L35MC 01

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

MAN B&W Diesel A/S
Page 1 (1)
L35MC
VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
90023
90050
90060
0027
0288
0002
Table of Contents, Volume II

Instructions for Main Engine
Checking & Maintenance Schedule
General - Safety Precautions
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
900
Volume II - Maintenance
No.
Edition
Title
900 - Introduction
Table of Contents
90023 0027 Instructions for Main Engine
90050 0288 Checking & Maintenance Schedule
90060 0002 General - Safety Precautions
901 - Cylinder Cover
101-01 0072 Cylinder Cover, Data
901-01 0255 Cylinder Cover
90151 0189 Cylinder Cover - Panel
90161 0107 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0100 Piston, Data
902-01 0288 Piston
102-02 0068 Piston Rod Stuffing Box, Data
902-02 0232 Piston Rod Stuffing Box
90251 0259 Piston and Piston Rod - Panel
90261 0103 Piston and Piston Rod - Tools
90264 0011 Piston and Piston Rod - Tilting Tools
90265 0002 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0077 Cylinder Liner, Data
903-01 0261 Cylinder Liner
103-02 0032 Cylinder Lubricator, Data
903-02 0255 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90366 0010 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0065 Crosshead Bearing, Data
904-01 0255 Crosshead Bearing
104-02 0067 Crosshead, Data
904-02 0254 Crosshead
104-03 0046 Reciprocating Parts, Data
904-03 0216 Reciprocating Parts
104-04 0059 Crankpin Bearing, Data
904-04 0235 Crankpin Bearing
104-05 0057 Connecting Rod, Data
904-05 0238 Connection Rod
90451 0143 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90464 0005 Crosshead - Hydraulic Tools
MAN B&W Diesel A/S
Page 1 (4)
Table of Contents
900
No.
Edition
Title
905 - Crankshaft, Thrust Bearing and Turning Gear

105-02 0083 Main Bearing, Data
905-02 0259 Main Bearing
105-03 0073 Thrust Bearing, Data
905-03 0226 Thrust Bearing
105-04 0048 Journal Bearing, Data
905-04 0232 Journal Bearing
105-05 0059 Axial Vibration Damper, Data
905-05 0226 Axial Vibration Damper
90551 0198 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0087 Main Bearing - Hydraulic Tools
90562 0124 Crankshaft - Tools
90564 0020 Crankshaft - Measuring Tools
90572 0003 Main Bearing - Measuring Tools
906 - Control Gear
106-01 0055 Chain, Data
906-01 0243 Chain
106-02 0064 Chain Tightener, Data
906-02 0228 Chain Tightener
106-03 0040 Camshaft, Data
906-03 0217 Camshaft
106-04 0042 Camshaft Bearing, Data
906-04 0225 Camshaft Bearings
106-06 0009 Replacement of Cams on Camshaft, Data
906-06 0203 Replacement of Cams on Camshaft
90651 0181 Chain Drive and Camshaft - Panel
90664 0003 Crankshaft - Pin Gauge
90668 0006 Camshaft - Pin Gauge
907 - Starting Air System
107-01 0021 Starting Air Distributor, Data
907-01 0220 Starting Air Distributor
107-02 0044 Start Air Valve, Data
907-02 0213 Starting Air Valve
908 - Exhaust Valve
108-01 0049 High-Pressure Pipe, Data
908-01 0230 High-Pressure Pipe
108-02 0091 Exhaust Valve, Data
908-02 0268 Exhaust Valve
108-03 0055 Exhaust Valve Actuator, Data
908-03 0245 Exhaust Valve Actuator
108-04 0039 Exhaust Valve Roller Guide, Data
MAN B&W Diesel A/S
Page 2 (4)
Table of Contents
900
No.
Edition
908-04
108-05
908-05
108-07
908-07
90851
90861
90862
90863
0221
0016
0217
0034
0216
0206
0033
0042
0007
Title
Exaust Valve Roller Guide
Exhaust Valve Cam, Data
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
Exhaust Valve - Panel
Exhaust Valve - Tools
Exhaust Valve - Hydraulic Tools
Exhaust Valve - Extra Tools
909 - Fuel Oil System

109-01 0062 Fuel Pump Lead, Data
909-01 0239 Fuel Pump Lead
109-03 0051 Fuel Pump Cam, Data
909-03 0228 Fuel Pump Cam
109-04 0059 Fuel Pump, Data
909-04 0221 Fuel Pump
109-05 0064 Fuel Pump Top Cover, Data
909-05 0222 Fuel Pump Top Cover
109-06 0051 Fuel Pump Barrel Assembly, Data
909-06 0218 Fuel Pump Barrel Assembly
109-07 0038 Fuel Pump Suction Valve, Data
909-07 0210 Fuel Pump Suction Valve
109-08 0053 Fuel Pump Puncture Valve, Data
909-08 0222 Fuel Pump Puncture Valve
109-09 0033 Fuel Pump Shock Absorber, Data
909-09 0212 Fuel System Shock Absorber
10911 0070 Fuel Valve, Data
90911 0236 Fuel Valve
10912 0049 Spindle Guide, Data
90912 0223 Spindle Guide
10914 0077 Fuel Oil High-Pressure Pipes, Data
90914 0235 Fuel Oil High-Pressure Pipes
10915 0059 Fuel Pump Roller Guide, Data
90915 0227 Fuel Pump Roller Guide
10916 0018 Fuel Pump Spec. Runni
90916 0212 Fuel Pump Special Running
90951 0453 Fuel Valve and Fuel Pump - Panel
90961 0037 Fuel Valve - Tools
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90980 0001 Mounting Tools - Air Piston Seals
MAN B&W Diesel A/S
Page 3 (4)
Table of Contents
900
No.
Edition
Title
910 - Turbocharger System

110-01 0057 Air Cooler Element, Data
910-01 0244 Air Cooler Element
110-02 0009 Non-Return Valve in Turbocharger, Data
910-02 0211 Non Return Valve in Tubocharger
110-03 0028 Auxilary Blower, Data
910-03 0221 Auxilary Blower
110-05 0010 Turbocharger Turbine, Data
910-05 0211 Turbocharger Turbine
110-06 0036 Water Mist Catcher, Data
910-06 0224 Water Mist Catcher
91063 0021 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0003 Air Cooler - Lifting Tools
91066 0010 Air Cooler - Lifting Tools
911 - Safety Equipment
111-01 0026 Safety Valve, Data
911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver - Safety Valve, Data
911-03 0001 Scavenge Air Receiver - Safety Valve
912 - Assembly of Large Parts
112-02 0015 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0208 Holding Down and End Chock Bolts (Epoxy)
112-03 0027 Stay Bolts, Data
912-03 0211 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91261 0072 Hydraulic Tools for Large Parts
91263 0059 Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
913 - General Tools
913-01 0206 Hydraulic Tools
913-04 0201 Standard Tightening Torques
913-05 0205 Torque Spanner
913-06 0205 Tightening Gauge
913-07 0207 Screws and Nuts
91311 0204 Lubricating
91351 0033 Accessories - Hydraulic Tools
91356 0052 Lifting Tools, etc.
91357 0003 Open-Ended Spanners
91358 0002 Open Ended Slugging Spanners
MAN B&W Diesel A/S
Page 4 (4)
Table of Contents
900
No.
91359
91360
91361
91362
91363
91364
91366
Edition
0002
0002
0052
0059
0040
0059
0065
Title
Torque Spanners
Pliers
Combination Spanners
Ring Slugging Spanners
Spanners
Open-Ended Spanners
Instruments
MAN B&W Diesel A/S
Page 5 (4)
Instructions for Main Engines

This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference 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 operation and maintenance in accordance with MAN B&W Diesel A/S instructions. Emissions related 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 contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.
A90023-0027
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

Teglholmsgade 41
DK-2450 Copenhagen
Denmark
Teleph.:+45 33 85 11 00
Telex :16592 manbw dk
Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
MAN B&W Diesel
Checking and Maintenance Schedule,

26-70 MC/MC-C Engines
900-1
The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the
engine and to carry out overhauls, if necessary,
based on the engine condition or on time criteria.
Design modifications may necessitate a revision of

the instructions, in which case the revised instructions and changed overhauling intervals, if any, will
apply and supersede those originally issued (see
e.g our Service Letters).
The stated Normal hours of service should only

be used as a guide, as differences in the actual
service conditions, the quality of the fuel oil or lubricating oil, the treatment of cooling water, etc.
will decisively influence the actual service results,
and thus the intervals between necessary overhauling.
In addition to the checking and overhauling intervals stated in this schedule, please note that the
periodical survey requirements of the classification
society may require additional checks and overhauls to be carried out. For further information
please refer to the classification society.
The procedures are divided into three categories:

Condition checking procedures
marked under the heading Normal hours of service with a C,

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

service are marked with an O, and opposite which, under the
heading Overhaul to be based on procedure No. (column P), a
procedure number is stated.
This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.
Time-based overhauling
procedures
also marked with an O under the headings Normal hours of service or Based on observations, are the procedures where an
actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling intervals
stated as a basis.
Where a symbol O or C is indicated in Based on observations
(column B), this is due to the fact that special service conditions
may make checking or overhauling necessary beyond the actual
standard schedules indicated.
When referring to this page, please quote Maintenance Schedule A90050 Edition 0288
Page 1 of 6
900-1
Page 2 of 6
Checking and Maintenance Schedule,

26-70 MC/MC-C Engines
MAN B&W Diesel
MAN B&W Diesel
Checking and Maintenance Schedule, 26-70 MC/MC-C Engines
V : See Volume I Operation

A : Adjustment to be carried out
C : Check the condition
M : See makers instructions

O : Overhaul to be carried out
H : Check new/overhauled parts after 500-1500 hours
Regular Checks
No.
Procedure
12
C,O
Crankshaft and Thrust Bearing

Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
Electronic axial vibration monitor
24
32
O
O
Remarks
* Check whenever exhaust

valve is removed
V
C*
903 Cylinder Liner and Cylinder Lubrication

-1 Cylinder liner
Inspection through scavenge ports
Measuring wear inside liner
-2 Cylinder lubricators
Accumulators nitrogen pressure
905
-2
-3
-3
-4
-5
16
C*
902 Piston with Rod and Stuffing box

-1 Piston
Inspection through scavenge ports
-2 Piston rod stuffing box
Crosshead with connecting rod

Crosshead bearing
Crosshead
Reciprocating parts
Crankpin bearing
Connecting rod
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x1000 hours of operation)
Daily Weekly Monthly
901 Cylinder Cover

-1 Cylinder cover
Indicator cock
904
-1
-2
-3
-4
-5
900-1
* Check clearances without

dismantling segments
O
C
C
C
C
A
A
V,M
C,O
C,O
C,O
C,O
O
C
C
C
C
C
C
C
C
C
C
C
C
C,O
C,O
C,O
C,O
O
C
C
Bearings should only be

opened up if bearing material
fragments fall out.
Bearings should only be

opened up if bearing material
fragments fall out.
Page 3 of 6
900-1


Regular Checks
No.
Procedure
-7
-8
Mechanical checking
Tacho pick-up
Angle encoder
906 Mechanical Control Gear

-1 Chains
-2 Chain tightener
Chain wheels, spray nozzles and guide bars
-3 Camshaft
-4 Camshaft bearings
Camshaft coupling, fitted bolts
-5 Moment compensator
Governor
Functional check of overspeed device
Functional check of speed-setting system
(engine with bridge control system)
907 Starting Air System
-1 Starting air distributor
-2 Starting air valve
908 Exhaust Valve
-1 High-pressure pipe
-2 Exhaust valve
Conventional hard-faced valve seats
Nimonic exhaust valves
-3 Exhaust valve actuator
Actuator safety valve
-4 Exhaust valve roller guide
-5 Exhaust valve cam
Page 4 of 6
MAN B&W Diesel
P : Refer to

2
12
16
24
32
C,O
C,O
M
M
R
A
R
C,A
C,O
Remarks
C
C,A
C
C
C
C,A
C
C
O
C
C
C
New or overhauled chain to be

checked/retightened after 500,
1500 and 4000 hours
C,A
M
M
M
C
C
C
C,O
O
O
O
O
C,A
C*
C*
C*
C*
O
O
* only inspection through

camshaft covers
MAN B&W Diesel


Regular Checks
No.
-7
Procedure
P : Refer to
12
16
24
32
Exhaust valve special running
909 Fuel Oil System

Fuel oil water content
-1 Fuel pump settings
-2 VIT system
-3 Fuel pump cam
-4 Fuel pump
-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
-9 Fuel system shock absorber
-10 Lifting gear for roller guide
-11 Fuel valve
Fuel nozzle
-12 Spindle guide
-13 Non-return valve
-14 Fuel oil high-pressure pipes
-15 Fuel pump roller guide
-16 Fuel pump special running
910
-1
-2
-3
-4
-5
900-1
Turbocharger System
Air cooler
Non-return valve
Auxiliary blower
Butterfly valves
Turbocharger turbine
Remarks
A,C
A
A
O
O
R
C,O
C,O
C
C
C
C,O
R
V
V
O
O
O
R
O
C*
C*
C
C
C
C*
O
O
O
O
O
O
O
C,O
* Only inspection through

camshaft covers
Check p and t
Check at every port inspection
V,M
Page 5 of 6
900-1


Regular Checks
No.
Procedure
-6
Turbocharger air filter

Protective grid before turbocharger
Turbocharger lubricating oil water content
Water mist catcher
911
-1
-2
-3
Safety Equipment
Overpressure indicator valve
Relief valve
Scavenge air receiver safety valve
Functional test of alarm system for thrust
bearing and slow down /shut down system
Checking and adjustment of pressure gauge
Checking and adjustment of thermometers
Checking and adjustment of thermostats
Checking and adjustment of pressurestats
Checking and adjustment of turning gear switch
912 Assembly of Large Parts

-2 Holding-down and end chock bolts
-3 Stay bolts
Top bracings
Diaphragm in crankcase oil outlet
System lubricating oil water content
System lubricating oil bottom tank
Cooling water quality
Crankcase
913 General Tools
-1 Hydraulic tools
Page 6 of 6
MAN B&W Diesel
P : Refer to

2
12
16
24
32
O
R
C
C*
C*
V
M
C,O
C
C
C
C
C
C
C
C
C
C*
* Check p
O
O
O
C
C
C
Remarks
A
A
A
A
A
M
M
M
M
M
M
C
C
* Initial check only
C
C
M
Empty and clean tank
O
C
V,M
* Check for loose nuts and
bearing material fragments
C*
General Safety Precautions
900-2
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.
SAFETY PRECAUTIONS
X
Stopped engine
Shut off starting air supply At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply Not ME-engines
Shut off control air supply
Shut off air supply to exhaust valve Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
When referring to this page, please quote Safety Precaution A90060 Edition 0001
MAN B&W Diesel A/S
Page 1 (1)

101-01
901-01
90151
90161
0072
0255
0189
0107
Cylinder Cover, Data

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

X
X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Shut off safety air supply Not ME engines
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D01-01
Exhaust valve stud, screwing-in torque
D01-05
Cylinder cover stud, check distance
D01-06
Cylinder cover, complete
510
kg
D01-07
Cylinder cover without valves
300
kg
D01-08
Cooling jacket
15
kg
D01-09
Exhaust valve stud
kg
D01-10
Cylinder cover stud
kg
D13-01
Hydraulic pressure, mounting
D13-02
Hydraulic pressure, dismantling
When referring to this page, please quote Data D10101 Edition 0072
200
Nm
90 - 91
mm
900
bar
800 - 990
bar
Page 1 (2)
Cylinder Cover
101-1
MAN B&W Diesel
Data
The task-specic tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the rst three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
Description
P90151
046
Grinding tool for exhaust valve seat
P90151
058
Milling and grinding wheel for fuel valve seat
P90151
060
Milling and grinding wheel for starting valve seat
P90151
083
Grinding handle
P90161
P91351
010
Hydraulic pump, pneumatically operated
P91351
034
Hose with unions (1000 mm), complete
P91351
058
P91351
130
9-way distributor block, complete
Page 2 (2)
Cylinder Cover
MAN B&W Diesel
Dismantling
Shut off Oil and Water Supply

1.
901-1.2
2.
Check engine blocking.

Check that the engine is stopped and
blocked according to the safety precautions given on the data sheet.
2. Shut off the oil supply.
3. Shut off the water supply.

Shut off the water outlet above the exhaust
valve.
Shut off the water supply placed on the exhaust side below the exhaust gas receiver.
M901010254D01
Close the fuel oil supply for the unit concerned.
3.
Open the drain next to the inlet valve.
M901010255C03
Open the venting cock next to the outlet

valve.
When referring to this page, please quote Procedure M90101 Edition 0255
Page 1 (13)
901-1.2
Cylinder Cover
Dismantling
MAN B&W Diesel
Dismantling of Pipe Connections

4.
4. Disconnect the oil pipes.
Remove the hydraulic high pressure pipe
for the exhaust valve. See Procedure
9081.2
Unscrew the drain pipe for the exhaust
valve.
M901010255D04
Remove the fuel oil high pressure pipes.

See Procedure 90914.2.
5.
Disconnect the pipes for return fuel oil from

the fuel valves.
5. Disconnect the water pipes.
Unscrew and remove the water outlet
pipes.
6. Exhaust gas compensator.
Remove the protective jacket enclosing the
insulation for the intermediate pipe or compensator. Remove the insulation.
M901010255D05
Remove the clamp ring on the anges

between the intermediate pipe and the exhaust receiver.
M901010255D06
6.
Page 2 (13)
Cylinder Cover
MAN B&W Diesel
7.
901-1.2
Dismantling
Disconnect the starting air pipe.

7.
Unscrew and remove the control air pipe
for the starting air valve.
Unscrew and remove the air pipe for the
starting valve.
8. Cylinder cover loosening.
Loosen and remove the cylinder cover nuts,

see Data.
For use of hydraulic tools, see Procedure
9131.
M901010255D07
Remove the protective caps from the cylinder cover nuts.
8.
M901010255D08
D1302
Page 3 (13)
901-1.2
Cylinder Cover
Dismantling
MAN B&W Diesel
Cylinder Cover Lifting and Landing

9.
D0106
9. Cylinder cover lifting.

Hook on the engine room crane to the lifting attachment on top of the exhaust valve.
Check that all cylinder cover connections
have been loosened and removed.
Lift away the cylinder cover complete.
M901010255D09
10. Cylinder cover landing.
11. Remove sealing ring.

Remove and discard the sealing ring between the cylinder cover and cylinder liner.
M901010255D10
10.
Land the cylinder cover on a couple of

wooden planks.
M901010255D11
11.
Page 4 (13)
Cylinder Cover
MAN B&W Diesel
Overhaul
Overhaul Preparations
1.
901-1.3
1.
Dismantle valves and pipes.

Dismantle all valves and pipes from the
cylinder cover. See Procedure 9072.2,
9082.2 and 90911.2.
D0109
Remove all studs on top of the cylinder

cover.
2. Remove the cooling water jacket.

Mount four eyebolts and the lifting chains
as shown in the sketch.
Remove the screws which secure the cooling jacket to the cylinder cover.
M901010255O01
Cooling Water Jacket
2.
Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.
D0107
Remove and discard the Orings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.
3. Mount the cooling water jacket.
Lift the cylinder cover and guide the jacket/

cover into position, using the guide pin as
a reference (manoeuvre side).
3.
M901010255O03
Fit and tighten the screws for the cooling

jacket.
D0108
M901010255O02
Provide the cylinder cover with new

Orings, well lubricated with oil.
Page 5 (13)
Cylinder Cover
901-1.3
Overhaul
MAN B&W Diesel
Reconditioning of Bores
4.
4. Seat reconditioning tools.

The tools for reconditioning of the valve
seats are found on tool panel 901.
5. Fuel valve bore.
The tool consists of a common spindle with
a handle, a guide, a carbon cutter, a seating face cutter and a grinding mandrel.
M901010255O04
Clean the fuel valve bores using the carbon

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. Carborundum No. 200).
5.
After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
M901010255O05
Page 6 (13)
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
6. Exhaust valve bore.

6.
The tool consists of a spindle with a 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).
7.
Starting valve bore.

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.
M901010255O06
After the grinding, clean the bore and seating carefully, and check that the seating is
not damaged.
7.
M901010255O07
When replacing the valves on a cylinder

cover while it is mounted on the engine,
recondition the valve bores/seating as described here, however, without removing
the studs.
Page 7 (13)
901-1.3
Cylinder Cover
Overhaul
MAN B&W Diesel
8. Indicator safety valve bore.

8.
Clean the bores for safety valve/indicator
cock.
Preparations before Mounting
9. Fitting of studs.
Lubricate the threads with Never Seize or
molybdenum disulphide (MoS2) and t the
valve studs.
M901010255O08
Tighten up the studs in accordance with

the screwingin torque stated on the data
sheet.
Fill up the grooves between the valve studs
and the bores for the valve studs with permatex to prevent water or oil from entering
the bores during operation of the engine.
9.
10. Mounting of valves.

Install the valves on the cylinder cover, see
Procedures 9072.4, 9082.4 and 90911.4.
M901010255O09
D0101
Page 8 (13)
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
Landing Preparation
1.
1.
Sealing ring.
Check that the liner sealing surface is
clean.
Place a new sealing ring on top of the cylinder liner.
2. Water connections.
Check that the water connections are clean
and provided with new Orings.
2.
M901010255M02
Lubricate the Orings with Vaseline and t

them on the cylinder liner.
M901010255M01
If necessary t a new klinger sealing ring

in the groove of the ange of the intermediate pipe.
Page 9 (13)
901-1.4
Cylinder Cover
Mounting
MAN B&W Diesel
Cylinder Cover Mounting

3.
3. Cylinder cover landing.
D0106
Carefully wipe the cylinder cover contact
surface facing the cylinder liner, while the
cover is resting on the support.
M901010255M03
Lift the cylinder cover by means of the

crane and lower it carefully into position.
During the landing, carefully check that
the cooling water connecting pipes engage correctly with the holes in the cooling
jacket.
4. Cylinder cover stud check distance.
If the cylinder cover studs have been removed and reinstalled, check the distance
the stud is protruding from the cylinder
cover.
4.
M901010254M04
D0105
If necessary, adjust to the distance D0105

by turning the stud.
Page 10 (13)
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
5. Cylinder cover tightening.

5.
Fit and tighten the cylinder cover nuts.
For operation of hydraulic jacks, see Procedure 9131.
Fit the protective caps on the cylinder cover studs.
D1301
Fitting Pipe Connections
Fit the pipe clamp on the anges between

the intermediate pipe and the exhaust receiver, tight the screws.
M901010255M05
6. Fit the exhaust gas compensator.
Note!
Lubricate the ange edges with Never
Seize or molybdenum disulphide (MoS2)
before tting.
6.
M901010255M06
Fit the insulating jacket around the intermediate pipe.
Page 11 (13)
901-1.4
Cylinder Cover
Mounting
7.
MAN B&W Diesel

Connect the starting air pipe.
7.
Connect and tighten the air pipe for the
starting valve.
Connect and tighten the control air pipe for
the starting air valve.
8. Connect the water pipes.
Mount and tighten the water outlet pipes.
M901010255M07
9. Connect the oil pipes.

Mount the hydraulic high pressure pipe for
the exhaust valve. See Procedure 9081.4.
Connect the drain pipe for the exhaust
valve.
8.
Connect the fuel oil high pressure pipes.
M901010255M08
Connect the pipes for return fuel oil from

the fuel valves.
M901010255M09
9.
Page 12 (13)
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
Open Oil and Water Supply

10.
10. Close the drain and open the water supply.
Close the venting cock next to the outlet
valve.
Close the drain next to the inlet valve.
Slowly open the water supply valve, placed
next to the cylinder liner cooling water jacket on the exhaust side.
Vent the unit by releasing air through the
venting cock next to the outlet valve.
When the venting is nished, close the
venting cock. Open the water outlet valve
on the exhaust side of the cylinder cover.
Open the fuel oil supply for the unit concerned.
M901010255M10
11. Open the oil supply.
M901010254M11
11.
Page 13 (13)
Cylinder Cover Panel
Plate
P90151-0189

0189
P90151
When referring to this page, please quote Plate P90151 Edition 0189
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90151-0189
Item
No.
010
022
046
058
060
071
083
095
105
117
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Grinding tool for exhaust valve seat
Cutting and grinding tool for fuel valve
seat
Cutting and grinding tool for starting
valve seat
Dismantling tool for fuel valve seat
Grinding handle
Grinding ring for starting valve
Grinding handle
Pressure tester for safety valve
Notes:
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90161-0107
Page 1 (2)
MAN B&W Diesel A/S
Plate
P90161-0107
Item
No.
027
039
052
064
088
090
100
206
Page 2 (2)
Item Description
Item
No.
Item Description
Hydraulic jack for cylinder cover

Support
O-ring with back-up ring
Tommy bar
Spanner
Stud setter
Hydraulic toolset, complete
MAN B&W Diesel A/S

102-01
902-01
102-02
902-02
90251
90261
90264
90265
90266
0100
0288
0068
0232
0259
0103
0011
0002
0002
Piston, Data
Piston
Piston Rod Stuffing Box, Data
Piston Rod Stuffing Box
Piston and Piston Rod - Panel
Piston and Piston Rod - Tools
Piston and Piston Rod - Tilting Tools
Piston and Piston Rod - Support Tools
Piston - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Piston
MAN B&W Diesel
102-1
Data

Stopped engine
X
X
X
X
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D01-05
Cylinder cover stud, check distance
D02-01
Test pressure
D02-02
Value
Unit
90 - 91
mm
bar
Piston rod/crosshead, tightening torque
210
Nm
D02-03
Piston rod/crown, tightening torque
150
Nm
D02-05
Piston skirt, tightening torque
50
Nm
D02-06
Cooling oil pipe, tightening torque
50
Nm
D02-07
Piston rod/crosshead, tightening torque+angle
D02-08
Piston ring new, radial width
D02-09
100/30
Nm/
12,5
mm
Piston ring worn, min. radial width
10
mm
D02-10
Groove No.1, max. vertical height
10.2
mm
D02-11
Groove Nos. 2, 3 and 4, max. vertical height
8.7
mm
D02-12
Piston top, max. permissible burn-away
11
mm
D02-13
Piston ring new, height of ring No. 1
9.4
mm
D02-14
Piston rings new, height of ring Nos. 2, 3 and 4
7.9
mm
D02-15
Minimum free ring gap ( before dismantling )
22
mm
D02-16
Minimum ring gap, ring No. 1 ( new ring in new liner )
3,5
mm
D02-17
Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner )
2,5
mm
D02-18
Vertical clearance, new parts
0.32
mm
D02-19
Vertical clearance, worn parts, max.
0.82
mm
D02-20
Piston complete
280
kg
D02-21
Piston crown
60
kg
D02-22
Piston rod
160
kg
D02-23
Piston skirt
16
kg
D02-24
Piston cooling pipe
kg
D02-25
Lifting tool, tightening torque
30
Nm
D02-46
CPR ring CL groove, min. depth
0.8
mm
Page 1 (2)
Piston
102-1
MAN B&W Diesel
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
Description
P90251
040
Lifting tool for piston rod foot
P90251
075
Template for piston top
P90251
087
Distance piece for stuffing box
P90251
099
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
Piston and Piston Rod - Tools
P90265
P90266
Page 2 (2)
Piston
MAN B&W Diesel
902-1.1
Checking
Scavenge Port Inspection
1.
To detect possible leakages from the piston

or cylinder cover, keep the cooling water
and cooling oil circulating during the scavenge port inspection.
Turn the engine at least a revolution, and

begin 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 passing downwards, inspect the piston skirt, all the piston rings,
the ring lands and the piston top.
M902010280C01
1. The scavenge port inspection is carried out

from the scavenge air receiver. An additional view of the rings is possible through
the cleaning cover on the manoeuvring
side.
2.
2. Ring inspection:
Inspect the rings, one at a time, and note
down the results. See Volume I, Operation,
Chapter 707.
M902010280C02
3. Ring tension:
Check the tension of the piston rings, by
pressing against them with a wooden stick.
M902010280C03
3.
Page 1 (22)
Piston
902-1.1
Checking
4.
MAN B&W Diesel
4. Ring grooves:
Measure the total clearance between the
piston ring and the ring groove. The total
clearance must not exceed the value stated
in Data.
D0218
D0219
Measure the clearance at the top (E) and

bottom (F) of the piston ring groove.
Total clearance = E + F.
M902010280C04
Max. 2mm
5. Uppermost piston ring:

If possible, measure the depth of the pressure relief grooves with a calliper. The piston rings must be replaced if the radial
depth of the grooves has worn down to
less than stated in Data D02-46.
Checking, in connection with piston
overhaul
5.
D0246
6. Piston support:
Remove the piston from the cylinder and
place it on the piston support.
See Procedure 902-1.2. For evaluation of
the rings, see Volume I, Chapter 707.
M902010280C05
Note!
It is recommended to replace all the piston rings whenever a piston is removed
from the engine.
M902010285C06
6.
Page 2 (22)
Piston
MAN B&W Diesel
902-1.1
Checking
7. Free ring gap:

Before dismantling the piston rings, measure the free ring gap of all the piston
rings.
7.
D0215
For dismantling the piston rings, see Procedure 902-1.3.
9. Ring grooves:
Clean the ring grooves and check them for
burn marks or other deformation.
Measure the ring grooves with a calliper
gauge, see Data D02-10 and D02-11.
M902010285C07
8. Radial ring width:

Measure the radial width of the rings. Note
down the results See Volume I, Operation,
Chapter 707.
8.
Clearance in piston ring grooves:
The maximum vertical height in a worn ring
groove must not exceed the value stated
in Data. The groove is also worn out if
there is no chromium layer.
D0208
New
M902010280C08
If the ring grooves are worn out, the piston

crown must be reconditioned, contact MAN
B&W Diesel A/S for advice.
D0209
Worn
9.
D02-10
D02-11
M902010280C09
Max 2mm
Page 3 (22)
Piston
902-1.1
Checking
10.
D0212
MAN B&W Diesel
10. Piston crown top:

Clean the piston crown and check the
burn-away by means of the template.
For maximum permissible burn away value,
see Data.
Check the burn-away on the whole circumference of the piston crown top.
M902010285C10
If the burn-away exceeds the values given

in Data, contact MAN B&W for advice.
Page 4 (22)
Note down the results for later reference.
Piston
MAN B&W Diesel
902-1.1
Dismantling
Preparations in the crankcase

1.
1. Access:
Open the crankcase door to the cylinder
concerned.
M90201280D01
Turn the crosshead down far enough to

give access to the piston rod stuffing box
and the piston rod/crosshead connection.
Page 5 (22)
902-1.1
Piston
Dismantling
2.
MAN B&W Diesel
2. Telescopic pipe:
Loosen and remove the screws which
tighten the telescopic pipe to the bend.
Remove one screw from the telescopic
stuffing box housing and mount the special
tool for suspending the telescopic pipe or
use the thread in the telescopic pipe stuffing box housing.
Turn the crosshead to TDC. Suspend the
telescopic pipe by means of the tool.
Turn the crosshead downward and remove
the distance pipe from the bend.
Note!
M902010288D02
When a piston is dismantled, never turn

the engine without first dismantling the
telescopic pipe from the crosshead.
Page 6 (22)
Piston
MAN B&W Diesel
902-1.1
Dismantling
3. Stuffing box:
Release the stuffing box by removing the
innermost screws from the stuffing box
flange.
3.
On engine models where the drain pipe is

connected directly to the stuffing box:
Disconnect the stuffing box drain pipe.
Do NOT remove the outermost screws

from the flange.
4. Loosen the piston rod-crosshead connection:

Remove the screws from the piston rod.
M902010280D03
Note!
M902010288D05
4.
Page 7 (22)
902-1.1
Piston
Dismantling
5. Stuffing box distance pieces:

Mount the two distance pieces on the piston rod foot to protect the lower scraper
ring and to guide the stuffing box.
M902010288D06
5.
MAN B&W Diesel
Page 8 (22)
Piston
MAN B&W Diesel
902-1.1
Dismantling
Preparations on the cylinder top
7.
D0225
6. Cylinder cover:
Remove the cylinder cover. See Procedure
901-1.2.
7. Piston lifting tool:
Turn the piston to TDC. The top of the piston is now free of the cylinder liner.
Note!
Make sure to mount the lifting tool correctly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.
M902010285D07
Clean the lifting groove of the piston crown

and mount the lifting tool.
Limited lifting high:

If the engine not is equipped with long distance pieces, remove one or two cylinder
cover studs, using a stud setter.
Page 9 (22)
Piston
902-1.1
Dismantling
MAN B&W Diesel
Piston lift
8.
8. Lift the piston out of the cylinder liner and
guide the piston rod foot through the stuffing box flange.
If the engine is equipped with long distance
pieces for the stuffing box, the piston rod
foot can pass between two cylinder cover
studs.
Place the two halves of the support around
one of the openings in the platform. Lower
the piston rod foot and stuffing box
through the opening in the platform. Secure
the two support halves with screws and
lower the piston on the support. Check the
piston is resting on the piston rod flange.
M902010285D08
D0220
Page 10 (22)
Piston
MAN B&W Diesel
902-1.1
Dismantling
9. Protect the crosshead bearing:

Place a cover over the opening for the piston rod stuffing box in the bottom of the
cylinder unit.
9.
Turn the crosshead down far enough to

permit mounting of the protective rubber
cover on the crosshead bearing cap. The
protective rubber cover is found on tool
panel 904.
The covers must remain in place to protect
the crosshead bearing journal from impurities until the piston is remounted.
M902010283D09
Clean, measure and recondition the cylinder liner. See Procedure 903-1.
Page 11 (22)
Piston
902-1.1
Overhaul
1.
D0220
MAN B&W Diesel
1. Piston support:
Place the piston in the support and remove
the piston lifting tool.
See Procedure 902-1.2.
Clean the piston top and the piston rings.
Check the free ring gap and the burn-off
on the piston top. See Procedure 902-1.1.
Remove the stuffing box. See Procedure
902-2.3.
M902010285O01
2. Piston ring dismantling:

Take off the piston rings by means of the
ring expanders. If the engine is equipped
with two ring expanders, the short ring expander is for the uppermost ring.
2.
First remove the uppermost ring, then ring

No. two, three and four.
Clean and inspect the rings and the ring
grooves. See Procedure 902-1.1.
3. Piston crown dismantling:
Remove the locking wire and the innermost
screws between the rod and the piston
crown.
M902010285O02
Lift the piston crown and skirt clear of the

piston rod.
3.
M902010284O03
D0221
+
D0223
Page 12 (22)
Piston
MAN B&W Diesel
902-1.1
Overhaul
4. Piston rod and cooling pipe:

Remove the screws from the cooling oil
pipe flange.
4.
D0224
Mount the eye bolts and lift out the cooling

oil pipe.
D0206
Clean and inspect the cooling oil pipe and

the piston rod, then remount the cooling oil
pipe, see Data.
Check that the surfaces of the O-ring
groove is clean and smooth.
5. Crown turning:
Unhook the crane from the piston lifting
tool, and connect the lifting tool and the
crane hook by means of a wire rope. Lift
up the piston crown.
M902010280O04
Mount a new O-ring on the piston rod

flange.
D0222
5.
Install a tackle in a suitable place with sufficient space below for the piston crown. Attach the tackle to the wire rope on the piston crown and carefully turn the piston
crown upside down. Use both cranes if the
engine room is equipped with two cranes.
Land the piston lifting tool and the piston
crown on a sufficient support of wood
pieces. Loosen the piston lifting tool and
lift the piston crown clear of the tool.
M902010286O05
Fit two eyebolts in the piston skirt and a

wire rope between the bolts as shown in
the sketch.
6.
6. Piston crown dismantling and cleaning:

Place the piston crown with skirt on a
wooden support as shown.
D0223
Discard the sealing ring on the piston skirt.
M902010284O05
Remove the locking wire and the screws in

the skirt. If necessary use two dismantling
screws to pull the skirt out of the piston
crown. Mount two eye bolts in the skirt. Lift
the skirt and land it on a couple of planks.
Page 13 (22)
Piston
902-1.1
Overhaul
MAN B&W Diesel
7. Piston crown assembly:

Mount a new O-ring on the piston skirt.
Check that the surfaces of the O-ring
groove are clean and smooth. Coat the ring
with lubricating oil before mounting.
7.
D0205
Mount the piston skirt on the piston crown.

Tighten the screws to specified torque, see
data D02-05. Lock the screws with locking
wire, see Procedure 913-7.
M902010284O06
8. Piston crown and skirt mounting:

Mount the guide screw to ensure the correct positioning of the piston rod in relation
to the piston crown.
Lubricate the O-ring on the piston rod
flange with lubricating oil.
8.
Land the overhauled piston crown and skirt

on the piston rod.
Remove the guide screw.
Mount and tighten the screws between the
piston rod and the piston crown, see Data.
M902010284O07
D0203
Page 14 (22)
Piston
MAN B&W Diesel
902-1.1
Overhaul
Sealing ring and pressure test

9.
9. Sealing ring test:

Mount the pressure-testing tool on the piston rod foot. Connect compressed air to
the testing tool and fill the piston to 4-5
bar. Close the valve on the testing tool and
remove the air connection. The piston must
now hold the pressure for minimum 30
minutes.
Spray a little soap water on to the surface
joints between piston rod/crown/skirt and
around the bolt heads to detect leaks.
M902010288O09
According to current class rules, the piston

must be pressure tested hydraulically. It is
possible to carry out a test of the sealing
rings with compressed air before filling the
piston with oil. The sealing ring test can
also be carried out when the piston is resting in the support tool.
10.
D0201
Dry off all soap water.
Fill the piston and piston rod with lubricating oil. Mount the pressure-testing tool on
the piston rod foot. Pressure-test the piston at the pressure stated on the Data
Sheet. Check the contact surfaces of the
piston and the sealing rings for tightness.
Check that there are no cracks in the piston crown.
M902010288O10
10. Pressure test:

For this test, the piston must be turned upside down (see next step to turn a complete piston).
Turn the piston upside up and drain out the

piston oil.
Page 15 (22)
902-1.1
Piston
Overhaul
11.
MAN B&W Diesel
11. Piston turning:

Lift the piston with the normal lifting tool.
Lower the piston rod foot until it is close to
the platform. Land the foot on a wooden
block.
Lower the piston crown to the platform and
land it on a wooden block in such a way
that it is possible to remove the lifting tool.
Attach the lifting bracket to the bottom of
the piston rod foot. Hook the crane on to
the lifting bracket. Lift the piston rod foot
clear of the wooden block. Keep lifting until
the piston rod is in a vertical position.
Note!
M902010283O10
During the lift, follow with the crane to

keep the crane positioned vertically
above the lifting point. The stuffing box
must be removed.
Page 16 (22)
Piston
MAN B&W Diesel
902-1.1
Overhaul
12. Piston completion:

Fit the new piston rings (alternately righthand and left-hand cuts, with the ring gaps
staggered 180 and with the TOP mark upwards), using the ring expander.
12.
A
B
When mounting the piston rings, use the

ring expanders to prevent unintended deformation of the rings.
C
D
Mount the piston rod stuffing box.

M902010285O11
Do not expand the rings more than necessary. The uppermost ring (CPR-ring) must
be mounted with the short ring expander, if
the engine is equipped with two ring expanders
Page 17 (22)
902-1.1
Piston
Mounting
MAN B&W Diesel
Preparation of piston
1.
1. Check the piston rings and piston crown in
accordance with Procedure 902-1.1, if not
already done.
Mount the lifting tool on the piston crown.
See Data D02-25.
M902010285M01
2. Stuffing box position:

Ensure that the stuffing box is correctly positioned over the distance pieces mounted
on the piston rod foot. Both the holes for
the flange and the drain hole for the drain
pipe must be positioned correctly.
M902010288M02
2.
Page 18 (22)
Piston
MAN B&W Diesel
902-1.1
Mounting
Preparation of cylinder liner

3.
3. Mount the guide ring:
Mount the guide ring in the top of the cylinder liner. The cut outs for the lifting tool
must be turned to fit the piston lifting tool.
4. Stuffing box cover:
Remove the cover from the piston rod
stuffing box opening in the bottom of the
cylinder unit.
5. Crosshead position:
Turn the crosshead to a position 45 from
TDC (crank web pointing towards exhaust
side).
M902010288M03
Clean the stuffing box flange.
M902010277M05
4.
M902010277M06
5.
45
Page 19 (22)
Piston
902-1.1
Mounting
MAN B&W Diesel
Mounting of piston
6.
D0220
6. Coat the O-rings of the stuffing box and
the piston rod with oil. Coat the piston
rings and cylinder liner with cylinder lubricating oil.
M902010288M06
Lower the piston into the cylinder liner

while guiding the piston rod foot through
the cut-out in the stuffing box flange until
the piston rings are inside the liner.
7.
7. Protective cover:
Remove the protective rubber cover from
the crosshead.
8. Crosshead alignment:
Turn the crosshead almost to TDC, while
checking that the guide ring of the crosshead enters the centre hole in the piston
rod.
M902010283M07
After turning the crosshead fully to TDC,

and ensuring that the piston rod has full
contact with the crosshead, unscrew the
lifting tool and remove the lifting tool and
the guide ring for piston rings.
M902010284M08
8.
Page 20 (22)
Piston
MAN B&W Diesel
902-1.1
Mounting
9. Stuffing box:
Turn down and land the stuffing box on the
stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
correctly centered.
9.
Tighten the piston rod stuffing box by

means of the screws through the inner
holes in the stuffing box flange. For Data,
see Procedure 902-2.
Mount the stuffing box drain pipe.

Remove the distance pieces from the piston rod foot.
10. Tightening of the piston rod-crosshead
connection:
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.
M902010280M09
On engine models where the drain pipe is

connected directly to the stuffing box:
10.
D0202
or
D0207
Turn up towards TDC until the telescopic

pipe is landed on the distance pipe.
11.
M902010288M11
Remove the suspending tool and mount

the screws and tighten the telescopic pipe
to the bend.
For data, see Procedure 904-2.
M902010288M10
11. Telescopic pipe

Place the distance pipe on the bend for the
telescopic pipe.
Page 21 (22)
902-1.1
Piston
Mounting
MAN B&W Diesel
12. Cylinder cover studs:

If the cylinder cover studs have been removed, remount them. Carefully clean the
surfaces around the base of the studs and
check the O-rings on the studs.
12.
Mount the cylinder cover studs with the

stud setter. Screw the stud down to contact and half a revolution back.
M902010288M12
13. Cylinder cover:

Land the cylinder cover on the liner and
check the distance that the stud is protruding from the cylinder cover. If necessary,
adjust the distance D01-05 by turning the
stud.
Tighten the cylinder cover nuts and mount
the necessary pipes.
13.
14. Running-in:
Smear the piston rod with molybdenum
disulphide, and turn the crankshaft a
couple of revolutions.
M902010280M14
D0105
Page 22 (22)
At the first opportunity, start the engine

and keep it running for about 15 minutes at
a speed corresponding to Dead Slow
Ahead.
Then stop the engine and inspect the piston rod and stuffing box.

MAN B&W Diesel
102-2
Data

X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D02-26
Description
Stuffing box flange, outer screws tightening torque
D02-27
80
Unit
Nm
Stuffing box flange, inner screws tightening torque
80
Nm
D02-28
Stuffing box halves, tightening torque
17
Nm
D02-44
Stuffing box complete
35
kg
D02-45
Stuffing box half
11
kg
D02-51
Ring-end clearance A
3x3
mm
D02-52
Ring-end clearance B
4x5
mm
D02-53
Ring-end clearance C
3x3
mm
D02-54
Ring-end clearance D
3x6
mm
D02-55
Springs for ring A, free length
327
mm
D02-56
Springs for ring B, free length
374
mm
D02-57
Springs for ring C, free length
293
mm
D02-58
Springs for ring D, free length
374
mm
Value
Page 1 (2)
102-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90251
109
Mounting tool for stuffing box spring
P90251
122
Worktable for stuffing box
P90251
195
Distance piece stuffing box assembling
Page 2 (2)
Piston Rod Stufng Box

MAN B&W Diesel
1.
902-2.1
Checking
After the piston rod stufng box has been

dismantled, check the following clearances:
1.
A
B
Uppermost scraper ring and sealing rings
C
Clearance at ring ends (scraper ring) A.
Total clearance (scraper ring) D0251.
Clearance at ring ends (sealing rings) B.

Total clearance (sealing rings) D0252.
Lowermost lamella scraper rings

Clearance at uppermost lamella ring ends C.
Total clearance D0253.
B
x3
Clearance at lowermost lamella ring ends D.

Total clearance D02-54.
As a general guide, it is recommended

depending on the overhauling intervals and
ones own experience to replace sealing
rings and scraper rings when the specied
clearance values have been halved.
2. Garter springs:
M902020232C01
The ring clearances stated in Data apply to

new rings.
x4
D
x3
x3
2.
Generally, it is recommended to renew the

springs when the sealing rings and scraper
rings are renewed.
M902020232C02
The springs can be checked as follows:

Place the springs on the table, measure Lo
(free length), and compare with Data. If a
spring is extended more than 8% from the
value given in data, it must be discarded.
D0255
D0256
D0257
D0258
Page 1 (11)
902-2.2

Dismantling
1.
MAN B&W Diesel
When dismantling the piston, remove only the

innermost screws in the stufng box ange.
If, in the period between piston overhauls, it
becomes necessary to inspect the piston rod
stufng box, proceed as follows:
1.
Turn the crosshead to about 90 from TDC.
M902020229D01
Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
3. Mount the worktable around the piston

rod so that the two remaining screws in
the stufng box ange can be loosened
through the holes.
M902020232D02
2.
2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diamentrically opposite in
the stufng box ange, longitudinally to the
engine.
M902020232D03
3.
Page 2 (11 )

MAN B&W Diesel
902-2.2
Dismantling
4. Remove the two long dismantling screws

from the worktable.
4.
Mount them in the stufng box through the

holes in the worktable.
Remove the remaining two screws from the
stufng box.
6. Remove the two long dismantling screws

from the stufng box and mount them in
the worktable.
5.
M902020232D05
By means of the short screws in the worktable, press the stufng box out of the
ange.
For overhauling the stufng box, see Procedure 9022.3.
M902020232D04
5. Turn the piston to BDC, thereby withdrawing the stufng box from the cylinder frame
bottom.
M902020232D06
6.
Page 3 (11)
902-2.3

Overhaul
MAN B&W Diesel
Normally, overhaul of the piston rod stufng

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 cutouts in the
top platform.
Work on the stufng box is then carried out
from the platform below.
M902020232O01
Overhaul inside the engine is carried out in the

same way as outside the engine.
1.
Mount two eye bolts in the stufng box

ange, and hook on two tackles.
Lift the stufng box a little up the piston
rod, and mount the worktable round the
piston rod at a suitable working height.
1.
D0244
Land the stufng box on the worktable,

and remove the tackles.
M902020232O02
2. Remove the Oring of the stufng box. If

the Oring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.
Remove the nuts from the stufng box assembling bolts.
M902020232O03
2.
Page 4 (11 )

MAN B&W Diesel
902-2.3
Overhaul
3. Take out the four bolts, and pull away one

stufng box half and remove it from the
work table.
3.
D0245
4. Remove the remaining stufng box half and

press all sealing rings and scraper rings
down against the worktable.
6. Dismantle and stack the rings in the same

order as when tted in the stufng box.
Carefully clean all the ring segments.
Inspect and assess the surface quality of
the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
7.
M902020232O04
5. Remove the springs one at a time and

measure the clearance between the ring
segments to determine whether replacement is necessary.
7.
Check the lengths of the springs.

M902020232C02
L
8. Inspect the surface of the piston rod.
If small longitudinal scratches have occurred (caused by poorly adapted stufng
box rings), smooth the piston rod surface
carefully with a ne grained carborundum
stone. In the case of coarse scratches, it
may prove necessary to machinegrind the
surface in a workshop.
D0255
D0256
D0257
D0258
M902020232O05
8.
Page 5 (11)
902-2.3
Overhaul
9.
1
1
MAN B&W Diesel
9. Lubricate the piston rod (in the area where

all the ring units in the stufng box will be
positioned) with molybdenum disulphide
(MoS2).
Assemble all the stufng box ring units
round the piston rod in the following way:
Place the distance ring marked 1 on the
work table.
Place the holders and segments for the

lowermost scraper ring on the worktable.
First assemble the holders as shown in Fig. A.
Secure them with the steel pins and place
them round the piston rod.
M902020232O09
Then assemble the holders as shown in

Fig. B.
10.
Secure with the steel pins and place them

round the piston rod in such a way that the
scraper rings t together with the holders
as shown in Fig. A.
10. Place the three springs round the scraper

rings and, by means of the two hooks, assemble the spring ends.
M902020232O10
Cross your arms before tightening the

springs.
Page 6 (11 )

MAN B&W Diesel
902-2.3
Overhaul
11. On top of the scraper rings, place No. 2

distance ring and then assemble the next
scraper rings, using the two hooks as described above.
11.
On top of the scraper ring, place No. 3 distance ring.
3
2
Each unit consists of a 4-part lower sealing

ring with two guide pins, an upper 4-part
sealing ring, an outer sealing ring, a holder
for the springs, and two springs.
When assembling one unit, rst place the
outer sealing ring round the piston rod.
Place the lower 4-part sealing ring inside
this outer sealing ring so that the two guide
pins face upwards, then place the upper 4part sealing ring in such a way that the two
guide pins in the lower sealing ring engage
with the two holes in the upper sealing
ring.
M902020232O11
12. On top of the scraper rings, assemble the

two sealing ring units.
12.
Finally, place the holder and two springs,

and assemble the springs by means of the
two hooks.
Place No. 4 distance ring between the sealing rings and assemble the last sealing unit
in the same way.
M902020232O12
4
3
2
1
Page 7 (11)
902-2.3

Overhaul
13. On top of the sealing section, place No. 5

distance rings.
13.
5
4
3
2
M902020232O13
14.
MAN B&W Diesel
Place the 3-part scraper ring on top of the

upper sealing unit.
Place the spring round the scraper ring
and, by means of the two hooks, assemble
the spring ends.
Check that all scraper and sealing rings
and distance rings are pressed down
against the work table.
14. Clean the halves of the stufng box housing.
Remove all the distance rings.
15. Place one stufng box half on the worktable.
M902020232O14
Push the stufng box half into contact with

the piston rod round the rings.
Page 8 (11 )

MAN B&W Diesel
902-2.3
Overhaul
16. Place the other half of the stufng box

housing on the worktable, pushing it into
place round the rings.
16.
D0228
Mount and tighten up the tted bolts to the
torque specied on the Data Sheet.
Mount the O-ring in the stufng box
groove.
Remove the worktable and lower the stuffing box until it rests against the distance
pieces on the piston rod foot.
Remove wire ropes and eye bolts.
M902020232O16
17. Mount eye bolts and wire ropes, and lift the
stufng box a little.
M902020232O17
17.
Page 9 (11)
902-2.4

Mounting
1.
1.
MAN B&W Diesel

In connection with mounting of the piston,
only the innermost ange screws are to be
mounted and tightened, see data.
After overhauling the stufng box inside the
engine, assemble the stufng box halves
on top of the two screws.
Mount the two long screws from the worktable in the stufng box.
M902020232M01
Turn down the short screws so that the

stufng box lands on the ange.
2.
2. Turn the piston upwards until the stufng

box is in place in the cylinder frame.
Note!
Make sure that the two guide pins in the
ange enter the guide holes in the bottom of the cylinder frame.
M902020232M02
3. Mount two screws in the ange through the

holes in the worktable.
M902020232M03
3.
Page 10 (11 )

MAN B&W Diesel
902-2.4
Mounting
4. Remove the long screws from the stufng

box and mount them in the worktable.
4.
Remove the worktable from the piston rod.

5. Mount the drain oil pipe.
Mount and tighten all the inner and outer
screws for the stufng box. See Data.
Smear the piston rod with molybdenum disulphide.

Then turn the crankshaft a couple of revolutions.
If possible: Start up the engine and keep it
running for about fteen minutes at a number of revolutions corresponding to very
slow or idle speed.
M902020232M04
6. Remove the protecting rubber cover from

the piston rod/crosshead.
5.
M902020232M05
Then stop the engine and inspect the piston rod and stufng box.
D0226
D0227
M902020229D01
6.
Page 11 (11)
Piston and Piston Rod Panel
Plate
P90251-0259

0259
P90251
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90251-0259
Item
No.
014
026
040
075
087
099
109
110
122
134
158
171
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Lifting tool for piston rod
Template for piston top
Distance piece for stuffing box
Cover
Hook for mounting of spring
Pressure tester
Worktable
Piston ring expander
Guide screw for piston crown
Dismantling screw
Page 2 (2)
MAN B&W Diesel A/S
Piston and Rod - Tools
Plate
P90261-0103

0103
P90261
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90261-0103
Item
No.
019
Item Description
Item
No.
Item Description
Guide ring for piston
Page 2 (2)
MAN B&W Diesel A/S
Piston and Piston Rod - TiltingTools
Plate
P90264-0011

0011
P90264
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90264-0011
Item
No.
015
027
039
Item Description
Item
No.
Item Description
Collar ring for piston

Support for tilting tool
Crossbar for cylinder liner
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90265-0002
Page 1 (2)
Plate
P90265-0002
Item
No.
010
Page 2 (2)
Item Description
Item
No.
Item Description
Support for piston
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90266-0002
Page 1 (2)
Plate
P90266-0002
Item
No.
016
Page 2 (2)

Item Description
Item
No.
Item Description
Lifting tool for piston
MAN B&W Diesel A/S

103-01
903-01
103-02
903-02
90361
90366
0077
0261
0032
0255
0084
0010
Cylinder Liner, Data

Cylinder Liner
Cylinder Lubricator, Data
Cylinder Lubricator
Cylinder Liner - Tools
Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
103-1
Data

Stopped engine
X
X
X
X
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D03-03
Cylinder diameter, new
350
mm
D03-05
Cylinder liner, complete
380
kg
D03-06
Cooling jacket
40
kg
Page 1 (2)
Cylinder Cover
103-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P90361
Measuring tool for cylinder liner
P90366
Page 2 (2)
Cyliner Liner
MAN B&W Diesel
903-1.1
Checking
1. Dismount the cylinder cover and piston.

1.
Clean the cylinder liner and scavenge air

ports.
D0303
2. Position the cylinder liner measuring tool.
3. Take measurements in the fore-and-aft and

athwartship directions.
4. Check and assess the condition of the cylinder liner according to the description
given in Volume I, Chapter 707.
M903010256C01
Measure the cylinder liner with an inside

micrometer at the positions indicated on
the measuring tool. See Data.
2.
5. Carefully scratch over any scores or marks
on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3.
6. Check the lubricating points of the cylinder
by pumping cylinder oil to all lubricating
points.
Mount the piston and the cylinder cover.

See Procedures 901-1.4 and 902-1.4.
M903010261C02
Clean any blocked lubricating duct.
M903010256C02
3.
Page 1 (9)
903-1.2
Cyliner Liner
Dismantling
1.
MAN B&W Diesel
1. Dismount the cylinder cover.

Discard the sealing ring from the top of the
cylinder liner.
Turn the piston down far enough to make it
possible to grind away the wear ridges at
the top of the liner.
M903010261D01
Dismount the piston.

Mount the two screws in the cooling jacket.

2. Disconnect at the non-return valves the
oil pipes leading from the cylinder lubricator
to the non-return valves.
M903010261D02
2.
Mount the lifting tool on the cylinder liner.
Page 2 (9)
Cyliner Liner
903-1.2
Dismantling
MAN B&W Diesel
3. Attach the crane to the lifting crossbar, and

lift the liner out of the cylinder frame.
3.
Note!
Low lifting height in the engine room
may require the removal of one or more
cylinder cover studs before dismantling
the cylinder liner.
Land the cylinder liner vertically on, for instance, a couple of planks.
D0305
Clean the cylinder frame internally, taking

special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Clean the pipes carefully.
M903010261D03
4. Discard the O-rings on the cooling water

pipes.
M903010261D04
4.
Page 3 (9)
Cyliner Liner
903-1.3
Overhaul
MAN B&W Diesel
1. Remove the clamps which fix the cooling

jacket to the cylinder liner.
1.
2. Lift away the cooling jacket and land it on

wooden planks.
M903010261O01
Remove the lifting tool from the cylinder

liner
D0306
M903010261O02
2.
Page 4 (9)
Journal Bearing
903-1.3
Overhaul
MAN B&W Diesel
3. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.
3.
Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
4. It is recommended to use a wear ridge

milling machine to create the groove. For
use of the milling machine, see suppliers
instruction.
M903010261O03
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 necessary to create a groove by grinding. The groove serves to prevent the
build-up of a new wear ridge.
A B
4.
5. Alternatively, place an old piston ring on

the top of the piston and turn to a position
that enables the grinding disc to rest on
the old piston ring while removing the wear
ridge. Use a grinding disc with a round
edge.
The maximum depth of the groove is calculated as Smax. = D x 0.0045.

Note!
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.
M903010256O04
Check the distance C before grinding to

ascertain that the wear ridge was caused
by the top ring at TDC.
5.
R=4-5 mm
M903010256O05
Page 5 (9)
903-1.3
Cyliner Liner
Overhaul
6.
MAN B&W Diesel
6. Unscrew the nuts on the non-return valves

and remove the valves.
Clean and inspect the non-return valves.
Remount the valves.
M903010261O06
7. Replace the two uppermost O-rings on the

cylinder liner.
M903010261O07
7.
Page 6 (9)
Journal Bearing
903-1.3
Overhaul
MAN B&W Diesel

8. Lubricate the O-rings with vaseline.
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.
M903010261O08
9. Mount the four clamps in the groove of the

liner, and tighten the screws.
M903010261O09
9.
Page 7 (9)
Cyliner Liner
903-1.4
Mounting
MAN B&W Diesel
1. Loosen the water connections on the cooling jacket.
1.
Mount the lowermost O-rings and apply a

little vaseline on the rings.
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
cooling water pipes with new O-rings.
Mount the cylinder liner in the cylinder
frame.
Note!
M903010261M01
Make sure that the scratch marks of the

cylinder liner and frame coincide.
D0305
M903010261M02
2.
If one or more cylinder cover studs have

been removed during the dismantling of the
cylinder cover, remount the studs using the
stud setter, see Procedure 901-1.4
Page 8 (9)
Cyliner Liner
MAN B&W Diesel
903-1.4
Mounting
3. Screw the pipes from the lubricator on to

the non-return valves, but do not tighten.
3.
Vent the cylinder lubricating system by

pumping all pipes through until oil, without
air bubbles, comes out from the union
pipe/non-return valve.
4. Remove the cylinder liner lifting tool. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston.
5. Mount the sealing ring and the cylinder
cover.
M903010261M03
When this is in order, tighten the pipes

firmly on the non-return valves and again
pump manually until it is certain that each
individual lubricating point functions correctly.
4.
M903010261M04
Tighten the upper water connections on

the cooling jacket as soon as the cylinder
cover is correctly positioned.
M903010256M05
5.
Page 9 (9)
Cylinder Lubricators
MAN B&W Diesel
103-2
Data

Stopped engine
X
X
X
X
X
X

X Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D03-22
minimum crankthrow angle
118
D03-23
maximum crankthrow angle
140
D03-24
optimum crankthrow angle
129
Page 1 (2)
103-2
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel
903-2.1
Checking
1. Further information concerning other than

nominal feed rates, feed rates for running-in
and for part load operation, and recommended oil types, is given in instruction
book Volume I, OPERATION.
1.
Lubrication point no. 1
Each cylinder has four injection points.

Check that the pumps of all injection points
are activated during one revolution of the
engine.
3. Turn the engine in the ahead direction until
the mark on the first lubricator housing is in
line with the mark on the scale at the leadin shaft. This indicates that the pump
stroke is completed for lubricating point
No. 1.
M903020255C01
2. The cylinder lubricator is mounted on the

camshaft side of the scavenge air cooler
housing.
3.
4. Check that the crankthrow for cylinder No.

1 is positioned between D03-22 and D0323 past BDC.
M903020255C02
Use the numbers on the turning wheel to

determine the exact position of the
crankthrows.
4.
Marks
Seen from fore
M903020255C03
D0322
D0323
Cyl. No. 1
Page 1 (3)
903-2.3
Adjustment
MAN B&W Diesel
1. Remove the guards over the couplings.
1.
Loosen the set screws in the couplings and

pull the coupling wheels out of contact with
the planet wheels.
2. For adjustment of the lubricator, turn the
crankshaft in ahead direction until the
crankthrow for cylinder No. 1 is D03-24
past BDC for cylinder No. 1.
M903020255O01
Use the indications on the turning wheel to

determine the exact position of the
crankthrows.
Seen from fore
2.
M903020255O02
D0324
Page 2 (3)
XXX
XXX
XXX
XXX
MAN B&W Diesel
903-2.3
Adjustment
3. Turn the pump shaft slowly in ahead direction until the mark on the scale at the leadin shaft is in line with the mark on the lubricator housing.
3.
4. Re-engage the coupling wheel and tighten

the set screw.
Re-check the setting.
M903020255O03
Mount the guard over the coupling.
Marks
M903020255O04
4.
Page 3 (3)
Plate
P90361-0084

0084
P90361
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90361-0084
Item
No.
036
Item Description
Item
No.
Item Description
Cylinder gauge, complete
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90366-0010

0010
P90366
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90366-0010
Item
No.
021
Item Description
Item
No.
Item Description
Crossbar for cylinder liner
Page 2 (2)
MAN B&W Diesel A/S

104-01
904-01
104-02
904-02
104-03
904-03
104-04
904-04
104-05
904-05
90451
90461
90464
0065
0255
0067
0254
0046
0216
0059
0235
0057
0238
0143
0068
0005
Crosshead Bearing, Data

Crosshead Bearing
Crosshead, Data
Crosshead
Reciprocating Parts, Data
Reciprocating Parts
Crankpin Bearing, Data
Crankpin Bearing
Connecting Rod, Data
Connection Rod
Connecting Rod and Crosshead - Panel
Connecting Rod - Hydraulic Tools
Crosshead - Hydraulic Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crosshead Bearing
MAN B&W Diesel
104-1
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
X Stop lubricating oil supply
Data
Ref.
Description
Value
Unit
D02-02
Piston rod/crosshead, tightening torque
210
Nm
D02-20
Piston complete
280
kg
D04-01
Crosshead bearing, top clearance max.
0.4
mm
D04-02
Crosshead bearing, top clearance min.
0.1
mm
D04-03
Oil wedge length, L
10
mm
D04-04
Crosshead bearing cap
52
kg
D04-05
Crosshead bearing shell, upper
kg
D04-06
Crosshead bearing shell, lower
kg
D04-07
Crosshead bearing cap with bearing shell
60
kg
D04-15
Telescopic pipe, tightening torque
40
Nm
D04-16
Thrust piece, tightening torque
60
Nm
D04-51
Connecting rod complete
415
kg
D04-66
Crosshead with piston and guide shoes
700
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crosshead Bearing
104-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
59
Lifting attachment - connecting rod
P90451
72
Chain for suspending piston
P90451
84
Retaining tool telescope pipe
P90451
96
Bracket for support, Crosshead
P90451
106
P90464
P91351
010
P91351
046
P91351
058
P91351
117
P91356
Lifting Tools, Etc.
P91359
Torque Spanners
P91366
Page 2 (2)
058
Feeler gauge
Crosshead Bearing
MAN B&W Diesel
904-1.1
Checking
Tin-Aluminium bearings
2.
The top clearance between the journal and a

new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.
For the top 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 crankthrow concerned to BDC.
M904010255C01
The top clearance for a new bearing will normally be in the range stated in Data. Note that
the figures are to be used for guidance only.
3.
3. Measure the clearance in the crosshead

bearing by inserting a feeler gauge between the bearing cap and the crosshead
journal at the top of the upper bearing
shell, at both sides and fore and aft. See
Data.
For evaluation of the bearing shell, see

Chapter 708, Bearings in the instruction
book, Volume I, OPERATION.
M904010255C02
4. The difference between the actual clearance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
crosshead bearing must be disassembled
for inspection.
D0401
D0402
5.
5. The wear limit for a crosshead bearing shell

is confined to a 50% reduction of the oil
wedge length L.
(Oil Wedge)
If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by
a new one.
M904010255C03
L
1/2
D0403
L
Page 1 (10)
904-1.1
Crosshead Bearing
Checking
MAN B&W Diesel
Alternate checking method:

8.
In case the reason for opening the crosshead
bearing is a routine inspection, the following
procedure is sufficient.
6. Perform the clearance measurement shown
in 904-1.1 section 3.
M904010255C04
7. Mount the two eyebolts and tackles in the

top of the crankcase in the fore and aft direction. Mount two eyebolts on top of the
guideshoes.
Turn to BDC, mount the connecting rod lifting attachments on the connecting rod.
Use tackles to hold the connecting rod in
the vertical position.
9.
Dismount the crosshead bearing cap hydraulic nuts. For operation of the hydraulic
jacks, see Section 913.
M904010255C05
8. Mount two eyebolts in the bearing cap and

use two small tackles in the athwartship direction to lift the bearing cap free of the
guidepins and to keep the bearing cap balanced.
D0466
9. Use the tackles in the crankcase top to lift

the crosshead and piston high enough to
allow inspection of the lower crosshead
bearing.
Note!
Ensure that the crosshead is lifted simultaneously fore and aft, i.e. by placing
marks on the guide planes using a felt
tipped pen
10. If the lower bearing shows no anomalies

the piston and crosshead is lowered again
and the crosshead bearing cap nuts are
mounted.
11. Recheck the bearing top clearance. Remove all tools.
12. If there are any doubt concerning damage
to the upper bearing, the bearing has to be
dismantled and checked according to 9041.2.
Page 2 (10)
Crosshead Bearing
904-1.2
Dismantling
MAN B&W Diesel
This procedure has been divided into two dismantling situations, as follows:
1.
with piston mounted

with piston removed
With piston mounted:
2. Mount two eye bolts in the top of the

crankcase and suspend two tackles in the
athwartship direction.
Mount the two chains for suspending the
piston rod.
M904010255C01
1. Turn the crankshaft down far enough to

give access to the nuts and screws on the
piston rod.
2.
3. Loosen and remove the four screws which
tighten the telescopic pipe to the bend.
Suspend the telescopic pipe from the stuffing box using the wing nut (tool).
Caution!
M904010255D02
When a piston is dismantled, never turn

the engine without first dismantling the
telescopic pipe from the crosshead.
M904010255D03
3.
Page 3 (10)
904-1.2
Crosshead Bearing
Dismantling
MAN B&W Diesel
4. Remove the locking wire from the screws,

loosen and remove the screws from the
piston rod foot. Remove the thrust pieces
from both side of the bearing cap.
4.
5. Mount a lifting eye bolt on each side of the

piston rod.
Turn the crosshead to TDC.
Hook the chains to the lifting eye bolts in
the piston rod.
M904010255D04
Turn the crosshead downward, and the piston rod will remain suspended from the two
chains.
With piston removed:
5.
6. Turn to BDC.
D0220
7. Hold the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.
M904010255D05
Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.
M904010255D06
7.
Page 4 (10)
D1302
Crosshead Bearing
904-1.2
Dismantling
MAN B&W Diesel
8. Mount the connecting rod lifting attachment

tool on the head of the connecting rod.
8.

crosshead bearing cap.
Hook the two tackles on to the eye bolts
and lift the crosshead bearing cap away
from the crosshead.
Take care that the studs for the crosshead bearing cap do not scratch the
crosshead journal.
10. Mount wire guide on the top of the crankcase door frame to prevent damage.
9.
M904010255D08
Lift the crosshead bearing cap out of the

engine.
M904010255D07
Note!
10.
M904010255D09
D0407
Page 5 (10)
Crosshead Bearing
904-1.2
Dismantling
MAN B&W Diesel
11. Place the bearing cap on one side on a

couple of wooden planks.
11.
D0407
Remove the thrust pieces for axial guidance of the connecting rod.
Check the bearing shell, see Procedure
904-1.1.
M904010255D10
12. Turn the crosshead to TDC. Ensure that the

connecting piece in the crosshead fits correctly in the holes of the piston rod.
Do not remove the chains or lifting eye
bolts.
D0405
13. Mount the four supports for guide shoes on
the crosshead guides.
12.
Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
Adjust the support brackets to the guide
shoes so that the weight of the crosshead
is evenly distributed on the four supports.
14. Hook the two tackles on to the eye bolts
screwed into the head of the connecting
rod.
M904010255D11
Haul the tackles tight.
13.
M904010251D16
D0220
Page 6 (10)
Crosshead Bearing
MAN B&W Diesel
904-1.2
Dismantling
15. Turn the crankthrow carefully towards BDC

while following with the tackles, thus continuously supporting the connecting rod.
15.
With the crosshead resting on the supports, check the lower part of the crosshead journal and the lower bearing shell.
D0451
Check the bearing shell, see Procedure

904-1.1.
For further evaluation of journal and bearing
shells, see also Volume I, OPERATION,
Chapter 708, Bearings.
16. In cases where it is necessary to remove
the lower bearing shell, tilt the connecting
rod towards the door in the camshaft side,
using the tackles.
M904010255D15
Dismount the lock screws, and lift the

bearing shell out of the engine.
16.
M904010255D16
D0406
Page 7 (10)
904-1.4
Crosshead Bearing
Mounting
MAN B&W Diesel
With the piston mounted/

With the piston removed:
1.
1. Mount and secure the bearing shell in the

bearing housing.
D0406
M904010255M01
The excess height X is to ensure the correct tightening-down of the bearing shell
and must not be eliminated.
2. Raise the connecting rod to an upright position.
Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.
Take care that the guide shoes do not
damage the bearing shell.
2.
M904010255M02
3. Remove the tackles from the connecting

rod. Remove the lifting attachment tool
from the connecting rod.
M904010255M03
3.
Page 8 (10)
Crosshead Bearing
904-1.4
Mounting
MAN B&W Diesel
4. Remove the supports from the crosshead

guides.
4.
Turn the crank throw to BDC.

If the piston is mounted, slowly turn down
until it is fully suspended from the chains.
Note!
Take care that the bearing studs do not
damage the crosshead.
6. Remove wire guide.
M904010251M03
5. Lift the bearing cap into the engine. Lower

the bearing cap onto the crosshead and remove the tackles. Remove the eye bolts
from the bearing cap.
5.
Tighten all four crosshead bearing cap nuts

simultaneously. See Data.
For operation of hydraulic jacks, see Section 913.
D0407
Mount the two thrust pieces on both sides

of the bearing cap. See Data.
M904010255M05
7. Mount the piston.

6.
D0416
M904010255M06
D1301
Page 9 (10)
904-1.4
Crosshead Bearing
Mounting
MAN B&W Diesel
With the piston mounted:

8.
8. Turn the crosshead upwards until the piston
rod lands on the crosshead. When mounting the piston on the crosshead, make sure
that the piston rod foot is correctly centered on the crosshead.
M904010255M07
9. 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.
10. Mount and tighten the screws on the piston
rod. See Data.
Mount the locking wire on the screws. The
locking wire is to be mounted in such a
way that the wire is tightened if a screw
works loose.
10.
D0202
After tightening the bearing cap, check the

top clearance once more.
If a new bearing shell has been mounted,
remember to note down the new top clearance in the Adjustment Sheet in Chapter
701, Volume I, OPERATION.
M904010255M08
11. Release the telescopic pipe from its suspension, mount and tighten the four screws
which tighten the telescopic pipe to the
bend. See Data.
11.
M904010255M09
D0415
Page 10 (10)
Crosshead
MAN B&W Diesel
104-2
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
D04-07
Crosshead bearing cap with bearing shell
D04-08
Value
Unit
60
kg
Cooling oil outlet pipe, tightening torque
135
Nm
D04-09
Inlet pipe, tightening torque
260
Nm
D04-10
Inlet pipe stud, screwing-in torque
150
Nm
D04-11
Guide strip nuts, tightening torque
60
Nm
D04-15
Telescopic pipe, tightening torque
40
Nm
D04-16
Thrust piece, tightening torque
60
Nm
D04-17
Cooling oil outlet pipe, tightening angle
D04-18
Inlet pipe, tightening angle
D04-20
Clearance between thrust piece and crosshead
D04-21
Crosshead complete
D04-22
Guide shoe
D04-51
Connecting rod complete
D04-23
135
45
0.15-0.30
mm
360
kg
35
kg
415
kg
Cooling oil outlet pipe
kg
D04-59
Telescopic pipe
kg
D04-60
Inlet pipe
kg
D04-62
Crosshead without guide shoes
285
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crosshead
104-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P90451
60
Lifting tools - crosshead
P90451
72
P90451
84
Retaining tool telescope pipe
P90464
P91351
010
P91351
046
P91351
058
P91351
105
P91356
Lifting Tools, Etc.
P91359
Torque Spanners
P91366
Page 2 (2)
058
Feeler gauge
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
1. Dismount the main bearing lubricating oil

pipes.
2.
2. Turn the crosshead to BDC to give access

to the nuts on the crosshead bearing cap.
Mount the retaining tool for the telescopic
pipe on the stuffing box housing for the
telescopic pipe.
Mount the spacer rings and the hydraulic

jacks for loosening the crosshead bearing
cap nuts.
For operation of the hydraulic tools, see
Procedure 913-1.
M904020247D02
Mount two eye bolts in the athwartship direction, and suspend two tackles.
D1302
4.
D0407
Loosen the nuts, remove the hydraulic

jacks and unscrew the nuts.
3. Turn the crosshead to TDC.
4. Turn to BDC and mount connecting rod lifting tools. Use two tackles to retain the
connecting rod in an upright position.
Mount two eye bolts in the crosshead
bearing cap and hook on the tackles from
the top of the crankcase.
M904020247D04
Suspend the telescopic pipe by means of

the tool. Suspend the piston. To suspend
the piston, see Procedure 904-1.
Lift the bearing cap out of the engine.

Remove the piston rod guide ring and the
shim from the crosshead.
Remove both thrust pieces on the crosshead bearing cap.
Page 1 (10)
Crosshead
904-2.2
Dismantling
MAN B&W Diesel
5. Dismount the guidepin for the oil inlet bend

using the special extractor.
5.
Remove the outlet pipe, dismount the bend

for the telescopic pipe and remove the
studs from the crosshead.
Mount the special lifting tool on the crosshead.
M904020254D05
Mount the lifting attachments for fixing the

connecting rod on the head of the connecting rod.
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.
D0421
Hook the tackles to the top lifting brackets

onto the lifting tool on the crosshead and
lift the crosshead.
6. Attach tackle chains from the two tackles in
the athwartship direction to the lifting tool.
M904020254D06
Lift the crosshead free of the connecting

rod.
Page 2 (10)
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
7. Use the tackles to tilt the connecting rod

to-wards the exhaust side, while turning
the crankthrow towards the camshaft side.
7.
D0451
Transfer the tackles from one lifting attachment to another, as necessary.
By alternate use of the tackles, tilt the connecting rod until it is out of the way.
8. Remove the oil pipes from the two adjacent main bearing caps.
9. Remove the guide strips and the stop
screws from the bottom of the guide
shoes.
M904020250D07
Stop turning when the crankthrow is in a

position where there is room in the adjacent cylinder units to pull the guide shoes
through the openings in the side walls just
above the main bearings.
9.
Mount lifting eye bolts in both guide shoes.

There has to be space in the adjacent cylinder units to pull the guide shoes through
the openings in the side walls just above
the main bearings.
It is recommended to tag the guide

strips and shims to avoid mixing them.
10. Lower the crosshead so that the guide

shoes are just below the cutout in the side
walls of the frame box.
M904020250D09
Note!
10.
Note!
M904020250D10
Make sure that the crosshead journal

does not touch the crank.
Page 3 (10)
904-2.2
Crosshead
Dismantling
MAN B&W Diesel
11. Hook the tackles on to the eye bolts in the

guide shoes.
11.
12. Mount two eye bolts in the holes for stop

screws in the guide shoes in the adjacent
cylinder units, and suspend two tackles
from the eye bolts.
13. Haul the tackles for the guide shoes tight
and, at the same time, pull the guide shoes
sideways until they are free of the crosshead.
M904020250D11
Take the guide shoes through the openings

in the side walls by means of the tackles in
the two adjacent cylinders. Lift the guide
shoes to provide space for turning the
crosshead.
M904020250D12
12.
13.
M904020254D13
D0462
D0422
Page 4 (10)
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
14. Turn the crosshead 90.
14.
15. Mount a tackle outside the engine and, by

means of wire rope and tackle, remove the
crosshead from the engine.
Land and protect the crosshead outside
the engine.
Remove the guide shoes from the engine
and tag them.
Take care that the crosshead does not

bump into anything as this will damage
the sliding surfaces of the crosshead.
M904020250D14
Note!
M904020250D15
15.
D0422
Page 5 (10)
Crosshead
904-2.4
MAN B&W Diesel
Mounting
1. Clean the crosshead and mount the lifting

tool.
1.
Mount the wire guide tool in the framebox

door opening.
M904020250M01
Suspend two tackles from the top of the

framebox between the guides.
Suspend two tackles from the top lifting
brackets in the framebox and use them in
conjunction with a tackle mounted outside
the engine to carefully lift the crosshead
and ease it into the crankcase.
D0421
2. Turn the crosshead 90 to enable mounting

of the guide shoes. Check that the oil inlet
and outlet holes are pointing towards the
exhaust side.
2.
3. Attach two tackles to the eye bolts at the
bottom of the guide shoes in the adjacent
cylinders.
Using these tackles and a tackle outside
the engine, carefully lift the guide shoes
into the engine.
Note!
M904020250M02
When handling the crosshead, take great

care that its surfaces are not scratched
or damaged. If necessary, protect the
crosshead with a cloth.
3.
M904020250M03
D0422
Page 6 (10)
Crosshead
MAN B&W Diesel
904-2.4
Mounting
4. Lubricate the sliding surfaces of the guide

shoes and the crosshead with plenty of
clean lubricating oil, and push the guide
shoes into position through the openings in
the side walls.
4.
5. Use the tackles in the top of the framebox

to lift the crosshead into a working position
and mount the guide strips and shims on
the side of the guide shoes.
Remove the tackles and the eye bolts from

the guide shoes.
6. Lift the crosshead to a position above the
connecting rod in the upright position.
M904020250M04
Mount the stop screws in the bottom of the

guide shoes.
5.
Raise the connecting rod to the upright position.
Lubricate the crosshead bearing liberally
with clean lubricating oil and carefully lower
the crosshead into place.
M904020250M05
7. Dismount the tackles and connecting rod

lifting tools from the connecting rod.
D0411
D0421
M904020254M06
6.
Page 7 (10)
Crosshead
904-2.4
MAN B&W Diesel
Mounting
8. Turn the connecting rod and crosshead to

BDC.
8.
D0408
D0409
D0410
Dismount the tackles and connecting rod

lifting tools from the connecting rod.
Remove the lifting tool from the crosshead.
Mount the studs for the cooling oil inlet
bend. Mount the bend and outlet pipe.
See Data.
M904020247M05
Mount the inlet and outlet pipes.
Page 8 (10)
Tighten the outlet pipe.

Mount the piston rod guide ring and the
shim on the crosshead.
Crosshead
MAN B&W Diesel
904-2.4
Mounting
9. Lift the crosshead bearing cap into the engine.
9.
Mount and tighten the crosshead bearing

cap.
Remoce the eye bolts.
10. Mount the two thrust pads on the sides of
the crosshead. See Data.
Always ensure that clearance exists fore

and aft between the thrust piece and the
crosshead before tightening the thrust
piece.
Mount the distance pipe on the telescopic

pipe bend.
M904020247M06
Note!
D1301
10.
11. Mount the piston. See Procedure 902-2.
M904020247M07
Remove the nut from the telescopic pipe

suspending tool. Turn downwards and
tighten the telescopic pipe, D04-15.
D0416
D0420
Page 9 (10)
904-2.4
Crosshead
MAN B&W Diesel
Mounting
12.
12. Tighten the hydraulic nuts.

For operation of hydraulic tools, see Procedure 913-1.
Remove the hydraulic tools and the eye bolts
from the engine.
Check the clearances between the guide
strips, guide shoes and crosshead guides.
See Procedure 904-3.
M904020250M10
Mount the main bearing lubricating oil pipes.

Mount the piston and the telescopic pipe.
Note!
At this point it is recommended to check
the crosshead bearing clearance.
13. Remove all tools from the engine.
Note!
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
Page 10 (10)
Reciprocating Parts
MAN B&W Diesel
104-3
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-25
PF+PA, N max.
0.70
mm
D04-26
PF+PA, O max.
0.90
mm
D04-28
E+G, H+F, N max.
0.40
mm
D04-29
E+G, H+F, N min.
0.10
mm
D04-30
E+G, H+F, O max.
0.70
mm
D04-34
J+X, L+Y, K+X, M+Y, N max.
0.80
mm
D04-35
J+X, L+Y, K+X, M+Y, N min.
0.40
mm
D04-36
J+X, L+Y, K+X, M+Y, O max.
1.00
mm
D04-39
QF/QA, O max.
0.80
mm
D04-41
ZF/ZA O min.
4.00
mm
D04-42
TF + TA, O max.
0.80
mm
N: New and cold engine with staybolts tightened

(less than 100 running hours).
O: Engine in service.
Page 1 (2)
Reciprocating Parts
104-3
MAN B&W Diesel
Data
Plate
P91366
Page 2 (2)
Item No.
058
Description
Feeler gauge
Reciprocating Parts
904-3.1
Checking
Reciprocating Parts
S42MC
0216
Checking
904-3.1
1.
In order to achieve uniform measuring conditions on board, the ship's trim must be as close
as possible to 0.
Bend each end approx. 250 mm up along

the framebox side. See T.
Fill the tube with water (possibly coloured)
until the water level is approx. 100 mm from
the end of the tube.
MA904-5.0 72 01
1. Mount a transparent plastic tube along the

length of the bedplate.
2.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Fore
Measurements are to be taken with a ruler.
Aft
2. Turn the crankshaft in ASTERN direction to

45 after BDC (the guide shoe must rest
against the crosshead guide).
Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction.
PA
PF
HN904-3.1 212 02
Check the centering of the piston in the cylinder liner by measuring the clearance (by
applying a long feeler gauge from the scavenge air space) between the piston skirt
and the cylinder liner in the Fore and Aft positions (PF-PA).
45
A
ste
rn
MAN B&W Diesel A/S
Page 1 (3)
Reciprocating Parts
904-3.1
Checking
3.
3. Measure the clearance between the crankthrow and the connecting rod.
4. Measure the clearance between the thrust
piece and the crosshead (TF and TA or QF
and QA.
Measure the clearance between the crosshead 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+X, K+Y,
L+Y and M+Y, 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.
MN904-3.1 215 04
Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.
BF and BA correspond to the thickness of
the shims and are only to be measured if an
adjustment is carried out.
4.
Exhaust Side
MN904-3.1 215 05
Camshaft Side
Page 2 (3)
MAN B&W Diesel A/S
Reciprocating Parts
904-3.1
Checking
5.
5. It is recommended that the measured results are noted down so that possible later
changes can be ascertained.
Cyl.
Piston/Liner
PF
PA
Shim
Thickness
Frame Box
BF
BA
E1
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
J+X
L+Y
K+X
MN904-3.1 215 06
M+Y
Crosshead
Connecting
Rod
Crankthrow
Connecting
Rod
MAN B&W Diesel A/S
QF/TF
QA/TA
ZF
ZA
Page 3 (3)
Crankpin Bearing
MAN B&W Diesel
104-4
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-43
Crankpin bearing clearance, max.
0.45
mm
D04-44
Crankpin bearing clearance, min.
0.15
mm
D04-46
Crankpin bearing, upper shell
kg
D04-47
Crankpin bearing, lower shell
kg
D04-48
Crankpin bearing cap + shell + bearing studs
55
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crankpin Bearing
104-4
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P90451
96
P90451
106
P90461
P91351
010
P91351
046
P91351
058
P91351
105
P91366
061
Slide caliper
Page 2 (2)
Crankpin Bearing
MAN B&W Diesel
904-4.1
Checking
The bottom clearance between the journal and

a new bearing shell is the result of a summation of the production tolerances of the bearing
assembly components.
2.
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.
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.
recorded in the Adjustment Sheet (or the
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
M904040235C01
2. Turn the crank concerned to BDC.
3.
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
M904040235C02
For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.
D0443
D0444
M904040235C03
5.
Page 1 (7)
904-4.2
Crankpin Bearing
Dismantling
MAN B&W Diesel
1. Turn the crank to BDC.
2.
2. Mount two eye bolts in the crankcase top

plate in the athwartship direction and suspend two tackles from the eye bolts.
3. Turn the crank to TDC.
Mount eye bolts in each side of the crankpin bearing cap. Hook the tackles on to the
eye bolts and haul tight.
M904040235D01
Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Section 913.
Remove the hydraulic jacks and the nuts.
3.
D1302
4. Lower the bearing cap while seeing carefully that the studs do not damage the
crankpin journal.
Land the bearing cap on a couple of planks
placed in the oil pan.
M904040235D02
Inspect the bearing shell.
4.
M904040235D03
D0448
Page 2 (7)
Crankpin Bearing
MAN B&W Diesel
904-4.2
Dismantling
5. If the bearing shell needs to be replaced,

remove the whole bearing cap from the
crankcase.
5.
Suspend a tackle from the lifting bracket

on the inside camshaft side of the frame
box above the crankcase door opening.
D0448
Hook the tackle on to an eye bolt on one

side of the bearing cap.
Using the tackle from the frame box inside

wall, together with a tackle suspended from
the platform bracket, lift the bearing cap
out of the crankcase.
6. Place the bearing cap on one side on a
couple of planks.
M904040235D04
Mount the wire guide in the top of the

crankcase door opening.
6.
D0447
Dismount the bearing shell lock screws and

replace the bearing shell by a new one.
The bearing shells must be replaced in
pairs.
Mount the four supports for guide shoes

on the crosshead guides.
Carefully turn the crank down until the
guide shoes rest on the supports.
7.
M904040235D06

is evenly distributed on the four supports.
M904040235D05
7. Turn to TDC.
Page 3 (7)
904-4.2
Crankpin Bearing
Dismantling
MAN B&W Diesel
8. Mount a lifting attachment for securing the

connecting rod at the lower end, on one
side.
8.
Hook on the tackle to a beam under the

gallery platform and haul tight.
M904040235D07
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 separate.
Continue turning the crankshaft until the
bearing surface can be freely inspected.
Inspect the bearing shell surface and the
crankpin journal.
9.
10. If it is necessary to replace the bearing
shell, proceed as follows:
Turn the crankshaft to BDC.
Release the tackle so that the connecting
rod is hanging freely.
M904040235D08
Dismount the bearing shell lock screws.

Carefully lower the bearing shell from the
connecting rod and remove it from the engine.
10.
M904040235D09
D0446
Page 4 (7)
Crankpin Bearing
MAN B&W Diesel
904-4.4
Mounting
1. Lift the upper bearing shell for the crankpin

concerned into the crankcase.
1.
Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.
D0446
Lubricate the upper crankpin bearing shell

and the crankpin journal with plenty of
clean lubricating oil.
Carefully turn the crankshaft upwards,
while following up with the tackle, making
sure that the upper part of the bearing enters the recess in the crankshaft when the
parts turn together.
M904040235D09
2. Hook the tackle on to a beam under the

gallery platform and on to the lifting attachment on the connecting rod, and haul tight.
2.
Remove the tackle and the lifting attachment from the connecting rod.
3. Turn the crosshead to TDC.
M904040235M02
Remove the guide shoe support brackets

from the crosshead guides.
M904040235D06
3.
Page 5 (7)
904-4.4
Crankpin Bearing
Mounting
MAN B&W Diesel
4. Mount two eye bolts in the crankcase

topplate in the two outer screw holes in the
athwartship direction and suspend two
tackles from the eye bolts..
4.
5. Turn the crankthrow towards the exhaust

side of the engine.
M904040235D01
Lift the bearing cap assembly into the

crankcase and land it on a couple of
planks placed in the oil pan.
5.
M904040235M05
D0448
Page 6 (7)
Crankpin Bearing
904-4.4
Mounting
MAN B&W Diesel

6. Turn the crankthrow to TDC.
6.
Hook the tackles on to the eye bolts of the

bearing cap and lubricate the bearing shell
with plenty of lubricating oil.
D0448
Lift the bearing cap into position against

the connecting rod.
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 connecting rod.
7. Mount the nuts and, by means of spacer
rings and hydraulic jacks, tighten the
crankpin bearing cap. See Data.
M904040235D03
Caution!
7.
For operation of hydraulic jacks, see Section 913.
D1301
M904040235M07
Remove the tackles, the eye bolts and the

hydraulic tools from the engine.
Page 7 (7)
Connecting Rod
MAN B&W Diesel
104-5
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D04-50
Connecting rod, without bearing caps
305
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Connecting Rod
104-5
MAN B&W Diesel
Data
Plate
Item No.
P90451
47
Wire guide
P90451
59
P90451
96
P90451
106
P90461
Description
P91351
010
P91351
046
P91351
058
P91351
105
P91356
Page 2 (2)
Lifting Tools, Etc.
Connecting Rod
MAN B&W Diesel
1.
904-5.2
Dismantling
Turn the crank to BDC.
1.
Dismount the nuts from the crosshead

bearing studs.
D1302

crankcase in the athwartship direction, and
suspend two tackles.
Mount the support brackets for the guide

shoes on the crosshead guides.
Carefully turn the crank down towards
the door opening, camshaft side, until the
crosshead shoes rest on the supports.
is distributed evenly on the four supports
M904050238D01
3. Turn the crank to TDC.
2.
M904050238D02
4. Dismount the crankpin bearing cap.

M904050238D03
3.
Page 1 (7)
904-5.2
Connecting Rod
Dismantling
5.
MAN B&W Diesel
5. Mount an eye bolt in each side of the connecting rod at the crosshead end, hook on
the tackles, and haul tight.
Mount the lifting attachment on the exhaust
side of the connecting rod, at the crankpin
end.
M904050238D04
6. Turn the crank carefully downwards while

following with the tackles to guide the
connecting rod when this separates from
the crosshead.
The weight of the crosshead, together with
the piston and crosshead bearing cap, is
now carried by the four supports.
M904050238D05
6.
Page 2 (7)
Connecting Rod
MAN B&W Diesel
7.
904-5.2
Dismantling
Open the crankcase door on the exhaust

side of the engine.
7.
Suspend a tackle from the platform bracket

and hook it on to the eye bolt in the connecting rod, crankpin end.
8. Remove the tackle from the connecting
rod, crosshead end, on the exhaust side.
When possible, change the lifting point

from the camshaft side to the exhaust side
of the connecting rod and guide the upper
part of the connecting rod towards and out
of the door opening as far as possible.
M904050238D06
9. Turn the crank carefully upwards while following with the tackle from the topplate
and the one on the exhaust side.
M904050238D07
8.
M904050238D08
9.
Page 3 (7)
904-5.2
Connecting Rod
Dismantling
MAN B&W Diesel
10. Place a wire rope round the connecting

rod, hook on the tackle and haul tight.
10.
Continue turning the crank to a position

about 25 after TDC, while following with
the two tackles.
M904050238D09
D0450
11. Lift the connecting rod out of the engine

using the two tackles and, if possible, using the engine room crane.
M904050238D10
11.
Page 4 (7)
Connecting Rod
MAN B&W Diesel
1.
904-5.4
Mounting
Equip the connecting rod with the same

lifting attachments as mentioned under dismantling.
2.
Turn the crank to a position about 25 past

TDC on the camshaft side.
Apply clean lubricating oil to the crankpin
bearing shell and journal.
Note!
Take care that the end of the connecting rod does not scratch the crankpin
journal.
M904050238M01
2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine
room crane and the tackle attached to the
lifting bracket mounted on the connecting
rod.
D0450
3.
3. Carefully land the connecting rod on the

crankpin journal.
When the upper end of the connecting rod

has passed the crankcase door, hook the
second tackle on to the eye bolt screwed
into the camshaft side of the connecting
rod.
4.
M904050238M03
Haul tight and remove the strap around the

connecting rod.
M904050238M02
4. Turn the crankthrow towards the exhaust

side of the engine, past TDC, while following with the tackle and the engine room
crane.
Page 5 (7)
Connecting Rod
904-5.4
Mounting
MAN B&W Diesel
5. Turn the crankthrow to 90 before BDC.
5.
Hook the third tackle on to the eye bolt

screwed into the exhaust side of the connecting rod.
6. Turn the crankthrow towards TDC while
following with the tackles.
M904050238M04
Caution!
Take care that the studs do not damage the crosshead bearing shell.
Remove the tackle from the lifting attachment at the lower end of the connecting
rod
7.
When the crank is in TDC, mount and tighten the crankpin bearing cap.
M904050238M04
6.
D1301
M904050238M05
7.
Page 6 (7)
Connecting Rod
MAN B&W Diesel
904-5.4
Mounting
8. Remove:
8.
the four supports from the crosshead

guides
the eye bolts and the lifting attachment
from the connecting rod
the eye bolts from the top of the crankcase.
M904050238M07
9. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.
D1301
M904050238M08
9.
Page 7 (7)
Connecting Rod and Crosshead Panel
Plate
P90451-0143

0143
P90451
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90451-0143
Item
No.
011
023
047
059
060
072
084
096
106
118
120
155
167
238
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Wire guide
Lifting attachment for connecting rod
Lifting tool for crosshead
Retaining tool for telescope pipe
Support for crosshead
Support for crosshead
Rubber cover for crosshead
Rubber cover for crosshead
Crowfoot wrench
Crowfoot wrench
Dismantling screw for crosshead
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90461-0068
Page 1 (2)
Plate
P90461-0068
Item
No.
Item Description
028
030
041
053
065
089
100
207
Hydraulic jack
Support
Tommy bar
Spanner
Stud setter
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90464-0005
Page 1 (2)
Plate
P90464-0005
Item
No.
Item Description
024
036
048
050
061
085
107
203
Jack-hydrualic, complete
Support
Tommy bar
Key, hexagon socket screw
Stud setter
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S

105-02
905-02
105-03
905-03
105-04
905-04
105-05
905-05
90551
90561
90562
90564
90572
0083
0259
0073
0226
0048
0232
0059
0226
0198
0087
0124
0020
0003
Main Bearing, Data

Main Bearing
Thrust Bearing, Data
Thrust Bearing
Journal Bearing, Data
Journal Bearing
Axial Vibration Damper, Data
Axial Vibration Damper
Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
Main Bearing - Hydraulic Tools
Crankshaft - Tools
Crankshaft - Measuring Tools
Main Bearing - Measuring Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Bearing
MAN B&W Diesel
105-2
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-01
Main bearing, top clearance max.
0.45
mm
D05-02
Main bearing, top clearance min.
0.15
mm
D05-03
Main bearing cap
D05-04
88
kg
Main bearing shell, upper
kg
D05-05
Main bearing shell, lower
kg
D13-01
D13-02
900
bar
800 - 990
bar
Page 1 (2)
Main Bearing
105-2
MAN B&W Diesel
Data
Plate
Item No.
P90464
Description
P90551
52
Handle, dismantling of main bearing shell
P90551
88
Dismantling tool, main bearing shell
P90561
P90562
Lifting tool for crankshaft
P90572
P91351
010
P91351
022
Hydraulic pump, hand operated
P91351
046
P91351
058
P91351
105
P91356
P91366
Page 2 (2)
Lifting Tools, etc.

073
Dial gauge and stand tool
Main Bearing
MAN B&W Diesel
905-2.1
Checking
General
1.
The condition of the main bearings can be

checked by:
Deection readings
Visual checking
Edge checking and
Crankshaft deection readings

Crankshaft deection readings should be taken
while the ship is aoat (i.e. not while in dry
dock).
As the alignment is inuenced by the engine
temperature as well as the loading conditions,
deection measurements should, for comparison purposes, always be made under nearly
the same temperature and load conditions.
2.
Positive (+)
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 throw. See also Chapter 708 in Volume I.
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
the readings when the throw passes the
positions:
Negative ()
M905010208C02
1.
M905020046C01
Measuring of top clearance.
3.
B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
B = 1/2 (B2+B1)
M905010204C03
Looking forward
B1
B2
B1
C
T
E
B2
(B1+B2)=B
Page 1 (15)
905-2.1
Main Bearing
Checking
4.
MAN B&W Diesel
4. When taking deection readings for the

three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise,
this pressure may falsify the readings.
M905020046C01
For evaluation of the crankshaft deection

readings, see Volume I, OPERATION, Chapter 708.
5.
If the crankshaft deection (alignment indicator) 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 bearing.
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.
As reference, use the after seatrial deection table.
M905010208C05
The condition of the bearing can be checked

as follows:
5. Visually look for bearing metal fragments in
the oil pan, and check the lters for metal
fragments.
Such fragments can be from crosshead,
guide shoe or crankpin bearings. If fragments are found, the damaged bearing can
be found by edge checking with a feeler.
General
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 during a crankcase inspection, and small, thin
pieces can enter the lter. A check of the
bearing edges together with inspection of the
crankcase and the lter normally provides a
good indication of the bearing condition.
Page 2 (15)
Main Bearing
MAN B&W Diesel
905-2.1
Checking
Checking the bearing edges

6.
6. Bearing edges can be checked with a
feeler 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 ashlight.
7.
Wirefeeler
It is rather easy to make a feeler (see
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 that the thickness of the white
metal is approx. 1.5 mm, which is why the
tip should be less than 1.2 mm thick, and
bigger than the max. top clearance. At the
other end of the tip, a handle should be
made by bending a hook or similar in the
same direction as the tip.
<1.2 mm
>0.7 mm 7-10 mm
60-70
2-3 mm
500-1000
7.
Hole in
the edge
M905010208C06
The No. 1 and the two aftmost main bearings are more difcult to access on the
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
The above dimensions of the

wirefeeler are guideline values and
may depend on the engine type as well
as individual, personal designs.
M905020252C06
Note!
Page 3 (15)
905-2.1
Main Bearing
Checking
8.
MAN B&W Diesel
8. Remove the lub. oil pipe from the main

bearing cap.
Calibrate the main bearing measuring tool:
See the wooden box for the measuring
tool.
M905020259C08
9. Insert the measuring tool and check the

clearance between the upper shell and the
journal.
10.
An appreciable increase in clearance may

be an indication of loose staybolts or wear
of the lower shell.
10. If there is too large a difference in the
crankshaft deection readings (autolog)
check the clearance in the individual bearings.
M905010208C08
Bearing clearance checks should also be

carried out during timebased overhauls,
surveys and during crankcase inspections.
Page 4 (15)
If there is a suspicion of a damaged bearing, it is recommended to edge check the

bearing, without opening up.
Main Bearing
MAN B&W Diesel
905-2.1
Checking
11. Before measuring, check that the feeler

blades are in good condition.
12.
The feeler is inserted along the crank

throw. When the feeler hits the journal,
gently attempt to enter the feeler gauge
into the bearing. Do not use force.
Measure until a Go/No go difference of
0.05 mm has been found, e.g. Go = 0.75
mm / No go = 0.8 mm.
Note!
The bearing clearances for a new bearing stated in Data (see Data 1052) are
for guidance purposes only.
M905020227C03
Check the feeler blades after measuring.
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 disassembled for
inspection, see Procedure 9052.2.
Page 5 (15)
Main Bearing
905-2.2
Dismantling
1.
Aftmost main bearing (= Journal bearing)
MAN B&W Diesel
Positioning the crankshaft

1.
Dismantling of main bearing.

The bearings are divided into two categories:
The main bearings
M905020238D01
The aftmost main bearing

often referred to as Journal bearing
(See Procedure 9054).
2. Before any dismantling, check and write
down the main bearing top clearances and
crankshaft deection readings for the cylinder unit concerned.
Main bearings
Thrust bearing
3. Turn the crank throw to the position shown

on the sketch and in such a way that the
top of the studs is ush with the crank
throw.
Note!
M905020238D02
Be sure that the crosshead for the

neighbouring cylinder is in a higher position than for the cylinder you are working
on, otherwise it will be impossible to lift
the cap.
3.
MANSIDE
M905020238D03
EXHSIDE
Page 6 (15)
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
Dismantling of main bearings (A)
4.
4. Disconnect the lubricating oil inlet pipe

from the main bearing cap (if not already
done during checking).
5. Turn the crankthrow so that it points towards the exhaust side of the engine.
Screw the two extension studs onto the

same two bearing cap studs (diagonally)
1+3, and subsequently 2+4.
Mount the double hydraulic jacks on the
studs.
M905020259D04
Place two spacers on two bearing cap

studs with the slots towards the centre of
the bearing cap.
5.
Connect the four hydraulic jacks to the
high-pressure pump by means of the distributor block and high-pressure hoses.
D1302
(For operation of the hydraulic tools, see

Chapter 913).
Repeat the sequence until all four nuts are

loose.
4
M905020259D05
Remove the hydraulic tools and unscrew

the nuts.
Then loosen the nuts.
Page 7 (15)
905-2.2
Main Bearing
Dismantling
7.
MAN B&W Diesel
6. Remove the rectangular nut washers from

the bearing cap.
7.
Remove the stop screw in the crosshead

guide shoe.
Mount the guide pulley with the lifting wire
rope in the bottom of the guide shoe.
Rig-up two tackles outside the engine.
Mount the outside tackles, one in the lifting
beam on the camshaft side, and one on
the exhaust side.
8. Fasten the lifting tool to the main bearing

cap with wire rope attached to the camshaft side tackle.
M905020259D07
Lift the bearing cap and, by means of the

handle, push the bearing cap free of the
frame and land it on the crank web.
8.
M905020259D08
D0503
Page 8 (15)
Main Bearing
MAN B&W Diesel
905-2.2
Dismantling
9. Remove the wire rope from the guide pulley, and fasten the two wire ropes from the
lifting tool in the two tackles outside on either side, and lift the bearing cap out of the
crankcase.
9.
Remove the guide pulley from the engine.

10. Mount the handle in the upper bearing shell
and remove the shell from the crankshaft.
See Volume I, OPERATION Chapter 708,

Bearings).
D0503
10.
M905020259D10
11. Check that there is clearance between the

journal and the bearing shell in the two adjacent main bearings.
M905020259D09
Inspect the bearing shell and the journal.
D0504
M905020259D11
11.
Page 9 (15)
Main Bearing
905-2.2
Dismantling
MAN B&W Diesel
12. Remove the screws from the sides of the

crosspiece and screw them into the threaded holes of the upper hydraulic jacks for
the main bearing.
12.
13. Place the crosspiece in the bedplate with

the ends resting on the crossgirders, and
place the hydraulic jacks beneath the crank
webs as shown.
Tighten the screws against the crank webs.
M905020259D12
Place a dial gauge to measure the lifting of

the crankshaft.
Connect the hydraulic jacks to the high
pressure pump and raise the pressure until
the crankshaft has lifted maximum 0.2 mm.
13.
14. Dismount the lock screws from the lower

shell.
Place the dismantling tool on the top of the
lower bearing shell, making sure that the
ap of the dismantling tool enters the oil
groove in the bearing shell.
M905020259D13
Pull the lower bearing shell round and up

until it lies over the main bearing journal.
Take out the lower shell from the crankcase
in the same way as the upper shell.
Max.0.2 mm
M905020259D14
14.
Page 10 (15)
D0505
Main Bearing
MAN B&W Diesel
1.
905-2.3
Overhaul
Clean and inspect the bearing shells. For

judging the condition of the bearing, see
Volume I, Chapter 708, Bearings.
1.
If the bearing shells are damaged, contact

MAN B&W Diesel for advice.
If, nevertheless, it is desired only to replace

one shell, it requires a careful evaluation
of the condition of the shell that is to be
reinstalled. See instruction book, Volume I,
Chapter 708.
For advice on replacing the bearing shells
individually, it is recommended to contact
MAN B&W Diesel A/S or the engine builder.
M905020259O01
We recommend that the main bearing

shells be replaced in pairs.
2. Before remounting:
Check the bearing support for damage
and burrs. If damage is found, contact
Make sure that all parts are clean, use
non-uffy cloth to clean between journal
and main bearing support.
Lubricate the bearing journal, the main
bearing support and the back of the
shell.
Page 11 (15)
Main Bearing
905-2.4
Mounting
1.
1.
MAN B&W Diesel

Lubricate the lower bearing shell and the
crankshaft journal with plenty of clean lubricating oil.
2. Land the lower bearing shell on the crankshaft journal.

Mount the handle on the lower bearing
shell and slide down the lower bearing shell
as far as possible.
M905020255M01
Remove the handle.

Using a caliper, check in both sides of
the bearing shell that the bearing shell is
mounted horizontally correct.
3. If necessary, use the bearing shell dismantling tool to push the lower bearing shell
fully down under the crankshaft journal.
2.
M905020259M02
D0505
Page 12 (15)
Main Bearing
MAN B&W Diesel
905-2.4
Mounting
4. Check visually that the shell does not prevent the locking screws from being fully
tightened to the bedplate, as this would
cause damage to the screws and shell
when tightening the bearing cap.
4.
See also Volume I, OPERATION, Chapter

708.
6. Lubricate the upper bearing shell with plenty of clean lubricating oil. Land the upper
bearing shell on the crankshaft journal.
Make sure that the edge of the upper bearing shell does not rest on the tip of the
bedplate.
M905020259M04
5. Lower the crankshaft and remove the

crosspiece and the hydraulic jacks from the
engine.
6.
If so, press the shell into place.

Mount the bearing cap. Make sure that the
guide pin from the bedplate enters the hole
in the bearing cap.
D0504
M905020259M06
7.
7.
M905020259M07
D0503
Page 13 (15)
Main Bearing
905-2.4
Mounting
MAN B&W Diesel
8. Mount the:
8.
rectangular washers
D1301
nuts
extension studs
spacers
double hydraulic jacks
4
M905020259M08
Tighten the main bearing cap. See Data.

9. The tightening is done in the following sequence:
1) Tighten nuts 1 + 3
9.
2) Tighten nuts 2 + 4
3) Retighten nuts 1 + 3
Remove the hydraulic tools.
3
10. After tightening the bearing cap, check the
top clearance once more.
M905020259M09
If a new bearing shell has been mounted,

remember to note down the new top clearance in the Adjustment Sheet in Volume I,
OPERATION, Chapter 701.
11. Mount the lubricating oil pipe.
M905020259M11
11.
Page 14 (15)
Main Bearing
MAN B&W Diesel
905-2.4
Mounting
12. Remove all tools from the engine.
12.
Note!
M905020238M14

behind.
Page 15 (15)
Thrust Bearing
MAN B&W Diesel
105-3
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-06
Thrust bearing segment
11
kg
D05-07
Segment stopper
44
kg
D05-28
Thrust bearing, top cover
85
kg
D05-29
Segment stopper, tightening torque.
650
Nm
Page 1 (2)
Thrust Bearing
105-3
MAN B&W Diesel
Data
Plate
P90551
Item No.
100
P91356
P91366
Page 2 (2)
Description
Tool for turning out segments
Lifting Tools, Etc.
058
Feeler gauge
Thrust Bearing
905-3.1
Checking
Thrust Bearing
S35MC
0226
Checking
905-3.1
1.
The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,
and for an engine in service it must not exceed
2.0 mm.
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.
BM905-3.1 226 01
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.
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).
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 overhauled.
3. Note down the wear for later reference.
GN905-3.1 224 02
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.
KN905-2.2 238 02
3.
MAN B&W Diesel A/S
Page 1 (5)
Thrust Bearing
905-3.2
Dismantling
Dismantling
905-3.2
1.
D05-28
1. Remove the cover above the thrust bearing.

Remove the lub. oil pipe from the thrust
segments.
2. Loosen and remove the screws from the
segment stoppers.
Screw an eye bolt into the stopper that is to
be removed.
Suspend a tackle above the stopper and
hook the tackle on to the eye bolt.
BM905-4.0 51 01
Remove the stopper from the engine above

the thrust segments ( AHEAD or ASTERN) that
are to be taken out. The other stopper is to
remain fitted.
2.
BM905-4.0 51 02
D05-07
Page 2 (5)
MAN B&W Diesel A/S
Thrust Bearing
905-3.2
Dismantling
3.
3. Suspend a tackle from the chain tightener

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

turning the engine, and remove the segment from the chain casing. Inspect the
segment and remount it before turning up
the next segment. See Procedure 905-3.4.
BM905-5.0 76 03
For turning-up the thrust segments, screw

the driving pin into the thrust shaft.
4.
Note!
D05-06
BG905-5.0 59 04
Never remove more than one segment at

a time.
MAN B&W Diesel A/S
Page 3 (5)
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.
Screw the driving pin into the thrust shaft.
2. Land the segment on the journal and remove the eye bolt from the segment.
BM905-5.0 76 03
Carefully slide the segment on to the driving pin. Turn the engine to dismantle the
next segment, see Procedure 905-3.2.
After the last segment has been mounted,
turn the driving pin up and dismount it.
2.
BM905-3.4 208 02
D05-06
Page 4 (5)
MAN B&W Diesel A/S
Thrust Bearing
905-3.4
Mounting
3.
3. Mount the segment stopper.

Mount and tighten the screws which fasten
the segment stopper. See Data.
D05-07
D05-29
Note!
Use only the tightening angle or the
tightening torque, not both.
4. Mount the lub. oil pipe.
BM905-4.0 51 02
Mount the cover above the thrust bearing.
D05-28
BM905-3.4 208 04
4.
MAN B&W Diesel A/S
Page 5 (5)
Journal Bearing
MAN B&W Diesel
105-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-11
Min. bearing clearance
0.20
mm
D05-12
Max. bearing clearance
0.50
mm
D05-13
Journal bearing cap
93
kg
D05-14
Upper bearing shell
kg
D05-15
Lower bearing shell
kg
D05-28
Thrust bearing, top cover
85
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Journal Bearing
105-4
MAN B&W Diesel
Data
Plate
Item No.
Description
P90551
52
Handle, dismantling of main bearing shell
P90551
88
Dismantling tool, main bearing shell
P90551
111
Lifting attachment
P90561
P90562
Lifting tool for crankshaft
P90572
P91351
010
P91351
022
P91351
046
P91351
058
P91351
105
P91356
P91366
Page 2 (2)
Lifting Tools, Etc.

073
Journal Bearing
MAN B&W Diesel
1.
905-4.1
Checking
Before any dismantling of journal bearing,

check the clearances according to Procedure 9052.1
1.
Aftmost main bearing (= Journal bearing)
Journal bearing clearance can only be

measured with the thrust bearing cover removed. See Procedure 9054.2.
2. Write down the journal bearing clearances.
M905040225C01
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
Main bearings
Thrust bearing
M905020238D02
2.
M905040225C03
3.
Page 1 (9)
Journal Bearing
905-4.2
Dismantling
MAN B&W Diesel
Dismantling of journal bearing in the thrust

shaft end.
4.
1.
D0528
Remove the screws from the cover placed

over the thrust bearing. Mount an eye bolt,
shackles and wire rope on the cover. Hook
on a tackle, and lift the cover away.
2. Disconnect the lubricating oil pipe used for

lubricating the bearing.
M905040232D04
3. Assemble the main bearing hydraulic jacks

on the bearing studs. Connect the hydraulic pump.
M905040232D05
5.
6.
M905040232D06
D1302
Page 2 (9)
Journal Bearing
MAN B&W Diesel
905-4.2
Dismantling
4. For operation of the hydraulic tools, see

Procedure 9131.
4.
Remove the hydraulic main bearing tools

from the engine.
Unscrew and remove the nuts from the
bearing studs.
By use of the tackle mounted below the

platform, above the journal bearing, lift
away the journal bearing cap.
6. Mount the bearing shell lifting tool and lift
the bearing shell away.
M905020238D02
5. Mount the lifting tool on the journal bearing

cap.
5.
M905040232D07
D0513
6.
M905040226D03
D0514
Page 3 (9)
905-4.2
Journal Bearing
Dismantling
7.
7.
MAN B&W Diesel
Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.
Tighten the screw against the turning wheel
and compress the jacks.
Connect the hydraulic jacks to the
highpressure pump, and raise the pressure
until the crankshaft has been lifted 0.20.5
mm
M905040232D08
8. Dismount the locking screws.

Place the dismantling tool on top of the
lower bearing shell. Make sure that the
ap on the dismantling tool enters the oil
groove in the bearing shell.
8.
9. Pull the lower shell around and up until it

lies over the bearing journal. Never use a
tackle larger than 0.5 tonne.
Note!
While pulling out the shell, it is recommended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
M905040225D08
10. Take the lower shell out of the engine in the

same way as the upper shell, by using the
lifting tool.
9.
M905040226D03
D0514
Page 4 (9)
Journal Bearing
MAN B&W Diesel
1.
905-4.3
Overhaul
Clean and inspect the bearing shells. It is

recommended that the main bearing shells
be replaced in pairs.
1. + 2.
If it is nevertheless desired to replace only

one shell, this requires a careful evaluation
of the condition of the shell that is to be
reinstalled.
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:
M905040232O01
See Instruction book, Volume I, Chapter

708.
Check the bearing support for damage

and burrs. If damage is found, contact
Make sure that all parts are clean, use
nonuffy cloth to clean between journal
and bearing support.
Lubricate the bearing journal, the bearing support and the back of the shell,
with main engine lubricating oil.
Page 5 (9)
905-4.4
Journal Bearing
Mounting
1.
1.
MAN B&W Diesel

Using the bearing shell lifting tool and tackles, lift the lower bearing shell to above the
crankshaft journal.
Lubricate the journal, the lower bearing
shell and the bearing support with clean
oil.
M905020255M01
2. Place the lower bearing shell on the journal

and remove the lifting tool from the bearing
shell. Push the shell down by hand.
To ensure that the shell is correctly mounted, check that the distance from the bearing support to the shell is equal in both
sides.
3.
Mount the locking screws in the bearing

support.
2.
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below the turning wheel.
M905040232M02
Wipe the contact surfaces between the upper and the lower bearing shells clean with
a nonuffy piece of cloth.
M905040232M03
3.
Page 6 (9)
Journal Bearing
MAN B&W Diesel
905-4.4
Mounting
4. Land the upper bearing shell on the journal

in the same way as the lower bearing shell.
4.
Make sure that none of the edges of the

upper bearing shell are resting on the edge
of the bearing support.
Clean the contact surfaces between the

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfaces.
5. Mount the lifting tool on the bearing cap.
Using the tackles and wire ropes on the
main bearing cap lifting tool, lift the bearing
cap back in reverse order to dismantling.
6.
M905040232M04
If necessary, place the special tool between the studs and press the shell into
place.
5.
Note!
Be sure that the cap lands correctly and
that the guide pin in the assembly surface enters the hole in the bearing cap.
M905040232M05
D0513
M905020238M09
6.
Page 7 (9)
Journal Bearing
905-4.4
Mounting
7.
7.
MAN B&W Diesel

Remove the bearing cap lifting tool.
Screw the nuts on to the main bearing
studs.
Using a tommy bar, tighten the nuts on
both sides of the bearing cap.
8. Assemble the main bearing hydraulic jacks

on the bearing studs. Connect the hydraulic pump.
M905020238M15
For tightening pressure, see Data.

For operation of the hydraulic tools, see
Procedure 9131.
8.
M905040232M08
D1301
Page 8 (9)
Journal Bearing
MAN B&W Diesel
9.
905-4.4
Mounting
Note!
9.
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.
Remove all tools from the engine.
Note!
10. Mount the lubricating oil pipe on the bearing cap, and mount the thrust bearing cover.
M905040232M09

behind.
D0511
D0512
10.
M905040232M10
D0528
Page 9 (9)

MAN B&W Diesel
105-5
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D05-17
Inner screws, tightening torque
50
Nm
D05-21
Outer screws, tightening torque
400
Nm
D05-23
Horizontal screws, tightening torque
120
Nm
D05-25
Damper housing, upper part
65
kg
Page 1 (2)
105-5
MAN B&W Diesel
Data
Plate
P90551
Item No.
111
Description
Lifting attachment
P90564
P91356
Lifting Tools, Etc.
P91359
Torque Spanners
Page 2 (2)
905-5.1
Checking
S35MC
0226
Checking
905-5.1
1.
For checking the effectiveness of the axial vibration 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. (Preferably 90% and 100% of MCR.)
As different equipment can have been mounted
on the specific engines, the checking procedure
describes three different systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, without angle encoder fore
C: Mechanical, with angle encoder fore.
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
movements and sends signals to the engine
control system.
KM905-7.1 35 01
A: Electronic, with Axial Vibration Monitor
1. Concerning overhaul and setting of the

electronic device, refer to makers instructions and Volume I, Operation, Chapter
701.
The peak-to-peak values displayed in mm
are to be compared with the original values
obtained during sea trial and the limits given in Volume I, Operation, Chapter 701.
If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.
MAN B&W Diesel A/S
Page 1 (8)
905-5.1

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.
BG905-5.1 223 01B
After tightening the shaft, dismount the

handle.
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!
BG905-5.1 223 02B
To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.
Page 2 (8)
MAN B&W Diesel A/S
905-5.1
Checking
3.
3. Start the engine, and let the speed rise to

the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)
S-2
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 calliper as shown in the sketch.
DM905-7.1 74 05
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.
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.
S1
For a standard measuring tool (L 1 = 38 mm

and L 2 = 200 mm), the ratio is 5.3. Therefore, S1 can be calculated as follows:
L1
S2
M90505-0229C10
If a non-standard tool is used, S1 can be

calculated as follows:
L2
Procedure 905-5.2.
MAN B&W Diesel A/S
Page 3 (8)
905-5.1

Checking
1.
C: Mechanical, with angle encoder fore

For engines with angle encoder fore, a measuring tool is available for mounting on the angle
encoder housing.
1. Stop the engine.
Dismount the protection shield over the angle 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.
BG905-5.1 223 01C
Note!
To obtain a correct measurement, the tip
of the pencil should protrude 10 mm from
the end of the arm.
MN905-5.1 214 05
2.
Page 4 (8)
MAN B&W Diesel A/S
905-5.1
Checking
3.
3. Start the engine, and let the speed rise to

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 paper, clipped onto a solid backing plate,
lightly sidewards against the tip of the pencil.
PULL
The axial movements (S2) recorded on the

paper must be measured with a slide calliper 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
the tool.
BG905-5.1 223 03
To ensure a certain inertia, the backing

plate should have a mass of approx. 1-2 kg.
4.
For a standard measuring tool (L 1 = 35 mm

and L 2 = 178 mm), the ratio is 5.1. Therefore, S1 can be calculated as follows:
Procedure 905-5.2.
MA905-5.1 212 07
If a non-standard tool is used, S1 can be

calculated as follows:
MAN B&W Diesel A/S
Page 5 (8)
905.5.2

Dismantling
Dismantling
905.5.2
1.
Dismantling of the axial vibration damper is carried out from the crankcase of cyl. No. 1.
1. Turn the engine to 90 after TDC.
Dismount the lubricating oil pipes for the
main bearing and axial vibration damper.
2. Loosen and remove the screws from the
damper housing upper part.
BG905-7.2 28 01
Only the upper part of the housing needs to

be removed, while the lower half remains
mounted on the bedplate.
3. Mount the lifting bracket and a shackle on
the upper part.
Dismount the plug screw above the axial vibration damper, on the fore end of the
frame box.
2.
By means of a tackle, mounted below the

foreend platform, and a wire rope, separate
and raise the upper part of the damper
housing to a position in which it is possible
to change the oil seals and springs.
Note!
BG905-7.2 28 02
Before starting work below the suspended upper part, secure the upper part
with, e.g. a wire rope or another tackle.
3.
BG905-5.2 216 03
D05-25
Page 6 (8)
MAN B&W Diesel A/S
905-5.3
Overhaul
Overhaul
905-5.3
1.
1. Dismantle and remove the springs from the

oil sealing rings.
Remove the oil sealing rings.
Note!
When mounting the new oil sealing rings,

first insert the lower half of the rings in the
lower housing.
Then press the tension springs into the
groove between the oil sealing ring half and
the housing.
HG905-5.2 201 01
It is recommended to discard both the

springs and the oil sealing rings.
2.
2. Mount all the upper halves of the oil sealing

rings in such a way that the clearance at
both the 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.
The lower half of the oil sealing rings will

protrude above the centreline.
HG905-5.2 201 02
Note!
MAN B&W Diesel A/S
Page 7 (8)
905-5.4

Mounting
Mounting
905-5.4
1.
1. Release and carefully lower the upper part

of the damper housing.
D05-25
When reaching the oil sealing rings, take

care that the rings enter the sealing ring
grooves correctly.
Before landing the upper part on the lower
part, be sure that the guide pins have entered the guide pin holes.
2. Mount the vertical and horizontal screws.
Tighten the screws. See Data.
Note!
BG905-5.4 223 01

behind.
Mount the lubricating oil pipes.
Mount the plug screw on the fore end of the
frame box.
2.
D05-17
D05-21
Note!
After overhaul of the axial vibration
damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
BG905-7.2 28 06
D05-23
Page 8 (8)
MAN B&W Diesel A/S
Crankshaft, Thrust Shaft, Main Bearing,

Etc., Panel
Plate
P90551-0198
Crankshaft, Thrust Shaft, Main Bearing, Etc., Panel

0198
P90551
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90551-0198
Item
No.
015
027
052
076
088
090
100
111
123
135
Crankshaft, Thrust Shaft, Main Bearing,

Etc., Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Handle for dimantling of main bearing
shell
Lifting tool for main bearing cap
Dismantling tool for main bearing shell
Mounting tool for thin bearing shell
Tool for turning out segment
Lifting tool for axial damper
Retaining tool for main bearing shell
Lifting tool for relief valve
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90561-0087
Page 1 (2)
Plate
P90561-0087
Item
No.
021
033
045
057
069
070
082
094
104
200
Page 2 (2)
Item Description
Item
No.
Item Description
Hydraulic jack, upper, complete

Hydraulic jack, lower, complete
Support
Extension stud
Tommy bar
Spanner
Stud setter
MAN B&W Diesel A/S
Crankshaft - Tools
Plate
P90562-0124
Crankshaft - Tools
0124
P90562
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90562-0124
Item
No.
015
027
039
Crankshaft - Tools
Item Description
Item
No.
Item Description
Support
Screw with special head
Nut
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90564-0020

0020
P90564
Flange on end of crankshaft
Flange on end cover fore
Z
When ordering item 016 or 028, please always state measurement Z
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90564-0020
Item
No.
016
028
041
053
Item Description
Item
No.
Item Description
Measuring instruments, axial vibration

damper
Shaft, measuring instruments axial vibration
Measuring instruments, axial vibration
damper
Handle - sundry types
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90572-0003

0003
P90572
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90572-0003
Item
No.
010
021
045
057
Item Description
Item
No.
Item Description
Measuring tool main bearing

clearence
Calibration tool
Key, hexagon socket screws
Wooden box
Page 2 (2)
MAN B&W Diesel A/S
906 - Control Gear

106-01
906-01
106-02
906-02
106-03
906-03
106-04
906-04
106-06
906-06
90651
90664
90668
0055
0243
0064
0228
0040
0217
0042
0225
0009
0203
0181
0003
0006
Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearing, Data
Camshaft Bearings
Replacement of Cams on Camshaft, Data
Replacement of Cams on Camshaft
Chain Drive and Camshaft - Panel
Crankshaft - Pin Gauge
Camshaft - Pin Gauge
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Chains
MAN B&W Diesel
106-1
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
3 chain
D06-18
Teeth on chain wheel, max. wear
2,5
mm
D06-19
Original length (chain pitch x 10 links)
762
mm
D06-20
10 links measurements + 1% of a tensioned chain = scrapping of chain
769,5
mm
Page 1 (2)
Chains
106-1
MAN B&W Diesel
Data
Plate
P90651
Page 2 (2)
Item No.
Description
Chain Drive and Camshaft - Panel
Chains
MAN B&W Diesel
906-1.1
Checking
1. The engine is equipped with a drive chain

for the camshaft.
1.
The chain is to be checked and, if necessary, dismantled and mounted in the same
way.
2. The chain can be accessed from within the
chainwheel frame.
Make a general inspection for loose

bolts and screws.
Inspect lube oil pipes for damage, and
check jet nozzles for possible stoppages or deformations.
Examine the rubber track of the guideways for cracks or other damage.
M906010243C01
3. Carry out the inspection as follows:
4.
Replace the guideway if bits have

started to be plucked out of the rubber track.
4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement
(See Data).
B
M906010243C02
Measurements are best taken by placing a

short straight-edge over points A and B
and then measuring the distance D06-18.
D0618
A
Page 1 (5)
906-1.1
Chains
Checking
5.
MAN B&W Diesel
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.
M906010238C05
In most cases, scratches caused by the

side plates of the chain will be found on
the sides of the teeth. Such scratches can
generally be considered normal.
6. The chains for the camshaft drive are
matched together to ensure an even load
distribution.
To keep such matching chains in their
pairs, the side plates of the outer link nearest to the assembled link have been
marked with year, month, day and chain
number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 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
defective rollers and side plates.
Check that the chain rollers can run freely
and that the chain links can freely move on
the pin and bushing (that they are not
seized between the pin and the bushing).
It is normal, however, that the rollers get
light, circumferential scratches during the
running-in period. These fine scratches are
of no importance and need not be considered.
It is recommended that each single link is
checked.
Page 2 (5)
Chains
MAN B&W Diesel
906-1.1
Checking
7. Check chain wear by measuring the length

of 10 chain links. Use two master squares
and a steel measuring tape as shown on
the sketch. Compare the result with the
value given in Data.
7.
If necessary, adjust the chain tightener.

Ma
M906010243C07
20
06
x.D
D0619
D0620
Page 3 (5)
906-1.2
Chains
Dismantling
1.
MAN B&W Diesel
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!
M906010243C01
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.
2.
When a new link is fitted in one chain,

the corresponding link in the other chain
must also be renewed.
1. Remove the tension on the chain by loosening 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 disassembled, is in a favourable position for
the work.
M906010238D02
2. Mount a wire round the link rollers a short

distance from the disassembly point, and
tighten the wire lightly with a tackle.
3.
Protect the link rollers over which the wire

is wrapped.
Note!
If the chain is to be completely removed,
contact MAN B&W Diesel for further information.
The riveting of the pins that are to be
pressed out is to be chiselled or ground
away.
M906010238D03
3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alternately tightening the screws on the tool.
Page 4 (5)
Chains
MAN B&W Diesel
906-1.4
Mounting
Before assembling the inner and outer

links, clean the pins and bushings.
1.
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.
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).
M906010238M01
2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
Page 5 (5)
Chain Tightener
MAN B&W Diesel
106-2
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D06-21
Tightening angle = 12 hexagons
720
D06-25
Mechanical or blocked chain tightener, clearance
0,1
mm
Page 1 (2)
Chain Tightener
106-2
MAN B&W Diesel
Data
Plate
P91366
Page 2 (2)
Item No.
058
Description
Feeler gauge
Chain Tightener
906-2.3
Adjustment
Chain Tightener
S42MC
0228
Adjustment
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,

C and D to free the chain tightener bolt.
A
B
2. Turn the engine so that the slack part of the

chains is on the same side as the tightener
wheel.
If the engine is equipped with flyweights,
continue turning until the flyweights are
hanging vertically downwards.
Then tighten nut B as stated in D06-21

(see Data).
C
D
HG906-2.3 218 01
3. Tighten nut B on the chain tightener bolt

until there is a clearance between the shaft
and the nut as stated in D06-25.
2.
HM906-2.2 95 01
For chain wear, see Procedure 906-1.1.
3.
D06-25
HG906-2.3 218 03
D06-21
MAN B&W Diesel A/S
Page 1 (2)
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.
HG906-2.3 218 05
The number of times that retightening can

be carried out depends on when the limit for
scrapping the chain has been reached. See
Data page 106-1.
5.
HG906-2.3 218 05
Page 2 (2)
MAN B&W Diesel A/S
Camshaft
MAN B&W Diesel
106-3
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

Shut off fuel oil

Data
Ref.
D06-27
D06-28
D06-29
D06-30
Description
Max. permissible change in lead angle
corresponding to
Pin gauge for top dead centre of crankthrow No.1
Pin gauge for camshaft, check measurement
Value
Unit
2
2,2
355
238
mm
mm
mm
Page 1 (2)
Camshaft
106-3
MAN B&W Diesel
Data
Plate
Item No.
Description
P90664
P90668
Page 2 (2)
Camshaft
906-3.1
Checking
Camshaft
K98MC
0227
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.
Check the TDC of cylinder 1 against the
mark on the turning wheel.
HM906-7.0 56 01
1. Turn the crankthrow for cylinder 1 to TDC.
2. Check the TDC position with the pin gauge

on the crankthrow, D06-29.
M90603-0217C02
2.
MAN B&W Diesel A/S
Page 1 (3)
Camshaft
906-3.1
Checking
3.
3. Position the camshaft pin gauge in the centre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see D06-27
and D06-28.
4. Check and, if necessary, adjust the cylinder
lubricator.
See Procedure 903-2.1 and 903-2.3.
D06-30
NA906-3.1 207 03
D06-27
D06-28
5.
Check the setting of the starting air distributor.

5. When checking the camshaft position, also
check the running surface of the cams.
As the inspection must include the entire
surface of the cam, the cam should be
turned one complete revolution during the
inspection.
The running surface of the cam must be
completely smooth and bright.
NA906-3.1 207 05
6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a fine carborundum stone. Such light scratches can appear
if the roller guide and the cam are not correctly aligned.
GN906-3.1 203 06
6.
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.
Page 2 (3)
MAN B&W Diesel A/S
Camshaft
906-3.3
Adjustment
Adjustment
906-3.3
1.
NA906-3.3 207 01
1. If the chains prove to be so heavily worn

that the deviation between the measuring
points and the pin gauge has reached the
maximum value stated in Data, MAN B&W
Diesel should be contacted for further instructions.
MAN B&W Diesel A/S
D06-27
D06-28
Page 3 (3)
Camshaft Bearings
MAN B&W Diesel
106-4
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D06-31
Screws for bearing cap, tightening torque
50
Nm
D06-33
Clearance between cap/bearing housing
30.3
mm
D06-34
Bearing shell, max. wear
0.1
mm
D06-37
Camshaft bearing cap
D06-65
Bearing shell, minimum thickness
4
5.34
kg
mm
Page 1 (2)
Camshaft Bearings
106-4
MAN B&W Diesel
Data
Plate
Item No.
P91359
P91366
Page 2 (2)
Description
Torque Spanners
073
Camshaft Bearing
MAN B&W Diesel
1.
906-4.1
Checking
As the upper shell of the camshaft bearing assembly has been dispensed with on
this engine, it is no longer necessary to
measure the top clearance of the camshaft
bearing.
1.
Dismount the inspection covers from the

front of 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.
M906040225C01
Check for wipedout metal at the bearing

ends, and for fragments of metal in the
camshaft housing.
If no anomalies are found during the visual

inspection, dismantling need not be carried
out.
When checking the camshaft bearings, it is
recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 9085 and 9093.
Page 1 (5)
906-4.2
Camshaft Bearing
Dismantling
MAN B&W Diesel

Warning!
1.
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.

1.
Remove the inspection covers on each side

of the bearing from the camshaft housing.
M906040225D01
Dismount the lubricating oil connecting

pipe and the plug screws from the baseplate above the bearing in question.
Lift the roller guide of the exhaust valve actuator. See Procedure 9087.
2.
2. Loosen the bearing cap screws through the
holes in the baseplate.
Remove the screws from the bearing cap.
Remove the bearing cap from the housing.
M906040225D02
D0637
Page 2 (5)
Camshaft Bearing
MAN B&W Diesel
906-4.2
Dismantling
3. Place a hydraulic jack between two pieces

of wood in the camshaft housing underneath the camshaft, close to the bearing.
3.
Max. 20/100 mm
Place a dial gauge on the camshaft, and lift

the camshaft 0.20 mm.
4. Press lightly on the upper edge of the shell
to turn the shell up over the camshaft.
M906040225D03
Remove the shell from the camshaft housing.
M906040225D04
4.
Page 3 (5)
906-4.3
Camshaft Bearing
Overhaul
1.
1.
MAN B&W Diesel

For assessment of the bearing condition,
see Volume I OPERATION, Chapter 708
Bearings.
M906040225O01
Inspect the entire surface of the bearing

journal for seizures.
D0634
D0665
If seizures are found on the bearing journal

surface (on account of bearing breakdown),
polish the surface with a ne carborundum
stone to reestablish 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 insufcient or
entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication.
Measure the thickness of the bearing shell
with a micrometer to check the amount of
wear.
Page 4 (5)
Camshaft Bearing
MAN B&W Diesel
1.
906-4.4
Mounting
Clean the bearing journal, the bearing support and the bearing shell.
1.
2. Coat the bearing journal and the bearing

shell with plenty of lubricating oil. Mount
the shell on the camshaft, and turn it into
place.
3. Place the bearing cap on the camshaft and

mount the outermost bearing cap screw.
Note!
Be careful not to scratch the camshaft
surface.
M906040225M01
Relieve the hydraulic jack of pressure

to lower the camshaft. Remove the dial
gauge, the pieces of wood and the hydraulic jack from the camshaft housing.
2.
Tighten the outermost screw lightly by

hand until the clearance given in D0633
is reached. Then mount and tighten the innermost screw with a torque spanner. See
Data D0631. This procedure ensures that
the outermost screw will obtain the correct
torque.
Check the clearance D0633 on both sides

of the camshaft. Then mount the lubricating
oil pipe and the plug screws in the baseplate.
D0633
M906040225M02
Check the torque on the outermost screw

with a torque spanner.
D0631
3.
4. Lower the exhaust valve actuator roller
guide. See Procedure 908-7.
M906040225M03
5. Clean the camshaft housing and mount the

inspection covers.
Page 5 (5)

MAN B&W Diesel
106-6
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
Description
Value
Unit
D06-47
Exhaust cam screws, tightening torque
120
Nm
D06-49
Fuel Cam screws, tightening torque
120
Nm
D06-50
Fuel cam, marking scratch
40
mm
D06-51
Fuel cam, axial movement
70
mm
D06-52
Exhaust cam, marking scratch
40
mm
D06-53
Exhaust cam, axial movement
95
mm
Page 1 (2)
Replacement of cams on Camshaft
106-6
MAN B&W Diesel
Data
Plate
Item No.
Description
P90851
173
Lifting tool for exhaust valve roller guide
P90951
082
Lifting tool for fuel pump roller guide
P91351
022
P91351
046
P91351
058
P91351
105
P91351
166
Angle union
P91351
201
Quick coupling, male
P91351
213
Quick coupling, female
P91351
225
Disc, round-plain, Cu 11x3 mm
P91351
237
Bleeder screw
P91351
249
P91359
P91366
Page 2 (2)
Torque Spanners
073
906-6.2
Dismantling
S42MC
0203
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft
housing.
2. Lift the roller guide from the cam in question. See Procedures 908-5 or 909-5.
3. Turn the camshaft so that the marking
scratch can be seen.
XZ906-6.2 201 01
4. Extend the marking scratch on the shaft by

D06-50. See Data.
XZ906-6.2 201 02
2.
XZ906-6.2 201 04
4.
0$1% :'LHVHO$6
D06-50
Page 1 (7)
906-6.2
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 hydraulic 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.
XZ906-6.2 201 05
7. The cam should be moved as stated in

D06-51 to be sure that it gets free of the liner for the roller guide.
8. In case the cam cannot be moved as described in item 6, MAN B&W should be contacted for further instructions.
XZ906-6.2 201 06
6.
7.
XZ906-6.2 201 07
D06-51
Page 2 (7)
D06-51
0$1% :'LHVHO$6
906-6.2
Dismantling
9.
Exhaust Cam
9. Remove the front cover of the camshaft
housing.
10. Lift the roller guide from the cam in question. See Procedure 908-5.
Extend the marking scratch on the exhaust

cam onto the camshaft by D06-52. See Data.
XZ906-6.2 201 01
11. Extend the marking scratch on the indicator

drive cam onto the camshaft.
XZ906-6.2 201 10
10.
XZ906-6.2 201 11
11.
0$1% :'LHVHO$6
D06-52
Page 3 (7)
906-6.2

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 hydraulic high-pressure pump.
Apply oil pressure to the cam, using the
high-pressure pump.
XZ906-6.2 201 12
When oil seeps out along the cam, press

the cam sideways, in the direction towards
the aft end of the engine.
XZ906-6.2 201 13
13.
XZ906-6.2 201 14
14.
Page 4 (7)
0$1% :'LHVHO$6
906-6.2
Dismantling
15.
15. The cam should be moved as stated in

D06-53 to be sure that it gets free of the liner 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.
XZ906-6.2 201 15
D06-53
0$1% :'LHVHO$6
D06-53
Page 5 (7)
906-6.4

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 opposite the roller.
Tighten the screws just hard enough to
avoid that the cam slips when the roller
guide is lowered onto the cam.
XZ906-6.4 201 01
Measure the fuel cam lead (see Procedures

909-1 and 909-2) and adjust if necessary.
Tighten the screws to D06-49 and check
that the gap is still equal at both sides.
Lock the screws with Loctite, type 242
(EN243S).
2.
3. Mount the cover on the front of the camshaft housing.
XZ906-6.4 201 02
D06-49
Page 6 (7)
0$1% :'LHVHO$6
906-6.4
Mounting
4.
Exhaust Cam
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.
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.
XZ906-6.4 201 04
5. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.
5.
6. Make sure that the marking scratches on

the cam and the camshaft coincide, and
that the running surface of the cam is opposite the roller.
Tighten the screws just hard enough to
avoid that the cam slips when the roller
guide is lowered onto the cam.
Tighten the screws to D06-47 and check

that the gap is still equal at both sides.
Lock the screws with Loctite, type 242
(EN243S).
XZ906-6.4 201 05
Measure the fuel cam lead (see Procedure

908-7) and adjust if necessary.
7. Mount the cover on the front of the camshaft housing.
XZ906-6.4 201 06
6.
D06-47
D06-49
0$1% :'LHVHO$6
Page 7 (7)
Chain Drive and Camshaft Panel
Plate
P90651-0181

0181
P90651
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90651-0181
Item
No.
019
020
044
056
068
140
Item Description
Item
No.
Item Description
Tool panel
Name plate
Face impact wrench, fuel cam
Chain assembling tool
Chain disassembling tool
Hydraulic tool - coupling
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90664-0003

0003
P90664
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90664-0003
Item
No.
010
Item Description
Item
No.
Item Description
Pin gauge for crankshaft
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90668-0006

0006
P90668
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90668-0006
Item
No.
011
Item Description
Item
No.
Item Description
Pin gauge for camshaft
Page 2 (2)
MAN B&W Diesel A/S

107-01
907-01
107-02
907-02
0021
0220
0044
0213
Starting Air Distributor, Data

Starting Air Distributor
Start Air Valve, Data
Starting Air Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S

MAN B&W Diesel
107-1
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D07-01
Gear wheel on camshaft, tightening torque
D07-03
Value
Unit
25
Nm
Clearance between gear wheel and bushing:
0.9 - 1.6
mm
D07-04
Clearance with roller in outermost position:
1.0 - 3.0
mm
D07-05
Clearance with roller in innermost position:
1.0 - 2.0
mm
Page 1 (2)
107-1
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
907-1.1
Checking
1. Turn the engine in AHEAD direction to bring

the piston of cylinder No. 1 to TDC.
1.
Check with the pin gauge.

2. Remove the plug screw and gasket from
the side of the distributor housing, and insert check pin K in slot S.
3. If the check pin cannot enter the slot, i.e. if

the slot is not aligned with the hole in the
distributor housing, the air distributor must
be adjusted.
M907010220C01
If pin K is not available, use the cylindrical

end of a drill of a suitable size.
2.
M907010220C02
Page 1 (4)
907-1.3
Adjustment
MAN B&W Diesel
1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.
1.
Check with the pin gauge.

2. Dismount the end cover of the camshaft
housing, along with the starting air distributor, from the engine.
Loosen the bolts on the gear wheel.
M907010220C01
Turn the coupling together with the distributor disc until check pin K enters slot S
in the disc and keep it there.
Tighten the gear wheel bolts as stated in
Data D07-01.
2.
M907010220O02
D0701
Page 2 (4)

MAN B&W Diesel
907-1.3
Adjustment
3. Check the clearance D07-03 between the

coupling wheel and the bushing.
If clearance does not correspond with D0703, please contact MAN B&W Diesel for
advice.
3.
4. Remove check pin K from the distributor

housing and mount the gasket and plug
screw.
M907010220O03
Mount the covers on the camshaft housing.
D0703
4.
M907010220O04
Page 3 (4)
907-1.3

Adjustment
MAN B&W Diesel
5. Check the clearance between the roller and

the two interlocking valves with the roller in
its innermost and outermost positions, respectively (ASTERN and AHEAD).
5.
M907010220O05
D0704
Page 4 (4)
D0705
Starting Air Valve

MAN B&W Diesel
107-2
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D07-09
Piston tightening torque
58
Nm
D07-10
Valve tightening torque
25
Nm
D07-12
Starting air valve
kg
Page 1 (2)
Starting Air Valve
107-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90151
095
Grinding ring for starting valve
P90151
105
Grinding handle for starting valve
Page 2 (2)
Starting Air Valve
907-2.1
Checking
Starting Air Valve
S42MC
0213
Checking
907-2.1
1.
1. When the starting air valve has been overhauled, 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 fully.
2. Shut off the air supply
Check that the valve closes fully.
BM907-2.1 206 01
3. Repeat steps 1 and 2 a couple of times.
BM907-2.1 206 02
2.
MAN B&W Diesel A/S
Page 1 (5)
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.
Unscrew the starting valve screws.
BG901-2.2 77 01
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
2.
BM907-2.2 206 02
D07-12
Page 2 (5)
MAN B&W Diesel A/S
Starting Air Valve
907-2.3
Overhaul
Overhaul
907-2.3
1.
1. Remove the top cover fixing screws and remove the cover.
Remove and discard the gasket.
2. Remove the split pin and screw off the nut
from the valve spindle.
Remove the disc, the piston, the valve
spring, the distance pipe, and the liner from
the top end of the valve housing.
BG907-2.3 208 01
Remove the valve spindle from the bottom

end of the valve housing. Remove and discard the O-ring.
BG907-2.3 208 02
2.
MAN B&W Diesel A/S
Page 3 (5)
907-2.3
Starting Air Valve

Overhaul
3.
3. Grind the valve housing seating with the

grinding ring after applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle and housing to match, using the face wrench to rotate the valve spindle.
Carborundum No. 500.
4. Thoroughly clean all parts before reassembling the valve.
Lubricate all internal parts (sliding surfaces) with, for instance, Molybdenum Disulphide, MoS 2.
BG907-2.3 208 03
First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring, the piston and the disc.
Mount the nut on the valve spindle and
tighten the nut, see D07-09.
Mount the split pin.
4.
Place a new gasket on the valve housing.
Mount and tighten the top cover.
Replace the O-ring on the valve housing.
BG907-2.3 208 04
If the starting air valve is not to be mounted

in the engine immediately after the overhaul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
Page 4 (5)
MAN B&W Diesel A/S
Starting Air Valve
907-2.4
Mounting
Mounting
907-2.4
1.
1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recondition the seat for the starting valve in the
bore.
If not already done, replace the O-ring on
the overhauled valve and lubricate with
Never Seize or Molybdenum Disulphide,
MoS 2.
For overhaul, see Procedure 907-2.3.
Mount and tighten the screws as stated in

Data.
AM907-4.0 49 08
2. Mount the valve in the cylinder cover.
Mount the control air pipe and turn on starting air and control air.
2.
BG901-2.2 77 03
D07-10
MAN B&W Diesel A/S
Page 5 (5)
908 - Exhaust Valve

108-01
908-01
108-02
908-02
108-03
908-03
108-04
908-04
108-05
908-05
108-07
908-07
90851
90861
90862
90863
0049
0230
0091
0268
0055
0245
0039
0221
0016
0217
0034
0216
0206
0033
0042
0007
High-Pressure Pipe, Data

High-Pressure Pipe
Exhaust Valve, Data
Exhaust Valve
Exhaust Valve Actuator, Data
Exhaust Valve Actuator
Exhaust Valve Roller Guide, Data
Exaust Valve Roller Guide
Exhaust Valve Cam, Data
Exhaust Valve Cam
Exhaust Valve - Special Running, Data
Exhaust Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
High-Pressure Pipe
MAN B&W Diesel
108-1
Data

X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D08-01
High-pressure pipe, tightening torque
30
Nm
D08-03
High-pressure pipe
12
kg
Page 1 (2)
High-Pressure Pipe
108-1
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description
High-Pressure Pipe
MAN B&W Diesel
Dismantling
Double Pipe:
1.
908-1.2
1.
When replacing the hydraulic high-pressure

pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing surfaces.
2. 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.
D0803
M908010230D01
3. Remove the screws in both ends of the

high-pressure pipe. Lift the high-pressure
pipe away from the engine.
M908010227D04
2.
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
1.
MAN B&W Diesel
The two ends of the pipe are identical and

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

exhaust valve.
Remove and discard the O-rings from the
thrust piece and the thrust ange.
Clean and inspect the conical seats of the
high-pressure pipe and the thrust piece.
M908010227O01
Note!
2.
The seats cannot be reconditioned.

If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust ange upwards.
Remove the spring ring from the two-part
sleeve.
3. Remove the thrust ange from the pipe
end.
M908010227O02
Remove and discard the internal O-rings.

Mount new internal O-rings lubricated with
a little camshaft lubricating oil.
4. Assemble the high-pressure pipe in the reverse order to disassembling.
M908010227O03
3.
Page 2 (3)
High-Pressure Pipe
MAN B&W Diesel
1.
908-1.4
Mounting
Mount the hydraulic high-pressure pipe as

follows:
1.
Position the high-pressure pipe with the

sealing surfaces ush against the surfaces
of the exhaust valve/actuator. Take care not
to damage the O-rings.
D0803
Mount and lightly tighten the screw by

hand. Ensure that there is a small clearance (approx. 4-6 mm) between the anges
of the pipe and the exhaust valve/actuator.
M908010230M01
2. After tting the pipe correctly in relation to

the exhaust valve and actuator, tighten up
the screws of the pressure anges diagonally, see Data.
D08-01
M90801-0230M02
2.
Page 3 (3)
Exhaust Valve
MAN B&W Diesel
108-2
Data

X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D08-04
D08-06
D08-07
D08-09
D08-10
D08-11
D08-12
D08-13
D08-14
D08-15
D08-16
D08-17
D08-18
D08-19
D08-20
D08-21
D08-24
D08-25
D08-26
D08-27
D08-28
D08-29
D08-30
D08-40
Safety valve, opening pressure

Oil cylinder, tightening torque
Safety valve, tightening torque
Bottom piece seat, grinding angle
Valve spindle seat, grinding angle
Bottom piece seat, max. grinding
Gap of bottom piece seat
Spindle, max. burn-off
Spindle, max. grinding
Spindle stem, measuring area, min.
Spindle stem, measuring area, max.
Spindle stem, min. diameter
Bushing max. diameter, top
Bushing max. diameter, bottom
Oil cylinder max. inside diameter
Piston rings, min. thickness
Exhaust valve, complete
Exhaust valve housing
Oil cylinder
Air cylinder
Spindle
Bottom piece
Air piston
Throttle valve, tightening torque
D13-01
D13-02

Value
Unit
21
110
50 - 80
29.9 - 30.0
30.3 - 30.4
2.3
0.5
5.0
2.0
145
205
29.8
30.5
32.0
36.1
1.5
200
120
26
12
16
15
2
50
bar
Nm
Nm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
kg
kg
Nm
900
800 - 990
bar
bar
Page 1 (2)
Exhaust Valve
108-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90851
077
Cone ring for pneumatic piston
P90851
089
Pressure tester for safety valve
P90851
090
Gauge for exhaust valve spindle
P90851
150
Gauge for exhaust valve bottom piece
P90851
185
Grinding ring for exhaust valve bottom piece
P90851
219
Eye bolts
P90862
Page 2 (2)
Exhaust Valve
MAN B&W Diesel
Checking
Checks during running

1.
908-2.1
1.
Check of valve spindle rotation:
The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the ridge on the
piston.
During engine operation, the spindle must
rotate. The rotation can vary with unit and
engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is
nished, lift the rotation indicator and lock
it in the top position.
M908020268C01
The engine must run when the valve function and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90 and let it rest on the air piston.
On Ridge
On Surface
2.
The indicator must not be in constant operation.
2. Check of bottom piece sealings:

With the exhaust valve mounted in the cylinder cover, check that the cooling water
inlet and outlet to the cylinder cover and
exhaust valve are open.
M908020262C02
Exhaust valve performance condition.

See volume I chapter 706 Performance
Evaluation.
Check the tightness of the sealing rings

between the bottom piece and the exhaust
valve housing. IF water ows from the small
bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is
leaking.
If water ows from the any of the rings, the
exhaust valve must be dismounted and the
sealing rings replaced.
Page 1 (22)
Exhaust Valve
908-2.1
Checking
MAN B&W Diesel
Check with stopped engine

3.
In connection with port stays, at an interval of
e.g. one month, an easy check of all exhaust
valves is recommended.
3. Check of spindle drop-down time:
Engage all rotation indicators on the exhaust valves.
SAFETY AIR
SUPPLY
AIR SUPPLY
EXHAUST VALVE
Shut off and release the spring air on the

valve next to the engine-side manoeuvring
stand.
Check the drop down time for all spindles:
M908020268C03
Spindles dropping down within 30 minutes: Check and overhaul, See next
step Check of Air Spring tightness.
Spindles dropping down between 30
minutes and 1 hour: Keep under observation.
CONTROL AIR
SUPPLY
Spindles dropping down after 1 hour:

OK.
When check of drop down time is nished,
lift the rotation indicators and lock them in
the top position.
Note!
If an air cylinder is tted with new sealing rings, the time the valve concerned is
closed may be considerably shorter than
15 minutes. The dropdown test should
not be carried out until after a runningin period of 500 hours on valves with
new sealing rings.
Page 2 (22)
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
4. Check of air spring tightness:
4.
Connect compressed air to the non return

valve (A) on the air cylinder.
Disconnect and remove the drain oil pipe
from the oil cylinder (C).
Open the ball-valve (B).
Check if air is coming out from:

The air bore (B): Leakage from spindle
stem sealing: change and overhaul.
Hole for drain oil (C): If yes, the leakage
comes from the air piston: change and
overhaul.
Remove the air supply to the non-return

valve on the air cylinder and check the
non-return valve for tightness.
The checks are for guidance only, minor
leaks are difcult to detect.
M90802-0268C04
Check the safety valve (D). If air is coming out: change and overhaul.
Page 3 (22)
908-2.2
Exhaust Valve
Dismantling
1.
1.
MAN B&W Diesel
Close off cooling water:

Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections:

Dismount the high-pressure pipe for the
hydraulic valve actuation.
See Procedure 908-1.2
M90802-0268D01
Dismount the return oil pipe from the exhaust valve.
M90802-0268D02
2.
Page 4 (22)
Exhaust Valve
MAN B&W Diesel
908-2.2
Dismantling
3. Disconnect pipe connections:
3.
Disconnect the cooling water connections

from the exhaust valve. Disconnect the air
pipes for the air spring and the sealing air
arrangement.
Remove the plate jacket and insulation
from the intermediate pipe.
Support the intermediate pipe by e.g. a

chain block and remove the screws.
4. Dismantling of nuts:
Remove the protective caps from the exhaust valve studs.
M90802-0268D03
Loosen the screws which attach the intermediate pipe to the exhaust valve housing.
4.
D1302
Loosen and remove the nuts hydraulically,

see Data.
M908020268D04
For use of hydraulic tools, See Procedure

913-1.
Page 5 (22)
908-2.2
Exhaust Valve
Dismantling
MAN B&W Diesel
5. Lift of exhaust valve:
5.
D0824
Check all connections to the valve are removed.

Attach the crane to the eye bolt tted on
top of the valve and start lifting the exhaust
valve. During the lift - check that 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 seating and sealing surfaces of the bore, if required.
M908020268D05
For overhaul of the exhaust valve, see Procedure 908-2.3.
Page 6 (22)
Exhaust Valve
MAN B&W Diesel
1.
908-2.3
Overhaul
Oil cylinder:
1.
Place the exhaust valve on a wooden support on the platform.
D0826
Remove the nuts from the oil cylinder.

Lift away and place the oil cylinder on a
wooden support.
2. Sealing air control unit:
M908020268O01
Loosen the union nuts. Unscrew and remove the sealing air control unit.
M908020268O02
2.
Page 7 (22)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
3. Conical locking ring:
3.
Relieve the air pressure through the nonreturn valve from below the piston. Use
a small screwdriver to press the ball into
the non-return valve. Cover the non-return
valve with a rag to catch the oil drops.
Remove the four screws from the ange
on top of the air piston and dismount the
ange.
M908020268O03
Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
4. Spindle:
4.
D0824
Use the oil cylinder as a lifting tool for the

exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
so that the load from the valve housing is
evenly distributed.
M908020268O04
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 spindle.
Page 8 (22)
D0828
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
5. Bottom piece:
5.
Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
D0825
If the bottom piece has become stuck, use

a tin hammer to release it.
Lift the valve housing away and land it on a
Remove the oil cylinder.
6. Air piston and cylinder:
Dismount the air piston from the air cylinder.
Mount two long screws in the air cylinder

and dismount the air cylinder.
Remove and discard the O-ring on the air
cylinder.
M908020268O05
Dismount the non-return valve from the air

cylinder/valve housing.
6.
D0829
D08-30
M90802-0268O06
D08-27
Page 9 (22)
Exhaust Valve
908-2.3
Overhaul
7.
7.
D0818
MAN B&W Diesel

Guide bushing:
Clean the exhaust valve housing.
Inspect the bushing in the spindle guide for
wear and measure the top and bottom diameters. See Data.
8. Bushing renewal:
M908020262O06
If it proves necessary to replace the bushing:

Place the valve housing on one side.
D0819
Knock out the bushing with a hammer and

a suitable mandrel.
Return the housing to an upright position.
8.
Fit a new bushing.
9. Bottom piece inspection:
Before cleaning the bottom piece, See Volume I, supplement 707-03.
M908020262O07
Inspect and evaluate the seating according

to Volume I.
M908020256O09
9.
Page 10 (22)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
10. Bottom piece measuring:
G3
10.
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.
D0812
Use the bottom piece template and a feeler

gauge, take measurements G2 and G3. All
measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating.
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 recommended.
D0811
M908020262O09
For maximum wear or grinding, see Data

D08-11 and D08-12.
D0809
G2
11.
11. Bottom piece sealing face:
Use carborundum 200 and the special

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.
M908020262O10
If necessary, grind the outside seating.
12. Bottom piece sealing rings:

12.
Make sure that the grooves for the sealing
rings are clean.
M908020262O11
Mount new sealing rings on the bottom

piece.
Page 11 (22)
908-2.3
Exhaust Valve
Overhaul
13.
MAN B&W Diesel
13. Bottom piece mounting:

exhaust valve housing.
Check the face on the valve housing is
clean.
If tted, 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 bottom piece. Mount and tighten the retaining
screws for the bottom piece.
14. Spindle inspection:
M90802-0268O13
Before cleaning the spindle, See Volume I,

supplement 707-03.
Inspect and evaluate the spindle according
to Volume I.
M908020256O14
14.
Page 12 (22)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
15. Spindle burn-off and grinding check:
15.
G1
In connection with evaluation of the spindle according to Volume I, burn-off and

wear or the total amount the seat has been
ground are measured as described below.
The burn-off F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge.
F1
M908020256O15
For the maximum allowable burn-off, see

Data D08-13.
D0814
D0810
A
D0813
D08-16
If necessary to grind the seat, see Data

D08-10 for correct grinding angle.
D08-15
16.
For maximum seat grinding, see Data D08
14.
16. Spindle stem check:
D08-17
In connection with evaluation of the spindle

according to Volume I, the spindle stem
wear is measured as described below.
Check the spindle stem for wear in the
area D08-15 to D08-16 measured from the
top of the spindle.
If the exhaust valve spindle needs reconditioning, contact MAN B&W Diesel for advice.
M90802-0268O14
For minimum stem diameter, see Data D08

-17.
Page 13 (22)
908-2.3
Exhaust Valve
Overhaul
17.
MAN B&W Diesel
17. Spindle mounting:

Lubricate the inside of the bushing in the
spindle guide with plenty of lubricating oil.
exhaust valve housing.
Carefully land the exhaust valve housing
with the bottom piece on the exhaust valve
spindle.
Remove the oil cylinder.
18. Air cylinder:
Dismount the safety valve housing from the
air cylinder.
M908020268O15
Disassemble the stufng box for the spindle stem, discard the sealing rings.
Clean the air cylinder and blow through all
bores in the air cylinder.
Check the bottom of the air cylinder for
possible coke, remove visible coke deposits.
18.
Reassemble the spindle stem stufng box
with new sealing rings, see the sketch.
Mount a new O-ring in the groove on the
outside of the air cylinder.
Fit a new or overhauled safety valve with
housing.
M908020268O16
For check of the safety valve see next step.
Page 14 (22)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
19. Safety valve:
19.
D0804
Unscrew the safety valve from the housing

Place the safety valve in the pressure testing device. Connect the testing device with
the high pressure pump by means of a
hose.
If the opening pressure is not correct, loosen the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated. Tighten the lock nut
and test the opening pressure once more.
Mount a new gasket and a new O-ring on
the safety valve. Mount the safety valve
in the housing. For tightening torque see
Data.
M908020268O17
Check the opening pressure, see Data.
D0807
20.
Finally, mount the protective cap.

20. Air cylinder mounting:
Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines
are not equipped with the locating pin
Note!
Take care not to damage the O-rings in
the inside the air cylinder.
M908020268O18
Lubricate the O-rings in the spindle bushing inside the air cylinder.
Page 15 (22)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
21. Air piston seals:

21.
5 min
Check the teon guide ring and teon

sealing ring for wear, if it is necessary to
replace 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.
100C
M908020267O29
Note!
22.
Before mounting, heat the new teon

rings in 100C hot water for at least ve
minutes. When mounting the teon rings,
be careful not to damage the running
surfaces.
After mounting, compress the teon rings
by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new O-rings in the inside grooves of
the air piston.
22. Air piston mounting:
Fit the conical guide ring for the air piston
on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press
the air piston down in the cylinder
M90802-0268O19
Remove the conical guide ring from the air

cylinder.
Page 16 (22)
Mount a new O-ring on the air cylinder.

Mount the non return valve for spring air.
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
23. Locking ring:

23.
Mount the two part conical locking ring and
apply compressed air below the air piston
to lift the piston.
Mount the ange on top of the air piston
and, by means of the four screws, tighten
the air piston and the ange together.
24. Oil cylinder:

Unscrew the cover for the throttle valve.
Unscrew and clean the throttle valve. Remove and discard the sealing disc. Check
and clean the bore in the top of the oil cylinder.
M908020268O20
On valve models where the bolts are designed for securing, secure the bolts. See
Procedure 913-7.
24.
Place the oil cylinder in a horizontal position. Remove the ange and take out the
piston. Inspect the bore in the oil cylinder
for scoring. Measure the cylinder diameter.
If the diameter of the oil cylinder exceeds
Data D08-20, send the complete oil cylinder to an authorised MAN B&W workshop
for overhaul.
M90802-0268O21
D08-20
Page 17 (22)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
25. Oil piston:
25.
Top
Remove the piston rings from the oil piston and check them for wear. If the thickness of the rings has worn down to the
minimum, see Data, discard the rings and
mount new ones. Check that the TOP mark
on the piston rings faces upwards, when
mounting.
26. Oil cylinder assembly:
M908020253O42
D0821
Mount the piston and the ange in the oil

cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright position. Mount a new sealing disc in the bore
for the throttle valve. Screw the throttle
valve into the bore. Mount the cover for the
throttle valve with a new gasket.
26.
M90802-0268O22
D08-40
Page 18 (22)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
27. Oil cylinder mounting:
27.
Mount the overhauled oil cylinder on top

of the air cylinder.
D0806
Mount and tighten the nuts. See Data.

28. Sealing air control unit:
Remove the lter plug screw from the sealing air control unit. Clean and check the
lter plug screw, and replace the O-ring.
Loosen and remove the screws and cover
the sealing air valve spindle in the control
unit. Remove the valve spindle and check
the sealing rings and the spring. If necessary, replace them.
Re-t the valve spindle and spring, and

tighten the cover, re-t the lter plug screw.
Mount the sealing air control unit on the
exhaust valve. Tighten the union nuts.
M908020268O23
Clean the housing and check all bores are

clean.
M90802-0268O24
28.
Page 19 (22)
Exhaust Valve
908-2.4
Mounting
1.
1.
MAN B&W Diesel

Checks before mounting:
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve is checked and prepared as follows:
D08-24
Connect compressed air to the air cylinder

to close the valve.
Lift up the valve with the engine room
crane.
Check that a 1.0 mm feeler gauge can be
inserted about 15 mm into gap G3, to ensure that there is a clearance between the
outer parts of the seating faces of valve
housing and spindle.
M90802-0268M01
Carry out the drop down test as described

in procedure 908-2.1.
Note!
2.
D08-24
If the air cylinder is tted with new sealing 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
period of 500 hours on valves with new
sealing rings.
Check the valve is tted with new sealingrings in the grooves on the bottom piece.
2. Exhaust valve landing:
Close the valve with compressed air.
Lubricate the sealing rings with Vaseline
and the threads of the studs with anti-seizure paste.
M90802-0268M02
Position the valve in the cylinder cover

bore, guiding it in accordance with the exhaust anges. Depending on model either
the guide pin on the exhaust side of the
exhaust valve or the water connection on
the manoeuvring side must t.
Page 20 (22)
Exhaust Valve
MAN B&W Diesel
908-2.4
Mounting
3. Mounting of nuts:
3.
Mount and tighten the nuts hydraulically,

see Data.
D13-01
For use of hydraulic tools, See Procedure

913-1.
Mount the protective caps on the exhaust
valve studs.
Connect the intermediate pipe to the exhaust valve.

Mount and tighten the screws to the exhaust valve housing.
Mount the insulation and plate jacket for
the intermediate pipe.
M90802-0268M03
4. Mount the pipe connections:
4.
Mount the cooling water connections for

the exhaust valve. Fit the air pipes for the
air spring and for the sealing air arrangement.
Mount the high-pressure pipe for the hydraulic valve actuation.

Mount the return oil pipe to the exhaust
valve.
5.
M90802-0268M05
Check that all pipe connections are properly tightened.
M90802-0268M04
5. Mount the oil pipe connections:
Page 21 (22)
Exhaust Valve
908-2.4
Mounting
MAN B&W Diesel
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 between the bottom piece and the exhaust
valve housing. See Procedure 908-2.1.
7.
Air spring check:
M90802-0268M06
The air supply to the exhaust valve must

always be connected and pressurised before turning on the oil supply to the exhaust
valve actuator.
If the lubricating oil pumps have been
started before the exhaust valve pneumatic
springs are pressurise:
Engage the indicators on top of the exhaust valves and wait until the exhaust
valves are closed.
7.
M90802-0268M07
Closing of the exhaust valves are eased

if the lubrication oil pumps are stopped
and the actuators are drained at the drain
screws.
Closed Valve
Page 22 (22)
Open Valve

MAN B&W Diesel
108-3
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
Description
D08-20
Oil cylinder max. inside diameter
D08-21
Value
Unit
36.1
mm
Piston rings, min. thickness
1.5
mm
D08-32
Hydraulic actuator, tightening torque
350
Nm
D08-34
Hydraulic actuator, tightening angle
46
D08-35
Hydraulic actuator
32
kg
Page 1 (2)
108-3
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
1.
908-3.1
Checking
The nonreturn valve A is built into the oil

inlet pipe to the actuator.
1.
M908030245C01
To check the valve, disconnect and clean

it and connect a supply of working air (7
bar) to the outlet side of the valve (the side
facing the actuator). If an air ow is felt at
the inlet side of the valve, it must be overhauled.
Page 1 (4)
908-3.2
Dismantling
1.
1.
MAN B&W Diesel
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 camshaft housing to inspect the position of the
exhaust cam.
Dismount the oil inlet pipe from the exhaust
valve actuator.
M908030245D01
Dismount the screws of the highpressure

pipe ange, and lift away the highpressure
pipe. See Data.
See Procedure 9081.
2. Fit eye bolts in the threaded holes of the
actuator housing and hook on a tackle.
2.
D0835
Unscrew the nuts on the two short studs,

then loosen the nuts on the long studs successively until the tension of the roller guide
spring is relieved.
Dismount the nuts and lift the housing
carefully up, leaving the piston on the top
of the roller guide.
Remove the spring.
M908030245D02
3. Remove the locking plate for the piston.

Turn the piston 90 to free it from the bayonet joint.
90
M908030245D03
3.
Remove the piston from the roller guide.
Page 2 (4)

MAN B&W Diesel
1.
908-3.3
Overhaul
Clean the piston in kerosene and dry with

nonuffy rags.
1.
Top
D0821
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.
Inspect the sliding surfaces of the piston
for scratching or seizure marks.
2. Clean the oil cylinder and inspect the bores
for deposits.
If the bore is seized or has worn up to the

maximum diameter, see Data, send the oil
cylinder to an MAN B&W authorised workshop for reconditioning.
M908030245O01
Check the bore of the oil cylinder for possible scores and measure it for wear.
2.
M908030245O02
D0820
Page 3 (4)
908-3.4
Mounting
1.
1.
90
MAN B&W Diesel

Mount the actuator piston in the roller guide
and turn 90 to lock it in the bayonet joint.
Mount the locking plate and tighten, see
Procedure 9134. Lubricate the piston with
plenty of lubricating oil.
2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the
piston, taking care not to damage the piston rings.
M908030245M01
Mount the washers and the nuts on the two

long studs and tighten alternately until the
actuator housing rests rmly against the
roller guide housing.
Mount the washers and nuts on the two
short studs. Tighten all four nuts as stated
in Data.
2.
Note!
M90803-0245M02
D08-35
D09-32
or
D08-34
Either use tightening torque or tightening

angle. Do NOT use both.
3. Mount the oil inlet pipe on the exhaust
valve actuator.
Mount the hydraulic high pressure pipe.
See Procedure 9081.
M908030245M03
3.
Page 4 (4)
Exhaust Valve Roller Guide

MAN B&W Diesel
108-4
Data

X
X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D08-36
Bushing/shaft pin, max. clearance
D08-38
Roller guide complete
Value
Unit
0,5
9
mm
kg
Page 1 (2)
108-4
MAN B&W Diesel
Data
Plate
P91366
Page 2 (2)
Item No.
073
Description

MAN B&W Diesel
1.
908-4.1
Checking
The exhaust valve roller guide can be partially checked while mounted on the engine,
using the following procedure:
2.
Lift the roller guide.

2. Remove the camshaft inspection cover.
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 possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide housing.
M908040221C02
Turn the engine to provide the maximum

space between the roller guide and the
cam disc.
5.
D0836
3. A more suitable and reliable method is

to check the roller guide and the bearing
clearance when the roller guide is dismounted.
For dismantling of the roller guide see Procedure 908-4.2.
M908040221C05
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. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
scratches.
5. To measure the clearance in the roller
guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.
6. Place a dial gauge against the roller. Then
lift the roller as much as the clearance permits, which makes it possible to read the
clearance directly on the dial, see Data.
Page 1 (4)
908-4.2

Dismantling
1.
1.
MAN B&W Diesel
Dismantle the hydraulic actuator above the

exhaust valve roller guide.
M908040221D01
2. Lift the roller guide out of the roller guide

housing by hand. Take care not to damage
the sliding surfaces of the roller guide when
lifting.
2.
M908040221D02
D0838
Page 2 (4)

MAN B&W Diesel
1.
908-4.3
Overhaul
Inspect and check the exhaust valve roller

guide.
1.
2. It is recommended that the roller guide

should ONLY be overhauled/dismantled if
irregularities when turning the roller,
damage to the roller,
seizure marks on the slide surfaces,

have been observed during the checking of
the roller guide.
Note!
M908040221O01
larger clearance than stated on the Data

sheet,
3.
For disassembling of the roller guide,

contact an MAN B&W authorized repair
shop.
M908040221O03
3. If no irregularities are found, just clean and

lubricate the roller guide before remounting
it in the roller guide bushing.
Page 3 (4)
908-4.4

Mounting
1.
1.
D0838
MAN B&W Diesel

Clean and lubricate the sliding surfaces of
the roller and the roller guide and lower it
carefully into the roller guide bushing by
hand.
M908040221M01
2. Mount the actuator.

M908040221D01
2.
Page 4 (4)
108-5
Exhaust Valve Cam

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D08-39
Description
Check lifting height
MAN B&W Diesel A/S
Value
Unit
10
mm
Page 1 (2)
108-5
Exhaust Valve Cam

Data
Plate
Item No.
Description
P90851
173
P91351
010
P91351
058
P91351
166
Angle union
P91351
225
P91366
073
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve Cam
908-5.1
Checking
1. Turn the crank throw of the cylinder concerned in AHEAD direction until TDC.
Check and write down the angle indicated
on the turning wheel.
1.
2. Remove the high pressure pipe, see procedure 908-1.2

Mount and tighten the lifting tool for the
exhaust valve roller guide to the actuator
piston (remove the screws for tightening to
the actuator housing and do not lift the
roller guide).
Mount a dial gauge (measuring range 0.00
- 20.00 mm) on the lifting tool for the exhaust valve roller guide.
Reset the scale and the pointer.
Press the dial gauge against the face of the
actuator housing until the reading D08-39 +
1.00 mm is obtained.
2.
Continue turning AHEAD until the roller

guide again is lifted to D08-39, and the dial
gauge gives the reading 1.00 mm.
Calculate the angle B, which is the number
of degrees the crank throw has turned from
TDC position to the present position.
M908050217C02
3. Turn the roller guide in AHEAD direction

until lifted to D08-39, and the dial gauge
gives the reading 1.00 mm and calculate
the angle A, which is the number of degrees the crank throw has turned from TDC
position to the present position.
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.
MAN B&W Diesel A/S
Page 1 (4)
908-5.1
Exhaust Valve Cam

Checking
4.
4. Calculate the lead angle as:

180 (A + B)/2
The lead angle is normally a negative figure.
The illustration shows the position of the
exhaust cam when the piston of the relevant cylinder is in TDC.
The position of the cam must be correct
within a tolerance of +/-0.5.
See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the lead angle
of the plant in question.
5.
5. The cam lead angle can be checked visually 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
Page 2 (4)
MAN B&W Diesel A/S
Exhaust Valve Cam
908-5.3
Adjustment
Normally, adjustment of the exhaust cams
should not be necessary. Before adjustment of any cams, see Volume I, Chapter
706.
1.
1. Remove the inspection cover from the

camshaft housing.
3. Turn the camshaft until there is access to

the oil duct in the exhaust cam through the
inspection hole.
If fitted, remove the plug from the oil duct
(using, for instance, a screwdriver).
M908050217O01
2. Dismount the exhaust valve high-pressure

pipe, see procedure 908-1.2.
Insert three copper gaskets in the oil duct.

3.
Mount one snap-on couplings in the oil
duct, but do not tighten it.
Fit a hose between the snap-on coupling
and the hydraulic high pressure pump.
Apply a light pressure to the hydraulic system 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 two
to five minutes before turning the cam.
Oil must sweep out with the pump running
during the operation.
M908050217O03
4. Mount the special spanner on the exhaust

cam disc, ensuring that the two pins enter
the holes in the cam.
4.
M908050217O04
Keep the cam pressurised during turning.
MAN B&W Diesel A/S
Page 3 (4)
908-5.3
Exhaust Valve Cam

Adjustment
5.
5. Turn the cam disc, using the fitted spanner,

until the desired change of lead is obtained. Check the change on the cam scale
To increase the lead angle and reduce the
compression pressure:
turn the cam disc ASTERN.
To reduce lead angle and increase the
compression pressure:
turn the cam disc AHEAD.
6. 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 plug again in the oil duct of the cam
disc.
After carrying out adjustment, measure the
exhaust cam lead again. See procedure
908-5.1.
Write down and file the new results for the
purpose of comparing with future measurements and adjustment.
7. Mount the inspection cover on the camshaft housing.
8. Mount the high pressure pipe for the exhaust valve. See procedure 908-1.4
9. After any adjustment of the cam position,
pcomp must be recorded and compared with
pcomp at a known engine reference load.
Page 4 (4)
MAN B&W Diesel A/S
108-7
Exhaust Valve Special Running

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
108-7
Exhaust Valve Special Running

Data
Plate
Item No.
Description
P90851
124
Tool for emergency open exhaust valve
P90851
173
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve
908-7
Special Running
Exhaust Valve
S35MC
0216
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:
2. Dismantle the hydraulic high-pressure pipe.

3. Dismantle the oil inlet pipe. Blank off the
connection from the main oil pipe with a
plug screw.
BM908-7.0 206 03
1. Lift the relevant fuel pump roller guide.

4.
4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.
Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible.
GN908-4.1 203 01
5. Position the lifting tool on the actuator and

screw the spindle into the top of the actuator piston.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position.
5.
BG908-5.0 53 02
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.
0$1% :'LHVHO$6
Page 1 (3)
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 air pipe and the non-return
valve on the aftmost side of the air cylinder
to let the air inside the air cylinder escape.
DM908-6.0 21 02
8. Dismantle the rotation indicator on the air

cylinder and mount the tool for opening of
the exhaust valve.
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.
BG908-6.0 13 04
8.
Page 2 (3)
0$1% :'LHVHO$6
Exhaust Valve
908-7
Special Running
9.
After overhaul of the cylinder unit, re-engage

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower
the roller guide on to the exhaust cam. Remove the tool.
10. If the engine has been running with the exhaust valve open, remove the tool mounted
in the air cylinder and mount the rotation indicator.
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 formation of a wear groove in the air piston
of the exhaust valve.
Re-connect the air supply to the air cylinder.
12. Mount the hydraulic high-pressure pipe.

13. Engage the fuel pump roller guide.
BG908-5.0 53 04
11. Remove the plug screw and mount the oil

inlet pipe.
BM908-7.0 206 11
11.
0$1% :'LHVHO$6
Page 3 (3)
MAN B&W Diesel A/S
Plate
P90851-0206
Page 1 (2)
Plate
P90851-0206
Item
No.
016
028
077
089
090
124
150
173
185
219
Page 2 (2)
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Conical ring, pneumatic piston
Pressure tester, safety valve
Gauge, exhaust valve spindle
Tool, emergency opening of exhaust
valve
Gauge, exhaust valve bottom piece
Lifting tool, exhaust valve roller guide
Grinding ring, exhaust valve bottom
piece
Eye bolts
MAN B&W Diesel A/S
Plate
P90861-0033

0033
P90861
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90861-0033
Item
No.
046
Item Description
Item
No.
Item Description
Grinding machine, complete
Notes:
Page 2 (2)
When ordering spare parts, please refer to the Chris Marine manual
MAN B&W Diesel A/S
Plate
P90862-0042

0042
P90862
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90862-0042
Item
No.
028
030
053
065
089
090
207
Item Description
Item
No.
Item Description
Jack-hydraulic, complete
Support
Tommy bar
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90863-0007
Page 1 (2)

0007
P90863
MAN B&W Diesel A/S
Plate
P90863-0007
Item
No.
011
Item Description
Item
No.
Item Description
Worktable
Page 2 (2)
MAN B&W Diesel A/S

109-01
909-01
109-03
909-03
109-04
909-04
109-05
909-05
109-06
909-06
109-07
909-07
109-08
909-08
109-09
909-09
10911
90911
10912
90912
10914
90914
10915
90915
10916
90916
90951
90961
90961
90966
0062
0239
0051
0228
0059
0221
0064
0222
0051
0218
0038
0210
0053
0222
0033
0212
0070
0236
0049
0223
0077
0235
0059
0227
0018
0212
0453
0037
0069
0008
Fuel Pump Lead, Data

Fuel Pump Lead
Fuel Pump Cam, Data
Fuel Pump Cam
Fuel Pump, Data
Fuel Pump
Fuel Pump Top Cover, Data
Fuel Pump Top Cover
Fuel Pump Barrel Assembly, Data
Fuel Pump Barrel Assembly
Fuel Pump Suction Valve, Data
Fuel Pump Suction Valve
Fuel Pump Puncture Valve, Data
Fuel Pump Puncture Valve
Fuel Pump Shock Absorber, Data
Fuel System Shock Absorber
Fuel Valve, Data
Fuel Valve
Spindle Guide, Data
Spindle Guide
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
Fuel Pump Spec. Runni
Fuel Pump Special Running
Fuel Valve and Fuel Pump - Panel
Fuel Valve - Tools
Fuel Valve - Tools
Fuel Valve Nozzle - Tools
MAN B&W Diesel A/S
90968
90974
90980
0001
0001
0001
Fuel Valve - Inspection Tools

Fuel Valve Nozzle - Cleaning Tools
Mounting Tools - Air Piston Seals
MAN B&W Diesel A/S
109-1
Fuel Pump Settings

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D09-01
One shim alters p-max
2.5
bar
D09-05
Nominal shim thickness
0.5
mm
D09-10
Max. number of shims
12
MAN B&W Diesel A/S
Page 1 (2)
109-1
Fuel Pump Settings

Data
Plate
P90951
Page 2 (2)
Item No.
200
Description
Hexagon head screw for topcover
MAN B&W Diesel A/S
Fuel Pump Settings
909-1.3
Adjustment
Fuel Pump Settings
S46MC-C
0239
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:
Remove the two screws in the threaded

holes of the top cover.
2. Screw the two dismantling screws (from the
tool panel) into the theaded holes of the top
cover, thus lifting the top cover to provide
space for inserting or removing shims.
EN909-1.3 239 01
1. Before Maximum Combustion Pressure

(p max) is adjusted, loosen the drain oil pipe
from the top cover and dismount the top
cover fixing nuts.
3.
To decrease p max, insert shims (delay injection).

One shim will alter p max approximately as
given in Data D09-01.
GN909-1.3 205 02
3. To increase p max, remove shims (advance

injection).
For nominal shim thickness, see Data D0905.
4.
For maximum inserted number of shims,

see Data D09-10.
Note down the new total shim thickness
(number of shims).
Note!
The individual p max value must not deviate more than 3 bar from the average
value for all cylinders.
GN909-1.3 205 03
4. Remove the dismantling screws, and press

down the top cover by hand. Mount the two
original screws to protect the threaded
holes. Mount and tighten the nuts for the
top cover, see Procedure 909-5.
0$1% :'LHVHO$6
Page 1 (2)
909-1.3
Fuel Pump Settings

Adjustment
5.
If the required p max adjustment cannot be

attained by inserting or removing shims, it
is possible to carry out the adjustment on
the fuel cam disc. Contact MAN B&W Diesel for advice.
MIP adjustment:
EN909-1.3 239 05.
5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump
index arm.
Increase index for higher p i.
Decrease index for lower p i.
Note!
The mean indicated pressure is one of
the most important parameters, in obtaining good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the average value for all cylinders. See Volume I,
Chapter 706.
Page 2 (2)
0$1% :'LHVHO$6
Fuel Pump Cam

MAN B&W Diesel
109-3
Data

X
X
X
X
X
X
Stopped engine
X Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
Fuel Pump Cam
109-3
MAN B&W Diesel
Data
Plate
Item No.
Description
P90651
044
Impact spanner for turning cam
P90951
045
Measuring tool for fuel pump
P91351
010
P91351
058
P91351
201
P91351
225
Page 2 (2)
Fuel Pump Cam
909-3.1
Checking
Fuel Pump Cam
S46MC-C
0228
Checking
909-3.1
1.
Fuel cam lead:

The lead C of the fuel cam is defined as the
number of mm the plunger is lifted from its bottom position when the main piston is in TDC.
1. To measure the fuel cam lead (top lift):
Dismantle the suction valve and the puncture valve. See Procedures 909-7.2 and
909-8.2.
x2
fuel cam
Make sure that the reversing mechanism is

in AHEAD direction.
ahead
EN909-3.1 228 00
2. Push down the measuring pin through the

top cover, until it rests against the pump
plunger.
x1 roller guide
Turn the engine until the lowest point of the

cam is found, use a calliper to find the
point.
Lowest position
of pump plunger
Main piston in TDC
3.
3. Measure the distance x from the top of the

measuring pin to the top cover.
Note down the result as x2.
4. Turn ahead until the main piston of the cylinder concerned is in TDC.
Again measure the distance x from the top
of the measuring tool to the top cover. Note
down the result as x1.
Calculate the fuel cam lead C (top lift) as:
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.
JG909-2.1 92 02
C = x1 x2 (mm)
4.
HM906-7.0 56 01
Remount the suction valve and the puncture valve.
0$1% :'LHVHO$6
Page 1 (3)
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 equipment, see Volume I, Chapter 706.
1. Remove the inspection cover from the camshaft housing.
GN909-3.3 203 01
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
2. Dismount the puncture valve and the suction valve from the fuel pump top cover, and
mount the measuring tool.
3. Turn the camshaft until there is access to
the oil ducts in the fuel cam through the inspection hole.
If fitted, remove the plugs from the oil ducts
(using, for instance, a screwdriver).
Insert three copper gaskets in each oil duct.
BM909-1.1 236 03
Mount snap-on couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snap-on couplings
and the distributor block and between the
distributor block and the hydraulic highpressure pump.
GN909-3.3 204 04
3.
Page 2 (3)
0$1% :'LHVHO$6
Fuel Pump Cam
909-3.3
Adjustment
4.
4. Mount the special spanner on the fuel cam

disc, ensuring that the two pins enter the
holes in the cam.
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snap-on couplings.
Keep the cam pressurised for at least five

minutes before turning the cam.
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,
until the desired change of lead is obtained.
GN909-3.3 204 05
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
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 purposes of comparison with future measurements and adjustment.
6. Mount the inspection cover on the camshaft
housing.
7. Mount a new O-ring on the puncture valve.
Mount the puncture valve and the fuel oil
high pressure pipes.
0$1% :'LHVHO$6
Page 3 (3)
Fuel Pump
MAN B&W Diesel
109-4
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-18
Pump housing nuts, tightening torque
350
Nm
D09-19
Pump housing nuts, tightening angle
108
D09-20
Pump housing
38
kg
D09-68
Fuel pump complete
58
kg
Page 1 (2)
Fuel Pump
109-4
MAN B&W Diesel
Data
Plate
P90951
Page 2 (2)
Item No.
070
Description
Lifting tool for fuel pump housing
Fuel Pump
909-4.2
Dismantling
Fuel Pump
S46MC-C
0221
Dismantling
909-4.2
2.
Note!
1. Dismantle the fuel pump top cover/plunger
barrel assembly.
2. Remove the fuel oil inlet pipe between the
fuel pump and the fuel oil inlet valve.
Discard the gaskets.
Mount the lifting tool and lift the fuel pump

housing away.
Note!
BM909-4.2 210 02
3. Remove the nuts at the base of the fuel

pump.
Take care not to damage the threads of

the studs.
3.
Land the fuel pump on wooden planks.
BM909-4.2 210 03
D09-20
MAN B&W Diesel A/S
Page 1 (5)
909-4.3
Fuel Pump
Overhaul
Overhaul
909-4.3
1.
1. Tilt the fuel pump housing into a horizontal

position on the wooden planks.
2. Remove the bottom plate from the fuel
pump housing.
If the bottom plate sticks, loosen it by
screwing two M8x50 mm screws into the
threaded holes of the bottom plate.
BM909-4.3 210 01
3. Dismantle the:
Fuel oil index arm.
Regulating guide.
BM909-4.3 210 02
2.
BM909-4.3 210 03
3.
Page 2 (5)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
4.
4. Dismantle and inspect the erosion plugs on

both sides of the fuel pump housing.
If heavily eroded, replace the erosion plugs.
5. Clean all the parts in diesel oil or kerosene.
Blow dry with compressed air.
Warning!
6. Mount a new sealing ring in the pointer for

the fuel oil index arm.
Note!
BM909-4.3 210 04
Always use eye protection when working

with compressed air.
Soak the sealing ring in lubricating oil

before mounting.
6.
Depending on engine type, the index pointer can have a different shape, see the
sketch.
HC909-3.4 121 11
BM909-4.3 210 06
7. Clean all inside surfaces of the fuel pump

housing.
MAN B&W Diesel A/S
Page 3 (5)
909-4.3
Fuel Pump
Overhaul
9.
8. Lubricate the following with molybdenum disulphide grease (MoS 2):

All internal surfaces of the fuel pump
housing.
The sliding surfaces of all the parts of the
regulating system.
BM909-4.3 210 09
The teeth of the:

Regulating guide.
Fuel index arm.
9. Mount the fuel oil index arm.
10.
Adjust the position of the fuel oil index arm

so that the scratch mark on the fuel oil index arm is aligned with the centre of the
fuel pump housing.
Mount the fuel oil index pointer.
10. Mount the regulating guide in the fuel pump
housing, ensuring that the scratch mark on
the regulating guide is aligned with the
scratch mark on the fuel oil index arm.
BM909-4.3 210 10
11. Mount the bottom plate on the fuel pump

housing.
BM909-4.3 210 02
11.
Page 4 (5)
MAN B&W Diesel A/S
Fuel Pump
909-4.4
Mounting
Mounting
909-4.4
1.
Note!
Before mounting the fuel pump housing,
make sure that all sliding faces and
threads are cleaned and lubricated with
molybdenum disulphide grease (MoS 2).
D09-19
D09-18
D09-20

1. Lower the fuel pump housing on to the
pump base, taking care not to damage the
threads of the studs.
Remove the lifting tool.
Mount and tighten the nuts at the base of
the fuel pump housing. See Data.
Only use either the tightening angle or

the tightening torque, not both.
2. Mount the fuel oil inlet pipe between the
fuel pump and the fuel inlet valve.
BM909-4.2 210 03
Note!
2.
BM909-4.4 210 02
3. Mount the fuel pump top cover/plunger-barrel assembly.

MAN B&W Diesel A/S
Page 5 (5)
Fuel Pump Top Cover

MAN B&W Diesel
109-5
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-23
Top cover studs, screwing-in torque
40
Nm
D09-24
Top cover nuts, tightening torque
30
Nm
D09-25
Pump barrel/top cover, tightening torque
15
Nm
D09-26
Outlet seat, max.grinding diameter
10
mm
D09-27
Top cover
12
kg
D09-28
Plunger/barrel assembly + top cover
20
kg
Page 1 (2)
Fuel Pump Top Cover
109-5
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
069
Lifting tool for fuel pump
P90951
094
Milling tool for fuel oil pipe seats
P90951
200
Hexagon head screw for topcover
P90951
212
Extraction tool for suctions valve
Page 2 (2)
Fuel Pump Top Cover
909-5.2
Dismantling
Fuel Pump Top Cover
S46MC-C
0222
Dismantling
909-5.2
1.
1. Close the oil inlet valve to the fuel oil pump

and drain the pump.
Dismount the drain oil pipe from the top
cover and the air pipe connection to the
puncture valve.
Dismount the high pressure pipes.
Dismount the fuel index pointer.

2. Dismount the suction valve by means of the
extractor tool.
GN909-5.2 208 01
Dismount the puncture valve from the top

cover. See Procedure 909-8.
2.
3. Remove the top cover fixing nuts, as well as

the two screws in the top cover.
Loosen the top cover by means of the two
dismantling screws from the tool panel.
GN909-5.2 205 02
Release the link for the regulating drive and

pull out the toothed rack as far as possible.
GN909-1.3 205 01
3.
0$1% :'LHVHO$6
Page 1 (7)
Fuel Pump Top Cover
909-5.2
Dismantling
4.
4. Mount the lifting tool on the fuel pump top

cover. Screw the centre screw of the tool
into the pump plunger. Ensure that the stop
ring on the centre screw is loose.
Pull the centre screw of the tool to lift the
plunger clear of the bayonet joint in the roller guide and the milled recess of the regulating guide.
To do this it may be necessary to move the
toothed rack and the centre screw of the
tool in relation to each other.
GN909-5.2 208 04
When the plunger has been lifted clear of

the roller guide and regulating guide, lock
the centre screw in this position with the
stop ring.
5. Lift the top cover and barrel with plunger
out of the fuel pump housing as one unit.
Remove the shims and tag them for reinstallation.
5.
D09-28
6. Set up the pump unit in a bench vice provided with soft jaws. Dismount the lifting
tool. Take care that the plunger does not
slide out of the barrel.
Press the plunger to the top of the barrel
and remove the barrel/plunger assembly
from the top cover.
GN909-5.2 205 05
Send the barrel/plunger assembly to an

MAN B&W authorised workshop for overhaul, or overhaul it on board.
GN909-5.2 205 06
6.
Page 2 (7)
0$1% :'LHVHO$6
Fuel Pump Top Cover
909-5.3
Overhaul
Overhaul
909-5.3
1.
1. Remove and discard the sealing rings.
D09-26
Carefully clean and examine the top cover.

Reconditioning of the seatings for the highpressure pipes is carried out by milling according to the following procedure:
Fill the oil ducts in the top cover with Vaseline or heavy grease.
GREASE
During the work the miller is guided by the

guide screwed into the thread for the highpressure pipe.
Turn the miller by means of, e.g. a tap
wrench, while tightening the guide screw
lightly to provide a suitable pressure between miller and seat.
For the max. milling/grinding diameter of

the seat, see Data D09-26.
GN909-5.3 205 01
During the milling, add drilling oil emulsion

liberally.
2. After completing the milling, blow out the

Vaseline/grease from the oil ducts by
means of compressed air.
2.
Warning!
GN909-5.3 205 02
Clean the top cover with diesel oil, and blow

dry with compressed air.
0$1% :'LHVHO$6
Page 3 (7)
909-5.3
Fuel Pump Top Cover

Overhaul
3.
3. Mount the sealing rings in the ring grooves.

Sealing between the top cover and the fuel
pump housing is provided by an O-ring.
Sealing between the top cover and pump
barrel is provided by two back-up rings and
an O-ring in between.
GN909-5.3 205 03
Prepare the back-up rings by twisting the

rings in the hand, in such a way that the diameter of the rings becomes smaller than
the diameter of the ring groove in which the
rings are to be mounted.
Screw the back-up rings onto the top cover, into the groove.
4.
D09-25
Finally, insert the O-ring between the backup rings in the ring groove.
Mount the O-ring which seals between top
cover/fuel pump housing.
GN909-5.2 205 06
4. Mount the overhauled top cover on top of

the pump barrel, guided by the guide pin.
Tighten the screws, see Data D09-25.
Page 4 (7)
0$1% :'LHVHO$6
Fuel Pump Top Cover
909-5.4
Mounting
Mounting
909-5.4
1.
1. Mount the supplied measuring pin on the

centre screw of the lifting tool as shown in
the sketch. Loosen the stop ring on the centre screw.
Place the tool on the pump housing and
press down the centre screw until the
measuring pin reaches the thrust piece of
the roller guide. Lock the centre screw in
this position with the stop ring.
Note!
The engine must not be turned until the
mounting of the barrel/plunger assembly
has been completed.
GN909-5.4 208 01
Keep the stop ring tightened in this position

until the plunger has been correctly mounted.
2.
2. Remove the tool from the pump housing
and remove the measuring pin from the
centre screw.
Mount the tool on the barrel/plunger and
top-cover assembly.
Tighten the tool to the top cover by means
of the two screws, and attach the plunger to
the centre screw.
The tool is now firmly attached to the assembly, enabling the correct position to be
obtained during mounting.
Pull the regulating toothed rack out as far
as possible.
Carefully lower the assembly into the pump

housing (taking special care not to damage
the O-ring and back-up rings on the barrel).
GN909-5.4 208 02
Pull the plunger as high up in the barrel as

possible.
Adjust the top cover so that the guide pin

enters the hole in the pump housing. Lower
the top cover on to the pump housing.
0$1% :'LHVHO$6
Page 5 (7)
909-5.4
Fuel Pump Top Cover

Mounting
3.
3. Press the plunger down into contact with

the thrust piece of the roller guide.
If necessary, turn the regulating guide a little (using the toothed rack) to make the foot
and regulating block of the plunger fit properly in the cutout of the regulating guide.
Check that the stop ring of the centre screw
is in full contact with the flange of the tool,
as when measuring.
GN909-5.4 208 03
When the plunger is in place, press the regulating toothed bar in, causing the plunger
foot to interlock with the bayonet joint of the
roller guide.
4.
Check through the inspection cover on the

fuel pump base and by pulling the centre
screw of the tool, that the plunger is correctly engaged.
When pulling on the centre screw it must
not be possible to lift the plunger more than
a few mm.
4. Unscrew the centre screw from the plunger
and remove the tool from the top cover.
GN909-5.4 208 024
5. Screw the two dismantling screws from the

tool panel into the threaded holes of the top
cover, thus lifting the top cover to provide
space for inserting shims.
GN909-1.3 205 02
5.
6. Insert shims between the pump housing

and the top cover. (If the barrel assembly is
the same as that dismounted, insert the
same number of shims as were removed).
If a new barrel assembly is mounted, insert
the number of shims specified in the test
bed report.
Page 6 (7)
0$1% :'LHVHO$6
Fuel Pump Top Cover
909-5.4
Mounting
7.
7. Replace the dismantling screws with the

two screws for mounting the lifting tool, and
press down the top cover.
Turn the engine one complete revolution,
and check that the top cover does not lift.
If the top cover lifts, the plunger is not correctly mounted and must be remounted.
Mount the top cover fastening nuts, and
tighten them diagonally.
See Data D09-24.
If any of the fuel pump top cover studs have
come loose, tighten them.
See Data D09-23.
Connect the drain oil pipe to the top cover

and the pipe connection to the puncture
valve.
Mount the two high-pressure pipes on the
top cover/fuel valves.
GN909-1.3 205 03
8. Mount the suction valve and the puncture

valve in the top cover.
9.
Mount the fuel index pointer

Mount the link for the regulating drive.
Open the fuel oil inlet.
GN909-5.4 208 09
For fuel pump settings, see Procedure 9091 and Volume I, OPERATION, Chapter 706.
0$1% :'LHVHO$6
Page 7 (7)

MAN B&W Diesel
109-6
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
D09-29
Description
Barrel assembly
Value
Unit
8
kg
Page 1 (2)
109-6
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description
909-6.3
Overhaul
S46MC-C
0218
Overhaul
909-6.3
1.
1. Remove the top cover with the barrel/plunger assembly from the fuel pump housing,
and dismantle the barrel/plunger assembly
from the top cover. See Procedure 909-5.2.
D09-29
2. Remove and discard the O-rings.
Note!
It is recommended not to remove the
plunger from the barrel, as this may
cause scratches to the plunger.
GN909-6.3 205 01
Clean the outside of the barrel.
3.
For evaluation of pump barrel/plunger, see

Volume I, OPERATION, Chapter 706.
Prepare the back-up ring by twisting the

ring in the hand, in such a way that the diameter of the ring becomes smaller than
the diameter of the barrel.
Screw the back-up ring on to the barrel,
into the groove.
EN909-6.3 218 03
3. The sealing ring on the pump barrel consists of an O-ring and a back-up ring..
Finally, position the O-ring in the ring

groove.
The O-ring must be above the back-up ring.
Note!
Take care that the plunger does not slide
out of the barrel.
4. If the barrel assembly is not to be mounted
immediately, cover all openings with plastic
to prevent dirt from entering the barrel assembly during storage.
For mounting the fuel pump barrel assembly, see Procedure 909-5.4 (fuel pump top
cover).
0$1% :'LHVHO$6
Page 1 (1)
109-7

Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-7

Data
Plate
P90951
Page 2 (2)
Item No.
212
Description
MAN B&W Diesel A/S
909-7.3
Overhaul
S35MC
0210
Overhaul
909-7.3
1.
1. Set up the suction valve in a bench vice

with soft jaws and press down the spring
by means of the cone to release the valve
spindle from the two-part conical ring.
Clean the parts thoroughly in clean diesel
oil and blow dry with compressed air.
If the seats are damaged, a new or reconditioned suction valve must be fitted. (Send
the damaged valve to an authorized MAN
B&W repair shop for reconditioning).
3. After cleaning and inspecting all the parts,
lubricate these with molybdenum disulphide (MoS 2) and assemble the suction
valve.
GN909-7.3 205 05
2. Inspect the seat on the valve spindle and

the seat on the valve housing for damage.
2.
Check the seats for tightness by filling the

inlet hole with diesel oil and waiting 5 minutes. No oil may pass through the seats.
GN909-7.3 205 06
4. If the suction valve is not to be mounted on

the engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve during storage.
GN909-7.3 205 07
3.
0$1% :'LHVHO$6
Page 1 (1)

MAN B&W Diesel
109-8
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

X Shut off fuel oil
Data
Ref.
D09-35
Description
Puncture valve, tightening torque
Value
Unit
250
Nm
Page 1 (2)
109-8
MAN B&W Diesel
Data
Plate
P90951
Page 2 (2)
Item No.
128
Description
Crowfoot spanner
909-8.2
Dismantling
1.
2.
Note!
2. Disconnect the air pipes from the puncture

valve.
Unscrew the puncture valve and remove it
from the fuel pump top cover.
M909080222D01
Remove the fuel oil high pressure pipes.

M909080222D02
2.
MAN B&W Diesel A/S
Page 1 (4)
909-8.3

Overhaul
1.
1. Set up the puncture valve in a bench vice

with "soft" jaws.
Loosen and remove the two screws and
dismount the cover.
Pull the upper part of the housing clear of
the lower part of the housing.
M909080222O01
Remove the spindle and the spring from

the upper part of the housing.
2.
Remove and discard all O-rings and sealing

rings.
Clean all the parts in clean diesel oil.
2. Mount the two O-rings in the uppermost
ring groove on the rod of the air piston,
and position the large cone on the rod.
Heat the sealing ring in 100C hot water for
minimum 5 minutes.
Place the sealing ring on the cone and, by
means of the pusher, push the sealing ring
on to the O-rings in the groove. Remove
the pusher and the large cone.
M909080222O02
Finally, compress the sealing ring by means

of the compression tool.
Page 2 (4)
3. Repeat step 2 on the lowermost ring

groove on the rod of the air piston.
MAN B&W Diesel A/S
909-8.3
Overhaul
4. Mount the O-ring in the ring groove on top
of the piston. Position the cone on the piston head.
4.
Heat the sealing ring in 100C hot water for

minimum 5 minutes.
Place the sealing ring on the cone and, using the pusher, push the sealing ring onto
the O-ring in the groove.
Finally, compress the sealing ring by means

of the compression tool.
5. Before assembling the puncture valve, lubricate all parts with molybdenum
disulphide, (MoS2).
M909080222O04
Remove the pusher and the cone.
5.
Mount new O-rings on the upper and the
lower part of the housing and the cover.
6. If the puncture valve is not to be mounted

on the engine immediately after the overhaul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
M909080222O05
Mount the spring and air piston in the upper part of the housing and assemble the
two housing parts and the cover by means
of the two screws.
MAN B&W Diesel A/S
Page 3 (4)
909-8.4

Mounting
1. Before mounting the puncture valve, check
that the bore in the top cover is clean and
check the O-ring on the puncture valve.
2.
D0935
Lubricate the thread on the puncture valve

with molybdenum disulphide grease
(MoS2).
M909080222M02
2. Screw in the puncture valve and tighten

with a crowfoot wrench and a torque spanner to the specified torque, see Data D0935.
Mount the air pipes for the puncture valve.
3. Mount the fuel oil high pressure pipes, see
Procedure 909-14.4
M909080222M03
3.
Page 4 (4)
MAN B&W Diesel A/S
Fuel Pump Shock Absorber

MAN B&W Diesel
109-9
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
D09-39
Description
Shock absorber
Value
Unit
12
kg
Page 1 (2)
Fuel Pump Shock Absorber
109-9
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description
909-9.1
Checking
S50MC-C
0212
Checking
909-9.1
1.
2. Remove the plug from the end cover of the

shock absorber. Check that air is pulsating
through the threaded hole.
Short bursts of air should be felt against the
hand, corresponding to the strokes of the
fuel pump.
HM909-4.0 09 01
1. To ensure satisfactory operation, the functioning of the fuel oil system shock absorber should be checked at regular intervals.
Normally, inspection is necessary only at
the intervals stated in the maintenance programme. The checks should be carried out
while the engine is operating.
2.
The air pulses occur when the shock absorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.
Increasing amounts indicate a deteriorating

piston sealing. Excessive amounts indicate
that the shock absorber requires overhauling.
GN909-9.1 212 02
3. To check the tightness of the piston, measure the amount of leakage oil flowing from
the drain pipe below the 3-way valve. Note
down the amounts measured and compare
with earlier measurements.
GN909-9.1 212 03
3.
0$1% :'LHVHO$6
Page 1 (3)
909-9.3

Overhaul
Overhaul
909-9.3
1.
Note !
Before dismantling any part of the fuel oil
system, make sure that the system has
GN909-9.3 212 01
1. Remove the 3-way valve and the drain

pipes. Loosen the screws holding the shock
absorber and remove it from the fuel oil
system.
2.
2. Remove the plug from the end cover of the

shock absorber. Fit a threaded rod between
the piston and the end cover to counteract
the force of the springs. Remove the locking
plates and loosen the screws of the end
cover. Remove the end cover and piston.
Discard the gasket.
3. Loosen the nut on the threaded rod to relieve 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.
HG909-9.2 201 02
4. Clean all parts and polish the sliding surfaces of the piston and the shock absorber
housing. Mount a new sealing ring in the
shock absorber housing and a new wear
ring on the piston.
5. Mount the springs and the spring guide between the end cover and the piston, using
the threaded rod.
4.
Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to damage the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.
HG909-9.2 201 04
6. Mount the end cover. Remove the threaded

rod and insert the plug.
Page 2 (3)
0$1% :'LHVHO$6
909-9.3
Overhaul
7. Fit a new gasket and mount the shock absorber. Mount the 3-way valve and the drain
pipes on the fuel oil system.
If an excessive amount of drain oil is still
observed after the overhaul, the shock absorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
0$1% :'LHVHO$6
Page 3 (3)
Fuel Valve
MAN B&W Diesel
109-11
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

X Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-40
Fuel valve opening pressure
300 - 380
bar
D09-41
Fuel valve tightening torque
20
Nm
D09-42
Inlet seat, max. diameter
10
mm
D09-43
Fuel valve
kg
Page 1 (2)
Fuel Valve
109-11
MAN B&W Diesel
Data
Plate
Item No.
Description
P90151
071
Dismantling tool for fuel valve
P90951
094
Milling tool for fuel oil pipe seats
P90951
165
Grinding mandrel for valve head
P90961
Page 2 (2)
Fuel Valve - Tools
Fuel Valve
909-11.1
Checking
Fuel Valve
S35MC
0236
Checking
909-11.1
1.
The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the
engine can be attributed to defects in these
valves.
In order to obtain reliable results during testing

of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and re-assembled
before testing.
GN909-11.1 204 01
If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.
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.
D09-41
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 50C.
For operation of the pressure testing pump,

see the suppliers instructions.
2. Place the fuel valve in the test rig and

mount the nuts. Tighten the nuts to the
torque stated in Data. Mount the connecting
piece and the oil pipe between the pressure
testing pump and the fuel valve.
If the pressure testing pump has no built-in
outlet valve, use a connecting piece with a
valve.
DM909-6.3 101 02
Note that the high-pressure pump should

be periodically checked in accordance with
the suppliers instructions.
MAN B&W Diesel A/S
Page 1 (11)
909-11.1
Fuel Valve
Checking
3.
3. Pressure testing procedure

The subsequent items must be followed in
the sequence stated. Items 4, 6, 7 and 8
are each divided into the following four subitems:
A.
B.
C.
D.
Objective
Procedure
Acceptance criteria
Cause of fault.
4. Flushing and jet control

A. Objective:
To remove air in the system and check the
fuel jet.
BM909-11.1 236 04
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the working pressure until
straight jets of oil are ejected from the nozzle holes (no atomization).
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Owing to the geometry of the internal part
of the nozzle and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
during normal engine operation the fuel
oil will not necessarily flow from all of the
nozzle holes.
D. Cause of fault:
If the jets do not fulfil the above point C, the
cause may be:
Page 2 (11)
Dirt in the nozzle holes.
The nozzle is not mounted correctly.
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
5.
5. Atomization test
Note!
The reason is that the atomization test may

damage the valve because it makes the
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
across the cut-off edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures between cut-off slide and nozzle.
BM909-11.1 236 05
Do NOT attempt to carry out an atomization test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.
6.
All of these conditions involve the risk of
seizure between the cut-off slide and the
nozzle.
D09-40
6. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN position.
Increase the oil pressure until oil is admitted through the nozzle holes.
Check the opening pressure on the pressure gauge. The pressure must correspond
to the pressure stated in Data D09-40.
If the opening pressure is lower than specified in D09-40, the cause may be that the
spring has sagged replace the spring, or
add a special thin disc.
BM909-11.1 236 06
D. Cause of fault:
If the opening pressure is higher than specified in D09-40, the cause may be that a
wrong type of spring is used replace the
spring in the spindle guide, if necessary, replace the complete spindle guide.
MAN B&W Diesel A/S
Page 3 (11)
909-11.1
Fuel Valve
Checking
7.
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 3.
7. Sealing test and sliding function
BM909-11.1 236 07
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 position.
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.
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.
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 replace the spindle guide.
Page 4 (11)
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
Too quick pressure drop:

the clearances of the movable parts,
inside the spindle guide are too large, or
the seat between the spindle guide and
the fuel valve head is damaged.
Examine and/or replace the spindle guide.
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
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 vent slide is blocked.
If so, disassemble and examine the spindle
guide, replace if necessary.
MAN B&W Diesel A/S
Page 5 (11)
909-11.1
Fuel Valve
Checking
8.
8. Pressure test, O-ring sealings

A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN position.
Build up a working pressure of about max.
10 bar until oil flows out of the leak oil outlet.
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100
bar.
Move the control handle to the CLOSED position.
The built-up pressure of about 100 bar
should be maintained.
BG909-6.3 66 07
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.
Page 6 (11)
MAN B&W Diesel A/S
Fuel Valve
909-11.2
Dismantling
Dismantling
909-11.2
1.
1. Close the fuel oil inlet and outlet valves,

and drain the high-pressure pipe and the
fuel valve.
Unscrew the union nut by means of the
hook spanner and take the union nut with
protective hose up along the pipe. Unscrew
the union nipple at both ends of the pipe
(fuel valve and fuel pump).
Disconnect the return oil pipe from the fuel

valve.
Remove the nuts and the tubular spacers.
BG901-2.1 97 01
Remove the high-pressure pipe.
2. Lift the valve. If the valve is sticking, use the

fuel valve dismantling tool to pull the fuel
valve clear of the top cover.
2.
BM909-11.2 209 02
3. Remove the valve from the engine. If the

valve is not to be overhauled immediately,
the valve should be placed immersed in
diesel oil until overhauling.
BM909-11.2 236 03
3.
MAN B&W Diesel A/S
Page 7 (11)
Fuel Valve
909-11.3
Overhaul
Overhaul
909-11.3
1.
When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
BM909-11.3 236 01
Use only clean, non-fluffy rags for wiping purposes. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings before reassembly.
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. Remove and discard the O-rings.

Disassemble the fuel valve by screwing off
the two socket head cap screws while retaining the valve in, for instance, a bench
vice provided with soft jaws.
Pull the valve head clear of the valve housing.
Remove the complete spindle guide and
the fuel nozzle from the valve housing.
BM909-11.3 236 02
Remove and discard all the O-rings.
Page 8 (11)
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
3.
3. Carefully clean and examine all surfaces of

the fuel valve housing and the fuel valve
head.
D09-42
If necessary, grind the seating surfaces by

means of the grinding mandrels supplied
and a fine-grain abrasive (such as Carborundum No. 500).
This grinding must only be carried out manually.
After the grinding, wash the parts in gas oil
and blow clean by means of compressed air
to remove any remains of the grinding compound.
Normally, the milling tool is turned by hand,

but it may be fitted in the chuck of a columntype drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An ample supply of cutting emulsion must be
used.
BG909-6.1 66 02
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.
4.
Note!
Take care not to exceed the maximum
diameter of the seat, see Data.
BM909-11.3 236 04
4. The complete spindle guide, including the

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.
MAN B&W Diesel A/S
Page 9 (11)
909-11.3
Fuel Valve
Overhaul
5.
5. Mount a new O-ring on the spindle guide

and lubricate it with MoS 2.
Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
Carefully slide the spindle guide down into
the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corresponds to the measurement taken before
the valve is disassembled.
Note!
Make sure that the fuel nozzle and spindle guide engage correctly with the guide
pin in the fuel valve housing. This can be
ascertained by attempting to turn the
nozzle after mounting. It must not be
possible to turn the nozzle.
BM909-11.3 236 05
Mount a new O-ring in the lowermost

groove of the fuel valve head.
Mount the fuel valve head on the fuel valve
housing, and tighten the screws.
Fit the uppermost groove of the valve head
with a new O-ring.
6.
6. When mounting the valve head, make sure

that the guide pin between valve housing
and valve head is intact, and check that the
guide pin between valve housing and valve
head engages correctly so as to prevent
relative turning of the parts.
BG909-6.1 66 06
After overhaul, the fuel valve must be tested in the test rig.
Page 10 (11)
7. If the fuel valve is not to be mounted in the

engine immediately after the overhaul, cover all openings of the valve with plastic to
prevent dirt from entering the valve during
storage.
MAN B&W Diesel A/S
Fuel Valve
909-11.4
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
which, if any, must be eliminated.
(For reconditioning of valve bore in cylinder
cover, see Procedure 901-1.3).
If not already done, mount a new O-ring on
the valve head. Mount a new O-ring in the
groove on the valve housing.
Mount the valve in position in the cylinder

cover.
2. Mount the tubular spacers and the nuts.
Tighten the nuts as stated in Data.
BM909-11.4 236 01
Lubricate the valve with copper grease.
2.
3. Lubricate the thread on the union nipple of
the fuel oil pipe with a heat resistant anti
seize grease before mounting.
D09-41
Mount the fuel oil high-pressure pipe and

tighten, using the crow foot wrench and a
torque wrench.
Turn on the fuel oil supply.

Note!
BM901-2.1 97 04
Reconnect the return oil pipe to the fuel

valve.
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
BM901-2.1 97 05
3.
MAN B&W Diesel A/S
Page 11 (11)
Spindle Guide
MAN B&W Diesel
109-12
Data

Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
Spindle Guide
109-12
MAN B&W Diesel
Data
Plate
P90951
Item No.
153
Description
Flange for dismantling of non return valve
P90968
P90966
P90974
Page 2 (2)
Spindle Guide/Non-return Valve
909-12.3
Overhaul
S35MC
0223
Overhaul
909-12.3
1.
Note!
The spindle guide and the non-return

valve have been integrated into one unit.
However, both terms will be used to
describe the part in this procedure.
BG909-6.2 66 01
Extreme care and accuracy should be

exercised when carrying out this operation.
2.
1. Clean the outside of the spindle guide in pure
gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, therefore only one guide should be disassembled
at a time.
All parts of the spindle guide/non-return

valve, except the springs and the fuel
nozzle are matched parts and may not be
replaced individually.
BM909-12.3 223 02
Note!
3.
Place the spindle guide/non-return valve in

a bench vice provided with soft jaws, and
use the spindle guide dismantling tool as
shown to remove the non-return valve from
the spindle guide.
2. Place the non-return valve part of the spindle guide in a bench vice provided with
soft jaws, and use a brass mandrel and a
hammer to remove the thrust piece from the
valve housing.
BM909-12.3 222 04
3. Mount the pulling tool around the fuel nozzle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
MAN B&W Diesel A/S
Page 1 (5)
909-12.3

Overhaul
4.
4. Clean all the parts of the spindle guide and

the non-return valve in gas oil, and blow
clean with compressed air.
Clean all parts again in kerosene or Electrocleaner, and blow dry with compressed
air.
BM909-12-3 223 04
5. Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
enlargement magnifying glass and an inspection lamp.
During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts.
5.
6. Remove any deposits or very fine scratches

by placing the spindle and vent slide in a
lathe, as shown, and polishing it with a very
fine conventional polishing linen grade
360.
Use also a little oil for the polishing (a
coarser polishing linen must absolutely
not be used).
Note!
BM909-12.3 223 05
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be damaged.
MA909-6.2 111 05
6.
Page 2 (5)
MAN B&W Diesel A/S
909-12.3
Overhaul
7.
7. Clean any carbon deposits from the central

bore of the fuel nozzle by means of the special brass brush. Clean the spray holes, using gas oil and the special drills supplied.
Note!
During this operation be very careful not
to push the drill too far to avoid scratching 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.
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
BM909-12.3 222 07
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
Note!
It is recommended that the fuel nozzle is
changed whenever the spindle guide is
being overhauled.
MAN B&W Diesel A/S
Page 3 (5)
909-12.3

Overhaul
8.
8. 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.
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 discarded.
9. Lubricate the sliding surfaces of all parts
with Molybdenum Disulphide (MoS 2).
10. Place the housing of the non-return valve in
a bench vice provided with soft jaws.
BM909-12.3 223 08
Insert the non-return valve spindle and the

spring in the housing. Place the thrust
piece at the end of the housing.
10.
Carefully tap the thrust piece into the housing with a lead hammer.
11. Place the lower part of the spindle guide
housing in a bench vice provided with soft
jaws.
BM909-12.3 223 10
Mount the spindle and the spring inside the

housing of the spindle guide using the spindle guide dismantling tool and a hammer.
12. Mount a new O-ring on the spindle guide/
non-return valve.
BM909-12.3 223 11
11.
Page 4 (5)
MAN B&W Diesel A/S
909-12.3
Overhaul
11.
13. Lubricate the sliding surfaces of the nozzle

and the spindle with a little Molybdenum Disulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Use the dismantling tool for the spindle
guide to align the parts.
Place the parts on the plane of a drilling
machine and mount the mounting tool in the
chuck. Make sure that all the parts are perfectly aligned.
Press the nozzle on to the spindle guide.
Note!
If no mounting tools are available, the nozzle can be mounted on the spindle guide using a short piece of pipe.
BM909-12.3 223 13
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
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 together the same way as when using the
mounting tools.
14. If the spindle guide is not to be mounted in a
fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
Page 5 (5)
Fuel Oil High-Pressure Pipe

MAN B&W Diesel
109-14
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

X Shut off fuel oil
Data
Ref.
Description
D09-47
Fuel oil high-pressure pipe, tightening torque
D09-52
Fuel oil pipe
Value
Unit
25
Nm
kg
Page 1 (2)
109-14
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
104
Milling tool for fuel oil pipe
P90951
116
Crowfoot spanner
Page 2 (2)
909-14.2
Dismantling
S35MC
0235
Dismantling
909-14.2
2.
High-Pressure Pipe with Double Pipe

1. Close the fuel oil inlet and outlet valves.
3. 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.
BM909-14.2 211 02
2. Unscrew the union nipple from the fuel

valve.
3.
Note!
It is recommended always to overhaul
the high-pressure pipe before remounting
it on the engine.
GN909-14.2 210 03
The overhaul should preferably take

place immediately after the high-pressure pipe has been dismantled.
D09-52
BM909-14.2 211 04
4.
0$1% :'LHVHO$6
Page 1 (4)
909-14.3

Overhaul
Overhaul
909-14.3
1.
Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before remounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed
as follows:
KB909-7.1 77 01
1. Lift up the union nut. Remove the spring

ring from the two-part sleeve. Remove the
sleeve.
2. Fasten the pipe in a vice with soft jaws.
Mount the miller on the pipe end.
Note!
2.
The two pipe ends are of different

designs see sketch.
Turn the upper tightening ring (A) until the
miller presses against the pipe end.
KB909-7.1 77 03
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
During the milling process, add drilling oil
emulsion liberally.
3. On both pipe ends a small groove has been
ground to indicate the maximum allowable
grinding of the pipe ends.
3.
Max. grind-away
The pipe ends may only be ground until the

ground surface is flush with the bottom of
the groove.
If the pipe ends are still not in order, the
pipe must be discarded.
KN909-14.3 223 03
After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.
Page 2 (4)
0$1% :'LHVHO$6
909-14.3
Overhaul
4.
4. Remove and discard both the internal and

external O-rings. Mount new O-rings.
KB909-7.1 77 04
Mount the two-part sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the high-pressure pipe.
0$1% :'LHVHO$6
Page 3 (4)
909-14.4
Mounting
Mounting
909-14.4
3.
D09-52
1. Ensure that the fuel valve is fitted with a

new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel
pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
BM909-14.4 211 03
3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
Screw the union nipples onto the fuel valve
and into the fuel pump top cover, by hand.
Note!
4.
D09-47
The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might otherwise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nipples have been screwed into position.
BM909-14.4 211 04
4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
pump to the torque stated in Data.
5.
6. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
GN909-14.4 210 05
D09-47
Page 4 (4)
0$1% :'LHVHO$6

MAN B&W Diesel
109-15
Data

Stopped engine
X
X
X
X
X
X

X Shut off fuel oil
Data
Ref.
Description
Value
Unit
D09-54
Clearance A
1.9 - 4.6
mm
D09-55
Clearance B
0.4 - 3.1
mm
D09-57
Roller/bushing/shaft pin, max. clearance
0,5
mm
D09-61
Fuel pump roller guide
16
kg
D09-62
Pump base
28
kg
Page 1 (2)
109-15
MAN B&W Diesel
Data
Plate
P90951
Page 2 (2)
Item No.
069
Description
Lifting tool, fuel pump
909-15.1
Checking
S35MC
0227
Checking
909-15.1
2.
Roller guide mounted in engine

The fuel pump roller guide can be partially
checked while mounted on the engine, using
the following procedure:
1. Lift the fuel pump roller guide.
2. Remove the cover on the camshaft housing
to inspect the fuel pump roller guide.
Turn the roller by hand to check that it can

move freely and without unnecessary resistance or hard points.
BM909-15.1 207 03
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no traces of bearing metal left in the roller guide
housing.
4.
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. Using the telegraph, move the roller guide

to the AHEAD position.
Check that the reversing link is fully tilted
over in AHEAD position.
BM909-15.1 207 05
3. Lower the roller guide onto the fuel cam

again.
Carry out the same check in the ASTERN position.
0$1% :'LHVHO$6
Page 1 (12)
909-15.1

Checking
5.
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:
5. Dismount the roller guide from the engine.
6. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness.
7. Turn the roller guide upside down and land
it in a vertical position on a couple of
planks, with the roller hanging freely.
BM909-15.1 207 07
Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clearance permits.
7.
BM909-15.1 207 08
D09-57
Page 2 (12)
0$1% :'LHVHO$6
909-15.2
Dismantling
Dismantling
909-15.2
1.
Note!
1. Dismantle the top cover with the barrel/
plunger assembly.
2. Turn the engine so that the roller guide
rests on the lowermost part of the fuel cam.
GN909-5.2 205 05
Inspect the position of the fuel cam through

the inspection cover opening on the camshaft housing.
BM909-15.1 207 03
2.
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Page 3 (12)
909-15.2

Dismantling
3.
3. Loosen and remove the nuts on the two

short studs.
Then loosen the nuts on the two long
threaded studs successively until the roller
guide spring is relieved.
Mount the lifting tool on the fuel pump studs
and hook the engine room crane on to the
lifting tool.
Remove the nuts from the two long threaded studs and lift away the fuel pump housing.
Note!
When lifting the fuel pump housing, take
care not to damage the threads on the
studs.
BM909-15.2 207 03
4. Lift the spring out of the roller guide.

Loosen and remove the screws from the
sealing cap on top of the roller guide inside
the pump base.
BM909-15.2 207 04
4.
Page 4 (12)
0$1% :'LHVHO$6
909-15.2
Dismantling
5.
5. Remove the sealing cap from the roller

guide.
Unscrew the two nuts from the pump base,
and lift away the pump base.
D09-62
When lifting, take care that the bushing of

the pump base slides against the neck of
the roller guide without scratching.
6. Mount the roller guide lifting tool as follows:
Lift the lock plate of the tool up on the
shaft of the tool.
Position the tool so that its foot rests on
the thrust piece in the bayonet joint of the
roller guide.
Lower the lock plate, thereby securing

the foot in the locked position.
Lift the roller guide out of the roller guide
housing, using the crane.
BM909-15.2 207 05
Turn the tool 90 so as to allow the foot to

engage properly in the bayonet joint.
6.
When lifting, take care that the slide surfaces of the roller guide do not scrape against
the roller guide bushing.
D09-61
Land the roller guide on wooden planks.
BM909-15.2 207 06
7. Check the roller guide.

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Page 5 (12)
909-15.3

Overhaul
Overhaul
909-15.3
1.
1. Inspect and check the fuel pump roller

guide.
D09-61
2. It is recommended that the roller guide

should ONLY be dismantled if
irregularities when turning the roller,
damage to the roller,
larger clearance than stated on the Data
sheet,
seizure marks on the slide surfaces,
have been observed when checking the
roller guide.
Note!
BM909-15.1 207 07
For disassembling of the roller guide,

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.
BM909-15.3 207 03
3.
Page 6 (12)
0$1% :'LHVHO$6
909-15.4
Mounting
Mounting
909-15.4
1.
1. Lubricate the roller guide with plenty of

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.
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.
BM909-15.4 207 01
2. After mounting the roller guide with the reversing link, check the clearance between
the roller guide and the guide plate mounted in the roller guide bushing.
2.
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.
D09-54
Connect working air to the air cylinder, and

check that the reversing mechanism is
working smoothly.
The clearances A and B must be approx.
the same in both positions. See Data.
AM909-8.0 50 15
D09-55
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Page 7 (12)
909-15.4

Mounting
3.
3. If adjustment is necessary, place the reversing arm in ASTERN position and remove
the four cap screws which tighten the flange
for the air cylinder to the roller guide bushing.
AM909-8.0 50 17A
Pull out the air cylinder with the flange as

much as possible.
4. Release the lock nut on the shaft.
4.
5. Turn the shaft to obtain the distance between the air cylinder flange and the surface of the roller guide bushing. See Data.
Tighten the nut on the shaft.
6. Mount the flange with the air cylinder on the
roller guide bushing and tighten the four
cap screws.
AM909-8.0 50 17B
Lock the screws with Loctite (EN243S)

type: 242.
Repeat the clearance check once more.
AM909-8.0 50 18
5.
AM909-8.0 50 19
6.
Page 8 (12)
0$1% :'LHVHO$6
909-15.4
Mounting
7.
7. Before mounting the pump base on the roller bushing, replace the O-ring between the
sealing bush and the bottom of the pump
base.
8. Mount the pump base on the roller guide
bushing, and tighten the nuts.
BM909-8.0 54 24
D09-62
BM909-15.4 207 08
8.
0$1% :'LHVHO$6
Page 9 (12)
909-15.4

Mounting
9.
9. 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 retaining flange and ring holder with scraper
ring.
10. Replace the axial scraper ring in the bottom
of the cap. Check that the O-ring and scraper ring are mounted correctly. See the
sketch.
11. Remove the scraper ring and O-ring from
the ring holder.
BM909-15.4 207 09
Place the new O-ring in the ring holder.

Before mounting, the new scraper ring must
be heated in 100C hot water or oil for at
least five minutes.
10.
Note!
When mounting the scraper ring in the
groove, fold the ring without making any
sharp edges, and be careful not to cut
the scraper ring on the edge of the ring
groove when pressing it in.
AM909-80.0 31 15
Check that the O-ring and scraper ring are

mounted correctly. See the sketch.
AM909-8.0 31 16
11.
Page 10 (12)
0$1% :'LHVHO$6
909-15.4
Mounting
12.
12. 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.
13. Mount a new O-ring in the groove on top of
the roller guide and on the pump base.
Tighten the sealing cap to the top of the

roller guide.
Tighten the nuts.
BM909-15.4 207 12
14. Mount the sealing cap over the roller guide.
Lock the nuts with Loctite type EN243S.
13.
BM909-15.4 207 13
Land the spring on the roller guide inside

the pump base.
BM909-15.2 207 14
14.
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Page 11 (12)
909-15.4

Mounting
15.
15. Mount the fuel pump housing.

16. Check the movement of the reversing link.
BM909-15.2 207 03
17. Mount the top cover and barrel/plunger assembly.

BM909-15.1 207 05
16.
Page 12 (12)
0$1% :'LHVHO$6

MAN B&W Diesel
109-16
Data

X
X
X
X
X
X
Stopped engine
X Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
109-16
MAN B&W Diesel
Data
Plate
Item No.
Description
P90951
082
Lifting tool for fuel pump roller guide
P90951
128
Crowfoot spanner
P90951
212
Page 2 (2)
909-16

S35MC
0212
909-16
2.
Disengagement of fuel pump

Warning!
Disengagement or re-engagement of the
fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
1. Engine trouble might require a cylinder to
be taken out of action. The engine can continue operation with the fuel and exhaust
systems of a single cylinder disconnected.
See Volume I, Section 704.
To disconnect the fuel pump of a single cylinder, proceed as follows:
2. Remove the fuel oil high pressure pipes
and the puncture valve from the fuel pump
top cover.

BM909-16.0 207 02
Note!
Screw a plug-screw into the control air pipe

of the puncture valve.
3.
Remove the inspection cover on the camshaft housing. Turn the engine until the fuel
pump roller is at on the circular part of the
cam.
AM909-1.1 76 04
3. Dismount the suction valve by means of the

extractor tool.
0$1% :'LHVHO$6
Page 1 (3)
909-16
4.
4. Mount the lifting tool on the fuel pump top

cover.
Turn the uppermost nut to screw the spindle
of the lifting tool into the fuel pump plunger.
5. Tighten the lowermost nut on the tool to pull
the roller guide upwards as far as possible.
Lock the tool in this position by means of
the lock nut.
GN909-16 202 04
6. Turn the engine one full revolution and inspect through the opening in the camshaft
housing to make sure that the roller guide
is clear of the fuel cam.
7. The engine can now operate on the remaining cylinders. See Volume I, Section 704.
GN909-16 202 05
5.
BM909-160 207 06
6.
Page 2 (3)
0$1% :'LHVHO$6
909-16
8.
Re-engagement of fuel pump

Warning!
Re-engagement of the fuel pump must
only take place at engine standstill.
8. Remove the cover on the camshaft housing. Turn the engine until the circular section of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in
the reverse order to lifting and remove the
lifting tool.
10. Re-mount the suction valve and the puncture valve. (See Procedure 909-8.4).
Note!
It is recommended always to mount new
or overhauled suction and puncture
valves.
BM909-16.0 207 08
Remove the plug screw from the control air

pipe.
10.
BG909-5.0 45 06
Mount the fuel oil high pressure pipes.

(See Procedure 909-14.4).
0$1% :'LHVHO$6
Page 3 (3)
Fuel Valve and Fuel Pump Panel
MAN B&W Diesel A/S
Plate
P90951-0453
Page 1 (2)
Plate
P90951-0453
Item
No.
010
021
045
057
069
082
094
104
116
128
153
165
177
189
190
200
212
319
Page 2 (2)
Fuel Valve and Fuel Pump Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Measuring tool for fuel pump lead
Lifting tool, fuel pump roller guide
Milling tool, fuel oil pipe seats
Milling tool, fuel oil pipe
Crowfoot spanner
Crowfoot spanner
Flange, dismantling of non return
valve
Grinding mandrel, valve head
Grinding mandrel, thrust spindle
Grinding mandrel, holder - outside
Grinding mandrel, holder - inside
Screw, topcover
Extractor tool, suctions valve
Hook spanner
MAN B&W Diesel A/S
Fuel Valve - Tools
Plate
P90961-0037
Fuel Valve - Tools

0037
P90961
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90961-0037
Item
No.
014
026
038
051
063
Fuel Valve - Tools
Item Description
Item
No.
Item Description
Connection piece
Test rig
High-pressure hose
Table
High-pressure pump
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve - Tools
MAN B&W Diesel A/S
Plate
P90961-0069
Page 1 (2)
Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122
Page 2 (2)
Fuel Valve - Tools
Item Description
Item
No.
Item Description
High-pressure pump
Table
Rig fuel oil valve
High-pressure hose
Connection piece, M42x2
Test rig, complete
Cover
Angle union
Gasket
Plug screw
Hose
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90966-0008
Page 1 (2)
Plate
P90966-0008
Item
No.
011
023
035
047
060
202
Item Description
Item
No.
Item Description
Tool box
Extractor for atomizer
Drift for atomizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When odering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90968-0001
Page 1 (2)
Plate
P90968-0001
Item
No.
Item Description
012
Probe light with magnifier, complete
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90974-0001
Page 1 (2)
Plate
P90974-0001
Item
No.
015
027
039
206

Item Description
Item
No.
Item Description
Drill*
Test mandrel*
Pin vice*
Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90980-0001

0001
P90980
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90980-0001
Item
No.
018
020
031
043
055
067
079
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Cone
Page 2 (2)
MAN B&W Diesel A/S

110-01
910-01
110-02
910-02
110-03
910-03
110-05
910-05
110-06
910-06
91063
91064
91066
91066
0057
0244
0009
0211
0028
0221
0010
0211
0036
0224
0021
0002
0003
0010
Air Cooler Element, Data

Air Cooler Element
Non-Return Valve in Turbocharger, Data
Non Return Valve in Tubocharger
Auxilary Blower, Data
Auxilary Blower
Turbocharger Turbine, Data
Turbocharger Turbine
Water Mist Catcher, Data
Water Mist Catcher
Air Cooler - Tools
Travelling Trolley
Air Cooler - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Air Cooler Element

MAN B&W Diesel
110-1
Data

Stopped engine
X
X
X
X
X
X

X
X
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
D10-02
Aft end cover
D10-04
Air cooler element, complete with covers, up to
D10-05
Front end cover
Value
Unit
75
kg
1100
kg
120
kg
Page 1 (2)
Air Cooler Element
110-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P91063
Air Cooler - Tools
P91064
Travelling Trolley
P91066
P91356
Lifting Tools, Etc.
Page 2 (2)
Air Cooler Element

MAN B&W Diesel
910-1.1
Checking
1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air
across the cooler while the engine is running.
1.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
the air side of the cooler.
A decrease in the air temperature drop
across the scavenge air cooler indicates
fouling of the water side of the cooler.
3. If the measurements indicate fouling of the
water side of the air cooler element, the element must be dismantled and overhauled/
cleaned.
M910010244C01
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see instruction book Volume I, Chapter 706.
2.
4. Remove the top cover of the air cooler.

5. Visually inspect the air cooler element
through the opening.
3.
M910010244C03
If the air side of the element is fouled,

clean the element using the spray pipe arrangement fitted above the air cooler element.
M910010244C02
If the measurements indicate fouling of the

air side of the air cooler element, it is recommended to inspect the air cooler element as follows:
Page 1 (7)
910-1.2
Air Cooler Element

Dismantling
1.
MAN B&W Diesel
1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off
the cooling water.
2. Dismount the cooling water inlet and outlet
pipes from the front end cover.
Remove and discard the gaskets.
M910010244D01
3. Dismantle the screws and pull out the

cooler element approx. 10 cm using the
dismantling screws.
M910010244D02
2.
M910010244D03
3.
Page 2 (7)
Air Cooler Element
910-1.2
Dismantling
MAN B&W Diesel

4. Mount the lifting tool on the front end
cover.
4.
Attach a shackle to the lifting tool. Hook a

tackle on to the shackle.
Using the tackle, lift the air cooler element
approx. 2-3 mm.
5. Mount the two guide rails on the frame

around the air cooler element.
6. Pull out the air cooler element far enough
to gain access to the aft end cover.
Mount shackles on the lifting brackets on
the aft end cover. Hook tackles on to the
shackles.
M910010244D04
Pull out the air cooler element approx. half

a metre.
5.
Using the tackles lift the air cooler element

away. Land the element on a couple of
wooden planks.
Note!
M910010244D05
During the lift, take care not to damage

the air cooler element.
6.
M910010244D06
D1004
Page 3 (7)
910-1.3
Air Cooler Element

Overhaul
MAN B&W Diesel
Cleaning the air side:

1.
1. The air side of the cooler is cleaned by injecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.
It is recommended to use one of the following cleaning fluids, or a similar product.
Product: ACC 9, produced by
Drew Chemical Corp., New York, USA
Product: 80B, produced by
Vecom Int., Maassluis, Holland
M910010244O01
2. Do not start cleaning until the engine has

been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
2.
Remove the covers on the scavenge air receiver to let vapours escape.
3. Follow the detailed cleaning instructions
displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
4. 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.
M910010244O02
5. After cleaning, flush the cooler with clean

water until the water in the sight glasses
appears clean and pure.
Page 4 (7)
6. Inspect the air cooler element by removing

the cover of the scavenge air cooler housing.
Air Cooler Element
910-1.3
Overhaul
MAN B&W Diesel

Cleaning the water side
2.
1. Dismantle the air cooler element and remove it from the engine.
D1005
2. Dismantle the front end cover of the air

cooler element.
4. Clean the water side of the cooler element

(the inside of the tubes) using the cleaning
brush mounted on a drilling machine. Flush
the tubes with clean fresh water.
In the event of a leaking tube, plug both
ends of the tube using a brass or copper
plug.
M910010244O03
3. Dismantle the aft end cover of the air

cooler element.
3.
D1002
In the event of leakages between a tube

and the tube plate, roll the tube using the
tube expander.
5. Clean and check the inside of the front end

and aft end covers. If necessary replace
the corrosion blocks.
Note!
If damaged, the coating inside the covers is to be repaired with the original
coating or a similar product.
M910010244O04
Tools for tube cleaning and the tube expander are supplied by the air cooler
manufacturer.
4.
6. When cleaning is complete, mount new

gaskets or packing paste and re-mount the
front end and aft end covers of the air
cooler element.
M910010244O05
7. Re-mount the air cooler element in the

scavenge air cooler housing.
Page 5 (7)
Air Cooler Element
910-1.4
Mounting
1.
D1004
MAN B&W Diesel
1. Lift the air cooler element and land the aft

end of the element on the guide rails
mounted on the air cooler housing.
Remove the tackles and shackles from the
aftmost lifting brackets.
2. Push the air cooler element inwards
approx. one metre.
M910010244D06
Remove the guide rails from the air cooler

housing.
2.
3. Clean the frame around the air cooler element and the contact surface of the front
end cover.
Apply a thin layer of silicone paste to the
frame around the air cooler element and
the contact surface of the front end cover.
M910010244M02
Push the air cooler element fully into the air

cooler housing.
M910010244M03
3.
Page 6 (7)
Air Cooler Element
910-1.4
Mounting
MAN B&W Diesel

4. Mount and tighten all the screws of the
front end cover.
4.
Remove the tackle, the shackle and the lifting bracket from the front end cover.
5. Mount the cooling water inlet and outlet
pipes on the front end cover.
6. Close the drain cocks and open the cooling
water inlet and outlet valves.
Remember to vent trapped air from the

air cooler element.
M910010244M04
Note!
M910010244D02
5.
M910010244M06
6.
Page 7 (7)
110-2
Non-Return Valve
Data
N
D
R
B
I
E

X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-2
Non-Return Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Non-Return Valve
910-2.3
Overhaul
Non-Return Valve
0211
Overhaul
910-2.3
1.
This procedure includes both the main non-return valve and the non-return valve for the auxiliary blowers.
Both sets of non-return valves are accessed via
the scavenge air receiver.
Note!
Main Non-Return Valve

1. The main non-return valve consists of four
valve flaps located inside the scavenge air
cooler housing.
BM910-2.3 208 01
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
2.
2. Remove the screws holding the valve flap.

Remove the valve from the engine.
3. Remove the spring pin from the valve shaft
and knock the valve shaft out of the valve
flap.
Clean the valve shaft and the slide bearings
inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul, it must be possible to
move the valve flap by the light touch of a
finger.
BM910-2.3 208 02
4. Assemble the valve and re-mount it in the

BM910-2.3 208 03
3.
0$1% :'LHVHO$6
Page 1 (2)
910-2.3
Non-Return Valve
Overhaul
5.
Non-Return Valve for Auxiliary Blowers

5. Inside the scavenge air cooler housing, lift
up the valve flap of the valve to be overhauled.
6. Remove the screws behind the valve flap.
Remove the valve from the engine.
BM910-2.3 208 05
7. Remove the spring pins from the valve shaft

and knock the valve shaft out of the valve
flap.
6.
Clean the valve shaft, the slide rings and

the slide bearings inside the valve flaps. Lubricate the valve shaft, the slide rings and
the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul it must be possible to
move the valve flap by the light touch of a
finger.
BM910-2.3 208 06
8. Assemble the valve and re-mount it in the

BM910-2.3 208 07
7.
Page 2 (2)
0$1% :'LHVHO$6
Auxiliary Blower
MAN B&W Diesel
110-3
Data

Stopped engine
X
X
X
X
X
X

Shut off fuel oil
Data
Ref.
D10-09
Description
Weight of blower unit, complete * up to
Value
Unit
600
kg
Page 1 (2)
Auxiliary Blower
110-3
MAN B&W Diesel
Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting Tools, Etc.
Auxiliary Blower
MAN B&W Diesel
910-3.3
Overhaul
1. Depending on the type of overhaul, disconnect the cable connections from one or
both blower motors.
2.
The overhaul can be carried out either by

dismantling the complete blower unit or
just dismantling the individual blower wheel
which is to be replaced/overhauled.
Hook a shackle and a tackle to the lifting

bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates.
Remove all screws in the outlet flange of
the blower unit.
M910030221O01
2. Complete Blower Unit
D1009
Remove all screws in the lower inlet flange

of the blower unit.
Remove all screws in the upper inlet flange
of the blower unit.
Lift away the blower unit and land it on
wooden planks for further dismantling/overhaul.
Page 1 (2)
910-3.3
Auxiliary Blower
Overhaul
3.
MAN B&W Diesel
3. Blower Wheel and Electric Motor

When cleaning and inspecting the auxiliary
blower, disengage the cable connections to
the blower motor.
M910030221O02
Wire ropes with shackle as well as two

tackles suspended from mountings on the
gallery bracket are to be hooked onto the
blower flange, before removing the screws
in the flange.
4.
4. The end cover complete with blower can

now be pulled free of the suction pipe by
means of the two tackles.
While pulling out the end cover with the
blower assembly, make sure that the
blower housing disengages from the air
pipe without deforming it.
Then inspect and clean the blower wheel
as well as the blower housing.
For overhaul of blower wheel and bearings,
see blower manufacturers instructions.
M910030221O03
Note!
Page 2 (2)
Exercise care when mounting the electric motor with blower wheel, as the
blower wheel is to catch the guide in
the blower housing.
110-5
Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-5
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
910-5.1
Cleaning
The dry cleaning method employs compressed
air to blow dry, solid, granules through the turbocharger, 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 deposits with this dry cleaning method.
Therefore, in order to prevent the build-up of
thick deposits, the turbine must be cleaned after 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 instruction plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger turbine, see turbine
manufacturers instructions.
See also Volume I, Chapter 706.
MAN B&W Diesel A/S
Page 1 (2)
910-5.3
Cleaning
Cleaning Procedure:
1.
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.
M910050211O01
4. Open valves B and C, to blow out any deposits and/or condensate in the connecting
pipe.
After about two minutes, close valves B
and C.
5. Slowly open valve A to relieve the pressure
in the tank.
2.
M910050211O02
TC type
NA34
NA40
NA48
NA57
NA70
NA83
VTR354/TPL77
VTR454/TPL80
VTR564
VTR714/TPL85
MET53SD/E
MET66SD/E
MET71SD/E
MET83SD/E
Page 2 (2)
Amount
dm3
0.5
1.0
1.5
2.0
3.0
3.5
1.5
2.0
2.5
3.0
1.6
2.6
2.6
3.5
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 granules. After one to two minutes, close valves
B and C.
9. Slowly open valve A to relieve the pressure
in the tank.
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.
MAN B&W Diesel A/S
Water Mist Catcher

MAN B&W Diesel
110-6
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

X Shut off cooling water
Shut off fuel oil
Data
Ref.
D10-11
Description
Water mist catcher
Value
Unit
65
kg
Page 1 (2)
Water Mist Catcher
110-6
MAN B&W Diesel
Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting Tools, Etc.
Water Mist Catcher

MAN B&W Diesel
910-6.2
Dismantling
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.
2. To dismantle the water mist catcher, dismantle the rectangular cover from the aft
end of the scavenge air cooler housing.
Loosen the screws at the end of the water
mist catcher.
Note!
3. Pull or push in the water mist catcher halfway out and mount an eye bolt in the top
of the water mist catcher.
Hook a tackle on to the eye bolt and lift
the water mist catcher away. Land it on a
M910060224D01
Note the position of the water mist

catcher. During mounting, the water mist
catcher must be re-mounted in the same
position.
4.
Note!
Take care not to damage the water mist
catcher during the lift.
4. Clean the water mist catcher with the same

cleaning fluid as used for the scavenge air
cooler element.
M910060224D02
D1011
Page 1 (2)
910-6.4
Water Mist Catcher

Mounting
MAN B&W Diesel
1. Slide the water mist catcher into the scavenge air cooler housing.
1.
Note!
D1011
M910060224M01
Air flow
Make sure to mount the water mist

catcher correctly. The screws of the water mist catcher must face the exhaust
side of the engine.
Also note the markings on the water
mist catcher.
When the water mist catcher is half-way in,
remove the tackle and the eye bolt, and
push the water mist catcher fully into the
2. Tighten the screws at the end of the water
mist catcher.
2.
M910060224M02
Apply a thin layer of silicone paste on the

frame and mount the rectangular covers on
the aft end of the scavenge air cooler
housing.
Page 2 (2)
Air Cooler - Tools
Plate
P91063-0021
Air Cooler - Tools

0021
P91063
Fore end
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91063-0021
Item
No.
015
027
Air Cooler - Tools
Item Description
Item
No.
Item Description
Guide rail for air cooler fore end

Guide rail for air cooler fore end
Page 2 (2)
MAN B&W Diesel A/S
Travelling Trolley
MAN B&W Diesel A/S
Plate
P91064-0002
Page 1 (2)
Plate
P91064-0002
Item
No.
010
Travelling Trolley
Item Description
Item
No.
Item Description
Travelling trolley*
Note:
* When ordering this tool, please state
load and track width.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P91066-0003

0003
P91066
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91066-0003
Item
No.
011
047
Item Description
Item
No.
Item Description
Lifting attachment air cooler fore end,

complete
Screw
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91066-0010
Page 1 (2)
Plate
P91066-0010
Item
No.
011
023
035
047
Page 2 (2)
Item Description
Item
No.
Item Description
Crame beam
Screw
Distance pipe
Nut
MAN B&W Diesel A/S

111-01
911-01
111-02
911-02
111-03
911-03
0026
0212
0013
0211
0001
0001
Safety Valve, Data

Safety Valve
Relief Valve, Data
Relief Valve
Scavenge Air Receiver - Safety Valve, Data
Scavenge Air Receiver - Safety Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Safety Valve
MAN B&W Diesel
111-1
Data

Stopped engine
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D11-01
Opening pressure
D11-02
Valve housing, tightening torque
Value
Unit
200 5
bar
45
Nm
Page 1 (2)
Safety Valve
111-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P91351
10
P91351
58
P90151
117
P91359
Page 2 (2)
Test equipment for combined safety valve

Torque Spanners
Safety Valve
MAN B&W Diesel
911-1.2
Dismantling
When Side-mounted
1.
1. Remove the guard surrounding the safety

valve.
Unscrew the safety valve from the extension pipe.
When Top-mounted
3. Unscrew the safety valve from the cylinder
cover.
2.
M911010211D02
Remove and discard the mild steel disc.
M911010211D01
2. Dismantle the indicator cock and the intermediate pipe.
M911010211D03
3.
Page 1 (5)
911-1.3
Safety Valve
Overhaul (Adjustment)
1.
MAN B&W Diesel
1. If necessary, dismantle the safety valve and

clean all the parts in either gas oil, kerosene, 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

M911010211O01
in the data, loosen and tighten again to

the torgue stated in the data.
3. Then mount:
the valve spindle
the spring
the adjusting screw
the lock nut
M911010211O02
2.
M911010211O03
3.
Page 2 (5)
Safety Valve
MAN B&W Diesel
911-1.3
Overhaul (Adjustment)
4. To set the safety valve opening pressure:
4.
Set up the safety valve in the Fuel valve

test rig.
Connect the testing device to the hydraulic pump. Alternatively the hydraulic
hans pump can be used.
Loosen the lock nut on the safety valve.

Turn the adjusting screw until the valve
just closes.
Bleed the valve and hose until oil, without air bubbles, flows out from the
openings of the safety valve.
Tighten the adjusting screw of the
Tighten the lock nut.

Test the opening pressure.
Remove the valve from the fuel valve
M911010212O04
safety valve until the correct pressure is

indicated (see Data).
test rig.
Page 3 (5)
911-1.4
Safety Valve
Mounting
MAN B&W Diesel
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.
M911010211M01
3. Mount a new sealing ring and a new or

overhauled safety valve.
When mounting the safety valve, apply
tools only on the hexagon on the safety
valve.
Mount the guard surrounding the safety
valve.
M911010211M02
2.
M911010211M03
3.
Page 4 (5)
Safety Valve
MAN B&W Diesel
911-1.4
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
M911010211M04
Mount a new mild steel disc in the bore.
M911010211M05
5.
Page 5 (5)
111-2
Relief Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
111-2
Relief Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Relief Valve
911-2.1
Checking
Relief Valve
60&
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 damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
If one or more plates in the flame arrester

are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
Note!
XZ911-2.1 209 01
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
The complete flame arrester has to be

replaced after a crankcase explosion.
XZ911-2.1 207 03
2.
0$1% :'LHVHO$6
Page 1 (1)
Scavenge Air Receiver Safety Valve

MAN B&W Diesel
111-3
Data

X
X
X
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
111-3
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
911-3.1
Checking
1. The scavenge air receiver safety valve

is calibrated at the factory and does not
require any adjustment.
2.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
If this operation cannot be performed

smoothly, the safety valve must be
dismantled and cleaned.
M911030001C02
Use a piece of cloth to wipe out any dirt

from the Oring packing and close the
valve again. Tighten the counter nut.
Page 1 (5)
911-3.2

Dismantling
1.
MAN B&W Diesel
1. Dismount the safety valve from the scavenge air receiver.
M911030001D01
2. On some engines, a cover has to be removed in order to gain access to the safety
valve.
M911030001D02
2.
Page 2 (5)

MAN B&W Diesel
911-3.3
Overhaul
1. Remove the split pin.
1.
Unscrew the nut thereby relieving the

spring tension.
Remove the nut, spring retainer and
washers.
Keep count of the washers.
2. Pull out the valve ap with spindle. If the

Oring seal is damaged remove it without
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.
M911030001O01
Pull out the spring.
M911030001O02
2.
Page 3 (5)
911-3.3

Overhaul
4.
MAN B&W Diesel
4. If the Oring seal has been removed mount

a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve ap and spindle while
taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the
washers.
M911030001O04
Tighten the nut until the split pin can be

mounted.
7. Check the valve according to 9113.1.
M911030001O05
5.
M911030001O01
6.
Page 4 (5)

MAN B&W Diesel
911-3.4
Mounting
1.
M911030001M01
1. Mount the safety valve on the scavenge air

receiver.
Page 5 (5)

112-02
912-02
112-03
912-03
912-05
91261
91263
0015
0208
0027
0211
0201
0072
0059
Holding Down and End Chock Bolts (Epoxy), Data

Holding Down and End Chock Bolts (Epoxy)
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Holding Down And End Chock Bolts

MAN B&W Diesel
112-2
Data

Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D12-02
Description
Value
Unit
Check holding down bolts and end chock bolts for correct tightening
after the following service hours:
D13-01
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
900
bar
Page 1 (2)
Holding Down and End Chock Bolts
112-2
MAN B&W Diesel
Data
Plate
Item No.
P91263
Description
Hydraulic Tools for Holding-Down
Bolts and End Chock Bolts, Epoxy
P91351
010
P91351
058
Page 2 (2)
912-2.1
Checking
.0&
0208
Checking
912-2.1
Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
Page 1 (5)
912-2.1

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 attempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pressure gauge when the nut comes loose
(loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.
EN912-1.1 205 01
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the tables from successive bolt checks.
If the loosening pressure' is below 80 per
cent of the tightening pressure, the relative
chocks shall always be checked for possible 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 followed.
Page 2 (5)
0$1% :'LHVHO$6
912-2.1
Checking
3.
Side Chocks and Side Chock Liners

3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The first time the ship is sailing in a fullyloaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the liners can be knocked further inward.
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.
GN912-2.1 203 03
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simultaneously.
The feeler gauge is applied at the 7 points

indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have
increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in
the table.
If this procedure does not improve the situation,
the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position
by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Page 3 (5)
912-2.1
Checking
Holding Down Bolts
Engine
frame Bolt
No.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page 4 (5)
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Port side
pressure
% dev.
remarks
Cylinder
No.
1
2
3
Starboard side
pressure
% dev.
remarks
Bolt
No.
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Engine
frame
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0$1% :'LHVHO$6
912-2.1
Checking
Side Chocks and End Chock Bolts
Port side
Point
c d e
Chock
No.
Starboard side
Cylinder
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Chock
d
e
f
Pres-
Port side
c, d, e, f, g
Starboard side
Devi-
Ch Bolt sure ation

2)
No. No. (kp/cm
%
bar
No.
A, B
FORE
c, d, e, f, g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
A, B
Point
c d e
Deviation
Point
Point
a b c d e
a b c d e
Pressure
(kp/cm 2 )
bar
1
2
Bolt Ch
No. No.
1
E
2
b
b
a
Contact face No. 1
No. 2
B1
0$1% :'LHVHO$6
B2
B2
B1
AFT
No. 2
Page 5 (5)
Stay Bolts
MAN B&W Diesel
112-3
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D12-04
Check measurement
0.4
mm
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Stay Bolts
112-3
MAN B&W Diesel
Data
Plate
Item No.
P91261
Description
Large Parts - Tools
P91351
010
P91351
046
P91351
058
P91351
105
Page 2 (2)
Stay Bolts
912-3.1
Checking
0211 Bolts
Stay
S42MC
Checking
912-3.1
1.
1. Before retightening the stay bolts, remove

the protective caps.
Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
3. If the engine is equipped with split staybolts
and one or more staybolts have been dismantled, make sure that the staybolts are
mounted in such a way that, when the uppermost staybolt nut is loosened, there is a
clearance, as stated in Data, between the
contact face of the lowermost nut and the
bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.
HM912-3.0 28 01
2. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other on the middle of
the engine.
2.
HM912-3.0 28 02
D13-01
3.
HM912-3.0 28 07
D12-05
MAN B&W Diesel A/S
Page 1 (2)
912-3.1
Stay Bolts
Checking
4.
4. Start the retightening of the stay bolts and

proceed to tighten the stay bolts in pairs,
working from the middle toward one end of
the engine and then from the middle again
toward the other end.
5. Maintain the hydraulic pressure at the value
indicated in D-1, and retighten the stay bolt
nuts with a tommy bar. Before relieving the
system of pressure, check with a feeler
gauge that the nuts bear against the contact face.
HM912-3.0 28 03
6. Reconnect the hydraulic tools to the pair of

stay bolts first tightened. Tighten to 10%
below D-2 and check if the nut is loose.
5.
D13-02
If the nut is not loose:

Tighten the stay bolts to D-2.
If the nut is loose:
Tighten all stay bolts once again to D-2.
HM912-3.0 28 04
7. After completing the retightening procedure, mount the protective caps.
HM912-3.0 28 06
6.
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
912-5.1
Checking
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing.
1.
If the water content of the main engine

lube oil is rising, this may indicate that
the crankcase oil outlet sealings are fractured.
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing
remove:
Screws A
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
M912050201C01
Note!
2.
Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
M912050201C02
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
Page 1 (2)
912-5.1
Checking
MAN B&W Diesel
Metal bellow sealing

4.
4. Remove all screws A and grating B.
C
D
5. Remount four of the screws A at diametrically opposite positions.
B
A
6. Remove:
Screws C
Cover plate D
Screws E.
M912050201C04
7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are
found in the metal bellow sealing, it must
be replaced.
Note!
7.
It is recommended to always replace the

metal bellow sealing during inspection.
8. Replace gaskets G and H.

9. Mount metal bellow sealing F.
M912050201C07
10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Page 2 (2)
Large Parts - Tools
Plate
P91261-0072
Large Parts - Tools

0072
P91261
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91261-0072
Item
No.
023
035
047
059
060
084
096
202
Large Parts - Tools
Item Description
Item
No.
Item Description
Hydraulic jack, complete

Support
Tommy bar
Tommy bar
Hydraulic tool set, complete
Page 2 (2)
MAN B&W Diesel A/S
Hydraulic Tools - Holding-Down and

End Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
Plate
P91263-0059
Page 1 (2)
Plate
P91263-0059
Item
No.
024
036
048
050
061
073
085
097
107
119
203
Page 2 (2)
Hydraulic Tools - Holding-Down and

End Chock Bolts (Epoxy Chocks)
Item Description
Item
No.
Item Description
Hydraulic jack for end-chock bolt M48

x 5.0
Hydraulic jack for holding-down bolt
M30 x 3.5
Support for end-chock bolt
Support for holding-down bolt
Tommy bar
Spanner
Hydraulic tool set, complete
MAN B&W Diesel A/S
913 - General Tools

913-01
913-04
913-05
913-06
913-07
91311
91351
91356
91357
91358
91359
91360
91361
91362
91363
91364
91366
0206
0201
0205
0205
0207
0204
0033
0052
0003
0002
0002
0002
0052
0059
0040
0059
0065
Hydraulic Tools
Standard Tightening Torques
Torque Spanner
Tightening Gauge
Screws and Nuts
Lubricating
Accessories - Hydraulic Tools
Lifting Tools, etc.
Open-Ended Spanners
Open Ended Slugging Spanners
Torque Spanners
Pliers
Spanners
Open-Ended Spanners
Instruments
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Hydraulic Tools
913-1
Hydraulic Tools
0206
913-1
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
L. Lifting tool
S. Clearance
BG913-1.0 15 01
K. Extension stud
U. Milled recess for feeler gauge

2.
Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts must
only be loosened and tightened up by means of
the hydraulic tools supplied.
1. The hydraulic tools, except those for the
main bearings, consist 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.
BG913-1.0 15 02
2. For the main bearings, the hydraulic tool

consists of a double jack with two extension
studs. This jack is designed for the simultaneous dismantling of both nuts on one side
of the main bearing.
0$1% :'LHVHO$6
Page 1 (12)
913-1
3.
Hydraulic Tools
3. 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 required, 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.
BG913-1.0 15 03
4. The hydraulic jacks are so designed that, in

the event that the Max. lift limit is exceeded, the pressure is relieved at the bottom of
the pressure chamber and the oil will be
pressed out into the space between the
stud and the spacer ring.
When the pressure is relieved in this way,
the lowermost sealing ring will in most cases be damaged. Therefore inspect and, if
necessary, replace this sealing ring.
The oil used must be pure hydraulic oil or
turbine oil (with a viscosity of about SAE
20). Oils such as, for instance, lubricating
oil (system oil) or cylinder lubricating oil
must not be used, as these oils are normally alkaline and can thus damage the backup rings.
The following instructions must be closely
followed to prevent accidents or damage,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.
Warning!
Eye protectors and gloves must be used
when using hydraulic tools.
Page 2 (12)
0$1% :'LHVHO$6
Hydraulic Tools
913-1
Loosening of Nut
Loosening of Nut
913-1
1.
Single Hydraulic Jack

1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar.
Place the spacer ring around the nut in
such a position that the tommy bar can be
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.
Unscrew the jack to create a clearance between the jack and spacer ring. See sketch.
BG913-1.1 15 01
Connect the hydraulic jack, the distributor

block and the high pressure pump by
means of high pressure hoses.
Loosen the bleed screw in the jack and fill

up the system with oil until oil without bubbles, flows out of the bleed hole. Then tighten the bleed screw again.
2.
When loosening nuts on very long bolts

(e.g. staybolts) it is recommended to unscrew the jack an additional half turn.
The clearance between the jack and spacer
ring ensures dismantling of the jack after
loosening the nut.
BG913-1.1 15 02
After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylinder of the jack.
0$1% :'LHVHO$6
Page 3 (12)
913-1
Hydraulic Tools
Loosening of Nut
3.
3. Increase the oil pressure to the prescribed

value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.
4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up
against the jack.
GN913-1 203 06
5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
Note!
Make sure not to exceed the max lift
stamped on the jack.
HM913-1.1 10 04
4.
GN913-1 203 08
5.
Page 4 (12)
0$1% :'LHVHO$6
Hydraulic Tools
913-1
Loosening of Nut
6.
Double Hydraulic Jack

6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.
Grease the tool attachment threads with
molybdenum disulphide grease or graphite
and oil or similar.
Mount the extension studs on the main
bearing studs.
Using the lifting tool, place the spacer ring
over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.
Mount the two jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.
BG913-1.1 15 06
Press the pistons and the cylinder of both

the hydraulic jacks firmly together.
Make sure that both the cylinders of the

jacks and the spacer ring are guided correctly together.
7.
Screw the upper nuts on to the threads of

the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.
7. The clearance between the pistons and the
cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm.
The clearance between the jack and spacer
ring ensures dismounting of the jack after
loosening the nut.
Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.
BG913-1.1 15 08
Connect the hydraulic jacks, the distributor

0$1% :'LHVHO$6
Page 5 (12)
913-1
Hydraulic Tools
Loosening of Nut
8.

value. If the nut does not come loose, the
pressure may be increased by approx. 90
bar.
Unscrew the lower nuts 1 turns with the
tommy bar, making sure that the nuts are
not screwed up against the extension stud.
the high-pressure pump, and remove the
hydraulic tools.
Note!
BG913-1.1 15 09
Make sure not to exceed the max lift

stamped on the jack.
BG913-1.1 15 11
9.
Page 6 (12)
0$1% :'LHVHO$6
Hydraulic Tools
913-1
Tightening of Nut
Tightening of Nut
913-1
1.
Single Hydraulic Jack

1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.
Clean and lubricate the tool attachment
thread and the thread in the nut with molybdenum disulphide grease or with graphite
and oil or similar.
Fit the round nut on the thread and tighten
it with the tommy bar.
Check with a feeler gauge that the contact
face of the nut bears on the entire circumference.
2. Press the piston and the cylinder of the jack

firmly together.
Screw the hydraulic jack on to the tool attachment thread.
BG913-1.2 15 01
Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot for the purpose of
tightening the nut.
2.
Make sure that the cylinder of the jack
bears firmly against the spacer ring and
that the parts are guided correctly together
Connect the hydraulic jack, the distributor
block and the high-pressure pump by
means of high-pressure hoses.
Loosen the bleed screw in the jack and fill
up the system with oil, until oil without bubbles flows out of the bleed hole.
BG913-1.2 15 02
Re-tighten the bleed screw.
0$1% :'LHVHO$6
Page 7 (12)
913-1
Hydraulic Tools
Tightening of Nut
3.

value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.
4. While maintaining the pressure, check with
a feeler gauge introduced through the recess at the bottom of the spacer ring that
the nut bears against the contact face.
the pump, and remove the hydraulic jack.
GN913-1 203 17
6. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nut as described under Loosening, points 6-7-8, and then
tighten the nut again according to the procedure under Tightening', points 3-4-5.
GN913-1 203 18
4.
Page 8 (12)
0$1% :'LHVHO$6
Hydraulic Tools
913-1
Tightening of Nut
7.
Double Hydraulic Jack

7. Thoroughly clean the nuts, the threads on
the main bearing studs, the contact faces,
and the surrounding parts.
Clean and lubricate the tool attachment
thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil.
Fit the round nuts on the threads and tighten them with the tommy bar.
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circumference.
Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of tightening the
nuts.
BG913-1.2 15 07
Mount the extension studs on the main

bearing studs.
8.
8. Press the piston and the cylinder of both

the hydraulic jacks firmly together.
Mount the two jacks (one by one using the
lifting tool) over the extension studs and
land them on the spacer ring.
Make sure that both the cylinders of the
jacks and the spacer ring are guided correctly together.
Screw the upper nuts on to the threads of
the extension studs until the cylinders of the
jacks bear firmly against each other and
against the spacer ring.
Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
Re-tighten the bleed screws.
BG913-1.2 15 08
Connect the hydraulic jacks, the distributor

0$1% :'LHVHO$6
Page 9 (12)
913-1
Hydraulic Tools
Tightening of Nut
9.

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
spacer ring.
10. While maintaining the pressure, check with
a feeler gauge introduced through the recesses at the bottom of the spacer ring that
the nuts bear against the contact face.
the pump, and remove the hydraulic tools.
BG913-1.2 15 10
12. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nuts as described under Loosening', point 8, and then tighten
the nuts again according to the procedure
under Tightening', points 9-10-11.
BG913-1.2 15 11
10.
Page 10 (12)
0$1% :'LHVHO$6
Hydraulic Tools
913-1
Maintenance
Maintenance
913-1
1.
1. The hydraulic jacks require no maintenance

except replacement of defective sealing
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.
The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of
compressed air.
Warning!
Make sure that there are no marks or

scratches on the sliding surfaces of the
parts. The presence of metal particles will
damage the sealing rings.
BG913-1.4 15 01

Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease.
2.
BG913-1.4 15 02
2. The pistons and cylinders of the double

jacks are separated in the same easy way
as described for the single jack.
0$1% :'LHVHO$6
Page 11 (12)
913-1
Hydraulic Tools
Maintenance
3.
3. When changing the sealing rings, first

mount the back-up ring and then the O-ring.
Warning!
Note that the back-up ring (1) must be
away from the pressure chamber and the
O-ring (2) close to the pressure chamber.
See the sketch for the correct mounting of
both the upper and the lower sealing rings.
The same principle applies to all the jacks.
BG913-1.4 15 03
4. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
BG913-1.4 15 04
4.
Page 12 (12)
0$1% :'LHVHO$6
913-4

.0&&
0201
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 lubricant.
Thread
Tightening
torque
Thread
Tightening
torque
M8
17 Nm
M22
400 Nm
M10
35 Nm
M24
460 Nm
M12
50 Nm
M27
610 Nm
M14
80 Nm
M30
950 Nm
M16
135 Nm
M33
1200 Nm
M18
190 Nm
M36
1650 Nm
M20
260 Nm
M39
2100 Nm
2. Self-locking nuts.
Thread
Tightening
torque
Thread
Tightening
torque
M8
20 Nm
M22
430 Nm
M10
40 Nm
M24
490 Nm
M12
60 Nm
M27
650 Nm
M14
90 Nm
M30
1000 Nm
M16
150 Nm
M33
1250 Nm
M18
210 Nm
M36
1700 Nm
M20
290 Nm
M39
2200 Nm
3. Screws and nuts locked with glue/Loctite.

Thread
Tightening
torque
Thread
Tightening
torque
M8
23 Nm
M22
580 Nm
M10
50 Nm
M24
680 Nm
M12
70 Nm
M27
900 Nm
M14
115 Nm
M30
1350 Nm
M16
190 Nm
M33
1700 Nm
M18
270 Nm
M36
2350 Nm
M20
380 Nm
M39
3000 Nm
0$1% :'LHVHO$6
Page 1 (1)
Torque Spanner
913-5
Torque Spanner
/0&
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient = 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 splitpin hole.
The torque spanner must not be used for torques 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 spanner, 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
Page 1 (1)
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.
= 0.10.12 (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 tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:
thread M8 M20 = 50 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. 3045 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.
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.

7
;

G
Q
D

0
+
0$1% :'LHVHO$6
Page 1 (1)
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Some screwed and bolted connections on the

engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.
1.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Make sure only to mount locking devices

on nuts and screws which have been
mounted with locking devices by the engine manufacturer.
1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers
are to be bent back over one of the flats of
the screw or nut concerned.
M913070207C01
Note!
2.
2. Used spring washers must be replaced.
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 of a procedure.
M913070207C02
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
M913070207C03
3.
Page 1 (4)
Screws and Nuts
913-7.1
Locking
Fig. 1
MAN B&W Diesel
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. Always fit new wire after tightening-up the units.
Fig. 2
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3
Fig. 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 approximately 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. 6
M913070207C04
Fig. 5
Fig. 4
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,
and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it
min. 3 twists, counterclockwise until tight.
Fig. 7
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
M913070207C05
Fig. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes oriented in different angles.
Page 2 (4)
Fig. 9
Screws and Nuts

MAN B&W Diesel
913-7.1
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. 10
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure.
Fig. 11
Fig. 13: Where drilling of locking wire holes has

caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.
Fig. 12
Fig. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible.
M913070207C06
Fig. 13
Fig. 14
Page 3 (4)
913-7.1
Screws and Nuts

Locking
Fig. 15
MAN B&W Diesel
Cam Lock Washers with rising cams on one

side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam
face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
M913070207C15
Fig. 16: Different uses of the cam lock washers.

Fig. 17: Don not use the cam lock washers in
conjunction with other loose washers.
Fig. 16.
Note!
M913070207C16
Cam lock washers must be installed in

pairs and are not to be substituted by
other typers of washers.
M913070207C17
Fig. 17
Page 4 (4)
Lubricating Procedures
913-11
Lubricating Procedures
.0&&
0204
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 circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote 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 mixture.
Protect the wet paste and cloth from dust
or other foreign particles.
0$1% :'LHVHO$6
Page 1 (1)
Accessories for Hydraulic Tools
Plate
P91351-0033

0033
P91351
Working Pressure 900 Bar
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91351-0033
Item
No.
010
046
058
105
117
130
166
201
213
225
237
249
Item Description
Item
No.
Item Description
Hydraulic pump, pneumatic operated

Hose with unions (1500mm), complete
Hose with unions (3000mm), complete
Angle union
Quick coupling, female
Disc, round-plain, Cu 11x3mm
Bleeder screw
Disc, round-plain, Fe 11x9mm
Page 2 (2)
MAN B&W Diesel A/S
Lifting Tools, Etc.
Plate
P91356-0052
Lifting Tools, Etc.

0052
P91356
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91356-0052
Item
No.
018
020
031
055
114
126
138
140
222
283
305
Lifting Tools, Etc.
Item Description
Item
No.
Item Description
Forged-bent screw shackle, 8mm

Lifting eye bolts, 10mm
Chain tackle, 1000kg
Pull lift, 750kg
Wire rope, 3m
Page 2 (2)
MAN B&W Diesel A/S
Open Ended Spanners
Plate
P91357-0003
Open Ended Spanners

0003
P91357
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91357-0003
Item
No.
013
Open Ended Spanners
Item Description
Item
No.
Item Description
Open-ended spanner, size NV65mm
Page 2 (2)
MAN B&W Diesel A/S
Open-Ended Slugging Spanners
Plate
P91358-0002

0002
P91358
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91358-0002
Item
No.
020
081
Item Description
Item
No.
Item Description
Open-ended slugging spanner, size

NV30mm
Open-ended slugging spanner, size
NV46mm
Page 2 (2)
MAN B&W Diesel A/S
Torque Spanners
Plate
P91359-0002
Torque Spanners
0002
P91359
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91359-0002
Item
No.
014
026
038
040
Torque Spanners
Item Description
Item
No.
Item Description
Torque wrench, 8 - 400Nm

Adapter for socket wrench, 10 x 12.5
mm
Page 2 (2)
MAN B&W Diesel A/S
Pliers
Plate
P91360-0002
P91360
Pliers
0002
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91360-0002
Pliers
Item
No.
010
021
033
116
128
130
141
Item Description
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Page 2 (2)
for
for
for
for
for
for
for
retaining
retaining
retaining
retaining
retaining
retaining
retaining
ring,
ring,
ring,
ring,
ring,
ring,
ring,
size
size
size
size
size
size
size
Item
No.
Item Description
0.9mm
1.3mm
1.8mm
0.9mm
1.1mm
1.8mm
2.3mm
MAN B&W Diesel A/S
MAN B&W Diesel
Plate
P91361-0052
Page 1 (2)
Plate
P91361-0052
Item
No.
015
027
039
040
052
064
076
088
090
100
111
123
135
147
159
160
172
184
196
206
218
220
231
Page 2 (2)
MAN B&W Diesel
Item Description
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
Item
No.
Item Description
NV10mm
NV11mm
NV12mm
NV13mm
NV14mm
NV15mm
NV16mm
NV17mm
NV18mm
NV19mm
NV21mm
NV22mm
NV24mm
NV27mm
NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
Plate
P91362-0059

0059
P91362
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91362-0059
Item
No.
010
022
034
046
058
071
083
095
105
117
Item Description
Item
No.
Item Description
Slugging spanners, ring size NV30mm

Page 2 (2)
MAN B&W Diesel A/S
Spanners
MAN B&W Diesel
Plate
P91363-0040
Page 1 (2)
Spanners
Plate
P91363-0040
MAN B&W Diesel
Item
No.
Item Description
016
028
030
041
100
150
161
Tool set, complete, size 10-22 mm

Tool set, complete, size 24-46 mm
Hex key tool set, complete
Adapter for socket wrench, 20->12.5 mm
Socket spanner, S=46 mm
Hex key, S=22 mm
Hex key, S=24 mm
Page 2 (2)
Item
No.
Item Description
Open-ended Spanners
Plate
P91364-0059
Page 1 (2)
MAN B&W Diesel A/S
Plate
P91364-0059
Item
No.
011
023
Page 2 (2)
Open-ended Spanners
Item Description
Item
No.
Item Description
Open ring wrench, 14 - 17mm

Open ring wrench, 19 - 22mm
MAN B&W Diesel A/S
Instruments
MAN B&W Diesel A/S
Plate
P91366-0065
Page 1 (2)
Plate
P91366-0065
Item
No.
048
050
061
073
Page 2 (2)
Instruments
Item Description
Item
No.
Item Description
Autolog, measuring tool for crankshaft

Feeler gauge
Slide caliper
MAN B&W Diesel A/S
Warning
S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
When referring to this page, please quote S900 Edition 0001

MAN B&W Diesel A/S
Page 1 (1)
L35MC
VOLUME III
COMPONENTS
DESCRIPTION
900 - Introduction
90001
90002
90003
90004
90023
90030
0029
0001
0001
0001
0027
0009
Table of Contents, Volume III

Cross Section through Engine
Ordering of Insulation
Designations and Symbols
Software Licence - Standard Conditions
Instructions for Main Engine
Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
900
Volume III - Components Description

No.
Edition
Title
900 - Introduction
Table of Contents
90001 0029 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence - Standard Conditions
90023 0027 Instructions for Main Engine
90030 0009 Description
90101 0138 Cylinder Cover
90103 0007 Indicator Cock - Mounting
90201 0217 Piston and Piston Rod
90205 0122 Piston Rod Stuffing Box
90301 0188 Cylinder Frame
90302 0192 Cylinder Liner and Cooling Jacket
90304 0025 Cylinder Liner - Details
90401 0145 Connecting Rod and Crosshead
90403 0009 Lubricating and Cooling Oil-Flow
90501 0179 Crankshaft
90502 0076 Arrangement of Fore End
90505 0170 Thrust- and Guide Bearing
90510 0120 Turning Gear
90511 0040 Turning Wheel
90512 0001 Turning Gear - Details
90513 0036 Tacho System
906 - Control Gear
90600 0068 Arrangement of Chain Drive and Camshaft
90601 0105 Chain Drive and Guide Bars
90602 0124 Chain Drive - Lubrication
90603 0059 Chain Tightener
90605 0076 Lubricator Drive
90611 0170 Camshaft and Chain Wheel
90613 0117 Camshaft Bearing
90615 0138 Arrangement of Governor
90618 0139 Regulating Shaft
MAN B&W Diesel A/S
Page 1 (2)
Table of Contents
900

No.
90620
90621
Edition
0107
0085
Title
Engine-Side Control Console
Engine-Side Control Console - Details

90702 0046 Main Starting Valve
90703 0068 Starting Air Distributor
90704 0050 Starting Valve
908 - Exhaust Valve
90801 0184 Exhaust Valve - Lower Parts
90802 0041 Exhaust Valve - Details
90803 0032 Exhaust Valve - Upper Parts
90804 0017 Exhaust Valve Upper Parts - Details
90805 0130 Exhaust Valve - Actuator
90806 0080 Exhaust Valve - Pipe System
90810 0092 Arrangement of Cooling Water Pipes
90901 0207 Fuel Pump
90902 0138 Fuel Pump Gear
90910 0152 Fuel Valve
90911 0021 Fuel Valve Function
90913 0096 High-Pressure Pipes
90914 0105 Fuel Oil System
90915 0076 Fuel Oil System - Details
91000 0016 Gas and Air System
91001 0125 Scavenge Air Receiver
91002 0127 Arrangement of Charging Air Pipe
91003 0197 Exhaust Pipes and Receiver
91004 0049 Exhaust Receiver - Details
91005 0132 Air Cooler
91006 0030 Arrangement of Auxiliary Blower
91009 0036 Air Cooler System - Cleaning
91010 0026 Air Cooler - Frame
91018 0006 Air Cooler System
91101 0037 Safety Valve - Cylinder
91102 0024 Relief Valve
91103 0017 Safety Valve - Scavenge Air System
91104 0108 Arrangement of Safety Cap
MAN B&W Diesel A/S
Page 2 (2)
Table of Contents
900

No.
Edition
Title

91201 0094 Arrangement of Stay Bolts
91205 0159 Frame Box
91207 0054 Arrangement of Piston Cooling
91208 0019 Chain Wheel Frame - Upper
91209 0007 Chain Wheel Frame - Lower
91210 0186 Bedplate
91211 0036 Axial Vibration Damper
91216 0007 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
91217 0004 Top Bracing - Arrangement
MAN B&W Diesel A/S
Page 3 (2)
Cross Section through Engine
MAN B&W Diesel A/S
Plate
P90001-0029
Page 1 (1)
Ordering of Insulation
MAN B&W Diesel
Plate
P90002-0001
Page 1 (1)
Designations and Symbols

MAN B&W Diesel
Normal layout
Plate
P90003-0001
Forward (fwd)
Starboard (stbd) side of
Port side of ship
Fore end
1
2
3
4
5
6
7
Manoeuvring side of engine
Aft end
Cyl. nos. always counted

from fore end
Exhaust side of engine
Propeller
Clockwise direction of rotation

defined from aft end of engine
Page 1 (1)
Software License, Standard Conditions

MAN B&W Diesel
Plate
P90004-0001
Standard Conditions of Software Licence

Software supplied by MAN B&W separately or included as a part of any system or embedded in
any device is licensed by MAN B&W Diesel A/S (MAN B&W) subject to the customer's acceptance of the following standard conditions of licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMERS ACCEPTANCE OF THESE
CONDITIONS.
1. Right of Ownership
Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W
against a once-for-all fee. MAN B&W and its software suppliers retain the right of ownership to the
software.
If the engine plant - for which the software is acquired - is transferred to a third party the customer has the right to assign the licence to this third party, provided that the third party agrees to
the terms of this licence agreement and provided that the customer does not retain any copies of
the software.
2. Copyright
The customer must not copy the software or any part thereof. Furthermore the customer is not
allowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software.
3. Support
If required by the customer MAN B&W shall provide technical support for installation and training
in use of the software against separate payment.
4. Updating
The non-exclusive user's licence does not include any updating of the software. If and to the extent MAN B&W updates the programs or develops new versions, such updates or new versions
shall be made available to the customer against separate payment.
5. Warranty & Liability
MAN B&W warrants that the software and data media containing the software are free of defects
in material and workmanship at the time of delivery. If the software and data media are found to
be defective and are returned to MAN B&W within 90 days from the date of delivery, they will be
replaced free of charge.
Except as stated above, MAN B&W disclaims liability for breach of conditions or warranties, either
expressed or implied, with respect to the software and data media, including warranties of suitability and applicability for a particular purpose.
Page 1 (2)
Plate
P90004-0001
Software License, Standard Conditions

MAN B&W Diesel
MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the
form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. MAN B&W shall in no event be liable for
any damages resulting from loss of data, profits or use of equipment, or for any special, incidental
consequential damages arising out of or in connection with the use or performance of the software.
The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&Ws software
suppliers.
6. Law
MAN B&W's tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.
Page 2 (2)
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 engine. Deviations may be found in a specific plant. In addition, the books can be used for reference 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 operation and maintenance in accordance with MAN B&W Diesel A/S instructions. Emissions related 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 contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.
A90023-0027
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

Teglholmsgade 41
DK-2450 Copenhagen
Denmark
Teleph.:+45 33 85 11 00
Telex :16592 manbw dk
Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
Engine Types 35-98MC/MC-C
A90030-0009
MAN B&W Diesel

901 Cylinder Cover
Cylinder Cover
The cylinder cover is made of steel.

On the 70-98MC type engines the cylinder cover is provided with welded-on
heat resistant material at the points of fuel oil injection in order to improve the
service condition.
Valve bores
The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.
The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet, safety valve and indicator cock.
Cooling
A cooling jacket is mounted on the lower part of the cylinder cover, whereby a
cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores, to the space around the
exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe:
On some engine types, an amount of water is also passed directly from the
cylinder cover to the exhaust valve housing through a cooling water connection.
Tightening
The cylinder cover is tightened against the top of the cylinder liner with nuts
and long studs fitted in the cylinder frame. The nuts are tightened with hydraulic tools.
Sealing between the cylinder cover and cylinder liner is obtained by means of a
sealing ring of mild steel.
902 Piston with Rod and Stuffing Box

Piston
The piston consists of two main parts:

Piston Crown
Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the piston skirt is tightened to the piston crown.
When referring to this page, please quote Description A90030 Edition 0009
Page 1 (23)
A90030-0009
MAN B&W Diesel

The piston crown is provided with one groove all the way around, or with three
smaller grooves for the fitting of lifting tools.
The piston crown is provided with chromium-plated grooves for four piston
rings.
Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR).
Piston rings Nos. 2, 3 and 4 have oblique cuts:
piston ring No. 3 has a right-hand cut,
and
piston rings Nos. 2 and 4 have left-hand cuts.
On some engines, the piston rings are provided with Alu-coating to improve
the running-in stability and to reduce the running-in period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel off.
Piston Rod
The piston rod has a through-going bore for the cooling oil pipe, which is secured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe
or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.
The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the flow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.
Page 2 (23)
A90030-0009
MAN B&W Diesel

Stuffing Box
The bore for the piston rod between the scavenge air space and the crankcase
is fitted with a piston rod stuffing box, which is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space.
The stuffing box also prevents scavenge air (in the scavenge air space) from
leaking into the crankcase.
The stuffing box housing consists of two parts, which are bolted together.
Scraper/sealing
rings
The housing is provided with a number of machined ring grooves:
The uppermost groove holds a scraper ring with oblique edges, which
serves to prevent sludge from the scavenge box from being drawn
down to the other rings.
Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC
type engines).
The ring grooves in the middle are fitted with sealing rings.
The lowermost ring grooves are fitted with scraper rings which scrape
the lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase through
bores in the stuffing box housing.
Through bores in the housing and a pipe, the stuffing box communicates with
a control funnel on the outside of the engine, which enables the sealing/scraping performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.
903 Cylinder Liner and Cylinder Lubrication

Cylinder Frame
The cylinder section of the engine consists of a cylinder frame with a bolted-on
or integrated camshaft housing. The cylinder section is tightened together with
the engine framebox and the bedplate by means of stay bolts. Alternatively as
a complete welded assembly integrating the scavenge air receiver into the cylinder frame.
Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes.
On the exhaust side of the cylinder frame there are openings which connect
the scavenge air space around the cylinder liner with the longitudinal scavenge
air receiver of the engine.
Page 3 (23)
A90030-0009

MAN B&W Diesel
There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.
Cylinder cover
studs
Studs for fastening the cylinder cover are mounted in the cylinder frame.
Cylinder Liner and The cylinder liner is fitted with a cooling jacket. The cooling water is supplied
Cooling Jacket
at the lower part of the cooling jacket.
On slim-type liners, the water continues directly to the upper part of the cooling jacket, whereas on the bore-cooled type liner, the water first passes
through the cooling bores. From the top of the cooling jackets, the water flows
through water connections to the cooling jacket on the lower part of the cylinder cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by the
tensioning force from the cylinder cover studs being transmitted via the cylinder cover.
Scavenge air ports
The part of the cylinder liner which is located in the scavenge air space of the
cylinder frame is provided with a number of scavenge air ports, which are un
covered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to
give the scavenge air a rotary movement in the cylinder.
Cylinder lubrication
In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with non-return valves for the supply of lubricating oil to the cylinder.
PC-ring
On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of
the cylinder liner. The purpose of the PC-ring is to prevent the building-up of
deposits on the piston topland and, in turn, prevent the wiping away of the cylinder lubricating oil. Consequently, the PC-ring contributes to reducing the
wear of liners and rings.
Cylinder
Lubricators
The engine is equipped with mechanically or electronically controlled cylinder

lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied.
See also Volume I, OPERATION, Chapter 707.
Page 4 (23)
A90030-0009
MAN B&W Diesel

904 Crosshead with Connecting Rod
Crosshead
The crosshead is provided with two guide shoes fitted on the crosshead ends.
The centre part of the crosshead is designed as a bearing journal which is
housed in the crosshead bearing.
The crosshead bearing cap is provided with a cut-out enabling the piston rod
to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
Piston rod foot
The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.
Lubrication
The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and through a bore in the connecting rod for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder
for the purpose of checking the temperature and flow before the oil is passed
on to the lube oil tank.
Guide shoes
The sliding faces of the guide shoes are lined with cast-on bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.
On some engines, the guide shoes are provided with counterweights.
Tightening
The crosshead bearing is held together by studs and nuts. The nuts are tightened with hydraulic tools.
The crankpin bearing is fitted with steel shells lined with bearing metal and assembled in the same way as the crosshead bearing.
905 Crankshaft and Turning Gear

Crankshaft
The crankshaft is either of the semi-built type, where the parts are shrunk together, or it is a one-piece forging.
The main bearings are lubricated via a main lubricating oil pipe that branches
off to the individual bearings, whereas oil for lubricating the crankpin bearings
is supplied from the crossheads through bores in the connecting rods.
Page 5 (23)
A90030-0009

MAN B&W Diesel
The crankshaft is provided with a chain wheel for the camshaft drive and a
turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order and 4th order moment compensators are installed, if required according to vibration calculations.
Marine engines (except geared plants):
At the aftmost end of the engine, a thrust bearing is fitted.
The thrust bearing serves the purpose of transmitting the axial thrust of the
propeller through propeller shaft and intermediate shafts to the ships hull.
The crankshaft is provided with a thrust collar which transmits the thrust to a
number of segments mounted in a thrust shoe on either side of the thrust collar.
The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal
cast onto the wearing faces against the thrust collar. See also Volume I, OP
ERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the en
gine. The oil is supplied between the segments through spray pipes and spray
nozzles.
The thrust bearing is provided with alarm, slow-down, and shut-down devices
for low lube oil pressure and high segment temperature. See also Volume I,
OPERATION, Chapter 701.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di
rection.
Axial Vibration
Damper
To counteract heavy axial vibrations, and any resultant adverse forces and
vibrations, the crankshaft is provided with an axial vibration damper. See also
Section 912, Assembly of large parts further on in this text.
The damper consists of a piston and a slit-type housing. The piston is made
as an integrated collar on one of the main bearing journals, and the housing is
mounted on the pertaining main bearing support.
The axial movement is damped as a result of the restrictions incorporated in
the bores which interconnect the oil-filled chambers on the two sides of the
piston.
Lubricating oil is supplied to both sides of the piston from the main system.
Page 6 (23)
A90030-0009
MAN B&W Diesel

Turning Gear
The turning gear is attached to the engine bedplate and is driven by an electric
motor incorporating a disc brake.
Through a planetary gearing, the motor drives a horizontal shaft equipped with
a gear wheel which can be axially displaced manually, so as to engage with the
turning wheel of the engine.
The turning gear is provided with a safety arrangement consisting of a safety
lever which must be lifted before the gear wheel of the turning gear can be
made to engage with the turning wheel.
When the safety lever is in its bottom position, it prevents the gear wheel of
the turning gear from engaging with the turning wheel.
Immediately the lever is lifted away from the disengaged position, an interlock
valve inserted in the starting air system of the engine is actuated. This interlock
prevents starting air from being supplied to the engine as long as the turning
gear is in the engaged position.
Warning!
Dismantling of
working parts:
During any dismantling of working parts of the

engine, the turning gear must be in the engaged
position in order to prevent outside forces from
turning the engine, thus causing injuries to personnel or damage to the machinery.
See Volume II, MAINTENANCE, DATA pages.
Pressure testing of starting

valves:
The turning gear must be in the disengaged position during pressure testing of starting valves, as
a leaky valve may cause the engine to rotate, and
damage the turning gear.
See Volume I, OPERATION, Chapter 703.
906 Mechanical Control Gear

Chain Drive
The camshaft with cams for operating the fuel pumps, exhaust valves and indicator drive (option) is driven from the crankshaft through a chain drive.
The chain drive consists of one or more roller chains running on chain wheels
fitted on the crankshaft and the camshaft. The chain is kept tightened by a
chain tightener placed in the chain casing between the crankshaft and the
camshaft.
The long free lengths of the chain are guided by rubber-clad guide bars. Lubricating oil is supplied through spray pipes fitted at the guide bars and chain
wheels.
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Camshaft
The camshaft is made in one or more sections.

If it is made in two or more sections, the sections are assembled by means of
flange couplings.
The camshaft has, for each cylinder:
one cam for operation of the fuel pump
one cam for operation of the exhaust valve
one cam for operation of the indicator drive (option)
The fuel pump and exhaust valve cams are shrunk on to the shaft by heating,
whereas the indicator cams are in two parts, which are assembled with fitted
bolts.
The camshaft rotation constantly follows that of the crankshaft.
Bearings
The camshaft is carried in bearing assemblies which are fitted in the roller
guide housings. See also Volume I, OPERATION, Chapter 708.
Engine timing
The engine timing is adjusted by forcing lubricating oil in between the cams,
couplings or chain wheel and the shaft, which enables the parts to be turned in
relation to each other. See Volume II, Chapters 906, 908 and 909.
Pin gauges
After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are delivered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.
Indicator Valve
Each cylinder is fitted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.
Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.
Note!
For indicator valves of the double-seated design with a spring-loaded closing
face:
In order to prevent overstressing, close the valve lightly before starting the
engine, and retighten the valve when the engine has reached its normal service temperature.
PMI-System
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See separate instructions for operating the PMI-system (option).
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Moment
Compensators
On the basis of calculations, the engine may be provided with fly

weights to counteract engine forces and moments.
Caution!
If the chain drives for the compensators have been dismantled, the
flyweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly fitted moment compensators may excite heavy vibrations.
1st order moment
Applicable on 4-cylinder engines. The moment compensator is arranged

as adjustable flyweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in
the main chain drive.
This moment compensator consists of a (new) chain-tightener wheel
with an incorporated flyweight and a flyweight rotating with the crank
shaft.
2nd order moment
Applicable on 4-5 and 6-cylinder engines. The moment compensator is

arranged as flyweights built into the main chain drive.
On some engines, flyweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a spring-loaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.
4th order moment
The moment compensator is arranged as flyweights built into chain

drives on both ends of the camshaft. Each chain drive is equipped with
a spring-loaded chain tightener, and each chain casing is fitted with a
relief valve.
907 Starting Air System

Starting Air System
The starting air system consists of the manoeuvring system and the
starting air components, which comprise:
Main Starting Valve
Starting Valves
The manoeuvring system is of electric/pneumatic design.
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Main Starting
Valve
The main starting valve is interposed in the starting air main pipe.
The main starting valve consists of a large ball valve and, optionally, a smaller
ball valve for slow-turning prior to starting the engine, which is fitted as a bypass for the large valve. Both valves are operated by pneumatic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted for setting the slow-turning speed.
Furthermore, a non-return valve is incorporated to prevent blow-back in the
event of excessive pressure in the starting air line.
The main starting valve is equipped with a blocking device consisting of a plate
which, by means of a handwheel, can be made to block the actuators.
The ball valves and their actuators are, together with the non-return valve and
blocking device, built together to form a unit.
Warning!
During all inspections of the engine, the blocking device of the main starting
valve must be in the BLOCKED position.
The only exception is when the starting valves are being tested for tightness,
in which case the blocking device of the main starting valve must be in the
WORKING position and the shut-off valve for the starting air distributor must
be in the CLOSED position. See Volume I, operation, Chapter 703, OPERATION after arrival in port.
Starting Air
Distributor
The starting air distributor controls the opening and the closing of the starting
valves.
Starting Valve
The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled

by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now flows from the starting
air pipe to the cylinder.
When the starting period is finished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.
The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.
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908 Exhaust Valve
Exhaust Valve
Each cylinder is equipped with an exhaust valve, which is mounted in a central

bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gas-tight seal against a seat in the cylinder cover.
Valve housing
The valve housing has an exchangeable bottom piece.

The bore for the valve spindle is provided with an exchangeable spindle guide
liner.
Cooling
The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from
the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.
Valve spindle
The part of the spindle stem which travels within the sealing arrangement of
the air cylinder is coated with a wear resistant mixture of metal carbide and super alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is fitted which
causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:
To enable checking the functioning of the exhaust valve while the engine is
running, a lifting/rotation check rod is mounted on top of the hydraulic cylinder on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod.
Note!
This check rod is only for checking purposes, and must not be permanently
activated.
Pistons
At the top of the spindle, two pistons are fitted:
1.
Air piston
The piston serves to close the exhaust valve. The piston is locked to
the spindle by a two-piece conical ring.
2.
Hydraulic piston
The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrangement,
designed to dampen the closing of the valve.
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Note!
After the exhaust valve has been overhauled, it is important to check the
damper, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.
Air cylinder
The air cylinder is mounted on top of the valve housing. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston.
A safety valve is mounted in the bottom of the air cylinder. The safety valve is
connected to the drain pipe which leads to the camshaft housing.
Hydraulic cylinder
The hydraulic cylinder is attached with studs and nuts on the air cylinder on
top of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by the
piston in the hydraulic cylinder.
Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerating the
oil system is fitted at the top of the cylinder.
When the exhaust valve is closed, the pressure in the hydraulic cylinder is low.
A thrust spring opens the valve, enabling oil and air, if any, to escape through
the throttle.
The oil is led through a duct to the space around the air cylinder and is
drained off through a bore X, together with leakage oil from the piston.
When the exhaust valve is activated, the high oil pressure closes the valve, and
the oil flow stops.
Sealing System
Sealing air (where used):

A sealing air arrangement is fitted around the spindle shaft below the air cylinder.
The sealing air is supplied from the air cylinder via a sealing air control unit.
The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear.
The oil content in the air from the air cylinder improves the service condition of
the sealing rings.
The sealing air control unit contains a valve which automatically cuts off the air
flow when the engine is in FINISHED WITH ENGINE status, and a filter housing.
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Sealing oil (where used):
A sealing oil arrangement is fitted around the spindle shaft below the air cylinder.
The sealing oil is supplied from a control unit fitted on top of the exhaust valve
hydraulic actuator.
During the exhaust valve lifting period, oil escapes from the hydraulic actuator
through the restriction chamber to the control unit which, in turn, gives a certain amount of oil (dosage oil) to the exhaust valve spindle.
The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear.
The oil improves the service condition of the sealing rings.
Hydraulic Valve
Actuating Gear
The exhaust valve is actuated by a cam on the camshaft through a hydraulic

transmission.
Hydraulic cylinder
The hydraulic cylinder is attached to the camshaft housing by studs and nuts.
A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck
of the roller guide and is locked to the roller guide by a bayonet joint.
The hydraulic cylinder on the camshaft housing is connected to the hydraulic
cylinder on the exhaust valve by a high-pressure pipe.
Oil is supplied from the lubricating oil system through a non-return valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained through
a pipe connection.
Puncture Valve
On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines, a puncture valve may be mounted on the exhaust valve actuator. During
starting, this valve prevents the exhaust valve from opening during the first part
of the actuator pistons upward stroke.
This function prevents the starting valve and exhaust valve from being open at
the same time, thus ensuring a safe start.
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909 Fuel Oil System
Fuel Pump
Each engine cylinder is equipped with its own fuel pump, which is mounted on
the camshaft housing over the camshaft section corresponding to the cylinder
concerned.
The pump housing is attached to the camshaft housing by studs and nuts.
The square base of the fuel pump housing is provided with a groove to receive
any leakage oil, which is subsequently drained off through a drain pipe.
In the base, a bore is provided for at toothed rack, i.e. the regulating guide,
which controls the quantity of fuel oil delivered by the pump.
Furthermore, for the VIT-type fuel pump, another bore is provided above the
bore for the regulating guide. This bore is provided with a rack, i.e. the timing
guide, which controls the engine timing.
At the top, the pump housing is closed by a top cover.
The top cover is provided with a suction valve and a puncture valve. These
two valves are on some engine types combined into one unit.
The pump housing contains the plunger and barrel. The plunger and barrel are
matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in the
milled keyway in the regulating guide. At the bottom it has a foot which rests
on a steel disc in the bayonet joint at the roller guide neck. A clearance of
approx. 0.1 mm between the plunger foot and the roller guide permits turning
of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing. On the
outside the regulating guide has a toothed rim to mesh with the above-mentioned toothed rack at the base of the pump housing. The toothed rim and
toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked together with the regulating
gear of the engine through a spring-loaded connection. Thus, in the event of a
sticking pump plunger, the regulating gear for the remaining fuel pumps will not
be blocked.
The pump barrel is provided with oil cut-off holes, which are covered and un
covered during the travel of the plunger within the barrel. This function, in con
junction with the turning of the plunger effected by the regulating gear, serves
to regulate the amount of oil injected into the engine cylinder.
Two screw plugs are fitted in the pump housing opposite the cut-off holes of
the barrel. The oil jets which are ejected through the cut-off holes at the end of
the delivery stroke will hit the screw plugs, which can be replaced when they
are eroded.
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Injection timing
Fuel pumps without VIT (Variable Injection Timing):

The pump barrel is attached to the top cover by means of screws.
The lower part of the barrel is guided in the bore of the pump housing. Two
sets of O-rings and back-up rings are fitted in grooves on the outside of the
barrel and the pump cover to seal between pump barrel/pump cover and
housing.
A number of semi-circular shims are inserted between the top cover and the
pump housing. By removing or inserting such shims, the pump barrel can be
slightly lowered or raised in relation to the plunger, and in this way the initial
moment of fuel oil injection into the engine cylinder can be adjusted, and the
maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum combustion pressure.
VIT-type fuel pumps:
The pump barrel is guided at the top and bottom of the pump housing. Low
friction sealing rings are fitted in grooves in the barrel to seal between barrel
and housing. The barrel is provided with a drain bore between the sealing rings
at the lower end.
The pump barrel has a threaded lower end which fits into the internal threads
of the timing guide.
The timing guide has a gear rim to mesh with the upper toothed rack at the
base of the pump housing. The gear rim and toothed rack are marked with
lines enabling the parts to be positioned correctly after disassembly. The
toothed rack is linked to a servo-air cylinder which is controlled mechanically
or electronically in relation to the engine load. The position of the upper
toothed rack determines the vertical position of the barrel relative to the
plunger through the threaded connection.
In this manner the initial moment of fuel oil injection into the cylinder can be
adjusted by a servo-air cylinder.
The pump barrel is prevented from turning by a guide screw mounted in the
pump housing.
Puncture valve
In the top cover of the pump, a puncture valve is fitted. The puncture valve
consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system, and when
STOP is activated, compressed air is supplied to the top of the piston, causing
the piston with pin to be pressed downward and keep the suction valve in the
open position. This will puncture the oil flow to the fuel valve. As long as the
puncture valve is activated, the fuel oil is returned through bores to the pump
housing, and no injection takes place.
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Fuel Oil Injection
During the suction stroke, the spring-loaded suction valve opens and the delivery chamber is filled with oil. As soon as the plunger has covered the cut-off
holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until the cut-off holes are
uncovered by the oblique cut-off edges of the plunger, following which the oil
is forced through two milled grooves at the side of the plunger and out through
the cut-off holes of the barrel during the rest of the delivery stroke.
Shock absorber
A shock absorber is installed on each pump housing or in the main fuel pipe to
take up pressure variations.
Fuel Pump
Actuating Gear
The camshaft housing contains the fuel pump and exhaust valve actuating gear
for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is transmitted through the roller guide to the plunger in the barrel of the pump housing
which through the high-pressure pipes is connected with the fuel valves on
the cylinder cover.
Reversible engines:
The roller guide of each fuel pump incorporates an angular displaceable reversing link.
Reversing is achieved by shifting the roller in the fuel pump drive mechanism at
each cylinder. The link connecting the roller guide and roller is provided with a
reversing arm, and a pivot is mounted at the top end of the reversing arm. The
pivot travels in a reversing guide connected to an air cylinder. The link is selflocking in either the ahead or astern position without the aid of external forces.
Each cylinder is reversed individually, and the reversing mechanism is activated
by compressed air.
The reversing arrangement may incorporate a damper in order to reduce the
mechanical stresses.
Fuel Oil HighPressure Pipes
All high-pressure pipes in the system are provided with a protective outer pipe.
The space between the pipe and the protective outer pipe communicates,
through bores in the union nipples, with a drain bore in the pump top cover.
Fuel Oil Leakage

Alarm
A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS.
35-98MC:
Each fuel pump is, via drain pipes, connected to a common drain tank, which
incorporates a level switch. The drain tank is also equipped with an overflow
pipe, which has a small drain bore below, whereby oil from small leakages can
be drained to the outlet, without actuating the level switch.
In the event of pipe fractures or major leakages in the system, the above-mentioned bore will not be large enough to allow the increased oil quantity to pass,
and the oil level in the drain tank will rise until it reaches the level of the over
flow pipe. The rising oil level will cause the level switch to set off an alarm.
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50-98MC:
Alternatively to the common drain tank, the drain pipes on 50-98MC engines
can be connected to a diaphragm valve, which sets off an alarm and activates
the puncture valve in order to stop the fuel oil flow from the pertaining pump.
On 60-98MC engines, which are provided with pneumatically operated fuel
pump roller guide lifting gear, automatic activation of the lifting gear by the diaphragm valve can be arranged in order to stop the fuel oil flow from the pertaining pump.
Fuel Valve
The fuel valve consists of a valve head and a valve housing. Fitted within the
valve housing is a non-return valve and a spindle and spindle guide with a
pressure spring, and a nozzle.
The spindle may be provided with a cut-off slide. When the fuel valve is fitted
in the cylinder cover, the valve parts are tightened together by the pressure
from the securing nuts.
Functioning
The functioning of the fuel valve is as follows:

The electrical fuel oil primary pump circulates preheated oil through the fuel
pump and fuel valve. The fuel oil passes through the fuel valve, leaving through
a circulation bore and the return oil pipe on the valve head.
When the pressure at the beginning of the fuel pumps delivery stroke has
reached the predetermined pressure, the circulating bores is closed.
When the pressure has reached the predetermined opening value for the fuel
valve, the spindle will be lifted and oil injected through the nozzle into the engine cylinder.
On completion of the fuel pumps delivery stroke, the valve spindle is pressed
against its seat and injection now ceases. Then the circulating bore is uncovered, and oil starts to recirculate through the valve.
910 Turbocharger System

Air System
The engine is supplied with scavenge air from one or more turbochargers, depending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger and,
through a common shaft, the turbine wheel drives the compressor wheel.
The compressor draws air from the engine room, through the air filters. From
the compressor outlet, the air passes through the charging air pipe to the
charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.
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The air cooler incorporates a water mist catcher, which is designed to separate
condensate from the air.
See also Charging Air Cooler further on in this Section.
When the air has passed the water mist catcher, it is pressed into the scav
enge air receiver through non-return valves. The non-return valves open by
pressure from the turbocharger.
From the scavenge air receiver, the air flows to the cylinder through the scavenge air ports when the piston is in the bottom position. When the exhaust
valves open, the exhaust gas is pressed into a common exhaust gas receiver,
from where the gas drives the turbine of the turbocharger with an even and
steady pressure
Scavenge Air
Receiver
The scavenge air receiver is a container having a large volume. The receiver is
bolted on to the cylinder frame, or alternatively integrated into the cylinder
frame, if welded. See Chapter 903.
Scavenge air is collected in the receiver after the air has passed through the
cooler, the water mist catcher and the non-return valves.
The receiver and the cylinder frame communicate through large openings.
The scavenge air receiver is provided with man-hole covers and a safety valve.
Auxiliary Blowers
The engine is provided with two or more auxiliary blowers. The suction sides
are connected to the space after the water mist catcher. The discharge sides
are connected to the scavenge air receiver. Separate non-return valves are installed at the suction side or discharge side of the auxiliary blowers, in order to
prevent reversed air flow.
See also item, Non-return valves, further on.
El. panels for

auxiliary blower
See special instructions supplied by the engine builder.
Running with
auxiliary blowers
During the starting of the engine, and when the engine is running at low load,
the turbocharger is not able to supply enough air for the engine process. In
these cases a pressure switch will automatically start the auxiliary blowers.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air filter and compressor side.
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Warning!
If the auxiliary blowers do not start during low-load running (because of
faults, or because the switch for the blowers is not in AUTO position), unburned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box fire.
In order to avoid such a fire:
obtain permission to stop the engine

stop the engine
remove any unburned fuel oil from the top of the pistons
re-establish the supply of scavenge air
start the engine
Note: the switch for the auxiliary blowers should be in

AUTO position during all modes of engine control, i.e.:
remote control
control from engine side control console.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air filter and compressor side.
The non-return valves fitted after the water mist catcher are now closed as a
result of partial vacuum and gravitation acting on the valve flaps.
There will be a lack of air supply if the non-return valves do not close.
Non-Return Valves
It is of the utmost importance that the non-return valves of the auxiliary blowers always function correctly and move easily. This can be checked either by
moving the valves manually in connection with the regular scavenge port inspections, or via locally placed inspection covers.
The non-return valves protect the blowers and engine during:
Start-up of the auxiliary blowers
Running with auxiliary blowers.
Starting the auxiliary blowers:
1.
Owing to the relatively high starting current, the blowers start in se

quence, with 6-10 seconds in between.
The non-return valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Otherwise, there is a risk that the electric motor will burn out when it starts.
2.
If an auxiliary blower fails to start, the non-return valve must be in the

closed position. Otherwise, the operating blower will not be able to
draw fresh air in through the turbocharger and air cooler. This is due to
differences in the air flow resistance.
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Running with auxiliary blowers:
If an auxiliary blower fails during running, the non-return valve must close to
ensure the continued supply of fresh air to the engine. See Starting the auxiliary blowers, Item 2, above.
Exhaust Gas
Receiver
From the exhaust valves, the exhaust gas is led to the exhaust gas receiver
where the pulsatory pressure from the individual exhaust valves is equalized
and led to the turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the seating by flexible supports. Compensators are inserted between the receiver and the exhaust valves, and between the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before the turbocharger.
The exhaust gas receiver and the exhaust pipe are insulated.
Charging Air
Cooler
The charging air cooler insert is of the block type. It is mounted in a housing
which is welded up of steel plates.
The cooler housing is provided with inspection covers.
The cooler is designed with an air reversing chamber which incorporates a water mist catcher. The water mist catcher is built up of a number of lamellas
which separate the condensation water from the scavenge air during the passage of the air flow.
The separated water is collected in the bottom of the cooler housing from
which it is removed by a drain system.
Caution!
It is important to check that the drain functions correctly, as otherwise water
droplets may enter the cylinders. See Volume I Operation, Chapter 706,
Cleaning of Turbochargers and Air Coolers.
An alarm device for high water level in the drain system is installed.
911 Safety Equipment

Safety Valves,
Cylinder Cover
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Each cylinder cover is provided with a spring-loaded safety valve which is set
to open at a pressure somewhat higher than the maximum firing pressure in
the cylinder.
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Relief Valves
On the exhaust side of the engine a number of spring-loaded relief valves are
fitted, which will open in the event of excessive pressure in the crankcase/
chain casing, for instance as a result of the ignition of oil mist.
Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the
risk of fire caused by hot air/gas emitted in the event that the relief valves
open.
Regarding how to:
avoid evaporation of the lubricating oil in the crankcase,
detect oil mist in the crankcase using an Oil Mist Detector.
see Volume I, OPERATION, Chapter 704.
Warning!
Do not stand near crankcase doors or relief valves or in corridors near
doors to the engine room casing in the event of an alarm for:
a)
b)
c)
d)
oil mist
high lube oil temperature
no piston cooling oil flow, or
scavenge box fire
Alarms b, c and d should be considered as pre-warnings of a possible increasing oil mist level.
See also our Service Letter SL97-348/ERO.
Note!
If there has been a crankcase explosion, the complete flame arrester of the
relief valves must be replaced.
Safety Valve,
Scavenge Air
Receiver
The scavenge air receiver is fitted with a safety valve which is set to open
should the pressure in the scavenge air receiver exceed a value somewhat
higher than the normal scavenge air pressure of the engine.
In some cases it may be necessary to open the valve manually, see Volume I,
Chapter 704, "Turbocharger Surging".
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Safety Cap in
Starting Air Line
Each starting valve inlet pipe is provided with a safety cap. The safety cap
consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders, in the event of a burst.
The cover is provided with a check plate, which shows if the bursting disc has
been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst,
and fit a new disc.
If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Fit a new bursting disc and
return the cover to the open position at the first opportunity.
912 Assembly of large Parts

Bedplate
The bedplate is made in one or more sections, depending on the number of

cylinders. If there are two or more sections, these are joined together with fitted bolts. The bedplate consists of two welded, longitudinal girders and a
number of cross girders which support the main bearings. The main bearings
consist of steel shells, lined with bearing metal.
Each main bearing has one or two main bearing caps which are secured by
studs and nuts, designed for tightening with hydraulic tools.
The bedplate is fitted with an axial vibration damper. For the design and functioning of the axial vibration damper, see Section 905 Crankshaft.
Marine engines (except geared plants):
The aft end of the bedplate incorporates the thrust bearing. See also Section
905 Crankshaft.
Stationary engines (and geared marine plants):
The bedplate incorporates the guide bearing. See also Section 905, Crank
shaft.
Framebox
A framebox is bolted on to the top of the bedplate. Like the bedplate, the
framebox consists of one or more sections. Together, the bedplate and the
framebox constitute the crankcase of the engine.
The framebox is fitted with steel-plate doors for access to the crossheads and
to the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe fitted to the crosshead or guide shoe is able to
travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to
the oil tray of the bedplate.
Page 22 (23)
A90030-0009
MAN B&W Diesel

Equipment for local checking of the cooling oil temperature and flow, and for
temperature and flow alarms, is installed in conjunction with the outlet pipe.
Staybolts
The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.
Engine Seating
Regarding the engine seating for the specific engine, see the suppliers special
instructions.
Page 23 (23)

90101
90103
0138
0007
Cylinder Cover
Indicator Cock - Mounting
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90101-0138
Cylinder Cover
Cylinder Cover
0138
P90101
G-O-G
F
F-F
G
O
A
A-O-A
C
B-O-B
C-O-C
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90101-0138
Item
No.
031
043
055
067
079
092
102
126
138
163
187
199
209
Cylinder Cover
Item Description
Item
No.
Item Description
Nut
Distance pipe
Stud
Cylinder cover
Screw
O-ring
Cooling jacket
Screw
Cooling water connection
Sealing ring
Nut
Stud
Pin
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90103-0007
Page 1 (2)
Plate
P90103-0007
Item
No.
019
032
056
068
081
093
103
115
139
140
152
176
188
Page 2 (2)
Item Description
Item
No.
Item Description
Connecting piece
Extension
Gasket
Gasket
Indicator cock
Screw
Locking plate
Flange
Guard
Screw
Lock washer
Stud
Nut, self-locking
MAN B&W Diesel A/S

90201
90205
0217
0122
Piston and Piston Rod

MAN B&W Diesel A/S
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90201-0217
Page 1 (2)
Plate
P90201-0217
Item
No.
011
023
035
047
072
084
096
106
118
131
143
155
167
179
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Screw
Locking wire
Piston skirt
Piston ring no. 1
Piston ring no. 2 + 4
Piston ring no. 3
Piston crown
Cooling oil pipe
Piston rod
D-ring
D-ring
Screw
Screw
MAN B&W Diesel A/S
Plate
P90205-0122
Page 1 (2)
Plate
P90205-0122
Item
No.
013
025
050
074
086
098
108
121
133
145
157
169
170
182
194
204
216
228
241
253
277
289
290
312
324
Page 2 (2)
Item Description
Item
No.
Item Description
O-ring
Nut, self-locking
Screw
Top scraper ring
Spring
Cover sealing ring
Spring pin
Pack sealing ring
Sealing ring, complete
Sealing ring
Spring
Holder
Lamella
Scraper ring
Spring
Top scraper ring, complete
Holder
Pin
Holder
Scraper ring, complete
Stuffing box housing in 2/2
Stuffing box housing, complete
Fitted bolt
Flange
Guide pin
MAN B&W Diesel A/S

90301
90302
90304
0188
0192
0025
Cylinder Frame
Cylinder Liner and Cooling Jacket
Cylinder Liner - Details
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Frame
MAN B&W Diesel
Plate
P90301-0188
Page 1 (2)
Cylinder Frame
Plate
P90301-0188
Item
No.
015
027
039
040
052
064
076
088
111
123
135
147
159
160
172
184
196
206
218
231
243
255
267
279
280
292
302
314
326
351
363
375
387
399
409
410
422
434
446
458
471
483
MAN B&W Diesel
Item Description
Item
No.
Item Description
Cover
O-ring
Screw
Stud
Nut
Pipe bend
Cleaning cover, complete
Sealing ring
Stud
Nut
Cylinder frame
Stud
Screw
Nut
Protective cap
Stud
Nut
Fitted bolt
Screw
Distance pipe
Screw
Cover
Screw
Cover
Dowel
Stud
Distance piece
Nut
Screw
Protective tube
Sealing ring
Bushing
Stuffing box, housing
Stud
O-ring
Stud
Distance pipe
Screw
Distance tube
Flange
Packing
Screw
Note:
*
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90302-0192
Page 1 (2)
Plate
P90302-0192
Item
No.
010
022
034
046
058
071
083
095
105
129
130
142
166
178
Page 2 (2)
Item Description
Item
No.
Item Description
Cooling jacket
Clamp
Screw
Cylinder liner
Packing
Plug screw
Packing
O-ring
O-ring
Cooling water connection
Packing
Screw
Stud
Nut
MAN B&W Diesel A/S
Plate
P90304-0025

0025
P90304
A A
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90304-0025
Item
No.
011
023
035
059
Item Description
Item
No.
Item Description
Head, non-return valve

Non-return valve
Housing, non-return valve
Non-return valve, complete
Page 2 (2)
MAN B&W Diesel A/S

90401
90403
0145
0009
Connecting Rod and Crosshead

Lubricating and Cooling Oil-Flow
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90401-0145

0145
P90401
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90401-0145
Item
No.
019
020
032
044
056
068
081
093
103
127
139
140
152
164
211
223
235
247
259
296
306
318
331
343
355
379
380
392
402
414
426
438
451
463
475
487
Item Description
Item
No.
Item Description
Screw
Telescope pipe
Nut, self-locking
Nut
Outled pipe
Screw
Lock washer
Stop screw
Guide shoe
Bracket
Crosshead bearing cap
Guide screw
Stud
Guide pin
Nut- self-locking
Shim, 0,50mm
Shim 0,25mm
Guide strip
Stud
Screw
Thrust piece
Crankpin bearing shell, complete
Guide pipe
Screw(*
Shim (*
Crosshead bearing shell, upper part
Crosshead
Stud
Guide pin
Crosshead bearing shell, lower part
Hydraulic nut
Connecting rod
Hydraulic nut
Stud
Crankpin bearing cap
Connecting rod, complete
Notes:
Page 2 (2)
(* Please state thickness of shim

MAN B&W Diesel A/S
Lubricating and Cooling Oil for Crosshead

Crankpin and Main Bearing
Plate
P90403-0009
0009
P90403
Lubricating and Cooling Oil for Crosshead Crankpin and Main Bearing
MAN B&W Diesel A/S
Page 1 (1)

90501
90502
90505
90510
90511
90512
90513
0179
0076
0170
0120
0040
0001
0036
Crankshaft
Arrangement of Fore End
Thrust- and Guide Bearing
Turning Gear
Turning Wheel
Turning Gear - Details
Tacho System
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crankshaft
MAN B&W Diesel
Plate
P90501-0179
Page 1 (2)
Crankshaft
Plate
P90501-0179
Item
No.
012
024
061
097
MAN B&W Diesel
Item Description
Item
No.
Item Description
Crankshaft
Chain wheel
Nut
Screw
Note:
*
Page 2 (2)

MAN B&W Diesel
Plate
P90502-0076
Page 1 (2)
Plate
P90502-0076
Item
No.
018
031
043
055
079
080
092
102
114
138
151
163
199
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Nut
Screw
End cover, lower part
Screw
Cover
Packing
Cover, complete
Packing
Plug
Plug
Cover
Lower end cover, complete
Thrust and Guide Bearing

MAN B&W Diesel
Plate
P90505-0170
Page 1 (2)
Plate
P90505-0170
Item
No.
014
026
038
051
063
075
099
109
110
122
134
146
158
171
183
217
230
242
254
266
278
291
337
349
350
362
374
386
Page 2 (2)
Thrust and Guide Bearing

MAN B&W Diesel
Item
No.
Item Description
Item Description
Screw
Cover
Screw
Flange
Lubricating oil pipe
Nut
Segment holder
Fitted bolt
Screw
Screw
Oil throw ring, complete
Scraper ring housing, complete
Scraper ring housing, upper part
Nut
Scraper ring housing, lower part
Screw
Screw
Screw
Nut
Segment stopper
Segment
Segment
Cover
Screw
Pipe holder
Spring pin
Spring
Plate
P90510-0120
Turning Gear
Turning Gear
0120
P90510
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90510-0120
Item
No.
011
023
035
047
059
072
084
096
106
118
143
155
167
179
180
192
202
226
238
251
263
275
287
299
310
Turning Gear
Item Description
Item
No.
Item Description
Turning gear
Screw
Distance pipe, L= 45
Nut
Washer
Gear wheel
Disenganging spindle
Stop screw
Stop ring
Bushing
Nut
Guide pin
Flange
Stop screw
Flange
Screw
Screw
Key
Screw
Handle
Washer
Hand wheel
Disc
Bushing
Stud
Page 2 (2)
MAN B&W Diesel A/S
Turning Wheel
Plate
P90511-0040
Turning Wheel
0040
P90511
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90511-0040
Item
No.
017
029
030
054
078
091
101
125
Turning Wheel
Item Description
Item
No.
Item Description
Spring pin
Screw
Washer
Dead center pointer
Screw
Fitted bolt
Nut, self-locking
Turning wheel
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90512-0001

0001
P90512
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90512-0001
Item
No.
012
024
048
061
073
097
107
119
132
156
168
181
203
215
227
240
252
264
276
311
323
Item Description
Item
No.
Item Description
Screw
Spring washer
3/2-way valve
Screw
Spring washer
Switch 0-110 volts
Screw
Spring washer
Bracket
Eye screw
Key ring
Chain
Cam
Stud with groove
Circlip
Cam
Bush
Screw
Spring washer
Lever
Bush
Page 2 (2)
MAN B&W Diesel A/S
Tacho System
MAN B&W Diesel
Plate
P90513-0036
Page 1 (2)
Tacho System
Plate
P90513-0036
Item
No.
018
031
043
055
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Bracket
Screw
Spring pin
Disc
906 - Control Gear

90600
90601
90602
90603
90605
90611
90613
90615
90618
90620
90621
0068
0105
0124
0059
0076
0170
0117
0138
0139
0107
0085
Arrangement of Chain Drive and Camshaft

Chain Drive and Guide Bars
Chain Drive - Lubrication
Chain Tightener
Lubricator Drive
Camshaft and Chain Wheel
Camshaft Bearing
Arrangement of Governor
Regulating Shaft
Engine-Side Control Console - Details
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Arrangement of Chain Drive Camshaft
Plate
P90600-0068
Arrangement of Chain Drive Camshaft

0068
P90600
MAN B&W Diesel A/S
Page 1 (1)

MAN B&W Diesel
Plate
P90601-0105
Page 1 (2)
Plate
P90601-0105
Item
No.
016
028
053
065
112
124
136
148
161
173
185
219
220
232
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Locking wire
Screw
Distance pipe
Guidebar
Bracket
Distance pipe
Guide pin
Stud
Screw
Washer
Nut
Outer link
Inner link
Chain link, complete

MAN B&W Diesel
Plate
P90602-0124
Page 1 (2)
Plate
P90602-0124
Item
No.
011
035
047
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description

Chain Tightener
MAN B&W Diesel
Plate
P90603-0059
Page 1 (2)
Chain Tightener
Plate
P90603-0059
Item
No.
017
029
030
042
066
078
091
101
113
125
137
149
150
162
174
198
208
221
233
245
269
270
282
294
316
328
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Distance piece
Shaft
Cover
Screw
Locking wire
Guide nut
Shaft
Cover
Screw
Guide nut
Lock washer
Nut
Tightening bolt
Shaft
Cover
Bushing
Lubricating pipe
Screw
Self-locking nut
Screw
Spray pipe
Shaft
Self-locking nut
Flange
Chain wheel
Bracket
Lubricator Drive
Plate
P90605-0076
Lubricator Drive
0076
P90605
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90605-0076
Item
No.
031
043
055
067
079
080
092
102
114
126
151
Lubricator Drive
Item Description
Item
No.
Item Description
Self-locking nut
Gear wheel
Key
Ball bearing
Circlip
Hosuing
Key
Shaft
Guide pin
Screw
Shaft - lubricator, complete
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90611-0170
Page 1 (2)
Plate
P90611-0170
Item
No.
010
022
046
058
095
117
129
130
142
154
178
191
201
213
MAN B&W Diesel

Item
No.
Item Description
Item Description
Repair cam - fuel, complete*

Screw*
Thrust disc
Chain wheel
Protective cap
Exhaust cam
Fuel cam
Camshaft
Screw*
Repair cam - exhaust, complete*
Washer
Screw
Locking wire
Gear wheel
Note:
* Optional extras
Page 2 (2)
Camshaft Bearing
MAN B&W Diesel A/S
Plate
P90613-0117
Page 1 (2)
Plate
P90613-0117
Item
No.
011
023
035
047
059
060
072
096
106
118
131
143
155
Page 2 (2)
Camshaft Bearing
Item Description
Item
No.
Item Description
Connecting pipe
Gasket
O-ring
Screw
Bearing cap
Guide pin
Screw
Guide disc
Plug screw
Bearing cap
Screw
Bearing shell
Screw
MAN B&W Diesel A/S
Plate
P90615-0138
0138
P90615
Clockwise
Counterclockwise
MAN B&W Diesel A/S
Air inlet
Page 1 (2)
Plate
P90615-0138
Item
No.
012
024
036
048
061
073
097
107
119
120
132
144
156
181
193
215
227
240
252
276
288
311
323
347
359
360
372
384
396
Item Description
Item
No.
Item Description
Governor
Screw
Screw
Coupling
Key
Shaft
Bracket
Bevel gear wheel
Nut
Split pin
Screw
Locking wire, L= 300
Washer
Spray pipe
Spray pipe
Union
Union
Guide pin
Screw
Bushing
Thrust washer
Key
Bevel gear wheel
Pipe, L= 600
Pipe, L= 700
Union
Union
Booster
Pipe, L= 600
Page 2 (2)
MAN B&W Diesel A/S
Regulating Shaft
MAN B&W Diesel
Plate
P90618-0139
Page 1 (2)
Plate
P90618-0139
Regulating Shaft
MAN B&W Diesel
Item
No.
Item Description
019
020
032
044
068
081
093
103
115
127
139
164
176
188
211
223
235
247
259
260
272
296
306
318
331
343
355
380
392
402
414
426
438
451
463
475
487
Bearing, complete
Nut, self-locking
Plate
Pull rod, complete
Screw
Clamping arm
Nut, self-locking
Pin
Screw
Locking wire
Switch 0-100 volts
Bearing
Screw
Washer
Distance pipe
Nut
Locking plate
Eye bolt
Spring
Pin
Regulating shaft
Bushing
Screw
Nut
Holder
Screw
Spring washer
Lever
Screw
Guide pin
Fitted bolt
Pin
Locking plate
Screw
Clamping arm
Fitted bolt
Spring-loaded lever, complete
Page 2 (2)
Item
No.
Item Description

MAN B&W Diesel
Plate
P90620-0107
Page 1 (2)
Plate
P90620-0107
Item
No.
021
033
045
069
070
116
128
141
153
165
177
189
190
200
212
224
236
248
261
273
285
307
319
320
332
356
368
381
393
403
415
427
439
452
476
511
523
535
Page 2 (2)

MAN B&W Diesel
Item
No.
Item Description
Item Description
Vibrations damper
Bracket
Screw
Multiple plug
Cable
Screw
5/2-way valve for remote locale console
Guide pin
Console
Bushing
Screw
Screw
Nut, self-locking
Control box
Pointer
Screw
Segment
Spring washer
Screw
Stop valve
Fitted bolt
Start valve
Nut, self-locking
Clamping arm
Nut, self-locking
Name plate
Stop ring
Pin
Pin
Handle grip
Lever
Pressure switch
Fitted bolt
Screw
Shaft
Guard
Screw
Non-return valve
Engine - Side Control Console, Details
Plate
P90621-0085

0085
P90621
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90621-0085
Item
No.
015
027
039
040
052
064
076
088
111
123
135
147
160
172
184
196
206
218
243
255
267
279
280
292
302
326
338
351
363
375
387
399
409
422
446
458
471
483
495
Item Description
Item
No.
Item Description
Nut, self-locking
Screw
Nut. self-locking
Pull rod, complete
Pull rod, complete
Bushing
Stop ring
Guide pin
Cone
Guide pin
Impact hand wheel
Impact socket
Clamping arm
Pull rod, complete
Fitted bolt
Lever
Grease nipple
Washer
Fitted bolt
Fitted bolt
Nut, self-locking
Screw
Guide pin
Clamping arm
Bushing
Lever
Switch, 110 volt
Screw
Lock washer
Spindle
Lever
Washer
Screw
Clamping arm
Shaft
Clamping arm
Screw
Nut, self-locking
Pin
Page 2 (2)
MAN B&W Diesel A/S

90702
90703
90704
0046
0068
0050
Main Starting Valve

Starting Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Starting Valve
Plate
P90702-0046
Main Starting Valve

0046
P90702
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90702-0046
Item
No.
015
027
039
040
052
064
076
088
111
135
147
159
160
172
184
196
206
231
243
255
267
279
280
292
302
314
326
351
363
375
399
409
530
547
Main Starting Valve
Item Description
Item
No.
Item Description
Name plate "Working"

Screw
Name plate "Blocked"
Handwheel
Screw
Switch
Spindle
Securing plate
Spring
Distance pipe
Base plate
Screw
Housing for non-return valve
Housing for non-return valve
Nut
Non-return valve
Gasket
Gasket
Nut
Washer
Spring ring
Split pin
Nut
Plug screw
Screw
Screw
Split pin
Chain
Screw
Screw
Ball valve with actuator
Stud
Upstream seat
Downstream seat
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90703-0068
Starting
P90703
0068
Air Distributor
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90703-0068
Item
No.
010
022
034
046
058
083
095
105
117
129
130
154
166
178
201
213
225
237
249
250
262
274
286
298
308
333
345
357
369
370
394
404
Item Description
Item
No.
Item Description
Spring pin
Screw
Gasket
Screw
3/2-way valve
Stud
Nut
Guide pin
Screw
Bracket
Name plate
Air cylinder
Fitted bolt
Self-locking nut
Flexible coupling
Lock washer
Nut
Key
Spring pin
Bushing
Distributor housing *)
Shaft
Reversing disc *)
Sealing ring
Distributor disc
Screw
Fitted bolt
Washer
Bracket
Sealing ring
Piston ring
Cover
*) Please state number of cylinders
Page 2 (2)
MAN B&W Diesel A/S
Starting Valve
MAN B&W Diesel A/S
Plate
P90704-0050
Page 1 (2)
Plate
P90704-0050
Item
No.
016
028
041
053
065
077
089
100
112
124
136
148
161
Page 2 (2)
Starting Valve
Item Description
Item
No.
Item Description
Cover
Gasket
Castle nut
Piston
Bushing
Spring
Washer
Bushing
Valve housing
Screw
O-Ring
Split
Valve spindle
MAN B&W Diesel A/S
908 - Exhaust Valve

90801
90802
90803
90804
90805
90806
90810
0184
0041
0032
0017
0130
0080
0092
Exhaust Valve - Lower Parts

Exhaust Valve - Details
Exhaust Valve - Upper Parts
Exhaust Valve Upper Parts - Details
Exhaust Valve - Actuator
Exhaust Valve - Pipe System
Arrangement of Cooling Water Pipes
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90801-0184

0184
P90801
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90801-0184
Item
No.
013
025
049
050
062
074
086
098
108
133
145
157
169
182
194
204
216
228
241
253
Item Description
Item
No.
Item Description
Spring pin
Sealing ring
Valve housing
Spring pin
Screw
Bottom piece
O-ring
Sealing ring
Valve spindle
Spindle guide
Cover
Packing
Screw
Water connection
Packing
Screw
Sealing ring
Flange
Packing
Screw
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90802-0041

0041
P90802
Air inlet.
Control air.
Sealing air.
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90802-0041
Item
No.
019
020
032
044
056
068
081
093
115
127
139
140
152
164
176
188
211
Item Description
Item
No.
Item Description
Sealing air control unit

Elbow coupling
Coupling
Pipe
Throttle valve
Restrictor screw
Screw
Cover
Sealing ring
Spring
Valve spindle
O-ring
O-ring
Valve housing
Packing
Filter housing, complete
Coupling, complete
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90803-0032
Page 1 (2)
Plate
P90803-0032
Item
No.
014
038
051
063
087
099
110
122
134
146
158
171
183
195
217
229
230
242
254
266
278
291
301
325
337
349
350
362
374
386
398
421
433
445
469
482
494
504
541
553
565
589
590
Page 2 (2)
Item Description
Item
No.
Item Description
Oil cylinder
Sealing ring
Air cylinder
Non-return valve
Sealing ring
Sealing ring
Screw
Spring washer
Disc
Guide ring
Sealing ring
Conical ring in 2/2
Piston
O-ring
Eye bolt
Flange
Union nut
Packing
Spacer ring
Throttle valve
Disc
Stud
Nut
Screw
Guide pin
Steel pipe
Union nut
Adapter
Packing ring
O-ring
Rotation check rod
Spring
Disc
Guide pin
Piston
Actuator piston
Spring
Disc
Piston ring
Disc
Screw
Screw
Actuator piston, complete
MAN B&W Diesel A/S
Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel
Plate
P90804-0017
Page 1 (2)
Plate
P90804-0017
Item
No.
021
033
045
069
905
Exhaust V
alve - Upper Parts, Details
Valve
MAN B&W Diesel
Item Description
Item
No.
Item Description
Sealing ring
Valve housing
Packing
Safety valve, with o-ring
O-ring*
Note:
* Optional extras
Page 2 (2)
Valve Gear
Plate
P90805-0130
Valve Gear
0130
P90805
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90805-0130
Item
No.
015
027
039
040
052
064
088
111
123
135
147
160
172
184
196
206
218
243
255
267
279
280
302
Valve Gear
Item Description
Item
No.
Item Description
Oil cylinder
Nut
Stud
Stud
Thrust piece
Roller guide
Screw
Key
Bushing
Roller guide housing
Guide pin
Plug
Piston ring
Piston
Disc
Locking plate
Screw
Shaft pin for roller
Stop screw
Roller
Roller guide, complete
Sealing ring
Spring
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90806-0080
Page 1 (2)
Plate
P90806-0080
Item
No.
010
022
034
058
071
095
105
129
130
154
166
178
201
213
225
249
250
274
286
308
Item Description
Item
No.
Item Description
Thrust flange
Spring ring
Sleeve in 2/2
Intermediate piece
Screw*
High pressure pipe
Screw
O-ring
Intermediate piece
Steel pipe
Reducing stand pipe
Coupling
Coupling
Steel pipe
Coupling
Sealing ring
Sealing ring
Steel pipe
Drain pipe, complete
High pressure pipe, complete
Note:
* These screws are special screws
for hot joints, they are marked with a
T and MUST NOT be used elsewhere !
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90810-0092
Page 1 (2)
Plate
P90810-0092
Item
No.
012
024
036
085
097
107
132
144
156
168
181
193
227
239
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Flange
Screw
Butterfly valve
Cooling pipe
Packing
Screw
Packing
Screw
Nut
Compensator
Orifice plate
Cooling pipe
Packing
Screw

90901
90902
90910
90911
90913
90914
90915
90915
90915
0207
0138
0152
0021
0096
0105
0076
0077
0078
Fuel Pump
Fuel Pump Gear
Fuel Valve
Fuel Valve Function
High-Pressure Pipes
Fuel Oil System
Fuel Oil System - Details
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Fuel Pump
MAN B&W Diesel A/S
Plate
P90901-0207
Page 1 (2)
Plate
P90901-0207
Fuel Pump
Item
No.
Item Description
017
029
030
042
054
066
091
113
125
149
150
162
174
198
208
221
233
245
257
270
282
294
316
328
341
353
365
377
390
424
436
461
485
497
507
519
520
544
556
568
593
615
627
639
640
652
664
676
711
723
Stud
Nut
Steel ball
Plug screw
Plug
Gasket
Guide pin
Plug screw
Gasket
Shim
Fuel pump housing
Guide bushing
Regulating guide
Plug screw
Gasket
Screw
O-ring
Back-up ring
Plunger
Flange
Screw
Toothed bar
Top cover
Guide pin
O-ring
Back-up ring
O-ring
Pump barrel
Felt ring
Restriction plug
Screw
Screw
O-ring
O-ring
Spring
Housing
O-ring
Screw
Cover
Air piston
O-ring
Housing
O-ring
Conical ring in 2/2
Cone
Spring
Spindle
Housing
Pump barrel, complete
Pump barrel and top cover, complete
Page 2 (2)
Item
No.
747
759
772
806
818
Item Description
Puncture valve, complete
Suction valve, complete
Comb.puncture valve and suction valve,
complete
Disc
Plug screw
MAN B&W Diesel A/S
Fuel Pump Gear

MAN B&W Diesel
Plate
P90902-0138
Page 1 (2)
Plate
P90902-0138
Item
No.
012
024
036
048
061
073
085
097
107
119
120
132
156
168
181
193
203
215
239
240
252
264
276
288
311
323
335
347
359
360
372
384
396
406
418
431
443
455
467
479
480
492
502
526
538
551
563
Page 2 (2)
Fuel Pump Gear

MAN B&W Diesel
Item
No.
Item Description
Sealing ring
Spring
Pump base
Bushing for roller guide, complete
Guide pin
Bushing
Guide pin
Guide block
Screw
Sealing ring
Plug screw
Stop screw
Reversing mechanism, complete
Guide
Shaft
Guide spindle
Guide spindle
Screw
Stud
Nut
Roller guide, complete
Thrust piece
Roller guide
Link for reversing
Guide pin
Baseplate
Shaft pin
Bushing
Shaft pin
Roller
Screw
Screw
Nut
Tab washer
Flange
Air cylinder
Fuel oil sealing, complete
Stud
Nut
Sealing ring
Sealing bush
Sealing ring
Screw
Stud
Nut
Bushing
Pin
575
587
599
609
610
622
646
658
671
683
Item Description
Screw
Cap
Flange
Screw
Cover
Screw
Holder
Scraper ring
Scraper ring
Flange
Fuel Valve
MAN B&W Diesel
Plate
P90910-0152
Page 1 (2)
Fuel Valve
Plate
P90910-0152
Item
No.
004
016
028
053
065
077
089
100
112
124
136
148
161
173
185
197
207
219
220
232
950
MAN B&W Diesel
Item Description
Item
No.
Item Description
Fuel valve, complete

Guide pin
Guide pin
Spindle guide
Nozzle
Holder
Sealing ring
Screw
Sealing ring
Valve head
Sealing ring
Spring
Housing
Thrust piece
Vent slide
Sealing ring
Spring
Disc
Cut-off shaft
Spindle guide, complete
Disc*
Note:
* Optional extras
Page 2 (2)
Fuel Valve Function
MAN B&W Diesel A/S
Plate
P90911-0021
Page 1 (2)
Plate
P90911-0021
Item
No.
Fuel Valve Function
Item Description
Item
No.
Item Description
Note:
D1 = Predetermined closing value for
non-return valve
D2 = Predetermined opening value for
cut-off spindle
Page 2 (2)
MAN B&W Diesel A/S
High-Pressure Pipes
Plate
P90913-0096
High-Pressure Pipes
0096
P90913
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90913-0096
Item
No.
012
024
036
048
061
073
085
097
107
120
132
High-Pressure Pipes
Item Description
Item
No.
Item Description
High-pressure pipe, complete

Spring pin
Sleeve
O-ring
Union nipple
Protective pipe
High-pressure pipe
Union nipple
O-ring
High-pressure pipe, complete
High-pressure pipe
Page 2 (2)
MAN B&W Diesel A/S
Fuel Oil System

MAN B&W Diesel
Plate
P90914-0105
Page 1 (2)
Fuel Oil System
Plate
P90914-0105
Item
No.
018
031
043
055
079
092
102
114
126
138
163
209
246
258
271
295
317
329
MAN B&W Diesel
Item Description
Item
No.
Item Description
Steel pipe
Steel pipe
Coupling
Steel pipe
Fuel oil pipe, return
Fuel oil pipe, return
Non-return valve
Copper pipe
Non-return valve
Copper pipe
Fuel oil pipe, inlet
Ball valve
Ball valve
Screw
Packing ring
Steel pipe
Lubrication oil pipe, inlet
Non-return valve
Note:
*
Page 2 (2)

MAN B&W Diesel
Plate
P90915-0076
Page 1 (2)
Plate
P90915-0076
Item
No.
013
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Drain box, complete

MAN B&W Diesel
Plate
P90915-0077
Page 1 (2)
Plate
P90915-0077
Item
No.
013
025
037
049
050
062
074
086
098
108
121
133
145
157
169
170
182
204
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Plug screw
Gasket
Spring guide
Stud
Nut
Lock washer
Packing
Sealing ring
Wearing ring
Packing
Screw
Spring
Flange
Stud
Spring
Piston
Housing
Shock absorber, complete

MAN B&W Diesel
Plate
P90915-0078
Page 1 (2)
Plate
P90915-0078
Item
No.
013
025
037
049
050
074
086
098
121
133
145
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
By-pass valve, complete

Valve housing
Valve housing
Sealing ring
Spring guide
Screw
Union nut
Nut
Sealing ring
Piston
Spring

91000
91001
91002
91003
91004
91005
91006
91009
91010
91018
0016
0125
0127
0197
0049
0132
0030
0036
0026
0006
Gas and Air System

Scavenge Air Receiver
Arrangement of Charging Air Pipe
Exhaust Pipes and Receiver
Exhaust Receiver - Details
Air Cooler
Arrangement of Auxiliary Blower
Air Cooler System - Cleaning
Air Cooler - Frame
Air Cooler System
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Gas and Air System
MAN B&W Diesel A/S
Plate
P91000-0016
Page 1 (1)
Plate
P91001-0125

0125
P91001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91001-0125
Item
No.
017
029
030
042
054
078
091
113
149
150
221
233
245
269
270
Item Description
Item
No.
Item Description
Screw
Guard
Screw
Cover
Gasket
Distance piece
Screw
Scavenge air receiver
Screw
O-ring
Support
Screw
Nut
Plug screw
Plug screw
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91002-0127
Page 1 (2)
Plate
P91002-0127
Item
No.
012
024
036
048
073
085
097
119
132
144
156
181
203
Page 2 (2)
Item Description
Item
No.
Item Description
Cover plate
Insulation material
Glass fibre cloth
Compensator
Plug screw
Gasket
Charging air pipe
Cover plate
Nut
Washer
Screw
Plug screw
Screw
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91003-0197
Page 1 (2)
Plate
P91003-0197
Item
No.
018
031
055
079
092
114
138
151
163
175
187
199
209
222
234
246
271
283
295
305
317
330
342
354
366
378
391
401
413
425
437
449
462
474
486
521
533
Item Description
Item
No.
Item Description
Cover
Insulation material
Gasket
Gasket
Plug screw
Wire gauze
Washer
Screw*
Plug screw
Gasket
Screw
Exhaust receiver
Screw*
Compensator
Nut
Screw*
Nut
Locking plate
End cover
Gasket
Plug screw
Gasket
Screw*
Clamp
Compensator
Insulation material
Cover
Heating shield
Screw*
Distance pipe
Junk ring
Screw*
Cover
Insulation material
Gasket
Screw
Nut
Note:
* These screws are special screws
for hot joints, they are marked with a
T, and MUST NOT be used elsewhere!
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Receiver, Details

MAN B&W Diesel
Plate
P91004-0049
Page 1 (2)
Exhaust Receiver, Details
Plate
P91004-0049
Item
No.
013
025
037
049
050
074
086
098
108
121
133
145
157
169
170
182
194
204
216
228
241
253
MAN B&W Diesel

Item
No.
Item Description
Item Description
Screw*
Distance pipe
Screw
Distance pipe
Spring pin
Nut
Support
Nut
Nut
Clamp
Spring pin
Spring plate
Shim
Support
Lock washer
Screw
Clamp
Spring pin
Screw
Screw
Washer
Screw
Note:
* These screws are special screws for
hot joints, they are marked with a T and
MUST NOT be used elsewhere !
Page 2 (2)
Air Cooler
MAN B&W Diesel A/S
Plate
P91005-0132
Page 1 (2)
Plate
P91005-0132
Item
No.
019
020
Air Cooler
Item Description
Item
No.
Item Description
Cooler insert*
Water mist catcher*
Note:
* When ordering Spare Parts for this
item, please state manufacturers Part
No.
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91006-0030
Page 1 (2)
Plate
P91006-0030
Item
No.
014
026
038
051
063
087
099
109
122
134
146
158
171
183
195
Item Description
Item
No.
Item Description
Valve flap
Slide bearing
Sealing ring
Support
Shaft
Support
Shaft
Valve flap
Auxiliary blower*
Distance pipe
Screw
Spring pin
Screw
Screw
Screw
Note:
* When ordering spare parts for this
item, please state manufacturers Part
No.
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91009-0036
Page 1 (2)
Plate
P91009-0036
Item
No.
010
034
046
058
Page 2 (2)
Item Description
Item
No.
Item Description
Screw
Cleaning pipe
Spray nozzle
Gasket
MAN B&W Diesel A/S
Air Cooler Frame

MAN B&W Diesel
Plate
P91010-0026
Page 1 (2)
Air Cooler Frame
Plate
P91010-0026
Item
No.
016
028
041
053
065
089
090
112
136
148
173
185
207
219
220
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Cover
Gasket
Plug screw
Air cooler
Screw
Distance piece
Plug screw
Plug screw
Plug screw
Stud
Nut
Cover
Screw
Gasket
Air Cooler System

MAN B&W Diesel
Plate
P91018-0006
Page 1 (2)
Air Cooler System
Plate
P91018-0006
Item
No.
021
033
045
057
069
070
082
094
104
116
128
141
153
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Packing
Cooling water pipe
Cooling water pipe
Plug screw
Plug screw
Butterfly valve
Screw
Flange
Nut
Stud
Ball valve
Nipple

91101
91102
91103
91104
0037
0024
0017
0108
Safety Valve - Cylinder

Relief Valve
Safety Valve - Scavenge Air System
Arrangement of Safety Cap
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Safety V
alve - Cylinder
Valve
MAN B&W Diesel
Plate
P91101-0037
Page 1 (2)
Safety V
alve - Cylinder
Valve
Plate
P91101-0037
Item
No.
010
022
034
046
058
071
083
095
105
117
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Spindle
Spring retainer
Lock nut
Spring
Valve housing
Stop ring
Valve flap
Valve guide
Gasket
Safety valve, complete
Relief Valve
MAN B&W Diesel A/S
Plate
P91102-0024
Page 1 (2)
Plate
P91102-0024
Item
No.
016
028
030
041
Relief Valve
Item Description
Item
No.
Item Description
Relief valve (P.C.D. 255mm) *

Screw*
Packing*
O-ring*
Note:
*When ordering, please state manufacturer of Relief Valve and
P.C.D. xxx mm
Page 2 (2)
MAN B&W Diesel A/S
Safety Valve, Scavenge Air System
Plate
P91103-0017

0017
P91103
4.1 Bar abs.
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91103-0017
Item
No.
011
023
035
047
060
072
084
096
106
131
143
Item Description
Item
No.
Item Description
Stud
Washer
Spring retainer
Spring
Valve flap
Screw
Nut
Split pin
Castle nut
Sealing ring
Valve seat
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P91104-0108
Page 1 (2)
Plate
P91104-0108
Item
No.
017
029
030
054
066
078
091
137
149
150
162
174
186
198
208
221

MAN B&W Diesel
Item Description
Item
No.
Item Description
Starting air pipe

Starting air pipe
Stud
Bursting cap, complete
Safety cap
Packing
Screw
Fitted bolt
Plate
Wing nut
Screw
Washer
Cover
Perforated cylinder
Housing
Disc
Note:
*
Page 2 (2)

91201
91205
91207
91208
91209
91210
91211
91216
91217
0094
0159
0054
0019
0007
0186
0036
0007
0004
Arrangement of Stay Bolts

Frame Box
Arrangement of Piston Cooling
Chain Wheel Frame - Upper
Chain Wheel Frame - Lower
Bedplate
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
Top Bracing - Arrangement
MAN B&W Diesel A/S
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P91201-0094
Page 1 (2)
Plate
P91201-0094
Item
No.
014
026
038
051
063
087
Page 2 (2)
Item Description
Item
No.
Item Description
Screw
Protective cap
Nut
Stay bolt assembly
Guide bushing
Stay bolt, complete
MAN B&W Diesel A/S
Plate
P91205-0159
Frame Box
Frame Box
0159
P91205
B-B
Front side
B
Fore end
A-A
Rear side
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91205-0159
Item
No.
016
028
041
053
065
077
089
100
112
124
136
173
197
219
220
232
244
256
268
293
303
315
327
339
340
Frame Box
Item Description
Item
No.
Item Description
Frame
Frame door
O-ring
Spring
Door fastener
Wing nut
Stud
Flange
Gasket
Screw
Plug screw
Gasket
Drain pipe
Banjo coupling
Pipe
Union
End shield
Gasket
Screw
Screw
Nut
Distance pipe
Distance pipe
Fitted bolt
Screw
Page 2 (2)
MAN B&W Diesel A/S
Plate
P91207-0054

0054
P91207
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91207-0054
Item
No.
017
029
030
042
054
066
078
091
113
125
137
149
150
162
174
198
Item Description
Item
No.
Item Description
Slotted pipe
Screw
Locking plate
Down pipe
Lock washer
Clamp
Locking plate
Nut
Union nut
Packing
Sight glass
Flange
Stop screw
Rubber packing
Packing
Bracket
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P91208-0019
Page 1 (2)
Plate
P91208-0019
Item
No.
012
024
048
061
073
085
107
120
144
156
181
193
215
227
252
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Guide pin
Screw
Cover
Gasket
Screw
Screw
Chain casing
Cover
Spring pin
Cover
Gasket
Stud
Nut
Cover

MAN B&W Diesel
Plate
P91209-0007
Page 1 (2)
Plate
P91209-0007
Item
No.
018
031
043
055
079
080
102
114
126
151
163
Page 2 (2)

MAN B&W Diesel
Item Description
Item
No.
Item Description
Cover
Screw
Cover
Gasket
Cover
Gasket
Cover
Screw
Gasket
Cover
Gasket
Bedplate
MAN B&W Diesel
Plate
P91210-0186
Page 1 (2)
Bedplate
Plate
P91210-0186
Item
No.
013
025
037
050
062
074
086
108
121
133
157
169
182
194
216
228
253
265
277
290
300
324
336
348
373
385
Page 2 (2)
MAN B&W Diesel

Item
No.
Item Description
Item Description
Bedplate
Screw
Grate
Main bearing cap
Stud
Baseplate
Nut
Screw
Flange
Packing
Spring pin
Screw
Stud
Nut
Pipe holder
Screw
Lubricating oil pipe, main bearing
Lubricating oil pipe, main bearing
Screw
Main bearing shell, upper
Main bearing shell, lower
Screw
Baseplate
Main bearing cap
Plate
P91211-0036
Page 1 (2)
MAN B&W Diesel A/S
Plate
P91211-0036
Item
No.
019
020
032
044
056
081
093
103
115
127
139
152
164
176
188
211
223
235
247
259
260
272
284
306
318
331
343
355
367
379
380
392
402
Page 2 (2)
Item Description
Item
No.
Item Description
Gasket
Flange
Lub. pipe
Screw
Self-locking nut
Screw
Pipe holder
Lub.oil pipe
Lub.oil pipe
Spring
Spring
Stud
Screw
Restriction for damper
Damper, upper part
Screw
Guide pin
Damper, lower part
Oil seal
Oil seal
Clamp
Bracket
Self-locking nut
Screw
Pipe holder
Screw
Screw
Screw
Guide pin
Axial vibration damper, complete
MAN B&W Diesel A/S
Holding-Down Bolts and End-Chock Bolts

(Epoxy Chocks)
Plate
P91216-0007
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

0007
P91216
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91216-0007
Item
No.
016
028
041
065
077
089
090
112
124
136
148
161
173
197
207
220
232
244
Holding-Down Bolts and End-Chock Bolts

(Epoxy Chocks)
Item Description
Item
No.
Item Description
Liner
Nut
Stud for end chock bolt, M48 x 5.0
Spherical washer
Spherical washer
Nut
Protective cap
Protective cap
Nut
Distance pipe
Screw
Washer
Locking plate
Liner for side chock, starboard
Liner for side chock, port side
Spherical washer
Spherical nut
Holding-down bolt, M30 x 3.5
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P91217-0004
Page 1 (2)
Plate
P91217-0004
Item
No.
011
023
059
060
072
084
106
131
143
155
179
180
202
214
MAN B&W Diesel
Item Description
Item
No.
Item Description
Screw
Friction shim
Distance pipe
Washer
Nut
Split pin
Plate, short*
Plate, large*
Plate
Guide pin
Screw
Disc spring
Plate
Friction shim
Note:
* When ordering this spare part, please
state length
Page 2 (2)

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Warning

When referring to this page, please quote S900 Edition 0001

Table of Contents, Volume II

MAN B&W Diesel A/S

MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear

909 - Fuel Oil System

MAN B&W Diesel A/S

910 - Turbocharger System

MAN B&W Diesel A/S

Instructions for Main Engines

M/S Nybo 7730 B&W P90201-0036 059

MAN B&W Diesel A/S

MAN B&W Diesel

Checking and Maintenance Schedule,

Design modifications may necessitate a revision of

The stated Normal hours of service should only

The procedures are divided into three categories:

marked under the heading Normal hours of service with a C,

are those procedures which under the heading Normal hours of

Checking and Maintenance Schedule,

MAN B&W Diesel

MAN B&W Diesel

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Crankshaft and Thrust Bearing

* Check whenever exhaust

903 Cylinder Liner and Cylinder Lubrication

902 Piston with Rod and Stuffing box

Crosshead with connecting rod

Service interval (x1000 hours of operation)

Daily Weekly Monthly

901 Cylinder Cover

* Check clearances without

Bearings should only be

Bearings should only be

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

906 Mechanical Control Gear

MAN B&W Diesel

Daily Weekly Monthly

Service interval (x1000 hours of operation)

New or overhauled chain to be

* only inspection through

MAN B&W Diesel

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Service interval (x1000 hours of operation)

Daily Weekly Monthly

Exhaust valve special running

909 Fuel Oil System

* Only inspection through

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Turbocharger air filter