S60MC-C 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)
S60MC-C
VOLUME II MAINTENANCE
900 - Introduction
Documents in this Chapter
Table of Contents, Volume II Instructions for Main Engine General - Safety Precautions
90023 90060
0027 0001
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
Volume II - Maintenance No. Edition Title
900
900 - Introduction Table of Contents 90023 0027 Instructions for Main Engine 90060 0001 General - Safety Precautions 901 - Cylinder Cover 101-01 0071 Cylinder Cover, Data 901-01 0254 Cylinder Cover 90151 0205 Cylinder Cover - Panel 90161 0110 Cylinder Cover - Tools 90163 0004 Cylinder Cover - Support Tool 90165 0001 Cylinder Cover - Lifting Tools 902 - Piston with Rod & Stuffing Box 102-01 0097 Piston, Data 902-01 0284 Piston 102-02 0060 Piston Rod Stuffing Box, Data 902-02 0229 Piston Rod Stuffing Box 90251 0246 Piston and Piston Rod - Panel 90261 0107 Piston and Piston Rod - Tools 90264 0012 Piston and Piston Rod - Tilting Tools 90265 0005 Piston and Piston Rod - Support Tools 90266 0005 Piston - Lifting Tools 903 - Cylinder Liner and Cylinder Lubrication 103-01 0072 Cylinder Liner, Data 903-01 0257 Cylinder Liner 103-02 0028 Cylinder Lubricator, Data 903-02 0249 Cylinder Lubricator 90361 0084 Cylinder Liner - Tools 90362 0005 Cylinder Liner - Milling Tools 90364 0004 Test Equipment for Lubricators 90366 0007 Cylinder Liner - Lifting Tools 904 - Crosshead with Connecting Rod 104-01 0059 Crosshead Bearing, Data 904-01 0249 Crosshead Bearing 104-02 0060 Crosshead, Data 904-02 0248 Crosshead 104-03 0041 Reciprocating Parts, Data 904-03 0217 Reciprocating Parts 104-04 0052 Crankpin Bearing, Data 904-04 0231 Crankpin Bearing 104-05 0051 Connecting Rod, Data 904-05 0228 Connection Rod
MAN B&W Diesel A/S Page 1 (4)
Table of Contents
Volume II - Maintenance No. 90451 90461 90462 90464 90465 Edition 0149 0068 0034 0005 0001 Title Connecting Rod and Crosshead - Panel Connecting Rod - Hydraulic Tools Connecting Rod - Tools Crosshead - Hydraulic Tools Crosshead - Tools
900
905 - Crankshaft, Thrust Bearing and Turning Gear 105-01 0006 Crankshaft Deflection, Data 905-01 0208 Crankshaft Deflection 105-02 0052 Main Bearing, Data 905-02 0245 Main Bearing 105-03 0044 Thrust Bearing, Data 905-03 0224 Thrust Bearing 105-04 0017 Journal Bearing, Data 905-04 0216 Journal Bearing 105-05 0037 Axial Vibration Damper, Data 905-05 0224 Axial Vibration Damper 90551 0237 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel 90561 0064 Main Bearing - Hydraulic Tools 90562 0133 Crankshaft - Tools 90563 0024 Segment Stopper - Hydraulic Tools 90564 0018 Crankshaft - Measuring Tools 90564 0020 Crankshaft - Measuring Tools 90570 0001 Thrust Shaft - Tools 90572 0005 Main Bearing - Measuring Tools 906 - Control Gear 106-01 0042 Chain, Data 906-01 0232 Chain 106-02 0035 Chain Tightener, Data 906-02 0230 Chain Tightener 106-03 0030 Camshaft, Data 906-03 0214 Camshaft 106-04 0029 Camshaft Bearing, Data 906-04 0218 Camshaft Bearings 106-06 0005 Replacement of Cams on Camshaft, Data 906-06 0204 Replacement of Cams on Camshaft 90651 0185 Chain Drive and Camshaft - Panel 90664 0005 Crankshaft - Pin Gauge 90668 0003 Camshaft - Pin Gauge 907 - Starting Air System 107-01 0018 Starting Air Distributor, Data 907-01 0217 Starting Air Distributor 107-02 0034 Start Air Valve, Data
Table of Contents
Volume II - Maintenance No. Edition 0216 Title Starting Air Valve
900
907-02
908 - Exhaust Valve 108-01 0031 High-Pressure Pipe, Data 908-01 0226 High-Pressure Pipe 108-02 0059 Exhaust Valve, Data 908-02 0240 Exhaust Valve 108-03 0034 Exhaust Valve Actuator, Data 908-03 0227 Exhaust Valve Actuator 108-04 0031 Exhaust Valve Roller Guide, Data 908-04 0217 Exaust Valve Roller Guide 108-05 0010 Exhaust Valve Cam, Data 908-05 0214 Exhaust Valve Cam 108-07 0031 Exhaust Valve - Special Running, Data 908-07 0226 Exhaust Valve 90851 0165 Exhaust Valve - Panel 90861 0037 Exhaust Valve - Tools 90862 0041 Exhaust Valve - Hydraulic Tools 90863 0014 Exhaust Valve - Extra Tools 90864 0003 Exhaust Valve - Extractor Tool 909 - Fuel Oil System 109-01 0055 Fuel Pump Lead, Data 909-01 0240 Fuel Pump Lead 109-02 0004 VIT System, Data 909-02 0207 VIT System 109-03 0047 Fuel Pump Cam, Data 909-03 0229 Fuel Pump Cam 109-04 0042 Fuel Pump, Data 909-04 0222 Fuel Pump 109-05 0045 Fuel Pump Top Cover, Data 909-05 0223 Fuel Pump Top Cover 109-06 0039 Fuel Pump Barrel Assembly, Data 909-06 0219 Fuel Pump Barrel Assembly 109-07 0029 Fuel Pump Suction Valve, Data 909-07 0214 Fuel Pump Suction Valve 109-08 0037 Fuel Pump Puncture Valve, Data 909-08 0217 Fuel Pump Puncture Valve 109-09 0026 Fuel Pump Shock Absorber, Data 909-09 0214 Fuel System Shock Absorber 10910 0018 Lifting Gear Roller Guide, Data 90910 0211 Lifting Gear for Roller Guide 10911 0066 Fuel Valve, Data 90911 0245 Fuel Valve 10912 0048 Spindle Guide, Data
Table of Contents
Volume II - Maintenance No. 90912 10913 90913 10914 90914 10915 90915 90961 90966 90967 90968 90974 90977 90979 90980 Edition 0228 0031 0206 0067 0235 0046 0226 0069 0008 0001 0001 0001 0001 0001 0001 Title Spindle Guide Non-Return Valve for Fuel Valve, Data Non-Return Valve for Fuel Valve Fuel Oil High-Pressure Pipes, Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide, Data Fuel Pump Roller Guide Fuel Valve - Tools Fuel Valve Nozzle - Tools Fuel Puncture Valve - Tools Fuel Valve - Inspection Tools Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals
900
910 - Turbocharger System 91064 0002 Travelling Trolley 91066 0001 Air Cooler - Lifting Tools 911 - Safety Equipment 111-01 0025 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 0009 Holding Down and End Chock Bolts (Epoxy), Data 912-02 0207 Holding Down and End Chock Bolts (Epoxy) 112-03 0018 Stay Bolts, Data 912-03 0212 Stay Bolts 912-05 0201 Crankcase Oil Outlet 91261 0073 Hydraulic Tools for Large Parts 91266 0001 Hydraulic Tools - End Chock Bolts (Epoxy Chocks) 913 - General Tools 913-01 0215 Hydraulic Tools 913-04 0201 Standard Tightening Torques 913-05 0205 Torque Spanner 913-06 0205 Tightening Gauge 913-07 0207 Screws and Nuts 91311 0204 Lubricating 91351 0037 Accessories - Hydraulic Tools
Table of Contents
Volume II - Maintenance No. 91356 91357 91358 91359 91360 91361 91362 91363 91364 91366 91368 Edition 0053 0007 0014 0003 0004 0052 0069 0040 0059 0066 0007 Title Lifting Tools, etc. Open-Ended Spanners Open Ended Slugging Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms
900
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. 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.
A90023-0027
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
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 X X X X X X X X X X 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)
901 - Cylinder Cover

101-01 901-01 90151 90161 90163 90165 0071 0254 0205 0110 0004 0001 Cylinder Cover, Data Cylinder Cover Cylinder Cover - Panel Cylinder Cover - Tools Cylinder Cover - Support Tool Cylinder Cover - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel Data
101-1
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X X X X X X X X X X X X Data Ref. D01-01 D01-02 D01-03 D01-06 D01-07 D01-08 D01-09 D13-01 D13-02 Description Exhaust valve stud, screwing-in torque Starting valve stud, screwing-in torque Fuel valve stud, screwing-in torque Cylinder cover, complete Cylinder cover without valves Cooling jacket Exhaust valve stud Hydraulic pressure, mounting Hydraulic pressure, dismantling Value 450 140 140 +/-20 2900 2050 73 50 1500 1400-1650 Unit Nm Nm Nm kg kg kg kg bar bar 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
When referring to this page, please quote Data D10101 Edition 0071
Page 1 (2)
101-1
Cylinder Cover
Data MAN B&W Diesel
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate P90151 P90151 P90151 P90151 P90163 P90161 P90165 P91351 P91351 P91351 P91351 10 34 58 130 Item No. 46 58 60 83 Description Grinding tool for exhaust valve seat Milling and grinding wheel for fuel valve seat Milling and grinding wheel for starting valve seat Grinding handle Cylinder Cover - Support Tool Cylinder cover tightening tool Cylinder Cover - Lifting Tools Hydraulic pump, pneumatic operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 9-way distributor block, complete
Page 2 (2)
Cylinder Cover
MAN B&W Diesel
Shut off Oil and Water Supply 1. 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. Close the fuel oil supply for the unit concerned.
M90101 0254D01
901-1.2
Dismantling
2.
3. Shut off the water supply. Close the water outlet above the exhaust valve. Close the water outlet on the exhaust side of the cylinder cover. Shut off the water supply placed on the exhaust side below the exhaust gas receiver. Open the drain next to the inlet valve.
3.
When referring to this page, please quote Procedure M90101 Edition 0254
M90101 0254D02
Page 1 (14)
901-1.2
Cylinder Cover
Dismantling MAN B&W Diesel
4.
Open the venting cock next to the outlet valve. Dismantling of Pipe Connections 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.
M90101 0254D03
Remove the fuel oil high pressure pipes. See Procedure 909-14.2. 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.
5.
Page 2 (14)
M90101 0254D05
M90101 0254D04
Remove the screws in the flange between the intermediate pipe and the exhaust receiver.
6.
Cylinder Cover
MAN B&W Diesel
7. 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. Remove the protective caps from the cylinder cover nuts.
M90101 0254D06
901-1.2
Dismantling
Loosen and remove the cylinder cover nuts, see Data. For use of hydraulic tools, see Procedure 913-1. Cylinder Cover Lifting and Landing 9. Cylinder cover supporting tool. Fit the cylinder cover supporting tool in the purposed holes on the uppermost platform.
8.
D13 02
M90101 0248D08
M90101 0254D07
9.
Page 3 (14)
901-1.2
Cylinder Cover
Dismantling
10. Cylinder cover lifting.
MAN B&W Diesel
10. Hook on the engine room crane to the lifting attachment on top of the exhaust valve.
D01 06
Check that all cylinder cover connections have been loosened and removed. Lift away the cylinder cover complete. 11. Cylinder cover landing. Land the cylinder cover on the supporting tool. If the cylinder cover is to be overhauled it is recommended instead to land the cylinder cover on a couple of wooden planks. Note!
Page 4 (14)
M90101 0254D10
M90101 0254D09
The cylinder cover supporting tool should only be used when the ship is in port.
11.
Cylinder Cover
MAN B&W Diesel
12. Remove sealing ring. 12. Remove and discard the sealing ring between the cylinder cover and cylinder liner.
901-1.2
Dismantling
M90101 0248D12
Page 5 (14)
901-1.3
Cylinder Cover
Overhaul
Overhaul Preparations
MAN B&W Diesel
1. 1. Dismantle valves and pipes.
D01 09
Dismantle all valves and pipes from the cylinder cover. See Procedure 907-2.2, 9082.2 and 909-11.2. Dismantle the starting air inlet block and the cooling water outlet block from the exhaust side of the cylinder cover. Remove all studs on top of the cylinder cover. Cooling Water Jacket 2. Remove the cooling water jacket.
M90101 0254O01
2.
Mount four eyebolts and the lifting chains as shown in the sketch. Remove the four screws which secure the cooling jacket to the cylinder cover. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. If the cooling jacket sticks, use dismantling screws to force the jacket/cover apart.
D01 07
M90101 0254O02
D01 08
Remove and discard the O-rings from the cover, and carefully clean the cooling jacket and the cylinder cover. 3. Mount the cooling water jacket. Provide the cylinder cover with new Orings, well lubricated with oil. Lift the cylinder cover and guide the jacket/ cover into position, using the guide pin as a reference (manoeuvre side). Fit and tighten the screws for the cooling jacket.
3.
Page 6 (14)
M90101 0254O03
Cylinder Cover
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.
M90101 0246O04
901-1.3
Overhaul
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). After the milling/grinding, clean the bore and seating carefully, and check that the seating is not damaged.
5.
M90101 0254O05
Page 7 (14)
901-1.3
Cylinder Cover
Overhaul
6. Exhaust valve bore.
MAN B&W Diesel
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). After the grinding, clean the bore and seating carefully, and check that the seating is not damaged.
M90101 0240O07
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. 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.
7.
Page 8 (14)
M90101 0243O07
Cylinder Cover
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 fit the valve studs.
M90101 0254O07
901-1.3
Overhaul
Tighten up the studs in accordance with the screwing-in torque stated on the data sheet. Fill up the grooves between the valve studs and the bores for the valve studs with permatex to prevent water or oil from entering the bores during operation of the engine. 10. Mounting of valves. Install the valves on the cylinder cover, see Procedures 907-2.4, 908-2.4 and 909-11.4.
9.
D01 01
D01 02
D01 03
M90101 0254O08
Page 9 (14)
901-1.4
Cylinder Cover
Mounting
Landing Preparation
MAN B&W Diesel
1. 1. Sealing ring. Check that the liner sealing surface is clean. Place a new sealing ring on top of the cylinder liner. If necessary fit a new klinger sealing ring in the groove of the flange of the intermediate pipe.
M90101 0254M01
2. Water connections. Check that the water connections are clean and provided with new O-rings. Lubricate the O-rings with Vaseline and fit them on the cylinder liner.
2.
Page 10 (14)
M90101 0254M02
Cylinder Cover
MAN B&W Diesel
Cylinder Cover Mounting 3. 3. Cylinder cover landing.
901-1.4
Mounting
D01 06
Carefully wipe the cylinder cover contact surface facing the cylinder liner, while the cover is resting on the support. 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. If necessary, adjust to the distance D01-05 by turning the stud.
M90101 0254M03
4.
D01 05
M90101 0254M04
Page 11 (14)
901-1.4
Cylinder Cover
Mounting MAN B&W Diesel
5. Cylinder cover tightening. 5. Fit and tighten the cylinder cover nuts. For operation of hydraulic jacks, see Procedure 913-1.
D13 01
Fit the protective caps on the cylinder cover studs. Fitting Pipe Connections 6. Mount the exhaust gas compensator.
M90101 0254M05
Fit the screws of the flange between the intermediate pipe and the exhaust receiver. Note! Lubricate the screws with Never Seize or molybdenum disulphide (MoS2) before fitting. Fit the insulating jacket around the intermediate pipe.
6.
Page 12 (14)
M90101 0254M06
Cylinder Cover
MAN B&W Diesel
7. 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. 9. Connect the oil pipes. Mount the hydraulic high pressure pipe for the exhaust valve. See Procedure 908-1.4. Connect the drain pipe for the exhaust valve. Connect the fuel oil high pressure pipes. See Procedure 909-14.4. Connect the pipes for return fuel oil from the fuel valves.
M90101 0254M07
901-1.4
Mounting
8.
M90101 0254M09
M90101 0254M08
9.
Page 13 (14)
901-1.4
Cylinder Cover
Mounting
Open Oil and Water Supply
MAN B&W Diesel
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 finished, close the venting cock. Open the two water outlet valves on the exhaust side of the cylinder cover.
M90101 0254M10
11. Open the oil supply. Open the fuel oil supply for the unit concerned.
11.
Page 14 (14)
M90101 0254M11
Cylinder Cover Panel

MAN B&W Diesel
Plate P90151-0205
When referring to this page, please quote Plate P90151 Edition 0205
Page 1 (2)
Plate P90151-0205 Item No.

010 022 046 058 060 071 083 095 105 117
Cylinder Cover Panel

MAN B&W Diesel Item No.
Item Description
Panel for tools Name plate Grinding tool, exhaust valve seat Milling and grinding tool, fuel valve seat Milling and grinding wheel, fuel starting valve Dismantling tool, fuel valve Handle, grinding tools Grinding ring, starting valve seat Pin spanner, starting valve Test equipment, combined safety valve
Item Description
Page 2 (2)
Cylinder Cover - T ools Tools

MAN B&W Diesel
Plate P90161-0110
Page 1 (2)

027 039 040 052 064 090 100 206
Cylinder Cover - T ools Tools

Item Description
Hydraulic jack for cylinder cover Support Stud setter O-ring with back-up ring O-ring with back-up ring Spanner Tommy bar Hydraulic tool set, complete
Item Description
Page 2 (2)
Cylinder Cover - Support Tool

MAN B&W Diesel
Plate P90163-0004
Page 1 (2)

016
Cylinder Cover - Support Tool

Item Description
Cylinder cover rack
Item Description
Page 2 (2)
Cylinder Cover - Lifting T ools Tools

MAN B&W Diesel
Plate P90165-0001
Page 1 (2)

017
Cylinder Cover - Lifting T ools Tools

Item Description
Lifting chains for cylinder cover
Item Description
Page 2 (2)
902 - Piston with Rod & Stuffing Box

102-01 902-01 102-02 902-02 90251 90261 90264 90265 90266 0097 0284 0060 0229 0246 0107 0012 0005 0005 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 Data
102-1

X X X X X X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D01-05 D02-01 D02-02 D02-03 D02-05 D02-06 D02-08 D02-09 D02-10 D02-11 D02-13 D02-14 D02-15 D02-16 D02-17 D02-18 D02-19 D02-20 D02-21 D02-22 D02-23 D02-24 D02-25 D02-46 D02-47 D02-48 D02-49 Description Cylinder cover stud, check distance Test pressure Piston rod/crosshead, tightening torque Piston rod/crown, tightening torque Piston skirt, tightening torque Cooling oil pipe, tightening torque Piston ring new, radial width Piston ring worn, min. radial width Groove No.1, max. vertical height Groove Nos. 2, 3 and 4, max. vertical height Piston ring new, height of ring No. 1 Piston rings new, height of ring Nos. 2, 3 and 4 Minimum free ring gap ( before dismantling ) Minimum ring gap, ring No. 1 ( new ring in new liner ) Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) Vertical clearance, new parts Vertical clearance, worn parts, max. Piston complete Piston crown Piston rod Piston skirt Piston cooling pipe Lifting tool, tightening torque CPR ring CL groove, min. depth Piston top centre, max. permissible burn-away Piston top centre diameter Piston top outer ring area, max. permissible burn-away Value 148 - 149 7 590 580 190 80 20.2 17 14.7 11.7 13.9 10.9 30.5 4.1 3 0.43 0.92 1600 310 1050 95 36 150 1.3 9 280 6 Unit mm bar Nm Nm Nm Nm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg Nm mm mm mm mm
Page 1 (2)
102-1
Piston
Data MAN B&W Diesel
Plate P90251 P90251 P90251 P90251 P90251 P90251 P90251 P90251 P90261 P90265 P90266 P90366 Item No. 40 75 87 99 110 134 158 171 Lifting tool for piston rod foot Template for piston top Distance piece for stuffing box Cover for stuffing box hole Pressure test tool for piston Piston ring expander Guide screw for piston crown Dismantling screw piston skirt Guide ring for piston Support for piston Lifting tool for piston Crossbar for cylinder liner Description
Page 2 (2)
Piston
MAN B&W Diesel
Scavenge Port Inspection To detect possible leakages from the piston or cylinder cover, keep the cooling water and cooling oil circulating during the scavenge port inspection. 1. The scavenge port inspection is carried out from the scavenge air receiver. An additional view of the rings is possible through the cleaning cover on the manoeuvring side. 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. 2. Ring inspection: Inspect the rings, one at a time, and note down the results. See Volume I, Operation, Chapter 707. 3. Ring tension: Check the tension of the piston rings, by pressing against them with a wooden stick.
M90201 0280C02 M90201 0280C01
902-1.1
Checking
1.
2.
3.
M90201 0280C03
Page 1 (20)
902-1.1
Piston
Checking MAN B&W Diesel
4.
D02 18
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.
E
D02 19
Measure the clearance at the top (E) and bottom (F) of the piston ring groove. Total clearance = E + F. 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
M90201 0280C04
Max. 2mm
5.
D02 46
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. Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine.
Page 2 (20)
M90201 0283C06
M90201 0280C05
6.
Piston
MAN B&W Diesel Checking
7.
902-1.1
7. Free ring gap: Before dismantling the piston rings, measure the free ring gap of all the piston rings. For dismantling the piston rings, see Procedure 902-1.3. 8. Radial ring width: Measure the radial width of the rings. Note down the results See Volume I, Operation, Chapter 707.
D02 15
Measure the ring grooves with a calliper gauge, see Data D02-10 and D02-11. Clearance in piston ring grooves: The maximum vertical height in a worn ring groove must not exceed the value stated in Data. The groove is also worn out if there is no chromium layer. If the ring grooves are worn out, the piston crown must be reconditioned, contact MAN B&W Diesel A/S for advice.
M90201 0280C07
9. Ring grooves: Clean the ring grooves and check them for burn marks or other deformation.
8.
D02 08
New
M90201 0280C08
D02 09
Worn
9.
D02-10 D02-11
Max 2mm
M90201 0280C09
Page 3 (20)
902-1.1
Piston
Checking MAN B&W Diesel
10.
10. Piston top template: Check that the piston top template is permanently marked with the piston top centre diameter D02-48. Check that the centre area C has been marked off, and write the maximum permissible burn-away rate on the template. See data D02-47. Mark the outer part of the template R for ring area, and write the maximum permissible burn-away rate for the ring shaped area. See data D02-49. 11. Piston crown top: Clean the piston crown and check the burn-away by means of the template.
C R
D02 48
M90201 0280C10
11.
D02 47 D02 49
For maximum permissible burn away on the piston top centre area, see Data D02-47. For the ring shaped area, see Data D02-49. Check the burn-away on the whole circumference of the piston crown top. If the burn-away exceeds the values given in Data, contact MAN B&W for advice. Note down the results for later reference.
Page 4 (20)
M90201 0280C11
Piston
MAN B&W Diesel
Preparations in the crankcase 1. Access: Open the crankcase door to the cylinder concerned. Turn the crosshead down far enough to give access to the piston rod stuffing box and the piston rod/crosshead connection. 2. Stuffing box: Release the stuffing box by removing the innermost screws from the stuffing box flange. On engine models where the drain pipe is connected directly to the stuffing box: Disconnect the stuffing box drain pipe. Note! Do NOT remove the outermost screws from the flange.
902-1.1
Dismantling
1.
3. Loosen the piston rod-crosshead connection: Remove the screws from the piston rod.
M90201 0284D04
M90201 0280D03
M90201 280D01
2.
3.
Page 5 (20)
902-1.1
Piston
4.
4. 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. Preparations on the cylinder top 5. Cylinder cover: Remove the cylinder cover. See Procedure 901-1.2. Make a scratch mark in liner and piston cleaning ring to ensure correct re-mounting. Remove the piston cleaning ring. Carefully remove any wear ridges at the top of the cylinder liner. See Procedure 903-1.3.
Page 6 (20)
M90201 0280D06
M90201 0280D05
5.
Piston
MAN B&W Diesel Dismantling
6.
902-1.1
6. Piston lifting tool: Turn the piston to TDC. The top of the piston is now free of the cylinder liner. Clean the lifting groove of the piston crown and mount the lifting tool. 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. Limited lifting high: If the engine not is equipped with long distance pieces, remove one or two cylinder cover studs, using a stud setter.
D02 25
M90201 0283D07
Page 7 (20)
902-1.1
Piston
7.
Piston lift 7. 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.
D02 20
Page 8 (20)
M90201 0283D08
Piston
MAN B&W Diesel
8. Protect the crosshead bearing: Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit. 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. Clean, measure and recondition the cylinder liner. See Procedure 903-1.
902-1.1
Dismantling
8.
M90201 0283D09
Page 9 (20)
902-1.1
Piston
Overhaul MAN B&W Diesel
1.
D02 20
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. 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. 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. Lift the piston crown and skirt clear of the piston rod.
M90201 0280O02
M90201 0280O01
2.
3.
D02 21 + D02 23
Page 10 (20)
M90201 0284O03
Piston
MAN B&W Diesel Overhaul
4.
902-1.1
4. Piston rod and cooling pipe: Remove the screws from the cooling oil pipe flange. Mount the eye bolts and lift out the cooling oil pipe. 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. Mount a new O-ring on the piston rod flange. 5. Piston crown dismantling and cleaning: Place the piston crown with skirt on a wooden support as shown. 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. Discard the sealing ring on the piston skirt. Thoroughly clean and inspect all parts of the crown and skirt. If coke deposits are found in the cooling spaces of the piston crown, they should be washed clean with Carbon Remover or a similar cleaning fluid. When all coke deposits have been dissolved, clean and inspect the piston crown again. Note! Coke deposits reduce heat transfer from the piston crown to the cooling oil. The deposits must be removed as a routine procedure when a piston is overhauled.
D02 24 D02 06
D02 22
M90201 0280O04
5.
D02 23
M90201 0284O05
Page 11 (20)
902-1.1
Piston
6.
D02 05
6. 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. 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. 7. 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. 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.
M90201 0284O06
7.
D02 03
M90201 0284O07
Page 12 (20)
Piston
MAN B&W Diesel
Sealing ring and pressure test 8. 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. 8. 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. Dry off all soap water. 9. Pressure test: For this test, the piston must be turned upside down (see next step to turn a complete piston). 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. Turn the piston upside up and drain out the piston oil.
oil
902-1.1
Overhaul
M90201 0277O16
9.
D02 01
M90201 0277O17
Page 13 (20)
902-1.1
Piston
10.
10. 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. Mount an eyebolt in the side of the lifting tool, hook on the crane and remove the lifting tool from the piston crown. Attach the lifting bracket to the bottom of the piston rod foot. Hook the crane on to the lifting bracket. Lift the piston rod foot clear of the wooden block. Keep lifting until the piston rod is in a vertical position. Note! During the lift, follow with the crane to keep the crane positioned vertically above the lifting point. The stuffing box must be removed.
Page 14 (20)
M90201 0283O10
Piston
11.
A
902-1.1
11. 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. When mounting the piston rings, use the ring expanders to prevent unintended deformation of the rings. Do not expand the rings more than necessary. The uppermost ring (CPR-ring) must be mounted with the short ring expander. Mount the piston rod stuffing box. See Procedure 902-2.3.
B A B D C C
TOP
M90201 0280O11
Page 15 (20)
902-1.1
Piston
1.
Preparation of piston 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. 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.
Page 16 (20)
M90201 0277M02
M90201 0283M01
2.
Piston
MAN B&W Diesel
Preparation of cylinder liner 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. Clean the stuffing box flange. 5. Crosshead position: Turn the crosshead to a position 45 from TDC (crank web pointing towards exhaust side).
M90201 0283M03
902-1.1
Mounting
3.
4.
M90201 0277M06
M90201 0277M05
5.
45
Page 17 (20)
902-1.1
Piston
Mounting
Mounting of piston
MAN B&W Diesel
6.
D02 20
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. 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. 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. 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.
Page 18 (20)
M90201 0284M08
M90201 0283M07
M90201 0283M06
7.
8.
Piston
MAN B&W Diesel Mounting
9. 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. 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.
M90201 0280M09
902-1.1
On engine models where the drain pipe is connected directly to the stuffing box: 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. 11. Piston cleaning ring: Mount the piston cleaning ring in accordance with the scratch mark. If the PC-ring is damaged (broken or cracked), it must be
10.
D02 02 or D02 07
M90201 0277M14
M90201 0284M10
11.
Page 19 (20)
902-1.1
Piston
replaced by another ring. See Procedure 903-1. 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. Mount the cylinder cover studs with the stud setter. Screw the stud down to contact and half a revolution back.
12.
M90201 0277M15
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. See Procedure 901-1.4. 14. Running-in: Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple of revolutions.
13.
D01 05
M90201 0280M14
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.
Page 20 (20)
Piston Rod Stuffing Box

Data
X X X X X X X X X X X
102-2
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
Ref. Description Value Unit
D02-26 D02-27 D02-28 D02-29 D02-30 D02-34 D02-38 D02-44 D02-45 D02-50
Stuffing box flange, outer screws tightening torque Stuffing box flange, inner screws tightening torque Stuffing box halves, tightening torque Uppermost rings, ring-end clearance Lowermost rings, ring-end clearance Sealing ring springs new, free length Scraper ring springs new, free length Stuffing box complete Stuffing box half Stuffing box halves fitted bolts, tightening torque
80 80 80 4x6 3x3 618 606 100 35 25
Nm Nm Nm mm mm mm mm kg kg Nm
When referring to this page, please quote Data D10202 Edition 0060 MAN B&W Diesel A/S
Page 1 (2)
102-2

Data
Plate P90251 P90251 P90451 Item No. 109 122 120 Description Mounting tool for stuffing box spring Worktable for stuffing box Rubber cover for crosshead
Page 2 (2)

Checking
902-2.1
1. After the piston rod stuffing box has been dismantled, check the following clearances: See Procedure 902-2.2. Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring). Total clearance (scraper ring). (D02-29) Clearance at ring ends (sealing rings). Total clearance (sealing rings). (D02-29) Lowermost scraper rings Clearance at ring ends. Total clearance. (D02-30) The ring clearances stated in Data apply to new rings. 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 specified clearance values D02-29 and D02-30 have been halved. 2. Garter springs: Generally, it is recommended to renew the springs when the sealing rings and scraper rings are renewed. The springs can be checked as follows: Place the springs on the table, measure Lo (free length), and compare with Data. If a spring is extended more than 8% from the value given in data, it must be discarded.
1.
D02 29 B
D02 30 A B
D02 29
M90202 0229C01
D02 30
2.
D02 34
D02 38
When referring to this page, please quote Procedure M90202 Edition 0229 MAN B&W Diesel A/S
M90202 0227C02
Page 1 (10)
902-2.2

Dismantling
In connection with dismantling of the piston, only the innermost screws in the stuffing box flange and the screws for the drain oil pipe should be removed. If, in the period between piston overhauls, it becomes necessary to inspect the piston rod stuffing box, proceed as follows: 1. Turn the crosshead to about 90 from TDC. Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities.
1.
M90202 0229D01
2.
2. Remove the drain oil pipe and all innermost screws and all outer screws except for two screws placed diametrically opposite in the stuffing box flange, longitudinally to the engine. 3. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes.
Page 2 (10)
M90202 0229D03
M90202 0229D02
3.

Dismantling
4. Remove the two long dismantling screws from the worktable. Mount them in the stuffing box through the holes in the worktable. Remove the remaining two screws from the stuffing box. 5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame bottom.
M90202 0229D04
902-2.2
4.
6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. By means of the four short screws in the worktable, press the stuffing box out of the flange. For overhauling the stuffing box, see Procedure 902-2.3.
5.
M90202 0229D06
M90202 0229D05
6.
Page 3 (10)
902-2.3

Overhaul
Normally, overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons. During such overhauls, the piston rests on a support placed over one of the cut-outs in the top platform. Work on the stuffing box is then carried out from the platform below. Overhaul inside the engine is carried out in the same way as outside the engine.
M90202 0229O01
1. Mount two eye bolts in the stuffing box flange, and hook on two tackles. Lift the stuffing box a little up the piston rod, and mount the worktable round the piston rod at a suitable working height. Land the stuffing box on the worktable, and remove the tackles and eye bolts.
1.
D02 44
2. Remove the O-rings of the stuffing box. If the O-rings are intact and are to be used again, move them up the piston rod and secure them in this position, for example with tape. Remove the nuts from the stuffing box assembling bolts.
Page 4 (10)
M90202 0229O03
M90202 0229O02
2.

Overhaul
3. Take out the six bolts, and pull away one stuffing box half. Mount two eye bolts on the stuffing box half and remove it from the worktable. 4. Using a feeler gauge, measure the vertical clearance of the rings. See Procedure 902-2.1. 5. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. 6. Measure the clearance between the ring segments to determine whether replacement is necessary. See Procedure 902-2.1. Dismantle and stack the rings in the same order as when fitted in the stuffing box. Carefully clean all the ring segments. Inspect and assess the surface quality of the sealing rings. If their sliding surfaces have scratches or marks, replace the rings. 7. Check the lengths of the springs. See Procedure 902-2.1. 8. Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface carefully with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to machine-grind the surface in a workshop. 9. Clean the halves of the stuffing box housing.
M90202 0227C02 M90202 0229O04
902-2.3
3.
D02 45
7.
D02 34
D02 38
8.
M90202 0229O08
Page 5 (10)
902-2.3

Overhaul
10.
A B
10. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS2). For correct mounting of the sealing and scraper rings see the sketch. The scraper ring in groove no. 4 must be without relief grooves on the underside.
Scraper ring
A Scraper ring
B Sealing ring
C No relief groove
M90202 0229O10
Relief groove
Page 6 (10)

Overhaul
11. Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way: Place the lowermost scraper ring segments on the worktable. Place the spring round the segments, and hook the spring ends together. Repeat this procedure for the remaining scraper rings.
M90202 0229O11
902-2.3
11.
On top of the scraper rings, assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring). Assemble the 8-part sealing ring so that the two guide pins face upwards, place the spring round the segments and, hook the spring ends together. Assemble the 4-part sealing ring above the 8-part sealing ring. Push the two rings together in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring. Finally, assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring). 12. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod until the ring units are opposite the corresponding grooves in the stuffing box housing. Subsequently, push the stuffing box half into contact with the piston rod, round the ring units. Note! If the stuffing box is assembled inside the engine, place two pieces of plywood of the same thickness as the flange on the worktable, to ease the assembling.
12.
M90202 0229O12
Page 7 (10)
902-2.3

Overhaul
13. Check the ring clearance again. Then place the other half of the stuffing box housing on the worktable, pushing it into place round the rings.
13.
D02 28
In the middle holes mount and tighten up the fitted bolts to the torque specified on the Data Sheet, See Data D02-50
D02 50
Mount the O-rings in the stuffing box grooves. 14. Mount eye bolts and wire ropes, and lift the stuffing box a little. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot. Remove wire ropes and screws. Mount and tighten the standard bolts to specified torque, See Data D02-28
M90202 0229O13
14.
D02 44
Page 8 (10)
M90202 0229O14

Mounting
902-2.4
1. In connection with mounting of the piston, only the innermost flange screws are to be mounted and tightened, see data. After overhauling the stuffing box inside the engine, assemble the stuffing box halves on top of the four screws. Mount the two long screws from the worktable in the stuffing box. Turn down the short screws so that the stuffing box lands on the flange. 2. Turn the piston upwards until the stuffing box is in place in the cylinder frame. Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. 3. Mount two screws in the flange through the holes in the worktable.
1.
M90202 0229M03
M90202 0229M02
M90202 0229M01
2.
3.
Page 9 (10)
902-2.3

Overhaul
4. Remove the long screws from the stuffing box and mount them itheworktable. Remove the worktable from the piston rod. 5. Mount the drain oil pipe. Mount and tighten all the inner and outer screws for the stuffing box. See Data. 6. Remove the protecting rubber cover from the piston rod/crosshead.
4.
M90202 0229M04
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 fifteen minutes at a number of revolutions corresponding to very slow or idle speed. Then stop the engine and inspect the piston rod and stuffing box.
5.
M90202 0229M05
D02 26 D02 27
6.
Page 10 (10)
M90202 0229D01
Piston and Piston Rod Panel
Plate P90251-0246
MAN B&W Diesel A/S
Page 1 (2)

014 026 040 051 075 087 099 109 110 122 134 158 183
Piston and Piston Rod Panel

Item Description Item No. Item Description
Panel for tools Name plate Lifting tool for piston rod foot Lifting tool for cylinder liner Template for piston top Distance piece for stuffing box Cover for stuffing box hole Mounting tool for stuffing box spring Pressure test tool for piston Worktable for stuffing box Piston ring expander Guide screw for piston crown Pulling tool for stuffing box
Page 2 (2)
MAN B&W Diesel A/S
Piston and Piston Rod - Tools
Plate P90261-0107
MAN B&W Diesel A/S
Page 1 (2)

019
Piston and Piston Rod - Tools

Guide ring for piston
Page 2 (2)
MAN B&W Diesel A/S
Piston and Piston Rod - Tilting Tools
Plate P90264-0012
MAN B&W Diesel A/S
Page 1 (2)

015 027 039 040
Piston and Piston Rod - Tilting Tools

Item No.
Item Description
Collar ring for piston Support for tilting tool Support for tilting tool Lifting and tilting screw
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools
Plate P90265-0005
MAN B&W Diesel A/S
Page 1 (2)

010
Piston and Piston Rod - Support Tools

Support iron for piston
Page 2 (2)
MAN B&W Diesel A/S
Piston - Lifting Tools

MAN B&W Diesel
Plate P90266-0005
Page 1 (2)

016
Piston - Lifting Tools

Item Description
Lifting tool for piston
Item Description
Page 2 (2)
903 - Cylinder Liner and Cylinder Lubrication

103-01 903-01 103-02 903-02 90361 90362 90364 90366 0072 0257 0028 0249 0084 0005 0004 0007 Cylinder Liner, Data Cylinder Liner Cylinder Lubricator, Data Cylinder Lubricator Cylinder Liner - Tools Cylinder Liner - Milling Tools Test Equipment for Lubricators Cylinder Liner - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Liner
Data
103-1
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
D03-01 D03-03 D03-04 D03-05 D03-06 D03-16 D03-17 D03-18
Lifting tool screws, tightening torque Cylinder diameter, new Piston cleaning ring diameter, new Cylinder liner, complete Cooling jacket Piston cleaning ring radial width, new PC-ring/Liner max. wear deviation PC-rings replacement criteria:
200 600 598.7 3700 200 13.1 0.6
Nm mm mm kg kg mm mm
Liner diameter: 600 mm Liner wear: 0 0.60 mm Install: Standard PC-ring (new max. diameter wear of 0.60 mm Oversize PC-ring No PC-ring
0.60 1.20 mm > 1.20 mm
Page 1 (2)
103-1
Cylinder Liner
Data
Plate P90251 P90361 P90362 P90366 Item No. 51 Lifting tool for cylinder liner Measuring tool for cylinder liner Cylinder Liner - Extra Tool Cylinder Liner - Lifting Tools Description
Page 2 (2)
Cylinder Liner
Checking
1. Dismount the cylinder cover, the piston cleaning ring and the piston. See Procedures 901-1.2 and 902-1.2. Clean the cylinder liner and scavenge air ports. 2. Position the cylinder liner measuring tool. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. Take measurements in the fore-and-aft and athwartship directions. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707. Note!
M90301 0257C02
903-1.1
1.
D03 03
If the cylinder liner is to be replaced, the piston cleaning ring must also be replaced. 3. Carefully scratch over any scores or marks and grind away the wear ridges. See Procedure 903-1.3. 4. Check the lubricating points of the cylinder by pumping cylinder oil to each lubricating point with the cylinder lubricator. Clean any blocked lubricating duct. Mount the piston and cylinder cover. See Procedures 902-1.4 and 901-1.4.
4.
M90301 0257C04
Page 1 (10)
903-1.1
Cylinder Liner
Checking
5. Piston cleaning (PC) ring: The PC-ring is to be regarded as an integrated part of the liner and it is intended to follow the service life of the liner. During inspection of the piston and the liner, the PC-ring must also be inspected. 6. Measure the PC-ring radial width B, and find the most worn place. Compare with Data D03-16 and calculate the wear of the PC-ring, multiply the wear by 2 to get the PC-ring diameter wear. Measure the liner in the fore-and-aft and athwartship directions at piston skirt TDC position, corresponding to measuring point No. 5 on the liner-measuring tool. Compare the measurements with the diameter of a new liner as stated in Data. Calculate the wear of the liner. 7. Compare the PC-ring diameter wear with the wear of the liner. If wear of the two components does not deviate more than D03-17 then reinstall the PC-ring. If the deviation between PC-ring wear and liner wear is more than D03-17 or if the PC-ring is broken or cracked, replace the ring with a new PC-ring, an oversize ring or no ring according to the table in D03-18 on the Data sheet. If it is necessary to install an oversize PCring, contact MAN B&W Diesel for advice. When a new liner is installed, also a new PC-ring must be installed. When a new liner is ordered, also a new PC-ring must be ordered.
6.
Page 2 (10)
M90301 0257C06
Cylinder Liner
Dismantling
1. Dismount the cylinder cover. See Procedure 901-1.2. Discard the sealing ring from the top of the cylinder liner. Turn the piston down far enough to make it possible to grind away the wear ridges at the top of the liner with a hand-grinder. See Procedure 903-1.3. Dismount the piston cleaning ring and the piston. See Procedure 902-1.2. 2. Screw the two lifting tools on to the cylinder liner. Check with a feeler gauge that there is no clearance between lifting tool and cylinder liner. For tightening torque, see Data. 3. Disconnect the oil pipes leading from the cylinder lubricator to the cylinder liner. Dismount the four cooling water pipes between the cooling jacket and cylinder cover and discard the O-rings from the pipes and clean them carefully.
903-1.2
2.
M90301 0257D02
D03 01
3.
M90301 0257D03
Page 3 (10)
903-1.2
Cylinder Liner
Dismantling
4. Remove the screws of the cooling water inlet pipe. 5. Attach the crane to the lifting crossbar. Hook the lifting tools on to the crossbar on both sides of the cylinder liner. Lift the liner with the cooling jacket out of the cylinder frame. Note!
4.
M90301 0257D04
Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner.
5.
Land the cylinder liner vertically on, for instance, a couple of planks.
D03 05
6. Clean the cylinder frame internally, taking special care with the contact surfaces for the cylinder liner at the top of the cylinder frame. The lifting tools are also used for transporting the cylinder liner.
Page 4 (10)
M90301 0257D05
Cylinder Liner
Overhaul
1. Remove the non-return valves for the cylinder liner lubrication Attach two tackles to the crossbar, as shown. Mount two lifting eye bolts in the cooling jacket. Hook the tackles on to the lifting eye bolts on the cooling jacket and haul tight. Loosen the screws on the clamps which fix the cooling jacket to the cylinder liner. Turn the clamps away from the liner. 2. Lower the cooling jacket by means of the tackles and land it on the wooden planks. 3. Mount the lifting tools on the cylinder liner. See Data. Lift the cylinder liner away from the cooling jacket. Clean the cooling jacket internally.
903-1.3
1.
M90301 0257O01
2.
D03 06
M90301 0257O03
M90301 0257O02
3.
Page 5 (10)
903-1.3
Cylinder Liner
Overhaul
4. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707. Carefully scratch over any scores or marks on the cylinder liner running surface, by means of a rough grindstone held in the hand. Check in the top of the liner for a wear ridge (where the piston rings reverse direction). If there is any sign of a wear ridge, it is necessary to create a groove by grinding.The groove serves to prevent the build-up of a new wear ridge. 5. It is recommended to use a wear ridge milling machine to create the groove. For use of the milling machine, see suppliers instruction. 6. Alternatively, place an old piston ring on the top of the piston and turn to a position that enables the grinding disc to rest on the old piston ring while removing the wear ridge. Use a grinding disc with a round edge. Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC.
4.
A B
M90301 0256O04
M90301 0257O04
5.
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.
6.
S D
R=4-5 mm
Page 6 (10)
M90301 0256O05
Cylinder Liner
Overhaul
7. Apply a thin layer of grease on the contact surface for the cooling jacket on the liner. Mount the lifting tools on the liner. Lift the liner a little and mount new O-rings for the cooling jacket. Then place the liner in the cooling jacket. Remove the lifting tools. 8. Lift the cooling jacket into position marking scratches jacket/cylinder liner must coincide (manoeuvre side).
M90301 0257O06
903-1.3
7.
8.
M90301 0257O07
Page 7 (10)
903-1.3
Cylinder Liner
Overhaul
9. Turn the clamps until they fit in the groove of the liner, and tighten the screws. Remove the tackles and the eye bolts from the cooling jacket. Mount the non-return valves for the cylinder liner lubrication.
9.
Page 8 (10)
M90301 0257O08
Cylinder Liner
Mounting
1. Mount the lifting tools on the cylinder liner and tighten to the specified torque. See Data. Hook the lifting tools on to the crossbar, and lift the jacket/liner assembly. Mount the lowermost O-ring and apply a little lubricating oil on the ring. 2. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Coat the joint surfaces with permatex or a similar liquid sealing compound. Mount the cylinder liner in the cylinder frame. Replace the O-rings on the water connections and mount the water connections on the cooling jacket. 3. If one or more cylinder cover studs have been removed during the dismantling, mount the studs. See Procedure 902-1.4. 4. Fit a new gasket between the cooling water inlet pipe and the cooling jacket. Mount and tighten the screws.
M90301 0257M02 M90301 0257M01
903-1.4
1.
D03 01
2.
D03 05
3.
M90301 0257M04
Page 9 (10)
903-1.2
Cylinder Liner
Dismantling
5. Screw the pipes from the lubricator on to the non-return valves, but do not tighten. Vent the cylinder lubricating system by pumping all pipes through until oil, without air bubbles, comes out from the union pipe/non-return valve. When this is in order, tighten the pipes firmly on the non-return valves and again pump until it is certain that each individual lubricating point functions correctly.
5.
M90301 0257M05
6. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston and the piston cleaning ring. See Procedure 902-1.4. Note!
7.
Make sure to mount the piston cleaning ring correctly, so that the scratching marks are aligned. 7. Mount the sealing ring and the cylinder cover. See Procedure 901-1.4. Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned.
Page 10 (10)
M90301 0257M06
Cylinder Lubricators
Data
X X X X X X X X
103-2
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
D03-10 D03-11 D03-13
Inlet accumulator, nitrogen pressure, Outlet accumulator, nitrogen pressure, Plug screw, tightening torque,
30 1.5 30
bar bar Nm
Page 1 (2)
103-2
Data
Plate P90364 Item No. Test Equipment for Lubricators Description
Page 2 (2)
MAN B&W Diesel
Check of Oil Injection: 1. With stopped engine and normally when the system has been disassembled: 1. Press the ESC + PRELUB.-button on the HMI control panel, and check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. 2. If the cylinder cover or the exhaust valve is removed, check inside the liner that all lubricating points are working properly. Otherwise, remove the covers for scavenge port inspection. Turn the piston to BDC and check inside the liner with a mirror and a powerful light source that all lubrication points are working properly.
M90302 0245C01
903-2.1
Checking
3.
M90302 0245C02
Page 1 (12)
903-2.1
Checking
With running engine:
MAN B&W Diesel
4.
Inlet
3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. The LEDs give signal when oil is injected. Check the pressure shocks from the injection of the lubricators on each lubricator pipe by feeling with a hand.
D03 11
M90302 0249C03
D03 10
If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow. Check of Accumulators: 4. Measuring the nitrogen pre-pressure can only be done with stopped engine and pressure-free lubrication system. Stop both oil pumps. Close the inlet valve and open the equalizing valve on the respective lubricator. The nitrogen pressure in the inlet accumulator (0.7 litre) can be checked without dismounting the accumulator. For use of the pressure setting tool, see Step 5. 5. To measure the nitrogen pressure in the outlet accumulator (0.16 litre), the accumulator or the lubricator with accumulator must be dismounted. See Procedure 903-2.2. For nitrogen pressure in the accumulators, see Data.
5.
Page 2 (12)
M90302 0245C05
7.
903-2.1
6. Use of Pressure Setting Tool Assemble the pressure setting tool as shown in Figure 5, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor. Mount a 0-60 bar pressure gauge on the filling valve when the inlet accumulator (0.7 litre) is to be checked, and a 0-10 bar pressure gauge when the outlet accumulator (0.16 litre) is to be checked. 7. Before mounting the filling valve on the accumulator, check that the accumulator top is clean. Mount the filling valve on the relevant accumulator with the union nut. Check that valves C and F are closed. Loosen the plug screw in the accumulator using a square drive handle in socket E. It is now possible to read the actual nitrogen pressure in the accumulator on the dial gauge on the filling valve. 8. If the accumulator needs to be refilled with nitrogen, open valve A and increase the outlet pressure from valve C on spindle B to 1-2 bar above the pressure stated in Data. Open valve C until the accumulator is filled to the correct pressure. Close valve C and tighten the plug screw with socket E to the torque stated in Data. Release the pressure in the filling valve at bleed screw F. Unscrew the filling valve from the accumulator. Retighten the plug screw to the torque stated in Data. Remount the accumulator.
C E
D03 13
B
M90302 0247C07
Page 3 (12)
903-2.2
Dismantling
Dismantling of lubricators:
MAN B&W Diesel
1. The engine must be stopped and blocked before dismounting a lubricator. Stop the cylinder oil pump station. 1. Close the supply valve for the lubricator and open the equalizing valve (turn both handles to a horizontal position). Remove the upper shield, if installed. Disconnect the electrical plug on the side of the lubricator.
M90302 0249D01
Inlet
2. Unscrew the six screws in the bottom of the lubricator and disconnect the cover with pertaining pipes.
2.
Inlet
3. Unscrew the four screws on the side that secure the lubricator to the hydraulic block, and remove the lubricator. Special running It is possible to change a lubricator while the engine is running if a spare lubricator with Orings and the necessary tools is available. The change should be done in a maximum of 15 minutes. Reduce the engine load to below 40% of MCR Let the lubricator pump station run Dismount the lubricator as described in steps 1-3 Mount a spare lubricator as described in Procedure 903-2.4.
Page 4 (12)
M90302 0249D02
MAN B&W Diesel
Dismantling of accumulators: 5. 4. The engine must be stopped and blocked before the accumulator is dismounted. Stop the cylinder oil pump station. Close the supply valve for the lubricator and open the equalizing valve. Note!
M90302 0249D04
903-2.2
Dismantling
Inlet
When the oil pressure is released, a nitrogen pre-pressure of 25-30 bar will remain in the accumulator.
Carefully unscrew the accumulator to release the remaining oil pressure in the system. Remove the accumulator from the hydraulic block.
Page 5 (12)
903-2.3
1.
1. Place the lubricator in a bench vice with soft jaws. Remove the adjusting screw with bushings. Unscrew the oil accumulator. Discard the O-ring from the adjusting screw. 2. Remove the screws from the cylinder block. 3. Pull up the cylinder block.
M90302 0247O01
Remove the spring and actuator piston with plungers. Remove and discard the O-ring from the cylinder block. Remove the cover for the non-return valves. Take out springs and balls. Remove and discard the O-rings.
2.
Page 6 (12)
M90302 0247O03
M90302 0247O02
3.
MAN B&W Diesel
4. Screw out the non-return valves and remove and discard the O-rings. Clean the valves and check them with compressed air. 5. Inspect the plungers, actuator piston and cylinder block for wear, using a magnifying glass. 6. Fit the non-return valve with new O-rings. Mount the non-return valves in the cylinder block.
903-2.3
Overhaul
4.
M90302 0247O06
M90302 0247O05
M90302 0247O04
5.
6.
Page 7 (12)
903-2.3
7.
7. Pre-assemble the cylinder blockwith the actuator piston and plungers to ensure the correct guidance of the plungers, before finally assembling the cylinder block unit. Mount the spring and press down the actuator piston with plungers. Mount an M6 x 60 screw with a washer to keep the spring compressed. Fit the cylinder block with a new O-ring.
Page 8 (12)
M90302 0247O07
8.
903-2.3
8. Remove the cover from the terminal box and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box and the plug for the solenoid valve. Carefully unscrew the feedback sensor and remove and discard the O-ring. Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.
Unscrew the solenoid valve. Discard the O-rings. 10. Solenoid valve: Disassemble and clean the valve. Check the slide for wear. If the slide is scratched or scuffed, the valve must be replaced by a new one. Lubricate the slide with oil and check that the slide can move lightly with a good fit in the housing.
See also manufacturers instructions.
M90302 0244O12
M90302 0247O09
Assemble the valve.
M90302 0247O08
Turn the lubricator upside down in the vice.
9.
10.
Page 9 (12)
903-2.3
11.
11. Before mounting the feedback sensor, check that the sensor is flush with the sensor housing. Mount the feedback sensor or a new one, if necessary, with a new O-ring. Check with an object with a straight edge (e.g. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder. Mount the terminal box.
M90302 0245O10
1 2 3 BN (brown) BK (black) 4 BU (blue) 5
1 2 Solenoid valve
11. Connect the wires and mount the cover on the terminal box. 13. Mount the solenoid valve fitted with new O-rings. Coat the O-rings with a little grease to keep the rings in place during mounting.
Feedback sensor
12.
LED
Brown+15 Blue OV Black FB signal

M90302 0242O08
13.
Page 10 (12)
M90302 0247O13
14.
903-2.3
14. Mount the cylinder block assembly in the cylinder housing. Check that the spring pin engages correctly with the cylinder block assembly. Mount the screws and tighten the block to the housing. Remove the M6 x 60 screw with disc. 15. Mount the adjusting screw fitted with a new O-ring and the distance bushing. Mount the oil accumulator. 16. If the lubricator is not to be mounted on the engine immediately after overhauling, cover all openings with plastic to prevent dirt from entering the lubricator during storage. Cover all surfaces with a thin layer of oil.
M90302 0247O01
M90302 0247O14
15.
Page 11 (12)
903-2.4
1.
Inlet
1. Before mounting the accumulator, check the nitrogen pressure, see Data. Mount the accumulator. 2. Mount new O-rings on the hydraulic block and on the cover with pipes. Mount the lubricator and tighten the screws on the hydraulic block. Tighten the screws in the bottom of the lubricator to the pipe connection.
M90302 0249M01
3. Close the equalizing valve and open the supply valve (handles to be in a vertical position). Mount the electrical plug. Check the injection of cylinder oil on the feedback LED on the terminal box for the specific lubricator.
2.
Inlet
M90302 0249M02
3.
Inlet
Page 12 (12)
M90302 0249M03
Cylinder Liner - Tools

Cylinder Liner - Tools 0084 P90361
Plate P90361-0084
MAN B&W Diesel A/S
Page 1 (2)

036
Cylinder Liner - Tools

Item No.
Item Description
Cylinder gauge, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Liner - Milling Tools
Plate P90362-0005
MAN B&W Diesel A/S
Page 1 (2)

018
Cylinder Liner - Milling Tools

Wear ridge milling machine
Page 2 (2)
MAN B&W Diesel A/S
Test Equipment for Lubricator

Test Equipment for Lubricator 0004 P90364
Plate P90364-0004
MAN B&W Diesel A/S
Page 1 (2)

019 020 032 044 056 068 081 103 115 139 152 164 176 211 223
Test Equipment for Lubricator

Item No.
Item Description
Tool box Nameplate Adaptor Pressure gauge Spanner Pressure gauge Adaptor Hose with 2 union Quick coupling, minimess Reducing valve Adaptor Adaptor Adaptor Adaptor Filling and testing valve
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Liner - Lifting Tools

Cylinder Liner - Lifting Tools 0007 P90366
Plate P90366-0007
MAN B&W Diesel A/S
Page 1 (2)

021
Cylinder Liner - Lifting Tools

Item No.
Item Description
Crossbar for cylinder liner
Item Description
Page 2 (2)
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

104-01 904-01 104-02 904-02 104-03 904-03 104-04 904-04 104-05 904-05 90451 90461 90462 90464 90465 0059 0249 0060 0248 0041 0217 0052 0231 0051 0228 0149 0068 0034 0005 0001 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 Connecting Rod - Tools Crosshead - Hydraulic Tools Crosshead - Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crosshead Bearing
Data
104-1
Data
D02-02 D02-07 D02-20 D04-01 D04-02 D04-03 D04-04 D04-06 D04-07 D04-21 D13-01 D13-02
Piston rod/crosshead, tightening torque Piston rod/crosshead, tightening torque+angle Piston complete Crosshead bearing, top clearance max. Crosshead bearing, top clearance min. Oil wedge length, L Crosshead bearing cap Crosshead bearing shell, lower Crosshead bearing cap with bearing shell Crosshead complete Hydraulic pressure, mounting Hydraulic pressure, dismantling
590 100/60 1483 0.55 0.20 15 277 20 297 1245 1500 1400-1650
Nm Nm/ kg mm mm mm kg kg kg kg bar bar
Page 1 (2)
104-1
Crosshead Bearing
Data
Plate P90451 P90451 P90451 P90451 P90464 P91356 P91366 58 Item No. 59 72 96 106 Description Lifting attachment - connecting rod Chain for suspending piston Bracket for support, crosshead Bracket for support, crosshead Crosshead - hydraulic tools Lifting tools, etc. Feeler gauge
Page 2 (2)
Crosshead Bearing
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. 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. 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. 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. 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. See Procedure 904-1.2. For evaluation of the bearing shell, see Chapter 708, Bearings in the instruction book, Volume I, OPERATION. 5. The wear limit for a crosshead bearing shell is confined to a 50% reduction of the oil wedge length L. If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by a new one.
(Oil Wedge) L 1/2
M90401 0249C05
904-1.1
M90401 0249C02
D04 01 D04 02
M90401 0249C03
5.
D04 03
L
Page 1 (11)
904-1.1
Crosshead Bearing
Checking
Alternate checking method:
8. In case the reason for opening the crosshead bearing is a routine inspection, the following procedure is sufficient. 6. Perform the clearance measurement shown in 904-1.1 section 3. 7. Mount the two eyebolts and tackles in the top of the crankcase in the fore and aft direction. Mount two eyebolts on top of the guideshoes.
M90401 0249C08
Turn to BDC, mount the connecting rod lifting attachments on the connecting rod. Use tackles to hold the connecting rod in the vertical position. Dismount the crosshead bearing cap hydraulic nuts. For operation of the hydraulic jacks, see Section 913. 8. Mount two eyebolts in the bearing cap and use two small tackles in the athwartship direction to lift the bearing cap free of the guidepins and to keep the bearing cap balanced. 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
9.
M90401 0249C09
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 (11) When referring to this page, please quote Procedure M90401 Edition 0249 MAN B&W Diesel A/S
Crosshead Bearing
Dismantling
This procedure applies to the following two dismantling situations: with piston mounted with piston removed With piston mounted: 1. Turn the crankshaft down far enough to give access to the nuts and screws on the piston rod.
M90401 0249D01
904-1.2
1.
2. Mount two chains in the inner screw holes in the top of the crankcase, in the athwarthship direction, for suspending the piston rod. 3. Loosen and remove the locking wire from the screws on the piston rod foot. Remove the screws.
2.
M90401 0249D03
M90401 0249D02
3.
Page 3 (11)
904-1.2
Crosshead Bearing
Dismantling
4. Mount a lifting eye bolt on each side of the piston rod. 5. Turn the crosshead to TDC. Hook the chains to the lifting eye bolts in the piston rod. Turn the crosshead downward, and the piston rod will then remain suspended from the two chains. With piston removed:
4.
M90401 0249D04
6. Turn to BDC. 7. Place 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. Remove the hydraulic jacks and the spacer rings, and unscrew the nuts.
5.
M90401 0249D05
7.
D13 02
M90401 0249D07
Page 4 (11)
Crosshead Bearing
Dismantling
8. Mount the lifting attachments on the head of the connecting rod. 9. Suspend two tackles from the lifting brackets, in the athwarthship direction. 10. Mount the wire guide at the top of the crankcase door frame to prevent damage. Mount two eye bolts in the top of the crosshead bearing cap. Hook the tackles on to the eye bolts, and remove the bearing cap from the engine. Check the upper part of the journal.
904-1.2
8.
M90401 0249D09
M90401 0249D08
9.
10.
D04 07
M90401 0249D10
Page 5 (11)
904-1.2
Crosshead Bearing
Dismantling
11. Place the bearing cap on one side on a couple of wooden planks.
11.
D04 07
Check the bearing shell, see Procedure 904-1.1. 12. Fasten tackles to the fixed lifting brackets on the frame box wall. 13. Turn the crosshead upwards until the piston rod lands on the crosshead. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod. Do not remove the chains or lifting eye bolts.
Page 6 (11)
M90401 0249D13
M90401 0249D12
M90401 0249D11
12.
13.
Crosshead Bearing
Dismantling
14. Turn to TDC and attach the tackle hooks to the lifting attachments. Haul the tackles tight. 15. Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down towards the exhaust side, until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. Haul the tackles tight. 16. Turn the crankthrow carefully towards BDC while following with the tackles, thus continuously supporting the connecting rod. 17. With the crosshead resting on the supports, check the lower part of the crosshead journal and the lower bearing shell. Regarding checking of journal and bearing shells, see Volume I, OPERATION, Chapter 708, Bearings.
904-1.2
14.
M90401 0249D15
M90401 0249D14
15.
16. 17.
D04 21 D02 20
M90401 0249D16
Page 7 (11)
904-1.2
Crosshead Bearing
Dismantling
18. In cases where it is necessary to remove the lower bearing shell, tilt the connecting rod towards the doorway on the camshaft side, using the tackles. Dismount the locking screws, and turn the bearing shell so far up that an eye bolt can be mounted. Lift the bearing shell out of the engine.
18.
D04 06
Page 8 (11)
M90401 0249D18
Crosshead Bearing
Mounting
With piston mounted/ With piston removed: 1. Mount and secure the bearing shell in the bearing housing. 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.
M90401 0249M01
904-1.4
1.
D04 06
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. 3. Remove the supports from the crosshead guides. Remove the tackles from the crosshead. Turn the crank throw to BDC. If the piston is mounted, slowly turn down until it is fully suspended from the chains.
2.
D04 21
M90401 0249M03
M90401 0249M02
3.
Page 9 (11)
904-1.4
Crosshead Bearing
Mounting
4. Lift the bearing cap into the engine. Lower the bearing cap onto the crosshead and remove the tackles. Remove the lifting attachments from the connecting rod and the wire guide from the door frame. Note! Take care that the bearing studs do not damage the crosshead.
4.
D04 07
M90401 0249M04
5. Tighten all four crosshead bearing cap nuts simultaneously. See Data. For operation of hydraulic jacks, see Section 913. 6. Mount the piston. See Procedure 902-1.4. With piston mounted: 7. Turn the crosshead upwards until the piston rod lands on the crosshead. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod.
5.
D13 01
M90401 0249M05
7.
Page 10 (11)
M90401 0249D13
Crosshead Bearing
Mounting
8. Unhook the chains from the lifting eye bolts in the piston rod. Remove the chains and eye bolts from the top of the crankcase, from the piston rod and from the crosshead bearing cap. 9. Turn down to BDC, tighten the screws in the piston rod, and lock with locking wire. See Data. Mount the locking wire in such a way that the wire is tightened if a screw works loose. See Procedure 913-7.
904-1.4
8.
M90401 0249D13
9.
D02 02 D02 07
M90401 0249M09
Page 11 (11)
Crosshead
Data
104-2
Data
D04-04 D04-08 D04-12 D04-13 D04-15 D04-19 D04-21 D04-22 D04-23 D04-50 D13-01 D13-02
Crosshead bearing cap Cooling oil outlet pipe, tightening torque Guide strip screws, tightening torque Guide plate, tightening torque Telescopic pipe, tightening torque Telescopic pipe, tightening angle Crosshead complete Guide shoe Cooling oil outlet pipe Connecting rod, without bearing caps Hydraulic pressure, mounting Hydraulic pressure, dismantling
277 80 350 3 x 350 1 x 80 80 60 1245 325 15 1820 1500 1400-1650
kg Nm Nm Nm Nm Nm kg kg kg kg bar bar
Page 1 (2)
104-2
Crosshead
Data
Plate P90451 P90451 P90451 P90451 P90451 P90451 P90451 P90462 P90463 P91351 P91351 P91351 P91351 P91356 P91359 40 10 46 58 117 Item No. 47 59 60 84 118 120 214 11 Wire guide Lifting attachment connecting rod Lifting tools crosshead Retaining tool telescope pipe Rubber cover for crosshead Rubber cover for crosshead Torque wrench offset tool Guide shoe extractor, complete Crosshead hydraulic tools Hydraulic pump, pneumatic operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 5-way distributor block, complete Lifting tools, etc. Torque spanners Description
Page 2 (2)
Crosshead
Dismantling
1. Unbolt the main bearing lubricating oil pipes. 2. Unbolt the cooling oil outlet pipe from the guide shoe and the drain oil slotted pipe. Loosen and remove the screws which secure the telescopic pipe to the guide shoe. In order to reach the screw in the corner behind the telescopic pipe, use the offset tool along with a socket wrench.
M90402 0248D01
904-2.2
1.
3. Mount the retaining tool for the telescopic pipe on the stuffing box housing for the telescopic pipe. Mount two eye bolts in the top of the crankcase in the fore-and-aft direction. Mount two eye bolts in the athwartship direction, and suspend two tackles.
2.
M90402 0248D03
M90402 0248D02
3.
Page 1 (9)
904-2.2
Crosshead
Dismantling
4. Turn the crosshead to TDC. Suspend the telescopic pipe by means of the tool. Suspend the piston. To suspend the piston, see Procedure 904-1.2. 5. Turn the crosshead to gain access to the nuts on the crosshead bearing studs. Mount the spacer rings and the hydraulic jacks for loosening the nuts on the crosshead bearing studs. For operation of the hydraulic tools, see Section 913. Loosen the nuts, remove the hydraulic jacks and unscrew the nuts. 6. Mount eye bolts in the crosshead bearing cap and hook the tackles on to the lifting brackets in the top of the crankcase. Remove the bearing cap and lift it out of the engine.
4.
M90402 0248D04
5.
D13 02
M90402 0248D05
6.
D04 04
Page 2 (9)
M90402 0248D06
Crosshead
Dismantling
Lifting of the crosshead: 7a. 7a. Mount the special lifting tool on the crosshead. 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. Hook the tackles to the top lifting brackets on to the lifting tool on the crosshead, and lift the crosshead. 7b. Alternate method. 7b. If the piston has been removed it is advisable to use the engine room crane and the flat plated wire strap to handle the crosshead. This is done by lowering the strap down through the cylinder and stuffing box and lifting the crosshead in the crosshead lifting tool. This eliminates the need for the tackles placed in the athwartship direction in the crankcase top. 8. Use the tackles to tilt the connecting rod towards the exhaust side, while turning the crankthrow towards the camshaft side. Transfer the tackles from one lifting attachment to another as necessary. When the crankthrow is 90 after BDC, stop turning. By alternate use of the tackles, tilt the connecting rod until it rests against a couple of wooden planks in the bottom of the bedplate.
M90402 0248D09 M90402 0248D07
904-2.2
D04 21
M90402 0248D08
8.
D04 50
Page 3 (9)
904-2.2
Crosshead
Dismantling
9. Lower the crosshead to a position just above the main bearing caps. Remove the guide strips and both guide plates from the guide shoes. Mount lifting eye bolts in both guide shoes. 10. Suspend two tackles from the eye bolts in the top of the crankcase, in the fore-andaft direction, and attach the tackles to the guide shoes.
9.
M90402 0248D10
Push one of the guide shoes towards the middle of the crosshead. If necessary, use the guide shoe extractor tool. 11. Pull the free end of the crosshead into the neighbouring cylinder unit. Mount the guide shoe extractor on the opposite guide shoe. Pull off the guide shoe, remove the extractor, and lift up the guide shoe.
10.
D04 22
M90402 0248D11
11.
D04 22
Page 4 (9)
M90402 0248D12
Crosshead
Dismantling
12. Pull the crosshead with guide shoe into the opposite neighbouring cylinder unit. Mount the guide shoe extractor tool on the remaining guide shoe. Pull off the guide shoe, remove the extractor tool and lift up the guide shoe. 13. Turn the crosshead 90. 14. Mount the wire guide tool in the framebox door opening. Remove the crosshead from the engine, using wire rope and tackles. Protect the crosshead, for instance with thick or corrugated paper, and land it outside the engine. If necessary, remove the guide shoes from the engine.
M90402 0248D13
904-2.2
12.
13.
M90402 0248D15
M90402 0248D14
14.
Page 5 (9)
904-2.4
Crosshead
Mounting
1. Lift the crosshead into the engine, using wire rope, tackles mounted in the top lifting brackets inside the engine. 2. Turn the crosshead 90. Pull the crosshead to one side under the web plates between the cylinders. 3. Lower one guide shoe in the other side of the crosshead and mount the guide shoe extractor tool. Use the guide shoe extractor tool to pull the crosshead so far through the guide shoe that the other guide shoe can be lowered. Follow the movement of the crosshead with the tackles mounted in the engine.
1.
Page 6 (9)
M90402 0248M03
M90402 0248M02
M90402 0248M01
2.
3.
Crosshead
Mounting
4. Lower the other guide shoe. Use the guide shoe extractor tool to push the crosshead towards the second guide shoe. Remove the extractor tool and adjust the position of the opposite guide shoe. 5. Mount the guide plates on the side of the guide shoes. Tighten the screws and lock them with locking wire. See Procedure 913-7. Remove the eye-bolts from the guide shoes. Use the tackles in the fore and aft eyebolts to lift the crosshead to a working position and mount the guide strips on the side of the guide shoes. Tighten the screws and lock them with locking wire. See Procedure 913-7. 6. Using the tackles, lift the connecting rod to a vertical position while turning the crankthrow to BDC.
M90402 0248M05
904-2.4
4.
D04 22
M90402 0248D12
5.
D04 13
D04 12
6.
D04 50
M90402 0248M06
Page 7 (9)
904-2.4
Crosshead
Mounting
7. When the connecting rod is in a vertical position, lower the crosshead and land it on the connecting rod. Remove the lifting attachments from the connecting rod head. Remove the lifting tool from the crosshead. 8. Lift the crosshead bearing cap into the engine. 9. Mount the spacer rings and the hydraulic jacks for tightening the nuts on the crosshead bearing studs. For operation of the hydraulic tools, see Procedure 913. Mount the drain oil slotted pipe and the cooling oil outlet pipe on the guide shoe.
7.
D04 21
M90402 0248D07
8.
D04 04
Turn the crankshaft to TDC. Land the telescopic pipe on the guide shoe.
M90402 0248D06
9.
D13 01
M90402 0248M09
Page 8 (9)
Crosshead
Mounting
10. For tightening the bolt in the corner behind the telescopic pipe, use the offset tool along with the torque wrench. Mount the cooling oil outlet pipe. 11. Mount the lubricating oil pipes on the main bearing caps. 12. Mount the piston. See Procedure 902-1.4. 13. Remove all tools from the engine. Note! Always search the crankcase to ensure that there are no tools, shackles or rags left behind.
M90402 0248M10
904-2.4
10.
D04 08
D04 15 D04 19
11.
M90402 0248M12
M90402 0248M11
12.
Page 9 (9)
Reciprocating Parts
Data
104-3
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
D04-25 D04-26 D04-28 D04-29 D04-30 D04-34 D04-35 D04-36 D04-41
PF+PA, N max. PF+PA, O max. E+G, H+F, N max. E+G, H+F, N min. E+G, H+F, O max. J+X, L+Y, K+X, M+Y, N max. J+X, L+Y, K+X, M+Y, N min. J+X, L+Y, K+X, M+Y, O max. ZF/ZA O min. N: New and cold engine with staybolts tightened (less than 100 running hours). O: Engine in service.
0.6 1.1 0.55 0.2 0.85 0.9 0.5 1.1 5
mm mm mm mm mm mm mm mm mm
Page 1 (2)
104-3
Reciprocating Parts
Data
Plate P91366 Item No. 58 Feeler gauge Description
Page 2 (2)
Reciprocating Parts
Checking
Reciprocating Parts S50ME-C 0217 Checking 904-3.1
904-3.1
In order to achieve uniform measuring conditions on board, the ships trim must be as close as possible to 0. 1. Mount a transparent plastic tube along the length of the bedplate. Bend each end approx. 250 mm up along the framebox side. See T. Fill the tube with water (possibly coloured) until the water level is approx. 100 mm from the end of the tube. Trim the ship until the difference between the water level S fore and aft is less than 1.5 mm per 1000 mm. Measurements are to be taken with a ruler. 2. Turn the engine in ASTERN direction to 45 after BDC (the guide shoe must rest against the crosshead guide). 3. Mount the tool between the guide shoe/ guide strip. For this purpose, use the third threaded hole from bottom of guide shoe (this hole is normally used for fastening the guide strip to the shoe). By means of the two screws in the middle of the tool, pull the guide shoes until they rest lightly against the end face of crosshead. Note! When the tool is mounted, it is not possible to turn past TDC and BDC.
1.
MA904-5.0 72 01
3.
When referring to this page, please quote Procedure M90403 Edition 0217 0$1 % : 'LHVHO $6
GN904-3.1 203 03
Page 1 (3)
904-3.1
Reciprocating Parts
Checking
4.
FORE AFT
4. Check the centering of the piston in the cylinder liner by measuring the clearance (from the scavenge air space with a long feeler gauge) between the piston skirt and the cylinder liner in the Fore and Aft positions (PF-PA).
D04-25 D04-26
D04-25
Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. 5. Measure the clearance between the guide strips and crosshead guides ( J, K, L and M ). The clearance J, K, L and M is adjusted by the insertion of shims so that it is symmetrical in relation to the clearance between the piston skirt and the cylinder liner. Parallelism between the guide strip and guide is to be kept within a tolerance of 0.2 mm per 1000 mm.
PA PF
GN904-3.1 213 04
ZF ZA
5.
D04-53 D04-54 D04-55
FUEL PUMP
Page 2 (3)
GN904-3.1 203 05
Reciprocating Parts
Checking
6.
Exhaust side Fuel pump
904-3.1
6. Check the clearance between guide shoe and crosshead guide ( E, F, G and H) with a feeler gauge. 7. It is recommended that the measured results are noted down so that possible later changes can be ascertained.
D04-28 D04-29 D04-30

GN904-3.1 203 06
7.
GN904-3.1 203 07
Page 3 (3)
Crankpin Bearing
Data
X X X X X X X X
104-4
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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil
Stop lubricating oil supply Lock the turbocharger rotors
Data
D04-43 D04-44 D04-46 D04-47 D04-48
Crankpin bearing clearance, max. Crankpin bearing clearance, min. Crankpin bearing, upper shell Crankpin bearing, lower shell Crankpin bearing cap + shell + bearing studs
0.7 0.45 35 28 260
mm mm kg kg kg
Page 1 (2)
104-4
Crankpin Bearing
Data
Plate P90451 P90451 P90451 P90461 P90462 P91351 P91351 P91351 P91351 P91356 P91366 58 59 10 46 58 105 Item No. 59 96 106 Description Lifting attachment - connecting rod Bracket for support, Cross Head Bracket for support, Cross Head Connecting Rod - Hydraulic Tools Lifting tool for crankshaft shell Hydraulic pump, pneumatic operated Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete Lifting Tools, Etc. Feeler gauge
Page 2 (2)
Crankpin Bearing
Checking
904-4.1
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. For the bottom clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume I, OPERATION. 1. Open the crankcase door at the relevant cylinder.
2.
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. 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 crankpin bearing must be disassembled for inspection. See Procedure 904-4.2. 5. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection. An average wear rate of 0.01 mm per 10,000 hours is regarded as normal. 6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in the instruction book, Volume I, OPERATION.
M90404 0231C02
2. Turn the crank concerned to BDC.
3.
D04 43 D04 44
M90404 0231C05
M90404 0231C03
5.
Page 1 (8)
904-4.2
Crankpin Bearing
Dismantling
1. Turn the crank to BDC. 2. Suspend two tackles from the lifting brackets, in the athwartship direction. 3. Turn the crank to TDC. Mount eye bolts in each side of the crankpin bearing cap and, using shackles and wire ropes, hook on the tackles and haul tight. Loosen the crankpin bearing stud nuts, using the hydraulic jacks. For operation of the hydraulic jacks, see Procedure 913-1. Remove the hydraulic jacks and the nuts.
2.
M90404 0231D02
3. 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.
D13 02
Inspect the bearing shell. For evaluation of bearings, see Volume I, Chapter 708.
M90404 0231D03
4.
D04 48
Page 2 (8)
M90404 0231D04
When referring to this page, please quote M90404 Edition 0231 MAN B&W Diesel A/S
Crankpin Bearing
Dismantling
5. If the bearing shell needs to be replaced, remove the whole bearing cap from the crankcase. Hook the tackle on to an eye bolt on one side of the bearing cap. Mount the wire guide in the top of the crankcase door opening. Using the tackle from the frame box inside wall, together with a tackle suspended from the platform bracket, lift the bearing cap out of the crankcase. 6. Place the bearing cap on one side on a couple of planks. Dismount the bearing shell lock screws and replace the bearing shell by a new one. Note! Normally bearing shells are replaced in pairs. If only one of the shells needs replacement, MAN B&W Diesel should be contacted for advice beforehand. 7. Turn to TDC. Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports.
904-4.2
5.
D04 48
M90404 0231D05
6.
D04 47
M90404 0231D07
M90404 0231D06
7.
Page 3 (8)
904-4.2
Crankpin Bearing
Dismantling
8. Mount a lifting attachment for securing the connecting rod at the lower end, on one side. Hook on the tackle to a beam under the gallery platform and haul tight. 9. Carefully turn the crankshaft downwards, while following with the tackle, making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to separate.
8.
M90404 0231D08
Continue turning the crankshaft until the bearing surface can be freely inspected. Inspect the bearing shell surface and the crankpin journal. 10. If it is necessary to replace the bearing shell, proceed as follows: Turn the crankshaft to HORIZONTAL. Release the tackle so that the connecting rod is hanging freely.
9.
Page 4 (8)
M90404 0231D10
M90404 0231D09
10.
When referring to this page, please quote M90404 Edition 0231 MAN B&W Diesel A/S
Crankpin Bearing
Dismantling
11. Mount an eye bolt in the bottom of each guide shoe. Suspend two tackles from the eye bolts. 12. Place the lifting tool for the crankpin upper shell on the crank webs and hook the tackles on to the lifting tool. Mount the tool on the bearing shell in the connecting rod, using the tackles, and haul tight.
M90404 0231D11
904-4.2
11.
13. Dismount the bearing shell lock screws. Lower the lifting tool with the bearing shell, using the tackles.
12.
M90404 0231D12
13.
D04 46
M90404 0231D13
Page 5 (8)
904-4.4
Crankpin Bearing
Mounting
1. Bearing shells of three mm undersize are available as spares in case of journal rectification. Please contact MAN B&W Diesel for advice. Coat the bearing shell surfaces and the journal with clean oil. The excess height X is to ensure the correct tightening-down of the bearing shell, and must not be eliminated. 2. Lift the upper bearing shell for the crankpin concerned into the crankcase. Carefully lift the bearing shell into position in the connecting rod, and mount the lock screws. 3. Remove the lifting tool, the tackles and the eye bolts from the guide shoes.
1.
M90404 0231M01
2.
D04 46
Page 6 (8)
M90404 0231M03
M90404 0231M02
3.
Crankpin Bearing
Mounting
4. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod, and haul tight. Carefully turn the crankshaft upwards, while following up with the tackle, making sure that the upper part of t he bearing enters the recess in the crankshaft when the parts turn together. Remove the tackle and the lifting attachment from the connecting rod. 5. Turn the crosshead to TDC. Remove the guide shoe support brackets from the crosshead guides.
M90404 0231M04
904-4.4
4.
5.
M90404 0231M05
Page 7 (8)
904-4.4
Crankpin Bearing
Mounting
6. Suspend the tackles from the lifting brackets in the top of the frame box. Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan.
6.
D04 48
7. Hook the tackles on to the wire ropes and lift the bearing cap into position against the connecting rod. Caution!
M90404 0231M06
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. Mount the nuts and, by means of spacer rings and hydraulic jacks, tighten the crankpin bearing cap. See Data. For operation of hydraulic jacks, see Section 913. Remove the tackles from the top of the frame box. Check the bearing clearance. See Procedure 904-4.1.
7.
M90404 0231M07
D13 01
Page 8 (8)
Connecting Rod
Data
X X X X X X X X
104-5
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil
Stop lubricating oil supply Lock the turbocharger rotors
Data
D04-48 D04-50 D13-01 D13-02
Crankpin bearing cap + shell + bearing studs Connecting rod, without bearing caps Hydraulic pressure, mounting Hydraulic pressure, dismantling
260 1850 1500 1400 - 1650
kg kg bar bar
Page 1 (2)
104-5
Connecting Rod
Data
Plate P90451 P90451 P90451 P90451 P90461 P91351 P91351 P91351 P91351 P91356 10 46 60 105 Item No. 47 59 96 106 Wire guide Lifting attachment - connecting rod Bracket for support, Cross Head Bracket for support, Cross Head Connecting Rod - Hydraulic Tools Hydraulic pump, pneumatic operated Hose with unions (1500 mm), complete Hose with unions (5000 mm), complete 3-way distributor block, complete Lifting Tools, etc. Description
Page 2 (2)
Connecting Rod
Dismantling
Connecting Rod S46MC-C 0228 Dismantling 904-5.2
904-5.2
1. Turn the crank to BDC. Dismount the crosshead bearing stud nuts. See Procedure 904-1.2. 2. Mount two shackles in the top of the crankcase in the lifting brackets, in the athwartship direction, and suspend two tackles. 3. Turn the crank to TDC. Dismount the crankpin bearing cap, and remove the bearing cap from the engine. See Procedure 904-4.2.
1.
D13-02
HN904-5.2 217 01
2.
HN904-5.2 217 02
3.
D13-02
D04-48
GN904-5.2 225 03
Page 1 (7)
904-5.2
Connecting Rod
Dismantling
4.
4. Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down towards the camshaft side, until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. 5. Mount the lifting attachments for securing the connecting rod on the head of the connecting rod. Fasten tackles to lifting brackets A and B on the frame box wall, and attach the tackle hooks to the mentioned lifting attachments on the connecting rod head.
HN904-5.2 217 04
5.
D04-50
A B
Haul the tackles tight. Also mount a lifting attachment on the lower end of the connecting rod, on the exhaust side. 6. Turn the crankthrow carefully towards BDC while following with the tackles, thus continuously supporting the connecting rod. The crosshead now rests on the four supports. Turn the crankthrow to 90 before BDC.
GN904-5.2 225 05
6.
Page 2 (7)
GN904-5.2 225 06
Connecting Rod
Dismantling
7.
904-5.2
7. Shift tackle B from the lifting attachment on one side of the connecting rod to the lifting attachment on the other side. Dismount the lifting attachment on the camshaft side of the connecting rod. Attach a tackle to lifting bracket C on the frame box wall and connect the tackle hook to the lifting attachment on the lower end of the connecting rod. Mount the wire guide on the door frame. Turn the crankthrow towards TDC while following with the tackles, thus continuously supporting and guiding the connecting rod towards the doorway. 8. Attach a tackle to the gallery-mounted lifting bracket E, and hook on to the lifting attachment on the connecting rod. Shift tackle A from the lifting attachment on the head of the connecting rod to the lifting attachment at the bottom of the connecting rod. Turn the crank carefully upwards while following with tackles A , B, C and E, guiding the head of the connecting rod out of the doorway. Shift the tackles from one lifting attachment to the other as necessary. 9. Mount a strap around the connecting rod and suspend the connecting rod from the engine room crane. Shift tackle B from the lifting attachment on the head of the connecting rod to the lifting attachment at the bottom of the connecting rod. Remove tackles A and E. Continue turning upwards till about 30 after TDC while following with the tackles and the engine room crane.
GN904-5.2 225 09 GN904-5.2 225 07
AA
8.
GN904-5.2 225 08
9.
A A
Page 3 (7)
904-5.2
Connecting Rod
Dismantling
10.
10. Shift the tackle from lifting bracket C to A . Lift the connecting rod out of the engine, using the tackles and the engine room crane. Remove the tackles, and lift the connecting rod away by means of the engine room crane.
Page 4 (7)
GN904-5.2 225 10
Connecting Rod
Mounting
Mounting 904-5.4
904-5.4
1. Equip the connecting rod with the same lifting attachments as mentioned under dismantling. 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. 2. Carefully lift the connecting rod into the crankcase by alternate use of the engine room crane and the tackles attached to lifting brackets A and B. 3. When the end of the connecting rod rests on the crankpin journal, attach a tackle to bracket C and the lower end of the connecting rod. 4. Turn the crankthrow towards BDC, past TDC, while following with the tackles and the engine room crane. Attach tackle B to the upper end of the connecting rod.
2.
A
D04-50
C
GN904-5.2 225 10
3.
A B
Attach a tackle to bracket E and the upper end of the connecting rod. Haul tight and remove the strap around the connecting rod.
GN904-5.4 225 03
4.
A B
GN904-5.4 225 04
Page 5 (7)
904-5.4
Connecting Rod
Mounting
5.
B
5. Turn the crankthrow to 90 before BDC.

A E
Shift tackle A from the lower end to the top of the connecting rod. Remove the tackle at E. Shift tackle B from the lifting attachment on one side to the other side of the connecting rod. Remove the tackle at C and the wire guide on the door frame.
GN904-5.4 225 05
Remove the lifting attachment at the lower end of the connecting rod. 6. Turn the crankthrow towards TDC while following with the tackles. Caution! Take care that the studs do not damage the crosshead bearing shell. 7. When the crank is in TDC, mount the crankpin bearing cap. See Procedure 904-4.4.
6.
GN904-5.4 225 06
7.
D13-01
Page 6 (7)
GN904-5.4 225 07
Connecting Rod
Mounting
8.
904-5.4
8. Remove the four supports from the crosshead guides and the lifting attachments from the connecting rod. Turn the crosshead down far enough to facilitate the tightening of the nuts. 9. Tighten all four crosshead bearing cap nuts simultaneously. See Data.
GN904-5.4 225 08
9.
HN904-5.2 217 01
D13-01
Page 7 (7)
Connecting Rod and Crosshead Panel
Plate P90451-0149
MAN B&W Diesel A/S
Page 1 (2)

011 023 047 059 060 072 084 096 106 118 120 214
Connecting Rod and Crosshead Panel

Panel for tools Name plate Wire guide, main bearing Lifting attchment, connecting rod Lifting tool, crosshead Chain, suspension of piston Retaining tool, telescope pipe Bracket, support of crosshead Bracket, support of crosshead Rubber cover for crosshead Rubber cover for crosshead Offsett tool, torque spanner
Page 2 (2)
MAN B&W Diesel A/S
Connecting Rod - Hydraulic Tools
Plate P90461-0068
MAN B&W Diesel A/S
Page 1 (2)

028 030 041 053 065 089 100 207
Connecting Rod - Hydraulic Tools

Item No.
Item Description
Hydraulic jack Support Tommy bar O-ring with back-up ring O-ring with back-up ring Spanner Stud setter Hydraulic toolset, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Connecting Rod - Tools
Plate P90462-0034
MAN B&W Diesel A/S
Page 1 (2)

011
Connecting Rod - Tools

Lifting tool for crankpin shell
Page 2 (2)
MAN B&W Diesel A/S
Crosshead - Hydraulic Tools
Plate P90464-0005
MAN B&W Diesel A/S
Page 1 (2)

024 036 048 050 061 085 107 203
Crosshead - Hydraulic Tools

Jack-hydrualic, complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Key, hexagon socket screw Stud setter Hydraulic toolset, complete
Page 2 (2)
MAN B&W Diesel A/S
Crosshead - Tools
Plate P90465-0001
MAN B&W Diesel A/S
Page 1 (2)

018
Crosshead - Tools
Guide shoe extractor
Page 2 (2)
MAN B&W Diesel A/S
905 - Crankshaft, Thrust Bearing and Turning Gear

105-01 905-01 105-02 905-02 105-03 905-03 105-04 905-04 105-05 905-05 90551 90561 90562 90563 90564 90564 90570 90572 0006 0208 0052 0245 0044 0224 0017 0216 0037 0224 0237 0064 0133 0024 0018 0020 0001 0005 Crankshaft Deflection, Data Crankshaft Deflection 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 Segment Stopper - Hydraulic Tools Crankshaft - Measuring Tools Crankshaft - Measuring Tools Thrust Shaft - Tools Main Bearing - Measuring Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Bearing
Data SAFETY PRECAUTIONS
Special Edition D10501 S42MC 105-1 Data 0006 Main Bearing
105-1
X X X X
Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil
Shut off lubricating oil Lock turbocharger rotors
Data
Page 1 (2)
105-1
Main Bearing
Data
Plate Item No. Description
P90572P91366-
048
Main Bearing - Measuring Tools Autolog, measuring tool for crankshaft
Page 2 (2)
Main Bearing
Checking
0208 Bearing Main Checking 905-1.1 S80MC-C
905-1.1
General The condition of the main bearings can be checked by: Deflection readings Visual checking Edge checking and Measuring of top clearance. Crankshaft deflection readings Crankshaft deflection readings should be taken while the ship is afloat (i.e. not while in dry dock). As the alignment is influenced by the engine temperature as well as the loading conditions, deflection measurements should, for comparison purposes, always be made under nearly the same temperature and load conditions. 1. Place a dial gauge axially in the crank throw opposite the crankpin, as illustrated on the sketch. The correct mounting position is marked with punch marks on the crank 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: B1 (near bottom) C (camshaft side) T (top) E (exhaust side) B2 (near bottom) 1/2 (B2+B1) = B
KN905-1.1 208 02 HM905-2.0 46 01
1.
2.
Positive (+)
Negative ( )
3.
XZ905-1.1 204 03
Page 1 (5)
905-1.1
Main Bearing
Checking
4.
4. When taking deflection readings for the three aftmost cylinders, the turning gear should, at each stoppage, be turned a little backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise, this pressure may falsify the readings. For evaluation of the crankshaft deflection readings, see Volume I, OPERATION, Chapter 708. If the crankshaft deflection (alignment 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 deflection table.
HM905-2.0 46 01
5.
The condition of the bearing can be checked as follows: 5. Visually look for bearing metal fragments in the oil pan, and check the filters for metal fragments. Such fragments can be from crosshead, guide shoe or crankpin bearings. If fragments are found, the damaged bearing can be found by edge checking with a feeler. General
KN905-1.1 208 05
Bearing damage usually propagates rather quickly towards the edge of the bearing where, eventually, it causes chips to be broken off, which means that loose pieces of white metal can fall down into the crankcase beneath the bearing support. Large, thick pieces will normally be found during a crankcase inspection, and small, thin pieces can enter the filter. A check of the bearing edges together with inspection of the crankcase and the filter normally provides a good indication of the bearing condition.
Page 2 (5)
Main Bearing
Checking
6.
905-1.1
Checking the bearing edges 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 flashlight. The No. 1 and the two aftmost main bearings are more difficult 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 7. 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. Note! The above dimensions of the wirefeeler are guideline values and may depend on the engine type as well as individual, personal designs.
Hole in the edge

KN905-1.1 208 06
7.
1
<1.2 mm >0.7 mm
7-10 mm
60-70 2-3 mm 500-1000
Wire feeler
KN905-17.02
Page 3 (5)
905-1.1
Main Bearing
Checking
8.
8. If there is too large a difference in the crankshaft deflection readings (autolog) check the clearance in the individual bearings. Bearing clearance checks should also be carried out during time-based overhauls and surveys. If there is a suspicion of a damaged bearing, it is recommended to edge check the bearing, without opening up. 9. Before measuring, check that the feeler blades are in good condition. The feeler is inserted along the crank throw. When the feeler hits the journal, it is horizontally pushed against the clearance. Now the feeler blade is pushed max. 20 mm into the gap.
KN905-1.1 208 08
9.
KN905-1.1 208 09
20
10. The clearance is measured at both the fore and the aft part of the bearing. Note!
10. The bearing clearances for a new bearing stated in Data (see Data 105-2) are for guidance purposes only.
Page 4 (5)
KN905-1.1 208 10
Main Bearing
Checking
905-1.1
11. 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 0.10 mm. If it does, see Volume I, Operation, Chapter 708. For evaluation of the bearing, see Volume I, Operation, Chapter 708. If the bearing needs to be diassembled for inspection, see procedure 905-2.2.
HN905-2.1 227 03
Page 5 (5)
Main Bearing
Special Edition D10502 S60MC-C 105-2 Data 0052 Main Bearing
105-2
X X X X
Data
D05-01 D05-02 D05-03 D05-04 D05-05 D13-01 D13-02
Main bearing, top clearance max. Main bearing, top clearance min. Main bearing cap Main bearing shell, upper Main bearing shell, lower Hydraulic pressure, mounting Hydraulic pressure, dismantling
0,75 0,45 507 35 36 1500 1400-1650
mm mm kg kg kg bar bar
Page 1 (2)
105-2
Main Bearing
Data
P90551 P90551 P90551 P90551 P90551 P90551 P90561 P90562 P90572 P91351 P91351 P91351 P91351 P91351 P91356
40 76 88 90 184 220
10 22 117 46 58
Pulley for wire for main bearing Lifting tool - main bearing cap Dismantling tool, main bearing shell Mounting tool for bearing shell Lifting tool for main bearing shell Wire guide Main Bearing - Hydraulic Tools Lifting tool for crankshaft Main Bearing - Measuring Tools Hydraulic pump, pneumatically operated Hydraulic pump, hand operated 5-way distributor block, complete Hose with unions (1500 mm), complete Hose with unions (3000 mm), complete Lifting Tools, Etc.
Page 2 (2)
Main Bearing
Dismantling
Main Bearing S60MC-C 0245 Dismantling 905-2.2
905-2.2
Positioning the crankshaft 1. Dismantling of main bearing. The bearings are divided into two categories: The main bearings The aftmost main bearing often referred to as Journal bearing (See Procedure 905-4). 2. Before any dismantling, check and write down the main bearing top clearances and crankshaft deflection readings for the cylinder unit concerned. 3. Turn the crank throw to the position shown on the sketch and in such a way that the top of the studs is flush with the crank throw. Note! 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.
1.
Aftmost main bearing (= Journal bearing)
KN905-2.2 238 01
Main bearings Thrust bearing
2.
KN905-2.2 238 02
3.
EXH-SIDE MAN-SIDE
KN905-2.2 238 03
Page 1 (16)
905-2.2
Main Bearing
Dismantling
4.
Oil pipes 4. Disconnect the lubricating oil pipe from the main pipe. Note! On some engines, the oil pipes for the Axial Vibration Damper (AVD) have to be removed together with the oil pipe on main bearing No. 1.
KN905-2.2 238 04
Note! Some engines have temperature sensors fitted to the main, crosshead, and crankpin bearings. These sensors must be carefully handled to avoid damaging the equipment.
Page 2 (16)
Main Bearing
Dismantling
1.
905-2.2
Mounting of tools and tackles 1. Mount pulley E on the web plate above the bearing cap. 2. Pulley E is used to lift the main bearing cap vertically and free of the bearing studs.
HN905-2.2 245 02
2.
HN905-2.2 227 03
Page 3 (16)
905-2.2
Main Bearing
Dismantling
3.
3. Mount pulley F in the bottom of the guide shoe. On some engines the pulley is mounted in the bottom of the guide screw, and on some engines it is necessary to remove the guide screw before mounting pulley F. F 4. Pulley F is used in combination with pulley E , to lift the bearing cap free of the web plate, the guides and the crankthrow. 5. Mount an eye bolt on the opposite web plate. The eye bolt is used in connection with a pull lift, to keep the main bearing cap clear of the guides when it is lifted out of the engine.
HN905-2.2 227 04
4.
HN905-2.2 227 05
5.
Page 4 (16)
HN905-2.2 227 06
Main Bearing
Dismantling
6.
905-2.2
6. Mount tackles in the following positions: A. Suspended from a wire strap below the crane beam. Adjust the suspension (fore-aft position) to ensure that chains and wire ropes go free of guides and crosshead. B. In the lifting bracket in the top of the crankcase, camshaft side. C. In the lifting bracket below the doorway. D. In the eye bolt on the web plate opposite the pulleys. Mount the wire guide in the top of the doorway. 7. Assemble the main bearing hydraulic jacks on the bearing studs. Connect the hydraulic pump. Loosen the nuts. Remove the hydraulic main bearing tools from the engine. Unscrew and remove the nuts from the main bearing studs. For operation of the hydraulic tools, see Procedure 913-1. 8. Mount the main bearing lifting tool on the main bearing cap, and place the wire rope as shown.
GN913-1.0 203 22
D
KN905-2.2 238 06
7.
D13-02
8.
HN905-2.2 227 09
Page 5 (16)
905-2.2
Main Bearing
Dismantling
9.
9. Attach tackle A to the wire rope and carefully lift the main bearing cap clear of the studs. 10. The lifting tool has one free wire rope. Place this wire rope around the wheel of pulley F mounted in the guide shoe. Hook the wire rope on to the chain of tackle C.
D05-03
11. Tighten tackle C and release tackle A, until the main bearing cap is suspended vertically below pulley F.
HN905-2.2 22710
10.
F C
HN905-2.2 227 11
11. F C A
D05-03
Page 6 (16)
HN905-2.2 227 12
Main Bearing
Dismantling
12.
905-2.2
12. Release tackle A from the wire rope of the lifting tool. Remove the wire rope of the lifting tool from pulley E mounted on the web plate. Mount the short wire rope with two shackles on the main bearing cap lifting tool. 13. Hook the chain of tackle D on to the short wire rope mounted on the main bearing lifting tool.
HN905-2.2 227 13
F C
Tighten tackle D and release tackle C at the same time, to get the bearing cap clear of the guides. 14. Attach the hook from tackle A around the wire rope of tackle B to keep the wire rope free from the crosshead and guide plates. At the same time, release tackle C until the main bearing cap is suspended vertically below tackle B.
13. F C D
HN905-2.2 227 14
14.
KN905-2.2 238 20
Page 7 (16)
905-2.2
Main Bearing
Dismantling
15.
B A
15. When the main bearing cap is hanging vertically below tackle B, remove tackle C and the wire rope around pulley F. Remove the hook of tackle A from the wire rope of tackle B. Attach tackle A to the short wire rope on the main bearing cap lifting tool. Note!
D
KN905-2.2 238 21
D05-03
C
Make sure that the wire rope of the main bearing lifting tool does not scrape against the edges of the guide shoe. 16. Mount the free wire rope in tackle A.
16.
B A
Now lift the bearing cap out of the engine and place it on a couple of wooden planks. Removal of upper bearing shell 17. Mount the bearing shell lifting tool on the upper main bearing shell, and remove the shell, using pulley F. Lift the upper bearing shell out of the engine in the same way as the bearing cap.
D
KN905-2.2 238 22
17.
A D
KN905-2.2 238 23
D05-04
Page 8 (16)
Main Bearing
Dismantling
18.
905-2.2
18. If the crankshaft is turned with the bearing cap dismounted, use the two stops to prevent the lower shell from being rolled out. 19. Place the crosspiece in the bedplate with the ends resting on the cross girders, and position the hydraulic jacks beneath the web plate as shown. Tighten the screws against the crank webs and compress the jacks. Connect the hydraulic jacks to the highpressure pump, and raise the pressure until the crankshaft has been lifted 0.2-0.5 mm, but max. the clearance in the two adjacent bearings. Note down the pressure for later reference. 20. Check that there is min. 0.1 mm clearance between journal and bearing shell, or between bearing shell and main bearing support, on both sides of the journal. If the clearance is less than 0.1 mm, move the crosspiece sideways until clearance is obtained. Normally, adjustment needs to be 50-150 mm to the exhaust side (the side where the clearance is missing). Note! The feeler blade must be inserted minimum 60 mm into the gap to pass the bore relief in the bearing shell.
KN905-2.2 238 27
KN905-2.2 238 24
19.
20.
Min. 0,1 mm
Note! The lower shell must be lifted out to the side with the most clearance, which is normally the camshaft side.
EXH
CAM
KN905-2.2 238 28
Min. 60 mm
Page 9 (16)
905-2.2
Main Bearing
Dismantling
21.
21. If repositioning of the crosspiece does not ensure a vertical lift, place a 5-tonne jack between the side wall and the crank throw, to correct the journal position in this way. If it is available, note down the pressure applied to the jack. This data is used to ensure that the crankshaft is in the same position when the new bearing is installed. 22. Dismount the locking screws.
KN905-2.2 238 25
Place the dismantling tool on top of the lower bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell. Note! It is recommended that the crankshaft lifting tool is only removed if it is urgently necessary and then only after the main bearing shell has been reinstalled.
22.
Page 10 (16)
KN905-2.2 238 26
Main Bearing
Dismantling
23.
905-2.2
23. Pull the lower shell around and up until it lies over the main bearing journal. Never use a tackle larger than 0.5 tonne. 24. Take the lower shell out of the engine in the same way as the upper shell, i.e. using the lifting tool. Note! While pulling out the shell, it is recommended to hold a foot or hand on the wire rope, to tighten it up and to observe whether the shell is sticking.
JM905-2.2 236 27
24.
D05-05
HN905-2.2 227 19
Page 11 (16)
905-2.3
Main Bearing
Overhaul
Overhaul 905-2.3
1 + 2.
1. Clean and inspect the bearing shells. It is recommended that the main bearing shells be replaced in pairs. If it is nevertheless desired to replace only one shell, this requires a careful evaluation of the condition of the shell that is to be reinstalled. See Instruction book, Volume I, Chapter 708. For advice on replacing individual bearing shells, it is recommended to contact MAN B&W Diesel A/S or the engine builder. 2. Before remounting:
KN905-2.2 238 25
Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice. Make sure that all parts are clean, use non-fluffy cloth to clean between journal and main bearing support. Lubricate the bearing journal, the main bearing support and the back of the shell, with main engine lubricating oil.
Page 12 (16)
Main Bearing
Mounting
Mounting 905-2.4
905-2.4
1. Clean and lubricate the journal, the lower bearing shell and the bearing support with clean oil. Place the dismantling tool between the bearing journal and the bearing support. Place the guide tool for the lower bearing shell on the main bearing support. 2. Using the bearing shell lifting tool, the pulleys and tackles, lift the lower bearing shell into the crankcase and land it on the crankshaft journal. Remove the lifting tool from the bearing shell. Check that the hydraulic pressure to the crosspiece jacks corresponds to the pressure used when the lower shell was removed, and that the crankshaft is still lifted max. 0.2 mm. 3. Using the dismantling tool, lower the bearing shell down between journal and support. Remove the dismantling tool and push the shell entirely down with a piece of wood, for instance a hammer handle. To ensure that the shell is correctly mounted, check that the distance from the main bearing support to the shell is equal in both sides.
1.
HN905-2.4 227 01
2.
D05-05
HN905-2.2 227 19
3.
HN905-2.4 227 03
Page 13 (16)
905-2.4
Main Bearing
Mounting
4.
4. Remove the guide tool when the lower bearing shell has been mounted. Mount the locking screws in the bearing support. Check with a feeler gauge that there is clearance around the head of the locking screws, to ensure correct centering of the bearing shell. 5. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below the crankshaft.
XZS905-13 07
5.
D05-04
Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fluffy piece of cloth. 6. Land the upper bearing shell on the main journal in the same way as the lower bearing shell.
XZS905-13 09
Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. 7. If necessary, place the special tool between the studs and press the shell into place. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces. 7. Mount the lifting tool on the bearing cap. Using the lifting tool and the tackles lift the bearing cap into the crankcase in the reverse order to dismantling. See Procedure 905-2.2. 7. 8. Using the pulleys mounted inside the crankcase, move the bearing cap into position vertically above the main bearing upper shell in the reverse order to dismantling. See Procedure 905-2.2.
D05-03
Page 14 (16)
KN905-2.2 238 20
HN905-2.2 227 18
Main Bearing
Mounting
9.
905-2.4
9. Land the bearing cap carefully on the upper bearing shell, using the bearing cap lifting tool . Check that the spring pin in the support enters the hole in the bearing cap. Take care not to displace the upper bearing shell. 10. Remove the lifting tool from the bearing cap. Screw the nuts on to the main bearing studs. Using a tommy bar, tighten in small alternate steps the nuts on both sides of the bearing cap. 11. Assemble the main bearing hydraulic jacks on the bearing studs.
KN905-2.4 238 09
10.
KN905-2.4 238 10
10.
GN9913-1.0 203 22
Page 15 (16)
905-2.4
Main Bearing
Mounting
12.
12. Connect the hydraulic jacks to the high pressure pump by means of the distributor block and high-pressure hoses.
D13-01
Bleed the hydraulic system and raise the pressure as indicated in Data. Using the hydraulic jacks, fully tighten the nuts on both sides of the bearing cap. For tightening pressure, see Data. For operation of the hydraulic tools, see Procedure 913-1. 13. Remove the bearing cap lifting tool. Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal. 14. Remove all the tools from the engine.
HN905-2.4 227 11
13.
Note!
KN 905-1.1 208 09
20
D05-01 D05-02
Search the crankcase to ensure that there are no tools, shackles or rags left behind.
14.
KN905-2.4 238 14
Page 16 (16)
Thrust Bearing
Special Edition D10503 S60MC-C 105-3 Data 0044 Thrust Bearing
105-3
X X X X
Data
D05-06 D05-07 D13-01 D13-02
Thrust bearing segment Segment stopper Hydraulic pressure, mounting Hydraulic pressure, dismantling
66 47 1500 1400-1650
kg kg bar bar
Page 1 (2)
105-3
Thrust Bearing
Data
P90551 P90563 P91351 P91351 P91351 P91351 P91356
100 Tool for turning out segments Segment Stopper - Hydraulic Tools 10 Hydraulic pump, pneumatically operated 34 Hose with unions (1000 mm), complete 58 Hose with unions (3000 mm), complete 105 3-way distributor block, complete Lifting Tools, etc.
Page 2 (2)
Thrust Bearing
Checking
Thrust Bearing S50MC-C 0224 Checking 905-3.1
905-3.1
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. In service it is only necessary to measure the wear of the thrust bearing pads, and to inspect for white metal below the thrust bearing. 1. To measure the wear in the thrust bearing, it is necessary to dismount the foremost segment stopper. For dismantling the segment stopper, see Procedure 905-3.2. A wear groove of 1 mm is positioned in the uppermost thrust segment. (The segment with thermometers). 2. To measure the wear, the thrust segment has to be pressed against the thrust cam, to eliminate any gap, i.e. by using a suitable crowbar on the back of the segment. If a feeler gauge of 0.1 mm is not able to enter the groove (the wear is more than 0,9 mm), the thrust bearing must be overhauled. 3. Note down the wear for later reference.
GN905-3.1 224 01
1.
2.
GN905-3.1 224 02
3.
KN905-2.2 238 02
Page 1 (5)
905-3.2
Thrust Bearing
Dismantling
Dismantling 905-3.2
1.
1. Remove the lub. oil pipe from the bearing, the protective shield, and the lub. oil pipe for the thrust segments. 2. Loosen and remove the nuts from the segment stoppers. For operation of the hydraulic jacks, see Procedure 913-1. Remove the segment stoppers above the thrust segments (AHEAD or ASTERN) that are to be taken out, and lift the stoppers out of the chain casing.
GN905-3.2 224 01
2.
D05-07
D13-02
GN905-3.2 224 02
Page 2 (5)
Thrust Bearing
Dismantling
3.
905-3.2
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. Mount the tool for turning out the segments on the protective edge on the chain wheel. 4. Turn up the segments, one at a time, by turning the engine, and remove the segment from the chain casing. Inspect the segment and remount it before turning up the next segment. See Procedure 905-3.4.
Note! Never remove more than one segment at a time.

GN905-3.2 224 03
4.
D05-06
GN905-3.2 224 04
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.
D13-01
Mount the tool for turning out segments on the chainwheel. Land the segment on the journal and remove the eye bolt from the segment. Carefully slide the segment on to the segment tool. Turn the engine to dismantle the next segment. See Procedure 905-3.2. 2. After the last segment has been mounted, turn the segment tool up and dismount it.
GN905-3.4 224 01
2.
GN905-3.4 224 02
Page 4 (5)
Thrust Bearing
Mounting
5.
905-3.4
3. Mount the segment stopper. Mount the hydraulic jacks and tighten the nuts on the stopper. For operating hydraulic jacks, see Procedure 913-1. 4. Mount the lub. oil pipe for the thrust segments, the protective shield and the lub. oil pipe on the bearing.
GN905-3.2 224 01
Page 5 (5)
Journal Bearing
Special Edition D10504 L60MC-C 105-4 Data 0017 Journal Bearing
105-4
X X X X
Data
D05-11 D05-12 D05-13 D05-14 D05-15 D05-16 D13-01 D13-02
Min. bearing clearance Max. bearing clearance Journal bearing cap Upper bearing shell Lower bearing shell End cover Hydraulic pressure, mounting Hydraulic pressure, dismantling
0.75 0.45 507 35 36 225 1500 1400-1650
mm mm kg kg kg kg bar bar
Page 1 (2)
105-4
Journal Bearing
Data
P90551 P90551 P90551 P90551 P90551 P90561 P90562 P90572 P91351 P91351 P91351 P91351 P91366
88 90 111 172 184
10 34 58 105 61
Dismantling tool, main bearing shell Mounting tool for bearing shell Lifting attachment Mounting tool, thin bearing shell Lifting tool for main bearing shell Main bearing hydraulic tools Lifting tool for crankshaft Main bearing measuring tools Hydraulic pump, pneumatic operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete Slide caliper
Page 2 (2)
Journal Bearing
Checking
0216 Bearing Journal Checking 905-4.1 S46MC-C
905-4.1
1. Before any dismantling of the journal bearing, check the clearances as described in Procedure 905-2.1. 2. Write down the journal bearing clearances. 3. Also check the journal bearing by visually searching the area underneath the bearing support.
1.
KN905-2.2 238 01
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
Page 1 (8)
905-4.2
Journal Bearing
Dismantling
Dismantling 905-4.2
2.
1. Dismount the screws for the end cover. Mount a -ton tackle above the end cover. Remove the end cover. 2. Disconnect the lubricating oil pipe from the main pipe. Remove the protective shield for the thrust bearing. Turn the crank throw for the aftmost cylinder to TDC.
GN905-2.2 204 13
3. Mount the extension studs, the spacers, the hydraulic jacks and the nuts on the extension studs. Loosen the bearing stud nuts, using the hydraulic jacks 3. For operation of the hydraulic tools, see Procedure 913-1. 4. Remove the hydraulic main bearing tools from the engine Unscrew and remove the nuts from the bearing studs.
D13-02
GN905-2.2 204 02
4.
Page 2 (8)
KN905-2.2 238 07
Journal Bearing
Dismantling
5.
905-4.2
5. Remove the rectangular nut washers from the bearing cap. Mount the lifting attachment at the journal bearing cap, and lift the cap out of the engine by using the -ton tackle above the bearing. 6. Mount the lifting attachment on the upper shell, and lift the shell out of the engine. 7. Place the crosspiece under the turning wheel as shown. Mount a dial gauge to measure the lift of the crankshaft. 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 0.2-0.5 mm, but max. the clearance in the adjacent bearing.
D05-13
GN905-2.2 224 16
6.
D05-14
GN905-2.2 224 17
7.
GN905-2.2 224 19
Page 3 (8)
905-4.2
Journal Bearing
Dismantling
8.
8. Dismount the locking screws. Place the dismantling tool on top of the lower bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell. Pull the lower bearing shell round and upwards until it lies over the bearing journal. Never use a tackle larger than 0.5 ton. 9. Take the lower shell out of the engine in the same way as the upper shell, i.e. using the lifting tool.
KN905-2.2 238 26
9.
D05-15
Page 4 (8)
GN905-2.2 224 17
Journal Bearing
Overhaul
Overhaul 905-4.3
905-4.3
1 + 2.
Make sure that all parts are clean, use non-fluffy 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.
KN905-2.2 238 25
Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice.
Page 5 (8)
905-4.4
Journal Bearing
Mounting
Mounting 905-4.4
1.
1. Lubricate the journal, the lower bearing shell and the bearing support with clean oil.
D05-15
Using the bearing shell lifting tool, lift the lower bearing shell into the crankcase and land it on the crankshaft journal. 2. Position the guide tool for the lower bearing shell on the bearing support. Remove the lifting tool from the bearing shell. Lubricate the journal, the lower bearing shell and the bearing support with clean oil. Place the lower bearing shell on the journal and push it 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. Remove the guide tool when the lower bearing shell has been mounted. Mount the locking screws in the bearing support. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from under the crankshaft.
GN905-2.2 224 17
2.
MC905-3.0 118 19
Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fluffy piece of cloth. 3.
Page 6 (8)
XZS905-13 07
Journal Bearing
Mounting
4.
905-4.4
4. Land the upper bearing shell on the main journal in the same way as the lower bearing shell. Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. If necessary, place the special tool between the studs and press the shell into place. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces. 5. Mount the lifting tool on the bearing cap. Using the lifting tool and the tackles, lift the bearing cap into the crank casing in reverse order to dismantling. See Procedure 905-4, step 5. 6. Note! Be sure that the cap lands correctly and that the guide pin in the assembly surface enters the hole in the bearing cap.
KN905-2.4 238 09
D05-14
XZS905-13 09
6.
7. Mount the rectangular nut washers, the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts. See Data. For operation of the hydraulic tools, see Procedure 913-1.
7.
D13-01
MN913-1 208 11
Page 7 (8)
905-4.4
Journal Bearing
Mounting
8.
8.
D05-11 D05-12
Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal.
9. Remove all tools from the engine.

KN 905-1.1 208 09
20
Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind.
9.
10. Mount the lubricating oil pipe on the bearing cap, and mount the end cover.
KN905-2.4 238 14
10.
Page 8 (8)
KN905-2.4 238 15
Journal Bearing
Checking
0216 Bearing Journal Checking 905-4.1 S46MC-C
905-4.1
1. Before any dismantling of the journal bearing, check the clearances as described in Procedure 905-2.1. 2. Write down the journal bearing clearances. 3. Also check the journal bearing by visually searching the area underneath the bearing support.
1.
KN905-2.2 238 01
2.
KN905-2.2 238 02
3.
KN905-4.1 202 03
Page 1 (8)
905-4.2
Journal Bearing
Dismantling
Dismantling 905-4.2
2.
1. Dismount the screws for the end cover. Mount a -ton tackle above the end cover. Remove the end cover. 2. Disconnect the lubricating oil pipe from the main pipe. Remove the protective shield for the thrust bearing. Turn the crank throw for the aftmost cylinder to TDC.
GN905-2.2 204 13
3. Mount the extension studs, the spacers, the hydraulic jacks and the nuts on the extension studs. Loosen the bearing stud nuts, using the hydraulic jacks 3. For operation of the hydraulic tools, see Procedure 913-1. 4. Remove the hydraulic main bearing tools from the engine Unscrew and remove the nuts from the bearing studs.
D13-02
GN905-2.2 204 02
4.
Page 2 (8)
KN905-2.2 238 07
Journal Bearing
Dismantling
5.
905-4.2
5. Remove the rectangular nut washers from the bearing cap. Mount the lifting attachment at the journal bearing cap, and lift the cap out of the engine by using the -ton tackle above the bearing. 6. Mount the lifting attachment on the upper shell, and lift the shell out of the engine. 7. Place the crosspiece under the turning wheel as shown. Mount a dial gauge to measure the lift of the crankshaft. 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 0.2-0.5 mm, but max. the clearance in the adjacent bearing.
D05-13
GN905-2.2 224 16
6.
D05-14
GN905-2.2 224 17
7.
GN905-2.2 224 19
Page 3 (8)
905-4.2
Journal Bearing
Dismantling
8.
8. Dismount the locking screws. Place the dismantling tool on top of the lower bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell. Pull the lower bearing shell round and upwards until it lies over the bearing journal. Never use a tackle larger than 0.5 ton. 9. Take the lower shell out of the engine in the same way as the upper shell, i.e. using the lifting tool.
KN905-2.2 238 26
9.
D05-15
Page 4 (8)
GN905-2.2 224 17
Journal Bearing
Overhaul
Overhaul 905-4.3
905-4.3
1 + 2.
Make sure that all parts are clean, use non-fluffy 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.
KN905-2.2 238 25
Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice.
Page 5 (8)
905-4.4
Journal Bearing
Mounting
Mounting 905-4.4
1.
1. Lubricate the journal, the lower bearing shell and the bearing support with clean oil.
D05-15
Using the bearing shell lifting tool, lift the lower bearing shell into the crankcase and land it on the crankshaft journal. 2. Position the guide tool for the lower bearing shell on the bearing support. Remove the lifting tool from the bearing shell. Lubricate the journal, the lower bearing shell and the bearing support with clean oil. Place the lower bearing shell on the journal and push it 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. Remove the guide tool when the lower bearing shell has been mounted. Mount the locking screws in the bearing support. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from under the crankshaft.
GN905-2.2 224 17
2.
MC905-3.0 118 19
Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fluffy piece of cloth. 3.
Page 6 (8)
XZS905-13 07
Journal Bearing
Mounting
4.
905-4.4
4. Land the upper bearing shell on the main journal in the same way as the lower bearing shell. Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. If necessary, place the special tool between the studs and press the shell into place. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces. 5. Mount the lifting tool on the bearing cap. Using the lifting tool and the tackles, lift the bearing cap into the crank casing in reverse order to dismantling. See Procedure 905-4, step 5. 6. Note! Be sure that the cap lands correctly and that the guide pin in the assembly surface enters the hole in the bearing cap.
KN905-2.4 238 09
D05-14
XZS905-13 09
6.
7. Mount the rectangular nut washers, the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts. See Data. For operation of the hydraulic tools, see Procedure 913-1.
7.
D13-01
MN913-1 208 11
Page 7 (8)
905-4.4
Journal Bearing
Mounting
8.
8.
D05-11 D05-12
Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal.
9. Remove all tools from the engine.

KN 905-1.1 208 09
20
Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind.
9.
10. Mount the lubricating oil pipe on the bearing cap, and mount the end cover.
KN905-2.4 238 14
10.
Page 8 (8)
KN905-2.4 238 15
Axial Vibration Damper

Special Edition D10505 S60MC-C 105-5 Data 0037 Axial Vibration Damper
105-5
X X X X
Data
D05-18 D05-19 D05-22 D05-23 D05-24 D05-25 D13-01 D13-02
Inner studs, screwing-in torque Nuts on inner studs, tightening torque Outer studs, screwing-in torque Horizontal screws, tightening torque Horizontal screws, tightening torque/angle Damper housing, upper part Hydraulic pressure, mounting Hydraulic pressure, dismantling
100 460 100 950 100/40 600 1500 1400-1650
Nm Nm Nm Nm Nm/ kg Bar Bar
Page 1 (2)
105-5

Data
P90551 P90564 P90463 P91356P91359P91366-
196
61
Tightening template A.V.D. Crankshaft measuring tools Crosshead hydraulic tools Lifting tools, etc. Torque spanners Slide caliper
Page 2 (2)

Checking
Axial Vibration Damper S46-S50MC-C 0224 Checking 905-5.1
905-5.1
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 may be mounted on the specific engines, the checking procedure describes three systems: A: Electronic, with Axial Vibration Monitor B. Mechanical, (without angle encoder fore) C: Mechanical, with angle encoder fore.
1.
A: Electronic, with Axial Vibration Monitor A proximeter probe is built on to the lower part of the damper housing. The probe is connected to a control unit which displays peak-to-peak movements and sends signals to the engine control system. 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 .
KM905-7.1 35 01
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. After tightening the shaft, dismount the handle.
BG905-5.1 223 01B
Screw the measuring arm into the small threaded hole beside the centre hole, so that the arm is perpendicular to the shaft piece. Tighten the lock nut. 2. Attach a pencil to the arm. Note! To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.
Page 2 (8)
BG905-5.1 223 02B

Checking
3.
905-5.1
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.) When measuring, press the measuring arm against the shaft piece with the one hand. With the other hand, move a sheet/block of paper, clipped on to a solid backing plate, lightly downwards against the tip of the pencil. To ensure a certain inertia, the backing plate should have a mass of approx. 1-2 kg. 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. For a standard measuring tool (L 1 = 38 mm and L 2 = 200 mm), the ratio is 5.3. Therefore, the S1 can be calculated as follows:
S-2
DM905-7.1 74 05
4.
S1
L2 L1 S2
If a non-standard tool is used, S1 can be calculated as follows:
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 .
M90505-0229C10
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. Attach a pencil to the arm.
BG905-5.1 223 01C
Note! To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.
2.
Page 4 (8)
MN905-5.1 214 05

Checking
3.
905-5.1
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.) 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.
S2
PULL To ensure a certain inertia, the backing plate should have a mass of approx. 1-2 kg. The axial movements (S2) recorded on the paper must be measured with a slide 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. 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:
BG905-5.1 223 03
4.
If a non-standard tool is used, S1 can be calculated as follows:
MA905-5.1 212 07
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 .
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.
D13-02
1. Turn the engine to 90 after TDC. Dismount the lubricating oil pipes for the main bearing and axial vibration damper. Loosen and remove the nuts from the inner studs and the hydraulic nuts from the outer studs. For operation of the hydraulic tools, see Procedure 913-1.
GN905-5.2 204 01
Loosen and remove the horizontal screws. Only the upper part of the housing needs to be removed, while the lower half remains mounted on the bedplate. 2. 2. Mount an eyebolt in the centre lifting hole on the upper part. Engines with chain box fore: Mount a tackle in the bracket above the axial vibration damper inside the chain box. Engines without chainbox fore: Mount a tackle below the fore end platform, and dismount the cover on the lifting hole above the axial vibration damper. 3. By means of the tackle and wire rope, 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. 3.
GN905-5.2 204 02
D05-25
Note! Before starting the work under the suspended upper part, secure the upper part with, e.g. a wire rope or another tackle.
Page 6 (8)
GN905-5.2 224 03

Overhaul
Overhaul 905-5.3
905-5.3
1. Dismantle and remove the springs from the oil sealing rings. Remove the oil sealing rings.
1.
Note! It is recommended to discard both the springs and the oil sealing rings. When mounting the new oil sealing rings, first insert the lower half of the rings in the lower housing. Then press the tension springs into the groove between the oil sealing ring half and the housing. 2. Mount all the upper halves of the oil sealing rings in such a way that the clearance at both joints on each oil sealing ring is the same. Now hook the new tension springs into place, ensuring that they are centralised in the grooves of the oil sealing rings. Note!
HG905-5.2 201 02
HG905-5.2 201 01
2.
The lower half of the oil sealing rings will protrude above the centreline.
Page 7 (8)
905-5.4

Mounting
Mounting 905-5.4
1.
1. Release and carefully lower the upper part of the damper housing. When reaching the oil sealing rings, take care that the rings enter the sealing ring grooves correctly.
D05-25
Before landing the upper part on the lower part, be sure that the guide pins have entered the guide pin holes. 2. Mount and tighten the vertical nuts. See Data . Mount and tighten the hydraulic nuts. For operation of the hydraulic tools, see Procedure 913-1. Mount and tighten the horizontal screws. See Data. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind. 2. Mount the lubricating oil pipes.
GN905-5.4 224 01
D05-18 D05-19 D05-22 D13-01
Engines without chainbox fore: Mount the cover for the lifting hole above the axial vibration damper.
Note! After overhaul of the axial vibration damper, it is recommended to check the axial vibrations. See Procedure 905-3.1.
D05-23 D05-24
Page 8 (8)
GN905-5.4 224 02
Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel
Plate P90551-0237
MAN B&W Diesel A/S
Page 1 (2)

015 027 040 064 076 088 090 100 111 123 135 147 159 160 172 184 196
Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel

Panel for tools Name plate Wire pulley for main bearing Wire pulley for main bearing Lifting tool for main bearing cap Dismanteling tool for main bearing shell Mounting tool for thin bearing shell Tool for turning out segments Lifting attachment Retaining tool for main bearing shell Lifting tool for relief valve Lifting tool for relief valve Eye bolt Wire Mounting tool for thin bearing shell Lifting tool for main bearing shell Tightening template A.V.D.
Page 2 (2)
MAN B&W Diesel A/S
Main Bearing - Hydraulic Tools
Plate P90561-0064
MAN B&W Diesel A/S
Page 1 (2)

021 033 045 057 069 070 082 094 104 116 128 141
Main Bearing - Hydraulic Tools

O-ring with back-up ring O-ring with back-up ring Lifting tool Nut Hydraulic jack, upper Extension stud Supporting block Stud setter O-ring with back-up ring O-ring with back-up ring Hydraulic jack, lower Hydraulic tool for main bearing, complete
Page 2 (2)
MAN B&W Diesel A/S
Crankshaft - Tools
MAN B&W Diesel
Plate P90562-0133
Page 1 (2)

015
Crankshaft - Tools
Item Description
Lifting tool for crankshaft
Item Description
Page 2 (2)
Turning Wheel - Tools
Plate P90563-0024
MAN B&W Diesel A/S
Page 1 (2)

022 034 046 058 060 083 095 201
Turning Wheel - Tools

Hydraulic jack Support Tommy bar O-ring with back-up ring O-ring with back-up ring Spanner Stud setter Hydraulic jack for segment stopper, complete
Page 2 (2)
MAN B&W Diesel A/S
Crankshaft - Measuring T ools Tools

MAN B&W Diesel
Plate P90564-0018
Page 1 (2)

016
Crankshaft - Measuring T ools Tools

Item Description
Measuring tool for axial movement
Item Description
Page 2 (2)
Crankshaft - Measuring Tools

Crankshaft - Measuring Tools 0020 P90564
Plate P90564-0020
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)

016 028 041 053
Crankshaft - Measuring Tools

Item No.
Item Description
Measuring instruments, axial vibration damper Shaft, measuring instruments axial vibration Measuring instruments, axial vibration damper Handle - sundry types
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Thrust Shaft - Tools
Plate P90570-0001
MAN B&W Diesel A/S
Page 1 (2)

019
Thrust Shaft - Tools

Lifting tool for thrust shaft
Page 2 (2)
MAN B&W Diesel A/S
Main Bearing - Measuring Tools
Plate P90572-0005
MAN B&W Diesel A/S
Page 1 (2)

010 021 033 045 069 070 082 094 104 116 128 141 153 165 177 189 190 200 212 224 236 248 261 332 344 356 368 381 393 403 415 427 439 440 452 464 476 488 511 523 535 547
Main Bearing - Measuring Tools

Feeler gauge set Feeler gauge set Feeler gauge set Feeler gauge set Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Feeler gauge Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler Spare tip for feeler
gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge
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 0042 0232 0035 0230 0030 0214 0029 0218 0005 0204 0185 0005 0003 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
Chain
Special Edition D10601 S60MC-C 106-1 Data 0042 Chain
106-1
X X X X
Data
D06-01 D06-02 D06-03 D06-04 D06-13 D06-14 D06-15 D06-16
1 Chain Teeth on chain wheel, max. wear Original length (chain pitch x 10 links) 10 links measurements + 1% of a tensioned chain = scrapping of chain 4 Chain Teeth on chain wheel, max. wear Original length (chain pitch x 10 links) 10 links measurements + 1% of a tensioned chain = scrapping of chain
0.9 mm 254 mm 256.5 mm
3.5 mm 1016 mm 1026 mm
Page 1 (2)
106-1
Chain
Data
P90651 P90651 P90651 P90651 P91356 P91359
56 68 70 81
Chain assembling tool Chain disassembling tool Chain assembling tool Chain disassembling tool Lifting tools, etc. Torque spanners
Page 2 (2)
Chains
Checking
Chains S60MC-C 0232 Checking 906-1.1
906-1.1
1. The engine is equipped with two sets of chains: the drive chains for the camshaft the drive chain for the cylinder lubricators Both sets of chains are to be checked and, if necessary, dismantled and mounted in the same way. Note! There are two sets of dismantling and mounting tools available, one for each set of chains. 2. Both sets of chains can be accessed from within the chainwheel frame. 3. Carry out the inspection as follows: 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. 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). Measurements are best taken by placing a short straight-edge over points A and B and then measuring the distance D-1.
HG906-2.1 97 02
2.
4.
KG906-1.1 202 04
D06-02 D06-14
Page 1 (5)
906-1.1
Chains
Checking
5.
5. If abnormal wear is observed at the bottom of the teeth, make a drawing in scale 1:1 of the teeth and wear profile. For assessing the wear profile, contact MAN B&W Diesel. In most cases, scratches caused by the side plates of the chain will be found on the sides of the teeth. Such scratches can 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)
KG906-1.1 203 05
Chains
Checking
7.
906-1.1
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. If necessary, adjust the chain tightener. See Procedure 906-2.3. S
D06-03 D06-04 D06-15 D06-16

84 -0 -5 66 D 00 16 . .D D06xx aa M M x. Ma
HM906-1.1 203 07
Page 3 (5)
906-1.2
Chains
Dismantling
Dismantling 906-1.2
1.
It may become necessary to disassemble the chain if, for instance, cracked rollers or seizures between pin and bushing have been discovered during the inspection. See Procedure 906-1.1. Note! Every time a chain link is disassembled, a new link must always be fitted as the link pin press-fit is destroyed when breaking the chain.
HG906-2.1 97 02
When a new link is fitted in one chain, the corresponding link in the other chain must also be renewed. 2. 1. Remove the tension on the chain by 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. 2. Mount a wire round the link rollers a short distance from the disassembly point, and tighten the wire lightly with a tackle.
GN906-1.2 203 02
Protect the link rollers over which the wire is wrapped. Note! 3. If the chain is to be completely removed, contact MAN B&W Diesel for further information. The riveting of the pins that are to be pressed out is to be chiselled or ground away. 3. Place the chain bursting tool over the outer chain link, and dismantle the link by alternately tightening the screws on the tool.
Page 4 (5)
GN906-1.2 203 03
Chains
Mounting
Mounting 906-1.4
906-1.4
Before assembling the inner and outer links, clean the pins and bushings. 1. Combine the inner chain link with the outer chain link and mount the compression tool. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool. 2. When the link has been assembled, remove the compression tool and lock the pin ends by riveting. 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).
GN906-1.4 203 01
1.
Page 5 (5)
Chain Tightener
Special Edition D10602 106-2 Data 0035 Chain S60MC-C Tightener
106-2
X X X X
Data
D06-21 D06-25
Tightening angle = 5.5 hexagons Mechanical or blocked chain tightener, clearance
330 /hex 0.1 mm
Page 1 (2)
106-2
Chain Tightener
Data
Page 2 (2)
Chain Tightener
Adjustment
Chain Tightener S60MC-C 0230 Adjustment 906-2.3
906-2.3
1. To retighten the chains, loosen nuts A, B, C and D to free the chain tightener bolt. 2. Turn the engine at least one revolution with the chain slackened on the same side as the chain tightener wheel. If the engine is equipped with flyweights, continue turning until the flyweights are hanging vertically downwards. 3. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D06-25. Then tighten nut B as stated in D06-21 (see Data) . For chain wear, see Procedure 906-1.1.
1. A B
C
HG906-2.3 218 01
2.
HM906-2.2 95 01
3.
D06-25 D06-21
HG906-2.3 218 03
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. 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.
C D
HG906-2.3 218 05
5. A
Page 2 (2)
HG906-2.3 218 05
Camshaft
Special Edition D10603 S60MC-C 106-3 Data 0030 Camshaft
106-3
X X X X
Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water
X X
Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors
Data
D06-27 D06-28 D06-29 D06-30
Max. permissible change in lead angle corresponding to Pin gauge for top dead centre of crankthrow No.1, check measurement Pin gauge for camshaft, check measurement
2 4.5 799 402
mm mm mm
Page 1 (2)
106-3
Camshaft
Data
P90668
Camshaft pin gauge
Page 2 (2)
Camshaft
Checking
Camshaft S46MC-C 0214 Checking 906-3.1
906-3.1
1. Turn the crankthrow for cylinder 1 to TDC. Turn in the AHEAD direction to ensure that the tension of the chain on the chain drive is correct. If necessary, adjust the chain tension. See Procedure 906-2.3. Check the TDC of cylinder 1 against the mark on the turning wheel. 2. Check the TDC position with the pin gauge on the crankthrow.
1.
HM906-7.0 56 01
2.
GN906-3.1 203 02
D06-29
Page 1 (3)
906-3.1
Camshaft
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 Data.

4. Check and, if necessary adjust the cylinder lubricator. See Procedure 903-2.1.
D06-30 D06-28
Check the setting of the starting air distributor. See Procedure 907-1.1. 5. When checking the camshaft position, also check the running surface of the cams.
GN906-3.1 203 03
D06-27
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. 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.
5.
GN906-3.1 203 05
In the event of heavier scratches or direct flaking of the material on the running path, MAN B&W Diesel should be contacted for further instructions. 6.
GN906-3.1 203 06
Page 2 (3)
Camshaft
Adjustment
Adjustment 906-3.3
906-3.3
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 Procedure 9063.1, MAN B&W Diesel should be contacted for further instructions.
1.
D06-28
GN906-3.3 203 01
D06-27
Page 3 (3)
Camshaft Bearings
Special D10604 106-4 Edition Data 0029 Camshaft S60MC-C Bearings
106-4
X X X X
Data
D06-31 D06-33 D06-34 D06-37
Screws for bearing cap, tightening torque Clearance between cap/bearing housing Bearing shell, max. wear Camshaft bearing cap
210 3+/-0.3 0.1 17
Nm mm mm kg
Page 1 (2)
106-4
Camshaft Bearings
Data
P90651 P90651 P91359 P91366
139 Lifting attachment for camshaft bearing 152 Hydraulic jack for lift of camshaft Torque Spanners 58 Feeler gauge
Page 2 (2)
Camshaft Bearing
Checking
Camshaft Bearing S60MC-C 0218 Checking 906-4.1
906-4.1
1. Dismount the inspection covers from the front of the camshaft housing. Check for wiped-out metal at the bearing ends, and for fragments of metal in the camshaft housing. In the event of any signs of anomalies, the bearing shell must be dismantled for closer investigation and, if necessary, the bearing shell must be replaced. If no anomalies are found during the visual inspection, dismantling need only be carried out in connection with Class surveys.
NA906-4.1 207 01
1.
Page 1 (6)
906-4.2
Camshaft Bearing
Dismantling
Dismantling 906-4.2
1. Caution! Before dismantling any camshaft bearings, the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts. See Procedure 906-2.3. 1. Remove the inspection covers from the camshaft housing. Remove and discard the gaskets.
NA906-4.2 207 01
Dismount the plug screws from the baseplate above the bearing in question. Lift the roller guide of the exhaust valve hydraulic pump. See Procedure 908-7. 2. 2. Dismount the lubricating oil connecting pipe. Using a socket spanner mounted on an extension, loosen the bearing cap screws through the outer holes in the baseplate. 3. Through the middle hole in the baseplate, screw the centre rod of the lifting tool into the bearing cap. Use the lock nut on the lifting tool to lift the bearing cap clear of the camshaft.
NA906-4.2 207 02
3.
D06-37
Page 2 (6)
HN906-4.2 218 03
Camshaft Bearing
Dismantling
4.
906-4.2
4. Place the hydraulic jack in the camshaft housing in front of the fuel cam. Place a dial gauge on the camshaft, and lift the camshaft 0.30 mm. 5. Press lightly on the upper edge of the shell to turn the shell up over the camshaft. Remove the shell from the camshaft housing.
HN906-4.2 218 04
5.
HN906-4.2 218 05
Page 3 (6)
906-4.3
Camshaft Bearing
Overhaul
Overhaul 906-4.3
1.
1. For assessment of the bearing condition, see Volume I OPERATION, Chapter 708 Bearings. Inspect the entire surface of the bearing journal for seizures. If seizures are found on the bearing journal surface (on account of bearing breakdown), polish the surface with a fine carborundum stone to re-establish a bright and smooth surface. By closely examining the sliding surface of the bearing shell visually, an impression can be formed of whether the lubrication of the bearing surface has been insufficient or entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication. Measure the thickness of the bearing shell with a micrometer to check the amount of wear.
HN906-4.3 218 01
D06-34
Page 4 (6)
Camshaft Bearing
Mounting
Mounting 906-4.4
906-4.4
1. Clean the bearing journal, the bearing support and the bearing shell. 2. Coat the bearing shell with oil, mount the shell on the camshaft, and turn it into place. Using a caliper at both sides of the bearing shell, check that the bearing is positioned absolutely horizontally. 3. Lower the camshaft and remove the dial gauge and the hydraulic jack from the engine. 4. Lower the bearing cap on to the camshaft. Remove the lifting tool from the bearing cap.
HN906-4.2 218 05
2.
3.
HN906-4.4 218 03
4.
D06-37
HN906-4.4 218 04
Page 5 (6)
906-4.4
Camshaft Bearing
Mounting
5.
5. Mount the bearing cap screws.
D06-31
Tighten both screws lightly. Using a socket spanner mounted on an extension and a torque wrench, tighten the screws to the torque stated in Data. Note! To ensure that the bearing cap is not displaced, the tightening must be done in steps as follows: 1. Tighten the outermost screw to half the torque stated in Data.
NA906-4.2 207 02
6.
2. Tighten the innermost screw to half the torque stated in Data.
D06-33
3. Tighten the outermost screw to the full torque stated in Data. 4. Tighten the innermost screw to the full torque stated in Data. 6. Check the clearance between the bearing cap and the bearing housing. Mount the lubricating oil pipe on the bearing cap. Mount the plug screws in the baseplate. 7. Clean the camshaft housing and mount the inspection covers, fitted with new gaskets.
NA906-4.4 207 06
7.
Page 6 (6)
NA906-4.4 207 07
Replacement of Cams on Camshaft

Special Edition D10606 S60MC-C 106-6 Data 0005 Replacement of Cams on Camshaft
106-6
X X X X
X X
Data
D06-47
Exhaust cam screws, tightening torque
D06-49
Fuel cam screws, tightening torque
D06-50 D06-51 D06-52 D06-53
Fuel cam, marking scratch Fuel cam, axial movement Exhaust cam, marking scratch Exhaust cam, axial movement
900 or 100 + 30 1820 or 100 +30 115 155 105 190
Nm Nm Nm Nm mm mm mm mm
Page 1 (2)
106-6

Data
P90851 P91351 P91351 P91351 P91351 P91351 P91359
173 22 34 58 166 105
Lifting tool for exhaust valve roller guide Hydraulic pump, hand operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete Angle union 3-way distributor block, complete Torque Spanners
Page 2 (2)

Dismantling
Replacement of Cams on Camshaft S60MC-C 0204 Dismantling 906-6.2
906-6.2
Fuel Cam 1. Remove the front cover of the camshaft housing. 2. Lift the roller guide from the cam in question. See Procedure 909-10. 3. Turn the camshaft so that the marking scratch can be seen. 4. Extend the marking scratch on the shaft by D06-50. See Data.
XZ906-6.2 201 01
1.
2.
HHN909-10.1 205 01
4.
XZ906-6.2 201 04
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.
6.
XZ906-6.2 201 06
7.
D06-51
XZ906-6.2 201 07
D06-51
Page 2 (7)

Dismantling
9.
906-6.2
Exhaust Cam 9. Remove the front cover of the camshaft housing. 10. Lift the roller guide from the cam in question. See Procedure 908-7. 11. Extend the marking scratch on the indicator drive cam onto the camshaft.
XZ906-6.2 201 01
Extend the marking scratch on the exhaust cam onto the camshaft by D06-52. See Data.
10.
JM908-5.0 55 03
11.
XZ906-6.2 201 11
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. 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 12
13.
XZ906-6.2 201 13
14.
Page 4 (7)
XZ906-6.2 201 14

Dismantling
15.
906-6.2
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.
D06-53
XZ906-6.2 201 15
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. Measure the fuel cam lead (see Procedures 909-1 and 909-3) and adjust if necessary.
XZ906-6.4 201 01
Tighten the screws to D06-49 and check that the gap is still equal at both sides. Lock the screws with Loctite, type 242 (EN243S). 3. Mount the cover on the front of the camshaft housing.
2.
D06-49
Page 6 (7)
XZ906-6.4 201 02

Mounting
4.
906-6.4
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. 5. Before mounting the two-part spare cam, the bore and the area on the shaft must be degreased. Place the two-part spare cam on the shaft, mount the four screws, and tighten slightly, so that the gap between the two parts is equal at both sides. 6. Make sure that the marking scratches on 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. Measure the exhaust cam lead (see Procedure 908-5 and adjust if necessary. 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). 7. Mount the cover on the front of the camshaft housing.
XZ906-6.4 201 04
5.
XZ906-6.4 201 05
6.
XZ906-6.4 201 06
D06-47 D06-49
Page 7 (7)
Chain Drive and Camshaft - Panel
Plate P90651-0185
MAN B&W Diesel A/S
Page 1 (2)

019 020 044 056 068 070 081 140 152
Chain Drive and Camshaft - Panel

Panel for tools Name plate Impact spanner, fuel cam Assembling tool, chain Disassembling tool, chain Assembling tool, chain Disassembling tool, chain Hydraulic jack, lift of camshaft Lifting attachment camshaft bearing
Page 2 (2)
MAN B&W Diesel A/S
Crankshaft - Pin Gauge
Plate P90664-0005
MAN B&W Diesel A/S
Page 1 (2)

021
Crankshaft - Pin Gauge

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

011
Camshaft - Pin Gauge

Pin gauge
Page 2 (2)
MAN B&W Diesel A/S
907 - Starting Air System

107-01 907-01 107-02 907-02 0018 0217 0034 0216 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
Starting Air Distributor

Special Edition D10701 107-1 Data 0018 Starting L60MC-C Air Distributor
107-1
X X X X
Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors
Data
Page 1 (2)
107-1

Data
Page 2 (2)

Checking
Starting Air Distributor L60MC-C 0217 Checking 907-1.1
907-1.1
1. Turn the engine to bring the piston of cylinder No. 1 to TDC. Check the position with the pin gauge. See Procedure 906-3.1. 2. Remove the small end cover of the distributor housing. 3. Check that the TDC marking scratch on the starting cam is positioned vertically at the valve slide of cylinder No. 1. 4. If necessary adjust the position of the starting cam by loosening the centre screw and turning the starting cam until the TDC marking scratch is positioned vertically at the valve slide of cylinder No. 1. Then tighten the centre screw.
HN907-1.1 205 02
2.
3.
HN907-1.1 205 03
4.
HN907-1.1 205 04
Page 1 (5)
907-1.3

Overhaul
Overhaul 907-1.3
2.
Difficulties in starting can be caused by the starting air distributor valve slides sticking (see Volume I, Chapter 703), so that these are not activated and pressed against the cam during the starting procedure. This can be caused by too high humidity in the main starting air system, which can result in the formation of rust, and also by dirt, preventing the slide valves from functioning. In both cases it is necessary to clean the valve slides and the liners in the distributor housing to remove dirt, rust and foreign particles.
HN907-1.3 205 02
3.
Experience will show how often this is necessary to prevent starting difficulties, as differences will be found from plant to plant. 1. Blank off the main starting air and the control air. If this is not possible, lock the main starting valve in the closed position with a padlock. 2. Remove all the pipes from the end of the distributor. Loosen and remove the screws from the small and large end covers. Dismount the end cover which gives access to the slide valves.
HN907-1.3 205 03
3. Turn the camshaft until the pin of the valve slide (cam follower) can be pushed clear of the starting cam. 4. 4. Remove the screws and the cap from the particular valve slide in question. Remove the guide screw for the valve slide.
HN907-1.3 205 04
Page 2 (5)

Overhaul
5.
907-1.3
5. Remove the complete slide valve (with spring and the upper liner) from the distributor housing by means of a brass mandrel. 6. Press-in the spring and remove the two part locking ring. 7. Remove the upper spring guide, the spring, the lower spring guide and the upper liner from the valve slide.
907-1.3 217 05
6.
907-1.3 217 06
7.
MC907-2.2 29 07
Page 3 (5)
907-1.3

Overhaul
8.
8. Clean all the sliding surfaces on the valve slide. Check the sliding surfaces for wear and seizures, also check the cam follower for wear. Clean the liners and the distributor housing. Test that the valve slide moves easily in the liners. Note! Polishing of the liners with emery cloth must not take place as small particles of the grinding material can stick in the surface of the liner. Lubricate all parts with Molybdenum Disulphide (MoS 2), also the cam follower must be well lubricated. 9. Place the upper liner, the lower spring guide, the spring and the upper spring guide over the valve slide. 10. Press-in the spring and mount the two-part locking ring. 11. Mount the complete slide valve in the distributor housing. (Check that the pin of the valve slide goes clear of the starting cam when mounting). Lubricate the groove in the starting cam with Molybdenum Disulphide (MoS 2).
907-1.3 217 08
10.
907-1.3 217 10
11.
907-1.3 217 11
Page 4 (5)

Overhaul
12.
907-1.3
12. Mount the guide screw for the valve slide. Mount the cap and the screws on top of the slide valve. 13. Check that the piston valve slides can be pushed up and down by hand just overcoming the force of the spring. 14. Finally, mount the two end covers and connect the main starting air and the control air.
HN907-1.3 205 04
14.
HN907-1.3 205 02
Page 5 (5)
Starting Air Valve

Special Edition D10702 L60MC-C 107-2 Data 0034 Starting Air Valve
107-2
X X X
Data
D07-11 D07-12
Valve tightening angle Starting air valve
60 52 kg
Page 1 (2)
107-2
Starting Air Valve

Data
P90151 P90151
95 105
Grinding ring for starting valve Grinding handle for starting valve
Page 2 (2)
Starting Air Valve

Checking
Starting Air Valve L60MC-C 0216 Checking 907-2.1
907-2.1
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 approx. 15-20 mm. 2. Shut off the air supply Check that the valve closes fully. 3. Repeat steps 1 and 2 a couple of times.
1.
HM907-2.1 202 01A
2.
HM907-2.1 202 01B
Page 1 (6)
907-2.2
Starting Air Valve

Dismantling
Dismantling 907-2.2
1.
1. Shut off the starting air and control air inlet. Dismount the control air pipe. Hook a lifting wire around the starting valve and attach the crane hook to the wire. Unscrew the fixing nuts of the starting valve flange. 2. Pull the starting air valve out of the cylinder cover and remove it from the engine.
JN907-2.2 205 01
2.
JN907-2.2 205 02
D07-12
Page 2 (6)
Starting Air Valve

Overhaul
Overhaul 907-2.3
907-2.3
1. Place the starting air valve horizontally in a bench vice provided with soft jaws. Remove and discard the O-ring from the valve housing. 2. Loosen and remove the screws from the top cover. Dismount the top cover. 3. Use the face wrench for the spindle as a back-stop when loosening the two screws which tighten the piston to the spindle. Remove the screws and discard the locking device. When unscrewing, the piston will partially be pressed out of the valve housing due to the spring force.
1.
HM907-4.0 39 01
2.
HM907-4.0 39 02
3.
HM907-4.0 39 03
Page 3 (6)
907-2.3
Starting Air Valve

Overhaul
4.
4. Remove the piston from the top end of the valve housing. Take out the spindle from the bottom end of the valve housing. Remove the spring from the top end of the housing. 5. Apply grinding paste, e.g. carborundum No. 200. Grind the valve housing seating with the grinding ring. 6. When lapping the seatings of the spindle and valve housing to match, use the face wrench to rotate the spindle. As grinding paste, use e.g. carborundum No. 500.
HM907-4.0 39 04
5.
HM907-4.0 39 05A
6.
MG907-4.0 51 05B
Page 4 (6)
Starting Air Valve

Overhaul
7.
907-2.3
7. Thoroughly clean the valve housing and all the parts in diesel oil or kerosene. Lubricate all internal parts and sliding surfaces with, e.g., Molybdenum Disulphide, MoS 2. Insert the spindle in the valve housing. Then mount the spring in the housing around the spindle and, finally, place the piston on top of the spindle. 8. Fit the discs and the two screws. When tightening the screws, the piston will compress the spring. Tighten the screws continuously until the piston faces tightly against the spindle. Use the face wrench as a back-stop.
HM907-4.0 39 07
Lock the screws with locking device. For correct use of locking device, see Procedure 913-7. 9. Mount and tighten the top cover. Fit a new O-ring on the valve housing. 10. Check the starting air valve. See Procedure 907-2.1. If the valve is not to be mounted in the engine immediately, cover all openings with plastic to prevent dirt from entering the valve during storage.
9.
HM907-4.0 39 09
Page 5 (6)
907-2.4
Starting Air Valve

Mounting
Mounting 907-2.4
1.
1. Carefully clean the starting valve bore in the cylinder cover and, if necessary, recondition the seat for the starting valve in the bore, see Procedure 901-1.3. If not already done, fit a new O-ring on the overhauled valve and lubricate with Never Seize or Molybdenum Disulphide, MoS 2. For overhaul, see Procedure 907-2.3 . 2. Mount the valve in the cylinder cover.
HG907-2.4 201 01
3. Mount the nuts and tighten-up in at least three steps, to reach the full tightening angle, see Data. Mount the control air pipe and turn on starting air and control air. 2.
JN907-2.4 205 02
D07-12
3.
D07-11
HM901-2.2 114 03
D07-11
Page 6 (6)
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 90864 0031 0226 0059 0240 0034 0227 0031 0217 0010 0214 0031 0226 0165 0037 0041 0014 0003 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 Exhaust Valve - Panel Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools Exhaust Valve - Extra Tools Exhaust Valve - Extractor Tool
MAN B&W Diesel A/S
MAN B&W Diesel A/S
High-Pressure Pipe
Special D10801 108-1 Edition Data 0031 High-Pressure S60MC-C Pipe
108-1
X X X
Data
D08-01 D08-02 D08-03
High-pressure pipe, tightening torque Distance of high-pressure pipe lower edge to pressure flange High-pressure pipe
70 Nm 16 mm 38 kg
Page 1 (2)
108-1
High-Pressure Pipe
Data
P90851
112 Grinding mandrel for high-pressure pipe
Page 2 (2)
High-Pressure Pipe
Dismantling
908-1.2 Disling 908-1.2 Dismantling
908-1.2
1.
1. When replacing the hydraulic high-pressure pipe, the exhaust valve or the hydraulic actuator, check and, if necessary, recondition the high-pressure pipe sealing surfaces. 2. Before dismantling the high-pressure pipe, stop the camshaft oil pump. Loosen the screws for the high-pressure pipe and lift the pipe slightly away from the actuator to let the oil in the pipe drain through the drain holes in the actuator.
D08 03
M90801 0226D02
M90801 0226D01
2.
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
1. Check the contact surfaces of the pressure pipe for marks and, if necessary, grind the pipe ends by means of the grinding mandrel and the two guiding tools. Start grinding with a coarse grinding paste, for example Carborundum No. 200, and finish with a fine grinding paste, for example Carborundum No. 500. 2. After reconditioning the contact surfaces of the pipe, measure the distance from the edge of the thrust bushing to the contact surface at both ends of the pipe. This measurement is to correspond with the value stated in Data. Check the thrust pads in the exhaust valve and the actuator for marks on the sealing surface. Replace the O-rings on the thrust pads. If considered necessary, replace the thrust pads. Lift the thrust pad free by, for example, using a screwdriver in the groove of the thrust pad.
1.
M90801 0226O01
Carborundum
2.
M90801 0226O02
D08 02
Page 2 (3)
High-Pressure Pipe
Mounting
1. Mount the hydraulic high-pressure pipe as follows: Position the high-pressure pipe with the sealing surfaces of the pipe resting on the thrust pads of the exhaust valve/actuator. Take care not to damage the O-rings on the thrust pads. After fitting the pipe correctly in relation to the exhaust valve and actuator, tighten up the screws of the pressure flanges diagonally, see Data. 2. Check the whole system for tightness. See Procedure 908-3.1.
908-1.4
1.
M90801 0226M01
D08 01
2.
M90801 0226M02
Page 3 (3)
Exhaust Valve
Special Edition D10802 L60MCC 108-2 Data 0059 Exhaust Valve
108-2
X X X X X
X X
Data
D08-04 D08-05 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 D08-22 D08-23 D08-24 D08-25 D08-26 D08-27 D08-28 D08-29 D08-30 D13-01 D13-02
Safety valve, opening pressure Screws for lifting eye bolt, tightening torque 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 Damper piston, min. distance Damper piston, max. distance Exhaust valve, complete Exhaust valve housing Oil cylinder Air cylinder Spindle Bottom piece Air piston Hydraulic pressure, mounting Hydraulic pressure, dismantling
21 50 100 50-80 30+0/-0.1 30.3+0.1/-0 2.3 1 9 2 280 410 71.8 72.6 74.5 85.4 3.2 48.4 51.4 710 380 100 30 73 100 9 1500 1400-1650
bar Nm Nm Nm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg kg kg bar bar
Page 1 (2)
108-2
Exhaust Valve
Data
P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90851 P90861 P90862
65 77 89 90 136 148 150 161 185
Lifting tool for exhaust valve Cone ring for pneumatic piston Pressure tester for safety valve Gauge for exhaust valve spindle Bridge gauge for exhaust valve Tool for hydraulic piston Gauge for exhaust valve bottom piece Lifting tool for exhaust valve spindle Grinding ring for exhaust valve bottom piece Valve seat and spindle grinder Hydraulic jack, complete
Page 2 (2)
Exhaust Valve
Checking
Exhaust Valve L60MC-C Checking 908-2.1 0240
908-2.1
Checks during running: Check of valve spindle rotation 1. 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. The indicator will now follow the movements of the valve spindle. During rotation of the valve spindle, the top position of the indicator will change about 6 mm, see the sketch. During engine operation, the spindle must rotate in the range of 0.5 to 5 rpm. 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 finished, lift the rotation indicator and lock it in the top position. Note! The indicator must not be in constant operation.
1.
NB908-2.1 229 01
On Surface
In Groove
2.
Check of bottom piece sealings 2. When the exhaust valve is mounted in the cylinder cover, and the cooling water inlet to the cylinder cover and exhaust valve is open, check the tightness of the sealing ring between the bottom piece and the cylinder cover by ensuring that water does not flow from the bore on the top side of the bottom piece on the manouevring side. If water does flow from this bore, the exhaust valve must be dismounted and the sealing rings replaced. Check of sealing oil control unit 3. When the engine is running, check that the indicator pin is moving regularly in connection with the valve opening. Alternatively, unscrew the sealing oil pipe and check that oil is coming out (only a small quantity).
MN908-2.1 214 02
3.
HH908-2.1 240 03
Page 1 (24)
908-2.1
Exhaust Valve
Checking
4.
Checks with stopped engine: Check of air sealings 4. Open the air supply to the air spring of the exhaust valve. Engage the rotation indicator and check that the exhaust valve is closed. Close the air supply to the exhaust valve, and vent the system. 5. Disengage the air pipe to the exhaust valve. The valve should remain closed for at least 15 minutes 6. An additional check with compressed air can be carried out as follows: Connect compressed air to the air cylinder to close the valve.
HH908-2.1 240 04
Closed valve
Open valve
After shutting-off the compressed air supply and releasing the air through the non-return valve on the side of the air cylinder, the exhaust valve should open. Hint! Use a small screwdriver to press the ball into the non-return valve, and cover it with a rag to catch the oil drops. After doing this a couple of times, leave the valve closed and shut-off the compressed air. The valve should remain closed for at least 15 minutes. If the valve opens within 15 minutes, the complete exhaust valve should be replaced by a new one, see Procedure 908-2.2.
5.
GN908-2.2 236 05
For overhaul of the exhaust valve, see Procedure 908-2.3.

Disengage the rotation indicator.
Page 2 (24)
Exhaust Valve
Dismantling
Dismantling 908-2.2
908-2.2
1. Close the cooling water inlet and outlet, and drain the exhaust valve. Dismount the high-pressure pipe for the hydraulic valve actuation. See Procedure 908-1.2. Disconnect the cooling water outlet pipe from the exhaust valve. Dismount the return oil pipe from the exhaust valve. 2. Dismount the air pipe for the pneumatic exhaust valve spring. Remove the screws of the cooling water inlet flange at the side of the exhaust valve. 3. Remove the plate jacket with insulation from the intermediate pipe and remove the screws which attach the intermediate pipe to the inlet pipe of the exhaust receiver.
GN908-2.2 236 01
1.
2.
GN908-2.2 236 03
GN908-2.1 236 05
3.
Page 3 (24)
908-2.2
Exhaust Valve
Dismantling
4.
D13-02
4. Remove the protective caps from the exhaust valve studs, and mount the four hydraulic jacks. Connect the high-pressure pump to the jacks by means of the distributor block and four high-pressure hoses. Bleed the hydraulic system and raise the pressure as stated in Data. Then loosen and remove the nuts. See Procedure 913-1.
HH908-2.2 240 04
5. Attach the crane to the eye bolt fitted on top of the valve and lift the exhaust valve away. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seating and sealing surfaces of the bore, if required. See Procedure 901-1.3.
5.
D08-24
HH908-2.2 240 05
Page 4 (24)
Exhaust Valve
Overhaul
Overhaul 908-2.3
908-2.3
1. Place the exhaust valve on a wooden support on the platform. Remove the oil pipe for the spindle sealing oil. 2. Remove the eight nuts and the safety strap from the oil cylinder. Lift away and place the oil cylinder on a wooden support.
HH908-2.3 240 01
1.
3. Dismount and inspect the O-rings and the thrust piece of the hydraulic high-pressure pipe for marks. See Procedure 908-1. Replace the O-rings and thrust piece, if necessary. Check the functioning of the exhaust valve rotation indicator.
2.
D08-26
HH908-2.3 240 02
3.
HH908-2.3 240 03
Page 5 (24)
908-2.3
Exhaust Valve
Overhaul
4.
4. Loosen the screws and remove the lifting eye from the oil cylinder to gain access to the orifice plug and the sealing oil control unit. Remove the sealing oil unit. Unscrew and clean the orifice plug. Check and clean the bore for the orifice plug in the top of the oil cylinder. 5. Sealing oil control unit: Normally, overhaul of the sealing oil unit should not be necessary. Check the unit according to Procedure 9082.1. Before remounting the unit, carefully clean it on the machined faces. If the unit needs to be overhauled, send it to an authorised MAN B&W repair shop.
HH908-2.3 240 04
5.
GN908-2.3 236 05
Page 6 (24)
Exhaust Valve
Overhaul
6.
908-2.3
6. Place the oil cylinder in a horizontal position. Remove and discard the sealing ring. Remove the flange and take out the piston. Inspect the bore of the oil cylinder for scoring and check its measurements. If the diameter of the bore exceeds the value stated in Data, send the oil cylinder to an MAN B&W authorized workshop for repair. 7. Relieve the air pressure through the non-return valve from below the piston. Use a small screwdriver to press the ball into the non-return valve. Cover the non-return valve with a rag to catch the oil drops. Remove the four screws from the flange on top of the air piston, and dismount the flange. Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring. 8. Pass lifting straps through the four bores of the valve housing and lift the valve housing clear of the valve spindle. Take care when the internal O-ring 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.
GN908-2.3 236 07 KG908-2.0 115 04
D08-20
7.
8.
GN908-2.3 236 08
Page 7 (24)
908-2.3
Exhaust Valve
Overhaul
9.
9. Unscrew and remove the lock screws which retain the bottom piece. Lift the valve housing approx. 10 mm.
D08-25
If the bottom piece has become stuck, use a tin hammer to release it. Lift the valve housing away and land it on a couple of wooden planks. Bottom piece: 10. Inspect the seating of the bottom piece carefully for damage and check with the bottom piece template. Note!
D08-29
GN908-2.3 236 09
Before using the bottom piece template, thoroughly clean the contact faces on the valve housing w-seat with a steel brush. All measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating.
10.
Small dent marks in the bottom piece seating are acceptable and need not be ground away, provided that the dent marks do not allow blow-by of exhaust gas from the combustion chamber to the exhaust gas receiver.
G3
For further evaluation of the bottom piece seating, see also Chapter 707 in the instruction book, Volume I, Operation.
Take measurements G 2 and G3, using a feeler gauge. Compare the results with the figures stated in Data D08-11 and D08-12. IF burn marks are visible on the bottom piece seating OR G3 does not equal D0812, THEN the bottom piece seat must be ground.
D08-09
G2
MB908-2.3 230 12
IF the template rests on the lower surface in the groove, i.e. G2 = 0, THEN the bottom piece seating must be discarded and replaced with a new bottom piece. Further grinding or reconditioning is not recommended.
Page 8 (24)
Exhaust Valve
Overhaul
11.
908-2.3
11. If it is necessary to grind the seating, proceed as follows: Before placing the bottom piece on the grinding machine, turn the grinding head away from the grinding table. Mount and secure the bottom piece in the grinding machine. Using a dial gauge, check that the bottom piece is correctly centered.
MB908-2.3 230 11
D08-09
Adjust the grinding head to achieve the correct grinding angle as stated in Data. Note! As the grinding angle is very important for the correct operation of the exhaust valve, make absolutely sure that the grinding head is correctly adjusted.
12.
D08-09 G3
Regarding the use of the grinding machine, see separate instructions from the grinding machine manufacturer.
12. During the grinding, use the bottom piece template frequently to ensure that maximum grinding is not exceeded. After grinding, inspect the bottom piece seating again, using a feeler gauge and the bottom piece template, to measure how much material has been ground away. Grind the recess so that gap G3 equals D08-12 as stated on the Data sheet. 13. After grinding the inside seating of the bottom piece, grind the outside seating using carborundum 200 and the special grinding tool. Note! Turn the special grinding tool by hand, alternately turning clockwise and anticlockwise. Grind until a smooth surface is achieved. Clean the bottom piece.
D08-09
MB908-2.3 230 12
G2
13.
MB908-2.3 233 13
Page 9 (24)
908-2.3
Exhaust Valve
Overhaul
14.
Valve spindle 14. When lifting or transporting the exhaust valve spindle, use the special valve spindle lifting tool. 15. Inspect the seating of the valve spindle for burn marks.
NA908-2.3 209 14
D08-28
Check the burn-off F1 of the valve spindle by measuring along the spindle template from point A to point D and in point E and compare with Data D08-13. Note! Before using the spindle template, thoroughly clean the contact faces on the valve spindle with a steel brush. All measurements should be taken at four diametrically opposite points on the circumference of the valve spindle. Make sure that the most burned-off point is measured.
15.
F-1
MA908-2.3 213 12
A
16.
Small dent marks in the valve spindle seating are acceptable and need not be ground away, provided that the dent marks do not allow blow-by of exhaust gas from the combustion chamber to the exhaust gas receiver.
For further evaluation of the valve spindle seating, see also Chapter 707 in the instruction book, Volume I, Operation.
G-1
16. Measure the gap G 1 between the spindle template and the seating of the spindle. 17. IF burn marks are visible on the seating, the spindle must be ground. IF gap G1 exceeds the maximum allowable value D08-14, see Data, OR the burn-off F 1 exceeds the maximum allowable burn-off D08-13, the spindle must not be ground. Instead the spindle must be reconditioned.
HC908-2.0 117 11
D08-10
Contact MAN B&W Diesel for advice on reconditioning.
Page 10 (24)
Exhaust Valve
Overhaul
18.
908-2.3
18. Mount and secure the spindle in the grinding machine. Using a dial gauge, check that the spindle is correctly centered. Adjust the grinding head to achieve the correct grinding angle as stated in Data. Note! As the grinding angle is very important to the operation of the exhaust valve, make absolutely sure to adjust the grinding head correctly.
D08-10
Regarding the use of the grinding machine, see separate instructions from the grinding machine manufacturer.
During grinding, measure gap G 1 frequently. The max. grinding of the spindle, see Data, must not be exceeded. If the max. grinding limit is reached, and burn marks are still visible on the seating of the spindle, contact MAN B&W Diesel for advice on reconditioning. Clean the spindle. 19. Check the spindle stem for wear in the area D08-15 to D08-16 measured from the top of the spindle. If the stem diameter is less than stated in Data, or the hard facing layer is worn away, contact MAN B&W Diesel for advice.
GM908-2.0 119 14
19.
D08-15
D08-16
D08-17
JM908-2.0 92 12
Page 11 (24)
908-2.3
Exhaust Valve
Overhaul
20.
20. Dismount the air piston from the air cylinder, and check the teflon guide ring and teflon sealing ring for wear. Mount two eye bolts in the air cylinder and dismount the air cylinder.
D08-30
21. Clean the air cylinder and check the running surface for wear or possible scores. Blow through the bore for sealing oil, with compressed air. 22. Remove the protective cap from the safety valve mounted near the bottom of the air cylinder and dismount the safety valve from the air cylinder.
D08-27
GN908-2.3 236 20
Place the safety valve in the pressure testing device. Connect the testing device with the highpressure pump by means of a hose. Check the opening pressure, see Data. 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.
21.
GN908-2.3 236 21
22.
D08-04
NB908-2.3 229 21
Page 12 (24)
Exhaust Valve
Overhaul
23.
908-2.3
23. Mount a new gasket and a new O-ring on the safety valve. Mount the safety valve in the bore near the bottom of the air cylinder. When mounting the safety valve in the air cylinder, use only the machined faces on the valve housing and tighten, see Data. Finally, mount the protective cap. 24. Remove and discard all the O-rings and the inside sealing ring.
NB908-2.3 209 22
D08-07
24.
GN908-2.3 236 24
Page 13 (24)
908-2.3
Exhaust Valve
Overhaul
25.
25. Inspect the bushing in the spindle guide for wear and measure the top and bottom diameters. See Data. 26. If it proves necessary to replace the bushing, knock out the bushing with a hammer and a suitable mandrel.
D08-18
Alternatively, if the extractor tool is available, mount the extractor tool and pull up the bushing. The extractor tool is optional, and can be ordered as sparepart.
D08-19
GN908-2.3 236 25
26.
NB908-2.3 229 25A
Page 14 (24)
Exhaust Valve
Overhaul
27.
908-2.3
27. Mount the O-rings and sealing ring on the stuffing box. Note! Make sure to mount the sealing ring correctly, see the sketch. 28. Mount new sealing rings on the bottom piece. One O-ring in the upper groove and one U-seal in the lower groove. See the sketch. 29. 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.
GN908-2.3 236 27
28.
HH908-2.3 240 28
29.
GN908-2.3 236 28
Page 15 (24)
908-2.3
Exhaust Valve
Overhaul
30.
30. Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle. 31. Lubricate the O-rings. Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin.
GN908-2.3 236 29
Note! Take care not to damage the O-rings on the outside of the stuffing box. 31.
D-4
GN908-2.3 236 30
Page 16 (24)
Exhaust Valve
Overhaul
32.
908-2.3
32. 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. Mount the new O-rings in the grooves of the air piston. Note!
MB908-2.0 90 15
Before mounting, heat the new teflon rings in 100C hot water for at least five minutes. When mounting the teflon rings, be careful not to damage the running surfaces. After mounting, compress the teflon rings by means of the conical ring. This is done by pressing the air piston through the conical ring. 33. Fill the groove on top of the flange and the lower part of the air cylinder with clean lubricating oil (approx. 0.5 litre). 34. Fit the conical guide ring for the air piston on the air cylinder. Lubricate the guide ring and the running surface of the air cylinder. Lower the air piston over the valve spindle down into the air cylinder. Note! To avoid damage, take great care when the internal sealing ring in the air piston passes the groove for the conical locking ring. Remove the conical guide ring from the air cylinder.
33.
GN908-2.3 236 32
34.
NB908-2.3 229 33
Page 17 (24)
908-2.3
Exhaust Valve
Overhaul
35.
35. Mount the two part conical locking ring and apply compressed air below the air piston through the non-return valve to lift the piston. Mount the flange on top of the air piston and, by means of the four screws, tighten the air piston and the flange together. For correct securing, see Procedure 913-7. 36. Remove the piston rings from the oil piston and check them for wear.
Compressed air
GN908-2.3 236 34
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.
36. 37. Mount the piston on top of the spindle and check the mesh of the damper piston by checking the height of the damper relative to the oil cylinder. Connect compressed air supply to the space below the air piston, so as to keep the valve closed, and to keep the air cylinder in close contact with the valve housing. Place the measuring tool on the air cylinder across the piston.
BG908-2.0 99 22
D08-21
37.
GN908-2.3 236 36
Page 18 (24)
Exhaust Valve
Overhaul
38.
908-2.3
38. Check the mesh of the damper piston by checking the distance from the upper edge of the crossbar to the top of the damper piston. See Data. If the measurement is outside the value stated in Data, an adjustment must be made by changing the disc in the damper piston as follows: 39. Place the piston in the special tool. Press out the disc with the centre screw. If necessary, replace also the spring and the piston. 40. Assemble the damper piston with the new disc in the special tool. Place the piston upside down in the tool and press the disc into place in the piston. Check the mesh once more.
GN908-2.3 236 37
D08-22 D08-23
39.
MA908-2.0 103 25
40.
S8211427
Page 19 (24)
908-2.3
Exhaust Valve
Overhaul
41.
41. Mount the piston and the flange in the oil cylinder. Mount the screws and tighten. Mount a new sealing ring in the inner groove. 42. Return the oil cylinder to an upright position.
HG908-2.3 217 34
Mount a new sealing disc in the bore for the orifice plug. Screw the orifice plug into the bore. Place a new gasket on top of the oil cylinder. Mount the sealing oil control unit. Mount the lifting bracket on the oil cylinder.
42.
D08-05
Mount the screws and tighten to the torque stated in Data. 43. Mount a new O-ring on the thrust piece. Mount the thrust piece in the oil cylinder.
HH908-2.3 240 42
43.
HH908-2.3 240 43
Page 20 (24)
Exhaust Valve
Overhaul
44.
908-2.3
44. Mount the overhauled oil cylinder on top of the air cylinder. Mount the safety strap and tighten the nuts. See Data. 45. Mount the sealing oil pipe.
D08-06
HH908-2.3 240 44
45.
HH908-2.3 240 45
Page 21 (24)
908-2.4
Exhaust Valve
Mounting
Mounting 908-2.4
1.
Check before mounting Before mounting an overhauled exhaust valve in the engine, it is recommended that the valve be checked and prepared as follows: 1. Lift up the valve with the engine room crane (whereby the valve may open). 2. Connect compressed air to the air cylinder to close the valve: Check that a 1.0 mm feeler gauge can be inserted about 15 mm into gap G3, to ensure that there is a clearance between the outer parts of the seating faces of valve housing and spindle. See Procedure 908-2.3. After shutting-off the compressed air supply and releasing the air through the non-return valve on the control unit, the exhaust valve should open. Hint! Use a small screwdriver to press the ball into the non-return valve, and cover it with a rag to catch the oil drops. After doing this a couple of times, leave the valve closed, and shut-off the compressed air.
D08-24
G3
HH908-2.4 240 01
2.
GN908-2.4 236 02
If the exhaust valve opens within 15 minutes, check for air leakages around the air spring. Check: Air piston sealing (air coming out of drain oil hole) Stem sealing (air coming out along spindle stem in exhaust gas duct) Non-return valve for air spring.
Page 22 (24)
Exhaust Valve
Mounting
3. Note! Before mounting the valve on the engine, connect 7 bar working air to the air cylinder to keep the exhaust valve closed during the mounting process. Mount a new O-ring in the upper groove on the bottom piece and a U-seal in the lower groove of bottom piece. Lubricate the sealing rings with vaseline and the threads of the studs with anti-seizure paste. Position the valve in the cylinder cover bore, guiding it in accordance with the exhaust flanges and the guide pin on the exhaust side of the exhaust valve. 4. Mount the nuts and the hydraulic jacks. Raise the pressure to the value indicated in Data and tighten the nuts.
908-2.4
3.
Compressed Air
Vaseline Copper Grease
For use of the hydraulic jacks, see also Procedure 913-1.

Relieve the system of pressure, remove the hydraulic jacks and high-pressure hoses, and fit the protective caps.
HH908-2.4 240 03
4.
D13-01
HH908-2.2 240 04
Page 23 (24)
908-2.4
Exhaust Valve
Mounting
5.
5. Connect the intermediate pipe to the flange at the exhaust valve, mount and tighten the screws. Attach the insulation jacket. 6. Mount the cooling water outlet pipe on the exhaust valve. Mount the high-pressure pipe and the return oil pipe, see Procedure 908-1.4. Open the lub. oil supply and the cooling water supply to the exhaust valve. Disconnect the compressed air and connect the normal air supply.
GN908-7.4 236 05
6.
Caution! The air supply to the exhaust valve must always be connected before turning on the oil supply to the exhaust valve actuator. 7. Check the tightness of the sealing ring between the bottom piece and the exhaust valve housing. See Procedure 908-1.1.
GN908-2.4 236 06
Page 24 (24)
Exhaust Valve Actuator

Special Edition D10803 L60MC-C 108-3 Data 0034 Exhaust Valve Actuator
108-3
X X X X
X X
Data
D08-20 D08-21 D08-32 D08-33 D08-34 D08-35
Oil cylinder max. inside diameter Piston rings, min. thickness Hydraulic actuator, tightening torque Locking plate, tightening torque Hydraulic actuator, tightening angle Hydraulic actuator
85.4 3.2 500 25 30 90
mm mm Nm Nm kg
Page 1 (2)
108-3

Data
Page 2 (2)

Checking
Exhaust Valve Actuator L60MC-C 0227 Checking 908-3.1
908-3.1
1. The non-return valve A is built into the oil inlet pipe to the actuator. To check the valve, dismantle and clean it and connect a supply of working air (7 bar) to the outlet side of the valve (the side facing the actuator). If the air flow can be felt at the inlet side of the valve, the valve must be overhauled. 2. Leakages in the exhaust valve can be measured during running of the engine by collecting the oil from the drain pipe C leading from the exhaust valve to the hydraulic actuator. Leakages may also be caused by leaky non-return valves and loose pressure pipe connections. If the pipe connections are tight and the leak oil amount from the exhaust valve is normal, any abnormally large leakages must originate from the hydraulic actuator from which leak oil quantities cannot be directly registered. The hydraulic actuator is then to be dismantled for checking of the parts. See Procedure 908-3.2
1.
HM908-3.0 70 1/3
Page 1 (4)
908-3.2

Dismantling
Dismantling 908-3.2
1.
1. Stop the engine and shut off the oil supply. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the roller guide housing to check the position of the exhaust cam. Dismount the inlet pipe and the drain pipe from the exhaust valve. Dismount the high-pressure pipe. See Procedure 908-1.2. 2. Release the mountings for the indicator drive from the actuator housing.
GM908-3.0 78 01
2.
Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.
D08-35
Unscrew the nuts on the two short studs, then loosen the nuts on the long studs successively until the roller guide spring is relieved. Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller guide. Remove the spring.
HG908-3.3 201 02
3. Remove the locking plate for the piston. Turn the piston 90 to release it from the bayonet joint. 3. Remove the piston from the roller guide. 4. Overhaul the actuator housing and the piston as required. See Procedure 908-3.3 .
Page 2 (4)
HM908-3.0 70 03

Overhaul
Overhaul 908-3.3
908-3.3
1. Clean the piston in kerosene and wipe dry with a clean piece of cloth. Take off the piston rings and check them for wear. If the ring thickness has worn down to the minimum (see Data) , discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards when mounting. 2. Inspect the sliding surfaces of the piston to ensure that there are no scratch marks or seizure marks. 3. Clean the oil cylinder and inspect the bores for deposits. Check the bore of the oil cylinder for possible scores and measure it for wear. If the bore is seized or worn down to the measurement stated in Data, send the oil cylinder to an MAN B&W authorised workshop for reconditioning.
HM908-3.0 69 04
1.
D08-21
3.
D08-20
JM908-3.0 73 05
Page 3 (4)
908-3.4

Mounting
Mounting 908-3.4
1.
D08-33
1. Mount the actuator piston in the roller guide and turn 90 to lock it in the bayonet joint. Mount the locking plate and tighten as stated in Data. Lubricate the piston with plenty of camshaft 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. Mount the washers and nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. Mount the washers and nuts on the two short studs. Tighten all four nuts as stated in Data. Note! Use only the tightening angle OR the tightening torque, NOT both.
KC908-3.0 76 05
2.
D08-32 or D08-34
HG908-3.4 201 02
3. Mount the oil inlet pipe and the drain pipe from the exhaust valve. Mount the hydraulic high pressure pipe. See Procedure 908-1.4.
3.
Page 4 (4)
HG908-3.4 201 03
Exhaust Valve Roller Guide

Special Edition D10804 L60MC-C 108-4 Data 0031 Exhaust Valve Roller Guide
108-4
X X X X
X X
Data
D08-36 D08-38
Bushing/shaft pin, max. clearance Roller guide complete
0.5 mm 45 kg
Page 1 (2)
108-4

Data
P90851
53
Lifting tool for roller guide
Page 2 (2)

Checking
Exhaust Valve Roller Guide L60MC-C 0217 Checking 908-4.1
908-4.1
1. The exhaust valve roller guide can be partially checked while mounted on the engine, using the following procedure: Lift the roller guide. See Procedure 908-7. 2. Remove the camshaft inspection cover. Turn the engine to provide the maximum space between the roller guide and the cam disc. 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. Check the clearance in the slide bearing by lifting the roller relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller. A more suitable and reliable method is to check the roller guide and the bearing clearance when the roller guide is dismounted. For dismantling of the roller guide, see Procedure 908-4.2. 3. Inspect the surfaces of the roller guide and the roller for damage marks, seizures or scratches. 4. To measure the clearance in the roller guide slide bearing, place the roller guide vertically upside down on a couple of planks with the roller hanging freely. 5. Place a dial gauge against the roller. Then lift the roller as much as the clearance permits, which makes it possible to read the clearance directly on the dial, see Data.
JN908-4.1 205 02
2.
3.
D08-36
KC908-4.0 57 05
Page 1 (4)
908-4.2

Dismantling
Dismantling 908-4.2
1.
1. Dismantle the hydraulic actuator above the exhaust valve roller guide. See Procedure 908-3.2. 2. Mount the roller guide lifting tool as follows: Lift the lock ring of the tool up on the shaft of the tool. Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. Turn the tool 90 so as to allow the foot to engage properly in the bayonet joint. Lower the lock ring, thereby securing the foot in the locked position. Lift the roller guide out of the roller guide housing, using the crane. Take care not to damage the sliding surfaces of the roller guide when lifting.
HG908-3.3 201 02
2.
D08-38
Page 2 (4)
HM908-4.0 51 02

Overhaul
Overhaul 908-4.3
908-4.3
1. Inspect and check the exhaust valve roller guide. See Procedure 908-4.1. 2. It is recommended that the roller guide should ONLY be overhauled/dismantled if irregularities when turning the roller, damage to the roller, larger clearance than stated on the Data sheet, seizure marks on the slide surfaces, have been observed during the checking of the roller guide. Note!
GM908-4.0 73 05
1.
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.
Page 3 (4)
908-4-4

Mounting
Mounting 908-4-4
1.
1. Mount the lifting tool for the roller guide as follows: Lift the lock ring of the tool up on the shaft of the tool. Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. Turn the tool 90 so as to allow the foot to engage properly in the bayonet joint. Lower the lock ring, thereby securing the foot in the locked position. Lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing. Remove the lifting tool. 2. When mounting the roller guide, check the clearance between the roller guide and the guide plate mounted in the roller guide liner.
HM908-4.0 51 02
2.
Turn the camshaft so that the roller guide is lifted approx. 20 mm. The clearance between the roller guide and the guide plate should be the same at both ends +/ 0.1 mm. 3. Mount the actuator. See Procedure 908-3.4.
Page 4 (4)
HM908-4.0 51 10
Exhaust Valve Cam

Special Edition D10805 L60MC-C 108-5 Data 0010 Exhaust Valve Cam
108-5
X X X X
X X
Data
D08-39
Check lifting height
12 mm
Page 1 (2)
108-5
Exhaust Valve Cam

Data
Page 2 (2)
Exhaust Valve Cam

Checking
Exhaust Valve Cam S42MC 0214 Checking 908-5.1
908-5.1
1. Turn the crankthrow of the cylinder concerned to TDC. Check and note down the angle indicated on the turning wheel. 2. Turn in AHEAD direction until the roller guide (measured on the activator plunger) is lifted corresponding to D08-39, and calculate the angle A, which is the number of degrees the crankthrow has turned from TDC position to the present position. For D08-39, see Data. Continue turning AHEAD until the roller guide (measured on the activator plunger) is lifted to distance D08-39, and calculate the angle B, which is the number of degrees the crankthrow 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.
HM906-7.0 56 01
1.
2.
D08-39 17 17 mm
17 mm
HM908-7.0 25 1/1
3. Calculate the lead angle as: 180 A + B 2 The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC. See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the "lead angle" of the plant in question. 4. 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.
D08-39
4.
HM908-7.0 25 1/1
Page 1 (1)
Exhaust Valve
Special Edition D10807 S42MC 108-7 Data 0031 Exhaust Valve
108-7
X X X X
Data
Page 1 (2)
108-7
Exhaust Valve
Data
P90851 P90851
124 173
Tool for emergency open exhaust valve Lifting tool for exhaust valve roller guide
Page 2 (2)
Exhaust Valve
Special Running
Exhaust Valve S60MC-C 0226 Special Running 908-7
908-7
Engine trouble might require that a cylinder be taken out of action. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. See Volume I, Section 704. This can take place with the exhaust valve locked in either the open or the closed position. Either way, carry out the following procedure: 1. Lift the relevant fuel pump roller guide. See Procedure 909-16. 2. Dismantle the hydraulic high-pressure pipe.See Procedure 908-1.3. 3. Dismantle the non-return valve on the oil inlet pipe. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one side. Mount the non-return valve on the oil pipe and blank off the non-return valve with the plug from tool panel 908. 4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC. 5. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston.
JN908-4.1 205 02 HN908-7.0 226 03
3.
4.
Tighten the lowermost nut on the tool to pull up the roller guide as far as possible. Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position. 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.
5.
JM908-5.0 55 03
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 venting plug screw, fitted just above the ball cock on the air cylinder, to let the air inside the air cylinder escape. 8. Dismantle the rotation indicator on the oil cylinder and mount the tool for opening of the exhaust valve. The tool is found on tool panel 908. The tool will keep the piston of the air cylinder in the bottom position and thus keep the exhaust valve open.
KC908-6.0 18 02
8.
Page 2 (3)
HN908-7.0 226 08
Exhaust Valve
Special Running
9.
908-7
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 oil 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. 11. Remove the plug from the non-return valve and re-connect the oil inlet pipe on the actuator housing. 12. Mount the hydraulic high-pressure pipe. See Procedure 908-1.2. 13. Engage the fuel pump roller guide. See Procedure 909-16.
JM908-5.0 55 06
11.
HN908-7.0 226 11
Page 3 (3)
Exhaust Valve - Panel
Plate P90851-0165
MAN B&W Diesel A/S
Page 1 (2)

016 028 053 065 077 089 090 100 112 124 136 148 150 161 173 185
Exhaust Valve - Panel

Panel for tools Name plate Lifting tool for roller guide Lifting tool for exhaust valve Cone ring Pressure testing device 0-50 bar Gauge for exhaust valve spindle Stepped drift Grinding tool for high pressure pipe Tool for opening of exhaust valve Bridge gauge for exhaust valve Tool for hydraulic piston Gauge for exhaust valve seat Lifting tool for exhaust valve spindle Lifting tool for exhaust valve roller guide Grinding ring for exhaust valve seat
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Tools
Plate P90861-0037
MAN B&W Diesel A/S
Page 1 (2)

046
Exhaust Valve - Tools

Item No.
Item Description
Grinding machine, complete* Note: * When ordering spare parts, please refer to the Chris Marine manual
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Hydraulic Tools
Plate P90862-0041
MAN B&W Diesel A/S
Page 1 (2)

028 030 053 065 089 090 100 207
Exhaust Valve - Hydraulic Tools

Hydraulic jack, complete Support O-ring with back-up ring O-ring with back-up ring Tommy bar Spanner Stud setter Hydraulic tool set, complete
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Extra Tools

Exhaust Valve - Extra Tools 0014 P90863
Plate P90863-0014
MAN B&W Diesel A/S
Page 1 (2)

011
Exhaust Valve - Extra Tools

Item No.
Item Description
Worktable
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Extractor Tool
Plate P90864-0003
MAN B&W Diesel A/S
Page 1 (2)

017
Exhaust Valve - Extractor Tool

Item No.
Item Description
Extractor tool, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
909 - Fuel Oil System

109-01 909-01 109-02 909-02 109-03 909-03 109-04 909-04 109-05 909-05 109-06 909-06 109-07 909-07 109-08 909-08 109-09 909-09 10910 90910 10911 90911 10912 90912 10913 90913 10914 90914 10915 90915 0055 0240 0004 0207 0047 0229 0042 0222 0045 0223 0039 0219 0029 0214 0037 0217 0026 0214 0018 0211 0066 0245 0048 0228 0031 0206 0067 0235 0046 0226 Fuel Pump Lead, Data Fuel Pump Lead VIT System, Data VIT System 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 Lifting Gear Roller Guide, Data Lifting Gear for Roller Guide Fuel Valve, Data Fuel Valve Spindle Guide, Data Spindle Guide Non-Return Valve for Fuel Valve, Data Non-Return Valve for Fuel Valve Fuel Oil High-Pressure Pipes, Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide, Data Fuel Pump Roller Guide
MAN B&W Diesel A/S
90961 90966 90967 90968 90974 90977 90979 90980
0069 0008 0001 0001 0001 0001 0001 0001
Fuel Valve - Tools Fuel Valve Nozzle - Tools Fuel Puncture Valve - Tools Fuel Valve - Inspection Tools Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals
MAN B&W Diesel A/S
Fuel Pump Settings

Special Edition D10901 S60MC-C 109-1 Data 0055 Fuel Pump Settings
109-1
X X X X
X X
Data
D09-02
Change of one index mark corresponds to pmax being altered approx.
3.0 - 4.0 bar
Page 1 (2)
109-1
Fuel Pump Settings

Data
Page 2 (2)
Fuel Pump Settings

Adjustment
Fuel Pump Settings S60MC-C 0240 Adjustment 909-1.3
909-1.3
Before adjustment of the fuel pump is carried out, see Volume I, Chapter 706, also the fuel cam lead should be checked, see Procedure 909-3.1. pmax adjustment: 1. The Maximum Combustion Pressure (pmax) is adjusted for the individual units at the fuel pump VIT index arm. For collective adjustments of pmax on all units, see Procedure 909-2. 2. Loosen lock nut B and then turn adjusting screw H. The link can be adjusted by approx. 3 index marks. 3. To increase p max, adjust to higher VIT index (advance injection). To decrease p max, adjust to lower VIT index (delay injection). One index mark will alter pmax approximately as given in Data D09-02. Note! The individual pmax value must not deviate more than 3 bar from the average value for all cylinders. 4. If the required pmax adjustment cannot be attained by adjustment on the VIT index arm, it is possible to carry out the adjustment on the fuel cam disc. Contact MAN B&W Diesel for advice.
HN909-1.3 240 01
1.
2.
HN909-1.3 240 02
Page 1 (2)
909-1.3
Fuel Pump Settings

Adjustment
5.
MIP adjustment: 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!
HN909-1.3 240 05
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)
VIT System
Special Edition D10902 S60MC-C 109-2 Data 0004 VIT System
109-2
X X X
Data
Page 1 (2)
109-2
VIT System
Data
Page 2 (2)
VIT System
Adjustment
The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection Timing) system. If the fuel quality has changed or if the fuel pumps are worn, the pmax will change. Adjusting the pmax of all the cylinders is done by adjusting the VIT system in the following way: Mechanical VIT system 1. The pilot valves have been pre-adjusted to 0.5-5.5 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin C. To check a pilot valve already mounted on the engine, remove the inlet and outlet pipe connections at A and P , and connect a pressure gauge at A and a pipe with working air (pressure 7 bar) at P , on the pilot valve.
M90902 0207C01
909-2.1
1.
A B
C Pbar 5 4 3 1.5 2 0.5 1 0.1 0
Curve 2
Check that the pressure on the pressure gauge and the pressing-in of pin C is in accordance with the curve. Any necessary adjustment is done by turning adjusting screw B. 2. Fine adjustment of the pmax pressure in the breakpoint (for all the cylinders) is to be carried out by axial displacement of the bracket with the pilot valve. Release the screw and nut which secure the bracket with the pilot valve to the larger bracket through the slotted holes. Increase the pmax pressure by moving the pilot valve toward the lever. Decrease the pmax pressure by moving the pilot valve away from the lever. See also Volume I, Chapter 703.
0 1 2 3 4 5 6 7 8 0.5
Pressing in mm
2.
M90902 0207C02
Page 1 (2)
909-2.1
VIT System
Adjustment
Electronic VIT system
3. 3. The adjustment should be based on a set of indicator diagrams taken when the engine is running just above the breakpoint. 4. On the panel in the engine room control room, change the poffset value in accordance with the required increase or decrease in the pmax pressure. One graduation mark on the poffset scale corresponds to a change in pmax of 1 bar. 5. Check the adjustment by taking a new set of indicator diagrams while the engine is running just above the breakpoint. 6. The I/P converter mounted on the engine receives a 4-20 mA signal I from the electronic control system and converts this into a 0.5-5.5 bar control air pressure pcontrol.
M90902 0207C03
7. To check the adjustment of the I/P converter, operate the panel in the engine control room to supply various signals I to the I/P converter. For operation of the panel, see the panel manufacturers instructions. On the pressure gauge mounted on the control air line after the I/P converter check that the control air pressures from the I/P converter are in accordance with the curve. 8. If the control air pressure is not in accordance with the curve, the I/P converter must be adjusted. Remove the hood of the I/P converter and adjust the I/P converter according to the manufacturers instructions.
6.
P control P supply
P control
5 4 3 2 I, mA 0 4 8 12 16 20
M90902 0207C02
1.5
1 0.5 0.1 0
Page 2 (2)
Fuel Pump Cam

Special Edition D10903 S60MC-C 109-3 Data 0047 Fuel Pump Cam
109-3
X X X X
X X
Data
Page 1 (2)
109-3
Fuel Pump Cam

Data
P90651 P90951 P91351 P91351 P91351 P91351 P91351 P91351
44 45 10 34 46 117 201 225
Impact wrench for turning cam Measuring tool for fuel pump Hydraulic pump, pneumatic operated Hose with unions (1000 mm), complete Hose with unions (1500 mm), complete 5-way distributor block, complete Quick coupling, male Disc, round-plain, Cu 11x3 mm
Page 2 (2)
Fuel Pump Cam

Checking
Fuel Pump Cam S60MC-C 0229 Checking 909-3.1
909-3.1
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 puncture valve. See Procedure 909-8.2. Make sure that the reversing mechanism is in AHEAD direction.
EN909-3.1 228 00
1.
C
x2
x1 roller guide
fuel cam
2. Push down the measuring pin through the top cover, until it rests against the pump plunger. Turn the engine until the lowest point of the cam is found, use a calliper to find the point. 3. Measure the distance x from the top of the measuring pin to the transverse piece. Note down the result as x2. 4. Turn ahead until the main piston of the cylinder concerned is in TDC. Again measure the distance x from the top of the measuring tool to the transverse piece. Note down the result as x1. Calculate the fuel cam lead C (top lift) as:
ahead
Lowest position of pump plunger
Main piston in TDC
3.
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. Remount the puncture valve.
HN909-3.1 229 03
C = x1 x2 (mm)
4.
HM906-7.0 56 01
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. Note!
HN909-3.3 207 01
Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. 2. Dismount the puncture valve from the fuel pump top cover, and mount the measuring tool to check the cam adjustment. 3. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. If fitted, remove the plugs from the oil ducts (using, for instance, a screwdriver). Insert three copper gaskets in each oil duct. Mount snap-on couplings in the oil ducts, but do not tighten them.
HN909-3.1 229 03
Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulic highpressure pump. 3.
Page 2 (3)
HN909-3.3 207 04
Fuel Pump Cam

Adjustment
4.
909-3.3
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. Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc. Keep the cam pressurised for at least five minutes before turning the cam. Keep the cam pressurised during turning. Turn the cam disc, using the fitted spanner, until the desired change of lead is obtained . To increase lead and p max: turn the cam disc AHEAD. To reduce lead and p max: turn the cam disc ASTERN. See Procedure 909-1. 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 the puncture valve. See Procedure 909-8.4. 8. After any adjustment of the cam position, pmax must be recorded and compared with pmax at a known engine reference load.
HN909-3.3 207 06
Page 3 (3)
Fuel Pump
Special Edition D10904 S60MC-C 109-4 Data 0042 Fuel Pump
109-4
X X X X
X X
Data
D09-18 D09-19 D09-20 D09-21 D09-39
Pump housing nuts, tightening torque Pump housing nuts, tightening angle Pump housing Bottom plate Shock absorber
785 60 200 13 27
Nm kg kg kg
Page 1 (2)
109-4
Fuel Pump
Data
P90951
70 Lifting tool for fuel pump housing
Page 2 (2)
Fuel Pump
Dismantling
Fuel Pump S60MC-C 0222 Dismantling 909-4.2
909-4.2
3. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1. Dismantle the fuel pump top cover. See Procedure 909-5.2. 2. Dismantle the barrel/plunger assembly. See Procedure 909-6.2. 3. Remove the screws holding the fuel oil inlet pipe between the fuel pump and the fuel inlet valve. Remove the fuel oil inlet pipe. Discard the gaskets. 4. Unscrew the nuts at the base of the fuel pump. Fit the lifting tool using the top cover studs/ nuts, and lift the pump housing away. Take care not to damage the threads of the studs. Land the fuel pump on wooden planks.
GN909-4.2 203 03
4.
D09-20
JG909-8.0 71 02
Page 1 (8)
909-4.3
Fuel Pump
Overhaul
Overhaul 909-4.3
3.
1. If the fuel index arm or the VIT index arm of the fuel pump is moving too tightly, the regulating and timing systems of the fuel pump must be overhauled. 2. In order to carry out this overhaul, the top cover and plunger/barrel assembly of the fuel pump must have been removed, and the fuel pump must have been dismantled from the pump base and landed on wooden planks. See Procedure 909-4.2. See Procedure 909-5.2. See Procedure 909-6.2. 3. Dismantle the actuator and actuator bracket.
GN909-4.3 203 03
4.
4. Dismantle the fuel pump shock absorber. If necessary, overhaul the fuel pump shock absorber. See Procedure 909-9.3.
D09-39
Page 2 (8)
HG909-9.2 201 01
Fuel Pump
Overhaul
5.
909-4.3
5. Tilt the fuel pump housing into a horizontal position on the wooden planks. 6. Dismantle the screws and the bottom plate from the fuel pump housing. If the bottom plate is stuck, loosen it by screwing two M10x70 mm screws into the holes of the bottom plate. 7. Dismantle the: Fuel index arm Sleeve Regulating guide
HC909-3.4 121 05
6.
D09-21
HC909-3.4 121 06
7.
HC909-3.4 121 07
Page 3 (8)
909-4.3
Fuel Pump
Overhaul
8.
8. Dismantle the: Guide screw VIT index arm Timing guide 9. Dismantle and inspect the plug screws in both sides of the fuel pump housing. If heavily eroded, replace the plug screws.
HC909-3.4 121 08
Replace the sealing rings and mount the plug screws. 10. Clean all parts thoroughly in diesel oil or kerosene. Blow dry with compressed air. 9. 11. Mount new sealing rings on the unions. Note! Soak the sealing rings in lubricating oil before mounting 12. Clean all inside surfaces of the fuel pump housing.
HC909-3.4 121 09
11.
Page 4 (8)
HC909-3.4 121 11
Fuel Pump
Overhaul
14.
909-4.3
Mounting 13. Lubricate the following with molybdenum disulphide (MoS 2): all internal machined surfaces of the fuel pump housing the sliding surfaces of all parts of the regulating and timing systems. the teeth of the:
HC909-3.4 121 14
regulating guide timing guide VIT index arm fuel index arm. 14. Mount the VIT index and the guide screw. Adjust the position of the VIT index arm so that the scratch mark is aligned with the centre of the fuel pump housing. 15. Mount the timing guide in the fuel pump housing. The timing guide must be mounted in such a way that the scratch mark on the timing guide is aligned with the scratch mark on the VIT index arm, which must be visible through the hole in the timing guide. 16. Mount the sleeve in the fuel pump housing, ensuring that the notch in the side of the sleeve is aligned with the pin hole in the fuel pump housing.
15.
HC909-3.4 121 15
16.
HC909-3.4 121 16
Page 5 (8)
909-4.3
Fuel Pump
Overhaul
17.
17. Mount the fuel index arm. Adjust the position of the fuel index arm so that the scratch mark on the fuel index arm is aligned with the centre of the fuel pump housing. 18. Mount the regulating guide in the fuel pump housing. The regulating guide must be mounted so that the scratch mark on the regulating guide is aligned with the scratch mark on the fuel index arm. 19. Mount the bottom plate on the fuel pump housing.
HC909-3.4 121 18
Page 6 (8)
HC909-3.4 121 06
HC909-3.4 121 17
18.
19.
Fuel Pump
Overhaul
20.
909-4.3
20. Mount the fuel pump shock absorber. 21. Mount the actuator and actuator bracket.
HC909-9.2 201 01
21.
GN909-4.3 203 03
Page 7 (8)
909-4.4
Fuel Pump
Mounting
Mounting 909-4.4
2.
D09-20
1. Before mounting the fuel pump housing, make sure that all sliding faces and threads are cleaned and lubricated with MOLYKOTE antifriction spray D321R or molybdenum disulphide (MoS 2). See Procedure 913-11. 2. Lower the fuel pump housing on to the pump base, taking care not to damage the threads of the studs. Remove the lifting tool. Fit and tighten the nuts at the base of the pump housing. Use either the tightening torque or the tightening angle. See Data. 3. Mount the fuel oil inlet pipe between the pump housing and the inlet valve. 4. Mount the barrel assembly in the fuel pump housing. See Procedure 909-6.4. 5. Mount the top cover on the fuel pump housing. See Procedure 909-5.4. 6. Mount the puncture valve, see Procedure 909-8.4.
D09-18 or D09-19
JG909-8.0 71 02
7. Mount the drain oil pipes, and the compressed air pipes.
3.
Page 8 (8)
GN909-4.2 203 03
Fuel Pump Top Cover

Special Edition D10905 S60MC-C 109-5 Data 0045 Fuel Pump Top Cover
109-5
X X X X
X X
Data
D09-23 D09-24 D09-26 D09-27
Top cover studs, screwing-in torque Top cover nuts, tightening torque Outlet seat, max.grinding diameter Top cover
240 300 26 52
Nm Nm mm kg
Page 1 (2)
109-5
Fuel Pump Top Cover

Data
P90951 P90951
69 Lifting tool for fuel pump 94 Milling tool for fuel oil pipe seats
Page 2 (2)
Fuel Pump Top Cover

Dismantling
Fuel Pump Top Cover S60MC-C 0223 Dismantling 909-5.2
909-5.2
1. Shut off the fuel oil inlet. Open the drain cock (at the bottom of the pump housing), and drain off any oil left in the high-pressure pipe and the fuel pump. Note ! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Dismount all drain pipes and the pipe connections to the puncture valve. Dismount the high-pressure pipes between the top cover and the fuel valves. See Procedure 909-14.2. Note ! If the puncture valve is to be overhauled, remove the puncture valve from the top cover at this stage. See Procedure 909-8.2. 2. Remove the top cover fixing nuts and mount the dismantling screws for top cover in the two threaded holes. Pull the top cover with suction valve and puncture valve (if still mounted) free by tightening the dismantling screws. When the top cover is loose, remove the dismantling screws and mount the lifting tool in the threaded holes instead. 3. Lift the top cover carefully off. For overhaul of top cover, puncture valve and suction valve, see Procedures 909-5.3, 909-7.3, 909-8.3. Discard the gasket.
GN909-5.2 204 03 GN909-5.2 204 01
1.
2.
GN909-5.2 204 02
3.
D09-27
Page 1 (3)
909-5.3
Fuel Pump Top Cover

Overhaul
Overhaul 909-5.3
2.
1. If not already done, dismount the protective cap and the puncture valve from the top cover. See Procedure 909-8.2. 2. Dismantle the suction valve and the lock washer from the top cover. See Procedure 909-7.2. 3. Fill the oil ducts of the top cover with vaseline or heavy grease. Screw the guide, with the miller, into the high-pressure pipe thread. Mill the seat until a smooth surface is achieved. For maximum seat diameter see Data.
HM909-3.3 74 03
3. After completing the milling, use compressed air to blow the vaseline/ grease out from the oil ducts.
D09-26
Clean the top cover with diesel oil/gas oil, and blow dry with compressed air. Note! Make sure that all bores and threads inside the top cover are absolutely clean.
GN909-5.3 204 04
If necessary, recondition the seats of the fuel oil high-pressure pipes. See Procedure 909-14. 3. 4. 4. Mount a new lock washer and a new or overhauled suction valve in the top cover. See Procedure 909-7.4.
Page 2 (3)
HM909-3.3 74 13
Fuel Pump Top Cover

Mounting
Mounting 909-5.4
909-5.4
1. Make sure that the inside of the fuel pump housing and the top of the fuel pump barrel is completely clean. 2. Mount a new gasket on top of the pump housing. Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide (MoS 2). See Procedure 913-11. Mount the overhauled top cover (with overhauled suction valve and reconditioned seatings for the high-pressure pipes) on the pump housing. Check that the guide pin in the top cover enters the hole in the pump housing. Warning ! As a safety precaution, and before mounting the top cover nuts, turn the engine one revolution. When doing this, the top cover must not move upwards! 3. Mount the top cover fixing nuts, and tighten them diagonally to the torque indicated in Data. For adjustment of the fuel pump, see Procedure 909-1.1. 4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure 909-8.4. Mount the protective cap over the puncture valve and the two screws in the top cover. Mount the high-pressure pipes and the drain screw in the pump housing. Mount the drain pipes on the top cover and the connecting pipe to the puncture valve. Open the fuel oil inlet.
GN909-5.4 204 04
1.
D09-27
GN909-5.2 204 03
3.
D09-24
GN909-5.4 204 03
4.
Page 3 (3)
Fuel Pump Barrel Assembly

Special Edition D10906 S60MC-C 109-6 Data 0039 Fuel Pump Barrel Assembly
109-6
X X X X
X X
Data
D09-29 D09-30
Barrel assembly Plunger
48 kg 11 kg
Page 1 (2)
109-6

Data
P90951 P90951 P90962
57 224
Lifting tool for fuel pump Tool for pmax rack Fuel pump seals mounting tools
Page 2 (2)

Dismantling
Fuel Pump Barrel Assembly S60MC-C 0219 Dismantling 909-6.2
909-6.2
1. Shut off the fuel oil inlet. Open the drain cock (at the bottom of the pump housing), enabling the oil which is left in the high-pressure pipe and the fuel pump to escape. Note! 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. Dismount the pipe connections to the puncture valve. Dismount the fuel oil high-pressure pipes. See Procedure 909-14-2. 2. If the top cover is to be overhauled, dismount the puncture valve. See Procedure 909-8.2. 3. Dismount the fuel pump top cover. See Procedure 909-5.2.
1.
GN909-5.2 204 01
2.
HN909-8.2 207 03
3.
GN909-5.2 204 03
Page 1 (9)
909-6.2

Dismantling
4.
4. Position the lifting tool for the barrel/plunger assembly (without measuring pin) in such a manner that the two distance tubes of the tool rest on the pump barrel. Make sure that the two guide pins in the bottom of the lifting tool enter the holes in the top of the plunger. Secure the lifting tool by screwing the two screws into the pump barrel.
GN909-6.2 204 01
Loosen the stop ring on the spindle of the tool and press the spindle down against the pump plunger. Turn the spindle in this position until the two guide pins engage with the two holes in the plunger top. Tighten the centre screw of the spindle against the plunger. 5. Remove the pump barrel guide screw from the pump housing.
5.
MB909-3.1 95 05
6. Disconnect the links for the timing drive and the regulating drive. Dismount the union and pointer for the timing drive and the regulating drive. 6. Note the position of the scratch mark on the lever arm. Remove the locking plate and the lever arm. Mount the extractor tool and connect the timing toothed rack to the pulling rod by means of the pin.
Page 2 (9)
GN909-6.2 204 03

Dismantling
7.
909-6.2
7. Turn the nut at the end of the pulling rod, whereby the timing rack will move outwards. Continue turning the nut until the pin reaches the outer position of the slot in the tool, whereby the thread of the fuel pump barrel goes clear of the timing guide. Keep the toothed rack in this position during the overhaul or replacement of the pump barrel. There is now a distance between the lifting tool and the pump housing. 8. Pull the regulating toothed rack outwards until the plunger foot has been turned clear of the bayonet joint in the roller guide. This can be ascertained by watching the handles on the spindle of the lifting tool. These will be parallel with the fore-and-aft direction of the engine when the plunger has been turned into position. Remove the cover of the pump base to make sure that the plunger is able to go clear of the bayonet joint. Lift the spindle so that the plunger foot goes clear of the bayonet joint. Move the stop ring of the spindle into contact with the upper flange of the tool, and lock the stop ring in this position by means of the stop screw. 9. Carefully lift the barrel/plunger assembly out of the pump housing. Dismount the tool. Press the plunger upwards to the bottom of the barrel. Send the barrel/plunger assembly to an MAN B&W authorized workshop for repair, or overhaul it on board as described in Procedure 909-6.3.
GN909-6.2 204 04
8.
GN909-6.2 204 05
9.
D09-29
GN909-6.2 204 06
Page 3 (9)
909-6.3

Overhaul
Overhaul 909-6.3
1.
1. Clean the outside of the barrel. Set up the pump barrel/plunger in a bench vice provided with soft jaws. Remove and discard the sealing rings from the barrel. 2. Pull the plunger carefully out of the barrel. Carefully clean the plunger (for example in clean kerosene) and wipe dry with a clean piece of cloth. Also clean the bores in the top of the plunger. Clean the barrel and wipe dry with a clean piece of cloth.
D09-29
MB909-3.2 95 01
2.
For evaluation of pump barrel/plunger, see Volume I, OPERATION, Chapter 706. 3. Before mounting new sealing rings on the barrel, heat them in 100C hot water for at least five minutes. 4. When mounting the new sealing rings on the lower end of the pump barrel, the inner sealing ring must be mounted first.
D09-30
MB909-3.2 95 02
Mount the guide stick in the barrel and position the big cone on the barrel. Place the spring-loaded sealing ring on the cone with the spring facing upwards, see the sketch.
4.
Use the pusher tool to push the sealing ring into the groove.
Page 4 (9)
MB909-3.2 95 04

Overhaul
5.
909-6.3
5. When mounting the sealing ring in the outer groove, place the spacer tool inside the cone to obtain the correct distance to the groove, and repeat the above procedure. After mounting the sealing rings, compress them by pressing the sizer tool over the sealing rings. 6. Mount the guide stick and cone on the top end of the barrel and mount the uppermost sealing ring in the same way as above.
MB909-3.2 95 05
Make sure that the spring faces downwards, see the sketch. 7. Lubricate the plunger with molybdenum disulphide (MoS 2). Carefully slide the plunger into the barrel and press it to the bottom. Note! Do not use force as this will damage the sliding surfaces of the plunger or barrel If the barrel assembly is not to be mounted immediately, all openings must be covered with plastic to prevent dirt from entering the barrel assembly during storage.
6.
MB909-3.2 95 06
7.
MB909-3.2 95 07
Page 5 (9)
909-6.4

Mounting
Mounting 909-6.4
1.
1. Place the supplied measuring pin which is of the same length as the plunger on the spindle of the lifting tool, and fasten it by tightening the centre screw of the spindle. Loosen the stop ring on the spindle. Place the tool on the pump housing, and press the spindle down until the pointed end of the measuring pin is in contact with the thrust piece of the roller guide. Then press the stop ring down until it reaches the flange of the tool and lock it there by tightening the screw of the stop ring against the spindle. The stop ring is to remain tightened in this position until the plunger has been correctly mounted. The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. 2. Dismount the tool from the pump housing and remove the measuring pin from the spindle. Then mount the tool on the barrel/ plunger assembly which is ready for mounting. Secure the tool to the barrel by tightening the two screws, and attach the plunger to the spindle of the tool by tightening the centre screw of the spindle. The tool is thus fixed on the barrel in such a way that its correct positioning is ensured during mounting. Before mounting the barrel/plunger in the pump housing, lubricate the thread for the timing guide and all sealing rings with molybdenum disulphide. Using the spindle of the tool, pull the plunger as high up in the barrel as possible, at the same time turning the spindle so as to position the plunger foot correctly in relation to the cutout of the regulating guide.
HN909-6.4 207 01
2.
Page 6 (9)
HN909-6.4 207 02

Mounting
3.
909-6.4
3. Pull the regulating toothed rack as far out as possible and check that the extractor tool is mounted correctly on the timing toothed rack when this is in its outer position. 4. Check that the slot in the barrel coincides with the hole for the guide screw. Lower the barrel assembly carefully into the pump housing. If necessary, turn the regulating guide a little (using the toothed rack) to make the foot and the regulating block of the plunger fit properly in the cutout of the regulating guide. Lowering the barrel assembly so far down into the pump housing that the sealing rings of the barrel are about to enter the bore in the pump housing. Then continue pressing down the barrel/ plunger assembly until the barrel assembly rests on top of the timing guide. There will be a gap between the tool and the pump housing.
GN909-6.4 204 03
4.
D09-29
GN909-6.4 204 04
Page 7 (9)
909-6.4

Mounting
5.
5. Loosen the nut on the extractor, disconnect the pulling rod from the timing toothed rack, and remove the extractor. Engaging the thread of the fuel pump barrel with the timing guide is accomplished by pressing-in the toothed rack. (A pressure of about 30 kg may be required). Check that the toothed rack is correctly engaged by pressing-in the rack. When doing this, the pump barrel shall move downwards. The top flange of the tool is now resting on the top of the pump housing. 6. After landing the barrel assembly, press the plunger down into contact with the thrust piece of the roller guide. Check that the stop disc of the spindle is in full contact with the flange of the tool, as when measuring.
GN909-6.4 204 05
6. If necessary, turn the regulating guide a little (using the toothed rack) to make the plunger foot fit properly in the cutout of the roller guide. Inspect the position of the plunger foot through the inspection hole. When the plunger is in place, press the regulating rod in, thereby turning the plunger by means of the regulating guide and causing the plunger foot to interlock with the bayonet joint of the roller guide. Check that the plunger is correctly engaged by pulling at the spindle of the lifting tool. When doing this, it must not be possible to lift the spindle. Mount the inspection hole cover.
Page 8 (9)
GN909-6.4 204 06

Mounting
7.
909-6.4
7. Mount the pointer and union for the timing rack. Mount the links for the timing drive and the regulating drive in place in accordance with the marks. 8. Mount the guide screw for the pump barrel in the pump housing. Remove the centre screw from the plunger, and remove the tool. 9. Mount the top cover without mounting the nuts. Turn the engine one revolution, and check that the top cover does not move upwards. If the top cover does move upwards, the barrel/plunger assembly has to be removed and re-inserted. 10. Mount the fuel pump top cover, including the nuts. See Procedure 909-5.4.
GN909-6.4 204 07
8.
GN909-6.4 204 08
Page 9 (9)
Fuel Pump Suction Valve

Special Edition D10907 S60MC-C 109-7 Data 0029 Fuel Pump Suction Valve
109-7
Data
D09-33 D09-34
Suction valve, tightening torque Suction valve
900 Nm 4 kg
Page 1 (2)
109-7

Data
P90951 P90967
128
Crowfoot wrench head Fuel puncture valve tools
Page 2 (2)

Checking
Fuel Pump Suction Valve S60MC-C 0214 Checking 909-7.1
909-7.1
1. Using a brass mandrel, check that the valve slide can slide freely up and down inside the suction valve. 2. Check the seats for tightness by filling the inlet hole with diesel oil or gas oil, and wait five minutes. No oil may seep through the seats of the slide/housing. 3. If the suction valve is not to be mounted on the engine immediately after the checking, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.
1.
HN909-7.1 207 01
2.
KB909-3.3 105 08
Page 1 (4)
909-7.2

Dismantling
Dismantling 909-7.2
1.
1.
Note! Before dismantling the top cover, it is recommended to dismantle the fuel pump puncture valve, see Procedure 909-8.2. Dismantle the fuel pump top cover and suction valve assembly from the fuel pump housing. See Procedure 909-5.2.
2. Mount two eye bolts in the bottom of the top cover and turn it upside down. 3. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. 2. Release the suction valve lock washer. Dismount the suction valve from the top cover. Remove and discard the lock washer.
GN909-5.3 204 02 GN909-5.2 204 03
3.
Page 2 (4)
KN909-7.2 213 03

Overhaul
Overhaul 909-7.3
909-7.3
1. Set up the suction valve in a bench vice with soft jaws and, using a brass mandrel and a hammer, release the spring guide from the valve thrust piece. Disassemble the other parts of the suction valve and clean the parts thoroughly in clean diesel oil. Remove and discard the sealing ring from the valve thrust piece. 2. Inspect the seat of the valve slide and the seat in the thrust piece for damage. If the seats are damaged, both the suction valve and the valve slide must be discarded. Lapping of the seats must not be attempted. 3. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust piece. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the groove. Note! Make sure that the sealing ring is mounted correctly. See the sketch. After mounting the sealing ring, compress it by pressing the sizer tool over the sealing ring. 4. Clean and overhaul all internal parts, and lubricate them with molybdenum disulphide (MoS 2). 5. Re-assemble the suction valve. 6. Check the suction valve after the overhaul. See Procedure 909-7.1.
1.
KB909-3.3 105 05
2.
KB909-3.3 105 06
3.
XZ909-7.3 204 03
Page 3 (4)
909-7.4

Mounting
Mounting 909-7.4
1.
D09-33
1. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. Lubricate the thread of the suction valve with copper grease. Make sure that the bore for the suction valve in the top cover is absolutely clean. Fit a new lock washer and mount a new or overhauled suction valve in the top cover. Fit the two screws which secure the lock washer. Tighten the suction valve with a torque spanner. See Data. Lock the suction valve in position by bending up an edge of the lock washer over one of the flats of the valve. 2. Remove the top cover from the bracket and mount the top cover in the fuel pump housing. See Procedure 909-5.4.
KN909-7.4 213 01
2.
Page 4 (4)
GN909-5.2 204 03
Fuel Pump Puncture Valve

Special Edition D10908 S60MC-C 109-8 Data 0037 Fuel Pump Puncture Valve
109-8
Data
D09-35 D09-36
Puncture valve, tightening torque Puncture valve
890 Nm 5 kg
Page 1 (2)
109-8

Data
P90951
128
Crowfoot wrench head
Page 2 (2)

Dismantling
Fuel Pump Puncture Valve S60MC-C 0217 Dismantling 909-8.2
909-8.2
1. Shut off the fuel oil inlet. Open the drain cock at the bottom of the pump housing and drain off any oil left in the fuel oil high-pressure pipe and fuel pump. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismantle the control air pipe and the protective cap above the puncture valve. 3. Unscrew and remove the puncture valve from the fuel pump top cover.
HN909-8.2 207 02
2.
4. After dismantling it is recommended always to overhaul the puncture valve. If the overhaul cannot take place immediately after the dismantling, it is recommended to place the puncture valve immersed in diesel oil until the overhaul.
3.
HN909-8.2 207 03
Page 1 (4)
909-8.3

Overhaul
Overhaul 909-8.3
1.
1. Remove and discard the O-rings from the puncture valve. Set up the puncture valve in a bench vice with soft jaws. Loosen and remove the four screws and dismount the plug. Use a screw to remove the air piston from the housing. Remove and discard the sealing rings from the air piston. Disassemble the other parts of the puncture valve, using a brass mandrel and a hammer. Take care not to damage the valve seat. Thoroughly clean all the parts in clean diesel oil. 2. Inspect the conical seats of the valve housing and the valve slide for wear marks or scratches. If the seats are damaged, the valve housing and the valve slide must be discarded. Lapping of the valve seats must not be attempted.
HN909-8.3 207 01
2.
Page 2 (4)
HG909-8.2 201 02

Overhaul
3.
909-8.3
3. When mounting the new sealing rings on the spindle of the air piston, the inner sealing ring must be mounted first. Mount the O-ring in the ring groove and position the large cone on the spindle. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the O-ring in the groove. After mounting the sealing ring, compress it by pressing the sizer' tool, over the sealing ring. Mount the outer sealing ring in the groove using the short cone, and repeating the above procedure. 4. The new sealing ring is mounted on the head of the air piston in accordance with the same procedure as above. Before assembling the puncture valve, lubricate all parts with MOLYKOTE anti-friction SPRAY D321R or molybdenum disulphide (MoS 2). Mount new O-rings on the housing. 5. 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.
GM909-3.3 89 10
4.
GM909-3.3 89 12
Page 3 (4)
909-8.4

Mounting
Mounting 909-8.4
2.
1. Make sure that the bore for the puncture valve in the fuel pump top cover is absolutely clean. If this has not already been done, mount new O-rings on the puncture valve. Lubricate the thread of the puncture valve with copper grease.
D09-35
2. Screw the puncture valve into the bore in the top cover. Using a crowfoot wrench and a torque spanner, tighten the puncture valve to the torque stated in Data. 3. Mount the protective cap and the control air pipe on top of the puncture valve. 4. If open, close the drain cock on the fuel pump and open the fuel oil inlet valve.
HN909-8.4 207 02
3.
Page 4 (4)
HN909-8.4 207 03
Fuel Pump Shock Absorber

Special Edition D10909 S60MC-C 109-9 Data 0026 Fuel Pump Shock Absorber
109-9
X X X X
Data
D09-39
Shock absorber
27 kg
Page 1 (2)
109-9

Data
Page 2 (2)

Checking
Fuel Pump Shock Absorber S60MC-C 0214 Checking 909-9.1
909-9.1
To ensure satisfactory operation, the functioning of the fuel pump 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. 1. Remove the plug from the end cover of the shock absorber. Check that air is pulsating through the threaded hole. Short bursts of air should be felt against the hand, corresponding to the strokes of the fuel pump. The air pulses occur when the shock absorber piston is working and the air below the piston is being compressed and forced out through the threaded hole. 2. To check the tightness of the piston, measure the amount of leakage oil flowing from the drain pipe of the shock absorber housing. Note down the amounts measured and compare with earlier measurements. Increasing amounts indicate a deteriorating piston sealing. Excessive amounts indicate that the shock absorber requires overhauling. See Procedure 909-9.3.
HM909-4.0 09 01
Page 1 (3)
909-9.3

Overhaul
Overhaul 909-9.3
1. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1. Remove the shock absorber drain pipe. Place a wire strap around the shock absorber and hook on the engine room crane. Loosen the screws holding the shock absorber and remove it from the fuel pump housing. 2. Remove the plug from the end cover of the shock absorber. Fit a threaded rod between the piston and the end cover to counteract the force of the springs. Loosen the screws of the end cover and remove the end cover and piston. Discard the gasket. 3. Loosen the nut on the threaded rod to 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. 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. 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. 6. Mount the end cover. For tightening the nuts, see Data. Lock with the locking device. Remove the threaded rod and insert the plug.
HG909-9.2 201 04
D09-39
GN909-9.3 204 01
2.
HG909-9.2 201 02
4.
Page 2 (3)

Overhaul
909-9.3
7. Fit a new gasket on the fuel pump housing and mount the shock absorber. Mount the shock absorber drain pipe. If an excessive amount of drain oil is still observed after the overhaul, the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning.
Page 3 (3)
Lifting Gear for Roller Guide

Data
X X X X X X X
109-10
Data
When referring to this page, please quote D10910 Edition 0018 MAN B&W Diesel A/S
Page 1 (2)
109-10
Lifting Gear for Roller Guide

Data
Plate P90951 Item No. 307 Pulling tool bell shaped Description
Page 2 (2)
Lifting Gear
Checking
Lifting Gear S60MC-C 211 Checking 909-10.1
909-10.1
1. Caution! Do not use the lifting tool for the fuel pump roller guide while the engine is running. If a fuel pump is to be put out of action, disconnect it in the following manner: 1. Stop the engine and engage the turning gear. Remove the inspection cover on the upper part of the camshaft housing in front of the fuel cam for the pertaining roller guide. Turn the engine until the roller is in the highest position on the cam (on the circular section of the cam). 2. Loosen the lock screw on top of the flange and the nut on the lifting tool. Press the shaft against the roller guide. When the shaft has been pressed fully in, the guide screw is positioned in line with the vertical slot of the flange.
HN909-10.1 205 01
2.
When referring to this page, please quote Procedure 909-10.1 Edition 211 0$1 % : 'LHVHO $6
HM909-5.0 44 1/2
Page 1 (2)
909-10.1
Lifting Gear
Checking
3.
3. Mount a socket spanner, a slide-T handle and an extension pipe on the shaft, and turn the shaft anti-clockwise until the guide screw is in top of the slot, which indicates that the roller guide is in the lifted position. 4. Lock the shaft in this position by tightening the lock screw and the nut on the lifting tool. Check through the inspection cover opening that the roller guide is clear of the fuel cam. The engine can now operate on the remaining cylinders, see Volume I, Section 704.
HN909-10.1 211 03
Re-engagement of the fuel pump roller guide 4. Caution! Re-engagement of the fuel pump roller guide must only take place when the engine is at a standstill. 5. Turn the engine until the circular section of the pertaining fuel cam is positioned upwards, and then lower the roller guide in the reverse order to lifting. NB! Remember to loosen the lock screw.
HM909-5.0 44 2/2
6.
6. When the roller guide has been lowered into the position where the guide screw is in the lowermost position, tighten the lifting tool nut against the flange whereby the lifting tool will be pulled away from the roller guide. The guide screw will now be positioned at the end of the horizontal part of the slot of the flange. Tighten the lock screw.
Page 2 (2)
HN909-10.1 205 05
Fuel Valve
Data
X X X X X X
109-11
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 lubricating oil pumps Engage turning gear Shut off cooling water
Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
D09-40 D09-42 D09-43
Fuel valve opening pressure Inlet seat, max. diameter Fuel valve
300 - 380 25 13
bar mm kg
Page 1 (2)
109-11
Fuel Valve
Data
Plate P90151 P90951 P90951 P90951 P90961 P90966 Item No. 71 94 165 297 Dismantling tool for fuel valve Milling tool for fuel oil pipe seats Grinding mandrel for valve head Assembling tool for fuel valve Fuel Valve tester, complete Fuel Valve Nozzle - Tools Description
Page 2 (2)
Fuel Valve
Checking
1. Fuel Valve 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. 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. 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. See Procedure 909-11.3 and 909-12.3.
M90911 0245C01
909-11.1
Note! In the event that the slide-type fuel valve is pressure tested without being cleaned between the fuel nozzle and the cut-off slide, the opening pressure value measured might be considerably lower than specified. All fuel valves must be function-tested before being mounted in the cylinder cover. Pressure testing pump 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 supplier's instructions. Note that the high-pressure pump should be periodically checked in accordance with the supplier's instructions. 2. Spring housing To ensure that over tightening has not taken place, check that the locking/indicating pin has not been bent or broken off. In the event of over tightening, replace the spring housing by a new one.
2.
M90911 0240C02
Page 1 (13)
909-11.1
Fuel Valve
Checking
3. Setting-up the fuel valve
3. Place the fuel valve in the test rig and secure it with the spring housings and nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housings. Mount the oil pipe between the pressure testing pump and the fuel valve.
Pressure testing procedure The following functions of the fuel valve must be checked: Flushing and jet control Opening pressure Sealing test and sliding function Pressure test, O-ring sealing 4. Flushing and jet control Remove air in the system and check the fuel jet in the following way. Slowly increase the oil pressure until straight jets of oil are ejected from the nozzle holes (no atomization). Acceptance criteria:
M90911 0240C04
M90911 0242C03
4.
There is to be a continuous jet of oil through at least one of the nozzle holes. Owing to the geometry of the internal part of the nozzle - and because of the height to which the spindle is lifted during pressure 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. Cause of fault: If the jets do not fulfil the above point, the cause may be: Dirt in the nozzle holes The nozzle is not mounted correctly
Page 2 (13)
Fuel Valve
Checking
5. Opening pressure 5. To check the opening pressure, increase the oil pressure until oil is admitted through the nozzle holes. Acceptance criteria: Check the opening pressure on the pressure gauge and compare with Data D09-40 on the datasheet. Note! Do NOT attempt to carry out an atomization test on the slide type fuel valvs, as this may damage the cut-off slide and nozzle. Cause of fault: If the opening pressure is higher than specified in D09-40, the cause may be that a wrong type of spring is used - replace the spring on the thrust spindle, if necessary, replace the complete thrust spindle. If the opening pressure is lower than specified in D09-40, the cause may be that the spring has sagged - replace the spring, or add a special thin disc. Note! Special thin discs are available as spares. If a spring or a disc has been changed, the pressure testing procedure of the fuel valve must be repeated.
909-11.1
D09 40
M90911 0240C05
Page 3 (13)
909-11.1
Fuel Valve
Checking
6. Sealing test and sliding function To check the needle valve seat for tightness and the slide for correct closing. Slowly increase the oil pressure to about 50 bar below the opening pressure. Maintain the built-up pressure by closing for the oil supply. Acceptance criteria: Oil must not flow from the nozzle holes.
6.
M90911 0240C06
The pressure drops relatively slowly to about 15 bar, after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). Note! Oil flows out of the leak oil outlet when the fuel valve is full of oil. Cause of fault: If oil flows out of the nozzle holes, the cause is either: Defective spindle guide at needle seat, or a sticking spindle. Examine and/or replace the spindle guide. See Procedure 909-12.3. Too quick pressure drop: - the clearances of the movable parts, both of the spindle guide and of the non-return valve, are too large, or the seats between the thrust piece/spindle in the spindle guide or thrust piece/valve slide in the non-return valve are damaged. Examine and/or replace both the spindle guide and non-return valve. See Procedure 909-12.3. See Procedure 909-13.3. If a quick pressure drop from 15 to 0 bar cannot be registered: The valve slide is sticking; The vent hole in the thrust piece is blocked. or
If so, disassemble and examine the spindle guide, replace if necessary. See Procedure 909-12.3.
Page 4 (13) When referring to this page, please quote Procedure M90911 Edition 0245 MAN B&W Diesel A/S
Fuel Valve
Checking
7. Pressure test, O-ring sealing 7. To ensure that the leak oil (circulation oil) remains in the closed system, build up a working pressure of about max. 10 bar until oil flows out of the leak oil outlet. Close the leak oil outlet with a gasket and plug screw. Increase the working pressure to about 100 bar. Acceptance criteria: The built-up pressure of about 100 bar should be maintained. Cause of fault: If oil leaks out at the union nut, the O-ring inside the fuel valve head is defective, and must be replaced. 8. Atomization test
Max. 100 bar Max. 100 bar Max. 10 bar
909-11.1
Note! Do NOT attempt to carry out an atomization test on slide type fuel valves, as this may damage the cut-off slide and nozzle. 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. All of these conditions involve the risk of seizure between the cut-off slide and the nozzle. 8.
M90911 0240C08
M90911 0240C07
Page 5 (13)
909-11.2
Fuel Valve
Dismantling
1. Close the fuel oil inlet and outlet valves, and drain the high-pressure pipe and the fuel valve. Dismantle and remove the fuel oil highpressure pipe. See Procedure 909-14.2. Disconnect the return oil pipe from the fuel valve. 2. Remove the nuts and the spring housings.
1.
M90911 0240D01
3. Take out the valve. If the valve is sticking, use the fuel valve dismantling tool to pull the fuel valve clear of the top cover. If the valve is not to be overhauled immediately, the valve should be placed immersed in diesel oil until overhauling.
2.
M90911 0240D02
3.
D09 43
Page 6 (13)
M90911 0239D03
Fuel Valve
Overhaul
When fuel valves are overhauled, all parts should be handled carefully and be kept clean. 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. Place the valve holder in a machine vice, mount the fuel valve in the holder and fit the valve with the guide disc from the grinding tool. 3. Compress the fuel valve and the spring inside, by means of a drilling machine, to avoid seizures in the union thread. Hold the fuel valve compressed and unscrew the union nut with a hook spanner. Remove the valve from the valve holder.
M90911 0240O01
909-11.3
1.
2.
M90911 0240O02
3.
M90911 0240O03
Page 7 (13)
909-11.3
Fuel Valve
Overhaul
4. Pull the valve head clear of the valve housing. Remove the: Non return valve Thrust spindle parts Thrust foot Spindle guide and fuel nozzle from the valve housing. Remove and discard all the O-rings.
4.
Page 8 (13)
M90911 0245O04
Fuel Valve
Overhaul
5. Carefully clean and examine all surfaces of the: Fuel valve housing Fuel valve head Thrust spindle If necessary, grind the seating surfaces by means of the grinding mandrels supplied and a fine-grain abrasive (such as Carborundum No. 500). This grinding must only be carried out manually. After the grinding, wash the parts in gas oil and blow clean by means of compressed air to remove any remains of the grinding compound. In the event of more serious damage to the seating surface for the high-pressure pipe in the valve head, the milling tool can be used. Normally, the milling tool is turned by hand, but it may be fitted in the chuck of a column-type drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. 100 r/min). An ample supply of cutting emulsion must be used.
909-11.3
5.
Note! Take care not to exceed the maximum diameter of the seat, see Data.
M90911 0242O05
Page 9 (13)
909-11.3
Fuel Valve
Overhaul
6. 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. See Procedure 909-12.3.
6.
Note! Do not attempt to remove the fuel nozzle from the spindle guide unless the spindle guide has been dismantled. Otherwise the cut-off slide on the spindle may be damaged. 7. The non-return valve should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the non-return valve may be overhauled on board. See Procedure 909-13.3. 8. 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 was 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.
Page 10 (13)
M90802 0253D05
M90911 0240O06
M90911 0240O05
7.
8.
Fuel Valve
Overhaul
9. Mount: the thrust foot the parts of the thrust spindle the non-return valve in the fuel valve housing. Mount a new O-ring in the uppermost groove of the fuel valve housing. Lubricate the thread of the valve head with molybdenum disulphide (MoS2). For the correct use of this lubricant, see Procedure 913-11. Fit the valve head with new O-rings. 10. Make sure that the guide pin between valve housing and valve head is intact, and press the valve head down into the valve housing. See that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts.
909-11.3
9.
M90911 0240O09
M90911 0242O09
10.
MoS 2
Page 11 (13)
909-11.3
Fuel Valve
Overhaul
11. Assemble the valve by means of the union nut. Place the valve in the valve holder in a drilling machine. Compress the fuel valve and the spring inside. Keep the valve compressed and tighten the union nut with a hook spanner. After overhaul, the fuel valve must be tested in the test rig. See Procedure 909-11.1. 12. If the fuel valve is not to be mounted in the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.
11.
Page 12 (13)
M90911 0240O10
Fuel Valve
Mounting
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 the valve bores in the cylinder cover, see Procedure 901-1.3). If not already done, mount new O-rings on the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2). 2. Mount the valve in position in the cylinder cover. Mount the spring housings and the nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housing. This must be done with great care, as the spring tension in the housing determines the correct tightening of the fuel valve to the cylinder cover as well as the correct compression of the fuel valve. 3. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting. Note! It is recommended to overhaul the fuel oil high-pressure pipe before mounting. See Procedure 909-14.3. As a minimum, the distance between the fuel oil pipe ends and the thrust bushings must be checked and, if necessary, adjusted. Mount the overhauled fuel oil high-pressure pipe and the return oil pipe. See Procedure 909-14.4.
M90911 0239M01
909-11.4
1.
D09 43
MoS 2
2.
Note! All fuel valves must be function-tested before being mounted in the cylinder cover, see Procedure 909-11.1.
M90911 0242M03
M90911 0245M02
3.
Page 13 (13)
Fuel Valve Spindle Guide

Data
109-12
Data
Ref. D09-70 Description Nozzel spray hole cleaning tool table Value Unit
Nozzel spray hole
Cleaning drill
Test pin
Nozzel spray hole
Cleaning drill
Test pin
0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55
0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50
0.94 0.99 1.04 1.09 1.14 1.20 1.24 1.30 1.34 1.39 1.44 1.49 1.54 1.59
1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25
1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.65 1.70 1.74 1.80 1.85 1.89 1.94 1.99 2.05 2.09 2.14 2.19 2.24 2.29
Page 1 (2)
109-12

Data
Plate P90966 Item No. Fuel Valve Nozzle - Tools Description
Page 2 (2)

Overhaul
909-12.3
Note! This instruction is only valid for spindle guides of the slide valve design. Extreme care and accuracy should be exercised when carrying out this operation. Based on service experience it is recommended to replace the complete spindle guide after 16000 hours of operation. 1. Clean the outside of the spindle guide in pure gas oil or similar. The individual parts of the spindle guide are not interchangeable, therefore only one guide is to be disassembled at a time. Note! The spindle guide, thrust piece and spindle are matched parts and may not be re-placed individually. 2. Place the spindle guide in a bench vice provided with soft jaws, and use the brass mandrel as shown to disassemble the spindle guide. 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. Note! The pulling tool is not standard for all engines, but may be delivered as an optional extra. 4. If no pulling tool is available, the fuel nozzle can be dismantled from the spindle guide using two screwdrivers. Place the screwdrivers opposite each other in the small gap between the fuel nozzle and the spindle guide and very carefully force the fuel nozzle off the spindle guide.
2.
M90912 0228O04
M90912 0228O02
4.
Page 1 (5)
909-12.3

Overhaul
5. Clean all the parts of the spindle guide in gas oil and wipe dry with a clean piece of cloth. Clean all parts again in gas oil or Electrocleaner and wipe dry with a clean piece of cloth. Place all the parts on a clean, soft, lint-free cloth and examine them through an 8-10 times magnification magnifying glass and an inspection lamp. During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts. 6. Remove any deposits or very fine scratches by placing the spindle, thrust piece or spindle guide respectively in a lathe, as shown, and polishing 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! The sliding surface of the cut-off slide may only be polished VERY carefully. The sliding surface must not be damaged. 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.
5.
Page 2 (5)
M90912 0228O06
M90912 0228O05
6.

Overhaul
7. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. Clean the fuel nozzle with gas oil and wipe dry with a clean cloth. 8. Read the nominal hole size on the cylindrical part of the nozzle, as shown in the figure. The hole size is given in 1/100 mm. Depending on the engine model, there can be one or more different sizes of the holes. Find the correct drill size and matching test pin in the table, D09-70, on the data sheet, via the nominal hole size. 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. Then test the spray holes with the test pin. If the test pin is able to enter just one of the holes, the fuel nozzle must be discarded. This also applies to nozzles with oval holes (can be ascertained with a magnifying glass). Check the fuel nozzle before mounting on the spindle guide, the cut-off slide must be able to move freely inside the nozzle. Note! It is recommended that the fuel nozzle is changed whenever the spindle guide is being overhauled or at maximum 8000 running hours. 8.
1 2 3 4
909-12.3
7.
M90912 0228O08
M90912 0228O07
XXXXXX
X X X*XXX XX
9.
M90912 0228O09
Page 3 (5)
909-12.3

Overhaul
10. Lubricate the spindle and the thrust piece with the cut-off slide with a little Molybdenum Disulphide (MoS2), see Procedure 91311. 11. Assemble the thrust piece, the spindle and the spindle guide and carefully knock the parts together using a soft hammer. 12. Shake the spindle guide back and forth. The spindle with the cut-off slide must be able to slide freely back and forth inside the spindle guide, with a clicking sound.
11.
Page 4 (5)
M90912 0228O12
M90912 0228O11
12.

Overhaul
13. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS2). See Procedure 913-11. Mount the nozzle on the spindle guide. Make sure that the half-circle shaped groove on the nozzle and the spring pin are in line. If nozzle and spindle guide are provided with scratch marks opposite the spring pin, they must be in line. Place the parts on the plane of a drilling machine or hydraulic press and position the mounting tool over the parts. Make sure that all the parts are perfectly aligned. Press the nozzle on to the spindle guide. Note! The mounting tools are not standard for all engines but may be delivered as optional extras. If no mounting tools are available, the nozzle can be mounted on the spindle guide using a short piece of pipe. Place the pipe around the nozzle, so that the lower end of the pipe rests on the foot of the fuel nozzle. Then press the parts together the same way as when using the mounting tools. Check that the spindle inside the spindle guide is able to move freely as in step 10. 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.
909-12.3
13.
Spring pin
Scratch marks
M90912 0228O13
Page 5 (5)
Non-return valve
Special D10913 109-13 Edition Data 0031 Non-return S60MC-C valve
109-13
Data
Page 1 (2)
109-13
Non-return valve
Data
P90951 P90968-
153 12
Flange for dismantling of non-return valve Probe light with magnifier, complete
Page 2 (2)
Non-return valve
Overhaul
Non-return valve K98MC-C 0206 Overhaul 909-13.3
909-13.3
1. Note! Extreme care and accuracy should be exercised when carrying out this operation. 1. Clean the outside of the non-return valve with pure gas oil. The individual parts are not interchangeable, therefore only one guide is to be disassembled at a time. Note! Except for the slide valve spring, defective parts cannot be replaced individually by new ones. Place the non-return valve as shown in Fig. 1 in a bench vice provided with soft jaws, and disassemble the non-return valve, using the disassembling tool and a hammer as shown. 2. Clean all the parts for the spindle guide in gas oil and wipe them dry with a clean piece of cloth. Finally, clean in either gas oil, kerosene or Electrocleaner', and wipe the parts dry with a clean piece of cloth. 3. Now place the parts on clean, lint-free rags and examine with an 8-10 times enlargement magnifying glass, and an inspection lamp with magnifying glass as shown in Fig. 3.

& 0
2.
B
% 1
3.
& 0
Page 1 (2)
909-13.3
Non-return valve
Overhaul
4.
4. Examine the slide faces of movable parts for coating. Vent slide B/housing A will be too tight if there is a coating. (The letters AD refer to the letters/parts in Fig. 2). Fix vent slide B and, subsequently, housing A in a lathe as shown in Fig. 4 and remove the coating by means of very fine conventional polishing linen grade 360'. Also a little oil should be used (a coarser polishing linen must absolutely not be used).
MC909-6.2 69 04
5. Check spring C for the thrust piece for outside wear marks. If defective, it should be exchanged. 5. Check the seat on thrust piece D/vent slide, and the seat on vent slide/housing. Use an inspection lamp and an 8-10 times 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. 6. Mount the non-return valve as follows: Lubricate all movable parts with molybdenum disulphide (MoS2). 6. Place the loosely-assembled non-return valve on the plane of a drilling machine, with the tool positioned as shown in Fig. 6. Make sure that the thrust piece and the other parts are perfectly aligned and that the thrust piece is guided in the vent slide. Press the handle until the housing and thrust piece meet. 7. If the non-return valve is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the non-return valve with plastic to prevent dirt from entering the valve during storage.
Page 2 (2)
MC909-6.3 69 06
NA909-13.3 205 05
Fuel Oil High-Pressure Pipe

Special Edition D10914 L70MC-C 109-14 Data 0067 Fuel Oil High-Pressure Pipe
109-14
X X X
Data
D09-47 D09-50 D09-52
Fuel oil high-pressure pipe, tightening torque Union nuts, tightening torque Fuel oil pipe
190 Nm 55 Nm 20 kg
Page 1 (2)
109-14

Data
P90951 P90951 P90951
104 128 130
Milling tool for fuel oil pipe Crowfoot spanner Crowfoot spanner
Page 2 (2)

Dismantling
Fuel Oil High-Pressure Pipe S35MC 0235 Dismantling 909-14.2
909-14.2
High-Pressure Pipe with Double Pipe 1. Close the fuel oil inlet and outlet valves. 2. Unscrew the union nipple from the fuel valve. 3. Unscrew the union nipple from the fuel pump. 4. Lift the pipe ends clear of the fuel valve/fuel pump, and remove the high-pressure pipe from the engine. Note! It is recommended always to overhaul the high-pressure pipe before remounting it on the engine. See Procedure 909-14.3. The overhaul should preferably take place immediately after the high-pressure pipe has been dismantled.
2.
BM909-14.2 211 02
3.
GN909-14.2 210 03
4.
D09-52
BM909-14.2 211 04
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: 1. Lift up the union nut. Remove the spring ring from the two-part sleeve. Remove the sleeve.
KB909-7.1 77 01
2. Fasten the pipe in a vice with soft jaws. Mount the miller on the pipe end. Note! The two pipe ends are of different designs see sketch. Turn the upper tightening ring (A) until the miller presses against the pipe end. Turn the miller with, for instance, a tap wrench while lightly tightening the upper tightening ring (A) to provide a suitable pressure between the miller and the pipe end.
2.
KB909-7.1 77 03
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.
Max. grind-away
3.
The pipe ends may only be ground until the ground surface is flush with the bottom of the groove. If the pipe ends are still not in order, the pipe must be discarded. After completing the milling, carefully clean the high-pressure pipe, and blow through the bore with compressed air.
KN909-14.3 223 03
Page 2 (4)

Overhaul
4.
909-14.3
4. Remove and discard both the internal and external O-rings. Mount new O-rings. Mount the two-part sleeve and lock the sleeve with the spring ring. Ensure that all parts are completely clean before mounting the high-pressure pipe.
KB909-7.1 77 04
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. 3. Mount the high-pressure pipe between the fuel valve and the fuel pump.
BM909-14.4 211 03
Screw the union nipples onto the fuel valve and into the fuel pump top cover, by hand. Note! 4.
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. 6. If dismantled, re-mount the return oil pipe on the fuel valve. Open the fuel oil inlet and outlet valves.
5.
D09-47
GN909-14.4 210 05
Page 4 (4)
Fuel Pump Roller Guide

Special Edition D10915 S60MC-C 109-15 Data 0046 Fuel Pump Roller Guide
109-15
X X X X
X X
Data
D09-53 D09-54 D09-55 D09-56 D09-57 D09-61 D09-62
Nut, reversing shaft, tightening torque Clearance A Clearance B Clearance C Roller/bushing/shaft pin, max. clearance Fuel pump roller guide Pump base
160 0.6 - 3.1 4.3 - 6.0 0.3 - 0.8 0.5 96 118
Nm mm mm mm mm kg kg
Page 1 (2)
109-15

Data
P90951
82
Lifting tool for fuel pump roller guide
Page 2 (2)

Checking
Fuel Pump Roller Guide S60MC-C 0226 Checking 909-15.1
909-15.1
Roller guide mounted in engine 1. The fuel pump roller guide can be partially checked while mounted on the engine, using the following procedure: 2. Lift the fuel pump roller guide. See Procedure 909-10. 3. Remove the cover on the camshaft housing to inspect the fuel pump roller guide.
HN909-10.1 205 01
3.
Turn the engine to provide the maximum space between the roller guide and the cam disc. Turn the roller by hand to check that it can move freely and without unnecessary resistance or hard points. 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. Check the clearance in the slide bearing by lifting the roller relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller. 4. Lower the roller guide onto the fuel cam again. See Procedure 909-10. 5. Using the telegraph, move the roller guide to the AHEAD position. Check that the reversing link is fully tilted over in AHEAD position. Carry out the same check in the ASTERN position.
5.
GN909-15.1 203 05
Page 1 (10)
909-15.1

Checking
7.
Roller guide removed from engine A more suitable and reliable method is to check the roller guide and the bearing clearance after the roller guide has been dismounted: 6. Dismount the roller guide from the engine. See Procedure 909-15.2. 7. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness. 8. Turn the roller guide upside down and land it in a vertical position on a couple of planks, with the roller hanging freely. Measure the clearance in the slide bearing by placing a dial gauge against the roller and lifting the roller as much as the clearance permits.
MA909-8.0 70 07
8.
D09-57
Page 2 (10)
MA909-8.0 70 06

Dismantling
Dismantling 909-15.2
909-15.2
1. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1. Dismantle the top cover of the fuel pump. See Procedure 909-5.2. 2. Dismantle the fuel pump barrel assembly. See Procedure 909-6.2.
GN909-5.2 204 03
2.
GN909-6.2 204 06
Page 3 (10)
909-15.2

Dismantling
3.
3. Dismantle the fuel pump housing, see Procedure 909-4.2. Note! When lifting the fuel pump housing, take care not to damage the threads on the studs. 4. Loosen and remove the screws from the sealing cap on top of the roller guide inside the pump base. Remove the sealing cap from the roller guide/pump base.
GN909-15.2 203 03
Dismantle the lubricating oil pipe and the drain pipe from the pump base. 5. Remove the cover on the camshaft housing to inspect the position of the roller guide. Turn the engine until the roller guide is at BDC.
4.
HN909-15.2 206 04
5.
Page 4 (10)
HN909-10.1 205 01

Dismantling
6.
909-15.2
6. Loosen the nuts on the two threaded studs successively until the roller guide springs are relieved. Remove the nuts, mount two eye bolts in the pump base and lift it away. When lifting, take care that the bushing of the pump base slides against the neck of the roller guide without scratching. Remove the springs from the roller guide. 7. Mount the roller guide lifting tool as follows: Lift the lock plate of the tool up on the shaft of the tool. Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide. Turn the tool 90 so as to allow the foot to engage properly in the bayonet joint. Lower the lock plate, thereby securing the foot in the locked position. Lift the roller guide out of the roller guide housing, using the crane. When lifting, take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing. Land the roller guide on wooden planks. 8. Check the roller guide. See Procedure 909-15.1.
HN909-15.2 206 06
D09-62
7.
D09-61
GN909-15.2 203 07
Page 5 (10)
909-15.3

Overhaul
Overhaul 909-15.3
1.
1. Inspect and check the fuel pump roller guide. See Procedure 909-15.1.
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!
MA909-8.0 70 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.
3.
Page 6 (10)
HN909-15.3 206 03

Mounting
Mounting 909-15.4
909-15.4
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. Make sure that the pin of the reversing link fits in the bracket of the reversing shaft. 2. After mounting the roller guide with the reversing link, check the clearance between the roller guide and the guide plate mounted in the roller guide bushing. Turn the camshaft so that the roller guide is lifted approx. 20 mm. The clearance C between the roller guide and the guide plate must be the same at both ends +/ 0.1 mm. The clearances A and B between the guideway and the pin of the reversing link (arm) must be checked in the AHEAD and ASTERN positions. Connect working air to the air cylinder, and check that the reversing mechanism is working smoothly. The clearances A and B must be approx. the same in both positions. See Data.
HN909-15.4 206 01
1.
D09-61
2.
D09-54 D09-56
D09-55
HN909-15.4 206 02
Page 7 (10)
909-15.4

Mounting
3.
3. If adjustment is necessary, it must take place in the ASTERN position. Remove the cover over the shaft connection. Loosen the nut on the reversing shaft and carry out the adjustment. After adjustment, shift to AHEAD position and check the clearances A and B once more. Finally, shift again to ASTERN.
D09-53
Tighten the nut on the reversing shaft to the torque stated in Data, and lock the nut with Loctite type: Screw Lock No. 59. Mount the cover over the shaft connection.
HN909-15.4 206 03
4. Turn the engine until the roller guide is at BDC. 5. Mount the springs and the spring seat discs over the roller guide. 5. Mount the pump base over the roller guide and the springs. Mount the two special nuts on the threaded studs.
D09-62
Using the special tube-shaped socket wrench, tighten the nuts until the pump base is fastened tightly to the roller guide bushing.
Page 8 (10)
HN909-15.2 206 06

Mounting
6.
909-15.4
6. Check the movement of the reversing link. See Procedure 909-15.1. 7. Replace the scraper rings in the sealing cap as follows: Loosen and remove the screws and nuts from the bottom of the cap, remove the retaining flange and ring holder with scraper ring. 8. Replace the O-ring in the top of the cap. Replace the axial scraper ring in the bottom of the cap. Check that the O-ring and scraper ring are mounted correctly. See the sketch .
GN909-15.1 203 05
7.
GN909-15.4 203 07
8.
MA909-8.0 70 21
Page 9 (10)
909-15.4

Mounting
9.
9. Remove the scraper ring and O-ring from the ring holder. Place the new O-ring in the ring holder. Before mounting, the new scraper ring must be heated in 100C hot water or oil for at least five minutes. 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.
AM909-8.0 31 16
10.
Check that the O-ring and scraper ring are mounted correctly. See the sketch. 10. Assemble the sealing cap, the ring holder and retaining flange. Tighten the nuts on the screws. After tightening, check that the holder can be moved. 11. Mount the lubricating oil pipe and the drain pipe on the pump base.
GN909-15.4 203 10
Mount the sealing cap on top of the roller guide, over the sealing bush inside the pump base. 11. Tighten the screws and lock with locking wire. 12. Mount the fuel pump housing. See Procedure 909-4.4. Mount the barrel assembly. See Procedure 909-6.4. Mount the top cover. See Procedure 909-5.4.
Page 10 (10)
HN909-15.4 206 11
Fuel Valve - Tools
Plate P90961-0069
MAN B&W Diesel A/S
Page 1 (2)

014 026 038 040 051 063 075 087 099 109 122
Fuel Valve - Tools

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
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve Nozzle - Tools
Plate P90966-0008
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 060 202
Fuel Valve Nozzle - Tools

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.
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Puncture Valve - Tools
Plate P90967-0001
MAN B&W Diesel A/S
Page 1 (2)

017
Fuel Puncture Valve - Tools

Tool for tightening of puncture valve
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve - Inspection Tools
Plate P90968-0001
MAN B&W Diesel A/S
Page 1 (2)

012
Fuel Valve - Inspection Tools

Probe light with magnifier, complete
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve Nozzle - Cleaning Tools
Plate P90974-0001
MAN B&W Diesel A/S
Page 1 (2)

015 027 039 206
Fuel Valve Nozzle - Cleaning Tools

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
Mounting Tools - Pump Barrel Seals

Mounting Tools - Pump Barrel Seals 0001 P90977
Plate P90977-0001
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 059 060 072
Mounting Tools - Pump Barrel Seals

Item No.
Item Description
Cone Pushing tool Compression tool Cone Pushing tool Compression tool Spacer ring
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Mounting Tools - Suction Valve Seals

Mounting Tools - Suction Valve Seals 0001 P90979
Plate P90979-0001
MAN B&W Diesel A/S
Page 1 (2)

012 024 036
Mounting Tools - Suction Valve Seals

Item No.
Item Description
Cone Pushing tool Compression tool
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Mounting Tools - Air Piston Seals

Mounting Tools - Air Piston Seals 0001 P90980
Plate P90980-0001
MAN B&W Diesel A/S
Page 1 (2)

018 020 031 043 055 067 079
Mounting Tools - Air Piston Seals

Item No.
Item Description
Cone Pushing tool Compression tool Cone Pushing tool Compression tool Cone
Item Description
Page 2 (2)
MAN B&W Diesel A/S
910 - Turbocharger System

91064 91066 0002 0001 Travelling Trolley Air Cooler - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Travelling Trolley
Plate P91064-0002
MAN B&W Diesel A/S
Page 1 (2)

010
Travelling Trolley
Travelling trolley* Note: * When ordering this tool, please state load and track width.
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler - Lifting Tools

Air Cooler - Lifting Tools 0001 P91066
Plate P91066-0001
MAN B&W Diesel A/S
Page 1 (2)

011 023
Air Cooler - Lifting Tools

Item No.
Item Description
Lifting attachment air cooler fore end, complete Screw
Item Description
Page 2 (2)
MAN B&W Diesel A/S
911 - Safety Equipment

111-01 911-01 111-02 911-02 111-03 911-03 0025 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
Data
X X X X X X X
111-1
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
D11-01 D11-02
Opening pressure Valve housing, tightening torque
200 5 45
bar Nm
Page 1 (2)
111-1
Safety Valve
Data
Plate P91351 P91351 P90151 P91359 Item No. 10 58 117 Description Hydraulic pump, pneumatically operated Hose with unions (3000 mm), complete Test equipment for combined safety valve Torque Spanners
Page 2 (2)
Safety Valve
MAN B&W Diesel
When Side-mounted 1. Remove the guard surrounding the safety valve. Unscrew the safety valve from the extension pipe. 2. Dismantle the indicator cock and the intermediate pipe.
911-1.2
Dismantling
1.
When Top-mounted 3. Unscrew the safety valve from the cylinder cover. Remove and discard the mild steel disc.
M91101 0211D03
M91101 0211D02
M91101 0211D01
2.
3.
Page 1 (5)
911-1.3
Safety Valve
Overhaul (Adjustment) MAN B&W Diesel
1.
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

in the data, loosen and tighten again to the torgue stated in the data.
M91101 0211O01
3. Then mount:
the valve spindle the spring the adjusting screw the lock nut
2.
Page 2 (5)
M91101 0211O03
M91101 0211O02
3.
Safety Valve
MAN B&W Diesel Overhaul (Adjustment)
911-1.3
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

safety valve until the correct pressure is indicated (see Data).
M91101 0212O04
Tighten the lock nut. Test the opening pressure. Remove the valve from the fuel valve
test rig.
Page 3 (5)
911-1.4
Safety Valve
Mounting
When Side-mounted
MAN B&W Diesel
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. 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.
Page 4 (5)
M91101 0211M03
M91101 0211M02
M91101 0211M01
2.
3.
Safety Valve
MAN B&W Diesel
When Top-mounted 4. 4. Pierce the bore in the cylinder cover, and blow it clean. Clean the thread and the sealing surface. 5. Mount a new or overhauled safety valve. Mount a new mild steel disc in the bore. When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
911-1.4
Mounting
M91101 0211M05
M91101 0211M04
5.
Page 5 (5)
Relief Valve
Data
X
111-2
Stopped engine Shut off starting air supply At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply Not ME-engines Shut off control air supply Shut off air supply to exhaust valve Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water
Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors
Data
Page 1 (2)
111-2
Relief Valve
Data
Page 2 (2)
Relief Valve
Checking
Relief Valve 60& 0211 Checking 911-2.1
911-2.1
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. Check on the whole circumference that all the plates in the flame arrester are evenly distributed and that no local openings exist. If one or more plates in the flame arrester are damaged, the relief valve must be disassembled and the flame arrester replaced. See separate instructions from the valve manufacturer.
1.
Note! The complete flame arrester has to be replaced after a crankcase explosion.
XZ911-2.1 209 01
2.
XZ911-2.1 207 03
Page 1 (1)
Scavenge Air Receiver Safety Valve

MAN B&W Diesel Data
111-3

X X X X X 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 lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply X Data Ref. Description Value Unit Lock the turbocharger rotors
Page 1 (2)
111-3

Data MAN B&W Diesel
Page 2 (2)

MAN B&W Diesel
1. The scavenge air receiver safety valve is calibrated at the factory and does not re quire any adjustment. 2. Check the scavenge air receiver safety valve by loosening the counter nut and turn the forced opening screw to open the valve approx. 10 millimetres. Use a piece of cloth to wipe out any dirt from the O ring packing and close the valve again. Tighten the counter nut. If this operation cannot be performed smoothly, the safety valve must be disman tled and cleaned.
M91103 0001C02
911-3.1
Checking
2.
Page 1 (5)
911-3.2

1.
1. Dismount the safety valve from the scavenge air receiver. 2. On some engines, a cover has to be removed in order to gain access to the safety valve.
Page 2 (5)
M91103 0001D02
M91103 0001D01
2.

MAN B&W Diesel
1. Remove the split pin. Unscrew the nut thereby relieving the spring tension. Remove the nut, spring retainer and wash ers. Keep count of the washers. Pull out the spring. 2. Pull out the valve ap with spindle. If the O ring seal is damaged remove it without damaging the O ring groove. 3. Clean the metal surfaces thoroughly.
911-3.3
Overhaul
1.
M91103 0001O02
M91103 0001O01
2.
Page 3 (5)
911-3.3

4.
4. If the O ring seal has been removed mount a new one using Locktite type AVX and Loc tite activator type T or similar. 5. Push in the valve ap and spindle while tak ing care not to damage the O ring seal. 6. Mount the spring, spring retainer and all the washers. Tighten the nut until the split pin can be mounted.
M91103 0001O04
7. Check the valve according to 911 3.1.
5.
M91103 0001O05
6.
Page 4 (5)
M91103 0001O01

MAN B&W Diesel Mounting
1.
911-3.4
1. Mount the safety valve on the scavenge air receiver.
M91103 0001M01
Page 5 (5)
912 - Assembly of Large Parts

112-02 912-02 112-03 912-03 912-05 91261 91266 0009 0207 0018 0212 0201 0073 0001 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 - End Chock Bolts (Epoxy Chocks)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Holding Down and End Chock Bolts

Special Edition D11202 112-2 Data 0009 Holding Down S60MC-C and End Chock Bolts
112-2
Data
D12-02
D13-01 D13-02
Check holding down bolts and end chock bolts for correct tightening after the following service hours: 1st check 2nd check 3rd check 4th check 5th check Subsequent checks at intervals of Tightening pressure Dismantling pressure
500 1000 2000 4000 8000 8000 1500 1400-1650
hours hours hours hours hours hours bar bar
Page 1 (2)
112-2

Data
P91263 P91351
Hydraulic tools for holding-down bolts Bolts and end chock bolts, epoxy 10 Hydraulic pump, pneumatically operated
Page 2 (2)

Checking
Holding Down and End Chock Bolts .0& 0207 Checking 912-2.1
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.
Page 1 (3)
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 table, see drawing Nos. 782225-0 and 782226-2, following which the bolts are tightened to the normal tightening pressure. The condition of the bolted joints, and thus the general condition of the foundation, can be effectively checked by comparing the 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 (3)
EN912-1.1 205 01

Checking
3.
912-2.1
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 liners located in way of each main bearing on either side of the engine must be fitted and knocked into position simultaneously. 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. The feeler gauge is applied at the 7 points indicated on drawing No. 782226-2, and the measurements found are to be entered in the relevant table. These results are used to determine whether refitting or, possibly, replacement of the liners is necessary. If the measurements at 3 points or more have increased 5/100 mm or more from the initial 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 on drawing No. 782226-2. If this procedure does not improve the situation, the liner must be removed, and it must be checked that the actual contact area is more than 80 per cent of the possible contact surface areas on both sides of the liner. The liners are secured in their correct position by means of hexagon socket set screws with cup point.
GN912-2.1 203 03
Page 3 (3)
Stay Bolts
Special Edition D11203 S60MC-C 112-3 Data 0018 Stay Bolts
112-3
X X X
Data
D12-04 D13-01 D13-02
Check measurement Hydraulic pressure, mounting Hydraulic pressure, dismantling
1803 mm 1500 bar 1400-1650 bar
Page 1 (2)
112-3
Stay Bolts
Data
P91351 P91351 P91351 P91351 P91261
10 34 58 105 23
Hydraulic pump, pneumatically operated Hose with unions (1000 mm), complete Hose with unions (3000 mm), complete 3-way distributor block, complete Hydraulic jack, complete
Page 2 (2)
Stay Bolts
Checking
Stay Bolts S60MC-C 0212 Checking 912-3.1
912-3.1
1. This check can be performed during several periods of stopped engine, but must be performed on complete twin stay bolt groups at a time, thereby ensuring uniform tension in the affected bearings. Note! The first time this check is performed it has to be completed in one operation. The following checks have to be completed within a 500-hour period. 2. Before retightening the stay bolts, remove the protective caps. 3. Check for loose staybolt nuts with the tommy bar. If a loose nut is found, unscrew the nut until a gap occurs between cylinder frame and nut. Loosen and unscrew the nut on the opposite stay bolt. Check for the correct mounting of the stay bolt by comparing with the check measurement on the Data Sheet. If the check measurement is not reached, indicating that the stay bolt is not screwed properly down in the thread of the bedplate, apply a screw and a counternut in the thread in the top of the stay bolt, and turn the stay bolt until the check measurement data is met. 4. Retighten the stay bolts in pairs (athwartship), working from fore to aft of the engine.
GN912-3.1 202 01
1.
One Group One Group
NA912-3.1 210 01
2.
3.
D13-02
D12-04
GN912-3.0 39 09
4.
D13-01
GN912-3.1 202 03
Page 1 (2)
912-3.1
Stay Bolts
Checking
5.
5. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other. Connect the high-pressure pump by means of the high-pressure hoses, so that the two stay bolts are tightened in one operation. 6. Maintain the mounting pressure, and retighten the stay bolt nuts with a tommy bar. Before relieving the system of pressure, check with a feeler gauge that the nuts bear against their contact faces.
D13-01
GN912-3.1 202 02
6.
7. When all stay bolts have been retightened, reconnect the hydraulic tools to the pair of stay bolts first tightened. Tighten to 10% below the mounting pressure and check whether the nut is loose. If the nut is not loose: Tighten the stay bolts concerned to the mounting pressure. If the nut is loose: Tighten all stay bolts once again to the mounting pressure. 8. After completing the retightening procedure, mount the protective caps.
HM912-3.0 28 04
7.
Page 2 (2)
HM912-3.0 28 05
Crankcase Oil Outlet

1.
912-5.1
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. Note! 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. 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. 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. 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.
M91205 0201C02
M91205 0201C01
2.
Page 1 (2)
912-5.1
Crankcase Oil Outlet

Checking
Metal bellow sealing
MAN B&W Diesel
4. 4. Remove all screws A and grating B.
C D F E
M91205 0201C04
B A
5. Remount four of the screws A at diametrically opposite positions. 6. Remove: Screws C Cover plate D Screws E.
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. 10. Mount: Screws E Cover plate D Screws C.
M91205 0201C07
11. Remove the four screws A. 12. Mount grating B. 13. Mount all screws A.
Page 2 (2)
Large Parts - Tools
Plate P91261-0073
MAN B&W Diesel A/S
Page 1 (2)

023 035 047 050 060 084 106 202
Large Parts - Tools

Hydraulic jack, complete Support Tommy bar Sealing ring with back-up ring Sealing ring with back-up ring Spanner Stud setter Hydraulic tool set, complete
Page 2 (2)
MAN B&W Diesel A/S
Hydraulic Tools - End-Chock Bolts (Epoxy Chocks)
Plate P91266-0001
MAN B&W Diesel A/S
Page 1 (2)

019 020 032 056 068 093 103
Hydraulic Tools - End-Chock Bolts (Epoxy Chocks)

Wooden box Hydraulic jack, complete Support O-ring with back-up ring O-ring with back-up ring Tommy bar Spanner
Page 2 (2)
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 91368 0215 0201 0205 0205 0207 0204 0037 0053 0007 0014 0003 0004 0052 0069 0040 0059 0066 0007 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 Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Hydraulic Tools
Description
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
M91301 0215C01
913-1.1
1.
C D E F G
J. Stud or bolt K. Extension stud L. Lifting tool S. Clearance U. Milled recess for feeler gauge 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. 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. 1. The hydraulic tools, except those for the main bearings and the cylinder cover, 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. 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.
H I J U
2.
I C D F E F K B J U I
A G
3.
M91301 0215C02
Page 1 (12)
913-1.1
Hyraulic Tools
Description
3. For the cylinder cover, the hydraulic tool consists of eight individual jacks suspended from a common lifting tool. A spacer ring is mounted below each jack using two spring pins. Operation of the cylinder cover jacks is identical to the operation of the single hydraulic jacks. 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 back-up rings. The following instructions must be closely followed to prevent accidents or damage, and after use the jacks should be cleaned and kept in the wooden boxes supplied. Warning! Eye protectors and gloves must be used when using hydraulic tools.
3.
Page 2 (12)
M91301 0215C04
M91301 0215C03
4.
Hydraulic Tools
Dismantling
Single Hydraulic Jack 1. 1. Carefully clean the tool attachment thread, the nut and the surrounding parts. Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar. Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot when the nut is to be loosened. 2. Screw the jack on to the tool attachment thread of the bolt/stud, until the cylinder of the jack bears firmly against the spacer ring. Screw back the jack a number of turns, according to the table shown on the sketch, to produce a clearance between the jack and the spacer ring. The clearance between the jack and spacer ring ensures dismantling of the jack after loosening the nut. When loosening nuts on very long bolts (e.g. staybolts) it is recommended to unscrew the jack an additional half turn. 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. After adjustment, check that the parts are guided correctly together and that there is no clearance between the piston and cylinder of the jack.
913-1.2
MoS2
M91301 0215D01
2.
Max. lift = Max. lift 10 mm 25 mm Loosening 1 turn 3 turn Tightening 1/4 trun 1/4 turn
M91301 0215D02
Page 3 (12)
913-1.2
Hydraulic Tools
Dismantling
3. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 150 bar. 4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up against the jack. 5. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.
3.
M91301 0215D03
Note! Make sure not to exceed the max lift stamped on the jack.
4.
Page 4 (12)
M91301 0215D05
M91301 0215D04
5.
Hydraulic Tools
Dismantling
Double Hydraulic Jack 6. 6. Carefully clean the tool attachment threads, the main bearing studs, the nuts and the surrounding parts. Grease the tool attachment threads with molybdenum disulphide grease or graphite and oil or similar. Mount the extension studs on the main bearing studs. Using the lifting tool, place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of loosening the nuts. Press the pistons and the cylinder of both the hydraulic jacks firmly together.
M91301 0215D06
913-1.2
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. 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.
MoS2
M91301 0215D07
Page 5 (12)
913-1.2
Hydraulic Tools
Dismantling
8. 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. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in both jacks, and fill up the system with oil until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws. 9. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 150 bar. 10. Unscrew the lower nuts 1 turns with the tommy bar, making sure that the nuts are not screwed up against the extension stud. 11. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.
8.
Max. lift 10 mm
3 mm
M91301 0215D09
M91301 0215D08
9.
Note! Make sure not to exceed the max lift stamped on the jack.
Page 6 (12)
Hydraulic Tools
Overhaul
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! Always use protective gloves and eye protection when working with compressed air. Make sure that there are no marks or scratches on the sliding surfaces of the parts. The presence of metal particles will damage the sealing rings. Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease. 2. The pistons and cylinders of the double jacks are separated in the same easy way as described for the single jack.
M91301 0215O01
913-1.3
1.
Air
2.
Air
Air
M91301 0215O02
Page 7 (12)
913-1.3
Hydraulic Tools
Overhaul
3. When changing the sealing rings, first mount the back-up ring and then the Oring. Note! Note that the back-up ring (1) must be away from the pressure chamber and the O-ring (2) close to the pressure chamber.
3.
1 2 2 1
See the sketch for the correct mounting of both the upper and the lower sealing rings. The same principle applies to all the jacks. 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.
Page 8 (12)
M91301 0215O03
Hydraulic Tools
Mounting
Single Hydraulic Jack 1. 1. Thoroughly clean the nut, the thread, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the thread in the nut with 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. 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.
M91301 0215D01
913-1.4
MoS2
2. Press the piston and the cylinder of the jack firmly together. Screw the hydraulic jack on to the tool attachment thread. Make sure that the cylinder of the jack bears firmly against the spacer ring and that the parts are guided correctly together Connect the hydraulic jack, the distributor block and the high-pressure pump by means of high-pressure hoses. Loosen the bleed screw in the jack and fill up the system with oil, until oil without bubbles flows out of the bleed hole. Re-tighten the bleed screw.
2.
Max. lift = Max. lift 10 mm 25 mm Loosening 1 turn 3 turn Tightening 1/4 trun 1/4 turn
M91301 0215D02
Page 9 (12)
913-1.4
Hydraulic Tools
Mounting
3. Increase the oil pressure to the prescribed 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. 5. Relieve the system of pressure, disconnect the pump, and remove the hydraulic jack.
3.
M91301 0215M03
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 17-18-19.
4.
Page 10 (12)
M91301 0215M04
Hydraulic Tools
Mounting
913-1.4
Double Hydraulic Jack 5. Thoroughly clean the nuts, the threads on the main bearing studs, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the threads in the nuts with 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. 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 tightening the nuts. 6. Press the piston and the cylinder of both the hydraulic jacks firmly together. Mount the two jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided 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.
5.
MoS2
M91301 0215D06
M91301 0215M05
6.
Page 11 (12)
913-1.4
Hydraulic Tools
Mounting
7. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in both jacks, and fill up the system with oil until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws. 8. Increase the oil pressure to the prescribed value, and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. 9. 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. 10. Relieve the system of pressure, disconnect the pump, and remove the hydraulic tools. 11. 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', points 12-13-14, and then tighten the nuts again according to the procedure under Tightening', points 24-25-26.
7.
Page 12 (12)
M91301 0215M09
M91301 0215M08
M91301 0215M07
8.
9.
Standard Tightening Torques
913-4
Standard Tightening Torques .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 M8 M10 M12 M14 M16 M18 M20 Tightening torque 17 Nm 35 Nm 50 Nm 80 Nm 135 Nm 190 Nm 260 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 400 Nm 460 Nm 610 Nm 950 Nm 1200 Nm 1650 Nm 2100 Nm
2. Self-locking nuts. Thread M8 M10 M12 M14 M16 M18 M20 Tightening torque 20 Nm 40 Nm 60 Nm 90 Nm 150 Nm 210 Nm 290 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 430 Nm 490 Nm 650 Nm 1000 Nm 1250 Nm 1700 Nm 2200 Nm
3. Screws and nuts locked with glue/Loctite. Thread M8 M10 M12 M14 M16 M18 M20 Tightening torque 23 Nm 50 Nm 70 Nm 115 Nm 190 Nm 270 Nm 380 Nm Thread M22 M24 M27 M30 M33 M36 M39 Tightening torque 580 Nm 680 Nm 900 Nm 1350 Nm 1700 Nm 2350 Nm 3000 Nm
Page 1 (1)
Torque Spanner
Torque Spanner /0& 0205 913-5
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.
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. See Procedure 913-5. Apply a pre-tightening torque of: thread M8 M20 = 50 Nm thread M22 M27 = 100 Nm thread M30 M39 = 150 Nm thread M42 M48 = 200 Nm This is in order to ensure a uniform basis for the subsequent tightening with gauge or tightening angle. Tightening with a tightening gauge After pre-tightening, place the tightening gauge round the nut, and mark off with chalk on the nut at slot A on the tightening gauge, and make another chalk mark on the contact face at slot B. Then tighten the nut until the two chalk marks coincide. Tightening without a tightening gauge For tightening angles of e.g. 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. See Procedure 913-5.
7 ; G Q D 0 +
Page 1 (1)
Screws and Nuts

MAN B&W Diesel Locking
1.
913-7.1
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. When reassembling the engine after overhauls, it is vital that all such screws and nuts are again locked correctly. Note! Make sure only to mount locking devices on nuts and screws which have been mounted with locking devices by the 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. 2. Used spring washers must be replaced. 3. Self-locking nuts may only be used five times. Therefore, give the nut a centre punch mark each time it is loosened. To tighten a self-locking nut to a specific torque, first measure the torque required to turn the nut itself, and then add this torque to the torque value stated on the data sheet of a procedure.
M91307 0207C03
M91307 0207C02
M91307 0207C01
2.
3.
Page 1 (4)
913-7.1
Screws and Nuts

Locking MAN B&W Diesel
Fig. 1
Fig. 2
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. Any tendency of the screws or nuts to loosen will be counteracted by a tightening of the locking wire. Do not secure more than four units in a series, unless otherwise specified.
Fig. 3
Fig. 4
Fig. 1: Insert wire, grasp the upper end of the wire and bend it around the head of the screw, then under the other end of the wire, be sure that the wire is tight around the head. Fig. 2: Twist the wire clockwise until it is just short of the hole in the second screw. Keeping the wire under tension, twist it until tight. When the wire is tight, the wire shall have 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. 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. 6: During the final twisting motion, bend the wire along the screw head. Cut off excess wire. Fig. 7-9: Show the preferred ways of mounting the locking wire on screws with wire holes oriented in different angles.
Fig. 5
M91307 0207C04
Fig. 6
Fig. 7
Fig. 8
M91307 0207C05
Fig. 9
Page 2 (4)
Screws and Nuts

MAN B&W Diesel
Fig. 10: Shows how to route the locking wire on screws in different planes. Fig. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread. Fig. 12: Wire that passes over the top of a nut is also an acceptable alternative if the hole is located as shown in the figure. Fig. 13: Where drilling of locking wire holes has caused a thin wall section, route the wire as shown in the figure, to prevent damage to the nut. Fig. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible.
913-7.1
Locking
Fig. 10
Fig. 11
Fig. 12
Fig. 13
M91307 0207C06
Fig. 14
Page 3 (4)
913-7.1
Screws and Nuts

Locking MAN B&W Diesel
Fig. 15
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. Fig. 16: Different uses of the cam lock washers. Fig. 17: Don not use the cam lock washers in conjunction with other loose washers. Note! Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers.
M91307 0207C15
Fig. 16.
M91307 0207C16
Fig. 17
M91307 0207C17
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.
Page 1 (1)
Accessories for Hydraulic Tools
Plate P91351-0037
MAN B&W Diesel A/S
Page 1 (2)

010 022 046 058 060 105 117 130 154 166 201 213 225 237 249
Accessories for Hydraulic Tools

Hydralic pump, pneumatic operated Hydralic pump, hand operated Hose with unions (1500mm), complete Hose with unions (3000mm), complete Hose with unions (5000mm), complete 2-way distributor block, complete 4-way distributor block, complete 9-way distributor block, complete Distributor block with shut-off valve Angle union Quick coupling, male Quick coupling, female Disc, round-plain, Cu o11x3mm Bleeder screw Disc, round-plain, Cu o11x9mm
Page 2 (2)
MAN B&W Diesel A/S
Lifting Tools, Etc.
Plate P91356-0053
MAN B&W Diesel A/S
Page 1 (2)

020 031 043 055 067 079 114 126 138 140 151 163 210 222 234 260 295 305
Lifting Tools, Etc.

Item Description Item No.
10mm 12mm 16mm 20mm 24mm 30mm
Item Description
Forged-bent screw shackle, Forged-bent screw shackle, Forged-bent screw shackle, Forged-bent screw shackle, Forged-bent screw shackle, Forged-bent screw shackle, Lifting eye bolts, 10mm Lifting eye bolts, 12mm Lifting eye bolts, 16mm Lifting eye bolts, 20mm Lifting eye bolts, 24mm Lifting eye bolts, 30mm Chain tackle, 500kg Chain tackle, 1000kg Chain tackle, 2000kg Chain tackle, 5000kg Pull lift, 3000kg Wire rope, 6m
Page 2 (2)
MAN B&W Diesel A/S
Open Ended Spanners
Plate P91357-0007
MAN B&W Diesel A/S
Page 1 (2)

013 037 049 050 062
Open Ended Spanners

Item Description Item No.
NV65mm NV75mm NV80mm NV85mm NV90mm
Item Description
Open-ended Open-ended Open-ended Open-ended Open-ended
spanner, spanner, spanner, spanner, spanner,
size size size size size
Page 2 (2)
MAN B&W Diesel A/S
Open-Ended Slugging Spanners
Plate P91358-0014
MAN B&W Diesel A/S
Page 1 (2)

164
Open-Ended Slugging Spanners

Open-ended slugging spanner, size NV85mm
Page 2 (2)
MAN B&W Diesel A/S
Torque Wrenches
Plate P91359-0003
MAN B&W Diesel A/S
Page 1 (2)

014 026 038 040 051
Torque Wrenches
Torque wrench, 8 - 400Nm Adapter for socket wrench, 10 x 12.5 mm Torque wrench, 40 - 200Nm Torque wrench, 140 - 760Nm Torque wrench, 750 - 2000Nm
Page 2 (2)
MAN B&W Diesel A/S
Pliers
Plate P91360-0004
MAN B&W Diesel A/S
Page 1 (2)

010 021 033 045 057 128 130 141 153 Pliers Pliers Pliers Pliers Pliers Pliers Pliers Pliers Pliers
Pliers
Item Description
for for for for for for for for for retaining retaining retaining retaining retaining retaining retaining retaining retaining ring, ring, ring, ring, ring, ring, ring, ring, ring, size size size size size size size size size 0.9mm 1.3mm 1.8mm 2.3mm 3.2mm 1.1mm 1.8mm 2.3mm 3.2mm
Item No.
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Combination Spanners
MAN B&W Diesel
Plate P91361-0052
Page 1 (2)

015 027 039 040 052 064 076 088 090 100 111 123 135 147 159 160 172 184 196 206 218 220 231
Combination Spanners
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 NV10mm NV11mm NV12mm NV13mm NV14mm NV15mm NV16mm NV17mm NV18mm NV19mm NV21mm NV22mm NV24mm NV27mm NV30mm NV32mm NV34mm NV36mm NV41mm NV46mm NV50mm NV55mm NV60mm
Item Description
Page 2 (2)
Ring Slugging Spanners
Plate P91362-0069
MAN B&W Diesel A/S
Page 1 (2)

022 034 046 058 060 071 083 095 105 117 120 130 142 154 166 178
Ring Slugging Spanners

Slugging spanner, ring size NV30mm Slugging spanner, ring size NV32mm Slugging spanner, ring size NV34mm Slugging spanner, ring size NV36mm Slugging spanner, ring size NV41mm Slugging spanner, ring size NV46mm Slugging spanner, ring size NV50mm Slugging spanner, ring size NV55mm Slugging spanner, ring size NV60mm Slugging spanner, ring size NV65mm Slugging spanner, ring size NV70mm Slugging spanner, ring size NV75mm Slugging spanner, ring size NV80mm Slugging spanner, ring size NV85mm Slugging spanner, ring size NV90mm Slugging spanner, ring size NV95mm
Page 2 (2)
MAN B&W Diesel A/S
Spanners
MAN B&W Diesel
Plate P91363-0040
Page 1 (2)

016 028 030 041 100 150 161
Spanners
Item Description
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
Item Description
Page 2 (2)
Open-ended Spanners
Plate P91364-0059
MAN B&W Diesel A/S
Page 1 (2)

011 023
Open-ended Spanners
Open ring wrench, 14 - 17mm Open ring wrench, 19 - 22mm
Page 2 (2)
MAN B&W Diesel A/S
Instruments
Plate P91366-0066
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 048 050 061 073
Instruments
Indicator, complete Indicator paper Plainmeter, complete Autolog, measuring tool for crankshaft Feeler gauge Slide caliper Dial gauge and stand tool
Page 2 (2)
MAN B&W Diesel A/S
Working Platforms
Plate P91368-0007
MAN B&W Diesel A/S
Page 1 (2)

013
Working Platforms
Platform board
Page 2 (2)
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)
S60MC-C
VOLUME III COMPONENTS DESCRIPTION
900 - Introduction
Table of Contents, Volume III Cross Section through Engine Ordering of Insulation Designations and Symbols Software Licence - Standard Conditions Instructions for Main Engine Description
90001 90002 90003 90004 90023 90030
0069 0001 0001 0001 0027 0009
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
Volume III - Components Description No. Edition Title
900
900 - Introduction Table of Contents 90001 0069 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations and Symbols 90004 0001 Software Licence - Standard Conditions 90023 0027 Instructions for Main Engine 90030 0009 Description 901 - Cylinder Cover 90101 0167 Cylinder Cover 90103 0004 Indicator Cock - Mounting 902 - Piston with Rod & Stuffing Box 90201 0220 Piston and Piston Rod 90205 0121 Piston Rod Stuffing Box 903 - Cylinder Liner and Cylinder Lubrication 90302 0193 Cylinder Liner and Cooling Jacket 90304 0036 Cylinder Liner - Details 90305 0127 Cylinder Lubricators 90307 0035 Cylinder Lubricator Unit 90308 0012 Cylinder Lubricator - Intermediate Box 90309 0026 Cylinder Lubricator System - Details 90312 0004 Electronic Components - Cylinder Lubrication 904 - Crosshead with Connecting Rod 90401 0171 Connecting Rod and Crosshead 90403 0012 Lubricating and Cooling Oil-Flow 905 - Crankshaft, Thrust Bearing and Turning Gear 90501 0170 Crankshaft 90502 0057 Arrangement of Fore End 90503 0018 Arrangement of Angle Encoder 90505 0147 Thrust- and Guide Bearing 90510 0123 Turning Gear 90511 0032 Turning Wheel 90512 0002 Turning Gear - Details 906 - Control Gear 90603 0083 Chain Tightener 90605 0071 Lubricator Drive 90610 0106 Bearing Housing - Mounting 90612 0099 Arrangement of Indicator System 90612 0100 Arrangement of Indicator System
Table of Contents
Volume III - Components Description No. 90613 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634 Edition 0118 0142 0146 0031 0102 0087 0071 0013 0014 0027 0001 Title Camshaft Bearing Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part
900
907 - Starting Air System 90702 0069 Main Starting Valve 90703 0106 Starting Air Distributor 90704 0055 Starting Valve 908 - Exhaust Valve 90801 0196 Exhaust Valve - Lower Parts 90802 0054 Exhaust Valve - Details 90803 0024 Exhaust Valve - Upper Parts 90804 0016 Exhaust Valve Upper Parts - Details 90805 0119 Exhaust Valve - Actuator 90806 0091 Exhaust Valve - Pipe System 90811 0015 Arrangement of Freshwater Pipes 909 - Fuel Oil System 90901 0195 Fuel Pump 90902 0147 Fuel Pump Gear 90903 0048 Fuel Pump Gear - Details 90904 0055 Fuel Pump - Details 90905 0026 Reversing Mechanism 90910 0144 Fuel Valve 90911 0022 Fuel Valve Function 90913 0160 High-Pressure Pipes 90914 0096 Fuel Oil System 90915 0060 Fuel Oil System - Details 90915 0075 Fuel Oil System - Details 910 - Turbocharger System 91000 0017 Gas and Air System 91001 0143 Scavenge Air Receiver 91002 0126 Arrangement of Charging Air Pipe 91003 0206 Exhaust Pipes and Receiver 91004 0067 Exhaust Receiver - Details
Table of Contents
Volume III - Components Description No. 91005 91006 91007 91011 91014 Edition 0130 0038 0017 0024 0019 Title Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Arrangement of Non-Return Valve Arrangement of Suction Pipe
900
911 - Safety Equipment 91101 0037 Safety Valve - Cylinder 91102 0028 Relief Valve 91102 0033 Relief Valve 91103 0018 Safety Valve - Scavenge Air System 91104 0088 Arrangement of Safety Cap 912 - Assembly of Large Parts 91201 0095 Arrangement of Stay Bolts 91204 0027 Frame - Details 91205 0208 Frame Box 91206 0107 End Shields 91207 0092 Arrangement of Piston Cooling 91208 0018 Chain Wheel Frame - Upper 91210 0163 Bedplate 91211 0081 Axial Vibration Damper 91216 0009 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) 91217 0002 Top Bracing - Arrangement
MAN B&W Diesel A/S
Page 3 (3)
Cross Section through Engine
Plate P90001-0069
MAN B&W Diesel A/S
Page 1 (1)
Ordering of Insulation
MAN B&W Diesel
Plate P90002-0001
Page 1 (1)
Designations and Symbols

MAN B&W Diesel
Plate P90003-0001
Normal layout
Forward (fwd)
Port side of ship
Starboard (stbd) side of
Fore end
1 2 3 4 5 6 7
Cyl. nos. always counted from fore end
Manoeuvring side of engine
Aft 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. 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.
A90023-0027
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

MAN B&W Diesel 901 Cylinder Cover
Cylinder Cover The cylinder cover is made of steel.
A90030-0009
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.
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MAN B&W Diesel
Stuffing Box
A90030-0009
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.
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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. 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. 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. 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.
Cylinder lubrication
PC-ring
Page 4 (23)

MAN B&W Diesel 904 Crosshead with Connecting Rod
Crosshead
A90030-0009
The crosshead is provided with two guide shoes fitted on the crosshead ends. The centre part of the crosshead is designed as a bearing journal which is housed in the crosshead bearing. The crosshead bearing cap is provided with a cut-out enabling the piston rod to be assembled with the crosshead journal. The crosshead is equipped with steel shells lined with bearing metal. The lower shell is provided with an overlayer coating. See also Volume I, OPERATION, Chapter 708.
Piston rod foot
The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the piston rod and the crosshead. 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.
Lubrication
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.
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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.
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)

MAN B&W Diesel
Turning Gear
A90030-0009
The turning gear is attached to the engine bedplate and is driven by an electric motor incorporating a disc brake. Through a planetary gearing, the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually, so as to engage with the turning wheel of the engine. The turning gear is provided with a safety arrangement consisting of a safety lever which must be lifted before the gear wheel of the turning gear can be made to engage with the turning wheel. When the safety lever is in its bottom position, it prevents the gear wheel of the turning gear from engaging with the turning wheel. Immediately the lever is lifted away from the disengaged position, an interlock valve inserted in the starting air system of the engine is actuated. This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position. See also Volume I, OPERATION, Chapter 703.
Warning! During any dismantling of working parts of the engine, the turning gear must be in the engaged position in order to prevent outside forces from turning the engine, thus causing injuries to personnel or damage to the machinery. See Volume II, MAINTENANCE, DATA pages. 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.
Dismantling of working parts:
Pressure testing of starting valves:
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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A90030-0009

MAN B&W Diesel
Camshaft
The camshaft is made in one or more sections. If it is made in two or more sections, the sections are assembled by means of flange couplings. The camshaft has, for each cylinder: one cam for operation of the fuel pump one cam for operation of the exhaust valve one cam for operation of the indicator drive (option) The fuel pump and exhaust valve cams are shrunk on to the shaft by heating, whereas the indicator cams are in two parts, which are assembled with fitted bolts. The camshaft rotation constantly follows that of the crankshaft.
Bearings
The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. See also Volume I, OPERATION, Chapter 708. 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. 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. 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.
Engine timing
Pin gauges
Indicator Valve
PMI-System
See separate instructions for operating the PMI-system (option).
Page 8 (23)

MAN B&W Diesel
Moment Compensators
A90030-0009
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 Air Distributor Starting Valves The manoeuvring system is of electric/pneumatic design. See also Volume I, OPERATION, Chapter 703.
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A90030-0009

MAN B&W Diesel
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 Starting Valve
The starting air distributor controls the opening and the closing of the starting valves. 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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MAN B&W Diesel 908 Exhaust Valve
Exhaust Valve
A90030-0009
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. The valve housing has an exchangeable bottom piece. The bore for the valve spindle is provided with an exchangeable spindle guide liner.
Valve housing
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. 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.
2.
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A90030-0009

MAN B&W Diesel
Note! After the exhaust valve has been overhauled, it is important to check the damper, to avoid knocking. See Volume II, MAINTENANCE, Procedure 908.
Air cylinder
The air cylinder is mounted on top of the valve housing. Air for closing the 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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MAN B&W Diesel
Sealing oil (where used):
A90030-0009
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 Hydraulic cylinder The exhaust valve is actuated by a cam on the camshaft through a hydraulic transmission. 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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A90030-0009

MAN B&W Diesel
909 Fuel Oil System

Fuel Pump Each engine cylinder is equipped with its own fuel pump, which is mounted on the camshaft housing over the camshaft section corresponding to the cylinder concerned. The pump housing is attached to the camshaft housing by studs and nuts. The square base of the fuel pump housing is provided with a groove to receive any leakage oil, which is subsequently drained off through a drain pipe. In the base, a bore is provided for at toothed rack, i.e. the regulating guide, which controls the quantity of fuel oil delivered by the pump. Furthermore, for the VIT-type fuel pump, another bore is provided above the bore for the regulating guide. This bore is provided with a rack, i.e. the timing guide, which controls the engine timing. At the top, the pump housing is closed by a top cover. The top cover is provided with a suction valve and a puncture valve. These two valves are on some engine types combined into one unit. The pump housing contains the plunger and barrel. The plunger and barrel are matched parts, and must not be replaced individually. The pump plunger is provided with a guide block designed to travel in the milled keyway in the regulating guide. At the bottom it has a foot which rests on a steel disc in the bayonet joint at the roller guide neck. A clearance of approx. 0.1 mm between the plunger foot and the roller guide permits turning of the plunger in the roller guide. The regulating guide is able to turn in the bottom of the pump housing. On the outside the regulating guide has a toothed rim to mesh with the above-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.
Page 14 (23)

MAN B&W Diesel
Injection timing Fuel pumps without VIT (Variable Injection Timing):
A90030-0009
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.
Page 15 (23)
A90030-0009

MAN B&W Diesel
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. A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations. 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.
Shock absorber
Fuel Pump Actuating Gear
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. 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.
Fuel Oil Leakage Alarm
Page 16 (23)

MAN B&W Diesel
50-98MC:
A90030-0009
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.
Page 17 (23)
A90030-0009

MAN B&W Diesel
The air cooler incorporates a water mist catcher, which is designed to separate condensate from the air. See also Charging Air Cooler further on in this Section. When the air has passed the water mist catcher, it is pressed into the scav enge air receiver through non-return valves. The non-return valves open by pressure from the turbocharger. From the scavenge air receiver, the air flows to the cylinder through the 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. See special instructions supplied by the engine builder.
El. panels for auxiliary blower 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.
Page 18 (23)

MAN B&W Diesel
Warning!
A90030-0009
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.
Page 19 (23)
A90030-0009

MAN B&W Diesel
Running with auxiliary blowers: If an auxiliary blower fails during running, the non-return valve must close to ensure the continued supply of fresh air to the engine. See Starting the 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 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.
Page 20 (23)

MAN B&W Diesel
Relief Valves
A90030-0009
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".
Page 21 (23)
A90030-0009

MAN B&W Diesel
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. See also Volume I, OPERATION, Chapter 708. Each main bearing has one or two main bearing caps which are secured by studs and nuts, designed for tightening with hydraulic tools. The bedplate is fitted with an axial vibration damper. For the design and 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) When referring to this page, please quote Description A90030 Edition 0009

MAN B&W Diesel
A90030-0009
Equipment for local checking of the cooling oil temperature and flow, and for temperature and flow alarms, is installed in conjunction with the outlet pipe. See also Volume I, OPERATION, Chapter 701. Staybolts The bedplate, framebox and the cylinder frame are tightened together to form one unit by means of staybolts. Regarding the engine seating for the specific engine, see the suppliers special instructions.
Engine Seating
Page 23 (23)
901 - Cylinder Cover

90101 90103 0167 0004 Cylinder Cover Indicator Cock - Mounting
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
Plate P90101-0167
Page 1 (2)

018 031 043 055 067 079 080 092 102 114 126 138 151 175 222 234 246 258
Cylinder Cover
Item Description
Screw Protective cap Nut Stud Cylinder cover Stud Washer Nut Stud Screw O-ring Cooling jacket Gasket Nut Stud Stud Pipe for fuel valve Spring housing, complete
Item Description
Page 2 (2)
Indicator Cock - Mounting

MAN B&W Diesel
Plate P90103-0004
Page 1 (2)

019 020 032 056 068 081 093 103 127 140 152 176 188 223 235
Indicator Cock - Mounting

Item Description
Indicator cock Gasket Gasket Disc Plug screw Sundry chain Key ring Eye screw Gasket Screw Nut Flange Extension Screw Extension
Item Description
Page 2 (2)
902 - Piston with Rod & Stuffing Box

90201 90205 0220 0121 Piston and Piston Rod Piston Rod Stuffing Box
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Piston and Piston Rod
Plate P90201-0220
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 059 060 072 084 096 106 118 131 143 167 179 192 202
Piston and Piston Rod

Item No.
Item Description
Piston ring no. 1 Piston ring no. 2 + 4 Piston ring no. 3 Piston crown Screw Disc D-ring D-ring Piston skirt Screw Locking wire Screw Screw Cooling pipe Screw Screw Piton
Item Description
Page 2 (2)
When referring to this page, please quote Plate
Edition
MAN B&W Diesel A/S
Plate P90205-0121
MAN B&W Diesel A/S
Page 1 (2)

013 025 037 049 062 074 086 098 121 133 157 170 182 204 216 241 253 289

Item No.
Item Description
O-ring Top scraper ring Pack sealing ring Cover sealing ring Nut Stuffing box, housing Flange Screw Guide pin Spring pin Lamella for scrapering Stuffing box, housing Fitted bolt Screw Scraper ring Spring Spring Scraper ring
Item Description
Page 2 (2)
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication

90302 90304 90305 90307 90308 90309 90312 0193 0036 0127 0035 0012 0026 0004 Cylinder Liner and Cooling Jacket Cylinder Liner - Details Cylinder Lubricators Cylinder Lubricator Unit Cylinder Lubricator - Intermediate Box Cylinder Lubricator System - Details Electronic Components - Cylinder Lubrication
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Liner and Cooling Jacket
Plate P90302-0193
MAN B&W Diesel A/S
Page 1 (2)

010 022 034 046 058 071 083 105 117 129 130 142 154 166 178 201 213 225
Cylinder Liner and Cooling Jacket

Packing Plug screw O-ring O-ring Cooling jacket Clamp Screw Piston cleaning ring Cylinder liner Cooling water connection Packing Pipe Spring pin Plug screw Gasket O-ring Cooling water connection Screw
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Liner - Details
Plate P90304-0036
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 059
Cylinder Liner - Details

Head for non-return valve Housing Non-return valve Non-return valve, complete
Page 2 (2)
MAN B&W Diesel A/S
Plate P90305-0127
MAN B&W Diesel A/S
Page 1 (2)

017 030 054 066 078 091 113 137 149
Item No.
Item Description
Screw Screw Guard Bracket Screw Nut Support Steel pipe Straight male stud, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Lubricator Unit

MAN B&W Diesel
Plate P90307-0035
Page 1 (2)

018 031 043 055 067 080 092 114 138 151 175 199 209 210 234 258 271 283 295 305 317 329 330 342 354 366 378 391 401 413 437 449 450 474 486 498 508 521 533 545 569 570 582 594
Cylinder Lubricator Unit

Item Description
Ball valve Stud Hydraulic block Nut Plug screw O-ring Intermediate pipe Adjustable elbow coupling Ball valve Stud Lubricator, complete Hydraulic block Gasket Membrane accumulator Screw Adjusting screw O-ring Spacer, tubular Cover O-ring Non-return valve O-ring Cylinder block O-ring Spring Plunger Actuator piston Straight stud coupling Screw Screw Cylinder housing Solenoid valve complete Screw Membrane accumulator Gasket O-ring O-ring Inductive sensor Cable Cable gland, complete Housing Plug Plug Screw
Item Description
Page 2 (2)
Intermediate Box
Plate P90308-0012
MAN B&W Diesel A/S
Page 1 (2)

013 037 049 050 074
Intermediate Box
Item No.
Item Description
Intermediate box, complete Electric enclosure with cables Circuitboard assy Screw Diode
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Lubrication System - Details
Plate P90309-0026
MAN B&W Diesel A/S
Page 1 (2)

019 020 032 044 068 081 093 103 115 139 152 176 188 211 223 247 259 260 296 306 343 367
Cylinder Lubrication System - Details

Stud Nut Steel pipe Steel pipe Pipe holder Screw Coupling Connection Coupling Pipe holder Coupling Screw Distributor block Sealing ring Distributor block Steel pipe Steel pipe Pipe holder Steel pipe Steel pipe Coupling Screw
Page 2 (2)
MAN B&W Diesel A/S
Cylinder Lubrication - Electronic Components
Plate P90312-0004
MAN B&W Diesel A/S
Page 1 (2)

015 027 039 040 052 064 076 088 111 159 160 184 196 206
Cylinder Lubrication - Electronic Components

Item No.
Item Description
Name plate Pilot lamp Name plate Selector switch Terminal Terminal Din rail Terminal Terminal HMI panel Mounting plate Nut Screw Terminal
Item Description
Page 2 (2)
MAN B&W Diesel A/S
904 - Crosshead with Connecting Rod

90401 90403 0171 0012 Connecting Rod and Crosshead Lubricating and Cooling Oil-Flow
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Connecting Rod and Crosshead

MAN B&W Diesel
Plate P90401-0171
Page 1 (2)

019 020 044 068 093 103 115 139 140 152 164 188 211 223 235 247 260 272 284 296 306 331 355 367 379 380 414 426 438 451 463 487 509 522
Connecting Rod and Crosshead

Item Description
Plate Screw Screw Crankpin bearing shell, complete Screw Outlet pipe Guide shoe, Fore Crosshead bearing cap Crosshead bearing shell, complete Guide pipe Crosshead Connecting rod Screw Crankpin bearing cap Guide pin Screw Screw Shim* Distance piece Bushing Housing for stuffing box Telescope pipe Guide shoe, Aft Shim* Shim* Guide strip Guide pin Stud Nut Nut Stud Screw Counterweight Connecting rod, complete Note: *When ordering, please state thickness of shim.
Item Description
Page 2 (2)
Lubricating and Cooling Oil Flow

MAN B&W Diesel
Plate P90403-0012
Page 1 (1)
905 - Crankshaft, Thrust Bearing and Turning Gear

90501 90502 90503 90505 90510 90511 90512 0170 0057 0018 0147 0123 0032 0002 Crankshaft Arrangement of Fore End Arrangement of Angle Encoder Thrust- and Guide Bearing Turning Gear Turning Wheel Turning Gear - Details
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crankshaft
Plate P90501-0170
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 061 073 085 097 107 119
Crankshaft
Item No.
Item Description
Locking wire Screw Flange Crankshaft Packing Cover Screw Locking wire Chain wheel
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Fore End
Plate P90502-0057
MAN B&W Diesel A/S
Page 1 (2)

018 031 043 067
Arrangement of Fore End

Item No.
Item Description
Fitted bolt Nut Locking wire Counterweight
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Angle Encoder

MAN B&W Diesel
Plate P90503-0018
Page 1 (2)

013 037 049 050 074 086 098 108 121 133 157 169 170 182 194 204 216 228 253 265
Arrangement of Angle Encoder

Item Description
Measuring instrument, axial vibration damper Screw Angle encoder Enclosure, complete Screw Shaft Housing Damping plate Coupling Cable tie Adjustment tool Packing Spring pin Screw Spring lock Shield lower part Packing Shaft Packing Washer
Item Description
Page 2 (2)
Thrust and Guide Bearing
Plate P90505-0147
MAN B&W Diesel A/S
Page 1 (2)

014 026 038 051 063 075 099 109 110 122 146 158 183 195 205 217 229 242 254 278 301 313 350 362 386 398 408 433 445 469 470 494 516 528 553 565 589 600 624 648 661 685 697 707 720 732 744 756 768 793
Thrust and Guide Bearing

Item No.
Item Description
Nut Stud Stopper segment, fore Spray pipe Segment Segment Lubricating oil pipe Spray pipe Screw Locking wire Screw Nut Oil pipe Spray pipe Stopper segment, fore Stopper segment, aft Segment Stopper segment, aft Spray pipe Oil throw ring, complete Plate Nut Cover Spray pipe Scraper ring housing, upper Screw Spring lock Cylinder pin Scraper ring housing, lower Lubricating oil pipe Screw Fitted bolt Nut Screw Screw Gasket Scraper ring housing, complete Fitted bolt Nut Screw Scraper ring, upper Scraper ring, complete Scraper ring, lower Spacer tubular Nut Distance pipe Guard Distance pipe Clamps Guard
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Turning Gear
Plate P90510-0123
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 059 072 084 096 106 131 143 155 167 214 226 251 263 299 309 310 322 334 346 358 383 405 417 429
Turning Gear
Item No.
Item Description
Bracket Bush Screw Spring washer Disc Switch Spring washer Screw Lever 3/2-way valve Screw Spring washer Chain Cylinder pin Turning gear Distance pipe Screw Gear wheel Disengaging device, complete Screw Disc Spring washer Stud Sleeve special Turning safety device, complete Key ring Eye screw Circlip
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Turning Wheel
Plate P90511-0032
MAN B&W Diesel A/S
Page 1 (2)

017 029 030 054 066 078 101 113 125
Turning Wheel
Item No.
Item Description
Guide pin Nut Nut Screw Screw Dead center pointer Fitted bolt Nut Turning wheel
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Turning Gear - Details

MAN B&W Diesel
Plate P90512-0002
Page 1 (2)

012 024 048 061 073 097 107 119 132 156 168 181 203 215 227 240 252 264 276 311 323
Turning Gear - Details

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 Disc with inicision Stud with groove Circlip Disc with inicision Sleeve Screw Spring washer Lever Bush
Item Description
Page 2 (2)
906 - Control Gear

90603 90605 90610 90612 90612 90613 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634 0083 0071 0106 0099 0100 0118 0142 0146 0031 0102 0087 0071 0013 0014 0027 0001 Chain Tightener Lubricator Drive Bearing Housing - Mounting Arrangement of Indicator System Arrangement of Indicator System Camshaft Bearing Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Chain Tightener
Plate P90603-0083
MAN B&W Diesel A/S
Page 1 (2)

017 029 030 042 054 066 091 101 113 125 150 162 174 198 208 221 233 245 270 282 294 304 316 328
Chain Tightener
Item No.
Item Description
Chain wheel Cup point screw Bushing Flange bearing Locking wire Screw Bracket Screw Shaft Flange bearing Distance piece Distance piece Plug screw Shaft Guide nut Lock washer Nut Tightening bolt Shaft Guide nut Circlip Circlip Shaft Bushing
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Lubricator Drive
MAN B&W Diesel
Plate P90605-0071
Page 1 (2)

018 031 043 055 079 080 092 102 114 138 163 175 187 199 210 222 234 246 258 271 295 305 317
Lubricator Drive
Item Description
Chain wheel Flange bearing Screw Locking wire Chain link, complete Screw Chain Outer link Inner link Screw Guide pin Shaft Bracket for guideway Screw Flange bearing Plug Sealing ring Screw Guidebar Nut Circlip Disc Sealing ring
Item Description
Page 2 (2)
Bearing Housing - Mounting
Plate P90610-0106
MAN B&W Diesel A/S
Page 1 (2)

015 027 040 052 064 076 088 111 135 147
Bearing Housing - Mounting

Item No.
Item Description
Screw Bearing cap Guide disc Stud Nut Stud Bearing housing Shim Bearing shell Guide pin
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Indicator System

MAN B&W Diesel
Plate P90612-0099
Page 1 (2)

028 053 065 077 089 100 112 124 136 148 173 197 207 219 220 244 256 268 281 293 303 315 327 339 340 352 364 388 411 423 435

Item Description
Roller guide Screw Washer Bracket, complete Bracket, indicator drive Screw Screw Nut Washer Sectional iron Screw Liner Circlip Shaft Needle bearing Guide pulley Round iron Circlip Washer Screw Handle Screw Roller guide Liner Key Housing Screw Spring pin Liner Spring Circlip Note: *
Item Description
Page 2 (2)

MAN B&W Diesel
Plate P90612-0100
Page 1 (2)

016 028 053 065 077 090 100 124 136

Item Description
PMI system users manual PMI install and start-up PMI software Component storage case Converter box PMI controller box, complete Junction box Handle Pressure transducer Note: *
Item Description
Page 2 (2)
Camshaft Bearing
Plate P90613-0118
MAN B&W Diesel A/S
Page 1 (2)

023 035 059 060 072 096 106 131 143 155 179 180 202 238 251 275 287
Camshaft Bearing
Item No.
Item Description
Screw Drain pipe Lubricating oil pipe Screw Bearing cap Screw Bearing shell Cylinder dowel Plug screw Plug screw Screw Orifice Baseplate Screw Plate Plate Packing
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Governor
Plate P90615-0142
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 061 073 085 107 119 120 132 144 156 168
Arrangement of Governor
Item No.
Item Description
Enclosure, complete Screw Screw Screw Spring washer Bracket Pull rod, complete Terminal box Fitted bolt Washer Self-locking nut Guide pin Plate
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Regulating Shaft
Plate P90618-0146
MAN B&W Diesel A/S
Page 1 (2)

019 020 032 056 115 127 139 152 164 176 188 223 235 247 259 260 284 306 318 331 343 355 367
Regulating Shaft
Item No.
Item Description
Sleeve coupling Regulating shaft Regulating shaft Flange bearing, complete Bracket Washer Screw Fitted bolt Self-locking nut Pull rod, complete Spring-loaded lever, complete Screw Shaft Lever Nut Spring Spring pin Shaft Circlip Shim Clamping block Washer Screw
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Load Transmitter
Plate P90619-0031
MAN B&W Diesel A/S
Page 1 (2)

014 026 038 063 075 087 099 109 110 122 134 158 171 183 205 217
Load Transmitter
Item No.
Item Description
Tooth belt disc Screw Tooth belt Bracket Screw Tooth belt disc Potentiometer Coupling Coupling Self-locking nut Screw Screw Nut Washer Screw Washer
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Engine Side Control Console
Plate P90620-0102
MAN B&W Diesel A/S
Page 1 (2)

021 045 057 069 070 082 094 104 116 128 153 165 177 189 190 212 224 236 261 273 285 307 319 320 332 344 368 381 393 403 427 439 440 464 476 488 523 547 559 560 572 596 606 618 631 643 667 679 680
Engine Side Control Console

Item No.
702 714 726 751
Item Description
Local manoeuvring console Name plate Screw Name plate 5/2-way manual valve Screw Name plate Name plate 5/2-way manual valve Name plate 3/2-way manual valve Name plate 3/2-way manual valve Name plate Name plate Coupling Coupling T-coupling, complete Screw Spring lock Pressure switch Bracket Screw Switch 0-110 Volt Screw Pressure switch Coupling Banjo coupling T-coupling, complete Reducing connection, complete Nut Screw Banjo coupling Enclosure, complete El-wiring Screw Coupling Stud Key ring Eye screw Sundry chain and link Shaft Stud Bakelite ball Name plate T-coupling, complete Nut Screw Non-return valve
Item Description
Coupling Reducing connection, complete Non-return valve Coupling, complete
Page 2 (2)
MAN B&W Diesel A/S
Engine - Side Control Console, Details

Engine - Side Control Console, Details 0087 P90621
Plate P90621-0087
MAN B&W Diesel A/S
Page 1 (2)

015 027 039 052 064 076 088 123 135 147 160 184 196 206 218 243 255 267 279 292 302 326 338 351 375 399 422 434 458 471
Engine - Side Control Console, Details

Item No.
Item Description
Dowel Dowel Lever Impact handwheel Impact socket Washer Nut Screw Bolt Washer Lever Screw Washer Lever Bushing Nut Disc Grease nipple Bushing Roller Screw Switch Screw Spring lock Cone Distance piece Pin Cone Lever Shaft
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Layshaft
Plate P90622-0071
MAN B&W Diesel A/S
Page 1 (2)

010 022 034 058 071 095 105 117 129 142 154 166 178 201 213 225 237 249 250 262 274 298 333 345 357 370 394 404 416 441 465
Arrangement of Layshaft
Item No.
Item Description
Spindle Ball bearing Circlip Hand wheel Thrust ring Handle Stud Self-locking nut Spring lock Key Grease nipple Self-locking nut Washer Pointer Screw Angle lever Screw Nut Slide shoe Screw Lock washer Circlip Distance pipe Clamping block Ball bearing Split pin Sealing ring Circlip Flange bearing Screw Thrust ring
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Chain Drive Guidebars - Upper Part

MAN B&W Diesel
Plate P90631-0013
Page 1 (2)

021 033 057 069 070 094 116 141 153
Chain Drive Guidebars - Upper Part

Item Description
Locking wire Screw Beam for guidebar Guidebar Screw Chain Chain, complete Outer link Inner link
Item Description
Page 2 (2)
Chain Drive Guidebars - Lower Part

MAN B&W Diesel
Plate P90632-0014
Page 1 (2)

111 123 135 147 159 172 196
Chain Drive Guidebars - Lower Part

Item Description
Screw Locking wire Beam for guidebar Screw Guidebar Beam for guidebar Beam for guidebar
Item Description
Page 2 (2)
Chain Drive Lubrication - Upper Part

MAN B&W Diesel
Plate P90633-0027
Page 1 (2)

010 022 058 071 083 095
Chain Drive Lubrication - Upper Part

Item Description
Lubricating pipe Spray nozzle Lubrication pipe Lubricating pipe Lubricating pipe Lubricating pipe
Item Description
Page 2 (2)
Chain Drive Lubrication - Lower Part
Plate P90634-0001
MAN B&W Diesel A/S
Page 1 (2)

016 041 053 077 089 090 112 124
Chain Drive Lubrication - Lower Part

Item No.
Item Description
Spray pipe Spray pipe Spray pipe Spray pipe Spray pipe Connection pipe Spray pipe Spray pipe
Item Description
Page 2 (2)
MAN B&W Diesel A/S
907 - Starting Air System

90702 90703 90704 0069 0106 0055 Main Starting Valve Starting Air Distributor Starting Valve
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Starting Valve
Plate P90702-0069
MAN B&W Diesel A/S
Page 1 (2)

027 039 052 064 076 088 123 135 147 160 184 196 206 218 231 255 279 280 292 314 326 338 351 363 387 399 410 422 434 458 471 495 505 517 529 530 542 554 566 591 601 625 637 650 674 698
Main Starting Valve

Item No.
708 900 912
Item Description
Screw Name plate "Working" Screw Washer Switch Distance pipe Spindle Screw Plate Ball valve with actuator* Nut Screw Starting air pipe Gasket Intermediate piece Name plate "Blocked" Nut Washer Hand wheel Securing plate Pin Spring Screw Gasket Gasket Plug screw Adjusting screw Nut Adapter Washer Screw Screw Guide Guide pin Screw Distance pipe Screw Ball valve with actuator* Nut Plug screw Gasket Plug screw Starting air pipe Non-return valve Housing Housing
Item Description
Screw Repair kit, actuator* Repair kit, ball valve* Note: * When ordering spare parts for this item, please state manufacturer's Part No.
Page 2 (2)
MAN B&W Diesel A/S
Plate P90703-0106
MAN B&W Diesel A/S
Page 1 (2)

010 022 034 046 058 071 083 095 105 129 130 142 166 178 191 201 213 225 237 249 250 262 274 286

Item No.
Item Description
Housing Screw Guide screw Disc Starting cam Lock washer Screw Cover Screw Piston valve slide Liner Guide pin Washer Screw Cover Screw Screw Flange Locking ring Spring guide Spring Spring guide Liner Cover
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Starting Valve
Plate P90704-0055
MAN B&W Diesel A/S
Page 1 (2)

016 028 041 053 065 077 089 090 100 112
Starting Valve
Item No.
Item Description
Screw Cover Screw Locking plate Piston Spring Bushing Valve housing Sealing ring Spindle
Item Description
Page 2 (2)
MAN B&W Diesel A/S
908 - Exhaust Valve

90801 90802 90803 90804 90805 90806 90811 0196 0054 0024 0016 0119 0091 0015 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 Freshwater Pipes
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Exhaust Valve - Lower Parts
Plate P90801-0196
MAN B&W Diesel A/S
Page 1 (2)

013 025 049 050 062 086 098 108 121 133 145 157 170 182 194 216 241 265 277 290
Exhaust Valve - Lower Parts

Item No.
Item Description
Sealimg ring Sealing ring Exhaust valve housing Cover Packing Screw Exhaust valve spindle Packing Flange Screw O-ring Bottom piece Screw Sealing ring Spindle guide-lower Flange Thread insert Packing Plug screw Sealing ring
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Details
Plate P90802-0054
MAN B&W Diesel A/S
Page 1 (2)

019
Exhaust Valve - Details

Item No.
Item Description
Sealing oil unit, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Upper Parts
Plate P90803-0024
MAN B&W Diesel A/S
Page 1 (2)

014 038 051 063 087 109 110 134 158 171 183 195 205 217 230 242 254 278 291 301 313 325 349 350 362 374 398 408 421 433 445 457 469 470 482 494 504 528 553 577 589 590 600 624
Exhaust Valve - Upper Parts

Item No.
Item Description
Pipe Lifting eye bolt Screw Lifting attachment Packing Orifice plug Disc Safty strap Piston Sliding bearing Sealing ring Sealing ring Packing Plug screw Oil cylinder Stud Nut Disc Locking plate Screw O-ring Air cylinder Disc Locking plate Screw Cone Screw Pin Rotation check Steel pipe-straight rod Union nut Screwed connection Packing O-ring Spring Disc Spring pin Non-return valve Pison ring Damper piston Spring Piston Disc Piston, complete
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust V alve - Upper Parts, Details Valve

MAN B&W Diesel
Plate P90804-0016
Page 1 (2)

021 045 905
Exhaust V alve - Upper Parts, Details Valve

Item Description
Gasket Safty valve, with o-ring O-ring* Note: * Optional extras
Item Description
Page 2 (2)
Valve Gear
Valve Gear 0119 P90805
Plate P90805-0119
MAN B&W Diesel A/S
Page 1 (2)

015 027 039 040 052 064 076 088 111 123 147 159 160 172 184 196 218 231 243 267 279 292 302 314 326 338 363 387
Valve Gear
Item No.
Item Description
Exhaust roller guide, complete Thrust guide Roller guide Shaft-pin for roller Plug Circlip Screw Bushing Disc Roller Bushing for roller guide Cylindrical pin Screw Bushing Guide block Plug Stud Stud Piston Nut Oil cylinder Piston ring Disc Screw Disc Spring Cylindrical pin Cylindrical pin
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve - Pipe System
Plate P90806-0091
MAN B&W Diesel A/S
Page 1 (2)

010 022 046 058 071 083 105 117 129 154 166 178 191 237 249 250
Exhaust Valve - Pipe System

Item No.
Item Description
Disc Sealing ring Clamp Nut Screw Support Coupling Drain pipe Coupling Thrust bushing Screw Hydraulic pipe Hose complete Hydraulic pipe, complete Plug screw Packing
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Freshwater Pipes
Plate P90811-0015
MAN B&W Diesel A/S
Page 1 (2)

018 031 043 055 067 079 080 102 114 126 138 151 175 199 210 234 246 258 271 295 317 329 330 354
Arrangement of Freshwater Pipes

Item No.
Item Description
Packing Screw Nut Orifice plate Freshwater pipe, outlet Ball valve Freshwater pipe, outlet Support Packing Screw Freshwater pipe, outlet Support Freshwater pipe, outlet Conical valve Screw Main pipe Packing Screw Nut Main pipe Angle valve Coupling Steel pipe Main pipe
Item Description
Page 2 (2)
MAN B&W Diesel A/S
909 - Fuel Oil System

90901 90902 90903 90904 90905 90910 90911 90913 90914 90915 90915 0195 0147 0048 0055 0026 0144 0022 0160 0096 0060 0075 Fuel Pump Fuel Pump Gear Fuel Pump Gear - Details Fuel Pump - Details Reversing Mechanism Fuel Valve Fuel Valve Function High-Pressure Pipes Fuel Oil System Fuel Oil System - Details Fuel Oil System - Details
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Fuel Pump
Fuel Pump 0195 P90901
Plate P90901-0195
MAN B&W Diesel A/S
Page 1 (2)

029 042 054 078 091 101 113 125 137 150 162 174 186 198 208 233 245 257 270 282 294 304 328 341 353 365 377 389 390 400 424 436 448 461 485 497 507 519 520 532 544 556 568 581 593 603 615
Fuel Pump
Item No.
640 652 664 711 723 735 747 760 772 784 796
Item Description
Packing Packing Plug screw Pump housing, complete Timing guide Sleeve Regulating guide Guide pin Screw Stud Guide pin Packing Guide screw Plug screw Throttle plug Guide pin Guide bushing, complete Guide bushing Screw Screw Top cover Lock washer Nut Screw Spring guide Spring Suction valve, complete Slide Valve thrust piece Sealing ring Sealing ring Pump barrel Pump barrel, complete Plunger Screw Lock washer Cover Sealing ring Sealing ring Puncture valve, complete Air piston Packing Valve housing O-ring Slide Spring Spring guide
Item Description
Throttle plug Packing Sealing ring Protective cap Screw Coupling Pipe Banjo coupling Plug screw Disc Pipe
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump Gear
Plate P90902-0147
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 048 061 073 085 097 107 120 144 156 168 181 193 215 227 239 240 252 264 288 323 347 359 360 372 384 396 418 431 443 455 467 479 492 514 526 538 551 563 587 599 609 610 622 658 671 683 695
Fuel Pump Gear

Item No.
705 717 729
Item Description
Fuel pump roller guide, complete Shaft-pin for link Plug Circlip Stop screw Roller Bushing Disc Shaft-pin for roller Plug Thrust disc Roller guide Plug Bushing Pin Link for reversing Pin Guide block Guide pin Screw Screw Bushing Pin Nut Bushing for roller guide Sealing ring Cap Self-locking nut Screw Scraper ring, axial Scraper ring Flange Holder for scraper ring Locking wire Screw Nut Pump base, complete Packing Cover, transparent Cover Screw Disc Stud Stud Spring Disc Pump base Sealing bush, complete Retaining ring Plug screw
Item Description
Sealing bush Guide bushing Cup point screw
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump Gear - Details
Plate P90903-0048
MAN B&W Diesel A/S
Page 1 (2)

031 043 055 067 079 080 092 102 114
Fuel Pump Gear - Details

Item No.
Item Description
Screw Nut Screw Guide screw Flange bearing Spindle Spring pin Sealing ring Catch
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump - Details
Plate P90904-0055
MAN B&W Diesel A/S
Page 1 (2)

013 025 037 049 050 062 074 098 108 121 133 145 169 170 182 194 204 228 241 253 265 277 289 290 300 324 336 348 361 373 385 397 407
Fuel Pump - Details

Item No.
419 420 432 444 456 468
Item Description
Shock absorber, complete Spring guide Bottom flange, complete Packing Plug screw Nut Locking washer Spring, left-hand Spring, right-hand Packing Sealing ring Stud Screw Packing Housing Wearing ring Piston Plug Nut Washer Bracket Screw Actuator Banjo coupling Screw Guide screw Toothed rack for regulation Felt ring Pointer Toothed rack for timing Forked lever Nut Union nut
Item Description
Circlip Pin Forked head Forked head Adjusting screw Nut
Page 2 (2)
MAN B&W Diesel A/S
Reversing Mechanism
Reversing Mechanism 0026 P90905
Plate P90905-0026
MAN B&W Diesel A/S
Page 1 (2)

019 020 032 044 056 068 093 103 115 127 139 152 164 176 211 235 247 259 272 284 296 306 318
Reversing Mechanism
Item No.
Item Description
Shaft Guide for reversing Distance pipe Nut Guard Screw Cover Screw Bolt Flange for air cylinder Reversing mechanism, complete Screw Bush Air cylinder Screw Ball valve Branch pipe Nut Coupling Orifice plate Non-return valve Nut Safety valve
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve
Plate P90910-0144
MAN B&W Diesel A/S
Page 1 (2)

016 028 065 089 090 100 124 136 148 161 173 197 207 219 220 232 244 256 268 281 950
Fuel Valve
Item No.
Item Description
Thrust piece Cut-off shaft Spindle guide, complete Spindle guide Spring pin Nozzle O-ring Holder Guide Union nut O-ring Sealing ring Valve head Guide pin Spring Non-return valve Disc Thrust spindle Spring Thrust foot Disc* Note: Note: Optional extras
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Valve Function
Plate P90911-0022
MAN B&W Diesel A/S
Page 1 (2)
Fuel Valve Function

Item No.
Item Description
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 P90913-0160
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 048 073 085 097 107 120 132 156 181 193 203 215 239 240 264 276 311 908
High-Pressure Pipes
Item No.
Item Description
Sleeve in 2/2 Retaining ring Union nipple Fuel oil pipe O-ring O-ring Housing Union nut Union nipple O-ring Fuel oil pipe, complete Steel pipe Screw Flange Housing Guide pin Fuel oil pipe T-coupling, complete Coupling Fuel oil pipe, complete Insulation of pipe* Note: *Optional extras
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Fuel Oil System

MAN B&W Diesel
Plate P90914-0096
Page 1 (2)

018 031 043 067 079 080 092 102 114 126 151 163 175 187 199 209 222 234 246
Fuel Oil System

Item Description
Fuel oil pipe, outlet Non-return valve Fuel oil pipe, outlet Distributor piece Screw Fuel oil pipe, outlet Coupling Steel pipe Coupling Steel pipe Packing Screw Fuel oil pipe, inlet Ball valve Screw Packing Fuel oil pipe, inlet Screw Nut
Item Description
Page 2 (2)
Fuel Oil System - Details
Plate P90915-0060
MAN B&W Diesel A/S
Page 1 (2)

013 025 037 049 050 074 086 098 121 133 145

Item No.
Item Description
By-pass valve, complete Valve housing Valve housing Sealing ring Spring guide Screw Union nut Nut Sealing ring Piston Spring
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Plate P90915-0075
MAN B&W Diesel A/S
Page 1 (2)

013 037 049 050 062 074

Item No.
Item Description
Drain box, complete Level switch Name plate Screw Gasket Drain box
Item Description
Page 2 (2)
MAN B&W Diesel A/S
910 - Turbocharger System

91000 91001 91002 91003 91004 91005 91006 91007 91011 91014 0017 0143 0126 0206 0067 0130 0038 0017 0024 0019 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 Butterfly Valve Arrangement of Non-Return Valve Arrangement of Suction Pipe
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Gas and Air System
Plate P91000-0017
MAN B&W Diesel A/S
Page 1 (1)
Plate P91001-0143
MAN B&W Diesel A/S
Page 1 (2)

017 029 030 042 066 078 091 101 113 125 149 162 186 208 221 245 257 269 270 282 294 304

Item No.
Item Description
Plug screw Scavenge air reciever Screw Cover Stud Distance pipe Nut Distance pipe Screw Screw Plug screw O-ring Nut Distance pipe Screw Stud Sectional iron Sectional iron Nut Stud Plate Plate
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Charging Air Pipe
Plate P91002-0126
MAN B&W Diesel A/S
Page 1 (2)

012 024 036 061 073 085 097
Arrangement of Charging Air Pipe

Item No.
Item Description
Nut Compensator Screw Nut Screw Charging air pipe Screw
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Pipes and Receiver

MAN B&W Diesel
Plate P91003-0206
Page 1 (2)

018 031 043 079 080 092 114 126 138 151 163 175 187 199 210 222 234 258 271 283 305 317 330 342 354 366 378 391 401 413 425
Exhaust Pipes and Receiver

Item Description
Exhaust reciever Screw* Nut Guide pin Screw Nut Split pin Hinge rod Washer Manhole cover Sealing ring Locking plate Distance pipe Screw* Packing Compensator Gas inlet Screw* Distance pipe Wire gauze Screw* Distance pipe Screw* Washer Nut Packing Packing Compensator Screw* Screw* Nut Note: * These screws are special screws for hot joints, they are marked with a "T", and MUST NOT be used elsewhere!
Item Description
Page 2 (2)
Exhaust Receiver , Details Receiver,

MAN B&W Diesel
Plate P91004-0067
Page 1 (2)

013 025 037 049 062 074 098 108 121 145 157 169 170 194 216 228 241 265 277
Exhaust Receiver , Details Receiver,

Item Description
Nut Distance pipe Screw Support Support Support Nut Washer Spring pin Clamp Shim Spring plate Screw Adjustment screw Spring pin Support Support Screw Support
Item Description
Page 2 (2)
Air Cooler
Plate P91005-0130
MAN B&W Diesel A/S
Page 1 (2)

020 032 044 056 068 081 093 103 115 127 139 140 152 164 176 188 223 235 247 259 260 272 284 296 306 318 331 343
Air Cooler
Cooler insert* Plate Steel bar Screw Distance pipe O-ring Screw Distance pipe Frame O-ring Frame Screw Water mist catcher* Cover Nut Locking plate Screw Hinge Support Spring pin Cover O-ring Flange Screw Cross member Washer Stud Air cooler housing Note: * When ordering Spare Parts for this item, please state manufacturers Part No.
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Auxiliary Blower
Plate P91006-0038
MAN B&W Diesel A/S
Page 1 (2)

014 038 051
Arrangement of Auxiliary Blower

Item No.
Item Description
Auxiliary blower* Screw Nut Note: * When ordering spare parts for this item, please state manufacturers Part No.
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Butterfly Valve
Plate P91007-0017
MAN B&W Diesel A/S
Page 1 (2)

021 033 045 057 069 070 082 116 128
Butterfly Valve
Item No.
Item Description
Cover Packing Locking wire Screw Locking plate Housing Screw Shaft Flap
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Non-return Valve
Plate P91011-0024
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 060 072 084 118 131
Arrangement of Non-return Valve

Item No.
Item Description
Locking wire Screw Screw Support Clamp Support Valve flap Spring pin Shaft
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Suction Pipe
Plate P91014-0019
MAN B&W Diesel A/S
Page 1 (2)

018 031 043 067 079 080 092 102 114 126
Arrangement of Suction Pipe

Item No.
Item Description
Steel pipe Pipe coupling Transition pipe Screw Screw Nut Flange O-ring Disc Packing
Item Description
Page 2 (2)
MAN B&W Diesel A/S
911 - Safety Equipment

91101 91102 91102 91103 91104 0037 0028 0033 0018 0088 Safety Valve - Cylinder Relief Valve 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)

010 022 034 046 058 071 083 095 105 117
Safety V alve - Cylinder Valve

Item Description
Spindle Spring retainer Lock nut Spring Valve housing Stop ring Valve flap Valve guide Gasket Safety valve, complete
Item Description
Page 2 (2)
Relief Valve
Relief Valve 0028 P91102
Plate P91102-0028
P.C.D.
MAN B&W Diesel A/S
Page 1 (2)

016 028 030 041
Relief Valve
Item No.
Item Description
Relief valve (P.C.D. 465mm)* Screw* Packing* O-ring* Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Relief Valve
Relief Valve 0033 P91102
Plate P91102-0033
MAN B&W Diesel A/S
Page 1 (2)

016 028 030 041
Relief Valve
Item No.
Item Description
Relief valve (P.C.D. 615mm)* Screw* Packing* O-ring* Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Safety Valve - Scavenge Air System

MAN B&W Diesel
Plate P91103-0018
Page 1 (2)

011 035 047 059 060 072 096 106 118 131 143 155
Safety Valve - Scavenge Air System

Item Description
Safety valve, complete Spindle Washer Spring retainer Castle nut Split pin Screw Nut Valve flap Seal Valve seat Spring
Item Description
Page 2 (2)
Arrangement of Safety Cap

MAN B&W Diesel
Plate P91104-0088
Page 1 (2)

017 029 042 054 066 078 101 125 149 150 162 174 186 198 208 221 233 245 257 269 270
Arrangement of Safety Cap

Item Description
Protective guard Screw Bursting cap cover Check plate Screw Perforated cylinder Fitted bolt Screw Wing nut Washer Stud Bursting disc Gasket Block Screw Starting air pipe Screw Nut Washer Packing Screw
Item Description
Page 2 (2)
912 - Assembly of Large Parts

91201 91204 91205 91206 91207 91208 91210 91211 91216 91217 0095 0027 0208 0107 0092 0018 0163 0081 0009 0002 Arrangement of Stay Bolts Frame - Details Frame Box End Shields Arrangement of Piston Cooling Chain Wheel Frame - Upper Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Top Bracing - Arrangement
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Arrangment of Stay Bolt
Plate P91201-0095
MAN B&W Diesel A/S
Page 1 (2)

014 026 038 063 087 109 110 134
Arrangment of Stay Bolt

Item No.
Item Description
Screw Washer Protective cap Nut Stay bolt Guide bushing Guide bushing Assembling of stay bolt
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Frame - Details
Plate P91204-0027
MAN B&W Diesel A/S
Page 1 (2)

010 022 034 046 058 071 083 095 105 117 130 142 154 178 191 201 225 249 250 262 274 286 308 333 357 370 382 394
Frame - Details
Item No.
Item Description
Damper, oil pipe Screw Flange Nut Stud Damper, oil pipe Pipe clamp Screw Locking wire Damper, oil pipe Screw Damper, oil pipe Damper, oil pipe Screw Pipe holder Lubrication oil pipe Lubrication oil pipe Screw Lubrication oil pipe Lubrcation oil pipe Stud Nut Screw Lubrication oil pipe Lubrication oil pipe Lubrication oil pipe Screw Distance pipe
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Frame Box
MAN B&W Diesel
Plate P91205-0208
Page 1 (2)

016 028 041 053 065 077 090 112 124 136 148 161 173 185 197 207 219 220 232 244 268 281 293 303 315 327 339 340 364 376 411 423 435 447 460 472 484
Frame Box
Item Description
Packing, round Drain pipe Cover Screw Cover Frame box Washer Screw Spacer, tubular Nut Screw Screw Cover Nut Door fastener Stud Frame box door Nut Stud Cover Screw Plate Screw Fitted stud Locking pin Spring Key ring Packing, round Packing Frame box door Wing nut Door fastener Spring Stud Cover Screw Cover
Item Description
Page 2 (2)
End Shields
End Shields 0107 P91206
Plate P91206-0107
MAN B&W Diesel A/S
Page 1 (2)

011 023 035 047 059 060 084 106 118 143 167 180
End Shields
Item No.
Item Description
Screw Flange Packing Packing Cover Plug Plug Screw Shield, upper Shield, lower Screw Gasket
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Arrangement of Piston Cooling

Arrangement of Piston Cooling 0092 P91207
Plate P91207-0092
F E
MAN B&W Diesel A/S
Page 1 (2)

017 030 042 054 066 091 101 125 137 150 162 186 198 208
Arrangement of Piston Cooling

Item No.
Item Description
Drain pipe-piston cooling Drain pipe-piston cooling Screw Locking wire Sight glass Screw Drain box Screw Locking plate Screw Distance pipe Flange Screw Packing
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Chain Wheel Frame - Upper

MAN B&W Diesel
Plate P91208-0018
Page 1 (2)

012 024 036 048 061 073 085 097 107 132 144 156 168 181 193 203 215 227 239 240 288 311 347 359 360 384 396
Chain Wheel Frame - Upper

Item Description
Cover Screw Flange Screw Cover Screw Screw Chainwheel frame Screw Nut Screw Cover Screw Screw Guid pin Cover Top guard Screw Cover Guard Distance pipe Screw Screw Screw Distance pipe Stud Distance pipe
Item Description
Page 2 (2)
Bedplate
MAN B&W Diesel
Plate P91210-0163
Page 1 (2)

013 037 050 062 086 098 108 121 145 157 194 216 228
Bedplate
Item Description
Nut Stud Screw Bedplate Main bearing cap Spring pin Main bearing, upper shell Main bearing, lower shell Screw Grate Lock washer Screw Cover plate
Item Description
Page 2 (2)
Plate P91211-0081
MAN B&W Diesel A/S
Page 1 (2)

019 020 044 056 081 093 103 115 127 139 164 176 188 211 259 260 272 296

Item No.
Item Description
Spring Spring Screw Restriction for damper Restriction for damper Restriction for damper Screw Locking wire Oil seal Oil seal Nut Nut Stud Stud Axial vibration damper, upper part Cylindrical pin Axial vibration damper, lower part Restriction for damper
Item Description
Page 2 (2)
MAN B&W Diesel A/S
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
Plate P91216-0009
MAN B&W Diesel A/S
Page 1 (2)

028 041 053 077 089 100 112 124 136 148 173 185 197 219 220 232 256
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

Screw Washer Locking plate Liner for side chock, port side Liner for side chock, starboard Liner end chock Spherical washer Spherical washer Nut Protective cap Protectice cap Nut Distance pipe Spherical washer Spherical nut Holding-down bolt, M36 x 4 Stud for end chock bolt, M60 x 5.5
Page 2 (2)
MAN B&W Diesel A/S
Top Bracing - Arrangement
Plate P91217-0002
MAN B&W Diesel A/S
Page 1 (2)

011 023 059 060 072 084 106 118 131 143 155 179 180 192 202 214 238 251
Top Bracing - Arrangement

Screw Friction shim Distance pipe Washer Nut Split pin Plate, short* Plate, medium* Plate, large* Plate Guide pin** Screw Disc spring Distance pipe Washer Nut Plate Friction shim Note: * When ordering this spare part, please state length ** Only to be used during mounting
Page 2 (2)
MAN B&W Diesel A/S

S60MC-C 01

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Warning

MAN B&W Diesel A/S

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Instructions for Main Engines

MAN B&W Diesel A/S

General Safety Precautions

The sketch gives the approximate location of the valves concerned:

901 - Cylinder Cover

MAN B&W Diesel A/S

MAN B&W Diesel A/S

SAFETY PRECAUTIONS For detailed sketch, see 900-2

MAN B&W Diesel

MAN B&W Diesel

1. 1. Dismantle valves and pipes.

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

Cylinder Cover Panel

Plate P90151-0205 Item No.

Cylinder Cover Panel

Cylinder Cover - T ools Tools

Plate P90161-0110 Item No.

Cylinder Cover - T ools Tools

Cylinder Cover - Support Tool

Plate P90163-0004 Item No.

Cylinder Cover - Support Tool

Cylinder Cover - Lifting T ools Tools

Plate P90165-0001 Item No.

Cylinder Cover - Lifting T ools Tools

902 - Piston with Rod & Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S

SAFETY PRECAUTIONS For detailed sketch, see 900-2

MAN B&W Diesel

Piston Rod Stuffing Box

80 80 80 4x6 3x3 618 606 100 35 25

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston Rod Stuffing Box

Piston and Piston Rod Panel

Plate P90251-0246 Item No.

Piston and Piston Rod Panel

Piston and Piston Rod - Tools

Plate P90261-0107 Item No.

Piston and Piston Rod - Tools

Guide ring for piston

Piston and Piston Rod - Tilting Tools

Plate P90264-0012 Item No.

Piston and Piston Rod - Tilting Tools

Piston and Piston Rod - Support Tools

Plate P90265-0005 Item No.

Piston and Piston Rod - Support Tools

Support iron for piston

Piston - Lifting Tools