L28/32H Instruction Manual - Marine Four-Stroke Genset Compliant with IMO Tier II MAN Diesel

L28/32H Instruction Manual - Marine Four-stroke GenSet compliant with IMO Tier II MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Engine data 500/600 Preface Description A6000 Warning Description A6001 Questionnaire Description A6002 Main particulars Description 600.00 (07H) Introduction Description 600.01 (08H) Safety Description 600.02 (06H) Cross section Description 600.05 (07H) Key for engine designation Description 600.10 (02H) Designation of cylinders Description 600.11 (01H) Engine rotation clockwise Description 600.12 (02H) Code identification for instruments Description 600.20 (03H) Introduction to planned maintenance programme Description 600.24 (02H) Planned maintenance programme Description 600.25 (33H) Operation data & set points Description 600.30 (50H) Green Passport Description 600.33 (02H) Data for pressure and tolerance Description 600.35 (16H) Data for tightening torque Description 600.40 (18H) Declaration of weight Description 600.45 (01H) Ordering of spare parts Description 600.50 (06H) How to return spare parts Description 600.51 (05H) Service letters Description 600.55 (01H) Conversion table Description 600.60 (01) Basic symbol for piping Description 600.65 (01H) Operation of engine 501/601 Operating Description 601.01 (21H) Out of service Description 601.05 (17H) Starting-up after out of service periods Description 601.10 (17H) Guidelines for longterm low-load operation on HFO Description 601.15 (03H) Guidelines regarding MAN Diesel GenSets operating on low Description 601.16 (02H) sulphur fuel oil Performance and condition 502/602 Engine performance and condition Description 602.01 (12H) Evaluation of readings regarding combustion condition Description 602.02 (11H) Condensate amount Description 602.05 (08H) Engine performance data Working card 602-01.00 (03H) Trouble shooting 503/603 Starting failure Description 603.01 (08H) Faults in fuel oil system Description 603.02 (09H) Disturbances during running Description 603.03 (08H) Ignition in crankcase Description 603.04 (09H) Trouble shooting guide for centrifugal by-pass filter Description 603.05 (08H) Trouble shooting guide for turbine starter Description 603.06 (09H) Trouble shooting guide for cooling water system Description 603.09 (08H) Trouble shooting guide for lubricating oil cooler Description 603.10 (01H) Media specification 504/604 Quality requirement for lube oil (SAE30) for heavy fuel oil operation Description 604.01 (27H) (HFO) MAN Diesel

Index GenSet

L28-2

Text Index Drawing No.

Quality requirem. for lube oil (SAE30) for operation with gas oil, diesel Description 604.01 (26H) oil (MGO/MDO) and biofuel Treatment and maintenance of lubricating oil Description 604.03 (11H) Criteria for cleaning/exchange of lubricating oil Description 604.04 (17H) Lubricating points Description 604.05 (01H) Lubricating points Description 604.05 (02H) Lubricating oil in base frame Description 604.06 (16H) Specific lube oil consumption - SLOC Description 604.07 (02H) Heavy fuel oil (HFO) specification Description 3.3.3-01 Diesel oil (MDO) specification Description 3.3.2-01 Gas oil / diesel oil (MGO) specification Description 3.3.1-01 Bio fuel specification Description 3.3.1-02 Viscosity-temperature diagram (VT diagram) Description 3.3.4-01 Fuel oil cleaning Description 604.30 (01H) Engine cooling water specifications Description 3.3.7-01 Cooling water inspecting Description 000.07-01 Cooling water system cleaning Description 000.08-01 Water specification for fuel-water emulsions Description 3.3.10-01 Specifications for intake air (combustion air) Description 3.3.11-01 Cylinder head 505/605 Cylinder head Description 605.01 (14H) Dismantling of cylinder head Working card 605-01.00 (01H) Inspection of inlet valve, exhaust valve and valve guide Working card 605-01.05 (06H) Reconditioning of valve spindle seat and valve seat ring Working card 605-01.10 (01H) Valve rotator Working card 605-01.15 (01H) Replacement of valve guide Working card 605-01.20 (05H) Safety valve Working card 605-01.25 (04H) Indicator valve Working card 605-01.26 (02H) Replacement of sleeve for fuel injector Working card 605-01.30 (04H) Replacement of valve seat ring Working card 605-01.35 (06H) Mounting of cylinder head Working card 605-01.40 (06H) Inspection of cylinder head cooling water space Working card 605-01.45 (01H) Cylinder head Plate 60501-19H Valve spindles and valve gear Plate 60502-31H Safety valve and indicator valve Plate 60508-11H Cylinder head, top cover Plate 60510-12H Piston/connecting rod 506/606 Piston, connecting rod and cylinder liner Description 606.01 (10H) Dismounting of piston and connecting rod Working card 606-01.00 (01H) Separation of piston and connecting rod Working card 606-01.05 (03H) Piston Working card 606-01.10 (09H) Connecting rod Working card 606-01.15 (04H) Criteria for replacement of connecting rod big-end and main bearing Working card 606-01.16 (02H) shells Mounting of piston and connecting rod Working card 606-01.20 (01H) Hydraulic tightening of connecting rod screws Working card 606-01.25 (04H) In-situ inspection of connecting rod big-end bearing Working card 606-01.30 (01H) Inspection and honing of cylinder liner Working card 606-01.35 (08H) Replacement of cylinder liner Working card 606-01.40 (01H) Grinding of seal face on cylinder liner and cylinder head Working card 606-01.45 (01H) Dismounting of piston and cylinder liner at low overhaul heights Working card 606-01.50 (01H) Piston and connecting rod (hydraulic tightened) Plate 60601-34H Cylinder liner Plate 60610-09H MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Camshaft 507/607 Camshaft and camshaft drive Description 607.01 (05H) Camshaft and camshaft drive Working card 607-01.00 (01H) Inspection and replacement of camshaft bearing Working card 607-01.05 (01H) Adjustment of camshaft for valve and injection timing Working card 607-01.20 (04H) Intermediate wheel Plate 60701-06H Camshaft and camshaft bearing Plate 60705-22H Operating gear 508/608 Operating gear for valves and fuel injection pumps Description 608.01 (12H) Inspection of valve roller guides Working card 608-01.00 (01H) Inspection of fuel injection pump roller guide Working card 608-01.05 (01H) Control and adjustment of valve clearance Working card 608-01.10 (01H) Roller guide and push rods Plate 60801-17H Control/safety 509/609 Control and safety system Description 609.01 (20H) Instruments and automatics Description 609.05 (11H) Lambda controller Description 609.10 (15H) Starting box Description 609.35 (06H) Converter for engine- and turbocharger RPM signal Description 609.40 (01H) Functional test and adjustment of safety, alarm and monitoring Working card 609-01.00 (01H) equipment Functional test and adjustment of overspeed trip Working card 609-01.05 (01H) Adjustment and test of ON/OFF pressostate Working card 609-05.00 (02H) Adjustment and test of ON/OFF thermostate Working card 609-05.01 (02H) Function and test of level switch (LAL 25) Working card 609-05.02 (02H) Adjustment and test of analogous transmitter Working card 609-05.03 (02H) Adjustment and test of analogous temperature transmitter Working card 609-05.04 (02H) Adjustment of lambda controller Working card 609-10.00 (16H) Governor and governor drive Plate 60901-13H Governor and governor drive Plate 60901-14H Governor and governor drive Plate 60901-15H Regulating mechanism Plate 60902-18H Overspeed device Plate 60903-38H Instrument panel Plate 60905-20H Instrument panel Plate 60905-27H Instrument panel Plate 60905-32H Thermometer Plate 60907-19H Pressostate, thermostate, diff. pressostate and pressure transmitter Plate 60907-02H Prelubricating oil alarm (LAL 25) Plate 60919-01H Level switch in oil sump (LAL/LAH 28) Plate 60920-01H Local starting box - No 1 Plate 60935-13H Local starting box - No 1 Plate 60935-16H Local starting box - No 2 Plate 60935-14H Local starting box - No 2 (incl. high lub. oil temp.) Plate 60935-15H Engine control box Plate 60936-08H Termnal box Plate 60936-07H Converter Plate 60956-01 Crankshaft 510/610 Crankshaft and main bearings Description 610.01 (12H) Checking of main bearings alignment (deflection), hydraulic Working card 610-01.00 (10H) tigthened connecting rod MAN Diesel

Index GenSet

L28-2

Text Index Drawing No.

Inspection of main bearing shells Working card 610-01.05 (05H) Inspection of guide bearing shells Working card 610-01.10 (08H) Vibration damper Working card 610-04.00 (01H) Crankshaft Plate 61001-15H Crankshaft Plate 61001-21H Resilient gear wheel Plate 61002-07H Coupling for central drive lub. oil pump Plate 61002-11H Coupling for central drive lub. oil pump Plate 61002-12H Coupling for central drive lub. oil pump Plate 61002-13H Coupling for central drive lub. oil pump Plate 61002-14H Resilient gear wheel Plate 61002-15H Resilient gear wheel Plate 61002-16H Resilient gear wheel Plate 61002-17H Flywheel with gear rim Plate 61003-02H Flywheel with gear rim Plate 61003-05H Flywheel with gear rim Plate 61003-06H Torsional vibration damper Plate 61004-05H Torsional vibration damper Plate 61004-12H Torsional vibration damper Plate 61004-13H Torsional vibration damper Plate 61004-14H Torsional vibration damper Plate 61004-15H Torsional vibration damper Plate 61004-16H Tuning wheel Plate 61004-06H Engine frame/Oil pan 511/611 Engine frame and base frame Description 611.01 (07H) Functional test of crankcase safety relief valves Working card 611-01.00 (04H) Frame with main bearings Plate 61101-11H Front cover for lubricating oil pump Plate 61102-09H Front cover for lubricating oil pump and cooling water pump Plate 61102-07H Front cover for lubricating oil pump and cooling water pumps Plate 61102-10H Covers on frame Plate 61106-20H Cover on frame Plate 61106-14H Turbocharger 512/612 Turbocharger system Description 612.01 (28H) Cleaning the turbocharger in service, water washing of compressor Description 612.05 (07H) Cleaning the turbocharger in service, dry cleaning - turbine Description 612.10 (09H) Cleaning the turbocharger in service, water washing - turbine side Description 612.15 (02H) Overhaul of charging air cooler Working card 612-01.00 (02H) Charge air cooler housing - draining Working card 612-01.05 (02H) Water washing of compressor side - turbochager type NR15/R - Working card 612-05.00 (03H) NR20/R - NR24/R - NR26/R Dry cleaning of turbocharger - turbine side Working card 612-10.00 (02H) Water washing of turbine side Working card 612-15.00 (01H) Charging air cooler - freshwater Plate 61201-12H Charging air cooler - freshwater Plate 61201-13H Charging air cooler - freshwater Plate 61201-14H Charging air cooler - freshwater Plate 61201-15H Charging air cooler - seawater Plate 61201-16H Charging air cooler - seawater Plate 61201-17H Charging air cooler Plate 61201-29H Exhaust pipe arrangement Plate 61202-23H Exhaust pipe arrangement with welded compensator Plate 61202-32H Exhaust pipe arrangement Plate 61202-26H MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Exhaust pipe arrangement with welded compensator Plate 61202-28H Exhaust pipe arrangement Plate 61202-27H Exhaust pipe arrangement with welded compensator Plate 61202-42H Water washing of compressor side Plate 61205-02H Steam trap Plate 61208-01H Blowgun for dry cleaning of turbocharger Plate 61210-02H Compressed air system 513/613 Compressed air system Description 613.01 (20H) Air filter Working card 613-01.21 (02H) Overhaul, test and inspection of turbine starter Working card 613-01.30 (02H) Main starting valve Working card 613-01.40 (01H) Check of compressed air piping system Working card 613-01.90 (02H) Turbine starter Plate 61309-05H Main starting valve Plate 61310-03H Muffler Plate 61312-02H Emergency starting valve Plate 61313-03H Starting valve Plate 61314-03H Main stop valve Plate 61315-03H Air strainer Plate 61316-03H Safety valve Plate 61319-01H ON-OFF valve for jet system Plate 61320-05H ON-OFF valve for jet system Plate 61320-06H Air filter Plate 61321-03H Pressure reduction valve Plate 61322-04H Turning gear Plate 61325-07H Pneumatic turning gear (motor power unit) Plate 61325-08H Pneumatic turning gear (spindle, gear case and gearing) Plate 61325-09H Fuel oil system 514/614 Internal fuel oil system Description 614.01 (25H) Fuel injection pump and fuel injection pipe Working card 614-01.05 (02H) Fuel injection pump and fuel injection pipe Working card 614-01.05 (05H) Fuel injection valve Working card 614-01.10 (03H) Fuel oil split filter Working card 614-01.15 (01H) Check of fuel oil piping system Working card 614-01.90 (01H) Adjustment of the maximum combustion pressure Working card 614-05.01 (02H) Fuel injection pump Plate 61401-03H Fuel injection pump Plate 61401-09H Fuel injection valve Plate 61402-04H Fuel injection valve, cooled Plate 61402-07H Fuel oil filter duplex Plate 61403-15H Fuel injection pipe Plate 61404-06H Pipes on cylinder section - forced lubrication with cooling oil pipes Plate 61430-03H Nozzle cooling pump Plate 61440-05H Lubricating oil system 515/615 Internal lubricating oil system Description 615.01 (29H) Lubricating oil cooler Description 615.06 (02H) Centrifugal by-pass filter Description 615.15 (05H) Crankcase ventilation Description 615.31 (03H) Lubricating oil pump, engine driven Working card 615-01.00 (01H) Prelubricating pump Working card 615-01.05 (02H) Lubricating oil filter Working card 615-01.10 (01H) MAN Diesel

Index GenSet

L28-2

Text Index Drawing No.

Lubricating oil, thermostatic valve Working card 615-01.20 (01H) Check of lubricating oil piping system Working card 615-01.90 (01H) Lubricating oil cooler Working card 615-06.00 (02H) Centrifugal by-pass filter Working card 615-15.00 (01H) Lubricating oil pump (central driven) Plate 61501-12H Lubricating oil pump (gear driven) Plate 61501-22H Lubricating oil filter (Type A) Plate 61502-11H Lubricating oil filter (Type B) Plate 61502-12H Lubricating oil filter (suppl. for plate 61502-11H/12H) Plate 61502-15H Lubricating oil thermostatic valve Plate 61503-08H Prelubricating pump with el-motor Plate 61504-04H Lubricating oil cooler Plate 61506-10H Centrifugal by-pass filter Plate 61515-09H Hand wing pump Plate 61525-02H Lubricating oil separator Plate 61530-07H Lubricating oil pipes on engine Plate 61530-02H Cooling water system 516/616 Cooling water system Description 616.01 (17H) Cooling water thermostatic valve Description 616.04 (15H) Check of cooling water system Working card 616-01.90 (01H) Cooling water thermostatic valve Working card 616-04.00 (01H) Cooling water thermostatic valve Plate 61604-07H High temperature fresh water pump Plate 61610-05H Low temperature fresh water pump Plate 61610-07H Low temperature fresh water pump Plate 61610-10H Sea water pump Plate 61615-04H Pipes on cylinder head Plate 61625-04H Cooling water pipes on engine Plate 61630-01H Preheater - fresh water Plate 61635-06H Special equipment 517/617 Kit for cylinder unit Kit 61704-02H Kit for overspeed device Kit 61743-01H Kit for covers on frame Kit 61751-01H Specific plant information 519/619 Resilient mounting of generating sets Description 619.03 (10H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (21H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (22H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (23H) Replacement of conicals Working card 619-03.05 (01H) Maintenance of conicals Working card 619-03.10 (01H) Flexible external connections Plate 61902-03H Conical element Plate 61903-04H Tools 520/620 Introduction to spare part plates for tools Description 620.01 (01H) Function of the hydraulic tools Working card 620-01.05 (03H) Application of hydraulic tools Working card 620-01.06 (01H) Hand lever pump Working card 620-01.07 (01H) Maintenance of hydraulic tools Working card 620-01.10 (01H) Tightening with torque spanner Working card 620-01.15 (01H) MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Tool combinations for tightening of connecting rod screws Working card 620-01.20 (01H) Max. pressure indicator Working card 620-01.25 (02H) Tools for cylinder head Plate 62005-03H Tools for piston, connecting rod and cylinder liner Plate 62006-11H Tools for operating gear for inlet valves, exhaust valves and fuel Plate 62008-03H injection pumps Tools for control and safety systems, automatics and instruments Plate 62009-02H Tools for crankshaft and main bearing Plate 62010-07H Tools for crankshaft and main bearing Plate 62010-10H Tools for crankshaft and main bearing Plate 62010-11H Tools for fuel oil system and injection equipment Plate 62014-02H Tools for lubricating oil system Plate 62015-02H Hydraulic tools Plate 62021-08H Tools for low overhaul height, piston, cylinder liner and connecting Plate 62050-01H rod Operating manual for testing tool (Fuel injection valve) Description GXO-D001 Engine data

500/600 MAN Diesel & Turbo

Instruction Manual for:

MAN Diesel & Turbo Identification No. for Instruction Manual.

Identification No. for Description: 000 . 00

Function

Section No.

Identification No. for Working Card: 000 - 00 . 00

Sub-function

Function

Section No.

Identification No. for Plates: 00000 - 00 H

H for Holeby

Edition

Section No. and Function

For ordering of spare parts, see page 500.50 / 600.50

All data provided in this document/manual is non-binding. This data serves informational purposes only and is especially not guaranteed in any way.

Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.

If this document/manual is delivered in another language than English and doubts arise concerning the translation, the English text shall prevail.

Original instructions

2011.06.28 MAN Diesel & Turbo

MAN Diesel & Turbo | PrimeServ The MAN Diesel & Turbo Group offers worldwide round-the-clock service, 365 days a year. Apart from the MAN Diesel & Turbo service headquarters in Augsburg, Copenhagen, Frederikshavn, Holeby, Stockport, St. Nazaire, Tur- bocharger and service centres on all continents provide comprehensive and continuous support. The long service life associated with MAN Diesel engines dictates a spare parts programme that ensures components are available for engines in operation for decades. Based on high-capacity machines, MAN Diesel & Turbo service production facilities are able to comply with special customer requests with the utmost precision and flexibility.

24-hour hotline number: +49 1801 15 15 15 http://www.mandieselturbo.com/primeserv

Copyright 2011 © MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany, registered with the Danish Commerce and Companies Agency under CVR Nr.: 31611792, (herein referred to as “MAN Diesel & Turbo”).

This document/manual must not, either wholly or partly, be copied, reproduced, made publich or in any other way made available to any third party without the written to this effect from MAN Diesel & Turbo.

MAN Diesel & Turbo PrimeServ Holeby MAN Diesel & Turbo H. Christoffersensvej 6 GenSet & Powerplant Branch of MAN Diesel & Turbo SE, 4960 Holeby Service & Spare Parts Germany Denmark CVR No.: 31611792 Phone: +45 54 69 31 00 Fax : +45 54 69 30 31 Head office: Teglholmsgade 41 Fax: +45 54 69 30 30 After office hours : +45 40 14 40 45 2450 Copenhagen SV, Denmark [email protected] German Reg.No.: HRB 22056 [email protected] Amtsgericht Augsburg www.mandieselturbo.com

2011.06.28 MAN Diesel & Turbo

Description Page 1 (1) Warning

General

Warning !

(Marine engines only)

It is important that all MAN Diesel & Turbo engines are operated within the given specifications and performance tolerances specified in the engines' Technical Files and are maintained according to the MAN Diesel & Turbo maintenance instructions in order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN Diesel & Turbo instructions including, but not limited to, the instructions to that effect included in the Technical File.

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1 (1) MAN Diesel & Turbo

Description 600.00 Page 1 (1) Main Particulars Edition 07H

L28/32H

Cycle : 4-stroke

Configuration : In-line

Cyl. Nos. available : 5-6-7-8-9

Power range : 1050-1980 kW

Speed : 720/750 rpm

Bore : 280 mm

Stroke : 320 mm

Stroke/bore ratio : 1.14:1

Piston area per cyl. : 616 cm2

Swept volume per cyl. : 19.7 ltr.

Compression ratio : 13.9:1

Max. combustion pressure : 130 bar

Turbocharging principle : Constant pressure system and intercooling

Fuel quality acceptance : HFO (up to 700 cSt/50° C, RMK700) MDO (DMB) - MGO (DMA, DMZ) according ISO8217-2010

Power lay-out MCR version

Speed rpm 720 750

Mean piston speed m/sec. 7.7 8.0

Mean effective pressure bar 17.8 17.9

Max. combustion pressure bar 130 130

Power per cylinder kW/cyl. 210 220

Overload rating (up to 10%) allowable in 1 hour for every 12 hours

Power per cylinder kW/cyl. 230 240

11.36 - ES1 - Tier II - WB2 - GenSet 10.47 -ES0 08028-0D/H5250/94.08.12 MAN Diesel&Turbo Description Page 1(1) lation, theEnglishtext shallprevail. than English and doubts arise concerning the trans- If an instruction book is delivered in another language to thiseffect fromMANDiesel& Turbo. available to any third party without the reproduced, made publicwritten or in any other way made consent This book must not, either wholly or partly, be copied, bookispresentandcorrect. this instruction care Every is taken to ensure that all information in contents ofthisbookandthe Technical File. engine room personnel are fully acquainted with the Technical File. Consequently, it is essential that the the in included effect that to instructions additional any and & instructions Diesel Turbo’s MAN in fied speci- as performed be shall engine diesel the of Turbo’s instructions. Emissions-related maintenance and maintenance in accordance with MAN operation Diesel & correct its upon conditional is plant the of operation economical and Reliable parts. spare ordering when reference a as used be also can It maintenance.and operation design, engine the on information general provides book instruction This Introduction Introduction Fig. 1. book. ofinstruction Structuring and parts lists. and parts working cards and the spare parts illustration plates de followedby technical systems/components, the of scriptions with starts sections these of Each a sectionofthisbook(section505-519). ponents/as com- main of number a into divided is engine The tools.The lastsection(520)comprises as well cards. asworking spare parts illustrations with appurtenant parts lists, de technical contain (505-519) sections as a guide to engine operation, and the next fifteen serve book the of (500-504) sections five first The diagramswiring andtestbedreports. electrical drawings, media-system basic as such inforplant-adapted with supplied, engine lar The book is a basic instruction manual for the particu Description semblies, each of which is described in described is which of each semblies, scrip General 600.01 Edition 08H mation tions, -

91.12 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(2) kept clear. unfastened, and thefl area ofapplication. Nomajorobjectsmust beleft panels (ifsupplied)intheengineroomcloseto tool boards. Specialtoolsshouldbefastened totool Hand toolsshouldbeplacedeasilyaccessible on Order also: "Ignitionincrankcase" insection603. is easilyinfl drenchedwithoilfromleakages insulating material paint andsolvents withalow fl drawn tothedangeroffi is furthermore of oiltanksandthespacebelow thefooler. Attention of explosions andfi welding andtheuseofnaked lightwillinvolve therisk If thecrankcase isopenedbefore theengineiscold, Fire be detected. maintainedsothatleakagescaneasily the paintwork The exterior oftheengineshouldbekept cleanand ger airintake fi unless thisisclosedorcovered, andtheturbo andchipsmustof grit beavoided neartheengine, In particular, welding whichcausesspread orwork and doorsintheengineroomshouldbeclosed. should bestoppedandventilating ducts, skylights, theventilation engine roomwhentheshipisinport, below thefl oor plates. orsandblows Ifgrit intothe The engineroomshouldbekept cleanabove and Cleanliness to theentireengineroomstaff. mentioned hereshouldtherefore beanatural routine safety intheengineroom. The general measures pointinobtaining optimum constitutes thecrucial Proper maintenance, whichistheaimofthisbook, General ammable andshouldbere lters arecovered. re. The sameappliestoinspec oor andpassagesshouldbe ash point. Porous re whenusing newed. See char- tion ing ing Safety engine isshutoff. Check airsupplytothe beforehand thatthestarting Crankcase work or fl ames willmove, andkeep clear. Think outbeforehand which way theliquids, gases touch thespray holes, as the jetmay piercetheskin. When testingfuelvalves withthehandpump, donot may thenblow outthevalve. piston crown, andifthepistonishot,anexplosion cylinder head)may down causeoiltorun tothe The removal offuelvalves (orothervalves inthe tobereleased. springs liquids orgases. may cause The dismantlingofparts The openingofcocks may causedischargeofhot Warning pipe systemsshouldbeemptiedofcoolingwater. engines,plant isoutofservice, pumps, coolers, and ofdamageduetofreezingwhenthe If thereisarisk Freezing be obtainable everywhere. able light,inexplosion-proof working fi placesintheengineroom,andport- at appropriate installed lightshouldbepermanently Ample working Light andreplenishedintime.at intervals mechanical damage. The stock shouldbechecked againstcorrosionandprotected preserved accessible by crane. shouldbewell The spareparts ced well strapped neartheareaofapplicationand should,asfar aspossible,Large spareparts bepla- Spares ttings, should General 600.02 Edition 06H MAN Diesel

600.02 Description Safety Page 2 (2) Edition 06H

General

Feeling over Turning with air

Whenever repairs or alterations have been made to After prolonged out-of-service periods or overhaul the running gear, apply the "Feel-over sequence" work which may involve a risk of accumulation of until ensured that there is no undue heating, oil- liquid in the combustion spaces, turning with open mist formation, blow-by, or failure of cooling water indicator cocks should always be effected, through or lubricating oil systems. at least two complete revolutions.

Feel-over sequence Check and maintain

Feel-over after 5-15 and 30 minutes' idle running and Lubricating oil condition, ﬁ lter elements and mea- ﬁ nally when the engine is running at full load. See suring equipment. also "Starting-up sequence" in the section 602.

91.12 - ES0U MAN Diesel & Turbo

Description 600.05 Page 1 (1) Cross Section Edition 07H

L28/32H

10.36 - ES1 MAN Diesel 04.08 - ES1 08028-0D/H5250/94.08.12 Description Page 1(1) Rating Design Variant Cyl. diam/stroke Engine Type No ofcylinders The enginetypesoftheMANB&Wprogramme areidentifi ed by thefollowing fi gures: Identifi Engine Type C : Economy continuous rating : ECR Maximum continuous rating : MCR 320/400 32/40 : 280/320 28/32 : 270/380 27/38 : 225/300 23/30 : 210/310 21/31 : 160/240 16/24 : V-built V : In-line L : 18 16, 12, 9 5, 8, 7, 6, cation Key for EngineDesignation 83 H MCR 6 L 28/32 General 600.10 Edition 02H MAN Diesel 89.17 -ES1S-L 08028-0D/H5250/94.08.12 Description Page 1(1) Front End Control Side/CamshaftLeft Designation ofCylinders Exhaust Side/Right Flywheel end L28/32H 600.11 Edition 01H MAN Diesel & Turbo

Description 600.12 Page 1 (1) Engine Rotation Clockwise Edition 02H

General

Direction of rotation seen from flywheel end “Clockwise”

Engine

Alternator

10.39 - ES1 MAN Diesel & Turbo

Description 600.20 Page 1 (2) Code Identification for Instruments Edition 03H

General

Explanation of Symbols

TI Measuring device 40 Local reading

Temperature Indicator No. 40 *

Measuring device PI Sensor mounted on engine/unit 22 Reading/identification mounted in a panel on the engine/unit

Pressure Indicator No. 22 *

Measuring device TAH Sensor mounted on engine/unit 12 Reading/identification outside the engine/unit

Temperature Alarm High No. 12 *

Measureing device PT Sensor mounted on engine/unit 22 Reading/identification in a panel on the engine/unit and reading/indication outside the engine/unit

Pressure Transmitting No. 22 *

* Refer to standard location and text for instruments on the following pages.

Specification of letter code for measuring devices 1st letter Following letters F Flow A Alarm L Level D Differential P Pressure E Element S Speed, System H High T Temperature I Indicating U Voltage L Low V Viscosity S Switching, Stop X Sound T Transmitting Z Position X Failure V Valve, Atuator

11.19 - ES1 MAN Diesel & Turbo

600.20 Description Edition 03H Code Identification for Instruments Page 2 (2)

General

Standard Text for Instruments

Diesel Engine/Alternator

LT Water System 01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler 02 outlet from air cooler 05 outlet from alternator 08 inlet to fresh water cooler (SW) 03 outlet from lub. oil cooler 06 outlet from fresh water cooler (SW) 09

HT Water System 10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler 10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler 11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater 12 outlet from engine 15 outlet from HT system 19A inlet to prechamber 13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber

Lubricating Oil System 20 inlet to cooler 24 sealing oil - inlet engine 28 level in base frame 21 outlet from cooler / inlet to filter 25 prelubricating 29 main bearings 22 outlet from filter / inlet to engine 26 inlet rocker arms and roller guides 23 inlet to turbocharger 27 intermediate bearing / alternator bearing

Charging Air System 30 inlet to cooler 34 charge air conditioning 38 31 outlet from cooler 35 surplus air inlet 39 32 jet assist system 36 inlet to turbocharger 33 outlet from TC filter / inlet to TC compr. 37 charge air from mixer

Fuel Oil System 40 inlet to engine 44 outlet from sealing oil pump 48 41 outlet from engine 45 fuel-rack position 49 42 leakage 46 inlet to prechamber 43 inlet to filter 47

Nozzle Cooling System 50 inlet to fuel valves 54 58 oil splash 51 outlet from fuel valves 55 valve timing 59 alternator load 52 56 injection timing 53 57 earth/diff. protection

Exhaust Gas System 60 outlet from cylinder 64 68 61 outlet from turbocharger 65 69 62 inlet to turbocharger 66 63 compustion chamber 67

Compressed Air System 70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system 71 inlet to stop cylinder 75 microswitch for turning gear 79 72 inlet to balance arm unit 76 inlet to turning gear 73 control air 77 waste gate pressure

Load Speed 80 overspeed air 84 engine stop 88 index - fuel injection pump 81 overspeed 85 microswitch for overload 89 turbocharger speed 82 emergency stop 86 shutdown 90 engine speed 83 engine start 87 ready to start

Miscellaneous 91 natural gas - inlet to engine 94 cylinder lubricating 97 remote 92 oil mist detector 95 voltage 98 alternator winding 93 knocking sensor 96 switch for operating location 99 common alarm 100 inlet to MDO cooler 101 outlet to MDO Cooler 102 alternator cooling air

11.19 - ES1 94.35 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) if any, before canstart. themaintenancework 3 through before canstart. themaintenancework The frontpageindicatesthefollowing: and illustrating themaintenance work. a frontpageandoneorseveral pages, describing cardscanbedividedinto two:Each oftheworking Working cards cards.guidance intheworking is tobeusedfor adjustingthetimetable statedfor for adjustmentoftimebetween overhaul. it Further withthespecifi Experience overhauls.necessary between resultsandthustheintervals actual service cooling water, etc, willdecisively infl oil,treatmentofthe of thefueloilandlubricating guidance asdifferent conditions, thequality service areonly forThe stated,recommendedintervals the engines'conditionand/ortimecriteria. crew overhauls, canmake thenecessary basedon forintervals thecomponents/systems, sothatthe gram, seepage600.25,indicatingtheinspection ofthemaintenancesystemiskeyThe crux dia- it canbeusedseparately. entire ship's/power station'smaintenance systemor maintenance programme, itcanbe integrated inthe andamountofinformation inthe With thestructure main withoutaneffectiveand optimaleconomicrunning itisnotpossibleIn thelongrun toobtainasecure which means70-100%ofMCR. a specifi The overhaul arebasedonoperation intervals on General 2 1 Reference out, whichmust towork, becarried . ofthework. description Abrief . Safety regulations, whichMUSTbecarried . tenance system. ed fuel oil quality at normal service output, service ed fueloilqualityatnormal Introduction toPlannedMaintenanceProgramme c plant/crew istobeused uence onthe Fig 1. for Guidanceinstruction cards. working that notalltoolsarestandardequip out thework. up-to-date.to abringing withthespecifi Experience as guide. The statedconsumptionofhoursisonlyintended for accomplishingthework. 5 expedient out. tocarry whichwould -orworks depending onthiswork be stated. Please note, thatthisisaconditionfor theintervals advisible themaintenancework. toreplaceduring 8 7 6 4 9 6 5 4 3 2 1 Various requisitehandtools. . Specialtools, whichmust beused. Pleasenote . Refers todata,whicharerequiredfor carrying . Indicatesxnumber ofmeninxnumber ofhours . Relatedprocedures-indicatesotherworks, . . Indicates the components/parts, whichitis Indicatesthecomponents/parts, . c station/crew may lead may station/crew c ment. General 600.24 Edition 02H 9 8 7 08028-0D/H5250/94.08.12 09.48 -ES0 MAN Diesel Description Page 1(4) Description Lubrication of camshaft bearing -Check ofcamshaft bearing . Lubrication Camshaft adjustment-Check thecondition . -Inspectionofclearance. Camshaft bearing etc. Camshaft -Inspectionofgear wheels, bolt,connections Camshaft andDrive: inframe . guide ring Cylinder linerremoved -Check thewater spaceand . Cylinder liner-Cleaning,honingandmeasuring Connecting rod-Retightening. shells . Inspection ofbig-endbearings ofbig-end bore. Connecting rod-Measuring clearance. Piston pinandbush for connectingrod-Check of . andscraper ring Piston ring Inspection ofpiston. Piston, Connecting Rod andCylinderLiner: Cylinder headnut -Retightening. Cylinder headcoolingwater space-Inspection. Indicator valve. pressure. Safety valve -Overhaul andadjustmentofopening Sleeve for fuelinjector. Check ofvalve enginerotation. rotatorsrotationduring Inspection ofinlet,exhaust valves andvalve guide. spindel andvalve seat. Inlet andexhaust valve -Overhaul of andregrinding Cylinder Head: rence to"EnginePerformance Data",section 602-1. Readings ofdatafor EngineandGenerator, withrefe- Operating ofEngine: ...... Planned MaintenanceProgram

● ■ ...... = = ...... Check thecondition Overhaul out tobecarried ......

200 200 200 Check new/ Overhauled parts after -hours

50 Time BetweenOverhaul 200 ■ 2000 ■ 8000 ● ● ● ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ 16000 ■ 32000 Daily ■ Weekly Montly 3th month ■ Observations 607-01.00 607-01.20 607-01.05 607-01.00 606-01.40 606-01.35 606-01.25 606-01.16 606-01.15 606-01.15 606-01.10 606-01.10 605-01.40 605-01.45 605-01.26 605-01.25 605-01.30 605-01.05 605-01.05 605-01.10 602-01.00 Working Card L28/32H No. 600.25 Edition 33H L28/32H 600.25 Edition 33H Main- and guide bearing cap-Retightening . Main- andguidebearing Counter weight -Retightening,see page600.40. water pumpetc. ofgearwheelforLubricating lub. oilpumpandcooling Vibration damper-Check thecondition. . Inspection ofguidebearing . Inspection afmainbearing Checking aligment,(autolog). of mainbearings Crankshaft andMainBearing: book, section609. Governor -Check oillevel, seegovernor instruction Pick-up -Adjustment. Jet system-Adjustment. Safety, equipment. andmonitoring alarm Instruments: Control andSafety System, Automatics and ofoperating gear-CheckLubricating . clearance. Inlet andexhaust valve -Check andadjustmentofvalve Roller guidehousing. Roller guidefor fuelinjectionpump. Valve gear- Valve pushrod,etc. bridge,spring, Roller guidefor valve gear. Fuel InjectionPumps: Operating Gearfor Inlet Valves, Exhaust Valves and Description ...... Planned MaintenanceProgram ......

● ■ = = Check thecondition Overhaul out tobecarried ......

200 200 Check new/ Overhauled parts after -hours

50 Time BetweenOverhaul 200 ■ 2000 ■ ■ ■ 8000 ■ ■ ■ ■ ■ ■ 16000 ■ ■ ■ 32000 Daily Weekly Montly ■ ■ ■ ■ 3th month Observations 610-01.10 610-01.05 610-04.00 610-01.10 610-01.05 610-01.00 609-10.00 609-01.00 609-01.00 608-01.05 608-01.00 608-01.10 608-01.10 608-01.05 608-01.10 608-01.00 Working MAN Diesel Card No. Description Page 2(4) 09.48 -ES0

08028-0D/H5250/94.08.12 08028-0D/H5250/94.08.12 09.48 -ES0 MAN Diesel Description Page 3(4) exceeds 0.7bar) (filter elementtobereplaced whenpressuredrop Drain ofbowl. Compressed airsystem-Check ofthesystem. Compressed airsystem-Draining . Muffler -Dismantlingandcleaning. separator -Dismantlingandcleaning. Dirt valves valve andemergencystart . valve, valve,Function test-Mainstarting starting main motor-Dismantlingand inspection. Air starter Compressed AirSystem: Exhaust pipe-Compensator. Charging aircoolerhousing-Draining. Charging aircooler-Cleaningandinspection. tion etc. book). (seeturbochargerinstruction Turbocharger complete-Dismantling,cleaning,inspec- book). charger instruction Cleaning ofairfilter-Compressorside(seeturbo- Water washing ofcompressorside. Wet cleaningofturbineside. cleaningofturbineside. Dry Turbocharger System: Safety cover -Functiontest. mountings. For flexible mountedengines-Check anti-vibration Retightening, seepage600.40. Bolts between engineframe andbaseframe - Holding down bolts-Retightening,seepage600.40. Engine FrameandBedplate: Description ...... Planned MaintenanceProgram

...... ● ■ ...... = = ...... Check thecondition Overhaul out tobecarried ......

200 200 200 Check new/ Overhauled parts after -hours

● ●

50 Time BetweenOverhaul 200 2000 ■ ■ ■ ■ 8000 16000 32000 ● Daily ● Weekly Montly ■ ■ 3th month ● ● ● ● ■ ■ ■ Observations 613-01.21 613-01.90 613-01.90 613-01.40 613-01.30 612-01.00 612-05.00 612-15.00 612-10.00 611-01.00 619-03.00 Working Card L28/32H No. 600.25 Edition 33H L28/32H 600.25 Edition 33H Cooling water system- Water samples, seesec. 604. Cooling water system-Check the system. valveThermostatic . fresh water) Cooling water pump-Enginedriven (seawater and Cooling Water System: oilsystem-CheckLubricating thesystem. oil-Oilsamples,Lubricating seesection604. filter-Cleaningand Centrifugal exhange ofpaper. valveThermostatic . pump-El.Prelubricating driven. oilcooler. Lubricating oilfilter-Cleaningand Lubricating exhange. oilpump-Enginedriven. Lubricating Lubricating OilSystem: Fuel oil-Oilsamplesafterevery bunkering, seesec.604. Nozzle coolingsystem-Check thesystem. Fuel oilsystem-Check thesystem. Adjustment ofthemaximum combustion pressure. Fuel oilhigh-pressurepipe-Dismantlingandcheck. Fuel injectionvalve -Adjustmentofopeningpressure. Fuel oilinjectionpump-Dismantlingandcleaning. Fuel oilfeed pump. Fuel oilfilter-Dismantlingandcleaning. Fuel OilSystemandInjectionEquipment: Description ...... Planned MaintenanceProgram

● ■ = = ...... Check thecondition Overhaul out tobecarried ......

200 Check new/ Overhauled parts after -hours

50 Time BetweenOverhaul 200 ■ ■ 2000 8000 ■ ■ ■ 16000 32000 ■ Daily Weekly ■ ■ Montly ■ ■ ■ ■ ■ 3th month ● ● ● ● ● ● ● ■ Observations 616-01.90 615-01.90 615-15.00 615-01.20 615-01.05 615-06.00 615-01.10 615-01.00 614-01.90 614-01.90 614-05.01 614-01.05 614-01.10 614-01.05 614-10.00 614-01.15 Working MAN Diesel Card No. Description Page 4(4) 09.48 -ES0

08028-0D/H5250/94.08.12 MAN Diesel & Turbo

Description 600.30 Page 1 (2) Operation Data & Set Points Edition 50H

L28/32H

Acceptable Normal Value at Full load value at shop at ISO conditions test or after Alarm Set point Autostop of engine repair

Lubricating Oil System Temp. before cooler SAE 30 TI 20 60-75° C <75° C TAH 20 90° C (outlet engine) SAE 40 TI 20 65-82° C <82° C TAH 20 100° C Temp. after cooler SAE 30 TI 22 45-65° C <65° C TAH 22 75° C TSH 22 85° C (inlet engine) SAE 40 TI 22 50-72° C <72° C TAH 22 85° C TSH 22 95° C Pressure after filter (inlet eng) PI 22 3.5-4 bar >4.0 bar PAL 22 3 bar PSL 22 2.5 bar Elevated pressure i.g. when centrifugal filter installed PI 22 4-5 bar >4.5 bar PAL 22 3.5 bar PSL 22 3.0 bar Pressure drop across filter PDAH 21-22 0.5-1 bar <0.5 bar PDAH 21-22 1.5 bar Prelubricating pressure LAL 25 level switch Pressure inlet turbocharger PI 23 1.5 ±0.2 bar >1.5 bar Lub. oil, level in base frame LAL 28/ low/high level LAH 28 Temp. main bearings TE 29 75-85° C <85° C TAH 29 95° C Fuel Oil System Pressure after filter MDO PI 40 2.5-5 bar PAL 40 1.5 bar HFO PI 40 5-16 bar (A) PAL 40 4 bar Leaking oil LAH 42 leakage Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (B) Temp. nozz. cool. oil, outlet eng. TI 51 80-90° C 95° C (B) Cooling Water System Press. LT-system, inlet engine PI 01 1-2.5 bar (D) >1.3 bar PAL 01 0.4 bar + (C) Press. HT-system, inlet engine PI 10 1.5-4.6 bar >1.8-<6 bar PAL 10 0.4 bar + (C) Temp. HT-system, inlet engine TI 10 60-75° C Temp. HT-system, outl. cyl.units TI 11 70-85° C <85° C Temp. HT-system, outlet engine TAH 12 90° C TSH 12 95° C TAH 12-2 93° C Temp. raise across cyl. units max. 10° C Exhaust Gas and Charge Air Exh. gas temp. before TC TI 62 425-475° C TAH 62 550° C TAH 62-2 600° C Exh. gas temp. outlet cyl. TI 60 270-380° C TAH 60 410° C Diff. between individual cyl. average TAD 60 average (F) ±25° C ±50° C Exh. gas temp. after TC TI 61 275-350° C TAH 61 500° C Ch. air press. after cooler PI 31 2-2.5 bar Ch. air temp. after cooler TI 31 35-55° C <55° C TAH 31 65° C Compressed Air System Press. inlet engine PI 70 7-9 bar >7.5-<9 bar PAL 70 7 bar

Specific plants will not comprise alarm equipment and autostop for all parameters listed above. For specific plants additional parameters can be included. For remarks to some parameters, see overleaf.

10° C change in ambient temperature correspond to approx. 15° C exhaust gas temperature change

11.33 - ES1 MAN Diesel & Turbo

600.30 Descriptoin Edition 50H Operation Data & Set Points Page 2 (2)

L28/32H

Acceptable Normal Value at Full load value at shop at ISO conditions test or after Alarm Set point Autostop of engine repair

Speed Control System Engine speed GenSets for 60 Hz Mechanical Elec. SI 90 720 rpm 820 rpm SAH 81 815 rpm SSH 81 825 rpm GenSets for 50 Hz SSH 81 815 rpm Mechanical Elec. SI 90 750 rpm 855 rpm SAH 81 850 rpm SSH 81 860 rpm SSH 81 850 rpm Turbocharger speed SI 89 (G) SAH 89 (E)

Remarks to individual Parameters E. Limits for Turbocharger Overspeed Alarm (SAH 89) A. Fuel Oil Pressure, HFO-operation.

Engine type 720 rpm 750 rpm When operating on HFO, the system pressure must 5L28/32H 42,680 42,680 be sufficient to depress any tendency to gasification 6L28/32H 42,680 42,680 of the hot fuel. 7L28/32H 34,900 34,900 8L28/32H 34,900 34,900 The system pressure has to be adjusted according 9L28/32H 36,180 36,180 to the fuel oil preheating temperature.

B. Nozzle Cooling Oil System F. Exhaust Gas Temperatures The nozzle cooling oil system is only applied for Tier II marine and stationary engines. The exhaust gas temperature deviation alarm is normally ±50° C with a delay of 1 min., but at start-up C. Cooling Water Pressure, Alarm Set Points. the delay is 5 min. Furthermore the deviation limit is ±100° C if the average temperature is below 200° C. As the system pressure in case of pump failure will depend on the height of the expansion tank above G. Turbocharger Speed the engine, the alarm set point has to be adjusted to 0.4 bar plus the static pressure. Normal value at full load of the turbocharger is de- pendent on engine type (cyl. no) and engine rpm. D. Press. LT -system, inlet engine (PI 01) The value given is just a guide line. Actual values can be found in the acceptance test protocol. With two-string cooling water system the normal value can be higher, max. 4.0 bar.

11.33 - ES1 MAN Diesel & Turbo

Description 600.33 Page 1 (1) "Green Passport" Edition 02H

General

In 2009 IMO adopted the „Hong Kong International Convention for the Safe and Environmentally Sound Recycling of Ships, 2009“

Until this convention enters into force the recommen- datory guidelines “Resolution A.962(23)” (adopted 2003) apply. This resolution has been implemented by some classification societies as “Green Passport”.

MAN Diesel & Turbo is able to provide a list of hazardous materials complying with the requirements of the IMO Convention. This list is accepted by classification societies as a material declaration for “Green Passport”.

This material declaration can be provided on request.

11.08 - ES0 MAN Diesel & Turbo

Description Data for Pressure and Tolerance 600.35 Page 1 (2) Edition 16H

L28/32H

Section Description mm. / bar

605 Safety valve to be adjusted to 170 bar Maximum inner diameter, valve guide 18.35 mm. For grinding of valve spindle and valve seat ring (see also working card 605-01.10) Minimum height of valve head, inlet valve and exhaust valve, "H" 1 6.5 mm. Maximum height of spindle above cylinder head, "H" 2 108.0 mm

606 Piston and piston ring grooves (see working card 606-01.10) Clearance between connecting rod bush and piston pin 0.15 - 0.25 mm. Maximum ovalness in big-end bore (without bearing) 0.10 mm. New cylinder liner, inside diameter 280.03 - 280.08 mm. Maximum inside diameter cylinder liner 280.60 mm.

607 Clearance between camshaft and camshaft bearing 0.13 - 0.22 mm. Maximum clearance between camshaft and camshaft bearing 0.35 mm. Clearance between tooths on intermediate wheel 0.20 - 0.30 mm Plunger lift at TDC, injection timing: IMO Tier II - D2, 720 rpm 8.30+0.05 mm* IMO Tier II - D2, 750 rpm 8.27+0.05 mm* *) for information on max settings check the engine's IMO Technical file. Plunger Lift, World Bank II** **) Standard injection timing value is based on ISO condition. Special injection timing of engines can be necessary due to Power plant size and/or Ambient conditions.

608 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm. Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.90 mm. Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm.

609 Clearance between pick-up and impulse wheel 1 ±0.3 mm Adjustment of Lambda controller. (see working card 609-10.00)

610 Clearance (equal on both sides) between main bearing cap and frame, before tightening of bracing screw (side screw) 0.06 ± 0.02 mm Deflection of crankchaft (autolog) (see working card 510-01.00) Clearance between crankshaft and sealing ring, (upper and lower part) 0.3 - 0.4 mm. Clearance in main bearing 0,2-0,344 mm Clearance in guide bearing (axial) 0.15 - 0.46 mm Maximum clearance in guide bearing (axial) 0.8 mm Clearance between bearing and gearwheel shaft: Clearance when new bearings are mounted 0.125-0.200 Maximum clearance 0.250 Clearance axial 0.2-0.3

611 Opening pressure of safety relief valves (on crankcase), max: 0.20 bar

12.08 - ESO, Tier II MAN Diesel & Turbo

600.35 Description Edition 16H Data for Pressure and Tolerance Page 1 (2)

L28/32H

Section Description mm. / bar

614 Maximum combustion pressure at full load Max 133 bar Individual cylinders; admissible deviation from average ± 3 bar A change of the height of the thrust piece spacer ring of 0.10 mm. will change the maximum pressure by 1 bar 1° turning of camshaft gear wheel changes max. pressure by approx 6 bar Measurement "X" between thrust piece and roller guide housing 11 ± 0.2 mm Opening pressure of fuel valve 320 bar Pressure testing, cooling oil sealing, on fuel valve 100 bar

12.08 - ESO, Tier II MAN Diesel & Turbo

Description 600.40 Page 1 (2) Data for Tightening Torque Edition 18H

L+V28/32H

Tightening Section Description Thread Torque Pressure Lubricant Nm bar

605 Cylinder head stud (in frame) Stud M 39 200 Loctite 243 Nut for cylinder head stud Nut M 39 x 3 700 Oil / Molykote (Unimol gl 82)

606 Connecting rod screw (see working card 606-01.25) Molykote Connecting rod screw (hydraulic Stud M 39 x 3 (Unimol gl 82) tightening) Nut M 39 x 3 700 –

Molykote 607 Camshaft assembling Nut M 12 85 (Unimol gl 82) Gear wheel on camshaft Screw M 12 70 – Intermediate wheel shaft Nut M 22 x 1.5 250 – Intermediate wheel assembling Nut M 12 50 – Gear wheel on crankshaft Nut M 12 50 –

608 Housing for valve gear Screw M 16 160 – Rocker arm bracket Nut M 12 40 –

610 Main bearing stud (in frame) Stud M 56 200 Loctite 243 Molykote Nut for main bearing stud Nut M 52 x 3 900 (Unimol gl 82) Main bearing side screw - L28/32H Screw M 24 350 – Main bearing side screw - V28/32H Screw M 30 600 – Counterweight on crankshaft Screw M 26 x 1.5 300 – Vibration damper on crankshaft Nut M 30 500 – Flywheel mountng (witout fitted bolt) Nut M30 1350 oil Flywheel mounting (with fitted bolt) - L28/32H Nut M 30 1350 – - V28/32H Nut M 30 480 – Gear rim on flywheel Screw M 16 75 –

611 Frame / baseframe Nut M 24 500 –

(3 x cross-tightening 614 Fuel-pump connecting piece Screw M 10 60 20 - 40 - 60 Nm) – Fuel-pump top flange (barrel) Screw M 12 100 – Fuel-pump cavitation plugs Plug M 20 x 1.5 100 - 120 – Fuel-pump mounting Screw M16 150 – Fuel-valve (nozzle nut) Nut M 26 x 1.5 100 - 120 – Fuel-valve mounting Nut M 16 30 – Fuel-valve (lock nut) Nut M 16 x 1.5 100 – High pressure pipe Nut M 22 x 1.5 60 –

09.24 MAN Diesel & Turbo

600.40 Description Edition 18H Data for Tightening Torque Page 2 (2)

L+V28/32H

Tightening Section Description Thread Torque Pressure Lubricant Nm bar

Molykote 615 Gear wheel on lub. oil pump Nut M 30 x 2 400 (Unimol gl 82)

616 Impeller and gear wheel on freshwater cooling pump - L28/32H Nut M 24 x 1.5 250 – Impeller and gear wheel on freshwater cooling pump - V28/32H Nut M 33 x 2 400 –

619 Conical elements mounting - L28/32H Upper mounting Screw M 20 150 – Lower mounting Screw/ M 20 320 – Nut

Sandwich elements mounting - V28/32H Upper mounting Screw M 16 165 – Lower mounting Screw M 16 165 –

09.24 MAN Diesel & Turbo

Description 600.45 Page 1 (1) Declaration of Weight Edition 01H

L28/32H

Section Component Plate No. Item No. Weight in Kg.

605 Cylinder Head, incl. rocker arms 60501-60502 255 60508-60510

606 Piston, complete 60601 08 40 Piston Pin 60601 01 19 Connecting Rod, complete 60601 06 81 Cylinder Liner, complete 60610 10 119 Cooling Water Jacket 60610 15 33

607 Camshaft, section 60705 02, 16, 20 29

608 Housing for Roller Guide 60801 20 17

609 Governor, complete 60901 01-09-10 28

611 Main Bearing Cap 61101 26 75 Guide Bearing Cap 61101 19 85 Front cover 61102 01 164 End cover, complete 61106 11 179

612 Turbocharger, complete See special instruction Intermediate piece 61202 26 9 Air Cooler 61203 38 450 Inlet Bend 61203 33 93 Charging Air Cooler Housing 61203 34 350

613 Air Starter 61309 63 40

614 Fuel Injection Pump 61401 01-02 15 Fuel Injection Valve 61402 02 5 Fuel Oil Feed Pump 61410 22 22

615 Lubricating Oil Pump 61501 35 45 Thermostatic Valve 61503 11 29 Prelubricating Oil Pump, incl. el-motor 61504 25 20 Centrifugal Filter 61515 33 24

616 Thermostatic Valve 61604 11 29 Cooling Water Pump 61610 19 30

00.32 - ES0U MAN Diesel & Turbo

Description 600.50 Page 1 (2) Ordering of Spare Parts Edition 06H

General

Spare parts can be ordered from MAN Diesel & Note: Turbo, PrimeServ. • Components from different engine builders When spare parts are ordered or inquired, the fol- cannot be considered as interchangeable. lowing data must be indicated, in order to ensure • A wide number of spare parts can be orders correct identification of the required parts: as spare part kits. • Selected components may be available in both • Name of customer original and upgraded version. • Name of plant /vessel • Vessel IMO No These data are necessary to ensure supply of the • Engine type correct spare parts for a particular engine, even • Engine serial No though the spare part illustrations contained in this • Engine builder book may not always be in complete accordance • Plate No and edition No with the individual components of a specific engine. • Item No • Quantity For ordering of spare parts for governor, turbocharger • Designation of the item No and alternator, please see the special chapter in the instruction book for these components.

Information found on the nameplate of the engine(s) Example: Name of customer Name of Plant/Vessel IMO No Engine type Engine Engine builder serial No Mercy Ship Africa Mercy L7803188 5L21/31 SB5L21-10799 MAN Diesel & Turbo or Licensee

Information found on each plate at the instruction manual:

Plate No Edition No Item No Qty. Description 51435 13 440 1 Leak oil pipe

12.11 - ES0 MAN Diesel & Turbo

Description 600.50500.50 Page 2 (2) Ordering of Spare Parts EditionEdition 06H 03

General

Name of customer Name of Plant/Vessel IMO No

Engine type Engine No Engine Builder

Plate No Edition No Item No Designation of the Item No Qty.

For ordering or inquiry for items in free text, kindly contact MAN PrimeServ Holeby at: +45 54 69 31 00 or via e-mail [email protected]

12.11 - ES0 11.09 -ES0 08028-0D/H5250/94.08.12 MAN Diesel&Turbo Description Page 1(1) Frederikshavn. or Holeby in Turbo,& PrimeServ Diesel MAN with agreement written a is there unless returned be to not are tools and/or parts spare that note Please Remarks: name andnumber onthebox (P-xxxxx) For return of tools please mark the box withour project order number orattachacopy ofourpacking list. our with box the mark Please credit-note. a issue will we condition, good receivedin are parts When Coordinators and/orSuperintendents. unless turned there is an agreement re- with our Sales be to not are parts your that noted be Please stating: Clearly or Frederikshavn: [email protected] [email protected] Holeby: Send anemailtoourofficevia procedureisasfollows:The return tous. your spareparts to return do not fit orparts is damaged in any way, you need spare your that occurs situation unfortunate the If and/ortools How toreturnspareparts ------If you return your spare parts and/or tools with- fee for returns. unauthorised out a written agreement you will be charged a Pictures of damaged parts –ifany.Pictures ofdamagedparts Your reference Reason for return Item numbers Our ordernumber How toReturnSpareParts and/or Tools returned toSingaporewarehouse.returned that have been purchased in Singapore that parts can be spare only is it that aware be Please Note: following address: For returns to Singapore warehouse please use the Please return by cheapest mean to the below address: - - - Tools: Spare Parts: If you return to Holeby instead of Frederikshavn, EUR 70,- you will have to pay freight charges of minimum Att.: LogisticCentre, Asia Singapore 639499 14 Tuas Avenue 1 MAN Diesel& Turbo SingaporePte. Ltd. Att: Dept.: Center(DC5) Service Denmark 9900 Frederikshavn Langerak 74 MAN Diesel& Turbo Att: Dept.: Store(WLS-FRH) Denmark 9900 Frederikshavn Niels Juels Vej 15 MAN Diesel& Turbo General 600.51 Edition 05H 91.14 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) regarding accumulated service experegarding accumulated service Letters"containingfi out "Service up-to-date operation ofourengines, send we regularly In ordertoensurethemosteffi Description of instruc of instruc as areference whenwe prepareup-datededitions recommendations for allenginetypes, andareused engine types, and orcontaingeneral instructions letterscaneitherdealwithspecifi The service tion books. cient, economicaland rst-hand information ri ence. Service LettersService c relevant book. chaptersofthisinstruction that enginestafffi tance totheoperation oftheplant,we recommend lettersmightbeofgreatSince new impor- service le themassupplementstothe General 600.55 Edition 01H MAN Diesel 04.37 - ES0 08028-0D/H5250/94.08.12 Description Page 1(3) * Also named "thermodynamic temperature" Alsonamed"thermodynamic * Length (m) SI Prefi Additional SIUnits SIUnits Supplementary Basic SlUnits Area (m atr rfix ybl atr rfix Symbol Prefi 1609m x Factor Symbol 10 0.3048m Prefi x 1852m 25.40mm=0.0254m Factor 0.9144 m nauticalmile) 1 nmile(international 1 statutemile=1760yds 1dm = 1 yd(yard) =3ft36inches 1 ft(foot) =12inches 60min 1l = 1 in(inch) 1h (p/180)rad = l 60s = 1° h 1 1min bar litre bar = pressure bar min hour sr ° rad volume10 minute degree plane angle time time steradian Quantity Name Symbol radian Defi nition solid angle s cd plane angle mol A Quantity Name Symbol K second candela ampere mole luminous intensity kg kelvin amount ofsubstance absolute temperature* current electric time mass kilogram length metre m Quantity Name Symbol q t(qaefo) 92.90x10 0.6452x10 1 sq. ft(squarefoot) 1 sq. in(squareinch) 10 10 10 10 10 10 deca 10 da 10 2 3 6 9 12 15 18 hecto kilo 10 h 10 k mega giga M 10 G 10 tera 10 T peta 10 P exa 10 E xes 2 ) -18 -15 -12 -9 -6 -3 -2 -1 nano n micro m milli centi c d deci at a atto femto f p pico 5 Pa μ 3 -3 Conversion Table m -3 m 2 2 Standardacceleration offreefall gn=9.80665m/s Canoccasionallybefound statedaskgf(kilogram force). * 1cSt(centistokes) =10 * Stress (1N/m Unitofforce intheft-lb-ssystem ** Force (1kgm/s Density Velocity, Speed(m/s)(3.6km/h=1m/s) I.T. Steam =International Table Exactvalue: 4.1868J * Energy, Work fromtheCGSsystem. (1Nm=1J, 1St=10 Wh) taken Kinematic viscosity(m 1 cP=mPa s=10 poise isaspecialnametakenfromtheCGSsystem.1P=0.1Pas Dynamic viscosity(Ns/m p 987 J 9.807 2.648x10 1 hph(metric) 1 kpm ona* 138.3x10 9.807N 1 poundal** 16.02kg/m 1 kp(kilopound)* 1 lb/cub. ft otherconversions,Cincerning seetable for length 1.852km/h=0.5144m/s 1 kn(knot)=nauticalmile/h 1 cal 92.90x10 1 sq.ft/s 47.88Ns/m 1 lbf/sq.ft 1 kps/m 6.895x10 1 lbf/sq. in(psi)=0.07031at 1 kp/mm b pudfre 4.448N 1 lbf(poundforce) ona /qf 1.488Ns/m 1 poundals/sq.ft t b 136 J 1.356 1.055x10 2.685x10 1 BTU(UK,US) 1 hph(UK,US) 1 ft. lbf I.T 4.187 * J* 2 2 9.807Ns/m =100kp/cm 2 =10 -3 2 Pa s =1N) 2 9.807 N/mm -6 -6 m N/mm 2 2 /s. Stokes isaspecialname /s) 6 6 J=075 kWh J=0.7355 .47 kWh J =0.7457 3 2 -3 .5 KJ J =1.055 ) m 2 2 2 =98.07P(poise) 2 ) 2 /s =92.90x10 -3 3 N -3 N/mm -4 2 m 2 /s 2 General 3 600.60 cSt* 2 Edition 01 General 600.60 Edition 01 (see "DerivedSIUnitswithspecialNames) Temperature levels (K) Temperature difference (K) Specifi *I = (kgm Moment ofInertia Moment ofForce, Torque (kgm Power (1kgm * t(°C)= T(K) - T ** Derived SiUnitswithSpecialNames asi g D=Diameterofgyration R =Radiusofgyration G = W =massinkg Seealsotable for specifi c fueloilconsumptionvalues * For mechanicalstressesN/mm * esu rmFhehi: t Celsius fromFahrenheit: p/ 987 W Can easilybederived fromtheabove tables. 9.807 W=0.7355kW 735.5 1 kcal =75kpm/s 1 hp(metric) 1 kpm/s oc nwo N 1kgm/s derived SIunits = 1N 1s 1N/m = supplementary = 1Hz or 1Pa N Hz Pa newton hertz pascal pressure, stress force frequency Quantity Name t Symbol t °C(Celsius) 1K 5/9K 1 °F(Fahrenheit) Expressed 1 °C(Celsius) 1.360g/kWh 1 g/hph(metric) in 1 WR 1 GD basic, lcrcptnil(C vl V = 1 W/A = 1 V 1Nm = V 1J volt J temperature Celsius joule potential (DC) electric power watt energy, quantityofheat working °C W 1°C 1 = 1 W k** = 1 J/s ° Fhehi) 5/9(t t°F (Fahrenheit) W 0.2931 W 1.356 W 745.7 1 BTU/h 1 hp(UK,US)=550ft.lbf/s 1 ftlbf/s arnetfo ecu: t Fahrenheit fromCelcius: ∫ dm 2 2 I.T. (l oain =4xI*kgm (oldnotation) (l oain* =1xI*kgm (oldnotation)* c fuelconsumption*(g/kWh) r xr /h 1.163 W 2 m 2 0 /s (K), where T 3 =1Nm/sJ/s W) r =massattheradius r 2 0 c c f ) =9/5xt =273.15K =5/9(t +273.15=K 2 iswidelyused. 1N/mm 2 2 f -32)+273.15=K f -32) 2 c +32 /s 2 =Nm) Conversion Table 2 =10 6 N/m 2 Heat transmission(W/(m Heat conductance(W/(mK)) Specifi Specifi * British British Unit(seetable forThermal energyconversions) * * British British Unit(seetable forThermal energyconversions) * 1 BTU*/(ft 1 kcal 1 BTU*/(lbx°F)=kcal 1 cal W/(mK) 1.731 1 BTU*/(ftxh°F) 1 kcal 1 cal 1 kcal lwriltpesr 1000mbar 298K 298K 42707kJ/kgk Fuel oillower calorifi c value (10200kcal/kg) Charge aircoolanttemperature 25°C Blower inletpressure Blower inlettemperature 25°C Reference conditions(ISO) and thefollowing reference conditions: Specifi c fueloilconsumptionvalues refer tobrake power, Reference conditions I.T. I.T. I.T. I.T. I.T. (mxsx°) 41.87x10 /(cm xs°C) W/(mK) 418.7 /(cm xs°C) c heatcapacity(J/(kgK)) c fueloilconsumption(SFOC) /(m W/(mK) 1.163 /(m xh°C) 4.187x10 /(kg x°C) 2 xhx° 568 W/(m 5.678 xh°F " xhx°) .6 W/(m 1.163 xh°C) -1 2 * 2 I.T. /k C 4.187x10 /(kg°C) 2 K)) 3 W/(m 2 2 2 3 3 MAN Diesel K) K) K) J/(kgK) J/(kgK) Description Page 2(3) 04.37 -ES0

08028-0D/H5250/94.08.12 04.37 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Description Page 3(3) Values intable provided gn=9.80665m/s Mercury. 1mmHg= Torr * Unitandmassintheft-lb-ssystem * r =densityinkg/m t =temp. in°C Nomenclature Some physical datainSIunits Water column(WC) ** (1 N/m Pressure Mass (kg) =8pints 1gallon=4quarts * Volume (1m aln U) 3.785x10 4.546x10 m 0.1590 1 barrel(USpetroleumbarrel)=42gallon(US) 1 gallon*(US) UK) 1 gallon*(imperial, t 1 atm ae,ha feaoain10C .1 a 2.256x10 1.013bar = 287 J/(kgxK) = Water, heatofevaporation 100°C Gas constantfor airandexhaust gas 1 atm(standardpressureatsealevel) 33.86 mbar 3386Pa = (T=273K) 1 inH 1 inHg* 1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar 133.3Pa = (T=273K) 1 mmH 1 mmHg* xas a 2040 1080 200-400 range 1.96x10 900 15 0 750mmHg=1bar =10 Viscosity: 100-140cSt at40°C * Exhaust gas Atmospheric air(dry)(p=1bar) oil(approx.)*Lubricating Water 18 kg 14.59 =1.033at 999 =68.95mbar 6895Pa 1 lbf/sq.in(psi) 1 atm 98.07x10 =10mH =735.5mmHg* =0.9678atm =1at 4.18 1 at 1 kp/cm2 kg 50.80 kg tons=907 0.907metric kg 0.4536 m 0.1156 m 2.832 kg 1 slug* 1.016metrictons=1016 ton(UK)=2000lbs 1 short 1 longton(UK)=20cwt2240lbs 1 cwt(UK)(hundredweight) =112lbs 28.32x10 1 lb(poundmass)=16ozs(ounces) 16.39x10 x 1 registerton=100cub. ft 1 bblbarrel,US) (dry 1 cub. ft(cubicfoot) 1 cub. in(cubicinch) 10 islegn eeec ul (seebelow) 41-43x10 43x10 Diesel enginereference fuel ISO 3046/1-1986standardreference fuel Fuel oil. Lower calorifi c value 10 750 mmHg* 2 O** (T = 277 K) 249.1 Pa = 2.491 mbar 249.1Pa = (T=277K) O** 2 2 =1Pa, 1bar=10 * T=27K 10 (T=277K) O** 3 =1000l) (standard atmosphere) 760 mmHg,1.013x10 (standard atmosphere) 3 C 5 P =1bar Pa 5 Pa 5 Pa, 1mbar=10 Δ K =temperature difference p =heatcapacityinJ/(kgDK) 2 2 O** (T = 277 K) (T= O** 760 mmHg=1013mbar Conversion Table 1.276 998 0-150 1005 -3 ρ C bar) 5 3 -4 Pa = 1013 mbar Pa = 0.9807 bar Pa = -3 -3 -3 -6 at= 9.807 Pa =98.07x10 m m m m 3 3 3 3 3 3 3 =3.785l =4.546l =28.32l p t C 3 3 6 J/kg -3 6 6 mbar J/kg J/kg p General 600.60 Edition 01 05.02 -ES0 MAN Diesel . GENERALCONVENTIONALSYMBOLS 1. No Symbol Symbol designation 08028-0D/H5250/94.08.12 PIPESANDPIPEJOINTS 2. Description Page 1(3) 2.13 2.12 2.11 2.10 2.9 2.8 2.7 2.6 2.5 2.4 2.3 2.2 2.1 1.8 1.7 1.6 1.5 1.4 1.3 1.2 1.1 Blank fl ange Cap nut Expansion pipe Expansion jointwithgland Joint, quick-releasing Joint, sleeve Joint, fl anged Joint, screwed general Expansion pipe(corrugated) Flexible pipe Tee pipe Crossing pipes, connected Crossing pipes, notconnected Tracing High-pressure pipe instruments Indicating andmeasuring Appliances Valves, gatevalves, cocks andfl aps Pipe withindicationofdirectionfl ow Pipe bled inoneunit Enclosure for several componentsas-sem- Basic Symbolsfor Piping . VALVES, GATE VALVES, COCKSANDFLAPS 3. No Symbol Symbol designation 2.18. 2.19 2.17 2.16 2.15 2.14 Gate valve Butterflvalve y Ball valve (cock) Regulating valve Quick-closing valve Quick-opening valve Self-closing valve Angle safety valve Safety valve valveNon-return (fl ap), angle, screw down valveNon-return (fl ap), angle valveNon-return (fl ap), straight Valve, three-way Valve, angle Valve, straight through Pneumatic fl ow orexhaust toatmosphere Snap coupling Loop expansion joint Orifi ce Orifi ce Spectacle fl ange down valveNon-return (fl ap), straight screw General 600.65 Edition 01H No Symbol Symbol designation General 600.65 Edition 01H 3.39 3.38 3.37 3.36 3.35 3.34 3.33 3.32 3.31 3.30 3.29 3.28 3.27 3.26 3.25 3.24 3.23 3.22 3.21 3.20 3.19 3.18 3.17 Reducing valve (adjustable) valve return 3/2 spring contr. by solenoid valve, return 2/2 spring closed normally valve, return 3/2 spring closed normally valveNon-return (air) 3-way valve withremote control(actuator) Valve withtestfl ange valveThermostatic Cock, three-way, withbottomconnection Cock, angle, withbottomconnection Cock, straight through,withbottomconn. Cock withbottomconnection Cock, four-way, straight throughinplug Cock, three-way, T-port inplug Cock, three-way, inplug L-port Cock, angle Cock, straight through Double-seated changeover valve, angle Double-seated changeover valve, straight Suction valve valves chestwithnon-return Suction valve chest Double-seated changeover valve directional valve return andwithspring On/off valve controlledby solenoidandpilot Basic Symbolsfor Piping 5. APPLIANCES . CONTROL ANDREGULATION PARTS 4. No Symbol Symbol designation 4.15 4.14 4.13 4.12 4.11 4.10 5.6 5.5 5.4 5.3 5.2 5.1 4.9 4.8 4.7 4.6 4.5 4.4 4.3 4.2 4.1 By plungerortracer Solenoid andpilotdirectionalvalve Solenoid Spring Push button Manual (atpneumaticvalves) Electromagnetic motor Electric Membrane Piston Float Mass Spring Remote control Fan-operated Centrifugal pump Centrifugal Steam trap Separator Magnetic fi lter Filter orstrainer Mudbox MAN Diesel Description Page 2(3) 05.02 -ES0

08028-0D/H5250/94.08.12 No. Symbol Symbol designation 05.02 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Description Page 3(3) 5.23 5.22 5.21 5.20 5.19 5.18 5.17 5.16 5.15 5.14 5.13 5.12 5.11 5.10 5.9 5.8 5.7 Steam trap Double returned actingcylinderwithspring returned Single actingcylinderwithspring tion offl ow Fixed capacitypneumaticmotorwithdirec- Silencer Air lubricator Water trap withmanual control Air fi lter withautomaticdrain Air fi lter withmanual control Air fi lter preheater Electric Heat exchanger Piston pump Various (text accessories tobeadded) Ejector Hand pump(bucket) Gear orscrew pump Basic Symbolsfor Piping No. Symbol Symbol designation . READINGINSTR. WITH ORDINARY DESIGNATIONS 7. 6. FITTINGS 7.5 7.4 7.3 7.2 7.1 6.9 6.8 6.7 6.6 6.5 6.4 6.3 6.2 6.1 Recorder Distance level indicator Level indicator glass Observation Sight fl ow indicator Overspeed device Water jacket Bearing Fuel oilpump Turbocharger Waste tray withplug Waste tray Drain Funnel /waste tray General 600.65 Edition 01H Operation of engine

501/601 MAN Diesel

Description 601.01 Page 1 (3) Operating Edition 21H

L+V28/32H

Preparations for Starting

The following describes what to do before starting, 4. Open the fuel oil supply to the feed pump. when the engine has been out of service for a longer period of time, or if major overhauls has been Starting on HFO: circulate preheated fuel through made. the pumps until correct working temperatures has been obtained. Takes normally 30-60 minutes. 1. Check the oil level in the base frame (or in the lub. oil tank if the engine is with dry sump), air 5. Check the pressure in the starting air receiver(s) lubricator and in the govenor. and open the starting air supply (blow-off water, if any, drain the starting air system before opening. Start-up the prelubricating pump. 6. Check that the sealing oil system for the injec- The engine shall be prelubricated at least 2 minutes tion pumps are working correct. prior to start. 7. Check in the regulating gear: Check oil pressures before and after the fi lter. - That all fuel pumps are at index "0" when the 2. Open the cooling water supply, start separate regulating shaft is in the STOP position. cooling water pumps where installed, and check the cooling water pressure. - That each fuel pump can be pressed by hand to full index when the regulating shaft is in the STOP Note: To avoid shock effects owing to large tempe- position, and that the pumps return automatically to rature fl uctuations just after the start, it is recom- the "0" index when the hand is removed. mended: - That the spring-loaded pull rod is working a) to preheat the engine, cooling water of at least correctly. 60 °C should be circulated through the frame and cylinder head for at least 2 hours before start. - That the stop cylinder for regulating shaft works properly, both when stopping normally and - either by means of cooling water from en gines at over speed and shut down. which are running or by means of a built-in preheater (if installed). - Testing is made by simulating these situati- ons. or 8. Open the indicator valves and turn the engine b) When starting without preheated cooling wa ter, some few revolutions, check that no liquid is fl owing the engine must only be started on MDO (Ma-rine out from any of the indicator valves during the tur- Diesel Oil). ning.

The engine should not be run up to more than 50% Slow-turning must always be carried out, before the load to begin with, and the increase to 100% should engine is started after prolonged out of-service pe- take place gradually over 5 to 10 minutes. riods and after overhauls, which may involve a risk of liquid having collected in the cylinders. Note: When starting on HFO (Heavy Fuel Oil), only item "a" should be used. 9. Close the indicator valves.

3. Open the nozzle cooling oil supply (only when 10. Disengage the turning gear, if ﬁ tted. Check started on HFO), circulate preheated oil through the that it is locked in the "OUT" position. nozzles for at least 15 minutes.

96.30 - ES0U MAN Diesel

601.01 Description Operating Page 2 (3) Edition 21H

L+V28/32H

Starting 6. The exhaust gases should be free from smoke at all loads. For normal exhaust temperatures, see 1. Start the engine, by activating the start but- the test sheet from shop and sea trials. tom. 7. Keep the charging air pressure and tempera- 2. Check the lubricating oil pressure, cooling ture under control. For normal values, see the test water pressure, fuel oil feed pressure. Check that sheet from shop and sea trials. the prelubricating oil pump is stopped. 8. Recharge the starting air recivers when the 3. Check that all alarms are connected. pressure has dropped to about 20 bar. Stop rechar- ging at 30 bar. See also "checks after starting-up". 9. To ensure the greatest possible operational liability, condition of the engine should be continuously Tending during running observed in order that preventive maintenance work can be carried out before serious break downs oc- When the engine is running, the planned maintenance cour. program and the following should be checked:

1. The lubricating oil pressure must be within Stopping the stated limits and must not fall below the stated minimum pressure. The paper fi ltering cartridges 1. Before stopping, it is recommended to run must be replaced before the pressure drop across the engine at reduced load, or to idle for about 5 the fi lter reaches the stated maximum value, or the minutes for cooling-down purposes. pressure after the fi lter has fallen below the stated minimum value. Dirty fi lter cartridges cannot be 2. The engine is stopped by keeping the fuel cleaned for re-use. pump delivery rate at "0", by turning the "load- limit" knob on the governor to "0", or by activating the 2. The lubricating oil temperature must be kept wi- remote stopping device. thin the stated limits indicated on the data sheet.

3. The fuel oil pressure must be kept at the stated Start and Stop on HFO value, and the ﬁ lter must be cleaned before the pressure drop across the ﬁ lter reaches the stated Start and stop of the engine should take place on maximum value. HFO in order to prevent any incompatibility problems by change-over to MDO. 4. The cylinder cooling water temperature must be kept within the limits indicated and the temperature MDO should only be used in connection with main- rise across the engine should not exceed 10°C. tenance work on the engine or longer periods of engine standstill. 5. The cooling water temperature at the charging air cooler inlet should be kept as low as possible; Before starting on HFO the engine must be properly however, not as low as to produce condensation preheated. as described in "Preparations for starting" water in the charging air space. and as below.

Adjustment takes place in the external system out- Stopping the engine on HFO is no problem, but it side the engine, and the amount of cooling water should be ensured that the temperature of fuel pipes must be so adjusted that the temperature rise across not are reduced to a level below the pour point of the charging air cooler is 3 - 5 °C. the fuel, otherwise reestabilishing of the circulation might cause problems.

96.30 - ES0U MAN Diesel

Description 601.01 Page 3 (3) Operating Edition 21H

L+V28/32H

Starting on MDO

For starting on MDO there are no restrictions except lubricating oil viscosity may not be higher than 1500 cSt (5° C SAE 30, or 10° C SAE 40).

Initial ignition may be difﬁ cult if the engine and ambient temperature are lower than 5° C, and 15° C cooling water temperature.

96.30 - ES0U MAN Diesel 92.02 -ES0U 08028-0D/H5250/94.08.12 Description Page 1(2) degrees aboveandbelowthejointsatbothsides. bearing cleranceatthetop, atthebottom,and10 rings clearanceswithafeeler gauge.Measure the from bearings,andcheckcrankpinmainbea- the bottomofoilsumpforfragmentsbabbitt 4.2 should berepeated before theengine. starting After overhaulofpistons,bearings,etc.thischeck inlet totherockerexceeds1bar. arms fitted whichdo not openuntiltheoilpressure atthe lubrication ofrocker asnon-return valvesare arms, heads andmakesure thatoilisnotsuppliedfor rings. Alsotakeoff thetop coversonthecylinder and checkthattheoilisfl pump, openupthecrancaseandcamshafthousing theelectricallydrivenprelubrication start warm, Works before MajorRepairs 4. for preservation oftheengines,are followed. vessel), werecommend thatourspecialin During thelay-upperiod(andalsowhenlaying-up Laid-up Vessels 3. prelubricating 2-3revolutions.. periodisturnd weekandthattheengineduring once every lub stand-by position)itisrecommended, thatthepre- in periods,duringestand-stilloftheengine(not MaintenanceduringStandstil 2. 10minutes. every lub ifthere orcontinuous pre-to start, isnotintermittent The engineshallbeprelubricated 2minutesprior to theoperationconditions. be continuouslycirculated attemperatures similar media coolingwater, fueloilandnozzleshould During enginestandstillinstand-byposition,the Stand-by Engines 1. 4.1 ricating oil pump is startet minimum 10minutes ricating oilpumpisstartet prelub.ricating installed.intermittent is2min Afterstoppingtheprelubricating pump,check . Afterstoppingtheengine,whileoilisstill owingfreely from allbea- struc Out-of Service tions starting theengine. starting carefullycleaning shouldbecarried outvery before system mayhavecaused ingress ofimpurities, 6.1 Works afterRepairs 6. coat withcleanlubricatingoil. Very thoroughly cleanthesumpandsubse the sludge,ifnotdonewithinaperiodofoneyear. 5.5 5.4 gine, andblowthrough blocked-updrainpipes. 5.3 camshaft(s). 5.2 foundation and checktheirlockingdevices.Alsoretighten 5.1 repairs. The followingshouldbemadeduringthemajor Works duringRepairs 5. this shouldbeopened. is installeddrainfasilitiesintheexhaustgassystem turbochargers, orthedraincockisopened,ifthere 4.7 forimmediateanalysis. laboratory 4.6 shaft. 4.5 4.4 (The elementscannotbeusedagain). the bottomofpaperlamellae. ofbearingmetal at can beexaminedforparticles differential pressure. Aftereremoval, elements dirty replaced before afterrepair start orduetoexcessive are inthelub.oilfi intact.Filtercartridges 4.3 Ifanopening-upofengine orlubricatingoil . Emptytheoilsumpoflubricatingandre . airpipesofwater. Drainstarting . Remedyleakagesofwaterandoilintheen- . Checkthevariousgearwheeldrivesfor . Retightenallboltsandnutsinthecrankcase . Drainplugsare unscrewed from thebottomof . Alubricatingoilsampleshouldbesendtoa . . Take defl Checkthecylinderwalls. . Open upallfi .

bolts. ection measurements ofthecrank- lters tocheckthatfi lter elements lter istobe General quently 601.05 Edition 17H move move MAN Diesel General 601.05 Edition 17H r.p.m. should betested. The rangefrom -5%to+from thesyn-chronous tuation ofthesynchronizer knobontheswitch adjusts ther.p.m. withasuitablequicknessafterac- ge number ofrevolutions. uptheengineandrunitatsynchronousStart 6.7 tions. cy-linder linersealingsandatcoolingwaterconnec- on thesystemforleakageatupperandlower 6.6 engine are mentionedunder601.01. 6.5 made, checks1,2,and5shouldberepated. If repair ofbearingsoralignmentenginehasbeen friction inbearingsandfuelpumpsissuffi move therod connectionsbyhandtocheckthatthe manoeuvring gear. and Disconnectthegovernor 6.4 the exhaustgassystemifmounted). 6.3 oftheengine. parts rodthe turning tocheckthemovability oftherelevant theengineatleasttworevolutionsturn bymeansof 6.2 ridges induetime. star carefullymust bewatchedvery aftercleaningand The differential pressure across thelub. oilfi 6.7 a nerator ontheswitchboard thattheservomotor . Check the governor asfollows: Checkthegovernor . Addcoolingwaterandcheckwithpressure . Chekstobemadejustbefore ofthe starting . Lubricatebearingsandrod connectionsinthe . Closedraincocksintheturbocharger(or . Afterrestoring lubricatingoilcircula normal . ting-up theengine.Besure toreplace fi Speedsetting: Checkbefore switching-in ) ciently low. lter cart- Out-of Service board. tion, tion, lter and 60. can generallybeobtainedatsettingsbetween40 paralleloperation 70 onthescale,andsatisfactory beincreasedThe settingshoulnotnormally beyond the settingofotherengines). that issubjecttothegreatest load(orbyreducing rectified byincreasing thespeeddrop oftheengine sharing betweentwoore more enginesthiscanbe according toWoodward's instructionmanual. that isthecase,repeat thecompensatingadjustment be anyvariationupanddownintheenginespeed.If major periodicalmovments,andneithermustthere any theregulatingis warm, levermustnotperform r.p.m., andwithoutload.Provided oil thegovernor of error. so thattheycanbeelimatedaspossiblesources and turbochargerare operatingcondition, inperfect Note ma is ef nor reacts tooslowly, compensatingadjustment established withinabout3seconds.Ifthegover- with otherengines,anevensharingofloadshallbe Iftheengineisoperatedinparallel the governor). of a littlelowerthanbefore owingtothespeeddrop r.p.m. about3seconds(althoughthisr.p.m. willbe some 8%,andtheenginemustreturn toaconstant must notcausethefrequency tofallbymore than majorpumporcompressor).80% (bystarting This engine, increase theloadinstantaneouslytoabout reaching oiltemperatures and normal ingovernor the switchboard andsettheloadtoabout40%.On 6.7 d 6.7 c 6.7 b nual (Compensatingadjustment). fected asindicatedinWoodward's instruction : Itisaconditionforthistestthattheengine Hunting:Runtheengineatsynchronous ) SpeedDrop: load incaseofunsatisfactory ) Adjustmentspeed:Switch-ingeneratoron ) Description Page 2(2) 92.02 -ES0U

08028-0D/H5250/94.08.12 96.30 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) roller guidesandgearwheels. and camshaftbearings,piston pins,cylinderliners, Feel: Mainbearings,big-end bearings,(alternator), arise andcauseundueheating. where frictionmay ofallmoving parts on thesurfaces crankcase andthecamshafthousingfeel-over After 5-15and30minutes'idlerunning,openthe that is: sequence" shouldalwaysbefollowed. especially afterrepairs oralterations,the"feel-over 2.1 Toif re bemadeduringthestarting-up, but only 2. Data "section600. should beaccording to"SetPointsandOperation device thattheenginestops.Theoverspeedsetting 1.5 fuel oil,coolingwaterandsystemoil. 1.4 temperatures). 1.3 1.2 1.1 To bemadeimmediately afterstarting 1. surveillanceandrecoraddition tonormal following checksmustbemadeinthestatedorder in aftersuchanout-of-serviceperiod,the When starting checksduringoutofserviceperiodshavebeen carried outasdescribedintheprevious chap - to repairs and been outofserviceforsometime,instancedue In thefollowingitisassumedthatenginehas cordingly. running.Thesequencehasbeenac- during normal im The followingenumerateschecksare tobemade mediately after starting, duringloadincrease, and mediately afterstarting, . If the condition of the machinery is not well-known, isnotwell-known, Iftheconditionofmachinery . Checkbysimulation oftheoverspeedshut . fortheenginespeed, isnormal Seethateveryting . Seethatallcylindersare ﬁ . Seethat thelubricatingoilpressure isinorder. . Seethat theturbochargerisrunning. . quired afterrepairs oralterationsmade Starting-up after Out of Service Periods afterOutofService Starting-up ring (seeexhaust ding. ter. : : down down to "0"index. cancauseallfuelpumps tomove that thegovernor sure thatallfuelpumpsare setatthesameindexand sequence, make After completingthestarting-up engine whenthepropeller isdeclutched. 2 or3,thusexcludingthepossibility ofracingthe fuel pumpstoanaveragepumpindexnotexceeding isabletomoveallthe in theSTOPpositiongovernor itmustbecheckedthatwhen two cylindersconcerned (statedintheprecedingFollowing thealterationofpumpindexoneor starting-up sequence). Indexexpressed as%offullloadindex = I% 100 I I = I% x I canbeemployed: following formula the indextoberead directly off thefuelpumps as apercentage oftheindexatfullload.To enable The pumpindexindicatedinthetableshasbeengiven 100%loadmaybeputon. 75%loadfor2hours 50%loadfor2hours 25%loadfor2hours may, forinstance,be: sequence The loadincrease duringthestarting-up switchboard andputonload. rpmandconnect tothe ase thespeedtonormal that there areno hotspotsintheengine. Thenincre- speed, e.g.400rpm,untilitcanbeknownforcertain sequenceatareduced engine Begin thestarting-up the serviceperiod. is notdirectly totheoutputthroughout proportional speed givessomeindicationoftheengineoutput,but the loadonelectricswitchboard. Theturbocharger onthebasisoffuelindexand output isdetermined gradually asindicatedinthetablesbelow. Theengine in period,i.e.theengineloadshouldbeincreased or bearings,allowancemustbemadeforarunning- After repair orrenewal ofcylinderliners,pistonrings tion 603. see also After thelastfeel-over, repeat check4page601.05, F Indexatfullload(from testbedtable) = Ignition inCrankcase F page603.04insec- L+V28/32H 601.10 Edition 17H MAN Diesel & turbo

Description 601.15 Page 1 (1) Guidelines for Longterm Low-Load Operation on HFO Edition 03H

General

Part load/low load operation and turbocharger. HFO-operation at loads lower than 20% MCR should therefore only take place within In certain ship and power station operation modes the certain time limitations according to the curves. diesel generating sets are exposed to part load/low load operation. After a certain period of HFO-operation at loads lower than 20% MCR, a change to MDO should take place During manoeuvring of the ship all diesel generating in order to prevent further retardation of the engine sets are often started up for safety reasons, result- performance condition. Alternatively, the engine load ing in low should be raised to 70% MCR over a period of 15 load operation of all the engines. During harbour stay minutes and maintained here for some time in order one diesel generator could be low-loaded when only to burn off the carbon deposits, thus re-establishing hotel purposes are consuming electricity. adequate performance condition. After such a "clean burning period" low load operation on HFO can be Island mode operation of diesel generating sets in continued. power stations is frequently exposed to low load operation like on a ship. However, the operator must be aware of the fact that fouling in the combustion air inlet channels, At part load/low load it is important to maintain if any, will not be cleaned at high load operation. constant media temperatures, i.e. for cooling water, Extensive low load running can therefore result in lubricating oil and fuel oil in order to ensure adequate the need for manual cleaning of the combustion air combustion chamber temperature and thus complete inlet channels. combustion. If special application conditions require continuous At loads lower than 20% MCR there is a risk of time HFO-operation at loads lower than 20% MCR and dependant retardation of the engine performance occasionally performed "clean-burning" periods are condition due to fouling of the exhaust gas channels inconvenient or impossible, special equipment and and combustion air channels, combustion chambers arrangements must be established.

Load % 20 Admissible low-load operation Necessary operating period (load percent/period) on HFO. with min. 70% load after low- load operation on HFO.

15 Running-up period to 70% load: approx. 15 min.

a b 70% load 10 HFO or MDO

5 a b

Operating period (h) Operating period (h) Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDO or b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to burn off residues. Afterwards low load operation on HFO can be continued.

Fig 1 Low-load operation.

08.20 - ES1 MAN Diesel & Turbo

Description Guidelines Regarding MAN Diesel & Turbo GenSets 601.16 Page 1 (1) Operating on Low Sulphur Fuel Oil Edition 02H

General

Exhaust emissions from marine diesel engines have Low sulphur distillates been the focus of recent legislation. Apart from nitrous oxides (NOx), sulphur oxides (SOx) are considered In general our GenSet is developed for continuous to be the most important pollution factor. A range of operation on HFO as well as on MDO/MGO. Occa- new regulations have been implemented and others sionally changes in operation mode between HFO will follow (IMO, EU Directive, and CARB). These and MDO/MGO are considered to be within normal regulations demand reduction of SOx emissions operation procedures for our engine types and do by restricting the sulphur content of the fuel. That is thus not require special precautions. to say sulphur limits for HFO as well as mandatory use of low sulphur distillate fuels for particular ap- Running on low sulphur fuel (< 0.1% S) will not cause plications. This guideline covers the engine related problems, but please notice the following restrictions: aspects of the use of such fuels. In order to avoid seizure of the fuel oil injection pump Low sulphur HFO components the viscosity at engine fuel oil inlet must be > 2.0 cSt. In order achieve this it may be necessary From an engine manufacturer’s point of view there to install a fuel oil cooler, when the engine is running is no lower limit for the sulphur content of HFO. We on MGO. This is both to ensure correct viscosity and have not experienced any trouble with the currently avoid heating up the service tank, which is important available low sulphur HFO, that are related to the as the fuel oil injection pumps are cooled by the fuel. sulphur content or specific to low sulphur HFO. This may change in the future if new methods are applied When operating on MDO/MGO a larger leak oil for the production of low sulphur HFO (desulphuriza- amount from fuel oil injection pumps and fuel oil tion, uncommon blending components). MAN Diesel injection valves can be expected compared to op- & Turbo will monitor developments and inform our eration on HFO. customers if necessary. In order to carry out a quick change between HFO If the engine is not operated permanently on low and MDO/MGO the change over should be carried sulphur HFO, then the lubricating oil should be se- out by means of the valve V1-V2 installed in front lected according to the highest sulphur content of of the engine. the fuels in operation. For the selection of the lubricating oil the same applies as for HFO. For temporary operation on distillate fuels including low sulphur distillates nothing has to be considered. A lubricating oil suitable for operation on diesel fuel should only be selected if a distillate fuel is used continuously.

10.16 - ES1 Performance and condition

502/602 MAN Diesel & Turbo

Description Engine Performance and Condition 602.01 Page 1 (3) Edition 12H

L+V28/32H

Performance Data and Engine Condition An increase in charge air temperature involves a corresponding increase in the exhaust gas temperature During operation small changes in the engine condi- level by a ratio of about 1:1.5, i.e. 1°C higher charge tion take place continuously as a result of combustion, air temperature causes about 1.5°C higher exhaust including fouling of airways and gasways, formation gas temperature. of deposits, wear, corrosion, etc. If continuously recorded, these changes in the condition can give Reduction of the charge air pressure results in a cor- valuable information about the operational and responding reduction of the compression pressure maintenance condition of the engine. Continuous and max. combustion pressure. observation can contribute to forming a precise and valuable basis for evaluation of the optimum operation When checking the max. pressure adjustment of the and maintenance programmes for the individual plant. engine, it is therefore to be ensured that the existing charge air pressure is correct.

Engine Performance Data Fuel Injection Pump If abnormal or incomprehensible deviations in operation are recorded, expert assistance in the evaluation The amount of fuel injected is equivalent to the thereof should be obtained. supplied energy and is thus an expression of the load and mean effective pressure of the engine. The We recommend taking weekly records of the most fuel pump index can therefore be assumed to be important performance data of the engine plant. Dur- proportional to the mean pressure. Consequently, ing recording (working card 502-01.00 can be used) it can be assumed that the connected values of the the observations are to be compared continuously in pump index are proportional to the load. order to ascertain alterations at an early stage and before these exert any appreciable influence on the The specific fuel consumption, SFOC (measured by operation of the plant. weight) will, on the whole, remain unchanged whether the engine is operating on HFO or on MDO, when As a reference condition for the performance data, considering the difference in calorimetric heat value. the testbed measurements of the engine or possibly However, when operating on HFO, the combination the measurements taken during the sea trial on the of density and calorific value may result in a change delivery of the ship can be used. If considerable de- of up to 6% in the volumetric consumption at a given viations from the normal conditions are observed, it load. This will result in a corresponding change in will be possible, in a majority of cases, to diagnose the fuel pump index, and attention should be paid to the cause of such deviations by means of a total this when adjusting the overload preventive device evaluation and a set of measurements, after which of the engine. possible adjustment/overhauls can be decided on and planned. To avoid overloading of the engine the charge air pressure and turbine speed recorded at the shop test should not be exceeded. Evaluation of Performance Data At the Power Control Synchronizing (PCS) panel in the Air Cooler engine control room it is possible to reduce the load by adjusting the setting for maximum MCR load limit Fouling of the air side of the air cooler will manifest itself as an increasing pressure drop, lower charge Abrasive particles in the fuel oil result in wear of fuel air pressure and an increased exhaust/charge air injection pumps and fuel valve nozzles. Effective temperature level (with consequential influence on treatment of the fuel oil in the purifier can keep the the overhaul intervals for the exhaust valves). content of abrasive particles to a minimum. Worn fuel injection pumps will result in an increase of the index on account of an increased loss in the pumps due to leakage.

12.04 - ES0 MAN Diesel & Turbo

602.01 Engine Performance and Condition Description Edition 12H Page 2 (3)

L+V28/32H

When evaluating operational results, a distinction is If, for any reason, the surface temperature of the fuel to be made between changes which affect the whole valve nozzle is lower than the condensation tempera- engine (all cylinder units) and changes which occur ture of sulphuric acid, sulphuric acid condensate in only one or a few cylinders. can form and corrosion take place (cold corrosion). The formation of sulphuric acid also depends on the Deviations occuring for a few cylinders are, as a rule, sulphur content in the fuel oil. caused by malfunctioning of individual components, for example a fuel valve with a too low opening pres- Normally, the fuel nozzle temperature will be higher sure, blocked nozzle holes, wear or other defects, an than the approx. 180°C at which cold corrosion inlet or exhaust valve with wrongly adjusted clearance, starts to occur. burned valve seat, etc. Abrasive particles in the fuel oil involve heavier wear of the fuel valve needle, seat, and fuel nozzle holes. Turbochargers Therefore, abrasive particles are to the greatest possible extent to be removed at the purification. Fouling of the turbine side of the turbocharger will, in its first phase, manifest itself in increasing turbocharger revolutions on account of increased gas Exhaust Valves velocity through the narrowed nozzle ring area. In the long run, the charging air quantity will decrease The overhaul intervals for exhaust valves is one of on account of the greater flow resistance through the the key parameters when the reliability of the entire nozzle ring, resulting in higher wall temperatures in engine is to be judged. The performance of the the combustion chambers. exhaust valves is therefore extremely informative.

Service experience has shown that the turbine side is Especially under unfavourable conditions, fuel quali- exposed to increased fouling when operating on HFO. ties with a high vanadium and sodium content will promote burning of the valve seats. Combinations of The rate of fouling and thereby the influence on vanadium and sodium oxides with a corrosive effect the operation of the engine is greatest for small will be formed during combustion. This adhesive ash turbochargers where the flow openings between the may, especially in the event of increased valve tem- guide vanes of the nozzle ring are relatively small. peratures, form deposits on the seats. An increasing Deposits occur especially on the guide vanes of the sodium content will reduce the melting point and nozzle ring and on the rotor blades. In the long run, thereby the adhesive temperature of the ash, which fouling will reduce the efficiency of the turbocharger will involve a greater risk of deposits. This condition na and thereby also the quantity of air supplied for the will be especially unfavourable when the va weight combustion of the engine. A reduced quantity of air ratio increases beyond 1:3. will result in higher wall temperatures in the combustion spaces of the engine. The exhaust valve temperature depends on the actual maintenance condition and the load of the engine. Detailed information and instructions regarding With correct maintenance, the valve temperature is water washing of the turbocharger are given in the kept at a satisfactory low level at all loads. The air instruction manual. supply to the engine (turbocharger/air cooler) and the maximum pressure adjustment are key parameters in this connection. Fuel Valves It is important for the functioning of the valves that Assuming that the fuel oil is purified effectively and the valve seats are overhauled correctly in accord- that the engine is well-maintained, the operational ance with our instructions. conditions for the fuel valves and the overhaul intervals will not normally be altered essentially when The use of rotocaps ensures a uniform distribution operating on HFO. of temperature on the valves.

12.04 - ES0 MAN Diesel & Turbo

Description Engine Performance and Condition 602.01 Page 3 (3) Edition 12H

L+V28/32H

Air Inlet Valves Engine Room Ventilation, Exhaust System

The operational conditions of the air inlet valves are Good ventilation of the engine room and suitable loca- not altered substantially when using residual fuel. tion of the fresh air intake on the deck are important. Sea water in the intake air might involve corrosive attack and influence the overhaul intervals for the Fuel Injection Pumps exhaust valves.

Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room operation of the fuel injection pumps will not be very should correspond to approximately 1.5 times the air much affected. consumption of the engines and possible boilers in operation. Under-pressure in the engine room will The occurrence of increasing abrasive wear of plunger involve an increased exhaust temperature level. and barrel can be a consequence of insufficient purification of the fuel oil, especially if a fuel which The exhaust back-pressure measured after the turbo- contains residues from catalytic cracking is used. chargers at full load must not exceed 300 mm water Water in the fuel oil increases the risk of cavitation in column. An increase in the exhaust back-pressure will connection with pressure impulses occurring at the also cause an increased exhaust valve temperature fuel injection pump cut-off. A fuel with a high asphalt level, and increased fuel consumption. content has deteriorating lubricating properties and can, in extreme cases, result in sticking of the fuel injection pump plungers.

12.04 - ES0 MAN Diesel & Turbo

Description Evaluation of Readings Regarding 602.02 Page 1 (1) Combustion Condition Edition 11H

General

PRESSURE DROP INCREASING (limit 50%) Air filters fouled.

PRESSURE DROP INCREASING (limit 50%) Air side of ALL CYLINDERS cooler fouled. Exhaust temp. increasing: Air system fouled TEMP. DIFFERENCE (Air filter-blower-cooler). TOO LARGE Exhaust system fouled Water flow too small (nozzle ring, turbine wheel). T

TEMP. DIFFERENCE TOO LARGE Air cooler fouled.

ONE CYLINDER DECREASING CHARGE Exhaust temp. in AIR PRESSURE: creasing: Fuel valve Decreasing air amount. needs overhaul. Fouled turbocharger, Compression too low air filter or charge owing to leakage of air cooler (air side). Pcomp and Pmax are measured by means exhaust valve or of max. pressure gauge. piston ring blow-by. Pcomp too low: Leaky combustion chamber, charging air pressure too low.

Pmax too low: to late injection timing, low charge air press., low comp. press., worn fuel pump

P comp too low, ignition too late.

Please also see Description 602.01, Engine Performance and Condition

11.23 - ES0 MAN Diesel 91.37 -ES1S 08028-0D/H5250/94.08.12 Description Page 1(2) the sameamount ofwater asbefore. cools theair. Then, normally, theaircannot absorb engine tak the abilitytoab Both higherpressureandlower tem Air Receiver Amount ofCondensation Water in The Charge on thepressureandtem the diagram. The abilitytoab The amountofwater inkg/kgaircanbefound from water intheairasitcanabsorbwith humidity issaidtobe100%andthereasmuch When theairissaturated withaqueousvapour, the There isalways amountofwater inair. acertain General Fig. 1. Nomogram for calculationofcondensateamount. i humidity air Relative

Water content of air in kg water / kg air es airfromoutside, compressesand 0.02 0.04 0.06 0.08 0.10 0 sorb wat 10 pe er. A turbocharged diesel fatmosphere content of water Max. A ra ra sorb thewater de tu 20 re oftheair. B pe out con ra ra Condensate Amount tu min i eprtr 1bar) (1 temperature air Ambient I re reduce 30 30 dens pends ing.

100%

i eprtr ntank. cooler. in after temperature temperature Air air Charge 90% 40 40 80% III hrearpesr 26 bar 2.6 % °C 90 50 Holeby engines. (Le) atfullloadcanbeused for MANDieselA/S, 35 °C As aguidance, anairconsumption of8.2kg/kWh kW 1260 Charge airpressure Charge airtemperature relative airhumidity air temperature Ambient aircondition: (P) 6L28/32H, 720rpm Example: the diagram canbeused. if condensationinthechargeairreceiver willoccur and thetemperature oftheambientair. To ﬁ nd out receiver isconsequentlydependentonthehumidity Condensation ofwater intheengine'schargeair 70%

60% 50 50 II 60 60

0bar 30

1.0 bar 70 70

3.0 bar 2.0 bar

Pressure General 602.05 in air tank Charge air pressure (Above atmospheric) Edition 08H General 602.05 Edition 08H charge airreceiver canbedrain valve canbelefthalf-open. Iftheamountissmall, draining ofthewater. Ifthereisagreat amount,the er/cooler ontheengine. This valve istobeusedfor standard avalve ismountedonthechargeairre the cylinder. This water have tobedrain ﬁ lled withwater, ofget thereisarisk charge airreceiver. Butifthechargeairre the engines. For MANB&WHoleby 4-stroke engine, This phenomenonwilloccuronalltur Draining ofCondensation Water. (0.033-0.021)x8.21260=123kg/h = (l-ll)xleP = kg/kg kg/kg 0.033 0.021 Amount ofcondensateinchargeairrecceiver. Max. water cont. ofair(ll) Water contentofair(l) Solution accordingtodiagram: re is no risk withasmallamountofwaterre isnorisk inthe ed pe ting water in rio rio Condensate Amount ed away. As di bo cal ceiv charg ly. ceiv- er is ed to (0.033-0.0015)x138=4.35 kg. 138kg = = (I-III)xm. = kg/kg 0.033 kg/kg Amount ofcondensateinairtank 0.0015 Max. water cont. ofair(lll) Water contentofair(l) = =31x10 Solution acc. toabove diagram: % 90 m = °C 35 Nm/kg.K 287 Weight ofairintank Relative bar airhumidity 30 °C=313K 40 Ambient airtemperature Gas constantfor air(R) press.Internal oftank(p) dm³ 4000 Temperature intank(T) Volumetric capacityoftank(V) Amount ofcondensateinairtank. Example: of 30bar. of thediagram, representinganoperating pressure ed by atthebottomtoright meansofthecurve The volume ofcondensateintheairtankisdetermin- Amount ofCondensate Water inAir Tanks. 287x313 31x10 Rx T px V 5 x4 5 N/m²(abs.) MAN Diesel Description Page 2(2) 91.37 -ES1S

08028-0D/H5250/94.08.12 MAN Diesel & Turbo

Working Card 602-01.00 Page 1 (4) Engine Performance Data Edition 03H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62005 10 Max. pressure Shut-off fuel oil indicator Shut-off cooling oil Stopped lub. oil circul.

Description: Hand tools:

Measurements of engine performance data.

Starting position:

Engine is running.

Related procedure:

Man power: Replacement and wearing parts:

Working time : ½ hour Plate no. Item no. Qty. / Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

11.25 - ES0 MAN Diesel & Turbo

602-01.00 Working Card Edition 03H Engine Performance Data Page 2 (4)

L28/32H

Engine Performance Data M/V Engine Type Engine No. Date/Year Hour Total Engine 1 2 3 4 5 6 running Hours

Engine RPM Fuel Type Turbocharger Turbocharger 7 8 Visc. Density 9 Type Serial No. 10 RPM

Switchboard Effect (kW) Voltage (V) Current (A) cos ϕ /kVAr 11 12 13 14

Cylinder Data Ave- 15 Cylinder No. 1 2 3 4 5 6 7 8 9 16 rage

17 Fuel Pump Index

18 Maximum Pressure (bar)

19 Compress. Pressure (bar)

20 Exhaust Temp. (° C)

21 Cooling Water (°C)

Turbocharger Temp. inlet blower (° C) Pressure before blower (mmWC) Temp. after blower (° C) 22 23 24

∇ Press. air cooler (mmWC) Temp. charge air (° C) Press. charge air (bar) 25 26 27

Temp. exhaust gas before TC (° C) Temp. exhaust gas after TC (° C) Press. exhaust gas after TC (mmWC) 28 29 30

Lubricating Oil System Temp. after engine (° C) Press. before filter (bar) Press. after filter (bar) 31 32 33

Temp. inlet engine (° C) Press. before TC (bar) 34 35 36

Cooling Water System LT temp. inlet air cooler (° C) LT temp. outlet air cooler (° C) LT press. inlet air cooler (bar) 37 38 39

LT temp. inlet lub. oil cooler (° C) LT temp. outlet lub. oil cooler (° C) LT temp. inlet alternator (° C) 40 41 42 LT temp. outlet alternator (° C) HT FW temp. inlet engine (° C) HT FW press. inlet engine (bar) 43 44 45

Fuel Oil System Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar) 46 47

Nozz. cool. oil press. inlet engine (bar) Nozz. cool. oil temp. outlet engine (° C) Sign. 48 49 50

11.25 - ES0 MAN Diesel & Turbo

Working Card 602-01.00 Page 3 (4) Engine Performance Data Edition 03H

L28/32H

The Instruction for Filling in the Diagram "Engine Cylinder Data. Performance Data". 15. Cylinder no. - can be read on engine plate. The numbers in the instruction are commensurate A/B is used for V-engines. with the numbers on the diagram. 16. Average for all engine cylinders for point: 17- The automatic symbols mentioned in the instruction 18-19-20-21. TI 01, TI 03, PI 01 etc, refer to the diagrams printed in the instruction books for specified plants. 17. Fuel pump index - can be read on each of the high pressure fuel oil injection pumps.

Engine Performance Data. 18. Max pressure (bar) can be read for each

cylinder by means of indicator or Pmax gauge. 1. Name of ship, if stationary name of plant. 19. Compression pressure (bar) - can be read for 2. Engine type. each cylinder by means of the indicator measurement, which is carried out during idling by nominal 3. Engine no. RPM.

4. Date/year of observations. 20. Exhaust temperature (°C) - Thermometer TI 60. 5. Hour, time of observations. 21. Water outlet cylinder (°C) (jacket cooling) 6. Total engine running hours - engineer's log- - Thermometer TI 11. book.

7. Engine revolutions per minute (RPM) - can be Turbocharger. read on tachometer SI 90. 22. Thermometer inlet blower (°C) can be read 8. Fuel oil type: The viscosity must be stated (in by means of a thermometer placed in the engine cSt) and the temperature by which the viscosity has room near the air filter of the TC. been measured f.inst. 180 cSt/50°C. Density must be stated: g/cm³. 23. Pressure before blower (mmWC) - can be read by means of a mmWC instrument placed in 9. Turbocharger: Type and serial number are the engine room near the TC. stated on the rating plate of turbocharger. 24. Temperature after blower (°C) - can be read 10. Turbocharger revolutions per minute (RPM) - by means of a thermometer TI 30. can be read on the tachometer SI 89. 25. ∆ Pressure air cooler (mm/WC).

Switchboard. 26. Charge air temperature (°C). Temperature of the charge air in the charge air receiver. 11. Effect alternator (kW) - can be read on the - Thermometer TI 31. main switchboard. 27. Pressure charge air (bar). Pressure of the 12. Voltage (V) - can be read on the switchboard. charge air in the charge air receiver. - Pressure gauge PI 31. 13. Current (A) - can be read on the switchboard. 28. Tempereture of the exhaust gas before TC 14. Cos ϕ/kVAr - can be read on the switchboard. (°C) - Thermometer TI 62.

11.25 - ES0 MAN Diesel & Turbo

602-01.00 Working Card Edition 03H Engine Performance Data Page 4 (4)

L28/32H

29. Temperature of the exhaust gas after TC (°C) 40. Temperature of the low temperature (LT) cool- - Thermometer TI 61. ing water (sea, raw or fresh) at inlet lub. oil cooler (°C) 30. Pressure of the exhaust gas after the TC (bar) - Thermometer TI 07. - Pressure gauge PI 61. 41. Temperature of the low temperature (LT) cooling water (sea, raw or fresh) at outlet lub. oil cooler Lubricating Oil System. °C) - Thermometer TI 03. 31. Temperature of the lub. oil inlet cooler (°C) - Thermometer TI 20. 42. Temperature of the low temperature (LT) cooling water (sea, raw or fresh) at inlet alternator (°C) 32. Pressure of the lub. oil before the filter (bar) - Thermometer TI 04. - Pressure gauge PI 21. 43. Temperature of the low temperature (LT) cool- 33. Pressure of the lub. oil after the filter (bar) ing water (sea, raw or fresh) at outlet alternator (°C) - Pressure gauge PI 22. - Thermometer TI 05.

The filter element should be replaced with a pres- 44. Temperature of the high temperature (HT) sure drop across the filter of 1.5 bar. fresh water (FW) at inlet engine (°C) - Thermometer TI 10. 34. Temperature of the lub. oil inlet engine (°C) - Thermometer TI 22. 45. Pressure of the high temperature (HT) fresh water (FW) of outlet engine (°C) 35. Pressure of the lub. oil before the turbocharger - Thermometer TI 10. (bar). - Pressure gauge PI 23. Fuel Oil System.

Cooling Water System. 46. Temperature of the fuel oil at inlet engine (°C) - Thermometer TI 40. 37. Temperature of low temperature (LT) cooling water (sea, raw or fresh) at inlet charge air cooler 47. Pressure of the fuel oil before engine (bar) (°C) - Pressure gauge PI 40. - Thermometer TI 01. 48. Nozzle cooling oil pressure at inlet engine 38. Temperature of low temperature (LT) cooling (bar) water (sea, raw or fresh) at outlet charge air cooler - Pressure gauge PI 50. (°C) - Thermometer TI 02. 49. Nozzle cooling oil pressure at outlet engine (bar) 39. Pressure of the low temperature (LT) cooling - Pressure gauge PI 51. water (sea, raw or fresh) at inlet charge air cooler (bar) 50. Signature. - Pressure gauge PI 01.

11.25 - ES0 Trouble shooting

503/603 90.46 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) depressed regularly but-tonis whenstart tooslowlyorir-Engine turns button isactivated whenstart Engine doesnotturn but-ton beingactivated valve isopened,withoutstart assoonshut-off Engine turns Trouble position valveisstickinginclose Start Worn airmotorparts Faults inelectricalsystem but doesnotrotate Air motorruns,pinionengages wheel Pinion doesnotengagethefl y Main valve(s)closed ver toolow Air pressure airrecei- instarting Faults inelectricalsystem Possible cause Starting FailuresStarting Check start valve Check start unserviceableparts determi-ning damag-ed. Usetheguidelinesfor re-place or anythatare worn air motor. and Examineallparts Remove anddisassemblethe Check electricalparts shafting, bearingorclutchjaws Check theairmotorforbroken clutch jawsorotherbroken parts forbrokenCheck theairstarter receiver andengine valve interposedinlinebetween Open valveatreceiver andstop receiver compressors, re-chargeStart air Check electricalparts Trouble shooting General 603.01 Edition 08H MAN Diesel 02.47 -ES0 08028-0D/H5250/94.08.12 Description Page 1(3) is injected,but ignition fails air, onstarting fuel Engine turns res infuelsystem no fuelisinjectedowing tofailu- air, onstarting butEngine turns actuated ignition fails. Fuelpumpsarenot air, onstarting butEngine turns Trouble Faults inFuelOilSystem Fuel valves ornozzlesdefective (4) Water inthefuel tion pumps(3) Too low pressurebefore fuelinjec- valve nozzles(4) Defective fuelinjectionvalves or Worn-out fuelpump valves (2) Air infuelpumpsandinjection tankempty Fuel oilservice cylinder Incorrect adjustmentoflimiter gear manoeuvring Incorrect adjustmentof Failures ingovernor down function(1) actuated owing touncancelledshut- Piston inLambdacontrolleris actuated Piston inLambdacontrolleris function isactivated Overspeed oranothershutdown Governor settingincorrect gear manoeuvring Sluggish movement of Possible cause Working Card614-01.10. Change defective fuelvalves, see of fuelpumps Drain offwater andrepeatventing pressure Increase thefueloilfeed pump Change defective fuelvalves Change fuelpumps the engi-neagain. valve before attemptingtostart If igni-tionstillfails, installaspare the re-spective fuelinjectionvalve. ignition fails injustonecyl.,vent with-out airbubbles appears. If Vent thefuelpumpsunitl Pump oilintothetank Adjust settingoflimitercylinder testbed chart in to "Adjustmentsaftertrials" fuel pumpindex iscorresponding Check rodconnec. Check that see specialinstr. manual properly. fault For location, further Check thatgovernor isworking devices res. Check for faults inshut-down Check pressuresandtempera-tu- isnotactuated. speed trip relieved. Check thattheover- Check thatpressureincylinderis Check thatpistonisnotsticking. Cancel shutdown function manual struction Adjust governor, seespecialin- gear nections inmanoeuvring andmobilizeLubricate rodcon- Trouble shooting L+V28/32H Cont. 603.02 Edition 09H MAN Diesel L+V28/32H 603.02 Edition 09H Remarks 3) 2) 1) Ifthefueloilpressuredrops, the fi lter may be Whetherairispresentinthefueloilsystem Iftheshut-down functionisduetooverspeed, may have opened. clogged up, ortheby-pass atthefeed pump seal. air throughadefective stuffi ng box oraleaky the resultoffueloilfeed pumpsucking-in crown. Airinthefueloilsystemmay alsobe cheked that nooilhascollectedonthepiston should bechangedandoverhauled. Itshouldbe of gasinthefuel. Ifasticking valve isfound, it may have asimilareffect owing toformation ken). Heatingoffueltoatoohightemperature open position(spindlesticking bro- orspring The causemay bethata fuelvalve iskept in seen berepeatingtheventing offuelpumps. Lambda controller/aircylinder. ting theoverspeed device andthusventing the the shut-down activation iscancelledby reset- Trouble runs erratically runs fety valves areopening). Engine First ignitionsaretooviolent(sa- Faults inFuelOilSystem Possible cause Fuel pumpindex tohigh gear Sluggish movement ofmanoeuvring Oil hascollectedonpistoncrown (7) Incorrect timingofcamshaft(6) toolow (5) start Compression during

6) 5) 4) Majoralterations ofthecom To obtain ignitiontemperature inthecylinders, Ifthefuelisforced intothecylinderthrough of thefuelvalves willalsodelay theinjection. (after dis cam-shaft sectionsmay beincorrectlyﬁ of thetimingfuelpumps. Oneormore ofthefuelmayteristics demandadjustment low compressionshouldbeinspected. starting.pressure during Cylindershaving too can bechecked by thecompression measuring seethetestbedchart. should benormal, This star the compressionpressureduring violent ignition. may prevent ignition,possibly followed by too atomizer holes, noortoosluggishatomi a defective fuelvalve orthroughworn-out mantling). Too highopeningpressure cylinder tobesetlower properly.nor isworking Limiter gear.euvring Check thatgover- Check rodconnectioninmano- gear euvring inmano- nections andbearings andmobilizeLubricate rodcon- ve, remove oil valves, tolocatedefective fuelval- withopenindicator Slow turning as well ascamshatadjustment and fuelvalve openingpressure Check fuelpumptimingadvance, and pistonrings for tightclosing. Check cyl. wear Check intake andexhaust valve Trouble shooting bustion charac- Description Page 2(3) zation tted ting 02.47 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 02.47 -ES0 08028-0D/H5250/94.08.12 Description Page 3(3)

7) Oilonthepistoncrown willinmostcaseshave the engine is started again. the engineisstarted lea-kage shouldbefound andremediedbefore these oilaccumulations aredangerous, the leaked down fromadefective fuelvalve. As Faults inFuelOilSystem L+V28/32H 603.02 Edition 09H MAN Diesel 05.08 -ES0 08028-0D/H5250/94.08.12 Description Page 1(3) Engine RPMdecreases decrease(s) Exhaust temperature(s) increase(s) Exhaust temperature(s) Trouble Disturbances duringRunning engine (5) in friction Increased internal Governor defective (4) Water inthefuel Fuel valve orfuelpumpdefective low Pressure before fuelpumpstoo sticking orleaking (Single cyls.) Fuelpumpplunger sticking (3) (Single cyls.) Spindleinfuelvalve and fuelinjectionvalve(s) (Single cyls.) Airinfuelpump(s) temperature (All cyls.) Decreasedchargingair cam (Single cyls.) Damagedfuelpump bustion chamber(2) (Single cyls.) Blow-by-leaky com- valves (1) (Single cyls.) Leakyexhaust nozzle defective (Single cyls.) Fuelvalve orvalve shaft (Maladjustment) (All cyls.) Wrong positionofcam- characteristics fuel oilorchangedcombustion (All cyls.) Insuffi cient cleaningof passages (All cyls.) Fouling orairandgas coolers temperature duetoineffective air (All cyls.) Increasedchargingair Possible cause Check P 604.25. See Description bine. Cleanairfi lters andcoolers Reduce loadandwater-wash tur- See Working Card612-01.00. Trouble shooting See "IgnitioninCrankcase" Replace defective governor pumps Drain offwater andvent thefuel Change defective valve orpump to normal. Check fi lter Raise fueloilfeed pumppressure assembly Change fuelpumpplunger/barrel fuel valve Change andoverhaul defective Check feed pumppressure without airbubbles appears. Venting offuelpump(s)until set andcorrectly properly is working pass valve) incoldwater system valveCheck thatthermostatic (by- pump Check timingadvance offuel See Working Card606-01.00. ce cyl. headwithdefective valve Check thevalve clearance. Repla- See Working Card614-01.10. justment max . Check camshaftad- L+V28/32H Cont. 603.03 Edition 08H MAN Diesel L+V28/32H 603.03 Edition 08H To limit thedamagetovalves, theseshould Remarks 1) Thismanifests itselfby of theexhaust rise and locking itinthisposition. out ofopera shouldbeput pump ofthecylinderconcerned be changedimmediately, ifpossible, orthefuel respective cylinder. and maximum combustion pressureofthe temperature andfalling ofthecompression Alternator oilpressurefailsLubricating Rising coolingwater temperature Exhaust valve knocking Smoky exhaust Engine stops Trouble tion by moving theindex tostop Disturbances duringRunning Short circuit Short Filters/cooler fouled oilpumpdefective.Lubricating (8) (7) Pump stopped. Increasedfriction da-maged ting loose. disc Pushrodthrust Adjsuting screw for valve set- hea-vy-oil operation) (6) lure ofcooling(especiallyduring "Trumpets" atnozzle holes. Fai- Fuel valves ornozzlesdefective Air supplytoolow gine RPM Turbine RPMlaggingbehinden- Shut-down Possible cause

2) Blow-by danger ofpiston meansaserious excess pressure inthecrankcase. resultinaheavy willnormally piston rings above,as described bemoved tostop. Leaky this isnotpossible, thefuelpumpindex must, stopped andthepistoninquestionpulled. If seizure, andtheenginemust ifpossible be guide pinreplaced Flywheel must bedismountedand tails, see"Ignitionincrankcase" Stop theengine. de- For further andremedyfaultased friction cooling water. Findcauseofincre- Stop theengine. Check the asnecessary parts Inspect andreplacedefective nozzle-cooling Overhaul fuelvalves. Re-establish See Working Card614-01.10. see section612. Fouling ofairandgaspassages, turbine(s) andcheck valves clean running, normal during res cal-ledfor. Ifsmokyexhaust when RPMincreases; nomeasu- Reasonably smoke isnormal Failures down devices. SeealsoStarting res. IfOK,check for faults inshut- Check pressureandtemperatu- Trouble shooting Description Page 2(3) 05.08 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 05.08 -ES0 08028-0D/H5250/94.08.12 Description Page 3(3) Whenthegovernor isdefective the engine 5) 4) 3) Usually a bearing failure Usuallyabearing willnotslow down the Thegovernor will notreducethefuelpump Ifthishappensthe fuelpumpbarrelandplun- Feel over andlookoutfor oilmist. theengineagain. beforeis necessary starting temperatures rise. Ifsuchcasesoccur, repair is employed, theindex willincreaseandexhaust the cylinderlinermightdoso. IfaPG-governor engine appreciably, but theseizureofapistonin book. instruction order. Regardinggovernor failure, seespecial fore, thattheoverspeed iskept trip inperfect case ofexcessive speed. Itisessential,there- trip, i.e. theengineisstoppedautomaticallyin is pro ﬂ will start of thegovernor oilpump, but theenginespeed tozerodelivery incaseof, for instance, failure new barrelandplunger. In thatcasethepumpcanbeprovided witha ispluckedcorroded areawherematerial out. the helicalcut-offedgewillshow apittedand inspection ofthefuelpumpplungeronwhich out.cases worn Usuallythisisconﬁ 10 index degrees, thefuelpumpisinmost to increasethefuelpumpindex by morethan load oftherespective cylinder, itisnecessary ger must bechanged,andif, toobtainfull tected againstracing by theoverspeed uctuating. Disturbances duringRunning rmed by rmed

8) 7) 6) If the lubricating oilpressuredropsbelow Ifthelubricating the Ifthecoolingwater temperature for theentire Ifthecoolingofatomizers fails (ifarranged load isobtained. Seesection602. andagainwhenfull 30 minutes afterstarting, theengine.before re-starting Feel over 5-15- of thepressuredropandremedydefect minimum mentionedinData; Findthecause starting-up. withopenindicatorvalvesturning atsubsequent water leakagehasnot arisen. Rememberslow thatinternal crankcase inspectiontoascertain cooling jackets. Check fi a littletoallow thewater slowly torise inthe valve isclosed. After15minutes itisopened be stoppedandlefttocool,whilethedischarge tooearly,the water returns theengineshould incylinderlinersandheads,arising if refore beheatedunduly. To avoid heatstresses water onthecoolingsurfaces, whichmay the- has de the dischargefromcylinders-whethersteam checked -by openingthetestcocks, iffi to90-100°C,engine hasrisen itshouldbe nozzle coolingshouldbewell maintained. sticking ofthevalve spindle. For thisreasonthe causes theenginetosmoke, orotwillcause which in theshapeofsmallconesortrumpets will build uproundthenozzleholes, some for carbonde oilcooling)whilerunning, veloped. Ifthisisthecase, thereisno lling attestcocks. Make L+V28/32H tted on 603.03 Edition 08H posits times 96.30 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) near doorsoftheengineroom casing. crankcase. Donotstayunnecessarily indoor Warning Measures (incaseofwhiteoilmist). frame. which isusuallyfi Presence ofoilmistmaybynotedattheventpipe, is recommended. from thefi must notbeusedagain,iftheyhavebeenremoved condition.Filtercartrid equipment isinperfect It istherefore thatthelubricatingoil fi important the lubricatingoil. failing lubricationpossiblycausedbypullutionof Overheating ofbearingsisaresult oftoobador avoid "hotspots"and(B)discoveroilmistintime. precautionEvery shouldtherefore betakento(A) doors andcausedfi re intheengineroom. consequential explosionhasthrown off crankcase the wholecrankcasehasbeenfi valves toopen.Inafewcases,whenpresumably pressure riseinthecrankcase,forsingrelief before maycauseconsiderable ignition,theburning oil mist.Ifalargequantityofmisthasdeveloped caused bythesame"hotspot"whichproduced the and spread afl abletonourish i.e. amilkywhiteoilmistisformed, tude ofminutedrops suspendedintheatmosphere, amulti- When theoilvapourscondensetheyform eva willcause to thecrankcase,heatedsurface orheatistransmittedotherwise sliding surfaces, If unduefrictionandthusheatingarisesbetween spray ofcoarseoildrops isfl proportions asintheambientair, butanintense contains thesamegases(N2-O2-CO2)in During running,theatmosphere inthecrankcase Cause B. A "Hotspots"incrankcase. . Oilmistincrankcase. poration ofthelubricatingoilsplashedontoit. : Keepawayfrom doorsandrelief valveson lter. Checkoftheoilconditionbyanalysis ame ifignited.Suchignitionmaybe tted to the topofengine ung around everywhere. lled withoilmist,the Ignition inCrankcase ltra ways ges tion tion cracked piston). an airjet(forinstanceblow-by, orblow-bythrough to "atomization"oflubricating oilbytheactionof remedied. rare Invery cases oilmistcouldbedue until thecauseofoilmisthasbeenfoundand hot spot,point7shouldbeintensifi Description 601.10,Point2. andagainwhenfull loadisobtained).See starting, heating shouldbefeltover(5-15-30minutesafter thatcausedthe Especially thefrictionalsurfaces two revolutions. SeeDescription601.05,Point4.1. the engine throughcrankcase whileturning atleast check oilfl time. toreplaceIt isequallyimportant fi involved. conditionofthefrictionalsurfaces tory given toensure lubricatingoilsupplyandsatisfac- repair.a permanent Specialattentionshouldbe steel). ration byheat(blistered oil,heated paint,burned Look forsqueezed-outbearingmetalanddiscolo- roller guides,etc.). (bearings, liners,pistons, over allslidingsurfaces employed atonce(inexplosion-proof fi Cut offair. starting gear, Engageturning iffi tted. light anddonotsmoke. keep clearofpossiblefl after stoppingoftheengine.Whenopeningup, Warning ment. away from them.Makeready fi 8 7 6 5 4 3 2. 1. Incaseithasnotbeenpossibletolocatethe . Stopandfeelover. Lookoutfor oilmist. . electricallydrivenlubricatingoilpumpand Start . Preventheating,preferably further bymaking . lampsshouldbe Locatethehotspot.Powerful . Take off alldoorsononesideofthecrank . Leavetheengineroom. Shutdoorsandkeep Stoptheengine : Donotopencrankcaseuntil10minutes ow from allbearingsandsplashpipesin ames. Donotusenaked re-fi equip- ghting ed andrepeated lter elementsin ttings). Feel L+V28/32H 603.04 Edition 09H case. MAN Diesel

Description 603.05 Page 1 (1) Trouble Shooting Guide for Centrifugal By-pass Filter Edition 08H

L+V28/32H

Tabulated below are the corresponding remedial actions to be taken if the following faults are observed:

Trouble Possible cause Trouble shooting

Oil leakage through cover nut Missing or damaged O-ring (see Replace O-ring Item 29, Plate 61515)

Seal face damaged Replace O-ring

Excessive vibrations Rotor out of balance owing to un- even build-up of deposit on rotor walls resulting from:

Missing or damaged O-ring, al- Replace O-ring lowing leakage (see Item 23, Plate 61515)

O-ring seat on rotor joint faces Replace rotor assembly damaged

Rotor assembly inadequately Tighten and bring to notice of main- tight ened tenance staff

Standtube incorrectly seated or Re-ﬁ t or replace if damaged damaged

Dirt deposit not completely remo- Clean and bring to notice of main- ved tenance staff

Rotor castings distorted through Replace rotor assembly maltreatment

Rotor assembly components ﬁ tted Follow sequence in Working Card in wrong sequence 615-15.00 in section 615.

Bushes loose or worn in tube as- Fit nes bearing tube assembly sembly

96.30 - ES0U 94.34 -ES0U-G 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(2) Excessive butt engagement. does notrotatefl ywheel. Motor runs,pinionengages, but Drive (36)of(57)willnotengage. Loss ofpower Motor willnotrun. Trouble Trouble ShootingGuidefor Turbine Starter components. drive (36)or(57) Damaged starter or fl ywheel. Damaged drive pinion(36)or(63) Damaged orbroken drive train. andsealsdry.O-rings orseals.(54), o-rings pistonassemblyDamaged orworn Fluid indrive unitcomponents. blocked. drive housingports Internal No pressuretodrive housingport. Damaged motorassembly. Exhaust fl ow restricted. Relay valve malfunctioning. airsupplyline.Restricted Low airpressuretostarter. Defective controlorrelay valve. Blocked exhaust system. piping. Foreign inmotorand/or material Damaged motorassembly (12). No airsupply. Possible cause replace worn ordamaged parts. replace worn Inspect drive componentsand and replaceifnecessary. Inspect drive pinionandfl ywheel ordamagedparts. worn Disassemble drive train andreplace and seals. o-rings Relubricate parts. Replace damagedorworn Remove fl uid. Remove blockage. Check airsupply. Replace motorassembly. moisture build-up tostarter. ice build-up. Melticeandreduce and cleanorremove. Check for Check orforeign for material dirt piping. Cleanorreplacepiping. Check for blocked ordamaged valve. relay Lubricate valve. Clean orreplacelinesrelay air lines. Check for blockage ordamageto Check airsupply. Replace controlvalve orrelay valve. and check for blockage. Remove housingexhaust cover (1) and remove theblockage. Remove motorassembly andpiping place motorassembly ifnecessary. train andrepairpower train orre- Inspect motorassembly andpower air supplylinesortank. Check for blockage ordamageto Trouble shooting Cont. .... L+V28/32H 603.06 Edition 09H MAN Diesel

603.06 Description Trouble Shooting Guide for Turbine Starter Page 2 (2) Edition 09H

L+V28/32H

Trouble Possible cause Trouble shooting

Low air pressure. Check air supply.

Wrong drive pinion. Replace with proper drive pinion.

Oil blowing out of exhaust. Oil in air supply line. Inspect air line and remove source of oil.

Splash deﬂ ector retaining screw (5) Install splash deﬂ ector retaining or pipe plug missing. screw or pipe plug.

Worn or damaged rotor seals or Replace static seals on outside of static o-rings. motor or send motor to Inger-soll- Rand to be rebuilt.

Oil leaking from gear case (28). Worn or damaged o-rings. Replace o-rings.

Loose joints. Make sure that joints ﬁ t properly and starter assembly cap screws are tightened to 60 ft-lb (81 Nm) torque. Make sure all seals and o-rings ﬁ t and seal properly at their perimeters. If they do not replace with new seals and o-rings.

Excessive high-speed operation. Operate according to recommendations.

High number of start cycles. Replace worn components.

Loose or leaking pipe plugs (10) Tighten or replace pipe plugs using or (11). Ingersoll-Rand No SMB-441 pipe sealant.

Splash deﬂ ector retaining screw Tighten splash deﬂ ector retaining loose or pipe plug missing. screw or replace pipe plug.

Air or gas leakage. Loose joints. Make sure that joints ﬁ t properly and starter assembly cap screws are tightened to 60 ft-lb (81 Nm) torque. Make sure all seals and o-rings ﬁ t and seal properly at their perimeters. If they do not replace with new seals and o-rings.

Excessive high-speed operation. Operate according to recommendations.

High number of start cycles. Replace worn components.

Loose or leaking pipe plugs. Tighten or replace pipe plugs.

Splash deﬂ ector retaining screw Tighten splash deﬂ ector retaining loose or pipe plug missing. screw or replace pipe plug.

94.34 - ES0U-G 91.14 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) driven through agearing. mounted onthefront coveroftheengineandis ture (HT)circuit isofthecentrifugaltypeand The built-onfresh waterpumpinthehightempera- Description will reduce thepumpcapacity. when necessary. Evenathinyholeinthesuctionline and gasketsare inorder andthattheyare renewed suction line.Itisessential,therefore, thatallpack mechanical faults,are mostoftenduetoleaks inthe Note! Runningtroubles from withthepump,apart delivery Pump doesnotgivemaximum mal operation Pump capacitydrops afternor- start The pumpdoesnotworkafter Trouble Trouble Shootingfor Cooling Water System Worn impeller and worn wearrings Worn impellerandworn Defective seals Suction valvenotfullyopen Fouled impeller Air leakagesofshaftseal Leaking shaftseal side Air cannotescapeondelivery The systemisnotfi lled-up Pump drawsinairatsuctionside Possible cause ings ings see workcard 616-02.00. itisrecommendedworn, toreplace theshaftseal, If thepumpleaksandshaftsealingringsare oil from thelubricatingoil systemoftheengine. The pumpbearingsare lubricatedautomaticallywith Overhaul thepump Replace theseals Open thesuctionvalve Clean theimpeller Overhaul theshaftseal Check theshaftseal Vent thesystem tank Check thelevelinexpansion tightness Check packingsandpipesfor Trouble shooting General 603.09 Edition 08H 92.08 -ESOU 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(2) the causeofdamage! around theplateheatexchanger inorder tolocalize carefully conditions First examinevery theexternal toreplacebe necessary them. In caseofdamagetoplatesorgaskets,itwilloften Trouble Shooting. Trouble gaskets) exchanger tominimumdimension) (Through thedrainholesof Leakage. (Even aftertighteningoftheplateheat Leakage. (Phase 2) Leakage. (Phase 1) Leakage. Leakage. Trouble Shootingfor LubricatingOilCooler plate. Defective gasketorbadlycorroded Gaskets. gaskets. Inelastic ordeformed plates. Fouled ordeformed Insuffitightening cient Too highpressure. Possible cause Visible Leakage 05.00. For worktobecarriedoutseeworkingcard 615- carefully! In caseofcorrosion, allplatesmustbeexamined material. there maybeariskoffatigue fracture inallthe sitate areplacement ofallplatesandgaskets-as In caseoffatiguefracture, neces- thiswillnormally and start itupagain. and start if any. itupagain. and start grains maycauseleakage. itupagain. and start all platesandgaskets. if any. joints are clean. andthatthefacesof non-deformed, or fouled. and checkiftheplatesare deformed procede withphase2. over 40°C. heat exchangerisunderpressure or dimension andnever, whentheplate - however, notundertheminimum "Operating Data&SetPoints". working pressure, seepage600.30 Assemble theplateheatexchanger Replace defectiveplatesandgaskets, Separate theplateheatexchanger. Assemble theplateheatexchanger Replace thegaskets. carefully.Clean theplatesvery Separate theplateheatexchanger. Note! Assemble theplateheatexchanger carefullyBefore assembling,cleanvery platesandgaskets, Replace deformed Check thatthegasketsare elasticand Separate theplateheatexchanger If theplateheatexchangerisstillleaky, Tighten uptheplateheatexchanger Reduce thepressure tothecorrect Trouble shooting Even tinyimpuritiessuchassand General 603.10 Edition 01H MAN Diesel General 603.10 Edition 01H Trouble increasing pressure drop. (Phase 2) (The fl uids getmixed) Leakage. (Phase 1) (The fl uids getmixed) Leakage. Reduced heattransmissionand/or Trouble Shootingfor LubricatingOilCooler nels. Corrosion orfatiguefracture. Holes inplates. Corrosion orfatiguefracture. Holes inplates. Fouled platesorchokedplatechan- Possible cause Non-Visible Leakage Trouble shooting with adyepenetrant! pressure. plates, ifany, byputtingonesideunder and checktofi nd more defective and gaskets. kets. etrant! platesides. on theotherwisedry be possibletofi nd moistareas, ifany, plateside! spraying ontothedry changer again.Take care toavoidwater of operationandopentheplateheatex- unpressurised andfree from liquid! channel). Keeptheotherplatechannels secondplate one plateside(every tighten it. in theplateheatexchangeragainand changer. pressure. plates, ifany, byputtingonesideunder and checktofi nd more defective and gaskets. penetrant. carefully.check theplatesvery changer. plates are leaking. pressure hasstabilized-oneorseveral the lowerpipeconnections-after pressure. nections. in thefollowingway: itupagain. and start check iftheplatesare fouled. If theunitisstillleaking,checkallplates up again. Start Assemble theplateheatexchanger Before assembling,cleanallplates Replace defectiveplatesandgas- Check theseareas withadyepen- By acareful studyoftheplatesitwill Stop thecirculation afterafewminutes Circulate mediumatfullcapacityon Put allplatestodry. Suspendtheplates Separate theplateheatexchanger. Close downtheplateheatex- upagain. Start Assemble theplateheatexchanger Before assembling,cleanallplates Check defectiveplatesandgaskets. Check suspectedplateswithadye Separate theplateheatexchangerand Close downtheplateheatex- If themediumcontinuestorunoutof Then puttheoppositesideunder Remove oneofthelowerpipecon- A suspectedleakagecanbelocalized Assemble theplateheatexchanger carefully.Clean theplatesvery Separate theplateheatexchangerand Description Page 2(2) 92.08 -ES0U

08028-0D/H5250/94.08.12 Media specification

504/604 MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01 Page 1 (5) heavy fuel oil operation (HFO) Edition 27H L28/32H V28/32H The specific output achieved by modern diesel en- Only lubricating oils that have been approved by gines combined with the use of fuels that satisfy MAN Diesel & Turbo may be used. These are listed For 500-serien vælg A og the quality requirements more and more frequently in the table entitled "Lubricating oils approved for B master, for 600-serien increase the demands on the performance of the use in heavy fuel oil-operated MAN Diesel & Turbo lubricating oil which must therefore be carefully se- four-stroke engines". vælg C og D master lected. Specifications Medium alkalinity lubricating oils have a proven track record as lubricants for the moving parts and Base oil turbocharger cylinder and for cooling the pistons. Lubricating oils of medium alkalinity contain addi- The base oil (doped lubricating oil = base oil + additives that, in addition to other properties, ensure a tives) must have a narrow distillation range and be higher neutralisation reserve than with fully doped refined using modern methods. If it contains par- engine oils (HD oils). affins, they must not impair the thermal stability or oxidation stability. International specifications do not exist for medium alkalinity lubricating oils. A test operation is there- The base oil must comply with the limit values in fore necessary for a corresponding period in ac- the table below, particularly in terms of its resist- cordance with the manufacturer's instructions. ance to ageing:

Properties/characteristics Unit Test method Limit values Make-up   Ideally paraffin based Low temperature behaviour, still flowable °C ASTM D 2500  15 Flash point (Cleveland) °C ASTM D 92 > 200 Ash content (oxidised ash) Weight % ASTM D 482 < 0.02 Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50 Ageing tendency following 100 hours of  MAN ageing oven *  heating up to 135 °C ASTM D 4055 or insoluble nheptane Weight % < 0.2 DIN 51592 Evaporation loss Weight %  < 2 Precipitation of resins orasphalt- MAN Diesel & Spot test (filter paper)  like ageing products must not be Turbo test identifiable. Table 1 Base oils - target values * Works' own method

11.01 - ES1 - 3.3.6 (2011-01-04) MAN Diesel & Turbo

604.01 Specification for lubricating oils (SAE30) for Description Edition 27H heavy fuel oil operation (HFO) Page 2 (5) L28/32H V28/32H Medium-alkaline lubricating oil For tips on selecting the base number, refer to the table entitled “Base number to be used for various The prepared oil (base oil with additives) must have operating conditions". the following properties: Evaporation tendency Additives The evaporation tendency must be as low as pos- The additives must be dissolved in the oil and their sible as otherwise the oil consumption will be ad- composition must ensure that as little ash as pos- versely affected. sible is left over, even if the engine is provisionally operated with distillate oil. Additional requirements

The ash must be soft. If this prerequisite is not met, The lubricating oil must not contain viscosity index it is likely the rate of deposition in the combustion improver. Fresh oil must not contain water or other chamber will be higher, particularly at the exhaust contaminants. valves and at the turbocharger inlet casing. Hard additive ash promotes pitting of the valve seats and Lubricating Oil Selection causes the valves to burn out, it also increases mechanical wear of the cylinder liners. Engine SAE–Class Additives must not increase the rate at which the 23/30H, 28/32H, 23/30A, 28/32A At cooling water temperatures > 32° C a filter elements in the active or used condition are 30 blocked. SAE40 oil can be used. In this case please contact MAN Diesel Washing ability Table 2 Viscosity (SAE class) of lube oils

The washing ability must be high enough to prevent the accumulation of tar and coke residue as a result Neutralisation properties (BN) of fuel combustion. The lubricating oil must not absorb the deposits produced by the fuel. Lubricating oils with medium alkalinity and a range of neutralisation capabilities (BN) are available on Dispersibility the market. According to current knowledge, a relationship can be established between the antici- The selected dispersibility must be such that com- pated operating conditions and the BN number as mercially-available lubricating oil cleaning systems shown in the table entitled "Base number to be can remove harmful contaminants from the oil used for various operating conditions". However, used, i.e. the oil must possess good filtering prop- the operating results are still the overriding factor in erties and separability. determining which BN number produces the most efficient engine operation. Neutralisation capability

The neutralisation capability (ASTM D2896) must be high enough to neutralise the acidic products produced during combustion. The reaction time of the additive must be harmonised with the process in the combustion chamber.

11.01 - ES1 - 3.3.6 (2011-01-04) MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01 Page 3 (5) heavy fuel oil operation (HFO) Edition 27H L28/32H V28/32H

approx. BN of fresh Engines / Operating conditions oil (mg KOH/g oil) Marine diesel oil (MDO) with a lower quality (ISO-F-DMC) or heavy fuel oil with a sulphur 20 content of less than 0.5 %

generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions. 30 For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with exclusive HFO operation only with sulphur content < 1.5 %.

With unfavourable operating conditions 23/30A, 28/32A and 28/32S and also where corresponding requirements in relation to the oil service life and washing ability exist. In general 40 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with exclusive HFO operation providing the sulphur content is greater than 1.5 %.

32/40, 32/44CR, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is 50 insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil consumption). Table 3 Base number to be used for various operating conditions

Operation with low sulphur fuel Speed controller

To comply with the emissions regulations, the sul- Multigrade oil 5W40 should ideally be used in me- phur content of fuels used nowadays varies. Fuels chanical-hydraulic controllers with a separate oil with a low-sulphur content must be used in envi- sump. If this oil is not available when filling, 15W40 ronmentally-sensitive areas (SECA). Fuels with a oil can be used instead in exceptional cases. In this high sulphur content may be used outside SECA case, it makes no difference whether synthetic or zones. In this case, the BN number of the lubricat- mineral-based oils are used. ing oil selected must satisfy the requirements for operation using fuel with a high-sulphur content. The military specification for these oils is O-236. A lubricating oil with low BN number may only be selected if fuel with a low-sulphur content is used Lubricating oil additives exclusively during operation. The use of other additives with the lubricating oil, or However, the results obtained in practise that dem- the mixing of different brands (oils by different man- onstrate the most efficient engine operation are the ufacturers), is not permitted as this may impair the factor that ultimately decides which additive fraction performance of the existing additives which have is permitted. been carefully harmonised with each another and also specifically tailored to the base oil. Cylinder lubricating oil Selection of lubricating oils / warranty In engines with separate cylinder lubrication, the pistons and cylinder liners are supplied with lubri- The majority of mineral oil companies are in close cating oil via a separate lubricating oil pump. The regular contact with engine manufacturers and can quantity of lubricating oil is set at the factory ac- therefore provide information on which oil in their cording to the quality of the fuel to be used and the specific product range has been approved by the anticipated operating conditions. engine manufacturer for the particular application. Irrespective of the above, lubricating oil manufac- Use a lubricating oil for the cylinder and lubricating turers are liable in any case for the quality and char- circuit as specified above. acteristics of their products. If you have any ques- tions, we will be happy to provide you with further information.

11.01 - ES1 - 3.3.6 (2011-01-04) MAN Diesel & Turbo

604.01 Specification for lubricating oils (SAE30) for Description Edition 27H heavy fuel oil operation (HFO) Page 4 (5) L28/32H V28/32H Oil during operation If the engine is operated provisionally with low-sulphur diesel fuel for more than 1000 h and is sub- There are no prescribed oil change intervals for sequently operated once again with HFO, a lubri- MAN Diesel & Turbo medium speed engines. The cating oil with a BN of 20 must be used. If the BN oil properties must be regularly analysed. The oil 20 lubricating oil by the same manufacturer as the can be used for as long as the oil properties remain lubricating oil used for HFO operation with higher within the defined limit values (see table entitled BN (30 or 40), an oil change will not be required "Limit values for used lubricating oil“). An oil sample when effecting the changeover. It will be sufficient must be analysed every 1-3 months (see mainte- to use BN 20 oil when replenishing the used lubri- nance schedule). The quality of the oil can only be cating oil. maintained if it is cleaned using suitable equipment (e.g. a separator or filter). If you wish to operate the engine with HFO once again, it will be necessary to change over in good Temporary operation with gas oil time to a lubricating oil with a higher BN (30 – 40). If the lubricating oil with higher BN is by the same Due to current and future emission regulations, manufacturer as the BN 20 lubricating oil, the heavy fuel oil cannot be used in designated regions. changeover can also be effected without an oil Low-sulphur diesel fuel must be used in these re- change. In doing so, the lubricating oil with higher gions instead. BN (30 – 40) must be used to replenish the used lubricating oil roughly 2 weeks prior to resuming If the engine is operated with low-sulphur diesel HFO operation. fuel for less than 1000 h, a lubricating oil which is suitable for HFO operation (BN 30 – 40 mg KOH/g) can be used during this period.

Limit value Procedure

Viscosity at 40 °C 75-160 mm2/s ISO 3104 or ASTM D 445

Base Number (BN) at least 50% of fresh oil ISO 3771

Flash Point (PM) at least 185 °C ISO 2719

Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744

nHeptan Insoluble max. 1.5% DIN 51592 or IP 316

depends on engine type and operating Metal Content conditions

Guide value only Fe max. 50 ppm Cr max. 10 ppm Cu max. 15 ppm Pb max. 20 ppm Sn max. 10 ppm Al max. 20 ppm

Table 4 Limit values for used lubricating oil

11.01 - ES1 - 3.3.6 (2011-01-04) MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01 Page 5 (5) heavy fuel oil operation (HFO) Edition 27H L28/32H V28/32H Examinations Note! No liability when using these oils We can analyse heavy fuel oil for customers at our laboratory. A 0.5 l sample is required for the test. MAN Diesel & Turbo does not assume liability for problems that occur when using these oils.

Manufacturer Base Number [mg KOH/g]

20 30 40

AGIP  Cladium 300 - SAE30 Cladium 400 - SAE30

BP Energol ICHFX 203 Energol ICHFX 303 Energol ICHFX 403

CASTROL TLX Plus 203 TLX Plus 303 TLX Plus 403

CEPSA  Troncoil 3030 Plus Troncoil 4030 Plus

CHEVRON Taro 20DP30 Taro 30DP30 Taro 40XL 30 (TEXACO, CALTEX) Taro 20DP30X Taro 30DP30X Taro 40XL30X

Mobilgard M330 Mobilgard M340 EXXON MOBIL  EXXMAR 30 TP 30 EXXMAR 40 TP 30

PETROBRAS Marbrax CCD320 Marbrax CCD330 Marbrax CCD340

REPSOL Neptuno NT 2030 Neptuno NT 3030 Neptuno NT 4030

SHELL Argina S 30 Argina T 30 Argina X 30

Aurelia XL 3030 Aurelia XL 3040 TOTAL Lubmarine  Aurelia TI 3030 Aurelia TI 3040 Table 5 Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo fourstroke engines.

11.01 - ES1 - 3.3.6 (2011-01-04) MAN Diesel&Turbo 10.20 -ES1 -3.3.5(2010-02-25) 08028-0D/H5250/94.08.12 Description Page 1(5) tion products. the engine and the neutralisation of acidic combus- things, ensure dirt absorption capability, cleaning of other amongst that, additives contain oils bricating lu- Doped piston. the cooling for also and charger turbo- cylinder, drive, the for lubricants as record Doped lubricating oils (HD oils) have a proven track lected. oil which lubricating must therefore be carefully se- the of performance the on demands the increase satisfy the quality requirements more and more frequently that fuels of use the with combined gines en- diesel achieved output modern specific by The * Works' own method Table 1 Flash point(Cleveland) Low temperature behaviour, stillflowable Make-up Properties/characteristics Spot test(filterpaper) Evaporation loss insoluble nheptane heating upto135 Ageing tendencyfollowing 100hoursof Coke residue(accordingtoConradson) Ash content(oxidised ash) Base oils-targetvalues Quality Requirementsfor LubeOil(SAE30)for Opera- tion withGasOil, DieselOil(MGO/MDO)andBiofuel °C Weight % Weight % Weight % Weight % Unit °C °C    MAN ageing oven * ASTM D4055or MAN Dieseltest ASTM D2500 Test method ASTM D189 ASTM D482 ASTM D92 ing. values, in particularly limit terms of followingits resistance to the age- with comply must oil base The oxidation stability. or stability thermal the impair not must they affins, par- itcontains If methods. modern using refined be and range distillation narrowhave musttives)a The base oil (doped lubricating oil = base oil + addi- Base oil Specifications be used. These arelistedinthetables below. may Diesel MAN byapproved oils lubricating Only DIN 51592   Precipitation ofresinsorasphalt- like ageingproductsmust notbe Ideally paraffin based Limit values identifiable. < < > <  <

0.50 0.02 200 0.2 15  2

V28/32H L28/32H 604.01 Edition 26H og Bdocumentmaster Master for GenSetvælgA D documentmaster for PropulsionvælgCog V28/32H L28/32H 604.01 Edition 26H versely affected. ad- be will consumption oil the otherwise as sible pos- as low as be must evaporationtendency The Evaporation tendency in thecombustion chamber. process the with harmonised be must additive the of time reaction combustion.The during produced products acidic the neutralise to enough high be must D2896) (ASTM capability neutralisation The Neutralisation capability andseparability.erties oil the prop- filtering good from possess must oil i.e.the used, contaminants harmful remove can systems cleaning oil mercially-available lubricating com- that such be must dispersibility selected The Dispersibility of fuelcombustion. the accumulation of tar and coke residue as a result The washing ability must be high enough to prevent Washing ability blocked. are condition used or active the in elements filter the which at rate the increase not must Additives chanical wear ofthecylinderliners. causes the valves to burn out, it also increases me- additive ash promotes pitting of the valve seats Hard and casing. inlet turbocharger the at and valves exhaust the at particularly higher, be will chamber combustion the in deposition of rate the likely is it The ash must be soft. If this prerequisite is not met, sible remainsfollowing combustion. pos- as ash little as that ensure must composition additivesThe their dissolvedand mustbe oil the in Additives properties: following the have must oil) lubricating (doped ed The base oil to which the additives have been add- Doped lubricatingoils(HD-oils) Quality Requirementsfor LubeOil(SAE30)for Opera- tion withGasOil, DieselOil(MGO/MDO)andBiofuel circuit asspecifiedabove. forlubricating oil and cylinder the lubricating a Use anticipated operating conditions. according to the factory quality of the fuel to be used and the the at set is oil lubricating of quantity pump.The oil lubricating separate a via oil cating - lubri with supplied are liners cylinder and pistons the lubrication, cylinder separate with engines In Cylinder lubricatingoil tion ultimatelydecidetheadditive content. results that ensure the most efficient engine opera- base number of roughly 20.a However,choose the should operating you used, is weight by % 2.5 to up of residues coke and ISO-F-DMC to according weight by % 2.0 to up of content sulphur a with oil diesel marine If contains. oil lubricating the frac- tions additive which determine the fuel the and of engine quality the of conditions operating The oils canbeused. lubricating O-278 specification Military mgKOH/g. MIL-L specifications 2104 or API-CD with a base number of BN 10 – 16 international to oils) (HD according oils lubricating doped recommend We Doped oilquality Lubricating OilSelection contaminants. other or improver.water contain not must Freshoil index viscosity contain not must oil lubricating The Additional requirements Table 2 Viscosity (SAEclass)oflubeoils In thiscasepleasecontactMANDiesel SAE40 oilcanbeused. At coolingwater temperatures >32°Ca 23/30H, 28/32H,23/30A,28/32A Engine 10.20 -ES1 -3.3.5(2010-02-25) MAN Diesel&Turbo SAE–Class 30 Description Page 2(5)

08028-0D/H5250/94.08.12 MAN Diesel&Turbo 10.20 -ES1 -3.3.5(2010-02-25) 08028-0D/H5250/94.08.12 Description Page 3(5) information. further with you provide to happy be will we tions, ques- any have you products.If their of acteristics turers are liable in any case for the quality manufacand - char- oil lubricating above, the of Irrespective application. particular the for manufacturer engine the by approved been has range product specific their in oil which on information provide therefore regular contact with engine manufacturers and can close in are companies oil mineral of majority The Selection oflubricatingoils/warranty also specificallytailoredtothebaseoil. and another each with harmonised carefully been have which additives existing the of performance the impair may this as permitted not is ufacturers), the mixing of different brands (oils by different man- The use of other additives with the lubricating oil, or Lubricating oiladditives specification The military fortheseoilsisO-236. mineral-based oilsareused. or synthetic whether difference no makes it case, oil can be used instead in exceptional cases. In this sump. oil availablenot is oil this If 15W40 filling, when separate a with controllers chanical-hydraulic me- in used be ideally should 5W40 oil Multigrade Speed controller a separator orfilter). tained if it is cleaned using suitable equipment (e.g. main- be only can oil the of schedule).quality The maintenance (see months 1-3 every analysed be "Limit values for oil“).used lubricating entitled An oil sample must table (see values limit defined the within remain properties oil the as forlong used as be can oil The analysed. regularly be must erties prop- foroil engines. The speed medium Diesel intervals MAN change oil prescribed no are There Oil duringOperation Quality Requirementsfor LubeOil(SAE30)for Opera- tion withGasOil, DieselOil(MGO/MDO)andBiofuel urctn ol ogl 2 ek pir o resuming HFO operation. to prior weeks 2 roughly oil lubricating used the replenish to used be must 40) – (30 BN oil higher with an oil the lubricating the so, without doing change.In effected oil, be lubricating also can BN20 changeover the as manufacturer same the by is BN higher with oil lubricating the If 40). – (30 BN higher a with oil lubricating a to time good in over change to necessary be will it again, once HFO with engine the operate to wish you If cating oil. - lubri used the replenishing when oil 20 BN use to sufficient be will changeover.It the effecting required when be not will change oil an 40), or (30 BN higher with operation HFO for used oil lubricating the manufactureras same the by oil lubricating 20 BN the If used. be must 20 of BN a with oil cating - lubri a HFO, with again once operated sequently sub- is and h 1000 than more for fuel diesel phur low-sul - with provisionallyoperated is engine the If thisperiod. can beusedduring suitable for HFO operation (BN 30 – 40 mg KOH/g) is which oil lubricating a h, 1000 than diesel less for fuel low-sulphur with operated is engine the If gions instead. re- these in used be must fuel diesel Low-sulphur regulations, emission heavy fuel future oil cannot be used and in designated regions. current to Due Temporary operationwithgasoil V28/32H L28/32H 604.01 Edition 26H V28/32H L28/32H 604.01 Edition 26H A Dee S wl nt sue iblt fr any for liability problems associatedwithusingtheseoils. assume not will SE Diesel MAN No liabilityassumediftheseoilsareused Note! be observed. relevant safety information by the fuel supplier must a environment.the The pose and safety health, to can danger this handled, improperly are fuels If Improper handlingoffuels Danger! laboratory. A0.5lsampleisrequiredfor thetest. Weforheavyour oil analyse at fuel can customers Tests Quality Requirementsfor LubeOil(SAE30)for Opera- tion withGasOil, DieselOil(MGO/MDO)andBiofuel Manufacturer SHELL REPSOL Q8 PETROBRAS EXXON MOBIL (Texaco, Caltex) CHEVRON CASTROL BP 2) 1) on gasoilandDiesel proved for the use in MAN Diesel four-stroke engines running Table 3 TOTAL Lubmarine STATOIL a basenumber (BN)ofroughly20shouldbeused. AGIP withasulphurcontentoflessthan1% dieseloilwithalow Ifmarine quality(ISO-F-DMC)isused, Approved lubricatingoilsSAE30 urctn ol (A3) hc hv be ap- been have which (SAE30) oils Lubricating 1016 Base Number Sirius FB30 Sirius Gadinia AL30 Gadinia 30 Neptuno NT1530 DP30 Mozart Marbrax CCD 310 Delvac 1630 Mobilgard ADL30 Mobilgard 312 Exxmar 12 TP 30 Delo SHP30 SAE30 Delo 1000Marine Taro 12XD30 Seamax Extra 30 Castrol MHP153 Castrol MLC30 Energol DS3153 Disola M3015 MarWay 1030 MarWay 1530 X30 Sirius/Rimula Sigma SSAE30 Cladium 120SAE30 1) [mgKOH/g] 10.20 -ES1 -3.3.5(2010-02-25) MAN Diesel&Turbo 2) 2) 2) 2) Description Page 4(5)

08028-0D/H5250/94.08.12 10.20 -ES1 -3.3.5(2010-02-25) 08028-0D/H5250/94.08.12 MAN Diesel&Turbo Description Page 5(5) Table 4 When operating withbiofuels: Base Number(BN) nHeptan Insoluble Viscosity at40 °C Flash Point (PM) Guide value only biofuel fraction Water Content Metal Content Limit values for oil usedlubricating Cu Sn Pb Quality Requirementsfor LubeOil(SAE30)for Opera- Fe Cr Al tion withGasOil, DieselOil(MGO/MDO)andBiofuel max. 0.2%(max. 0.5%for periods) brief depends onenginetypeandoperating at least50%offreshoil at least185 °C 75-160 mm max. 20 ppm max. 10 ppm max. 20 ppm max. 15 ppm max. 10 ppm max. 50 ppm Limit value max. 1.5% max 12% conditions 2 /s ISO 3733 orASTMD1744 ISO 3104 orASTMD445 DIN 51592 orIP316 Procedure ISO 2719 ISO 3771 FT-IR V28/32H L28/32H 604.01 Edition 26H MAN Diesel & Turbo 604.03 Description Treatment and maintenance of lubricating oil Page 1 (4) Edition 11H

L32/40, L28/32H, V28/32H

General Operation on Heavy Fuel Oil (HFO) During operation of trunk engines the lubricating oil HFO-operated engines require effective lubricating will gradually be contaminated by small particles oil cleaning. In order to ensure a safe operation it is originating from the combustion. necessary to use supplementary cleaning equip- Engines operated on heavy fuels will normally ment together with the built-on full flow depth filter. increase the contamination due to the increased It is mandatory to run bypass separators continu- content of carbon residues and other contaminants. ously for engines operated on HFO, as an optimal Contamination of lubricating oil with either freshwa- lubricating oil treatment is fundamental for a reliable ter or seawater can also occur. working condition. Therefore it is mandatory to clean the lubricating oil with a bypass separator, so A certain amount of contaminants can be kept sus- that the wear rates are reduced and the lifetime of pended in the lubricating oil without affecting the the engine is extended. lubricating properties. The condition of the lubricating oil must be kept Bypass equipment under observation (on a regular basis) by analyzing oil samples. See Section 504.04 "Criteria for Clean- As a result of normal operation, the lubricating oil ing/Exchange of Lubricating Oil". contains abraded particles and combustion residues which have to be removed by the bypass The moving parts in the engine are protected by the cleaning system and to a certain extent by the built-on duplex full-flow lubricating oil filter. The duplex full-flow lubricating oil filter as well. replaceable paper filter cartridges in each filter chamber have a fineness of 10-15 microns. The With automatic mesh filters this can result in an safety filter, at the centre of each filter chamber, is a undesirable and hazardous continuous flushing. In basket filter element, with a fineness of 60 microns view of the high cost of cleaning equipment for (sphere passing mesh). removing micro impurities, this equipment is only rated for a certain proportion of the oil flowing The pressure drop across the replaceable paper fil- through the engine since it is installed in a bypass. ter cartridges is one parameter indicating the contamination level. The higher the dirt content in the The bypass cleaning equipment is operated oil, the shorter the periods between filter cartridge ▪ continuously when the engine is in operation or replacement and cleaning. at standstill The condition of the lubricating oil can be main- For cleaning of lubricating oil the following bypass tained / re-established by exchanging the lubricat- cleaning equipment can be used: ing oil at fixed intervals or based on analyzing oil ▪ Separator unit samples. ▪ Decanter unit Operation on Marine Diesel Oil (MDO) & ▪ Self cleaning automatic bypass mesh filter Marine Gas Oil (MGO) ▪ Centrifugal bypass filter (Holeby Gensets can be delivered with this built-on filter) For engines exclusively operated on MDO/MGO we recommend to install a built-on centrifugal bypass ▪ Bypass depth filter filter as an additional filter to the built-on full flow The separator unit, decanter unit, the self-cleaning depth filter. automatic bypass mesh filter and the bypass depth It is advisable to run bypass separators continu- filter capacity must be adjusted according to ously for engines operated on MDO/MGO as sepa- maker’s recommendations. rators present the best cleaning solution. Mesh fil- In case full flow filtration equipment is chosen, this ters have the disadvantage that they cannot remove must only be installed as in-line cleaning upstream water and their elements clog quickly. to the duplex full-flow lubricating oil filter, built onto the engine.

2012.05.15 - ES1 MAN Diesel & Turbo 604.03 Treatment and maintenance of lubricating oil Description Edition 11H Page 2 (4)

L32/40, L28/32H, V28/32H

The most appropriate type of equipment for a par- Lubricating oil preheating ticular application depends on the engine output, the type and amount of combustion residues, the The installed heater on the separator unit ensures annual operating time and the operating mode of correct lubricating oil temperature during separa- the plant. Even with a relatively low number of oper- tion. When the engine is at standstill, the heater can ating hours there can be a great deal of combustion be used for two functions: residues if, for instance, the engine is inadequately ▪ The oil in the sump can be preheated to 95 – preheated and quickly accelerated and loaded. 98 °C by the heater and cleaned continuously by the separator. Separator ▪ The heater can also be used to maintain an oil temperature of at least 40 °C, depending on Continuous lubricating oil cleaning during engine installation of the lubricating oil system. operation is mandatory. An optimal lubricating oil treatment is fundamental for a reliable working condition of the engine. Cleaning capacity If the lubricating oil is circulating without a separator Normally, it is recommended to use a self-cleaning in operation, the lubricating oil will gradually be con- filtration unit in order to optimize the cleaning period taminated by products of combustion, water and/or and thus also optimize the size of the filtration unit. acid. In some instances cat-fines may also be Separators for manual cleaning can be used when present. the reduced effective cleaning time is taken into In order to prolong the lubricating oil lifetime and consideration by dimensioning the separator remove wear elements, water and contaminants capacity. from the lubricating oil, it is mandatory to use a bypass separator. The required flow The separator will reduce the carbon residue content and other contaminants from combustion on In order to calculate the required lubricating oil flow engines operated on HFO, and keep the amount through the separator, the separator maker’s rec- within MDT’s recommendation, on condition that ommendation must be followed. the separator unit is operated according to maker's As a guidance, the following formula should form recommendations. the basis for choosing the required flow for the sep- When operating a cleaning device, the following arator capacity: recommendations must be followed: Q = P x 1.36 x n ▪ The optimum cleaning effect is achieved by T keeping the lubricating oil in a state of low viscosity for a long period in the separator bowl. Q = required flow (l/h) ▪ Sufficiently low viscosity is obtained by preheat- P = engine output kW) ing the lubricating oil to a temperature of 95°C - t = actual effective separator operating 98°C, when entering the separator bowl. time per day (hour) ▪ The separator unit capacity must be adjusted n = number of turnovers per day of the according to maker’s recommendations. theoretical oil volume correspond- Slow passage of the lubricating oil through the sep- ing to 1.36 l/kW or 1 l/HP arator is obtained by using a reduced flow rate and The following values for "n" are recommended: by operating the separator 24 hours a day, stopping only for maintenance, according to maker's n = 5 for HFO operation (residual) recommendation. n = 4 for MDO operation n = 3 for distillate fuel

2012.05.15 - ES1 MAN Diesel & Turbo 604.03 Description Treatment and maintenance of lubricating oil Page 3 (4) Edition 11H

L32/40, L28/32H, V28/32H

Example 1 Three 1000 kW engines operating on HFO connec- For multi-engine plants, one separator per engine in ted to a common self-cleaning separator with a operation is recommended. daily effective separating period of 23 hours:

Separator installation With multi-engine plants, one separator per engine in operation is recommended, but if only one separator is in operation, the following layout can be used: ▪ A common separator can be installed, with one in reserve if possible for operation of all engines Figure 1: Example 1 through a pipe system, which can be carried out in various ways. The aim is to ensure that One 1000 kW engine operating on HFO connected the separator is only connected to one engine to a self-cleaning separator with a daily effective at a time. This to ensure that there is no suction separating period of 23 hours: and discharging from one engine to another. It is recommended that inlet and outlet valves are connected, so that they can only be changed over simultaneously. Example 2 With only one engine in operation there are no As alternative one common separator can be instal- problems with separating, but if several engines are led, with one in reserve if possible, for multi-engine in operation for some time it is recommended to plants. split up the time so that there is separation on all engines, which are operating in turns. The capacity of the separator has to correspond with the separating of oil on the single engine n times during the available time, every 24 hours. See section regarding required flow.

Check of lubricating oil system For cleaning of the lubricating oil system after overhauls and inspection of the lubricating oil piping system the following checks must be carried out: 1. Examine the piping system for leaks. 2. Retighten all bolts and nuts in the piping system. 3. Move all valves and cocks in the piping system. Lubricate valve spindles with graphite or similar. 4. Blow through drain pipes. 5. Check flexible connections for leaks and damages. 1 Interconnected valves 6. Check manometers and thermometers for pos- Figure 2: Example 2 sible damages.

2012.05.15 - ES1 MAN Diesel & Turbo 604.03 Treatment and maintenance of lubricating oil Description Edition 11H Page 4 (4)

L32/40, L28/32H, V28/32H

rous particles and rust are active. Furthermore, the Deterioration of oil lacquer and varnish oxidation products of the oil itself have an accelerating effect. Continuous clean- Oil seldomly loses its ability to lubricate, i.e. to form ing of the oil is therefore important to keep the a friction-decreasing oil film, but it may become cor- sludge content low. rosive to the steel journals of the bearings in such a way that the surface of these journals becomes too Water washing rough and wipes the bearing surface. In that case the bearings must be renewed, and the Water washing of HD oils (heavy duty) must not be journals must also be polished. The corrosiveness carried out. of the lubricating oil is either due to far advanced oxidation of the oil itself (TAN) or to the presence of Water in the oil inorganic acids (SAN). In both cases the presence If the TAN is low, a minor increase in the fresh water of water will multiply the effect, especially sea water content of the oil is not immediately detrimental as the chloride ions act as an inorganic acid. while the engine is in operation. Naturally, it should be brought down again as quickly as possible Signs of deterioration (below 0.2% water content, which is permissible, If circulating oil of inferior quality is used and the oxi- see description "B 12 15 0/504.04 criteria for dative influence becomes grave, prompt action is exchange of lube oil”). If the engine is stopped while necessary as the last stages in the deterioration will corrosion conditions are unsatisfactory, the crank- develop surprisingly quickly, within one or two shaft must be turned ½ - ¾ revolution once every weeks. Even if this seldomly happens, it is wise to hour. Please make sure that the crankshaft stops in be acquainted with the signs of deterioration. different positions, to prevent major damage to bearings and journals. The lubricating oil must be These may be some or all of the following: circulated and separated continuously to remove ▪ Sludge precipitation in the separator multiplies water. ▪ Smell of oil becomes acrid or pungent Water in the oil may be noted by steam formation on the sight glasses, by appearance, or ascertained ▪ Machined surfaces in the crankcase become by immersing a piece of glass or a soldering iron coffee-brown with a thin layer of lacquer heated to 200-300°C in an oil sample. If there is a ▪ Paint in the crankcase peels off or blisters hissing sound, water is present. If a large quantity of ▪ Excessive carbon is formed in the piston cool- water has entered the lubricating oil system, it has ing chamber to be removed. Either to suck up sediment water from the bottom, or replace the oil in the sump. An In a grave case of oil deterioration the system must oil sample must be analysed immediately for chlor- be cleaned thoroughly and refilled with new oil. ide ions.

Oxidation of oils At normal service temperature the rate of oxidation is insignificant, but the following factors will accelerate the process: High temperature If the coolers are ineffective, the temperature level will generally rise. A high temperature will also arise in electrical pre-heaters if the circulation is not continued for 5 minutes after the heating has been stopped, or if the heater is only partly filled with oil. Catalytic action Oxidation of the oil will be accelerated considerably if catalytic particles are present in the oil. Wear particles of copper are especially harmful, but also fer-

2012.05.15 - ES1 MAN Diesel & turbo

Description 604.04 Page 1 (2) Criteria for Cleaning/Exchange of Lubricating Oil Edition 17H

General

Replacement of Lubricating Oil Unit : cSt (mm2/s)

The expected lubricating oil lifetime in operation is Possible test difficult to determine. The lubricating oil lifetime is methods : ASTM D-445, DIN 51562/53018, depending on the fuel oil quality, the lubricating oil ISO 3104 quality, the lubricating oil consumption, the lubricating oil cleaning equipment efficiency and the engine Increasing viscosity indicates problems with inso- operational conditions. lubles, HFO contamination, water contamination, oxidation, nitration and low load operation. Decrea- In order to evaluate the lubricating oil condition a sing viscosity is generally due to dilution with lighter sample should be drawn on regular basis at least viscosity oil. once every three month or depending on the latest analysis result. The lubricating oil sample must be drawn before the filter at engine in operation. The 2. Flash Point sample bottle must be clean and dry, supplied with sufficient indentification and should be closed im- Min. value : 185° C mediately after filling. The lubricating oil sample must be examined in an approved laboratory or in Possible test the lubricating oil suppliers own laboratory. method : ASTM D-92, ISO 2719

A lubricating oil replacement or an extensive lubri- Normally used to indicate fuel dilution. cating oil cleaning is required when the MAN Diesel exchange criteria's have been reached. 3. Water Content

Evaluation of the Lubricating Oil Condition Max. value : 0.2 %

Based on the analysis results, the following guidance Unit : Weight % are normally sufficient for evaluating the lubricating oil condition. The parameters themselves can not be Possible test jugded alonestanding, but must be evaluated together method : ASTM D4928, ISO 3733 in order to conclude the lubricating oil condition. Water can originate from contaminated fuel oil, an engine cooling water leak or formed as part of the 1. Viscosity combustion process. If water is detected also Sodium, Glycol or Boron content should be checked in order Limit value : to confirm engine coolant leaks.

Normal min. max. value value value 4. Base Number (BN)

SAE 30 [cSt@40° C] 95 - 125 75 160 Min. value : The BN value should not be lower SAE 30 [cSt@100° C] 11 - 13 9 15 than 50% of fresh lubricating oil value, but minimum BN level never SAE 40 [cSt@40° C] 135 - 165 100 220 to be lower than 10-12 at operating on HFO! SAE 40 [cSt@100° C] 13.5 - 15.0 11 19 Unit : mg KOH/g

Possible test method : ASTM D-2896, ISO 3771

07.11 - ES1 MAN Diesel & turbo

604.04 Description Edition 17H Criteria for Cleaning/Exchange of Lubricating Oil Page 2 (2)

General

The neutralization capacity must secure that the acidic Unit : Weight % combustion products, mainly sulphur originate from the fuel oil, are neutralized at the lube oil consumption Possible test level for the specific engine type. Gradually the BN method : ASTM D-893 procedure B in n- will be reduced, but should reach an equilibrium. Heptane, DIN 51592

Additionally 5. Total Acid Number (TAN) test : If the level in n-Heptane insolubles is considered high for the type of Max. value : 3.0 acc. to fresh oil value oil and application, the test could be followed by a supplementary Unit : mg KOH/g determination in Toluene.

Possible test Total insolubles is maily derived from products of method : ASTM D-664 combustion blown by the piston rings into the crankcase. It also includes burnt lubricating oil, additive TAN is used to monitor oil degradation and is a ash, rust, salt, wear debris and abrasive matter. measure of the total acids present in the lubricating oil derived from oil oxidation (weak acids) and acidic products of fuel combustion (strong acids). 7. Metal Content

6. Insolubles Content Metal content Remarks Attention limits Iron Depend upon max. 50 ppm Max. value : 1.5 % generally, depending upon Chromium engine type and max. 10 ppm Copper operating condi- max. 15 ppm actual dispersant value and the Lead tions max. 20 ppm increase in visco sity. Tin max. 10 ppm Aluminium max. 20 ppm Silicon max. 20 ppm

07.11 - ES1 92.02 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) yrui ol Hydraulic oilorturbineoil. (withaviscocityofaboutSAE20). insection618orseparate instruction. Seespecialinstructions SAE10Wnon-detergentoil. SeeGovernorinsection609. instruction Hydraulic tools oil. Enginesystemlubricating Lub. Alternator Airlubricator Oil Governor Turbocharger oilspecifi SAE30oilaccordingtolubricating cation onpage604.01. Type oil. Enginesystemlubricating Description Lubricating Oil Types usedintheEngine. Lubricating Points General 604.05 Edition 01H 93.05 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) yrui ol Hydraulic oilorturbineoil. (withaviscocityofaboutSAE20). insection618orseparate instruction. Seespecialinstructions SAE10Wnon-detergentoil. SeeGovernorinsection609. instruction Hydraulic tools oil. Enginesystemlubricating Lub. Alternator Airlubricator Oil Governor Turbocharger oilspecifi SAE40oilaccordingtolubricating cation onpage604.01. Type oil. Enginesystemlubricating Description Lubricating Oil Types usedintheEngine. Lubricating Points General 604.05 Edition 02H MAN Diesel 06.39 -ES1 08028-0D/H5250/94.08.12 Description Page 1(1) Max. litreH3 Min. litreH2 Max. level H3(mm) Min. level H2(mm) Type L28/32H Lubricating OilinBaseFrame 5 cyl. 1111 792 365 265 6 cyl. 1311 935 365 265 7 cyl. 1511 1078 365 265 8 cyl. 1710 1220 365 265 9 cyl. 1910 1362 365 265 L28/32H 604.06 Edition 16H MAN Diesel 04.46 -ES1 08028-0D/H5250/94.08.12 Description Page 1(2) exceed thevalues stated. theSLOCmayPlease note, enginerunning-in during SLOC, 504.07. seethedescription *P period run.hrs oiladded[dm (lubricating SLOC [g/kWh]= SLOC: The following formula isusedtocalculatethe (P Please notethatonlymaximum continuous rating ρ is usedtocalculate temperature inthebaseframe. The following formula in ordertoconvert oildensity,The lubricating ρ lubricating oil lubricating lubricating oil@15°C lubricating MCR (kW))shouldbeusedinordertoevaluate the [kg/m [kg/m 3 ] = 3/0 2/5 0.7-1.1 0.4-0.8 0.6-1.0 0.6-1.0 0.4-0.8 720/750 720/750 0.6-1.0 0.4-0.8 720/750 0.4-0.8 720/750 L32/40 720/750 SLOC[g/kWh] V28/32S 720/750/900 V28/32H 900/1000 L28/32H 1000/1200 L27/38 RPM L23/30H L21/31 L16/24 Engine type Specifi ρ ρ 3 ] –0,64*(t to the present lubricating oil tothepresentlubricating : ρ @15°Cmust beknown 3 ]) * c LubricatingOilConsumption-SLOC MCR ρ lubricating oil lubricating [kW] lubricating oil lubricating [°C]–15) [kg/m 3 ] The enginemaximum continuous designrating (P g/kWh, dependingontheenginetype. must beexpected, witchcorrespondsuptill±0.1 A deviation of±1mmwiththedipstick measurement Note *) are representative. average values oiladdings ofanumber oflubricating hoursormore,after 1,000running whereonlythe oil,theSLOCcanonlybeevaluatedlubricating in thecalculation. Duetoinaccuracy * oiladdingmust beused since thelastlubricating the individualmeasurements, hours andtherunning must always beusedinordertoable tocompare ) atadding General 604.07 Edition 02H MCR ) MAN Diesel 04.46 -ES0 08028-0D/H5250/94.08.12 Description Page 2(2) Specifi c LubricatingOilConsumption-SLOC General 604.07 Edition 02H MAN Diesel & Turbo 3.3.3

Heavy fuel oil (HFO) specification

Prerequisites

MAN four-stroke diesel engines can be operated with any heavy fuel oil

obtained from crude oil that also satisfies the requirements in Table 1, pro- 6680 3.3.3-01 viding the engine and fuel processing system have been designed accordingly. To ensure that the relationship between the fuel, spare parts and repair / maintenance costs remains favorable at all times, the following points should be observed.

Heavy fuel oil (HFO) Origin/Refinery process The quality of the heavy fuel oil largely depends on the quality of crude oil and on the refining process used. This is why the properties of heavy fuel oils with the same viscosity may vary considerably depending on the bunker positions. Heavy fuel oil is normally a mixture of residual oil and distillates. The components of the mixture are normally obtained from modern refinery processes, such as Catcracker or Visbreaker. These processes can adversely affect the stability of the fuel as well as its ignition and combustion properties. The processing of the heavy fuel oil and the operating result of the engine also depend heavily on these factors. Bunker positions with standardised heavy fuel oil qualities should preferably be used. If oils need to be purchased from independent dealers, also ensure that these also comply with the international specifications. The engine operator is responsible for ensuring that suitable heavy fuel oils are chosen. Specifications Fuels intended for use in an engine must satisfy the specifications to ensure sufficient quality. The limit values for heavy fuel oils are specified in Table 1. The entries in the last column of Table 1 provide important background information and must therefore be observed. Different international specifications exist for heavy fuel oils. The most important specifications are ISO 8217-2010 and CIMAC-2003, which are more or less identical. The ISO 8217 specification is shown in Fig. 1. All qualities in these specifications up to K700 can be used, providing the fuel preparation system has been designed accordingly. To use any fuels, which do not comply with these specifications (e.g. crude oil), consultation with Technical Serv- ice of MAN Diesel & Turbo SE in Augsburg is required. Heavy fuel oils with a maximum density of 1,010 kg/m3 may only be used if up-to-date separators are installed. Important Even though the fuel properties specified in the table entitled "The fuel specification and corresponding properties for heavy fuel oil" satisfy the above requirements, they probably do not adequately define the ignition and combustion properties and the stability of the fuel. This means that the operating behaviour of the engine can depend on properties that are not defined in the specification. This particularly applies to the oil property that causes formation of deposits in the combustion chamber, injection system, gas ducts and exhaust gas system. A number of fuels have a tendency towards incompatibility with lubricating oil which leads to deposits being formed in the fuel delivery pump that can block the pumps. It may therefore be necessary to 2012-05-16 - de exclude specific fuels that could cause problems. Blends The addition of engine oils (old lubricating oil, ULO –used lubricating oil) and additives that are not manufactured from mineral oils, (coal-tar oil, for example), and residual products of chemical or other processes such as solvents Heavy fuel oil (HFO) specification General

6680 3.3.3-01 EN 1 (12) 3.3.3 MAN Diesel & Turbo

(polymers or chemical waste) is not permitted. Some of the reasons for this are as follows: abrasive and corrosive effects, unfavourable combustion characteristics, poor compatibility with mineral oils and, last but not least, adverse effects on the environment. The order for the fuel must expressly state what is not permitted as the fuel specifications that generally apply do not include this limitation. If engine oils (old lubricating oil, ULO – used lubricating oil) are added to fuel, 6680 3.3.3-01 this poses a particular danger as the additives in the lubricating oil act as emulsifiers that cause dirt, water and catfines to be transported as fine sus- pension. They therefore prevent the necessary cleaning of the fuel. In our experience (and this has also been the experience of other manufacturers), this can severely damage the engine and turbocharger components. The addition of chemical waste products (solvents, for example) to the fuel is prohibited for environmental protection reasons according to the resolution of the IMO Marine Environment Protection Committee passed on 1st January 1992. Leak oil collector Leak oil collectors that act as receptacles for leak oil, and also return and overflow pipes in the lube oil system, must not be connected to the fuel tank. Leak oil lines should be emptied into sludge tanks.

Viscosity (at 50 ℃) mm2/s (cSt) max. 700 Viscosity/injection viscosity Viscosity (at 100 ℃) max. 55 Viscosity/injection viscosity Density (at 15 °C) g/ml max. 1.010 Heavy fuel oil processing Flash point °C min. 60 Flash point (ASTM D 93) Pour point (summer) max. 30 Low-temperature behaviour (ASTM D 97) Pour point (winter) max. 30 Low-temperature behaviour (ASTM D 97) Coke residue (Conrad- Weight % max. 20 Combustion properties son) Sulphur content 5 or Sulphuric acid corrosion legal requirements Ash content 0.15 Heavy fuel oil processing Vanadium content mg/kg 450 Heavy fuel oil processing Water content Vol. % 0.5 Heavy fuel oil processing Sediment (potential) Weight % 0.1 Aluminium and silicium mg/kg max. 60 Heavy fuel oil processing content (total) Acid number mg KOH/g 2.5 Hydrogen sulphide mg/kg 2 Used lubricating oil mg/kg The fuel must be free of lubri- (ULO) cating oil (ULO = used lubricating oil, old oil). Fuel is considered as contaminated with lubricating oil when the following concentrations occur: 2012-05-16 - de Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > Heavy fuel oil (HFO) specification General 15 ppm.

2 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.3

Asphaltene content Weight % 2/3 of coke residue Combustion properties

(according to Conradson) Sodium content mg/kg Sodium < 1/3 Vanadium, Heavy fuel oil processing Sodium<100 The fuel must be free of admixtures that cannot be obtained from mineral oils, such as vegetable or coal-tar oils. It must also be

free of tar oil and lubricating oil (old oil), and also chemical waste products such as solvents or polymers. 6680 3.3.3-01 Table 1: Table_The fuel specification and corresponding characteristics for heavy fuel oil 2012-05-16 - de Heavy fuel oil (HFO) specification General

6680 3.3.3-01 EN 3 (12) 3.3.3 MAN Diesel & Turbo

6680 3.3.3-01 2012-05-16 - de

Heavy fuel oil (HFO) specification General Figure 1: ISO 8217-2010 specification for heavy fuel oil

4 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.3

6680 3.3.3-01 2012-05-16 - de

Heavy fuel oil (HFO) specification General Figure 2: ISO 8217-2010 specification for heavy fuel oil (continued)

6680 3.3.3-01 EN 5 (12) 3.3.3 MAN Diesel & Turbo

Additional information

The purpose of the following information is to show the relationship between the quality of heavy fuel oil, heavy fuel oil processing, the engine operation and operating results more clearly. Selection of heavy fuel oil Economic operation with heavy fuel oil within the limit values specified in the 6680 3.3.3-01 table entitled "The fuel specification and corresponding properties for heavy fuel oil" is possible under normal operating conditions, provided the system is working properly and regular maintenance is carried out. If these requirements are not satisfied, shorter maintenance intervals, higher wear and a greater need for spare parts is to be expected. The required maintenance intervals and operating results determine, which quality of heavy fuel oil should be used. It is an established fact that the price advantage decreases as viscosity increases. It is therefore not always economical to use the fuel with the highest viscosity as in many cases the quality of this fuel will not be the best. Viscosity/injection viscosity Heavy fuel oils with a high viscosity may be of an inferior quality. The maximum permissible viscosity depends on the preheating system installed and the capacity (flow rate) of the separator. The prescribed injection viscosity of 12 - 14 mm2/s (for GenSets, 23/30H and 28/32H: 12 - 18 cSt) and corresponding fuel temperature upstream of the engine must be observed. This is the only way to ensure efficient atomisation and mixture formation and therefore low-residue combustion. This also prevents mechanical overloading of the injection system. For the prescribed injection viscosity and/or the required fuel oil temperature upstream of the engine, refer to the viscosity temperature diagram. Heavy fuel oil processing Whether or not problems occur with the engine in operation depends on how carefully the heavy fuel oil has been processed. Particular care should be taken to ensure that highly-abrasive inorganic foreign matter (catalyst particles, rust, sand) are effectively removed. It has been shown in practice that wear as a result of abrasion in the engine increases considerably if the alumi- num and silicium content is higher than 15 mg/kg. Viscosity and density influence the cleaning effect. This must be taken into account when designing and making adjustments to the cleaning system. Settling tank Heavy fuel oil is precleaned in the settling tank. The longer the fuel remains in the tank and the lower the viscosity of heavy fuel oil is, the more effective the precleaning process will be (maximum preheating temperature of 75 °C to prevent the formation of asphalt in heavy fuel oil). A settling tank is sufficient for heavy fuel oils with a viscosity of less than 3802/s at 50 °C. If the heavy fuel oil has a high concentration of foreign matter, or if fuels in accordance with ISO-F-RM, G/H/K380 or H/K700 are to be used, two settling tanks will be required one of which must be sized for 24-hour operation. Before the content is moved to the service tank, water and sludge must be drained from the settling tank. Separators A separator is particularly suitable for separating material with a higher specific density – water, foreign matter and sludge, for example. The separators must be self-cleaning (i.e. the cleaning intervals must be triggered automatically).

Only new generation separators should be used. They are extremely effective 2012-05-16 - de throughout a wide density range with no changeover required, and can separate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C. Heavy fuel oil (HFO) specification General

6 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.3

Table "Achievable proportion of foreign matter and water (following separation)" shows the prerequisites that must be met by the separator. These limit values are used by manufacturers as the basis for dimensioning the separator and ensure compliance. The manufacturer's specifications must be complied with to maximize the cleaning effect. 6680 3.3.3-01

Application in ships and stationary use: parallel installation 1 Separator for 100 % flow rate 1 Separator (reserve) for 100 % flow rate

Figure 3: Location of heavy fuel oil cleaning equipment and/or separator The separators must be arranged according to the manufacturers' current recommendations (Alpha Laval and Westfalia). The density and viscosity of the heavy fuel oil in particular must be taken into account. If separators by other manufacturers are used, MAN Diesel should be consulted. If processing is carried out in accordance with the MAN Diesel specifications and the correct separators are chosen, it may be assumed that the results stated in the table entitled "Achievable proportion of foreign matter and water" for inorganic foreign matter and water in the heavy fuel oil will be achieved at the engine inlet. Results obtained during operation in practiсe show that the wear occurs as a result of abrasion in the injection system and the engine will remain within acceptable limits if these values are complied with. In addition, an optimum lubricating oil treatment process must be ensured.

Definition Particle size Quantity Inorganic foreign matter < 5 µm < 20 mg/kg including catalyst particles Al+Si content -- < 15 mg/kg Water content -- < 0.2 % by vol. % Table 2: Achievable proportion of foreign matter and water (after separation) Water It is particularly important to ensure that the water separation process is as thorough as possible as the water takes the form of large droplets, and not a finely distributed emulsion. In this form, water also promotes corrosion and sludge formation in the fuel system and therefore impairs the supply, atomi- 2012-05-16 - de sation and combustion of the heavy fuel oil. If the water absorbed in the fuel is seawater, harmful sodium chloride and other salts dissolved in this water will enter the engine. Heavy fuel oil (HFO) specification General

6680 3.3.3-01 EN 7 (12) 3.3.3 MAN Diesel & Turbo

Water-containing sludge must be removed from the settling tank before the separation process starts, and must also be removed from the service tank at regular intervals. The tank's ventilation system must be designed in such a way that condensate cannot flow back into the tank. Vanadium/Sodium If the vanadium/sodium ratio is unfavorable, the melting point of the heavy fuel oil ash may fall in the operating area of the exhaust-gas valve which can lead to high-temperature corrosion. Most of the water and water-soluble 6680 3.3.3-01 sodium compounds it contains can be removed by pretreating the heavy fuel oil in the settling tank and in the separators. The risk of high-temperature corrosion is low if the sodium content is one third of the vanadium content or less. It must also be ensured that sodium does not enter the engine in the form of seawater in the intake air. If the sodium content is higher than 100 mg/kg, this is likely to result in a higher quantity of salt deposits in the combustion chamber and exhaust-gas system. This will impair the function of the engine (including the suction function of the turbocharger). Under certain conditions, high-temperature corrosion can be prevented by using a fuel additive that increases the melting point of the heavy fuel oil ash (also see "Additives for heavy fuel oils”). Ash Fuel ash consists for the greater part of vanadium oxide and nickel sulphate (see above chapter for more information). Heavy fuel oils containing a high proportion of ash in the form of foreign matter, e.g. sand, corrosion compounds and catalyst particles, accelerate the mechanical wear in the engine. Catalyst particles produced as a result of the catalytic cracking process may be present in the heavy fuel oils. In most cases, these are aluminium silicate particles that cause a high degree of wear in the injection system and the engine. The aluminium content determined, multiplied by a factor of between 5 and 8 (depending on the catalytic bond), is roughly the same as the proportion of catalyst remnants in the heavy fuel oil. Homogeniser If a homogeniser is used, it must never be installed between the settling tank and separator as otherwise it will not be possible to ensure satisfactory separation of harmful contaminants, particularly seawater. Flash point (ASTM D 93) National and international transportation and storage regulations governing the use of fuels must be complied with in relation to the flash point. In general, a flash point of above 60 °C is prescribed for diesel engine fuels. Low-temperature behaviour The pour point is the temperature at which the fuel is no longer flowable (ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher than 0 °C, the bunker facility must be preheated, unless fuel in accordance with RMA or RMB is used. The entire bunker facility must be designed in such a way that the heavy fuel oil can be preheated to around 10 °C above the pour point. Pump characteristics If the viscosity of the fuel is higher than 1000 mm2/s (cST), or the temperature is not at least 10 °C above the pour point, pump problems will occur. For more information, also refer to “Low-temperature behaviour (ASTM D 97)”. Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con- radson), combustion may be delayed which in turn may increase the formation of combustion residues, leading to such as deposits on and in the injec-

tion nozzles, large amounts of smoke, low output, increased fuel consump- 2012-05-16 - de tion and a rapid rise in ignition pressure as well as combustion close to the cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt

Heavy fuel oil (HFO) specification General to coke residues reaches the limit 0.66, and if the asphalt content exceeds 8%, the risk of deposits forming in the combustion chamber and injection

8 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.3

system is higher. These problems can also occur when using unstable heavy fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an increased deposition of asphalt (see "Compatibility”). Ignition quality Nowadays, to achieve the prescribed reference viscosity, cracking-process products are used as the low viscosity ingredients of heavy fuel oils although the ignition characteristics of these oils may also be poor. The cetane number of these compounds should be > 35. If the proportion of aromatic hydro- 6680 3.3.3-01 carbons is high (more than 35 %), this also adversely affects the ignition quality. The ignition delay in heavy fuel oils with poor ignition characteristics is longer; the combustion is also delayed which can lead to thermal overloading of the oil film at the cylinder liner and also high cylinder pressures. The ignition delay and accompanying increase in pressure in the cylinder are also influenced by the end temperature and compression pressure, i.e. by the compression ratio, the charge-air pressure and charge-air temperature. The disadvantages of using fuels with poor ignition characteristics can be limited by preheating the charge air in partial load operation and reducing the output for a limited period. However, a more effective solution is a high compression ratio and operational adjustment of the injection system to the ignition characteristics of the fuel used, as is the case with MAN Diesel piston engines. The ignition quality is one of the most important properties of the fuel. This value does not appear in the international specifications because a standardised testing method has only recently become available and not enough experience has been gathered at this point in order to determine limit values. The parameters, such as the calculated carbon aromaticity index (CCAI), are therefore aids that are derived from quantifiable fuel properties. We have established that this method is suitable for determining the approximate ignition quality of the heavy fuel oil used. A testing instrument has been developed based on the constant volume combustion method (fuel combustion analyser FCA) and is currently being tested by a series of testing laboratories. The instrument measures the ignition delay to determine the ignition quality of a fuel and this measurement is converted into a an instrument-specific cetane number (FIA-CN or EC). It has been established that in some cases, heavy fuel oils with a low FIA cetane number or ECN number can cause operating problems. As the liquid components of the heavy fuel oil decisively influence the ignition quality, flow properties and combustion quality, the bunker operator is responsible for ensuring that the quality of heavy fuel oil delivered is suitable for the diesel engine. (Also see illustration entitled "Nomogram for determining the CCAI – assigning the CCAI ranges to engine types"). 2012-05-16 - de Heavy fuel oil (HFO) specification General

6680 3.3.3-01 EN 9 (12) 3.3.3 MAN Diesel & Turbo

6680 3.3.3-01

V Viscosity in mm2/s (cSt) at 50° C A Normal operating conditions D Density [in kg/m3] at 15° C B The ignition characteristics can be poor and require adapting the engine or the operating conditions. CCAI Calculated Carbon Aromaticity C Problems identified may lead to Index engine damage, even after a short period of operation. 1 Engine type 2 The CCAI is obtained from the straight line through the density and viscosity of the heavy fuel oils.

Figure 4: Nomogram for determining the CCAI – assigning the CCAI ranges to engine types The CCAI can be calculated using the following formula: CCAI = D - 141 log log (V+0.85) - 81 Sulphuric acid corrosion The engine should be operated at the cooling water temperatures prescribed in the operating handbook for the relevant load. If the temperature of the components that are exposed to acidic combustion products is below the acid dew point, acid corrosion can no longer be effectively prevented, even if alkaline lubricating oil is used. 2012-05-16 - de The BN values specified in Section 3.3.6 are sufficient, providing the quality of lubricating oil and the engine's cooling system satisfy the requirements. Heavy fuel oil (HFO) specification General

10 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.3

Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and remains stable, even after the standard storage period. If different bunker oils are mixed, this can lead to separation and the associated sludge formation in the fuel system during which large quantities of sludge accumulate in the separator that block filters, prevent atomisation and a large amount of residue as a result of combustion. This is due to incompatibility or instability of the oils. Therefore heavy fuel oil 6680 3.3.3-01 as much as possible should be removed in the storage tank before bunkering again to prevent incompatibility. Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) to obtain the required quality or viscosity of heavy fuel oil, it is extremely important that the components are compatible (see "Compatibility"). Additives for heavy fuel oils MAN Diesel & Turbo SE engines can be operated economically without additives. It is up to the customer to decide whether or not the use of additives is beneficial. The supplier of the additive must guarantee that the engine operation will not be impaired by using the product. The use of heavy fuel oil additives during the warranty period must be avoided as a basic principle. Additives that are currently used for diesel engines, as well as their probable effects on the engine's operation, are summarised in the table below "Addi- tives for heavy fuel oils – classification/effects".

Precombustion additives ▪ Dispersing agents/stabil- isers ▪ Emulsion breakers ▪ Biocides Combustion additives ▪ Combustion catalysts (fuel savings, emissions) Post-combustion additives ▪ Ash modifiers (hot corrosion) ▪ Soot removers (exhaustgas system) Table 3: Additives for heavy fuel oils – Classification/effects Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul- sulphur content phur content of heavy fuel oils does not exist. We have not identified any problems with the low-sulphur heavy fuel oils currently available on the market that can be traced back to their sulphur content. This situation may change in future if new methods are used for the production of low-sulphur heavy fuel oil (desulphurisation, new blending components). MAN Diesel & Turbo will monitor developments and inform its customers if required. If the engine is not always operated with low-sulphur heavy fuel oil, corresponding lubricating oil for the fuel with the highest sulphur content must be selected.

Improper handling of operating fluids If operating fluids are improperly handled, this can pose a danger to health, safety and the environment. The relevant safety information by 2012-05-16 - de the supplier of operating fluids must be observed. Heavy fuel oil (HFO) specification General

6680 3.3.3-01 EN 11 (12) 3.3.3 MAN Diesel & Turbo

Tests Sampling To check whether the specification provided and/or the necessary delivery conditions are complied with, we recommend you retain at least one sample of every bunker oil (at least for the duration of the engine's warranty period). To ensure that the samples taken are representative of the bunker oil, a sam-

6680 3.3.3-01 ple should be taken from the transfer line when starting up, halfway through the operating period and at the end of the bunker period. “Sample Tec" by Mar-Tec in Hamburg is a suitable testing instrument which can be used to take samples on a regular basis during bunkering. Analysis of samples Our department for fuels and lubricating oils (Augsburg factory, department EQC) will be pleased to provide further information on request. We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test.

2012-05-16 - de Heavy fuel oil (HFO) specification General

12 (12) 6680 3.3.3-01 EN MAN Diesel & Turbo 3.3.2

Diesel oil (MDO) specification

Marine diesel oil Other designations Marine diesel oil, marine diesel fuel. Origin Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F- 6680 3.3.2-01 DMB) exclusively for marine applications. MDO is manufactured from crude oil and must be free of organic acids and non-mineral oil products.

Specification

The suitability of fuel depends on the design of the engine and the available cleaning options, as well as compliance with the properties in the following table that refer to the as-delivered condition of the fuel. The properties are essentially defined using the ISO 8217-2010 standard as the basis. The properties have been specified using the stated test procedures.

Properties Unit Testing method Designation ISO-F specification DMB Density at 15 °C kg/m3 ISO 3675 900 Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104 > 2,0 < 11 * Pour point (winter quality) °C ISO 3016 < 0 Pour point (summer quality) °C < 6 Flash point (Pensky Martens) °C ISO 2719 > 60 Total sediment content % by weight ISO CD 10307 0.10 Water content % by vol. ISO 3733 < 0.3 Sulphur content % by weight ISO 8754 < 2.0 Ash content % by weight ISO 6245 < 0.01 Carbon residue (MCR) % by weight ISO CD 10370 < 0.30 Cetane number or cetane index - ISO 5165 > 35 Hydrogen sulphide mg/kg IP 570 < 2 Acid value mg KOH/g ASTM D664 < 0.5 Oxidation resistance g/m3 ISO 12205 < 25 Lubricity μm ISO 12156-1 < 520 (wear scar diameter) Copper strip test - ISO 2160 < 1 Other specifications: British Standard BS MA 100-1987 Class M2 ASTM D 975 2D

2012-03-21 - de ASTM D 396 Nr. 2 Table 1: Marine diesel oil (MDO) – characteristic values to be adhered to

* For engines 27/38 with 350 resp. 365 kW/cyl the viscosity must not exceed 6 mm2/s @ 40 °C, as this would reduce the lifetime of the injection system. Diesel oil (MDO) specification General

6680 3.3.2-01 EN 1 (2) 3.3.2 MAN Diesel & Turbo

Additional information

During transshipment and transfer, MDO is handled in the same manner as residual oil. This means that it is possible for the oil to be mixed with high- viscosity fuel or heavy fuel oil – with the remnants of these types of fuels in the bunker ship, for example – that could significantly impair the properties of

6680 3.3.2-01 the oil. Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may no longer be sufficient. Before using diesel fuels with low sulphur content, you should therefore ensure that their lubricity is sufficient. This is the case if the lubricity as specified in ISO 12156-1 does not exceed 520 μm. The fuel must be free of lubricating oil (ULO – used lubricating oil, old oil). Fuel is considered as contaminated with lubricating oil when the following concentrations occur: Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > 15 ppm. The pour point specifies the temperature at which the oil no longer flows. The lowest temperature of the fuel in the system should be roughly 10 °C above the pour point to ensure that the required pumping characteristics are maintained. A minimum viscosity must be observed to ensure sufficient lubrication in the fuel injection pumps. The temperature of the fuel must therefore not exceed 45 °C. Seawater causes the fuel system to corrode and also leads to hot corrosion of the exhaust valves and turbocharger. Seawater also causes insufficient atomisation and therefore poor mixture formation accompanied by a high proportion of combustion residues. Solid foreign matter increase mechanical wear and formation of ash in the cylinder space. We recommend the installation of a separator upstream of the fuel filter. Sep- aration temperature: 40 – 50°C. Most solid particles (sand, rust and catalyst particles) and water can be removed, and the cleaning intervals of the filter elements can be extended considerably.

Analyses

We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test. 2012-03-21 - de Diesel oil (MDO) specification General

2 (2) 6680 3.3.2-01 EN MAN Diesel & Turbo 3.3.1

Gas oil / diesel oil (MGO) specification

Diesel oil Other designations Gas oil, marine gas oil (MGO), diesel oil Gas oil is a crude oil medium distillate and therefore must not contain any 6680 3.3.1-01 residual materials.

Military specification

Diesel oils that satisfy specification F-75 or F-76 may be used.

Specification

The suitability of fuel depends on whether it has the properties defined in this specification (based on its composition in the as-delivered state). The DIN EN 590 and ISO 8217-2010 (Class DMA or Class DMZ) standards have been extensively used as the basis when defining these properties. The properties correspond to the test procedures stated.

Properties Unit Test procedure Typical value Density at 15 °C ≥ 820.0 kg/m3 ISO 3675 ≤ 890.0 Kinematic viscosity at 40 °C ≥ 2 mm2/s (cSt) ISO 3104 ≤ 6.0 Filterability* in summer and °C DIN EN 116 ≤ 0 in winter °C DIN EN 116 ≤ -12 Flash point in closed cup °C ISO 2719 ≥ 60 Sediment content (extraction method) weight % ISO 3735 ≤ 0.01 Water content Vol. % ISO 3733 ≤ 0.05 Sulphur content ISO 8754 ≤ 1.5

Ash weight % ISO 6245 ≤ 0.01 Coke residue (MCR) ISO CD 10370 ≤ 0.10 Hydrogen sulphide mg/kg IP 570 < 2 Acid number mg KOH/g ASTM D664 < 0.5 Oxidation stability g/m3 ISO 12205 < 25 Lubricity μm ISO 12156-1 < 520 (wear scar diameter) Cetane number or cetane index - ISO 5165 ≥ 40 Copper strip test - ISO 2160 ≤ 1 Other specifications: British Standard BS MA 100-1987 M1 2011-07-06 - de ASTM D 975 1D/2D Table 1: Diesel fuel (MGO) – properties that must be complied with. Gas oil / diesel (MGO) specification General

6680 3.3.1-01 EN 1 (2) 3.3.1 MAN Diesel & Turbo

* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining

the cloud point in accordance with ISO 3015

Additional information

6680 3.3.1-01 Use of diesel oil If distillate intended for use as heating oil is used with stationary engines instead of diesel oil (EL heating oil according to DIN 51603 or Fuel No. 1 or no. 2 according to ASTM D 396), the ignition behaviour, stability and behaviour at low temperatures must be ensured; in other words the requirements for the filterability and cetane number must be satisfied. Viscosity To ensure sufficient lubrication, a minimum viscosity must be ensured at the fuel pump. The maximum temperature required to ensure that a viscosity of more than 1.9 mm2/s is maintained upstream of the fuel pump, depends on the fuel viscosity. In any case, the fuel temperature upstream of the injection pump must not exceed 45 °C. Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may no longer be sufficient. Before using diesel fuels with low sulphur content, you should therefore ensure that their lubricity is sufficient. This is the case if the lubricity as specified in ISO 12156-1 does not exceed 520 μm. You can ensure that these conditions will be met by using motor vehicle diesel fuel in accordance with EN 590 as this characteristic value is an integral part of the specification.

Analyses

We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test. 2011-07-06 - de Gas oil / diesel (MGO) specification General

2 (2) 6680 3.3.1-01 EN MAN Diesel & Turbo 3.3.1

Bio fuel specification

Biofuel Other designations Biodiesel, FAME, vegetable oil, rapeseed oil, palm oil, frying fat Origin Biofuel is derived from oil plants or old cooking oil. 6680 3.3.1-02 Provision

Transesterified and non-transesterified vegetable oils can be used. Transesterified biofuels (biodiesel, FAME) must comply with the standard EN 14214. Non-transesterified biofuels must comply with the specifications listed in Table 1. These specifications are based on experience to d/ate. As this experience is limited, these must be regarded as recommended specifications that can be adapted if necessary. If future experience shows that these specifications are too strict, or not strict enough, they can be modified accordingly to ensure safe and reliable operation. When operating with bio-fuels, lubricating oil that would also be suitable for operation with diesel oil (see Sheet 3.3.5) must be used.

Properties/Characteristics Unit Test method Density at 15 °C 900 - 930 kg/m3 DIN EN ISO 3675, EN ISO 12185 Flash point > 60 °C DIN EN 22719 lower calorific value > 35 MJ/kg DIN 51900-3 (typical: 37 MJ/kg) Viscosity/50 °C < 40 cSt (corresponds to a viscos- DIN EN ISO 3104 ity/40 °C of < 60 cSt) Cetane number > 40 FIA Coke residue < 0.4% DIN EN ISO 10370 Sediment content < 200 ppm DIN EN 12662 Oxidation stability (110 °C) > 5 h ISO 6886 Phosphorous content < 15 ppm ASTM D3231 Na and K content < 15 ppm DIN 51797-3 Ash content < 0.01% DIN EN ISO 6245 Water content < 0.5% EN ISO 12537 Iodine number < 125g/100g DIN EN 14111 TAN (total acid number) < 5 mg KOH/g DIN EN ISO 660 Filterability < 10 °C below the lowest temper- EN 116 ature in the fuel system Table 1: Non-transesterified bio-fuel - Specifications 2011-03-25 - de Bio fuel specification General

6680 3.3.1-02 EN 1 (2) 3.3.1 MAN Diesel & Turbo

6680 3.3.1-02

Analyses

We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test. 2011-03-25 - de Bio fuel specification General

2 (2) 6680 3.3.1-02 EN MAN Diesel & Turbo 3.3.4

Viscosity-temperature diagram (VT diagram)

Explanations of viscosity-temperature diagram Viscosity-temperature diagram (VT diagram)

Figure 1: Viscosity-temperature diagram (VT diagram)

In the diagram, the fuel temperatures are shown on the horizontal axis and the viscosity is shown on the vertical axis. The diagonal lines correspond to viscosity-temperature curves of fuels with different reference viscosities. The vertical viscosity axis in mm2/s (cSt) applies for 40, 50 or 100 °C.

Determining the viscosity-temperature curve and the required preheating temperature

Example: Heavy fuel oil with Prescribed injection viscosity Required temperature of heavy fuel oil 180 mm²/s at 50 °C in mm²/s at engine inlet* in °C ≥ 12 126 (line c) 2011-03-25 - de ≤ 14 119 (line d) Table 1: Determining the viscosity-temperature curve and the required preheating

temperature Viscosity-temperature diagram (VT diagram) General

6680 3.3.4-01 EN 1 (2) 3.3.4 MAN Diesel & Turbo

* With these figures, the temperature drop between the last preheating device and the fuel injection pump is not taken into account. A heavy fuel oil with a viscosity of 180 mm2/s at 50 °C can reach a viscosity of 1000 mm2/s at 24 °C (line e) – this is the maximum permissible viscosity of fuel that the pump can deliver. A heavy fuel oil discharge temperature of 152 °C is reached when using a recent state-of-the-art preheating device with 8 bar saturated steam. At higher temperatures there is a risk of residues forming in the preheating system – this leads to a reduction in heating output and thermal overloading of the heavy fuel oil. Asphalt is also formed in this case, i.e. quality deterioration. The heavy fuel oil lines between the outlet of the last preheating system and the injection valve must be suitably insulated to limit the maximum drop in temperature to 4 °C. This is the only way to achieve the necessary injection viscosity of 14 mm2/s for heavy fuel oils with a reference viscosity of 700 mm2/s at 50 °C (the maximum viscosity as defined in the international specifications such as ISO CIMAC or British Standard). If heavy fuel oil with a low reference viscosity is used, the injection viscosity should ideally be 12 mm2/s

Viscosity-temperature diagram (VT diagram) in order to achieve more effective atomisation to reduce the combustion residue. The delivery pump must be designed for heavy fuel oil with a viscosity of up to 1 000 mm2/s. The pour point also determines whether the pump is capa- ble of transporting the heavy fuel oil. The bunker facility must be designed so as to allow the heavy fuel oil to be heated to roughly 10 C above the pour point.

Viscosity The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the engine must be at least 1.9 mm2/s. If the viscosity is too low, this may cause seizing of the pump plunger or nozzle needle valves as a result of insufficient lubrication.

This can be avoided by monitoring the temperature of the fuel. Although the maximum permissible temperature depends on the viscosity of the fuel, it must never exceed the following values: ▪ 45 °C at the most with MGO (DMA) and MDO (DMB) and ▪ 60 °C at the most with MDO (DMC). A fuel cooler must therefore be installed. If the viscosity of the fuel is < 2 cSt at 40 °C, consult the technical service of MAN Diesel & Turbo SE in Augsburg. 2011-03-25 - de Viscosity-temperature diagram (VT diagram) General

2 (2) 6680 3.3.4-01 EN 92.04 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(2) High content Series operation Series Purifi er +Clarifi er ofcatalystfi nes Highcontent Purifi er /Purifi er Parallel operation Densityat15°C below 1% Purifi er +Clarifi er operation Series Purifi er /Purifi below 0.991 below er Densityat15°C Parallel operation below 1% Water Water content 0.991 Two inseries. centrifuges or content Two inparallel. centrifuges aspurifi Singlecentrifuge er. Table 1. CleaningofHFO. the centrifuge bowlthe centrifuge aslongtimepossible. fuel oilaspossible andallow thefueloiltoremainin withaslowoperate thecentrifuge aviscosityofthe to optimum cleaningitisoftheutmostimportance maker'scentrifuging recommendations. To obtain tobeatleastaccordingthe installed centrifuges of acentrifuge. We recommendthecapacityof cleaned fueloils. blends may resultfromtheuseofinadequately Also increasedfouling ofgasways andturbocharger liner wear theexhaust anddeteriorate valve seats. and fuelvalves, canresultinincreasedcylinder either freshwater orsaltwater. catalysts. Liquidcontaminantsaremainlywater, i.e. sand, dustandre-fi in thefuelaremainlyrust, contaminants before use. The solidcontami-nants fore bethoroughlycleanedfor solidaswell asliquid Effective cleaningcanonlybeensuredby means cancausedamagetofuelpumps The impurities Fuel oilsarealways contaminatedandshouldthere- Purifi conditions Extreme conditions Normal options Operating cation Recommendations. Cleaning ofH.F.O. by Centrifuging Optimum operating confi gurations Fuel OilCleaning nery nery recommendation. in correspondancewithtoday's fuelqualitiesandfl erations shouldbegiven toinstallingnew equipment above consid- resultsandrecommendationsserious flow rate may beconsidered. However, inview ofthe parallel operation inordertoobtainaneven lower isavailable,fuel oilandifmorethanonecentrifuge corresponding tothespecifi operating modeinquestion. rate recommendedby maker thecentrifuge for the quired by theengine, withoutexceeding thefl canhandlethetotalamountoffuelre- centrifuge provided theoperating capacityofeachindividual to thepreviously recommendedparallel operation, a maximum ofsafety isafullyacceptedalternative series, inpurifi is achieved areoperated in whenthecentrifuges fect, especiallyasregardsremoval ofcatalystfi residual fuel,have shown thatthebestcleaningef- oncentrifuges,treatingtoday'stal work qualitiesof available for fuelcleaning. Resultsfromexperimen- basis ofthespecifi c gravity ofthefuel. screw adjustmentwhichshouldbechosenonthe removal. manual statesthediscor The centrifuge for effiity discsareofspecialimportance cient water adjustment oftheregulatingscrews and/orthegrav- should notbeunderestimated. Correctchoiceand need for ("shootingfrequency") cleaningcentrifuges a day cleaning. except necessary during quently, shouldoperate for thecentrifuge 24hours the enginewithoutexcessive re-circulating. Conse- that itcorrespondstotheamountoffuelrequiredby by adjustingthefl preheater. oil (208°F) shouldbemaintainedinthecentrifuge RW/100°F) thehighestpossible temperature 98°C If the installed centrifuge capacityisonthelowIf theinstalledcentrifuge side Therefore ensuring operation ofcentrifuges -series Normal practice istohaveNormal atleasttwo centrifuges Taking today's fuelqualitiesintoconsideration the The fueliskept aslongpossible inthecentrifuge Especially for fuelsabove 180cST/50°C(1500sec. er/clarifi ow so rate throughthecentrifuge er mode. er c viscosityoftheused General 604.30 Edition 01H nes ow ow ow ow General 604.30 Edition 01H after centrifuging. possible water andsludgestillpresentinthefuel tohomogenizeas asupplementtothecentrifuges be usedasaguidance. maker,the centrifuge but onfi thecurves g. 1,can generally advisetofollow therecommendationsof A Homogenizer may beinstalled inthefueloilsystem capacity,For ofcentrifuging thedetermination we Fuel OilCleaning iy ofcentrifuge. city Flowrate relatedtonominelcapa- throughcentrifuge Fig. 1. lwRate Flow o scales Log 104 122 140 158 176 194 212 °F 100 100 °C % eae oRtdCpct fCentrifuge of Capacity Rated to Related 40 50 60 70 80 90 20 40 60 80 eaainTemperature Separation 200 30 15 400 60 80 545 25 600 1500 180 3500 380 75 100 600 130 6000 e.RI/100°F sec. cST/50°C cSt/80°C MAN Diesel Description Page 2(2) 92.04 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel & Turbo 3.3.7

Engine cooling water specifications

Preliminary remarks

As is also the case with the fuel and lubricating oil, the engine cooling water

must be carefully selected, handled and checked. If this is not the case, cor- 6680 3.3.7-01 rosion, erosion and cavitation may occur at the walls of the cooling system in contact with water and deposits may form. Deposits obstruct the transfer of heat and can cause thermal overloading of the cooled parts. The system must be treated with an anticorrosive agent before bringing it into operation for the first time. The concentrations prescribed by the engine manufacturer must always be observed during subsequent operation. The above especially applies if a chemical additive is added.

Requirements Limit values The properties of untreated cooling water must correspond to the following limit values:

Properties/Characteristic Properties Unit Water type Distillate or fresh water, free of foreign matter. - The following are prohibited: Seawater, brackish water, river water, brines, industrial waste water and rainwater. Total hardness max. 10 °dH* pH value 6.5 - 8 - Chloride ion content Max. 50 mg/l** Table 1: Cooling water - properties to be observed

*) 1°dH (German hard- ≙ 10 mg CaO in 1 litre of water ≙ 17.9 mg CaCO3/l ness) ≙ 0.357 mval/l ≙ 0.179 mmol/l **) 1 mg/l ≙ 1 ppm Testing equipment The MAN Diesel water testing equipment incorporates devices that determine the water properties referred to above in a straightforward manner. The manufacturers of anticorrosive agents also supply user-friendly testing equipment. For information on monitoring cooling water, refer to Work Card 000.07.

Additional information Distillate If distilled water (from a fresh water generator, for example) or fully desalinated water (from ion exchange or reverse osmosis) is available, this should ideally be used as the engine cooling water. These waters are free of lime and salts which means that deposits that could interfere with the transfer of heat to the cooling water, and therefore also reduce the cooling effect, cannot form. However, these waters are more corrosive than normal hard water as the thin film of lime scale that would otherwise provide temporary corro-

2012-05-09 - de sion protection does not form on the walls. This is why distilled water must be handled particularly carefully and the concentration of the additive must be regularly checked. Engine cooling water specifications General

6680 3.3.7-01 EN 1 (8) 3.3.7 MAN Diesel & Turbo

Hardness The total hardness of the water is the combined effect of the temporary and permanent hardness. The proportion of calcium and magnesium salts is of overriding importance. The temporary hardness is determined by the carbonate content of the calcium and magnesium salts. The permanent hardness is determined by the amount of remaining calcium and magnesium salts (sulphates). The temporary (carbonate) hardness is the critical factor that determines the extent of limescale deposit in the cooling system. 6680 3.3.7-01 Water with a total hardness of > 10°dGH must be mixed with distilled water or softened. Subsequent hardening of extremely soft water is only necessary to prevent foaming if emulsifiable slushing oils are used.

Damage to the cooling water system Corrosion Corrosion is an electrochemical process that can widely be avoided by selecting the correct water quality and by carefully handling the water in the engine cooling system. Flow cavitation Flow cavitation can occur in areas in which high flow velocities and high turbulence is present. If the steam pressure is reached, steam bubbles form and subsequently collapse in high pressure zones which causes the destruction of materials in constricted areas. Erosion Erosion is a mechanical process accompanied by material abrasion and the destruction of protective films by solids that have been drawn in, particularly in areas with high flow velocities or strong turbulence. Stress corrosion cracking Stress corrosion cracking is a failure mechanism that occurs as a result of simultaneous dynamic and corrosive stress. This may lead to cracking and rapid crack propagation in water-cooled, mechanically-loaded components if the cooling water has not been treated correctly.

Processing of engine cooling water Formation of a protective The purpose of treating the engine cooling water using anticorrosive agents film is to produce a continuous protective film on the walls of cooling surfaces and therefore prevent the damage referred to above. In order for an anticorrosive agent to be 100 % effective, it is extremely important that untreated water satisfies the requirements in the Section Requirements. Protective films can be formed by treating the cooling water with an anticorrosive chemical or an emulsifiable slushing oil. Emulsifiable slushing oils are used less and less frequently as their use has been considerably restricted by environmental protection regulations, and because they are rarely available from suppliers for this and other reasons. Treatment prior to initial Treatment with an anticorrosive agent should be carried out before the commissioning of engine engine is brought into operation for the first time to prevent irreparable initial damage.

Treatment of the cooling water The engine must not be brought into operation without treating the cooling water first. 2012-05-09 - de

Engine cooling water specifications General

2 (8) 6680 3.3.7-01 EN MAN Diesel & Turbo 3.3.7

Additives for cooling water

Only the additives approved by MAN Diesel and listed in the tables under the section entitled "Approved cooling water additives“ may be used. Required approval A cooling water additive may only be permitted for use if tested and approved as per the latest directives of the ICE Research Association (FVV) "Suitability test of internal combustion engine cooling fluid additives.” The test 6680 3.3.7-01 report must be obtainable on request. The relevant tests can be carried out on request in Germany at the staatliche Materialprüfanstalt (Federal Institute for Materials Research and Testing), Abteilung Oberflächentechnik (Surface Technology Division), Grafenstraße 2 in D-64283 Darmstadt. Once the cooling water additive has been tested by the FVV, the engine must be tested in the second step before the final approval is granted. Only in closed circuits Additives may only be used in closed circuits where no significant consumption occurs, apart from leaks or evaporation losses.

Chemical additives Sodium nitrite and sodium borate based additives etc. have a proven track record. Galvanised iron pipes or zinc sacrificial anodes must not be used in cooling systems. This corrosion protection is not required due to the prescribed cooling water treatment and electrochemical potential reversal can occur due to the cooling water temperatures which are normally present in engines nowadays. If necessary, the pipes must be deplated.

Slushing oil This additive is an emulsifiable mineral oil with added slushing ingredients. A thin film of oil forms on the walls of the cooling system. This prevents corrosion without interfering with the transfer of heat and also prevents limescale deposits on the walls of the cooling system. The significance of emulsifiable corrosion-slushing oils is fading. Oil-based emulsions are rarely used nowadays for environmental protection reasons and also because stability problems are known to occur in emulsions.

Anti-freeze agents If temperatures below the freezing point of water in the engine cannot be excluded, an anti-freeze solution that also prevents corrosion must be added to the cooling system or corresponding parts. Otherwise, the entire system must be heated. (Military specification: Sy-7025). Sufficient corrosion protection can be provided by adding the products listed in the table entitled "Anti-freeze solutions with slushing properties" while observing the prescribed concentration. This concentration prevents freezing at temperatures down to -22 °C. However, the quantity of anti-freeze solution actually required always depends on the lowest temperatures that are to be expected at the place of use. Anti- freezes are generally based on ethylene glycol. A suitable chemical anticorrosive agent must be added if the concentration of the anti-freeze solution prescribed by the user for a specific application does not provide an appro- 2012-05-09 - de priate level of corrosion protection, or if the concentration of anti-freeze solution used is lower due to less stringent frost protection requirements and does not provide an appropriate level of corrosion protection. For information on the compatibility of the anti-freeze solution with the anticorrosive agent Engine cooling water specifications General

6680 3.3.7-01 EN 3 (8) 3.3.7 MAN Diesel & Turbo

and the required concentrations, contact the manufacturer. As regards the chemical additives indicated in the table „Nitrite-Containing Chemical Addi- tives“, their compatibility with ethylene glycol-based antifreezes has been proved. Anti-freeze solutions may only be mixed with one another with the consent of the manufacturer, even if these solutions have the same composition. Before an anti-freeze solution is used, the cooling system must be thoroughly 6680 3.3.7-01 cleaned. If the cooling water contains an emulsifiable slushing oil, anti-freeze solution must not be added as otherwise the emulsion would break up and oil sludge would form in the cooling system. Observe the applicable environmental protection regulations when disposing of cooling water containing additives. For more information, consult the additive supplier.

Biocides If you cannot avoid using a biocide because the cooling water has been contaminated by bacteria, observe the following steps: ▪ You must ensure that the biocide to be used is suitable for the specific application. ▪ The biocide must be compatible with the sealing materials used in the cooling water system and must not react with these. ▪ The biocide and its decomposition products must not contain corrosion- promoting components. Biocides whose decomposition products contain chloride or sulphate ions are not permitted. ▪ Biocides that cause foaming of cooling water are not permitted.

Prerequisite for effective use of an anticorrosive agent

Clean cooling system As contamination significantly reduces the effectiveness of the additive, the tanks, pipes, coolers and other parts outside the engine must be free of rust and other deposits before the engine is started up for the first time and after repairs are carried out on the pipe system. The entire system must therefore be cleaned with the engine switched off using a suitable cleaning agent (see Work Cards 000.03 and 000.08 by MAN Diesel). Loose solid matter in particular must be removed by flushing the system thoroughly as otherwise erosion may occur in locations where the flow velocity is high. The cleaning agents must not corrode the seals and materials of the cooling system. In most cases, the supplier of the cooling water additive will be able to carry out this work and, if this is not possible, will at least be able to provide suitable products to do this. If this work is carried out by the engine operator, he should use the services of a specialist supplier of cleaning agents. The cooling system must be flushed thoroughly following cleaning. Once this has been done, the engine cooling water must be treated immediately with anticorrosive agent. Once the engine has been brought back into

operation, the cleaned system must be checked for leaks. 2012-05-09 - de Engine cooling water specifications General

4 (8) 6680 3.3.7-01 EN MAN Diesel & Turbo 3.3.7

Regular checks of the cooling water condition and cooling water

system Treated cooling water may become contaminated when the engine is in operation, which causes the additive to loose some of its effectiveness. It is therefore advisable to regularly check the cooling system and the cooling water condition. To determine leakages in the lube oil system, it is advisable

to carry out regular checks of water in the compensating tank. Indications of 6680 3.3.7-01 oil content in water are, e.g. discoloration or a visible oil film on the surface of the water sample. The additive concentration must be checked at least once a week using the test kits specified by the manufacturer. The results must be documented.

Concentrations of chemical additives The chemical additive concentrations shall not be less than the minimum concentrations indicated in the table „Nitrite-containing chemical additives“.

Excessively low concentrations can promote corrosion and must be avoided. If the concentration is slightly above the recommended concentration this will not result in damage. Concentrations that are more than twice the recommended concentration should be avoided. Every 2 to 6 months send a cooling water sample to an independent laboratory or to the engine manufacturer for integrated analysis. Emulsifiable anticorrosive agents must generally be replaced after abt. 12 months according to the supplier's instructions. When carrying this out, the entire cooling system must be flushed and, if necessary, cleaned. Once filled into the system, fresh water must be treated immediately. If chemical additives or anti-freeze solutions are used, cooling water should be replaced after 3 years at the latest. If there is a high concentration of solids (rust) in the system, the water must be completely replaced and entire system carefully cleaned. Deposits in the cooling system may be caused by fluids that enter the cooling water, or the break up of emulsion, corrosion in the system and limescale deposits if the water is very hard. If the concentration of chloride ions has increased, this generally indicates that seawater has entered the system. The maximum specified concentration of 50 mg chloride ions per kg must not be exceeded as otherwise the risk of corrosion is too high. If exhaust gas enters the cooling water, this may lead to a sudden drop in the pH value or to an increase in the sulphate content. Water losses must be compensated for by filling with untreated water that meets the quality requirements specified in the section Requirements. The concentration of the anticorrosive agent must subsequently be checked and adjusted if necessary. Subsequent checks of cooling water are especially required if the cooling water had to be drained off in order to carry out repairs or maintenance. 2012-05-09 - de Engine cooling water specifications General

6680 3.3.7-01 EN 5 (8) 3.3.7 MAN Diesel & Turbo

Protective measures

Anticorrosive agents contain chemical compounds that can pose a risk to health or the environment if incorrectly used. Comply with the directions in the manufacturer's material safety data sheets. Avoid prolonged direct contact with the skin. Wash hands thoroughly after 6680 3.3.7-01 use. If larger quantities spray and/or soak into clothing, remove and wash clothing before wearing it again. If chemicals come into contact with your eyes, rinse them immediately with plenty of water and seek medical advice. Anticorrosive agents are generally harmful to the water cycle. Observe the relevant statutory requirements for disposal.

Auxiliary engines

If the same cooling water system used in a MAN Diesel & Turbo two-stroke main engine is used in a marine engine of type 16/24, 21/ 31, 23/30H, 27/38 or 28/32H, the cooling water recommendations for the main engine must be observed.

Analysis

We analyse cooling water for our customers in our chemical laboratory. A 0.5 l sample is required for the test.

Permissible cooling water additives

Nitrite-containing chemical additives

Manufacturer Product designation Initial dosing for Minimum concentration ppm 1,000 litres Product Nitrite Na-Nitrite

(NO2) (NaNO2) Drew Marine Liquidewt 15 l 15,000 700 1,050 One Drew Plaza Maxigard 40 l 40,000 1,330 2,000 Boonton New Jersey 07005 USA Wilhelmsen (Unitor) Rocor NB Liquid 21.5 l 21,500 2,400 3,600 KJEMI-Service A.S. Dieselguard 4.8 kg 4,800 2,400 3,600 P.O.Box 49/Norway 3140 Borgheim Nalfleet Marine Nalfleet EWT Liq 3 l 3,000 1,000 1,500 Chemicals (9-108) P.O.Box 11 Nalfleet EWT 9-111 10 l 10,000 1,000 1,500 Northwich Nalcool 2000 30 l 30,000 1,000 1,500 Cheshire CW8DX, U.K. Nalco Nalcool 2000 30 l 30,000 1,000 1,500 TRAC 102 30 l 30,000 1,000 1,500

TRAC 118 3 l 3,000 1,000 1,500 2012-05-09 - de Maritech AB Marisol CW 12 l 12,000 2,000 3,000 P.O.Box 143

Engine cooling water specifications General S-29122 Kristianstad

6 (8) 6680 3.3.7-01 EN MAN Diesel & Turbo 3.3.7

Manufacturer Product designation Initial dosing for Minimum concentration ppm

1,000 litres Product Nitrite Na-Nitrite

(NO2) (NaNO2) Uniservice N.C.L.T. 12 l 12,000 2,000 3,000 Via al Santuario di N.S. della Guardia 58/A Colorcooling 24 l 24,000 2,000 3,000

16162 Genova, Italy 6680 3.3.7-01 Marichem – Marigases D.C.W.T. - 48 l 48,000 2,400 - 64 Sfaktirias Street Non-Chromate 18545 Piraeus, Griechen- land Marine Care Caretreat 2 16 l 16,000 4,000 6,000 3144 NA Maasluis The Netherlands Vecom Cool Treat NCLT 16 l 16,000 4,000 6,000 Schlenzigstraße 7 21107 Hamburg Deutschland Table 2: Nitrite-containing chemical additives

Nitrite-free additives (chemical additives)

Manufacturer Product designation Initial dosing Minimum concentration for 1 000 litres Arteco Technologiepark Havoline XLI 75 l 7.5 % Zwijnaarde 2 B-9052 Gent, Belgium Total Lubricants WT Supra 75 l 7.5 % Paris, France Q8 Oils Q8 Corrosion Inhibitor 75 l 7.5 % Long-Life Table 3: Chemical additives - nitrite free

Emulsifiable slushing oils

Manufacturer Product (designation) BP Marine, Breakspear Way, Hemel Hempstead, Diatsol M Herts HP2 4UL Fedaro M Castrol Int., Pipers Way, Swindon SN3 1RE, UK Solvex WT 3 Deutsche Shell AG, Überseering 35, Oil 9156 22284 Hamburg, Germany Table 4: Emulsifiable slushing oils 2012-05-09 - de Engine cooling water specifications General

6680 3.3.7-01 EN 7 (8) 3.3.7 MAN Diesel & Turbo

Anti-freeze solutions with slushing properties

Manufacturer Product designation Minimum concentration BASF Glysantin G 48 Carl-Bosch-Str. Glysantin 9313 67063 Ludwigshafen, Glysantin G 05 Rhein

6680 3.3.7-01 Deutschland Castrol Int. Antifreeze NF, SF Pipers Way Swindon SN3 1RE, UK BP, Britannic Tower Anti-frost X2270A Moor Lane, London EC2Y 9B, UK 35% Deutsche Shell AG Glycoshell Überseering 35 22284 Hamburg Deutschland Mobil Oil AG Frostschutz 500 Steinstraße 5 20095 Hamburg Deutschalnd Arteco, Technologiepark Havoline XLC Zwijnaarde 2 B-9052 Gent, Belgium Total Lubricants Glacelf Auto Supra Paris, France Total Organifreeze Table 5: Anti-freeze solutions with slushing properties

2012-05-09 - de Engine cooling water specifications General

8 (8) 6680 3.3.7-01 EN MAN Diesel & Turbo 000.07

Cooling water inspecting

Summary

Acquire and check typical values of the operating media to prevent or limit damage. The fresh water used to fill the cooling water circuits must satisfy the specifi- 6682 000.07-01 cations. The cooling water in the system must be checked regularly in accordance with the maintenance schedule. The following work/steps is/are necessary: Acquisition of typical values for the operating fluid, evaluation of the operating fluid and checking the concentration of the anticorrosive agent.

Tools/equipment required Equipment for checking the The following equipment can be used: fresh water quality ▪ The MAN Diesel & Turbo water testing kit, or similar testing kit, with all necessary instruments and chemicals that determine the water hardness, pH value and chloride content (obtainable from MAN Diesel & Turbo or Mar-Tec Marine, Hamburg) Equipment for testing the When using chemical additives: concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations. Testing kits from the supplier also include equipment that can be used to determine the fresh water quality.

Testing the typical values of water Short specification Typical value/property Water for filling Circulating water and refilling (without additive) (with additive) Water type Fresh water, free of foreign matter Treated cooling water Total hardness ≤ 10°dGH 1) ≤ 10°dGH 1) pH value 6.5 - 8 at 20 °C ≥ 7.5 at 20 °C Chloride ion content ≤ 50 mg/l ≤ 50 mg/l 2) Table 1: Quality specifications for cooling water (abbreviated version)

1) dGH German hardness 1°dGh = 10 mg/l CaO

= 17.9 mg/l CaCO3 = 0.179 mmol/L 2) 1mg/l = 1 ppm

2011-06-21 - de Cooling water General

6682 000.07-01 EN 1 (2) 000.07 MAN Diesel & Turbo

Testing the concentration of anticorrosive agents Short specification Anticorrosive agent Concentration Chemical additives according to the quality specification in Volume 010.005 Engine - Operating Instructions, Chapter 3, Sheet 3.3.7

6682 000.07-01 Anti-freeze agents according to the quality specification in Volume 010.005 Engine - Operating Instructions, Chapter 3, Sheet 3.3.7 Table 2: Concentration of the cooling water additive Testing the concentration of The concentration should be tested every week, and/or according to the chemical additives maintenance schedule, using the testing instruments, reagents and instructions of the relevant supplier. Chemical slushing oils can only provide effective protection if the right concentration is precisely maintained. This is why the concentrations recommended by MAN Diesel & Turbo (quality specifications in Volume 010.005 Engine – Operating Instructions, Chapter 3, Page 3.3.7) must be complied with in all cases. These recommended concentrations may be other than those specified by the manufacturer. Testing the concentration of The concentration must be checked in accordance with the manufacturer's anti-freeze agents instructions or the test can be outsourced to a suitable laboratory. If in doubt, consult MAN Diesel & Turbo. Regular water samplings Small quantities of lubricating oil in cooling water can be found by visual check during regular water sampling from the expansion tank. Testing We test cooling water for customers in our laboratory. To carry out the test, we will need a representative sample of abt. 0.5 l. 2011-06-21 - de Cooling water General

2 (2) 6682 000.07-01 EN MAN Diesel & Turbo 000.08

Cooling water system Cleaning

Summary

Remove contamination/residue from operating fluid systems, ensure/re- establish operating reliability. Cooling water systems containing deposits or contamination prevent effec- 6682 000.08-01 tive cooling of parts. Contamination and deposits must be regularly elimina- ted. This comprises the following: Cleaning the system and, if required, removal of limescale deposits, flushing the system.

Cleaning

The cooling water system must be checked for contamination at regular intervals. Cleaning is required if the degree of contamination is high. This work should ideally be carried out by a specialist who can provide the right cleaning agents for the type of deposits and materials in the cooling circuit. The cleaning should only be carried out by the engine operator if this cannot be done by a specialist. Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high concentration of anticorrosive agents can be removed by flushing the system with fresh water to which some cleaning agent has been added. Suitable cleaning agents are listed alphabetically in the table entitled "Cleaning agents for removing oil sludge". Products by other manufacturers can be used providing they have similar properties. The manufacturer's instructions for use must be strictly observed.

Manufacturer Product Concentration Duration of cleaning procedure/temperature Drew HDE - 777 4 - 5% 4 h at 50 – 60 °C Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature Vecom Ultrasonic 4% 12 h at 50 – 60 °C Multi Cleaner Table 1: Cleaning agents for removing oil sludge Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the concentration of the anticorrosive agent is too low. A thin lime scale layer can be left on the surface as experience has shown that this protects against corrosion. However, limescale deposits with a thickness of more than 0.5 mm obstruct the transfer of heat and cause thermal overloading of the components being cooled. Rust that has been flushed out may have an abrasive effect on other parts of the system, such as the sealing elements of the water pumps. Together with the elements that are responsible for water hardness, this forms what is known as ferrous sludge which tends to gather in areas where the flow

2010-02-09 - de velocity is low. Products that remove limescale deposits are generally suitable for removing rust. Suitable cleaning agents are listed alphabetically in the table entitled

"Cleaning agents for removing lime scale and rust deposits". Products by Cooling water system General

6682 000.08-01 EN 1 (3) 000.08 MAN Diesel & Turbo

other manufacturers can be used providing they have similar properties. The manufacturer's instructions for use must be strictly observed. Prior to cleaning, check whether the cleaning agent is suitable for the materials to be cleaned. The products listed in the table entitled "Cleaning agents for removing lime scale and rust deposits" are also suitable for stainless steel.

Manufacturer Product Concentration Duration of cleaning procedure/temperature Drew SAF-Acid 5 - 10% 4 h at 60 - 70 °C 6682 000.08-01 Descale-IT 5 - 10% 4 h at 60 - 70 °C Ferroclean 10% 4 - 24 h at 60 - 70 °C Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 ℃ Unitor Descalex 5 - 10% 4 - 6 h at approx. 60 °C Vecom Descalant F 3 – 10% Approx. 4 h at 50 – 60°C Table 2: Cleaning agents for removing limescale and rust deposits In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used in exceptional cases if a special cleaning agent that removes limescale deposits without causing problems is not available. Observe the following during application: ▪ Stainless steel heat exchangers must never be treated using diluted hydrochloric acid. ▪ Cooling systems containing non-ferrous metals (aluminium, red bronze, brass, etc.) must be treated with deactivated aminosulphonic acid. This acid should be added to water in a concentration of 3 - 5 %. The temperature of the solution should be 40 - 50 °C. ▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydrochloric acid is used as the cleaning agent, there is always a danger that acid will remain in the system, even when the system has been neutral- ised and flushed. This residual acid promotes pitting. We therefore recommend you have the cleaning carried out by a specialist. The carbon dioxide bubbles that form when limescale deposits are dissolved can prevent the cleaning agent from reaching boiler scale. It is therefore absolutely necessary to circulate the water with the cleaning agent to flush away the gas bubbles and allow them to escape. The length of the cleaning process depends on the thickness and composition of the deposits. Values are provided for orientation in the table entitled "Detergents for removing lime scale and rust deposits“. Following cleaning The cooling system must be flushed several times once it has been cleaned using cleaning agents. Replace the water during this process. If acids are used to carry out the cleaning, neutralise the cooling system afterwards with suitable chemicals then flush. The system can then be refilled with water that has been prepared accordingly.

Only carry out the cleaning operation once the engine has cooled down Start the cleaning operation only when the engine has cooled down. Hot engine components must not come into contact with cold water. Open the venting pipes before refilling the cooling water system. Blocked venting pipes prevent air from escaping which can lead to 2010-02-09 - de thermal overloading of the engine. Cooling water system General

2 (3) 6682 000.08-01 EN MAN Diesel & Turbo 000.08

Cleaning products can cause damage The products to be used can endanger health and may be harmful to the environment. Follow the manufacturer's handling instructions without fail.

The applicable regulations governing the disposal of cleaning agents or acids 6682 000.08-01 must be observed. 2010-02-09 - de Cooling water system General

6682 000.08-01 EN 3 (3) MAN Diesel & Turbo 3.3.10

Water specification for fuel-water emulsions

Prerequisites

The water used for the fuel-water emulsion is an operating fluid that must be carefully selected, processed (if necessary) and monitored. If this is not done, deposits, corrosion, erosion and cavitation may occur on the fuel system components that come into contact with the fuel-water emulsion.

Specifications Limit values The characteristic values of the water used must be within the following limit values:

Properties/ Characteristic value Unit Characteristic Water type Seawater, brackish water, river water, brines, -

industrial waste water and rainwater, distilled Water specification for fuel-water emulsions or fresh water Total hardness max. 10 ºdH* pH value 6.5 - 8 - Chloride ion content max. 50 mg/l Table 1: Fuel-water emulsion - characteristic values to be observed

*) 1º dH (German hard- ≙ 10 mg CaO ≙ 17.9 mg CaCO3/l ness) in 1l water ≙ 0.357 mval/l ≙ 0.179 mmol/l Testing instruments The MAN Diesel water testing kit contains instruments that allow the water characteristics referred to above (and others) to be easily determined.

Additional information Distillate If distillate (e.g. from the fresh water generator) or fully desalinated water (ion exchanger) is available, this should ideally be used for the fuel-water emulsion. These types of water are free of lime and salts. Hardness The total hardness of the water is the combined effect of the temporary and permanent hardness. It is largely determined by the calcium and magnesium salts. The temporary hardness depends on the hydrocarbonate content in the calcium and magnesium salts. The lasting (permanent) hardness is determined by the remaining calcium and magnesium salts (sulphates). Water with hardness greater than 10°dH (German total hardness) must be blended or softened with distillate. It is not necessary to increase the hardness of extremely soft water.

Treatment with anticorrosive agents not required Treatment with anticorrosive agents is not required and must be omitted. 2011-03-25 - de Water specification for fuel-water emulsions General

6680 3.3.10-01 EN 1 (1) MAN Diesel & Turbo 3.3.11

Specifications for intake air (combustion air)

General

The quality and condition of intake air (combustion air) have a significant effect on the power output, wear and emissions of the engine. In this regard, not only are the atmospheric conditions extremely important, but also contamination by solid and gaseous foreign matter. Mineral dust in the intake air increases wear. Chemicals and gases promote corrosion. This is why effective cleaning of intake air (combustion air) and regular maintenance/cleaning of the air filter are required. When designing the intake air system, the maximum permissible overall pressure drop (filter, silencer, pipe line) of 20 mbar must be taken into consideration. Specifications for intake air (combustion air) Requirements

Gas engines or dual-fuel engines may only be equipped with a dry filter. An oil filter should not be installed, because they enrich air with oil mist, which is not permissible for gas operated engines. Filters of efficiency class G4 according to EN 779 must be used. The concentrations downstream of the air filter and/or upstream of the turbocharger inlet must not exceed the following limit values:

Properties Typical value Unit *

3 Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm Chlorine max. 1.5

Sulphur dioxide (SO2) max. 1.25

Hydrogen sulphide (H2S) max. 5 Salt (NaCl) max. 1 * One Nm3 corresponds to one cubic meter of gas at 0 °C and 101.32 kPa. Table 1: Intake air (combustion air) - typical values to be observed

Intake air shall not contain any flammable gases Intake air shall not contain any flammable gases. Make sure that the combustion air is not explosive.

2012-01-17 - de Specifications for intake air (combustion air) General

6680 3.3.11-01 EN 1 (1) Cylinder head

505/605 MAN Diesel & Turbo 605.01 Description Cylinder head Page 1 (1) Edition 14H

L28/32H, V28/32H

General and is encased by the seating collar (5) which over- laps it. The assembled valve rotator is held The cylinder head is made of cast iron and is tight- together, when removed, by the retaining ring (6). ened to form a gas-tight seal against a sealing ring on the cylinder liner by means of 6 nuts and 6 studs, which are screwed into the engine frame. The nuts are tightened by means of hydraulic jacks. Each cylinder head is equipped with two air inlet and two exhaust valves which are actuated by rocker arms running in bearings on a shaft supported in a bracket on top of the cylinder head. The fuel injection valve (see section 614) is located in a interchangeable sleeve in the center of the cylinder head. Furthermore the cylinder head is equipped with an indicator valve and a safety valve. The cylinder head has a screwed-on coaming which encloses the valves. The coaming is closed 1 Retainer body 2 Balls with a top cover and thus provides an oil tight 3 Ball race 4 Spring washer enclosure for the valve gear. The coaming is equipped with an inspection cover for the rotators. 5 Seating collar 6 Retainer ring 7 Valve spindle Air inlet and exhaust valves Figure 1: Valve rotator The inlet valve spindles are identical to the exhaust spindles. As the valve starts to open, the increasing valve The valves are made of heat-resistant material. spring-load causes the spring washer to flatten, and Hard metal is welded on to the valve spindle seats the load applied to the balls in the pockets of the to avoid depressions by combustion particles. retainer body forces the balls in the ball race to roll down the inclined races. The transfer of the reaction The valve spindles are fitted with valve rotators load of the ball race to the spring washer reduces which turn the spindles a little each time the valves the reaction load of the spring washer on the inner open. rim of the retainer body. Ball race, spring washer, The cylinder head is equipped with interchangeable seating collar and valve springs are, however, force- seat rings and valve guides for inlet and exhaust locked by friction grip. The reaction load of the balls valves.The valve seat rings and valve guides for inlet on the inclined races induces rotation to the retainer and exhaust valves are identical. body and valve with relation to the seating collar The seat rings are made of heat-resistant steel, and the valve springs. As the valve closes, load is directly hardened on the seating surface and the released from the spring washer and thus from the seat rings are directly water cooled in order to balls, allowing them to be returned to their original assure low valve temperature. positions without rolling by the tangential force of the coil springs. Valve rotator The retainer body of the valve rotator (1) has a number of pockets, arranged in circumferential direction, with balls that are forced against the upper end of an inclined race by coil springs acting in tangential direction. The ball race (3) serves as ball track in the opposite direction. The spring washer (4) seats against the inner rim of the retainer body

1990.10.29 - ES0 MAN Diesel & Turbo

Working Card 605-01.00 Page 1 (2) Dismantling of Cylinder Head Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62021 10 Shut-off fuel oil 62021 01 Oil injector, Shut-off cooling oil (complete) Stopped lub. oil circul. 62021 50 6 Piece 62021 51 1 Piece 62021 15 Description: 62005 01 62021 25 Hydraulic tools Dismantling of cylinder head for inspection 62014 15 and/or overhaul.

Starting position:

Cooling water has been drained from engine. Hand tools:

Ring and open end spanner 14 mm. Ring and open end spanner 17 mm. Ring and open end spanner 24 mm.

Related procedure:

Dismounting of piston and connecting rod, 606-01.00 Dismounting and inspection of inlet valve, exhaust valve and valve guide, 605-01.05 Safety valve, 605-01.25 Dismantling, overhaul and test pressure of fuel oil valve, 614-01.10

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty./ Capacity : 2 men

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

91.45 - ES0S MAN Diesel & Turbo

605-01.00 Working Card Edition 01H Dismantling of Cylinder Head Page 2 (2)

L/V28/32H

1) Open the drain cock and vent cock for cool ing water. 8) Remove the exhaust pipe flange screws.

2) Take off the rocker arm top cover. 9) Remove the cylinder head nuts, as shown, by means of hydraulic jacks, see working card 3) Take off the cover which gives access to the 620-01.05. injection pump. 10) Mount the lifting tool on the cylinder head. 4) Disconnect the fuel oil high-pressure pipe. 11) Attach the hook to the lifting tool and lift the 5) Disconnect the cooling oil pipes, (inlet and cylinder head away. outlet.

6) Disconnect the rocker arm lubricating oil pi pe. V28/32H L28/32H 7) Remove the thermometer attachment branch (cooling water outlet pipe).

Fig. 2

Fig. 1

91.45 - ES0S MAN Diesel & Turbo

Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05 Page 1 (3) Valve Guide Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note Shut-off starting air Shut-off cooling water 62005 01 Shut-off fuel oil 62005 05 Shut-off cooling oil 62005 25/30 Extra tools Stopped lub. oil circul. 62005 55

Description

Dismounting of inlet and exhaust valve, inspection of valve guide and mounting of inlet and exhaust valve. Hand tools

Ring and open end spanner, 19 mm. Ring and open end spanner, 24 mm. Starting position Small screw driver. Measuring tools. Cylinder head, dismantled from engine 605-01.00

Related procedure

Reconditioning of valve spindle seat and valve seat ring, 605-01.10 Valve rotator, 605-01.15 Replacement of valve guide, 605-01.20 Replacement of valve seat ring, 605-01.35 Mounting of cylinder head, 605-01.45

Man power Replacement and wearing parts

Working time : 1 hour Plate no Item no Qty. / Capacity : 1 man 60501 017 4/cyl. Data

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

00.43 - ES0 MAN Diesel & Turbo

605-01.05 Inspection of Inlet Valve, Exhaust Valve and Working Card Edition 06H Valve Guide Page 2 (3)

L+V28/32H

Dismantling of Inlet and Exhaust Valve 3) Turn back the rocker arm and remove the spring- Spindles loaded valve bridge over the valve spindles.

1) Land and fasten the cylinder head upon the spe 4) After having removed the valve bridge and cial work table and remove the lifting tool. turned the rocker arm back, the tool should be fitted by means of the screws (A), see fig 2 tightened in the threaded holes in the cylinder Or as an Alternative: head.

Land the cylinder head on the floor upon wooden supports and remove the lifting tool.

2) Mount the supporting devices for the valve spindle heads on the work table.

Or as an Alternative:

Place wooden blocks under the valve spindle heads.

V28/32H L28/32H

Fig 2

5) Now compress the valve springs by tighten ing the nut (B), after which the cone rings can be re-moved, see fig 3.

Fig 1 Fig 3

00.43 - ES0 MAN Diesel & Turbo

Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05 Page 3 (3) Valve Guide Edition 06H

L+V28/32H

6) Release the springs again. Remove the nut Inspection of valve guide (B) and the traverse (C). Now valve rotator and springs can be removed. 10) Too much clearance between valve spindle and spindle guide may cause increas ed lub. oil 7) Remove the supporting devices under the work consumption, fouling up of the spindle guide and table and take out the valve spindle. thus give the risk of a sticking valve spindle.

8) Repeat point 4 - 7 to remove the two other Too much clearance also means insuf ficient valve spindles. guid-ance of the valve spindle, and thus bad alignment between spindle head and valve seat ring. In connec tion with overhaul of the Inspection of Valves/Valve Seats cylinder head, the valve spindle guides should be cleaned, inspected and measured for wear. 9) A slight grinding of valve/valve seat can be If the inner diameter of the valve spindle guide carried out by means of the handle as shown, exceeds the tolerance, see page 600.35 the see fig 4. valve spindle guide must be replaced. See working card 605-01.20. If the valve seat is heavily burnt or scarred, it should be ground using the valve seat grinder according to 11) For mounting of valve spindle follow the in- working card 605-01.10. structions in point 4 - 7 in reversed order.

Fig 4 Fig 5

00.43 - ES0 MAN Diesel & Turbo

Working Card Reconditioning of Valve Spindle Seat 605-01.10 Page 1 (3) and Valve Seat Ring Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62005 40 Grinding machine Shut-off fuel oil for valve spindle. Shut-off cooling oil 62005 35 Grinding machine Stopped lub. oil circul. for valve seat ring. (Extra tools).

Description:

Reconditioning of valve spindle seat and valve seat ring, with special grinding machine. Hand tools:

All the hand tools and new stones, are included in the tools box for grinding machine. Starting position:

Valve spindle has been removed, 605-01.05

Related procedure:

Mounting of valve spindle, 605-01.05

Man power: Replacement and wearing parts:

Working time : 6 Hours Plate no. Item no. Qty./ Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

91.45 - ES0S MAN Diesel & Turbo

605-01.10 Reconditioning of Valve Spindle Seat Working Card Edition 01H and Valve Seat Ring Page 2 (3)

L/V28/32H

Reconditioning of Valve Seat Ring. However when the seat "S" has been ground to such an extent, that the recess "R" disappears, the valve Reconditioning of valve seat rings by machining is seat ring has to be scrapped and a new one to must carried out by means of a grinding machine, the installed, see working card 605-01.35 pilot spindle of which is to be mounted in the valve spindle guide. For operation of the grinding machine, see separate instructions. Reconditioning of Valve Spindle.

The grinding of the valve seat ring should be carried Reconditioning by machining is carried out with the out according to the following sequence: valve spindle being rotated in a turning lathe and a special grinding machine mounted on the tool post 1) The seating surface itself is ground with a feed of the turning latch. 0,10°. at an angle "A" of 30° ± 0. For operation of the grinding machine, see separa The grinding should be continued until a clean and ted instructions. uniform surface condition has been obtained. 1) The seating surface itself is ground with a feed 0. Carry out the final grinding with a feed in direction at an angel "A" of 30° ± 0,25°. from inside to outwards, as normally the best surface quality is obtained in this way. 2) The grinding shoud be continued until a clean and uniform surface condition has been obtained.

3) After completing the grinding, the height "H"1 of the valve head should be checked.

0,10° "A" 30 ± 0 "H"1 has to be at least, see page 600.35. "R"

"S" If measured to be less, the spindle has to be scrap ped.

"H"1 Fig. 1.

0 "A" 30° ± 0,25°

2) Normally the valve seat ring can be recon di tioned several times. Fig. 2.

91.45 - ES0S MAN Diesel & Turbo

Working Card Reconditioning of Valve Spindle Seat 605-01.10 Page 3 (3) and Valve Seat Ring Edition 01H

L/V28/32H

After assembling the valves, check - on account of the valve motion - that distance "H"2 between the upper edge of the cylinder head and the upper edge of the valve spindle does not exceed the maximum value, see page 600.35.

"H"2

Fig. 3.

91.45 - ES0S MAN Diesel & Turbo

Working Card 605-01.15 Page 1 (2) Valve Rotator Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62005 05 Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Dismantling, inspection and mounting of valve rotator. Hand tools:

Small screw driver. Ring and open end spanner 24 mm.

Starting position:

Valve spindles has been removed, 605-01.05

Related procedure:

Mounting of valve spindles, 605-01.05

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./ Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

91.45 - ES0S MAN Diesel & Turbo

605-01.15 Working Card Edition 01H Valve Rotator Page 2 (2)

L/V28/32H

Inspection of Rotocap. When inserting the balls and the tangential springs, note that all balls on the inclined races of the ball Dirt especially in the ball pockets due to residues in pockets point in the same direction, see fig. 1. the oil (abrasives, combustion products), can cause the individual parts to become stuck, and hinder the movement of the balls.

Rotocap valve rotators need no servicing under normal operating conditions.

Unusual operating conditions may lead to disturban ces. Rotation of the valve should be checked at the intervals specified in the "Maintenance program". Rotator performance is satisfactory when the valve rotates visibly and evenly.

Fig. 1. Dismantling of Rotocap.

See working card 605-01.05, point 3 to 6. The inner ring of the spring washer should rest on the retainer body.

Overhauls Note ! Having assembled the valve rotator in dry condition it should be placed in clean lubricating Valve rotators should be cleaned and inspected for oil for a short period of time. wear and ball impressions whenever the valves are removed. The individual parts can be disassembled after removal of the retaining ring, by means of which Mounting of Rotocap the seating collar is fastened to the retainer body. See working card 605-01.05, point 3 to 6 , opposite Parts showing wear grooves or depressions formed direction. by the balls should be replaced.

91.45 - ESOS MAN Diesel & Turbo

Working Card 605-01.20 Page1 (2) Replacement of Valve Guide Edition 05H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62005 60 Lytra tools Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description

Dismantling and mounting of valve guide, for inlet and exhaust valve. Hand tools

Hammer.

Nitrogen (N2), or similar. Starting position

Valve spindle has been removed, 605-01.05

Related procedure

Mounting of valve spindles, 605-01.05

Man power Replacement and wearing parts

Working time : 3/4 Hour Plate no. Item no. Qty. / Capacity : 1 man 60501 017 4/cyl. Data 60501 029 4/cyl.

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

00.43 - ES0 MAN Diesel & Turbo

605-01.20 Working Card Edition 05H Replacement of Valve Guide Page 2 (2)

L+V28/32H

If the clearance exceeds the shown max. limit, (see 3) Before mounting the new valve guide, it has to page 600.35), the valve guide must be replaced. be cooled down to approx. -70°C with nitrogen or similar.

Dismounting of valve guide When the new valve guide has been inserted into the bore be sure that the shoulder bears 1) The valve guide is knocked out from the bottom against the cylinder head, by knocking slightly of the cylinder head,by means of a mandrel, with the mandrel and a hammer. which has a shoulder turning that fits into the valve guide, see fig. 1. 4) Before mounting of the valve spindle insert a new o-ring in the valve guide.

Valve seat ring

Mandrel

Fig 2. Valve guide

Correct mounting can easily be done by the use of two valve spindles as mounting tool, one spindle to be used as support and the other spindle to be used Fig 1 for pushing the o-ring downwards.

Screw drivers or other sharp tools should never be 2) After having knocked out the valve guide, caused for this purpose. refully clean the bore of the cylinder head and inspect for marks that can prvent mounting of 5) For mounting of valve spindle, see working a new valve guide. card 605-01.05.

00.43 -ESO MAN Diesel & Turbo

Working Card 605-01.25 Page 1 (3) Safety Valve Edition 04H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note Shut-off starting air Shut-off cooling water 62014 01 Pressure test Shut-off fuel oil pump. Shut-off cooling oil 62014 04 Pipe for fuel Stopped lub. oil circul. injector

Description: Hand tools:

Dismantling, inspection, reassembling and Open end spanner, 32 mm. pressure testing of safety valve. Small hammer. Copaslip.

Starting position:

Related procedure:

Indicator valve 605-01.26

Man power: Replacement and wearing parts:

Working time : 1 hour Plate no Item no Qty. / Capacity : 1 man 60508 14 1/cyl.

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

96.27 - ES0S MAN Diesel & Turbo

605-01.25 Working Card Edition 04H Safety Valve Page 2 (3)

L+V28/32H

Maintenance and Checking. 2. Reassembling.

During extended periods of standstill and at general 2.1 Lubricate the threads on valve housing (2) engine overhauls, the safety valves should be tho with copaslip or similar. roughly cleaned. 2.2 Reassemble the safety valve, reverse se- Note: Do not attempt to stop a safety valve from quence of operations outlined above, point 1.1 to leaking by increasing the spring load. 1.5.

The setting of the opening pressure is stamped onto the cap nut (1), see fig 1. 3. Test of Safety Valve.

The valve is to be tested after each overhaul by 1. Dismantling. making a leakage test and testing the opening pres-sure. 1.1 Screw the safety valve out of the cylinder head. 3.1 Mount the safety valve in the fuel injection test pump by using the test pipe for fuel injections.

3.2 Vent the system by pumping until the oil flows free of air bubbles through the valve ports (7) in the valve housing (2).

Leakage Test

3.3 Increase the pressure to 135 bar.

3.4 Check that the pressure do not sink below 135 bar within 1 minute. 1. Cap nut 5. Split pin 2. Valve housing 6. Valve cone 3. Pressure spring 7. Valve ports 4. Valve spindle If the pressure is Then

Fig 1. Safety valve OK Continue with point 3.5.

1.2 Clamp valve in vice. below 135 bar Scrap the valve. or 1.3 Unscrew cap nut (1). Lap the valve cone and 1.4 Remove pressure spring (3), valve spindle seat. (4) and valve cone (6).

1.5 Inspect and carefully clean all parts and condition valve, if necessary.

96.27 - ES0S MAN Diesel & Turbo

Working Card 605-01.25 Page 3 (3) Safety Valve Edition 04H

L+V28/32H

Test of Opening Pressure 4. Adjustment of Opening Pressure

3.5 Increase the pressure to the opening pres- 4.1 Increase the pressure to the opening pressure. sure.

4.2 Turn the cap nut (1) to the correct opening pressure. If the opening pressure is Then 4.3 Drill a new hole for mounting of split pin (5). OK The procedure is ended.

Not OK The valve must be 5. Mounting of Safety Valve adjusted, see point 4. 5.1 Lubricate the threads on the valve housing (2) with copaslip or similar.

5.2 Mount the safety valve on the cylinder head.

96.27 - ES0S MAN Diesel & Turbo

Working Card 605-01.26 Page 1 (2) Indicator Valve Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate No Item No Note Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Dismounting, inspection and mounting of indicator valve. Hand tools:

Ring and open end spanner 10 mm Ring and open end spanner 27 mm Steel brush Copaslip Starting position:

Related procedure:

Safety valve 605-01.25

Man power:

Working time : 1/2 hour Capacity : 1 man Replacement and wearing parts:

Data: Plate No Item No Qty./

Data for pressure and tolerance (Page 600.35) 60508 16 1/Cyl. Data for torque momen (Page 600.40) Declaration of weight (Page 600.45)

94.26 - ES0S MAN Diesel & Turbo

605-01.26 Working Card Edition 02H Indicator Valve Page 2 (2)

L+V28/32H

Maintenance

By normal working conditions the indicator valve require very little maintenance except an inspection in connection with the normal cylinder cover overhaul.

Inspection of the Indicator Valve:

1. Disassemble the indicator valve.

2. Check the valve seat and the cone for "burning through".

If the valve seat in the housing is "burned", the entire valve is to be replaced. 1. Indicator valve, complete 2. Connecting piece 3. Clean and lubricate all components before remounting.

Fig 1 Indicator valve. 4. Ensure that the spindle is in "OPEN" position when assembling the valve.

NOTE: Otherwise cone and seat may be damaged.

94.26 - ES0S MAN Diesel & Turbo

Working Card 605-01.30 Page 1 (2) Replacement of Sleeve for Fuel Injector Edition 04H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description

Dismounting, inspection and mounting of sleeve for fuel injector. Hand tools

Brass mandrel. Hammer. Lub. oil. Starting position Two small screw driver. Loctite 572. The cylinder head has been dismounted from engine, 605-01.00 The fuel injector has been removed, 614-01.10

Related procedure

Mounting of fuel valve, 614-01.10

Man power Replacement and wearing parts

Working time : 1 Hour Plate no. Item no. Qty./ Capacity : 1 man 60501 125 1/cyl. Data 60501 137 1/cyl. 60501 149 1/cyl. Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

00.43 - ES0 MAN Diesel & Turbo

605-01.30 Working Card Edition 04H Replacement of Sleeve for Fuel Injector Page 2 (2)

L+V28/32H

Dismounting of Sleeve for Fuel Injector 4) Coat the sealing ring zone in the bore with grease or lub. oil. 1) Remove the snap ring by means of two screw drivers.

2) The sleeve can now be driven out of the bo Snap ring re by use of a brass mandrel and a hammer. O-ring Sleeve Loctite 572

Brass mandrel

Fig 2

5) Install new sealing rings on the sleeve.

6) Coat the sealing surfaces on the sleeve with Fig 1 loctite 572.

7) Insert the sleeve in the bore. Inspection of Bore in Cylinder Head and mounting of the Sleeve: 8) Mount the snap ring.

3) Clean and inspect the bore in the cylinder head. Any marks which could prevent mounting of the sleeve, should be gently smoothed.

00.43 - ES0 MAN Diesel & Turbo

Working Card 605-01.35 Page 1 (4) Replacement of Valve Seat Ring Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62021 01 Shut-off fuel oil 62021 50 1 piece Shut-off cooling oil 62005 45 Extra tools Stopped lub. oil circul. 62005 50 Extra tools 62021 46 1 piece

Description

Replacement of valve seat ring, for inlet and exhaust valve.

Starting position

Inlet and exhaust valves have been Hand tools removed, 605-01.05 Ring and open end spanner 36 mm Hammer. Loctite, 648. Lub. oil. Related procedure

Mounting of valve spindles, 605-01.05

Man power Replacement and wearing parts

Working time : 1 1/2 Hours Plate no. Item no. Qty. / Capacity : 1 man 60501 245 4/cyl. Data 60501 257 4/cyl.

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

00.43 - ES0 MAN Diesel & Turbo

605-01.35 Working Card Edition 06H Replacement of Valve Seat Ring Page 2 (4)

L+V28/32H

Dismounting of Valve Seat Rings Procedure for Dismounting a Valve Seat Ring When reconditioning of a valve seat ring no longer is possible due to dimensions exceeding the scrapping 1) By means of the guide pin (7) the guide disc criteria, the seat ring has to be replaced. (5) is led vertically through the valve seat ring. Then the guide disc (5) is lifted with the guide Dismounting of a valve seat ring is carried out by pin (7) until the latter is guided by the valve means of a special extractor tool set somprising seat ring. The stud (1) is then screwed in until following components, see fig 1. it rests in the valve guide.

9 3

5 10 6

1 Stud 6 Eye screw 2 Collar nut hexagon 7 Guide pin Fig 2 3 Guide disc 8 Valve guide 4 Disc 9 Hydraulic jack 5 Guide disc 10 Valve seat ring

2) The guide disc (3) is positioned so that it bears against the bottom of the cylinder head, and the hydraulic jack is clamped with the disc (4) and Fig 1 collar nut hexagon (2), see fig 1. The hydraulic jack is the one used for main bearing caps.

00.43 - ES0 MAN Diesel & Turbo

Working Card 605-01.35 Page 3 (4) Replacement of Valve Seat Ring Edition 06H

L+V28/32H

3) By pumping up the pack, see working card 3) To facilitate mounting of the valve seat ring it is 620-01.05 for the use of hydraulic tools, the cooled down, however to no more than -25°C valve seat is pressed out max. 6 mm, and the or the O-ring can be damaged. pressure is released again. The collar nut hexagon is tightenied and the operation is continued 4) Place the O-ring on the valve seat ring and until the valve seat ring can be removed. coat with oil/loctite as shown in fig 4, just before positioning it in the bore.

Mounting of Valve Seat Rings

1) Prior to mounting of a new valve seat ring, the bore must be cleaned thoroughly and inspected for marks. Marks that can hinder mounting of Coat with loctite 648 the valve seat ring must be removed. Valve seat ring 2) Tools for mounting of valve seat rings are shown in fig 3. O-Ring Coat with oil

Fig 4

5) The valve seat ring is positioned in the bore, handle with stud inserted as shown in fig 5, and washer with screw is screwed tight. 1

3 4

1 Handle 2 Stud 3 Washers 4 Hexagon nut with collar

Fig 5

Fig 3

00.43 - ES0 MAN Diesel & Turbo

605-01.35 Working Card Edition 06H Replacement of Valve Seat Ring Page 4 (4)

L+V28/32H

6) By knocking on the handle and at the same time tightening the nut (4), the valve seat ring slides in place in the bore and it is felt on the knocks when it bears in the bore.

7) Prior to mounting of the valve spindle the valve seat ring must be ground to ensure correct centering of valve guide and valve seat ring. This can be done according to working card 605-01.05 or 605-01.10.

00.43 - ES0 MAN Diesel & Turbo

Working Card 605-01.40 Page 1 (2) Mounting of Cylinder Head Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62021 10 Shut-off fuel oil 62021 01 Shut-off cooling oil 62021 50 6 Pieces Stopped lub. oil circul. 62021 51 1 Piece 62021 15 62005 01 62010 01 Description 62021 25 62014 15 Mounting of cylinder head after inspection and/or overhaul.

Hand tools Starting position Ring and open end spanner, 14 mm. Cylinder head is completely Ring and open end spanner, 17 mm. assembled, 605-01.05 to 605-01.35 Ring and open end spanner, 24 mm. Valve gear of respective cylinder is in right posi- Lub. oil and copaslip. tion (valve closed). Control of the surface on the cylinder liner, 606-01.45

Related procedure

Adjustment of valve clearance 608-01.10

Replacement and wearing parts Man power Plate no. Item no. Qty. / Working time : 1 1/2 Hour Capacity : 2 men 60501 269 2/cyl. 60510 08 1/cyl. Data 60610 01 2/cyl. 61202 31 1/cyl. Data for pressure and tolerance (Page 600.35) 61625 01 2/cyl. Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

00.44 - ES0 MAN Diesel & Turbo

605-01.40 Working Card Edition 06H Mounting of Cylinder Head Page 2 (2)

L+V28/32H

1) Check the jointing surfaces of the cylinder Place the spacer ring around the nuts with the slot in head/cylinder liner to see that they are clean such a position that the tommy bar can be used. and without damage marks, see working card 606-01.45, Fit new o-rings on the water pas- Tighten the hydraulic jacks and make sure that the sage, lubricate the o-rings with a little oil. cylinder of the jacks bears firmly against the spacer ring. Tighten up all the nuts, see page 600.40. For 2) Check all contact faces on the cylinder head using the hydraulic tools, see working card 620- and nuts, including threads, and make sure that 01.05. these are plane and smooth and absolutely free from foreign particles.

3) Attach the lifting tool to the cylinder head that has been made ready for installation, and position it carefully on the cylinder liner.

V28/32H L28/32H

Fig 2

7) If new studs or nuts have been fitted, the nuts must be tightened and loosened three times, in order to compensate for deformation of the thread and in order to ensure a safe minimum load of the studs through the tightening.

8) Adjust the valve clearance, see working card 608-01.10. Fig 1 9) Fit the pipes for fuel oil, lub. oil, cooling oil. cooling water and the flange for exhaust 4) Make sure that the nuts run easily on the threads pipe. and that they bear on their entire contact surfaces. 10) Prior to start up check for leakages, and after start up check for leakages and oil flow. 5) Coat threads and contact faces with copaslip before fitting the nuts. 11) Mount the cover for rocker arm and the front cover for fuel pump. 6) Screw nuts onto the studs and tighten lightly with the tommy bar.

00.44 - ES0 MAN Diesel & Turbo

Working Card 605-01.45 Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Inspection of cylinder head cooling water space. Hand tools:

Steel brush

Starting position:

The cylinder head dismantled from engine, 605-01.00

Related procedure:

Man power:

Working time : ¼ Hour Replacement and wearing parts: Capacity : 1 man Plate no. Item no. Qty./

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

93.20 - ES0S MAN Diesel & Turbo

605-01.45 Working Card Edition 01H Inspection of Cylinder Head Cooling Water Space Page 2 (2)

L/V28/32H

Inspection of Cylinder Head Cool. Water Space.

1) Inspect the cooling water inlet at the bottom and the cooling water outlet in the top of the cylinder Cooling water, head, see fig. 1. outlet

2) Remove all possible deposits.

3) Pour water into the cooling water outlet and make sure, that water is coming out of all the cooling water inlet bores at the bottom of the cylinder head.

4) Clean if necessary the cooling water inlet and outlet by means of a steel brush. Flush the cooling water space after cleaning. Cooling water, inlet 5) Should the cylinder head cooling water space contrary to expectation be blocked with deposits, contact MAN B&W Diesel, Holeby for further instruc- Fig. 1. Cylinder Head tions.

93.20 - ES0S MAN Diesel

Plate Page 1 (2) Cylinder Head 60501-19H

L+V28/32H

091 125 101 137 113 149 101 017 113 029 054 162 174 066 186 078

198

208 270 221 233 245 030 042 257

269

304

282

294

03.44 - ES0 MAN Diesel

Plate 60501-19H Cylinder Head Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 4/C O-ring O-ring 304 Cylinder head (as 294) Cylinderdæksel (som with brackets and 294) monteret med buk- 029 4/C Valve guide, inlet and Ventilstyr, indstr. og rockerarms installed ke og vippearne. exhaust udstr.

030 6/C Plug screw Propskrue

042 6/C Gasket Pakning

054 2/C Nut Møtrik

066 2/C Distance pipe Afstandsrør

078 2/C Stud Tap

091 2/C Thrust collar Trykﬂ ange

101 4/C Plug screw Propskrue

113 4/C Gasket Pakning

125 1/C Snap ring Låsering

137 1/C Sleeve for fuel valve Foring for br. ventil

149 1/C O-ring O-ring

162 8/C Nut Møtrik

174 8/C Stud Tap

186 4/C Stud Tap

198 4/C Spring pin Fjederstift

208 2/C Plug screw Propskrue

221 2/C Screw Skrue

233 2/C Coupling Kobling

245 4/C O-ring O-ring

257 4/C Valve seat ring, Ventilsædering, (inlet and exhaust) (indstr. og udstødning)

269 2/C O-ring O-ring

270 2/C Plug screw Propskrue

282 Cylinder head with Cylinderdæksel mon- valve guide sleeve for teret med spindelstyr, fuel valve and valve foring for br. ventil og seat rings ventilsæderinge

294 Cylinder head (as 282) Cylinderdæksel (som with valve spindles 282), monteret med installed ventilspindler

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

03.44 - ES0 MAN Diesel 08.28 -ES0 08028-0D/H5250/94.08.12 Page 1(2) Plate 12 10 09 08 07 05 04 38 36 02 01 06 11 Valve Spindlesand Valve Gear 17 16 15 03 14 07 06 13 34 35 11 10 09 08 32 21 37 12 33 22/23 26 25 20 19 19 31 30 29 28 27 L+V28/32H 60502-31H L+V28/32H 00-1 Valve Spindlesand Valve Gear 60502-31H * Only available kit. ofaspareparts aspart = Qty./ = Qty./Individual Qty./Cylinder Qty./C = * When ordering spare parts, 600.50. seealsopage

09 Item No 27 26 25 23 22 21 20 19 17 16 15 14 13 12 11 10 08 07 06 05 04 03 02 01 .

24/C 24/C Qty. 2/C 4/C 4/C 2/C 2/C 4/C 2/C 2/C 2/C 2/C 1/C 4/C 4/C 4/C 4/C 4/C 4/C 4/C 2/C 1/C 4/C 2/C 2/C Designation Nut Retainer ring Spring washer Ball Spring 30, 31) (Item 03, 27, 28, 29, Rocker arm, compl. Rocker armshaft incl springpin Rocker armbracket Securing ring Ball guide Spring Thrust piece Valve bridge,exhaust marine engines) spindle exh. only for and exhaust (valve Valve spindle, inlet Outer spring Inner spring 26 incl. item22, 23, 25, Rotocap, complete Conical ringin2/2 Thrust piece Circlip Thrust screw inlet Valve bridge, Plug screw Nut Thrust piece Benævnelse Møtrik Låsering Fjederskive Kugle Fjeder 30, 31) (Item 03,27,28,29 komplet Vippearm, Aksel for vippearm spændstift Buk for inkl vippearm Sikring Kuglestyr Fjeder Trykstykke Ventilbro, udstødning motorer) uds. kunfor marine og uds. (ventilspindel Ventilspindel, inds. Udvendig fjeder Indvendig fjeder 25, 26 plet inkl. item22,23, Rotationsgiver, kom- Konisk 2/2 ring Trykstykke Fjederring Trykskrue indstrømning Ventilbro, Propskrue Møtrik Trykstykke * Kun tilgængeligsomendelafetreservedelssæt. Antal/Individuelt = Antal/I = Antal/Cylinder Antal/C = * Ved bestillingafreservedele, seogsåside600.50. Item No 38 37 36 35 34 33 32 31 30 29 28 . Qty. 2/C 4/C 1/C 1/C 1/C 2/C 2/C 2/C 2/C /I /I Loctite 243 engines) stationary exhaust (only for Valve spindle, Screw 14, 15, 16and17 01, 02, 05, 06, 07, 13, complete incl. item Valve bridge, exhaust 14, 15, 16and17 01, 02, 04, 05, 06, 07, complete incl. item Valve bridge, inlet Plate 60502 Plate 60501+ Cylinder headas Loctite 572 Thrust pin Bearing bush Thrust screw Rocker arm einto Benævnelse Designation Loctite 243 motorer) (kun for stationære Ventilspindel, uds. Skrue 14, 15,16og17 01, 02,05,06,07,13, komplet inkl. item Ventilbro, udstødning 14, 15,16og17 01, 02,04,05,06,07, komplet inkl. item Ventilbro, indstrømning Plate 60502 Plate 60501+ Cylinderdæksel som Loctite 572 Trykskrue Lejebøsning Trykskrue Vippearm MAN Diesel Page 2(2) Plate 08.28 -ES0

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Safety Valve and Indicator Valve 60508-11H

L+V28/32H

94.25 - ES0S MAN Diesel

Plate 60508-11H Safety Valve and Indicator Valve Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

03* 1/C Valve cone Ventilkugle

06* 1/C Pressure spring Trykfjeder

13 1/C Safety valve, com- Sikkerhedsventil, plete incl. item 03, komplet inkl. item 03, 06, 25, 26, 27, 28 06, 25, 26, 27, 28

14 1/C Gasket Pakning

15 1/C Gasket Pakning

16 1/C Gasket Pakning

17 1/C Connecting piece Forbindelsesstykke

18 1/C Indicator valve, Indikatorventil, complete komplet

25* 1/C Valve housing Ventilhus

26* 1/C Valve spindle Ventilspindel

27* 1/C Cap nut Dækselmøtrik

28* 1/C Split pin Fjedernot

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

94.25 - ES0S MAN Diesel

Plate Page 1 (2) Cylinder Head, Top Cover 60510-12H

L+V28/32H

05, 16

15 13

08 09 10

06.32 - ES0S MAN Diesel

Plate 60510-12H Cylinder Head, Top Cover Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 4/C Handle Håndtag

02 4/C O-ring O-ring

05 4/C Nut Møtrik

06 1/C Top cover Topdæksel

07 1/C Top cover, compl. Topdæksel, kompl. incl. item Nos. inkl. pos. nr. 01, 02, 05, 06 01, 02, 05, 06

08 1/C Gasket Pakning

09 6/C Spring pin Fjederstift

10 1/C Coaming Karm

11 1/C Gasket Pakning

13 18/C Washer Skive

15 18/C Screw Skrue

16 /I Loctite 638 Loctite 638

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

06.32 - ES0S Piston/connecting rod

506/606 MAN Diesel 90.43 -ES0U 08028-0D/H5250/94.08.12 Description Page 1(1) and toprevent relative movement oftheparts. capareserrated toensurepreciselocation bearing cylinder liner. The jointfaces onconnectingrodand necting rodassembly tobewithdrawn upthroughthe inclined jointinordertofacilitate thepistonandcon- The connectingrodisdie-forged. The big-endhasan Connecting Rod (seeger rings). is upwords inplaceaxialdirectionby two circlips well asintheconnectingrodbush. The pistonpin freelyin the pinbossesofpistonas can turn The pistonpinisfullyfl Piston Pin oilsystem. used oilfromtheengine'slubricating thepistonmovement. during arising Ascoo thus thecoolingeffect isbasedontheshaker effect crown zone. andthepistonring and The heattransport The pistonhasacoolingoilspaceclosetothe minimum wear rate. pack isoptimized for maximum sealingeffect and surfaceplated running onallrings, thepistonring with different barrel-shapedprofi By theuseofacombinationcompressionrings and1scraper ring. compression rings type madeofnodularcastiron,isequippedwith3 The piston,whichisoil-cooledandofthemonobloc Piston Piston, ConnectingRodandCylinderLiner oating whichmeansthatit les andchrome- ling oilis water oilmist. orlubricating will reveal any sealingmalfunctionby signofleaking andleadingtotheexteriorbetween thesealingrings Tell-tale fromalevel intheframe, borings starting in theliner. whicharefi rings rubber the coolingwater isobtainedby meansofsilicone oftheengine. therunning heated during Sealingfor The linercanthusexpand freelydownwards, when tom ofthecoolingwater spaceoftheengineframe. cylinder headandisguidedby aboreatthebot- cast ironsealingrings. The linerisclampedby the the linerandframe therearefi Between thelinerandcylinderheadbe cast ironandisfi The cylinderlinerismadeoffi Cylinder Liner sed intotheconnectingrod. typeandispres- isoftrimetal The small-endbearing kind ofadaption. therefore tobefi shellsareoftheprecisiontypeand The bearing layer.a running Designasplaintypeorrillen lined withtin-aluminiumorlead-bronze coatedwith type, isoftrimetal i.e.The big-endbearing steelshells tted withoutscraping orany other tted inaboretheengineframe. tted ingrooves machined ne-grained, pearlite pearlite ne-grained, tted repla tted L/V28/32H 606.01 Edition 10H ceable tween type. 96.06 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(3) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1 Capacity : 2 : Working time men Man power: liner, 606-01.35 605-01.00 Inspection andhoningofcylinder rod, 606-01.05 Separation ofpistonandconnecting Related procedure: Crank caseopen. from engine, Cylinder headhasbeendismounted position: Starting sembly, for inspection and/oroverhaul. Dismounting ofpistonandconnectingrodas- Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Dismounting ofPistonandConnectingRod lt o Ie o Qty./ Itemno. Plate no. Replacement andwearingparts: Small adjustable spanner. Scraper orsimilar. Wire. Open endspanner32mm. Threaded pinM16. Hand tools: 140-760Nm rod screw, card620-01.20. seeworking 28 2 01 Tool combinationfor dismountingofconnecting pieces 22 62010 62006 09 03 62006 Note. 01 62006 62006 62006 Itemno. Plateno. Special tools: 606-01.00 L28/32H Edition 01H 606-01.00 L28/32H Edition 01H slightly. cylinder headstuds, screw onthenut andtightenit the pistonwithdrawal)liner during ononeofthe Mountthetube(for holdingdown thecylinder d) tool. ring ontopofthefl Placeausedpistonring c) inthecylinderattopofpiston. ring Mountthetoolfor dismountingofthefl b) Turn thepistontobuttom. a) continue withitemNo2. If thelinerisnotmountedwithafl with itemNoatoe. If thelinerismountedwithafl deposited inthisarea. piston may getstuck removal during inthecarbon 1) Fig. 1. Mountingoftools. (placing). Clean the upper part ofthecylinder, Cleantheupperpart ifnot,the Dismounting ofPistonandConnectingRod thenstart ame ring then ame ring ame ame wire ropetight. a shackle, hookthewireontoatackle andpullthe Fig. 2. Removal cap. ofbearing head studs, screw onthenut andtightenitslightly. thepistonwithdrawal)during ononeofthecylinder Mount thetube(for holdingdown thecylinder liner mount theeye screw. seefi closetocylinderlinershirt, being very g. 1. This positionisidentifi TDC. intoapositionapprox.concerned 50degrees before 3) to improve theaccessconditions. outagainstthecylinderliner.the pistonring outofthecylinder,ring whilethefl Info: whichpushesthefl Itistheusedpistonring Turn thepistonintop, inordertopushthefl outofthecylinderbyring meansofthetool. e) 5) 4) 2) Attachawirerope totheeye boltby meansof Cleanthethreadedholeinpistontop, and Turn thecrank thecrankshaft throw tobring Remove thegangway, ifany installed,inorder able by theconnectingrodshaft ame ring tool guides toolguides ame ring MAN Diesel Working Card Page 2(3) ame ame 96.06 -ES0S

08028-0D/H5250/94.08.12 96.06 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(3) Fig. 3. Removal shell. ofupperbig-endbearing see fi g. 3. upwards andremove shell, theupperbig-endbearing 10) rod. the guidepin,seefi g. 2. and dis the holeinguidepin,andunscrew thescrews. of thethreadedholesandfi one oftheupperscrews. 6) the new crank throw position. ofthecrankshaft andtightenedupagainin turning screws, thewireropemust beslackened before forpears necessary accestotheconnectingrod If minoradjustmentofthecrank throw positionap- 9) 8) 7) Mounttheguidepinfor capinone thebearing Unloadtheconnectingrodscrews andun Pull thepistonandconnectingrodassembly Remove theguidepinfromconnecting Remove thescrewdriver fromtheguidepin, mount the bearing capbymount thebearing slidingitalong Dismounting ofPistonandConnectingRod t ascrewdrive orsimilarin screw

Fig. 4. Liftofpistonandconnectingrod assembly. the bearing capfromthecrankcase.the bearing cap, andtofacilitate easyhandlingwhenremoving sur any jointfaces damageofcrank journal, orbearing NOTE: see fi g. 4. up throughthecylinderlinerandoutofengine, 11) face dismounting ofthebearing to occur during Lift thepistonandconnectingrodassembly oftheguidepin istopreventThe purpose 606-01.00 L28/32H Edition 01H MAN Diesel 92.08 -ES0S 08028-0D/H5250/94.08.12 Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: hour 1/4 Capacity : : 1 Working time 606-01.16 man Man power: 606-01.15 big-end bearing, Inspection ofconnectingrod connecting rod, 606-01.00 Inspection or/andoverhaul of 606-01.10 Inspection or/andoverhaul ofpiston, Related procedure: from engine, Piston andconnectingrodaredismounted position: Starting inspection or/andoverhaul. Assembly ofthepistonandconnectingrodafter spection or/andoverhaul. Separation ofpistonandconnectingrodfor in- Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Separation ofPistonandConnectingRod lt o Ie o Qty./ Itemno. Plate no. Replacement andwearingparts: Wire. Wooden support. Wooden wedge, 2pieces. Open endspanner, 32mm. Hand tools: V28/32H L28/32H L28/32H 20 05 03 62006 Note. 01 62006 62006 62006 Itemno. Plateno. Special tools: L/V28/32H 606-01.05 Edition 03H L/V28/32H 606-01.05 Edition 03H crown, seefi positionresting onthetopfacein upright ofthepiston from thepistoncrown, seefi g. 1or2. Fig. 2. V28/32H see fi g. 1or2. serrated jointfaces handlingoftheassembly, during screws tightenedonlyby hand,inordertoprotectthe seefi scraper ring, topreventon wooden support damageofpistonand Separation ofthePistonandConnectingRod: Fig. 1. L28/32H 4) 3) 2) 1) Remove the shackle andeye screw/lifting tool capshouldbemountedwiththe Thebearing Landthepistonandconnectingrodcarefully Place thepistonandconnecting rodassembly g.3. g. 1or2. Separation ofPistonandConnectingRod see point1-6inoppositedirection. 7) Assembly ofthePistonandConnectingRod. away. push outthepistonpinandliftconnectingrod see fi g. 3 necting rod,attachatackle andtightenthewirerope, position. theliftingintoupright during piston skirt necting rodfromswinging outandthusimpactthe Wooden wedges shouldbeusedtoprevent thecon- Fig. 3. 8) 6) 5) Lubricate thepistonpinbefore Lubricate assembling. For assembly ofthepistonandconnectingrod, Take (seegercirclips), ring, outthesecuring Place awirearoundthebig-endofcon- MAN Diesel Working Card Page 2(2) 92.08 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 01.16 -ES0 08028-0D/H5250/94.08.12 Working Card Page 1(4) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data Hour 1/2 Capacity : : 1 Working time man Man power 606-01.20 606-01.05 connecting rod Mounting ofpistonand Related procedure connecting rod Piston hasbeendismantletfrom position Starting grooves. andring scraper ring ring, Cleaning andinspectionofpiston. Controlofpiston Description Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions Piston (withﬂ ame ring) lt o tmn Qty. / Itemno Plateno Replacement andwearingparts scraper etc. Tools for cleaningofpiston,steelbrush, Hand tools 16 15 Note. 13 62006 62006 Itemno 62006 Plateno Special tools L+V28/32H 606-01.10 Edition 09H L+V28/32H 606-01.10 Edition 09H blow-by orbroken rings. deformation whichmightcause result inpermanent must notbeused,asthiswouldthe sameprinciple Straps toexpand on gaportools working thering shouldbeused. the rings openerwhichpreventsring localover stressingof again, andfor allmountingofrings, onlythespecial For removal ofpistonrings, whicharetobeused Removal ofPistonRing Piston (withﬂ ame ring) Inspection ofPiston 4) 3) 2) 1) Clean and examine the piston rings to determine Cleanandexamine todetermine thepistonrings for wear, seepage3. grooves andscraper ring Inspect thepistonring Clean thepistonoutsideandinside. if reuseisacceptable, seepage 3. Remove thepistonandscraper rings. MAN Diesel Working Card Page 2(4) 01.16 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 01.16 -ES0 08028-0D/H5250/94.08.12 Working Card Page 3(4) Fig 1 Wear limitsfor grooves ring The pistonhastobescrapped if: Thecylinder linermust behonedaccording - Thepistonandscraperringmust beex- - Note: Ateach pistonoverhaul: Theclearance between thenew piston/scraper B) or Thewear limitonthetestingmandrelisex A) scrapped. limits areex mandrel isexceeded, thespecifi onthetesting If thewear limit(2mmmark) A) Testing Mandrelfor RingGrooves Wear limitline. to theinstructions. changed. groove andring ring isexceeded, seefi g 1B. ed, seefi g 1A ce ed with thenominalsize. The handleismarked ed, andthepistonmust be Piston (withfl ed max. ed wear ceed- ame ring) limit for grooves ring Table 1Nominalsize, new groove ring tolerance andwear B) ClearanceRing/Groove Scraper ring Piston ring Piston ring Piston ring no 3 no 2 no 1 Piston andoil Nominal scraper ring. ring and ring groove: andring ring 0.45mm. between new pistonring/scraper clearanceMaximum vertical 4.95 mm 5.0 mm 5.0 mm 8.0 mm New New New New size. 8.0 mm 5.0 mm 5.0 mm 5.0 mm 0.45 Tolerances. New ring grooves. +0.10 +0.12 +0.12 +0.14 +0.12 +0.14 +0.16 +0.18 Max. wear limit. Ring grooves. L+V28/32H 8.43 mm 5.43 mm 5.43 mm 5.43 mm 606-01.10 Edition 09H L+V28/32H 606-01.10 Edition 09H production codes. Note: Identifi tofacecation marks upwards againstthepistoncrown whenmounted. Marking ofPistonandScraperRings Position ofPistonandScraperRings mayThe marking includeotherfi gures thanmentionedabove, for and instancetrade mark Piston (withfl Marking or "0950". no "top1600381-8" marked withident. Piston RingNo3: or "1242". no "top1619394-4" marked withident. Piston RingNo2: or "1242". no "top1619394-4" marked withident. Piston RingNo1: or "0121". no "top1600387-9" marked withident. Scraper ring: ame ring) MAN Diesel Working Card Page 4(4) 01.16 -ES0

08028-0D/H5250/94.08.12 97.24 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(4) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/2 Capacity : : 1 Working time man Man power: 606-01.20 connecting rod, Mounting ofpistonand 606-01.05 Related procedure: dismantlet frompiston, Connecting rodhasbeen position: Starting connecting rod. Cleaning, inspectionandtestmeasurementof Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stoppedengine Safety precautions: Connecting Rod lt o Ie o Qty. / Itemno. Plate no. Replacement andwearingparts: Feeler gauge0,15-0,20mm. Inside micrometer(242mm). Hand tools: 140-760 Nm Note. 28 62006 Itemno. Plateno. Special tools: L/V28/32H 606-01.15 Edition 04H L/V28/32H 606-01.15 Edition 04H screw headsisinspectedfor seizureandpittings. bottom positionby hand. The contactsurface ofthe must confi in thethreadedholes connectingrod. The test The threadsareinspectedfor seizuresandtested ed. The connectingrodscrews aretobecarefullyclean- the engine. including new bea be rejected,andanew connectingrodassembly In caseofdamagetheserration, reusemust by gentleand carefullocaltreatmentwithafi le. causedbySingle dentmarks impactcanberectifi therefore behandledwithcare. Note ! andoverhaul dismounting,transport work. during capcanbedamagedbybearing improperhandling The serration ontheconnectingrodand a fi le. be gentlysmoothedby careful,localtreatmentwith Single distinctlyraised spotscausedby pittingshould ceable atafi fi ngernail. Pittingsarenotonlyvisible but also noti- Wear arevisible marks but notappreciable ata "Connecting RodInspection". Seepage4. damagesshouldberegisteredintheschem Observed or even cracks in highlyloadedzones. show damagesinform andpittings ofwear marks relative movements between themating surfaces, The serration ontheconnectingrodmay, dueto The serrated jointfaces areinspected. air. withworking dry are tobedegreased withavolatile solvent andblown The serrated jointfaces andthreadedscrew holes surfaces. The connectingrodiscleanedonallmachined Cleaning andInspectionofBig-endBore. capmust The connectingrodandbearing into thatthescrews can beturned rm, ngernail. ring shellsmust bemountedin ring Connecting Rod ed Fig. 1. Point ofmeasurement Measurement ofBig-endBore. must berenewed. intothethreaded holes by hand, cannot beturned Screws, whicharedamagedasmentionedabove or "Con seefi of theboring, Five different diametersaremeasuredinthemiddle meter. isexecutedThe measuring withaninsidemicro- centerline. Seefi g. 1. Measurements cap,bearing Note ! 606-01.25. torque, card up withtheprescribed seeworking shells, andtheconnectingrodscrews aretightened capbut is mountedwiththebearing withoutbearing measured inacondition,wheretheconnectingrod For check ofroundnessthebig-endborehastobe page 600.35. measured. For maximum allowable ovalness see ference between biggestandsmallestdiamenter The maximum ovalnees iscalculatedasthedif- nec The identno. ontheconnectingrodand ting RodInspection". Seepage 4. A

must x x must C C ofserration D L g. 1andregistered inthescheme always bethesame, seeﬁ g. 3. betaken 30 mmfromseration

B x x MAN Diesel C 30 mm Working Card Page 2(4) 97.24 -ES0S

08028-0D/H5250/94.08.12 97.24 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(4) rejected. 0,125 mmandtherefore theconnectingrod is being For connectingrodno. 2 themaximum ovalness is 0,07 mmandreusethusacceptable. For connectingrodno. 1 themaximum ovalness is MAN B&WDieselA/S, Holeby for overhaul). specifi ed maximum ovalness isexceeded, contact scheme "ConnectingRodInspection",(Incasethe da The example, seefi g. 2shows measurementsand Fig. 2. "Connectingrodinspection". mounted intheengine. ding new screws andnew shellshastobe bearing rejected andanew completeconnectingrod,in If theovalness exceeds thisvalue, reusemust be ma ge observations forge observations two connectingrods, onthe ob tobe rejected reused tobe 12,5 +3,5 7,0 +5,5 +3,0 -5,0 +5,0 -7,0 -1,5 -3,0 -2,0 -0,5 Connecting Rod clu- Fig. 3. bearing, see working card606-01.16. seeworking bearing, forCriteria replacementofconnectingrodbig-end Bearing Shellsfor Big-end. MAN B&WDieselA/S, Holeby for replacement. In casethespecifi and bush, seepage600.35. piston pinandbush, max. clearance between pin ting rodbush. Measuretheclearance between the Inspect thesurface ofthepistonpinandcon Connecting RodBush. and identifi fication, shouldalsobeproperly lled in. Please notethatsquaresfor statementofinformation Ident no. Connecting rod ed clearance isexceeded, con L/V28/32H 606-01.15 Edition 04H nec- tact L/V28/32H 606-01.15 Edition 04H Connecting Rod MAN Diesel Working Card Page 4(4) 97.24 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 96.41 -ES0S 08028-0D/H5250/94.08.12 Working Card Page 1(8) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/4 Capacity : : 1 Working time 610-01.10 man 610-01.05 Man power: 610-01.10 610-01.05 Guide bearing, 606-01.20and606-01.30 Main bearing, Big-end bearing, shells: Mounting afbearing Related procedure: Guide bearing, Main bearing, 606-01.00and606-01.30 or Big-end bearing, shellsremovedBearing fromengine: position: Starting shells.Inspection ofbearing Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Connecting RodBig-endandMainBearingShells Criteria for Replacementof lt o Ie o Qty. / Itemno. Plateno. Replacement andwearingparts: Magnifi(x30). er Hand tools: Note. 55 Itemno. 62006 Plateno. Special tools: L+V28/32H 606-01.16 Edition 02H L+V28/32H 606-01.16 Edition 02H metal, seefi g. 1. 75 %galvanic overlay and approx. 25%light-alloy surfaceA new shellhasarunning bearing withapprox. e failures, thecauseoffailure must befound and ed, ofcourse, andinordertoavoid bearing further In thesecases, shellsmust beex thebearing inthispaper.are notdescribed Overloading, overheating a.s.o. - Corrosion - oil. inthelubricating particles Cavitation. - surface oftherunning Scoring duetoforeign - di damagescausedby con- Bearing incorrectrunning ope normal when wear appearsontherun shells the connectingrodbig-endandmainbearing This papergives information abouttheevaluation of Fig. 1. Runningsurface shell. ofthebearing li tions, like mi na ted. ra ra ting conditions. Connecting RodBig-endandMainBearingShells ning surface under Criteria for Replacementof (max.5%) Nickel strike (~25%) Light metal (~75%) Overlay chang- negative infl withoutany emptyslotscanrun withpartly bearings overlay ismissingintheslots. Practice hasshown, that ofthe canalsooperate althoughpart The bearing wear ofthebearing. for the determining areaareimportant of theworn and thewidthofslotaswell asthedimension The ratio between thewidthoflight-alloy metal metal asthelightarea. lay areaandthelight-alloy canbeseenasthedark withamagnifi determined The gravity surface’s oftherunning wear must be almost constant,i.e. ap the light-alloy metalandtheoverlay wear isby further re in thesoftoverlay, wheretheoverlay intheslotsis primarily Wear surface running ofthebearings starts conditions, thelowest possible limitsarevalid. In caseofacombinationtheabove mentioned 5. overlay 4. 1. into 5groups: The valuation shellconditionisdivided ofthe bearing as comparison. the overlay ataminorstressedareamust beused shell, the conditionofthebearing By determining 3. 2. duced ap Empty slots. breakageonthe Limitingcase-permanent Limitingcase-locallevelling Limitingcase-wear Re-use prox. 0.001mm. The difference between uence ontheoperation ofthebea prox. 0.005mm. er (x30),hereby theover- MAN Diesel Working Card Page 2(8) ring. 96.41 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel MAN Diesel MAN Diesel L+V28/32H 606-01.16 Edition 02H Fig. 10. shown inﬁ Condition LimitCase-Levelling 3. Fig. 11. g.10. : The slotsarelocallytotallylevelled as a.5mm o 5 width max. of 10% max. Connecting RodBig-endandMainBearingShells Criteria for Replacementof r Fig. 12. exceeded shellsmust beexchanged. thebearing Valuation : Ifthelimitsshown inﬁ a.1%o width of 10% max. g. 11and12are max. 5%

of extent MAN Diesel Working Card Page 6(8) 96.41 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel L+V28/32H 606-01.16 Edition 02H Fig. 17. slots, seeﬁ g. 17. Condition LimitCase-EmptySlots 5. Fig. 18. a.3%o width of 30% max. : Insomeareasthereisnooverlay inthe Connecting RodBig-endandMainBearingShells

max. 15% of extent Criteria for Replacementof Fig. 19. ex ex and 19,areex Valuation chang ed. : Ifthelimitsshown inthebelow ﬁ ceeded, the bearing shellsmust be ceeded, thebearing a.5mm or 5 width max. of 10% max. MAN Diesel Working Card Page 8(8) g 18 g. 96.41 -ES0S

08028-0D/H5250/94.08.12 91.49 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(4) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hours 11/2 Capacity : : 2 Working time men Man power: 605-01.40 Mounting ofcylinderhead, Tightening ofconnectingrodscrews, Related procedure: card606-01.35. is OK,seeworking positionandthecylinderliner intheright turned Piston mountedontheconnectingrod,crank-shaft position: Starting after overhaul and/orinspection. Mounting ofpistonandconnectingrodassembly, Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Assembling ofPistonandConnectingRod 606-01.25 661 2 1/cyl. 1/cyl. 1/cyl. 1/cyl. 12 11 10 Qty./ 60601 09 60601 60601 60601 Itemno. Plate no. Replacement andwearingparts: oil. Clean lubricating Open endspanner32mm. Hand tools: 22 13 11 62006 03 62006 Note. 01 62006 62006 62006 Itemno. Plateno. Special tools: 606-01.20 L28/32H Edition 01H 606-01.20 L28/32H Edition 01H ing. low further during andcylinderlinerskirt journal allowing theconnectingrodtogoclearofbothcrank Fig. 1. of theassembly. thesubsequentlowering to minimize during friction oilinorder withcleanlubricating and scraper ring, piston,pistonrings stop thelowering, coatguidering, liner, seefi ontopofthecylinder place thepistonguidering 3) card606-01.10. and working mount thepistonandscraper rings, seepoint14, shackle andwireropeonthepiston. 1) 5) 4) 2) Make surethatthecrank throw isinaposition Liftupthepistonandconnectingrod When the piston approaches the guide ring, When thepistonapproachesguidering, Remove thebackstop for cylinderlinerand Mount theliftingdevice eye comprising screw, g.1. Assembling ofPistonandConnectingRod er- Fig. 2. of thebig-endbearing. molycote pastaorsimilarandmounttheuppershell shells(ainfi ends ofthebearing mountingprocedure. further TDC willensurethisandalsobesuitable for the A crank throw positionofapprox 50degrees before journal, seefi journal, hand toensurecorrectapproach andlandingonthe thistheconnectingrodmust beguidedbyDuring into correctlandingonthejournal. 8) oil. 6) 7) Lower the piston further down, the Lower lubricate thepistonfurther Now lower thepistonandconnectingrodslow withcleanlubricating Coatthecrank journal g.3. a g. 2)withcopaslip, a MAN Diesel Working Card Page 2(4) 91.49 -ES0S ly

08028-0D/H5250/94.08.12 91.49 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(4) Fig. 4. cap,bearing must always bethesame, seefi g. 4. Note ! Fig. 3. The identno. onthe connectingrodandonthe Con. Rod-IdentNo. Assembling ofPistonandConnectingRod socalled piston ring opener.socalled pistonring fi tted tothepistonby theuseofaspecialtool, 14) Fitting ofPistonandScraperRings. card 606-01.25. Procedure for ConnectingRodScrews", seework 13) Fig. 5. screw/shackle fromthepiston. 12) using anopenendspanner. 11) similar. necting rodscrews withcopaslip, molycotepastaor 10) 4. usingthe guidepin,seefi of thebig-endbearing, 9) Mount the bearing cap with inserted lower shell capwithinserted Mountthebearing Piston rings shouldonlyberemoved Pistonrings fromand Mountthescrews andtightenthemslightly threadsandcontactface Lubricate ofthecon- Tighten thescrews according to"Tightening Slacken thetackle anddismounttheeye 606-01.20 L28/32H Edition 01H ing g. 606-01.20 L28/32H Edition 01H the ring joints,the ring facing upwords. ca shouldbeinstalledwiththeiden The pistonrings surface.to thecylinderinnerrunning andwillnotconfi distorted become permanently ofoverstressing,is arisk will whichmeans thatrings there thannecessary areopenedfurther If therings Fig. 6. tion mark, which is stamped into the ring closeto whichisstampedintothering tion mark, coil spring Joint pinfor Assembling ofPistonandConnectingRod ced opposite to ring joint ced oppositetoring jointtobepla- Coil spring Ring joint rm ti fi - setting the ring joint180°toeachother.setting thering intopositionsoff- shouldbeturned the pistonrings To prevent joints gasleakagethroughcoincidingring can bemoved alltheway round. Adequate clearance ispresentofthefeeler gauge and groove. a feeler gaugeofadequatethickness between ring that they canmove freely. Itisalsoadvisable toinsert pushed back inthegrooves andforth tomake sure shouldbe When installedonthepiston,rings ispressedagainstthebottomofgroove.ring face isbelow ofthering thegroove edge, whenthe clearance.The back clearance issuffi correctassembling by checkingAscertain the back te groove insuchaway jointisap thatthering groovein thering isfi thenthescraper ring the jointpin. isplacedandassembledThe coilspring by isdismantledfromthering removalcoil spring of Before fi the loadedscraper ring, tting thecoilspring ly 180° offset to the spring joint. ly 180°offsettothespring ent whenthe MAN Diesel tted inthe prox Working Card Page 4(4) 91.49 -ES0S i ma-

08028-0D/H5250/94.08.12 97.43 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/2 Capacity : : 2 Working time men Man Power: Related Procedure: cap preassembled. shellsandbearing Piston, connectingrod,bearing Position:Starting condition. Check ofconnectingrodscrews, tightening screws. Tightening procedurefor connectingrod Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety Precautions: Hydraulic Tightening ofConnectingRodScrews

606-01.20 lt o tmN Qty./ ItemNo PlateNo Replacement and Wearing Parts: Hand Tools: Note 62021 ItemNo PlateNo Special Tools: L+V28/32H 606-01.25 Edition 04H L+V28/32H 606-01.25 Edition 04H Please see Working Card 620-01.10 Note: it fromthescrews. 11) be tightenedthenrepeatthepoints7,8and9. 10) to remove tensionsinthescrews, ifany. Note: 8) pos 6. 600.40, screws simultaneously). 6) see Working Card620-01.05 cylinder before addingpressuretothetool. Please adjust thedistancebetween the pistonandthe Be aware ofthemax. liftingheigtofthetooland 3) withthenuts,lower pos. part 4. rod by hand. 9) 7) 5) 4) 2) 1) Tightenthenuts again. Addthehydraulic pressuretothetool. Relieve thehydraulic pressureonthetool. hydraulic Addtheprescribed pressure, (toboth Connectthetooltohydraulic tool. Mountthehydraulic tool,pos. 5. Tightenthenuts by hand. Relieve thepressureontoolandremove Iftherestillisadistanceandthenuts stillcan General instruction abouthydraulic General instruction tightening. Mount the lower part pos.Mount thelower part 2andfasten the Tighten thescrew pos. 3hometotheconnecting The Points 7to9are tobefollowed inorder andtightenthescrews by usingahandle, Hydraulic Tightening ofConnectingRodScrews Please see Description PleaseseeDescription Fig. 1 3 1 4 2 MAN Diesel 5 Working Card Edition 2(2) 6 97.43 -ES0S

08028-0D/H5250/94.08.12 91.22 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(3) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hours 11/2 Capacity : : 1 606-01.25 Working time man Man power: 606-01.16 rod screws, Tightening andcheck ofconnecting big-end bearing Inspection ofconnectingrod Related procedure: 614-01.00 Top cover for cylinder headremoved. Crankcase open. Fuel injectordismounted, position: Starting moun-ting. dismountingand necting rodbig-endbearing, In-situ inspectionand/orreplacementofcon- Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: In-situ InspectionofConnectingRodBig-endBearing lt o Ie o Qty. / Itemno. Plate no. Replacement andwearingparts: Open endspanner32mm. Hand tools: 140-760Nm rod screw, card620-01.20. seeworking 28 Tool combinationfor tighteningofconnecting 22 62006 Note. 07 62006 62006 Itemno. Plateno. Special tools: 606-01.30 L28/32H Edition 01H 606-01.30 L28/32H Edition 01H means ofatackle itisslightlytightened. the threadholeinpiston,seefi through thefuelinjectorsleeve andisscrewed into the especiallylongeye boltismounted. Itisinserted Fig. 1. dismounted, seefi g. 1. thus allowing captobe theconnectingrodbearing untilthe piston inaposition the crankshaft isturned sen po Dismounting. and connectingrodassembly fromtheengine. replaced in-situi.e. withoutdismountingthepiston shellscanbe inspectedand/or The big-endbearing 2) 1) si Before removing cap, connectingrodbearing ed. Having loosenedtheconnectingrodscrews, tion allowing theconnectingrodscrews tobelo- The crankshaft of the engine is turned intoa The crankshaft oftheengineisturned In-situ InspectionofConnectingRodBig-endBearing g. 2. Then by Fig. 2. dismounting of the upper bearing shell,seefidismounting oftheupperbearing g. 3. thanjusttoallow ting rodshouldnotbeliftedfurther journal.rod isliftedfromthebearing Piston/connec- shell have beendismounted, thepiston/connecting guide pin. mount shellaredis- capandbearing necting rodbearing 4) 3) Having tightenedthetackle slightly, thecon- When connecting rod bearing cap and bearing capandbearing When connectingrodbearing ed, see working card606-01.00,fored, seeworking useof MAN Diesel Working Card Page 2(3) 91.22 -ES0S

08028-0D/H5250/94.08.12 91.22 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(3) into correctlandingonthe journal. lower thepistonandconnecting rodassembly slowly 3) a positionofapprox 50degrees before TDC. cap respectively. contact surface oftheconnectingrod,bearing contact surfaces oftheshells tobeinparallel tothe 1) Note: components must becleaned. Before remountingofinspectedornew all bearing, Mounting. card 606-01.16 Fig. 3. 2) 5) Coat the journal with clean lubricating oiland withcleanlubricating Coatthejournal thatthecrank isin throw concerned Ascertain The bearing shellisplacedinthebore,The bearing the For shell,seeworking inspectionofbearing See also working card606-01.20. See alsoworking In-situ InspectionofConnectingRodBig-endBearing card 606-01.25. Procedure for ConnectingRodScrew", seeworking 8) from thepistoncrown. using anopen-endspanner. necting rodscrews withcopasliporsimilar. shell,usingtheguidepin. big-end bearing seefi the journal, by handtoensurecorrectapproachandlandingon While lowering theconnectingrod,itmust beguided Fig. 4. 7) 6) 5) 4) Tightenthescrews accordingto"Tightening Mountthescrews andtightenthemslightly threadsandcontactface Lubricate ofthecon- lower capwithinserted Mountthebearing Slacken thetackle anddismounttheeye screw g.4. 606-01.30 L28/32H Edition 01H 05.28 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(4) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/2 Capacity : : 1 Working time man Man power: 606-01.45 606-01.20 606-01.40 head andcylinderliner, ofsealfaceGrinding oncylinder 606-01.00 Replacement ofcylinderliner, connecting rod, Mounting ofpistonand Related procedure: removed, Piston andconnectingrodis position: Starting ning brush. Inspection andhoningofcylinderlinerwithho- Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Inspection andHoningofCylinderLiner lt o Ie o Qty./ Itemno. Plate no. Replacement andwearingparts: Gas oil. Honing oil. machine60-180rpm. Drilling Hand tools: Extra tools Extra tools Extra tools 60 51 Note. 50 62006 62006 62006 Itemno. Plateno. Special tools: L+V28/32H 606-01.35 Edition 08H L+V28/32H 606-01.35 Edition 08H Fig. 1. nel. engine frame andby theuseofbelongingfun- orwithlinermountedinthe liner intheworkshop ex-changed. con-ditions, thecylinderlinerinquestionshouldbe too troublesome tomaintain satisfactory service indicated onpage600.35,i.e. whenitbecomes When thewear ofacylinderlinerexceeds thevalue has theapproximately same temperature astheliner. transverse aswell asinlongitudinal direction. The renovation canbemadeeitherwithdismantled Honing theCylinderLiner. take tool When measuring, carethatthemeasuring betaken in The measurementsshouldnormally cylinder liner, seefi g. 1. halfwaypiston ring, down andatthebottomof pointsat with measuring TDC-position for up ments aretaken by meansofaninsidemicrometer, latter ismeasuredtorecordthewear. The mea While thepistonisremoved fromthecylinder, the Measurement ofCylinderDiameter. Inspection andHoningofCylinderLiner per per sure- most Fig. 2. piston ring. always mountedinthecylinderwhenreplacinga used fl outthehoningprocess. carrying the fl fl hastobecleanedinwater.ame ring Subsequently, 80 and 160 rpm ischosen. 80 and160rpm fi ness grains 80-120. Arevolution speedbetween by scraping. wear edgesinthetopoflinermust beremoved Note: After thehoningprocesshastaken placethe If thecylinderisoffl The honingismadeby meansofafl Prior tothehoning,depositsofcokePrior andpossible isremountedinthecylinderbeforeame ring isdiscarded.ame ring Anew fl is ame ring 80-160 rpm. type,ame ring theused ex-honer with ex-honer MAN Diesel Working Card Page 2(4) 05.28

08028-0D/H5250/94.08.12 MAN Diesel 05.28 08028-0D/H5250/94.08.12 Working Card page 3(4) have beenremoved. gas oil,andmake surethatallabrasive particles with honingoilorcuttingoil. of glaze . has aslightmattappearance andwithoutany signs wall iscovered by honinggrooves andthesurface lead frombelow upanddown in2sec.) 2 sec. for onedouble movement (theﬂ justed toabout1m/sec. whichcorresponds toabout honing grooves, seeﬁ After thehoning,lineriscarefullycleanedwith freely tolubricate thehoningitisimportant During The procedureistobecontinued untilthecylinder In ordertoachieve therequiredanglebetween the g. speedisad- 2,thevertical Inspection andHoningofCylinderLiner ex honeris Fig. 3. L+V28/32H 606-01.35 60° Edition 08H L+V28/32H 606-01.35 Edition 08H ae Sign.: Date: Plant/ship: Measurements ofCylinder Liner

iiu 200 2 2 1 3 9 3 2 280.0 1 280.60 7 1 3 3 2 1 6 Maximum 280H8 3 Minimum 2 25°CNom. 1 diameter 5 Tem. 3 of cyl. liner 2 1 4 3 2 1 3 3 2 1 2 D C B 3 2 A 1 Pos. cSt no. 1 Separator:Fuel: Yes Running hours: 2 2 8 Inspection andHoningofCylinderLiner Cyl. Engine Type: A-side Engine No.: B-side MAN Diesel Working Card Page 4(4) 05.28

08028-0D/H5250/94.08.12 91.22 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(3) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Hours Data: 2 Capacity : : 2 Working time men Man power: 606-01.20 606-01.45 head andcylinderliner, ofsealfaceGrinding oncylinder connecting rod, Mountingofpistonand Related procedure: 01.00. card605-01.00and606- mantled,working Cylinder headandpiston/connectingroddis- position: Starting guide jacket. Dismounting andmountingofcoolingwater Replacement ofcylinderliner. Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Replacement ofCylinderLiner 660 1 2/cyl. 2/cyl. 12/cyl. 1/cyl. 11 See alsoplate60610. 08 07 Qty. 60610 / 04 60610 60610 60610 Itemno. Plate no. Replacement andwearingparts: Adjustable spanner. Allen key, 8mm. Hand tools: Note. 45 62006 Itemno. Plateno. Special tools: L/V28/32H 606-01.40 Edition 01H L/V28/32H 606-01.40 Edition 01H copper protectingpiecesofthecrossbar. the upperedgeoflinerliealignedagainst Fig. 1. of aposible remountingoftheliner, seeﬁ g. 1. and frame have beenmarked tomatch,for thesake ting fromtheframe, itmust beensuredthattheliner Dismounting ofCylinderLiner. 4) 3) 2) 1) Turn theliftingeye nut topullouttheliner, until Mount theliftingtoolasshown, seeﬁ g. 2. Prior tomountingoftheliftingtoolanddis Prior Dismount thecoolingwater guidejacket. Hole for rollerguidehouse Marking scratch frameMarking Hole for chargingair Marking scratch liner Marking Replacement ofCylinderLiner moun- of cylinderliner, card606-02.00. seeworking wear, accordingtothedescription. For mea frame andstanditcarefulontowooden supports. and thecrossbar, andliftthelineroutfromengine Fig. 2. 6) 5) Clean all parts andinspectfor damageand Cleanallparts Attachatackle hooktotheeye nut orthewire L28/32H V28/32H MAN Diesel su Working Card re Page 2(3) ment 91.22 -ES0S

08028-0D/H5250/94.08.12 91.22 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(3) 10) sealing ontopoftheframe. withalittleoil. andlubricate the o-rings Placeanew liner. the eye nut ortothewireincrossbarandlift cylinder liner, are perfectly andsealingrings clean. Mounting ofCylinderLiner. Fit anew andmountthejacket. sealingring water connectionsand changeairconnections. ing water jacket, mountnew onthecooling o-rings 11) frame controlside(ifmounted). fl ange coinsidewiththefi or alignthelinersothatmillinggroove intheliner ontheframepoints tothescratch asillustrated, mark onthelinerfl the linersothatscratch mark When thefi frame. 9) 8) 7) Check grooves thattheo-ring areclean. Mount Mounttheliftingtool,attachatackle hookto Lower thecylinderlinercarefullyintoen Afterhaving cleanedandinspectedthecool- Check thatthesealingsurfaces onengine, rst o-ring touchesthesealingface,rst o-ring align xing pieceontheengine Replacement ofCylinderLiner ange gine gine Fig. 3. hole intheframe, seefi g. 3. leakages ofwater andoil,includingtheinspection 13) and 605-01.40. card606-01.20 cylinder headaccordingtoworking ment seepage600.40),piston/connectingrodand 12) hole Inspection When preparing the start-up, check thestart-up, Whenpreparing for possible Mount thecoolingwater jacket, (for torquemo- L/V28/32H 606-01.40 Edition 01H MAN Diesel 91.45 -ES0S 08028-0D/H5250/94.08.12 Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Hour Data: 1 Capacity : : 1 Working time man Man power: 605-01.40 605-01.00 Mounting ofcylinderhead, Related procedure: Cooling water guidejacket, removed. from theengine, Cylinder headhasbeenremoved position: Starting pasta. head by toolsandgrinding hand,withgrinding ofsealfaceGrinding oncylinderlinerand Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Cylinder LinerandHead. Grinding ofSealFace on 660 8 1/cyl. Qty. / 08 60610 Itemno. Plate no. Replacement andwearingparts: pasta. Grinding Hand tools: Note. 20 62005 Itemno. Plateno. Special tools: L/V28/32H 606-01.45 Edition 01H L/V28/32H 606-01.45 Edition 01H to distribute evenly. from timetotime, toallow compound thegrinding To doso, move thetoolback andliftitout andforth Fig. 2. tool. the grinding head, seefi fl ange, see fi it out. Grinding. Fig. 1. on thecylinderhead(2),seefi g. 1. groove inthelinerfl Note: 2) 1) Face-grind sealinggroove incylinderliner inlinerfl Loosenthesealingring The grinding toolisusedforThe grinding the bothgrinding g. 3. pastaand With theuseofgrinding g. 2andsealingsurface onthecylinder ange (1) andtheseatingsurface Cylinder LinerandHead Grinding ofSealFace on ange andtake Fig. 4. than 0,5mm,seefi g. 4. between measurementsyandzmust notbeless liner isnolessthan0,5mm,thatis, thedifference thatthegapbetweenbe observed cylinderheadand 4) compound. and grinding 3) Fig. 3. Whenhaving ground thecontact faces, itmust remove Aftergrinding, alltraces ofabrasive y -z=0,5mm,min. MAN Diesel Working Card Page 2(2) 91.45 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 94.38 -ES0S-G 08028-0D/H5250/94.08.12 Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hours 2½ Capacity : : 2 Working time men Manpower: Inspection andhoningofcylinderliner. Separation ofpistonandconnectingrod. Related procedure: Crankcase open. engine. Cylinder headhasbeendismountingfromthe position: Starting liner for inspectionand/oroverhaul. Dismounting ofpiston,connectingrodandcylinder Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Dismounting ofPistonandCylinderLiner at Low OverhaulHeights lt o tmn Qty/ Itemno Plateno Replacement andwearingparts: 620-01.20 Feeler gauge0,15-0,20mm. Inside micrometer(195mm). Hand tools: If necessary rod screw, 01 Tool combinationfor dismountingofconncting 65 2 28 62010 pieces 24 62006 22 62006 09 62006 05 Note 62006 62006 62006 Itemno 62050 Plateno Special tools: L+V28/32H 606-01.50 Edition 01H L+V28/32H 606-01.50 Edition 01H Heights. Dismantling ofPistonatLow Overhaul ing rodinonepiece. outtheconnectingrodby of thepull-lifts. piston andtheconnect- connectingrodby means sufﬁ cient topulloutthe Remove thepistonand The overhaul heightis the moveone piece. thepistonandpull Then and connectingrodin the connectingrod,re- too low topulloutpiston Dismountthepistonfrom The overhaul heightis If Mountpull-liftsonthecollar. 4) pull-lifts. Placethepistonwithcollaroncylinder 3) Mountcollarontheconnectingrod,seeplate 2) 1) Lift up the piston and the connecting rod through Liftupthepistonandconnecting rodthrough 1) liner. 62050, item1896. liner. the cylinderlineruntilpistonisclearof Dismounting ofPistonandCylinderLiner at Low OverhaulHeights ) Take outthelinerover thecamshaftside. 5) Attachpull-liftsontheliftingtoolfor thecylinder 4) Mountspecialliftingtoolfor cylinderlinersat 3) Carefullypullthecylinderlinerhalf-way outof 2) liftingtoolfor Mountnormal cylinderliners. 1) Heights. Dismantling ofCylinderLineratLow Overhaul liner, seeplate62050,item1895 1895. low overhaul heights, seeplate62050,item the frame. MAN Diesel Working Card Page 2(2) 94.38 -ES0S-G

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 60601-34H

L28/32H

07.01 - ES0 MAN Diesel

Plate 60601-34H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)

L28/32H

Item Item No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/C Piston pin incl. Stempelpind inkl. item No 02 pos. nr. 02

02 4/C Socket screw Kraterskrue

03 2/C Retaining ring Sikringsring

04 1/C Plug screw Propskrue

05 1/C Bush for Plejlstangs- connecting rod bøsning

06 1/C Connecting rod Plejlstang inkl. incl. item Nos pos. nr. 04, 05, 14, 15, 16 04, 05, 14, 15, 16

08 1/C Piston Stempel

09 1/C Piston ring Stempelring

10 1/C Piston ring Stempelring

11 1/C Piston ring Stempelring

12 1/C Oil scraper ring Olieskrabering

13 1/C Connecting rod Plejlstangs- bearing 2/2 leje 2/2

14 1/C Plug screw Propskrue

15 2/C Connecting rod stud Plejlstangsbolt

16 2/C Nut Møtrik

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

07.01 - ES0 MAN Diesel & Turbo

Plate Page 1 (2) Cylinder Liner and Water Guide Jacket 60610-09H

L28/32H

94.07 - ES0S MAN Diesel & Turbo

Plate 60610-09H Cylinder Liner and Water Guide Jacket Page 2 (2)

L28/32H Item Item No Qty. Designation Beskrivelse No Qty Designation Beskrivelse

01 2/C O-ring O-ring

02 1/C Sleeve Muffe

03 1/C Water guide Kølekappe jacket

04 1/C O-ring O-ring

05 6/C Sealing ring Tætningsring

06 6/C Plug screw Propskrue

07 12/C O-ring O-ring

08 1/C Sealing ring Tætningsring

09 6/C Cooling water Kølevands- connection overgang

10 1/C Cylinder liner Cylinderforing

11 2/C O-ring O-ring

12 4/C Hexagon screw Unbracoskrue

13 4/C Washer Skive

14 4/C Sleeve Foring

15 1/C Water guide jacket Kølekappe inkl. item nr. incl. item no. 05 and 05 og 06 06.

16 1/C Sealing ring Tætningsring

17 1/C Flame ring Flammering

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

94.07 - ES0S Camshaft

507/607 91.03 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) aftmost section. wheel connectionofgovernor arescrewed onthe wheel for thecamshaftaswell asagear driving thefueloilfeeddriving pump(ifmounted). The gear The foremost sectionisequippedwithaclutchfor sections areidenticalandtherefore interchange Except for theforemost andtheaftmostones, the journals. made fl by boltingoftheampledimensionedandpre valve andexhaust valve. The sectionsareassem cams for operation offuelinjectionpump, airinlet cylinder unit. Each sectionisequippedwithfi The camshaftisbuilt-up ofsections, onefor each means oflock screws. able andlocked inpositiontheengineframe by bores intheengineframe, isreplace- eachbearing bushes inbearing whicharefi and iscarried control side, (leftside, seenfromthefl The camshaftisplacedintheengineframe atthe half ofthatthecrankshaft, seefi wheel,androtatedby aspeedwhichis intermediate driven by agearwheelonthecrankshaft throughan valves, exhaust valves andfuelinjectionpumpsis The camshaftwhichcontrolstheactuationofinlet General ange connections, whichalsoactasbearing Camshaft andDrive g.1. ywheel end) ywheel tted in tted cision able. bled xed direction ofrotationtheengine. mesh. by The positionofthenozzlesisdetermined the oilatpointswheregearwheelsarein equipped withnozzleswhichareadjustedtoapply oilpipesforThe lubricating thegearwheelsare Fig. 1. wheel Intermediate Engine seenfromaft-fl y wheelend Clockwise rotationdirection L28/32H 607.01 Edition 05H 92.13 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Hours Data: 3 Capacity : 1 : Working time man Man power: Related procedure: position: Starting and lubricatingsystem. Checking ofgearwheels,boltedconnections Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: Camshaft andDrive 616 4 1/eng. 1/cyl. 1/cyl. 3/eng. 14 6/eng. 13 11 61106 24 Qty./ 61106 12 61106 60705 60705 Itemno. Plateno. Replacement andwearingparts: Socket spanner, 19mm. Ring andopenendspanner, 19mm. Allen key, 12mm. Hand tools: 20-120Nm. 26 Note. 62006 Itemno. Plateno. Special tools: L/V28/32H 607-01.00 Edition 01H MAN Diesel L/V28/32H 607-01.00 Edition 01H ma Examine allgearwheelsforcracks,wearandde gear wheels,camshaftandcrankcase. 1) torques, seepage600.40. check thattheyhavenotworkedloose.Tigh wheel housing,camshafthousingandcrank including lockingdeviceseverywhere inthegear tion alloverthecircumference ofthegearwheels. 2) tions. While turning theenginetoenablein tions. Whileturning Checkallscrews, nutsandboltedcon Dismount thecoverswhichgiveaccessto Camshaft andDrive nec case to te spec- tions, tions, ning for- at thepointswhere thewheels mesh. to checkthattheoiljethitsgearwheelscorrectly check theoilfl les. 4) 3) Examinealllubricatingoilspray pipenozz- Start theelectricallubricatingoilpumpand Start ow everywhere. Be particularly careow everywhere. Beparticularly Working Card Page 2(2) 92.13 -ES0U ful

08028-0D/H5250/94.08.12 01.51 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Hours Data 2 Capacity : 2 : Working time men Man power 607-01.00 Camshaft andcamshaftdrive, Related procedure removed. Cover forcamshaftandgearwheelhasbeen position Starting Replacement ofcamshaftbearing. shaft bearing. Check ofroller pathofcamsandcheckcam- Description Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions Inspection andReplacementofCamshaftBearing 675 1 1/cyl. 1/cyl. 1/eng. 21 03 Qty. / 01 60705 60705 ItemNo 60705 PlateNo Replacement andwearingparts Big screw driver. Feeler gauge. Socket spanner, 19mm. Ring andopenendspanner, 19mm. Hand tools 20-120Nm. 26 Note 62006 ItemNo PlateNo Special tools L+V28/32H 607-01.05 Edition 01H MAN Diesel L+V28/32H 607-01.05 Edition 01H free fl Check thelubricatingoilducts tothebearingfor the engineframe,seefi g. 1. andpushthebearingoutofboreconcerned in Take outthelocatingscrew ofthecamshaftbearing is free. far aheadthatthebearingwhichistobereplaced Pull thedisconnectedsectionsofcamshaftso card 608-01.00and608-01.05. forward ofthedisassemblingposition,seeworking replaced. Dismountallroller guidesthatare located aft (toward fl relation toeachother. Disassemblethecamshaft check thatthecamshaftsectionsare markedin Dismount thefueloilfeedpump,ifmountedand dismantled. or partly should bereplaced thecamshaftmustbewholly To ReplaceCamshaftBearing. gauge, seedatasheet600.35. The bearingclearanceismeasured withafeeler be discoloured, aswell. andinthatcasethebearingwillnodoubt journal, of whitemetalatthecircumference ofthecamshaft bearings willbecomeapparent ofburrs intheform cam ings cannotbecheckedwithoutdismountingthe To Check CamshaftBearings. 01.00. be replaced byanewone, seeworkingcard 608- of therollers maybeblocked,ifso,theroller must Note: the rollers oftheroller guides. cams forcracks,cracklesandruffl discs andinparticular, checktheroller path ofall To Check RollerPath ofCams. 3) 2) 1) Ifoneorseveralofthecamshaftbearings ofthecamshaftbear- Thewearingsurface theengine,examinecam Whileturning shaft. However, wearofoneormore ab-normal ow. ifthere are flat spots ontheroller andifsome y wheel) ofthebearingthatistobe Inspection andReplacementofCamshaftBearing e.Alsoexamine Fig. 1. pump. Mount allroller guidesaswell the fueloilfeed sheet 600.40. Tighten thenutswithatorque spanner, seedata Molycote orsimilar). Assemble thesectionsandfi coincide. position, makingsure that themarksonfl clean lubricatingoilandpushthecamshaftinto ofthecamshaftsectionwith Coat allthejournals must bepolished. removed from concerned theengine,andjournal If necessary, thecamshaftsectionmustbeentirely forseizures.Inspect thecamshaftjournal of thebearingitcanbecooleddownwithCo provided withanewgasket.To facilitatethefi ring bymeansofthelocatingscrew, whichistobe in thebearingisacorrect position.Lockthebea- sure ofthelocatingscrew thattheholeforinsertion Mount anewcamshaftbearinginthebore andmake Camshaft bearing Locating screw Hole forlubricatingoil t thebolts(coatedwith Frame Working Card anges Page 2(2) 2 tting . 01.51 -ES0

08028-0D/H5250/94.08.12 MAN Diesel & Turbo

Working Card 607-01.20 Page 1 (4) Adjustment of Camshaft for Valve and Injection Timing Edition 04H

L28/32H Tier II

Safety precautions Special tools

Stopped engine Plate no Item no Note Shut-off starting air Shut-off cooling water 62006 26 20 - 120 Nm. Shut-off fuel oil 62010 01 Shut-off cooling oil 62008 05 Stopped lub. oil circul.

Description

Adjustment of the injection timing.

Hand tools

Starting position Ring and open end spanner, 19 mm. Socket spanner, 19 mm. Depth gauge. Plastic hammer.

Related procedure

Manpower Replacement and wearing parts

Working time : 2-5 hours Plate no Item no Qty / Capacity : 1 man 60801 23 1 set/cyl Data:

Data for pressure and tolerance (Page 500.35) Data for torque moment (Page 500.40) Declaration of weight (Page 500.45)

11.37 - ES0 - Tier II MAN Diesel & Turbo

607-01.20 Working Card Edition 04H Adjustment of Camshaft for Valve and Injection Timing Page 2 (4)

L28/32H

Measure of fuel pump lead 4) Insert the dial gauge into the support.

1) Dismantle covers for fuel camshaft and fuel 5) Set the dial gauge to "Zero". pump and covers for gear whell 6) Turn the engine until the TDC mark (ignition 2) Check the mobility of the regulating device. DC) for the actual cylinder is reached. Turn engine to pos. cylinder No. 1 until the Read the dial gauge and note down the gauge cambase circle is reached (approx. 40° BTDC). value.

3) Position the support of the measuring tool on 7) Determine the values for the other cylinders in the two bolts of the camshaft covering. Slip on the same way. the distance sleeves and fasten to the cylinder crankcase by means of hexagon nuts. Calculate the average value of all measurements. Note: During attaching, pay attention to the correct fitting position of the contact point, see fig 1.

1. Contact point 2 Lever Fixing screws and discs of enclosing 2 cover used

Fig 1 Fitting position of the contact point.

11.37 - ES0 - Tier II MAN Diesel & Turbo

Working Card Adjustment of Camshaft for Valve and Injection Timing 607-01.20 Page 3 (4) Edition 04H

L28/32H

8) Compare the calculated value determined with the value mentioned below.

9) If the values exceeds the limits, an adjustment must be done in order to correct the errors, on the X-measure or reset the gear wheel, see following text for changing "X"-measuring.

Cyl. kW/Cyl. rpm Average value

5-6-7-8-9 210 720 See section 600, 5-6-7-8-9 220 750 Desription 600.35

Fig 2 Plunger lift (average value)

To get a consistent lifting values on the plunger/ combustion pressure on the different cylinders the "X"-measure can be changed. Fig 3 Gear wheel with engraved scale.

When changing “X” it must be ensured that the distance between the upper edge of the roller guide The gear wheel is provided with an engraved scale, housing and the thrust piece on the roller guide is not see fig 3, and the hub of the cam shaft is provided exceeded, when the roller is resting on the circular with a mark. part of the fuel cam, please see description 500.35. When the screws, which fasten the gear wheel, are In all cases “X” must be checked and adjusted, if loosened the gear wheel is turned (by turning the necessary, when fuel oil pump, roller guide, roller crankshaft) in relation to the camshaft. guide housing and/or camshaft section have been replaced/dismantled. If the crankshaft is turned in the engines normal direction of rotation the injection timin is retarded Note: If several fuel oil pumps, roller guides, roller (closer to TDC). guide housings and/or camshaft sections are dismantled at the same time it is advisable to number the If the crankshaft is turned against the engines normal parts in order to facilitate remounting and adjustment. direction of rotation the injection timing is advanced (away from TDC).

After the adjustment the screws are fastened with a torque wrench, please see description 500.40, and secured.

11.37 - ES0 - Tier II MAN Diesel & Turbo

607-01.20 Working Card Edition 04H Adjustment of Camshaft for Valve and Injection Timing Page 4 (4)

L28/32H

The injection timing can be altered on each cylinders Thicker and/or more shims (reduction of the distance by inserting or removing shims under the thrust piece “X”) results in an advanced injection. on the roller guide, thus changing the measure “X”, see Fig 4. If the distance “X” is to be changed the trigger (1) is used for dismantling of the thrust piece (2), where- Thinner and/or fewer shims (increase of the distance after the thickness and/or the number of shims (3) “X”) results in a retarded injection timing. can be changed.

After replacement of shims the thrust piece is re- mounted, see fig 5, in the roller guide (4) with a soft hammer (5). Measure "x"

1 5

1 2 2 3 2 Total height 3 3 4 4 4

1 Extractor 2 Thrust piece 3 Shims 4 Roller guide 5 Soft hammer

Fig 4 Measure "X" Fig 5 Remounting of thrust piece.

Action Results

Total height Distance Injection Max. combustion on roller guide "x" timing pressure

increased ↑ Reduced ↓ Advanced ↑ increased ↑

Reduced ↓ increased ↑ Delayed ↓ Reduced ↓

Fig 6

10) Remove the complete measuring tool.

11) Mount all camshaft covers.

12) Plunger lift value, please see description 500.35.

11.37 - ES0 - Tier II MAN Diesel

Plate Page 1 (2) Intermediate Wheel 60701-06H

L28/32H

01 13

03 15 11

12+ 05 08+

06.28 - ES0 MAN Diesel

Plate 60701-06H Intermediate Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 6/E Screw Skrue

02 6/E Lock plate Sikringsplade

03 3/E Gasket Pakning

04 1/E Union Vinkelforskruning

05 1/E Pipe Rør

06 1/E Union Vinkelforskruning

07 1/E Spray pipe Sprøjterør

08+ 3/E Fitted bolt Pasbolt

09 3/E Self locking Selvlåsende nut møtrik

10 1/E Cover Dæksel

11 1/E Gear wheel, Tandhjul, kompl. complete

12+ 1/E Axle journal Lejetap

13 4/E Self locking nut Selvlåsende møtrik

14 1/E Spur gear Tandhjul

15 1/E Spur gear Tandhjul

16 4/E Bolt Bolt

17 1/E Bearing bush Lejebøsning

+ Item No. 08 and + Item nr. 08 og 12 12 require an indivi- kræver en individuel dual matching, before tilpasning, før monte- mounting, contact ring kontakt MAN B&W, MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

06.28 - ES0 MAN Diesel

Plate Page 1 (2) Camshaft and Camshaft Bearing 60705-22H

L28/32H

11 06

05 19 06 07 08

01 20 02, 29, 32, 33, 34 26 03 27 03 28 14 29

15 21 22

16 29 29 29 29 14 5 cyl. 16 03 03 01 03 03 03 35 20 20 20 20 02 6 cyl. 03 03 03 03 01 03 03 03 36 26 26 26 26 26 32 23 7 cyl. 06 03 03 03 01 03 03 03 03 25 37 27 27 27 27 27 27 33 8 cyl. 03 03 03 03 01 03 03 03 03 38 28 28 28 28 28 28 28 34 9 cyl. 0303 03 03 01 03 03 03 03 03

06.43 - ES0 MAN Diesel

Plate 60705-22H Camshaft and Camshaft Bearing Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Camshaft bearing Styreakselleje 26 5/E Camshaft, Styreaksel, intermediate, mellem 02 1/E Camshaft section Styreakselssektion 7 cyl. engine 7 cyl. motor "aft", 6 cyl. engine "agter", 6 cyl. motor 27 6/E Camshaft, Styreaksel, 03 1/C Camshaft bearing Styreakselleje intermediate, mellem 8 cyl. engine 8 cyl. motor 04 1/E Hub Nav 28 7/E Camshaft, Styreaksel, 05 6/E Screw Skrue intermediate, mellem 9 cyl. engine 9 cyl. motor 06 24/E Disc spring Skivefjeder 29 4/E Camshaft section Styreakselsektion 07 1/E Guide ring Styrering "aft", 5 cyl. engine "agter", 5 cyl. motor

08 1/E Shaft pin Akseltap 32 1/E Camshaft section Styreakselssektion "aft", 7 cyl. engine "agter", 7 cyl. motor 11 12/E Screw Skrue 33 1/E Camshaft section Styreakselssektion 13 1/E Gear wheel Tandhjul "aft", 8 cyl. engine "agter", 8 cyl. motor

14 Self locking nut Selvlåsende møtrik 34 1/E Camshaft section Styreakselssektion 70/E 6 cyl. engine 6 cyl. motor "aft", 9 cyl. engine "agter", 9 cyl. motor 52/E 7 cyl. engine 7 cyl. motor 66/E 8 cyl. engine 8 cyl. motor 35 1/E Camshaft "Fore" Styreaksel "For" 92/E 9 cyl. engine 9 cyl. motor 6 cyl. engine 6 cyl. motor

Screw Skrue 36 1/E Camshaft "Fore" Styreaksel "For" 15 60/E 6 cyl. engine 6 cyl. motor 7 cyl. engine 7 cyl. motor 42/E 7 cyl. engine 7 cyl. motor 56/E 8 cyl. engine 8 cyl. motor 37 1/E Camshaft "Fore" Styreaksel "For" 82/E 9 cyl. engine 9 cyl. motor 8 cyl. engine 8 cyl. motor

16 1/E Camshaft "Fore" Styreaksel "For" 38 1/E Camshaft "Fore" Styreaksel "For" 5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor

19 10/E Screw Skrue

20 4/E Camshaft, Styreaksel, intermediate, mellem, 6 cyl. engine 6 cyl. motor

21 Gasket Pakning 7/E 6 cyl. engine 6 cyl. motor 8/E 7 cyl. engine 7 cyl. motor 9/E 8 cyl. engine 8 cyl. motor 10/E 9 cyl. engine 9 cyl. motor

22 Guide screw Styreskrue 7/E 6 cyl. engine 6 cyl. motor 8/E 7 cyl. engine 7 cyl. motor 9/E 8 cyl. engine 8 cyl. motor 10/E 9 cyl. engine 9 cyl. motor

23 1/E Coupling ﬂ ange Koblingssﬂ ange

25 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder Qty./E = Qty./Engine Antal/E = Antal/Motor

06.43 - ES0 Operating gear

508/608 MAN Diesel 91.13 -ES0S 08028-0D/H5250/94.08.12 Description Page 1(1) cylinder head. by socket aguide whichrestsinaspherical inthe shoeontherockerthrust andatthebottom arm iscontrolledby On itstopthebridge aspherical valve clearance. it isfi shoeandintheotherend with apressed-onthrust the valve spindlesandintheoneenditisprovided the two valve sets. isplacedbetween The bridge valve andspring-loaded toeachof arms bridges exhaust istransmitted viathepushrodsrocker The movment fromtherollerguidesfor inletand Operating Gearfor InletandExhaust Valves plate ofthefuelinjectionpump. which isfi The rollerispresseddown ontothecamby aspring, from therollerguide. the rollerguidehousingisactivated pieces viathrust The injectionpumpswhichismounteddirectlyon Operating Gearfor FuelInjectionPumps a lock screw. sed intotherollerguideandsecuredby meansof onabushThe rollerruns fi housing isboltedtotheengineframe. bores inacommonhousingfor eachcylinder, this fuel pump, inletandexhaust valves arelocatedin camshaft throughrollerguides. The rollerguidesfor and exhaust valves areoperated by thecams, onthe The fuelinjectionpumpsandtherocker for arms inlet Roller Guides screwtted withathrust for adjustmentofthe xed between therollerguideandfoot Operating Gearfor Valve andFuelInjectionPumps tted onapinthatispres- Fig. 1. Valve Operating Gear. Valve spindle av rdeRocker arm Valve bridge Protecting Tube Roller guide Roller guide Camshaft housing Roller Pin Valve spring Push rod L/V28/32H 608.01 Edition 12H MAN Diesel & Turbo

Working Card 608-01.00 Page 1 (2) Inspection of Valve Roller Guides Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62006 26 20 - 120 Nm Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description: Hand tools:

Dismounting, inspection and/or overhaul, and Ring and open end spanner, 19 mm. mounting of valve roller guides. Socket spanner, 19 mm. Inspection of roller guide housing. Socket spanner, 24 mm. Allen key, 3 mm. Ratchet spanner. Hammer. Starting position: Drift.

Top cover for cylinder head and cover for fuel injection pump removed.

Related procedure:

Inspection of fuel injection pump roller guide, 608-01.05 Control and adjusting of valve clearance, 608-01.10

Man power: Replacement and wearing parts:

Working time : 2 Hours Plate no. Item no. Qty. / Capacity : 1 man 60801 04 4/cyl. Data: 60801 08 2/cyl. 60801 09 1/cyl. Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) See also plate 60801. Declaration of weight (Page 600.45)

12.24 - ES0 MAN Diesel & Turbo

608-01.00 Working Card Edition 01H Inspection of Valve Roller Guides Page 2 (2)

L/V28/32H

Dismounting of Roller Guide. 5) Dismount the screws (3) which secure the roller guide top cover, take off the cover, and lift out 1) Turn the engine so that the roller, rests on the the roller guide (5). circular part of the cam. Disconnect any pipes that may be in the way (lub. 2) Unscrew the nuts which secure the rocket arm oil and fuel oil pipes). brackets, and lift off the rocker arm with brackets. 6) If the roller guide housing is to be dismantled, 3) Remove the push rods (1), see fig. 1. the fuel injection pump and the fuel injection pump roller guide are to be dismounted, see working card 614-01.05 and a number af lubricating oil and fuel oil pipes are also to be disconnected.

1 The roller guide housing (6) cannot be dismantled with the roller guides fitted.

7) If the event of any marks or scores from sezu- 2 res, these must be polished away.

8) Inspect the spherical stud for deformations 3 (replace as necessary).

4 Examine the surface of the roller for marks and other deformations. 6 Make sure that there is free rotation between the roller and the bush and the shaft pin, and replace the bush, if necessary.

5 Replacement of Roller, Bush and Shaft Pin.

9) Remove the lock screw which secures the roller guide shaft pin and push out the shaft pin.

The roller, shaft pin, and bush can now be replaced as required.

10) Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lubri cating grooves.

Mounting of Roller Guide.

Fig. 1. 11) When assembling the parts, which is carried out in the reverse order to the above care must be exercised not to damage the o-rings when mounting 4) Loosen the lock screw for the push rod pro the proctecting tube. tecting tube, see plate 60801, item 07, on the roller guide top cover and lift up and remove the protecting 12) Adjusting of valve clearance, see working card tube (2). 608-01.10.

12.24 - ES0 MAN Diesel & Turbo

Working Card 608-01.05 Page 1 (2) Inspection of Fuel Injection Pump Roller Guide Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description: Hand tools:

Dismounting, inspection and/or overhaul, and Allen key, 3mm. mounting af roller guide for fuel injection pump. Hammer. Drift.

Starting position:

Cover for fuel injection pump removed. Fuel injection pump has been removed, 614-01.05

Related procedure:

Adjustment and/or check of max. combustion pressure, 614-01.20

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./ Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

12.24 - ES0 MAN Diesel & Turbo

608-01.05 Working Card Edition 01H Inspection of Fuel Injection Pump Roller Guide Page 2 (2)

L/V28/32H

Dismounting of Roller Guide. 3) Inspect the spherical stud for deformations (replace as necessary). 1) Remove the support ring (1) and spring (2) and take up the roller guide (3), see fig. 1. Examani the surface of the roller for marks and other deformations.

Make sure that there is free rotation between the roller and the bush and the shaft pin, and replace the bush if necessary.

1 Replacement of Roller, Bush and Shaft Pin. 2 4) Remove the lock screw which secures the roller guide shaft pin and push out the shaft pin. 3 The roller, shaft pin, and bush can now be replaced as required.

5) Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lubri cating grooves.

Mounting of Roller Guide.

6) When assembling the parts which is carried out in the reverse order. Fig. 1. 7) For adaption of the thrust piece of the roller guide, see working card 614-01.20. Inspection of Roller Guide.

2) If the event of any marks or scores from sezu- res, these must be polished away.

12.24 - ES0 MAN Diesel & Turbo

Working Card 608-01.10 Page 1 (3) Control and Adjusting of Valve Clearance Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water 62008 02 Exhaust Shut-off fuel oil 62008 01 Inlet Shut-off cooling oil 62010 01 Stopped lub. oil circul.

Description: Hand tools:

Control and/or adjusting of valve clearance. Ring and open end spanner, 30 mm. Big screw driver.

Starting position:

Cover for rocker arm are removed. All indicator valves open.

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/4 Hour Plate no. Item no. Qty./ Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) See also plate 60502. Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

91.45 - ES0S MAN Diesel & Turbo

608-01.10 Working Card Edition 01H Control and Adjusting of Valve Clearance Page 2 (3)

L/V28/32H

Adjusting of Inlet Valve Clearance.

1) Turn the engine so that the roller, rests on the circular part of the cam, i.e. the inlet valves and the exhaust valves are closed.

2) Loosen the adjustment screws on valve bridge and rocker arm, see fig. 1.

Fig. 2.

8) Check that the clearance is correct simultaneo usly at both valve spindles.

Adjusting af Exhaust Valve Clearance.

Fig. 1. 9) Carry out adjusment in the same way as dese- ribed for the inlet valves, but using the feeler gauge for exhaust valve clearance o,90 mm. 3) Clearance between valve bridge and valve spindle, see page 600.40.

4) Place the feeler gauge marked with "correct" o,4 mm above the valve spindle nearest to the rocker arm bracket, see fig. 1.

5) Adjust the clearance between valve bridge and valve spindle by means of the adjustment screw on the rocker arm (above the push rod) and tighten the lock nut.

The feeler gauge is to remain in this position when adjusting the clearance of the other valve.

6) Place another feeler gauge, at the same size o,40 mm above the other valve spindle, see fig. 2. Fig. 3. 7) Adjust the clearance between valve bridge and valve spindle by means of the adjusment screw on the valve bridge, and tighten the lock nut, see fig. 2.

91.45 - ES0S MAN Diesel & Turbo

Working Card 608-01.10 Page 3 (3) Control and Adjusting of Valve Clearance Edition 01H

L/V28/32H

10) The feeler gauges for checking the clearance have two gauges which are marked "incorrect" and "correct", the latter to be used when adjusting the valve clearance, see fig. 4.

After tightening up the counter nuts on rocker arms and valves bridge, be sure that the feeler gaugs marked "correct" can be inserted into the two clearances simultaneously as where it must not be possible to insert the gauges marked "incorrect".

Fig. 4.

91.45 - ES0S MAN Diesel & Turbo

Plate Page 1 (2) Roller Guide and Push Rods 60801-17H

L28/32H

01 02* 38 04 03 01 04

05 17 06 18 07 19 08 20+

28 09

22 23

10 24 11 12 12

26 25 27 13 13 14 14 15 15

11.36 - ES0 MAN Diesel & Turbo

Plate 60801-17H Roller Guide and Push Rods Page 2 (2)

L28/32H

Item Item no Qty. Designation Benævnelse no Qty. Designation Benævnelse

01 4/C Thrust piece Trykstykke 27 1/C Roller guide for fuel Rullestyr for brændsels injection pump, com- pumpe, komplet inkl. 02* 2/C Pipe Rør plete incl. item 12, 13, item 12, 13, 14, 15, 14, 15, 24, 25 24, 25 03 2/C Protecting tube Skærmrør 28 4/C Screw Skrue 04 4/C Sealing ring Tætningsring 38 2/C Push rod, complete Stødstang, komplet inkl. 05 4/C Screw Skrue incl. item 01, 02 item 01, 02

06 2/C Cover Dæksel

07 2/C Screw Skrue + Item no 20 require + Item nr. 20 kræver 08 2/C Gasket Pakning an individual match en individuel tilpasning ing before mounting, før montering, kontakt 09 1/C Gasket Pakning contact MAN Diesel & MAN Diesel & Turbo, Turbo, Holeby Holeby 10 2/C Ball pin Kugletap

11 2/C Roller guide Rullestyr

12 3/C Pin Tap

13 3/C Stop screw Stopskrue

14 3/C Bush Foring

15 3/C Roller Rulle

16 1/C Washer for spring Skive for fjeder

17 1/C Spring Fjeder

18 2/C Guide pin Styrestift

19 8/C Screw Skrue

20+ 1/C Housing for Hus for roller guides rullestyr

22 1/C Thrust piece Tryktap

23 1/C 1 set shims (0.1, 0.3, 1 sæt shims (0,1, 0,3, 0.5 and 1.0 mm) 0,5 og 1,0 mm)

24 1/C Thrust piece Tryktap

25 1/C Roller guide Rullestyr

26 2/C Roller guide for Rullestyr for ventilbe valve gear, complete vægelse, komplet inkl. incl. item 10, 11, 12, item 10, 11, 12, 13, 13, 14, 15 14, 15

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

11.36 - ES0 Control/safety

509/609 MAN Diesel

Description 609.01 Page 1 (2) Control and Safety Systems Edition 20H

L+V28/32H

Governor Should a fuel pump plunger seize in its barrel, thus blocking the regulating guide, governing of the The engine speed is controlled by a hydraulic go- remaining fuel pumps may continue un impaired vernor. The purpose of the governor is to regulate owing to the spring-loaded linkage between the the rate of delivery from the fuel pumps, so that the blocked pump and the regulating shaft. engine speed is kept within certain limits, indepen- ding on the load. Stop Screw for Max. Delivery Rate Information about the design, function and operation of the governor is found in the special governor The bracket for stop cylinder/limiting cylinder is fi tted instruction book. with a stop screw which prevents the fuel pumps from being set to a higher delivery rate than what The governor is mounted on the fl y wheel end of corresponds to the permissible overload rating. the engine and is driven from the camshaft via a cy lindrical gear wheel and a set of bevel gears. This is effected by the arm on the regulating shaft being stopped by the stop screw, see fi g. 1.

Pick-up for Engine RPM Mechanical Overspeed (SSH 81) The pick-up for transfer of signal to the tachometer instrument for engine RPM is mounted on the ﬂ y The engine is protected against overspeeding in the wheel end cover of the engine. event of, for instance, governor failure by means of an overspeed trip. A signal varying proportionally to engine RPM is created in the pick-up by the rotating toothed im- The engine is equipped with a stopping device pulse wheel mounted on the camshaft end. which starts to operate if the maximum permissible revo lution number is exceeded.

Pick-up for Turbocharger RPM The overspeed tripping device is ﬁ tted to the end cover of the lubricating oil pump and is driven See turbocharger instruction book, section 612. through this pump.

If the pre-set tripping speed is exceeded, the spring- Regulating Shaft loaded fl y weight (1), see fi g. 1, will move outwards and press down the arm (2). The governor movements are transmitted through a spring-loaded pull rod to the fuel pump regulating The arm is locked in its bottom position by the lock shaft which is fi tted along the engine. pin (3) which is pressed in by the spring (4).

The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the give full deﬂ ection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens, manoeuv ring system keep the fuel pump regulating whereby compressed air will be led to the Lambda shaft at "no fuel" position. cylinder , see Description 609.10, in which the piston is pressed forward and turns the fuel pump Each fuel pump is connected to the common, lon- regulating rod to STOP position, thereby the engine gitudinal regulating shaft by means of a two-piece, stops, the spring-loaded pull rod connection to the spring-loaded arm. governor being compressed.

08.43 - ES0 MAN Diesel

609.01 Description Control and Safety Systems Page 2 (2) Edition 20H

L+V28/32H

The engine can be stopped manually by pressing The overspeed alarm (SAH 81) is activated by means down the button (7), see ﬁ g. 1, which will activate the of the micro switch (9). spring-loaded ﬂ y weight (1) through the lever (8).

If the overspeed has been activated the overspeed must be reset before the engine can be started. Reset is done by means of the button (10).

3 8 1

5 2

6 1. Flyweight 1 2. Arm 3. Lock pin 9 4. Spring 5. Spindle 6. Pneumatic valve Normal Overspeed poisition activated 7. Button 8. Lever 9. micro switch 10. Button 2 5 3 4 10 10

Fig 1 Mechanical overspeed (SSH 81).

08.43 - ES0 MAN Diesel 94.28 -ES2S 08028-0D/H5250/94.08.12 Description Page 1(3) Illu ca ment panel,comprisinginstrumentsforvisualindi- As standard theengineisequippedwithaninstru- Main instrumentpanel Fig. 1.Lay-outofinstrumentpanel tion ofthemostessentialpressures. * Ifnozzlecoolingoilappliedonly. SwitchforPI21/22 (*) Fueloil,inlettoengine Nozz.cool. oil,inlettofuelvalves Chargeair, outletfrom cooler Lub.oil,inlettoturbocharger PI50(*) PI40 HTfresh water, PI31 inletengine Lubricatingoil,inlet/outlettofi lter LT fresh PI23 water, inlettoaircooler PI21/22 PI10 PI01 Pressure gaugefor: essential pressures. The followingincorporatingpressure gaugesforthemost panel. On theengineisasstandard mounted aninstrument strated onfi g. 1. Instruments andAutomatics Fig. 2.Cross sectionofinstrumentpanel tions. filters are forlevelling outpressure inserted fl uc In thechargingairandnozzleoilpipingdamping the manometersduringoperation. ped withvalveswhichmakeitpossibletoreplace The connectingpipestothemanometersare equip- shown onfi g. 2. nec elements andallmanometerconnectionsare con- The instrumentpanelismountedfl Push button Valves ted tothepanelbymeansoffl exible hoses,as exibly onrubber Rubber element Flexible hose L28/32H 609.05 Edition 11H tua- MAN Diesel L28/32H 609.05 Edition 11H Shut-down Switches for As standard theengineisequippedwith: damage byrunningontheseconditions. a shut-downisgiveniftheenginecouldbesevere because I.e. ashut-downis"worse"thananalarm functions shallstoptheenginebefore abreak down. which canleadtobreak downandtheshut-down working condition, againstanabnormal panel worn shallviathealarm shut-down functions.Thealarms and The engineissuppliedwithanumberofalarm- Pressostates and Thermostates For codeidentifi cation see600.20. plant inthesections612-613-614-615-616. plant canbeseenonthediagramsforspecifi The actualnumberoftheinstrumentationfor Exhaustgas-outletturbocharger *) Ifnozzlecoolingoilappliedonly. TI61 Exhaustgas-outleteachcylinder TI60 Thermometer Fueloil-inlettoengine Thermometer TI40 Chargeair-outletfrom cooler TI Thermometer*) 51 TI31 Chargeair-inlettocooler Thermometer TI30 Lubricatingoil-outletfrom fi lter Thermometer TI22 Lubricatingoil-inlettocooler Thermometer TI20 Thermometer HTfresh water-inlettoengine Thermometer TI10 LT water -outletfrom lub.oilcooler TI Thermometer TI03 LT water -outletfrom aircooler Thermometer 11 TI02 LT water -inletaircooler Thermometer TI01 Thermometer Thermometer instrumentation mountedlocalontheengine: As standard theengineissuppliedwithfollowing Instrumentation

Alarm Switches for

(level alarm) ------toolowlubricatingoilpressure -inletengine toohighHTFWtemperature -outletengine toohighenginespeed(overspeed) leakingfueloil toolowlubricatingoilpressure -inletengine toolowprelubricating oil pressure HT fresh water-outleteachcylinder Nozz. cool.oil-outletfrom fuelvalves Instruments andAutomatics c leakage alarm unit. leakage alarm and enginefeedpump(ifmounted)isledtoafuel injection equipment,fuelvalves,high-pressure pipes Waste andleakoilfrom thecomparement, forthe Leakage Alarm(LAH42) list"inthissection. "Engine Automaticpart down switchesfortheplantcanbeseeninlist andshut- The actualnumberandtypeofthealarm- Fig. 4.Fueloilleakagealarm. High level Normal leakage - - - - toohighenginespeed(overspeed) airpressure toolowstarting -inletengine toohighHTFWtemperature -outletengine toohighpress. drop across lub.oilﬁ Normal level Normal Alarm Leak alarm C A Waste oiloutlet lter Leakoil Description B Page 2(3) 94.28 -ES2S

08028-0D/H5250/94.08.12 MAN Diesel 94.28 -ES2S 08028-0D/H5250/94.08.12 Description Page 3(3) out through thetopofpipe"B". activated. Thelargeramountofleakoilwillbelead in theboxwillriseandlevelswitch"C"be leakage,the level In caseofalargerthennormal "B" asillustrated. this willbeledoutthrough thebore "A"inthepipe ler amountofwaste/leakoilfrom thecompare conditionsthereUnder normal willalwaysbeasmal- ste/leak oil. free drainagepassageeven forhigh-viscouswa- unit inorder tokeepheatedup,thereby ensuring The supplyfueloiltotheengineisledthrough the for levelmonitoring,seefi g. 4. unitconsistofaboxwithfl The alarm Instruments andAutomatics oat switch oat ment, overspeed. The latterfunctionisaback-upforthemechanical solenoid inthegovernor. for overspeed(SAH81)andactivatetheshut-down 609.01 fi When themechanicaloverspeedisactivated,see Alarm andShut-down for Overspeed 25) mountedinthemainlubricatingoilpipe. is stoppedgivenbymeansofalevelswitch(LAL formissingprelubricating,Alarm when theengine Alarm for Prelubricating(LAL25) g. 2,amicro-switch willrelease thealarm L28/32H 609.05 Edition 11H MAN Diesel

Description 609.10 Page 1 (2) Lambda Controller Edition 15H

L28/32H

Purpose Thus the solenoid valve (4) opens. The jet system is activated, the turbocharger accelerates and increases The purpose with the lambda controller is to prevent the charge air pressure, thereby pressing the piston injection of more fuel in the combustion chamber than (3) backwards in the lambda cylinder (5). When the can be burned during a momentary load in-crease. lambda ratio is satisfactory, the jet system will be This is carried out by controlling the relation between de-activated. the fuel index and the charge air pressure. At a 50% load change the system will be activated The Lambda controller is also used as stop cylin- for about 3-8 seconds. der. If the system is activated more than 10 seconds, the solenoid valve will be shut off and there will be Advantages a remote signal for "jet system failure".

The lambda controller has the following advantages: Fuel oil limiting during start procedure

- Reduction of visible smoke in case of sudden During the start procedure the lambda controller is momentary load increases. used as an index limiter.

- Improved load ability. Hereby heavy smoke formation is prevented during start procedure and further the regulating device - Less fouling of the engine's exhaust gas ways. cannot over-react.

- Limitation of fuel oil index during starting procedure. Air Consumption

At 50% step load the air consumption will be as Principles for functioning follows:

Figure 1 illustrates the controller's operation mode. In case of a momentary load increase, the regulat- Cyl. no. 5 6 7 8 9 ing device will increase the index on the injection pumps and hereby the regulator arm (1) is turned, Nm3 1.12 1.35 1.57 1.80 2.02 the switch (2) will touch the piston arm (3) and be pushed downwards, whereby the electrical circuit will be closed. 08028-0D/H5250/94.08.12

04.15 - ES0 MAN Diesel

609.10 Description Lambda Controller Page 2 (2) Edition 15H

L28/32H

1. Regulating arm 2. Switch (Pick-up) 3. Piston 4. Solenoid valve 5. Lambda controller 6. Overspeed device (mecanical activated 3/2 valve)

5 Charge air receiver 3 2 1 ~

4 Engine's compression air system

Fig 1 Lambda controller incl. start limitation

04.15 - ES0 MAN Diesel & Turbo

Description 609.35 Page 1 (1) Starting Box Edition 06H

L28/32H

Description Engine / Turbocharger RPM

The starting box is mounted on the engine's control By activating the "Engine RPM/TC RPM" button, the side. On front of the box there are the following in- indication is changed. dications/pushbuttons: Engine RPM indication is green light-emitting diodes – Indication of engine or turbocharger RPM and turbocharger RPM indication is red light-emitting – Indication of electronic overspeed diodes. – Pushbutton for "Manual Start" – Pushbutton for "Manual Stop" External Indications – Pushbutton for "Remote" * – Pushbutton for "Local" * There are output signals for engine RPM and tur- – Pushbutton for "Blocking" * bocharger RPM. – Pushbutton for change-over between engine Engine: 0 - 1200 RPM ~ 4-20 mA and turbocharger RPM TC: 0 - 60000 RPM ~ 4-20 mA

* The function chosen is indicated in the pushbutton. The pushbuttons for "Remote", "Local" and "Blocking" See fig. 1. have potential free switches for external indication.

Manual Start All components in the starting box are wired to the built-on terminal box. The engine can be started by means of the start button, but only if the button "Local" is activated.

The manual, local start is an electrical, pneumatic start, i.e. when activating the start button a solenoid valve opens for air to the air starter, thereby engaging the starter and starting the diesel engine. Throughout the starting cycle the start button must be activated.

The air starter is automatically disengaged when the diesel engine exceeds 110 RPM. If the start button is disengaged before the diesel engine has exceeded 110 RPM, further starting cycles are blocked, until 5 sec. after the engine is at standstill.

Remote Start

Remote start can only take place if the pushbutton for "Remote" is activated.

Manual Stop

The "Manual Stop" button is connected to the stop coil on the governor.

Blocking

If "Blocking" is activated, it is not possible to start the diesel engine. Fig 1 Starting box.

12.01 - ES1 96.30 -ES2S 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) at 200RPM. been over710RPMthesignal willbedeactivated the speedis640RPM.If enginespeedhaven't The enginerunsignalwill bedeactivatedwhen run" signal. givesa"engine RPM +10seconds,theconverter When theenginespeedreach 710RPM or 200 Engine run signalthroughsignal andaalarm a relay. tronic givesashutdown overspeedtheconverter When theenginespeedreach thesetpointfor elec- Overspeed forengineRPM. Fig 1.Converter Further, hasfollowingsignals: theconverter proportional 4-20mA~0-1200RPMsignal. where intoa converter), thesignalistransformed is sentthrough (frequency/current anf/Iconverter on ananaloguetachometer, thefrequency signal on theRPM.To beabletoshowtheengine'sRPM on theengineisusedgivingafrequency depending For measuringtheengine'sRPM,apick-upmounted Engine RPMsignal - - - - tacho fail safe start engine run overspeed Converter for Engine-and Turbocharger RPMSignal engine. boxon ismounted intheterminal The converter RPM. transferred intoaproportional 4-20mA~0-60000 (frequency/current where converter), thesignalis the frequency signalissentthrough af/Iconverter turbocharger's RPMonananaloguetachometer, depending ontheRPM.To beabletoshowthe mounted ontheengineisusedgivingafrequency For measuringtheturbochargerRPM,apick-up Turbocharger RPMsignal boxontheengine. the terminal forengineRPMsignalismountedin The converter supply failure. signal willbedeactivated.E.g.ifthere ispower failesthe Ifthepick-uporconverter normal. is The tachofailsignalwillbeonwheneverything Tacho fail duringrotation.for theairstarter Further, signalisablockingfunction thesafestart willbeshut-off.starter Whentheenginereachcan start. 140RPMtheair signalisactivatedtheengine When thesafestart Safe start blockingatstart/stop. lub. oilpumporalarm One forsynchronizing ofpre. andoneforstart/stop The "enginerun"signalswillbegiventhrough arelay. Fig 2. Converter forTCRPM. Fig 2.Converter L+V28/32H 609.40 Edition 01H 03.32 - ES0U 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torquemoment (Page 600.35) Data for pressure andtolerance hours Data Capacity : : Working time man Man power 609-05.02 609-01.05 609-05.03 609-05.04 Analog temperature transmitter Analog pressuretransmitter Level switch (LAL25) 609-05.01 Thermostate Pressostate 609-05.00 Overspeed trip Related procedure position Starting equipment. monitoring Function testandadjustmentofsafety, and alarm Description Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stoppedengine Safety precautions Functional Test andAdjustmentofSafety, Alarm andMonitoringEquipment Hand tools Special tools lt o tmN Qty. / ItemNo PlateNo Replacement andwearingparts See RelatedProcedure SeeRelatedProcedure Note. ItemNo PlateNo

609-01.00 General Edition 01H MAN Diesel 609-01.00 General Edition 01H able fromplanttoplant. The extent andsafety ofthealarm functionsisvari- cards. three monthaccordingtothementionedworking every It isrecommendedthatallfunctionsaretested until itcanbestopped. the enginehastobeunderconstantobservation possible situation, becauseofthepresentworking have toberepairedimmediately. Ifthisis not they If someofthesefunctionsareoutoperation, 100%. shutdown andoverspeed devices arefunctioning ventive systemaswell asthe isthatthealarm work parameters inthepre- One ofthemostimportant stems Maintenance ofmonitoringandsafety sy- Functional Test andAdjustmentofSafety, Alarm andMonitoringEquipment and/or shutdown functions. areequippedwithslowdown alarms The mostserious system. tance ofthealarm familiar withandwell trained intheuseandimpor- all enginecrew membersare isinsigniﬁ No alarm gation andremedyoftheerror. leadtopromptinvesti- thatallalarms It isimportant Alarm System mentioned underrelatedprocedureonpage1. For check cards ofthesefunctionsusetheworking cant. that Itistherefore important Working Card Page 2(2) 03.32 -ES0U

08028-0D/H5250/94.08.12 91.45 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Hour Data: 1 Capacity : 1 : Working time man Man power: Related procedure: 609-01.00 andmonitoringequipment, alarm Functional testandadjustmentofsafety position: Starting trip. Functional testandadjustmentofoverspeed Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: Functional Test andAdjustmentofOverspeed Trip lt o Ie o Qty. / Itemno. Plateno. Replacement andwearingparts: Allen key, 2mm. Allen key, 4mm. Hand tools: Note. 01 62009 Itemno. Plateno. Special tools: 609-01.05 General Edition 01H MAN Diesel 609-01.05 General Edition 01H Fig. 1. overspeed trippingdevice,seefi g. 1. Adjustment ofOverspeed Trip. be adjusted. or inthe"Test theoverspeeddevicemust Report" number different from thatstatedonpage600.30 now movedtozero index, andtheenginestops. cylinders. Thefuelinjectionpumpcontrol rods are ping devicemustfunction,thusactuatingthestop page 600.30orin"Test theoverspeedtrip- Report", On reaching therevolution numberindicatedon tachometer. "synchronizer") andatno load,whilewatchingthe 1) 3) 2) Removebothcoversonthehousingof Iftheoverspeeddivicetripatarevolution The engineisrunupmanually, (ongovernor Functional Test andAdjustmentofOverspeed Trip the tubularpinspannersupplied,sefi g. 2. the lockscrew theadjustingscrew, andturn using the openingonsideofhousing.Nowloosen Turn theengineuntiladjustingscrew isopposite Fig. 2. can alwaysmovewithsuffi cient ease. means ofthepushbuttontoensure thatthefl engine isatastandstill,tomovethefl carried outwithoutload). the engineshouldthusstop.(Thistestmustalsobe release oftheairvalveforstopcylindersand fig. 1.Thiswill activatethefl by depressing thebuttonontopafhousing,see functions atcorrect revolution number. and testtheoverspeeddeviceagain. may touchtherelease Tightenthelockscrew arm. not toscrew theadjustingscrew sofaroutthatit spring) toreduce therevolution number. Becareful Turn theadjustingscrew outwards (slackenfl 6) 5) 4) Itisrecommended nowandthen,whilethe Theoverspeeddevice canbetestedmanually Refi t thecoverswhenoverspeed device yweight and the arm for yweight andthe arm yweight by yweight y y Working Card Page 2(2) weight weight weight 91.45 -ES0S

Fig. 1. time thescalepos.2isread. can besetwiththespindlepos.1whileatsame locking screw pos.5,fi 1) Adjustment: al, thespindlepos.3mustbeusedtomake 3) 2) Whenthepressostate coverisremoved and Shut off systempressure withthe valvepos. In pressostates havinganadjustabledif 5. 4. 3. 2. Locking 1. Differential Differential Range Range screw. scale. spindle. scale. spindle. Adjustment and Test ofOn/OffPressostate g. 1isloosened,therange fe ren- the valvepos.3. the testingpump,mount screw pos.2andopen point. es, andcheckthatithappensatthestatedalarm 7) Alarm for Rising Pressure: the pressure point. statedasthealarm it mustbecheckedthattheswitchchangebackto changed. Thepressure willslowly berelieved and 6) Alarm for Falling Pressure: 1. Fig. 2. 5) 4) 8) Afterthefi Pumpupthe pressure untiltheswitchhas Mountthetestingpumpontrialfl Removethescrew pos.2. Pump upthepressure untiltheswitch chang- 3. 2. 1. Valve. Drain Trial screw. fl ange. nalcheckandadjustment, remove ange pos. Working Card Page 2(2) 91.45 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel

Working Card 609-05.01 Page 1 (2) Adjustment and Test of On/Off Thermostate Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Adjustment and test of on/off thermostate. (lub. oil, fuel oil, water etc.). Hand tools:

Screw driver. Special testing devices.

Starting position:

Functional test and adjustment of safety alarm and monitoring equipment, 609-01.00

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. / Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

96.26 - ES0S MAN Diesel

609-05.01 Working Card Edition 02H Adjustment and Test of On/Off Thermostate Page 2 (2)

L+V28/32H

Adjustment: Test:

1) When the thermostate cover is removed and 3) The funcional test of the thermostate is to be locking screw pos. 5, ﬁ g. 1 is loosened, the range carried out according to the following procedure. can be set with the spindle pos. 1 while at the same time the scale pos. 2 is read. 4) Take out the sensor of the pocket.

5) Test the sensor in a water bath, where the temperature can be controlled.

Alarm for Falling temperature:

6) Raise the temperature until the switch has changed.

Then the temperature must slowly be reduced, and check that the switch changes back at the tem pe rature stated in the list page 600.30.

Alarm for Rising temperature:

1. Range spindle. 2. Range scale. 7) Raise the temperature until the switch chang- 3. Differential spindle. es and check that is happens at the stated alarm 4. Differential scale. points. 5. Locking screw. 8) Adjust if necessary.

9) The sensor is mounted again. Fig. 1.

2) Thermostates having an adjustable dif fe ren ti al, the spindle pos. 3 can be used while the scale pos. 4 is read.

Set points, see page 600.30.

96.26 - ES0S 91.03 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Data: Hour 1/2 Capacity : 1 : Working time man Man power: Related procedure: 609-01.00 andmonitoringequipment, alarm Functional testandadjustmentofsafety position: Starting lubricating oilsystem. Function andtestoflevelswitch,LAL25,in Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: Function and Test ofLevel Switch (LAL25) lt o Ie o Qty. / Itemno. Plateno. Replacement andwearingparts: Hand tools: Note. Itemno. Plateno. Special tools: 609-05.02 General Edition 02H MAN Diesel 609-05.02 General Edition 02H oil viscosity. must bereleased after0-5min.,depending ofthe 4) run about5min. ped. The testiscarriedoutwhentheenginestop- Test: starts. alarm which meansthatlevelswitchislowered andthe oil willrunoutofthesystemthrough thebearings, isdisconnected. alarm which meansthatthelevelswitchisliftedand lubricating oilpipewillbeﬁ Function. for missingprelubricating oil. main lubricatingoilpipeoftheengine,givesalarm The levelswitchLAL25,whichismountedonthe 3) 2) 1) Stoptheprelubricating oilpump.Thealarm Whentheprelubricating isinterrupted,thelub. theprelubricating Bystarting oilpumpthemain Start thelubricatingoilpump,andletpump Start Function and Test ofLevel Switch (LAL25) lled withlubricatingoil, Fig. 1. Vent pipe Main lubricatingoilpipe Level switch Working Card Page 2(2) 91.03 -ES0S

08028-0D/H5250/94.08.12 91.45 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Data: Hour 1/2 Capacity : 1 : Working time man Man power: Related procedure: 609-01.00 andmonitoringequipment, alarm Functional testandadjustmentofsafety position: Starting trans Adjustment andtestofanalogouspressure Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: mit ter. Adjustment and Test ofAnalogousPressure Transmitter lt o Ie o Qty./ Itemno. Plateno. Replacement andwearingparts: Testing pump. Ring andopenendspanner, 10mm. Hand tools: Note. Itemno. Plateno. Special tools: 609-05.03 General Edition 02H MAN Diesel 609-05.03 General Edition 02H Fig. 1. which adjuststhepressure. sure andmarksthechange toanelectricalsignal, The pressure transmitterregisters theactualpres- 3. 2. 1. Valve. Drain Trial screw. fl ange. Adjustment and Test ofAnalogousPressure Transmitter to thefollowingprocedure: pressure transmitter. Thisiscarriedoutaccording Test: Set points,seepage600.30. plant. plant. Kindlyseetheinstructionbookforalarm limitmustbesetonthealarm ed, butthealarm Adjustment: pos. 3.isopenedafterthetestfi nished. adjusted). plantis on page600.30isexceeded(ifthealarm limitwhichisstated whenthealarm any alarm, plantgives be carriedoutbywatchingifthealarm sure canberead onthis.Otherwisethetestcan planthasaninstrumentunit,thepres-If thealarm area ofthetransmitter. pos. 1.andpumponapressure withintheworking 5) 4) 3) 2) 1) 6) Itispossibletomakeafunctionaltestofthe Thescrew pos.2ismounted,andthevalve Mountthetestingapparatusontrialfl Removethescrew pos.2. Shut off systempressure withthevalvepos.3. Thepressure transmittershallnotbead Working Card Page 2(2) ange just- 91.45 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel

Working Card Adjustment and Test of 609-05.04 Page 1 (2) Analogous Temperature Transmitter Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Adjustment and test of analogous temperature transmitter, (PT 100 sensor). Hand tools:

Special testing devices.

Starting position:

Functional test and adjustment of safety alarm and monitoring equipment, 609-01.00

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./ Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

96.26 - ES0S MAN Diesel

609-05.04 Adjustment and Test of Working Card Edition 02H Analogous Temperature Transmitter Page 2 (2)

L+V28/32H

The PT 100 sensor consist of a resistance wire Otherwise the test can be carried out by watching which changes resistance depending on the tem- if the alarm plant gives any alarm, when the alarm pe ra ture. limit which is stated on page 600.30 is exceeded (if the alarm plant is adjusted). Look and design varify depending on the place of measurement and manufacture. 5) The sensor is mounted again.

Adjustment:

1) The PT 100 sensor connot be adjusted, but the alarm limit must be set on the alarm plant.

Set point, see page 600.30.

Test:

2) The functional trial of the PT 100 sensor can be carried out according to the following procedure.

3) Take out the sensor of the pocket.

4) Test the sensor by diving the sensor in the water. Compare the signal from the sensor with the water temperature.

If the alarm plant has an instrument unit, the tempe- Fig. 1. ra ture can be read on this.

96.26 - ES0S MAN Diesel

Working Card 609-10.00 Page 1 (2) Lambda Controller Edition 16H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note Shut off starting air Shut off cooling water Shut off fuel oil Shut off cooling oil Stopped lub. oil circul.

Description: Hand tools:

Adjustment of lambda controller. Allen key.

Starting position:

Related procedure:

Manpower: Replacement and wearing parts:

Working time : 1 hour Plate no Item no Qty / Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

10.23 - ES0 MAN Diesel

609-10.00 Working Card Lambda Controller Page 2 (2) Edition 16H

L28/32H

Adjustment of the Lamda Controller

All adjustments are made when the engine is in 1. Compressed air from 1 overspeed device standstill position. 2. Lambda cylinder 3. Charge air pressure 4. Piston of the 1. Check that the free space between the pick- 2 lambda cylinder 5. Regulating arm up and the band steel on the regulating arm 6. Adjustment screw is min. 1 mm, see fig 1.

6 5

Fig 3.

2. Turn the lever (fig 2) of the governor a few times to full load with an adjustable spanner (spring between governor and fuel rack full com-pressed). Check that the fuel index is 24 mm at the fuel pump.

Note: Be sure that the fuel index is 24 mm at the fuel pump when the engine is started. Fig 1. 3. In case of large deviation from index 24 adjustment is done by turning the regulating arm (5), fig 3. Finally adjustment is done at the adjustment screw (6), fig 3.

4. Adjustment completed.

Adjustment of the stop screw

5. Remove pipe for charge air pressure, see fig 3.

6. Supply air pressure until the piston rod reaches its upper position.

7. Adjust the stop screw, see fig 2, to 110% load according to the test bed, plus 1.5 index. Use the index arm on the fuel pump nearest to the lambda controller as control for the index.

Fig 2. 8. Adjustment finished.

10.23 - ES0 MAN Diesel

Plate Page 1 (2) Governor and Governor Drive 60901-13H

L28/32H

For actuator, see special instruction book 10

12 13 14 16 15 17 02 18 03 20 19+

04 05 21 06 22 07 23 08 24 25

26 27

30 29

06.33 - ES0 MAN Diesel

Plate 60901-13H Governor and Governor Drive Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

02 1/E Plug screw Propskrue 29 1/E Wear disc Slidskive 03 1/E Gasket Pakning 30 1/E Key Feder 04 4/E Nut Møtrik

05 2/E Stud Tap + Item No. 19 require + Item nr. 19 kræver an individual match- en individual tilpasning 06 1/E O-ring O-ring ing (by shims) before (med shims) før monte- mounting, contact, ring, kontakt MAN B&W, 07 1/E Castle nut Kronemøtrik MAN B&W, Holeby Holeby.

08 1/E Split pin Split

10 1/E Actuator Aktuator

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 - 0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

06.33 - ES0 MAN Diesel

Plate Page 1 (2) Governor and Governor Drive 60901-14H

L28/32H

01 09

For governor, 10 see special instruction book

12 13 14 16 15 17 02 18 03 20 19+

04 05 21 06 22 07 23 08 24 25

26 27

30 29

06.33 - ES0 MAN Diesel

Plate 60901-14H Governor and Governor Drive Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Synchronnizing Synchroniserings- 29 1/E Wear disc Slidskive motor motor 30 1/E Key Feder 02 1/E Plug screw Propskrue

03 1/E Gasket Pakning + Item No. 19 require + Item nr. 19 kræver an individual match- en individual tilpasning 04 4/E Nut Møtrik ing (by shims) before (med shims) før monte- mounting, contact, ring, kontakt MAN B&W, 05 2/E Stud Tap MAN B&W, Holeby Holeby.

06 1/E O-ring O-ring

07 1/E Castle nut Kronemøtrik

08 1/E Split pin Split

09 1/E Shut down Shut-down solenoid spole

10 1/E Governor - incl. Regulator - inkl. item 01, 09 and 12 item 01, 09 og 12

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 - 0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

06.33 - ES0 MAN Diesel

Plate Page 1 (2) Governor and Governor Drive 60901-15H

L28/32H

31 For governor, see special instruction book 10 11

13 14 16 15 17 02 18 03 20 19+

04 05 21 06 22 07 23 08 24 25

26 27

30 29

06.47 - ES0 MAN Diesel

Plate 60901-15H Governor and Governor Drive Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

02 1/E Plug screw Propskrue 30 1/E Key Feder

03 1/E Gasket Pakning 31 1/E Shutdown solenoid Shutdown spole

04 4/E Nut Møtrik + Item No. 19 require + Item nr. 19 kræver 05 2/E Stud Tap an individual match- en individual tilpasning ing (by shims) before (med shims) før mon- 06 1/E O-ring O-ring mounting, contact, tering, kontakt MAN MAN Diesel A/S. Diesel A/S. 07 1/E Castle nut Kronemøtrik

08 1/E Split pin Split

09 1/E Synchronizing motor Synkroniseringsmotor

10 1/E Governor, Europa Regulator, Europa (720/750 rpm) (720/750 rpm)

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 - 0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

29 1/E Wear disc Slidskive

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

06.47 - ES0 MAN Diesel

Plate Page 1 (3) Regulation Mechanism 60902-18H

L28/32H

Governor Plate 60901

17 15, 70 18 01 13 19 02 16 03

04 05 14

19 06 25 20 07 26 18 08 27 17 09 28 21 22 10 24 25 23 11 12 64 13 65 02

56, 92, 93, 94, 95 68

48 49 69 57 50 58 51 52 55 53

61 54 62 59 63 60

06.35 - ES0 MAN Diesel

Plate 60902-18H Regulation Mechanism Page 2 (3)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/R Split pin Split 28 2/R Spring pin Fjederstift

02 2/R Pull rod head Trækstangshoved 48 1/C Linkage Lænkeled

03 1/R Pull rod end Trækstangsende 49 1/C Pin Stift

04 1/R Cylindrical pin Cylindrisk stift 50 1/C Spring Fjeder

05 1/R Spring housing Fjederhus 51 1/C Spring arm Fjederarm

06 1/R Pointed screw Pinolskrue 52 3/C Spring pin Fjederstift

07 1/R Spring Fjeder 53 1/C Arm holder Armholder

08 1/R Pull rod Trækstang 54 1/C Screw Skrue

09 1/R Cylindrical pin Cylindrisk stift 55 1/C Spring loaded Fjederbelastet lever, complete arm, komplet 10 1/R Guide ring Styrering 56 1/E Regulating shaft Reguleringsaksel 11 1/R Guide ring Styrering 5 cyl. engine 5 cyl. motor

12 1/R Nut Møtrik 57 1/C Split pin Split

13 2/R Locking plate Låseblik 58 1/C Pin Stift

14 1/R Spring loaded pull Fjederbelastet træk- 59 1/C Bush Bøsning rod, complete stang, komplet 60 1/C Bearing bracket Lejeblik 15 1/R Governor arm, Regulator arm, incl. item 59 inkl. item 59 Woodward Woodward 61 2/C Screw Skrue 16 1/R Screw Skrue 62 2/C Washer Skive 17 2/R Split pin Split 63 2/C Spring pin Fjederstift 18 2/R Self locking nut Selvlåsende møtrik 64 1/E Stop ring Stopring 19 2/R Screw for ball head Skrue for kuglehoved 65 1/E Screw Skrue 20 1/R Arm Arm 66 2/E Screw Skrue 21 1/R Spring pin Fjederstift 67 2/E Screw Skrue 22 1/R Locking plate Låseblik 68 1/E Bracket Konsol 23 1/R Screw Skrue 69 2/E Nut Møtrik 24 1/R Bearing housing Lejehus incl. item 25 inkl. item 25 70 1/E Governor arm, Regulator arm, Europa Europa 25 2/R Bush Bøsning 92 1/E Regulting shaft Reguleringsaksel 26 2/R Screw Skrue 6 cyl. engine 6 cyl. motor

27 2/R Washer Skive 93 1/E Regulating shaft Reguleringsaksel 7 cyl. engine 7 cyl. motor

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme

06.35 - ES0 MAN Diesel

Plate Page 3 (3) Regulation Mechanism 60902-18H

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

94 1/E Regulating shaft Reguleringsaksel 8 cyl. engine 8 cyl. motor

95 1/E Regulating shaft Reguleringsaksel 9 cyl. engine 9 cyl. motor

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

06.35 - ES0 MAN Diesel & Turbo

Plate Page 1 (2) Overspeed Device 60903-38H

L+V28/32H 01 02 03 04 05 06 07 09 08 10 11 12 13

16 14 17 15 18 21 46 19 20

24 48 22 25 23

30 26 33 27 31 32 34 37 35 39 38 36 40

47 44

11.02 - ES0 MAN Diesel & Turbo

Plate 60903-38H Overspeed Device Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Socket Muffe 32 1/E Button Knap

02 1/E Button Knap 33 1/E Nipple Nippel

03 1/E Spring pin Fjederstift 34 1/E Spindle Spindel

04 1/E Spring Fjeder 35 1/E Spring (left) Fjeder (venstre)

05 4/E Screw Skrue 36 1/E Spindle Spindel

06 1/E Screw Skrue 37 2/E Washer Skive

07 1/E Cover Dæksel 38 2/E Screw Skrue

08 1/E Spindle Spindel 39 1/E Ball bearing Kugleleje

09 1/E Spring pin Fjederstift 40 1/E Elastic coupling Elastisk kobling

10 1/E Cylindrical pin Cylindrisk stift 41 1/E Spring (right) Fjeder (højre)

11 1/E Lever Arm 42 1/E Valve attachment Ventilholder

12 1/E Screw Skrue 43 4/E Screw Skrue

13 1/E Flyweight housing Hus for svingvægt 44 1/E Pneumatic valve Pneumatisk ventil

14 1/E Adjusting screw Justeringsskrue 45 1/E Silencer Lyddæmper

15 1/E Spring Fjeder 46 1/E Overspeed device, Overspeed anordning, complete excl. item 27, komplet eksl. item 27, 16 1/E Circlip Sikringsring 37, 38, 44 37, 38, 44

17 1/E Flyweight Svingvægt 47 1/E Spare parts kit for Reservedelskit for item 44 item 44 18 1/E Key Not 48 1/E Limit switch (optinal) Afbryder (option) 19 1/E Ball bearing Kugleleje

20 1/E Housing Hus

21 1/E Cover Dæksel

22 4/E Washer Skive

23 4/E Screw Skrue

24 1/E Pin Stift

25 1/E Lever Arm

26 1/E Nut Møtrik

27 1/E Gasket Pakning

30 1/E Spindle Spindel

31 1/E Spring Fjeder

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

11.02 - ES0 MAN Diesel

Plate Page 1 (2) Instrument Panel 60905-20H

L28/32H

33 33A 04 04 03

01 16

09 10

03 04

04 29 08 24-26 13

05 05 14

06 20 19 25 12

30 28 15 02 06 11 18 02A

PI 01 LT fresh water, inlet to air cooler PI 10 HT fresh water, inlet engine PI 21/22 Lubricating oil, inlet/outlet to ﬁ lter PI 23 Lub. oil, inlet to turbocharger PI 31 Charge air, outlet from cooler PI 40 Fuel oil, inlet to engine PI 50 Nozz. cool. oil, inlet to fuel valves

06.35 - ES0S MAN Diesel

Plate 60905-20H Instrument Panel Page 2 (2)

L28/32H Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Housing for instru- Hus for instrument pa- 28 1/E Washer Skive ment panel nel 29 1/E Pressure gauge 0-10 Manometer 0-10 bar, 02 1/E Bracket for instrument Konsol for instrument bar, PI 40 PI 40 panel , L23/30H panel, L23/30H 30 4/E Packing ring Pakningsring 02A 1/E Bracket for instrunent Konsol for instrument panel, L28/32H panel, L28/32H 33 1/E Instrument panel, Instrument panel, kom- complete, L23/30H plet, L23/30H 03 2/E Pressure gauge 0-3 Manometer 0-3 bar (PI bar (PI 31 and PI 23) 31 og PI 23) 33A 1/E Instrument panel, Instrument panel, kom- complete, L28/32H plet, L28/32H 04 4/E Pressure gauge 0-6 Manometer 0-6 bar, bar, PI 01, PI 10, PI 50, PI 01, PI 10, PI 50, PI PI 21-22 21-22

05 8/E Needle valve Nåleventil

06 1/E 3-way valve for PI 3-vejsventil for PI 21- 21-22 22

07 3/E Pressure gauge hose Manometer slange 195 mm 195 mm

08 2/E Pressure gauge hose Manometer slange 140 mm 140 mm

09 1/E Pressure gauge hose Manometer slange 300 mm 300 mm

10 2/E Pressure gauge hose Manometer slange 340 mm 340 mm

11 1/E Damper Dæmper (charging air) (ladeluft)

12 1/E Damper (fuel oil) Dæmper (fuel oil)

13 4/E Rubber clutch Gummikobling

14 2/E Union Forskruning

15 1/E Screwed connection Skrue forbindelse

16 8/E Packing ring Pakningsring

18 2/E Union Forskruning

19 2/E Union Forskruning

20 3/E Screw Skrue

24 8/E Nut Møtrik

25 4/E Serrated washer Stjerneskrue

26 8/E Washer Skive

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

06.35 - ES0S MAN Diesel

Plate Page 1 (2) Instrument Panel 60905-27H

L28/32H

94.28 - ES0S MAN Diesel

Plate 60905-27H Instrument Panel Page 2 (2)

L28/32H

Item Item No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/E Housing for instru- Hus for instrument- 23 1/E Damper (charging air) Dæmper (ladeluft) ment panel panel 43 4/E Screw Skrue 02 1/E Bracket for instru- Konsol for instrument- ment panel panel 44 4/E Serrated lock washer Stjernefjederskive

03 4/E Rubber clutch Gummikobling 45 2/E Screw Skrue

04 8/E Nut Møtrik 46 2/E Serrated lock washer Stjernefjederskive

05 8/E Spring lock Fjederskive 47 8/E Screw Skrue

06 2/E Pressure gauge Manometer 48 1/E Side plate Sideplade 0-3 bar 0-3 bar (PI 31 and PI 23) (PI 31 og PI 23) 49 1/E Instrument panel, Instrument panel, complete komplet 07 4/E Pressure gauge Manometer 0-6 bar 0-3 bar (PI 01, PI 10, PI 50, (PI 01, PI 10, PI 50, PI 21-22) PI 21-22)

08 1/E Pressure gauge Manometer 0-10 bar (PI 40) 0-10 bar (PI 40)

09 7/E Needle valve Nåleventil

10 1/E 3-way valve for 3-vejsventil for PI 21-22 PI 21-22

11 1/E Washer Skive

12 1/E Pipe Rør

13 1/E Angle union Vinkelforskruning

14 2/E Straight union Ligeforskruning

15 2/E Pressure gauge hose Manometer slange 195 mm 195 mm

16 2/E Pressure gauge hose Manometer slange 140 mm 140 mm

17 2/E Pressure gauge hose Manometer slange 300 mm 300 mm

18 1/E Pressure gauge hose Manometer slange 340 mm 340 mm

19 7/E Packing ring Pakningsring

20 2/E Reduction Reduktion

21 1/E Damper (fuel oil) Dæmper (fuel oil)

22 2/E Coupling for mano- Kobling for manometer meter

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

94.28 - ES0S MAN Diesel

Plate Page 1 (2) Instrument Panel 60905-32H

L28/32H

49 19 07 06 07

01 17

47 07 08

48 07 06

04-05 03 02 14 09

11 43-44-45 20 20 12 23 21 13 14 22 22

95.20 - ES0S MAN Diesel

Plate 60905-32H Instrument Panel Page 2 (2)

L28/32H

Item Item No Qty. Designation Benævnelse No Qty. Designation Benævnelse

03 4/E Rubber clutch Gummikobling 45 4/E Nut Møtrik

04 8/E Nut Møtrik 47 8/E Screw Skrue

05 8/E Spring lock Fjederskive 48 1/E Side plate Sideplade

06 2/E Pressure gauge Manometer 49 1/E Instrument panel, Instrument panel, 0-3 bar 0-3 bar complete komplet (PI 31 and PI 23) (PI 31 og PI 23)

07 4/E Pressure gauge Manometer 0-6 bar 0-3 bar (PI 01, PI 10, PI 50, (PI 01, PI 10, PI 50, PI 21-22) PI 21-22)

08 1/E Pressure gauge Manometer 0-10 bar (PI 40) 0-10 bar (PI 40)

09 7/E Needle valve Nåleventil

10 1/E 3-way valve for 3-vejsventil for PI 21-22 PI 21-22

11 1/E Washer Skive

12 1/E Pipe Rør

13 1/E Angle union Vinkelforskruning

14 2/E Straight union Ligeforskruning

15 2/E Pressure gauge hose Manometer slange 195 mm 195 mm

16 2/E Pressure gauge hose Manometer slange 140 mm 140 mm

17 2/E Pressure gauge hose Manometer slange 300 mm 300 mm

18 1/E Pressure gauge hose Manometer slange 340 mm 340 mm

19 7/E Packing ring Pakningsring

20 2/E Reduction Reduktion

21 1/E Damper (fuel oil) Dæmper (fuel oil)

22 2/E Coupling for mano- Kobling for manometer meter

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

95.20 - ES0S MAN Diesel

Plate Page 1 (3) Thermometer 60907-19H

L28/32H

Scale Length Item Fig. Code °F °C L L1 No

40-240 0-120 110 100 TI 01 01

TI 02

TI 31

L 40-240 0-120 110 63 TI 22 02

TI 20

40-600 0-300 150 100 TI 30 03 L1

40-400 0-200 110 40 TI 40 04

TI 51

40-220 0-120 110 100 TI 03 05

TI 10

TI 11 L

04.11 - ES0 MAN Diesel

Plate 60907-19H Thermometer Page 2 (3)

L28/32H

Scale Length Item Fig. Code °F °C L L1 No.

100- 1300 50-650 100 115 TI 60 06

°C°F

Pocket 115 07

100- 1300 50-650 65 215 TI 61 08

°C°F

Pocket 215 09

04.11 - ES0 MAN Diesel

Plate Page 3 (3) Thermometer 60907-19H

L28/32H

Scale Length Item Fig. Code °F °C L L1 No.

120-1200 50-650 140 215 TI 61 10

TI 62

Thermo- meter 11

Feeler NiCr-Ni 12

Pocket 100 13

120-1200 50-650 165 115 TI 60 14

120-1200 50-650 190 115 TI 60 15

Feeler NiCr-Ni 16

Thermo- meter 17

Pocket 200 18

04.11 - ES0 MAN Diesel

Plate Pressostate, Thermostate Page 1 (2) Difference Pressostate and Pressure Transmitter 60907-02H

General

Fig. and Description Range Code L Item No.

0-8 bar PSL 22 01 PAL 10 PAL 22

6-18 bar PAL 70 02 PAL 24

10-35 bar 03

1-10 bar PAL 40 04 Pressostate

20-60°C TAL 10 2 m 05 5 m 06

50-100°C 2 m 07 5 m 08 8 m 09

70-120°C TAH 12 2 m 10 TSH 12 5 m 11 TAH 20 8 m 12 L TSH 22 TSH 12 Thermostate

0.2-2.5 bar PDAH 21-22 13

Difference Pressostate

99.33 - ES0S MAN Diesel

Pressostate, Thermostate Plate 60907-02H Difference Pressostate and Pressure Transmitter Page 2 (2)

General

Fig. and Description Range Code L Item No.

0-2.5 bar PT 31 14

0-4 bar PT 10 15

0-6 bar PT 22 16

0-10 bar PT 40 17

0-16 bar PT 70 18

0-40 bar 19

0-400 bar 20 Pressure Transmitter

Needle Valve with 3/8" pipe thread 25

Needle valve with 1/2" pipe thread 26

Needle Valve

99.33 - ES0S MAN Diesel

07.11 -ES0 08028-0D/H5250/94.08.12 Page 1(2) Plate rlbiaigOlAam(A 5 60919-01H Prelubricating OilAlarm(LAL25) Switch point 04 03 02 01 L+V28/32H L+V28/32H 60919-01H * Only available kit. ofaspareparts aspart = Qty./Engine Qty./E = * When ordering spare parts, 600.50. seealsopage

Item No 04 03 02 01 .

Qty. 1/E 1/E 1/E 1/E Level switch Loctite 577 Packing ring Plug screw Designation Prelubricating OilAlarm(LAL25) Benævnelse Niveauafbryder Loctite 577 Pakningsring Propskrue

Item * Kun tilgængeligsomendelafetreservedelssæt. = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 07.11 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 07.12 -ES0 08028-0D/H5250/94.08.12 Page 1(2) Plate 08 15 13 07 Level Switch inOilSump(LAL/LAH28)

MIN MAX 0 9 13 08 06 16 05 01 15 04 10 60920-01H L28/32H 03 02 04 60920-01H L28/32H * Only available kit. ofaspareparts aspart = Qty./Engine Qty./E = * When ordering spare parts, 600.50. seealsopage

Item No 16 15 13 10 09 08 07 06 05 04 03 02 01 .

Qty. 1/E 2/E 1/E 2/E 2/E 1/E 1/E 4/E 4/E 1/E 1/E 1/E /I O-ring Loctite 577 Reduction adaptor Dipstick complete Reduction adaptor Level switch Pipe, LAH Pipe, LAL Nut Screw Packing Flange Level alarm Designation Level Switch inOilSump(LAL/LAH28) Benævnelse O-ring Loctite 577 Reduktionsadapter Pejlestok komplet Reduktionsadapter Niveaukontakt Rør, LAH Rør, LAL Møtrik Skrue Pakning Flange Niveaualarm

Item * Kun tilgængeligsomendelafetreservedelssæt. = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 07.12 -ES0

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Local Starting Box - No 1 60935-13H

L+V28/32H

07.45 - ES0 MAN Diesel

Plate 60935-13H Local Starting Box - No 1 Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty.Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0 07.45 -ES0 - TCR lader 08028-0D/H5250/94.08.12 MAN Diesel Page 1(2) Plate OVERSPEED REMOTE START Local Starting BoxLocal Starting -No1 300 140 ENG. 0 10000 TC 0 20000 LOCAL STOP 30000 RPM 600 60000 40000 720 50000 750 1200 ENGINE RPM BLOCKING 9 TC RPM 00 029 017 60935-16H L28/32H 60935-16H L28/32H = Only available kit. ofaspareparts aspart = Qty./Enigne. Qty./E = * When ordering spare parts, 600.50. seealsopage Item No 029 017 . Qty. 1/E 1/E Starting boxStarting Panel Designation Startboks Panel Benævnelse Local Starting BoxLocal Starting -No1 = Kun tilgængeligsomen delafetreservedelssæt. = Qty./Motor Qty./E = * Ved bestillingafreservedele, seogsåside600.50. Item No . t.Benævnelse Qty. Designation 07.45 -ES0 - TCR lader MAN Diesel Page 2(2) Plate

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Local Starting Box - No 2 60935-14H

L+V28/32H

07.45 - ES0 MAN Diesel

Plate 60935-14H Local Starting Box - No 2 Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty.Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0 MAN Diesel

Plate Page 1 (2) Local Starting Box - No 2 (incl. high lub. oil temp.) 60935-15H

L+V28/32H

07.45 - ES0 MAN Diesel

Plate 60935-15H Local Starting Box - No 2 (incl. high lub. oil temp.) Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty.Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0 MAN Diesel & Turbo

Plate Page 1 (2) Engine Control Box 60936-08H

General Beijer ELECTRONICS 70 T EXTER

536

727 715 703

345 345

0 4 0 4 1 5 1 5 OK OK 2 6 2 6

3 7 3 7 INPUT OUTPUT AC/DC OUT AC/DC OUT AC/DC DC INPUTS ANALOG ANALOG ISOLATED RELAY ISOLATED RELAY 095 0 4 8 12 585 Allen-Bradley 1 5 9 13 2 6 10 14 3 7 11 15

DC/RELAY OUT

0 4 8 573 1 5 9 333 -K6.6 2 6 10 3 7 11 -K8.0 -K7.0 -K9.0 -K9.6 644

656

-K9.2 404 11 12 13 14

394 GND 0 GND 274 GND 0 GND -F3.0 416 -F3.0.1 561 GND 0 GND 142 548 41 42 43 44

10.51 - ES0 MAN Diesel & Turbo

Plate 60936-08H Engine Control Box Page 2 (2)

General

Item Item no Qty Designation Benævnelse no Qty Designation Benævnelse

095 1/E Safety system, Sikkerhedssystem, Base unit Base unit

142 1/E Terminal, earth Jordklemme

274 3/E End stop Endestop

333 1/E Analog Analog output module outputmodul

345 2/E Digital Digital output module outputmodul

394 2/E Fuse terminal Sikringsklemme

404 1/E End plate Endeplade

416 4/E Fuse Sikring

536 1/E Panel Panel

548 50/E Terminal double Klemme, dobbelt

561 1/E End plate Endeplade

573 1/E Processor unit (CPU) Processor unit (CPU)

585 1/E End cap Endestykke

644 1/E Analog Analog input module inputmodul

656 1/E Converter Konverter

668 1/E Cable Kabel

703 8/E Cable union Kabelforskruning

715 3/E Cable union Kabelforskruning

727 2/E Cable union Kabelforskruning

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty/E = Qty/Engine Qty/E = Qty/Motor

10.51 - ES0 MAN Diesel 07.45 -ES0 08028-0D/H5250/94.08.12 Page 1(2) Plate 632 5 6 681 416 3 225 9 9 9 7 3 4

F1/1 F1/2

SSH 81 4P1 ( SAH 81 ) UX 95 4 500 9 X:1 0 607 Terminal Box 5K6

48 477 3K2

9 3K3 3K9 4K2

4K3 620 61 4K4 9

465 453 4K5 4K6 4K7 5K4 5K9 X:2 656 274 60936-07H 536 250 668 644 274 L28/32H 60936-07H L28/32H = Only available kit. ofaspareparts aspart = Qty/Engine Qty/E = * When ordering spare parts, 600.50. seealsopage Item 693 681 668 656 644 632 620 619 607 597 536 500 490 489 477 465 453 416 394 274 250 225 no 54/E 12/E 11/E 11/E Qty 3/E 3/E 2/E 1/E 1/E 1/E 1/E 2/E 2/E 2/E 2/E 2/E 2/E 2/E 2/E 4/E 1/E 1/E Nut M32 Cable unionM32 Diode terminal Terminal Terminal engine 750rpm Speed converter, Socket Aux. relay Timer engine 720rpm Speed converter, Panel Nut M25 Cable unionM25 Nut M20 Cable unionM20 Nut M16 Cable unionM16 Fuse 2A Fuse terminal End stop Conduit Conduit Designation Møtrik M32 Kabelunion M32 Diode klemme Klemme Klemme motor 750omdr Speed converter, Sokkel Hjælperelæ Timer motor 720omdr Speed converter, Panel Møtrik M25 Kabelunion M25 Møtrik M20 Kabelunion M20 Møtrik M16 Kabelunion M16 2A Sikring Sikringsklemme Endestop Ledningskanal Ledningskanal Benævnelse Terminal Box = Kun tilgængeligsomen delafetreservedelssæt. = Qty/Motor Qty/E = * Ved bestillingafreservedele, seogsåside600.50. Item no Qty Designation Benævnelse MAN Diesel Page 2(2) Plate 07.45 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 07.37 -ES0 08028-0D/H5250/94.08.12 Page 1(2) Plate (RS 485) DATA + ADAM

DATA - CONVERTER RS-422/RS-485 RS-232 TO

TX + (RS-232) (RS 422)

TX - ADAM-4520 RX + RX -

(R) +Vs (B) GND 10 ovre 60956-01 Converter 021 045 033 General 60956-01 General = Only available kit. ofaspareparts aspart = Qty/Engine Qty/E = * When ordering spare parts, 600.50. seealsopage Item 045 033 021 no Qty 1/E 1/E 1/E Designation Cable, length10m Cable, length1.8m Coverter Kabel, længde10m Kabel, længde1.8m Converter Benævnelse Converter = Kun tilgængeligsomen delafetreservedelssæt. = Qty/Motor Qty/E = * Ved bestillingafreservedele, seogsåside600.50. Item no Qty Designation Benævnelse MAN Diesel Page 2(2) Plate 07.37 -ES0

08028-0D/H5250/94.08.12 Crankshaft

510/610 MAN Diesel 91.45 -ES0U 08028-0D/H5250/94.08.12 Description Page 1(1) connection for lub. oilandwater pumps. coupling for thelub. oilpumporafl a alternator. Attheoppositeendthereisaclaw-type coupling fl the camshaft. Also fi wheeldrives wheel whichthroughanintermediate At thefl a centrally placedscrew. shaft by meansofdovetail joints andsecuredwith counterweights, whichareattached tothecrank- pressurethecrankshaft isprovidedbearing with surface.coated withawearing To attainasuitable shells, whichare are equippedwithinsertion-type pended ininderslungbearings. The mainbearings andcrankpin issus- ground journals, mainbearing The crankshaft, whichisaone-pieceforging with Crankshaft ywheel endthecrankshaft isfi ange for connectionofareductiongearor tted hereisthe fl Crankshaft andMainBearings exible gear wheel tted withagear ywheel and a and thedamperfl and theonlyconnectionbetween thecrankshaft connected tothefrontendofenginecrankshaft is fi between thecasingandfl closed inalightcasing. Asmallclearance isallowed consists essentiallyofaheavy fl the crankshaft tolimittorsionalvibrations. The damper In specialcasesavibration damper ismountedon Vibration Damper energy isabsorbedandappearsasheat. fore action,andvibration undergoesashearing flywheel andthecasing. The viscousfl andrelative motionoccursbetween the its inertia, the fl of ywheel tendstorotateuniformly by virtue casing follows themovement ofthecrankshaft but As thetorsionalvibration amplitudesincrease, the required tosheartheviscousfi fl ywheel tendtorotateasoneunit,sincetheforce conditions ofnovibration, thecasing anddamper lled withahighlyviscousfl ywheel isthroughthefl uid. The casingisrigidly ywheel, andthisspace lm isconsi-derable. ywheel totallyen- uid fi uid.Under L/V28/32H lm there- 610.01 Edition 12H 99.25 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(6) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: hours 11/2 Capacity : : 2 Working time men Man power: Related procedure: All indicatorvalves open. frame. Cover for crankshaft hasbeenremoved from Turning gearinengagement. (Ifmounted). position: Starting tion). Checking alignment(defl ofmainbearings Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Checking ofMainBearingsAlignment(Defl (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened ec- lt o Ie o Qty. / Itemno. Plate no. Replacement andwearingparts: Hand tools: 05 Note. 01 62010 62010 Itemno. Plateno. Special tools: 21 5 Angle 62010 35 for ection) crank web mounting on 610-01.00 L28/32H Edition 10H 610-01.00 L28/32H Edition 10H reading ofthe gauge. tal-top-horizontal-near bottom (P-T-S-Y infi thethrow isstoppedinthepositionho turning is inthenear-bottom(x fi The dialgaugeissettozero, when thecrank throw positions oneitherside. is tobereplacedby theaverage ofthetwo nearby the throw, themeasurementfor thebottomposition connecting rodwillmeetnearthebottompositionof ofthethrow, theturning As during thegaugeand therefore negative. In theexample, page3,the defl as negative, (compressionofthegauge). "Closing" ofthethrow intopdeadcentre is regarded provided for seefi thispurpose, g. 1. dialgaugeinthecentrepunchmarks springloaded The defl Defl Effecting The engine. ormisalignmnetofthe be wear ofthebearings positionmayThe causeofincorrectmainbearing in clearance atthebottomshellofbearings. stiff, any great deviations inthealignmentwillresult As thecrankshafts ofmediumspeedenginesarevery and conditionofthebearing. itismeasuredasacheckbearing, onthealignment to thedifference intheheightof in proportion shor As themagnitudeofsuchaxiallengtheningand bottom positionand"opens"intopposition. bend insuchaway into thatit"closes"whenturned crankform anarc, throw causingtheintermediate to crankshaft centrelinewillinthisplacebelowered to areplacedtoolow,If two adjacentmainbearings the main bearings. crankshaft tobendandincreasetheloadonsome tal) line. Deviations fromthiscentrelinecausethe crankshaft centeredinastraight (ashorehorizon- so thatthey ofthe keep journals themainbearing The lower shellsshouldbeposi mainbearing Alignment ofMainBearings. ten ection measurementiseffected by placinga ing during the turning ofthethrow increases theturning ing during Checking ofMainBearingsAlignment(Defl ection Measurement. g. the 8)andduring (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened ection reading is g. 8)for tion ri zon- ed

readings. wheel asthispressuremay otherwise falsify the the tangentialpressureon theteethofturning alittlebackwardsstoppage beturned to easeoff gearshouldateach aftmost cylinders, theturning When takingthesedefl Engines Equippedwith Turning Gear. journals. can beinfl Besides misalignmentofthebearings, thereadings fi gures inthetable fi Similarly, horizontalmisalignmentproceduresthe the mainbearings. These fi entered infi g. 4. frombottomtotoppositionis theturning during The totaldefl two "nearbottom"readingsXand Y, fi g. 3. As "bottom"readingisusedthemeanvalue ofthe example infi g. 2-6. The readingisenteredinthetable page6, see Defl Checking The i.1 Placingofdialgauge Fig. 1 misalignmentof gures areduetovertical uenced by ovality ofthe oreccentricity ection ("opening-closing")ofthethrow ection Measurement. g.5. ectionreadingsfor thethree ection) MAN Diesel Working Card Page 2(6) 99.25 -ES0S

08028-0D/H5250/94.08.12 99.25 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(6) Fig. 7. Fig. 3. Fig. 2. C and D should be nearly thesame,C andDshouldbenearly readingfor cylinder4toberepeated. Cyl. No. Defl ection ofcrankshaft in1/100mm. (0.01mm). otm(, ) B -. 0 05 1 0 -0.5 0 -0.5 1 B Bottom (0,5x Y) = o T 3 5-2 Bottom -2 4 3 Y 2 -1 0 1 0 2 S stop Right 3 -2 2 0 0 1 side Top P 2 0 2 0 -1 2 Left side Bottom X 0 0 0 start Crank 1 2 3 4 5 6 position negative. "Closing" ofthecrankthrow isconsidered Checking ofMainBearingsAlignment(Defl (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened Fig. 6. Fig. 5. Fig. 4. Fig. 8. rP-S= - 2 0 1 1 -1 0 0 2 -1 H 2 or P-S= Right side-left -2 4.5 zontal misalignment 4 Defl ection fromhori- -1.5 2 V or T -B= top -bottom misalignment Defl ection fromvertical edns D - 4 - 3 -1 0 4 4 -2 -2 5.5 5 4 D P+S= -2.5 readings 4 gauge C T+B= Check on Start inposition X. Start Turn Front anti end clockwise view. S Y ection) T X P 610-01.00 L28/32H Edition 10H 610-01.00 L28/32H Edition 10H cetbe r-610 mm 6/100 +or- Acceptable +or- mm 4/100 +or- Aimfor is recommendedifdefl ections exceed For realignment aggregate inservice For new orrealignedaggregate cetbe Acceptable - 10/100mm - 14/100mm -7/100 mm Aimfor ifdefl ection exceeds realignment recommendable For new orrealigned 10/100mm - aggregate For aggregate inservice engine exceedson warm 4/100mm recommended ifdefl + ection measured to 0 For realignmentis aggregate inservice Flexible couplingbetween dieselengineanddriven machine aggregate For new orrealigned diesel engineanddriven machine Rigid couplingbetween oiotldfleto = Difference inside-sidereadings. = Difference intop-bottomreadings. = Horizontal defl ection Vertical defl ection Difference indialindicatorreadingstwo diametrically = Crank throw defl ection Measurement ofCrank Throw Defl Checking ofMainBearingsAlignment(Defl Vertical andHorizontalDefl Unless otherwisestatedthevalues refer to coldengine. Unless otherwisestatedthevalues refer to coldengine. (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened Vertical Defl ection ofCrank Throw atFlywheel ced 180°. opposite crank throw positions, i.e. two positionsdispla- ections by MeansofDialIndicator(Autolog) ections ofCrank Throws ection) 10/100 mm MAN Diesel Working Card Pagee 4(6) 99.25 -ES0S

08028-0D/H5250/94.08.12 99.25 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 5(6) Remarks/Bemærkninger Page of/Sideaf Date/Dato I.D. Engineer/Operatør Instruction/Instruktion no. Engine Type/Motortype Plant/Anlæg Process/Proces Cyl. 123 no Checking ofMainBearingsAlignment(Defl Right side Left side 1/100 mm (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened Right side Bottom end/ Cyl. 123 no Cyl. 123 no Bund slut Right side Left side Top ection) Bottom start/ Bund start Left side 610-01.00 L28/32H Edition 10H 610-01.00 L28/32H Edition 10H (0.5xY)=B Bottom D C P +S= T +B= readings. Check ongauge H side orP-S= Left side-Right alignment. horizontal mis- Deflfrom ection V or T -B= Top -bottom ment. misalign- vertical Deflfrom ection Page of/Sideaf Y Bottom T S Warm/Varm Rightside Top P Leftside Cold/Kold Onboard/Ombord I.D. Bottom no. X Cyl. Plant/Maskinhal Test bed/prøvehal 0 0 Type6 789 12345 Tilstand no. Teststed/ Condition Test place/ Process/Proces Component/Komponent Motornr.: Engine no.: Checking ofMainBearingsAlignment(Defl (Hydraulic Tightened Connecting Rod) Connecting (Hydraulic Tightened ection) MAN Diesel Working Card Page 6(6) 99.25 -ES0S

08028-0D/H5250/94.08.12 96.30 -ES0S-G 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(3) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance hours Data: 2 Capacity : : 2 Working time men Manpower: 610-01.10 606-01.16 forCriteria replacementofbearings, shell, Inspection ofguidebearing Related procedure: position: Starting shells.mounting ofmainbearing Dismantling, inspectionand/orreplacementand Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Inspection ofMainBearingShells lt o tmn Qty/ Itemno Plateno Replacement andwearingparts: Copaslip. Silastene. Lead hammer. Socket spanner, 36mm. Allen key, 12mm. 2 Hand tools: pieces Hydraulic 20 tools Extra 51 tools 2 50 62021 pieces 40 62021 30 62021 2 15 62021 pieces 01 62010 Note 62010 10 62010 Itemno 62010 Plateno Special tools: 62010 20 L+V28/32H 610-01.05 Edition 05H L+V28/32H 610-01.05 Edition 05H engine frame withaleadhammerorsimilar. studnuts areremoved.when themainbearing tach itasshown, soastokeep capinplace thebearing Pass thewiresuppliedthrougheye screw andat- cap,holes inthemainbearing seeﬁ g 2. Dismantling oftheMainBearingCap nuts somewhat. Fig 1. MountingofHydraulic Tools. see working card620-01.05. see working studnuts.bearing For operation ofthehydraulic tools, ent positionfor outthework. carrying concerned. site thebearing 1) ing Make Ready for DismantlingoftheMainBear- 7) 6) 5) 4) 3) 2) Work caploosefromthe themainbearing Dismountthehydraulic toolsandslacken the Mountthehydraulic toolsandloosenthemain Dismountthebracing screw (sidescrew). Turn theengineuntilcrank isinacon Dismountcrankcase covers infrontandoppo- Fit theeye screws, diagonally, inthethreaded Inspection ofMainBearingShells ve ve ni- shell by turning thecrankshaft,shell by seeﬁ turning outtheupperbearing hole inthecrankshaft andturn shell,inthelubricating ling ofuppermainbearing 11) cap andtake shell. outthebearing 10) Dismantling oftheMainBearingShells the collarofguidetubes. studs andlower captomake thebearing itreston studnut. the bearing Fig 2. Mountingof Wire Straps. Fig 3. Mountingoftoolfor uppermainbearing. 9) 8) Lift the main bearing capalittleandunscrew Liftthemainbearing Fitthetoolfor for uppermainbearing, dis-mant- Remove thelocking piecefromthebearing Fit guidetubesonthethreadsofbearing bearing Tool for upper main g 3. g MAN Diesel Working Card Page 2(3) 96.30 -ES0S-G

08028-0D/H5250/94.08.12 96.30 -ES0S-G 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(3) molycote pastaorsimilar. 16) then remove thetoolfor uppermainbearing. Make surethattheshellentersitscorrectposition thecrankshaft. shellbybearing turning intheupper holeinthecrankshaft andturn ricating 15) as possible. 14) Mounting oftheMainBearingShells same size. when replaceditmust beby anew ofthe bearing Note: card606-01.16. working 13) Inspection ofMainBearingShells cap, shells. stud,nuts andbearing 12) Cleaning Lubricate the end of the bearing shellswith theendofbearing Lubricate shellasfar Pushtheupperbearing intopo shellsaccordingto Inspectthemainbearing Fit thetoolfor inthelub- uppermainbearing Clean allmachinedsurfaces, onframe, bearing ismarked accordingtosizeThe bearing and Inspection ofMainBearingShells si tion spanner asindicatedonpage600.40. 22) or similar. screws') hexagonal headwithathincoatofsilastene 21) page 600-40. on 620-01.05, andtightenthenuts asprescribed 20) 19) are intheircorrectposition. shell Make capandbearing surethatthebearing pasta orsimilarandﬁ studnuts.t thebearing the guidetubes, studswithmo coatthebearing 18) Mounting oftheMainBearingCap oil. lubricating withclean shellandjournal thebearing Lubricate cap andmountthelocking piece. 17) Coattheback sideofthebracing screws' (side Mountthehydraulic tools, card seeworking Dismantlethewirestraps. capintoposition,dismount Raisethebearing thelower shellinthebearing bearing Insert Mount thescrews andtightenwithatorque L+V28/32H 610.01-05 Edition 05H ly co te 02.47 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(4) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance hours Data 2 Capacity : : 2 Working time men Manpower shells. 606-01.16 610-01.05 forCriteria replacementofbearing shells.Inspection ofmainbearing Related procedure position Starting washer. shellsandthrust and mountingofguidebearing Dismantling, inspectionand/orreplacement Description Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stoppedengine Safety precautions Inspection ofGuideBearingShells 601 0 2 pieces Hydraulic 20 tools Extra 51 tools 2 50 62021 pieces 40 62021 30 62021 140-760Nm 15 62021 2 25 62010 pieces 01 62010 20 62010 28 10 Note 62010 62010 62010 62006 Itemno Plateno Special tools lt o tmn Qty/ Itemno Plateno Replacement andwearingparts Molycote Silastene Lead hammer Socket spanner, 36mm Allen key, 12mm Hand tools

L+V28/32H 610-01.10 Edition 08H L+V28/32H 610-01.10 Edition 08H Fig 1MountingofHydraulic Tools Pass thewiresuppliedthrougheye screw Dismantling oftheGuideBearingCap Bearing Make Ready for DismantlingoftheGuide 7) 6) 5) 4) 3) 2) 1) Work cap loosefromthe theguidebearing Fittheeye screws, diagonally, inthethreaded Dismountthehydraulic tools and slacken the Mountthehydraulic tools, seefi g 1,and Dismountthebracing screw (sidescrew). Dismountthecrankcase covers oppositethe engine frame with a leadhammerorsimilar. stud nuts areremoved. capinplacewhentheguidebearing bearing and attachitasshown, soastokeep the cap,holes intheguidebearing seefi g 2. nuts somewhat. 620-01.05. ration ofthehydraulic tools, card seeworking studnuts.loosen theguidebearing For ope- position for outthework. carrying Turn theengineuntilcrank isinaconvenient concerned. bearing Inspection ofGuideBearingShells To pump Fig 2Mountingof Wire Straps after lowering the bearing cap,after lowering thebearing seefi g 3. means offour screwed-on clampswhich are visible countersunk intotheengine frame andattachedby washer is partially The thrust oftheguidebearing with Fig 3GuideBearing Thrust Washer 10) Dismantling oftheGuideBearingShells 9) 8) Fit guide tubes on the threads of the bearing Fitguidetubesonthethreadsofbearing cap alittleandunscrew Lifttheguidebearing Remove thelocking piecefromthebearing cap andtake shell. outthebearing on thecollarofguidetubes. studs andlower captomake the bearing itrest studnut. the bearing Thrust washerThrust MAN Diesel Working Card Page 2(4) 02.47 -ES0

08028-0D/H5250/94.08.12 MAN Diesel 02.47 -ES0 08028-0D/H5250/94.08.12 Working Card Page 3(4) Fig 4DismountingofUpperShell 13) Afterthat,dismount theguidetubes, fi t and 12) 11) With theguideshelltool,whichisguidedby Fitthetoolsfor dismantlingofupperguide Unscrew theclamnsandpushoutthrust bearing shellandtheguidetool. bearing on thecollarofguidetubes. Take outthe dismount thenuts andlower cap thebearing cap. outintothebearing carefully turned Then cap,the bearing shellis the upperbearing tighten thenuts slightly. that theguideshellisnotbeingdamaged. capintoposition,makingsure raise thebearing shell,seefi bearing washers. g 4, in the bearing capand g 4,inthebearing Inspection ofGuideBearingShells of theguideshelltooltodislodgeit. studs, andbearing usetheboltonbackbearing In casetheguideshelltoolislocked between guide 15) Inspection ofGuideBearingShells 14) Cleaning ofComponents 17) 16) shell istobefi tted, seefi g 5. ning ontheengineframe whentheupperbearing For aguidetoolissuppliedfor thispurpose positio- rect inthebore. essential thattheshellsarepositionedperfectly cor- than theborefor anditistherefore theguide bearing identical tothoseofthemainbearings, arenarrower whichare shellsoftheguidebearing, The bearing Mounting oftheGuideBearingShells Fig 5MountingofUpperShellinGuideBearing

Insert the guide shell tool in the bearing cap, theguideshelltoolinbearing Insert shellasfar Pushthe bearing aspossible into working card606-01.16. working shells according to Inspect theguidebearing cap, shells. stud,nuts andbearing Clean allmachinedsurfaces, onframe, bearing bes. which isrestingonthecollar oftheguidetu- position throughthisguide tool. Guide for mountingofuppershell. L+V28/32H 610-01.10 Edition 08H L+V28/32H 610-01.10 Edition 08H 23) 22) Note: 21) 20) 19) 18) Insert the lower bearing shell in the bearing thelower shellinthebearing bearing Insert Thenunscrew studnuts, thebearing fi Now shellintoitscorrect pushthebearing capwiththeguideshelltool Raisethebearing cap, andmountthelocking piece. molycote pastaorsimilar. shellswith theendofbearing Lubricate 600.35. washersFit thethrust andclamps. tubes andlower cap again. thebearing that theshellentersitscorrectposition. position withtheguideshelltool.Make sure slightly. tubes, fi studnuts t andtightenthebearing into itscorrectposition,dismounttheguide Clearance in guide bearing axially, Clearance inguidebearing seepage Inspection ofGuideBearingShells t the guide t theguide 28) 27) 26) 25) Make washers, surethatthethrust shell bearing 24) oil. lubricating withclean shellandjournal thebearing Lubricate Bearing Cap Mountthescrews andtightenwithatorque Coattheback sideofthebracing screws' (side Mountthehydraulic tools, card seeworking Dismantlethewirestraps. capintoposition,dismount Raisethebearing spanner asindicatedonpage600.40. silastene orsimilar. screws') hexagonal headwithathincoatof on page600-40. 620-01.05, andtightenthenuts asprescribed capareintheircorrectposition. and bearing stud nuts. molycote pastaorsimilarandfi the guidetubes, studwith coatthebearing t thebearing MAN Diesel Working Card Page 4(4) 02.47 -ES0

08028-0D/H5250/94.08.12 10.15 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(3) Declaration ofweight Data for torque moment Data for pressure andtolerance Data: Capacity Working time Man power: Related procedure: position: Starting Taking asiliconeoilsample Description: Safety precautions: Stopped lub. oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater air Shut-off starting Stopped engine : :

2-4 1 man hours (Page 600.45) (Page 600.40) (Page 600.35) Vibration Damper Special tools: See plate61004 Replacement andwearingparts: Ring andopenendspanner, 19mm. Hand tools: Plate no. Plate no.

Item no. Item no.

Note. Qty. / 610-04.00 General Edition 01H 610-04.00 General Edition 01H the damper. to access for pump, water cooling the or pump oil lub.the dismount to necessary is it cases some In flange (A)onthefrontendcover (B)seefig. 1. down toapproximately 40°C. plate 61004. Holeby,Turbo,see & PrimeServ Diesel required MAN from be can that tube special a of means by A silicone oil sample should be extracted as follows is possible. efficiency damper the of assessment approximate Corresponding to the condition of the silicone oil an having todismantleit. viscosity of the silicone oil inside the the testing damper of without opportunity the provide which plugs extraction with equipped is damper vibration The Fig. 1. Mountingof Vibration Damper. 2. 1.

For access to the damper remove the blank the remove damper the to access For cool damper let stopped is engine the After F

F. E. D. C. B. A.

E Crankshaft. (Frame)Main bearing Gearwheel (ifmounted) Damper. Front endcover. Blank flangeorcooling water pump. Vibration Damper A B D C

2 A. fig.see position, optimal in damper the of (6) plugs

one ofitscaps(11),seefig. 2 C. Fig. 2. Vibration Damper 3. 4.

Rotate the engine in order to bring the extraction Prepare the sample container (10) by removing B A C 10 5 3 7 6 5 11 MAN Diesel Working Card Page 2(3) 6 6 10.15 -ES0

08028-0D/H5250/94.08.12 10.15 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(3) Seal bothplugsby caulkingtheirgrooves. forefinger then turn them further 45° (about 20 Nm). Now closethesecond sideofthecontainer. (7). washers sealing new with together plugs the sealing jaceroundtheextraction holeandscrew in Removethe off wipe casing, damper the cap.from container the the by container sample the close If possible it,canbespeededupby meansof: viscosity the process needs a certain amount of time. flow out from the free end. to begins Depending (5) onfluid thesilicone until silicone wait and container one revolution. If meeting the ring (3) inertia unscrew the container (10). container sample the with it replace and (6) plugs 8. 7. 6. 5.

B A Tighten both extraction plugs with thumb and flow, to begins fluid silicone the as soon As sample the from cap second the Remove extraction the of one remove and Unscrew plug too. Temporarily removing the second extraction thecrankshaft. ner isunderneath Turning the damper until the sample contai- Vibration Damper up to10suchsamplescanbetaken withoutrisk. The quantity of silicone oil removed its so small that page 600.25.

can forward theresultofanalysiscorrectly. The sample must be marked in such a way that we 10. 9.

For hours between taking new samples, see samples, new taking between hours For Denmark 4960 Holeby 2 Østervej Holeby PrimeServ MAN Diesel& Turbo Send thesamplecontainerto: - - - - - Data for vibration damper. Running hours. Engine no. Engine type. Name ofship. 610-04.00 General Edition 01H MAN Diesel

Plate Page 1 (2) Crankshaft 61001-15H

L28/32H

12 13 09

06 05

02+ 15+

01 16 17 18

07-14

08-14

06.33 - ES0 MAN Diesel

Plate 61001-15H Crankshaft Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Crankshaft Krumtapaksel 6 cyl. engine 6 cyl. motor

02+ /I Counterweight Kontravægt 6,7,9 cyl. engine 6,7,9 cyl. motor

03 1/W Locking plate Sikringsplade

04 1/W Locking plate Sikringsplade

05 2/W Screw Skrue

06 1/W Screw for Skrue for counterweight kontravægt

07 1/C Plug screw Propskrue

08 1/E Plug screw Propskrue

09 12/E Screw Skrue

10 12/E Self locking nut Selvlåsende møtrik

11 12/E Washer Skive

12 1/E Oil throw ring Olieafslyngningsring

13 1/E Gear wheel Tandhjul (crankshaft) (krumtap)

14 /I Loctite 242 Loctite 242

15+ /I Counterweight Kontravægt 8 cyl. engine 8 cyl. motor

16 1/E Crankshaft Krumtapaksel 7 cyl. engine 7 cyl. motor

17 1/E Crankshaft Krumtapaksel 8 cyl. engine 8 cyl. motor

18 1/E Crankshaft Krumtapaksel 9 cyl. engine 9 cyl. motor

+ Item No. 02 and 15 + Item nr. 02 og 15 require an indi vi- kræver en individuel dual matching tilpasning før before mounting montering, kontakt contact MAN Diesel, MAN Diesel, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt Qty./I = Qty./Individual Antal/I = Antal/Individuelt Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

06.33 - ES0 MAN Diesel

Plate Page 1 (2) Crankshaft 61001-21H

5L28/32H

15+ 12 13 03 09 04

06 05

02+

07-14

08-14

06.33 - ES0 MAN Diesel

Plate 61001-21H Crankshaft Page 2 (2)

5L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Crankshaft Krumtapaksel

02+ /I Counterweight Kontravægt

03 1/W Locking plate Sikringsplade

04 1/W Locking plate Sikringsplade

05 2/W Screw Skrue

06 1/W Screw for Skrue for counterweight kontravægt

07 1/C Plug screw Propskrue

08 1/E Plug screw Propskrue

09 12/E Screw Skrue

10 12/E Self locking nut Selvlåsende møtrik

11 12/E Washer Skive

12 1/E Oil throw ring Olieafslyngningsring

13 1/E Gear wheel Tandhjul (crankshaft) (krumtap)

14 /I Loctite 242 Loctite 242

15+ /I Counterweight Kontravægt

+ Item No. 02 and 15 + Item nr. 02 og 15 require an indivi- kræver en individuel dual matching tilpasning før before mounting montering, kontakt contact MAN Diesel, MAN Diesel, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

06.33 - ES0 MAN Diesel

Plate Page 1 (2) Resilient Gear Wheel 61002-07H

L28/32H

Crankshaft 19+ (Plate 61001)

05 03

07 18

08 04 09

10 10

17 16

96.01 - ES0S MAN Diesel

Plate 61002-07H Resilient Gear Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul, wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut, for Selvlåsende møtrik, Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en individual matching individuel tilpasning during mounting, før montering, kontakt contact MAN Diesel, MAN Diesel, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

96.01 - ES0S MAN Diesel

Plate Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-11H

6-7-8-9L28/32H

Crankshaft (Plate 61001)

07.02 - ES0 MAN Diesel

Plate 61002-11H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

6-7-8-9L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling ﬂ ange Koblingsﬂ ange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.02 - ES0 MAN Diesel

Plate Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-12H

5L28/32H

Crankshaft (Plate 61001)

04 01

07.02 - ES0 MAN Diesel

Plate 61002-12H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

5L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling ﬂ ange Koblingsﬂ ange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

04 1/E Flyweight Svingklods

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.02 - ES0 MAN Diesel

Plate Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-13H

5L28/32H

Crankshaft (Plate 61001)

04 01

07.03 - ES0 MAN Diesel

Plate 61002-13H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

5L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling ﬂ ange Koblingsﬂ ange

04 1/E Flyweight Svingklods

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0 MAN Diesel

Plate Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-14H

L28/32H

Crankshaft (Plate 61001)

07.03 - ES0 MAN Diesel

Plate 61002-14H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling ﬂ ange Koblingsﬂ ange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0 MAN Diesel

Plate Page 1 (2) Resilient Gear Wheel 61002-15H

L28/32H

Crankshaft (Plate 61001)

05 03

07 18

08 09 04

10 10

17 16

07.03 - ES0 MAN Diesel

Plate 61002-15H Resilient Gear Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul, wheel, compl. komplet

02 1/E Axle journal Akseltap

03 6/E Stud Tap

04 12/E Self locking nut, Selvlåsende møtrik, for Item No. 03 for Item nr. 03

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0 MAN Diesel

Plate Page 1 (2) Resilient Gear Wheel 61002-16H

L28/32H

Crankshaft 19+ (Plate 61001)

05 03

07 18

08 04 09

10 10

17 16

07.03 - ES0 MAN Diesel

Plate 61002-16H Resilient Gear Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul, wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut,for Selvlåsende møtrik, Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en individual matching individuel tilpasning during mounting, før montering, kontakt contact MAN diesel, MAN Diesel, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0 MAN Diesel

Plate Page 1 (2) Resilient Gear Wheel 61002-17H

L28/32H

Crankshaft 19+ (Plate 61001)

05 03

07 18

08 04 09

10 10

17 16

07.03 - ES0 MAN Diesel

Plate 61002-17H Resilient Gear Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul, wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut,for Selvlåsende møtrik, Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en individual matching individuel tilpasning during mounting, før montering, kontakt contact MAN Diesel, MAN Diesel, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0 MAN Diesel

Plate Page 1 (2) Flywheel with Gear Rim 61003-02H

5L28/32H

11 05

01 Crankshaft (plate 61001) 03 02

07.02 - ES0 MAN Diesel

Plate 61003-02H Flywheel with Gear Rim Page 2 (2)

5L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0 MAN Diesel

Plate Page 1 (2) Flywheel with Gear Rim 61003-05H

L28/32H

11 05

01 Crankshaft (plate 61001) 03 02

07.02 - ES0 MAN Diesel

Plate 61003-05H Flywheel with Gear Rim Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0 MAN Diesel

Plate Page 1 (2) Flywheel with Gear Rim 61003-06H

L28/32H

11 05

01 Crankshaft (plate 61001) 03 02

07.02 - ES0 MAN Diesel

Plate 61003-06H Flywheel with Gear Rim Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-05H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-05H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving- onal vibration damper ningsdæmper (the kit includes an (Sættet er inklusiv en analysis of the sample analyse af prøven. Alle taken. All information informationer er til- is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-12H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-12H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-13H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-13H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-14H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-14H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-15H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-15H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Torsional Vibration Damper 61004-16H

L28/32H

04* 05 02*

03*

10.14 - ES0 MAN Diesel

Plate 61004-16H Torsional Vibration Damper Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Torsional vibration Svingningsdæmper damper, with 30 mm med 30 mm monte- mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings- beholder

04* 1/E O-ring O-ring

+ See also working + Se også arbejdskort card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0 MAN Diesel

Plate Page 1 (2) Tuning Wheel 61004-06H

L28/32H

94.23 - ES0S MAN Diesel

Plate 61004-06H Tuning Wheel Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Tuning wheel with, Afstemningshjul med 30 mm mounting ﬂ an- 30 mm monterings- ge ﬂ an-ge

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

94.23 - ES0S Engine frame/Oil pan

511/611 91.13 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) without scraping. equip sides oftheengineframe.Themainbearingsare into thesidesofcapsandtightenedagainst of bracingscrews, whichare screwed horizontally main bearingcapsare secured further bymeans with theaidofhydraulictools.Aftermounting, studs andnuts,whichare loosenedandtightened The mainbearingcapsare attachedbymeansof bearing caps. shaft isunderslung,i.e.itcarriedbythemain with bores forthemainbearingsinwhichcrank- bolts. Thecross girders oftheframeare provided tached tothetopofbaseframebymeans The engineframeismadeofcastiron, andisat- Frame ped withreplaceable shellswhichare fi Engine FrameandBase tted "wet sump". The baseframeisusedaslubricatingoilreservoir a commonbaseframewhichisinweldeddesign. (gear,Engine andalternator pump)are mountedon Base Frame ignited, forinstanceintheeventofahotbearing. which willact,shouldoilvapoursinthecrankcasebe case. Someofthecoversare fitted withrelief valves to thecamshaft,chargeairreceiver andcrank- On thesidesofframethere are coversforacces wheel endoftheengine. The crankshaftguidebearingislocatedatthefl y- L28/32H 611.01 Edition 07H 06.46 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/4 Capacity : : 1 Working time man Man power: Related procedure: position: Starting ves. Functional testofcrankcase safety reliefval- Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Functional Test ofCrankcaseSafety Relief Valves 616 5 1/relief 1/cyl. valve 12/relief 45 valve 39 Qty. / 61106 13 61106 61106 Itemno. Plateno. Replacement andwearingparts: Hand tools: Note. Itemno. Plateno. Special tools: 611-01.00 General Edition 04H MAN Diesel 611-01.00 General Edition 04H Ifthesafety reliefvalves areactuated,the Thereliefvalve must openunderthispres- 3) 2) follows: To check theproperopening pressure, proceedas Check ofOpeningPressure the safety reliefvalves withpaint. When paintingtheengine, take carenottoblock up When Painting the valve fl engine, but itmust bechecked overhauls during that valves operation cannotbeperformed ofthe during Functional testingofthecrankcase safety relief Functional Testing 4) 1) Remountthereliefvalve cover oftheengine. Applyaweight at18kgonthepressure Placethecover onthefl oor withthepressure Remove thereliefvalve cover fromtheengi- 503.04, IgnitioninCrankcase. and thefault isdetected, untilthecauseisdetected must notberestarted engine must bestoppedimmediately, andit sure. area. area upwards. ne. ap ismovable. Functional Test ofCrankcaseSafety Relief Valves see also description seealsodescription

i Cover withreliefvalve Fig 1 valve Relief Cover Working Card Page 2(2) 06.46 -ES0

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Frame with Main Bearings 61101-11H

01 L28/32H 02 03 05 04 06 03 10 04 11 09 12

16 14 17 15 18 21+ 19+

20 10 22 23 13 25 27

24 15 14

10 26+ 23 22 21+ 24

Cover ( Plate 61102)

06.49 - ES0 MAN Diesel

Plate 61101-11H Frame with Main Bearings Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/C Wear ring Slidring 27 1/C Cylindrical pin Cylindrisk stift

02 3/C Protective cap, Beskyttelseshætte, plastic plastik + Item No. 19, 21 and + Item nr. 19, 21 og 26 03 6/C Nut for Møtrik for 26 require an indi- kræver en individuel cylinder cover cylinderdæksel vidual tilpasning før monte- matching before ring, 04 6/C Cylinder cover Tap for mounting, contact kontakt MAN B&W, stud cylinderdæksel MAN B&W, Holeby Holeby

05 3/C Protective cap, Beskyttelseshætte, metal metal

06 3/C O-ring O-ring

09 6/C Sealing kit Tætningssæt for for cap dæksel

10 Loctite 243 Loctite 243

11 Silicone oil Silikoneolie

12 1/E Frame Stativ

13 1/B Main bearing Hovedleje- shell 2/2 skaller 2/2

14 1/B Locking piece Låsestykke

15 2/B Screw Skrue

16 4/E Safety sleeve Sikkerhedsbøsning

17 4/E Screw Skrue

18 1/E Cylindrical pin Cylindrisk stift

19+ 1/E Guide bearing cap Styrelejedæksel

20 2/E Thrust bearing Trykleje

21+ 2/B Distance piece Afstandsstykke

22 6/B Screw Skrue

23 2/B Main bearing stud Hovedleje tap

24 2/B Nut for main Møtrik for bearing stud hovedlejetap

25 2/B Bracing screw Sideskrue

26+ 1/C Main bearing cap Hovedlejedæksel

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty/Cylinder Antal/C = Antal/Cylinder Qty./B = Qty/Bearing Antal/B = Antal/Leje

06.49 - ES0 MAN Diesel

Plate Front Cover for 61102-09H Page 1 (2) Lubricating Oil Pump

L28/32H

02 For lubricating oil pump, see Plate 61501

06 04 07

91.45 - ES0S MAN Diesel

61102-09H Front Cover for Plate Lubricating Oil Pump Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Cover Dæksel

02 40/E Screw Skrue

03 2/E Guide pin Styrestift

04 2/E Nut Møtrik

05 1/E Gasket Pakning

06 1/E Cover Dæksel

07 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

91.45 - ES0S MAN Diesel

Plate Front Cover for 61102-07H Page 1 (2) Lubricating Oil Pump and Cooling Water Pump

L28/32H

Fresh water cooling pump (Plate 61610)

13 01 14 02 03

12 04 11 10

09 08 04 05+

06 07

10 09 10 04

Lub. oil pump (Plate 61501)

91.40 - ES0S MAN Diesel

61102-07H Front Cover for Plate Lubricating Oil Pump and Cooling Water Pump Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 4/E Screw Skrue

02 4/E Locking plate Låseskive

03 2/E Spray pipe Sprøjterør

04 52/E Screw Skrue

05+ 1/E Cover Dæksel

06 2/E Guide pin Styrestift

07 2/E Nut Møtrik

08 2/E Gasket Pakning

09 2/E Cover Dæksel

10 18/E Screw Skrue

11 1/E Gasket Pakning

12 1/E Cover Dæksel

13 2/E Guide pin Styrestift

14 2/E Nut Møtrik

+ Item No. 05 + Item nr. 05 kræver require an indi vidual en individuel til- matching before pasning før montering, mounting, contact kontakt MAN B&W, MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

91.40 - ES0S MAN Diesel

Plate Front Cover for 61102-10H Page 1 (2) Lubricating Oil Pump and Cooling Water Pumps

L28/32H

Fresh water cooling pumps (Plate 61610)

13 01 14 02 03

04 12 11 05+

10 06 07

09 10 04

Lub. oil pump (Plate 61501)

92.38 - ES0S MAN Diesel

61102-10H Front Cover for Plate Lubricating Oil Pump and Cooling Water Pumps Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 6/E Screw Skrue

02 6/E Locking plate Låseskive

03 3/E Spray pipe Sprøjterør

04 58/E Screw Skrue

05+ 1/E Cover Dæksel

06 2/E Guide pin Styrestift

07 2/E Nut Møtrik

08 1/E Gasket Pakning

09 1/E Cover Dæksel

10 12/E Screw Skrue

11 1/E Gasket Pakning

12 1/E Cover Dæksel

13 4/E Guide pin Styrestift

14 4/E Nut Møtrik

+ Item No. 05 + Item nr. 05 kræver require an indi vidual en individuel til- matching before pasning før montering, mounting, contact kontakt MAN B&W, MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

92.38 - ES0S MAN Diesel & Turbo

Plate Page 1 (2) Covers on Frame 61106-20H

L28/32H

06.06 - ES0 MAN Diesel & Turbo

Plate 61106-20H Covers on Frame Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Guard end aft Skærm, agter 27 /I Cover Dæksel

02 12/E Washer Skive 28 /I Gasket Pakning

03 12/E Screw Skrue 39 12/D Washer Skive

04 1/C Intermediate guard Mellemskærm 40 1/D Flange Flange

05 1/C Handle, upper Håndtag, øverst 45 1/D O-ring O-ring

06 1/C Handle, lower Håndtag, nederst

07 1/E Guard end fore Skærm, for + Item 14, 15 and 16 + Item 14, 15 og 16 er are only mounted if kun monteret hvis mo- 08 1/C Intermediate gauge Mellemskærm, the engine is delive- toren er leveret uden complete, Item 04, komplet, Item 04, red without fuel oil fuel olieforpumpe 05 and 06 05 and 06 feed pump

09 12/C Screw Skrue

10 1/C Cover for camshaft Dæksel for housing Kamakselhus

11 1/C O-ring O-ring

12 Cover for Dæksel for crankcase krumtaphus 7/E 5 cyl. engine 5 cyl. motor 8/E 6 cyl. engine 6 cyl. motor 10/E 7 cyl. engine 7 cyl. motor 11/E 8 cyl. engine 8 cyl. motor 12/E 9 cyl. engine 9 cyl. motor

13 2/C O-ring O-ring

+14 6/E Screw Skrue

+15 1/E Cover Dæksel

+16 1/E Gasket Pakning

17 6/D Self locking nut Selvlåsende møtrik

19 6/D Screw Skrue

24 Cover with safety Dæksel med sikker- valve complete hedsventil komplet 3/E 5 cyl. engine 5 cyl. motor 4/E 6 cyl. engine 6 cyl. motor 4/E 7 cyl. engine 7 cyl. motor 5/E 8 cyl. engine 8 cyl. motor 6/E 9 cyl. engine 9 cyl. motor

25 1/D Safety valve Sikkerhedsventil, complete komplet

26 /I Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder Qty./D = Qty./Safety cover Antal/D = Antal/Sikkerhedsdæksel Qty./I = Qty./Individual Antal/I = Antal/Individuelt

06.06 - ES0 MAN Diesel & Turbo

Plate Page 1 (2) Covers on Frame 61106-14H

L28/32H

01 04

15 05 02

14 06 12 07 08 13 16 09

11 10 11

07.08 - ES0 MAN Diesel & Turbo

Plate 61106-14H Covers on Frame Page 2 (2)

L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 12/E Screw Skrue

02 1/E Sealing ring 2/2 Tætningsring 2/2

03 2/E Guide pin Styrestift

04 2/E Cylindrical pin Cylindrisk stift

05 2/E Screw Skrue

06 6/E Screw Skrue

07 1/E Flange Flange

08 1/E Gasket Pakning

09 4/E Guide pin Styrestift

10 39/E Screw Skrue

11 1/E Cover 2/2 Dæksel 2/2

12 18/E Screw Skrue

13 1/E Cover Dæksel

14 1/E Gasket Pakning

15 2/E Nut Møtrik

16 4/E Nut Møtrik

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

07.08 - ES0 Turbocharger

512/612 MAN Diesel

Description 612.01 Page 1 (2) Turbocharger System Edition 28H

L28/32H

Fig. 1. Diagram for Turbocharger System

Turbocharger System The charging air cooler is of the compact tube-type with a large cooling surface. The cooling water is pas- The turbocharger system of the engine, which is a sed twice through the cooler, the end covers being constant pressure system, consists of an exhaust designed with partitions which cause the cooling gas receiver, a turbocharger, a charging air cooler water to turn. and a charging air receiver, the latter being inte grated in the engine frame. The cooling water tubes are ﬁ xed to the tube plates by expansion. The turbine wheel of the turbocharger is driven by the engine exhaust gas, and the turbine wheel drives From the exhaust valves, the exhaust is led through the turbocharger compressor, which is mounted on water cooled intermediate pieces to the exhaust gas the same shaft. receiver where the pulsatory pressure from the individual exhaust valves is equalized and passed to the Turbocharger, see separate manual. turbocharger as a constant pressure, and further to the exhaust outlet and silencer arrangement. The turbocharger pumps the air through the charging air cooler to the charging air receiver. From the The exhaust gas receiver is made of pipe sections, charging air receiver, the air ﬂ ows to each cylinder one for each cylinder. The pipe sections are connected through the inlet valves. to each other with compensators. This prevents excessive stress in the pipes due to heat expansion.

03.26 - EO2S MAN Diesel

612.01 Description Edition 28H Turbocharger System Page 2 (2)

L28/32H

In the cooled intermediate piece a thermometer for The purpose is to increase the compressor perfor- reading the exhaust gas temperature is ﬁ tted. It is mance. With this system the engine can take up a also possible to ﬁ t a sensor for remote reading. large momentary load increase.

To avoid excessive thermal loss and to ensure a The system is activated automatically and only when reasonably low surface temperature, the exhaust the engine is exposed to a large momentary load gas receiver is insulated. increase, see section 609.

The turbocharger is equipped with a jet system for supply of extra driving torque to the compressor.

03.26 - EO2S 94.01 -ES0U 08028-0D/H5250/94.08.12 MAN Diesel Description Page 1(1) mechanical cleaning. for betweenthe intervals dismantlingnecessary fouling rate considerably, andconsequentlyprolong water before thecompressorwheelwillreduce operation byRegular cleaningduring injectionof Severe fouling ofairways may even resultin compressor - Increasingexhaust gastemperature. surge. - Decreasingturbochargerrotorspeed. - Decreasingchargingairpressure. - meters: may aschangesinperformance beobserved para- Fouling ofairﬁ fresh airventilation systemoftheengineroom. of thegasandoiltightnessengineson maintenance conditionofthemachinery, i.e. mainly onthegeneral oftheinletairandthus, rity inturn, Fouling oftheairways onthepu- dependsprimarily Compressor lter, compressororchargingaircooler Cleaning the Turbocharger InService Water Washing ofCompressor observations andexperience.observations rate plant,i.e. offouling intheparticular basedon should beadjustedafterassessingthedegree and betweenThe intervals cleaningby injectionofwater under nocircumstancesbeused. of depositsonthecompressorwheel,andshould typesofﬂ Certain effect fromtheimpactofwater droplets. isbasedonthemechanical process asthisprimarily Chemical cleaningwillnotimprove thecleaning uid solvents cangive formation General 612.05 Edition 07H MAN Diesel

Description Cleaning the Turbocharger in Service 612.10 Page 1 (3) Dry Cleaning - Turbine Edition 09H

L+V28/32H

Description Cleaning System

The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent char gers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and which are a result of the load and the maintenance a removable cover. Furthermore the system consists con di tion of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap fuel oil used. on connectors.

Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each the combustion chamber components and will also en gine plant. The blow-gun is working according to lead to a higher fuel consumption rate. the ejector principle with pressure air (working air) at 5-7 bar as driven medium. Injection time approx. Tests and practical experience have shown that ra di- 2 min. Air consumption approx. 5 Nm3/2 min. al-ﬂ ow turbines can be successfully cleaned by the dry cleaning method.

This cleaning method employs cleaning agents con- sisting of dry solid bodies in the form of granules. A certain amount of these granules, depending on the turbocharger size, is, by means of compressed air, blown into the exhaust gas line before the gas inlet casing of the turbocharger.

The injection of granules is done by means of working air with a pressure of 5-7 bar.

On account of their hardness, particularly suited blasting agents such as nut-shells, broken or arti ﬁ - ci ally shaped activated charcoal with a grain size of 1.0 mm to max. 1.5 mm should be used as cleaning a gents. 1 Closing valve 2 Container The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling turbine blades. Fig 1 Arrangement of dry cleaning of turbocharger - Turbine. Dry cleaning can be executed at full engine load and does not require any subsequent operating period of the engine in order to dry out the exhaust system.

Experience has shown that regular cleaning intervals are essential to successful cleaning, as ex-cessive fouling is thus avoided. Cleaning every second day during operation is recommended.

The cleaning intervals can be shorter or longer based on operational experience.

97.08 - ES2S MAN Diesel

612.10 Cleaning the Turbocharger in Service Description Page 2 (3) Edition 09H Dry Cleaning - Turbine

L+V28/32H

Dry cleaning of turbochargers

Suppliers of cleaning agents:

1. "Solf Blast Grit, Grade 14/25"

TURCO Products B.V. Verl. Blokkenweg 12, 617 AD EDE - Holland Tel.:08380 - 31380, Fax.: 08380 - 37069

2. Designation unknown

Neptunes Vinke B.V. Schuttevaerweg 24, 3044 BB Rotterdam Potbus 11032, 3004 E.A. Rotterdam, Holland Tel.: 010 - 4373166 Fax.: 4623466

3. "Grade 16/10"

FA. Poul Auer GmbH Strahltechnik D-6800 Mainheim 31, Germany

4. "Granulated Nut Shells"

Eisenwerke Würth GmbH + Co. 4107 Bad Friederichshall, Germany Tel.: 0 71 36-60 01

5. "Soft Blasting Grade 12/3a"

H.S. Hansen Eftf. Kattegatvej 2 2100 Copenhagen Ø, Denmark Tel.:(31) 29 97 00 Telex: 19038

6. "Crushed Nutshells"

Brigantine, Hong Kong

7. "Turbine Wash"

Ishikawajima-Harima Heavy Industries Co. Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku Tokyo 104, Japan Tel.: 03-2 77-42 91

97.08 - ES2S MAN Diesel

Description Cleaning the Turbocharger in Service 612.10 Page 3 (3) Dry Cleaning - Turbine Edition 09H

L+V28/32H

8. "A-C Cleaner" (Activated Coal)

Mitsui Kozan Co. Ltd. (Fuel Dept.) Yamaguchi Bldg., 2-1-1 Nihonbashi Muromachi, Chuo-Ku Tokyo 103, Japan

9. "OMT-701"

Marix KK Kimura Bldg., 6-2-1 Shinbashi Minato-Ku, Tokyo 105, Japan Tel.: 03-4 36-63 71, Telex: 242-7232 MAIX J

10. "OMT-701"

OMT Incorporated 4F, Kiji Bldg., 2-8 Hatchobori, 4-chome, Chuo-Ku, Tokyo 104, Japan Tel.: 03-5 53-50 77, Telex: 252-2747 OMTINC J

11. "Marine Grid No. 14" (Walnut)

Hikawa Marine Kaigan-Dori 1-1-1, Kobe 650, Japan Tel.: 0 78-3 21-66 56

12. "Marine Grid No. 14"

Mashin Shokai Irie-Dori, 3-1-13, Hyogo-Ku Kobe 652, Japan Tel.: 0 78-6 51-15 81

13. Granulate

MAN B&W Diesel A/S Teglholmsgade 41 2450 København SV, Danmark Tel.: +45 33 851100 Fax.: +45 33 851030

The list is for guidance only and must not be considered complete. We under- take no responsibility that might be caused by these or other products.

97.08 - ES2S MAN Diesel 92.01 -ES0U 08028-0D/H5250/94.08.12 Description Page 1(1) temperature. about20°Caboveturbine hasrisen thenormal when theexhaust gastempe However, theturbinemust bewashed atthelatest orlonger. canbeshorter fuel qualitytheseintervals hours istherefore recommended. De fouling isthusavoided. Washing atinter vals isessentialtosuccessfulcleaning,asexcessive hasshown,Experience thatwashing atregularinter- load willalsoreducetemperature shocks. low engineloadapprox. 20%MCR. Cleaningatlow The bestcleaningeffect isobtainedby cleaningat the turbocharger. the turbinecasing,whichcanresultindamageon ofaaccumulation ofwater risk in there isacertain disappear. Iftherecommendedwater flow isex mentioned water fl experience hasshownService thattheabove that suffi cient water hasbeeninjected. the drainage openinginthegasoutlet. Thus ensuring evaporate, but about 0.25l/min. willfl injected pertimeunitsothat,nottheentirefl flow andthegastemperature. Enoughwater must be water fl The necessary im of thedepositsandonmechanicalaction The cleaningeffect isbasedonthewater solubility by injectionwater intotheinletpipeofturbine. radial-fl ow turbinescanbesuccessfully cleaned Tests andpractical experience have shown that also leadtoalower performance. of thecombustion chambercomponentsandwill gas temperatures andhighersurface temperatures Fouling ofthegasways willcausehigherexhaust fuel oilused. condition oftheengineaswell asthequalityof which arearesultoftheloadonandmaintenance chargers dependsonthecombustion conditions, The tendencytofouling onthegassideofturbo- Description pinging water droplets andthewater fl ow gives theoptimalreducedor ow isdependentonthegas Cleaning the Turbocharger inService rature upstreamofthe Water Washing - Turbine Side ow offthrough pending onthe vals of100 ow rate. ow owwill ceed, the drain pipeinthegasoutlet. The water whichisnotevaporated, isledoutthrough turbocharger. a channeltoleadthewater tothegasinletof the exhaust fl pipeintermediate lating valve, water isledthroughthe3-way cock to By activating valve themanoeuvring andtheregu- disconnected afterwater washing. hose withcouplings. The fl the external freshwater systemthroughafl The water for washing theturbine, issuppliedfrom card 612-15.00. valve fromthegasoutlet,seeillustration onwork valve, a3-way cock andadrain pipewithadrain equipped witharegulatingvalve, amanoeuvring The water washing systemconsistsofapipe WaterSystem Washing aredry.hour before stopsothatallparts upon completingofwater washing far run atleast1 To avoid standstill,theenginemust, corrosionduring solvents needtobeaddedthewater. system orsaltwater system. Nocleaningagentsare water systemandnotfromthefreshcoolingwater The washing water shouldbetaken fromthefresh cleaned. ped andtheturbochargerdismantledmanually due toheavy fouling, andtheengine must bestop- repeated. Ifunbalancestillexists, thisispre out,thewashingshing hasbeencarried shouldbe If vibration intheturbochargeroccurafterwater-wa- an overhaul, cannotbecleanedby thismethod. beginningorafter fromthevery cleaned periodically Heavily contami nated turbines, whichwherenot exible hosemust be ange, equipped with General sumably 612.15 Edition 02H exible MAN Diesel 96.30 -ES0S-G 08028-0D/H5250/94.08.12 Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hours 3-4 Capacity : : 2 Working time men Man power: Related procedure: position: Starting Overhaul ofchargingaircooler. Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Overhaul ofCharging AirCooler 623 9 1/cooler 1/cooler 1/cooler 39 8/cooler 37 61203 35 Qty. / 61203 14 61203 61203 Itemno. Plateno. Replacement andwearingparts: Tackle. Wire rope. Allen key, 10mm. Ring andopenendspanner, 24mm. Ring andopenendspanner, 19mm. Ring andopenendspanner, 13mm. Hand tools: Note. Itemno. Plateno. Special tools: L+V28/32H 612-01.00 Edition 02H L+V28/32H 612-01.00 Edition 02H chamber (4)andsideplates (5). Fig. 1. a coupleofwooden planksonthefl and pulledoutofthecoolerhousinglandedon tach atackle hook,afterwhichtheelementsarelifted Place awireroperoundthecoolerelementandat- ing, andpullthecoolerelementhalf-way out. end cover ofthecoolerelementto cooler hous- and disconnectthepipes. Overhaul ofCharging AirCooler. 602. satisfactory,the coolerdoesnotwork seesection Maintenance Program", prove orifobservations that overhauled indicatedinthe"Planned attheintervals cleanedand The chargingaircoolerisnormally 3) 2) 1) Remove screws (2)andend cover (3)reversal Remove thescrew (1),fi Closethecoolingwater inletandoutletvalves 4 g. 1,whichsecurethe Overhaul ofCharging AirCooler oor. 6 5 2 3 1 for theentiresystem isfollowed. At freshwater coolantsystemsrecommendations open. with freshwater andleftwithdrain and venting cocks drained ifthecoolantisseawater followed by fl theaircooleris outofservice At longerperiods Periods.Out ofService kets. steel brush. The pipeinnerdiameteris13mm. ved by usingahandormachineoperated circular these blocks. Note: corrosion (6)andrenew ifne with ananti-corrosionblocks agent. Inspecttheanti- cylinder liners. in thewater willdamagevalves, pistonrings, and with theairtocylinderswheresaltcontained as any seawater along thatleaksinwillbecarried that thechargingaircoolerisnotleaky It isimportant withplugs.blanking ofthetube(s)concerned expending thetubeendsintoplatesorby it/they must immediatelybemadetight,eitherby Should oneoremorecoolertubesbecomeleaky pressure dropacrossthecoolerconsiderably. carefully straightened, asbentfi If nevertheless, themetalisdamaged,itshouldbe pressure. the thinfi ling cleaningandmountingthecoolerelement,as The greatest caremust beexercised whendis mend After usingcleaningagentsthemanufacting re sides. 7) 6) 5) 4) Fouling anddepositeinthepipescanberemo- Also cleanendcover andcoatitontheinside Cleanthecoolerelementofwater andair ting must befollowed. When mountingtheaircooler, renew allgas- That paintorsimilarmust notbeappliedto ns ofthetubescannotstandimpactsand ces ns willincreasethe sa ry. MAN Diesel Working Card ushing Page 2(2) 96.30 -ES0S-G mant- com-

08028-0D/H5250/94.08.12 MAN Diesel 97.08 -ES0S 08028-0D/H5250/94.08.12 Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Capacity : : 1 Working time person Man Power: Related Procedure: Position:Starting Check ofdrain fromchargeaircoolerhousing. Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety Precautions: Charge AirCoolerHousing-Draining lt o tmN Qty. / ItemNo PlateNo Replacement and Wearing Parts: Hand Tools: Note ItemNo PlateNo Special Tools: L+V28/32H 612-01.05 Edition 02H L+V28/32H 612-01.05 Edition 02H purities, ifany. discharger hastobeloosenedandcleanedofim- could foul them. components arefreeofforeign substanceswhich discharger hastotake placetosecurethatthese Therefore, frequentcontrolofthedrain andthewater corrosion oftheintake components. in increasingwear. Further, thewater willcause oilfi the lubricating air tobesucked intotheengine, whereitwilldestroy This installationwillprevent water fromthecharge water discharger. cooler isequippedwithadrain andanautomatic cooler andthechargeairreceiver, thechargeair of thegasoutletturbocharger, thechargeair In ordertoprevent water fromcollectingatthebottom water discharger. -aconstantairfl ow ispresent: If, withthedrainscrew dismounted 1) Thedrain screw atthebottom ofthewater 2. 1. Mount thedrain screw atthe bottomofthe isallright. Everything lm onthecylinderwalls, resulting Charge AirCoolerHousing-Draining water discharger. thataconstantairfl ow ispresent. water. coolerinordertosecureaclearpassageof Cleanthedischargeholeinchargeair pipeby meansofcompressedair. -no constant airfl ow ispresent: If, with thedrainscrew dismounted 3. 2. 1. Fig 1PlacementofSteam Trap Mount thedrain screw atthe bottomofthe Mount thedrain pipeandcheck withyour hand Dismount thedrain pipeandblow-through the MAN Diesel Working Card Page 2(2) 97.08 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel

Working Card Water Washing of Compressor Side 612-05.00 Page 1 (3) Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R. Edition 03H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Water washing of compressor side. Turbocharger cleaning with engine in service. Hand tools:

Starting position:

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/4 hour Plate no Item no Qty. / Capacity : 1 man See the special instructions for turbocharger. Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

96.30 - ES0S MAN Diesel

612-05.00 Water Washing of Compressor Side Working Card Edition 03H Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R Page 2 (3)

L+V28/32H

Before Cleaning

The cleaning process is only to be carried out when 3) Fill the container with 2 litres fresh water (see the engine is at operating temperature (see Opera- the scale on the container). ting Data 600.30) and when it is loaded as close as possible to full load (see Main Data 600.00). Warning: Do not use sea water or cooling water. See also "Description for Water Washing of Com- pressor side", 612.05. 4) Mount the top cover on the container.

Cleaning Procedure 5) Blow air into the container by means of a blow gun, until an operation pressure of 3 bar is reached 1) Run the engine with as high a load as pos- (see ﬁ g 2). sible.

2) Discharge the excesspressure in the container The safety valve will open at a pressure of 4 bar. by drawing out the spindle in the safety valve (see ﬁ g. 1) before loosening the top cover. Excesspressure will discharge through the safety valve. The spindle returns automatically by means of a built-in spring.

Fig 1 Fig 2

96.30 - ES0S MAN Diesel

Working Card Water Washing of Compressor Side 612-05.00 Page 3 (3) Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R. Edition 03H

L+V28/32H

6) Connect the plug-in coupling of the lance to the snap coupling on the pipe (see ﬁ g 3).

7) Depress the handle on the hand valve until the water is completely injected into the compressor (approx. 30 seconds).

The water will enter the compressor in atomized condition, impinge the vanes of the compressor wheel with high velocity and thus wash off the dirt deposited.

8) Release the plug-in coupling and vent the container by drawing the spindle out of the safety valve.

After Cleaning

9) Run the engine for minimum 10 minutes at 1 Injection tube 5 Hand valve with handle un al ter ed high load. 2 Pipe 6 Container 3 Snap coupling 7 Charge air line 4 Plug-in coupling 10) Compare the measurements of the operating data (see ﬁ g 4) before and after the cleaning procedure (see Operating Data 600.30). Fig 3

IF THEN

the comparison indicates success of the the water washing of the compressor side washing procedure is ﬁ nished

the comparison indicates lack of the wa- carry out the washing procedure from step shing procedure 1 with 10 minutes interval from the initial washing

severe dirt is being deposited in the com- dismantling of the compressor components pressor for manual cleaning is necessary (see special turbocharger manual in section 612).

Fig 4

96.30 - ES0S MAN Diesel

Working Card 612-10.00 Page 1 (2) Dry Cleaning of Turbocharger - Turbine Side Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note. Shut-off starting air Shut-off cooling water Blow gun with container. Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circul.

Description:

Dry cleaning of turbine side, cleaning with engine in service. Hand tools:

Starting position:

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. / Capacity : 1 man See the special instruction for turbocharger.

Data:

Data for pressure and tolerance (Page 600.35) Data for torque moment (Page 600.40) Declaration of weight (Page 600.45)

97.07 - ES0S MAN Diesel

612-10.00 Working Card Edition 02H Dry Cleaning of Turbocharger - Turbine Side Page 2 (2)

L+V28/32H

Cleaning Procedure.

1) The cleaning is carried out during high engine 2) Before connecting the "blow-gun" open the load minimum 75 % at full load. closing valve (1), see ﬁ g 1 and check whether there is free passage.

3) Fill cleaning granulated substance into the container (2) for turbocharger type:

NR20/R - NR20S: 0.2 - 0.3 liters. NR24/R - NR26/R: 0.3 - 0.4 liters.

Connect to the working air system (4), 5 -7 bar.

4) Connect the "blow-gun" to valve (1). Open air valve (3).

Then open valve (1) slowly until a whisling sound indicates that blowing-in of granulated substance takes place.

1 Closing valve 2 Container Injection time approx. 2 min. 3 Air valve 4 working air inlet 5 Exhaust pipe 6 Snap coupling For dry cleaning of turbine side, see also description 612.10 "Cleaning the Turbocharger in Service, Dry Cleaning - Turbine Side. Fig 1 Arrangement of dry cleaning of turbocharger - Turbine.

97.07 - ES0S 91.04 -ES0S 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance Data: Hour 1/2 Capacity : : 1 Working time man Man power: Related procedure: position: Starting engine inservice. Water washing ofturbineside, cleaningwith Description: Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Stopped engine Safety precautions: Water Washing of Turbine Side lt o Ie o Qty. / forSee thespecialinstruction turbocharger. Itemno. Plateno. Replacement andwearingparts: Hand tools: Note. Itemno. Plateno. Special tools: 612-15.00 General Edition 01H 612-15.00 General Edition 01H Fig. 1. Arrangement for water washing. Fig. 2. 3-way cock. and check for freepassage, seefi g. 1. 2) the enginestabilize for 10min. Cleaning Procedure. 1) Regulating valve valve Manoeuvering ing instruction Plate withclean- Openthedrain cock attheturbochargeroutlet Adjusttheengineloadtoapprox. 20%andlet inlet Cleaning water 3-way cock Water Washing of Turbine Side Drain cock tion for water washing. For water washing ofturbineside, see alsode be notexceeded. The water injectiontimementionedinitem6must position. valveThe manoeuvring must notbelocked inopen slowly. Note: for atleast1hourbefore stop. condition. increasing theloadtonormal that thewater drain fl ow hasstopped. Turn the3-way cock toposition1, "Closed" andcheck the water supply. the drain water isfreeofparticles. fl ow untilthedrain fl Then opentheregulatingvalve and adjust thewater 5) system. water wash position3"Wash". fi g. 2andcheck for freepassage. tothe Ifokturn 9) 8) 7) 6) 4) 3) Afterthewater washing, theengineshouldrun Continue atthisloadleast5min. before valve Releasethemanoeuvring anddis Continue thewater washing 5-10min. oruntil Activate valve, themanoeuvring seefi g. 1. Connectthewater supplytothewater wash Turn the3-way cock toposition2"Open",see The regulatingvalve hastobeopened ow isapprox. 0,25l/min. MAN Diesel Working Card con Page 2(2) scrip- 91.04 -ES0S nect nect

08028-0D/H5250/94.08.12 MAN Diesel 97.06 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Freshwater 5-6L28/32H 61201-12H 5-6L28/32H 61201-12H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 304 282 257 245 233 221 208 198 186 174 162 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

22/K 32/K Qty. 1/E 1/K 1/K 1/K 4/K 1/K 5/K 5/K 5/K 1/K 1/K 1/K 1/K 8/K 4/K 1/K 4/K 4/K 1/K 1/K 2/K 1/K 1/K 233 and245 174, 186, 198, 208, 221, 125, 137, 149, 150, 162, 066, 078, 091, 101, 113, 017, 029, 030, 042, 054, complete, incl. item Charging aircooler, Screw Gasket Plug O-ring Screw Side plateleft Screw Cu-washer Screw Crossmember Screw Reversing cover cover Gasket reversing Side plateright Screw Nut End cover Cu-washer Plug screw Gasket endcover Cooler block Pipe Crossmember Crossmember Designation Charging AirCooler-Freshwater Benævnelse 208, 221,233og245 150, 162,174,186,198, 101, 113,125,137,149, 042, 054,066,078,091, inkl. item017,029, 030, Ladeluftkøler, komplet, Skrue Pakning Prop O-ring Skrue Sideplade venstre Skrue Cu-skive Skrue Travers Skrue Vendekammer mer Pakning vendekam- Sideplade højre Skrue Møtrik Endedæksel Cu-skive Propskrue Pakning endedæksel Kølerblok Rør Travers Travers

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 97.06 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 97.06 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Freshwater 7-8-9L28/32H 61201-13H 7-8-9L28/32H 61201-13H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 304 282 257 245 233 221 208 198 186 174 162 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 97.06 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 97.06 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Freshwater 5-6L28/32H 61201-14H 5-6L28/32H 61201-14H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 304 294 282 270 269 257 233 221 208 198 186 174 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

22/K 32/K Qty. 1/E 1/K 1/K 1/K 1/K 1/K 8/K 1/K 5/K 5/K 5/K 1/K 1/K 1/K 8/K 4/K 1/K 4/K 4/K 1/K 1/K 2/K 1/K 1/K 269, 270and294 186, 198, 208, 221, 233, 125, 137, 149, 150, 174, 066, 078, 091, 101, 113, 017, 029, 030, 042, 054, complete, incl. item Charging aircooler, Water mistcatcher Screw Drain pipefor WMC Ring Gasket O-ring Screw Side plateleft Screw Cu-washer Screw Screw Reversing cover cover Gasket reversing Side plateright Screw Nut End cover Cu-washer Plug screw Gasket endcover Cooler block Pipe Crossmember Crossmember Designation Charging AirCooler-Freshwater Benævnelse og 294 208, 221,233,269,270 150, 174,186,198, 101, 113,125,137,149, 042, 054,066,078,091, inkl. item017,029, 030, Ladeluftkøler, komplet, Vandudskiller Skrue Drænrør for WMC Ring Pakning O-ring Skrue Sideplade venstre Skrue Cu-skive Skrue Skrue Vendekammer mer Pakning vendekam- Sideplade højre Skrue Møtrik Endedæksel Cu-skive Propskrue Pakning endedæksel Kølerblok Rør Travers Travers

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 97.06 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 97.06 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Freshwater 7-8-9L28/32H 61201-15H 7-8-9L28/32H 61201-15H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 304 294 282 270 269 257 233 221 208 198 186 174 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 97.06 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 97.45 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Seawater 5-6L28/32H 61201-16H 5-6L28/32H 61201-16H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 294 282 270 269 257 233 221 208 198 186 174 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

22/K 32/K Qty. 1/K 1/K 1/K 1/K 1/K 8/K 1/K 5/K 5/K 5/K 1/K 1/K 1/K 8/K 4/K 1/K 4/K 4/K 1/K 1/K 2/K 1/K 1/K Water mistcatcher Screw water mistcatcher Drain pipefor Ring Gasket O-ring Screw Bottom plate Screw Cu-washer Screw Screw Reversing cover reversing cover Gasket Top plate Screw Nut End cover Cu-washer Plug screw end cover Gasket Cooler block Pipe Crossmember Crossmember Designation Charging AirCooler-Seawater Benævnelse Vandudskiller Skrue vandudskiller Drænrør for Ring Pakning O-ring Skrue Bundplade Skrue Cu-skive Skrue Skrue Vendekammer vendekammer Pakning Topplade Skrue Møtrik Endedæksel Cu-skive Propskrue endedæksel Pakning Kølerblok Rør Travers Travers

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item 341 328 316 304 No .

12/K 12/K Qty. 6/K 1/E einto Benævnelse Designation Stud Anti-corrosion block Nut 328, 341 233, 269, 270, 294, 316, 174, 186, 198, 208, 221, 113, 125, 137, 149, 150, 054, 066, 078, 091, 101, 017, 029, 030, 042, complete, incl. item Charging aircooler, Tapskrue Anode Møtrik 316, 328,341 221, 233,269,270,294, 150, 174,186,198,208, 101, 113,125,137,149, 042, 054,066,078,091, inkl. item017,029,030, Ladeluftkøler, komplet, MAN Diesel Page 2(2) Plate 97.45 -ES0S

08028-0D/H5250/94.08.12 MAN Diesel 97.45 -ES0S 08028-0D/H5250/94.08.12 Page 1(2) Plate Charging AirCooler-Seawater 7-8-9L28/32H 61201-17H 7-8-9L28/32H 61201-17H = Only available kit. ofaspareparts aspart = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 294 282 270 269 257 233 221 208 198 186 174 150 149 137 125 113 101 091 078 066 054 042 030 029 017 No .

= Kun tilgængeligsomen delafetreservedelssæt. Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item 341 328 316 304 No .

08028-0D/H5250/94.08.12 07.12 -ES0 08028-0D/H5250/94.08.12 MAN Diesel 06 211 176 223 176 164 272 1 115 103 247 235 Page 1(2) 88 Plate 8 2 8 4 127 260 259 007 140 0 Charging AirCooler-Freshwater 8 1 152 093 306 296 176 31 8 093 056 020 032 61201-29H L28/32H 330 019 0 044 139 8 1 61201-29H L28/32H = Only available kit. ofaspareparts aspart Qty./IIndividual = = Cooler Qty./K = Qty./Engine. Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 296 284 272 260 259 247 235 223 211 188 176 164 152 140 139 127 115 103 093 081 068 056 044 032 020 019 007 No .

32/K Qty. 4/K 8/E 4/K 8/K 8/K 1/K 1/K 8/K 8/K 8/K 4/K 2/K 2/K 1/K 1/K 1/K 1/K 5/K 5/K 5/K 1/K 1/K 2/K 1/K 1/K /I Plug screw Screw Lock, sidecover Spring, sidecover slotted Spring, straightpin water mistcatcher Drain pipefor Water mistcatcher Washer Screw Screw Locktite Nut Distance pipe Crossmember Side cover- left Side cover- right O-ring Ring by drainpipe Screw Screw Gasket ring Screw Cooler block reversing chamber Gasket for Reversing chamber end cover Gasket for End cover Designation Charging AirCooler-Freshwater Benævnelse Propskrue Skrue Lås, sideplade Fjeder, sideplade Spændestift vandudskiller Drænrør for Vandudskiller Skive Skrue Skrue Locktite Møtrik Afstandsrør Travers Sidedæksel -venstre Sidedæksel -højre O-ring Ring ved drænrør Skrue Skrue Pakningsring Skrue Kølerblok vendekammer Pakning for Vendekammer endedæksel Pakning for Endedæksel

na/ Individuelt Kun tilgængeligsomen delafetreservedelssæt. Antal/I = Køler = Antal/K = Antal/Motor Antal/E = * Ved bestillingafreservedele, seogsåside600.50. Item No 330 318 306 .

Qty. 1/K 1/E 4/K Gasket complete Charge aircooler, Gasket einto Benævnelse Designation Pakning komplet Ladeluftkøler, Pakning MAN Diesel Page 2(2) Plate 07.12 -ES0

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement 61202-23H

5,6L28/32H

11 08 05 05 06 10 08 10 11 07 05 10 04 09 11

16 14 13 15 12

23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

91.18 - ES0S MAN Diesel

Plate 61202-23H Exhaust Pipe Arrangement Page 2 (2)

5,6L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag 30 1/C Gasket Pakning

05 Exhaust pipe Udstødsrør 31 1/C Gasket Pakning 4/E 5 cyl. engine 5 cyl. motor 5/E 6 cyl. engine 6 cyl. motor 32 1/C O-ring O-ring

06 1/E Exhaust pipe, Udstødsrør, tilgang 33 1/C Cooling water Kølevandsnippel inlet TC. turbolader nipple

07 1/E Exhaust pipe for Udstødsrør for 34 1/C O-ring O-ring cyl. 1 cyl. 1

08 Compensator Kompensator 4/E 5 cyl. engine 5 cyl. motor 5/E 6 cyl. engine 6 cyl. motor

09 1/E Compensator Kompensator

10 Gasket Pakning 9/E 5 cyl. engine 5 cyl. motor 11/E 6 cyl. engine 6 cyl. motor

11 3/E Gasket Pakning

12 Screw Skrue 108/E 5 cyl. engine 5 cyl. motor 132/E 6 cyl. engine 6 cyl. motor

13 Nut Møtrik 108/E 5 cyl. engine 5 cyl. motor 132/E 6 cyl. engine 6 cyl. motor

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-32H

5,6L28/32H

17 06 11 07 08 04 09 05 11

16 14 15 23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

92.38 - ES0S MAN Diesel

Plate 61202-32H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

5,6L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 Exhaust pipe Udstødsrør 4/E 5 cyl. engine 5 cyl. motor 5/E 6 cyl. engine 6 cyl. motor

06 1/E Exhaust pipe, Udstødsrør, tilgang inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for cyl. 1 cyl. 1

08 Compensator Kompensator 4/E 5 cyl. engine 5 cyl. motor 5/E 6 cyl. engine 6 cyl. motor

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

92.38 - ES0S MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement 61202-26H

7,8L28/32H

17 08 05 05 06 10 08 10 11 07 05 10 04 09 11

16 14 13 15 12

23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

91.18 - ES0S MAN Diesel

Plate 61202-26H Exhaust Pipe Arrangement Page 2 (2)

7,8L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag 29 1/C Plug screw Propskrue

05 Exhaust pipe Udstødsrør 30 1/C Gasket Pakning 6/E 7 cyl. engine 7 cyl. motor 7/E 8 cyl. engine 8 cyl. motor 31 1/C Gasket Pakning

06 1/E Exhaust pipe, Udstødsrør, tilgang 32 1/C O-ring O-ring inlet TC. turbolader 33 1/C Cooling water Kølevandsnippel 07 1/E Exhaust pipe for Udstødsrør for nipple cyl. 1 cyl. 1 34 1/C O-ring O-ring 08 Compensator Kompensator 6/E 7 cyl. engine 7 cyl. motor 7/E 8 cyl. engine 8 cyl. motor

09 1/E Compensator Kompensator

10 Gasket Pakning 13/E 7 cyl. engine 7 cyl. motor 15/E 8 cyl. engine 8 cyl. motor

11 2/E Gasket Pakning

12 Screw Skrue 156/E 7 cyl. engine 7 cyl. motor 180/E 8 cyl. engine 8 cyl. motor

13 Nut Møtrik 156/E 7 cyl. engine 7 cyl. motor 180/E 8 cyl. engine 8 cyl. motor

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-28H

7,8L28/32H

17 06 11 07 08 04 09 05 11

16 14 15 23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

92.07 - ES0S MAN Diesel

Plate 61202-28H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

7,8L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 Exhaust pipe Udstødsrør 6/E 7 cyl. engine 7 cyl. motor 7/E 8 cyl. engine 8 cyl. motor

06 1/E Exhaust pipe, Udstødsrør, tilgang inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for cyl. 1 cyl. 1

08 Compensator Kompensator 6/E 7 cyl. engine 7 cyl. motor 7/E 8 cyl. engine 8 cyl. motor

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

92.07 - ES0S MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement 61202-27H

9L28/32H

16 08 05 05 06 10 08 10 11 07 05 10 04 09 11

15 14 12 13 13 12

23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

91.18 - ES0S MAN Diesel

Plate 61202-27H Exhaust Pipe Arrangement Page 2 (2)

9L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 8/E Exhaust pipe Udstødsrør

06 1/E Exhaust pipe, Udstødsrør, tilgang inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for cyl. 1 cyl. 1

08 8/E Compensator Kompensator

09 1/E Compensator Kompensator

10 17/E Gasket Pakning

11 2/E Gasket Pakning

12 216/E Screw Skrue

13 216/E Nut Møtrik

14 12/E Screw Skrue

15 12/E Screw Skrue

16 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water nipple Kølevandsnippel

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S MAN Diesel

Plate Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-42H

9L28/32H

17 06 11 07 08 04 09 05 11

16 14 15 23 28 22 29 30 20 31 21 22 23 24 25 26 32 27 33 34

97.08 - ES0S MAN Diesel

Plate 61202-42H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

9L28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 8/E Exhaust pipe Udstødsrør

06 1/E Exhaust pipe, Udstødsrør, tilgang inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for cyl. 1 cyl. 1

08 8/E Compensator Kompensator

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 12/E Screw Skrue

15 12/E Nut Møtrik

16 24/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

97.08 - ES0S MAN Diesel & Turbo

Plate Page 1 (2) Water Washing of Compressor Side 61205-02H

L+V28/32H

26* 23 25*

24* 27 01*

02*

03* 07 04* 08 05* 09 06* 10 22

21 11

20 12

19 13*

14*

15*

94.01 - ES0S MAN Diesel & Turbo

Plate 61205-02H Water Washing of Compressor Side Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01* 1/E Top cover with non- Topdæksel med kon- 25* 1/E Straight male stud Ligeforskruning return valve traventil coupling

02* 1/E O-ring for top cover O-ring for topdæksel 26* 1/E Plug in coupling Kobling

03* 1/E O-ring for non-return O-ring for kontraventil 27 1/E Lance complete, incl. Lanse komplet, inkl. valve item 24-25 and 26 item 24-25 og 26

04* 1/E Valve seat Ventilsæde 28 1/E Container complete, Beholder komplet, som as shown on plate vist på plate 05* 1/E Spring for non-return Fjeder for kontraventil valve

06* 1/E Cap screw for non- Omløber til return valve kontraventil

07 1/E Top cover with non- Topdæksel med kontra- return valve complete, ventil komplet, inkl. item incl. item 01-02-03-04- 01-02-03-04-05 og 06 05 and 06

08 1/E Safety valve Sikkerhedsventil

09 2/E O-ring O-ring

10 2/E Finger nut Fingermøtrik

11 1/E Cap Top

12 1/E Gasket for the cap Pakning for top

13* 1/E Cable binder Kabelbinder

14* 1/E Strap Gjord

15* 1/E Eye for strap Øje for gjord

16 1/E Strap complete, incl. Gjord komplet, inkl. item item 13-14 and 15 13-14 og 15

17 1/E Container Beholder

18 1/E Flexible pipe Fleksibel slange

19 1/E Handle with flexible Håndtag med fleksibel pipe and cap screw slange og omløber

20 1/E Filter insert Filterinsats

21 1/E Gasket for handle Pakning til håndtag

22 1/E Hand valve Håndventil

23 1/E Gasket for Pakning til hand valve håndventil

24* 1/E Lance Lanse

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor

94.01 - ES0S MAN Diesel

Plate Page 1 (2) Steam Trap 61208-01H

L+V28/32H

05 02

06 03

97.07 - ES0S MAN Diesel

Plate 61208-01H Steam Trap Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Steam trap, Vandudlader, complete komplet

02 1/E Packing Pakning

03 1/E Clip Klemme

04 1/E House, bottom Hus, bund

05 1/E House, top Hus, top

06 1/E Swimmer Svømmer

07 1/E Valve Ventil

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Qty./E = Qty./Motor

97.07 - ES0S 01.12 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Page 1(2) Plate 1 1 2 4 028 041 028 112 016 100 089 Blowgun for Cleaningof Dry Turbocharger 0 5 3 136 148 6 077 065 61210-02H General 61210-02H General * Only available kit. ofaspareparts aspart = Qty./IQty./Individual = Qty./Engine Qty./E = * When ordering spare parts, 600.50. seealsopage

Item 148 136 112 100 089 077 065 053 041 028 016 No .

Qty. 1/E 1/E 1/E 1/E 1/E 1/E 1/E 1/E 2/E 1/E /I Granulate Blowgun, complete Socket Container, complete Packing ring Snap coupling Snap coupling Ball valve Tee Nipple Snap coupling Designation Blowgun for Cleaningof Dry Turbocharger Benævnelse Granulat Rensepistol, complete Muffe beholder, komplet Pakningsring Snapkobling Snapkobling Kugleventil T-stykke Nippel Snapkobling

* Kun tilgængeligsomendelafetreservedelssæt. = Qty./I = Qty./Individuelt Qty./Motor Qty./E = * Ved bestillingafreservedele, seogsåside600.50. Item No .

Qty. einto Benævnelse Designation MAN Diesel Page 2(2) Plate 01.12 -ES0

08028-0D/H5250/94.08.12 Compressed air system

513/613 MAN Diesel 94.23 -ES0S 08028-0D/H5250/94.08.12 Description Page 1(2) of theengine. the enginemustnotbeinterrupted duringoperation Note: plant. particular accor ply system,andhastherefore tobedetermined depend ontheconditionofairinmainsup- The intervalsbetweencleaninganddrainingwill parator ismountedintheinletlinetoengine. To se- system,adirt intheinternal particles avoiddirt from compressed airissuppliedtotheengine. receivers (30bar)through areduction station,where The compressed airissuppliedfrom air thestarting system. system. Further, thesystemsuppliesairtojet control system,starting systemandsafety a starting The compressed airsystemontheenginecontains General Fig. 1.DiagramforCompressed Air System ding toserviceexperience gainedwiththe Duetothesafetysystem,air supplyto Overspeed device Stop cylinder for jet-system On-off valve starting valve starting Emergency Cyl. 1 Compressed AirSystem Starting Starting valve Air starter signal orviatheenginecontrol boxifsupplied. spool goesthrough forengine RPM theconverter signaltothestarting starting connected sothatevery For remote spoolmust be activation,thestarting remote control, manualorautomatic. ting boxontheengine,anditcanbearrangedfor The valvecanbeactivatedmanuallyfrom thestar- valve). matic 3/2waysolenoidvalve(starting isactivatedelectricallywithapneu- The airstarter Control System valve. main starting pinion. Further, systemconsistsofa thestarting with gearbox,safetyclutchanddriveshaft starter, motortype whichisoftheturbinestarter bymeansofabuilt-onair The engineisstarted System Starting starting starting valve Main L28/32H 613.01 Edition 20H K1 MAN Diesel L28/32H 613.01 Edition 20H of ascrew-driver orsimilar asillustratedinfi g. 2. valveisactivatedbymeans The emergencystarting Emergency Starting Valve manuallyincaseofapowerfailure.air starter valvewhichmakesitpossibletoactivatethe starting Further, thesystemisequippedwithanemergency Fig. 2. Emergency start valve Fig. 2.Emergencystart Press down ⇓ Compressed AirSystem start valve start Emergency the air starter isdisengaged. the airstarter valveisclosedwherebyhas takenplace,thestarting When theRPMexceedsapprox. 110,atwhichfi sequence. limiting thefuelsupplyduringstart will besuppliedtothefuellimitatingcylinder, thus Simultaneously withairsupplyforthestarter, air theengine. turn air willbeledtothestarter, to which willstart fl valve,wherebyow to,andopenthemainstarting When thepinionisfullyengaged,pilotairwill on theenginefl y wheel. the drivepinionintoengagementwithgearrim The airsupplywill-byactivatingapistonbring to thedriveshafthousingofairstarter. valveisopened,airwillbesup When thestarting Sequence Pneumatic Start index tozero andstopthe engine. controlled stopcylinder, whichwillbringthefuel the overspeeddevicewillactivateapneumatically RPMisexceeded, When themaximumpermissible section 609. from thepumpthrough aresilient coupling,see of theenginedrivenlubricatingpumpandis is exceeded.Thisdevicefi RPM tooperateifthemaximumpermissible starts ma As standard theengineisequippedwithapneu- Safety System ti cal ly/mechanically overspeeddevice,which tted totheendcover Description Page 2(2) plied plied ring 94.23 -ES0S

08028-0D/H5250/94.08.12 02.46 -ES0 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) Manpower Related procedure position Starting Cleaning and/ormaintenanceofairﬁ lter. Description Stoppedlub. oilcircul. Shut-offcoolingoil Shut-offfueloil Shut-offcoolingwater air Shut-offstarting Safety precautions elrto fwih (Page 600.45) (Page 600.40) Declaration ofweight Data for torque moment (Page 600.35) Data for pressure andtolerance hours Data Capacity : : Working time man Stopped engine Air Filter Replacement andwearingparts Hand tools Special tools lt o tmn Qty/ Itemno Plateno lt o tmn Note Itemno Plate no

613-01.21 General Edition 02H MAN Diesel 613-01.21 General Edition 02H body. place. Alignarrow onbowl guardwitharrow onfi rotate bowl guardclockwise tosecurelylock in 6) have beenreinstalledorreplaced. 5) clothormilddetergent. bowl withasoftdry 4) nessesary. 3) counter-clockwise.turning 2) 1) Cleaning AirFilter i AirFilter Fig 1 Reinstallbowl andbowl guardassembly and insurethatallseals Before toservice, returning cleanitby wipingthe Ifbowl becomesdirty Inspectbowl for damagesealsandreplace, if Remove bowl andbowl guardassembly by Depressurize unit. lter Air Filter body. place. Alignarrow onbowl guardwitharrow onfi rotate bowl guardclockwise tosecurelylock in 13) have beenreinstalledorreplaced. 12) reverse order. 11) 10) 9) counter-clockwise. 8) 7) To replacefi Unscrew baffl Remove bowl andbowl assembly by turning Depressurize unit. Reinstallbowl andbowl guardassembly and insurethatallseals Before toservice, returning Installnew fi Remove fi lter elementanddiscard. lter element lter elementandreassemble in counter-clockwise.e by turning Working Card Page 2(2) lter 02.46 -ES0

08028-0D/H5250/94.08.12 03.47 -ES0-G

08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(9) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Hours Data: 4 Capacity : 1 : Working time man Man power: Related procedure: isremoved.moved, andairstarter havebeenre-All connectiontotheairstarter position: Starting starter. Disassembly, overhaulandassemblyoftheair Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: Overhaul, Test andInspectionof Turbine Starter lt o Ie o Qty./ See plate61309. Itemno. Plateno. Replacement andwearingparts: Bearing pressing tool. Impact Wrench Bearing puller. Sleeve. Copaslip orsimilar. Lubricating oil. Plastic hammer. Retaining ringpliers. Chisel. Big screwdriver. Screwdriver. Allen key(long),8mm. Allen key, 4mm. Hand tools: 20-120Nm. xx Note. 62006 Itemno. Plateno. Special tools: L+V28/32H 613-01.30 Edition 02H MAN Diesel L+V28/32H 613-01.30 Edition 02H housing. the housingcover canberemoved fromthemotor Using aplastichammer, until taptheearsalternately cover, rotateituntiltheearsclearmotorhousing. motor housing(8). To dislodgethehousing exhaust and washers (7),Seefi and remove assembly capscrews thestarter (6) cover (67)fromthehousingexhaust cover (1). gear case(28)andinspect. chips areanindicationofaproblem. Disassemble move andreinstallplugs. or particles Largeparticles particles. Very fi arenormal. Re- ne metalparticles Inspect themagnetichousingplugs(10)for metal beforegearing beginning disassembly ofthestarter. both housingplugs(10)anddrain theoilfrom Motor Housing ofthreadedmembers.true andhelppreventpart distortion. This isparticularly copper-covered visejaws toprotectthesurface ofthe starter. anyon handbefore overhaul starting oftheturbine foris necessary replacementorrepairs. or onasubassembly unlesstheremoval ofthatpart ordamagedparts. toreplaceworn necessary isreassembled.relative positionwhenthestarter (38) sothesememberscanbelocatedinthesame gear case(13),(28)anddrive housing exhaust cover (1),motorhousing(8),intermediate . Pullthe housingexhaust cover (1)from the 4. Usingan8mmhex-head wrench,unscrew 3. Usingascrew driver, unscrew theexhaust 2. Ifreplacingthe motorassembly (12), remove 1. Housing ExhaustCover, MotorAssembly, and inavise, always Whengrasping apart use 4. Always have acompletesetofsealsando-rings 3. Do notremove whichisa pressfi any part 2. Never drive inasolvent. wash theinertia Never reuseoldsealsoro-rings. Note onthehousing Always adjacentparts mark 1. General Information : than any further Donotdisassemble thestarter Overhaul, Test andInspectionof Turbine Starter g 1. g t in t (3) fromthehousingexhaust cover (1),Seefi g 2. fl (4)andthesplashdefl ectorretai-ningspring . Remove thedefl 5. Fig 2. housing inorder tofreethemotorassembly. motor assembly toward theexhaust sideofthemotor push themotorpinionwhich isonthefrontof pull itfromtherearofmotor housing(8). gearcase(13). to dislodgeitfromtheintermediate If themotorassembly (12)isdiffi Grasp therearofmotorassembly (12)and 7. Tap themotorhousingwithaplastichammer 6. Fig 1. ector retaining screw (5),de- cult toremove, lightly Working Card Page 2(9) ector 03.47 -ES0-G

08028-0D/H5250/94.08.12 03.47 -ES0-G

08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 3(9) Fig 3. gear case(13),Seefi g 3. (15)fromtheintermediate front gearcaseo-ring (26). Remove (14)and the rear gearcaseo-ring from theviseandremove pinion theintermediate gear case. planet gearframe assembly outoftheintermediate injury. diate gearcaseandcompomentscouldfall causing retaining screw iscompletelyremoved, theinterme- pinion onabenchandiftheintermediate ported only.(27) 1-1/2turns Donotremove. securely. pinion the viseonlyenoughtoholdintermediate pinion (26)issecuredinthejaws ofthevise. Tighten bench inacopperfaced visesothattheintermediate (28). plastic hammertodislodgeitfromthegearcase 1. Remove gearcaseassembly theintermediate 12. Tap pinionlightlytoback the theintermediate 11. Warning: pinionretainingscrew Loosen theintermediate 10. Position gearcase(13) ona theintermediate 9. Tap gearcase(13)witha the intermediate 8. If the intermediate gearcaseisnotsup- Iftheintermediate Overhaul, Test andInspectionof Turbine Starter washer spacerisdamaged. orfrontbearing ing onthefrontofplanetgearframe shaft. (23) fromthefrontofplanetgearframe by press- pullerandthegearshaftretainingwashera bearing ers (21). spac- (20) and bearing (19), planetgearbearings See fi g. 4. and remove thegearshaftretainingwasher (23), puller the planetgearframe (18),usingabearing gearcase. and outoftherearintermediate (17)fromthefrontend the frontgearframe bearing (17), presstheplanetgearframe shaftseal(16)and tacts theouterrace ofthefrontgearframe bearing gearcase.the intermediate Usingasleeve thatcon- vise with the starter supported onthe workbench. supported vise withthestarter Remove thegearshaftretainingwasher onlyifthe Remove spacer(25),using thefrontbearing 15. Remove theplanetgearshafts(22), gears Remove (24)from thereargearframe bearing 14. Remove theplanetgearframe assembly from 13. . Grasp thedrive pinion(63)inacopper-faced 1. Drive Housing Fig 4. L+V28/32H 613-01.30 Edition 02H MAN Diesel L+V28/32H 613-01.30 Edition 02H screwdriver andthearborpress. not usecompressedairtoloadthepiston. (59) before removing thebulkhead retainer(45). Do spring the arborpresstocompresspistonreturn piston endup. Applyaloadtothepiston(54)using topersonnel. in injury mer tohelpdislodgeitfromthegearcase(28). screws (38)andlock washers (39). intotheendofdrivelog hex shaft. inserted impact wrenchwitha5/16"(8mm)x8"(203 (65)offthedrive shaft(57). pinion spring drive pinion(63). thread. which hasaright-hand (42) orthedrive housingseal(43)unless replace- shaft. (40). inner bulkhead (48). ring (54). the drive housingfromthearborpress. the bulkhead outofthedrive housingbefore removing Caution Remove thebulkhead retainer(45). Usinga 10. Placethe drive housing(40)inanarborpress, 9. Warning: Tap thedrive housing(40)withaplasticham- 8. Unscrew andremove thedrive housingcap 7. Unscrew thedrive gearscrew (34). Usingan 6. sleeve Slidethepinionspring (64)andthe 5. Remove thedrive pinionwasher (62)andthe 4. Removefromthevise. thestarter 3. Remove thedrive pinionretainingscrew (61) 2. Note: (59)offthedrive spring Pullthepistonreturn 14. Slidethedrive shaft(57)fromthedrive housing 13. Remove theouterbulkhead (47)andthe ring 12. Remove thebulkhead (46)fromthepiston 11. Donotremove thefrontdrive shaftbearing : Make pushes surethetensionofspring Failure tofollow thisprocedurecouldresult Overhaul, Test andInspectionof Turbine Starter the drive gear. pliers.(33), usingretainingring is defective, installanew orfactory-rebuilt unit. oftheturbinepowered starters.parts Ifthedrive shaft access holesinthegearweb, Seefi g 5. throughthe pliersandworking using retainingring (58)off Pressthereardrive shaftbearing b. Cutandremove thesmalldrive shaftbear- a. needstobereplaced,proceedasfollows:bearing shaft (57)outofthepiston. Ifthereardrive shaft (53) usingascrewdriver. screw (37)anddrive gearscrew ring (34). gear cup(36),drive gearlock washer (35),drive gear (51). remove cupretainer(49). theclutchspring (54). removed fromthedrive housing. and/orthesealwillalwaysbearing bedamagedwhen areavailable. andnew parts ment isnecessary The 2. Remove (31) from the reardrive gear bearing 26. Remove retainer thedrive gearshaftbearing 25. Note Pullthedrive gear(29)outofthe gearcase. 24. Remove retainer(32), thedrive gearbearing 23. Placethegearcase(28)onaworkbench. 22. anddrive Pressthereardrive shaftbearing 21. Remove retainer thelargedrive shaft bearing 20. Remove (30),drive thefrontdrive gearbearing 19. Remove thetwo clutchjaws (52). 18. Remove cupandclutchspring theclutchspring 17. cup(50)down Presstheclutchspring and 16. Remove (55)fromthepiston thepistonring 15. : Donotdisassemble thedrive gearandclutch the drive shaft. chisel. ing retainedinthedrive shaft,usingasmall Working Card Page 4(9) 03.47 -ES0-G

08028-0D/H5250/94.08.12 03.47 -ES0-G

08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 5(9) Fig 5. (33), using retaining ring pliers.(33), usingretainingring using aplastichammer. case by tap-pingtheopposite endofthedrive gear, rear endofthedrive gear, usinganarborpress. rear endofthedrive gear. with athinfi lm ofoilbefore installation. ofthreadedmembers. true This isparticularly andhelppreventthe surface ofthepart distortion. leather-covered, copper-covered visejaws toprotect recess. inabearing when pressingthebearing onashaft. when installingthebearing 4. Install the drive gear shaft bearing retainer Installthe drive gearshaft bearing 4. intothegear Seatthereardrive gearbearing 3. (31)ontothe Pressthereardrive gearbearing 2. retainerover Placethedrive gearbearing the 1. Gear Case Always andwipeevery cleanevery part part, 4. Whenever inavise, always grasping apart use 3. Always ofaballbearing pressontheouterring 2. Always ofaballbearing pressontheinnerring 1. Assembly oftheStarter Overhaul, Test andInspectionof Turbine Starter drive pinion (63)willremaininengagementwiththe conditions occurs, thepistoncannot retract andthe ment oftheplanetgearframe shaftseal(16). Ifthis to prevent pressure build-up whichwillcausemove- new piston (54).Thepistonsealmust beremoved piston sealhasbeenremoved fromthe rearofthe ing (40)anddrive components, make surethat the cup retainer(49). and installtheclutchspring shaft. shaft. shaft. driven clutchjaw teethfacing down intothedrive clutchjawand installthedriving teethfacing upand shaft. ALVANIA EPOgrease. the insidediameterofdrive shaftwithSHELL Unit intothedrive shaft,screwhead down. Lubricate splined enddown. Placeassembled drive shaftscrew gear screw (37). o-ring gear lock washer (35),drive gearcup(36)anddrive new retainer. packagedaccordance withthein-structions withthe fi rst, ontothedrive shaft. Pressitintopositionin the drive shaft. 240 mlofSHELLALVANIA EPOgrease. holes inthegearweb. throughtheaccess pliersandworking retaining ring Note intothedrive shaft, parts Press theinserted 15. cup(50)intothe drive theclutchspring Insert 14. (51)intothedrive theclutchspring Insert 13. withSHELLALVANIA Lubricate EPOgrease 12. (30)intothedrive Slidethedrive gearbearing 11. Grasp thedrive shaft(57)inavise, external 10. Assemble thedrive gearSchrew (34),drive 9. retainerconvex Slidethesmallbearing side 8. (58)onto Pressthereardrive shaftbearing 7. thedrive gearwithapproximately Lubricated 6. retainer, Installthedrive gearbearing using 5. : toreplacethedrive hous- Ifitisnecessary L+V28/32H 613-01.30 Edition 02H MAN Diesel L+V28/32H 613-01.30 Edition 02H sure thedrive shaftpassesthroughthebearing. down ontherearface ofthepiston. bulkhead (46). (47)andtheInnerbulkhead (48) onthe ring o-ring into thedrive housing. (53). retainer that itisagainstthelargedrive shaftbearing drive shaftandsnapitintothefrontofpistonso bearing. seat (60)ontopoffrontdrive shaft spring return (42).of thefrontdrive shaftbearing Dropthepiston it seats, usingasleeve thatcontactstheouterrace pinion. so thatthelipofsealfaces away fromthedrive the propersize, pressthesealintodrive housing (43) intothedrive housing. Usingapressingsleeve of pinion-end down andinstallthedrive housingseal the groove ofthepiston. screwdriver toassistinthisoperation. usingathinfl of thedrive shaftbearing, into thegroove ofthepistontoretainouterrace seatsintothepiston. the reardrive shaftbearing it loosefromthepiston. ascrewdriver insidethelipofsealandpry sert motor.and/or starter To remove thepistonseal,infl drive train ywheel, causingdamagetothestarter Note Withthedrive housinginthearborpress, press 25. Slidethebulkhead ontothepiston. 24. andinstalltheouterbulkhead Lubricate o- 23. theassembled drive shaft andinsert Lubricate 22. (59)ontothe spring Slidethepistonreturn 21. intothedrive housinguntil Press thebearing 20. Position thedrive housinginanarborpress, 19. (55)andinstallitin thepistono-ring Lubricate 18. retainer(53) Coilthelargedrive shaftbearing 17. Installthepiston(54)ontodrive shaftuntil 16. : Feel theunderside ofthedrive housingtomake Overhaul, Test andInspectionof Turbine Starter a blade at torque. the endofdrive shaftandtightenitto108.5Nm thread. is right-hand pinion retainingscrew (61). onaworkbench. supported vise withthestarter install thedrive pinion(63). the drive shaft. sleevethe pinionspring (64)over thepinionendof intotheendofdrivemm longhex shaft. inserted torque, usinganimpact wrenchwitha8mmx203 tighten to28Nmtorque. ers (39)andthedrive housingcapscrews (38)and drive housing. seal. ofthegearcaseand Alignthepunchmarks onto thegearcasesoasnottodamagepiston the drive housing. bench. The as-sembled toaccept unitmust beupright (41) inthegroove ofthedrive housing. press. topersonnel. arbor pressresultingininjury toseparate whenremovedretained parts fromthe the arborpress. Failure todosowill allow improperly seated inthemotorhousinggroove before easingoff screwdriver. 3 . Installthedrive pinionretaining screw into 36. Note: Placethedrive pinionwasher (62)ontodrive 35. Grasp thedrive pinioninacopper-covered 34. Greasethepinionendofdrive shaftand 33. (65)and Grease andslidethepinionspring 32. Tightenthedrive gearscrew (34)77.3Nm 31. Installthedrive housingcapscrew lock wash- 30. Carefully positiontheassembled drive housing (40) Position theassembled gearcaseonawork- 29. andinstallthedrive housingo-ring Lubricate 28. Remove thedrive housingfromthearbor 27. Warning: Installthebulkhead retainer(45),usinga 26. The threadonthedrive pinionretainingscrew Make surethebulkhead retainerisproperly Working Card Page 6(9) 03.47 -ES0-G

08028-0D/H5250/94.08.12 03.47 -ES0-G

08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 7(9) repeat step5. assembled to components, makingitnecessary of theplanetgearframe assembly coulddislodge until step6and7have beencompleted. Movement remaining planetgearsandcomponents. ing washer (23). Repeattheprocedurefor thetwo of theshaftcontactsplanetgearretain- ofthekeyed sothatthelargerportion bearing end integral keyed enddown, throughthespacersand planetgearshaft(22), planet gearframe andinsert withholesin Align holesinspacersandbearing into theslotsinsideofplanetgearframe. andgear.and bottomofbearing Slidethecomponents planet gear(19). spacers(21)ontop Placebearing down. (20)insideof Placetheplanet gearbearing frame andgearcase. could resultinleakagebetween theplanetgear installationas this spacerduring the frontbearing before installingit. Becarefulnottogougeorscratch snugly inposition. gear frame toholdthegearshaftretainingwasher spacer(25)onthefrontshaftofplanet bearing the frontofplanetgearframe (18). Pressthefront o-rings. gearcase.the frontofintermediate coatboth (15)inthegrooveand thefrontgearcaseo-ring at groove gearcase attherear oftheintermediated against thebearing. oftheseal. the outerring usingasleevegear frame bearing, whichcontacts gearcaseoverthe rearofintermediate thefront pressingtoolofthepropersize.bearing gearcase(13),usinga the rearofintermediate Assembly andHousingExhaustCover Note Placeplanetgearframe onabench,shaftside 5. Note Installonegearshaftretainingwasher (23)on 4. (14)inthe Installthereargearcaseo-ring 3. Note Presstheplanetgearframe shaftseal(16)into 2. (17)into Pressthefrontgearframe bearing 1. Intermediate GearCase, MotorHousing, Motor : Donotmove over orturn theplanetgearframe : spacerwithgearLube Coatthefrontbearing : Make surethefl Overhaul, Test andInspectionof Turbine Starter at sideofthesealisinstalled toward thefront. the motorhousingwith gearedendoftherotor assembly. inside ofthecylinderbefore installingthe motor meshes withthedrive gear. of thegearcase. pinion Make suretheintermediate case withaplastichammeruntilitseatsintherear gear case andgeartaptheintermediate one orientation. vise andsetitonabench. mediate pinionretainingscrew to122Nmtorque. the jaws ofthecopperfaced vise. Tighten theinter- pinionissecuredin gear casesotheintermediate enough toholdassembly together. from theendofscrew. Installscrew andtighten abond HM118tothethreadsapproximately 3mm retaining screw (27)andapply2-3dropsofPerm- gear frame. with thenotchesandtangsinshaftofplanet sure thatthenotchesatrearofpinionalign gear.ring Usecaresoastonotdamagetheseal. (13), makingsurethattheplanetgearsmeshwith end fi gearcase rst, intotherearofintermediate tool. proper size inserting bearing shaft attherearofplanetgearframe, usingthe gear. washer over theshaftatrearof planet 1 . Installthemotorassembly throughtherear of 13. onthemotorassemblyCoat theo-rings andthe gear ontheintermediate Align thepunchmarks Note: Remove gearcasefromthe theintermediate 12. For fi nal tightening,positiontheintermediate 11. pinion Cleanthethreadsofintermediate 10. pinion(26),making Installtheintermediate 9. Slidetheplanetgearframe assembly, coupling 8. (24)onthe Press thereargearframe bearing 7. Installtheotherplanetgearshaftretaining 6. The intermediate gear case will work inonly gear casewillwork The intermediate L+V28/32H 613-01.30 Edition 02H MAN Diesel L+V28/32H 613-01.30 Edition 02H Fig 6. Turbine Starter. in thegroove onthehousingexhaust cover. screw with Ingersoll-RandSMB-441sealant. rear ofthehousingexhaust cover. (4)anddefl ing spring it seats on the rear of the intermediate gearcase. it seatsontherearofintermediate and tapthemotorhousingwithaplastichammeruntil gearcase ontheintermediate with thepunchmarks fl ush withtherearofcylinder. sure thattherearofmotorassembly isinstalled on therotormesheswithplanetgears. Make 1 . Coattheexhaust cover seal(2)andinstallit 16. Note: 1. Installthesplashdefl 15. onthemotorhousing Alignthepunchmarks 14. Note: Turn pinionsothatthegear theintermediate Coat thethreadsofdefl Overhaul, Test andInspectionof Turbine Starter ector retainingscrew (5)inthe ector (3), defl etr retaining ector ector retain- side plughole. specifi cation, e.g. SHELLDONAX TA, throughthe automatic transmission fl side withtheplughole upward. Add175ml housing pluginletboss(11). onits Putthestarter all plugs. exhaust cover (1). a fi nal torqueof61to68Nmincrements. hex-head wrenchtotighteneachalittleattime screws (6) and capscrew washers (7). Use an8mm assembly cap of themotorhousingusingstarter hammer untilitseats. and tapthehousingexhaust cover withaplastic cover onthemotorhousing withthepunch marks 2 . Installthebottomhousing plug(10)andthe 20. Note: Mounttheexhaust cover (68)onthehousing 19. Installthehousingexhaust cover ontherear 18. onthehousingexhaust Alignthepunchmarks 17. Use Intersoll-RandSMB-441pipesealanton uid fulfi uid lling DEXRON IID Working Card Page 8(9) 03.47 -ES0-G

08028-0D/H5250/94.08.12 03.47 -ES0-G

08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 9(9) It shouldbe69.0+2.0mm). shaft pinion(63)totheface ofthemountingfl that noairisescaping. kPa) pressuretothe “IN” port. Check andmake sure should escapefromthe “OUT” port. drive shaftpinion(63)shouldmove outward andair bar/345 kPa) pressuretotheengagement “IN” port. loosen housingplugs(10)and(11)tovent motor. housing capscrews (38)tovent gearcase(28). Also, fail toretract). Ifthisconditionoccurs, loosenthedrive “OUT” willresultindrive malfunction(pinionwill port hand. rotation.starter byThe drive shaftpinionshouldturn drive shaftpinion(63)oppositethedirectionof ing action. The clutchshouldrachet smoothly withaslightclick- rotation.(63) by handinthedirectionofstarter to 6.813.6Nmtorque. Caution: Measure thedimensionfromface ofthedrive Plug the “OUT” andapply150psig(10.3bar/1034 port 3. Note: 2. 1. Test andInspectionProcedure Install thesidehousingplug(10)andtightenallplugs Pinion Engagement: Motor andGearingFreeness: Clutch Ratcheting Inadvertent applicationofairpressuretothe Inadvertent Do notoverfi Overhaul, Test andInspectionof Turbine Starter ll. : Turn thedrive shaftpinion Apply50psig(3.4 Tur n the the n Tur ange. is properly sealed,nobobblesis properly willappear. non-fl the motor. for 30secondsino Immersethestarter 20 psig(1.38bar/138kPa) pressuretotheinletof smoothly.should run (9 mm)supplylinetotheinletofmotor. starter ply 90psig(6.2bar/620kPa) pressureusinga3/8" 45.0 +2.0mm. the face ofthemountingfl the distanceform theface ofthedrive shaftpinion edge ofthegeartooth. Chamfer onpinionteethshouldbethetrailing must rotateinthedirectionstampedonnameplate. rotation.to themotorandobserve drive pinion(63) sealed, nobubbles willappear. gearsystem. isproperly intermediate Ifthestarter in thegearcaseareaorshaftseal o non-fl ammable, bubble-producing liquid. of themotor. for 30secondsin Immersethestarter apply 20psig(1.38bar/138kPa) pressuretotheinlet 6. 5. 4. Remove thepressurefrom “IN” port. Measure 7. There shouldbenoleakageinthehousingjoints GearCaseSeals: ammable, bubble-producing liquid. Ifthestarter Motor Seals: Motor Action: Confi rm DriveRotation: Plugtheexhaust andslowly apply Secure starter inaviseandap- Securestarter Plugtheexhaust andslowly Applylow pressure ange. Itshouldbe L+V28/32H 613-01.30 Edition 02H 91.08 -ES0S-G 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Hour Data: 1 Capacity : 1 : Working time man Man power: Related procedure: position: Starting system. valveinstarting starting Lubricating, disassemblyandreassembly ofmain Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: Main Starting Main Starting Valve 630 7 1/eng. 1/eng. 1/eng. 07 1/eng. 04 61310 03 Qty. / 61310 02 61310 61310 Itemno. Plateno. Replacement andwearingparts: Allen key, 1/4". Locking ringplier. Soft hammer. Hand tools: Note. Itemno. Plateno. Special tools: L+V28/32H 613-01.40 Edition 01H MAN Diesel L+V28/32H 613-01.40 Edition 01H Fig. 1. Main starting valve. Fig. 1.Mainstarting the plugopening. about30gof10woilintothevalvethroughsquirt 1) ri valveshouldbeperiodicallylub- The mainstarting Important: bled off. ing valvebefore thestart Do notattemptanymaintenanceonthemainstart- Warning: 3) 2) cat Reinstalltheplug. Removetheplugscrew (A),seefi Blendoff theairpressure. ed asfollows: 2 1 7Bme 8Spring O-ring 10 11O-ring Piston Piston o-ring 4 o-ring 6 Retaining 9 ring 7 Bumper O-ringretainer Piston 5 2 End Pilotair 3 plug B Valve 1 housing airinlet Starting D airoutlet Starting C Plugscrew A 11 D 7 9 ing airsystemhasbeen 3 B Main Starting Main Starting Valve g. 1.and 10 8 5 6 4 C A 11) (7). solvent. retainer (5),bumper(7)and spring(8). (2) assembly. housing (1)lightlywithasofthammeruntilitdoes. plug (3)shouldspringout.Ifitdoesnot,tapthevalve the lockingring(9)endup. Disassembly: diameter thantheendplugo-ring(11). Note: (6) onthepiston(2). new pistono-ring(4)andtheupper Reassembly: sembly, installtheendpluglocking ring(9). spring.

opening overthepistono-ring. against thebeveliedface. sing. Pushonthepistonuntilo-ringseats housing (1)witho-ringlubricant. o-ring (11)ontheendplug(3). new endplugsealo-ring(10)andthe 10) 17) 16) 15) 14) 13) 12) 8) 7) 6) 5) 4) 9) Using o-ring lubricant, lubricate and install the Usingo-ringlubricant,lubricateandinstallthe Turn thenewbum thepistonoverandinsert Wash inaclean,nonﬂ allotherparts ammable Removeanddiscard allusedo-rings,o-rings Removetheendplug(3),spring(8)andpiston Carefully remove thelockingring(9).Theend valve,inavicewith Clampthemainstarting Usingapress toholddowntheend plugas- Place the end plug assembly on the piston Placetheendplugassembly onthepiston Placethenewpistonspring(8)onpiston. Installthenewo-ringretainer (5)withthelarge Insert thepistonassemblyintovalvehou- Insert Lubricatethelowersmallbore ofthevalve The upper piston o-ring (6) is slightly larger in Theupperpistono-ring(6)isslightlylargerin Using o-ringlubricant,lubricateandinstallthe Working Card Page 2(2) 91.08 -ES0S-G ber ber

08028-0D/H5250/94.08.12 94.21 -ES0U-G 08028-0D/H5250/94.08.12 MAN Diesel Working Card Page 1(2) elrto fwih (Page600.45) (Page600.40) Declaration ofweight Data fortorque moment (Page600.35) Data forpressure andtolerance Data: Capacity : 1 Working time man Man power: Related procedure: Compressed airconnectedtotheengine. position: Starting Check ofcompressed oilpipingsystem. Description: Stoppedlub.oilcircul. Shut-off coolingoil Shut-off fueloil Shut-off coolingwater Shut-offair starting Stoppedengine Safety precautions: : ½ hour Check ofCompressedAirPipingSystem lt o Ie o Qty. / Itemno. Plateno. Replacement andwearingparts: Screwdriver. Hand tools: Note. Itemno. Plateno. Special tools: L+V28/32H 613-01.90 Edition 02H MAN Diesel L+V28/32H 613-01.90 Edition 02H ges. 4) should bebasedonobservations. 3) 2) 1) With airconnected. 5) Check ﬂexible connectionsforleaksanddama- Examine thepipingsystemforleaks. Check manometers. Drain thesystemforcondensedwater. -This Retighten allboltsandnutsinthepipingsystem. Check ofCompressedAirPipingSystem of theemergencyvalve.Seedescription613.01. Lubricate valvespindleswithgraphiteorsimilar. 7) 6) With airdisconnectedandstoppedengine. Connect theairsupplyandmakeafunctiontest Move allvalvesandcocksinthepipingsystem. Working Card Page 2(2) 94.21 -ES0U-G

08028-0D/H5250/94.08.12 MAN Diesel

Plate Page 1 (3) Turbine Starter 61309-05H

L+V28/32H

96.26- ES0S-G MAN Diesel

Plate 61309-05H Turbine Starter Page 2 (3)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

1 1/S Housing exhaust Hus for udstøds-dæk- 22 1/S Planet gear shaft. Planetgearaksel. cover. sel. 23 2/S Gear shaft retainer Spænderingsskive for 2 1/S Exhaust cover seal. Tætningsring for ud- washer. gearaksel. stødsdæksel. 24 1/S Rear gear frame Bagerste gearstelleje. 3 1/S Splash deﬂ ector. Stænk deﬂ ektor. bearing.

4 1/S Deﬂ ector return Returfjeder for de- 25 1/S Front bearing spa- Forreste gearstelleje. spring. ﬂ ektor. cer.

5 !/S Deﬂ ector retaining Spændeskive for 26 1/S Intermediate pinion. Mellemtandhjul. screw. deﬂ ektor. 27 1/S Intermediate pinion Spændeskrue for mel- 6 4/S Starter assembly cap Dækselskrue for mon- retaining screw. lemtandhjul. screw. tage af starter. 28 1/S Gear case. Gearkasse. 7 4/S Cap screw washer. Skive for dækselskrue. 29 1/S Drive gear. Drivgear. 8 1/S Motor housing. Motorhus. 30 1/S Front drive gear Forreste drivgearleje. 10 1/S Housing plug. Prop til motorhus. bearing.

11 1/S Housing plug inlet Tilgangsknast for prop 31 1/S Rear drive gear Bagerste drivgearleje. boss. til motorhus. bearing.

12 1/S Motor assembly. Motor samling. 32 1/S Drive gear bearing Spændskrue for driv- retainer. gearleje. 12A 2/S Cylinder o-ring seal. O-ringstætning for cylinder. 33 1/S Drive gear shaft Spændskrue for driv- bearing retainer. gearakselleje. 12B 2/S Housing o-ring seal. O-ringstætning for motorhus. 34 1/S Drive gear screw. Drivgearskrue.

13 1/S Intermediate gear Mellem gearkasse. 35 1/S Drive gear lock Skive for drivgear. case. washer.

14 1/S Rear gear case o- Bagerste gearkasse 36 1/S Drive gear cup. Dæksel for drivgear. ring. o-ring. 37 1/S Drive gear screw O-ring for drivgear- 15 1/S Front gear case Forreste gearkasse o-ring. skrue. o-ring. o-ring. 38 8/S Drive housing cap Dækselskrue for driv- 16 1/S Planet gear frame Tætningsring for pla- screw. gear. shaft seal. netgearakselstel. 39 8/S Drive housing cap Skive for dækselskrue 16A 1/S Spacer ring. Afstandsring. screw lock washer. til drivgearhus.

17 1/S Front gear frame Forreste gearstelleje. 40 1/S Drive housing kit. Drivgearhus. bearing. 41 1/S Drive housing o-ring O-ring for drivgearhus. 18 1/S Planet gear frame. Planetgearstel. 42 1/S Front shaft bearing. Forreste akselleje. 19 1/S Planet gear. Planetgear. 43 1/S Drive housing seal. Tætningsring for driv- 20 1/S Planet gear needle Nålevalse for planet- gearhus. roller. gear. 44 1/S Drive housing vent Aﬂ uftningsprop for 21 1/S Bearing spacer. Ligemellemstykke. plug. drivgearhus.

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty.//E = Qty./Engine Qty./E = Qty./Motor Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter

96.26 - ES0S-G MAN Diesel

Plate Page 3 (3) Turbine Starter 61309-05H

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

45 1/S Bulkhead retainer. Skotholder 69A 2/E Turbine star- Turbinestar- ter, complete. ter, komplet. 46 1/S Bulkhead kit. Skotsæt V28/32H. V28/32H.

47 1/S Outer bulkhead Ydre skot o-ring. 70 Spare parts Reservedels- o-ring. kit, incl. item sæt incl. item 2, 12A, 12B, 2, 12A, 12B, 48 1/S Inner bulkhead o- Indre skot o-ring. 14, 15, 16, 14, 15, 16, ring. 16A, 17, 21, 16A, 17, 21, 23, 24, 25, 41, 23, 24, 25, 41, 49 1/S Clutch spring cup Fjedertallerken holder. 45, 47, 48, 55, 45, 47, 48, 55, retainer. 61 and 62 61 og 62.

50 1/S Clutch spring cup. Fjedertallerken.

51 1/S Clutch spring. Koblingsfjeder.

52 1/S Clutch jaw kit. Koblingssæt.

53 1/S Large drive shaft Stor lejespændering bearing retainer. for drivaksel.

54 1/S Piston kit. Stempelsæt.

55 1/S Piston o-ring. Stempel o-ring.

57 1/S Drive shaft kit. Drivakselsæt.

58 1/S Rear drive shaft Bagerste drivakselleje. bearing.

59 1/S Piston return spring. Stempel returfjeder.

60 1/S Seat. Sædering.

61 1/S Drive pinion retain- Tandhjulsspænde- ing screw. skrue.

62 1/S Drive pinion washer. Tandhjulsskive.

63 1/S Drive pinion. Tandhjul. L28/32H. L28/32H

63A 1/S Drive pinion. Tandhjul. V28/32H. V28/32H

64 1/S Pinion spring sleeve. Tandhjulsbøsning.

65 1/S Pinion spring. Tandhjulsfjeder.

66 1/S Inlet ﬂ ange kit. Tilgangsﬂ angesæt.

67 3/S Cover Dæksel

68 1/S Self drilling screws Selvborende skruer

69 1/E Turbine starter, com- Turbinestarter, kom- plete. L28/32H plet. L28/32H.

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Qty./E = Qty./Motor Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter

96.26 - ES0S-G MAN Diesel

Plate Page 1 (2) Main Starting Valve 61310-03H

L+V28/32H

03*

01*

04* 02* 05 07*

08 06*

08.03 - ES0-G MAN Diesel

Plate 61310-03H Main Starting Valve Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01* 1/V O-ring O-ring

02* 1/V O-ring retainer O-ring holder

03* 1/V O-ring O-ring

04* 1/V Bumper Stødfanger

05 1/V Spring Fjeder

06* 1/V O-ring O-ring

07* 1/V O-ring O-ring

08 1/E Main starting valve, Hovedstartventil, complete komplet

09 1/V Spare part kit Reservedelssæt Item No. 01, 02, 03, Item nr. 01, 02, 03, 04, 06 and 07 04, 06 og 07

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./E = Qty./Engine Antal/E = Antal/Motor Qty./V = Qty./Valve Antal/V = Antal/Ventil

08.03 - ES0-G MAN Diesel

Plate Page 1 (2) Mufﬂ er 61312-02H

L+V28/32H

91.20 - ES0S-G MAN Diesel

Plate 61312-02H Mufﬂ er Page 2 (2)

L+V28/32H

Item Item No. Qty. Designation Benævnelse No. Qty Designation Benævnelse

01 1/S Mufﬂ er Dæmper

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt. Qty./S = Qty./Starting air motor Antal/S = Antal/Startemotor

91.20 - ES0S-G