Bergen B35:40 - Part 4: Routine Maintenance Schedule

S = Spot check
Instr 1502 C = Check all
W = Clean / adjust
O = Overhaul
R = Replace
ID Instr Draw no 1012_09
1 CYLINDER HEADS COMMENTS C S W O R
101 2404 Cylinder head bolts Retighten approx. 50-100 hrs after refitting of cyl.head 15
102 2408 Cylinder head: max. firing pressure 1st check 1k after main overhaul 2
104 4301 Inlet, exhaust and gas admission valve clearance Check also 50-100 hrs after refitting of cyl.head 2
105 2401 Inlet and exhaust valve rotators (rotocaps) 15
106 2401 Valve gear system for inlet and exhaust valves 15
107 2401 Inlet and exhaust valves / valve seats: overhaul / replace according to wear 15
108 2401 Inlet and exhaust valve guides: overhaul / replace according to wear 15
109 2408 Indicator valves 15
111 7230 Prechamber nozzle 15
112 7220 Gas control valves 5 15
113 7225 Gas admission valves 5 15
114 7240 Spark plugs and silicone seals: replace every 2k and after refitting of cyl.head. First "W" after 1k, then "R" at 2k, and then alternating "W"/"R" every other 1k 1 2
115 7230 Prechamber check valve assembly (ball valve assembly) 2 6
116 7232 Orifice prechamber gas supply First "W" after 2k 5
117 7240 High voltage cables and connectors: resistor check 5 15
118 - Cylinder pressure sensors (optional) 10
3 CYLINDER LINERS C S W O R
301 2301 Honing: overhaul / replace according to wear 15 30
302 2301 Remove liner / check water jacket / replace sealing 30
303 2301 Carbon cutting ring 15 30 60
4 PISTON / CONNECTING RODS C S W O R
401 3201 Gudgeon pin bushing Replace when off limit 30 15 60
402 3201 Gudgeon pin 30 15
403 3201 Piston including piston ring grooves (gap / clearance) 30 15 60
404 3201 Piston rings 15 30
405 3202 Big end bearing shells 3-piece connecting rod 15
407 3201 Big end bearing assembly (ovality control and surface check) 30 15
408 3201 Connecting rod bolts and shims between the big end bearing housing and the shank (3-piece connecting rod) 30
409 3201 Big end bearing bolts (3-piece connecting rod) 15
410 3201 Shim, nut, upper and lower studs (oblique split connecting rod) 15
5 CRANKSHAFT C S W O R
501 2201 Main bearings and thrust washers (including surface check of journal) 15 30
502 3102 Crankshaft deflection Check before and after every main service / docking 15
503 b) Flexible couplings (not applicable to generators directly bolted to the flywheel) 5
504 3302 Flywheel ring gir teeth and starting motor pinion (insert Molycote paste before use) 5
506 3101 Torsional vibration damper spring type 30
507 3101 Torsional vibration damper fluid type Subsequent fluid samples to be taken according to supplier's indications 15
508 3105 Flexible gear wheel, pump drive (pump end): Overhaul when replacing torsional vibration damper
509 3102 Crank pin (surface check) 15
6 CAMSHAFT C S W O R
601 4101 Camshaft bearings and thrust washers 15 45
603 4101 Inlet and exhaust cams 15
604 4102 Camshaft drive with gear wheels 15
605 5202 Governor drive 5 30
7 LUBRICATING OIL C S W O R
701 8201 Clean lubr.oil tank / sump 60
702 1503 Lubr.oil analysis 500 hrs after piston replacement 1
703 8204 Main lubricating oil pump 30
704 8206 Lub.oil filters with paper elements Replace at least every 6 months or at diff. pressure
705 8206 Lub.oil filters with fibre glass elements First replacement at 2k, then at diff.pressure
707 8207 Centrifugal separation filter lubr.oil: paper insert to be changed when required 1
708 8203 Lubricating oil priming pump (electrical) 5
709 b) Lubr.oil cooler: see section 9 cooling water quality / parameters Clean when necessary
8 CHARGE AIR AND EXHAUST SYSTEM C S W O R
801 b) Turbocharger bearings: see sign on turbocharger housing See separate instructions
802 b) Turbocharger rotor: see sign on turbocharger housing See separate instructions
803 b) Turbocharger air filters: clean when dirty See separate instructions
804 7106 Turbocharger - water washing of compressor: every 50 hrs See separate instructions
805 b) Charge air cooler: clean when necessary See separate instructions
806 7301 Exhaust manifold bellows 5
807 7301 Exhaust manifold insulation 5
808 b) Turbocharger VTG (Variable Turbine Geometry) / Wastegate See separate instructions
9 COOLING WATER C S W O R
901 8501 Cooling water quality and flow Check monthly
902 8503 Cooling water pumps with drive (high and low temperature) Mechanical seal must be replaced after min. 5 years 15
903 b) Jacket water cooler (optional) Clean when necessary
10 ALARM / CONTROL SYSTEM - FUNCTION TEST INTERVALS C S W O R
1001 1501 Auto stops According to classification requirements
1003 1501 Overspeed protection Replace pneumatic solenoid valve every 5 years
1004 1501 Interlocks According to classification requirements or at least once a year
1006 1501 Emergency start Check monthly
1007 1501 Alarm system communication Every year
1009 1501 Oil mist detector See separate instructions
1010 1501 Temperature PID controller Every 3 months
1011 1501 Lubrication of fuel pumps Check weekly or at every start
1013 1501 Control shaft linkages and fuel rack calibration Check weekly / lubricate
1014 1501 Speed pick-up clearance and cleaning Check monthly
1015 1501 Tightening of connectors and screw terminals Check once every 6 months
1016 1501 Pressure transmitters and temperature sensors Every 3 months (according to classification requirements)
1018 1501 Cleaning and visual checking of all electrical equipment Every 3 months
1019 1501 Auxiliary equipment Every year
1020 1501 Earth fault Check weekly
1021 - NOx sensor (optional) Replace according to condition 5
11 MISCELLANEOUS C S W O R
1105 - Resilient mounting of engine (optional): check for cracks / damages / loose bolts Every 6 months
1106 - All flexible connections: hoses, bellows etc. Check every 2 months
1107 b) Governor / actuator Change oil every 3 months 15 30
1108 - Governor control shaft with bearings, linkages and couplings Check / lubricate weekly, overhaul/replace according to wear
1109 b) Start air motor: clean strainer each year, drain air filter (when fitted) daily See separate instructions (Gali table for long cranking cycle > 5 sec)
1110 7301 Exhaust pipe insulation According to SOLAS regulations
1113 Gas Regulating Unit: yearly inspection including filter replacement According to classification requirements
1115 7229 Leakage test of gas pipe: outer annular volume - main gas According to classification requirements
1116 7229 Leakage test of gas pipe: outer annular volume - prechamber gas According to classification requirements
1119 7227 Flexible fuel gas connections: replace O-rings and gaskets 15
1 = 1000 hrs (1k)
We strongly recommend never to exceed service intervals on function critical parts and systems. In general we recommend not to exceed any indicated service interval.
S = Dismantle / inspect 1 item and check condition (leakage, abnormal wear, cracks, contamination etc.)
The intervals indicated in the RMS matrix are to be interpreted as repeating cycles, as running hours are accumulating.
If a cell shows a replacement interval range ("x-y"), the component is inspection dependable from the first interval.
Rev G November 2017
Routine Maintenance Schedule
B35:40 GAS Marine Operation
Main service every 15k
The intervals are reflecting what can be achieved under operation within specification by adequate maintenance and proactive attendance to any symptoms/negative trends by rectifying its origin prior to consequential defects and/or when operational disturbance occur.
The RMS is only valid for normal operating conditions as defined in the contracts, service agreements or other relevant technical documentation from Rolls-Royce.
The intervals are for guidance only and are subject to local ambient conditions. The schedule is applicable to engines with more than 2000 annual operating hrs.
The RMS may only be changed by a service letter from Rolls-Royce.
C = Check all - all specified components must be checked.
W = Clean / adjust - fine-tune the components to ensure optimal operation.
O = Overhaul - complete renovation in order to restore the components to original specifications.
R = Replace - replace the complete units with genuine parts.
b) = See separate instructions