Engine mounted sealing flaps maintenance

Diesel Customer Information No.
303
Action Code:
Immediately
Engine mounted
sealing flaps
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.
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.
The efficiency of the engine and the operational

performance of the turbocharger are improved by
opening the different flaps under different conditions.
Filing Advice
Assembly group / work card 280, 289
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.
MAN Diesel & Turbo SE

Head office (& postal address)
PrimeServ
After Sales Augsburg
PrimeServ
After Sales Technical
PrimeServ
After Sales Commercial
Stadtbachstrae 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 0
Fax:
+49 (0) 821 322 3382
mandiesel-de@mandieselturbo.com
www.mandieselturbo.com
Stadtbachstrae 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 3509
Fax:
+49 (0) 821 322 1530
primeserv-aug@mandieselturbo.com
Stadtbachstrae 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 1499 (24-h-hotline)
Fax:
+49 (0) 821 322 3838
primeserv-aug-technical@mandieselturbo.com
Stadtbachstrae 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 1799 (24-h-hotline)
Fax:
+49 (0) 821 322 3574
primeserv-aug-commercial@mandieselturbo.com
MAN Diesel & Turbo a member of the MAN Group
DCI / No. 303 - May 2011
The scope of work includes the removal and inspection of the flap/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: primeserv-aug-technical@mandieselturbo.com
Robert Glauber
Senior Vice President
After Sales
Jrn 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.
Diesel Customer Information Engine mounted sealing flaps - Page 2 of 2
Maintenance schedule
(Systems)
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
6628 4.7.1-02
4.7.1
MAN Diesel & Turbo
Fuel system
004
Check the system components for

leakage (visual inspection)
0.20
Engine
005
Service tank: Check the fuel level; drain A

the service tank and settling tank
0.20
Engine
006
Check Viscosimat (carry out

comparative temperature
measurement)
0.10
Unit
007
Clean fuel filter (depending on the

differential pressure)
Filter
1 1 1 1 1 1 1 1 1 1 1
008
Overhaul the fuel delivery pump
Pump
3 3 3 3 3 3 3 3 3 3 3
009
Inspect/overhaul the buffer piston(s)
434.04
Unit
Lube oil system

011

0.20
Engine
012
Service tank for engine and cylinder

lubrication: Check oil level
0.10
Engine
014
Examine oil sample (spot test)
000.05
0.20
Engine
015
Have the oil sample analysed
000.04
0.30
Engine
016
Change oil filling (depending on results

of analysis), clean the tank
000.04
Engine
017
Check oil drain from piston, connecting A

rod and crankshaft bearings, from the
gear drive system and the turbocharger
(visually) - see also 401
0.20
018
Check oil drain (visually) from camshaft

bearings, high-pressure pumps and
valve gear (in the rocker arm casing) see also 401
020
Overhaul the lubricating oil pump
300.01
023
Clean the lubricating oil service filter

(depending on scavenging intervals)
Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
Filter
1 1 1 1 1 1 1 1 1 1 1
Clean the lubricating oil indicator filter

B
1
(dependent upon the differential
pressure)
24 ...
Repetition interval in operating hours
X
Maintenance work due
*
x 1000 h
1
As required/depending on condition
3
According to specification of manufacturer
4
If component/system is given
Filter
1 1 1 1 1 1 1 1 1 1 1
6628 4.7.1-02 EN
32/40
1 1 1 1 1 1 1 1 1 1 1
2011-04-05 - de
024
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
6628 4.7.1-02
1,
2,
3
025
Clean the lubricating oil preheater

(dependent on separating temperature
at required flow rate). Possibly have
cleaning carried out by a specialist
company
Unit
1 1 1 1 1 1 1 1 1 1 1
026
Check, clean and overhaul the

lubricating oil separator (selfdischarging)
Unit
1 1 1 1 1 1 1 1 1 1 1
027
Clean the lubricating oil cooler (possibly C

performed by specialist company)
Unit
1 1 1 1 1 1 1 1 1 1 1
Cooling water system (cylinder and nozzle cooling)

031
Compensating tank: Check the cooling

water level
0.20
Engine
032
Check nozzle cooling water outlet (for

unobstructed drainage and possible
traces of fuel)
0.10
Engine
033
Cooling water: Check the corrosion

protection - refer to 401
000.07
Engine
035
Check cooling spaces, chemically clean 000.08

the system (cylinder and nozzle
cooling). Possibly have cleaning carried
out by a specialist company
Engine
1 1 1 1 1 1 1 1 1 1 1
036
Cooling water heat exchanger: Clean

the cooling spaces, possibly by
specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1
Compressed air and control air system

042
Compressed air tank: drain water after

every filling (if there is no automatic
drainage)
0.10
Unit
043
Clean the inside of the compressed air

tank, overhaul the valves (in
accordance with the regulations of the
classification society)
10
Unit
1 1 1 1 1 1 1 1 1 1 1
044
Control air system: Drain water

separator and air filter
125.10
0.10
Engine
045
Control air system: Clean water

125.10
Engine
0.10
X
X
Charge air system
2 (4)
Charge air cooler/charge air pipe:

Check condensed water discharge for
quantity/free flow
Clean charge air cooler on both water

322.01 2
and air sides, possibly by specialist
322.02
company
24 ...
X
*
x 1000 h
1
3
4
6628 4.7.1-02 EN
15
Pipe
Radiator 1 1 1 1 1 1 1 1 1 1 1
2011-04-05 - de
053
32/40
052
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
054
Charge air bypass/blow-off device:

A
Check system components for leakage
(visually). Check control and monitoring
elements for proper function
Engine
055
Shut-off flaps on engine: Dismount and 280.02

check for cracks. Every 6000
operational hours or once a year
Engine
Engine
1 1 1 1 1 1 1 1 1 1 1
6628 4.7.1-02
4.7.1
MAN Diesel & Turbo
Exhaust gas system

062
Exhaust gas blow-off device: Check

A
system components for leakage
063
Exhaust pipe: Check flange

connections and compensators for
tightness (visually)
289.01
0.20
Pipe
064

Unit
1 1 1 1 1 1 1 1 1 1 1
Measuring, control and regulation systems

072
Switching and shut-down devices:

Check functional capability and
switching points - also see 402
Engine
073
Dismantle the control valves in the 10

and 30 bar system, replace wear parts
125.xx
24
Engine
074
Battery: Check the charge status and

the acid level
0.50
Engine
075
Inspect/overhaul the oil mist detector
Engine
076
Check the exhaust gas temperature

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3
Engine foundation/pipe connections

082
Foundation bolts: Check pretension.

012.01
Check firm seating of stoppers,
brackets and resilient elements (in case
of marine engines also after collision or
grounding) - see also 402
Engine
083
Resilient mounting: Determine the

amount of setting of the elastic
elements
012.01
Engine
084
Elastic pipe connections: Check all

hoses
Engine
14
Engine
6628 4.7.1-02 EN
1 1 1 1 1 1 1 1 1 1 1
32/40
Elastic pipe connections: Replace

A
2
hoses for fuel, lubricating oil, cooling
water, steam and compressed air
24 ...
X
*
x 1000 h
1
3
4
2011-04-05 - de
085
3 (4)
4.7.1
MAN Diesel & Turbo
086
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
6628 4.7.1-02
1,
2,
3
Screwed connections: check for tight
000.30
fit/proper pretension (e.g. on exhaust
gas and charge air pipe, charge air
cooler and turbocharger) - see also 402
10
Engine
Flexible coupling/turning gear

092
Flexible coupling: Check alignment and 000.09

rubber elements
Engine
093
Coupling bolts: check for tight fit/proper 020.04

pretension - see also 402
Engine
094
Inspect/overhaul the turning gear
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
Unit
Additionally required
401
2011-04-05 - de
Check installed new parts or installed

D
overhauled parts/newly added
lubricants once after the indicated
interval - applies to 072, 082, 086, 093
24 ...
X
*
x 1000 h
1
3
4
32/40
402

interval - applies to 017, 018, 033
4 (4)
6628 4.7.1-02 EN
(systems - biofuel operation)
per
24
150
250
500
1-2*
2-3*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
6628 4.7.1-03
4.7.1
MAN Diesel & Turbo
Fuel system
002
Analyse fuel sample (all characteristics

of the specification)
000.05
0.20
Engine
003
Analyse the fuel sample for acid

content (TAN)
000.04
0.30
Engine
004

0.20
Engine
005

0.20
Engine
006

measurement)
0.10
Unit
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
009
434.04
Unit
Lube oil system

011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
Engine
017

0.20
018

020
300.01
1 1 1 1 1 1 1 1 1 1 1
Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
Filter
1 1 1 1 1 1 1 1 1 1 1
6628 4.7.1-03 EN
32/40

B
1
24 ...
X
*
x 1000 h
1
3
4
2011-04-05 - de
023
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
2-3*
5-6*
10-12*
20-24*
30-40*
50-60*
6628 4.7.1-03
1,
2,
3
024

pressure)
Filter
1 1 1 1 1 1 1 1 1 1 1
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1

031

water level
0.20
Engine
032

traces of fuel)
0.10
Engine
033

000.07
Engine
035

Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1
042

drainage)
0.10
Unit
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
Engine
X
X
Charge air system
2 (4)

A
1
quantity/free flow
24 ...
X
*
x 1000 h
1
3
4
6628 4.7.1-03 EN
0.10
Pipe
X
2011-04-05 - de
052
32/40
per
24
150
250
500
1-2*
2-3*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
053

company
054
055
322.01
322.02
15
Radiator 1 1 1 1 1 1 1 1 1 1 1

A
Engine

Engine
Engine
1 1 1 1 1 1 1 1 1 1 1
6628 4.7.1-03
4.7.1
MAN Diesel & Turbo
Exhaust gas system

062

A
063

289.01
0.20
Pipe
064

Unit
1 1 1 1 1 1 1 1 1 1 1

072

Engine
073

125.xx
24
Engine
074

the acid level
0.50
Engine
075
Engine
076

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3

012.01
Engine
083

elements
012.01
Engine
084

hoses
Engine
14
Engine
085

A
2
24 ...
X
*
x 1000 h
1
3
4
6628 4.7.1-03 EN
4
1 1 1 1 1 1 1 1 1 1 1
32/40
082
2011-04-05 - de
3 (4)
4.7.1
MAN Diesel & Turbo
086
per
24
150
250
500
1-2*
2-3*
5-6*
10-12*
20-24*
30-40*
50-60*
6628 4.7.1-03
1,
2,
3
000.30
10
Engine

092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
Unit
401
2011-04-05 - de

D
24 ...
X
*
x 1000 h
1
3
4
32/40
402

4 (4)
6628 4.7.1-03 EN
(Systems)
per
24
150
250
500
1500
3000
6000
12000
24000
30000
36000
1,
2,
3
6640 4.7.1-01
4.7.1
MAN Diesel & Turbo
Fuel system
004

0.20
Engine
005

0.20
Engine
006

measurement)
0.10
Unit
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
009
434.04
Unit
Lube oil system

011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
Engine
017

0.20
018

020
300.01
022
Overhaul the cylinder lubricating oil unit

or pump, the block distributor and the
monitoring devices
023

Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
302.01
Unit
1 1 1 1 1 1 1 1 1 1 1
Filter
1 1 1 1 1 1 1 1 1 1 1

B
1
pressure)
24 ...
X
1
3
4
Filter
1 1 1 1 1 1 1 1 1 1 1
6640 4.7.1-01 EN
L58/64
1 1 1 1 1 1 1 1 1 1 1
2011-04-04 - de
024
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1500
3000
6000
12000
24000
30000
36000
6640 4.7.1-01
1,
2,
3
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1

031

water level
0.20
Engine
032

traces of fuel)
0.10
Engine
033

000.07
Engine
035

Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1

042

drainage)
0.10
Unit
1 1 1 1 1 1 1 1 1 1 1
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
Engine
0.10
X
X
Charge air system
2 (4)

quantity/free flow

322.01 2
322.02
company
24 ...
X
1
3
4
6640 4.7.1-01 EN
15
Pipe
Radiator 1 1 1 1 1 1 1 1 1 1 1
2011-04-04 - de
053
L58/64
052
per
24
150
250
500
1500
3000
6000
12000
24000
30000
36000
1,
2,
3
054

A
Engine
1 1 1 1 1 1 1 1 1 1 1
055

Engine
Engine
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1
6640 4.7.1-01
4.7.1
MAN Diesel & Turbo
Exhaust gas system

062

A
063

289.01
0.20
Pipe
064

Unit

072

Engine
073

125.xx
24
Engine
074

the acid level
0.50
Engine
075
Engine
076

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3
082

012.01
Engine
083

elements
012.01
Engine
084

hoses
Engine
085

14
Engine

000.30 2
24 ...
X
1
3
4
10
Engine
6640 4.7.1-01 EN
1 1 1 1 1 1 1 1 1 1 1
L58/64
086
2011-04-04 - de
3 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1500
3000
6000
12000
24000
30000
36000
6640 4.7.1-01
1,
2,
3
092

rubber elements
Engine
093

preload - see also 402
Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
Unit
401
2011-04-04 - de

D
24 ...
X
1
3
4
L58/64
402

4 (4)
6640 4.7.1-01 EN
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
6706 4.7.1-01
4.7.1
MAN Diesel & Turbo
Fuel system
002

000.05
0.15
Engine
003

content (TAN)
000.04
0.30
Engine
004

0.20
Engine
005

0.20
Engine
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
009
434.04
Unit
Lube oil system

011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
Engine
017

0.20
018

bearings, injection pumps and valve
gear (in the rocker arm casing) - see
also 401
020
300.02
B
023

Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
Filter
1 1 1 1 1 1 1 1 1 1 1

B
1
pressure)
24 ...
X
*
x 1000 h
1
3
4
Filter
1 1 1 1 1 1 1 1 1 1 1
6706 4.7.1-01 EN
48/60B
1 1 1 1 1 1 1 1 1 1 1
2011-04-04 - de
024
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6706 4.7.1-01
1,
2,
3
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1
Cooling water system

031

water level
0.20
Engine
033
cooling water: Check the corrosion

protection - see also 401
000.07
0.50
Engine
035

Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1
X
X

042
Drain the water from the compressed

A
air tank (if it is not automatically drained)
0.10
Unit
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
B
0.10
Engine
045

125.10
B
0.50
Engine
Pipe
X
X

quantity/free flow
0.10
053

company
322.01
322.03
15
2 (4)

A
1
24 ...
X
*
x 1000 h
1
3
4
6706 4.7.1-01 EN
0.50
Radiator 1 1 1 1 1 1 1 1 1 1 1
Engine
1 1 1 1 1 1 1 1 1 1 1
2011-04-04 - de
052
054
48/60B
Charge air system
055
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
Engine
Exhaust gas system

062

A
0.50
Engine
063

0.20
Pipe
064

Unit
6706 4.7.1-01
4.7.1
MAN Diesel & Turbo
1 1 1 1 1 1 1 1 1 1 1

072

Engine
073

125.xx
24
Engine
074

the acid level
0.50
Engine
075
Engine
076

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3

082

012.01
Engine
083

elements
012.01
Engine
084

hoses
Engine
085

14
Engine

000.30 2
24 ...
X
*
x 1000 h
1
3
4
10
Engine
6706 4.7.1-01 EN
48/60B
1 1 1 1 1 1 1 1 1 1 1
2011-04-04 - de
086
3 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6706 4.7.1-01
1,
2,
3
092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
401
Unit
2011-04-04 - de

D
24 ...
X
*
x 1000 h
1
3
4
48/60B
402

4 (4)
6706 4.7.1-01 EN
(Systems)
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
6706 4.7.1-02
4.7.1
MAN Diesel & Turbo
Fuel system
002

000.05
0.15
Engine
003

content (TAN)
000.04
0.30
Engine
004

0.20
Engine
005

0.20
Engine
006

measurement)
0.10
Unit
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
009
434.04
Unit
Lube oil system

011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
017

0.20
018

also 401
Engine
020
300.02
B
10
Pump
1 1 1 1 1 1 1 1 1 1 1
X
1 1 1 1 1 1 1 1 1 1 1
X
Overhaul the cylinder lubricating oil unit A

1
4
Unit
1 1 1 1 1 1 1 1 1 1 1
monitoring devices
24 ...
X
*
x 1000 h
1
2
Checking of new or overhauled parts required (once after the mentioned time)
3
4
6706 4.7.1-02 EN
48/60B
Unit;Cyl. 2
2011-04-04 - de
022
Engine
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6706 4.7.1-02
1,
2,
3
023

Filter
1 1 1 1 1 1 1 1 1 1 1
024

pressure)
Filter
1 1 1 1 1 1 1 1 1 1 1
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1

031

water level
0.20
Engine
032

traces of fuel)
0.10
Engine
033

000.07
0.50
Engine
2 X
035

Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1
042

A
0.10
Unit
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
0.50
Engine
X
X
052
2 (4)

A
1
0.10
Pipe
X
quantity/free flow
24 ...
X
*
x 1000 h
1
2
3
4
6706 4.7.1-02 EN
2011-04-04 - de
Charge air system
48/60B
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
053

company
322.01
322.03
15
Radiator 1 1 1 1 1 1 1 1 1 1 1
054

280.02
Check system components for leakage A
0.50
Engine
055

Engine
1 1 1 1 1 1 1 1 1 1 1
6706 4.7.1-02
4.7.1
MAN Diesel & Turbo
Exhaust gas system

062

289.02
A
0.50
Engine
063

289.01
0.20
Pipe
064

Unit
1 1 1 1 1 1 1 1 1 1 1

072

Engine
073

125.xx
24
Engine
074

the acid level
0.50
Engine
075
Engine
076

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3
3

2
Engine
083

elements
Engine
2011-04-04 - de
084
012.01

A
1
1
Engine
4
hoses
24 ...
X
*
x 1000 h
1
2
3
4
6706 4.7.1-02 EN
48/60B

012.01
082
3 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6706 4.7.1-02
1,
2,
3
085

086

000.30
14
Engine
10
Engine
1 1 1 1 1 1 1 1 1 1 1

092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
4
2
401
2011-04-04 - de

D
Unit
X
24 ...
X
*
x 1000 h
1
2
3
4
48/60B
402

4 (4)
6706 4.7.1-02 EN
(Systems)
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-35*
36-40*
1,
2,
3
6727 4.7.1-02
4.7.1
MAN Diesel & Turbo
Fuel system
004

0.20
Engine
005

0.20
Engine
006

measurement)
0.10
Unit
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
009
Check/clean the leakage container of

the high pressure, fracture and longterm leakage
0.50
Unit
011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
017

0.20
018

020
300.02
B
022
Overhaul the cylinder lubricating oil unit

monitoring devices
X
1 1 1 1 1 1 1 1 1 1 1
Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
Unit
1 1 1 1 1 1 1 1 1 1 1

B
1
24 ...
X
*
x 1000 h
1
3
4
Filter
1 1 1 1 1 1 1 1 1 1 1
6727 4.7.1-02 EN
48/60CR
023
2011-04-01 - de
Lube oil system
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-35*
36-40*
6727 4.7.1-02
1,
2,
3
024

pressure)
Filter
1 1 1 1 1 1 1 1 1 1 1
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1

031

water level
0.20
Engine
032

traces of fuel)
0.10
Engine
033

000.07
0.50
Engine
035

Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1
042

drainage)
0.10
Unit
1 1 1 1 1 1 1 1 1 1 1
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
Engine
X
X
Charge air system
2 (4)

A
1
quantity/free flow
24 ...
X
*
x 1000 h
1
3
4
6727 4.7.1-02 EN
0.10
Pipe
X
2011-04-01 - de
052
48/60CR
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-35*
36-40*
1,
2,
3
053

company
322.01
322.03
15
Radiator 1 1 1 1 1 1 1 1 1 1 1
054

280.02
Check system components for leakage A
0.50
Engine
055

Engine
1 1 1 1 1 1 1 1 1 1 1
6727 4.7.1-02
4.7.1
MAN Diesel & Turbo
Exhaust gas system

062

289.02
A
0.50
Engine
1 1 1 1 1 1 1 1 1 1 1
063

289.01
0.20
Pipe
1 1 1 1 1 1 1 1 1 1 1
064

Unit

072

Engine
073

125.xx
24
Engine
074
Accumulator pack for interruption-free

power supply of the Common Rail
control system: Check charge status
0.50
Engine
075
Accumulator pack for interruption-free

power supply of the Common Rail
control system: replace
0.50
Engine
076
Engine
077
Check measuring system for exhaust

gas temperatures
Engine
Engine

012.01 2
elements
24 ...
X
*
x 1000 h
1
3
4
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3
2011-04-01 - de
083

012.01
6727 4.7.1-02 EN
48/60CR
082
3 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-35*
36-40*
6727 4.7.1-02
1,
2,
3
084

hoses
Engine
085

14
Engine
086

000.30
10
Engine
1 1 1 1 1 1 1 1 1 1 1

092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
Unit
D

D
24 ...
X
*
x 1000 h
1
3
4
48/60CR
402

4 (4)
2011-04-01 - de
401
6727 4.7.1-02 EN
(Systems)
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
6730 4.7.1-02
4.7.1
Fuel system
004

0.20
Engine
005

0.20
Engine
006

measurement)
0.10
Unit
007

Filter
1 1 1 1 1 1 1 1 1 1 1
008
Pump
3 3 3 3 3 3 3 3 3 3 3
Lube oil system

011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
017

0.20
018

020
300.01
023

Unit;Cyl.
Engine
10
Pump
1 1 1 1 1 1 1 1 1 1 1
Filter
1 1 1 1 1 1 1 1 1 1 1

B
1
2
Filter
1 1 1 1 1 1 1 1 1 1 1
pressure)
24 ...
X
*
x 1000 h
1
2
3
4
6730 4.7.1-02 EN
32/44CR
1 1 1 1 1 1 1 1 1 1 1
2011-04-06 - de
024
1 (4)
4.7.1
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
6730 4.7.1-02
1,
2,
3
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

1 1 1 1 1 1 1 1 1 1 1

031

water level
0.20
Engine
032
Check the nozzle cooling water return

(for unhindered flow and eventual
traces of fuel - when using heavy fuel)
0.10
Engine
033

000.07
0.50
Engine
035

1 1 1 1 1 1 1 1 1 1 1
036
cooling water heat exchanger: Clean

specialist company
1 1 1 1 1 1 1 1 1 1 1

042

A
0.10
Unit
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
0.50
Engine
0.10
Pipe
X
X
Charge air system
2 (4)

quantity/free flow

322.01 2
15
Radiator 1 1 1 1 1 1 1 1 1 1 1
company
24 ...
X
*
x 1000 h
1
2
3
4
6730 4.7.1-02 EN
2011-04-06 - de
053
32/44CR
052
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
1,
2,
3
054
In case available: <br/> Charge air

280.02
bypass/blow-off device: Check system
components for leakages (visually).
Check control and monitoring elements
for proper function
0.50
Engine
055
Shut-off valves on engine: Dismount

and check for cracks. Every 6000
Engine
280.02
000.34
1 1 1 1 1 1 1 1 1 1 1
6730 4.7.1-02
4.7.1
Exhaust gas system

062
In case available: <br/> Exhaust gas

A
blow-off device: Check system
components for leakages (visually).
Check control and monitoring elements
for proper function
0.50
Engine
1 1 1 1 1 1 1 1 1 1 1
063

289.01
0.20
Pipe
064
Shut-off valves on engine: Dismount

and check for cracks. Every 6000
289.02
000.34
Unit

072

Engine
073

125.xx
24
Engine
074
Batteries in the control cabinet: replace A
0.50
Engine
075
Engine
X
X
3 3 3 3 3 3 3 3 3 3 3

2
Engine
083

elastic elements settling value
012.01
Engine
084

hoses
Engine
085

14
Engine
2011-04-06 - de
086
4
4
1 1 1 1 1 1 1 1 1 1 1

000.30 2
10
Engine
24 ...
X
*
x 1000 h
1
2
3
4
6730 4.7.1-02 EN
32/44CR

012.01
082
3 (4)
4.7.1
per
24
150
250
500
1-2*
3-4*
5-6*
10-12*
20-24*
30-40*
50-60*
6730 4.7.1-02
1,
2,
3
092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
D
4 (4)

D
X
24 ...
X
*
x 1000 h
1
2
3
4
32/44CR
402

2011-04-06 - de
401
6730 4.7.1-02 EN
(Systems)
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
6736 4.7.1-01
4.7.1
MAN Diesel & Turbo
Fuel system/pilot oil system

004

0.20
Engine
005

0.20
Engine
007
Clean main fuel filter and replace pilot

oil cartridge (dependent upon
Filter
1 1 1 1 1 1 1 1 1 1 1
008
Fuel delivery pump and pilot oil pump
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
434.04
Unit
Gas system
500
Check gas pipe and gas control route

for tightness (visually)
230.01
0.20
Engine
501
Check the shut-off valves for leakage
0.20
Engine
1 1 1 1 1 1 1 1 1 1 1
502
Clean gas filter, replace if necessary
Filter
1 1 1 1 1 1 1 1 1 1 1
503
Check gas pressure regulator and

replace diaphragm if necessary
Unit
011

0.20
Engine
012

0.10
Engine
014
000.05
0.20
Engine
015
000.04
0.30
Engine
016

000.04
017

0.20
018

also 401
020
X
1 1 1 1 1 1 1 1 1 1 1
Unit;Cyl. 2
Engine
300.02 2
10
Pump
1 1 1 1 1 1 1 1 1 1 1
B
x 1000 h
6736 4.7.1-01 EN
51/60DF
24 ...
X
*
1
2
3
4
Engine
2011-04-04 - de
Lube oil system
1 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6736 4.7.1-01
1,
2,
3
023

Filter
1 1 1 1 1 1 1 1 1 1 1
024

pressure)
Filter
1 1 1 1 1 1 1 1 1 1 1
025

company
Unit
1 1 1 1 1 1 1 1 1 1 1
026

Unit
1 1 1 1 1 1 1 1 1 1 1
027

Unit
1 1 1 1 1 1 1 1 1 1 1
Cooling water system

031

water level
0.20
Engine
033

000.07
0.50
Engine
2 X
035
Check cooling channels, chemically

clean the system (cylinder cooling).
Possibly have cleaning carried out by a
specialist company
000.08
Engine
1 1 1 1 1 1 1 1 1 1 1
036

specialist company
Unit
1 1 1 1 1 1 1 1 1 1 1

042

A
0.10
Unit
043

10
Unit
1 1 1 1 1 1 1 1 1 1 1
044

125.10
0.10
Engine
045

125.10
0.50
Engine
0.10
Pipe
X
X
053
2 (4)

quantity/free flow

322.01 2
15
Radiator 1 1 1 1 1 1 1 1 1 1 1
322.03
company
24 ...
X
*
x 1000 h
1
2
3
4
6736 4.7.1-01 EN
2011-04-04 - de
052
51/60DF
Charge air system
per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
1,
2,
3
054
Compressor by-pass: Check control

and monitoring elements for proper
function
0.50
Engine
055

Engine
1 1 1 1 1 1 1 1 1 1 1
6736 4.7.1-01
4.7.1
MAN Diesel & Turbo
Exhaust gas system

063

289.01
0.20
Pipe
064

Unit

072

Engine
073

125.xx
24
Engine
074

the acid level
0.50
Engine
075
Engine
076

measuring system
Engine
X
4
3 3 3 3 3 3 3 3 3 3 3
3

2
Engine
083

elements
012.01
Engine
084

hoses
Engine
085

14
Engine
2011-04-04 - de
086
4
1 1 1 1 1 1 1 1 1 1 1

000.30 2
10
Engine
2
24 ...
X
*
x 1000 h
1
2
3
4
6736 4.7.1-01 EN
51/60DF

012.01
082
3 (4)
4.7.1
MAN Diesel & Turbo

per
24
150
250
500
1-2*
3-4*
5-6*
10-15*
20-24*
25-30*
30-40*
6736 4.7.1-01
1,
2,
3
092

rubber elements
Engine
093

Engine
094
Unit
3 3 3 3 3 3 3 3 3 3 3
Unit
4
2
D

D
Unit
X
24 ...
X
*
x 1000 h
1
2
3
4
51/60DF
402

2011-04-04 - de
401
4 (4)
6736 4.7.1-01 EN

Engine mounted sealing flaps maintenance

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Engine mounted sealing flaps maintenance

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Diesel Customer Information No.

DCI / 303 - May 2011

The efficiency of the engine and the operational

MAN Diesel & Turbo SE

DCI / No. 303 - May 2011

Please forward this information to your technical operational personnel and

Diesel Customer Information Engine mounted sealing flaps - Page 2 of 2

MAN Diesel & Turbo

Check the system components for

Service tank: Check the fuel level; drain A

Check Viscosimat (carry out

Clean fuel filter (depending on the

Overhaul the fuel delivery pump

Inspect/overhaul the buffer piston(s)

Lube oil system

Check the system components for

Service tank for engine and cylinder

Examine oil sample (spot test)

Have the oil sample analysed

Change oil filling (depending on results

Check oil drain from piston, connecting A

Check oil drain (visually) from camshaft

Overhaul the lubricating oil pump

Clean the lubricating oil service filter

Clean the lubricating oil indicator filter

MAN Diesel & Turbo

Clean the lubricating oil preheater

Check, clean and overhaul the

Clean the lubricating oil cooler (possibly C

Cooling water system (cylinder and nozzle cooling)

Compensating tank: Check the cooling

Check nozzle cooling water outlet (for

Cooling water: Check the corrosion

Check cooling spaces, chemically clean 000.08

Cooling water heat exchanger: Clean

Compressed air and control air system

Compressed air tank: drain water after

Clean the inside of the compressed air

Control air system: Drain water

Control air system: Clean water

Charge air system

Charge air cooler/charge air pipe:

Clean charge air cooler on both water

Charge air bypass/blow-off device:

Shut-off flaps on engine: Dismount and 280.02

MAN Diesel & Turbo

Exhaust gas system

Exhaust gas blow-off device: Check

Exhaust pipe: Check flange

Shut-off flaps on engine: Dismount and 289.02

Measuring, control and regulation systems

Switching and shut-down devices:

Dismantle the control valves in the 10

Battery: Check the charge status and

Inspect/overhaul the oil mist detector

Check the exhaust gas temperature

Engine foundation/pipe connections

Foundation bolts: Check pretension.

Resilient mounting: Determine the

Elastic pipe connections: Check all

Elastic pipe connections: Replace

MAN Diesel & Turbo