Warning MAN B&W S900-0002maytau.ut.edu.vn/userfiles/files/S42MC-PART 1.pdf · 105-02 0084 Main Bearing, Data 905-02 0260 Main Bearing. Table of Contents 900 Volume II - Maintenance

Page 1 (1)When referring to this page, please quote S-Instruction Edition

MAN B&W

Warning!

It is important that all MAN Diesel A/S engines are operated within the given specifi cations and performance tolerances specifi ed in the engines’ Technical Files and are maintained according to the MAN Diesel A/S maintenance instructions in order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specifi ed in MAN Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

Warning

S900-0002

S900 0002

S42MC VOLUME IIMAINTENANCE

MAN B&W Diesel A/S

900 - Introduction

Documents in this Chapter

Table of Contents, Volume II

90050 0288 Checking & Maintenance Schedule

90060 0002 General - Safety Precautions

MAN B&W Diesel A/S

Table of Contents 900

Volume II - Maintenance

Page 1 (4)MAN B&W Diesel A/S

No. Edition Title

900 - IntroductionTable of Contents

90050 0288 Checking & Maintenance Schedule90060 0002 General - Safety Precautions

901 - Cylinder Cover101-01 0075 Cylinder Cover, Data901-01 0258 Cylinder Cover90151 0211 Cylinder Cover - Panel90161 0103 Cylinder Cover - Tools

902 - Piston with Rod & Stuffing Box102-01 0103 Piston, Data902-01 0292 Piston102-02 0059 Piston Rod Stuffing Box, Data902-02 0233 Piston Rod Stuffing Box90251 0255 Piston and Piston Rod - Panel90264 0010 Piston and Piston Rod - Tilting Tools90265 0005 Piston and Piston Rod - Support Tools90266 0004 Piston - Lifting Tools

903 - Cylinder Liner and Cylinder Lubrication103-01 0079 Cylinder Liner, Data903-01 0237 Cylinder Liner103-02 0033 Cylinder Lubricator, Data903-02 0258 Cylinder Lubricator90361 0084 Cylinder Liner - Tools

904 - Crosshead with Connecting Rod104-01 0067 Crosshead Bearing, Data904-01 0256 Crosshead Bearing104-02 0069 Crosshead, Data904-02 0256 Crosshead104-03 0047 Reciprocating Parts, Data904-03 0215 Reciprocating Parts104-04 0061 Crankpin Bearing, Data904-04 0226 Crankpin Bearing104-05 0059 Connecting Rod, Data904-05 0238 Connection Rod90451 0144 Connecting Rod and Crosshead - Panel90461 0066 Connecting Rod - Hydraulic Tools

905 - Crankshaft, Thrust Bearing and Turning Gear105-02 0084 Main Bearing, Data905-02 0260 Main Bearing




No. Edition Title

105-03 0074 Thrust Bearing, Data905-03 0227 Thrust Bearing105-04 0049 Journal Bearing, Data905-04 0233 Journal Bearing105-05 0060 Axial Vibration Damper, Data905-05 0226 Axial Vibration Damper90551 0248 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel90561 0085 Main Bearing - Hydraulic Tools90562 0128 Crankshaft - Tools90572 0003 Main Bearing - Measuring Tools

906 - Control Gear106-01 0055 Chain, Data906-01 0245 Chain106-02 0066 Chain Tightener, Data906-02 0230 Chain Tightener106-03 0042 Camshaft, Data906-03 0219 Camshaft106-04 0044 Camshaft Bearings, Data906-04 0225 Camshaft Bearings106-06 0010 Replacement of Cams on Camshaft, Data906-06 0203 Replacement of Cams on Camshaft90651 0193 Chain Drive and Camshaft - Panel90664 0005 Crankshaft - Pin Gauge90668 0005 Camshaft - Pin Gauge

907 - Starting Air System107-01 0020 Starting Air Distributor, Data907-01 0218 Starting Air Distributor107-02 0045 Start Air Valve, Data907-02 0220 Starting Air Valve

908 - Exhaust Valve108-01 0050 High-Pressure Pipe, Data908-01 0214 High-Pressure Pipe108-02 0092 Exhaust Valve, Data908-02 0263 Exhaust Valve108-03 0056 Exhaust Valve Actuator, Data908-03 0226 Exhaust Valve Actuator108-04 0040 Exhaust Valve Roller Guide, Data908-04 0221 Exaust Valve Roller Guide108-05 0016 Exhaust Valve Cam, Data908-05 0218 Exhaust Valve Cam108-07 0034 Exhaust Valve - Special Running, Data908-07 0226 Exhaust Valve




No. Edition Title

90851 0205 Exhaust Valve - Panel90861 0036 Exhaust Valve - Tools90862 0041 Exhaust Valve - Hydraulic Tools90863 0006 Exhaust Valve - Extra Tools90863 0016 Exhaust Valve - Extra Tools

909 - Fuel Oil System90961 0069 Fuel Valve - Tools90961 0071 Fuel Valve - Tools90966 0008 Fuel Valve Nozzle - Tools90968 0001 Fuel Valve - Inspection Tools90974 0001 Fuel Valve Nozzle - Cleaning Tools90980 0001 Mounting Tools - Air Piston Seals

910 - Turbocharger System110-01 0059 Air Cooler Element, Data910-01 0247 Air Cooler Element110-02 0009 Non-Return Valve after Air Cooler, Data910-02 0211 Non Return Valve after Air Cooler110-03 0030 Auxilary Blower, Data910-03 0215 Auxilary Blower110-05 0010 Turbocharger Turbine, Data910-05 0212 Turbocharger Turbine110-06 0038 Water Mist Catcher, Data910-06 0217 Water Mist Catcher91061 0071 Turbocharger System - Tools91063 0017 Air Cooler - Tools91064 0002 Travelling Trolley91066 0001 Air Cooler - Lifting Tools

911 - Safety Equipment111-01 0026 Safety Valve, Data911-01 0212 Safety Valve111-02 0013 Relief Valve, Data911-02 0211 Relief Valve111-03 0001 Scavenge Air Receiver Safety Valve, Data911-03 0001 Scavenge Air Receiver Safety Valve

912 - Assembly of Large Parts112-02 0008 Holding Down & End Chock Bolts, Data912-02 0208 Holding Down and End Chock Bolts112-03 0017 Stay Bolts, Data912-03 0211 Stay Bolts912-05 0201 Crankcase Oil Outlet91261 0070 Hydraulic Tools for Large Parts




No. Edition Title

91263 0058 Hydraulic Tools - Holding-Down and End Chock Bolts (Epoxy Chocks)

913 - General Tools913-01 0212 Hydraulic Tools913-04 0202 Standard Tightening Torques913-05 0205 Torque Spanner913-06 0205 Tightening Gauge913-07 0207 Screws and Nuts91311 0204 Lubricating91351 0036 Accessories - Hydraulic Tools91356 0059 Lifting Tools, etc.91357 0003 Open-Ended Spanners91358 0012 Open Ended Slugging Spanners91359 0002 Torque Spanners91360 0002 Pliers91361 0052 Combination Spanners91362 0064 Ring Slugging Spanners91363 0040 Spanners91364 0059 Open-Ended Spanners91366 0066 Instruments91368 0007 Working Platforms

When referring to this page, please quote Maintenance Schedule A90050 Edition 0288 Page 1 of 6

Checking and Maintenance Schedule,26-70 MC/MC-C Engines

900-1MAN B&W Diesel

The Checking and Maintenance Schedules indi-cate the intervals at which it is deemed appropri-ate to inspect the individual components of theengine and to carry out overhauls, if necessary,based on the engine condition or on time criteria.

The stated Normal hours of service should onlybe used as a guide, as differences in the actualservice conditions, the quality of the fuel oil or lu-bricating oil, the treatment of cooling water, etc.will decisively influence the actual service results,and thus the intervals between necessary over-hauling.

Design modifications may necessitate a revision ofthe instructions, in which case the revised instruc-tions and changed overhauling intervals, if any, willapply and supersede those originally issued (seee.g our Service Letters).

In addition to the checking and overhauling inter-vals stated in this schedule, please note that theperiodical survey requirements of the classificationsociety may require additional checks and over-hauls to be carried out. For further informationplease refer to the classification society.

The procedures are divided into three categories:

Condition checking procedures marked under the heading Normal hours of service with a C,deal with the service condition of a number of engine compo-nents, and form the basis for estimating whether further overhaul-ing is necessary. In a number of cases the condition checkingprocedures refer to Volume I of the instruction book, in whichmore detailed descriptions and working procedures can be found.

Condition-based overhaulingprocedures

are those procedures which under the heading Normal hours ofservice are marked with an O, and opposite which, under theheading Overhaul to be based on procedure No. (column P), aprocedure number is stated.

This procedure number normally refers to one of the above condi-tion checking procedures which form the basis of the overhaul.For this reason, the intervals stated are for guidance only.

Time-based overhaulingprocedures

also marked with an O under the headings Normal hours of ser-vice or Based on observations, are the procedures where anactual basis for estimation is lacking. It is recommended, there-fore, to carry out these procedures at the overhauling intervalsstated as a basis.

Where a symbol O or C is indicated in Based on observations(column B), this is due to the fact that special service conditionsmay make checking or overhauling necessary beyond the actualstandard schedules indicated.

When referring to this page, please quote Maintenance Schedule A90050 Edition 0288Page 2 of 6

Checking and Maintenance Schedule,26-70 MC/MC-C Engines

900-1 MAN B&W Diesel

MAN B&W Diesel Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 900-1

V : See Volume I “Operation”

A : Adjustment to be carried out

C : Check the condition

M : See maker’s instructions

O : Overhaul to be carried out

H : Check new/overhauled parts after 500-1500 hours

R : Parts to be replaced

B : Based on observations

P : Refer to

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

Regular Checks Service interval (x1000 hours of operation)


901 Cylinder Cover

-1 Cylinder cover C* O

Indicator cock O

902 Piston with Rod and Stuffing box

-1 Piston C,O O

Inspection through scavenge ports C V

-2 Piston rod stuffing box C* O

903 Cylinder Liner and Cylinder Lubrication

-1 Cylinder liner O

Inspection through scavenge ports C

Measuring wear inside liner C

-2 Cylinder lubricators C A V,M

Accumulators nitrogen pressure C A

904 Crosshead with connecting rod

-1 Crosshead bearing C C C,O V

-2 Crosshead C C C,O

-3 Reciprocating parts C C,O

-4 Crankpin bearing C C C,O V

-5 Connecting rod O

905 Crankshaft and Thrust Bearing

-2 Main bearing C C C,O V

-3 Thrust bearing C C C,O

-3 Guide bearing C C C,O

-4 Journal bearing C C C,O V

-5 Axial vibration damper O

Electronic axial vibration monitor C

* Check whenever exhaust

valve is removed

Bearings should only be

opened up if bearing material

fragments fall out.

* Check clearances without

dismantling segments

Bearings should only be

opened up if bearing material

fragments fall out.


Checking and Maintenance Schedule, 26-70 MC/MC-C Engines900-1









P : Refer to



MAN B&W Diesel

Mechanical checking C

-7 Tacho pick-up C,O M

-8 Angle encoder C,O M

906 Mechanical Control Gear

-1 Chains C C R V

-2 Chain tightener C,A C,A A

Chain wheels, spray nozzles and guide bars C C R

-3 Camshaft C C C,A

-4 Camshaft bearings C C,O

Camshaft coupling, fitted bolts C

-5 Moment compensator C C C,A

Governor O M

Functional check of overspeed device C M

Functional check of speed-setting system C M

(engine with bridge control system)

907 Starting Air System

-1 Starting air distributor C C A

-2 Starting air valve C,O

908 Exhaust Valve

-1 High-pressure pipe O

-2 Exhaust valve

Conventional hard-faced valve seats O

Nimonic exhaust valves O

-3 Exhaust valve actuator O

Actuator safety valve C,A

-4 Exhaust valve roller guide C* C* C O

-5 Exhaust valve cam C* C* O

New or overhauled chain to be

checked/retightened after 500,

1500 and 4000 hours

* only inspection through

camshaft covers

MAN B&W Diesel Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 900-1









P : Refer to




-7 Exhaust valve special running O

909 Fuel Oil System

Fuel oil water content C

-1 Fuel pump settings A,C V

-2 VIT system A V

-3 Fuel pump cam A

-4 Fuel pump C O O

-5 Fuel pump top cover O

-6 Fuel pump barrel assembly R

-7 Fuel pump suction valve C,O

-8 Fuel pump puncture valve C,O

-9 Fuel pump shock absorber C O

-9 Fuel system shock absorber C O

-10 Lifting gear for roller guide C O

-11 Fuel valve C,O

- Fuel nozzle R

-12 Spindle guide R

-13 Non-return valve O

-14 Fuel oil high-pressure pipes O

-15 Fuel pump roller guide C* C* C O

-16 Fuel pump special running O

910 Turbocharger System

-1 Air cooler C O V

-2 Non-return valve C O

-3 Auxiliary blower O

-4 Butterfly valves C O

-5 Turbocharger turbine C* C C,O V,M

* Only inspection through

camshaft covers

Check ∆p and ∆t

Check at every port inspection


Checking and Maintenance Schedule, 26-70 MC/MC-C Engines900-1









P : Refer to



MAN B&W Diesel

Turbocharger air filter C O

Protective grid before turbocharger C R V

Turbocharger lubricating oil water content C* M

-6 Water mist catcher C* C,O

911 Safety Equipment

-1 Overpressure indicator valve C O

-2 Relief valve C O

-3 Scavenge air receiver safety valve C O

Functional test of alarm system for thrust

bearing and slow down /shut down system C C M

Checking and adjustment of pressure gauge C A M

Checking and adjustment of thermometers C A M

Checking and adjustment of thermostats C A M

Checking and adjustment of pressurestats C A M

Checking and adjustment of turning gear switch C A M

912 Assembly of Large Parts

-2 Holding-down and end chock bolts C C* C

-3 Stay bolts C C

Top bracings C C

Diaphragm in crankcase oil outlet C R

System lubricating oil water content C M

System lubricating oil bottom tank O

Cooling water quality C A V,M

Crankcase C*

913 General Tools

-1 Hydraulic tools O M

* Check for loose nuts and

bearing material fragments

Empty and clean tank

* Initial check only

* Check ∆p

Page 1 (1)

SAFETY PRECAUTIONS

General – Safety Precautions 900-2

When referring to this page, please quote Safety Precaution A90060 Edition 0001

MAN B&W Diesel A/S

X

X

X

X

X

X

X

X

X

X

X

X

Stopped engine

Shut off starting air supply – At starting air receiver

Block the main starting valve

Shut off starting air distributor/distributing system supply

Shut off safety air supply – Not ME-engines

Shut off control air supply

Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps

Engage turning gear

Shut off cooling water

Shut off fuel oil

Stop lubricating oil supply

Lock the turbocharger rotors

Before maintenance work is carried out, the engine must be stopped and blocked according to thesafety precautions given on the specific Data Sheet.

The sketch gives the approximate location of the valves concerned:

MAN B&W Diesel A/S

901 - Cylinder Cover


101-01 0075 Cylinder Cover, Data

901-01 0258 Cylinder Cover

90151 0211 Cylinder Cover - Panel

90161 0103 Cylinder Cover - Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data

For detailed sketch, see 900-2

Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 200 Nm

D01-05 Cylinder cover stud, check distance 110±3 mm

D01-06 Cylinder cover, complete 1100 kg

D01-07 Cylinder cover without valves 700 kg

D01-08 Cooling jacket 40 kg

D01-09 Exhaust valve stud 25 kg

D01-10 Cylinder cover stud 15 kg

D13-01 Hydraulic pressure, mounting 900 bar

D13-02 Hydraulic pressure, dismantling 800 - 990 bar

Cylinder Cover

X Stopped engine

X Shut off starting air supply – At starting air receiver

X Block the main starting valve

X Shut off starting air distributor/distributing system supply

X Shut off safety air supply – Not ME engines

X Shut off control air supply

X Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X Engage turning gear

X Shut off cooling water

X Shut off fuel oil

X Stop lubricating oil supply

X Lock the turbocharger rotors

When referring to this page, please quote Data D10101 Edition 0075

101-1

Page 2 (2)

MAN B&W Diesel

The task-specifi c tools used in this procedure are shown on the plates at the end of this chapter or in

the chapters indicated by the fi rst three digits in the plate number, e.g. P90951 refers to chapter 909.

Data

Plate Item No. Description

P90151 046 Grinding tool for exhaust valve seat

P90151 058 Milling and grinding wheel for fuel valve seat

P90151 060 Milling and grinding wheel for starting valve seat

P90151 083 Grinding handle

P90151 130 Lifting chains

P90161 Cylinder Cover - Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete


P91351 130 9-way distributor block, complete

Cylinder Cover


101-1

Page 1 (13)

901-1.2

When referring to this page, please quote Procedure M90101 Edition 0258

MAN B&W Diesel Dismantling

Cylinder Cover

M90101-0

255C

03

M90101-0

254D

01

3.

2.Shut off Oil and Water Supply

1. Check engine blocking.

Check that the engine is stopped and

blocked according to the safety precau-

tions given on the data sheet.

2. Shut off the oil supply.

Close the fuel oil supply for the unit con-

cerned.

3. Shut off the water supply.

Shut off the water outlet on the main pipe

above the exhaust valve.

Shut off the water supply placed on the ex-

haust side of the main pipe.

Open the drain next to the inlet valve.

Open the venting cock next to the outlet

valve.

Cylinder Cover

Page 2 (13)

901-1.2


MAN B&W DieselDismantlingM

90101-0258D

05

M90101-0258D

04

4.

5.

Dismantling of Pipe Connections

4. Disconnect the oil pipes.

Remove the hydraulic high pressure pipe

for the exhaust valve. See Procedure

908-1.2

Unscrew the drain pipe for the exhaust

valve.

Remove the fuel oil high pressure pipes.

See Procedure 909-14.2.

Disconnect the pipes for return fuel oil from

the fuel valves.

5. Disconnect the water pipes.

Unscrew and remove the water outlet

pipes.

6. Exhaust gas compensator.

Remove the protective jacket enclosing the

insulation for the intermediate pipe or com-

pensator. Remove the insulation.

Remove the screws from the fl anges be-

tween the intermediate pipe and the ex-

haust receiver.

6.

M90101-0258D

06

Page 3 (13)

901-1.2



Cylinder Cover

M90101-0258D

08

D13-02

M90101-0258D

07

7. Disconnect the starting air pipe.

Unscrew and remove the control air pipe

for the starting air valve.

Unscrew and remove the air pipe for the

starting valve.

8. Cylinder cover loosening.

Remove the protective caps from the cylin-

der cover nuts.

Loosen and remove the cylinder cover nuts,

see Data.

For use of hydraulic tools, see Procedure

913-1.

7.

8.

Cylinder Cover

Page 4 (13)

901-1.2



90101-0258D

11

M90101-0258D

10

Cylinder Cover Lifting and Landing

9. Cylinder cover lifting.

Hook on the engine room crane to the lift-

ing attachment on top of the exhaust valve.

Check that all cylinder cover connections

have been loosened and removed.

Lift away the cylinder cover complete.

10. Cylinder cover landing.

Land the cylinder cover on a couple of

wooden planks.

11. Remove sealing ring.

Remove and discard the sealing ring be-

tween the cylinder cover and cylinder liner.

9.

10.

11.

M90101-0258D

09

D01-06

Page 5 (13)

901-1.3


MAN B&W Diesel Overhaul

Cylinder Cover

M90101-0258O

03

M90101-0258O

02

D01-07

Overhaul Preparations

1. Dismantle valves and pipes.

Dismantle all valves and pipes from the

cylinder cover. See Procedure 907-2.2,

908-2.2 and 909-11.2.

Remove all studs on top of the cylinder

cover.

Cooling Water Jacket

2. Remove the cooling water jacket.

Mount four eyebolts and the lifting chains

as shown in the sketch.

Remove the screws which secure the cool-

ing jacket to the cylinder cover.

Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.

Remove and discard the O-rings from the

cover, and carefully clean the cooling jacket

and the cylinder cover.

3. Mount the cooling water jacket.

Provide the cylinder cover with new

O-rings, well lubricated with oil.

Lift the cylinder cover and guide the jacket/

cover into position, so the marking scratch-

es on the cover and the cooling jacket are

in line (manoeuvre side).

Fit and tighten the screws for the cooling

jacket.

1.

3.

2.M

90101-0258O

01

D01-09

Cylinder Cover

Page 6 (13)

901-1.3


MAN B&W DieselOverhaulM

90101-0258O

05

1 32

M90101-0258O

04

Reconditioning of Bores

4. Seat reconditioning tools.

The tools for reconditioning of the valve

seats are found on tool panel 901.

5. Fuel valve bore.

The tool consists of a common spindle with

a handle, a guide, a carbon cutter, a seat-

ing face cutter and a grinding mandrel.

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. Carborun-

dum No. 200).

After the milling/grinding, clean the bore

and seating carefully, and check that the

seating is not damaged.

4.

5.

Page 7 (13)

901-1.3



Cylinder Cover

M90101-0

255O

07

M90101-0

255O

06

6. Exhaust valve bore.

The tool consists of a spindle with a handle

and a grinding disc.

After cleaning the valve bore and seating,

grind the seating with the grinding disc and

a grinding compound (e.g. Carborundum

No. 200).

After the grinding, clean the bore and seat-

ing carefully, and check that the seating is

not damaged.

7. Starting valve bore.

The tool consists of a guide, a cutter, and a

grinding disc.

Recondition the starting valve bore and

seating in the same way as described for

the fuel valve bore.

When replacing the valves on a cylinder

cover while it is mounted on the engine,

recondition the valve bores/seating as de-

scribed here, however, without removing

the studs.

6.

7.

Cylinder Cover

Page 8 (13)

901-1.3



90101-0258O

09

D01-01

M90101-0

255O

08

8. Indicator - safety valve bore.

Clean the bores for safety valve/indicator

cock.

Preparations before Mounting

9. Fitting of studs.

Lubricate the threads with ‘Never Seize’ or

molybdenum disulphide (MoS2) and fi t the

valve studs.

Tighten up the studs in accordance with

the screwing-in torque stated on the data

sheet.

Fill up the grooves between the valve studs

and the bores for the valve studs with per-

matex to prevent water or oil from entering

the bores during operation of the engine.

10. Mounting of valves.

Install the valves on the cylinder cover, see

Procedures 907-2.4, 908-2.4 and 909-11.4.

8.

9.

Page 9 (13)

901-1.4


MAN B&W Diesel Mounting

Cylinder Cover

M90101-0258M

01

M90101-0

255M

02

Landing Preparation

1. Sealing ring.

Check that the liner sealing surface is

clean.

Place a new sealing ring on top of the cyl-

inder liner.

If necessary fi t a new ‘klinger’ sealing ring

in the groove of the fl ange of the intermedi-

ate pipe.

2. Water connections.

Check that the water connections are clean

and provided with new O-rings.

Lubricate the O-rings with Vaseline and fi t

them on the cylinder liner.

1.

2.

Cylinder Cover

Page 10 (13)

901-1.4


MAN B&W DieselMountingM

90101-0258M

03

D01-06

M90101-0

254M

04

D01-05

Cylinder Cover Mounting

3. Cylinder cover landing.

Carefully wipe the cylinder cover contact

surface facing the cylinder liner.

Lift the cylinder cover by means of the

crane and lower it carefully into position.

During the landing, carefully check that

the cooling water connecting pipes en-

gage correctly with the holes in the cooling

jacket.

4. Cylinder cover stud - check distance.

If the cylinder cover studs have been re-

moved and reinstalled, check the distance

the stud is protruding from the cylinder

cover.

If necessary, adjust to the distance D01-05

by turning the stud.

3.

4.

Page 11 (13)

901-1.4



Cylinder Cover

M90101-0258M

06

M90101-0258M

05

D13-01

5. Cylinder cover tightening.

Fit and tighten the cylinder cover nuts.

For operation of hydraulic jacks, see Proce-

dure 913-1.

Fit the protective caps on the cylinder cov-

er studs.

Fitting Pipe Connections

6. Fit the exhaust gas compensator.

Fit the screws in the fl anges between the

intermediate pipe and the exhaust receiver,

tight the screws.

Fit the insulating jacket around the interme-

diate pipe.

5.

6.

Note!

Lubricate the screws with ‘Never Seize’

or molybdenum disulphide (MoS2) before

fi tting.

Cylinder Cover

Page 12 (13)

901-1.4


MAN B&W DieselMountingM

90101-0258M

09

M90101-0258M

08

M90101-0258M

07

7. Connect the starting air pipe.

Connect and tighten the air pipe for the

starting valve.

Connect and tighten the control air pipe for

the starting air valve.

8. Connect the water pipes.

Mount and tighten the water outlet pipes.

9. Connect the oil pipes.

Mount the hydraulic high pressure pipe for

the exhaust valve. See Procedure 908-1.4.

Connect the drain pipe for the exhaust

valve.

Connect the fuel oil high pressure pipes.


Connect the pipes for return fuel oil from

the fuel valves.

Check that all the pipe connections are fi t-

ted and tightened.

7.

8.

9.

Page 13 (13)

901-1.4



Cylinder Cover

M90101-0

254M

11

M90101-0

255M

10

Open Oil and Water Supply

10. Close the drain and open the water sup-

ply.

Close the venting cock next to the outlet

valve.

Close the drain next to the inlet valve.

Slowly open the water supply valve, placed

on the exhaust side of the main pipe.

Vent the unit by releasing air through the

venting cock next to the outlet valve.

When the venting is fi nished, close the

venting cock. Open the water outlet valve

on the main pipe.

11. Open the oil supply.

Open the fuel oil supply for the unit con-

cerned.

10.

11.

Plate

Page 1 (2)When referring to this page, please quote Plate EditionMAN B&W Diesel A/S

Cylinder Cover PanelP90151-0211

P90151 0211

Plate

Page 2 (2) When referring to this page, please quote Plate EditionMAN B&W Diesel A/S

P90151-0211Cylinder Cover Panel

ItemNo.

Item Description ItemNo.

Item Description

P90151 0211

010 Panel for tools022 Name plate046 Grinding tool, exhaust valve seat058 Milling and grinding tool, fuel valve

seat060 Milling and grinding wheel, fuel start-

ing valve071 Dismantling tool, fuel valve083 Handle, grinding tools095 Grinding ring, starting valve seat105 Pin spanner, starting valve117 Test equipment, combined safety

valve130 Lifting chains, cylinder cover

When referring to this page, please quote Plate P90161 Edition 0103 Page 1 (2)MAN B&W Diesel A/S

Cylinder Cover - Tools PlateP90161-0103

0103Cylinder Cover - ToolsP90161

Page 2 (2) When referring to this page, please quote Plate P90161 Edition 0103MAN B&W Diesel A/S

Cylinder Cover - ToolsPlateP90161-0103

Item No.

Item Description

027 Hydraulic jack, complete

039 Support

040 Support

052 O-ring with back-up ring


090 Key, hexagon socket screw

100 Tommy bar

111 Stud setter

206 Hydraulic, tool set, complete

218 Hydraulic, tool set, complete

Item No.

Item Description

MAN B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


102-01 0103 Piston, Data

902-01 0292 Piston

102-02 0059 Piston Rod Stuffing Box, Data

902-02 0233 Piston Rod Stuffing Box

90251 0255 Piston and Piston Rod - Panel

90264 0010 Piston and Piston Rod - Tilting Tools

90265 0005 Piston and Piston Rod - Support Tools

90266 0004 Piston - Lifting Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D01-05 Cylinder cover stud, check distance 110±3 mm

D02-01 Test pressure 7 bar

D02-02 Piston rod/crosshead, tightening torque 280 Nm

D02-03 Piston rod/crown, tightening torque 200 Nm

D02-05 Piston skirt, tightening torque 90 Nm

D02-06 Cooling oil pipe, tightening torque 50 Nm

D02-07 Piston rod/crosshead, tightening torque/angle 100/30 Nm/°

D02-08 Piston ring new, radial width 14.5 mm

D02-09 Piston ring worn, min. radial width 12.0 mm

D02-10 Groove No.1, max. vertical height 11.7 mm

D02-11 Groove Nos. 2, 3 and 4, max. vertical height 8.7 mm

D02-12 Piston top, max. permissible burn-away 13 mm

D02-13 Piston ring new, height of ring No. 1 10.9 mm

D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 7.9 mm

D02-15 Minimum free ring gap ( before dismantling ) 25 mm

D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 4.0 mm

D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 3.0 mm

D02-18 Vertical clearance, new parts 0.32 mm

D02-19 Vertical clearance, worn parts, max. 0.82 mm

D02-20 Piston complete 480 kg

D02-21 Piston crown 130 kg

D02-22 Piston rod 320 kg

D02-23 Piston skirt 30 kg

D02-24 Piston cooling pipe 14 kg

D02-25 Lifting tool, tightening torque 50 Nm

D02-46 CPR ring CL groove, min. depth 0.9 mm

Piston

X Stopped engine









X Shut off fuel oil




102-1

Page 2 (2)

MAN B&W Diesel



Data


P90251 040 Lifting tool for piston rod foot

P90251 075 Template for piston top

P90251 087 Distance piece for stuffi ng box

P90251 099 Cover for stuffi ng box hole

P90251 110 Pressure test tool for piston

P90251 134 Piston ring expander

P90251 146 Support

P90251 158 Guide screw for piston crown

P90251 171 Dismantling screw piston skirt

P90265 Piston and Piston Rod - Support Tools

P90266 Piston - Lifting Tools

P90451 84 Retaining tool telescope pipe

P90451 120 Rubber cover for crosshead

Piston


102-1

Page 1 (22)

902-1.1


MAN B&W Diesel Checking

Piston

M90201-0

280C

03

M90201-0

280C

02

M90201-0

280C

01

2.

3.

1.Scavenge Port Inspection

To detect possible leakages from the piston

or cylinder cover, keep the cooling water

and cooling oil circulating during the scav-

enge port inspection.

1. The scavenge port inspection is carried out

from the scavenge air receiver. An addition-

al view of the rings is possible through the

cleaning cover on the manoeuvring side.

Turn the engine at least ½ a revolution, and

begin with a unit arriving downwards, just

above the scavenge air ports. Inspect the

piston rod and the lower part of the cylin-

der wall.

While the piston is passing downwards,

inspect the piston skirt, all the piston rings,

the ring lands and the piston top.

2. Ring inspection:

Inspect the rings, one at a time, and note

down the results. See Volume I, Operation,

Chapter 707.

3. Ring tension:

Check the tension of the piston rings, by

pressing against them with a wooden stick.

Piston

Page 2 (22)

902-1.1


MAN B&W DieselChecking

M90201-0

285C

06

M90201-0

280C

04

D02-18

Max. 2mm

E

F

D02-19

M9

02

01

-02

80

C0

5

D02-465.

6.

4.4. Ring grooves:

Measure the total clearance between the

piston ring and the ring groove. The total

clearance must not exceed the value stated

in Data.

Measure the clearance at the top (E) and

bottom (F) of the piston ring groove.

Total clearance = E + F.

5. Uppermost piston ring:

If possible, measure the depth of the pres-

sure relief grooves with a calliper. The

piston rings must be replaced if the radial

depth of the grooves has worn down to

less than stated in Data D02-46.

Checking, in connection with piston over-

haul

6. Piston support:

Remove the piston from the cylinder and

place it on the piston support.

See Procedure 902-1.2. For evaluation of

the rings, see Volume I, Chapter 707.

Note!

It is recommended to replace all the pis-

ton rings whenever a piston is removed

from the engine.

Page 3 (22)

902-1.1



Piston

M90201-0

285C

07

D02-15

M90201-0

280C

09

D02-10

D02-11

Max 2mm

M9

02

01

-02

80

C0

8

New

Worn

D02-08

D02-09

8.

9.

7.7. Free ring gap:

Before dismantling the piston rings, mea-

sure the free ring gap of all the piston

rings.

For dismantling the piston rings, see Proce-

dure 902-1.3.

8. Radial ring width:

Measure the radial width of the rings. Note

down the results See Volume I, Operation,

Chapter 707.

9. Ring grooves:

Clean the ring grooves and check them for

burn marks or other deformation.

Measure the ring grooves with a calliper

gauge, see Data D02-10 and D02-11.

Clearance in piston ring grooves:

The maximum vertical height in a worn ring

groove must not exceed the value stated

in Data. The groove is also worn out if

there is no chromium layer.

If the ring grooves are worn out, the piston

crown must be reconditioned, contact MAN

B&W Diesel A/S for advice.

Piston

Page 4 (22)

902-1.1



M90201-0

285C

10

D02-12

10. Piston crown top:

Clean the piston crown and check the

burn-away by means of the template.

For maximum permissible burn away value,

see Data.

Check the burn-away on the whole circum-

ference of the piston crown top.

If the burn-away exceeds the values given

in Data, contact MAN B&W for advice.

Note down the results for later reference.

10.

Page 5 (22)

902-1.1



Piston

M90201-2

80D

01

Preparations in the crankcase

1. Access:

Open the crankcase door to the cylinder

concerned.

Turn the crosshead down far enough to

give access to the piston rod stuffi ng box

and the piston rod/crosshead connection.

1.

Piston

Page 6 (22)

902-1.1


MAN B&W DieselDismantling

M90201-0

292D

02

2. Telescopic pipe:

Loosen and remove the screws which tight-

en the telescopic pipe to the bend. Lift up

the telescopic pipe and fi t the wing nut on

the protuding stud and land the pipe on the

wing nut.

Tighten the wing nut and check that the

telescopic pipe is safely suspended.

2.

Note!

When a piston is dismantled, never turn

the engine without fi rst dismantling the

telescopic pipe from the crosshead.

Page 7 (22)

902-1.1



Piston

M90201-0

288D

05

M90201-0

280D

03

3. Stuffi ng box:

Release the stuffi ng box by removing the

innermost screws from the stuffi ng box

fl ange.

On engine models where the drain pipe is

connected directly to the stuffi ng box:

Disconnect the stuffi ng box drain pipe.

4. Loosen the piston rod-crosshead connec-

tion:

Remove the screws from the piston rod.

3.

4.

Note!

Do NOT remove the outermost screws

from the fl ange.

Piston

Page 8 (22)

902-1.1



M90201-0

288D

06

5. Stuffi ng box distance pieces:

Mount the two distance pieces on the pis-

ton rod foot to protect the lower scraper

ring and to guide the stuffi ng box.

5.

Page 9 (22)

902-1.1



Piston

M90201-0

285D

07

D02-25Preparations on the cylinder top

6. Cylinder cover:

Remove the cylinder cover. See Procedure

901-1.2.

7. Piston lifting tool:

Turn the piston to TDC. The top of the pis-

ton is now free of the cylinder liner.

Clean the lifting groove of the piston crown

and mount the lifting tool.

Limited lifting high:

If the engine not is equipped with long dis-

tance pieces, remove one or two cylinder

cover studs, using a stud setter.

7.

Note!

Make sure to mount the lifting tool cor-

rectly, so that the claws of the lifting tool

enter the lifting grooves of the piston

crown.

Piston

Page 10 (22)

902-1.1



M90201-0

285D

08

D02-20

Piston lift

8. Lift the piston out of the cylinder liner and

guide the piston rod foot through the stuff-

ing box fl ange.

If the engine is equipped with long distance

pieces for the stuffi ng box, the piston rod

foot can pass between two cylinder cover

studs.

Place the two halves of the support around

one of the openings in the platform. Low-

er the piston rod foot and stuffi ng box

through the opening in the platform. Secure

the two support halves with screws and

lower the piston on the support. Check the

piston is resting on the piston rod fl ange.

8.

Page 11 (22)

902-1.1



Piston

M90201-0

283D

09

9. Protect the crosshead bearing:

Place a cover over the opening for the pis-

ton rod stuffi ng box in the bottom of the

cylinder unit.

Turn the crosshead down far enough to

permit mounting of the protective rubber

cover on the crosshead bearing cap. The

protective rubber cover is found on tool

panel 904.

The covers must remain in place to protect

the crosshead bearing journal from impuri-

ties until the piston is remounted.

Clean, measure and recondition the cylin-

der liner. See Procedure 903-1.

9.

Piston

Page 12 (22)

902-1.1


MAN B&W DieselOverhaul

M90201-0

284O

03

D02-21

+

D02-23

M9

02

01

-02

85

O0

2M

90

20

1-0

28

5O

01

D02-20

1. Piston support:

Place the piston in the support and remove

the piston lifting tool.


Clean the piston top and the piston rings.

Check the free ring gap and the burn-off

on the piston top. See Procedure 902-1.1.

Remove the stuffi ng box. See Procedure

902-2.3.

2. Piston ring dismantling:

Take off the piston rings by means of the

ring expanders. If the engine is equipped

with two ring expanders, the short ring ex-

pander is for the uppermost ring.

First remove the uppermost ring, then ring

No. two, three and four.

Clean and inspect the rings and the ring

grooves. See Procedure 902-1.1.

3. Piston crown dismantling:

Remove the locking wire and the innermost

screws between the rod and the piston

crown.

Lift the piston crown and skirt clear of the

piston rod.

1.

2.

3.

Page 13 (22)

902-1.1



Piston

M9

02

01

-02

86

O0

5M

90201-0

280O

04

D02-06

D02-24

D02-22

4. Piston rod and cooling pipe:

Remove the screws from the cooling oil

pipe fl ange.

Mount the eye bolts and lift out the cooling

oil pipe.

Clean and inspect the cooling oil pipe and

the piston rod, then remount the cooling oil

pipe, see Data.

Check that the surfaces of the O-ring

groove is clean and smooth.

Mount a new O-ring on the piston rod

fl ange.

5. Crown turning:

Unhook the crane from the piston lifting

tool, and connect the lifting tool and the

crane hook by means of a wire rope. Lift

up the piston crown.

Fit two eyebolts in the piston skirt and a

wire rope between the bolts as shown in

the sketch.

Install a tackle in a suitable place with suf-

fi cient space below for the piston crown.

Attach the tackle to the wire rope on the

piston crown and carefully turn the piston

crown upside down. Use both cranes if the

engine room is equipped with two cranes.

Land the piston lifting tool and the piston

crown on a suffi cient support of wood

pieces. Loosen the piston lifting tool and

lift the piston crown clear of the tool.

6. Piston crown dismantling and cleaning:

Place the piston crown with skirt on a

wooden support as shown.

Remove the locking wire and the screws in

the skirt. If necessary use two dismantling

screws to pull the skirt out of the piston

crown. Mount two eye bolts in the skirt. Lift

the skirt and land it on a couple of planks.

Discard the sealing ring on the piston skirt.

4.

5.

M90201-0

284O

05

D02-23

6.

Piston

Page 14 (22)

902-1.1



M90201-0

284O

07

D02-03

M90201-0

284O

06

D02-05

7. Piston crown assembly:

Mount a new O-ring on the piston skirt.

Check that the surfaces of the O-ring

groove are clean and smooth. Coat the ring

with lubricating oil before mounting.

Mount the piston skirt on the piston crown.

Tighten the screws to specifi ed torque, see

data D02-05. Lock the screws with locking

wire, see Procedure 913-7.

8. Piston crown and skirt mounting:

Mount the guide screw to ensure the cor-

rect positioning of the piston rod in relation

to the piston crown.

Lubricate the O-ring on the piston rod

fl ange with lubricating oil.

Land the overhauled piston crown and skirt

on the piston rod.

Remove the guide screw.

Mount and tighten the screws between the

piston rod and the piston crown, see Data.

7.

8.

Page 15 (22)

902-1.1



Piston

M90201-0

288O

10

D02-01

M90201-0

288O

09

Sealing ring and pressure test

According to current class rules, the piston

must be pressure tested hydraulically. It is

possible to carry out a test of the sealing

rings with compressed air before fi lling the

piston with oil. The sealing ring test can

also be carried out when the piston is rest-

ing in the support tool.

9. Sealing ring test:

Mount the pressure-testing tool on the

piston rod foot. Connect compressed air

to the testing tool and fi ll the piston to 4-5

bar. Close the valve on the testing tool and

remove the air connection. The piston must

now hold the pressure for minimum 30

minutes.

Spray a little soap water on to the surface

joints between piston rod/crown/skirt and

around the bolt heads to detect leaks.

Dry off all soap water.

10. Pressure test:

For this test, the piston must be turned

upside down (see next step to turn a com-

plete piston).

Fill the piston and piston rod with lubricat-

ing oil. Mount the pressure-testing tool

on the piston rod foot. Pressure-test the

piston at the pressure stated on the Data

Sheet. Check the contact surfaces of the

piston and the sealing rings for tightness.

Check that there are no cracks in the pis-

ton crown.

Turn the piston upside up and drain out the

piston oil.

9.

10.

Piston

Page 16 (22)

902-1.1



M90201-0

283O

10

11. Piston turning:

Lift the piston with the normal lifting tool.

Lower the piston rod foot until it is close to

the platform. Land the foot on a wooden

block.

Lower the piston crown to the platform and

land it on a wooden block in such a way

that it is possible to remove the lifting tool.

Attach the lifting bracket to the bottom of

the piston rod foot. Hook the crane on to

the lifting bracket. Lift the piston rod foot

clear of the wooden block. Keep lifting until

the piston rod is in a vertical position.

Note!

During the lift, follow with the crane

to keep the crane positioned vertically

above the lifting point. The stuffi ng box

must be removed.

11.

Page 17 (22)

902-1.1



Piston

M90201-0

285O

11

A

B

C

D

A

B

C

D

12. Piston completion:

Fit the new piston rings (alternately

right-hand and left-hand cuts, with the ring

gaps staggered 180° and with the TOP

mark upwards), using the ring expander.

When mounting the piston rings, use the

ring expanders to prevent unintended de-

formation of the rings.

Do not expand the rings more than neces-

sary. The uppermost ring (CPR-ring) must

be mounted with the short ring expander,

if the engine is equipped with two ring ex-

panders

Mount the piston rod stuffi ng box.


12.

Piston

Page 18 (22)

902-1.1


MAN B&W DieselMounting

M90201-0

288M

02

M90201-0

285M

01

Preparation of piston

1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1, if not

already done.

Mount the lifting tool on the piston crown.

See Data D02-25.

2. Stuffi ng box position:

Ensure that the stuffi ng box is correctly po-

sitioned over the distance pieces mounted

on the piston rod foot. Both the holes for

the fl ange and the drain hole for the drain

pipe must be positioned correctly.

1.

2.

Page 19 (22)

902-1.1



Piston

M90201-0

283M

03

M90201-0

277M

06

45°

M90201-0

277M

05

Preparation of cylinder liner

3. Mount the guide ring:

Mount the guide ring in the top of the cyl-

inder liner. The cut outs for the lifting tool

must be turned to fi t the piston lifting tool.

4. Stuffi ng box cover:

Remove the cover from the piston rod

stuffi ng box opening in the bottom of the

cylinder unit.

Clean the stuffi ng box fl ange.

5. Crosshead position:

Turn the crosshead to a position 45° from

TDC (crank web pointing towards exhaust

side).

3.

4.

5.

Piston

Page 20 (22)

902-1.1



M90201-0

283M

07

M90201-0

288M

06

D02-20

M9

02

01

-02

84

M0

8

Mounting of piston

6. Coat the O-rings of the stuffi ng box and

the piston rod with oil. Coat the piston

rings and cylinder liner with cylinder lubri-

cating oil.

Lower the piston into the cylinder liner

– while guiding the piston rod foot through

the cut-out in the stuffi ng box fl ange – until

the piston rings are inside the liner.

7. Protective cover:

Remove the protective rubber cover from

the crosshead.

8. Crosshead alignment:

Turn the crosshead almost to TDC, while

checking that the guide ring of the cross-

head enters the centre hole in the piston

rod.

After turning the crosshead fully to TDC,

and ensuring that the piston rod has full

contact with the crosshead, unscrew the

lifting tool and remove the lifting tool and

the guide ring for piston rings.

6.

7.

8.

Page 21 (22)

902-1.1



Piston

M90201-0

292M

11

M9

02

01

-02

88

M1

0

D02-02

or

D02-07

M90201-0

280M

09

9. Stuffi ng box:

Turn down and land the stuffi ng box on the

stuffi ng box fl ange. Check that the holes in

the stuffi ng box and stuffi ng box fl ange are

correctly centered.

Tighten the piston rod stuffi ng box by

means of the screws through the inner

holes in the stuffi ng box fl ange. For Data,

see Procedure 902-2.

On engine models where the drain pipe is

connected directly to the stuffi ng box:

• Mount the stuffi ng box drain pipe.

Remove the distance pieces from the pis-

ton rod foot.

10. Tightening of the piston rod-crosshead

connection:

Mount and tighten the piston rod screws.

Tighten the screws to the specifi ed torque

and lock with locking wire.

See Data. Use either Data D02-02 or Data

D02-07.

11. Telescopic pipe:

Loosen the wing nut and land the telescop-

ic pipe on the bend.

Fit the screws and tighten the telescopic

pipe to the bend.

For data, see Procedure 904-2.

9.

10.

11.

Piston

Page 22 (22)

902-1.1



M90201-0

288M

12

M90201-0

280M

14

D01-05

12. Cylinder cover studs:

If the cylinder cover studs have been re-

moved, 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 con-

tact and half a revolution back.

13. Cylinder cover:

Land the cylinder cover on the liner and

check the distance that the stud is protrud-

ing from the cylinder cover. If necessary,

adjust the distance D01-05 by turning the

stud.

Tighten the cylinder cover nuts and mount

the necessary pipes.


14. Running-in:

Smear the piston rod with molybdenum di-

sulphide, and turn the crankshaft a couple

of revolutions.

At the fi rst opportunity, start the engine

and keep it running for about 15 minutes

at a speed corresponding to “Dead Slow”

Ahead.

Then stop the engine and inspect the pis-

ton rod and stuffi ng box.

12.

13.

Page 1 (2)

SAFETY PRECAUTIONS

Data

D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm

D02-28 Stuffing box halves, tightening torque 40 Nm

D02-29 Uppermost rings, ring-end clearance 4x6 mm

D02-30 Lowermost rings, ring-end clearance 3x3 mm

D02-34 Sealing ring springs new, free length 525 mm

D02-38 Scraper ring springs new, free length 370 mm

D02-44 Stuffing box complete 53 kg

D02-45 Stuffing box half 15 kg

Piston Rod Stuffing Box

Data

102-2


MAN B&W Diesel A/S

X

X

X

X

X

X

X

X

X

X


Stopped engine




Shut off safety air supply – Not ME engines


Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

Engage turning gear


Shut off fuel oil




Page 2 (2)

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in thechapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.

Piston Rod Stuffing Box

Data

102-2


MAN B&W Diesel A/S

P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box


Page 1 (10)

902-2.1



Piston Rod Stuffi ng Box

M90202-0

227C

02

D02-34

D02-38

A

B

BAM

90202-0

228C

01

D02-29

D02-30

D02-29 D02-30

2.

1.1. After the piston rod stuffi ng box has been

dismantled, check the following clearances:


Uppermost scraper ring and sealing rings

Clearance at ring ends (scraper ring).

Total clearance (scraper ring). (D02-29)

Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D02-29)

Lowermost scraper rings

Clearance at ring ends.

Total clearance. (D02-30)

The ring clearances stated in Data apply to

new rings.

As a general guide, it is recommended –

depending on the overhauling intervals and

one’s own experience – to replace sealing

rings and scraper rings when the specifi ed

clearance values D02-29 and D02-30 have

been halved.

2. Garter springs:

Generally, it is recommended to renew the

springs when the sealing rings and scraper

rings are renewed.

The springs can be checked as follows:

Place the springs on the table, measure Lo

(free length), and compare with Data. If a

spring is extended more than 8% from the

value given in data, it must be discarded.


Page 2 (10)

902-2.2



90202-0

228D

03

M90202-0

228D

02

M90202-0

228D

01

2.

3.

1.If, in the period between piston overhauls, it

becomes necessary to inspect the piston rod

stuffi ng box, proceed as follows:

1. Turn the crosshead to about 90° from TDC.

Mount the rubber cover around the piston

rod to protect the crosshead bearing from

impurities.

2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two

screws placed diametrically opposite in the

stuffi ng box fl ange, longitudinally to the en-

gine.

3. Mount the worktable around the piston

rod so that the two remaining screws in

the stuffi ng box fl ange can be loosened

through the holes.

Page 3 (10)

902-2.2




M90202-0

228D

06

M90202-0

228D

05

M90202-0

228D

04

5.

6.

4.4. Remove the two long dismantling screws

from the worktable.

Mount them in the stuffi ng box through the

holes in the worktable.

Remove the remaining two screws from the

stuffi ng box.

5. Turn the piston to BDC, thereby withdraw-

ing the stuffi ng box from the cylinder frame

bottom.

Remove the two long dismantling screws

from the stuffi ng box and mount them in

the worktable.

6. By means of the four short screws in the

worktable, press the stuffi ng box out of the

fl ange.

For overhauling the stuffi ng box, see Proce-

dure 902-2.3.


Page 4 (10)

902-2.3



Normally, overhaul of the piston rod stuffi ng

box is carried out by routine methods in con-

nection with the dismantling (pulling) of the

pistons.

During such overhauls, the piston rests on a

support placed over one of the cut-outs in the

top platform.

Work on the stuffi ng box is then carried out

from the platform below.

1. Mount two eye bolts in the stuffi ng box

fl ange, and hook on two tackles.

Lift the stuffi ng box a little up the piston

rod, and mount the worktable round the

piston rod at a suitable working height.

Land the stuffi ng box on the worktable,

and remove the tackles and eye bolts.

2. Remove the O-ring of the stuffi ng box. If

the O-ring is intact and is to be used again,

move it up the piston rod and secure it in

this position, for example with tape.

Remove the nuts from the stuffi ng box as-

sembling bolts.

M90202-0

228O

01

M90202-0

228O

02

D02-44

M90202-0

228O

03

1.

2.

Page 5 (10)

902-2.3




3. Take out the six bolts, and pull away one

stuffi ng box half.

Mount two eye bolts on the stuffi ng box

half and remove it from the worktable.

4. Using a feeler gauge, measure the vertical

clearance of the rings.


5. Remove the remaining stuffi ng box half and

press all sealing rings and scraper rings

down against the worktable.

6. Measure the clearance between the ring

segments to determine whether replace-

ment is necessary.


Dismantle and stack the rings in the same

order as when fi tted in the stuffi ng box.

Carefully clean all the ring segments.

Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces

have scratches or marks, replace the rings.

7. Check the lengths of the springs.


8. Inspect the surface of the piston rod.

If small longitudinal scratches have oc-

curred (caused by poorly adapted stuffi ng

box rings), smooth the piston rod surface

carefully with a fi ne grained carborundum

stone. In the case of coarse scratches, it

may prove necessary to machine-grind the

surface in a workshop.

9. Clean the halves of the stuffi ng box hous-

ing.

M90202-0

228O

04

D02-45

M90202-0

228O

08

8.

3.


Page 6 (10)

902-2.3



90

20

2-0

23

3O

10

Scraperring

Sealingring

No reliefgroove

Reliefgroove

A

B

C

Scraperring

A

B

C

10.10. Lubricate the piston rod (in the area where

all the ring units in the stuffi ng box will be

positioned) with molybdenum disulphide

(MoS2)

For correct mounting of the sealing and

scraper rings see the sketch. The scraper

ring in groove No. 4 must be without relief

grooves on the underside.

Page 7 (10)

902-2.3




11. Lubricate the piston rod (in the area where

all the ring units in the stuffi ng box will be

positioned) with molybdenum disulphide

(MoS2).

Assemble all the stuffi ng box ring units

round the piston rod, on the worktable, in

the following way:

• Place the lowermost scraper ring seg-

ments on the worktable.

• Place the spring round the segments,

and hook the spring ends together.

Repeat this procedure for the remaining

scraper rings.

On top of the scraper rings, assemble the

two sealing ring units (each consisting of a

4-part and an 8-part ring).

Assemble the 8-part sealing ring so that

the two guide pins face upwards, place the

spring round the segments and, hook the

spring ends together.

Assemble the 4-part sealing ring above

the 8-part sealing ring. Push the two rings

together in such a manner that the guide

pins in the lower sealing ring engage with

the two holes in the upper sealing ring.

Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an

8-part sealing ring).

12. Use the stuffi ng box half on the worktable

to adjust the height of all the assembled

ring units on the piston rod until the ring

units are opposite the corresponding

grooves in the stuffi ng box housing. Sub-

sequently, push the stuffi ng box half into

contact with the piston rod, round the ring

units.

M9

02

02

-02

28

O1

0M

90202-0

228O

11

12.

11.


Page 8 (10)

902-2.3



13. Check the ring clearance again.

Then place the other half of the stuffi ng

box housing on the worktable, pushing it

into place round the rings.

Mount and tighten up the fi tted bolts to the

torque specifi ed on the Data Sheet.

Mount the O-ring in the stuffi ng box

groove.

14. Mount eye bolts and wire ropes, and lift the

stuffi ng box a little.

Remove the worktable and lower the stuff-

ing box until it rests against the distance

pieces on the piston rod foot.

Remove wire ropes and screws.

M9

02

02

-02

28

O1

2

D02-28

M90202-0

228O

12

14.

13.

Page 9 (10)

902-2.4




M90202-0

228M

01

M90202-0

228M

02

M90202-0

228M

03

2.

3.

1.1. After overhauling, assemble the stuffi ng

box halves on top of the four screws.

Mount the two long screws from the work-

table in the stuffi ng box.

Turn down the short screws so that the

stuffi ng box lands on the fl ange.

2. Turn the piston upwards until the stuffi ng

box is in place in the cylinder frame.

Note!

Make sure that the two guide pins in the

fl ange enter the guide holes in the bot-

tom of the cylinder frame.

3. Mount two screws in the fl ange through the

holes in the worktable.


Page 10 (10)

902-2.4



4. Remove the long screws from the stuffi ng

box and mount them in the worktable.

Remove the worktable from the piston rod.

5. Mount and tighten all the inner and outer

screws for the stuffi ng box. See Data.

6. Remove the protecting rubber cover from

the piston rod/crosshead.

Smear the piston rod with molybdenum di-

sulphide.

Then turn the crankshaft a couple of revo-

lutions.

Start up the engine and keep it running for

about fi fteen minutes at a number of revo-

lutions corresponding to very slow or idle

speed.

Then stop the engine and inspect the pis-

ton rod and stuffi ng box.

M90202-0

228M

04

M90202-0

228M

05

D02-26

D02-27

M90202-0

228M

06

5.

6.

4.


Piston and Piston Rod Panel PlateP90251-0255

0255Piston and Piston Rod PanelP90251


Piston and Piston Rod PanelPlateP90251-0255

Item No.

Item Description

014 Panel for tools

026 Name plate

040 Lifting tool for piston rod

063 Lifting and tilting screw

075 Template for piston top

087 Distance piece for stuffing box

099 Cover for stuffing box hole

109 Hook for mounting of stuffing box

spring

110 Pressure test

122 Work table for stuffing box

134 Piston ring expander

146 Support for tilting tool

158 Guide screw for piston crown

171 Dismantling screw for piston skrit

Item No.

Item Description


Piston and Piston Rod - Extra Tools PlateP90264-0010

0010Piston and Piston Rod - Extra ToolsP90264


Piston and Piston Rod - Extra ToolsPlateP90264-0010

Item No.

Item Description

015 Lifting collar for piston

027 Support for tilting tool

Item No.

Item Description

Plate


Piston and Piston Rod - Support ToolsP90265-0005

P90265 0005

Plate


P90265-0005Piston and Piston Rod - Support Tools

ItemNo.

Item DescriptionItemNo.

Item Description

P90265 0005

010 Support iron for piston

Plate


Piston - Lifting ToolsP90266-0004

P90266 0004

Plate


P90266-0004Piston - Lifting Tools

ItemNo.


Item Description

P90266 0004

016 Lifting tool, piston

MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


103-01 0079 Cylinder Liner, Data

903-01 0237 Cylinder Liner

103-02 0033 Cylinder Lubricator, Data

903-02 0258 Cylinder Lubricator

90361 0084 Cylinder Liner - Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D03-01 Lifting tool screws, tightening torque 200 Nm

D03-03 Cylinder diameter, new 420 mm

D03-04 Piston cleaning ring diameter, new 418,4 mm

D03-16 Piston cleaning ring radial width, new 33,3 mm

D03-17 PC-ring/Liner max. wear deviation 0,42 mm

D03-05 Cylinder liner, complete 1200 kg

D03-06 Cooling jacket 110 kg

D03-18 PC-rings replacement criteria:

Cylinder Liner

X Stopped engine









X Shut off fuel oil


X Lock the turbocharger rotors


103-1

Page 2 (2)

MAN B&W Diesel



Data


P90251 051 Lifting tool for cylinder liner

P90361 Cylinder Liner - Tools

P90362 Cylinder Liner - Extra Tools

P90366 Cylinder Liner - Lifting Tools

Cylinder Liner


103-1

When referring to this page, please quote Procedure M90301 Edition 0237 Page 1 (10)MAN B&W Diesel A/S

Cylinder Liner 903-1.1

Checking

0237 S42MC-CCylinder Liner

903-1.1Checking

1. Dismount the cylinder cover and piston.

See Procedure 901-1.2.See Procedure 902-1.2.

Clean the cylinder liner and scavenge airports.

2. Position the cylinder liner measuring tool.

Measure the cylinder liner with an inside

micrometer at the positions indicated on themeasuring tool. See Data.

3. Take measurements in the fore-and-aft andathwartship directions.

4. Check and assess the condition of the cyl-inder liner according to the description giv-en in Volume I, Chapter 707.

5. Carefully scratch over any scores or markson the cylinder liner running surface, and

grind away the wear ridges. See Procedure903-1.3.

6. Check the lubricating points of the cylinderby pumping cylinder oil to each individuallubricating point.

Clean any blocked lubricating duct.

1.

DM

903

-2.0

90

01

D03-03

2.

GN

90

3-1

.12

03

03

4.

EN

90

3-1

.12

20

04

Page 2 (10) When referring to this page, please quote Procedure M90301 Edition 0237MAN B&W Diesel A/S

Cylinder Liner903-1.1

Checking

7. Piston cleaning (PC) ring:

The PC ring is to be regarded as an inte-grated part of the liner and it is intended to

follow the service life of the liner.

During inspection of the piston and liner,

the PC ring must also be inspected.

8. Measure the PC ring radial width B, and

find the most worn place. Compare withdata D03-16 and calculate the wear of thePC ring. Multiply the wear by 2 to get the

PC ring diameter wear.

Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDCposition, corresponding to measuring pointNo. 5 on the liner measuring tool. Compare

the measurements with the diameter of anew liner as stated in data. Calculate thewear of the liner.

Compare the PC ring diameter wear withthe wear of the liner. If wear of the two com-

ponents does not deviate more than D03-17, then reinstall the PC ring.

If the deviation between PC ring wear andliner wear is more than D03-17, or if the PCring is broken or cracked, replace the ring

with a new PC ring, an oversize ring or adummy ring according to the table in D03-18 on the Data sheet.

If it is needed to install an oversize PC ring,contact MAN B&W Diesel for advice.

When a new liner is installed, also a newPC ring must be installed. When a new liner

is ordered, also a new PC ring must be or-dered.

8.

DM

903

-1.1

23

70

8



Dismantling

903-1.2Dismantling

1. Dismount the cylinder cover.


Discard the sealing ring from the top of the

cylinder liner.

Turn the piston down far enough to make it

possible to remove the wear ridges at thetop of the liner.See Procedure 903-1.3.

Dismount the piston.See Procedure 902-1.2.

Mount the two lifting screws in the cylinderliner.

2. Disconnect – at the exhaust side of the cyl-inder – the oil pipes leading from the cylin-der lubricator to the non-return valves.

Dismount the four cooling water pipes – be-tween the cooling jacket and cylinder cover

– and clean them carefully.

Note!

Tighten the lifting screws to the torquestated in Data.

Check with a 0.05 mm feeler gauge thatthere is no clearance between the screwsand the cylinder liner.

This must be done whenever the liftingtools are mounted on the liner.

1.

GN

90

3-1

.222

40

1

D03-01

2.

GN

90

3-1

.22

24

02



Dismantling

3. Remove the screws of the cooling water in-

let pipe.

4. Attach the crane hook to the lifting cross-

bar.

Hook the chains from the lifting tools on to

the crossbar and lift the cylinder liner withthe cooling jacket out of the cylinder frame.

Land the cylinder liner vertically on, for in-stance, a couple of planks.

Clean the cylinder frame internally, takingspecial care with the contact surfaces forthe cylinder liner at the top of the cylinder

frame.

Discard the O-rings on the cooling water

pipes.

Clean the pipes carefully.

Note!

Low lifting height in the engine room may

require the removal of one or more cylin-der cover studs before dismantling thecylinder liner.

3.

EN

903

-1.4

20

50

3

4.

GN

90

3-1

.222

40

4

D03-05



Dismantling

5. The lifting screws are also used for trans-

porting the cylinder liner.

Note!

The cylinder liner is not in balance, evenwith the cooling jacket mounted.

To keep the liner in a horizontal positionduring transportation, use e.g. a wire

rope connected from the scavenge portsto the traverse as shown on the sketch.

5.

GN

90

3-1

.22

24

05

D03-05



Overhaul

903-1.3Overhaul

1. Unscrew the nuts on the non-return valves

and remove the valves.

Clean and inspect the non-return valves.

2. Attach two tackles to the crossbar, asshown.

Mount two lifting eye bolts in the coolingjacket.

Hook the tackles on to the lifting eye boltson the cooling jacket and haul tight.

Remove the two lifting screws from the cyl-inder liner.

Remove the four clamps which fix the cool-ing jacket to the cylinder liner.

3. Lift the cooling jacket away by means of thetackles, and land it on the wooden planks.

1.

GN

90

3-1

.32

24

01

2.

EN

903

-1.3

23

70

2

3.

EN

90

3-1

.32

37

03

D03-06



Overhaul

4. Check and assess the condition of the cyl-

inder liner according to the description giv-en in Volume I, Chapter 707.

Carefully scratch over any scores or markson the cylinder liner running surface, bymeans 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). Ifthere is any sign of a wear ridge, it is nec-essary to create a groove by grinding.The

groove serves to prevent the build-up of anew wear ridge.

5. It is recommended to use a wear ridge mill-ing machine to create the groove. For useof the milling machine, see supplier’s in-struction.

6. Alternatively, place an old piston ring on the

top of the piston and turn to a position thatenables the grinding disc to rest on the oldpiston ring while removing the wear ridge.

Use a grinding disc with a round edge.

Check the distance C before grinding to as-

certain that the wear ridge was caused bythe top ring at TDC.

The maximum depth of the groove is calcu-lated as Smax. = D x 0.0045.

Note!

It is of the utmost importance that the

groove is made with a regular roundingas shown in the sketch.

4.

HN

90

3-1

.322

10

4

5.

MB

903

-1.3

23

10

4

S

D

C

C

R=

4-5

mm

6.

MN

90

3-1

.322

90

5



Overhaul

7. Replace the two uppermost O-rings on the

cylinder liner.

8. Lower the cooling jacket on to the cylinder

liner.

9. Mount the four clamps in the groove of theliner, and tighten the screws.

Remove the tackles from the lifting cross-bar and the cooling jacket lifting eye bolts.

10. Mount the non-return valves for cylinder lu-brication. Tighten the nuts and connect the

lubricating oil pipes.

Note!

Make sure that the scratch marks in thecamshaft side of the cylinder liner and

cooling jacket coincide.

7.

GN

90

3-1

.32

03

04

8.

D03-06

EN

90

3-1

.32

37

08

9.

EN

90

3-1

.32

37

09



Mounting

903-1.4Mounting

1. Loosen the water connections on the cool-

ing jacket.

Mount the two lifting screws in the cylinder

liner. See Data D03-01.

Hook the chains from the lifting crossbar on

to the lifting screws, and lift the jacket/linerassembly.

Mount the lowermost O-ring and apply a lit-tle lubricating oil on the ring.

2. Check that the joint surfaces on the cylinderframe and cylinder liner are completelyclean.

Coat the joint surfaces with permatex or asimilar liquid sealing compound.

Mount the cylinder liner in the cylinderframe. Replace the O-rings on the water

connections and mount the water connec-tions on the cooling jacket.

1.

DM

903

-1.4

23

70

1

D03-01

2.

GN

903

-1.4

22

40

2



Mounting

3. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount andtighten the screws.

4. Connect and tighten the oil pipes for thecylinder lubrication.

Vent the cylinder lubricating system untiloil, without air bubbles, comes out from thenon-return valves. Check that there is no

leakage from the system.

When this is in order, check that each indi-

vidual lubricating point functions correctly.

5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil andmount the piston and the PC ring.See Procedure 902-1.4.

6. Mount the sealing ring and the cylinder cov-er.


Tighten the upper water connections on the

cooling jacket as soon as the cylinder coveris correctly positioned.

3.

EN

903

-1.4

20

503

4.

GN

903

-1.4

22

40

4G

N9

01

-1.4

20

30

1

6.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D03-22 minimum crankthrow angle 105 °

D03-23 maximum crankthrow angle 116 °

D03-24 optimum crankthrow angle 110 °

Cylinder Lubricators

X Stopped engine









Shut off fuel oil




103-2

Page 2 (2)

MAN B&W Diesel



Data




103-2

Page 1 (2)

903-2.1




M90302-0

255C

03

Seen from fore

Cyl. No. 1

D03-22D03-23

M90302-0

258C

02

Marks

M90302-0

258C

01

HJ7 LUBRICATOR

Lubrication point No. 1

1. Further information concerning other than

nominal feed rates, feed rates for running-

in and for part load operation, and recom-

mended oil types, is given in instruction

book Volume I, OPERATION.

2. The cylinder lubricator is mounted on the

front end of the engine.

3. Each cylinder has four injection points.

Check that the pumps for all injection

points are activated during one revolution

of the engine.

4. Turn the engine in AHEAD direction until the

mark on the lubricator housing is in line

with the mark on the scale at the lead-in

shaft. This indicates that the pump stroke

is completed for lubricating point No. 1.

5. Check that the crankthrow for cylinder No.

1 is positioned between D03-22 and D03-

23 degrees past BDC.

Use the numbers on the turning wheel to

determine the exact position of the crank-

throws.

6. If the crankthrow is not in the correct posi-

tion, adjust the lubricator.


1.

5.

4.


Page 2 (2)

903-2.3


MAN B&W DieselAdjustment

M90302-0

255O

02

XXX XXX XXXXXX

Seen from fore

D03-24

M90302-0

258O

01

1. Remove the guard over the coupling.

Loosen the set screw in the coupling and

pull the coupling wheel out of contact with

the planet wheel.

2. For adjustment of the lubricator, turn the

crankshaft in AHEAD direction until the

crankthrow for cylinder No. 1 is D03-24 de-

grees past BDC for the lubricator.

If necessary, turn the lubricator shaft in

AHEAD direction.

Push the coupling wheel in to contact with

the planet wheel for the lubricator and fas-

ten the screw.

Use the numbers on the turning wheel to

determine the exact position of the crank-

throw.

Mount the guard over the coupling.

1.

2.


Cylinder Liner - Tools PlateP90361-0084

0084Cylinder Liner - ToolsP90361


Cylinder Liner - ToolsPlateP90361-0084

Item No.

Item Description

036 Cylinder gauge, complete

Item No.

Item Description

MAN B&W Diesel A/S

904 - Crosshead with Connecting Rod


104-01 0067 Crosshead Bearing, Data

904-01 0256 Crosshead Bearing

104-02 0069 Crosshead, Data

904-02 0256 Crosshead

104-03 0047 Reciprocating Parts, Data

904-03 0215 Reciprocating Parts

104-04 0061 Crankpin Bearing, Data

904-04 0226 Crankpin Bearing

104-05 0059 Connecting Rod, Data

904-05 0238 Connection Rod

90451 0144 Connecting Rod and Crosshead - Panel

90461 0066 Connecting Rod - Hydraulic Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D02-02 Piston rod/crosshead, tightening torque 280 Nm

D02-07 Piston rod/crosshead, tightening torque/angle 100/30 Nm/°

D02-20 Piston complete 480 kg

D04-01 Crosshead bearing, top clearance max. 0.5 mm

D04-02 Crosshead bearing, top clearance min. 0.15 mm

D04-03 Oil wedge length, L 10 mm

D04-04 Crosshead bearing cap 98 kg

D04-05 Crosshead bearing shell, upper 12.5 kg

D04-06 Crosshead bearing shell, lower 17 kg

D04-07 Crosshead bearing cap with bearing shell 110 kg

D04-15 Telescopic pipe, tightening torque 40 Nm

D04-16 Thrust piece, tightening torque 260 Nm

D04-51 Connecting rod complete 700 kg

D04-66 Crosshead with piston and guide shoes 1160 kg



Crosshead Bearing

X Stopped engine









Shut off fuel oil




104-1

Page 2 (2)

MAN B&W Diesel



Data


P90161 Cylinder Cover - Tools

P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod

P90451 72 Chain for suspending piston


P90451 96 Bracket for support, Crosshead




P91366 058 Feeler gauge





P91356 Lifting Tools, Etc.

P91359 Torque Spanners

P91368 Working Platforms

Crosshead Bearing


104-1

Page 1 (10)

904-1.1



Crosshead Bearing

M90401-0

255C

02

D04-01

D04-02

M90401-0

255C

01

3.

5.

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 as-

sembly components.

The top clearance for a new bearing will nor-

mally be in the range stated in Data. Note that

the fi gures are to be used for guidance only.

For the top clearance of a specifi c bearing, see

the measurement in the Adjustment Sheet in

Volume I, OPERATION.

1. Open the crankcase door at the relevant

cylinder.

2. Turn the crankthrow concerned to BDC.

3. Measure the clearance in the crosshead

bearing by inserting a feeler gauge between

the bearing cap and the crosshead journal

at the top of the upper bearing shell, at

both sides and fore and aft. See Data.

4. The difference between the actual clear-

ance 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.


For evaluation of the bearing shell, see

Chapter 708, ‘Bearings’ in the instruction

book, Volume I, OPERATION.

5. The wear limit for a crosshead bearing shell

is confi ned to a 50% reduction of the oil

wedge length L.

If the wear limit exceeds the 50% reduc-

tion, the bearing shell must be replaced by

a new one.

M90401-0

256C

05

(Oil Wedge)

L1/2

L

D04-03

Crosshead Bearing

Page 2 (10)

904-1.1



M90401-0

254C

08

Alternate checking method:

In case the reason for opening the crosshead

bearing is a routine inspection, the following

procedure is suffi cient.

6. Perform the clearance measurement shown

in 904-1.1 section 3.

7. Mount the two eyebolts and tackles in the

top of the crankcase in the fore and aft di-

rection. Mount two eyebolts on top of the

guideshoes.

Turn to BDC, mount the connecting rod lift-

ing attachments on the connecting rod. Use

tackles to hold the connecting rod in the

vertical position.

Dismount the crosshead bearing cap hy-

draulic nuts. For operation of the hydraulic

jacks, see Section 913.

8. Mount two eyebolts in the bearing cap and

use two small tackles in the athwartship

direction to lift the bearing cap free of the

guidepins and to keep the bearing cap bal-

anced.

9. Use the tackles in the crankcase top to lift

the crosshead and piston high enough to

allow inspection of the lower crosshead

bearing.

10. If the lower bearing shows no anomalies

the piston and crosshead is lowered again

and the crosshead bearing cap nuts are

mounted.

11. Recheck the bearing top clearance. Re-

move all tools.

12. If there are any doubt concerning damage

to the upper bearing, the bearing has to

be dismantled and checked according to

904-1.2.

Note!

Ensure that the crosshead is lifted si-

multaneously fore and aft, i.e. by placing

marks on the guide planes using a felt

tipped pen

8.

9.

M90401-0

256C

09

D04-66

904-1.2


Crosshead Bearing

Page 3 (10)When referring to this page, please quote Procedure M90401 Edition 0256

M90401-0

255D

03

M90401-0

255D

02

M90401-0

255C

01

This procedure has been divided into two dis-

mantling situations, as follows:

• with piston mounted

• with piston removed

With piston mounted:

1. Turn the crankshaft down far enough to

give access to the nuts and screws on the

piston rod.

2. Mount two eye bolts in the top of the

crankcase and suspend two tackles in the

athwartship direction.

Mount the two chains for suspending the

piston rod.

3. Loosen and remove the four screws which

tighten the telescopic pipe to the bend.

Suspend the telescopic pipe from the stuff-

ing box using the wing nut (tool).

Caution!

When a piston is dismantled, never turn

the engine without fi rst dismantling the

telescopic pipe from the crosshead.

1.

2.

3.

Crosshead Bearing904-1.2


Page 4 (10) When referring to this page, please quote Procedure M90401 Edition 0256

M90401-0

255D

06 D13-02

M90401-0

255D

05

D02-20

M90401-0

255D

04

4. Remove the locking wire from the screws,

loosen and remove the screws from the

piston rod foot. Remove the thrust pieces

from both side of the bearing cap.

5. Mount a lifting eye bolt on each side of the

piston rod.

Turn the crosshead to TDC.

Hook the chains to the lifting eye bolts in

the piston rod.

Turn the crosshead downward, and the pis-

ton rod will remain suspended from the two

chains.

With piston removed:

6. Turn to BDC.

7. Hold the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.

Loosen the crosshead bearing cap nuts.

For operation of the hydraulic jacks, see

Procedure 913.

Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.

4.

5.

7.

904-1.2


Crosshead Bearing


M90401-0

256D

08

M90401-0

256D

09 D04-07

Note!

Take care that the studs for the cross-

head bearing cap do not scratch the

crosshead journal.

8. Screw two eye bolts into the head of the

connecting rod.


crosshead bearing cap.

Hook the two tackles on to the eye bolts

and lift the crosshead bearing cap away

from the crosshead.

10. Mount wire guide on the top of the crank-

case door frame to prevent damage.

Lift the crosshead bearing cap out of the

engine.

8.

9.

10.

M90401-0

256D

10

D04-07




11. Place the bearing cap on one side on a

couple of wooden planks.

Remove the thrust pieces for axial guidance

of the connecting rod.

Check the bearing shell, see Procedure

904-1.1.

12. Turn the crosshead to TDC. Ensure that the

connecting piece in the crosshead fi ts cor-

rectly in the holes of the piston rod.

Do not remove the chains or lifting eye

bolts.

13. Mount the four supports for guide shoes on

the crosshead guides.

Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on

the supports.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead

is evenly distributed on the four supports.

14. Hook the two tackles on to the eye bolts

screwed into the head of the connecting

rod.

Haul the tackles tight.

11.

12.

13.

M90401-0

256D

11

D04-07

D04-05

M90401-0

256D

12

M90401-0

251D

16

D02-20

904-1.2


Crosshead Bearing


M90401-0

255D

16

D04-06

M90401-0

255D

15

D04-51

15.

16.

15. Turn the crankthrow carefully towards BDC

while ‘following’ with the tackles, thus con-

tinuously supporting the connecting rod.

With the crosshead resting on the supports,

check the lower part of the crosshead jour-

nal and the lower bearing shell.

Check the bearing shell, see Procedure

904-1.1.

For further evaluation of journal and bear-

ing shells, see also Volume I, OPERATION,

Chapter 708, ‘Bearings’.

16. In cases where it is necessary to remove

the lower bearing shell, tilt the connecting

rod towards the door in the camshaft side,

using the tackles.

Dismount the lock screws, and lift the bear-

ing shell out of the engine.




M90401-0

256M

02

M90401-0

256M

01

X X

D04-06

With the piston mounted/

With the piston removed:

1. Mount and secure the bearing shell in the

bearing housing.

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell

and must not be eliminated.

2. Raise the connecting rod to an upright po-

sition.

Turn to TDC while ‘following’ with the tack-

les, for assembling the crosshead and the

connecting rod.

Take care that the guide shoes do not dam-

age the bearing shell.

3. Remove the tackles from the connecting

rod. Remove the eye bolts from the con-

necting rod.

1.

2.

3.

M90401-0

256M

03

904-1.4


Crosshead Bearing


M90401-0

251M

03

M90401-0

255M

06

D04-16

D13-01

M90401-0

255M

05

D04-07

4. Remove the supports from the crosshead

guides.

Turn the crank throw to BDC.

If the piston is mounted, slowly turn down

until it is fully suspended from the chains.

5. Lift the bearing cap into the engine. Lower

the bearing cap onto the crosshead and

remove the tackles. Remove the eye bolts

from the bearing cap.

6. Remove wire guide.

Tighten all four crosshead bearing cap nuts

simultaneously. See Data.

For operation of hydraulic jacks, see Sec-

tion 913.

Mount the two thrust pieces on both sides

of the bearing cap. See Data.

7. Mount the piston.


Note!

Take care that the bearing studs do not

damage the crosshead.

4.

5.

6.




M90401-0

255M

09

D04-15

M90401-0

255M

08

D02-02

M90401-0

255M

07

With the piston mounted:

8. Turn the crosshead upwards until the piston

rod lands on the crosshead. When mount-

ing the piston on the crosshead, make sure

that the piston rod foot is correctly cen-

tered on the crosshead.

9. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and

eye bolts from the top of the crankcase,

from the piston rod and from the crosshead

bearing cap.

10. Mount and tighten the screws on the piston

rod. See Data.

Mount the locking wire on the screws. The

locking wire is to be mounted in such a

way that the wire is tightened if a screw

works loose.


After tightening the bearing cap, check the

top clearance once more.

If a new bearing shell has been mounted,

remember to note down the new top clear-

ance in the Adjustment Sheet in Chapter

701, Volume I, OPERATION.

11. Release the telescopic pipe from its sus-

pension, mount and tighten the four screws

which tighten the telescopic pipe to the

bend. See Data.

8.

10.

11.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D04-07 Crosshead bearing cap with bearing shell 110 kg

D04-08 Cooling oil outlet pipe, tightening torque 260 Nm

D04-09 Inlet pipe, tightening torque 260 Nm

D04-10 Inlet pipe stud, screwing-in torque 150 Nm

D04-11 Guide strip nuts, tightening torque 60 Nm

D04-15 Telescopic pipe, tightening torque 40 Nm

D04-16 Thrust piece, tightening torque 260 Nm

D04-20 Clearance between thrust piece and crosshead 0.05-0.35 mm

D04-21 Crosshead complete 580 kg

D04-22 Guide shoe 58 kg

D04-23 Cooling oil outlet pipe 3 kg

D04-51 Connecting rod complete 700 kg

D04-59 Telescopic pipe 13 kg

D04-60 Inlet pipe 20 kg

D04-62 Crosshead without guide shoes 455 kg



Crosshead

X Stopped engine









Shut off fuel oil




104-2

Page 2 (2)

MAN B&W Diesel



Data



P90451 60 Lifting tools - crosshead

P90451 72 Chain for suspending piston


P90464 Crosshead - Hydraulic Tools







P91368 Working Platforms

Crosshead


104-2

Page 1 (9)

904-2.2



Crosshead

M90401-0256D

10

D04-07

M90402-0

247D

02

D13-02

4.

2.1. Dismount the main bearing lubricating oil

pipes.

2. Turn the crosshead to BDC to give access

to the nuts on the crosshead bearing cap.

Mount the retaining tool for the telescopic

pipe on the stuffi ng box housing for the

telescopic pipe.

Mount two eye bolts in the athwartship di-

rection, and suspend two tackles.

Mount the spacer rings and the hydraulic

jacks for loosening the crosshead bearing

cap nuts.

For operation of the hydraulic tools, see

Procedure 913-1.

Loosen the nuts, remove the hydraulic

jacks and unscrew the nuts.

3. Turn the crosshead to TDC.

Suspend the telescopic pipe by means of

the tool. Suspend the piston. To suspend

the piston, see Procedure 904-1.

4. Turn to BDC and mount connecting rod

lifting tools. Use two tackles to retain the

connecting rod in an upright position.

Mount two eye bolts in the crosshead

bearing cap and hook on the tackles from

the top of the crankcase.

Lift the bearing cap out of the engine.

Remove the piston rod guide ring and the

shim from the crosshead.

Remove both thrust pieces on the cross-

head bearing cap.

Crosshead

Page 2 (9)

904-2.2



M90402-0256D

06

D04-21

M90402-0256D

05

6.

5.5. Dismount the guidepin for the oil inlet bend

using the special extractor.

Remove the outlet pipe, dismount the bend

for the telescopic pipe and remove the

studs from the crosshead.

Mount the special lifting tool on the cross-

head.

Mount the lifting attachments for fi xing the

connecting rod on the head of the connect-

ing rod.

Fasten tackles to the lifting brackets on the

frame box wall and attach the tackle hooks

to the lifting attachments. Haul the tackles

tight.

Hook the tackles to the top lifting brackets

onto the lifting tool on the crosshead and

lift the crosshead.

6. Attach tackle chains from the two tackles in

the athwartship direction to the lifting tool.

Lift the crosshead free of the connecting

rod.

Page 3 (9)

904-2.2



Crosshead

M90402-0

250D

10

M90402-0

250D

07

D04-51

7. Use the tackles to tilt the connecting rod

to-wards the exhaust side, while turning the

crankthrow towards the camshaft side.

Transfer the tackles from one lifting attach-

ment to another, as necessary.

Stop turning when the crankthrow is in a

position where there is room in the adja-

cent cylinder units to pull the guide shoes

through the openings in the side walls just

above the main bearings.

By alternate use of the tackles, tilt the con-

necting rod until it is out of the way.

8. Remove the oil pipes from the two adjacent

main bearing caps.

9. Remove the guide strips and the stop

screws from the bottom of the guide shoes.

Mount lifting eye bolts in both guide shoes.

There has to be space in the adjacent cyl-

inder units to pull the guide shoes through

the openings in the side walls just above

the main bearings.

10. Lower the crosshead so that the guide

shoes are just below the cutout in the side

walls of the frame box.

Note!

It is recommended to tag the guide

strips and shims to avoid mixing them.

Note!

Make sure that the crosshead journal

does not touch the crank.

9.

10.

7.

M90402-0256D

09

Crosshead

Page 4 (9)

904-2.2



M90402-0256D

13

D04-62

D04-22

M90402-0256D

12

M90402-0256D

11

11. Hook the tackles on to the eye bolts in the

guide shoes.

12. Mount two eye bolts in the holes for stop

screws in the guide shoes in the adjacent

cylinder units, and suspend two tackles

from the eye bolts.

13. Haul the tackles for the guide shoes tight

and, at the same time, pull the guide shoes

sideways until they are free of the cross-

head.

Take the guide shoes through the openings

in the side walls by means of the tackles in

the two adjacent cylinders. Lift the guide

shoes to provide space for turning the

crosshead.

11.

12.

13.

Page 5 (9)

904-2.2



Crosshead

14. Turn the crosshead 90°.

15. Mount a tackle outside the engine and, by

means of wire rope and tackle, remove the

crosshead from the engine.

Land and protect the crosshead outside

the engine.

Remove the guide shoes from the engine

and tag them.

Note!

Take care that the crosshead does not

bump into anything as this will damage

the sliding surfaces of the crosshead.

14.

15.M

90402-0256D

14

M90402-0256D

15

D04-22

Crosshead

Page 6 (9)

904-2.4



M90402-0256M

01

D04-21

1. Clean the crosshead and mount the lifting

tool.

Mount the wire guide tool in the framebox

door opening.

Suspend two tackles from the top of the

framebox between the guides.

Suspend two tackles from the top lifting

brackets in the framebox and use them in

conjunction with a tackle mounted outside

the engine to carefully lift the crosshead

and ease it into the crankcase.

2. Turn the crosshead 90° to enable mounting

of the guide shoes. Check that the oil inlet

and outlet holes are pointing towards the

exhaust side.

3. Attach two tackles to the eye bolts at the

bottom of the guide shoes in the adjacent

cylinders.

Using these tackles and a tackle outside

the engine, carefully lift the guide shoes

into the engine.

Note!

When handling the crosshead, take great

care that its surfaces are not scratched

or damaged. If necessary, protect the

crosshead with a cloth.

1.

2.

3.

M90402-0256M

02

M90402-0256M

03

D04-22

Page 7 (9)

904-2.4



Crosshead

M90402-0256M

04

4. Lubricate the sliding surfaces of the guide

shoes and the crosshead with plenty of

clean lubricating oil, and push the guide

shoes into position through the openings in

the side walls.

5. Use the tackles in the top of the framebox

to lift the crosshead into a working position

and mount the guide strips and shims on

the side of the guide shoes.

Mount the stop screws in the bottom of the

guide shoes.

Remove the tackles and the eye bolts from

the guide shoes.

6. Lift the crosshead to a position above the

connecting rod in the upright position.

Raise the connecting rod to the upright po-

sition.

Lubricate the crosshead bearing liberally

with clean lubricating oil and carefully lower

the crosshead into place.

7. Dismount the tackles and connecting rod

lifting tools from the connecting rod.

4.

5.

6.

M90402-0256M

06

M90402-0256M

05

D04-11

D04-21

Crosshead

Page 8 (9)

904-2.4



M9

04

02

-02

47

M0

7

D04-16

D04-20

M90402-0

247M

06 D13-01

M90402-0256M

08

D04-08

D04-09

D04-10

8. Turn the connecting rod and crosshead to

BDC.

Dismount the tackles and connecting rod

lifting tools from the connecting rod.

Remove the lifting tool from the crosshead.

Mount the studs for the cooling oil inlet

bend. Mount the bend and outlet pipe.

See Data.

Mount the inlet and outlet pipes.

Tighten the outlet pipe.

Mount the piston rod guide ring and the

shim on the crosshead.

9. Lift the crosshead bearing cap into the en-

gine.

Mount and tighten the crosshead bearing

cap.

Remoce the eye bolts.

10. Mount the two thrust pads on the sides of

the crosshead. See Data.

Mount the distance pipe on the telescopic

pipe bend.

11. Mount the piston. See Procedure 902-2.

Remove the nut from the telescopic pipe

suspending tool. Turn downwards and tight-

en the telescopic pipe, D04-15.

8.

9.

Note!

Always ensure that clearance exists fore

and aft between the thrust piece and the

crosshead before tightening the thrust

piece.

10.

Page 9 (9)

904-2.4



Crosshead

12. Tighten the hydraulic nuts.

For operation of hydraulic tools, see Proce-

dure 913-1.

Remove the hydraulic tools and the eye

bolts from the engine.

Check the clearances between the guide

strips, guide shoes and crosshead guides.

See Procedure 904-3.

Mount the main bearing lubricating oil

pipes.

Mount the piston and the telescopic pipe.


13. Remove all tools from the engine.

Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left

behind.

Note!

At this point it is recommended to check

the crosshead bearing clearance.


12.

M90402-0

250M

10

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D04-24 Acceptance criteria with piston in centre (F-A direction)

D04-25 PF+PA, N max. 0.50 mm

D04-26 PF+PA, O max. 0.70 mm

D04-28 E+G, H+F, N max. 0.45 mm

D04-29 E+G, H+F, N min. 0.20 mm

D04-30 E+G, H+F, O max. 0.75 mm

D04-34 J+X, L+Y, K+X, M+Y, N max. 0.70 mm

D04-35 J+X, L+Y, K+X, M+Y, N min. 0.40 mm

D04-36 J+X, L+Y, K+X, M+Y, O max. 0.90 mm

D04-39 QF/QA, O max. 0.80 mm

D04-41 ZF/ZA O min. 4.0 mm

D04-42 TF + TA 0.80 mm

Reciprocating Parts

X Stopped engine









Shut off fuel oil




104-3

Page 2 (2)

MAN B&W Diesel



Data



Reciprocating Parts


104-3

When referring to this page, please quote Procedure M90403 Edition 0215 Page 1 (3)��

Reciprocating Parts 904-3.1

Checking

0215S90MC-CReciprocating Parts

904-3.1Checking

In order to achieve uniform measuring condi-tions on board, the ship’s trim must be as closeas possible to 0°.

1. Mount a transparent plastic tube along thelength of the bedplate.

Bend each end approx. 250 mm up alongthe framebox side. See T.

Fill the tube with water (possibly coloured)until the water level is approx. 100 mm fromthe end of the tube.

Trim the ship until the difference betweenthe water level S fore and aft is less than1.5 mm per 1000 mm.

Measurements are to be taken with a ruler.

2. Turn the crankshaft in ASTERN direction to45° after BDC (the guide shoe must restagainst the crosshead guide).

Check the centering of the piston in the cyl-inder liner by measuring the clearance (byapplying a long feeler gauge from the scav-enge air space) between the piston skirtand the cylinder liner in the Fore and Aft po-sitions (PF-PA).

Make sure that the piston is clear of the cyl-inder liner in the fore-and-aft direction.

3. Turn in astern direction until the bottom ofthe guide shoe is 50 mm in the vertical di-rection above the top of the cut out in theweb plate.

1.

MA

90

4-5

.0 7

2 0

1

PF

PA

Fore Aft

45° Astern

2.

HN

90

4-3

.1 2

12

02

EXH CAM

50

E 1-2

F 1-2

G 1-2

H 1-2

10

3.

HN

90

4-3

.1 2

12

03

Page 2 (3) When referring to this page, please quote Procedure M90403 Edition 0215��

Reciprocating Parts904-3.1

Checking

4. Measure the clearance between the crank-throw and the connecting rod.

5. Measure the clearance between the thrustpiece and the crosshead (TF and TA or QFand QA.

Measure the clearance between the cross-head guides and the guide shoes (E, F, Gand H).

Measure the clearance between the guidestrips and crosshead guides (J, K, L andM).

The clearance, calculated as J+X, K+Y,L+Y and M+Y, is adjusted by the insertionof shims so that it is symmetrical in relationto the clearance between the piston skirtand the cylinder liner.

Parallelism between the guide strip andguide is to be kept within a tolerance of 0.2mm per 1000 mm.

BF and BA correspond to the thickness ofthe shims and are only to be measured if anadjustment is carried out.

MN

90

4-3

.1 2

15

04

4.

Exhaust Side

Camshaft Side

5.

MN

90

4-3

.1 2

15

05


Reciprocating Parts 904-3.1

Checking

6. It is recommended that the measured re-sults are noted down so that possible laterchanges can be ascertained. Piston/Liner

Frame Box

CrossheadConnectingRodCrankthrowConnectingRod

ShimThickness

Cyl. 1 2 3 4

PF

BF

PA

BA

E1

F1

G1

H1

E2

F2

G2

H2

E3

F3

G3

H3

E4

F4

G4

H4

J+X

K+X

L+Y

M+Y

QF/TF

QA/TA

ZF

ZA

MN

90

4-3

.1 2

15

06

6.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D04-43 Crankpin bearing clearance, max. 0.50 mm

D04-44 Crankpin bearing clearance, min. 0.15 mm

D04-45 Crankpin bearing cap complete 90 kg

D04-46 Crankpin bearing, upper shell 11 kg

D04-47 Crankpin bearing, lower shell 9 kg

D04-48 Crankpin bearing cap + shell + bearing studs 100 kg



Crankpin Bearing

X Stopped engine









Shut off fuel oil




104-4

Page 2 (2)

MAN B&W Diesel



Data






P90461 Connecting Rod - Hydraulic Tools







P91366 61 Slide caliper

Crankpin Bearing


104-4


Crankpin Bearing 904-4.1

Checking

0226S46MC-CCrankpin Bearing

904-4.1Checking

The bottom clearance between the journal anda new bearing shell is the result of a summationof the production tolerances of the bearing as-sembly components.

For the bottom clearance of a specific bearing,see the measurement in the Adjustment Sheetin Volume I, OPERATION.

1. Open the crankcase door at the relevantcylinder.

2. Turn the crank concerned to BDC.

3. Measure the clearance in the crankpinbearing by inserting a feeler gauge at thebottom of the bearing shell in both sides.See Data for bottom clearance.

4. The difference between the actual clear-ance measurement and the measurementrecorded in the Adjustment Sheet (or theclearance noted for a new bearing installedlater) must not exceed 0.1 mm. If so, thecrankpin bearing must be disassembled forinspection.See Procedure 904-4.2.

5. The wear limit for the crankpin bearingshells is based on an evaluation of thebearing condition at the time of inspection.

An average wear rate of 0.01 mm per10,000 hours is regarded as normal.

6. For further external inspection of the crank-pin bearing, see Chapter 708 ‘Bearings' inthe instruction book, Volume I, OPERA-TION.

2.

GW

90

4-1

.1 2

39 0

23.

D04-43

GM

90

4-6

.1 6

9 0

3

D04-44

5.

GN

904

-4.1

21

9 0

5


Crankpin Bearing904-4.2

Dismantling

904-4.2Dismantling

1. Turn the crank to BDC.

2. Suspend two tackles from the lifting brack-ets, in the athwartship direction.

3. Turn the crank to TDC.

Mount eye bolts in each side of the crankpinbearing cap and, using shackles and wireropes, hook on the tackles and haul tight.

Loosen the crankpin bearing stud nuts, us-ing the hydraulic jacks.

For operation of the hydraulic jacks, seeProcedure 913-1.

Remove the hydraulic jacks and the nuts.

4. Lower the bearing cap while seeing care-fully that the studs do not damage thecrankpin journal.

Land the bearing cap on a couple of planksplaced in the oil pan.

Inspect the bearing shell.

For evaluation of bearings, see Volume I,Chapter 708.

2.

GW

90

4-2

22

6 0

2

3.

GN

90

4-4

.2 2

03

03

D13-02

4.

GW

904

-4.2

22

6 0

4

D04-48



Dismantling

5. If the bearing shell needs to be replaced,remove the whole bearing cap from thecrankcase.

Hook the tackle on to an eye bolt on oneside of the bearing cap.

Mount the wire guide in the top of thecrankcase door opening.

Using the tackle from the frame box insidewall, together with a tackle suspended fromthe platform bracket, lift the bearing cap outof the crankcase.

6. Place the bearing cap on one side on acouple of planks.

Inspect the bearing shell. See Volume I, Chapter 708.

If necessary, dismount the bearing shelllock screws and replace the bearing shellby a new one.

7. Turn to TDC.

Mount the four supports for guide shoes onthe crosshead guides.

Carefully turn the crank down until theguide shoes rest on the supports.

Adjust the support brackets to the guideshoes so that the weight of the crossheadis evenly distributed on the four supports.

Note!

Normally bearing shells are replaced in pairs.

If only one of the shells needs replace-ment, MAN B&W Diesel should be con-tacted for advice beforehand.

5.

GW

904

-4.2

22

6 0

5

D04-48

6.

D04-47

GN

90

4-4

.2 2

03

06

7.

HN

90

4-4

.2 2

17

07



Dismantling

8. Mount a lifting attachment for securing theconnecting rod at the lower end, on oneside.

Hook on the tackle to a beam under the gal-lery platform and haul tight.

9. Carefully turn the crankshaft downwards,while ‘following’ with the tackle, makingsure that the upper part of the bearingcomes completely clear of the recess in thecrankshaft when the parts begin to ‘sepa-rate’.

Continue turning the crankshaft until thebearing surface can be freely inspected.

Inspect the bearing shell surface and thecrankpin journal.

10. If it is necessary to replace the bearingshell, proceed as follows:

Turn the crankshaft to BDC.

Release the tackle so that the connectingrod is hanging freely.

8.

GW

90

4-4

.2 2

26

08

9.

GW

90

4-4

.2 2

26

09

10.

GW

90

4-4

.2 2

26

10



Dismantling

11. Dismount the bearing shell lock screws andlift out the bearing shell.

11.

GN

90

4-4

.2 2

19

11

D04-46



Mounting

904-4.4Mounting

1. Bearing shells of three mm undersize areavailable as spares in case of journal recti-fication. Please contact MAN B&W Dieselfor advice.

Coat the bearing shell surfaces and thejournal with clean oil.

The excess height X is to ensure the cor-rect tightening-down of the bearing shell,and must not be eliminated.

2. Lift the upper bearing shell for the crankpinconcerned into the crankcase.

Carefully lift the bearing shell into positionin the connecting rod, and mount the lockscrews.

1.

HM

90

4-6

.0 6

1 1

6

2.

GN

90

4-4

.4 2

19

02

D04-46



Mounting

3. Hook the tackle on to a beam under the gal-lery platform and on to the lifting attach-ment on the connecting rod, and haul tight.

Carefully turn the crankshaft upwards,while following up with the tackle, makingsure that the upper part of the bearing en-ters the recess in the crankshaft when theparts turn together.

Remove the tackle and the lifting attach-ment from the connecting rod.

4. Turn the crosshead to TDC.

Remove the guide shoe support bracketsfrom the crosshead guides.

4.

GW

90

4-4

.4 2

26 0

4

5.

HN

90

4-4

.4 2

17

05



Mounting

5. Suspend the tackles from the lifting brack-ets in the top of the frame box.

Lift the bearing cap assembly into thecrankcase and land it on a couple of planksplaced in the oil pan.

6. Hook the tackles on to the wire ropes andlift the bearing cap into position against theconnecting rod.

Mount the nuts and, by means of spacerrings and hydraulic jacks, tighten the crank-pin bearing cap. See Data.

For operation of hydraulic jacks, see Sec-tion 913.

Remove the tackles from the top of theframe box.

Check the bearing clearance. See Procedure 904-4.1.

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 con-necting rod.

6.

GW

90

4-4

.4 2

26 0

6

D04-48

7.

GW

90

4-4

.4 2

26

07

D13-01

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D04-50 Connecting rod, without bearing caps 700 kg



Connecting Rod

X Stopped engine









Shut off fuel oil




104-5

Page 2 (2)

MAN B&W Diesel



Data






P90461 Connecting Rod - Hydraulic Tools







Connecting Rod


104-5

Page 1 (7)

904-5.2



Connecting Rod

M90405-0

238D

03

M90405-0

238D

02

M90405-0

238D

01

D13-02

1. Turn the crank to BDC.

Dismount the nuts from the crosshead

bearing studs.



crankcase in the athwartship direction, and

suspend two tackles.

3. Turn the crank to TDC.

Mount the support brackets for the guide

shoes on the crosshead guides.

Carefully turn the crank down towards

the door opening, camshaft side, until the

crosshead shoes rest on the supports.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead

is distributed evenly on the four supports

4. Dismount the crankpin bearing cap.


1.

2.

3.

Connecting Rod

Page 2 (7)

904-5.2



M90405-0

238D

05

M90405-0

238D

04

5. Mount an eye bolt in each side of the con-

necting rod at the crosshead end, hook on

the tackles, and haul tight.

Mount the lifting attachment on the exhaust

side of the connecting rod, at the crankpin

end.

6. Turn the crank carefully downwards while

“following” with the tackles to guide the

connecting rod when this separates from

the crosshead.

The weight of the crosshead, together with

the piston and crosshead bearing cap, is

now carried by the four supports.

5.

6.

Page 3 (7)

904-5.2



Connecting Rod

M9

04

05

-02

38

D0

6M

90405-0

238D

08

M90405-0

238D

07

7. Open the crankcase door on the exhaust

side of the engine.

Suspend a tackle from the platform bracket

and hook it on to the eye bolt in the con-

necting rod, crankpin end.

8. Remove the tackle from the connecting

rod, crosshead end, on the exhaust side.

9. Turn the crank carefully upwards while “fol-

lowing” with the tackle from the topplate

and the one on the exhaust side.

When possible, change the lifting point

from the camshaft side to the exhaust side

of the connecting rod and guide the upper

part of the connecting rod towards and out

of the door opening as far as possible.

7.

8.

9.

Connecting Rod

Page 4 (7)

904-5.2



M90405-0

238D

10

10. Place a wire rope round the connecting

rod, hook on the tackle and haul tight.

Continue turning the crank to a position

about 25° after TDC, while “following” with

the two tackles.

11. Lift the connecting rod out of the engine

using the two tackles and, if possible, us-

ing the engine room crane.

10.

11.

M90405-0

238D

09

D04-50

Page 5 (7)

904-5.4



Connecting Rod

M90405-0

238M

03

M90405-0

238M

02

M90405-0

238M

01

D04-50

1. Equip the connecting rod with the same

lifting attachments as mentioned under dis-

mantling.

Turn the crank to a position about 25° past

TDC on the camshaft side.

Apply clean lubricating oil to the crankpin

bearing shell and journal.

2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine

room crane and the tackle attached to the

lifting bracket mounted on the connecting

rod.

3. Carefully land the connecting rod on the

crankpin journal.

4. Turn the crankthrow towards the exhaust

side of the engine, past TDC, while ‘follow-

ing’ with the tackle and the engine room

crane.

When the upper end of the connecting rod

has passed the crankcase door, hook the

second tackle on to the eye bolt screwed

into the camshaft side of the connecting

rod.

Haul tight and remove the strap around the

connecting rod.

Note!Take care that the end of the connect-

ing rod does not scratch the crankpin

journal.

2.

3.

4.

Connecting Rod

Page 6 (7)

904-5.4



M90405-0

238M

05

D13-01

M90405-0

238M

04

M90405-0

238M

04

5. Turn the crankthrow to 90° before BDC.

Hook the third tackle on to the eye bolt

screwed into the exhaust side of the con-

necting rod.

6. Turn the crankthrow towards TDC while

‘following’ with the tackles.

Remove the tackle from the lifting attach-

ment at the lower end of the connecting

rod

7. When the crank is in TDC, mount and tight-

en the crankpin bearing cap.


Caution!

Take care that the studs do not dam-

age the crosshead bearing shell.

5.

6.

7.

Page 7 (7)

904-5.4



Connecting Rod

M90405-0

238M

08

D13-01

M90405-0

238M

07

8. Remove:

• the four supports from the crosshead

guides

• the eye bolts and the lifting attachment

from the connecting rod

• the eye bolts from the top of the crank-

case.

9. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.

8.

9.


Connecting Rod and Crosshead Panel PlateP90451-0144

0144Connecting Rod and Crosshead PanelP90451


Connecting Rod and Crosshead PanelPlateP90451-0144

Item No.

Item Description

011 Tool panel

023 Name plate

047 Wire guide

059 Lifting attchment - connecting rod

060 Lifting tools - crosshead

072 Chain for suspending piston

084 Nut

096 Bracket - support of x-head

106 Bracket - support of x-head

118 Rubber cover for crosshead

120 Rubber cover for crosshead

155 Crowfoot wrench head

Item No.

Item Description

Plate


Connecting Rod - Hydraulic ToolsP90461-0066

P90461 0066

Plate


P90461-0066Connecting Rod - Hydraulic Tools

ItemNo.


Item Description

P90461 0066

028 Hydraulic jack030 Support041 Tommy bar053 O-ring with back-up ring065 O-ring with back-up ring089 Spanner100 Stud setter207 Hydraulic toolset, complete

MAN B&W Diesel A/S

905 - Crankshaft, Thrust Bearing and Turning Gear


105-02 0084 Main Bearing, Data

905-02 0260 Main Bearing

105-03 0074 Thrust Bearing, Data

905-03 0227 Thrust Bearing

105-04 0049 Journal Bearing, Data

905-04 0233 Journal Bearing

105-05 0060 Axial Vibration Damper, Data

905-05 0226 Axial Vibration Damper

90551 0248 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel

90561 0085 Main Bearing - Hydraulic Tools

90562 0128 Crankshaft - Tools

90572 0003 Main Bearing - Measuring Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D05-01 Main bearing, top clearance max. 0.55 mm

D05-02 Main bearing, top clearance min. 0.20 mm

D05-03 Main bearing cap 149 kg

D05-04 Main bearing shell, upper 12 kg

D05-05 Main bearing shell, lower 13 kg



Main Bearing

X Stopped engine









Shut off fuel oil




105-2

Page 2 (2)

MAN B&W Diesel



Data


P90551 76 Lifting tool - main bearing cap

P90551 123 Retaining tool for main bearing shell

P90551 88 Dismantling tool, main bearing shell

P90551 255 Handle for dismantling of mainbearing shell

P90561 Main Bearing - Hydraulic Tools

P90562 Lifting tool for crankshaft

P90572 Main Bearing - Measuring Tools


P91351 22 Hydraulic pump, hand operated





P91351 166 Angle union


P91366 48 Autolog, measuring tool for crankshaft

P91368 Foot gratings

Main Bearing


105-2

Page 1 (17)

905-2.1



Main Bearing

M9

05

01

-02

04

C0

3

T

EC

B1B

B2

Looking forward

B1CTEB2½ (B1+B2)=B

M9

05

01

-02

08

C0

2

“Negative” (-)

“Positive” (+)

M90502-0

046C

01

General

The condition of the main bearings can be

checked by:

• Defl ection readings

• Visual checking

• Edge checking and

• Measuring of top clearance.

Crankshaft defl ection readings

Crankshaft defl ection readings should be taken

while the ship is afl oat (i.e. not while in dry

dock).

As the alignment is infl uenced by the engine

temperature as well as the loading conditions,

defl ection measurements should, for compari-

son purposes, always be made under nearly

the same temperature and load conditions.

1. Place a dial gauge axially in the crank

throw opposite the crankpin, as illustrated

on the sketch. The correct mounting posi-

tion is marked with punch marks on the

crank throw. See also Chapter 708 in Vol-

ume I.

2. “Closing” of the crank throw (compression

of the gauge) is regarded as negative (–)

and “opening” as positive (+).

3. Set the dial gauge to zero at the B1 side

near BDC. Whilst turning clockwise, take

the readings when the throw passes the

positions:

B1 (near bottom)

C (camshaft side)

T (top)

E (exhaust side)

B2 (near bottom)

B = 1/2 (B2+B1)

1.

3.

2.

Main Bearing

Page 2 (17)

905-2.1



M9

05

01

-02

08

C0

5M

90502-0

046C

01

4. When taking defl ection readings for the

three aftmost cylinders, the turning gear

should, at each stoppage, be turned a little

backwards to ease off the tangential pres-

sure on the turning wheel teeth. Otherwise,

this pressure may falsify the readings.

For evaluation of the crankshaft defl ec-

tion readings, see Volume I, OPERATION,

Chapter 708.

If the crankshaft defl ection (alignment in-

dicator) is approaching the tolerance limits

(see Vol. I, OPERATION), the two adjacent

main bearings must be checked for wear.

See next page for checking of main bear-

ing.

If the bearings are found to be in good

order, please contact MAN B&W Diesel or

the engine manufacturer for checking of the

bedplate alignment.

As reference, use the “after seatrial” defl ec-

tion table.

The condition of the bearing can be checked

as follows:

5. Visually look for bearing metal fragments in

the oil pan, and check the fi lters for metal

fragments.

Such fragments can be from crosshead,

guide shoe or crankpin bearings. If frag-

ments are found, the damaged bearing can

be found by edge checking with a feeler.

General

Bearing damage usually propagates rather

quickly towards the edge of the bearing where,

eventually, it causes chips to be broken off,

which means that loose pieces of white metal

can fall down into the crankcase beneath the

bearing support.

Large, thick pieces will normally be found dur-

ing a crankcase inspection, and small, thin

pieces can enter the fi lter. A check of the

bearing edges together with inspection of the

crankcase and the fi lter normally provides a

good indication of the bearing condition.

4.

5.

Page 3 (17)

905-2.1



Main Bearing

M90502-0

252C

06

1

<1.2 mm>0.7 mm

7-10 mm

60-70

2-3 mm

500-1

000

Wire feeler

M9

05

01

-02

08

C0

6

Hole inthe edge

Checking the bearing edges

6. Bearing edges can be checked with a

“feeler” that is able to follow the bearing

edge against the journal the whole way

round on each side. If white metal is miss-

ing at the edge, the tip of the “feeler” will

enter the hole, thus locating the damage.

In most cases this hole can be seen by the

naked eye as a dark spot when using a

strong fl ashlight.

The No. 1 and the two aftmost main bear-

ings are more diffi cult to access on the

whole circumference on each side, but it is

often possible to bend the “feeler” to suit

the situation and thus reach as far round

as possible.

Wire-feeler

7. It is rather easy to make a feeler (see

sketch). The “feeler” should be made from

a piece of steel wire (e.g. a welding rod)

approx. 0.6 1 m long depending on the

engine type, and 2 to 3 mm thick. Ap-

prox. 7 to 10 mm of the wire should be

bent to an angle of approx. 65° to form a

“feeler tip”. Grind the tip smooth to obtain

the shape and dimension shown on the

sketch. Note that the thickness of the white

metal is approx. 1.5 mm, which is why the

tip should be less than 1.2 mm thick, and

bigger than the max. top clearance. At the

other end of the tip, a “handle” should be

made by bending a hook or similar in the

same direction as the tip.

Note!

The above dimensions of the “wire-feel-

er” are guideline values and may depend

on the engine type as well as individual,

personal designs.

6.

7.

Main Bearing

Page 4 (17)

905-2.1



M9

05

01

-02

08

C0

8M

90502-0

259C

08

8. Remove the lub. oil pipe from the main

bearing cap.

Calibrate the main bearing measuring tool:

See the wooden box for the measuring

tool.

9. Insert the measuring tool and check the

clearance between the upper shell and the

journal.

An appreciable increase in clearance may

be an indication of loose staybolts or wear

of the lower shell.

10. If there is too large a difference in the

crankshaft defl ection readings (autolog)

check the clearance in the individual bear-

ings.

Bearing clearance checks should also be

carried out during time-based overhauls,

surveys and during crankcase inspections.

If there is a suspicion of a damaged bear-

ing, it is recommended to edge check the

bearing, without opening up.

8.

10.

Page 5 (17)

905-2.1



Main Bearing

M9

05

02

-02

27

C0

3

11. Before measuring, check that the feeler

blades are in good condition.

The feeler is inserted along the crank

throw. When the feeler hits the journal,

gently attempt to enter the feeler gauge

into the bearing. Do not use force.

Measure until a Go/No go difference of

0.05 mm has been found, e.g. Go = 0.75

mm / No go = 0.8 mm.

Check the feeler blades after measuring.

12. The difference between the actual clear-

ance measurement and the measurement

recorded in the adjustment sheet (or the

clearance noted for a new bearing installed

later) must not exceed 0.10 mm. If it does,

see Volume I, Operation, Chapter 708.

For evaluation of the bearing, see Volume I,

Operation, Chapter 708.

If the bearing needs to be disassembled for

inspection, see Procedure 9052.2.

Note!

The bearing clearances for a new bear-

ing stated in Data (see Data 105-2) are

for guidance purposes only.

12.

Main Bearing

Page 6 (17)

905-2.2



M90502-0

260D

03

EXH-SIDE MAN-SIDE

M90502-0

260D

02

Positioning the crankshaft

1. Dismantling of main bearing.

The bearings are divided into two catego-

ries:

• The main bearings

• The aftmost main bearing often referred

to as “Journal bearing” (See Procedure

905-4).

2. Before any dismantling, check and write

down the main bearing top clearances and

crankshaft defl ection readings for the cylin-

der unit concerned.

3. Turn the crank throw to the position shown

on the sketch and in such a way that the

top of the studs is fl ush with the crank

throw.

Note!

Be sure that the crosshead for the neigh-

bouring cylinder is in a higher position

than for the cylinder you are working on,

otherwise it will be impossible to lift the

cap.

1.

3.

2.

M90502-0

260D

01

Aftmost main bearing (= Journal bearing)

Main bearings

Thrust bearing

Page 7 (17)

905-2.2



Main Bearing

M90502-0

260D

04

Oil pipes

4. Disconnect the lubricating oil pipe from the

main pipe.

5. Place the two double spacer rings over the

four nuts.

Mount an extension stud on one stud in

each spacer ring and a special hydraulic

jack on the other stud.

Mount a distance piece with the cutout and

a round distance piece around each exten-

sion stud.

Finally mount a hydraulic jack.

For operation of the hydraulic jacks, see

Procedure 913-1.

6. Remove the hydraulic main bearing tools

from the engine.

Unscrew and remove the nuts from the

main bearing studs.

Remove the rectangular nut washers from

the bearing cap.

Note!

On some engines, the oil pipes for the

Axial Vibration Damper (AVD) have to be

removed together with the oil pipe on

main bearing No. 1.

Note!

Some engines have temperature sensors

fi tted to the main, crosshead, and crank-

pin bearings. These sensors must be

carefully handled to avoid damaging the

equipment.

4.

5.M

90502-0

260D

05

D13-02

Main Bearing

Page 8 (17)

905-2.2



M90502-0

260D

09

M90502-0

260D

08

D05-03

M90502-0

260D

07

7. Remove the stop screw in the crosshead

guide shoe.

Mount the guide pulley with the lifting wire

in the bottom of the guide shoe.

8. Fasten the lifting tool to the main bearing

cap.

Lift the bearing cap and, by means of the

handle, push the bearing cap free of the

frame and land it on the crank web.

9. If it is required to lift the cap completely

out of the engine, mount an eye bolt in top

of the bearing cap, through the lifting tool.

Hook on the tackle inside the engine and

haul taut.

Loosen the guide pulley from the engine.

Hook on the tackle outside the engine and

lift the bearing cap out of the engine.

10. Mount the handle in the upper bearing

shell and remove the bearing shell from the

crankshaft.

Inspect the bearing and the journal, see

Volume I Operation, Chapter 707, ‘Bear-

ings’.

7.

9.

8.

Page 9 (17)

905-2.2



Main Bearing

M90502-0

260D

11

70°

11. To dismantle a lower bearing shell, turn the

crankthrow for the pertaining cylinder to a

position about 70° before TDC.

Use the two stops which prevent the lower

shell from being rolled out.

12. Mount the dismantling handle on the upper

main bearing shell, and lift out the shell by

hand.

11.

12.

M90502-0

260D

12

Main Bearing

Page 10 (17)

905-2.2



M9

05

02

-02

38

D2

8

EXH CAMMin

. 6

0 m

m

min0.1 mm

M9

05

02

-02

38

D2

7M

90502-0

260D

13

13. If the crankshaft is turned with the bearing

cap dismounted, use the two stops to pre-

vent the lower shell from being rolled out.

14. Place the crosspiece in the bedplate with

the ends resting on the cross girders, and

position the hydraulic jacks beneath the

crank webs as shown.

Tighten the screws against the crank webs

and compress the jacks.

Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure until

the crankshaft has been lifted 0.2-0.5 mm,

but max. the clearance in the two adjacent

bearings.

Note down the pressure for later reference.

15. Check that there is min. 0.1 mm clearance

between journal and bearing shell, or be-

tween bearing shell and main bearing sup-

port, on both sides of the journal.

If the clearance is less than 0.1 mm, move

the crosspiece sideways until clearance is

obtained. Normally, adjustment needs to

be 50-150 mm to the exhaust side (the side

where the clearance is missing).

Note!

The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the

bore relief in the bearing shell.

Note!

The lower shell must be lifted out to the

side with the most clearance, which is

normally the camshaft side.

13.

15.

14.

Page 11 (17)

905-2.2



Main Bearing

M90502-0

260D

17

16. If re-positioning of the crosspiece does not

ensure a vertical lift, place a 5-tonne jack

between the side wall and the crank throw,

to correct the journal position in this way.

If it is available, note down the pressure

applied to the jack. This data is used to

ensure that the crankshaft is in the same

position when the new bearing is installed.

17. Dismount the locking screws.

Place the dismantling tool on top of the

lower bearing shell. Make sure that the

fl ap on the dismantling tool enters the oil

groove in the bearing shell.

Note!

It is recommended that the crankshaft

lifting tool is only removed if it is urgently

necessary and then only after the main

bearing shell has been reinstalled.

16.

17.M

90502-0

260D

16

Main Bearing

Page 12 (17)

905-2.2



M90502-0

260D

18

18. Pull the lower shell around and up until it

lies over the main bearing journal. Never

use a tackle larger than 0.5 tonne.

19. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the

lifting tool.

Note!

While pulling out the shell, it is recom-

mended to hold a foot or hand on the

wire rope, to tighten it up and to observe

whether the shell is sticking.

18.

19.

M90502-0

260D

12

Page 13 (17)

905-2.3



Main Bearing

M90502-0

260O

01

1. Clean and inspect the bearing shells. It is

recommended that the main bearing shells

be replaced in pairs.

If it is nevertheless desired to replace only

one shell, this requires a careful evaluation

of the condition of the shell that is to be re-

installed.

See Instruction book, Volume I, Chapter

708.

For advice on replacing individual bearing

shells, it is recommended to contact MAN

B&W Diesel A/S or the engine builder.

2. Before remounting:

• Check the bearing support for damage

and burrs. If damage is found, contact

MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fl uffy cloth to clean between journal

and main bearing support.

• Lubricate the bearing journal, the main

bearing support and the back of the

shell, with main engine lubricating oil.

1 + 2.

Main Bearing

Page 14 (17)

905-2.4



M90502-0

260M

02

M90502-0

260M

01

Mounting of bearing shells

1. Lubricate the journal and the bearing sup-

port with clean oil

Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and

land it on the crankshaft journal.

2. Position the guide tool for the lower bearing

shell on the main bearing support. Remove

the lifting tool from the bearing shell.

Place the lower bearing shell on the journal

and push it down by hand.

To ensure that the shell is correctly mount-

ed, 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 hy-

draulic jacks and the crosspiece from be-

low the crankshaft.

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with

a non-fl uffy piece of cloth.

1.

3.

2.

M90502-0

260M

03

Page 15 (17)

905-2.4



Main Bearing

M90502-0

255M

04

M90502-0

255M

05

4. Land the upper bearing shell on the main

journal in the same way as the lower bear-

ing shell.

Make sure that none of the edges of the

upper bearing shell are resting on the edge

of the bearing support.

If necessary, place the special tool be-

tween the studs and press the shell into

place.

Clean the contact surfaces between the

bearing support and the bearing cap. Make

sure that no oil is left on the contact sur-

faces.

5. Mount the lifting tool on the bearing cap.

Using the tackles and pulleys, lift the cap

into the crankcase in reverse order to dis-

mantling.

See Procedure 905-2.2, steps 12-9.

Note!

Be sure that the cap lands correctly and

that the spring pin in the assembly sur-

face enters the hole in the bearing cap.

4.

5.

Main Bearing

Page 16 (17)

905-2.4



M90502-0

260M

07

20

D05-01D05-02

M90502-0

260M

06

D13-01

6. Mount the rectangular nut washers and

screw the round nuts on to the main bear-

ing studs.

Using the hydraulic jacks, fully tighten the

nuts on both sides of the bearing cap.

For tightening pressure, see Data.

For operation of the hydraulic tools,


7.


Note!

Before removing the hydraulic jacks,

check the top clearance between the up-

per bearing shell and the journal.

Note!

Search the crankcase to ensure that there

are no tools, shackles or rags left behind.

6.

8.

7.

M90502-0

260M

08

C

Page 17 (17)

905-2.4



Main Bearing

M90502-0

260M

09

9. Mount the lubricating oil pipe on the main

bearing cap.9.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D05-06 Thrust bearing segment 25 kg

D05-09 Segment stopper, fore 25 kg

D05-10 Segment stopper, aft 20 kg

D05-29 Segment stopper, tightening torque. 450 Nm

Thrust Bearing

X Stopped engine









Shut off fuel oil




105-3

Page 2 (2)

MAN B&W Diesel



Data


P90551 100 Tool for turning out segments




Thrust Bearing


105-3


Thrust Bearing 905-3.1

Checking

0227S42MCThrust Bearing

905-3.1Checking

The clearance in the thrust bearing was meas-ured during testbed trials of the engine and not-ed down in the ‘Adjustment Sheet' which isinserted 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 exceed2.0 mm.

In service it is only necessary to measure thewear of the thrust bearing pads, and to inspectfor white metal below the thrust bearing.

1. To measure the wear in the thrust bearing,it is necessary to dismount the foremostsegment stopper.For dismantling the segment stopper, seeProcedure 905-3.2.

A wear groove of 1 mm is positioned in theuppermost thrust segment. (The segmentwith thermometers).

2. To measure the wear, the thrust segmenthas to be pressed against the thrust cam,to eliminate any gap, i.e. by using a suitablecrowbar on the back of the segment.

If a feeler gauge of 0.1 mm is not able to

enter the groove (the wear is more than 0,9mm), the thrust bearing must be over-hauled.

3. Note down the wear for later reference.

��

DM

905-

3.4

45 0

2��

GN

905-

3.1

224

02

��

KN

905-

2.2

238

02


Thrust Bearing905-3.2

Dismantling

905-3.2Dismantling

1. Remove the protective shield, and the lub.oil pipe for the thrust segments.

Loosen and remove the screws from thesegment stoppers.

Remove the segment stoppers above thethrust segments (AHEAD or ASTERN) that areto be taken out, and lift the stoppers out ofthe chain casing.

2. For turning up the thrust segments, mountthe tools on the chain wheel.

3. Turn up the segments, one at a time, byturning the engine, and remove the seg-ment from the chain casing. Inspect thesegment and remount it before turning upthe next segment.See Procedure 905-3.4.

Note!

Never remove more than one segment at a time.

��

DM

90

5-5

.0 6

7 0

1

D05-09D05-10

��

DM

90

5-5

.06

704

D05-06

��

DM

90

5-3

.4 2

27

02


Thrust Bearing 905-3.4

Mounting

905-3.4Mounting

1. Suspend a tackle above the segmentswhich are to be mounted. Still, it is possibleto lift the segments by hand.

Mount the tool for turning out segments onthe chainwheel.

Land the segment on the journal and re-move the eye bolt from the segment.

Carefully slide the segment on to the seg-ment tool. Turn the engine to dismantle thenext segment.See Procedure 905-3.2.

2. After the last segment has been mounted,turn the segment tool up and dismount it.

1.

DM

90

5-3

.4 2

27

01

2.

DM

90

5-3

.4 2

27

02


Thrust Bearing905-3.4

Mounting

3. Mount the segment stopper.

Tighten the screws on the stopper.

Mount the lub. oil pipe for the thrust seg-ments and the protective shield.

��

DM

90

5-3

.4 2

27

03

D05-09D05-10D05-29

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D05-11 Min. bearing clearance 0.25 mm

D05-12 Max. bearing clearance 0.60 mm

D05-13 Journal bearing cap 156 kg

D05-14 Upper bearing shell 12 kg

D05-15 Lower bearing shell 13 kg

D05-16 End cover 70 kg



Journal Bearing

X Stopped engine









Shut off fuel oil




105-4

Page 2 (2)

MAN B&W Diesel



Data


P90561 Main Bearing - Hydraulic Tools

P90551 76 Lifting tool - main bearing cap

P90551 123 Retaining tool for main bearing shell

P90551 88 Dismantling tool, main bearing shell

P90551 255 Handle for dismantling of mainbearing shell

P90562 Lifting tool for crankshaft

P90572 Main Bearing - Measuring Tools








P91368 Foot gratings

Journal Bearing


105-4

Page 1 (8)

905-4.1



Journal Bearing

M90504-0

225C

03

M9

05

02

-02

38

D0

2M

90504-0

225C

01

Aftmost main bearing (= Journal bearing)

Main bearings

Thrust bearing

1. Before any dismantling of the journal bear-

ing, check the clearances as described in

Procedure 905-1.1.

2. Write down the journal bearing clearances.

3. Also check the journal bearing by visually

searching the area underneath the bearing

support.

1.

3.

2.

Journal Bearing

Page 2 (8)

905-4.2



90504-0

233D

02

D05-16

M90504-0

233D

03

D13-02

M90504-0

227D

04

1. Dismount the screws for the end cover.

Mount a ½-ton tackle above the end cover.

Remove the end cover.

2. Disconnect the lubricating oil pipe from the

main pipe.

Remove the protective shield for the thrust

bearing.

Turn the crank throw for the aftmost cylin-

der to TDC.

3. Mount the extension studs, the spacers,

the hydraulic jacks and the nuts on the

extension studs. Loosen the bearing stud

nuts, using the hydraulic jacks

For operation of the hydraulic tools, see

Procedure 913-1.

4. Remove the hydraulic main bearing tools

from the engine

Unscrew and remove the nuts from the

bearing studs.

2.

4.

3.

Page 3 (8)

905-4.2



Journal Bearing

M90504-0

233D

07

EXH CAM

Min. 0,1 mm

Min

.60

mm

M90504-0

233D

05

M90504-0

233D

06

D05-14

5. Remove the rectangular nut washers from

the bearing cap.

Mount the lifting attachment on the jour-

nal bearing cap, and lift the cap out of the

engine using the ½-ton tackle above the

bearing.

6. Mount the dismantling handle on the upper

shell, and lift the shell out of the engine.

7. Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure

until the crankshaft has been lifted 0.2-0.5

mm, but max. the clearance in the adjacent

bearing.

Dismount the lower bearing shell by lifting

the crankshaft on the aftmost cylinder sec-

tion as shown in Procedure 905-2.

If necessary, the aftmost main bearing cap

nuts can be loosened to attain the required

clearance.

5.

7.

6.

Journal Bearing

Page 4 (8)

905-4.2



M90504-0

233D

09

D05-15

M90504-0

233D

08

8. Dismount the locking screws.

Place the dismantling tool on top of the

lower bearing shell. Make sure that the

fl ap on the dismantling tool enters the oil

groove in the bearing shell.

Pull the lower bearing shell round and up-

wards until it lies over the bearing journal.

Never use a tackle larger than 0.5 ton.

9. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the

dismantling handle.

8.

9.

Page 5 (8)

905-4.3



Journal Bearing

M90504-0

232O

01

1. Clean and inspect the bearing shells. It is

recommended that the main bearing shells

be replaced in pairs.

If it is nevertheless desired to replace only

one shell, this requires a careful evaluation

of the condition of the shell that is to be

reinstalled.

See Instruction book, Volume I,

Chapter 708.

For advice on replacing individual bearing

shells, it is recommended to contact MAN

B&W Diesel A/S or the engine builder.

2. Before remounting:

• Check the bearing support for damage

and burrs. If damage is found, contact

MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fl uffy cloth to clean between journal

and bearing support.

• Lubricate the bearing journal, the bear-

ing support and the back of the shell,

with main engine lubricating oil.

1 + 2.

Journal Bearing

Page 6 (8)

905-4.4



M90504-0

233M

02

M90504-0

233M

01

1. Lubricate the journal, the lower bearing

shell and the bearing support with clean

oil.

Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and

land it on the crankshaft journal.

2. Position the guide tool for the lower bear-

ing shell on the bearing support. Remove

the lifting tool from the bearing shell.

Lubricate the journal, the lower bearing

shell and the bearing support with clean

oil.

Push the lower bearing shell downwards

while holding the shell back with the dis-

mantling tool.

Check that the bearing shell is positioned

with the same distance on both sides.

3. Remove the guide tool when the lower

bearing shell has been mounted.

Mount the locking screws in the bearing

support.

Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from un-

der the crankshaft.

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with

a non-fl uffy piece of cloth.

1.

3.

2.

M90504-0

233M

03

Page 7 (8)

905-4.4



Journal Bearing

M90504-0

233M

07

D13-01

M9

05

02

-02

38

M0

9M

90504-0

233M

04

4. Land the upper bearing shell on the main

journal in the same way as the lower bear-

ing shell.

Make sure that none of the edges of the

upper bearing shell are resting on the edge

of the bearing support.

If necessary, place the special tool be-

tween the studs and press the shell into

place.

Clean the contact surfaces between the

bearing support and the bearing cap. Make

sure that no oil is left on the contact sur-

faces.

5. Mount the lifting tool on the bearing cap.

Using the lifting tool and the tackles, lift

the bearing cap into the crank casing in re-

verse order to dismantling.

See Procedure 905-4, step 5.

6.

7. Mount the rectangular nut washers, the

nuts, the spacer rings, the hydraulic jacks,

and tighten the nuts. See Data.

For operation of the hydraulic tools,


Note!

Be sure that the cap lands correctly and

that the guide pin in the assembly sur-

face enters the hole in the bearing cap.

4.

7.

6.

Journal Bearing

Page 8 (8)

905-4.4



M9

05

02

-02

52

M1

3M

90

50

2-0

23

8M

14

C

M9

05

04

-02

24

M1

0

20

D05-11

D05-12

8.


10. Mount the lubricating oil pipe on the bear-

ing cap, and mount the end cover.

Note!

Before removing the hydraulic jacks,

check the top clearance between the up-

per bearing shell and the journal.

Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left

behind.

1.

3.

2.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D05-17 Inner screws, tightening torque 250 Nm

D05-21 Outer screws, tightening torque 800 Nm

D05-23 Horizontal screws, tightening torque 230 Nm

D05-24 Horizontal screws, tightening torque/angle 100/17 Nm/°

D05-25 Damper housing, upper part 125 kg



Axial Vibration Damper

X Stopped engine









Shut off fuel oil




105-5

Page 2 (2)

MAN B&W Diesel



Data


P90551 111 Lifting tool - AVD



Axial Vibration Damper


105-5


Axial Vibration Damper 905-5.1

Checking

0226S35MCAxial Vibration Damper

905-5.1Checking

For checking the effectiveness of the axial vi-bration damper, it is necessary to measure thelongitudinal movements of the fore end of thecrankshaft during running.

The measurement (or reading) should be takenat the same r/min as during the sea trials. (Pref-erably 90% and 100% of MCR.)

As different equipment can have been mountedon the specific engines, the checking proceduredescribes three different systems:

A: Electronic, with Axial Vibration Monitor

B. Mechanical, without angle encoder fore

C: Mechanical, with angle encoder fore.

A: Electronic, with Axial Vibration Monitor

A proximeter probe is built on to the lower partof the damper housing. The probe is connectedto a control unit which displays peak-to-peakmovements and sends signals to the enginecontrol system.

1. Concerning overhaul and setting of theelectronic device, refer to makers instruc-tions and Volume I, Operation, Chapter701.

The peak-to-peak values displayed in mmare to be compared with the original valuesobtained during sea trial and the limits giv-en in Volume I, Operation, Chapter 701.

If the peak-to-peak value exceeds the Nor-mal Service Value, it is necessary to over-haul the axial vibration damper, seeProcedure 905-5.2.

1.

KM

90

5-7

.1 3

5 0

1


Axial Vibration Damper905-5.1

Checking

B: Mechanical, without angle encoder fore

1. Stop the engine.

Unscrew the two plugs from the cover at thefront of the engine.

2. Mount the shaft piece in the end of thecrankshaft, using the handle.

After tightening the shaft, dismount thehandle.

Screw the measuring arm into the smallthreaded hole beside the centre hole, sothat the arm is perpendicular to the shaftpiece. Tighten the lock nut.

Attach a pencil to the arm.

Note!

To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.

1.

BG

90

5-5

.1 2

23 0

1B

2.

BG

90

5-5

.1 2

23

02

B



Checking

3. Start the engine, and let the speed rise tothe number of revolutions at which themeasurement is to be taken. (Preferably90% and 100% of MCR.)

When measuring, press the measuring armagainst the shaft piece with the one hand.With the other hand, move a sheet/block ofpaper, clipped on to a solid backing plate,lightly downwards against the tip of thepencil.

To ensure a certain inertia, the backingplate should have a mass of approx. 1-2 kg.

The axial movements (S2) recorded on thepaper must be measured with a slide calli-per as shown in the sketch.

4. Before comparing the measured value (S2)with the Normal Service Value (S1), statedin Volume I, Operation, Chapter 701, it isnecessary to compensate for the ratio inthe tool.

For a standard measuring tool (L1 = 38 mm

and L2 = 200 mm), the ratio is 5.3. There-

fore, S1 can be calculated as follows:

If a non-standard tool is used, S1 can becalculated as follows:


3.

DM

90

5-7

.1 7

4 0

5

S-2

M905

05-0

229C

10

L2

L1

S1

S2

4.



Checking

C: Mechanical, with angle encoder fore

For engines with angle encoder fore, a meas-uring tool is available for mounting on the angleencoder housing.

1. Stop the engine.

Dismount the protection shield over the an-gle encoder. (Not always on engine).

Dismount the cover on the angle encoderhousing.

Apply some MolycoteTM on the fore side ofthe shaft cam.

2. Mount the axial vibration measuring tool,using the screws from the cover.

Note!

To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.

1.

BG

90

5-5

.1 2

23

01C

2.

MN

90

5-5

.1 2

14

05



Checking

3. Start the engine, and let the speed rise tothe number of revolutions at which themeasurement is to be taken. (Preferably90% and 100% of MCR.)

When measuring, pull the measuring armagainst the shaft cam with one hand. Withthe other hand, move a sheet/block of pa-per, clipped onto a solid backing plate,lightly sidewards against the tip of the pen-cil.

To ensure a certain inertia, the backingplate should have a mass of approx. 1-2 kg.

The axial movements (S2) recorded on thepaper must be measured with a slide calli-per as shown in the sketch.

4. Before comparing the measured value (S2)with the Normal Service Value (S1), statedin Volume I, Operation, Chapter 701, it isnecessary to compensate for the ratio inthe tool.

For a standard measuring tool (L1 = 35 mm

and L2 = 178 mm), the ratio is 5.1. There-

fore, S1 can be calculated as follows:

If a non-standard tool is used, S1 can becalculated as follows:


3.

BG

90

5-5

.1 2

23

03

PULL

S2

4.

MA

90

5-5

.1 2

12

07


Axial Vibration Damper905.5.2

Dismantling

905.5.2Dismantling

Dismantling of the axial vibration damper is car-ried out from the crankcase of cyl. No. 1.

1. Turn the engine to 90º after TDC.

Dismount the lubricating oil pipes for themain bearing and axial vibration damper.

2. Loosen and remove the screws from thedamper housing upper part.

Only the upper part of the housing needs tobe removed, while the lower half remainsmounted on the bedplate.

3. Mount the lifting bracket and a shackle onthe upper part.

Dismount the plug screw above the axial vi-bration damper, on the fore end of theframe box.

By means of a tackle, mounted below theforeend platform, and a wire rope, separateand raise the upper part of the damperhousing to a position in which it is possibleto change the oil seals and springs.

Note!

Before starting work below the suspen-ded upper part, secure the upper part with, e.g. a wire rope or another tackle.

1.

BG

90

5-7

.2 2

8 0

1

2.

BG

90

5-7

.2 2

8 0

2

3.

BG

905

-5.2

21

6 0

3

D05-25



Overhaul

905-5.3Overhaul

1. Dismantle and remove the springs from theoil sealing rings.

Remove the oil sealing rings.

When mounting the new oil sealing rings,first insert the lower half of the rings in thelower housing.

Then press the tension springs into thegroove between the oil sealing ring half andthe housing.

2. Mount all the upper halves of the oil sealingrings in such a way that the clearance atboth the joints on each oil sealing ring is thesame.

Now hook the new tension springs intoplace, ensuring that they are centralised inthe grooves of the oil sealing rings.

Note!

It is recommended to discard both the springs and the oil sealing rings.

Note!

The lower half of the oil sealing rings will protrude above the centreline.

1.

HG

90

5-5

.2 2

01

01

2.H

G90

5-5

.2 2

01 0

2



Mounting

905-5.4Mounting

1. Release and carefully lower the upper partof the damper housing.

When reaching the oil sealing rings, takecare that the rings enter the sealing ringgrooves correctly.

Before landing the upper part on the lowerpart, be sure that the guide pins have en-tered the guide pin holes.

2. Mount the vertical and horizontal screws.

Tighten the screws. See Data.

Mount the lubricating oil pipes.

Mount the plug screw on the fore end of theframe box.

Note!

Search the crankcase to ensure that there are no tools, shackles or rags left behind.

Note!

After overhaul of the axial vibration damper, it is recommended to check the axial vibrations. See Procedure 905-3.1.

1.

BG

90

5-5

.4 2

23

01

D05-25

2.

BG

90

5-7

.2 2

8 0

6

D05-17D05-21

D05-23

Plate

Page 1 (2)When referring to this page, please quote Plate Edition

MAN B&W Diesel

Crankshaft, Thrust Shaft, Main Bearing, etc. -

Panel P90551-0248

P90551 0248

Plate

Page 2 (2) When referring to this page, please quote Plate Edition

MAN B&W Diesel

ItemNo.


Item Description

P90551-0248

Crankshaft, Thrust Shaft, Main Bearing,

etc. - Panel

015 Panel for tools027 Name plate076 Lifting tool for main bearing cap088 Dismantling tool for main bearing shell090 Mounting tool for thin bearing shell100 Tool for turning out segments111 Lifting tool for AVD123 Retaining tool, main bearing shell135 Lifting tool for relief valve172 Mounting tool for thin bearing shell196 Tightening template for AVD255 Handle, dismounting of main bearing

shell

P90551 0248


Main Bearing - Hydraulic Tools PlateP90561-0085

0085Main Bearing - Hydraulic ToolsP90561


Main Bearing - Hydraulic ToolsPlateP90561-0085

Item No.

Item Description

021 Hydraulic jack, upper

033 Hydraulic jack, lower

045 Support

057 Distance bolck

069 Spacer ring

070 Extension stud

082 Support



116 Stud setter for main bearing studs

128 Ball handle

130 Key, hexagon socket screw

200 Hydraulic tool set, complete

Item No.

Item Description


Crankshaft - Tools PlateP90562-0128

0128Crankshaft - ToolsP90562


Main Bearing - Measuring Tools PlateP90572-0003

0003Main Bearing - Measuring ToolsP90572


Main Bearing - Measuring ToolsPlateP90572-0003

Item No.

Item Description

010 Measuring tool main bearing clearence

021 Calibration tool

045 Key, hexagon socket screws

057 Wooden box

Item No.

Item Description

MAN B&W Diesel A/S

906 - Control Gear


106-01 0055 Chain, Data

906-01 0245 Chain

106-02 0066 Chain Tightener, Data

906-02 0230 Chain Tightener

106-03 0042 Camshaft, Data

906-03 0219 Camshaft

106-04 0044 Camshaft Bearings, Data

906-04 0225 Camshaft Bearings

106-06 0010 Replacement of Cams on Camshaft, Data

906-06 0203 Replacement of Cams on Camshaft

90651 0193 Chain Drive and Camshaft - Panel

90664 0005 Crankshaft - Pin Gauge

90668 0005 Camshaft - Pin Gauge

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

3” chain

D06-18 Teeth on chain wheel, max. wear 2,5 mm

D06-19 Original length (chain pitch x 10 links) 762 mm

D06-20 10 links measurements + 1% of a tensioned chain = scrapping of chain 769,5 mm

Chains

Data

106-1



Stopped engine







Engage turning gear


Shut off fuel oil




X

X

X

X

X

X

X

X

Page 2 (2)

MAN B&W Diesel


Chains

Data

106-1


P90651 Chain Drive and Camshaft - Panel


Page 1 (6)

906-1.1



Chains

M90601-0

245C

02

D06-18

M90601-0

245C

01

1. The engine is equipped with a set of

chains:

• the drive chains for the camshaft

The set of chains is to be checked and, if

necessary, dismantled and mounted in the

same way.

2. The chains can be accessed from within

the chainwheel frame.

3. Carry out the inspection as follows:

• Make a general inspection for loose

bolts and screws.

• Inspect lube oil pipes for damage, and

check jet nozzles for possible stoppag-

es or deformations.

• Examine the rubber track of the guide-

ways for cracks or other damage.

• Replace the guideway if bits have start-

ed to be “plucked out” of the rubber

track.

4. Check the teeth of the chain wheels. If ab-

normal wear is found, take a measurement

(See Data).

Measurements are best taken by placing a

short straight-edge over the straight part

of the chain wheel and then measuring the

distance D06-18.

1.

4.

Chains

Page 2 (6)

906-1.1



M90601-0

244C

05

0

10

10

0

Scale 1:1

5. If abnormal wear is observed at the bottom

of the teeth, make a drawing in scale 1:1 of

the teeth and wear profi le.

Draw two rulers on the drawing.

For assessing the wear profi le, contact

MAN B&W Diesel.

In most cases, scratches caused by the

side plates of the chain will be found on

the sides of the teeth. Such scratches can

generally be considered normal.

6. The chains for the camshaft drive are

matched together to ensure an even load

distribution.

To keep such matching chains in their

pairs, the side plates of the outer link

nearest to the assembled link have been

marked with year, month, day and chain

number.

Example:

No. 1 order,

840520 1A

840520 1B

(840520 2C, possible 3rd chain)

No. 2 order,

840520 2A

840520 2B

(840520 2C, possible 3rd chain)

On the same links there is an arrow (–>)

which indicates the mounting direction.

Check the chains for cracks on possibly

defective rollers and side plates.

Check that the chain rollers can run freely

and that the chain links can freely move

on the pin and bushing (that they are not

“seized” between the pin and the bushing).

It is normal, however, that the rollers get

light, circumferential scratches during the

running-in period. These fi ne scratches are

of no importance and need not be consid-

ered.

It is recommended that each single link is

checked.

5.

Page 3 (6)

906-1.1



Chains

M90601-0

245C

07

D06-19D06-20

Max.D

06-2

0

7. Check chain wear by measuring the length

of 10 chain links. Use two master squares

and a steel measuring tape as shown on

the sketch. Compare the result with the

value given in Data.

If necessary, adjust the chain tightener.


7.

Chains

Page 4 (6)

906-1.2



M90601-0

245C

01

M9

06

01

-02

38

D0

2

It may become necessary to disassemble

the chain if, for instance, cracked rollers

or seizures between pin and bushing have

been discovered during the inspection.


1. Remove the tension on the chain by loos-

ening the chain tightener.

(See Procedure 906-2.3).

Turn the engine until the slack part of the

chain, with the chain link that is to be dis-

assembled, is in a favourable position for

the work.

2. Mount a wire round the link rollers a short

distance from the disassembly point, and

tighten the wire lightly with a tackle.

Protect the link rollers over which the wire

is wrapped.

The riveting of the pins that are to be

pressed out is to be chiselled or ground

away.

Note!

Every time a chain link is disassembled,

a new link must always be fi tted as

the link pin press-fi t is destroyed when

breaking the chain.

When a new link is fi tted in one chain,

the corresponding link in the other chain

must also be renewed.

Note!

If the chain is to be completely removed,

contact MAN B&W Diesel for further in-

formation.

1.

2.

Page 5 (6)

906-1.2



Chains

M90601-0

238D

03

3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter-

nately tightening the screws on the tool.

3.

Chains

Page 6 (6)

906-1.4



M9

06

01

-02

38

M0

1

Before assembling the inner and outer

links, clean the pins and bushings.

1. Combine the inner chain link with the outer

chain link and mount the compression tool.

Force the loose side plate of the outer

link into place by alternately tightening the

screws on the compression tool.

2. When the link has been assembled, remove

the compression tool and lock the pin ends

by riveting.

Repeat this procedure until the chain has

been assembled.

Remove the tackle and wire and adjust the

chain tension.

(See Data and Procedure 906-2.3).

1.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D06-21 Tightening angle = 10 hexagons 600/10 ° / hex

D06-25 Mechanical or blocked chain tightener, clearance 0,1 mm

Chain Tightener

X Stopped engine









Shut off fuel oil




106-2

Page 2 (2)

MAN B&W Diesel



Data


P90651 070 Chain assembling tool

P90651 081 Chain disassembling tool


Chain Tightener


106-2


Chain Tightener 906-2.3

Adjustment

0230S60MC-CChain Tightener

906-2.3Adjustment

1. To retighten the chains, loosen nuts A, B,C and D to free the chain tightener bolt.

2. Turn the engine at least one revolution withthe chain slackened on the same side asthe chain tightener wheel.

If the engine is equipped with flyweights,continue turning until the flyweights arehanging vertically downwards.

3. Tighten nut B on the chain tightener boltuntil there is a clearance between the shaftand the nut as stated in D06-25.

Then tighten nut B as stated in D06-21 (see Data).

For chain wear, see Procedure 906-1.1.

1.

HG

90

6-2

.3 2

18 0

1

A

B

C

D

2.H

M90

6-2

.2 9

5 0

1

3.

HG

90

6-2

.3 2

18

03

D06-25

B

D06-21


Chain Tightener906-2.3

Adjustment

4. Tighten nut C hard against the contact faceof the shaft.

Tighten nut D.

Lock nuts C and D with the tab washer.

5. Tighten nut A.

Lock nuts A and B with the tab washer.

The number of times that retightening canbe carried out depends on when the limit forscrapping the chain has been reached. SeeData page 106-1.

4.

HG

90

6-2

.3 2

18

05

C

D

5.

HG

90

6-2

.3 2

18

05

A

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D06-27 Max. permissible change in lead angle 2 °

D06-28 corresponding to 5.9 mm

Camshaft

X Stopped engine









Shut off fuel oil




106-3

Page 2 (2)

MAN B&W Diesel



Data


P90664 Crankshaft - Pin Gauge

P90668 Camshaft - Pin Gauge


Camshaft


106-3

Page 1 (4)

906-3.1



Camshaft

M90603-0

219C

02

Check

Check

M90603-0

218C

01

1. Turn the crankthrow for cylinder 1 to TDC.

Turn in the ahead direction to ensure that

the tension of the chain on the chain drive

is correct. If necessary, adjust the chain

tension.


Check the TDC of cylinder 1 against the

mark on the turning wheel.

2. Use the check measurement value

stamped on the pin gauges to check the

pin gauges for deformation.

On some engines the pin gauges can be

checked against punch marks made on the

front cylinder frame.

1.

2.

Camshaft

Page 2 (4)

906-3.1



M90603-0

219C

06

M90603-0

219C

04

D06-28

D06-27

M90603-0

218C

03

3.3. Check the TDC position with the pin gauge

on the crankthrow.

Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,

if any, in lead angle.

For max. permissible change, see D06-27

and D06-28.

4. Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,

if any, in lead angle.

For max. permissible change, see D06-28.

5. Check and, if necessary, adjust the cylinder

lubricator.


Check the setting of the starting air dis-

tributor.


6. When checking the camshaft position, also

check the running surface of the cams.

As the inspection must include the entire

surface of the cam, the cam should be

turned one complete revolution during the

inspection.

The running surface of the cam must be

completely smooth and bright.

4.

6.

Page 3 (4)

906-3.1



Camshaft

M90603-0

219C

07

7. If light scratches are ascertained, remove

them by carefully polishing the cam in the

direction of rotation with a fi ne carborun-

dum stone. Such light scratches can ap-

pear if the roller guide and the cam are not

correctly aligned.

In the event of heavier scratches or direct

fl aking of the material on the running path,

MAN B&W Diesel should be contacted for

further instructions.

6.

Camshaft

Page 4 (4)

906-3.3


MAN B&W DieselAdjustment

M90603-0

219O

01

D06-28

1. If the chains prove to be so heavily worn

that the deviation between the measuring

points and the pin gauge has reached the

maximum value D06-28 stated in Data, MAN

B&W Diesel should be contacted for further

instructions.

1.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D06-31 Screws for bearing cap, tightening torque 150 Nm

D06-33 Clearance between cap/bearing housing 3 ± 0.3 mm

D06-34 Bearing shell, max. wear 0,1 mm

D06-37 Camshaft bearing cap 13 kg

D06-65 Bearing shell, minimum thickness 5,8 mm

Camshaft Bearing

X Stopped engine









Shut off fuel oil




106-4

Page 2 (2)

MAN B&W Diesel



Data




P91366 073 Dial gauge and stand tool



Camshaft Bearing


106-4

Page 1 (5)

906-4.1



Camshaft Bearing

M90604-0

225C

01

1.1. As the upper shell of the camshaft bear-

ing assembly has been dispensed with on

this engine, it is no longer necessary to

measure the top clearance of the camshaft

bearing.

Dismount the inspection covers from the

front of the camshaft housing.

Check for wiped-out metal at the bearing

ends, and for fragments of metal in the

camshaft housing.

In the event of any signs of anomalies, the

bearing shell must be dismantled for closer

investigation and, if necessary, the bearing

shell must be replaced.

If no anomalies are found during the visual

inspection, dismantling need not be carried

out.

When checking the camshaft bearings, it is

recommended also to check the condition

of the fuel and exhaust cams.

See Procedures 908-5 and 909-3.

Camshaft Bearing

Page 2 (5)

906-4.2



M90604-0

225D

02

D06-37

M90604-0

225D

01


1. Remove the inspection covers on each side

of the bearing from the camshaft housing.

Dismount the lubricating oil connecting

pipe and the plug screws from the base-

plate above the bearing in question.

Lift the roller guide of the exhaust valve ac-

tuator. See Procedure 908-7.

2. Loosen the bearing cap screws through the

holes in the baseplate.

Remove the screws from the bearing cap.

Remove the bearing cap from the housing.

Warning!

Before dismantling any camshaft bear-

ings, the main chain must be relieved of

tension by loosening the chain tightener

to avoid damaging engine parts.

1.

2.

Page 3 (5)

906-4.2



Camshaft Bearing

M90604-0

225D

04

M90604-0

225D

03

Max. 20/100 mm3. Place a hydraulic jack between two pieces

of wood in the camshaft housing under-

neath the camshaft, close to the bearing.

Place a dial gauge on the camshaft, and lift

the camshaft 0.20 mm.

4. Press lightly on the upper edge of the shell

to turn the shell up over the camshaft.

Remove the shell from the camshaft hous-

ing.

3.

4.

Camshaft Bearing

Page 4 (5)

906-4.3



M90604-0

225O

01

D06-34

D06-65

1. For assessment of the bearing condition,

see Volume I OPERATION, Chapter 708

‘Bearings’.

Inspect the entire surface of the bearing

journal for seizures.

If seizures are found on the bearing journal

surface (on account of bearing breakdown),

polish the surface with a fi ne carborundum

stone to re-establish a bright and smooth

surface.

By closely examining the sliding surface

of the bearing shell visually, an impression

can be formed of whether the lubrication of

the bearing surface has been insuffi cient or

entirely missing. Normally, camshaft bear-

ing damage only occurs due to faulty lubri-

cation.

Measure the thickness of the bearing shell

with a micrometer to check the amount of

wear.

1.

Page 5 (5)

906-4.4



Camshaft Bearing

M90604-0

225M

03

M90604-0

225M

02

D06-31

D06-33

M90604-0

225M

01

1. Clean the bearing journal, the bearing sup-

port and the bearing shell.

2. Coat the bearing journal and the bearing

shell with plenty of lubricating oil. Mount

the shell on the camshaft, and turn it into

place.

Relieve the hydraulic jack of pressure

to lower the camshaft. Remove the dial

gauge, the pieces of wood and the hydrau-

lic jack from the camshaft housing.

3. Place the bearing cap on the camshaft and

mount the outermost bearing cap screw.

Tighten the outermost screw lightly by

hand until the clearance given in D06-33

is reached. Then mount and tighten the in-

nermost screw with a torque spanner. See

Data D06-31. This procedure ensures that

the outermost screw will obtain the correct

torque.

Check the torque on the outermost screw

with a torque spanner.

Check the clearance D06-33 on both sides

of the camshaft. Then mount the lubricating

oil pipe and the plug screws in the base-

plate.

4. Lower the exhaust valve actuator roller

guide. See Procedure 908-7.

5. Clean the camshaft housing and mount the

inspection covers.

Note!

Be careful not to scratch the camshaft

surface.

1.

2.

3.

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D06-47 Exhaust cam screws, tightening torque 360 Nm

D06-48 Indicator cam screws, tightening torque 60 Nm

D06-49 Fuel Cam screws, tightening torque 930 Nm

D06-50 Fuel cam, marking scratch 130 mm

D06-51 Fuel cam, axial movement 126 mm

D06-52 Exhaust cam, marking scratch 110 mm

D06-53 Exhaust cam, axial movement 104 mm

Replacement of Cams on Camshaft

X Stopped engine









X Shut off fuel oil




106-6

Page 2 (2)

MAN B&W Diesel



Data


P90951 082 Lifting tool for fuel pump roller guide







Replacement of Cams on Camshaft


106-6


Replacement of Cams on Camshaft 906-6.2

Dismantling

0203S42MCReplacement of Cams on Camshaft

906-6.2Dismantling

Fuel Cam

1. Remove the front cover of the camshafthousing.

2. Lift the roller guide from the cam in ques-tion. See Procedures 908-5 or 909-5.

3. Turn the camshaft so that the markingscratch can be seen.

4. Extend the marking scratch on the shaft byD06-50. See Data.

XZ

90

6-6

.2 2

01 0

1

1.

XZ

906

-6.2

20

1 0

22.

XZ

906

-6.2

20

1 0

4

4.

D06-50


Replacement of Cams on Camshaft906-6.2

Dismantling

5. Remove the plug from the cam and mountgaskets and snap-on connectors instead.

6. Connect the snap-on connectors to the hy-draulic high-pressure pump.

Apply oil pressure to the cam, using thehigh-pressure pump.

When oil seeps out along the cam, pressthe cam sideways, in the direction towardsthe forward end of the engine.

7. The cam should be moved as stated inD06-51 to be sure that it gets free of the lin-er for the roller guide.

8. In case the cam cannot be moved as de-scribed in item 6, MAN B&W should be con-tacted for further instructions.

XZ

90

6-6

.2 2

01 0

5

5.

XZ

90

6-6

.2 2

01 0

6

6.

XZ

906

-6.2

20

1 0

7

7.

D06-51

D06-51



Dismantling

Exhaust Cam

9. Remove the front cover of the camshafthousing.

10. Lift the roller guide from the cam in ques-tion. See Procedure 908-5.

11. Extend the marking scratch on the indicatordrive cam onto the camshaft.

Extend the marking scratch on the exhaustcam onto the camshaft by D06-52. See Da-ta.

XZ

90

6-6

.2 2

01 0

1

9.

XZ

90

6-6

.2 2

01

10

10.X

Z90

6-6

.2 2

01 1

1

11.

D06-52



Dismantling

12. Dismantle and remove the indicator drivecam from the camshaft when fitted.

13. Remove the plug from the cam and mountgaskets and snap-on connectors instead.

14. Connect the snap-on connectors to the hy-draulic high-pressure pump.

Apply oil pressure to the cam, using thehigh-pressure pump.

When oil seeps out along the cam, pressthe cam sideways, in the direction towardsthe aft end of the engine.

XZ

90

6-6

.2 2

01 1

2

12.

XZ

906

-6.2

20

1 1

3

13.

XZ

90

6-6

.2 2

01

14

14.



Dismantling

15. The cam should be moved as stated inD06-53 to be sure that it gets free of the lin-er for the roller guide.

16. In the event that the cam cannot be movedas described in item 14, MAN B&W shouldbe contacted for further instructions.

XZ

906

-6.2

20

1 1

5

15.

D06-53

D06-53



Mounting

906-6.4Mounting

Fuel Cam

1. Before mounting the two-part spare cam,the bore and the area on the shaft must bedegreased.

Place the two-part spare cam on the shaft,mount the four screws, and tighten slightly,so that the gap between the two parts isequal at both sides.

2. Make sure that the marking scratches onthe cam and the camshaft coincide, andthat the running surface of the cam is op-posite the roller.

Tighten the screws just hard enough toavoid that the cam slips when the rollerguide is lowered onto the cam.

Measure the fuel cam lead (see Procedures909-1 and 909-2) and adjust if necessary.

Tighten the screws to D06-49 and checkthat the gap is still equal at both sides.

Lock the screws with Loctite, type 242(EN243S).

3. Mount the cover on the front of the cam-shaft housing.

XZ

906

-6.4

20

1 0

1

1.

XZ

90

6-6

.4 2

01 0

2

2.

D06-49



Mounting

Exhaust Cam

4. Mount the indicator drive cam and adjustaccording to Chapter 706 in the Operationmanual when fitted.

Tighten the self-locking nuts as stated inD06-48.

5. Before mounting the two-part spare cam,the bore and the area on the shaft must bedegreased.

Place the two-part spare cam on the shaft,mount the four screws, and tighten slightly,so that the gap between the two parts isequal at both sides.

6. Make sure that the marking scratches onthe cam and the camshaft coincide, andthat the running surface of the cam is op-posite the roller.

Tighten the screws just hard enough toavoid that the cam slips when the rollerguide is lowered onto the cam.

Measure the fuel cam lead (see Procedure908-7) and adjust if necessary.

Tighten the screws to D06-47 and checkthat the gap is still equal at both sides.

Lock the screws with Loctite, type 242(EN243S).

7. Mount the cover on the front of the cam-shaft housing.

XZ

90

6-6

.4 2

01 0

4

4.

XZ

90

6-6

.4 2

01

05

5.X

Z9

06

-6.4

20

1 0

6

6.

D06-47D06-49


Chain Drive and Camshaft Panel PlateP90651-0193

0193Chain Drive and Camshaft PanelP90651


Chain Drive and Camshaft PanelPlateP90651-0193

Item No.

Item Description

019 Panel for tools

020 Name plate

044 Pin spanner for fuel cams

070 Chain assembling tool

081 Chain opener

Item No.

Item Description

Plate


Crankshaft - Pin GaugeP90664-0005

P90664 0005

Plate


P90664-0005Crankshaft - Pin Gauge

ItemNo.


Item Description

P90664 0005

021 Pin gauge for crankshaft


Camshaft - Pin Gauge PlateP90668-0005

0005Camshaft - Pin GaugeP90668


Camshaft - Pin GaugePlateP90668-0005

Item No.

Item Description

011 Pin gauge for camshaft

Item No.

Item Description

MAN B&W Diesel A/S

907 - Starting Air System


107-01 0020 Starting Air Distributor, Data

907-01 0218 Starting Air Distributor

107-02 0045 Start Air Valve, Data

907-02 0220 Starting Air Valve

MAN B&W Diesel A/S

Page 1 (2)

SAFETY PRECAUTIONS

Data

D07-01 Gear wheel on camshaft, tightening torque 90 Nm

D07-03 Clearance between gear wheel and bushing:Min. Max. 0.9-1.6 mm

D07-04 Clearance with roller in outermost position:Min. Max. 1.0-3.0 mm

D07-05 Clearance with roller in innermost position:Min. Max. 1.0-2.0 mm

Starting Air Distributor

Data

107-1


MAN B&W Diesel A/S

X

X

X

X

X

X

X


Stopped engine







Engage turning gear


Shut off fuel oil




Page 2 (2)


Starting Air Distributor

Data

107-1


MAN B&W Diesel A/S




Starting Air Distributor 907-1.1

Checking

0218L42ME/MCStarting Air Distributor

907-1.1Checking

1. Turn the engine in AHEAD direction to bring

the piston of cylinder No. 1 to TDC.

Check with the pin gauge.

2. Remove the plug screw and gasket from theside of the distributor housing, and insert

check pin K in slot S.

If pin K is not available, use the cylindrical

end of a drill of a suitable size.

3. If the check pin cannot enter the slot, i.e. if

the slot is not aligned with the hole in thedistributor housing, the air distributor mustbe adjusted.


1.

GN

90

6-3

.1 2

03

02

2.

EN

90

7-1

.3 2

04

02

K

S

S


Starting Air Distributor907-1.3

Adjustment

907-1.3Adjustment

1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.

Check with the pin gauge.

2. Dismount the end cover of the camshafthousing, along with the starting air distrib-

utor, from the engine.

Remove the plug screw and gasket from the

side of the distributor housing, and insertcheck pin K in slot S.

Turn the shaft together with the distributordisc until check pin K enters slot S in thedisc and keep it there.

3. Check and, if necessary, adjust clearanceD07-03 between the gear wheel and the

bushing.

1.

GN

90

6-3

.1 2

03

02

2.

EN

90

7-1

.3 2

04 0

2

K

S

S

3.

D07-03

GN

907

-1.3

20

3 0

3


Starting Air Distributor 907-1.3

Adjustment

4. Remove the lower half of the gearwheel

drive cover. Mount the upper half of thegearwheel drive cover with the completestarting air distributor after loosening the

gear wheel on the camshaft, and then en-gage the two gear wheels by turning thewheel on the camshaft.

Tighten and lock the gear wheel screws onthe camshaft, see Data, D07-01.

Mount the lower half of the gearwheel drivecover.

5. Remove check pin K from the distributorhousing and mount the gasket and plug

screw.

6. Check the clearance between the roller and

the two interlocking valves with the roller inits innermost and outermost positions, re-spectively (ASTERN and AHEAD).

4.

GN

90

7-1

.3 2

03

02

D07-01

5.

KS

GN

90

7-1

.3 2

03 0

2

6.

DL

90

7-1

.3 2

18 0

6

D07-05

D07-04

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D07-09 Piston tightening torque 110 Nm

D07-10 Valve tightening torque 25 Nm

D07-12 Starting air valve 12 kg

Starting Air Valve

X Stopped engine







Engage turning gear


Shut off fuel oil




107-2

Page 2 (2)

MAN B&W Diesel



Data


P90151 095 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve

Starting Air Valve


107-2

Page 1 (6)

907-2.1



Starting Air Valve

1. When the starting air valve has been over-

hauled, see Procedure 907-2.3, connect a

supply of working air to the control air inlet

at the top of the valve.

Check that the valve opens approx. 15-20

mm.

2. Shut off the air supply

Check that the valve closes fully.

3. Repeat steps 1 and 2 a couple of times.

M90702-0

220C

01

M90702-0

220C

02

1.

2.

Starting Air Valve

Page 2 (6)

907-2.2



1. Shut off the starting air and control air in-

let.

Dismount the control air pipe.

Unscrew the starting valve nuts.

2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.

M90702-0

220D

01

M90702-0

220D

02

D07-12

1.

2.

Page 3 (6 )

907-2.3



Starting Air Valve

1. Remove the top cover fi xing screws and re-

move the cover.

Remove and discard the gasket.

2. Remove the split pin and screw off the nut

from the valve spindle.

3. Remove the disc, the piston, the valve

spring, the distance pipe, and the liner from

the top end of the valve housing.

Remove the valve spindle from the bottom

end of the valve housing. Remove and dis-

card the O-ring.

M90702-0

220O

01

M90702-0

220O

02

M90702-0

220O

03

1.

2.

3.

Starting Air Valve

Page 4 (6)

907-2.3



4. Grind the valve housing seating with the

grinding ring after applying grinding paste.

Carborundum No. 200.

Grind the seatings of the spindle and hous-

ing to match, using the face wrench to ro-

tate the valve spindle.

Carborundum No. 500.

5. Thoroughly clean all parts before reassem-

bling the valve.

Lubricate all internal parts (sliding surfaces)

with, for instance, Molybdenum Disulphide,

MoS2.

6. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,

the spring, the piston and the disc.

M90702-0

220O

04

M90702-0

220O

03

4.

6.

Page 5 (6 )

907-2.3



Starting Air Valve

7. Mount the nut on the valve spindle and

tighten the nut, see Data D07-09.

Mount the split pin.

8. Place a new gasket on the valve housing.

Mount and tighten the top cover.

Replace the O-ring on the valve housing.

9. If the starting air valve is not to be mount-

ed in the engine immediately after the

overhaul, all openings of the valve should

be covered with plastic to prevent dirt from

entering the valve during storage.

M90702-0

220O

07

D07-09

M90702-0

220O

01

7.

8.

Starting Air Valve

Page 6 (6)

907-2.4



1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recon-

dition the seat for the starting valve in the

bore.


If not already done, replace the O-ring on

the overhauled valve and lubricate with

‘Never Seize’ or Molybdenum Disulphide,

MoS2.

For overhaul, see Procedure 907-2.3.

2. Mount the valve in the cylinder cover.

Mount and tighten the screws as stated in

Data.

Mount the control air pipe and turn on

starting air and control air.

M90702-0

220M

01

M90702-0

220M

02

D07-10

1.

2.

MAN B&W Diesel A/S

908 - Exhaust Valve


108-01 0050 High-Pressure Pipe, Data

908-01 0214 High-Pressure Pipe

108-02 0092 Exhaust Valve, Data

908-02 0263 Exhaust Valve

108-03 0056 Exhaust Valve Actuator, Data

908-03 0226 Exhaust Valve Actuator

108-04 0040 Exhaust Valve Roller Guide, Data

908-04 0221 Exaust Valve Roller Guide

108-05 0016 Exhaust Valve Cam, Data

908-05 0218 Exhaust Valve Cam

108-07 0034 Exhaust Valve - Special Running, Data

908-07 0226 Exhaust Valve

90851 0205 Exhaust Valve - Panel

90861 0036 Exhaust Valve - Tools

90862 0041 Exhaust Valve - Hydraulic Tools

90863 0006 Exhaust Valve - Extra Tools

90863 0016 Exhaust Valve - Extra Tools

MAN B&W Diesel A/S

Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data



D08-01 High-pressure pipe, tightening torque 30 Nm

D08-03 High-pressure pipe 22 kg

High-Pressure Pipe

X Stopped engine







Engage turning gear


Shut off fuel oil




108-1

Page 2 (2)

MAN B&W Diesel



Data


High-Pressure Pipe


108-1


High-Pressure Pipe 908-1.2

Dismantling

0214S42MCHigh-Pressure Pipe

908-1.2Dismantling

1. When replacing the hydraulic high-pressure

pipe, exhaust valve or hydraulic actuator,check the high-pressure pipe sealing sur-faces.

2. Before dismounting the high-pressure pipe,stop the camshaft oil pump.

Loosen the screws for the high-pressurepipe and lift the pipe slightly away from the

actuator to let the oil in the pipe drainthrough the drain holes in the actuator.

3. Remove the screws in both ends of thehigh-pressure pipe. Lift the high-pressurepipe away from the engine.

1.

GN

90

8-1

.2 2

03

01

D08-03

2.

GN

90

8-1

.2 2

03

02


High-Pressure Pipe908-1.3

Overhaul

908-1.3Overhaul

The two ends of the pipe are identical and

should both be overhauled as follows:

1. Remove the thrust piece from the actuator/

exhaust valve.

Remove and discard the O-rings from the

thrust piece and the thrust flange.

Clean and inspect the conical seats of the

high-pressure pipe and the thrust piece.

2. To change the internal O-ring, proceed asfollows:

Lift the thrust flange upwards.

Remove the spring ring from the two-partsleeve.

3. Remove the thrust flange from the pipeend.

Remove and discard the internal O-rings.

Mount new internal O-rings lubricated with

a little camshaft lubricating oil.

4. Assemble the high-pressure pipe in the re-

verse order to disassembling.

Note!

The seats cannot be reconditioned. If a seat is damaged, the thrust piece/

high-pressure pipe must be replaced.

1.

GN

908

-1.3

20

3 0

1

2.

DM

908

-1.1

61

02

3.

DM

90

8-1

.1 6

1 0

3


High-Pressure Pipe 908-1.4

Mounting

908-1.4Mounting

1. Mount new O-rings, lubricated with a little

engine lubricating oil, on the thrust piecesand thrust flanges.

Mount the thrust pieces on the actuator/ex-haust valve.

Mount the high-pressure pipe on the en-gine.

2. After fitting the pipe to the exhaust valve

and actuator, tighten up the screws of thepressure flanges diagonally, see Data.

3. Check the system for tightness.See Procedure 908-3.1.

Note!

When mounting the high-pressure pipe,

take care not to damage the conical seats of the pipe/thrust pieces.

1.

GN

90

8-1

.2 2

03

01

2.

GN

90

8-1

.4 2

03

02

D08-01