6S 50 MC-C, Vol. II - Maintenance Manual

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)
S50MC-C
DS 09091718
VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
90023
90060
0027
0001
Table of Contents, Volume II

Instructions for Main Engine
General - Safety Precautions
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Table of Contents
900
Volume II - Maintenance
No.
Edition
Title
900 - Introduction
Table of Contents
90023 0027 Instructions for Main Engine
90060 0001 General - Safety Precautions
901 - Cylinder Cover
101-01 0041 Cylinder Cover, Data
901-01 0250 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0065 Piston, Data
902-01 0270 Piston
102-02 0048 Piston Rod Stuffing Box, Data
902-02 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0056 Cylinder Liner, Data
903-01 0253 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0253 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0048 Crosshead Bearing, Data
904-01 0239 Crosshead Bearing
104-02 0050 Crosshead, Data
904-02 0239 Crosshead
104-03 0034 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0042 Crankpin Bearing, Data
904-04 0226 Crankpin Bearing
104-05 0043 Connecting Rod, Data
904-05 0231 Connection Rod
90451 0151 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
MAN B&W Diesel A/S
Page 1 (5)
Table of Contents
900
No.
90462
Edition
0020
Title
Connecting Rod - Tools
905 - Crankshaft, Thrust Bearing and Turning Gear

105-01 0004 Crankshaft Deflection, Data
905-01 0209 Crankshaft Deflection
105-02 0044 Main Bearing, Data
905-02 0241 Main Bearing
105-03 0039 Thrust Bearing, Data
905-03 0224 Thrust Bearing
105-04 0003 Journal Bearing, Data
905-04 0212 Journal Bearing
105-05 0033 Axial Vibration Damper, Data
905-05 0224 Axial Vibration Damper
105-08 0007 Angle Encoder, Data
905-08 0204 Angle Encoder
90551 0227 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0093 Main Bearing - Hydraulic Tools
90562 0125 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90570 0004 Thrust Shaft - Tools
90572 0003 Main Bearing - Measuring Tools
90573 0002 Tuning Wheel - Tools
906 - Control Gear
106-01 0041 Chain, Data
906-01 0236 Chain
106-02 0054 Chain Tightener, Data
906-02 0239 Chain Tightener
106-03 0036 Camshaft, Data
906-03 0214 Camshaft
106-04 0034 Camshaft Bearings, Data
906-04 0216 Camshaft Bearings
106-05 0024 Moment Compensator, Data
906-05 0220 Moment Compensator
106-06 0007 Replacement of Cams on Camshaft, Data
906-06 0203 Replacement of Cams on Camshaft
90651 0173 Chain Drive and Camshaft - Panel
90662 0046 Camshaft - Hydraulic Tools
90664 0005 Crankshaft - Pin Gauge
90668 0003 Camshaft - Pin Gauge
907 - Starting Air System
107-01 0017 Starting Air Distributor, Data
907-01 0216 Starting Air Distributor
107-02 0032 Start Air Valve, Data
MAN B&W Diesel A/S
Page 2 (5)
Table of Contents
900
No.
Edition
907-02
0214
Title
Starting Air Valve
908 - Exhaust Valve

108-01 0017 High-Pressure Pipe, Data
908-01 0212 High-Pressure Pipe
108-02 0087 Exhaust Valve, Data
908-02 0256 Exhaust Valve
108-03 0017 Exhaust Valve Actuator, Data
908-03 0218 Exhaust Valve Actuator
108-04 0015 Exhaust Valve Roller Guide, Data
908-04 0210 Exaust Valve Roller Guide
108-05 0002 Exhaust Valve Cam, Data
908-05 0203 Exhaust Valve Cam
108-07 0020 Exhaust Valve - Special Running, Data
908-07 0210 Exhaust Valve
90851 0200 Exhaust Valve - Panel
90862 0043 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90863 0016 Exhaust Valve - Extra Tools
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 0205 VIT System
109-03 0044 Fuel Pump Cam, Data
909-03 0229 Fuel Pump Cam
109-04 0050 Fuel Pump, Data
909-04 0224 Fuel Pump
109-05 0052 Fuel Pump Top Cover, Data
909-05 0223 Fuel Pump Top Cover
109-06 0042 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0034 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0043 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0025 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10911 0047 Fuel Valve, Data
90911 0231 Fuel Valve
10912 0038 Spindle Guide, Data
90912 0222 Spindle Guide
10913 0031 Non-Return Valve for Fuel Valve, Data
90913 0206 Non-Return Valve for Fuel Valve
MAN B&W Diesel A/S
Page 3 (5)
Table of Contents
900
No.
10914
90914
10915
90915
10916
90916
90951
90961
90966
90968
90974
90977
90979
90980
Edition
0060
0235
0050
0226
0016
0204
0462
0069
0008
0001
0001
0001
0001
0001
Title
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
Fuel Pump Spec. Running
Fuel Pump Special Running
Fuel Valve and Fuel Pump - Panel
Fuel Valve - Tools
Fuel Valve Nozzle - 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
910 - Turbocharger System

110-01 0032 Air Cooler Element, Data
910-01 0229 Air Cooler Element
110-02 0009 Non-Return Valve in Turbocharger, Data
910-02 0205 Non Return Valve in Tubocharger
910-03 0218 Auxilary Blower
110-03 0019 Auxilary Blower, Data
110-04 0005 Butterfly Valve, Data
910-04 0208 Butterfly Valves
110-05 0005 Turbocharger Turbine, Data
910-05 0206 Turbocharger Turbine
110-06 0018 Water Mist Catcher, Data
910-06 0214 Water Mist Catcher
91061 0071 Turbocharger System - Tools
91063 0017 Air Cooler - Tools
91063 0019 Air Cooler - Tools
91064 0002 Travelling Trolley
91066 0001 Air Cooler - Lifting Tools
911 - Safety Equipment
111-01 0025 Safety Valve, Data
911-01 0211 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 0007 Holding Down and End Chock Bolts (Epoxy), Data
912-02 0207 Holding Down and End Chock Bolts (Epoxy)
MAN B&W Diesel A/S
Page 4 (5)
Table of Contents
900
No.
Edition
112-03
912-03
912-05
91261
91265
91268
0015
0210
0201
0073
0003
0001
Title
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
Hydraulic Tools - End Chock Bolts (Iron 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
91356 0058 Lifting Tools, etc.
91357 0005 Open-Ended Spanners
91358 0013 Open Ended Slugging Spanners
91359 0003 Torque Spanners
91360 0003 Pliers
91361 0052 Combination Spanners
91362 0064 Ring Slugging Spanners
91363 0040 Spanners
91364 0059 Open-Ended Spanners
91366 0066 Instruments
91368 0004 Working Platforms
MAN B&W Diesel A/S
Page 5 (5)
Instructions for Main Engines

This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes, for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:
1. Name of vessel
2. Engine No.
built by
3. Plate No.
4. Part No.
5. Quantity required (and description)
Example:
M/S Nybo 7730 B&W P90201-0036 059

10 off (piston ring)
)The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.
To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation D refers to the information given on the
data sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN B&W Diesel A/S instructions. Emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.
A90023-0027
This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.
MAN B&W Diesel A/S

Teglholmsgade 41
DK-2450 Copenhagen
Denmark
Teleph.:+45 33 85 11 00
Telex :16592 manbw dk
Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
General Safety Precautions
900-2
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.
SAFETY PRECAUTIONS
X
Stopped engine
Shut off starting air supply At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply Not ME-engines
Shut off control air supply
Shut off air supply to exhaust valve Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
When referring to this page, please quote Safety Precaution A90060 Edition 0001
MAN B&W Diesel A/S
Page 1 (1)
901 - Cylinder Cover

101-01
901-01
90151
90161
0041
0250
0199
0105
Cylinder Cover, Data

Cylinder Cover
Cylinder Cover - Panel
Cylinder Cover - Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Cylinder Cover
101-1
Data
SAFETY PRECAUTIONS
D10101 Data
Special Edition 0041
101-1
Cylinder Cover
S50ME-C
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Shut off lubricating oil

Lock turbocharger rotors
Data
Ref.
D01-01
D01-02
D01-03
D01-04
D01-05
D01-06
D01-07
D01-08
D01-09
D01-10
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 stud, screwing-in torque
Cylinder cover stud, check distance
Cylinder cover, complete
Cylinder cover without valves
Cooling jacket
Exhaust valve stud
Cylinder cover stud
Hydraulic pressure, mounting
Hydraulic pressure, dismantling
When referring to this page, please quote Data D10101 Edition 0041
MAN B&W Diesel A/S
Value Unit
680
150
40
500
128 - 129
1700
1200
40
8
22
1500
1400 -1650
Nm
Nm
Nm
Nm
mm
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Cylinder Cover
101-1
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90151
P90151
P90151
P90151
P90151
P90161
P91351
P91351
P91351
P91351
Page 2 (2)
Item No. Description
46
58
60
83
130
10
34
58
130
Grinding tool for exhaust valve seat

Milling and grinding wheel for fuel valve seat
Milling and grinding wheel for starting valve seat
Grinding handle
Lifting chains
Cylinder cover tightening tool
Hydraulic pump, pneumatically operated
Hose with unions (1000 mm), complete
9-way distributor block, complete
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
901-1.2
Dismantling
1. Set blocking device A on the main starting

valve in the blocked position.
1.
Engage turning gear B.
C
D
Close fuel oil inlet valve C.
Close cooling water inlet valve B.

Close cooling water outlet valve E.
Open cooling water drain cocks F and G.
Shut off the air supply for the pneumatic
exhaust valve spring, and vent the system.
2. Connect a pressure gauge at minimess

point 455.
Close valve 420 and open valve 421 on the

hydraulic block.
Check that the system is pressure free.
M90101 0250D01
Check the pressure.
2.
When referring to this page, please quote Procedure M90101 Edition 0250
Page 1 (12)
901-1.2
Cylinder Cover
Dismantling
3.
MAN B&W Diesel
3. Close valve 531 for hydraulic operation of

the exhaust valve.
4. Remove the cooling water inlet and outlet
pipes from the exhaust valve and cylinder
cover.
Remove the drain pipe from the intermediate pipe between the cylinder cover and
the exhaust valve.
M90101 0250D03
Remove the oil supply pipe for the hydraulic damper in the exhaust valve.
4.
Dismount the fuel oil high-pressure pipes

between fuel valves and fuel pump.
See Procedure 909-14.2.
Dismount the control air pipe from the
starting valve.
Remove the starting air pipe.
Disconnect the plug for the electrical exhaust valve sensor.
M90101 0248D04
5. Remove the exhaust valve high-pressure

pipe.
Dismount the drain oil pipe from the exhaust valve oil cylinder and air cylinder, the
air pipe for pneumatic closing of the exhaust valve, and the pipes for the sealing
air arrangement.
M90101 0248D05
5.
Page 2 (12)
Cylinder Cover
MAN B&W Diesel
901-1.2
Dismantling
6. Remove the protective jacket enclosing the

intermediate pipe between the exhaust receiver and the exhaust valve.
6.
Dismount the screws in the flange between

the intermediate pipe and the exhaust receiver. The four lowermost screws need not
be dismantled, just loosened.
7. Place eight spacer rings, one around each

nut, and screw the eight hydraulic jacks
onto the studs.
Connect the high-pressure pump to the
jacks by means of the distributor block and
the high-pressure hoses.
M90101 0248D06
Remove the protective caps from the cylinder cover nuts.
7.
Using the vent screws of the hydraulic
jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913-1.
Loosen the nuts by applying the tommy
bar through the slots in the spacer rings.
Disconnect the high-pressure hoses from

the jacks.
Remove the hydraulic jacks and spacer
rings, and unscrew the nuts.
M90101 0250D07
Relieve the system of pressure.
8.
8. Hook the engine room crane on to the lifting attachment on top of the exhaust valve.
M90101 0248D11
Lift away the cylinder cover complete, and

land it on a couple of wooden planks.
Page 3 (12)
901-1.2
Cylinder Cover
Dismantling
9. Remove and discard the sealing ring between cylinder cover and cylinder liner.
M90101 0248D12
9.
MAN B&W Diesel
Page 4 (12)
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
1. Dismount all valves and pipes on the cylinder cover.

See Procedure 907-2.2, 908-2.2 and 90911.2.
1.
D01 09
Dismount all studs on top of the cylinder

cover.
2. Remove the four screws which secure the
cooling jacket to the cylinder cover.
Remove and discard the O-rings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.
3. Provide the cylinder cover with new Orings, well lubricated with oil.
M90101 0248O01
Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.
2.
D01 07
4. Lift the cylinder cover and guide the jacket/

cover into position, using the guide pin as
a reference (camshaft side).
Mount and tighten the screws for the cooling jacket.
M90101 0248O02
D01 08
M90101 0248O03
3.
4.
Page 5 (12)
901-1.3
Cylinder Cover
Overhaul
5.
MAN B&W Diesel
5. Recondition the valve bores as follows:

Fuel valve bore
6. The tool consists of a common spindle with
handle, a guide, a carbon cutter, a seating
face cutter and a grinding mandrel.
M90101 0246O04
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.
6.
Exhaust valve bore
7. The tool consists of a spindle with handle
and a grinding disc.
M90101 0246O06
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 0248O07
7.
Page 6 (12)
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
Starting valve bore

8.
8. The tool consists of a guide, a cutter, and
a grinding disc.
Recondition the starting valve bore and
seating in the same way as described for
the fuel valve bore.
When replacing valves on a cylinder cover
that is mounted on the engine, recondition
the valve bores/seating in the same way as
described here, but without dismounting
the studs.
M90101 0248O08
9. Clean the bores for safety valve/indicator

cock.
M90101 0248O09
9.
Page 7 (12)
Cylinder Cover
901-1.3
Overhaul
10.
10. Lubricate the threads with Never Seize' or

Molybdenum Disulphide (MoS2) and mount
the valve studs.
D01 01
D01 03
M90101 0248O10
D01 02
MAN B&W Diesel
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.
Provide the water connection flanges with
new gaskets, and keep the cylinder cover
ready for replacement.
Always fit new or overhauled valves before
a cylinder cover is mounted on the engine.
Page 8 (12)
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
1. Place a new sealing ring on top of the cylinder liner with the guide tabs in the fore
and aft direction.
1.
D01 06
This is to ensure that the tabs fit into the

two gas blow-out grooves milled in the cylinder cover guide recess.
Provide the cooling water connecting pipes

with new O-rings and lubricate them with
grease or soft soap.
Mount a new sealing ring in the groove of
the flange of the intermediate pipe.
Lower the cover carefully into position.
M90101 0248M01
2. Lift the cylinder cover by means of the

crane and carefully wipe the contact surface which faces the cylinder liner.
2.
During the landing, carefully check that the

cooling water connecting pipes engage
correctly with the holes in the cooling
jacket.
If necessary, adjust the distance D01-05 by

turning the stud.
M90101 0248M02
3. If cylinder cover studs have been removed

and remounted, check the distance the
stud is protruding from the cylinder cover.
3.
M90101 0246M03
D01 05
Page 9 (12)
901-1.4
Cylinder Cover
Mounting
4.
MAN B&W Diesel
4. Mount the cover nuts on the studs and

screw down.
Place eight spacer rings, one around each
nut, and mount the eight hydraulic jacks on
the studs.
M90101 0250D07
Connect the high-pressure pump to the

jacks by means of the distributor block and
the high-pressure hoses.
Using the vent screws of the hydraulic
jacks, vent the system, and then increase
the pressure as stated in Data.
Procedure 913-1.
Tighten the nuts by applying the tommy bar
through the slots in the spacer rings.
5.
Relieve the system of pressure.
Finally, remove the hydraulic jacks and
spacer rings from the nuts.
M90101 0248M04
5. Mount the protective caps on the cylinder

cover studs.
Align the intermediate pipe so that the
holes in the flange of the intermediate pipe
are in line with the threaded holes in the
exhaust receiver.
Mount the screws of the flange between
the intermediate pipe and the exhaust receiver.
Note!
Lubricate the screws with anti-seize
paste containing Molybdenum Disulphide
(MoS2) before mounting.
Mount the insulating jacket around the intermediate pipe.
Page 10 (12)
Cylinder Cover
901-1.4
Mounting
MAN B&W Diesel
6. Mount the drain oil pipes and the air pipe

for pneumatic closing of the exhaust valve.
6.
Mount the high-pressure pipe for the hydraulic valve gear.

7. Mount the starting air pipe and control air
pipe for the starting valve.
Mount the plug for the electrical sensor for

the exhaust valve.
Mount the drain pipe on the intermediate
pipe between the exhaust valve and the
cylinder cover.
M90101 0248M05
Mount the cooling water inlet and outlet

pipes on the exhaust valve.
7.
Mount the fuel oil high-pressure pipes for
the fuel valves.
Mount the oil supply pipe for the hydraulic
damper in the exhaust valve.
Shut the drain valves and open the cooling

water inlet. After venting the cylinder section, shut the vent cocks and open the
cooling water outlet valve.
Open the fuel oil. Open the lubricating oil
and air supplies to the exhaust valve.
M90101 0248M06
Connect the outlet pipe from the return oil

pipe on the fuel valves.
Caution!
The air supply to the exhaust valve must
always be connected before starting the
hydraulic oil pumps.
Page 11 (12)
901-1.4
Cylinder Cover
Mounting
8.
MAN B&W Diesel
8. Open valve 531 for hydraulic operation of

the exhaust valve.
M90101 0250M07
9. Close valve 421 and open valve 420 on the

hydraulic block.
M90101 0250M08
9.
Page 12 (12)
Cylinder Cover Panel
Plate
P90151-0199
P90151
0199
When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90151-0199
Item
No.
010
022
046
058
060
071
083
095
105
117
130
201
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Grinding tool for exhaust valve seat
Milling and grinding wheel for fuel
valve seat
Milling and grinding wheel for starting
valve seat
Dismantling tool for fuel valve seat
Handle for cutting and grinding tool
Grinding ring for starting valve
Grinding handle
Pressure tester for safety valve
Lifting chains
Handle for cutting and grinding tool
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90161-0105
Page 1 (2)
MAN B&W Diesel A/S
Plate
P90161-0105
Item
No.
Item Description
027
039
040
052
064
090
100
111
206
218
Hydraulic jack, complete

Support
Support
O-ring with back-up ring
Spanner
Tommy bar
Stud setter
Hydraulic tool set, complete
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
902 - Piston with Rod & Stuffing Box

102-01
902-01
102-02
902-02
90251
90261
90264
90265
90266
0065
0270
0048
0221
0237
0108
0002
0001
0002
Piston, Data
Piston
Piston Rod Stuffing Box, Data
Piston Rod Stuffing Box
Piston and Piston Rod - Panel
Piston and Piston Rod - Tools
Piston and Piston Rod - Tilting Tools
Piston and Piston Rod - Support Tools
Piston - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Piston
102-1
Data
SAFETY PRECAUTIONS
D10201 Data
102-1
S50ME-C
Piston
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
D01-05
D02-01
D02-02
D02-03
D02-05
D02-06
D02-07
D02-08
D02-09
D02-10
D02-11
D02-12
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
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 rod/crosshead, tightening torque + angle
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 top, max. permissible burn-away
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
MAN B&W Diesel A/S
Value Unit
128 - 129
7
430
300
80
80
100/30
17.2
14.2
13.2
10.2
15
12.4
9.4
28
3.4
2.4
0.35-0.4
0.87
921
200
565
57
21
150
1.1
mm
bar
Nm
Nm
Nm
Nm
Nm/
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
Nm
mm
Page 1 (2)
Piston
102-1
Data
Plate
P90251
P90251
P90251
P90251
P90251
P90251
P90251
P90251
P90261
P90264
P90265
P90266
P90366
P90451
Page 2 (2)
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
Tools for tilted lift
Support for piston
Lifting tool for piston
Crossbar for cylinder liner
118 Rubber cover for crosshead
MAN B&W Diesel A/S
Piston
902-1.1
Checking
Piston
S60MC-C
0270
Checking
902-1.1
1.
Scavenge port inspection

To detect possible leakages from the piston or
cylinder cover, keep the cooling water and cooling oil circulating during the scavenge port inspection.
Turn the engine at least a revolution and

start with a unit arriving downwards, just
above the scavenge air ports.
Inspect the piston rod and the lower part of
the cylinder wall. While the piston is passing downwards, inspect the piston skirt, all
the piston rings, the ringlands and the piston top.
HN902-1.1 256 01
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 maneouvring side.
2.
2. Inspect the rings, one at a time, and note

down the results. See Volume I, Operation,
Chapter 707.
HN902-1.1 256 02
3. Check the movability and the tension of the

piston rings, by pressing against them with
a wooden stick.
HG902-1.1 204 03
3.
MAN B&W Diesel A/S
Page 1 (20)
Piston
902-1.1
Checking
4.
4. Ring grooves:
Measure the total clearance between the
piston rings and the ring grooves.
D02-18
The total clearance must not exceed the

value stated in Data.
Measurements are to be taken at the top
(E) and bottom (F) between the piston ring
and piston ring groove.
D02-19
Total clearance = E + F.
5. Uppermost piston ring:
If possible, measure the depth of the pressure relief grooves with a caliper.
HM902-1.1 246 15
The piston rings must be replaced if the radial depth of the grooves has worn down to
less than stated in Data D02-46.
5.
D02-46
Min. 1
mm
Checking of piston rings and piston crown,

in connection with piston overhaul:
6. Remove the piston from the cylinder and
place it on the piston support.
Note!
GN902-1.2 204 08
It is recommended to replace all the piston rings whenever a piston is removed

from the engine.
GN902-1.2 204 08
6.
For evaluation of the rings, see Volume I,

Chapter 707.
Page 2 (20)
MAN B&W Diesel A/S
Piston
902-1.1
Checking
7.
7. Before dismantling the piston rings, measure the free ring gap of all the piston rings.
D02-15
8. Take off the piston rings by means of the

ring expander.
Clean and inspect the rings.
BM902-1.1 232 07
9. Measure the radial width of the rings. Note

down the results
See Volume I, Operation, Chapter 707.
GN902-1.1 222 14
8.
9.
GN902-1.1 204 08
D02-08
D02-09
MAN B&W Diesel A/S
New
Worn
Page 3 (20)
Piston
902-1.1
Checking
10.
10. Clean the ring grooves and check them for

burn marks or other deformation.
Measure the ring grooves with a caliper
gauge, see Data D02-10 and D02-11.
D02-10
D02-11
Clearance in piston ring grooves:

The maximum vertical height in a worn ring
groove must not exceed the value stated in
Data.
Max 2 mm
Max 2 mm
The groove is also worn out if there is no

chromium layer.
KM902-3.0 47 05
11. Clean the piston crown and check the burnaway by means of the template. For maximum permissible burn-away value, see Data.
11.
D02-12
Check the burn-away on the whole circumference of the piston crown. Note down the
results for later reference.
AM902-3.0 77 04
12. 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 expander to prevent unintended deformation of the rings.
Do not expand the rings more than necessary. The upper ring (CPR-ring) should not
be expanded more than to the milled mark
on the ring expander.
GN902-1.1 222 14
12.
Page 4 (20)
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
Dismantling
902-1.2
1.
1. Turn the crosshead down far enough to give

access to the piston rod stuffing box and
the screws for the piston rod.
2. Release the stuffing box by removing the
innermost screws from the stuffing box
flange.
Note!
3. Remove the screws from the piston rod.
MN902-1.2 235 01
Do NOT remove the outermost screws

from the flange.
GN902-1.2 204 02
2.
HN902-1.2 237 03
3.
MAN B&W Diesel A/S
Page 5 (20)
902-1.2
Piston
Dismantling
4.
4. Mount the two distance pieces on the piston

rod foot to protect the lower scraper ring
and to guide the stuffing box.
5. Dismount the cylinder cover.
Carefully smooth out any wear ridges at the
top of the cylinder liner.
HN902-1.2 256 04
6. Make a scratch mark in liner and piston

cleaning ring to ensure the correct mounting.
Remove the piston cleaning ring.
Carefully remove any wear ridges at the top
of the cylinder liner.
GN902-1.2 204 05
5.
GN902-1.2 237 06
6.
Page 6 (20)
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
7.
7. Turn the crosshead towards TDC, while

checking that the stuffing box lands correctly on the distance pieces.
8. Turn to TDC.
Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two fixed claws of the tool fit into
the lifting groove of the piston.
Fit the third, adjustable, claw of the tool to
the lifting groove and tighten it up against
the stop of the tool, see Data D02-25.
GN902-1.2 204 06
The top of the piston is now free of the cylinder liner.
8.
GN902-1.2 204 07
Lift the piston out of the cylinder liner.
MAN B&W Diesel A/S
Page 7 (20)
Piston
902-1.2
Dismantling
9.
9. If the lifting height is limited, it can be necessary to guide the piston rod foot in between the cylinder cover studs.
Note!
Alternatively, with low lifting height,
remove one of the cylinder cover studs
with the stud setter.
MN902-1.2 256 09
10. Lower the piston rod foot and stuffing box

through the opening in the platform.
Place the two halves of the support around
the piston rod and secure the two halves
with screws.
11. Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit.
10.
Clean, measure and recondition the cylinder liner.

See Procedure 903-1.
GN902-1.2 204 08
D02-20
GN902-1.2 204 09
11.
Page 8 (20)
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
12.
12. Turn the crosshead down far enough to permit mounting of the protective rubber cover
on the crosshead bearing cap.
The protective rubber cover should remain
in place to protect the crosshead bearing
journal from impurities until the piston is remounted.
If the space conditions above the engine make

it impossible to remove the piston in the normal
way, the piston can be removed as follows:
13. Remove one or two cylinder cover studs,
using the stud setter.
GN902-1.2 204 10
Low lifting height
Lift the piston high enough to give ample

room over the cylinder cover studs.
13.
GN902-1.2 243 11
Place the supporting tools on the cylinder

cover studs.
MAN B&W Diesel A/S
Page 9 (20)
902-1.2
Piston
Dismantling
14.
14. Place the collar ring on the supporting tools

and mount the clamp on the collar ring.
Check that the distance pieces have contact with the piston.
Remove the lifting tool from the piston.
Hook the crossbar on to the crane and attach the collar ring to the crossbar.
15. Lift the piston to the maximum crane height.
Run the crane athwartship and, at the same
time, tilt the piston.
Note!
Tilting of the piston must only take place
with the piston rod stuffing box mounted
on the piston rod.
GN902-1.2 243 12
Keep the piston rod clear of the cylinder liner and studs while carrying out the tilting.
When space conditions permit, straighten
up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
15.
When the piston is at a suitable height
above the platform cut-out, position the piston support around the piston rod and
clamp.
Now lower the piston while guiding the support to the platform cut-out.
After landing the piston and ensuring that it
rests correctly on the support, remove the
tilting tool.
Note!
GN902-1.2 243 13
On engines with extremely low lifting

height, use the engine room double-jib
crane instead of the transverse piece.
Page 10 (20)
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
Overhaul
902-1.3
1.
1. Ease the piston down so that the stuffing

box is below the floor.
D02-20
2. Assemble the two halves of the piston support around the piston rod and land the piston on the support.
3. Dismount the locking wire and the innermost screws between the rod and the piston crown.
JM902-1.3 234 01
Check and remove the piston rings.

JM902-1.3 234 02
2.
JM902-1.3 234 03
3.
MAN B&W Diesel A/S
Page 11 (20)
Piston
902-1.3
Overhaul
4.
4. Dismount the locking wire and screw up the

support screws of the piston support to a
position just below the piston skirt.
Remove the piston skirt screws.
D02-23
5. Screw the four screws of the support downwards until the skirt rests on the support.
If the skirt will not budge, free it by means
of two dismantling screws.
JM902-1.3 234 04
Lift away the piston crown.

Remove and discard the sealing rings on
the piston rod and on the skirt.
6. Dismount the bolts of the cooling oil pipe
flange.
5.
D02-21
Mount the eye bolts and lift out the cooling

oil pipe.
JM902-1.3 234 05
After inspection of the cooling oil pipe, remount the pipe.
6.
D02-24
GN902-1.3 204 06
D02-06
Page 12 (20)
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
7.
Alternatively, the piston can be dismantled

in the following way:
7. With the piston standing in the piston support tool, remove the piston rod stuffing
box, see Procedure 902-2.3.
8. Lift the piston with the lifting tool. Land the
piston rod foot on a wooden plank.
During the lift, follow with the crane to

keep the crane positioned vertically
above the lifting point.
KM902-1.3 240 06
Note!
Lower the piston crown to the platform and

land it on a wooden plank, so that it is possible to remove the lifting tool.
10. Lift the piston rod foot clear of the wooden

plank.
GN902-1.3 243 08
9. 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.
8.
9.
GN902-1.3 243 09
Keep lifting until the piston rod is in a vertical position.
KM902-1.3 240 09
10.
MAN B&W Diesel A/S
Page 13 (20)
Piston
902-1.3
Overhaul
11.
11. Place the piston in an upright position with

the piston crown resting on wooden blocks.
Dismount the locking wire and the innermost screws between the rod and the piston crown. Lift the piston rod away and land
it in a horizontal position on a couple of
wooden planks.
D02-22
GN902-1.3 243 11
12. Remove the locking wire and the screws in

the skirt and mount two eye bolts in the
holes intended for dismantling screws. Lift
the skirt and land it on a couple of planks.
13. Thoroughly clean and inspect all parts of
the piston.
Regarding check of the piston crown, see
Procedure 902-1.1.
12.
Replace all sealing rings of the piston. All
the new sealing rings must be coated with
lubricating oil before the piston is assembled.
D02-23
Coat all screws with Molybdenum Disulphide (MoS 2).
GN902-1.3 204 11
Assemble the piston in the reverse order to

disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.
Tighten all the screws diagonally to the
torque stated in Data.
13.
D02-03
GN902-1.3 204 12
D02-05
Page 14 (20)
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
14.
14. Lock all the screws with locking wire.

Mount the locking wire in such a way that
the wire is tightened if one of the screws
works loose.
15. Fill the piston and piston rod with lubricating oil.
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.
HM902-1.3 204 13
Mount the pressure-testing tool around the

base of the piston rod.
15.
Check that there are no cracks in the piston

crown.
For overhaul of the stuffing box, see Procedure 902-2.3.
D02-01
MB902-1.3 204 14
Oil
MAN B&W Diesel A/S
Page 15 (20)
Piston
902-1.4
Mounting
Mounting
902-1.4
2.
1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1.
D02-20
Coat the piston rings, piston rod and cylinder liner with lubricating oil.
2. Mount the lifting tool on the piston crown.
3. Ensure that the stuffing box is correctly positioned over the guide pins in the distance
pieces mounted on the piston rod foot.
Coat the O-rings of the stuffing box with oil.
JM902-1.3 234 01
4. Remove the protective rubber cover from

the crosshead.
GN902-1.4 204 03
3.
GN902-1.2 204 10
4.
Page 16 (20)
MAN B&W Diesel A/S
Piston
902-1.4
Mounting
5.
5. Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit.
6. Turn the crosshead to a position 45 from
TDC.
7. Lower the piston into the cylinder liner

while guiding the piston rod foot through the
cut-out in the stuffing box flange until the
piston rings are inside the liner.
GN902-1.2 204 09
Mount the guide ring for piston rings on the

cylinder liner.
GN902-1.4 204 06
6.
GN902-1.4 204 07
7.
MAN B&W Diesel A/S
Page 17 (20)
902-1.4
Piston
Mounting
8.
8. Turn the crosshead nearly to TDC while

checking that the guide ring of the crosshead enters the centre hole in the piston
rod.
9. After turning the crosshead fully to TDC,
and ensuring that the piston rod has full
contact with the crosshead, unscrew the
adjustable claw of the lifting tool and pull
the lifting tool free of the lifting groove in the
piston
KB902-1.4 225 08
Remove the lifting tool and the guide ring

for piston rings.
9.
10. Turn down and land the stuffing box on the

stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
correctly centred.
GN902-1.4 204 09
Remove the distance pieces from the piston

rod foot.
KB902-1.4 225 09
10.
Page 18 (20)
MAN B&W Diesel A/S
Piston
902-1.4
Mounting
11.
12. Mount and tighten the piston rod screws.

Tighten the screws to the specified torque
and lock with locking wire. See Data. Use
either Data D02-02 or Data D02-07.
13. Mount the piston cleaning ring according to
the scratch mark.
GN902-1.2 204 02
11. Tighten down the piston rod stuffing box by

means of the screws, through the inner
holes in the stuffing box flange.
If the PC-ring is damaged (broken or

cracked), it must be replaced by another
ring. See Procedure 903-1.
12.
HN902-1.4 237 12
D02-02
or
D02-07
HN902-1.4 237 13
13.
MAN B&W Diesel A/S
Page 19 (20)
Piston
902-1.4
Mounting
14.
14. 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
one half revolution back.
15. Land the cylinder cover on the liner and
check the distance the stud is protruding
from the cylinder cover.
If necessary, adjust the distance D01-05 by
turning the stud.
GN902-1.4 204 12
16. Tighten the cylinder cover and mount the

necessary pipes.

Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple
of revolutions.
15.
D01-05
Start the engine and keep it running for

about 15 minutes at a number of revolutions
corresponding to very slow.
HN902-1.4 256 15
Then stop the engine and inspect the piston

rod and stuffing box.
Page 20 (20)
MAN B&W Diesel A/S
102-2
Data
SAFETY PRECAUTIONS
D10202 Data
102-2
PistonS50ME-C
Rod Stuffing Box
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
D02-26
D02-27
D02-28
D02-29
D02-30
D02-33
D02-34
D02-35
D02-36
D02-37
D02-38
D02-39
D02-40
D02-44
D02-45
Description
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
Check length for the six uppermost springs:
F 0 = 0 N................ L 0 =
F 1 = 153 +/ 7 N....... L 1 =
F 2 = 163 +/ 10 N..... L 2 =
Check length for the four lowermost springs:
F 0 = 0 N................ L 0 =
F 1 = 150 +/ 7 N....... L 1 =
F 2 = 200 +/ 10 N..... L 2 =
Stuffing box complete
Stuffing box half
MAN B&W Diesel A/S
Value Unit
80
80
80
4x6
3x3
Nm
Nm
Nm
mm
mm
639 mm
763 mm
835 mm
496
646
714
63
19
mm
mm
mm
kg
kg
Page 1 (2)
102-2
Data
Plate
P90251
P90251
P90451
Page 2 (2)
109 Mounting tool for stuffing box spring

122 Worktable for stuffing box
120 Rubber cover for crosshead
MAN B&W Diesel A/S
902-2.1
Checking
Piston
0221 Rod Stuffing Box
S46MCC
Checking
902-2.1
1.
1. After the piston rod stuffing box has been

dismantled, check the following clearances:.
D02-29
Uppermost scraper ring and sealing rings
Clearance at ring ends (scraper ring).

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

Total clearance (sealing rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends.
Total clearance. (D02-30)
B
A
The ring clearances stated in Data apply to

new rings.
2. Check the length of the springs at different

loads. Adjust the loads to achieve the
lengths stated in Data.
D02-30
D02-29
NB902-2.1 216 01
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.
D02-33
If the loads necessary are outside the limits

stated in Data, the springs must be discarded.
It is recommended to renew the springs for
the sealing rings when the rings are renewed.
HM902-5.0 70 02
D02-37
0$1 % : 'LHVHO $6
Page 1 (9)
902-2.2

Dismantling
Dismantling
902-2.2
1.
In connection with dismantling of the piston,

only the innermost screws in the stuffing box
flange should be removed.
If, in the period between piston overhauls, it becomes necessary to inspect the piston rod
stuffing box, proceed as follows:
1. Turn the crosshead to about 90 from TDC.
GN902-2.2 203 01
Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
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.
DM902-5.2 108 02
3. Mount the worktable around the piston rod

so that the two remaining screws in the
stuffing box flange can be loosened through
the holes.
DM902-5.2 108 03
3.
Page 2 (9)
0$1 % : 'LHVHO $6
902-2.2
Dismantling
4.
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.
6. Remove the two long dismantling screws

from the stuffing box and mount them in the
worktable.
DM902-5.2 108 04
5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame
bottom.
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.
DM902-5.2 108 05
5.
EN902-2.2 221 06
6.
0$1 % : 'LHVHO $6
Page 3 (9)
902-2.3
Overhaul
Overhaul
902-2.3
Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a
support placed over one of the cut-outs in the
top platform.
Work on the stuffing box is then carried out
from the platform below.
GM902-5.1 90 01
Overhaul inside the engine is carried out in the

same way as outside the engine.
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.
1.
Land the stuffing box on the worktable, and

remove the tackles and eye bolts.
D02-44
D02-44
2. Remove the O-ring of the stuffing box. If the

O-ring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.
2222041a
Remove the nuts from the stuffing box assembling bolts.
2222042a
2.
Page 4 (9)
0$1 % : 'LHVHO $6
902-2.3
Overhaul
3.
3. Take out the six bolts, and pull away one

stuffing box half.
D02-45
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.
6. Measure the clearance between the ring

segments to determine whether replacement is necessary.
2222043a
5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.
7.
Dismantle and stack the rings in the same
order as when fitted in the stuffing box.
D02-33
Carefully clean all the ring segments.

Inspect and assess the surface quality of
the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D02-37
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.
HM902-5.0 70 02
7. Check the lengths of the springs.

8.
HC902-5.1 98 07
9. Clean the halves of the stuffing box housing.
0$1 % : 'LHVHO $6
Page 5 (9)
902-2.3

Overhaul
10.
10. Lubricate the piston rod (in the area where

all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).
Assemble all the stuffing box ring units
round the piston rod, on the worktable, in
the following way:
Place the lowermost scraper ring segments on the worktable.
NB902-3 217 10
Place the spring round the segments,

and hook the spring ends together.
Repeat this procedure for the remaining
scraper rings.
11.
On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).
HC902-5.1 98 11
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).
11. Use the stuffing box half on the worktable
to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. 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.
Page 6 (9)
0$1 % : 'LHVHO $6
902-2.3
Overhaul
12.
12. 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.
D02-28
Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.
Mount the O-ring in the stuffing box groove.
Remove the worktable and lower the stuffing box until it rests against the distance
pieces on the piston rod foot.
HC902-5.1 98 12
13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.
Remove wire ropes and screws.
13.
22320313
D02-44
0$1 % : 'LHVHO $6
Page 7 (9)
902-2.4

Mounting
Mounting
902-2.4
1.
1. In connection with mounting of the piston,

only the innermost flange screws are to be
mounted and tightened, see data.
After overhauling the stuffing box inside the
engine, assemble the stuffing box halves on
top of the four screws.
Mount the two long screws from the worktable in the stuffing box.
Turn down the short screws so that the
stuffing box lands on the flange.
22420416
2. Turn the piston upwards until the stuffing

box is in place in the cylinder frame.
2.
Note!
Make sure that the two guide pins in the
flange enter the guide holes in the bottom
of the cylinder frame.
DM902-5.2 108 08
3. Mount two screws in the flange through the

holes in the worktable.
DM902-5.2 108 09
3.
Page 8 (9)
0$1 % : 'LHVHO $6
902-2.4
Mounting
4.
4. Remove the long screws from the stuffing

box and mount them in the worktable.
Remove the worktable from the piston rod.
5. Mount and tighten all the inner and outer
screws for the stuffing box. See Data.
6. Remove the protecting rubber cover from
the piston rod/crosshead.
Then turn the crankshaft a couple of revolutions.
DM902-5.2 108 10
Smear the piston rod with molybdenum disulphide.
Start up the engine and keep it running for

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

rod and stuffing box.
DM902-5.2 108 11
D02-26
D02-27
GN902-2.2 203 01
6.
0$1 % : 'LHVHO $6
Page 9 (9)
Piston and Piston Rod Panel
MAN B&W Diesel A/S
Plate
P90251-0237
Page 1 (2)
Plate
P90251-0237
Item
No.
014
026
040
051
075
087
099
109
110
122
134
158
160
Page 2 (2)
Piston and Piston Rod Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Lifting tool, piston rod foot
Lifting tool, cylinder liner
Template, piston top
Distance piece, stuffing box
Cover, stuffing box hole
Mounting tool, stuffing box spring
Pressure test tool, piston
Worktable, stuffing box
Expander, piston ring
Guide screw, piston crown
Guide screw, piston crown
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90261-0108
Page 1 (2)
Plate
P90261-0108
Item
No.
019
Page 2 (2)
Item Description
Item
No.
Item Description
Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Extra Tools
Plate
P90264-0002
P90264
Piston
0002 and Piston Rod - Extra Tools
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90264-0002
Item
No.
015
027
Piston and Piston Rod - Extra Tools
Item Description
Item
No.
Item Description
Lifting collar
Support for tilting tool
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90265-0001
Page 1 (2)
Plate
P90265-0001
Item
No.
010
Page 2 (2)
Item Description
Item
No.
Item Description
Support iron for piston
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90266-0002
Page 1 (2)
Plate
P90266-0002
Item
No.
016
Page 2 (2)

Item Description
Item
No.
Item Description
Lifting tool for piston
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication

103-01
903-01
103-02
903-02
90361
90362
90364
90366
0056
0253
0031
0253
0084
0002
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
103-1
Data
SAFETY PRECAUTIONS
103-1
D10301 Data
Cylinder Liner
S50ME-C
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
D03-01
D03-03
D03-04
D03-05
D03-06
D03-16
D03-17
D03-18
Description
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-ring replacement criteria:
Value Unit
150
500
498.3
1820
170
38.8
0.5
Nm
mm
mm
kg
kg
mm
mm
Liner diameter: 500 mm

Liner wear:
Install:
0 0.50 mm
Standard PC-ring
(new or max. wear of diameter 0.50 mm)
0.50 1 mm
Oversize PC-ring
> 1 mm
Dummy ring
MAN B&W Diesel A/S
Page 1 (2)
Cylinder Liner
103-1
Data
Plate
P90251
P90361
P90362
P90366
Page 2 (2)
51 Lifting tool for cylinder liner

Measuring tool for cylinder liner
Cylinder Liner - Extra Tool
MAN B&W Diesel A/S
Cylinder Liner
903-1.1
Checking
Cylinder
S50MC Liner
0253
Checking
903-1.1
1.
1. Dismount the cylinder cover, piston and

PC-ring.
D03-03
Clean the cylinder liner and scavenge air

ports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside
micrometer at the positions indicated on the
measuring tool. See Data.
4. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.
5. Carefully scratch over any scores or marks
on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3.
DM903-2.0 90 01
3. Take measurements in the fore-and-aft and

athwartship directions.
2.
6. Check the lubricating points of the cylinder

by pumping cylinder oil to each individual
lubricating point.
GN903-1.1 203 03
Clean any blocked lubricating duct.
GM903-1.1 253 04
4.
MAN B&W Diesel A/S
Page 1 (10)
903-1.1
Cylinder Liner
Checking
7.
7. 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 liner,
the PC ring must also be inspected.
GW903-1.1 247 07
When the piston is removed, the PC-ring

must always be taken up before the piston.
8.
8. Measure the PC ring radial width B, and

find the most worn place. Compare with
data D03-16 and calculate the wear of the
PC ring. Multiply the wear by 2 to get the
PC ring diameter wear.
DM903-1.1 237 08
Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner measuring tool. Compare
the measurements with the diameter of a
new liner as stated in data. Calculate the
wear of the liner.
Compare the PC ring diameter wear with
the wear of the liner. If wear of the two components does not deviate more than D0317, then reinstall the PC ring.
If the deviation between PC ring wear and
liner wear is more than D03-17, or if the PC
ring is broken or cracked, replace the ring
with a new PC ring, an oversize ring or a
dummy ring according to the table in D0318 on the Data sheet.
If it is needed to install an oversize PC ring,
contact MAN B&W Diesel for advice.
When a new liner is installed, also a new
PC ring must be installed. When a new liner
is ordered, also a new PC ring must be ordered.
Page 2 (10)
MAN B&W Diesel A/S
Cylinder Liner
903-1.2
Dismantling
Dismantling
903-1.2
1.
1. Dismount the cylinder cover.

Discard the sealing ring from the top of the
cylinder liner.
Turn the piston down far enough to make it
possible to remove the wear ridges at the
top of the liner.
D03-01
Dismount the piston and the PC-ring.

Note!
Tighten the lifting screws to the torque
stated in Data.
GN903-1.2 224 01
Mount the two lifting screws in the cylinder

liner.
2.
Check with a 0.05 mm feeler gauge that

there is no clearance between the screws
and the cylinder liner.
This must be done whenever the lifting
tools are mounted on the liner.
Dismount the four cooling water pipes between the cooling jacket and cylinder cover
and clean them carefully.
GN903-1.2 224 02
2. Disconnect at the exhaust side of the cylinder the oil pipes leading from the cylinder lubricator to the non-return valves.
MAN B&W Diesel A/S
Page 3 (10)
903-1.2
Cylinder Liner
Dismantling
3.
3. Remove the screws of the cooling water inlet pipe.

4. Attach the crane hook to the lifting crossbar.
Hook the chains from the lifting tools on to
the crossbar and lift the cylinder liner with
the cooling jacket out of the cylinder frame.
Note!
EN903-1.4 205 03
Low lifting height in the engine room may

require the removal of one or more cylinder cover studs before dismantling the
cylinder liner.
4.
D03-05
Land the cylinder liner vertically on, for instance, a couple of planks.
Clean the cylinder frame internally, taking
special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Discard the O-rings on the cooling water
pipes.
GN903-1.2 224 04
Clean the pipes carefully.
Page 4 (10)
MAN B&W Diesel A/S
Cylinder Liner
903-1.2
Dismantling
5.
5. The lifting screws are also used for transporting the cylinder liner.
HN903-1.2 244 05
D03-05
MAN B&W Diesel A/S
Page 5 (10)
Cylinder Liner
903-1.3
Overhaul
Overhaul
903-1.3
1.
1. Unscrew the nuts on the non-return valves

and remove the valves.
Clean and inspect the non-return valves.
2. Attach two tackles to the crossbar, as
shown.
Mount two lifting eye bolts in the cooling
jacket.
GN903-1.3 224 01
Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
Remove the two lifting screws from the cylinder liner.
Remove the four clamps which fix the cooling jacket to the cylinder liner.
2.
EN903-1.3 237 02
3. Lift the cooling jacket away by means of the

tackles, and land it on the wooden planks.
3.
EN903-1.3 237 03
D03-06
Page 6 (10)
MAN B&W Diesel A/S
Cylinder Liner
903-1.3
Overhaul
4.
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.
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.
HN903-1.3 221 04
5. It is recommended to use a wear ridge milling machine to create the groove. For use
of the milling machine, see suppliers instruction.
5.
The maximum depth of the groove is calculated as S max. = D x 0.0045.
MB903-1.3 231 04
Check the distance C before grinding to ascertain that the wear ridge was caused by
the top ring at TDC.
Note!
6.
It is of the utmost importance that the

groove is made with a regular rounding
as shown in the sketch.
S
R=4-5 mm
MN903-1.3 229 05
MAN B&W Diesel A/S
Page 7 (10)
Cylinder Liner
903-1.3
Overhaul
7.
7. Replace the two uppermost O-rings on the

cylinder liner.
8. Lower the cooling jacket on to the cylinder
liner.
Note!
GN903-1.3 203 04
Make sure that the scratch marks in the

fuel pump side of the cylinder liner and
cooling jacket coincide.
9. Mount the four clamps in the groove of the
liner, and tighten the screws.
Remove the tackles from the lifting crossbar and the cooling jacket lifting eye bolts.
8.
10. Mount the non-return valves for cylinder lubrication. Tighten the nuts and connect the
lubricating oil pipes.
EN903-1.3 237 08
D03-06
EN903-1.3 237 09
9.
Page 8 (10)
MAN B&W Diesel A/S
Cylinder Liner
903-1.4
Mounting
Mounting
903-1.4
1.
1. Loosen the water connections on the cooling jacket.

Mount the two lifting screws in the cylinder
liner. See Data D03-01.
Hook the chains from the lifting crossbar on
to the lifting screws, and lift the jacket/liner
assembly.
Mount the lowermost O-ring and apply a little lubricating oil on the ring.
D03-01
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.
Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connections on the cooling jacket.
DM903-1.4 237 01
Coat the joint surfaces with permatex or a

similar liquid sealing compound.
GN903-1.4 224 02
2.
MAN B&W Diesel A/S
Page 9 (10)
903-1.4
Cylinder Liner
Mounting
3.
3. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount and
tighten the screws.
4. Connect and tighten the oil pipes for the
cylinder lubrication.
Vent the cylinder lubricating system until
oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.
EN903-1.4 205 03
When this is in order, check that each individual lubricating point functions correctly.
4.
5. Lubricate the upper part inside of the cylinder liner with cylinder lubricating oil and
mount the piston and the PC ring.
6. Mount the sealing ring and the cylinder cover.
GM903-1.4 253 04
Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.
GN901-1.4 203 01
6.
Page 10 (10)
MAN B&W Diesel A/S
Cylinder Lubricator
MAN B&W Diesel
103-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X
X
X
X
X
X
Stopped engine
Shut off safety air supply Not ME engines
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
Cylinder Lubricator
103-2
MAN B&W Diesel
Data
Plate
P90364
Page 2 (2)
Item No.
Description
Test Equipment for Lubricator
When referring to this page, please quote D10302 Edition 0031
Cylinder Lubricators
MAN B&W Diesel
903-2.1
Checking
Check of Oil Injection:
1.
With stopped engine and normally when the

system has been disassembled:
Turn the piston concerned to BDC and

check inside the liner with a mirror and a
powerful light source that all lubrication
points are working properly.
For use of the MOP Panel, see Volume I
Chapter 703.
M90302 0242C02
1. Activate the prelub.-function on the MOP

control panel, and check that the lubricators concerned are operating correctly by
watching through the covers for scavenge
port inspection.
With running engine:

2. The system is automatically checked.
The Engine Control System will generate an
alarm if faults occur.
Additionally, it is possible to check the
pressure shocks from the injection of the
lubricators on each lubricator pipe by feeling with a hand.
If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow.
Page 1 (8)
903-2.2
Dismantling
MAN B&W Diesel
Dismantling of lubricators:
1.
The engine must be stopped and blocked before dismounting a lubricator. Stop the cylinder
oil pump station.
Disconnect the electrical plug on the side of
the lubricator.
00:00
ON
OFF
Bourdon Sedeme
CC
M90302 0253D01
565
560
2.
1. Mount a pressure gauge at minimess

point 565.
Check the pressure.
Close valve 560. Check that the cylinder lubricator is pressure free. If pressure is still
present, activate the prelub function on
the MOP panel to remove the pressure.
Close the supply valve for cylinder lubricating oil.
Remove the electrical plug for the lubricator.
2. Unscrew the top cover screws and disconnect the cover with pertaining pipes.
M90302 0253D02
Check that the cylinder supply is closed.

Disconnect the cylinder oil supply pipe.
Disconnect the drain pipe.
3. Unscrew the four screws on the side that
secure the lubricator to the hydraulic cylinder unit.
Pull the pipe flange aftwards and pull the
lubricator out and clear of the guide pins.
3.
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.
M90302 0253D03
Reduce the engine load to below 40%

of MCR
Page 2 (8)
Dismount the lubricator as described in

steps 1-3
Mount a spare lubricator as described
in Procedure 903-2.4.
MAN B&W Diesel
903-2.3
Overhaul
1. Place the lubricator in a bench vice with

soft jaws.
1.
Remove the adjusting screw with bushings.

Discard the O-ring from the adjusting screw.
2. Push down the cylinder block and remove
the four screws from the cylinder block.
Remove the springs and actuator piston

with plungers.
Remove and discard the O-ring from the
cylinder block.
M90302 0246O01
3. Pull up the cylinder block.
M90302 0246O02
2.
M90302 0253O03
3.
Page 3 (8)
903-2.3
Overhaul
4.
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.
M90302 0246O04
6. Fit the non-return valve with new O-rings.

Mount the non-return valves in the cylinder
block.
M90302 0253O05
5.
M90302 0246O06
6.
Page 4 (8)
MAN B&W Diesel
903-2.3
Overhaul
7. Fit the cylinder block with a new O-ring.

Pre-assemble the cylinder block with the
actuator piston and plungers to ensure correct guidance of the plungers, before finally
assembling the cylinder block unit.
7.
8. Remove the cover from the terminal box,

and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box.
M90302 0253O07
Mount the spring and press down the actuator piston with plungers. Mount the special screw supplied with the test equipment
for accumulators to keep the spring compressed.
Carefully unscrew the feedback sensor and

remove and discard the O-ring.
8.
M90302 0246O08
Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.
M90302 0246O09
9.
Page 5 (8)
903-2.3
MAN B&W Diesel
M90302 0242O08
Overhaul
Page 6 (8)
MAN B&W Diesel
903-2.3
Overhaul
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.
13.
14. Mount the cylinder block assembly in the

cylinder housing.
Check that the spring pin engages correctly with the cylinder block assembly.
Remove the special screw.

15. Mount the adjusting screw fitted with a
new O-ring and the distance bushing.
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.
M90302 0246O13
Mount the screws and tighten the block to

the housing.
14.
M90302 0253O14
Cover all surfaces with a thin layer of oil.
M90302 0246O01
15.
Page 7 (8)
903-2.4
Mounting
MAN B&W Diesel
1. Mount new O-rings on the lubricator and

on the cover with pipes.
1.
x6
Use a little clean grease to keep the Orings in place during mounting.
2. Mount the lubricator and tighten the screws
on the hydraulic cylinder unit.
Tighten the top cover screws in the end of
the lu-bricator to the pipe connection.
M90302 0253M01
Mount the cylinder oil supply pipe.

Mount the drain pipe.
Open for the cylinder lubrication oil supply.
3. Mount the electrical plug.
2.
Open valve 560 for hydraulic oil supply.

Open the valve for cylinder lubricating oil
supply.
M90302 0253M02
When possible, test the prelubrication of

the cylinder on the MOP panel.
M90302 0253M03
3.
560
Page 8 (8)
Plate
P90361-0084
P90361
0084
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90361-0084
Item
No.
036
Item Description
Item
No.
Item Description
Cylinder gauge, complete
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90362-0002
P90362
0002
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90362-0002
Item
No.
018
Item Description
Item
No.
Item Description
Wear ridge milling machine
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90364-0004
Page 1 (2)
P90364
Test
0004Equipment for Lubricator
MAN B&W Diesel A/S
Plate
P90364-0004
Item
No.
019
020
032
044
056
068
081
103
115
139
152
164
176
211
223
Item Description
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
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90366-0007
P90366
0007
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90366-0007
Item
No.
021
Item Description
Item
No.
Item Description
Crossbar for cylinder liner
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
0048
0239
0050
0239
0034
0217
0042
0226
0043
0231
0151
0069
0020
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
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Crosshead Bearing
104-1
Data
SAFETY PRECAUTIONS
104-1
S50ME-C
D10401 Data
Crosshead Bearing
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
D02-02
D02-07
D02-20
D04-01
D04-02
D04-03
D04-04
D04-05
D04-06
D04-07
D04-21
D04-51
D13-01
D13-02
Description

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, upper
Crosshead bearing shell, lower
Crosshead bearing cap with bearing shell
Crosshead complete
Connecting rod complete
MAN B&W Diesel A/S
Value Unit
430
100/30
921
0.55
0.15
10
160
13
28
173
1100
1400
1500
1400 -1650
Nm
Nm/
kg
mm
mm
mm
kg
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Crosshead Bearing
104-1
Data
Plate
P90451
P90451
P90451
P90451
P90451
P90463
P91351
P91351
P91351
P91351
P91356
P91359
P91366
Page 2 (2)
47
59
72
96
106
10
46
58
117
58
Wire guide
Lifting attachment - connecting rod
Chain for suspending piston
Bracket for support, crosshead
Crosshead - Hydraulic Tools
Lifting Tools, Etc.
Torque Spanners
Feeler gauge
MAN B&W Diesel A/S
Crosshead Bearing
904-1.1
Checking
Crosshead
S50ME-C Bearing
0239
Checking
904-1.1
2.
Tin-Aluminium bearings
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.
For the top clearance of a specific bearing, see

the measurement in the Adjustment Sheet in
Volume I, OPERATION.
1. Open the crankcase door at the relevant
cylinder.
GW904-1.1 239 02
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.
D04-01
D04-02
3.
2. Turn the crankthrow concerned to BDC.
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.
DM904-1.1 232 03
3. Measure the clearance in the crosshead

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

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

is confined to a 50% reduction of the oil
wedge length L.
(Oil Wedge)
DM904-1.1 232 05
If the wear limit exceeds the 50% reduction,

the bearing shell must be replaced by a
new one.
0$1 % : 'LHVHO $6
D04-03
Page 1 (10)
904-1.2
Crosshead Bearing
Dismantling
Dismantling
904-1.2
1.
This procedure applies to the following two dismantling situations:

with piston mounted
with piston removed
With piston mounted:
GW 904-1.1 239 02
1. Turn the crankshaft down far enough to give

access to the nuts and screws on the piston
rod.
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.
HN904-1.2 222 02
2.
HN904-1.2 222 03
3.
Page 2 (10)
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
4.
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.
6. Turn to BDC.
7. Place the spacer rings around the nuts and
screw the hydraulic jacks on to the studs.
HN904-1.2 222 04
With piston removed:
5.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.
HN904-1.2 222 05
Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.
7.
HN904-5.2 217 01
D13-02
0$1 % : 'LHVHO $6
Page 3 (10)
Crosshead Bearing
904-1.2
Dismantling
8.
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.
JN904-1.2 227 08
Hook the tackles on to the eye bolts, and remove the bearing cap from the engine.
Check the upper part of the journal.
JN904-1.2 227 09
9.
D04-07
JN904-1.2 227 10
10.
Page 4 (10)
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
11.
11. Place the bearing cap on one side on a

couple of wooden planks.
D04-07
Check the bearing shell, see Procedure

904-1.1.
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.
HG904-1.2 238 11
12. Fasten tackles to the fixed lifting brackets

on the frame box wall.
D04-05
12.
HG904-1.2 238 12
Do not remove the chains or lifting eye

bolts.
GN904-1.2 203 13
13.
0$1 % : 'LHVHO $6
Page 5 (10)
Crosshead Bearing
904-1.2
Dismantling
14.
14. Turn to TDC and attach the tackle hooks to

the lifting attachments. Haul the tackles
tight.
15. Mount the four supports for guide shoes on
the crosshead guides.
Carefully turn the crank down towards the
exhaust side, until the guide shoes rest on
the supports.
HG904-1.2 238 14
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.
15.
17. With the crosshead resting on the supports,

check the lower part of the crosshead journal and the lower bearing shell.
JN904-1.2 227 15
Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chapter 708, Bearings.
D04-21
D02-20
JN904-1.2 227 16
16.
17.
Page 6 (10)
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
18. In cases where it is necessary to remove

the lower bearing shell, tilt the connecting
rod towards the doorway on the fuel pump
side, using the tackles.
18.
D04-06
Dismount the locking screws, and turn the

bearing shell so far up that an eye bolt can
be mounted.
JN904-1.2 227 18
Lift the bearing shell out of the engine.
0$1 % : 'LHVHO $6
Page 7 (10)
904-1.4
Crosshead Bearing
Mounting
Mounting
904-1.4
1.
With piston mounted/

With piston removed:
D04-06
1. Mount and secure the bearing shell in the
bearing housing.
The excess height X is to ensure the correct tightening-down of the bearing shell
and must not be eliminated.
2. Raise the connecting rod to an upright position.
JN904-1.4 227 01
Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.
Take care that the guide shoes do not damage the bearing shell.
2.
D04-21
3. Remove the supports from the crosshead

guides.
Remove the tackles from the crosshead.
Turn the crank throw to BDC.
JN904-1.4 227 02
If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
JN904-1.4 227 03
3.
Page 8 (10)
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.4
Mounting
4.
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.
D04-07
Note!
5. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.
For operation of hydraulic jacks, see Section 913.
JN904-1.4 227 04
Take care that the bearing studs do not

damage the crosshead.
6. Mount the piston.

5.
With piston mounted:

HN904-5.2 217 01
D13-01
GN904-1.4 203 07
7.
0$1 % : 'LHVHO $6
Page 9 (10)
Crosshead Bearing
904-1.4
Mounting
8.
8. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and
eye bolts from the top of the crankcase,
from the piston rod and from the crosshead
bearing cap.
9. Turn down to BDC, tighten the screws in the
piston rod, and lock with locking wire. See
Data.
GN904-1.2 203 19

the wire is tightened if a screw works loose.
D02-02
D02-07
HN904-1.4 222 09
9.
Page 10 (10)
0$1 % : 'LHVHO $6
Crosshead
104-2
Data
SAFETY PRECAUTIONS
104-2
S50ME-C
D10402 Data
Crosshead
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D04-04
D04-08
D04-12
D04-13
D04-15
D04-19
D04-21
D04-22
D04-23
D04-50
D13-01
D13-02
Description
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
MAN B&W Diesel A/S
Value Unit
160
50
100
135
50
25
1100
159
9
1020
1500
1400 -1650
kg
Nm
Nm
Nm
Nm
kg
kg
kg
kg
bar
bar
Page 1 (2)
Crosshead
104-2
Data
Plate
P90451
P90451
P90451
P90451
P90451
P90451
P90462
P90463
P91351
P91351
P91351
P91351
P91356
P91359
P91366
Page 2 (2)
47
59
60
72
84
214
11
10
46
58
117
58
Wire guide
Lifting tools - crosshead
Chain for suspending piston
Retaining tool telescopic pipe
Torque wrench offset tool
Guide shoe extractor, complete
Lifting Tools, Etc.
Torque Spanners
Feeler gauge
MAN B&W Diesel A/S
Crosshead
904-2.2
Dismantling
Crosshead
S50ME-C
0239
Dismantling
904-2.2
2.
1. Dismount the piston.

2. Dismount the main bearing lubricating oil
pipes.
3. Dismount the cooling oil outlet pipe from
the guide shoe and the drain oil slotted
pipe.
In order to reach the screw in the corner behind the telescopic pipe, use the offset tool
along with a socket wrench.
GN904-2.2 203 02
Loosen and remove the screws which secure the telescopic pipe to the guide shoe.
4. Mount the retaining tool for the telescopic

pipe on the stuffing box housing for the telescopic pipe.
3.
Turn the crosshead to TDC.

Suspend the telescopic pipe by means of
the tool.
Turn the crosshead to gain access to the
nuts on the crosshead bearing studs.
Mount the spacer rings and the hydraulic

jacks for loosening the nuts on the crosshead bearing studs.
GN904-2.2 204 03
Mount two eye bolts in the top of the crankcase in the fore-and-aft direction.

Section 913.
4.
D04-23
D13-02
HN904-2.2 223 04
Loosen the nuts, remove the hydraulic jacks

and unscrew the nuts.
0$1 % : 'LHVHO $6
Page 1 (7)
904-2.2
Crosshead
Dismantling
5.
5. Mount eye bolts in the crosshead bearing

cap and hook the tackles on to the lifting
brackets in the top of the crankcase.
Dismount the bearing cap and lift it out of
the engine.
6. Mount the special lifting tool on the crosshead.
HN904-2.2 223 05
Mount the lifting attachments for fixing the

connecting rod, on the head of the connecting rod.
Fasten tackles to the lifting brackets on the
frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles
tight.
6.
Attach the flat-plaited wire strap to the engine room crane.
D04-21
Hook the engine room crane on to the lifting

tool on the crosshead, and lift the crosshead.
7. Using the tackles, tilt the connecting rod towards the exhaust side, while turning the
crankthrow towards the camshaft side.
GN904-2.2 232 06
Transfer the tackles from one lifting attachment to another as necessary.

When the crankthrow is 90 after BDC, stop
turning.
7.
HN904-2.2 223 07
D04-50
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.
Page 2 (7)
0$1 % : 'LHVHO $6
Crosshead
904-2.2
Dismantling
8.
8. 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.
Push one of the guide shoes against the

middle of the crosshead. If necessary, use
the guide shoe extractor tool.
GN904-2.2 232 08
9. Suspend two tackles from the eye bolts in

the top of the crankcase, in the fore-and-aft
direction, and attach the tackles to the
guide shoes.
10. Pull the free end of the crosshead into the

neighbouring cylinder unit.
Mount the guide shoe extractor on the opposite guide shoe.
9.
D04-22
GN904-2.2 232 09
Pull off the guide shoe, remove the extractor, and lift up the guide shoe.
10.
GN904-2.2 232 10
D04-22
0$1 % : 'LHVHO $6
Page 3 (7)
904-2.2
Crosshead
Dismantling
11.
11. Pull the crosshead with guide shoe into the

opposite neighbouring cylinder unit.
Mount the guide shoe extractor tool on the
remaining guide shoe.
Pull off the guide shoe, remove the extractor tool and lift up the guide shoe.
12. Turn the crosshead 90.
GN904-2.2 232 11
13. Mount the wire guide tool in the framebox

door opening.
Remove the crosshead from the engine, using wire rope and tackles.
12.
Protect the crosshead, for instance with

thick or corrugated paper, and land it outside the engine.
HN904-2.2 223 11
If necessary, remove the guide shoes from

the engine.
HN904-2.2 223 12
13.
Page 4 (7)
0$1 % : 'LHVHO $6
Crosshead
904-2.4
Mounting
Mounting
904-2.4
1.
1. Attach the flat-plaited wire strap to the engine room crane.
D04-22
D04-21
Lift the crosshead into the engine, using

wire rope, tackles, and the engine room
crane.
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.
HN904-2.2 223 11
2. Turn the crosshead 90. Pull the crosshead

to one side under the web plates between
the cyliners.
3.
Follow the movement of the crosshead with
the engine room crane.
4. Lower the other guide shoe.
Use the guide shoe extractor tool to push
the crosshead towards the second guide
shoe.
GN904-2.4 232 03
Remove the extractor tool and adjust the

position of the opposite guide shoe.
GN904-2.4 232 04
4.
0$1 % : 'LHVHO $6
Page 5 (7)
Crosshead
904-2.4
Mounting
5.
D04-13
D04-12
5. Mount the guide plates on the side of the

guide shoes.
Tighten the screws and lock them with locking wire.
Using the engine room crane, lift the crosshead to a working position and mount the
guide strips on the side of the guide shoes.
HN904-2.4 223 05
Tighten the screws and lock them with locking wire.

6. Using the tackles, lift the connecting rod to
a vertical position while turning the crankthrow to BDC.
6.
D04-50
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.
HN904-2.4 223 06
Remove the lifting tool from the crosshead.
EN904-2.4 237 07
7.
Page 6 (7)
0$1 % : 'LHVHO $6
Crosshead
904-2.4
Mounting
8.
8. Lift the crosshead bearing cap into the engine.
D04-04
9. Mount the spacer rings and the hydraulic

jacks for tightening the nuts on the crosshead bearing studs.
Procedure 913.
Turn the crankshaft to TDC.

Land the telescopic pipe on the guide shoe.
HN904-2.2 223 05
Mount the drain oil slotted pipe and the

cooling oil outlet pipe on the guide shoe.
10. For tightening the bolt in the corner behind

the telescopic pipe, use the offset tool
along with the torque wrench.
9.
D13-01
11. Mount the lubricating oil pipes on the main

bearing caps.
D04-15
D04-19
D04-08
HN904-2.2 223 04
12. Mount the piston.

10.
GN904-2.2 204 03
D04-15
D04-19
0$1 % : 'LHVHO $6
Page 7 (7)
Reciprocating Parts
104-3
Data
SAFETY PRECAUTIONS
104-3
S50ME-C
D10403 Data
Reciprocating Parts
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D04-25
D04-26
D04-28
D04-29
D04-30
D04-53
D04-54
D04-55
Description
Acceptance criteria with piston in centre (F-A direction)

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, L, K, M, N max.
J, L, K, M, N min.
J, L, K, M, O max.
N: New and cold engine with staybolts tightened
(less than 100 running hours).
O: Engine in service.
MAN B&W Diesel A/S
Value Unit
0.5
0.7
0.5
0.2
0.8
0.9
0.5
1.1
mm
mm
mm
mm
mm
mm
mm
mm
Page 1 (2)
Reciprocating Parts
104-3
Data
Plate
P90451
P91366
Page 2 (2)
226 Alignment tool

58 Feeler gauge
MAN B&W Diesel A/S
Reciprocating Parts
904-3.1
Checking
Reciprocating Parts
S50ME-C
0217
Checking
904-3.1
1.
In order to achieve uniform measuring conditions on board, the ships trim must be as close
as possible to 0.
Bend each end approx. 250 mm up along

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

length of the bedplate.
3.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Measurements are to be taken with a ruler.
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).
GN904-3.1 203 03
2. Turn the engine in ASTERN direction to 45

after BDC (the guide shoe must rest against
the crosshead guide).
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.
0$1 % : 'LHVHO $6
Page 1 (3)
Reciprocating Parts
904-3.1
Checking
4.
FORE
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).
AFT
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).
PA
PF
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.
GN904-3.1 213 04
Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.
ZF
ZA
5.
D04-53
D04-54
D04-55
GN904-3.1 203 05
FUEL PUMP
Page 2 (3)
0$1 % : 'LHVHO $6
Reciprocating Parts
904-3.1
Checking
6.
6. Check the clearance between guide shoe

and crosshead guide (E, F, G and H) with
a feeler gauge.
Exhaust side
Fuel pump
7. It is recommended that the measured results are noted down so that possible later
changes can be ascertained.
GN904-3.1 203 06
D04-28
D04-29
D04-30
GN904-3.1 203 07
7.
0$1 % : 'LHVHO $6
Page 3 (3)
Crankpin Bearing
104-4
Data
SAFETY PRECAUTIONS
104-4
S50ME-C
D10404 Data
Crankpin Bearing
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D04-43
D04-44
D04-46
D04-47
D04-48
D13-01
D13-02
Description
Crankpin bearing clearance, max.

Crankpin bearing clearance, min.
Crankpin bearing, upper shell
Crankpin bearing, lower shell
Crankpin bearing cap + shell + bearing studs
MAN B&W Diesel A/S
Value Unit
0.6
0.2
17
13
150
1500
1400 -1650
mm
mm
kg
kg
kg
bar
bar
Page 1 (2)
Crankpin Bearing
104-4
Data
Plate
P90451
P90451
P90451
P90451
P90461
P91356
P91366
P91351
P91351
P91351
P91351
Page 2 (2)
47
59
96
106
58
10
46
58
105
Wire guide
Lifting Tools, Etc.
Feeler gauge
MAN B&W Diesel A/S
Crankpin Bearing
904-4.1
Checking
Crankpin
S46MC-CBearing
0226
Checking
904-4.1
2.
The bottom clearance between the journal and

a new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.
For the bottom clearance of a specific bearing,
see the measurement in the Adjustment Sheet
in Volume I, OPERATION.
2. Turn the crank concerned to BDC.

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.
GW904-1.1 239 02
1. Open the crankcase door at the relevant

cylinder.
3.
recorded in the Adjustment Sheet (or the
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.
GM904-6.1 69 03
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.
D04-43
D04-44
GN904-4.1 219 05
5.
0$1 % : 'LHVHO $6
Page 1 (8)
904-4.2
Crankpin Bearing
Dismantling
Dismantling
904-4.2
2.
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.
GW904-2 226 02
Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
Procedure 913-1.
Remove the hydraulic jacks and the nuts.
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.
GN904-4.2 203 03
For evaluation of bearings, see Volume I,

Chapter 708.
4.
GW904-4.2 226 04
D04-48
Page 2 (8)
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.2
Dismantling
5.
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.
D04-48
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.
Inspect the bearing shell.

See Volume I, Chapter 708.
If necessary, dismount the bearing shell
lock screws and replace the bearing shell
by a new one.
GW904-4.2 226 05
6. Place the bearing cap on one side on a

couple of planks.
6.
Note!
D04-47
If only one of the shells needs replacement, MAN B&W Diesel should be contacted for advice beforehand.
GN904-4.2 203 06
Normally bearing shells are replaced in

pairs.
7. Turn to TDC.
7.
Mount the four supports for guide shoes on

Carefully turn the crank down until the
guide shoes rest on the supports.
HN904-4.2 217 07

0$1 % : 'LHVHO $6
Page 3 (8)
904-4.2
Crankpin Bearing
Dismantling
8.
8. Mount a lifting attachment for securing the

connecting rod at the lower end, on one
side.
Hook on the tackle to a beam under the gallery platform and haul tight.
GW904-4.2 226 08
9. Carefully turn the crankshaft downwards,

while following with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to separate.
Continue turning the crankshaft until the
bearing surface can be freely inspected.
9.
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 BDC.
GW904-4.2 226 09
Release the tackle so that the connecting

rod is hanging freely.
GW904-4.2 226 10
10.
Page 4 (8)
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.2
Dismantling
11.
11. Dismount the bearing shell lock screws and

lift out the bearing shell.
GN904-4.2 219 11
D04-46
0$1 % : 'LHVHO $6
Page 5 (8)
904-4.4
Crankpin Bearing
Mounting
Mounting
904-4.4
1.
1. Bearing shells of three mm undersize are

available as spares in case of journal rectification. Please contact MAN B&W Diesel
for advice.
HM904-6.0 61 16
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.
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.
GN904-4.4 219 02
D04-46
Page 6 (8)
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.4
Mounting
4.
3. 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 the bearing enters the recess in the crankshaft when the
parts turn together.
Remove the tackle and the lifting attachment from the connecting rod.
4. Turn the crosshead to TDC.
GW904-4.4 226 04
Remove the guide shoe support brackets

from the crosshead guides.
HN904-4.4 217 05
5.
0$1 % : 'LHVHO $6
Page 7 (8)
Crankpin Bearing
904-4.4
Mounting
6.
5. 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. Hook the tackles on to the wire ropes and
lift the bearing cap into position against the
connecting rod.
D04-48
Caution!
During mounting, take care that the studs
do not damage the crankpin journal, and
check that the guide pins mounted in the
bearing cap enter the holes in the connecting rod.
GW904-4.4 226 06
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.
7.
Remove the tackles from the top of the

frame box.
GW904-4.4 226 07
Check the bearing clearance.

Page 8 (8)
D13-01
0$1 % : 'LHVHO $6
Connecting Rod
104-5
Data
SAFETY PRECAUTIONS
104-5
S50ME-C
D10405 Data
Connecting Rod
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D02-02
D04-01
D04-02
D04-07
D04-43
D04-44
D04-48
D04-50
Description

Crosshead bearing, top clearance max.
Crosshead bearing, top clearance min.
Crosshead bearing cap with bearing shell
Crankpin bearing clearance, max.
Crankpin bearing clearance, min.
Crankpin bearing cap + shell + bearing studs
Connecting rod, without bearing caps
MAN B&W Diesel A/S
Value Unit
430
0.55
0.15
173
0.6
0.2
150
1020
Nm
mm
mm
kg
mm
mm
kg
kg
Page 1 (2)
Connecting Rod
104-5
Data
Plate
P90461
P90463
P90451
P90451
P90451
P90451
P91356
P91359
P91366
P91351
P91351
P91351
P91351
Page 2 (2)
47
59
96
106
58
10
46
58
117

Wire guide
Bracket for support, Crosshead
Bracket for support, Crosshead
Lifting Tools, Etc.
Torque Spanners
Feeler gauge
MAN B&W Diesel A/S
Connecting Rod
904-5.2
Dismantling
Connecting
S50ME-C Rod
0231
Dismantling
904-5.2
1.
1. Turn to BDC.
Mount chains for suspending the piston.
Measure the clearance in the crosshead

2. Measure the crankpin bearing clearance
fore and aft.
HN904-5.2 230 01
Suspend two tackles from the top lifting

brackets. Mount the wire guide on the door
frame.
3. Turn the crank to TDC.

2.
Dismount the crankpin bearing cap.
GM904-6.1 69 03
Suspend the piston.

C
A
3.
D04-48
HN904-5.2 230 03
0$1 % : 'LHVHO $6
Page 1 (8)
Connecting Rod
904-5.2
Dismantling
4.
D04-07
4. Turn the crank to BDC.

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

attachments on the exhaust side of the connecting rod.
HN904-5.2 230 04
Attach tackles A and C to the upper lifting

attachment and tackle D to the lower lifting
attachment.
6. Mount the four supports for guide shoes on
A
5.
Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
D04-50

HN904-5.2 230 05
HN904-5.2 230 06
6.
Page 2 (8)
0$1 % : 'LHVHO $6
Connecting Rod
904-5.2
Dismantling
A
7.
7. As soon as the connecting rod is free of the

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

oil drain pipe on the manoeuvring side, this
has to be taken into account.
As soon as possible attach tackle E to the

upper lifting attachment, move tackle C to
the lower lifting attachment and remove
tackle D.
GW904-5.2 231 07
8. Mount tackles in E and F, turn slowly towards TDC while loosening tackles C and
D.
8.
B
E
Turn a little more and shift tackle B to the

lower lifting attachment. Attach tackle F to
the upper lifting attachment. Turn to 50 before TDC.
9. Move tackle E to the lower lifting attachment.
GW904-5.2 231 08
Tighten tackles B, E and F to lift the connecting rod free of the crankshaft. When
the connecting rod is free of the crankshaft,
remove tackle C and turn to TDC.
9.
GW904-5.2 231 09
D04-50
0$1 % : 'LHVHO $6
Page 3 (8)
Connecting Rod
904-5.2
Dismantling
10.
10. Mount a tackle fore or aft of tackle F.

Take the connecting rod out of the crankcase by pulling it around the corner.
E+F
HN904-5.2 230 10
Land the connecting rod on wooden planks.
Page 4 (8)
0$1 % : 'LHVHO $6
Connecting Rod
904-5.4
Mounting
Mounting
904-5.4
1.
1. Mount tackles on the gallery lifting point

and lift the connecting rod into the engine.
Mount the wire guide on the door frame.
E+F
Caution!
D04-50
Take great care not to damage bearings

and crankpin.
E
Slowly turn the crankshaft towards the connecting rod.
HN904-5.2 230 10
2. When the connecting rod is in line with the

crankcase door opening, attach tackle B to
the lower lifting point and shift tackle E to
the upper lifting point.
2.
Lubricate the crankpin and bearing liberally.
Carefully move the connecting rod onto the
crankshaft.
B
E
3. Attach tackle C to the lower lifting attachment and move tackle B to the upper lifting
attachment.
D
GW904-5.4 231 02
Turn towards the exhaust side while tightening tackle C, and tighten tackle B when
possible. Attach tackle D to the lower lifting
attachment.
3.
GW904-5.4 231 03
0$1 % : 'LHVHO $6
Page 5 (8)
Connecting Rod
904-5.4
Mounting
B
4.
E
C
4. Take care not to damage the piston cooling

oil drain pipe if fitted.
Turn the crankshaft slowly downwards while
following with the tackles.
When the crankshaft is turned to approx.
50 after TDC, use tackle C to raise the
connecting rod. Disconnect tackle B when
practical. Lubricate the crosshead bearing
liberally
GW904-5.4 231 04
5. Turn the crankshaft up until the crosshead

is lifted free of the crosshead support
brackets. Remove the lifting attachments
and tackles C and D.
5.
6. Mount the crankpin bearing cap:

HN904-5.4 230 05
6.
HN904-5.4 230 06
Page 6 (8)
0$1 % : 'LHVHO $6
Connecting Rod
904-5.4
Mounting
A
7.
7. Turn to BDC.
B
E
Lubricate the crosshead and bearing cap.
Mount the crosshead bearing cap.

8. Measure the crankpin bearing clearance
fore and aft.
GW904-5.4 231 07
D
8.
GM904-6.1 69 03
D04-43
D04-44
GN904-1.4 203 07
9.
0$1 % : 'LHVHO $6
Page 7 (8)
Connecting Rod
904-5.4
Mounting
10.
10. Turn down to BDC, tighten the screws in the

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

the wire is tightened if a screw works loose.
HN904-5.2 230 01
D04-01
D04-02
Measure the clearance in the crosshead

11. Remove all tools from the engine.
Note!
11.
KN905-2.4 238 14
Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.
Page 8 (8)
0$1 % : 'LHVHO $6
Connecting Rod and Crosshead Panel

MAN B&W Diesel
Plate
P90451-0151
Page 1 (2)
Plate
P90451-0151
Item
No.
011
023
047
059
060
072
084
096
106
118
120
214
226
Page 2 (2)
Connecting Rod and Crosshead Panel

MAN B&W Diesel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Wire guide, main bearing
Lifting attachment, connecting rod
Lifting tool, crosshead
Chain, suspending of piston
Retaining tool, telescope pipe
Bracket, support of crosshead
Bracket, support of crosshead
Rubber cover, crosshead
Rubber cover with hole, crosshead
Offset tool, torque spanner
Alignment tool
Plate
P90461-0069
P90461
0069
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90461-0069
Item
No.
028
030
053
065
089
090
100
207
Item Description
Item
No.
Item Description
Jack-hydraulic, complete
Support
Sealing ring with back-up ring
Key, hexagon socket screw
Tommy bar
Stud setter
Hydraulic toolset, complete
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90462-0020
P90462
0020
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90462-0020
Item
No.
011
Item Description
Item
No.
Item Description
Guide shoe extractor, complete
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
105-08
905-08
90551
90561
90562
90564
90570
90572
90573
0004
0209
0044
0241
0039
0224
0003
0212
0033
0224
0007
0204
0227
0093
0125
0018
0004
0003
0002
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
Angle Encoder, Data
Angle Encoder
Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
Main Bearing - Hydraulic Tools
Crankshaft - Tools
Crankshaft - Measuring Tools
Thrust Shaft - Tools
Main Bearing - Measuring Tools
Tuning Wheel - Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Main Bearing
105-1
Data
SAFETY PRECAUTIONS
105-1
S50MC-C
0004
Special Data
Standard Tools: See Section 913
Main Bearing
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value Unit
MAN B&W Diesel A/S
Page 1 (2)
Main Bearing
105-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Main Bearing
905-1.1
Checking
Main
S50MC-C
0209 Bearing
Checking
905-1.1
1.
General
The condition of the main bearings can be
checked by:
Deflection readings
Visual checking
Edge checking and
Crankshaft deflection readings

Crankshaft deflection readings should be taken
while the ship is afloat (i.e. not while in dry
dock).
HM905-2.0 46 01
Measuring of top clearance.
2.
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.
Positive (+)
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.
KN905-1.1 208 02
2. Closing of the crank throw (compression

of the gauge) is regarded as negative ()
and opening as positive (+).
Negative ( )
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:
3.
XZ905-1.1 204 03
B1
(near bottom)
C
(camshaft side)
T
(top)
E
(exhaust side)
B2
(near bottom)
1/2 (B2+B1) = B
0$1 % : 'LHVHO $6
Page 1 (4)
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.
HM905-2.0 46 01
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.
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.
KN905-1.1 208 05
General
Bearing damage usually propagates rather
quickly towards the edge of the bearing where,
eventually, it causes chips to be broken off,
which means that loose pieces of white metal
can fall down into the crankcase beneath the
bearing support.
Large, thick pieces will normally be found during a crankcase inspection, and small, thin
pieces can enter the 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 (4)
0$1 % : 'LHVHO $6
Main Bearing
905-1.1
Checking
6.
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.
Hole in
the edge
KN905-1.1 208 06
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.
7.
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.
<1.2 mm
>0.7 mm
7-10 mm
60-70
500-1000
2-3 mm
Wire feeler
The above dimensions of the wirefeeler are guideline values and may
depend on the engine type as well as
individual, personal designs.
KN905-17.02
Note!
0$1 % : 'LHVHO $6
Page 3 (4)
905-1.1
Main Bearing
Checking
8.
8. Remove the lub. oil pipe from the main

bearing cap.
Calibrate the main bearing measuring tool:
See the wooden box for the measuring tool.
9. Insert the measuring tool and check the
clearance between the upper shell and the
journal.
BG905-3.1 71 01
Note!
The bearing clearances for a new bearing stated in Data (see Data 105-2) are
for guidance purposes only.
9.
recorded in the adjustment sheet (or the
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.
For evaluation of the bearing, see Volume
I, Operation, Chapter 708.
BM905-2.1 239 03
If the bearing needs to be diassembled for

inspection, see procedure 905-2.2.
HN905-2.1 227 03
10.
Page 4 (4)
0$1 % : 'LHVHO $6
Main Bearing
105-2
Data
SAFETY PRECAUTIONS
105-2
S50MC-C
0044
Special Data
Main Bearing
Stopped engine
Engage turning gear

2 x 600 kg
Shut off fuel oil

X

x2
Data
Ref.
Description
Value Unit
Top clearance in main

bearing
Max. .....................................
Min. ......................................
0.65 mm
0.35 mm
D-1
Main bearing cap
290 kg
D-2
Main bearing shells

upper
lower
4 x 1,5 m
1x3m
D-3
Hydraulic pressure
dismantling
tightening
[ NJ
20 kg
20 kg
1500-1650 bar
1500 bar
MAN B&W Diesel A/S
Page 1 (2)
Main Bearing
105-2
Data
Plate
1175465-2
90551
Spare Parts
Plate Item No.
Description
Qty
91210-xxxx 050
Screw
91210-xxxx 108
Main bearing, upper shell
91210-xxxx 121
Main bearing, lower shell
Page 2 (2)
MAN B&W Diesel A/S
Main Bearing
905-2.2
Dismantling
Main
S50MC-C
0241 Bearing
Dismantling
905-2.2
1.
Positioning the crankshaft
Aftmost main bearing (= Journal bearing)
1. Dismantling of main bearing.

The bearings are divided into two categories:
The main bearings
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.
KN905-2.2 238 01
The aftmost main bearing

often referred to as Journal bearing
(See Procedure 905-4).
Main bearings
Thrust bearing
2.
Note!
KN905-2.2 238 02
Be sure that the crosshead for the neighbouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
3.
MAN-SIDE
KN905-2.2 238 03
EXH-SIDE
0$1 % : 'LHVHO $6
Page 1 (13)
905-2.2
Main Bearing
Dismantling
4.
Oil pipes
4. Disconnect the lubricating oil pipe from the
main pipe.
Note!
KN905-2.2 238 04
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.
Note!
2.
Some engines have temperature sensors

fitted to the main, crosshead, and crankpin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.
5. Mount the extension studs, the spacers, the
hydraulic jacks and the nuts on the extension studs. Loosen the main bearing stud
nuts, using the hydraulic jacks.
Procedure 913-1.
GN905-2.2 204 02
6. Remove the hydraulic main bearing tools

from the engine.
Unscrew and remove the nuts from the
main bearing studs.
Remove the rectangular nut washers from
the bearing cap.
KN905-2.2 238 07
5.
Page 2 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
7.
7. Mount the lifting tool on the main bearing

cap.
Mount the pulley on the web-plate over the
main bearing, and mount the wire rope from
the lifting tool in the pulley.
Mount an eye bolt in one of the threaded
holes on the opposite web-plate.
8. Mount the wire guide as shown.
Mount tackles in the following positions:

A + B: Two 2-ton chain tackles, below the
platform.
GN905-2.2 241 07
Move the lifting pipes below the platform

outside the relevant cylinder.
8.
C: One 1-ton chain tackle.

D: One -ton chain tackle, in the eye bolt
on the opposite web-plate.
9. Attach the wire rope from the lifting tool to
tackle A.
Note!
GN905-2.2 241 08
Using tackle A, lift the main bearing cap

free of the studs.
Owing to space requirements below the

web-plate, it might be necessary to dismount the eye bolt from the lifting tool.
9.
P
GN905-2.2 241 09
0$1 % : 'LHVHO $6
Page 3 (13)
Main Bearing
905-2.2
Dismantling
10.
10. Pull the bearing cap clear of the crosshead

guides by using chain tackle D.
11. Attach tackle C to the eye bolt in the centre

of the lifting tool.
Dismount the balancing handle from the lifting tool for main bearing cap.
Tighten tackle C, and release tackles A and

D.
GN905-2.2 241 10
When released, dismount tackle A from the

wire rope, and dismount the wire rope from
the pulley.
12. Lift out the bearing cap, using tackles B and
A.
11.
GN905-2.2 241 11
12.
A
B
C
GN905-2.2 241 12
Page 4 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
13.
13. Mount the lifting tool on the upper main

bearing shell, and lift out the shell by hand.
14. If the crankshaft is turned with the bearing
cap dismounted, use the two stops to prevent the lower shell from being rolled out.
15. Place the crosspiece in the bedplate with
the ends resting on the cross girders, and
position the hydraulic jacks beneath the
crank webs as shown.
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.
EN905-2.2 206 08
Tighten the screws against the crank webs

and compress the jacks.
Note down the pressure for later reference.
KN905-2.2 238 24
14.
KN905-2.2 238 27
15.
0$1 % : 'LHVHO $6
Page 5 (13)
Main Bearing
905-2.2
Dismantling
16.
Min. 0,1 mm
16. 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.
Note!
The feeler blade must be inserted minimum 60 mm into the gap to pass the bore
relief in the bearing shell.
Min. 60 mm
KN905-2.2 238 28
EXH
17.
CAM
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 lower shell must be lifted out to the
side with the most clearance, which is
normally the camshaft side.
KN905-2.2 238 25
17. If re-positioning of the crosspiece does not

ensure a vertical lift, place a 5-tonne jack
between the side wall and the crank throw,
to correct the journal position in this way.
If it is available, note down the pressure applied to the jack. This data is used to ensure that the crankshaft is in the same
position when the new bearing is installed.
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.
Page 6 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
18.
18. 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.
19. Pull the lower shell around and up until it
lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.
Note!
KN905-2.2 238 26
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
19.
0$1 % : 'LHVHO $6
Page 7 (13)
905-2.2
Main Bearing
Dismantling
20. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.
EN905-2.2 206 08
20.
Page 8 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.3
Overhaul
Overhaul
905-2.3
1. Clean and inspect the bearing shells. It is

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

one shell, this requires a careful evaluation
of the condition of the shell that is to be reinstalled.
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.
Check the bearing support for damage

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

non-fluffy cloth to clean between journal
and main bearing support.
Lubricate the bearing journal, the main
bearing support and the back of the
shell, with main engine lubricating oil.
0$1 % : 'LHVHO $6
Page 9 (13)
905-2.4
Main Bearing
Mounting
Mounting
905-2.4
1.
Mounting of bearing shells

1. Lubricate the journal and the bearing support with clean oil
Using the bearing shell lifting tool, lift the
lower bearing shell into the crankcase and
land it on the crankshaft journal.
GN905-2.4 241 01
2. Position the guide tool for the lower bearing

shell on the main bearing support. Remove
the lifting tool from the bearing shell.
Place the lower bearing shell on the journal
and push it down by hand.
2.
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.
3. Mount the locking screws in the bearing
support.
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below
the crankshaft.
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.
XZS905-13 07
3.
Page 10 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.4
Mounting
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.
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.
XZS905-13 09
If necessary, place the special tool between

the studs and press the shell into place.
Using the tackles and pulleys, lift the cap

into the crankcase in reverse order to dismantling.
See Procedure 905-2.2, steps 12-9.
5.
Note!
KN905-2.4 238 09
Be sure that the cap lands correctly and

that the spring pin in the assembly surface enters the hole in the bearing cap.
0$1 % : 'LHVHO $6
Page 11 (13)
Main Bearing
905-2.4
Mounting
6.
6. Mount the rectangular nut washers and

screw the round nuts on to the main bearing
studs.
Using the hydraulic jacks, fully tighten the
nuts on both sides of the bearing cap.
For tightening pressure, see Data.
For operation of the hydraulic tools,
see Procedure 913-1.
7.
'

!
Note!

"
(
I
H
Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.
7.

Note!
KN 905-1.1 208 09

behind.
20
KN905-2.4 238 14
8.
Page 12 (13)
0$1 % : 'LHVHO $6
Main Bearing
905-2.4
Mounting
9.
KN905-2.4 238 15
9. Mount the lubricating oil pipe on the main

bearing cap.
0$1 % : 'LHVHO $6
Page 13 (13)
Thrust Bearing
105-3
Data
SAFETY PRECAUTIONS
105-3
S50MC-C
0039
Special Data
Thrust Bearing
Stopped engine
Engage turning gear

2 x 1 m, 1 x 3 m

Shut off fuel oil
X
M12

500 kg
Data
Ref.
Description
Value Unit
D05-07 Segment stopper
37 kg
D05-06 Thrust bearing segment
30 kg
Hydraulic pressure
D13-02 dismantling
D13-01 tightening
1500-1650 bar
1500 bar
MAN B&W Diesel A/S
Page 1 (2)
Thrust Bearing
105-3
Data
1175479-6.0
Plate
90551
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Thrust Bearing
905-3.1
Checking
Thrust
S50MC-C
0224 Bearing
Checking
905-3.1
1.
The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,
and for an engine in service it must not exceed
2.0 mm.
1. To measure the wear in the thrust bearing,

it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.
GN905-3.1 224 01
In service it is only necessary to measure the

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).
If a feeler gauge of 0.1 mm is not able to

enter the groove (the wear is more than 0,9
mm), the thrust bearing must be overhauled.
3. Note down the wear for later reference.
GN905-3.1 224 02
2. To measure the wear, the thrust segment

has to be pressed against the thrust cam,
to eliminate any gap, i.e. by using a suitable
crowbar on the back of the segment.
KN905-2.2 238 02
3.
MAN B&W Diesel A/S
Page 1 (5)
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.
Procedure 913-1.
GN905-3.2 224 01
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.
2.
D05-07
GN905-3.2 224 02
D13-02
Page 2 (5)
MAN B&W Diesel A/S
Thrust Bearing
905-3.2
Dismantling
3.
3. Suspend a tackle from the chain tightener

bracket above the segments which are to
be removed. Nevertheless, the weight is no
heavier than it is possible to lift the segment
by hand.
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.
Note!
GN905-3.2 224 03
Never remove more than one segment at

a time.
D05-06
GN905-3.2 224 04
4.
MAN B&W Diesel A/S
Page 3 (5)
905-3.4
Thrust Bearing
Mounting
Mounting
905-3.4
1.
1. Suspend a tackle above the segments

which are to be mounted. Still, it is possible
to lift the segments by hand.
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.
GN905-3.4 224 01
2. After the last segment has been mounted,

turn the segment tool up and dismount it.
GN905-3.4 224 02
2.
Page 4 (5)
MAN B&W Diesel A/S
Thrust Bearing
905-3.4
Mounting
5.
3. Mount the segment stopper.

Mount the hydraulic jacks and tighten the
nuts on the stopper.
For operating hydraulic jacks,
GN905-3.2 224 01
4. Mount the lub. oil pipe for the thrust segments, the protective shield and the lub. oil
pipe on the bearing.
MAN B&W Diesel A/S
Page 5 (5)
Journal Bearing
105-4
Data
SAFETY PRECAUTIONS
105-4
S50MC-C
0003
Special Data
Journal Bearing
Stopped engine
Engage turning gear

x2
Shut off fuel oil

X

2x3m
Data
Ref.
Description
Value Unit
D-1
Min. bearing clearance
0.35 mm
D-2
Max. bearing clearance
0.65 mm
D-3
Main bearing cap
290 kg
D-4
Upper bearing shell
20 kg
D-5
Lower bearing shell
20 kg
D-6
Hydraulic pressure
dismantling
1500-1650 bar
Hydraulic pressure
tightening
1500 bar
D-7
MAN B&W Diesel A/S
[ NJ
Page 1 (2)
Journal Bearing
105-4
Data
Plate
1175465-2
90551
Spare Parts
Plate Item No.
Description
Qty
91210-xxx 108
Screw
91210-xxx 121
Main bearing
Page 2 (2)
MAN B&W Diesel A/S
Journal Bearing
905-4.1
Checking
Journal
0212 Bearing
S50MC-C
Checking
905-4.1
1.
1. Before any dismantling of the journal bearing, check the clearances as described in
Procedure 905-1.1.
Aftmost main bearing (= Journal bearing)
2. Write down the journal bearing clearances.
KN905-2.2 238 01
3. Also check the journal bearing by visually

searching the area underneath the bearing
support.
Main bearings
Thrust bearing
KN905-2.2 238 02
2.
KN905-4.1 202 03
3.
MAN B&W Diesel A/S
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.

Procedure 913-1.
4. Remove the hydraulic main bearing tools
from the engine
GN905-2.2 204 02
Unscrew and remove the nuts from the

bearing studs.
KN905-2.2 238 07
4.
Page 2 (8)
MAN B&W Diesel A/S
Journal Bearing
905-4.2
Dismantling
5.
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.
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.
GN905-2.2 224 16
6. Mount the lifting attachment on the upper

shell, and lift the shell out of the engine.
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.
GN905-2.2 224 17
6.
GN905-2.2 224 19
7.
MAN B&W Diesel A/S
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.
KN905-2.2 238 26
9. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.
GN905-2.2 224 17
9.
Page 4 (8)
MAN B&W Diesel A/S
Journal Bearing
905-4.3
Overhaul
Overhaul
905-4.3
1. Clean and inspect the bearing shells. It is

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

one shell, this requires a careful evaluation
of the condition of the shell that is to be reinstalled.
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.
Check the bearing support for damage

and burrs. If damage is found, contact
MAN B&W Diesel for advice.
KN905-2.2 238 25
2. Before remounting:
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.
MAN B&W Diesel A/S
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.
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.
GN905-2.2 224 17
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.
2.
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.
MC905-3.0 118 19
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from under
the crankshaft.
Wipe the contact surfaces between the upper and the lower bearing shells clean with
a non-fluffy piece of cloth.
XZS905-13 07
3.
Page 6 (8)
MAN B&W Diesel A/S
Journal Bearing
905-4.4
Mounting
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.
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.
XZS905-13 09
If necessary, place the special tool between

the studs and press the shell into place.
6.
6.
Note!
7. Mount the rectangular nut washers, the

nuts, the spacer rings, the hydraulic jacks,
and tighten the nuts. See Data.
KN905-2.4 238 09
Be sure that the cap lands correctly and

that the guide pin in the assembly surface enters the hole in the bearing cap.
For operation of the hydraulic tools,

MN913-1 208 11
7.
MAN B&W Diesel A/S
Page 7 (8)
Journal Bearing
905-4.4
Mounting
8.
8.
Note!
Before removing the hydraulic jacks,
check the top clearance between the
upper bearing shell and the journal.
KN 905-1.1 208 09

20
Note!
behind.
9.
KN905-2.4 238 14
10. Mount the lubricating oil pipe on the bearing cap, and mount the end cover.
KN905-2.4 238 15
10.
Page 8 (8)
MAN B&W Diesel A/S
105-5
Data
SAFETY PRECAUTIONS
105-5
S50MC-C
0033
Special Data
Stopped engine
Engage turning gear

140 - 760 Nm
2x1m
1x3m
Shut off fuel oil

X

Data
1 x M12
Ref.
Description
D05-25
Damper housing,
upper part
D13-02
D13-01
D05-22
D05-19
Hydraulic pressure
dismantling
tightening
280 kg
1500-1650 bar
1500 bar
Screwing-in torque
outer studs
300 Nm
Tightening torque
nuts on inner studs
500 Nm
D05-18
Screwing-in torque
inner studs
D05-23
Tightening torque
horizontal screws
D05-24
Value Unit
1. tightening torque
2. tightening angle
150 Nm
450 Nm
or
100 Nm
25
MAN B&W Diesel A/S
90662
Page 1 (2)
105-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
905-5.1
Checking
Axial
S46-S50MC-C
0224 Vibration Damper
Checking
905-5.1
1.
For checking the effectiveness of the axial vibration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken
at the same r/min as during the sea trials. (Preferably 90% and 100% of MCR.)
As different equipment 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.
A proximeter probe is built on to the lower part

of the damper housing. The probe is connected
to a control unit which displays peak-to-peak
movements and sends signals to the engine
control system.
KM905-7.1 35 01
A: Electronic, with Axial Vibration Monitor
1. Concerning overhaul and setting of the

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

Checking
1.
B: Mechanical (without angle encoder fore)

1. Stop the engine.
Unscrew the two plugs from the cover at the
front of the engine.
2. Mount the shaft piece in the end of the
crankshaft, using the handle.
BG905-5.1 223 01B
After tightening the shaft, dismount the

handle.
Screw the measuring arm into the small
threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.
2.
Attach a pencil to the arm.

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

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

the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)
S-2
To ensure a certain inertia, the backing

plate should have a mass of approx. 1-2 kg.
The axial movements (S2) recorded on the
paper must be measured with a slide calliper as shown in the sketch.
DM905-7.1 74 05
When measuring, press the measuring arm

against the shaft piece with the one hand.
With the other hand, move a sheet/block of
paper, clipped on to a solid backing plate,
lightly downwards against the tip of the
pencil.
4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.
S1
For a standard measuring tool (L 1 = 38 mm

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

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

Checking
1.
C: Mechanical, with angle encoder fore

For engines with angle encoder fore, a measuring tool is available for mounting on the angle
encoder housing.
1. Stop the engine.
Dismount the protection shield over the angle encoder. (Not always on engine).
Dismount the cover on the angle encoder
housing.
Apply some Molycote TM on the fore side of
the shaft cam.
2. Mount the axial vibration measuring tool,
using the screws from the cover.
BG905-5.1 223 01C
Attach a pencil to the arm.

Note!
MN905-5.1 214 05
2.
To obtain a correct measurement, the tip

of the pencil should protrude 10 mm from
the end of the arm.
Page 4 (8)
MAN B&W Diesel A/S
905-5.1
Checking
3.
3. Start the engine, and let the speed rise to

the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)
S2
When measuring, pull the measuring arm

against the shaft cam with one hand. With
the other hand, move a sheet/block of paper, clipped onto a solid backing plate,
lightly sidewards against the tip of the pencil.
PULL
The axial movements (S2) recorded on the

paper must be measured with a slide calliper as shown in the sketch.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.
BG905-5.1 223 03
To ensure a certain inertia, the backing

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

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

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

Dismantling
Dismantling
905.5.2
1.
Dismantling of the axial vibration damper is carried out from the crankcase of cyl. No. 1.
D13-02
1. Turn the engine to 90 after TDC.
Dismount the lubricating oil pipes for the
main bearing and axial vibration damper.
GN905-5.2 204 01
Loosen and remove the nuts from the inner

studs and the hydraulic nuts from the outer
studs. For operation of the hydraulic tools,
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.
GN905-5.2 204 02
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.
D05-25
Note!
GN905-5.2 224 03
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)
MAN B&W Diesel A/S
905-5.3
Overhaul
Overhaul
905-5.3
1.
1. Dismantle and remove the springs from the

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

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

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

rings in such a way that the clearance at
both joints on each oil sealing ring is the
same.
Now hook the new tension springs into
place, ensuring that they are centralised in
the grooves of the oil sealing rings.
The lower half of the oil sealing rings will

protrude above the centreline.
HG905-5.2 201 02
Note!
MAN B&W Diesel A/S
Page 7 (8)
905-5.4
Mounting
Mounting
905-5.4
1.
1. Release and carefully lower the upper part

of the damper housing.
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.
GN905-5.4 224 01
Note!
behind.
2.
Mount the lubricating oil pipes.
D05-18
D05-19
D05-22
Engines without chainbox fore:

Mount the cover for the lifting hole above
the axial vibration damper.
D13-01
Note!
GN905-5.4 224 02
D05-23
D05-24
After overhaul of the axial vibration

damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
Page 8 (8)
MAN B&W Diesel A/S
Angle Encoder
105-8
Data
SAFETY PRECAUTIONS
105-8
MC
D10508 Data
Angle Encoder
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Angle Encoder
105-8
Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
Angle Encoder
905-8.1
Checking
Angle
S42MC
0204 Encoder
Checking
905-8.1

1. Turn the crankthrow for cylinder 1 to TDC.
2. Check that power is supplied to the intermediate box.

The green indicator should now light.
HM906-7.0 56 01
Check the TDC of cylinder 1 against the

mark on the turning wheel.
For adjustment of the angle encoder, see

Procedure 905-8.3.
MN905-8.1 202 03

0$1 % : 'LHVHO $6
Page 1 (4)
905-8.2
Angle Encoder
Dismantling
Dismantling
905-8.2

1. Remove the inspection cover.

Cut the cable tie which holds the rubber
damper around the coupling, in the end
nearest to the engine, and loosen the coupling.
2. Loosen the three adjusting screws on the
front flange, and remove the angle encoder
and the coupling.
XR905-8.2 204 01
3. Screw out the flange screws and remove

the encoder housing. Take care not to damage the guide pins.
XR905-8.2 204 02

XR905-8.2 204 03

Page 2 (4)
0$1 % : 'LHVHO $6
Angle Encoder
905-8.3
Adjustment
Adjustment
905-8.3

Check the TDC position with the pin gauge

on the crankthrow, cylinder 1.
Note!
HM906-7.0 56 01

Before using the pin gauge, check the

measurement from tip to tip with the
value stamped on the pin gauge, and/or
the check-marks stamped on the fore
end of the cylinder frame.
Tighten the screws to secure the encoder in

the correct position.
BG906-7.0 58 02
2. Loosen the adjusting screws which fasten

the encoder to the housing. Slowly turn the
encoder until the green indicator lights on
the intermediate box.

MN905-8.3 202 02

0$1 % : 'LHVHO $6
Page 3 (4)
905-8.4
Angle Encoder
Mounting
Mounting
905-8.4
1.
1. Mount the encoder housing. The two guide

pins indicate the correct positioning of the
housing. Tighten the screws.
2. Mount the angle encoder and the coupling.
Tighten the coupling, and mount new cable
ties around the rubber damper.
XR905-8.4 204 01
Adjust the angle encoder according to Procedure 905-8.3.

Note!
2.
The adjustment will be easier if mounting

is in the same crank position as dismantling.
XR905-8.4 204 02
3. Mount the cover.
XR905-8.4 204 03
3.
Page 4 (4)
0$1 % : 'LHVHO $6
Crankshaft, Thrust Shaft, Main Bearing,

Etc. -Panel
Plate
P90551-0227
P90551
Crankshaft, Thrust Shaft, Main Bearing, Etc. -Panel
0227
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90551-0227
Item
No.
015
027
040
076
088
090
100
111
123
135
172
184
Crankshaft, Thrust Shaft, Main Bearing,

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

Name plate
Pulley for wire
Lifting tool for main bearing cap
Dismantling 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
Mounting tool thin bearing shell
Lifting tool main bearing shell
Page 2 (2)
MAN B&W Diesel A/S

MAN B&W Diesel
Plate
P90561-0093
Page 1 (2)
Plate
P90561-0093

MAN B&W Diesel
Item
No.
Item Description
021
033
045
057
069
070
082
094
104
130
141
165
200
Jack-hydraulic, support
Stud
Nut
Spanner
Ball handle
Lifting tool
Stud setter
Page 2 (2)
Item
No.
Item Description
Crankshaft - Tools
Plate
P90562-0125
P90562
Crankshaft - Tools
0125
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90562-0125
Item
No.
015
039
052
Crankshaft - Tools
Item Description
Item
No.
Item Description
Support
Screw with special head
Nut
Page 2 (2)
MAN B&W Diesel A/S
Tools
MAN B&W Diesel
Plate
P90564-0018
Page 1 (2)
Plate
P90564-0018
Item
No.
016
Page 2 (2)
Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
Measuring tool for axial movement
Plate
P90570-0004
P90570
Thrust
0004 Shaft - Tools
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90570-0004
Item
No.
019
Item Description
Item
No.
Item Description
Lifting tool for thrust shaft
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90572-0003
P90572
Main
0003 Bearing - Measuring Tools
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90572-0003
Item
No.
010
021
045
057
Item Description
Item
No.
Item Description
Measuring tool main bearing

clearence
Calibration tool
Key, hexagon socket screws
Wooden box
Page 2 (2)
MAN B&W Diesel A/S
Turning Wheel - Tools

MAN B&W Diesel
Plate
P90573-0002
Page 1 (2)
Plate
P90573-0002
Item
No.
027
039
040
052
076
090
206
Page 2 (2)
Turning Wheel - Tools

MAN B&W Diesel
Item Description
Item
No.
Item Description
Support
Spanner
Tommy bar
906 - Control Gear

106-01
906-01
106-02
906-02
106-03
906-03
106-04
906-04
106-05
906-05
106-06
906-06
90651
90662
90664
90668
0041
0236
0054
0239
0036
0214
0034
0216
0024
0220
0007
0203
0173
0046
0005
0003
Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearings, Data
Camshaft Bearings
Moment Compensator, Data
Moment Compensator
Replacement of Cams on Camshaft, Data
Replacement of Cams on Camshaft
Chain Drive and Camshaft - Panel
Camshaft - Hydraulic Tools
Crankshaft - Pin Gauge
Camshaft - Pin Gauge
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Chain
106-1
Data
SAFETY PRECAUTIONS
106-1
L60MC-C
D10601 Data
Chain
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D06-10
D06-11
D06-12
Description
Teeth on chain wheel, max. wear

Original length (chain pitch x 10 links)
10 links measurements + 1% of a tensioned chain = scrapping of
chain
MAN B&W Diesel A/S
Value Unit
3.0 mm
889 mm
897.9 mm
Page 1 (2)
Chain
106-1
Data
Plate
P90651
P90651
P91356
P91359
Page 2 (2)
70 Chain assembling tool

81 Chain disassembling tool
Lifting Tools, Etc.
Torque Spanners
MAN B&W Diesel A/S
Chains
906-1.1
Checking
Chains
S50MC-C
0236
Checking
906-1.1
4.
Carry out the inspection as follows:

1. Make a general inspection for loose bolts
and screws.
2. Inspect lube oil pipes for damage, and
check jet nozzles for possible stoppages or
deformations.
3. Examine the rubber track of the guideways
for cracks or other damage.
Replace the guideway if bits have started to
be plucked out of the rubber track.
4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement
(see Data).
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.
HN906-1.1 204 04
Measurements are best taken by placing a

short straight-edge over points A and B and
then measuring the distance D06-10.
For assessing the measurement results,

contact MAN B&W Diesel.
D06-10
5.
HN906-1.1203 05
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.
MAN B&W Diesel A/S
Page 1 (4)
Chains
906-1.1
Checking
7.
D06-11
D06-12
8
11-5
6-06
D0 D 1 2
x.
Ma D06MN906-1.1 226 07
6. The chains for the camshaft drive are

matched together to ensure an even load
distribution.
To keep such matching chains in their pairs,
the side plates of the outer link nearest to
the assembled link have been marked with
year, month, day and chain number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 1C, possible 3rd chain)
No. 2 order,
840520 2A
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.
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 values given in Data.
If necessary, adjust the chain tightener.
Page 2 (4)
MAN B&W Diesel A/S
Chains
906-1.2
Dismantling
Dismantling
906-1.2
1.
It may become necessary to disassemble

the chain if, for instance, cracked rollers or
seizures between pin and bushing have
been discovered during the inspection.
Note!
When a new link is fitted in one chain, the

corresponding link in the other chain
must also be renewed.
GN906-1.2 203 01
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.
1. Remove the tension on the chain by loosening the chain tightener.

(See Procedure 906-2.3).
2.
2. Mount a wire round the link rollers a short

distance from the disassembly point, and
tighten the wire lightly with a tackle.
Protect the link rollers over which the wire
is wrapped.
GN906-1.2 203 02
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. If the engine is equipped with balanceweights, continue the turning until the
balanceweights are hanging vertically
downwards, as shown in the sketch.
3.
Note!
If the chain is to be completely removed,
contact MAN B&W Diesel for further
information.
3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alternately tightening the screws on the tool.
GN906-1.2 203 03
The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.
MAN B&W Diesel A/S
Page 3 (4)
906-1.4
Chains
Mounting
Mounting
906-1.4
1.
Before assembling the inner and outer

links, clean the pins and bushings.
1. Combine the inner chain link with the outer
chain link and mount the compression tool.
Force the loose side plate of the outer link
into place by alternately tightening the
screws on the compression tool.
GN906-1.4 203 01
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).
Page 4 (4)
MAN B&W Diesel A/S
106-2
Chain Tightener
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
X Engage turning gear
Shut off fuel oil
X Shut off lubricating oil

Data
Ref.
Description
Value
Unit
D06-21
Tightening angle = xx hexagons
720/12
/ hex
D06-23
Reduced tightening angle = xx hexagons
600/10
D06-25
Mechanical or blocked chain tightener, clearance
0.1
mm
D06-26
Max.distance
265
mm
D06-66
D max.
165
mm
MAN B&W Diesel A/S
Page 1 (2)
106-2
Chain Tightener
Data
Plate
P91366
Page 2 (2)
58
Feeler gauge
MAN B&W Diesel A/S
Chain Tightener
906-2.3
Adjusting
Chain
S50MC-C
0239 Tightener
Adjusting
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,

C and D to free the chain tightener bolt.
2. Turn the engine so that the slack part of the
chains is on the same side as the tightener
wheel.
3. With the balanceweights in this position,

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).
M90602-0239O01
If balanceweights are mounted, continue

the turning until they are hanging vertically
downwards.
M90602-0239O02
2.
3.
D06-21
M90602-0239O03
D06-25
MAN B&W Diesel A/S
Page 1 (2)
Chain Tightener
906-2.3
Adjusting
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.
M90602-0239O04
6. Measure distance X.
7. If the chain is worn (X > D06-66 mm), repeat the procedure from step 1, but tighten
nut B only to the reduced tightening angle,
see Data D06-23.
If distance X exceeds the max. distance
(see Data), find and eliminate the cause of
the abnormal chain elongation, e.g. a defective chain, damaged chain wheels or
bearings, etc. Repeat the procedure from
step 1.
5.
M90602-0239O05
6.
M90602-0239O06
Page 2 (2)
MAN B&W Diesel A/S
Camshaft
106-3
Data
SAFETY PRECAUTIONS
106-3
S50MC-C
D10603 Data
Camshaft
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D06-27
D06-28
D06-29
D06-30
Description
Max. permissible change in lead angle

corresponding to
Pin gauge for top dead centre of crankthrow No.1,
check measurement
Pin gauge for camshaft, check measurement
MAN B&W Diesel A/S
Value Unit
2
3.5 mm
697 mm
340 mm
Page 1 (2)
Camshaft
106-3
Data
Plate
P90664
P90668
Page 2 (2)

MAN B&W Diesel A/S
Camshaft
906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1
1.
Turn in the AHEAD direction to ensure that

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

on the crankthrow.
GN906-3.1 203 02
2.
MAN B&W Diesel A/S
D06-29
Page 1 (3)
Camshaft
906-3.1
Checking
3.
3. Position the camshaft pin gauge in the centre punch mark, and measure the deviation,
if any, in lead angle.
For max. permissible change, see 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
5.
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.
GN906-3.1 203 05
6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a fine carborundum stone. Such light scratches can appear
if the roller guide and the cam are not correctly aligned.
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.
GN906-3.1 203 06
6.
Page 2 (3)
MAN B&W Diesel A/S
Camshaft
906-3.3
Adjustment
Adjustment
906-3.3
1.
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.
GN906-3.3 203 01
D06-28
D06-27
MAN B&W Diesel A/S
Page 3 (3)
Camshaft Bearings
106-4
Data
SAFETY PRECAUTIONS
106-4
S50MC-C
D10604 Data
Camshaft Bearings
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D06-31
D06-33
D06-34
D06-37
D06-65
Description
Screws for bearing cap, tightening torque

Clearance between cap/bearing housing
Bearing shell, max. wear
Camshaft bearing cap
Bearing shell, minimum thickness
MAN B&W Diesel A/S
Value Unit
125
3 0.3
0.1
13
7.35
Nm
mm
mm
kg
mm
Page 1 (2)
Camshaft Bearings
106-4
Data
Plate
P91351
P91351
P90651
P91356
P91359
P91366
Page 2 (2)
Item
No.
22
58
152
61
Description
Hydraulic pump, hand operated

Hydraulic jack for lift of camshaft
Lifting Tools, Etc.
Torque Spanners
Slide caliper
MAN B&W Diesel A/S
Camshaft Bearing
906-4.1
Checking
Camshaft
S46MC-C Bearing
0216
Checking
906-4.1
1.
1. Dismount the inspection covers from the

front of the camshaft housing.
Check for wiped-out metal at the bearing
ends, and for fragments of metal in the
camshaft housing. In the event of any signs
of anomalies, the bearing shell must be dismantled for closer investigation and, if necessary, the bearing shell must be replaced.
GN906-4.1 203 01
If no anomalies are found during the visual

inspection, dismantling need only be carried out in connection with Class surveys.
0$1 % : 'LHVHO $6
Page 1 (6)
906-4.2
Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Warning!
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
GN906-4.2 203 01
1. Remove the inspection cover from the camshaft housing.

Dismount the lubricating oil connecting pipe
and the plug screws from the baseplate
over the bearing in question.
Lift the roller guide of the exhaust valve hydraulic pump. See Procedure 908-7.
2.
2. Loosen the bearing cap screws through the

holes in the baseplate.
Remove the screws from the bearing cap.
Mount two 10 mm eye bolts in the pertaining threads on top of the bearing cap.
3. Slide the bearing cap carefully towards the
exhaust cam disc.
GN906-4.2 203 02
Turn the bearing cap and pull it out through

the inspection opening.
3.
GN906-4.2 203 03
D06-37
Page 2 (6)
0$1 % : 'LHVHO $6
Camshaft Bearing
906-4.2
Dismantling
4.
4. Place the hydraulic jack in the camshaft

housing underneath the circular part of the
exhaust 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.
GN906-4.2 203 04
Remove the shell from the camshaft housing.
GN906-4.2 203 05
5.
0$1 % : 'LHVHO $6
Page 3 (6)
Camshaft Bearing
906-4.3
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.
GN906-4.3 203 01
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.
D06-34
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.
Page 4 (6)
0$1 % : 'LHVHO $6
Camshaft Bearing
906-4.4
Mounting
Mounting
906-4.4
2.
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.
3. Place the bearing cap on the camshaft next
to the exhaust cam.
Be careful not to scratch the exhaust cam

roller surface.
Turn the bearing cap to an upright position
and slide it carefully onto the bearing shell.
GN906-4.4 203 02
Note!
Remove the eye bolts and mount the outermost bearing cap screw.
3.
4. Tighten the outermost screw lightly until the

clearance given in D06-33 is reached. Then
mount and tighten the innermost screw with
a torque spanner. See Data D06-31. This
procedure ensures that the outermost
screw will obtain the correct torque.
GN906-4.4 203 03
Check the torque on the outermost screw

with a torque spanner.
4.
GN906-4.4 203 04
D06-31
0$1 % : 'LHVHO $6
D06-33
Page 5 (6)
Camshaft Bearing
906-4.4
Mounting
5.
5. Check the clearance D06-33. Then mount

the lubricating oil pipe and the plug screw
in the baseplate.
6. Lower the camshaft into position. Remove
the hydraulic jack from the camshaft housing.
GN906-4.4 203 05
7. Clean the camshaft housing and mount the

inspection covers.
D06-33
GN906-4.4 203 06
6.
GN906-4.4 203 07
7.
Page 6 (6)
0$1 % : 'LHVHO $6
106-5
Moment Compensator
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D06-38
Nominal spring force
F=
D06-44
Spring length, new
L=
mm
D06-45
Spring length, nominal
L=
mm
MAN B&W Diesel A/S
11800
Page 1 (2)
106-5
Moment Compensator
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
906-5.1
Moment Compensator
Checking
If dismantling has been necessary, the flyweights must be assembled in the correct position in relation to the engine crankshaft. Incorrectly mounted flyweights can cause (heavy)
vibrations of the engine.
(For 4 cylinder engines)

Viewed from
AFT
Viewed from
FORE
Note!
The following applies to a clockwise-rotating engine
90
Aftmost 2nd Order Moment Compensator

Turn the crankthrow of cylinder No. 1 in the
AHEAD direction to the position shown in the figures for 4, 5, 6-cylinder engines, respectively.
M90605 0220C01
Cylinder No. 1
Check that the flyweights point vertically downwards (max. deviation one-half chainwheel
tooth pitch).
Cylinder No. 1

Viewed from
AFT
Viewed from
FORE
Turn the camshaft relative to the crankshaft in

accordance with the valve opening diagram',
and then mount the chain.
Tighten the chain in accordance with the instruction.
Foremost 2nd Order Moment Compensator
M90605 0220C02

AHEAD direction to TDC and carry out fine adjustment of the camshaft.
99
Cylinder No. 1

AHEAD direction to the position shown in the figures for 4, 5, 6-cylinder engines, respectively.
Cylinder No. 1

Viewed from
FORE
Viewed from
AFT
Check that the flyweights point vertically downwards (max. deviation one-half chainwheel
tooth pitch) and then mount the chain.
Tighten the chain in accordance with the instruction.
105
15
For an anticlockwise-rotating engine,

the degrees mentioned in the respective figures must be before tdc, not
after tdc.
M90605 0220C03
Note!
Cylinder No. 1
MAN B&W Diesel A/S
Cylinder No. 1
Page 1 (3)
906-5.2
Moment Compensator
Adjustment
1. When tightening the chain, bring the two
flyweights to a vertical downward position.
1.
2. Release the lock washers and loosen nuts

A1, A2 and B2.
M90605 0220O01
3. Tighten nut B1 until the spring is completely compressed. Then loosen nut B1
until the length of the spring matches the
number of mm indicated on the dataplate
mounted on the spring, (D06-38, D06-44,
D06-45).
2.
A2
B2
M90605 0220O02
A1
M90605 0220O03
3.
Page 2 (3)
B1
MAN B&W Diesel A/S
906-5.2
Moment Compensator
Adjustment
4. Tighten nut A1 lightly.
4.
A2
Make sure that this does not compress the

spring further.
Tighten nut A2 while holding nut A1 with a
spanner.
Lock both nuts with the lock washer.
5. Tighten nut B1 until the thrust flange of the
spring lies hard against the distance tube.
M90605 0220O04
Tighten nut B2, and lock both nuts with the

lock washer.
A1
5.
B1
M90605 0220O05
B2
MAN B&W Diesel A/S
Page 3 (3)
106-6
Data
SAFETY PRECAUTIONS
106-6
S50MC-C
D10606 Data
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D06-47
D06-48
D06-49
D06-50
D06-51
D06-52
D06-53
Description
Exhaust cam screws, tightening torque

Indicator cam screws, tightening torque
Fuel cam screws, tightening torque
Fuel cam, marking scratch
Fuel cam, axial movement
Exhaust cam, marking scratch
Exhaust cam, axial movement
MAN B&W Diesel A/S
Value Unit
560
50
880
65
145
55
220
Nm
Nm
Nm
mm
mm
mm
mm
Page 1 (2)
106-6
Data
Plate
P91351
P91351
P91351
P91359
Page 2 (2)
22
58
105
Hydraulic pump, hand operated

Torque spanners
MAN B&W Diesel A/S
906-6.2
Dismantling
S42MC
0203
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft
housing.
2. Lift the roller guide from the cam in question. See Procedures 908-5 or 909-5.
3. Turn the camshaft so that the marking
scratch can be seen.
XZ906-6.2 201 01
4. Extend the marking scratch on the shaft by

D06-50. See Data.
XZ906-6.2 201 02
2.
XZ906-6.2 201 04
4.
0$1 % : 'LHVHO $6
D06-50
Page 1 (7)
906-6.2
Dismantling
5.
5. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.
6. Connect the snap-on connectors to the hydraulic high-pressure pump.
Apply oil pressure to the cam, using the
high-pressure pump.
When oil seeps out along the cam, press
the cam sideways, in the direction towards
the forward end of the engine.
XZ906-6.2 201 05
7. The cam should be moved as stated in

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

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

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

Dismantling
12.
12. Dismantle and remove the indicator drive

cam from the camshaft when fitted.
13. Remove the plug from the cam and mount
gaskets and snap-on connectors instead.
14. Connect the snap-on connectors to the hydraulic high-pressure pump.
Apply oil pressure to the cam, using the
high-pressure pump.
XZ906-6.2 201 12
When oil seeps out along the cam, press

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

D06-53 to be sure that it gets free of the liner for the roller guide.
16. In the event that the cam cannot be moved
as described in item 14, MAN B&W should
be contacted for further instructions.
XZ906-6.2 201 15
D06-53
0$1 % : 'LHVHO $6
D06-53
Page 5 (7)
906-6.4

Mounting
Mounting
906-6.4
1.
Fuel Cam
1. Before mounting the two-part spare cam,
the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,
mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
2. Make sure that the marking scratches on
the cam and the camshaft coincide, and
that the running surface of the cam is opposite the roller.
Tighten the screws just hard enough to
avoid that the cam slips when the roller
guide is lowered onto the cam.
XZ906-6.4 201 01
Measure the fuel cam lead (see Procedures

909-1 and 909-2) and adjust if necessary.
Tighten the screws to D06-49 and check
that the gap is still equal at both sides.
Lock the screws with Loctite, type 242
(EN243S).
2.
3. Mount the cover on the front of the camshaft housing.
XZ906-6.4 201 02
D06-49
Page 6 (7)
0$1 % : 'LHVHO $6
906-6.4
Mounting
4.
Exhaust Cam
4. Mount the indicator drive cam and adjust
according to Chapter 706 in the Operation
manual when fitted.
Tighten the self-locking nuts as stated in
D06-48.
Place the two-part spare cam on the shaft,

mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
XZ906-6.4 201 04
5. Before mounting the two-part spare cam,

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

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

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

908-7) and adjust if necessary.
7. Mount the cover on the front of the camshaft housing.
XZ906-6.4 201 06
6.
D06-47
D06-49
0$1 % : 'LHVHO $6
Page 7 (7)
Chain Drive and Camshaft Panel
MAN B&W Diesel A/S
Plate
P90651-0173
Page 1 (2)
Plate
P90651-0173
Item
No.
019
020
044
056
068
152
Page 2 (2)
Chain Drive and Camshaft Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Impact spanner, fuel cam
Assembling tool, chain
Disassembling tool, chain
Hydraulic jack, lift of camshaft
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90662-0046
Page 1 (2)
Plate
P90662-0046
Item
No.
020
032
044
056
068
093
103
211
Page 2 (2)
Item Description
Item
No.
Item Description
Jack - hydraulic, complete

Support
Tommy bar
Spanner
Stud setter
MAN B&W Diesel A/S
Plate
P90664-0005
Page 1 (2)
MAN B&W Diesel A/S
Plate
P90664-0005
Item
No.
021
Page 2 (2)
Item Description
Item
No.
Item Description
Pin gauge for crankshaft
MAN B&W Diesel A/S
Plate
P90668-0003
Page 1 (2)
MAN B&W Diesel A/S
Plate
P90668-0003
Item
No.
011
Page 2 (2)

Item Description
Item
No.
Item Description
Pin gauge
MAN B&W Diesel A/S
907 - Starting Air System

107-01
907-01
107-02
907-02
0017
0216
0032
0214
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
107-1
Data
SAFETY PRECAUTIONS
107-1
S46MC-C
D10701 Data
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
D07-01
D07-03
D07-04
D07-05
Description
Gear wheel on camshaft, tightening torque

Clearance between gear wheel and bushing:
Clearance with roller in outermost position:
Clearance with roller in innermost position:
MAN B&W Diesel A/S
Value Unit
90
0.9 - 1.6
1.0 - 3.0
1.0 - 2.0
Nm
mm
mm
mm
Page 1 (2)
107-1
Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
907-1.1
Checking
Starting Air
S46MCC Distributor
0216
Checking
907-1.1
1.
1. Turn the engine in AHEAD direction to bring

the piston of cylinder No. 1 to TDC.
Check with the pin gauge.
If pin K is not available, use the cylindrical

end of a drill of a suitable size.
3. If the check pin cannot enter the slot, i.e. if
the slot is not aligned with the hole in the
distributor housing, the air distributor must
be adjusted.
GN906-3.1 203 02
2. Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.
2.
EN907-1.3 204 02
0$1 % : 'LHVHO $6
Page 1 (3)
907-1.3
Adjustment
Adjustment
907-1.3
1.
1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.
Check with the pin gauge.
GN906-3.1 203 02
2. Dismount the end cover of the camshaft

housing, along with the starting air distributor, from the engine.
Remove the plug screw and gasket from the
side of the distributor housing, and insert
check pin K in slot S.
Turn the shaft together with the distributor
disc until check pin K enters slot S in the
disc and keep it there.
2.
3. Check and, if necessary, adjust clearance

D07-03 between the gear wheel and the
bushing.
EN907-1.3 204 02
GN907-1.3 203 03
3.
Page 2 (3)
D07-03
0$1 % : 'LHVHO $6
907-1.3
Adjustment
4.
4. Remove the lower half of the gearwheel

drive cover. Mount the upper half of the
gearwheel drive cover with the complete
starting air distributor after loosening the
gear wheel on the camshaft, and then engage the two gear wheels by turning the
wheel on the camshaft.
Tighten and lock the gear wheel screws on
the camshaft, see Data, D07-01.
Mount the lower half of the gearwheel drive
cover.
5. Remove check pin K from the distributor
housing and mount the gasket and plug
screw.
GN907-1.3 203 02
6. Check the clearance between the roller and

the two interlocking valves with the roller in
its innermost and outermost positions, respectively ( ASTERN and AHEAD).
D07-01
5.
GN907-1.3 203 02
6.
EN907-1.3 204 06
D07-01
0$1 % : 'LHVHO $6
D07-04
Page 3 (3)
Starting Air Valve
107-2
Data
SAFETY PRECAUTIONS
107-2
S46MC-C
D10702 Data
Starting Air Valve
Stopped engine

Engage turning gear
Shut off fuel oil
Data
Ref.
D07-09
D07-10
D07-11
D07-12
Description
Piston tightening torque

Valve tightening torque
Valve tightening angle
Starting air valve
MAN B&W Diesel A/S
Value Unit
180
17520
50/30
20
Nm
Nm
Nm/
kg
Page 1 (2)
Starting Air Valve
107-2
Data
Plate
P90151
P90151
Page 2 (2)
95
105
Grinding ring for starting valve

Grinding handle for starting valve
MAN B&W Diesel A/S
Starting Air Valve
907-2.2
Dismantling
Starting Air
S46MC-C Valve
0214
Dismantling
907-2.2
1.
1. Shut off the starting air and control air inlet.

Dismount the control air pipes.
Unscrew the fixing nuts of the starting valve
flange.
GN907-2.2 203 01
2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.
2.
GN907-2.2 203 02
D07-12
0$1 % : 'LHVHO $6
Page 1 (5)
907-2.3
Starting Air Valve

Overhaul
Overhaul
907-2.3
1.
1. Remove the top cover fixing screws and remove the cover.
Remove and discard the gasket.
2. Screw off the valve spindle nut and remove
the valve spindle from the valve housing.
Take out the piston, distance pipe, valve
spring, and the liner.
EN907-2.3 0212 01
Remove and discard the O-ring.
EN907-2.3 0212 02
2.
Page 2 (5)
0$1 % : 'LHVHO $6
Starting Air Valve
907-2.3
Overhaul
3.
3. Grind the valve housing seating with the

grinding ring after applying grinding paste.
Carborundum No. 200.
Grind the seatings of the spindle and housing to match, using the face wrench to rotate the valve spindle.
Carborundum No. 500.
4. Thoroughly clean all parts before reassembling the valve.
Lubricate all internal parts (sliding surfaces) with Molybdenum Disulphide, MoS 2
grease.
GN907-2.3 203 03
5. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring and the piston.
EN907-2.3 0212 05
5.
0$1 % : 'LHVHO $6
Page 3 (5)
907-2.3
Starting Air Valve

Overhaul
6.
D07-09
6. Mount the nut on the valve spindle and

tighten the nut, see D07-09.
7. Place a new gasket on the valve housing.
Mount and tighten the top cover.
Replace the O-ring on the valve housing.
EN907-2.3 0212 06
8. If the starting air valve is not to be mounted

in the engine immediately after the overhaul, all openings of the valve should be
covered with plastic to prevent dirt from entering the valve during storage.
EN907-2.3 0212 07
7.
Page 4 (5)
0$1 % : 'LHVHO $6
Starting Air Valve
907-2.4
Mounting
Mounting
907-2.4
1.
1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recondition the seat for the starting valve in the
bore.
If not already done, replace the O-ring on
the overhauled valve and lubricate with
Neverseize or Molybdenum Disulphide,
MoS 2.
For overhaul, see Procedure 907-2.3.
3. Mount the nuts and tighten-up, according to

data D07-10 or D07-11.
GN907-2.4 203 01
2. Mount the valve in the cylinder cover.
Mount the control air pipes and turn on

starting air and control air.
2.
GN907-2.4 203 02
D07-12
3.
GN907-2.4 203 03
D07-10
or
D07-11
0$1 % : 'LHVHO $6
Page 5 (5)
908 - Exhaust Valve

108-01
908-01
108-02
908-02
108-03
908-03
108-04
908-04
108-05
908-05
108-07
908-07
90851
90862
90863
90863
0017
0212
0087
0256
0017
0218
0015
0210
0002
0203
0020
0210
0200
0043
0014
0016
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 - Hydraulic Tools
Exhaust Valve - Extra Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
High-Pressure Pipe
108-1
Data
SAFETY PRECAUTIONS
108-1
S50MC-C
0017
Special Data
High-Pressure Pipe
Stopped engine

Engage turning gear
10-120 Nm

Shut off fuel oil
X

Data
Ref.
Description
Value Unit
D-1
Weight of high-pressure pipe
34 kg
D-2
Tightening torque
High-pressure pipe
36 Nm
MAN B&W Diesel A/S
Page 1 (2)
High-Pressure Pipe
108-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
High-Pressure Pipe
908-1.2
Dismantling
High-Pressure Pipe
S50MC-C
0212
Dismantling
908-1.2
1.
1. When replacing the hydraulic high-pressure

pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing surfaces.
2. Before dismounting the high-pressure pipe,
stop the camshaft oil pump.
Loosen the screws for the high-pressure
pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator.
D-1
GN908-1.2 203 01
3. Remove the screws in both ends of the

high-pressure pipe. Lift the high-pressure
pipe away from the engine.
GN908-1.2 203 02
2.
0$1 % : 'LHVHO $6
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
Overhaul
908-1.3
1.
The two ends of the pipe are identical and

should both be overhauled as follows:
1. Remove the thrust piece from the actuator/
exhaust valve.
Remove and discard the O-rings from the
thrust piece and the thrust flange.
Clean and inspect the conical seats of the
high-pressure pipe and the thrust piece.
GN908-1.3 203 01
Note!
The seats cannot be reconditioned.
If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-part
sleeve.
3. Remove the thrust flange from the pipe
end.
DM908-1.1 61 02
Remove and discard the internal O-rings.

Mount new internal O-rings lubricated with
a little camshaft lubricating oil.
4. Assemble the high-pressure pipe in the reverse order to disassembling.
DM908-1.1 61 03
3.
Page 2 (3)
0$1 % : 'LHVHO $6
High-Pressure Pipe
908-1.4
Mounting
Mounting
908-1.4
1.
1. Mount new O-rings, lubricated with a little

camshaft lubricating oil, on the thrust pieces and thrust flanges.
Mount the thrust pieces on the actuator/exhaust valve.
Mount the high-pressure pipe on the engine.
Note!
When mounting the high-pressure pipe,
take care not to damage the conical
seats of the pipe/thrust pieces.
3. Check the system for tightness.
GN908-1.2 203 01
2. After fitting the pipe to the exhaust valve

and actuator, tighten up the screws of the
pressure flanges diagonally, see Data.
2.
GN908-1.4 203 02
D-2
0$1 % : 'LHVHO $6
Page 3 (3)
Exhaust Valve
MAN B&W Diesel
108-2
Data

Stopped engine
X
X
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
X
X

Data
Ref.
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
D08-24
D08-25
D08-26
D08-27
D08-28
D08-29
D08-30
D13-01
D13-02
Description
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
Exhaust valve, complete
Exhaust valve housing
Oil cylinder
Air cylinder
Spindle
Bottom piece
Air piston
Value
Unit
21
50
70
50 - 80
29.9 - 30.0
30.5 - 30.6
2.3
1.0
8.0
2.0
235
345
59.8
60.6
62.0
71.2
2.6
460
260
65
20
45
55
6
1500
1400-1650
bar
Nm
Nm
Nm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Exhaust Valve
108-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90851
065
Lifting tool for exhaust valve
P90851
077
Cone ring for pneumatic piston
P90851
089
Pressure tester for safety valve
P90851
090
Gauge for exhaust valve spindle
P90851
150
Gauge for exhaust valve bottom piece
P90851
161
Lifting tool for exhaust valve spindle
P90851
185
Grinding ring for exhaust valve bottom piece
P90862
P91351
010
P91351
034
P91351
058
P91351
117
Page 2 (2)
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
Checks during running:
1.
1. Check of valve spindle rotation
The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the groove in the
piston.
During engine operation, the spindle must
rotate. The rotation can vary with unit and
engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is
finished, lift the rotation indicator and lock
it in the top position.
M90802 0252C01
The engine must run when the valve function and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90 and let it rest on the air piston.
On Surface
InGroove
2.
The indicator must not be in constant operation.
2. Check of sealing oil unit

Check that the injection indicator moves
regularly with the valve opening. Alternatively, unscrew the sealing oil pipe, and
check that oil is coming out (very small
quantity).
M90802 0256C02
Exhaust valve performance condition

See volume I chapter 706 Performance
Evaluation
Depending on valve model the indicator is

placed either on the manoeuvre side or the
front side
Page 1 (24)
Exhaust Valve
908-2.1
Checking
MAN B&W Diesel
3. Check of bottom piece sealings

3.
With the exhaust valve mounted in the cylinder cover, check the cooling water inlet
and outlet to the cylinder cover and exhaust valve is open.
M90802 0254C03
Check the tightness of the sealing rings between the bottom piece and the exhaust
valve housing. IF water flows from the small
bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is
leaking.
If water flows from the any of the rings, the
exhaust valve must be dismounted and the
sealing rings replaced.
Check with stopped engine:
4.
In connection with port stays, at an interval
of e.g. one month, an easy check of all exhaust valves is recommended.
4. Check of spindle drop-down time:
Engage all rotation indicators on the exhaust valves.
SAFETY AIR
SUPPLY
Shut off and release the spring air on the

valve, next to the engine-side manoeuvring
stand.
AIR SUPPLY
EXHAUST VALVE
Check the drop down time for all spindles:
Spindles dropping down within 30 min-
M90802 0256C04
utes: Check and overhaul, See next

step Check of Air Spring tightness.
Spindles dropping down between 30

minutes and 1 hour: Keep under observation.
CONTROL AIR
SUPPLY
Spindles dropping down after 1 hour:

OK.
When check of drop down time is finished,
lift the rotation indicators and lock them in
the top position.
Page 2 (24)
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
5. Check of Air spring tightness

5.
Connect compressed air to the non return
(A) valve on the air cylinder.
Disconnect and remove the drain oil pipe
from the oil cylinder (C).
Disconnect the sealing oil pipe and banjo
coupling from the air cylinder (B).
Check if air is coming out from:
The sealing oil bore (B): Leakage from

spindle stem sealing , change and overhaul.
Hole for drain oil (C): If yes, the leakage
comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and overhaul.
Remove the air supply to the non-return

valve on the air cylinder and check the
non-return valve for tightness.
The checks is for guidance only, minor
leaks is difficult to detect.
M90802 0256C05
C
B
Page 3 (24)
908-2.2
Exhaust Valve
Dismantling
MAN B&W Diesel
1. Close off cooling water

1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections
Dismount the high-pressure pipe for the hydraulic valve actuation.
See Procedure 908-1.2
M90802 0256D01
Dismount the return oil pipe from the exhaust valve.
M90802 0256D02
2.
Page 4 (24)
Exhaust Valve
MAN B&W Diesel
908-2.2
Dismantling
3. Disconnect pipe connections

3.
Disconnect the cooling water connections
from the exhaust valve and the air pipe for
the air spring.
Remove the plate jacket and insulation
from the intermediate pipe.
Support the intermediate pipe by e.g. a

chain block and remove the screws.
4. Dismantling of hydraulic nuts.
Remove the protective caps from the exhaust valve studs.
M90802 0256D03
Loosen the screws which attach the intermediate pipe to the exhaust valve housing.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 913-1.
M90802 0256D04
D13 02
Page 5 (24)
Exhaust Valve
908-2.2
Dismantling
MAN B&W Diesel
5. Lift of exhaust valve

5.
D08 24
Check all connections to the valve are removed.

Attach the crane to the eye bolt fitted on
top of the valve and start lifting the exhaust
valve. During the lift - check the valve goes
clear of all other engine components.
Land the exhaust valve on a wooden plate
on the platform.
Carefully clean the exhaust valve bore in
the cylinder cover and recondition the seating and sealing surfaces of the bore, if required.
M90802 0256D06
For overhaul of the exhaust valve, see Procedure 908-2.3
Page 6 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
1. Oil cylinder
1.
Place the exhaust valve on a wooden support on the platform.
D08 26
Remove the nuts and the safety strap from

the oil cylinder.
Depending on valve model, remove the
sealing oil pipe.
Lift away and place the oil cylinder on a
wooden support.
2. Conical locking ring
Remove the four screws from the flange on

top of the air piston and dismount the
flange.
2.
M90802 0256O02
Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
M90802 0256O01
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.
Page 7 (24)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
3. Spindle
3.
D08-24
Use the oil cylinder as a lifting tool for the

exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
so that the load from the valve housing is
evenly distributed.
Lift the valve housing clear of the valve
spindle. Take care when the internal Oring in the air piston and the internal rings
for the sealing arrangement at the bottom
of the air cylinder pass the groove for the
conical ring at the top of the spindle.
4. Bottom piece
M90802 0256O04
Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
If the bottom piece has become stuck, use
a tin hammer to release it.
Lift the valve housing away and land it on a
couple of wooden planks.
4.
Remove the oil cylinder.
M90802 0256O05
D08-29
Page 8 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
5. Air piston and cylinder

5.
Dismount the air piston from the air cylinder.
Dismount the non-return valve from the air
cylinder/valve housing.
D08-30
D08-27
Mount two eye bolts in the air cylinder and

dismount the air cylinder.
6. Guide bushing
Clean the exhaust valve housing.
Inspect the bushing in the spindle guide for
wear and measure the top and bottom diameters. See Data.
M90802 0256O06
Remove and discard the O-ring on the air

cylinder.
6.
M90802 0255O10
D08 18
D08 19
Page 9 (24)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
7. Bushing renewal
7.
If it proves necessary to replace the bushing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.
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 spare part.
When a new bushing is mounted, mount a
new O-ring for sealing between bushing
and exhaust valve housing. Mount and
tighten the screws for the bushing.
M90802 0256O08
8. Bottom piece inspection

Before cleaning the bottom piece, See Volume I, supplement 707-03
Inspect and evaluate the seating according
to Volume I.
M90802 0256O09
8.
Page 10 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
9. Bottom piece Measuring

9.
In connection with evaluation of the bottom
piece according to Volume I, wear or the
total amount the seat has been ground, is
measured as described below.
G3
D08 12
Use the bottom piece template and a feeler

gauge, take measurements G2 and G3. All
measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating.
For maximum wear or grinding, see Data
D08-11 and D08-12.
D08 09
IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN Further
grinding or reconditioning is not recommended.
10. Bottom piece sealing face
If necessary grind the outside seating.
Use carborundum 200 and the special
grinding tool. Turn the special grinding tool
by hand, turning alternately clockwise and
anticlockwise. Grind until a smooth surface
is achieved.
M90802 0255O14
If the seat or the recess G3 is ground, see

Data D08 09 for correct grinding angle.
G2
D08 11
10.
M90802 0255O15
Clean the bottom piece.
Page 11 (24)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
11. Bottom piece sealing rings

11.
Mount new sealing rings on the bottom
piece.
Mount one O-ring in the upper groove.
Make sure that the groove for the U-seal is
clean.
M90802 0256O12
Heat the U-seal in 100C hot water for

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

exhaust valve housing.
Check the face on the valve housing is
clean.
If fitted, check that the guide pin in the
bottom piece enters the hole in the bottom
of the exhaust valve housing.
M90802 0256O13
Land the exhaust valve housing on the bottom piece. Mount and tighten the retaining
screws for the bottom piece.
Page 12 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
13. Spindle inspection

13.
Before cleaning the spindle, See Volume I,
supplement 707-03
Inspect and evaluate the spindle according
to Volume I.
In connection with evaluation of the spindle

according to Volume I, burn-off and wear or
the total amount the seat has been ground,
are measured as described below.
The burn-off F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
M90802 0256O14
14. Spindle burn-off and grinding check
14.
For the maximum allowable burn-off, see
Data D08-13.
G1
The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge.
D08 14
For maximum seat grinding, see data D08

14.
M90802 0256O15
If necessary to grind the seat, see Data

D08-10 for correct grinding angle.
F1
D08 10
A
D08 13
Page 13 (24)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
15. Spindle stem check

15.
In connection with evaluation of the spindle
according to Volume I, the spindle stem
wear is measured as described below.
D08 16 D08 15
D08 17
Check the spindle stem for wear in the

area D08-15 to D08-16 measured from the
top of the spindle.
For minimum stem diameter, see data D08
-17.
If the exhaust valve spindle needs reconditioning, contact MAN B&W Diesel for advice.
16. Spindle transport
M90802 0252O19
When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
16.
M90802 0255O16
D08 28
Page 14 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
17. Spindle bushing sealing-rings

17.
Check the top of the spindle bushing and
the face on the housing is clean.
Fit new o-rings on the spindle bushing as
shown in the sketch.
18. Spindle mounting

exhaust valve housing.
Carefully land the exhaust valve housing
with the bottom piece on the exhaust valve
spindle.
M90802 0256O18
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
18.
M90802 0256O19
Remove the oil cylinder.
Page 15 (24)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel
19. Air cylinder

19.
Clean the air cylinder.
Dismount the safety valve from the air cylinder, use the machined faces to unscrew
the valve.
Unscrew and clean the Banjo coupling for
sealing oil to the spindle stem bushing.
Blow through all bores in the air cylinder.
Check the non-return valve in the Banjo
coupling with compressed air. Clean the
bottom of the air cylinder for possible
coke. Remount the Banjo coupling. Mount
a new O-ring in the groove on the outside
of the air cylinder.
Compressed Air
20. Safety valve
M90802 0256O20
Place the safety valve in the pressure testing device. Connect the testing device with
the high pressure pump by means of a
hose.
Check the opening pressure, see Data.
If the opening pressure is not correct,
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.
20.
D08-04
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.
M90802 0256O21
Finally, mount the protective cap.
D08-07
Page 16 (24)
Exhaust Valve
908-2.3
Overhaul
MAN B&W Diesel

21. Air cylinder mounting
21.
Lubricate the O-rings on the spindle bushing.
Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines
are not equipped with the locating pin
Take care not to damage the O-rings on

the outside of the spindle bushing.
22. Air piston seals

Check the teflon guide ring and teflon sealing ring for wear, if it is necessary to replace the sealing rings on the air piston,
cut them and remove them.
M90802 0256O22
Note!
22.
Be careful not to damage the edges of the

ring grooves in the piston.
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.
M90802 0252O32
Note!
After mounting, compress the teflon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new O-rings in the inside grooves of
the air piston.
Page 17 (24)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
23. Air piston mounting

23.
Fit the conical guide ring for the air piston
on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.
Use a nylon block and a hammer to press
the air piston down in the cylinder
Remove the conical guide ring from the air
cylinder.
Mount the non return valve for spring air
24. Locking ring
M90802 0256O24
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
Mount the flange on top of the air piston
and, by means of the four screws, tighten
the air piston and the flange together.
On valve models where the bolts are designed for securing, secure the bolts. See
Procedure 913-7.
M90802 0256O25
24.
Page 18 (24)
Compressed Air
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
25. Oil cylinder

25.
Loosen the screws and remove the lifting
bracket from the oil cylinder to gain access
to the orifice plug.
Remove the sealing oil unit.
Remove and discard the gasket. Unscrew
and clean the orifice plug. Remove and discard the sealing disc. Check and clean the
bore for the orifice plug in the top of the oil
cylinder.
26. Sealing oil control unit.
26.
M90802 0255O37
Normally overhaul of the sealing oil unit

should not be necessary. Check the unit
according to Procedure 908- 2.1. Before remounting the unit, carefully clean it on the
machined faces. If the unit needs to be
overhauled, send it to an authorised MAN
B&W repair workshop.
D08-20
M90802 0256O26
Place the oil cylinder in a horizontal position. Remove the flange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylinder diameter. If the diameter of the oil cylinder exceeds Data D08-20, either renew the
liner or send the complete oil cylinder to an
authorised MAN B&W workshop for overhaul, depending on the valve model.
Page 19 (24)
908-2.3
Exhaust Valve
Overhaul
MAN B&W Diesel
27. Oil piston

27.
Top
Remove the piston rings from the oil piston

and check them for wear. If the thickness
of the rings has worn down to the minimum, see Data, discard the rings and
mount new ones. Check that the TOP mark
on the piston rings faces upwards, when
mounting
Check the mesh once more.
28. Oil cylinder assembly
M90802 0253O42
D08 21
Mount the piston and the flange in the oil

cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright position. Mount a new sealing disc in the bore
for the orifice plug. Screw the orifice plug
into the bore. Place a new gasket on top of
the oil cylinder. Mount the sealing oil unit.
Mount the lifting bracket on the oil cylinder.
Mount the screws and tighten to the torque
stated in Data.
28.
M90802 0256O31
D08-05
Page 20 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
29. Oil cylinder mounting

29.
Mount the overhauled oil cylinder on top
of the air cylinder. Mount the safety strap
and tighten the nuts. See Data.
D08 06
M90802 0256O32
Mount the sealing oil pipe
Page 21 (24)
Exhaust Valve
908-2.4
Mounting
MAN B&W Diesel
1. Checks before mounting
1.
Before mounting an overhauled exhaust

valve in the engine, it is recommended that
the valve is checked and prepared as follows:
D08 24
Connect compressed air to the air cylinder

to close the valve.
Lift up the valve with the engine room
crane.
Check that a 1.0 mm feeler gauge can be
inserted about 15 mm into gap G3, to ensure that there is a clearance between the
outer parts of the seating faces of valve
housing and spindle.
M90802 0256M01
G3
Check that the valve stays closed for a

minimum of 5 minutes.
Carry out the drop down test as described
in procedure 908-2.1.
Check the valve is fitted with new sealing rings in the grooves on the bottom piece.
2.
2. Exhaust valve landing

Close the valve with compressed air.
Lubricate the sealing rings with vaseline
and the threads of the studs with anti-seizure paste.
Compressed Air
Position the valve in the cylinder cover
Copper Grease
M90802 0256M02
Vaseline
Page 22 (24)
Exhaust Valve
MAN B&W Diesel
908-2.4
Mounting
bore, guiding it in accordance with the exhaust flanges and the guide pin on the exhaust side of the exhaust valve.
3.
D13 01
3. Mounting of hydraulic nuts.

Mount and tighten the hydraulic nuts, see
Data.
4. Mount the pipe connections

Connect the intermediate pipe to the exhaust valve.
Mount and tighten the screws to the exhaust valve housing.
M90802 0256M03
Mount the protective caps on the exhaust

valve studs.
4.
Mount the insulation and plate jacket

for the intermediate pipe.
Mount the cooling water connections for
the exhaust valve and the air pipe for the
air spring.
Mount the high-pressure pipe for the hydraulic valve actuation.

Mount the return oil pipe to the exhaust
M90802 0256M04
5. Mount the oil pipe connections
M90802 0256M05
5.
Page 23 (24)
Exhaust Valve
908-2.4
Mounting
MAN B&W Diesel

valve.
6.
Check that all pipe connections are properly tightened.

6. Open cooling water supply
Check that all water connections are
mounted and tightened.
Open the cooling water inlet supply, and
vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring between the bottom piece and the exhaust
valve housing. See Procedure 908-2.1.
M90802 0256M06
7. Air spring check

The air supply to the exhaust valve must always be connected and pressurized before turning on the oil supply to the exhaust valve actuator.
If the lubricating oil pumps have been
started before the exhaust valve pneumatic
springs are pressurize:
7.
Engage the indicators on top of the exhaust valves and wait until the exhaust
valves are closed.
M90802 0256M07
Closing of the exhaust valves are eased if

the lubrication oil pumps are stopped and
the actuators are drained at the drain
screws.
Closed Valve
Page 24 (24)
Open Valve
108-3
Data
SAFETY PRECAUTIONS
108-3
S50MC-C
0017
Special Data
Stopped engine
Engage turning gear

Shut off fuel oil
10-120 Nm, 140-760 NM

2 x M12
Data
Ref.
Description
D-1
33 kg
D-2
Weight of hydraulic actuator
70 kg
D-3
Oil cylinder, inside diameter

max.
71.2 mm
D-4
Piston rings, min. thickness
2.6 mm
D-5
Hydraulic actuator
tightening torque or
tightening angle
300 Nm
25
D-6
Locking plate
tightening torque
Value Unit
10 Nm
MAN B&W Diesel A/S
Page 1 (2)
108-3
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
908-3.1
Checking
S50MC-C
0218
Checking
908-3.1
1.
1. The non-return valve A is built into the oil

inlet pipe to the actuator.
To check the valve, dismantle and clean it
and connect a supply of working air (7 bar)
to the outlet side of the valve (the side facing the actuator). If the air flow can be felt
at the inlet side of the valve, the valve must
be overhauled.
D-1
For a normal system, the oil quantity will be

smaller than the number of litres per hour
stated in Data.
Leakages may also be caused by leaky
non-return valves and loose pressure pipe
connections.
DM908-3.0 92 02
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.
If the pipe connections are tight and the

leak oil amount from the exhaust valve is
correct, 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.
0$1 % : 'LHVHO $6
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.
DM908-3.0 92 02
Dismount the high-pressure pipe.

2. Release the mountings for the indicator
drive from the actuator housing.
2.
D-2
Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.
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.
DM908-3.0 92 03
Remove the spring.

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.
HM908-3.0 70 03
4. Overhaul the actuator housing and the piston as required.

Page 2 (4)
0$1 % : 'LHVHO $6
908-3.3
Overhaul
Overhaul
908-3.3
1.
1. Clean the piston in kerosene and wipe dry

with a clean piece of cloth.
D-4
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.
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
Check the bore of the oil cylinder for possible scores and measure it for wear.
3.
DM908-3.0 92 06
D-3
0$1 % : 'LHVHO $6
Page 3 (4)
908-3.4
Mounting
Mounting
908-3.4
1.
1. Mount the actuator piston in the roller guide

and turn 90 to lock it in the bayonet joint.
Mount the locking plate and tighten as stated in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
D-6
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.
KC908-3.0 76 05
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.
2.
D-2
Note!
Use only the tightening angle OR the
tightening torque, NOT both.
D-5
3. Mount the oil inlet pipe and the drain pipe

from the exhaust valve.
DM908-3.0 92 08
Mount the hydraulic high pressure pipe.

DM908-3.0 92 09
3.
Page 4 (4)
0$1 % : 'LHVHO $6
Exhaust Valve Roller Guide
108-4
Data
SAFETY PRECAUTIONS
108-4
S50MC-C
0015
Special Data
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D-1
Weight of roller guide,

complete
37 kg
Max. clearance
roller/bushing/shaft pin
0.5 mm
D-2
Value Unit
MAN B&W Diesel A/S
Page 1 (2)
108-4
Data
Plate
1175386-1
90851
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
908-4.1
Checking
S50MC-C
0210
Checking
908-4.1
2.
1. The exhaust valve roller guide can be partially checked while mounted on the engine,
using the following procedure:
Lift the roller guide.
2. Remove the camshaft inspection cover.
Check the movability of the roller by turning

this by hand to ascertain if the roller moves
freely and without unnecessary resistance
or hard points.
GN908-4.1 203 01
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
5.
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.
3. A more suitable and reliable method is to
check the roller guide and the bearing
clearance when the roller guide is dismounted.
For dismantling of the roller guide see Procedure 908-4.2.
5. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.
GN908-4.3 203 02
4. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
scratches.
6. Place a dial gauge against the roller. Then

lift the roller as much as the clearance permits, which makes it possible to read the
clearance D-2 directly on the dial.
0$1 % : 'LHVHO $6
Page 1 (4)
908-4.1

Checking
7. It is recommended that the roller guide

shold 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 during the checking of
the roller guide.
Note!
For disassembling of the roller guide,
contact an MAN B&W authorized repair
shop.
Page 2 (4)
0$1 % : 'LHVHO $6
908-4.2
Dismantling
Dismantling
908-4.2
1.
1. Dismantle the hydraulic actuator above the

exhaust valve roller guide.
2. Mount the roller guide lifting tool as follows:
Lift the lock ring of the tool up on the
shaft of the tool.
Place the tool in such a manner that its
foot rests on the thrust piece in the bayonet joint of the roller guide.
Turn the tool 90 so as to allow the foot to
engage properly in the bayonet joint.
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.
GN908-4.2 203 01
Lower the lock ring, thereby securing the

foot in the locked position.
2.
GN908-4.2 203 02
D-1
0$1 % : 'LHVHO $6
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.
D-1
Place the tool in such a manner that its

foot rests on the thrust piece in the bayonet joint of the roller guide.
Lower the lock ring, thereby securing the
foot in the locked position.
Clean and lubricate the sliding surfaces of
the roller and the roller guide and lower it
carefully into the roller guide bushing.
GN908-4.2 203 02
Remove the lifting tool.
Page 4 (4)
2. Mount the actuator.

0$1 % : 'LHVHO $6
Exhaust Valve Cam
108-5
Data
SAFETY PRECAUTIONS
108-5
S50MC-C
0002
Special Data
Exhaust Valve Cam
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value Unit
MAN B&W Diesel A/S
Page 1 (2)
Exhaust Valve Cam
108-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Exhaust Valve Cam
908-5.1
Checking
Exhaust Valve Cam
S50MC-C
0203
Checking
908-5.1
For checking the position of the exhaust cam,

turn the engine in AHEAD direction until the roller guide (measured on the activator plunger)
has been lifted 10 mm.
If the cam has been correctly adjusted, the
crankthrow for the cylinder concerned will then
be in a position of A past its TDC.
To check the lead angle, continue turning in
direction until the roller guide has been
lifted 10 mm, corresponding to a turn of B of
the crankshaft.
AHEAD
The lead angle is then

180 - A + B
2
The correct position of the cam must be within
+/-0.5.
The illustration shows the position of the exhaust cam for a 6-cyl. standard engine, when
the piston of the cylinder concerned is in TDC.
See the adjustment sheet in Volume I, OPERATION, Chapter 701, for the lead angle of the
plant in question.
The cam lead 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.
0$1 % : 'LHVHO $6
Page 1 (1)
Exhaust Valve
108-7
Data
SAFETY PRECAUTIONS
108-7
S50MC-C
0020
Special Data
Exhaust Valve
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D-1
Value Unit
34 kg
MAN B&W Diesel A/S
Page 1 (2)
Exhaust Valve
108-7
Data
Plate
1175386-1
90851
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Exhaust Valve
908-7
Special Running
Exhaust Valve
S50MC-C
0210
Special
908-7 Running
3.
Engine trouble might require that a cylinder be

taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve
locked in either the open or the closed position.
Either way, carry out the following procedure:
2. Dismantle the hydraulic high-pressure

pipe.See Procedure 908-1.2.
3. Dismantle the connecting sleeve and the oil
inlet pipe. Discard the sealing rings. Blank
off the connection from the main oil pipe
with a plug screw.
GN908-7 203 03
1. Lift the relevant fuel pump roller guide.

4.
5. Position the lifting tool on the actuator and

screw the spindle into the top of the actuator piston.
Tighten the lowermost nut on the tool to pull
up the roller guide as far as possible.
GN908-4.1 203 01
4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.
Tighten the upper nut of the tool against the

lower nut to secure the roller guide in this
position.
5.
GN908-7 203 05
6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.
0$1 % : 'LHVHO $6
Page 1 (3)
908-7
Exhaust Valve
Special Running
7.
If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:
7. Turn off the air to the exhaust valve.
Remove the 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 air
cylinder and mount the tool for opening of
the exhaust valve.
KC908-6.0 18 02
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.
GN908-7 203 08
8.
Page 2 (3)
0$1 % : 'LHVHO $6
Exhaust Valve
908-7
Special Running
9.
After overhaul of the cylinder unit, re-engage

the exhaust valve gear as follows:
9. Loosen the nuts of the lifting tool to lower
the roller guide on to the exhaust cam. Remove the tool.
10. If the engine has been running with the exhaust valve open, remove the tool mounted
in the air cylinder and mount the rotation indicator.
Re-connect the air supply to the air cylinder.
11. Mount the oil inlet pipe and the connecting
sleeve on the actuator housing, after fitting
new sealing rings on the connecting sleeve.
13. Engage the fuel pump roller guide.

GN908-7 203 05
12. Mount the hydraulic high-pressure pipe.

GN908-7 203 11
11.
0$1 % : 'LHVHO $6
Page 3 (3)
MAN B&W Diesel A/S
Plate
P90851-0200
Page 1 (2)
Plate
P90851-0200
Item
No.
016
028
041
053
065
077
089
090
124
150
161
173
185
Page 2 (2)
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Tightening template, actuator
Lifting tool , roller guide
Lifting tool, exhaust valve
Conical ring, pneumatic piston
Pressure tester, safety valve
Gauge, exhaust valve spindle
Tool, emergency opening of exhaust
valve
Gauge, exhaust valve bottom piece
Lifting tool, exhaust valve spindle
Lifting tool, exhaust valve roller guide
Grinding ring, exhaust valve bottom
piece
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90862-0043
Page 1 (2)
Plate
P90862-0043
Item
No.
Item Description
028
030
053
065
077
090
100
207
Support
Tommy bar
Spanner
Stud setter
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
Plate
P90863-0014
Page 1 (2)
P90863
0014
MAN B&W Diesel A/S
Plate
P90863-0014
Item
No.
011
Item Description
Item
No.
Item Description
Worktable
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90863-0016
P90863
0016
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90863-0016
Item
No.
011
Item Description
Item
No.
Item Description
Grinding machine for exhaust valve

spindle seat
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
10911
90911
10912
90912
10913
90913
10914
90914
10915
90915
10916
90916
0055
0240
0004
0205
0044
0229
0050
0224
0052
0223
0042
0219
0034
0214
0043
0217
0025
0214
0047
0231
0038
0222
0031
0206
0060
0235
0050
0226
0016
0204
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
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 Spec. Running
MAN B&W Diesel A/S
90951
90961
90966
90968
90974
90977
90979
90980
0462
0069
0008
0001
0001
0001
0001
0001
Fuel Valve and Fuel Pump - Panel

Fuel Valve - Tools
MAN B&W Diesel A/S
Fuel Pump Settings
109-1
Data
SAFETY PRECAUTIONS
109-1
S60MC-C
D10901 Data
Fuel Pump Settings
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D09-02
Description
Change of one index mark corresponds to pmax being altered approx.
MAN B&W Diesel A/S
Value Unit
3.0 - 4.0 bar
Page 1 (2)
Fuel Pump Settings
109-1
Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump Settings
909-1.3
Adjustment
Fuel
S60MC-C
0240Pump Settings
Adjustment
909-1.3
1.
Before adjustment of the fuel pump is carried

out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.
pmax adjustment:
2. Loosen lock nut B and then turn adjusting

screw H. The link can be adjusted by approx. 3 index marks.
HN909-1.3 240 01
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.
3. To increase p max, adjust to higher VIT index

(advance injection).
2.
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!
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 02
The individual pmax value must not deviate more than 3 bar from the average
value for all cylinders.
0$1 % : 'LHVHO $6
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.
HN909-1.3 240 05
Note!
Page 2 (2)
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.
0$1 % : 'LHVHO $6
VIT System
109-2
Data
SAFETY PRECAUTIONS
109-2
S60MC-C
D10902 Data
VIT System
Stopped engine

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
VIT System
109-2
Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
VIT System
.0&&
0205
Adjustment
909-2.3
1.
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
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.
Check that the pressure on the pressure
gauge and the pressing-in of pin C is in accordance with the curve.
HM909-1.3 67 01
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.
2.
Any necessary adjustment is done by turning adjusting screw B.

2. Fine adjustment of the p max pressure in the
breakpoint (for all the cylinders) is to be
carried out by axial displacement of the
bracket with the pilot valve.
Increase the pmax pressure by moving the

pilot valve toward the lever.
Decrease the p max pressure by moving the
pilot valve away from the lever.
XZ909-2.1 203 02
Release the screw and nut which secure

the bracket with the pilot valve to the larger
bracket through the slotted holes.
See also Volume I, Chapter 703.
0$1 % : 'LHVHO $6
Page 1 (2)
VIT System
909-2.3
Adjustment
3.
Electronic VIT system

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 p offset value in accordance with the required increase or decrease in the p max pressure. One
graduation mark on the p offset scale corresponds to a change in p max of 1 bar.
5. Check the adjustment by taking a new set
of indicator diagrams while the engine is
running just above the breakpoint.
S9148001.WPG
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 p control.
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.
6.
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.
P control
P supply
P control
5
4
3
XZ909-2.3 204 06
1.5
Page 2 (2)
0.5
0.1
2
1
I, mA
0
0
12
16
20
0$1 % : 'LHVHO $6
Fuel Pump Cam
109-3
Data
SAFETY PRECAUTIONS
109-3
S42MC
D10903 Data
Fuel Pump Cam
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Fuel Pump Cam
109-3
Data
Plate
P90651
P90666P91351
P91351
P91351
Page 2 (2)
44
10
34
105
Impact wrench for turning cam

Camshaft Coupling - Hydraulic Tools
Hydralic pump, pneumatic operated
Hose with unions (1000mm), complete
MAN B&W Diesel A/S
Fuel Pump Cam
909-3.1
Checking
Fuel
S60MC-C
0229Pump Cam
Checking
909-3.1
1.
Fuel cam lead:

The lead C of the fuel cam is defined as the
number of mm the plunger is lifted from its bottom position when the main piston is in TDC.
1. To measure the fuel cam lead (top lift):
Dismantle the puncture valve.
x2
x1 roller guide
fuel cam
Make sure that the reversing mechanism is

in AHEAD direction.
Turn the engine until the lowest point of the

cam is found, use a calliper to find the
point.
ahead
EN909-3.1 228 00
2. Push down the measuring pin through the

top cover, until it rests against the pump
plunger.
Lowest position
of pump plunger
Main piston in TDC
3.
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.
C = x1 x2 (mm)
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.
HN909-3.1 229 03
Calculate the fuel cam lead C (top lift) as:
4.
HM906-7.0 56 01
Remount the puncture valve.
0$1 % : 'LHVHO $6
Page 1 (3)
909-3.3
Fuel Pump Cam

Adjustment
Adjustment
909-3.3
1.
Normally, adjustment of the fuel cam should not

be necessary. Before adjustment of fuel equipment, see Volume I, Chapter 706.
1. Remove the inspection cover from the camshaft housing.
HN909-3.3 207 01
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
2. Dismount the puncture valve 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.
HN909-3.3 207 04
3.
Page 2 (3)
0$1 % : 'LHVHO $6
Fuel Pump Cam
909-3.3
Adjustment
4.
4. Mount the special spanner on the fuel cam

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

minutes before turning the cam.
Keep the cam pressurised during turning.
Turn the cam disc, using the fitted spanner,
until the desired change of lead is obtained.
HN909-3.3 207 06
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
To increase lead and p max:

turn the cam disc AHEAD.
To reduce lead and p max:
turn the cam disc ASTERN.
5. After completing the desired turning of the
cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes the cam must be
allowed time to settle before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the
fuel cam lead again.
Note down and file the new results for purposes of comparison with future measurements and adjustment.
6. Mount the inspection cover on the camshaft
housing.
7. Mount the puncture valve.
8. After any adjustment of the cam position,
pmax must be recorded and compared with
pmax at a known engine reference load.
0$1 % : 'LHVHO $6
Page 3 (3)
Fuel Pump
109-4
Data
SAFETY PRECAUTIONS
D10904 Data
109-4
S50MC-C
Fuel Pump
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D09-18
D09-19
Pump housing nuts, tightening torque

Pump housing nuts, tightening angle
D09-20
Pump housing
MAN B&W Diesel A/S
Value Unit
300 Nm
62
96 kg
Page 1 (2)
Fuel Pump
109-4
Data
Plate
P90951
Page 2 (2)
70
Lifting tool for fuel pump housing
MAN B&W Diesel A/S
Fuel Pump
909-4.2
Dismantling
Fuel
K90MC-C
0224 Pump
Dismantling
909-4.2
1.
1. Close the fuel oil inlet valve.

Open the drain cock, enabling the oil to escape.
Note!
2. Dismantle the fuel pump top cover and connected pipes.

3. Dismantle the barrel/plunger assembly.
MA909-1.1 223 03

4.
4. Remove the screws holding the fuel oil inlet

pipe between the fuel pump and the fuel inlet valve.
D09-39
Remove the fuel oil inlet pipe.

Remove the shock absorber.
Remove the fuel oil outlet pipe.
Discard the gaskets.
Remove the control air pipes from the actuator for the VIT index arm.
MA909-4.2 214 04
5. Remove the drain pipes from the fuel pump

housing.
MAN B&W Diesel A/S
Page 1 (9)
909-4.2
Fuel Pump
Dismantling
6.
6. Loosen the four nuts by means of a slugging spanner. Remove the nuts.
7. Fit the lifting tool using the top cover studs/
nuts, and lift the pump housing away.
Take care not to damage the threads of the
studs.
MA909-4.2 214 06
Land the fuel pump on wooden planks.
7.
MA909-4.2 214 07
D09-20
Page 2 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
Overhaul
909-4.3
3.
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.
3. Dismantle the actuator and actuator bracket.
MA909-4.3 214 03
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.
4. Tilt the fuel pump housing into a horizontal

position on the wooden planks.
4.
D09-20
5. Dismantle the screws and the bottom plate

from the fuel pump housing.
MA909-4.3 214 04
If the bottom plate is stuck, loosen it by

screwing two M10x80 mm screws into the
holes of the bottom plate.
5.
MA909-4.3 214 05
D09-21
MAN B&W Diesel A/S
Page 3 (9)
909-4.3
Fuel Pump
Overhaul
6.
6. Dismantle the:
Fuel index arm
Regulating guide
Sleeve
7. Dismantle the:
Guide screw
MA909-4.3 214 06
VIT index arm

Timing guide
8. Remove the caps from the back of the fuel
pump housing.
7.
Remove the orifice plug from the front side
of the fuel pump housing.
MA909-4.3 214 07
Discard all sealing rings and gaskets.
MA909-4.3 214 08
8.
Page 4 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
9.
9. Dismantle and inspect the plug screws in

both sides of the fuel pump housing.
If eroded, replace the plug screws.
10. Clean all the dismantled parts of the fuel
pump thoroughly in diesel oil or kerosene.
Dry all parts carefully.
Clean all inside surfaces of the fuel pump
housing.
Check that all the bores of the fuel pump
housing are clean.
Mount the caps and the orifice plug.

Mount new sealing rings on the plug screws
and mount the plug screws.
MA909-4.3 214 09
11. Mount new sealing rings and gaskets.
11.
Note!
Lubricate the threads of all the parts with
Molybdenum Disulphide (MoS 2) before
mounting.
Note!
MA909-4.3 214 11
12. Mount new sealing rings in the sleeves that

are provided with a pointer scratch.
Soak the sealing rings in lubricating oil

before mounting.
HC909-3.4 121 11
12.
MAN B&W Diesel A/S
Page 5 (9)
909-4.3
Fuel Pump
Overhaul
14.
Mounting
13. Lubricate the following with molybdenum disulphide (MoS 2):
all internal surfaces of the fuel pump
housing
the sliding surfaces of all parts of the
regulating and timing systems.
the teeth of the:
MA909-4.3 214 14
regulating guide
timing guide
VIT index arm
15.
fuel index arm.

14. Mount the VIT index arm and the guide
screw.
Adjust the position of the VIT index arm so
that the scratch mark is aligned with the
centre of the fuel pump housing.
15. Mount the timing guide in the fuel pump
housing.
MA909-4.3 214 15
The timing guide must be mounted in such

a way that the scratch marks on the timing
guide, on the VIT index arm and on the fuel
pump housing are aligned.
MA909-4.3 214 16
16.
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.
Page 6 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.3
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.
20. Return the fuel pump to a vertical position.

Mount the actuator and actuator bracket on
the side of the fuel pump.
MA909-4.3 214 17
19. Mount the bottom plate on the fuel pump

housing.
MA909-4.3 214 18
18.
MA909-4.3 214 05
19.
MAN B&W Diesel A/S
Page 7 (9)
Fuel Pump
909-4.4
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).
2. Mount the lifting tool on the fuel pump top
cover studs. Lift the fuel pump housing on
to the pump base, taking care not to damage the threads of the studs.
Remove the lifting tool.
3. Mount the nuts on the studs and tighten to
the specified torque or angle, see Data.
Note!
MA909.4.2 214 07
Use either the tightening torque or the

tightening angle.
3.
MA909-4.2 214 06
D09-18
or
D09-19
Page 8 (9)
MAN B&W Diesel A/S
Fuel Pump
909-4.4
Mounting
5.
4. Mount the drain oil pipes on the fuel pump

housing.
Connect the control air pipes to the actuator
for the VIT index arm.
D09-39
5. Fit new gaskets on the fuel pump inlet pipe.

Mount the pipe between the fuel pump
housing and the fuel oil inlet and outlet
valve.
Mount the shock absorber.
7. Mount the top cover on the fuel pump housing. See Procedure 909-5.4.
Mount the air pipe for the puncture valve.
MA909-4.2 214 04
6. Mount the barrel assembly in the fuel pump

housing. See Procedure 909-6.4.
8.
MA909-1.1 223 09
8. Close the drain cock and open the fuel oil

inlet valve.
MAN B&W Diesel A/S
Page 9 (9)
Fuel Pump Top Cover
109-5
Data
SAFETY PRECAUTIONS
109-5
S50MC-C
D10905 Data
Fuel Pump Top Cover
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D09-23
D09-24
D09-26
D09-27
Description
Top cover studs, screwing-in torque

Top cover nuts, tightening torque
Outlet seat, max. grinding diameter
Top cover
MAN B&W Diesel A/S
Value Unit
100
210
18
34.1
Nm
Nm
mm
kg
Page 1 (2)
Fuel Pump Top Cover
109-5
Data
Plate
P90951
P90951
P90951
P90951
Page 2 (2)
69
82
94
320
Lifting tool for fuel pump

Lifting tool for fuel pump roller guide
Milling tool for fuel oil pipe seats
Plunger locking tool
MAN B&W Diesel A/S
Fuel Pump Top Cover
909-5.2
Dismantling
Fuel
S60MC-C
0223 Pump Top Cover
Dismantling
909-5.2
1.
1. Shut off the fuel oil inlet.

Open the drain cock (at the bottom of the
pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.
Note !
Dismount all drain pipes and the pipe connections to the puncture valve.
GN909-5.2 204 01

Dismount the high-pressure pipes between

the top cover and the fuel valves.
2.
Note !
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.
GN909-5.2 204 02
If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
3.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
D09-27
3. Lift the top cover carefully off.

For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.
GN909-5.2 204 03
Discard the gasket.
0$1 % : 'LHVHO $6
Page 1 (3)
Fuel Pump Top Cover
909-5.3
Overhaul
Overhaul
909-5.3
2.
1. If not already done, dismount the protective

cap and the puncture valve from the top
cover.
2. Dismantle the suction valve and the lock
washer from the top cover.
3. Fill the oil ducts of the top cover with vaseline or heavy grease.
HM909-3.3 74 03
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.
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!
GN909-5.3 204 04
Make sure that all bores and threads

inside the top cover are absolutely clean.
If necessary, recondition the seats of the
fuel oil high-pressure pipes.
4. Mount a new lock washer and a new or
overhauled suction valve in the top cover.
HM909-3.3 74 13
4.
Page 2 (3)
0$1 % : 'LHVHO $6
Fuel Pump Top Cover
909-5.4
Mounting
Mounting
909-5.4
1.
1. Make sure that the inside of the fuel pump

housing and the top of the fuel pump barrel
is completely clean.
D09-27
2. Mount a new gasket on top of the pump

housing.
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.
GN909-5.2 204 03
Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide
(MoS 2). See Procedure 913-11.
3.
D09-24
Warning !
As a safety precaution, and before
mounting the top cover nuts, turn the
engine one revolution.
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.
GN909-5.4 204 03
When doing this, the top cover must not

move upwards!
4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure
909-8.4.
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.
GN909-5.4 204 04
Mount the drain pipes on the top cover and

the connecting pipe to the puncture valve.
Open the fuel oil inlet.
0$1 % : 'LHVHO $6
Page 3 (3)
109-6
Data
SAFETY PRECAUTIONS
109-6
S50MC-C
D10906 Data
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
D09-29
D09-30
Description
Barrel assembly
Plunger
MAN B&W Diesel A/S
Value Unit
27.5 kg
6.2 kg
Page 1 (2)
109-6
Data
Plate
P90951
P90951
P90962
Page 2 (2)
57
224
Lifting tool for fuel pump

Tool for pmax rack
Fuel Pump Seals - Mounting Tools
MAN B&W Diesel A/S
909-6.2
Dismantling
Fuel
S60MC-C
0219Pump Barrel Assembly
Dismantling
909-6.2
1.

Open the drain cock (at the bottom of the
pump housing), enabling the oil which is left
in the high-pressure pipe and the fuel pump
to escape.

Dismount the pipe connections to the puncture valve.
GN909-5.2 204 01
Note!
2.
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.
HN909-8.2 207 03
3. Dismount the fuel pump top cover.

GN909-5.2 204 03
3.
0$1 % : 'LHVHO $6
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.
5.
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.
MB909-3.1 95 05
5. Remove the pump barrel guide screw from

the pump housing.
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.
GN909-6.2 204 03
Mount the extractor tool and connect the

timing toothed rack to the pulling rod by
means of the pin.
Page 2 (9)
0$1 % : 'LHVHO $6
909-6.2
Dismantling
7.
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.
GN909-6.2 204 04
7. Turn the nut at the end of the pulling rod,

whereby the timing rack will move outwards.
8.
There is now a distance between the lifting

tool and the pump housing.
8. Pull the regulating toothed rack outwards
until the plunger foot has been turned clear
of the bayonet joint in the roller guide.
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.
GN909-6.2 204 05
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.
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.
9. Carefully lift the barrel/plunger assembly

out of the pump housing.
D09-29
Dismount the tool.
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 06
Press the plunger upwards to the bottom of

the barrel.
0$1 % : 'LHVHO $6
Page 3 (9)
909-6.3

Overhaul
Overhaul
909-6.3
1.
1. Clean the outside of the barrel.
D09-29
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.
MB909-3.2 95 01
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.
For evaluation of pump barrel/plunger, see
Volume I, OPERATION, Chapter 706.
2.
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.
MB909-3.2 95 02
D09-30
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.
Use the pusher tool to push the sealing ring
into the groove.
MB909-3.2 95 04
4.
Page 4 (9)
0$1 % : 'LHVHO $6
909-6.3
Overhaul
5.
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.
Make sure that the spring faces downwards, see the sketch.
7. Lubricate the plunger with molybdenum disulphide (MoS 2).
MB909-3.2 95 05
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.
6.
Carefully slide the plunger into the barrel
and press it to the bottom.
Note!
If the barrel assembly is not to be mounted

immediately, all openings must be covered
with plastic to prevent dirt from entering the
barrel assembly during storage.
MB909-3.2 95 06
Do not use force as this will damage the

sliding surfaces of the plunger or barrel
MB909-3.2 95 07
7.
0$1 % : 'LHVHO $6
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.
HN909-6.4 207 01
The engine must not be turned until the

mounting of the barrel/plunger assembly
has been completed.
2.
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.
HN909-6.4 207 02
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.
Page 6 (9)
0$1 % : 'LHVHO $6
909-6.4
Mounting
3.
3. Pull the regulating toothed rack as far out

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer position.
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.
GN909-6.4 204 03
4. Check that the slot in the barrel coincides

with the hole for the guide screw.
4.
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.
D09-29
GN909-6.4 204 04
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.
0$1 % : 'LHVHO $6
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.
GN909-6.4 204 05
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.
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.
GN909-6.4 204 06
Mount the inspection hole cover.
Page 8 (9)
0$1 % : 'LHVHO $6
909-6.4
Mounting
7.
7. Mount the pointer and union for the timing

rack.
8. Mount the guide screw for the pump barrel

in the pump housing.
Remove the centre screw from the plunger,
and remove the tool.
GN909-6.4 204 07
Mount the links for the timing drive and the

regulating drive in place in accordance with
the marks.
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.
8.
GN909-6.4 204 08
10. Mount the fuel pump top cover, including

the nuts. See Procedure 909-5.4.
0$1 % : 'LHVHO $6
Page 9 (9)
109-7
Data
SAFETY PRECAUTIONS
109-7
S50MC-C
D10907 Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D09-33
D09-34
Description
Suction valve, tightening torque

Suction valve
MAN B&W Diesel A/S
Value Unit
900 Nm
2 kg
Page 1 (2)
109-7
Data
Plate
P90951
P90967
P90962
Page 2 (2)
128 Crowfoot wrench head

0001 Fuel puncture valve tools
0062 Mounting Tools for Fuel Pump Seals
MAN B&W Diesel A/S
909-7.1
Checking
Fuel
S60MC-C
0214 Pump Suction Valve
Checking
909-7.1
1.
1. Using a brass mandrel, check that the valve

slide can slide freely up and down inside
the suction valve.
2. Check the seats for tightness by filling the
inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.
HN909-7.1 207 01
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.
KB909-3.3 105 08
2.
0$1 % : 'LHVHO $6
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.
GN909-5.2 204 03
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.
GN909-5.3 204 02
Remove and discard the lock washer.
KN909-7.2 213 03
3.
Page 2 (4)
0$1 % : 'LHVHO $6
909-7.3
Overhaul
Overhaul
909-7.3
1.
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.
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.
KB909-3.3 105 05
Remove and discard the sealing ring from

the valve thrust piece.
3. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust
piece.
2.
Note!
Make sure that the sealing ring is
mounted correctly. See the sketch.
KB909-3.3 105 06
Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on
to the groove.
After mounting the sealing ring, compress it

by pressing the sizer tool over the sealing
ring.
3.
4. Clean and overhaul all internal parts, and

lubricate them with molybdenum disulphide
(MoS 2).
5. Re-assemble the suction valve.
XZ909-7.3 204 03
6. Check the suction valve after the overhaul.

0$1 % : 'LHVHO $6
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.
KN909-7.4 213 01
Lock the suction valve in position by bending up an edge of the lock washer over one
of the flats of the valve.
GN909-5.2 204 03
2.
2. Remove the top cover from the bracket and

mount the top cover in the fuel pump housing. See Procedure 909-5.4.
Page 4 (4)
0$1 % : 'LHVHO $6
109-8
Data
SAFETY PRECAUTIONS
109-8
S50MC-C
D10908 Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D09-35
D09-36
Description
Puncture valve, tightening torque

Puncture valve
MAN B&W Diesel A/S
Value Unit
890 Nm
5 kg
Page 1 (2)
109-8
Data
Plate
P90951
Page 2 (2)
141
Crowfoot wrench head
MAN B&W Diesel A/S
909-8.2
Dismantling
Fuel
S60MC-C
0217Pump Puncture Valve
Dismantling
909-8.2
2.

Open the drain cock at the bottom of the
pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.
Note!
2. Dismantle the control air pipe and the protective cap above the puncture valve.
4. After dismantling it is recommended always

to overhaul the puncture valve.
3.
HN909-8.2 207 03
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.
HN909-8.2 207 02
3. Unscrew and remove the puncture valve

from the fuel pump top cover.
0$1 % : 'LHVHO $6
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.
HN909-8.3 207 01
Lapping of the valve seats must not be attempted.
HG909-8.2 201 02
2.
Page 2 (4)
0$1 % : 'LHVHO $6
909-8.3
Overhaul
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.
Before assembling the puncture valve, lubricate all parts with MOLYKOTE anti-friction SPRAY D321R or molybdenum
disulphide (MoS 2).
GM909-3.3 89 10
4. The new sealing ring is mounted on the

head of the air piston in accordance with
the same procedure as above.
4.
Mount new O-rings on the housing.
GM909-3.3 89 12
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.
0$1 % : 'LHVHO $6
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.
HN909-8.4 207 02
4. If open, close the drain cock on the fuel

pump and open the fuel oil inlet valve.
HN909-8.4 207 03
3.
Page 4 (4)
0$1 % : 'LHVHO $6
Fuel Pump Shock Absorber
109-9
Data
SAFETY PRECAUTIONS
109-9
S46MC-C
D10909 Data
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
D09-39
Description
Shock absorber
MAN B&W Diesel A/S
Value Unit
20 kg
Page 1 (2)
109-9
Data
Plate
Page 2 (2)
MAN B&W Diesel A/S
909-9.1
Checking
Fuel
S60MC-C
0214 Pump Shock Absorber
Checking
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.
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.
HM909-4.0 09 01
1. Remove the plug from the end cover of the

shock absorber. Check that air is pulsating
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.
0$1 % : 'LHVHO $6
Page 1 (3)
909-9.3

Overhaul
Overhaul
909-9.3
1.
Note!
D09-39

GN909-9.3 204 01
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.
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.
HG909-9.2 201 02
4. Clean all parts and polish the sliding surfaces of the piston and the shock absorber
housing. Mount a new sealing ring in the
shock absorber housing and a new wear
ring on the piston.
4.
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.
HG909-9.2 201 04
6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking device. Remove the threaded rod and insert
the plug.
Page 2 (3)
0$1 % : 'LHVHO $6
909-9.3
Overhaul
7. Fit a new gasket on the fuel pump housing

and mount the shock absorber. Mount the
shock absorber drain pipe.
If an excessive amount of drain oil is still
observed after the overhaul, the shock absorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.
0$1 % : 'LHVHO $6
Page 3 (3)
Fuel Valve
109-11
Data
SAFETY PRECAUTIONS
109-11
S46MC-C
D10911 Data
Fuel Valve
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
D09-40
D09-41
D09-42
D09-43
Description
Fuel valve opening pressure

Fuel valve tightening torque
Inlet seat, max. diameter
Fuel valve
MAN B&W Diesel A/S
Value Unit
320 - 380
25
18
7.2
bar
Nm
mm
kg
Page 1 (2)
Fuel Valve
109-11
Data
Plate
P90151
P90951
P90951
P90961
P90966
Page 2 (2)
71
94
165
14
Dismantling tool for fuel valve

Milling tool for fuel oil pipe seats
Grinding mandrel for valve head
Fuel valve tester, complete
Fuel valve nozzle - tools
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
Fuel
S60MC-C
0231Valve
Checking
909-11.1
1.
The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the
engine can be attributed to defects in these
valves.
In order to obtain reliable results during testing

of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3.
GN909-11.1 204 01
If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.
2.
Note!
In the event that the slide-type fuel valve is
pressure tested without being cleaned
between the fuel nozzle and the cut-off slide,
the opening pressure value measured might
be considerably lower than specified.
All fuel valves must be function-tested before
being mounted in the cylinder cover.
1. Pressure testing pump
If an air supply of 10 bar is not available,
working air of seven bar can be used. Use
only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50C.
For operation of the pressure testing pump,

see the suppliers instructions.
2. Spring housing
To ensure that overtightening has not taken
place, check that the locking/indicating pin
has not been bent or broken off.
HM909-6.3 70 01A
Note that the high-pressure pump should

be periodically checked in accordance with
the suppliers instructions.
In the event of overtightening, replace the

spring housing by a new one.
MAN B&W Diesel A/S
Page 1 (14)
909-11.1
Fuel Valve
Checking
3.
3. Setting-up the fuel valve

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.
4. Pressure testing procedure
HM909-6.3 70 01B
The subsequent items must be followed in

the sequence stated. Items 5, 7, 8 and 9
are each divided into the following four subitems:
4.
A.
B.
C.
D.
Objective
Procedure
Acceptance criteria
Cause of fault.
Note!
If working air of 10 bar is not available,

pressures down to 7 bar are acceptable
for all the tests.
5. Flushing and jet control
HM909-6.0 67 00
A. Objective:
To remove air in the system and check the
fuel jet.
5.
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the working pressure until
straight jets of oil are ejected from the nozzle holes (no atomization).
NA909-11.1 215 05
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Page 2 (14)
Owing to the geometry of the internal part

of the nozzle and because the height to
which the spindle is lifted during pressure
testing is lower than the height it is lifted
during normal engine operation the fuel
oil will not necessarily flow from all of the
nozzle holes.
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
6.
D. Cause of fault:
If the jets do not fulfil the above point C, the
cause may be:
Dirt in the nozzle holes.
The nozzle is not mounted correctly.
6. Atomization test
Do NOT attempt to carry out an atomization test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.
MN909-11.1 222 06
Note!
The reason is that the atomization test may

damage the valve because it makes the
needle oscillate, with a small lift at a very
high frequency. The high pressure drop
across the cut-off edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures between cut-off slide and nozzle.
7.
D-3
All of these conditions involve the risk of

seizure between the cut-off slide and the
nozzle.
7. Opening pressure
A. Objective:
To check the opening pressure.
B. Procedure:
The control handle is to be in the OPEN position.
Increase the oil pressure until oil is admitted through the nozzle holes.
GN909-11.1 204 06
Check the opening pressure on the pressure gauge.
MAN B&W Diesel A/S
Page 3 (14)
909-11.1
Fuel Valve
Checking
8.
D. Cause of fault:
If the opening pressure is higher than specified in D-3, the cause may be that a wrong
type of spring is used replace the spring
on the thrust spindle, if necessary, replace
the complete thrust spindle.
If the opening pressure is lower than specified in D-3, the cause may be that the
spring has sagged replace the spring, or
add a special thin disc.
Note!
Special thin discs are available as
spares.
If a spring or a disc has been changed, the
pressure testing procedure of the fuel valve
must be repeated from step 4.
8. Sealing test and sliding function
A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
GN909-11.1 204 07
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the oil pressure to about 50
bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when
the fuel valve is full of oil.
Page 4 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
D. Cause of fault:
D.1 Sealing test
If oil flows out of the nozzle holes, the
cause is either:
Defective spindle guide at needle seat, or
a sticking spindle. Examine and/or replace the spindle guide.
Too quick pressure drop:
the clearances of the movable parts,
both of the spindle guide and of the nonreturn valve, are too large, or
the seats between the thrust piece/
spindle in the spindle guide or thrust
piece/valve slide in the non-return valve
are damaged.
Examine and/or replace both the spindle
guide and non-return valve.
D.2 Sliding function
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
There will always be an oil flow from the

leak oil outlet when the fuel valve is full of
oil.
If a quick pressure drop from 15 to 0 bar
cannot be registered:
GN909-11.1 204 07
Note!
The valve slide is sticking; or

the vent hole in the thrust piece is
blocked.
If so, disassemble and examine the spindle
guide, replace if necessary.
MAN B&W Diesel A/S
Page 5 (14)
909-11.1
Fuel Valve
Checking
9.
9. Pressure test, O-ring sealings

A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.
B. Procedure:
The control handle is to be in the OPEN position.
Build up a working pressure of about max.
10 bar until oil flows out of the leak oil outlet.
Close the leak oil outlet with a gasket and
plug screw.
Increase the working pressure to about 100
bar.
Move the control handle to the CLOSED position.
The built-up pressure of about 100 bar
should be maintained.
GN909-11.1 204 08
D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
Page 6 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.2
Dismantling
Dismantling
909-11.2
1.
1. Close the fuel oil inlet and outlet valves,

and drain the high-pressure pipe and the
fuel valve.
Dismantle and remove the fuel oil highpressure pipe.
Disconnect the return oil pipe from the fuel
valve.
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.
KB901-2.1 104 01
2. Remove the nuts and the spring housings.
If the valve is not to be overhauled immediately, the valve should be placed immersed
in diesel oil until overhauling.
HG909-11.3 201 02
2.
3.
HG909-11.2 221 03
D-2
MAN B&W Diesel A/S
Page 7 (14)
Fuel Valve
909-11.3
Overhaul
Overhaul
909-11.3
1.
When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.
MN909-11.3 219 01
Use only clean, non-fluffy rags for wiping purposes. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings before reassembly.
1. Measure the length A of the protruding part
of the nozzle, and write down the result for
correct re-assembling of the valve.
2.
2. 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.
MN909-11.3 222 02
Remove the valve from the valve holder.
MN909-11.3 222 03
3.
Page 8 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
4.
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.
GN909-11.3 204 01
Remove and discard all the O-rings.
MAN B&W Diesel A/S
Page 9 (14)
Fuel Valve
909-11.3
Overhaul
5.
5. Carefully clean and examine all surfaces of

the:
Fuel valve housing
D-1
Fuel valve head

Thrust spindle
If necessary, grind the seating surfaces by
means of the grinding mandrels supplied
and a fine-grain abrasive (such as 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 columntype drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An ample supply of cutting emulsion must be
used.
Note!
GN909-11.3 204 02
Take care not to exceed the maximum

diameter of the seat, see Data.
Page 10 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
6.
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.
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.
NA909-11.3 215 03
Note!
7.
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.
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.
GN909-11.3 204 04
8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
8.
Note!
MN909-11.3 219 05
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.
MAN B&W Diesel A/S
Page 11 (14)
909-11.3
Fuel Valve
Overhaul
9.
9. Mount:
the thrust foot
the parts of the thrust spindle
the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost
groove of the fuel valve housing.
Lubricate the thread of the valve head with
molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
10. Make sure that the guide pin between valve
housing and valve head is intact, and press
the valve head down into the valve housing.
GN909-11.3 204 06
See that the guide pin between valve housing and valve head engages correctly so as
to prevent relative turning of the parts.
GN909-11.3 204 07
10.
Page 12 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
11.
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.
MN909-11.3 222 09
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.
MAN B&W Diesel A/S
Page 13 (14)
Fuel Valve
909-11.4
Mounting
Mounting
909-11.4
1.
D-2
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 (MoS 2).
MA901-2.1 72 03
2. Mount the valve in position in the cylinder

cover.
2.
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!
HG909-11.4 201 04
It is recommended to overhaul the fuel oil

high-pressure pipe before mounting.
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.
KB901-2.1 104 06
Note!
Page 14 (14)
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
MAN B&W Diesel A/S
Spindle Guide
109-12
Data
SAFETY PRECAUTIONS
D10912 Data
109-12
Spindle Guide
S60MC-C
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Spindle Guide
109-12
Data
Plate
P90966P90968-
Page 2 (2)
12

Probe light with magnifier, complete
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
Spindle
S50ME-C
0222 Guide
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle
guides of the slide valve design.
Extreme care and accuracy should be
exercised when carrying out this operation.
Based on service experience it is recommended to replace the complete spindle
guide after 8000 hours of operation.
Note!
The spindle guide, thrust piece and spindle are matched parts and may not be replaced individually.
GW909-12.3 222 02
1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, therefore only one guide is to be disassembled at
a time.
4.
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.
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.
GW909-12.3 222 04
4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.
MAN B&W Diesel A/S
Page 1 (5)
909-12.3
Spindle Guide
Overhaul
5.
5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in kerosene or Electrocleaner and wipe dry with a clean piece
of cloth.
Place all the parts on a clean, lint-free cloth
and examine them through an 8-10 times
magnification magnifying glass and an inspection lamp.
During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts.
GW909-12.3 222 05
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).
6.
Note!
MA909-6.2 111 05
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be damaged.
Page 2 (5)
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.
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
7.
7. Clean any carbon deposits from the central

bore of the fuel nozzle by means of the special brass brush. Clean the spray holes, using gas oil and the special drills supplied.
Note!
During this operation be very careful not
to push the drill too far to avoid scratching the snug-fit surface on the inside of
the fuel nozzle.
Clean the fuel nozzle with kerosene and
wipe dry with a clean cloth.
Then test the spray holes with the test pin.
If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.
Check the fuel nozzle before mounting on

the spindle guide, the cut-off slide must be
able to move freely inside the nozzle.
GW909-12.3 222 07
This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
Note!
It is recommended that the fuel nozzle is
changed whenever the spindle guide is
being overhauled.
MAN B&W Diesel A/S
Page 3 (5)
909-12.3
Spindle Guide
Overhaul
9.
8. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybdenum Disulphide (MoS 2), see Procedure
913-11.
9. Assemble the thrust piece, the spindle and
the spindle guide and carefully knock the
parts together using a soft hammer.
MN909-12.3 215 09
10. Shake the spindle guide back and forth.

The spindle with the cut-off slide must be
able to slide freely back and forth inside the
spindle guide, with a clicking sound.
GW909-12.3 222 10
10.
Page 4 (5)
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
11.
11. Lubricate the sliding surfaces of the nozzle

and the spindle with a little Molybdenum Disulphide (MoS 2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
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!
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.
GW909-12.3 222 11
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
Check that the spindle inside the spindle

guide is able to move freely, by shaking
the spindle guide.
12. If the spindle guide is not to be mounted in a
fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
Page 5 (5)
Non-return valve
109-13
Data
SAFETY PRECAUTIONS
D10913 Data
109-13
Non-return valve
S60MC-C
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Non-return valve
109-13
Data
Plate
P90951
P90968-
Page 2 (2)
153
12
Flange for dismantling of non-return valve

MAN B&W Diesel A/S
Non-return valve
909-13.3
Overhaul
Non-return
K98MC-C valve
0206
Overhaul
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.
(
(
"

%

(

(
8
H
2.
!

%

!
"

"

(

(
7
I
3.
"

(
(
"

%

(

(
8
H
0$1 % : 'LHVHO $6
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'.
MC909-6.2 69 04
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
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.
NA909-13.3 205 05
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be 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.
MC909-6.3 69 06
Press the handle until the housing and

thrust piece meet.
Page 2 (2)
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.
0$1 % : 'LHVHO $6
Fuel Oil High-Pressure Pipe
109-14
Data
SAFETY PRECAUTIONS
109-14
S50ME-C
D10914 Data
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
D09-47
D09-52
Description
Fuel oil high-pressure pipe, tightening torque

Fuel oil pipe
MAN B&W Diesel A/S
Value Unit
100 Nm
7.3 kg
Page 1 (2)
109-14
Data
Plate
P90951
P90951
Page 2 (2)
104 Milling tool for fuel oil pipe

128 Crowfoot wrench head
MAN B&W Diesel A/S
909-14.2
Dismantling
Fuel
S35MC
0235 Oil High-Pressure Pipe
Dismantling
909-14.2
2.
High-Pressure Pipe with Double Pipe

1. Close the fuel oil inlet and outlet valves.
3. Unscrew the union nipple from the fuel

pump.
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.
BM909-14.2 211 02
2. Unscrew the union nipple from the fuel

valve.
3.
Note!
It is recommended always to overhaul
the high-pressure pipe before remounting
it on the engine.
GN909-14.2 210 03
The overhaul should preferably take

place immediately after the high-pressure pipe has been dismantled.
D09-52
BM909-14.2 211 04
4.
0$1 % : 'LHVHO $6
Page 1 (4)
909-14.3

Overhaul
Overhaul
909-14.3
1.
Whenever the fuel oil high-pressure system has

been dismantled, it is necessary, before remounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the pipe
ends, together with their seats in fuel valves
and fuel pump top cover.
If the pipe ends require reconditioning, proceed
as follows:
KB909-7.1 77 01
1. Lift up the union nut. Remove the spring

ring from the two-part sleeve. Remove the
sleeve.
2. Fasten the pipe in a vice with soft jaws.
Mount the miller on the pipe end.
Note!
2.
The two pipe ends are of different

designs see sketch.
Turn the upper tightening ring (A) until the
miller presses against the pipe end.
KB909-7.1 77 03
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
During the milling process, add drilling oil
emulsion liberally.
3. On both pipe ends a small groove has been
ground to indicate the maximum allowable
grinding of the pipe ends.
3.
Max. grind-away
The pipe ends may only be ground until the

ground surface is flush with the bottom of
the groove.
If the pipe ends are still not in order, the
pipe must be discarded.
KN909-14.3 223 03
After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.
Page 2 (4)
0$1 % : 'LHVHO $6
909-14.3
Overhaul
4.
4. Remove and discard both the internal and

external O-rings. Mount new O-rings.
KB909-7.1 77 04
Mount the two-part sleeve and lock the

sleeve with the spring ring. Ensure that all
parts are completely clean before mounting
the high-pressure pipe.
0$1 % : 'LHVHO $6
Page 3 (4)
909-14.4
Mounting
Mounting
909-14.4
3.
D09-52
1. Ensure that the fuel valve is fitted with a

new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
2. Ensure that the union nipple at the fuel
pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
BM909-14.4 211 03
3. Mount the high-pressure pipe between the

fuel valve and the fuel pump.
Screw the union nipples onto the fuel valve
and into the fuel pump top cover, by hand.
Note!
4.
D09-47
The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might otherwise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nipples have been screwed into position.
BM909-14.4 211 04
4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
pump to the torque stated in Data.
5.
6. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
GN909-14.4 210 05
D09-47
Page 4 (4)
0$1 % : 'LHVHO $6
109-15
Data
SAFETY PRECAUTIONS
D10915 Data
109-15

S50MC-C
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D09-53
D09-54
D09-55
D09-56
D09-57
D09-60
D09-61
D09-62
Description
Nut, reversing shaft, tightening torque

Clearance A
Clearance B
Clearance C, max.
Roller/bushing/shaft pin, max. clearance
Housing for sealing arrangement
Fuel pump roller guide
Pump base
MAN B&W Diesel A/S
Value Unit
80
2.8 - 5.3
0.7 - 3.2
0.45
0.5
70
60
31
Nm
mm
mm
mm
mm
kg
kg
kg
Page 1 (2)
109-15
Data
Plate
P90851
Page 2 (2)
173
Lifting tool for exhaust valve roller guide
MAN B&W Diesel A/S
909-15.1
Checking
Fuel
S60MC-C
0226Pump Roller Guide
Checking
909-15.1
3.
Roller guide mounted in engine

1. The fuel pump roller guide can be partially
checked while mounted on the engine, using the following procedure:
2. Lift the fuel pump roller guide.
Turn the engine to provide the maximum

space between the roller guide and the cam
disc.
Turn the roller by hand to check that it can
move freely and without unnecessary resistance or hard points.
HN909-10.1 205 01
3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.
5.
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.
Check that the reversing link is fully tilted

over in AHEAD position.
Carry out the same check in the ASTERN position.
GN909-15.1 203 05
5. Using the telegraph, move the roller guide

to the AHEAD position.
When referring to this page, please quote Procedure 909-15.1 Edition 0226
0$1 % : 'LHVHO $6
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.
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.
MA909-8.0 70 07
Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clearance permits.
8.
MA909-8.0 70 06
D09-57
Page 2 (10)
0$1 % : 'LHVHO $6
909-15.2
Dismantling
Dismantling
909-15.2
1.
Note!
1. Dismantle the top cover of the fuel pump.
GN909-5.2 204 03
2. Dismantle the fuel pump barrel assembly.

GN909-6.2 204 06
2.
0$1 % : 'LHVHO $6
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.
HN909-15.2 206 04
4.
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.
HN909-10.1 205 01
5.
Page 4 (10)
0$1 % : 'LHVHO $6
909-15.2
Dismantling
6.
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.
D09-62
When lifting, take care that the bushing of

the pump base slides against the neck of
the roller guide without scratching.
Remove the springs from the roller guide.
7. Mount the roller guide lifting tool as follows:
Lift the lock plate of the tool up on the
shaft of the tool.

Lower the lock plate, thereby securing
the foot in the locked position.
HN909-15.2 206 06
Position the tool so that its foot rests on

the thrust piece in the bayonet joint of the
roller guide.
7.
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.
D09-61
Land the roller guide on wooden planks.
GN909-15.2 203 07
8. Check the roller guide.

0$1 % : 'LHVHO $6
Page 5 (10)
909-15.3

Overhaul
Overhaul
909-15.3
1.
1. Inspect and check the fuel pump roller

guide.
D09-61
2. It is recommended that the roller guide

should ONLY be dismantled if
irregularities when turning the roller,
damage to the roller,
larger clearance than stated on the Data
sheet,
seizure marks on the slide surfaces,
have been observed when checking the
roller guide.
Note!
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.
HN909-15.3 206 03
3.
Page 6 (10)
0$1 % : 'LHVHO $6
909-15.4
Mounting
Mounting
909-15.4
1.
1. Lubricate the roller guide with plenty of

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
During mounting, take care not to scratch
the sliding surfaces of the roller guide.
D09-61
Make sure that the pin of the reversing link

fits in the bracket of the reversing shaft.
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 clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.
HN909-15.4 206 01
The clearance C between the roller guide

and the guide plate must be the same at
both ends +/ 0.1 mm.
Connect working air to the air cylinder, and

check that the reversing mechanism is
working smoothly.
2.
The clearances A and B must be approx.

the same in both positions. See Data.
D09-54
D09-56
HN909-15.4 206 02
D09-55
0$1 % : 'LHVHO $6
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.
Mount the pump base over the roller guide
and the springs.
5.
Mount the two special nuts on the threaded

studs.
Using the special tube-shaped socket
wrench, tighten the nuts until the pump
base is fastened tightly to the roller guide
bushing.
HN909-15.2 206 06
D09-62
Page 8 (10)
0$1 % : 'LHVHO $6
909-15.4
Mounting
6.
6. Check the movement of the reversing link.

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.
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
8. Replace the O-ring in the top of the cap.
GN909-15.4 203 07
7.
MA909-8.0 70 21
8.
0$1 % : 'LHVHO $6
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!
AM909-8.0 31 16
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.
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.
GN909-15.4 203 10
11. Mount the lubricating oil pipe and the drain

pipe on the pump base.
Mount the sealing cap on top of the roller
guide, over the sealing bush inside the
pump base.
11.
Tighten the screws and lock with locking

wire.
12. Mount the fuel pump housing.
Mount the barrel assembly.
HN909-15.4 206 11
Mount the top cover.

Page 10 (10)
0$1 % : 'LHVHO $6
109-16
Data
SAFETY PRECAUTIONS
109-16
S46MC-C
D10916 Data
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
109-16
Data
Plate
P90951
P90951
Page 2 (2)
82
212
Lifting tool for fuel pump roller guide

Extraction tool for suction valve
MAN B&W Diesel A/S
S50MC-C
Fuel Pump Emergency Running
909-16
Fuel
S50MC-C
201 Pump Emergenc y Running
909-16
2.
Disengagement of fuel pump

Warning !
1. Engine trouble might require a cylinder to

be taken out of action. The engine can continue operation with the fuel and exhaust
systems of a single cylinder disconnected.
See Volume I, Section 704.
To disconnect the fuel pump of a single cylinder, proceed as follows:
GN909-16 201 02
Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.
3.
2. Remove the puncture valve from the fuel
pump.
Plug the air supply pipe to the puncture
valve.

3. Remove the cover on the camshaft housing. Turn the engine until the fuel pump roller is at TDC.
GN909-16 201 03
Note !
4.
4. Mount the lifting tool on the fuel pump top
cover and secure it in position with the two
screws.
GN909-16 201 04
Turn the uppermost nut to screw the spindle

of the lifting tool into the fuel pump plunger.
When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
Page 1 (2)
909-16
5.
Fuel Pump Emergency Running
S50MC-C
5. Tighten the lowermost nut on the tool to pull

the roller guide upwards as far as possible.
Tighten the middle nut of the tool against
the lowermost nut to secure the roller guide
in this position.
6. Turn the engine one full revolution and inspect through the opening in the camshaft
housing to make sure that the roller guide
is clear of the fuel cam.
GN909-16 201 05
7. If necessary, disengage the exhaust valve

actuator.
The engine can now operate on the remaining cylinders. See Volume I, Section 704.
6.
Re-engagement of fuel pump
Warning !
Re-engagement of the fuel pump must
only take place at engine standstill.
GN909-16 201 03
8. Remove the cover on the camshaft housing. Turn the engine until the circular section of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in
the reverse order to lifting.
10. Remove the lifting tool and re-mount the
puncture valve.
GN909-16 201 10
10.
Page 2 (2)
When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
Fuel Valve and Fuel Pump Panel

MAN B&W Diesel
Plate
P90951-0462
Page 1 (2)
Plate
P90951-0462
Item
No.
010
021
045
057
069
070
082
094
104
116
128
130
141
153
165
177
189
190
200
224
236
248
250
273
297
307
Page 2 (2)
Fuel Valve and Fuel Pump Panel

MAN B&W Diesel
Item
No.
Item Description
Item Description
Panel for tools

Name plate
Measuring tool, fuel pump lead
Lifting tool for fuel pump plunger barrel
Lifting tool, fuel pump
Lifting tool, fuel pump housing
Lifting tool, roller guide
Milling tool, fuel oil pipe seats
Milling tool, fuel oil pipe
Crowfoot spanner
Crowfoot spanner
Crowfoot spanner
Crowfoot spanner
Flange, dismantling of non-return valve
Grinding mandrel, valve head
Grinding mandrel, thrust spindle
Grinding mandrel, holder, outside
Grinding mandrel, holder, inside
Screw, topcover
Tool for P. max rack
Pin spanner
Hook spanner
Drift, spindle guide
Drift, non-return valve
Assembling tool, fuel valve
Hook spanner
Fuel Valve - Tools
MAN B&W Diesel A/S
Plate
P90961-0069
Page 1 (2)
Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122
Page 2 (2)
Fuel Valve - Tools
Item Description
Item
No.
Item Description
High-pressure pump
Table
Rig fuel oil valve
High-pressure hose
Connection piece, M42x2
Test rig, complete
Cover
Angle union
Gasket
Plug screw
Hose
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90966-0008
Page 1 (2)
Plate
P90966-0008
Item
No.
011
023
035
047
060
202
Item Description
Item
No.
Item Description
Tool box
Extractor for atomizer
Drift for atomizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When odering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90968-0001
Page 1 (2)
Plate
P90968-0001
Item
No.
Item Description
012
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Plate
P90974-0001
Page 1 (2)
Plate
P90974-0001
Item
No.
015
027
039
206

Item Description
Item
No.
Item Description
Drill*
Test mandrel*
Pin vice*
Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90977-0001
P90977
0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90977-0001
Item
No.
011
023
035
047
059
060
072
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Spacer ring
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90979-0001
P90979
0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90979-0001
Item
No.
012
024
036
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Page 2 (2)
MAN B&W Diesel A/S
Plate
P90980-0001
P90980
0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90980-0001
Item
No.
018
020
031
043
055
067
079
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Cone
Page 2 (2)
MAN B&W Diesel A/S
910 - Turbocharger System

110-01
910-01
110-02
910-02
910-03
110-03
110-04
910-04
110-05
910-05
110-06
910-06
91061
91063
91063
91064
91066
0032
0229
0009
0205
0218
0019
0005
0208
0005
0206
0018
0214
0071
0017
0019
0002
0001
Air Cooler Element, Data

Air Cooler Element
Non-Return Valve in Turbocharger, Data
Non Return Valve in Tubocharger
Auxilary Blower
Auxilary Blower, Data
Butterfly Valve, Data
Butterfly Valves
Turbocharger Turbine, Data
Turbocharger Turbine
Water Mist Catcher, Data
Water Mist Catcher
Turbocharger System - Tools
Air Cooler - Tools
Air Cooler - Tools
Travelling Trolley
Air Cooler - Lifting Tools
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Air Cooler Element
110-1
Data
SAFETY PRECAUTIONS
110-1
S50MC-C
0032
Special Data
Air Cooler Element
Stopped engine

Engage turning gear
2 x 2000 kg
Shut off fuel oil

Data
Ref.
Description
D-1
Air cooler element
Value Unit
1550 kg
MAN B&W Diesel A/S
Page 1 (2)
Air Cooler Element
110-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Air Cooler Element
910-1.1
Checking
Air Cooler
S80MC Element
0229
Checking
910-1.1
1.
1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air
across the cooler while the engine is running.
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
the air side of the cooler.
A decrease in the air temperature drop
across the scavenge air cooler indicates
fouling of the water side of the cooler.
GN910-1.1 206 01
Compare these measurements with the

testbed data. For further evaluation of the
measurements, see instruction book Volume I, Chapter 706.
4.
3. If the measurements indicate fouling, it is
recommended to inspect the air cooler elements as follows:
4. Remove the front end cover of the air cooler.
5. Visually inspect the air cooler element
through the opening.
If the element needs to be dismantled for

further inspection or replacement, see Procedure 910-1.2.
GN910-1.1 206 04
Clean the element if it is fouled.

GN910-1.1 206 06
5.
MAN B&W Diesel A/S
Page 1 (9)
910-1.2
Air Cooler Element

Dismantling
Dismantling
910-1.2
1.
The cooler element normally does not need to

be dismantled for inspection purposes. It is only
in the event that the cooler element has suffered damage that it has to be dismantled and
replaced.
Note!
During dismantling, take care not to damage the cooler element.
GN910-1.2 206 01
1. Close the cooling water inlet and outlet

valves. Open the drain cocks in the aft end
cover to drain off the cooling water.
2. Dismount the cooling water inlet and outlet
pipes from the aft end cover.
2.
3. Release the screws and remove the frame
around the front end cover.
Remove and discard the O-ring.
GN910-1.2 206 02
Remove the sealing plate.
GN910-1.2 206 03
3.
Page 2 (9)
MAN B&W Diesel A/S
Air Cooler Element
910-1.2
Dismantling
4.
4. Mount the first set of guide rails on the

frame around the front end cover.
5. When mounting the guide rails, hold them
up against the wheels of the cooler element
and mount, but do not tighten, the lowermost screws. Mount and tighten the uppermost screws.
6. Mount the lifting bracket on the aft end cover.
JN910-1.2 213 04
Finally, tighten the lowermost screws and

the thrust nuts on the uppermost screws simultaneously. This results in loosening and
lifting the cooler element.
Mount a travelling trolley on the beam

above the aft end cover.
5.
GN910-1.2 206 05
Mount a tackle between the travelling trolley

and the lifting bracket, and use the tackle to
lift the air cooler element approx. 1-2 mm.
GN910-1.2 228 06
6.
MAN B&W Diesel A/S
Page 3 (9)
Air Cooler Element
910-1.2
Dismantling
7.
7. Mount a second tackle on the lifting bracket, and use it to pull out the air cooler element approx. half a metre.
8. Mount the second set of guide rails on the
frame around the air cooler element.
9. Pull out the air cooler element until the front
end cover of the air cooler element is clear
of the air cooler housing.
GN910-1.2 228 07
Mount a second travelling trolley on the

beam above the air cooler.
Mount a tackle between the second travelling trolley and the lifting holes in the upper
corners of the front end cover of the air
cooler element.
8.
Using the tackles, lift the air cooler element
away and land it on a couple of wooden
planks.
Note!
GN910-1.2 228 08
Depending on the engine layout and

engine room installation, it may be necessary to remove some pipes or floor
plates.
9.
GN910-1.2 228 09
D-2
Page 4 (9)
MAN B&W Diesel A/S
Air Cooler Element
910-1.3
Overhaul
Overhaul
910-1.3
1.
Cleaning the air side:

The air side of the cooler is cleaned by injecting
a chemical fluid through the spray pipe arrangement fitted to the air chamber above the cooler
element.
It is recommended to use one of the following
cleaning fluids, or a similar product.
2) Product: 80B, produced by

Vecom Int., Maassluis, Holland
Cleaning should be carried out in the following
sequence:
GN910-1.3 206 01
1) Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
2.
1. Do not start cleaning until the engine has
been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
2. Follow the detailed cleaning instructions
displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
3. Continue the cleaning process for at least
30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
5. Inspect the element either by removing the

cover on top of the cooler or by dismantling
the charging air pipe.
KE910-5.1 61 02
4. After cleaning, flush the cooler with clean

water until the water appearing in the sight
glasses is clean and pure.
MAN B&W Diesel A/S
Page 5 (9)
910-1.3
Air Cooler Element

Overhaul
6.
Cleaning the water side

6. Close the cooling water inlet and outlet
valves. Remove the plug screws from the
front end cover and the aft end cover to
drain off the cooling water.
7. Dismount the cooling water inlet and outlet
pipes from the aft end cover.
GN910-1.2 206 01
8. Screw two eye bolts into the upper flange of

the aft end cover. Mount a lifting wire rope
between the eye bolts.
Mount a travelling trolley on the beam
above the aft end cover.
Mount a tackle between the travelling trolley
and the lifting wire rope. Tighten up the
tackle.
GN910-1.2 206 02
7.
GN910-1.3 206 03
8.
Page 6 (9)
MAN B&W Diesel A/S
Air Cooler Element
910-1.3
Overhaul
9.
9. Mount a shackle in each of the two lifting

eyes on the front end cover.
Mount two tackles above the front end of
the air cooler.
Hook the tackles on to the shackles and
tighten up.
Lower both covers and land them on a couple of wooden planks. Discard the gaskets.
11. Clean the inside of the tubes, using the
cleaning brush mounted on a drilling machine. In the event of leakages between
cooling tube and tube plate, the tubes are
rolled with the tube expander.
GN910-1.3 206 04
10. Remove the screws of the front end and aft

end covers.
10.
Tools for tube cleaning and the tube expander are supplied by the air cooler manufacturer.
Clean the front-end and aft-end covers inside with a stiff brush and then rinsed with
fresh water.
Note!
If damaged, the coating inside the covers
is to be repaired with the original coating
or a similar product.
GN910-1.3 206 05
Replace the anti-corrosion blocks, if necessary.
D-1
D-3
D
11.
GN910-1.3 206 06
12. When cleaning is complete, mount the covers in the reverse order to dismantling.
MAN B&W Diesel A/S
Page 7 (9)
Air Cooler Element
910-1.4
Mounting
Mounting
910-1.4
1.
1. Lift the air cooler element and land the front

end of the element on the guide rails
mounted on the aft end of the air cooler
housing.
Remove the tackle from the front end of the
cooler.
GN910-1.4 228 01
D-2
2. Push the air cooler element inwards approx. one metre.

Remove the guide rails from the aft end of
the air cooler housing.
3. Clean the frame around the air cooler element and the contact surface of the aft end
cover.
2.
Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the aft end cover.
GN910-1.4 228 02
Push the air cooler element fully into the air

cooler housing.
GN910-1.4 228 03
3.
Page 8 (9)
MAN B&W Diesel A/S
Air Cooler Element
910-1.4
Mounting
4.
4. Mount and tighten all the screws of the aft

end cover.
Remove the tackle and the lifting bracket
from the aft end cover.
5. Remove the guide rails from the front end
cover.
7. Mount the cooling water inlet and outlet

pipes on the aft end cover.
8. Close the drain cocks, and open the cooling
water inlet and outlet valves.
GN910-1.4 228 04
6. Mount the sealing plate, a new O-ring and

the frame around the front end cover.
5.
Note!
JN910-1.4 213 04
Remember to vent trapped air from the

air cooler element.
GN910-1.2 206 03
6.
MAN B&W Diesel A/S
Page 9 (9)
110-2
Non-Return Valve
Data
N
D
R
B
I
E

X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-2
Non-Return Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Non-Return Valve
910-2.3
Overhaul
Non-Return
S50MC-C Valv e
205
Overhaul
910-2.3
1.
The non-return valves are accessed from the

scavenge air receiver.
Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.
Main Non-Return Valve
GN910-2.3 205 01
Note!
1. Inside the scavenge air receiver, lift up the

valve flap of the valve that is to be overhauled.
2.
3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.
4. For further dismantling, remove the two
screws which hold the clamp and the support together as an assembly.
GN910-2.3 205 02
2. Remove the screws behind the valve flap.

Remove the valve from the engine.
3.
Clean the valve shaft and the slide bearings

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybdenum disulphide (MoS 2).
After the overhaul, it must be possible to

move the valve flap by the light touch of a
finger.
6. Re-mount the valve in the scavenge air receiver.
MC910-6.0 26 02
5. Assemble the valve
MC910-6.0 26 03
4.
MAN B&W Diesel A/S
Page 1 (1)
Auxiliary Blower
910-3.3
Overhaul
Auxiliary Blower
60&&
0218
Overhaul
910-3.3
1.
1. When cleaning and inspecting the auxiliary

blower, disengage the cable connections to
the blower motor.
Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the
blower flange, before removing the screw in
the flange.
2. The end cover complete with blower can
now be pulled free of the suction pipe by
means of the two tackles.
MC910-8.0 31 01
While pulling out the end cover with the

blower assembly, make sure that the blower
housing disengages from the air pipe without deforming it.
D10-12
2.
Then inspect and clean the blower wheel as

well as the blower housing.
For overhaul of blower wheel and bearings,
see blower manufacturers instructions.
Exercise care when mounting the electric motor with blower wheel, as the
blower wheel is to catch the guide in the
blower housing.
MC910-8.0 31 02
Note!
0$1 % : 'LHVHO $6
Page 1 (1)
Auxiliary Blower
110-3
Data
SAFETY PRECAUTIONS
110-3 Edition 0019
D11003
Special Data
Auxiliary Blower
S60MC
Stopped engine

Engage turning gear
Shut off fuel oil
Data
Ref.
D10-12
Description
Electric motor, impeller and motorplate
MAN B&W Diesel A/S
Value Unit
556 kg
Page 1 (2)
Auxiliary Blower
110-3
Data
Plate
P91356
Page 2 (2)
Lifting Tools, Etc.
MAN B&W Diesel A/S
110-4
Butterfly Valves
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-4
Butterfly Valves
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Butterfly Valves
910-4.1
Checking
1. It is important that the automatic non-return valves (butterfly valves) are always
able to function easily and unimpeded.
The movability of the valve flaps should
therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.
1.
Flow direction
Reach down through the opening in the top

of the valve and move the valve flaps.
3. If the valve flaps in one of the butterfly
valves cannot be moved by a light touch of
a fingertip, it must be dismantled and overhauled.
M91004 0208C01
2. To check the valve, remove the cover on

the top of the butterfly valve.
2.
M91004 0208C02
4. Re-mount the cover on the top of the butterfly valve.
MAN B&W Diesel A/S
Page 1 (1)
110-5
Data
SAFETY PRECAUTIONS
110-5
.0&&
0005
Special Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value Unit
MAN B&W Diesel A/S
Page 1 (2)
110-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
910-5.3
Cleaning
.0&&
0206
Cleaning
910-5.3
The dry cleaning method employs compressed

air to blow dry, solid, granules through the turbocharger, thus removing most of the deposits
which may have formed on the nozzle vanes
and turbine blades.
On account of their hardness, nut-shells, or
broken or artificially shaped pieces of activated
charcoal with a size of between 1.0 and max.
1.5 mm are particularly suited as blasting
agents.
Note!
We do not recommend the use of rice or
grain as cleaning materials, as these may
possibly stick in the exhaust gas boiler.
It is not always possible to remove thick deposits with this dry cleaning method.
Therefore, in order to prevent the build-up of
thick deposits, the turbine must be cleaned after every 24 to 50 hours of operation.
Generally, turbocharger cleaning can be carried
out without, or with very little, reduction of the
engine load.
More detailed information regarding the amount
of granules to be used is stated on the instruction plate located close to the turbocharger.
Note!
Regarding water washing of turbocharger
turbine, see turbine manufacturers
instructions.
See also Volume I, Chapter 706.
0$1 % : 'LHVHO $6
Page 1 (2)
910-5.3
Cleaning
Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours
of operation, based on observations.
2. Preferably clean the turbocharger at full
load. Do not clean below half load.
3. Close valve A.
XX706-12 40B
4. Open valves B and C, to blow out any deposits and/or condensate in the connecting
pipe.
After about two minutes, close valves B and
C.
5. Slowly open valve A to relieve the pressure
in the tank.
6. Fill the tank with the quantity of granules
specified in the table.
7. Close valve A.
8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves
B and C.
HM910-5.3 50 02
9. Slowly open valve A to relieve the pressure

in the tank.
Caution!
1.The drain openings in the gas casings
must remain closed while dry cleaning
the turbine.
2. It is possible that during dry cleaning
of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.
Page 2 (2)
0$1 % : 'LHVHO $6
Water Mist Catcher
110-6
Data
SAFETY PRECAUTIONS
110-6
S50MC-C
0018
Special Data
Water Mist Catcher
Stopped engine

Engage turning gear

Shut off fuel oil
1000 kg
Data
Ref.
Description
D-1
Water mist catcher
Value Unit
119 kg
MAN B&W Diesel A/S
Page 1 (2)
Water Mist Catcher
110-6
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Water Mist Catcher
910-6.2
Dismantling
Water
S46MC-C
0214 Mist Catcher
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the

water mist catcher element from the scavenge air cooler housing. If, however, the
water mist catcher element has been fouled
or damaged, it must be dismantled for
cleaning or repair.
3. Via access through the upper part of the

scavenge air cooler housing, loosen the
four screws which press against the water
mist catcher.
EN910-6.2 214 02
2. To dismantle the water mist catcher, dismantle the water mist catcher cover and upper cover to give access to the air cooler
housing.
4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the
water mist catcher.
3.
Attach a tackle to the eye bolt and tighten

up the tackle.
EN910-6.2 214 03
5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
GN910-6.2 205 06
4.
0$1 % : 'LHVHO $6
Page 1 (3)
Water Mist Catcher
910-6.4
Mounting
Mounting
910-6.4
1.
1. Lubricate the two supports on the underside of the water mist catcher with plenty of
grease.
Apply a thin layer of silicone paste to the
frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.
Note!
EN910-6.4 214 01
Make sure to mount the water mist

catcher correctly. See the sketch.
Air flow
2.
2. Slide the water mist catcher into the scavenge air cooler housing.
When the water mist catcher is half-way in,
remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.
GN910-6.4 205 02
3. Via access through the upper part of the

scavenge air cooler housing, tighten the
four screws which press against the water
mist catcher.
EN910-6.4 214 03
3.
Page 2 (3)
0$1 % : 'LHVHO $6
Water Mist Catcher
910-6.4
Mounting
4.
4. Clean the water mist catcher cover and apply a thin layer of silicone paste along the
edges of the cover. Mount the cover.
EN910-6.2 214 02
Clean the upper cover and apply a thin layer of silicone paste along the edges of the
cover. Mount the cover.
0$1 % : 'LHVHO $6
Page 3 (3)
Tools
MAN B&W Diesel
Plate
P91061-0071
Page 1 (2)
Tools
Plate
P91061-0071
Item
No.
014
026
Page 2 (2)
MAN B&W Diesel
Item Description
Item
No.
Item Description
Pulling tool
Lifting eye bolt
Air Cooler - Tools
MAN B&W Diesel A/S
Plate
P91063-0017
Page 1 (2)
Plate
P91063-0017
Item
No.
015
027
Page 2 (2)
Air Cooler - Tools

Item Description
Item
No.
Item Description
Guide rail, air cooler fore end

Guide rail, air cooler fore end
MAN B&W Diesel A/S
Air Cooler - Tools
MAN B&W Diesel A/S
Plate
P91063-0019
Page 1 (2)
Plate
P91063-0019
Item
No.
015
027
Page 2 (2)
Air Cooler - Tools

Item Description
Item
No.
Item Description
Guide rail, rear end

Guide rail, rear
When referring to this page, please quote Plate
Edition
MAN B&W Diesel A/S
Travelling Trolley
MAN B&W Diesel A/S
Plate
P91064-0002
Page 1 (2)
Plate
P91064-0002
Item
No.
010
Travelling Trolley
Item Description
Item
No.
Item Description
Travelling trolley*
Note:
* When ordering this tool, please state
load and track width.
Page 2 (2)
MAN B&W Diesel A/S
Plate
P91066-0001
P91066
0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91066-0001
Item
No.
011
023
Item Description
Item
No.
Item Description
Lifting attachment air cooler fore end,

complete
Screw
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
0211
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
111-1
Safety Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D11-01
Opening pressure
D11-02
Valve housing, tightening torque
MAN B&W Diesel A/S
Value
Unit
200 5
bar
45
Nm
Page 1 (2)
111-1
Safety Valve
Data
Plate
Item No.
Description
P91351
10
P91351
58
P90151
117
P91359
Page 2 (2)
Test equipment for combined safety valve

Torque Spanners
MAN B&W Diesel A/S
Safety Valve
911-1.2
Dismantling
When Side-mounted
1.
1. Remove the guard surrounding the safety

valve.
Unscrew the safety valve from the extension pipe.
M91101 0211D01
2. Dismantle the indicator cock and the intermediate pipe.
M91101 0211D02
2.
When Top-mounted
3.
3. Unscrew the safety valve from the cylinder

cover.
M91101 0211D03
Remove and discard the mild steel disc.
MAN B&W Diesel A/S
Page 1 (5)
911-1.3
Safety Valve
Overhaul (adjustment)
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

M91101 0211O01
in the data, loosen and tighten again to

the torgue stated in the data.
3. Then mount:
the valve spindle
the spring
the adjusting screw
the lock nut
M91101 0211O02
2.
M91101 0211O03
3.
Page 2 (5)
MAN B&W Diesel A/S
Safety Valve
911-1.3
Overhaul (adjustment)
4. To set the safety valve opening pressure:
4.
Set up the safety valve in the testing
D11 01
device.
Connect the testing device to the hydraulic pump.
Loosen the lock nut on the safety valve.

Turn the adjusting screw until the valve
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
M91101 0211O04
just closes.
safety valve until the correct pressure is

indicated (see Data).
Tighten the lock nut.

Test the opening pressure.
Remove the valve from the testing device.
MAN B&W Diesel A/S
Page 3 (5)
911-1.4
Safety Valve
Mounting
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.
M91101 0211M01
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.
M91101 0211M02
2.
M91101 0211M03
3.
Page 4 (5)
MAN B&W Diesel A/S
Safety Valve
911-1.4
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
M91101 0211M04
Mount a new mild steel disc in the bore.
M91101 0211M05
5.
MAN B&W Diesel A/S
Page 5 (5)
111-2
Relief Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
111-2
Relief Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Relief Valve
911-2.1
Checking
Relief
60&
0211 Valve
Checking
911-2.1
1.
1. During running of the engine, check if there

are any leaks.
If a leak occurs, replace the O-ring inside
the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
If one or more plates in the flame arrester

are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
Note!
XZ911-2.1 209 01
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
The complete flame arrester has to be

replaced after a crankcase explosion.
XZ911-2.1 207 03
2.
0$1 % : 'LHVHO $6
Page 1 (1)
Scavenge Air Receiver Safety Valve

MAN B&W Diesel
111-3
Data

X
X
X
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
111-3
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
911-3.1
Checking
1. The scavenge air receiver safety valve is

calibrated at the factory and does not require any adjustment.
2.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
If this operation cannot be performed

smoothly, the safety valve must be dismantled and cleaned.
M91103 0001C02
Use a piece of cloth to wipe out any dirt

from the O-ring packing and close the
valve again. Tighten the counter nut.
Page 1 (5)
911-3.2

Dismantling
1. Dismount the safety valve from the scavenge air receiver.
M91103 0001D01
1.
MAN B&W Diesel
Page 2 (5)

MAN B&W Diesel
911-3.3
Overhaul
1. Remove the split pin.
1.
Unscrew the nut thereby relieving the

spring tension.
Remove the nut, spring retainer and washers.
Keep count of the washers.
2. Pull out the valve flap with spindle. If the

O-ring seal is damaged remove it without
damaging the O-ring groove.
3. Clean the metal surfaces thoroughly.
M91103 0001O01
Pull out the spring.
M91103 0001O02
2.
Page 3 (5)
911-3.3

Overhaul
4.
MAN B&W Diesel
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 flap and spindle while
tak-ing care not to damage the O-ring seal.
6. Mount the spring, spring retainer and all the
washers.
M91103 0001O04
Tighten the nut until the split pin can be

mounted.
7. Check the valve according to 911-3.1.
M91103 0001O05
5.
M91103 0001O01
6.
Page 4 (5)

MAN B&W Diesel
911-3.4
Mounting
1.
M91103 0001M01
1. Mount the safety valve on the scavenge air

receiver.
Page 5 (5)
912 - Assembly of Large Parts

112-02
912-02
112-03
912-03
912-05
91261
91265
91268
0007
0207
0015
0210
0201
0073
0003
0001
Holding Down and End Chock Bolts (Epoxy), Data

Holding Down and End Chock Bolts (Epoxy)
Stay Bolts, Data
Stay Bolts
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
Hydraulic Tools - End Chock Bolts (Iron Chocks)
MAN B&W Diesel A/S
MAN B&W Diesel A/S
Holding Down and End Chock Bolts
112-2
Data
SAFETY PRECAUTIONS
112-2 Data
.0&
0007
Special
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D-1
Tightening pressure for

holding down bolts and
end chock bolts
D-2
Value Unit
1500 bar
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
Subsequently at
intervals of
500 hours
1000 hours
2000 hours
4000 hours
8000 hours
8000 hours
Engine on Epoxy supporting chocks
MAN B&W Diesel A/S
Page 1 (2)
112-2
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
912-2.1
Checking
Holding
.0& Down and End Chock Bolts
0207
Checking
912-2.1
Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1 % : 'LHVHO $6
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.
EN912-1.1 205 01
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the tables from successive bolt checks.
If the loosening pressure' is below 80 per
cent of the tightening pressure, the relative
chocks shall always be checked for possible defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been
welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins
and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be followed.
Page 2 (3)
0$1 % : 'LHVHO $6
912-2.1
Checking
3.
Side Chocks and Side Chock Liners

3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The first time the ship is sailing in a fullyloaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the liners can be knocked further inward.
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
GN912-2.1 203 03
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simultaneously.
The feeler gauge is applied at the 7 points

indicated 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.
0$1 % : 'LHVHO $6
Page 3 (3)
Stay Bolts
112-3
Data
SAFETY PRECAUTIONS
112-3
S50MC-C
0015
Special Data
Stay Bolts
Stopped engine

Engage turning gear
1x3m
2x1m
Shut off fuel oil

Data
Ref.
Description
D-1
Check measurement
D-2
Hydraulic pressure
mounting
1500 bar
Hydraulic pressure
dismantling
1400-1650 bar
D-3
Value Unit
148 mm
MAN B&W Diesel A/S
Page 1 (2)
Stay Bolts
112-3
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
MAN B&W Diesel A/S
Stay Bolts
912-3.1
Checking
Stay
K98MC
0210 Bolts
Checking
912-3.1
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.
One Group
One Group
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.
NA912-3.1 210 01
Note!
2. Before retightening the stay bolts, remove

the protective caps.
2.
3. Check for loose staybolt nuts with the tommy bar.
Check for the correct mounting of the stay

bolt by comparing with the check measurement on the Data Sheet, D-1.
If the check measurement is not reached,
indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the
thread in the top of the stay bolt, and turn
the stay bolt until D-1 is met.
4. Retighten the stay bolts in pairs (athwartship), working from fore to aft of the engine.
3.
'
GN912-3.0 39 09
Loosen and unscrew the nut on the opposite stay bolt.
GN912-3.1 202 01
If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 03
4.
0$1 % : 'LHVHO $6
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.
GN912-3.1 202 02
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.
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.
HM912-3.0 28 04
8. After completing the retightening procedure, mount the protective caps.
HM912-3.0 28 05
7.
Page 2 (2)
0$1 % : 'LHVHO $6

MAN B&W Diesel
912-5.1
Checking
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing.
1.
If the water content of the main engine

lube oil is rising, this may indicate that
the crankcase oil outlet sealings are fractured.
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing
remove:
Screws A
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
M91205 0201C01
Note!
2.
Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
M91205 0201C02
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
Page 1 (2)
912-5.1
Checking
MAN B&W Diesel
Metal bellow sealing

4.
4. Remove all screws A and grating B.
C
D
5. Remount four of the screws A at diametrically opposite positions.
B
A
6. Remove:
Screws C
Cover plate D
Screws E.
M91205 0201C04
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.
M91205 0201C07
10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Page 2 (2)
Large Parts - Tools
MAN B&W Diesel A/S
Plate
P91261-0073
Page 1 (2)
Plate
P91261-0073
Item
No.
023
035
047
050
060
084
106
202
Page 2 (2)
Large Parts - Tools

Item Description
Item
No.
Item Description

Support
Tommy bar
Spanner
Stud setter
MAN B&W Diesel A/S
Hydraulic Tools - Holding Down Bolts

(Epoxy Chocks)
Plate
P91265-0003
P91265
Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)
0003
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91265-0003
Item
No.
025
037
049
050
074
098
204
Hydraulic Tools - Holding Down Bolts

(Epoxy Chocks)
Item Description
Item
No.
Item Description

Support
Tommy bar
Key, hexagon socket screw
Page 2 (2)
MAN B&W Diesel A/S
HydraulicTools - End Chock Bolts

(Iron Chocks)
MAN B&W Diesel A/S
Plate
P91268-0001
Page 1 (2)
Plate
P91268-0001
HydraulicTools - End Chock Bolts

(Iron Chocks)
Item
No.
Item Description
021
033
057
069
094
104
200

Support
Tommy bar
Spanner
Page 2 (2)
Item
No.
Item Description
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
0058
0005
0013
0003
0003
0052
0064
0040
0059
0066
0004
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
913-1.1
Hydraulic Tools
Description
A. Snap-on coupling
B. Tool attachment thread
1.
C. Bleed screw
D. Piston
C
D
E
E. Cylinder
F. Sealing rings
G. Spacer ring
H. Tommy bar
J. Stud or bolt
K. Extension stud
L. Lifting tool
S. Clearance
U. Milled recess for feeler gauge
M91301 0215C01
I. Nut
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.
G
3.
D
F
E
M91301 0215C02
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.
I
J
2.
Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts
must only be loosened and tightened up by
means of the hydraulic tools supplied.
The jacks must never be overloaded or exposed to blows or impacts. They are marked
with a Max. lift, which must not be exceeded.
K
B
J
U
I
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.
MAN B&W Diesel A/S
Page 1 (12)
913-1.1
Hyraulic Tools
Description
3.
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.
M91301 0215C03
Operation of the cylinder cover jacks is

identical to the operation of the single hydraulic jacks.
4.
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!
M91301 0215C04
Eye protectors and gloves must be used

when using hydraulic tools.
Page 2 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1.2
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.
MoS2
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.
M91301 0215D01
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.
2.
Max. lift =
Max. lift 10 mm 25 mm
Loosening 1 turn 3 turn
Tightening 1/4 trun 1/4 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.
M91301 0215D02
After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylinder of the jack.
MAN B&W Diesel A/S
Page 3 (12)
913-1.2
Hydraulic Tools
Dismantling
3.
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.
M91301 0215D03
5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
Note!
Make sure not to exceed the max lift
stamped on the jack.
M91301 0215D04
4.
M91301 0215D05
5.
Page 4 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1.2
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.
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.
M91301 0215D06
Press the pistons and the cylinder of both

the hydraulic jacks firmly together.
7.
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.
M91301 0215D07
MoS2
MAN B&W Diesel A/S
Page 5 (12)
913-1.2
Hydraulic Tools
Dismantling
8.
8. The clearance between the pistons and the

cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm.
Max. lift 10 mm
3 mm
The clearance between the jack and spacer

ring ensures dismounting of the jack after
loosening the nut.
M91301 0215D08
Connect the hydraulic jacks, the distributor

9.
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.
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.
M91301 0215D09

the high-pressure pump, and remove the
hydraulic tools.
Page 6 (12)
Note!
Make sure not to exceed the max lift
stamped on the jack.
MAN B&W Diesel A/S
913-1.3
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.
1.
The piston and cylinder are easily separated by taking out the bleed screw and
pressing the parts apart with the help of
compressed air.
Air
Warning!
Always use protective gloves and eye
protection when working with compressed air.
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
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.
2.
Air
M91301 0215O02
Air
MAN B&W Diesel A/S
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.
3.
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.
1
2
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.
M91301 0215O03
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.
Page 8 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1.4
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.
MoS2
Fit the round nut on the thread and tighten

it with the tommy bar.
Check with a feeler gauge that the contact
face of the nut bears on the entire circumference.
2. Press the piston and the cylinder of the

jack firmly together.
Screw the hydraulic jack on to the tool attachment thread.
Make sure that the cylinder of the jack
bears firmly against the spacer ring and
that the parts are guided correctly together
M91301 0215D01
Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot for the purpose of
tightening the nut.
2.
Max. lift =
Max. lift 10 mm 25 mm
Loosening 1 turn 3 turn
Tightening 1/4 trun 1/4 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.
M91301 0215D02
Re-tighten the bleed screw.
MAN B&W Diesel A/S
Page 9 (12)
913-1.4
Hydraulic Tools
Mounting
3.

value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.
4. While maintaining the pressure, check with
a feeler gauge introduced through the recess at the bottom of the spacer ring that
the nut bears against the contact face.
M91301 0215M03

the pump, and remove the hydraulic jack.
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.
M91301 0215M04
4.
Page 10 (12)
MAN B&W Diesel A/S
Hydraulic Tools
913-1.4
Mounting
Double Hydraulic Jack
5.
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.
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.
M91301 0215M05
Fit the round nuts on the threads and

tighten them with the tommy bar.
MoS2
6.
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.
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.
M91301 0215D06
Make sure that both the cylinders of the

jacks and the spacer ring are guided correctly together.
MAN B&W Diesel A/S
Page 11 (12)
913-1.4
Hydraulic Tools
Mounting
7.
7. Connect the hydraulic jacks, the distributor

Loosen the bleed screws in both jacks, and
fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.
M91301 0215M07
Re-tighten the bleed screws.

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.
8.
the pump, and remove the hydraulic tools.
M91301 0215M08
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.
M91301 0215M09
9.
Page 12 (12)
MAN B&W Diesel A/S
Standard Tightening Torques
913-4
Standard
.0&&Tightening Torques
0201
913-4
When tightening screws or nuts for which no

torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a
Molybdenum Disulphide (MoS 2) based lubricant.
Thread
Tightening
torque
Thread
Tightening
torque
M8
17 Nm
M22
400 Nm
M10
35 Nm
M24
460 Nm
M12
50 Nm
M27
610 Nm
M14
80 Nm
M30
950 Nm
M16
135 Nm
M33
1200 Nm
M18
190 Nm
M36
1650 Nm
M20
260 Nm
M39
2100 Nm
2. Self-locking nuts.
Thread
Tightening
torque
Thread
Tightening
torque
M8
20 Nm
M22
430 Nm
M10
40 Nm
M24
490 Nm
M12
60 Nm
M27
650 Nm
M14
90 Nm
M30
1000 Nm
M16
150 Nm
M33
1250 Nm
M18
210 Nm
M36
1700 Nm
M20
290 Nm
M39
2200 Nm
3. Screws and nuts locked with glue/Loctite.

Thread
Tightening
torque
Thread
Tightening
torque
M8
23 Nm
M22
580 Nm
M10
50 Nm
M24
680 Nm
M12
70 Nm
M27
900 Nm
M14
115 Nm
M30
1350 Nm
M16
190 Nm
M33
1700 Nm
M18
270 Nm
M36
2350 Nm
M20
380 Nm
M39
3000 Nm
0$1 % : 'LHVHO $6
Page 1 (1)
Torque Spanner
913-5
Torque
/0&
0205 Spanner
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are
to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened
to the stated torque and then to the next splitpin hole.
The torque spanner must not be used for torques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided
with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,
there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle
appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl
system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the spanner, and a small click is heard.
When the torque spanner is not in use, the
spring inside should be released by adjusting to
minimum torque.
0$1 % : 'LHVHO $6
Page 1 (1)
Tightening Gauge
913-6
Tightening Gauge
0205
913-6
Preparations
Before screwing on the nuts, grease the
threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
= 0.10.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:
thread M8 M20 = 50 Nm
This is in order to ensure a uniform basis for the
subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge
round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 3045 and 60,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
When tightening new studs or bolts for the first
time, loosen again and repeat the procedure
including pre-tightening with a torque spanner,
to allow the parts to settle.
#

%

"
(
U
Y
#

%

"
(
H
C
0$1 % : 'LHVHO $6
Page 1 (1)
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Some screwed and bolted connections on the

engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.
1.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Make sure only to mount locking devices

on nuts and screws which have been
mounted with locking devices by the engine manufacturer.
1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers
are to be bent back over one of the flats of
the screw or nut concerned.
M91307 0207C01
Note!
2.
2. Used spring washers must be replaced.
To tighten a self-locking nut to a specific

torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data
sheet of a procedure.
M91307 0207C02
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
M91307 0207C03
3.
Page 1 (4)
Screws and Nuts
913-7.1
Locking
Fig. 1
MAN B&W Diesel
Locking wire should be fitted after the screws

or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Always fit new wire after tightening-up the units.
Fig. 2
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3
Fig. 1: Insert wire, grasp the upper end of the

wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.
Fig. 2: Twist the wire clockwise until it is just
short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approximately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180, equal
to half of a complete turn.
Fig. 6
M91307 0207C04
Fig. 5
Fig. 4
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,
and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it
min. 3 twists, counterclockwise until tight.
Fig. 7
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
M91307 0207C05
Fig. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes oriented in different angles.
Page 2 (4)
Fig. 9
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Fig. 10: Shows how to route the locking wire

on screws in different planes.
Fig. 11: Wire that passes over the top of a nut
is an acceptable alternative only if it routes
around the protruding screw thread.
Fig. 10
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure.
Fig. 11
Fig. 13: Where drilling of locking wire holes has

caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.
Fig. 12
Fig. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible.
M91307 0207C06
Fig. 13
Fig. 14
Page 3 (4)
913-7.1
Screws and Nuts

Locking
Fig. 15
MAN B&W Diesel
Cam Lock Washers with rising cams on one

side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam
face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
M91307 0207C15
Fig. 16: Different uses of the cam lock washers.

Fig. 17: Don not use the cam lock washers in
conjunction with other loose washers.
Fig. 16.
Note!
M91307 0207C16
Cam lock washers must be installed in

pairs and are not to be substituted by
other typers of washers.
M91307 0207C17
Fig. 17
Page 4 (4)
Lubricating Procedures
913-11
Lubricating
.0&& Procedures
0204
913-11
Molybdenum Disulphide (MoS2)

The following procedure is to be followed prior
to the mounting of metal surfaced parts which
are to function as seals.
Clean the surface with a cleaning fluid
and ensure that the entire surface is
completely free of grease.
Allow 5 minutes for the cleaning fluid to
evaporate.
With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote G-n Plus, or the like) hard onto the
metal surface.
Remove any excessive paste and ensure
that the metal surface is only coated with
a thin, uniform, layer of the above mixture.
Protect the wet paste and cloth from dust
or other foreign particles.
0$1 % : 'LHVHO $6
Page 1 (1)
Accessories for Hydraulic Tools
MAN B&W Diesel A/S
Plate
P91351-0037
Page 1 (2)
Plate
P91351-0037
Item
No.
010
022
046
058
060
105
117
130
154
166
201
213
225
237
249
Page 2 (2)
Accessories for Hydraulic Tools

Item Description
Item
No.
Item Description
Hydralic pump, pneumatic operated

Hydralic pump, hand operated
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
MAN B&W Diesel A/S
Lifting Tools, Etc.
Plate
P91356-0058
P91356
Lifting
0058 Tools, Etc.
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91356-0058
Item
No.
020
031
043
055
067
079
114
126
138
140
151
163
210
222
234
258
295
305
Lifting Tools, Etc.
Item Description
Forged-bent screw shackle,
Lifting eye bolts, 10mm
Chain tackle, 500kg
Chain tackle, 1000kg
Pull lift, 3000kg
Wire rope, 6m
Page 2 (2)
Item
No.
Item Description
10mm
12mm
16mm
20mm
24mm
30mm
MAN B&W Diesel A/S
Open Ended Spanners
Plate
P91357-0005
P91357
Open
0005 Ended Spanners
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91357-0005
Item
No.
013
025
037
050
Open Ended Spanners
Item Description
Open-ended
Open-ended
Open-ended
Open-ended
Page 2 (2)
spanner,
spanner,
spanner,
spanner,
size
size
size
size
Item
No.
Item Description
NV65mm
NV70mm
NV75mm
NV85mm
MAN B&W Diesel A/S
Open-Ended Slugging Spanners
Plate
P91358-0013
P91358
0013
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91358-0013
Item
No.
127
Item Description
Item
No.
Item Description
Open-ended slugging spanner, size

NV65mm
Page 2 (2)
MAN B&W Diesel A/S
Torque Wrenches
MAN B&W Diesel A/S
Plate
P91359-0003
Page 1 (2)
Plate
P91359-0003
Item
No.
014
026
038
040
051
Page 2 (2)
Torque Wrenches
Item Description
Item
No.
Item Description
Torque wrench, 8 - 400Nm

Adapter for socket wrench, 10 x 12.5
mm
MAN B&W Diesel A/S
Pliers
Plate
P91360-0003
P91360
Pliers
0003
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91360-0003
Pliers
Item
No.
010
021
033
128
130
141
153
Item Description
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Page 2 (2)
for
for
for
for
for
for
for
retaining
retaining
retaining
retaining
retaining
retaining
retaining
ring,
ring,
ring,
ring,
ring,
ring,
ring,
size
size
size
size
size
size
size
Item
No.
Item Description
0.9mm
1.3mm
1.8mm
1.1mm
1.8mm
2.3mm
3.2mm
MAN B&W Diesel A/S
MAN B&W Diesel
Plate
P91361-0052
Page 1 (2)
Plate
P91361-0052
Item
No.
015
027
039
040
052
064
076
088
090
100
111
123
135
147
159
160
172
184
196
206
218
220
231
Page 2 (2)
MAN B&W Diesel
Item Description
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
Item
No.
Item Description
NV10mm
NV11mm
NV12mm
NV13mm
NV14mm
NV15mm
NV16mm
NV17mm
NV18mm
NV19mm
NV21mm
NV22mm
NV24mm
NV27mm
NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
Ring Slugging Spanner
MAN B&W Diesel A/S
Plate
P91362-0064
Page 1 (2)
Plate
P91362-0064
Item
No.
022
034
046
058
060
071
083
095
105
117
129
130
142
Page 2 (2)
Ring Slugging Spanner
Item Description
Item
No.
Item Description
Slugging spanners, ring size

NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
NV65mm
NV70mm
NV75mm
NV80mm
MAN B&W Diesel A/S
Spanners
MAN B&W Diesel
Plate
P91363-0040
Page 1 (2)
Spanners
Plate
P91363-0040
MAN B&W Diesel
Item
No.
Item Description
016
028
030
041
100
150
161
Tool set, complete, size 10-22 mm

Tool set, complete, size 24-46 mm
Hex key tool set, complete
Adapter for socket wrench, 20->12.5 mm
Socket spanner, S=46 mm
Hex key, S=22 mm
Hex key, S=24 mm
Page 2 (2)
Item
No.
Item Description
Open-ended Spanners
Plate
P91364-0059
Page 1 (2)
MAN B&W Diesel A/S
Plate
P91364-0059
Item
No.
011
023
Page 2 (2)
Open-ended Spanners
Item Description
Item
No.
Item Description
Open ring wrench, 14 - 17mm

Open ring wrench, 19 - 22mm
MAN B&W Diesel A/S
Instruments
MAN B&W Diesel A/S
Plate
P91366-0066
Page 1 (2)
Plate
P91366-0066
Item
No.
012
024
036
048
050
061
073
Page 2 (2)
Instruments
Item Description
Item
No.
Item Description
Indicator, complete
Indicator paper
Plainmeter, complete
Autolog, measuring tool for crankshaft
Feeler gauge
Slide caliper
Dial gauge and stand tool
MAN B&W Diesel A/S
Working Platforms
Plate
P91368-0004
P91368
Working Platforms
0004
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91368-0004
Item
No.
013
Working Platforms
Item Description
Item
No.
Item Description
Foot grating, 800 x 250 x 40mm
Page 2 (2)
MAN B&W Diesel A/S

6S 50 MC-C, Vol. II - Maintenance Manual

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Warning

When referring to this page, please quote S900 Edition 0001

Table of Contents, Volume II

MAN B&W Diesel A/S

MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear

908 - Exhaust Valve

910 - Turbocharger System

913 - General Tools

MAN B&W Diesel A/S

Instructions for Main Engines

M/S Nybo 7730 B&W P90201-0036 059

MAN B&W Diesel A/S

General Safety Precautions

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

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:

901 - Cylinder Cover

Cylinder Cover, Data

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Block the starting mechanism

Shut off starting air supply

Engage turning gear

Shut off cooling water

Shut off fuel oil

Shut off lubricating oil

Exhaust valve stud, screwing-in torque

Item No. Description

Grinding tool for exhaust valve seat

1. Set blocking device A on the main starting

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve B.

2. Connect a pressure gauge at minimess

Close valve 420 and open valve 421 on the

Check the pressure.

MAN B&W Diesel

3. Close valve 531 for hydraulic operation of

Dismount the fuel oil high-pressure pipes

5. Remove the exhaust valve high-pressure

6. Remove the protective jacket enclosing the

Dismount the screws in the flange between

7. Place eight spacer rings, one around each

Remove the protective caps from the cylinder cover nuts.

Disconnect the high-pressure hoses from

Relieve the system of pressure.

Lift away the cylinder cover complete, and

MAN B&W Diesel

1. Dismount all valves and pipes on the cylinder cover.

Dismount all studs on top of the cylinder

Remove and discard the O-rings from the

Lift the cylinder cover free of the cooling

4. Lift the cylinder cover and guide the jacket/

MAN B&W Diesel

5. Recondition the valve bores as follows: