel A/S
Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
L60MC-C
0217
Checking
907-1.1
2.
1. Turn the engine to bring the piston of cylin-
der No. 1 to TDC. Check the position with
the pin gauge.
2. Remove the small end cover of the distrib-

utor housing.
3. Check that the TDC marking scratch on the

starting cam is positioned vertically at the
valve slide of cylinder No. 1.
4. If necessary adjust the position of the start-
HN907-1.1 205 02
ing cam by loosening the centre screw and
turning the starting cam until the TDC
marking scratch is positioned vertically at
the valve slide of cylinder No. 1. Then tight-
en the centre screw.
HN907-1.1 205 03 3.
4.
HN907-1.1 205 04
MAN B&W Diesel A/S
907-1.3 Starting Air Distributor
Overhaul
Overhaul
907-1.3
2. Difficulties in starting can be caused by the

starting air distributor valve slides “sticking”
(see Volume I, Chapter 703), so that these are
not activated and pressed against the cam dur-
ing the starting procedure.
This can be caused by too high humidity in the

main starting air system, which can result in the
formation of rust, and also by dirt, preventing
the slide valves from functioning.
HN907-1.3 205 02
In both cases it is necessary to clean the valve

slides and the liners in the distributor housing
to remove dirt, rust and foreign particles.
3.
Experience will show how often this is neces-
sary to prevent starting difficulties, as differenc-
es will be found from plant to plant.
1. Blank off the main starting air and the con-

trol air. If this is not possible, lock the main
starting valve in the closed position with a
padlock.
2. Remove all the pipes from the end of the

distributor.
Loosen and remove the screws from the

small and large end covers. Dismount the
end cover which gives access to the slide
valves.
HN907-1.3 205 03
3. Turn the camshaft until the pin of the valve

slide (cam follower) can be pushed clear of
the starting cam.
4. 4. Remove the screws and the cap from the

particular valve slide in question.
Remove the guide screw for the valve slide.

HN907-1.3 205 04
MAN B&W Diesel A/S
Overhaul
5. Remove the complete slide valve (with 5.

spring and the upper liner) from the distrib-
utor housing by means of a brass mandrel.
6. Press-in the spring and remove the two part

locking ring.
7. Remove the upper spring guide, the spring,

the lower spring guide and the upper liner
from the valve slide.
907-1.3 217 05
907-1.3 217 06 6.
7.
MC907-2.2 29 07
MAN B&W Diesel A/S
907-1.3 Starting Air Distributor
Overhaul
8. 8. Clean all the sliding surfaces on the valve

slide. Check the sliding surfaces for wear
and seizures, also check the cam follower
for wear.
Clean the liners and the distributor housing.

Test that the valve slide moves easily in the
liners.
Note!
Polishing of the liners with emery cloth

must not take place as small particles of
907-1.3 217 08
the grinding material can stick in the sur-

face of the liner.
Lubricate all parts with Molybdenum Disul-

10. phide (MoS 2), also the cam follower must
be well lubricated.
9. Place the upper liner, the lower spring

guide, the spring and the upper spring
guide over the valve slide.
10. Press-in the spring and mount the two-part

locking ring.
11. Mount the complete slide valve in the dis-

tributor housing. (Check that the pin of the
valve slide goes clear of the starting cam
when mounting).
907-1.3 217 10
Lubricate the groove in the starting cam

with Molybdenum Disulphide (MoS 2).
11.
907-1.3 217 11
MAN B&W Diesel A/S
Overhaul
12. Mount the guide screw for the valve slide. 12.
Mount the cap and the screws on top of the
slide valve.
13. Check that the piston valve slides can be

pushed up and down by hand just overcom-
ing the force of the spring.
14. Finally, mount the two end covers and con-

nect the main starting air and the control
air.
HN907-1.3 205 04
HN907-1.3 205 02 14.
MAN B&W Diesel A/S
Starting Air Valve 107-2
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10702
107-2 Data 0034 Starting Air Valve
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D07-11 Valve tightening angle 60 °

D07-12 Starting air valve 52 kg
MAN B&W Diesel A/S
107-2 Starting Air Valve
Data
P90151 95 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve
MAN B&W Diesel A/S
Starting Air Valve 907-2.1
Checking
Starting Air Valve
L60MC-C
0216
Checking
907-2.1
1.
1. When the starting air valve has been over-
hauled, see Procedure 907-2.3, connect a
supply of working air to the control air inlet
at the top of the valve.
Check that the valve opens approx. 15-20

mm.
2. Shut off the air supply
Check that the valve closes fully.
3. Repeat steps 1 and 2 a couple of times.
HM907-2.1 202 01A
2.
HM907-2.1 202 01B
MAN B&W Diesel A/S
907-2.2 Starting Air Valve
Dismantling
Dismantling
907-2.2
1. 1. Shut off the starting air and control air inlet.
Dismount the control air pipe.
Hook a lifting wire around the starting valve

and attach the crane hook to the wire.
Unscrew the fixing nuts of the starting valve

flange.
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
JN907-2.2 205 01
2.
JN907-2.2 205 02
D07-12
MAN B&W Diesel A/S
Overhaul
Overhaul
907-2.3
1. Place the starting air valve horizontally in a 1.

bench vice provided with “soft” jaws.
Remove and discard the O-ring from the

valve housing.
2. Loosen and remove the screws from the top

cover.
Dismount the top cover.
3. Use the face wrench for the spindle as a

back-stop when loosening the two screws
which tighten the piston to the spindle.
HM907-4.0 39 01
Remove the screws and discard the locking
device.
When unscrewing, the piston will partially 2.

be pressed out of the valve housing due to
the spring force.
HM907-4.0 39 02
3.
HM907-4.0 39 03
MAN B&W Diesel A/S
Overhaul
4. 4. Remove the piston from the top end of the

valve housing.
Take out the spindle from the bottom end of

the valve housing.
Remove the spring from the top end of the

housing.
5. Apply grinding paste, e.g. carborundum No.

200. Grind the valve housing seating with
the grinding ring.
6. When lapping the seatings of the spindle

and valve housing to match, use the face
wrench to rotate the spindle.
As grinding paste, use e.g. carborundum

No. 500.
HM907-4.0 39 04
5.
HM907-4.0 39 05A
6.
MG907-4.0 51 05B
MAN B&W Diesel A/S
Overhaul
7. Thoroughly clean the valve housing and all 7.

the parts in diesel oil or kerosene.
Lubricate all internal parts and sliding sur-

faces with, e.g., Molybdenum Disulphide,
MoS 2.
Insert the spindle in the valve housing.

Then mount the spring in the housing
around the spindle and, finally, place the
piston on top of the spindle.
8. Fit the discs and the two screws.
When tightening the screws, the piston will

compress the spring.
Tighten the screws continuously until the

piston faces tightly against the spindle. Use
the face wrench as a back-stop.
Lock the screws with locking device.

HM907-4.0 39 07
For correct use of locking device, see Pro-

cedure 913-7.
9. Mount and tighten the top cover.
Fit a new O-ring on the valve housing. 9.
10. Check the starting air valve.

If the valve is not to be mounted in the en-

gine immediately, cover all openings with
plastic to prevent dirt from entering the
valve during storage.
HM907-4.0 39 09
MAN B&W Diesel A/S
Mounting
Mounting
907-2.4
1. 1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recon-
dition the seat for the starting valve in the
bore, see Procedure 901-1.3.
If not already done, fit a new O-ring on the

overhauled valve and lubricate with ‘Never
Seize’ or Molybdenum Disulphide, MoS 2.
For overhaul, see Procedure 907-2.3 .
2. Mount the valve in the cylinder cover.
3. Mount the nuts and tighten-up in at least

HG907-2.4 201 01
three steps, to reach the full tightening an-

gle, see Data.
Mount the control air pipe and turn on start-

ing air and control air.
2.
JN907-2.4 205 02
D07-12
3.
D07-11
D07-11
HM901-2.2 114 03
MAN B&W Diesel A/S
908 Exhaust Valve
108-1 0031 High-Pressure Pipe, Data

908-1 0216 High-Pressure Pipe
108-2 0059 Exhaust Valve, Data
108-3 0034 Exhaust Valve Actuator, Data
908-3 0227 Exhaust Valve Actuator
108-4 0031 Exhaust Valve Roller Guide, Data
908-4 0217 Exaust Valve Roller Guide
108-5 0010 Exhaust Valve Cam, Data
908-5 0214 Exhaust Valve Cam
108-7 0031 Exhaust Valve - Special Running, Data
90851 0165 Exhaust Valve - Panel
90861 0037 Exhaust Valve - Tools
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90864 0003 Exhaust Valve - Extractor Tool
MAN B&W Diesel A/S

MAN B&W Diesel A/S
High-Pressure Pipe 108-1
Data
SAFETY PRECAUTIONS
Special
D10801 Data 0031
108-1 Edition High-Pressure
S60MC-C Pipe
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D08-01 High-pressure pipe, tightening torque 70 Nm

D08-02 Distance of high-pressure pipe lower edge to pressure flange 16 mm
D08-03 High-pressure pipe 38 kg
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data
P90851 112 Grinding mandrel for high-pressure pipe
MAN B&W Diesel A/S
High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
L60MCC
0216
Dismantling
908-1.2
1.
1. When replacing the hydraulic high-pressure
pipe, the exhaust valve or the hydraulic ac-
tuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.
2. Before dismantling the high-pressure pipe,

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

pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator.
D08-03
HM908-1.0 48 01
2.
GM908-1.0 55 02
0$1% :'LHVHO$6
908-1.3 High-Pressure Pipe
Overhaul
Overhaul
908-1.3
1. 1. Check the contact surfaces of the pressure

pipe for marks and, if necessary, grind the
pipe ends by means of the grinding mandrel
and the two guiding tools.
Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and fin-
ish with a fine grinding paste, for example
HM908-1.0 48 03
Carborundum No. 500.
2. After reconditioning the contact surfaces of

the pipe, measure the distance from the
edge of the thrust bushing to the contact
2.
surface at both ends of the pipe. This meas-
urement is to correspond with the value
stated in Data.
Check the thrust pads in the exhaust valve

and the actuator for marks on the sealing
surface.
HM908-1.0 48 04
Replace the O-rings on the thrust pads.

D08-02
If considered necessary, replace the thrust
pads.
Lift the thrust pad free by, for example, us-

ing a screwdriver in the groove of the thrust
pad.
0$1% :'LHVHO$6
High-Pressure Pipe 908-1.4
Mounting
Mounting
908-1.4
1. Mount the hydraulic high-pressure pipe as 1.

follows:
Position the high-pressure pipe with the

sealing surfaces of the pipe resting on the
thrust pads of the exhaust valve/actuator.
Take care not to damage the O-rings on the
thrust pads.
After fitting the pipe correctly in relation to

the exhaust valve and actuator, tighten up
HM908-1.0 48 05
the screws of the pressure flanges diago-
nally, see Data. D08-01
2. Check the whole system for tightness.

See Procedure 908-3.1. 2.
HM908-1.0 48 04
0$1% :'LHVHO$6
Exhaust Valve 108-2
MAN B&W Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X Stopped engine
X Shut off starting air supply – At starting air receiver
X Block the main starting valve
X Shut off starting air distributor/distributing system supply
X Shut off safety air supply – Not ME engines
X Shut off control air supply
X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors
Data
D08-04 Safety valve, opening pressure 23 bar

D08-05 Screws for lifting eye bolt, tightening torque 50 Nm
D08-06 Oil cylinder, tightening torque 100 Nm
D08-07 Safety valve, tightening torque 50-80 Nm
D08-09 Bottom piece seat, grinding angle 29.9-30.0 °
D08-10 Valve spindle seat, grinding angle 30.3-30.4 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1 mm
D08-13 Spindle, max. burn-off 9 mm
D08-14 Spindle, max. grinding 2 mm
D08-15 Spindle stem, measuring area, min. 280 mm
D08-16 Spindle stem, measuring area, max. 410 mm
D08-17 Spindle stem, min. diameter 71.8 mm
D08-18 Bushing max. diameter, top 72.6 mm
D08-19 Bushing max. diameter, bottom 74.5 mm
D08-20 Oil cylinder max. inside diameter 85.4 mm
D08-21 Piston rings, min. thickness 3.2 mm
D08-24 Exhaust valve, complete 710 kg
D08-25 Exhaust valve housing 380 kg
D08-26 Oil cylinder 100 kg
D08-27 Air cylinder 30 kg
D08-28 Spindle 73 kg
D08-29 Bottom piece 100 kg
D08-30 Air piston 9 kg
108-2 Exhaust Valve
Data MAN B&W
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.
P90851 065 Lifting tool for exhaust valve

P90851 077 Cone ring for pneumatic piston
P90851 089 Pressure tester for safety valve
P90851 090 Gauge for exhaust valve spindle
P90851 148 Tool for hydraulic piston
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece
P90862 Jack-hydraulic, complete

Exhaust Valve 908-2.1
MAN B&W Checking
Checks during running:

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

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

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

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

eration.
Exhaust valve performance condition

See volume I chapter 706 Performance
Evaluation
2. Check of bottom piece sealings

M908020254C03
With the exhaust valve mounted in the cyl-

inder cover, check the cooling water inlet
and outlet to the cylinder cover and ex-
haust valve is open.
Check the tightness of the sealing rings

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

exhaust valve must be dismounted and the
sealing rings replaced.
908-2.1 Exhaust Valve
Checking MAN B&W
Check with stopped engine:

3.
In connection with port stays, at an interval
of e.g. one month, an easy check of all ex-
haust valves is recommended.
3. Check of spindle dropdown time:
Engage all rotation indicators on the ex-

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

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

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

M908020273C03
minutes and 1 hour: Keep under obser-

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

lift the rotation indicators and lock them in
the top position.
MAN B&W Checking
4. Check of Air spring tightness

4.
Connect compressed air to the non return
(A) valve on the air cylinder.
Disconnect and remove the drain oil pipe

from the oil cylinder (C).
Check if air is coming out from:

B A
• The bore (B): Leakage from spindle
stem sealing , change and overhaul.
• Hole for drain oil (C): If yes, the leakage

comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and over-
haul.
• Remove the air supply to the nonreturn

valve on the air cylinder and check the
nonreturn valve for tightness.
D A
The checks is for guidance only, minor
leaks is difficult to detect.
D
C
C
M908020273C04
Dismantling MAN B&W
1. Close off cooling water

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

draulic valve actuation.
See Procedure 9081.2
Dismount the return oil pipe from the ex-

haust valve.
M908020273D01
2.
M908020273D02
MAN B&W Dismantling
3. Disconnect pipe connections

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

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

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

chain block and remove the screws.
M908020273D03
4. Dismantling of hydraulic nuts.
Remove the protective caps from the ex-

haust valve studs.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 9131.
D1302
M908020273D04
Dismantling MAN B&W
5. Lift of exhaust valve

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

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

on the platform.
Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
ing and sealing surfaces of the bore, if re-
quired.
See Procedure 9011.3.
For overhaul of the exhaust valve, see Pro-

cedure 9082.3
M908020273D05
MAN B&W Overhaul
1. Oil cylinder
1.
Place the exhaust valve on a wooden sup-
port on the platform.
Remove the nuts and the safety strap from

the oil cylinder.
D0826
Lift away and place the oil cylinder on a
wooden support.
2. Conical locking ring
Relieve the air pressure through the

nonreturn valve from below the piston. Use
a small screwdriver to press the ball into
the nonreturn valve. Cover the nonreturn
valve with a rag to catch the oil drops.
Unscrew the non-return valve from the air

cylinder.
M908020273O01
Remove the four screws from the flange

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

ing ring by means of a tin hammer, and re-
move the conical locking ring. 2.
M908020273O02
Overhaul MAN B&W
3. Spindle
3.
Use the oil cylinder as a lifting tool for the
exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
D0824 so that the load from the valve housing is
evenly distributed.
Lift the valve housing clear of the valve

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

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
M908020273O03
If the bottom piece has become stuck, use

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

couple of wooden planks.
4.
Remove the oil cylinder.
D0829
M908020273O04
MAN B&W Overhaul
5. Air piston and cylinder

5.
Dismount the air piston from the air cylin- D08-30
der.
Mount two eye bolts in the air cylinder and

dismount the air cylinder.
D08-27
Remove and discard the Oring on the air
cylinder.
6. Guide bushing
Clean the exhaust valve housing.
M908020273O05
Inspect the bushing in the spindle guide for
wear and measure the top and bottom di-
ameters. See Data.
6.
D0818
M908020255O10
D0819
Overhaul MAN B&W
7. Bushing renewal
7.
If it proves necessary to replace the bush-
ing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.
Alternatively, if the extractor tool is avail-

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

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

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

M908020256O08
ume I, supplement 70703
Inspect and evaluate the seating according

to Volume I.
8.
M908020256O09
MAN B&W Overhaul
9. Bottom piece Measuring

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

D0811 and D0812.
D0809
If the seat or the recess G3 is ground, see
Data D08 – 09 for correct grinding angle.
IF the template rests on the lower surface

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

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

M908020255O15
Overhaul MAN B&W
11. Bottom piece sealing rings

11.
Mount new sealing rings on the bottom
piece.
Mount one Oring in the upper groove.
Make sure that the groove for the Useal is

clean.
Heat the Useal in 100°C hot water for min-

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

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

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

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

tom piece. Mount and tighten the retaining
screws for the bottom piece.
M908020273O12
MAN B&W Overhaul
13. Spindle inspection

13.
Before cleaning the spindle, See Volume I,
supplement 70703
Inspect and evaluate the spindle according

to Volume I.
14. Spindle burnoff and grinding check
In connection with evaluation of the spindle

according to Volume I, burnoff and wear or
the total amount the seat has been ground,
are measured as described below.
M908020256O14
The burnoff F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
14.
For the maximum allowable burnoff, see G1
Data D0813.
The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge. D0814
For maximum seat grinding, see data D08

– 14. F1
If necessary to grind the seat, see Data D0810
M908020256O15
D0810 for correct grinding angle.

A
D0813 D E
Overhaul MAN B&W
15. Spindle stem check

15.
In connection with evaluation of the spindle
according to Volume I, the spindle stem
wear is measured as described below.
D0816 D0815
Check the spindle stem for wear in the
area D0815 to D0816 measured from the
top of the spindle.
D0817
For minimum stem diameter, see data D08
17.
If the exhaust valve spindle needs recondi-

tioning, contact MAN Diesel for advice.
16. Spindle transport
When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
M908020252O19
16.
D0828
M908020255O16
MAN B&W Overhaul
17. Spindle bushing sealingrings

17.
Check the top of the spindle bushing and
the face on the housing is clean.
Fit new orings on the spindle bushing as

shown in the sketch.
18. Spindle mounting
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
M908020256O18
exhaust valve housing.
Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
18.
Remove the oil cylinder.
M908020273O18
Overhaul MAN B&W
19. Air cylinder

19.
Clean the air cylinder.
Dismount the safety valve from the air cyl-

inder, use the machined faces to unscrew
the valve.
Unscrew the plug for the bore to the spin-

dle stem bushing. Blow through all bores
in the air cylinder. Clean the bottom of the
air cylinder for possible coke deposits. Re-
mount the plug. Mount a new Oring in the
Compressed Air groove on the outside of the air cylinder.
20. Safety valve
Place the safety valve in the pressure test-

ing device. Connect the testing device with
the high pressure pump by means of a
hose.
M908020256O20
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
20. and test the opening pressure once more.
Mount a new gasket and a new Oring on

the safety valve. Mount the safety valve in
the bore near the bottom of the air cylinder.
When mounting the safety valve in the air
D08-04 cylinder, use only the machined faces on
the valve housing and tighten, see Data.
Finally, mount the protective cap.

M908020256O21
D08-07
MAN B&W Overhaul
21. Air cylinder mounting

21.
Lubricate the Orings on the spindle bush-
ing.
Carefully land the air cylinder on the ex-

haust valve housing and check correct en-
gaging with the locating pin. Some engines
are not equipped with the locating pin.
Note!
Take care not to damage the Orings on
the outside of the spindle bushing.
M908020256O22
22. Air piston seals
Check the teflon guide ring and teflon seal-

ing ring for wear, if it is necessary to re- 22.
place the sealing rings on the air piston, cut
them and remove them.
Be careful not to damage the edges of the

ring grooves in the piston.
Note!
Before mounting, heat the new teflon
rings in 100°C hot water for at least five
minutes. When mounting the teflon rings,
M908020252O32
be careful not to damage the running

surfaces.
After mounting, compress the teflon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new Orings in the inside grooves of

the air piston.
Overhaul MAN B&W
23. Air piston mounting

23.
IMPORTANT!
Fill the bottom of the air cylinder up to
the drain hole with clean lubricating oil.
Clean oil
Fit the conical guide ring for the air piston
Oil level on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press

the air piston down in the cylinder
Remove the conical guide ring from the air

cylinder.
Mount the non return valve for spring air
24. Locking ring

M908020273O23
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
Mount the flange on top of the air piston

24. and, by means of the four screws, tighten
the air piston and the flange together.
On valve models where the bolts are de-

signed for securing, secure the bolts. See
Procedure 9137.
Compressed Air
M908020273O24
MAN B&W Overhaul
25. Oil cylinder

25.
Loosen the screws and remove the lifting
bracket from the oil cylinder to gain access
to the orifice plug.
Remove and discard the gasket. Unscrew

and clean the orifice plug. Remove and dis-
card the sealing disc. Check and clean the
bore for the orifice plug in the top of the oil
cylinder.
Place the oil cylinder in a horizontal posi-

tion. Remove the flange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylin-
der diameter. If the diameter of the oil cylin-
der exceeds Data D0820, either renew the D08-20
liner or send the complete oil cylinder to an
authorised MAN Diesel workshop for over-
haul, depending on the valve model.
M908020273O25
26. Oil piston
Remove the piston rings from the oil pis-

ton and check them for wear. If the thick-
ness of the rings has worn down to the
minimum, see Data, discard the rings and
mount new ones. Check that the TOP mark 26.
on the piston rings faces upwards, when Top
mounting
Check the mesh once more.
D0821
M908020253O42
Overhaul MAN B&W
27. Oil cylinder assembly

27.
Mount the piston and the flange in the oil
cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright posi-

tion. Mount a new sealing disc in the bore
for the orifice plug. Screw the orifice plug
into the bore. Place a new gasket on top
of the oil cylinder. Mount the lifting bracket
on the oil cylinder. Mount the screws and
tighten to the torque stated in Data.
28. Oil cylinder mounting

D08-05 Mount the overhauled oil cylinder on top of
the air cylinder. Mount the safety strap and
tighten the nuts. See Data.
M908020273O27
28.
D0806
M908020273O29
MAN B&W Mounting
1. Checks before mounting

1.
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve is checked and prepared as fol-
lows:
Check the oil level in the bottom of the air

cylinder. Unscrew and remove the non-re-
turn valve and the safety valve.
Fill oil into the non-return valve hole until oil

flows out from the safety valve hole.
Refit the two valves again.
Connect compressed air to the air cylinder D0824

to close the valve.
Lift up the valve with the engine room
crane.
G3
Check that a 1.0 mm feeler gauge can be
inserted about 15 mm into gap G3, to en-
M908020273M01
sure that there is a clearance between the

outer parts of the seating faces of valve
housing and spindle.
The valve must be able to stay closed for a

minimum of 15 minutes or according to the
dropdown test in Procedure 908-2.1. 2.
Note!
If the air cylinder is fitted with new seal-
ing rings, the time the valve is closed
may be considerably shorter than 15
minutes. The dropdown test should not
be carried out until after a »running-in« Compressed Air
period of 500 hours on valves with new
sealing rings.
Check the valve is fitted with new sealing

rings in the grooves on the bottom piece.
2. Exhaust valve landing
Close the valve with compressed air. Copper Grease

Vaseline
Lubricate the sealing rings with vase-
line and the threads of the studs with
antiseizure paste.
M908020273M02
Position the valve in the cylinder cover

bore, guiding it in accordance with the ex-
haust flanges and the guide pin on the ex-
haust side of the exhaust valve.
Mounting MAN B&W
3. Mounting of hydraulic nuts.

3.
Mount and tighten the hydraulic nuts, see
Data.
D1301 See Procedure 9131.
Mount the protective caps on the exhaust

valve studs.
4. Mount the pipe connections
Connect the intermediate pipe to the ex-

haust valve.
M908020273M03
Mount and tighten the screws to the ex-

haust valve housing.
Mount the insulation and plate jacket
4. for the intermediate pipe.
Mount the cooling water connections for

the exhaust valve and the air pipe for the
air spring.
5. Mount the oil pipe connections
Mount the highpressure pipe for the hy-

draulic valve actuation.
See Procedure 9081.2
Mount the return oil pipe to the exhaust-

M908020273M04
valve.
Check that all pipe connections are prop-

erly tightened.
5.
M908020273M05
MAN B&W Mounting
6. Open cooling water supply

6.
Check that all water connections are
mounted and tightened.
Open the cooling water inlet supply, and

vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 9082.1.
7. Air spring check
The air supply to the exhaust valve must al-

ways be connected and pressurized before
turning on the oil supply to the exhaust
valve actuator.
M908020273M06
If the lubricating oil pumps have been

started before the exhaust valve pneumatic
springs are pressurize:
Engage the indicators on top of the ex-

haust valves and wait until the exhaust
valves are closed. 7.
Closing of the exhaust valves are eased

if the lubrication oil pumps are stopped
and the actuators are drained at the drain
screws.
M908020256M07
Closed Valve Open Valve
Exhaust Valve Actuator 108-3
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10803
108-3 Data 0034 Exhaust Valve Actuator
X Stopped engine
X Shut off fuel oil
Data
D08-20 Oil cylinder max. inside diameter 85.4 mm

D08-21 Piston rings, min. thickness 3.2 mm
D08-32 Hydraulic actuator, tightening torque 500 Nm
D08-33 Locking plate, tightening torque 25 Nm
D08-34 Hydraulic actuator, tightening angle 30 °
D08-35 Hydraulic actuator 90 kg
MAN B&W Diesel A/S
108-3 Exhaust Valve Actuator
Data
MAN B&W Diesel A/S
Exhaust Valve Actuator 908-3.1
Checking
Exhaust Valve Actuator
L60MC-C
0227
Checking
908-3.1
1.
1. The non-return valve A is built into the oil
inlet pipe to the actuator.
To check the valve, dismantle and clean it

and connect a supply of working air (7 bar)
to the outlet side of the valve (the side fac-
ing the actuator). If the air flow can be felt
at the inlet side of the valve, the valve must
be overhauled.
2. Leakages in the exhaust valve can be

measured – during running of the engine –
by collecting the oil from the drain pipe C
leading from the exhaust valve to the hy-
draulic actuator.
Leakages may also be caused by leaky

non-return valves and loose pressure pipe
connections.
If the pipe connections are tight and the

leak oil amount from the exhaust valve is
normal, any abnormally large leakages
must originate from the hydraulic actuator
from which leak oil quantities cannot be di-
rectly registered.
The hydraulic actuator is then to be disman-

tled for checking of the parts.
See Procedure 908-3.2
HM908-3.0 70 1/3
0$1% :'LHVHO$6
908-3.2 Exhaust Valve Actuator
Dismantling
Dismantling
908-3.2
1. 1. Stop the engine and shut off the oil supply.
Turn the camshaft so that the roller rests on

the circular part of the cam.
Remove the inspection cover of the roller

guide housing to check the position of the
exhaust cam.
Dismount the inlet pipe and the drain pipe

from the exhaust valve.
Dismount the high-pressure pipe.

GM908-3.0 78 01
2. Release the mountings for the indicator

drive from the actuator housing.
2. Fit eye screws in the lifting holes of the ac-

tuator housing and hook on a tackle.
D08-35
Unscrew the nuts on the two short studs,
then loosen the nuts on the long studs suc-
cessively until the roller guide spring is re-
lieved.
Dismount the nuts and lift the housing care-

fully, leaving the piston on top of the roller
guide.
Remove the spring.

HG908-3.3 201 02
3. Remove the locking plate for the piston.

Turn the piston 90° to release it from the
bayonet joint.
3. Remove the piston from the roller guide.
4. Overhaul the actuator housing and the pis-

ton as required.
HM908-3.0 70 03
0$1% :'LHVHO$6
Exhaust Valve Actuator 908-3.3
Overhaul
Overhaul
908-3.3
1. Clean the piston in kerosene and wipe dry 1.

D08-21
with a clean piece of cloth.
Take off the piston rings and check them for

wear. If the ring thickness has worn down
to the minimum (see Data), discard the
rings and mount new ones.
Check that the TOP mark on the piston

rings faces upwards when mounting.
2. Inspect the sliding surfaces of the piston to

ensure that there are no scratch marks or
seizure marks.
3. Clean the oil cylinder and inspect the bores

for deposits.
Check the bore of the oil cylinder for possi-

ble scores and measure it for wear.
HM908-3.0 69 04
If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised work-
shop for reconditioning.
3.
D08-20
JM908-3.0 73 05
0$1% :'LHVHO$6
908-3.4 Exhaust Valve Actuator
Mounting
Mounting
908-3.4
1. 1. Mount the actuator piston in the roller guide

and turn 90° to lock it in the bayonet joint.
D08-33
Mount the locking plate and tighten as stat-
ed in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
2. Mount the spring on the roller guide. Care-

fully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
Mount the washers and nuts on the two

long studs and tighten alternately until the
KC908-3.0 76 05
actuator housing rests firmly against the

roller guide housing.
Mount the washers and nuts on the two

2. short studs. Tighten all four nuts as stated
in Data.
Note!
Use only the tightening angle OR the

tightening torque, NOT both.
D08-32
3. Mount the oil inlet pipe and the drain pipe
or
from the exhaust valve.
D08-34
Mount the hydraulic high pressure pipe.
HG908-3.4 201 02
3.
HG908-3.4 201 03
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 108-4
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10804
108-4 Data 0031 Exhaust Valve Roller Guide
X Stopped engine
X Shut off fuel oil
Data
D08-36 Bushing/shaft pin, max. clearance 0.5 mm

D08-38 Roller guide complete 45 kg
MAN B&W Diesel A/S
108-4 Exhaust Valve Roller Guide
Data
P90851 53 Lifting tool for roller guide
MAN B&W Diesel A/S
Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valve Roller Guide
L60MC-C
0217
Checking
908-4.1
2.
1. The exhaust valve roller guide can be par-
tially checked while mounted on the engine,
using the following procedure:
Lift the roller guide.

2. Remove the camshaft inspection cover.
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
JN908-4.1 205 02
Check the movability of the roller by turning
this by hand to ascertain if the roller moves
freely and without unnecessary resistance
or “hard” points.
Also inspect the surface of the roller for 3.

possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide hous-
D08-36
ing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
A more suitable and reliable method is to

check the roller guide and the bearing
clearance when the roller guide is dis-
mounted.
For dismantling of the roller guide, see Pro-
cedure 908-4.2.
3. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
KC908-4.0 57 05
scratches.
4. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.
5. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance directly on the dial, see Data.
0$1% :'LHVHO$6
908-4.2 Exhaust Valve Roller Guide
Dismantling
Dismantling
908-4.2
1. 1. Dismantle the hydraulic actuator above the

exhaust valve roller guide.
2. Mount the roller guide lifting tool as follows:
• Lift the lock ring of the tool up on the

shaft of the tool.
• Place the tool in such a manner that its

foot rests on the thrust piece in the bayo-
net joint of the roller guide.
• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.
• Lower the lock ring, thereby securing the

foot in the locked position.
Lift the roller guide out of the roller guide

housing, using the crane. Take care not to
damage the sliding surfaces of the roller
guide when lifting.
HG908-3.3 201 02
2.
D08-38
HM908-4.0 51 02
0$1% :'LHVHO$6
Exhaust Valve Roller Guide 908-4.3
Overhaul
Overhaul
908-4.3
1. Inspect and check the exhaust valve roller 1.

guide.
2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
• seizure marks on the slide surfaces,
have been observed during the checking of

the roller guide.
Note!
For disassembling of the roller guide,

GM908-4.0 73 05
contact an MAN B&W authorized repair

shop.
3. If no irregularities are found, just clean and

lubricate the roller guide before remounting
it in the roller guide bushing.
0$1% :'LHVHO$6
908-4-4 Exhaust Valve Roller Guide
Mounting
Mounting
908-4-4
1. 1. Mount the lifting tool for the roller guide as

follows:
• Lift the lock ring of the tool up on the

shaft of the tool.
• Place the tool in such a manner that its

foot rests on the thrust piece in the bayo-
net joint of the roller guide.

• Lower the lock ring, thereby securing the

foot in the locked position.
Lubricate the sliding surfaces of the roller

and the roller guide and lower it carefully
into the roller guide bushing.
Remove the lifting tool.
2. When mounting the roller guide, check the

HM908-4.0 51 02
clearance between the roller guide and the

guide plate mounted in the roller guide lin-
er.
2. Turn the camshaft so that the roller guide is

lifted approx. 20 mm. The clearance be-
tween the roller guide and the guide plate
should be the same at both ends +/– 0.1
mm.
3. Mount the actuator.

HM908-4.0 51 10
0$1% :'LHVHO$6
Exhaust Valve Cam 108-5
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10805
108-5 Data 0010 Exhaust Valve Cam
X Stopped engine
X Shut off fuel oil
Data
D08-39 Check lifting height 12 mm
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
Data
MAN B&W Diesel A/S
Exhaust Valve Cam 908-5.1
Checking
Exhaust Valve Cam
S42MC
0214
Checking
908-5.1
1.
1. Turn the crankthrow of the cylinder con-
cerned to TDC. Check and note down the
angle indicated on the turning wheel.
2. Turn in AHEAD direction until the roller guide
HM906-7.0 56 01
(measured on the activator plunger) is lifted
corresponding to D08-39, and calculate the
angle A, which is the number of degrees
the crankthrow has turned from TDC posi-
tion to the present position. For D08-39, 2.
see Data.
Continue turning AHEAD until the roller

guide (measured on the activator plunger)
is lifted to distance D08-39, and calculate
the angle B, which is the number of de-
grees the crankthrow has turned from TDC
position to the present position.
D08-39
17
17 mm
Note!
When calculating the angles A and B,

remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees.
17 mm
HM908-7.0 25 1/1
3. Calculate the lead angle as: D08-39
180° – A° + B°
2
The illustration shows the position of the 4.

exhaust cam when the piston of the rele-
vant cylinder is in TDC.
See the Adjustment Sheet in Volume I, OP-

ERATION, Chapter 701, for the "lead an-
gle" of the plant in question.
4. The cam lead angle can be checked visu-

ally by reading directly the scale position of
the exhaust cam over the marking scratch
on the camshaft and comparing this angle
with the angle stated in the Adjustment
Sheet.
At the same time, it is recommended to

check the position of the camshaft with the
pin gauge. See Procedure 906-3.1.
HM908-7.0 25 1/1
0$1% :'LHVHO$6
Exhaust Valve 108-7
Data
SAFETY PRECAUTIONS
Special Edition
S42MC
D10807
108-7 Data 0031 Exhaust Valve
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
108-7 Exhaust Valve
Data
P90851 124 Tool for emergency open exhaust valve

P90851 173 Lifting tool for exhaust valve roller guide
MAN B&W Diesel A/S
Exhaust Valve 908-7
Special Running
Exhaust Valve
S60MC-C
0226
Special Running
908-7
3.
Engine trouble might require that a cylinder be
taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve

locked in either the open or the closed position.
Either way, carry out the following procedure:
1. Lift the relevant fuel pump roller guide.

HN908-7.0 226 03
2. Dismantle the hydraulic high-pressure
pipe.See Procedure 908-1.3.
3. Dismantle the non-return valve on the oil in-

let pipe. Loosen the union nut in the bottom
of the oil pipe and turn the pipe to one side. 4.
Mount the non-return valve on the oil pipe
and blank off the non-return valve with the
plug from tool panel 908.
4. Remove the inspection cover of the cam-

shaft housing. Turn the engine until the ex-
haust roller guide is at TDC.
5. Position the lifting tool on the actuator and

screw the spindle into the top of the actua-
tor piston.
Tighten the lowermost nut on the tool to pull

JN908-4.1 205 02
up the roller guide as far as possible.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position. 5.
6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.
JM908-5.0 55 03
0$1% :'LHVHO$6
908-7 Exhaust Valve
Special Running
7. If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:
7. Turn off the air to the exhaust valve.
Remove the venting plug screw, fitted just

above the ball cock on the air cylinder, to let
the air inside the air cylinder escape.
8. Dismantle the rotation indicator on the oil

cylinder and mount the tool for opening of
the exhaust valve. The tool is found on tool
panel 908.
The tool will keep the piston of the air cyl-

inder in the bottom position and thus keep
the exhaust valve open.
KC908-6.0 18 02
8.
HN908-7.0 226 08
0$1% :'LHVHO$6
Exhaust Valve 908-7
Special Running
After overhaul of the cylinder unit, re-engage 9.

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower

the roller guide on to the exhaust cam. Re-
move the tool.
10. If the engine has been running with the ex-

haust valve open, remove the tool mounted
in the oil cylinder and mount the rotation in-
dicator.
Note!
The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.
Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the for-
mation of a wear groove in the air piston
JM908-5.0 55 06
of the exhaust valve.
Re-connect the air supply to the air cylin-

der.
11.
11. Remove the plug from the non-return valve
and re-connect the oil inlet pipe on the ac-
tuator housing.
12. Mount the hydraulic high-pressure pipe.

13. Engage the fuel pump roller guide.

HN908-7.0 226 11
0$1% :'LHVHO$6
Exhaust Valve Panel Plate
P90851-0165
Exhaust Valve Panel
0165
P90851
MAN B&W Diesel A/S
Plate Exhaust Valve Panel
P90851-0165
Item Item
No. No.
016 Panel for tools

028 Name plate
053 Lifting tool for roller guide
065 Lifting tool for exhaust valve
077 Cone ring
089 Pressure testing device 0-50 bar
090 Gauge for exhaust valve spindle
100 Stepped drift
112 Grinding tool for high pressure pipe
124 Tool for opening of exhaust valve
136 Bridge gauge for exhaust valve
148 Tool for hydraulic piston
150 Gauge for exhaust valve seat
161 Lifting tool for exhaust valve spindle
173 Lifting tool for exhaust valve roller
guide
185 Grinding ring for exhaust valve seat
MAN B&W Diesel A/S
Exhaust Valve - Tools Plate P90861-0037
Exhaust Valve - Tools

0037
P90861
When referring to this page, please quote Plate P90861 Edition 0037
MAN B&W Diesel A/S
Plate P90861-0037 Exhaust Valve - Tools
Item Item
Part Description Part Description
No. No.
46 Grinding machine, complete
When ordering spare parts, please

refer to the Chris Marine manual
When referring to this page, please quote Plate P90861 Edition 0037
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools Plate
P90862-0041
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0041

No. No.
028 Hydraulic jack, complete

030 Support
089 Tommy bar
090 Spanner
100 Stud setter
207 Hydraulic tool set, complete
MAN B&W Diesel A/S
Exhaust Valve - Extra Tools Plate
P90863-0014
Exhaust Valve - Extra Tools
0014
P90863
MAN B&W Diesel A/S
Plate Exhaust Valve - Extra Tools
P90863-0014
Item Item
No. No.
011 Worktable
MAN B&W Diesel A/S
Exhaust Valve - Extractor Tool Plate
P90864-0003
MAN B&W Diesel A/S
Plate Exhaust Valve - Extractor Tool
P90864-0003

No. No.
017 Extractor tool, complete
MAN B&W Diesel A/S
909 - Fuel Oil System
109-01 0055 Fuel Pump Settings, Data

909-01 0240 Fuel Pump Settings
109-02 0004 VIT System, Data
909-02 0205 VIT System
109-03 0047 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0042 Fuel Pump, Data
909-04 0222 Fuel Pump
109-05 0045 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0039 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0029 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0037 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0026 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10910 0013 Lifting Gear Roller Guide, Data
90910 0211 Lifting Gear for Roller Guide
10911 0063 Fuel Valve, Data
90911 0233 Fuel Valve
10912 0038 Spindle Guide, Data
90912 0221 Spindle Guide
10913 0031 Non-Return Valve in Fuel Valve, Data
90913 0206 Non-Return Valve in Fuel Valve
10914 0055 Fuel Oil High-Pressure Pipes, Data
90914 0234 Fuel Oil High-Pressure Pipes
10915 0046 Fuel Pump Roller Guide, Data
90915 0226 Fuel Pump Roller Guide
MAN Diesel A/S

90951 0431 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90967 0001 Fuel Puncture Valve - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
MAN Diesel A/S

Fuel Pump Settings 109-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10901
109-1 Data 0055 Fuel Pump Settings
X Stopped engine
X Shut off fuel oil
Data
D09-02 Change of one index mark corresponds to pmax being altered approx. 3.0 - 4.0 bar
MAN B&W Diesel A/S
109-1 Fuel Pump Settings
Data
MAN B&W Diesel A/S
Fuel Pump Settings 909-1.3
Adjustment
Fuel Pump Settings
S60MC-C
0240
Adjustment
909-1.3
1.
Before adjustment of the fuel pump is carried
out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:
1. The Maximum Combustion Pressure (pmax)

is adjusted for the individual units at the fuel
pump VIT index arm. For collective adjust-
ments of pmax on all units, see Procedure
909-2.
HN909-1.3 240 01
2. Loosen lock nut B and then turn adjusting
screw H. The link can be adjusted by ap-
prox. 3 index marks.
3. To increase p max, adjust to higher VIT index 2.

(advance injection).
To decrease p max, adjust to lower VIT index

(delay injection).
One index mark will alter pmax approximate-

ly as given in Data D09-02.
Note!
The individual pmax value must not devi-

ate more than 3 bar from the average
value for all cylinders.
4. If the required pmax adjustment cannot be

HN909-1.3 240 02
attained by adjustment on the VIT index

arm, it is possible to carry out the adjust-
ment on the fuel cam disc. Contact MAN
B&W Diesel for advice.
0$1% :'LHVHO$6
909-1.3 Fuel Pump Settings
Adjustment
5. MIP adjustment:
5. The Mean Indicated Pressure (pi) for a cer-

tain cylinder is adjusted on the fuel pump
index arm.
Increase index for higher p i.
Decrease index for lower p i.
Note!
HN909-1.3 240 05
The mean indicated pressure is one of

the most important parameters in obtain-
ing good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the aver-
age value for all cylinders. See Volume I,
Chapter 706.
0$1% :'LHVHO$6
VIT System 109-2
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10902
109-2 Data 0004 VIT System
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-2 VIT System
Data
MAN B&W Diesel A/S
VIT System 909-2.3
Adjustment
VIT System
0205
.0&&
Adjustment
909-2.3
1.
The engine may be equipped with either a me-
chanical or an electronic VIT (Variable Injection
Timing) system.
If the fuel quality has changed or if the fuel

pumps are worn, the pmax will change. Adjust-
ing the pmax of all the cylinders is done by ad-
justing the VIT system in the following way:
Mechanical VIT system
1. The pilot valves have been pre-adjusted to

0.5-5.5 bar control air pressure, corre-
sponding to 0.5-8.0 mm pressing-in of pin
C.
To check a pilot valve already mounted on

the engine, remove the inlet and outlet pipe
connections at A and P, and connect a
pressure gauge at A and a pipe with work-
ing air (pressure 7 bar) at P, on the pilot
HM909-1.3 67 01
valve.
Check that the pressure on the pressure

gauge and the pressing-in of pin C is in ac-
cordance with the curve.
2.
Any necessary adjustment is done by turn-
ing adjusting screw B.
2. Fine adjustment of the p max pressure in the

breakpoint (for all the cylinders) is to be
carried out by axial displacement of the
bracket with the pilot valve.
Release the screw and nut which secure

the bracket with the pilot valve to the larger
bracket through the slotted holes.
XZ909-2.1 203 02
Increase the pmax pressure by moving the

pilot valve toward the lever.
Decrease the p max pressure by moving the

pilot valve away from the lever.
See also Volume I, Chapter 703.
0$1% :'LHVHO$6
909-2.3 VIT System
Adjustment
3. Electronic VIT system
3. The adjustment should be based on a set

of indicator diagrams taken when the en-
gine is running just above the breakpoint.
4. On the panel in the engine room control

room, change the p offset value in accord-
ance with the required increase or de-
crease in the p max pressure. One
graduation mark on the p offset scale corre-
sponds to a change in p max of 1 bar.
5. Check the adjustment by taking a new set

of indicator diagrams while the engine is
running just above the breakpoint.
6. The I/P converter mounted on the engine

receives a 4-20 mA signal I from the elec-
tronic control system and converts this into
a 0.5-5.5 bar control air pressure p control.
S9148001.WPG
7. To check the adjustment of the I/P convert-

er, operate the panel in the engine control
room to supply various signals I to the I/P
converter.
6.
For operation of the panel, see the panel
manufacturer’s instructions.
On the pressure gauge mounted on the

control air line after the I/P converter check
that the control air pressures from the I/P
converter are in accordance with the curve.
8. If the control air pressure is not in accord-

ance with the curve, the I/P converter must
P control be adjusted. Remove the hood of the I/P
converter and adjust the I/P converter ac-
cording to the manufacturer’s instructions.
P supply
P control
5
4
3
2
1.5
1
0.5
XZ909-2.3 204 06
0.1 0 I, mA
0 4 8 12 16 20
0$1% :'LHVHO$6
Fuel Pump Cam 109-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10903
109-3 Data 0047 Fuel Pump Cam
X Stopped engine
X Shut off fuel oil
Data
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
Data
P90651 44 Impact wrench for turning cam

P90951 45 Measuring tool for fuel pump
P91351 201 Quick coupling, male
P91351 225 Disc, round-plain, Cu ø11x3 mm
MAN B&W Diesel A/S
Fuel Pump Cam 909-3.1
Checking
Fuel Pump Cam
S60MC-C
0229
Checking
909-3.1
1.
Fuel cam lead:
C
The lead C of the fuel cam is defined as the
x2 x1 roller guide
number of mm the plunger is lifted from its bot-
tom position when the main piston is in TDC.
1. To measure the fuel cam lead (top lift):

Dismantle the puncture valve.
See Procedure 909-8.2. fuel cam
Make sure that the reversing mechanism is

in AHEAD direction.
ahead
2. Push down the measuring pin through the
EN909-3.1 228 00
top cover, until it rests against the pump
plunger. Lowest position Main piston in TDC
of pump plunger
Turn the engine until the lowest point of the
cam is found, use a calliper to find the 3.
point.
3. Measure the distance x from the top of the

measuring pin to the transverse piece.
Note down the result as x2.
4. Turn ahead until the main piston of the cyl-

inder concerned is in TDC.
Again measure the distance x from the top

of the measuring tool to the transverse
piece. Note down the result as x1.
Calculate the fuel cam lead C (top lift) as:
C = x1 – x2 (mm)
HN909-3.1 229 03
5. Note down the result for comparison with

the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.
4.
Remount the puncture valve.
HM906-7.0 56 01
0$1% :'LHVHO$6
909-3.3 Fuel Pump Cam
Adjustment
Adjustment
909-3.3
1. Normally, adjustment of the fuel cam should not

be necessary. Before adjustment of fuel equip-
ment, see Volume I, Chapter 706.
1. Remove the inspection cover from the cam-

shaft housing.
Note!
HN909-3.3 207 01
Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
2. Dismount the puncture valve from the fuel
pump top cover, and mount the measuring
tool to check the cam adjustment.
3. Turn the camshaft until there is access to

the oil ducts in the fuel cam through the in-
spection hole.
If fitted, remove the plugs from the oil ducts

(using, for instance, a screwdriver).
Insert three copper gaskets in each oil duct.
Mount snap-on couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snap-on couplings

HN909-3.1 229 03
and the distributor block and between the

distributor block and the hydraulic high-
pressure pump.
3.
HN909-3.3 207 04
0$1% :'LHVHO$6
Fuel Pump Cam 909-3.3
Adjustment
4. Mount the special spanner on the fuel cam 4.

disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least five

minutes before turning the cam.
HN909-3.3 207 06
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,

until the desired change of lead is obtained.
To increase lead and p max:

– turn the cam disc AHEAD.
To reduce lead and p max:

– turn the cam disc ASTERN.
5. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the

fuel cam lead again.
Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.
6. Mount the inspection cover on the camshaft

housing.
7. Mount the puncture valve.

8. After any adjustment of the cam position,

pmax must be recorded and compared with
pmax at a known engine reference load.
0$1% :'LHVHO$6
Fuel Pump 109-4
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10904
109-4 Data 0042 Fuel Pump
X Stopped engine
X Shut off fuel oil
Data
D09-18 Pump housing nuts, tightening torque 785 Nm

D09-19 Pump housing nuts, tightening angle 60 °
D09-20 Pump housing 200 kg
D09-21 Bottom plate 13 kg
D09-39 Shock absorber 27 kg
MAN B&W Diesel A/S
109-4 Fuel Pump
Data
P90951 70 Lifting tool for fuel pump housing
MAN B&W Diesel A/S
Fuel Pump 909-4.2
Dismantling
Fuel Pump
S60MC-C
0222
Dismantling
909-4.2
3.
Note!

1. Dismantle the fuel pump top cover.

2. Dismantle the barrel/plunger assembly.

GN909-4.2 203 03
3. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel in-
let valve.
Remove the fuel oil inlet pipe. 4.
Discard the gaskets.

D09-20
4. Unscrew the nuts at the base of the fuel
pump.
Fit the lifting tool using the top cover studs/

nuts, and lift the pump housing away.
Take care not to damage the threads of the

studs.
Land the fuel pump on wooden planks.

JG909-8.0 71 02
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul
Overhaul
909-4.3
3. 1. If the fuel index arm or the VIT index arm

of the fuel pump is moving too tightly, the
regulating and timing systems of the fuel
pump must be overhauled.
2. In order to carry out this overhaul, the top

cover and plunger/barrel assembly of the
fuel pump must have been removed, and
the fuel pump must have been dismantled
from the pump base and landed on wooden
planks.
GN909-4.3 203 03
3. Dismantle the actuator and actuator brack-

et.
4. 4. Dismantle the fuel pump shock absorber.
If necessary, overhaul the fuel pump shock

absorber.
D09-39 See Procedure 909-9.3.
HG909-9.2 201 01
0$1% :'LHVHO$6
Fuel Pump 909-4.3
Overhaul
5. Tilt the fuel pump housing into a horizontal 5.

position on the wooden planks.
6. Dismantle the screws and the bottom plate

from the fuel pump housing.
If the bottom plate is stuck, loosen it by

screwing two M10x70 mm screws into the
holes of the bottom plate.
7. Dismantle the:
• Fuel index arm
HC909-3.4 121 05
• Sleeve
• Regulating guide
6.
D09-21
HC909-3.4 121 06
7.
HC909-3.4 121 07
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul
8. 8. Dismantle the:
• Guide screw
• VIT index arm
• Timing guide
9. Dismantle and inspect the plug screws in

both sides of the fuel pump housing.
If heavily eroded, replace the plug screws.

HC909-3.4 121 08
Replace the sealing rings and mount the

plug screws.
10. Clean all parts thoroughly in diesel oil or

kerosene. Blow dry with compressed air.
9.
11. Mount new sealing rings on the unions.
Note!
Soak the sealing rings in lubricating oil

before mounting
12. Clean all inside surfaces of the fuel pump

housing.
HC909-3.4 121 09
11.
HC909-3.4 121 11
0$1% :'LHVHO$6
Fuel Pump 909-4.3
Overhaul
Mounting 14.
13. Lubricate the following with molybdenum di-

sulphide (MoS 2):
• all internal machined surfaces of the fuel

pump housing
• the sliding surfaces of all parts of the

regulating and timing systems.
• the teeth of the:

regulating guide
HC909-3.4 121 14
timing guide
VIT index arm
fuel index arm. 15.
14. Mount the VIT index and the guide screw.
Adjust the position of the VIT index arm so

that the scratch mark is aligned with the
centre of the fuel pump housing.
15. Mount the timing guide in the fuel pump

housing.
The timing guide must be mounted in such

a way that the scratch mark on the timing
guide is aligned with the scratch mark on
HC909-3.4 121 15
the VIT index arm, which must be visible

through the hole in the timing guide.
16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
16.
sleeve is aligned with the pin hole in the
fuel pump housing.
HC909-3.4 121 16
0$1% :'LHVHO$6
909-4.3 Fuel Pump
Overhaul
17. 17. Mount the fuel index arm.
Adjust the position of the fuel index arm so

that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.
18. Mount the regulating guide in the fuel pump

housing.
The regulating guide must be mounted so

that the scratch mark on the regulating
guide is aligned with the scratch mark on
HC909-3.4 121 17
the fuel index arm.
19. Mount the bottom plate on the fuel pump

housing.
18.
HC909-3.4 121 18
19.
HC909-3.4 121 06
0$1% :'LHVHO$6
Fuel Pump 909-4.3
Overhaul
20. Mount the fuel pump shock absorber. 20.
21. Mount the actuator and actuator bracket.
HC909-9.2 201 01
21.
GN909-4.3 203 03
0$1% :'LHVHO$6
909-4.4 Fuel Pump
Mounting
Mounting
909-4.4
2. 1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum di-
sulphide (MoS 2).
D09-20 See Procedure 913-11.
2. Lower the fuel pump housing on to the

pump base, taking care not to damage the
D09-18 threads of the studs.
or
D09-19 Remove the lifting tool.
Fit and tighten the nuts at the base of the

pump housing. Use either the tightening
torque or the tightening angle. See Data.
3. Mount the fuel oil inlet pipe between the

pump housing and the inlet valve.
4. Mount the barrel assembly in the fuel pump

housing.
5. Mount the top cover on the fuel pump hous-

ing.
6. Mount the puncture valve, see Procedure

909-8.4.
7. Mount the drain oil pipes, and the com-

JG909-8.0 71 02
pressed air pipes.
3.
GN909-4.2 203 03
0$1% :'LHVHO$6
Fuel Pump Top Cover 109-5
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10905
109-5 Data 0045 Fuel Pump Top Cover
X Stopped engine
X Shut off fuel oil
Data
D09-23 Top cover studs, screwing-in torque 240 Nm

D09-24 Top cover nuts, tightening torque 300 Nm
D09-26 Outlet seat, max.grinding diameter 26 mm
D09-27 Top cover 52 kg
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
Data
P90951 69 Lifting tool for fuel pump

P90951 94 Milling tool for fuel oil pipe seats
MAN B&W Diesel A/S
Fuel Pump Top Cover 909-5.2
Dismantling
Fuel Pump Top Cover
S60MC-C
0223
Dismantling
909-5.2
1.
1. Shut off the fuel oil inlet.
Open the drain cock (at the bottom of the

pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.
Note !

GN909-5.2 204 01
Dismount all drain pipes and the pipe con-
nections to the puncture valve.
Dismount the high-pressure pipes between

the top cover and the fuel valves. 2.
Note !
If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
2. Remove the top cover fixing nuts and

mount the dismantling screws for top cover
GN909-5.2 204 02
in the two threaded holes.
Pull the top cover with suction valve and

puncture valve (if still mounted) free by
tightening the dismantling screws.
3.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
D09-27
3. Lift the top cover carefully off.
For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.
Discard the gasket.

GN909-5.2 204 03
0$1% :'LHVHO$6
909-5.3 Fuel Pump Top Cover
Overhaul
Overhaul
909-5.3
2. 1. If not already done, dismount the protective

cap and the puncture valve from the top
cover.
2. Dismantle the suction valve and the lock

washer from the top cover.
3. Fill the oil ducts of the top cover with vase-

line or heavy grease.
Screw the guide, with the miller, into the

high-pressure pipe thread.
HM909-3.3 74 03
Mill the seat until a smooth surface is

achieved. For maximum seat diameter see
Data.
3.
After completing the milling, use com-
pressed air to blow the vaseline/ grease out
from the oil ducts.
Clean the top cover with diesel oil/gas oil,

D09-26 and blow dry with compressed air.
Note!
Make sure that all bores and threads

inside the top cover are absolutely clean.
GN909-5.3 204 04
If necessary, recondition the seats of the

fuel oil high-pressure pipes.
4. 4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
HM909-3.3 74 13
0$1% :'LHVHO$6
Fuel Pump Top Cover 909-5.4
Mounting
Mounting
909-5.4
1. Make sure that the inside of the fuel pump 1.

housing and the top of the fuel pump barrel
is completely clean.
D09-27
2. Mount a new gasket on top of the pump
housing.
Lubricate all sliding faces, studs and seal-

ing rings with molybdenum disulphide
(MoS 2). See Procedure 913-11.
Mount the overhauled top cover (with over-

hauled suction valve and reconditioned
GN909-5.2 204 03
seatings for the high-pressure pipes) on the
pump housing.
Check that the guide pin in the top cover

enters the hole in the pump housing.
3.
D09-24
Warning !
As a safety precaution, and before

mounting the top cover nuts, turn the
engine one revolution.
When doing this, the top cover must not

move upwards!
3. Mount the top cover fixing nuts, and tighten

them diagonally to the torque indicated in
GN909-5.4 204 03
Data.
For adjustment of the fuel pump, see Pro-

cedure 909-1.1.
4. Finally, mount a new or overhauled punc- 4.

ture valve on the top cover. See Procedure
909-8.4.
Mount the protective cap over the puncture

valve and the two screws in the top cover.
Mount the high-pressure pipes and the
drain screw in the pump housing.
Mount the drain pipes on the top cover and

the connecting pipe to the puncture valve.
Open the fuel oil inlet.
GN909-5.4 204 04
0$1% :'LHVHO$6
Fuel Pump Barrel Assembly 109-6
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10906
109-6 Data 0039 Fuel Pump Barrel Assembly
X Stopped engine
X Shut off fuel oil
Data
D09-29 Barrel assembly 48 kg

D09-30 Plunger 11 kg
MAN B&W Diesel A/S
109-6 Fuel Pump Barrel Assembly
Data
P90951 57 Lifting tool for fuel pump

P90951 224 Tool for pmax rack
P90962 Fuel pump seals – mounting tools
MAN B&W Diesel A/S
Fuel Pump Barrel Assembly 909-6.2
Dismantling
Fuel Pump Barrel Assembly
S60MC-C
0219
Dismantling
909-6.2
1.
Open the drain cock (at the bottom of the

pump housing), enabling the oil which is left
in the high-pressure pipe and the fuel pump
to escape.
Note!

GN909-5.2 204 01
Dismount the pipe connections to the punc-
ture valve.
Dismount the fuel oil high-pressure pipes. 2.

See Procedure 909-14-2.
2. If the top cover is to be overhauled, dis-

mount the puncture valve.
3. Dismount the fuel pump top cover.

HN909-8.2 207 03
3.
GN909-5.2 204 03
0$1% :'LHVHO$6
909-6.2 Fuel Pump Barrel Assembly
Dismantling
4. 4. Position the lifting tool for the barrel/plunger

assembly (without measuring pin) in such a
manner that the two distance tubes of the
tool rest on the pump barrel.
Make sure that the two guide pins in the

bottom of the lifting tool enter the holes in
the top of the plunger.
Secure the lifting tool by screwing the two

screws into the pump barrel.
Loosen the stop ring on the spindle of the

GN909-6.2 204 01
tool and press the spindle down against the

pump plunger.
Turn the spindle in this position until the two

guide pins engage with the two holes in the
5. plunger top.
Tighten the centre screw of the spindle

against the plunger.
5. Remove the pump barrel guide screw from

the pump housing.
MB909-3.1 95 05
6. Disconnect the links for the timing drive and

the regulating drive. Dismount the union
and pointer for the timing drive and the reg-
ulating drive.
6.
Note the position of the scratch mark on the
lever arm.
Remove the locking plate and the lever

arm.
Mount the extractor tool and connect the

timing toothed rack to the pulling rod by
means of the pin.
GN909-6.2 204 03
0$1% :'LHVHO$6
Dismantling
7. Turn the nut at the end of the pulling rod, 7.

whereby the timing rack will move out-
wards.
Continue turning the nut until the pin reach-

es the outer position of the slot in the tool,
whereby the thread of the fuel pump barrel
GN909-6.2 204 04
goes clear of the timing guide.
Keep the toothed rack in this position during

the overhaul or replacement of the pump
barrel.
8.
There is now a distance between the lifting
tool and the pump housing.
8. Pull the regulating toothed rack outwards

until the plunger foot has been turned clear
of the bayonet joint in the roller guide.
This can be ascertained by watching the

handles on the spindle of the lifting tool.
These will be parallel with the fore-and-aft
direction of the engine when the plunger
has been turned into position.
Remove the cover of the pump base to

make sure that the plunger is able to go
GN909-6.2 204 05
clear of the bayonet joint.
Lift the spindle so that the plunger foot goes

clear of the bayonet joint.
Move the stop ring of the spindle into con- 9.

tact with the upper flange of the tool, and
lock the stop ring in this position by means
of the stop screw.
9. Carefully lift the barrel/plunger assembly D09-29

out of the pump housing.
Dismount the tool.
Press the plunger upwards to the bottom of

the barrel.
Send the barrel/plunger assembly to an

MAN B&W authorized workshop for repair,
or overhaul it on board as described in Pro-
cedure 909-6.3.
GN909-6.2 204 06
0$1% :'LHVHO$6
Overhaul
Overhaul
909-6.3
1. 1. Clean the outside of the barrel.
Set up the pump barrel/plunger in a bench

vice provided with “soft” jaws.
D09-29
Remove and discard the sealing rings from
the barrel.
2. Pull the plunger carefully out of the barrel.
Carefully clean the plunger (for example in

clean kerosene) and wipe dry with a clean
piece of cloth. Also clean the bores in the
top of the plunger.
MB909-3.2 95 01
Clean the barrel and wipe dry with a clean

piece of cloth.
2. For evaluation of pump barrel/plunger, see

Volume I, OPERATION, Chapter 706.
3. Before mounting new sealing rings on the

barrel, heat them in 100°C hot water for at
least five minutes.
4. When mounting the new sealing rings on

the lower end of the pump barrel, the inner
sealing ring must be mounted first.
Mount the guide stick in the barrel and po-

D09-30 sition the big cone on the barrel.
MB909-3.2 95 02
Place the spring-loaded sealing ring on the

cone with the spring facing upwards, see
the sketch.
4. Use the pusher tool to push the sealing ring

into the groove.
MB909-3.2 95 04
0$1% :'LHVHO$6
Overhaul
5. When mounting the sealing ring in the outer 5.

groove, place the spacer tool inside the
cone to obtain the correct distance to the
groove, and repeat the above procedure.
After mounting the sealing rings, compress

them by pressing the “sizer” tool over the
sealing rings.
6. Mount the guide stick and cone on the top

end of the barrel and mount the uppermost
sealing ring in the same way as above.
Make sure that the spring faces down-
MB909-3.2 95 05
wards, see the sketch.
7. Lubricate the plunger with molybdenum di-

sulphide (MoS 2).
6.
Carefully slide the plunger into the barrel
and press it to the bottom.
Note!
Do not use force as this will damage the

sliding surfaces of the plunger or barrel
If the barrel assembly is not to be mounted

immediately, all openings must be covered
with plastic to prevent dirt from entering the
barrel assembly during storage.
MB909-3.2 95 06
7.
MB909-3.2 95 07
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Mounting
Mounting
909-6.4
1. 1. Place the supplied measuring pin – which

is of the same length as the plunger – on
the spindle of the lifting tool, and fasten it
by tightening the centre screw of the spin-
dle. Loosen the stop ring on the spindle.
Place the tool on the pump housing, and

press the spindle down until the pointed
end of the measuring pin is in contact with
the thrust piece of the roller guide.
Then press the stop ring down until it

reaches the flange of the tool and lock it
there by tightening the screw of the stop
ring against the spindle.
The stop ring is to remain tightened in this

position until the plunger has been correctly
mounted.
The engine must not be turned until the

mounting of the barrel/plunger assembly
HN909-6.4 207 01
has been completed.
2. Dismount the tool from the pump housing

and remove the measuring pin from the
spindle. Then mount the tool on the barrel/
2. plunger assembly which is ready for mount-
ing.
Secure the tool to the barrel by tightening

the two screws, and attach the plunger to
the spindle of the tool by tightening the cen-
tre screw of the spindle. The tool is thus
fixed on the barrel in such a way that its cor-
rect positioning is ensured during mount-
ing.
Before mounting the barrel/plunger in the

pump housing, lubricate the thread for the
timing guide and all sealing rings with mo-
lybdenum disulphide.
Using the spindle of the tool, pull the plung-

er as high up in the barrel as possible, at
the same time turning the spindle so as to
position the plunger foot correctly in relation
to the cutout of the regulating guide.
HN909-6.4 207 02
0$1% :'LHVHO$6
Mounting
3. Pull the regulating toothed rack as far out 3.

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer posi-
tion.
4. Check that the slot in the barrel coincides

with the hole for the guide screw.
Lower the barrel assembly carefully into the
GN909-6.4 204 03
pump housing.
If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
and the regulating block of the plunger fit
properly in the cutout of the regulating 4.
guide.
Lowering the barrel assembly so far down

into the pump housing that the sealing rings D09-29
of the barrel are about to enter the bore in
the pump housing.
Then continue pressing down the barrel/

plunger assembly until the barrel assembly
rests on top of the timing guide. There will
be a gap between the tool and the pump
housing.
GN909-6.4 204 04
0$1% :'LHVHO$6
Mounting
5. 5. Loosen the nut on the extractor, disconnect

the pulling rod from the timing toothed rack,
and remove the extractor.
Engaging the thread of the fuel pump barrel

with the timing guide is accomplished by
pressing-in the toothed rack. (A pressure of
about 30 kg may be required).
Check that the toothed rack is correctly en-

gaged by pressing-in the rack. When doing
this, the pump barrel shall move down-
wards.
The top flange of the tool is now resting on

the top of the pump housing.
6. After ‘landing’ the barrel assembly, press

the plunger down into contact with the
GN909-6.4 204 05
thrust piece of the roller guide.
Check that the stop disc of the spindle is in

full contact with the flange of the tool, as
when measuring.
6.
If necessary, turn the regulating guide a lit-
tle (using the toothed rack) to make the
plunger foot fit properly in the cutout of the
roller guide. Inspect the position of the
plunger foot through the inspection hole.
When the plunger is in place, press the reg-

ulating rod in, thereby turning the plunger
by means of the regulating guide and caus-
ing the plunger foot to “interlock” with the
bayonet joint of the roller guide.
Check that the plunger is correctly engaged

by pulling at the spindle of the lifting tool.
When doing this, it must not be possible to
lift the spindle.
Mount the inspection hole cover.

GN909-6.4 204 06
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Mounting
7. Mount the pointer and union for the timing 7.

rack.
Mount the links for the timing drive and the

regulating drive in place in accordance with
the marks.
8. Mount the guide screw for the pump barrel

in the pump housing.
GN909-6.4 204 07
Remove the centre screw from the plunger,
and remove the tool.
9. Mount the top cover without mounting the 8.

nuts. Turn the engine one revolution, and
check that the top cover does not move up-
wards. If the top cover does move upwards,
the barrel/plunger assembly has to be re-
moved and re-inserted.
10. Mount the fuel pump top cover, including

the nuts. See Procedure 909-5.4.
GN909-6.4 204 08
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Fuel Pump Suction Valve 109-7
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10907
109-7 Data 0029 Fuel Pump Suction Valve
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Data
D09-33 Suction valve, tightening torque 900 Nm

D09-34 Suction valve 4 kg
MAN B&W Diesel A/S
109-7 Fuel Pump Suction Valve
Data
P90951 128 Crowfoot wrench head

P90967 Fuel puncture valve – tools
MAN B&W Diesel A/S
Fuel Pump Suction Valve 909-7.1
Checking
Fuel Pump Suction Valve
S60MC-C
0214
Checking
909-7.1
1.
1. Using a brass mandrel, check that the valve
slide can slide freely up and down inside
the suction valve.
2. Check the seats for tightness by filling the

inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.
3. If the suction valve is not to be mounted on

the engine immediately after the checking,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.
HN909-7.1 207 01
2.
KB909-3.3 105 08
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909-7.2 Fuel Pump Suction Valve
Dismantling
Dismantling
909-7.2
1. 1.
Note!
Before dismantling the top cover, it is

recommended to dismantle the fuel pump
puncture valve, see Procedure 909-8.2.
Dismantle the fuel pump top cover and suc-

tion valve assembly from the fuel pump
housing. See Procedure 909-5.2.
2. Mount two eye bolts in the bottom of the top

cover and turn it upside down.
3. Mount the top cover in an upside down po-

GN909-5.2 204 03
sition in the top cover bracket mounted on

the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
er.
2.
Release the suction valve lock washer.
Dismount the suction valve from the top

cover.
Remove and discard the lock washer.

GN909-5.3 204 02
3.
KN909-7.2 213 03
0$1% :'LHVHO$6
Fuel Pump Suction Valve 909-7.3
Overhaul
Overhaul
909-7.3
1. Set up the suction valve in a bench vice 1.

with “soft” jaws and, using a brass mandrel
and a hammer, release the spring guide
from the valve thrust piece.
Disassemble the other parts of the suction

valve and clean the parts thoroughly in
clean diesel oil.
Remove and discard the sealing ring from

the valve thrust piece.
2. Inspect the seat of the valve slide and the

seat in the thrust piece for damage. If the
seats are damaged, both the suction valve
and the valve slide must be discarded.
KB909-3.3 105 05
Lapping of the seats must not be attempt-
ed.
3. Mount the O-ring in the groove of the seal- 2.

ing ring and position the cone on the thrust
piece.
Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the groove.
Note!
KB909-3.3 105 06
Make sure that the sealing ring is

mounted correctly. See the sketch.
After mounting the sealing ring, compress it 3.

by pressing the “sizer” tool over the sealing
ring.
4. Clean and overhaul all internal parts, and

lubricate them with molybdenum disulphide
(MoS 2).
5. Re-assemble the suction valve.
6. Check the suction valve after the overhaul.

XZ909-7.3 204 03
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909-7.4 Fuel Pump Suction Valve
Mounting
Mounting
909-7.4
1. 1. Mount the top cover in an upside down po-

sition in the top cover bracket mounted on
the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
D09-33 er.
Lubricate the thread of the suction valve

with copper grease.
Make sure that the bore for the suction

valve in the top cover is absolutely clean.
Fit a new lock washer and mount a new or

overhauled suction valve in the top cover.
Fit the two screws which secure the lock

washer.
Tighten the suction valve with a torque

spanner. See Data.
Lock the suction valve in position by bend-

ing up an edge of the lock washer over one
KN909-7.4 213 01
of the flats of the valve.
2. Remove the top cover from the bracket and

mount the top cover in the fuel pump hous-
2. ing. See Procedure 909-5.4.
GN909-5.2 204 03
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Fuel Pump Puncture Valve 109-8
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10908
109-8 Data 0037 Fuel Pump Puncture Valve
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D09-35 Puncture valve, tightening torque 890 Nm

D09-36 Puncture valve 5 kg
MAN B&W Diesel A/S
109-8 Fuel Pump Puncture Valve
Data
MAN B&W Diesel A/S
Fuel Pump Puncture Valve 909-8.2
Dismantling
Fuel Pump Puncture Valve
S60MC-C
0217
Dismantling
909-8.2
2.
Open the drain cock at the bottom of the

pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.
Note!

2. Dismantle the control air pipe and the pro-

tective cap above the puncture valve.
3. Unscrew and remove the puncture valve

from the fuel pump top cover.
4. After dismantling it is recommended always

HN909-8.2 207 02
to overhaul the puncture valve.
If the overhaul cannot take place immedi-

ately after the dismantling, it is recommend-
ed to place the puncture valve immersed in
diesel oil until the overhaul. 3.
HN909-8.2 207 03
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909-8.3 Fuel Pump Puncture Valve
Overhaul
Overhaul
909-8.3
1. 1. Remove and discard the O-rings from the

puncture valve.
Set up the puncture valve in a bench vice

with “soft” jaws.
Loosen and remove the four screws and

dismount the plug. Use a screw to remove
the air piston from the housing.
Remove and discard the sealing rings from

the air piston.
Disassemble the other parts of the punc-

ture valve, using a brass mandrel and a
hammer. Take care not to damage the valve
seat.
Thoroughly clean all the parts in clean die-

sel oil.
2. Inspect the conical seats of the valve hous-

ing and the valve slide for wear marks or
scratches.
If the seats are damaged, the valve housing

and the valve slide must be discarded.
Lapping of the valve seats must not be at-

HN909-8.3 207 01
tempted.
2.
HG909-8.2 201 02
0$1% :'LHVHO$6
Fuel Pump Puncture Valve 909-8.3
Overhaul
3. When mounting the new sealing rings on 3.

the spindle of the air piston, the inner seal-
ing ring must be mounted first.
Mount the O-ring in the ring groove and po-

sition the large cone on the spindle.
Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the O-ring in the groove.
After mounting the sealing ring, compress it

by pressing the ‘sizer' tool, over the sealing
ring.
Mount the outer sealing ring in the groove

using the short cone, and repeating the
above procedure.
4. The new sealing ring is mounted on the

head of the air piston in accordance with
the same procedure as above.
GM909-3.3 89 10
Before assembling the puncture valve, lu-

bricate all parts with “MOLYKOTE anti-fric-
tion SPRAY D321R” or molybdenum
disulphide (MoS 2).
4.
Mount new O-rings on the housing.
5. If the puncture valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
GM909-3.3 89 12
0$1% :'LHVHO$6
909-8.4 Fuel Pump Puncture Valve
Mounting
Mounting
909-8.4
2. 1. Make sure that the bore for the puncture

valve in the fuel pump top cover is absolute-
ly clean.
If this has not already been done, mount

new O-rings on the puncture valve.
Lubricate the thread of the puncture valve

with copper grease.
D09-35 2. Screw the puncture valve into the bore in

the top cover.
Using a crowfoot wrench and a torque

spanner, tighten the puncture valve to the
torque stated in Data.
3. Mount the protective cap and the control air

pipe on top of the puncture valve.
4. If open, close the drain cock on the fuel

pump and open the fuel oil inlet valve.
HN909-8.4 207 02
3.
HN909-8.4 207 03
0$1% :'LHVHO$6
Fuel Pump Shock Absorber 109-9
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10909
109-9 Data 0026 Fuel Pump Shock Absorber
X Stopped engine
X Shut off fuel oil
Data
D09-39 Shock absorber 27 kg
MAN B&W Diesel A/S
109-9 Fuel Pump Shock Absorber
Data
MAN B&W Diesel A/S
Fuel Pump Shock Absorber 909-9.1
Checking
Fuel Pump Shock Absorber
S60MC-C
0214
Checking
909-9.1
To ensure satisfactory operation, the function-

ing of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspec-
tion is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is oper-
ating.
1. Remove the plug from the end cover of the

shock absorber. Check that air is ‘pulsating’
through the threaded hole.
Short bursts of air should be felt against the
HM909-4.0 09 01
hand, corresponding to the strokes of the
fuel pump.
The air pulses occur when the shock ab-

sorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.
2. To check the ‘tightness’ of the piston, meas-

ure the amount of leakage oil flowing from
the drain pipe of the shock absorber hous-
ing. Note down the amounts measured and
compare with earlier measurements.
Increasing amounts indicate a deteriorating

piston sealing. Excessive amounts indicate
that the shock absorber requires overhaul-
ing.
0$1% :'LHVHO$6
909-9.3 Fuel Pump Shock Absorber
Overhaul
Overhaul
909-9.3
1.
Note!

D09-39 has been drained off.
1. Remove the shock absorber drain pipe.

Place a wire strap around the shock ab-
sorber and hook on the engine room crane.
Loosen the screws holding the shock ab-
GN909-9.3 204 01
sorber and remove it from the fuel pump

housing.
2. Remove the plug from the end cover of the

shock absorber. Fit a threaded rod between
2. the piston and the end cover to counteract
the force of the springs. Loosen the screws
of the end cover and remove the end cover
and piston. Discard the gasket.
3. Loosen the nut on the threaded rod to re-

lieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.
4. Clean all parts and polish the sliding sur-

faces of the piston and the shock absorber
housing. Mount a new sealing ring in the
HG909-9.2 201 02
shock absorber housing and a new wear

ring on the piston.
5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
4. the threaded rod.
Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to dam-
age the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.
6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking de-
vice. Remove the threaded rod and insert
the plug.
HG909-9.2 201 04
0$1% :'LHVHO$6
Fuel Pump Shock Absorber 909-9.3
Overhaul
7. Fit a new gasket on the fuel pump housing

and mount the shock absorber. Mount the
shock absorber drain pipe.
If an excessive amount of drain oil is still

observed after the overhaul, the shock ab-
sorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
0$1% :'LHVHO$6
Lifting Gear for Roller Guide 109-10
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10910
109-10 Data 0013 Lifting Gear for Roller Guide
X Stopped engine
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-10 Lifting Gear for Roller Guide
Data
MAN B&W Diesel A/S
Lifting Gear 909-10.1
Checking
Lifting Gear
S60MC-C
211
Checking
909-10.1
1.
Caution!
Do not use the lifting tool for the fuel

pump roller guide while the engine is run-
ning.
If a fuel pump is to be put out of action, dis-

connect it in the following manner:
1. Stop the engine and engage the turning

gear.
HN909-10.1 205 01
Remove the inspection cover on the upper
part of the camshaft housing in front of the
fuel cam for the pertaining roller guide.
Turn the engine until the roller is in the high-

est position on the cam (on the circular sec- 2.
tion of the cam).
2. Loosen the lock screw on top of the flange

and the nut on the lifting tool.
Press the shaft against the roller guide.

When the shaft has been pressed fully in,
the guide screw is positioned in line with
the vertical slot of the flange.
HM909-5.0 44 1/2
When referring to this page, please quote Procedure 909-10.1 Edition 211 Page 1 (2)
0$1% :'LHVHO$6
909-10.1 Lifting Gear
Checking
3. 3. Mount a socket spanner, a slide-T handle

and an extension pipe on the shaft, and
turn the shaft anti-clockwise until the guide
screw is in top of the slot, which indicates
that the roller guide is in the lifted position.
4. Lock the shaft in this position by tightening

the lock screw and the nut on the lifting tool.
Check through the inspection cover open-

ing that the roller guide is clear of the fuel
cam. The engine can now operate on the
remaining cylinders, see Volume I, Section
HN909-10.1 211 03
704.
Re-engagement of the fuel pump roller guide
4.
Caution!
Re-engagement of the fuel pump roller

guide must only take place when the
engine is at a standstill.
5. Turn the engine until the circular section of

the pertaining fuel cam is positioned up-
wards, and then lower the roller guide in the
reverse order to lifting.
NB! Remember to loosen the lock screw.

HM909-5.0 44 2/2
6. When the roller guide has been lowered

into the position where the guide screw is
in the lowermost position, tighten the lifting
tool nut against the flange whereby the lift-
6. ing tool will be pulled away from the roller
guide. The guide screw will now be posi-
tioned at the end of the horizontal part of
the slot of the flange.
Tighten the lock screw.

HN909-10.1 205 05
Page 2 (2) When referring to this page, please quote Procedure 909-10.1 Edition 211
0$1% :'LHVHO$6
Fuel Valve 109-11
Data
SAFETY PRECAUTIONS
Special Edition
L60MC-C
D10911
109-11 Data 0063 Fuel Valve
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-40 Fuel valve opening pressure 300 - 380 bar

D09-42 Inlet seat, max. diameter 25 mm
D09-43 Fuel valve 13 kg
MAN B&W Diesel A/S
109-11 Fuel Valve
Data
P90151 71 Dismantling tool for fuel valve

P90951 94 Milling tool for fuel oil pipe seats
P90951 165 Grinding mandrel for valve head
P90951 297 Assembling tool for fuel valve
P90961 14 Fuel Valve tester, complete
P90966 Fuel Valve Nozzle - Tools
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
Fuel Valve
S60MC-C
0233
Checking
909-11.1
1.
The fuel valves must be given the utmost atten-
tion and care, as the greater part of irregulari-
ties that may occur during the running of the
engine can be attributed to defects in these
valves.
If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.
GN909-11.1 204 01
In order to obtain reliable results during testing
of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disassem-
bled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3. 2.
Note!
In the event that the slide-type fuel valve is

pressure tested without being cleaned
between the fuel nozzle and the cut-off slide,
the opening pressure value measured might
be considerably lower than specified.
All fuel valves must be function-tested before

being mounted in the cylinder cover.
1. Pressure testing pump
If an air supply of 10 bar is not available,

working air of seven bar can be used. Use
only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50°C.
For operation of the pressure testing pump,

see the supplier’s instructions.
Note that the high-pressure pump should

be periodically checked in accordance with
the supplier’s instructions.
HM909-6.3 70 01A
2. Spring housing
To ensure that overtightening has not taken

place, check that the locking/indicating pin
has not been bent or broken off.
In the event of overtightening, replace the

spring housing by a new one.
0$1% :'LHVHO$6
909-11.1 Fuel Valve
Checking
3. 3. Setting-up the fuel valve
Place the fuel valve in the test rig and se-

cure it with the spring housings and nuts.
Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housings. Mount the oil pipe be-
tween the pressure testing pump and the
fuel valve.
4. Pressure testing procedure
The subsequent items must be followed in

HM909-6.3 70 01B
the sequence stated. Items 5, 7, 8 and 9

are each divided into the following four sub-
items:
A. Objective
4. B. Procedure
C. Acceptance criteria
D. Cause of fault.
Note!
If working air of 10 bar is not available,

pressures down to 7 bar are acceptable
for all the tests.
5. Flushing and jet control
A. Objective:
HM909-6.0 67 00
To remove air in the system and check the

fuel jet.
B. Procedure:
5. The control handle must be in the OPEN po-
sition.
Slowly increase the working pressure until
straight jets of oil are ejected from the noz-
zle holes (no atomization).
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Owing to the geometry of the internal part

of the nozzle – and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
NA909-11.1 215 05
during normal engine operation – the fuel

oil will not necessarily flow from all of the
nozzle holes.
0$1% :'LHVHO$6
Fuel Valve 909-11.1
Checking
D. Cause of fault: 6.
If the jets do not fulfil the above point C, the
cause may be:
• Dirt in the nozzle holes.
• The nozzle is not mounted correctly.
6. Atomization test
Note!
MN909-11.1 222 06
Do NOT attempt to carry out an atomiza-
tion test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.
The reason is that the atomization test may

damage the valve because it makes the 7.
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
D09-40
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.
All of these conditions involve the risk of

seizure between the cut-off slide and the
nozzle.
7. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Increase the oil pressure until oil is admit-

ted through the nozzle holes.
Check the opening pressure on the pres-
sure gauge.
GN909-11.1 204 06
0$1% :'LHVHO$6
909-11.1 Fuel Valve
Checking
8. 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.
8. Sealing test and sliding function
A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
B. Procedure:
The control handle must be in the OPEN po-
sition.
Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
GN909-11.1 204 07
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to

about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when

the fuel valve is full of oil.
0$1% :'LHVHO$6
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.
0$1% :'LHVHO$6
909-11.1 Fuel Valve
Checking
9. 9. Pressure test, O-ring sealings
A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN po-
sition.
Build up a working pressure of about max.

10 bar until oil flows out of the leak oil out-
let.
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100

bar.
Move the control handle to the CLOSED po-

sition.
The built-up pressure of about 100 bar

should be maintained.
D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
GN909-11.1 204 08
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Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2
1. Close the fuel oil inlet and outlet valves, 1.

and drain the high-pressure pipe and the
fuel valve.
Dismantle and remove the fuel oil high-

pressure pipe.
Disconnect the return oil pipe from the fuel

valve.
2. Remove the nuts and the spring housings.
KB901-2.1 104 01
3. Take out the valve. If the valve is sticking,
use the fuel valve dismantling tool to pull
the fuel valve clear of the top cover.
If the valve is not to be overhauled immedi-

ately, the valve should be placed immersed 2.
in diesel oil until overhauling.
HG909-11.3 201 02
3.
D09-43
MN909-11.2 206 03
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909-11.3 Fuel Valve
Overhaul
Overhaul
909-11.3
1. When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
A fore reassembly.
MN909-11.3 219 01
1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.
2. 2. Place the valve holder in a machine vice,

mount the fuel valve in the holder and fit the
valve with the guide disc from the grinding
tool.
3. Compress the fuel valve and the spring in-

side, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the un-
ion nut with a hook spanner.
Remove the valve from the valve holder.

MN909-11.3 222 02
3.
MN909-11.3 222 03
0$1% :'LHVHO$6
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.
HN909-11.3 223 04
0$1% :'LHVHO$6
909-11.3 Fuel Valve
Overhaul
5. 5. Carefully clean and examine all surfaces of

the:
• Fuel valve housing

D-09-42 • 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.
HN909-11.3 223 05
0$1% :'LHVHO$6
Fuel Valve 909-11.3
Overhaul
6. The complete spindle guide, including the 6.

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
Note!
Do not attempt to remove the fuel nozzle
NA909-11.3 215 03
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
7.
7. The non-return valve should be sent to an
authorised MAN B&W repair shop for over-
haul. If this is not possible, the non-return
valve may be overhauled on board.
8. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.
Carefully slide the spindle guide down into

MC909-6.1 99 04
the valve holder, and turn the nozzle until

the spindle guide engages correctly with
the guide pin. Check that distance A corre-
sponds to the measurement taken before
the valve was disassembled.
8.
Note!
Make sure that the fuel nozzle and spin-

dle guide engage correctly with the guide
pin in the fuel valve housing. This can be
ascertained by attempting to turn the
nozzle after mounting. It must not be
possible to turn the nozzle.
MN909-11.3 219 05
0$1% :'LHVHO$6
909-11.3 Fuel Valve
Overhaul
9. 9. Mount:
• the thrust foot
• the parts of the thrust spindle
• the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost

groove of the fuel valve housing.
Lubricate the thread of the valve head with

molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
10. Make sure that the guide pin between valve

housing and valve head is intact, and press
the valve head down into the valve housing.
See that the guide pin between valve hous-

ing and valve head engages correctly so as
HN909-11.3 223 09
to prevent relative turning of the parts.
10.
GN909-11.3 204 07
0$1% :'LHVHO$6
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
0$1% :'LHVHO$6
909-11.4 Fuel Valve
Mounting
Mounting
909-11.4
1. 1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover
and check the seating in the bore for marks
D09-43 which, if any, must be eliminated.
(For reconditioning of the valve bores in the
cylinder cover, see Procedure 901-1.3).
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS 2).
2. Mount the valve in position in the cylinder

cover.
MA901-2.1 72 03
Mount the spring housings and the nuts.

Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housing. This must be done with
2. great care, as the spring tension in the
housing determines the correct tightening
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.
3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.
Note!
It is recommended to overhaul the fuel oil

HG909-11.4 201 04
high-pressure pipe before mounting.

As a minimum, the distance between the

fuel oil pipe ends and the thrust bushings
3.
must be checked and, if necessary,
adjusted.
Mount the overhauled fuel oil high-pressure

pipe and the return oil pipe.
Note!
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
KB901-2.1 104 06
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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
S60MC-C
0221
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle

guides of the slide valve design.
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
Based on service experience it is recom-

mended to replace the complete spindle
guide after 8000 hours of operation.
1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.
Note!
MA909-6.2 111 02
The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.
2. Place the spindle guide in a bench vice pro- 4.

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.
3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
Note!
The pulling tool is not standard for all

engines, but may be delivered as an
optional extra.
4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.
Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
and the spindle guide and very carefully
MA909-6.2 111 03
force the fuel nozzle off the spindle guide.
0$1% :'LHVHO$6
909-12.3 Spindle Guide
Overhaul
5. 5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in kerosene or ‘Elec-

trocleaner’ and wipe dry with a clean piece
of cloth.
Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
magnification magnifying glass and an in-
spection lamp.
During the examination, pay special atten-

tion to the seating surfaces and sliding sur-
faces of the parts.
6. Remove any deposits or very fine scratches

by placing the spindle, thrust piece or spin-
dle guide respectively in a lathe, as shown,
and polishing with a very fine conventional
polishing linen ‘grade 360’.
MA909-6.2 111 04
Use also a little oil for the polishing (a

coarser polishing linen must absolutely
not be used).
6.
Note!
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be dam-
aged.
After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat
on spindle/guide. Use an inspection lamp
and an 8-10 times enlargement magnifying
glass.
MA909-6.2 111 05
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
0$1% :'LHVHO$6
Overhaul
7. Clean any carbon deposits from the central 7.

bore of the fuel nozzle by means of the spe-
cial brass brush. Clean the spray holes, us-
ing gas oil and the special drills supplied.
Note!
During this operation be very careful not

to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
the fuel nozzle.
Clean the fuel nozzle with kerosene and

wipe dry with a clean cloth.
Then test the spray holes with the test pin.

If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
MN909-12.3 213 07
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
Note!
It is recommended that the fuel nozzle is

changed whenever the spindle guide is
being overhauled.
0$1% :'LHVHO$6
909-12.3 Spindle Guide
Overhaul
9. 8. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybde-
num Disulphide (MoS 2), see Procedure
913-11.
9. Assemble the thrust piece, the spindle and

the spindle guide and carefully knock the
parts together using a soft hammer.
10. Shake the spindle guide back and forth.

The spindle with the cut-off slide must be
able to slide freely back and forth inside the
spindle guide, with a ‘clicking’ sound.
MN909-12.3 215 09
10.
MN909-12.3 215 10
0$1% :'LHVHO$6
Overhaul
11. Lubricate the sliding surfaces of the nozzle 11.

and the spindle with a little Molybdenum Di-
sulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Make sure that the half-circle shaped

groove on the nozzle and the spring pin are
in line. 6SULQJSLQ
If nozzle and spindle guide are provided

with scratch marks opposite the spring pin,
they must be in line.
Place the parts on the plane of a drilling

machine or hydraulic press and position the
mounting tool over the parts. Make sure
that all the parts are perfectly aligned.
6FUDWFKPDUNV
Press the nozzle on to the spindle guide.
HN909-12.3 221 11
Note!
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
If no mounting tools are available, the noz-

zle can be mounted on the spindle guide
using a short piece of pipe.
Place the pipe around the nozzle, so that

the lower end of the pipe rests on the ‘foot’
of the fuel nozzle. Then press the parts to-
gether the same way as when using the
mounting tools.
Check that the spindle inside the spindle

guide is able to move freely as in step 10.
12. If the spindle guide is not to be mounted in a

fuel valve immediately after the overhaul, cov-
er all openings of the spindle guide with plas-
tic to prevent dirt from entering the spindle
guide during storage.
0$1% :'LHVHO$6
Non-return valve 109-13
Data
SAFETY PRECAUTIONS
Special
D10913 Data 0031
109-13 Edition Non-return
S60MC-Cvalve
Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
109-13 Non-return valve
Data
P90951 153 Flange for dismantling of non-return valve

P90968- 12 Probe light with magnifier, complete
MAN B&W Diesel A/S
Non-return valve 909-13.3
Overhaul
Non-return valve
K98MC-C
0206
Overhaul
909-13.3
1.
Note!
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
1. Clean the outside of the non-return valve

with pure gas oil. The individual parts are
not interchangeable, therefore only one
guide is to be disassembled at a time.
Note!
Except for the slide valve spring, defec-

tive parts cannot be replaced individually

by new ones.

&
Place the non-return valve as shown in Fig. 0
1 in a bench vice provided with “soft” jaws,

A
and disassemble the non-return valve, us- 2.
ing the disassembling tool and a hammer
as shown.
2. Clean all the parts for the spindle guide in

gas oil and wipe them dry with a clean B C D
piece of cloth.

Finally, clean in either gas oil, kerosene or

‘Electrocleaner', and wipe the parts dry with

%
1
a clean piece of cloth.
3. Now place the parts on clean, lint-free rags 3.

and examine with an 8-10 times enlarge-
ment magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.

&
0
0$1% :'LHVHO$6
909-13.3 Non-return valve
Overhaul
4. 4. Examine the slide faces of movable parts

for coating. Vent slide B/housing A will be
too tight if there is a coating. (The letters A-
D refer to the letters/parts in Fig. 2).
Fix vent slide B and, subsequently, housing

A in a lathe as shown in Fig. 4 and remove
the coating by means of very fine conven-
tional polishing linen ‘grade 360'.
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
MC909-6.2 69 04
5. Check spring C for the thrust piece for out-

side wear marks. If defective, it should be
exchanged.
5. Check the seat on thrust piece D/vent slide,

and the seat on vent slide/housing. Use an
inspection lamp and an 8-10 times enlarge-
ment magnifying glass.
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
NA909-13.3 205 05
6. Mount the non-return valve as follows:
• Lubricate all movable parts with molyb-

denum disulphide (MoS2).
6.
• Place the loosely-assembled non-return
valve on the plane of a drilling machine,
with the tool positioned as shown in Fig.
6.
• Make sure that the thrust piece and the

other parts are perfectly aligned and that
the thrust piece is guided in the vent
slide.
• Press the handle until the housing and

thrust piece meet.
7. If the non-return valve is not to be mounted

in a fuel valve immediately after the over-
haul, cover all openings of the non-return
valve with plastic to prevent dirt from enter-
MC909-6.3 69 06
ing the valve during storage.
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 109-14
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10914
109-14 Data 0055 Fuel Oil High-Pressure Pipe
X Stopped engine
Engage turning gear
X Shut off fuel oil
Data
D09-47 Fuel oil high-pressure pipe, tightening torque 190 Nm

D09-51 Distance from pipe end to thrust bushing lower edge 14 mm
(fuel pump end and fuel valve end)
D09-52 Fuel oil pipe 16 kg
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data
P90951 104 Milling tool for fuel oil pipe

MAN B&W Diesel A/S
Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S60MC-C
0234
Dismantling
909-14.2
2.
High-Pressure Pipe with Protective Hose
1. Close the fuel oil inlet and outlet valves.
2. Using a hook spanner, unscrew the union

nut at the fuel valve end of the high-pres-
sure pipe.
Pull the union nut and the protective hose

clear of the union nipple.
Unscrew the union nipple from the fuel

valve.
HN909-14.2 209 02
3. Using a hook spanner, unscrew the union
nut at the fuel pump end of the high-pres-
sure pipe.
Pull the union nut and the protective hose 3.

clear of the union nipple.
Unscrew the union nipple from the fuel

pump.
4. Lift the pipe ends clear of the fuel valve/fuel

pump, and remove the high-pressure pipe
from the engine.
Note!
It is recommended always to overhaul

HN909-14.2 209 03
the high-pressure pipe before remounting

it on the engine.
The overhaul should preferably take

4.
place immediately after the high-pres-
sure pipe has been dismantled.
D09-52
HN909-14.2 209 04
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3
1. 1. Whenever the fuel oil high-pressure system

has been dismantled, it is necessary, be-
D09-51
fore remounting the high-pressure pipes, to
carefully inspect the tapered contact surfac-
es of the pipe ends, together with their
seats in fuel valves and fuel pump top cov-
er.
Furthermore, the position of the thrust

bushing on the pipe end must be checked.
If the distance is incorrect, compared with
the measurement stated in Data, it should
be adjusted by screwing the thrust bushing
up or down the pressure pipe.
2. If any of the pipe ends requires recondition-

ing, dismantle the high-pressure pipe as
HM909-7.0 59 01
follows:
D09-51
• Lift up the union nut with flexible protec-
tive hose, together with the coupling nut,
on the high-pressure pipe and screw off
2. the thrust bushing.
• Remove the coupling nut and, when the

thrust bushings at both ends of the pipe
have been dismounted, pull the flexible
protective hose with union nuts off the
high-pressure pipe.
3. Shape-up the threads on the pipe ends with

the nut die.
MC909-7.0 67 02
3.
MC909-7.0 67 04
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 909-14.3
Overhaul
4. Mount the guide on the pipe end, place the 4.

miller in the guide and lightly screw on the
union nut.
5. Turn the miller with, for instance, a tap

wrench while lightly tightening the union nut
to provide a suitable pressure between mill-
er and pipe end. During the milling, add
drilling oil emulsion liberally.
After completing the milling, carefully clean

the high-pressure pipe with diesel oil and
wipe dry with a clean piece of cloth.
MC909-7.0 67 03
6. When assembling the high-pressure pipe,
screw the thrust bushings so high up on the
thread of the pressure pipe that the dis-
tance between the pipe end and the bottom
edge of the thrust bushing is as stated in 5.
Data.
Replace the O-rings.
Before mounting a high-pressure pipe,

check the centre distances between pipe
ends and seats, and lubricate the threads
of the union nuts with molybdenum disul-
phide (MoS 2).
It is of great importance for the mounting,

and a condition for obtaining tight joints,
GN909-14.3 204 05
that the pipes fit the seats accurately.
For reconditioning of seat in fuel valve, see

Procedure 909-11.3.
For reconditioning of seat in fuel pump top 6.

cover, see Procedure 909-5.3.
D09-51
HM909-7.0 62 06
0$1% :'LHVHO$6
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
Mounting
909-14.4
4. 1. Check that the distance between the thrust

bushing and the pipe end is correct at both
ends of the pipe. See Procedure 909-14.3.
2. Ensure that the fuel valve is fitted with a

D09-52 new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
3. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
HN909-14.4 209 04
4. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
Screw the union nipples onto the fuel valve

5. and into the fuel pump top cover, by hand.
Note!
The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nip-
ples have been screwed into position.
5. Use a crowfoot wrench and a torque

HN909-14.4 209 05
D09-47
wrench to tighten the union nipple at the
fuel valve to the torque stated in Data.
Screw the union nut onto the union nipple

6. by hand, and tighten lightly with a hook
spanner.
6. Use a crowfoot wrench and a torque

wrench to tighten the union nipple at the
fuel pump to the torque stated in Data.
Screw the union nut onto the union nipple

by hand, and tighten lightly with a hook
spanner.
7. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
HN909-14.4 209 06
D09-47
0$1% :'LHVHO$6
Fuel Pump Roller Guide 109-15
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D10915
109-15 Data 0046 Fuel Pump Roller Guide
X Stopped engine
X Shut off fuel oil
Data
D09-53 Nut, reversing shaft, tightening torque 160 Nm

D09-54 Clearance A 0.6 - 3.1 mm
D09-55 Clearance B 4.3 - 6.0 mm
D09-56 Clearance C 0.3 - 0.8 mm
D09-57 Roller/bushing/shaft pin, max. clearance 0.5 mm
D09-61 Fuel pump roller guide 96 kg
D09-62 Pump base 118 kg
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
Data
P90951 82 Lifting tool for fuel pump roller guide
MAN B&W Diesel A/S
Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
S60MC-C
0226
Checking
909-15.1
3.
Roller guide mounted in engine
1. The fuel pump roller guide can be partially

checked while mounted on the engine, us-
ing the following procedure:
2. Lift the fuel pump roller guide.

3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.
Turn the engine to provide the maximum
HN909-10.1 205 01
space between the roller guide and the cam
disc.
Turn the roller by hand to check that it can

move freely and without unnecessary re-
sistance or “hard” points. 5.
Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no trac-
es of bearing metal left in the roller guide
housing.
Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.
4. Lower the roller guide onto the fuel cam

again.
5. Using the telegraph, move the roller guide

to the AHEAD position.
GN909-15.1 203 05
Check that the reversing link is fully tilted

over in AHEAD position.
Carry out the same check in the ASTERN po-

sition.
0$1% :'LHVHO$6
909-15.1 Fuel Pump Roller Guide
Checking
7. Roller guide removed from engine
A more suitable and reliable method is to check

the roller guide and the bearing clearance after
the roller guide has been dismounted:
6. Dismount the roller guide from the engine.

7. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.
8. Turn the roller guide upside down and land

it in a vertical position on a couple of
planks, with the roller hanging freely.
Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clear-
ance permits.
MA909-8.0 70 07
8.
D09-57
MA909-8.0 70 06
0$1% :'LHVHO$6
Dismantling
Dismantling
909-15.2
1.
Note!

1. Dismantle the top cover of the fuel pump.

2. Dismantle the fuel pump barrel assembly.

GN909-5.2 204 03
2.
GN909-6.2 204 06
0$1% :'LHVHO$6
Dismantling
3. 3. Dismantle the fuel pump housing, see Pro-

cedure 909-4.2.
Note!
When lifting the fuel pump housing, take

care not to damage the threads on the
studs.
4. Loosen and remove the screws from the

sealing cap on top of the roller guide inside
the pump base.
Remove the sealing cap from the roller

guide/pump base.
Dismantle the lubricating oil pipe and the

GN909-15.2 203 03
drain pipe from the pump base.
5. Remove the cover on the camshaft housing

to inspect the position of the roller guide.
Turn the engine until the roller guide is at
4.
BDC.
HN909-15.2 206 04
5.
HN909-10.1 205 01
0$1% :'LHVHO$6
Dismantling
6. Loosen the nuts on the two threaded studs 6.

successively until the roller guide springs
are relieved.
Remove the nuts, mount two eye bolts in

the pump base and lift it away. D09-62
When lifting, take care that the bushing of
the pump base slides against the neck of
the roller guide without scratching.
Remove the springs from the roller guide.
7. Mount the roller guide lifting tool as follows:
• Lift the lock plate of the tool up on the

shaft of the tool.
• Position the tool so that its foot rests on

the thrust piece in the bayonet joint of the
roller guide.
HN909-15.2 206 06

• Lower the lock plate, thereby securing

the foot in the locked position.
7.
Lift the roller guide out of the roller guide
housing, using the crane.
When lifting, take care that the slide surfac-

es of the roller guide do not scrape against
the roller guide bushing. D09-61
Land the roller guide on wooden planks.
8. Check the roller guide.

GN909-15.2 203 07
0$1% :'LHVHO$6
Overhaul
Overhaul
909-15.3
1. 1. Inspect and check the fuel pump roller

guide.
2. It is recommended that the roller guide

D09-61 should ONLY be dismantled if
• irregularities when turning the roller,
• damage to the roller,
• larger clearance than stated on the Data

sheet,
• seizure marks on the slide surfaces,
have been observed when checking the

roller guide.
Note!
For disassembling of the roller guide,

MA909-8.0 70 07
contact an MAN B&W authorized repair

shop.
3. If no irregularities are found, just clean and

3. lubricate the roller guide before remounting
it in the roller guide bushing.
HN909-15.3 206 03
0$1% :'LHVHO$6
Mounting
Mounting
909-15.4
1. Lubricate the roller guide with plenty of 1.

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
During mounting, take care not to scratch

the sliding surfaces of the roller guide.
D09-61
Make sure that the pin of the reversing link
fits in the bracket of the reversing shaft.
2. After mounting the roller guide with the re-

versing link, check the clearance between
the roller guide and the guide plate mount-
ed in the roller guide bushing.
Turn the camshaft so that the roller guide is

lifted approx. 20 mm.
The clearance C between the roller guide

and the guide plate must be the same at
both ends +/– 0.1 mm.
HN909-15.4 206 01
The clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.
Connect working air to the air cylinder, and 2.

check that the reversing mechanism is
working smoothly.
The clearances A and B must be approx.

the same in both positions. See Data.
D09-54
D09-56
D09-55
HN909-15.4 206 02
0$1% :'LHVHO$6
Mounting
3. 3. If adjustment is necessary, it must take

place in the ASTERN position.
Remove the cover over the shaft connec-

tion.
Loosen the nut on the reversing shaft and

carry out the adjustment.
After adjustment, shift to AHEAD position

and check the clearances A and B once
more.
Finally, shift again to ASTERN.
Tighten the nut on the reversing shaft to the

D09-53 torque stated in Data, and lock the nut with
Loctite type: Screw Lock No. 59.
Mount the cover over the shaft connection.
4. Turn the engine until the roller guide is at

HN909-15.4 206 03
BDC.
5. Mount the springs and the spring seat discs

over the roller guide.
5. Mount the pump base over the roller guide

and the springs.
Mount the two special nuts on the threaded

studs.
Using the special tube-shaped socket

D09-62 wrench, tighten the nuts until the pump
base is fastened tightly to the roller guide
bushing.
HN909-15.2 206 06
0$1% :'LHVHO$6
Mounting
6. Check the movement of the reversing link. 6.

7. Replace the scraper rings in the sealing

cap as follows:
Loosen and remove the screws and nuts

from the bottom of the cap, remove the re-
taining flange and ring holder with scraper
ring.
8. Replace the O-ring in the top of the cap.
Replace the axial scraper ring in the bottom

of the cap. Check that the O-ring and scrap-
GN909-15.1 203 05
er ring are mounted correctly. See the
sketch.
7.
GN909-15.4 203 07
8.
MA909-8.0 70 21
0$1% :'LHVHO$6
Mounting
9. 9. Remove the scraper ring and O-ring from

the ring holder.
Place the new O-ring in the ring holder.
Before mounting, the new scraper ring must

be heated in 100°C hot water or oil for at
least five minutes.
Note!
When mounting the scraper ring in the

groove, fold the ring without making any
AM909-8.0 31 16
sharp edges, and be careful not to cut

the scraper ring on the edge of the ring
groove when pressing it in.
10. Check that the O-ring and scraper ring are

mounted correctly. See the sketch.
10. Assemble the sealing cap, the ring holder

and retaining flange.
Tighten the nuts on the screws.
After tightening, check that the holder can

be moved.
11. Mount the lubricating oil pipe and the drain

pipe on the pump base.
GN909-15.4 203 10
Mount the sealing cap on top of the roller

guide, over the sealing bush inside the
pump base.
11. Tighten the screws and lock with locking

wire.
12. Mount the fuel pump housing.

Mount the barrel assembly.

Mount the top cover.

HN909-15.4 206 11
0$1% :'LHVHO$6
Fuel valve and Fuel Pump Panel Plate
MAN B&W P90951-0431
Plate Fuel valve and Fuel Pump Panel
P90951-0431 MAN B&W

No.
010 Panel for tools
021 Name plate
045 Measuring tool for fuel pump lead
057 Lifting tool for fuel pump plunger
barrel
069 Lifting tool for fuel pump
070 Lifting tool for fuel pump housing
094 Milling tool for fuel oil pipe seat
104 Milling tool for fuel oil pipe
116 Crowfoot wrench head
153 Flange for dismantling of non-return
valve
165 Grinding mandrel for valve head
177 Grinding mandrel for thrust spindle
189 Grinding mandrel for holder, outside
190 Grinding mandrel for holder, inside
200 Screw
224 Tool for P. max rack
236 Pin wrench, special
248 Hook wrench
250 Drift for spindle guide
261 Drift for puncture valve
297 Assembly tool
307 Hook wrench
Fuel Valve - Tools Plate
MAN B&W P90961-0069
Plate
Fuel Valve - Tools
P90961-0069 MAN B&W

No. No.
014 High-pressure pump

026 Table
038 Rig fuel oil valve
040 High-pressure hose
051 Connection piece
063 Test rig, complete
075 Cover
087 Angle union
099 Gasket
109 Plug screw
122 Hose
Fuel Valve Nozzle - Tools Plate
MAN B&W P90966-0008
Plate Fuel Valve Nozzle - Tools
P90966-0008 MAN B&W

No.
011 Tool box
023 Extractor for atomizer
035 Drift for atomiizer
047 Cleaning brush
060 Instruction plate
202 Toolset, complete
Note:
When ordering new cleaning tool,
please state P/N on fuel nozzle.
910 Turbocharger System
110-1 0039 Air Cooler Element, Data

910-1 0234 Air Cooler Element
110-2 0007 Non-Return Valve in Turbocharger, Data
910-2 0215 Non Return Valve in Tubocharger
910-3 0218 Auxilary Blower
110-3 0017 Auxilary Blower, Data
110-4 0004 Butterfly Valve, Data
910-4 0207 Butterfly Valves
110-5 0008 Turbocharger Turbine, Data
910-5 0207 Turbocharger Turbine
110-6 0024 Water Mist Catcher, data
910-6 0219 Water Mist Catcher
91064 0002 Travelling Trolley
91066 0005 Air Cooler, Lifting Tools
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Air Cooler Element 110-1
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11001
110-1 Data 0039 Air Cooler Element
X Stopped engine
Shut off fuel oil
Data
D10-02 Aft end cover 300 kg

D10-04 Air cooler element, complete with covers, up to 3500 kg
D10-05 Front end cover (waterflow reversing chamber) 300 kg
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data
Travelling trolley
P91066 Air Cooler - Lifting tools
Guide rail air cooler, fore end
Guide rail air cooler, rear end
MAN B&W Diesel A/S
Air Cooler Element 910-1.1
Checking
Air Cooler Element
S60M-CC
0234
Checking
910-1.1

1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the OPERATION man-
ual, Volume I, Chapter 706.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of

the air side of the cooler.

A decrease in the air temperature drop

1
across the scavenge air cooler indicates -
fouling of the water side of the cooler.

3. If the measurements indicate fouling of the
water side of the air cooler element, the el-
ement must be 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 top inspection cover of the air

cooler.

Unlock and swing open the inspection 1
-
hatch at the bottom of the air cooler.

5. Visually inspect the air cooler element
through the openings.
For further information, see the OPERA-

TION manual, Volume I, Chapter 702
“Checks during Standstill Periods”.
If the air side of the element is fouled, clean

the element using the spray pipe arrange-
ment fitted above the air cooler element.

1
-
0$1% :'LHVHO$6
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2
1. The cooler element normally does not need to

be dismantled for inspection purposes. It is only
in the event that the cooler element has suf-
fered damage that it has to be dismantled and
replaced.
Note!
During dismantling, take care not to dam-

age the cooler element.
1. Close the cooling water inlet and outlet

JN910-1.2 213 01
valves. Open the drain cocks on the water

inlet/outlet cover to drain off the cooling wa-
ter.
2. Dismount the cooling water inlet and outlet

2. pipes from the water inlet/outlet cover.
3. Release the screws and remove the frame

around the reversing chamber.
Remove and discard the O-ring.
Remove the sealing plate.

JN910-1.2 213 02
3.
JN910-1.2 213 03
0$1% :'LHVHO$6
Dismantling
4. Mount the first set of guide rails on the 4.

frame around the reversing chamber.
5. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount the lowermost screws. Mount
and tighten the uppermost screws.
Tighten the thrust nuts on the uppermost

screws simultaneously. This results in loos-
ening and lifting the cooler element.
6. Mount the lifting bracket on the water inlet/

outlet cover.
Mount two travelling trolleys on the beam

above the water inlet/outlet cover.
Mount a tackle between the travelling trolley JN910-1.2 213 04
nearest to the air cooling housing and the

lifting bracket, and use the tackle to lift the
air cooler element approx. 1-2 mm.
5.
JN910-1.2 213 05
6.
JN910-1.2 213 06
0$1% :'LHVHO$6
Dismantling
7. 7. Mount a second tackle on the lifting brack-

et, and use it to pull out the air cooler ele-
ment approx. half a metre.
Shift the lifting tackle between the two trav-

elling trolleys to avoid damaging pipes,
valves, etc.
8. Mount the second set of guide rails on the

frame around the air cooler element.
9. Pull out the air cooler element until the

wheels on the reversing chamber interlock
with the recess in the guide rails.
JN910-1.2 213 07
8.
JN910-1.2 213 08
9.
D10-04
JN910-1.2 213 09
0$1% :'LHVHO$6
Overhaul
Overhaul
910-1.3
Cleaning the air side: 1.
The air side of the cooler is cleaned by injecting

a chemical fluid through the spray pipe arrange-
ment fitted to the air chamber above the cooler
element.
It is recommended to use one of the following

cleaning fluids, or a similar product.
1) Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
2) Product: 80B, produced by

Vecom Int., Maassluis, Holland
Cleaning should be carried out in the following

sequence:
1. Do not start cleaning until the engine has

been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
JN910-1.3 213 01
ply to the exhaust valve.
2. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pres- 2.
sure must be at least 0.7 bar.
3. Continue the cleaning process for at least

30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
4. After cleaning, flush the cooler with clean

water until the water appearing in the sight
glasses is clean and pure.
5. Inspect the element as described in Proce-

dure 910-1.1.
KE910-5.1 61 02
0$1% :'LHVHO$6
Overhaul
6. Cleaning the water side
6. Close the cooling water inlet and outlet

valves. Open the drain cocks on the water
inlet/outlet cover to drain off the cooling wa-
ter.
7. Dismount the cooling water inlet and outlet

pipes from the water inlet/outlet cover.
8. Screw two eye bolts into the upper flange of

the water inlet/outlet cover. Mount a lifting
wire rope between the eye bolts.
JN910-1.2 213 01
Mount a travelling trolley on the beam

above the water inlet/outlet cover.
Mount a tackle between the travelling trolley

7. and the lifting wire rope. Tighten up the
tackle.
JN910-1.2 213 02
8.
JN910-1.3 213 08
0$1% :'LHVHO$6
Overhaul
9. Mount a shackle in each of the two lifting 9.

eyes on the reversing chamber.
Mount two tackles above the reversing

chamber.
Hook the tackles on to the shackles and

tighten up.
10. Remove the screws of the water inlet/outlet

cover and the reversing chamber.
Lower both covers and land them on a cou-

ple of wooden planks. Discard the gaskets.
JN910-1.3 213 09
11. Clean the inside of the tubes, using the
cleaning brush (delivered by the cooler el-
ement manufacturer) mounted on a drilling
machine. In the event of leakages between 10. D10-02
cooling tube and tube plate, the tubes are D10-05
rolled with the tube expande (also delivered
by the cooler element manufacturer).
Clean the front-end and aft-end covers in-

side with a stiff brush and then rinse with
fresh water.
Replace the anti-corrosion blocks, if neces-

sary.
Note!
JN910-1.3 213 10
If damaged, the coating inside the covers

D-1
is to be repaired with the original coating
or a similar product.
11.
12. When cleaning is complete, mount the cov-
ers in the reverse order to dismantling.
JN910-1.3 213 11
0$1% :'LHVHO$6
Mounting
Mounting
910-1.4
1. 1. Push the air cooler element inwards ap-

prox. one metre.
Remove the guide rails from the water inlet/

outlet cover end of the air cooler housing.
2. Clean the frame around the air cooler ele-

ment and the contact surface of the water
inlet/outlet cover.
Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the water inlet/outlet cov-
er.
Push the air cooler element fully into the air

cooler housing.
JN910-1.4 213 01
Shift the lifting tackles bsetween the two

travelling trolleys to avoid damaging pipes,
valves etc.
2.
JN910-1.4 213 02
0$1% :'LHVHO$6
Mounting
3. Mount and tighten all the screws of the wa- 3.

ter inlet/outlet cover.
Remove the tackle and the lifting bracket

from the water inlet/outlet cover.
4. Remove the guide rails from the reversing

chamber end of the air cooler housing.
5. Mount the sealing plate, a new O-ring and

the frame around the reversing chamber.
6. Mount the cooling water inlet and outlet

pipes on the water inlet/outlet cover.
JN910-1.4 213 03
7. Close the drain cocks, and open the cooling
water inlet and outlet valves.
4.
Note!
Remember to vent trapped air from the

air cooler element.
JN910-1.4 213 04
0$1% :'LHVHO$6
Non-Return Valve 110-2
Data
SAFETY PRECAUTIONS
Special Edition
S60MCC
D11002
110-2 Data 0007 Non-Return Valve
X Stopped engine
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
S60MC-C
0215
Overhaul
910-2.3
1.
The non-return valves are accessed from the
scavenge air receiver.
Note!
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
HN910-2.3 215 01
Main Non-Return Valve
1. Inside the scavenge air receiver, lift up the

valve flap of the valve that is to be over- 2.
hauled.
2. Remove the screws behind the valve flap.

Remove the valve from the engine.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
HN910-2.3 215 02
4. For further dismantling, remove the two

screws which hold the clamp and the sup-
port together as an assembly.
Clean the valve shaft and the slide bearings 3.

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybde-
num disulphide (MoS 2).
5. Assemble the valve
After the overhaul, it must be possible to

move the valve flap by the light touch of a
MC910-6.0 26 02
finger.
6. Re-mount the valve in the scavenge air re-

ceiver.
4.
MC910-6.0 26 03
0$1% :'LHVHO$6
Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
0218
60&&
Overhaul
910-3.3
1.
1. When cleaning and inspecting the auxiliary
blower, disengage the cable connections to
the blower motor.
Wire ropes with shackle as well as two tack-

les suspended from mountings on the gal-
lery bracket are to be hooked onto the
blower flange, before removing the screw in
the flange.
2. The end cover complete with blower can

now be pulled free of the suction pipe by
means of the two tackles. D10-12
MC910-8.0 31 01
While pulling out the end cover with the
blower assembly, make sure that the blower
housing disengages from the air pipe with-
out deforming it.
2.
Then inspect and clean the blower wheel as
well as the blower housing.
For overhaul of blower wheel and bearings,

see blower manufacturer’s instructions.
Note!
Exercise care when mounting the elec-

tric motor with blower wheel, as the
blower wheel is to “catch” the guide in the
blower housing.
MC910-8.0 31 02
0$1% :'LHVHO$6
Auxiliary Blower 110-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11003
110-3 Data 0017 Auxiliary Blower
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-12 Electric motor, impeller and motorplate 610 kg
MAN B&W Diesel A/S
110-3 Auxiliary Blower
Data

P91361 Combination wrenches
MAN B&W Diesel A/S
Butterfly Valves 110-4
Data
SAFETY PRECAUTIONS
Special Edition
S46MC-C
D11004
110-4 Data 0004 Butterfly Valves
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
MAN B&W Diesel A/S
110-4 Butterfly Valves
Data
P91361 Combination Wrenches
MAN B&W Diesel A/S
Butterfly Valves 910-4.1
Checking
Butterfly Valves
S60MC-C
0207
Checking
910-4.1
1.
1. It is important that the automatic non-return
valves (butterfly valves) are always able to
function easily and unimpeded.
The movability of the valve flaps should

therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.
2. To check the valve, remove the cover on the

top of the butterfly valve.
GN910-4.1 203 01
Reach down through the opening in the top
of the valve and move the valve flaps.
3. If the valve flaps in one of the butterfly

valves cannot be moved by a light touch of
2.
a fingertip, it must be dismantled and over-
hauled.
4. Re-mount the cover on the top of the but-

terfly valve.
XZ910-9.0 15 02
0$1% :'LHVHO$6
Turbocharger Turbine 110-5
Data
SAFETY PRECAUTIONS
Special
D11005 Data 0008
110-5 Edition Turbocharger
L60MCCTurbine
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
0207
/0&&
Cleaning
910-5.3
The dry cleaning method employs compressed

air to blow dry, solid, granules through the tur-
bocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.
On account of their hardness, nut-shells, or

broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.
Note!
We do not recommend the use of rice or

grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.
It is not always possible to remove thick depos-

its with this dry cleaning method.
Therefore, in order to prevent the build-up of

thick deposits, the turbine must be cleaned af-
ter every 24 to 50 hours of operation.
Generally, turbocharger cleaning can be carried

out without, or with very little, reduction of the
engine load.
More detailed information regarding the amount

of granules to be used is stated on the instruc-
tion plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger

turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.
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
S60MC-C
D11006
110-6 Data 0024 Water Mist Catcher
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D10-11 Water mist catcher 180 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
S46MC
0219
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the
water mist catcher from the scavenge air
cooler housing. If, however, the water mist
catcher has been fouled or damaged, it
must be dismantled for cleaning or repair.
2. Dismantle the rectangular covers from both

the front and aft ends of the scavenge air
cooler housing.
3. Loosen the screws at both ends of the wa-

ter mist catcher.
GM910-6.2 213 02
Note!
Note the position of the water mist

catcher. During mounting, the water mist
catcher must be re-mounted in the same 4.
position.
4. Pull or push the water mist catcher halfway

out and mount an eye bolt in the top of the
water mist catcher. D10-11
Hook a tackle on to the eye bolt and lift the
water mist catcher away. Land it on a cou-
ple of wooden planks.
Note!
GM910-6.2 213 04
Take care not to damage the water mist

catcher during the lift.
5. Clean the water mist catcher with the same

cleaning fluid as used for the scavenge air
cooler element.
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4
1. 1. Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face away from the engine when
the water mist catcher is mounted (the side
opposite to the screws).
Toward
Engine 2. Slide the water mist catcher into the scav-
enge air cooler housing.
Note!
Make sure to mount the water mist

catcher correctly. The screws of the
GM910-6.4 213 01
water mist catcher must face the exhaust

side of the engine.
6LOLFRQH
When the water mist catcher is half-way in,

2. remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.
3. Tighten the screws at both ends of the wa-

ter mist catcher.
Apply a thin layer of silicone paste on the

D10-11 frame and mount the rectangular covers on
the front and aft ends of the scavenge air
cooler housing.
GM910-6.4 213 02
3.
GM910-6.4 213 03
0$1% :'LHVHO$6
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
Air Cooler - Tools Plate
P91063-0019
Air Cooler - Tools
0019
P91063
Rear end
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0019
Item Item
No. No.
015 Guide rail, rear end - left

027 Guide rail, rear end - right
039 Screw
040 Screw
052 Nut
MAN B&W Diesel A/S
Travelling Trolley Plate
P91064-0002
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0002

No. No.
010 Travelling trolley *
Note:
* When ordering this tool, please state

load and track width.
MAN B&W Diesel A/S
Air Cooler - Lifting Tools Plate
P91066-0005
Air Cooler - Lifting Tools
0005
P91066
MAN B&W Diesel A/S
Plate Air Cooler - Lifting Tools
P91066-0005
Item Item
No. No.
011 Lifting attachment air cooler fore end,

complete
047 Screw
MAN B&W Diesel A/S
911 Safety Equipment
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
X Lock turbocharger rotors
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
912 Assembly of Large Parts
112-2 0009 Holding Down and End Chock Bolts (Epoxy) , Data
912-2 0207 Holding Down and End Chock Bolts (Epoxy)
112-3 0018 Stay Bolts, Data
912-3 0212 Stay Bolts
91261 0073 Large Parts - Tools
91266 0001 HydraulicTools - End Chock Bolts (IEpoxy Chocks)
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Holding Down and End Chock Bolts 112-2
Data
SAFETY PRECAUTIONS
Special Edition
D11202
112-2 Data 0009 Holding Down
S60MC-C
and End Chock Bolts
Stopped engine
Engage turning gear
Shut off fuel oil
Data
D12-02 Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
1st check 500 hours
2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequent checks at intervals of 8000 hours
D13-01 Tightening pressure 1500 bar
D13-02 Dismantling pressure 1400-1650 bar
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data
P91263 Hydraulic tools for holding-down bolts

Bolts and end chock bolts, epoxy
MAN B&W Diesel A/S
Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0207
Checking
912-2.1
Note!
The hydraulic jack used for tightening the

holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the

end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking
1. Checking the Bolt Tightening
1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking table, see drawing Nos.
782225-0 and 782226-2, following which
the bolts are tightened to the normal tight-
ening pressure.
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.
If the ‘loosening pressure' is below 80 per

EN912-1.1 205 01
cent of the tightening pressure, the relative

chocks shall always be checked for possi-
ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.
0$1% :'LHVHO$6
Holding Down and End Chock Bolts 912-2.1
Checking
Side Chocks and Side Chock Liners 3.
3. After fitting the liners to an 80 per cent con-

tact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simulta-
neously.
The first time the ship is sailing in a fully-

loaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.
GN912-2.1 203 03
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
The feeler gauge is applied at the 7 points

indicated on drawing No. 782226-2, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated on

drawing No. 782226-2.
If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Stay Bolts 112-3
Data
SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11203
112-3 Data 0018 Stay Bolts
X Stopped engine
Engage turning gear
Shut off fuel oil
Data
D12-04 Check measurement 180±3 mm

MAN B&W Diesel A/S
112-3 Stay Bolts
Data

P91261 23 Hydraulic jack, complete
MAN B&W Diesel A/S
Stay Bolts 912-3.1
Checking
Stay Bolts
S60MC-C
0212
Checking
912-3.1
1.
1. This check can be performed during several
periods of stopped engine, but must be per- One Group
formed on complete twin stay bolt groups at One Group
a time, thereby ensuring uniform tension in
the affected bearings.
Note!
The first time this check is performed it

has to be completed in one operation.
NA912-3.1 210 01
The following checks have to be com-
pleted within a 500-hour period.
2. Before retightening the stay bolts, remove

the protective caps. 2.
3. Check for loose staybolt nuts with the tom-

my bar.
If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 01
Loosen and unscrew the nut on the oppo-

site stay bolt.
Check for the correct mounting of the stay

bolt by comparing with the check measure-
ment on the Data Sheet. 3.
D13-02
If the check measurement is not reached,
indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the
D12-04
thread in the top of the stay bolt, and turn
the stay bolt until the check measurement
GN912-3.0 39 09
data is met.
4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.
D13-01
GN912-3.1 202 03
0$1% :'LHVHO$6
912-3.1 Stay Bolts
Checking
5. 5. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
D13-01 stay bolts are tightened in one operation.
6. Maintain the mounting pressure, and

retighten the stay bolt nuts with a tommy
bar. Before relieving the system of pres-
sure, check with a feeler gauge that the
nuts bear against their contact faces.
GN912-3.1 202 02
7. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below the mounting pressure and check
6. whether the nut is loose.
If the nut is not loose:

Tighten the stay bolts concerned to the
mounting pressure.
If the nut is loose:

Tighten all stay bolts once again to the
mounting pressure.
8. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 04
7.
HM912-3.0 28 05
0$1% :'LHVHO$6
Large Parts - Tools Plate
P91261-0073
Large Parts - Tools
0073
P91261
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0073
Item Item
No. No.

035 Support
047 Tommy bar
050 Sealing ring with back-up ring
060 Sealing ring with back-up ring
084 Key, hexagon socket screw
106 Stud setter
202 Hydraulic tool set, complete
MAN B&W Diesel A/S
Hydraulic Tools - End-Chock Bolts Plate
P91266-0001
(Epoxy Chocks)
MAN B&W Diesel A/S
Plate Hydraulic Tools - End-Chock Bolts
P91266-0001
(Epoxy Chocks)
No. No.
019 Wooden box

032 Support
056 O-ring with back-up ring 110/120mm
068 O-ring with back-up ring 85/95mm
093 Tommy bar
103 Spanner
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 0053 Lifting Tools, Etc.
91358 0014 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0004 Pliers
91361 0052 Combination Spanners
91362 0069 Ring Slugging Spanners
91363 0035 Spanners
91366 0065 Instruments
91368 0007 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.
:KHQUHIHUULQJWRWKLVSDJHSOHDVHTXRWH3URFHGXUH0(GLWLRQ 3DJH
0$1% :'LHVHO$6
+\GUDXOLF7RROV
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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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.

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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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913-1
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Maintenance
913-1
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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
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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
P91356-0053
Lifting Tools, Etc.
0053
P91356
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0053
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
P91357-0007
Open Ended Spanners
0007
P91357
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0007
Item Item
No. No.
013 Open-ended spanner, size NV65mm

MAN B&W Diesel A/S
Open-Ended Slugging Spanners Plate
P91358-0014
Open-Ended Slugging Spanners
0014
P91358
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0014
Item Item
No. No.
164 Open-ended slugging spanner, size

NV85mm
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 - 40Nm

026 Adapter for socket wrench, 10 x 12.5
mm
MAN B&W Diesel A/S
Pliers Plate
P91360-0004
P91360
Pliers
0004
MAN B&W Diesel A/S
Plate Pliers
P91360-0004
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
P91362-0069
MAN B&W Diesel A/S
Plate Ring Slugging Spanners
P91362-0069

No. No.
022 Slugging spanner, ring size NV30mm

MAN B&W Diesel A/S
Spanners Plate
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
P91366-0065
MAN B&W Diesel A/S
Plate Instruments
P91366-0065

No. No.
048 Autolog, measuring tool for crankshaft

050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool
MAN B&W Diesel A/S
Working Platforms Plate
P91368-0007
Working Platforms
0007
P91368
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0007
Item Item
No. No.
013 Platform board
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

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

No. Edition Title

90465 0001 Crosshead - Tools

905 Crankshaft, Thrust Bearing and Turning Gear

906 Mechanical Control Gear

907 Starting Air System

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

No. Edition Title

908 Exhaust Valve

909 Fuel Oil System

910 Turbocharger System

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

No. Edition Title

911 Safety Equipment

912 Assembly of Large Parts

913 General Tools

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

The Checking and Maintenance Programme B. Condition-based overhauling

A. Condition checking procedures, Where a symbol O or C is indicated under

Where a procedure number is stated under

901 CYLINDER COVER

902 PISTON WITH ROD AND STUFFING BOX

903 CYLINDER LINER AND LUBRICATION

-1 Cylinder liner 901-1

904 CROSSHEAD WITH CONNECTING ROD

-1 Crosshead bearings 904-4

-4 Crankpin bearings 904-1

905 CRANKSHAFT, THRUST BEARING

-2 Main bearings 904-1

-5 Axial vibration damper

906 MECHANICAL CONTROL GEAR

907 STARTING AIR SYSTEM

-1 Starting air distributor

-2 Starting air valve

908 EXHAUST VALVE

-3 Exhaust valve actuator

-4 Exhaust valve roller guide

-5 Exhaust valve cam

-7 Exhaust valve emergency running C

909 FUEL OIL SYSTEM

-1 Fuel pump lead

-3 Fuel pump cam

-5 Fuel pump top cover

-6 Fuel pump barrel assembly

-7 Fuel pump suction valve

-8 Fuel pump puncture valve

-9 Fuel pump shock absorber