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Guiding Overhaul Intervals - Updated Tables
Service Letter SL09-509/SBJ
Action code:
WHEN CONVENIENT
Guiding Overhaul Intervals
Updated Tables
SL09-509/SBJ
April 2009
Concerns
Owners and operators of MAN B&W
two-stroke diesel engines.
Type: ME/ME-C, ME-B and MC/MC-C
Dear Sirs
Based on the latest service experience and experience with Condition
Based Overhaul (CBO), we are pleased to issue a revised version of
Guiding Overhaul Intervals tables. The guiding overhaul intervals apply
to both electronically controlled engines (ME types) and mechanically,
controlled engines (MC types).
Please note that the intervals in the lists apply only to engines with so-
called high topland pistons. High topland pistons are pistons where the
topland is signiicantly higher than the ringland.
For engines with high topland pistons, overhauls can normally be ex-
tended even further than described in the tables, typically to more than
32,000 hours. The means to obtain and document this are described in
SL07-483/HRR.
Please direct any inquiries and questions regarding tables or condition-
based overhaul to our Operation Department at
leo@mandiesel.com
or
to our Service Department at
PrimeServ-cph@mandiesel.com.
Yours faithfully
Mikael C Jensen
Vice President, Engineering
Stig B Jakobsen
Senior Manager, Engineering
Overhaul of cylinder unit on large bore
engine
Head ofice (& postal address)
MAN Diesel
Teglholmsgade 41
2450 Copenhagen SV
Denmark
Phone: +45 33 85 11 00
Fax: +45 33 85 10 30
mandiesel-cph@mandiesel.com
www.mandiesel.com
PrimeServ
Teglholmsgade 41
2450 Copenhagen SV
Denmark
Phone: +45 33 85 11 00
Fax: +45 33 85 10 49
PrimeServ-cph@mandiesel.com
Production
Teglholmsgade 35
2450 Copenhagen SV
Denmark
Phone: +45 33 85 11 00
Fax: +45 33 85 10 17
manufacturing-dk@mandiesel.com
Forwarding & Receiving
Teglholmsgade 35
2450 Copenhagen SV
Denmark
Phone: +45 33 85 11 00
Fax:
MAN Diesel
Branch of MAN Diesel SE, Germany
CVR No.: 31611792
Head ofice: Teglholmsgade 41
2450 Copenhagen SV, Denmark
German Reg.No.: HRB 22056
Amtsgericht Augsburg
MAN Diesel – a member of the MAN Group
+45 33 85 10 16
Service Letter SL09-509/SBJ
ME-B engines
Guiding overhaul intervals and expected service life
Component
Overhaul interval (hours)
Expected service life (hours) Remarks
Cylinder liner
Bore sizes
60-50
Bore sizes
60-46
Check the overall cylinder condition
through the scavenge ports at least
once a month.
16,000
60,000
46-35
12,000
40-35
50,000
Piston rings
Bore sizes
60-50
Bore sizes
60-35
16,000
16,000
46-35
12,000
Piston crown
Bore sizes
60-50
Bore sizes
60-46
Pressure test at every 2
nd
piston
overhaul, recondition/rechrome when
required (typically every 24-32,000
hours). Piston crown can be recondi-
tioned by welding-up twice.
16,000
60,000
46-35
12,000
40-35
50,000
Stufing box
Bore sizes
60-50
Bore sizes
60-50
16,000
32,000
46-35
12,000
Check lamellas
46-35
24,000
Renew lamellas
Exhaust valve spindle
and bottom piece (cage)
Inspection of seat and air spring:
Bore sizes
50-35
DuraSpindle exhaust valve 50,000
Normally, HVOF coated stems need
no reconditioning.
Bore sizes
60-35
First inspection 1)
6,000
Bore size
60
DuraSpindle or
Nimonic exhaust valve
Usually only light grinding of seats is
required at subsequent inspections.
Bore sizes
50-35
Subsequent inspections 2) 16,000
100,000
1) Condition check
Inspection of air spring according
to instruction manual. Two or three
valves to be inspected.
To be obtained for DuraSpindle and
Nimonic valve with reconditioning of
seat and possible re-welding of disk
underside
Bore size
60
Subsequent inspections 2) 32,000
2) Subsequent inspection
Condition check + possible complete
overhaul. Max burn off rate of spindle
disc underside to be estimated and
calculated for lifetime of spindle. All
valves to be inspected.
Main hydraulic pump
32,000 Engine lifetime
Check and replace hydrostatic bear-
ings at overhaul. Check and replace
cylinder set and piston if required.
Proportional valve for
main hydraulic pump
20,000 Replace valve after 20,000 hours
Pressure relief valve for
main hydraulic pumps
40,000 Engine lifetime
Replace sealings at overhaul
Exhaust valve actuator
32,000 Engine lifetime
Replace static sealing rings at over-
haul.
ELFI valve
32,000
64,000 Check and replace if required
Fuel valve
8,000
Valve nozzle
16,000
Check and replace if required
- depending on fuel quality
Spindle guide
16,000
Fuel oil pressure booster
32,000
64,000
Change piston rings on hydraulic pis-
ton and suction valve at overhaul.
- based on engine observations
Replace or recondition
Guiding Overhaul Intervals. Page 2 of 7 pages
Service Letter SL09-509/SBJ
ME-B engines
Guiding overhaul intervals and expected service life
Component
Overhaul interval (hours)
Expected service life (hours) Remarks
Cylinder cover
96,000 Check for burned grooves at fuel valve
nozzle holes. Weld-up if required, up
to 2-3 times during service life.
Starting valve
12,000 Engine lifetime
Cylinder lubricator
24,000 Engine lifetime
Check timing and adjustment
Crosshead bearings
Main bearings
Crank bearings
Thrust bearings
Check clearances and crankshaft
delection: once a year.
Check bearing edges by wire gauges:
once a year
64,000
Do not open bearings unless
bearing material fragments fall out or
other bearing inspection measures
indicate so.
96,000
96,000
96,000
Tie rods including
bracing screws
Tighten rods and screws:
once a year
Engine lifetime
Holding down bolts
Tighten: once a year
Engine lifetime
Turbocharger
According to manufacturer’s
recommendations.
According to manufacturer’s
recommendations.
According to manufacturer’s
recommendations.
Air cooler(s)
Cleaning:
based on engine observations
45,000
or according to manufacturer’s rec-
ommendations.
Clean before differential pressure has
increased 50% compared to sea trial
value.
Flaps and butterly
valves in scavenge air
receiver
Check movement at every
scavenge port inspection.
Engine lifetime
Various fuel and
lubricating oil ilters
Cleaning:
based on engine observations
Lubricating oil bottom
tank
Cleaning:
32,000
Typically done at 5 years docking
Chains
Retighten chains:
3,000-4,000
96,000 New or overhauled chains to be
checked/retightened after 500, 1,500
hours.
- every six months
Accumulators on
HPS and HCU
N2 pressure
3,000
Engine lifetime
Replace membranes after 5 years
Rubber membranes:
32,000
Hydraulic hoses
32,000 Replace after 5 years
Angle encoder
Visual inspection:
6,000
64,000 Replace if failing
Marker sensor
Visual inspection:
6,000
64,000 Replace if failing
MPC, MOP A, MOP B
Visual inspection:
6,000
64,000 Replace if failing
Cables
Visual inspection:
6,000
96,000 Replace if failing
Guiding Overhaul Intervals. Page 3 of 7 pages
Service Letter SL09-509/SBJ
ME/ME-C engines
Guiding overhaul intervals and expected service life
Component
Overhaul interval (hours)
Expected service life (hours) Remarks
Cylinder liner
Bore sizes
98-80
Bore sizes
98-90
Check the overall cylinder condition
through the scavenge ports at least
once a month.
24,000
80,000
Bore sizes
70-50
80-65
70,000
16,000
60-50
60,000
Piston rings
Bore sizes
98-80
Bore sizes
98-80
24,000
24,000
Bore sizes
70-50
16,000
Bore sizes
70-50
16,000
Piston crown
Bore sizes
98-90
Bore sizes
98-90
Pressure test at every 2
nd
piston
overhaul, recondition/rechrome when
required (typically every 24-32,000
hours). Piston crown can be recondi-
tioned by welding-up twice.
24,000
80,000
80-65
70,000
Bore sizes
70-50
60-50
60,000
16,000
Stufing box
Bore sizes
98-80
24,000
32,000
32,000
Renew lamellas
70-50
16,000
Check lamellas
Exhaust valve spindle
and bottom piece (cage)
Inspection of seat and air spring:
Bore sizes
98-60
Nimonic exhaust valve
Normally, HVOF coated stems need
no reconditioning.
Bore sizes
98-50
First inspection 1)
100,000
6,000
To be obtained for Nimonic valve with
reconditioning of seat and possible
re-welding of disk underside
Usually only light grinding of seats is
required at subsequent inspections.
Bore sizes
98-50
Subsequent inspections 2) 32,000
1) Condition check
Inspection of air spring according
to instruction manual. Two or three
valves to be inspected.
2) Subseq. Inspection
Condition check + possible complete
overhaul. Max burn off rate of spindle
disc underside to be estimated and
calculated for lifetime of spindle.
All valves to be inspected.
Main hydraulic pump
32,000 Engine lifetime
Check and replace hydrostatic bear-
ings at overhaul. Check and replace
cylinder set and piston if required.
Proportional valve for
main hydraulic pump
20,000 Replace valve after 20,000 hours
Pressure relief valve for
main hydraulic pumps
40,000 Engine lifetime
Replace sealings at overhaul
Exhaust valve actuator
32,000 Engine lifetime
Replace static sealing rings at over-
haul.
FIVA valve
32,000
64,000 Check and replace if required
Fuel valve
8,000
Valve nozzle
16,000
Check and replace if required
- depending on fuel quality
Spindle guide
16,000
Fuel oil pressure booster
32,000
64,000
Change piston rings on hydraulic pis-
ton and suction valve at overhaul.
- based on engine observations
Replace or recondition
Guiding Overhaul Intervals. Page 4 of 7 pages
Service Letter SL09-509/SBJ
ME/ME-C engines
Guiding overhaul intervals and expected service life
Component
Overhaul interval (hours)
Expected service life (hours) Remarks
Cylinder cover
96,000 Check for burned grooves at fuel valve
nozzle holes. Weld-up if required, up
to 2-3 times during service life.
Starting valve
12,000 Engine lifetime
Cylinder lubricator
24,000 Engine lifetime
Check timing and adjustment
Crosshead bearings
Main bearings
Crank bearings
Thrust bearings
Check clearances and crankshaft
delection: once a year.
Check bearing edges by wire gauges:
once a year
64,000
Do not open bearings unless
bearing material fragments fall out or
other bearing inspection measures
indicate so.
96,000
96,000
96,000
Tie rods including
bracing screws
Tighten rods and screws:
once a year
Engine lifetime
Holding down bolts
Tighten: once a year
Engine lifetime
Turbocharger
According to manufacturer’s
recommendations.
According to manufacturer’s
recommendations.
According to manufacturer’s
recommendations.
Air cooler(s)
Cleaning:
based on engine observations
45,000
or according to manufacturer’s rec-
ommendations
Clean before differential pressure has
increased 50% compared to sea trial
value.
Flaps and butterly
valves in scavenge air
receiver
Check movement at every
scavenge port inspection
Engine lifetime
Various fuel and
lubricating oil ilters
Cleaning:
based on engine observations
Lubricating oil bottom
tank
Cleaning:
32,000
Typically done at 5 years docking
Chains
Retighten chains:
3,000-4,000
96,000 New or overhauled chains to be
checked/retightened after 500, 1,500
hours.
- every six months
Gear wheel drive for
hydraulic pumps
First inspection:
500
Gear wheel: Engine lifetime
Gear wheel bearings:
Subsequent inspections:
6,000
96,000
Accumulators on
HPS and HCU
N2 pressure:
3,000
Engine lifetime
Replace membranes after 5 years
Rubber membranes:
32,000
Hydraulic hoses
32,000 Replace after 5 years
MPC, MOP A, MOP B
Visual inspection:
6,000
64,000 Replace if failing
CCU and ACU ampliiers Visual inspection:
6,000
64,000 Replace if failing
LVDT and LDI hydraulic
pump ampliiers
Visual inspection:
6,000
64,000 Replace if failing
Fuel booster sensor
Visual inspection:
6,000
64,000 Replace if failing
Exhaust valve sensor
Visual inspection:
6,000
64,000 Replace if failing
Angle encoder
Visual inspection:
6,000
64,000 Replace if failing
Marker sensor
Visual inspection:
6,000
64,000 Replace if failing
Cables
Visual inspection:
6,000
96,000
Guiding Overhaul Intervals. Page 5 of 7 pages
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