902

Piston 102-1
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0056
102-1 Piston
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
D01-05 Cylinder cover studs–check distance 1014±2 mm
D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 280 Nm
D02-03 Piston rod/crown, tightening torque 200 Nm
D02-05 Piston skirt, tightening torque 90 Nm
D02-06 Cooling oil pipe, tightening torque 50 Nm
D02-08 Piston ring new, radial width 14.7 mm
D02-09 Piston ring worn, min. radial width 12.2 mm
D02-10 Groove No.1, max. vertical height 11.7 mm
D02-11 Groove Nos. 2,3 and 4, max. vertical height 8.7 mm
D02-12 Piston top max. permissible burn-away 13 mm
D02-13 Piston ring new, height of ring no 1 10.9 mm
D02-14 Piston rings new, height of ring no 2,3 and 4 7.9 mm
D02-15 Minimum free ring gap ( before dismantling ) 27 mm
D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 2.9 mm
D02-17 Minimum ring gap, ring Nos. 2,3 and 4 ( new ring in new liner ) 2.1 mm
D02-18 Vertical clearance, new parts 0.45-0.5 mm
D02-19 Vertical clearance, worn parts, max. 0.8 mm
D02-20 Piston complete 556 kg
D02-21 Piston crown 121 kg
D02-22 Piston rod 311 kg
D02-23 Piston skirt 28 kg
D02-24 Piston cooling pipe 12 kg
D04-15 Telescopic pipe, tightening torque 40 Nm
When referring to this page, please quote Data D10201 Edition 0056 Page 1 (2)
MAN B&W Diesel A/S
102-1 Piston
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 40 Lifting tool for piston rod foot
75 Template for piston top
87 Distance piece for stuffing box
99 Cover for stuffing box hole
110 Pressure test tool for piston
134 Piston ring expander
158 Guide screw for piston crown
171 Dismantling screw piston skirt
P90261 Guide ring for piston
P90264 Tools for tilted lift
P90265 Support for piston
P90266 16 Lifting tool for piston
P90361 36 Cylinder gauge, complete
P90366 Crossbar for cylinder liner
Page 2 (2) When referring to this page, please quote Data D10201 Edition 0056
MAN B&W Diesel A/S
Piston 902-1.1
Checking
0251
Piston S42MC
Checking
902-1.1

Scavenge port inspection
To detect possible leakages from the piston or

cylinder 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.
Note!
The scavenge port inspection can also

be carried out from within the scavenge

air receiver.

1
*
Clean the openings.

Begin the inspection at the cylinder whose
piston is nearest BDC.
2. With the piston in BDC, inspect the piston

crown and the cylinder wall.
Note down the results.

See Volume I, OPERATION, Chapter 707.
3. Turn the engine. While the piston is passing

the scavenge air ports, inspect the piston
rings, the ringlands and the piston skirt.
Check the movability and the tension of the

piston rings, by pressing against them with

a wooden stick.

Note down the results. 1
*

*
+
When referring to this page, please quote Procedure M90201 Edition 0251 Page 1 (20)
0$1% :'LHVHO$6
902-1.1 Piston
Checking
4. After turning the piston upwards, past the

scavenge air ports, inspect the piston rod
and 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 and

1
place it on the piston support.
*
See Procedure 902-1.2.
6.
Note!
It is recommended to replace all the pis-

D02-20 ton rings whenever a piston is removed
from the engine.
All the following measurements should be

used as a guideline for the running time of
a set of new piston rings.
Depending on the extent of the wear, the

running time can be increased or de-
creased.
BG902-4.1 72 02
For evaluation of the rings, see Volume I,

OPERATION , Chapter 707.
7. Before dismantling the piston rings, meas-

ure the free ring gap of all the piston rings.
7.
D02-15
BM902-1.1 232 07
Page 2 (20) When referring to this page, please quote Procedure M90201 Edition 0251
0$1% :'LHVHO$6
Piston 902-1.1
Checking
8. Take off the piston rings by means of the 8.

ring expander.
Clean and inspect the rings.
9. Measure and record the radial width of the

rings.
See Volume I, Operation, Chapter 707.
Worn rings must be replaced if the radial

width is less than stated in Data.
10. Piston rings with milled pressure relief

grooves must be replaced if the radial depth
of the grooves has worn down to less than
1 mm.
GN902-1.1 222 14

' 1HZ

'

:RUQ

1
*
10. Min. 1 mm
GN902-1.1 204 09
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902-1.1 Piston
Checking
11. 11. Clean the ring grooves and check them for
D02-10 burn marks or other deformation.
D02-11
Measure the ring grooves with a caliper
gauge.
Clearance in piston ring grooves:
Max. 2 mm 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

KM902-3.0 47 05
chromium layer.
12. Clean the piston crown and check the burn-

away by means of the template. For maxi-
mum permissible burn-away value, see Da-
12. ta.
D02-12
Check the burn-away on the whole circum-
ference of the piston crown.
13. Before mounting a new piston ring, meas-

ure the piston ring gap.
When measuring, insert the piston ring in

either a new cylinder liner or in the bottom
of a used cylinder (below the ring travel
zone).
For minimum ring gap, see Data.

AM902-3.0 77 04
13.
D02-16
GN902-1.1 222 13
D02-17
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Piston 902-1.1
Checking
14. Fit the piston rings (alternately right-hand 14.

and left-hand cuts with the ring gaps stag-
gered 180° and with the TOP mark up-
wards).
When mounting the piston rings, use the

ring expander to prevent unintended defor-
mation of the rings.
Do not expand the rings more than neces-

sary. The upper ring (CPR ring) should not
be expanded more than to the milled mark
on the ring expander.
15. Check the vertical clearance between the

new piston ring and the new or recondi-
tioned ring groove with a feeler gauge. See
Data.
GN902-1.1 222 14
Worn ring groove:
Measure the total clearance between the

piston rings and the ring grooves.
The total clearance must not exceed the 15.

value stated in Data.
D02-18
Measurements are to be taken at the top
(E) and bottom (F) between the piston ring
and piston ring groove.
Total clearance = E + F. ( (
D02-19
) )
0D[PP

0
+
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902-1.2 Piston
Dismantling
Dismantling
902-1.2
1. Turn the crosshead down far enough to give

access to the piston rod stuffing box, the
tightening screws for the piston rod, and to
the telescopic pipe.
2. Release the stuffing box by removing the

innermost screws from the stuffing box
flange.
Note!
'R127UHPRYHWKHRXWHUPRVWVFUHZV

IURPWKHIODQJH

3. Remove the four screws and nuts which
0
' tighten the telescopic pipe to the bend.
Disconnect the telescopic pipe from the

bend and fasten the pipe flange to the stuff-
ing box by means of the wing-screw from
the tool panel.
Note!
:KHQDSLVWRQLVGLVPDQWOHGQHYHUWXUQ

WKHHQJLQHZLWKRXWILUVWGLVPDQWOLQJWKH

WHOHVFRSLFSLSHIURPWKHFURVVKHDG

1
*

0
'
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Piston 902-1.2
Dismantling
4. Remove the screws from the piston rod.
5. Mount the two distance pieces on the piston

rod foot to protect the lower scraper ring
and to guide the stuffing box.
6. Turn the crosshead to TDC, while checking

that the stuffing box lands correctly on the
distance pieces.

0
'

0
'
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902-1.2 Piston
Dismantling
7. 7. Dismount the cylinder cover.

8. Piston cleaning ring (PC-ring):
Make a short scratch mark in liner and PC-

ring to ensure the correct mounting.
Remove the PC-ring.
Carefully remove wear ridges at the top of

the cylinder liner.
See Procedure 903-1.
DM902-1.2 251 07
8.
HN902-1.2 237 06
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Piston 902-1.2
Dismantling
9. The top of the piston is now free of the cyl- 9.

inder liner. D02-20
If necessary, remove one or two cylinder
cover studs, using a stud setter.
Clean the lifting groove of the piston crown

and mount the lifting tool in such a manner
that the two ‘fixed’ claws of the tool fit into
the lifting groove of the piston.
Fit the third, adjustable, claw of the tool to

the lifting groove and tighten it up against
DM902-1.1 105 06
the stop of the tool.
10. Place the two halves of the support around

one of the openings in the platform.
Lift the piston out of the cylinder and lower 10.

the piston rod foot and stuffing box through
the opening in the platform.
Place the two halves of the support around

the piston rod and secure the two halves
with screws.
11. 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.
BG 902-4.1 72 02
11.
BG902-4.1 72 02
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902-1.2 Piston
Dismantling
12. 12. Turn the crosshead down far enough to per-

mit mounting of the protective rubber cover
on the crosshead bearing cap.
The protective rubber cover should remain

in place to protect the crosshead bearing
journal from impurities until the piston is re-
mounted.
Low lifting height
If the space conditions above the engine make

it impossible to remove the piston in the normal
GN902-1.2 204 10
way, the piston can be removed as follows:
13. Remove one or two cylinder cover studs,

using the stud setter.
13. Lift the piston high enough to give ample

room over the cylinder cover studs.
Mount the clamp on the piston rod so that

its distance piece lies true against the pis-
' ton.
DM902-1.2 251 13
0$1% :'LHVHO$6
Piston 902-1.2
Dismantling
14. Place the supporting tools on the cylinder

cover studs and lower the piston until the
clamp rests on the tools.
Remove the lifting tool from the piston.
Hook the transverse piece on to the crane

and attach it to the clamp for tilting the pis-
ton.
15. Lift the piston to the maximum crane height.

Run the crane athwartship and, at the same
time, tilt the piston.
Keep the piston rod clear of the cylinder lin-

er and studs while carrying out the tilting.
When space conditions permit, straighten

up the piston and lead it over to the cut-out
in the platform for overhauling the piston.
When the piston is at a suitable height

above the platform cut-out, position the pis-
ton support around the piston rod and
clamp.
Now lower the piston while guiding the sup-

port to the platform cut-out.

After landing the piston and ensuring that it

rests correctly on the support, remove the 0

'
tilting tool.

Note!
2QHQJLQHVZLWKH[WUHPHO\ORZOLIWLQJ
KHLJKWXVHWKHHQJLQHURRPGRXEOHMLE
FUDQHLQVWHDGRIWKHWUDQVYHUVHSLHFH

0
'
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
Overhaul
902-1.3
1. Ease the piston down so that the stuffing

box is below the floor.
2. Assemble the two halves of the piston sup-

port around the piston rod.
'
Land the piston on the support, taking care
that the piston is not resting on the head of
the piston rod bolts.
Dismount the piston rings.


3. Dismount the stuffing box and distance

pieces.


0
%

*
%

*
%
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Piston 902-1.3
Overhaul
4. Lift the piston with the normal lifting tool. 4.
Lower the piston rod foot near to the plat-

form. Pull the piston rod foot a bit to the
side by hand to tilt the piston. Land the foot
on a wooden block.
Note!
During the lift, follow with the crane to

keep the crane positioned vertically
above the piston crown.
BM902-1.3 236 04
5. Lower the piston crown to the platform and
land it on a wooden block.
6. Remove the lifting tool from the piston

crown. 5.
Attach the lifting bracket to the bottom of

the piston rod foot. Hook the crane on to the
lifting bracket.
7. Lift the piston rod foot clear of the wooden

BM902-1.3 236 05
block.
Note!
'XULQJWKHOLIWIROORZZLWKWKHFUDQHWR 6.
NHHSWKHFUDQHSRVLWLRQHGYHUWLFDOO\
DERYHWKHSLVWRQURGIRRW
Keep lifting until the piston rod is in a verti-

cal position.
BM902-1.3 236 06
7.
BM902-1.3 236 07
0$1% :'LHVHO$6
902-1.3 Piston
Overhaul
8. Place the piston in an upright position with

the 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 land
it in a horizontal position on a couple of
wooden blocks.
9. Remove the locking wire and the screws in

the skirt and mount two eye bolts in the
holes intended for dismantling screws. Lift
the skirt and land it on a couple of planks.

10. Thoroughly clean and inspect all parts of

the piston.

0
%
If coke deposits are found in the cooling

spaces of the piston crown, the piston
crown cooling spaces should be washed
out with Carbon Remover or a similar
cleaning fluid. When all coke deposits have
been dissolved, clean and inspect the pis-
ton crown again.
' Regarding check of the piston crown, see
Procedure 902-1.1.
Replace all sealing rings of the piston. All

the new sealing rings must be coated with
lubricating oil before the piston is assem-
' bled.

Coat all screws with Molybdenum Disul-

phide (MoS 2).

0
%
Assemble the piston in the reverse order to

disassembly. Use the guide screw to ensure
the correct positioning of the piston rod in
relation to the piston crown.
'
Tighten all the screws diagonally to the
torque stated in Data.
'

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%
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Piston 902-1.3
Overhaul
11. Lock all the screws with locking wire.
Mount the locking wire in such a way that

the wire is tightened if one of the screws
works loose.
12. Fill the piston and piston rod with lubricat-

ing oil.
Mount the pressure-testing tool around the

base of the piston rod.
Pressure-test the piston at the pressure

stated on the data sheet.

Check the contact surfaces of the piston 0

+
and the sealing rings for tightness.

12.
Check that there are no cracks in the piston
crown.
13. Tilt the piston to an upright position and

land it on the piston support tool. '
Mount the stuffing box.

Mount new piston rings. 2LO

BM902-1.3 236 12
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902-1.4 Piston
Mounting
Mounting
902-1.4
1. Check the piston rings and piston crown in

accordance with Procedure 902-1.1.
2. Mount the lifting tool on the piston crown.

'
3. Ensure that the stuffing box is correctly po-
sitioned over the distance pieces mounted
on the piston rod foot.
Coat the O-rings of the stuffing box with oil.
4. Remove the protective rubber cover from

the crosshead.

0
%

0
'

1
*
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Piston 902-1.4
Mounting
5. 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° from

TDC.
7. Coat the piston rings, piston rod and cylin-

der liner with lubricating oil.
Coat the O-rings of the stuffing box with oil.
Mount the guide ring for piston rings on the

cylinder liner.

Lower the piston into the cylinder liner –

while guiding the piston rod foot through the 1
*
cut-out in the stuffing box flange – until the

piston rings are inside the liner.

0
'

0
%
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902-1.4 Piston
Mounting
8. Turn the crosshead to TDC while checking

that the guide ring of the crosshead enters
the centre hole in the piston rod.
After turning the piston fully to TDC, un-

screw the adjustable claw of the lifting tool
and pull the lifting tool free of the lifting
groove in the piston
Remove the lifting tool and the guide ring

for piston rings.
9. Turn the crosshead with the piston rod

down far enough to give access to the tel-

escopic pipe stuffing box.

0
%
Loosen the telescopic pipe and land it on
the bend.

Mount and tighten the screws for the tele-
scopic pipe. See Data.
10. Remove the distance pieces for the stuffing

' box.
Mount and tighten the piston rod screws.

See Data.
Lock the screws with locking wire.
Mount the locking wire in such a way that

the wire is tightened if one of the screws

works loose.


0
'

'

*
%
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Piston 902-1.4
Mounting
11. Tighten down the piston rod stuffing box by 11.

means of the screws through the inner
holes in the stuffing box flange.
12. If the cylinder cover studs have been re-

moved, mount them with the stud setter.
See Data.
Carefully clean the surfaces around the

base of the mounted studs and refill the
roots properly with Permatex 3.
GN902-1.2 204 02
13. Smear the piston rod with molybdenum di-
sulphide, and turn the crankshaft a couple
of revolutions.
Mount the cylinder cover.

See Procedure 901-1.4. 12.
14. Mount the piston cleaning ring according to

the scratch mark.
If the PC-ring is damaged (broken or

cracked), it must be replaced by a dummy
ring with an over-seize bore, to ensure
proper sealing between cylinder cover and
cylinder liner.
D01-05
BM902-1.4 230 12
14.
HN902-1.4 237 13
0$1% :'LHVHO$6
902-1.4 Piston
Mounting
15. 15. Mount the cylinder cover.

16. Start the engine and keep it running for

about 15 minutes at a number of revolutions
corresponding to very slow.
Then stop the engine and inspect the piston

rod and stuffing box.
GN902-1.2 204 05
0$1% :'LHVHO$6
Piston Rod Stuffing Box 102-2
Data
SAFETY PRECAUTIONS
Special Data
S42MC
0042
102-2 Piston Rod Stuffing Box
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
D02-26 Stuffing box flange, outer screws tightening torque 50 Nm
D02-27 Stuffing box flange, inner screws tightening torque 50 Nm
D02-28 Stuffing box halves, tightening torque 40 Nm
D02-29 Uppermost rings, ring-end clearance 4*6 mm
D02-30 Lowermost rings, ring-end clearance 3*3 mm
D02-31 Vertical clearance, uppermost rings 0,15-0,35 mm
D02-32 Vertical clearance, lowermost rings 0,05-0,20 mm
D02-33 Check length for the six uppermost springs:
D02-34 –F0=0N L0= 525 mm
D02-35 – F 1 = 33 +/– 2 N L1= 590 mm
D02-36 – F 2 = 63 +/– 5 N L2= 650 mm
D02-37 Check length for the four lowermost springs:
D02-38 –F0=0N L0= 370 mm
D02-39 – F 1 = 41 +/– 3 N L1= 506 mm
D02-40 – F 2 = 71 +/– 5 N L2= 606 mm
D02-44 Stuffing box complete 76 kg
D02-45 Stuffing box half 26 kg
When referring to this page, please quote Data D10202 Edition 0042 Page 1 (2)
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
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 109 Mounting tool for stuffing box spring
P90251 122 Worktable for stuffing box
Page 2 (2) When referring to this page, please quote Data D10202 Edition 0042
MAN B&W Diesel A/S
Piston Rod Stuffing Box 902-2.1
Checking
0219 Rod Stuffing Box
Piston S42MC
Checking
902-2.1
1.
1. After the piston rod stuffing box has been
dismantled, check the following clearanc-
es:.
See Procedure 902-2.2. D02-29
Uppermost scraper ring and sealing rings

A
Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D02-29) D02-30
Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends.

Total clearance. (D02-30)
B
The ring clearances stated in Data apply to A B
new rings.
As a general guide, it is recommended –

depending on the overhauling intervals and
one’s own experience – to replace sealing D02-29 D02-30
rings and scraper rings when the specified
DM902-2.1 219 01
clearance values D02-29 and D02-30 have

been halved.
2. Check the length of the springs at different

loads. Adjust the loads to achieve the
2.
lengths stated in Data. D02-33
If the loads necessary are outside the limits
stated in Data, the springs must be discard-
ed.
D02-37
HM902-5.0 70 02
MAN B&W Diesel A/S
902-2.2 Piston Rod Stuffing Box
Dismantling
Dismantling
902-2.2
1. If, in the period between piston overhauls, it be-

comes necessary to inspect the piston rod
stuffing box, proceed as follows:
1. Turn the crosshead to about 90° from TDC.
Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diametrically opposite in the
GN902-2.2 203 01
stuffing box flange, longitudinally to the en-

gine.
3. Mount the worktable around the piston rod

so that the two remaining screws in the
2. stuffing box flange can be loosened through
the holes.
DM902-5.2 108 02
3.
DM902-5.2 108 03
MAN B&W Diesel A/S
Dismantling
4. Remove the two long dismantling screws 4.

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

holes in the worktable.
Remove the remaining two screws from the

stuffing box.
5. Turn the piston to BDC, thereby withdraw-

ing the stuffing box from the cylinder frame
bottom.
DM902-5.2 108 04
Remove the two long dismantling screws
from the stuffing box and mount them in the
worktable.
6. By means of the four short screws in the

worktable, press the stuffing box out of the 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
DM902-5.2 108 05
6.
DM902-5.2 108 06
MAN B&W Diesel A/S
Overhaul
Overhaul
902-2.3
Outside the engine
Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.
During such overhauls, the piston rests on a

support placed over one of the cut-outs in the
top platform.
Work on the stuffing box is then carried out

from the platform below.
1. Mount two eye bolts in the stuffing box

DG902-5.1 83 01
flange, and hook on two tackles.
Lift the stuffing box a little up the piston rod,

and mount the worktable round the piston
1. rod at a suitable working height.
Land the stuffing box on the worktable, and

remove the tackles and eye bolts.
2. Remove the O-ring of the stuffing box. If the

D02-44 O-ring is intact and is to be used again,
move it up the piston rod and secure it in
this position, for example with tape.
Remove the nuts from the stuffing box as-

sembling bolts.
DG902-5.1 83 02
2.
DG902-5.1 83 03
MAN B&W Diesel A/S
Overhaul
3. Take out the six bolts, and pull away one 3.

stuffing box half.
Mount two eye bolts on the stuffing box half

and remove it from the worktable.
4. Using a feeler gauge, measure the vertical D02-45

clearance of the rings.
5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.
DG902-5.1 83 04
6. Measure the clearance between the ring
segments to determine whether replace-
ment is necessary.
7.
Dismantle and stack the rings in the same D02-33
order as when fitted in the stuffing box.
Carefully clean all the ring segments.
Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D02-37
7. Check the lengths of the springs.
8. Inspect the surface of the piston rod. If

HM902-5.0 70 02
small longitudinal scratches have occurred

(caused by poorly adapted stuffing box
rings), smooth the piston rod surface care-
fully with a fine grained carborundum stone.
In the case of coarse scratches, it may 8.
prove necessary to machine-grind the sur-
face in a workshop.
9. Clean the halves of the stuffing box hous-

ing.
HC902-5.1 98 07
MAN B&W Diesel A/S
Overhaul
10. 10. Lubricate the piston rod (in the area where
all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).
Assemble all the stuffing box ring units

round the piston rod, on the worktable, in
the following way:
• Place the lowermost scraper ring seg-

ments on the worktable.
• Place the spring round the segments,

and hook the spring ends together.
NB902-3 217 10
Repeat this procedure for the remaining

scraper rings.
11. On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).
Assemble the 8-part sealing ring so that the

two guide pins face upwards, place the
spring round the segments and, hook the
spring ends together.
Assemble the 4-part sealing ring above the

8-part sealing ring. Push the two rings to-
gether in such a manner that the guide pins
in the lower sealing ring engage with the
two holes in the upper sealing ring.
DM902-2.3 219 11
Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).
11. Use the stuffing box half on the worktable

to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. Subse-
quently, push the stuffing box half into con-
tact with the piston rod, round the ring units.
MAN B&W Diesel A/S
Overhaul
12. Check the ring clearance again. 12.
Then place the other half of the stuffing box

housing on the worktable, pushing it into D02-28
place round the rings.
Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.
Mount the O-ring in the stuffing box groove.
13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.
DG902-5.1 83 11
Remove the worktable and lower the stuff-
ing box until it rests against the distance
pieces on the piston rod foot.
Remove wire ropes and screws. DG902-5.1 83 12 13.
MAN B&W Diesel A/S
Mounting
Mounting
902-2.4
1. 1. After overhauling, assemble the stuffing

box 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 the

stuffing box lands on the flange.
2. Turn the piston upwards until the stuffing

box is in place in the cylinder frame.
Note!
DM902-5.2 108 07
Make sure that the two guide pins in the

flange enter the guide holes in the bottom
of the cylinder frame.
2.
3. Mount two screws in the flange through the
holes in the worktable.
DM902-5.2 108 08
3.
DM902-5.2 108 09
MAN B&W Diesel A/S
Mounting
4. Remove the long screws from the stuffing 4.

box and mount them in the worktable.
Remove the worktable from the piston rod.
5. Mount and tighten all the inner and outer

screws for the stuffing box. See Data.
6. Remove the protecting rubber cover from

the piston rod/crosshead.
Smear the piston rod with molybdenum di-

sulphide.
DM902-5.2 108 10
Then turn the crankshaft a couple of revo-
lutions.
Start up the engine and keep it running for

about fifteen minutes at a number of revo- 5.
lutions corresponding to very slow or idle
speed.
Then stop the engine and inspect the piston

rod and stuffing box.
D02-26
DM902-5.2 108 11
D02-27
6.
GN902-2.2 203 01
MAN B&W Diesel A/S
Piston and Piston Rod Panel Plate
P90251-0255
Piston
0255 and Piston Rod Panel
P90251
When referring to this page, please quote Plate P90251 Edition 0255 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0255
Item Item
Item Description Item Description
No. No.
014 Panel for tools

026 Name plate
040 Lifting tool for piston rod
051 Lifting tool for cylinder liner
063 Lifting and tilting screw
075 Template for piston top
087 Distance piece for stuffing box
099 Cover for stuffing box hole
109 Hook for mounting of stuffing box
spring
110 Pressure test
122 Work table for stuffing box
134 Piston ring expander
146 Support for tilting tool
158 Guide screw for piston crown
171 Dismantling screw for piston skrit
Page 2 (2) When referring to this page, please quote Plate P90251 Edition 0255
MAN B&W Diesel A/S
Piston and Piston Rod - Tools Plate
P90261-0107
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0107
Item Item Description Item Item Description

No. No.
019 Guide ring for piston
MAN B&W Diesel A/S
Piston and Piston Rod - Support Tools Plate
P90265-0005
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0005

No. No.
010 Support iron for piston
MAN B&W Diesel A/S
Piston - Lifting Tools Plate
P90266-0004
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0004

No. No.
016 Lifting tool, piston
MAN B&W Diesel A/S

902

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Piston 102-1

Plate Item No. Description

To detect possible leakages from the piston or

1. Remove the inspection covers on the cam-

The scavenge port inspection can also 

Clean the openings.

2. With the piston in BDC, inspect the piston

Note down the results.

3. Turn the engine. While the piston is passing

Check the movability and the tension of the

 4. After turning the piston upwards, past the

Note down the results.

5. Re-mount the inspection covers on the cyl-

It is recommended to replace all the pis-

All the following measurements should be

Depending on the extent of the wear, the

For evaluation of the rings, see Volume I,

7. Before dismantling the piston rings, meas-

8. Take off the piston rings by means of the 8.

Clean and inspect the rings.

9. Measure and record the radial width of the

Worn rings must be replaced if the radial

10. Piston rings with milled pressure relief

Clearance in piston ring grooves:

Max. 2 mm The maximum vertical height in a worn ring

The groove is also worn out if there is no

12. Clean the piston crown and check the burn-

13. Before mounting a new piston ring, meas-

When measuring, insert the piston ring in

For minimum ring gap, see Data.

14. Fit the piston rings (alternately right-hand 14.

When mounting the piston rings, use the

Do not expand the rings more than neces-

15. Check the vertical clearance between the

Worn ring groove:

Measure the total clearance between the

The total clearance must not exceed the 15.

 1. Turn the crosshead down far enough to give

2. Release the stuffing box by removing the

 Disconnect the telescopic pipe from the

4. Remove the screws from the piston rod. 

5. Mount the two distance pieces on the piston

6. Turn the crosshead to TDC, while checking

7. 7. Dismount the cylinder cover.

8. Piston cleaning ring (PC-ring):

Make a short scratch mark in liner and PC-

Remove the PC-ring.

Carefully remove wear ridges at the top of

9. The top of the piston is now free of the cyl- 9.

Clean the lifting groove of the piston crown

Fit the third, adjustable, claw of the tool to

10. Place the two halves of the support around

Lift the piston out of the cylinder and lower 10.

Place the two halves of the support around

11. Place a cover over the opening for the pis-

Clean, measure and recondition the cylin-

12. 12. Turn the crosshead down far enough to per-

The protective rubber cover should remain

Low lifting height

The scavenge port inspection can also

4. After turning the piston upwards, past the

1. Turn the crosshead down far enough to give

Disconnect the telescopic pipe from the

4. Remove the screws from the piston rod.

14. Place the supporting tools on the cylinder

1. Ease the piston down so that the stuffing

8. Place the piston in an upright position with

11. Lock all the screws with locking wire.

Pressure-test the piston at the pressure

stated on the data sheet.

1. Check the piston rings and piston crown in

5. Remove the cover from the piston rod stuff-

8. Turn the crosshead to TDC while checking