Instructions for Main Engines
Type S80MC-C
This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and to
describe the constructional features of a standard version of an MAN B&W main diesel engine. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes,
for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by us to ensure the
supply of the correct parts for the individual engines:
Name of vessel
Engine No.
built by
Plate No.
Part No.
Quantity required (and description)
Example:
M/S Nybo 7730 B&W P90201-0036 059
10 off (piston ring)
To ensure optimum efficiency, reliability and lifetime of the engine and its components, only original
spare parts should be used when replacing parts on the engine.
When used in texts and illustrations, the designation D refers to the information given on the data
sheets inserted in the respective books.
Reliable and economical operation of the diesel engines is conditional upon its correct operation
and maintenance in accordance with MAN Diesel instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN Diesel instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room
personnel are fully acquainted with the contents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out
in the Technical File.
This book is subject to copyright protection, and should therefore not, in whole or in part, be copied,
reproduced, made public or in any other way made available to a third party without the written consent of this effect from MAN Diesel.
A90023-0028
DOOSAN ENGINE Co., Ltd.
69-3, Sinchon-dong, Technical Service : +82 55 260 6689
Changwon-City
Parts Sales
: +82 55 260 6260
Gyeongnam, Korea
Telefax
: +82 55 260 6772
CVR No. 31 61 17 92
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DETAIL REPORT FOR ENGINE DEFECT
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MAN B&W
Checking and Maintenance Schedule,
80-108MC/MC-C Engines
The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the
engine and to carry out overhauls, if necessary,
based on the engine condition or a criterion of
time.
The stated Regular checks or Service interval
are intended primarily as a guide, as differences
in the actual service conditions, the quality of the
fuel oil or lubricating oil, the treatment of cooling
water, etc., will decisively influence the actual
service results, and thus the intervals between
necessary overhauling.
Plate
Edition
Page
900-1
0297
1 (6)
Design modifications may necessitate a revision of
the instructions, in which case the revised instructions and changed overhauling intervals, if any, will
apply and supersede those originally issued (see
e.g our Service Letters).
In addition to the checking and overhauling intervals stated in this schedule, please note that the
periodical survey requirements of the classification society may require additional checks and
reference is made to be carried out. For further
information reference is made to the classification
society.
The procedures are divided into five categories:
Time-based condition checking
procedures
marked with a C, under the heading Regular checks or Service
interval, deal with the service condition of a number of engine
components, and form the basis for estimating whether further
overhauling is necessary. In a number of cases the condition
checking procedures refer to Volume I of the instruction book, in
which more detailed descriptions and working procedures can be
found.
Condition-based overhauling
procedures
are marked with an O, under the heading Regular checks or
Service interval. Under the heading Refer to (column P), a reference to additional information is stated.
This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.
Time-based overhauling
procedures
also marked with an O, under the headings Regular checks or
Service interval or Based on observations, are the procedures
where an actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling
intervals stated as a basis.
The letters O or C in Based on observations (column B), indicate that special service conditions may make checking or
overhauling necessary beyond the actual standard schedules
indicated.
(continued)
A90050 Edition 0297
MAN B&W
Checking and Maintenance Schedule,
80-108MC/MC-C Engines
Initial checking procedures
Plate
Edition
Page
900-1
0297
2 (6)
marked with a C, under the heading Check new/overhauled
parts at 500, 1000 and 1500 hours (column H), deal with initial
checks that must be carried out on a new engine, or when parts
have been replaced.
After the three initial checks have been completed, checks need
only be carried out as per heading Regular checks or Service
interval.
When using electronic maintenance planning systems, special
attention should be paid to all initial checking procedures, as
handling of such procedures often can not be done automatically.
Instead such procedures must be handled manually.
Initial adjustment procedures
marked with an A, under the heading Check new/overhauled
parts at 500, 1000 and 1500 hours (column H), deal with initial
adjustment that must be carried out on a new engine, or when
parts have been replaced.
After the three initial adjustments have been completed, adjustments need only be carried out as per headings Regular checks
or Service interval.
When using electronic maintenance planning systems, special
attention should be paid to all initial adjustment procedures, as
handling of such procedures often can not be done automatically.
Instead such procedures must be handled manually.
NOTE!
Special attention should be paid to the chain tightener,
which must be adjusted three times (at 500, 1000 and 1500
hours of operation) on a new engine, or when chains or
chain wheels have been replaced.
A90050 Edition 0297
MAN B&W
Checking and Maintenance Schedule, 80-108 MC/MC-C Engines
V : See Volume I Operation
A : Adjustment to be carried out
C : Check the condition
M : See makers instructions
O : Overhaul to be carried out
H : Check new/overhauled parts at 500, 1000 and 1500 hours
Regular Checks
No.
Procedure
901
1
Cylinder Cover
Cylinder cover
Indicator cock
902
1
Piston with Rod and Stuffing box
Piston
Inspection through scavenge ports
Piston rod stuffing box
2
903
1
Daily
Crosshead with connecting rod
Crosshead bearing
Crosshead
Reciprocating parts
Crankpin bearing
Connecting rod
905
2
3
3
4
5
Crankshaft and Thrust Bearing
Main bearing
Thrust bearing
Guide bearing
Journal bearing
Axial vibration damper
Electronic axial vibration monitor
Mechanical checking
A90050 Edition 0297
Service interval (x 1000 hours of operation)
Weekly Monthly
12
16
24
32
C*
O
O
C,O
C*
Remarks
* Check whenever exhaust valve
is removed
V
* Check clearances without
dismantling segments
O
C
C
C
A
A
V,M
C,O
C,O
C,O
C,O
O
C
C
C
C
C
C
C
C
C
C
C
C
C,O
C,O
C,O
C,O
O
C
C
C
900-1
0297
3 (6)
R : Parts to be replaced
B : Based on observations
P : Refer to
Cylinder Liner and Cylinder Lubrication
Cylinder liner
Inspection through scavenge ports
Measuring wear inside liner
Cylinder lubricators
Accumulators
904
1
2
3
4
5
Plate
Edition
Page
C
C
Bearings should only be
opened if bearing material
fragments fall out.
Bearings should only be
opened if bearing material
fragments fall out.
MAN B&W
Checking and Maintenance Schedule, 80-108 MC/MC-C Engines
V : See Volume I Operation
A : Adjustment to be carried out
C : Check the condition
M : See makers instructions
O : Overhaul to be carried out
H : Check new/overhauled parts at 500, 1000 and 1500 hours
Regular Checks
No.
Procedure
7
8
Tacho pickup
Angle encoder
906
1
2
Mechanical Control Gear
Chains
Chain tightener
Chain wheels, spray nozzles and guide bars
Camshaft
Camshaft bearings
Camshaft coupling, fitted bolts
Moment compensator
Governor
Functional check of overspeed device
Functional check of speed-setting system
(engine with bridge control system)
-3
-4
-5
907
-1
-2
Starting Air System
Starting air distributor
Starting air valve
908
-1
-2
-3
Exhaust Valve
Hith-pressure pipe
Exhaust valve
Exhaust valve actuator
Actuator safety valve
Exhaust valve roller guide
Exhaust valve cam
Exhaust valve special running
-4
-5
-7
909
Fuel Oil System
Fuel oil water content
A90050 Edition 0297
Plate
Edition
Page
Daily
Weekly Monthly
900-1
0297
4 (6)
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x 1000 hours of operation)
2
C
C,A
C
C
C
C,A
C
C
O
12
16
24
32
C
C
C
C,O
C,O
M
M
R
A
R
C,A
C,O
Remarks
New or overhauled chain to be
checked/retightened after 500,
1500 and 4000 hours
C,A
M
M
M
C
C
C
C,O
O
O
O
C,A
C*
C*
C*
C*
O
O
O
* Only inspection through
camshaft covers
MAN B&W
Checking and Maintenance Schedule, 80-108 MC/MC-C Engines
V : See Volume I Operation
A : Adjustment to be carried out
C : Check the condition
M : See makers instructions
O : Overhaul to be carried out
H : Check new/overhauled parts at 500, 1000 and 1500 hours
Regular Checks
No.
Procedure
-1
-2
-3
-4
-5
-6
-7
-8
-9
-9
-10
11
12
13
14
-15
16
Fuel pump settings
VIT system
Fuel pump cam
Fuel pump
Fuel pump top cover
Fuel pump barrel assembly
Fuel pump suction valve
Fuel pump puncture valve
Fuel pump shock absorber
Fuel system shock absorber
Lifting gear for roller guide
Fuel valve
Fuel nozzle
Spindle guide
Nonreturn valve
Fuel oil highpressure pipes
Fuel pump roller guide
Fuel pump special running
910
1
2
3
4
5
Turbocharger System
Air cooler
Nonreturn valve
Auxiliary blower
Butterfly valves
Turbocharger turbine
Turbocharger air filter
Protective grid before turbocharger
Turbocharger lubricating oil water content
Water mist catcher
A90050 Edition 0297
Plate
Edition
Page
Daily
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x 1000 hours of operation)
Weekly Monthly
12
16
24
32
C,O
C,O
C
C
C
C,O
A,C
A
A
O
O
R
V
V
R
R
* HIP compound type nozzles only.
Other type: 8000 hours
O
C*
C*
C
C
C
C
C
O
O
O
O
O
O
O
C,O
O
R
C*
C*
Remarks
O
O
O
R*
R
C*
C
900-1
0297
5 (6)
C,O
* Only inspection through
camshaft covers
Check p and t
Check at every port inspection
* Check at every port inspection
V,M
V
M
* Dry cleaning daily
* Only if separate oil system
* Check p
MAN B&W
Checking and Maintenance Schedule, 80-108 MC/MC-C Engines
V : See Volume I Operation
A : Adjustment to be carried out
C : Check the condition
M : See makers instructions
O : Overhaul to be carried out
H : Check new/overhauled parts at 500, 1000 and 1500 hours
Regular Checks
No.
Procedure
911
1
2
3
Safety Equipment
Overpressure indicator valve
Relief valve
Scavenge air receiver safety valve
Functional test of alarm system for thrust
bearing and slow down /shut down system
Checking and adjustment of pressure gauge
Checking and adjustment of thermometers
Checking and adjustment of thermostats
Checking and adjustment of pressurestats
Checking and adjustment of turning gear switch
912
2
3
913
1
Assembly of Large Parts
Holdingdown and end chock bolts
Stay bolts
Top bracings
Diaphragm in crankcase oil outlet
System lubricating oil water content
System lubricating oil bottom tank
Cooling water quality
Crankcase
General Tools
Hydraulic tools
A90050 Edition 0297
Plate
Edition
Page
Daily
Weekly Monthly
R : Parts to be replaced
B : Based on observations
P : Refer to
Service interval (x 1000 hours of operation)
2
12
16
24
32
C
C
C
C
Remarks
O
O
O
C
C
C
C
C
C
C
C
C
900-1
0297
6 (6)
A
A
A
A
A
M
M
M
M
M
M
C
C
C
C
M
Empty and clean tank
O
C
V,M
C*
* Check for loose nuts and
bearing material fragments
General - Safety Precautions
MAN B&W
Plate
Edition
Page
900-2
0002
1 (2)
Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specic Data Sheet.
SAFETY PRECAUTIONS
X
X
X
X
X
X
X
X
X
X
X
X
Stopped engine
Shut off starting air supply At starting air receiver
Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply Not ME engines
Shut off control air supply
Shut off air supply to exhaust valve Only with stopped lubricating oil pumps
Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
The sketch gives the approximate location of the valves concerned:
FUEL OIL SUPPLY
COOLING WATER
SAFETY AIR
SUPPLY
STARTING AIR SUPPLY
AIR SUPPLY
EXHAUST VALVE
TURNING GEAR
A90060-0001C01
CONTROL AIR
SUPPLY
90002 Edition 0002
MAIN STARTING VALVE
DISTRIBUTING SUPPLY
MAN B&W
General - Safety Precautions
Safety Equipment - Recommendations
1.
In order to perform maintenance in a safe and
correct way, MAN B&W Diesel A/S recommends
use of the following personal safety gear:
Safety shoes.
Hearing protection.
Work gloves.
Protective head wear, such as a baseball
cap with a hard protective liner.
Safety goggles.
Fall arrestor equipment.
Safety shoes, hearing protection, work gloves
and protective head wear should be used when
there is a risk of falling objects, loud noises and
sharp edges or oily surfaces.
A90060-0002C01
1.
2.
Use safety goggles when working with compressed air, grinders, hydraulics and when there
is a risk of getting foreign objects in the eyes.
3. This is especially needed when mounting eyebolts and hanging tackles inside the
crankcase, and when working on the hydraulic pump station on some ME engines.
A90060-0002C02
2. We strongly recommend the use of fall
protection harness and arrestor equipment
when working in places on the engine where
there is a risk of falling or slipping.
A90060-0002C03
3.
90002 Edition 0002
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900-2
0002
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