Draw.no: 1012/13 Routine Maintenance Schedule 80.

000
Instruction no: 1502 Valid for Bergen K25:30 Engines for MDO, Marine Application
Revision: November 2015 Rev B

S = Spot Check, C = Check All, L = Lubricate, W = Clean / Adjust, O = Overhaul, R = Replace

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Item Instr.

100
500
No. No. a)
1 CYLINDER HEADS 1
101 2404 Cylinder head bolts: retighten approx. 100 hrs after refitting of cyl.head C C C C C C C C C 101
102 2408 Cylinder head: max.firing pressure C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 102
a) See service 103 4301 Inlet and exhaust valve clearance. Also approx.100 hrs after refitting of cyl.head C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 103
manual instructions
104 2405 Inlet and exhaust valve rotators (rotocaps) C C C C C C C C C R C C C C C C C C C R C C C C C C C C C R C C C C C C C C C R 104
105 2401 Valve gear system for inlet and exhaust valves C C C C O C C C C O C C C C O C C C C O C C C C O C C C C O C C C C O C C C C O 105
106 2401 Inlet and exhaust valves / valve seats: overhaul / replace according to wear R R R R R R R R 106
b) See separate 107 2401 Inlet and exhaust valve guides C C C C C C C C 107
instructions 108 2408 Indicator valves C C C C C C C C 108
109 2410 Starting air valves O O O O O O O O 109
2 FUEL OIL SYSTEM 2
c) See engine
201 7208 Fuel injection nozzle holder W W W O W W W O W W W O W W W O 201
alarm list
202 7208 Fuel injection nozzles R R R R R R R R R R R R R R R R 202
203 7207 Fuel injection pump drive: alternating spot checks S S S O S S S O S S S O S S S O 203
The schedule is 204 7206 Fuel injection pump O O O O 204
only valid for 205 7206 Fuel injection pump: erosion plug S S S R S S S R S S S R S S S R 205
normal operating 206 5501 Fuel injection pump: auto stop cylinder emergency stop test Check monthly 206
conditions as 207 7206 Fuel injection pump: fuel rack - lubricate and check every pump for signs of sticking Weekly and before start 207
defined in the 208 7205 Fuel oil filter Replace every 6 months or at diff. pressure 208
contracts, service
209 - Flexible fuel connections C C R C C R C C R C C R C C R C C R C C R C C R 209
agreements or
relevant technical
210 8308 Engine driven fuel oil booster pump O O O O 210
documentation 211 - All fuel pipes (high and low pressure) C C C C C C C C C C C C C C C C 211
from Rolls-Royce 212 - Fuel oil sample When bunkering 212
3 CYLINDER LINERS 3
301 2301 Honing: overhaul / replace according to wear O O O O 301
302 2301 Remove liner / check water jacket / replace sealing O O O O 302
The intervals in this
303 2301 Carbon cutting ring (optional) C C C C 303
schedule are for
guidance only and 4 PISTONS / CONNECTING RODS 4
are subject to local 401 3201 Gudgeon pin bushing: replace when off limit C C C R 401
ambient conditions. 402 3201 Gudgeon pin C C C C 402
The schedule is 403 3201 Piston including piston ring grooves (gap / clearence): replace after 80.000 hrs C C C R 403
applicable to 404 3201 Piston rings: also replace after honing of cyl. liner R R R R 404
engines with more 405 3202 Big end bearing shells R R R R 405
than 2000 annual
406 3201 Big end bearing assembly (ovality control, surface check and boroscope inspection of threads) C C C C 406
operating hrs
407 3201 Big end bearing bolts R R R R 407
5 CRANKSHAFT 5
501 2201 Main bearings and thrust washers S R S R 501
S = Dismantle / 502 3102 Crankshaft deflection: check before and after every major overhaul / docking C C C C C C C C C C C C C C C C 502
inspect 1 item and 503 b) Flexible couplings (not applicable to generators directly bolted to the flywheel) S S S S S S S S S S S S S S S S 503
check condition 504 3101 Torsional vibration damper: fluid type (subsequent fluid samples to be taken according to supplier's indications) C 504
(leakage, abnormal
505 3105 Flexible gear wheel, pump drive (pump end) S S S S S S S S S S S S S S S S 505
wear, cracks,
contamination etc.) 6 CAMSHAFTS 6
601 4101 Camshaft bearings and thrust washers S S S R S S S R 601
602 4101 Fuel cams S S S S S S S S S S S S S S S S 602
603 4101 Inlet and exhaust cams with drive S S S S S S S S S S S S S S S S 603
The schedule may 604 4102 Camshaft drive with gear wheels S S S S S S S S S S S S S S S S 604
only be changed
605 4102 Camshaft drive chain (30.000 hrs intervals with lower output and shorter camshaft length) R R R R R 605
by a service letter
606 5202 Governor drive S S S O S S S O S S S O S S S O 606
from Rolls-Royce
607 5103 Pilot starting air distributor with drive L L L O L L L O L L L O L L L O 607
7 LUBRICATING OIL 7
701 - Clean lubr.oil tank / sump when changing lubr.oil W W W W 701
702 1503 Lubr.oil analysis C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 702
C
703 8204 Main lubricating oil pump O O 703
704 8206 Lub. oil filters, by-pass valves and filter elements: replace at least every 6 months or at diff. pressure R R R R R R R R R R R R R R R R R R R R 704
705 8207 Centrifugal separation filter lubr.oil: clean every 500 hrs, paper insert to be changed when required W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W 705
706 b) Lubricating oil priming pump (electrical) C C C C C C C C C C C C C C C C 706
707 b) Lubr.oil cooler: see section 9 - cooling water quality / parameters Clean when necessary 707
708 8301 Valve gear lub. oil system: lubricating oil tank W W W W 708
709 8304 Valve gear lub. oil system: filter Clean daily 709
710 8303 Valve gear lub. oil system: strainer W W W W W W W W W W W W W W W W 710
8 CHARGE AIR AND EXHAUST SYSTEM 8
801 b) Turbocharger bearings: see sign on turbo charger housing See separate instructions 801
802 b) Turbocharger rotor: see sign on turbo charger housing See separate instructions 802
803 b) Turbocharger air filters: clean when dirty See separate instructions 803
804 b) Turbocharger lub. oil: change depending on oil quality and operating conditions, 100 hrs after overhaul See separate instructions 804
805 7106 Turbocharger - water washing of compressor: every 50 hrs See separate instructions 805
806 b) Charge air cooler: clean when necessary See separate instructions 806
807 7301 Exhaust manifold bellows C C C C C C C C C C C C C C C C 807
808 7301 Exhaust manifold insulation C C C C C C C C C C C C C C C C 808
9 COOLING WATER 9
901 8501 Cooling water quality and flow: check monthly C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 901
902 8503 Cooling water pumps with drive (high and low temperature) S O S O S O S O 902
903 b) Jacket water cooler (optional): clean when necessary O O O O 903
904 b) Sea water pump with drive (optional) C O C O C O C O C O C O C O C O 904
10 ALARM / CONTROL SYSTEM - FUNCTION TEST INTERVALS 10
1001 c) Auto stops According to classification requirements 1001
1002 - Interlocks According to classification requirements or at least once a year 1002
1003 - Emergency start Check monthly 1003
1004 b) Oil mist detector (optional) See separate instructions 1004
1005 - Temperature PID controller (optional) Every 3 months 1005
1006 - Control shaft linkages and fuel rack calibration Check weekly / lubricate 1006
1007 - Speed pick-up clearance and cleaning Check monthly 1007
1008 - Tightening of connectors and screw terminals Check once every 6 months 1008
1009 - Pressure transmitters and temperature sensors Every 3 months (according to classification requirements) 1009
1010 - Cleaning and visual checking of all electrical equipment Every 3 months 1010
1011 - Auxiliary equipment Every year 1011
1012 - Earth fault Check weekly 1012
11 MISCELLANEOUS 11
1101 2102 Resilient mounting of engine (optional): check for cracks / damages / loose bolts Every 6 months 1101
1102 - All flexible connections: hoses, bellows etc. Check every 2 months 1102
1103 5301 Governor / actuator Change oil every 3 months R R 1103
1104 - Governor control shaft with linkages and couplings Check / lubricate weekly 1104
1105 - Exhaust pipe insulation According to SOLAS regulations 1105
1106 - Screw and pipe connections - outside and inside on engine C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C 1106