Warning

MAN B&W S900-0002

Warning!

It is important that all MAN Diesel A/S engines are operated within the given specifications
and performance tolerances specified in the engines’ Technical Files and are maintained
according to the MAN Diesel A/S maintenance instructions in order to comply with given
emissions regulations.

In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C,
§94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part
94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel
engine shall be performed as specified in MAN Diesel A/S instructions, including, but not
limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote S-Instruction S900 Edition 0002 Page 1 (1)
S42MC VOLUME II
MAINTENANCE
 Instructions for Main Engines

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 en-
gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-
erence 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:

1. Name of vessel
2. Engine No. built by
3. Plate No.
4. Part No.
5. Quantity required (and description)

Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

10 off (piston ring)
+ )The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.

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 oper-
ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re-
lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ 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 con-
tents of this book and, in respect of instructions on emissions related maintenance of the die-
sel 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 B&W Diesel A/S.

MAN B&W Diesel A/S STX Engine Co.,Ltd. STX HI Co.,Ltd.

Teglholmsgade 41 MAN B&WChangwon,
80, Seongsan-dong, Diesel66-5,
A/S Sinchon-dong, Changwon,
A90023-0027

DK-2450 Copenhagen Kyungnam, Republic of Korea Kyungnam, Republic of Korea

Denmark
Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen
Technical Service Telex :16592 manbw dk
Technical Service
Denmark
Teleph.:+82 55 282 0590
Telefax:+45 33 85 10 30
Teleph.:+45 33 85 11 00 Teleph.:+82 55 278 9651
Telex :16592 manbw dk Telefax :+82 55 282 6907 Telefax :+82 55 278 2169
CVR No. 39 66 13 14
Part Sales
Telefax: +45 33 85 10 30
Teleph.:+82 55 280 0550~6
Telefax.:+82 55 282 1388
 Checking and Maintenance Schedule,
MAN B&W 2670 MC/MCC Engines

The Checking and Maintenance Schedules indi- Design modifications may necessitate a revision of
cate the intervals at which it is deemed appropri- the instructions, in which case the revised instruc-
ate to inspect the individual components of the tions and changed overhauling intervals, if any, will
engine and to carry out overhauls, if necessary, apply and supersede those originally issued (see
based on the engine condition or a criterion of e.g our Service Letters).
time.
In addition to the checking and overhauling inter-
The stated Regular checks or Service interval vals stated in this schedule, please note that the
are intended primarily as a guide, as differences periodical survey requirements of the classifica-
in the actual service conditions, the quality of the tion society may require additional checks and
fuel oil or lubricating oil, the treatment of cooling reference is made to be carried out. For further
water, etc., will decisively influence the actual information reference is made to the classification
service results, and thus the intervals between society.
necessary overhauling.

The procedures are divided into five categories:

Time-based condition checking marked with a C, under the heading Regular checks or Service
procedures 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 are marked with an O, under the heading Regular checks or
procedures Service interval. Under the heading Refer to (column P), a refer-
ence to additional information is stated.

This procedure number normally refers to one of the above condi-

tion checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.

Time-based overhauling also marked with an O, under the headings Regular checks or
procedures Service interval or Based on observations, are the procedures
where an actual basis for estimation is lacking. It is recommend-
ed, 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), in-

dicate that special service conditions may make checking or
overhauling necessary beyond the actual standard schedules
indicated.

(continued)

When referring to this page, please quote Maintenance Schedule A90050 Edition 0296 Page 1 of 7
 Checking and Maintenance Schedule,
2670 MC/MCC Engines MAN B&W

Initial checking procedures marked with a C, under the heading Check new/overhauled
parts after 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 after 500, 1000 and 1500 hours (column H), deal with ini-
tial adjustment that must be carried out on a new engine, or when
parts have been replaced.

After the three initial adjustments have been completed, adjust-

ments 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 (after 500, 1000 and
1500 hours of operation) on a new engine, or when chains
or chain wheels have been replaced.

Page 2 of 7 When referring to this page, please quote Maintenance Schedule A90050 Edition 0296
MAN B&W Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 9001

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to
Regular Checks Service interval (x 1000 hours of operation)
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

901 Cylinder Cover

1 Cylinder cover C* O * Check whenever exhaust valve
is removed
Indicator cock O

902 Piston with Rod and Stuffing box

1 Piston C,O O
Inspection through scavenge ports C V
2 Piston rod stuffing box C* O
* Check clearances without
dismantling segments
903 Cylinder Liner and Cylinder Lubrication
1 Cylinder liner O
Inspection through scavenge ports C
Measuring wear inside liner C
2 Cylinder lubricators C A V,M
Accumulators (Only for Alpha Lubricator) C O A

904 Crosshead with connecting rod

1 Crosshead bearing C C C,O V Bearings should only be
opened if bearing material
2 Crosshead C C C,O fragments fall out.
3 Reciprocating parts C C,O
4 Crankpin bearing C C C,O V
5 Connecting rod O

905 Crankshaft and Thrust Bearing

2 Main bearing C C C,O V Bearings should only be
opened if bearing material
3 Thrust bearing C C C,O
fragments fall out.
3 Guide bearing C C C,O
4 Journal bearing C C C,O V
5 Axial vibration damper O
Electronic axial vibration monitor (If applied) C
Mechanical checking C

When referring to this page, please quote Maintenance Schedule A90050 Edition 0296 Page 3 of 6
9001 Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W
V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced
A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to
Regular Checks Service interval (x 1000 hours of operation)
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

7 Tacho pickup C,O M

8 Angle encoder (Only for Alpha Lubricator) C,O M

906 Mechanical Control Gear

1 Chains C C R V New or overhauled chain to be
checked/retightened after 500,
2 Chain tightener C,A C,A A 1500 and 4000 hours
Chain wheels, spray nozzles and guide bars C C R
-3 Camshaft C C C,A
-4 Camshaft bearings C C,O
Camshaft coupling, fitted bolts C
-5 Moment compensator C C C,A
Governor O M
Functional check of overspeed device C M
Functional check of speed-setting system C M
(engine with bridge control system)

907 Starting Air System

-1 Starting air distributor C C A
-2 Starting air valve C,O

908 Exhaust Valve

-1 High-pressure pipe O
-2 Exhaust valve
Conventional hard-faced valve seats O
Nimonic / Dura spindle exhaust valves O See also MAN Diesel service
letter SL01-397.
-3 Exhaust valve actuator O
Actuator safety valve C,A
-4 Exhaust valve roller guide C* C’ C O * Only inspection through
camshaft covers
-5 Exhaust valve cam C* C* O
-7 Exhaust valve special running O

Page 4 of 6 When referring to this page, please quote Maintenance Schedule A90050 Edition 0296
MAN B&W Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 9001

V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced

A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to
Regular Checks Service interval (x 1000 hours of operation)
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

909 Fuel Oil System

Fuel oil water content C
-1 Fuel pump settings A,C V
-2 VIT system (If applied) A V
-3 Fuel pump cam A
-4 Fuel pump C O O
-5 Fuel pump top cover O
-6 Fuel pump barrel assembly R
-7 Fuel pump suction valve C,O
-8 Fuel pump puncture valve C,O
-9 Fuel pump shock absorber C O
-9 Fuel system shock absorber C O
-10 Lifting gear for roller guide C O
11 Fuel valve C,O
* HIP compound type nozzles
 Fuel nozzle R* R
only. Other types: 8000 hours
12 Spindle guide R R
13 Nonreturn valve O
* Only inspection through
14 Fuel oil highpressure pipes O
camshaft covers
-15 Fuel pump roller guide C* C* C O
16 Fuel pump special running O

910 Turbocharger System Check p and t

Check at every port inspection
1 Air cooler C O V
2 Nonreturn valve (Not for belt-driven aux.blower ) C O
3 Auxiliary blower O
4 Butterfly valves C O
5 Turbocharger turbine C* C C,O V,M
Turbocharger air filter C O

When referring to this page, please quote Maintenance Schedule A90050 Edition 0296 Page 5 of 6
9001 Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W
V : See Volume I “Operation” M : See maker’s instructions R : Parts to be replaced
A : Adjustment to be carried out O : Overhaul to be carried out B : Based on observations
C : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to
Regular Checks Service interval (x 1000 hours of operation)
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P Remarks

Protective grid before turbocharger C R V * Only if separate oil system

Turbocharger lubricating oil water content C* M * Check p
6 Water mist catcher C* C,O

911 Safety Equipment

1 Overpressure indicator valve C O
2 Relief valve C O
3 Scavenge air receiver safety valve C O
Functional test of alarm system for thrust
bearing and slow down /shut down system C C M
Checking and adjustment of pressure gauge C A M
Checking and adjustment of thermometers C A M
Checking and adjustment of thermostats C A M
Checking and adjustment of pressurestats C A M
Checking and adjustment of turning gear switch C A M

912 Assembly of Large Parts

2 Holdingdown and end chock bolts C C
3 Stay bolts C C
Top bracings C C
Diaphragm in crankcase oil outlet C R
System lubricating oil water content C M
System lubricating oil bottom tank O Empty and clean tank
Cooling water quality C A V,M
Crankcase C* * Check for loose nuts and
bearing material fragments

913 General Tools

1 Hydraulic tools C O M

Page 6 of 6 When referring to this page, please quote Maintenance Schedule A90050 Edition 0296
 General – Safety Precautions 900-2

Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.

SAFETY PRECAUTIONS

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
X Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors

The sketch gives the approximate location of the valves concerned:

When referring to this page, please quote Safety Precaution A90060 Edition 0002 Page 1 (1)
MAN B&W Diesel A/S
900-2 General - Safety Precautions
MAN B&W Diesel

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:

1. • Safety shoes.
• Hearing protection.
• Work gloves.
• Protective head wear, such as a baseball
cap with a hard protective liner.
• Safety goggles.
• Fall arrestor equipment.

A90060-0002C01
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.
2.
Use safety goggles when working with com-
pressed air, grinders, hydraulics and when there
is a risk of getting foreign objects in the eyes.

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.

3. This is especially needed when mount-

ing eyebolts and hanging tackles inside the
crankcase, and when working on the hydrau-
lic pump station on some ME engines.
A90060-0002C02

3.
A90060-0002C03

Page 2 (2) When referring to this page, please quote Safety Precaution A90060 Edition 0002