Checking and Maintenance Schedules Ara. saw The Checking and Maintenance Schedules indi- cate the intervals at which it is deemed appropri- ate to inspect the individual components of the engine and to carry out overhauls, if necessary, based on the engine condition or on time criteria. The stated Normal hours of service should only be used as a guide, as differences in the actual service conditions, the quality of the fuel oil or tu- bricating oil, the treatment of cooling water, etc. will decisively influence the actual service re- sults, and thus the intervals between necessary 900-1 Design modifications may necessitate a revision of the instructions, in which case the revised in- structions and changed overhauling intervals, if any, will apply and supersede those originally is- sued (see e.g our Service Letters). In addition to the checking and overhauling inter- vals stated in this schedule, please note that the Periodical survey requirements of the classifica tion society may require additional checks and overhauls to be carried out. For further informa- tion please refer to the classification society. ‘overhauling. The procedures are divided into three categories: Condition checking procedures —_ marked under the heading Normal hours of service with aC, deal with the service condition of a number of engine compo- nents, and form the basis for estimating whether further over- hauling is necessary. In a number of cases the condition checking procedures refer to Volume | of the instruction book, in which more detailed descriptions and working procedures can be found. Condition-based overhauling procedures are those procedures which under the heading Normal hours of service are marked with an O, and opposite which, under the heading Overhaul to be based on procedure No. (column P), a procedure number is stated. This procedure number normally refers to one of the above con- dition checking procedures which form the basis of the overhaul. For this reason, the intervals stated are for guidance only. Time-based overhauling proce- dures also marked with an © under the headings Normal hours of service 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 inter- vals stated as a basis. Where a symbol O or C is indicated in Based on observations (column B), this is due to the fact that special service conditions may make checking or overhauling necessary beyond the actual standard schedules indicated. When referring to this page, please quote Maintenance Schedules A90050 Edition 0270 Page 1 (5) MAN B&W Diesel A/S(ae8\ Checking and Maintenance Schedules 900-1 Vz See Volume 1 “Operation” A: Adjustment to be carried out C: Check the condition M: See maker's instructions ©: Overhaul to be carried out Ri: Parts to be replaced H: Check new/overhauled parts after 500-1500 hours B: Based on observations P: Overhaul to be based on procedure No. or refer to Normal hours of service (1000) No. Procedure H | 2 4 Cylinder Cover 1000 hours and 2000 hours: Inspection through scavenge ports Axial Vibration Damper "Check inlet accumulator nitrogen pressure ** Check outlet accumulator nitrogen pressure When referring to this page, please quote Maintenance Schedules A90050 Edition 0270 MAN B&W Diesel A/S Page 2 (6)(aa0\ Checking and Maintenance Schedules 900-1 See Volume 1 "Operation” ‘Adjustment to be carried out Check the condition See maker's instructions Overhaul to be carried out Parts to be replaced pozors H: Check new/overhauled parts after 500-1500 hours B: Based on observations P: Overhaul to be based on procedure No. or refer to Normal hours of service (x1000) Procedure 16 | 32 | B Mechanical Control Gear Chain Tightener New or overhauled chain to be checked/ retightened after 500, 1500 and 4000 hours 907 Starting Air System Exhaust Valve Nimonic exhaust valves; check new valves after 6000 hours subsequently, overhaul at intervals of 16000 When referring to this page, please quote Maintenance Schedules AS00650 Edition 0270 MAN B&W Diesel A/S Page 3 (6)Checking and Maintenance Schedules 900-1 san aw 77 ea ia Opa Ti Greve pas oar S00 HG RO 1 Annet seared Bem nantes C: Check the condition P: Overhaul to be based on procedure No. or refer to te: Sue mat’t tte ©: oven cared ot fasta orepend sao aan No. Procedure H | 2 4 6 8 | 16 | 32/ B P 909 a a 3 “ 5 * Fuel Pump Roller Guide ‘Turbocharger System 2 -4 Butterfly Valves 8 Turbocharger Turbine -6 Water Mist Catcher 911 Safety Equipment Sia ace ee When referring to this page, please quote Maintenance Schedules A90050 Edition 0270 MAN B&W Diesel A/S Page 4 (65)(a3 Checking and Maintenance Schedules 900-1 ‘See Volume “Operation” ‘Adjustment to be carried out ‘Check the condition ‘See maker's instructions (Overhaul to be carried out Parts to be replaced poza>< 1H: Check new/overhauled parts after 500-1500 hours B: Based on observations P: Overhaul to be based on procedure No. or refer to ‘Normal hours of service (x1000) Procedure Checking and adjustment of thermostats Checking and adjustment of turning gear switch 912 Assembly of Large Parts -1 Holding Down and End Chock Bolts (Cast Iron) Stay Bolts General Tools Standard Tightening Torques Tightening Gauge Lubricating Procedures Checking and adjustment of pressure gauge When referring to this page, please quote Maintenance Schedules 90050 Edition 0270 MAN B&W Diesel A/S Page 5 (5)Exhaust Valve Panel I . \@te | Ik | KO aH O B41 lg)Plate Exhaust Valve Panel 90851-0187 (a5) an Item Description rem Item Description 016 Panel for tools 028 | Name plate 053 | Lifting tool, roller guide 065 Lifting tool, exhaust valve 077 Conical ring, pneumatic piston 089 | Pressure tester, safety valve 090 Gauge, exhaust valve spindle 112 Grinding tool, H. P. pipe 124 Tool, emergency opening of exhaust valve 136 | Bridge gauge, exhaust valve 148 | Tool for hydraulic piston 150 Gauge, exhaust valve bottom piece 161 Lifting tool, exhaust valve 173, Lifting tool, exhaust valve roller guide 185 Grinding ring, exhaust valve bottom piece 197 | Test tool, safety valve 207 Compression tool, fuel and exhaust actuator springs 244 | Extractor, safely valve seat Page 2 (2) When referring to this page, please quote Plate P90851 Edition 0187 MAN B&W Diesel A/SExhaust Valve Actuator san Checking 1. Non-return Valve The non-return valve A is built into the oil inlet pipe to the actuator. To check the valve, dismantle and clean it and connect a supply of working air (7 bar) to the outlet side of the vaive (the side fac- ing the actuator). If the air flow can be felt at the inlet side of the valve, the valve must be overhauled. 2. Safety Valve: Before the safety valve can be checked it must be dismounted from the exhaust valve actuator. See Procedure 908-3.3. 3. Clean all parts of the safety valve, and mount the valve in the pressure testing tool. Lubricate the thread of the cap nut with copper grease. Mount the guide screw and tighten the cap nut as stated in Data. 4. Connect the pressure testing tool to the fuel valve test rig. + Increase the oil pressure slowly (during 5-10 sec.) until the valve opens. Note down the opening pressure. + Release the pressure to 0 bar. + Compare the result with Data. If neces- sary, adjust the opening pressure. See Procedure 908-3.3. Note! The pressure test should only be carried out one time. A second attempt will nor- mally show a lower opening pressure. If a second test is necessary, the valve must be disassembled to release the pres- sure, otherwise wait minimum 15 minutes before next test. 908-3.1 (raonas taboe When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/S Page 1)(aan Exhaust Valve Actuator Baw Dismantling 5. Mount the spacer rings and the hydraulic jacks over the nuts. Pump up the hydraulic jacks to the dismantling pressure, as spec- ified in Data. Loosen and remove the nuts. For use of hydraulic tools, see also Proce- dure 913-1. 6. Turn the spindle of the spring compres: tool clockwise to release the actuator spring. 908-3.2 Note! When releasing the spring, the actuator housing will move upwards. Remove the spring compression tool. 7. Fit eye bolts in the lifting holes of the actu- ator housing, and hook on tackles and a lift- ing wire rope. Using the engine room crane, lift away the actuator housing. Remove the spring. 8. Remove the locking plate, and turn the ton 90° to release it from the bayonet Remove the piston from the roller guide. Overhaul the actuator housing and the pis- ton as required. See Procedure 908-3.3. When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/S908-3.3 7] aoe SE Exhaust Valve Actuator Overhaul sen Clean the piston in kerosene and wipe dry with a clean piece of cloth. Take off the piston rings and check them for wear. If the ring thickness has worn down to the minimum (see Data), discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards when mounting. Inspect the sliding surfaces of the piston to ensure that there are no scratch-marks or seizure marks. Unscrew the guide screw from the cylinder. Unscrew the cap nut and remove the parts of the safety valve. 2 g 3 When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/SExhaust Valve Actuator 908-3.3 Overhaul 4. Mount the extraction tool in top of the safety | 4 valve seat with two screws. Pull up the seat by means of the hammer bushing. Clean all parts of the safety valve, and check the opening pressure. See Procedure 908-3. 1. 5. Ifitis necessary to adjust the opening pres- sure of the valve, unscrew the cap for the pilot valve with a spanner and a brass man- dret with a good fit to the lower hole, see the figure. 6. Add or remove shims below the pilot spring \ as necessary. Tighten the pilot cap to the specified torque, see Data. After adjustment, check the opening pres- sure of the safety valve with the pressure testing tool. See Procedure 908-3. 1. } IS \ & LLL Weoousy WEE When referring to this page, please quote Procedure M90803 Edition 0229 Page 5 (9) MAN B&W Diesel A/S908-3.3 Exhaust Valve Actuator Overhaul Baw 7. Tilt the actuator to a horizontal position. Clean the liner inside the oil cylinder, and inspect the bores for deposits. 8. Check the liner inside the oil cylinder for possible scores and measure it for wear. 9. Ifthe liner is seized or has worn down to the measurement stated in Data, the liner must be dismantled and replaced. Remove the screws of the liner. Screw two M12x100 mm screws into the dismantling holes of the liner to pull the lin- er clear of the oil cylinder. Note! Make sure to turn the two screws evenly, turn each screw one half revolution at a time, Mount a new liner in the oil cylinder. Mount and tighten the screws to the torque stated in Data. Page 6 (®) When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/S.(een Exhaust Valve Actuator Overhaul 10. Return the oil cylinder to a vertical position. Clean all the parts of the safety valve. Mount the parts in the bore at the top of the actuator. Check that the hole in the seat is correctly positioned for the guide screw. Mount the guide screw fitted with a new sealing disc. Mount the cap nut over the safety valve parts, and tighten to the torque stated in Data. 10. When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/S. Page 7 (9)908-3.4 Exhaust Valve Actuator Mounting 1. Mount the actuator piston in the roller guide and turn 90° to lock it in the bayonet joint. Mount the locking plate and tighten as stat- ed in Data, Lubricate the piston with plenty of camshaft lubricating oil. 2. Mount the spring on the roller guide. Care- fully lower the actuator housing on to the piston, taking care not to damage the piston rings or the threads of the studs. 3. Screw the extension stud of the spring com- pression tool into the top of the actuator piston and mount the rest of the spring compression tool on the actuator housing. TORT ) [rae ear Tae BA Page 8 (9) When referring to this page, please quote Procedure M90803 Edition 0229 MAN B&W Diesel A/S.(Gen) Exhaust Valve Actuator 908-3.4 Baw Mounting 4. Turn the spindle of the spring compression tool anti-clockwise to compress the actua- tor spring and to lower the actuator housing on to the roller guide bushing. For conven- ience, a pneumatic impact spanner may be used for turning the spindle. 5. Screw the nuts on to the studs. Mount the spacer rings and the hydraulic jacks over the nuts. Pump up the jacks to the tighten- ing pressure, as specified in Data. Tighten the nuts, and remove the hydraulic jacks and the spacer rings. For use of hydraulic tools, see also Proce- dure 913-1. 6. Remove the spring compression tool. 7. Mount the oil inlet pipes and the drain pipe from the exhaust valve. Mount the hydraulic high pressure pipe and the sealing disc fitted with new O-rings. See Procedure 908-1.4. WSBT When referring to this page, please quote Procedure M90803 Euition 0229 Page 9 (9) MAN B&W Diesel A/S