32-200343-09 OTL Lek oe edited Automatic prelubrication | Check operation 982 ‘Crankshatt Marine engine: In a stopped engine, turn the crankshaft 1 into a new position. Start process Test start (if the engine on stand-by). Air coolers ‘Check draining of air coolers 18.5 Check that the draining pipe is open, check if any leakage. | 03.4.1 Cooling water system | Check water level in cooling system. 19.1.4 Check the water level in the expansion tank(s) and/or the sfatic pressure in the engine cooling circuits. ‘Connecting rod Check tightening of the connecting rod screws 1.3.4 Check the tightening of the connecting rod screws after the | 07.3. first 50 operating hours on a new engine and, after overhaul, those screws that have been opened. Note! Pump to stated pressure. Tighten if possible. Do not loosen! Fuel and lub. oll fiters Check pressure drop indicators 08.4.1 Change filter cartridges if high pressure drop is indicated. Ng eZ ‘Gauges ond indicators | Take readings a Read and record (using eg. form No. WV98V091) all temperature and pressure Gauges, cnd at the same time the load of the engine, ‘Govemnor, actuator Check oil level in governor 22.4 Check oil level, and look for leaks 22.4.1 Injection and fuel system | Check leak fuel quantity 03.4.1 Check the amount of leak fuel rom the injection pumps and nozzles. | 17.1 Lubricating oil sump, Check oil level in sump ao Check cil level by means of dip stick, compensate for 02.2 consumption. Main bearings Check tightening of main bearing screws 10.2.3 Check the tightening of main bearing screws after the first 50 | 07.3 Operating hours on a new engine and, affer overhaul, those screws that have been opened Note! Pump to stated pressure. Tighten if possible. Do not loosen! Running:in titer Remove the running-in filter After the first 50 operating hours, remove the running-in filter ‘and pump up the hyairaulic jack, Turbocharger Water cleaning of compressor 15.3.3 Clean the compressor by injecting water. Turbocharger Check turbocharger oil level 182 VIR-chargers Check oil level, and look for leaks. Change oll after the fist | 02.2.5 100 service hours in both oil spaces. Continue 04-3UTIL editors cd Rye eke Valve mechanism Check valve clearances Check the valve clearances after 50 hours’ running in new and overhauled engines, 12.2.4 06.1 Turbocharger Water cleaning of turbine Clean the turbine by injecting water, 15.3.2 ‘Centrifugal filter Clean centrifugal filter(s) 18.8.2 Clean more often if necessary. Remember to open the valve before the fitter after cleaning. Control mechanism Maintenance of control mechanism 22.2 Check for tree movement, clean and lubricate. Cooling water Check water quality eo Check content of additives. 02.3 Cylinder pressure Check cylinder pressure 12.2.3 Record firing pressures of all cylinders. 03.4.3 Lubricating olf Take oil sample 02.2.3 In. anew installation of after change to use of a new lub- icating oll brand, take samples for analyzing Turbocharger Change lubricating oil in turbocharger(s) 02.2.5 VIR-chargers Lubricating oll change interval according to lubricating oil in use, See section 02.2.5, Take care that the furbine oil is not mixed with the engine 18.2 lubricating oil, Air filter (on-built) Clean turbocharger air filter 15.2 Remove the filter(s) and clean according to instructions of the manufacturer (more offen, if necessary). Automation Functional check of automation 23.1.4 Check function of the sensors for the alarm system and o12 dutomatic stop devices Electrical fuel feed ump ~— Regrease el. fuel feed pump V5 Regrease the pump under running condition, El. lubricating ollpump —_ Regrease prelubricating pump 189 Regrease the pump under running condition, Flexible coupling Oil change/check of the coupling Geislinger (Oil filed) At frst interval, change oil of the coupling Following (1000h) intervals, check oll level. See manufacturers instructions Fuel filter Replace fuel oil filter cartridges 17.62 Clean the wire gauze and filter housing. Replace the filter m4 Carttidges. (The cartridges are to be replaced when the 72 pressure difference indicator shows too high pressure drop). ‘Continue 04-432-200343-09 OTL Lek oe edited Lubricating oll filter Replace lub. oil filter cartridges 18.72 Drain the filter housings. Clean the wire gauze and filter 18.2 housing. Replace the fliter cartridges. (The cartridges are to be replaced when the pressure difference indicator shows too high pressure drop.) Valves Check valve condition 12.2.4 Check that the inlet and exhaust valves move freely in their 06.1 guides, This should preferably be done when the engine has Been out of operation for a couple of hours. Check valve clearances. Check cylinder tightness (valves, piston rings) with a 12.8 pneumatic test. Air cooler(s) Check water side of charge air cooler(s) 18.5 The first time check and possible cleaning of the waterside. If in good condition and deposits insignificant: future intervals 4000 running hours. Injection valves Inspect injection valves 16.44 Test the opening pressure. Dismantle and clean nozzles. Check the effective needic lift, Check the springs. Replace the O-tings. Check the nozzle condition in a test pump. Replace the nozzles if necessary. Lubricating oil ‘Change lubricating oil 18.2 Change oil in a new installation (wet sump installations) Take | 02.2 samples for analyzing. If the analyzing values are positive and if the oll supplier or engine manufacturer so recommend, the intervals between changes can be prolonged in steps of 500 ‘operating hours. in dry sump installations the oll change intervals may be in the order of 8000 hours or more. Clean ail oll spaces when changing lub. oll Measuring instruments Check gauges 23.1.4.1 Shock pressure and temperature gauges, Replace faulty ‘Govemor ‘Change oil in governor 02.2.4 Change lubricating oi. 22.4.1 Mec, overspeed trip device | Check function of mechanical overspeed trip device | 22.5.2 Check function and tripping speed 06.1 pared overspeed trip, | Check el.-pneumatic overspeed trip device 22.6.3 Check function and tipping speed 06.1 04-5Maintenance Schedule Rye eke Air cooler(s) Clean the charge air cooler(s) 186 Clean and pressure test. Look carefully for corrosion. ‘Automation Check connectors and cables 23.3 Check mounting and connections. Apply contact lubricant to Contact surfaces. check lighiness of connections, Check Eondition of cabies, wires and cable glands, Replace damaged connectors and cables. Camshatt Inspect contact faces of camshaft 142 Check the contact faces of the cams and tappetrolies. Check | 03.1 that the roles rotate. Rotate the engine with the ‘uming gear. Cooling water spaces Inspect jacket water spaces on engine with cooled | 152 turbocharger Inspect turbocharger cooling water ducts for possible deposits it the deposits are Imm or thicker, clean and Inspect | 19.1.2 the water side of one cylinder ner through the plugin the | 02.3 engine block. If the deposits are thicker than 1 mm, clean all | 10.5 liners and engine block water space. Improve the cooling water treatment. Inspect jacket water spaces on engine with 182 uncooled turbocharger Inspect the water side of one cylinder through the plug in the | 19.2 engine block. If the deposits are thicker than I mm, clean all | 19.1.2 liners and engine block water space, Improve the cooling | 02:3 water treatment. 10.5 ‘Control mechanism Check control mechanism 22.2 Check for wear in all connecting links between the governor and ail injection pumps. ‘Crankshaft ‘Check crankshaft alignment. W.22 Check alignment, use form No. WV98V036. Alignment check is performed on a warm engine. Crankshaft Check thrust bearing clearance 123 Check axial clearance 06.2 Exhaust manifold Check for leaks ce Check for leaks once a year Replace paris if necessary. Flexible coupling Oil change of the coupling Geislinger (Oil filled) Change oil of the coupling. See manufacturers instructions Fuel system Check and adjustment of fuel system V7. Check and adjustment of fuel system once a year, Injection valves Inspect injection valves 16.4.4 Test the opening pressure, Dismantle and clean nozzles Check the effective needie lift. Check the springs. Replace the O-tings. Check the nozzle condition In a test pump. HFO: Recommendation: Replace the nozzle by new ones on 6000 h at the latest. DO (LFO): Recommendation: Replace the nozzle by new ones on 8000 h at the latest Continue32-200343-09 OTL Lek oe edited Lube oll coolers Clean the lube oil cooler 18.5 If the lube oil temperature before the engine is within normal | 19.2 operating values (Section 01.1), the interval can be prolonged, Unnecessary opening of the plate cooler should be avoided. Clean the lube oil cooler before the alarm limit is reached. Examine carefully for corrosion. Starting fuel limiter Check starting fuel limiter 22.7 Check the adjustment and function. Balancing shaft gear Inspect balancing shaft gear WAZ 4R32 Replace parts if necessary. Governor diving gear Inspect governor driving gear 242 Replace pars if necessary. 06.2 Flexible coupling Flexible rubber coupling Check the flexible coupling Check flexible rubber elements visually ace. to makers recommendations. Dismantle if necessary. HT-water pump Inspect HT-water pump 19.3.1 Dismantle and check. Replace worn parts. 19.3.2 HT-water pump driving gear | Inspect HT-water pump driving gear 19.3.1 Replace parts if necessary. 06.2 HT-water thermostatic valve Clean and inspect HT-water thermostatic valve 19.1 Clean and check the thermostatic element, valve cone-cas- ing and sealings. U-water pump Inspect LT-water pump 19.3.7 Dismantle and check. Replace worn parts. 19.3.2 Ut-water pump driving gear] Inspect LT-water pump driving gear 19.3.7 Replace parts if necessary. 06.2 U-water thermostatic valve | Clean and inspect LT-water thermostatic valve 19a. Clean and check the thermostatic element, valve cone-cas-_ 19.4.2 ing, indicator pin and sealings. Lube oil pump Inspect the lube oil pump. eis Replace parts if necessary. Lube oll pump diving gear | Inspect lube oil pump driving gear 18.3.4 Replace parts if necessary. 06.2 Ollthermostatic vaive | Clean and inspect oil thermostatic valve 18.6 Clean and check the thermostatic element, valve cone-cas- ing and sealings Napier Na-chargers Turbocharger Replace turbocharger bearings 182 ViR-chargers See manufacturers instructions. Turbocharger Inspect turbocharger bearings 15.2 Check and change if necessary. See manufacturers instructions Turbocharger ABB TPL-chargers Inspect turbocharger bearings 15.2 Check and change if necessary. See manufacturers instructions, 04-7UTIL editors cd Rye eke HFO 2 12 000 16 000 HFO 1 16 000 20 000 DO 20 000 24 000 NG 20.000 24.000 ‘Connecting rods Replace big end bearing 11.3.3 Replace big end bearing. Inspect mating surface serrations. | 06.2 Measure the big end bore, use form No, 3211V016 or form No, 3211V012 (LN-engines) Connecting reds Replace connecting rod screws (not three-piece design) Replace connecting rod screws by new ones on 24 000 h at 11.3.3 the latest. Connecting rods Replace connecting rod screws (ihtee-piece design) Replace connecting rod screws by new ones at every second | 11.3.3 ‘overhaul when doing piston overhauls at 12 - 16 000 h intervals and at every overhaul when doing piston overhauls cat longer intervals than 16 000 h. ‘Connecting rods Replace connecting rod shims (three-piece design) Replace connecting rod shims by new ones at every second | 11.3.3 ‘overhaul when doing piston overhauls at 12 - 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h ‘Connecting rods Inspect the small end bearings Inspect the small end bearings. Replace if necessary. uss ‘Cylinder heads Overhaul of cylinder head 12.2.3 Dismantle and clean the underside, inlet and exhaust valves 12.2 and ports. Inspect cooling spaces and clean, if necessary. 12:3 Grind the valves. Inspect the valve rotators. Check rocker 14.1.3 ams. Replace the O-rings in the valve guides. Replace the O-rings at bottom of cylinder head screws at every overhaul. Cylinder iners Inspect the cylinder liners 10.8.1 Measure the bore using form No. 3210V014 or form 06.2 No. 3210V020 (LN-engines), replace liner it wear limits are exceeded. Hone the liners. Renew the anti-polishing ring ‘Cylinder liners Inspect cylinder liner water side 19.2 Pull one cylinder liner, on V-engines one per cylinder bank. If | 10.5 the depostts are thicker than I'mm, clean all iners and the engine block water space. Replace the O-rings in the bottom part by new ones at every overhaul. Pistons Inspect the pistons tn Composite pistons must be dismantled for inspection of mating surfaces between piston skirt and piston crown, Inspect and clean oil spaces. Continue 04-832-200343-09 OTL Lek oe edited Piston, piston rings Inspect pistons and piston rings Pull, inspect and clean. Check the height of the ring grooves, Use form No. 3211V016 oF form No. 3211V021 (LN-engines). Check the retainer tings of the gudgeon pins. Replace complete set of piston rings. Note the running-in programme. Starting valves Check starting valves Check starting valves in cylinder head.Replace parts if necessary. Camshatt driving gear | Inspect intermediate gears 13.1 Replace parts if necessary. 06.2 Flexible coupling Check the flexible coupling (Ol filled) Dismantle and check flexible coupling according to manufacturers instructions Fuel feed pump General overhaul of fuel feed pump 75 Inspect pump and replace gaskets. Replace worn parts. Governor dive ‘Check govemor drive bearing 242 Check govemor driving shaft bearing clearance in situ, 06.2 Governor General overhaul of the governor Can be sent to engine manufacturer for overhaul. Booster servomotor General overhaul of the booster servomotor for governor Replace wom parts. See manufacturers instructions. Turing device ‘Change oil in tuning device 02.2.6 Regrease the drive shat 03.9 Vibration damper Viscous type Take oll sample from vibration damper Take oil sample for analyzing. 121 Vibration damper Check vibration damper 121 for main bearing caps Geisinger Dismantle and check vibration damper every 32000 hours. = 16.000 20 000 Camshaft Inspect camshaft bearings 10.4.1 Replace if necessary, 06.2 Valve mechanism Check valve mechanism parts 14.1.3 Check tappets. 06.2 ‘Crankshaft Inspect main bearings 10.2.2 One main bearing to be inspected, if in bad condition, 06.2 ‘change and check/change alll main bearings. Note the type of bearing in use and do the inspection accordingly. Hydraulic jack ‘Check function 10.2.1 Change O-tings in the hydraulic jaick if they are leaking when lifting the main bearing cap. 04-9UTIL editors cd Rye eke HFO 2 16 000 HFO 1 16 000 DO 24 000 NG 24 000 Injection pumps ‘Overhaul of injection pumps 16.2.4 Clean and inspect injection pumps. replace worn parts. Replace the erosion plugs. Balancing shatt Inspect balancing shaft bearing Tad AR32 Take one bush out for inspection. If in bad condition check the other too. Replace if necessary. Engine fastening bolls.” Check tightening of engine fastening bolts 073 Replace if necessary. Exhaust manifold Check expansion bellows 20.2 Replace it necessary. Flexible coupling Check the flexible coupling (Ol supply from engine) _Dismantle and check tlexible coupling according to manufacturers instructions Main starting valve General overhaul of main starting valve 212 Replace worn parts. Mec. overspeed tip device General overhaul of mechanical overspeed trip device] 22.5.4 Check function and tripping speed. 22.5.2 Starting air distributor General overhaul of starting air ibutor 21.3.2 Replace worn parts. Turbocharger Inspect turbocharger bearings 182 ABB TPL-chargers ‘Check and change if necessary. See manufacturers instructions, 04-1032-200343-09 OTL Lek oe edited Balancing shaft gear Replace bearing bushes 11.43 4R32 Replace parts. ‘Camshatt driving gear | Replace intermediate gear bearings 13.1 Replace parts 06.2 Crankshaft Inspect crankshaft Inspect the crankshaft for wear. 06.2 Engine foundation Check flexible elements of engine foundation Flexible mounted Replace if necessary. Flexible coupling Check the flexible coupling Dismantle and check flexible coupling according to manufacturers instructions. Replace spring packs/inner star if necessary. Turbocharger Replace rotor 15.2 Lifetime dependent of operating conditions. See manufacturers instructions 04-11