MAN B&W Diesel A/S

Service Letter SL03-429/ANR

August 2003

Lifting Tools for Main Bearing Cap

Engine types: 60-98MC/MC-C, delivered 2000-2003
Action Code: AT FIRST OPPORTUNITY

Dear Sirs

Three years ago, MAN B&W Diesel introduced a new set of lifting tools for the main
bearing cap on all the above-mentioned two-stroke diesel engines. This set of tools
consists of a lifting tool with two wire ropes for mounting on the bearing cap, and guide
rollers to guide the lifting wire ropes in the correct direction.

During these three years, we have collected feedback with the new tools and their
instructions, and this indicates that some indispensable updates and corrections are
called for.

A summary of the experience obtained and the required actions is given below.

All engines:

• Wire-lock in lifting tool for main bearing cap must be checked before use, and
replaced if found not to be in accordance with the specification, in order to avoid
a dangerous situation.
See Enclosure A.

• In some cases, the mounting instruction for the wire-pulley for mounting below
the guide shoe is not exact. The procedure for mounting the tool needs to be
updated, in order to avoid a dangerous situation.
See Enclosure B.

• In some cases, the hourglass-shaped roller on the wire-pulley for mounting on

the web-plate has not been hardened in accordance with the specification.
Inexpedient to work with.
See Enclosure D, Part II.
HEAD OFFICE (& Postal address) DIESEL SERVICE PRODUCTION FORWARDING MAN B&W Diesel A/S
Teglholmsgade 41 Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Denmark
DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV CVR.No.: 39 66 13 14
Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00
Telex: 16592 manbw dk Telex: 31197 manbw dk Telex: 19023 manfw dk Telex: 19023 manfw dk
Telefax: +45 33 85 10 30 Telefax: +45 33 85 10 49 Telex: 19042 manfw dk Telex: 19042 manfw dk
E-mail: manbw@manbw.dk E-mail: diesel-service@manbw.dk Telefax: +45 33 85 10 17 Telefax: +45 33 85 10 16
http://www.manbw.dk E-mail: manufacturing/copenhagen@manbw.dk
 2

K98MC/MC-C, K90MC-C, S90MC-C and S80MC-C:

• In some cases, the wire-length in lifting tool for main bearing cap is inexpedient
for correct use.
See Enclosure C.

• In some cases, the instruction is impossible or inexpedient to follow due to

incorrect wire-length and the impossibility of mounting the tools. New instruction
to be delivered.
See Enclosure C.

K98MC/MC-C, S90MC-C and S80MC-C:

• In some cases, the lifting tool for hydraulic jack for main bearing is not secured
in accordance with the specification. This could lead to very dangerous
situations. Must be corrected before use of the tool.
See Enclosure D, Part I.

• The set of tools is difficult to use. Wire-pulley for mounting on web-plate must
be equipped with a wire-guide, and wire-pulley for mounting below the guide
shoe must be omitted.
See Enclosure C.

K98MC/MC-C, K90MC/MC-C and L90MC:

• In some cases, the wire-pulley for mounting below the guide shoe does not fulfil
the requirements for safety-factor. Pin for improving the safety of the tool must
be mounted. The tool will be abolished on S80MC-C, S90MC-C, and nearly all
K98MC and K98MC-C engines.
See Enclosure B.

K90MC-C, L70MC and S60MC-C:

• In some case, the wire-lock in lifting tool for main bearing cap is not able to
enter through the hole in the main bearing cap. The tool is impossible to use
until it has been updated.
See Enclosure A

Checking the tools and filling-in the check-table can, expectedly, be carried out in less
than 30 minutes. Any required updating of tools can be effected in two hours.

Please forward this Service Letter, with enclosures and check-table, to all ships with
the above-mentioned two-stroke engines (60-98MC-C), delivered within the last three
years. When you return the completed check-table (by fax or e-mail), we will send you
the necessary updates for tools and new overhaul instructions for main bearings.
 3

To avoid future problems, we recommend that you mount and check the main bearing
cap lifting tool and pulleys inside the engine when convenient. This can be done
simply by dismantling a main bearing lubricating oil pipe.

Questions or comments regarding this SL should be directed to our Dept. 2140.

Yours faithfully
MAN B&W Diesel A/S

Carl-Erik Egeberg Kjeld Aabo

Encl.
MAN B&W Diesel A/S

Enclosure A
Wire-lock in Lifting tool for Main Bearing Cap

All engines
Wire lock
The lifting tool for the main bearing cap (see Fig. 1) is designed to be
as small as possible above the cap, for which reason the wire rope is
attached below the tool. This has been done by using a special wire-
lock specified by MAN B&W Diesel for this purpose (Eureka, see Fig.
2). One of the characteristics of the wire-lock is the wave-shape inside
the lock (see Fig. 3 A).
Wire lock
The wire-lock has been tested by MAN B&W Diesel, and fulfils all
demands concerning safety for this lifting purpose. The wire-lock
has been approved by Lloyds Register of Shipping and the Danish
Working Environment Authority.
Wire lock
Wire-locks similar to the Eureka have been developed by some of our
licensees, lately with acceptable results according to our tests. But,
unfortunately, it has been found that some of these wire-locks do not Fig. 1
fulfil our specifications.

Some of these wire-locks were made without the wave-shape inside

(see Fig. 3 B). These wire-locks are dangerous, both to the personnel
and the engine, and must be replaced before use of the tools.

Other wire-locks have been machined leaving sharp edges inside (see
Fig. 3 C), which may increase the wear of the wire rope. This wire-lock
is useable, but to reduce the wear of the wire, it is necessary to grind
off the sharp edges to approximately R10.

If your wire-lock is of type B or C, please fill out and return the check-
table, and we will supply a new wire-lock.

Fig. 2
K90MC-C, L70MC and S60MC-C
A
For the above engine types wire-locks have been designed which are
too big to enter the lubricating oil hole in the main bearing cap, thus
making it impossible to mount the tool on the cap.

We have therefore reduced the size of the wire-lock for these engine
types.
B
To be sure that a correct wire-lock is on board, we ask you to check
that your wire-lock is able to enter the lubricating oil hole in the main
bearing cap. This can be done by checking that the wire-lock can enter
a hole of the following size:

K90MC-C: Ø48 mm
L70MC: Ø38 mm C
S60MC-C: Ø35 mm

If your wire-lock cannot enter the hole, please fill out and return the
check-table, and we will supply a new wire-lock.

Fig. 3

2140/ANR/JCB
August 2003
 MAN B&W Diesel A/S

Enclosure B
Wire-pulley for mounting below guide shoe
All engines
The pulley shown in Fig. 4 is to be mounted below the guide shoe. As
the resulting force is angled to the mounting stud, when using the tool, it
is very important that the tool is mounted with full surface contact
between the mounting stud and the guide shoe.
We have seen some cases where the stud has been either broken or
bent. We have made a complete test of this tool, which showed that the
stud had been bent or broken because it had not been tightened to full
surface contact.
We have decided to update the instructions, to avoid similar accidents
in the future. Please cut out the instruction below, and glue it into the
instruction book onboard. Fig. 4

5. Mount pulley E, pulley F, and the special eye
bolt D, as shown on the sketch.
The pulley F must be tightened to full surface
contact, i.e. by use of a spanner. On some
engines, the stop screw in the guide shoe has
to be removed. Some are provided with a
threaded hole.
Check with a 0.05 mm feeler gauge that there
is no clearance between the pulley and the
stop screw (guide shoe).

Note !
Do not use pulley F if it is not
tightened to full surface contact.

K98MC/MC-C, K90MC/MC-C and L90MC

Our tests with the pulley showed that the safety
factor of the horizontal stud is on the low side,
which we want to improve.
As a retrofit solution, we have found that by insert-
ing a pin in a drilled hole (see Fig. 5), the safety
factor of the tool is raised to an adequate level.
We find this solution easy to carry out for crew
members.
Please fill out and return the check-table, and we
will send you both the drill instruction and the pin
to be inserted. On most K98MC/MC-C, and all
S90MC-C engines, this tool will be abolished and Fig. 5
updating is therefore unnecessary, see Encl. C.

2140/ANR/JCB
August 2003
MAN B&W Diesel A/S

Enclosure C
Set of tools, impossible or inexpedient to use
K98MC/MC-C, S90MC-C and S80MC-C
Due to increased space above the main bearing cap on engines with triangle support of the
crosshead guides, the tool set, as delivered, has to be modified.
The situation is that both when mounting the pulley on the web-plate and the pulley for
mounting below the guide shoe (pulleys E and F on the instruction drawing, Enclosure B),
the engine has to be turned to a position where working on the crank-throw is very difficult.
Furthermore, on the K98MC/MC-C, the wire-length of the lifting tool for main bearing cap
(see Fig. 1, Encl. A) is too short.
After carefully examining the problem, we found that the best solution to this problem is as
follows:
• Omit the pulley for mounting below the guide shoe.
• Mount a special wire-guide on the pulley placed on the web-plate.
• Move the wire-lock on the lifting tool for main bearing cap to achieve uneven wire-
lengths (will be loosened anyway when checking the wire-lock).

The special wire-guide, for mounting on the pulley

for the web-plate, makes it easy to take out the cap
associated with the wire sliding over sharp edges
(see Fig. 6).
The wire-lengths, after repositioning, must be as
shown in the table below.
Please fill out and return the check-table, and you
will receive the special wire-guide, instructions for
changing the tools, and a new procedure for main
bearing overhaul for the instruction book.

K90MC-C Fig. 6
For the K90MC-C, we have experienced that the main bearing overhaul procedure becomes
much easier if the wire ropes are changed to be of uneven length. We therefore suggest that
the wire-lock be repositioned when checking the wire-lock.
The wire-lengths after repositioning must be as shown in the table below.
Please fill out and return the check-table, and you will receive the instructions for changing the
wire-length and a new main bearing overhaul procedure for the instruction book.

Wire-length, today Wire-length, future

K98MC/
2 x 1700 mm 2300 and 1100 mm
K98MC-C
S90MC-C/ 2 x 1900 mm 2400 and 1400 mm
S80MC-C (2 x 1700 mm) (2400 and 1200 mm)
K90MC-C 2 x 1700 mm 1900 and 1500 mm

2140/ANR/JCB
August 2003
MAN B&W Diesel A/S

Enclosure D
Part I
Lifting tool for hydraulic jack for main bearing
K98MC/MC-C, S90MC-C and S80MC-C
The hydraulic jacks for these engine types have a lifting attachment that allows them to be
lifted into the engine as one unit. Part of this lifting attachment consists of an eyenut (see
Fig. 7), which must be secured by welding (as specified).

Not secured

Fig. 8 Fig. 7

Unfortunately, this welding has been omitted on some of the tools delivered (see Fig. 8). This
is very dangerous and creates a risk of injuries to the crew and damage to the tools.
Therefore: Do not use the tool without securing the eyenut!

Part II
Missing hardening of hourglass-shaped guide roller
All engines
We have also seen some tools where the hourglass-shaped
roller on the pulley for mounting on the web-plate (see Fig. 6,
Encl. C) had not been hardened as specified.
This appears from the clearly marked seizure from the wire rope
on the roller. This does not damage the wire rope.
However, we have experienced that when the wire grips the
roller, there is an increased risk that it will be forced over the
edge of the roller, which would be very inexpedient in the middle
of a lift.
When the wire rope begins to slide towards the edge of the roller,
it is possible to press it back towards the middle by hand, while
carefully avoiding to get caught.
If your hourglass-shaped roller has been seized by use, please
mark it off in the check-table, and we will send you a new roller
free of charge.
Fig. 9

2140/ANR/JCB
August 2003
MAN B&W Diesel A/S

Check-table – Tools for Main Bearing Cap

After filling out the check-table, please send as fax to:

MAN B&W Diesel A/S, Copenhagen, Denmark

Fax No.: +45 33 85 10 30 att: Dept. 2140
Ship name: Engine type: IMO No. / Lloyds No.: Date:

Delivery address, for tool updates and instructions:

Wire-lock shape (all engines)

Wave shape inside Straight hole inside Sharp edges inside

Wire-lock size (K90MC-C, L70MC, S60MC-C)

The wire-lock enters Ømin: The wire-lock DOES NOT
the specified hole size. K90MC-C: Ø48
enter the specified hole size.
L70MC: Ø38
S60MC-C: Ø35
Special wire-guide for web-plate pulley
(K98MC/MC-C, S90MC-C, S80MC-C)
Please Double side type: 2 x single side type
mark-off
your type of
web-plate
pulley(s).

Hourglass-shaped roller (all engines)

Roller not seized by use Roller seized by use Roller not used

Procedures in Instruction Book (all engines)

The procedures match the tools and is The procedures need to be updated to
updated with the tightening instruction match the tools.
from Enclosure B.

2140/ANR/JCB
August 2003