volume 2

907

904906

909

903902901908

910

911

905912

S60MC-C Maintenance

S60MC-C VOLUME IIEDITION 1 MAINTENANCE

Instructions for Main Engine

Type S60MC-C

This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATIONVol. II MAINTENANCEVol. III COMPONENTS AND DESCRIPTIONS

The purpose of these books is to provide general guidance on operation and maintenance andto describe the constructional features of a standard version of the above engine type. Deviationsmay be found in a specific plant. In addition, the books can be used for reference purposes, forinstance in correspondance and when ordering spare parts.

It is essential that the following data is stated in spare parts orders as it is used by us to ensurethe supply of the correct parts for the individual engines:

1. Name of vessel2. Engine No. built by3. Plate No.4. Part No.5. Quantity required (and description)

Examble: M/S Nybo - 7730 B&W - 90201 - 00 - 059 10 off (piston ring)

Furthermore, to ensure optimum efficiency, reliability and lifetime of the engine and itscomponents, only original spare parts should be used.

The designation 'D' used in texts and illustrations refers to the information given on the data-sheets inserted in the respective books.

As reliable and economical operation of the diesel engines is conditional on correct operation andmaintenance, it is essential that the engine-room personnel is fully acquainted with the contentsof this book.

This book is subject to copyright protection. The book must not, either wholly or partly, be copied,reproduced, made public or in any other way made available to a third party withoutthe written consent of this effect from MAN B&W Diesel A/S.

MAN B&W Diesel A/STeglholmsgade 41 Teleph.:+45 33 85 11 00 DK-2450 Copenhagen Telex :16592 manbw dkDenmark Telefax:+45 33 85 10 30

Section 900Introduction

Title Data Procedure

Checking and Maintenanceprogramme

900-1

Cross Section through Engine Plate 90001-54

S60MC-C

CHECKING AND MAINTENANCE PROGRAMME 900-1and list of working procedures Edition 207

Page 1 (7)

The Checking and Maintenance Programmeindicates the intervals at which it is deemedappropriate to inspect the individual compo-nents of the engine and to carry out over-hauls, if necessary, based on the enginecondition or on time criteria.

The procedures contained in the instructionbook are arranged in a logical order, and thefollowing Checking and Maintenance Pro-gramme can be used as a table of contents.

The stated `Normal hours of service' are onlyto be used as a guidance, as difference inthe actual service conditions, the quality ofthe fuel oil, lubricating oil, treatment of cool-ing water, etc. will decisively influence theactual service results, and thus the intervalsbetween necessary overhauling.

Design modifications may necessitate a revi-sion of the instructions, and in that case therevised instructions and changed overhau-ling intervals, if any, will apply and supersedethose originally issued (see e.g our ServiceLetters).

The procedures are divided into three cate-gories:

A. Condition checking procedures,marked under the heading `Normal hours ofservice' by C, deal with the service conditionof a number of engine components, and formthe basis for estimating whether further over-hauling is necessary. In a number of casesthe condition checking procedures refer toVolume I, OPERATION, in which more detai-led descriptions and working procedures canbe found.

Where a procedure number is stated underthe heading `Related procedure', it will beappropriate to carry out this procedure at thesame time.

B. Condition-based overhaulingprocedures

are those procedures which under theheading `Normal hours of service' are mar-ked by O, and opposite which, under the he-ading `Overhaul to be based on procedureNo.', a procedure number is stated.

This procedure number normally refers toone of the above condition checking proce-dures which form the basis of the overhaul.For this reason, the intervals stated are forguidance only.

Where several procedures are to be carriedout on the same estimation basis, and thesebelong together with regard to the work, thisis stated under the heading `Related proce-dure'.

C. Time-based overhauling procedures,also marked by O under the headings `Nor-mal hours of service' or `Based on observa-tions', are the procedures where an actualbasis for estimation is lacking. It is recom-mended, therefore, to carry out these proce-dures at the overhauling intervals stated as abasis.

Where a symbol O or C is indicated underthe heading `Based on observations', this isdue to the fact that special service conditionsmay make checking or overhauling neces-sary beyond the actual programme.

CHECK ING AND M AINTENANCEPRO G RAM M E

Norm a l hou rsof s ervice 900-1

No. PROCEDURE

Edition 20 7

Pa g e 2 (7)S60MC-C

*) : See Vol. I Opera tion** : See m a k er s ins tru ctions)

*** : See s pecia l notes)C : Check the conditionO : Overha u l to be ca rried ou tA : Adju s tm ent to be ca rried ou t

901 CYLINDER COVER

-1 Cylinder cover-1.2 Dismantling-1.3 Overhaul O-1.4 Mounting

902 PISTON WITH ROD AND STUFFING BOX

-1 Piston 901-1-1.1 Checking * C C)-1.2 Dismantling 901-1-1.3 Overhaul *** O O)-1.4 Mounting

-2 Stuffing box-2.1 Checking C-2.2 Dismantling 902-1-2.3 Overhaul O-2.4 Mounting

903 CYLINDER LINER AND LUBRICATION

-1 Cylinder liner 901-1-1.1 Checking *** C C 902-1)-1.2 Dismantling-1.3 Overhaul O O-1.4 Mounting

-2 Cylinder lubricators-2.1 Checking * ** C( )-2.3 Adjustment A

904 CROSSHEAD WITH CONNECTING ROD

-1 Crosshead bearings 904-4-1.1 Checking C 905-2-1.2 Dismantling C O-1.4 Mounting

-2 Crosshead-2.2 Dismantling O-2.4 Mounting

-3 Reciprocating parts-3.1 Checking O



No. PROCEDURE

Edition 20 7

Pa g e 3 (7)S60MC-C



-4 Crankpin bearings 904-1-4.1 Checking C C 905-2-4.2 Dismantling-4.4 Mounting

-5 Connecting rod-5.2 Dismantling O 904-1-5.4 Mounting

905 CRANKSHAFT, THRUST BEARINGAND TURNING GEAR

-1 Deflection of Crankshaft-1.1 Checking * C C)

-2 Main bearings 904-1-2.1 Checking 905-1 C C 904-4-2.2 Dismantling C C-2.4 Mounting A

-3 Thrust bearings-3.1 Checking C C-3.2 Dismantling C-3.4 Mounting

-5 Axial vibration damper-5.1 Checking C-5.2 Dismantling-5.3 Overhaul O-5.4 Mounting

906 MECHANICAL CONTROL GEAR

-1 Chains-1.1 Checking * C C)-1.2 Dismantling-1.4 Mounting

-2 Chain tightener-2.3 Adjustment A

-3 Camshaft-3.1 Checking C C C-3.3 Adjustment A



No. PROCEDURE

Edition 20 7

Pa g e 4 (7)S60MC-C



-4 Camshaft bearings-4.1 Checking C-4.2 Dismantling-4.3 Overhaul O-4.4 Mounting

907 STARTING AIR SYSTEM

-1 Starting air distributor-1.1 Checking C C-1.3 Overhaul O

-2 Starting air valve-2.1 Checking C-2.2 Dismantling-2.3 Overhaul O-2.4 Mounting

908 EXHAUST VALVE

-1 High-pressure pipe-1.2 Dismantling-1.3 Overhaul O-1.4 Mounting

-2 Exhaust valve-2.1 Checking C-2.2 Dismantling-2.3 Overhaul ! Nimonic valve spindle C*) O

! valve spindle with hard facing O*) When new exhaust valve is fitted

-2.4 Mounting

-3 Exhaust valve actuator-3.1 Checking-3.2 Dismantling-3.3 Overhaul O-3.4 Mounting

-4 Exhaust valve roller guide-4.1 Checking * C C)-4.2 Dismantling-4.3 Overhaul O-4.4 Mounting



No. PROCEDURE

Edition 20 7

Pa g e 5 (7)S60MC-C



-5 Exhaust valve cam-5.1 Checking C

-7 Exhaust valve emergency running C

909 FUEL OIL SYSTEM

-1 Fuel pump lead-1.1 Checking * C)-1.3 Adjustment A

-2 VIT system-2.3 Adjustment A

-3 Fuel pump cam-3.3 Adjustment 909-1 A

-4 Fuel pump-4.2 Dismantling-4.3 Overhaul O-4.4 Mounting

-5 Fuel pump top cover-5.2 Dismantling-5.3 Overhaul O-5.4 Mounting

-6 Fuel pump barrel assembly-6.2 Dismantling-6.3 Overhaul O-6.4 Mounting

-7 Fuel pump suction valve-7.1 Checking C-7.2 Dismantling-7.3 Overhaul O 909-5-7.4 Mounting

-8 Fuel pump puncture valve-8.2 Dismantling-8.3 Overhaul C O 909-5-8.4 Mounting

-9 Fuel pump shock absorber-9.1 Checking C-9.3 Overhaul O



No. PROCEDURE

Edition 20 7

Pa g e 6 (7)S60MC-C



-10 Lifting gear-10.1 Checking C C

-11 Fuel valve-11.1 Checking C C-11.2 Dismantling-11.3 Overhaul O-11.4 Mounting

-12 Spindle guide-12.3 Overhaul O

-13 Fuel valve non-return valve-13.3 Overhaul O

-14 Fuel oil high-pressure pipe-14.2 Dismantling-14.3 Overhaul O 909-5-14.4 Mounting

-15 Fuel pump roller guide-15.1 Checking C-15.2 Dismantling-15.3 Overhaul O-15.4 Mounting

910 TURBOCHARGER SYSTEM

-1 Air cooler element *)-1.1 Checking-1.2 Dismantling-1.3 Overhaul O O-1.4 Mounting

-2 Non-return valve-2.3 Overhaul C O

-3 Auxiliary blower-3.3 Overhaul O

-5 Turbocharger turbine-5.3 Cleaning ** O)

-6 Watermist catcher-6.2 Dismantling 910-1-6.4 Mounting



No. PROCEDURE

Edition 20 7

Pa g e 7 (7)S60MC-C



911 SAFETY EQUIPMENT

-1 Safety valve-1.2 Dismantling-1.3 Overhaul C O-1.4 Mounting

-2 Relief valve-2.1 Checking C O

912 ASSEMBLY OF LARGE PARTS

-1 Holding down bolts and end chock bolts,cast iron

-1.1 Checking C C

-2 Holding down bolts and end chock bolts,epoxy

-2.1 Checking C C

-3 Stay bolts-3.1 Checking C C

913 GENERAL TOOLS

-1 Hydraulic tools

-5 Torque spanner

-6 Tightening gauge

-7 Screws and nuts ! locking

-11 Lubricating procedures

SPECIAL NOTES

Piston overhaul ! Section 902:8000 h piston rings only16000 h piston complete

Cylinder liner ! Section 903:1000 + 2000 h inspection through

scavenge ports8000 h measuring inside liner

Section 901Cylinder Cover


Cylinder Cover 101-1 901-1

S60MC-C 101-1Cylinder CoverDataSAFETY PRECAUTIONS

Data

Special Data05S60MC-C Cylinder Cover101-1

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oil

Shut off lubricating oilX Lock turbocharger rotors

Ref. Description Value Unit

D-1 Weight of exhaust valve stud 50 kg

D-2 Weight of cyl. covercomplete with valves 2900 kg

D-3 Weight of cooling jacket 73 kg

D-4 Screwing-in torque exhaust valve studs

450 Nm

D-5 Screwing-in torque starting valve studs

140 Nm

D-6 Screwing-in torque fuel valve studs

140 Nm

D-7 Hydraulic pressure dismantling 1500-1650 bar

D-8 Hydraulic pressure tightening 1500 barWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 913

50-300 Nm140-760 Nm

1 x 3 m 8 x 1 m1-1 Edition 05 Page 1 (2)

Cylinder Cover S60MC-C101-1DataSpare Parts

Plate Item No. Description Qty

90101-113 080 O-rings 290101-113 102 Sealing ring 190302-130 201 O-rings 490810-050 024 Packings 291104-071 186 Packings 2Page 2 (2) When referring to this page, please quote Data Sheet 101-1 Edition 05MAN B&W Diesel A/S

S60MC-C Cylinder Cover 901-1.2Dismantling

1.

HN

901-

1.2

206

01206S60MC-CCylinder Cover901-1.2Dismantling

1. Set blocking device A on the main startingvalve in the BLOCKED position.

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve D.

Close cooling water outlet valves E and F.

Open cooling water drain cocks G and H.

Shut off the control air and safety air sup-ply. Vent the manoeuvring system throughthe ball valve.

Also shut off the air supply on the reductionunit for the hydraulic/pneumatic exhaustvalve, and vent the system.When referring to this page, please quote Procedure 901-1.2 Edition 206 Page 1 (10)MAN B&W Diesel A/S

(10) When referring to th

Cylinder Cover901-1.2 S60MC-CDismantling

2.

HN

901-

1.2

206

02

3.

HN

901-

1.2

206

03

4.

HN

901-

1.2

206

042. Remove the cooling water outlet pipe fromthe exhaust valve.

Remove the screws which fasten the cool-ing water outlet pipe to the block on the cyl-inder cover.

Dismount the fuel oil high-pressure pipes.See Procedure 909-14.2.

Dismount the control air pipe from the start-ing valve.

Remove the screws which fasten the start-ing air inlet pipe to the block on the cylindercover.

3. Dismount the hydraulic high-pressure pipe,see Procedure 908-1.2.

Dismount the drain oil pipe between the ex-haust valve and the hydraulic activator, theair pipe for the pneumatic exhaust valve,and the pipes for the sealing air arrange-ment.

4. Remove the protective jacket enclosing theintermediate pipe between the exhaust re-ceiver and the exhaust valve.

Dismount the screws in the flange betweenthe intermediate pipe and the exhaust re-ceiver. The four lowermost screws need notbe dismantled, just loosened.

Remove the protective caps from the cylin-der cover nuts.is page, please quote Procedure 901-1.2 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Cover 901-1.2Dismantling

5.

HN

901-

1.2

206

05

D-7

6.H

N90

1-1.

2 20

6 06

D-2

7.

JN90

1-1.

2 20

7 075. Position the cylinder cover tightening toolover the cylinder cover.

Place the spacer rings over the nuts.

For operation of the hydraulic tools, seeChapter 913.

6. Hook the engine room crane on to the liftingattachment on top of the exhaust valve.

Lift away the cylinder cover complete, andland it on a couple of wooden planks.

7. Remove and discard the sealing ring be-tween cylinder cover and cylinder liner. When referring to this page, please quote Procedure 901-1.2 Edition 206 Page 3 (10)MAN B&W Diesel A/S


Cylinder Cover901-1.3 S60MC-COverhaul

1.

HN

901-

1.3

206

01

D-1

2.

HN

901-

1.3

206

02

D-3

3.

HN

901-

1.3

206

04901-1.3Overhaul

1. Dismount all valves and pipes on the cylin-der cover. See Procedure 907-2.2, 908-2.2and 909-11.2.

Dismount the starting air inlet block and thecooling water outlet block from the exhaustside of the cylinder cover.

Dismount all studs on the top of the cylindercover.

2. Unscrew the four screws which secure thecooling jacket to the cylinder cover.

Lift the cylinder cover free of the coolingjacket and land it on a couple of planks.

If the cooling jacket sticks, use dismantlingscrews to force the jacket/cover apart.

3. Remove and discard the O-rings from thecover, and carefully clean the cooling jacketand the cylinder cover.

4. Provide the cylinder cover with new O-rings, well lubricated with oil.

Lift the cylinder cover and guide the jacket/cover into position, using the guide pin asreference (camshaft side).

Mount and tighten the screws for the cool-ing jacket. is page, please quote Procedure 901-1.3 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Cover 901-1.3Overhaul

5.

HN

901-

1.3

206

056.

GN

901-

1.3

203

06

7.

GI9

01-3

.1 9

8 055. Recondition the valve bores as follows:

Fuel valve bore

6. The tool consists of a common spindle withhandle, and of a guide, a carbon cutter, aseating face cutter, and a grinding mandrel.

Clean the fuel valve bores, using the car-bon cutter. If required, recondition the fuelvalve seating with the appropriate cutter.

Grind the seating with the grinding mandreland a grinding compound (e.g. Carborun-dum No. 200).

After the milling/grinding, clean the boreand seating carefully, and check that theseating is not damaged.

Exhaust valve bore

7. The tool consists of a spindle with handleand a grinding disc.

After cleaning the valve bore and seating,grind the seating with the grinding disc anda grinding compound (e.g. CarborundumNo. 200).

After the grinding, clean the bore and seat-ing carefully, and check that the seating isnot damaged.When referring to this page, please quote Procedure 901-1.3 Edition 206 Page 5 (10)MAN B&W Diesel A/S


Cylinder Cover901-1.3 S60MC-COverhaul

8.

HN

901-

1.3

2036

08

9.

HN

901-

1.3

206

09Starting valve bore

8. The tool consists of a guide, a cutter, anda grinding disc.

Recondition the starting valve bore andseating in the same way as described forthe fuel valve bore.

When replacing valves on a cylinder coverthat is mounted on the engine, reconditionthe valve bores/seating in the same way asdescribed here, but without dismounting thestuds.

9. Clean the bores for safety valve/indicatorcock.is page, please quote Procedure 901-1.3 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Cover 901-1.3Overhaul

10.

HN

901-

1.3

206

10

D-4

D-5

D-6

11.

HN

901-

1.3

206

1010. Lubricate the threads with Never Seize' orMolybdenum Disulphide (MoS2) and mountthe valve studs.

Tighten up the studs in accordance with thescrewing-in torque stated on the datasheet.

Fill up the grooves between the valve studsand the bores for the valve studs with per-matex to prevent water or oil from enteringthe bores during operation of the engine.

Provide the water connection flanges withnew gaskets, and keep the cylinder coverready for replacement.

Always fit new or overhauled valves beforea cylinder cover is mounted on the engine.

11. Clean the starting air inlet block and thecooling water outlet block.

Mount the blocks and new packings on thecylinder cover.When referring to this page, please quote Procedure 901-1.3 Edition 206 Page 7 (10)MAN B&W Diesel A/S


Cylinder Cover901-1.4 S60MC-CMounting

1.

HN

901-

1.4

206

01

D-2

2.

HN

901-

1.4

206

02901-1.4Mounting

1. Place a new sealing ring on top of the cyl-inder liner.

2. Lift the cylinder cover by means of thecrane and carefully wipe the contact sur-face which faces the cylinder liner.

Provide the cooling water connecting pipeswith new O-rings and lubricate them withgrease or soft soap.

Mount a new klinger sealing ring in thegroove of the flange of the intermediatepipe.

Lower the cover carefully into position.

During the landing, carefully check that thecooling water connecting pipes engage cor-rectly with the holes in the cooling jacket.is page, please quote Procedure 901-1.4 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Cover 901-1.4Mounting

3.

HN

901-

1.2

206

05

D-8

4.

HN

901-

1.4

206

043. Mount all eight nuts on the studs and screwthem down to the cylinder cover.

Place the eight spacer rings over the nuts.

Position the cylinder cover tightening toolover the cylinder cover.

Pull down the hydraulic jacks of the tighten-ing tool and screw the jacks on to the studs.

For operation of hydraulic jacks, see Proce-dure 913-1.

Connect the hydraulic hoses to the jacksand raise the pressure to the level stated inData. Tighten the nuts with a tommy bar.

Release the pressure. Remove the hydrau-lic jacks and the spacer rings.

4. Mount the protective caps on the cylindercover studs.

Align the intermediate pipe so that theholes in the flange of the intermediate pipeare in line with the threaded holes in the ex-haust valve.

Mount the screws of the flange between theintermediate pipe and the exhaust receiver.

Note!

Lubricate the screws with Never Seize or Molybdenum Disulphide (MoS2) before mounting.When referring to this page, please quote Procedure 901-1.4 Edition 206 Page 9 (10)MAN B&W Diesel A/S


Cylinder Cover901-1.4 S60MC-CMounting

5.

HN

901-

1.4

206

05

6.

HN

901-

1.4

206

06

7.

HN

901-

1.4

206

075. Mount the insulating jacket around the in-termediate pipe.

6. Mount the return oil pipe, the sealing airpipe and the air pipe for pneumatic closingof the exhaust valve.

Mount the high-pressure pipe for the hy-draulic valve gear.See Procedure 908-1.4.

7. Mount the control air pipe for the startingvalve. Mount the screws which fasten thestarting air inlet pipe to the block on the cyl-inder cover.

Mount the cooling water outlet pipe on theexhaust valve. Mount the screws which fas-ten the cooling water outlet pipe to theblock on the cylinder cover.

Using a crowfoot wrench and torque span-ner, mount the fuel oil high-pressure pipes.See Procedure 909-14.4.

8. Connect the outlet pipe from the return oilpipe on the fuel valves.

Shut the drain valves and open the coolingwater inlet. After venting the cylinder sec-tion, shut the vent cocks and open the cool-ing water outlet valve.

Open the fuel oil, lubricating oil and air sup-plies to the alarm system.

Caution !

The air supply to the exhaust valve must always be connected before turning on the oil supply to the exhaust valve actua-tor.

This is very important, because other-wise the valve will open more than intended.is page, please quote Procedure 901-1.4 Edition 206MAN B&W Diesel A/S

Section 902Piston with Rod and Stuffing Box


Piston 102-1 902-1

Piston Rod Stuffing Box 102-2 902-2

S60MC-C 102-1PistonData

35 kg80 Nm

974 kg500 Nm

7 bar2890 kg

450 Nm

590 Nm58 80 NmD-11 Piston cooling pipeD-12 Tightening torque

cooling pipeD-13 Piston rodD-14 Tightening torque

piston crown/rodD-15 Test pressureD-16 Cyl. cover with exhaust valveD-17 Screwing-in torque

cylinder cover studsD-18 Tightening torque of piston

or tightening angleD-19 Tightening torque

stuffing boxSAFETY PRECAUTIONS

Data

Special Data05S60MC-C Piston102-1

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oilX Shut off lubrication oil

Lock turbocharger rotors


D-1 Radial width: new piston ring 20 mm worn piston ring 17 mm

D-2 Maximum vertical height: groove Nos. 1 and 2 14.7 mm groove Nos. 3 and 4 11.7 mm

D-3 Max. permissible burn-away: standard piston top 20 mm inconel piston top 8 mm

D-4 Nominal height: ring groove Nos. 1 and 2 14 mm ring groove Nos. 3 and 4 11 mm piston ring Nos. 1 and 2 14 mm piston ring Nos. 3 and 4 11 mm

D-5 Minimum ring gap 4 mmD-6 Vertical clearance 0.40-0.45 mmD-7 Piston complete 1593 kgD-8 Piston crown 350 kgD-9 Piston skirt 93 kgD-10 Tightening torque

piston skirt190 NmWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 913

10120, 50300, 280760 Nm

2 x M122-1 Edition 05 Page 1 (2)

Piston S60MC-C102-1DataSpare Parts


90301-119 338 Gasket 190201-153 072 Piston ring No. 1 190201-153 084 Piston ring No. 2 190201-153 096 Piston ring No. 3 190201-153 106 Piston ring No. 4 190201-153 047 Locking wire 190201-153 167 D-ring 190201-153 179 D-ring 190101-113 102 Gasket 1Page 2 (2) When referring to this page, please quote Data Sheet 102-1 Edition 05MAN B&W Diesel A/S

S60MC-C Piston 902-1.1Checking

1.

GN

902-

1.1

204

01G

N90

2-1.

1 20

4 02

2.

3.

HG

902-

1.1

201

03207S60MC-CPis ton902-1.1Check ing

Scavenge port inspection

To detect possible leakages from the piston orcylinder cover, keep the cooling water and cool-ing oil circulating during the scavenge port in-spection.

1. Remove the inspection covers on the cam-shaft side of the cylinder frame.

Clean the openings.

Begin the inspection at the cylinder whosepiston is nearest BDC.

2. With the piston in BDC, inspect the pistoncrown and the cylinder wall.

Note down the results. See Volume I, Operation, Chapter 707.

3. Turn the engine. While the piston is passingthe scavenge air ports, inspect the pistonrings, the ringlands and the piston skirt.

Check the movability and the tension of thepiston rings, by pressing against them witha wooden stick.

Note down the results.

Note!

The scavenge port inspection can also be carried out from within the scavenge air receiver.When referring to this page, please quote Procedure 902-1.1 Edition 207 Page 1 (19)MAN B&W Diesel A/S


Piston902-1.1 S60MC-CChecking

4.

GN

902-

1.1

204

04

6.

GN

902-

1.4

204

024. After turning the piston upwards, past thescavenge air ports, inspect the piston rodand the lower part of the cylinder wall.

Note down the results.

5. Re-mount the inspection covers on the cyl-inder frame. If necessary, replace the gas-kets.

Piston rings and piston crown

6. Remove the piston from the cylinder andplace it on the piston support. See Procedure 902-1.2.is page, please quote Procedure 902-1.1 Edition 207MAN B&W Diesel A/S


7.

GN

902-

1.1

204

07

8.

AM90

2-3.

0 54

02

D-1

D-1

New

Worn

9.

GN

902-

1.1

204

097. Take off the piston rings by means of thering expander.

Clean and inspect the rings.

8. Measure and record the radial width andthe height of the rings. See Volume I, Operation, Chapter 707.

Worn rings must be replaced if the radialwidth is less than stated in Data.

9. Piston rings with milled pressure reliefgrooves must be replaced if the radialdepth of the grooves has worn down to lessthan 1 mm.When referring to this page, please quote Procedure 902-1.1 Edition 207 Page 3 (19)MAN B&W Diesel A/S


Piston902-1.1 S60MC-CChecking

10.

KM90

2-3.

0 47

05

11.

GN

902-

1.1

204

11

12.

KC90

2-3.

0 83

04

D-310. Clean the ring grooves and check them forburn marks or other deformation.

Measure the ring grooves with a dial gaugeor a caliper gauge.

Clearance in piston ring grooves:

The maximum vertical height in a worn ringgroove must not exceed the value stated inData.

The groove is also worn out if there is nochromium layer.

11. The nominal ring groove heights for a newpiston crown or new piston rings are asstated in Data.

12. Clean the piston crown and check the burn-away by means of the template that indi-cates the maximum permissible burn-awayvalue, see Data.

Check the burn-away on the whole circum-ference of the piston crown.

Regarding the maximum permissible burn-away of piston top with welded-on layer ofInconel, see Data.is page, please quote Procedure 902-1.1 Edition 207MAN B&W Diesel A/S


13.

DM

902-

3.0

64 0

314.

GN

902-

1.1

204

07

15.

KC90

2-3.

0 83

06

D-613. Before mounting a new piston ring, meas-ure the piston ring gap.

Insert the piston ring in either a new cylin-der liner or in the bottom of a used cylinder(below the ring travel zone) during themeasuring.

For minimum ring gap, see Data.

14. Fit the piston rings (alternately right-handand left-hand cuts with the ring gaps stag-gered 180 and with the TOP mark upwards)by means of the ring expander.

The ring expander prevents unintended de-formation of the rings.

15. Check the vertical clearance between thenew piston ring and the new or recondi-tioned ring groove with a feeler gauge. SeeData.When referring to this page, please quote Procedure 902-1.1 Edition 207 Page 5 (19)MAN B&W Diesel A/S


Piston902-1.2 S60MC-CDismantling

1.

GN

902-

1.2

204

01

2.

GN

902-

1.2

204

02

3.

GN

902-

1.2

204

03902-1.2Dismantling

1. Turn the crosshead down far enough togive access to the piston rod stuffing box,the tightening screws for the piston rod, andto the telescopic pipe.

2. Release the stuffing box by removing theinnermost screws from the stuffing boxflange.

3. Remove the screws from the piston rod.

Note!

Do NOT remove the outermost screws from the flange.is page, please quote Procedure 902-1.2 Edition 207MAN B&W Diesel A/S

S60MC-C Piston 902-1.2Dismantling

4.

GN

902-

1.2

204

04

5.

HN

902-

1.2

207

05

D-16

6.

GN

902-

1.2

204

064. Mount the two distance pieces on the pis-ton rod foot to protect the lower scraper ringand to guide the stuffing box.

5. Dismount the cylinder cover.See Procedure 901-1.3.

Carefully smooth out any wear ridges at thetop of the cylinder liner by using a handgrinder.See Procedure 903-1.2.

6. Turn the crosshead to TDC, while checkingthat the guide pins of the distance piecesenter the holes in the stuffing box.When referring to this page, please quote Procedure 902-1.2 Edition 207 Page 7 (19)MAN B&W Diesel A/S



7.

GN

902-

1.2

204

07

8.

GN

902-

1.2

204

08

9.

GN

902-

1.2

204

097. The top of the piston is now free of the cyl-inder liner.

If necessary, remove one or two cylindercover studs, using a stud setter.

Clean the lifting groove of the piston crownand mount the lifting tool in such a mannerthat the two fixed claws of the tool fit intothe lifting groove of the piston.

Fit the third, adjustable, claw of the tool tothe lifting groove and tighten it up againstthe stop of the tool.

8. Place the two halves of the support aroundone of the openings in the platform.

Lift the piston out of the cylinder and lowerthe piston rod foot and stuffing box throughthe opening in the platform.

Place the two halves of the support aroundthe piston rod and secure the two halveswith screws.

9. Place a cover over the opening for the pis-ton rod stuffing box in the bottom of the cyl-inder unit.

Clean, measure and recondition the cylin-der liner.See Procedure 903-2.1.is page, please quote Procedure 902-1.2 Edition 207MAN B&W Diesel A/S

S60MC-C Piston 902-1.2Dismantling

10.

GN

902-

1.2

204

1011.

GN

902-

1.2

204

1110. Turn the crosshead down far enough tomount the protective rubber cover on thecrosshead bearing cap.

The protective rubber cover should remainin place to protect the crosshead bearingjournal from impurities until the piston is re-mounted.

Low lifting height

If the space conditions above the engine makeit impossible to remove the piston in the normalway, the piston can be removed as follows:

11. Remove one or two cylinder cover studs,using the stud setter.

Lift the piston high enough to give ampleroom over the cylinder cover studs.

Mount the clamp on the piston rod so thatthe distance piece of the clamp lies trueagainst the piston.When referring to this page, please quote Procedure 902-1.2 Edition 207 Page 9 (19)MAN B&W Diesel A/S



12.

GN

902-

1.2

204

12

13.

GN

902-

1.2

204

1312. Place the supporting tools on the cylindercover studs and lower the piston until theclamp rests on the tools.

Remove the lifting tool from the piston.

Hook the transverse piece on to the craneand attach it to the clamp for tilting the pis-ton.

13. Lift the piston to the maximum crane height.Run the crane athwartship and, at the sametime, tilt the piston.

Keep the piston rod clear of the cylinder lin-er and studs while carrying out the tilting.

When space conditions permit, straightenup the piston and lead it over to the cut-outin the platform for overhauling the piston.

When the piston is at a suitable heightabove the platform cut-out, position the pis-ton support around the piston rod andclamp.

Now lower the piston while guiding the sup-port to the platform cut-out.

After landing the piston and ensuring that itrests correctly on the support, remove thetilting tool.

Note!

On engines with extremely low lifting height, use the engine room double-jib crane instead of the transverse piece.is page, please quote Procedure 902-1.2 Edition 207MAN B&W Diesel A/S

S60MC-C Piston 902-1.3Overhaul

1.

GN

902-

1.3

204

012.

GN

902-

1.3

204

02

3.

GN

902-

1.3

204

03902-1.3Overhaul

1. Position new O-rings on the platformaround the piston overhaul cut-out.

2. Ease the piston down so that the stuffingbox is below the floor.

Lift the O-rings and assemble the twohalves of the piston support around the pis-ton rod.

Position the O-rings on the piston support.

3. Dismount the locking wire and screw up thesupport screws of the piston support to aposition just below the piston skirt.

Remove the piston skirt screws.When referring to this page, please quote Procedure 902-1.3 Edition 207 Page 11 (19)MAN B&W Diesel A/S


Piston902-1.3 S60MC-COverhaul

4.

GN

902-

1.3

204

04

5.

GN

902-

1.3

204

05

6.

GN

902-

1.3

204

064. Screw the four screws of the support down-wards until the skirt rests on the support.

If the skirt will not budge, free it by meansof two dismantling screws.

5. Dismount the locking wire and the inner-most screws between the rod and the pis-ton crown.

Lift away the piston crown.

6. Dismount the screws of the cooling oil pipeflange.

Mount the eye screws and lift out the cool-ing oil pipe.is page, please quote Procedure 902-1.3 Edition 207MAN B&W Diesel A/S


7.

GN

902-

1.3

204

07

8.

GN

902-

1.3

204

08G

N90

2-1.

3 20

4 09

9.Alternatively, the piston can be dismantledin the following way:

7. While the complete piston is hanging fromthe lifting tool, mount the collar round thepiston rod so that the distance pieces of thecollar obtain contact with the piston.

Lower the piston so that the collar rests onthe platform.

Remove the lifting tools from the top of thepiston crown.

Hook the engine room crane on to the liftingcrossbar and hook the chains of the liftingcrossbar on to the shackles of the collar.

8. Lift the piston, tilt it to the horizontal posi-tion, and land it in this position on a coupleof wooden blocks. Remove the lifting cross-bar and chains from the collar.

9. Attach the lifting tool to the bottom of thepiston rod foot. Hook the crane on to thelifting tool.

Lift the foot of the piston rod clear of thewooden block. Move the piston rod stuffingbox up the piston rod until it is in contactwith the collar. Remove the two distancepieces from the piston rod foot.

Keep lifting until the piston rod is in a ver-tical position.

Note!

Tilting of the piston must only take place with the piston rod stuffing box mounted on the piston rod.

Note!

During the lift, follow with the crane to keep the crane positioned vertically above the foot of the piston rod.When referring to this page, please quote Procedure 902-1.3 Edition 207 Page 13 (19)MAN B&W Diesel A/S


Piston902-1.3 S60MC-COverhaul

10.

GN

902-

1.3

204

10

11.

GN

902-

4.3

92 0

4

12.

GN

902-

1.3

204

1210. Place the piston in an upright position withthe piston crown resting on wooden blocks.

Dismount the locking wire and the inner-most screws between the rod and the pis-ton crown. Lift the piston rod away and landit in a horizontal position on a couple ofwooden blocks.

11. Remove the locking wire and the screws inthe skirt and mount two eye screws in theholes intended for dismantling screws. Liftthe skirt and land it on a couple of planks.

12. Thoroughly clean and inspect all parts ofthe piston. Regarding check of the piston crown, seeProcedure 902-1.1.

Replace all sealing rings of the piston. Allthe new sealing rings must be coated withlubricating oil before the piston is assem-bled.

Coat all screws with Molybdenum Disul-phide (MoS2).

Assemble the piston in the reverse order todisassembly. Use the guide screw to en-sure the correct positioning of the pistonrod in relation to the piston crown.

Tighten all the screws diagonally to thetorque stated in Data.is page, please quote Procedure 902-1.3 Edition 207MAN B&W Diesel A/S


13.

HM

902-

4.2

52 07

14.M

B902

-4.0

96

1413. Lock all the screws with locking wire.

Mount the locking wire in such a way thatthe wire is tightened if one of the screwsworks loose. See Procedure 913-7.

14. Fill the piston and piston rod with lubricat-ing oil.

Mount the pressure-testing tool around thebase of the piston rod.

Pressure-test the piston at the pressurestated on the data sheet.

Check the contact surfaces of the pistonand the sealing rings for tightness.

Check that there are no cracks in the pistoncrown.When referring to this page, please quote Procedure 902-1.3 Edition 207 Page 15 (19)MAN B&W Diesel A/S


Piston902-1.4 S60MC-CMounting

2.

GN

902-

1.4

204

02

3.

GN

902-

1.4

204

03

4.

GN

902-

1.2

204

10902-1.4Mounting

1. Check the piston rings and piston crown inaccordance with Procedure 902-1.1.

Coat the piston rings, piston rod and cylin-der liner with lubricating oil.

2. Mount the lifting tool on the piston crown.

3. Ensure that the stuffing box is correctly po-sitioned over the guide pins in the distancepieces mounted on the piston rod foot.

Coat the O-rings of the stuffing box with oil.

4. Remove the protective rubber cover fromthe crosshead.is page, please quote Procedure 902-1.4 Edition 207MAN B&W Diesel A/S

S60MC-C Piston 902-1.4Mounting

5.

GN

902-

1.2

204

096.

GN

902-

1.4

204

06

7.

GN

902-

1.4

204

075. Remove the cover from the piston rod stuff-ing box opening in the bottom of the cylin-der unit.

6. Turn the crosshead to a position 45 fromTDC.

Mount the guide ring for piston rings on thecylinder liner.

7. Lower the piston into the cylinder liner while guiding the piston rod foot through thecut-out in the stuffing box flange until thepiston rings are inside the liner, corre-sponding to the lifting tool lacking about 30mm in landing on the guide ring.When referring to this page, please quote Procedure 902-1.4 Edition 207 Page 17 (19)MAN B&W Diesel A/S


Piston902-1.4 S60MC-CMounting

8.

GN

902-

1.4

204

08

9.

GN

902-

1.4

204

09

10.

GN

902-

1.2

204

038. Turn the crosshead to TDC while checkingthat the guide ring of the crosshead entersthe centre hole in the piston rod.

9. After turning the piston fully to TDC, un-screw the adjustable claw of the lifting tooland pull the lifting tool free of the liftinggroove in the piston

Remove the lifting tool and the guide ringfor piston rings.

Turn the crosshead with the piston rod andthe telescopic pipe down far enough to per-mit tightening of the piston rod screws.

10. Remove the distance pieces from the pis-ton rod foot.

Mount and tighten the piston rod screws.See Data.

Lock the screws with locking wire.

Mount the locking wire in such a way thatthe wire is tightened if one of the screwsworks loose. See Procedure 913-7.is page, please quote Procedure 902-1.4 Edition 207MAN B&W Diesel A/S

S60MC-C Piston 902-1.4Mounting

11.

GN

902-

1.2

204

0212.

GN

902-

1.4

204

12

13.

D-16

HN

902-

1.2

207

0511. Tighten down the piston rod stuffing box bymeans of the screws through the innerholes in the stuffing box flange. See Data.

12. Mount the cylinder cover studs with thestud setter. See Data.

Carefully clean the surfaces around thebase of the mounted studs and refill theroots properly with Permatex 3.

13. Smear the piston rod with molybdenum di-sulphide, and turn the crankshaft a coupleof revolutions.

Mount the cylinder cover.See Procedure 901-1.4.

14. Start the engine and keep it running forabout 15 minutes at a number of revolu-tions corresponding to very slow.

Then stop the engine and inspect the pistonrod and stuffing box.When referring to this page, please quote Procedure 902-1.4 Edition 207 Page 19 (19)MAN B&W Diesel A/S

S60MC-C 102-2Piston Rod Stuffing BoxData

3 x 3 mm

618 mm902 mm983 mm

606 mm780 mm844 mmD-9 Ring-end clearances lowermost rings

D-10 Check length for the sixuppermost springs: F0 = 0 N................. L0 = F1 = 106+/ 7 N...... L1 = F2 = 136 +/ 7 N..... L2 =

D-11 Check length for the fourlowermost springs: F0 = 0 N.................. L0 = F1 = 100 +/ 7 N...... L1 = F2 = 136 +/ 10 N.... L2 =SAFETY PRECAUTIONS

Data

Special Data62S60MC-C Piston Rod Stuff ing Box102-2

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oilX Shut off lubrication oil


Ref. Description Value UnitD-1 Stuffing box complete 109 kg

D-2 Stuffing box half 35 kg

D-3 Tightening torque forstuffing box halves

80 Nm

D-4 Tightening torque for stuffing box flanges

80 Nm

D-5 Tightening torque for inner screws

80 Nm

D-6 Vertical clearance uppermost rings

0.18-0.30 mm

D-7 Vertical clearance lowermost rings

0.10-0.17 mm

D-8 Ring-end clearances uppermost rings

4 x 6 mmWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 9132-2 Edition 06 Page 1 (2)

Piston Rod Stuffing Box S60MC-C102-2DataSpare Parts


90205-97 013 O-ring 190205-97 025 Top scraper ring 190205-97 037 Pack sealing ring 390205-97 049 Cover sealing ring 290205-97 157 Lamellae for scraper ring 1690205-97 216 Scraper ring 490205-97 241 Spring 690205-97 253 Spring 4Page 2 (2) When referring to this page, please quote Data Sheet 102-2 Edition 06MAN B&W Diesel A/S

S60MC-C Piston Rod Stuffing Box 902-2.1Checking

1.

GN

902-

2.1

203

01

2.

HM

902-

5.0

70 0

2207S60MC-CPis ton Rod Stuffing Box902-2.1Check ing

1. After the piston rod stuffing box has beendismantled. See Procedure 902-2.2, check the followingring clearances:

Uppermost scraper ring and sealing rings

Vertical clearance between sealing ringsection and groove.

Clearance at ring ends (scraper ring). Total clearance (scraper ring).

Clearance of ring ends (sealing rings). Total clearance (sealing rings).

Lowermost scraper rings

Vertical clearance between scraper ringand groove.

Clearance at ring ends. Total clearance.

The ring clearances stated in Data apply tonew rings.

As a general guide, it is recommended depending on the overhauling intervals andones own experience to replace sealingrings and scraper rings when the specifiedclearance values have changed by morethan 50%.

2. Check the length of the springs at differentloads. Adjust the loads to achieve thelengths stated in Data.

If the loads necessary are outside the limitsstated in Data, the springs must be discard-ed.When referring to this page, please quote Procedure 902-2.1 Edition 207 Page 1 (9)MAN B&W Diesel A/S


Piston Rod Stuffing Box902-2.2 S60MC-CDismantling

1.

GN

902-

2.2

203

01

2.

MB9

02-5

.2 9

4 02

3.

MB9

02-5

.2

94 0

3902-2.2Dismantling

If, in the period between piston overhauls, it be-comes necessary to inspect the piston rodstuffing box, proceed as follows:

1. Turn the crosshead to about 90 from TDC.

Mount the rubber hose around the pistonrod to protect the crosshead bearing fromimpurities.

2. Remove the drain oil pipe and all innermostscrews and all outer screws except for twoscrews placed diametrically opposite in thestuffing box flange, longitudinally to the en-gine.

3. Mount the worktable round the piston rodso that the two screws can be loosenedthrough the holes. is page, please quote Procedure 902-2.2 Edition 207MAN B&W Diesel A/S

S60MC-C Piston Rod Stuffing Box 902-2.2Dismantling

4.

MB9

02-5

.2 9

4 04

5.M

B902

-5.2

94

05

6.

MB9

02-5

.2 9

4 064. Remove the two long screws from theworktable.

Mount them in the stuffing box through theholes in the worktable.

Remove the remaining two screws from thestuffing box.

5. Turn the piston to BDC, thereby withdraw-ing the stuffing box from the cylinder framebottom.

Remove the two long dismantling screwsfrom the stuffing box and mount them in theworktable.

6. By means of the four short screws in theworktable, press the stuffing box out of theflange. For overhauling the stuffing box, see Pro-cedure 902-2.3.When referring to this page, please quote Procedure 902-2.2 Edition 207 Page 3 (9)MAN B&W Diesel A/S


Piston Rod Stuffing Box902-2.3 S60MC-COverhaul

GM

902-

5.1

90 0

1

1.

HC9

02-5.

1 98

02

2.

HC9

02-5

.1 9

8 03902-2.3Overhaul

Outside the engine

Normally, overhaul of the piston rod stuffing boxis carried out by routine methods in connectionwith dismantling (pulling) of the pistons.

During such overhauls the piston rests on asupport placed over one of the cut-outs in thetop platform.

Work on the stuffing box is then carried outfrom the platform below.

1. Mount two eye screws in the stuffing boxflange, and hook on two tackles.

Then lift the stuffing box a little up the pis-ton rod, and mount the worktable round thepiston rod at a suitable working height.

Land the stuffing box on the worktable, andremove the tackles and screws.

2. Remove the O-ring of the stuffing box. If theO-ring is intact and is to be used again,move it up the piston rod and secure it inthis position, for example with tape.

Remove the nuts from the stuffing box as-sembling bolts. is page, please quote Procedure 902-2.3 Edition 207MAN B&W Diesel A/S

S60MC-C Piston Rod Stuffing Box 902-2.3Overhaul

3.

HC9

02-5

.1 9

8 04

7.H

M90

2-5.

0 70

02

8.

HC9

02-5.

1 98

073. Take out the six bolts, and pull away onestuffing box half.

Mount two eye screws on the stuffing boxhalf and remove it from the worktable.

4. Using a feeler gauge, measure the verticalclearance of the rings. See Procedure 902-2.1.

5. Remove the remaining stuffing box half andpress all sealing rings and scraper ringsdown against the worktable.

6. Measure the clearance between the ringsegments to determine whether replace-ment is necessary.See Procedure 902-2.1.

Dismantle and stack the rings in the sameorder as when fitted in the stuffing box.

Carefully clean all the ring segments.

Inspect and assess the surface quality ofthe sealing rings. If their sliding surfaceshave scratches or marks, replace the rings.

7. Check the lengths of the springs. See Procedure 902-2.1.

8. Inspect the surface of the piston rod. Ifsmall longitudinal scratches have occurred(caused by poorly adapted stuffing boxrings), smooth the piston rod surface care-fully with a fine grained carborundum stone.In the case of coarse scratches, it mayprove necessary to machine-grind the sur-face in a workshop.

9. Clean the halves of the stuffing box hous-ing.When referring to this page, please quote Procedure 902-2.3 Edition 207 Page 5 (9)MAN B&W Diesel A/S


Piston Rod Stuffing Box902-2.3 S60MC-COverhaul

10.

HM

902-

5.1

70 0

9

11.

HC9

02-5

.1 9

8 1110. Lubricate the piston rod (in the area whereall the ring units in the stuffing box will bepositioned) with molybdenum disulphide(MoS2).

Assemble all the stuffing box ring unitsround the piston rod, on the worktable, inthe 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 remainingscraper rings.

On top of the scraper rings, assemble thetwo sealing ring units (each consisting of a4-part and an 8-part ring).

Assemble the 8-part sealing ring so that thetwo guide pins face upwards, place thespring round the segments and, hook thespring ends together.

Assemble the 4-part sealing ring above the8-part sealing ring. Push the two rings to-gether in such a manner that the guide pinsin the lower sealing ring engage with thetwo holes in the upper sealing ring.

Finally, assemble the uppermost ring unit(consisting of a 4-part scraper ring and an8-part sealing ring).

11. Use the stuffing box half on the worktableto adjust the height of all the assembledring units on the piston rod until the ringunits are opposite the correspondinggrooves in the stuffing box housing. Subse-quently, push the stuffing box half into con-tact with the piston rod, round the ring units.is page, please quote Procedure 902-2.3 Edition 207MAN B&W Diesel A/S

S60MC-C Piston Rod Stuffing Box 902-2.3Overhaul

12.

HC9

02-5

.1 9

8 12

13.H

C902

-5.1

98

1312. Check the ring clearance again.

Then place the other half of the stuffing boxhousing on the worktable, pushing it intoplace round the rings.

Mount and tighten up the fitted bolts to thetorque specified on the Data Sheet.

Mount the O-ring in the stuffing box groove.

13. Mount eye screws and wire ropes, and liftthe stuffing box a little.

Remove the worktable and lower the stuff-ing box until it rests against the distancepieces on the piston rod foot.

Remove wire ropes and screws. When referring to this page, please quote Procedure 902-2.3 Edition 207 Page 7 (9)MAN B&W Diesel A/S


Piston Rod Stuffing Box902-2.4 S60MC-CMounting

1.

MB9

02-5

.2 9

4 06

2.

MB9

02-5

.2 9

4 08

3.

MB9

02-5

.2

94 0

9902-2.4Mounting

1. After overhauling, assemble the stuffingbox halves on top of the four screws.

Mount the two long screws from the workta-ble in the stuffing box.

Turn down the short screws so that thestuffing box lands on the flange.

2. Turn the piston upwards until the stuffingbox is in place in the cylinder frame.

3. Mount two screws in the flange through theholes in the worktable.

Note!

Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame.is page, please quote Procedure 902-2.4 Edition 207MAN B&W Diesel A/S

S60MC-C Piston Rod Stuffing Box 902-2.4Mounting

4.

MB9

02-5

.2 9

4 10

5.M

B902

-5.2

94

11

6.

GN

902-

2.2

203

014. Remove the long screws from the stuffingbox and mount them in the worktable.

Remove the worktable from the piston rod.

5. Mount and tighten all the inner and outerscrews for the stuffing box. See Data.

6. Remove the protecting rubber cover fromthe 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 forapprox. fifteen minutes at a number of rev-olutions corresponding to very slow or idlespeed.

Then stop the engine and inspect the pistonrod and stuffing box.When referring to this page, please quote Procedure 902-2.4 Edition 207 Page 9 (9)MAN B&W Diesel A/S

Section 903Cylinder Liner and Lubrication


Cylinder Liner 103-1 903-1

Cylinder Lubricators 103-2 903-2

S60MC-C 103-1Cylinder LinerDataSAFETY PRECAUTIONS

Data

Special Data05S60MC-C Cylinder Liner103-1

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oilX Shut off lubricating oil



D-1 Cylinder diameter, new 600 mm

D-2 Cylinder liner, complete 3200 kg

D-3 Cooling jacket 290 kg

D-4 Screwing-in torque cylinder cover studs

1100 Nm

D-5 Cylinder cover stud 60 kgWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 913

7502000 Nm3-1 Edition 05 Page 1 (2)

Cylinder Liner S60MC-C103-1DataSpare Parts


90101-113 138 Sealing ring 190302-130 201 O-ring 890302-130 071 O-ring 290302-130 095 O-ring 190302-130 129 Gasket 490302-130 046 Cylinder liner 1Page 2 (2) When referring to this page, please quote Data Sheet 103-1 Edition 05MAN B&W Diesel A/S

S60MC-C Cylinder Liner 903-1.1Checking

2.

EN90

3-1.

1 20

5 02

D-1

3.

GN

903-

1.1

203

03

4.

EN90

3-1.

1 20

5 04206S60MC-CCylinder Liner903-1.1Check ing

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 insidemicrometer 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.

Carefully scratch over any scores or markson the cylinder liner running surface, bymeans of a rough grindstone held in thehand.

Using a grinding machine, remove the wearridges at the top and bottom of the cylinderliner (where the piston rings reverse direc-tion), so that a smooth transition is formed.

Check the lubricating points of the cylinderby manually pumping cylinder oil to each in-dividual lubricating point.

Clean any blocked lubricating duct.

Mount the piston and cylinder cover. See Procedure 902-1.4.See Procedure 901-1.4.When referring to this page, please quote Procedure 903-1.1 Edition 206 Page 1 (9)MAN B&W Diesel A/S


Cylinder Liner903-1.2 S60MC-CDismantling

1.

EN90

3-1.

2 20

5 01

2.

EN90

3-1.

2 20

5 02903-1.2Dismantling

1. Dismount the cylinder cover. See Procedure 901-1.2.

Discard the sealing ring from the top of thecylinder liner.

Turn the piston down far enough to make itpossible to grind away the wear ridges atthe top of the liner with a hand-grinder.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 non-return valves theoil pipes leading from the cylinder lubricatorto the non-return valves. Screw off the sixnon-return valves.

Dismount the four cooling water pipes be-tween the cooling jacket and cylinder cover and clean them carefully.is page, please quote Procedure 903-1.2 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Liner 903-1.2Dismantling

3.

HN

903-

1.2

206

034.

EN90

3-1.

2 20

5 043. Remove the screws of the cooling water in-let pipe.

4. Attach the crane to the lifting crossbar.

Hook the chains from the lifting crossbar onto the lifting screws and lift the cylinder linerwith the cooling jacket out of the cylinderframe.

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 cylinderframe.

Discard the O-rings on the cooling waterpipes.

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 the cylinder liner.When referring to this page, please quote Procedure 903-1.2 Edition 206 Page 3 (9)MAN B&W Diesel A/S


Cylinder Liner903-1.2 S60MC-CDismantling

5.

EN90

3-1.

2 20

5 05

D-25. The lifting screws are also used for trans-porting the cylinder liner.

Note!

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

To keep the liner in a horizontal position during transportation, use e.g. a wire rope connected from the scavenge ports to the traverse as shown on the sketch.is page, please quote Procedure 903-1.2 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Liner 903-1.3Overhaul

1.

EN90

3-1.

3 20

5 01

2.

EN90

3-1.

3 20

5 02

D-3903-1.3Overhaul

1. Attach two tackles to the crossbar, asshown.

Mount two lifting eye bolts in the coolingjacket.

Hook the tackles on to the lifting screws onthe cooling jacket and haul tight.

Remove the two lifting screws in the cylin-der liner.

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

2. Lift away the cooling jacket by means of thetackles and land it on the wooden planks.When referring to this page, please quote Procedure 903-1.3 Edition 206 Page 5 (9)MAN B&W Diesel A/S


Cylinder Liner903-1.3 S60MC-COverhaul

3.

GN

903-

1.3

203

03

4.

GN

903-

1.3

203

043. 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 thehand.

Using a grinding machine, remove the wearridges at the top and bottom of the cylinderliner (where the piston rings reverse direc-tion), so that a smooth transition is formed.

Clean the cylinder liner and the coolingjacket both internally and externally. Payspecial attention to the O-ring grooves andlubricating ducts.

4. Replace the two uppermost O-rings on thecylinder liner.is page, please quote Procedure 903-1.3 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Liner 903-1.3Overhaul

5.

EN90

3-1.

3 20

5 05

D-3

6.

EN90

3-1.

3 20

5 065. Lower the cooling jacket on to the cylinderliner.

6. 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.

Note!

Make sure that the scratch marks in the camshaft side of the cylinder liner and cooling jacket coincide.When referring to this page, please quote Procedure 903-1.3 Edition 206 Page 7 (9)MAN B&W Diesel A/S


Cylinder Liner903-1.4 S60MC-CMounting

1.

EN90

3-1.

4 20

5 01

D-2

2.

EN90

3-1.

4 20

5 02

D-4903-1.4Mounting

1. Loosen the water connections on the cool-ing jacket.

Mount the two lifting screws in the cylinderliner.

Hook the chains from the lifting crossbar onto 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 waterconnections and mount the water connec-tions on the cooling jacket.

If one or more cylinder cover studs havebeen removed during the dismantling of thecylinder cover, remount the studs using thestud setter and a torque wrench, see Data.is page, please quote Procedure 903-1.4 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Liner 903-1.4Mounting

3.

HN

903-

1.2

206

034.

EN90

3-1.

4 20

5 04

HN

901-

1.4

206

01

6.3. Fit a new gasket between the cooling waterinlet pipe and the cooling jacket. Mount andtighten the screws.

4. Mount the non-return valves for cylinder lu-brication in the bores of the liner.

Screw the pipes from the lubricator on tothe non-return valves, but do not tighten.

Vent the cylinder lubricating system bymanually pumping each individual pipethrough until oil, without air bubbles, comesout from the union pipe/non-return valve.

When this is in order, tighten the pipes firm-ly on the non-return valves and again pumpmanually until it is certain that each individ-ual lubricating point functions correctly.

5. Lubricate the inside of the cylinder linerwith cylinder lubricating oil and mount thepiston. See Procedure 902-1.4.

6. Mount the sealing ring and the cylinder cov-er. See Procedure 901-1.4.

Tighten the upper water connections on thecooling jacket as soon as the cylinder coveris correctly positioned.When referring to this page, please quote Procedure 903-1.4 Edition 206 Page 9 (9)MAN B&W Diesel A/S

S60-70MC-C 103-2Cylinder LubricatorsDataSAFETY PRECAUTIONS

Data

Special Data05S60-70MC-C Cylinder Lubricators103-2

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gear

Shut off cooling waterShut off fuel oilShut off lubrication oilLock turbocharger rotors


D-1 Cylinder oil feed rate: 0.8-1.2 g/bhph1.1-1.6 g/kWhWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 9133-2 Edition 05 Page 1 (2)

Cylinder Lubricators S60-70MC-C103-2DataSpare Parts

Plate Item No. Description QtyPage 2 (2) When referring to this page, please quote Data Sheet 103-2 Edition 05MAN B&W Diesel A/S

S60MC-C Cylinder Lubricators 903-2.1Checking

1.

GN

903-

2.1

203

01

4.

GN

903-

2.1

203

04206S60MC-CCylinder Lubricators903-2.1Check ing

1. Further information concerning other thannominal feed rates, feed rates for running-in and for part load operation, and recom-mended oil types, is given in instructionbook Volume I, OPERATION.

2. The cylinder lubricators are mounted on thefront end of the engine.

Each cylinder has six injection points.Check that the pumps of all injection pointsare activated during one revolution of theengine.

3. Set the reversing mechanism of the enginein the AHEAD position.

4. Turn the engine until the mark on the firstlubricator housing is in line with the mark onthe scale at the lead-in shaft. This indicatesthat the pump stroke is completed for lubri-cating point No. 1.When referring to this page, please quote Procedure 903-2.1 Edition 206 Page 1 (4)MAN B&W Diesel A/S


Cylinder Lubricators903-2.1 S60MC-CChecking

5.

GN

903-

2.1

203

05

104

115

6.

GN

903-

2.1

203

04

7.

GN

903-

2.1

203

05

104

1155. Check that the crankthrow for cylinder No.1 is positioned between 104 and 115 pastBDC.

Use the numbers on the turning wheel todetermine the exact position of the crank-throws.

6. Turn the engine further until the mark onthe second lubricator housing is in line withthe mark on the scale at the lead-in shaft.This indicates that the pump stroke is com-pleted for lubricating point No. 15.

7. Check that the crankthrow for cylinder No.5 is positioned between 104 and 115 pastBDC.

8. If one of the crankthrows is not in the cor-rect position, adjust the lubricators. See Procedure 903-2.3.is page, please quote Procedure 903-2.1 Edition 206MAN B&W Diesel A/S

S60MC-C Cylinder Lubricators 903-2.3Adjustment

1.

DM

903-

4.0

62 0

42.

GN

903-

2.3

203

02

104

115903-2.3Adjustment

1. Remove the guards over the couplings.

Loosen the set screws in the couplings andpull the coupling wheels out of contact withthe planet wheels.

2. For adjustment of lubricator No. 1, turn thecrankshaft in AHEAD direction until thecrankthrow for cylinder No. 1 is 108 pastBDC for lubricator No. 1.

For adjustment of lubricator No. 2, turn thecrankshaft in AHEAD direction until thecrankthrow for cylinder No. 5 is 109 pastBDC.

Use the numbers on the turning wheel todetermine the exact position of the crank-throws.

Note!

Any adjustment of lubricator No. 1 will alter the setting of lubricator No. 2.

Therefore, any adjustment of lubricator No. 1 must be followed by a re-adjust-ment of lubricator No. 2.When referring to this page, please quote Procedure 903-2.3 Edition 206 Page 3 (4)MAN B&W Diesel A/S


Cylinder Lubricators903-2.3 S60MC-CAdjustment

3.

DM

903-

4.0

62 06

4.

DM

903-

4.0

62 0

73. Turn the pump shaft slowly in AHEAD direc-tion until the mark on the scale at the lead-in shaft is in line with the mark on the lubri-cator housing.

4. Re-engage the coupling wheel and tightenthe set screw.

Repeat step 1 to re-check the setting.

Mount the guard over the coupling.is page, please quote Procedure 903-2.3 Edition 206MAN B&W Diesel A/S

Section 904Crosshead with Connecting Rod


Crosshead Bearing 104-1 904-1

Crosshead 104-2 904-2

Reciprocating Parts 104-3 904-3

Crankpin Bearing 104-4 904-4

Connecting Rod 104-5 904-5

S60MC-C 104-1Crosshead BearingData

58 tightening angleSAFETY PRECAUTIONS

Data

Special Data05S60MC-C Crosshead Bearing104-1




D-1 Top clearance in crossheadbearing:Max. 0.32 mmMin. 0.20 mm

D-2 Oil wedge length, L = 15 mm

D-3 Hydraulic pressure dismantling 1500-1650 bar tightening 1500 bar

D-4 Crosshead bearing cap 277 kg

D-5 Crosshead + piston compl. 2840 kg

D-6 Bearing shell, lower 20 kg

D-7 Crosshead, complete 1245 kg

D-8 Piston rod tightening torque or 590 NmWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 913

2 x 2400 kg, 2 x 600 kg

50-300 Nm, 280-760 Nm

2 x M12, 2 x M202 x M24, 2 x M30

1 x 1.5 m, 4 x 3 m

2 x 1000 kg2 x 2000 kg4-1 Edition 05 Page 1 (2)

Crosshead Bearing104-1Data

S60MC-CSpare Parts


S60MC-C Crosshead Bearing 904-1.1Checking

2.

GN

904-

1.1

203

023.

GN

904-

1.1

203

04

4.

D-1

5.

GN

904-

1.1

203

05 D-2206S60MC-CCrosshead Bearing904-1.1Check ing

The top clearance between the journal and anew bearing shell is the result of a summationof the production tolerances of the bearing as-semblies.

For the top clearance of a specific bearing, seethe measurement in the adjustment sheet.

1. Open the crankcase door at the relevantcylinder.

2. Turn the crankthrow concerned to 90 be-fore BDC on the exhaust side.

3. Measure the clearance in the crossheadbearing by inserting a feeler gauge be-tween the bearing cap and the crossheadjournal, exactly next to the landing surfacefor the piston rod foot. See Data.

4. When checking the clearances, the dis-crepancy between the actual measure-ments and the measurements recorded inthe adjustment sheet (or the clearance not-ed for a new bearing installed later) mustnot exceed 0.1 mm. If so, the crossheadbearing must be disassembled for inspec-tion. See Procedure 904-1.2.

5. The wear limit for a crosshead bearing shellis confined to 50% reduction of the oilwedge length (L). See Data.

6. For further external inspection of the cross-head bearing, see Chapter 708, Bearingsin the instruction book, Volume I, OPERA-TION.When referring to this page, please quote Procedure 904-1.1 Edition 206 Page 1 (10)MAN B&W Diesel A/S


Crosshead Bearing904-1.2Dismantling

S60MC-C

1.

GN

904-

1.1

203

02

2.

GN

904-

1.2

203

02

3.

GN

902-

1.2

204

03904-1.2Dismantling

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 togive access to the nuts and screws on thepiston rod.

2. Mount two chains in the inner screw holesin the top of the crankcase in the athwarth-ship direction for suspending the piston rod.

3. Loosen and remove the locking wire fromthe screws on the piston rod foot. Removethe screws.is page, please quote Procedure 904-1.2 Edition 206MAN B&W Diesel A/S

S60MC-C Crosshead Bearing 904-1.2Dismantling

4.

GN

904-

1.2

203

045.

GN

904-

1.2

203

05

7.

GN

904-

1.2

203

07

D-34. Mount a lifting eye bolt on each side of thepiston rod.

5. Turn the crosshead to TDC.

Hook the chains to the lifting eye bolts inthe piston rod.

Turn the crosshead downward, and the pis-ton rod will then remain suspended fromthe two chains.

With piston removed:

6. Turn to BDC.

7. Hold the spacer rings around the nuts andscrew the hydraulic jacks on to the studs.

Loosen the crosshead bearing cap nuts.For operation of the hydraulic jacks, seeProcedure 913.

Remove the hydraulic jacks and the spacerrings and unscrew the nuts.When referring to this page, please quote Procedure 904-1.2 Edition 206 Page 3 (10)MAN B&W Diesel A/S



S60MC-C

8.

GN

904-

1.2

203

08

9.

GN

904-

1.2

203

09

10.

GN

904-

1.2

203

10

D-48. Mount the lifting attachments on the headof the connecting rod.

9. Suspend two tackles from the lifting brack-ets in the athwarthship direction.

10. Mount two eye bolts in the top of the cross-head bearing cap.

Hook the tackles on to the eye bolts in thecrosshead bearing cap and remove the capfrom the engine. Check the upper part ofthe journal.is page, please quote Procedure 904-1.2 Edition 206MAN B&W Diesel A/S


11.

GN

904-

1.2

203

11

12.

GN

904-

1.2

203

12

13.

GN

904-

1.2

203

1311. Place the bearing cap on one side on acouple of wooden planks.

12. Fasten tackles to the fixed lifting bracketson the frame box wall.

13. Turn the crosshead upwards until the pistonrod lands on the crosshead. Ensure that theguide ring in the crosshead fits correctly inthe centre hole of the piston rod.

Do not remove the chains or lifting eyebolts.When referring to this page, please quote Procedure 904-1.2 Edition 206 Page 5 (10)MAN B&W Diesel A/S



S60MC-C

14.

GN

904-

1.2

203

14

15.

GN

904-

1.2

203

15

16.17.

GN

904-

1.2

203

16

D-514. Turn to TDC and attach the tackle hooks tothe lifting attachments. Haul the tacklestight.

15. Mount the four supports for guide shoes onthe crosshead guides.

Carefully turn the crank down towards theexhaust side, until the guide shoes rest onthe supports.

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

16. Turn the crankthrow towards BDC whilefollowing with the tackles, thus continu-ously supporting the connecting rod.

17. With the crosshead resting on the supports,check the lower part of the crosshead jour-nal and the lower bearing shell.

Regarding checking of journal and bearingshells, see Volume I, OPERATION, Chap-ter 708, Bearings.is page, please quote Procedure 904-1.2 Edition 206MAN B&W Diesel A/S


18.

GN

904-

1.2

203

18

D-618. In cases where it is necessary to removethe lower bearing shell, tilt the connectingrod towards the door in the camshaft sideby means of the tackles.

Dismount the locking screws, and turn thebearing shell so far up that an eye bolt canbe mounted.

Lift the bearing shell out of the engine.When referring to this page, please quote Procedure 904-1.2 Edition 206 Page 7 (10)MAN B&W Diesel A/S


Crosshead Bearing904-1.4Mounting

S60MC-C

1.

GN

904-

1.4

203

01

D-6

2.

GN

904-

1.4

203

02

D-7

3.

GN

904-

1.4

203

03904-1.4Mounting

With the piston mounted/With the piston removed:

1. Mount and secure the bearing shell in thebearing housing.

The excess height X is to ensure the cor-rect tightening-down of the bearing shelland 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 theconnecting rod.

Take care that the guide shoes do not dam-age the bearing shell.

3. Remove the supports from the crossheadguides.

Remove the tackles from the crosshead.

Turn the crank throw to BDC.

If the piston is mounted, slowly turn downuntil it is fully suspended from the chains.is page, please quote Procedure 904-1.4 Edition 206MAN B&W Diesel A/S

S60MC-C Crosshead Bearing 904-1.4Mounting

4.

GN

904-

1.4

203

04

D-4

5.G

N90

4-1.

2 20

3 07

D-3

7.

GN

904-

1.4

203

074. Lift the bearing cap into the engine. Lowerthe bearing cap onto the crosshead and re-move the tackles. Remove the lifting at-tachments from the connecting rod.

5. Tighten all four crosshead bearing cap nutssimultaneously. See Data.For operation of hydraulic jacks, see Sec-tion 913.

6. Mount the piston. See Procedure 902-1.4.

With the piston mounted:

7. Turn the crosshead upwards until the pistonrod lands on the crosshead. Ensure that theguide ring in the crosshead fits correctly inthe centre hole of the piston rod.

Note!

Take care that the bearing studs do not damage the crosshead.When referring to this page, please quote Procedure 904-1.4 Edition 206 Page 9 (10)MAN B&W Diesel A/S


Crosshead Bearing904-1.4Mounting

S60MC-C

8.

GN

904-

1.2

203

19

9.

GN

904-

1.4

203

098. Unhook the chains from the lifting eye boltsin the piston rod. Remove the chains andeye bolts from the top of the crankcase,from the piston rod and from the crossheadbearing cap.

9. Turn down to BDC and tighten the screwsin the piston rod and lock by means of lock-ing wire. See Data.

Mount the locking wire in such a way thatthe wire is tightened if one of the screwsworks loose. See Procedure 913-7.is page, please quote Procedure 904-1.4 Edition 206MAN B&W Diesel A/S

S60MC-C 104-2CrossheadData

275 Nm

80 Nm60 D-9 Nuts on guide strips tightening torque

D-10 Telescopic pipe tightening torque tightening angleSAFETY PRECAUTIONS

Data

Special Data07S60MC-C Crosshead104-2




D-1 Hydraulic pressure dismantling 1500-1650 bar tightening 1500 bar

D-2 Crosshead bearing cap 277 kg

D-3 Crosshead complete 1250 kg

D-4 Connecting rod 2375 kg

D-5 Guide shoe 366 kg

D-6 Cooling oil outlet pipe 15 kg

D-7 Outlet pipe tightening torque 80 Nm

D-8 Guide plate tightening torque 275 NmWhen referring to this page, please quote Data Sheet 10MAN B&W Diesel A/S Standard Tools: See Section 913

50-300 Nm

1 x 1.5 m4 x 3 m

4 x M204 x M30

2 x 2000 kg4-2 Edition 07 Page 1 (2)

Crosshead S60MC-C104-2DataSpare Parts


S60-70MC-C Crosshead 904-2.2Dismantling

2.

GN

904-

2.2

203

023.

GN

904-

2.2

204

03

4.

D-6D-1

GN

904-

2.2

204

04207S60-70MC-CCrosshead904-2.2Dismantling

1. Dismount the piston. See Procedure 902-1.2.

2. Dismount the main bearing lubricating oilpipes.

3. Dismount the cooling oil outlet pipe fromthe guide shoe and the drain oil slottedpipe.

Loosen and remove the screws which se-cure the telescopic pipe to the guide shoe.

In order to reach the screw in the corner be-hind the telescopic pipe, use the offset toolalong with a socket wrench.

4. Mount the retaining tool for the telescopicpipe on the stuffing box housing for the tel-escopic pipe.

Turn the crosshead to TDC.

Suspend the telescopic pipe by means ofthe tool.

Turn the crosshead to gain access to thenuts on the crosshead bearing studs.

Mount two eye bolts in the top of the crank-case in the fore-and-aft direction.

Mount the spacer rings and the hydraulicjacks for loosening the nuts on the cross-head bearing studs.

For operation of the hydraulic tools, seeSection 913.

Loosen the nuts, remove the hydraulicjacks and unscrew the nuts.When referring to this page, please quote Procedure 904-2.2 Edition 207 Page 1 (7)MAN B&W Diesel A/S


Crosshead904-2.2 S60-70MC-CDismantling

5.

GN

904-

1.2

203

06

D-2

6.

D-3

GN

904-

2.2

203

05

7.

GN

904-

2.2

203

06

D-45. Mount eye bolts in the crosshead bearingcap and hook the tackles on to the liftingbrackets in the top of the crankcase.

Dismount the bearing cap and lift it out ofthe engine.

6. Mount the special lifting tool on the cross-head.

Mount the lifting attachments for fixing theconnecting rod, on the head of the connect-ing rod.

Fasten tackles to the lifting brackets on theframe box wall and attach the tackle hooksto the lifting attachments. Haul the tacklestight.

Attach the flat-plaited wire strap to the en-gine room crane.

Hook the engine room crane on to the liftingtool on the crosshead, and lift the cross-head.

7. Using the tackles, tilt the connecting rod to-wards the exhaust side, while turning thecrankthrow towards the camshaft side.

Transfer the tackles from one lifting attach-ment to another as necessary.

When the crankthrow is 90 after BDC, stopturning.

By alternate use of the tackles, tilt the con-necting rod until it rests against a couple ofwooden planks in the bottom of the bed-plate.is page, please quote Procedure 904-2.2 Edition 207MAN B&W Diesel A/S

S60-70MC-C Crosshead 904-2.2Dismantling

8.

GN

904-

2.2

204

089.

GN

904-

2.2

204

09

D-5

10.

GN

904-

2.2

204

108. Lower the crosshead to a position justabove the main bearing caps.

Remove the guide strips and both guideplates from the guide shoes.

Mount a lifting eye bolt in one of the guideshoes, and hook on a tackle.

Squeeze in a plank between the guideshoes.

9. Suspend two tackles from the eye bolts inthe top of the crankcase in the fore-and-aftdirection.

Mount an eye bolt in the top of each guideshoe.

Mount the guide shoe extractor tool on theguide shoe.

Hook the tackles on to the eye bolts in theguide shoes, haul tight and, at the sametime, using the guide shoe extractor tool,pull the crosshead towards the extractortool until it is free of the opposite guideshoe.

Follow the movement of the crosshead withthe engine room crane.

Lift up the free guide shoe.

10. Using the guide shoe extractor tool, pushthe crosshead away from the remainingguide shoe, until the crosshead is free ofthe guide shoe.


Dismount the guide shoe extractor tool.

Lift up the guide shoe.When referring to this page, please quote Procedure 904-2.2 Edition 207 Page 3 (7)MAN B&W Diesel A/S


Crosshead904-2.2 S60-70MC-CDismantling

11.

GN

904-

2.2

204

11

D-5

12.

GN

904-

2.2

203

1111. Turn the crosshead 90.

12. Mount the wire guide tool in the frameboxdoor opening.

By means of wire rope and tackles, removethe crosshead from the engine.

Protect the crosshead, for instance withthick or corrugated paper, and land it out-side the engine.

If necessary, remove the guide shoes fromthe engine.is page, please quote Procedure 904-2.2 Edition 207MAN B&W Diesel A/S

S60-70MC-C Crosshead 904-2.4Mounting

1.

GN

904-

2.2

203

11

D-5D-3

3.G

N90

4-2.

2 20

4 10

4.

GN

904-

2.2

204

09904-2.4Mounting

1. Attach the flat-plaited wire strap to the en-gine room crane.

Lift the crosshead into the engine, usingwire rope, tackles, and the engine roomcrane.

2. Turn the crosshead 90.

3. Lower one guide shoe and mount the guideshoe extractor tool.

Use the guide shoe extractor tool to pull thecrosshead so far through the guide shoethat the other guide shoe can be lowered.


4. Lower the other guide shoe.

Use the guide shoe extractor tool to pushthe crosshead towards the second guideshoe.

Follow the movement of the crosshead withthe engine room crane.When referring to this page, please quote Procedure 904-2.4 Edition 207 Page 5 (7)MAN B&W Diesel A/S


Crosshead904-2.4 S60-70MC-CMounting

5.

GN

904-

2.2

203

07

D-8 D-9

6.

GN

904-

2.4

203

06

D-4

7.

GN

904-

2.2

203

055. Mount the guide plates on the side of theguide shoes.

Tighten the screws and lock them with lock-ing wire.See Procedure 913-7.

Using the engine room crane, lift the cross-head to a workin

volume 2

Documents

engine plate

number of engine components

engineroom personnel

correct parts

normal hours of service

original spare parts

spare parts orders

diesel engines