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Instruction Book

Engine Type
L28/32H
Your Notes :

08031-0D/H5250/94.09.07
Instruction book for :
STX/OLDENDROFF
S-1217
9L28/32H

MAN B&W Diesel Identification No. for Instruction Book.

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 600.50.

This book must not, either wholly or partly, be copied, reproduced, made public or in any other way made
available to any third party without the written consent to this effect from MAN B&W A/S, Holeby.

MAN Diesel A/S, STX Engine.Co., Ltd.


Holeby 80, Seongsan-dong, Changwon, Kyungnam
stervej 2, DK-4960 Holeby Republic of Korea
Denmark
Technical Service
Telephone + 45 54 69 31 00 Telephone : + 82 55 280 0590
Telefax : + 82 55 282 6907
Marketing
Telefax : + 45 54 69 30 30 Part Sales
Cables : oildiesel maribo Telephone : + 82 55 280 0550~6
Telex : 40646 hodiel dk Telefax : + 82 55 282 1388
Reg. No. : 24231

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
INSTRUCTIONS FOR ENGINE TYPE L28/32H

Introduction

This instruction book has been prepared to provide general guidance on operation and maintenance and
to give a description of the design of a standard version of the above engine type. Deviations may be
found in a specific plant. The book may also be used for reference purposes when ordering spares.

The first five sections (600-604) of the book serve as a guide on the operation of the engine, and the next
fifteen sections (605-619) contain technical descriptions, spare parts illustrations with pertaining parts lists
as well as overhauling procedures. The last section (620) comprises tools. The engine is divided into a
number of main components/assemblies, each one described in a section of this book (sections 605-619).
Each of these sections is prefaced by a short technical description, followed by spare parts illustrations
and parts lists. Later the overhauling procedures are to be found, each initiated by a Data-sheet
specifying the data relevant for the specific procedure.

As reliable and economical operation of the diesel engines is conditional on correct operation and
maintenance, it is essential that the engine-room personnel is fully acquainted with the contents of this
book.

This book, or parts of it, must not be copied without the written permission of MAN B&W Diesel A/S,
Holeby.
ORDERING OF SPARE PARTS, ENGINE TYPE L28/32H

Whenever spare parts are ordered (or reference is made in correspondance etc.) the following data must
be indicated for the particular engine:

1. Name of plant

2. Engine No. - -, built by

3. Illustration plate number (complete with Ed. figures)

4. Item No.

5. Quantity required (and description)

This data is used by us to ensure supply of the correct spare parts for the individual engines, even though
the spare parts illustrations contained in this book may not always be in complete accordance with the
individual components of a specific engine.
Index
Page 1(1) Engine Data 600

L28/32H
Description

Main data for gensets ------------------------------------------------------------------------ 600.00


Introduction ------------------------------------------------------------------------------------- 600.01 (07H)
Safety ---------------------------------------------------------------------------------------------600.02 (06H)
Cross section ----------------------------------------------------------------------------------- 600.05 (06H)
Key for engine designation ------------------------------------------------------------------600.10 (01H)
Designation of cylinders --------------------------------------------------------------------- 600.11 (01H)
Engine rotation clockwise ------------------------------------------------------------------- 600.12 (02H)
Code identification for instruments --------------------------------------------------------600.20 (01H)
Introduction to planned maintenance programme ------------------------------------ 600.24 (02H)
Planned maintenance programme -------------------------------------------------------- 600.25 (16H)
Maintenance Schedule - NICO ------------------------------------------------------------ 600.25 (20H)
Operation data and set points --------------------------------------------------------------600.30 (33H)
Data for pressure and tolerance ----------------------------------------------------------- 600.35 (13H)
Data for torque moments -------------------------------------------------------------------- 600.40 (15S)
Declaration of weight ------------------------------------------------------------------------- 600.45 (01H)
Ordering of spare parts ---------------------------------------------------------------------- 600.50 (01H)
Service letters ---------------------------------------------------------------------------------- 600.55 (01H)
Conversion table -------------------------------------------------------------------------------600.60 (01H)
Basic symbols for piping ---------------------------------------------------------------------600.65 (01H)

Working Card

Plates

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Page 1 (1) Warning 000.00

General

Warning !

(Marine engines only)

It is important that all MAN B&W Diesel A/S engines


are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to the
MAN B&W Diesel A/S 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 B&W
Diesel A/S instructions including, but not limited to,
the instructions to that effect included in the
Technical File.
08028-0D/H5250/94.08.12

03.38 - ES0
Your Notes :

08031-0D/H5250/94.09.07
Description
Main Data for GenSets 600.00
Page 1(1)

L28/32H

Main Data for Engine Type L28/32H


Engine Nos 4
(SB9L28-4839/40/41/42)

Number of cylinders 9
Cycle 4 stroke
Cylinder bore 280 mm
Stroke 320 mm
Engine speed 720 rpm
Engine outpur (on flywheel) 1890 Kw
Compression ratio 13.3 : 1
Max. combustion pressure 132.5 kg/cm2
Firing order 1-5-9-3-6-8-2-4-7
Rotation C.W view from flywheel

Main Data for Alternator Make HYUNDAI


Type HFC5 639-14K
Serial No for engine No.1 20070579RAL05001
Serial No for engine No.2 20070579RAL05002
Serial No for engine No.3 20070579RAL05003
Serial No for engine No.4 20070579RAL05004
Capacity 2250.0 kVA
Rating 720 rpm
Voltage 450 V
Frequency 60 Hz
Power factor 0.8

Main Data for Turbocharger Make ENPACO-MAN


Type NR24/S047
Serial No for engine No.1 SLK 0837
Serial No for engine No.2 SLK 0838
Serial No for engine No.3 SLK 0839
Serial No for engine No.4 SLK 0840

Main Data for Governor Make WOODWARD


Type UG8D
Serial No for engine No.1 14957365
Serial No for engine No.2 15444587
Serial No for engine No.3 15504833
Serial No for engine No.4 15504834

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Introduction 600.01
Page 1 (1) Edition 07H

General

Description

This instruction book earn the purpose to provide Reliable and economical operation of the plant is
general information for operation and maintenance, conditional upon its correct operation and mainte-
to describe the design and to be used for reference nance in accordance with MAN B&W Diesel A/S'
when ordering spare parts. instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in
MAN B&W Diesel A/S' instructions and any addi-
tional instructions to that effect included in the Tech-
nical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the
contents of this book and, in respect of instructions
on emissions related maintenance of the diesel
engine, also the additional instructions to that effect
Section 505-519
Spare parts plates set out in the Technical File.

The book is a basic instruction manual for the


Working card particular engine supplied with plant-adapted infor-
mation such as principle media-system drawings,
electric wiring diagrams and test bed reports.
Description

The first five sections (600-604) of the book serve as


a guide on the operation of the engine, and the next
fifteen sections (605-619) contain technical descrip-
tions, spare parts illustrations with pertaining parts
lists as well as working cards.

The last section (620) comprises tools.

The engine is divided into a number of main compo-


Fig. 1. Structuring of instruction book.
nents/assemblies, each of which is described in a
section of this book (section 605-619).

Each of these sections starts with technical de-


scriptions of the systems/components, followed by
working cards. Later the spare parts illustration
plates and parts lists are to be found.
08028-0D/H5250/94.08.12

03.36 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Description
Safety 600.02
Page 1 (2)
Edition 06H

General

General Spares

Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be
constitutes the crucial point in obtaining optimum placed well strapped near the area of application and
safety in the engine room. The general measures accessible by crane. The spare parts should be well
mentioned here should therefore be a natural routine preserved against corrosion and protected against
to the entire engine room staff. mechanical damage. The stock should be checked
at intervals and replenished in time.

Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room when the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light, in explosion-proof fittings, should
and doors in the engine room should be closed. be obtainable everywhere.

In particular, welding or work which causes spread-


ing of grit and chips must be avoided near the engine, Freezing
unless this is closed or covered, and the turbochar-
ger air intake filters are covered. If there is a risk of damage due to freezing when the
plant is out of service, engines, pumps, coolers, and
The exterior of the engine should be kept clean and pipe systems should be emptied of cooling water.
the paintwork maintained so that leakages can easily
be detected.
Warning

Fire The opening of cocks may cause discharge of hot


liquids or gases. The dismantling of parts may cause
If the crankcase is opened before the engine is cold, springs to be released.
welding and the use of naked light will involve the risk
of explosions and fire. The same applies to inspec- The removal of fuel valves (or other valves in the
tion of oil tanks and the space below the fooler. cylinder head) may cause oil to run down to the
Attention is furthermore drawn to the danger of fire piston crown, and if the piston is hot, an explosion
when using paint and solvents with a low flash point. may then blow out the valve.
Porous insulating material drenched with oil from
leakages is easily inflammable and should be re- When testing fuel valves with the hand pump, do not
newed. See also: "Ignition in crankcase" in section touch the spray holes, as the jet may pierce the skin.
603. Think out beforehand which way the liquids, gases or
flames will move, and keep clear.
08028-0D/H5250/94.08.12

Order
Crankcase work
Hand tools should be placed easily accessible on
tool boards. Special tools should be fastened to tool Check beforehand that the starting air supply to the
panels (if supplied) in the engine room close to the engine is shut off.
area of application. No major objects must be left
unfastened, and the floor and passages should be
kept clear.

91.12 - ES0U
600.02 Safety Description
Edition 06H Page 2 (2)

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-mist liquid in the combustion spaces, turning with open
formation, blow-by, or failure of cooling water or indicator cocks should always be effected, through
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, filter elements and
finally when the engine is running at full load. See measuring equipment.
also "Starting-up sequence" in the section 602.

91.12 - ES0U
Description 600.05
Page 1 (1) Cross Section Edition 06H

L28/32H
08028-0D/H5250/94.08.12

99.40 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description 600.10
Page 1 (1) Key for Engine Designation Edition 01H

General

Engine Type Identification

The engine types of the MAN B&W Holeby programme are identified by the following figures:

6 L 28/32 H MCR

No of cylinders

5, 6, 7, 8, 9
12, 16, 18

Engine Type

L : In-line
V : V-built

Cyl. diam/stroke

16/24 : 160/240
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400

Design Variant

Rating
08028-0D/H5250/94.08.12

MCR : Maximum continuous rating


ECR : Economy continuous rating

97.40 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description 600.11
Page 1 (1) Designation of Cylinders Edition 01H

L28/32H

Front End Flywheel end

Exhaust Side / Right Side

Control Side / Camshaft Side / Left Side


08028-0D/H5250/94.08.12

89.17 - ES1S-L
Your Notes :

08031-0D/H5250/94.09.07
Description
Engine Rotation Clockwise 600.12
Page 1 (1) Edition 02H

General
08028-0D/H5250/94.08.12

98.18 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description
Code Identification for Instruments 600.20
Page 1 (3) Edition 01H

General

Symbol explanation:

Measuring device
TI
Locally reading
40
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 *

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

Specification of letter code for measuring devices

1 st letter Following letters

F Flow A Alarm

L Level D Differential

P Pressure E Element

S Speed H High
08028-0D/H5250/94.08.12

T Temperature I Indicating

U Voltage L Low

V Viscosity S Switching, Stop

Z Position T Transmitting

X Failure

92.03 - ES1U
600.20 Code Identification for Instruments Description
Edition 01H Page 2 (3)

General

Standard text for instruments

Diesel engine/generator

LT Water System

01 inlet to air cooler 05 outlet from alternator


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

HT Water System

10 inlet to engine 15
11 outlet each cylinder 16 outlet turbocharger
12 outlet from engine 17 outlet fresh water cooler
13 18 inlet fresh water cooler
14 19

Lubricating Oil System

20 inlet to cooler 25 prelubricating


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

Charging Air System

30 inlet to cooler 35 surplus air inlet


31 outlet from cooler 36 inlet to turbocharger
32 jet assist system 37
33 outlet from TC filter / inlet to TC compressor 38
34 39

Fuel Oil System


08028-0D/H5250/94.08.12

40 inlet to engine 45
41 outlet from engine 46
42 leakage 47
43 inlet to filter 48
44 outlet sealing oil pump 49

92.03 - ES1U
Description
Code Identification for Instruments 600.20
Page 3 (3) Edition 01H

General

Cooling Oil System

50 inlet to fuel valves 55


51 outlet from fuel valves 56
52 57
53 58
54 59

Exhaust Gas System

60 outlet cylinder 65
61 outlet turbocharger 66
62 inlet turbocharger 67
63 68
64 69

Compressed Air System

70 inlet to engine 75 micro switch for turning gear


71 inlet to stop cylinder 76
72 inlet to balance arm unit 77
73 control air 78
74 inlet to reduction valve 79

Load Speed

80 85 micro switch for overload


81 overspeed 86
82 87
83 88 index - fuel-pump
84 89 turbocharger speed
90 engine speed

Miscellaneous

91 Natural gas - inlet to engine 95 voltage


92 96
08028-0D/H5250/94.08.12

93 97
94 98
99

92.03 - ES1U
Your Notes :

08031-0D/H5250/94.09.07
Description
Introduction to Planned Maintenance Programme 600.24
Page 1 (1)
Edition 02H

General

General 4. Related procedures - indicates other works,


depending on this work - or works which would be
The overhaul intervals are based on operation on a expedient to carry out.
specified fuel oil quality at normal service output,
which means 70-100% of MCR. 5. Indicates x number of men in x number of hours
for accomplishing the work.
In the long run it is not possible to obtain a secure and
optimal economic running without an effective main- The stated consumption of hours is only intended as
tenance system. guide.

With the structure and amount of information in the Experience with the specific station/crew may lead to
maintenance programme, it can be integrated in the a bringing up-to-date.
entire ship's/power station's maintenance system or
it can be used separately. 6. Refers to data, which are required for carrying
out the work.
The crux of the maintenance system is the key
diagram, see page 600.25, indicating the inspection 7. Special tools, which must be used. Please note
intervals for the components/systems, so that the that not all tools are standard equipment.
crew can make the necessary overhauls, based on
the engines' condition and/or the time criteria. 8. Various requisite hand tools.

The stated, recommended intervals are only for 9. Indicates the components/parts, which it is
guidance as different service conditions, the quality advisible to replace during the maintenance work.
of the fuel oil and the lubricating oil, treatment of the Please note, that this is a condition for the intervals
cooling water, etc, will decisively influence on the stated.
actual service results and thus the intervals between
necessary overhauls.

Experience with the specific plant/crew is to be used


for adjustment of time between overhaul. Further it is
to be used for adjusting the timetable stated for
guidance in the working cards.

1
7
Working cards
2
Each of the working cards can be divided into two: a
front page and one or several pages, describing and
illustrating the maintenance work. 3
8
The front page indicates the following:
08028-0D/H5250/94.08.12

1. Safety regulations, which MUST be carried


through before the maintenance work can start.
5
9
2. A brief description of the work.
6

3. Reference to work, which must be carried out,


if any, before the maintenance work can start.

Fig 1. Guidance instruction for working cards.

94.35 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Description 600.25
Page 1 (4) Planned Maintenance Program Edition 16H

L+V28/32H

Time Between Overhaul

l Working

Observations
= Overhaul to be carried out
Description n

3th month
Card

50

Weekly
6000
200

12000
24000
2000

Montly
Daily
= Check the condition
No.

Operating of Engine:

Readings of data for Engine and Generator, with refe-


rence to "Engine Performance Data", section 602-1 ...... n 602-01.00

Cylinder Head:

Inlet and exhaust valve - Overhaul and regrinding of


spindel and valve seat .................................................... l 605-01.10
Inspection of inlet, exhaust valves and valve guide ........ n 605-01.05
Check of valve rotators rotation during engine rotation .. n 605-01.05
Sleeve for fuel injector .................................................... n 605-01.30
Safety valve - Overhaul and adjustment of opening
pressure ......................................................................... n 605-01.25
Indicator valve ................................................................ n n 605-01.26

Cylinder head cooling water space - Inspection ............. n 605-01.45


Cylinder head nut - Retightening .................................... 200 605-01.40

Piston, Connecting Rod and Cylinder Liner:

Inspection of piston ........................................................ n 606-01.10


Piston ring and scraper ring ........................................... l 606-01.10

Piston pin and bush for connecting rod - Check of


clearance ........................................................................ n 606-01.15
Connecting rod - Measuring of big-end bore .................. n 606-01.15
Inspection of big-end bearings shells ............................. n 606-01.16

Connecting rod - Retightening ........................................ 200 n 606-01.25


Cylinder liner - Cleaning, honing and measuring ............ l 606-01.35
Cylinder liner removed - Check the water space and
guide ring in frame.......................................................... n 606-01.40
Overhauled parts
Check new/

after -hours

Camshaft and Camshaft Drive:


50

Camshaft - Inspection of gear wheels, bolt, connections


etc. ................................................................................. 200 n 607-01.00
Camshaft bearing - Inspection of clearance ................... n 607-01.05
Camshaft adjustment - Check the condition ................... n 607-01.20

Lubrication of camshaft bearing - Check ........................ n 607-01.00

97.27 - ES0U
600.25 Description
Edition 16H
Planned Maintenance Program Page 2 (4)

L+V28/32H

Time Between Overhaul

Overhauled parts
l Working

Observations
= Overhaul to be carried out
Description n

3th month
Check new/

after -hours
Card

2000
6000
50

Weekly
200

24000
12000

Montly
Daily
= Check the condition
No.

Operating Gear for Inlet Valves, Exhaust Valves and


Fuel Injection Pumps:

n
n
Roller guide for valve gear ............................................. 608-01.00

n
Valve gear - Valve bridge, spring, push rod, etc ............. 608-01.10
Roller guide for fuel injection pump ................................ 608-01.05

Roller guide housing ....................................................... n 608-01.10

n
Inlet and exhaust valve - Check and adjustment of valve
clearance ........................................................................ 608-01.10

Lubricating of operating gear - Check ............................ n 608-01.00


608-01.05

Control and Safety System, Automatics and


Instruments:

Safety, alarm and monitoring equipment ........................ n 609-01.00

n
n
Jet system - Adjustment ................................................. 609-01.00
Pick-up - Adjustment ...................................................... 609-10.00

n
Governor - Check oil level, see governor instruction
book, section 609 ...........................................................

Crankshaft and Main Bearing:

n
n
Checking of main bearings aligment, (autolog) .............. 610-01.00

n
Inspection af main bearing ............................................. 610-01.05
Inspection of guide bearing ............................................ 610-01.10

Vibration damper - Check the condition ......................... n 610-04.00


08028-0D/H5250/94.08.12

n
Lubricating of gear wheel for lub. oil pump and cooling

n
water pump etc. ..............................................................
Counter weight - Retightening, see page 600.40 ........... 200

Main- and guide bearing cap - Retightening ................... 200 n 610-01.05


610-01.10

97.27 - ES0U
Description 600.25
Page 3 (4) Planned Maintenance Program Edition 16H

L+V28/32H

Time Between Overhaul

Overhauled parts
l Working

Observations
= Overhaul to be carried out
Description n

3th month
Check new/

after -hours

2000
6000
50
Card

Weekly
200

24000
12000

Montly
Daily
= Check the condition
No.

Engine Frame and Bedplate:

Holding down bolts - Retightening, see page 600.40 ..... 200 n


n
Bolts between engine frame and base frame -
Retightening, see page 600.40 ...................................... 200

n
For flexible mounted engines - Check anti-vibration
619-03.00
n
mountings ....................................................................... 200
Safety cover - Function test ............................................ 611-01.00

Turbocharger System:

l 612-10.00
l
Dry cleaning of turbine side ............................................
612-15.00
l
Wet cleaning of turbine side ...........................................
Water washing of compressor side ................................ 612-05.00

Cleaning of air filter - Compressor side (see turbo-


charger instruction book) ................................................
Turbocharger complete - Dismantling, cleaning, inspec-

n
tion etc. (see turbocharger instruction book) ..................
Charging air cooler - Cleaning and inspection ................ 612-01.00

l
n
Charging air cooler housing - Draining ...........................
Exhaust pipe - Compensator ..........................................

Compressed Air System:

Air starter motor - Dismantling and inspection ................ n 613-01.30

n
Function test - Main starting valve, starting valve, main
valves and emergency start valve .................................. 613-01.40

l
l
Dirt separator - Dismantling and cleaning ......................
Muffler - Dismantling and cleaning .................................

l 613-01.90
n
Compressed air system - Draining .................................
Compressed air system - Check of the system .............. 613-01.90

Drain of bowl .................................................................. l 613-01.21


(filter element to be replaced when pressure drop
exceeds 0.7 bar)

97.27 - ES0U
600.25 Description
Edition 16H
Planned Maintenance Program Page 4 (4)

L+V28/32H

Time Between Overhaul

Overhauled parts
l Working

Observations
= Overhaul to be carried out
Description n

3th month
Check new/

after -hours
Card

2000
6000
50

Weekly
200

24000
12000

Montly
Daily
= Check the condition
No.

Fuel Oil System and Injection Equipment:

l 614-01.15
l
Fuel oil filter - Dismantling and cleaning .........................
614-10.00
l
Fuel oil feed pump ..........................................................
Fuel oil injection pump - Dismantling and cleaning ......... 614-01.05

n 614-01.10
n
Fuel injection valve - Adjustment of opening pressure ... 200
614-01.05
l
Fuel oil high-pressure pipe - Dismantling and check ......
Adjustment of the maximum combustion pressure ......... 614-05.01

n 614-01.90
n
Fuel oil system - Check the system ................................
Nozzle cooling system - Check the system .................... 614-01.90

Fuel oil - Oil samples after every bunkering, see sec.604

Lubricating Oil System:

n 615-01.00
l
Lubricating oil pump - Engine driven ..............................
615-01.10
l
Lubricating oil filter - Cleaning and exhange ..................
Lubricating oil cooler ...................................................... 615-06.00

n 615-01.05
n
Prelubricating pump - El. driven .....................................
615-01.20
l
Thermostatic valve .........................................................
Centrifugal filter - Cleaning and exhange of paper ......... 615-15.00

n
n
Lubricating oil - Oil samples, see section 604 ................
Lubricating oil system - Check the system ..................... 615-01.90

Cooling Water System:

n
Cooling water pump - Engine driven (sea water and
08028-0D/H5250/94.08.12

n
fresh water) ....................................................................

n
Thermostatic valve .........................................................
Cooling water system - Check the system ..................... 616-01.90

Cooling water system - Water samples, see sec. 604 .... n n

97.27 - ES0U
Description
Maintenance Schedule NICO 600.25
Page 1 (1) Edition 20H

L28/32H

Time Between Overhaul


Description = Replace Working

dismantlement

Observations
3th month
= Inspection Card

Montly
16000
24000
32000

Every
2000
5000
= Inspection or replace No.

Fuel Injection Pump:

Seal parts.............................................................................
Spring : Delivery valve ......................................................... 614-01.05
Delivery valve ......................................................................
Plunger, complete................................................................
Spring : Plunger ...................................................................
Guide : Plunger....................................................................
Deflector ..............................................................................
Other parts...........................................................................

Fuel Injection Valve: 614-01.10

Seal parts.............................................................................
Atomizer, complete (Nozzle needle and nozzle body) ......
Other parts

Replcace : the dismantled parts must be replaced with new


parts.

Inspection : you have only to inspect the dismantled parts


except these arent considered faultily. When those
considered faultiry, you should consult MAN B&W Diesel
A/S, Holeby on whether replace or not.

Inspection or Replace : The dismantled parts are


inspected and those considered faultily are replaced.
08028-0D/H5250/94.08.12

94.47-ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Operation Data & Set Points 600.30
Page 1 (2) Edition 33H

L28/32H

Normal Value at Full load Alarm Set point Autostop of engine

Lubricating Oil System

Temp. before cooler SAE 30 TI 20 60-75 C TAH 20 90 C


(outlet engine) SAE 40 TI 20 65-82 C TAH 20 100 C

Temp. after cooler SAE 30 TI 22 45-65 C TAH 22 75 C TSH 22 85 C


(inlet engine) SAE 40 TI 22 50-72 C TAH 22 85 C TSH 22 95 C

Pressure after filter (inlet eng) PI 22 3-4 bar PAL 22 3 bar PSL 22 2.5 bar
Elevated pressure i.g. when
centrifugal filter installed PI 22 4-5 bar PAL 22 4 bar PSL 22 2.5 bar
Pressure drop across filter PDAH 21-22 0.5-1 bar PDAH 21-22 1.5 bar

Prelubricating pressure PI 25 0.1-0.5 bar LAL 25 level switch


Pressure inlet turbocharger PI 23 1.5 0.2 bar

Lub. oil, level in base frame LAL 28/LAH 28 low/high level

Temp. main bearings TE 29 75-85 C TAH 29 95 C


Fuel Oil System

Pressure after filter MDO PI 40 2-3 bar PAL 40 1.5 bar


HFO PI 40 (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 (C)
Temp. nozz. cool. oil, outlet eng. TI 50 80-90 C (C)

Cooling Water System


Press. LT-system, inlet engine PI 01 1-2.5 bar PAL 01 0.4 bar + (B)

Press. HT-system, inlet engine PI 10 1-3.0 bar PAL 10 0.4 bar + (B)

Temp. HT-system, inlet engine TI 10 60-75 C


Temp. HT-system, outl. cyl.units TI 11 70-85 C

Temp. HT-system, outlet engine TAH 12 90 C


TAH 12-2 93 C TSH 12 95 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. TAD 60 average 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 TAH 31 65 C
08028-0D/H5250/94.08.12

Compressed Air System

Press. inlet engine PI 70 7-9 bar PAL 70 7 bar

Speed Control System


Engine speed
GenSets for 60 Hz
Mechanical SSH 81 825 rpm
Elec. SI 90 720 rpm SAH 81 815 rpm SSH 81 815 rpm
GenSets for 50 Hz
Mechanical SSH 81 860 rpm
Elec. SI 90 750 rpm SAH 81 850 rpm SSH 81 850 rpm

Turbocharger speed SI 89 SAH 89 (D)


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.

03.50 - ES1
600.30 Operation Data & Set Points Description
Edition 33H Page 2 (2)

L28/32H

Remarks to individual Parameters C. Nozzle Cooling Oil System

The nozzle cooling oil system is only applied for


A. Fuel Oil Pressure, HFO-operation. stationary engines.

When operating on HFO, the system pressure must


be sufficient to depress any tendency to gasification D. Limits for Turbocharger Overspeed Alarm
of the hot fuel. (SAH 89)

The system pressure has to be adjusted according to Engine type 720 rpm 750 rpm
the fuel oil preheating temperature. 5L28/32H 42,680 42,680
6L28/32H 42,680 42,680
B. Cooling Water Pressure, Alarm Set Points. 7L28/32H 34,900 34,900
8L28/32H 34,900 34,900
As the system pressure in case of pump failure will 9L28/32H 36,180 36,180
depend on the height of the expansion tank above
the engine, the alarm set point has to be adjusted to
0.4 bar plus the static pressure.

08028-0D/H5250/94.08.12

03.50 - ES1
Description
Data for Pressure and Tolerance 600.35
Page 1 (1) Edition 13H

L+V28/32H

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

608 Valve clearance, Inlet valve (cold engine 15 - 55C) 0.40 mm.
Valve clearance, Exhaust valve (cold engine 15 - 55C) 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 between main bearing cap and frame,


before tightening of bracing screw (side screw) 0.06 0.01 mm.
Deflection of crankchaft (Autolog) (see working card 610-01.00)
Clearance between crankshaft and sealing ring, (upper and lower part) 0.30 - 0.40 mm.

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

614 Maximum combustion pressure at full load 130 3 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 1.0 mm
Opening pressure of fuel valve 320 bar
Pressure testing, cooling oil sealing, on fuel valve 100 bar

03.36 - ES0
Your Notes :

08031-0D/H5250/94.09.07
Description 600.40
Page 1 (2) Data for Tightening Torque Edition 15S

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 50 (Unimol gl 82)
Gear wheel on camshaft Screw M 12 50
Intermediate wheel shaft Nut M 22 x 1.5 250
Intermediate wheel assembling Nut M 12 40
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 mounting (fitted bolt)
- L28/32H Nut M 30 480
- V28/32H Nut M 30 360
Gear rim on flywheel Screw M 16 75

611 Frame / baseframe Nut M 27 500


08028-0D/H5250/94.08.12

(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

03.36 - ES0
600.40 Description
Edition 15S
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 fresh-


water cooling pump - L28/32H Nut M 24 x 1.5 250
Impeller and gear wheel on fresh-
water 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

08028-0D/H5250/94.08.12

03.36 - ES0
Description
Declaration of Weight 600.45
Page 1 (1)
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
08028-0D/H5250/94.08.12

Centrifugal Filter 61515 33 24

616 Thermostatic Valve 61604 11 29


Cooling Water Pump 61610 19 30

00.32 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Ordering of Spare Parts 600.50
Page 1 (2)
Edition 01H

General

Whenever spare parts are ordered (or reference is This data is used by us to ensure supply of the
made in correspondance etc.) the following data correct spare parts for the individual engines, even
must be indicated for the particular engine: though the spare part illustrations contained in this
book may not always be in complete accordance
1. Name of plant with the individual components of a specific engine.
2. Engine type and engine No. ----, built by
3. Illustration plate number (complete with ed. Note: For ordering of spare parts for Governor,
figures). Turbocharger and Alternator, please see special
4. Item No. instruction book for these components.
5. Quantity required (and description)

Information found on page 600.15 or on the nameplate on the engine(s):

Example: Name of plant Eng. type Eng. No. Built by


DANYARD 6L28/32H 20433 MAN B&W Holeby

Information found on each plate:

Plate No. Edition Item No. Qty. (and description)


60601 13H 10 10 pcs (Piston ring)

Pla
Page te
1 (2)

Piston
and Conn
ecting
Rod
60601-
13H
L/V28/
08
32H
09
10
11
12

01
02
03

04
05
607
608
609

06
610
08028-0D/H5250/94.08.12

611

13
612

07
3
61
4

91.4
61

6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62

91.46 - ES2S
Description
Ordering of Spare Parts 600.50
Page 2 (2) Edition 01H

General

Name of Plant:

Engine type: Engine Number: Built by:

Plate No. Ed. No. Item No. Description Qty.


08028-0D/H5250/94.08.12

91.46 - ES2S
Description Service Letters 600.55
Page 1 (1) Edition 01H

General

Description great importance to the operation of the plant, we


recommend that engine staff file them to supplement
In order to ensure the most efficient, economic, and the relevant chapters of this instruction book.
up-to-date operation of our engines, we regularly send
out "Service Letters", containing first-hand information
regarding accumulated service experience.

The service letters can either deal with specific


engine types, or contain general instructions and
recommendations for all engine types, and are used
as a reference when we prepare up-dated instruction
book editions.

Therefore, since New Service Letters could be of


08028-0D/H5250/94.08.12

91.14 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Description 600.60
Page 1 (3) Conversion Table Edition 01H

General
SI Base Units Length (m)

Quantity Name Symbol 1 in (inch) 25.40 mm = 0.0254 m

1 ft (foot) = 12 inches 0.3048 m

lenght metre m 1 yd (yard) = 3 ft = 36 inches 0.9144 m

mass kilogram kg 1 statute mile = 1760 yds 1609 m

time second s 1 n mile (international nautical mile) 1852 m

electric current ampere A

absolute temperature* kelvin K

amount of substance mole mol SI Prefixes


luminous intensity candela cd
Factor Prefix Symbol Factor Prefix Symbol
* Also named "Thermodynamic temperature"

1018 exa E 10-1 deci d


15
10 peta P 10-2 centi c
Supplementary SI Units
1012 tera T 10-3 milli m
Quantity Name Symbol 9
10 giga G 10 -6
micro m

106 mega M 10-9 nano n


plane angle radian rad 3
10 kilo k 10-12 pico p
solid angle steradian sr 102 hecto h 10-15 femto f

10 deca da 10-18 atto a

Derived Si Units with Special Names


Quantity Name Symbol Expressed in base, Area (m2)
supplementary or
derived SI units 1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2


frequency hertz Hz 1 Hz = 1 s-1

force newton N 1N = 1 kg m/s2

pressure, stress pascal Pa 1 Pa = 1 N/m2* Volume (1 m3 = 1000 l)


energy, work quantity of heat joule J 1J = 1 Nm
1 cub. in (cubic inch) 16.39 x 10-6 m3
power watt W 1W = 1 J/s
1 cub. ft (cubic foot) 28.32 x 10-3 m3 = 28.32 l
electric potential volt V 1V = 1 W/A
1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l
temperature Celcius C 1C = 1 k**
1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l
* For mechanical stresses N/mm2 is widely used. 1 N/mm2 = 106 N/m2
1 barrel (US petroleum barrel) =
** t (C) = T(K) - T0(K), where T0 = 273.15 K
42 gallon (US) 0.1590 m3

1 bbl (dry barrel, US) 0.1156 m3

Additional SU Units 1 register ton = 100 cub. ft 2.832 m3

* 1 gallon = 4 quarts = 8 pints


Quantity Name Symbol Definition

time minute min 1 min = 60 s Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
08028-0D/H5250/94.08.12

time hour h 1h = 60 min


1 kn (knot) = 1 nautical mile/h 1.852 km/h = 05144 m/s
plane angle degree 1 = (p/180) rad
For other conversions, see table for length
volume litre l 1l = 1 dm3

pressure bar bar 1 bar = 105 Pa

92.16 - ES0U
600.60 Conversion Table Description
Edition 01H Page 2 (3)

General

Mass (kg) Dynamic viscosity (N s/m2)

1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)

1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg 1 poundal s/sq.ft 1.488 N s/m2

1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg 1 lbf/sq.ft 47.88 N s/m2

1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg poise is a special name taken from the CGS system. 1 P = 0.1 Pa s

1 slug* 14.59 kg 1 cP = 1 mPa s = 10-3 Pa s

* Unit and mass in the ft-lb-s system

Kinematic viscosity (m2/s)


Density
1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *

1 lb/cub. ft 16.02 kg/m3 * 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name taken from the

CGS system. 1 St = 10-4 m2/s

Force (1 kg m/s2 = 1 N)
Energy, Work (1 Nm = 1 J, Wh)
1 kp (kilopound)* 9.807 N

1 poundal** 138.3 x 10-3 N 1 cal I.T* 4.187 J*


1 lbf (pound force) 4.448 N 1 kpm 9.807 J
* Can occasionally be found stated as kgf (kilogram force). 1 hph (metric) 2.648 x 106 J = 0.7355 kWh
Standard acceleration of free fall gn = 9.80665 m/s2 1 ft. lbf 1.356 J
** Unit of force in the ft-lb-s system 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh

1 BTU (UK, US) 1.055 x 103J = 1.055 KJ

* Exact value: 4.1868 J


Pressure I.T. = International Steam Table
(1 N/M2 = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10-3 bar)

1 kp/cm2 = 1 at = 0.9678 atm 98.07 x 10 3 Pa = 0.9807 bar

1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K) Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W)


750 mm Hg* 105 Pa = 1 bar
1 kpm/s 9.807 W
1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar
1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW
1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 x 10-3 mbar
1 kcalI.T./h 1.163 W
1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar
1 ft lbf/s 1.356 W
1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 atm (standard atmosphere) = 760 mm Hg, 1.013 x 105 Pa = 1013 mbar
1 BTU/h 0.2931 W
1 atm = 1.033 at

1 lbf/sq.in (psi) 6895 Pa = 68.95 mbar

* Mercury. 1 mm Hg = 1 Torr
Moment of Force, Torque (kg m2/s2 = Nm)
Values in Table provided gn = 9.80665 m/s2

** Water column (WC) Can easily be derived from the above tables.
08028-0D/H5250/94.08.12

Stress ( 1 N/m2 = 10 -6
N/mm2) Moment of Inertia (kg m2)

1 kp/mm2 = 100 kp/cm2 9.807 N/mm2 1 GD2 (old notation) = 4 x I* kg m2

1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2 1 WR2 (old notation)* = 1 x I* kg m2

*I = dmr x r2 mr = mass at the radius r


G = W = mass in kg D = Diameter of gyration
R = Radius of gyration

92.16 - ES0S
Description 600.60
Page 3 (3) Conversion Table Edition 01H

General

Specific fuel consumption* (g/kWh) Some physical data in SI units


1 g/hph (metric) 1.360 g/kWh
Nomenciature
* See also table for specific fuel oil consumption values t = temp. in C DK = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)

Temperature difference (K) t r Cp t Cp


range
1 C (Celsius) 1K
1 F (Fahrenheit) 5/9 K Water 18 999 4.18 x 103
Lubricating oil (approx.)* 15 900 1.96 x 103
Atmosphereric air (dry) (p= 1 bar) 0 1.276 998 0-150 1005
Exhaust gas 200-400 1080
Temperature levels (K) (see "Derived SI Units with special
Names) * Viscosity: 100-140 cSt at 40C
750 mm Hg = 1 bar = 105 Pa
t C (Celsius) tc + 273.15 = K 1 atm (standard pressure at sealevel) = 760 mm Hg = 1013 mbar
tF (Fahrenheit) 5/9(tf - 32) + 273.15 = K Gas constant for air and exhaust gas = 287 J/(kg x K)
Celsius from Fahrenheit: tc = 5/9(tf - 32) Water, heat of evaporation 100C 1.013 bar 2.256 x 106 J/kg
Fahrenheit from Celcius: tf = 9/5 x tc + 32 Fuel oil. Lower caloric value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)

Specific heat capacity (J/(kg K))


1 kcalI.T./(kg x C) 4.187 x 103 J/(kg K)
1 BTU*/(lb x F) = 1 kcalI.T. /(kg C) 4.187 x 103 J/(kg K) Specific fuel oil consumption (SFOC)
* British Thermal Unit (see table for energy conversions)

Reference conditions
Specific fuel oil consumption values refer to brake power, and the following
Heat conductance (W/(m K)) reference conditions:

1 calI.T./(cm x s x C) 418.7 W/(m K) Reference Conditions (ISO)


1 kcalI.T./(m x h x C) 1.163 W/(m K)
1 BTU*/(ft x h x F) 1.731 W/(m K) Blower inlet temperature 25C 298 K
* British Thermal Unit (see table for energy conversions) Blower inlet pressure 1000 mbar
Charge air coolant temperature 25C 298 K
Fuel oil lower calorific value (10200 kcal/kg) 42707 kJ/kgk

Heat transmittion (W/(m2 K))


1 calI.T./(cm x s x C) 41.87 x 103 W/(m2 K)
1 kcalI.T./(m" x h x C) 1.163 W/(m2 K)
1 BTU*/(ft2 x h x F 5.678 W/(m2 K)
08028-0D/H5250/94.08.12

92.16 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Basic Symbols for Piping 600.65
Page 1 (3) Edition 01H

General

No. Symbol Symbol designation No. Symbol Symbol designation

1. GENERAL CONVENTIONAL SYMBOLS 2.14 Spectacle flange

1.1 Pipe 2.15 Orifice

1.2 Pipe with indication of direction of flow 2.16 Orifice

1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint

1.4 Appliances 2.18. Snap-coupling

1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere

1.6 High pressured pipe 3. VALVES, GATE VALVES, COCKS AND FLAPS

1.7 Tracing 3.1 Valve, straight through

Enclosure for several components as-


1.8 sembled in one unit 3.2 Valve, angle

2. PIPES AND PIPE JOINT 3.3 Valve, three-way

2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight

2.2 Crossing pipe, connected 3.5 Non-return valve (flap), angle

2.3 Tee pipe 3.6 Non-return valve (flap), straight screw

2.4 Flexible pipe 3.7 down

2.5 Expansion pipe (corrugated) general 3.8 Non-return valve (flap), angle, screw

2.6 Joint, screwed 3.9 down

2.7 Joint, flanged 3.10 Safety valve

2.8 Joint, sleeve 3.11 Angle safety valve


08028-0D/H5250/94.08.12

2.9 Joint, quick-releasing 3.12 Self-closing valve

2.10 Expansion joint with gland 3.13 Quick-opening valve

2.11 Expansion pipe 3.14 Quick-closing valve

2.12 Cap nut 3.15 Regulating valve

2.13 Blank flange 3.16 Ball valve (-cock)

92.47 - ES0S
600.65 Basic Symbols for Piping Description
Edition 01H Page 2 (3)

General

No. Symbol Symbol designation No. Symbol Symbol designation

4. CONTROL AND REGULATION PARTS


3.17 Butterfly valve

4.1 Han-operated
3.18 Gate valve

4.2 Remote control


3.19 Double-seated changeover valve

4.3 Spring
3.20 Suction valve chest

4.4 Mass
3.21 Suction valve chest with non-return

4.5 Float
3.22 valves

4.6 Piston
3.23 Double-seated changeover valve, straight

4.7 Membrane
3.24 Double-seated changeover valve, angle

4.8 Electric motor


3.25 Cock, straight through

4.9 Electro-magnetic
3.26 Cock, angle

4.10 Manual (at pneumatic valves)


3.27 Cock, three-way, L-port in plug

4.11 Push button


3.28 Cock, three-way T-port in plug

4.12 Spring
3.29 Cock, four-way, straight through in plug

4.13 Solenoid
3.30 Cock with bottom connect.

4.14 Solenoid and pilot directional valve


3.31 Cock, straight through, with bottom conn.

4.15 By plunger or tracer


3.32 Cock, angle, with bottom connection

5. APPLIANCES
3.33 Cock, three-way with bottom connection

5.1 Mudbox
3.34 Thermostatic valve
08028-0D/H5250/94.08.12

5.2 Filter or strainer


3.35 Valve with test flange

5.3 Magnetic filter


3.36 3-way valve with remote control

5.4 Separator
3.37 (actuator)

5.5 Steam trap


3.38 Non-return valve (air)
On/off valve controlled by solenoid and
5.6 Centrifugal pump
pilot directional
3/2 spring returnvalve andnormally
valve, with spring
closed
3.39
return

2/2 spring return valve, normally closed


92.47 - ES0S
3/2 spring return valve contr. by solenoid
Description
Basic Symbols for Piping 600.65
Page 3 (3) Edition 01H

General

No. Symbol Symbol designation No. Symbol Symbol designation

5.7 Gear or screw pump 6. FITTINGS

5.8 Hand pump (bucket) 6.1 Funnel / waste tray

5.9 Ejector 6.2 Drain

5.10 Various accessories (text to be added) 6.3 Waste tray

5.11 Piston pump 6.4 Waste tray with plug

5.12 Heat exchanger 6.5 Turbocharger

5.13 Electric preheater 6.6 Fuel oil pump

5.14 Air filter 6.7 Bearing

5.15 Air filter with manual control 6.8 Water Jacket

5.16 Air filter with automatic drain 6.9 Overspeed device

5.17 Water trap with manual control 7. READING INSTR. WITH ORDINARY DESIGNATIONS

5.18 Air lubricator 7.1 Sight flow indicator

5.19 Silencer 7.2 Observation glass

Fixed capacity penumatic motor with on


5.20 7.3 Level indicator
direction of flow

5.21 Single acting cylinder with spring returned 7.4 Distance level indicator

5.22 Double acting cylinder with spring 7.5 Recorder

5.23 returned

Steam trap
08028-0D/H5250/94.08.12

92.47 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Index
Page 1(1) Operation of Engine 601

L28/32H
Description

Operating ------------------------------------------------------------------------------------------ 601. 01 (21H)


Out of service -------------------------------------------------------------------------------------601. 05 (17H)
Starting-up after out of service periods ---------------------------------------------------- 601. 10 (17H)
Guidelines for longterm low-load operation on HFO ------------------------------------601. 15 (02H)

Working Card

Plates

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Operating 601.01
Page 1 (3)
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 made. Starting on HFO: circulate preheated fuel through
the pumps until correct working temperatures has
1. Check the oil level in the base frame (or in the been obtained. Takes normally 30-60 minutes.
lub. oil tank if the engine is with dry sump), air
lubricator and in the govenor. 5. Check the pressure in the starting air
receiver(s) and open the starting air supply (blow-off
Start-up the prelubricating pump. water, if any, drain the starting air system before
opening.
The engine shall be prelubricated at least 2 minutes
prior to start. 6. Check that the sealing oil system for the injec-
tion pumps are working correct.
Check oil pressures before and after the filter.
7. Check in the regulating gear:
2. Open the cooling water supply, start separate
cooling water pumps where installed, and check the - That all fuel pumps are at index "0" when the
cooling water pressure. regulating shaft is in the STOP position.

Note: To avoid shock effects owing to large tempe- - That each fuel pump can be pressed by hand
rature fluctuations just after the start, it is recom- to full index when the regulating shaft is in the STOP
mended: position, and that the pumps return automatically to
the "0" index when the hand is removed.
a) to preheat the engine, cooling water of at least
60 C should be circulated through the frame and - That the spring-loaded pull rod is working
cylinder head for at least 2 hours before start. correctly.

- either by means of cooling water from engines - That the stop cylinder for regulating shaft
which are running or by means of a built-in preheater works properly, both when stopping normally and at
(if installed). overspeed and shut down.

or - Testing is made by simulating these situations.

b) When starting without preheated cooling wa- 8. Open the indicator valves and turn the engine
ter, the engine must only be started on MDO (Ma- some few revolutions, check that no liquid is flowing
rine Diesel Oil). out from any of the indicator valves during the
turning.
The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should Slow-turning must always be carried out, before the
take place gradually over 5 to 10 minutes. engine is started after prolonged out of-service pe-
riods and after overhauls, which may involve a risk of
Note: When starting on HFO (Heavy Fuel Oil), only liquid having collected in the cylinders.
item "a" should be used.
9. Close the indicator valves.
3. Open the nozzle cooling oil supply (only when
started on HFO), circulate preheated oil through the 10. Disengage the turning gear, if fitted. Check
nozzles for at least 15 minutes. that it is locked in the "OUT" position.

96.30 - ES0U
601.01 Description
Edition 21H
Operating Page 2 (3)

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 buttom. the test sheet from shop and sea trials.

2. Check the lubricating oil pressure, cooling 7. Keep the charging air pressure and tempera-
water pressure, fuel oil feed pressure. Check that the ture under control. For normal values, see the test
prelubricating oil pump is stopped. sheet from shop and sea trials.

3. Check that all alarms are connected. 8. Recharge the starting air recivers when the
pressure has dropped to about 20 bar. Stop rechar-
See also "checks after starting-up". ging at 30 bar.

9. To ensure the greatest possible operational


Tending during running liability, condition of the engine should be contin-
uously observed in order that preventive mainte-
When the engine is running, the planned mainte- nance work can be carried out before serious break-
nance program and the following should be checked: downs occour.

1. The lubricating oil pressure must be within the


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

3. The fuel oil pressure must be kept at the stated


value, and the filter must be cleaned before the Start and Stop on HFO
pressure drop across the filter reaches the stated
maximum value. Start and stop of the engine should take place on
HFO in order to prevent any incompatibility problems
4. The cylinder cooling water temperature must by change-over to MDO.
be kept within the limits indicated and the tempera-
ture rise across the engine should not exceed 10C. MDO should only be used in connection with main-
tenance work on the engine or longer periods of
5. The cooling water temperature at the charging engine standstill.
air cooler inlet should be kept as low as possible;
however, not as low as to produce condensation Before starting on HFO the engine must be properly
water in the charging air space. preheated. as described in "Preparations for star-
ting" and as below.
Adjustment takes place in the external system outside
the engine, and the amount of cooling water must be Stopping the engine on HFO is no problem, but it
so adjusted that the temperature rise across the should be ensured that the temperature of fuel pipes
charging air cooler is 3 - 5 C. not are reduced to a level below the pour point of the
fuel, otherwise reestabilishing of the circulation might
cause problems.

96.30 - ES0U
Description
Operating 601.01
Page 3 (3) 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 difficult if the engine and


ambient temperature are lower than 5 C, and 15 C
cooling water temperature.

96.30 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Out-of Service 601.05
Page 1 (2) Edition 17H

General

1. Stand-by Engines 4.3. Open up all filters to check that filter elements
are intact. Filter cartridges in the lub. oil filter is to be
During engine standstill in stand-by position, the replaced before start after repair or due to excessive
media cooling water, fuel oil and nozzle oil should be differential pressure. After eremoval, dirty elements
continuously circulated at temperatures similar to the can be examined for particles of bearing metal at the
operation conditions. bottom of the paper lamellae.
(The elements can not be used again).
The engine shall be prelubricated 2 minutes prior to
start, if there is not intermittent or continuous prelub- 4.4. Check the cylinder walls.
ricating installed. intermittent prelub. is 2 min every 10
minutes. 4.5. Take deflection measurements of the crank-
shaft.

2. Maintenance during Standstil 4.6. A lubricating oil sample should be send to a


laboratory for immediate analysis.
in periods, duringe stand-still of the engine (not in
stand-by position) it is recommended, that the prelub- 4.7. Drain plugs are unscrewed from the bottom of
ricating oil pump is startet minimum 10 minutes once turbochargers, or the drain cock is opened, if there is
every week and that the engine during the prelubricating installed drain fasilities in the exhaust gas system this
period is turnd 2-3 revolutions.. should be opened.

3. Laid-up Vessels 5. Works during Repairs

During the lay-up period (and also when laying-up the The following should be made during the major repairs.
vessel), we recommend that our special instructions
for preservation of the engines, are followed. 5.1. Retighten all bolts and nuts in the crankcase
and check their locking devices. Also retighten
foundation bolts.
4. Works before Major Repairs
5.2. Check the various gear wheel drives for the
4.1 After stopping the engine, while the oil is still camshaft(s).
warm, start the electrically driven prelubrication pump,
open up the crancase and camshaft housing and 5.3. Remedy leakages of water and oil in the engine,
check that the oil is flowing freely from all bearings. and blow through blocked-up drain pipes.
Also take off the top covers on the cylinder heads and
make sure that oil is not supplied for lubrication of 5.4. Drain starting air pipes of water.
rocker arms, as non-return valves are fitted which do
not open until the oil pressure at the inlet to the rocker 5.5. Empty the oil sump of lubricating oil and remove
arms exceeds 1 bar. the sludge, if not done within a period of one year. Very
thoroughly clean the sump and subsequently coat
08028-0D/H5250/94.08.12

After overhaul of pistons, bearings, etc. this check with clean lubricating oil.
should be repeated before starting the engine.

4.2. After stopping the prelubricating pump, check 6. Works after Repairs
the bottom of the oil sump for fragments of babbitt
from bearings, and check crankpin and main bearings 6.1. If an opening-up of engine or lubricating oil
clearances with a feeler gauge. Measure the bearing system may have caused ingress of impurities,
clerance at the top, at the bottom, and 10 degrees cleaning should be carried out very carefully before
above and below the joints at both sides. starting the engine.

The differential pressure across the lub. oil filter must

92.02 - ES0U
601.05 Description
Edition 17H
Out-of Service Page 2 (2)

General

be watched very carefully after cleaning and starting- reaching normal oil temperatures in governor and
up the engine. Be sure to replace filter cartridges in engine, increase the load instantaneously to about
due time. 80% ( by starting major pump or compressor). This
must not cause the frequency to fall by more than
6.2. After restoring normal lubricating oil circulation, some 8%, and the engine must return to a constant
turn the engine at least two revolutions by means of r.p.m. about 3 seconds (although this r.p.m. will be a
the turning rod to check the movability of the relevant little lower than before owing to the speed drop of
parts of the engine. the governor). If the engine is operated in parallel with
other engines, an even sharing of load shall be
6.3. Close drain cocks in the turbocharger (or in the established within about 3 seconds. If the governor
exhaust gas system if mounted). reacts too slowly, compensating adjustment is ef-
fected as indicated in Woodward's instruction manual
6.4. Lubricate bearings and rod connections in the (Compensating adjustment).
manoeuvring gear. Disconnect the governor and move
the rod connections by hand to check that the friction Note: It is a condition for this test that the engine and
in bearings and fuel pumps is sufficiently low. If repair turbocharger are in perfect operating condition, so
of bearings or alignment of engine has been made, that they can be elimated as possible sources of error.
checks 1, 2, and 5 should be repated.
6.7 c) Hunting: Run the engine at synchronous
6.5. Cheks to be made just before starting of the r.p.m., and without load. Provided the governor oil is
engine are mentioned under 601.01. warm, the regulating lever must not perform any major
periodical movments, and neither must there be any
6.6. Add cooling water and check with pressure on variation up and down in the engine speed. If that is
the system for leakage at the upper and lower cy- the case, repeat the compensating adjustment
linder liner sealings and at cooling water connections. according to Woodward's instruction manual.

6.7. Check the governor as follows: 6.7 d) Speed Drop: in case of unsatisfactory load
Start up the engine and run it at the synchronous sharing between two ore more engines this can be
number of revolutions. rectified by increasing the speed drop of the engine
that is subject to the greatest load (or by reducing the
6.7 a) Speed setting: Check before switching-in setting of the other engines).
generator on the switchboard that the servomotor
adjusts the r.p.m. with a suitable quickness after The setting shoul not normally be increased beyond
actuation of the synchronizer knob on the switch- 70 on the scale, and satisfactory parallel operation
board. The range from - 5% to + 5% from the syn- can generally be obtained at settings between 40 and
chronous r.p.m. should be tested. 60.

6.7 b) Adjustment speed: Switch-in generator on


the switchboard and set the load to about 40%. On
08028-0D/H5250/94.08.12

92.02 - ES0U
Description
Starting-up after Out of Service Periods 601.10
Page 1 (1)
Edition 17H

L+V28/32H

The following enumerates checks are to be made After the last feel-over, repeat check 4 page 601.05,
immediately after starting, during load increase, and see also Ignition in Crankcase page 603.04 in
during normal running. The sequence has been section 603.
accordingly.
After repair or renewal of cylinder liners, piston rings
In the following it is assumed that the engine has or bearings, allowance must be made for a running-
been out of service for some time, for instance due in period, i.e. the engine load should be increased
to repairs and gradually as indicated in the tables below. The
engine output is determined on the basis of the fuel
- checks during out of service periods have index and the load on the electric switchboard. The
been carried out as described in the previous chap- turbocharger speed gives some indication of the
ter. engine output, but is not directly proportional to the
output throughout the service period.
When starting after such an out-of-service period,
the following checks must be made in the stated Begin the starting-up sequence at a reduced engine
order in addition to normal surveillance and recor- speed, e.g. 400 rpm, until it can be known for certain
ding. that there areno hot spots in the engine. Then
increase the speed to the normal rpm and connect to
the switchboard and put on load.
1. To be made immediately after starting:
The load increase during the starting-up sequence
1.1. See that the turbocharger is running. may, for instance, be:

1.2. See that the lubricating oil pressure is in order. 25 % load for 2 hours
50 % load for 2 hours
1.3. See that all cylinders are firing (see exhaust 75 % load for 2 hours
temperatures). 100 % load may be put on.

1.4. See that everyting is normal for the engine The pump index indicated in the tables has been
speed, fuel oil, cooling water and system oil. given as a percentage of the index at full load. To
enable the index to be read directly off the fuel pumps
1.5. Check by simulation of the overspeed shut- the following formula can be employed:
down device that the engine stops. The overspeed
setting should be according to " Set Points and I = I% x IF
Operation Data " section 600. 100

IF = Index at full load (from testbed table)


2. To be made during the starting-up, but
only if required after repairs or alterations made: I% = Index expressed as % of full load index
(stated in the preceding starting-up
2.1. If the condition of the machinery is not well- sequence).
08028-0D/H5250/94.08.12

known, especially after repairs or alterations, the


"feel-over sequence" should always be followed. Following the alteration of the pump index of the one
that is: or two cylinders concerned it must be checked that
when in the STOP position the governor is able to
After 5-15 and 30 minutes' idle running, open the move all the fuel pumps to an average pump index
crankcase and the camshaft housing and feel-over not exceeding 2 or 3, thus excluding the possibility of
on the surfaces of all moving parts where friction may racing of the engine when the propeller is declutched.
arise and cause undue heating.
After completing the starting-up sequence, make
Feel: Main bearings, big-end bearings, (alternator), sure that all fuel pumps are set at the same index and
and camshaft bearings, piston pins, cylinder liners, that the governor can cause all fuel pumps to move
roller guides and gear wheels. to "0" index.

96.30 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Guidelines for Longterm Low-Load Operation on HFO 601.15
Page 1 (1) Edition 02H

General

Part load/low load operation HFO-operation at loads lower than 20% MCR should
therefore only take place within certain time limita-
In certain ship operation situations the diesel-gen- tions according to the curves.
erator sets are sometimes exposed to part load/low
load operation. After a certain period of HFO-operation at a load
lower than 20% MCR, a change to MDO should take
During manoeuvring all diesel-generator sets are place in order to prevent further retardation of the
often started up for safety reasons, resulting in low engine performance condition, or the engine load
load conditions for all sets. should over a period of 15 minutes be raised to 70%
MCR and maintained here for a certain period of time
During harbour stay even one diesel-generator run- in order to burn off the carbon deposits, thus reestab-
ning could be lowloaded when hotel purposes are lishing adequate performance condition. After such
the only electricity consumers. "cleanburning period" low-load operation on HFO
can be continued.
At part load/low load it is important to maintain
constant media temperatures, i.e. for cooling water, However the operator must be aware of the fact that
lubricating oil and fuel oil, in order to ensure ad- fouwling in the air inlet channels, if any, will not be
equate combustion chamber temperature and thus cleaned with high load running. Extensive low-load
complete combustion. running can therefore result in necessity off manual
cleaning of the inlet channels.
At loads lower than 20% MCR there is risk of timede-
pendant retardation of the engine performance con- If special application conditions demand continuous
dition due to fouling of gas- and air channels, com- HFO-operation at loads lower than 20% MCR. and
bustion chambers and the turbocharger. occasionally performed "clean-burning" periods are
inconvenient or impossible, special equipment and
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
08028-0D/H5250/94.08.12

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.

00.11 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Index
Page 1(1) Engine Performance and Condition 602

L28/32H
Description

Engine performance and condition ----------------------------------------------------------602. 01 (09H)


Evaluation of readings regarding combustion condition ------------------------------- 602. 02 (07H)
Condensate amount ---------------------------------------------------------------------------- 602. 05 (08H)

Working Card

Engine performance data ----------------------------------------------------------------------602- 01 .00 (03H)

Plates

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description Engine Performance and Condition 602.01
Page 1 (3) Edition 09H

General
An increase of charge air temperature involves a
Performance Data and Engine Condition corresponding increase of the exhaust gas temperature
level in a ratio of about 1:1.5 i.e. 1C higher charge air
During the operation, small alterations of the engine temperature causes about 1.5C higher exhaust gas
condition continuously take place as a result of the temperature.
combustion, including fouling of the airways and
gasways, formation of deposits, wear, corrosion, etc. Reduction of the charge air pressure results in a
If continuously recorded, these alterations of the corresponding reduction of the compression pressure
condition can give valuable information about the and max. combustion pressure. When checking the
operational and maintenance condition of the engine. max. pressure adjustment of the engine, it is therefore
Continual observations can contribute to forming a to be ensured that the existing charge air pressure is
precise and valuable basis for evaluation lay down the correct.
optimal operation and maintenance programmes for
the individual plant. The injected amount of fuel is equivalent to supplied
energy and is thus an expression of the load and mean
We recommend taking weekly records of the most pressure of the engine. The fuel pump index can
important performance data of the engine plant. At the therefore be assumed to be proportional to the mean
recording (Working Card 602-01.00 can be used), the pressure. Consequently, it can be assumed that the
observations are to be continually compared in order connected values of the pump index are proportional
to ascertain alterations at an early stage and before to the load.
these exert any appreciable influence on the operation
of the plant. The specific fuel consumption, SFOC (measured by
weight) will, on the whole, remain unaltered whether
As a reference condition for the performance data, the the engine is operating on HFO or on marine diesel oil,
testbed measurements of the engine or possibly the when considering the difference in calorimetric
measurements taken during the trial trip at the delivery combustion value. However, when operation on HFO,
of the ship can be used. If considerable deviations the combination of density and calorific value may
from the normal condition are observed, it will, in the result in an alteration of up to 6% in the volumetric
great majority of cases, be possible to diagnose the consumption at a given load. This will result in a
cause of such deviations by means of a total evaluation corresponding alteration in the fuel pump index, and
and a set of measurements, after which possible regard should be paid to this when adjusting the
adjustment/overhauls can be decided and planned. overload preventative device of the engine.

Abrasive particles in the fuel oil result in wear of fuel


Evaluation of Performance Data pumps and fuel valve nozzles. Effective treatment of
the fuel oil in the purifier can limit the content of
For example, fouling of the air side of the air cooler will abrasive particles to a minimum. Worn fuel pumps will
manifest itself in an increasing pressure drop, lower result in an increase of the index on account of an
charge air pressure and an increased exhaust increased loss in the pumps due to leakage.
temperature level (with consequential influence on
the overhaul intervals for the exhaust valves). When evaluating operational results, a distinction is
08028-0D/H5250/94.08.12

to be made between alterations which affect the whole


Fouling of the turbine side of the turbocharger will, in engine (all cylinder units) and alterations which occur
its first phase, manifest itself in increasing turbocharger in only one or a few cylinders. Deviations occuring for
revolutions on account of increased gas velocity a few cylinders are, as a rule, caused by malfunctioning
through the narrowed nozzle ring area. In the long run, of individual components, for example, a fuel valve
the charging air quantity will decrease on account of with a too low opening pressure, blocked nozzle
the greater flow resistance through the nozzle ring, holes, wear, or other defects, an inlet or exhaust valve
resulting in higher wall temperatures in the combustion with wrongly adjusted clearance, burned valve seat
chambers. etc.

The operational observations supplemented by the daily

92.02 - ES0U
602.01 Engine Performance and Condition Description
Edition 09H Page 2 (3)

General
routine monitoring contribute to ensuring that faulty fuel nozzle temperature decreases, it may be
adjustments and other deviations in the performance advantageous at continuous operation to reduce the
of individual components are observed in time to fuel nozzle cooling to avoid corrosion.
avoid operational disturbances and so that normal
routine overhauls can be carried out as scheduled. Abrasive particles in the fuel oil involve a heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
If abnormal or incomprehensible deviations in the Therefore, abrasive particles are, to the greatest
operation are recorded, expert assistance for the possible extent, to be removed at the purification.
evaluation of these should be obtained.

Exhaust Valves
Turbochargers
The overhaul intervals of exhaust valves is one of the
Service experience has shown that the turbine side is key parameters when reliability of the entire engine is
exposed to increased fouling when operating on HFO. to be judged. Operation on HFO has a negative effect
on these intervals. The performance of the exhaust
The rate of fouling and thereby the influence on the valves is therefore extremely informative.
operation of the engine is greatest for small
turbochargers where the flow openings between the Especially under favourable conditions, fuel qualities
guide vanes of the nozzle ring are relatively small. with a high vanadium and sodium content will promote
Deposits especially occur on the guide vanes of the burning of the valve seats. Combinations of vanadium
nozzle ring and on the rotor blades. In the long run, and sodium oxides with a corrosive effect will be
fouling will reduce the efficiency of the turbocharger formed during the combustion. This adhesive ash
and thereby also the quantity of air supplied for the may, especially in the case of increased valve
combustion of the engine. A reduced quantity of air temperatures, form deposits on the seats. An
will result in higher wall temperatures in the combustion increasing sodium content will reduce the melting
spaces of the engine. point and thereby the adhesive temperature for the
ash, which will involve a greater risk for deposits. This
Detailed information and instructions regarding water condition will be especially unfavourable when the
washing of the turbocharger are given in the section weight ratio Na increases beyond 1:3.
612. Va

The exhaust valve temperature depends on the actual


Fuel Valves maintenance condition and the load of the engine.
With correct maintenance, the valve temperature is
Assuming that the fuel oil is effectively purified and kept at a satisfactory low level at all loads. The air
that the engine is well maintained, the operational supply to the engine (turbocharger/air cooler) and the
conditions for the fuel valves and the overhaul intervals maximum pressure adjustment are key parameters in
will not normally be essentially altered when operating this connection.
on HFO.
It is important for the functioning of the valves that the
08028-0D/H5250/94.08.12

If, for any reason, the surface temperature of the fuel valve seats are overhauled correctly in accordance
valve nozzle is lower than the condensation with our instructions.
temperature of sulphuric acid, sulphuric acid
condensate can form and corrosion take place (cold The use of rotocaps ensures a uniform distribution of
corrosion). The formation of sulphuric acid further temperature on the valves.
depends on the sulphur content in the fuel oil.

Normally, the fuel nozzle temperature will be Air Inlet Valves


higher than the approx. 180C, at which cold
corrosion starts to occur. At low load where the The operational conditions of the air inlet valves are not
substantially altered when using residual fuel.

92.02 - ES0U
Description Engine Performance and Condition 602.01
Page 3 (3) Edition 09H

General
might involve corrosive attack and influence the
Fuel Pumps overhaul intervals for the exhaust valves.

Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room is
operation of the fuel pumps will not be very much to correspond to approximately 1.5 times the air
affected. consumption of the engines and possible boilers in
operation. Sub-pressure in the engine room will involve
The occurrence of increasing abrasive wear of plunger an increased exhaust temperature level.
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if using a fuel The exhaust back-pressure measured after the
which contains residues from catalytic cracking. turbochargers at full load should not exceed 250-300
Water in the fuel oil involves an increased risk of mm water gauge. An increase of the exhaust back-
cavitation in connection with pressure impulses pressure will also involve an increased exhaust valve
occurring at the cutting-off of the fuel pump. A fuel temperature level.
with a high asphalt content has deteriorating lubricating
properties and can, in extreme cases, result in sticking
of the fuel pump plungers.

Engine Room Ventilation, Exhaust System

Good ventilation of the engine room and a


suitable location of the fresh air intake on the
deck are important. Seawater in the intake air
08028-0D/H5250/94.08.12

92.02 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description Evaluation of Readings Regarding 602.02
Page 1 (1) Combustion Condition Edition 07H

L+V28/32H

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

PRESSURE DROP
INCREASING
(limit 50%)
Air side of
cooler fouled.
ALL CYLINDERS
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).

TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.

ONE CYLINDER DECREASING CHARGE AIR


Exhaust temp. in- 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).
exhaust valve or piston
08028-0D/H5250/94.08.12

ring blow-by.
Pcomp and Pmax ARE MEASURED by means
of max. pressure gauge.
Pcomp too low: Leaky combustion chamber,
charging air pressure too low.
See also:
Pmax too low:
P comp too low, ignition too late. Engine Performance
and Condition 602.01

00.44 - ES0S-G
Your Notes :

08031-0D/H5250/94.09.07
Description
Condensate Amount 602.05
Page 1 (2) Edition 08H

General

Ambient air temperature (1 bar)

(Above atmospheric)
10 20 30 40 50 60 70
0.10
of air in kg water / kg air

r
ba
1.0

r
0.08

ba
0
2.

air pressure
0.06

r
ba
Max. water content

Charge
0
of atmosphere

3.
Water content

I %
%
0%

%
%

60
70
80
90
10

0.04

A B

in air tank
Pressure
0.02

II

30 bar
III

Relative 0
air humidity 30 40 50 60 70

Charge air temperature after cooler.


Air temperature in tank.

Fig. 1. Nomogram for calculation of condensate amount.

General Condensation of water in the engine's charge air


receiver is consequently dependent on the humidity
There is always a certain amount of water in air. When and the temperature of the ambient air. To find out if
the air is saturated with aqueous vapour, the humidity condensation in the charge air receiver will occur the
is said to be 100% and there is as much water in the diagram can be used.
air as it can absorb without condensing. The amount
of water in kg/kg air can be found from the diagram. Example:
08028-0D/H5250/94.08.12

The ability to absorb the water depends on the


pressure and temperature of the air. 6L28/32H, 720 rpm (P) 1260 kW
Ambient air condition:
air temperature 35 C
Amount of Condensation Water in The Charge Air relative air humidity 90 %
Receiver Charge air temperature 50 C
Charge air pressure 2.6 bar
Both higher pressure and lower temperature reduce
the ability to absorb water. A turbocharged diesel As a guidance, an air consumption of 8.2 kg/kWh (Le)
engine takes air from outside, compresses and cools at full load can be used for MAN B&W Diesel A/S,
the air. Then, normally, the air cannot absorb the Holeby engines.
same amount of water as before.

91.37 - ES1S
602.05 Condensate Amount Description
Edition 08H Page 2 (2)

General
Solution according to diagram:
The volume of condensate in the air tank is determin-
Water content of air (l) 0.033 kg/kg ed by means of the curve at the bottom to the right of
Max. water cont. of air (ll) 0.021 kg/kg the diagram, representing an operating pressure of 30
bar.
Amount of condensate in charge air recceiver.
Example:
= (l - ll) x le x P
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h Amount of condensate in air tank.

Volumetric capacity of tank(V) 4000 dm


Draining of Condensation Water. Temperature in tank (T) 40 C=313K
Internal press. of tank (p) 30 bar
This phenomenon will occur on all turbocharged = 31 x 105 N/m(abs.)
engines. For MAN B&W Holeby 4-stroke engine, Gas constant for air (R) 287 Nm/kg.K
there is no risk with a small amount of water in the Ambient air temperature 35 C
charge air receiver. But if the charge air receiver is Relative air humidity 90 %
filled with water, there is a risk of getting water into the Weight of air in tank
cylinder. This water have to be drained away. As
standard a valve is mounted on the charge air receiv-
er/cooler on the engine. This valve is to be used for m= = = 138 kg
pxV 31 x 105 x 4
draining of the water. If there is a great amount, the
valve can be left half-open. If the amount is small, the RxT 287 x 313
charge air receiver can be drained periodically. Solution acc. to above diagram:

Water content of air (l) 0.033 kg/kg


Amount of Condensate Water in Air Tanks. Max. water cont. of air (lll) 0.0015 kg/kg

Amount of condensate in air tank

= (I - III) x m.
= (0.033 - 0.0015) x 138 = 4.35 kg.
08028-0D/H5250/94.08.12

91.37 - ES1S
Working Card 602-01.00
Page 1 (4) Engine Performance Data Edition 03H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005-01 10 Max. pressure
Shut-off fuel oil indicator
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Measurements of engine performance data.

Hand tools:

Starting position:

Engine is running.

Related procedure:
08028-0D/H5250/94.08.12

Man power:
Replacement and wearing parts:
Working time : hour
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)

96.37 - ES0U
602-01.00 Engine Performance Data Working Card
Edition 03H Page 2 (4)

L+V28/32H
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 j /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 A


B

18 Maximum Pressure (bar) A


B

19 Compress. Pressure (bar) A


B

20 Exhaust Temp. ( C) A
B

21 Cooling Water (C) A


B

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


08028-0D/H5250/94.08.12

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 ( Sign.
48
C) 49 50

96.37 - ES0U
Working Card
Engine Performance Data 602-01.00
Page 3 (4) Edition 03H

L+V28/32H

The Instruction for Filling in the Diagram 14. Cos j/kVAr - can be read on the switchboard.
"Engine Performance Data".

The numbers in the instruction are commensurate Cylinder Data.


with the numbers on the diagram.
15. Cylinder no. - can be read on engine plate.
The automatic symbols mentioned in the instruction A/B is used for V-engines.
TI 01, TI 03, PI 01 etc, refer to the diagrams printed
in the instruction books for specified plants and page 16. Average for all engine cylinders for point: 17-
600.20. 18-19-20-21.

17. Fuel pump index - can be read on each of the


Engine Performance Data. high pressure fuel oil injection pumps.

1. Name of ship, if stationary name of plant. 18. Max pressure (bar) can be read for each
cylinder by means of indicator or Pmax gauge.
2. Engine type.
19. Compression pressure (bar) - can be read for
3. Engine no. each cylinder by means of the indicator measure-
ment, which is carried out during idling by nominal
4. Date/year of observations. RPM.

5. Hour, time of observations. 20. Exhaust temperature (C)


- Thermometer TI 60.
6. Total engine running hours - engineer's log-
book. 21. Water outlet cylinder (C) (jacket cooling)
- Thermometer TI 11.
7. Engine revolutions per minute (RPM) - can be
read on tachometer SI 90.
Turbocharger.
8. Fuel oil type: The viscosity must be stated (in
cSt) and the temperature by which the viscosity has 22. Thermometer inlet blower (C) can be read
been measured f.inst. 180 cSt/50C. Density must by means of a thermometer placed in the engine
be stated: g/cm. room near the air filter of the TC.

9. Turbocharger: Type and serial number are 23. Pressure before blower (mmWC) - can be
stated on the rating plate of turbocharger and page read by means of a mmWC instrument placed in the
600.00. engine room near the TC.

10. Turbocharger revolutions per minute (RPM) - 24. Temperature after blower (C) - can be read
08028-0D/H5250/94.08.12

can be read on the tachometer SI 89. by means of a thermometer TI 30.

25. D Pressure air cooler (mm/WC).


Switchboard.
26. Charge air temperature (C). Temperature of
11. Effect alternator (kW) - can be read on the the charge air in the charge air receiver.
main switchboard. - Thermometer TI 31.

12. Voltage (V) - can be read on the switchboard. 27. Pressure charge air (bar). Pressure of the
charge air in the charge air receiver.
13. Current (A) - can be read on the switchboard. - Pressure gauge PI 31.

96.37 - ES0U
602-01.00 Engine Performance Data Working Card
Edition 03H Page 4 (4)

L+V28/32H
28. Tempereture of the exhaust gas before TC 40. Temperature of the low temperature (LT) cool-
(C) - Thermometer TI 62. ing water (sea, raw or fresh) at inlet lub. oil cooler (C)
- Thermometer TI 07.
29. Temperature of the exhaust gas after TC (C)
- Thermometer TI 61. 41. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet lub. oil cooler
30. Pressure of the exhaust gas after the TC (bar) C)
- Pressure gauge PI 61. - Thermometer TI 03.

42. Temperature of the low temperature (LT) cool-


Lubricating Oil System. ing water (sea, raw or fresh) at inlet alternator (C)
- Thermometer TI 04.
31. Temperature of the lub. oil inlet cooler (C)
- Thermometer TI 20. 43. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet alternator (C)
32. Pressure of the lub. oil before the filter (bar) - Thermometer TI 05.
- Pressure gauge PI 21.
44. Temperature of the high temperature (HT)
33. Pressure of the lub. oil after the filter (bar) fresh water (FW) at inlet engine (C)
- Pressure gauge PI 22. - Thermometer TI 10.

The filter element should be replaced with a pressure 45. Pressure of the high temperature (HT) fresh
drop across the filter of 1.5 bar (see section 615). water (FW) of outlet engine (C)
- Thermometer TI 10.
34. Temperature of the lub. oil inlet engine (C)
- Thermometer TI 22.
Fuel Oil System.
35. Pressure of the lub. oil before the turbocharger
(bar). 46. Temperature of the fuel oil at inlet engine (C)
- Pressure gauge PI 23. - Thermometer TI 40.

47. Pressure of the fuel oil before engine (bar)


Cooling Water System. - Pressure gauge PI 40.

37. Temperature of low temperature (LT) cooling 48. Nozzle cooling oil pressure at inlet engine
water (sea, raw or fresh) at inlet charge air cooler (bar)
(C) - Pressure gauge PI 50.
- Thermometer TI 01.
49. Nozzle cooling oil pressure at outlet engine
38. Temperature of low temperature (LT) cooling (bar)
08028-0D/H5250/94.08.12

water (sea, raw or fresh) at outlet charge air cooler - Pressure gauge PI 51.
(C)
- Thermometer TI 02. 50. Signature.

39. Pressure of the low temperature (LT) cooling


water (sea, raw or fresh) at inlet charge air cooler
(bar)
- Pressure gauge PI 01.

96.37 - ES0U
Index
Page 1(1) Trouble Tracing 603

L28/32H
Description

Starting failures -----------------------------------------------------------------------------------603. 01 (08H)


Faults in fuel oil system ------------------------------------------------------------------------ 603. 02 (09H)
Disturbances during running ------------------------------------------------------------------603. 03 (08H)
Ignition in crankcase ----------------------------------------------------------------------------603. 04 (09H)

Trouble shooting guide for turbine starter ------------------------------------------------- 603. 06 (09H)


Trouble shooting for cooling water system ------------------------------------------------603. 09 (08H)
Trouble shooting for lubricating oil cooler ------------------------------------------------- 603. 10 (01H)

Working Card

Plates

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Starting Failures 603.01
Page 1 (1)
Edition 08H

General

Trouble Possible cause Trouble shooting

Engine turns as soon as shut-off Faults in electrical system Check electrical parts
valve is opened, without start but-
ton being activated

Engine does not turn when start Air pressure in starting air receiver Start compressors, re-charge air
button is activated too low receiver

Main valve(s) closed Open valve at receiver and stop


valve interposed in line between
receiver and engine

Pinion does not engage the fly Check the air starter for broken
wheel clutch jaws or other broken parts

Air motor runs, pinion engages but Check the air motor for broken
does not rotate shafting, bearing or clutch jaws

Faults in electrical system Check electrical parts

Engine turns too slowly or Worn air motor parts Remove and disassemble the air
irregularly when start but-ton is motor. Examine all parts and re-
depressed place any that are worn or damag-
ed. Use the guidelines for determi-
ning unserviceable parts

Start valve is sticking in close Check start valve


position
08028-0D/H5250/94.08.12

90.46 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Faults in Fuel Oil System 603.02
Page 1 (3) Edition 09H

L+V28/32H

Trouble Possible cause Trouble shooting

Engine turns on starting air, but Sluggish movement of Lubricate and mobilize rod con-
ignition fails. Fuel pumps are not manoeuvring gear nections in manoeuvring gear
actuated
Governor setting incorrect Adjust governor, see special in-
struction manual

Overspeed or another shutdown Cancel shutdown function


function is activated

Piston in Lambda controller is Check that piston is not sticking.


actuated Check that pressure in cylinder
is relieved. Check that the
overspeed trip is not actuated.

Piston in Lambda controller is Check pressures and tempera-


actuated owing to uncancelled tures. Check for faults in shut-
shut-down function (1) down devices

Failures in governor Check that governor is working


properly. For further fault
location, see special instr.
manual

Incorrect adjustment of Check rod connec. Check that


manoeuvring gear fuel pump index is corresponding
to "Adjustments after trials" in
testbed chart

Engine turns on starting air, but Incorrect adjustment of limiter Adjust setting of limiter cylinder
no fuel is injected owing to cylinder
failures in fuel system

Fuel oil service tank empty Pump oil into the tank

Air in fuel pumps and fuel injection Vent the fuel pumps unitl fuel
valves (2) with-out air bubbles appears. If
ignition fails in just one cyl., vent
the re-spective fuel injection
valve. If igni-tion still fails, install a
spare valve before attempting to
start the engi-ne again.
08028-0D/H5250/94.08.12

Worn-out fuel pump Change fuel pumps

Defective fuel injection valves or Change defective fuel valves


valve nozzles (4)

Too low pressure before fuel Increase the fuel oil feed pump
injection pumps (3) pressure

Engine turns on starting air, fuel Water in the fuel Drain off water and repeat
is injected, but ignition fails venting of fuel pumps

Fuel valves or nozzles defective Change defective fuel valves,


(4) see Working Card 614-01.10.

Cont.

02.47 - ES0
603.02 Faults in Fuel Oil System Description
Edition 09H Page 2 (3)

L+V28/32H

Trouble Possible cause Trouble shooting

Compression during start too low Check intake and exhaust valve
(5) for tight closing. Check cyl. wear
and piston rings

Incorrect timing of camshaft (6) Check fuel pump timing advance,


and fuel valve opening pressure
as well as camshat adjustment

First ignitions are too violent Oil has collected on piston crown Slow turning with open indicator
(safety valves are opening). (7) valves, to locate defective fuel
Engine runs erratically val-ve, remove oil

Sluggish movement of manoeuvring Lubricate and mobilize rod


gear connections and bearings in
manoeuvring gear

Fuel pump index to high Check rod connection in


manoeuvring gear. Check that
governor is working properly.
Limiter cylinder to be set lower

Remarks

1) If the shut-down function is due to overspeed, 4) If the fuel is forced into the cylinder through a
the shut-down activation is cancelled by resetting defective fuel valve or through worn-out atomizer
the overspeed device and thus venting the holes, no or too sluggish atomization may
Lambda controller/air cylinder. prevent ignition, possibly followed by too violent
ignition.

2) Whether air is present in the fuel oil system is


seen be repeating the venting of fuel pumps. 5) To obtain ignition temperature in the cylinders,
The cause may be that a fuel valve is kept in the compression pressure during starting should
open position (spindle sticking or spring broken). be normal, see the testbed chart. This can be
Heating of fuel to a too high temperature may checked by measuring the compression
have a similar effect owing to formation of gas pressure during starting. Cylinders having too
in the fuel. If a sticking valve is found, it should low compression should be inspected.
08028-0D/H5250/94.08.12

be changed and overhauled. It should be cheked


that no oil has collected on the piston crown. Air
in the fuel oil system may also be the result of 6) Major alterations of the combustion charac-
the fuel oil feed pump sucking-in air through a teristics of the fuel may demand adjustment of
defective stuffing box or a leaky seal. the timing of the fuel pumps. One or more cam-
shaft sections may be incorrectly fitted (after
dismantling). Too high opening pressure of the
3) If the fuel oil pressure drops, the filter may be fuel valves will also delay the injection.
clogged up, or the by-pass at the feed pump
may have opened.

02.47 - ES0
Description
Faults in Fuel Oil System 603.02
Page 3 (3) Edition 09H

L+V28/32H
7) Oil on the piston crown will in most cases have
leaked down from a defective fuel valve. As
these oil accumulations are dangerous, the lea-
kage should be found and remedied before the
engine is started again.
08028-0D/H5250/94.08.12

02.47 - ES0
Your Notes :

08031-0D/H5250/94.09.07
MAN B&W Diesel

Description
Disturbances during Running 603.03
Page 1 (3) Edition 08H

L+V28/32H

Trouble Possible cause Trouble shooting

Exhaust temperature(s) (All cyls.) Increased charging air See Working Card 612-01.00.
increase(s) temperature due to ineffective air
coolers

(All cyls.) Fouling or air and gas Reduce load and water-wash tur-
passages bine. Clean air filters and coolers

(All cyls.) Insufficient cleaning of See Description 604.25.


fuel oil or changed combustion
characteristics

(All cyls.) Wrong position of cam- Check Pmax. Check camshaft ad-
shaft (Maladjustment) justment

(Single cyls.) Fuel valve or valve See Working Card 614-01.10.


nozzle defective

(Single cyls.) Leaky exhaust Check the valve clearance.


valves (1) Repla-ce cyl. head with defective
valve

(Single cyls.) Blow-by-leaky See Working Card 606-01.00.


com-bustion chamber (2)

(Single cyls.) Damaged fuel Check timing advance of fuel


pump cam pump

Exhaust temperature(s) (All cyls.) Decreased charging air Check that thermostatic valve
decrease(s) temperature (by-pass valve) in cold water
system is working properly and
correctly set

(Single cyls.) Air in fuel pump(s) Venting of fuel pump(s) until fuel
and fuel injection valve(s) without air bubbles appears.
Check feed pump pressure

(Single cyls.) Spindle in fuel valve Change and overhaul defective


sticking (3) fuel valve

(Single cyls.) Fuel pump plunger Change fuel pump plunger/barrel


sticking or leaking assembly
08028-0D/H5250/94.08.12

Engine RPM decreases Pressure before fuel pumps too Raise fuel oil feed pump pressure
low to normal. Check filter

Fuel valve or fuel pump defective Change defective valve or pump

Water in the fuel Drain off water and vent the fuel
pumps

Governor defective (4) Replace defective governor

Increased internal friction in See "Ignition in Crankcase"


engine
(5)
Cont.

05.08 - ES0
MAN B&W Diesel
603.03 Description
Edition 08H
Disturbances during Running Page 2 (3)

L+V28/32H

Trouble Possible cause Trouble shooting

Engine stops Shut-down Check pressure and


temperatures. If OK, check for
faults in shut-down devices. See
also Starting Failures

Smoky exhaust Turbine RPM lagging behind en- Reasonably smoke is normal
gine RPM when RPM increases; no
measures cal-led for. If smoky
exhaust during normal running,
clean turbine(s) and check
valves

Air supply too low Fouling of air and gas passages,


see section 612.

Fuel valves or nozzles defective See Working Card 614-01.10.

"Trumpets" at nozzle holes. Overhaul fuel valves. Re-


Failure of cooling (especially establish nozzle-cooling
during hea-vy-oil operation) (6)

Exhaust valve knocking Adjsuting screw for valve setting Inspect and replace defective
loose. Push rod thrust disc da- parts as necessary
maged

Rising cooling water tempera- Pump stopped. Increased friction Stop the engine. Check the
ture (7) cooling water. Find cause of
increased friction and remedy
fault

Lubricating oil pressure fails Lubricating oil pump defective. Stop the engine. For further
(8) Filters/cooler fouled details, see "Ignition in
crankcase"

Alternator Short circuit Flywheel must be dismounted


and guide pin replaced
08028-0D/H5250/94.08.12

Remarks

1) This manifests itself by rise of the exhaust 2) Blow-by means a serious danger of piston
temperature and falling of the compression and seizure, and the engine must if possible be
maximum combustion pressure of the stopped and the piston in question pulled. If this
respective cylinder. is not possible, the fuel pump index must, as
described above, be moved to stop. Leaky
To limit the damage to the valves, these should piston rings will normally result in a heavy
be changed immediately, if possible, or the fuel excess pressure in the crankcase.
pump of the cylinder concerned should be put
out of operation by moving the index to stop and
locking it in this position.

05.08 - ES0
MAN B&W Diesel

Description
Disturbances during Running 603.03
Page 3 (3) Edition 08H

L+V28/32H

3) If this happens the fuel pump barrel and plunger 6) If the cooling of the atomizers fails (if arranged
must be changed, and if, to obtain full load of the for oil cooling) while running, carbon deposits
respective cylinder, it is necessary to increase will build up round the nozzle holes, sometimes
the fuel pump index by more than 10 index in the shape of small cones or trumpets which
degrees, the fuel pump is in most cases worn causes the engine to smoke, or ot will cause
out. Usually this is confirmed by inspection of sticking of the valve spindle. For this reason the
the fuel pump plunger on which the helical cut- nozzle cooling should be well maintained.
off edge will show a pitted and corroded area
where material is plucked out. In that case the
pump can be provided with a new barrel and 7) If the cooling water temperature for the entire
plunger. engine has risen to 90-100 C, it should be
checked - by opening the test cocks, if fitted on
the discharge from cylinders - whether steam
4) The governor will not reduce the fuel pump has developed. If this is the case, there is no
delivery to zero in case of, for instance, failure water on the cooling surfaces, which may
of the governor oil pump, but the engine speed therefore be heated unduly. To avoid heat
will start fluctuating. stresses arising in cylinder liners and cylinder
heads, if the water returns too early, the engine
When the governor is defective the engine is should be stopped and left to cool, while the
protected against racing by the overspeed trip, discharge valve is closed. After 15 minutes it is
i.e. the engine is stopped automatically in case opened a little to allow the water to rise slowly
of excessive speed. It is essential, therefore, in the cooling jackets. Check filling at test
that the overspeed trip is kept in perfect order. cocks. Make crankcase inspection to ascertain
Regarding governor failure, see special instruc- that internal water leakage has not arisen.
tion book. Remember slow turning withopen indicator
valves at subsequent starting-up.

5) Usually a bearing failure will not slow down the


engine appreciably, but the seizure of a piston 8) If the lubricating oil pressure drops below the
in the cylinder liner might do so. If a PG- minimum mentioned in Data; Find the cause of
governor is employed, the index will increase the pressure drop and remedy the defect before
and exhaust temperatures rise. If such cases re-starting the engine. Feel over 5-15-30 minutes
occur, repair is necessary before starting the after starting, and again when full load is obtained.
engine again. Feel over and look out for oil mist. See section 602.
08028-0D/H5250/94.08.12

05.08 - ES0
Your Notes :

08031-0D/H5250/94.09.07
Description
Ignition in Crankcase 603.04
Page 1 (1)
Edition 09H

L+V28/32H

Cause 1. Stop the engine

During running, the atmosphere in the crankcase 2. Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of coarse oil drops is flung around everywhere.
If undue friction and thus heating arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is transmitted otherwise to after stopping of the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed on to it. When do not smoke.
the oil vapours condense they form a multitude of
minute drops suspended in the atmosphere, i.e. a 3. Take off all doors on one side of the crankcase.
milky white oil mist is formed, able to nourish and Cut off starting air. Engage turning gear, if fitted.
spread a flame if ignited. Such ignition may be
caused by the same "hot spot" which produced the 4. Locate the hot spot. Powerful lamps should be
oil mist. If a large quantity of oil mist has developed employed at once (in explosion-proof fittings). Feel
before ignition, the burning may cause considerable over all sliding surfaces (bearings, liners, pistons,
pressure rise in the crankcase, forsing the relief roller guides, etc.).
valves to open. In a few cases, when presumably the
whole crankcase has been filled with oil mist, the Look for squeezed-out bearing metal and discolo-
consequential explosion has thrown off crankcase ration by heat (blistered paint, burned oil, heated
doors and caused fire in the engine room. steel).

Every precaution should therefore be taken to (A) 5. Prevent further heating, preferably by making
avoid "hot spots" and (B) discover oil mist in time. a permanent repair. Special attention should be
given to ensure lubricating oil supply and satisfactory
condition of the frictional surfaces involved. It is
A. "Hot spots" in crankcase. equally important to replace filter elements in time.

Overheating of bearings is a result of too bad or 6. Start electrically driven lubricating oil pump
failing lubrication possibly caused by pullution of the and check oil flow from all bearings and splash pipes
lubricating oil. in crankcase while turning the engine through at
least two revolutions. See Description 601.05, Point
It is therefore important that the lubricating oil filtra- 4.1.
tion equipment is in perfect condition. Filter cartrid-
ges must not be used again, if they have been 7. Stop and feel over. Look out for oil mist.
removed from the filter. Check of the oil condition by
analysis is recommended. Especially the frictional surfaces that caused the
heating should be felt over (5-15-30 minutes after
starting, and again when full load is obtained). See
B. Oil mist in crankcase. Description 601.10, Point 2.
08028-0D/H5250/94.08.12

Presence of oil mist may by noted at the vent pipe, 8. In case it has not been possible to locate the
which is usually fitted to the top of the engine frame. hot spot, point 7 should be intensified and repeated
until the cause of the oil mist has been found and
Measures (in case of white oil mist). remedied. In very rare cases oil mist could be due to
"atomization" of lubricating oil by the action of an air
Warning: Keep away from doors and relief valves on jet (for instance blow-by, or blow-by through cracked
crankcase. Do not stay unnecessarily in doorways piston).
near doors of the engine room casing.

96.30 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description 603.06
Page 1 (2) Trouble Shooting Guide for Turbine Starter Edition 09H

L+V28/32H

Trouble Possible cause Trouble shooting

Motor will not run. No air supply. Check for blockage or damage to air
supply lines or tank.

Damaged motor assembly (12). Inspect motor assembly and power


train and repair power train or
replace motor assembly if
necessary.

Foreign material in motor and/or Remove motor assembly and piping


piping. and remove the blockage.

Blocked exhaust system. Remove housing exhaust cover (1)


and check for blockage.

Defective control or relay valve. Replace control valve or relay valve.

Loss of power Low air pressure to starter. Check air supply.

Restricted air supply line. Check for blockage or damage to air


lines.

Relay valve malfunctioning. Clean or replace lines or relay valve.


Lubricate relay valve.

Exhaust flow restricted. Check for blocked or damaged


piping. Clean or replace piping.
Check for dirt or foreign material and
clean or remove. Check for ice build-
up. Melt ice and reduce moisture
build-up to starter.

Damaged motor assembly. Replace motor assembly.

Drive (36) of (57) will not engage. No pressure to drive housing port. Check air supply.

Internal drive housing ports blocked. Remove blockage.

Fluid in drive unit components.


Remove fluid.
Damaged or worn piston assembly
(54), o-rings or seals. Replace damaged or worn parts.

O-rings and seals dry. Relubricate o-rings and seals.


08028-0D/H5250/94.08.12

Motor runs, pinion engages, but Damaged or broken drive train. Disassemble drive train and replace
does not rotate flywheel. worn or damaged parts.

Excessive butt engagement. Damaged drive pinion (36) or (63) or Inspect drive pinion and flywheel
flywheel. and replace if necessary.

Damaged starter drive (36) or (57) Inspect drive components and


components. replace worn or damaged parts.

Cont. ....

94.34 - ES0U-G
603.06 Description
Edition 09H
Trouble Shooting Guide for Turbine Starter Page 2 (2)

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 deflector retaining screw (5) Install splash deflector 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 fit properly and


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

Excessive high-speed operation. Operate according to recommen-


dations.

High number of start cycles. Replace worn components.

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

Splash deflector retaining screw Tighten splash deflector retaining


loose or pipe plug missing. screw or replace pipe plug.

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

Excessive high-speed operation. Operate according to recommen-


dations.

High number of start cycles. Replace worn components.

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

Splash deflector retaining screw Tighten splash deflector retaining


loose or pipe plug missing. screw or replace pipe plug.

94.34 - ES0U-G
Description
Trouble Shooting for Cooling Water System 603.09
Page 1 (1)
Edition 08H

General

Description The pump bearings are lubricated automatically with


oil from the lubricating oil system of the engine.
The built-on fresh water pump in the high tempera-ture
(HT) circuit is of the centrifugal type and is mounted If the pump leaks and the shaft sealing rings are worn,
on the front cover of the engine and is driven through it is recommended to replace the shaft seal, see work
a gearing. card 616-02.00.

Trouble Possible cause Trouble shooting

The pump does not work after Pump draws in air at suction side Check packings and pipes for
start tightness

The system is not filled-up Check the level in the expansion


tank

Air cannot escape on delivery side Vent the system

Leaking shaft seal Check the shaft seal

Pump capacity drops after Air leakages of shaft seal Overhaul the shaft seal
normal operation
Fouled impeller Clean the impeller

Pump does not give maximum Suction valve not fully open Open the suction valve
delivery
Defective seals Replace the seals

Worn impeller and worn wear rings Overhaul the pump

Note! Running troubles with the pump, apart from


mechanical faults, are most often due to leaks in the
suction line. It is essential, therefore, that all packings
and gaskets are in order and that they are renewed
when necessary. Even a thiny hole in the suction line
will reduce the pump capacity.
08028-0D/H5250/94.08.12

91.14 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description 603.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H

General
Trouble Shooting. In case of fatigue fracture, this will normally necessitate
a replacement of all plates and gaskets - as there may
In case of damage to plates or gaskets, it will often be be a risk of fatigue fracture in all the material.
necessary to replace them. In case of corrosion, all plates must be examined
First examine very carefully the external conditions carefully!
around the plate heat exchanger in order to localize For work to be carried out see working card 615-05.00.
the cause of the damage!

Visible Leakage

Trouble Possible cause Trouble shooting

Leakage. Too high pressure. Reduce the pressure to the correct


working pressure, see page 600.30
"Operating Data & Set Points".

Leakage. Insufficient tightening Tighten up the plate heat exchanger -


(Phase 1) however, not under the minimum di-
mension and never, when the plate
heat exchanger is under pressure or
over 40C.

If the plate heat exchanger is still leaky,


procede with phase 2.

Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or deformed gaskets. check if the plates are deformed or
fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets,
if any.
Before assembling, clean very care-
fully all plates and gaskets.
Assemble the plate heat exchanger
and start it up again.
Note! Even tiny impurities such as
sand grains may cause leakage.

Leakage. Gaskets. Separate the plate heat exchanger.


08028-0D/H5250/94.08.12

(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension) Replace the gaskets.
Assemble the plate heat exchanger
and start it up again.

Leakage.
(Through the drain holes of the gas- Defective gasket or badly corroded Separate the plate heat exchanger.
kets) plate. Replace defective plates and gaskets,
if any.
Assemble the plate heat exchanger
and start it up again.

92.08 - ESOU
603.10 Trouble Shooting for Lubricating Oil Cooler Description
Edition 01H Page 2 (2)

General

Non-Visible Leakage

Trouble Possible cause Trouble shooting

Reduced heat transmission and/or Fouled plates or choked plate Separate the plate heat exchanger
increasing pressure drop. channels. and check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger
and start it up again.

Leakage. Holes in plates. A suspected leakage can be localized


(The fluids get mixed) Corrosion or fatigue fracture. in the following way:
(Phase 1) Remove one of the lower pipe connec-
tions.
Then put the opposite side under pres-
sure.
If the medium continues to run out of
the lower pipe connections- after the
pressure has stabilized - one or sev-
eral plates are leaking.
Close down the plate heat exchanger.
Separate the plate heat exchanger
and check the plates very carefully.
Check suspected plates with a dye
penetrant.
Check defective plates and gaskets.
Before assembling, clean all plates
and gaskets.
Assemble the plate heat exchanger
and check to find more defective plates,
if any, by putting one side under pres-
sure.
Start up again.

Leakage. Holes in plates.


(The fluids get mixed) Corrosion or fatigue fracture. Close down the plate heat exchanger.
(Phase 2) Separate the plate heat exchanger.
Put all plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on
one plate side (every second plate
channel). Keep the other plate chan-
nels unpressurised and free from liq-
uid!
Stop the circulation after a few minutes
08028-0D/H5250/94.08.12

of operation and open the plate heat


exchanger again. Take care to avoid
water spraying onto the dry plate side!
By a careful study of the plates it will be
possible to find moist areas, if any, on
the otherwise dry plate sides.
Check these areas with a dye pen-
etrant!
Replace defective plates and gaskets.
Before assembling, clean all plates
and gaskets.
Assemble the plate heat exchanger
and check to find more defective plates,
if any, by putting one side under pres-
sure.
Start up again.
If the unit is still leaking, check all plates 92.08 - ES0U
with a dye penetrant!
Index Specification and Treatment
Page 1(1) 604
Lubricating Oil, Fuel Oil and Cooling Water

L28/32H
Description

Lubricating oil specification --------------------------------------------------------------------604. 01 (12H)


Maintenance of lubricating oil condition ----------------------------------------------------604. 03 (09H)
Criteria for cleaning/exchange of lubricating oil 604. 04 (13H)
Lubricating points --------------------------------------------------------------------------------604. 05 (01H)
Lubricating oil in base frame ------------------------------------------------------------------604. 06 (14H)
Specific Lube Oil Consumption SLOC ----------------------------------------------------- 604. 07 (01H)
Fuel oil specification ---------------------------------------------------------------------------- 604. 20 (04H)
Fuel oil quality ------------------------------------------------------------------------------------ 604. 25 (02H)
Nomogram for determination of CCAI ------------------------------------------------------604. 26 (02H)
Analysis data --------------------------------------------------------------------------------------604. 27 (02H)
Fuel oil cleaning ----------------------------------------------------------------------------------604. 30 (01H)
Fresh water system treatment ----------------------------------------------------------------604. 40 (03H)

Working Card

Plates

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Lubricating Oil Specification 604.01
Page 1 (1) Edition 12H

General

Requirement Guiding Values

This document is valid for the following engine types: Based on typical load profile for marine GenSet (50-
L16/24, L21/31, L23/30H, L27/38, L28/32H, V28/32H, 60% of rated power)
V28/32S
Oil type TBN TBN TBN
For the engines, a HD-lub. oil (heavy duty) corre- (initial) (equilibrium) (min. level)
sponding to at least type CD Comercial Class D after
API service system (meets MIL-L-2104 C and D) has Gas oil 8-12 6-8 6
to be used.
Marine diesel 10-15 8-10 8

The oil should be rust and oxidation inhibited. Heavy fuel (S<1.5) 10-15 8-10 8

When selecting a lubricating oil, attention must be Heavy fuel (1.5<S<2.5) 15-20 10-14 8
paid to the fuel oil sulphur content.
Heavy fuel (2.5<S<3.5) 20-25 10-14 8

Due to generating running mode for HOLEBY's en- Heavy fuel (3.5<S<4.5) 20-25 10-14 8
gines, where the lub. oil consumption depends on
running time and the fuel oil consumption and follow-
ing the sulphur input to the lub. oil depends on the Based on typical load profile for stationary GenSets
load, a lower TBN-value (Total Base Number) than (50-100% of rated power)
normal for main engines is needed.
Oil type TBN TBN TBN
(initial) (equilibrium) (min. level)
Viscosity
Gas oil 8-12 6-8 6
Marine
Marine diesel 10-15 8-10 8

Engine SAE class Heavy fuel (S<1.5) 15-20 8-10 8


L23/30H, L+V28/32H
30* 105 mm2/sec at 40 C Heavy fuel (1.5<S<2.5) 20-25 10-14 8
L16/24, L21/31, L27/38
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
40 145 mm2/sec at 40 C
Heavy fuel (3.5<S<4.5) 20-30 10-14 8
Stationary

L16/24, L21/31, L27/38 Based on typical load profile for variable speed
L23/30H, L+V28/32H, V28/32S engine, pumps (10-100% of rated power)
40 145 mm2/sec at 40 C
Oil type TBN TBN TBN
08028-0D/H5250/94.08.12

* At cooling water temperatures above 32 C SAE 40 (initial) (equilibrium) (min. level)


oil can be used. In this case, please contact MAN
B&W, Holeby. Gas oil 10-14 6-8 6

Marine diesel 12-16 8-10 8


If load profile is different, this should be taken in
consideration. Heavy fuel (S<1.5) 15-20 8-10 8

In the long run though, the operation results are the Heavy fuel (1.5<S<2.5) 20-30 10-14 8
criteria that prove which TBN is the most economical
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
one for efficient engine operation.
Heavy fuel (3.5<S<4.5) 25-30 10-14 8

01.24 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description 604.03
Page 1 (2) Maintenance of Lubricating Oil Condition Edition 09H

General
General A more economical solution is to maintain the condi-
tion by continuous treatment. Experience has proved
During operation of trunk engines the lubricating oil that centrifuging is superior to other methods of
will be contaminated slowly by small particles origi- cleaning lubricating oils.
nating from the combustion.
The optimum cleaning effect is achieved by keeping
The burning of heavy fuels will normally increase this the lubricating oil in a state of low viscosity for a long
contamination due to the increased content of car- period in the centrifuge bowl.
bon residues and other impurities.
Low viscosity is obtained by preheating the lubricat-
Contamination of lubricating oil with water, fresh or ing oil to a temperature of 85C - 95C.
salt, can also take place.
Slow passage of the lubricating oil through the
A certain amount of contaminants can be kept sus- centrifugal separator is obtained by using a reduced
pended in the lubricating oil without affecting the flow rate and by operating the separator 24 hours a
lubricating properties. day, stopping only when cleaning of the bowl is
necessary.
But the condition of the lubricating oil should be kept
under observation by analyzing oil samples. See When treating detergent type lubricating oil, the flow
also 504.04 "Criteria for Cleaning/Exchange of rate is usually recommended to be reduced to 15-
Lubricating Oil". 25% of the rated flow of the separator.

The engine bearings are protected by the full-flow In order to keep the amount of lubricating oil in the
lubricating oil filter built onto the engine, the filter engine in good condition, it is necessary to treat 0.3-
cartridges having a fineness of 15 micron and the 0.4 l/kw per hour.
safety filter a fineness of 60 micron.
A centrifuge for treating this amount of lubricating oil
The condition of the lubricating oil can be main- under the aforementioned derated flow conditions
tained/reestablished by exchanging the oil at fixed should have a rated capacity of 1.5-2.5 l/kw per hour,
intervals or based on analysis results. but in each case the separator manufacturer's rec-
ommendations for capacity and operating instruc-
tions should be followed.
Operation on Marine Diesel Oil (MDO)
For engines with cartridge-type oil filters (depth
The built-on full-flow dept filter cleans the oil thor- filters), continuous and efficient purification of the oil
oughly. For operation on MDO we recommend to in the separator is essential to ensure a long service
install a built-on centrifugal by-pass filter too. life for the cartridge filters.

For cleaning of the lubricating oil system after over-


Operation on Heavy Fuel Oil (HFO) hauls and inspection of the lubricating oil piping
system, see section 515.
08028-0D/H5250/94.08.12

For engines operating on HFO a lub. oil centrifugal


unit is required.
Deterioration of Oil
Continuous lub. oil centrifugation plus a built-on full-
flow depth filter clean the oil in a sufficient and safe Oil seldom loses its ability to lubricate, i.e. to form a
way. Any other filter system is not necessary, but not friction-decreasing oil film, but it may become cor-
wasted. rosive to the steel journals of the bearings in such a
way that the surface of these journals becomes too
rough and wipes the bearing surface.

02.16 - ES0 - G
604.03 Maintenance of Lubricating Oil Condition Description
Edition 09H Page 2 (2)

General

In that case not only must the bearings be renewed, These may be some or all of the following:
but the journals must also be polished. The corro-
siveness of the lubricating oil is either due to far - Sludge precipitation in purifier multiplies.
advanced oxidation of the oil itself (TAN) or to the
presence of inorganic acids (SAN). In both cases the - Smell of oil becomes acrid or pungent.
presence of water will multiply the effect, especially
an influx of sea water as the chloride ions act as an - Machined surfaces in crankcase become cof-
inorganic acid. fee brown with a thin layer of lacquer.

- Paint in crankcase peels off or blisters.


Oxidation of Oils
- Excessive carbon is formed in the piston cool-
At normal service temperature the rate of oxidation ing chamber.
is insignificant, but the following factors will accele-
rate the process: In a grave case of oil deterioration, the system
should be cleaned thoroughly and refilled with new
oil.
High Temperature

If the coolers are ineffective the temperature level Water Washing


will generally rise.
Water washing of HD oils must not be carried out.
A high temperature will also arise in electrical preheat-
ers if circulation is not continued for 5 minutes after
the heating has been stopped, or if the heater is only Water in the Oil
partly filled with oil.
If the TAN is low, a minor increase in the fresh water
content of the oil is not immediately detrimental while
Catalytic Action the engine is running. Naturally, it should be brought
down again as quickly as possible (below 0.2%
Oxidation of the oil will be accelerated considerably water content, which is permissible). If the engine is
if catalytic particles are present in the oil. Wear stopped while corrosion conditions are unsatisfac-
particles of copper are especially harmful, but also tory it should be turned just over 1/2 revolution once
ferrous particles and rust are active. Furthermore, every hour (i.e. stop in different positions) while the
the lacquer and varnish-like oxidation products of oil circulation and purifying at a high preheating
the oil itself have an accelerating effect. Continuous temperature continue to remove water. Water in the
cleaning of the oil is therefore important to keep the oil may be noted by steam formation on the sight
sludge content low. glasses, by appearance, or ascertained by immers-
ing a piece of glass or a soldering iron heated to 200-
300C in an oil sample. If there is a hissing sound,
08028-0D/H5250/94.08.12

Signs of Deterioration water is present. If a large quantity of water has


entered the oil system, it may be profitable to suck up
If circulating oil of inferior quality is used and the sedimented water from the bottom of the tank. Taste
oxidative influence becomes grave, prompt action is the water for salt. If salty, an oil sample should be
necessary as the last stages in the deterioration may analysed immediately for chloride ions.
develop surprisingly quickly, i.e. within one or two
weeks. Even if this seldom happens, it is wise to be
acquainted with the signs of deterioration.

02.16 - ES0 - G
Description
Criteria for Cleaning/Exchange of Lubricating Oil 604.04
Page 1 (2) Edition 13H

General

Replacement of Lubricating Oil 3. Water Content

It is not possible to predict the expected life time for Limit value : < 0.5
lubricating oil, as it is not possible for the engine preferred < 0.2 (higher value is
manufacturer to know which fuel and lubricating oil permissible in a shorter period)
qualities will be used and under which operation
conditions the engine will be operated. Possible test
method : Patable test unit or gas chrom-
A replacement of lubricating oil is required when the atography (or infra red distil).
oil's identification values have changed no that the If the limit value is exceeded, a
lubricating cleaning and neutralization properties no supplementary test for chlorides
longer are sufficient. (ASTM D-878) can be made.

Exchange of the lub. oil has to be based on the oil


suppliers evaluation of samples of oil in service. 4. Total Base Number (TBN-Number)
Samples should be forwarded at appropriate inter-
vals at least once every three months depending of Limit value : Ref. to fresh-oil TBN% : > 70%
running-mode and results of last analysis.
Unit : mg KOH/g
The oil sample should be taken after the filter and, if
possible, while the engine is running as this will Possible test
ensure that the test will be representative for the method : ASTM D-2896
whole change in the engine.
Due to the generating running mode for HOLE-
BY's engines, where the lub. oil consumption
Evaluation of the Lubricating Oil Condition depends on running time and the fuel oil con-
sumption and following the sulphur input to the
For evaluating the conditions of a used oil, the lub. oil depends on the load, a lower TBN-value
following guidance conditions are normally suffi- than normal for main engines is needed.
cient. Anyway, all parameters have to be evaluated
as a whole, and no single can be taken as a criterion Following guiding values can be given:
for changing oil.
Oil type TBN TBN (equi-
(initial) librium)
1. Viscosity
Gas oil 10 7
Limit value : < 1 viscosity grade
Marine diesel 15 10
Heavy fuel (S>2.5) 15 10
Units : SAE-units
Heavy fuel (S>4) 20 14
08028-0D/H5250/94.08.12

Possible test
method : ASTM D-445 (modified) The TBN is normally reduced gradually with the
time of operation. The influential elements are the
sulphur content in the fuel oil, the lubricating oil
2. Flash Point amount and the amount of re-filling due to normal
consumption. After a certain time of ope-ration,
Limit value : > 185 C the TBN will stabilize at a lower value, the TBN
equilibrium.
Possible test
method : Setaflash tests (cut of point cor
relates with 204 C i ASTM D-92
(coc)

96.44 - ES1
604.04 Criteria for Cleaning/Exchange of Lubricating Oil Description
Edition 13H Page 2 (2)

General

Re-filling should be carried out with lubricating oil of Unit : Weight %


the initial TBN.
Possible test
method : ASTM D-893 procedure B in n-
5. Neutralization Number Heptane.

Limit value : 0.4-1.0 above typical level Additionally


test : If the level in n-Heptane insolub-
Unit : mg KOH/g les is considered high for the ty-
pe of oil and application, the test
Possible test could be followed by a supple-
method : ASTM D-974 mentary determination in Tolu-
ene.

6. The Total Contamination (insolubles Con- Also infra red test can be used.
tent) Heptane insolubles

Limit value : < 1.5 generally, depending upon


actual dispersant value and the
increase in viscosity.

08028-0D/H5250/94.08.12

96.44 - ES1
Description
Lubricating Points 604.05
Page 1 (1) Edition 01H

General
Lubricating Oil Types used in the Engine.

Description Lub. Oil Type

Engine system lubricating oil. SAE 30 oil according to lubricating oil specification on page 604.01.

Turbocharger Engine system lubricating oil.

Governor See Governor instruction in section 609.

Air lubricator SAE 10W non-detergent oil.

Alternator See special instructions in section 618 or separate instruction.

Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12

92.02 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Description
Lubricating Oil in Base Frame 604.06
Page 1 (1) Edition 14H

L28/32H

Type L28/32H 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.

Min. level H1 (mm) 265 265 265 265 265


08028-0D/H5250/94.08.12

Max. level H2 (mm) 365 365 365 365 365

Min. litre 792 935 1078 1220 1362

Max. litre 1111 1311 1511 1710 1910

99.03 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description
Specific Lube Oil Consumption SLOC 604.07
Page 1 (2) Edition 01H

General

In order to determine the engine condition, the lube In order to evaluate the correct engine SLOC, the
oil consumption needs to be recorded. To secure a following circumstances must be noticed and
uniform method to evaluate the SLOC, the following subtracted from the engine SLOC:
method should be used as guidance:
A1) Desludging interval and sludge amount from
During the routinely engine inspections the lube oil the lube oil separator (or automatic lube oil filters).
level in the base frame must be observed. The The expected lube oil content of the sludge amount
engine must be in operation or the pre-lubricating is 30%.
pump must be running during this inspection!
The following does also have an influence on the
The lube oil volume between maximum and minimum SLOC and must be considered in the SLOC
level at the dipstick is described in the Instruction evaluation:
Manual or in the Product Manual. If the lube oil level
is at the minimum, lube oil is added until the max level A2)
is reached at the dipstick. Lube oil evaporation
Lube oil leakages
The lube oil volume added, the lube oil temperature Lube oil losses at lube oil filter exchange
and the engine running hours are recorded and the
readings could be filled in the attached data sheet.
The engine maximum continuous rating (PMCR) must
The lube oil density, @ 15C must be known in always be used in order to be able to compare the
order to convert to the present lube oil temperature individual measurements, and the running hours
in the base frame. The following formula is used to since the last lube oil adding must be used in the
calculate : calculation. Due to inaccuracy *) at adding lube oil,
the SLOC can only be evaluated after 1,000 running
lube oil [kg/m3] = hours or more, where only the average values of a
number of lube oil addings are representative.
lube oil @15C [kg/m3] 0,64 * (tlube oil [C] 15)
If the SLOC deviates from the nominal value stated
in the Instruction Manual or in the Product Manual,
The following formula is used to calculate the SLOC: the engine cylinder condition should be inspected.

SLOC [g/kWh] =

(lube oil added A1 A2 [dm3]) * lube oil [kg/m3] Note *)


run.hrs period * PMCR [kW] A deviation of 1 mm with the dipstick measurement
must be expected, witch corresponds 5 dm3,
depending on the engine type.
08028-0D/H5250/94.08.12

03.14 - ES0
Description
Specific Lube Oil Consumption SLOC 604.07
Page 2 (2) Edition 01H

General

Plant / Ship
Lube oil consumption
Engine type:___________________ Engine # :__________________

Lube oil brand/type:__________________________________________

Density @15C:_____________ [kg/m3]


Date Run. hrs Add. Lube oil A1 + A2 L.O.Temperature SLOC Remarks
[h] [dm] [dm] [C] [g/kWh]
08028-0D/H5250/94.08.12

03.14 - ES0
Description
Fuel Oil Specification 604.20
Page 1 (3) Edition 03H

General

Commercially available fuel oils with a viscosity up to The data refer to the fuel as supplied, i.e. before
700 cSt at 50 C corresponding to 55 cSt at 100 C any on-board cleaning.
can be used for MAN B&W Holeby 4-stroke medium
speed diesel engines.

For guidance on purchase, reference is made to ISO Property Units Value


8216/17, BS 6843 and to CIMAC recommendations
regarding requirements for heavy fuel for diesel Density at 15C kg/m3 991*
engines, third edition 1990. From these maximum
accepted grades are RMH 55 and K55. The mention- Kinematic
ed ISO and BS standards supersedes BS MA 100 in viscosity
which the limit is M9. at100C cSt 55
at 50 C cSt 700
It means that engines can be operated on the same
fuel oils as MAN B&W 2-stroke low-speed diesel Flash point C > 60
engines.
Pour point C 30
The data in the above HFO standards and specifica-
tions refer to the same fuel type as delivered to the Carbon redisue % (m/m) 22
ship, i.e. before on-board cleaning.
Ash % (m/m) 0.15
In order to ensure effective and sufficient cleaning of
the HFO, i.e. removal of water and solid contaminants, Total sediment
the fuel oil specific gravity at 15 C (60 F) should be after ageing % (m/m) 0.10
below 0.991. Higher densities can be allowed if
special treatment systems are installed. Water % (v/v) 1.0

Current analysis information is not sufficient for Sulphur % (m/m) 5.0


estimating the combustion properties of the oil.
This means that service results depend on oil pro- Vanadium mg/kg 600
perties which cannot be known beforehand. This
especially applies to the tendency of the oil to form Aluminium +
deposits in combustion chambers, gas passages Silicon mg/kg 80
and turbines. It may, therefore, be necessary to rule
out some oils that cause difficulties.
m/m = mass V/V = volume

Guiding Heavy Fuel Oil Specification *) May be increased to 1.010 provided adequate
cleaning equipment is installed, and modern
Based on our general service experience we have, type of centrifuges.
08028-0D\H5250\94.08.12

as a supplement to the above-mentioned standards,


drawn up the guiding HFO-specification shown below.
If heavy fuel oils, with analysis data exceeding the
Heavy fuel oils limited by this specification have, to above figures, are to be used, especially with regard
the extent of the commercial availability, been used to viscosity and specific gravity, the engine builder
with satisfactory results on MAN B&W GenSets. should be contacted for advice regarding possible
changes in the fuel oil system.

95.49
604.20 Fuel Oil Specification Description
Edition 03H Page 2 (3)

General

Fuel Oil Condition, when Entering the Engine

As practically all fuel oil specifications including the For fuels above 180 cSt/50 C a pressurerized fuel
above standards refer to the same fuel type as oil system is necessary to avoid boiling and foaming
supplied, the fuel supplied to a ship has to be treated of the fuel.
on board before use. For running on the oil quality
mentioned above it is necessary that equipment The viscosity leaving the heaters should be 10-15
exists on board, which can treat, viz clean and cSt and approx. 12-18 cSt entering the engine. The
preheat, the fuel oil with optimum efficiency. maximum temperature of oil after preheater should
be 150 C to avoid to rapid fouling of preheater.
In B 11 00 0 "Cleaning Recommendations" our
recommendations are outlined. The preheating chart on page 3 illustrates the expect-
ed preheating temperature as function of the specific
For economical HFO operation the fuel oil condition fuel oil viscosity.
at engine inlet should be as recommended below.

Property Units Max. value

Water % by volume max. 0.2

Solid
particles ppm (mg/kg) max. 20

Particle size Micron max. 5

Viscosity cSt Range 12-18

08028-0D\H5250\94.08.12

95.49
Description
Fuel Oil Specification 604.20
Page 3 (3) Edition 03H

General

Fuel oil - preheating chart

Approx. viscosity
after preheater

Temperature sec.
cSt
after preheater C Rw.

7 43

170

160 10 52

Normal preheating limit 12 59


150
15 69
140

20 87
130

120
30 125

110

100

90

80

70

60
Approx. pumping limit
50

40

30
Log scales 10 15 25 35 45 55 cSt/100 C

30 60 100 180 380 700 cSt/50 C


200 400 800 1500 3500 7000 sec. Rw/100 F
08028-0D\H5250\94.08.12

Viscosity of fuel

This chart is based on information from oil suppliers regarding typical marine fuels with viscosity index 70-80.
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary,
dependent on the viscosity and viscosity index of the fuel.

95.49
Your Notes :

08031-0D/H5250/94.09.07
Description
Fuel Oil Specification 604.20
Page 1 (3) Edition 04H

General

Commercially available fuel oils with a viscosity up to The data refer to the fuel as supplied, i.e. before
700 cSt at 50 C corresponding to 55 cSt at 100 C any on-board cleaning.
can be used for MAN B&W Holeby 4-stroke medium
speed diesel engines.

For guidance on purchase, reference is made to ISO Property Units Value


8216/17, BS 6843 and to CIMAC recommendations
regarding requirements for heavy fuel for diesel Density at 15C kg/m3 991*
engines, third edition 1990. From these maximum
accepted grades are RMH 55 and K55. The mention- Kinematic
ed ISO and BS standards supersedes BS MA 100 in viscosity
which the limit is M9. at100C cSt 55
at 50 C cSt 700
It means that engines can be operated on the same
fuel oils as MAN B&W 2-stroke low-speed diesel Flash point C > 60
engines.
Pour point C 30
The data in the above HFO standards and specifica-
tions refer to the same fuel type as delivered to the Carbon residue % (m/m) 22
ship, i.e. before on-board cleaning.
Ash % (m/m) 0.15
In order to ensure effective and sufficient cleaning of
the HFO, i.e. removal of water and solid contaminants, Total sediment
the fuel oil specific gravity at 15 C (60 F) should be after ageing % (m/m) 0.10
below 0.991. Higher densities can be allowed if
special treatment systems are installed. Water % (v/v) 1.0

Current analysis information is not sufficient for Sulphur % (m/m) 5.0


estimating the combustion properties of the oil.
This means that service results depend on oil pro- Vanadium mg/kg 600
perties which cannot be known beforehand. This
especially applies to the tendency of the oil to form Aluminium +
deposits in combustion chambers, gas passages Silicium mg/kg 80
and turbines. It may, therefore, be necessary to rule
out some oils that cause difficulties.
m/m = mass V/V = volume

Guiding Heavy Fuel Oil Specification *) May be increased to 1.010 provided adequate
cleaning equipment is installed, and modern
Based on our general service experience we have, type of centrifuges.
08028-0D\H5250\94.08.12

as a supplement to the above-mentioned standards,


drawn up the guiding HFO-specification shown below.
If heavy fuel oils, with analysis data exceeding the
Heavy fuel oils limited by this specification have, to above figures, are to be used, especially with regard
the extent of the commercial availability, been used to viscosity and specific gravity, the engine builder
with satisfactory results on MAN B&W GenSets. should be contacted for advice regarding possible
changes in the fuel oil system.

01.34 - ES1
604.20 Fuel Oil Specification Description
Edition 04H Page 2 (3)

General

Fuel Oil Condition, when Entering the Engine

As practically all fuel oil specifications including the For fuels above 180 cSt/50 C a pressurerized fuel
above standards refer to the same fuel type as oil system is necessary to avoid boiling and foaming
supplied, the fuel supplied to a ship has to be treated of the fuel.
on board before use. For running on the oil quality
mentioned above it is necessary that equipment The viscosity leaving the heaters should be 10-15
exists on board, which can treat, viz clean and cSt and approx. 12-18 cSt entering the engine. The
preheat, the fuel oil with optimum efficiency. maximum temperature of oil after preheater should
be 150 C to avoid to rapid fouling of preheater.
In B 11 00 0 "Cleaning Recommendations" our
recommendations are outlined. The preheating chart on page 3 illustrates the expect-
ed preheating temperature as function of the specific
For economical HFO operation the fuel oil condition fuel oil viscosity.
at engine inlet should be as recommended below.

Property Units Max. value

Water % by volume max. 0.2

Solid
particles ppm (mg/kg) max. 20

Particle size Micron max. 5

Viscosity cSt Range 12-18

08028-0D\H5250\94.08.12

01.34 - ES1
Description
Fuel Oil Specification 604.20
Page 3 (3) Edition 04H

General

Fuel oil - preheating chart

Approx. viscosity
after preheater

Temperature sec.
cSt
after preheater C Rw.

7 43

170

160 10 52

Normal preheating limit 12 59


150
15 69
140

20 87
130

120
30 125

110

100

90

80

70

60
Approx. pumping limit
50

40

30
Log scales 10 15 25 35 45 55 cSt/100 C

30 60 100 180 380 700 cSt/50 C


200 400 800 1500 3500 7000 sec. Rw/100 F
08028-0D\H5250\94.08.12

Viscosity of fuel

This chart is based on information from oil suppliers regarding typical marine fuels with viscosity index 70-80.
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary,
dependent on the viscosity and viscosity index of the fuel.

01.34 - ES1
Your Notes :

08031-0D/H5250/94.09.07
Description
Fuel Oil Quality 604.25
Page 1 (2) Edition 02H

General

General Considerations Combustion Quality

The quality of a fuel oil is stated, in analysis data, in Combustion quality is the ability of the fuel oil to ignite
terms of physical and chemical properties, which are and burn in a proper way. The ignition quality,
decisive to the suitability of the fuel oil for different combustion intensity, and length and completeness
applications. For diesel engine fuels the combustion of combustion are properties influenced by the
quality, the content of impurities and the handling chemical combustion and structure of the fuel oil.
properties are the main quality criteria.
Ignition quality relates to ignition delay, i.e. the time
Since residual fuels are traded and designated elapsed between the start of injection and the start of
according to viscosity, it has become common combustion.
practice to associate viscosity with quality. This
practice can be very misleading, especially with Ignition quality is expressed by the cetane number,
modern residual fuels, as a fuel oil of low viscosity diesel index or cetane index. In all cases the higher
can often be just as bad, or even worse, than other the value, the better the ignition quality. For diesel oil
fuel oils of very high viscosity. the ignition quality is expressed by the cetane number
determined by a specified method in a standard
The quality of refinery residues is dependent on the engine running under standard conditions.
origin of the crude oil, the grade of utilization when
refining the crude oil, and the refinery technique For residual fuels the ignition quality can be expressed
used. by the diesel index or cetane index, both to be
calculated from physical properties such as the
Some of the residues used in fuel oil production are aniline point, specific gravity and mid-distillation
of a viscosity requiring visbreaking, a process which temperature. The cetane number, diesel index or
will reduce the viscosity without improving the quality cetane index of a certain fuel oil will show reasonable
at all. correlation between the numerical values.

When producing residual fuels from visbreaked, A FIA cetane number test is also good for evaluation
cracked residues and from "straight run" residues, of the combustion quality.
the final adjustment of viscosity to fulfil the
requirements of the different grades of intermediate The combustion condition of the fuel oils is normally
fuels is achieved by adding gas oil. evaluated from Conradson Carbon residue and the
asphaltene contents.
However, it must be noted that considerable reduction
of the viscosity is achieved by adding a relatively
small amount of gas oil, which will give only a minor Content of Impurities
improvement of the quality of the blend. This means
that the quality to a major extent depends on residues The content of impurities of diesel engine fuels
present in the blend. Therefore the quality also should be kept as low as possible, and harmful and
08028-0D/H5250/94.08.12

depends on the density, see 504.26. unwanted impurities should, to the greatest possible
extent, be removed in the pre-treatment system in
As a consequence of the possible variations in the order to minimize wear and corrosion of engine
quality of residues and the influence of adding gas components. Impurities derive from the crude oil
oil, the quality of blended fuels can vary, even for fuel itself, from refinery processes and from handling and
oils of equal nominal viscosity. storage of oils. Some impurities, such as sulphur and
vanadium, are oil soluble and therefore impossible
to remove in a conventional mechanical fuel oil
treatment system, while the amount of water and
solid impurities can be reduced by centrifuging and
filtration.

02.16 - ESO - G
604.25 Fuel Oil Quality Description
Edition 02H Page 2 (2)

General

Sand, rust, metal oxides and catalyst particles can The flash point is related to the volatility of the
be found as solid particles in fuel oil. amount and nature of lighter fractions in the fuel oil,
and might thus be used to estimate the propensity of
Fuel-related wear and corrosion in diesel engines gasification in non-pressurized parts of the fuel
take the form of mechanical wear and chemically system.
induced corrosion, the latter in the form of high and
low temperature corrosion. The pour point defines the temperature at which wax
crystallization will take place and prevent the fuel oil
The solid impurities and particles produced during from flowing and from being pumped.
combustion, collectively known as ash, cause
mechanical wear of engine components. Therefore, the pour point must be taken into account
when deciding the presence and capacity of heating
Especially catalyst particles, silicone and aluminium coils in bunker tanks.
oxides and silicates in the form of sand are very
abrasive. From vanadium and sodium corrosive ash
in the form of oxides, carbonates and sulphates, is Quality Fuel Oil Main Effects
created during combustion. Criteria Characteristics

Combustion Conradson carbon Ignition ability.


The sulphur content of a fuel oil may lead to low quality asphaltenes + Combustion condition.
temperature corrosion of combustion chamber FIA test Fouling of gasways.
components and the formation of deposits on these.
The corrosive effect is due to the formation of sulphuric Sulphur Corrosive wear. Cold
acid. corrosion.

Vanadium Formation of deposits on


Water in the fuel oil may lead to several detrimental Sodium exhaust valves and turbo-
effects to the fuel system and to the diesel engine in chargers.
general by giving rise to mechanical and corrosive High temperature corrosion.
wear, as well as fouling.
Water Disturbance of combustion
process.
Increased heat-load of com-
Handling Properties Content of bustion chamber compo-
impurities nents, fouling of gas ways,
mechanical wear and cavita-
Handling of the fuel, i.e. storage, pumping and
tion of fuel injection system.
treatment, is affected mainly by physical properties
such as viscosity, density, flash point and pour point, Ash Mechanical and corrosive
but other fuel oil properties such as stability, emul- wear of combustion
sification tendency, viscosity index and the nature chamber components.
Formation of deposits.
and amount of water and solid impurities will also
Catalyst fines Mechanical wear of fuel in-
08028-0D/H5250/94.08.12

influence the handling system. jection system, cylinder


liners and piston rings.
The nominal viscosity is decisive for the preheating
temperature necessary to achieve adequate viscosity Viscosity Temperatures, pressures,
Density and capacities of fuel oil
for pumping, settling, centrifuging and injection.
Handling Pour point systems for storage,
properties pumping and pre-treatment.
The density influences the gravitational settling of
water and solid contaminants in settling tanks. Flash point Safety requirements.
Specific gravity is also an important parameter in the
centrifuging process. The flash point is, for safety Table 1. Fuel properties affecting diesel engine and fuel systems.
reasons, limited to a minimum of 60C (140F) by
classification societies and other authorities.

02.16 - ES0 - G
Description
Nomogram for Determination of CCAI 604.26
Page 1 (2) Edition 02H

General
08028-0D/H5250/94.08.12

Fig 1 Nomogram for determination of CCAI.

01.34 - ES1
604.26 Nomogram for Determination of CCAI Description
Edition 02H Page 2 (2)

General

Example: Ignition quality is an important fuel parameter. The


reason why it does not appear in the international
Viscosity: 180 cSt at 50C specifications is that there are no standardized testing
Density: 990 kg/m at 15C method is non-existent. Therefore, parameters such
as the Calculated Carbon Aromaticity Index (CCAI)
The combining straight line across density (990 kg/ are resorted to as an aid which is derived from
m) and viscosity (180 cSt) of a heavy fuel oil results determinable fuel parameters. According to our
in CCAI (859). From CCAI, conclusions may be experience, only a rough assessment of the ignition
derived with regard to the ignition qualities. quality of the heavy fuel oil is possible with the help
of this method.
CCAI may be calculated with the aid of the following
formula: However, the CCAI has become so well-known in
widespread publications that, in spite of the
CCAI = D - 141 log (log (v + 0.85)) - 81 reservations mentioned above. We were compelled
to classify the respective MAN B&W Diesel A/S,
Holeby engines according to CCAI-rating, too.

08028-0D/H5250/94.08.12

01.34 - ES1
Description
Analysis Data 604.27
Page 1 (4) Edition 02H

General

Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating proper-
ties of the fuel oil and, in extreme cases, high
Carbon Residue asphalteness content may lead to fuel injection
pump sticking.
The carbon residue of a fuel oil indicates its coke-
forming tendency and can be used to determine the Fuel oils with a high asphalteness content will have
tendency to form deposits in the combustion cham- a tendency to form sludge, especially if the water
ber and gasways. The higher the carbon residue content is also high. The asphaltenes content of a
value, the higher the fouling tendency. fuel oil is influenced by pre-treatment. The heaviest
semi-solid asphaltenes, and asphaltenes bound to
Some changes in the combustion process, requiring water as sludge, can be separated by centrifuging.
adjustment of the maximum pressure, may also be
attributed to a high carbon residue content. The
value is measured by standardized tests, such as Diesel Index
the Conradson or Ramsbottom tests which give
similar results. Diesel index is a calculated value to determine the
ignition quality of a fuel oil. The ignition quality is
The non-vaporized residue from the carbonizing test related to the hydrocarbon composition, paraffin
consists of carbonaceous material and inorganic being of high quality, n-heptanes of moderate quality
impurities and is expressed as percentage weight of and aromatics of low quality.
the fuel sample tested. Carbon residue and
asphaltenes content generally move in parallel, both With certain exceptions the properties of the aniline
in relation to the carbon-to-hydrogen ratio, with in- point and the specific gravity reflect the hydrocarbon
creasing values for a higher ratio. composition of a fuel oil, and are therefore used in
the following simple formula as an expression of
The carbon-to-hydrogen ratio and thus also the ignition quality:
carbon residue depends on the source of the crude
oil and the type of refinery processing used. Diesel index = (aniline point F x API gravity) x 0.01.

The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at com-
percentage weight called carbon residue. paratively low temperatures, whereas paraffins re-
quire considerably higher temperatures before they
are completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sample fuel, and consequently a fuel oil of good ignition
which is insoluble in heptane. The content of quality. Similarly, a high API gravity number denotes
08028-0D/H5250/94.08.12

asphalteness is expressed as percentage weight of a low specific gravity and high paraffinicity, and
the fuel oil sample tested. again a good ignition quality.

Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process to above the cetane number.
the carbon residue, the main impact being fouling of
gasways. The stability of the fuel oil is related to the Fuel oils with poor ignition quality and a low diesel
asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.

02.16 - ES0 - G
604.27 Analysis Data Description
Edition 02H Page 2 (4)

General

In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and de-
posit formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation of
of gasways. detrimental vanadium-sodium ash by effective cen-
trifuging, which will remove sodium salts together
with water. If a very low content of sodium is ensured,
Sulphur a relatively high vanadium content might be accept-
able.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects on
may be formed on components in the combustion the fuel oil system, and corrosion and cavitation of
chamber and in the gasways, where the temperature fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.

The detrimental effect of sulphur in fuel oil is counter- Due to its content of sodium, salt water in combina-
acted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done to
content. The amounts of these are measured by the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium
08028-0D/H5250/94.08.12

derives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, determined by a combustion test and it is expressed
and also from contamination with salt water during as a percentage weight residue from complete com-
storage and transport of the fuel oil. Sodium is water- bustion of the oil sample tested.
soluble and, regardless of derivation, tends to com-
bine with the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.

02.16 - ES0 - G
Description
Analysis Data 604.27
Page 3 (4) Edition 02H

General

Ash-forming materials exist both as solid contami- Viscosity of Marine Gas Oil (MGO) and Marine
nants and in soluble compounds. The solid contami- Diesel Oil (MDO) are expressed in centistokes (cSt)
nants may lead to abrasive wear in the fuel injection at 40 C.
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion Viscosity is an important parameter in connection
chamber components and give rise to formation of with pumping, pre-treatment and injection of fuel oil,
detrimental deposits. It is therefore essential, to the since the possibility and efficiency of these processes
greatest possible extent, to reduce the amount of to a large extent depend on adequate viscosity.
ash-forming materials by centrifuging.
Adjustment of viscosity to adequate values is possible
Solid contaminants such as sand, rust, certain metal by taking advantage of the interdependence between
oxides and catalyst fines can be removed by centri- the temperature and viscosity index of the fuel oil.
fuging, and the same goes for water-soluble salts
such as sodium. The nominal viscosity of a fuel oil is the factor
determining the preheating temperatures necessary
Some of the components included in the ash content to obtain adequate viscosity for pumping, centrifug-
have been found to be particularly harmful and are ing and injection of the fuel oil, and thus also the
therefore stated individually in the analysis data. factor determining the capacity of the preheating
equipment in the fuel oil system.

Silicium and Aluminium Oxides


Density
Residual fuels produced by refineries using fluid
catalytic cracking may be contaminated by catalyst Density is defined as the mass of a unit volume and
particles in the form of silicium and aluminium ox- is expressed in g/cm at a temperature of 15C
ides. Any catalyst particles are shown by the ash (59F).
content value. Separate values for silicium oxide
content and aluminium oxide content are measured Specific gravity is the ratio of the mass of a given
by analyzing the ash content. volume of liquid at 60F (15.6C) and the mass of an
equal volume of water at the same temperature. For
The amount of silicium and aluminium oxides is a given liquid, the specific gravity will generally give
expressed in ppm in relation to the weight of the the same numerical value as the density.
original fuel oil sample being tested for ash content.
API gravity is an arbitrary scale calibrated in degrees
As catalyst particles are very hard and abrasive, they and related to specific gravity by the following for-
can cause extreme mechanical wear of the fuel mula:
injection system, cylinder liners and piston rings. 141.5
API gravity = specific gravity/50F + 131.5
Catalyst particles, being solid and insoluble, can be
removed from the fuel oil. The guidelines for
08028-0D/H5250/94.08.12

dimensioning the centrifuge size are based on the As the formula indicates, the API gravity is in inverse
fact that approx. 1/3 of the catalyst particles in terms proportion to density and specific gravity.
of weight is removed.
Density is an important parameter in the centrifuging
process, where separating water and water-dis-
Viscosity solved impurities from the fuel oil is based on the
difference in densities. If the density of the fuel oil
Basically viscosity is a measure of the internal fric- approaches that of water, centrifuging thus becomes
tion or resistance of a liquid to flow. less effective, necessitating a reduced flow rate and
therefore increased centrifuge capacity.

02.16 - ES0 - G
604.27 Analysis Data Description
Edition 02H Page 4 (4)

General

The water separation ability of fuel oil is increased by Pour Point


preheating the fuel oil prior to centrifuging since the
densities of fuel oil and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making it possi- oil will flow or can be poured. The pour point is
ble to optimize density differences. measured under specific test conditions. Fuel oil
must be stored, handled and pumped at tempera-
To some extent the quality of a fuel oil can be judged tures above the pour point to avoid wax crystalliza-
by the density, since this is directly proportional to tion, which may result in precipitation in storage
the carbon-to-hydrogen ratio, which again is in direct tanks, blocking of filters and pipe lines and preven-
proportion to aromativity, carbon residue and tion of pumpability. Normally, the pour point of re-
asphaltene content, but in reverse ratio to calorific sidual fuel oil does not create any problems, since
value. the temperature needed to reduce the viscosity to
pumpable levels will be adequately in excess of the
pour point.
Analysis Data for Fuel Oils

Carbon Residue % weight Flash Point


Asphaltenes % weight
Diesel Index The flash point of an oil is defined as the temperature
Engine- FIA
at which it gives off sufficient vapour to create an
Relevant Ash % weight
Properties Sulphur % weight inflammable mixture with air. This mixture will ignite
Water % volume or flash under the influence of an open flame, but will
Vanadium ppm not support combustion itself. The flash point of fuel
Sodium ppm oil is normally tested by the Pensky-Martens closed-
Silicium Oxide ppm
up method.
Aluminium Oxide ppm

Viscosity cSt/50C In order to provide a sufficient margin of safety from


Installation- Density g/ml fire risk during storage, handling and transportation,
Relevant Flash Point C fuel oils for shipboard use must meet the classifica-
Properties Pour Point C
tion societies' requirements of flash point, limited to
a minimum of 60C (140F).
Table 2 Analysis data for fuels.

08028-0D/H5250/94.08.12

02.16- ES0 - G
Description
Fuel Oil Cleaning 604.30
Page 1 (2) Edition 01H

General
Purification Recommendations. RW/100F) the highest possible temperature 98C
(208F) should be maintained in the centrifuge oil
Fuel oils are always contaminated and should therefore preheater.
be thoroughly cleaned for solid as well as liquid
contaminants before use. The solid contami-nants in The fuel is kept in the centrifuge as long as possible
the fuel are mainly rust, sand, dust and re-finery by adjusting the flow rate through the centrifuge so
catalysts. Liquid contaminants are mainly water, i.e. that it corresponds to the amount of fuel required by
either fresh water or salt water. the engine without excessive re-circulating.
Consequently, the centrifuge should operate for 24
The impurities can cause damage to fuel pumps and hours a day except during necessary cleaning.
fuel valves, can result in increased cylinder liner wear
and deteriorate the exhaust valve seats. Also increased Taking today's fuel qualities into consideration the
fouling of gas ways and turbocharger blends may need for cleaning centrifuges ("shooting frequency")
result from the use of inadequately cleaned fuel oils. should not be underestimated. Correct choice and
adjustment of the regulating screws and/or the gravity
Effective cleaning can only be ensured by means of discs are of special importance for efficient water
a centrifuge. We recommend the capacity of the removal. The centrifuge manual states the disc or
installed centrifuges to be at least according to the screw adjustment which should be chosen on the
centrifuging maker's recommendations. To obtain basis of the specific gravity of the fuel.
optimum cleaning it is of the utmost importance to
operate the centrifuge with as low a viscosity of the Normal practice is to have at least two centrifuges
fuel oil as possible and allow the fuel oil to remain in available for fuel cleaning. Results from experimental
the centrifuge bowl as long time as possible. work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning
Especially for fuels above 180 cST/50C (1500 sec. effect, especially as regards removal of catalyst fines
is achieved when the centrifuges are operated in
series, in purifier/clarifier mode.
Cleaning of H.F.O. by Centrifuging

Therefore - series operation of centrifuges ensuring a


Operating Single centrifuge as purifier.
maximum of safety is a fully accepted alternative to
options Two centrifuges in parallel.
the previously recommended parallel operation,
Two centrifuges in series.
provided the operating capacity of each individual
Optimum operating configurations centrifuge can handle the total amount of fuel required
by the engine, without exceeding the flow rate
Water content Parallel operation recommended by the centrifuge maker for the operating
below 1 % Purifier / Purifier mode in question.
Normal
conditions or
Density at 15C Series operation If the installed centrifuge capacity is on the low side
below 0.991 Purifier + Clarifier corresponding to the specific viscosity of the used
fuel oil and if more than one centrifuge is available,
parallel operation in order to obtain an even lower flow
08028-0D/H5250/94.08.12

Water content
below 1 % Parallel operation rate may be considered. However, in view of the
above results and recommendations serious
Extreme Density at 15C Purifier / Purifier considerations should be given to installing new
conditions below 0.991 equipment in correspondance with today's fuel
qualities and flow recommendation.
High content Series operation
of catalyst fines Purifier + Clarifier For the determination of centrifuging capacity, we

Table 1. Cleaning of HFO.

92.04 - ES0S
604.30 Fuel Oil Cleaning Description
Edition 01H Page 2 (2)

General

generally advise to follow the recommendations of the


centrifuge maker, but the curves on fig. 1, can be used Flow Rate
as a guidance. Related to Rated Capacity of Centrifuge
%
100
A Homogenizer may be installed in the fuel oil system
as a supplement to the centrifuges to homogenize 80
possible water and sludge still present in the fuel after 60
centrifuging. 40
20

Separation Temperature
F C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
100
15 25 45 75 130 cSt/80C

Log scales 30 60 80 180 380 600 cST/50C

200 400 600 1500 3500 6000 sec. RI/100F

Fig. 1. Flowrate through centrifuge related to nominel


capacity of centrifuge.

08028-0D/H5250/94.08.12

92.04 - ES0S
Description
Freshwater System Treatment 604.40
Page 1 (5) Edition 03H

General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as slightly
Cooling System alkaline cleaning agents can be used for the degrea-
sing process, whereas ready-mixed cleaning agents
The engine fresh water must be carefully treated, which involve the risk of fire must obviously not be
maintained and monitored so as to avoid corrosion or used. For descaling with acid, especially products
the formation of deposits which can result in insuffi- based on amino-sulphonic acid, citric acid, and tar-
cient heat transfer, it is necessary to treat the cooling taric acid are recommendable, as these acids are
water. MAN B&W recommend that this treatment is usually obtainable as solid substances, easily solu-
carried out according to the following procedure: ble in water, and do not emit poisonous vapours.

The cleaning agents should not be directly admixed,


Clean the cooling water system. but should be dissolved in water and then added to the
cooling water system.
Fill up with deionized or distilled cooling water
(for example from the freshwater generator) Normally, cleaning can be executed without any
with corrosion inhibitor added. dismantling of the engine. We point out that the water
should be circulated in the engine to achieve the best
Carry out regular checks of the cooling water possible result.
system and the condition of the cooling water.
As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
Observance of these precautions, and correct ven- inspection should be carried out during the cleaning
ting of the system, will reduce service difficulties process. The acid content of the system oil should
caused by the cooling water to a minimum. also be checked immediately after cleaning, and 24
hours afterwards.

Cleaning of the Cooling Water System


Cooling Water - Inhibitors
Before starting the inhibition process, any existing
deposits of lime or rust, or any oil sludge, should be The filling-up with cooling water and the admixture of
removed in order to improve the heat transfer and to the inhibitor is to be carried out directly after the
ensure uniform protection of the surface by means of cleaning in order to prevent formation of rust on the
the inhibitor. cleaned surfaces.

The cleaning should comprise degreasing to remove Raw Water


oil sludge, and descaling with acid afterwards to
remove rust and lime deposits. The formation of lime stone on cylinder liners and in
cylinder heads may reduce the heat transfer, which
Ready-mixed cleaning agents, specially made for will result in unacceptably high temperatures in the
cleaning the cooling water system, can be obtained material.
08028-0D/H5250/94.08.12

from companies specializing in cooling water treat-


ment. These companies offer assistance and control Therefore, it is recommended that deionized or distil-
of the treatment in all major ports. A number of these led water (for example from the freshwater generator)
companies are mentioned on the enclosed list. We is used as cooling water. However, on account of its
point out that the directions given by them should be lack of hardness, this water will be relatively corro-
closely followed. It is of particular importance to flush sive, and a corrosion inhibitor should therefore always
the system completely after cleaning. be added.

00.11- ES1
604.40 Freshwater System Treatment Description
Edition 03H Page 2 (5)

General

If deionized or distilled water cannot be obtained, Checking of the Cooling Water System and
normal drinking water can be used in exceptional the Sooling Water during Service
cases. If so, the total hardness of the water must not
exceed 9 dH (German hardness degrees). The chlo- If the cooling water is contaminated during service,
ride, chlorine, sulphate, and silicate contents are also sludge or deposits may form. The condition of the
to be checked. These contents should not exceed the cooling water system should therefore be regularly
following values: checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces or, if necessary, the entire system
Chlorine 10 ppm (10 mg/litre) should be cleaned.
Sulphate 100 ppm (100 mg/litre)
Silicate 150 ppm (150 mg/litre) According to experience, a zinc galvanized coating in
the freshwater cooling system is often very suscep-
There should be no sulphide and ammonia content. tible to corrosion, which results in heavy formation of
Rain water must not be used, as it may be heavily sludge, even if the cooling water is correctly inhibited.
contaminated. The initial descaling with acid will, to a great extent,
remove the galvanized coating. Generally, therefore,
It should be noted that softening of water does not we advise against the use of galvanized piping in the
reduce its sulphate and chloride contents. freshwater cooling system.

Corrosion Inhibitors The quality of the cooling water is to be checked


regularly, if possible once a week. Basically the
To protect freshwater cooling systems in marine inhibitor concentration, the pH value and the chloride
diesel engines against corrosion, various types of concentration should be in accordance with limits
inhibitors are available. stated by inhibitor manufacturer. For this purpose the
inhibitor manifactures normally supply simple test
Generally, only nitrite-borate based inhibitors are kits.
recommended.
As a general guidance values the pH value should be
A number of the products marketed by major compa- 7-10 measured at 20 C and the chloride concentra-
nies are specified on the enclosed list, together with tion should not exceed 50 ppm (50 mg/litre).
the necessary dosages and admixing procedures.
We recommend that these directions are strictly The water sample for these tests is to be taken from
observed. the circulating system, and not from the expansion
tank or the pipe leading to it.
Treatment of the cooling water with inhibting oils is not
recommended, as such treatment involves the risk of The concentration of inhibitor must under no
oil adhering to the heat transmitting surfaces. circumstances be allowed to fall below that re-
commended by the producer, as this would in-
Chromate inhibitors must not be used in plants crease the risk of corrosion.
08028-0D/H5250/94.08.12

connected to a freshwater generator.


A clear record of all measuring results should be kept,
Evaporated cooling water is to be replaced with so that the actual condition and trend of the system
noninhibited water, whereas a loss of water through may be currently ascertained and evaluated.
leakage must be replaced with inhibited water.
A sudden or gradual increase in the chloride content
When overhauling individual cylinders, a new dosage of the cooling water may be indicative of salt water
of inhibitor must, if necessary, be added im-mediately leakages. Such leakages are to be traced and repai-
after completing the job. red at the first opportunity.

00.11- ES1
Description
Freshwater System Treatment 604.40
Page 3 (5) Edition 03H

General

A chloride content in the cooling water higher than the The cooling water system must not be kept under
50 ppm specified might, in exceptional cases be pressure.
tolerated. However, in that case the upper limit speci-
fied by the individual inhibitor supplier must not be Check, and repair any leaks.
exceed.
Drain the system and fill up completely with clean tap
A clear record of all measuring results should be kept, water, in order to flush out any oil or grease from the
so that the actual condition and trend of the system tank.
may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual degrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased by Descaling with Acid Solution
adding inhibtor; however, if major quantities are ne-
cessary, the water should be replaced. Fill up with clean tap water and heat to 70-75 C.

Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound in
sent ashore for laboratory analysis, in particular to a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the acid
compound, while stirring vigorously. Then fill the drum
up completely with hot water while continuing to stir
Cleaning and Inhibiting Procedure (e.g. using a steam hose).

The engine must not be running during the cleaning Be careful - use protective spectacles and gloves.
procedure, as this may involve the risk of overheating
when draining. For engines which have been treated before the trial
trip, the lowest concentration recommended by the
supplier will normally be sufficient.
Degreasing
For untreated engines, a higher concentration - de-
Use clean tap water for filling-up. The cooling water in pending on the condition of the cooling system - will
the system can be used, if it does not contain normally be necessary.
inhibitors.
Drain some water from the system and add the acid
Heat the water to 60 C and circulate the water solution via the expansion tank.
continuously.
The cooling water system must not be put under
Drain to lowest water level in expansion tank. pressure.
08028-0D/H5250/94.08.12

Add the amount of degreasing chemical specified by Keep the temperature of the water between 70 C and
the supplier, preferably from the suction side of the 75 C, and circulate it constantly. The duration of the
freshwater pump. treatment will depend on the degree of fouling. Nor-
mally, the shortest time recommended by the supplier
Drain to lowest water level in the expansion tank will be sufficient for engines which are treated before
directly afterwards. the trial trip. For untreated engines, a longer time must
be reckoned with. Check every hour, for example with
Circulate the cleaning chemical for the period speci- pH-paper, that the acid in the solution has not been
fied by the supplier. used up.

00.11- ES1
604.40 Freshwater System Treatment Description
Edition 03H Page 4 (5)

General

A number of descaling preparations contain colour Adding of Inhibitors


indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution Fill up the cooling water system with water from the
can be added, in which case, the weakest recom- evaporator to the lowest water level in the expansion
mended concentration should be used. tank.

The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum solu- Add the solution via the expansion tank to the sys-
bility. tem. Then fill up to normal water level with water from
the evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized with Allow the engine to run for not less than 24 hours to
clean tap water containing 10 kg soda per ton of water. ensure that a stable protection of the cooling surfaces
Circulate the mixture for 30 minutes, then drain and is formed.
flush the system.
Subsequently, test the cooling water with a test kit
The cooling water system must not be put under (available from the inhibitor supplier) to ensure that an
pressure. adequate inhibitor concentration has been obtained.

Continue to flush until water used is neutral (pH This should be checked every week.
approx. 7).
The acid content of the system oil is to be checked
directly after the descaling with acid, and again 24
hours afterwards.

08028-0D/H5250/94.08.12

00.11- ES1
Description
Freshwater System Treatment 604.40
Page 5 (5) Edition 03H

General

Nitrite-borate corrosion inhibitors


for cooling water treatment

Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*

Castrol Limited Castrol Powder 3 kg/1000 l


Swindon Solvex WT4
Wiltshire, England Castrol Liquid 20 l/1000 l
Solvex WT2

Drew Ameriod DEWT-NC Powder 3.2 kg/1000 l


Marine Liquidewt Liquid 8 l/1000 l
Boonton, N.J./U.S.A Maxiguard Liquid 16 l/1000 l

Houseman Scandinavia Cooltreat 651 Liquid 5 l/1000 l


3660 Stenlse
Denmark Cooltreat 652 Liquid 5 l/1000 l

Nalfleet Marine Chemicals Nalfleet EWT Liq


Northwich, (9-108) Liquid 3 l/1000 l
Cheshire CW8DX, England Nalfleet EWT 9-131C Liquid 10 l/1000 l
Nalfleet EWT 9-111 Liquid 10 l/1000 l
Nalcool 2000 Liquid 10 l/1000 l

Rohm & Haas RD11 DIA PROSIM Powder 3 kg/1000 l


(ex Duolite) RD25 DIA PROSIM Liquid 50 l/1000 l
Paris, France

Unitor Rochem Dieselguard NB Powder 3 kg/1000 l


Marine Chemicals Rocor NB Liquid Liquid 10 l/1000 l
Oslo, Norway

* Initial dosage may be larger


08028-0D/H5250/94.08.12

The list is for guidance only and must not be The suppliers are listed in alpabetical order.
considered complete. We undertake no responsibil-
ity for difficulties that might be caused by these or Suitable cleaners can normally be supplied by these
other water inhibitos/chemicals. firms.

00.11- ES1
Your Notes :

08031-0D/H5250/94.09.07
Index
Page 1(1) Cylinder Head 605

L28/32H
Description

Cylinder head -------------------------------------------------------------------------------------605. 01 (14H)

Working Card

Dismantling of cylinder head ------------------------------------------------------------------605- 01 .00 (01H)


Inspection of inlet valve, exhaust valve and valve guide ------------------------------ 605- 01 .05 (06H)
Reconditioning of valve spindle seat and valve seat ring ----------------------------- 605- 01 .10 (01H)
Valve rotator -------------------------------------------------------------------------------------- 605- 01 .15 (01H)
Replacement of valve guide ------------------------------------------------------------------ 605- 01 .20 (05H)
Safety valve ---------------------------------------------------------------------------------------605- 01 .25 (04H)
Indicator valve ------------------------------------------------------------------------------------605- 01 .26 (02H)
Replacement of sleeve for fuel injector ---------------------------------------------------- 605- 01 .30 (04H)
Replacement of valve seat ring --------------------------------------------------------------605- 01 .35 (06H)
Mounting of cylinder head ---------------------------------------------------------------------605- 01 .40 (06H)
Inspection of cylinder head cooling water space ---------------------------------------- 605- 01 .45 (01H)

Plates

Cylinder head --------------------------------------------------------------------------------------------60501- 13H


Valve spindles and valve gear ---------------------------------------------------------------------- 60502- 21H
Safety valve and Indicator valve --------------------------------------------------------------------60508- 11H
Cylinder head, top cover ------------------------------------------------------------------------------60510- 12H

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Cylinder Head 605.01
Page 1 (1)
Edition 14H

L/V28/32H

General Valve Rotator

The cylinder head is made of cast iron and is The retainer body of the valve rotator (1) has a
tightened to form a gas-tight seal against a sealing number of pockets, arranged in circumferential
ring on the cylinder liner by means of 6 nuts and 6 direction, with balls that are forced against the upper
studs, which are screwed into the engine frame. The end of an inclined race by coil springs acting in
nuts are tightened by means of hydraulic jacks. tangential direction. The ball race (3) serves as ball
track in the opposite direction. The spring washer (4)
Each cylinder head is equipped with two air inlet and seats against the inner rim of the retainer body and
two exhaust valves which are actuated by rocker is encased by the seating collar (5) which overlaps
arms running in bearings on a shaft supported in a it. The assembled valve rotator is held together,
bracket on top of the cylinder head. when removed, by the retaining ring (6).

The fuel injection valve (see section 614) is located


in a interchangeable sleeve in the center of the
cylinder head.
7
Furthermore the cylinder head is equipped with an
indicator valve and a safety valve. 1
2
3
The cylinder head has a screwed-on coaming which
encloses the valves. The coaming is closed with a
top cover and thus provides an oil tight enclosure for 4
the valve gear. The coaming is equipped with an 5
inspection cover for the rotators.
6

1 Retainer body 4 Spring washer


Air Inlet and Exhaust Valves 2 Balls 5 Seating collar
3 Ball race 6 Retainer ring
The inlet valve spindles are identical to the exhaust 7 Valve spindle
spindles.
Fig. 1. Valve rotator
The valves are made of heat-resistant material.
Hard metal is welded on to the valve spindle seats
to avoid depressions by combustion particles.
As the valve starts to open, the increasing valve
The valve spindles are fitted with valve rotators spring-load causes the spring washer to flatten, and
which turn the spindles a little each time the valves the load applied to the balls in the pockets of the
open. retainer body forces the balls in the ball race to roll
down the inclined races. The transfer of the reaction
08028-0D/H5250/94.08.12

The cylinder head is equipped with interchangeable load of the ball race to the spring washer reduces the
seat rings and valve guides for inlet and exhaust reaction load of the spring washer on the inner rim
valves.The valve seat rings and valve guides for of the retainer body. Ball race, spring washer,
inlet and exhaust valves are identical. seating collar and valve springs are, however, force-
locked by friction grip. The reaction load of the balls
The seat rings are made of heat-resistant steel, on the inclined races induces rotation to the retainer
directly hardened on the seating surface and the seat body and valve with relation to the seating collar and
rings are directly water cooled in order to assure low the valve springs. As the valve closes, load is
valve temperature. released from the spring washer and thus from the
balls, allowing them to be returned to their original
positions without rolling by the tangential force of the
coil springs.

90.44 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Dismantling of Cylinder Head 605-01.00
Page 1 (2) 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 and/ 62014 15
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
08028-0D/H5250/94.08.12

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

L/V28/32H

1) Open the drain cock and vent cock for cooling 8) Remove the exhaust pipe flange screws.
water.
9) Remove the cylinder head nuts, as shown, by
2) Take off the rocker arm top cover. means of hydraulic jacks, see working card 620-
01.05.
3) Take off the cover which gives access to the
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
cylinder head away.
5) Disconnect the cooling oil pipes, (inlet and
outlet.

6) Disconnect the rocker arm lubricating oil pipe.


V28/32H
7) Remove the thermometer attachment branch L28/32H
(cooling water outlet pipe).

Fig. 2

Fig. 1
08028-0D/H5250/94.08.12

91.45 - ES0S
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, inspec-


tion 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
08028-0D/H5250/94.08.12

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


the nut (B), after which the cone rings can be
re-moved, see fig 3.

08028-0D/H5250/94.08.12

Fig 1 Fig 3

00.43 - ES0
Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05
Page 3 (3)
Valve Guide Edition 04H

L+V28/32H

6) Release the springs again. Remove the nut (B) Inspection of valve guide
and the traverse (C). Now valve rotator and
springs can be removed. 10) Too much clearance between valve spindle
and spindle guide may cause increased lub. oil
7) Remove the supporting devices under the consumption, fouling up of the spindle guide
work table and take out the valve spindle. and thus give the risk of a sticking valve
spindle.
8) Repeat point 4 - 7 to remove the two other
valve spindles. Too much clearance also means insufficient
guid-ance of the valve spindle, and thus bad
alignment between spindle head and valve
Inspection of Valves/Valve Seats seat ring. In connection with overhaul of the
cylinder head, the valve spindle guides should
9) A slight grinding of valve/valve seat can be be cleaned, inspected and measured for wear.
carried out by means of the handle as shown, If the inner diameter of the valve spindle guide
see fig 4. exceeds the tolerance, see page 600.35 the
valve spindle guide must be replaced. See
If the valve seat is heavily burnt or scarred, it should working card 605-01.20.
be ground using the valve seat grinder according to
working card 605-01.10. 11) For mounting of valve spindle follow the
instructions in point 4 - 7 in reversed order.
08028-0D/H5250/94.08.12

Fig 4 Fig 5

00.43 - ES0
Your Notes :

08031-0D/H5250/94.09.07
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


08028-0D/H5250/94.08.12

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
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 pilot installed, see working card 605-01.35
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 of
1) The seating surface itself is ground with a feed the turning latch.
at an angle "A" of 30 0,10.
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
Carry out the final grinding with a feed in direction at an angel "A" of 30 0.0,25.
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.
"A" 30 0,10
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.

08028-0D/H5250/94.08.12

"H"1
Fig. 1.
0
"A" 30 0,25

2) Normally the valve seat ring can be recondi-


tioned several times.
Fig. 2.

91.45 - ES0S
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.
08028-0D/H5250/94.08.12

91.45 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Valve Rotator 605-01.15
Page 1 (2) 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


08028-0D/H5250/94.08.12

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
605-01.15 Valve Rotator Working Card
Edition 01H 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 oil
Valve rotators should be cleaned and inspected for 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.
08028-0D/H5250/94.08.12

91.45 - ESOS
Working Card
Replacement of Valve Guide 605-01.20
Page1 (2) 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


08028-0D/H5250/94.08.12

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
605-01.20 Replacement of Valve Guide Working Card
Edition 05H 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. -70C 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 bot- against the cylinder head, by knocking slightly
tom 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
08028-0D/H5250/94.08.12

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, used for this purpose.
carefully clean the bore of the cylinder head
and inspect for marks that can prvent mounting 5) For mounting of valve spindle, see working
of a new valve guide. card 605-01.05.

00.43 -ESO
Working Card
Safety Valve 605-01.25
Page 1 (3) 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:

Dismantling, inspection, reassembling and


pressure testing of safety valve. Hand tools:

Open end spanner, 32 mm.


Small hammer.
Copaslip.
Starting position:

Related procedure:

Indicator valve 605-01.26

Man power:
08028-0D/H5250/94.08.12

Working time : 1 hour Replacement and wearing parts:


Capacity : 1 man
Plate no Item no Qty. /

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
605-01.25 Safety Valve Working Card
Edition 04H 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
Note: Do not attempt to stop a safety valve from sequence 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.

Scrap the valve.


08028-0D/H5250/94.08.12

1.2 Clamp valve in vice. below 135 bar or

1.3 Unscrew cap nut (1). Lap the valve cone and
seat.
1.4 Remove pressure spring (3), valve spindle
(4) and valve cone (6).

1.5 Inspect and carefully clean all parts and


condition valve, if necessary.

96.27 - ES0S
Working Card
Safety Valve 605-01.25
Page 3 (3) 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 pres-
sure. 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.

5. Mounting of Safety Valve


Not OK The valve must be
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.


08028-0D/H5250/94.08.12

96.27 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Indicator Valve 605-01.26
Page 1 (2) 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:
08028-0D/H5250/94.08.12

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
605-01.26 Indicator Valve Working Card
Edition 02H 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
3. Clean and lubricate all components before 2. Connecting piece
remounting.

4. Ensure that the spindle is in "OPEN" position


when assembling the valve. Fig 1 Indicator valve.

NOTE: Otherwise cone and seat may be damaged.

08028-0D/H5250/94.08.12

94.26 - ES0S
Working Card
Replacement of Sleeve for Fuel Injector 605-01.30
Page 1 (2) 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 dis-
mounted from engine, 605-01.00
The fuel injector has been removed, 614-01.10

Related procedure

Mounting of fuel valve, 614-01.10


08028-0D/H5250/94.08.12

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
605-01.30 Replacement of Sleeve for Fuel Injector Working Card
Edition 04H 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 bore Snap ring
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.
08028-0D/H5250/94.08.12

00.43 - ES0
Working Card
Replacement of Valve Seat Ring 605-01.35
Page 1 (4) 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


08028-0D/H5250/94.08.12

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
605-01.35 Replacement of Valve Seat Ring Working Card
Edition 06H 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 (5)
criteria, the seat ring has to be replaced. 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 seat
means of a special extractor tool set somprising ring. The stud (1) is then screwed in until it rests
following components, see fig 1. in the valve guide.

9
3

5
10
6

8
08028-0D/H5250/94.08.12

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)
Fig 1
and collar nut hexagon (2), see fig 1. The
hydraulic jack is the one used for main bearing
caps.

00.43 - ES0
Working Card
Replacement of Valve Seat Ring 605-01.35
Page 3 (4) Edition 06H

L+V28/32H

3) By pumping up the pack, see working card


620-01.05 for the use of hydraulic tools, the 3) To facilitate mounting of the valve seat ring it is
valve seat is pressed out max. 6 mm, and the cooled down, however to no more than -25C
pressure is released again. The collar nut or the O-ring can be damaged.
hexagon is tightenied and the operation is
continued until the valve seat ring can be 4) Place the O-ring on the valve seat ring and
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


Coat with
bore must be cleaned thoroughly and inspected
loctite 648
for marks. Marks that can hinder mounting of
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
1 washer with screw is screwed tight.

3
4
08028-0D/H5250/94.08.12

1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar

Fig 5

Fig 3

00.43 - ES0
605-01.35 Replacement of Valve Seat Ring Working Card
Edition 06H 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.

08028-0D/H5250/94.08.12

00.43 - ES0
Working Card
Mounting of Cylinder Head 605-01.40
Page 1 (2) 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


08028-0D/H5250/94.08.12

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
605-01.40 Mounting of Cylinder Head Working Card
Edition 06H 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 01.05.
that 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 pipe.
08028-0D/H5250/94.08.12

4) Make sure that the nuts run easily on the


threads and that they bear on their entire 10) Prior to start up check for leakages, and after
contact surfaces. start up check for leakages and oil flow.

5) Coat threads and contact faces with copaslip 11) Mount the cover for rocker arm and the front
before fitting the nuts. cover for fuel pump.

6) Screw nuts onto the studs and tighten lightly


with the tommy bar.

00.44 - ES0
Working Card
Inspection of Cylinder Head Cooling Water Space 605-01.45
Page 1 (2) 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 : Hour


08028-0D/H5250/94.08.12

Capacity : 1 man Replacement and wearing parts:

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
605-01.45 Inspection of Cylinder Head Cooling Water Space Working Card
Edition 01H 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
5) Should the cylinder head cooling water space water, inlet
contrary to expectation be blocked with deposits,
contact MAN B&W Diesel, Holeby for further instruc-
tions. Fig. 1. Cylinder Head

08028-0D/H5250/94.08.12

93.20 - ES0S
Plate
Page 1 (2) Cylinder Head 60501-13H

L/V28/32H
08028-0D/H5250/94.08.12

91.18-ES0S
Plate
60501-13H Cylinder Head Page 2 (2)

L+V28/32H

Item Item
Qty. Designation Qty. Designation
No. No.
01 4/C O-ring
02 4/C Valve Guide
04 1/C Cylinder Head, as Plate 60501
05 6/C Plug screw
06 6/C Gasket
08 2/C Nut
09 2/C Distance pipe
10 2/C Stud
11 2/C Trust collar
12 4/C Plug screw
13 4/C Gasket
14 1/C Snap ring
15 1/C Sleeve
16 1/C O-ring
19 8/C Nut
20 8/C Stud
21 4/C Stud
22 4/C Spring pin
24 2/C Plug screw
25 2/C Screw
26 2/C Coupling
27 4/C O-ring
28 4/C Valve seat ring, (inlet and exhaust)
29 2/C O-ring
30 2/C Plug screw

08031-0D/H5250/94.09.07

When ordering spare parts, see also page 600.50.

* = Only available as part of a spare parts kit.


Qty./C = Qty./Cylinder

91.18-ES0S
Plate
Page 1 (2) Valve Spindles and Valve Gear 60502-21H

18
L+V28/32H
19
20
21
32
03

27
28
29
01
34
30
02
35
36 31
32 13
19
04
14
05
06
06 07
07

15

16
08 17
08
09
09
10 10

11
11
33
08028-0D/H5250/94.08.12

22/23

25

26

12
12

97.44 - ES0S
Plate
60502-21H Valve Spindles and Valve Gear Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

01 2/C Thrust piece Trykstykke 29 2/C Thrust screw Trykskrue

02 2/C Nut Mtrik 30 2/C Bearing bush Lejebsning

03 4/C Plug screw Propskrue 31 2/C Thrust pin Trykskrue

04 1/C Valve bridge, inlet Ventilbro, indstrmning 32 /I Loctite 572 Loctite 572

05 2/C Thrust screw Trykskrue 33 1/C Cylinder head as Cylinderdksel som


Plate 60501 + Plate 60501 +
06 4/C Circlip Fjederring Plate 60502 Plate 60502

07 4/C Thrust piece Trykstykke 34 1/C Valve bridge, inlet Ventilbro, indstrmning
complete incl. item komplet inkl. item
08 4/C Conical ring in 2/2 Konisk ring 2/2 01, 02, 04, 05, 06, 07, 01, 02, 04, 05, 06, 07,
14, 15, 16 and 17 14, 15, 16 og 17
09 4/C Rotocap, complete Rotationsgiver, komplet
incl. item 22, 23, 25, 26 inkl. item 22, 23, 25, 26 35 1/C Valve bridge, exhaust Ventilbro, udstdning
complete incl. item komplet inkl. item
10 4/C Inner spring Indvendig fjeder 01, 02, 05, 06, 07, 13, 01, 02, 05, 06, 07, 13,
14, 15, 16 and 17 14, 15, 16 og 17
11 4/C Outer spring Udvendig fjeder
36 4/C Screw Skrue
12 4/C Valve spindle, inlet Ventilspindel, inds.
and outlet og uds.

13 1/C Valve bridge,exhaust Ventilbro, udstdning

14 2/C Thrust piece Trykstykke

15 2/C Spring Fjeder

16 2/C Ball guide Kuglestyr

17 2/C Securing ring Sikring

18 4/C Spring pin Spndstift

19 4/C Rocker arm Buk for vippearm


Bracket

20 2/C Rocker arm shaft Aksel for vippearm

21 2/C Rocker arm, compl. Vippearm, komplet


(Item 03, 27, 28, 29, (Item 03, 27, 28, 29
30, 31) 30, 31)

22 24/C Spring Fjeder

23 24/C Ball Kugle


08028-0D/H5250/94.08.12

25 4/C Spring washer Fjederskive

26 4/C Retainer ring Lsering

27 2/C Nut Mtrik

28 2/C Rocker arm Vippearm

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

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./ = Qty./Individual Antal/I = Antal/Individuelt

97.44 - ES0S
Plate
Page 1 (2) Safety Valve and Indicator Valve 60508-11H

L+V28/32H

18

16

17

15

94.25 - ES0S
Plate
60508-11H Safety Valve and Indicator Valve Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

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 Dkselmtrik

28* 1/C Split pin Fjedernot

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

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

94.25 - ES0S
Plate
Page 1 (2) Cylinder Head, Top Cover 60510-12H

L+V28/32H

01

02

05

06

07

15
13

08
09
10

11

93.47 - ES0S
Plate
60510-12H Cylinder Head, Top Cover Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

01 4/C Handle Hndtag

02 4/C O-ring O-ring

05 4/C Nut Mtrik

06 1/C Top cover Topdksel

07 1/C Top cover, compl. Topdksel, 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

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

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

93.47 - ES0S
Index
Page 1(1) Piston, Connecting Rod and Cylinder Liner 606

L28/32H
Description

Piston, connecting rod and cylinder liner -------------------------------------------------- 606. 01 (10H)

Working Card

Dismounting of piston and connecting rod ------------------------------------------------ 606- 01 .00 (01S)


Separation of piston and connecting rod -------------------------------------------------- 606- 01 .05 (03S)
Piston (with flame ring) -------------------------------------------------------------------------606- 01 .10 (13H)
Connecting rod -----------------------------------------------------------------------------------606- 01 .15 (04H)
Criteria for replacement of connecting rod big-end and main bearing shells -----606- 01 .16 (02H)
Mounting of piston and connecting rod ---------------------------------------------------- 606- 01 .20 (01S)
Hydraulic tightening of connecting rod screws -------------------------------------------606- 01 .25 (04H)
In-situ inspection of connecting rod big-end bearing ----------------------------------- 606- 01 .30 (01S)
Inspection and honing of cylinder liner -----------------------------------------------------606- 01 .35 (01H)
Replacement of cylinder liner ---------------------------------------------------------------- 606- 01 .40 (01H)
Grinding of seal face on cylinder liner and cylinder head ----------------------------- 606- 01 .45 (01H)
Dismounting of piston and cylinder liner at low overhaul height ---------------------606- 01 .50 (01H)

Plates

Piston and connecting rod (hydraulic tightened) ------------------------------------------------60601- 34H


Cylinder liner and water guide jacket --------------------------------------------------------------60610- 19S

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Piston, Connecting Rod and Cylinder Liner 606.01
Page 1 (1)
Edition 10H

L/V28/32H

Piston

The piston, which is oil-cooled and of the monobloc


type made of nodular cast iron, is equipped with 3 The big-end bearing is of trimetal type, i.e. steel
compression rings and 1 scraper ring. shells lined with tin-aluminium or lead-bronze coated
with a running layer. Design as plain type or rillen-
By the use of a combination of compression rings type. The bearing shells are of the precision type and
with different barrel-shaped profiles and chrome- are therefore to be fitted without scraping or any
plated running surface on all rings, the piston ring other kind of adaption.
pack is optimized for maximum sealing effect and
minimum wear rate. The small-end bearing is of trimetal type and is
pressed into the connecting rod.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transport
and thus the cooling effect is based on the shaker Cylinder Liner
effect arising during the piston movement. As coo-
ling oil is used oil from the engine's lubricating oil The cylinder liner is made of fine-grained, pearlite
system. cast iron and is fitted in a bore in the engine frame.
Between the liner and the cylinder head and between
the liner and the frame there are fitted replaceable
Piston Pin cast iron sealing rings. The liner is clamped by the
cylinder head and is guided by a bore at the bottom
The piston pin is fully floating which means that it can of the cooling water space of the engine frame. The
turn freely in the pin bosses of the piston as well as liner can thus expand freely downwards, when
in the connecting rod bush. The piston pin is upwords heated during the running of the engine. Sealing for
in place in axial direction by two circlips (seeger the cooling water is obtained by means of silicone
rings). rubber rings which are fitted in grooves machined in
the liner.

Connecting Rod Tell-tale borings in the frame, starting from a level


between the sealing rings and leading to the exterior
The connecting rod is die-forged. The big-end has an will reveal any sealing malfunction by sign of leaking
inclined joint in order to facilitate the piston and water or lubricating oil mist.
connecting rod assembly to be withdrawn up through
the cylinder liner. The joint faces on connecting rod
and bearing cap are serrated to ensure precise
location and to prevent relative movement of the
parts.
08028-0D/H5250/94.08.12

90.43 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Separation of Piston and Connecting Rod 606-01.05
Page 1 (2) Edition 03H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 01 L28/32H
Shut-off fuel oil 62006 03 L28/32H
Shut-off cooling oil 62006 05 V28/32H
Stopped lub. oil circul. 62006 20

Description:

Separation of piston and connecting rod for


inspection or/and overhaul.
Assembly of the piston and connecting rod after
inspection or/and overhaul.

Starting position: Hand tools:

Piston and connecting rod are dismounted Open end spanner, 32 mm.
from engine, 606-01.00 Wooden wedge, 2 pieces.
Wooden support.
Wire.

Related procedure:

Inspection or/and overhaul of piston, 606-01.10


Inspection or/and overhaul of
connecting rod, 606-01.15
Inspection of connecting rod
big-end bearing, 606-01.16
08028-0D/H5250/94.08.12

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)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

92.08 - ES0S
606-01.05 Separation of Piston and Connecting Rod Working Card
Edition 03H Page 2 (2)

L/V28/32H

Separation of the Piston and Connecting Rod: Wooden wedges should be used to prevent the
connecting rod from swinging out and thus impact
1) Land the piston and connecting rod carefully the piston skirt during the lifting into upright position.
on wooden support to prevent damage of piston and
scraper ring, see fig. 1 or 2. 5) Place a wire around the big-end of the connec-
ting rod, attach a tackle and tighten the wire rope,
see fig. 3

6) Take out the securing ring, (seeger circlips),


push out the piston pin and lift the connecting rod
away.

Fig. 1. L28/32H

2) The bearing cap should be mounted with the


screws tightened only by hand, in order to protect the
serrated joint faces during handling of the assembly,
see fig. 1 or 2.

Fig. 3.

Assembly of the Piston and Connecting Rod.


08028-0D/H5250/94.08.12

Fig. 2. V28/32H

7) For assembly of the piston and connecting rod,


see point 1-6 in opposite direction.
3) Remove the shackle and eye screw/lifting tool
from the piston crown, see fig. 1 or 2.
8) Lubricate the piston pin before assembling.
4) Place the piston and connecting rod assembly
in upright position resting on the top face of the piston
crown, see fig. 3.

92.08 - ES0S
Working Card
Separation of Piston and Connecting Rod 606-01.05
Page 1 (2) Edition 03S

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
62006 01 L28/32H
Shut-off cooling water 62006 03 L28/32H
Shut-off fuel oil 62006 05 V28/32H
Shut-off cooling oil 62006 20
Stopped lub. oil circul.

Description:

Separation of piston and connecting rod for


inspection or/and overhaul.
Assembly of the piston and connecting rod after
inspection or/and overhaul.

Starting position: Hand tools:

Piston and connecting rod are dismounted Open end spanner, 32 mm.
from engine, 606-01.00 Wooden wedge, 2 pieces.
Wooden support.
Wire.

Related procedure:

Inspection or/and overhaul of


piston, 606-01.10
Inspection or/and overhaul of
connecting rod, 606-01.15
Inspection of connecting rod
big-end bearing, 606-01.16

Man power: Replacement and wearing parts:


08028-0D/H5250/94.08.12

Working time : 1/4 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)

94.47-ES0U
606-01.05 Separation of Piston and Connecting Rod Working Card
Edition 03S Page 2 (2)

L/V28/32H

Separation of the Piston and Connecting Wooden wedges should be used to prevent
Rod: the connecting rod from swinging out and thus
impact the piston skirt during the lifting into
1) Land the piston and connecting rod care- upright position.
fully on wooden support to prevent damage of
piston and scraper ring, see fig. 1 or 2. 5) Place a wire around the big-end of the
connecting rod, attach a tackle and tighten the
wire rope, see fig.3

6) Take out the securing ring, (seeger


circlips), push out the piston pin and lift the
connecting rod away.

Fig.1. L28/32H

2) Tighten the screw and fasten the lower


part bearing cap with the nuts by hand. in
order to protect the serrated joint faces during
handling of the assembly, see fig. 1 or 2.

Fig.3.
Fig.2. V28/32H
08031-0D/H5250/94.09.07

Assembly of the Piston and Connecting


3) Remove the shackle and eye screw/lifting Rod.
tool from the piston crown, see fig. 1 or 2.
7) For assembly of the piston and connecting
4) Place the piston and connecting rod rod, see point 1-6 in opposite direction.
assembly in upright position resting on the top
face of the piston crown, see fig.3. 8) Lubricate the piston pin before assembling

94.47-ES0U
Working Card
Piston (with flame ring) 606-01.10
Page 1 (4)
Edition 13H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note.


Shut-off starting air
Shut-off cooling water 62006 13
Shut-off fuel oil 62006 15
Shut-off cooling oil 62006 16
Stopped lub. oil circul.

Description Hand tools

Cleaning and inspection of piston. Control of Tools for cleaning of piston, steel brush,
piston ring, scraper ring and ring grooves. scraper etc.

Starting position

Piston has been dismantlet from


connecting rod 606-01.05

Related procedure

Mounting of piston and


connecting rod 606-01.20
08028-0D/H5250/94.08.12

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)

03.19 - ES0
606-01.10 Piston (with flame ring) Working Card
Edition 13H Page 2 (4)

L+V28/32H

Removal of Piston Ring Inspection of Piston

For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to
the rings should be used. determine if reuse is acceptable, see page 3.

Straps to expand the ring gap or tools working on the 3) Clean the piston outside and inside.
same principle must not be used, as this would result
in permanent deformation which might cause blow- 4) Inspect the piston ring and scraper ring grooves
by or broken rings. for wear, see page 3.

08028-0D/H5250/94.08.12

03.19 - ES0
Working Card
Piston (with flame ring) 606-01.10
Page 3 (4)
Edition 13H

L+V28/32H
The piston has to be scrapped if:
Piston and oil New ring
Ring grooves.
scraper ring. grooves.
A) The wear limit on the testing mandrel is ex- Max. wear limit.
Nominal size. Tolerances.
ceeded, see fig 1A
Piston ring New +0.18
or 5.0 mm 5.43 mm
no 1 5.0 mm +0.16
B) The clearance between the new piston/scraper
Piston ring New +0.14
ring and ring groove is exceeded, see fig 1B. 5.0 mm 5.43 mm
no 2 5.0 mm +0.12

Piston ring New +0.14


Note: At each piston overhaul: 5.0 mm 5.43 mm
no 3 4.95 mm +0.12
- The piston and scraper ring must be ex-
New +0.12
changed. Scraper ring 8.0 mm 8.43 mm
8.0 mm +0.10
- The cylinder liner must be honed accord-
ing to the instructions. Table 1 Nominal size, new ring groove tolerance and wear
limit for ring grooves

A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove

If the wear limit (2 mm mark) on the testing


mandrel is exceeded, the specified max. wear
limits are exceeded, and the piston must be
scrapped.

0.45

Wear limit line.

Maximum vertical clearance


between new piston ring/scraper
ring and ring groove: 0.45 mm.

The handle is marked


with the nominal size.
08028-0D/H5250/94.08.12

Fig 1 Wear limits for ring grooves

03.19 - ES0
606-01.10 Piston (with flame ring) Working Card
Edition 13H Page 4 (4)

L+V28/32H

Position of Piston and Scraper Rings

Piston Ring No 1:
marked with ident. no
"GOE CK36 TOP K,
1693961-4".

Piston Ring No 2:
marked with ident. no
"GOE TOP, 1678572-6".

Piston Ring No 3:
marked with ident. no
"GOE TOP, 1678573-8".

Scraper ring:
marked with ident. no
"GOE, 1678575-1".

Marking of Piston and Scraper Rings


08028-0D/H5250/94.08.12

Marking

Identification marks to face upwards against the piston crown when mounted.
Note: The marking may include other figures than mentioned above, for instance trade mark and
production codes.

03.19 - ES0
Working Card
Connecting Rod 606-01.15
Page 1 (4) Edition 04H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 28 140-760 Nm
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Cleaning, inspection and test measurement of


connecting rod.

Hand tools:

Starting position: Inside micrometer (242 mm).


Feeler gauge 0,15 - 0,20 mm.
Connecting rod has been
dismantlet from piston, 606-01.05

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
08028-0D/H5250/94.08.12

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)

97.24 - ES0S
606-01.15 Connecting Rod Working Card
Edition 04H Page 2 (4)

L/V28/32H

Cleaning and Inspection of Big-end Bore. Screws, which are damaged as mentioned above or
cannot be turned into the threaded holes by hand,
The connecting rod is cleaned on all machined must be renewed.
surfaces.

The serrated joint faces and threaded screw holes Measurement of Big-end Bore.
are to be degreased with a volatile solvent and blown
dry with working air.

The serrated joint faces are inspected.

The serration on the connecting rod may, due to


relative movements between the mating surfaces,
show damages in form of wear marks and pittings or
even cracks in highly loaded zones.

Observed damages should be registered in the


schem "Connecting Rod Inspection". See page 4.

Wear marks are visible but not appreciable at a


fingernail. Pittings are not only visible but also
noticeable at a fingernail.

Single distinctly raised spots caused by pitting should


Fig. 1. Point of measurement
be gently smoothed by careful, local treatment with
a file.
For check of roundness the big-end bore has to be
The serration on the connecting rod and on the measured in a condition, where the connecting rod is
bearing cap can be damaged by improper handling mounted with the bearing cap but without bearing
during dismounting, transport and overhaul work. shells, and the connecting rod screws are tightened
up with the prescribed torque, see working card 606-
Note ! The connecting rod and bearing cap must 01.25.
therefore be handled with care.
Note ! The ident no. on the connecting rod and the
Single dent marks caused by impact can be rectified bearing cap, must always be the same, see fig. 3.
by gentle and careful local treatment with a file.
Measurements must be taken 30 mm from seration
In case of damage of the serration, reuse must be centerline. See fig. 1.
rejected, and a new connecting rod assembly includ-
ing new bearing shells must be mounted in the The measuring is executed with an inside micro-
engine. meter.
08028-0D/H5250/94.08.12

The connecting rod screws are to be carefully clean- Five different diameters are measured in the middle
ed. of the boring, see fig. 1 and registered in the scheme
"Connecting Rod Inspection". See page 4.
The threads are inspected for seizures and tested in
the threaded holes in the connecting rod. The test The maximum ovalnees is calculated as the diffe-
must confirm, that the screws can be turned into rence between biggest and smallest diamenter
bottom position by hand. The contact surface of the measured. For maximum allowable ovalness see
screw heads is inspected for seizure and pittings. page 600.35.

97.24 - ES0S
Working Card
Connecting Rod 606-01.15
Page 3 (4) Edition 04H

L/V28/32H

If the ovalness exceeds this value, reuse must be Please note that squares for statement of informa-
rejected and a new complete connecting rod, inclu- tion and identification, should also be properly filled
ding new screws and new bearing shells has to be in.
mounted in the engine.

Connecting Rod Bush.

Inspect the surface of the piston pin and the connec-


ting rod bush. Measure the clearance between the
piston pin and bush, max. clearance between pin
and bush, see page 600.35.
- 0,5 - 3,0
- 2,0 - 7,0 In case the specified clearance is exceeded, contact
- 1,5 - 5,0 MAN B&W Diesel A/S, Holeby for replacement.
+ 5,0 + 5,5
+ 3,0 + 3,5
7,0 12,5 Bearing Shells for Big-end.

Criteria for replacement of connecting rod big-end


bearing, see working card 606-01.16.

to be to be
reused rejected

Fig. 2. "Connecting rod inspection".

The example, see fig. 2 shows measurements and


damage observations for two connecting rods, on
the scheme "Connecting Rod Inspection", (In case
the specified maximum ovalness is exceeded, con-
tact MAN B&W Diesel A/S, Holeby for overhaul).
Connecting rod
For connecting rod no. 1 the maximum ovalness is Ident no.
08028-0D/H5250/94.08.12

0,07 mm and reuse thus acceptable.

For connecting rod no. 2 the maximum ovalness is


0,125 mm and therefore the connecting rod is being Fig. 3.
rejected.

97.24 - ES0S
606-01.15 Connecting Rod Working Card
Edition 04H Page 4 (4)

L/V28/32H

08028-0D/H5250/94.08.12

97.24 - ES0S
Working Card
Mounting of Piston and Connecting Rod 606-01.20
Page 1 (4) Edition 01S

L28/32H

Safety precautions : Special tools :

Stopped engine Plate no. Item no. Note.


Shut-off starting air
62006 01
Shut-off cooling water 62006 03
Shut-off fuel oil 62006 11
Shut-off cooling oil 62006 13
Stopped lub. oil circul. 62006 22

Description :

Mounting of piston and connecting rod


assembly, after overhaul and /or inspection. Hand tools :

Open end spanner 32 mm.


Clean lubricating oil.
Starting position :

Piston mounted on the connecting rod,


crankshaft turned in the right position and the
cylinder liner is OK, see working card 606-
01.35.

Related procedure :

Thightening of connecting
rod screws, 606-01.25
Mounting of cylinder head, 606-01.40

Man power : Replacement and wearing parts :


08028-0D/H5250/94.08.12

Working time : 1 1/2 Hours Plate no. Item no. Qty./


Capacity : 2 men
60601 09 1/cyl.
60601 10 1/cyl.
60601 11 1/cyl.
Data : 60601 12 1/cyl.

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.49-ES0S
606-01.20 Mounting of Piston and Connecting Rod Working Card
Edition 01S Page 2 (4)

L28/32H

1) Mount the lifting device comprising eye A crank throw position of approx 50 degrees
screw, shackle and wire rope on the piston. before TDC will ensure this and also be
suitable for the further mounting procedure.
2) Lift up the piston and connecting rod
and mount the piston and scraper rings, see 6) Lower the piston further down, lubricate
point 14, and working card 606-01.10. the ends of the bearing shells (a in fig. 2) with
copaslip, molycote pasta or similar and mount
3) Remove the backstop for cylinder liner the upper shell of the big-end bearing.
and place the piston guide ring on top of the
cylinder liner, see fig. 1.

4) When the piston approaches the guide


ring, stop the lowering, coat guide ring, piston,
piston rings and scraper ring, with clean
lubricating oil on order to minimize friction
during the subsequent lowering of the
assembly.

Fig. 2.

7) Coat the crank journal with clean


lubricating oil.
Fig. 1.
08031-0D/H5250/94.09.07

8) Now lower the piston and connecting


5) Make sure that the crank throw is in a rod slowly into correct landing on the journal.
position allowing the connecting rod to go
clear of both crank journal and cylinder liner During this the connecting rod must be guided
skirt during further lowering. by hand to ensure correct approach and
landing on the journal, see fig. 3.

91.49-ES0S
Working Card
Mounting of Piston and Connecting Rod 606-01.20
Page 3 (4) Edition 01S

L28/32H

9) Mount the bearing cap with inserted


lower shell of the big-end bearing, using the
guide pin, see fig. 4.

10) Lubricate threads and contact face of


the connecting rod screws with copaslip,
molycote pasta or similar.

11) Mount the screws and tighten them


slightly using an open end spanner.

12) Slacken the tackle and dismount the


eye screw/shackle from the piston.

Fig. 3.

Note ! The ident no. on the connecting rod


and on the bearing cap, must always be the
same, see fig. 4.

Fig. 5.

13) Tighten the screws according to Tight-


ening Procedure for Connecting Rod Screws,
see working card 606-01.25.
08028-0D/H5250/94.08.12

Fitting of Piston and Scraper Rings.

14) Piston rings should only be removed


from and fitted to the piston by the use of a
special tool, the socalled piston ring opener.

Fig. 4.

91.49-ES0S
606-01.20 Mounting of Piston and Connecting Rod Working Card
Edition 01S Page 4 (4)

L28/32H

If the rings are opened further than necessary Before fitting the coil spring loaded scraper
there is a risk of overstressing, which means ring, the coil spring is dismantled form the ring
that rings will become permanently distorted by removal of the joint pin. The coil spring is
and will not confirm to the cylinder inner placed and assembled in the ring groove then
running surface. the scraper ring is fitted in the groove in such
away that the ring joint is approximately 180
The piston rings should be installed with the offset to the spring joint.
identification mark, which is stamped into the
ring close to the ring joints, facing upwords. Ascertain correct assembling by checking the
back clearance. The back clearance is suffient
when the face of the ring is below the groove
edge, when the ring is pressed against the
bottom of the groove.

When installed on the piston, the rings should


be pushed back and forth in the grooves to
make sure that they can move freely. It is also
advisable to insert a feeler gauge of adequate
thickness between ring and groove.

Adequate clearance is present of the feeler


gauge can be moved all the way round.

To prevent gas leakage through coinciding


ring joints the piston rings should be turned
Fig. 6. into positions offsetting the ring joint 180to
each other.

08031-0D/H5250/94.09.07

91.49-ES0S
Working Card
Hydraulic Tightening of Connecting Rod Screws 606-01.25
Page 1 (2) Edition 04H

L+V28/32H

Safety Precautions: Special Tools:

Stopped engine Plate No Item No Note


Shut-off starting air
Shut-off cooling water 62021
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Tightening procedure for connecting rod screws.


Check of connecting rod screws, tightening con- Hand Tools:
dition.

Starting Position:

Piston, connecting rod, bearing shells and bearing


cap preassembled. 606-01.20

Related Procedure:

Man Power: Replacement and Wearing Parts:


08028-0D/H5250/94.08.12

Working time : 1/2 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)

97.43 -ES0S
606-01.25 Hydraulic Tightening of Connecting Rod Screws Working Card
Edition 04H Edition 2 (2)

L+V28/32H

1) Tighten the screw pos. 3 home to the connecting


rod by hand.

2) Mount the lower part pos. 2 and fasten the


lower part with the nuts, pos. 4.

3) Tighten the nuts by hand.

4) Mount the hydraulic tool, pos. 5.

Be aware of the max. lifting heigt of the tool and


adjust the distance between the piston and the
cylinder before adding pressure to the tool. Please
see Working Card 620-01.05

5) Connect the tool to the hydraulic tool.

6) Add the prescribed hydraulic pressure, (to


both screws simultaneously). Please see Description
600.40, and tighten the screws by using a handle,
pos 6.
2
7) Relieve the hydraulic pressure on the tool. 6
1

8) Add the hydraulic pressure to the tool.

9) Tighten the nuts again.

Note: The Points 7 to 9 are to be followed in order to 5


remove tensions in the screws, if any.
3
10) If there still is a distance and the nuts still can 4
be tightened then repeat the points 7, 8 and 9.

11) Relieve the pressure on the tool and remove it


from the screws. Fig. 1

Note: General instruction about hydraulic tightening.


Please see Working Card 620-01.10
08028-0D/H5250/94.08.12

97.43 - ES0S
Working Card In-situ Inspection of Connecting 606-01.30
Page 1 (3)
Rod Big-end Bearing Edition 01S

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


62006 07
Shut-off starting air
62006 22
Shut-off cooling water 62006 28 140 - 760 Nm
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul. Tool combination for tightening of connecting
rod screw, see working card 620-01.20.

Description:

In-situ inspection and/or replacement of


connecting rod big-end bearing, dismounting
and mounting. Hand tools:

Open end spanner 32 mm.

Starting position:

Fuel injector dismounted, 614-01.00


Crankcase open.
Top cover for cylinder head removed.

Related procedure:

Inspection of connecting rod


big-end bearing 606-01.16
Tightening and check of
connecting rod screws, 606-01.25

Replacement and wearing parts:

Man power: Plate no Item no Qty/


08028-0D/H5250/94.08.12

Working time : 1 1/2 Hours


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)

91.22-ES0S
606-01.30 In-situ Inspection of Connecting Working Card
Page 2 (3)
Edition 01S Rod Big-end Bearing
L28/32H

The big-end bearing shells can be inspected


and/or replaced in-situ i.e. without
dismounting the piston and connecting rod
assembly from the engine.

Dismounting.

1) The crankshaft of the engine is turned


into a position allowing the connecting rod
screws to be loosened. Having loosened the
connecting rod screws, the crankshaft is
turned until the piston in a position thus
allowing the connecting rod bearing cap to be
dismounted, see fig. 1.

Fig. 2.

3) Having tightened the tackle slightly, the


connecting rod bearing cap and bearing shell
are dismounted, see working card 606-01.00

4) When connecting rod bearing cap and


bearing shell have been dismounted, the
piston/connecting rod is lifted from the bearing
journal. Piston/connecting rod should not be
lifted further than just to allow dismounting of
the upper bearing shell, see fig. 3.

Fig. 1.
08031-0D/H5250/94.09.07

2) Before removing connecting rod bearing


cap, the especially long eye bolt is mounted. It
is inserted through the fuel injector sleeve and
is screwed into the thread hole in the piston,
see fig. 2. Then by means of a tackle it is
slightly tightened.

91.22-ES0S
Working Card In-situ Inspection of Connecting 606-01.30
Page 3 (3)
Rod Big-end Bearing Edition 01S

L28/32H

While lowering the connecting rod, it must be


guided by hand to ensure correct approach
and landing on the journal, see fig. 4.

4) Mount the bearing cap with inserted lower


big-end bearing shell, using the guide pin.

5) lubricated threads and contact face of the


connecting rod screws with copaslip or similar.

6) Mount the screws and tighten them


slightly using an open-end spanner.

7) Slacken the tackle and dismount the eye


screw from the piston crown.

8) Tighten the screws according to


Tightening Procedure for Connecting Rod
Screw, see working card 606-01.25.

Fig. 3.

5) For inspection of bearing shell, see


working card 606-01.16

Mounting.

Before remounting of inspected or new


bearing, all components must be cleaned.

Note : See also working card 606-01.20.

1) The bearing shell is placed in the bore,


the contact surfaces of the shells to be in
parallel to the contact surface of the
connecting rod, the bearing cap respectively.
08028-0D/H5250/94.08.12

2) Ascertain that the crank throw


concerned is in a position of approx 50
degrees before TDC. Fig. 4.

3) Coat the journal with clean lubricating oil


and lower the piston and connecting rod
assembly slowly into correct landing on the
journal.

91.22-ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Inspection and Honing of Cylinder Liner 606-01.35
Page 1 (4) 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 50 Extra tools
Shut-off fuel oil 62006 51 Extra tools
Shut-off cooling oil 62006 60 Extra tools
Stopped lub. oil circul.

Description:

Inspection and honing of cylinder liner with ho-


ning brush. Hand tools:

Drilling machine 60-180 rpm.


Honing oil.
Gas oil.
Starting position:

Piston and connecting rod is


removed, 606-01.00

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
Replacement of cylinder liner, 606-01.40
Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12

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)

96.04 - ES0S
606-01.35 Inspection and Honing of Cylinder Liner Working Card
Edition 01H Page 2 (4)

L+V28/32H

Measurement of Cylinder Diameter. Prior to the honing, deposits of coke and possible
wear edges in the top of the liner must be removed
While the piston is removed from the cylinder, the by scraping.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, If the cylinder is of the flame ring type, the used flame
with measuring points at TDC-position for upper- ring has to be cleaned in water. Subsequently, the
most piston ring, halfway down and at the bottom of flame ring is remounted in the cylinder before carry-
the cylinder liner, see fig. 1. ing out the honing process.

Note: After the honing process has taken place the


used flame ring is discarded. A new flame ring is
always mounted in the cylinder when replacing a
piston ring.

80-160 rpm.

Fig. 1.

The measurements should normally be taken in


transverse as well as in longitudinal direction.

When measuring, take care that the measuring tool


has the approximately same temperature as the
liner. When the wear of a cylinder liner exceeds the
08028-0D/H5250/94.08.12

value indicated on page 600.35, i.e. when it becomes


too troublesome to maintain satisfactory service
con-ditions, the cylinder liner in question should be
ex-changed.
Fig. 2.

Honing the Cylinder Liner.


The honing is made by means of a flex-honer with
The renovation can be made either with dismantled finess grains 80-120. A revolution speed between 80
liner in the workshop or with liner mounted in the and 160 rpm is chosen.
engine frame and by the use of the belonging funnel.

96.04 - ES0S
Working Card
Inspection and Honing of Cylinder Liner 606-01.35
page 3 (4) Edition 01H

L+V28/32H

In order to achieve the required angle between the


honing grooves, see fig. 2, the vertical speed is
adjusted to about 1 m/sec. which corresponds to
about 2 sec. for one double movement (the flex
honer is lead from below up and down in 2 sec.)

The procedure is to be continued until the cylinder 60


wall is covered by honing grooves and the surface
has a slight matt appearance and without any signs
of glaze .

During the honing it is important to lubricate freely


with honing oil or cutting oil.
Fig. 3.
After the honing, the liner is carefully cleaned with
gas oil, and make sure that all abrasive particles
have been removed.
08028-0D/H5250/94.08.12

96.04 - ES0S
606-01.35 Inspection and Honing of Cylinder Liner Working Card
Edition 01H Page 4 (4)

L+V28/32H

08028-0D/H5250/94.08.12

96.04 - ES0S
Working Card
Replacement of Cylinder Liner 606-01.40
Page 1 (3) 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 45
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Replacement of cylinder liner.


Dismounting and mounting of cooling water guide Hand tools:
jacket.
Allen key, 8 mm.
Adjustable spanner.

Starting position:

Cylinder head and piston/connecting rod dis-


mantled,working card 605-01.00 and 606-01.00.

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 2 Hours Plate no. Item no. Qty. /


Capacity : 2 men
60610 04 1/cyl.
Data: 60610 07 12/cyl.
60610 08 2/cyl.
Data for pressure and tolerance (Page 600.35) 60610 11 2/cyl.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45) See also plate 60610.

91.22 - ES0S
606-01.40 Replacement of Cylinder Liner Working Card
Edition 01H Page 2 (3)

L/V28/32H

Dismounting of Cylinder Liner.

1) Dismount the cooling water guide jacket.


L28/32H
2) Prior to mounting of the lifting tool and dis- V28/32H
mounting from the frame, it must be ensured that the
liner and frame have been marked to match, for the
sake of a posible remounting of the liner, see fig. 1.

Hole for charging air

Hole for roller guide house

Marking scratch frame

Marking scratch liner

Fig. 2.

Fig. 1.
5) Attach a tackle hook to the eye nut or the wire
and the cross bar, and lift the liner out from the
3) Mount the lifting tool as shown, see fig. 2. engine frame and stand it careful onto wooden
supports.
4) Turn the lifting eye nut to pull out the liner, until
the upper edge of the liner lie aligned against the 6) Clean all parts and inspect for damage and
copper protecting pieces of the cross bar. wear, according to the description. For measure-
08028-0D/H5250/94.08.12

ment of cylinder liner, see working card 606-02.00.

91.22 - ES0S
Working Card
Replacement of Cylinder Liner 606-01.40
Page 3 (3) Edition 01H

L/V28/32H

Mounting of Cylinder Liner. 12) Mount the cooling water jacket, (for torque
moment see page 600.40), piston/connecting rod
7) Check that the sealing surfaces on engine, and cylinder head according to working card 606-
cylinder liner, and sealing rings are perfectly clean. 01.20 and 605-01.40.

8) Mount the lifting tool, attach a tackle hook to 13) When preparing the start-up, check for possible
the eye nut or to the wire in the cross bar and lift the leakages of water and oil, including the inspection
liner. hole in the frame, see fig. 3.

9) Check that the o-ring grooves are clean. Mount


the o-rings and lubricate with a little oil. Place a new
sealing on top of the frame.

10) Lower the cylinder liner carefully into the en-


gine frame.

When the first o-ring touches the sealing face, align


the liner so that the scratch mark on the liner flange
points to the scratch mark on the frame as illustrated,
or align the liner so that the milling groove in the liner Inspection
flange coinside with the fixing piece on the engine hole
frame control side (if mounted).

11) After having cleaned and inspected the cool-


ing water jacket, mount new o-rings on the cooling
water connections and change air connections.

Fit a new sealing ring and mount the jacket.

Fig. 3.
08028-0D/H5250/94.08.12

91.22 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card Grinding of Seal Face on 606-01.45
Page 1 (2) Cylinder Liner and 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 62005 20
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Grinding of seal face on cylinder liner and cylin-


der head by hand, with grinding tools and grin- Hand tools:
ding pasta.
Grinding pasta.

Starting position:

Cylinder head has been removed


from the engine, 605-01.00
Cooling water guide jacket, removed.

Related procedure:

Mounting of cylinder head, 605-01.40


08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty. /


Capacity : 1 man
60610 08 1/cyl.
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
606-01.45 Grinding of Seal Face on Working Card
Edition 01H Cylinder Liner and Cylinder Head Page 2 (2)

L/V28/32H

Note: The grinding tool is used for both grinding the


groove in the liner flange (1) and the seating surface
on the cylinder head (2), see fig. 1.

Fig. 3.
Fig. 1.

3) After grinding, remove all traces of abrasive


Grinding. and grinding compound.

1) Loosen the sealing ring in liner flange and take 4) When having ground the contact faces, it must
it out. be observed that the gap between cylinder head and
liner is no less than 0,5 mm, that is, the difference
2) Face-grind sealing groove in cylinder liner between measurements y and z must not be less
flange, see fig. 2 and sealing surface on the cylinder than 0,5 mm, see fig. 4.
head, see fig. 3. With the use of grinding pasta and
the grinding tool.

08028-0D/H5250/94.08.12

y - z = 0,5 mm, min.


Fig. 2.

To do so, move the tool back and forth and lift it out
from time to time, to allow the grinding compound to Fig. 4.
distribute evenly.

91.45 - ES0S
Working Card Dismounting of Piston and Cylinder Liner 606-01.50
Page 1 (2)
at Low Overhaul Heights Edition 01H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62050
Shut-off fuel oil 62006 05
Shut-off cooling oil 62006 09 2 pieces
Stopped lub. oil circul. 62006 22
62006 24
62006 28
62006 65
Description: 62010 01 If necessary

Dismounting of piston, connecting rod and cylin- Tool combination for dismounting of conncting
der liner for inspection and/or overhaul. rod screw, 620-01.20

Starting position: Hand tools:

Cylinder head has been dismounting from the Inside micrometer (195 mm).
engine. Feeler gauge 0,15 - 0,20 mm.
Crankcase open.

Related procedure:

Separation of piston and connecting rod.


Inspection and honing of cylinder liner.

Manpower:

Working time : 2 Hours


08028-0D/H5250/94.08.12

Capacity : 2 men
Replacement and wearing parts:

Data: Plate no Item no Qty/

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

94.38 - ES0S-G
606-01.50 Dismounting of Piston and Cylinder Liner Working Card
Edition 01H at Low Overhaul Heights Page 2 (2)

L+V28/32H

Dismantling of Piston at Low Overhaul Heights. Dismantling of Cylinder Liner at Low Overhaul
Heights.
1) Lift up the piston and the connecting rod through
the cylinder liner until the piston is clear of the 1) Mount normal lifting tool for cylinder liners.
liner.
2) Carefully pull the cylinder liner half-way out of
2) Mount collar on the connecting rod, see plate the frame.
62050, item 1896.
3) Mount special lifting tool for cylinder liners at
3) Place the piston with the collar on the cylinder low overhaul heights, see plate 62050, item
liner. 1895.

4) Mount pull-lifts on the collar. 4) Attach pull-lifts on the lifting tool for the cylinder
liner, see plate 62050, item 1895
If Then
5) Take out the liner over the camshaft side.
The overhaul height is Dismount the piston from
too low to pull out piston the connecting rod, re-
and connecting rod in move the piston and pull
one piece. out the connecting rod by
the pull-lifts.

The overhaul height is Remove the piston and


sufficient to pull out the connecting rod by means
piston and the connect- of the pull-lifts.
ing rod in one piece.

08028-0D/H5250/94.08.12

94.38 - ES0S-G
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 60601-34H

L28/32H

04.06 - ES0
Plate
60601-34H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)

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

01 1/C Piston pin incl. Stempelpind inkl.


item No 02 pos. nr. 02

02 4/C Socket screw Kraterskrue

03 1/C Retaining ring Sikringsring

04 1/C Plug screw Propskrue

05 1/C Bush for Plejlstangs-


connecting rod bsning

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 Mtrik

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

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

04.06 - ES0
Plate
Page 1 (2) Cylinder Liner and Water Guide Jacket 60610-19S

L28/32H
08028-0D/H5250/94.08.12

94.02-ES0S
Plate
60610-19S Cylinder Liner and Water Guide Jacket Page 2 (2)

L28/32H

Item Item
Qty. Designation Qty. Designation
No. No.
01 2/C O-ring
02 1/C Sleeve
03 1/C Water guide jacket
04 1/C O-ring
07 12/C O-ring
08 1/C Sealing ring
09 6/C Cooling water connection
10 1/C Cylinder liner
11 2/C O-ring
12 4/C Hexagon screw
13 4/C Washer
14 4/C Sleeve
16 1/C Sealing ring
17 1/C Flame ring

08031-0D/H5250/94.09.07

When ordering spare parts, see also page 600.50

* = Only available as part of a spare parts kit.


Qty./C = Qty./Cylinder

94.02-ES0S
Index
Page 1(1) Camshaft and Camshaft Drive 607

L28/32H
Description

Camshaft and Camshaft Drive --------------------------------------------------------------- 607. 01 (05H)

Working Card

Camshaft and Camshaft Drive --------------------------------------------------------------- 607- 01 .00 (01H)


Inspection and Replacement of Camshaft Bearing -------------------------------------607- 01 .05 (01H)
Adjustment of Camshaft ----------------------------------------------------------------------- 607- 01 .20 (01H)

Plates

Intermediate wheel -------------------------------------------------------------------------------------60701- 06H


Camshaft and Camshaft Bearing -------------------------------------------------------------------60705- 11S

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Camshaft and Camshaft Drive 607.01
Page 1 (1)
Edition 05H

L28/32H

General The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply
The camshaft which controls the actuation of inlet the oil at the points where the gear wheels are in
valves, exhaust valves and fuel injection pumps is mesh. The position of the nozzles is determined by
driven by a gear wheel on the crankshaft through an direction of rotation of the engine.
intermediate wheel, and rotated by a speed which is
half of that of the crankshaft, see fig. 1.

The camshaft is placed in the engine frame at the Engine seen from aft - fly wheel end
control side, (left side, seen from the flywheel end)
and is carried in bearing bushes which are fitted in
bores in the engine frame, each bearing is replace-
able and locked in position in the engine frame by
means of lock screws.

The camshaft is built-up of sections, one for each


cylinder unit. Each section is equipped with fixed
cams for operation of fuel injection pump, air inlet
valve and exhaust valve. The sections are assem-
bled by bolting of the ample dimensioned and pre-
cision made flange connections, which also act as
bearing journals.

Except for the foremost and the aftmost ones, the


sections are identical and therefore interchange-
able. The foremost section is equipped with a clutch
for driving the fuel oil feed pump (if mounted). The
gear wheel for driving the camshaft as well as a gear
wheel connection of governor are screwed on the Clockwise rotation direction
aftmost section.

Fig. 1. Intermediate wheel


08028-0D/H5250/94.08.12

91.03 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Camshaft and Camshaft Drive 607-01.00
Page 1 (2) 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:

Checking of gear wheels, bolted connections and


lubricating system. Hand tools:

Allen key, 12 mm.


Ring and open end spanner, 19 mm.
Socket spanner, 19 mm.
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 3 Hours Plate no. Item no. Qty./


Capacity : 1 man
60705 12 6/eng.
Data: 60705 24 3/eng.
61106 11 1/cyl.
Data for pressure and tolerance (Page 600.35) 61106 13 1/cyl.
Data for torque moment (Page 600.40) 61106 14 1/eng.
Declaration of weight (Page 600.45)

92.13 - ES0U
607-01.00 Camshaft and Camshaft Drive Working Card
Edition 01H Page 2 (2)

L/V28/32H

1) Dismount the covers which give access to the 3) Examine all lubricating oil spray pipe nozzles.
gear wheels, camshaft and crankcase.
4) Start the electrical lubricating oil pump and
Examine all gear wheels for cracks, wear and defor- check the oil flow everywhere. Be particularly careful
mations. While turning the engine to enable inspec- to check that the oil jet hits the gear wheels correctly
tion allover the circumference of the gear wheels. at the points where the wheels mesh.

2) Check all screws, nuts and bolted connec-


tions, including locking devices everywhere in the
gear wheel housing, camshaft housing and crank-
case to check that they have not worked loose.
Tightening torques, see page 600.40.

08028-0D/H5250/94.08.12

92.13 - ES0U
Working Card
Inspection and Replacement of Camshaft Bearing 607-01.05
Page 1 (2) 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:

Check of roller path of cams and check of cam-


shaft bearing. Hand tools:
Replacement of camshaft bearing.
Ring and open end spanner, 19 mm.
Socket spanner, 19 mm.
Feeler gauge.
Starting position: Big screw driver.

Cover for camshaft and gear wheel has been


removed.

Related procedure:

Camshaft and camshaft drive, 607-01.00


08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 2 Hours Plate no. Item no. Qty. /


Capacity : 2 men
60705 01 1/eng.
Data: 60705 03 1/cyl.
60705 21 1/cyl.
Data for pressure and tolerance (Page 600.35)
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

92.13 - ES0S
607-01.05 Inspection and Replacement of Camshaft Bearing Working Card
Edition 01H Page 2 (2)

L/V28/32H

To Check Roller Path of Cams.

1) While turning the engine, examine the cam Camshaft bearing


discs and in particular, check the roller path of all Hole for lubricating oil
cams for cracks, crackles and ruffle. Also examine
the rollers of the roller guides.

Note: if there are flat spots on the roller and if some


of the rollers may be blocked, if so, the roller must be
replaced by a new one, see working card 608-01.00.

To Check Camshaft Bearings.

2) The wearing surface of the camshaft bearings


cannot be checked without dismounting the cam- Locating screw
shaft. However, ab-normal wear of one or more
Frame
bearings will become apparent in the form of burrs of
white metal at the circumference of the camshaft
journal, and in that case the bearing will in no doubt
be discoloured, as well. Fig. 1.

The bearing clearance is measured with a feeler


gauge, see data sheet 600.35. Mount a new camshaft bearing in the bore and make
sure that the hole for insertion of the locating screw
in the bearing is in a correct position. Lock the
To Replace Camshaft Bearing. bearing by means of the locating screw, which is to
be provided with a new gasket. To facilitate the fitting
3) If one or several of the camshaft bearings of the bearing it can be cooled down with Co2.
should be replaced the camshaft must be wholly or
partly dismantled. Inspect the camshaft journal for seizures.

Dismount the fuel oil feed pump, if mounted and If necessary, the camshaft section must be entirely
check that the camshaft sections are marked in removed from the engine, and the journal concerned
relation to each other. Disassemble the camshaft aft must be polished.
(toward flywheel) of the bearing that is to be replaced.
Dismount all roller guides that are located forward of Coat all the journals of the camshaft section with
the disassembling position, see working card 608- clean lubricating oil and push the camshaft into
01.00 and 608-01.05. position, making sure that the marks on the flanges
coincide.
08028-0D/H5250/94.08.12

Pull the disconnected sections of the camshaft so far


a head that the bearing which is to be replaced is Assemble the sections and fit the bolts (coated with
free. copaslip or similar).

Take out the locating screw of the camshaft bearing Tighten the nuts with a torque spanner, see data
concerned and push the bearing out of the bore in the sheet 600.40.
engine frame, see fig. 1.
Mount all roller guides as well as the fuel oil feed
Check the lubricating oil ducts to the bearing for free pump.
flow.

92.13 - ES0S
Working Card
Adjustment of Camshaft 607-01.20
Page 1 (2) Edition 01H

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:

Nominal adjustment of camshaft. (Adjustment of


camshaft in relation to crankshaft). Hand tools:

Depth gauge.

Starting position:

Camshaft assembled as per timing order, moun-


ted in frame and roller gear house.

Related procedure:

Adjustment of the maximum


combustion pressure, 614-05.01
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 3 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)

96.30 - ES0S
607-01.20 Adjustment of Camshaft Working Card
Edition 01H Page 2 (2)

L28/32H

If the intermediate wheel has been dismantled a


nominal adjustment of the camshaft compared to the
crankshaft (timing) must be made as follows: "Nominal
size"
1) The crankshaft is turned to TDC (top dead
centre) for cylinder no. 1.

Cylinder numbering, see page 600.11.

2) Roller guide for fuel oil pump cylinder no. 1 is


mounted and the camshaft is turned in a position
where the roller guide rests on the cicular part af the
cam, see fig. 1.

Roller guide

Cam for
exhaust valve
Cam for fuel Fig. 2.
oil pump

4) The camshaft is turned - in the engines direc-


tion of rotation (see page 600.12) - until the "nominal
size" (as described in item 3) is reduced with the
lead, mentioned in "Lead of Fuel Pump".
Seen from front edge
Note: "Lead of fuel pump" is shown in the table
"Adjusment after the trail" in the Shop Test Protocol.

Fig. 1. 5) When items 1 - 4 are completed and correct


the intermediate wheel can be mounted and tighte-
ned up again (torque moment, see page 600.40).
3) The "nominal size" is measured with a depth
gauge, i.e. the distance from the upper edge of the For adjustment of the single fuel oil pumps (separa-
roller guide house to the thrust gauge pressed into tely and assembled), see working card 614-05.01.
the roller guide, see fig. 2.
08028-0D/H5250/94.08.12

96.30 - ES0S
Plate
Page 1 (2) Intermediate Wheel 60701-06H

L28/32H

09

10

01

02

07

03 11

04

12+
05 08+

06

91.41 - ES0S
Plate
60701-06H Intermediate Wheel Page 2 (2)

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

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 Rr

06 1/E Union Vinkelforskruning

07 1/E Spray pipe Sprjterr

08+ 3/E Fitted bolt Pasbolt

09 3/E Self locking Selvlsende


nut mtrik

10 1/E Cover Dksel

11 1/E Gear wheel, Tandhjul, kompl.


complete

12+ 1/E Axle journal Lejetap

+ Item No. 08 and 12 + Item nr. 08 og 12 kr-


require an individual ver en individuel tilpas-
matching, before ning, fr montering kon-
mounting, contact takt MAN B&W, Holeby
MAN B&W, Holeby

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

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

91.41 - ES0S
Plate
Page 1 (2) Camshaft and Camshaft Bearing 60705-11S

L28/32H
08028-0D/H5250/94.08.12

92.08-ES0S
Plate
60705-11S Camshaft and Camshaft Bearing Page 2 (2)

L28/32H

Item Item
Qty. Designation Qty. Designation
No. No.
01 1/E Camshaft bearing Aft 23 1/E Coupling flange
02 1/E Camshaft section aft 24 3/E Locking plate
03 1/C Camshaft bearing 25 6/E Screw
04 1/E Hub
05 6/E Screw
06 6/E Locking plate
07 1/E Guide ring
08 1/E Shaft pin
11 12/E Screw
12 12/E Locking plate
13 1/E Gear wheel
14 Self locking nut
50/E 5 cyl. engine
70/E 6 cyl. engine
52/E 7 cyl. engine
66/E 8 cyl. engine
92/E 9 cyl. engine
15 Screw
40/E 5 cyl. engine
60/E 6 cyl. engine
42/E 7 cyl. engine
56/E 8 cyl. engine
82/E 9 cyl. engine
16 1/E Camshaft Fore
19 10/E Screw
20 1/C Camshaft, intermediate
21 Gasket
6/E 5 cyl. engine
7/E 6 cyl. engine
8/E 7 cyl. engine
9/E 8 cyl. engine
08031-0D/H5250/94.09.07

10/E 9 cyl. engine


22 Guide screw
6/E 5 cyl. engine
7/E 6 cyl. engine
8/E 7 cyl. engine
9/E 8 cyl. engine
10/E 9 cyl. engine

When ordering spare parts, see also page 600.50

*= Only available as part of a spare parts kit.


Qty./C = Qty./Cylinder
Qty./E = Qty./Engine

92.08-ES0S
Index Operating Gear for Inlet Valves,
Page 1(1) 608
Exhaust Valves and Fuel Injection Pumps

L28/32H
Description

Operating gear for valves and fuel injection pumps ------------------------------------ 608. 01 (12H)

Working Card

Inspection of valve roller guide ---------------------------------------------------------------608- 01 .00 (01S)


Inspection of fuel injector pump roller guide ----------------------------------------------608- 01 .05 (01H)
Control and adjustment of valve clearance ----------------------------------------------- 608- 01 .10 (01H)

Plates

Roller guide and push rods -------------------------------------------------------------------------- 60801- 14S

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Operating Gear for Valve and Fuel Injection Pumps 608.01
Page 1(1)
Edition 12H

L/V28/32H

Roller Guides

The fuel injection pumps and the rocker arms for inlet
and exhaust valves are operated by the cams, on the
camshaft through roller guides. The roller guides for Valve bridge Rocker arm
fuel pump, inlet and exhaust valves are located in
bores in a common housing for each cylinder, this
housing is bolted to the engine frame.

The roller runs on a bush fitted on a pin that is pressed


into the roller guide and secured by means of a lock
screw.

Operating Gear for Fuel Injection Pumps


Valve spring
Valve spindle
The injection pumps which is mounted directly on the
roller guide housing is activated via thrust pieces Push rod
from the roller guide.
Protecting Tube

The roller is pressed down on to the cam by a spring, Roller guide


which is fixed between the roller guide and the foot housing
plate of the fuel injection pump.
Roller guide

Operating Gear for Inlet and Exhaust Valves Pin

The movment from the roller guides for inlet and Roller
exhaust is transmitted via the push rods the rocker
arms and spring-loaded valve bridges to each of the
two valve sets. The bridge is placed between the Camshaft
valve spindles and in the one end it is provided with
a pressed-on thrust shoe and in the other end it is
fitted with a thrust screw for adjustment of the valve
clearance. Fig. 1. Valve Operating Gear.

On its top the bridge is controlled by a spherical


thrust shoe on the rocker arm and at the bottom by
a guide which rests in a spherical socket in the
cylinder head.
08028-0D/H5250/94.08.12

91.13 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Inspection of Valve Roller Guides 608-01.00
Page 1 (3) Edition 01S

L/V23/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
62006 26 20 - 120 Nm
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Dismounting, inspection and/or overhaul, and


mounting of valve roller guides. Hand tools:
Inspection of roller guide housing.
Ring and open end spanner, 19 mm
Socket spanner, 19 mm.
Socket spanner, 24 mm.
Starting position: Allen key, 3 mm.
Ratchet spanner.
Top cover for cylinder head and cover for fuel Hammer.
injection pump removed. Drift.

Related procedure:

Inspection of fuel injection


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

Replacement and wearing parts:


Man power:
08028-0D/H5250/94.08.12

Plate no Item no Qty/


Working time : 2 hours
Capacity : 1 man 60801 04 4/cyl.
60801 08 2/cyl.
60801 09 1/cyl.

Data: See also plate 60801.

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45-ES0S
608-01.00 Inspection of Valve Roller Guides Working Card
Edition 01S Page 2 (3)

L/V28/32H

Dismounting of Roller Guide. 5) Dismount the screws (3) which secure


the roller guide top cover, take off the cover,
1) Turn the engine so that the roller, and lift out the roller guide (5).
rests on the circular part of the cam.
Disconnect any pipes that may be in the way
2) Unscrew the nuts which secure the (lub. oil and fuel oil pipes).
rocket arm brackets, and lift off the rocker arm
with brackets. 6) If the roller guide housing is to be
dismantled, the fuel injection pump and the
3) Remove the push rods (1), see fig. 1. 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.

The roller guide housing (6) cannot be


dismantled with the roller guides fitted.

7) If the event of any marks or scores


from sezures, these must be polished away.

8) Inspect the spherical stud for


deformations (replace as necessary).

Examine the surface of the roller for marks


and other deformations.

Make sure that there is free ply between the


roller and the bush and the shaft pin, and
replace the bush, if necessary.

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


08031-0D/H5250/94.09.07

roller guide and roller guide housing, and


clean the lubricating grooves.

Mounting of Roller Guide.


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

91.45-ES0S
Working Card
Inspection of Valve Roller Guides 608-01.00
Page 3 (3) Edition 01S

L/V28/32H

13) When the roller guide housing(6) to be


* replaced into a new part, special care should
be done at the mounting checking the contact
surface between each cam & roller to give a
smooth rolling motion, especially for the
alignment of center line between cam shaft
and roller guide housing.
08028-0D/H5250/94.08.12

91.45-ES0S
Your Notes :

08031-0D/H5250/94.09.07
Working Card
Inspection of Fuel Injection Pump Roller Guide 608-01.05
Page 1 (2) 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:

Dismounting, inspection and/or overhaul, and


mounting af roller guide for fuel injection pump. Hand tools:

Allen key, 3mm.


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
08028-0D/H5250/94.08.12

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)

91.02 - ES0S
608-01.05 Inspection of Fuel Injection Pump Roller Guide Working Card
Edition 01H 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 ply 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


sezures, these must be polished away.
08028-0D/H5250/94.08.12

91.02 - ES0S
Working Card
Control and Adjusting of Valve Clearance 608-01.10
Page 1 (3) 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:

Control and/or adjusting of valve clearance.


Hand tools:

Ring and open end spanner, 30 mm.


Big screw driver.

Starting position:

Cover for rocker arm are removed.


All indicator valves open.

Related procedure:
08028-0D/H5250/94.08.12

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
608-01.10 Control and Adjusting of Valve Clearance Working Card
Edition 01H 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 simulta-


neously at both valve spindles.

Adjusting af Exhaust Valve Clearance.

Fig. 1. 9) Carry out adjusment in the same way as


deseribed 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
08028-0D/H5250/94.08.12

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
Working Card
Control and Adjusting of Valve Clearance 608-01.10
Page 3 (3) 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 clear-
ances simultaneously as where it must not be pos-
sible to insert the gauges marked "incorrect".

Fig. 4.
08028-0D/H5250/94.08.12

91.45 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Plate
Page 1 (2) Roller Guide and Push Rods 60801-14S

L+V28/32H
08028-0D/H5250/94.08.12

99.41 - ES0
Plate
60801-14S Roller Guide and Push Rods Page 2 (2)

L+V28/32H
Item Item
no Qty. Designation Benvnelse no Qty. Designation Benvnelse

01 4/C Thrust piece Trykstykke 27 1/C Roller guide for Rullestyr for brnd-
fuel injection pump, selspumpe, komplet
02* 2/C Pipe Rr complete incl. item 12, inkl. item 12, 13, 14, 15,
13, 14, 15, 22, 23, 24, 22, 23, 24, 25
03 2/C Protecting tube Skrmrr 25

04 4/C Sealing ring Ttningsring 28 4/C Screw Skrue

05 4/C Screw Skrue 38 2/C Push rod, complete Stdstang, komplet inkl.
incl. item 01, 02 item 01, 02
06 2/C Cover Dksel

07 2/C Screw Skrue

08 2/C Gasket Pakning + Item no 20 require + Item nr. 20 krver


an individual match- en individuel tilpasning
09 1/C Gasket Pakning ing before mounting, fr montering, kontakt
contact MAN B&W, MAN B&W, Holeby
10 2/C Ball pin Kugletap Holeby

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 st 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-


08028-0D/H5250/94.08.12

valve gear, complete vgelse, komplet inkl.


incl. item 10, 11, 12, item 10, 11, 12, 13, 14,
13, 14, 15 15

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

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

99.41 - ES0
Index Control and Safety Systems
Page 1(1) 609
Automatics and Instruments

L28/32H
Description

Control and safety systems ---------------------------------------------------------------- 609. 01 (14S)


Instrument and automatics ----------------------------------------------------------------- 609. 05 (11H)
Lambda controller ---------------------------------------------------------------------------- 609. 10 (12H)
Starting box ------------------------------------------------------------------------------------ 609. 35 (02H)
Converter for engine- and turbocharger RPM signal -------------------------------- 609. 40 (01H)

Working Card

Functional test and adjustment of safety, alarm and monitoring equipment ---609- 01 .00 (01H)
Function test and adjustment of overspeed trip ---------------------------------------609- 01 .05 (01H)
Adjustment and test of ON/OFF pressostate ------------------------------------------609- 05 .00 (02S)
Adjustment and test of ON/OFF thermostate ------------------------------------------609- 05 .01 (02S)
Function and test of level switch (LAL 25) --------------------------------------------- 609- 05 .02 (02H)
Adjustment and test of analogous pressure transmitter ---------------------------- 609- 05 .03 (02S)
Adjustment and test of analogous temperature transmitter ------------------------609- 05 .04 (02H)
Adjustment of lambda controller ---------------------------------------------------------- 609- 10 .00 (10H)

Plates

Governor and governor drive ---------------------------------------------------------------------60901- 07H


Regulation Mechanism -----------------------------------------------------------------------------60902- 18H
Overspeed device ----------------------------------------------------------------------------------- 60903- 38H
Fuel oil leakage alarm (LAH 42) ----------------------------------------------------------------- 60905- 09S
Prelubricating oil alarm (LAL 25) ---------------------------------------------------------------- 60905- 13H
Instrument panel ------------------------------------------------------------------------------------- 60905- 27H
Level switch in oil sump (LAL/LAH 28) ---------------------------------------------------------60905- 35H
Thermometer ----------------------------------------------------------------------------------------- 60907- 01S
Pressostate, thermostate, difference pressostate and pressure transmitter --------- 60907- 02S
Lambda controller ----------------------------------------------------------------------------------- 60910- 03H
Starting box ------------------------------------------------------------------------------------------- 60935- 07H

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Control and Safety Systems 609.01
Page 1 (3) Edition 14S

General

Governor

The engine speed is controlled by a hydraulic


governor. The purpose of the governor is to
regulate the rate of delivery from the fuel pumps,
so that the engine speed is kept within certain
limits, independing on the load.

Information about the design, function and


operation of the governor is found in the special
governor instruction book.

The governor is mounted on the fly wheel end of


the engine and is driven from the camshaft via a
cylindrical gear wheel and a set of bevel gears.

Pick-up for Engine RPM

The pick-up for transfer of signal to the tachometer Fig. 1.


instrument for engine RPM is mounted on the fly
wheel end cover of the engine.

A signal varying proportionally to engine RPM is


created in the pick-up by the rotating toothed
impulse wheel mounted on the camshaft end.

Pick-up for Turbocharger RPM

See turbocharger instruction book, section 612.

Fuel Oil Limiting Function

When starting the engine, the function of fuel oil


regulating is carried out automatically, so called,
the starting valve become to activate and the
starting air sis entered into air starter (see Section
613) and then simultaneously the regulating arm
(fig.2, pos5) will rotate into the direction of
increasing the injection fuel oil volume resultantly to
be touched with the piston rod & adjustment screw
of stop cylinder (Lambda cylinder). Fig. 2.

After that, the excessive movement of regulating


08028-0D/H5250/94.08.12

arm is avoided by the force balance between the Regulating Shaft


charge air pressure and the spring force (fig.2,
pos.2) in the stop cylinder (Lambda cylinder) and The governor movements are transmitted through
resultantly the fuel oil index of fuel oil pump is a spring-loaded pull rod to the fuel pump regulating
regulated on a balanced position. shaft which is fitted along the engine.

In sequence, the charging air pressure will increase


in proporation to engine rpm as the engine rpm
reaching at the rated rpm and this pressure will be
supplied into no.3 hole of fig.1 of stop cylinder
(Lambda cylinder), to push up the spring by boost
air pressure and position of fuel pump index is
regulated & balanced at the proper position of
engine running condition.

92.04-ES0S
609.01 Control and Safety Systems Description
Edition 14S Page 2 (3)

General

The spring-leaded pull rod permits the press the piston in the Lambda controller
governor to give full deflection even if the stop downwards and force the index at the fuel
cylinder of the manoeuvring system keep the pumps to zero. See also Description 609.10
fuel pump regulating shaft at "no fuel" position.

Each fuel pump is connected to the common, Mechanical Overspeed (SSH 81)
longitudinal regulating shaft by means of a
two-piece, spring-loaded arm. The engine is protected against overspeeding
in the event of, for instance, governor failure
Should a fuel pump plunger seize in its barrel, by means of an overspeed trip.
thus blocking the regulating guide, governing
of the remaining fuel pumps may continue The engine is equipped with a stopping
unimpede owing to the spring-loaded linkage device which starts to operate if the maximum
between the blocked pump and the regulating permissible revolution number is exceeded.
shaft.
The overspeed tripping device is fitted to the
end cover of the lubricating oil pump and is
Shut Down Function driven through this pump.

The shut down function is carried out by the If the pre-set tripping speed is exceeded, the
Lambda controller. In case of an shut down spring loaded fly weight (1), see fig.2, will
situation e.g. overspeed lubricating oil move outwards and press down the arm (2).
pressure low or high temperature for H.T
water, compressed air will

08031-0D/H5250/94.09.07

Fig. 2. Mechanical overspeed (SSH 81).

92.04-ES0S
Description
Control and Safety Systems 609.01
Page 3 (3) Edition 14S

General

The arm is looked in its bottom position by The engine can be stopped manually by
the lock pin (3) which is pressed in by the pressing down the button (7), see fig.2, which
spring (4). will activate the spring-loaded fly weight (1)
through the lever (8).
At the same time the arm (2) presses down
the spindle (5), and the pneumatic valve (6) If the overspeed has been activated the
opens, whereby compressed air will be led to overspeed must be reset before the engine
the stop cylinder, see fig. 1, in which the can be started. Reset is done by means of the
piston is pressed forward and, through the button (10).
arm, turns the fuel pump regulating shaft to
STOP position, thereby the engine stops, the The overspeed alarm (SAH 81) is activated by
spring-loaded pull rod connection to the meads of the micro switch (9).
governor being compressed.
08028-0D/H5250/94.08.12

92.04-ES0S
Your Notes :

08031-0D/H5250/94.09.07
Description
Instruments and Automatics 609.05
Page 1 (3) Edition 11H

L28/32H

Main instrument panel

As standard the engine is equipped with an instru- The instrument panel is mounted flexibly on rubber
ment panel, comprising instruments for visual indi- elements and all manometer connections are con-
cation of the most essential pressures. nected to the panel by means of flexible hoses, as
Illustrated on fig. 1. shown on fig. 2.

Flexible hose

Rubber element

Valves

Push button

On the engine is as standard mounted an instrument panel.

The following incorporating pressure gauges for the most


essential pressures. Fig. 2. Cross section of instrument panel

Pressure gauge for:


08028-0D/H5250/94.08.12

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter The connecting pipes to the manometers are equip-
PI 23 Lub. oil, inlet to turbocharger ped with valves which make it possible to replace the
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
manometers during operation.
PI 50 (*) Nozz. cool. oil, inlet to fuel valves
Switch for PI 21/22 In the charging air and nozzle oil piping damping
(*) If nozzle cooling oil applied only.
filters are inserted for levelling out pressure fluctua-
tions.

Fig. 1. Lay-out of instrument panel

94.28 - ES2S
609.05 Instruments and Automatics Description
Edition 11H Page 2 (3)

L28/32H

Instrumentation - too high press. drop across lub. oil filter


- too high HT FW temperature - outlet engine
As standard the engine is supplied with the following - too low starting air pressure - inlet engine
instrumentation mounted local on the engine: - too high engine speed (overspeed)

Thermometer TI 01 LT water - inlet air cooler The actual number and type of the alarm- and shut-
Thermometer TI 02 LT water - outlet from air cooler down switches for the plant can be seen in the list
Thermometer TI 03 LT water - outlet from lub. oil cooler "Engine Automatic part list" in this section.
Thermometer TI 10 HT fresh water - inlet to engine
Thermometer TI 11 HT fresh water - outlet each cylinder
Thermometer TI 20 Lubricating oil - inlet to cooler Leakage Alarm (LAH 42)
Thermometer TI 22 Lubricating oil - outlet from filter
Thermometer TI 30 Charge air - inlet to cooler Waste and leak oil from the comparement, for the
Thermometer TI 31 Charge air - outlet from cooler injection equipment, fuel valves, high-pressure pipes
Thermometer TI 40 Fuel oil - inlet to engine and engine feed pump (if mounted) is led to a fuel
Thermometer*) TI 51 Nozz. cool. oil - outlet from fuel valves leakage alarm unit.
Thermometer TI 60 Exhaust gas - outlet each cylinder
Thermometer TI 61 Exhaust gas - outlet turbocharger

*) If nozzle cooling oil applied only. Normal leakage

C
The actual number of the instrumentation for the
plant can be seen on the diagrams for the specific
plant in the sections 612-613-614-615-616.
For code identification see 600.20. B
Leak alarm
Normal level

Pressostates and Thermostates

The engine is supplied with a number of alarm- and


shut-down functions. The alarms shall via the alarm
panel worn against an abnormal working condition, A
which can lead to break down and the shut-down
functions shall stop the engine before a break down.
I.e. a shut-down is "worse" than an alarm because High level
a shut-down is given if the engine could be severe
damage by running on these conditions.
Leakoil

As standard the engine is equipped with:


08028-0D/H5250/94.08.12

Alarm
Shut-down Switches for Normal

- too low lubricating oil pressure - inlet engine


- too high HT FW temperature - outlet engine
- too high engine speed (over speed)

Alarm Switches for


Waste oil outlet
- leaking fuel oil
- too low lubricating oil pressure - inlet engine
- too low prelubricating oil pressure (level alarm) Fig. 4. Fuel oil leakage alarm.

94.28 - ES2S
Description
Instruments and Automatics 609.05
Page 3 (3) Edition 11H

L28/32H

The alarm unit consist of a box with a float switch for Alarm for Prelubricating (LAL 25)
level monitoring, see fig. 4.
Alarm for missing prelubricating, when the engine is
The supply fuel oil to the engine is led through the unit stopped is given by means of a level switch (LAL 25)
in order to keep heated up, thereby ensuring free mounted in the main lubricating oil pipe.
drainage passage even for high-viscous waste/leak
oil.
Alarm and Shut-down for Overspeed
Under normal conditions there will always be a
smaller amount of waste/leak oil from the compare- When the mechanical overspeed is activated, see
ment, this will be led out through the bore "A" in the 609.01 fig. 2, a micro-switch will release the alarm
pipe "B" as illustrated. for overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger then normal leakage, the level in
the box will rise and the level switch "C" will be The latter function is a back-up for the mechanical
activated. The larger amount of leak oil will be lead overspeed.
out through the top of the pipe "B".
08028-0D/H5250/94.08.12

94.28 - ES2S
Your Notes :

08031-0D/H5250/94.09.07
Description
Lambda Controller 609.10
Page 1 (1) Edition 12H

L28/32H

Purpose At a 50% load change the system will be activated for


about 3-8 seconds.
The purpose with the lambda controller is to prevent If the system is activated more than 10 seconds, the
injection of more fuel in the combustion chamber solenoid valve will be shut off and there will be a
than can be burned during a momentary load in- remote signal for "system failure".
crease. This is carried out by controlling the relation
between the fuel index and the charge air pressure.
Fuel oil limiting during start procedure
The Lambda controller is also used as stop cylinder.
During the start procedure the lambda controller is
used as an index limiter.
Advantages
Hereby heavy smoke formation is prevented during
The lambda controller has the following advantages: start procedure and further the regulating device
cannot over-react.
- Reduction of visible smoke in case of sudden
momentary load increases. The jet system is blocked during the starting proce-
dure until the engine has reached 110 RPM.
- Improved load ability.

- Less fouling of the engine's exhaust gas ways.


1. Regulating arm
2. Switch (Pick-up)
- Limitation of fuel oil index during starting 3. Piston

procedure. 4. Solenoid valve


5. Lambda controller
6. Overspeed device
(mecanical activated 3/2 valve)

Principles for functioning 6

Figure 1 illustrates the controller's operation mode.


In case of a momentary load increase, the regulating
device will increase the index on the injection pumps
and hereby the regulator arm (1) is turned, the switch
(2) will touch the piston arm (3) and be pushed 5 Charge air
receiver
downwards, whereby the electrical circuit will be
closed. 3
2
Thus the solenoid valve (4) opens. The jet system is
activated, the turbocharger accelerates and increases 1
the charge air pressure, thereby pressing the piston ~
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, the jet system will be de- 4 Engine's
compression
activated. air system

Fig 1. Principle drawing of lambda controller

96.26 - ES0S
Your Notes :

08031-0D/H5250/94.09.07
Description 609.35
Page 1 (1) Starting Box Edition 02H

L+V28/32H

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 indication is changed.
indications/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
- Pushbutton for "Blocking" * turbocharger 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 enga-
ging 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 140 RPM. If the start button
is disengaged before the diesel engine has exceeded
140 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.
08028-0D/H5250/94.08.12

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

94.20 - ES2S
Your Notes :

08031-0D/H5250/94.09.07
Description 609.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 01H

L+V28/32H

Engine RPM signal The "engine run" signals will be given through a
relay. One for synchronizing and one for start/stop of
For measuring the engine's RPM, a pick-up mounted pre. lub. oil pump or alarm blocking at start/stop.
on the engine is used giving a frequency depending
on the RPM. To be able to show the engine's RPM
on an analogue tachometer, the frequency signal is Safe start
sent through an f/I converter (frequency/current
converter), where the signal is transformed into a When the safe start signal is activated the engine
proportional 4-20 mA ~ 0-1200 RPM signal. can start. When the engine reach 140 RPM the air
starter will be shut-off.
Further, the converter has following signals:
Further, the safe start signal is a blocking function for
- overspeed the air starter during rotation.
- engine run
- safe start
- tacho fail Tacho fail

The tacho fail signal will be on when everything is


normal. If the pick-up or the converter failes the
signal will be deactivated. E.g. if there is power
supply failure.

The converter for engine RPM signal is mounted in


the terminal box on the engine.

Turbocharger RPM signal

For measuring the turbocharger RPM, a pick-up


mounted on the engine is used giving a frequency
depending on the RPM. To be able to show the
Fig 1. Converter for engine RPM. turbocharger's RPM on an analogue tachometer,
the frequency signal is sent through a f/I converter
(frequency/current converter), where the signal is
Overspeed transferred into a proportional 4-20 mA ~ 0-60000
RPM.
When the engine speed reach the setpoint for
electronic overspeed the converter gives a shutdown
signal and a alarm signal through a relay.
08028-0D/H5250/94.08.12

Engine run

When the engine speed reach 710 RPM or 200 RPM


+ 10 seconds, the converter gives a "engine run"
signal.
Fig 2. Converter for TC RPM.
The engine run signal will be deactivated when the
speed is 640 RPM. If the engine speed haven't been
over 710 RPM the signal will be deactivated at 200 The converter is mounted in the terminal box on
RPM. engine.

96.30 - ES2S
Your Notes :

08031-0D/H5250/94.09.07
Working Card Functional Test and Adjustment of Safety, 609-01.00
Page 1 (2) Alarm and Monitoring Equipment Edition 01H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water See Related Procedure
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Function test and adjustment of safety, alarm and


monitoring equipment. Hand tools:

See Related Procedure

Starting position:

Related procedure:

Overspeed trip 609-01.05


Pressostate 609-05.00
Thermostate 609-05.01
Level switch (LAL 25) 609-05.02
Analog pressure transmitter 609-05.03
Analog temperature transmitter 609-05.04
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : xxx hours Plate no. Item no. Qty. /


Capacity : xxx man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

92. 04 - ES0U
609-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 01H Alarm and Monitoring Equipment Page 2 (2)

General

Maintenance of monitoring and safety systems. It is recommended that all functions are tested every
three month according to the mentioned working
One of the most important parameters in the pre- cards.
ventive work is that the alarm system as well as the
shutdown and overspeed devices are functioning The extent of the alarm and safety functions is vari-
100%. able from plant to plant.

If some of these functions are out of operation, they For check of these functions use the working cards
have to be repaired immediately. If this is not pos- mentioned under related procedure on page 1.
sible because of the present working situation, the
engine has to be under constant observation until it
can be stopped.

08028-0D/H5250/94.08.12

92.04 - ES0U
Working Card
Functional Test and Adjustment of Overspeed Trip 609-01.05
Page 1 (2) Edition 01H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62009 01
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Functional test and adjustment of overspeed trip.


Hand tools:

Allen key, 4 mm.


Allen key, 2 mm.

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

Man power: 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)

91.45 - ES0S
609-01.05 Functional Test and Adjustment of Overspeed Trip Working Card
Edition 01H Page 2 (2)

General

1) The engine is run up manually, (on governor Turn the engine until the adjusting screw is opposite
"synchronizer") and at no load, while watching the the opening on the side of the housing. Now loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular pin spanner supplied, se fig. 2.
On reaching the revolution number indicated on
page 600.30 or in "Test Report", the overspeed
tripping device must function, thus actuating the stop
cylinders. The fuel injection pump control rods are
now moved to zero index, and the engine stops.

2) If the overspeed divice trip at a revolution


number different from that stated on page 600.30 or
in the "Test Report" the overspeed device must be
adjusted.

Fig. 2.

Turn the adjusting screw outwards (slacken fly-


weight spring) to reduce the revolution number. Be
careful not to screw the adjusting screw so far out
that it may touch the release arm. Tighten the lock
screw and test the overspeed device again.

4) Refit the covers when the overspeed device


functions at correct revolution number.

5) The overspeed device can be tested manually


Fig. 1. by depressing the button on top af the housing,see
fig. 1. This will activate the flyweight and the arm for
release of the air valve for the stop cylinders and the
Adjustment of Overspeed Trip. engine should thus stop. (This test must also be
carried out without load).
08028-0D/H5250/94.08.12

3) Remove both covers on the housing of the


overspeed tripping device, see fig. 1. 6) It is recommended now and then, while the
engine is at a standstill, to move the flyweight by
means of the push button to ensure that the flyweight
can always move with sufficient ease.

91.45 - ES0S
Working Card
Adjustment and Test of On/Off Pressostate S609-05.00
Page 1 (2) Edition 02H
08028-0D/H5250/94.08.12
S609-05.00 Adjustment and Test of On/Off Pressostate Working Card
Edition 02H Page 2 (2)

08031-0D/H5250/94.09.07
Working Card
Adjustment and Test of On/Off Thermostate S609-05.01
Page 1 (2) Edition 02H

L28/32H
08028-0D/H5250/94.08.12
S609-05.01 Adjustment and Test of On/Off Thermostate Working Card
Edition 02H Page 2 (2)

L28/32H

08031-0D/H5250/94.09.07
Working Card
Adjustment and Test of On/Off Thermostate 609-05.01
Page 1 (2) 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)

91.03 - ES0S
609-05.01 Adjustment and Test of On/Off Thermostate Working Card
Edition 02H 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, fig. 1 is loosened, the range can carried out according to the following procedure.
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 tempera-
ture 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 differenti-


al, the spindle pos. 3 can be used while the scale pos.
4 is read.

Set points, see page 600.30.

91.03 - ES0S
Working Card
Function and Test of Level Switch (LAL 25) 609-05.02
Page 1 (2) Edition 02H

General

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:

Function and test of level switch, LAL 25, in


lubricating oil system. Hand tools:

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

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)

91.03 - ES0S
609-05.02 Function and Test of Level Switch (LAL 25) Working Card
Edition 02H Page 2 (2)

General

The level switch LAL 25, which is mounted on the


main lubricating oil pipe of the engine, gives alarm for
missing prelubricating oil. Vent pipe

Function.

1) By starting the prelubricating oil pump the


main lubricating oil pipe will be filled with lubricating
oil, which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig. 1.

Test:

The test is carried out when the engine is stopped.

3) Start the lubricating oil pump, and let the pump


run about 5 min.

4) Stop the prelubricating oil pump. The alarm


must be released after 0 - 5 min., depending of the
oil viscosity.

08028-0D/H5250/94.08.12

91.03 - ES0S
Working Card Adjustment and Test of Anologous S609-05.03
Page 1 (2)
Pressure Transmitter Edition 02H

L28/32H
08028-0D/H5250/94.08.12
S609-05.03 Adjustment and Test of Anologous Working Card
Page 2 (2)
Edition 02H Pressure Transmitter
L28/32H

08031-0D/H5250/94.09.07
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
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 which the alarm plant gives any alarm, when the alarm limit
changes resistance depending on the temperature. 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-


rature can be read on this. Fig. 1.

Otherwise the test can be carried out by watching if

96.26 - ES0S
Working Card
Lambda Controller 609-10.00
Page 1 (2) Edition 10H

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:


08028-0D/H5250/94.08.12

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)

95.27 - ES0S
609-10.00 Working Card
Edition 10H
Lambda Controller Page 2 (2)

L28/32H

Lambda Controller

Normally the lambda controller does not need ad-


justment. The only time adjustment is needed, is
when the controller or the governor has been dis-
mantled. The adjustment is to be carried out in
standstill position.

1. Check that the free space between the pick-up


and the band steel on the regulating arm is min 1 mm,
see fig 1.

Fig 3.

2. Set the index of the fuel pumps according to


the Shop Test Protocol by means of the governor
arm, see plate 60902-18H, item 15.

Note: Set the "load limit" control knob at max in order


to protect the governor.

3. Fit the adjustment screw (4), fig 2, until the


piston has contact with the spring without com-
pressing the spring.
Fig 1.

4. Fasten the adjustment screw.

5. Adjustment finished.

Adjustment of the stop screw.

6. Remove pipe for charge air pressure, see fig 3.


08028-0D/H5250/94.08.12

7. Supply air pressure until the piston rod reaches


its upper position.

8. 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.

9. Adjustment finished.
Fig 2.

95.27 - ES0S
Plate
Page 1 (2) Governor and Governor Drive 60901-07H

L28/32H
09
01

For governor, see spe-


cial instruction book
10

11

12
13
14
15
16
02
17
03 18

19+

20

04
05
21
06
22
07
08

23
24
25

26
30 27

28
29

94.28 - ES0S
Plate
60901-07H Governor and Governor Drive Page 2 (2)

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

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 krver en


an individual matching individual tilpasning
04 4/E Nut Mtrik (by shims) before (med shims) fr 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 Kronemtrik

08 1/E Split pin Split

09 1/E Shut down Shut-down


solenoid spole

10 1/E Governor Regulator

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlg (st 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 Kronemtrik

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 Bsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

28 1/E Pointed screw Pinolskrue

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

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

94.28 - ES0S
Plate
Page 1 (2) Regulation Mechanism 60902-18H

L28/32H

Governor Plate 60901

17
15
18
01 13
19 16
02
03

04
05 14

19
06 25 20
07 18
26
08 27 17
28 21
09
24 22
10
25 23
11
12
64
13
65
02

66

67

56
68

48
49 69
57
50
58 51
52
55 53

61 54
62 59
63
60

94.36 - ES0S
Plate
60902-18H Regulation Mechanism Page 2 (2)

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

01 1/R Split pin Split 48 1/C Linkage Lnkeled

02 2/R Pull rod head Trkstangshoved 49 1/C Pin Stift

03 1/R Pull rod end Trkstangsende 50 1/C Spring Fjeder

04 1/R Cylindrical pin Cylindrisk stift 51 1/C Spring arm Fjederarm

05 1/R Spring housing Fjederhus 52 3/C Spring pin Fjederstift

06 1/R Pointed screw Pinolskrue 53 1/C Arm holder Armholder

07 1/R Spring Fjeder 54 1/C Screw Skrue

08 1/R Pull rod Trkstang 55 1/C Spring loaded Fjederbelastet


lever, complete arm, komplet
09 1/R Cylindrical pin Cylindrisk stift
56 1/E Regulating shaft Reguleringsaksel
10 1/R Guide ring Styrering
57 1/C Split pin Split
11 1/R Guide ring Styrering
58 1/C Pin Stift
12 1/R Nut Mtrik
59 1/C Bushing Bsning
13 2/R Locking plate Lseblik
60 1/C Bearing bracket Lejeblik
14 1/R Spring loaded pull Fjederbelastet trk-
rod, complete stang, komplet 61 2/C Screw Skrue

15 1/R Governor arm Regulator arm 62 2/C Washer Skive

16 1/R Screw Skrue 63 2/C Spring pin Fjederstift

17 2/R Split pin Split 64 1/E Stop ring Stopring

18 2/R Self locking nut Selvlsende mtrik 65 1/E Screw Skrue

19 2/R Screw for ball head Skrue for kuglehoved 66 2/E Screw Skrue

20 1/R Arm Arm 67 2/E Screw Skrue

21 1/R Spring pin Fjederstift 68 1/E Bracket Konsol

22 1/R Locking plate Lseblik 69 2/E Nut Mtrik

23 1/R Screw Skrue

24 1/R Bearing housing Lejehus

25 2/R Bush Bsning

26 2/R Screw Skrue

27 2/R Washer Skive

28 2/R Spring pin Fjederstift

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

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
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

94.36 - ES0S
Plate
Page 1 (2) Overspeed Device 60903-38H

L+V28/32H
08028-0D/H5250/94.08.12

98.14 - ES0S
Plate
60903-38H Overspeed Device Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

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 Dksel 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 (hjre)

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 svingvgt 44 1/E Pneumatic valve Pneumatisk ventil

14 1/E Adjusting screw Justeringsskrue 45 1/E Silencer Lyddmper

15 1/E Spring Fjeder 46 1/E Overspeed device, Overspeed anordning,


complete excl. item komplet eksl. item 27,
16 1/E Circlip Sikringsring 27, 37, 38, 44 37, 38, 44

17 1/E Flyweight Svingvgt 47 1/E Spare parts kit for Reservedelskit for
item 44 item 44
18 1/E Key Not

19 1/E Ball bearing Kugleleje

20 1/E Housing Hus

21 1/E Cover Dksel

22 4/E Washer Skive

23 4/E Screw Skrue

24 1/E Pin Stift

25 1/E Lever Arm

26 1/E Nut Mtrik


08028-0D/H5250/94.08.12

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 ogs side 600.50.

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

98.14 - ES0S
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 60905-09S

L28/32H
08028-0D/H5250/94.08.12

91.41-ES0S
Plate
60905-09S Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)

L28/32H

Item Item
Qty. Designation Qty. Designation
No. No.
01 1/E Cable union
02 1/E Mounting plug
03 1/E Gasket
04 1/E Level switch
05 1/E Plug screw
06 1/E Gasket
07 1/E Fuel oil leakage alarm, complete
08 1/E Ball valve

08031-0D/H5250/94.09.07

When ordering spare parts, see also page 600.50

* = Only available as part of a spare parts kit.


Qty./E = Qty./Engine

91.41-ES0S
Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 60905-13H

General
08028-0D/H5250/94.08.12

91.44-ES0S
Plate
60905-13H Prelubricating Oil Alarm (LAL 25) Page 2 (2)

General

Item Item
Qty. Designation Qty. Designation
No. No.
01 1/E Plug screw
02 1/E Packing ring
03 1/E Packing ring
04 1/E Level switch

08031-0D/H5250/94.09.07

When ordering spare parts, see also page 600.50

* = Only available as part of a spare parts kit.


Qty./E = Qty./Engine

91.44-ES0S
Plate
Page 1 (2) Instrument Panel 60905-27H

L28/32H

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
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

94.28 - ES0S
Plate
60905-27H Instrument Panel Page 2 (2)

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

01 1/E Housing for instru- Hus for instrumentpanel 23 1/E Damper (charging air) Dmper (ladeluft)
ment panel
43 4/E Screw Skrue
02 1/E Bracket for instrument Konsol for instrument-
panel panel 44 4/E Serrated lock washer Stjernefjederskive

03 4/E Rubber clutch Gummikobling 45 2/E Screw Skrue

04 8/E Nut Mtrik 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 Nleventil

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 Rr

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) Dmper (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 ogs side 600.50.

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

94.28 - ES0S
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 60905-35H

L+V28/32H
08028-0D/H5250/94.08.12

95.21 - ES0S
Plate
60905-35H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)

L+V28/32H

Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

01 1/E Level alarm Niveaualarm

02 1/E Plate Plade

03 1/E Packing Pakning

04 4/E Hexagon screw Hexagonskrue

05 4/E Nut Mtrik

06 1/E Pipe Rr

07 1/E Pipe Rr

08 2/E Level switch Niveaukontakt

09 2/E Reduction adaptor Reduktionsadapter

10 1/E Dipstick complete Pejlestok komplet

08028-0D/H5250/94.08.12

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

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

95.21 - ES0S
Plate
Page 1 (2) Thermometer 60907-01S

L28/32H
08028-0D/H5250/94.08.12

91.44-ES0S
Plate
60907-01S Thermometer Page 2 (2)

L28/32H

08031-0D/H5250/94.09.07

91.44-ES0S
Plate Pressostate, Thermostate Difference
Page 1 (2) 60907-02S
Pressostate and Pressure Transmitter
General
08028-0D/H5250/94.08.12

91.44-ES0S
Pressostate, Thermostate Difference Plate
60907-02S Page 2 (2)
Pressostate and Pressure Transmitter
General

08031-0D/H5250/94.09.07

91.44-ES0S
Plate
Page 1 (2) Lambda Controller 60910-03H

L28/32H

94.28 - ES0S
Plate
60910-03H Lambda Controller Page 2 (2)

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

01 1/E Regulating arm, Reguleringsarm,


complete komplet

02 1/E Pick-up, Pick-up,


incl. sleeve incl. afstandsring

03 1/E Lambda cylinder, Lambdacylinder,


complete komplet

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

94.28 - ES0S
Plate
Page 1 (2) Starting Box 60935-07H

L28/32H
08028-0D/H5250/94.08.12

99.40 - EO0
Plate
60935-07H Starting Box Page 2 (2)

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

01 1/E Panel Panel

02 1/E Starting box Starting box

08028-0D/H5250/94.08.12

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

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

99.40 - EO0
Index
Page 1(1) Crankshaft and Main Bearings 610

L28/32H
Description

Crankshaft and main bearings --------------------------------------------------------------- 610. 01 (12H)

Working Card

Checking of main bearing alignment (deflection) ----------------------------------- 610- 01 .00 (10H)


(hydraulic tightened connecting rod)
Inspection of main bearing shells ----------------------------------------------------------- 610- 01 .05 (05H)
Inspection of guide bearing shells ---------------------------------------------------------- 610- 01 .10 (08H)
Vibration damper --------------------------------------------------------------------------------610- 40 .00 (01H)

Plates

Crankshaft ----------------------------------------------------------------------------------------------- 61001- 15H


Resilient gear wheel -----------------------------------------------------------------------------------61002- 07H
Flywheel with gear rim -------------------------------------------------------------------------------- 61003- 02H
Torsional vibration damper -------------------------------------------------------------------------- 61004- 05H

STX Engine
Your Notes :

08031-0D/H5250/94.09.07
Description
Crankshaft and Main Bearings 610.01
Page 1 (1)
Edition 12H

L/V28/32H

Crankshaft Vibration Damper

The crankshaft, which is a one-piece forging with In special cases a vibration damper is mounted on
ground main bearing and crankpin journals, is sus- the crankshaft to limit torsional vibrations. The dam-
pended in inderslung bearings. The main bearings per consists essentially of a heavy flywheel totally
are equipped with insertion-type shells, which are enclosed in a light casing. A small clearance is
coated with a wearing surface. To attain a suitable allowed between the casing and the flywheel, and
bearing pressure the crankshaft is provided with this space is filled with a highly viscous fluid. The
counterweights, which are attached to the crank- casing is rigidly connected to the front end of the
shaft by means of dovetail joints and secured with a engine crankshaft and the only connection between
centrally placed screw. the crankshaft and the damper flywheel is through
the fluid. Under conditions of no vibration, the casing
At the flywheel end the crankshaft is fitted with a gear and damper flywheel tend to rotate as one unit, since
wheel which through an intermediate wheel drives the force required to shear the viscous film is consi-
the camshaft. Also fitted here is the flywheel and a derable. As the torsional vibration amplitudes
coupling flange for connection of a reduction gear or increase, the casing follows the movement of the
a alternator. At the opposite end there is a claw-type crankshaft but the flywheel tends to rotate uniformly
coupling for the lub. oil pump or a flexible gear wheel by virtue of its inertia, and relative motion occurs
connection for lub. oil and water pumps. between the flywheel and the casing. The viscous
fluid film therefore undergoes a shearing action, and
vibration energy is absorbed and appears as heat.
08028-0D/H5250/94.08.12

91.45 - ES0U
Your Notes :

08031-0D/H5250/94.09.07
Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00
Page 1 (6) (Hydraulic Tightened Connecting Rod) Edition 10H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62010 01
Shut-off fuel oil 62010 05
Shut-off cooling oil 62010 35 Angle for
Stopped lub. oil circul. mounting on
crank web

Description:

Checking of main bearings alignment (deflection).


Hand tools:

Starting position:

Turning gear in engagement. (If mounted).


Cover for crankshaft has been removed from
frame.
All indicator valves open.

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 1/2 hours 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)

99.25 - ES0S
610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 10H (Hydraulic Tightened Connecting Rod) Page 2 (6)

L28/32H

Alignment of Main Bearings.

The lower main bearing shells should be positioned


so that they keep the main bearing journals of the
crankshaft centered in a straight (ashore horizontal)
line. Deviations from this centre line cause the
crankshaft to bend and increase the load on some
main bearings.

If two adjacent main bearings are placed too low, the


crankshaft centre line will in this place be lowered to
form an arc, causing the intermediate crank throw to
bend in such a way that it "closes" when turned into
bottom position and "opens" in top position.

As the magnitude of such axial lengthening and


shortening during the turning of the throw increases Fig. 1 Placing of dial gauge
in proportion to the difference in the height of the
bearing, it is measured as a check on the alignment
and condition of the bearing.
Checking The Deflection Measurement.
As the crankshafts of medium speed engines are
very stiff, any great deviations in the alignment will The reading is entered in the table page 6, see
result in clearance at the bottom shell of the bearings. example in fig. 2 - 6.

The cause of incorrect main bearing position may be As "bottom" reading is used the mean value of the
wear of the bearings or misalignmnet of the engine. two "near bottom" readings X and Y, fig. 3.

The total deflection ("opening-closing") of the throw


Effecting The Deflection Measurement. during the turning from bottom to top position is
entered in fig. 4.
The deflection measurement is effected by placing a
springloaded dial gauge in the centre punch marks These figures are due to vertical misalignment of the
provided for this purpose, see fig. 1. main bearings.

"Closing" of the throw in top dead centre is regarded Similarly, horizontal misalignment procedures the
as negative, (compression of the gauge). figures in the table fig. 5.

In the example, page 3, the deflection reading is Besides misalignment of the bearings, the readings
therefore negative. can be influenced by ovality or eccentricity of the
journals.
08028-0D/H5250/94.08.12

As during the turning of the throw, the gauge and the


connecting rod will meet near the bottom position of
the throw, the measurement for the bottom position Engines Equipped with Turning Gear.
is to be replaced by the average of the two near by
positions on either side. When taking these deflection readings for the three
aftmost cylinders, the turning gear should at each
The dial gauge is set to zero, when the crank throw stoppage be turned a little backwards to ease off the
is in the near-bottom (x in fig. 8) and during the tangential pressure on the teeth of the turning wheel
turning the throw is stopped in the position horizon- as this pressure may otherwise falsify the readings.
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.

99.25 - ES0S
Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00
Page 3 (6) (Hydraulic Tightened Connecting Rod) Edition 10H

L28/32H

Deflection of crankshaft in 1/100 mm. (0.01 mm).


Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig. 4.
Left side P 2 0 2 0 -1 2

Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment

Bottom stop Y 2 -1 0 1 0 2 Right side - left side


or P - S = H -1 2 0 0 -1 1

Fig. 2. Fig. 5.

Bottom (0,5 x Y) = B 1 -0.5 0 -0.5 0 1 Check on T+B= C 4 -2.5 4 5.5 -2 4


gauge
readings P+S= D 5 -2 4 0 -1 3
Fig. 3.

Fig. 6.

C and D should be nearly the same, reading for cylinder 4 to be repeated.

S P
08028-0D/H5250/94.08.12

Y X

Front end view.


"Closing" of the crankthrow is considered nega- Start in position X.
tive. Turn anti clockwise

Fig. 7. Fig. 8.

99.25 - ES0S
610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 10H (Hydraulic Tightened Connecting Rod) Pagee 4 (6)

L28/32H

Measurement of Crank Throw Deflections by Means of Dial Indicator (Autolog)

Crank throw deflection = Difference in dial indicator readings in two diametrically


opposite crank throw positions, i.e. two positions dis-
placed 180.

Vertical deflection = Difference in top-bottom readings.

Horizontal deflection = Difference in side-side readings.

Vertical of Horizontal Deflections of Crank Throws

Unless otherwise stated the values refer to cold engine.

For new or realigned aggregate Aim for + or - 4/100 mm


Acceptable + or - 6/100 mm

For aggregate in service realignment


is recommended if deflections exceed + or -10/100 mm

Vertical Deflection of Crank Throw at Flywheel

Unless otherwise stated the values refer to cold engine.

Rigid coupling between Flexible coupling between


diesel engine and driven machine diesel engine and driven machine
08028-0D/H5250/94.08.12

For new or realigned For new or realigned


aggregate 0 to + 4/100 mm aggregate Aim for - 7/100 mm
Acceptable - 10/100 mm

For aggregate in service realignment is For aggregate in service


recommended if deflection measured realignment recommendable
on warm engine exceeds - 10/100 mm if deflection exceeds - 14/100 mm

99.25 - ES0S
Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00
Page 5 (6) (Hydraulic Tightened Connecting Rod) Edition 10H

L28/32H

Process/Proces I.D. no.

Plant/Anlg Page of/Side af

Engine Type/Motortype Engineer/Operatr Date/Dato

Instruction/Instruktion

Top

Right side Left side

Bottom end/ Bottom start/


1/100 mm Bund slut Bund start

Right side Right side

Cyl. no 1 2 3 Cyl. no 1 2 3

Left side Cyl. no 1 2 3

Left side

Remarks/Bemrkninger
08028-0D/H5250/94.08.12

99.25 - ES0S
610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 10H (Hydraulic Tightened Connecting Rod) Page 6 (6)

L28/32H

Component/Komponent Type I.D. no.

Process/Proces Page of/Side af

Test place/ Test bed/prvehal Cold/Kold


Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal

Engine no.:
Motornr.:

Cyl. no. 1 2 3 4 5 6 7 8 9

Bottom X 0 0 0 0 0 0 0 0 0

Left side P

Top T

Right side S

Bottom Y

Bottom
(0.5xY)=B

Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V

Deflection from
horizontal mis-
08028-0D/H5250/94.08.12

alignment.
Left side - Right
side or P - S = H

Check on gauge
readings.

T+B= C

P+S= D

99.25 - ES0S
Working Card
Inspection of Main Bearing Shells 610-01.05
Page 1 (3) Edition 05H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62010 10 2 pieces
Shut-off fuel oil 62010 20
Shut-off cooling oil 62010 01
Stopped lub. oil circul. 62010 15 2 pieces
62010 30 Extra tools
62021 40 Hydraulic tools
62021 50 2 pieces
Description: 62021 51
62021 20
Dismantling, inspection and/or replacement and
mounting of main bearing shells.
Hand tools:

Allen key, 12 mm.


Socket spanner, 36 mm.
Starting position: Lead hammer.
Silastene.
Copaslip.

Related procedure:

Inspection of guide bearing shell, 610-01.10


Criteria for replacement of bearings, 606-01.16

Manpower:
08028-0D/H5250/94.08.12

Working time : 2 hours Replacement and wearing parts:


Capacity : 2 men
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)

96.30 - ES0S-G
610-01.05 Inspection of Main Bearing Shells Working Card
Edition 05H Page 2 (3)

L+V28/32H

Make Ready for Dismantling of the Main Bearing

1) Dismount crankcase covers in front and oppo-


site the bearing concerned.

2) Turn the engine until the crank is in a conveni-


ent position for carrying out the work.

3) Dismount the bracing screw (side screw).

4) Mount the hydraulic tools and loosen the main


bearing stud nuts. For operation of the hydraulic
tools, see working card 620-01.05.

Fig 2. Mounting of Wire Straps.

8) Lift the main bearing cap a little and unscrew


the bearing stud nut.

9) Fit guide tubes on the threads of the bearing


studs and lower the bearing cap to make it rest on the
collar of the guide tubes.

Dismantling of the Main Bearing Shells

10) Remove the locking piece from the bearing


cap and take out the bearing shell.

11) Fit the tool for upper main bearing, for dis-
mantling of upper main bearing shell, in the lubricating
Fig 1. Mounting of Hydraulic Tools. hole in the crankshaft and turn out the upper bearing
shell by turning the crankshaft, see fig 3.

5) Dismount the hydraulic tools and slacken the


nuts somewhat.

Dismantling of the Main Bearing Cap


08028-0D/H5250/94.08.12

6) Fit the eye screws, diagonally, in the threaded


holes in the main bearing cap, see fig 2.

Pass the wire supplied through the eye screw and


attach it as shown, so as to keep the bearing cap in
place when the main bearing stud nuts are removed. Tool for upper main
bearing

7) Work the main bearing cap loose from the


engine frame with a lead hammer or similar. Fig 3. Mounting of tool for upper main bearing.

96.30 - ES0S-G
Working Card
Inspection of Main Bearing Shells 610.01-05
Page 3 (3) Edition 05H

L+V28/32H

Cleaning 17) Insert the lower bearing shell in the bearing


cap and mount the locking piece.
12) Clean all machined surfaces, on frame, bearing
cap, stud, nuts and bea