Professional Documents
Culture Documents
04.
Maintenance schedule
The actual operating conditions, and above all the quality of the fuel used, largely determine
the maintenance necessity for the engine. Because of the difficulty in anticipating the
various operating conditions that may be encountered in the field, the periods stated in the
schedule are for guidance only. However, do not exceed them during the warranty period.
If there are any indications that the maintenance procedure is required in advance of the
recommended time period, perform the suggested maintenance. Additionally, if inspection
or observation reveals that a part shows wear or use beyond the prescribed tolerances,
renew the part immediately.
See the instruction books of the turbocharger and the governor, separate instructions for
additional equipment and chapter 03 Start, Stop and Operation.
NOTE
Before performing any maintenance work, carefully read the sections Risk
reduction, Welding precautions and Hazardous substances in chapter 00.
Before starting any procedure, carefully read the corresponding instructions in this
manual.
During all maintenance work, observe the utmost cleanliness and order.
Before dismantling, check that all systems concerned have been drained or the pressure
has been released. After dismantling, immediately cover the holes for lubricating oil, fuel
oil, gas and air with tape, plugs, clean cloth or the like.
When exchanging a worn-out or damaged part provided with an identification mark
stating the cylinder number, mark the new part with the same number on the same spot.
Enter every exchange in the engine log and state the reason clearly.
CAUTION
Do not mark bearings as it may cause damage.
Always renew all gaskets, sealing rings and O-rings during maintenance work.
NOTE
Do not lubricate the O-rings in the cooling water system with oil-based
lubricants. Use soap or similar.
After reassembling, check that all screws and nuts have been tightened and, if
necessary, locked.
WARNING
When overhauling the engine, make absolutely sure that any automatic start and
the priming pump are disconnected. Also, make sure that the starting air shutoff valve located before the main starting valve is closed. Then drain the engine
starting air system to avoid engine damage or personal injury.
DBAC576117-
04-1
WARNING
When overhauling the engine, to avoid accidental turning of the crankshaft,
make absolutely sure that the generator breaker is secured and the gearbox is
not engaged. Accidental turning of the crankshaft may cause engine damage or
personal injury.
04.1
v3
The length of some maintenance intervals depends on the average operating load and the
characteristics of the used fuel.
Average operating load and fuel type
Average operating load
Fuel type
The fuel types HFO 1 and HFO 2 are defined in section 02.1.2.
04.2
Component
Procedure
Section
Automatic prelubrication
03.2
18.4
Crankshaft
Marine engine: If the engine has not been running, turn the crankshaft into a
new position.
03.1
04.3
v3
Procedure
Section
Start process
03.2
04-2
DBAC576117-
04.4
v9
Procedure
Section
Air coolers
15
03.5.1
19.2
Connecting rod
11.2.6
07.3
Crankshaft
07.3
Take readings.
Read and record (using for example form No. WV98V091) all temperatures and
pressures together with the associated engine load.
03.5.1
Governor, actuator
02.2.3
22.4
Fuel filter
18
02
03.5.1
17
Injection pipes
07.1
16.3
03.5.1
18.8
18.1
Main bearings
10.2.3
07.3
Multiduct
07.1
Running-in filter
Turbocharger
15
Continued on next page
DBAC576117-
04-3
Procedure
Section
Valve mechanism
12.5
06.1
04.5
v5
Procedure
Section
Turbocharger
Chapter 15
04.6
v8
Procedure
Section
Centrifugal filter
18.9.1
Air cooler(s)
Chapter 15
Control mechanism
22.2
Cooling water
19.6
02.3
Cylinder pressure
12.8
03.5.3
Injection pumps
16.2
Lubricating oil
Turbocharger
04-4
Chapter 15
DBAC576117-
04.7
v12
Procedure
Section
15
Flexible coupling
Geislinger (Oil filled)
Fuel filter
Valves
04.8
v12
Procedure
Section
Air cooler(s)
15.4
Automation
01.2
23.2
Electro-pneumatic
overspeed trip device
22.1
06.1
23.1
Flexible hoses
Governor
02.2.3
22.4
Injection valves
16.4
DBAC576117-
04-5
Procedure
Section
Turning device
02.2.5
03.10
04.9
v27
Procedure
Section
Air cooler(s)
15.4
Automation
23
Camshaft
14.1.1
03.1
02
10
15
19
Control mechanism
22.2
Crankshaft
11.1.1
11.1.2
06.2
Exhaust manifold
20
Flexible coupling
Geislinger (Oil filled)
Fuel system
17
Injectors
16.4
18.6
04-6
DBAC576117-
Procedure
Section
22.1
04.10
v7
Procedure
Automation
23
Check the wiring condition inside the cabinets and boxes.
Check for wear of insulation, loose terminals, loose wires and leakages.
Check for wear of cable insulation, breakages, loose cable glands, connectors,
holders and loose grounding shields.
Check for loose grounding straps and corrosion.
Check the sensors, actuators, solenoids etc. for leakages, physical damages. Also
check the signal/ measurement where applicable.
Check soft damper's condition if it is flattened, worn out or broken.
Check if the electrical displays/meters are dark or broken.
Check the electronic modules visually for damages, leakages or smoke residuals.
Rectify, improve or replace the equipment, if necessary
Flexible coupling
Centax
Wastegate
04.11
Section
18.8.1
18.1
15
v6
Procedure
Section
Flexible hoses
Fuel system
(Only V-engines)
17
22.4
06.2
HT water pump
19.7
19.7.1
06.2
Continued on next page
DBAC576117-
04-7
Procedure
Section
HT water thermostatic valve Clean and inspect the HT water thermostatic valve.
For externally-mounted thermostatic valves, see the supplier's operation and
maintenance manual.
Clean and check the thermostatic element, valve cone-casing and O-rings.
19.8.2
LT water pump
19.7
19.7.1
06.2
LT water thermostatic valve Clean and inspect the LT water thermostatic valve.
For externally-mounted thermostatic valves, see the supplier's operation and
maintenance manual.
Clean and check the thermostatic element, valve cone casing and O-rings.
19.8.1
18
Lubricating oil pump driving Inspect the lubricating oil pump driving gear.
gear
Replace parts, if necessary.
18
06.2
18
18
Turbocharger
ABB
04.12
v5
Procedure
Section
Electro-pneumatic
overspeed trip device
22.6
Injection pumps
16.2.3
16.2
04.13
v6
This overhaul interval depends on the fuel characteristics and the average load level
according to the table below.
04-8
DBAC576117-
HFO 2
12000
16000
HFO 1
16000
20000
DO
20000
24000
Component
Procedure
Section
Connecting rods
11.2.3
06.2
11.2
11.2
11.2.3
06.2
Cylinder heads
12.3
12.2
12.4
12.3.1
Cylinder liners
10.4.1
06.2
Pistons
11.2.3
11.2.3
06.2
11.2
03.9
Lubricating oil
Starting valves
DBAC576117-
21.3
04-9
04.14
v12
Procedure
Section
13.1
06.2
Flexible coupling
(Oil filled)
Governor drive
Governor
10.2.1
Turning device
02.2.4
03.10
Vibration damper
Viscous type
11.1
Vibration damper
Geislinger
11.1
04.15
22.4.1
06.2
v3
Overhaul interval
16 000
20 000
Component
Procedure
Section
Camshaft
10.3.1
06.2
Crankshaft
10.2.2
06.2
Valve mechanism
14.1.1
06.2
04-10
DBAC576117-
04.16
v16
Procedure
Section
Replace the drive electronics, such as coil drivers, fuel injection controls and 23
actuator controls.
At the latest, the electronics must be replaced every 10th year.
Replace vibration dampers (rubber elements).
Replace the rubber elements for components such as: the connection boxes,
control modules, connection rails and the main cabinet.
Replace the vibration dampers every 24000 operating hours or every 4 th
depending on whichever comes first.
07.3.1
Exhaust manifold
20.1
Flexible coupling
(Oil supply from engine)
21.1
21.2.1
04.17
v4
Procedure
Section
Automation
23
13.1
06.2
Crankshaft
06.2
Engine foundation
Flexible mounted
Flexible coupling
Turbocharger
DBAC576117-
15
04-11
04-12
DBAC576117-