Assignment on opening up of

complete cylinder unit including

crosshead bearing, connecting
rod bearing, & main bearing for
continuous machinery survey

Compiled by P.H.D.R. SUSANTHA (Marine Engineer Sri

Lanka)

Content

1. Planning
2. Safety precautions
3. Overhauling & calibration procedure
4. Spare parts used
5. References

1. Planning
Information requested prior to survey
1. Refer class status report
2. Consult technical manager and discuss intended procedure
3. Check spare parts inventory and order if necessary. In this case it has to be
taken into account R.O.B after finishing the job too.
4. Inform master work schedule, Discuss with chief officer and arrange any
support if necessary
5. Previous survey report, engine running hours when survey was carried out,
Details of recoded clearances, details of any possible marking on pin, bearing
condition.
6. Lifting gear condition including engine room crane and test certificates has to
be checked and make sure conditions are satisfactory in advance to prevent
accidents, unnecessary delays, damages and personnel injuries.

02. Safety precautions

1)

Inform company, confirm duration of port stay and take permission

2)
Take immobilization certificate from port authority. This process may take
some times therefore early inform to authority will avoid delays
3)
Read the manual and have a toll box meeting with everyone involved in
the job. Discuss the procedure.
4)

Prepare important tools and spares to be used in this operation

5)
A risk assessment of all personnel doing the operation to be prepared and
documented
6)

Shut main engine starting air

7)

Engage turning gear to the main engine crankshaft

8)

Open indicator cocks of all cylinders

9)
10)

Stop main engine lube oil pump after cooling down of engine
Open crank case doors of fore and aft unit

11) Open crank case doors of that unit in which maintenance is to be carried
out.
12) Put blower and ventilate the crankcase thoroughly as it is an enclosed
space.

13)

Prepare enclosed space entry checklist.

14)

After sufficient ventilation wearing proper PPE enter C/C

15. Before start the job checked condition of high pressure hydraulic pump and
hoses always used proper safety equipment when handling the unit.

03. Overhauling & calibration

procedure
Each procedure has prepared as they have been carried out
separately while safety precautions are given above as they are
similar to all process more or less.

Procedure for Cylinder head and piston overhauling and

calibration
1. Set blocking device A on the main
2.
3.
4.
5.

starting valve 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.
6. Open cooling water drain cocks G and
H.
7. Shut off the control air and safety air
supply.
8. Vent the manoeuvring system through
the ball valve.
9. Also shut off the air supply on the
reduction unit for the
hydraulic/pneumatic exhaust valve, and
vent the system.

Dismantling of cylinder cover carried out according to the manufactures

instruction given in maintenance manual always under supervision of responsible
engineer.
All the O-rings and sealing rings were renewed with original spares.
Photographs of all parts before and after cleaning were taken to attach survey
report
Condition of seating faces, condition of cooling spaces should be carefully
checked. Efficiency of cooling water treatment process evaluated by the
condition of cooling spaces.
All mountings of the cylinder cover were removed and valve bores reconditioned
as described in the maintenance manual. After the grinding, cleaned the bore
and seating carefully, and checked that the seating is not damaged.
When reassembling the cylinder cover exhaust valve, fuel valves, starting air
valve were replaced with overhauled and tested spares.
After dismantling the piston according to the instruction given by manufacturers
following checks and tests carried out to ascertain the condition of the piston
assembly.
Checking, in connection with piston overhaul
After removing the piston from the
cylinder and place it on the piston
support.
Note!
It is recommended to replace all the
piston rings whenever a piston is
removed from the engine.
Free ring gap:
Before dismantling the piston rings,
measure the free ring gap of all the
piston rings.

Radial ring width:

Measure the radial width of the rings.
Note down the results
Ring grooves:
Clean the ring grooves and check
them for burn marks or other
deformation.
Measure the ring grooves with a
calliper gauge,
Clearance in piston ring grooves:
The maximum vertical height in a
worn ring groove must not exceed
the value stated in Data. The groove
is also worn out if there is no chromium layer.
If the ring grooves are worn out, the piston
crown must be reconditioned, contact MAN
B&W Diesel A/S for advice.
Piston top template:
Check that the piston top template is
permanently marked with the piston top
centre diameter D02_48.
Check that the centre area C has been
marked off, and write the maximum
permissible burn away rate on the template.
Mark the outer part of the template R for ring
area, and write the maximum permissible
burn away rate for the ring shaped area.
Piston crown top:
Clean the piston crown and check the burn
away by means of the template.
For maximum permissible burn away on the
piston top centre area
Check the burn away on the whole
circumference of the piston crown top.
If the burn away exceeds the values given in
Data, contact MAN B&W for advice.
Note down the results for later reference.

Calibration of piston rod stuffing box

1. After the piston rod stuffing box has
been dismantled, check the following
clearances:
Uppermost scraper ring and sealing
rings
Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D0229)
Clearance at ring ends (sealing rings).
Total clearance (sealing rings). (D0229)
Lowermost scraper rings
Clearance at ring ends.
Total clearance. (D02-30)
The ring clearances stated in Data
apply to new rings.
As a general guide, it is recommended
depending on the overhauling
intervals and ones own experience
to replace sealing rings and scraper
rings when the specified clearance
values D02-29 and D02-30 have been
halved.
2. Garter springs:

Generally, it is recommended to renew the springs when the sealing rings and
scraper rings are renewed.
The springs can be checked as follows:
Place the springs on the table, measure Lo
(Free length), and compare with Data. If a spring is extended more than 8% from
the value given in data, it must be discarded.

Procedure for crosshead bearing overhauling and

calibration
Following procedure was followed when carrying out crosshead bearing removal
of a MAN MC-C engine:

1. Turn the crank throw to 90 before BDC.

2. Check the bearing clearance by inserting feeler gauge b/w bearing cap and
crosshead journal exactly next to the landing surface of the piston rod foot.

The wear limit for a cross head bearing shell is limited to 50% reduction of the oil
wedge length (L).[ L=10mm]
3. Turn the crankshaft down enough to give access to nuts and screws on piston
rod.
4. Mount two chain blocks on the top of the crankcase for suspending the piston
rod.
5. Loosen and remove the locking wire and screws on the piston rod foot.

6. Mount the lifting eye bolt on each side of the piston rod foot.
7. Turn the crosshead to TDC.
8. Hook the chain blocks to the eye bolt on the piston rod foot. And turn the
crosshead down so that piston is now suspended on the chain blocks.
9. Turn to BDC.
10.Mount the hydraulic jack on the crosshead bearing cap nut and loosen them.
[Pressure: 1500-1650 bars]
11.Mount the lifting attachment on the head of the connecting rod.
12.Suspend the two chain blocks from the lifting brackets in the athwart ship
direction.

13.Mount the 2 eye bolts on the top of the cross head bearing cap.
14.With the help of the two chain blocks lift the bearing cap. Take it out of the
engine and place it on a wooden base.
15.To check the upper bearing shell, remove the locking screws and push the
shell out.
16.Mount the chain blocks to the lifting brackets on the frame box wall.

17.Turn the crosshead up until the piston rod lands on the crosshead. Ensure that
the guide ring in the crosshead fits correctly in the centre hole of the piston
rod.
18.Do not remove the chain blocks or the lifting eye bolts.

19.Turn the crosshead to TDC and attach the chain blocks to the lifting
arrangement and haul it tight.
20.Mount the four supports for the guide shoes on the crosshead guide.
21.Carefully and slowly turn the crankshaft towards to exhaust side and make
sure the crosshead guide sits on the supports.
22.Turn the crank throw towards BDC slowly while following with the chain
blocks, thus continuously supporting the connecting rod.

23.In case it is necessary to remove the lower bearing shell, tilt the connecting
rod towards the door on the cam shaft side with means of chain blocks.

24.Dismount the locking screws and turn the bearing shell so far up that an eye
bolt can be mounted. Lift the bearing shell out.
Top clearance in crosshead bearing:-Max: 0.29mm, Min: 0.17mm

The procedure for opening and

calibration of connecting rod
bearing
MAN B&W Checking
Crankpin Bearing
The bottom clearance between the journal and a new bearing shell is the result
of a summation of the production tolerances of the bearing assembly
components.
1. Open the crankcase door at the relevant cylinder.

2. Turn the crank concerned to BDC.

3. Measure the clearance in the crankpin bearing
by inserting a feeler gauge at the bottom of the
bearing shell in both sides..
4. The difference between the actual clearance
measurement and the measurement recorded in
the Adjustment Sheet (or the clearance noted for
a new bearing installed later) must not exceed
0.1 mm. If so, the crankpin bearing must be
disassembled for inspection.
5. The wear limit for the crankpin bearing shells
is based on an evaluation of the bearing
condition at the time of inspection.
An average wear rate of 0.01 mm per 10,000 hours is regarded as normal.

The procedure for opening and

calibration of main bearing
1. Make sure that the main bearing measuring tool (depth gauge) is calibrate
and set to 0.
2. Open the screws of lube oil pipe connection and insert the depth gauge and
measure the clearance between upper bearing keep and journal.

3. Compare this reading with the earlier reading in the record or the new bearing
reading.
4. Now disconnect the lube oil pipe line.
5. Turn the crank throw so that it is towards the exhaust side.
6. Now mount the hydraulic jacks and loosen the main bearing stud nuts.
7. Mount the lifting tool for main bearing keep and lift the keep using a pulley
and a wire rope.
8. Note the marking on the main bearing keep before lifting for correct direction
of the keep.
9. Guide the keep safely outside with a help of another chain block and place it
on a wooden base once it is out.
10.Mount the tool for lifting the upper bearing shell and place it safely outside.
11.Place the strong back (cross piece) support on the bed plate so that its ends
rest on the cross girders.
12.Mount the hydraulic jack on the cross piece placing it such that it lies beneath
the crank webs.
13.Mount a dial gauge on the adjacent main bearing so that the lift of the crank
shaft can be recorded.
14.Now with hydraulic pressure (1500-1650 bar) lift the crankshaft corresponding
to the main bearing clearance to the adjacent main bearing, and check the lift
with the help of a dial gauge.
15.Remove the lock screws from the lower shell.
16.Place the dismantling tool on the lower bearing shell such that the flap enters
the oil groove.
17.Pull the bearing shell round and up so that it lies on the journal and take it out
safely.

Top Main bearing clearance: max- 0.58mm, min- 0.40mm

Checking the bearing edges

6. Bearing edges can be checked with a feeler that is able to follow the bearing
edge against the journal the whole way round on each side. If white metal is
missing at the edge, the tip of the feeler will enter the hole, thus locating the
damage. In most cases this hole can be seen by the naked eye as a dark spot
when using a strong flashlight.
The No. 1 and the two aft most main bearings are more difficult to access on the
whole circumference on each side, but it is often possible to bend the feeler to
suit the situation and thus reach as far round as possible.
Wire-feeler
7. It is rather easy to make a feeler (see sketch). The feeler should be made
from a piece of steel wire (e.g. a welding rod) approx. 0.6 - 1 m long depending
on the engine type, and 2 to 3 mm thick. Approx. 7 to 10 mm of the wire should

be bent to an angle of approx. 65 to

form a feeler tip. Grind the tip smooth
to obtain the shape and dimension
shown on the sketch. Note that the
thickness of the white metal is approx.
1.5 mm, which is why the tip should be
less than 1.2 mm thick, and bigger than
the max. Top clearance. At the other
end of the tip, a handle should be
made by bending a hook or similar in
the same direction as the tip.
8. If there is too large a difference in
the crankshaft deflection readings
(autolog) check the clearance in the individual bearings.
Bearing clearance checks should also be carried out during time-based overhauls
and surveys.
If there is a suspicion of a damaged bearing, it is recommended to edge check
the bearing, without opening up.
9. Before measuring, check that the feeler blades are in good condition. The
feeler is inserted along the crank throw.
When the feeler hits the journal, it is horizontally pushed against the clearance.
Now the feeler blade is pushed max. 20 mm into the gap.
10. The clearance is measured at both the fore and the aft part of the bearing.
11. The difference between the actual clearance measurement and the
measurement recorded in the adjustment sheet (or the clearance noted for a
new bearing installed later) must not exceed 0.10 mm

04.Spare parts used

Description

Part number

ROB at
biginin
g of
month

used

ROB

Cylinder Cover
O-ring
Gasket
Spring Housing
Gasket
Gasket
Gasket

Piston
Piston
Piston
Piston

assembly
ring No. 01
ring No. 02+04
ring No. 03

Piston stuffing box

O-ring
Fitted bolt
Fitted bolt
Lemella for scraper ring
Garter spring

P90101-0173126
P90101-0173151
P90101-0173187
P90103-0004020
P90103-0004032
P90103-0004127

2
1
2
1
1
1

1
2
1
2
2
4
8
2

05. Reference:
MAN B&W MC-C Engine maintenance manual
Class NK CSM Survey guidance

Image credit: