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S900-1
0001
S900-1
Warning!
It is important that all MAN B&W Diesel A/S engines are operated within the given
specifications and performance tolerances specified in the engines Technical Files
and are maintained according to the MAN B&W Diesel A/S maintenance instructions
in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations,
Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the
diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions,
including, but not limited to, the instructions to that effect included in the Technical
File.
Page 1 (1)
S50MC-C
DS 09091718
VOLUME II
MAINTENANCE
900 - Introduction
Documents in this Chapter
90023
90060
0027
0001
Table of Contents
900
Volume II - Maintenance
No.
Edition
Title
900 - Introduction
Table of Contents
90023 0027 Instructions for Main Engine
90060 0001 General - Safety Precautions
901 - Cylinder Cover
101-01 0041 Cylinder Cover, Data
901-01 0250 Cylinder Cover
90151 0199 Cylinder Cover - Panel
90161 0105 Cylinder Cover - Tools
902 - Piston with Rod & Stuffing Box
102-01 0065 Piston, Data
902-01 0270 Piston
102-02 0048 Piston Rod Stuffing Box, Data
902-02 0221 Piston Rod Stuffing Box
90251 0237 Piston and Piston Rod - Panel
90261 0108 Piston and Piston Rod - Tools
90264 0002 Piston and Piston Rod - Tilting Tools
90265 0001 Piston and Piston Rod - Support Tools
90266 0002 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication
103-01 0056 Cylinder Liner, Data
903-01 0253 Cylinder Liner
103-02 0031 Cylinder Lubricator, Data
903-02 0253 Cylinder Lubricator
90361 0084 Cylinder Liner - Tools
90362 0002 Cylinder Liner - Milling Tools
90364 0004 Test Equipment for Lubricators
90366 0007 Cylinder Liner - Lifting Tools
904 - Crosshead with Connecting Rod
104-01 0048 Crosshead Bearing, Data
904-01 0239 Crosshead Bearing
104-02 0050 Crosshead, Data
904-02 0239 Crosshead
104-03 0034 Reciprocating Parts, Data
904-03 0217 Reciprocating Parts
104-04 0042 Crankpin Bearing, Data
904-04 0226 Crankpin Bearing
104-05 0043 Connecting Rod, Data
904-05 0231 Connection Rod
90451 0151 Connecting Rod and Crosshead - Panel
90461 0069 Connecting Rod - Hydraulic Tools
MAN B&W Diesel A/S
Page 1 (5)
Table of Contents
900
Volume II - Maintenance
No.
90462
Edition
0020
Title
Connecting Rod - Tools
Page 2 (5)
Table of Contents
900
Volume II - Maintenance
No.
Edition
907-02
0214
Title
Starting Air Valve
Page 3 (5)
Table of Contents
900
Volume II - Maintenance
No.
10914
90914
10915
90915
10916
90916
90951
90961
90966
90968
90974
90977
90979
90980
Edition
0060
0235
0050
0226
0016
0204
0462
0069
0008
0001
0001
0001
0001
0001
Title
Fuel Oil High-Pressure Pipes, Data
Fuel Oil High-Pressure Pipes
Fuel Pump Roller Guide, Data
Fuel Pump Roller Guide
Fuel Pump Spec. Running
Fuel Pump Special Running
Fuel Valve and Fuel Pump - Panel
Fuel Valve - Tools
Fuel Valve Nozzle - Tools
Fuel Valve - Inspection Tools
Fuel Valve Nozzle - Cleaning Tools
Mounting Tools - Pump Barrel Seals
Mounting Tools - Suction Valve Seals
Mounting Tools - Air Piston Seals
Page 4 (5)
Table of Contents
900
Volume II - Maintenance
No.
Edition
112-03
912-03
912-05
91261
91265
91268
0015
0210
0201
0073
0003
0001
Title
Stay Bolts, Data
Stay Bolts
Crankcase Oil Outlet
Hydraulic Tools for Large Parts
Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)
Hydraulic Tools - End Chock Bolts (Iron Chocks)
Page 5 (5)
)The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.
To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation D refers to the information given on the
data sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN B&W Diesel A/S instructions. Emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.
A90023-0027
This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.
Teleph.:+45 33 85 11 00
Telex :16592 manbw dk
Telefax:+45 33 85 10 30
CVR No. 39 66 13 14
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 air supply to exhaust valve Only with stopped lubriating oil pumps
When referring to this page, please quote Safety Precaution A90060 Edition 0001
MAN B&W Diesel A/S
Page 1 (1)
0041
0250
0199
0105
Cylinder Cover
101-1
Data
SAFETY PRECAUTIONS
D10101 Data
Special Edition 0041
101-1
Cylinder Cover
S50ME-C
Stopped engine
Data
Ref.
D01-01
D01-02
D01-03
D01-04
D01-05
D01-06
D01-07
D01-08
D01-09
D01-10
D13-01
D13-02
Description
When referring to this page, please quote Data D10101 Edition 0041
MAN B&W Diesel A/S
Value Unit
680
150
40
500
128 - 129
1700
1200
40
8
22
1500
1400 -1650
Nm
Nm
Nm
Nm
mm
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Cylinder Cover
101-1
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90151
P90151
P90151
P90151
P90151
P90161
P91351
P91351
P91351
P91351
Page 2 (2)
46
58
60
83
130
10
34
58
130
When referring to this page, please quote Data D10101 Edition 0041
MAN B&W Diesel A/S
Cylinder Cover
MAN B&W Diesel
901-1.2
Dismantling
1.
C
D
M90101 0250D01
2.
When referring to this page, please quote Procedure M90101 Edition 0250
Page 1 (12)
901-1.2
Cylinder Cover
Dismantling
3.
M90101 0250D03
Remove the oil supply pipe for the hydraulic damper in the exhaust valve.
4.
M90101 0248D04
M90101 0248D05
5.
Page 2 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Cylinder Cover
MAN B&W Diesel
901-1.2
Dismantling
6.
M90101 0248D06
7.
Using the vent screws of the hydraulic
jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913-1.
Loosen the nuts by applying the tommy
bar through the slots in the spacer rings.
M90101 0250D07
8.
8. Hook the engine room crane on to the lifting attachment on top of the exhaust valve.
M90101 0248D11
When referring to this page, please quote Procedure M90101 Edition 0250
Page 3 (12)
901-1.2
Cylinder Cover
Dismantling
9. Remove and discard the sealing ring between cylinder cover and cylinder liner.
M90101 0248D12
9.
Page 4 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
1.
D01 09
M90101 0248O01
2.
D01 07
M90101 0248O02
D01 08
M90101 0248O03
3.
4.
When referring to this page, please quote Procedure M90101 Edition 0250
Page 5 (12)
901-1.3
Cylinder Cover
Overhaul
5.
M90101 0246O04
Clean the fuel valve bores, using the carbon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.
Grind the seating with the grinding mandrel
and a grinding compound (e.g. Carborundum No. 200).
After the milling/grinding, clean the bore
and seating carefully, and check that the
seating is not damaged.
6.
Exhaust valve bore
7. The tool consists of a spindle with handle
and a grinding disc.
M90101 0246O06
M90101 0248O07
7.
Page 6 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Cylinder Cover
MAN B&W Diesel
901-1.3
Overhaul
M90101 0248O08
M90101 0248O09
9.
When referring to this page, please quote Procedure M90101 Edition 0250
Page 7 (12)
Cylinder Cover
901-1.3
Overhaul
10.
D01 01
D01 03
M90101 0248O10
D01 02
Page 8 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Cylinder Cover
MAN B&W Diesel
901-1.4
Mounting
1. Place a new sealing ring on top of the cylinder liner with the guide tabs in the fore
and aft direction.
1.
D01 06
M90101 0248M01
2.
M90101 0248M02
3.
M90101 0246M03
D01 05
When referring to this page, please quote Procedure M90101 Edition 0250
Page 9 (12)
901-1.4
Cylinder Cover
Mounting
4.
M90101 0250D07
5.
Relieve the system of pressure.
Finally, remove the hydraulic jacks and
spacer rings from the nuts.
M90101 0248M04
Page 10 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Cylinder Cover
901-1.4
Mounting
6.
M90101 0248M05
7.
Mount the fuel oil high-pressure pipes for
the fuel valves.
See Procedure 909-14.4.
Mount the oil supply pipe for the hydraulic
damper in the exhaust valve.
M90101 0248M06
Caution!
The air supply to the exhaust valve must
always be connected before starting the
hydraulic oil pumps.
When referring to this page, please quote Procedure M90101 Edition 0250
Page 11 (12)
901-1.4
Cylinder Cover
Mounting
8.
M90101 0250M07
M90101 0250M08
9.
Page 12 (12)
When referring to this page, please quote Procedure M90101 Edition 0250
Plate
P90151-0199
P90151
Cylinder Cover Panel
0199
When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90151-0199
Item
No.
010
022
046
058
060
071
083
095
105
117
130
201
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
Plate
P90161-0105
When referring to this page, please quote Plate P90161 Edition 0105
Page 1 (2)
Plate
P90161-0105
Item
No.
Item Description
027
039
040
052
064
090
100
111
206
218
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P90161 Edition 0105
MAN B&W Diesel A/S
0065
0270
0048
0221
0237
0108
0002
0001
0002
Piston, Data
Piston
Piston Rod Stuffing Box, Data
Piston Rod Stuffing Box
Piston and Piston Rod - Panel
Piston and Piston Rod - Tools
Piston and Piston Rod - Tilting Tools
Piston and Piston Rod - Support Tools
Piston - Lifting Tools
Piston
102-1
Data
SAFETY PRECAUTIONS
D10201 Data
Special Edition 0065
102-1
S50ME-C
Piston
Stopped engine
Data
Ref.
D01-05
D02-01
D02-02
D02-03
D02-05
D02-06
D02-07
D02-08
D02-09
D02-10
D02-11
D02-12
D02-13
D02-14
D02-15
D02-16
D02-17
D02-18
D02-19
D02-20
D02-21
D02-22
D02-23
D02-24
D02-25
D02-46
Description
When referring to this page, please quote Data D10201 Edition 0065
MAN B&W Diesel A/S
Value Unit
128 - 129
7
430
300
80
80
100/30
17.2
14.2
13.2
10.2
15
12.4
9.4
28
3.4
2.4
0.35-0.4
0.87
921
200
565
57
21
150
1.1
mm
bar
Nm
Nm
Nm
Nm
Nm/
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
Nm
mm
Page 1 (2)
Piston
102-1
Data
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
P90251
P90251
P90251
P90251
P90251
P90251
P90251
P90251
P90261
P90264
P90265
P90266
P90366
P90451
Page 2 (2)
40
75
87
99
110
134
158
171
When referring to this page, please quote Data D10201 Edition 0065
MAN B&W Diesel A/S
Piston
902-1.1
Checking
Piston
S60MC-C
0270
Checking
902-1.1
1.
HN902-1.1 256 01
2.
HN902-1.1 256 02
HG902-1.1 204 03
3.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 1 (20)
Piston
902-1.1
Checking
4.
4. Ring grooves:
Measure the total clearance between the
piston rings and the ring grooves.
D02-18
D02-19
Total clearance = E + F.
5. Uppermost piston ring:
If possible, measure the depth of the pressure relief grooves with a caliper.
HM902-1.1 246 15
The piston rings must be replaced if the radial depth of the grooves has worn down to
less than stated in Data D02-46.
5.
D02-46
Min. 1
mm
GN902-1.2 204 08
GN902-1.2 204 08
6.
Page 2 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.1
Checking
7.
7. Before dismantling the piston rings, measure the free ring gap of all the piston rings.
D02-15
BM902-1.1 232 07
GN902-1.1 222 14
8.
9.
GN902-1.1 204 08
D02-08
D02-09
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
New
Worn
Page 3 (20)
Piston
902-1.1
Checking
10.
D02-10
D02-11
KM902-3.0 47 05
11. Clean the piston crown and check the burnaway by means of the template. For maximum permissible burn-away value, see Data.
11.
D02-12
Check the burn-away on the whole circumference of the piston crown. Note down the
results for later reference.
AM902-3.0 77 04
12. Fit the new piston rings (alternately righthand and left-hand cuts, with the ring gaps
staggered 180 and with the TOP mark upwards), using the ring expander.
When mounting the piston rings, use the
ring expander to prevent unintended deformation of the rings.
Do not expand the rings more than necessary. The upper ring (CPR-ring) should not
be expanded more than to the milled mark
on the ring expander.
GN902-1.1 222 14
12.
Page 4 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
Dismantling
902-1.2
1.
MN902-1.2 235 01
GN902-1.2 204 02
2.
HN902-1.2 237 03
3.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 5 (20)
902-1.2
Piston
Dismantling
4.
HN902-1.2 256 04
GN902-1.2 204 05
5.
GN902-1.2 237 06
6.
Page 6 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
7.
GN902-1.2 204 06
8.
GN902-1.2 204 07
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 7 (20)
Piston
902-1.2
Dismantling
9.
9. If the lifting height is limited, it can be necessary to guide the piston rod foot in between the cylinder cover studs.
Note!
Alternatively, with low lifting height,
remove one of the cylinder cover studs
with the stud setter.
MN902-1.2 256 09
10.
GN902-1.2 204 08
D02-20
GN902-1.2 204 09
11.
Page 8 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.2
Dismantling
12.
12. Turn the crosshead down far enough to permit mounting of the protective rubber cover
on the crosshead bearing cap.
The protective rubber cover should remain
in place to protect the crosshead bearing
journal from impurities until the piston is remounted.
GN902-1.2 204 10
13.
GN902-1.2 243 11
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 9 (20)
902-1.2
Piston
Dismantling
14.
GN902-1.2 243 12
Keep the piston rod clear of the cylinder liner and studs while carrying out the tilting.
When space conditions permit, straighten
up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
15.
When the piston is at a suitable height
above the platform cut-out, position the piston support around the piston rod and
clamp.
Now lower the piston while guiding the support to the platform cut-out.
After landing the piston and ensuring that it
rests correctly on the support, remove the
tilting tool.
Note!
GN902-1.2 243 13
Page 10 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
Overhaul
902-1.3
1.
D02-20
2. Assemble the two halves of the piston support around the piston rod and land the piston on the support.
3. Dismount the locking wire and the innermost screws between the rod and the piston crown.
JM902-1.3 234 01
JM902-1.3 234 02
2.
JM902-1.3 234 03
3.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 11 (20)
Piston
902-1.3
Overhaul
4.
D02-23
5. Screw the four screws of the support downwards until the skirt rests on the support.
If the skirt will not budge, free it by means
of two dismantling screws.
JM902-1.3 234 04
5.
D02-21
JM902-1.3 234 05
6.
D02-24
GN902-1.3 204 06
D02-06
Page 12 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
7.
KM902-1.3 240 06
Note!
GN902-1.3 243 08
8.
9.
GN902-1.3 243 09
KM902-1.3 240 09
10.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 13 (20)
Piston
902-1.3
Overhaul
11.
D02-22
GN902-1.3 243 11
D02-23
GN902-1.3 204 11
13.
D02-03
GN902-1.3 204 12
D02-05
Page 14 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.3
Overhaul
14.
HM902-1.3 204 13
15.
D02-01
MB902-1.3 204 14
Oil
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 15 (20)
Piston
902-1.4
Mounting
Mounting
902-1.4
2.
D02-20
Coat the piston rings, piston rod and cylinder liner with lubricating oil.
2. Mount the lifting tool on the piston crown.
3. Ensure that the stuffing box is correctly positioned over the guide pins in the distance
pieces mounted on the piston rod foot.
Coat the O-rings of the stuffing box with oil.
JM902-1.3 234 01
GN902-1.4 204 03
3.
GN902-1.2 204 10
4.
Page 16 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.4
Mounting
5.
5. Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit.
6. Turn the crosshead to a position 45 from
TDC.
GN902-1.2 204 09
GN902-1.4 204 06
6.
GN902-1.4 204 07
7.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 17 (20)
902-1.4
Piston
Mounting
8.
KB902-1.4 225 08
9.
GN902-1.4 204 09
KB902-1.4 225 09
10.
Page 18 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Piston
902-1.4
Mounting
11.
GN902-1.2 204 02
12.
HN902-1.4 237 12
D02-02
or
D02-07
HN902-1.4 237 13
13.
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
Page 19 (20)
Piston
902-1.4
Mounting
14.
14. If the cylinder cover studs have been removed, remount them.
Carefully clean the surfaces around the
base of the studs and check the O-rings on
the studs.
Mount the cylinder cover studs with the stud
setter. Screw the stud down to contact and
one half revolution back.
15. Land the cylinder cover on the liner and
check the distance the stud is protruding
from the cylinder cover.
If necessary, adjust the distance D01-05 by
turning the stud.
GN902-1.4 204 12
15.
D01-05
HN902-1.4 256 15
Page 20 (20)
When referring to this page, please quote Procedure M90201 Edition 0270
MAN B&W Diesel A/S
102-2
Data
SAFETY PRECAUTIONS
D10202 Data
Special Edition 0048
102-2
PistonS50ME-C
Rod Stuffing Box
Stopped engine
Data
Ref.
D02-26
D02-27
D02-28
D02-29
D02-30
D02-33
D02-34
D02-35
D02-36
D02-37
D02-38
D02-39
D02-40
D02-44
D02-45
Description
When referring to this page, please quote Data D10202 Edition 0048
MAN B&W Diesel A/S
Value Unit
80
80
80
4x6
3x3
Nm
Nm
Nm
mm
mm
639 mm
763 mm
835 mm
496
646
714
63
19
mm
mm
mm
kg
kg
Page 1 (2)
102-2
Data
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
P90251
P90251
P90451
Page 2 (2)
When referring to this page, please quote Data D10202 Edition 0048
MAN B&W Diesel A/S
902-2.1
Checking
Piston
0221 Rod Stuffing Box
S46MCC
Checking
902-2.1
1.
D02-29
D02-30
B
A
D02-30
D02-29
NB902-2.1 216 01
2.
D02-33
HM902-5.0 70 02
D02-37
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
Page 1 (9)
902-2.2
1.
GN902-2.2 203 01
2.
DM902-5.2 108 02
DM902-5.2 108 03
3.
Page 2 (9)
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
902-2.2
Dismantling
4.
DM902-5.2 108 04
5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame
bottom.
DM902-5.2 108 05
5.
EN902-2.2 221 06
6.
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
Page 3 (9)
902-2.3
Overhaul
Overhaul
902-2.3
GM902-5.1 90 01
1.
D02-44
D02-44
2222041a
2222042a
2.
Page 4 (9)
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
902-2.3
Overhaul
3.
D02-45
2222043a
7.
Dismantle and stack the rings in the same
order as when fitted in the stuffing box.
D02-33
D02-37
HM902-5.0 70 02
8.
HC902-5.1 98 07
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
Page 5 (9)
902-2.3
10.
NB902-3 217 10
HC902-5.1 98 11
Page 6 (9)
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
902-2.3
Overhaul
12.
D02-28
Remove the worktable and lower the stuffing box until it rests against the distance
pieces on the piston rod foot.
HC902-5.1 98 12
13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.
13.
22320313
D02-44
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
Page 7 (9)
902-2.4
1.
22420416
2.
Note!
Make sure that the two guide pins in the
flange enter the guide holes in the bottom
of the cylinder frame.
DM902-5.2 108 08
DM902-5.2 108 09
3.
Page 8 (9)
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
902-2.4
Mounting
4.
DM902-5.2 108 10
5.
DM902-5.2 108 11
D02-26
D02-27
GN902-2.2 203 01
6.
When referring to this page, please quote Procedure M90202 Edition 0221
0$1 % : 'LHVHO $6
Page 9 (9)
When referring to this page, please quote Plate P90251 Edition 0237
MAN B&W Diesel A/S
Plate
P90251-0237
Page 1 (2)
Plate
P90251-0237
Item
No.
014
026
040
051
075
087
099
109
110
122
134
158
160
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90251 Edition 0237
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90261 Edition 0108
MAN B&W Diesel A/S
Plate
P90261-0108
Page 1 (2)
Plate
P90261-0108
Item
No.
019
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90261 Edition 0108
MAN B&W Diesel A/S
Plate
P90264-0002
P90264
Piston
0002 and Piston Rod - Extra Tools
When referring to this page, please quote Plate P90264 Edition 0002
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90264-0002
Item
No.
015
027
Item Description
Item
No.
Item Description
Lifting collar
Support for tilting tool
Page 2 (2)
When referring to this page, please quote Plate P90264 Edition 0002
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90265 Edition 0001
MAN B&W Diesel A/S
Plate
P90265-0001
Page 1 (2)
Plate
P90265-0001
Item
No.
010
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90265 Edition 0001
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90266 Edition 0002
MAN B&W Diesel A/S
Plate
P90266-0002
Page 1 (2)
Plate
P90266-0002
Item
No.
016
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P90266 Edition 0002
MAN B&W Diesel A/S
0056
0253
0031
0253
0084
0002
0004
0007
Cylinder Liner
103-1
Data
SAFETY PRECAUTIONS
103-1
D10301 Data
Special Edition 0056
Cylinder Liner
S50ME-C
Stopped engine
Data
Ref.
D03-01
D03-03
D03-04
D03-05
D03-06
D03-16
D03-17
D03-18
Description
Value Unit
150
500
498.3
1820
170
38.8
0.5
Nm
mm
mm
kg
kg
mm
mm
Install:
0 0.50 mm
Standard PC-ring
(new or max. wear of diameter 0.50 mm)
0.50 1 mm
Oversize PC-ring
> 1 mm
Dummy ring
When referring to this page, please quote Data D10301 Edition 0056
MAN B&W Diesel A/S
Page 1 (2)
Cylinder Liner
103-1
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90251
P90361
P90362
P90366
Page 2 (2)
When referring to this page, please quote Data D10301 Edition 0056
MAN B&W Diesel A/S
Cylinder Liner
903-1.1
Checking
Cylinder
S50MC Liner
0253
Checking
903-1.1
1.
D03-03
4. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.
5. Carefully scratch over any scores or marks
on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3.
DM903-2.0 90 01
2.
GN903-1.1 203 03
GM903-1.1 253 04
4.
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Page 1 (10)
903-1.1
Cylinder Liner
Checking
7.
GW903-1.1 247 07
8.
DM903-1.1 237 08
Page 2 (10)
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Cylinder Liner
903-1.2
Dismantling
Dismantling
903-1.2
1.
D03-01
Note!
Tighten the lifting screws to the torque
stated in Data.
GN903-1.2 224 01
2.
Dismount the four cooling water pipes between the cooling jacket and cylinder cover
and clean them carefully.
GN903-1.2 224 02
2. Disconnect at the exhaust side of the cylinder the oil pipes leading from the cylinder lubricator to the non-return valves.
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Page 3 (10)
903-1.2
Cylinder Liner
Dismantling
3.
EN903-1.4 205 03
D03-05
Land the cylinder liner vertically on, for instance, a couple of planks.
Clean the cylinder frame internally, taking
special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Discard the O-rings on the cooling water
pipes.
GN903-1.2 224 04
Page 4 (10)
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Cylinder Liner
903-1.2
Dismantling
5.
5. The lifting screws are also used for transporting the cylinder liner.
HN903-1.2 244 05
D03-05
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Page 5 (10)
Cylinder Liner
903-1.3
Overhaul
Overhaul
903-1.3
1.
GN903-1.3 224 01
2.
EN903-1.3 237 02
3.
EN903-1.3 237 03
D03-06
Page 6 (10)
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Cylinder Liner
903-1.3
Overhaul
4.
4. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.
Carefully scratch over any scores or marks
on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
Check in the top of the liner for a wear ridge
(where the piston rings reverse direction). If
there is any sign of a wear ridge, it is necessary to create a groove by grinding.The
groove serves to prevent the build-up of a
new wear ridge.
HN903-1.3 221 04
5. It is recommended to use a wear ridge milling machine to create the groove. For use
of the milling machine, see suppliers instruction.
5.
MB903-1.3 231 04
Check the distance C before grinding to ascertain that the wear ridge was caused by
the top ring at TDC.
Note!
6.
R=4-5 mm
MN903-1.3 229 05
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Page 7 (10)
Cylinder Liner
903-1.3
Overhaul
7.
GN903-1.3 203 04
EN903-1.3 237 08
D03-06
EN903-1.3 237 09
9.
Page 8 (10)
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Cylinder Liner
903-1.4
Mounting
Mounting
903-1.4
1.
D03-01
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.
DM903-1.4 237 01
GN903-1.4 224 02
2.
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Page 9 (10)
903-1.4
Cylinder Liner
Mounting
3.
EN903-1.4 205 03
When this is in order, check that each individual lubricating point functions correctly.
4.
5. Lubricate the upper part inside of the cylinder liner with cylinder lubricating oil and
mount the piston and the PC ring.
See Procedure 902-1.4.
6. Mount the sealing ring and the cylinder cover.
See Procedure 901-1.4.
GM903-1.4 253 04
GN901-1.4 203 01
6.
Page 10 (10)
When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Cylinder Lubricator
MAN B&W Diesel
103-2
Data
Stopped engine
Shut off starting air supply At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply Not ME engines
Shut off control air supply
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Data
Ref.
Description
When referring to this page, please quote Data D10302 Edition 0031
Value
Unit
Page 1 (2)
Cylinder Lubricator
103-2
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
P90364
Page 2 (2)
Item No.
Description
Test Equipment for Lubricator
Cylinder Lubricators
MAN B&W Diesel
903-2.1
Checking
1.
M90302 0242C02
When referring to this page, please quote Procedure M90302 Edition 0253
Page 1 (8)
903-2.2
Cylinder Lubricators
Dismantling
Dismantling of lubricators:
1.
The engine must be stopped and blocked before dismounting a lubricator. Stop the cylinder
oil pump station.
Disconnect the electrical plug on the side of
the lubricator.
00:00
ON
OFF
Bourdon Sedeme
CC
M90302 0253D01
565
560
2.
M90302 0253D02
3.
Special running
It is possible to change a lubricator while the
engine is running if a spare lubricator with Orings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
M90302 0253D03
Page 2 (8)
Cylinder Lubricators
MAN B&W Diesel
903-2.3
Overhaul
1.
M90302 0246O01
M90302 0246O02
2.
M90302 0253O03
3.
When referring to this page, please quote Procedure M90302 Edition 0253
Page 3 (8)
903-2.3
Cylinder Lubricators
Overhaul
4.
4. Screw out the non-return valves and remove and discard the O-rings.
Clean the valves and check them with
compressed air.
5. Inspect the plungers, actuator piston and
cylinder block for wear, using a magnifying
glass.
M90302 0246O04
M90302 0253O05
5.
M90302 0246O06
6.
Page 4 (8)
When referring to this page, please quote Procedure M90302 Edition 0253
Cylinder Lubricators
MAN B&W Diesel
903-2.3
Overhaul
7.
M90302 0253O07
Mount the spring and press down the actuator piston with plungers. Mount the special screw supplied with the test equipment
for accumulators to keep the spring compressed.
8.
M90302 0246O08
Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.
M90302 0246O09
9.
When referring to this page, please quote Procedure M90302 Edition 0253
Page 5 (8)
903-2.3
Cylinder Lubricators
MAN B&W Diesel
M90302 0242O08
Overhaul
Page 6 (8)
When referring to this page, please quote Procedure M90302 Edition 0253
Cylinder Lubricators
MAN B&W Diesel
903-2.3
Overhaul
13.
M90302 0246O13
14.
M90302 0253O14
M90302 0246O01
15.
When referring to this page, please quote Procedure M90302 Edition 0253
Page 7 (8)
903-2.4
Cylinder Lubricators
Mounting
1.
x6
Use a little clean grease to keep the Orings in place during mounting.
2. Mount the lubricator and tighten the screws
on the hydraulic cylinder unit.
Tighten the top cover screws in the end of
the lu-bricator to the pipe connection.
M90302 0253M01
2.
M90302 0253M02
M90302 0253M03
3.
560
Page 8 (8)
When referring to this page, please quote Procedure M90302 Edition 0253
Plate
P90361-0084
P90361
Cylinder Liner - Tools
0084
When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90361-0084
Item
No.
036
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S
Plate
P90362-0002
P90362
Cylinder Liner - Extra Tool
0002
When referring to this page, please quote Plate P90362 Edition 0002
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90362-0002
Item
No.
018
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90362 Edition 0002
MAN B&W Diesel A/S
Plate
P90364-0004
When referring to this page, please quote Plate P90364 Edition 0004
Page 1 (2)
P90364
Test
0004Equipment for Lubricator
Plate
P90364-0004
Item
No.
019
020
032
044
056
068
081
103
115
139
152
164
176
211
223
Item Description
Item
No.
Item Description
Tool box
Nameplate
Adaptor
Pressure gauge
Spanner
Pressure gauge
Adaptor
Hose with 2 union
Quick coupling, minimess
Reducing valve
Adaptor
Adaptor
Adaptor
Adaptor
Filling and testing valve
Page 2 (2)
When referring to this page, please quote Plate P90364 Edition 0004
MAN B&W Diesel A/S
Plate
P90366-0007
P90366
Cylinder Liner - Lifting Tools
0007
When referring to this page, please quote Plate P90366 Edition 0007
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90366-0007
Item
No.
021
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90366 Edition 0007
MAN B&W Diesel A/S
0048
0239
0050
0239
0034
0217
0042
0226
0043
0231
0151
0069
0020
Crosshead Bearing
104-1
Data
SAFETY PRECAUTIONS
104-1
S50ME-C
D10401 Data
Special Edition 0048
Crosshead Bearing
Stopped engine
Data
Ref.
D02-02
D02-07
D02-20
D04-01
D04-02
D04-03
D04-04
D04-05
D04-06
D04-07
D04-21
D04-51
D13-01
D13-02
Description
When referring to this page, please quote Data D10401 Edition 0048
MAN B&W Diesel A/S
Value Unit
430
100/30
921
0.55
0.15
10
160
13
28
173
1100
1400
1500
1400 -1650
Nm
Nm/
kg
mm
mm
mm
kg
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Crosshead Bearing
104-1
Data
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
P90451
P90451
P90451
P90451
P90451
P90463
P91351
P91351
P91351
P91351
P91356
P91359
P91366
Page 2 (2)
47
59
72
96
106
10
46
58
117
58
Wire guide
Lifting attachment - connecting rod
Chain for suspending piston
Bracket for support, crosshead
Bracket for support, crosshead
Crosshead - Hydraulic Tools
Hydraulic pump, pneumatically operated
Hose with unions (1500 mm), complete
Hose with unions (3000 mm), complete
5-way distributor block, complete
Lifting Tools, Etc.
Torque Spanners
Feeler gauge
When referring to this page, please quote Data D10401 Edition 0048
MAN B&W Diesel A/S
Crosshead Bearing
904-1.1
Checking
Crosshead
S50ME-C Bearing
0239
Checking
904-1.1
2.
Tin-Aluminium bearings
The top clearance between the journal and a
new bearing shell is the result of a summation
of the production tolerances of the bearing assembly components.
GW904-1.1 239 02
The top clearance for a new bearing will normally be in the range stated in Data. Note that
the figures are to be used for guidance only.
D04-01
D04-02
3.
4. The difference between the actual clearance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
crosshead bearing must be disassembled
for inspection.
See Procedure 904-1.2.
DM904-1.1 232 03
5.
(Oil Wedge)
DM904-1.1 232 05
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
D04-03
Page 1 (10)
904-1.2
Crosshead Bearing
Dismantling
Dismantling
904-1.2
1.
GW 904-1.1 239 02
HN904-1.2 222 02
2.
HN904-1.2 222 03
3.
Page 2 (10)
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
4.
6. Turn to BDC.
7. Place the spacer rings around the nuts and
screw the hydraulic jacks on to the studs.
HN904-1.2 222 04
5.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.
HN904-1.2 222 05
7.
HN904-5.2 217 01
D13-02
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Page 3 (10)
Crosshead Bearing
904-1.2
Dismantling
8.
JN904-1.2 227 08
Hook the tackles on to the eye bolts, and remove the bearing cap from the engine.
Check the upper part of the journal.
JN904-1.2 227 09
9.
D04-07
JN904-1.2 227 10
10.
Page 4 (10)
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
11.
D04-07
HG904-1.2 238 11
D04-05
12.
HG904-1.2 238 12
GN904-1.2 203 13
13.
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Page 5 (10)
Crosshead Bearing
904-1.2
Dismantling
14.
HG904-1.2 238 14
15.
JN904-1.2 227 15
D04-21
D02-20
JN904-1.2 227 16
16.
17.
Page 6 (10)
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.2
Dismantling
18.
D04-06
JN904-1.2 227 18
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Page 7 (10)
904-1.4
Crosshead Bearing
Mounting
Mounting
904-1.4
1.
D04-06
1. Mount and secure the bearing shell in the
bearing housing.
The excess height X is to ensure the correct tightening-down of the bearing shell
and must not be eliminated.
2. Raise the connecting rod to an upright position.
JN904-1.4 227 01
Turn to TDC while following with the tackles, for assembling the crosshead and the
connecting rod.
Take care that the guide shoes do not damage the bearing shell.
2.
D04-21
JN904-1.4 227 02
JN904-1.4 227 03
3.
Page 8 (10)
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Crosshead Bearing
904-1.4
Mounting
4.
D04-07
Note!
JN904-1.4 227 04
5.
HN904-5.2 217 01
D13-01
GN904-1.4 203 07
7.
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Page 9 (10)
Crosshead Bearing
904-1.4
Mounting
8.
GN904-1.2 203 19
D02-02
D02-07
HN904-1.4 222 09
9.
Page 10 (10)
When referring to this page, please quote Procedure M90401 Edition 0239
0$1 % : 'LHVHO $6
Crosshead
104-2
Data
SAFETY PRECAUTIONS
104-2
S50ME-C
D10402 Data
Special Edition 0050
Crosshead
Stopped engine
Data
Ref.
D04-04
D04-08
D04-12
D04-13
D04-15
D04-19
D04-21
D04-22
D04-23
D04-50
D13-01
D13-02
Description
When referring to this page, please quote Data D10402 Edition 0050
MAN B&W Diesel A/S
Value Unit
160
50
100
135
50
25
1100
159
9
1020
1500
1400 -1650
kg
Nm
Nm
Nm
Nm
kg
kg
kg
kg
bar
bar
Page 1 (2)
Crosshead
104-2
Data
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
P90451
P90451
P90451
P90451
P90451
P90451
P90462
P90463
P91351
P91351
P91351
P91351
P91356
P91359
P91366
Page 2 (2)
47
59
60
72
84
214
11
10
46
58
117
58
Wire guide
Lifting attachment - connecting rod
Lifting tools - crosshead
Chain for suspending piston
Retaining tool telescopic pipe
Torque wrench offset tool
Guide shoe extractor, complete
Crosshead - Hydraulic Tools
Hydraulic pump, pneumatically operated
Hose with unions (1500 mm), complete
Hose with unions (3000 mm), complete
5-way distributor block, complete
Lifting Tools, Etc.
Torque Spanners
Feeler gauge
When referring to this page, please quote Data D10402 Edition 0050
MAN B&W Diesel A/S
Crosshead
904-2.2
Dismantling
Crosshead
S50ME-C
0239
Dismantling
904-2.2
2.
In order to reach the screw in the corner behind the telescopic pipe, use the offset tool
along with a socket wrench.
GN904-2.2 203 02
Loosen and remove the screws which secure the telescopic pipe to the guide shoe.
3.
GN904-2.2 204 03
Mount two eye bolts in the top of the crankcase in the fore-and-aft direction.
4.
D04-23
D13-02
HN904-2.2 223 04
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Page 1 (7)
904-2.2
Crosshead
Dismantling
5.
HN904-2.2 223 05
D04-21
GN904-2.2 232 06
HN904-2.2 223 07
D04-50
By alternate use of the tackles, tilt the connecting rod until it rests against a couple of
wooden planks in the bottom of the bedplate.
Page 2 (7)
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Crosshead
904-2.2
Dismantling
8.
GN904-2.2 232 08
9.
D04-22
GN904-2.2 232 09
Pull off the guide shoe, remove the extractor, and lift up the guide shoe.
10.
GN904-2.2 232 10
D04-22
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Page 3 (7)
904-2.2
Crosshead
Dismantling
11.
GN904-2.2 232 11
12.
HN904-2.2 223 11
HN904-2.2 223 12
13.
Page 4 (7)
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Crosshead
904-2.4
Mounting
Mounting
904-2.4
1.
D04-22
D04-21
HN904-2.2 223 11
3.
Follow the movement of the crosshead with
the engine room crane.
4. Lower the other guide shoe.
Use the guide shoe extractor tool to push
the crosshead towards the second guide
shoe.
GN904-2.4 232 03
GN904-2.4 232 04
4.
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Page 5 (7)
Crosshead
904-2.4
Mounting
5.
D04-13
D04-12
HN904-2.4 223 05
D04-50
7. When the connecting rod is in a vertical position, lower the crosshead and land it on
the connecting rod.
Remove the lifting attachments from the
connecting rod head.
HN904-2.4 223 06
EN904-2.4 237 07
7.
Page 6 (7)
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Crosshead
904-2.4
Mounting
8.
D04-04
HN904-2.2 223 05
9.
D13-01
D04-15
D04-19
D04-08
HN904-2.2 223 04
10.
GN904-2.2 204 03
D04-15
D04-19
When referring to this page, please quote Procedure M90402 Edition 0239
0$1 % : 'LHVHO $6
Page 7 (7)
Reciprocating Parts
104-3
Data
SAFETY PRECAUTIONS
104-3
S50ME-C
D10403 Data
Special Edition 0034
Reciprocating Parts
Stopped engine
Data
Ref.
D04-25
D04-26
D04-28
D04-29
D04-30
D04-53
D04-54
D04-55
Description
When referring to this page, please quote Data D10403 Edition 0034
MAN B&W Diesel A/S
Value Unit
0.5
0.7
0.5
0.2
0.8
0.9
0.5
1.1
mm
mm
mm
mm
mm
mm
mm
mm
Page 1 (2)
Reciprocating Parts
104-3
Data
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
P90451
P91366
Page 2 (2)
When referring to this page, please quote Data D10403 Edition 0034
MAN B&W Diesel A/S
Reciprocating Parts
904-3.1
Checking
Reciprocating Parts
S50ME-C
0217
Checking
904-3.1
1.
In order to achieve uniform measuring conditions on board, the ships trim must be as close
as possible to 0.
MA904-5.0 72 01
3.
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.
Measurements are to be taken with a ruler.
GN904-3.1 203 03
When referring to this page, please quote Procedure M90403 Edition 0217
0$1 % : 'LHVHO $6
Page 1 (3)
Reciprocating Parts
904-3.1
Checking
4.
FORE
4. Check the centering of the piston in the cylinder liner by measuring the clearance
(from the scavenge air space with a long
feeler gauge) between the piston skirt and
the cylinder liner in the Fore and Aft positions (PF-PA).
AFT
D04-25
D04-26
D04-25
Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction.
5. Measure the clearance between the guide
strips and crosshead guides (J, K, L and
M).
PA
PF
GN904-3.1 213 04
ZF
ZA
5.
D04-53
D04-54
D04-55
GN904-3.1 203 05
FUEL PUMP
Page 2 (3)
When referring to this page, please quote Procedure M90403 Edition 0217
0$1 % : 'LHVHO $6
Reciprocating Parts
904-3.1
Checking
6.
Exhaust side
Fuel pump
7. It is recommended that the measured results are noted down so that possible later
changes can be ascertained.
GN904-3.1 203 06
D04-28
D04-29
D04-30
GN904-3.1 203 07
7.
When referring to this page, please quote Procedure M90403 Edition 0217
0$1 % : 'LHVHO $6
Page 3 (3)
Crankpin Bearing
104-4
Data
SAFETY PRECAUTIONS
104-4
S50ME-C
D10404 Data
Special Edition 0042
Crankpin Bearing
Stopped engine
Data
Ref.
D04-43
D04-44
D04-46
D04-47
D04-48
D13-01
D13-02
Description
When referring to this page, please quote Data D10404 Edition 0042
MAN B&W Diesel A/S
Value Unit
0.6
0.2
17
13
150
1500
1400 -1650
mm
mm
kg
kg
kg
bar
bar
Page 1 (2)
Crankpin Bearing
104-4
Data
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
P90451
P90451
P90451
P90451
P90461
P91356
P91366
P91351
P91351
P91351
P91351
Page 2 (2)
47
59
96
106
58
10
46
58
105
Wire guide
Lifting attachment - connecting rod
Bracket for support, crosshead
Bracket for support, crosshead
Connecting Rod - Hydraulic Tools
Lifting Tools, Etc.
Feeler gauge
Hydraulic pump, pneumatically operated
Hose with unions (1500 mm), complete
Hose with unions (3000 mm), complete
3-way distributor block, complete
When referring to this page, please quote Data D10404 Edition 0042
MAN B&W Diesel A/S
Crankpin Bearing
904-4.1
Checking
Crankpin
S46MC-CBearing
0226
Checking
904-4.1
2.
GW904-1.1 239 02
3.
4. The difference between the actual clearance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2.
GM904-6.1 69 03
6. For further external inspection of the crankpin bearing, see Chapter 708 Bearings' in
the instruction book, Volume I, OPERATION.
D04-43
D04-44
GN904-4.1 219 05
5.
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Page 1 (8)
904-4.2
Crankpin Bearing
Dismantling
Dismantling
904-4.2
2.
GW904-2 226 02
Loosen the crankpin bearing stud nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Procedure 913-1.
Remove the hydraulic jacks and the nuts.
3.
4. Lower the bearing cap while seeing carefully that the studs do not damage the
crankpin journal.
Land the bearing cap on a couple of planks
placed in the oil pan.
D13-02
GN904-4.2 203 03
4.
GW904-4.2 226 04
D04-48
Page 2 (8)
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.2
Dismantling
5.
D04-48
GW904-4.2 226 05
6.
Note!
D04-47
If only one of the shells needs replacement, MAN B&W Diesel should be contacted for advice beforehand.
GN904-4.2 203 06
7. Turn to TDC.
7.
HN904-4.2 217 07
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Page 3 (8)
904-4.2
Crankpin Bearing
Dismantling
8.
GW904-4.2 226 08
9.
GW904-4.2 226 09
GW904-4.2 226 10
10.
Page 4 (8)
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.2
Dismantling
11.
GN904-4.2 219 11
D04-46
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Page 5 (8)
904-4.4
Crankpin Bearing
Mounting
Mounting
904-4.4
1.
HM904-6.0 61 16
GN904-4.4 219 02
D04-46
Page 6 (8)
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Crankpin Bearing
904-4.4
Mounting
4.
3. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod, and haul tight.
Carefully turn the crankshaft upwards,
while following up with the tackle, making
sure that the upper part of the bearing enters the recess in the crankshaft when the
parts turn together.
Remove the tackle and the lifting attachment from the connecting rod.
4. Turn the crosshead to TDC.
GW904-4.4 226 04
HN904-4.4 217 05
5.
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Page 7 (8)
Crankpin Bearing
904-4.4
Mounting
6.
5. Suspend the tackles from the lifting brackets in the top of the frame box.
Lift the bearing cap assembly into the
crankcase and land it on a couple of planks
placed in the oil pan.
6. Hook the tackles on to the wire ropes and
lift the bearing cap into position against the
connecting rod.
D04-48
Caution!
During mounting, take care that the studs
do not damage the crankpin journal, and
check that the guide pins mounted in the
bearing cap enter the holes in the connecting rod.
GW904-4.4 226 06
GW904-4.4 226 07
Page 8 (8)
D13-01
When referring to this page, please quote Procedure M90404 Edition 0226
0$1 % : 'LHVHO $6
Connecting Rod
104-5
Data
SAFETY PRECAUTIONS
104-5
S50ME-C
D10405 Data
Special Edition 0043
Connecting Rod
Stopped engine
Data
Ref.
D02-02
D04-01
D04-02
D04-07
D04-43
D04-44
D04-48
D04-50
Description
When referring to this page, please quote Data D10405 Edition 0043
MAN B&W Diesel A/S
Value Unit
430
0.55
0.15
173
0.6
0.2
150
1020
Nm
mm
mm
kg
mm
mm
kg
kg
Page 1 (2)
Connecting Rod
104-5
Data
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
P90461
P90463
P90451
P90451
P90451
P90451
P91356
P91359
P91366
P91351
P91351
P91351
P91351
Page 2 (2)
47
59
96
106
58
10
46
58
117
When referring to this page, please quote Data D10405 Edition 0043
MAN B&W Diesel A/S
Connecting Rod
904-5.2
Dismantling
Connecting
S50ME-C Rod
0231
Dismantling
904-5.2
1.
1. Turn to BDC.
Mount chains for suspending the piston.
HN904-5.2 230 01
GM904-6.1 69 03
C
A
3.
D04-48
HN904-5.2 230 03
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Page 1 (8)
Connecting Rod
904-5.2
Dismantling
4.
D04-07
B
Dismount the crosshead bearing cap and
remove the bearing cap from the engine using tackles mounted on the gallery outside
the engine. See Procedure 904-1.2.
HN904-5.2 230 04
5.
D04-50
HN904-5.2 230 05
HN904-5.2 230 06
6.
Page 2 (8)
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Connecting Rod
904-5.2
Dismantling
A
7.
B
E
When possible attach tackle B to upper lifting attachment on the connecting rod and
remove tackle C.
D04-50
GW904-5.2 231 07
8. Mount tackles in E and F, turn slowly towards TDC while loosening tackles C and
D.
8.
B
E
GW904-5.2 231 08
Tighten tackles B, E and F to lift the connecting rod free of the crankshaft. When
the connecting rod is free of the crankshaft,
remove tackle C and turn to TDC.
9.
GW904-5.2 231 09
D04-50
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Page 3 (8)
Connecting Rod
904-5.2
Dismantling
10.
HN904-5.2 230 10
Page 4 (8)
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Connecting Rod
904-5.4
Mounting
Mounting
904-5.4
1.
E+F
Caution!
D04-50
HN904-5.2 230 10
2.
Lubricate the crankpin and bearing liberally.
Carefully move the connecting rod onto the
crankshaft.
B
E
3. Attach tackle C to the lower lifting attachment and move tackle B to the upper lifting
attachment.
D
GW904-5.4 231 02
Turn towards the exhaust side while tightening tackle C, and tighten tackle B when
possible. Attach tackle D to the lower lifting
attachment.
3.
GW904-5.4 231 03
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Page 5 (8)
Connecting Rod
904-5.4
Mounting
B
4.
E
C
GW904-5.4 231 04
5.
HN904-5.4 230 05
6.
HN904-5.4 230 06
Page 6 (8)
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Connecting Rod
904-5.4
Mounting
A
7.
7. Turn to BDC.
B
E
GW904-5.4 231 07
D
9. 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.
GM904-6.1 69 03
D04-43
D04-44
GN904-1.4 203 07
9.
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
Page 7 (8)
Connecting Rod
904-5.4
Mounting
10.
D02-02
HN904-5.2 230 01
D04-01
D04-02
Note!
11.
KN905-2.4 238 14
Page 8 (8)
When referring to this page, please quote Procedure M90405 Edition 0231
0$1 % : 'LHVHO $6
When referring to this page, please quote Plate P90451 Edition 0151
Plate
P90451-0151
Page 1 (2)
Plate
P90451-0151
Item
No.
011
023
047
059
060
072
084
096
106
118
120
214
226
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90451 Edition 0151
Plate
P90461-0069
P90461
Connecting Rod - Hydraulic Tools
0069
When referring to this page, please quote Plate P90461 Edition 0069
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90461-0069
Item
No.
028
030
053
065
089
090
100
207
Item Description
Item
No.
Item Description
Jack-hydraulic, complete
Support
Sealing ring with back-up ring
Sealing ring with back-up ring
Key, hexagon socket screw
Tommy bar
Stud setter
Hydraulic toolset, complete
Page 2 (2)
When referring to this page, please quote Plate P90461 Edition 0069
MAN B&W Diesel A/S
Plate
P90462-0020
P90462
Connecting Rod - Tools
0020
When referring to this page, please quote Plate P90462 Edition 0020
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90462-0020
Item
No.
011
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90462 Edition 0020
MAN B&W Diesel A/S
0004
0209
0044
0241
0039
0224
0003
0212
0033
0224
0007
0204
0227
0093
0125
0018
0004
0003
0002
Main Bearing
105-1
Data
SAFETY PRECAUTIONS
105-1
S50MC-C
0004
Special Data
Main Bearing
Stopped engine
Data
Ref.
Description
Value Unit
When referring to this page, please quote Data D10501 Edition 0004
MAN B&W Diesel A/S
Page 1 (2)
Main Bearing
105-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10501 Edition 0004
MAN B&W Diesel A/S
Main Bearing
905-1.1
Checking
Main
S50MC-C
0209 Bearing
Checking
905-1.1
1.
General
The condition of the main bearings can be
checked by:
Deflection readings
Visual checking
Edge checking and
HM905-2.0 46 01
2.
As the alignment is influenced by the engine
temperature as well as the loading conditions,
deflection measurements should, for comparison purposes, always be made under nearly
the same temperature and load conditions.
Positive (+)
Negative ( )
3.
XZ905-1.1 204 03
B1
(near bottom)
C
(camshaft side)
T
(top)
E
(exhaust side)
B2
(near bottom)
1/2 (B2+B1) = B
When referring to this page, please quote Procedure M90501 Edition 0209
0$1 % : 'LHVHO $6
Page 1 (4)
905-1.1
Main Bearing
Checking
4.
HM905-2.0 46 01
KN905-1.1 208 05
General
Bearing damage usually propagates rather
quickly towards the edge of the bearing where,
eventually, it causes chips to be broken off,
which means that loose pieces of white metal
can fall down into the crankcase beneath the
bearing support.
Large, thick pieces will normally be found during a crankcase inspection, and small, thin
pieces can enter the filter. A check of the bearing edges together with inspection of the crankcase and the filter normally provides a good
indication of the bearing condition.
Page 2 (4)
When referring to this page, please quote Procedure M90501 Edition 0209
0$1 % : 'LHVHO $6
Main Bearing
905-1.1
Checking
6.
Hole in
the edge
KN905-1.1 208 06
The No. 1 and the two aftmost main bearings are more difficult to access on the
whole circumference on each side, but it is
often possible to bend the feeler to suit
the situation and thus reach as far round as
possible.
7.
Wire-feeler
7. It is rather easy to make a feeler (see
sketch). The feeler should be made from
a piece of steel wire (e.g. a welding rod)
approx. 0.6 - 1 m long depending on the
engine type, and 2 to 3 mm thick. Approx.
7 to 10 mm of the wire should be bent to an
angle of approx. 65 to form a feeler tip.
Grind the tip smooth to obtain the shape
and dimension shown on the sketch. Note
that the thickness of the white metal is approx. 1.5 mm, which is why the tip should
be less than 1.2 mm thick, and bigger than
the max. top clearance. At the other end of
the tip, a handle should be made by bending a hook or similar in the same direction
as the tip.
<1.2 mm
>0.7 mm
7-10 mm
60-70
500-1000
2-3 mm
Wire feeler
The above dimensions of the wirefeeler are guideline values and may
depend on the engine type as well as
individual, personal designs.
KN905-17.02
Note!
When referring to this page, please quote Procedure M90501 Edition 0209
0$1 % : 'LHVHO $6
Page 3 (4)
905-1.1
Main Bearing
Checking
8.
BG905-3.1 71 01
Note!
The bearing clearances for a new bearing stated in Data (see Data 105-2) are
for guidance purposes only.
9.
10. The difference between the actual clearance measurement and the measurement
recorded in the adjustment sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.
For evaluation of the bearing, see Volume
I, Operation, Chapter 708.
BM905-2.1 239 03
HN905-2.1 227 03
10.
Page 4 (4)
When referring to this page, please quote Procedure M90501 Edition 0209
0$1 % : 'LHVHO $6
Main Bearing
105-2
Data
SAFETY PRECAUTIONS
105-2
S50MC-C
0044
Special Data
Main Bearing
Stopped engine
x2
Data
Ref.
Description
Value Unit
0.65 mm
0.35 mm
D-1
290 kg
D-2
4 x 1,5 m
1x3m
D-3
Hydraulic pressure
dismantling
tightening
[ NJ
20 kg
20 kg
1500-1650 bar
1500 bar
When referring to this page, please quote Data D10502 Edition 0044
MAN B&W Diesel A/S
Page 1 (2)
Main Bearing
105-2
Data
Plate
1175465-2
90551
Spare Parts
Plate Item No.
Description
Qty
91210-xxxx 050
Screw
91210-xxxx 108
91210-xxxx 121
Page 2 (2)
When referring to this page, please quote Data D10502 Edition 0044
MAN B&W Diesel A/S
Main Bearing
905-2.2
Dismantling
Main
S50MC-C
0241 Bearing
Dismantling
905-2.2
1.
KN905-2.2 238 01
Main bearings
Thrust bearing
2.
Note!
KN905-2.2 238 02
Be sure that the crosshead for the neighbouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
3.
MAN-SIDE
KN905-2.2 238 03
EXH-SIDE
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 1 (13)
905-2.2
Main Bearing
Dismantling
4.
Oil pipes
4. Disconnect the lubricating oil pipe from the
main pipe.
Note!
KN905-2.2 238 04
Note!
2.
GN905-2.2 204 02
KN905-2.2 238 07
5.
Page 2 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
7.
GN905-2.2 241 07
8.
Note!
GN905-2.2 241 08
9.
P
GN905-2.2 241 09
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 3 (13)
Main Bearing
905-2.2
Dismantling
10.
GN905-2.2 241 10
GN905-2.2 241 11
12.
A
B
C
GN905-2.2 241 12
Page 4 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
13.
Connect the hydraulic jacks to the highpressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.
EN905-2.2 206 08
KN905-2.2 238 24
14.
KN905-2.2 238 27
15.
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 5 (13)
Main Bearing
905-2.2
Dismantling
16.
Min. 0,1 mm
Min. 60 mm
KN905-2.2 238 28
EXH
17.
CAM
KN905-2.2 238 25
Page 6 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.2
Dismantling
18.
KN905-2.2 238 26
While pulling out the shell, it is recommended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
JM905-2.2 236 27
19.
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 7 (13)
905-2.2
Main Bearing
Dismantling
EN905-2.2 206 08
20.
Page 8 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.3
Overhaul
Overhaul
905-2.3
1 + 2.
KN905-2.2 238 25
2. Before remounting:
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 9 (13)
905-2.4
Main Bearing
Mounting
Mounting
905-2.4
1.
GN905-2.4 241 01
2.
To ensure that the shell is correctly mounted, check that the distance from the main
bearing support to the shell is equal in both
sides.
3. Mount the locking screws in the bearing
support.
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below
the crankshaft.
MC905-3.0 118 19
Wipe the contact surfaces between the upper and the lower bearing shells clean with
a non-fluffy piece of cloth.
XZS905-13 07
3.
Page 10 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.4
Mounting
4.
XZS905-13 09
5.
Note!
KN905-2.4 238 09
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 11 (13)
Main Bearing
905-2.4
Mounting
6.
'
!
Note!
"
(
I
H
7.
KN 905-1.1 208 09
KN905-2.4 238 14
8.
Page 12 (13)
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Main Bearing
905-2.4
Mounting
9.
KN905-2.4 238 15
When referring to this page, please quote Procedure M90502 Edition 0241
0$1 % : 'LHVHO $6
Page 13 (13)
Thrust Bearing
105-3
Data
SAFETY PRECAUTIONS
105-3
S50MC-C
0039
Special Data
Thrust Bearing
Stopped engine
M12
500 kg
Data
Ref.
Description
Value Unit
37 kg
30 kg
Hydraulic pressure
D13-02 dismantling
D13-01 tightening
1500-1650 bar
1500 bar
When referring to this page, please quote Data D10503 Edition 0039
MAN B&W Diesel A/S
Page 1 (2)
Thrust Bearing
105-3
Data
1175479-6.0
Plate
90551
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10503 Edition 0039
MAN B&W Diesel A/S
Thrust Bearing
905-3.1
Checking
Thrust
S50MC-C
0224 Bearing
Checking
905-3.1
1.
The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.
For a new engine the clearance is 0.5-1.0 mm,
and for an engine in service it must not exceed
2.0 mm.
GN905-3.1 224 01
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).
GN905-3.1 224 02
KN905-2.2 238 02
3.
When referring to this page, please quote Procedure M90503 Edition 0224
MAN B&W Diesel A/S
Page 1 (5)
905-3.2
Thrust Bearing
Dismantling
Dismantling
905-3.2
1.
GN905-3.2 224 01
2.
D05-07
GN905-3.2 224 02
D13-02
Page 2 (5)
When referring to this page, please quote Procedure M90503 Edition 0224
MAN B&W Diesel A/S
Thrust Bearing
905-3.2
Dismantling
3.
Note!
GN905-3.2 224 03
D05-06
GN905-3.2 224 04
4.
When referring to this page, please quote Procedure M90503 Edition 0224
MAN B&W Diesel A/S
Page 3 (5)
905-3.4
Thrust Bearing
Mounting
Mounting
905-3.4
1.
D13-01
GN905-3.4 224 01
GN905-3.4 224 02
2.
Page 4 (5)
When referring to this page, please quote Procedure M90503 Edition 0224
MAN B&W Diesel A/S
Thrust Bearing
905-3.4
Mounting
5.
GN905-3.2 224 01
4. Mount the lub. oil pipe for the thrust segments, the protective shield and the lub. oil
pipe on the bearing.
When referring to this page, please quote Procedure M90503 Edition 0224
MAN B&W Diesel A/S
Page 5 (5)
Journal Bearing
105-4
Data
SAFETY PRECAUTIONS
105-4
S50MC-C
0003
Special Data
Journal Bearing
Stopped engine
2x3m
Data
Ref.
Description
Value Unit
D-1
0.35 mm
D-2
0.65 mm
D-3
290 kg
D-4
20 kg
D-5
20 kg
D-6
Hydraulic pressure
dismantling
1500-1650 bar
Hydraulic pressure
tightening
1500 bar
D-7
When referring to this page, please quote Data D10504 Edition 0003
MAN B&W Diesel A/S
[ NJ
Page 1 (2)
Journal Bearing
105-4
Data
Plate
1175465-2
90551
Spare Parts
Plate Item No.
Description
Qty
91210-xxx 108
Screw
91210-xxx 121
Main bearing
Page 2 (2)
When referring to this page, please quote Data D10504 Edition 0003
MAN B&W Diesel A/S
Journal Bearing
905-4.1
Checking
Journal
0212 Bearing
S50MC-C
Checking
905-4.1
1.
1. Before any dismantling of the journal bearing, check the clearances as described in
Procedure 905-1.1.
KN905-2.2 238 01
Main bearings
Thrust bearing
KN905-2.2 238 02
2.
KN905-4.1 202 03
3.
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Page 1 (8)
905-4.2
Journal Bearing
Dismantling
Dismantling
905-4.2
2.
GN905-2.2 204 13
GN905-2.2 204 02
KN905-2.2 238 07
4.
Page 2 (8)
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Journal Bearing
905-4.2
Dismantling
5.
GN905-2.2 224 16
Connect the hydraulic jacks to the highpressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the adjacent
bearing.
GN905-2.2 224 17
6.
GN905-2.2 224 19
7.
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Page 3 (8)
905-4.2
Journal Bearing
Dismantling
8.
KN905-2.2 238 26
GN905-2.2 224 17
9.
Page 4 (8)
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Journal Bearing
905-4.3
Overhaul
Overhaul
905-4.3
1 + 2.
KN905-2.2 238 25
2. Before remounting:
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Page 5 (8)
905-4.4
Journal Bearing
Mounting
Mounting
905-4.4
1.
GN905-2.2 224 17
2.
To ensure that the shell is correctly mounted, check that the distance from the bearing support to the shell is equal in both
sides.
3. Remove the guide tool when the lower
bearing shell has been mounted.
Mount the locking screws in the bearing
support.
MC905-3.0 118 19
Lower the crankshaft and remove the hydraulic jacks and the crosspiece from under
the crankshaft.
Wipe the contact surfaces between the upper and the lower bearing shells clean with
a non-fluffy piece of cloth.
XZS905-13 07
3.
Page 6 (8)
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Journal Bearing
905-4.4
Mounting
4.
XZS905-13 09
6.
6.
Note!
KN905-2.4 238 09
MN913-1 208 11
7.
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
Page 7 (8)
Journal Bearing
905-4.4
Mounting
8.
8.
Note!
Before removing the hydraulic jacks,
check the top clearance between the
upper bearing shell and the journal.
KN 905-1.1 208 09
Note!
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
9.
KN905-2.4 238 14
10. Mount the lubricating oil pipe on the bearing cap, and mount the end cover.
KN905-2.4 238 15
10.
Page 8 (8)
When referring to this page, please quote Procedure M90504 Edition 0212
MAN B&W Diesel A/S
105-5
Data
SAFETY PRECAUTIONS
105-5
S50MC-C
0033
Special Data
Stopped engine
2x1m
1x3m
Data
1 x M12
Ref.
Description
D05-25
Damper housing,
upper part
D13-02
D13-01
D05-22
D05-19
Hydraulic pressure
dismantling
tightening
280 kg
1500-1650 bar
1500 bar
Screwing-in torque
outer studs
300 Nm
Tightening torque
nuts on inner studs
500 Nm
D05-18
Screwing-in torque
inner studs
D05-23
Tightening torque
horizontal screws
D05-24
Value Unit
1. tightening torque
2. tightening angle
150 Nm
450 Nm
or
100 Nm
25
When referring to this page, please quote Data D10505 Edition 0033
MAN B&W Diesel A/S
90662
Page 1 (2)
105-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10505 Edition 0033
MAN B&W Diesel A/S
905-5.1
Checking
Axial
S46-S50MC-C
0224 Vibration Damper
Checking
905-5.1
1.
For checking the effectiveness of the axial vibration damper, it is necessary to measure the
longitudinal movements of the fore end of the
crankshaft during running.
The measurement (or reading) should be taken
at the same r/min as during the sea trials. (Preferably 90% and 100% of MCR.)
As different equipment may be mounted on the
specific engines, the checking procedure describes three systems:
A: Electronic, with Axial Vibration Monitor
B. Mechanical, (without angle encoder fore)
C: Mechanical, with angle encoder fore.
KM905-7.1 35 01
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
Page 1 (8)
905-5.1
1.
Page 2 (8)
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
905-5.1
Checking
3.
S-2
DM905-7.1 74 05
4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.
S1
L1
S2
M90505-0229C10
L2
If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
Page 3 (8)
905-5.1
1.
MN905-5.1 214 05
2.
Page 4 (8)
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
905-5.1
Checking
3.
S2
BG905-5.1 223 03
4.
If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see
Procedure 905-5.2.
MA905-5.1 212 07
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
Page 5 (8)
905.5.2
1.
Dismantling of the axial vibration damper is carried out from the crankcase of cyl. No. 1.
D13-02
1. Turn the engine to 90 after TDC.
Dismount the lubricating oil pipes for the
main bearing and axial vibration damper.
GN905-5.2 204 01
3. By means of the tackle and wire rope, separate and raise the upper part of the damper housing to a position in which it is
possible to change the oil seals and
springs.
3.
D05-25
Note!
GN905-5.2 224 03
Before starting the work under the suspended upper part, secure the upper part
with, e.g. a wire rope or another tackle.
Page 6 (8)
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
905-5.3
Overhaul
Overhaul
905-5.3
1.
Note!
HG905-5.2 201 01
2.
HG905-5.2 201 02
Note!
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
Page 7 (8)
905-5.4
Mounting
Mounting
905-5.4
1.
D05-25
Before landing the upper part on the lower
part, be sure that the guide pins have entered the guide pin holes.
2. Mount and tighten the vertical nuts. See
Data.
Mount and tighten the hydraulic nuts. For
operation of the hydraulic tools, see Procedure 913-1.
Mount and tighten the horizontal screws.
See Data.
GN905-5.4 224 01
Note!
Search the crankcase to ensure that
there are no tools, shackles or rags left
behind.
2.
Mount the lubricating oil pipes.
D05-18
D05-19
D05-22
D13-01
Note!
GN905-5.4 224 02
D05-23
D05-24
Page 8 (8)
When referring to this page, please quote Procedure M90505 Edition 0224
MAN B&W Diesel A/S
Angle Encoder
105-8
Data
SAFETY PRECAUTIONS
105-8
MC
D10508 Data
Special Edition 0007
Angle Encoder
Stopped engine
Data
Ref.
Description
When referring to this page, please quote Data D10508 Edition 0007
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Angle Encoder
105-8
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
Page 2 (2)
When referring to this page, please quote Data D10508 Edition 0007
MAN B&W Diesel A/S
Angle Encoder
905-8.1
Checking
Angle
S42MC
0204 Encoder
Checking
905-8.1
HM906-7.0 56 01
MN905-8.1 202 03
When referring to this page, please quote Procedure M90508 Edition 0204
0$1 % : 'LHVHO $6
Page 1 (4)
905-8.2
Angle Encoder
Dismantling
Dismantling
905-8.2
XR905-8.2 204 01
XR905-8.2 204 02
XR905-8.2 204 03
Page 2 (4)
When referring to this page, please quote Procedure M90508 Edition 0204
0$1 % : 'LHVHO $6
Angle Encoder
905-8.3
Adjustment
Adjustment
905-8.3
HM906-7.0 56 01
BG906-7.0 58 02
MN905-8.3 202 02
When referring to this page, please quote Procedure M90508 Edition 0204
0$1 % : 'LHVHO $6
Page 3 (4)
905-8.4
Angle Encoder
Mounting
Mounting
905-8.4
1.
XR905-8.4 204 01
2.
XR905-8.4 204 02
XR905-8.4 204 03
3.
Page 4 (4)
When referring to this page, please quote Procedure M90508 Edition 0204
0$1 % : 'LHVHO $6
Plate
P90551-0227
P90551
Crankshaft, Thrust Shaft, Main Bearing, Etc. -Panel
0227
When referring to this page, please quote Plate P90551 Edition 0227
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90551-0227
Item
No.
015
027
040
076
088
090
100
111
123
135
172
184
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90551 Edition 0227
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90561 Edition 0093
Plate
P90561-0093
Page 1 (2)
Plate
P90561-0093
Item
No.
Item Description
021
033
045
057
069
070
082
094
104
130
141
165
200
Jack-hydraulic, complete
Jack-hydraulic, complete
Jack-hydraulic, support
Stud
Nut
Sealing ring with back-up ring
Sealing ring with back-up ring
Sealing ring with back-up ring
Spanner
Ball handle
Lifting tool
Stud setter
Hydraulic tool set, complete
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P90561 Edition 0093
Crankshaft - Tools
Plate
P90562-0125
P90562
Crankshaft - Tools
0125
When referring to this page, please quote Plate P90562 Edition 0125
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90562-0125
Item
No.
015
039
052
Crankshaft - Tools
Item Description
Item
No.
Item Description
Support
Screw with special head
Nut
Page 2 (2)
When referring to this page, please quote Plate P90562 Edition 0125
MAN B&W Diesel A/S
Tools
Crankshaft - Measuring Tools
MAN B&W Diesel
When referring to this page, please quote Plate P90564 Edition 0018
Plate
P90564-0018
Page 1 (2)
Plate
P90564-0018
Item
No.
016
Page 2 (2)
Tools
Crankshaft - Measuring Tools
MAN B&W Diesel
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90564 Edition 0018
Plate
P90570-0004
P90570
Thrust
0004 Shaft - Tools
When referring to this page, please quote Plate P90570 Edition 0004
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90570-0004
Item
No.
019
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90570 Edition 0004
MAN B&W Diesel A/S
Plate
P90572-0003
P90572
Main
0003 Bearing - Measuring Tools
When referring to this page, please quote Plate P90572 Edition 0003
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90572-0003
Item
No.
010
021
045
057
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90572 Edition 0003
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90573 Edition 0002
Plate
P90573-0002
Page 1 (2)
Plate
P90573-0002
Item
No.
027
039
040
052
076
090
206
Page 2 (2)
Item Description
Item
No.
Item Description
Support
Jack-hydraulic, complete
O-ring with back-up ring
O-ring with back-up ring
Spanner
Tommy bar
Hydraulic tool set, complete
When referring to this page, please quote Plate P90573 Edition 0002
0041
0236
0054
0239
0036
0214
0034
0216
0024
0220
0007
0203
0173
0046
0005
0003
Chain, Data
Chain
Chain Tightener, Data
Chain Tightener
Camshaft, Data
Camshaft
Camshaft Bearings, Data
Camshaft Bearings
Moment Compensator, Data
Moment Compensator
Replacement of Cams on Camshaft, Data
Replacement of Cams on Camshaft
Chain Drive and Camshaft - Panel
Camshaft - Hydraulic Tools
Crankshaft - Pin Gauge
Camshaft - Pin Gauge
Chain
106-1
Data
SAFETY PRECAUTIONS
106-1
L60MC-C
D10601 Data
Special Edition 0041
Chain
Stopped engine
Data
Ref.
D06-10
D06-11
D06-12
Description
When referring to this page, please quote Data D10601 Edition 0041
MAN B&W Diesel A/S
Value Unit
3.0 mm
889 mm
897.9 mm
Page 1 (2)
Chain
106-1
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90651
P90651
P91356
P91359
Page 2 (2)
When referring to this page, please quote Data D10601 Edition 0041
MAN B&W Diesel A/S
Chains
906-1.1
Checking
Chains
S50MC-C
0236
Checking
906-1.1
4.
HN906-1.1 204 04
D06-10
5.
HN906-1.1203 05
When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
Page 1 (4)
Chains
906-1.1
Checking
7.
D06-11
D06-12
8
11-5
6-06
D0 D 1 2
x.
Ma D06MN906-1.1 226 07
Page 2 (4)
When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
Chains
906-1.2
Dismantling
Dismantling
906-1.2
1.
GN906-1.2 203 01
2.
GN906-1.2 203 02
3.
Note!
If the chain is to be completely removed,
contact MAN B&W Diesel for further
information.
GN906-1.2 203 03
When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
Page 3 (4)
906-1.4
Chains
Mounting
Mounting
906-1.4
1.
GN906-1.4 203 01
Page 4 (4)
When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
106-2
Chain Tightener
Data
SAFETY PRECAUTIONS
X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Data
Ref.
Description
Value
Unit
D06-21
720/12
/ hex
D06-23
600/10
D06-25
0.1
mm
D06-26
Max.distance
265
mm
D06-66
D max.
165
mm
When referring to this page, please quote Data D10602 Edition 0054
MAN B&W Diesel A/S
Page 1 (2)
106-2
Chain Tightener
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
P91366
Page 2 (2)
58
Feeler gauge
When referring to this page, please quote Data D10602 Edition 0054
MAN B&W Diesel A/S
Chain Tightener
906-2.3
Adjusting
Chain
S50MC-C
0239 Tightener
Adjusting
906-2.3
1.
M90602-0239O01
M90602-0239O02
2.
3.
D06-21
M90602-0239O03
D06-25
When referring to this page, please quote Procedure M90602 Edition 0239
MAN B&W Diesel A/S
Page 1 (2)
Chain Tightener
906-2.3
Adjusting
4.
M90602-0239O04
6. Measure distance X.
7. If the chain is worn (X > D06-66 mm), repeat the procedure from step 1, but tighten
nut B only to the reduced tightening angle,
see Data D06-23.
If distance X exceeds the max. distance
(see Data), find and eliminate the cause of
the abnormal chain elongation, e.g. a defective chain, damaged chain wheels or
bearings, etc. Repeat the procedure from
step 1.
5.
M90602-0239O05
6.
M90602-0239O06
Page 2 (2)
When referring to this page, please quote Procedure M90602 Edition 0239
MAN B&W Diesel A/S
Camshaft
106-3
Data
SAFETY PRECAUTIONS
106-3
S50MC-C
D10603 Data
Special Edition 0036
Camshaft
Stopped engine
Data
Ref.
D06-27
D06-28
D06-29
D06-30
Description
When referring to this page, please quote Data D10603 Edition 0036
MAN B&W Diesel A/S
Value Unit
2
3.5 mm
697 mm
340 mm
Page 1 (2)
Camshaft
106-3
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
P90664
P90668
Page 2 (2)
When referring to this page, please quote Data D10603 Edition 0036
MAN B&W Diesel A/S
Camshaft
906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1
1.
HM906-7.0 56 01
GN906-3.1 203 02
2.
When referring to this page, please quote Procedure M90603 Edition 0214
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.
D06-30
D06-28
Check the setting of the starting air distributor. See Procedure 907-1.1.
5. When checking the camshaft position, also
check the running surface of the cams.
GN906-3.1 203 03
D06-27
5.
GN906-3.1 203 05
GN906-3.1 203 06
6.
Page 2 (3)
When referring to this page, please quote Procedure M90603 Edition 0214
MAN B&W Diesel A/S
Camshaft
906-3.3
Adjustment
Adjustment
906-3.3
1.
GN906-3.3 203 01
D06-28
D06-27
When referring to this page, please quote Procedure M90603 Edition 0214
MAN B&W Diesel A/S
Page 3 (3)
Camshaft Bearings
106-4
Data
SAFETY PRECAUTIONS
106-4
S50MC-C
D10604 Data
Special Edition 0034
Camshaft Bearings
Stopped engine
Data
Ref.
D06-31
D06-33
D06-34
D06-37
D06-65
Description
When referring to this page, please quote Data D10604 Edition 0034
MAN B&W Diesel A/S
Value Unit
125
3 0.3
0.1
13
7.35
Nm
mm
mm
kg
mm
Page 1 (2)
Camshaft Bearings
106-4
Data
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
P91351
P91351
P90651
P91356
P91359
P91366
Page 2 (2)
Item
No.
22
58
152
61
Description
When referring to this page, please quote Data D10604 Edition 0034
MAN B&W Diesel A/S
Camshaft Bearing
906-4.1
Checking
Camshaft
S46MC-C Bearing
0216
Checking
906-4.1
1.
GN906-4.1 203 01
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
Page 1 (6)
906-4.2
Camshaft Bearing
Dismantling
Dismantling
906-4.2
1.
Warning!
Before dismantling any camshaft bearings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.
See Procedure 906-2.3.
GN906-4.2 203 01
2.
3.
GN906-4.2 203 03
D06-37
Page 2 (6)
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
Camshaft Bearing
906-4.2
Dismantling
4.
GN906-4.2 203 04
GN906-4.2 203 05
5.
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
Page 3 (6)
Camshaft Bearing
906-4.3
Overhaul
Overhaul
906-4.3
1.
GN906-4.3 203 01
D06-34
Page 4 (6)
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
Camshaft Bearing
906-4.4
Mounting
Mounting
906-4.4
2.
1. Clean the bearing journal, the bearing support and the bearing shell.
2. Coat the bearing shell with oil, mount the
shell on the camshaft, and turn it into place.
3. Place the bearing cap on the camshaft next
to the exhaust cam.
GN906-4.4 203 02
Note!
Remove the eye bolts and mount the outermost bearing cap screw.
3.
GN906-4.4 203 03
4.
GN906-4.4 203 04
D06-31
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
D06-33
Page 5 (6)
Camshaft Bearing
906-4.4
Mounting
5.
GN906-4.4 203 05
D06-33
GN906-4.4 203 06
6.
GN906-4.4 203 07
7.
Page 6 (6)
When referring to this page, please quote Procedure M90604 Edition 0216
0$1 % : 'LHVHO $6
106-5
Moment Compensator
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X
Stopped engine
Data
Ref.
Description
Value
Unit
D06-38
F=
D06-44
L=
mm
D06-45
L=
mm
When referring to this page, please quote Data D10605 Edition 0024
MAN B&W Diesel A/S
11800
Page 1 (2)
106-5
Moment Compensator
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
Page 2 (2)
Item No.
Description
When referring to this page, please quote Data D10605 Edition 0024
MAN B&W Diesel A/S
906-5.1
Moment Compensator
Checking
If dismantling has been necessary, the flyweights must be assembled in the correct position in relation to the engine crankshaft. Incorrectly mounted flyweights can cause (heavy)
vibrations of the engine.
Viewed from
FORE
Note!
The following applies to a clockwise-rotating engine
90
M90605 0220C01
Cylinder No. 1
Check that the flyweights point vertically downwards (max. deviation one-half chainwheel
tooth pitch).
Cylinder No. 1
Viewed from
FORE
M90605 0220C02
99
Cylinder No. 1
Cylinder No. 1
Viewed from
AFT
Check that the flyweights point vertically downwards (max. deviation one-half chainwheel
tooth pitch) and then mount the chain.
Tighten the chain in accordance with the instruction.
See Procedure 906-5.3.
105
15
M90605 0220C03
Note!
Cylinder No. 1
When referring to this page, please quote Procedure M90605 Edition 0220
MAN B&W Diesel A/S
Cylinder No. 1
Page 1 (3)
906-5.2
Moment Compensator
Adjustment
1. When tightening the chain, bring the two
flyweights to a vertical downward position.
1.
M90605 0220O01
3. Tighten nut B1 until the spring is completely compressed. Then loosen nut B1
until the length of the spring matches the
number of mm indicated on the dataplate
mounted on the spring, (D06-38, D06-44,
D06-45).
2.
A2
B2
M90605 0220O02
A1
M90605 0220O03
3.
Page 2 (3)
B1
When referring to this page, please quote Procedure M90605 Edition 0220
MAN B&W Diesel A/S
906-5.2
Moment Compensator
Adjustment
4. Tighten nut A1 lightly.
4.
A2
A1
5.
B1
M90605 0220O05
B2
When referring to this page, please quote Procedure M90605 Edition 0220
MAN B&W Diesel A/S
Page 3 (3)
106-6
Data
SAFETY PRECAUTIONS
106-6
S50MC-C
D10606 Data
Special Edition 0007
Stopped engine
Data
Ref.
D06-47
D06-48
D06-49
D06-50
D06-51
D06-52
D06-53
Description
When referring to this page, please quote Data D10606 Edition 0007
MAN B&W Diesel A/S
Value Unit
560
50
880
65
145
55
220
Nm
Nm
Nm
mm
mm
mm
mm
Page 1 (2)
106-6
Data
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
P91351
P91351
P91351
P91359
Page 2 (2)
22
58
105
When referring to this page, please quote Data D10606 Edition 0007
MAN B&W Diesel A/S
906-6.2
Dismantling
Replacement of Cams on Camshaft
S42MC
0203
Dismantling
906-6.2
1.
Fuel Cam
1. Remove the front cover of the camshaft
housing.
2. Lift the roller guide from the cam in question. See Procedures 908-5 or 909-5.
3. Turn the camshaft so that the marking
scratch can be seen.
XZ906-6.2 201 01
XZ906-6.2 201 02
2.
XZ906-6.2 201 04
4.
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
D06-50
Page 1 (7)
906-6.2
Dismantling
5.
XZ906-6.2 201 05
XZ906-6.2 201 06
6.
7.
XZ906-6.2 201 07
D06-51
Page 2 (7)
D06-51
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
906-6.2
Dismantling
9.
Exhaust Cam
9. Remove the front cover of the camshaft
housing.
10. Lift the roller guide from the cam in question. See Procedure 908-5.
XZ906-6.2 201 01
XZ906-6.2 201 10
10.
XZ906-6.2 201 11
11.
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
D06-52
Page 3 (7)
906-6.2
12.
XZ906-6.2 201 12
XZ906-6.2 201 13
13.
XZ906-6.2 201 14
14.
Page 4 (7)
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
906-6.2
Dismantling
15.
XZ906-6.2 201 15
D06-53
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
D06-53
Page 5 (7)
906-6.4
1.
Fuel Cam
1. Before mounting the two-part spare cam,
the bore and the area on the shaft must be
degreased.
Place the two-part spare cam on the shaft,
mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.
2. Make sure that the marking scratches on
the cam and the camshaft coincide, and
that the running surface of the cam is opposite the roller.
Tighten the screws just hard enough to
avoid that the cam slips when the roller
guide is lowered onto the cam.
XZ906-6.4 201 01
2.
XZ906-6.4 201 02
D06-49
Page 6 (7)
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
906-6.4
Mounting
4.
Exhaust Cam
4. Mount the indicator drive cam and adjust
according to Chapter 706 in the Operation
manual when fitted.
Tighten the self-locking nuts as stated in
D06-48.
XZ906-6.4 201 04
5.
XZ906-6.4 201 05
XZ906-6.4 201 06
6.
D06-47
D06-49
When referring to this page, please quote Procedure M90606 Edition 0203
0$1 % : 'LHVHO $6
Page 7 (7)
When referring to this page, please quote Plate P90651 Edition 0173
MAN B&W Diesel A/S
Plate
P90651-0173
Page 1 (2)
Plate
P90651-0173
Item
No.
019
020
044
056
068
152
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90651 Edition 0173
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90662 Edition 0046
MAN B&W Diesel A/S
Plate
P90662-0046
Page 1 (2)
Plate
P90662-0046
Item
No.
020
032
044
056
068
093
103
211
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90662 Edition 0046
MAN B&W Diesel A/S
Plate
P90664-0005
When referring to this page, please quote Plate P90664 Edition 0005
Page 1 (2)
Plate
P90664-0005
Item
No.
021
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90664 Edition 0005
MAN B&W Diesel A/S
Plate
P90668-0003
When referring to this page, please quote Plate P90668 Edition 0003
Page 1 (2)
Plate
P90668-0003
Item
No.
011
Page 2 (2)
Item
No.
Item Description
Pin gauge
When referring to this page, please quote Plate P90668 Edition 0003
MAN B&W Diesel A/S
0017
0216
0032
0214
107-1
Data
SAFETY PRECAUTIONS
107-1
S46MC-C
D10701 Data
Special Edition 0017
Stopped engine
Data
Ref.
D07-01
D07-03
D07-04
D07-05
Description
When referring to this page, please quote Data D10701 Edition 0017
MAN B&W Diesel A/S
Value Unit
90
0.9 - 1.6
1.0 - 3.0
1.0 - 2.0
Nm
mm
mm
mm
Page 1 (2)
107-1
Data
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
Page 2 (2)
When referring to this page, please quote Data D10701 Edition 0017
MAN B&W Diesel A/S
907-1.1
Checking
Starting Air
S46MCC Distributor
0216
Checking
907-1.1
1.
GN906-3.1 203 02
2.
EN907-1.3 204 02
When referring to this page, please quote Procedure M90701 Edition 0216
0$1 % : 'LHVHO $6
Page 1 (3)
907-1.3
Adjustment
Adjustment
907-1.3
1.
GN906-3.1 203 02
2.
EN907-1.3 204 02
GN907-1.3 203 03
3.
Page 2 (3)
D07-03
When referring to this page, please quote Procedure M90701 Edition 0216
0$1 % : 'LHVHO $6
907-1.3
Adjustment
4.
D07-01
5.
GN907-1.3 203 02
6.
EN907-1.3 204 06
D07-01
When referring to this page, please quote Procedure M90701 Edition 0216
0$1 % : 'LHVHO $6
D07-04
Page 3 (3)
107-2
Data
SAFETY PRECAUTIONS
107-2
S46MC-C
D10702 Data
Special Edition 0032
Stopped engine
Data
Ref.
D07-09
D07-10
D07-11
D07-12
Description
When referring to this page, please quote Data D10702 Edition 0032
MAN B&W Diesel A/S
Value Unit
180
17520
50/30
20
Nm
Nm
Nm/
kg
Page 1 (2)
107-2
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90151
P90151
Page 2 (2)
95
105
When referring to this page, please quote Data D10702 Edition 0032
MAN B&W Diesel A/S
907-2.2
Dismantling
Starting Air
S46MC-C Valve
0214
Dismantling
907-2.2
1.
GN907-2.2 203 01
2.
GN907-2.2 203 02
D07-12
When referring to this page, please quote Procedure M90702 Edition 0214
0$1 % : 'LHVHO $6
Page 1 (5)
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
EN907-2.3 0212 02
2.
Page 2 (5)
When referring to this page, please quote Procedure M90702 Edition 0214
0$1 % : 'LHVHO $6
907-2.3
Overhaul
3.
GN907-2.3 203 03
EN907-2.3 0212 05
5.
When referring to this page, please quote Procedure M90702 Edition 0214
0$1 % : 'LHVHO $6
Page 3 (5)
907-2.3
6.
D07-09
EN907-2.3 0212 06
EN907-2.3 0212 07
7.
Page 4 (5)
When referring to this page, please quote Procedure M90702 Edition 0214
0$1 % : 'LHVHO $6
907-2.4
Mounting
Mounting
907-2.4
1.
GN907-2.4 203 01
2.
GN907-2.4 203 02
D07-12
3.
GN907-2.4 203 03
D07-10
or
D07-11
When referring to this page, please quote Procedure M90702 Edition 0214
0$1 % : 'LHVHO $6
Page 5 (5)
0017
0212
0087
0256
0017
0218
0015
0210
0002
0203
0020
0210
0200
0043
0014
0016
High-Pressure Pipe
108-1
Data
SAFETY PRECAUTIONS
108-1
S50MC-C
0017
Special Data
High-Pressure Pipe
Stopped engine
Data
Ref.
Description
Value Unit
D-1
34 kg
D-2
Tightening torque
High-pressure pipe
36 Nm
When referring to this page, please quote Data D10801 Edition 0017
MAN B&W Diesel A/S
Page 1 (2)
High-Pressure Pipe
108-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10801 Edition 0017
MAN B&W Diesel A/S
High-Pressure Pipe
908-1.2
Dismantling
High-Pressure Pipe
S50MC-C
0212
Dismantling
908-1.2
1.
D-1
GN908-1.2 203 01
GN908-1.2 203 02
2.
When referring to this page, please quote Procedure M90801 Edition 0212
0$1 % : 'LHVHO $6
Page 1 (3)
908-1.3
High-Pressure Pipe
Overhaul
Overhaul
908-1.3
1.
GN908-1.3 203 01
Note!
The seats cannot be reconditioned.
If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:
Lift the thrust flange upwards.
Remove the spring ring from the two-part
sleeve.
3. Remove the thrust flange from the pipe
end.
DM908-1.1 61 02
DM908-1.1 61 03
3.
Page 2 (3)
When referring to this page, please quote Procedure M90801 Edition 0212
0$1 % : 'LHVHO $6
High-Pressure Pipe
908-1.4
Mounting
Mounting
908-1.4
1.
GN908-1.2 203 01
2.
GN908-1.4 203 02
D-2
When referring to this page, please quote Procedure M90801 Edition 0212
0$1 % : 'LHVHO $6
Page 3 (3)
Exhaust Valve
MAN B&W Diesel
108-2
Data
X
X
X
X
X
X
X
X
X
X
X
Data
Ref.
D08-04
D08-05
D08-06
D08-07
D08-09
D08-10
D08-11
D08-12
D08-13
D08-14
D08-15
D08-16
D08-17
D08-18
D08-19
D08-20
D08-21
D08-24
D08-25
D08-26
D08-27
D08-28
D08-29
D08-30
D13-01
D13-02
Description
Safety valve, opening pressure
Screws for lifting eye bolt, tightening torque
Oil cylinder, tightening torque
Safety valve, tightening torque
Bottom piece seat, grinding angle
Valve spindle seat, grinding angle
Bottom piece seat, max. grinding
Gap of bottom piece seat
Spindle, max. burn-off
Spindle, max. grinding
Spindle stem, measuring area, min.
Spindle stem, measuring area, max.
Spindle stem, min. diameter
Bushing max. diameter, top
Bushing max. diameter, bottom
Oil cylinder max. inside diameter
Piston rings, min. thickness
Exhaust valve, complete
Exhaust valve housing
Oil cylinder
Air cylinder
Spindle
Bottom piece
Air piston
Hydraulic pressure, mounting
Hydraulic pressure, dismantling
When referring to this page, please quote Data D10802 Edition 0087
Value
Unit
21
50
70
50 - 80
29.9 - 30.0
30.5 - 30.6
2.3
1.0
8.0
2.0
235
345
59.8
60.6
62.0
71.2
2.6
460
260
65
20
45
55
6
1500
1400-1650
bar
Nm
Nm
Nm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
kg
kg
bar
bar
Page 1 (2)
Exhaust Valve
108-2
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
P90851
065
P90851
077
P90851
089
P90851
090
P90851
150
P90851
161
P90851
185
P90862
P91351
010
P91351
034
P91351
058
P91351
117
Page 2 (2)
When referring to this page, please quote Data D10802 Edition 0087
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
1.
The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the groove in the
piston.
During engine operation, the spindle must
rotate. The rotation can vary with unit and
engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is
finished, lift the rotation indicator and lock
it in the top position.
M90802 0252C01
The engine must run when the valve function and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90 and let it rest on the air piston.
On Surface
InGroove
2.
M90802 0256C02
When referring to this page, please quote Procedure M90802 Edition 0256
Page 1 (24)
Exhaust Valve
908-2.1
Checking
M90802 0254C03
Check the tightness of the sealing rings between the bottom piece and the exhaust
valve housing. IF water flows from the small
bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is
leaking.
If water flows from the any of the rings, the
exhaust valve must be dismounted and the
sealing rings replaced.
Check with stopped engine:
4.
In connection with port stays, at an interval
of e.g. one month, an easy check of all exhaust valves is recommended.
4. Check of spindle drop-down time:
Engage all rotation indicators on the exhaust valves.
SAFETY AIR
SUPPLY
AIR SUPPLY
EXHAUST VALVE
M90802 0256C04
Page 2 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.1
Checking
M90802 0256C05
C
B
When referring to this page, please quote Procedure M90802 Edition 0256
Page 3 (24)
908-2.2
Exhaust Valve
Dismantling
M90802 0256D01
M90802 0256D02
2.
Page 4 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.2
Dismantling
M90802 0256D03
Loosen the screws which attach the intermediate pipe to the exhaust valve housing.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 913-1.
M90802 0256D04
D13 02
When referring to this page, please quote Procedure M90802 Edition 0256
Page 5 (24)
Exhaust Valve
908-2.2
Dismantling
D08 24
M90802 0256D06
Page 6 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
1. Oil cylinder
1.
Place the exhaust valve on a wooden support on the platform.
D08 26
2.
M90802 0256O02
Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.
M90802 0256O01
Relieve the air pressure through the non-return valve from below the piston. Use a
small screwdriver to press the ball into the
non-return valve. Cover the non-return
valve with a rag to catch the oil drops.
When referring to this page, please quote Procedure M90802 Edition 0256
Page 7 (24)
908-2.3
Exhaust Valve
Overhaul
3. Spindle
3.
D08-24
M90802 0256O04
4.
M90802 0256O05
D08-29
Page 8 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
D08-30
D08-27
6. Guide bushing
Clean the exhaust valve housing.
Inspect the bushing in the spindle guide for
wear and measure the top and bottom diameters. See Data.
M90802 0256O06
6.
M90802 0255O10
D08 18
When referring to this page, please quote Procedure M90802 Edition 0256
D08 19
Page 9 (24)
908-2.3
Exhaust Valve
Overhaul
7. Bushing renewal
7.
If it proves necessary to replace the bushing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.
Alternatively, if the extractor tool is available, mount the extractor tool and pull up
the bushing.
The extractor tool is optional, and can be
ordered as spare part.
When a new bushing is mounted, mount a
new O-ring for sealing between bushing
and exhaust valve housing. Mount and
tighten the screws for the bushing.
M90802 0256O08
M90802 0256O09
8.
Page 10 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
G3
D08 12
D08 09
M90802 0255O14
G2
D08 11
10.
M90802 0255O15
When referring to this page, please quote Procedure M90802 Edition 0256
Page 11 (24)
908-2.3
Exhaust Valve
Overhaul
M90802 0256O12
12.
M90802 0256O13
Land the exhaust valve housing on the bottom piece. Mount and tighten the retaining
screws for the bottom piece.
Page 12 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
M90802 0256O14
14.
For the maximum allowable burn-off, see
Data D08-13.
G1
D08 14
F1
D08 10
A
D08 13
When referring to this page, please quote Procedure M90802 Edition 0256
Page 13 (24)
Exhaust Valve
908-2.3
Overhaul
D08 16 D08 15
D08 17
M90802 0252O19
16.
M90802 0255O16
D08 28
Page 14 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
M90802 0256O18
18.
M90802 0256O19
When referring to this page, please quote Procedure M90802 Edition 0256
Page 15 (24)
Exhaust Valve
908-2.3
Overhaul
Compressed Air
M90802 0256O20
Place the safety valve in the pressure testing device. Connect the testing device with
the high pressure pump by means of a
hose.
Check the opening pressure, see Data.
If the opening pressure is not correct,
loosen the lock nut and, using a screwdriver, adjust the safety valve until the correct pressure is indicated. Tighten the lock
nut and test the opening pressure once
more.
20.
D08-04
M90802 0256O21
D08-07
Page 16 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
908-2.3
Overhaul
21.
Lubricate the O-rings on the spindle bushing.
Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines
are not equipped with the locating pin
M90802 0256O22
Note!
22.
M90802 0252O32
Note!
When referring to this page, please quote Procedure M90802 Edition 0256
Page 17 (24)
908-2.3
Exhaust Valve
Overhaul
M90802 0256O24
M90802 0256O25
24.
Page 18 (24)
Compressed Air
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
26.
M90802 0255O37
D08-20
M90802 0256O26
Place the oil cylinder in a horizontal position. Remove the flange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylinder diameter. If the diameter of the oil cylinder exceeds Data D08-20, either renew the
liner or send the complete oil cylinder to an
authorised MAN B&W workshop for overhaul, depending on the valve model.
When referring to this page, please quote Procedure M90802 Edition 0256
Page 19 (24)
908-2.3
Exhaust Valve
Overhaul
M90802 0253O42
D08 21
28.
M90802 0256O31
D08-05
Page 20 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.3
Overhaul
D08 06
M90802 0256O32
When referring to this page, please quote Procedure M90802 Edition 0256
Page 21 (24)
Exhaust Valve
908-2.4
Mounting
1.
D08 24
M90802 0256M01
G3
2.
Copper Grease
M90802 0256M02
Vaseline
Page 22 (24)
When referring to this page, please quote Procedure M90802 Edition 0256
Exhaust Valve
MAN B&W Diesel
908-2.4
Mounting
bore, guiding it in accordance with the exhaust flanges and the guide pin on the exhaust side of the exhaust valve.
3.
D13 01
M90802 0256M03
4.
M90802 0256M04
M90802 0256M05
5.
When referring to this page, please quote Procedure M90802 Edition 0256
Page 23 (24)
Exhaust Valve
908-2.4
Mounting
6.
M90802 0256M06
7.
Engage the indicators on top of the exhaust valves and wait until the exhaust
valves are closed.
M90802 0256M07
Closed Valve
Page 24 (24)
Open Valve
When referring to this page, please quote Procedure M90802 Edition 0256
108-3
Data
SAFETY PRECAUTIONS
108-3
S50MC-C
0017
Special Data
Stopped engine
Data
Ref.
Description
D-1
33 kg
D-2
70 kg
D-3
71.2 mm
D-4
2.6 mm
D-5
Hydraulic actuator
tightening torque or
tightening angle
300 Nm
25
D-6
Locking plate
tightening torque
Value Unit
10 Nm
When referring to this page, please quote Data D10803 Edition 0017
MAN B&W Diesel A/S
Page 1 (2)
108-3
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10803 Edition 0017
MAN B&W Diesel A/S
908-3.1
Checking
Exhaust Valve Actuator
S50MC-C
0218
Checking
908-3.1
1.
D-1
DM908-3.0 92 02
When referring to this page, please quote Procedure M90803 Edition 0218
0$1 % : 'LHVHO $6
Page 1 (4)
908-3.2
Dismantling
Dismantling
908-3.2
1.
DM908-3.0 92 02
D-2
Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.
Unscrew the nuts on the two short studs,
then loosen the nuts on the long studs successively until the roller guide spring is relieved.
Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller
guide.
DM908-3.0 92 03
HM908-3.0 70 03
Page 2 (4)
When referring to this page, please quote Procedure M90803 Edition 0218
0$1 % : 'LHVHO $6
908-3.3
Overhaul
Overhaul
908-3.3
1.
D-4
HM908-3.0 69 04
Check the bore of the oil cylinder for possible scores and measure it for wear.
3.
DM908-3.0 92 06
D-3
When referring to this page, please quote Procedure M90803 Edition 0218
0$1 % : 'LHVHO $6
Page 3 (4)
908-3.4
Mounting
Mounting
908-3.4
1.
D-6
2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.
KC908-3.0 76 05
2.
D-2
Note!
Use only the tightening angle OR the
tightening torque, NOT both.
D-5
DM908-3.0 92 08
DM908-3.0 92 09
3.
Page 4 (4)
When referring to this page, please quote Procedure M90803 Edition 0218
0$1 % : 'LHVHO $6
108-4
Data
SAFETY PRECAUTIONS
108-4
S50MC-C
0015
Special Data
Stopped engine
Data
Ref.
Description
D-1
37 kg
Max. clearance
roller/bushing/shaft pin
0.5 mm
D-2
Value Unit
When referring to this page, please quote Data D10804 Edition 0015
MAN B&W Diesel A/S
Page 1 (2)
108-4
Data
Plate
1175386-1
90851
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10804 Edition 0015
MAN B&W Diesel A/S
908-4.1
Checking
Exhaust Valve Roller Guide
S50MC-C
0210
Checking
908-4.1
2.
1. The exhaust valve roller guide can be partially checked while mounted on the engine,
using the following procedure:
Lift the roller guide.
See Procedure 908-4.2.
2. Remove the camshaft inspection cover.
GN908-4.1 203 01
5.
'
GN908-4.3 203 02
When referring to this page, please quote Procedure M90804 Edition 0210
0$1 % : 'LHVHO $6
Page 1 (4)
908-4.1
Page 2 (4)
When referring to this page, please quote Procedure M90804 Edition 0210
0$1 % : 'LHVHO $6
908-4.2
Dismantling
Dismantling
908-4.2
1.
GN908-4.2 203 01
2.
GN908-4.2 203 02
D-1
When referring to this page, please quote Procedure M90804 Edition 0210
0$1 % : 'LHVHO $6
Page 3 (4)
908-4.4
Mounting
Mounting
908-4.4
1.
D-1
GN908-4.2 203 02
Page 4 (4)
When referring to this page, please quote Procedure M90804 Edition 0210
0$1 % : 'LHVHO $6
108-5
Data
SAFETY PRECAUTIONS
108-5
S50MC-C
0002
Special Data
Stopped engine
Data
Ref.
Description
Value Unit
When referring to this page, please quote Data D10805 Edition 0002
MAN B&W Diesel A/S
Page 1 (2)
108-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10805 Edition 0002
MAN B&W Diesel A/S
908-5.1
Checking
Exhaust Valve Cam
S50MC-C
0203
Checking
908-5.1
AHEAD
When referring to this page, please quote Procedure M90805 Edition 0203
0$1 % : 'LHVHO $6
Page 1 (1)
Exhaust Valve
108-7
Data
SAFETY PRECAUTIONS
108-7
S50MC-C
0020
Special Data
Exhaust Valve
Stopped engine
Data
Ref.
Description
D-1
Value Unit
34 kg
When referring to this page, please quote Data D10807 Edition 0020
MAN B&W Diesel A/S
Page 1 (2)
Exhaust Valve
108-7
Data
Plate
1175386-1
90851
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D10807 Edition 0020
MAN B&W Diesel A/S
Exhaust Valve
908-7
Special Running
Exhaust Valve
S50MC-C
0210
Special
908-7 Running
3.
GN908-7 203 03
4.
GN908-4.1 203 01
4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC.
5.
GN908-7 203 05
When referring to this page, please quote Procedure M90807 Edition 0210
0$1 % : 'LHVHO $6
Page 1 (3)
908-7
Exhaust Valve
Special Running
7.
KC908-6.0 18 02
The tool will keep the piston of the air cylinder in the bottom position and thus keep
the exhaust valve open.
GN908-7 203 08
8.
Page 2 (3)
When referring to this page, please quote Procedure M90807 Edition 0210
0$1 % : 'LHVHO $6
Exhaust Valve
908-7
Special Running
9.
GN908-7 203 05
GN908-7 203 11
11.
When referring to this page, please quote Procedure M90807 Edition 0210
0$1 % : 'LHVHO $6
Page 3 (3)
When referring to this page, please quote Plate P90851 Edition 0200
MAN B&W Diesel A/S
Plate
P90851-0200
Page 1 (2)
Plate
P90851-0200
Item
No.
016
028
041
053
065
077
089
090
124
150
161
173
185
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P90851 Edition 0200
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90862 Edition 0043
MAN B&W Diesel A/S
Plate
P90862-0043
Page 1 (2)
Plate
P90862-0043
Item
No.
Item Description
028
030
053
065
077
090
100
207
Jack-hydraulic, complete
Support
O-ring with back-up ring
O-ring with back-up ring
Tommy bar
Spanner
Stud setter
Hydraulic toolset, complete
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P90862 Edition 0043
MAN B&W Diesel A/S
Plate
P90863-0014
When referring to this page, please quote Plate P90863 Edition 0014
Page 1 (2)
P90863
Exhaust Valve - Extra Tools
0014
Plate
P90863-0014
Item
No.
011
Item Description
Item
No.
Item Description
Worktable
Page 2 (2)
When referring to this page, please quote Plate P90863 Edition 0014
MAN B&W Diesel A/S
Plate
P90863-0016
P90863
Exhaust Valve - Extra Tools
0016
When referring to this page, please quote Plate P90863 Edition 0016
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90863-0016
Item
No.
011
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P90863 Edition 0016
MAN B&W Diesel A/S
0055
0240
0004
0205
0044
0229
0050
0224
0052
0223
0042
0219
0034
0214
0043
0217
0025
0214
0047
0231
0038
0222
0031
0206
0060
0235
0050
0226
0016
0204
90951
90961
90966
90968
90974
90977
90979
90980
0462
0069
0008
0001
0001
0001
0001
0001
109-1
Data
SAFETY PRECAUTIONS
109-1
S60MC-C
D10901 Data
Special Edition 0055
Stopped engine
Data
Ref.
D09-02
Description
When referring to this page, please quote Data D10901 Edition 0055
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
109-1
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
Page 2 (2)
When referring to this page, please quote Data D10901 Edition 0055
MAN B&W Diesel A/S
909-1.3
Adjustment
Fuel
S60MC-C
0240Pump Settings
Adjustment
909-1.3
1.
HN909-1.3 240 01
2.
HN909-1.3 240 02
The individual pmax value must not deviate more than 3 bar from the average
value for all cylinders.
When referring to this page, please quote Procedure M90901 Edition 0240
0$1 % : 'LHVHO $6
Page 1 (2)
909-1.3
5.
MIP adjustment:
5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump
index arm.
Increase index for higher p i.
Decrease index for lower p i.
HN909-1.3 240 05
Note!
Page 2 (2)
When referring to this page, please quote Procedure M90901 Edition 0240
0$1 % : 'LHVHO $6
VIT System
109-2
Data
SAFETY PRECAUTIONS
109-2
S60MC-C
D10902 Data
Special Edition 0004
VIT System
Stopped engine
Data
Ref.
Description
When referring to this page, please quote Data D10902 Edition 0004
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
VIT System
109-2
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
Page 2 (2)
When referring to this page, please quote Data D10902 Edition 0004
MAN B&W Diesel A/S
VIT System
909-2.3
Adjustment
VIT System
.0&&
0205
Adjustment
909-2.3
1.
The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection
Timing) system.
If the fuel quality has changed or if the fuel
pumps are worn, the pmax will change. Adjusting the pmax of all the cylinders is done by adjusting the VIT system in the following way:
Mechanical VIT system
HM909-1.3 67 01
2.
XZ909-2.1 203 02
When referring to this page, please quote Procedure M90902 Edition 0205
0$1 % : 'LHVHO $6
Page 1 (2)
VIT System
909-2.3
Adjustment
3.
S9148001.WPG
P control
P supply
P control
5
4
3
XZ909-2.3 204 06
1.5
Page 2 (2)
0.5
0.1
2
1
I, mA
0
0
12
16
20
When referring to this page, please quote Procedure M90902 Edition 0205
0$1 % : 'LHVHO $6
109-3
Data
SAFETY PRECAUTIONS
109-3
S42MC
D10903 Data
Special Edition 0044
Stopped engine
Data
Ref.
Description
When referring to this page, please quote Data D10903 Edition 0044
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
109-3
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
P90651
P90666P91351
P91351
P91351
Page 2 (2)
44
10
34
105
When referring to this page, please quote Data D10903 Edition 0044
MAN B&W Diesel A/S
909-3.1
Checking
Fuel
S60MC-C
0229Pump Cam
Checking
909-3.1
1.
x2
x1 roller guide
fuel cam
ahead
EN909-3.1 228 00
Lowest position
of pump plunger
3.
C = x1 x2 (mm)
5. Note down the result for comparison with
the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.
HN909-3.1 229 03
4.
HM906-7.0 56 01
When referring to this page, please quote Procedure M90903 Edition 0229
0$1 % : 'LHVHO $6
Page 1 (3)
909-3.3
1.
HN909-3.3 207 01
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
2.
HN909-3.1 229 03
HN909-3.3 207 04
3.
Page 2 (3)
When referring to this page, please quote Procedure M90903 Edition 0229
0$1 % : 'LHVHO $6
909-3.3
Adjustment
4.
HN909-3.3 207 06
Page 3 (3)
Fuel Pump
109-4
Data
SAFETY PRECAUTIONS
D10904 Data
Special Edition 0050
109-4
S50MC-C
Fuel Pump
Stopped engine
Data
Ref.
Description
D09-18
D09-19
D09-20
Pump housing
When referring to this page, please quote Data D10904 Edition 0050
MAN B&W Diesel A/S
Value Unit
300 Nm
62
96 kg
Page 1 (2)
Fuel Pump
109-4
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
P90951
Page 2 (2)
70
When referring to this page, please quote Data D10904 Edition 0050
MAN B&W Diesel A/S
Fuel Pump
909-4.2
Dismantling
Fuel
K90MC-C
0224 Pump
Dismantling
909-4.2
1.
MA909-1.1 223 03
4.
D09-39
Remove the control air pipes from the actuator for the VIT index arm.
MA909-4.2 214 04
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Page 1 (9)
909-4.2
Fuel Pump
Dismantling
6.
6. Loosen the four nuts by means of a slugging spanner. Remove the nuts.
7. Fit the lifting tool using the top cover studs/
nuts, and lift the pump housing away.
Take care not to damage the threads of the
studs.
MA909-4.2 214 06
7.
MA909-4.2 214 07
D09-20
Page 2 (9)
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
Overhaul
909-4.3
3.
MA909-4.3 214 03
4.
D09-20
MA909-4.3 214 04
5.
MA909-4.3 214 05
D09-21
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Page 3 (9)
909-4.3
Fuel Pump
Overhaul
6.
6. Dismantle the:
Fuel index arm
Regulating guide
Sleeve
7. Dismantle the:
Guide screw
MA909-4.3 214 06
MA909-4.3 214 07
MA909-4.3 214 08
8.
Page 4 (9)
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
9.
MA909-4.3 214 09
11.
Note!
Lubricate the threads of all the parts with
Molybdenum Disulphide (MoS 2) before
mounting.
Note!
MA909-4.3 214 11
HC909-3.4 121 11
12.
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Page 5 (9)
909-4.3
Fuel Pump
Overhaul
14.
Mounting
13. Lubricate the following with molybdenum disulphide (MoS 2):
all internal surfaces of the fuel pump
housing
the sliding surfaces of all parts of the
regulating and timing systems.
the teeth of the:
MA909-4.3 214 14
regulating guide
timing guide
VIT index arm
15.
MA909-4.3 214 15
MA909-4.3 214 16
16.
Page 6 (9)
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Fuel Pump
909-4.3
Overhaul
17.
MA909-4.3 214 17
MA909-4.3 214 18
18.
MA909-4.3 214 05
19.
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Page 7 (9)
Fuel Pump
909-4.4
Mounting
Mounting
909-4.4
2.
D09-20
MA909.4.2 214 07
3.
MA909-4.2 214 06
D09-18
or
D09-19
Page 8 (9)
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Fuel Pump
909-4.4
Mounting
5.
D09-39
7. Mount the top cover on the fuel pump housing. See Procedure 909-5.4.
Mount the air pipe for the puncture valve.
MA909-4.2 214 04
8.
MA909-1.1 223 09
When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
Page 9 (9)
109-5
Data
SAFETY PRECAUTIONS
109-5
S50MC-C
D10905 Data
Special Edition 0052
Stopped engine
Data
Ref.
D09-23
D09-24
D09-26
D09-27
Description
When referring to this page, please quote Data D10905 Edition 0052
MAN B&W Diesel A/S
Value Unit
100
210
18
34.1
Nm
Nm
mm
kg
Page 1 (2)
109-5
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
P90951
P90951
P90951
P90951
Page 2 (2)
69
82
94
320
When referring to this page, please quote Data D10905 Edition 0052
MAN B&W Diesel A/S
909-5.2
Dismantling
Fuel
S60MC-C
0223 Pump Top Cover
Dismantling
909-5.2
1.
Dismount all drain pipes and the pipe connections to the puncture valve.
GN909-5.2 204 01
2.
Note !
GN909-5.2 204 02
3.
When the top cover is loose, remove the
dismantling screws and mount the lifting
tool in the threaded holes instead.
D09-27
GN909-5.2 204 03
When referring to this page, please quote Procedure M90905 Edition 0223
0$1 % : 'LHVHO $6
Page 1 (3)
909-5.3
Overhaul
Overhaul
909-5.3
2.
HM909-3.3 74 03
D09-26
GN909-5.3 204 04
HM909-3.3 74 13
4.
Page 2 (3)
When referring to this page, please quote Procedure M90905 Edition 0223
0$1 % : 'LHVHO $6
909-5.4
Mounting
Mounting
909-5.4
1.
D09-27
Mount the overhauled top cover (with overhauled suction valve and reconditioned
seatings for the high-pressure pipes) on the
pump housing.
Check that the guide pin in the top cover
enters the hole in the pump housing.
GN909-5.2 204 03
Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide
(MoS 2). See Procedure 913-11.
3.
D09-24
Warning !
As a safety precaution, and before
mounting the top cover nuts, turn the
engine one revolution.
GN909-5.4 204 03
4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure
909-8.4.
4.
GN909-5.4 204 04
When referring to this page, please quote Procedure M90905 Edition 0223
0$1 % : 'LHVHO $6
Page 3 (3)
109-6
Data
SAFETY PRECAUTIONS
109-6
S50MC-C
D10906 Data
Special Edition 0042
Stopped engine
Data
Ref.
D09-29
D09-30
Description
Barrel assembly
Plunger
When referring to this page, please quote Data D10906 Edition 0042
MAN B&W Diesel A/S
Value Unit
27.5 kg
6.2 kg
Page 1 (2)
109-6
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
P90951
P90951
P90962
Page 2 (2)
57
224
When referring to this page, please quote Data D10906 Edition 0042
MAN B&W Diesel A/S
909-6.2
Dismantling
Fuel
S60MC-C
0219Pump Barrel Assembly
Dismantling
909-6.2
1.
GN909-5.2 204 01
Note!
2.
HN909-8.2 207 03
GN909-5.2 204 03
3.
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
Page 1 (9)
909-6.2
4.
GN909-6.2 204 01
5.
MB909-3.1 95 05
GN909-6.2 204 03
Page 2 (9)
When referring to this page, please quote Procedure M90906 Edition 0219
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
8.
GN909-6.2 204 05
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.
D09-29
GN909-6.2 204 06
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
Page 3 (9)
909-6.3
1.
D09-29
MB909-3.2 95 01
2.
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)
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
909-6.3
Overhaul
5.
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.
Carefully slide the plunger into the barrel
and press it to the bottom.
Note!
MB909-3.2 95 06
MB909-3.2 95 07
7.
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
Page 5 (9)
909-6.4
1.
HN909-6.4 207 01
2.
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)
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
909-6.4
Mounting
3.
GN909-6.4 204 03
4.
D09-29
GN909-6.4 204 04
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
Page 7 (9)
909-6.4
5.
GN909-6.4 204 05
GN909-6.4 204 06
Page 8 (9)
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
909-6.4
Mounting
7.
GN909-6.4 204 07
8.
GN909-6.4 204 08
When referring to this page, please quote Procedure M90906 Edition 0219
0$1 % : 'LHVHO $6
Page 9 (9)
109-7
Data
SAFETY PRECAUTIONS
109-7
S50MC-C
D10907 Data
Special Edition 0034
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
D09-33
D09-34
Description
When referring to this page, please quote Data D10907 Edition 0034
MAN B&W Diesel A/S
Value Unit
900 Nm
2 kg
Page 1 (2)
109-7
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
P90951
P90967
P90962
Page 2 (2)
When referring to this page, please quote Data D10907 Edition 0034
MAN B&W Diesel A/S
909-7.1
Checking
Fuel
S60MC-C
0214 Pump Suction Valve
Checking
909-7.1
1.
HN909-7.1 207 01
KB909-3.3 105 08
2.
When referring to this page, please quote Procedure M90907 Edition 0214
0$1 % : 'LHVHO $6
Page 1 (4)
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.
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
KN909-7.2 213 03
3.
Page 2 (4)
When referring to this page, please quote Procedure M90907 Edition 0214
0$1 % : 'LHVHO $6
909-7.3
Overhaul
Overhaul
909-7.3
1.
KB909-3.3 105 05
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.
3.
XZ909-7.3 204 03
When referring to this page, please quote Procedure M90907 Edition 0214
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.
Page 4 (4)
When referring to this page, please quote Procedure M90907 Edition 0214
0$1 % : 'LHVHO $6
109-8
Data
SAFETY PRECAUTIONS
109-8
S50MC-C
D10908 Data
Special Edition 0043
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
D09-35
D09-36
Description
When referring to this page, please quote Data D10908 Edition 0043
MAN B&W Diesel A/S
Value Unit
890 Nm
5 kg
Page 1 (2)
109-8
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
P90951
Page 2 (2)
141
When referring to this page, please quote Data D10908 Edition 0043
MAN B&W Diesel A/S
909-8.2
Dismantling
Fuel
S60MC-C
0217Pump Puncture Valve
Dismantling
909-8.2
2.
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
When referring to this page, please quote Procedure M90908 Edition 0217
0$1 % : 'LHVHO $6
Page 1 (4)
909-8.3
1.
HN909-8.3 207 01
HG909-8.2 201 02
2.
Page 2 (4)
When referring to this page, please quote Procedure M90908 Edition 0217
0$1 % : 'LHVHO $6
909-8.3
Overhaul
3.
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.
Mount new O-rings on the housing.
GM909-3.3 89 12
When referring to this page, please quote Procedure M90908 Edition 0217
0$1 % : 'LHVHO $6
Page 3 (4)
909-8.4
2.
D09-35
HN909-8.4 207 02
HN909-8.4 207 03
3.
Page 4 (4)
When referring to this page, please quote Procedure M90908 Edition 0217
0$1 % : 'LHVHO $6
109-9
Data
SAFETY PRECAUTIONS
109-9
S46MC-C
D10909 Data
Special Edition 0025
Stopped engine
Data
Ref.
D09-39
Description
Shock absorber
When referring to this page, please quote Data D10909 Edition 0025
MAN B&W Diesel A/S
Value Unit
20 kg
Page 1 (2)
109-9
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
Page 2 (2)
When referring to this page, please quote Data D10909 Edition 0025
MAN B&W Diesel A/S
909-9.1
Checking
Fuel
S60MC-C
0214 Pump Shock Absorber
Checking
909-9.1
To ensure satisfactory operation, the functioning of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspection is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is operating.
HM909-4.0 09 01
2. To check the tightness of the piston, measure the amount of leakage oil flowing from
the drain pipe of the shock absorber housing. Note down the amounts measured and
compare with earlier measurements.
Increasing amounts indicate a deteriorating
piston sealing. Excessive amounts indicate
that the shock absorber requires overhauling.
See Procedure 909-9.3.
When referring to this page, please quote Procedure M90909 Edition 0214
0$1 % : 'LHVHO $6
Page 1 (3)
909-9.3
1.
Note!
D09-39
GN909-9.3 204 01
2.
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
Page 2 (3)
When referring to this page, please quote Procedure M90909 Edition 0214
0$1 % : 'LHVHO $6
909-9.3
Overhaul
When referring to this page, please quote Procedure M90909 Edition 0214
0$1 % : 'LHVHO $6
Page 3 (3)
Fuel Valve
109-11
Data
SAFETY PRECAUTIONS
109-11
S46MC-C
D10911 Data
Special Edition 0047
Fuel Valve
Stopped engine
Data
Ref.
D09-40
D09-41
D09-42
D09-43
Description
When referring to this page, please quote Data D10911 Edition 0047
MAN B&W Diesel A/S
Value Unit
320 - 380
25
18
7.2
bar
Nm
mm
kg
Page 1 (2)
Fuel Valve
109-11
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate
P90151
P90951
P90951
P90961
P90966
Page 2 (2)
71
94
165
14
When referring to this page, please quote Data D10911 Edition 0047
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
Fuel
S60MC-C
0231Valve
Checking
909-11.1
1.
The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the
engine can be attributed to defects in these
valves.
GN909-11.1 204 01
If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme.
See Chapter 900-1.
2.
Note!
In the event that the slide-type fuel valve is
pressure tested without being cleaned
between the fuel nozzle and the cut-off slide,
the opening pressure value measured might
be considerably lower than specified.
All fuel valves must be function-tested before
being mounted in the cylinder cover.
1. Pressure testing pump
If an air supply of 10 bar is not available,
working air of seven bar can be used. Use
only hydraulic oil (rust-preventing) with a
viscosity of between 7 and 10 cSt at 50C.
2. Spring housing
To ensure that overtightening has not taken
place, check that the locking/indicating pin
has not been bent or broken off.
HM909-6.3 70 01A
Page 1 (14)
909-11.1
Fuel Valve
Checking
3.
HM909-6.3 70 01B
4.
A.
B.
C.
D.
Objective
Procedure
Acceptance criteria
Cause of fault.
Note!
A. Objective:
To remove air in the system and check the
fuel jet.
5.
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the working pressure until
straight jets of oil are ejected from the nozzle holes (no atomization).
NA909-11.1 215 05
C. Acceptance criteria:
There is to be a continuous jet of oil through
at least one of the nozzle holes.
Page 2 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
6.
D. Cause of fault:
If the jets do not fulfil the above point C, the
cause may be:
6. Atomization test
Do NOT attempt to carry out an atomization test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.
MN909-11.1 222 06
Note!
7.
D-3
GN909-11.1 204 06
C. Acceptance criteria:
Check the opening pressure on the pressure gauge.
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 3 (14)
909-11.1
Fuel Valve
Checking
8.
D. Cause of fault:
If the opening pressure is higher than specified in D-3, the cause may be that a wrong
type of spring is used replace the spring
on the thrust spindle, if necessary, replace
the complete thrust spindle.
If the opening pressure is lower than specified in D-3, the cause may be that the
spring has sagged replace the spring, or
add a special thin disc.
Note!
Special thin discs are available as
spares.
If a spring or a disc has been changed, the
pressure testing procedure of the fuel valve
must be repeated from step 4.
8. Sealing test and sliding function
A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.
GN909-11.1 204 07
B. Procedure:
The control handle must be in the OPEN position.
Slowly increase the oil pressure to about 50
bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
C. Acceptance criteria:
Oil must not flow from the nozzle holes.
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when
the fuel valve is full of oil.
Page 4 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.1
Checking
D. Cause of fault:
D.1 Sealing test
If oil flows out of the nozzle holes, the
cause is either:
Defective spindle guide at needle seat, or
a sticking spindle. Examine and/or replace the spindle guide.
See Procedure 909-12.3.
Too quick pressure drop:
the clearances of the movable parts,
both of the spindle guide and of the nonreturn valve, are too large, or
the seats between the thrust piece/
spindle in the spindle guide or thrust
piece/valve slide in the non-return valve
are damaged.
Examine and/or replace both the spindle
guide and non-return valve.
See Procedure 909-12.3.
See Procedure 909-13.3.
D.2 Sliding function
The pressure drops relatively slowly to
about 15 bar, after which it drops quickly to
0 (the slide is pressed against the conical
seat and opens for circulation oil).
GN909-11.1 204 07
Note!
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 5 (14)
909-11.1
Fuel Valve
Checking
9.
GN909-11.1 204 08
D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
Page 6 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.2
Dismantling
Dismantling
909-11.2
1.
KB901-2.1 104 01
If the valve is not to be overhauled immediately, the valve should be placed immersed
in diesel oil until overhauling.
HG909-11.3 201 02
2.
3.
HG909-11.2 221 03
D-2
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 7 (14)
Fuel Valve
909-11.3
Overhaul
Overhaul
909-11.3
1.
MN909-11.3 219 01
Use only clean, non-fluffy rags for wiping purposes. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings before reassembly.
1. Measure the length A of the protruding part
of the nozzle, and write down the result for
correct re-assembling of the valve.
2.
MN909-11.3 222 02
MN909-11.3 222 03
3.
Page 8 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
4.
GN909-11.3 204 01
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 9 (14)
Fuel Valve
909-11.3
Overhaul
5.
D-1
GN909-11.3 204 02
Page 10 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
6.
NA909-11.3 215 03
Note!
7.
7. The non-return valve should be sent to an
authorised MAN B&W repair shop for overhaul. If this is not possible, the non-return
valve may be overhauled on board.
See Procedure 909-13.3.
GN909-11.3 204 04
8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.
8.
Note!
MN909-11.3 219 05
Make sure that the fuel nozzle and spindle guide engage correctly with the guide
pin in the fuel valve housing. This can be
ascertained by attempting to turn the
nozzle after mounting. It must not be
possible to turn the nozzle.
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 11 (14)
909-11.3
Fuel Valve
Overhaul
9.
9. Mount:
the thrust foot
the parts of the thrust spindle
the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost
groove of the fuel valve housing.
Lubricate the thread of the valve head with
molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.
Fit the valve head with new O-rings.
10. Make sure that the guide pin between valve
housing and valve head is intact, and press
the valve head down into the valve housing.
GN909-11.3 204 06
See that the guide pin between valve housing and valve head engages correctly so as
to prevent relative turning of the parts.
GN909-11.3 204 07
10.
Page 12 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Fuel Valve
909-11.3
Overhaul
11.
MN909-11.3 222 09
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Page 13 (14)
Fuel Valve
909-11.4
Mounting
Mounting
909-11.4
1.
D-2
MA901-2.1 72 03
2.
HG909-11.4 201 04
3.
KB901-2.1 104 06
Note!
Page 14 (14)
When referring to this page, please quote Procedure M90911 Edition 0231
MAN B&W Diesel A/S
Spindle Guide
109-12
Data
SAFETY PRECAUTIONS
D10912 Data
Special Edition 0038
109-12
Spindle Guide
S60MC-C
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
Description
When referring to this page, please quote Data D10912 Edition 0038
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Spindle Guide
109-12
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
P90966P90968-
Page 2 (2)
12
When referring to this page, please quote Data D10912 Edition 0038
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
Spindle
S50ME-C
0222 Guide
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle
guides of the slide valve design.
Extreme care and accuracy should be
exercised when carrying out this operation.
Based on service experience it is recommended to replace the complete spindle
guide after 8000 hours of operation.
Note!
The spindle guide, thrust piece and spindle are matched parts and may not be replaced individually.
GW909-12.3 222 02
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.
GW909-12.3 222 04
When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
Page 1 (5)
909-12.3
Spindle Guide
Overhaul
5.
GW909-12.3 222 05
Note!
MA909-6.2 111 05
Page 2 (5)
When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
7.
GW909-12.3 222 07
Note!
It is recommended that the fuel nozzle is
changed whenever the spindle guide is
being overhauled.
When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
Page 3 (5)
909-12.3
Spindle Guide
Overhaul
9.
MN909-12.3 215 09
GW909-12.3 222 10
10.
Page 4 (5)
When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
Spindle Guide
909-12.3
Overhaul
11.
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
When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
Page 5 (5)
Non-return valve
109-13
Data
SAFETY PRECAUTIONS
D10913 Data
Special Edition 0031
109-13
Non-return valve
S60MC-C
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
Description
When referring to this page, please quote Data D10913 Edition 0031
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
Non-return valve
109-13
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
P90951
P90968-
Page 2 (2)
153
12
When referring to this page, please quote Data D10913 Edition 0031
MAN B&W Diesel A/S
Non-return valve
909-13.3
Overhaul
Non-return
K98MC-C valve
0206
Overhaul
909-13.3
1.
Note!
Extreme care and accuracy should be
exercised when carrying out this operation.
1. Clean the outside of the non-return valve
with pure gas oil. The individual parts are
not interchangeable, therefore only one
guide is to be disassembled at a time.
Note!
Except for the slide valve spring, defective parts cannot be replaced individually
by new ones.
Place the non-return valve as shown in Fig.
1 in a bench vice provided with soft jaws,
and disassemble the non-return valve, using the disassembling tool and a hammer
as shown.
2. Clean all the parts for the spindle guide in
gas oil and wipe them dry with a clean
piece of cloth.
Finally, clean in either gas oil, kerosene or
Electrocleaner', and wipe the parts dry with
a clean piece of cloth.
3. Now place the parts on clean, lint-free rags
and examine with an 8-10 times enlargement magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.
(
(
"
%
(
(
8
H
2.
!
%
!
"
"
(
(
7
I
3.
"
(
(
"
%
(
(
8
H
When referring to this page, please quote Procedure M90913 Edition 0206
0$1 % : 'LHVHO $6
Page 1 (2)
909-13.3
Non-return valve
Overhaul
4.
MC909-6.2 69 04
NA909-13.3 205 05
MC909-6.3 69 06
Page 2 (2)
When referring to this page, please quote Procedure M90913 Edition 0206
0$1 % : 'LHVHO $6
109-14
Data
SAFETY PRECAUTIONS
109-14
S50ME-C
D10914 Data
Special Edition 0060
Stopped engine
Data
Ref.
D09-47
D09-52
Description
When referring to this page, please quote Data D10914 Edition 0060
MAN B&W Diesel A/S
Value Unit
100 Nm
7.3 kg
Page 1 (2)
109-14
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
P90951
P90951
Page 2 (2)
When referring to this page, please quote Data D10914 Edition 0060
MAN B&W Diesel A/S
909-14.2
Dismantling
Fuel
S35MC
0235 Oil High-Pressure Pipe
Dismantling
909-14.2
2.
BM909-14.2 211 02
3.
Note!
It is recommended always to overhaul
the high-pressure pipe before remounting
it on the engine.
See Procedure 909-14.3.
GN909-14.2 210 03
D09-52
BM909-14.2 211 04
4.
When referring to this page, please quote Procedure M90914 Edition 0235
0$1 % : 'LHVHO $6
Page 1 (4)
909-14.3
1.
KB909-7.1 77 01
2.
KB909-7.1 77 03
3.
Max. grind-away
KN909-14.3 223 03
Page 2 (4)
When referring to this page, please quote Procedure M90914 Edition 0235
0$1 % : 'LHVHO $6
909-14.3
Overhaul
4.
KB909-7.1 77 04
When referring to this page, please quote Procedure M90914 Edition 0235
0$1 % : 'LHVHO $6
Page 3 (4)
909-14.4
Mounting
Mounting
909-14.4
3.
D09-52
BM909-14.4 211 03
D09-47
BM909-14.4 211 04
4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
valve to the torque stated in Data.
5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel
pump to the torque stated in Data.
5.
GN909-14.4 210 05
D09-47
Page 4 (4)
When referring to this page, please quote Procedure M90914 Edition 0235
0$1 % : 'LHVHO $6
109-15
Data
SAFETY PRECAUTIONS
D10915 Data
Special Edition 0050
109-15
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
D09-53
D09-54
D09-55
D09-56
D09-57
D09-60
D09-61
D09-62
Description
When referring to this page, please quote Data D10915 Edition 0050
MAN B&W Diesel A/S
Value Unit
80
2.8 - 5.3
0.7 - 3.2
0.45
0.5
70
60
31
Nm
mm
mm
mm
mm
kg
kg
kg
Page 1 (2)
109-15
Data
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
P90851
Page 2 (2)
173
When referring to this page, please quote Data D10915 Edition 0050
MAN B&W Diesel A/S
909-15.1
Checking
Fuel
S60MC-C
0226Pump Roller Guide
Checking
909-15.1
3.
HN909-10.1 205 01
5.
GN909-15.1 203 05
When referring to this page, please quote Procedure 909-15.1 Edition 0226
0$1 % : 'LHVHO $6
Page 1 (10)
909-15.1
7.
MA909-8.0 70 07
8.
MA909-8.0 70 06
D09-57
Page 2 (10)
When referring to this page, please quote Procedure 909-15.1 Edition 0226
0$1 % : 'LHVHO $6
909-15.2
Dismantling
Dismantling
909-15.2
1.
Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
1. Dismantle the top cover of the fuel pump.
See Procedure 909-5.2.
GN909-5.2 204 03
GN909-6.2 204 06
2.
When referring to this page, please quote Procedure 909-15.2 Edition 0226
0$1 % : 'LHVHO $6
Page 3 (10)
909-15.2
3.
GN909-15.2 203 03
HN909-15.2 206 04
4.
HN909-10.1 205 01
5.
Page 4 (10)
When referring to this page, please quote Procedure 909-15.2 Edition 0226
0$1 % : 'LHVHO $6
909-15.2
Dismantling
6.
D09-62
HN909-15.2 206 06
7.
D09-61
GN909-15.2 203 07
When referring to this page, please quote Procedure 909-15.2 Edition 0226
0$1 % : 'LHVHO $6
Page 5 (10)
909-15.3
1.
D09-61
MA909-8.0 70 07
HN909-15.3 206 03
3.
Page 6 (10)
When referring to this page, please quote Procedure 909-15.3 Edition 0226
0$1 % : 'LHVHO $6
909-15.4
Mounting
Mounting
909-15.4
1.
D09-61
HN909-15.4 206 01
2.
D09-54
D09-56
HN909-15.4 206 02
D09-55
When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1 % : 'LHVHO $6
Page 7 (10)
909-15.4
Mounting
3.
D09-53
HN909-15.4 206 03
5.
HN909-15.2 206 06
D09-62
Page 8 (10)
When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1 % : 'LHVHO $6
909-15.4
Mounting
6.
GN909-15.1 203 05
GN909-15.4 203 07
7.
MA909-8.0 70 21
8.
When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1 % : 'LHVHO $6
Page 9 (10)
909-15.4
9.
AM909-8.0 31 16
GN909-15.4 203 10
HN909-15.4 206 11
Page 10 (10)
When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1 % : 'LHVHO $6
109-16
Data
SAFETY PRECAUTIONS
109-16
S46MC-C
D10916 Data
Special Edition 0016
Stopped engine
Data
Ref.
Description
When referring to this page, please quote Data D10916 Edition 0016
MAN B&W Diesel A/S
Value Unit
Page 1 (2)
109-16
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
P90951
P90951
Page 2 (2)
82
212
When referring to this page, please quote Data D10916 Edition 0016
MAN B&W Diesel A/S
S50MC-C
909-16
Fuel
S50MC-C
201 Pump Emergenc y Running
909-16
2.
GN909-16 201 02
3.
2. Remove the puncture valve from the fuel
pump.
Plug the air supply pipe to the puncture
valve.
GN909-16 201 03
Note !
4.
4. Mount the lifting tool on the fuel pump top
cover and secure it in position with the two
screws.
GN909-16 201 04
When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
Page 1 (2)
909-16
5.
S50MC-C
GN909-16 201 05
GN909-16 201 03
8. Remove the cover on the camshaft housing. Turn the engine until the circular section of the fuel cam is positioned upwards.
9. Lower the roller guide on to the fuel cam in
the reverse order to lifting.
10. Remove the lifting tool and re-mount the
puncture valve.
GN909-16 201 10
10.
Page 2 (2)
When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90951 Edition 0462
Plate
P90951-0462
Page 1 (2)
Plate
P90951-0462
Item
No.
010
021
045
057
069
070
082
094
104
116
128
130
141
153
165
177
189
190
200
224
236
248
250
273
297
307
Page 2 (2)
Item Description
Item Description
When referring to this page, please quote Plate P90951 Edition 0462
When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S
Plate
P90961-0069
Page 1 (2)
Plate
P90961-0069
Item
No.
014
026
038
040
051
063
075
087
099
109
122
Page 2 (2)
Item Description
Item
No.
Item Description
High-pressure pump
Table
Rig fuel oil valve
High-pressure hose
Connection piece, M42x2
Test rig, complete
Cover
Angle union
Gasket
Plug screw
Hose
When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S
Plate
P90966-0008
Page 1 (2)
Plate
P90966-0008
Item
No.
011
023
035
047
060
202
Item Description
Item
No.
Item Description
Tool box
Extractor for atomizer
Drift for atomizer
Cleaning brush
Instruction plate
Toolset, complete
Note:
When odering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S
Plate
P90968-0001
Page 1 (2)
Plate
P90968-0001
Item
No.
Item Description
012
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S
When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S
Plate
P90974-0001
Page 1 (2)
Plate
P90974-0001
Item
No.
015
027
039
206
Item
No.
Item Description
Drill*
Test mandrel*
Pin vice*
Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
Page 2 (2)
When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S
Plate
P90977-0001
P90977
Mounting Tools - Pump Barrel Seals
0001
When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90977-0001
Item
No.
011
023
035
047
059
060
072
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Spacer ring
Page 2 (2)
When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S
Plate
P90979-0001
P90979
Mounting Tools - Suction Valve Seals
0001
When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90979-0001
Item
No.
012
024
036
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Page 2 (2)
When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S
Plate
P90980-0001
P90980
Mounting Tools - Air Piston Seals
0001
When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P90980-0001
Item
No.
018
020
031
043
055
067
079
Item Description
Item
No.
Item Description
Cone
Pushing tool
Compression tool
Cone
Pushing tool
Compression tool
Cone
Page 2 (2)
When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S
0032
0229
0009
0205
0218
0019
0005
0208
0005
0206
0018
0214
0071
0017
0019
0002
0001
110-1
Data
SAFETY PRECAUTIONS
110-1
S50MC-C
0032
Special Data
Stopped engine
2 x 2000 kg
Data
Ref.
Description
D-1
Value Unit
1550 kg
When referring to this page, please quote Data D11001 Edition 0032
MAN B&W Diesel A/S
Page 1 (2)
110-1
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D11001 Edition 0032
MAN B&W Diesel A/S
910-1.1
Checking
Air Cooler
S80MC Element
0229
Checking
910-1.1
1.
1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air
across the cooler while the engine is running.
GN910-1.1 206 01
4.
3. If the measurements indicate fouling, it is
recommended to inspect the air cooler elements as follows:
4. Remove the front end cover of the air cooler.
5. Visually inspect the air cooler element
through the opening.
GN910-1.1 206 04
GN910-1.1 206 06
5.
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
Page 1 (9)
910-1.2
1.
GN910-1.2 206 01
GN910-1.2 206 02
GN910-1.2 206 03
3.
Page 2 (9)
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
910-1.2
Dismantling
4.
JN910-1.2 213 04
5.
GN910-1.2 206 05
GN910-1.2 228 06
6.
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
Page 3 (9)
910-1.2
Dismantling
7.
7. Mount a second tackle on the lifting bracket, and use it to pull out the air cooler element approx. half a metre.
8. Mount the second set of guide rails on the
frame around the air cooler element.
9. Pull out the air cooler element until the front
end cover of the air cooler element is clear
of the air cooler housing.
GN910-1.2 228 07
GN910-1.2 228 08
9.
GN910-1.2 228 09
D-2
Page 4 (9)
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
910-1.3
Overhaul
Overhaul
910-1.3
1.
GN910-1.3 206 01
2.
1. Do not start cleaning until the engine has
been at a standstill for about 30 minutes.
Do not disconnect the compressed air supply to the exhaust valve.
2. Follow the detailed cleaning instructions
displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pressure must be at least 0.7 bar.
3. Continue the cleaning process for at least
30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.
KE910-5.1 61 02
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
Page 5 (9)
910-1.3
6.
GN910-1.2 206 01
GN910-1.2 206 02
7.
GN910-1.3 206 03
8.
Page 6 (9)
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
910-1.3
Overhaul
9.
Lower both covers and land them on a couple of wooden planks. Discard the gaskets.
11. Clean the inside of the tubes, using the
cleaning brush mounted on a drilling machine. In the event of leakages between
cooling tube and tube plate, the tubes are
rolled with the tube expander.
GN910-1.3 206 04
10.
Tools for tube cleaning and the tube expander are supplied by the air cooler manufacturer.
Clean the front-end and aft-end covers inside with a stiff brush and then rinsed with
fresh water.
Note!
If damaged, the coating inside the covers
is to be repaired with the original coating
or a similar product.
GN910-1.3 206 05
D-1
D-3
D
11.
GN910-1.3 206 06
12. When cleaning is complete, mount the covers in the reverse order to dismantling.
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
Page 7 (9)
910-1.4
Mounting
Mounting
910-1.4
1.
GN910-1.4 228 01
D-2
2.
GN910-1.4 228 02
GN910-1.4 228 03
3.
Page 8 (9)
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
910-1.4
Mounting
4.
GN910-1.4 228 04
5.
Note!
JN910-1.4 213 04
GN910-1.2 206 03
6.
When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
Page 9 (9)
110-2
Non-Return Valve
Data
N
D
R
B
I
E
Stopped engine
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
Ref.
Description
When referring to this page, please quote Data D11002 Edition 0009
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-2
Non-Return Valve
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
Page 2 (2)
Item No.
Description
When referring to this page, please quote Data D11002 Edition 0009
MAN B&W Diesel A/S
Non-Return Valve
910-2.3
Overhaul
Non-Return
S50MC-C Valv e
205
Overhaul
910-2.3
1.
GN910-2.3 205 01
Note!
2.
GN910-2.3 205 02
3.
MC910-6.0 26 02
MC910-6.0 26 03
4.
When referring to this page, please quote Procedure 910-2.3 Edition 205
MAN B&W Diesel A/S
Page 1 (1)
Auxiliary Blower
910-3.3
Overhaul
Auxiliary Blower
60&&
0218
Overhaul
910-3.3
1.
D10-12
2.
Exercise care when mounting the electric motor with blower wheel, as the
blower wheel is to catch the guide in the
blower housing.
MC910-8.0 31 02
Note!
When referring to this page, please quote Procedure M91003 Edition 0218
0$1 % : 'LHVHO $6
Page 1 (1)
Auxiliary Blower
110-3
Data
SAFETY PRECAUTIONS
110-3 Edition 0019
D11003
Special Data
Auxiliary Blower
S60MC
Stopped engine
Data
Ref.
D10-12
Description
When referring to this page, please quote Data D11003 Edition 0019
MAN B&W Diesel A/S
Value Unit
556 kg
Page 1 (2)
Auxiliary Blower
110-3
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
P91356
Page 2 (2)
When referring to this page, please quote Data D11003 Edition 0019
MAN B&W Diesel A/S
110-4
Butterfly Valves
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X
Stopped engine
Shut off air supply to exhaust valve Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
Ref.
Description
When referring to this page, please quote Data D11004 Edition 0005
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
110-4
Butterfly Valves
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
Page 2 (2)
Item No.
Description
When referring to this page, please quote Data D11004 Edition 0005
MAN B&W Diesel A/S
Butterfly Valves
910-4.1
Checking
1. It is important that the automatic non-return valves (butterfly valves) are always
able to function easily and unimpeded.
The movability of the valve flaps should
therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.
1.
Flow direction
M91004 0208C01
2.
M91004 0208C02
When referring to this page, please quote Procedure M91004 Edition 0208
MAN B&W Diesel A/S
Page 1 (1)
Turbocharger Turbine
110-5
Data
SAFETY PRECAUTIONS
110-5
.0&&
0005
Special Data
Turbocharger Turbine
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
Description
Value Unit
When referring to this page, please quote Data D11005 Edition 0005
MAN B&W Diesel A/S
Page 1 (2)
Turbocharger Turbine
110-5
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D11005 Edition 0005
MAN B&W Diesel A/S
Turbocharger Turbine
910-5.3
Cleaning
Turbocharger Turbine
.0&&
0206
Cleaning
910-5.3
When referring to this page, please quote Procedure M91005 Edition 0206
0$1 % : 'LHVHO $6
Page 1 (2)
910-5.3
Turbocharger Turbine
Cleaning
Cleaning Procedure:
1. Carry out cleaning for every 24 to 50 hours
of operation, based on observations.
2. Preferably clean the turbocharger at full
load. Do not clean below half load.
3. Close valve A.
XX706-12 40B
4. Open valves B and C, to blow out any deposits and/or condensate in the connecting
pipe.
After about two minutes, close valves B and
C.
5. Slowly open valve A to relieve the pressure
in the tank.
6. Fill the tank with the quantity of granules
specified in the table.
7. Close valve A.
8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves
B and C.
HM910-5.3 50 02
Caution!
1.The drain openings in the gas casings
must remain closed while dry cleaning
the turbine.
2. It is possible that during dry cleaning
of the turbine, some of the blown-in solid
particles or sparks will escape through
the funnel.
Page 2 (2)
When referring to this page, please quote Procedure M91005 Edition 0206
0$1 % : 'LHVHO $6
110-6
Data
SAFETY PRECAUTIONS
110-6
S50MC-C
0018
Special Data
Stopped engine
1000 kg
Data
Ref.
Description
D-1
Value Unit
119 kg
When referring to this page, please quote Data D11006 Edition 0018
MAN B&W Diesel A/S
Page 1 (2)
110-6
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D11006 Edition 0018
MAN B&W Diesel A/S
910-6.2
Dismantling
Water
S46MC-C
0214 Mist Catcher
Dismantling
910-6.2
2.
EN910-6.2 214 02
2. To dismantle the water mist catcher, dismantle the water mist catcher cover and upper cover to give access to the air cooler
housing.
3.
EN910-6.2 214 03
GN910-6.2 205 06
4.
When referring to this page, please quote Procedure M91006 Edition 0214
0$1 % : 'LHVHO $6
Page 1 (3)
910-6.4
Mounting
Mounting
910-6.4
1.
1. Lubricate the two supports on the underside of the water mist catcher with plenty of
grease.
Apply a thin layer of silicone paste to the
frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.
Note!
EN910-6.4 214 01
2.
2. Slide the water mist catcher into the scavenge air cooler housing.
When the water mist catcher is half-way in,
remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.
GN910-6.4 205 02
EN910-6.4 214 03
3.
Page 2 (3)
When referring to this page, please quote Procedure M91006 Edition 0214
0$1 % : 'LHVHO $6
910-6.4
Mounting
4.
4. Clean the water mist catcher cover and apply a thin layer of silicone paste along the
edges of the cover. Mount the cover.
EN910-6.2 214 02
Clean the upper cover and apply a thin layer of silicone paste along the edges of the
cover. Mount the cover.
When referring to this page, please quote Procedure M91006 Edition 0214
0$1 % : 'LHVHO $6
Page 3 (3)
Tools
Turbocharger System - Tools
MAN B&W Diesel
When referring to this page, please quote Plate P91061 Edition 0071
Plate
P91061-0071
Page 1 (2)
Tools
Turbocharger System - Tools
Plate
P91061-0071
Item
No.
014
026
Page 2 (2)
Item Description
Item
No.
Item Description
Pulling tool
Lifting eye bolt
When referring to this page, please quote Plate P91061 Edition 0071
When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S
Plate
P91063-0017
Page 1 (2)
Plate
P91063-0017
Item
No.
015
027
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S
When referring to this page, please quote Plate P91063 Edition 0019
MAN B&W Diesel A/S
Plate
P91063-0019
Page 1 (2)
Plate
P91063-0019
Item
No.
015
027
Page 2 (2)
Item
No.
Item Description
Edition
MAN B&W Diesel A/S
Travelling Trolley
When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S
Plate
P91064-0002
Page 1 (2)
Plate
P91064-0002
Item
No.
010
Travelling Trolley
Item Description
Item
No.
Item Description
Travelling trolley*
Note:
* When ordering this tool, please state
load and track width.
Page 2 (2)
When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S
Plate
P91066-0001
P91066
Air Cooler - Lifting Tools
0001
When referring to this page, please quote Plate P91066 Edition 0001
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91066-0001
Item
No.
011
023
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P91066 Edition 0001
MAN B&W Diesel A/S
0025
0211
0013
0211
0001
0001
111-1
Safety Valve
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
X
Stopped engine
Shut off air supply to exhaust valve Only with stopped lubriating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
Ref.
Description
D11-01
Opening pressure
D11-02
When referring to this page, please quote Data D11101 Edition 0025
MAN B&W Diesel A/S
Value
Unit
200 5
bar
45
Nm
Page 1 (2)
111-1
Safety Valve
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
P91351
10
P91351
58
P90151
117
P91359
Page 2 (2)
When referring to this page, please quote Data D11101 Edition 0025
MAN B&W Diesel A/S
Safety Valve
911-1.2
Dismantling
When Side-mounted
1.
M91101 0211D01
M91101 0211D02
2.
When Top-mounted
3.
M91101 0211D03
When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
Page 1 (5)
911-1.3
Safety Valve
Overhaul (adjustment)
1.
the spring
M91101 0211O02
2.
M91101 0211O03
3.
Page 2 (5)
When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
Safety Valve
911-1.3
Overhaul (adjustment)
4. To set the safety valve opening pressure:
4.
D11 01
device.
M91101 0211O04
just closes.
When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
Page 3 (5)
911-1.4
Safety Valve
Mounting
When Side-mounted
1.
1. Pierce the bore in the cylinder cover, and
blow it clean.
2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe
and the indicator cock.
M91101 0211M01
M91101 0211M02
2.
M91101 0211M03
3.
Page 4 (5)
When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
Safety Valve
911-1.4
Mounting
When Top-mounted
4.
4. Pierce the bore in the cylinder cover, and
blow it clean.
Clean the thread and the sealing surface.
5. Mount a new or overhauled safety valve.
When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.
M91101 0211M04
M91101 0211M05
5.
When referring to this page, please quote Procedure M91101 Edition 0211
MAN B&W Diesel A/S
Page 5 (5)
111-2
Relief Valve
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2
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
Data
Ref.
Description
When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S
Value
Unit
Page 1 (2)
111-2
Relief Valve
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
Page 2 (2)
Item No.
Description
When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S
Relief Valve
911-2.1
Checking
Relief
60&
0211 Valve
Checking
911-2.1
1.
Note!
XZ911-2.1 209 01
XZ911-2.1 207 03
2.
When referring to this page, please quote Procedure M91102 Edition 0211
0$1 % : 'LHVHO $6
Page 1 (1)
111-3
Data
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
Data
Ref.
Description
When referring to this page, please quote Data D11103 Edition 0001
Value
Unit
Page 1 (2)
111-3
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
Page 2 (2)
Item No.
Description
When referring to this page, please quote Data D11103 Edition 0001
911-3.1
Checking
2.
M91103 0001C02
When referring to this page, please quote Procedure M91103 Edition 0001
Page 1 (5)
911-3.2
M91103 0001D01
1.
Page 2 (5)
When referring to this page, please quote Procedure M91103 Edition 0001
911-3.3
Overhaul
1.
M91103 0001O01
M91103 0001O02
2.
When referring to this page, please quote Procedure M91103 Edition 0001
Page 3 (5)
911-3.3
4.
M91103 0001O04
M91103 0001O05
5.
M91103 0001O01
6.
Page 4 (5)
When referring to this page, please quote Procedure M91103 Edition 0001
911-3.4
Mounting
1.
M91103 0001M01
When referring to this page, please quote Procedure M91103 Edition 0001
Page 5 (5)
0007
0207
0015
0210
0201
0073
0003
0001
112-2
Data
SAFETY PRECAUTIONS
112-2 Data
.0&
0007
Special
Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
Ref.
Description
D-1
D-2
Value Unit
1500 bar
500 hours
1000 hours
2000 hours
4000 hours
8000 hours
8000 hours
When referring to this page, please quote Data D11202 Edition 0007
MAN B&W Diesel A/S
Page 1 (2)
112-2
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D11202 Edition 0007
MAN B&W Diesel A/S
912-2.1
Checking
Holding
.0& Down and End Chock Bolts
0207
Checking
912-2.1
Note!
The hydraulic jack used for tightening the
holding down bolts is marked with:
For: Holding down bolts
The larger jack used for tightening the
end chock bolts is marked with:
For: End chock bolts
Hydraulic tightening of holding down bolts and
end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.
When referring to this page, please quote Procedure M91202 Edition 0207
0$1 % : 'LHVHO $6
Page 1 (3)
912-2.1
1.
EN912-1.1 205 01
Page 2 (3)
When referring to this page, please quote Procedure M91202 Edition 0207
0$1 % : 'LHVHO $6
912-2.1
Checking
3.
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
When referring to this page, please quote Procedure M91202 Edition 0207
0$1 % : 'LHVHO $6
Page 3 (3)
Stay Bolts
112-3
Data
SAFETY PRECAUTIONS
112-3
S50MC-C
0015
Special Data
Stay Bolts
Stopped engine
Data
Ref.
Description
D-1
Check measurement
D-2
Hydraulic pressure
mounting
1500 bar
Hydraulic pressure
dismantling
1400-1650 bar
D-3
Value Unit
148 mm
When referring to this page, please quote Data D11203 Edition 0015
MAN B&W Diesel A/S
Page 1 (2)
Stay Bolts
112-3
Data
Spare Parts
Plate Item No.
Page 2 (2)
Description
Qty
When referring to this page, please quote Data D11203 Edition 0015
MAN B&W Diesel A/S
Stay Bolts
912-3.1
Checking
Stay
K98MC
0210 Bolts
Checking
912-3.1
1.
One Group
One Group
NA912-3.1 210 01
Note!
2.
3.
'
GN912-3.0 39 09
GN912-3.1 202 01
GN912-3.1 202 03
4.
When referring to this page, please quote Procedure M91203 Edition 0210
0$1 % : 'LHVHO $6
Page 1 (2)
912-3.1
Stay Bolts
Checking
5.
5. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other.
Connect the high-pressure pump by means
of the high-pressure hoses, so that the two
stay bolts are tightened in one operation.
GN912-3.1 202 02
6.
HM912-3.0 28 04
HM912-3.0 28 05
7.
Page 2 (2)
When referring to this page, please quote Procedure M91203 Edition 0210
0$1 % : 'LHVHO $6
912-5.1
Checking
1.
M91205 0201C01
Note!
2.
Note!
It is strongly recommended to always replace the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.
M91205 0201C02
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.
When referring to this page, please quote Procedure M91205 Edition 0201
Page 1 (2)
912-5.1
Checking
C
D
B
A
6. Remove:
Screws C
Cover plate D
Screws E.
M91205 0201C04
7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are
found in the metal bellow sealing, it must
be replaced.
Note!
7.
M91205 0201C07
10. Mount:
Screws E
Cover plate D
Screws C.
11. Remove the four screws A.
12. Mount grating B.
13. Mount all screws A.
Page 2 (2)
When referring to this page, please quote Procedure M91205 Edition 0201
When referring to this page, please quote Plate P91261 Edition 0073
MAN B&W Diesel A/S
Plate
P91261-0073
Page 1 (2)
Plate
P91261-0073
Item
No.
023
035
047
050
060
084
106
202
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P91261 Edition 0073
MAN B&W Diesel A/S
Plate
P91265-0003
P91265
Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)
0003
When referring to this page, please quote Plate P91265 Edition 0003
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91265-0003
Item
No.
025
037
049
050
074
098
204
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P91265 Edition 0003
MAN B&W Diesel A/S
When referring to this page, please quote Plate P91268 Edition 0001
MAN B&W Diesel A/S
Plate
P91268-0001
Page 1 (2)
Plate
P91268-0001
Item
No.
Item Description
021
033
057
069
094
104
200
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P91268 Edition 0001
MAN B&W Diesel A/S
0215
0201
0205
0205
0207
0204
0037
0058
0005
0013
0003
0003
0052
0064
0040
0059
0066
0004
Hydraulic Tools
Standard Tightening Torques
Torque Spanner
Tightening Gauge
Screws and Nuts
Lubricating
Accessories - Hydraulic Tools
Lifting Tools, etc.
Open-Ended Spanners
Open Ended Slugging Spanners
Torque Spanners
Pliers
Combination Spanners
Ring Slugging Spanners
Spanners
Open-Ended Spanners
Instruments
Working Platforms
913-1.1
Hydraulic Tools
Description
A. Snap-on coupling
B. Tool attachment thread
1.
C. Bleed screw
D. Piston
C
D
E
E. Cylinder
F. Sealing rings
G. Spacer ring
H. Tommy bar
J. Stud or bolt
K. Extension stud
L. Lifting tool
S. Clearance
U. Milled recess for feeler gauge
M91301 0215C01
I. Nut
G
3.
D
F
E
M91301 0215C02
I
J
2.
Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts
must only be loosened and tightened up by
means of the hydraulic tools supplied.
The jacks must never be overloaded or exposed to blows or impacts. They are marked
with a Max. lift, which must not be exceeded.
K
B
J
U
I
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 1 (12)
913-1.1
Hyraulic Tools
Description
3.
M91301 0215C03
4.
M91301 0215C04
Page 2 (12)
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Hydraulic Tools
913-1.2
Dismantling
Single Hydraulic Jack
1.
1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.
Grease the tool attachment thread with
molybdenum disulphide grease or with
graphite and oil or similar.
Place the spacer ring around the nut in
such a position that the tommy bar can be
applied through the slot when the nut is to
be loosened.
MoS2
Screw back the jack a number of turns, according to the table shown on the sketch,
to produce a clearance between the jack
and the spacer ring.
The clearance between the jack and spacer
ring ensures dismantling of the jack after
loosening the nut.
When loosening nuts on very long bolts
(e.g. staybolts) it is recommended to unscrew the jack an additional half turn.
M91301 0215D01
2.
Max. lift =
Max. lift 10 mm 25 mm
Loosening 1 turn 3 turn
Tightening 1/4 trun 1/4 turn
M91301 0215D02
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 3 (12)
913-1.2
Hydraulic Tools
Dismantling
3.
M91301 0215D03
Note!
Make sure not to exceed the max lift
stamped on the jack.
M91301 0215D04
4.
M91301 0215D05
5.
Page 4 (12)
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Hydraulic Tools
913-1.2
Dismantling
Double Hydraulic Jack
6.
6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.
Grease the tool attachment threads with
molybdenum disulphide grease or graphite
and oil or similar.
Mount the extension studs on the main
bearing studs.
Using the lifting tool, place the spacer ring
over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.
M91301 0215D06
7.
M91301 0215D07
MoS2
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 5 (12)
913-1.2
Hydraulic Tools
Dismantling
8.
Max. lift 10 mm
3 mm
M91301 0215D08
9.
M91301 0215D09
Page 6 (12)
Note!
Make sure not to exceed the max lift
stamped on the jack.
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
913-1.3
Hydraulic Tools
Overhaul
1. The hydraulic jacks require no maintenance
except replacement of defective sealing
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.
1.
The piston and cylinder are easily separated by taking out the bleed screw and
pressing the parts apart with the help of
compressed air.
Air
Warning!
Always use protective gloves and eye
protection when working with compressed air.
M91301 0215O01
2.
Air
M91301 0215O02
Air
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 7 (12)
913-1.3
Hydraulic Tools
Overhaul
3. When changing the sealing rings, first
mount the back-up ring and then the Oring.
3.
Note!
Note that the back-up ring (1) must be
away from the pressure chamber and
the O-ring (2) close to the pressure
chamber.
1
2
4. After fitting the sealing rings, coat the piston and cylinder with molybdenum
disulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
M91301 0215O03
2
1
Page 8 (12)
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Hydraulic Tools
913-1.4
Mounting
Single Hydraulic Jack
1.
1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.
Clean and lubricate the tool attachment
thread and the thread in the nut with molybdenum disulphide grease or with graphite and oil or similar.
MoS2
M91301 0215D01
2.
Max. lift =
Max. lift 10 mm 25 mm
Loosening 1 turn 3 turn
Tightening 1/4 trun 1/4 turn
M91301 0215D02
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 9 (12)
913-1.4
Hydraulic Tools
Mounting
3.
M91301 0215M03
M91301 0215M04
4.
Page 10 (12)
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Hydraulic Tools
913-1.4
Mounting
5.
M91301 0215M05
MoS2
6.
M91301 0215D06
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
Page 11 (12)
913-1.4
Hydraulic Tools
Mounting
7.
M91301 0215M07
8.
10. Relieve the system of pressure, disconnect
the pump, and remove the hydraulic tools.
M91301 0215M08
11. When new studs, bolts or nuts are tightened for the first time, do not remove the
jacks, but loosen the nuts as described under Loosening', points 12-13-14, and then
tighten the nuts again according to the procedure under Tightening', points 24-25-26.
M91301 0215M09
9.
Page 12 (12)
When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
913-4
Standard
.0&&Tightening Torques
0201
913-4
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
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
When referring to this page, please quote Procedure M91304 Edition 0201
0$1 % : 'LHVHO $6
Page 1 (1)
Torque Spanner
913-5
Torque
/0&
0205 Spanner
913-5
When referring to this page, please quote Procedure M91305 Edition 0205
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.
See Procedure 913-5.
Apply a pre-tightening torque of:
thread M8 M20 = 50 Nm
thread M22 M27 = 100 Nm
thread M30 M39 = 150 Nm
thread M42 M48 = 200 Nm
This is in order to ensure a uniform basis for the
subsequent tightening with gauge or tightening
angle.
Tightening with a tightening gauge
After pre-tightening, place the tightening gauge
round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.
Tightening without a tightening gauge
For tightening angles of e.g. 3045 and 60,
we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,
respectively. Then tighten the nut until the two
marks coincide.
When tightening new studs or bolts for the first
time, loosen again and repeat the procedure
including pre-tightening with a torque spanner,
to allow the parts to settle.
See Procedure 913-5.
#
%
"
(
U
Y
#
%
"
(
H
C
When referring to this page, please quote Procedure M91306 Edition 0205
0$1 % : 'LHVHO $6
Page 1 (1)
913-7.1
Locking
1.
M91307 0207C01
Note!
2.
M91307 0207C02
M91307 0207C03
3.
When referring to this page, please quote Procedure M91307 Edition 0207
Page 1 (4)
913-7.1
Locking
Fig. 1
Fig. 2
Fig. 3
Fig. 6
M91307 0207C04
Fig. 5
Fig. 4
Fig. 7
Fig. 8
M91307 0207C05
Page 2 (4)
Fig. 9
When referring to this page, please quote Procedure M91307 Edition 0207
913-7.1
Locking
Fig. 10
Fig. 11
Fig. 12
M91307 0207C06
Fig. 13
Fig. 14
When referring to this page, please quote Procedure M91307 Edition 0207
Page 3 (4)
913-7.1
Fig. 15
M91307 0207C15
Fig. 16.
Note!
M91307 0207C16
M91307 0207C17
Fig. 17
Page 4 (4)
When referring to this page, please quote Procedure M91307 Edition 0207
Lubricating Procedures
913-11
Lubricating
.0&& Procedures
0204
913-11
When referring to this page, please quote Procedure M91311 Edition 0204
0$1 % : 'LHVHO $6
Page 1 (1)
When referring to this page, please quote Plate P91351 Edition 0037
MAN B&W Diesel A/S
Plate
P91351-0037
Page 1 (2)
Plate
P91351-0037
Item
No.
010
022
046
058
060
105
117
130
154
166
201
213
225
237
249
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P91351 Edition 0037
MAN B&W Diesel A/S
Plate
P91356-0058
P91356
Lifting
0058 Tools, Etc.
When referring to this page, please quote Plate P91356 Edition 0058
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91356-0058
Item
No.
020
031
043
055
067
079
114
126
138
140
151
163
210
222
234
258
295
305
Item Description
Forged-bent screw shackle,
Forged-bent screw shackle,
Forged-bent screw shackle,
Forged-bent screw shackle,
Forged-bent screw shackle,
Forged-bent screw shackle,
Lifting eye bolts, 10mm
Lifting eye bolts, 12mm
Lifting eye bolts, 16mm
Lifting eye bolts, 20mm
Lifting eye bolts, 24mm
Lifting eye bolts, 30mm
Chain tackle, 500kg
Chain tackle, 1000kg
Chain tackle, 2000kg
Chain tackle, 3000kg
Pull lift, 3000kg
Wire rope, 6m
Page 2 (2)
Item
No.
Item Description
10mm
12mm
16mm
20mm
24mm
30mm
When referring to this page, please quote Plate P91356 Edition 0058
MAN B&W Diesel A/S
Plate
P91357-0005
P91357
Open
0005 Ended Spanners
When referring to this page, please quote Plate P91357 Edition 0005
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91357-0005
Item
No.
013
025
037
050
Item Description
Open-ended
Open-ended
Open-ended
Open-ended
Page 2 (2)
spanner,
spanner,
spanner,
spanner,
size
size
size
size
Item
No.
Item Description
NV65mm
NV70mm
NV75mm
NV85mm
When referring to this page, please quote Plate P91357 Edition 0005
MAN B&W Diesel A/S
Plate
P91358-0013
P91358
Open-Ended Slugging Spanners
0013
When referring to this page, please quote Plate P91358 Edition 0013
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91358-0013
Item
No.
127
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P91358 Edition 0013
MAN B&W Diesel A/S
Torque Wrenches
When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S
Plate
P91359-0003
Page 1 (2)
Plate
P91359-0003
Item
No.
014
026
038
040
051
Page 2 (2)
Torque Wrenches
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S
Pliers
Plate
P91360-0003
P91360
Pliers
0003
When referring to this page, please quote Plate P91360 Edition 0003
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91360-0003
Pliers
Item
No.
010
021
033
128
130
141
153
Item Description
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Pliers
Page 2 (2)
for
for
for
for
for
for
for
retaining
retaining
retaining
retaining
retaining
retaining
retaining
ring,
ring,
ring,
ring,
ring,
ring,
ring,
size
size
size
size
size
size
size
Item
No.
Item Description
0.9mm
1.3mm
1.8mm
1.1mm
1.8mm
2.3mm
3.2mm
When referring to this page, please quote Plate P91360 Edition 0003
MAN B&W Diesel A/S
Combination Spanners
MAN B&W Diesel
When referring to this page, please quote Plate P91361 Edition 0052
Plate
P91361-0052
Page 1 (2)
Combination Spanners
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)
Item Description
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
Combination
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
spanners,
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
size
Item
No.
Item Description
NV10mm
NV11mm
NV12mm
NV13mm
NV14mm
NV15mm
NV16mm
NV17mm
NV18mm
NV19mm
NV21mm
NV22mm
NV24mm
NV27mm
NV30mm
NV32mm
NV34mm
NV36mm
NV41mm
NV46mm
NV50mm
NV55mm
NV60mm
When referring to this page, please quote Plate P91361 Edition 0052
When referring to this page, please quote Plate P91362 Edition 0064
MAN B&W Diesel A/S
Plate
P91362-0064
Page 1 (2)
Plate
P91362-0064
Item
No.
022
034
046
058
060
071
083
095
105
117
129
130
142
Page 2 (2)
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P91362 Edition 0064
MAN B&W Diesel A/S
Spanners
MAN B&W Diesel
When referring to this page, please quote Plate P91363 Edition 0040
Plate
P91363-0040
Page 1 (2)
Spanners
Plate
P91363-0040
Item
No.
Item Description
016
028
030
041
100
150
161
Page 2 (2)
Item
No.
Item Description
When referring to this page, please quote Plate P91363 Edition 0040
Open-ended Spanners
Plate
P91364-0059
When referring to this page, please quote Plate P91364 Edition 0059
Page 1 (2)
Plate
P91364-0059
Item
No.
011
023
Page 2 (2)
Open-ended Spanners
Item Description
Item
No.
Item Description
When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S
Instruments
When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S
Plate
P91366-0066
Page 1 (2)
Plate
P91366-0066
Item
No.
012
024
036
048
050
061
073
Page 2 (2)
Instruments
Item Description
Item
No.
Item Description
Indicator, complete
Indicator paper
Plainmeter, complete
Autolog, measuring tool for crankshaft
Feeler gauge
Slide caliper
Dial gauge and stand tool
When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S
Working Platforms
Plate
P91368-0004
P91368
Working Platforms
0004
When referring to this page, please quote Plate P91368 Edition 0004
MAN B&W Diesel A/S
Page 1 (2)
Plate
P91368-0004
Item
No.
013
Working Platforms
Item Description
Item
No.
Item Description
Page 2 (2)
When referring to this page, please quote Plate P91368 Edition 0004
MAN B&W Diesel A/S