cus303e engine mounted sealing flaps

34
Action Code: Immediately Diesel Customer Information No. 303 MAN Diesel & Turbo – a member of the MAN Group MAN Diesel & Turbo SE Head office (& postal address) Stadtbachstraße 1 86153 Augsburg Germany Phone: +49 (0) 821 322 0 Fax: +49 (0) 821 322 3382 [email protected] www.mandieselturbo.com PrimeServ After Sales Augsburg Stadtbachstraße 1 86153 Augsburg Germany Phone: +49 (0) 821 322 3509 Fax: +49 (0) 821 322 1530 [email protected] PrimeServ After Sales Technical Stadtbachstraße 1 86153 Augsburg Germany Phone: +49 (0) 821 322 1499 (24-h-hotline) Fax: +49 (0) 821 322 3838 [email protected] PrimeServ After Sales Commercial Stadtbachstraße 1 86153 Augsburg Germany Phone: +49 (0) 821 322 1799 (24-h-hotline) Fax: +49 (0) 821 322 3574 [email protected] Engine mounted sealing flaps DCI / 303 - May 2011 Concerns MAN Diesel & Turbo four-stroke engines: 28/33D, 32/40, 32/44CR, 40/54, 48/60B, 48/60CR, 51/60DF, L58/64 Summary Addition to maintenance schedule. Filing Advice Assembly group / work card 280, 289 General information The basis for the reliable operation of technical machinery is the careful execution of the specified maintenance work. This also extends to the flaps and valves which are fitted to the Diesel engines. Our diesel engines feature a number of different air pipes, which are controlled by sealing flaps. These air pipes can be charge air blow by, charge air blow off and waste gate. The efficiency of the engine and the operational performance of the turbocharger are improved by opening the different flaps under different conditions. Background Due to an increased number of requests regarding information for the maintenance of engine mounted flaps, we would like to take this opportunity to address this matter. We include the flaps in the general maintenance schedule of the engine. Advice The inspection interval is recommended every 6,000 operating hours at the latest or after one year.

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Page 1: Cus303E Engine mounted sealing flaps

Action Code:

Immediately

Diesel Customer Information No. 303

MAN Diesel & Turbo – a member of the MAN Group

MAN Diesel & Turbo SE

Head offi ce (& postal address)

Stadtbachstraße 1

86153 Augsburg

Germany

Phone: +49 (0) 821 322 0

Fax: +49 (0) 821 322 3382

[email protected]

www.mandieselturbo.com

PrimeServ

After Sales Augsburg

Stadtbachstraße 1

86153 Augsburg

Germany

Phone: +49 (0) 821 322 3509

Fax: +49 (0) 821 322 1530

[email protected]

PrimeServ

After Sales Technical

Stadtbachstraße 1

86153 Augsburg

Germany

Phone: +49 (0) 821 322 1499 (24-h-hotline)

Fax: +49 (0) 821 322 3838

[email protected]

PrimeServ

After Sales Commercial

Stadtbachstraße 1

86153 Augsburg

Germany

Phone: +49 (0) 821 322 1799 (24-h-hotline)

Fax: +49 (0) 821 322 3574

[email protected]

Engine mountedsealing fl aps

DCI / 303 - May 2011

Concerns

MAN Diesel & Turbo four-stroke

engines:

28/33D, 32/40, 32/44CR, 40/54,

48/60B, 48/60CR, 51/60DF, L58/64

Summary

Addition to maintenance schedule.

Filing Advice

Assembly group / work card 280, 289

General information

The basis for the reliable operation of technical machinery

is the careful execution of the specifi ed maintenance work.

This also extends to the fl aps and valves which are fi tted

to the Diesel engines.

Our diesel engines feature a number of different air pipes,

which are controlled by sealing fl aps. These air pipes can

be charge air blow by, charge air blow off and waste gate.

The effi ciency of the engine and the operational

performance of the turbocharger are improved by

opening the different fl aps under different conditions.

Background

Due to an increased number of requests regarding

information for the maintenance of engine mounted fl aps,

we would like to take this opportunity to address this

matter. We include the fl aps in the general maintenance

schedule of the engine.

Advice

The inspection interval is recommended every 6,000

operating hours at the latest or after one year.

Page 2: Cus303E Engine mounted sealing flaps

The scope of work includes the removal and inspection of the fl ap/s including crack detection on all

moveable inner parts.

If provided the inspection should also include the protection screen.

Contact

Should you have any queries, our Technical Service will be pleased to be of assistance:

MAN Diesel & Turbo SE

86224 Augsburg

Tel.: +49 (0) 821 322-3208

Fax: +49 (0) 821 322-3838

E-mail: [email protected]

Robert Glauber

Senior Vice President

After Sales

Jörn Holst

Senior Manager

After Sales Technical

Please forward this information to your technical operational personnel and remember to inform us of the current operating hours of your MAN Diesel & Turbo engines.

DCI / No. 303 - May 2011

Diesel Customer Information »Engine mounted sealing fl aps« - Page 2 of 2

Page 3: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given20

11-0

4-05

- d

e

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-02

32/4

0

MAN Diesel & Turbo 4.7.1

6628 4.7.1-02 EN 1 (4)

Page 4: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine 4

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-02

32/4

0

2011

-04-

05 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6628 4.7.1-02 EN

Page 5: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

05 -

de

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-02

32/4

0

MAN Diesel & Turbo 4.7.1

6628 4.7.1-02 EN 3 (4)

Page 6: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-02

32/4

0

2011

-04-

05 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6628 4.7.1-02 EN

Page 7: Cus303E Engine mounted sealing flaps

Maintenance schedule(systems - biofuel operation)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.20 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

05 -

de

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-03

32/4

0

MAN Diesel & Turbo 4.7.1

6628 4.7.1-03 EN 1 (4)

Page 8: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine 4

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-03

32/4

0

2011

-04-

05 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6628 4.7.1-03 EN

Page 9: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

05 -

de

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-03

32/4

0

MAN Diesel & Turbo 4.7.1

6628 4.7.1-03 EN 3 (4)

Page 10: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

28 4

.7.1

-03

32/4

0

2011

-04-

05 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6628 4.7.1-03 EN

Page 11: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

302.01 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e66

40 4

.7.1

-01

L58/

64

MAN Diesel & Turbo 4.7.1

6640 4.7.1-01 EN 1 (4)

Page 12: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit 1 1 1 1 1 1 1 1 1 1 1

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

40 4

.7.1

-01

L58/

64

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6640 4.7.1-01 EN

Page 13: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe 1 1 1 1 1 1 1 1 1 1 1

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e66

40 4

.7.1

-01

L58/

64

MAN Diesel & Turbo 4.7.1

6640 4.7.1-01 EN 3 (4)

Page 14: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e66

40 4

.7.1

-01

L58/

64

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6640 4.7.1-01 EN

Page 15: Cus303E Engine mounted sealing flaps

Maintenance schedule

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.15 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-01

48/6

0B

MAN Diesel & Turbo 4.7.1

6706 4.7.1-01 EN 1 (4)

Page 16: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10B

1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10B

1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-01

48/6

0B

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6706 4.7.1-01 EN

Page 17: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

A 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-01

48/6

0B

MAN Diesel & Turbo 4.7.1

6706 4.7.1-01 EN 3 (4)

Page 18: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-01

48/6

0B

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6706 4.7.1-01 EN

Page 19: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.15 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. 2 X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine 2 X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

A 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-02

48/6

0B

MAN Diesel & Turbo 4.7.1

6706 4.7.1-02 EN 1 (4)

Page 20: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine 2 X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-02

48/6

0B

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6706 4.7.1-02 EN

Page 21: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

280.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

289.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine 2 X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-02

48/6

0B

MAN Diesel & Turbo 4.7.1

6706 4.7.1-02 EN 3 (4)

Page 22: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine 2 X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine 2 X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

06 4

.7.1

-02

48/6

0B

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6706 4.7.1-02 EN

Page 23: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Check/clean the leakage container ofthe high pressure, fracture and long-term leakage

1 0.50 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 0 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

A 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

01 -

de

Mai

nten

ance

sch

edul

e67

27 4

.7.1

-02

48/6

0CR

MAN Diesel & Turbo 4.7.1

6727 4.7.1-02 EN 1 (4)

Page 24: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 cooling water: Check the corrosionprotection - refer to 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit 1 1 1 1 1 1 1 1 1 1 1

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

27 4

.7.1

-02

48/6

0CR

2011

-04-

01 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6727 4.7.1-02 EN

Page 25: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

280.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

289.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe 1 1 1 1 1 1 1 1 1 1 1

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Accumulator pack for interruption-freepower supply of the Common Railcontrol system: Check charge status

A 1 0.50 Engine 4

075 Accumulator pack for interruption-freepower supply of the Common Railcontrol system: replace

A 1 0.50 Engine X

076 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

077 Check measuring system for exhaustgas temperatures

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

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.7.1

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6727 4.7.1-02 EN 3 (4)

Page 26: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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2011

-04-

01 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6727 4.7.1-02 EN

Page 27: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

06 -

de

Mai

nten

ance

sch

edul

e67

30 4

.7.1

-02

32/4

4CR

4.7.1

6730 4.7.1-02 EN 1 (4)

Page 28: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check the nozzle cooling water return(for unhindered flow and eventualtraces of fuel - when using heavy fuel)

A 1 0.10 Engine 4

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 1 1 1 1 1 1 1 1 1 1 1

036 cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01 2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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ance

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edul

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.7.1

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4CR

2011

-04-

06 -

de

4.7.1

2 (4) 6730 4.7.1-02 EN

Page 29: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

054 In case available: <br/> Charge airbypass/blow-off device: Check systemcomponents for leakages (visually).Check control and monitoring elementsfor proper function

280.02 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off valves on engine: Dismountand check for cracks. Every 6000operational hours or once a year

280.02000.34

1 2 Engine 4

Exhaust gas system

062 In case available: <br/> Exhaust gasblow-off device: Check systemcomponents for leakages (visually).Check control and monitoring elementsfor proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off valves on engine: Dismountand check for cracks. Every 6000operational hours or once a year

289.02000.34

1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Batteries in the control cabinet: replace A 1 0.50 Engine X

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theelastic elements’ settling value

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

06 -

de

Mai

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30 4

.7.1

-02

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4CR

4.7.1

6730 4.7.1-02 EN 3 (4)

Page 30: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

Mai

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ance

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.7.1

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4CR

2011

-04-

06 -

de

4.7.1

4 (4) 6730 4.7.1-02 EN

Page 31: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system/pilot oil system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

007 Clean main fuel filter and replace pilotoil cartridge (dependent upondifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Fuel delivery pump and pilot oil pump B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

009 Clean pilot oil fuel cooler Unit 1 1 1 1 1 1 1 1 1 1 1

010 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Gas system

500 Check gas pipe and gas control routefor tightness (visually)

230.01 1 0.20 Engine X

501 Check the shut-off valves for leakage A 1 0.20 Engine 1 1 1 1 1 1 1 1 1 1 1

502 Clean gas filter, replace if necessary B 1 1 Filter 1 1 1 1 1 1 1 1 1 1 1

503 Check gas pressure regulator andreplace diaphragm if necessary

B 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. 2 X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine 2 X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

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ance

sch

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e67

36 4

.7.1

-01

51/6

0DF

MAN Diesel & Turbo 4.7.1

6736 4.7.1-01 EN 1 (4)

Page 32: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine 2 X

035 Check cooling channels, chemicallyclean the system (cylinder cooling).Possibly have cleaning carried out by aspecialist company

000.08 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

Mai

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ance

sch

edul

e67

36 4

.7.1

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2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6736 4.7.1-01 EN

Page 33: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

054 Compressor by-pass: Check controland monitoring elements for properfunction

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine 2 X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine 2 X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

de

Mai

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.7.1

-01

51/6

0DF

MAN Diesel & Turbo 4.7.1

6736 4.7.1-01 EN 3 (4)

Page 34: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine 2 X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

Mai

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ance

sch

edul

e67

36 4

.7.1

-01

51/6

0DF

2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6736 4.7.1-01 EN

Page 35: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Check/clean the leakage container ofthe high pressure, fracture and long-term leakage

1 0.50 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 0 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

A 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

01 -

de

Mai

nten

ance

sch

edul

e67

27 4

.7.1

-02

48/6

0CR

MAN Diesel & Turbo 4.7.1

6727 4.7.1-02 EN 1 (4)

Page 36: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 cooling water: Check the corrosionprotection - refer to 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit 1 1 1 1 1 1 1 1 1 1 1

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

Mai

nten

ance

sch

edul

e67

27 4

.7.1

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48/6

0CR

2011

-04-

01 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6727 4.7.1-02 EN

Page 37: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

280.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

289.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe 1 1 1 1 1 1 1 1 1 1 1

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Accumulator pack for interruption-freepower supply of the Common Railcontrol system: Check charge status

A 1 0.50 Engine 4

075 Accumulator pack for interruption-freepower supply of the Common Railcontrol system: replace

A 1 0.50 Engine X

076 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

077 Check measuring system for exhaustgas temperatures

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

01 -

de

Mai

nten

ance

sch

edul

e67

27 4

.7.1

-02

48/6

0CR

MAN Diesel & Turbo 4.7.1

6727 4.7.1-02 EN 3 (4)

Page 38: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-3

5*36

-40*

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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Maintenance schedule(engine)

Maintenance schedule1,2,3

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0080

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000

1600

032

000

6400

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Service data 000

101 Engine start up (recommendation): After12 hrs down time, open the sealingplug for the indicator cock and turn theengine over with the turning gear.Check whether there is no fuel, oil orcooling water emission.

000.01 1 0.50 Engine X

102 Check the exhaust clouding (visually) A 1 0.10 Engine X

103 Record operating data and compare toearlier records.

000.02000.25

1 1 Engine X

104 Check ignition pressures (for monthlyrecording of operating data)

000.02000.25

1 0.10 Cyl. X

105 Check and test oil mist detectoremergency stops

000.02 1 0.40 Engine 4

106 Check and test metal particle detector 000.02 1 0.40 Engine X

Crankcase 012

111 Check crankcase pressure A 1 0.10 Engine X

112 Safety valves in crankcase covers:Check all valves for ease of movement

073.01 1 0.40 Cyl. X

Running gear/Crankshaft 020

113 Check running gear (visual check) - seealso 404

A 2 0.20 Cyl. 2 X

114 Crankshaft: Measure crank webdeflection (in the case of marineengines also after collision orgrounding) - see also 405

000.10 2 0.14 Cyl. 2 X

Crankshaft bearing 021

122 Locating bearing: Check axialclearance. See also 405

021.03 2 0.50 Bearing 2 X

123 Lower one bearing cap and inspectlower bearing shell. If bearing shellcannot be used again, check allbearings. Check pressure for looseningbearing bolts.

000.11012.02021.01

2 6 Bearing X

124 Replace all bearing shells and checkcrankshaft journals. Replace locatingbearing and oil seal.

020.06021.01021.03

2 6 Bearing X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 years

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6400

0

Torsional vibration damper 027

131 12V and 16V engines: Check viscosityof the liquids in viscose-damper bydamper manufacturer. Next samplingdate has to be recommended by thedamper manufacturer.

027.05 1 1 Engine X

132 12V and 16V engines: Replacevibration damper of the crankshaft.(Depending on results of viscosityanalysis)

027.05 2 6 Engine 1

133 20V engines: Remove and checkvibration damper of the crankshaft.Replace worn parts and sealing rings.

027.03 2 6 Engine X

134 20V engines: Remove and replacevibration damper of the crankshaft.

027.03 2 6 Engine 1

Connecting rod/Big-end bearing 030

141 Replace all non-return valves. C 1 1.50 Bearing X

142 Remove 1 connecting rod per cylinderbank and check. Check big-endbearing bore for ovality. Check bearingsurface of the bearing shells and pistonpin bushing. Remeasure bolts on thebig-end bearing cap.

030.04034.01

2 6 Bearing X7

143 Remove all connecting rods and check.Check big-end bearing bore for ovality.Check the bearing surface of the pistonpin bushing. Remeasure bolts on thebig-end bearing cap. Replace all big-end bearing shells.

030.04034.01

2 6 Bearing X

144 Remove connecting rods and replacewith overhauled ones.

034.01 2 2 Cyl. X

Piston/piston pin 034

152 Remove, clean and check 1 piston percylinder bank. Measure the piston ringsand ring grooves. Check pressure forreleasing bolts on connecting rodshank. Document data recorded (seeWork Card).

034.01034.02

2 2.50 Cyl. X7

153 Remove, clean and inspect all pistons.Measure ring grooves. Replace allpiston rings. Caution: Re-hone thecylinder liner when replacing the pistonrings! Replace piston crowns ifnecessary. Document data recorded(see Work Card)

034.01034.02

2 2.50 Cyl. X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 yearsM

aint

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154 Remove all piston pins, check pistonpin bushing, check clearance

034.04 2 0.30 Cyl. X

157 Replace piston crowns 034.04 2 1.50 Cyl. X

158 Replace complete piston 034.01 2 2 Cyl. X

Cylinder liner 050

161 Check all cylinder liners during injectionnozzle replacement using an interscope

050.07 1 0.30 Cyl. X

162 Measure one cylinder liner (per cylinderbank). Document data recorded (seeWork Cards)

050.02 2 0.30 Cyl. X7

163 Remove, clean,measure and hone allcylinder liners. Replace seal rings. Ifnecessary, the complete cylinder linersmust be replaced.

034.01050.02

2 2 Cyl. X

164 Replace all cylinder liners. 034.01 2 1.50 Cyl. X

Cylinder head 055

172 Replace the seal of the cylinder headcover

111.01 1 0.10 Cyl. X

173 Remove, clean and check one cylinderhead per cylinder bank. Checkpressure for releasing the cylinder headbolts.

055.01055.02

2 2.50 Cyl. X7

174 Remove, clean and check all cylinderheads Replace worn parts.

055.01055.02

2 2.50 Cyl. X

Control device operating mechanism 100

202 Check gears, measure the backlash -see also 406

100.01 2 1 Engine X

203 Remove camshaft drive, check andmeasure, replace individual parts ifnecessary

C 2 8 Engine X

Camshaft/camshaft bearing/cam follower 101/102/112

212 Check cams (visual inspection). Seealso 405

209.01 1 0.10 Cyl. X

213 Clean camshaft thrust bearing, replaceif necessary

102.03 1 3 Engine X

214 Remove drive section pieces on bothsides and check. Check bearingbushes.

101.10 2 2 Cyl. X

215 Remove the camshafts, check themand replace worn parts. Replacebearing bushes.

101.10C

2 2 Cyl. X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 years

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Valve timing/rocker arms 111/112

222 Check rocker arm and associatedbolted connections (visually)

111.01 1 0.10 Cyl. X

223 Dismantle rocker arm and check it.Replace worn parts

055.02 2 2 Cyl. X

225 Check tappet casing and tappets.Replace worn parts

112.03 1 0.30 Cyl. X

226 Remove and overhaul tappet casingand tappet

112.03 1 1 Cyl. X

Inlet and exhaust valves 113/114

233 Check the valve clearance - see also405

111.01 2 0.20 Cyl. X

234 Remove 2 inlet valves (per cylinderbank). Check valve seats, valve cones,valve guides and valve rotators.Replace worn parts.

C 1 2 Cyl. X7

235 Remove all inlet valves. Replace allvalve cones, valve seat rings and valverotators.

C 2 3 Cyl. X

242 Remove 2 exhaust valves (per cylinderbank). Check valve seats, valve conesand valve guides. Replace worn parts.

C 1 2 Cyl. X7

243 Remove all exhaust valves. Replace allvalve cones, valve guides, valve seatrings and valve rotators.

C 2 3 Cyl. X

Electronic injection/speed sensor 140

266 Check the pulse sensor forcontamination and correct distance

A 1 0.20 Engine 1 1 1 1 1 1 1 1 1 1 1

Starter 171

271 Maintain starter according tomaintenance instructions ofmanufacturer

B 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

272 Check starter toothed ring 171.01 1 1 Engine X

273 Replace starter 171.02 1 2 Engine X

274 Check turning gear, overhaul ifnecessary

B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Fuel injection pump with drive 200/201

301 Replace fuel injection pumps withoverhauled pumps

200.03 1 1 Pump X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 years

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Fuel injection valve/injection pipe 221

322 Remove the injection valves. Replaceinjection nozzles, distance disc andsealing rings. Alternatively, replacecomplete injection valves.

221.01 1 2 Valve X

323 Fuel oil system: Replace injection pipes 200.03 1 0.30 Valve X

Attached fuel supply pump 300

331 Fuel supply pump: Open sealing plug ofleakage bore and check for leakages.

A 1 0.10 Pump X

332 Replace attached fuel supply pump 300.01 1 2 Pump X

Engine lube oil system

342 Check system components fortightness (visually)

000.01 1 0.20 Engine X

343 Check oil drain (visually) afteroverhauling or replacement of: piston,connecting rod big-end and crankshaftmain bearings, camshaft bearings,valve gear in the rocker arm casing,gear drive and the turbocharger - referto 404

A 1 0.30 Unit;Cyl. 1 1 1 1 1 1 1 1 1 1 1

344 Engine lubrication: Check lube oil levelin oil sump

000.01 1 0.10 Engine X

345 Attached lubricating oil pump includingpressure relief valve. Replace withservice exchange unit.

300.01 1 2 Pump X

346 Replace lubricating oil filter, dependingon differential pressure

000.01310.02

1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

347 Clean the lube oil cooler. Replace ifnecessary

C 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

Engine cooling water system

351 Check the cooling water spaces, cleanif necessary

000.08 X

352 Check attached HT/LT water pumpsincluding gear. Replace with serviceexchange units if necessary.

350.04 1 2.50 Pump 1 1 X

353 Check attached sea water pumpsincluding gear. Replace with serviceexchange units if necessary.

350.04 1 2.50 Pump 1 1 X

Engine exhaust gas system

361 Dismantle exhaust gas system onengine, check compensators andreplace all seals

289.01 2 10 Unit X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 years

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6739 4.7.2-02 EN 5 (6)

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Charge air system on engine

362 Charge air cooler/pipe: Check systemfor leakages, condensation waterdrainage for quantity/free pass-through

000.01 1 0.10 Pipe X

363 Blow-off valve: Dismount and check forcracks. Every 4000 operational hoursor once a year

000.34322.01

1 2 Engine 4

364 Bypass valve: Dismount and check forcracks. Every 4000 operational hoursor once a year

000.34322.01

1 2 Engine 4

365 Emergency stop shut-off valve: Checkin accordance with the maintenancemanual

000.34322.01

1 2 Engine X7

366 Check charge air piping forcontamination.

322.01 1 1 Engine X7

367 Clean the charge air cooler, dependingon differential pressure

322.01 2 15 Engine 1 1 1 1 1 1 1 1 1 1 1

368 Charge air cooler: Replace cooler insert 322.01 2 15 Engine X

Measuring, control and regulation systems

372 Engine electronic equipment: Checkand calibrate - refer to 405

125.22 2 8 Engine X

373 Dismantle the control valves in the 10and 30 bar system, replace wear parts

A 1 24 Engine X

Additionally required

403 Bolted connections: Check for tight fit(e.g. on exhaust gas and charge airpipe, charge-air cooler andturbocharger) and proper fastening(according to work cards) - refer to 404

000.30 2 10 Engine 2 X

404 Check parts installed in new orreconditioned condition and operatingmedia applied in new or improvedcondition once after the time given -applies to 113, 341 and 403

D X

405 Check parts installed in new orreconditioned condition and operatingmedia applied in new or improvedcondition once after the time given -applies to 114, 122, 212, 233

D X

406 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 202

D 0 X

24 (Daily) ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given7 After .... operating hours or after 2 years

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6 (6) 6739 4.7.2-02 EN

Page 45: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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6730 4.7.1-02 EN 1 (4)

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24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check the nozzle cooling water return(for unhindered flow and eventualtraces of fuel - when using heavy fuel)

A 1 0.10 Engine 4

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 1 1 1 1 1 1 1 1 1 1 1

036 cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01 2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

054 In case available: <br/> Charge airbypass/blow-off device: Check systemcomponents for leakages (visually).Check control and monitoring elementsfor proper function

280.02 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off valves on engine: Dismountand check for cracks. Every 6000operational hours or once a year

280.02000.34

1 2 Engine 4

Exhaust gas system

062 In case available: <br/> Exhaust gasblow-off device: Check systemcomponents for leakages (visually).Check control and monitoring elementsfor proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off valves on engine: Dismountand check for cracks. Every 6000operational hours or once a year

289.02000.34

1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Batteries in the control cabinet: replace A 1 0.50 Engine X

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theelastic elements’ settling value

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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6730 4.7.1-02 EN 3 (4)

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250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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Page 49: Cus303E Engine mounted sealing flaps

Maintenance schedule(systems - biofuel operation)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.20 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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6628 4.7.1-03 EN 1 (4)

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1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine 4

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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1,2,3

per

24 150

250

500

1-2*

2-3*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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Page 53: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given20

11-0

4-05

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Page 54: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine 4

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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2 (4) 6628 4.7.1-02 EN

Page 55: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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6628 4.7.1-02 EN 3 (4)

Page 56: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

2*20

-24*

30-4

0*50

-60*

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpretension - see also 402

020.04 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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4.7.1 MAN Diesel & Turbo

4 (4) 6628 4.7.1-02 EN

Page 57: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

Fuel system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, high-pressure pumps andvalve gear (in the rocker arm casing) -see also 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.01 2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

302.01 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

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04 -

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6640 4.7.1-01 EN 1 (4)

Page 58: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 Cooling water: Check the corrosionprotection - refer to 401

000.07 1 1 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Compressed air tank: drain water afterevery filling (if there is no automaticdrainage)

A 1 0.10 Unit 1 1 1 1 1 1 1 1 1 1 1

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 1 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.02

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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2 (4) 6640 4.7.1-01 EN

Page 59: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 1 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe 1 1 1 1 1 1 1 1 1 1 1

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

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1,2,3

per

24 150

250

500

1500

3000

6000

1200

024

000

3000

036

000

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D 0 Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D 0 Unit X

24 ... Repetition interval in operating hoursX Maintenance work due1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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4 (4) 6640 4.7.1-01 EN

Page 61: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system/pilot oil system

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

007 Clean main fuel filter and replace pilotoil cartridge (dependent upondifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Fuel delivery pump and pilot oil pump B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

009 Clean pilot oil fuel cooler Unit 1 1 1 1 1 1 1 1 1 1 1

010 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Gas system

500 Check gas pipe and gas control routefor tightness (visually)

230.01 1 0.20 Engine X

501 Check the shut-off valves for leakage A 1 0.20 Engine 1 1 1 1 1 1 1 1 1 1 1

502 Clean gas filter, replace if necessary B 1 1 Filter 1 1 1 1 1 1 1 1 1 1 1

503 Check gas pressure regulator andreplace diaphragm if necessary

B 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. 2 X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine 2 X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

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6736 4.7.1-01 EN 1 (4)

Page 62: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine 2 X

035 Check cooling channels, chemicallyclean the system (cylinder cooling).Possibly have cleaning carried out by aspecialist company

000.08 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

054 Compressor by-pass: Check controland monitoring elements for properfunction

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine 2 X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine 2 X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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6736 4.7.1-01 EN 3 (4)

Page 64: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine 2 X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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4 (4) 6736 4.7.1-01 EN

Page 65: Cus303E Engine mounted sealing flaps

Maintenance schedule(Systems)

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.15 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

006 Check Viscosimat (carry outcomparative temperaturemeasurement)

B 1 0.10 Unit X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. 2 X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine 2 X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

022 Overhaul the cylinder lubricating oil unitor pump, the block distributor and themonitoring devices

A 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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6706 4.7.1-02 EN 1 (4)

Page 66: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system (cylinder and nozzle cooling)

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

032 Check nozzle cooling water outlet (forunobstructed drainage and possibletraces of fuel)

A 1 0.10 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine 2 X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10 1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10 1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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2 (4) 6706 4.7.1-02 EN

Page 67: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

280.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

289.02A

1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

289.01 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine 2 X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine 2 X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

2011

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MAN Diesel & Turbo 4.7.1

6706 4.7.1-02 EN 3 (4)

Page 68: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine 2 X

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine 2 X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition2 Checking of new or overhauled parts required (once after the mentioned time)3 According to specification of manufacturer4 If component/system is given

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4.7.1 MAN Diesel & Turbo

4 (4) 6706 4.7.1-02 EN

Page 69: Cus303E Engine mounted sealing flaps

Maintenance schedule

Maintenance schedule1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Fuel system

002 Analyse fuel sample (all characteristicsof the specification)

000.05 1 0.15 Engine X

003 Analyse the fuel sample for acidcontent (TAN)

000.04 1 0.30 Engine X

004 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

005 Service tank: Check the fuel level; drainthe service tank and settling tank

A 1 0.20 Engine X

007 Clean fuel filter (depending on thedifferential pressure)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

008 Overhaul the fuel delivery pump B 1 1 Pump 3 3 3 3 3 3 3 3 3 3 3

009 Inspect/overhaul the buffer piston(s) 434.04 1 1 Unit X

Lube oil system

011 Check the system components forleakage (visual inspection)

A 1 0.20 Engine X

012 Service tank for engine and cylinderlubrication: Check oil level

A 1 0.10 Engine X

014 Examine oil sample (spot test) 000.05 1 0.20 Engine X

015 Have the oil sample analysed 000.04 1 0.30 Engine X

016 Change oil filling (depending on resultsof analysis), clean the tank

000.04 1 5 Engine 1 1 1 1 1 1 1 1 1 1 1

017 Check oil drain from piston, connectingrod and crankshaft bearings, from thegear drive system and the turbocharger(visually) - see also 401

A 1 0.20 Unit;Cyl. X

018 Check oil drain (visually) from camshaftbearings, injection pumps and valvegear (in the rocker arm casing) - seealso 401

A 1 2 Engine X

020 Overhaul the lubricating oil pump 300.02B

2 10 Pump 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lubricating oil service filter(depending on scavenging intervals)

B 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1

024 Clean the lubricating oil indicator filter(dependent upon the differentialpressure)

B 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

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Mai

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48/6

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MAN Diesel & Turbo 4.7.1

6706 4.7.1-01 EN 1 (4)

Page 70: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

025 Clean the lubricating oil preheater(dependent on separating temperatureat required flow rate). Possibly havecleaning carried out by a specialistcompany

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

026 Check, clean and overhaul thelubricating oil separator (self-discharging)

B 1 4 Unit 1 1 1 1 1 1 1 1 1 1 1

027 Clean the lubricating oil cooler (possiblyperformed by specialist company)

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Cooling water system

031 Compensating tank: Check the coolingwater level

A 1 0.20 Engine X

033 cooling water: Check the corrosionprotection - see also 401

000.07 1 0.50 Engine X

035 Check cooling spaces, chemically cleanthe system (cylinder and nozzlecooling). Possibly have cleaning carriedout by a specialist company

000.08 0 Engine 1 1 1 1 1 1 1 1 1 1 1

036 Cooling water heat exchanger: Cleanthe cooling spaces, possibly byspecialist company

C 0 Unit 1 1 1 1 1 1 1 1 1 1 1

Compressed air and control air system

042 Drain the water from the compressedair tank (if it is not automatically drained)

A 1 0.10 Unit X

043 Clean the inside of the compressed airtank, overhaul the valves (inaccordance with the regulations of theclassification society)

B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1

044 Control air system: Drain waterseparator and air filter

125.10B

1 0.10 Engine X

045 Control air system: Clean waterseparator and air filter

125.10B

1 0.50 Engine X

Charge air system

052 Charge air cooler/charge air pipe:Check condensed water discharge forquantity/free flow

A 1 0.10 Pipe X

053 Clean charge air cooler on both waterand air sides, possibly by specialistcompany

322.01322.03

2 15 Radiator 1 1 1 1 1 1 1 1 1 1 1

054 Charge air bypass/blow-off device:Check system components for leakage(visually). Check control and monitoringelements for proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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e67

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.7.1

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2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

2 (4) 6706 4.7.1-01 EN

Page 71: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

055 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

280.02 1 2 Engine 4

Exhaust gas system

062 Exhaust gas blow-off device: Checksystem components for leakage(visually). Check control and monitoringelements for proper function

A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

063 Exhaust pipe: Check flangeconnections and compensators fortightness (visually)

A 1 0.20 Pipe X

064 Shut-off flaps on engine: Dismount andcheck for cracks. Every 6000operational hours or once a year

289.02 1 2 Unit 4

Measuring, control and regulation systems

072 Switching and shut-down devices:Check functional capability andswitching points - also see 402

A 2 6 Engine X

073 Dismantle the control valves in the 10and 30 bar system, replace wear parts

125.xx 1 24 Engine X

074 Battery: Check the charge status andthe acid level

A 1 0.50 Engine 4

075 Inspect/overhaul the oil mist detector B 1 1 Engine 3 3 3 3 3 3 3 3 3 3 3

076 Check the exhaust gas temperaturemeasuring system

A 1 6 Engine 3

Engine foundation/pipe connections

082 Foundation bolts: Check pretension.Check firm seating of stoppers,brackets and resilient elements (in caseof marine engines also after collision orgrounding) - see also 402

012.01 2 8 Engine X

083 Resilient mounting: Determine theamount of setting of the elasticelements

012.01 2 3 Engine 4

084 Elastic pipe connections: Check allhoses

A 1 1 Engine 4

085 Elastic pipe connections: Replacehoses for fuel, lubricating oil, coolingwater, steam and compressed air

A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1

086 Screwed connections: check for tightfit/proper pretension (e.g. on exhaustgas and charge air pipe, charge aircooler and turbocharger) - see also 402

000.30 2 10 Engine X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

2011

-04-

04 -

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MAN Diesel & Turbo 4.7.1

6706 4.7.1-01 EN 3 (4)

Page 72: Cus303E Engine mounted sealing flaps

1,2,3

per

24 150

250

500

1-2*

3-4*

5-6*

10-1

5*20

-24*

25-3

0*30

-40*

Flexible coupling/turning gear

092 Flexible coupling: Check alignment andrubber elements

000.09 2 8 Engine 4

093 Coupling bolts: check for tight fit/properpreload - see also 402

020.02 1 1 Engine X

094 Inspect/overhaul the turning gear B 1 1 Unit 3 3 3 3 3 3 3 3 3 3 3

Additionally required

401 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 017, 018, 033

D Unit X

402 Check installed new parts or installedoverhauled parts/newly addedlubricants once after the indicatedinterval - applies to 072, 082, 086, 093

D Unit X

24 ... Repetition interval in operating hoursX Maintenance work due* x 1000 h1 As required/depending on condition3 According to specification of manufacturer4 If component/system is given

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sch

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e67

06 4

.7.1

-01

48/6

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2011

-04-

04 -

de

4.7.1 MAN Diesel & Turbo

4 (4) 6706 4.7.1-01 EN