s50mc Vol II

Warning
MAN B&W
S900-0002
Warning!
It is important that all MAN 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 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 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 S-Instruction S900
Edition 0002
Page 1 (1)
S50MC
VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
90023
90050
90060
0027
0288
0002
MAN Diesel A/S
Table of Contents, Volume II

Instructions for Main Engine
Checking & Maintenance Schedule
General - Safety Precautions
MAN Diesel A/S
Table of Contents
900
Volume II - Maintenance
No.
Edition
Title
900 - Introduction
Table of Contents
90023 0027 Instructions for Main Engine
90050 0288 Checking & Maintenance Schedule
90060 0002 General - Safety Precautions
901 - Cylinder Cover
101-01 0066 Cylinder Cover, Data
901-01 0246 Cylinder Cover
90151 0210 Cylinder Cover - Panel
90161 0106 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0095 Piston, Data
902-01 0285 Piston
102-02 0062 Piston Rod Stuffing Box, Data
902-02 0230 Piston Rod Stuffing Box
90251 0196 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0074 Cylinder Liner, Data
903-01 0252 Cylinder Liner
103-02 0028 Cylinder Lubricator, Data
903-02 0249 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
904 - Crosshead with Connecting Rod
104-01 0061 Crosshead Bearing, Data
904-01 0251 Crosshead Bearing
104-02 0063 Crosshead, Data
904-02 0250 Crosshead
104-03 0043 Reciprocating Parts, Data
904-03 0216 Reciprocating Parts
104-04 0054 Crankpin Bearing, Data
904-04 0232 Crankpin Bearing
104-05 0053 Connecting Rod, Data
904-05 0233 Connection Rod
90451 0139 Connecting Rod and Crosshead - Panel
90461 0068 Connecting Rod - Hydraulic Tools
90464 0008 Crosshead - Hydraulic Tools
MAN Diesel A/S
Page 1 (4)
Table of Contents
900
No.
Edition
Title
905 - Crankshaft, Thrust Bearing and Turning Gear

90551 0212 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel
90561 0088 Main Bearing - Hydraulic Tools
90562 0130 Crankshaft - Tools
90564 0018 Crankshaft - Measuring Tools
90567 0002 Segment Stopper & Vibration Damper - Tools
90570 0003 Thrust Shaft - Tools
90571 0002 Main Bearing Shell - Tools
906 - Control Gear
106-01 0054 Chain, Data
906-01 0241 Chain
106-02 0059 Chain Tightener, Data
906-02 0231 Chain Tightener
106-03 0039 Camshaft, Data
906-03 0215 Camshaft
106-04 0040 Camshaft Bearings, Data
906-04 0219 Camshaft Bearings
106-08 0002 Camshaft Coupling
906-08 0001 Camshaft Coupling
907 - Starting Air System
107-01 0020 Starting Air Distributor, Data
907-01 0216 Starting Air Distributor
107-02 0042 Start Air Valve, Data
907-02 0214 Starting Air Valve
908 - Exhaust Valve
108-01 0045 High-Pressure Pipe, Data
908-01 0226 High-Pressure Pipe
108-02 0082 Exhaust Valve, Data
908-02 0256 Exhaust Valve
108-03 0052 Exhaust Valve Actuator, Data
908-03 0227 Exhaust Valve Actuator
108-04 0038 Exhaust Valve Roller Guide, Data
908-04 0220 Exaust Valve Roller Guide
108-05 0015 Exhaust Valve Cam, Data
908-05 0216 Exhaust Valve Cam
108-07 0034 Exhaust Valve - Special Running, Data
908-07 0234 Exhaust Valve
90851 0207 Exhaust Valve - Panel
90862 0041 Exhaust Valve - Hydraulic Tools
90863 0014 Exhaust Valve - Extra Tools
90863 0016 Exhaust Valve - Extra Tools
MAN Diesel A/S
Page 2 (4)
Table of Contents
900
No.
Edition
Title
909 - Fuel Oil System

109-01 0063 Fuel Pump Settings, Data
909-01 0241 Fuel Pump Settings
109-02 0005 VIT System, Data
909-02 0206 VIT System
109-03 0050 Fuel Pump Cam, Data
909-03 0233 Fuel Pump Cam
109-04 0058 Fuel Pump, Data
909-04 0222 Fuel Pump
109-05 0063 Fuel Pump Top Cover, Data
909-05 0234 Fuel Pump Top Cover
109-06 0050 Fuel Pump Barrel Assembly, Data
909-06 0219 Fuel Pump Barrel Assembly
109-07 0039 Fuel Pump Suction Valve, Data
909-07 0214 Fuel Pump Suction Valve
109-08 0050 Fuel Pump Puncture Valve, Data
909-08 0217 Fuel Pump Puncture Valve
109-09 0032 Fuel Pump Shock Absorber, Data
909-09 0214 Fuel System Shock Absorber
10910 0018 Lifting Gear Roller Guide, Data
90910 0209 Lifting Gear for Roller Guide
10911 0068 Fuel Valve, Data
90911 0244 Fuel Valve
10912 0047 Spindle Guide, Data
90912 0222 Spindle Guide
10913 0033 Non-Return Valve in Fuel Valve, Data
90913 0207 Non-Return Valve in Fuel Valve
10914 0074 Fuel Oil High-Pressure Pipes, Data
90914 0234 Fuel Oil High-Pressure Pipes
10915 0058 Fuel Pump Roller Guide, Data
90915 0234 Fuel Pump Roller Guide
90951 0441 Fuel Valve and Fuel Pump - Panel
90961 0069 Fuel Valve - Tools
90966 0008 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90977 0001 Mounting Tools - Pump Barrel Seals
90979 0001 Mounting Tools - Suction Valve Seals
90980 0001 Mounting Tools - Air Piston Seals
910 - Turbocharger System
110-01 0047 Air Cooler Element, Data
910-01 0236 Air Cooler Element
110-02 0009 Non-Return Valve after Air Cooler, Data
MAN Diesel A/S
Page 3 (4)
Table of Contents
900
No.
Edition
910-02
110-03
910-03
110-04
910-04
110-06
910-06
91061
91064
91065
0214
0024
0220
0005
0206
0031
0219
0067
0002
0001
Title
Non Return Valve after Air Cooler
Auxilary Blower, Data
Auxilary Blower
Butterfly Valve, Data
Butterfly Valves
Water Mist Catcher, Data
Water Mist Catcher
Turbocharger System - Tools
Travelling Trolley
Exhaust Receiver - Tools
911 - Safety Equipment

111-01 0026 Safety Valve, Data
911-01 0212 Safety Valve
111-02 0013 Relief Valve, Data
911-02 0211 Relief Valve
111-03 0001 Scavenge Air Receiver Safety Valve, Data
911-03 0001 Scavenge Air Receiver Safety Valve
912 - Assembly of Large Parts
112-02 0015 Holding Down & End Chock Bolts, Data
912-02 0208 Holding Down and End Chock Bolts
112-03 0028 Stay Bolts, Data
912-03 0216 Stay Bolts
912-05 0201 Crankcase Oil Outlet
91263 0060 Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
913 - General Tools
913-01 0209 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 0038 Accessories - Hydraulic Tools
91356 0058 Lifting Tools, etc.
91357 0005 Open-Ended 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
MAN Diesel A/S
Page 4 (4)
Instructions for Main Engines
This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and to
describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes,
for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure the
supply of the correct parts for the individual engines:

Name of vessel
Engine No.
built by
Plate No.
Part No.
Quantity required (and description)

Example:

M/S Nybo 7730 B&W P90201-0036 059

10 off (piston ring)
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 Diesel instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN Diesel instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room
personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out
in the Technical File.
This book is subject to copyright protection, and should therefore not, in whole or in part, be copied,
reproduced, made public or in any other way made available to a third party without the written consent of this effect from MAN Diesel.
MAN Diesel A/S

A90023-0028

Teglholmsgade 41

DK-2450 Copenhagen

Denmark

Teleph. : +45 33 85 11 00
Telefax : +45 33 85 10 30
manbw@dk.manbw.com
www.manbw.com
CVR No. 39 66 13 14
MAN B&W
Checking and Maintenance Schedule,

26-70 MC/MC-C Engines
9001
The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the
engine and to carry out overhauls, if necessary,
based on the engine condition or on time criteria.
Design modifications may necessitate a revision of

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

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

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

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

of service are marked with an O, and opposite which, under the
heading Overhaul to be based on procedure No. (column P), a
procedure number is stated.
This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.
Time-based overhauling
procedures
also marked with an O under the headings Normal hours of service or Based on observations, are the procedures where an
actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling intervals
stated as a basis.
Where a symbol O or C is indicated in Based on observations
(column B), this is due to the fact that special service conditions
may make checking or overhauling necessary beyond the actual
standard schedules indicated.
When referring to this page, please quote Maintenance Schedule A90050 Edition 0288
Page of 6
9001
Page of 6
Checking and Maintenance Schedule,

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

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

O : Overhaul to be carried out
H : Check new/overhauled parts after 5001500 hours
Regular Checks
No.
Procedure
901
1
Cylinder Cover
Cylinder cover
Indicator cock
902
1
Piston with Rod and Stuffing box

Piston
Inspection through scavenge ports
Piston rod stuffing box
2
903
1
Daily
Crosshead with connecting rod

Crosshead bearing
Crosshead
Reciprocating parts
Crankpin bearing
Connecting rod
905
2
3
3
4
5
Crankshaft and Thrust Bearing

Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
Electronic axial vibration monitor
Mechanical checking
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x 1000 hours of operation)
Weekly Monthly
12
16
C*
24
32
C,O
C*
Remarks
* Check whenever exhaust valve

is removed
O
O
Cylinder Liner and Cylinder Lubrication

Cylinder liner
Inspection through scavenge ports
Measuring wear inside liner
Cylinder lubricators
Accumulators nitrogen pressure
904
1
2
3
4
5
9001
V
* Check clearances without
dismantling segments
O
C
C
C
C
A
A
V,M
C,O
C,O
C,O
C,O
O
C
C
C
C
C
C
C
C
C
C
C
C
C,O
C,O
C,O
C,O
O
C
C
Bearings should only be

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

opened if bearing material
fragments fall out.
Page of 6


Regular Checks
No.
Procedure
7
8
Tacho pickup
Angle encoder
906
1
2
Mechanical Control Gear

Chains
Chain tightener
Chain wheels, spray nozzles and guide bars
Camshaft
Camshaft bearings
Camshaft coupling, fitted bolts
Moment compensator
Governor
Functional check of overspeed device
Functional check of speed-setting system
(engine with bridge control system)
-3
-4
-5
907
-1
-2
Starting Air System

Starting air distributor
Starting air valve
908
-1
-2
Exhaust Valve
Hith-pressure pipe
Exhaust valve
Conventional hard-faced valve seats
Nimonic exhaust valves
Exhaust valve actuator
Actuator safety valve
Exhaust valve roller guide
Exhaust valve cam
Exhaust valve special running
-3
-4
-5
-7
MAN B&W
9001
Page of 6
Daily
Weekly Monthly
P : Refer to

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

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

camshaft covers
MAN B&W


Regular Checks
No.
Procedure
909
Fuel Oil System

Fuel oil water content
Fuel pump settings
VIT system
Fuel pump cam
Fuel pump
Fuel pump top cover
Fuel pump barrel assembly
Fuel pump suction valve
Fuel pump puncture valve
Fuel pump shock absorber
Fuel system shock absorber
Lifting gear for roller guide
Fuel valve
Fuel nozzle
Spindle guide
Nonreturn valve
Fuel oil highpressure pipes
Fuel pump roller guide
Fuel pump special running
-1
-2
-3
-4
-5
-6
-7
-8
-9
-9
-10
11
12
13
14
-15
16
910
1
2
3
4
5
Turbocharger System
Air cooler
Nonreturn valve
Auxiliary blower
Butterfly valves
Turbocharger turbine
Turbocharger air filter
Protective grid before turbocharger
9001
Daily
P : Refer to
Weekly Monthly
12
16
24
32
A,C
A
A
O
O
R
V
V
Remarks
C,O
C,O
C
C
C
C,O
R
O
O
O
R
O
C*
C*
C
C
C
C*
C
C
C
O
O
O
O
O
O
O
C,O
O
R
* Only inspection through

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


Regular Checks
No.
Procedure
Turbocharger lubricating oil water content

Water mist catcher
911
1
2
3
912
2
3
913
1
MAN B&W
9001
Safety Equipment
Overpressure indicator valve
Relief valve
Scavenge air receiver safety valve
Functional test of alarm system for thrust
bearing and slow down /shut down system
Checking and adjustment of pressure gauge
Checking and adjustment of thermometers
Checking and adjustment of thermostats
Checking and adjustment of pressurestats
Checking and adjustment of turning gear switch
Assembly of Large Parts
Holdingdown and end chock bolts
Stay bolts
Top bracings
Diaphragm in crankcase oil outlet
System lubricating oil water content
System lubricating oil bottom tank
Cooling water quality
Crankcase
General Tools
Hydraulic tools
Page of 6
Daily
Weekly Monthly
P : Refer to

2
12
16
24
32
C*
C*
O
O
O
C
C
C
C
C
A
A
A
A
A
C
C
C
* Only if separate oil system

* Check p
C,O
C
C
C
Remarks
M
M
M
M
M
M
C
C
C
C
M
O
V,M
Empty and clean tank

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

101-01
901-01
90151
90161
0066
0246
0210
0106
MAN Diesel A/S
Cylinder Cover, Data

Cylinder Cover
Cylinder Cover - Panel
Cylinder Cover - Tools
MAN Diesel A/S
101-1
Cylinder Cover
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X
Stopped engine
Shut off safety air supply Not ME engines
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D01-01
Exhaust valve stud, screwing-in torque
680
Nm
D01-02
Starting valve stud, screwing-in torque
175 -195
Nm
D01-03
Fuel valve stud, screwing-in torque
140 -160
Nm
D01-05
Cylinder cover stud, check distance
139 - 140
mm
D01-06
Cylinder cover, complete
1700
kg
D01-07
Cylinder cover without valves
1200
kg
D01-08
Cooling jacket
55
kg
D01-09
Exhaust valve stud
kg
D01-10
Cylinder cover stud
22
kg
D13-01
Hydraulic pressure, mounting
900
bar
D13-02
Hydraulic pressure, dismantling
800 - 990
bar
When referring to this page, please quote Data D10101 Edition 0066
MAN B&W Diesel A/S
Page 1 (2)
101-1
Cylinder Cover
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
Description
P90151
046
Grinding tool for exhaust valve seat
P90151
058
Milling and grinding wheel for fuel valve seat
P90151
060
Milling and grinding wheel for starting valve seat
P90151
083
Grinding handle
P90161
P91351
010
Hydraulic pump, pneumatically operated
P91351
046
Hose with unions (1500 mm), complete
P91351
058
P91351
130
9-way distributor block, complete
Page 2 (2)
MAN B&W Diesel A/S
901-1.2
Cylinder Cover
Dismantling
1. Set blocking device A on the main starting
valve in the BLOCKED position.
1.
F
H
Engage turning gear B.
Close fuel oil inlet valve C.

Close cooling water inlet valve D.
Close cooling water outlet valves E and F.

Open cooling water drain cocks G and H.
Shut off the control air and safety air supply. Vent the manoeuvring system through
the ball valve.
M901010246D01
Also shut off the air supply on the reduction unit for the hydraulic/pneumatic exhaust valve, and vent the system.
When referring to this page, please quote Procedure M90101 Edition 0246
MAN B&W Diesel A/S
Page 1 (10)
901-1.2
Cylinder Cover
Dismantling
2.
2. Remove the cooling water inlet and outlet

pipes from the exhaust valve.
Remove the screws which fasten the cooling water outlet pipe to the cylinder cover.
Dismount the fuel oil high-pressure pipes.
See Procedure 909-14.2.
Dismount the control air pipe from the
starting valve.
M901010246D02
Remove the starting air pipe.
3.
3. Dismount the hydraulic high-pressure pipe,

see Procedure 908-1.2.
Dismount the drain oil pipe between the
exhaust valve and the hydraulic actuator,
the air pipe for the pneumatic exhaust
valve.
4. Remove the plate cover and the insulating
material from the exhaust receiver and intermediate pipe.
Dismount the clamp from the exhaust pipe/
intermediate pipe flanges.
M901010246D03
Remove the protective caps from the cylinder cover nuts.
M901010246D04
4.
Page 2 (10)
MAN B&W Diesel A/S
Cylinder Cover
901-1.2
Dismantling
5. Place eight spacer rings, one around each
nut and screw the eight hydraulic jacks
onto the studs.
5.
Raise the pressure and loosen and remove

the nuts.
D1302
For operation of the hydraulic tools, see
Chapter 913.
Lift away the cylinder cover complete, and

land it on a couple of wooden planks.
7. Remove and discard the sealing ring between cylinder cover and cylinder liner.
M901010246D05
6. Hook the engine room crane on to the lifting attachment on top of the exhaust valve.
M901010246D06
6.
M901010246D07
7.
MAN B&W Diesel A/S
Page 3 (10)
901-1.3
Cylinder Cover
Overhaul
1.
D0109
1. Dismount all valves and pipes on the cylinder cover. See Procedure 907-2.2, 908-2.2
and 909-11.2.
Dismount all studs on the top of the cylinder cover.
2. Unscrew the four screws which secure the
cooling jacket to the cylinder cover.
If the cooling jacket sticks, use dismantling
screws to force the jacket/cover apart.
M901010246O01
Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.
3. Remove and discard the O-rings from the
cover, and carefully clean the cooling jacket
and the cylinder cover.
2.
D0107
Provide the cylinder cover with new Orings, well lubricated with vaseline.
4. Lift the cylinder cover and guide the jacket/
cover into position, using the guide pin as
reference (manoeuvre side).
M901010246O02
Mount and tighten the screws for the cooling jacket.
D0108
M901010246O03
3.
Page 4 (10)
MAN B&W Diesel A/S
Cylinder Cover
901-1.3
Overhaul
5. Recondition the valve bores as follows:
5.
Fuel valve bore

6. The tool consists of a common spindle with
handle, and of a guide, a carbon cutter, a
seating face cutter, and a grinding mandrel.
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.
M901010246O04
Clean the fuel valve bores, using the carbon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.
6.
7. Exhaust valve bore
The tool consists of a spindle with handle
and a grinding disc.
After the grinding, clean the bore and seating carefully, and check that the seating is
not damaged.
M901010246O06
After cleaning the valve bore and seating,

grind the seating with the grinding disc and
a grinding compound (e.g. Carborundum
No. 200).
M901010240O07
7.
MAN B&W Diesel A/S
Page 5 (10)
901-1.3
Cylinder Cover
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.
M901010246O08
9. Clean the bores for safety valve/indicator

cock.
M901010246O09
9.
Page 6 (10)
MAN B&W Diesel A/S
901-1.3
Cylinder Cover
Overhaul
10. Lubricate the threads with Never Seize' or
Molybdenum Disulphide (MoS2) and mount
the valve studs.
1.
D0101
Tighten up the studs in accordance with

the screwing-in torque stated on the data
sheet.
D0103
Fill up the grooves between the valve studs

and the bores for the valve studs with
permatex to prevent water from entering
the bores during operation of the engine.
M901010246O10
Always fit new or overhauled valves before

a cylinder cover is mounted on the engine.
D0102
MAN B&W Diesel A/S
Page 7 (10)
901-1.4
Cylinder Cover
Mounting
1. Place a new sealing ring on top of the cylinder liner.
1.
2. Lift the cylinder cover by means of the

crane and carefully wipe the contact surface which faces the cylinder liner.
Provide the cooling water connecting pipes
with new O-rings and lubricate them with
grease or soft soap.
M901010246M01
Mount a new klinger sealing ring in the

groove of the flange of the intermediate
pipe.
Lower the cover carefully into position.
During the landing, carefully check that the
cooling water connecting pipes engage
correctly with the holes in the cooling
jacket.
2.
M901010246M02
D0106
Page 8 (10)
MAN B&W Diesel A/S
901-1.4
Cylinder Cover
Mounting
3. If cylinder cover studs have been removed
and remounted, check the distance the
stud is protruding from the cylinder cover.
3.
D0105
If necessary, adjust to the distance D01-05

by turning the stud.
4. Mount all eight nuts on the studs and
screw them down to the cylinder cover.
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 the increase the
pressure as stated in Data.
M901010246M03
Place eight spacer rings, one around each

nut, and mount the eight hydraulic jacks on
the studs.
4.
For operation of hydraulic jacks, see Procedure 913-1.
D1301
5. When mounting the clamp connecting the

compensator and the intermediate pipe/exhaust valve it may, in some case, become
necessary to use the engine room crane.
Clean the flanges and the clamp ring carefully and lubricate all contact faces with
Molycote.
M901010246M04
Remove the hydraulic jacks and the spacer

rings.
M901010246M05
5.
MAN B&W Diesel A/S
Page 9 (10)
901-1.4
Cylinder Cover
Mounting
6.
6. Mount the insulating jacket around the intermediate pipe.

7. Mount the return oil pipe and the air pipe
for pneumatic closing of the exhaust valve.
8. Mount the high-pressure pipe for the hydraulic valve gear.
M901010246M06
Mount the starting air pipe and control air

pipe for the starting valve.
Mount the cooling water inlet and outlet
pipes on the exhaust valve.
Mount the drain pipe on the intermediate
pipe between the exhaust valve and the
cylinder cover.
7.
Using a crowfoot wrench and torque spanner, mount the fuel oil high-pressure pipes.
Connect the outlet pipe from the return oil
pipe on the fuel valves.
M901010246M07
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.
8.
Open the fuel oil, lubricating oil and air

supplies to the alarm system.
Caution!
The air supply to the exhaust valve must
always be connected before turning on
the oil supply to the exhaust valve actuator.
M901010246M08
This is very important, because otherwise the valve will open more than intended.
Page 10 (10)
MAN B&W Diesel A/S
Cylinder Cover Panel
When referring to this page, please quote Plate P90151 Edition 0210
MAN B&W Diesel A/S
Plate
P90151-0210
Page 1 (2)
Plate
P90151-0210
Item
No.
010
022
046
058
060
071
083
095
105
117
130
201
Page 2 (2)
Cylinder Cover Panel
Item Description
Item
No.
Item Description
Panel for tools

Name plate
Grinding tool for exhaust valve seat
Milling and grinding wheel for fuel
valve
Milling and grinding wheel for starting
valve
Dismantling lever for fuel valve
Handle
Grinding ring for starting valve
Spanner for starting valve
Pressure tester for safety valve
Lifting chains
Handle
MAN B&W Diesel A/S

MAN B&W
When referring to this page, please qoute Plate P90161 Edition 0106
Plate
P90161-0106
Page 1 (2)
Plate
P90161-0106
Item
No.
027
039
052
064
088
090
100
206
Page 2 (2)

MAN B&W
Item Description
Hydraulic jack cylinder cover

Support
O-ring with back-up ring
Tommy bar
Spanner
Stud setter
Hydraulic tool kit, complete

102-01
902-01
102-02
902-02
90251
90261
90264
90266
0095
0285
0062
0230
0196
0108
0002
0002
MAN Diesel A/S
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 - Lifting Tools
MAN Diesel A/S
Piston
MAN B&W Diesel
102-1
Data

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

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D01-05
Cylinder cover stud, check distance
D02-01
Test pressure
D02-02
Value
Unit
139 - 140
mm
bar
Piston rod/crosshead, tightening torque
430
Nm
D02-03
Piston rod/crown, tightening torque
300
Nm
D02-05
Piston skirt, tightening torque
80
Nm
D02-06
Cooling oil pipe, tightening torque
80
Nm
D02-07
Piston rod/crosshead, tightening torque+angle
D02-08
Piston ring new, radial width
17,2
mm
D02-09
Piston ring worn, min. radial width
14,2
mm
D02-10
Groove No.1, max. vertical height
13,2
mm
D02-11
Groove Nos. 2, 3 and 4, max. vertical height
10,2
mm
D02-12
Piston top, max. permissible burn-away
15
mm
D02-13
Piston ring new, height of ring No. 1
12,4
mm
D02-14
Piston rings new, height of ring Nos. 2, 3 and 4
9,4
mm
D02-46
CPR ring CL groove, min. depth
1,1
mm
D02-15
Minimum free ring gap ( before dismantling )
25
mm
D02-16
Minimum ring gap, ring No. 1 ( new ring in new liner )
3,4
mm
D02-17
Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner )
2,4
mm
D02-18
Vertical clearance, new parts
0,38
mm
D02-19
Vertical clearance, worn parts, max.
0,87
mm
D02-20
Piston complete
900
kg
D02-21
Piston crown
210
kg
D02-22
Piston rod
550
kg
D02-23
Piston skirt
60
kg
D02-24
Piston cooling pipe
20
kg
D02-25
Lifting tool, tightening torque
100
Nm
100/54
Nm/
Page 1 (2)
Piston
102-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P90251
075
Template for piston top
P90251
087
Distance piece for stuffing box
P90251
099
Cover for stuffing box hole
P90251
110
Pressure test tool for piston
P90251
134
Piston ring expander
P90251
158
Guide screw for piston crown
P90261
P90265
Piston and Piston Rod - Support Tools
P90266
Page 2 (2)
Piston
MAN B&W Diesel
902-1.1
Checking
Scavenge Port Inspection
1.
To detect possible leakages from the piston

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

begin with a unit arriving downwards, just
above the scavenge air ports. Inspect the
piston rod and the lower part of the cylinder wall.
While the piston is passing downwards, inspect the piston skirt, all the piston rings,
the ring lands and the piston top.
M902010280C01
1. The scavenge port inspection is carried out

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

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

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

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

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

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

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

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

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

give access to the piston rod stuffing box
and the piston rod/crosshead connection.
Page 5 (22)
902-1.1
Piston
Dismantling
2.
MAN B&W Diesel
2. Telescopic pipe:
Loosen and remove the screws which
tighten the telescopic pipe to the bend.
Remove one screw from the telescopic
stuffing box housing and mount the special
tool for suspending the telescopic pipe or
use the thread in the telescopic pipe stuffing box housing.
Turn the crosshead to TDC. Suspend the
telescopic pipe by means of the tool.
Turn the crosshead downward and remove
the distance pipe from the bend.
Note!
M902010280D02
When a piston is dismantled, never turn

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

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

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

Remove the screws from the piston rod.
M902010280D03
Note!
M902010285D04
4.
Page 7 (22)
902-1.1
Piston
Dismantling
5.
MAN B&W Diesel
5. Stuffing box distance pieces:

Mount the two distance pieces on the piston rod foot to protect the lower scraper
ring and to guide the stuffing box.
Preparations on the cylinder top
6. Cylinder cover:
Remove the cylinder cover. See Procedure
901-1.2.
Make a scratch mark in liner and piston
cleaning ring to ensure correct re-mounting.
Remove the piston cleaning ring.
M902010280D05
Carefully remove any wear ridges at the

top of the cylinder liner. See Procedure
903-1.3.
M902010285D06
6.
Page 8 (22)
Piston
MAN B&W Diesel
902-1.1
Dismantling
7. Piston lifting tool:

Turn the piston to TDC. The top of the piston is now free of the cylinder liner.
7.
D0225
Clean the lifting groove of the piston crown

and mount the lifting tool.
Note!
Limited lifting high:

If the engine not is equipped with long distance pieces, remove one or two cylinder
cover studs, using a stud setter.
M902010285D07
Make sure to mount the lifting tool correctly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.
Page 9 (22)
Piston
902-1.1
Dismantling
MAN B&W Diesel
Piston lift
8.
8. Lift the piston out of the cylinder liner and
guide the piston rod foot through the stuffing box flange.
If the engine is equipped with long distance
pieces for the stuffing box, the piston rod
foot can pass between two cylinder cover
studs.
Place the two halves of the support around
one of the openings in the platform. Lower
the piston rod foot and stuffing box
through the opening in the platform. Secure
the two support halves with screws and
lower the piston on the support. Check the
piston is resting on the piston rod flange.
M902010285D08
D0220
Page 10 (22)
Piston
MAN B&W Diesel
902-1.1
Dismantling
9. Protect the crosshead bearing:
9.
Place a cover over the opening for the piston rod stuffing box in the bottom of the
cylinder unit.
Turn the crosshead down far enough to
permit mounting of the protective rubber
cover on the crosshead bearing cap. The
protective rubber cover is found on tool
panel 904.
The covers must remain in place to protect
the crosshead bearing journal from impurities until the piston is remounted.
M902010285D09
Clean, measure and recondition the cylinder liner. See Procedure 903-1.
Page 11 (22)
Piston
902-1.1
Overhaul
1.
D0220
MAN B&W Diesel
1. Piston support:
Place the piston in the support and remove
the piston lifting tool.
Clean the piston top and the piston rings.
Check the free ring gap and the burn-off
on the piston top. See Procedure 902-1.1.
Remove the stuffing box. See Procedure
902-2.3.
M902010285O01
2. Piston ring dismantling:

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

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

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

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

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

the piston rod, then remount the cooling oil
pipe, see Data.
Check that the surfaces of the O-ring
groove is clean and smooth.
5. Piston crown dismantling and cleaning:

Place the piston crown with skirt on a
wooden support as shown.
M902010280O04
Mount a new O-ring on the piston rod

flange.
D0222
5.
D0223
Remove the locking wire and the screws in

the skirt. If necessary use two dismantling
screws to pull the skirt out of the piston
crown. Mount two eye bolts in the skirt. Lift
the skirt and land it on a couple of planks.
Thoroughly clean and inspect all parts of

the crown and skirt. If coke deposits are
found in the cooling spaces of the piston
crown, they should be washed clean with
Carbon Remover or a similar cleaning fluid.
When all coke deposits have been dissolved, clean and inspect the piston crown
again.
M902010284O05
Discard the sealing ring on the piston skirt.
Note!
Coke deposits reduce heat transfer from
the piston crown to the cooling oil. The
deposits must be removed as a routine
procedure when a piston is overhauled.
Page 13 (22)
Piston
902-1.1
Overhaul
MAN B&W Diesel
6. Piston crown assembly:

Mount a new O-ring on the piston skirt.
Check that the surfaces of the O-ring
groove are clean and smooth. Coat the ring
with lubricating oil before mounting.
6.
D0205
Mount the piston skirt on the piston crown.

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

Mount the guide screw to ensure the correct positioning of the piston rod in relation
to the piston crown.
Lubricate the O-ring on the piston rod
flange with lubricating oil.
7.
Land the overhauled piston crown and skirt

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

8.
8. Sealing ring test:

Mount the pressure-testing tool on the piston rod foot. Connect compressed air to
the testing tool and fill the piston to 4-5
bar. Close the valve on the testing tool and
remove the air connection. The piston must
now hold the pressure for minimum 30
minutes.
Spray a little soap water on to the surface
joints between piston rod/crown/skirt and
around the bolt heads to detect leaks.
M902010277O16
According to current class rules, the piston

must be pressure tested hydraulically. It is
possible to carry out a test of the sealing
rings with compressed air before filling the
piston with oil. The sealing ring test can
also be carried out when the piston is resting in the support tool.
9.
D0201
Dry off all soap water.

9. Pressure test:
For this test, the piston must be turned upside down (see next step to turn a complete piston).
M902010277O17
Fill the piston and piston rod with lubricating oil. Mount the pressure-testing tool on
the piston rod foot. Pressure-test the piston at the pressure stated on the Data
Sheet. Check the contact surfaces of the
piston and the sealing rings for tightness.
Check that there are no cracks in the piston crown.
oil
Turn the piston upside up and drain out the

piston oil.
Page 15 (22)
902-1.1
Piston
Overhaul
10.
MAN B&W Diesel
10. Piston turning:

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

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

Fit the new piston rings (alternately righthand and left-hand cuts, with the ring gaps
staggered 180 and with the TOP mark upwards), using the ring expander.
11.
A
B
When mounting the piston rings, use the

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

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

Ensure that the stuffing box is correctly positioned over the distance pieces mounted
on the piston rod foot. Both the holes for
the flange and the drain hole for the drain
pipe must be positioned correctly.
M902010277M02
2.
Page 18 (22)
Piston
MAN B&W Diesel
902-1.1
Mounting
Preparation of cylinder liner

3.
3. Mount the guide ring:
Mount the guide ring in the top of the cylinder liner. The cut outs for the lifting tool
must be turned to fit the piston lifting tool.
4. Stuffing box cover:
Remove the cover from the piston rod
stuffing box opening in the bottom of the
cylinder unit.
5. Crosshead position:
Turn the crosshead to a position 45 from
TDC (crank web pointing towards exhaust
side).
M902010283M03
Clean the stuffing box flange.
M902010277M05
4.
M902010277M06
5.
45
Page 19 (22)
Piston
902-1.1
Mounting
MAN B&W Diesel
Mounting of piston
6.
D0220
6. Coat the O-rings of the stuffing box and
the piston rod with oil. Coat the piston
rings and cylinder liner with cylinder lubricating oil.
M902010285M06
Lower the piston into the cylinder liner

while guiding the piston rod foot through
the cut-out in the stuffing box flange until
the piston rings are inside the liner.
7.
7. Protective cover:
Remove the protective rubber cover from
the crosshead.
8. Crosshead alignment:
Turn the crosshead almost to TDC, while
checking that the guide ring of the crosshead enters the centre hole in the piston
rod.
M902010285M07
After turning the crosshead fully to TDC,

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

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

Remove the distance pieces from the piston rod foot.
10. Tightening of the piston rod-crosshead
connection:
Mount and tighten the piston rod screws.
Tighten the screws to the specified torque
and lock with locking wire.
See Data. Use either Data D02-02 or Data
D02-07.
M902010280M09
On engine models where the drain pipe is

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

pipe is landed on the distance pipe.
11.
M902010280M11
Remove the suspending tool and mount

the screws and tighten the telescopic pipe
to the bend.
For data, see Procedure 904-2.
M902010285M10
11. Telescopic pipe

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

Mount the piston cleaning ring in accordance with the scratch mark. If the PC-ring
is damaged (broken or cracked), it must be
replaced by another ring.
See Procedure 903-1.
12.
M902010285M12
13. Cylinder cover studs:

If the cylinder cover studs have been removed, remount them. Carefully clean the
surfaces around the base of the studs and
check the O-rings on the studs.
Mount the cylinder cover studs with the
stud setter. Screw the stud down to contact and half a revolution back.
14. Cylinder cover:
Land the cylinder cover on the liner and
check the distance that the stud is protruding from the cylinder cover. If necessary,
adjust the distance D01-05 by turning the
stud.
13.
Tighten the cylinder cover nuts and mount

the necessary pipes.
M902010277M15
15. Running-in:
Smear the piston rod with molybdenum
disulphide, and turn the crankshaft a
couple of revolutions.
At the first opportunity, start the engine
and keep it running for about 15 minutes at
a speed corresponding to Dead Slow
Ahead.
14.
Then stop the engine and inspect the piston rod and stuffing box.
M902010280M14
D0105
Page 22 (22)
102-2

Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
Value
Unit
D02-26
Stuffing box flange, outer screws tightening torque
80
Nm
D02-27
Stuffing box flange, inner screws tightening torque
80
Nm
D02-28
Stuffing box halves, tightening torque
80
Nm
D02-29
Uppermost rings, ring-end clearance
4x6
mm
D02-30
Lowermost rings, ring-end clearance
3x3
mm
D02-34
Sealing ring springs new, free length
639
mm
D02-38
Scraper ring springs new, free length
496
mm
D02-44
Stuffing box complete
65
kg
D02-45
Stuffing box half
20
kg
D02-50
Stuffing box halves fitted bolts, tightening torque
25
Nm
When referring to this page, please quote D10202 Edition 0062

MAN B&W Diesel A/S
Page 1 (2)
102-2

Data
Plate
Item No.
Description
P90251
109
Mounting tool for stuffing box spring
P90251
122
Worktable for stuffing box
Page 2 (2)
MAN B&W Diesel A/S
902-2.1

Checking
1. After the piston rod stuffing box has been

dismantled, check the following clearances:
1.
Uppermost scraper ring and sealing rings

Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D02-29)
D0229
B
Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends.
Total clearance. (D02-30)
D0230
A
As a general guide, it is recommended

depending on the overhauling intervals and
ones own experience to replace sealing
rings and scraper rings when the specified
clearance values D02-29 and D02-30 have
been halved.
2. Garter springs:
M902020230C01
The ring clearances stated in Data apply to

new rings.
D0229
2.
D0230
D0234
Generally, it is recommended to renew the

springs when the sealing rings and scraper
rings are renewed.
The springs can be checked as follows:
Place the springs on the table, measure Lo
(free length), and compare with Data. If a
spring is extended more than 8% from the
value given in data, it must be discarded.
M902020227C02
D0238
MAN B&W Diesel A/S
Page 1 (10)
902-2.2

Dismantling
1.
In connection with dismantling of the piston,

only the innermost screws in the stuffing box
flange and the screws for the drain oil pipe
should be removed.
If, in the period between piston overhauls, it
becomes necessary to inspect the piston rod
stuffing box, proceed as follows:
1. Turn the crosshead to about 90 from TDC.
M902020229D01
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.
M902020230D02
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.
M902020230D03
3.
Page 2 (10)
MAN B&W Diesel A/S
902-2.2
Dismantling
4. Remove the two long dismantling screws
from the worktable.
4.
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.
5.
M902020229D05
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.
M902020230D04
5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame
bottom.
M902020230D05
6.
MAN B&W Diesel A/S
Page 3 (10)
902-2.3

Overhaul
Normally, overhaul of the piston rod stuffing
box is carried out by routine methods in connection with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a
support placed over one of the cut-outs in the
top platform.
Work on the stuffing box is then carried out
from the platform below.
M902020230O04
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.
M902020230O01
D0244
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.
Remove the nuts from the stuffing box assembling bolts.
M902020230O02
2.
Page 4 (10)
MAN B&W Diesel A/S
902-2.3

Overhaul
3. Take out the six bolts, and pull away one
stuffing box half.
3.
Mount two eye bolts on the stuffing box

half and remove it from the worktable.
D0245
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.
Dismantle and stack the rings in the same
order as when fitted in the stuffing box.
M902020230O03
5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.
7.
D0234
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.
D0238
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.
M902020227C02
7. Check the lengths of the springs.

8.
M902020230O08
9. Clean the halves of the stuffing box housing.
MAN B&W Diesel A/S
Page 5 (10)
902-2.3

Overhaul
10.
A
B
C
10. Lubricate the piston rod (in the area where

all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS2).
For correct mounting of the sealing and
scraper rings see the sketch. The scraper
ring in groove no. 4 must be without relief
grooves on the underside.
Scraper
ring
A
Scraper
ring
B
Sealing
ring
M902020230O10
No relief
groove
Page 6 (10)
Relief
groove
MAN B&W Diesel A/S
902-2.3
Overhaul
11. Assemble all the stuffing box ring units
round the piston rod, on the worktable, in
the following way:
11.
Place the lowermost scraper ring segments on the worktable.

Place the spring round the segments,
and hook the spring ends together.
On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).
Assemble the 8-part sealing ring so that
the two guide pins face upwards, place the
spring round the segments and, hook the
spring ends together.
M902020229O11
Repeat this procedure for the remaining

scraper rings.
12.
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.
12. Use the stuffing box half on the worktable

to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. Subsequently, push the stuffing box half into contact with the piston rod, round the ring
units.
M902020230O12
Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
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.
MAN B&W Diesel A/S
Page 7 (10)
902-2.3

Overhaul
13. Check the ring clearance again.
13.
Then place the other half of the stuffing

box housing on the worktable, pushing it
into place round the rings.
D0228
In the middle holes mount and tighten up

the fitted bolts to the torque specified on
the Data Sheet, See Data D02-50
D0250
14. Mount eye bolts and wire ropes, and lift

the stuffing box a little.
M902020230O13
14.
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.
D0244
Remove wire ropes and screws.
M902020230O14
Mount and tighten the standard bolts to

specified torque, See Data D02-28
Page 8 (10)
MAN B&W Diesel A/S
902-2.4
Mounting
1. In connection with mounting of the piston,

only the innermost flange screws are to be
mounted and tightened, see data.
1.
After overhauling the stuffing box inside the

engine, assemble the stuffing box halves
on top of the four screws.
Turn down the short screws so that the

stuffing box lands on the flange.
2. Turn the piston upwards until the stuffing
box is in place in the cylinder frame.
M902020230M01
Mount the two long screws from the worktable in the stuffing box.
Note!
Make sure that the two guide pins in the
flange enter the guide holes in the bottom of the cylinder frame.
2.
M902020230M02
3. Mount two screws in the flange through the

holes in the worktable.
M902020230M03
3.
MAN B&W Diesel A/S
Page 9 (10)
902-2.3

Overhaul
4. Remove the long screws from the stuffing
box and mount them itheworktable.
4.
Remove the worktable from the piston rod.

5. Mount the drain oil pipe.
Mount and tighten all the inner and outer
screws for the stuffing box. See Data.
M902020230M04
6. Remove the protecting rubber cover from

the piston rod/crosshead.
Smear the piston rod with molybdenum
disulphide.
Then turn the crankshaft a couple of revolutions.
5.
If possible: Start up the engine and keep it

running for about fifteen minutes at a number of revolutions corresponding to very
slow or idle speed.
M902020230M05
Then stop the engine and inspect the piston rod and stuffing box.
D0226
D0227
M902020229D01
6.
Page 10 (10)
MAN B&W Diesel A/S
Piston and Piston Rod Panel
MAN B&W Diesel A/S
Plate
P90251-0196
Page 1 (2)
Plate
P90251-0196
Piston and Piston Rod Panel
Item
No.
Item Description
014
026
040
051
075
087
099
109
110
122
134
158
160
Tool panel
Name plate
Lifting tool for piston rod foot
Lifting tool for cylinder liner
Template for piston top
Distance piece
Cover for stuffing box hole
Mounting tool for stuffing box springs
Pressure test tool for piston
Worktable for stuffing box
Piston ring expander
Guide screw for piston crown
Screw
Page 2 (2)
Item
No.
Item Description
MAN B&W Diesel A/S

MAN B&W
Plate
P90261-0108
Page 1 (2)
Plate
P90261-0108
Item
No.
019
Page 2 (2)
MAN B&W
Item Description
Guide ring for piston

MAN B&W
Plate
P90264-0002
Page 1 (2)
Plate
P90264-0002
Item
No.
015
027
Page 2 (2)

MAN B&W
Item Description
Lifting collar
Support for tilting tool

MAN B&W
Plate
P90266-0002
Page 1 (2)
Plate
P90266-0002
Item
No.
016
Page 2 (2)
MAN B&W
Item Description
Lifting tool for piston

103-01
903-01
103-02
903-02
90361
90362
90364
0074
0252
0028
0249
0084
0002
0004
MAN Diesel A/S
Cylinder Liner, Data

Cylinder Liner
Cylinder Lubricator, Data
Cylinder Lubricator
Cylinder Liner - Tools
Cylinder Liner - Milling Tools
Test Equipment for Lubricators
MAN Diesel A/S
103-1
Cylinder Liner
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
Value
Unit
D03-01
Lifting tool screws, tightening torque
150
Nm
D03-03
Cylinder diameter, new
500
mm
D03-04
Piston cleaning ring diameter, new
498.3
mm
D03-05
Cylinder liner, complete
1600
kg
D03-06
Cooling jacket
130
kg
D03-16
Piston cleaning ring radial width, new
38.9
mm
D03-17
PC-ring/Liner max. wear deviation
0.50
mm
D03-18
PC-rings replacement criteria:
Liner
diameter
500 mm
Liner wear
Install :
Standard PC-ring (new or
max.diameter wear of
0,50 mm)
0-
0,50 mm
0,50 -
1 mm
Oversize PC-ring
>
1 mm
Dummy ring
MAN B&W Diesel A/S
Page 1 (2)
103-1
Cylinder Liner
Data
Plate
P90251
P90361
Page 2 (2)
Item No.
051
Description
Lifting tool for cylinder liner
MAN B&W Diesel A/S
Cylinder Liner
903-1.1
Checking
Cylinder Liner
S60MC
0252
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.
GM903-1.1 218 02
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.
HM903-1.1 252 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 tools to the torque
stated in Data.
HM903-1.2 252 01
Mount the two lifting tools 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.
HH903-1.2 239 03
2. Disconnect the oil pipes leading from the

cylinder lubricator to the non-return valves.
MAN B&W Diesel A/S
Page 3 (10)
Cylinder Liner
903-1.2
Dismantling
3.
3. Attach the crane hook to the lifting crossbar.
D03-05
Hook the chains from the lifting tools on to

the crossbar and lift the cylinder liner with
the cooling jacket out of the cylinder frame.
Note!
Low lifting height in the engine room may
require the removal of one or more cylinder cover studs before dismantling the
cylinder liner.
4. Land the cylinder liner vertically on, for instance, a couple of planks.
HM903-1.2 252 03
Clean the cylinder frame internally, paying

special attention to the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Dismount the four cooling water pipes between the cooling jacket and the cylinder
frame and clean them carefully.
5.
5. The lifting screws are also used for transporting the cylinder liner.
Note!
The cylinder liner is not in balance, even
with the cooling jacket mounted.
HM903-1.2 252 05
To keep the liner in a horizontal position

during transportation, use e.g. a wire
rope connected from the scavenge ports
to the traverse, as shown on the sketch.
Page 4 (10)
MAN B&W Diesel A/S
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.
Remove the two lifting screws from the cylinder liner.
HM903-1.3 252 01
Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
Remove the four clamps which fix the cooling jacket to the cylinder liner.
2.
HM903-1.3 252 02
3. Lift the cooling jacket away by means of the

tackles, and land it on the wooden planks.
3.
HM903-1.3 252 03
D03-06
MAN B&W Diesel A/S
Page 5 (10)
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.
5. It is recommended to use a wear ridge milling machine to create the groove. For use
of the milling machine, see suppliers instruction.
HN903-1.3 221 04
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.
5.
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.
The maximum depth of the groove is calculated as S max. = D x 0.0045.
Note!
6.
It is of the utmost importance that the

groove is made with a regular rounding
as shown in the sketch.
S
R=4-5 mm
MN903-1.3 229 05
Page 6 (10)
MAN B&W Diesel A/S
Cylinder Liner
903-1.3
Overhaul
7.
7. Replace the two uppermost O-rings on the

cylinder liner. Lubricate the O-rings with
vaseline.
8. Lower the cooling jacket on to the cylinder
liner.
Note!
9. Mount the four clamps in the groove of the

liner, and tighten the screws.
HM903-1.3 252 04
Make sure that the scratch marks in the

fuel pump side of the cylinder liner and
cooling jacket coincide.
Remove the tackles from the lifting crossbar and the cooling jacket lifting eye bolts.
8.
HM903-1.3 252 08
D03-06
HM903-1.3 252 09
9.
MAN B&W Diesel A/S
Page 7 (10)
903-1.3
Cylinder Liner
Overhaul
10. Mount the non-return valves for cylinder lubrication. Tighten the nuts and connect the
lubricating oil pipes.
HM903-1.3 252 10
10.
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 tools in the cylinder liner. See Data D03-01.
Hook the chains from the lifting tools onto
the crossbar, and lift the jacket/liner assembly.
Mount the lowermost O-rings and apply a
little lubricating oil on the rings.
D03-01
2. Check that the joint surfaces on the cylinder

frame and cylinder liner are completely
clean.
Coat the joint surfaces with permatex or a
similar liquid sealing compound.
Mount the cooling water pipes in the cylinder frame.
HM903-1.4 252 01
Mount new O-rings on the four lowermost

cooling water pipes.
Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the uppermost water connections and mount the water connections on the cooling jacket.
2.
D03-05
HM903-1.4 252 02
3. Remove the lifting tools from the cylinder

liner.
MAN B&W Diesel A/S
Page 9 (10)
903-1.4
Cylinder Liner
Mounting
4.
4. Connect and tighten the oil pipes for the

cylinder lubrication.
Vent the cylinder lubricating system until
oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.
When this is in order, check that each individual lubricating point functions correctly.
HM903-1.4 252 04
5. Lubricate the upper part inside of the cylinder liner with cylinder lubricating oil and
mount the piston and the PC ring.
7.
6. If one or more cylinder cover studs have

been removed, mount them again.
7. Mount the sealing ring and the cylinder cover.
GN901-1.4 203 01
Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.
Page 10 (10)
MAN B&W Diesel A/S
103-2
Cylinder Lubricators
Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
D03-10
Inlet accumulator, nitrogen pressure,
30
bar
D03-11
Outlet accumulator, nitrogen pressure,
1.5
bar
D03-13
Plug screw, tightening torque,
30
Nm
MAN B&W Diesel A/S
Page 1 (2)
103-2
Data
Plate
P90364
Page 2 (2)
Item No.
Description
Test Equipment for Lubricators
MAN B&W Diesel A/S
MAN B&W Diesel
903-2.1
Checking
Check of Oil Injection:

1.
With stopped engine and normally when the
system has been disassembled:
1. Press the ESC + PRELUB.-button on the
HMI control panel, and check that all lubricators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.
2. If the cylinder cover or the exhaust valve is
removed, check inside the liner that all lubricating points are working properly.
Otherwise, remove the covers for scavenge
port inspection.
M903020245C01
Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
source that all lubrication points are working properly.
M903020245C02
3.
Page 1 (12)
903-2.1
Checking
MAN B&W Diesel
With running engine:

4.
3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator.
Inlet
The LEDs give signal when oil is injected.

Check the pressure shocks from the injection of the lubricators on each lubricator
pipe by feeling with a hand.
M903020249C03
D0311
5.
D0310
If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow.
Check of Accumulators:
4. Measuring the nitrogen pre-pressure can
only be done with stopped engine and
pressure-free lubrication system.
Stop both oil pumps. Close the inlet valve
and open the equalizing valve on the respective lubricator.
M903020245C05
The nitrogen pressure in the inlet accumulator (0.7 litre) can be checked without dismounting the accumulator. For use of the
pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the
outlet accumulator (0.16 litre), the accumulator or the lubricator with accumulator
must be dismounted.
For nitrogen pressure in the accumulators,
see Data.
Page 2 (12)
Checking
6. Use of Pressure Setting Tool

Assemble the pressure setting tool as
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor.
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7
litre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumulator (0.16 litre) is to be checked.
7. Before mounting the filling valve on the accumulator, check that the accumulator top
is clean.
Mount the filling valve on the relevant accumulator with the union nut. Check that
valves C and F are closed.
7.
D0313
B
M903020247C07
MAN B&W Diesel
903-2.1
Loosen the plug screw in the accumulator

using a square drive handle in socket E.
It is now possible to read the actual nitrogen pressure in the accumulator on the dial
gauge on the filling valve.
8. If the accumulator needs to be refilled with
nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in
Data.
Open valve C until the accumulator is filled
to the correct pressure.
Close valve C and tighten the plug screw
with socket E to the torque stated in Data.
Release the pressure in the filling valve at
bleed screw F.
Unscrew the filling valve from the accumulator. Retighten the plug screw to the
torque stated in Data. Remount the accumulator.
Page 3 (12)
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.
Inlet
1. Close the supply valve for the lubricator

and open the equalizing valve (turn both
handles to a horizontal position). Remove
the upper shield, if installed.
M903020249D01
Disconnect the electrical plug on the side

of the lubricator.
2.
2. Unscrew the six screws in the bottom of

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

secure the lubricator to the hydraulic block,
and remove the lubricator.
Special running
M903020249D02
It is possible to change a lubricator while the

engine is running if a spare lubricator with Orings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
Reduce the engine load to below 40%
of MCR
Let the lubricator pump station run
Dismount the lubricator as described in
steps 1-3
Mount a spare lubricator as described
in Procedure 903-2.4.
Page 4 (12)
MAN B&W Diesel
903-2.2
Dismantling
Dismantling of accumulators:
5.
4. The engine must be stopped and blocked
before the accumulator is dismounted.
Inlet
Stop the cylinder oil pump station.

Close the supply valve for the lubricator
and open the equalizing valve.
When the oil pressure is released, a nitrogen pre-pressure of 25-30 bar will remain in the accumulator.
M903020249D04
Note!
Carefully unscrew the accumulator to release the remaining oil pressure in the system. Remove the accumulator from the hydraulic block.
Page 5 (12)
903-2.3
Overhaul
1.
MAN B&W Diesel
1. Place the lubricator in a bench vice with

soft jaws.
Remove the adjusting screw with bushings.
Unscrew the oil accumulator.
Discard the O-ring from the adjusting
screw.
2. Remove the screws from the cylinder
block.
M903020247O01
3. Pull up the cylinder block.

Remove the spring and actuator piston
with plungers.
Remove and discard the O-ring from the
cylinder block.
2.
M903020247O02
Remove the cover for the non-return

valves. Take out springs and balls. Remove
and discard the O-rings.
M903020247O03
3.
Page 6 (12)
MAN B&W Diesel
903-2.3
Overhaul
4. Screw out the non-return valves and remove and discard the O-rings.
4.
Clean the valves and check them with

compressed air.
5. Inspect the plungers, actuator piston and
cylinder block for wear, using a magnifying
glass.
Mount the non-return valves in the cylinder

block.
M903020247O04
6. Fit the non-return valve with new O-rings.
M903020247O05
5.
M903020247O06
6.
Page 7 (12)
903-2.3
Overhaul
7.
MAN B&W Diesel
7. Pre-assemble the cylinder blockwith the

actuator piston and plungers to ensure the
correct guidance of the plungers, before finally assembling the cylinder block unit.
Mount the spring and press down the actuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
M903020247O07
Fit the cylinder block with a new O-ring.
Page 8 (12)
MAN B&W Diesel
903-2.3
Overhaul
8. Remove the cover from the terminal box

and disconnect the wires for the feedback
(pick-up) sensor.
8.
Remove the terminal box and the plug for

the solenoid valve.
Carefully unscrew the feedback sensor and
remove and discard the O-ring.
Turn the lubricator upside down in the vice.

Unscrew the solenoid valve.
Discard the O-rings.
10. Solenoid valve:
M903020247O08
Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.
9.
Disassemble and clean the valve.

Check the slide for wear. If the slide is
scratched or scuffed, the valve must be replaced by a new one.
Assemble the valve.

See also manufacturers instructions.
M903020247O09
Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
the housing.
M903020244O12
10.
Page 9 (12)
903-2.3
Overhaul
MAN B&W Diesel
11. Before mounting the feedback sensor,

check that the sensor is flush with the sensor housing.
11.
Mount the feedback sensor or a new one,

if necessary, with a new O-ring.
Check with an object with a straight edge
(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.
M903020245O10
Mount the terminal box.

1
2
3 BN (brown)
BK (black)
4
BU (blue)
5
1
2 Solenoid valve
11. Connect the wires and mount the cover on

the terminal box.
Feedback sensor
12.
LED
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.
2
Brown+15
Blue OV
M903020242O08
Black FBsignal
M903020247O13
13.
Page 10 (12)
MAN B&W Diesel
903-2.3
Overhaul
14. Mount the cylinder block assembly in the

cylinder housing.
14.
Check that the spring pin engages correctly with the cylinder block assembly.
Mount the screws and tighten the block to
the housing.
Remove the M6 x 60 screw with disc.
Mount the oil accumulator.

16. If the lubricator is not to be mounted on
the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during storage.
M903020247O14
15. Mount the adjusting screw fitted with a

new O-ring and the distance bushing.
15.
M903020247O01
Cover all surfaces with a thin layer of oil.
Page 11 (12)
903-2.4
Mounting
1.
Inlet
MAN B&W Diesel
1. Before mounting the accumulator, check

the nitrogen pressure, see Data.
Mount the accumulator.
2. Mount new O-rings on the hydraulic block
and on the cover with pipes.
Mount the lubricator and tighten the screws
on the hydraulic block.
M903020249M01
Tighten the screws in the bottom of the lubricator to the pipe connection.
Inlet
Mount the electrical plug. Check the injection of cylinder oil on the feedback LED on
the terminal box for the specific lubricator.
M903020249M02
2.
3. Close the equalizing valve and open the

supply valve (handles to be in a vertical position).
3.
M903020249M03
Inlet
Page 12 (12)

MAN B&W
Plate
P90361-0084
Page 1 (2)
Plate
P90361-0084
Item
No.
036
Page 2 (2)
MAN B&W
Item Description
Cylinder gauge, complete

MAN B&W
Plate
P90362-0002
Page 1 (2)
Plate
P90362-0002

MAN B&W
Item
No.
Item Description
018
Wear ridge milling machine
Page 2 (2)
Test Equipment for Lubricator

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

MAN B&W
Item
No.
Item Description
014
026
038
040
051
063
075
087
099
109
122
205
Reducing valve
Adaptor
Adaptor
Adaptor
Adaptor
Adaptor
Adaptor
Adaptor
Quick coupling, minimess
Quick coupling, minimess
Special screw
Test equipment for accumulators set,
complete
Page 2 (2)

104-01
904-01
104-02
904-02
104-03
904-03
104-04
904-04
104-05
904-05
90451
90461
90464
0061
0251
0063
0250
0043
0216
0054
0232
0053
0233
0139
0068
0008
MAN Diesel A/S
Crosshead Bearing, Data

Crosshead Bearing
Crosshead, Data
Crosshead
Reciprocating Parts, Data
Reciprocating Parts
Crankpin Bearing, Data
Crankpin Bearing
Connecting Rod, Data
Connection Rod
Connecting Rod and Crosshead - Panel
Connecting Rod - Hydraulic Tools
Crosshead - Hydraulic Tools
MAN Diesel A/S
104-1
Crosshead Bearing
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D04-01
Crosshead bearing, top clearance max.
0,5
mm
D04-02
Crosshead bearing, top clearance min.
0,15
mm
D04-03
Oil wedge length, L
15
mm
D04-04
Crosshead bearing cap
300
kg
D04-05
Crosshead bearing shell, upper
25
kg
D04-06
Crosshead bearing shell, lower
34
kg
D04-07
Crosshead bearing cap with bearing shell
325
kg
D13-01
900
bar
D13-02
800 - 990
bar
MAN B&W Diesel A/S
Page 1 (2)
104-1
Crosshead Bearing
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
Lifting attachment - connecting rod
P90451
72
Chain for suspending piston
P90451
84
Retaining tool telescope pipe
P90451
96
Bracket for support, Crosshead
P90451
106
P90451
118
Rubber cover for crosshead
P90451
120
P90464
P91351
010
P91351
046
P91351
058
P91351
117
P91356
P91366
Page 2 (2)
Lifting Tools, Etc.

058
Feeler gauge
MAN B&W Diesel A/S
904-1.1
Crosshead Bearing
Checking
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing
components.
1.
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.
3. Measure the clearance in the crosshead

bearing by inserting a feeler gauge between the bearing cap and the crosshead
journal, exactly next to the landing surface
for the piston rod foot. See Data.
M904040232C02
2. Turn the crankthrow concerned to BDC.
2.
D0401
D0402
5. The wear limit for a crosshead bearing shell

is confined to 50% reduction of the oil
wedge length (L). See Data.
6. For further external inspection of the crosshead bearing, see Chapter 708, Bearings
in the instruction book, Volume I, OPERATION.
M904010251C03
4. The difference between the actual clearance measurements and the measurements
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.
3.
M904010251C05
(Oil Wedge)
MAN B&W Diesel A/S
L
1/2
D0403
L
Page 1 (10)
904-1.1
Crosshead Bearing
Checking
Alternate checking method:
8.
In case the reason for opening the crosshead
bearing is a routine inspection, the following
procedure is sufficient.
6. Perform the clearance measurement shown
in 904-1.1 section 3.
M904010251C08
7. Mount the two eyebolts and tackles in the

top of the crankcase in the fore and aft direction. Mount two eyebolts on top of the
guideshoes.
9.
Turn to BDC, mount the connecting rod lifting attachments on the connecting rod.
Use tackles to hold the connecting rod in
the vertical position.
Dismount the crosshead bearing cap hydraulic nuts. For operation of the hydraulic
jacks, see Section 913.
M904010251C09
8. Mount two eyebolts in the bearing cap and

use two small tackles in the athwartship direction to lift the bearing cap free of the
guidepins and to keep the bearing cap balanced.
9. Use the tackles in the crankcase top to lift
the crosshead and piston high enough to
allow inspection of the lower crosshead
bearing.
Note!
Ensure that the crosshead is lifted simultaneously fore and aft, i.e. by placing
marks on the guide planes using a felt
tipped pen.
10. If the lower bearing shows no anomalies

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

with piston removed
With piston mounted:
2. Mount two chains in the inner screw holes

at the top of the crankcase, in the
athwartship direction, for suspending the
piston rod.
3. Loosen and remove the locking wire from
the screws on the piston rod foot. Remove
the screws.
M904040232C02
1. Turn the crosshead down far enough to

give access to the nuts and screws on the
piston rod, the crosshead bearing cap, and
the screws on the telescopic pipe.
2.
Mount the spacer rings and the hydraulic

jacks for loosening the crosshead bearing
cap nuts.
Loosen the nuts.
Remove the hydraulic jacks and unscrew

the nuts.
M904010251D02

Procedure 913.
3.
M904010251D03
D1302
MAN B&W Diesel A/S
Page 3 (10)
904-1.2
Crosshead Bearing
Dismantling
4.
4. Mount a lifting eye bolt on each side of the

bearing cap and on the piston rod.
5. Loosen and remove the screws which secure the telescopic pipe to the bend.
Remove one screw from the telescopic
stuffing box housing and mount the special
tool for suspending the telescopic pipe.
M904010251D04
6. Turn the crosshead to TDC.
5.
Hook the ends of the chains to the lifting

eye bolts in the piston rod.
Suspend the telescopic pipe, using the
tool. See Procedure 902-1.2.
Turn the crosshead downward and the piston rod will remain suspended from the two
chains.
Remove the distance pipe from the bend
for the telescopic pipe.
With piston removed:
7. Turn to BDC.
M904010251D05
8. Place the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.
6.
Loosen the crosshead bearing cap nuts.

For operation of the hydraulic jacks, see
Procedure 913-1.
Remove the hydraulic jacks and the spacer
rings and unscrew the nuts.
Caution!
M904010251D06
When a piston is dismantled, never turn

the engine without first dismantling the
telescopic pipe from the crosshead.
Page 4 (10)
MAN B&W Diesel A/S
904-1.2
Crosshead Bearing
Dismantling
9. Mount the lifting attachments on the head
of the connecting rod.
9.
10. Suspend two tackles from the lifting brackets in the athwarthship direction.
11. Mount two eye bolts in the top of the
crosshead bearing cap.
M904010251D09
Hook the tackles on to the eye bolts in the

crosshead bearing cap and remove the cap
from the engine. Check the upper part of
the journal.
M904010251D10
10.
D0407
M904010251D11
11.
MAN B&W Diesel A/S
Page 5 (10)
904-1.2
Crosshead Bearing
Dismantling
12. Place the bearing cap on one side on a
couple of wooden planks.
12.
D0405
Remove the thrust pieces for axial guidance of the connecting rod.
M904010251D12
13. Fasten tackles to the fixed lifting brackets

on the frame box wall.
14. Turn the crosshead upwards until the piston rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.
Do not remove the chains or lifting eye
bolts.
M904010251D13
13.
M904010251D14
14.
Page 6 (10)
MAN B&W Diesel A/S
904-1.2
Crosshead Bearing
Dismantling
15. Turn to TDC and attach the tackle hooks to
the lifting attachments. Haul the tackles
tight.
15.
16. Mount the four supports for guide shoes

on the crosshead guides.
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.
17. Turn the crankthrow carefully towards BDC
while following with the tackles, thus continuously supporting the connecting rod.
M904010251D15
Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.
16.
18. With the crosshead resting on the supports, check the lower part of the crosshead journal and the lower bearing shell.
Regarding checking of journal and bearing
shells, see Volume I, OPERATION, Chapter
708, Bearings.
M904010251D16
D0220
17.
M904010251D17
D0451
MAN B&W Diesel A/S
Page 7 (10)
904-1.2
Crosshead Bearing
Dismantling
19.
D0406
19. In cases where it is necessary to remove

the lower bearing shell, tilt the connecting
rod towards the door in the camshaft side
by means of the tackles.
Dismount the locking screws, and turn the
bearing shell so far up that an eye bolt can
be mounted.
M904010251D19
Lift the bearing shell out of the engine.
Page 8 (10)
MAN B&W Diesel A/S
904-1.4
Crosshead Bearing
Mounting
With piston mounted/With piston removed:
1.
D0406
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. Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.
Note!
Take care that the bearing studs do not
damage the crosshead.
M904010251M01
Raise the connecting rod to an upright position.
2.
D0451
3. Remove the supports from the crosshead
guides.
Remove the tackles from the crosshead.
If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
M904010251M02
Turn the crank throw to BDC.
M904010251M03
3.
MAN B&W Diesel A/S
Page 9 (10)
904-1.4
Crosshead Bearing
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.
D0407
5. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.
For operation of hydraulic jacks, see Section 913.
M904010251M04
Mount the thrust pieces for axial guidance

For tightening torque, see Data.
6. Mount the piston.
With piston mounted:
5.
7. Turn the crosshead upwards until the piston rod lands on the crosshead. Ensure
that the guide ring in the crosshead fits
correctly in the centre hole of the piston
rod.
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.
M904010251M05
D0416
D1301
For tigthening of piston rod bolts and

mounting of the telescopic pipe, see Procedure 902-1.4.
Check the top clearance in the bearing.
M904010251M07
7.
Page 10 (10)
MAN B&W Diesel A/S
Crosshead
MAN B&W Diesel
104-2
Data

Stopped engine
X
X
X
X
X
X

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D04-07
325
kg
D04-08
Cooling oil outlet pipe, tightening torque
260
Nm
D04-09
Inlet pipe, tightening torque
460
Nm
D04-10
Inlet pipe stud, screwing-in torque
120
Nm
D04-11
Guide strip nuts, tightening torque
100
Nm
D04-15
Telescopic pipe, tightening torque
50
Nm
D04-16
Thrust piece, tightening torque
460
Nm
D04-20
Clearance between thrust piece and crosshead
0.05-0.35
mm
D04-21
Crosshead complete
D04-22
Guide shoe
D04-23
Cooling oil outlet pipe
D04-49
Connecting rod studs , screwing-in torque
D04-51
Connecting rod complete
D04-58
Stuffing box, telescopic pipe, tightening torque
D04-59
1230
kg
106
kg
13
kg
180
Nm
1220
kg
200
Nm
Telescopic pipe
17
kg
D04-60
Inlet pipe
14
kg
D04-62
Crosshead without guide shoes
1018
kg
D13-01
900
bar
D13-02
800 - 990
bar
Page 1 (2)
Crosshead
104-2
MAN B&W Diesel
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P90451
60
Lifting tools - crosshead
P90451
72
P90451
84
P90451
118
P90451
120
P90464
P91356
Lifting Tools, Etc.
P91366
58
Feeler gauge
P91366
61
Slide caliper
P91351
10
Hydraulic pump, pneumatic operated
P91351
46
P91351
58
P91351
117
Page 2 (2)
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
1. Dismount the main bearing lubricating oil

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

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

jacks for loosening the crosshead bearing
cap nuts.
Procedure 913-1.
M904020250D02
Mount two eye bolts in the athwartship direction, and suspend two tackles.
D1302
4.
Loosen the nuts, remove the hydraulic
jacks and unscrew the nuts.
D0407
4. Turn to BDC and mount connecting rod lifting tools. Use two tackles to retain the
connecting rod in an upright position.
Mount two eye bolts in the crosshead
bearing cap and hook on the tackles from
the top of the crankcase.
M904020250D04
Suspend the telescopic pipe by means of

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

Remove the piston rod guide ring and the
shim from the crosshead.
Remove both thrust pieces on the crosshead bearing cap.
Page 1 (9)
Crosshead
904-2.2
Dismantling
MAN B&W Diesel
5. Dismount the four bearing cap studs, using

the stud setter.
5.
D0423
D0460
Dismount the guide pin for the oil inlet

bend using the special extractor.
Mount the eye bolt in one of the threaded
holes in the bend, hook on a tackle and
haul tight.
M904020250D05
Remove the outlet pipe, dismount the bend

for the telescopic pipe and remove the
studs from the crosshead.
Mount the special lifting tool on the crosshead.
6. Attach tackle chains from the two tackles in
the athwartship direction to the lifting tool.
6.
Lift the crosshead free of the connecting
rod.
M904020250D06
D0421
Page 2 (9)
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
7. Use the tackles to tilt the connecting rod

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

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

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

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

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

does not touch the crank.
Page 3 (9)
904-2.2
Crosshead
Dismantling
MAN B&W Diesel
11. Hook the tackles on to the eye bolts in the

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

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

in the side walls by means of the tackles in
the two adjacent cylinders. Lift the guide
shoes to provide space for turning the
crosshead.
M904020250D12
12.
13.
M904020250D13
D0462
Page 4 (9)
Crosshead
MAN B&W Diesel
904-2.2
Dismantling
14. Turn the crosshead 90.
14.
15. Mount a tackle outside the engine and, by

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

bump into anything as this will damage
the sliding surfaces of the crosshead.
M904020250D14
Note!
M904020250D15
15.
D0422
Page 5 (9)
Crosshead
904-2.4
MAN B&W Diesel
Mounting
1. Clean the crosshead and mount the lifting

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

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

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

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

care that its surfaces are not scratched
or damaged. If necessary, protect the
crosshead with a cloth.
3.
M904020250M03
D0422
Page 6 (9)
Crosshead
MAN B&W Diesel
904-2.4
Mounting
4. Lubricate the sliding surfaces of the guide

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

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

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

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

lifting tools from the connecting rod.
D0411
D0421
M904020250M06
6.
Page 7 (9)
Crosshead
904-2.4
Mounting
D0408
D0409
D0410
D0449
8.
MAN B&W Diesel
8. Turn the connecting rod and crosshead to

BDC.
Remove the lifting tool from the crosshead.
Mount the studs for the cooling oil inlet
bend. Mount the bend and outlet pipe.
See Data.
M904020250M08
Mount the cylindrical dowel with threaded

hole in the bend, and mount the bearing
cap studs.
Mount the piston rod guide ring and the
shim on the crosshead.
9. Lift the crosshead bearing cap into the engine.
9.
Lubricate the crosshead journal with plenty

of clean lubricating oil.
Carefully land the bearing cap on the
crosshead.
D0458
D0459
Mount the hydraulic nuts.

Mount the two thrust pieces on the sides of
the crosshead bearing cap. Tighten the
screws to the torque stated in Data.
D0407
D1301
M904020250M09
D0416
D0420
Page 8 (9)
Crosshead
MAN B&W Diesel
904-2.4
Mounting
10. Tighten the hydraulic nuts.
10.
For operation of hydraulic tools, see Procedure 913-1.

Remove the hydraulic tools and the eye
bolts from the engine.
Mount the main bearing lubricating oil

pipes.
Mount the piston and the telescopic pipe.
M904020250M10
Check the clearances between the guide

strips, guide shoes and crosshead guides.
Note!
At this point it is recommended to check
the crosshead bearing clearance.
11. Remove all tools from the engine.
Note!
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
Page 9 (9)
104-3
Reciprocating Parts
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
Acceptance criteria with piston in centre (F-A direction)

D04-25
PF+PA, N max.
0,5
mm
D04-26
PF+PA, O max.
0,7
mm
D04-28
E+G, H+F, N max.
0,5
mm
D04-29
E+G, H+F, N min.
0,2
mm
D04-30
E+G, H+F, O max.
0,8
mm
D04-34
J+X, L+Y, K+X, M+Y, N max.
0,9
mm
D04-35
J+X, L+Y, K+X, M+Y, N min.
0,5
mm
D04-36
J+X, L+Y, K+X, M+Y, O max.
1,1
mm
D04-39
QF/QA, O max.
0,8
mm
D04-41
ZF/ZA O min.
mm
D04-42
TF + TA O max.
0,8
mm
N: New and cold engine with staybolts tightened (less than 100 running hours).
O: Engine in service.
MAN B&W Diesel A/S
Page 1 (2)
104-3
Reciprocating Parts
Data
Plate
P91366
Page 2 (2)
Item No.
58
Description
Feeler gauge
MAN B&W Diesel A/S
Reciprocating Parts
904-3.1
Checking
Reciprocating Parts
S42MC
0216
Checking
904-3.1
1.
In order to achieve uniform measuring conditions on board, the ship's trim must be as close
as possible to 0.
Bend each end approx. 250 mm up along

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

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

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

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

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D04-43
Crankpin bearing clearance, max.
0.55
mm
D04-44
Crankpin bearing clearance, min.
0.2
mm
D04-45
Crankpin bearing cap complete
135
kg
D04-46
Crankpin bearing, upper shell
20
kg
D04-47
Crankpin bearing, lower shell
15
kg
D04-48
Crankpin bearing cap + shell + bearing studs
175
kg
D04-51
1220
kg
D13-01
900
bar
D13-02
800 - 990
bar
MAN B&W Diesel A/S
Page 1 (2)
104-4
Crankpin Bearing
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P91356
Lifting Tools, Etc.
P91366
58
Feeler gauge
P91366
61
Slide caliper
P91351
10
P91351
46
P91351
58
P91351
105
Page 2 (2)
MAN B&W Diesel A/S
Crankpin Bearing
904-4.1
Checking
The bottom clearance between the journal and
a new bearing shell is the result of a summation of the production tolerances of the bearing
assembly components.
2.
For the bottom clearance of a specific bearing,

see the measurement in the Adjustment Sheet
in Volume I, OPERATION.
1. Open the crankcase door at the relevant
cylinder.
3. Measure the clearance in the crankpin

bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
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 0.05 mm. If so, the
crankpin bearing must be disassembled for
inspection.
M904040232C02
2. Turn the crank concerned to BDC.
3.
D0443
D0444
An average wear rate of 0.01 mm per

10,000 hours is regarded as normal.
6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.
M904040231C03
5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
5.
M904040232C05
D0446
MAN B&W Diesel A/S
Page 1 (8)
904-4.2
Crankpin Bearing
Dismantling
1. Suspend two tackles from the lifting brackets, in the athwartship direction.
1.
Mount the wire guide in the top of the

crankcase door opening.
2. 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.
M904040232D01
Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Procedure 913-1.
2.
Remove the hydraulic jacks and the nuts.

3. 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.
Inspect the bearing shell.
M904040232D02
D1302
3.
M904040232D03
D0448
Page 2 (8)
MAN B&W Diesel A/S
Crankpin Bearing
904-4.2
Dismantling
4. If the bearing shell needs to be replaced,
remove the whole bearing cap from the
crankcase.
4.
D0448
Suspend a tackle outside the engine above

the crankcase door opening.
Using the tackle from the frame box inside

wall, together with the tackle suspended
outside the engine, lift the bearing cap out
of the crankcase.
5. Place the bearing cap on one side on a
couple of planks.
Dismount the bearing shell lock screws and
replace the bearing shell by a new one.
M904040232D04
Turn the crankthrow to the exhaust side to

give space for lifting out the crankpin bearing cap.
5.
The bearing shells must be replaced in

pairs.
D0447
6. Turn to TDC.
Carefully turn the crank to the camshaft

side and down until the guide shoes rest
on the supports.
M904040232D05
Mount the four supports for guide shoes

on the crosshead guides.
6.
M904040232D06
D0451
MAN B&W Diesel A/S
Page 3 (8)
904-4.2
Crankpin Bearing
Dismantling
7.
7. Mount a lifting attachment for securing the

connecting rod at the lower end, on the
camshaft side.
Hook the tackle on to the lifting attachment.
M904040232D07
8. 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.
If necessary suspend a second tackle from
the bracket below the doorway.
Continue turning the crankshaft until the
bearing surface can be freely inspected.
8.
Inspect the bearing shell surface and the
crankpin journal.
9. If it is necessary to replace the bearing
shell, proceed as follows:
Turn the crankshaft to horizontal position.
M904040232D08
Release the tackle so that the connecting

rod is hanging freely.
M904040232D09
9.
Page 4 (8)
MAN B&W Diesel A/S
Crankpin Bearing
904-4.2
Dismantling
10. Dismount the bearing shell lock screws.
10.
Lower the bearing shell and remove it from

the crankcase.
M904040232D10
D0446
MAN B&W Diesel A/S
Page 5 (8)
904-4.4
Crankpin Bearing
Mounting
1. If necessary, replace the bearing shells with
new ones. The bearing shells must be replaced in pairs.
1.
Bearing shells of three mm undersize are

available as spares in case of journal rectification.
Coat the bearing shell surfaces and the
journal with clean oil.
M904040231M01
The excess height X is to ensure the correct tightening-down of the bearing shell,
and must not be eliminated.
2. Lift the upper bearing shell for the crankpin
concerned into the crankcase.
Carefully lift the bearing shell into position
in the connecting rod, and mount the lock
screws.
2.
M904040232M02
D0446
Page 6 (8)
MAN B&W Diesel A/S
Crankpin Bearing
904-4.4
Mounting
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.
3.
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 four guide shoe support
brackets from the crosshead guides.
M904040232M04
Remove the tackle and the lifting attachment from the connecting rod.
M904040232M05
4.
MAN B&W Diesel A/S
Page 7 (8)
904-4.4
Crankpin Bearing
Mounting
5.
D0448
5. Suspend the tackles from the lifting brackets in the side 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.
Remove the wire guide tool from the engine.
M904040232M06
6. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.
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.
6.
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 Procedure 913-1.
Remove the tackles from the side of the
frame box.
M904040232M07
D1301
Page 8 (8)
MAN B&W Diesel A/S
104-5
Connecting Rod
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D04-07
325
kg
D04-16
Thrust piece, tightening torque
460
Nm
D04-49
Connecting rod studs , screwing-in torque
180
Nm
D04-50
Connecting rod, without bearing caps
1160
kg
D04-51
1220
kg
D04-52
Connecting rod stud
kg
D13-01
D13-02
MAN B&W Diesel A/S
900
bar
800 - 990
bar
Page 1 (2)
104-5
Connecting Rod
Data
Plate
Item No.
Description
P90451
47
Wire guide
P90451
59
P90451
60
Lifting tools - crosshead
P90451
72
P90451
84
P90451
96
P90451
106
P90451
118
P90451
120
P90464
P91356
Lifting Tools, Etc.
P91366
58
Feeler gauge
P91366
61
Slide caliper
P91351
10
P91351
46
P91351
58
P91351
105
P91351
117
Page 2 (2)
MAN B&W Diesel A/S
Connecting Rod
904-5.2
Dismantling
Connecting Rod
K90MC
0233
Dismantling
904-5.2
1.
1. Suspend the piston rod and dismount the

crosshead bearing cap. See Procedure
904-1.2.
2. Suspend two tackles from the two lifting
brackets at the sides of the frame box.
Mount the wire guide in the top of the
crankcase doorway.
Dismantle the crankpin bearing cap, and remove it from the engine. See Procedure
904-4.2.
Mount the four support brackets for guide
shoes on the crosshead guides.
GM904-5.2 215 02
3. Turn the crank to TDC.
D13-02
D04-07
MA904-5.2 218 02
2.
MA904-5.2 218 03
3.
MAN B&W Diesel A/S
Page 1 (6)
Connecting Rod
904-5.2
Dismantling
4.
4. Mount the lifting attachments for fixing the

connecting rod on the head of the connecting rod.
A
B
Use the tackles fastened to lifting brackets

A and B on the frame box wall, and attach
the tackle hooks to the mentioned lifting attachments on the connecting rod.
Haul the tackles tight.
Also mount a lifting attachment in the
crankpin end of the connecting rod, on the
exhaust side.
MA904-5.2 218 04
Carefully turn the crank down towards the

exhaust side, until the crosshead shoes
rest on the supports.
5.
D04-51
D04-52
5. Turn the crankthrow towards BDC while

following with the tackles, thus continuously supporting the connecting rod.
6. Turn the crankthrow to 90 before BDC.
Remove the four studs from the connecting
rod.
MA904-5.2 218 05
Shift the hook of the tackle attached to lifting bracket B from the lifting attachment on
the lowermost side of the connecting rod to
the lifting attachment on the uppermost
side.
Page 2 (6)
MAN B&W Diesel A/S
Connecting Rod
904-5.2
Dismantling
7.
7. By means of the tackle from lifting bracket

A, tilt the connecting rod towards the camshaft side until the connecting rod is leaning out of the doorway.
Attach a tackle to lifting bracket C on the

frame box wall and connect the tackle hook
to the lifting attachment at the lower end of
the connecting rod.
8. Attach a tackle to the gallery-mounted lifting bracket E, and hook on to the lifting attachment on the connecting rod.
MA904-5.2 218 07
Turn the crank carefully upwards while following with the tackles, guiding the head of
the connecting rod out of the doorway.
Shift the tackles from one lifting bracket/attachment to the other, as required.
8.
Remove the floor chequer plate for the pertaining cylinder.
AA
9. Place a wire rope round the connecting rod,

hook on the engine room crane and haul
tight.
Lift the connecting rod out of the engine using the engine room crane and the tackles.
MA904-5.2 218 08
Continue turning upwards till about 30 after TDC, while following with the tackles
and the engine room crane.
9.
E
A
MA904-5.2 218 09
D04-51
MAN B&W Diesel A/S
Page 3 (6)
Connecting Rod
904-5.4
Mounting
Mounting
904-5.4
2.
1. Equip the connecting rod with the same lifting attachments as mentioned under dismantling.
A
Turn the crank to a position about 30 past

TDC on the camshaft side.
Apply clean lubricating oil to the crankpin

bearing shell and journal.
MA904-5.4 218 02
D04-51
2. Lift the connecting rod carefully into the

crankcase by alternate use of the engine
room crane and the tackles attached to lifting brackets A and B.
Attach a tackle to bracket E and the upper
end of the connecting rod.
3.
E
A
3. When the end of the connecting rod rests

on the crankpin journal, attach a tackle to
bracket C and the lower end of the connecting rod.
4. Turn the crankthrow towards BDC, past
TDC, while following with the tackles. Lower the engine room crane and remove the
strap around the connecting rod.
MA904-5.2 218 09
Shift tackle B from the lower end to the upper end of the connecting rod.
4.
E
A
MA904-5.2 218 08
Page 4 (6)
MAN B&W Diesel A/S
Connecting Rod
904-5.4
Mounting
5.
5. Turn the crankthrow to 90 before BDC, and

use the tackles to raise the connecting rod
to an upright position.
Shift tackle A from the lower end to the top

Remove the tackle at E.
Remove the tackle at C.

Remove the lifting attachment at the lower
end of the connecting rod.
MA904-5.4 218 05
Shift tackle B from the lifting attachment on

one side to the other side of the connecting
rod.
6.
6. Screw the studs into the connecting rod.

Using the stud setter and a torque wrench,
tighten the studs to the torque stated in
Data.
Lubricate the crosshead bearing shell and
journal.
7. Turn the crankthrow towards TDC while following with the tackles, carefully land the
crosshead on the connecting rod.
Take care that the studs do not damage

the crosshead bearing journal.
MA904-5.4 218 06
Note!
D04-49
MA904-5.4 218 07
7.
MAN B&W Diesel A/S
Page 5 (6)
904-5.4
Connecting Rod
Mounting
8.
8. When the crank is in TDC, mount the crankpin bearing cap.

Turn to BDC and mount the crosshead
bearing cap and the piston.
9. Remove the tackles and lifting attachments.
MA904-5.4 218 08
10. Turn the crosshead to BDC.

Tighten all four crosshead bearing cap nuts
simultaneously. See Data.
For use of hydraulic jacks, see Procedure
913-1.
D04-48
Mount the thrust pieces for axial guidance

of the connecting rod, and tighten to the
specified torque. See Data.
MA904-5.4 218 09
9.
GM904-5.2 215 01
10.
Page 6 (6)
D13-01
D04-16
MAN B&W Diesel A/S

MAN B&W
Plate
P90451-0139
Page 1 (2)
Plate
P90451-0139
Item
No.
011
023
047
059
060
072
084
096
106
118
120
155
167
Page 2 (2)

MAN B&W
Item Description
Panel for tools

Name plate
Wire guide, main bearing
Lifting attachment, connecting rod
Lifting tool, crosshead
Chain, suspension piston
Retaining tool, telescope pipe
Bracket, support of crosshead
Bracket, support of crosshead
Rubber cover, crosshead
Rubber cover with hole, crosshead
Crowfoot spanner
Crowfoot spanner

MAN B&W
Plate
P90461-0068
Page 1 (2)
Plate
P90461-0068

MAN B&W
Item
No.
Item Description
028
030
041
053
065
089
100
207
Hydraulic jack
Support
Tommy bar
Spanner
Stud setter
Hydraulic toolset, complete
Page 2 (2)

MAN B&W
Plate
P90464-0008
Page 1 (2)
Plate
P90464-0008

MAN B&W
Item
No.
Item Description
024
036
048
050
061
085
097
107
203
Hydraulic jack, complete

Support
Tommy bar
Tommy bar
Spanner
Stud setter
Hydraulic tool kit, complete
Page 2 (2)

90551
90561
90562
90564
90567
90570
90571
0212
0088
0130
0018
0002
0003
0002
MAN Diesel A/S
Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel

Main Bearing - Hydraulic Tools
Crankshaft - Tools
Crankshaft - Measuring Tools
Segment Stopper & Vibration Damper - Tools
Thrust Shaft - Tools
Main Bearing Shell - Tools
MAN Diesel A/S
Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel
MAN B&W Diesel A/S
Plate
P90551-0212
Page 1 (2)
Plate
P90551-0212
Item
No.
015
027
040
076
100
123
135
184
218
231
Page 2 (2)
Crankshaft, Thrust Shaft, Main Bearing, Etc. Panel

Item Description
Item
No.
Item Description
Tool panel
Name plate
Pulley for wire for main bearing
Lifting tool for main bearing cap
Tool for turning out segments
Retaining tool for main bearing shells
Lifting tool for relief valve
Lifting tool for main bearing shell
Wire for dismantling of mainbearing
shell
Protective cap
MAN B&W Diesel A/S

MAN B&W
Plate
P90561-0088
Page 1 (2)
Plate
P90561-0088

MAN B&W
Item
No.
Item Description
021
033
045
057
069
070
082
094
200

Support
Tommy bar
Tommy bar
Spanner
Stud setter
Hydraulic tool set, complete
Page 2 (2)
Crankshaft - Tools
MAN B&W
Plate
P90562-0130
Page 1 (2)
Crankshaft - Tools
Plate
P90562-0130
Item
No.
015
027
Page 2 (2)
MAN B&W
Item Description
Lifting tool for crankshaft

Screw with speciale head

MAN B&W
Plate
P90564-0018
Page 1 (2)
Plate
P90564-0018
Item
No.
016
Page 2 (2)

MAN B&W
Item Description
Measuring tool for axial movement

MAN B&W
Plate
P90567-0002
Page 1 (2)
Plate
P90567-0002
Item
No.
012
Page 2 (2)

MAN B&W
Item Description
Segment stopper and vibration

damper - tool

MAN B&W
Plate
P90570-0003
Page 1 (2)
Plate
P90570-0003
Item
No.
019
Page 2 (2)
MAN B&W
Item Description
Lifting tool, thrust shaft

MAN B&W
Plate
P90571-0002
Page 1 (2)
Plate
P90571-0002
Item
No.
014
Page 2 (2)
MAN B&W
Item Description
Extractor for guide pin
906 - Control Gear

106-01
906-01
106-02
906-02
106-03
906-03
106-04
906-04
106-08
906-08
0054
0241
0059
0231
0039
0215
0040
0219
0002
0001
MAN Diesel A/S
Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearings, Data
Camshaft Bearings
Camshaft Coupling
Camshaft Coupling
MAN Diesel A/S
106-1
Chain
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
1 Chain
D06-02
Teeth on chain wheel, max. wear
0.9
mm
D06-03
Original length (chain pitch x 10 links)
254
mm
D06-04
10 links measurements + 1% of a tensioned chain = scrapping of chain
256.5
mm
mm
3.5" chain
D06-18
Teeth on chain wheel, max. wear
D06-19
Original length (chain pitch x 10 links)
889
mm
D06-20
10 links measurements + 1% of a tensioned chain = scrapping of chain
898
mm
MAN B&W Diesel A/S
Page 1 (2)
106-1
Chain
Data
Plate
Item No.
Description
P90651
056
Chain assembling tool
P90651
068
Chain disassembling tool
P90651
070
Chain assembling tool
P90651
081
Chain disassembling tool
P91356
Page 2 (2)
Lifting Tools, Etc.
MAN B&W Diesel A/S
906-1.1
Chains
Checking
1. The engine is equipped with two sets of

chains:
1.
the drive chains for the camshaft

the drive chain for the cylinder lubricators
Note!
There are two sets of dismantling and
mounting tools available, one for each
set of chains.
2. Both sets of chains can be accessed from
within the chainwheel frame.
M906010238C02
Both sets of chains are to be checked and,

if necessary, dismantled and mounted in
the same way.
4.
3. Carry out the inspection as follows:

Make a general inspection for loose
bolts and screws.
Inspect lube oil pipes for damage, and
check jet nozzles for possible stoppages or deformations.
Replace the guideway if bits have

started to be plucked out of the rubber track.
M906010241C04
Examine the rubber track of the guideways for cracks or other damage.
D0602
D0618
B
A
4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement
(See Data).
Measurements are best taken by placing a
short straight-edge over points A and B
and then measuring the distance D06-02 or
D06-18.
MAN B&W Diesel A/S
Page 1 (5)
906-1.1
Chains
Checking
5.
5. If abnormal wear is observed at the bottom

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.
For assessing the wear profile, contact
MAN B&W Diesel.
M906010238C05
In most cases, scratches caused by the

side plates of the chain will be found on
the sides of the teeth. Such scratches can
generally be considered normal.
6. The chains for the camshaft drive are
matched together to ensure an even load
distribution.
To keep such matching chains in their
pairs, the side plates of the outer link nearest to the assembled link have been
marked with year, month, day and chain
number.
Example:
No. 1 order,
840520 1A
840520 1B
(840520 2C, possible 3rd chain)
No. 2 order,
840520 2A
840520 2B
(840520 2C, possible 3rd chain)
On the same links there is an arrow (>)
which indicates the mounting direction.
Check the chains for cracks on possibly
defective rollers and side plates.
Check that the chain rollers can run freely
and that the chain links can freely move on
the pin and bushing (that they are not
seized between the pin and the bushing).
It is normal, however, that the rollers get
light, circumferential scratches during the
running-in period. These fine scratches are
of no importance and need not be considered.
It is recommended that each single link is
checked.
Page 2 (5)
MAN B&W Diesel A/S
906-1.1
Chains
Checking
7. Check chain wear by measuring the length
of 10 chain links. Use two master squares
and a steel measuring tape as shown on
the sketch. Compare the result with the
value given in Data.
7.
D0603
D0604
D0619
D0620
M906010241C07
04
06 0
x.D
2
Ma .D06
x
Ma
If necessary, adjust the chain tightener.

MAN B&W Diesel A/S
Page 3 (5)
906-1.2
Chains
Dismantling
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!
M906010238C02
Every time a chain link is disassembled,

a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.
2.
When a new link is fitted in one chain,

the corresponding link in the other chain
must also be renewed.
1. Remove the tension on the chain by loosening the chain tightener.

(See Procedure 906-2.3).
Turn the engine until the slack part of the
chain, with the chain link that is to be disassembled, is in a favourable position for
the work.
M906010238D02
2. Mount a wire round the link rollers a short

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

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

chain link, and dismantle the link by alternately tightening the screws on the tool.
Page 4 (5)
MAN B&W Diesel A/S
Chains
906-1.4
Mounting
Before assembling the inner and outer
links, clean the pins and bushings.
1.
1. Combine the inner chain link with the outer

chain link and mount the compression tool.
Force the loose side plate of the outer link
into place by alternately tightening the
screws on the compression tool.
Repeat this procedure until the chain has

been assembled.
Remove the tackle and wire and adjust the
chain tension.
(See Data and Procedure 906-2.3).
M906010238M01
2. When the link has been assembled, remove

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

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D06-21
Tightening angle = 8 hexagons
D06-25
Mechanical or blocked chain tightener, clearance
MAN B&W Diesel A/S
Value
Unit
480/8
0,1
/hex
mm
Page 1 (2)
106-2
Chain Tightener
Data
Plate
P91366
Page 2 (2)
Item No.
58
Description
Feeler gauge
MAN B&W Diesel A/S
Chain Tightener
906-2.3
Adjustment
Chain Tightener
S60MC-C
0231
Adjustment
906-2.3
1.
1. To retighten the chains, loosen nuts A, B,

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

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

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

until there is a clearance between the shaft
and the nut as stated in D06-25.
2.
HM906-2.3 222 02
For chain wear, see Procedure 906-1.1.
3.
HG906-2.3 218 03
D06-25
D06-21
0$1% :'LHVHO$6
Page 1 (2)
906-2.3
Chain Tightener
Adjustment
4.
4. Tighten nut C hard against the contact face

of the shaft.
Tighten nut D.
Lock nuts C and D with the tab washer.
5. Tighten nut A.
Lock nuts A and B with the tab washer.
HG906-2.3 218 05
The number of times that retightening can

be carried out depends on when the limit for
scrapping the chain has been reached. See
Data page 106-1.
5.
HG906-2.3 218 05
Page 2 (2)
0$1% :'LHVHO$6
106-3
Camshaft
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D06-27
Max. permissible change in lead angle
D06-28
corresponding to
3,5
mm
D06-29
Pin gauge for top dead centre of crankthrow No.1, check measurement
501
mm
D06-30
Pin gauge for camshaft, check measurement
251
mm
MAN B&W Diesel A/S
Page 1 (2)
106-3
Camshaft
Data
Plate
Item No.
Description
P90664
Crankshaft - Pin Gauge
P90668
Camshaft - Pin Gauge
Page 2 (2)
MAN B&W Diesel A/S
Camshaft
906-3.1
Checking
Camshaft
S60MC
0215
Checking
906-3.1
1.
Turn in the AHEAD direction to ensure that

the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
Check the TDC of cylinder 1 against the
mark on the turning wheel.
HM906-7.0 56 01
1. Turn the crankthrow for cylinder 1 to TDC.
2. Check the TDC position with the pin gauge

on the crankthrow, D06-29.
BG906-7.0 58 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 D06-27

and D06-28.
D06-30
4. Check and, if necessary, adjust the cylinder

lubricator.
Check the setting of the starting air distributor.
MA906-3.1 210 03
5. When checking the camshaft position, also

check the running surface of the cams.
D06-27
D06-28
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.
5.
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.
KC906-3.0 07 01
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.
MA906-3.1 210 06
6.
Page 2 (3)
MAN B&W Diesel A/S
Camshaft
906-3.3
Adjustment
Adjustment
906-3.3
1.
KB906-7.0 72 04
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 D06-27 and D06-28 stated
in Data, MAN B&W Diesel should be contacted for further instructions.
MAN B&W Diesel A/S
D06-27
D06-28
Page 3 (3)
106-4
Cylinder Cover
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D06-34
Bearing shell, max. wear
0.1
mm
D06-36
Oil pan
20
kg
D06-37
Camshaft bearing cap
54
kg
D06-65
Bearing shell, minimum thickness
4.8
mm
D13-01
900
bar
D13-02
800 - 990
bar
MAN B&W Diesel A/S
Page 1 (2)
106-4
Cylinder Cover
Data
Plate
Item No.
P90464
Description
P90651
127
Pulley for wire for camshaft bearing
P90651
139
Lifting attachment for camshaft bearing
P91351
010
P91351
046
P91351
058
P91351
105
Page 2 (2)
MAN B&W Diesel A/S
Camshaft Bearing
906-4.1
Checking
Camshaft Bearing
S60MC
0219
Checking
906-4.1
1.
1. As the upper shell of the camshaft bearing

assembly has been dispensed with on this
engine, it is no longer necessary to measure the top clearance of the camshaft bearing.
However, with normal inspection through
the inspection hole in the roller guide housing, we recommend a visual inspection of
the condition of the shell in the bearing cap
from each side.
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
HC906-5.0 57 01
Check for wiped-out metal at the bearing

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

inspection, dismantling need not be carried
out.
When checking the camshaft bearings, it is
recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 908-5 and 909-3.
MAN B&W Diesel A/S
Page 1 (5)
906-4.2
Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Caution!
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
HC906-5.0 57 02
1. Dismount the oil outlet pipe from the oil tray.

Mount an eye bolt in the cylinder frame behind the oil tray.
Release the sealing flanges on the roller
guide housing, loosening the screws
mounted in the roller guide housing.
Remove only the screws in the lower half of
the sealing flange.
2.
2. Attach a wire rope to the eye bolt. Place the

wire rope in the lifting fitting of the oil tray,
hook on a tackle and haul tight.
D06-36
Remove the screws securing the oil tray to

the roller guide housing. Ease off the oil
tray, landing it on the platform.
HC906-5.0 57 03
3. Mount lifting fittings on both sides of the

bearing half. Mount grooved pulleys on the
roller guide housing, and hook wire ropes/
tackles on to the lifting fittings/grooved pulleys. Tighten up the tackles.
HG906-4.3 201 03
3.
Page 2 (5)
MAN B&W Diesel A/S
Camshaft Bearing
906-4.2
Dismantling
4.
4. Mount the hydraulic jacks and loosen the

bearing nuts. For use of hydraulic jacks,
see Procedure 913-1.
Remove the hydraulic jacks and dismount
the nuts.
HG906-4.3 201 04
5. Lower the bearing cap and place it on the

platform.
D13-02
5.
HC906-5.0 57 06
D06-37
MAN B&W Diesel A/S
Page 3 (5)
906-4.3
Camshaft Bearing
Overhaul
Overhaul
906-4.3
1.
1. For assessment of the bearing condition,

see Volume I OPERATION, Chapter 708
Bearings.
Inspect the entire surface of the bearing
journal for seizures.
If seizures are found on the bearing journal
surface (on account of bearing breakdown),
polish the surface with a fine carborundum
stone to re-establish a bright and smooth
surface.
HC906-5.0 57 07
2. 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.
2.
MA906-4.3 209 02
Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.
Page 4 (5)
D06-34
D06-65
MAN B&W Diesel A/S
Camshaft Bearing
906-4.4
Mounting
Mounting
906-4.4
1.
1. Clean the bearing journal, the bearing support and the bearing shell.
Mount the bearing shell in the bearing cap,
after coating the shell with oil. Then pull the
bearing cap into place by means of tackles/
wire rope fitted through the grooved pulleys
to the lifting fittings. Check that the guide
pins enter correctly.
Remove the lifting fittings and grooved pulleys from the roller guide housing.
HC906-5.0 57 06
2. Mount and tighten up the nuts by means of

the hydraulic tools.
See Data.
3. Hoist the oil tray into place, positioning it by

means of the guide pins.
D06-37
2.
Then fasten it to the roller guide housing by

tightening up uniformly all round the circumference.
Remove the shackle and eye bolt.
Mount the screws that fasten the sealing
flanges to the roller guide housing. Mount
the oil pipe on the oil tray.
HG906-4.3 201 04
D13-01
3.
HC906-5.0 57 03
D06-36
MAN B&W Diesel A/S
Page 5 (5)
106-8
Camshaft Coupling
Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
Camshaft coupling bolts, tightening torque

D06-67
L 42 MC
130
Nm
D06-60
S/K/L 50 MC
300
Nm
D06-61
S/K/L 60 MC
460
Nm
D06-62
S/L 70 MC
700
Nm
D06-63
S/K/L 80 MC
985
Nm
D06-64
S/K/L 90 MC
1350
Nm
MAN B&W Diesel A/S
Page 1 (2)
106-8
Camshaft Coupling
Data
Plate
P90651
Item No.
152
Description
Crowfoot wrench for coupling flange
P91356
Lifting Tools, Etc.
P91359
Torque Spanners
P91366
Page 2 (2)
58
Feeler gauge
MAN B&W Diesel A/S
Camshaft Coupling
906-8.1
Checking
Camshaft Coupling
S80MC
0001
Checking
906-8.1
1.
Checking of Bolts in Camshaft Couplings

1. In order to gain access to the camshaft coupling bolts, remove one or all of the following:
top guard
split flange
scraper ring
2. Check the connection between the camshaft coupling flanges with a 0.05 mm feeler gauge.
KM906-8.1 01 01
The extent of disassembling must be evaluated in each case.
2.
Note!
KM906-8.1 01 02
If any gap can be measured on the entire

circumference of the couplings, MAN
B&W Diesel should be contacted for further instructions.
MAN B&W Diesel A/S
Page 1 (2)
906-8.1
Camshaft Coupling
Checking
3.
3. Remove the locking wire, if fitted, from the

nuts on the camshaft coupling bolts.
Check the tightening torque of the camshaft
coupling bolts.
See Data D06-60 and D06-64.
If the torque needed to move the nut deviates less than 25% from the value in Data,
the torque is within its limits.
KM906-8.1 01 03
If the torque needed to move the nut deviates more than 25% from the value stated
in Data, retighten the nut to the value stated
in Data and recheck the tightening torque
after 500-1500 hours of running.
Note!
4.
If the tightening torque during the

recheck deviates more than 25% from
the value stated in Data, MAN B&W Diesel must be contacted for further instructions.
KM906-8.1 01 04
4. Mount the locking wire that locks the nuts

on the camshaft coupling bolts.
See Volume II, Maintenance, Chapter 913.
Page 2 (2)
5. Mount the top guard, split flange, scraper

ring etc. with liquid gasket and gaskets in
the relevant places.
Tighten all screws.
MAN B&W Diesel A/S

107-01
907-01
107-02
907-02
0020
0216
0042
0214
MAN Diesel A/S
Starting Air Distributor, Data

Starting Air Distributor
Start Air Valve, Data
Starting Air Valve
MAN Diesel A/S
107-1

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description
D07-01
Gear wheel on camshaft, tightening torque
D07-03
Value
Unit
90
Nm
Clearance between gear wheel and bushing:Min. Max.
0.9-1.6
mm
D07-04
Clearance with roller in outermost position:Min. Max.
1.0-3.0
mm
D07-05
Clearance with roller in innermost position:Min. Max.
1.0-2.0
mm
MAN B&W Diesel A/S
Page 1 (2)
107-1

Data
Plate
P91366
Page 2 (2)
Item No.
058
Description
Feeler gauge
MAN B&W Diesel A/S
907-1.1
Checking
S46MCC
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)
107-2
Starting Air Valve

Data
X
Stopped engine

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D07-09
Piston tightening torque
180
Nm
D07-10
Valve tightening torque
17520
Nm
D07-11
Valve tightening angle
D07-12
Starting air valve
MAN B&W Diesel A/S
50/30
24
kg
Page 1 (2)
107-2
Starting Air Valve

Data
Plate
Item No.
Description
P90151
095
Grinding ring for starting valve
P90151
105
Grinding handle for starting valve
P91359
Page 2 (2)
Torque Spanners
MAN B&W Diesel A/S
Starting Air Valve
907-2.2
Dismantling
Starting Air Valve
S46MC-C
0214
Dismantling
907-2.2
1.
1. Shut off the starting air and control air inlet.

Dismount the control air pipes.
Unscrew the fixing nuts of the starting valve
flange.
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
0045
0226
0082
0256
0052
0227
0038
0220
0015
0216
0034
0234
0207
0041
0014
0016
MAN Diesel A/S
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 Diesel A/S
108-1
High-Pressure Pipe
Data
X
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
Description
Value
Unit
D08-01
High-pressure pipe, tightening torque
36
Nm
D08-02
Distance of high pressure pipe lower edge to pressure flange
15
mm
D08-03
High-pressure pipe
25
kg
MAN B&W Diesel A/S
Page 1 (2)
108-1
High-Pressure Pipe
Data
Plate
P90851
Page 2 (2)
Item No.
112
Description
Grinding mandrel for h.p. pipe
MAN B&W Diesel A/S
High-Pressure Pipe
908-1.2
Dismantling
908-1.2
Disling
908-1.2
Dismantling
1.
1. When replacing the hydraulic high-pressure

pipe, the exhaust valve or the hydraulic actuator, check and, if necessary, recondition
the high-pressure pipe sealing surfaces.
2. Before dismantling the high-pressure pipe,
stop the camshaft oil pump.
Loosen the screws for the high-pressure
pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator.
M908010226D01
D0803
M908010226D02
2.
MAN B&W Diesel A/S
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
1. Check the contact surfaces of the pressure
pipe for marks and, if necessary, grind the
pipe ends by means of the grinding mandrel and the two guiding tools.
1.
M908010226O01
Start grinding with a coarse grinding paste,

for example Carborundum No. 200, and
finish with a fine grinding paste, for example Carborundum No. 500.
Carborundum
2. After reconditioning the contact surfaces of

the pipe, measure the distance from the
edge of the thrust bushing to the contact
surface at both ends of the pipe. This measurement is to correspond with the value
stated in Data.
Check the thrust pads in the exhaust valve
and the actuator for marks on the sealing
surface.
2.
Replace the O-rings on the thrust pads.

If considered necessary, replace the thrust
pads.
M908010226O02
Lift the thrust pad free by, for example, using a screwdriver in the groove of the
thrust pad.
Page 2 (3)
D0802
MAN B&W Diesel A/S
908-1.4
High-Pressure Pipe
Mounting
1. Mount the hydraulic high-pressure pipe as
follows:
1.
After fitting the pipe correctly in relation to

the exhaust valve and actuator, tighten up
the screws of the pressure flanges diagonally, see Data.
2. Check the whole system for tightness.
M908010226M01
Position the high-pressure pipe with the

sealing surfaces of the pipe resting on the
thrust pads of the exhaust valve/actuator.
Take care not to damage the O-rings on
the thrust pads.
D0801
M908010226M02
2.
MAN B&W Diesel A/S
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.
Description
Value
Unit
D08-04
Safety valve, opening pressure
21
bar
D08-05
Screws for lifting eye bolt, tightening torque
50
Nm
D08-06
Oil cylinder, tightening torque
70
Nm
D08-07
Safety valve, tightening torque
50 - 80
Nm
D08-09
Bottom piece seat, grinding angle
29.9 - 30.0
D08-10
Valve spindle seat, grinding angle
30.4 - 30.5
D08-11
Bottom piece seat, max. grinding
2.3
mm
D08-12
Gap of bottom piece seat
1.0
mm
D08-13
Spindle, max. burn-off
8.0
mm
D08-14
Spindle, max. grinding
2.0
mm
D08-15
Spindle stem, measuring area, min.
235
mm
D08-16
Spindle stem, measuring area, max.
345
mm
D08-17
Spindle stem, min. diameter
59.8
mm
D08-18
Bushing max. diameter, top
60.6
mm
D08-19
Bushing max. diameter, bottom
62.0
mm
D08-20
Oil cylinder max. inside diameter
71.2
mm
D08-21
Piston rings, min. thickness
2.6
mm
D08-24
Exhaust valve, complete
460
kg
D08-25
Exhaust valve housing
260
kg
D08-26
Oil cylinder
65
kg
D08-27
Air cylinder
20
kg
D08-28
Spindle
45
kg
D08-29
Bottom piece
55
kg
D08-30
Air piston
kg
D13-01
D13-02
900
bar
800 - 990
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
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
P91351
010
P91351
046
P91351
058
P91351
117
Page 2 (2)
Exhaust Valve
MAN B&W Diesel
Checking
Checks during running:

1.
908-2.1
1.
Check of valve spindle rotation
The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the 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
nished, lift the rotation indicator and lock
it in the top position.
M908020252C01
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).
M908020256C02
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.
M908020254C03
Check the tightness of the sealing rings

between the bottom piece and the exhaust
valve housing. IF water ows from the small
bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is
leaking.
If water ows from the any of the rings, the
exhaust valve must be dismounted and the
sealing rings replaced.
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 dropdown 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 engineside manoeuvring
stand.
AIR SUPPLY
EXHAUST VALVE
Check the drop down time for all spindles:
Spindles dropping down within 30 min-
M908020256C04
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 nished,
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 nonreturn

valve on the air cylinder and check the
nonreturn valve for tightness.
The checks is for guidance only, minor
leaks is difcult to detect.
M908020256C05
C
B
Page 3 (24)
908-2.2
Exhaust Valve
Dismantling
1.
MAN B&W Diesel
Close off cooling water
1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.
Close the air supply to the exhaust valve.
2. Dismount the oil pipe connections
Dismount the highpressure pipe for the hydraulic valve actuation.
See Procedure 9081.2
M908020256D01
Dismount the return oil pipe from the exhaust valve.
M908020256D02
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.
M908020256D03
Loosen the screws which attach the intermediate pipe to the exhaust valve housing.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 9131.
M908020256D04
D1302
Page 5 (24)
Exhaust Valve
908-2.2
Dismantling
MAN B&W Diesel
5. Lift of exhaust valve

5.
D0824
Check all connections to the valve are removed.

Attach the crane to the eye bolt tted on
top of the valve and start lifting the exhaust
valve. During the lift check 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.
See Procedure 9011.3.
M908020256D06
For overhaul of the exhaust valve, see Procedure 9082.3
Page 6 (24)
Exhaust Valve
MAN B&W Diesel
1.
908-2.3
Overhaul
Oil cylinder
1.
Place the exhaust valve on a wooden support on the platform.
D0826
Remove the nuts 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 ange

on top of the air piston and dismount the
ange.
2.
M908020256O02
Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
M908020256O01
Relieve the air pressure through the

nonreturn valve from below the piston. Use
a small screwdriver to press the ball into
the nonreturn valve. Cover the nonreturn
valve with a rag to catch the oil drops.
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
M908020256O04
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.
M908020256O05
D08-29
Page 8 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
Remove the oil cylinder.
5.
5. Air piston and cylinder
D08-30
Dismount the air piston from the air cylinder.
D08-27
Dismount the nonreturn valve from the air

cylinder/valve housing.
Remove and discard the Oring on the air

cylinder.
6. Guide bushing
M908020256O06
Mount two eye bolts in the air cylinder and

dismount the air cylinder.
Clean the exhaust valve housing.

6.
Inspect the bushing in the spindle guide for
wear and measure the top and bottom diameters. See Data.
M908020255O10
D0818
D0819
Page 9 (24)
908-2.3
Exhaust Valve
Overhaul
7.
MAN B&W Diesel

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 Oring for sealing between bushing and exhaust valve housing. Mount and
tighten the screws for the bushing.
M908020256O08
8. Bottom piece inspection

Before cleaning the bottom piece, See Volume I, supplement 70703
Inspect and evaluate the seating according
to Volume I.
M908020256O09
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
D0812
Use the bottom piece template and a feeler

gauge, take measurements G2 and G3. All
measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating.
For maximum wear or grinding, see Data
D0811 and D0812.
D0809
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.
M908020255O14
If the seat or the recess G3 is ground, see

Data D08 09 for correct grinding angle.
G2
D0811
10.
M908020255O15
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 Oring in the upper groove.
Make sure that the groove for the Useal is
clean.
M908020256O12
Heat the Useal in 100C hot water for minimum ve 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 tted, check that the guide pin in the
bottom piece enters the hole in the bottom
of the exhaust valve housing.
M908020256O13
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 70703
Inspect and evaluate the spindle according
to Volume I.
In connection with evaluation of the spindle

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

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

14.
M908020256O15
If necessary to grind the seat, see Data

D0810 for correct grinding angle.
F1
D0810
A
D0813
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.
D0816 D0815
D0817
Check the spindle stem for wear in the

area D0815 to D0816 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
M908020252O19
When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
16.
M908020255O16
D0828
Page 14 (24)
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
17. Spindle bushing sealingrings

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

exhaust valve housing.
Carefully land the exhaust valve housing
with the bottom piece on the exhaust valve
spindle.
M908020256O18
Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.
18.
M908020256O19
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 nonreturn 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
Oring in the groove on the outside of the
air cylinder.
Compressed Air
20. Safety valve
M908020256O20
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 Oring on

the safety valve. Mount the safety valve in
the bore near the bottom of the air cylinder.
When mounting the safety valve in the air
cylinder, use only the machined faces on
the valve housing and tighten, see Data.
M908020256O21
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 Orings 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 Orings on

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

Check the teon guide ring and teon sealing ring for wear, if it is necessary to replace the sealing rings on the air piston, cut
them and remove them.
M908020256O22
Note!
22.
Be careful not to damage the edges of the

ring grooves in the piston.
Before mounting, heat the new teon

rings in 100C hot water for at least ve
minutes. When mounting the teon rings,
be careful not to damage the running
surfaces.
M908020252O32
Note!
After mounting, compress the teon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.
Mount new Orings 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
M908020256O24
Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.
Mount the ange on top of the air piston
and, by means of the four screws, tighten
the air piston and the ange together.
On valve models where the bolts are designed for securing, secure the bolts. See
Procedure 9137.
M908020256O25
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 orice plug.
Remove the sealing oil unit.
Remove and discard the gasket. Unscrew
and clean the orice plug. Remove and discard the sealing disc. Check and clean the
bore for the orice plug in the top of the oil
cylinder.
26. Sealing oil control unit.
26.
M908020255O37
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
M908020256O26
Place the oil cylinder in a horizontal position. Remove the ange 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 D0820, 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
M908020253O42
D0821
Mount the piston and the ange in the oil

cylinder. Tighten and lock the screws.
Return the oil cylinder to an upright position. Mount a new sealing disc in the bore
for the orice plug. Screw the orice 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.
M908020256O31
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.
D0806
M908020256O32
Mount the sealing oil pipe.
Page 21 (24)
Exhaust Valve
908-2.4
Mounting
1.
1.
MAN B&W Diesel

Checks before mounting
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve is checked and prepared as follows:
D0824
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.
M908020256M01
G3
Check that the valve stays closed for a

minimum of 5 minutes.
Check the valve is tted with new sealing
rings in the grooves on the bottom piece.
2. Exhaust valve landing
Close the valve with compressed air.
2.
Lubricate the sealing rings with vaseline and the threads of the studs with
antiseizure paste.
Compressed Air
Position the valve in the cylinder cover

bore, guiding it in accordance with the exhaust anges and the guide pin on the exhaust side of the exhaust valve.
Copper Grease
M908020256M02
Vaseline
Page 22 (24)
Exhaust Valve
MAN B&W Diesel
908-2.4
Mounting
3. Mounting of hydraulic nuts.

3.
Mount and tighten the hydraulic nuts, see
Data.
See Procedure 9131.
D1301
Mount the protective caps on the exhaust

valve studs.
4. Mount the pipe connections
Mount and tighten the screws to the exhaust valve housing.

Mount the insulation and plate jacket
for the intermediate pipe.
M908020256M03
Connect the intermediate pipe to the exhaust valve.
4.
Mount the cooling water connections for

the exhaust valve and the air pipe for the
air spring.
5. Mount the oil pipe connections
Mount the return oil pipe to the exhaustvalve.

Check that all pipe connections are properly tightened.
M908020256M04
Mount the highpressure pipe for the hydraulic valve actuation.

See Procedure 9081.2
M908020256M05
5.
Page 23 (24)
Exhaust Valve
908-2.4
Mounting
MAN B&W Diesel
6. Open cooling water supply

6.
Check that all water connections are
mounted and tightened.
Open the cooling water inlet supply, and
vent the exhaust valve, open the cooling
water outlet valve
Open the air supply to the exhaust valve.
Check the tightness of the sealing ring between the bottom piece and the exhaust
valve housing. See Procedure 9082.1.
7.
Air spring check
M908020256M06
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:
Engage the indicators on top of the exhaust
valves and wait until the exhaust valves are
closed.
7.
M908020256M07
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
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D08-20
Oil cylinder max. inside diameter
D08-21
Value
Unit
71.2
mm
Piston rings, min. thickness
2.6
mm
D08-32
Hydraulic actuator, tightening torque
300
Nm
D08-33
Locking plate, tightening torque
10
Nm
D08-34
Hydraulic actuator, tightening angle
D08-35
Hydraulic actuator
MAN B&W Diesel A/S
100/25
55
Nm/
kg
Page 1 (2)
108-3

Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
908-3.1
Checking
L60MC-C
0227
Checking
908-3.1
1.
1. The non-return valve A is built into the oil

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

See Procedure 908-3.2
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.
GM908-3.0 78 01
Dismount the high-pressure pipe.

2. Release the mountings for the indicator
drive from the actuator housing.
Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.
2.
D08-35
Unscrew the nuts on the two short studs,
then loosen the nuts on the long studs successively until the roller guide spring is relieved.
Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller
guide.
HG908-3.3 201 02
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.
D08-21
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.
JM908-3.0 73 05
D08-20
0$1% :'LHVHO$6
Page 3 (4)
908-3.4

Mounting
Mounting
908-3.4
1.
D08-33
1. Mount the actuator piston in the roller guide

and turn 90 to lock it in the bayonet joint.
Mount the locking plate and tighten as stated in Data. Lubricate the piston with plenty
of camshaft lubricating oil.
2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
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.
Note!
Use only the tightening angle OR the
tightening torque, NOT both.
D08-32
or
3. Mount the oil inlet pipe and the drain pipe

from the exhaust valve.
D08-34
HG908-3.4 201 02
Mount the hydraulic high pressure pipe.

HG908-3.4 201 03
3.
Page 4 (4)
0$1% :'LHVHO$6
108-4
Exhaust Valve Roller Guide

Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D08-36
Bushing/shaft pin, max. clearance
0.5
mm
D08-38
Roller guide complete
30
kg
MAN B&W Diesel A/S
Page 1 (2)
108-4

Data
Plate
P90851
Page 2 (2)
Item No.
053
Description
Lifting tool for roller guide
MAN B&W Diesel A/S
908-4.1
Checking
1. The exhaust valve roller guide can be partially checked while mounted on the engine, using the following procedure:
2.
Lift the roller guide.

2. Remove the camshaft inspection cover.
Check the movability of the roller by turning this by hand to ascertain if the roller
moves freely and without unnecessary resistance or hard points.
Also inspect the surface of the roller for
possible damage marks, seizures or
scratches. Make sure that no traces of
bearing metal exist in the roller guide housing.
M908040220C02
Turn the engine to provide the maximum

space between the roller guide and the
cam disc.
5.
D0836
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.
M908040220C05
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.
MAN B&W Diesel A/S
Page 1 (4)
908-4.1

Checking
7. 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 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)
MAN B&W Diesel A/S
908-4.2

Dismantling
1. Dismantle the hydraulic actuator above the
exhaust valve roller guide.
1.
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.
M908040220D01
Lower the lock ring, thereby securing

the foot in the locked position.
2.
D0838
M908040220D02
90 O
MAN B&W Diesel A/S
Page 3 (4)
908-4.4

Mounting
1. Mount the lifting tool for the roller guide as
follows:
1.
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
D0838
90

Lower the lock ring, thereby securing
Clean and lubricate the sliding surfaces of
the roller and the roller guide and lower it
carefully into the roller guide bushing.
M908040220D02
Remove the lifting tool.
Page 4 (4)
2. Mount the actuator.

MAN B&W Diesel A/S
108-5
Exhaust Valve Cam

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

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

Data
Plate
Item No.
Description
P90651
044
Impact spanner for turning cam
P90851
173
Lifting tool for exhaust valve roller guide
P91351
010
P91351
034
P91351
058
P91351
154
Conical valve, 0 - 15
P91351
225
Disc, round-plain, Cu 11x3 mm
P91366
073
Dial gauge and stand tool
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve Cam
908-5.1
Checking
1. Turn the crank throw of the cylinder concerned in AHEAD direction until TDC.
Check and write down the angle indicated
on the turning wheel.
1.
2. Remove the high pressure pipe, see procedure 908-1.2

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

until lifted to D08-39, and the dial gauge
gives the reading 1.00 mm and calculate
the angle A, which is the number of degrees the crank throw has turned from TDC
position to the present position.
Continue turning AHEAD until the roller
guide again is lifted to D08-39, and the dial
gauge gives the reading 1.00 mm.
Calculate the angle B, which is the number
of degrees the crank throw has turned from
TDC position to the present position.
Note!
When calculating the angles A and B, remember to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees
MAN B&W Diesel A/S
Page 1 (4)
908-5.1
Exhaust Valve Cam

Checking
4.
4. Calculate the lead angle as:

180 (A + B)/2
The lead angle is normally a negative figure.
The illustration shows the position of the
exhaust cam when the piston of the relevant cylinder is in TDC.
The position of the cam must be correct
within a tolerance of +/-0.5.
See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the lead angle
of the plant in question.
5.
5. The cam lead angle can be checked visually by reading directly the scale position of
the exhaust cam over the marking scratch
on the camshaft and comparing this angle
with the angle stated in the Adjustment
Sheet.
At the same time, it is recommended to
check the position of the camshaft with the
pin gauge. See Procedure 906-3.1
Page 2 (4)
MAN B&W Diesel A/S
Exhaust Valve Cam
908-5.3
Adjustment
Normally, adjustment of the exhaust cams
should not be necessary. Before adjustment of any cams, see Volume I, Chapter
706.
1.
1. Remove the oil tray from the camshaft

housing. See procedure 906-4.2
3. Turn the camshaft until there is access to

the oil ducts in the exhaust 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.
M908050216O01
2. Dismount the exhaust valve high-pressure

pipe, see procedure 908-1.2.
3.
Mount snap-on couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snap-on couplings
and the distributor block and between the
distributor block and the hydraulic high
pressure pump.
4. Mount the special spanner on the exhaust
cam disc, ensuring that the two pins enter
the holes in the cam.
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snap-on couplings.
Raise the hydraulic pressure until oil seeps
out along the camshaft under the cam disc.
4.
Keep the cam pressurised for at least two

to five minutes before turning the cam.
Oil must sweep out with the pump running
during the operation.
Keep the cam pressurised during turning.
MAN B&W Diesel A/S
Page 3 (4)
908-5.3
Exhaust Valve Cam

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

until the desired change of lead is obtained. Check the change on the cam scale
To increase the lead angle and reduce the
compression pressure:
turn the cam disc ASTERN.
To reduce lead angle and increase the
compression pressure:
turn the cam disc AHEAD.
6. After completing the desired turning of the
cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.
Wait at least 15 minutes the cam must be
allowed time to settle before mounting
the plugs again in the oil ducts of the cam
disc.
After carrying out adjustment, measure the
exhaust cam lead again. See procedure
908-5.1.
Write down and file the new results for the
purpose of comparing with future measurements and adjustment.
7. Mount the oil tray on the camshaft housing.
See procedure 906-4.4.
8. Mount the high pressure pipe for the exhaust valve. See procedure 908-1.4
9. After any adjustment of the cam position,
pcomp must be recorded and compared with
pcomp at a known engine reference load.
Page 4 (4)
MAN B&W Diesel A/S
108-7
Exhaust Valve Special Running

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

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

Data
Plate
Item No.
Description
P90851
124
Tool for emergency open exhaust valve
P90851
173
Page 2 (2)
MAN B&W Diesel A/S
Exhaust Valve
908-7.1
Special running
Warning!
3.
Engine trouble might require that a cylinder be

taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.
This can take place with the exhaust valve
locked in either the open or the closed position. Either way, carry out the following procedure:
1. Stop the engine.
M908070234O03
Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place
at engine standstill.
4.
Stop the lubricating oil pump.

Lift the relevant fuel pump roller guide.
3. Dismantle the non-return valve on the oil

inlet pipe. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one
side. Mount the non-return valve on the oil
pipe and blank off the non-return valve with
the plug from tool panel 908.
M908040220C02
2. Dismantle the hydraulic high-pressure pipe

and the connecting sleeve.
4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.
MAN B&W Diesel A/S
Page 1 (4)
908-7.1
Exhaust Valve
Special Running
5.
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.
Tighten the upper nut of the tool against
the lower nut to secure the roller guide in
this position.
6. If the cylinder is to operate with the exhaust valve closed, the air supply must remain connected to the air cylinder of the
exhaust valve. No further action is required.
M908070234O05
If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:
Hint!
Use a small screwdriver to press the ball
into the non-return valve, and cover it
with a rag to catch the oil drops.
M908070234O07
7.
7. Shut off the compressed air supply and remove the air pipe connection to the exhaust valve and plug the pipe. Release the
air from the air spring through the non-return valve on the side of the air cylinder.
Page 2 (4)
MAN B&W Diesel A/S
Exhaust Valve
908-7.1
Special running
8. Dismantle the rotation indicator on the air
cylinder and mount the tool for opening of
the exhaust valve.
8.
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.
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.
The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.
Leaving the rotation indicator in the engaged position continuously might damage the exhaust valve due to the formation of a wear groove in the air piston of
the exhaust valve.
M908070234O08
Note!
9.
M908070234O05
Re-connect the air supply to the air cylinder.
MAN B&W Diesel A/S
Page 3 (4)
908-7.1
Exhaust Valve
Special Running
11.
11. Remove the plug from the non-return valve

and re-connect the oil inlet pipe and the
connecting sleeve on the actuator housing,
after fitting new sealing rings on the connecting sleeve.
12. Mount the hydraulic high-pressure pipe.
M908070234O11
13. Engage the fuel pump roller guide.

Page 4 (4)
MAN B&W Diesel A/S

MAN B&W
Plate
P90851-0207
Page 1 (2)
Plate
P90851-0207

MAN B&W
Item
No.
Item Description
016
028
041
053
065
077
089
090
100
112
Panel for tools

Name plate
Tightening template for actuator
Lifting tool for roller guide
Lifting tool for exhaust valve
Conical ring for pneumatic piston
Gauge for exhaust valve spindle
Stepped drift for roller guide
Grinding mandrel for high-pressure
pipe
Tool for emergency opening of
exhaust valve
Gauge for exhaust valve bottom piece
Lifting tool for exhaust valve spindle
Lifting tool for exhaust valve roller
guide
Grinding ring, exhaust valve bottom
piece
124
150
161
173
185
Page 2 (2)

MAN B&W
Plate
P90862-0041
Page 1 (2)
Plate
P90862-0041

MAN B&W
Item
No.
Item Description
028
030
053
065
089
090
100
207

Support
Tommy bar
Spanner
Stud setter
Page 2 (2)

MAN B&W
Plate
P90863-0014
Page 1 (2)
Plate
P90863-0014
Item
No.
011
Page 2 (2)
MAN B&W
Item Description
Worktable

MAN B&W
Plate
P90863-0016
Page 1 (2)
Plate
P90863-0016
Item
No.
011
Page 2 (2)

MAN B&W
Item Description
Grinding machine for exhaust valve

spindle seat

109-01
909-01
109-02
909-02
109-03
909-03
109-04
909-04
109-05
909-05
109-06
909-06
109-07
909-07
109-08
909-08
109-09
909-09
10910
90910
10911
90911
10912
90912
10913
90913
10914
90914
10915
90915
0063
0241
0005
0206
0050
0233
0058
0222
0063
0234
0050
0219
0039
0214
0050
0217
0032
0214
0018
0209
0068
0244
0047
0222
0033
0207
0074
0234
0058
0234
MAN Diesel A/S
Fuel Pump Settings, Data

Fuel Pump Settings
VIT System, Data
VIT System
Fuel Pump Cam, Data
Fuel Pump Cam
Fuel Pump, Data
Fuel Pump
Fuel Pump Top Cover, Data
Fuel Pump Top Cover
Fuel Pump Barrel Assembly, Data
Fuel Pump Barrel Assembly
Fuel Pump Suction Valve, Data
Fuel Pump Suction Valve
Fuel Pump Puncture Valve, Data
Fuel Pump Puncture Valve
Fuel Pump Shock Absorber, Data
Fuel System Shock Absorber
Lifting Gear Roller Guide, Data
Lifting Gear for Roller Guide
Fuel Valve, Data
Fuel Valve
Spindle Guide, Data
Spindle Guide
Non-Return Valve in Fuel Valve, Data
Non-Return Valve in Fuel Valve
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
90951
90961
90966
90968
90974
90977
90979
90980
0441
0069
0008
0001
0001
0001
0001
0001
MAN Diesel A/S
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
109-1
Fuel Pump Settings

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
D09-02
Description
Change of one index mark, corresponds to p-max being altered approx.
MAN B&W Diesel A/S
Value
Unit
3-4
bar
Page 1 (2)
109-1
Fuel Pump Settings

Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Fuel Pump Settings
909-1.3
Adjustment
Fuel Pump Settings
K98MC-C
0241
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 p max 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 p max value must not deviate more than 3 bar from the average
value for all cylinders.
MAN B&W Diesel A/S
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!
6.
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.
M90901-0242O06
6. After adjustment of the fuel pumps a set of

observations must be taken, to evaluate the
adjustments see Volume I.
Page 2 (2)
MAN B&W Diesel A/S
109-2
VIT System
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-2
VIT System
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
VIT System
K98MC-C
0206
Adjustment
909-2.3
1.
Before adjustment of any part of the VIT system, see Volume I, Chapter 706. All adjustments should be based on a set of
observations including a set of indicator diagrams taken when the engine is running just
above the breakpoint (90% MCR).
If the fuel quality has changed or if the fuel

pumps are worn, the pmax will change, this
change can be corrected by adjusting the pmax
of all the cylinders with the VIT system, see
Fine adjustment.
M90902-0206O01
The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection
Timing) system.
Normally the VIT system is adjusted to start at

40% engine load and to have break point at
90% of MCR engine output. Look in the test
sheet for actual start- and break point.
2.
Mechanical VIT system

Basic adjustment:
When the basic adjustment is carried out the
engine must be stopped, normally only fine adjustment is necessary.
1. Engage the manual engine control, and adjust the regulating shaft to a fuel pump index corresponding to 90% engine load.
(The fuel index must correspond to 90%
load taken by measurement or from the test
bed sheet).
M90902-0206O02
2. Check that the VIT lever is resting on both

rollers (break point for all cylinders).
MAN B&W Diesel A/S
Page 1 (5)
VIT System
909-2.3
Adjustment
3.
3. If necessary, adjust the lever by loosening

the nut A and turn the clamping arm B, until
lever contact with both rollers and tighten
nut A.
4. Spare pilot valves should be pre-adjusted

to 0.5-5.0 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin
C.
M90602-0238O03
B
A
4.
Adjust the VIT air pressure to 3.0 bar, by

axial displacement of the bracket with the
pilot valve and read the pressure on the
pressure gauge C. See figure 2.
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.
Pbar
5
4
3
2
1.5
0.5 1
0.1
Pressing
in mm
0 1 2 3 4 5 6 7 8
0.5
Check that the pressure on the pressure

gauge and the pressing-in of pin C is in accordance with the curve.
Any necessary adjustment is done by turning adjusting screw B.
M90902-0206O04
Page 2 (5)
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
5.
Fine adjustment:
5. When the fine adjustment is carried out, the
engine must run at 90% load or just above.
Take a new set of indicator diagrams and
calculate the engine load.
Adjust the VIT air pressure to obtain cylinder p max of 140 bar. The VIT air pressure
must be maximum 5.0 bar.
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.
6. Run the engine at maximum load and check

that p max is 140 bar.
6.
M90902-0206O06
If the maximum combustion pressure deviates more than 3.0 bar from 140 bar, adjust
the pressure by replacement of the lowermost roller.
M90902-0206O05
For adjustment of pmax on a single cylinder,

see procedure 909-1.
MAN B&W Diesel A/S
Page 3 (5)
VIT System
909-2.3
Adjustment
Pmax
adjusted on
lowermost roller
7.
Pbar
Electronic VIT system
Break point
Pmax
adjusted on
uppermost roller
8. The adjustment should be based on a set

of indicator diagrams taken when the engine is running just above the breakpoint.
M90902-0206O07
Pcomp
40
90
100
%Load
9. 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.
10. Check the adjustment by taking a new set
of indicator diagrams while the engine is
running just above the breakpoint.
M90902-0206O08
8.
7. The uppermost roller is used to adjust the

VIT start point (40% engine load).
Page 4 (5)
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
11.
11. The I/P converter mounted on the engine

receives a 4-20 mA signal I from the electronic governor system and converts this
into a 0.5-5.0 bar control air pressure
pcontrol .
12. To check the adjustment of the I/P converter, operate the panel in the engine control
room to supply various signals I to the I/P
converter.
For operation of the panel, see the panel
manufacturers instructions.
P control
P supply
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.
5
4
3
M90902-0206O11
13. 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
1.5
0.5
0.1
2
1
I, mA
0
0
MAN B&W Diesel A/S
12
16
20
Page 5 (5)
109-3
Fuel Pump Cam

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-3
Fuel Pump Cam

Data
Plate
Item No.
Description
P90651
44
Impact spanner for turning cam
P90951
45
Measuring tool for fuel pump
P91351
10
P91351
46
P91351
58
P91351
154
Conical valve, 0 - 15
P91351
201
Quick coupling, male
P91351
225
Disc, round-plain, Cu 11x3 mm
Page 2 (2)
MAN B&W Diesel A/S
909-3.1
Fuel Pump Cam

Checking
Fuel cam lead:
1.
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.
C
X2
X1
Roller guide
1. To measure the fuel cam lead (top lift):

Dismantle the puncture valve.
2. Push down the measuring pin through the

top cover, until it rests against the pump
plunger.
Turn the engine until the lowest point of the
cam is found, use a calliper to find the
point.
M909030233C01
Make sure that the reversing mechanism is

in AHEAD direction.
Fuel cam
Ahead
Lowest position
of pump plunger
Main piston in TDC
2.
X
3. Measure the distance x from the top of the

measuring pin to the transverse piece.
Note down the result as x2.
Again measure the distance x from the top

of the measuring tool to the transverse
piece. Note down the result as x1.
Calculate the fuel cam lead C (top lift) as:
C = x1 x2 (mm)
M909030233C03
4. Turn ahead until the main piston of the cylinder concerned is in TDC.
3.
5. Note down the result for comparison with

the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.
M909030233C04
Remount the puncture valve.
MAN B&W Diesel A/S
Page 1 (4)
909-3.2
Fuel Pump Cam

Adjustment
Normally, adjustment of the fuel cam should
not be necessary. Before adjustment of fuel
equipment, see Volume I, Chapter 706.
1.
1. Remove the inspection cover from the

camshaft housing.
Note!
M909030233O01
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. Dismount the puncture valve from the fuel

pump top cover, and mount the measuring
tool to check the cam adjustment.
2.
X
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.
M909030233C03
Mount snap-on couplings in the oil ducts,

but do not tighten them.
Fit hoses between the snap-on couplings
and the distributor block and between the
distributor block and the hydraulic highpressure pump.
M909030233O03
3.
Page 2 (4)
MAN B&W Diesel A/S
Fuel Pump Cam
909-3.2
Adjustment
4. Mount the special spanner on the fuel cam
disc, ensuring that the two pins enter the
holes in the cam.
4.
For better access to the cam, remove the

oil tray and carry out the adjustment from
the bottom of the cam shaft housing.
See Procedure 906-4.2
Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.
Keep the cam pressurised for at least two
to five minutes before turning the cam.
M909030233O04
Apply a light pressure to the hydraulic system and, after venting the system, tighten
the snap-on couplings.
Oil must seep out with the pump running

during the operation to keep the cam
pressurised during turning.
Turn the cam disc, using the fitted spanner,
until the desired change of lead is obtained.
To increase lead and pmax:
turn the cam disc AHEAD.
To reduce lead and pmax:
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.
MAN B&W Diesel A/S
Page 3 (4)
909-3.2
Fuel Pump Cam

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.
Page 4 (4)
MAN B&W Diesel A/S
109-4
Fuel Pump
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D09-18
Pump housing nuts, tightening torque
D09-19
Pump housing nuts, tightening angle
D09-20
Pump housing
D09-21
Bottom plate
D09-68
Fuel pump complete
D09-39
Shock absorber
MAN B&W Diesel A/S
Value
Unit
450
150/60
Nm
Nm/
100
kg
kg
210
kg
20
kg
Page 1 (2)
109-4
Fuel Pump
Data
Plate
P90951
Page 2 (2)
Item No.
070
Description
Lifting tool for fuel pump housing
MAN B&W Diesel A/S
Fuel Pump
909-4.2
Dismantling
Fuel Pump
S60MC-C
0222
Dismantling
909-4.2
3.
Note!
2. Dismantle the barrel/plunger assembly.

3. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel inlet valve.
GN909-4.2 203 03
1. Dismantle the fuel pump top cover.

4.
Remove the fuel oil inlet pipe.

Discard the gaskets.
D09-20
4. Unscrew the nuts at the base of the fuel

pump.
Fit the lifting tool using the top cover studs/
nuts, and lift the pump housing away.
Take care not to damage the threads of the
studs.
JG909-8.0 71 02
Land the fuel pump on wooden planks.
0$1% :'LHVHO$6
Page 1 (8)
909-4.3
Fuel Pump
Overhaul
Overhaul
909-4.3
3.
1. If the fuel index arm or the VIT index arm

of the fuel pump is moving too tightly, the
regulating and timing systems of the fuel
pump must be overhauled.
GN909-4.3 203 03
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.
4. Dismantle the fuel pump shock absorber.
4.
HG909-9.2 201 01
D09-39
If necessary, overhaul the fuel pump shock

absorber.
Page 2 (8)
0$1% :'LHVHO$6
Fuel Pump
909-4.3
Overhaul
5.
5. Tilt the fuel pump housing into a horizontal

position on the wooden planks.
6. Dismantle the screws and the bottom plate
from the fuel pump housing.
If the bottom plate is stuck, loosen it by
screwing two M10x70 mm screws into the
holes of the bottom plate.
7. Dismantle the:
Sleeve
Regulating guide
HC909-3.4 121 05
Fuel index arm
6.
HC909-3.4 121 06
D09-21
HC909-3.4 121 07
7.
0$1% :'LHVHO$6
Page 3 (8)
909-4.3
Fuel Pump
Overhaul
8.
8. Dismantle the:
Guide screw
VIT index arm
Timing guide
9. Dismantle and inspect the plug screws in
both sides of the fuel pump housing.
HC909-3.4 121 08
If heavily eroded, replace the plug screws.

Replace the sealing rings and mount the
plug screws.
10. Clean all parts thoroughly in diesel oil or
kerosene. Blow dry with compressed air.
9.
11. Mount new sealing rings on the unions.
Note!
Soak the sealing rings in lubricating oil
before mounting
HC909-3.4 121 09
12. Clean all inside surfaces of the fuel pump

housing.
HC909-3.4 121 11
11.
Page 4 (8)
0$1% :'LHVHO$6
Fuel Pump
909-4.3
Overhaul
14.
Mounting
13. Lubricate the following with molybdenum disulphide (MoS 2):
all internal machined surfaces of the fuel
pump housing
the sliding surfaces of all parts of the
regulating and timing systems.
regulating guide
timing guide
VIT index arm
HC909-3.4 121 14
the teeth of the:
fuel index arm.
15.
14. Mount the VIT index and the guide screw.

Adjust the position of the VIT index arm so
that the scratch mark is aligned with the
centre of the fuel pump housing.
The timing guide must be mounted in such

a way that the scratch mark on the timing
guide is aligned with the scratch mark on
the VIT index arm, which must be visible
through the hole in the timing guide.
16.
HC909-3.4 121 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.
HC909-3.4 121 15
15. Mount the timing guide in the fuel pump

housing.
0$1% :'LHVHO$6
Page 5 (8)
909-4.3
Fuel Pump
Overhaul
17.
17. Mount the fuel index arm.

Adjust the position of the fuel index arm so
that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.
HC909-3.4 121 17
18. Mount the regulating guide in the fuel pump

housing.
The regulating guide must be mounted so
that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.
19. Mount the bottom plate on the fuel pump
housing.
HC909-3.4 121 18
18.
HC909-3.4 121 06
19.
Page 6 (8)
0$1% :'LHVHO$6
Fuel Pump
909-4.3
Overhaul
20.
20. Mount the fuel pump shock absorber.
HC909-9.2 201 01
21. Mount the actuator and actuator bracket.
GN909-4.3 203 03
21.
0$1% :'LHVHO$6
Page 7 (8)
Fuel Pump
909-4.4
Mounting
Mounting
909-4.4
2.
1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum disulphide (MoS 2).
D09-20
D09-18
or
D09-19
2. Lower the fuel pump housing on to the

pump base, taking care not to damage the
threads of the studs.
Remove the lifting tool.
Fit and tighten the nuts at the base of the
pump housing. Use either the tightening
torque or the tightening angle. See Data.
3. Mount the fuel oil inlet pipe between the
pump housing and the inlet valve.
4. Mount the barrel assembly in the fuel pump
housing.
5. Mount the top cover on the fuel pump housing.
6. Mount the puncture valve, see Procedure
909-8.4.
JG909-8.0 71 02
7. Mount the drain oil pipes, and the compressed air pipes.
GN909-4.2 203 03
3.
Page 8 (8)
0$1% :'LHVHO$6
109-5
Fuel Pump Top Cover

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D09-23
Top cover studs, screwing-in torque
130
Nm
D09-24
Top cover nuts, tightening torque
210
Nm
D09-26
Outlet seat, max.grinding diameter
18
mm
D09-27
Top cover
35
kg
MAN B&W Diesel A/S
Page 1 (2)
109-5
Fuel Pump Top Cover

Data
Plate
Item No.
Description
P90951
069
Lifting tool for fuel pump
P90951
094
Milling tool for fuel oil pipe seats
Page 2 (2)
MAN B&W Diesel A/S
Fuel Pump Top Cover
909-5.1
Checking
1. Shut off the fuel oil inlet.
1.
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.
Dismount the high-pressure pipes between
the top cover and the fuel valves.
M909050234D01

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.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
M909050234D02
If the puncture valve is to be overhauled,

remove the puncture valve from the top
cover at this stage.
3.
D0927
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.
M909050234D03
Discard the gasket.
MAN B&W Diesel A/S
Page 1 (3)
909-5.2
Fuel Pump Top Cover

Dismantling
1. If not already done, dismount the protective
cap and the puncture valve from the top
cover.
1.
2. Mount the top cover in special bracket and

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.
M909050234O02
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.
2.
After completing the milling, use compressed air to blow the vaseline/ grease
out from the oil ducts.
D0926
Clean the top cover with diesel oil/gas oil,

and blow dry with compressed air.
Note!
M9099050234O03
Make sure that all bores and threads inside the top cover are absolutely clean.
4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
M9099050234O04
3.
If necessary, recondition the seats of the

fuel oil high-pressure pipes.
Page 2 (3)
MAN B&W Diesel A/S
909-5.2
Fuel Pump Top Cover

Dismantling
1. Make sure that the inside of the fuel pump
housing and the top of the fuel pump barrel is completely clean.
1.
D0927
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.
Warning!
M909050234M01
Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide
(MoS2). See Procedure 913-11.
3.
D0924
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.
4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure
909-8.4.
M909050234M03
When doing this, the top cover must not

move upwards!
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.
M909050234M04
Mount the drain pipes on the top cover

and the connecting pipe to the puncture
valve. Open the fuel oil inlet.
MAN B&W Diesel A/S
Page 3 (3)
109-6

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
D09-29
Barrel assembly
D09-30
Plunger
MAN B&W Diesel A/S
Value
Unit
28
kg
kg
Page 1 (2)
109-6

Data
Plate
Item No.
Description
P90951
057
Lifting tool for barrel and plunger
P90951
224
Tool for P. max rack
P90977
Page 2 (2)
Mounting Tools - Pump Barrel Seals
MAN B&W Diesel A/S
909-6.2
Dismantling
S60MC-C
0219
Dismantling
909-6.2
1.

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

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
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
X
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
Description
Value
Unit
D09-33
Suction valve, tightening torque
900
Nm
D09-34
Suction valve
2.5
kg
MAN B&W Diesel A/S
Page 1 (2)
109-7

Data
Plate
P90951
P90979
Page 2 (2)
Item No.
128
Description
Crowfoot spanner
MAN B&W Diesel A/S
909-7.1
Checking
S60MC-C
0214
Checking
909-7.1
1.
1. Using a brass mandrel, check that the valve

slide can slide freely up and down inside
the suction valve.
2. Check the seats for tightness by filling the
inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.
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
X
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
D09-35
Description
Puncture valve, tightening torque
MAN B&W Diesel A/S
Value
Unit
890
Nm
Page 1 (2)
109-8

Data
Plate
Item No.
Description
P90951
Crowfoot spanner
P90980
Page 2 (2)
MAN B&W Diesel A/S
909-8.2
Dismantling
S60MC-C
0217
Dismantling
909-8.2
2.

Open the drain cock at the bottom of the
pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.
Note!
2. Dismantle the control air pipe and the 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
109-9
Fuel Pump Shock Absorber

Data
X
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)
Item No.
Description
MAN B&W Diesel A/S
909-9.1
Checking
S60MC-C
0214
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)
109-10

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description

MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-10

Data
Plate
P90951
Page 2 (2)
Item No.
307
Description
Pulling tool bell shaped
MAN B&W Diesel A/S
909-10.1
Checking
K98MC-C
209
Checking
909-10.1
1.
Warning!
Do NOT use the lifting gear for the fuel
pump roller guide while the engine is running.
If a fuel pump is to be put out of action, disconnect it in the following manner:
Remove the inspection cover on the upper

part of the camshaft housing in front of the
fuel cam for the pertaining roller guide.
GG909-10.0 202 01
1. Stop the engine and engage the turning

gear.
2. Turn the camshaft until the roller is in the

highest position on the cam (i.e. on the circular section of the fuel cam).
2.
GM909-5.0 59 02
Mount the pulling tool over the lifting device

and screw the spindle into the stud.
When referring to this page, please quote Procedure 909-10.1 Edition 209
MAN B&W Diesel A/S
Page 1 (2)
909-10.1

Checking
3.
3. Lift the roller guide by tightening the spindle

nut as much as possible, i.e. until the
sleeve is pressed against the housing.
4. The roller guide is now locked in a position
free of the fuel cam, and the engine can be
operated on the remaining cylinders, see
Volume I, Chapter 704.
Re-engagement of the fuel pump roller guide

Warining!
Re-engagement of the fuel pump roller
guide must only take place at engine
standstill.
GM909-5.0 59 03
5. Turn the engine until the circular section of

the fuel cam is positioned upwards.
Page 2 (2)
Loosen the spindle nut of the pulling tool to

lower the roller guide onto the fuel cam.
When the roller guide has been lowered
into position and the nut on the spindle is
released, remove the pulling tool from the
lifting device.
MAN B&W Diesel A/S
109-11
Fuel Valve
Data
X
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
Description
D09-40
Fuel valve opening pressure
D09-42
Inlet seat, max. diameter
D09-43
Fuel valve
MAN B&W Diesel A/S
Value
Unit
300 - 380
bar
18
mm
kg
Page 1 (2)
109-11
Fuel Valve
Data
Plate
Item No.
Description
P90151
071
Dismantling tool for fuel valve
P90951
094
P90951
165
Grinding mandrel for valve head
P90951
177
Grinding mandrel for thrust spindel
P90951
189
Grinding mandrel for holder - outside
P90951
190
Grinding mandrel for holder - inside
P90951
248
Hook spanner
P90951
297
Assembling tool for fuel valve
P90961
Page 2 (2)
Fuel Valve - Tools
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
1. Fuel Valve
1.
The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the
engine can be attributed to defects in these
valves.
If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 900-1.
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.
M909110244C01
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.
2.
All fuel valves must be function-tested before

being mounted in the cylinder cover.
Pressure testing pump
Use only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50C.
For operation of the pressure testing pump,
see the supplier's instructions.
Note that the high-pressure pump should be
periodically checked in accordance with the
supplier's instructions.
To ensure that over tightening has not taken

place, check that the locking/indicating pin has
not been bent or broken off.
In the event of over tightening, replace the
spring housing by a new one.
M909110240C02
2. Spring housing
MAN B&W Diesel A/S
Page 1 (14)
909-11.1
Fuel Valve
Checking
3. Setting-up the fuel valve
3.
Place the fuel valve in the test rig and secure it
with the spring housings and nuts.
Tighten the nuts until the top face of the pressure disc is flush with the top face of the
spring housings. Mount the oil pipe between
the pressure testing pump and the fuel valve.
M909110242C03
4.
Pressure testing procedure

The following functions of the fuel valve must
be checked:
Flushing and jet control
Opening pressure
Sealing test and sliding function
Pressure test, O-ring sealing
4. Flushing and jet control
Remove air in the system and check the fuel
jet in the following way.
Slowly increase the oil pressure until straight
jets of oil are ejected from the nozzle holes (no
atomization).
Acceptance criteria:
M909110244C04
There is to be a continuous jet of oil through at

least one of the nozzle holes.
Owing to the geometry of the internal part of
the nozzle - and because of the height to
which the spindle is lifted during pressure testing is lower than the height it is lifted during
normal engine operation - the fuel oil will not
necessarily flow from all of the nozzle holes.
Cause of fault:
If the jets do not fulfil the above point, the
cause may be:
Dirt in the nozzle holes
The nozzle is not mounted correctly
Page 2 (14)
MAN B&W Diesel A/S
909-11.1
Fuel Valve
Checking
5. Opening pressure
5.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle
holes.
D0940
Check the opening pressure on the pressure
gauge and compare with Data D09-40 on the
datasheet.
Note!
Do NOT attempt to carry out an atomization
test on the slide type fuel valvs, as this may
damage the cut-off slide and nozzle.
If the opening pressure is higher than specified

in D09-40, the cause may be that a wrong type
of spring is used - replace the spring on the
thrust spindle, if necessary, replace the complete thrust spindle.
If the opening pressure is lower than specified
in D09-40, the cause may be that the spring
has sagged - replace the spring, or add a special thin disc.
M909110244C05
Cause of fault:
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.
MAN B&W Diesel A/S
Page 3 (14)
909-11.1
Fuel Valve
Checking
6.
6. Sealing test and sliding function

To check the needle valve seat for tightness
and the slide for correct closing.
Slowly increase the oil pressure to about 50
bar below the opening pressure. Maintain the
built-up pressure by closing for the oil supply.
M909110240C06
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.
Cause of fault:
If oil flows out of the nozzle holes, the cause is
either:
Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
Too quick pressure drop:
- the clearances of the movable parts, both of
the spindle guide and of the non-return valve,
are too large, or the seats between the thrust
piece/spindle in the spindle guide or thrust
piece/valve slide in the non-return valve are
damaged.
Examine and/or replace both the spindle guide
and non-return valve. See Procedure 909-12.3.
If a quick pressure drop from 15 to 0 bar cannot be registered:
The valve slide is sticking;
The vent hole in the thrust piece is
blocked.
or
If so, disassemble and examine the spindle

guide, replace if necessary. See Procedure
909-12.3.
Page 4 (14)
MAN B&W Diesel A/S
909-11.1
Fuel Valve
Checking
7. Pressure test, O-ring sealing
7.
Max. 10 bar
To ensure that the leak oil (circulation oil) remains in the closed system, build up a working
pressure of about max. 10 bar until oil flows
out of the leak oil outlet.
Close the leak oil outlet with a gasket and plug
screw.
Increase the working pressure to about 100
bar.
The built-up pressure of about 100 bar should
be maintained.
Max. 100 bar
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.
M909110241C07
Max. 100 bar
MAN B&W Diesel A/S
Page 5 (14)
909-11.1
Fuel Valve
Checking
8. Atomization test
8.
Note!
M909110244C08
Do NOT attempt to carry out an atomization test on slide type fuel valves, as
this may damage the cut-off slide and
nozzle.
The atomization test may damage the valve because it makes the needle oscillate, with a
small lift at a very high frequency. The high
pressure drop across the cut-off edge and the
high contact pressure between slide and fuel
nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures between cut-off slide and nozzle.
All of these conditions involve the risk of seizure between the cut-off slide and the nozzle.
Page 6 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.2
Dismantling
1. Close the fuel oil inlet and outlet valves,
and drain the high-pressure pipe and the
fuel valve.
1.
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.
2.
M909110240D02
If the valve is not to be overhauled immediately, the valve should be placed immersed
in diesel oil until overhauling.
M909110240D01
2. Remove the nuts and the spring housings.
3.
M909110241D03
D0943
MAN B&W Diesel A/S
Page 7 (14)
909-11.3
Fuel Valve
Overhaul
When fuel valves are overhauled, all parts
should be handled carefully and be kept clean.
1.
M909110244O01
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.
2.
1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.
2. Place the valve holder in a machine vice,
mount the fuel valve in the holder and fit
the valve with the guide disc from the
grinding tool.
3. Compress the fuel valve and the spring inside, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the
union nut with a hook spanner.
M909110240O02
Remove the valve from the valve holder.
M909110240O03
3.
Page 8 (14)
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
4. Pull the valve head clear of the valve housing.
4.
Remove the:
Non return valve
Thrust spindle parts
Thrust foot
Spindle guide and fuel nozzle
from the valve housing.
M909110244O04
Remove and discard all the O-rings.
MAN B&W Diesel A/S
Page 9 (14)
909-11.3
Fuel Valve
Overhaul
5. Carefully clean and examine all surfaces of
the:
5.
Fuel valve housing

Fuel valve head
D0942
Thrust spindle
If necessary, grind the seating surfaces by
means of the grinding mandrels supplied
and a fine-grain abrasive (such as
Carborundum No. 500).
This grinding must only be carried out
manually.
After the grinding, wash the parts in gas oil
and blow clean by means of compressed
air to remove any remains of the grinding
compound.
In the event of more serious damage to the
seating surface for the high-pressure pipe
in the valve head, the milling tool can be
used.
Normally, the milling tool is turned by hand,
but it may be fitted in the chuck of a column-type drilling machine provided that the
number of revolutions is kept at a minimum
(not exceeding approx. 100 r/min). An
ample supply of cutting emulsion must be
used.
Note!
M909110244O05
Take care not to exceed the maximum

diameter of the seat, see Data.
Page 10 (14)
MAN B&W Diesel A/S
909-11.3
Fuel Valve
Overhaul
6. The complete spindle guide, including the
fuel nozzle, should be sent to an
authorised MAN B&W repair shop for overhaul. If this is not possible, the spindle
guide may be overhauled on board.
6.
Do not attempt to remove the fuel nozzle

from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
7. The non-return valve should be sent to an
authorised MAN B&W repair shop for overhaul. If this is not possible, the non-return
valve may be overhauled on board.
M909110244O06
Note!
7.
8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
Note!
8.
M909110244O08
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.
M909110240O06
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.
MAN B&W Diesel A/S
A
Page 11 (14)
909-11.3
Fuel Valve
Overhaul
9. Mount:
9.
the thrust foot

the parts of the thrust spindle
the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost
groove of the fuel valve housing.
Lubricate the thread of the valve head with
molybdenum disulphide (MoS2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
M909110244O09
10. Make sure that the guide pin between

valve housing and valve head is intact, and
press the valve head down into the valve
housing.
See that the guide pin between valve housing and valve head engages correctly so as
to prevent relative turning of the parts.
M909110241O10
10.
Page 12 (14)
MoS 2
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
11. Assemble the valve by means of the union
nut.
11.
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.
M909110240O10
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)
909-11.4
Fuel Valve
Mounting
1. Before mounting the fuel valve, thoroughly
clean the valve bore in the cylinder cover
and check the seating in the bore for
marks which, if any, must be eliminated.
(For reconditioning of the valve bores in the
cylinder cover, see Procedure 901-1.3).
1.
D0943
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2).
MoS 2
M909110244M01
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.
M909110244M02
Note!
3.
It is recommended to overhaul the fuel

oil high-pressure pipe before mounting.
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.
Note!
M909110244M03
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
Page 14 (14)
MAN B&W Diesel A/S
109-12
Spindle Guide
Data
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-12
Spindle Guide
Data
Plate
Item No.
Description
P90966
P90968
P90974
Page 2 (2)
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
Spindle Guide
S50ME-C
0222
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle
guides of the slide valve design.
Extreme care and accuracy should be
exercised when carrying out this 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)
109-13
Non-return Valve for Fuel Valve

Data
Stopped engine
Shut off star ting air supply At star ting air receiver
Block the main star ting valve
Shut off star ting air distributor/distributing system supply
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
109-13

Data
Plate
P90951
P90968
Page 2 (2)
Item No. Description
153
Flange for dismantling of non return valve

MAN B&W Diesel A/S
909-13.3
Overhaul
Note!
1.
Extreme care and accuracy should be

exercised when carrying out this operation.
Note!
Except for the slide valve spring, defective parts cannot be replaced individually
by new ones.
M909130207O01
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.
2.
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.
Finally, clean in either gas oil, kerosene or

Electrocleaner', and blow the parts dry
with compressed air as shown in Fig. 2.
3.
M909130207O03
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.
M909130207O02
2. Clean all the parts for the spindle guide in

gas oil and then blow clean.
MAN B&W Diesel A/S
Page 1 (2)
909-13.3

Overhaul
4.
4. Examine the slide faces of movable parts

for coating. Vent slide B/housing A will be
too tight if there is a coating. (The letters
A-D refer to the letters/parts in Fig. 2).
Fix vent slide B and, subsequently, housing
A in a lathe as shown in Fig. 4 and remove
the coating by means of very fine conventional polishing linen grade 360'.
M909130207O04
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
5.
5. Check spring C for the thrust piece for outside wear marks. If defective, it should be
exchanged.
Check the seat on thrust piece D/vent
slide, and the seat on vent slide/housing.
Use an inspection lamp and an 8-10 times
enlargement magnifying glass.
If the seats are not in order, i.e. if there are
pressing-in marks or similar on the seats,
the complete spindle guide must be discarded.
M909130207O05
6. Mount the non-return valve as follows:

Lubricate all movable parts with molybdenum disulphide (MoS2).
Place the loosely-assembled non-return
valve on the plane of a drilling machine,
with the tool positioned as shown in
Fig. 6.
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.
M909130207O06
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 nonreturn valve with plastic to prevent dirt from
entering the valve during storage.
MAN B&W Diesel A/S
109-14
Fuel Oil High-Pressure Pipe

Data
X
Stopped engine

Engage turning gear
Shut off fuel oil

Data
Ref.
Description
D09-47
Fuel oil high-pressure pipe, tightening torque
D09-51
Distance from pipe end to thrust bushing lower edge
D09-52
Fuel oil pipe

MAN B&W Diesel A/S
Value
Unit
100
Nm
11
mm
kg
Page 1 (2)
109-14

Data
Plate
Item No.
Description
P90951
104
Milling tool for fuel oil pipe
P90951
128
Crowfoot spanner
P90951
141
Crowfoot spanner
P90951
319
Hook wrench for hose pipe
Page 2 (2)
MAN B&W Diesel A/S
909-14.2
Dismantling
S60MC-C
0234
Dismantling
909-14.2
2.
High-Pressure Pipe with Protective Hose

1. Close the fuel oil inlet and outlet valves.
2. Using a hook spanner, unscrew the union
nut at the fuel valve end of the high-pressure pipe.
Unscrew the union nipple from the fuel

valve.
3. Using a hook spanner, unscrew the union
nut at the fuel pump end of the high-pressure pipe.
HN909-14.2 209 02
Pull the union nut and the protective hose

clear of the union nipple.
3.
Pull the union nut and the protective hose

clear of the union nipple.
Unscrew the union nipple from the fuel
pump.
4. Lift the pipe ends clear of the fuel valve/fuel
pump, and remove the high-pressure pipe
from the engine.
It is recommended always to overhaul

the high-pressure pipe before remounting
it on the engine.
HN909-14.2 209 03
Note!
The overhaul should preferably take

place immediately after the high-pressure pipe has been dismantled.
4.
HN909-14.2 209 04
D09-52
0$1% :'LHVHO$6
Page 1 (4)
909-14.3
Overhaul
Overhaul
909-14.3
1.
D09-51
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.
Furthermore, the position of the thrust
bushing on the pipe end must be checked.
If the distance is incorrect, compared with
the measurement stated in Data, it should
be adjusted by screwing the thrust bushing
up or down the pressure pipe.
HM909-7.0 59 01
2. If any of the pipe ends requires reconditioning, dismantle the high-pressure pipe as
follows:
D09-51
2.
Lift up the union nut with flexible protective hose, together with the coupling nut,
on the high-pressure pipe and screw off
the thrust bushing.
Remove the coupling nut and, when the
thrust bushings at both ends of the pipe
have been dismounted, pull the flexible
protective hose with union nuts off the
high-pressure pipe.
MC909-7.0 67 02
3. Shape-up the threads on the pipe ends with

the nut die.
MC909-7.0 67 04
3.
Page 2 (4)
0$1% :'LHVHO$6
909-14.3
Overhaul
4.
4. Mount the guide on the pipe end, place the

miller in the guide and lightly screw on the
union nut.
5. Turn the miller with, for instance, a tap
wrench while lightly tightening the union nut
to provide a suitable pressure between miller and pipe end. During the milling, add
drilling oil emulsion liberally.
6. When assembling the high-pressure pipe,

screw the thrust bushings so high up on the
thread of the pressure pipe that the distance between the pipe end and the bottom
edge of the thrust bushing is as stated in
Data.
MC909-7.0 67 03
After completing the milling, carefully clean

the high-pressure pipe with diesel oil and
wipe dry with a clean piece of cloth.
5.
Replace the O-rings.
It is of great importance for the mounting,

and a condition for obtaining tight joints,
that the pipes fit the seats accurately.
For reconditioning of seat in fuel valve, see
Procedure 909-11.3.
GN909-14.3 204 05
Before mounting a high-pressure pipe,

check the centre distances between pipe
ends and seats, and lubricate the threads
of the union nuts with molybdenum disulphide (MoS 2).
For reconditioning of seat in fuel pump top

cover, see Procedure 909-5.3.
6.
HM909-7.0 62 06
D09-51
0$1% :'LHVHO$6
Page 3 (4)
909-14.4
Mounting
Mounting
909-14.4
4.
1. Check that the distance between the thrust

bushing and the pipe end is correct at both
ends of the pipe. See Procedure 909-14.3.
2. Ensure that the fuel valve is fitted with a
new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
D09-52
HN909-14.4 209 04
3. Ensure that the union nipple at the fuel

pump end of the high-pressure pipe is fitted
with a new O-ring. Lubricate the thread on
the union nipple with a heat resistant
grease.
4. 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.
5.
Note!
HN909-14.4 209 05
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.
D09-47
5. Use a crowfoot wrench and a torque

wrench to tighten the union nipple at the
fuel valve to the torque stated in Data.
Screw the union nut onto the union nipple
by hand, and tighten lightly with a hook
spanner.
6.
6. Use a crowfoot wrench and a torque

wrench to tighten the union nipple at the
fuel pump to the torque stated in Data.
HN909-14.4 209 06
Screw the union nut onto the union nipple

by hand, and tighten lightly with a hook
spanner.
Page 4 (4)
7. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
D09-47
0$1% :'LHVHO$6
109-15

Data
X
Stopped engine

Engage turning gear

Shut off fuel oil

Data
Ref.
Description
Value
Unit
D09-53
Nut, reversing shaft, tightening torque
80
Nm
D09-57
Roller/bushing/shaft pin, max. clearance
0.5
mm
D09-61
60
kg
D09-62
Pump base
68
kg
MAN B&W Diesel A/S
Page 1 (2)
109-15

Data
Plate
P90851
Page 2 (2)
Item No.
173
Description
MAN B&W Diesel A/S
909-15.1
Checking
Roller guide mounted in engine
3.
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.
3. Remove the cover on the camshaft housing
to inspect the fuel pump roller guide.
Turn the engine to provide the maximum
space between the roller guide and the
cam disc.
Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no
traces of bearing metal left in the roller
guide housing.
5.
M909150234C02
4. Lower the roller guide onto the fuel cam

again.
M909150234C01
Turn the roller by hand to check that it can

move freely and without unnecessary resistance or hard points.
MAN B&W Diesel A/S
Page 1 (10)
909-15.1

Checking
Roller guide removed from engine
7.
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.
M909150234C03
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.
D0957
M909150234C04
8.
Page 2 (10)
MAN B&W Diesel A/S
909-15.2
Dismantling
Note!
1.

1. Dismantle the top cover of the fuel pump.

M909150234D01
2. Dismantle the fuel pump barrel assembly.

M909150234D02
2.
MAN B&W Diesel A/S
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.
M909150234D03
4. Loosen and remove the screws from the

sealing cap on top of the roller guide inside
the pump base.
Dismantle the lubricating oil pipe and the

drain pipe from the pump base.
5. Remove the cover on the camshaft housing
to inspect the position of the roller guide.
Turn the engine until the roller guide is at
BDC.
M909150234D04
4.
Remove the sealing cap from the roller

guide/pump base.
M909150234C02
5.
Page 4 (10)
MAN B&W Diesel A/S
909-15.2

Dismantling
6. Loosen the nuts on the two threaded studs
successively until the roller guide springs
are relieved.
6.
D0962
Remove the nuts, mount two eye bolts in

the pump base and lift it away.
When lifting, take care that the bushing of
the pump base slides against the neck of
the roller guide without scratching.
Remove the springs from the roller guide.
7. Mount the roller guide lifting tool as follows:
Lift the lock plate of the tool up on the
shaft of the tool.

Lower the lock plate, thereby securing
Lift the roller guide out of the roller guide
housing, using the crane.
M909150234D06
Position the tool so that its foot rests on

the thrust piece in the bayonet joint of
the roller guide.
7.
D0961
When lifting, take care that the slide surfaces of the roller guide do not scrape
against the roller guide bushing.
Land the roller guide on wooden planks.
M909150234D06
8. Check the roller guide.

MAN B&W Diesel A/S
Page 5 (10)
909-15.3

Overhaul
1. Inspect and check the fuel pump roller
guide.
1.
2. It is recommended that the roller guide

should ONLY be dismantled if
D0961
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.
M909150234O01
Note!
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.
M909150234O02
2.
Page 6 (10)
MAN B&W Diesel A/S
909-15.4
Mounting
1. Lubricate the roller guide with plenty of
camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.
1.
During mounting, take care not to scratch

the sliding surfaces of the roller guide.
Make sure that the pin of the reversing link
fits in the bracket of the reversing shaft.
2. After mounting the roller guide with the reversing link, check the clearance between
the roller guide and the guide plate
mounted in the roller guide bushing.
Turn the camshaft so that the roller guide is
lifted approx. 20 mm.
The clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.
Connect working air to the air cylinder, and
check that the reversing mechanism is
working smoothly.
M909150234M01
The clearance C between the roller guide

and the guide plate must be the same at
both ends +/ 0.1 mm.
2.
The clearances A and B must be approx.

the same in both positions. Neither A nor B
must be less than 0.2 mm.
M909150234M02
MAN B&W Diesel A/S
Page 7 (10)
909-15.4

Mounting
3. If adjustment is necessary, it must take
place in the ASTERN position.
3.
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
Tighten the nut on the reversing shaft to
the torque stated in Data, and lock the nut
with Loctite type: Screw Lock No. 243.
D0953
Mount the cover over the shaft connection.
M909150234M03
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.
D0962
Mount the two

threaded studs.
special
nuts
on
the
M909150234D06
Using the special tube-shaped socket

wrench, tighten the nuts until the pump
base is fastened tightly to the roller guide
bushing.
Page 8 (10)
MAN B&W Diesel A/S
909-15.4
Mounting
6. Check the movement of the reversing link.
6.
7. Replace the scraper rings in the sealing

cap as follows:
8. 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.
M909150234C02
Loosen and remove the screws and nuts

from the bottom of the cap, remove the retaining flange and ring holder with scraper
ring.
M909150234M07
7.
M909150234M08
8.
MAN B&W Diesel A/S
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.

Water/Oil
100C/5 min.
M909150234M09
Before mounting, the new scraper ring

must be heated in 100C hot water or oil
for at least five minutes.
Note!
When mounting the scraper ring in the
groove, fold the ring without making any
sharp edges, and be careful not to cut
the scraper ring on the edge of the ring
groove when pressing it in.
Check that the O-ring and scraper ring are
mounted correctly. See the sketch.
10.
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.
M909150234M10
11. Mount the drain pipe on the pump base.
11.
Mount a new O-ring in the groove on top

of the roller guide.
Mount the sealing cap on top of the roller
guide, over the sealing bush inside the
pump base.
Tighten the screws and lock with locking
wire.
12. Mount the fuel pump housing.
Mount the barrel assembly.
M909150234M11
Mount the top cover.

Page 10 (10)
MAN B&W Diesel A/S
Fuel valve and Fuel Pump Panel

MAN B&W
Plate
P90951-0441
Page 1 (2)
Plate
P90951-0441
Fuel valve and Fuel Pump Panel

MAN B&W
Item
No.
Item Description
010
021
045
057
Panel for tools

Name plate
Measuring tool for fuel pump
Lifting tool for fuel pump plunger
barrel
Lifting tool for fuel pump
Lifting tool for fuel pump housing
Milling tool for fuel oil pipe
Crowfoot spanner
Crowfoot spanner
Crowfoot spanner
Crowfoot spanner
Flange for dismantling of non return
valve
Grinding mandrel for valve head
Grinding mandrel for thrust spindle
Grinding mandrel for holder - outside
Grinding mandrel for holder - inside
Screw for topcover
Tool for P.max rack
Pin spanner
Hook spanner
Drift for spindle guide
Drift for non return valve
Assembly tool for fuel valve
Extractor tool for roller guide
Hook spanner
Crowfoot spanner
069
070
094
104
116
128
130
141
153
165
177
189
190
200
224
236
248
250
273
297
307
319
356
Page 2 (2)
Fuel Valve - Tools

MAN B&W
Plate
P90961-0069
Page 1 (2)
Fuel Valve - Tools
Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122
Page 2 (2)
MAN B&W
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
Plate
P90966-0008
Page 1 (2)
Plate
P90966-0008
Item
No.
011
023
035
047
060
202
MAN B&W
Item Description
Tool box
Extractor for atomizer
Drift for atomiizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)

MAN B&W
Plate
P90968-0001
Page 1 (2)
Plate
P90968-0001

MAN B&W
Item
No.
Item Description
012
Probe light with magnifier, complete
Page 2 (2)

MAN B&W
Plate
P90974-0001
Page 1 (2)
Plate
P90974-0001

MAN B&W
Item
No.
Item Description
015
027
039
206
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)
Mounting Tools - Fuel Pump Seals

MAN B&W
Plate
P90977-0001
Page 1 (2)
Mounting Tools - Fuel Pump Seals
Plate
P90977-0001
Item
No.
011
023
035
047
059
060
072
Page 2 (2)
MAN B&W
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Spacer ring

MAN B&W
Plate
P90979-0001
Page 1 (2)
Plate
P90979-0001
Item
No.
012
024
036
Page 2 (2)
Mounting Tools - Suction Valve Sealsl

MAN B&W
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool

MAN B&W
Plate
P90980-0001
Page 1 (2)
Plate
P90980-0001
Item
No.
018
020
031
043
055
067
079
Page 2 (2)
MAN B&W
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Cone

110-01
910-01
110-02
910-02
110-03
910-03
110-04
910-04
110-06
910-06
91061
91064
91065
0047
0236
0009
0214
0024
0220
0005
0206
0031
0219
0067
0002
0001
MAN Diesel A/S
Air Cooler Element, Data

Air Cooler Element
Non-Return Valve after Air Cooler, Data
Non Return Valve after Air Cooler
Auxilary Blower, Data
Auxilary Blower
Butterfly Valve, Data
Butterfly Valves
Water Mist Catcher, Data
Water Mist Catcher
Travelling Trolley
MAN Diesel A/S
110-1
Air Cooler Element

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
Description
D10-02
Aft end cover
D10-04
D10-05
Value
Unit
350
kg
Air cooler element, complete with covers, up to
3100
kg
Front end cover (waterflow reversing chamber)
350
kg
MAN B&W Diesel A/S
Page 1 (2)
110-1
Air Cooler Element

Data
Plate
Item No.
Description
P91063
Air Cooler - Tools
P91064
Travelling Trolley
P91066
Air Cooler - Lifting Tools
P91356
Lifting Tools, Etc.
Page 2 (2)
MAN B&W Diesel A/S
Air Cooler Element
910-1.1
Checking
Air Cooler Element
S60MC
0236
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.
Compare these measurements with the
testbed data. For further evaluation of the
measurements, see instruction book Volume I, Chapter 706.
A decrease in the air temperature drop

across the scavenge air cooler indicates
fouling of the water side of the cooler.
3. If the measurements indicate fouling of the
water side of the air cooler element, the element must be dismantled and overhauled/
cleaned.
GM910-1.1 221 01
2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of
the air side of the cooler.
4.
If the measurements indicate fouling of the

air side of the air cooler element, it is recommended to inspect the air cooler element as follows:
4. Remove the inspection cover from the air
cooler.
If the air side of the element is fouled, clean

the element using the spray pipe arrangement fitted above the air cooler element.
GM910-1.1 221 04
5. Visually inspect the air cooler element

through the opening.
MAN B&W Diesel A/S
Page 1 (7)
910-1.2
Air Cooler Element

Dismantling
Dismantling
910-1.2
1.
1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off the
cooling water.
2. Dismount the cooling water inlet and outlet
pipes from the end cover.
Remove and discard the gaskets.
3. Dismantling the waterflow reversing
chamber:
GM910-1.2 221 01
Mount a screw shackle at the top of the outer end cover of the cooler housing.
Suspend a tackle from the lifting bracket on
the cooler housing.
Fasten the chain hook in the shackle.
2.
Remove the screws from the end cover and

lower the cover.
Mount another shackle at the top of the waterflow reversing chamber, and lower it in
the same way, after removing the screws.
Dismantling the inlet/outlet end cover:
GM910-1.2 221 02
Attach an eye bolt to the top of the inlet/outlet end cover.

Fasten a tackle to the lifting bracket on the
cooler housing.
D10-06
D10-07
GM910-1.2 221 03
3.
Attach the chain hook to the shackle and

remove the screws from the end cover and
from the inlet and outlet valves.
Then lower the end cover.
Page 2 (7)
MAN B&W Diesel A/S
Air Cooler Element
910-1.2
Dismantling
4.
4. Mount two rails, each with a guide rail on

top, on the gallery.
5. Mount the pair of wheels for the foremost

tube plate, and tighten the thrust screws to
make the wheels support the cooler element.
Mount the pair of wheels for the aftmost
tube plate, and tighten the thrust screws to
make the wheels support the cooler element.
GM910-1.2 221 04
Press the cooler element free, using dismantling screws.
5.
6. Pull the cooler element halfway out of the
cooler housing, checking during this procedure that the aftmost pair of wheels is being
centered between the two guide rails.
8. Pull out the cooler element until it is clear

of the cooler housing. Lift the air cooler element away.
GM910-1.2 221 05
7. When the cooler element has been pulled

halfway out, mount the support on which
the foremost pair of wheels can run.
Note!
6.
GM910-1.2 221 06
During the lift, take care not to damage

the air cooler element.
D10-04
GM910-1.2 221 08
8.
MAN B&W Diesel A/S
Page 3 (7)
910-1.3
Air Cooler Element

Overhaul
Overhaul
910-1.3
1.
Cleaning the air side:

1. The air side of the cooler is cleaned by injecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.
It is recommended to use one of the following cleaning fluids, or a similar product.
Product: ACC 9, produced by
Drew Chemical Corp., New York, USA
GM910-1.3 221 01
Product: 80B, produced by

Vecom Int., Maassluis, Holland
3.
2. Do not start cleaning until the engine has

been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
Remove the covers on the scavenge air receiver to let vapours escape.
3. Follow the detailed cleaning instructions
displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
DG910-5.1 62 01
4. Continue the cleaning process for at least

30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
5. After cleaning, flush the cooler with clean
water until the water in the sight glasses appears clean and pure.
6. Inspect the air cooler element by removing
the cover of the scavenge air cooler housing.
Page 4 (7)
MAN B&W Diesel A/S
Air Cooler Element
910-1.3
Overhaul
8.
Cleaning the water side

7. It is not necessary to remove the air cooler
element from the engine to clean the waterside.
8. Dismantle the inlet/outlet end cover of the
air cooler element. See Procedure 910-1.2.
10. Clean the inside of the tubes, using the

cleaning brush (supplied by the cooler element manufacturer) mounted on a drilling
machine.
BG910-1.3 215 02
9. Dismantle the waterflow reversing end cover of the air cooler element. See Procedure
910-1.2.
9.
In the event of leakages between cooling
tubes and tube plate, the tubes are rolled
with the tube expander (also supplied by
the cooler element manufacturer).
11. Clean and check the inside of both end covers. If necessary, replace the corrosion
blocks.
If damaged, the coating inside the covers

is to be repaired with the original coating
or a similar product.
10.
GN910-1.3 207 04
12. When cleaning is complete, mount new

gaskets or packing paste and re-mount
both end covers of the air cooler element.
BM910-5.2 49 06
Note!
MAN B&W Diesel A/S
Page 5 (7)
910-1.4
Air Cooler Element

Mounting
Mounting
910-1.4
1.
1. Mount a new gasket to seal between cooler

element and air cooler housing.
Lift the air cooler element and land the aft
end of the element on the guide rails
mounted on the air cooler housing.
2. Push the air cooler element inwards approx. one metre.
GM910-1.2 221 08
Remove the support from the foremost pair

of wheels.
3. Clean the frame around the air cooler element and the contact surface of the cooler
housing.
2.
Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the cooler housing.
Push the air cooler element fully into the air
cooler housing.
GM910-1.2 221 06
4. Remove the front and aft end wheels and

the guide rails.
GM910-1.4 221 06
3.
Page 6 (7)
MAN B&W Diesel A/S
Air Cooler Element
910-1.4
Mounting
5.
5. Mount the inlet/outlet end cover with a new

gasket to which a thin layer of silicone
paste has been applied.
D10-06
D10-07
Mount the waterflow reversing chamber

with a new gasket to which a thin layer of
silicone paste has been applied.
Mount the outer end cover on the reversing

chamber end with a new gasket to which a
thin layer of silicone paste has been applied.
Mount and tighten all the screws of the end
cover.
GM910-1.2 221 03
Mount and tighten all the screws of the inlet/outlet cover and the reversing chamber.
6.
Mount the inspection cover on the cooler
housing.
Remove the tackles and shackles.
6. Mount the cooling water inlet and outlet
pipes on the end cover.
Note!
Remember to vent trapped air from the
air cooler element.
GM910-1.2 221 02
7. Close the drain cocks and open the cooling

water inlet and outlet valves.
GM910-1.4 221 07
7.
MAN B&W Diesel A/S
Page 7 (7)
110-2
Non-Return Valve
Data
N
D
R
B
I
E

X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-2
Non-Return Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Non-Return Valve
910-2.3
Overhaul
0214
Non-Return
Valve
S80MC
Overhaul
910-2.3
Access to the non-return valves in the scavenge air receiver takes place after the engine has been stopped through the inspection
openings of the receiver.
Warning!
Access to the scavenge air receiver must
not take place until the air in the receiver is
clean.
Replacement of non-return valve assembly:
Remove the two outermost screws and the middle screw (which fasten the valve assembly to
the housing).
Lift the complete valve assembly out and mount
a new assembly instead.
Overhaul of non-return valve assembly:
Knock out the spring pin which secures the axle
of the valve flap and press out the axle. Now
the valve flap is free and can be replaced.
For further dismantling, remove the two screws
which hold the parts together as an assembly.
HG910-2.3 212 01
When mounting, again secure the axle of the

valve flap by means of the spring pin.
MAN B&W Diesel A/S
Page 1 (1)
110-3
Auxiliary Blower
Data
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
D10-09
Description
Weight of blower unit, complete * up to
Value
Unit
700
kg
350
kg
*) Depending on electric motor type and number of cylinders of

engine (size and capacity of auxiliary blower)
D10-12
Electric motor, impeller and motorplate
MAN B&W Diesel A/S
Page 1 (2)
110-3
Auxiliary Blower
Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting Tools, Etc.
MAN B&W Diesel A/S
910-3.3
Auxiliary Blower
Overhaul
When cleaning and inspecting the auxiliary
blower, take out the electric motor and the
blower wheel as one whole assembly.
1.
D1012
1. Disengage the cable connections to the

blower motor.
Remove the screws in the blower wheel

flange, and pull the electric motor with
flange and blower wheel out of the end
cover, using the tackle.
2. Inspect and clean the blower wheel as well
as the blower housing.
M910030220O01
Attach a wire rope with shackle to the lifting mounting on the blower flange, and
hook-on the tackle suspended from
mountings on the gallery bracket.
3.
3. If the whole blower assembly is to be dismounted, the inspection covers on the
scavenge air receiver are first to be removed.
D1009
Caution!
Make sure that the air in the receiver is
clean before making the access.
Remove all screws holding the end cover.

The end cover complete with blower can
now be pulled free of the suction pipe by
means of the two tackles. While pulling out
the end cover with the blower assembly,
make sure that the blower housing disengages from the air pipe without deforming
it.
4. When mounting the end cover with the
complete blower, the parts are to be
guided into place with care, making sure
that the pipe in the receiver catches the
guide bosses (A) of the blower housing
flange.
The gasket (B) constitutes the sealing between blower housing and pipe.
4.
M910030220O03
Attach two wire ropes with shackles to the

lifting mountings on the end cover, and
hook on the tackles.
M910030220O02
Suspend two tackles from the mountings

on the gallery bracket above the end cover.
MAN B&W Diesel A/S
Page 1 (1)
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
910-4.1
Butterfly Valves
Checking
Butterfly Valves
S50MC
206
Checking
910-4.1
1.
1. It is important that the automatic non-return

valves (butterfly valves) are always able to
function easily and unimpeded.
The movability of the valve flaps should
therefore be checked at suitable intervals.
The valves shall open for the air flow from
the valve housing to the auxiliary blowers.
Access to the butterfly valves is made
through the manhole covers of the receiver
after the engine has stopped running and it
has been ascertained that the air in the receiver is pure.
2. To check the valve, remove the cover on the
top of the butterfly valve.
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.
d ir e c
tion
HM910-9.0 11 01
Reach down through the opening in the top

of the valve and move the valve flaps.
Flow
2.
XZ910-9.0 15 02
4. Re-mount the cover on the top of the butterfly valve.
MAN B&W Diesel A/S
Page 1 (1)
110-6
Water Mist Catcher

Data
X
Stopped engine
Engage turning gear

Shut off fuel oil
Data
Ref.
D-10-11
Description
Water mist catcher
MAN B&W Diesel A/S
Value
Unit
119
kg
Page 1 (2)
110-6
Water Mist Catcher

Data
Plate
P91356
Page 2 (2)
Item No.
Description
Lifting tools
MAN B&W Diesel A/S
Water Mist Catcher
910-6.2
Dismantling
Water Mist Catcher
S46MC
0219
Dismantling
910-6.2
2.
1. Normally it is not necessary to remove the

water mist catcher from the scavenge air
cooler housing. If, however, the water mist
catcher has been fouled or damaged, it
must be dismantled for cleaning or repair.
2. Dismantle the rectangular covers from both
the front and aft ends of the scavenge air
cooler housing.
Note!
Note the position of the water mist
catcher. During mounting, the water mist
catcher must be re-mounted in the same
position.
4. Pull or push the water mist catcher halfway
out and mount an eye bolt in the top of the
water mist catcher.
GM910-6.2 213 02
3. Loosen the screws at both ends of the water mist catcher.
4.
D10-11
Hook a tackle on to the eye bolt and lift the

water mist catcher away. Land it on a couple of wooden planks.
Take care not to damage the water mist

catcher during the lift.
GM910-6.2 213 04
Note!
5. Clean the water mist catcher with the same

cleaning fluid as used for the scavenge air
cooler element.
0$1% :'LHVHO$6
Page 1 (2)
Water Mist Catcher
910-6.4
Mounting
Mounting
910-6.4
1.
1. Apply a thin layer of silicone paste to the

frame of the water mist catcher on the side
which will face away from the engine when
the water mist catcher is mounted (the side
opposite to the screws).
Toward
Engine
2. Slide the water mist catcher into the scavenge air cooler housing.
GM910-6.4 213 01
Note!
6LOLFRQH
2.
Make sure to mount the water mist

catcher correctly. The screws of the
water mist catcher must face the exhaust
side of the engine.
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.
3. Tighten the screws at both ends of the water mist catcher.
Apply a thin layer of silicone paste on the
frame and mount the rectangular covers on
the front and aft ends of the scavenge air
cooler housing.
GM910-6.4 213 02
D10-11
GM910-6.4 213 03
3.
Page 2 (2)
0$1% :'LHVHO$6

MAN B&W
Plate
P91061-0067
Page 1 (2)
Plate
P91061-0067
Item
No.
014
026
Page 2 (2)
MAN B&W
Item Description
Lifting eye bolt

Turnbuckle
Travelling Trolley
MAN B&W
Plate
P91064-0002
Page 1 (2)
Travelling Trolley
Plate
P91064-0002
Item
No.
010
MAN B&W
Item Description
Travelling trolley*
Note:
* When ordering this tool, please state
load and track width.
Page 2 (2)

MAN B&W
Plate
P91065-0001
A-A
Page 1 (2)
Plate
P91065-0001
Item
No.
016
028
041
053
065
Page 2 (2)
MAN B&W
Item Description
Screw
Compensator extender
Screw
Nut
Tool set, complete

111-01
911-01
111-02
911-02
111-03
911-03
0026
0212
0013
0211
0001
0001
MAN Diesel A/S
Safety Valve, Data

Safety Valve
Relief Valve, Data
Relief Valve
Scavenge Air Receiver Safety Valve, Data
Scavenge Air Receiver Safety Valve
MAN Diesel A/S
Safety Valve
MAN B&W Diesel
111-1
Data

Stopped engine
X
X
X
X
X
X
X

Engage turning gear
Shut off fuel oil
Data
Ref.
Description
D11-01
Opening pressure
D11-02
Valve housing, tightening torque
Value
Unit
200 5
bar
45
Nm
Page 1 (2)
Safety Valve
111-1
MAN B&W Diesel
Data
Plate
Item No.
Description
P91351
10
P91351
58
P90151
117
P91359
Page 2 (2)
Test equipment for combined safety valve

Torque Spanners
Safety Valve
MAN B&W Diesel
911-1.2
Dismantling
When Side-mounted
1.
1. Remove the guard surrounding the safety

valve.
Unscrew the safety valve from the extension pipe.
When Top-mounted
3. Unscrew the safety valve from the cylinder
cover.
2.
M911010211D02
Remove and discard the mild steel disc.
M911010211D01
2. Dismantle the indicator cock and the intermediate pipe.
M911010211D03
3.
Page 1 (5)
911-1.3
Safety Valve
Overhaul (Adjustment)
1.
MAN B&W Diesel
1. If necessary, dismantle the safety valve and

clean all the parts in either gas oil, kerosene, or electro-cleaner.
2. Assemble the safety valve in two steps:
Insert the valve flap and the stop ring in

the valve guide and screw on the valve
housing.
Tighten the housing to the torque stated

M911010211O01
in the data, loosen and tighten again to

the torgue stated in the data.
3. Then mount:
the valve spindle
the spring
the adjusting screw
the lock nut
M911010211O02
2.
M911010211O03
3.
Page 2 (5)
Safety Valve
MAN B&W Diesel
911-1.3
Overhaul (Adjustment)
4. To set the safety valve opening pressure:
4.
Set up the safety valve in the Fuel valve

test rig.
Connect the testing device to the hydraulic pump. Alternatively the hydraulic
hans pump can be used.
Loosen the lock nut on the safety valve.

Turn the adjusting screw until the valve
just closes.
Bleed the valve and hose until oil, without air bubbles, flows out from the
openings of the safety valve.
Tighten the adjusting screw of the
Tighten the lock nut.

Test the opening pressure.
Remove the valve from the fuel valve
M911010212O04
safety valve until the correct pressure is

indicated (see Data).
test rig.
Page 3 (5)
911-1.4
Safety Valve
Mounting
MAN B&W Diesel
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.
M911010211M01
3. Mount a new sealing ring and a new or

overhauled safety valve.
When mounting the safety valve, apply
tools only on the hexagon on the safety
valve.
Mount the guard surrounding the safety
valve.
M911010211M02
2.
M911010211M03
3.
Page 4 (5)
Safety Valve
MAN B&W Diesel
911-1.4
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
M911010211M04
Mount a new mild steel disc in the bore.
M911010211M05
5.
Page 5 (5)
111-2
Relief Valve
Data
X
Stopped engine
Engage turning gear
Shut off fuel oil

Data
Ref.
Description
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
111-2
Relief Valve
Data
Plate
Page 2 (2)
Item No.
Description
MAN B&W Diesel A/S
Relief Valve
911-2.1
Checking
Relief Valve
60&
0211
Checking
911-2.1
1.
1. During running of the engine, check if there

are any leaks.
If a leak occurs, replace the O-ring inside
the relief valve. See separate instructions
from the valve manufacturer.
2. If work involving risks of mechanical damage to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.
If one or more plates in the flame arrester

are damaged, the relief valve must be disassembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
Note!
XZ911-2.1 209 01
Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.
The complete flame arrester has to be

replaced after a crankcase explosion.
XZ911-2.1 207 03
2.
0$1% :'LHVHO$6
Page 1 (1)

MAN B&W Diesel
111-3
Data

X
X
X
X
Stopped engine

Engage turning gear

Shut off fuel oil
Data
Ref.
Description
Value
Unit
Page 1 (2)
111-3
MAN B&W Diesel
Data
Plate
Page 2 (2)
Item No.
Description

MAN B&W Diesel
911-3.1
Checking
1. The scavenge air receiver safety valve

is calibrated at the factory and does not
require any adjustment.
2.
2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.
If this operation cannot be performed

smoothly, the safety valve must be
dismantled and cleaned.
M911030001C02
Use a piece of cloth to wipe out any dirt

from the Oring packing and close the
valve again. Tighten the counter nut.
Page 1 (5)
911-3.2

Dismantling
1.
MAN B&W Diesel
1. Dismount the safety valve from the scavenge air receiver.
M911030001D01
2. On some engines, a cover has to be removed in order to gain access to the safety
valve.
M911030001D02
2.
Page 2 (5)

MAN B&W Diesel
911-3.3
Overhaul
1. Remove the split pin.
1.
Unscrew the nut thereby relieving the

spring tension.
Remove the nut, spring retainer and
washers.
Keep count of the washers.
2. Pull out the valve ap with spindle. If the

Oring seal is damaged remove it without
damaging the Oring groove.
3. Clean the metal surfaces thoroughly.
M911030001O01
Pull out the spring.
M911030001O02
2.
Page 3 (5)
911-3.3

Overhaul
4.
MAN B&W Diesel
4. If the Oring seal has been removed mount

a new one using Locktite type AVX and
Loctite activator type T or similar.
5. Push in the valve ap and spindle while
taking care not to damage the Oring seal.
6. Mount the spring, spring retainer and all the
washers.
M911030001O04
Tighten the nut until the split pin can be

mounted.
7. Check the valve according to 9113.1.
M911030001O05
5.
M911030001O01
6.
Page 4 (5)

MAN B&W Diesel
911-3.4
Mounting
1.
M911030001M01
1. Mount the safety valve on the scavenge air

receiver.
Page 5 (5)

112-02
912-02
112-03
912-03
912-05
91263
0015
0208
0028
0216
0201
0060
MAN Diesel A/S
Holding Down & End Chock Bolts, Data

Holding Down and End Chock Bolts
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)
MAN Diesel A/S
Holding-down and End Chock Bolts

MAN B&W
112-2
Data

X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
D13-01
Description
Value
900
Unit
bar
Page 1 (2)
Holding-down and End Chock Bolts
112-2
MAN B&W
Data
The task-specic tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the rst three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
P91263
Description
Hydraulic Tools for Holding-Down Bolts and End Chock Bolts, Epoxy
P91351
010
P91351
058
Page 2 (2)
912-2.1
Checking
.0&
0208
Checking
912-2.1
Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
0$1% :'LHVHO$6
Page 1 (5)
912-2.1

Checking
1.
Checking the Bolt Tightening

1. The holding down bolts and end chock bolts
must be checked for correct tightness at the
intervals indicated on the Data sheet.
For this purpose, raise the pressure on the
hydraulic tool slowly while constantly attempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pressure gauge when the nut comes loose
(loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.
EN912-1.1 205 01
The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the tables from successive bolt checks.
If the loosening pressure' is below 80 per
cent of the tightening pressure, the relative
chocks shall always be checked for possible defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.
Checking of Epoxy Supporting Chocks
2. If a number of measuring pins have been
welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.
The distance between the measuring pins
and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be followed.
Page 2 (5)
0$1% :'LHVHO$6
912-2.1
Checking
3.
Side Chocks and Side Chock Liners

3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.
The first time the ship is sailing in a fullyloaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the liners can be knocked further inward.
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.
GN912-2.1 203 03
The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simultaneously.
The feeler gauge is applied at the 7 points

indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.
If the measurements at 3 points or more have
increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed:
1. Loosen the hexagon screws.
2. Try to knock the liner further inward.
3. Measure again at the 7 points indicated in
the table.
If this procedure does not improve the situation,
the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.
The liners are secured in their correct position
by means of hexagon socket set screws with
cup point.
0$1% :'LHVHO$6
Page 3 (5)
912-2.1
Checking
Holding Down Bolts
Engine
frame Bolt
No.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page 4 (5)
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Port side
pressure
% dev.
remarks
Cylinder
No.
1
2
3
Starboard side
pressure
% dev.
remarks
Bolt
No.
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
Engine
frame
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0$1% :'LHVHO$6
912-2.1
Checking
Side Chocks and End Chock Bolts
Port side
Point
c d e
Chock
No.
Starboard side
Cylinder
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Chock
d
e
f
Pres-
Port side
c, d, e, f, g
Starboard side
Devi-
Ch Bolt sure ation

2)
No. No. (kp/cm
%
bar
No.
A, B
FORE
c, d, e, f, g
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
A, B
Point
c d e
Deviation
Point
Point
a b c d e
a b c d e
Pressure
(kp/cm 2 )
bar
1
2
Bolt Ch
No. No.
1
E
2
b
b
a
Contact face No. 1
No. 2
B1
0$1% :'LHVHO$6
B2
B2
B1
AFT
No. 2
Page 5 (5)
Stay Bolts
MAN B&W
112-3
Data

X
X
X
X
X
X
Stopped engine
Engage turning gear
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D12-03
Check measurement
0.4
mm
D13-01
900
bar
D13-02
800-990
bar
Page 1 (2)
Stay Bolts
112-3
MAN B&W
Data
The task-specic tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the rst three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Item No.
P91261
Description
Large Parts - Tools
P91351
010
P91351
046
P91351
058
P91351
105
Page 2 (2)
Stay Bolts
MAN B&W
1.
912-3.1
Checking
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.
1.
Note!
Before retightening the stay bolts, remove

the protective caps.
2. Clean the contact faces and mount the
hydraulic tools on a pair of stay bolts positioned opposite each other on the middle
of the engine.
M912030215C01
The rst time this check is performed it

has to be completed in one operation.
The following checks have to be completed within a 500-hour period.
2.
Connect the highpressure pump by means

of the highpressure hoses, so that the two
stay bolts are tightened in one operation.
M912030215C02
D1301
Page 1 (3)
Stay Bolts
912-3.1
Checking
3.
D1203
MAN B&W
3. If the engine is equipped with split staybolts and one or more staybolts have been
dismantled, make sure that the staybolts
are mounted in such a way that, when the
uppermost staybolt nut is loosened, there
is a clearance, as stated in Data, between
the contact face of the lowermost nut and
the bedplate. If the engine is equipped with
staybolts in one piece, please disregard the
above.
M912030216C03
4. Retighten the stay bolts in pairs (athwartship), working from fore to aft of the engine.
M912030216C04
4.
5. Pump up the hydraulic pressure to 10%

below the value indicated in D1301, and
retighten the stay bolt nuts with a tommy
bar if possible. Before relieving the system
of pressure, check with a feeler gauge that
the nuts bear against the contact face.
5.
M912030215C05
D1301
Page 2 (3)
Stay Bolts
MAN B&W
912-3.1
Checking
6. Reconnect the hydraulic tools to the pair of

stay bolts rst tightened. Tighten to 10%
below D1301 and check if the nut is loose.
6.
If the nut is not loose:

Tighten the stay bolts to D1301.
If the nut is loose:
7.
After completing the retightening procedure, mount the protective caps.
M912030215C06
Tighten all stay bolts once again to D1301.
Page 3 (3)

MAN B&W Diesel
912-5.1
Checking
The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing.
1.
If the water content of the main engine

lube oil is rising, this may indicate that
the crankcase oil outlet sealings are fractured.
Rubber diaphragm sealing
1. To access the rubber diaphragm sealing
remove:
Screws A
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.
M912050201C01
Note!
2.
Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
M912050201C02
2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.
Note!
Remember to fit new locking plates at
screws A.
Page 1 (2)
912-5.1
Checking
MAN B&W Diesel
Metal bellow sealing

4.
4. Remove all screws A and grating B.
C
D
5. Remount four of the screws A at diametrically opposite positions.
B
A
6. Remove:
Screws C
Cover plate D
Screws E.
M912050201C04
7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are
found in the metal bellow sealing, it must
be replaced.
Note!
7.
It is recommended to always replace the

metal bellow sealing during inspection.
8. Replace gaskets G and H.

9. Mount metal bellow sealing F.
M912050201C07
10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Page 2 (2)
Hydraulic Tools - Holding-Down and

End Chock Bolts (Epoxy Chocks)
MAN B&W
Plate
P91263-0060
Page 1 (2)
Plate
P91263-0060
Hydraulic Tools - Holding-Down and

End Chock Bolts (Epoxy Chocks)
MAN B&W
Item
No.
Item Description
024
Hydraulic jack for end-chock bolt M56

x 5.5
Hydraulic jack for holding-down bolt
M36 x 4.0
Support for end-chock bolt
Support for holding-down bolt
Tommy bar
Spanner
Tommy bar
036
048
050
061
073
085
097
107
119
132
203
Page 2 (2)
913 - General Tools

913-01
913-04
913-05
913-06
913-07
91311
91351
91356
91357
91359
91360
91361
91362
91363
91364
91366
0209
0201
0205
0205
0207
0204
0038
0058
0005
0003
0003
0052
0064
0040
0059
0066
MAN Diesel A/S
Hydraulic Tools
Standard Tightening Torques
Torque Spanner
Tightening Gauge
Screws and Nuts
Lubricating
Accessories - Hydraulic Tools
Lifting Tools, etc.
Open-Ended Spanners
Torque Spanners
Pliers
Combination Spanners
Ring Slugging Spanners
Spanners
Open-Ended Spanners
Instruments
MAN Diesel A/S
+\GUDXOLF7RROV

Hydraulic Tools
S50MC
0209
913-1.1
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913-4

.0&&
0201
913-4
When tightening screws or nuts for which no

torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.
1. Standard screws and nuts lubricated with a
Molybdenum Disulphide (MoS 2) based lubricant.
Thread
Tightening
torque
Thread
Tightening
torque
M8
17 Nm
M22
400 Nm
M10
35 Nm
M24
460 Nm
M12
50 Nm
M27
610 Nm
M14
80 Nm
M30
950 Nm
M16
135 Nm
M33
1200 Nm
M18
190 Nm
M36
1650 Nm
M20
260 Nm
M39
2100 Nm
2. Self-locking nuts.
Thread
Tightening
torque
Thread
Tightening
torque
M8
20 Nm
M22
430 Nm
M10
40 Nm
M24
490 Nm
M12
60 Nm
M27
650 Nm
M14
90 Nm
M30
1000 Nm
M16
150 Nm
M33
1250 Nm
M18
210 Nm
M36
1700 Nm
M20
290 Nm
M39
2200 Nm
3. Screws and nuts locked with glue/Loctite.

Thread
Tightening
torque
Thread
Tightening
torque
M8
23 Nm
M22
580 Nm
M10
50 Nm
M24
680 Nm
M12
70 Nm
M27
900 Nm
M14
115 Nm
M30
1350 Nm
M16
190 Nm
M33
1700 Nm
M18
270 Nm
M36
2350 Nm
M20
380 Nm
M39
3000 Nm
0$1% :'LHVHO$6
Page 1 (1)
Torque Spanner
913-5
Torque Spanner
/0&
0205
913-5
Before screwing the nuts on, the threads and

the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient = 0.1-0.12
(e.g. MOLYKOTE paste type G).
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
In the case of new nuts and studs, the nuts are
to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.
Nuts secured with a split pin are to be tightened
to the stated torque and then to the next splitpin hole.
The torque spanner must not be used for torques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.
Rahsol Torque Spanner
The handle of the torque spanner is provided
with a scale indicating the torques at which the
spanner can be set.
For setting the spanner at the required torque,
there is a ball on a small arm at the end of the
handle.
When the ball is pulled, a small crank handle
appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:
The above-mentioned spring acts on a pawl
system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the spanner, and a small click is heard.
When the torque spanner is not in use, the
spring inside should be released by adjusting to
minimum torque.
0$1% :'LHVHO$6
Page 1 (1)
Tightening Gauge
913-6
Tightening Gauge
0205
913-6
Preparations
Before screwing on the nuts, grease the
threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.
= 0.10.12 (e.g. MOLYKOTE paste type G)
The nuts should fit easily on the thread, and it
should be checked that they bear on the entire
contact face.
Pre-tightening with a torque spanner
Before tightening the nuts according to a tightening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
Apply a pre-tightening torque of:
thread M8 M20 = 50 Nm
This is in order to ensure a uniform basis for the
subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge
round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 3045 and 60,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
When tightening new studs or bolts for the first
time, loosen again and repeat the procedure
including pre-tightening with a torque spanner,
to allow the parts to settle.

7
;

G
Q
D

0
+
0$1% :'LHVHO$6
Page 1 (1)
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Some screwed and bolted connections on the

engine, as well as some movable joints, are secured against untimely loosening by means of
different types of locking devices.
1.
When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.
Make sure only to mount locking devices

on nuts and screws which have been
mounted with locking devices by the engine manufacturer.
1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers
are to be bent back over one of the flats of
the screw or nut concerned.
M913070207C01
Note!
2.
2. Used spring washers must be replaced.
To tighten a self-locking nut to a specific

torque, first measure the torque required to
turn the nut itself, and then add this torque
to the torque value stated on the data
sheet of a procedure.
M913070207C02
3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.
M913070207C03
3.
Page 1 (4)
Screws and Nuts
913-7.1
Locking
Fig. 1
MAN B&W Diesel
Locking wire should be fitted after the screws

or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Always fit new wire after tightening-up the units.
Fig. 2
Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.
Fig. 3
Fig. 1: Insert wire, grasp the upper end of the

wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.
Fig. 2: Twist the wire clockwise until it is just
short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approximately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180, equal
to half of a complete turn.
Fig. 6
M913070207C04
Fig. 5
Fig. 4
Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.
Fig. 4: Bend the lower wire around the screw,
and under the end protruding from the screw.
Fig. 5: Keeping the wire under tension, twist it
min. 3 twists, counterclockwise until tight.
Fig. 7
Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
M913070207C05
Fig. 7-9: Show the preferred ways of mounting

the locking wire on screws with wire holes oriented in different angles.
Page 2 (4)
Fig. 9
Screws and Nuts

MAN B&W Diesel
913-7.1
Locking
Fig. 10: Shows how to route the locking wire

on screws in different planes.
Fig. 11: Wire that passes over the top of a nut
is an acceptable alternative only if it routes
around the protruding screw thread.
Fig. 10
Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure.
Fig. 11
Fig. 13: Where drilling of locking wire holes has

caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut.
Fig. 12
Fig. 14: Locking wire can be mounted to any

other part of the assembly if nothing else is
possible.
M913070207C06
Fig. 13
Fig. 14
Page 3 (4)
913-7.1
Screws and Nuts

Locking
Fig. 15
MAN B&W Diesel
Cam Lock Washers with rising cams on one

side and radial teeth on the other.
Fig. 15: The washers are installed in pairs, cam
face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.
M913070207C15
Fig. 16: Different uses of the cam lock washers.

Fig. 17: Don not use the cam lock washers in
conjunction with other loose washers.
Fig. 16.
Note!
M913070207C16
Cam lock washers must be installed in

pairs and are not to be substituted by
other typers of washers.
M913070207C17
Fig. 17
Page 4 (4)
Lubricating Procedures
913-11
Lubricating Procedures
.0&&
0204
913-11
Molybdenum Disulphide (MoS2)

The following procedure is to be followed prior
to the mounting of metal surfaced parts which
are to function as seals.
Clean the surface with a cleaning fluid
and ensure that the entire surface is
completely free of grease.
Allow 5 minutes for the cleaning fluid to
evaporate.
With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote G-n Plus, or the like) hard onto the
metal surface.
Remove any excessive paste and ensure
that the metal surface is only coated with
a thin, uniform, layer of the above mixture.
Protect the wet paste and cloth from dust
or other foreign particles.
0$1% :'LHVHO$6
Page 1 (1)
Accessories for Hydraulic Tools

MAN B&W
Plate
P91351-0038
Working Pressure 900 Bar
Page 1 (2)
Plate
P91351-0038
Accessories for Hydraulic Tools

MAN B&W
Item
No.
Item Description
010
022
046
Hydralic pump, pneumatic operated

Hydralic pump, hand operated
Hose with unions (1500mm),
complete
complete
complete
Distributor block with shut-off valve
Angle union
Quick coupling, male
Quick coupling, female
Disc, round-plain, Cu o11x3mm
Bleeder screw
Disc, round-plain, Cu o11x9mm
058
060
105
117
130
154
166
201
213
225
237
249
Page 2 (2)
Lifting Tools, Etc.

MAN B&W
Plate
P91356-0058
Page 1 (2)
Lifting Tools, Etc.
Plate
P91356-0058
Item
No.
020
031
043
055
067
079
114
126
138
140
151
163
210
222
234
258
295
305
Page 2 (2)
MAN B&W
Item Description
Forged-bent screw shackle, 10mm

Lifting eye bolts, 10mm
Chain tackle, 500kg
Chain tackle, 1000kg
Pull lift, 3000kg
Wire rope, 6m
Open Ended Spanners

MAN B&W
Plate
P91357-0005
Page 1 (2)
Plate
P91357-0005
Item
No.
013
025
037
050
Page 2 (2)
Open Ended Spanners

MAN B&W
Item Description
Open-ended spanner, size 65mm

Torque Wrenches
MAN B&W
Plate
P91359-0003
Page 1 (2)
Torque Wrenches
Plate
P91359-0003
MAN B&W
Item
No.
Item Description
014
026
Torque wrench, 8 - 400Nm

Adapter for socket wrench, 10 x 12.5
mm
038
040
051
Page 2 (2)
Pliers
MAN B&W
Plate
P91360-0003
Page 1 (2)
Pliers
Plate
P91360-0003
Item
No.
010
021
033
128
130
141
153
Page 2 (2)
MAN B&W
Item Description
Pliers for retaining ring, size 0.9mm

MAN B&W
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
Item Description
Combination spanners, size 10mm


MAN B&W
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)

MAN B&W
Item Description
Slugging spanners, ring size 30mm

Spanners
MAN B&W
Plate
P91363-0040
Page 1 (2)
Spanners
Plate
P91363-0040
Item
No.
016
028
030
100
150
161
MAN B&W
Item Description
Tool set, complete, size 10-22 mm

Tool set, complete, size 24-46 mm
Hex key tool set, complete
Socket spanner, 46 mm
Hex key, 22 mm
Hex key, 24 mm
Note:
*
Page 2 (2)
Open-ended Spanners
MAN B&W
Plate
P91364-0059
Page 1 (2)
Plate
P91364-0059
Item
No.
011
023
Page 2 (2)
Open-ended Spanners
MAN B&W
Item Description
Open ring wrench, 14 - 17mm

Open ring wrench, 19 - 22mm
Instruments
MAN B&W
Plate
P91366-0066
Page 1 (2)
Instruments
Plate
P91366-0066
MAN B&W
Item
No.
Item Description
012
024
036
048
050
061
073
Indicator, complete
Indicator paper
Plainmeter, complete
Autolog, measuring tool for crankshaft
Feeler gauge
Slide caliper
Dial gauge and stand tool
Page 2 (2)
Warning
MAN B&W
S900-0002
Warning!
It is important that all MAN 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 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 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 S-Instruction S900
Edition 0002
Page 1 (1)
S50MC
VOLUME III
COMPONENTS
DESCRIPTION
900 - Introduction
90001
90002
90003
90004
90023
90030
0039
0001
0001
0001
0027
0009
MAN Diesel A/S
Table of Contents, Volume III

Cross Section through Engine
Ordering of Insulation
Designations and Symbols
Software Licence, Std
Instructions for Main Engine
Description
MAN Diesel A/S
Table of Contents
900
Volume III - Components Description

No.
Edition
Title
900 - Introduction
Table of Contents
90001 0039 Cross Section through Engine
90002 0001 Ordering of Insulation
90003 0001 Designations and Symbols
90004 0001 Software Licence, Std
90023 0027 Instructions for Main Engine
90030 0009 Description
90101 0175 Cylinder Cover
90201 0204 Piston and Piston Rod
90205 0115 Piston Rod Stuffing Box
90301 0182 Cylinder Frame
90302 0185 Cylinder Liner and Cooling Jacket
90304 0037 Cylinder Liner - Details
90305 0134 Cylinder Lubricators
90307 0035 Cylinder Lubricator Unit
90308 0012 Cylinder Lubricator - Intermediate Box
90309 0021 Cylinder Lubricator System - Details
90310 0013 Cylinder Frame - Rear Side
90312 0002 Electronic Components - Cylinder Lubrication
90401 0170 Connecting Rod and Crosshead
90403 0011 Lubricating and Cooling Oil Flow
90501 0164 Crankshaft
90503 0025 Arrangement of Angle Encoder
90504 0014 Axial Vibration Monitor
90505 0117 Thrust- and Guide Bearing
90510 0125 Turning Gear
90511 0049 Turning Wheel
90512 0002 Turning Gear - Details
906 - Control Gear
90600 0137 Arrangement of Chain Drive and Camshaft
90603 0073 Chain Tightener
MAN Diesel A/S
Page 1 (3)
Table of Contents
900

No.
90611
90612
90613
90618
90619
90632
90634
Edition
0172
0088
0103
0151
0036
0028
0031
Title
Camshaft and Chain Wheel
Arrangement of Indicator System
Camshaft Bearing
Regulating Shaft
Load Transmitter
Chain Drive Guidebars - Lower Part
Chain Drive Lubrication - Lower Part

90702 0070 Main Starting Valve
90703 0120 Starting Air Distributor
90704 0059 Starting Valve
908 - Exhaust Valve
90801 0206 Exhaust Valve - Lower Parts
90803 0040 Exhaust Valve - Upper Parts
90804 0016 Exhaust Valve Upper Parts - Details
90805 0144 Exhaust Valve - Actuator
90806 0098 Exhaust Valve - Pipe System
90810 0090 Arrangement of Cooling Water Pipes
90812 0003 Arrangement of Drain Pipes Freshwater
90901 0177 Fuel Pump
90902 0171 Fuel Pump Gear
90903 0021 Fuel Pump Gear - Details
90904 0059 Fuel Pump - Details
90905 0025 Reversing Mechanism
90910 0139 Fuel Valve
90911 0017 Fuel Valve Function
90913 0124 High-Pressure Pipes
90914 0099 Fuel Oil System
90914 0101 Fuel Oil System
90915 0060 Fuel Oil System - Details
91000 0012 Gas and Air System
91001 0134 Scavenge Air Receiver
91002 0149 Arrangement of Charging Air Pipe
91003 0235 Exhaust Pipes and Receiver
91004 0069 Exhaust Receiver - Details
91005 0136 Air Cooler
91006 0044 Arrangement of Auxiliary Blower
MAN Diesel A/S
Page 2 (3)
Table of Contents
900

No.
91007
91009
91011
91011
Edition
0007
0041
0019
0029
Title
Butterfly Valve
Air Cooler System - Cleaning
Arrangement of Non-Return Valve

91101 0037 Safety Valve - Cylinder
91102 0028 Relief Valve
91103 0016 Safety Valve - Scavenge Air System
91104 0069 Arrangement of Safety Cap
91201 0094 Arrangement of Stay Bolts
91203 0015 Frame Box - Details
91205 0194 Frame Box
91206 0122 End Shields
91207 0101 Arrangement of Piston Cooling
91210 0181 Bedplate
91211 0091 Axial Vibration Damper
91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
MAN Diesel A/S
Page 3 (3)
Cross Section through Engine

MAN B&W
Plate
P90001-0039
Page 1 (1)
Ordering of Insulation
MAN B&W
Plate
P90002-0001
Page 1 (1)
Designations and Symbols

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

from fore end
Exhaust side of engine
Propeller
Clockwise direction of rotation

defined from aft end of engine
Page 1 (1)
Software License, Standard Conditions

MAN B&W
Plate
P90004-0001
Standard Conditions of Software Licence

Software supplied by MAN Diesel separately or included as a part of any system or embedded in
any device is licensed by MAN Diesel A/S (MAN Diesel) subject to the customers acceptance of
the following standard conditions of licence.
TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMERS ACCEPTANCE OF THESE
CONDITIONS.
1. Right of Ownership
Software is delivered under a nonexclusive and nontransferable users licence from MAN Diesel
against a onceforall fee. MAN Diesel and its software suppliers retain the right of ownership to the
software.
If the engine plant for which the software is acquired is transferred to a third party the customer
has the right to assign the licence to this third party, provided that the third party agrees to the
terms of this licence agreement and provided that the customer does not retain any copies of the
software.
2. Copyright
The customer must not copy the software or any part thereof. Furthermore the customer is not allowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software.
3. Support
If required by the customer MAN Diesel shall provide technical support for installation and training in
use of the software against separate payment.
4. Updating
The nonexclusive users licence does not include any updating of the software. If and to the extent
MAN Diesel updates the programs or develops new versions, such updates or new versions shall be
made available to the customer against separate payment.
5. Warranty & Liability
MAN Diesel warrants that the software and data media containing the software are free of defects
in material and workmanship at the time of delivery. If the software and data media are found to be
defective and are returned to MAN Diesel within 90 days from the date of delivery, they will be replaced free of charge.
Except as stated above, MAN Diesel disclaims liability for breach of conditions or warranties, either
expressed or implied, with respect to the software and data media, including warranties of suitability
and applicability for a particular purpose.
Page 1 (2)
Plate
P90004-0001
Software License, Standard Conditions

MAN B&W
MAN Diesels liability for damages to the customer for any cause whatsoever, regardless of the form
of any claim or action, shall not exceed the total licence fee paid by the customer for the license to
use this software under this license agreement. MAN Diesel shall in no event be liable for any damages resulting from loss of data, prots or use of equipment, or for any special, incidental consequential damages arising out of or in connection with the use or performance of the software.
The limitations in liability stipulated above in this clause 0 shall also apply to MAN Diesels software
suppliers.
6. Law
MAN Diesels tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.
Page 2 (2)
Instructions for Main Engines
This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and to
describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes,
for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure the
supply of the correct parts for the individual engines:

Name of vessel
Engine No.
built by
Plate No.
Part No.
Quantity required (and description)

Example:

M/S Nybo 7730 B&W P90201-0036 059

10 off (piston ring)
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 Diesel instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN Diesel instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room
personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out
in the Technical File.
This book is subject to copyright protection, and should therefore not, in whole or in part, be copied,
reproduced, made public or in any other way made available to a third party without the written consent of this effect from MAN Diesel.
MAN Diesel A/S

A90023-0028

Teglholmsgade 41

DK-2450 Copenhagen

Denmark

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CVR No. 39 66 13 14
Engine Types 35-98MC/MC-C
A90030-0009
MAN B&W
901 Cylinder Cover
Cylinder Cover
The cylinder cover is made of steel.

On the 7098MC type engines the cylinder cover is provided with weldedon
heat resistant material at the points of fuel oil injection in order to improve the
service condition.
Valve bores
The cover has a central bore for the exhaust valve, which is attached by
means of four studs and nuts.
The cover furthermore has bores for the fuel valves, starting valve, starting air
inlet, safety valve and indicator cock.
Cooling
A cooling jacket is mounted on the lower part of the cylinder cover, whereby a
cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when
the exhaust valve is installed. These two spaces communicate through a large
number of cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and
passes through water connections to the cooling jacket surrounding the cylin
der cover and, further on, through the cooling bores, to the space around the
exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe:
On some engine types, an amount of water is also passed directly from the
cylinder cover to the exhaust valve housing through a cooling water connec
tion.
Tightening
The cylinder cover is tightened against the top of the cylinder liner with nuts
and long studs tted in the cylinder frame. The nuts are tightened with hydrau
lic tools.
Sealing between the cylinder cover and cylinder liner is obtained by means of a
sealing ring of mild steel.
902 Piston with Rod and Stuffing Box

Piston
The piston consists of two main parts:

Piston Crown
Piston Skirt
The piston crown is tightened to the upper end of the piston rod, and the pis
ton skirt is tightened to the piston crown.
When referring to this page, please quote Description A90030 Edition 0009
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The piston crown is provided with one groove all the way around, or with three
smaller grooves for the tting of lifting tools.
The piston crown is provided with chromiumplated grooves for four piston
rings.
Piston ring No. 1 is a ControlledPressure Relief ring (CPR).
Piston rings Nos. 2, 3 and 4 have oblique cuts:
piston ring No. 3 has a righthand cut,
and
piston rings Nos. 2 and 4 have lefthand cuts.
On some engines, the piston rings are provided with Alucoating to improve
the runningin stability and to reduce the runningin period.
Handle with care, as impact may cause the coating to crack and peel off.
Stationary Engines:
The CPR ring may have been coated with PM14 on the external surface.
Handle with care, as impacts may cause the coating to crack and peel off.
Piston Rod
The piston rod has a throughgoing bore for the cooling oil pipe, which is se
cured to the piston rod top.
Cooling oil is supplied through a telescopic pipe connection on the guideshoe
or on the crosshead and passed through a bore in the piston rod foot and
through the cooling oil pipe in the piston rod, to the piston crown.
The oil is passed on, through a number of bores in the thrust part of the piston
crown, to the space around the cooling oil pipe in the piston rod.
From the bore in the piston rod foot, the oil is led through the crosshead to a
discharge spout and to a slotted pipe inside the engine framebox as well as
through a control device for checking the ow and temperature.
The piston rod foot rests on a face cut out in the crosshead pin.
A shim is inserted between the piston rod and the crosshead. The thickness of
the shim is predetermined to match the actual engine layout.
The piston rod is fastened to the crosshead pin with screws or studs and nuts.
The nuts are tightened with hydraulic tools.
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Stufng Box
The bore for the piston rod between the scavenge air space and the crankcase
is tted with a piston rod stufng box, which is designed to prevent the lubri
cating oil in the crankcase from being drawn up into the scavenge air space.
The stufng box also prevents scavenge air (in the scavenge air space) from
leaking into the crankcase.
The stufng box housing consists of two parts, which are bolted together.
Scraper/sealing
rings
The housing is provided with a number of machined ring grooves:
The uppermost groove holds a scraper ring with oblique edges, which
serves to prevent sludge from the scavenge box from being drawn
down to the other rings.
Furthermore, a sealing ring is tted below the scraper ring (except on 35MC
type engines).
The ring grooves in the middle are tted with sealing rings.
The lowermost ring grooves are tted with scraper rings which scrape
the lubricating oil off the piston rod.
Oil which is scraped off the piston rod is returned to the crankcase through
bores in the stufng box housing.
Through bores in the housing and a pipe, the stufng box communicates with
a control funnel on the outside of the engine, which enables the sealing/scrap
ing performance to be checked.
Gaps at the ends of the ring segments ensure that the rings will bear against
the piston rod even in worn condition.
903 Cylinder Liner and Cylinder Lubrication

Cylinder Frame
The cylinder section of the engine consists of a cylinder frame with a boltedon
or integrated camshaft housing. The cylinder section is tightened together with
the engine framebox and the bedplate by means of stay bolts. Alternatively as
a complete welded assembly integrating the scavenge air receiver into the cyl
inder frame.
Bores and openings Central bores at the top of the cylinder frame enclose the cylinder liners.
Central bores in the bottom of the cylinder frame enclose the piston rod stuff
ing boxes.
On the exhaust side of the cylinder frame there are openings which connect
the scavenge air space around the cylinder liner with the longitudinal scavenge
air receiver of the engine.
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There are also inlet pipes for cooling and lubricating oil. The cylinder frame is
provided with cleaning and inspection covers giving access to the scavenge air
spaces.
Cylinder cover
studs
Studs for fastening the cylinder cover are mounted in the cylinder frame.
Cylinder Liner and The cylinder liner is tted with a cooling jacket. The cooling water is supplied
Cooling Jacket
at the lower part of the cooling jacket.
On slimtype liners, the water continues directly to the upper part of the cool
ing jacket, whereas on the borecooled type liner, the water rst passes
through the cooling bores. From the top of the cooling jackets, the water ows
through water connections to the cooling jacket on the lower part of the cylin
der cover.
Leakage of cooling water is prevented by silicone rubber rings.
The cylinder liner is tightened against the top of the cylinder frame by the
tensioning force from the cylinder cover studs being transmitted via the cylin
der cover.
Scavenge air ports
The part of the cylinder liner which is located in the scavenge air space of the
cylinder frame is provided with a number of scavenge air ports, which are un
covered by the piston when this is in its bottom position. The scavenge air
ports are bored at an oblique angle to the axis of the cylinder liner so as to
give the scavenge air a rotary movement in the cylinder.
Cylinder lubrication
In the free part of the cylinder liner, between the cooling jacket and the cylinder
frame, there are a number of bores with nonreturn valves for the supply of lu
bricating oil to the cylinder.
PCring
On 8098MC type engines a piston cleaning (PC) ring is mounted at the top of
the cylinder liner. The purpose of the PCring is to prevent the buildingup of
deposits on the piston topland and, in turn, prevent the wiping away of the cyl
inder lubricating oil. Consequently, the PCring contributes to reducing the
wear of liners and rings.
Cylinder
Lubricators
The engine is equipped with mechanically or electronically controlled cylinder

lubricators for lubrication of the running surface of liners and rings.
Regarding the cylinder lubricators proper, reference is made to the special in
struction manuals supplied.
See also Volume I, OPERATION, Chapter 707.
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904 Crosshead with Connecting Rod
Crosshead
The crosshead is provided with two guide shoes tted on the crosshead ends.
The centre part of the crosshead is designed as a bearing journal which is
housed in the crosshead bearing.
The crosshead bearing cap is provided with a cutout enabling the piston rod
to be assembled with the crosshead journal.
The crosshead is equipped with steel shells lined with bearing metal. The lower
shell is provided with an overlayer coating.
Piston rod foot
The piston rod foot is fastened to the crosshead. To match different engine lay
outs, a shim of predetermined thickness is inserted between the piston rod and
the crosshead.
Lubrication
The crosshead is provided with bores for distributing the oil supplied through
the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil
for the crosshead bearing and guide shoes and through a bore in the con
necting rod for lubricating the crankpin bearing.
The piston cooling oil outlet is led through a control device for each cylinder
for the purpose of checking the temperature and ow before the oil is passed
on to the lube oil tank.
Guide shoes
The sliding faces of the guide shoes are lined with caston bearing metal.
The guide shoes are guided by crosshead guides in the engine framebox and
properly secured against displacement by guide strips fastened to the guide
shoes.
On some engines, the guide shoes are provided with counterweights.
Tightening
The crosshead bearing is held together by studs and nuts. The nuts are tight
ened with hydraulic tools.
The crankpin bearing is tted with steel shells lined with bearing metal and as
sembled in the same way as the crosshead bearing.
905 Crankshaft and Turning Gear

Crankshaft
The crankshaft is either of the semibuilt type, where the parts are shrunk to
gether, or it is a onepiece forging.
The main bearings are lubricated via a main lubricating oil pipe that branches
off to the individual bearings, whereas oil for lubricating the crankpin bearings
is supplied from the crossheads through bores in the connecting rods.
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The crankshaft is provided with a chain wheel for the camshaft drive and a
turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a
chain wheel drive for 2nd order and 4th order moment compensators are in
stalled, if required according to vibration calculations.
Marine engines (except geared plants):
At the aftmost end of the engine, a thrust bearing is tted.
The thrust bearing serves the purpose of transmitting the axial thrust of the
propeller through propeller shaft and intermediate shafts to the ships hull.
The crankshaft is provided with a thrust collar which transmits the thrust to a
number of segments mounted in a thrust shoe on either side of the thrust col
lar.
The thrust shoes rest on surfaces in the thrust bearing housing and are held in
place by means of stoppers or cross bars. The segments have white metal
cast onto the wearing faces against the thrust collar. See also Volume I, OPERATION, Chapter 708.
The thrust bearing is lubricated by the pressure lubrication system of the en
gine. The oil is supplied between the segments through spray pipes and spray
nozzles.
The thrust bearing is provided with alarm, slowdown, and shutdown devices
for low lube oil pressure and high segment temperature. See also Volume I,
OPERATION, Chapter 701.
Stationary engines and geared marine plants:
The crankshaft is provided with a collar for the guide bearing. The purpose of
the guide bearing is to keep the crankshaft in its proper position in the axial di
rection.
Axial Vibration
Damper
To counteract heavy axial vibrations, and any resultant adverse forces and
vibrations, the crankshaft is provided with an axial vibration damper. See also
Section 912, Assembly of large parts further on in this text.
The damper consists of a piston and a slittype housing. The piston is made
as an integrated collar on one of the main bearing journals, and the housing is
mounted on the pertaining main bearing support.
The axial movement is damped as a result of the restrictions incorporated in
the bores which interconnect the oillled chambers on the two sides of the
piston.
Lubricating oil is supplied to both sides of the piston from the main system.
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Turning Gear
The turning gear is attached to the engine bedplate and is driven by an electric
motor incorporating a disc brake.
Through a planetary gearing, the motor drives a horizontal shaft equipped with
a gear wheel which can be axially displaced manually, so as to engage with the
turning wheel of the engine.
The turning gear is provided with a safety arrangement consisting of a safety
lever which must be lifted before the gear wheel of the turning gear can be
made to engage with the turning wheel.
When the safety lever is in its bottom position, it prevents the gear wheel of
the turning gear from engaging with the turning wheel.
Immediately the lever is lifted away from the disengaged position, an interlock
valve inserted in the starting air system of the engine is actuated. This interlock
prevents starting air from being supplied to the engine as long as the turning
gear is in the engaged position.
Warning!
Dismantling of
working parts:
During any dismantling of working parts of the

engine, the turning gear must be in the engaged
position in order to prevent outside forces from
turning the engine, thus causing injuries to personnel or damage to the machinery.
See Volume II, MAINTENANCE, DATA pages.
Pressure testing of starting

valves:
The turning gear must be in the disengaged position during pressure testing of starting valves, as
a leaky valve may cause the engine to rotate, and
damage the turning gear.
See Volume I, OPERATION, Chapter 703.
906 Mechanical Control Gear

Chain Drive
The camshaft with cams for operating the fuel pumps, exhaust valves and indi
cator drive (option) is driven from the crankshaft through a chain drive.
The chain drive consists of one or more roller chains running on chain wheels
tted on the crankshaft and the camshaft. The chain is kept tightened by a
chain tightener placed in the chain casing between the crankshaft and the
camshaft.
The long free lengths of the chain are guided by rubberclad guide bars. Lubri
cating oil is supplied through spray pipes tted at the guide bars and chain
wheels.
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Camshaft
The camshaft is made in one or more sections.

If it is made in two or more sections, the sections are assembled by means of
ange couplings.
The camshaft has, for each cylinder:
one cam for operation of the fuel pump
one cam for operation of the exhaust valve
one cam for operation of the indicator drive (option)
The fuel pump and exhaust valve cams are shrunk on to the shaft by heating,
whereas the indicator cams are in two parts, which are assembled with tted
bolts.
The camshaft rotation constantly follows that of the crankshaft.
Bearings
The camshaft is carried in bearing assemblies which are tted in the roller
guide housings. See also Volume I, OPERATION, Chapter 708.
Engine timing
The engine timing is adjusted by forcing lubricating oil in between the cams,
couplings or chain wheel and the shaft, which enables the parts to be turned in
relation to each other. See Volume II, Chapters 906, 908 and 909.
Pin gauges
After the engine has been testrun, the camshaft parts and the cylinder frame
will be provided with pin gauge marks, and the necessary pin gauges are deliv
ered together with the engine, enabling the camshaft timing to be checked and
readjusted if the parts have been dismantled.
Indicator Valve
Each cylinder is tted with an indicator valve, which communicates with the
combustion chamber of the cylinder through a bore.
Operating Instructions!
When opening the indicator valve, the spindle must be screwed right back to
the stop in order to avoid burns and carbon in the guide.
Note!
For indicator valves of the doubleseated design with a springloaded closing
face:
In order to prevent overstressing, close the valve lightly before starting the
engine, and retighten the valve when the engine has reached its normal service temperature.
PMISystem
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See separate instructions for operating the PMIsystem (option).
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Moment
Compensators
On the basis of calculations, the engine may be provided with y

weights to counteract engine forces and moments.
Caution!
If the chain drives for the compensators have been dismantled, the
yweights must be positioned correctly in relation to the crankshaft.
See the instruction book, Volume II, MAINTENANCE.
Incorrectly tted moment compensators may excite heavy vibrations.
1st order moment
Applicable on 4cylinder engines. The moment compensator is arranged

as adjustable yweights on both ends of the crankshaft.
Alternatively, the 1st order moment compensator can be positioned in
the main chain drive.
This moment compensator consists of a (new) chaintightener wheel
with an incorporated yweight and a yweight rotating with the crank
shaft.
2nd order moment
Applicable on 45 and 6cylinder engines. The moment compensator is

arranged as yweights built into the main chain drive.
On some engines, yweights are built into a second chain drive, which
is driven from the opposite end of the crankshaft. This chain drive is
equipped with a springloaded chain tightener, which on some engines
is equipped with a hydraulic damper.
Optionally, an electrically driven compensator can be installed.
4th order moment
The moment compensator is arranged as yweights built into chain

drives on both ends of the camshaft. Each chain drive is equipped with
a springloaded chain tightener, and each chain casing is tted with a
relief valve.
907 Starting Air System

Starting Air System
The starting air system consists of the manoeuvring system and the
starting air components, which comprise:
Main Starting Valve
Starting Valves
The manoeuvring system is of electric/pneumatic design.
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Main Starting
Valve
The main starting valve is interposed in the starting air main pipe.
The main starting valve consists of a large ball valve and, optionally, a smaller
ball valve for slowturning prior to starting the engine, which is tted as a by
pass for the large valve. Both valves are operated by pneumatic actuators.
If the smaller ball valve is installed, an adjusting screw will be mounted for set
ting the slowturning speed.
Furthermore, a nonreturn valve is incorporated to prevent blowback in the
event of excessive pressure in the starting air line.
The main starting valve is equipped with a blocking device consisting of a plate
which, by means of a handwheel, can be made to block the actuators.
The ball valves and their actuators are, together with the nonreturn valve and
blocking device, built together to form a unit.
Warning!
During all inspections of the engine, the blocking device of the main starting
valve must be in the BLOCKED position.
The only exception is when the starting valves are being tested for tightness,
in which case the blocking device of the main starting valve must be in the
WORKING position and the shutoff valve for the starting air distributor must
be in the CLOSED position. See Volume I, operation, Chapter 703, OPERATION after arrival in port.
Starting Air
Distributor
The starting air distributor controls the opening and the closing of the starting
valves.
Starting Valve
The starting valve (springloaded) is tted on the cylinder cover. It is controlled

by control air from the starting air distributor.
When the main starting valve is open, the chamber below the piston of the
starting valve is pressurised through the starting air pipe.
The starting valve is kept closed by the spring. When the chamber above the
piston of the starting valve is pressurised with control air from the starting air
distributor, the starting valve opens, and starting air now ows from the starting
air pipe to the cylinder.
When the starting period is nished, the chamber above the piston is vented
through the vent pipe of the starting air distributor, and the starting valve will
close.
The starting air in the chamber below the piston and the starting air pipe is
vented slowly through small holes in the starting air pipe.
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908 Exhaust Valve
Exhaust Valve
Each cylinder is equipped with an exhaust valve, which is mounted in a central

bore in the cylinder cover. The valve housing is attached with four studs and
nuts to form a gastight seal against a seat in the cylinder cover.
Valve housing
The valve housing has an exchangeable bottom piece.

The bore for the valve spindle is provided with an exchangeable spindle guide
liner.
Cooling
The valve housing is water cooled. The cooling water is passed to the valve
housing after it has passed the cylinder cover. The water is discharged from
the upper part of the valve housing.
On the front of the valve housing there is a cleaning cover through which the
cooling water space can be checked and cleaned.
Valve spindle
The part of the spindle stem which travels within the sealing arrangement of
the air cylinder is coated with a wear resistant mixture of metal carbide and su
per alloy, applied by the HVOF process.
On the lower cylindrical part of the valve spindle a vane wheel is tted which
causes the valve spindle to rotate while the engine is running.
Lifting/rotation check rod:
To enable checking the functioning of the exhaust valve while the engine is
running, a lifting/rotation check rod is mounted on top of the hydraulic cylin
der on the exhaust valve.
Spindle rotation is indicated by regular changes in the top and bottom posi
tions of the check rod.
Note!
This check rod is only for checking purposes, and must not be permanently
activated.
Pistons:
At the top of the spindle, two pistons are tted:
1.
Air piston
The piston serves to close the exhaust valve. The piston is locked to
the spindle by a twopiece conical ring.
2.
Hydraulic piston
The piston serves to open the exhaust valve.
The hydraulic piston has two piston rings and a damper arrangement,
designed to dampen the closing of the valve.
For small bore engine types (26-70MC/MC-C) the damper arrangement
is of self-adjusting type.
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Note!
For damper arrangements of non-self-adjusting type, it is important to check
the damper after the exhaust valve has been overhauled, to avoid knocking.
See Volume II, MAINTENANCE, Procedure 908.
Air cylinder
The air cylinder is mounted on top of the valve housing. Air for closing the ex
haust valve is supplied through a nonreturn valve to the space below the pis
ton.
A safety valve is mounted in the bottom of the air cylinder. The safety valve is
connected to the drain pipe which leads to the camshaft housing.
Hydraulic cylinder
The hydraulic cylinder is attached with studs and nuts on the air cylinder on
top of the exhaust valve housing.
The exhaust valve is opened by the valve spindle being forced down by the
piston in the hydraulic cylinder.
Throttle/valve:
On some engine types, a combined throttle/valve designed for deaerating the
oil system is tted at the top of the cylinder.
When the exhaust valve is closed, the pressure in the hydraulic cylinder is low.
A thrust spring opens the valve, enabling oil and air, if any, to escape through
the throttle.
The oil is led through a duct to the space around the air cylinder and is
drained off through a bore X, together with leakage oil from the piston.
When the exhaust valve is activated, the high oil pressure closes the valve, and
the oil ow stops.
Sealing System
Sealing air (where used):

A sealing air arrangement is tted around the spindle shaft below the air cylin
der.
The sealing air is supplied from the air cylinder via a sealing air control unit.
The sealing air will prevent the exhaust gas and particles from penetrating up
wards and wearing out the running surfaces and polluting the pneumatic sys
tem of the valve gear.
The oil content in the air from the air cylinder improves the service condition of
the sealing rings.
The sealing air control unit contains a valve which automatically cuts off the air
ow when the engine is in FINISHED WITH ENGINE status, and a lter hous
ing.
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Sealing oil (where used):
A sealing oil arrangement is tted around the spindle shaft below the air cylin
der.
The sealing oil is supplied from a control unit tted on top of the exhaust valve
hydraulic actuator.
During the exhaust valve lifting period, oil escapes from the hydraulic actuator
through the restriction chamber to the control unit which, in turn, gives a cer
tain amount of oil (dosage oil) to the exhaust valve spindle.
The sealing oil will prevent the exhaust gas and particles from penetrating up
wards and wearing out the running surfaces and polluting the pneumatic sys
tem of the valve gear.
The oil improves the service condition of the sealing rings.
Hydraulic Valve
Actuating Gear
The exhaust valve is actuated by a cam on the camshaft through a hydraulic

transmission.
Hydraulic cylinder
The hydraulic cylinder is attached to the camshaft housing by studs and nuts.
A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck
of the roller guide and is locked to the roller guide by a bayonet joint.
The hydraulic cylinder on the camshaft housing is connected to the hydraulic
cylinder on the exhaust valve by a highpressure pipe.
Oil is supplied from the lubricating oil system through a nonreturn valve.
Leakage oil from the hydraulic cylinder on the exhaust valve is drained through
a pipe connection.
Puncture Valve
On 4cylinder reversible engines as well as on 5cylinder reversible 50MC en

gines, a puncture valve may be mounted on the exhaust valve actuator. During
starting, this valve prevents the exhaust valve from opening during the rst part
of the actuator pistons upward stroke.
This function prevents the starting valve and exhaust valve from being open at
the same time, thus ensuring a safe start.
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909 Fuel Oil System
Fuel Pump
Each engine cylinder is equipped with its own fuel pump, which is mounted on
the camshaft housing over the camshaft section corresponding to the cylinder
concerned.
The pump housing is attached to the camshaft housing by studs and nuts.
The square base of the fuel pump housing is provided with a groove to receive
any leakage oil, which is subsequently drained off through a drain pipe.
In the base, a bore is provided for at toothed rack, i.e. the regulating guide,
which controls the quantity of fuel oil delivered by the pump.
Furthermore, for the VITtype fuel pump, another bore is provided above the
bore for the regulating guide. This bore is provided with a rack, i.e. the timing
guide, which controls the engine timing.
At the top, the pump housing is closed by a top cover.
The top cover is provided with a suction valve and a puncture valve. These
two valves are on some engine types combined into one unit.
The pump housing contains the plunger and barrel. The plunger and barrel are
matched parts, and must not be replaced individually.
The pump plunger is provided with a guide block designed to travel in the
milled keyway in the regulating guide. At the bottom it has a foot which rests
on a steel disc in the bayonet joint at the roller guide neck. A clearance of
approx. 0.1 mm between the plunger foot and the roller guide permits turning
of the plunger in the roller guide.
The regulating guide is able to turn in the bottom of the pump housing. On the
outside the regulating guide has a toothed rim to mesh with the abovemen
tioned toothed rack at the base of the pump housing. The toothed rim and
toothed rack are marked with lines enabling the parts to be positioned cor
rectly after disassembly. The toothed rack is linked together with the regulating
gear of the engine through a springloaded connection. Thus, in the event of a
sticking pump plunger, the regulating gear for the remaining fuel pumps will not
be blocked.
The pump barrel is provided with oil cutoff holes, which are covered and un
covered during the travel of the plunger within the barrel. This function, in con
junction with the turning of the plunger effected by the regulating gear, serves
to regulate the amount of oil injected into the engine cylinder.
Two screw plugs are tted in the pump housing opposite the cutoff holes of
the barrel. The oil jets which are ejected through the cutoff holes at the end of
the delivery stroke will hit the screw plugs, which can be replaced when they
are eroded.
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Injection timing
Fuel pumps without VIT (Variable Injection Timing):

The pump barrel is attached to the top cover by means of screws.
The lower part of the barrel is guided in the bore of the pump housing. Two
sets of Orings and backup rings are tted in grooves on the outside of the
barrel and the pump cover to seal between pump barrel/pump cover and
housing.
A number of semicircular shims are inserted between the top cover and the
pump housing. By removing or inserting such shims, the pump barrel can be
slightly lowered or raised in relation to the plunger, and in this way the initial
moment of fuel oil injection into the engine cylinder can be adjusted, and the
maximum combustion pressure thus changed.
Refer to Volume II, Chapter 909, regarding adjustment of the maximum com
bustion pressure.
VITtype fuel pumps:
The pump barrel is guided at the top and bottom of the pump housing. Low
friction sealing rings are tted in grooves in the barrel to seal between barrel
and housing. The barrel is provided with a drain bore between the sealing rings
at the lower end.
The pump barrel has a threaded lower end which ts into the internal threads
of the timing guide.
The timing guide has a gear rim to mesh with the upper toothed rack at the
base of the pump housing. The gear rim and toothed rack are marked with
lines enabling the parts to be positioned correctly after disassembly. The
toothed rack is linked to a servoair cylinder which is controlled mechanically
or electronically in relation to the engine load. The position of the upper
toothed rack determines the vertical position of the barrel relative to the
plunger through the threaded connection.
In this manner the initial moment of fuel oil injection into the cylinder can be
adjusted by a servoair cylinder.
The pump barrel is prevented from turning by a guide screw mounted in the
pump housing.
Puncture valve
In the top cover of the pump, a puncture valve is tted. The puncture valve
consists of a piston which communicates with the control air system of the en
gine. In the event of actuation of the shutdown system, and when
STOP is activated, compressed air is supplied to the top of the piston, causing
the piston with pin to be pressed downward and keep the suction valve in the
open position. This will puncture the oil ow to the fuel valve. As long as the
puncture valve is activated, the fuel oil is returned through bores to the pump
housing, and no injection takes place.
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Fuel Oil Injection
During the suction stroke, the springloaded suction valve opens and the deliv
ery chamber is lled with oil. As soon as the plunger has covered the cutoff
holes during its upward movement in the pump barrel, the injection com
mences through the fuel valves. The injection will last until the cutoff holes are
uncovered by the oblique cutoff edges of the plunger, following which the oil
is forced through two milled grooves at the side of the plunger and out through
the cutoff holes of the barrel during the rest of the delivery stroke.
Shock absorber
A shock absorber is installed on each pump housing or in the main fuel pipe to
take up pressure variations.
Fuel Pump
Actuating Gear
The camshaft housing contains the fuel pump and exhaust valve actuating gear
for each cylinder.
The fuel pump is actuated by a cam on the camshaft. The movement is trans
mitted through the roller guide to the plunger in the barrel of the pump housing
which through the highpressure pipes is connected with the fuel valves on
the cylinder cover.
Reversible engines:
The roller guide of each fuel pump incorporates an angular displaceable revers
ing link.
Reversing is achieved by shifting the roller in the fuel pump drive mechanism at
each cylinder. The link connecting the roller guide and roller is provided with a
reversing arm, and a pivot is mounted at the top end of the reversing arm. The
pivot travels in a reversing guide connected to an air cylinder. The link is self
locking in either the ahead or astern position without the aid of external forces.
Each cylinder is reversed individually, and the reversing mechanism is activated
by compressed air.
The reversing arrangement may incorporate a damper in order to reduce the
mechanical stresses.
Fuel Oil High

Pressure Pipes
All highpressure pipes in the system are provided with a protective outer pipe.
The space between the pipe and the protective outer pipe communicates,
through bores in the union nipples, with a drain bore in the pump top cover.
Fuel Oil Leakage

Alarm
A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS.
3598MC:
Each fuel pump is, via drain pipes, connected to a common drain tank, which
incorporates a level switch. The drain tank is also equipped with an overow
pipe, which has a small drain bore below, whereby oil from small leakages can
be drained to the outlet, without actuating the level switch.
In the event of pipe fractures or major leakages in the system, the abovemen
tioned bore will not be large enough to allow the increased oil quantity to pass,
and the oil level in the drain tank will rise until it reaches the level of the over
ow pipe. The rising oil level will cause the level switch to set off an alarm.
Page 16 (23)
A90030-0009
MAN B&W
5098MC:
Alternatively to the common drain tank, the drain pipes on 5098MC engines
can be connected to a diaphragm valve, which sets off an alarm and activates
the puncture valve in order to stop the fuel oil ow from the pertaining pump.
On 6098MC engines, which are provided with pneumatically operated fuel
pump roller guide lifting gear, automatic activation of the lifting gear by the dia
phragm valve can be arranged in order to stop the fuel oil ow from the per
taining pump.
Fuel Valve
The fuel valve consists of a valve head and a valve housing. Fitted within the
valve housing is a nonreturn valve and a spindle and spindle guide with a
pressure spring, and a nozzle.
The spindle may be provided with a cutoff slide. When the fuel valve is tted
in the cylinder cover, the valve parts are tightened together by the pressure
from the securing nuts.
Functioning
The functioning of the fuel valve is as follows:

The electrical fuel oil primary pump circulates preheated oil through the fuel
pump and fuel valve. The fuel oil passes through the fuel valve, leaving through
a circulation bore and the return oil pipe on the valve head.
When the pressure at the beginning of the fuel pumps delivery stroke has
reached the predetermined pressure, the circulating bores is closed.
When the pressure has reached the predetermined opening value for the fuel
valve, the spindle will be lifted and oil injected through the nozzle into the en
gine cylinder.
On completion of the fuel pumps delivery stroke, the valve spindle is pressed
against its seat and injection now ceases. Then the circulating bore is uncov
ered, and oil starts to recirculate through the valve.
910 Turbocharger System

Air System
The engine is supplied with scavenge air from one or more turbochargers, de
pending on the engine type and layout.
The engine exhaust gas drives the turbine wheel of the turbocharger and,
through a common shaft, the turbine wheel drives the compressor wheel.
The compressor draws air from the engine room, through the air lters. From
the compressor outlet, the air passes through the charging air pipe to the
charging air cooler where the air is cooled down.
The charging air pipe, with compensator, is insulated.
Page 17 (23)
A90030-0009

MAN B&W
The air cooler incorporates a water mist catcher, which is designed to separate
condensate from the air.
See also Charging Air Cooler further on in this Section.
When the air has passed the water mist catcher, it is pressed into the scav
enge air receiver through nonreturn valves. The nonreturn valves open by
pressure from the turbocharger.
From the scavenge air receiver, the air ows to the cylinder through the scav
enge air ports when the piston is in the bottom position. When the exhaust
valves open, the exhaust gas is pressed into a common exhaust gas receiver,
from where the gas drives the turbine of the turbocharger with an even and
steady pressure
Scavenge Air
Receiver
The scavenge air receiver is a container having a large volume. The receiver is
bolted on to the cylinder frame, or alternatively integrated into the cylinder
frame, if welded. See Chapter 903.
Scavenge air is collected in the receiver after the air has passed through the
cooler, the water mist catcher and the nonreturn valves.
The receiver and the cylinder frame communicate through large openings.
The scavenge air receiver is provided with manhole covers and a safety valve.
Auxiliary Blowers
The engine is provided with two or more auxiliary blowers. The suction sides
are connected to the space after the water mist catcher. The discharge sides
are connected to the scavenge air receiver. Separate nonreturn valves are in
stalled at the suction side or discharge side of the auxiliary blowers, in order to
prevent reversed air ow.
See also item, Nonreturn valves, further on.
El. panels for

auxiliary blower
See special instructions supplied by the engine builder.
Running with
auxiliary blowers
During the starting of the engine, and when the engine is running at low load,
the turbocharger is not able to supply enough air for the engine process. In
these cases a pressure switch will automatically start the auxiliary blowers.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air lter and compressor side.
Page 18 (23)
A90030-0009
MAN B&W
Warning!
If the auxiliary blowers do not start during lowload running (because of
faults, or because the switch for the blowers is not in AUTO position), unburned fuel oil may accumulate on top of the pistons.
This will involve the risk of a scavenge air box re.
In order to avoid such a re:
obtain permission to stop the engine

stop the engine
remove any unburned fuel oil from the top of the pistons
reestablish the supply of scavenge air
start the engine
Note: the switch for the auxiliary blowers should be in

AUTO position during all modes of engine control, i.e.:
remote control
control from engine side control console.
When the auxiliary blowers are operating, they draw air from the engine room
through the turbochargers air lter and compressor side.
The nonreturn valves tted after the water mist catcher are now closed as a
result of partial vacuum and gravitation acting on the valve aps.
There will be a lack of air supply if the nonreturn valves do not close.
NonReturn Valves
It is of the utmost importance that the nonreturn valves of the auxiliary blow
ers always function correctly and move easily. This can be checked either by
moving the valves manually in connection with the regular scavenge port in
spections, or via locally placed inspection covers.
The nonreturn valves protect the blowers and engine during:
Startup of the auxiliary blowers
Running with auxiliary blowers.
Starting the auxiliary blowers:
1.
Owing to the relatively high starting current, the blowers start in se

quence, with 610 seconds in between.
The nonreturn valve of the blower that has not yet started must be in
the closed position to prevent the blower from rotating backwards. Oth
erwise, there is a risk that the electric motor will burn out when it starts.
2.
If an auxiliary blower fails to start, the nonreturn valve must be in the

closed position. Otherwise, the operating blower will not be able to
draw fresh air in through the turbocharger and air cooler. This is due to
differences in the air ow resistance.
Page 19 (23)
A90030-0009
MAN B&W
Running with auxiliary blowers:
If an auxiliary blower fails during running, the nonreturn valve must close to
ensure the continued supply of fresh air to the engine. See Starting the auxil
iary blowers, Item 2, above.
Exhaust Gas
Receiver
From the exhaust valves, the exhaust gas is led to the exhaust gas receiver
where the pulsatory pressure from the individual exhaust valves is equalized
and led to the turbocharger at a constant pressure.
The exhaust gas receiver is fastened to the seating by exible supports. Com
pensators are inserted between the receiver and the exhaust valves, and be
tween the receiver and the turbocharger.
Inside the exhaust gas receiver, a protective grating is mounted before the tur
bocharger.
The exhaust gas receiver and the exhaust pipe are insulated.
Charging Air
Cooler
The charging air cooler insert is of the block type. It is mounted in a housing
which is welded up of steel plates.
The cooler housing is provided with inspection covers.
The cooler is designed with an air reversing chamber which incorporates a wa
ter mist catcher. The water mist catcher is built up of a number of lamellas
which separate the condensation water from the scavenge air during the pas
sage of the air ow.
The separated water is collected in the bottom of the cooler housing from
which it is removed by a drain system.
Caution!
It is important to check that the drain functions correctly, as otherwise water droplets may enter the cylinders. See Volume I Operation, Chapter 706,
Cleaning of Turbochargers and Air Coolers.
An alarm device for high water level in the drain system is installed.
911 Safety Equipment

Safety Valves,
Cylinder Cover
Page 20 (23)
Each cylinder cover is provided with a springloaded safety valve which is set
to open at a pressure somewhat higher than the maximum ring pressure in
the cylinder.
A90030-0009
MAN B&W
Relief Valves
On the exhaust side of the engine a number of springloaded relief valves are
tted, which will open in the event of excessive pressure in the crankcase/
chain casing, for instance as a result of the ignition of oil mist.
Warning!
Keep the areas around the relief valves free of oil, grease, etc. to prevent the
risk of re caused by hot air/gas emitted in the event that the relief valves
open.
Regarding how to:
avoid evaporation of the lubricating oil in the crankcase,
detect oil mist in the crankcase using an Oil Mist Detector.
see Volume I, OPERATION, Chapter 704.
Warning!
Do not stand near crankcase doors or relief valves or in corridors near
doors to the engine room casing in the event of an alarm for:
a) oil mist
b) high lube oil temperature
c) no piston cooling oil ow, or
d) scavenge box re
Alarms b, c and d should be considered as prewarnings of a possible increasing oil mist level.
See also our Service Letter SL97348/ERO.
Note!
If there has been a crankcase explosion, the complete ame arrester of the
relief valves must be replaced.
Safety Valve,
Scavenge Air
Receiver
The scavenge air receiver is tted with a safety valve which is set to open
should the pressure in the scavenge air receiver exceed a value somewhat
higher than the normal scavenge air pressure of the engine.
In some cases it may be necessary to open the valve manually, see Volume I,
Chapter 704, Turbocharger Surging.
Page 21 (23)
A90030-0009
MAN B&W
Safety Cap in
Starting Air Line
Each starting valve inlet pipe is provided with a safety cap. The safety cap
consists of a bursting disc enclosed by a perforated cylinder and a perfo
rated cover in order to protect any bystanders, in the event of a burst.
The cover is provided with a check plate, which shows if the bursting disc has
been damaged.
If the bursting disc of the safety cap is damaged by excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst,
and t a new disc.
If a new disc is not available immediately, turn the cover in relation to the cylin
der, in order to reduce the leakage of starting air. Fit a new bursting disc and
return the cover to the open position at the rst opportunity.
912 Assembly of large Parts

Bedplate
The bedplate is made in one or more sections, depending on the number of

cylinders. If there are two or more sections, these are joined together with t
ted bolts. The bedplate consists of two welded, longitudinal girders and a
number of cross girders which support the main bearings. The main bearings
consist of steel shells, lined with bearing metal.
Each main bearing has one or two main bearing caps which are secured by
studs and nuts, designed for tightening with hydraulic tools.
The bedplate is tted with an axial vibration damper. For the design and func
tioning of the axial vibration damper, see Section 905 Crankshaft.
Marine engines (except geared plants):
The aft end of the bedplate incorporates the thrust bearing. See also Section
905 Crankshaft.
Stationary engines (and geared marine plants):
The bedplate incorporates the guide bearing. See also Section 905, Crank
shaft.
Framebox
A framebox is bolted on to the top of the bedplate. Like the bedplate, the
framebox consists of one or more sections. Together, the bedplate and the
framebox constitute the crankcase of the engine.
The framebox is tted with steelplate doors for access to the crossheads and
to the main and crankpin bearings.
For each cylinder, the framebox is equipped with a slotted pipe in which the
piston cooling oil outlet pipe tted to the crosshead or guide shoe is able to
travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to
the oil tray of the bedplate.
Page 22 (23)
A90030-0009
MAN B&W
Equipment for local checking of the cooling oil temperature and ow, and for
temperature and ow alarms, is installed in conjunction with the outlet pipe.
Staybolts
The bedplate, framebox and the cylinder frame are tightened together to form
one unit by means of staybolts.
Engine Seating
Regarding the engine seating for the specic engine, see the suppliers special
instructions.
Page 23 (23)

90101
0175
MAN Diesel A/S
Cylinder Cover
MAN Diesel A/S
Cylinder Cover
Plate
P90101-0175
Page 1 (2)
MAN B&W
Cylinder Cover
Plate
P90101-0175
Item
No.
018
031
043
055
067
079
080
092
102
114
138
151
163
175
187
209
Page 2 (2)
MAN B&W
Item Description
Screw
Protective cap
Nut
Stud
Nut
Stud
Cylinder cover
O-ring
Cooling jacket
Screw
Nut
Spring house complete
Stud
Stud
Pipe for fuel valve
Guide pin

90201
90205
0204
0115
MAN Diesel A/S
Piston and Piston Rod

MAN Diesel A/S

MAN B&W
Plate
P90201-0204
A
A
Page 1 (2)
Plate
P90201-0204
Item
No.
011
023
035
047
059
060
084
096
106
118
143
155
167
179
180
192
Page 2 (2)
MAN B&W
Item Description
Screw
Screw
Screw
Locking wire
Screw
Screw
Piston ring
Piston ring
Piston ring
Piston crown
Pipe for cooling
Piston rod
D-ring
D-ring
Piston skirt
Screw
Plate
P90205-0115
MAN B&W
A
B
Page 1 (2)
Plate
P90205-0115
Item
No.
013
025
037
049
050
062
086
098
121
145
157
169
170
182
204
216
241
253
Page 2 (2)

MAN B&W
Item Description
Nut
Housing for stuffing box
Scraper ring
Scraper ring
Flange
Guide pin
Screw
Spring pin
Lamella
O-ring
Scraper ring
Sealing ring
Sealing ring
Screw
Fitted bolt
Housing for stuffing box, complete
Spring
Spring

90301
90302
90304
90305
90307
90308
90309
90310
90312
90312
90312
0182
0185
0037
0134
0035
0012
0021
0013
0002
0003
0004
MAN Diesel A/S
Cylinder Frame
Cylinder Liner and Cooling Jacket
Cylinder Liner - Details
Cylinder Lubricator Unit
Cylinder Lubricator - Intermediate Box
Cylinder Lubricator System - Details
Cylinder Frame - Rear Side
Electronic Components - Cylinder Lubrication
MAN Diesel A/S
Cylinder Frame
Plate
P90301-0182
Page 1 (2)
MAN B&W
Cylinder Frame
Plate
P90301-0182
Item
No.
015
027
039
040
052
076
088
123
135
147
196
206
218
255
267
279
280
302
314
326
338
363
387
399
409
422
446
458
471
483
495
505
517
529
542
554
566
578
591
601
613
625
637
Page 2 (2)
MAN B&W
Item Description
Screw
Protective cap
Nut
Stud
Sealing ring
Nut
O-ring
Nut
Stud
Distance pipe
Cylinder frame
Distance pipe
Screw
Screw
Protective tube
Gasket
Stud
Nut
Distance Pipe
Bushing
Stuffing box housing
Screw
Screw
Fitted stud
Fitted stud
Fitted stud
Fitted stud
Screw
Screw
Screw
Fitted stud
Stud
Nut
Stud
Screw
Screw
Rail for sealing
Packing
Stud
Distance pipe
Self-locking nut
Cleaning cover
Sealing ring

MAN B&W
Plate
P90302-0185
Page 1 (2)
Plate
P90302-0185
Item
No.
010
022
034
046
058
071
095
154
178
191
201
213
237
249
Page 2 (2)

MAN B&W
Item Description
O-ring
Cooling water connection
Screw
Gasket
Clamp
Screw
Pipe
Cylinder liner
Pipe
Cooling jacket
Gasket
Piston cleaning ring
O-ring
O-ring

MAN B&W
Plate
P90304-0037
Page 1 (2)
Plate
P90304-0037

MAN B&W
Item
No.
Item Description
011
023
035
047
Non-return valve, complete

Head
Valve
Housing
Page 2 (2)
MAN B&W
Plate
P90305-0134
Page 1 (2)
Plate
P90305-0134
Item
No.
017
030
054
066
078
091
101
125
137
150
162
186
Page 2 (2)
MAN B&W
Item Description
Screw
Steel pipe
Screw
Bracket
Distance pipe
Screw
Nut
Guard
Screw
Screw
Nut
Screw

MAN B&W
Plate
P90307-0035
Page 1 (2)
Plate
P90307-0035
Item
No.
018
031
043
055
067
080
092
114
138
151
175
199
209
210
234
258
271
283
295
305
317
329
330
342
354
366
378
391
401
413
437
449
450
474
486
498
508
521
533
545
569
570
582
594

MAN B&W
Item Description
Ball valve
Stud
Hydraulic block
Nut
Plug screw
O-ring
Intermediate pipe
Adjustable elbow coupling
Ball valve
Stud
Lubricator, complete
Hydraulic block
Gasket
Membrane accumulator
Screw
Adjusting screw
O-ring
Spacer, tubular
Cover
O-ring
Non-return valve
O-ring
Cylinder block
O-ring
Spring
Plunger
Actuator piston
Straight stud coupling
Screw
Screw
Cylinder housing
Solenoid valve complete
Screw
Membrane accumulator
Gasket
O-ring
O-ring
Inductive sensor
Cable
Cable gland, complete
Housing
Plug
Plug
Screw
Note:
*
Page 2 (2)
Intermediate Box
MAN B&W
Plate
P90308-0012
A-A
Page 1 (2)
Intermediate Box
Plate
P90308-0012
Item
No.
013
037
049
050
074
Page 2 (2)
MAN B&W
Item Description
Intermediate box, complete

Electric enclosure with cables
Circuitboard assy
Screw
Diode

MAN B&W
Plate
P90309-0021
Page 1 (2)
Plate
P90309-0021
Item
No.
019
020
032
044
056
068
081
093
103
127
139
152
176
188
211
223
235
Page 2 (2)
MAN B&W
Item Description
Screw
Pipe holder
Coupling
Stud
Nut
Pipe holder
Steel pipe
Pipe holder
Steel pipe
Coupling
Connection
Steel pipe
Distributor block
Screw
Steel pipe
Steel pipe
Steel pipe
Plate
P90310-0013
MAN B&W
Aft
C.C.
Cyl. 1
A
A
B
B
A-A
B-B
Page 1 (2)
Plate
P90310-0013
Item
No.
014
026
038
063
075
087
Page 2 (2)
MAN B&W
Item Description
Nut
Distance pipe
Stud
Nut
Distance pipe
Stud
Cylinder Lubrication Electronic Components

MAN B&W
Plate
P90312-0002
Page 1 (2)
Plate
P90312-0002
Item
No.
027
039
040
052
Page 2 (2)
MAN B&W
Item Description
Enclosure, complete
Master control unit
Circuit board
Backup control unit
Cylinder Lubrication - Electronic Components

MAN B&W
Plate
P90312-0003
Page 1 (2)
Plate
P90312-0003
Item
No.
015
027
039
052
064
076
088
111
123
135
147
166
184
206
Page 2 (2)
Cylinder Lubrication - Electronic Components

MAN B&W
Item Description
Item
No.
Item Description
Electronic enclosure, complete

Screw
Nut
Bracket
Screw
Nut
Distance pipe
Terminal
Terminal
Terminal
Rail
Electronic enclosure
Terminal
Terminal

MAN B&W
Plate
P90312-0004
Page 1 (2)
Plate
P90312-0004
Item
No.
015
027
039
040
052
064
076
088
111
159
160
184
196
206
Page 2 (2)
MAN B&W
Item Description
Name plate
Pilot lamp
Name plate
Selector switch
Terminal
Terminal
Din rail
Terminal
Terminal
HMI panel
Mounting plate
Nut
Screw
Terminal

90401
90403
0170
0011
MAN Diesel A/S
Connecting Rod and Crosshead

Lubricating and Cooling Oil Flow
MAN Diesel A/S

MAN B&W
Plate
P90401-0170
Page 1 (2)
Plate
P90401-0170
Item
No.
019
044
056
081
093
103
115
139
140
152
164
176
188
223
247
260
296
306
331
343
355
367
380
392
402
414
426
451
463
487
499
509
510
522
534
546
571
595

MAN B&W
Item Description
Screw
Nut
Screw
Outlet pipe
Guide shoe
Lock washer
Stop screw
Telescope pipe
Distance pipe
Bracket
Stud
Plug
Spring pin
Throttle plug
Crosshead
Crosshead bearing shell, complete
Guide strip
Screw
Thrust piece
Crankpin bearing shell, complete
Guide screw
Crankpin bearing cap
Screw
Shim*
Nut
Crosshead bearing cap
Self-locking nut
Stud
Guide pipe
Shims*
Nut
Stud
Guide pin
Connecting rod
Stud
Connecting rod, complete
Shims *
Plug
Note:
*When ordering, please state
thickness of shim.
Page 2 (2)
Lubricating and Cooling Oil Flow

MAN B&W Diesel
Plate
P90403-0011
Page 1 (1)

90501
90503
90504
90505
90510
90511
90512
0164
0025
0014
0117
0125
0049
0002
MAN Diesel A/S
Crankshaft
Arrangement of Angle Encoder
Axial Vibration Monitor
Thrust- and Guide Bearing
Turning Gear
Turning Wheel
Turning Gear - Details
MAN Diesel A/S
Crankshaft
MAN B&W
Plate
P90501-0164
Page 1 (2)
Crankshaft
Plate
P90501-0164
Item
No.
012
024
048
061
073
085
097
107
Page 2 (2)
MAN B&W
Item Description
Screw
Crankshaft
Guard
Guard
Chain wheel
Packing ring
Cover
Screw

MAN B&W
Plate
P90503-0025
Page 1 (2)
Plate
P90503-0025
Item
No.
013
025
037
050
062
074
086
098
108
121
133
145
157
170
182
194
204
253
Page 2 (2)
MAN B&W
Item Description
Screw
Angle encoder
Packing
Intermediate box
Screw
Screw
Shaft
Housing
Coupling
Washer
Packing
Screw
Spring lock
Shaft
Shield, lower part
Packing
Guide pin
Adjustment tool
Plate
P90504-0014
MAN B&W
D
C
A
A-A
A
C-C
B-B
B
Page 1 (2)
Plate
P90504-0014
Item
No.
019
020
044
056
081
093
115
139
140
Page 2 (2)
MAN B&W
Item Description
Steel pipe
Coupling
Bracket
Axial vibration monitor
Screw
Locking wire
Male stud complete
Pipe holder
Screw

MAN B&W
Plate
P90505-0117
Page 1 (2)
Plate
P90505-0117
Item
No.
014
026
038
051
063
075
087
099
110
122
146
158
171
183
195
205
217
229
230
242
254
266
291
301
313
325
337
349
362
374
386
398
408
421
433
445
Page 2 (2)

MAN B&W
Item Description
Locking wire
Screw
Lubricating oil pipe
Stopper
Thrust shoe, complete
Spray pipe
Oil throw ring, complete
Screw
Oil throw ring in 2/2
Self-locking nut
Nut
Self-locking nut
Segment
Segment with sensor pockets
Scraper ring housing, complete
Scraper ring housing, upper part
Screw
Guide pin
Scraper ring housing, lower part
Nut
Screw
Screw
Thrust shoe
Spray pipe
Screw
Pipe holder
Thrust shoe, complete
Screw
Fitted bolt
Guide screw
Scraper ring in 2/2
Nut
Scraper ring, complete
Turning Gear
MAN B&W
Plate
P90510-0125
Page 1 (2)
Turning Gear
Plate
P90510-0125
Item
No.
011
023
035
047
059
072
084
096
106
131
143
155
167
192
202
214
226
238
251
263
299
309
310
322
334
346
358
405
417
429
Page 2 (2)
MAN B&W
Item Description
Bracket
Bush
Screw
Spring lock
Disc
Switch
Spring lock
Screw
Lever
3/2-way valve
Screw
Spring lock
Chain
Nut
Distance pipe
Pin
Turning gear
Distance pipe
Distance pipe
Screw
Gear wheel
Disengaging divice, complete
Screw
Disc
Spring lock
Stud
Sleeve
Key ring
Eye screw
Circlip
Turning Wheel
Plate
P90511-0049
Page 1 (2)
MAN B&W
Turning Wheel
Plate
P90511-0049
Item
No.
017
029
030
054
066
078
101
113
125
Page 2 (2)
MAN B&W
Item Description
Guide pin
Nut
Nut
Screw
Screw
Dead centre pointer
Turning wheel
Nut
Fitted bolt

MAN B&W
Plate
P90512-0002
Page 1 (2)
Plate
P90512-0002
Item
No.
012
024
048
061
073
097
107
119
132
156
168
181
203
215
227
240
252
264
276
311
323
Page 2 (2)
MAN B&W
Item Description
Screw
Spring washer
3/2-way valve
Screw
Spring washer
Switch 0-110 volts
Screw
Spring washer
Bracket
Eye screw
Key ring
Chain
Disc with inicision
Stud with groove
Circlip
Disc with inicision
Sleeve
Screw
Spring washer
Lever
Bush
906 - Control Gear

90600
90603
90611
90612
90613
90618
90619
90632
90634
0137
0073
0172
0088
0103
0151
0036
0028
0031
MAN Diesel A/S
Arrangement of Chain Drive and Camshaft

Chain Tightener
Camshaft Bearing
Regulating Shaft
Load Transmitter
MAN Diesel A/S
Arrangement of Chain Drive and Camshaft

MAN B&W
Plate
P90600-0137
Page 1 (1)
Chain Tightener
Plate
P90603-0073
Page 1 (2)
MAN B&W
Chain Tightener
Plate
P90603-0073
Item
No.
017
029
042
054
066
078
113
137
149
150
186
208
233
245
270
304
316
328
341
353
365
377
389
Page 2 (2)
MAN B&W
Item Description
Locking wire
Screw
Flange bearing
Bracket
Shaft
Flange
Screw
Chain wheel
Cup point screw
Bearing bush
Screw
Distance piece
Shaft
Tightening bolt
Shaft
Nut
Lock washer
Guide nut
Circlip
Guide nut
Circlip
Bushing
Shaft
Plate
P90611-0172
MAN B&W
Page 1 (2)
Plate
P90611-0172
Item
No.
010
022
046
058
071
083
095
105
117
142
166
178
191
201
213
225
237
249
250
274
286
298
321
Page 2 (2)
MAN B&W
Item Description
Camshaft
Nut
Fitted bolt
Coupling flange
Camshaft
Exhaust cam
Fuel cam
Indicator cam
Coupling flange
O-ring
Chain wheel
Camshaft
Indicator cam
Nut
Indicator cam
Screw
Protective cap
Chain wheel
Thrust disc
Gear wheel
Flange screw
Locking wire
Disc

MAN B&W
Plate
P90612-0088
B
C
Page 1 (2)
Plate
P90612-0088
Item
No.
016
028
041
053
077
089
100
124
136
148
161
173
185
197
207
219
220
232
244
268
281
293
303
315
327
339
340
352
364
Page 2 (2)
MAN B&W
Item Description
Spring pin
Liner
Spring
Packing
Packing
Connecting piece
Circlip
Stud
Self-locking nut
Extension
Packing
Flange
Screw
Indicator valve
Screw
Washer
Extension
Liner
Circlip
Handle
Screw
Roller guide
Liner
Cup point screw
Key
Screw
Housing
Needle bearing
Shaft
Camshaft Bearing
MAN B&W
Plate
P90613-0103
Page 1 (2)
Camshaft Bearing
Plate
P90613-0103
Item
No.
011
023
035
047
059
060
096
106
131
143
155
167
180
192
202
214
238
251
263
275
287
309
310
322
334
346
371
383
405
417
430
Page 2 (2)
MAN B&W
Item Description
Screw
End cover "Fore"
Gasket
Gasket
Rubber cord
Nut
Bolt for camshaft bearing
Housing
Bearing shell in 2/2
Guide screw
Bearing cap
Cover
Fitted bolt
Screw
Screw
Screw
End cover "Aft", complete
Nut
Gasket
Cover
Screw
Gasket
Cover
Screw
Washer
Oil pan
Screw
Cover
Screw
Rubber cord
Oil pan
Regulating Shaft
MAN B&W
Plate
P90618-0151
Page 1 (2)
Regulating Shaft
Plate
P90618-0151
Item
No.
019
020
032
044
056
068
093
103
127
139
140
164
176
211
223
235
247
259
272
284
296
306
331
343
355
367
380
392
402
414
438
451
463
475
487
499
509
522
546
558
583
595
605
629
Page 2 (2)
MAN B&W
Item Description
Sleeve coupling, complete

Screw
Spring washer
Sleeve coupling
Nut
Key
Regulating shaft
Regulating shaft
Circlip
Pin
Pull rod, complete
Resilient arm, complete
Screw
Arm holder
Pin
Circlip
Nut
Spring
Washer
Fitted bolt
Circlip
Pin
Self-locking nut
Movable arm
Shim
Shaft
Screw
Washer
Screw
Bracket
Bearing housing
Ball bearing
Spring pin
Bracket
Nut
Washer
Fitted bolt
Screw
Key
Nut
Lever
Self-locking nut
Guide pin
Bearing housing
Load Transmitter
MAN B&W
Plate
P90619-0036
Page 1 (2)
Load Transmitter
Plate
P90619-0036
Item
No.
014
038
051
063
087
109
110
122
134
146
171
195
205
229
230
242
266
278
291
313
325
349
362
374
386
408
421
Page 2 (2)
MAN B&W
Item Description
Screw
Cover
Washer
Self-locking nut
Screw
Nut
Pull rod
Ball joint
Fork head
Screw
Nut
Space tubular
Screw
Screw
Disc
Clamping arm
Shim
Pipe clamp
Potentiometer
Self-locking nut
Screw
Washer
Bracket
Washer
Nut
Self-locking nut
Washer

MAN B&W
Plate
P90632-0028
Page 1 (2)
Plate
P90632-0028
Item
No.
015
027
039
040
052
064
076
088
111
123
135
159
160
172
184
206
218
231
243
255
Page 2 (2)

MAN B&W
Item Description
Locking wire
Disc
Screw
Guidebar
Screw
Beam for guidebar
Screw
Screw
Beam for guidebar
Bracket for guideway
Screw
Guidebar
Screw
Beam for guidebar
Screw
Beam for guidebar
Guidebar
Screw

MAN B&W
Plate
P90634-0031
Page 1 (2)
Plate
P90634-0031
Item
No.
016
041
065
077
090
100
124
136
148
173
185
207
220
244
268
281
Page 2 (2)
MAN B&W
Item Description
Spray pipe
Lubricating pipe
Spray pipe
Lubricating pipe
Spray pipe
Spray pipe
Spray pipe
Spray pipe
Lubricating pipe
Lubricating pipe
Lubricating pipe
Spray pipe
Spray pipe
Spray pipe
Lubricating pipe
Lubricating pipe

90702
90703
90704
0070
0120
0059
MAN Diesel A/S
Main Starting Valve

Starting Valve
MAN Diesel A/S
Main Starting Valve

MAN B&W
Plate
P90702-0070
Page 1 (2)
Main Starting Valve
Plate
P90702-0070
Item
No.
015
027
039
052
064
076
111
123
135
147
159
172
184
196
206
231
243
267
279
280
292
302
326
338
351
363
375
387
399
409
410
422
434
446
458
471
483
495
505
517
529
530
542
900
924
936
948
Page 2 (2)
MAN B&W
Item Description
Screw
Switch
Distance pipe
Screw
Plate
Ball valve with actuator*
Plug screw
Packing ring
Packing ring
Plug screw
Intermediate piece
Nut
Washer
Handwheel
Locking plate
Spring
Spindle
Nut
Screw
Nut
Starting air pipe
Packing ring
Screw
Washer
Guide pin
Sundry chain
Split pin
Key ring
Screw
Nut, low
Ball valve with actuator*
Screw
Packing ring
Disc
Housing
Screw
Screw
Stud
Starting air pipe
Housing
Non-return valve
Nut
Adjusting screw, "slow turning"
Repair kit, slave actuator, slow
turning*
Repair kit, slave ball valve, slow
turning*
Repair kit, main actuator, slow
turning*
Repair kit, main ball valve, slow
turning*

MAN B&W
Plate
P90703-0120
Page 1 (2)
Plate
P90703-0120
Item
No.
010
022
034
046
058
083
095
105
117
129
130
154
166
191
201
225
237
249
262
274
286
298
308
333
345
357
370
382
394
404
416
428
441
490
500
MAN B&W
Item Description
Screw
Packing
Screw
Name plate
Bracket
Fitted bolt
Self-locking nut
Air cylinder
Spring pin
Screw
3/2-way valve
Stud
Nut
Guide pin
Guide pin
Gear wheel
Lock washer
Nut
Bushing
Spring pin
Key
Screw
Bracket
Distributor housing*
Shaft
Sealing ring
Reversing disc*
Sealing ring
Distributor disc
Piston ring
Cover
Fitted bolt
Washer
Adaptor
Coupling
Note:
* When ordering spare parts, please
state number of cylinders.
Page 2 (2)
Starting Valve
MAN B&W
Plate
P90704-0059
Page 1 (2)
Starting Valve
Plate
P90704-0059
Item
No.
016
028
041
053
077
089
090
100
112
124
136
Page 2 (2)
MAN B&W
Item Description
Screw
Cover
Gasket
Self-locking nut
Piston
Spring
Distance pipe
Liner
Valve housing
Sealing ring
Valve spindle
908 - Exhaust Valve

90801
90803
90804
90805
90806
90810
90812
0206
0040
0016
0144
0098
0090
0003
MAN Diesel A/S
Exhaust Valve - Lower Parts

Exhaust Valve - Upper Parts
Exhaust Valve Upper Parts - Details
Exhaust Valve - Actuator
Exhaust Valve - Pipe System
Arrangement of Cooling Water Pipes
Arrangement of Drain Pipes Freshwater
MAN Diesel A/S
Plate
P90801-0206
MAN B&W
A
A
Page 1 (2)
Plate
P90801-0206
Item
No.
013
025
037
062
074
098
108
121
133
157
194
204
228
241
253
265
277
289
300
324
336
Page 2 (2)
MAN B&W
Item Description
Packing
Covers
Screw
Packing
Flange
Screw
O-ring
Bottom piece
Sealing ring
Valve spindle
Valve housing
Spindle guide lower
Packing
Plug screw
Spring pin
Screw
Sealing ring
Sealing ring
Tread insert
Packing
Plug screw
Plate
P90803-0040
MAN B&W
B B
C
A A
C
D
E
D
E
Page 1 (2)
Plate
P90803-0040
Item
No.
014
026
038
063
087
099
110
134
158
183
205
217
229
230
242
254
266
278
291
301
313
325
337
349
362
374
386
408
421
433
445
457
469
470
482
494
504
516
528
541
553
565
577
590
600
612
624
636
648
661
Page 2 (2)
MAN B&W
Item Description
Lifting eye bolt

Plate
Coupling
Steel pipe
Orifice plug
Disc
Safety handrail
Piston, air cylinder
Sealing ring
Coupling
Disc
Locking plate
Screw
Screw
Packing
Oil cylinder
Plug
Stud
Nut
Non-return valve
Plug
Plug
Sealing ring
Air cylinder, complete
Flange
Sliding bearing
Sealing ring
Oil control unit
Screw
Pin
Steel pipe
Union nut
Adapter
Packing ring
O-ring
Spring
Disc
Spring pin
Rotation check rod
Non-return valve
Locking wire
Screw
Conical ring 2/2
Piston
Slide
Piston
Spring
Disc
Piston, complete
Piston ring
Exhaust Valve - Upper Parts, Details

MAN B&W
Plate
P90804-0016
Page 1 (2)
Exhaust Valve - Upper Parts, Details
Plate
P90804-0016
Item
No.
021
045
905
MAN B&W
Item Description
Gasket
Safty valve, with o-ring
O-ring*
Note:
* Optional extras
Page 2 (2)

MAN B&W
Plate
P90805-0144
Page 1 (2)
Plate
P90805-0144
Item
No.
015
027
039
040
052
064
076
088
111
123
147
159
160
184
196
206
218
255
267
279
280
292
314
326
338
Page 2 (2)
MAN B&W
Item Description
Nut
Oil cylinder
Stud
Stud
Piston
Roller guide, complete
Thrust disc
Roller guide
Shaftpin for roller
Plug
Screw
Bushing
Disc
Bushing for roller guide
Cylindrical pin
Screw
Bushing
Piston ring
Disc
Screw
Disc
Spring
Cylindrical pin
Roller
Guide block
Plate
P90806-0098
MAN B&W
C
A
A
B
D
Page 1 (2)
Plate
P90806-0098
Item
No.
010
022
046
058
071
083
105
117
129
130
154
178
201
225
249
250
262
274
286
308
321
Page 2 (2)

MAN B&W
Item Description
Sealing ring
Disc
Clamp
Nut
Screw
Support
Thrust bushing
Screw
Pipe
Hose, complete
Coupling
Drain pipe
Coupling
Hydraulic pipe, complete
Packing
Flange
Sealing ring
Screw
Cooling water connection
Packing
Plug screw

MAN B&W
Plate
P90810-0090
Page 1 (2)
Plate
P90810-0090
Item
No.
012
024
048
061
073
085
097
107
119
120
132
144
156
181
193
203
215
239
240
252
264
276
288
323
Page 2 (2)
MAN B&W
Item Description
Screw
Butterfly valve
Plug
Outlet pipe
Screw
Packing
Nut
Compensator
Orifice plate
Outlet pipe
Nut
Packing
Packing
Ball valve
Screw
Screw
Outlet pipe
Outlet pipe
Screw
Packing
Inlet pipe
Screw
Screw
Packing
Arrangement of Drain Water Pipes

MAN B&W
Plate
P90812-0003
Page 1 (2)
Arrangement of Drain Water Pipes
Plate
P90812-0003
Item
No.
013
025
037
Page 2 (2)
MAN B&W
Item Description
Straight valve
Drain pipe
Drain pipe

90901
90902
90903
90904
90905
90910
90911
90913
90914
90914
90915
90915
90915
0177
0171
0021
0059
0025
0139
0017
0124
0099
0101
0060
0074
0075
MAN Diesel A/S
Fuel Pump
Fuel Pump Gear
Fuel Pump Gear - Details
Fuel Pump - Details
Reversing Mechanism
Fuel Valve
Fuel Valve Function
High-Pressure Pipes
Fuel Oil System
Fuel Oil System
Fuel Oil System - Details
MAN Diesel A/S
Fuel Pump
MAN B&W
Plate
P90901-0177
Page 1 (2)
Fuel Pump
Plate
P90901-0177
Item
No.
017
030
042
054
078
101
113
125
137
149
162
174
186
198
208
221
233
257
269
270
282
294
341
389
390
400
412
436
448
461
473
520
532
544
556
568
603
615
627
639
640
652
664
676
688
711
723
735
747
772
Page 2 (2)
MAN B&W
Item Description
Gasket
Cylindrical pin
Gasket
Plug screw
Pump housing, complete
Timing guide
Sleeve
Regulating guide
Guide pin
Screw
Stud
Gasket
Guide screw
Guide pin
Guide pin
Guide bushing, complete
Guide bushing
Screw
Screw
Top cover
Lock washer
Plug screw
Orifice plate
Nut
Screw
Spring guide
Spring
Suction valve, complete
Slide
Thrust piece
Sealing ring
Sealing ring
Pump barrel
Pump barrel, complete
Plunger
Sealing ring
Screw
Lock washer
Cover
Sealing ring
Sealing ring
Puncture valve, complete
Air piston
Gasket
Valve housing
O-ring
Slide
Spring
Spring guide
Throttle plug
Item
No.
784
867
879
880
892
902
914
926
Item Description
Gasket
Protective cap
Coupling
Pipe
Banjo coupling
Plug screw
Disc
Pipe
Fuel Pump Gear
Plate
P90902-0171
Page 1 (2)
MAN B&W
Fuel Pump Gear
Plate
P90902-0171
Item
No.
012
024
036
048
061
073
085
097
107
119
120
144
156
181
193
215
227
240
252
264
276
288
311
323
347
359
360
372
384
396
418
431
443
455
467
479
492
514
526
538
551
563
587
599
609
622
646
671
683
695
Page 2 (2)
MAN B&W
Item Description

Shaft
Needle bearing
Pin
Screw
Roller
Bushing
Dics
Shaft
Plug
Dowel pin
Plate
Roller Guide
Bushing
Pin
Link for reversing
Pin
Pin
Guide block
Screw
Pin
Bushing roller guide
Screw
Name plate
Nut
Bushing roller guide
Sealing ring
Cap
Self locking nut
Screw
Scraper ring
Scraper ring
Retaining flange
Holder for scraper ring
Locking wire
Screw
Nut
Pump base
Packing
Cover
Packing
Screw
Spring seat disk
Stud
Stud
Spring
Spring seat disk
Flange
Screw
Sealing bush
Item
No.
717
730
742
766
791
Item Description
Screw
Screw
Screw
Locking wire
Plug

MAN B&W
Plate
P90903-0021
Page 1 (2)
Plate
P90903-0021
Item
No.
018
031
043
055
067
079
080
092
114
126
138
151
Page 2 (2)
MAN B&W
Item Description
Lifting tool
Sealing ring
Spring
Nut
Locking plate
Crosspiece
Bolt
Guide pin
Screw
Screw
Guide plate
Guide pin
Fuel Pump - Details

MAN B&W
Plate
P90904-0059
Page 1 (2)
Fuel Pump - Details
Plate
P90904-0059
Item
No.
013
025
037
049
050
062
074
086
108
121
133
157
169
170
182
194
216
228
241
253
265
277
Page 2 (2)
MAN B&W
Item Description
Plug
Nut
Washer
Bracket
Screw
Actuator
Coupling
Screw
Guide screw
Toothed bar, regulation
Packing
Union
Pointer
Toothed bar, timing
Nut
Forked lever
Retaining ring
Shaft
Forked lever
Forked lever
Adjusting screw
Nut
Reversing Mechanism
MAN B&W
Plate
P90905-0025
Page 1 (2)
Plate
P90905-0025
Item
No.
019
020
032
044
056
068
093
103
115
127
139
152
164
176
211
223
235
247
259
Page 2 (2)
Reversing Mechanism
MAN B&W
Item Description
Shaft
Guide for reversing
Distance pipe
Self-locking nut
Guard
Screw
Cover
Screw
Bolt
Flange for air cylinder
Reversing mechanism, complete
Screw
Bush
Air cylinder
Screw
Union
Reducing socket
Ball valve
Union
Fuel Valve
MAN B&W
Plate
P90910-0139
Page 1 (2)
Fuel Valve
Plate
P90910-0139
Item
No.
016
041
053
065
077
089
090
100
112
124
148
161
173
185
197
219
220
232
244
950
MAN B&W
Item Description
Thrust piece
Cut-off shaft
Spindle guide
Fuel nozzle
Spindle guide
O-ring
Holder, fuel nozzle
Guide pin
Union
O-ring
O-ring
Head
Guide pin
Spring
Non-return valve
Thrust spindle
Spring
Spring guide
Foot
Disc*
Note:
* Optional extras
Page 2 (2)
Fuel Valve Function

MAN B&W
Plate
P90911-0017
Page 1 (1)
High-Pressure Pipes
MAN B&W
Plate
P90913-0124
Page 1 (2)
High-Pressure Pipes
Plate
P90913-0124
Item
No.
012
024
036
048
061
073
097
107
119
132
156
181
193
203
215
227
239
240
252
264
Page 2 (2)
MAN B&W
Item Description
High-pressure pipe, complete

Union nipple
Thrust bushing
Union nut
High-pressure pipe
Flexible hose, complete
O-ring
Union nipple
O-ring
High-pressure pipe, complete
High-pressure pipe
Pipe, L=400
Housing
Flange
Screw
Elbow coupling
Tee-coupling
Guide pin
Screw
Flange
Fuel Oil System
Plate
P90914-0099
Page 1 (2)
MAN B&W
Fuel Oil System
Plate
P90914-0099
Item
No.
018
031
043
067
079
080
092
102
126
138
151
163
Page 2 (2)
MAN B&W
Item Description
Fuel oil pipe, outlet

Non-return valve
Fuel oil pipe, outlet
Packing
Screw
Fuel oil pipe, inlet
Plug screw
Ball valve
Fuel oil pipe, inlet
Packing ring
Screw
Nut
Fuel Oil System
Plate
P90914-0101
Page 1 (2)
MAN B&W
Fuel Oil System
Plate
P90914-0101
Item
No.
018
043
055
067
080
092
114
126
151
Page 2 (2)
MAN B&W
Item Description
Fuel oil pipe

Stud, complete
Distributor piece
Screw
Screw
Drain pipe
Steel pipe
Coupling
Steel pipe

MAN B&W
Plate
P90915-0060
Page 1 (2)
Plate
P90915-0060
Item
No.
013
025
037
049
050
074
086
098
121
133
145
Page 2 (2)
MAN B&W
Item Description
By-pass valve, complete

Valve housing
Valve housing
Sealing ring
Spring guide
Screw
Union nut
Nut
Sealing ring
Piston
Spring

MAN B&W
Plate
P90915-0074
Page 1 (2)
Plate
P90915-0074
Item
No.
013
037
049
050
062
074
086
098
108
121
133
145
157
169
170
182
Page 2 (2)

MAN B&W
Item Description
Shock absorber, complete

Spring guide
Stud
Nut
Lock washer
Packing
Sealing ring
Wearing ring
Packing
Screw
Spring
Flange
Stud
Spring
Piston
Housing

MAN B&W
Plate
P90915-0075
Page 1 (2)
Plate
P90915-0075
Item
No.
013
037
049
050
062
074
Page 2 (2)
MAN B&W
Item Description
Drain box, complete

Level switch
Name plate
Screw
Gasket
Drain box

91000
91001
91002
91003
91004
91005
91006
91007
91009
91011
91011
0012
0134
0149
0235
0069
0136
0044
0007
0041
0019
0029
MAN Diesel A/S
Gas and Air System

Scavenge Air Receiver
Arrangement of Charging Air Pipe
Exhaust Pipes and Receiver
Exhaust Receiver - Details
Air Cooler
Arrangement of Auxiliary Blower
Butterfly Valve
MAN Diesel A/S
Gas and Air System

MAN B&W
Plate
P91000-0012
Page 1 (1)
Plate
P91001-0134
MAN B&W
Page 1 (2)
Plate
P91001-0134
Item
No.
017
029
030
042
066
091
101
137
150
162
186
198
Page 2 (2)
MAN B&W
Item Description
Cover
Packing
Screw
Cover
Screw
Screw
Nut
Scavenge air reciever
Screw
Packing
Distance pipe
Screw

MAN B&W
Plate
P91002-0149
Page 1 (2)
Plate
P91002-0149
Item
No.
012
024
036
048
061
085
097
107
119
120
Page 2 (2)
MAN B&W
Item Description
Item
No.
Item Description
Compensator
Plug screw
Packing
Charging air pipe
Flange
Nut
Washer
Screw
Plug screw
Screw

MAN B&W
Plate
P91003-0235
Page 1 (2)
Plate
P91003-0235
Item
No.
018
031
043
055
067
079
080
092
102
138
151
163
187
199
209
210
222
234
246
258
271
283
295
305
317
329
342
366
378
391
401
425
437
449
450
Page 2 (2)

MAN B&W
Item Description
Item
No.
Item Description
Wing nut
Steel bar
Steel bar
Stud
Packing
Screw
Nut
Screw
Packing
Plug screw
Packing
Exhaust receiver
Wire gauze
Grid
Clamp with lock, complete
Compensator
Special nut
Guide pin
Clamp
Disc
Screw
Nut
Locking plate
Locking device
Support
Compensator
Spring pin
Screw
Pipe-exhaust valve
Screw
Nut
Screw
Screw
Nut
Washer

MAN B&W
Plate
P91004-0069
Page 1 (2)
Plate
P91004-0069
Item
No.
013
025
037
049
050
062
074
086
108
121
133
157
169
182
194
204
216
228
253
277
289
300
312
324
336
348
373
385
420
432
444
456
Page 2 (2)
MAN B&W
Item Description
Nut
Clamp
Support
Nut
Washer
Nut
Distance pipe
Screw
Screw
Distance pipe
Spring pin
Spring pin
Screw
Nut
Distance pipe
Shim
Nut
Clamp
Screw
Spring pin
Washer
Screw
Nut
Distance pipe
Screw
Support
Clamp
Support
Nut
Washer
Spring pin
Screw
Air Cooler
MAN B&W
Plate
P91005-0136
Page 1 (2)
Air Cooler
Plate
P91005-0136
Item
No.
019
020
032
044
056
068
081
093
103
115
140
152
164
176
211
223
247
259
260
284
296
306
331
343
355
367
380
392
MAN B&W
Item Description
Cooler insert
Steel bar
Sealing plate
O-ring
Air cooler housing
Screw
Screw
Support
Spring pin
Cover
Cross member
Stud
Washer
Nut
Screw
Steel bar
Locking plate
Hinge
O-ring
Distance pipe
Steel bar
Sealing plate
Screw
Distance pipe
Cover
Screw
Water mist catcher
Cover
Note:
* When ordering Spare Parts for this
item, please state manufacturer's Part
No.
Page 2 (2)

MAN B&W
Plate
P91006-0044
Page 1 (2)
Plate
P91006-0044
Item
No.
014
026
038
051
Page 2 (2)
MAN B&W
Item Description
Screw
Nut
O-ring
Auxiliaru blower
Butterfly Valve
Plate
P91007-0007
Page 1 (2)
MAN B&W
Butterfly Valve
Plate
P91007-0007
Item
No.
021
033
045
057
070
082
094
116
128
Page 2 (2)
MAN B&W
Item Description
Nut
Locking plate
Locking device
Pin
Valve housing
Screw
Spring lock
Shaft
Valve flap
Plate
P91009-0041
MAN B&W
A-A
Page 1 (2)
Plate
P91009-0041
Item
No.
010
022
046
071
083
095
105
117
130
154
166
178
201
213
225
249
250
262
274
298
308
333
345
357
370
382
394
416
441
453
465
489
490
500
512
536
561
585
607
619
620
644
656
Page 2 (2)
MAN B&W
Item Description
Cleaning pipe
Cleaning pipe
Cleaning pipe
Nut
Stud
Stud
Nut
Packing
Main pipe-cleaning
Guide-cleaning pipe
Cleaning pipe
Guide-cleaning pipe
Packing
Screw
Nut
Flange
Packing
Screw
Nut
Packing
Stud
Support
Straight valv
Straight male stud
Packing
Screw
Nut
Main pipe-cleaning
Screw
Nut
Packing
Butterfly valv
Screw
Nut
Main pipe-cleaning
Main pipe cleaning
Straight valv
Main pipe-cleaning
Main pipe-cleaning
Drain box, complete
Main pipe-cleaning
Orifice plate
Screw

MAN B&W
Plate
P91011-0019
Page 1 (2)
Plate
P91011-0019
Item
No.
023
035
047
059
072
096
106
118
143
Page 2 (2)
MAN B&W
Item Description
Shaft
Screw
Lock washer
Support
Screw
Clamp
Spring pin
Support
Valve flap

MAN B&W
Plate
P91011-0029
Page 1 (2)
Plate
P91011-0029
Item
No.
011
023
035
047
060
072
084
106
131
155
167
179
180
192
202
214
226
238
251
263
275
287
299
309
310
322
334
346
358
371
383
Page 2 (2)

MAN B&W
Item Description
Suction pipe
Clamp
Locking plate
Nut
Screw
Screw
Locking plate
Nut
Disc special
Body for non-return valve
Screw
Screw
Lock washer
Support
Clamp
Spring pin
Valve flap
Screw
Locking plate
Washer
Mounting fixture
Spring pin
Screw
Nut
Locking plate
Washer
Support
Screw
Suction pipe
Screw
Shaft

91101
91102
91103
91104
0037
0028
0016
0069
MAN Diesel A/S
Safety Valve - Cylinder

Relief Valve
Safety Valve - Scavenge Air System
Arrangement of Safety Cap
MAN Diesel A/S

MAN B&W
Plate
P91101-0037
Page 1 (2)
Plate
P91101-0037
Item
No.
010
022
034
046
058
071
083
095
105
117
Page 2 (2)
MAN B&W
Item Description
Spindle
Spring retainer
Lock nut
Spring
Valve housing
Stop ring
Valve flap
Valve guide
Gasket
Safety valve, complete
Relief Valve
MAN B&W
Plate
P91102-0028
P.C.D.
Page 1 (2)
Relief Valve
Plate
P91102-0028
Item
No.
016
028
030
041
MAN B&W
Item Description
Relief valve (P.C.D. 465mm)*

Screw*
Packing*
O-ring*
Note:
*When ordering, please state
manufacturer of Relief Valve and
P.C.D. xxx mm
Page 2 (2)

MAN B&W
Plate
P91103-0016
3.85 Bar abs.
Page 1 (2)
Plate
P91103-0016
Item
No.
011
023
035
047
060
072
084
096
106
131
143
Page 2 (2)
MAN B&W
Item Description
Spindle
Washer
Spring retainer
Spring
Valve flap
Screw
Nut
Split pin
Castle nut
Seal
Valve seat

MAN B&W
Plate
P91104-0069
Page 1 (2)
Plate
P91104-0069
Item
No.
017
029
030
042
054
066
078
091
101
125
137
149
150
162
174
221
233
257
270
Page 2 (2)
MAN B&W
Item Description
Gasket
Bursting cap
Check plate
Screw
Perforated cylinder
Starting air pipe
Screw
Nut
Screw
Screw
Protective guard
Wing nut
Washer
Stud
Bursting disc
Nut
Screw
Washer
Bursting cap, complete

91201
91203
91205
91206
91207
91210
91211
91216
0094
0015
0194
0122
0101
0181
0091
0008
MAN Diesel A/S
Arrangement of Stay Bolts

Frame Box - Details
Frame Box
End Shields
Arrangement of Piston Cooling
Bedplate
Axial Vibration Damper
Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)
MAN Diesel A/S
Arrangment of Stay Bolt

MAN B&W
Plate
P91201-0094
Page 1 (2)
Arrangment of Stay Bolt
Plate
P91201-0094
Item
No.
014
026
038
051
063
087
Page 2 (2)
MAN B&W
Item Description
Screw
Protective cap
Nut
Stay bolt assembly
Guide bushing
Stay bolt, complete
Frame Box - Details
Plate
P91203-0015
MAN B&W
A
B
A
C
A-A
B-B
C-C
D-D
Page 1 (2)
Frame Box - Details
Plate
P91203-0015
Item
No.
015
027
040
052
076
088
111
Page 2 (2)
MAN B&W
Item Description
Distance pipe
Screw
Nut
Disc
Distance pipe
Distance pipe
Fitted stud
Frame Box
Plate
P91205-0194
MAN B&W
Front side
Fore end
Rear side
Aft end
Page 1 (2)
Frame Box
Plate
P91205-0194
Item
No.
016
028
053
065
077
089
100
124
136
148
173
185
197
219
220
244
256
281
293
303
315
339
340
364
388
423
447
460
472
496
506
518
543
567
579
Page 2 (2)
MAN B&W
Item Description
Frame box door

Sealing material
Wing nut
Door fastener
Spring
Stud
Drain pipe
Flange
Packing
Screw
Packing
Frame door-rear
Screw
Stud
Nut
Stud
Nut
Screw
Cleaning cover
Packing
Washer
Screw
Cover
Frame box
Cover
Bushing
Cover
Screw
Cover
Locking pin
Spring
Key ring
Cover
Flange
Screw
End Shields
MAN B&W
Plate
P91206-0122
Page 1 (2)
End Shields
Plate
P91206-0122
Item
No.
023
035
047
059
072
084
096
106
131
143
167
179
180
202
226
238
251
275
Page 2 (2)
MAN B&W
Item Description
Screw
Plug
Plug
Screw
Nut
Stud
Cover
Gasket
Packing
Cover
Cover
Packing
Gasket
Shield-upper
Stud
Nut
Shield-lower
Screw
Plate
P91207-0101
MAN B&W
B-B
B
A-A
Page 1 (2)
Plate
P91207-0101
Item
No.
017
029
030
054
066
078
101
113
137
150
174
186
198
208
233
245
Page 2 (2)

MAN B&W
Item Description
Locking plate
Fitted bolt
Nut
Bracket
Locking plate
Screw
Plate
Screw
Drain pipe-piston cooling
Sight glass, complete
Sight glass
Flange
Packing
Screw
Fitted bolts
Screw
Bedplate
MAN B&W
Plate
P91210-0181
Page 1 (2)
Bedplate
Plate
P91210-0181
Item
No.
025
049
050
062
074
086
121
133
145
157
169
170
182
194
204
228
241
253
265
277
290
300
324
336
348
361
373
385
397
407
456
468
481
493
503
540
MAN B&W
Item Description

Locking wire
Screw
Shim*
Nut
Main bearing stud
Main bearing cap
Screw
Main bearing shell, complete
Bearing shell, upper
Shim*
Screw
Bearing shell, lower
Screw
Cover plate
Pipe holder
Lock washer
Screw
Screw
Self-locking nut
Locating pin
Screw
Lock washer
Grate
Screw
Cover
Stud
Cover
Screw
Bedplate
Note:
When ordering, please state
thickness
Page 2 (2)

MAN B&W
Plate
P91211-0091
Page 1 (2)
Plate
P91211-0091
Item
No.
019
020
032
044
056
068
081
093
103
115
127
139
140
152
164
176
188
211
223
235
247
259
272
284
296
306
Page 2 (2)

MAN B&W
Item Description

Screw
Spring
Spring
Locking wire
Screw
Restriction for damper
Screw
Locking wire
Guide pin
Oil seal in 2/2
Oil seal in 2/2
Locking wire
Nut
Nut
Stud
Stud
Axial vibration damper, complete
Damper, upper part
Guide pin
Damper, lower part
HoldingDown Bolts and End

Chock Bolts (Epoxy Chocks)
MAN B&W
Plate
P91216-0008
Page 1 (2)
Plate
P91216-0008
Item
No.
016
028
041
053
077
090
100
112
148
161
173
197
207
219
232
244
256
281
Page 2 (2)
HoldingDown Bolts and End

Chock Bolts (Epoxy Chocks)
MAN B&W
Item Description
Screw
Washer
Lock plate
Liner for sidechock, port side
Liner for sidechock, starboard side
Protecting cap
Nut
Distance tube
Spherical washer
Spherical nut
Holding down bolt
Nut
Protecting cap
End chock bolt
Liner for end chock
Spherical washer
Spherical washer
Nut

s50mc Vol II

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s50mc Vol II

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Warning

When referring to this page, please quote S-Instruction S900

MAN Diesel A/S

Table of Contents, Volume II

MAN Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear

909 - Fuel Oil System

911 - Safety Equipment

MAN Diesel A/S

Instructions for Main Engines

M/S Nybo 7730 B&W P90201-0036 059

MAN Diesel A/S

Checking and Maintenance Schedule,

Design modifications may necessitate a revision of

The stated Normal hours of service should only

The procedures are divided into three categories:

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

are those procedures which under the heading Normal hours

Checking and Maintenance Schedule,

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Piston with Rod and Stuffing box

Crosshead with connecting rod

Crankshaft and Thrust Bearing

Service interval (x 1000 hours of operation)

* Check whenever exhaust valve

Cylinder Liner and Cylinder Lubrication

Bearings should only be

Bearings should only be

V : See Volume I Operation

M : See makers instructions

Mechanical Control Gear

Starting Air System

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

Service interval (x 1000 hours of operation)

New or overhauled chain to be

* Only inspection through

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

V : See Volume I Operation

M : See makers instructions

Fuel Oil System

Service interval (x 1000 hours of operation)

* Only inspection through

V : See Volume I Operation

M : See makers instructions

Turbocharger lubricating oil water content

Checking and Maintenance Schedule, 26-70 MC/MC-C Engines

Service interval (x 1000 hours of operation)

* Only if separate oil system

Empty and clean tank

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