Service Letter SL2018-664/PRP

Action code: IMMEDIATELY

Risk of breakage of
cylinder liner lifting tool
In case of foreseeable misuse
Dear Sir or Madam
SL2018-664/PRP
We have received a report on an incident where a cylinder liner September 2018
lifting tool broke while lifting a cylinder liner, which was therefore
dropped. Obviously, such an incident poses a serious potential Concerns
threat to property and persons, and may potentially even result in Owners and operators of MAN B&W
bodily injuries and/or fatal casualties two-stroke marine diesel engines.
Types: S40MC-C9, S40ME-B9,
A root cause analysis has identified the cause to be incorrect us- K60MC-S, S35ME-B9, S35MC-C9 and
age of the tool. This particular design of the cylinder liner lifting S50ME-B9
tool is only to be used for vertical lifting. In case the cylinder liner
needs to be tilted from horizontal to vertical position, a different Summary
tool and procedure must be used. The cylinder liner lifting tool is only to
be used for vertical lifting and may not
MAN Energy Solutions has therefore updated the relevant chapter be used for lifting and transporting of
in the instruction manual. A recommendation on how to tilt and cylinders in horizontal position.
transport a cylinder liner is included in the updated work card.

This particular tool design for the mentioned engine types has the
restriction of vertical lifting only. The cylinder liner lifting tool for
other engine types does not have this restriction.

An example of an updated work card and data sheet is enclosed

with this letter. Furthermore, MAN Energy Solutions recommends
adding a tag to the lifting tool with the following text:
“For vertical lifting only!”

Please insert the updated work card in the instruction manual,

introduce the mentioned tag, and inform your crew.

Online versions of the relevant work cards are available via our
Nexus extranet (see Encl. 3). If you have any questions regarding
the content of this Service Letter, please contact our Maintenance
Tools department, via e-mail: lee3@man-es.com.

Yours faithfully

Encl.:
Work Card No. 2265-0601-0009
Mikael C Jensen Per Pallisgaard Work Card No. 2265-0600-0011
Vice President, Engineering Manager, Product Safety List of Updated Work Cards

Head office (& po. address) PrimeServ Production Forwarding & Receiving MAN Energy Solutions
MAN Energy Solutions Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Branch of MAN Energy Solutions
Teglholmsgade 41 2450 Copenhagen SV 2450 Copenhagen SV 2450 Copenhagen SV SE, Germany
2450 Copenhagen SV Denmark Denmark Denmark CVR No.: 31611792
Denmark Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 Phone: +45 33 85 11 00 Head office: Teglholmsgade 41
Phone: +45 33 85 11 00 Fax: +45 33 85 10 49 Fax: +45 33 85 10 17 Fax: +45 33 85 10 16 2450 Copenhagen SV, Denmark
Fax: +45 33 85 10 30 PrimeServ-cph@mandieselturbo.com manufacturing-dk@mandieselturbo.com shipping-cph@mandieselturbo.com German Reg.No.: HRB 22056
info-cph@mandieselturbo.com Amtsgericht Augsburg
www.man-es.com
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SL2018-664/PRP

MAN B&W 2265-0601-0009

For information on cylinder liner condition and scavenge port

Cylinder Liner • Checking

inspection, See description 2245-0100.

For information on the condition of the lubrication points and non-

return valves, See work card 3065-0601.

1. Preparation Dismount the cylinder cover and the

piston.
See work card 2265-0301 and
2265-0401.

2. Taking liner Position the cylinder liner measuring

measurements tool.

Measure the cylinder liner with the

special measuring tool at the positions
indicated on the measuring tool. Make
sure to take measurements in the fore-
and-aft and athwartships directions.

Check and assess the condition of the

cylinder liner.

For new cylinder diameter, See data

T22-107.

For detailed information on taking

cylinder wear measurements and
assessing liner condition, See
description 2245-0100, item 4.5

If the piston is removed, mount the

stuffing box cover before
measuring the liner.

If it is necessary to use a ladder,

use one in good condition, with
rubber ends and a hook to ensure
standstill.

3. Piston cleaning (PC) When removing the piston cleaning (PC)

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2265-0601-0009

ring ring between the liner and the cylinder

cover, make sure to mark the position
Work Card

of the ring to allow fitting of the PC-ring

in the same position as it is worn
together with the liner.

The PC-ring is to be regarded as an

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 2265-0601-0009 MAN B&W

integrated part of the liner and it is

intended to follow the service life of the
Cylinder Liner • Checking

liner.

During inspection of the piston and the

liner, the PC-ring must also be
inspected.

For the piston cleaning ring

measurements, Data T22-108 and
T22-109

• If the PC-ring is undamaged, re-mount the PC-ring in the cylinder liner in

the original position (Scratch marks, made before removal, must align).
• If the PC-ring is broken or cracked and the cylinder liner wear (measured
by the skirt TDC position, i.e. by the liner measuring point No. 5) is below
0.1% of the nominal diameter, replace the PC-ring with a new standard
PC-ring.
• If the PC-ring is broken or cracked and the cylinder liner wear is above
0.1% of the nominal diameter, contact MAN Diesel & Turbo.

When a new cylinder liner is installed, a

new PC-ring must also be installed.
When a new liner is ordered, a new PC-
ring must also be ordered.

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2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

1. Preparations

Cylinder Liner • Dismantling

Dismantle the cylinder cover.
See work card 2265-0301.

Discard the gasket (mild steel ring) from

the top of the cylinder liner.

Dismantle the piston cleaning ring and

the piston.
See work card 2265-0401.

The lifting tool is designed for

vertical lifts only and shall never be
used to tilt the cylinder liner.

In rare occasions it can be

necessary to tilt the cylinder liner
for e.g. for transportation. For
description, see instruction for
tilting the cylinder liner in the tilt
and transporting section.

2. Lifting tools Suspend the liner lifting tool from the

engine room crane.

Remove the lifting bolt from the tool.

Lower the tool into the liner until the
horizontal pipe is aligned with the lifting
holes.

Insert the lifting bolt into the lifting holes

through the scavenge air space.

When the bolt head has face contact

with the liner, secure the lifting bolt by
tightening the locking screw.
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2265-0601-0009
Work Card

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 2265-0601-0009 MAN B&W

3. Lubricator pipes Disconnect the oil pipes leading from

the cylinder lubricator to the cylinder
Cylinder Liner • Dismantling

liner.

4. Cooling water inlet Remove the screws of the cooling

water inlet pipe.

5. Remove the liner Dismount the four cooling water pipes –

between the cooling jacket and cylinder
cover.

Discard the O-rings and clean the

cooling water pipes.

Carefully lift the cylinder liner out of the

cylinder frame.

Low lifting height

Low lifting height in the engine
room may require the removal of
one or more cylinder cover studs
before dismantling the cylinder
liner.

Land the cylinder liner vertically on, for

instance, a couple of planks.
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2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

6. Cylinder frame Clean the cylinder frame internally,

taking special care with the contact

Cylinder Liner • Dismantling

surfaces for the cylinder liner at the top
of the cylinder frame.

The lifting tools are also used for

transporting the cylinder liner.

Discard the O-rings on the cooling

water pipes.

Clean the pipes carefully.

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Work Card

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 2265-0601-0009 MAN B&W

1. Before removing the

Cylinder Liner • Overhaul

Remove the non-return valves for the

cooling jacket cylinder liner lubrication, including the
"dummy" valves below the cooling
jacket.

Hook the engine room crane on to the

crossbar and attach two tackles to the
crossbar, as shown.

Safe working load (SWL)

Always use lifting gear with
sufficient SWL.
See data.

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.

Loosen the screws on the clamps

which fix the cooling jacket to the
cylinder liner.

Turn the clamps away from the liner.

2. Remove the cooling Lower the cooling jacket by means of

jacket the tackles and land it on the wooden
planks.

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Work Card

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 MAN B&W 2265-0601-0009

3. Moving the cylinder Hook the engine room crane to the

liner from the cooling lifting tool.

Cylinder Liner • Overhaul

jacket
Lift the cylinder liner away from the
cooling jacket.

Remove and discard all O-rings.

Clean the cooling jacket internally.

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2265-0601-0009
Work Card

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 2265-0601-0009 MAN B&W

4. Inspect the liner Check and assess the condition of the

cylinder liner.
Cylinder Liner • Overhaul

See description 2245-0100.

Remove 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 necessary to create a groove
by grinding. The groove serves to
prevent the build-up of a new wear
ridge.

5. Creating the groove It is recommended to use a wear ridge

milling machine to create the groove.

For use of the milling machine,

see supplier’s instruction.

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2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

6. Alternate groove Alternatively, place an old piston ring on

the top of the piston and turn to a

Cylinder Liner • Overhaul

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.

It is of utmost importance that the

groove is made with a regular
rounding as shown in the sketch.
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2265-0601-0009
Work Card

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 2265-0601-0009 MAN B&W

7. Returning the cooling Apply a thin layer of grease on the

jacket to liner contact surface for the cooling jacket
Cylinder Liner • Overhaul

on the liner.

If removed, re-mount the lifting tool.

Lift the liner a little and mount new

Orings for the cooling jacket.

Then place the liner in the cooling

jacket.

In rare occasions it can be

necessary to tilt the cylinder liner
for e.g. for transportation. For
description, see instruction for
tilting the cylinder liner later in the
tilt and transporting section.

8. Mount the cooling Using the crossbar and two tackles, lift
jacket the cooling jacket into position.

Make sure that the scratch marks

in the manoeuvring side of the
cylinder liner and cooling jacket
coincide.

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2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

9. Fasten the cooling Turn the clamps into position in the

jacket and mount non groove of the liner, and tighten the

Cylinder Liner • Overhaul

return valves. screws.

Remove the tackles and the eye bolts

from the cooling jacket.

Mount the non-return valves for the

cylinder liner lubrication.

Remove the crossbar.

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Work Card

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 2265-0601-0009 MAN B&W

Tilt and Transporting

Cylinder Liner

1. Precondition Dismantle the cylinder cover and piston.

Dismantle the cylinder liner and remove
the cooling jacket.
See Dismantling

2. Mount round sling Mount round sling by sliding it down

through the cylinder liner center and out
through the air ports in a "self locking
way" and hook on to the engine room
crane.
Haul the crane tight.
Secure the liner in the bottom by
attaching a round sling around multiple
scavenging air ports, and connecting it
to a tackle.

In order to prevent the scavenging

air ports to be damaged, sew the
sling around multiple ports.

Secure the tackle to a fixed point that

the tackle is supporting and keeping the
bottom of the cylinder liner in place
during the tilt.

Always use approved round slings

with a SWL greater than the weight
of the lifted component.

Make sure to mount the round

sling in a "self locking way". 2018-07-03 - en
2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

3. Tilt the cylinder liner Ensure to have contact with the floor during the whole tilt.

Cylinder Liner
Slowly tilt the liner by raising the crane a little

Lower the cylinder liner slowly and safely.

Safely land the cylinder liner on wooden planks.

Secure that the cylinder liner can not roll by using wooden obstacles on both
sides before slacking the round sling

Remove the round sling.

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Work Card

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 2265-0601-0009 MAN B&W

4. Lifting the cylinder Use the chafing to protect the sling against sharp edges. See tool 7670-0300
liner in horizontal
Cylinder Liner

position Mount round sling through the cylinder liner and the scavenging air ports. Hook it
on to the engine room crane via a tackle. See data T22-128.

Adjust the balance using the tackle.

Lift the cylinder liner away.

The angle between the two ends of the round sling must not exceed
120°.

Always keep the cylinder liner in balance when transporting.

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2265-0601-0009
Work Card

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 MAN B&W 2265-0601-0009

5. From horizontal to In order to get cylinder liner from

vertical horizontal to vertical direction follow

Cylinder Liner
step 2 - 4 in reverse order. Note that
the bottom round sling should be fixed
in opposite direction in order to support
the cylinder liner during the lift.
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2265-0601-0009
Work Card

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 2265-0601-0009 MAN B&W

1. Prepare for lift

Cylinder Liner • Mounting

Loosen the water connections on the

cooling jacket.

Mount the lifting tool on the cylinder

liner.

Secure the lifting bolt by tightening the

locking screw. Lift the jacket/liner
assembly.

Mount the lowermost O-ring and apply

a little lubricating oil on the ring

2. Mount the liner 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
connections on the cooling jacket.

Remove the lifting tool.

3. Studs If one or more cylinder cover studs have

been removed during the dismantling of
the cylinder cover, remount the studs
using the stud setter.
See work card 2265-0301.

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Work Card

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 MAN B&W 2265-0601-0009

4. Cooling water inlet Mount a new gasket between the

cooling water inlet pipe and the cooling

Cylinder Liner • Mounting

jacket. Mount and tighten the screws.

Close the drain and open the valves

5. Mount the piston and Lubricate the inside of the cylinder liner
cylinder cover with cylinder lubricating oil and mount
the piston and the piston cleaning ring.
See work card 2265-0401.

Mount the gasket (mild steel ring) and

the cylinder cover.
See work card 2265-0301.

Do not apply any kind of lubricant

to the gasket (mild steel ring).

Tighten the upper water connections on

the cooling jacket as soon as the
cylinder cover is correctly positioned.
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2265-0601-0009
Work Card

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 2265-0601-0009 MAN B&W

6. Lubricator pipes Connect and tighten the oil pipes for

the cylinder lubrication.
Cylinder Liner • Mounting

Activate the Lubricator test sequence

on the MOP for the pertaining cylinder.
See description 6645-0260 'Cylinder
Lubricators'.

Vent the cylinder lubricating system by

loosening the unions at the non-return
valves until oil, without air bubbles,
comes out from the pipes.

Oil spray risk

Use eye protection when venting
the pipes.

Tighten the unions.

Check that there is no leakage from the

system.

Check that each individual lubricating

point functions correctly by making a
scavenge port inspection. Check that
oil comes from each lubricator point.
See work card 3065-0601.

Stop the Lubricator test sequence on

the MOP.

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Work Card

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 Encl. 2 of 3 to
SL2018-664/PRP

MAN B&W 2265-0600-0011

Safety O Stop the Engine

Cylinder Liner, Data

Precautions O Shut off starting air supply - At starting air receiver
For detailed sketch O Block the main starting valve
see 0545-0100
O Shut off starting air distributor/distributing system supply
O Shut off control air supply
O Shut off air supply to exhaust valve - Only with stopped lub. oil pumps
O Engage turning gear
O Shut off cooling water
O Shut off fuel oil
O Stop lubricating oil supply
O Shut down hydraulic power supply

Data
�

Ref. Description Value Unit

T22-107 Cylinder diameter, new 500 mm
T22-108 Piston cleaning ring inner diameter, new 498.3±0.1 mm
T22-109 Piston cleaning ring radial width, new 9.85 mm
T22-111 Cylinder liner, complete 2100 kg
T22-112 Cooling jacket 200 kg
T22-128 Round sling table - -
T22-128 Minimum WLL and lenght for Round sling - -
T22-128 35 Bore: 2 tonnes , 4 metre -
T22-128 40 Bore: 2 tonnes , 4 metre -
T22-128 50 Bore: 3 tonnes , 5 metre -
T22-128 60 Bore: 3 tonnes , 4 metre -

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 two digits in the plate num-
ber, e.g. 2570-0010 refers to chapter 25, Bearings.

Tools
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2265-0600-0011

Plate Item No. Description

Work Card

2270-0610 - Measuring tool for cylinder liner

2270-0640 - Lifting tool for cylinder liner
7670-0200 - Torque spanners
7670-0300 032 Chafing device for roundslings

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 2265-0600-0011 MAN B&W

Tools (continued) .
Cylinder Liner, Data

Plate Item No. Description

7670-0410 066 Slide caliper

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2265-0600-0011
Work Card

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SL2018-664/PRP

List of Updated Work Cards

The following updated cylinder liner work cards are available online at our Nexus extranet:

Document ID no. Engine type

2265-0600-0009 S35ME-B9
2265-0600-0011 S50ME-B9
2265-0600-0024 S50ME-B9
2265-0600-0040 S40ME-B9
2265-0600-0041 S35ME-B9
2265-0600-0042 S50ME-B9
2265-0600-0043 S35ME-B9
2265-0601-0001 S40ME-B9
2265-0601-0007 S35ME-B9
2265-0601-0009 S50ME-B9
2265-0601-0011 S35ME-B9

Log on to Nexus and use the link below to search for the relevant documents:
https://extranet.mandieselturbo.com/SingleSheets/News/Index/MasterManuals

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