Cylinder Liner: Ref. Description Value Unit

Cylinder Liner 103-1
Data
SAFETY PRECAUTIONS
Special Edition
D10301
103-1 Data 0050 Cylinder
S46MC-C Liner
X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
Data
Ref. Description Value Unit
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
D03-05 Cylinder liner, complete 1114 kg
D03-06 Cooling jacket 102 kg
D03-16 Piston cleaning ring radial width, new 33.5 mm
D03-17 PC-ring/Liner max. wear deviation 0.42 mm
D03-18 PC-ring replacement criteria:
Liner diameter: 420 mm

Liner wear: Install:
0 – 0,42 mm Standard PC-ring
(new or max. wear of diameter 0,42mm)
0,42– 0,84mm Oversize PC-ring
> 0,84 mm Dummy ring
When referring to this page, please quote Data D10301 Edition D10301 Edition 0044 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
Data
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90366 Crossbar for cylinder liner
Page 2 (2) When referring to this page, please quote Data D10301 Edition D10301 Edition 0044
MAN B&W Diesel A/S
Cylinder Liner 903-1.1
Checking
Cylinder Liner
S50MC
0253
Checking
903-1.1
1.
1. Dismount the cylinder cover, piston and
PC-ring.
See Procedure 901-1.2. D03-03
See Procedure 902-1.2.
Clean the cylinder liner and scavenge air

ports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an inside

micrometer at the positions indicated on the
measuring tool. See Data.
3. Take measurements in the fore-and-aft and

athwartship directions.
4. Check and assess the condition of the cyl-

inder liner according to the description giv-
en in Volume I, Chapter 707.
DM903-2.0 90 01
5. Carefully scratch over any scores or marks

on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3. 2.
6. Check the lubricating points of the cylinder
by pumping cylinder oil to each individual
lubricating point.
Clean any blocked lubricating duct.

GN903-1.1 203 03
4.
GM903-1.1 253 04
When referring to this page, please quote Procedure M90301 Edition 0253 Page 1 (10)
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking
7. 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.
When the piston is removed, the PC-ring

must always be taken up before the piston.
GW903-1.1 247 07
8. Measure the PC ring radial width B, and

find the most worn place. Compare with
data D03-16 and calculate the wear of the
PC ring. Multiply the wear by 2 to get the
8. PC ring diameter wear.
Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner measuring tool. Compare
the measurements with the diameter of a
new liner as stated in data. Calculate the
wear of the liner.
Compare the PC ring diameter wear with

the wear of the liner. If wear of the two com-
DM903-1.1 237 08
ponents does not deviate more than D03-

17, then reinstall the PC ring.
If the deviation between PC ring wear and

liner wear is more than D03-17, or if the PC
ring is broken or cracked, replace the ring
with a new PC ring, an oversize ring or a
dummy ring according to the table in 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 new

PC ring must be installed. When a new liner
is ordered, also a new PC ring must be or-
dered.
Page 2 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
Dismantling
Dismantling
903-1.2
1. Dismount the cylinder cover. 1.

Discard the sealing ring from the top of the

cylinder liner.
Turn the piston down far enough to make it

possible to remove the wear ridges at the
top of the liner.
See Procedure 903-1.3. D03-01
Dismount the piston and the PC-ring.
Mount the two lifting screws in the cylinder

liner.
Note! GN903-1.2 224 01
Tighten the lifting screws to the torque

stated in Data.
Check with a 0.05 mm feeler gauge that 2.

there is no clearance between the screws
and the cylinder liner.
This must be done whenever the lifting

tools are mounted on the liner.
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
GN903-1.2 224 02
– and clean them carefully.
MAN B&W Diesel A/S
Dismantling
3. 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 with
the cooling jacket out of the cylinder frame.
Note!
Low lifting height in the engine room may

EN903-1.4 205 03
require the removal of one or more cylin-

der cover studs before dismantling the
cylinder liner.
4. Land the cylinder liner vertically on, for in-

D03-05 stance, a couple of planks.
Clean the cylinder frame internally, taking

special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.
Discard the O-rings on the cooling water

pipes.
Clean the pipes carefully.

GN903-1.2 224 04
MAN B&W Diesel A/S
Dismantling
5. The lifting screws are also used for trans- 5.

porting the cylinder liner.
D03-05
HN903-1.2 244 05
MAN B&W Diesel A/S
Overhaul
Overhaul
903-1.3
1. 1. Unscrew the nuts on the non-return valves

and remove the valves.
Clean and inspect the non-return valves.
2. Attach two tackles to the crossbar, as

shown.
Mount two lifting eye bolts in the cooling

jacket.
Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
GN903-1.3 224 01
Remove the two lifting screws from the cyl-

inder liner.
Remove the four clamps which fix the cool-

2. ing jacket to the cylinder liner.
3. Lift the cooling jacket away by means of the

tackles, and land it on the wooden planks.
EN903-1.3 237 02
3.
D03-06
EN903-1.3 237 03
MAN B&W Diesel A/S
Overhaul
4. Check and assess the condition of the cyl- 4.

inder liner according to the description giv-
en in Volume I, Chapter 707.
Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.
Check in the top of the liner for a wear ridge

(where the piston rings reverse direction). If
there is any sign of a wear ridge, it is nec-
essary to create a groove by grinding.The
groove serves to prevent the build-up of a
new wear ridge.
5. It is recommended to use a wear ridge mill-

ing machine to create the groove. For use
of the milling machine, see supplier’s in-
struction.
6. Alternatively, place an old piston ring on the

HN903-1.3 221 04
top of the piston and turn to a position that

enables the grinding disc to rest on the old
piston ring while removing the wear ridge.
Use a grinding disc with a round edge.
5.
Check the distance C before grinding to as-
certain that the wear ridge was caused by
the top ring at TDC.
MB903-1.3 231 04
The maximum depth of the groove is calcu-

lated as S max. = D x 0.0045.
Note!
6.
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.
D
R=4-5 mm
C
C
MN903-1.3 229 05
MAN B&W Diesel A/S
Overhaul
7. 7. Replace the two uppermost O-rings on the

cylinder liner.
8. Lower the cooling jacket on to the cylinder

liner.
Note!
Make sure that the scratch marks in the

fuel pump side of the cylinder liner and
cooling jacket coincide.
GN903-1.3 203 04
9. Mount the four clamps in the groove of the

liner, and tighten the screws.
Remove the tackles from the lifting cross-

bar and the cooling jacket lifting eye bolts.
8.
10. Mount the non-return valves for cylinder lu-
brication. Tighten the nuts and connect the
lubricating oil pipes.
D03-06
EN903-1.3 237 08
9.
EN903-1.3 237 09
MAN B&W Diesel A/S
Mounting
Mounting
903-1.4
1. Loosen the water connections on the cool- 1.

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/liner
assembly.
Mount the lowermost O-ring and apply a lit-

tle lubricating oil on the ring.
D03-01
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.
Coat the joint surfaces with permatex or a

similar liquid sealing compound.
Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connec-
DM903-1.4 237 01
tions on the cooling jacket.
2.
GN903-1.4 224 02
MAN B&W Diesel A/S
Mounting
3. 3. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount and
tighten the screws.
4. Connect and tighten the oil pipes for the

cylinder lubrication.
Vent the cylinder lubricating system until

oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.
When this is in order, check that each indi-

EN903-1.4 205 03
vidual lubricating point functions correctly.
5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil and
mount the piston and the PC ring.
4. 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 cover
is correctly positioned.
GM903-1.4 253 04
6.
GN901-1.4 203 01
MAN B&W Diesel A/S
Cylinder Lubricators 103-2
MAN B&W Diesel Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
Ref. Description Value Unit
D03-22 minimum crankthrow angle 105 °

D03-23 maximum crankthrow angle 116 °
D03-24 optimum crankthrow angle 110 °
When referring to this page, please quote Data D10302 Edition 0033 Page 1 (2)
103-2 Cylinder Lubricators
Data MAN B&W Diesel
The task-speciﬁc tools used in this procedure are shown on the plates at the end of this chapter or in
the chapters indicated by the ﬁrst three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
Page 2 (2) When referring to this page, please quote Data D10302 Edition 0033
Cylinder Lubricators 903-2.1
MAN B&W Diesel Checking
1. Further information concerning other than

1.
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 six 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.
4.
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.
5. Seen from fore
D0322
D0323
M903020255C03
Cyl. No. 1
903-2.3 Cylinder Lubricators
Adjustment MAN B&W Diesel
1. Remove the guard over the coupling.

1.
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.
M903020258O01
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

2. Seen from fore determine the exact position of the crank-
throw.
Mount the guard over the coupling.
D0324
M903020255O02
XXX XXX
XXX XXX
Cylinder Liner - Tools Plate
P90361-0084
Cylinder Liner - Tools
0084
P90361
When referring to this page, please quote Plate P90361 Edition 0084 Page 1 (2)
MAN B&W Diesel A/S
Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366
When referring to this page, please quote Plate P90366 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007
Item Item
Item Description Item Description
No. No.
021 Crossbar for cylinder liner
Page 2 (2) When referring to this page, please quote Plate P90366 Edition 0007
MAN B&W Diesel A/S
Plate Cylinder Liner - Tools
P90361-0084
Item Item
Item Description Item Description
No. No.
036 Cylinder gauge, complete
Page 2 (2) When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S

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Cylinder Liner 103-1

D03-01 Lifting tool screws, tightening torque 200 Nm

Liner diameter: 420 mm

Plate Item No. Description

P90251 51 Lifting tool for cylinder liner

P90366 Crossbar for cylinder liner

Clean the cylinder liner and scavenge air

2. Position the cylinder liner measuring tool.

Measure the cylinder liner with an inside

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

4. Check and assess the condition of the cyl-

5. Carefully scratch over any scores or marks

Clean any blocked lubricating duct.

7. 7. Piston cleaning (PC) ring:

The PC ring is to be regarded as an inte-

During inspection of the piston and liner,

When the piston is removed, the PC-ring

8. Measure the PC ring radial width B, and

Measure the liner in the fore-and-aft and

Compare the PC ring diameter wear with

ponents does not deviate more than D03-

If the deviation between PC ring wear and

If it is needed to install an oversize PC ring,

When a new liner is installed, also a new

1. Dismount the cylinder cover. 1.

Discard the sealing ring from the top of the

Turn the piston down far enough to make it

Mount the two lifting screws in the cylinder

Note! GN903-1.2 224 01

Tighten the lifting screws to the torque

Check with a 0.05 mm feeler gauge that 2.

This must be done whenever the lifting

2. Disconnect – at the exhaust side of the cyl-

Dismount the four cooling water pipes – be-

– and clean them carefully.

3. 3. Remove the screws of the cooling water in-

4. Attach the crane hook to the lifting cross-

Hook the chains from the lifting tools on to

Low lifting height in the engine room may

require the removal of one or more cylin-

4. Land the cylinder liner vertically on, for in-

Clean the cylinder frame internally, taking

Discard the O-rings on the cooling water

Clean the pipes carefully.

5. The lifting screws are also used for trans- 5.

1. 1. Unscrew the nuts on the non-return valves

Clean and inspect the non-return valves.

2. Attach two tackles to the crossbar, as

Mount two lifting eye bolts in the cooling

Hook the tackles on to the lifting eye bolts

Remove the two lifting screws from the cyl-

Remove the four clamps which fix the cool-

3. Lift the cooling jacket away by means of the

4. Check and assess the condition of the cyl- 4.

Carefully scratch over any scores or marks

Check in the top of the liner for a wear ridge

5. It is recommended to use a wear ridge mill-

6. Alternatively, place an old piston ring on the

top of the piston and turn to a position that