Professional Documents
Culture Documents
Engine
Operating Instructions B1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 7L 58/64 CD
6721-- 1
MAN Diesel SE : D-86224 Augsburg : Telefon (0821) 3 22-0
All copyrights reserved for reprinting, photomechanical reproduction (photocoying/microcopying) and translation of
this documents or part of it.
N 1 Introduction
: : : N 1.1 Preface
: : : N 1.2 Product Liability
: : N 1.3 How the Operating Instruction Manual is organized, and how to use it
: : N 1.4 Addresses/Telephone numbers
N 2 Technical details
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
N 3 Operation/Operating media
N 3.1 Prerequisites
: : N 3.1.1 Prerequisites/Warranty
N 3.2 Safety regulations
: : N 3.2.1 General remarks
: : : N 3.2.2 Destination/suitability of the engine
: : : N 3.2.3 Risks/dangers
: : : N 3.2.4 Safety instructions
: : : N 3.2.5 Safety regulations
N 3.3 Operating media
: : N 3.3.1 Quality requirements on gas oil/diesel fuel (MGO)
: : N 3.3.2 Quality requirements for Marine Diesel Fuel (MDO)
: : N 3.3.3 Quality requirements for heavy fuel oil (HFO)
: : N 3.3.4 Viscosity/Temperature diagram for fuel oils
: : N 3.3.5 Quality requirements for lube oil
: : N 3.3.6 Quality requirements for lube oil
: : N 3.3.7 Quality requirements for engine cooling water
: N 3.3.8 Analyses of operating media
: : N 3.3.11 Quality requirements for intake air (combustion air)
N 3.4 Engine operation I -- Starting the engine
: : N 3.4.1 Preparations for start/ Engine starting and stopping
: : N 3.4.2 Change--over from Diesel fuel oil to heavy fuel oil and vice versa
: : N 3.4.3 Admissible outputs and speeds
: : : N 3.4.4 Engine Running--in
N 3.5 Engine operation II -- Control the operating media
: : N 3.5.1 Monitoring the engine/ performing routine jobs
: : N 3.5.2 Engine log book/ Engine diagnosis/Engine management
: : N 3.5.3 Load curve during acceleration/manoeuvring
: : N 3.5.4 Part--load operation
: N 3.5.5 Determine the engine output and design point
: : N 3.5.6 Engine operation at reduced speed
: : N 3.5.7 Equipment for adapting the engine to special operating conditions
: N 3.5.8 Bypassing of charge air
: N 3.5.9 Condensed water in charge air pipes and pressure vessels
: : N 3.5.10 Load application
: N 3.5.11 Exhaust gas blow--off
N 3.6 Engine operation III -- Operating faults
: : N 3.6.1 Faults/Deficiencies and their causes (Trouble Shooting)
: : N 3.6.2 Emergency operation with one cylinder failing
: : N 3.6.3 Emergency operation on failure of one turbocharger
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
N 4 Maintenance/Repair
N 5 Annex
: : N 5.1 Designations/Terms
: : N 5.2 Formulae
: : N 5.3 Units of measure/ Conversion of units of measure
: : N 5.4 Symbols and codes
: : N 5.5 Brochures
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
1 Introduction
2 Technical details
3 Operation/
Operating media
4 Maintenance/Repair
5 Annex
N 1 Introduction
: : : N 1.1 Preface
: : : N 1.2 Product Liability
: : N 1.3 How the Operating Instruction Manual is organized, and how to use it
: : N 1.4 Addresses/Telephone numbers
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
Engines -- characteristics, Engines produced by MAN B&W Diesel AG have evolved from decades of
justified expectations, continuous, successful research and development work. They satisfy high
prerequisites standards and have ample redundancy of withstanding adverse or detri-
mental influences. However, to meet such expectations, they have to be
used to purpose and serviced properly. Only if these prerequisites are ful-
filled, unrestricted efficiency and long service life can be expected.
Purpose of the operating and The operating instructions as well as the working instructions (work cards)
working instructions are thought to assist you in becoming familiar with the engine. They are
also thought to provide answers to questions that may turn up later on,
and to serve as a guidance in your activities of engine operation and when
carrying out maintenance work. Furthermore, we attach equal importance
to familiarising you with the methods of operation, causes and conse-
quences, and to conveying the empirical knowledge we have. Not least, in
providing the operating and working instructions, we comply with our legal
duty of warning the user of the hazards which can be caused by the en-
gine or its components - in spite of a high level of development and much
constructive efforts - or which an inappropriate or wrong use of our prod-
ucts involve.
Condition 1 The technical management and also the persons carrying out mainten-
ance and overhaul work have to be familiar with the operating instructions
and working instructions (work cards). These have to be available for con-
sultation at all times.
Condition 3 The technical documentation is tailored to the specific plant. There may be
considerable differences to other plants. Informations valid in one case
may, therefore, lead to problems in others.
To be observed as well ... Please also observe the notes on product liability given in the following
section and the safety regulations in Section 3.
The reliable and economically efficient operation of the engine system re-
quires that the operator has a comprehensive knowledge. Similarly, proper
performance can only then be maintained or restored by maintenance or
repair work if such work is done by qualified specialists with the adequate
expertise and skill. Rules of good workmanship have to be observed,
negligence is to be avoided.
1 Introduction
2 Technical details
3 Operation/Operating media
4 Maintenance/Repair
5 Annex
Engine design The operating manual will be continually updated, and matched to the de-
sign of the engine as ordered. There may nevertheless be deviations be-
tween the sheets of a primarily describing/illustrating content and the defi-
nite design.
Technical details For technical details of your engine, please refer to:
- Section 2, “Technical Details”
- Volume A1, to the publication “..... Continuous Development”
- Volume B2, Work Card 000.30
- Volume B5, test run record and commissioning record
- Volume D1, list of measuring, control and regulating instruments
- Volume E1, installation drawing
With the exception of the above-mentioned publication, all documents
have been specifically matched to the respective engine.
Maintenance schedule/ The maintenance schedule is closely related to the work cards of Volume
work cards B2. The work cards describe how a job is to be done, and which tools and
facilities are required for doing it. The maintenance schedule, on the other
hand, gives the periodical intervals and the average requirements in per-
sonnel and time.
Addresses Table 1 contains the addresses of Works of the MAN Diesel SE and of the
Technical Branch Office in Hamburg. The addresses of MAN Diesel SE
service centers, agencies and authorised repair workshops can be looked
up in the brochure “Diesel and Turbocharger Service Worldwide” in
Volume A1.
Company Address
Work Augsburg MAN Diesel SE
D--86224 Augsburg
Phone +49 (0)821 322 0
Fax +49 (0)821 322 3382
Work Hamburg MAN Diesel SE
Service Center, Werk Hamburg
Rossweg 6
D--20457 Hamburg
Phone +49 (0)40 7409 0
Fax +49 (0)40 7409 104
Technical Branch Office Hamburg MAN Diesel SE
Vertriebsbüro Hamburg
Admiralitätstraße 56
D--20459 Hamburg
Phone +49 (0)40 378515 0
Fax +49 (0)40 378515 10
MAN Diesel SE Service Center, Please look up in the brochure
agencies and authorised repair “Diesel and Turbocharger Service
workshops Worldwide”
Table 1. Companies and addresses of the MAN Diesel SE
Contact Table 2 contains the names, telephone and fax numbers of the competent
persons who can give advise and render assistance to you if required.
Your contact
Work Augsburg Work Hamburg MAN Diesel SE Ser-
Service Center vice Center, agencies,
Phone: Phone: authorised repair
+49 (0)821 322 ..... +49 (0)40 7409 ..... workshops
Fax: Fax:
+49 (0)821 322 ..... +49 (0)40 7409 .....
Service Engines Holst MST Ruthenberg MST4 Look up in the brochure
Phone ..... 3930 Phone ..... 273 “Diesel and Turbochar-
Fax ..... 3838 Fax ..... 277 ger Service Worldwide”
g
Service Turbocharger Litzenberg TS i Volume
in V l A1
Phone ..... 4272
Fax ..... 3998
Service Spare parts Stadler MSC
Phone ..... 3580
Fax ..... 3720
Table 2. Persons to be contacted, telepone and fax numbers
1 Introduction
2 Technical details
3 Operation/
Operating media
4 Maintenance/Repair
5 Annex
N 2 Technical details
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
Items supplied The next page is a list of the items we have supplied. We are giving you
this list to ensure that you contact the right partner for obtaining
information/assistance.
For all items supplied by us ... For all questions you have on items supplied by us, please contact
- MAN B&W Diesel AG in Augsburg,
and for typical service questions,
- MAN B&W service centers,
- agencies and
- authorised repair workshops all over the world.
For all items not supplied by us ... For all items not supplied by us, please directly contact the subsuppliers,
except the components/systems supplied by MAN B&W Diesel AG are
concerned to a major extent or similar, obvious reasons apply.
L 58/64 CD engine -- an impor- Engines with the designation L 58/64 CD are supercharged four-stroke
tant member of the medium- engines in in-line design with a cylinder bore of 580 mm and a piston
speed engine family stroke of 640 mm. They are used for power generation in ships and in
stationary power plants.
Characteristics in key words When viewing onto the coupling, the exhaust gas pipe is located on the
right (exhaust side, AS) and the charge air pipe on the left (exhaust
counter side, AGS).
The camshaft lies in a trough on the exhaust counter side. It serves for
actuating the inlet and exhaust valves and for driving the injection pumps.
The injection timing can be changed by means of an adjusting device.
The engine is suitable for fuels up to 700 mm2/s at 50 C up to, and includ-
ing CIMAC H/K 55. On demand, the engine can be adapted for operation
on MDO.
Engines of this series have a large stroke/bore ratio and a high compres-
sion ratio. These characteristics facilitate an optimisation of the combus-
tion chamber design and contribute to a good part-load behaviour and a
high efficiency.
The engines are equipped with MAN B&W turbochargers of the TCA
series.
Figure 1. 6--cylinder engine L 58/64 CD, viewed from the exhaust counter side
Crankcase
1 Cylinder head
2 Backing ring
3 Tie rod
4 Crankcase
5 Crankshaft
6 Main bearing cap
7 Cross tierods
The oil sump or the foundation frame collects the oil dripping from the run-
ning gear components and routes it to the lube oil tank arranged at a lower
level. In the case of rigidly or semi-resiliently supported engines, an oil
sump of standard design is used, while in the case of resiliently supported
engines, a reinforced oil sump is used. If the engine is set up on a founda-
tion frame, the latter serves as a lube oil tank at the same time.
Bearing cap/tie rod The main bearings consist of one upper and one lower bearing shell each,
as well as the main bearing cap (6, refer to Figure 3 ). The main bearing
cap, which is arranged in suspended position, is fastened to the crankcase
by means of tie rods (3) and cross tierods (7).
3Tie rod
4Crankcase
5Crankshaft
6Main bearing cap
7Bore hole for the cross
tierod
8 Lower bearing shell
21 Drive wheel
Locating bearing The locating bearing, which determines the axial position of the crankshaft,
is arranged on the coupling end. It consists of a two-part drive wheel (21)
located on the crankshaft, and of butting rings that are supported by the
first bearing pedestals (refer to Figure 3 ).
Crankshaft
Crankshaft/balance weights/ The forged crankshaft is arranged in suspended position and has two bal-
drive wheel ance weights per cylinder, which serve for balancing the oscillating
masses (refer to Figure 4 ). The drive wheel for the camshaft drive con-
sists of two sections, and is mounted to the crankshaft by means of tan-
gentially arranged bolts.
Flywheel The flywheel is arranged on the coupling flange of the crankshaft. When
doing maintenance work, the running gear can be turned by the gear rim
of the flywheel using a turning gear.
Connecting rod
Connecting rod with parting line The parting line of the connecting rod is located underneath the connect-
ing rod small end (refer to Figure 6 ). It is, therefore, not necessary to
open the big end bearing when the piston is pulled. Moreover, this design
Piston
9 Piston crown
10 Undercut bolt
11 Compression ring
12 Oil control ring
20 Piston pin bore
Design characteristics Basically, the piston consists of two parts (refer to Figure 7 ), the piston
crown (9) and the piston skirt. In the piston crown, the ring grooves for the
compression rings are located; in the piston skirt, the connecting rod is
inserted by means of the piston pin (20). The piston pin is supported in
the piston in a floating manner and axially fixed in place by means of re-
taining rings. Piston crown and piston skirt are connected by means of
undercut bolts (10).
Cylinder liner
2 Backing ring
14 Top land ring
15 Cylinder liner
Figure 8. Cylinder liner with backing ring and top land ring
Cylinder liner/backing ring/ In the upper range, the cylinder liner (15) is centred by the backing ring. In
top land ring the lower range, the cylinder liner is guided by the crankcase. The top
land ring (14) is located on the collar of the cylinder liner.
Combined effect of The top land ring (14), which projects over the cylinder liner bore, together
stepped piston/top land ring with the set-back piston crown (9) of the stepped piston prevent the coke
deposits adhering to the piston crown from coming into contact with the
running surface of the cylinder liner (15).
Cooling The cooling water reaches the cylinder liner via the backing ring, from
where the upper part of the cylinder liner is cooled. Afterwards, the cool-
ing water flows through the top land ring and then through bore holes in
the backing ring to the cooling spaces of the cylinder head. Cylinder head,
backing ring and top land ring can be drained together.
The inspection bores in the backing ring permit checking the top land ring,
cylinder liner and cylinder head for gas tightness and cooling water leak-
ages.
The cylinder heads are forced onto the top land ring by means of eight
studs each.
Rocker arm casing/valve drive At the top, the cylinder head is closed by the rocker arm casing and by a
cover, through which the inlet and exhaust valves, as well as the injection
valve are easily accessible (refer to Figure 10 ).
Figure 10. Cylinder head with rocker arm casing and valve drive
1 Crankshaft
2 Camshaft
Arrangement of the camshaft The camshaft drive is integrated in the crankcase (refer to Figure 1 ).
drive and the intermediate It is arranged on the coupling end between the first main bearings. The
wheels drive of the camshaft (2) is effected by intermediate wheels over a gear
rim on the crankshaft (1).
Lubricating oil supply The lubricating oil supply to the bearing bushes of the intermediate wheels
is effected through the axles, while the supply to the meshing is ensured
by spray nozzles.
Camshaft
Figure 2. Camshaft
Camshaft The engine has a multisectional camshaft, which actuates the inlet and
exhaust valves as well as the injection pumps (refer to Figure 2 ).
Valve drive
Valves
Valves/valve guides Per cylinder head, there are two inlet (11) and exhaust valves (12) each.
They are guided by pressed-in valve guides (15) - refer to Figure 5 .
10 Cylinder head
11 Inlet valve
12 Exhaust valve
15 Valve guide
Figure 5. Cylinder head
Valves/seat rings The exhaust valve cone and the appertaining seat ring are provided with
an armouring. In addition, the seat ring of the exhaust valve is of water-
cooled design. As regards the inlet valve, only the valve cone has an ar-
mouring (refer to Figure 5 ).
Rotators The inlet valves (11) are turned by valve rotators. The exhaust valves (12)
have propeller blades above the valve plate, which cause the valves to
rotate by the effect of the passing gas current. The rotators counteract
high thermal stresses, which individual spots are subjected to, and ensure
that the valve seats are gas tight.
Speed governor
Depending on the field of application and the operating mode of the en-
gine, a mechanical-hydraulic, a mechanical-electronic or a fully electronic
speed governor is used.
System components of the ... The mechanical-hydraulic speed and performance control system consists
... mechanical-hydraulic of the mechanical speed governor with the hydraulic actuator, the remote
speed control system speed control system and the shut-off device. The speed pick-ups are
required for emergency shut-off.
... electronic-hydraulic In the case of the electronic-hydraulic speed and performance control sys-
speed control system tem, an electro-hydraulic converter, an electronic speed governor and an
oil cooler are added to the above.
Using the injection timing adjusting device, the injection timing can be
adapted to different fuel qualities. For this purpose, the cam followers of
the injection pumps are moved by eccentric shafts.
1 Driving motor
2 Worm gear
3 Limit switch
4 Hydraulic brake
Arrangement/drive The fuel injection pumps are arranged on the camshaft trough. The drive
is effected by the fuel cams, via the cam followers (8). The lifting move-
ment of the cam follower is transmitted to the pump plunger of the fuel in-
jection pump via a tappet with roller.
Method of operation The fuel is supplied to the pump cylinder of the fuel injection pump via an
annulus, where the baffle screws are also arranged. The pump cylinder is,
on top, closed by the valve body. On the inside, constant-pressure relief
valves are arranged, which prevent cavitation and pressure fluctuations
within the fuel system to a very large extent.
Admission setting The delivery rate in accordance with the required performance-speed com-
bination is reached by turning the pump plunger and the control edges.
Each injection pump is equipped with an emergency stop piston.
18 Control shaft
23 Control rod
24 Buckling lever
30 Injection pump
Figure 8. Control shaft with buckling lever
The actuator actuates the con- The fuel rack is actuated by the speed governor or the appertaining actua-
trol shaft tor, whose lever movement is transmitted to the control shaft (18), which
is located in bearing blocks that are screwed to the crankcase in front of
the injection pumps. By the rotating movement, the control rods (23) of
the injection pumps (30) are shifted.
Buckling lever Due to their spring-loaded tripping mechanism, the buckling levers (24)
permit both stopping and starting the engine in case the control rod of a
cylinder is blocked.
The fuel is supplied to the injection valves through the fuel injection pipes
(25) and via the lances.
23 Control shaft
24 Buckling lever
25 Fuel injection pipe
(double-walled)
Figure 9. Injection pump with fuel injection pipe
Injection valve
26 Lance
27 Cylinder head
28 Nozzle body
29 Combustion chamber
32 Injection nozzle
Figure 10. Fuel injection valve
Fuel admission The fuel injection valve is arranged centrally in the cylinder head. The fuel
supply is effected via the lance (26), which is lead through the cylinder
head (27) and screwed to the nozzle body (28). The fuel is by the injec-
tion valve directly injected into the combustion chamber (29).
Cooling The injection valves are cooled by a separate nozzle cooling water sys-
tem. Coolant inlet and outlet are located in the centre area of the valve.
Supercharged system/turbocharger
1 Turbocharger
2 Diffuser
3 Charge air cooler
4 Charge air pipe
5 Exhaust pipe
A Fresh air
B Exhaust gas
Figure 1. Turbocharger with charge-air cooler
The charge air pipe consists of sections, which are connected to one
another by means of special clamps. Charge air pipe section and rocker
arm casing form a unit.
Lube oil pipe/ All lubricating points of the engine are supplied with pressurised oil by a
route of the lubricating oil lube oil pipe located on the control side. The lube oil inlet flange is ar-
ranged on the free engine end. The lubricating oil is supplied to the main
bearings and through the crankshaft to the torsional vibration damper and
to the big-end bearings via stub lines. The connecting rod then routes the
lubricating oil to the piston crown, from where the oil runs back into the oil
sump.
Further stub lines supply oil to the camshaft bearings, the cam followers,
the injection pumps and the rocker arms.
The spray nozzles for the camshaft drive gears, the turbocharger and the
speed governor are supplied with lubricating oil from a distributing pipe on
the coupling end.
Cylinder liner lubrication The lubrication of the cylinder liner running surfaces is effected by means
of splash oil and oil mist. The piston ring package is supplied with oil via
bore holes in the cylinder liner. The engine is equipped with one cylinder
lube oil pump, which routes the lubricating oil to the individual cylinder
liners via a hydraulically controlled block distributor. The pump distributor
unit is located on the free engine end.
Valve seat lubrication Another pump distributor unit is arranged on the coupling end. It serves
for inlet valve seat lubrication.
Fuel pipes
Fuel supply/fuel return The fuel is supplied to the injection pumps via a common supply pipe. Ex-
cessive fuel is carried off via the return pipe running in parallel. The con-
nections of both pipes are arranged on the free engine end. The buffer
pistons of both pipes serve for reducing the pressure surges within the fuel
system.
First of all, the charge air cooler, stage 1 (HT), is supplied with fresh water.
With the emerging water, the cylinder liners and the cylinder heads are
then cooled via the backing rings. Fresh water, raw water or sea water
can be admitted to the charge air cooler stage 2 (LT). The fuel injection
nozzles are cooled by a separate fresh water system.
Venting/drainage On the uppermost points of the cylinder heads and the charge air cooler,
permanent venting pipes are connected.
The water accumulating downstream of the charge air cooler and in the
charge air pipe due to the compression and cooling of the air, is dis-
charged via a drain valve.
Crankcase venting
Venting valve The crankcase venting connection is located on the free engine end and
serves for pressure compensation as against the atmosphere.
Relief valves Further relief valves are arranged in the casing covers of the crankcase.
They permit quick pressure reduction in case of an explosion in the crank-
case.
Starting device
Main starting valve The connection from the air bottles to the starting valves in the cylinder
heads is opened and closed respectively by the interconnected main start-
ing valve. The main starting valve is arranged on the free end of the
crankcase. The starting air pipe is directly mounted to the backing rings.
Starting air pilot valve The starting air pilot valves are arranged next to the injection pumps and
basically consist of a pipe with control piston, as well as a starting cam on
the camshaft.
In the case of marine engines: Control and monitoring of marine engines takes place by means of pre-
standardised control cabinet fabricated system components, installed in a switch cabinet. Depending
on the definition of the scope of supply, it consists of the following el-
ements:
- The remote control system with equipment for manual remote start/re-
mote stop including start blocking/start release and coupling control,
- the safety system which includes, among other things, equipment for
manual/automatic emergency stop, automatic output reduction and
override command,
- the alarm system with limiting-value, wire-break and device-failure
monitoring,
- the system for indicating operating data and operating conditions,
- various controls for auxiliaries, e.g., for the charge-air bypass, cylinder
lubrication, temperature control ...,
- serial interfaces to the ship’s alarm system (record printer, common
alarm, hooter, etc.) and to the MAN B&W engine diagnosis system
EDS.
Tableau for control and Data processing for these input and output signals takes place in the pro-
monitoring grammable control elements. By means of a tableau (control station), in-
stalled in the door of the switch cabinet, the engine can be controlled and
monitored, and the listed functions can be controlled. For this purpose,
two keyboards and one display are available. In the display, the operating
data as well as operating and control conditions are indicated.
In the case of engines for sta- In the case of stationary plants, this prefabricated system, which can partly
tionary applications ... be tested together with the engine, is used in exceptional cases only. For
such plants, it is reasonable to combine the control and monitoring scope
of the engine with that of the complete plant. As a rule, only one terminal
box with the controls desired for the auxiliary equipment is, therefore, de-
livered for the engine.
The charge air blow-off device withdraws charge air downstream of the
charge air cooler and blows it off into the engine room. This is necessary
in certain situations in order to limit the firing pressure at full load or over-
load.
The charge air bypass device serves for increasing the charge air pres-
sure of marine propulsion engines in part-load operation. It basically con-
sists of a connecting pipe between the charge air pipe and the exhaust
pipe, which can be controlled by an electro-pneumatic flap.
The exhaust gas blow-off device serves for protection from turbocharger
overspeed, especially in the part-load range. It basically consists of a con-
necting pipe between the exhaust pipe upstream of the turbocharger and
the exhaust pipe downstream of the turbocharger, an electro-pneumatic
flap and its control
Using the adjusting system for injection timing, the firing pressure can be
adjusted to varying fuel qualities. In this connection, the position of the
eccentric shafts of the injection pump cam followers is changed by an
electric drive. This adjustment exerts an influence on the injection timing
and thus also the firing pressure.
Slow-turn device
This device permits turning the engine slowly, by approx. two revolutions,
with the aim of verifying whether all cylinder spaces are free of liquid
media for the subsequent starting process. The equipment is based on
the available starting system and works with a reduced starting air pres-
sure of approx. 8 bars.
CoCoS Products
The term CoCoS covers software products, order-related data sets and, in
the case of CoCoS-EDS, also sensors and hardware components.
Gallery
Galleries on the engine are necessary in order that maintenance work can
be carried out safely. For this reason, engine-mounted galleries are avail-
able for marine engines, while free-standing galleries are available for en-
gines installed in stationary plants.
Engine support
Rigid support The most simple solution for mounting the engine on the foundation is a
rigid connection for both stationary plants and ship installations. With this
solution, free forces due to gravity and moments of inertia, as well as
structure-borne noise are transferred to the foundation.
Indirect resilient support Where stationary plants are concerned, the engine/generator unit is, in the
case of indirect resilient support, often set up on a resiliently supported
foundation block, reducing the excitation of vibrations and the transmission
of structure-borne noise to the periphery in this way.
Semi-resilient support Where marine propulsion plants are concerned, the engine is, in the case
of semi-resilient support, connected with the foundation by means of steel
diaphragms.
Direct resilient support Direct resilient support is the most expensive solution separating the en-
gine, with regard to vibrations, from the foundation and, by means of a
highly flexible coupling, also from the elements to be driven.
Auxiliaries drive
The auxiliaries drive, arranged on the free engine end, is required for driv-
ing cooling water and/or lube oil pumps. It consists of a gear wheel, which
is attached in front of the torsional vibration damper, on the free end of the
crankshaft.
Figure 4. Engine-mounted pumps (cooling water on top, lube oil at the bottom)
Two cooling water pumps and lube oil pumps each can be driven by the
auxiliaries drive. The pumps are attached on the covering on the free en-
gine end. The lube oil pumps are fitted at the bottom, the cooling water
pumps on top.
The temperatures of the main bearings are measured just underneath the
bearing shells in the bearing caps. This is done by means of resistance
temperature sensors (Pt 100), which are fitted in an oil-tight manner (refer
to Figure 5 ).
The splash-oil monitoring system is part of the safety system. Using sen-
sors, the temperatures of each individual running gear (or running gear
pair in the case of V-type engines) are indirectly monitored by means of
the splash oil.
Figure 8. Temperature sensor, picture was taken with the cylinder head dis-
mantled
Tools
In addition to the set of tools, which belongs to the standard scope of the
engine, a series of further important tools is available on request. Among
these are a valve cone grinder, a valve seat lathe, a set of grinders and
milling cutters for the seats in the cylinder head, a grinder for the sealing
faces in the cylinder head/top land ring and a pneumatic honing device for
the cylinder liners. These tools are necessary for, or can facilitate main-
tenance work.
Figure 1. Fresh air/charge air/exhaust gas system. Variants in Figure 1a -- Silencer, 1b -- Intake casing (diagramm analo-
gously also valid for V-type engines)
The route of the exhaust gases The exhaust gases leave the cylinder head on the side facing the charge
air pipe. They are collected in the exhaust manifold (18) and routed to the
turbine side of the turbocharger. Thermo couples in the cylinder heads
both before and after the turbocharger are used for monitoring the tem-
perature. The exhaust manifold consists of cylinder-length elements. The
connection to the cylinder head is made using a clamping connection. For
interconnection and for the connection to the turbocharger, corrugated
tube compensators are used. The exhaust gases flow radially away from
the turbine wheel.
Condensed water On the casing of the charge air cooler and at the start of the charge air
pipe, condensed water pipes are connected. Any water accumulating is
removed by the float valve (16). The blockable overflow pipe (17) must be
monitored by the plant system itself.
Cleaning the charge air coolers On the air side charge air coolers can be cleaned with cleaning fluids with-
out dismantling. For this purpose, blind disks are to be inserted down-
stream of the turbocharger and upstream of the charge air pipe. They are
part of the special tools.
Cleaning the turbocharger: There are nozzles (19) fitted in the intake casing and/or in the silencer for
the compressor side using water the regular cleaning of the compressor wheel and compressor casing.
Water is injected through the nozzles. The cleaning effect results from the
high impact speed of the water drops compared to the rotating wheel.
Figure 2. Compressor cleaning by means of charge air (on the left) or pressure
sprayer (on the right))
The water is either filled into the tank (21) and blown out to connection A
using the charge air pressure (variant 1 in Fig. 2 ) or filled into a pressure
sprayer (22), where it is pressurised by means of an air pump (23) and
displaced by a cushion of air (variant 2).
or using solid matter Alternatively or additionally, cleaning can take place using granulated, soft
solid matter. The cleaning agent is blown into the exhaust manifold at the
same point (C), using compressed air.
3 Turbocharger
C Turbine cleaning
J Exhaust gas from the
engine
D Dirt water
Charge air blow-off device Use of the charge air blow-off device (refer to Figure 4 ) is limited to oper-
ation with overload. The device serves the purpose of limiting the charge
air pressure and the ignition pressure. By means of a blow-off flap in the
charge air pipe, the excessive charge air is blown into the enring room.
3 Turbocharger
40 Shut-off flap
43 Blow-off pipe
Compressed air is required for starting the engine and for a number of
pneumatic controls. For starting, $ 30 bar is required. For the controls, 30
bar, 8 bar or lower pressures are required.
13 Starting valve
30 Cylinder head
31 Inlet valve
32 Exhaust valve
Starting air valve According to the setting of the camshaft (28), the starter control damper
(21) air vent on one cylinder is covered by the starter cam (27) (see Fig.
4 ). Thus a piston in the starting air valve opens the passage, and air
flows over the control pipe (15) to the starting valve affected and opens it.
The compressed air present flows into the cylinder and presses the piston
down, i.e. the crankshaft starts to turn. When the starter cam runs out of
the area of the pulse pipe, the starting air valve (21) closes, the air feed is
interrupted and the pipe (15) is vented. The start periods of individual
cylinders overlap in order to guarantee a secure starting at each
crankshaft setting.
Fill limit The fill limit during the start procedure and shortly after the start is carried
out in normal mode through control by the controller from the automatic
device and in emergency mode manually directly on the controller.
Firestop A firestop is built in to each branch conduit (14) and prevents a blowback
of flame in the case of a damaged starting valve (see Fig. 1 ).
Drainage There is a drain tap in the connection pipe between the compressed air
cylinder and the feed pipe (6) at the lowest point. This tap must be opened
at regular intervals in order to release any condensed water from the
pipes. It is also used for venting the pipes before assembly work. The
relief tap on the main starter valve serves the same purpose and is
arranged parallel to the relief pipe of the venting valve.
Relieving the pipe Before starting maintenance work, the relief tap must be opened. This
before assembly work prevents pressure building up in front of the main starter valve through
leaks in the compressed air blockers.
Emergency stop There is an emergency stop device for the fastest possible halt to the
engine in the case of emergency. On activating it, the emergency stop
valve (19) is opened electrically and air flows over the pipe (20) to the stop
pistons (23) on the fuel injection pumps (22) and sets the control rods to
zero fill. Switching off the engine therefore depends on the setting of the
controlling rod assembly and the speed governor.
Blow through Before starting the engine, the combustion chambers must be blown
through using compressed air. This is done by starting up the start
procedure with open indicator valves. In doing so, the fill of the fuel pumps
must be at zero/the emergency stop button must be depressed.
Turning with slow-turn device With engines which are started in automatic mode, the opening of the
indicator valves is not assured. Before starting, the slow-turn device is
activated.
The device allows the engine to be slowly turned over through approx.
2 1/2 revolutions with the aim of checking whether all cylinders chambers
are free of liquid for the subsequent start. The device is based on the
existing starter system. It works with a reduced starter presure of approx.
8 bar.
Figure 1. Fuel diagram (figure shows engine L58/64 -- applies also to L+V 48/60)
The fuel is fed from a free-standing pump through a filter into the
distributor pipe (3) (see Fig. 1 ). From here, an supply pipe (11) branches
to each fuel injection pump (15) with a stop cock (10) (see also Fig. 2 ).
The return of excess fuel is carried out through the manifold (1) which is
also connected through return pipes (13) with stop cocks (14) to the
injection pumps. In this way, each individual pump can be blocked from the
fuel inlet and removed without the whole pipe system having to be drained.
Buffer piston A small venting pipe (6) is connected to the manifold (1) so that no air
cushions can form. The buffer pistons (16) attached to the pipes (1 and 3)
dampen the shock pressures which occur in the pipes (see Fig. 3 ).
Pressure control valve The excess fuel flows back over the pressure control valve (17) at the end
of the manifold to the mix container (see diagram, Fig. 1 ). This
arrangement means that pre-heated fuel can be pumped around to warm
the pipe system and the fuel injection pumps before starting the engine.
Heat pipe The heat pipe (2) for the heavy oil mode arranged between the distributor
and the manifold is also used for compensating heat losses. The heat
return pipes serve the purpose to heat the leakage fuel pipe.
Fuel injection pipe/ The fuel injection pumps (15) feed the fuel in the injection pipes (12) to the
Leakage fuel pipe injection valves (5) (see Fig. 4 ). The leakage fuel (B) running from the
injection valves and fuel injection pumps is collected in the leakage
collector pipe (4) and fed to the manifold (8) at the foot of the fuel injection
pumps (see diagram, Fig. 1 ).
With automatic installations, the injection pipes (12) are monitored for
leaking fuel. For this purpose, the injection pipes are encased. The leaking
fuel resulting from untight screw fittings or damaged pipes runs into the
sleeve pipes to the leakage collector pipes (9) and on to the leakage
collector pipe (7). It is possible to attach to this pipe a container with level
monitoring to trigger an alarm.
Pressure system The higher end temperature required of high viscosity heavy oils needs a
(for ships’ engines) pressure system to prevent de-gasing problems in which the system
pressure is 1 bar above the evaporation pressure of water. All components
between the feed pump (23) and the pressure control valve (31) as well as
the mix container (29) are under this pressure (see Fig. 5 ).
Heavy oil route One pipe leads to the three-way cock (33) from each of the operating
containers for heavy oil (19) and diesel oil (20). From there, the fuel flows
through the double filter (21) to the feed pumps (23) and through the
automatic filter (25) or the reserve filter (26) to the mix container (29). It
flows on through the booster pump (30), the final pre-heater (32), the
viscosity measuring and control device (36) and the double filter (37) to the
distributor pipe on the engine.
Figure 5. Fuel system, installation side (pressure system for ships’ engines)
Switching over from diesel to Using the three-way cock (33), it is possible to switch from diesel to heavy
heavy oil mode and vice versa oil modes and back again. The return pipe (35) and both shut-off valves
(39 and 40) allow the return of diesel oil to the diesel oil service tank (20).
The required system pressure is set and maintained at the pressure
regulating valves (24 and 31). When the feed pumps are running with the
engine out of operation, the whole delivery is fed through the pressure
regulating valve (24) back to the inlet side of the pumps. In this way, the
cooler (22) built into the return pipe prevents excessive heating of the fuel.
In normal cases, the automatic filter (25) is used as the operational filter.
The reserve filter (26), which has to be cleaned manually, should only be
used if the automatic filter should fail (maintenance, repair). In the mix
container (29), the diesel oil located in the tank after converting from diesel
oil to heavy oil is mixed with the subsequent heavy oil until only heavy oil
is present in the system. The reverse happens on switching from heavy oil
to diesel oil. In this way the transfer from one type of fuel to the other and
the associated temperature change is achieved slowly. In addition, during
commissioning the gas-air mixture present in the system collects in the
mix container (29). The necessity for manual degasing is indicated by
means of a float switch which triggers an alarm in good time. The final
pre-heater (32) and viscosity measurement and control device (36) are
used in heavy oil operation to maintain the fuel temperature required for
the prescribed injection viscosity.
Excess fuel Only part of the fuel supplied is used by the engine. The excess is fed
back to the mix container (29) through the return pipe (35). In the case of
prolonged diesel operation, the shut-off valves (39 and 40) must be
switched so that excess diesel oil flows back through the pressure
regulating valve (31) and the return pipe (38) to the diesel oil service tank
(20). In this way the diesel oil can be heated reliably (see also sheet
3.4.1).
Flushing the systems The three-way cock (34) and the flush pipe (27) allow the heavy oil present
in the system to be flushed out using diesel oil. For this purpose, the
three-way cock (33) is set to diesel mode and the three-way cock (34) set
to flush and 1 pump for each (23 and 30) are maintained in operation until
the system is filled with diesel oil. The fuel flowing out is led to the service
tank for heavy oil (19).
Open system With stationary engines, the demands on the system reservoir are not
(for stationary engines) quite so great as in ship installations. Here a so-called open system is
generally used. All components between the feed pump (44) and the
pressure control valve (17) are under the required system pressure (see
Fig. 6 ). The mix container (42) is depressurized.
Figure 6. Fuel system, on the installation side (open system for stationary engines)
Tasks/contexts
The most important tasks The following tasks have to be carried out in the context of engine power
and engine speed:
- parameters have to be changed or
- kept constant,
- there must be certain reactions to disturbances,
- values must be limited and
- if there are several engines in an installation, then these have to be
balanced to one another.
Systems involved These tasks cannot be managed by one element/one system alone.
Depending on the design of the installation, the following are required in
different levels of completeness:
- a speed and power limitation system,
- a speed and power control system, possibly
- a synchronization system,
- a load distribution system and
- a frequency control system.
Everything is carried out through It is only possible to actively influence the engine speed and the engine
the filling setting. power through the capacity setting of the fuel pumps. This is done using
the control rod assembly and the speed governor. Certain capacity
settings (filling settings) produce,
- in engines which drive generators, a certain power point on the
(constant) nominal speed line -
f A Pvar / nconst;
- in the case of engines which drive fixed propellers, a point on the
propeller curve and
- in the case of engines which drive adjustable pitch propellers, a point
on the combiner curve/in the propeller characteristic diagram.
In these two cases, the following applies:
f A Pvar / nvar.
Speed and power control system The speed and power control system compares the actual speed to the
target speed. To do so, an actual value must be recorded and a target
value or, under certain circumstances, a selected target value, must be
stated. The controller determines the required correction signal. In
addition, through its setting it establishes the reaction ratios of the control
and it limits speeds and thus power.
Synchronization device A synchronization device is required in engines which drive rotary current
generators. Rotary current systems may only be interconnected if
frequencies (speeds), voltages and phase position agree and if the energy
producing engines have the same power efficiency. The first conditions
must be created by influencing the generator (voltage) and the engine
(frequency/speed and phase position). The second condition must be
fulfilled by conscientious setting of the speed governor.
Frequency control system The load distribution system is usually combined with a frequency control
system in generator units. In this, the busbar frequency must be compared
to the pre-stated frequency (e.g. 50 Hz or 60 Hz) and, in the event of
discrepancies, compensated through pulses on the speed controls.
Components The hydraulic speed and power control system -- or, more simply named,
the speed controller -- is used mainly in stationary installations and
consists in a restricted sense of the remote speed adjuster (setpoint
generator), the mechanical speed governor (4) with the hydraulic final
positioning device and the stop device (see Fig. 1 and 2 ). When used
in main ship’s engine, this list also includes the fill limits.
2 Pulse detector
4 Speed governor with
final positioning device
5 Rods
6 Control shaft
12 Inductive position pick-up
14 Booster servomotor
15 Tacho machine
Arrangement The speed governor is located on the coupling end. It is driven by the
control shaft drive and is mechanically connected via the rods (5) to the
control shaft (6) of the fuel injection pumps (see Fig. 2 ). The actual
speed governor is located on the hydraulic final positioning device (4). The
booster servomotor (14) supports the final positioning device. It assures
the oil pressure necessary for starting the engine. The remote adjustment
and stopping device is installed either on the engine or remote from it, as
required.
17 Speed spring
18 Governor weights
The force of the governor weights attempts to lift the slide valve whilst the
force of the speed spring works against this. When the engine is running
at a constant speed, the forces are counterbalanced and the governor
weights are vertical. Any change in the balance of forces leads to a
movement in the slide valve. This movement is converted into a rotation
and thus moves the control rods of the fuel pumps. This changes the
amount of fuel injected into the combustion chambers.
Articulated lever The control rods of the fuel pumps are connected to the control shaft using
articulated levers. The articulated lever is designed so that it can bend in
either direction of movement if a certain controlling torque is exceeded
(see Fig. 4 ). This means that a jammed control rod or a control rod pump
piston unable to rotate cannot block the other fuel injection pumps.
Normally, the divided lever is held in its bearings by an extension spring.
1 Control shaft
2 Articulated lever
3 Tension spring
4 Adjustable joint rod
5 Control rod
(shown in rotated
position)
Figure 4. Effect of the articulated lever (a Starting position, b Control rod blocked in ZERO position, c Control rod blocked in
FULL position)
Starting and accelerating On starting and accelerating the engine, certain amounts of fill must not be
(fill limit) exceeded, e.g. to guarantee an accelerating which is as free as possible of
smoke, or manoevring without overstraining. To do this, the charge air
pressure is fed directly into the limiting device in the speed governor.
Stopping the engine Normally, the engine is stopped on setting the charge back to ”Zero”. This
can be done using the remote control device or at the operator’s stand.
Emergency shut-down In cases of emergency, the engine can be stopped by feeding control air to
the emergency stop piston of the fuel injection pumps (see section 2.4.2).
Charge display/charge sensor At the end of the control shaft, its deflection is transfered to an inductive
position pick-up (12) (see Fig. 2 ). In this way, 4-20 mA signals are
created, which permit a remote display or another type of processing. At
the control rods of the fuel injection pumps, the charge can be read off the
impressed scale.
22 Oil cooler
23 Switch-over device
(mechanical --
electronic)
Arrangement/Mode of operation Three pulse detectors are arranged radially to the camshaft drive, two of
which supply the actual speed value to the electronic control device (see
Fig. 6 ). The third is used to check the engine speed for the emergency
shut-down.
In the electronic control device, the difference between the actual and
target speeds is evaluated. In this, the amount and the direction of the
deviation, the duration and the speed of change is taken into
consideration. As a result, a correction signal is transferred in the form of
an electric variable to the final positioning device and there converted,
using an electro-hydraulic converter, into the force required to adjust the
filling rods.
Starting and accelearting (fill The limit curves can be freely programmed in the controller. This is done
limit) using a small programming device or at the generator itself.
Stopping the engine On stopping, electronic impulses are fed to the control electrics. In cases
of emergency, the engine can be stopped by feeding control air to the
emergency stop piston of the fuel injection pumps (see section 2.4.2).
Functional description The cam follower (6) for driving the injection pump is supported on the
eccentric shaft (7) -- refer to Figure 2 . This shaft can be turned by
means of lever (1) and threaded rod (2), which is supported in the counter
bearing (3) -- refer to Figure 1 . Thereby, the position of the cam follower
to the camshaft (7) is changed.
Injection time adjustment Depending on the direction of shifting, start of injection can be advanced
or deferred. This way, injection timing can easily be adjusted to different
fuel oil qualities. By adjustment in the direction of “Early” (max. +3 ), an
increase of the ignition pressure to the design point is possible within the
scope of service work. On the other hand, adjustment in the “Later”
direction (max. --2 ), leads to a considerable reduction of nitrogen oxide
emission, in connection with a drop in ignition pressure. The respective
adjustment is indicated by pointer (4) on scale (5).
1 Lever
2 Threaded rod
3 Counter bearing
4 Pointer
5 Scale
6 Cam follower
7 Eccentric shaft
9 Injection pump
Functional description A three-phase geared motor (9) drives the eccentric shaft via a worm gear
(10) -- refer to Figure 3 . In order to comply with the IMO requirements,
two positions can be selected. They can be defined via two infinitely
variable limit switches (11) which are attached to the casing.
Brake On the coupling side and on the free engine end (depending on the
number of cylinders) of the eccentric shaft, hydraulic brakes are mounted
which keep the shaft in its position. On the coupling side, the hydraulic
brake is located in the gear casing (12). On the free engine end, it is
separately fastened to the eccentric shaft.
9 Three-phase geared
motor
10 Worm gear
11 Limit switch
12 Hydraulic brake
Oil flows through bore holes in the crankshaft from the main bearings (24)
to the big-end bearings (26) and from there through bore holes in the con-
necting rods to the piston-pin bushes (27) and on to the cooling spaces of
the pistons (6). From the pistons, it runs freely off into the crankcase
through bore holes. The first main bearing between the coupling flange
and the camshaft drive is supplied with oil by the supply pipe (12), the
short branch pipe (16) and a duct in the crankcase. Branch pipes lead
from the supply pipe (12) to the external camshaft bearing (14), to the in-
termediate wheel bearings (15 and 17), to the different bearing points in
the governor drive (18) and the spray nozzle (19) at the bottom. The three
upper spray nozzles (9) for the meshing in the camshaft drive are also
connected to the supply pipe (12) by short branch pipes.
Lubricating the camshaft and in- The distributing pipe (34), which branches off the distributing pipe (1) on
jection pump the free engine end, is arranged in the camshaft trough. Branch pipes
(30) lead from the distributing pipe to the camshaft bearings (29), the ec-
centric shaft bearings (31) and to the bearings of the rocker arms (5) in the
cylinder heads. The oil flows from the eccentric shaft bearing (31) through
bore holes in the eccentric shaft (32) to the cam followers (33) for the
valve and injection pump drives. The drive tappets of the injection pumps
(4) are also lubricated through short branch pipes (28) from the distributing
pipe (34), whilst the injection pumps (4) themselves are supplied with oil
via the supply pipe (8) and short branch pipes (2).
Return to the crankcase The oil running off the rocker arm bearings collects on the respective cylin-
der head and runs through the pipe (3) and the protective tube of the push
rod into the camshaft trough and from there back into the crankcase.
Oil sump The oil sump is used as a collecting tank for the lubricating oil dripping
from all the bearing points. On the coupling side and the free end, drain
pipes are connected to the front end, in which the oil can be returned to
the service tank.
Speed governor The speed governor (22) has its own lubricating oil circuit and is thus not
connected to the lubricating oil circuit of the engine. In the case of marine
engines, the branch pipe (20) leads to the load control pilot valve in the
speed governor, and the drain pipe (21) leads back to the crankcase.
Turbocharger The turbocharger is supplied via supply pipe (10). For a description,
please refer to the Operating instructions of the turbocharger in Vol-
ume C1.
35 Cylinder liner
36 Lubrication bore hole
37 Cylinder crankcase
38 Lubrication bore hole
39 Connection pipe
40 Connection pipe
41 Supply pipe
42 Drain pipe
43 Oil pump
44 Supply pipe
45 Drain pipe
46 Block distributor
47 Proximity switch
48 Drain pipe
The running surfaces of the pistons are supplied with oil through lubrica-
tion bore holes in each cylinder liner by an oil pump and a block distributor.
The oil pump (43) and the block distributor (46) are fitted on the exhaust
side (see Figures 2 and 3 ). Circulating oil from the distributing pipe is
sucked in by the oil pump through the supply pipe (44) and fed to the block
distributor through the supply pipe (41). Connection pipes (39 and 40) lead
from there to the lubrication bore holes (36 and 38) in each cylinder liner
(35). The movements of the main piston of the block distributor are moni-
tored by a proximity switch (47) and a pulse evaluation device. The ex-
cessive oil delivered is routed through the drain pipes (45 and 48) back to
the oil pump and/or through the drain pipe (42) into the cylinder crankcase.
* The number of supply and drain pipes connected to the block distributor depends on the number of cylinders of the engine and may deviate
from the diagram!
The temperatures of the running gears and big-end bearings are moni-
tored by temperature sensors in the crankcase covers. For this purpose,
one Pt 100 resistance temperature sensor is installed in one crankcase
cover (74) per running gear. This resistance temperature sensor determi-
nes the temperatures of the splash oil (see Figure 6 ). The splash oil is
collected in an oil collector tray (75) on the inside of the respective crank-
case cover. Via measuring cables (80), the ascertained temperatures are
The operating unit is equipped with a display panel, where all measured
temperatures as well as their deviations from the mean value can be read
off. On the operating panel of the control, the present system conditions -
plant in operation/pre-alarm/alarm - are indicated.
51 Collection chamber
52 Separator
53 Detector
54 Transmitting LED
55 Flow control
56 Temperature sensor
57 Air filter
58 Infrared filter
59 Receiving diode
60 Measuring section
61 Air jet pump
62 Control and monitoring
unit
C from the crankcase to
the collection chamber
D from the separator to
the detector
E to the air jet pump
F Air stream
The receiving diode (59) located at the outlet supplies an electrical signal
to the monitoring unit (62), according to the amount of light received.
Figure 1. Cylinder/nozzle cooling water system (drawn up for two-stage charge-air cooler)
Overview
Circulation/coolant To guarantee the lowest possible thermal stresses, the following must be
cooled
- the components which form the combustion chambers and
(through a separate system)
- the fuel injection valves.
The charge air heated in the turbo supercharger is cooled down using the
supercharger intercooler. This is done in the interest of increasing the air
mass available for combustion.
Cylinder cooling
The cooling water distributor pipe (9) is attached to the exhaust side of the
engine. From here, inlet pipes (6) lead to the backing rings (4) of the
cylinder (see Fig. 1 ). In the backing ring, the water is fed upwards
around the upper part of the cylinder liner (5). The water flows through
bore holes from the backing ring into the cooling chamber of the cylinder
head (2), rinses around the lower part of the injection valve (3) and
emerges at the top at the cylinder head.
Part of the cooling water flows out of the cooling chamber in the cylinder
head to the valve cages of the exhaust valves (1) and then also flows into
drainage pipe (15). To dismantle the exhaust valve, the feed and drainage
bore holes (13 and 14) can be blocked off using a tap (12).
Nozzle cooling
The fuel injection valves are cooled in their own fresh water circulation.
The distributor pipe (22) lies on the exhaust side (see Fig. 2 ). It flows
through the inlet pipe (23) into the cooling chamber of the injection valve
(3) and from here through the drainage pipe (20) to the distribution pipe
(18) on the control side.
Draining To disassemble an injection valve, the pipes to the engine can be drained.
To do this, the shut-off valves (19) must be closed and the drainage valve
opened (21).
3 Injection valve
18 Distribution pipe
19 Shut-off valve
20 Drainage pipe
21 Drainage valve
22 Distributor pipe
23 Inlet pipe
Supercharger intercooler Water from two cooling water circulations flows through the supercharger
intercooler:
- stage I, high temperature water coming from the engine,
- stage II, low temperature water.
The inlet and outlet of water is carried out in the HT circulation using pipes
(33 and 32) (see Fig. 3 ). To vent and drain, there are sealing plugs (31
and 29). Condensed water which can occur in considerable amounts in
intercoolers and charge pipes under certain circumstances is fed to the
condensed water discharge (28) through a float valve. Above the float
valve there is an overspill pipe branch which leads to a tank with level
monitoring. The additional condensed water discharge (34) at the other
end of the charge pipe must be opened by hand if required.
24 Drainage pipe
25 Turbo supercharger
26 Inlet pipe
27 Waste water drain
28 Condensed water
discharge
29 Drainage screw
30 Charge air cooler
31 Drainage screw
32 Drainage pipe
33 Inlet pipe
34 Condensed water
discharge
I High temperature
circulation
II Low temperature
circulation
Figure 3. Cooling water diagram of the supercharger intercooler and the turbo supercharger
Turbocharger The turbo supercharger is connected to the cooling water circulation of the
engine. The inlet pipe (26) branches away from the distributor pipe on the
engine and from below leads to the bearing housing of the turbo
supercharger. The drainage pipe (24) is connected to the bearing housing
above.
CHATCO The engines must be controlled in use in the tropics in order to avoid
condensed water in the charge pipe and also with regard to the charge air
temperature. This is carried out using the CHATCO temperature control
(see Fig. 4 ), where the following physical boundary conditions apply: In
compressing and cooling the charge air, water is precipitated. Under
unfavourable conditions up to 1000 kg/h with larger engines. The amount
increases:
- with an increase in inlet air temperature,
- with an increase in inlet air humidity,
- if the charge air pressure increases and
- if the charge air temperature falls.
The amount of condensed water must be reduced as much as is possible.
Water must not enter the engine. This is guaranteed through constructive
measures and can be supported by controlled charge air temperatures.
CHATCO covers a 3-way temperature control valve in the low temperature
branch of the supercharger intercooler, an electronic temperature control-
ler and two temperatur gauges -- one in the charge pipe and one in the
inlet area of the turbo supercharger (e.g. in the inlet air flue).
1 Supercharger
intercooler
2 Temperature control
valve
3 CHATCO cabinet
A Charge air
B Cooling water
c inlet air temperature
d Charge air temperature
ST Engine speed
GT Fuel pump fill
TE1 inlet air temperature
TE2 Charge air temperature
TC Temperature controller
The charge air temperature is increased continually from a certain inlet air
temperature. The control is active in all operational modes in which no
charge air pre-heating takes place.
Designations/work numbers
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7L 58/64 CD
Works number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 110 467
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCA 66
Works number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 151 300
Turbocharging method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . constant pressure
Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BV
Operation/monitoring Correct
Automatic remote control . . . . . . . . . . . . . . . . . . . . . . . . . ..............
Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... X.....
Central control/unmanned operation . . . . . . . . . . . . . . . ....... X.....
Standard monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
Technical data
Service temperatures*
Starting air/control air Starting air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. approx. 15, max. 30 bar
Control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, min. 5.5 bar
Cooling water Engine cooling water and charge air cooler HT . . . . . . . . . . . . . . 3 ... 4 bar
Injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ... 5 bar
Charge air cooler LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 ... 3 bar
* Applicable at rated outputs and speeds. For conclusive reference values, see test run or commissioning record in Volume B5 and “List of
measuring and control units” in Volume D.
80 Controlled temperature
Components from top down- Rocker arm casing with rockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1141 kg
wards Rocker arm casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 kg
Cylinder head with valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 kg
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1826 kg
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kg
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . 1066 kg
Backing ring of the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 kg
Top land ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 kg
Piston with connecting rod small end and piston pin . . . . . . . . . . . . . 800 kg
Piston without piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 kg
Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 kg
Connecting rod (connecting rod shank, connecting rod small end,
big-end bearing cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 kg
Connecting rod small end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 kg
Connecting rod shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 kg
Big-end bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 kg
Main bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 kg
Main bearing shell (shell half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 kg
Crankshaft with balance weights . . . . . . 6L 58/64 CD . . . . . . . . . 20700 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7L 58/64 CD . . . . . . . . . 23650 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L 58/64 CD . . . . . . . . . 26650 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L 58/64 CD . . . . . . . . . 29600 kg
Balance weight of the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 kg
Crankshaft gear wheel (two-part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 kg
Torsional vibration damper (crankshaft) 6L 58/64 CD . . . . . . . . . . 2785 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7L 58/64 CD . . . . . . . . . . 3686 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L 58/64 CD . . . . . . . . . . 3686 kg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L 58/64 CD . . . . . . . . . . 3850 kg
Erläuterungen Explanations
Die nachstehende Tabelle ist geordnet nach dem The table below has been organised by the MAN
MAN--Baugruppensystem, d.h. nach den fett subassembly group system, i.e. by the subassembly
gedruckten, in den Zwischentiteln rechts angeordneten group numbers in bold face entred at the right of the
Baugruppennummern. intermediate titles.
Toleranzangaben werden aus drucktechnischen For convenience of printing, tolerances are not given
Gründen nicht wie üblich like
+0,080 +0.080
200 200
+0,055 +0.055
A * -- **
A 440 -0,040 -- --
B -- 0,366 ... 0,495 *
C 344 -0,100 -- --
D -- 0,500 ... 0,760 0,95
* Grenzwert für Lagerschalendicke im Haupt- * Limiting value for thickness of bearing shells in the
belastungsbereich. Austauschkriterien siehe zone of maximum loading. For criterias of
Arbeitskarte 000.11. replacement see work card 000.11
A 420 -0,040 -- --
B -- 0,360 ... 0,480 *
C 250 +0,300/+0,230 -- --
D -- 0,250 ... 0,310 0,500
E 250 -0,020 -- --
F -- 0,600 ... 1,200 --
G 220 -- --
H 1450 -- --
J 666 -- --
K 2025 -- --
* Grenzwert für Lagerschalendicke im Haupt- * Limiting value for thickness of bearing shells in the
belastungsbereich. Austauschkriterien siehe zone of maximum loading. For criterias of
Arbeitskarte 000.11. replacement see work card 000.11
A 250 +0,040/+0,020 -- --
B -- 0,025 ... 0,074 0,120
C 250 -0,005/-0,034 -- --
D 495 -- --
E 919 -- --
F 580* -- --
G ** -- --
* Die Außendurchmesser sind infolge der ballig-- * Checking the outer dimensions of the piston is
ovalen Form nur schwer zu kontrollieren. Auf die rather difficult due to its crowned, oval form. Exact
Angabe genauer Maße wurde verzichtet, da die dimensions are not listed because normaly the life
Lebensdauer des Kolbens normalerweise durch of the piston is, in any case, determined by the
den Verschleiß der Ringnuten bestimmt wird. wear of the ring grooves.
** Kompressionsabstand - siehe Abnahmeprotokoll ** Compression clearance - see acceptance record
A 10 +0,300/+0,280 -- --
B -- 0330 ... 0,390 0,800
C 10 -0,050/-0,090 -- --
D -- 0,296 ... 0,350 0,500
E 10 -0,016/+0,050 -- --
F 10 +0,180/+0,150 -- --
G -- 0,166 ... 0,230 0,300
H 12 +0,080/+0,060 -- --
J -- 0,076 ... 0,130 0,250
K 12 -0,016/-0,050 -- --
L* -- 1,000 ... 1,400 ****
L** -- 1,400 ... 2,000 ****
L*** -- 2,200 ... 2,600 ****
A 580 +0,070 -- --
B2* -- -- 1,740
B4* -- -- 0,464
B5* -- -- 0,174
C** -- -- 0,600
D 780 -- --
E 670 -- --
F 1452 -- --
G 996 -- --
H 652 -- --
K 108 -- --
Maße A, B, C gültig für Zylinderbuchse, nicht für Dimensions A, B, C apply to cylinder liner, not to top
Feuerstegring. land ring.
Das Maß A wird im oberen Umkehrpunkt des ersten The dimension A is measured at the point of reversal
Kolbenringes quer und längs zur Motorlängsachse of the top ring parallel with and at right angles to the
gemessen. longitudinal engine axis.
A 774 -- --
B 996 -- --
C 1315 -- --
D 791,6 -- --
E 2113 -- --
F/G M64x4 -- --
D 180 +0,182/+0,123 -- --
E -- 0,143 ... 0,227 0,280*
F 180 -0,020/-0,045 -- --
G -- 0,650... 1,050 1,200
H -- 0,700... 1,200 1,300
A 200 +0,235/+0,204 -- --
B -- 0,204 ... 0,264 *
C 200 -0,029 -- --
D -- 0,300 ... 0,500 1,200
* Grenzwert für Lagerschalendicke im Haupt- * Limiting value for thickness of bearing shells in the
belastungsbereich. Austauschkriterien siehe zone of maximum loading. For criterias of
Arbeitskarte 000.11. replacement see work card 000.11
A 110 +0,154/+0,026 -- --
B -- 0,066 ... 0,214 0,260
C 110 -0,040/-0,060 -- --
D 60 +0,240/+0,210 -- --
E -- 0,117 ... 0,220 0,300
F 60 +0,033/+0,020 -- --
G -- 0,300 ... 1,300 --
H -- 0,400 ... 0,600 --
A 45 +0,039 -- --
B -- 0,050 ... 0,105 0,150
C 45 -0,050/-0,066 -- --
D 75 +0,046 -- --
E -- 0,030 ... 0,106 0,150
F 75 -0,030/-0,060 -- --
G -- 0,030 ... 0,400 0,600
H -- 0,150 ... 0,390 0,600
J* -- 0,156 ... 0,308 0,350
K* -- 0,150 ... 0,372 0,450
A 15 +0,120/+0,100 -- --
B -- 0,100 ... 0,150 0,200
C 15 -0,030 -- --
D 55+0,074 -- --
E -- 0,026 ... 0,150 --
F (55,15 -0150) -- --
G 95 +0,046/+0,120 -- --
H -- 0,120 ... 0,209 0,250
J 95 -0,035 -- --
N1) 45 -- --
A 110 +0,155/+0,002 -- --
B -- 0,065 ... 0,225 0,300
C 110 -0,036/-0,070 -- --
D 75 +0,100/+0,070 -- --
E -- 0,080 ... 0,129 0,200
F 75 -0,010/-0,029 -- --
G 75 +0,090/+0,060 -- --
H -- 0,070 ... 0,119 0,100
J 75,15 +0,030 -- --
K -- 0,150 ... 0,199 0,270
L 75 -0,019 -- --
M -- 0,050 ... 0,142 0,250
N 205 -0,050/-0,096 -- --
O 205 +0,046 -- --
A* -- 1,3 +0,050 --
B** -- -- --
C 543 -- --
D 100 -- --
Antrieb für am Motor angebaute Pumpen Drive for engine-mounted pumps 300/350
A 90 +0,035 -- --
B -- 0,036 ... 0,106 0,110
C 90 -0,036/-0,071 -- --
1 Introduction
2 Technical details
3 Operation/
Operating media
4 Maintenance/Repair
5 Annex
N 3 Operation/Operating media
N 3.1 Prerequisites
: : N 3.1.1 Prerequisites/Warranty
N 3.2 Safety regulations
: : N 3.2.1 General remarks
: : : N 3.2.2 Destination/suitability of the engine
: : : N 3.2.3 Risks/dangers
: : : N 3.2.4 Safety instructions
: : : N 3.2.5 Safety regulations
N 3.3 Operating media
: : N 3.3.1 Quality requirements on gas oil/diesel fuel (MGO)
: : N 3.3.2 Quality requirements for Marine Diesel Fuel (MDO)
: : N 3.3.3 Quality requirements for heavy fuel oil (HFO)
: : N 3.3.4 Viscosity/Temperature diagram for fuel oils
: : N 3.3.5 Quality requirements for lube oil
: : N 3.3.6 Quality requirements for lube oil
: : N 3.3.7 Quality requirements for engine cooling water
: N 3.3.8 Analyses of operating media
: : N 3.3.11 Quality requirements for intake air (combustion air)
N 3.4 Engine operation I -- Starting the engine
: : N 3.4.1 Preparations for start/ Engine starting and stopping
: : N 3.4.2 Change--over from Diesel fuel oil to heavy fuel oil and vice versa
: : N 3.4.3 Admissible outputs and speeds
: : : N 3.4.4 Engine Running--in
N 3.5 Engine operation II -- Control the operating media
: : N 3.5.1 Monitoring the engine/ performing routine jobs
: : N 3.5.2 Engine log book/ Engine diagnosis/Engine management
: : N 3.5.3 Load curve during acceleration/manoeuvring
: : N 3.5.4 Part--load operation
: N 3.5.5 Determine the engine output and design point
: : N 3.5.6 Engine operation at reduced speed
: : N 3.5.7 Equipment for adapting the engine to special operating conditions
: N 3.5.8 Bypassing of charge air
: N 3.5.9 Condensed water in charge air pipes and pressure vessels
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
Day-to-day prerequisites
Warranty
Item 4
“The warranty shall not cover normal wear and parts which, owing to their
inherent material properties or the use they are intended for, are subject to
premature wear; damage caused by improper storage, handling or
treatment, overloading, the use of unsuitable fuels, oils etc., faulty
construction work or foundations, unsuitable building ground, chemical,
electrochemical or electrical influences.”
Item 5
“The Purchaser may only claim the warranty of MAN B&W Diesel AG if
- the equipment was installed and put into operation by personnel of
MAN B&W Diesel AG,
- MAN B&W Diesel AG have been advised in writing of the claimed
defect immediately, but not later than two months after expiry of the
warranty period,
- the Purchaser has observed the instructions issued by MAN B&W
Diesel AG in respect of the handling and maintenance of the equipment
and, in particular, has duly carried out any specified checks,
- no subsequent adustments have been carried out without the approval
of MAN B&W Diesel AG,
- no spare parts of outside make have been used.”
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
Safe use German laws and standards as well as guidelines of the European Com-
munity (EC) require that technical products ensure the necessary safety
for the users and that they are in conformity with the generally accepted
technical rules. In this connection, it is emphasised that the safe use and
the safety of machines is to be guaranteed by proper planning and design
and that this cannot be reached by means of restrictive rules of conduct.
Intended use The technical documentation must contain statements regarding the “in-
tended use” and concerning restrictions in the use.
MAN B&W Diesel AG’s These requirements are adhered to by MAN B&W Diesel AG by special
contribution efforts in development, design and execution and by drawing up the
technical documentation accordingly, especially by the remarks contained
in this section. The compilation (partially in key words) does, however, not
release the operating personnel from observing the respective sections of
the technical documentation. Please also note that incorrect behaviour
might result in the loss of warranty claims.
Persons who have to proceed to the danger area within a radius of 2.5 m
of the engine for operational reasons are to be instructed with regard to
the prevailing dangers. Admittance to the danger area is permitted on
condition that the engine is in proper operating condition and only if a suit-
able safety outfit is worn. An unnecessary stay within the danger area is
prohibited.
Attention!
Beware of a danger spot!
Inflammable material!
Hot surface!
Explanations with regard to the warning sign, meaning of the symbols Prohibitions
Situation/characteristic on condition of
(Marine engine) for operation at full load in arctic waters or Charge-air blow-off device
(stationary engines) operated temporarily at overload
Part-load operation with improved acceleration ability Charge-air blow-by device
Safe operation in the upper load range with part-load optimised Charge-air blow-off device
turbochargers
Fast and to a large extent soot-free acceleration Jet-assist device
Part-load operation with improved combustion and reduced Two-stage charge-air cooler
formation of residues
Operation with optimised part-load operating values by means of Timing adjustment device
timing adjustment (only engine 32/40)
Operation with optimised injection timing Injection timer
Slow turning prior to starting (in case of automatic operation) Slow-turn device
Low-vibration and low-noise (structure-borne) operation Semi-elastic/elastic support
Output on the free engine end Crankshaft extension
Cleaning of the turbocharger/s (during operation) Cleaning device/s
Cleaning of the charge-air cooler/s Cleaning device
Supplementary, the following Persons responsible for the operational control must be in possession of a
applies qualification certificate/patent which is in accordance with the national re-
quirements and international agreements (STCW). The number of re-
quired persons and their minimum qualification are, as a rule, specified by
national requirements, otherwise by international agreements (STCW).
Supplementary, the following For persons responsible for the operational control and for persons carry-
applies ing out/supervising maintenance and repair work, proof must be furnished
in Germany in accordance with the power economy law (Energiewirts-
chaftsgesetz = EnWG) that, among other things, the technical operation is
ensured by a sufficient number of qualified personnel. In other countries,
comparable laws/guidelines are to be observed. Deficiencies regarding
personnel/level of training cannot be compensated by other efforts.
Tables 4 and 5 Dangers do not only result from components and systems but also from
certain operating conditions or actions taken. Dangers of this type are
listed in the Tables 4 and 5, which contain additional instructions to the
listing in key--words in Section 3.2.2.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
Engines are usually operated under remote control. Regular rounds ac-
cording to the rules of “observation--free operation” are required. In this
connection, measurement, control and regulating devices as well as other
areas of the plant, which require special attention, are preferably checked.
A continuous stay in the immediate vicinity of the running engine/ turbo-
charger is not planned.
Maintenance and repair work are, if possible, not to be carried out in the
vicinity of the danger zones listed in Table 1 or in Figures 1 and 2.
This includes wearing of protective working clothing and safety shoes, the
use of a safety helmet, safety goggles, ear protection and gloves.
The general protective outfit/equipment must at least comply with the fol-
lowing standards and be adequate for the working place described:
Turning gear (3) Toothed rim//area of gear meshing Body/limbs may get caught, squeezed
Insulation and jacketing of fuel and Hot surfaces, inflammable medium, parts under high Burning, squirting out of fuel, under certain circumstances in
injection pipes (9) internal pressure piercing jets
Exhaust pipe and covering of the Hot surfaces, parts under internal pressure, filled with
Burning, escape of hot gases, danger of fire
exhaust pipe (10) hot gas
Measuring, control and regulating Electric shock, burning, risk of lightning; in case of incorrect
Under voltage behaviour, the function is adversely affected
L 58/64
Hydraulic tensioning tools, Parts under high internal pressure may tear, break,
Injuries due to coming off/coming loose parts, due to escaping
high--pressure hoses, become untight; escape of hydraulic oil in piercing jets
hydraulic oil
high--pressure pump (18) is possible, hydraulic oil is noxious
Operation at reduced speed Increase in torque, negative influence on operating Contamination, wear, overloading of components,
(marine main engines) values turbocharger surging
Idling operation or low--load Operation beyond the operating range, deterioration
Incomplete combustion, residues in the combustion chamber
operation of the operating values
6640
overloading
turbocharger
Emergency operation with shut--off Reduction in output is necessary, operating values
fuel pump may be exceeded
Reduction in output is necessary, operating values
Emergency operation with may be exceeded, imminent starting difficulties, Increased attention required
removed running gear critical vibrations may occur
Emergency operation after
Reduction in output is necessary, operating values
dismounting of rocker arms/push Increased attention required
may be exceeded
rods
Table 4. Danger situations in case of pa
artially inappropriate use
L 58/64
108/ 09
Danger zone Source of hazard Possible consequences
Taking into operation of the Initial damage on components, negative influence on Increased wear, permanent damage, influence on the oil
engine/of parts without running in running faces consumption, in the extreme case piston seizure
Operation with impaired operating
Overheating due to lack of cooling and air, seizure due to lack
media/voltage supply (including Failure of operating media or voltage supply
6640
of lube oil
black--out and black--out test)
Operation within restricted speed Increased, under certain conditions resonance--like
Endangering of components and screw connections
3.2.3--01 E
Characterisation/danger scale
Characterisation According to the relevant laws, guidelines and standards, attention must
be drawn to dangers by means of safety instructions. This applies to the
marking used on the product and in the technical documentation. In this
connection, the following information is to be provided:
The statements and tables in Section 3.2.3 follow this regulation, just as
the other safety instructions in the technical documentation do.
Danger scale The imminence/extent of danger is characterised by a five--step scale as
follows:
Examples
▲▲▲ Danger! The flywheel can catch body/limbs so that they are
squashed or hit.
Do not remove the flywheel enclosure. Keep your hands out of the
operating area.
Prerequisites
Personnel The engine and its system may only be started, operated and stopped by
authorised personnel. The personnel has to be trained for this purpose,
possess complete understanding of the plant and should be aware of the
existing potential dangers.
Technical documentation The personnel must be familiar with the technical documentation of the
plant, in particular the operating manual of the engine and the accessories
required for engine operation. Particular attention must be paid to the re-
spective safety regulations.
Service log book It is advisable resp. required by supervisory authorities to keep a service
log book into which all the essential jobs and deadlines for their perform-
ance, the operating results and special events are entered. The purpose of
this log book is that in the event of a change in personnel the successors
are in a position to duly continue operation using this data log. Moreover,
the log book permits to derive a certain trend analysis and to trace back
faults in operation.
Regulations for accident pre- The regulations for accident prevention valid for the plant should be ob-
vention served during engine operation as well as during maintenance and over-
haul work. It is advisable to post those regulations conspicuously in the
engine room and to stress the danger of accidents over and over again.
Following advice The following advice covers the measures against moving of running gear
parts and general precautions for work/occurrences on the engine, its
neighbouring systems and in the engine room. It does not claim to be
complete. Safety requirements mentioned in other passages of the techni-
cal documentation are valid supplementarily and are to be observed in the
same way.
Causes Unintentional turning of the crankshaft and thus movement of the con-
nected components may be caused:
- in marine propulsion plants by the vessel in operation or when the
vessel is at standstill due to the flow of water against the propeller,
- in gensets by maloperation when the mains voltage is applied,
- by unintentional or negligent starting of the engine,
- by unintentional or negligent actuation of the engine turning device
(turning gear).
Precautions The following protective measures are to be taken:
The resistance of the engine turning device is not sufficient to reliably pre-
vent the crankshaft from turning. When the turning device is engaged, only
the start-up is electrically blocked and the control air supply to the main
starting valve is interrupted.
- Mount a warning sign to the operating devices permitting a start-up of
the engine.
- For gensets and shaft generators: Secure the generator switch (es-
pecially of asynchronous generators) against switching-on. Mount a
warning sign. As far as possible the safeguards/safeguarding elements
are to be opened in additon.
- For main marine engines with variable-pitch propeller:
Pitch of the engine at standstill to be set to zero-thrust, not to zero.
- For single-engine plants with fixed-pitch or variable-pitch propeller:
The above-mentioned measures are to be carried out. Further precau-
tions are not required.
- For multi-engine plants with reduction gearbox/es, when work is carried
out on one engine while the other engine is running:
J When using flexible couplings their rubber elements have to be re-
moved.
J When using flexible couplings with intermediate rings the latter have to
be removed; the resulting free space must by no means be bridged.
Coupling parts becoming loose as a result have to be supported if re-
quired.
J When using clutch-type couplings between the engine and the gearbox
these have to be removed completely. Switching off/opening of the
coupling, as well as shutting off the switching medium compressed air/
oil is not sufficient.
J When using clutch-type couplings in the gearbox the flexible couplings
have to be partly disassembled in accordance with the first two points.
- For engines with mechanical dredger pump drive on which work at the
dredger pump gearbox or at the dredger pump is carried out during en-
gine operation, measures have to be taken which are in accordance
with the above-mentioned points.
Opening of crankcase doors Crankcase doors must not be opened prior to ten minutes after an alarm/
engine stop, due to excessive bearing temperatures or oil vapour con-
centration.
Opening of pipes/pressure Before opening pipes, flanges, screwed connections or fittings, check if
vessels the system is depressurized/emptied.
Use of hydraulic tensioning When using hydraulic tensioning tools, observe the particular safety re-
tools gulations in work card 000.33.
Releasing compression springs For releasing compression springs, use the devices provided (refer to the
work cards that apply).
Coverings Following assembly work, check whether all the coverings over moving
parts and laggings over hot parts have been mounted in place again. En-
gine operation with coverings removed is only permissible in special
cases, e.g. if the valve rotator is to be checked for proper performance.
Use of self-locking hexagon nuts Self-locking hexagon nuts are to be used once only.
After they have been used for assembly, they must be replaced by new
self-locking hexagon nuts.
Use of cleaning agents When using cleaning agents, the suppliers instructions with respect to use,
potential risks and disposal are to be observed.
Use of anti-corrosion agents ▲ Attention! Anti-corrosion agents may contain inflammable sol-
vents which, in closed spaces, may form explosive mixtures (see
work card 000.14).
Use of high-pressure cleaning When using high-pressure cleaning equipment, be careful to apply it
equipment properly. Shaft ends including ones with lip seal rings, controllers, splash
water protected monitoring equipment, cable entries and sound/heat insu-
lating parts covered by water-permeable materials have to be appropri-
ately covered or excluded from high-pressure cleaning.
Failure of the speed governor/ In case of speed governor or overspeed governor failure, the engine has
overspeed governor to be stopped immediately. Engine operation with the speed governor
and/or overspeed governor failing can only be tolerated in emergency situ-
ations and is the operator’s responsibility.
Maintenance and repair work on Work on the alarm and safety system (electric/pneumatic/hydraulic) may
the alarm and safety system only be done by certified, qualified personnel. Moreover, it is imperative to
subject the alarm and safety system to a comprehensive, complete oper-
ational test after this work has been carried out, particularly if overhauled
or new spare parts were installed. This operational test must ensure
that the entire signal path has been checked! Particular attention is
to be paid to the emergency-stop functions of the engine!
Fire hazard The use of fuel and lube oils involves an inherent fire hazard in the engine
room. Fuel and lube oil pipes must not be installed in the vicinity of un-
lagged, hot engine components (exhaust pipe, turbocharger). After carry-
ing out overhaul work on exhaust gas pipes and turbochargers, all insula-
tions and coverings must be carefully refitted completely. The tightness of
all fuel oil and oil pipes should be checked regularly. Leaks are to be elim-
inated immediately.
In case of fire, the supply of fuel and lube oil must be stopped immediately
(stop the engine, stop the delivery pumps, shut the valves), and the fire
must be attempted to be extinguished using the portable fire-fighting
equipment. Should these attempts be without success, or if the engine
room is no longer accessible, all openings are to be locked, thus cutting off
the admission of air to quench the fire. It is a prerequisite for success that
all openings are efficiently sealed (doors, skylights, ventilators, chimney as
far as possible). Fuel oil requires much oxygen for combustion, and iso-
lating the source of fire from air is one of the most effective measures of
fighting the fire.
Temperature in the engine room The engine room temperatures should not drop below +5 C. Should the
temperature drop below this value, the cooling water spaces must be emp-
tied unless anti-freeze has been added to the cooling water. Otherwise,
material cracks/damage to components might occur due to freezing.
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
Diesel fuel
Other designations Gas oil, Marine Gas Oil (MGO), High Speed Diesel Oil, Huile de Diesel
Diesel fuel is a medium class distillate of crude oil which therefore must
not contain any residual components.
Specification
Suitability of the fuel depends on the conformity with the characteristic va-
lues as specified hereunder, pertaining to the condition on delivery.
Using fuel oil If, in case of stationary engines a distillate intended for oil firing (for in-
stance Fuel Oil EL to DIN 51603 or Fuel Oil No 1 or No 2 according to
ASTM D--396, resp.), is used instead of Diesel fuel, adequate ignition qual-
ity and resistance to cold must be ensured, i.e. the requirements as to
characteristic values concerning filterability and cetane number must be
met.
Investigations
Fuel analyses are carried out in our chemical laboratory for our customers
at cost price. For examination a sample of approx. 1 dm3 is required.
Other designations Diesel Fuel Oil, Diesel Oil, Bunker Diesel Oil, Marine Diesel Fuel.
Origine Marine Diesel Oil (MDO) is offered as heavy distillate (designation ISO-F-
DMB) or as a blend of distillate and small amounts of residual oil (designa-
tion ISO-F-DMC) exclusively for marine applications. The commonly used
term for the blend, which is of dark brown to black colour, is Blended
MDO. MDO is produced from crude oil and must be free from organic
acids.
Specification
The usability of a fuel depends upon the engine design and available
cleaning facilities as well as on the conformity of the characteristic values
with those listed in the table below which refer to the condition on delivery.
Supplementary information
The fuel shall be free of used lubricating oil (ULO). A fuel shall be con-
sidered to be free of ULO if one or more of the elements Zn, P and Ca are
below the specified limits (Zn: 15 ppm, P: 15 ppm, Ca: 30 ppm).
The Pour Point indicates the temperature at which the oil will refuse to
flow. The lowest temperature the fuel oil may assume in the system, must
be approx. 10C above the pour point so as to ensure it can still be
pumped.
Sea water, in particular, tends to increase corrosion in the fuel oil system
and hot corrosion of exhaust valves and in the turbocharger. It is also the
cause of insufficient atomization and thus poor mixture formation and com-
bustion with a high proportion of combustion residues.
Solid foreign matter increase the mechanical wear and formation of ash in
the cylinder space.
Investigations
Fuel analyses are carried out in our chemical laboratory for our customers
at cost price. For examination a sample of approx. 1 dm3 is required.
Prerequisites
Provenance/refining process The quality of the heavy fuel oil is largely determined by the crude oil
grade (provenance) and the refining process applied. This is the reason
why heavy fuel oils of the same viscosity may differ considerably, depend-
ing on the bunker places. Heavy fuel oil normally is a mixture of residue
oil and distillates. The components of the mixture usually come from state-
of-the-art refining processes such as visbreaker or catalytic cracking
plants. These processes may have a negative effect on the stability of the
fuel and on its ignition and combustion properties. In the essence, these
factors also influence the heavy fuel oil treatment and the operating results
of the engine.
Bunker places where heavy fuel oil grades of standardised quality are of-
fered should be given preference. If fuels are supplied by independent
traders, it is to be made sure that these, too, keep to the international
specifications. The responsibility for the choice of appropriate fuels rests
with the engine operator.
Specifications Mineral oil companies have internally established specifications for heavy
fuel oils, and experience shows that these specifications are observed
world-wide and are within the limits of international specifications (e.g. ISO
8217, CIMAC, British Standards MA-100). As a rule, the engine builders
expect that fuels satisfying these specifications are being used.
Blends The admixing of engine oils (used oils), of non-mineral oil constituents
(such as coal oil) and of residual products from refining or other processes
(such as solvents) is prohibited. The reasons are, for example: the
abrasive and corrosive effects, the adverse combustion properties, a poor
compatibility with mineral oils and, last but not least, the negative
environmental effects. The order letter for the fuel should expressly
mention what is prohibited, as this constraint has not yet been
incorporated in the commonly applied fuel specifications.
The admixing of engine oil (used oil) to the fuel involves a substantial
danger because the lube oil additives have an emulsifying effect and keep
Leaked oil tanks Leaked oil tanks in which leaked oil and residue pipes as well as overflow
pipes of the lube oil system, in particular, end must not have any connec-
tion to fuel tanks. Leaked oil tanks are to be emptied into sludge tanks.
Specifications
The heavy fuel oils ISO F-RMK 35/45/55, with a maximum density of
1010 kg/m, can only be used if appropriate modern separators are available.
In the fuel ordering form, the limit values as per Table 2 , which have an
influence on the engine operation, should be specified, for example in the
bunkering or charter clause. Please note the entries in the last column of
Table 2 , because they provide important background information.
Supplementary remarks
The following remarks are thought to outline the relations between heavy
fuel oil grade, heavy fuel oil treatment, engine operation and operating re-
sults.
2. Viscosity/injection viscosity
Heavy fuel oils if having a higher viscosity may be of lower quality. The
maximum permissible viscosity depends on the existing preheating equip-
ment and the separator rating (throughput).
Settling tank The heavy fuel oil is precleaned in the settling tank. This precleaning is all
the more effective the longer the fuel remains in the tank and the lower the
viscosity of the heavy fuel oil is (maximum preheating temperature 75C to
prevent formation of asphalt in the heavy fuel oil). One settling tank will
generally be sufficient for heavy fuel oil viscosities below 380 mm2/s at
50C. If the concentration of foreign matter in the heavy fuel oil is excess-
ive, or if a grade according to ISO-F-RM G/H/K35, H/K45 or H/K55 is pre-
ferred, two settling tanks will be required, each of which must be ad-
equately rated to ensure trouble-free settling within a period of not less
than 24 hours. Prior to separating the content into the service tank, the
water and sludge have to be drained from the settling tank.
Table 3 shows the demands made on the separator. These are limit va-
lues which the manufacturers of these separators take as a basis and
which they also guarantee.
1 separator for
100% throughput
1 separator (standby) for
100% throughput
Water Attention is to be paid to very thorough water separation, since the water
is not a finely distributed emulsion but in the form of adversely large
droplets. Water in this form promotes corrosion and sludge formation also
in the fuel system, which has an adverse effect on the delivery and atom-
isation and thus also on the combustion of the heavy fuel oil. If the water
involved is sea water, harmful sodium chloride and other salts dissolved in
the water will enter the engine.
The water-containing sludge must be removed from the settling tank prior
to each separating process, and at regular intervals from the service tank.
The venting system of the tanks must be designed in such a way that con-
densate cannot flow back into the tanks.
If the sodium content is lower than 30% of the vanadium content, the risk
of high-temperature corrosion will be small. It must also be prevented that
sodium in the form of sea water enters the engine together with the intake
air.
If the sodium content is higher than 100 mg/kg, an increase of salt de-
posits is to be expected in the combustion chamber and in the exhaust
system. This condition will have an adverse effect on engine operation
(among others, due to surging of the turbocharger). In the case of engines
with PTO, the content of sodium has to be limited to 50 mg/kg.
Under certain conditions, high-temperature corrosion may be prevented by
a fuel additive that raises the melting temperature of the heavy fuel oil ash
(also refer to item 12).
Ash Heavy fuel oils with a high ash content in the form of foreign particles such
as sand, corrosion and catalyst residues, promote the mechanical wear in
the engine. There may be catalyst fines (catfines) in heavy fuel oils coming
from catalytic cracking processes. In most cases, these catfines will be
aluminium silicate, which causes high wear in the injection system and in
the engine. The aluminium content found multiplied by 5-8 (depending on
the catalyst composition) will approximately correspond to the content of
catalyst materials in the heavy fuel oil.
Homogenizer If a homogenizer is used, it must not be installed between the settling tank
and the separator on any account, since in that case, harmful contam-
inants, and in particular seawater, cannot be separated out sufficiently.
Pourpoint The pour point is the temperature at which the fuel is no longer fluid
(pumpable). Since many of the low-viscosity heavy fuel oils have a pour
point greater than 0C, too, the bunkering system has to be preheated un-
less fuel in accordance with CIMAC A30 is used. The entire bunkering
system should be designed so as to permit preheating of the heavy fuel oil
Cloudpoint to approx. 10C above the pour point. For filter clogging, the cloud point is
of interest.
8. Ignition quality
Cracked products which nowadays are preferred as low-viscosity blend
constituents of the heavy fuel oil in order to achieve the specified refer-
ence viscosity may have poor ignition qualities. The cetane number of
these constituents has to be higher than 35. An increased aromatics con-
tent (above 35%) also leads to a decrease in ignition quality.
Fuel oils of insufficient ignition qualities will show extended ignition lag and
delayed combustion, which may lead to thermal overloading of the oil film
on the cylinder liner and excessive pressures in the cylinder. Ignition lag
and the resultant pressure rise in the cylinder are also influenced by the
final temperature and pressure of compression, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
Preheating of the charge-air in the part-load range and output reduction for
a limited period of time are possible measures to reduce detrimental in-
fluences of fuel of poor ignition qualities. More effective, however, are a
high compression ratio and the in-service matching of the injection system
to the ignition qualities of the fuel oil used, as is the case in MAN Diesel
trunk piston engines.
The ignition quality is an essential characteristic of the fuel. The reason
why it does not appear in the international specifications is the absence of
a standardised testing method. Therefore, parameters such as the Calcu-
lated Carbon Aromaticity Index (CCAI) are resorted to as an aid, which are
derived from determinable fuel characteristics. We have found this to be
an appropriate method of roughly assessing the ignition quality of the
heavy fuel oil used.
A Normal operating
conditions
B Difficulties may be
encountered
C Problems encountered
may increase up to
engine damage after a
short time of operation
1 Engine type
2 The combining straight
line across density and
viscosity of a heavy
fuel oil results in CCAI.
CCAI can also be calculated with the aid of the following formula:
CCAI = D -- 141 log log (V+0.85) -- 81.
9. Sulphuric acid corrosion
Pre-combustion : Dispersants/stabilizers
: Emulsion breakers
: Biocides
Combustion : Combustion catalysts
(fuel economy, emissions)
Post-combustion : Ash modifier (hot corrosion)
: Carbon remover (exhaust system)
Table 4. Additives to heavy fuel oils - Classification/effects
Examinations
Analysing samples The samples received from the bunkering company are frequently not
identical with the heavy fuel oil bunkered. It is also appropriate to verify the
characteristic values stated in the bunker papers for the heavy fuel oil
such as, e.g., with regard to density, viscosity, pour point. If these values
should deviate from those of the heavy fuel oil bunkered, one runs the risk
that the heavy fuel oil separator and the preheating temperature are not
set correctly for the given injection viscosity. The characteristic values of
heavy fuel oil and lubricating oil which are relevant for an economic engine
operation can be determined by means of the “MAN Diesel Fuel and Lub
Analysis set”.
Our department for fuels and lube oils (Augsburg Works, Department QC)
will be glad to furnish further information if required.
Example: Heavy fuel oil of A vertical line is drawn starting from a reference temperature of 50C and
180 mm2/s at 50 C a horizontal line (a) starting from a viscosity of 180 mm2/s. From the point
of intersection of both these lines, a line is drawn parallel to the diagonals
entered in the diagram (b). This line represents the viscosity-temperature
line of a heavy fuel oil with 180 mm2/s at 50C.
A heavy fuel oil of 180 mm2/s at 50C reaches a viscosity of 1000 mm2/s
at 24C (line e) which is the max. permissible viscosity with respect to the
pumpability of the fuel.
HFO temperature Using a state-of-the-art final preheater a heavy fuel oil outlet temperature
of 152 C will be obtained at 8 bar saturated steam. Higher temperatures
involve the risk of increased residue formation in the preheater, resulting in
a reduction of the heating power and thermal overloading of the heavy fuel
oil. This causes new asphalt to form, i.e. a deterioration of quality.
Injection viscosity The fuel pipes from the final preheater outlet up to the injection valve must
be insulated adequately ensuring that a temperature drop will be limited to
max. 4 C. Only then can the prescribed injection viscosity of max.
14 mm2/s be achieved with a heavy fuel oil of a reference viscosity of 700
mm2/s = cSt/50 C (representing the maximum viscosity of international
specifications such as ISO, CIMAC or British Standard). If a heavy fuel oil
of a lower reference viscosity is used, an injection viscosity of 12 mm2/s
should be aimed at, ensuring improved heavy fuel oil atomisation, and
consequently a heavy fuel oil combustion in the engine with less residues.
Gas oil or Diesel oil (Marine Diesel fuel) must neither show a too low
viscosity or a higher viscosity than that specified for the fuel oil as entering
the injection pump. With a too low viscosity, insufficient lubricity may cause
the seizure of the pump plungers or the nozzle needles. This can be
avoided if the fuel temperature is kept to
- max. 60 C for Marine Diesel Fuel operation and
- max. 50 C for gas oil operation
Therefoe a fuel oil cooler has to be installed. In case of fuel viscosities
< 2.5 mm2/s, consultation with the technical department of MAN Diesel SE
in Augsburg is required.
Lube oil for operation on gas oil and Diesel oil (MGO/MDO)
The specific power output offered by today’s Diesel engines and the use of
fuels, which more and more often approach the limit in quality, increase
the requirements placed on the lube oil and make it imperative that the
lube oil is chosen carefully. Doped lube oils (HD oils) have proven to be
suitable for lubricating the running gear, the cylinders, the turbochargers
and for cooling the pistons. Doped lube oils contain additives which,
amongst other things, provide them with sludge carrying, cleaning and
neutralization capabilities.
Only lube oils, which have been released by MAN B&W, are to be used.
These are listed in Table 3 .
Specifications
Base oil The base oil (doped lube oil = base oil + additives) must be a narrow dis-
tillation cut and must be refined in accordance with modern procedures.
Brightstocks, if contained, must neither adversely affect the thermal nor
the oxidation stability. The base oil must meet the limit values as specified
below, particularly as concerns its aging stability.
Doped lube oils (HD-oils) The base oil, which has been mixed with additives (doped lube oil) must
have the following properties:
Additives The additives must be dissolved in the oil and must be of such a composi-
tion that an absolute minimum of ash remains as residue after combustion.
The ash must be soft. If this prerequisite is not complied with, increased
deposits are to be expected in the combustion chamber, especially at the
outlet valves and in the inlet housing of the turbochargers. Hard additive
ash promotes pitting on the valves seats, as well as valve blow-by and
increased mechanical wear.
Detergency The detergency must be so high that the build-up of coke and tar-like resi-
dues forming during the combustion of fuel is precluded.
Dispersancy The dispersancy must be selected such that commercially available lube-
oil cleaning equipment can remove the detrimental contaminations from
the used oil.
Neutralisation capacity The neutralisation capacity (ASTM-D2896) must be so high that the acidic
products which result during combustion are neutralized. The reaction time
of the additives must be matched to the process in the cylinder crankcase.
Evaporation tendency The tendency to evaporate must be as low as possible, otherwise the oil
consumption is adversely affected.
Further conditions The lube oil must not form a stable emulsion with water. Less than 40 ml
emulsion are acceptable in the ASTM-D1401 test after one hour.
Doped grade Doped lube oils (HD oils) corresponding to international specifications
MIL-L 2104 D or API-CD, and having a base number (BN) of 12-15 mg
KOH/g are recommended by us.
(Designation for armed forces of Germany: O-278)
The content of additves included in the lube oil depends upon the condi-
tions under which the engine is operated, and the quality of fuel used. If
marine Diesel fuel is used, which has a sulphur content of up to 2.0 weight
% as per ISO-F DMC, and coke residues of up to 2.5 weight % as per
Conradson, a BN of approx. 20 is of advantage. Ultimately, the operating
results are the decisive criterion as to which content of additives ensures
the most economic engine operation.
Cylinder lube oil In the case of engines with separate cylinder lubrication, the pistons and
the cylinder liner are supplied with lube oil by means of a separate oil
pump. The oil supply rate is factory-set to conform to both the quality of
the fuel to be used in service and to the anticipated operating conditions.
A lube oil as specified above is to be used for the cylinder lubrication and
the lubricating circuit.
The oil quality specified by the manufacturer is to be used for the remain-
ing equipment fitted to the engine.
Lube-oil additives We strongly advise against subsequently adding additives to the lube oil,
or mixing the different makes (brands) of the lube oil, as the performance
of the carefully matched package of additives which is suiting itself and
adapted to the base oil, may be upset. Also, the lube oil company (oil
supplier) is no longer responsible for the oil.
Selection of lube oils/ Most of the mineral oil companies are in close and permanent consultation
warranty with the engine manufacturers and are therefore in a the position to quote
the oil from their own product line that has been approved by the engine
manufacturer for the given application. Independent of this release, the
lube oil producers are in any case responsible for quality and performance
of their products. In case of doubt, we are more than willing to provide you
with further information.
Examinations
We carry out the examinations on lube oil in our laboratories for our cus-
tomers who need only pay the self-costs (net-costs). A representative
sample of about 1 dm3 is required for the examination.
Table 3. Lubricating oils which have been released for the use in MAN B&W Diesel
four-stroke engines running on gas oil and Diesel oil
The specific power output offered by today’s Diesel engines and the use of
fuels which more and more often approach the acceptable limit in quality
increase the requirements placed on the lube oil and make it imperative
that the lube oil is chosen carefully. Medium-alkaline lube oils have proven
to be suitable for lubricating the running gear, the cylinders, the turbo-
charger and for cooling of the pistons. Medium-alkaline oils contain addi-
tives which, amongst other things, provide them with a higher neutralisa-
tion capacity than doped (HD) engine oils have.
Only lube oils, which have been released by MAN B&W, are to be used.
These are listed in Table 4 .
Requirements
Base oil The base oil (medium-alkaline lube oil = base oil + additives) must be a
narrow distillation cut and must be refined in accordance with modern pro-
cedures. Brightstocks, if contained, must neither adversely affect the ther-
mal nor the oxidation stability.
The base oil must meet the limit values of the following Table, particularly
as concerns its aging stability.
Medium-alkaline lube oil The base oil (medium-alkaline lube oil) with which additives have been
mixed must demonstrate the following properties:
Additives The additives must be dissolved in the oil and must be of such a composi-
tion that an absolute minimum of ash remains as residue after combustion,
Additives must not promote clogging of the filter elements, neither in their
active nor in their exhausted state.
Detergency The detergency must be so high that the build-up of coke and tar-like resi-
dues forming during the combustion of heavy fuel oil is precluded.
Dispersancy The dispersancy must be selected such that commercially available lube-
oil cleaning equipment can remove the detremental contaminations from
the used oil, i.e., the used oil must have good separating and filtering prop-
erties
Diesel-Performance The Diesel performance (without taking the neutralisation capacity into
consideration) must, at least, comply with MIL-L-2104 D resp. API-CD.
Neutralisation capacity The neutralisation capacity (ASTM-D2896) must be so high that the acidic
products resulting from combustion are neutralised at the lube oil con-
sumption rate that is specific for the engine. The reaction time of the addi-
tives must be matched to the processes in the cylinder crankcase. Hints
concerning the selection of the BN are given in Table 3 .
Evaporation tendency The tendency to evaporate must be as low as possible, otherwise the oil
consumption is adversely affected.
Further conditions The lube oil must not form a stable emulsion with water. Less than 40 ml
emulsion are acceptable in the ASTM-D 1410 test after one hour. The
foaming behaviour (ASTM-D 892) must meet the following conditions:
after 10 minutes < 20 ml. The lube oil must not contain agents to improve
the viscosity index. Fresh oil must not contain any water or other conta-
minations.
Neutralisation capacity (BN) Medium-alkaline lube oils having differently high levels of neutralisation
capacity (BN) are available on the market. According to the present-day
state of knowledge, operating conditions to be expected and BN can be
correlated as follows (refer to Table 3 ). The operating results will in the
essence be the decisive criterion as to which BN will ensure the most
economic engine operation.
Cylinder lube oil In the case of engines with separate cylinder lubrication, the pistons and
the cylinder liner are supplied with lube oil by means of a separate oil
pump. The lube oil supply rate is factory-set to conform to both the quality
of the fuel to be used in service and to the anticipated operating condi-
tions.
A lube oil as specified above is to be used for the cylinder lubrication and
the lubricating circuit.
Speed governor In case of mechanic-hydraulic governors with separate oil sump, multi-
grade oil 5W-40 is preferably used. If this oil is not available as refill, an oil
15W-40 can be used for once. In this context it is not important, if multi-
grade oils based on synthetic or mineral oil are used. According to the
mineral oil companies they can be mixed in all cases.
The oil quality specified by the manufacturer is to be used for the remain-
ing equipment fitted to the engine.
Lube-oil additives We strongly advise against subsequently adding additives to the lube oil,
or mixing the different makes (brands) of the lube oil, as the performance
of the carefully matched package of additives, which is suiting itself and
adapted to the base oil, may be upset. Also, the lube oil company (oil
supplier) is no longer responsible for the oil.
Selection of lube oils/ Most of the mineral oil companies are in close and permanent consultation
warranty with the engine manufacturers and are, therefore, in a the position to
quote the oil from their own product line that has been approved by the
engine manufacturer for the given application. Independent of this release,
the lube oil manufacturers are in any case responsible for quality and per-
formance of their products. In case of doubt, we are more than willing to
provide you with further information.
Examinations
We carry out the lube oil examinations in our laboratories for our cus-
tomers who need only pay the self-costs (net-costs). A representative
sample of about 1 dm3 is required for the examination.
Preconditions
The engine cooling water, like the fuel and lubricating oil, is a medium
which must be carefully selected, treated and controlled. Otherwise, corro-
sion, erosion and cavitation may occur on the walls of the cooling system
in contact with water and deposits may form. Deposits impair the heat
transfer and may result in thermal overload on the components to be
cooled. The treatment with an anti-corrosion agent has to be effected be-
fore the first commissioning of the plant. During subsequent operations the
concentration specified by the engine manufacturer must always be en-
sured. In particular, this applies if a chemical additive is used.
Requirements
Limiting values The characteristics of the untreated cooling water must be within the fol-
lowing limits:
Test device The MAN Diesel water test kit includes devices permitting, i.a., to deter-
mine the above-mentioned water characteristics in a simple manner. More-
over, the manufacturer of anti-corrosion agents are offering test devices
that are easy to operate. For further information regarding checking the
cooling water condition, please refer to work card 000.07.
Supplementary information
Distillate If a distillate (e.g. from the freshwater generator) or fully desalinated water
(ion exchanger) is available, this should preferably be used as engine cool-
ing water. These waters are free from lime and metal salts, i.e. major de-
posits affecting the heat transfer to the cooling water and worsening the
cooling effect cannot form. These waters, however, are more corrosive
than normal hard water since they do not form a thin film of lime on the
walls which provides a temporary protection against corrosion. This is the
Hardness The total hardness of the water is composed of temporary and permanent
hardness. It is largely determined by calcium and magnesium salts. The
temporary hardness is determined by the hydrogencarbon content of the
calcium and magnesium salts. The permanent hardness can be deter-
mined from the remaining calcium and magnesium salts (sulphates). The
decisive factor for the formation of calcareous deposits in the cooling sys-
tem is the temporary (carbonate) hardness.
Water with more than 10 dH (German total hardness) must be mixed with
distillate or be softened. A rehardening of excessively soft water is only
necessary to suppress foaming if an emulsifiable anti-corrosion oil is used.
Flow cavitation Flow cavitation may occur in regions of high flow velocity and turbulence.
If the pressure falls below the evaporation pressure, steam bubbles will
form which then collapse in regions of high pressure, thus producing mate-
rial destruction in closely limited regions.
Corrosion fatigue Corrosion fatigue is a damage caused by simultaneous dynamic and cor-
rosive stresses. It may induce crack formation and fast crack propagation
in water-cooled, mechanically stressed components if the cooling water is
not treated correctly.
Formation of a protective film The purpose of engine cooling water treatment is to produce a coherent
protective film on the walls of the cooling spaces by the use of anti-corro-
sion agents so as to prevent the above-mentioned damage. A significant
prerequisite for the anti-corrosion agent to develop its full effectivity is that
the untreated water which is used satisfies the requirements mentioned
under point 2.
Treatment before operating the Treatment with an anti-corrosion agent should be done before the engine
engine for the first time is operated for the first time so as to prevent irreparable initial damage.
Permission required Only the additives approved by MAN Diesel and listed in the Tables 2 to
5 are permitted to be used. The suppliers are to warrant the effectivity of
A cooling water additive can be approved for use if it has been tested ac-
cording to the latest rules of the Forschungsvereinigung Verbrennungs-
kraftmaschinen (FVV), ”Testing the suitability of coolant additives for cool-
ing liquids of internal combustion engines” (FVV publication R 443/1986).
The test report is to be presented if required. The necessary testing is car-
ried out by Staatliche Materialprüfanstalt, Department Oberflächentechnik,
Grafenstraße 2, 64283 Darmstadt on request.
To be used only in closed circuits Additives can only be used in closed circuits where no appreciable con-
sumption occurs except leakage and evaporation losses.
1. Chemical additives
Additives based on sodium nitrite and sodium borate, etc. have given good
results. Galvanised iron pipes or zinc anodes providing cathodic protection
in the cooling systems must not be used. Please note that this kind of cor-
rosion protection, on the one hand, is not required since cooling water
treatment is specified and, on the other hand, considering the cooling wa-
ter temperatures commonly practiced nowadays, it may lead to potential
inversion. If necessary, the pipes must be dezinced.
2. Anti-corrosion oil
The manufacturer must guarantee the stability of the emulsion with the
water available or has to prove this stability by presenting empirical values
from practical operation. If a completely softened water is used, the possi-
bility of preparing a stable, non-foaming emulsion must be checked in
cooperation with the supplier of the anti-corrosion oil or by the engine user
himself. Where required, adding an anti-foam agent or hardening (see
work card 000.07) is recommended.
Anti-corrosion oil is not suitable if the cooling water may reach tempera-
tures below 0 C or above 90 C . If so, an anti-freeze or chemical additive
is to be used.
3. Anti-freeze agent
For the disposal of cooling water treated with additives, observe the envi-
ronmental protection legislation. For information, contact the suppliers of
the additives.
4. Biocides
If the use of a biocide is inevitable because the cooling water has been
contaminated by bacteria, the following has to be observed:
- It has to be ensured that the biocide suitable for the particular applica-
tion is used.
- The biocide must be compatible with the sealing materials used in the
cooling water system; it must not attack them.
- Neither the biocide nor its decomposition products contain corrosion-
stimulating constituents. Biocides whose decomposition results in
chloride or sulphate ions are not permissible.
- Biocides due to the use of which the cooling water tends to foam are
not permissible.
Before starting the engine for the first time and after repairs to the piping
system, it must be ensured that the pipes, tanks, coolers and other equip-
ment outside the engine are free from rust and other deposits because dirt
will considerably reduce the efficiency of the additive. The entire system
has therefore to be flushed using an appropriate cleaning agent with the
engine shut down (refer to work cards 000.03 and 000.08).
The agent used for cleaning must not attack the materials and the seal-
ants in the cooling system. This work is in many cases done by the sup-
plier of the cooling water additive, at least the supplier can make available
the suitable products for this purpose. If this work is done by the engine
user it is advisable to make use of the services of an expert of the cleaning
Treated cooling water may become contaminated in service and the addi-
tive will loose some of its effectivity as a result. It is therefore necessary to
check the cooling system and the condition of the cooling water at regular
intervals.
Concentrations that are too low may promote corrosive effects and have
therefore to be avoided. Concentrations that are too high do not cause
damages. However, concentrations more than double as high should be
avoided for economical reasons.
If excessive concentrations of solids (rust) are found, the water charge has
to be renewed completely, and the entire system has to be thoroughly
cleaned.
Protective measures
If chemicals have splashed into the eyes, immediately wash with plenty of
water and consult a doctor.
Manufacturer Product
designation
BP Marine, Breakspear Way, Hemel Hempstead, Diatsol M
Herts HP2 4UL, UK Fedaro M
Castrol Int., Pipers Way, Swindon SN3 1RE, UK Solvex WT 3
Deutsche Shell AG, Überseering 35, Oil 9156
22284 Hamburg, Germany
Table 4. Emulsifiable anti-corrosion oils
Checking is important
The engine oil and cooling water require checking during engine operation
because contamination and acidification set limits to the useful life of the
lube oil, and inadequate water quality or insufficient concentrations of the
corrosion inhibitor in the cooling water may cause damage to the engine.
Test kit
of interest for
P
Property
t Fuel Water Lubricati P
Property t is
i indicative
i di ti off Testt
T
on oil or decisive for kit
Density x x Separator setting A
Viscosity x x Separating temperature, injection A*
viscosity, lube oil dilution
Ignition performance x Ignition and combustion behaviour, A
CCAI/CII ignition pressure, pressure increase
rate, starting behaviour
Water content x x Fuel oil supply
pp y and atomisation,, A
Checking for sea water x x corrosion
i tendency
t d A
Total Base Number (TBN) x Remaining neutralisation capacity A
pH value x B
Pour point x x Storing capacity/pumpability A
Water hardness x Cooling water treatment B
Chloride ion concentration x Salt deposits in the cooling system B
Concentration of corrosion x Corrosion protection in the cooling **
inhibiting oil system
in the cooling water
Drop test x Total contamination of lube oil A
Spot Test (ASTM-D2781) x Compatibility of HFO blending A
components
* Test kit A contains the Viscomar unit that allows the viscosity to be measured at various reference temperatures. In combination with the
Calcumar processing unit, the viscosity/temperature interdependence can be determined (e.g. injection and pumping temperatures).
Refills of the chemicals that are used are available. Each test kit includes
a comprehensive User’s Guide containing everything you need to know
about its use.
Lube Oil Tec To determine the water content, the Total Base Number (TBN) and the
viscosity of lube oils (scaled down alternative to test kit A)
port-A-lab For testing lube oil. Tests comparable to those performed by Lube Oil Tec.
Refractometer For monitoring how much anti-freeze is dispensed (in stationary systems).
Sources
Source Address
1 MAN B&W Diesel AG, Augsburg, Dept. SK
2 Drew Marine Mar-Tec GmbH, Stenzelring 8, 21107 Hamburg
3 Martechnic GmbH, Schnackenbergallee 13, 22525 Hamburg
4 Supplier of corrosion inhibitor
5 Müller Gerätebau GmbH, Rangerdinger Straße 35, 72414 Höfendorf
General
The quality and the condition of the intake air (combustion air) exert great
influence on the engine output. In this connection, not only the atmos-
pherical condition is of great importance but also the pollution by solid and
gaseous matter.
Mineral dust particles in the intake air will result in increased wear. Chemi-
cal/gaseous constituents, however, will stimulate corrosion.
For this reason, effective cleaning of the intake air (combustion air) and
regular maintenance/cleaning of the air filter are required.
Requirements
Limiting values The concentrations after the air filter and/or before the turbocharger inlet
must not exceed the following limiting values:
When designing the intake air system, it has to be kept in mind that the
total pressure drop (filter, silencer, piping) must not exceed 20 mbar.
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
Activate/check the systems In the case of short downtimes, the fuel pumps should remain in operation;
put them into operation if necessary. Switch on pumps for lubricating oil
and cooling water unless mounted on the engine. Prime the engine. After
downtimes exceeding 12 hours, additionally open the indicator valves and
turn the running gear by approx. three revolutions using the turning gear.
On engines which are started automatically, activate the slow-turn instead.
Check whether the cooling water and lubricating oil have been preheated
(if possible). Set the shut-off elements of all systems to in-service position.
The engine is then ready to be started.
Check the fuel viscosity On engines operated on heavy fuel oil, check whether the viscosity of the
fuel corresponds to the operating viscosity (see Section 3.3).
Engine start is initiated by a pulse transmitted through valve M 388/1 to
valve M 329/1 in the engine-mounted operating device. In case of an
emergency, the valve M 329/1 can also be actuated manually.
Additionally, please observe the requirements applicable for remote control
of marine engines.
The engine can also be started on heavy fuel oil provided the necessary
heating equipment is available. In this connection, the conditions appli-
cable for pier-to-pier operation are to be observed:
Pier-to-pier operation In the case of pier-to-pier operation, landing and departure of the ship
takes place in heavy-fuel-oil operation, without switching over to Diesel oil
operation.
Starting the engine For starting the engine on heavy fuel oil, proceed as follows:
on heavy fuel oil
in the case of
- According to the conditions for pier-to-pier operation, the tank heaters,
fuel delivery pump, final preheater and, if necessary, the tracing type
pier-to-pier operation
heating, as well as the preheating pumps in the fuel system are already
in operation.
- Switch on the pump for cylinder cooling water and subsequently, if
necessary, the preheater. Temperature required: approx. 60C.
- Switch on the pump for nozzle cooling water and subsequently the pre-
heater. Temperature required: approx. 55C.
- Switch on the preheater for lubricating oil (heating coil in the service
tank), or preheat the lubricating oil in the by-pass (separator circuit).
Temperature required: approx. 40C.
Important! The lube oil service pump and/or stand-by pump must
not be switched on until approx. 10 minutes prior to engine start in order to
avoid that the turbocharger(s) is/are overlubricated because of the ab-
sence of sealing air at standstill.
After overhaul work or after prolonged downtimes (several weeks) the fol-
lowing work has to be done before the engine is started:
Fuel oil system - Dewater and top up the settling tank and service tank.
- Drain the filters and clean the inserts.
- Set all the shut-off elements to in-service position.
For starting HFO-operated engines on Diesel fuel:
Switch the three-way cock so that Diesel fuel flows from the service
tank to the mixing tank (see the system-specific fuel oil diagram in Vol-
ume E1).
- Switch on the delivery pump and evacuate air from the injection pumps,
pipes and filters.
- Check the zero admission on the control rod of each injection pump
and verify that the linkage moves easily.
- For HFO operation: Start the heating equipment (unless permanently
on) and check it.
- Switch the delivery pump and the heating for the final preheater off
again (danger of overheating).
Cooling water system - Remove sludge from cooling water tank, coolers, pumps and pipes (en-
gine, injection valves, charge-air cooler).
- Top up the cooling water, check the concentration of the anti-corrosion
agent.
- Switch on the cooling water pumps or stand-by pumps (engine and in-
jection valves).
- Evacuate air from the cooling water spaces and check all connections
for tightness.
- Check, i.e. open the leaked water drain from the cylinder liner sealing in
the backing ring and from the charge-air cooler casing to verify that
they are tight.
- Check the cooling water pressure and the water volume in the compen-
sating tank.
- Check the compensating tank for separations of anti-corrosion oil (cyl-
inder cooling) and fuel oil (injection valve cooling).
- Switch off the cooling water pumps.
Lube oil system - Pump the lubricating oil out of (oil sump and) storage tank and clean
the oil spaces (make sure not to forget the exhaust gas turbocharger).
- Clean the oil filters, separators and oil coolers.
Top up new lubricating oil, or separate the oil charge in use.
- Set all the cocks to in-service position and switch on the electrically
driven lube oil pump or stand-by pump.
- Check the running gear as well as the injection pump drive and the
valve gear to verify that oil is supplied to all bearing points.
- Check the pipe connections and pipes for leakages.
- Check the lube oil pressure upstream of the engine and upstream of
the exhaust gas turbocharger.
- Disengage the turning gear again and switch off the lube oil pump.
Starting system - Dewater the compressed air tank and check the pressure, top up if
necessary.
- Check the shut-off valves for ease of movement.
- Check the starting valves in the cylinder heads for tightness
(see Work Card in Volume B2).
1 Indication
2 Admission lever
3 Push-button
4 Actuating lever
1 Indication
3 Push-button
4 Actuating lever
Steps - Set the actuating lever (4) to “NORMAL OPERATION WITH ELECTRI-
CAL GOVERNOR”.
- Prior to starting, adjust the nominal speed to approx. 30% using the
adjusting knob provided for this purpose.
- Verify that the indication (1) “DON’T START” is not glowing (if the in-
dication is glowing, the engine cannot be started.)
- Press push-button (3) “START” until the engine starts running.
- Adjust the nominal speed by means of the adjusting knob provided.
▲ Attention! Observe remarks in Sections 3.4 to 3.7 (Operational
control I - IV)!
1 Indication
2 Admission lever
3 Push-button
4 Actuating lever
5 Fine regulating valve
1 Indication
3 Push-button
4 Actuating lever
5 Fine regulating valve
Steps - Set the actuating lever (4) to “NORMAL OPERATION WITH ELECTRI-
CAL GOVERNOR”.
- Prior to starting, adjust the nominal speed to approx. 30% using the
fine regulating valve (5).
- Verify that the indication (1) “DON’T START” is not glowing (if the in-
dication is glowing, the engine cannot be started.)
- Press the push-button (3) “START” until the engine starts running.
- Adjust the nominal speed on the fine regulating valve (5).
▲ Attention! Observe the remarks in Sections 3.4 to 3.7 (Operational
control I - IV) !
Engine shut-down from opera- After shutting the engine down from HFO operation, the following is to be
tion on HFO in case of pier-to- observed:
pier operation
- The cooling circuits of the engine remain in operation until the engine
has cooled down.
J HT cooling water pump shut off, while the preheating pump remains in
operation.
J Nozzle cooling water pump shut off.
J Lube oil pump shut off.
- LT cooling water pump remains in operation. Engine preheating is ef-
fected by a servomotor.
- Tank heating equipment, fuel delivery pump, final preheater and tracing
type heating in the fuel system (where available) remain in operation.
Required HFO temperature in the service tank: approx. 75C.
Emergency stop
Engine after emergency stop In order to permit quick engine shut-down in case a disturbance occurs, a
pneumatic shut-off piston has been fitted in every injection pump which,
when operated by compressed air, sets the injection pump to zero admis-
sion.
At the same time, the speed governor is induced to move the control link-
age of the governor also to zero admission.
Engine in HFO operation In case the engine has to be shut down directly from HFO operation, the
Engine start after emergency following is to be observed (see system-related fuel diagram in Section 2):
stop - If the engine is to be restarted after a few minutes, it is sufficient to
keep the heating equipment and one delivery pump operating.
- In case of longer engine downtime, switch the three-way cock (15) to
Diesel fuel operation and the three-way cock (16) to flushing. The deliv-
ery pump is to be kept operating until the heavy fuel oil has been re-
pumped into the HFO service tank and the piping system has been
filled with Diesel fuel oil. Subsequently, reswitch the three-way cock
(16) to normal operation and switch the delivery pump off.
Preliminary remarks In the case of engines equipped with a pressurised fuel oil system for HFO
operation, there exists the risk that on prolonged operation on Diesel fuel
oil the maximum admissible Diesel fuel temperature is exceeded due to
hot Diesel fuel being recirculated into the mixing tank. Excessive
temperatures imply low viscosity and lubricity involving corresponding
danger for the injection pumps. Therefore, the shut-off valves in the return
pipe have in this case to be switched so that the Diesel fuel oil is returned
to the service tank instead of the mixing tank (refer to Section 2.4 or the
system-specific fuel oil diagram).
Steps - Switch on the heaters for the mixing tank and heavy fuel oil pipes, if
available.
- Switch the three-way cock to HFO operation (refer to system-specific
fuel oil diagram).
- For engine systems equipped with viscosity measuring system and
manual control of preheating temperature: Adjust the heating capacity
of the final preheater in accordance with the viscosimeter data so that
the viscosity shown in the viscosity/temperature diagram is obtained at
the injection pumps (depending on the heavy fuel oil used).
- In case of engine systems with automatic heavy fuel oil viscosity
control: The viscosity control system is adjusted on initial putting into
operation of the engine, and should not be changed normally.
- The temperature of the cooling water as leaving the cylinder is to be
maintained at approx. 80C. In the case of heavy fuel oils with a high
sulphur concentration, in particular, make sure that the temperature
does not drop below this value.
Preliminary remarks In Diesel engines designed to operate prevalently on HFO the injection
valves are to be cooled during operation on HFO. In the case of operation
on Diesel fuel oil (MGO or MDO) exceeding 72 hrs, the nozzle cooling is to
be switched off and the supply line is to be closed. The return pipe,
however, has to remain open.
Steps - Switch the three-way cock (please refer to system-specific fuel oil
diagram) to Diesel fuel oil approx. 30 minutes prior to engine
shut-down.
- Final preheaters controlled by hand have to be switched off.
Background
Power, speed ... The following relationships exist between engine power, speed, torque and
mean effective pressure:
1200 ô P e
pe
and
VH ô n ô z
9550 ô P e
Md
n
Where
Mean pressure The mean effective pressure is the mean value of the cylinder pressure
over the whole four-stroke cycle. It is proportional to the power and the
torque and inversely proportional to the speed. If the mechanical efficiency
hmech is known, it can be calculated from the mean value of the indicated
pressures:
p e
pi ô ®mech
n
60pô f
Where
Operating points/characteristic Stable engine operating points are only obtained when there is a balance
curves between output, speed and the feed rate setting of the fuel pumps (filling).
The energy supply must correspond to the energy requirements.
In service, the maximum speed and torque have to be limited in the first
approximation to 100 %, the continuous output in diesel operation to be-
tween 0 and 100 %, and in HFO mode to between 151) and 100 %. This is
to some extent achieved through design measures but must be supple-
mented by operational techniques.
The permitted operating ranges for marine engines are shown in Figure
1 and 2 .
1) 15 % not applicable for L/V 20/27 and 25/30, for which 20 % is the lower limit for continuous part-load operation.
- Engines that are being used as the main source of propulsion for fixed-
pitch or variable-pitch propellers are blocked at 100 % output. For a
short period of time, fixed-pitch propeller plants may be operated with a
maximum of 10 % reduction in speed, variable-pitch propellers with a
maximum of 5 % reduction in speed.
- Engines being used as the diesel-electric source of propulsion for fixed-
pitch or variable-pitch propellers are blocked at 110 % output. However,
outputs 100 % may only be applied temporarily for acceleration pur-
poses.
- Engines being used for dredging operation are blocked at between 100
and 90 % output depending on engine size and may be operated with a
maximum of 30 % reduction in speed.
- Engines used as source of propulsion in fishing boots or tugs are
blocked at 100 % output and may be operated with a 20 % reduction in
speed.2)
The above information is for guidance purposes only. The procedures to
be used under operational conditions will be agreed between the pur-
chaser, shipyard/planning office and engine manufacturer.
Preconditions
Supplementary information
Adjustment required Surface irregularities on the piston rings and the cylinder liner running sur-
face are smoothed out during the running-in process. The process is
ended when the first piston ring forms a perfect seal towards the combus-
tion chamber, i.e. the first piston ring exhibits an even running surface
around its entire circumference. If the engine is subjected to a higher load
before this occurs, the hot exhaust gases will escape between the piston
rings and the cylinder liner running surface. The film of oil will be destroyed
at these locations. The consequence will be material destruction (e.g.
scald marks) on the running surface of the rings and the cylinder liner and
increased wear and high oil consumption during subsequent operation.
Operating media
Fuel Diesel oil or heavy fuel oil can be used for the running-in process. The fuel
used must satisfy the quality requirements (Section 3.3) and be appropri-
ate for the fuel system layout.
The gas that is to be later used under operational conditions is best used
when running-in spark-ignited gas engines. Dual-fuel engines are run in in
diesel mode using the fuel that will later be used as pilot oil.
Lubricating oil The lubricating oil to be used while running-in the engine must satisfy the
quality requirements (Section 3.3) relating to the relevant fuel quality.
Cylinder lubrication During the entire running-in process, the cylinder lubrication is to be
switched to the “Running-in” mode. This is done at the control cabinet
and/or the operator’s panel (under “Manual Operation”) and causes the
cylinder lubrication to be activated over the entire load range already when
the engine is started. The increased oil supply has a favourable effect on
the running-in of the piston rings and pistons. After completion of the run-
ning-in process, the cylinder lubrication is to be switched back to “Normal
Mode”.
At 85% load and on reaching operational output levels, the operating data
(firing pressures, exhaust gas temperatures, charge air pressure, etc.) are
to be checked and compared with the acceptance record.
Standard running-in programme Running-in can be carried out with a fixed-pitch, controllable-pitch, or zero-
thrust-pitch propeller. During the entire running-in period, the engine out-
put is to remain within the output range that has been marked in Figure 1
and 2 respectively, i.e. below the theoretical propeller curve. Critical
speed ranges are to be avoided.
Running-in during commissioning Four-stroke engines are, with a few exceptions, always subjected to a test
at site run in the manufacturer’s works, so that the engine has been run in, as a
rule. Nevertheless, repeated running is required after assembly at the final
place of installation if pistons or bearings were removed for inspection
after the test run or if the engine was partly or completely disassembled for
transportation.
Running-in after installation of In case cylinder liners, pistons and/or piston rings are replaced on the oc-
new running gear components casion of overhaul work, the engine has to be run in again. Running-in is
also required if the rings have been replaced on one piston only. Run-
ning-in is to be carried out according to Figures 1 and 2 and/or the
pertinent explanations.
The cylinder liner requires rehoning according to work card 050.05 unless
it is replaced. A portable honing device can be obtained from one of our
service bases.
Running-in after refitting used If used bearing shells were refitted or new bearing shells installed, the
or installing new bearing respective bearings have to be run in. The running-in period should be
shells (main bearing, big-end three to five hours, applying load in stages. The remarks in the previous
and piston pin bearing) paragraphs, especially under “Checks”, as well as Figure 1 and 2
respectively are to be observed.
Idling at high speed over an extended period is to be avoided, wherever
possible.
Running-in after low-load ope- Continuous operation in the low-load range may result in heavy internal
ration contamination of the engine. Combustion residues from the fuel and lubri-
cating oil may deposit on the top-land ring of the piston, in the ring grooves
and possibly also in the inlet ducts. Besides, the charge-air and exhaust
As also the piston rings will have adapted themselves to the cylinder liner
according to the loads they have been subjected to, accelerating the en-
gine too quickly will result in increased wear and possibly cause other
types of engine damage (piston ring blow-by, piston seizure).
A Controllable-pitch propeller
(engine speed)
B Fixed-pitch propeller
(engine speed)
C Engine output
(specified range)
D Running-in period in [h]
E Engine speed and output
in [%]
Figure 1. Standard running-in programme for marine propulsion engines (variable
speed) of the 32/40 + 32/44 CR engine type
A Controllable-pitch propeller
(engine speed)
B Fixed-pitch propeller
(engine speed)
C Engine output
(specified range)
D Running-in period in [h]
E Engine speed and output
in [%]
Figure 2. Standard running-in programme for marine propulsion engines (variable
speed) of the 40/54, 48/60, 58/64 engine types
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
It is the operator’s duty to carry out the checks listed below, at least during
the warranty period. However, they should be continued after the warranty
term expires. The expense in time and costs is low compared to that in-
curred for remedying faults or damage that was not recognised in time.
Results, observations and actions taken in connection with such checks
are to be entered in an engine log book. Reference values should be de-
fined to make an objective assessment of findings possible.
Regular checks The regular checks should include the following measures:
(every hour/daily)
- Assess the operating status of the propulsion system, check for alarms
and shut-downs,
- visual and audible assessment of the systems,
- checking performance and consumption data,
- checking the contents of all tanks containing operating media,
- checking the most essential engine operating data and ambient condi-
tions,
- checking the engine, turbocharger, generator/propeller for smooth run-
ning.
Periodic checks In addition to the regular checks, further checks should be made at some-
(daily/every week) what longer intervals for the following purposes:
- Determine the operating hours logged, and verify the balancing of oper-
ating times in case of multi-engine systems,
- evaluate the number of starting events,
- check the printers or recording instruments,
- check all the relevant engine operating data,
- evaluate the stability of the governor and control linkage,
- check the engine systems for unusual vibrations and extraordinary
noise,
- check all the systems, units and main components for proper perform-
ance,
- check the condition of operating media.
The following routine jobs are to be carried out at appropriate intervals with
due regard to their importance:
Fuel oil system - Check the service tanks (diesel fuel and heavy fuel oil) and top up in
time. Prior to changeover to another tank, drain the water from the
latter.
- Never run the service tank completely dry. This would permit air to
enter the piping so that the injection system would have to be vented.
- Regularly drain or exhaust water and sludge from the service tanks.
Otherwise sediments could rise up to the outlet connection level.
- Clean the filters and separators at regular intervals.
- Ensure cleanliness during fuel pumping. Perform a spot test of the fuel
on every bunkering (see work card 000.05) and keep these together
with the engine operating data logs. The fuel has to meet the quality
specifications.
Engines operated on heavy fuel oil:
- Heat the heavy oil to a temperature at which the prescribed viscosity
will be attained at the entry into the injection pumps. Refer to Figure 1.
Supplementary information is given in the viscosity/temperature dia-
gram, Section 3.3.4
- Do not mix heavy oils of different viscosities, and do not blend heavy oil
with distillate as instability may occur and cause engine operating
trouble.
- Submit the heavy fuel oil to one-stage or two-stage separation, de-
pending on the system layout.
Lube oil system - Check the lube oil level in the service tank and top up if necessary.
- Check the lube oil temperatures upstream and downstream of the
cooler.
- Monitor the lube oil pressure at the control console and, if necessary,
adjust to the specified service pressure. If the oil pressure rises above
normal when starting the cold engine, this is of no significance as the
oil pressure will drop to the specified service pressure as the oil heats
up.
▲ Attention! The engine must be shut down immediately if the oil
pressure drops!
Supplementary jobs/notes
Operating values - Although the cylinders develop the same output, the exhaust gas tem-
peratures may vary slightly. It is not admissible to adjust the cylinders
to the same exhaust gas temperatures.
- The cylinders should be loaded as evenly as possible. This can be veri-
fied by comparison of the ignition pressures and the control linkage
position of the injection pumps.
- The exhaust gas temperatures have to be checked and compared with
the previously measured temperatures (acceptance certificate).
If larger differences should be found, the cause is to be traced and the
fault eliminated.
- The exhaust discoloration is to be checked. Oil in the combustion
chamber will give the exhaust gases a bluish colour, poor combustion
or overloading will give the exhaust gases a darker resp. black colour.
Since the opinions on what should be contained in the engine log book
differ widely, we have abstained from making proposals. However, we
would gladly assist you if desired, especially in fixing the reference values.
The information sources of reference should be the test run and
commissioning records as well as the “List of measuring and control units”.
Visual and audible checks of the engine plant, entries in the engine log
book and evaluations on the basis of the operating time serve for the
conventional way of determining the present and/or future condition.
Information at a higher level can be obtained by using a portable ignition
pressure and injection pressure measuring unit, e.g. the Baewert HLV-94.
Using this device, the pressure (if required, of several engines) at the
indicator connection is recorded and indicated on an LC display in form of
a diagram over the crank angle or in form of a table. The appertaining
mean indicated pressures are also calculated. Via a connection cable, the
measuring results can also be printed or made accessible to computer
evaluation via a COM1 or COM2 interface. In a similar way, the injection
pressure is recorded and delivered. For this purpose, however, DMS
sensors are required which are to be attached to the injection pipes.
Trend The trend analysis graphically represents the registered and memorised
changes in condition. It is a very helpful method for early diagnosis of
irregularities in an engine’s operating condition.
Figure 4. CoCoS-EDS trend - operating values are displayed over a certain period
of time
Diagnosis Every five minutes, the so-called tentative diagnosis is made, enabling
recognition and display of deviations of an operating value from its normal
value, independent from the present load point and from external
influences.
The three modules provide the user with the necessary information on the
actual condition of the engine, and all the experience gained by the MAN
B&W engine developers and service engineers.
It is not permitted to apply load to and withdraw load from Diesel engines
as quickly as desired. Instead, allowance is to be made for
- thermal and mechanical loads,
- exhaust gas colouration, and
- the turbocharger capacity.
The shortest possible load application and load reduction for marine
propulsion engines is shown in Figure 1.
Acceleration In the AHEAD direction, 60% of the engine output are permitted to be
applied only after 15 seconds have elapsed under emergency
manoeuvring conditions or 30 seconds resp. under normal manoeuvring
conditions. 100% engine output is not allowed to be reached earlier than
after 30 seconds or 3 minutes resp. Diagram, part 3.
Load reduction At least 15 seconds must elapse during load reduction from FULL AHEAD
to STOP, at least 10 seconds during load reduction from FULL ASTERN to
STOP. Diagram, part 1/4. In case of faster load reduction, the
turbocharger may start surging
Besides, please note ... Marine main engines in preheated condition should be operated at a
speed not exceeding approx 75% or a load not exceeding approx. 40%, if
possible. Operation at full load is admissible after the service temperatures
have been reached.
In fixing the load application and load reduction times it should be noted
that the time constants for the dynamic behaviour of the engine relative to
the prime mover and/or the vessel may be wide apart. Ratios of 1:100 are
encountered in the case of marine propulsion engines. This means that
the engine responds much faster than the ship does. Faster load
application and load reduction rates will therefore have but a minor effect
on the ship’s behaviour during manoeuvring (except, e.g. tug boats and
ferries).
Better conditions Engines are genuinely better equipped for low-load operation
- if they have a two-stage charge-air cooler, the second stage of which
can be switched off in order to improve the operating data or
- if they have a two-stage charge-air cooler and switch-over from HT to
LT has been provided for, permitting the admission of HT water to the
LT stage.
Operation on heavy fuel oil Because of the aforementioned reasons, low-load operation < 20 % of full
load output on heavy fuel oil is subjected to certain limitations. According
to Figure 1 , the engine must, after a phase of part-load operation, either
be switched over to Diesel oil operation or be operated at high load (>70 %
of full load output) for a certain period of time in order to reduce the de-
posits in the cylinder and exhaust gas turbocharger again.
In case the engine is to be operated at low-load for a period exceeding
that shown in Figure 1 , the engine is to be switched over to Diesel oil
operation beforehand.
For continuous heavy-fuel oil operation at part loads in the range below
25 % of the full engine output, co-ordination with MAN B&W Diesel AG is
absolutely necessary.
Operation on Diesel fuel oil For low-load operation on Diesel fuel oil, the following rules apply:
- A continuous operation below 15 % of the full load output is to be
avoided, if possible.
Should this be absolutely necessary, MAN B&W Diesel AG has to be
consulted for special arrangements (e.g. the use of part-load injection
nozzles).
- A no-load operation, especially at nominal speed (generator operation)
is only permitted for a maximum period of 1 ... 2 hours.
No limitations are required for loads above 15 % of full load, as long as the
spezified operating data of the engine will not be exceeded.
Figure 1. Time limits for part-load operation on heavy fuel oil (on the left), duration of “Relieving operation” (on the right)
Explanations Figure on the left: Time limits for part-load operation on heavy fuel oil.
Right-hand figure: Necessary operating time at > 70 % of full-load output
after part-load operation on heavy fuel oil. Acceleration time from present
output to 70 % of full-load output not less than 15 minutes.
Preliminary remarks
How to proceed
In the case of marine The effective engine output Pe cannot be easily measured on marine pro-
propulsion engines pulsion engines. For this purpose, it would be necessary to measure the
torque. In the case of medium-speed four-stroke Diesel engines, the indi-
cated output Pi cannot be determined from indicator diagrams either.
In the case of Diesel generator The effective engine output for generator sets can be determined relatively
sets precisely from the effective generator output Pw, which is measured con-
tinually, and from the generator efficiency ®gen, which varies but slightly
within the usual operating range. This method, however, does not permit
any judgement to be made of changes that may occur on the engine or
generator. As an alternative or additional method, design points can be
determined as outlined above, and the results obtained can be compared.
Preparatory work
The mean value of pump admission settings plotted over the output is re-
corded during the engine works trials and included in the acceptance cer-
tificate in the form of a curve, both for marine and stationary engines. In
the case of marine engines, this data is also entered on an additional
sheet together with three propeller curves. The diagram corresponds to
Figure 1 . For determining the design point and the engine output, the
diagram of the acceptance certificate relating to the respective plant is,
therefore, to be used.
Important! Diesel fuel oil (MDO) or gas oil (MGO) is used for the
engine trials as a rule. In heavy fuel oil (HFO) operation, pump admission
settings are approximately the same.
Example (marine propulsion Determining the design point and the engine output are to be carried out
engine) analogously using the example shown in Figure 1 , where:
Evaluation of results
The design point that has been determined has to be within the admissible
service range. For marine propulsion engines, at least with a new vessel
and new engine, therefore, it has to be to the right of the theoretical pro-
peller curve.
The shifting of design points towards the left, with the other basic condi-
tions being the same, is attributable to the increased resistance of the
ship’s hull, propeller modifications (larger diameter, increased pitch) or pro-
peller defects.
Since there are numerous potential influencing factors, whose effects can-
not be easily determined, we recommend that in case of doubt you contact
the nearest service center or the service head office of MAN B&W Diesel
AG, Augsburg.
Under these conditions, the engine will still reach the full torque but no
longer the full speed -- at least not with the admissible rated output.
Operation of the engine under these conditions of reduced speed/
fuel-limited speed is limited as follows:
Overview
Table 1 lists the equipment for adapting the engine to special operating
conditions/for optimising the operating performance. It also lists the
preferred fields of application. This table is intended to provide you with a
summary of the existing possibilities and their object.
Brief descriptions
Charge air blow-off device When engines are operated at full load at low intake temperature, the high
air density involves the danger of excessive charge air pressure leading to
an inadmissibly high ignition pressure. In order to avoid such conditions,
the excessive charge air is withdrawn upstream or downstream of the
charge air cooler and blown off into the engine room. This is achieved by
means of an electro-pneumatically controlled or spring-loaded throttle flap.
See Section 2.4.1 and 3.5.12.
Charge air bypass device The charge air pipe is connected to the exhaust pipe via a reduced
diameter pipe and a bypass flap. The flap is closed in normal operation.
During propeller operation between 25 and 60% load, the volume of air
which is available for the engine is relatively small and the charge air
pressure is relatively low. To increase the air volume that is available for
the engine under these conditions, charge air is blown into the exhaust
pipe. For this purpose, the bypass flap is opened. The resultant pressure
Device for raising the High air temperatures during part-load operation contribute to improved
charge air temperature combustion and, consequently, reduced exhaust gas discoloration. This
(two-stage charge air cooler) condition can be achieved if a two-stage charge air cooler is used and the
charge air is heated by means of the low-temperature (LT) stage during
part-load operation (20 to 60% load).
Control of the charge air The charge air temperature control CHATCO reduces the amount of
temperature (CHATCO) condensed water that accumulates during engine operation under tropical
conditions. In this connection, the charge air temperature is kept constant
up to a certain intake temperature. If this value is exceeded, the charge air
temperature is constantly raised. Please refer to Section 2.4.7.
Device for accelerating the This equipment is used where special demands exist regarding fast
turbocharger (jet assist) acceleration and/or load application. In such cases, compressed air is
drawn from the starting air vessels and reduced to a pressure of max.
4 bar (relative) before being passed into the compressor casing of the
turbocharger to be admitted to the compressor wheel via inclined bored
passages. In this way, additional air is supplied to the compressor which in
turn is accelerated, thereby increasing the charge air pressure. Operation
of the accelerating system is initiated by a control, and limited to a fixed
load range. Please refer to the figure in Section 2.4.1.
Device for blowing off the By blowing off exhaust gas upstream of the turbine and returning it to the
exhaust gas (waste gate) exhaust pipe downstream of the turbine, an exhaust gas pressure
reduction on the turbocharger and/or a drop in turbine speed at full load is
effected. This measure is necessary if the turbocharger has been
designed for optimised part load operation. See section 3.5.11.
Device for adjusting the injection Adjustment on the 32/40 engine is achieved by means of a camshaft that
timing permits adjustment relative to the direction of rotation using a turning,
axially moving and helically toothed bushing which is in mesh with the
toothing provided on the camshaft. A shifting of the bush causes the
camshaft to be turned, whereby the injection timing is changed. For
details, please refer to Section 2.4.5.
Technical layout
This equipment for the bypassing of charge air essentially consists of the
connection between the charge air pipe (1) and the exhaust pipe (8), the
throttle flap (4) and the associated electropneumatic control.
The rate of air flow through the interconnecting pipe can be limited by a
diaphragm (2). The throttle flap is pneumatically operated. The end
positions of the power cylinders can be fixed by adjusting screws (5). The
compensator (7) serves to absorb deformations/displacements in the
interconnecting pipe.
Functional description
The supply of air to the pneumatic drive is controlled by the 4/2-way valve
(6) and its solenoid valve. The passage 1 - 2 to open the flap is cleared
when the solenoid valve is energised. The valve is switched over to
passage 1 - 3 for closing the flap when the valve is de-energised. The
switching condition of the solenoid valve (energised) is determined by the
following conditions:
- engine speed > 60 ... < 85%*,
- pump rack setting > 25 ... < 65%*,
- engine is not started/engine is not connected (stable load condition).
* The upper limit depends on the engine size and number of cylinders (up to 95 or 75% respectively)
Figure 2. Output/speed range for the bypassing of charge air (example, valid for
fixed-pitch propeller drive)
The bypassing of charge air into the exhaust pipe causes the charge air
pressure and specific air/exhaust gas volume to be increased, and the
exhaust gas temperature upstream and downstream of the turbine to be
reduced.
Setting
The settings of all elements are fixed during the engine test run and/or
during sea trials/commissioning. They must not be changed during the
warranty period without the approval of MAN B&W Diesel AG.
If necessary, the 4/2-way valve can be switched over by hand using the
lever (9) on the underside of the valve. The throttle flap can be turned
through the slot provided in the shaft end (10). See Figure 3.
9 Lever for
4/2-way valve
10 Slotted shaft end
Figure 3. Actuation of the 4/2-way valve and the throttle flap in case of emergency
Background
Air contains finely dispersed water in the form of steam. Some of this
water condenses out as the air is compressed and cooled by the turbo-
charger and charge air cooler, and this also happens with the compressed
air in air vessels. Condensation increases as
- the air temperature rises,
- the air humidity rises,
- the charge air pressure rises, and
- the charge air temperature drops.
Up to 1000 kg of water per hour can accumulate under certain conditions,
and on large engines, in the charge air pipe downstream of the charge air
cooler. This is due to the large volume of air and the relatively high charge
air pressures. Under tropical temperatures, this effect is intensified.
Example 1 -- Determine the amount of water accumulating in the charge air pipe
3rd step The difference between I and II is the condensed water amount A.
A
I II
0.033 0.021
0.012 kg of water/kg of air.
Q A
A ô P ô le
0.012 ô 12, 400 ô 7.1
1.055 kg water/h
1 t water/h.
3rd step The difference between I and III is the condensed water amount B.
B
I III
0.033 0.0015
0.0315 kg of water/kg of air.
4th step Multiplied by the air volume m in the vessel, the amount of water, QB, is
obtained which accumulates as the pressure vessel is filled.
Q B
B ô m.
m is calculated as follows:
pôV
m
.
RôT
Legend
Absolute pressure in the vessel, pabs 31 ô 10 5 Nm2,
volume V of the pressure vessel 4000 dm3 = 4 m3,
gas constant R for air 287 Nm/kgôK,
temperature T of the air in the vessel 40 C = 313 K.
m
31 ô 10 ô 4
5
138 kg of air.
287 ô 313
Final result
Q B
B ô m
0.0315 ô 138 kg
4.35 kg of water.
* The specific air flow rate depends on the engine type and engine loading. To obtain a rough estimate of the condensed water volume, the
following approximate values can be used:
Isolated operation
Application of load dependent Large applications of load, such as occur in a ship’s auxiliary engine in the
on medium pressure ship network or in stationary engines in isolated operation, cannot be dealt
with in one step. According to the International Association of
Classification Societies (IACS) and the internationally valid standard ISO
8528-5, applications of load must be carried out in stages. See Figure 1.
The number of stages and their level depend on the effective medium
pressure of the engine.
1 1. Stage
2 2. Stage
3 3. Stage
Pe Application of load as a
% of continuous power
pe medium effective
pressure in continuous
power
For the 32/40, 40/54, 48/60 and 58/64 engines with medium pressures
between 21.9 ... 24.9 bar, the following load stages apply:
1. Stage 33%,
2. Stage 23%,
3. Stage 18%,
4. Stage 26%.
Larger load stages can possibly be achieved using special layouts. These
will require the written agreement of MAN Diesel SE.
Application of load dependent The diagram in Figure 2 applies for applications of load based on the
on the actual power current value.
------ Standard
--- Engine with Jet-Assist
Load shedding Even at load shedding of up to 100% of the nominal power, the following
can be guaranteed:
Details of the connecting of load and load shedding must be agreed with
MAN Diesel SE in the planning stage. They require approval.
In parallel mode with engines using other high power current generators,
basic jumps in load do not occur. The course of engine loading is not
determined here through external influences but through its own
measurements. The loading/unloading of the engine are controlled by the
regulations in section 3.5.3.
Technical layout
The device for blowing off the exhaust gas essentially consists of the con-
nection between the exhaust pipe upstream of the turbocharger (11) and
the exhaust pipe downstream of the turbocharger (9), the blow-off flap (1)
and its electro-pneumatic control.
Figure 2. Arrangement of the exhaust gas blow-off pipe (figure shows the V 48/60
engine type - the design of the pipe fitted may differ from that shown in the figure)
Figure 3. Arrangement of the exhaust gas blow-off pipe (figure shows the V 48/60
engine type - the design of the pipe fitted may differ from that shown in the figure)
The air supply to the pneumatic drive of the flap is controlled by the
5/2-way solenoid valve (M367). The way 1 - 4 for opening the flap is clear
when the solenoid valve is excited. In de-excited condition, the way 1 - 2
for closing the flap is clear.
The turbocharger speed serves as a criterion for the activation of the blow-
off flap. In case the speed transmitter fails, the activation is effected as a
function of the fuel admission. If the turbocharger speed or the fuel admis-
sion are in the critical range, the active flap position is maintained in order
to prevent constant switching-over (hysteresis) of the blow-off flap. In
case the actual value in turn exceeds and/or falls below the limit value, the
flap control causes switching over of the blow-off flap.
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
Preliminary remarks
Trouble shooting with the aid of Tables 1-3 contain a number of potential operating faults and their possible
Tables 1-3 causes. They are intended to contribute to reliable fault diagnosis and effi-
cient elimination of their causes.
Example The code number 15, for example, appears at three different points in the
tables (marked by -). The meaning behind it: Supposed the injection tim-
ing is too far in the “late” direction, the following possible effects must be
expected:
- The engine does not reach the full output/speed,
- the exhaust gas temperatures are excessive, and
- the exhaust plume is visible, of dark colour.
Trouble shooting on the To be noted: The operating instruction manual for the turbocharger con-
turbocharger tains its own table for trouble shooting.
Order of entries The order of entries does not permit to draw conclusions on the probability
of causes. The order rather follows the principle: Causes related to en-
gine operating media and operating media systems in the first place, fol-
lowed by engine, turbocharger, and possibly ship.
Crankshaft does not turn on start, turns too slowly, or swings back
Compressed air system Pressure in the compressed air tank too low 01
Main starting valve defective 162.xx 02
Starting valve defective 161.xx 03
Starting air pilot valve defective 160.xx 05
Control and monitoring Fault in the pneumatic or electronic control system 63
system
Remote starting interlocked 83
Turning gear Turning gear not completely disengaged 79
Noise coming from the valve or injection pump drive (noise depending on speed)
Injection pump/IP drive Injection pump plunger sticking, spring broken 200.xx 17
Drive roller defective, or spring broken 200.xx (32/40, 46
40/45), 201.xx
(40/54 ... 58/64)
Inlet and exhaust valves Inlet or exhaust valves sticking, valve spring broken, 113.xx, 114.xx 26
valve not tight
Smoke issuing from crankcase/crankcase venting, hollow-sounding noise coming from the crankcase
Lubricating oil Oil contains too much water 3.3, 000.05 81
Engine Crankcase venting blocked 93
Piston/piston rings Piston rings stuck or broken 034.xx 32
Running gear/crankshaft Piston or bearing runs hot or starts seizing 2.4, 3.5 31
Emergency operation with one Even if the engine is operated with adequate care, serious faults occuring
or two cylinders failing
- on the injection system or injection pump drive,
- on the inlet or exhaust valves or the gear of these,
- on the cylinder head, or
- on the connecting rod, piston or cylinder liner
cannot be completely ecxluded. If such a fault occurs, the engine has to
be stopped and the damage has to be remedied. If this is not possible, the
possibilities of emergency operation are to be checked and the necessary
provisions are to be made, if any. The engine can then be further operated
under certain conditions, and at reduced output in most cases. If for some
important reason the engine cannot be stopped, it should at least be at-
tempted to take all appropriate measures for avoiding consequential dam-
age.
Table 1 lists such emergency cases, the relevant conditions and counter
measures. The texts following after the table describe the exemplary
cases of emergency in more details and give supplementary hints.
Case 1 Operating faults which necessitate the switching off of the injection pump
(fuel admission = zero) but permit operation of the cylinder/piston involved
against the normal compression resistance (the compression), such as
- fault in the injection system due to a defective nozzle,
- fault on the cylinder head due to a defective valve, due to gas leaking
at the cylinder head, due to a broken cylinder head bolt.
Case 2 Operating faults which necessitate the removing of rocker arms and push
rods and the switching off of the injection pump (fuel admission = zero) but
permit operation of the respective cylinder/piston to be continued against
compression (valves closed), such as
- fault in the valve timing gear,
- fault on the cylinder head due to gas leaking on the sealing rings, due
to max. two broken cylinder head bolts.
Important! Cases 1 and 2 are less problematic from the vibrations
point of view than case 3 is, because the running gear components remain
in place.
Case 3 Operating faults making the removal of a complete running gear (piston,
connecting rod, push rods) necessary.
Case 4 Operating faults making the removing of two complete running gears (pis-
ton, connecting rod, push rods) necessary.
1 Switch off the injection pump as described in work card 200.02 (L40/54
and L48/60 engine types) or work card 200.01 (L58/64 engine type).
2 - Remove the rocker arm as described in work card 111.01.
- Remove both push rods as described in work card 112.01, swing up the
cam follower and secure it in this position using a wire rope and clamp-
ing screw from the basic tools stock3). Plug the lube oil bores.
- Plug the oil pipe for rocker arm lubrication.
3 - Remove the piston and connecting rod.
- Plug the lube oil bores in the crank pin as described in work
card 020.04.
- Plug the starting air pipe leading to the silenced cylinder.
4 For adequate balancing of the rotating mass moments, remove a balance
weight at the throw of the defective cylinder as described in
work card 020.01 (only L58/64 engine type).
5 For adequate balancing of the rotating mass moments, remove two bal-
ance weights at the throw of the defective cylinder as described in
work card 020.01 (L40/54 and L48/60 engine types).
6 Reduce the engine output (and speed) in accordance with the instruction
plate attached to the control console. Theoretically available output and/or
speed in accordance with the conditions which are explained below.
7 Observe the operating data. The exhaust gas temperatures and turbo-
charger speeds must not exceed the admissible limits.
9 Due to one piston being removed, problems in engine starting may occur
at certain crankshaft positions.
11 Mass balancing upset. Critical vibrations may occur on the engine or in the
ship’s hull (natural hull frequencies) also outside the speed ranges which
have been barred as a result of the torsional vibration calculation. Such
ranges should be avoided/passed quickly. The engine output is to be re-
duced to 50%.
With
PN Rated output nN Rated speed Z Number of
cylinders
Z 5 6 7 8 9 10 12 14 16 18
¯Z--1
Z
0.89 0.91 0.93 0.94 0.94 0.95 0.96 0.96 0.97 0.97
Table 2. Factors to determine the speed reduction required when a cylinder fails
Barred ranges/ Switching off the injection pump on one cylinder may result in critical
Torsional vibrations speeds requiring further restrictions of the operating speed range. The
barred ranges to be observed under these abnormal operating conditions
are given on the instruction plates.
Should it become necessary to suppress the ignition of more than one cyl-
inder, make sure to consult MAN B&W Diesel AG, Werk Augsburg.
Preliminary remarks
General Turbochargers are turbo machines subjected to high stresses. They oper-
ate at very high speeds and relatively high temperatures and pressures.
In spite of careful system operation, disturbances may occur, which re-
quire emergency operation.
Failure of one turbocharger The following criteria may be an indication of turbocharger damage/failure:
- Sudden drop in turbocharger speed
- Severe vibrations or noise caused by the turbocharger
- High exhaust gas temperatures, which are unusual for the engine’s
load conditions
▲▲ Caution! In these cases, an immediate examination/elimination
of the disturbance is required!
Engine must not be stopped for ▲▲▲ Danger! Attention is drawn to the fact that, in spite of taking
imperative reasons the below-mentioned measures, there is a risk of turbocharger de-
struction! In this case, there is imminent danger of persons being
injured and property being damaged! Such emergency operation of
the engine is only permissible for the period required for warding off
the emergency situation!
Measures to be taken:
- Reduce the output of the engine so that
-- the maximum exhaust gas temperature after cylinder
Measures to be taken:
- Stop the engine
- Carry out the necessary work on the turbocharger
-- Remove the turbine rotor (see working instructions in Volume C2)
(recommended by the turbocharger manufacturer)
or
-- block the turbine rotor (see working instructions in Volume C2)
(only if the turbine rotor cannot be removed for reasons of time)
- Adjust the engine (see working instructions in Volume B2)
- After restarting the engine, limit the maximum output so as to ensure
that
-- the maximum exhaust gas temperature after cylinder is not
exceeded,
-- the maximum exhaust gas temperature before turbocharger
is not exceeded,
-- an increased exhaust gas discoloration is minimised.
- DANGER! Do not stay in the vicinity of the turbocharger!
- Take the necessary precautions for possibly required fire-extinguishing
measures!
- At the next opportunity, initiate checking the damage and fault elimin-
ation!
The following criteria limit the engine load achievable in emergency oper-
ation:
-- maximum exhaust gas temperature after cylinder,
-- maximum exhaust gas temperature before turbocharger,
-- exhaust gas discoloration.
The above outputs are reference values only. If necessary, the output has
to be reduced further.
The term “black out” designates the sudden failure of the electrical mains
supply. As a result, the cooling water, lube oil and fuel oil supply pumps
will fail, too, unless they are driven by the engine proper. However, other
vital supply equipment and measuring, control and regulating units are
affected, too.
If black out occurs at high engine output, the cooling water which now is
no longer circulating is heated by engine components that are subject to
high thermal loading, and steam bubbles may form locally. Therefore, be
careful with venting and discharge pipes!
This applies to all cases, where the pumps cannot start operation again
within a few seconds, which is possible if a spare unit automatically takes
over the electric power supply. This emergency stop process can, in the
case of marine main engines, be cancelled for a limited period of time, at
the worst, according to the requirement “ship takes precedence over
engine”. On engines with disengaging coupling, the engines are to be
disconnected. On ships equipped with a controllable--pitch propeller, the
pitch is to be set to zero immediately in order to prevent propeller reverse
power. These processes must automatically be triggered in case of
decreasing lube oil pressure.
Emergency lubrication equip- The oil supply of engines equipped with a directly connected,
ment engine-driven lube oil pump (and an electrically driven stand-by pump) is
maintained by this pump on black out.
Marine engines, which are equipped with two electrically driven lube oil
pumps, involving the potential risk that the engine is operated on reverse
power while the ship is gradually run down, are to be equipped with an
emergency lubrication oil tank. From this elevated tank, the oil supply is to
be ensured (temporarily) during this phase.
Stationary engines equipped with two electrically driven pumps are set to
“Zero” admission on black out. Emergency lubrication of the engine during
the relatively short (1 ... 3 minutes) coasting without load is dispensed with
as a rule.
The turbocharger(s) is/are supplied with oil for some time during the
run-down period from an attached oil tank on rigidly mounted engines, or
from a separate oil tank is case of resiliently mounted engines, irrespective
of the lube oil system layout.
Automatically operated systems After the normal supply of electrical power has been restored, the pumps
and ventilators have to be started automatically and in the order as stated:
1. Lube oil pump and fuel oil supply pump,
2. cooling water pump,
3. engine room ventilation system,
4. sea water pump.
▲ Attention! Under no circumstances must the engine be allowed
to start up automatically after black out.
Manually operated engine plants Manually operated engines have to be immediately stopped after black out
so as to avoid severe damage as a result of lubrication failure or thermal
overloading. After the electrical power supply has been restored, proceed
as in the case of automatic operation. It is essential in this case, too, that
the engine is restarted and load is applied gradually.
Putting into operation of the Depending on the load at which the engine was being operated prior to the
engine after black out sudden shut-down, the cooling water which then is no longer circulating is
heated to high temperatures by the hot engine components, possibly
leading to the accumulation of steam in the cooling spaces of the cylinder
head.
Emergency operation with Supply of lube oil to the piston running surfaces, piston rings and cylinder
cylinder lubrication failing liners is ensured by splash oil in the crankcase and by the additional
cylinder lubrication. If the cylinder lubrication system should fail in part or
completely, engine operation can be continued for a short period
(app. 250 h).
1 Indication
3 Push-button
4 Operating lever
Steps - Switch the operating lever (4) to “Emergency operation with mech.
governor” (refer to Figure 1 ).
- Turn the admission limitation knob (2) on the governor to position 4 ... 5
(refer to Figure 2 ).
- Adjust the desired speed value to minimum by means of the turning
knob (5) (to the stop, counterclockwise).
- Check whether all systems are working (oil, cooling water, lube oil) and
whether the indication (1) is glowing/not glowing.
- Depress the push-button “Starting” (3) until the engine ignites.
- Set the admission limitation to the desired value (normally “Full”) by
means of the admission limitation knob (2).
- Adjust the desired speed value on the turning knob (5).
In case of twin-engine plants which drive a shaft, only one engine is run in
manual operation.
▲ Attention! Observe the remarks in Sections 3.4 to 3.7, Engine
operation!
Reverse Acting n case of a dropping signal, admission is set to “Full”. The speed
increases. After a certain speed is reached, the mechanic-hydraulic speed
governor takes charge of the speed control.
General remarks
Operating values/limit values Operating values, e.g. temperatures, pressures, flow resistances and all
other safety--relevant values/characteristics, must be kept within the range
of nominal values. Limit values must not be exceeded. Binding reference
values are contained in the test run and commissioning records (in
Volume B5) and in the “List of measuring and control devices” (in
Volume D).
Alarms, reduction and stop Depending on the extent to which values are exceeded and on the
signals potential risks, alarms, reduction or stop signals are released for the more
important operating values. This is effected by means of the alarm system
and the safety controls. Reduction signals cause a reduction of the engine
output on vessel plants. This is effected by reducing the pitch of
controllable--pitch propeller plants. Stop signals cause an engine stop.
Behaviour in emergency cases -- Acoustic or visual warnings can be acknowledged. The displays remain
technical possibilities active until the malfunction is eliminated. Reduction or stop signals can in
the case of vessel plants be suppressed by means of the override function
of the valuation “ship takes precedence over engine”. For stationary
plants, this possibility is not provided.
Fixing alarm and limit values For fixing the alarm and the safety--relevant limit values, the requirements
of the classification societies and the own assessment are decisive.
Examples Stop criteria are, e.g., overspeed, too low lube oil pressure and too high
temperatures of the main bearing. In case the oil mist detector reacts, a
stop is usually effected as well. The occurrence of too high cooling water
temperatures causes a reduction in output of vessel plants.
Legal situation
Alarm, reduction and safety signals serve the purpose of warning against
dangers or of avoiding them. Their causes are to be traced with the
necessary care. The sources of malfunctions are to be eliminated
consistently. They must not be ignored or suppressed, except on
instructions from the management or in cases of a more severe danger.
General
Monitoring of the running gear The temperatures of the running gear in the crankcase are transmitted to
temperature the surrounding lubricating oil. Big-end bearing damage, piston seizures
and blow-bys from the combustion chamber cause a change in lube oil
temperature. For the splash-oil monitoring system, part of the splash oil
from each crank pin is collected. The temperature of the splash oil from
each individual crank pin is monitored and compared with that of the other
pins. In case a defined maximum temperature is exceeded or if the
difference between the temperatures of the individual running gears is too
large, an alarm is first triggered and, if necessary, the engine is then shut
off automatically.
Risk of personal injuries and da- ▲▲▲ Danger! Bearing damage, piston seizures and blow-bys pro-
mage to property! mote the formation of oil mist, which includes an acute risk of per-
sonal injuries and damage to property. An explosion may occur in
the crankcase, and engine, crankshaft, as well as running-gear com-
ponents may suffer severe damage.
If the splash-oil monitoring system does not work properly, the engine is
not monitored. In this case, incipient damage cannot be recognised, at
least not in time.
Checking the alarms After an alarm occurred, the splash-oil temperatures are to be observed
further. Should the temperature which caused the alarm to be triggered
not decrease to the normal value again after a short while, the engine is to
be stopped, and the running gear concerned is to be checked. Following
an automatic engine stop, the running gear must be checked.
Checking the running gear After waiting for 10 minutes - which is required because of the possible
explosion hazard on entry of air (see the safety regulations) - all crankcase
covers are to be removed. The further checks include the following:
- measuring all bearing temperatures,
- visual inspection of the running gear components as well as the oil
sump for chips, discolouration and warping of material,
- visual inspection of all piston skirts and cylinder liners.
Pistons from aluminium alloy suffer contact damage already at an early
stage, skirts from grey cast iron are less easily damaged.
If no damage is ascertained, the search for damage is to be extended to
those items of the trouble-shooting list which have not been checked so
far. If necessary, the nearest service base should be contacted.
Important! The engine may only be restarted after it has been es-
tablished that no damage occurred or after the damage causing the alarm
has been eliminated.
3.1 Prerequisites
3.2 Safety regulations
3.3 Operating media
3.4 Engine operation I - Starting the engine
3.5 Engine operation II - Control the operating data
3.6 Engine operation III - Operating faults
3.7 Engine operation IV - Engine shut- down
For longer periods of engine shut down (e.g. when the engine is put in
stock) it must be emptied, cleaned and preserved. The relevant
information is given in work card 000.14 “Corrosion inhibitors/preservation
of Diesel engines”. The necessary preliminaries, preservation proper and
the appropriate preservation agents are described.
1 Introduction
2 Technical details
3 Operation/
Operating media
4 Maintenance/Repair
5 Annex
N 4 Maintenance/Repair
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
Maintenance schedule/ The jobs to be done are shown in the maintenance schedule, which
maintenance intervals/ contains
personnel and time required
- a brief description of the job,
- the intervals of repetition,
- the personnel and time required, and it makes reference to
- the corresponding work cards/instructions.
Preliminary remarks
Maintenance schedules: The maintenance schedule of the engine comprises work to be done on
Systems 4.7.1 components of peripherical systems and components/subassemblies of
Engine 4.7.2 the engine itself (refer to Section 4.7). The maintenance schedule for the
Turbocharger 4.7.3 turbocharger is part of Volume C1 of the Technical Documentation.
Validity of the maintenance The maintenance schedules 4.7.1 and 4.7.2 are valid in combination and
schedule comprise jobs to be done at regular intervals and/or within regular interval
ranges.
Adaption of the maintenance The maintenance schedules have been drawn up for standard operating
schedule conditions. The stipulations contained therein are non committal recom-
mendations and approximative values. In order to gain emprical values, it
is recomended to observe the lower interval ranges first, as approximate
values. After a critical evaluation of the operating results and conditions,
shorter intervals may become necessary provided external operating
conditions (timetable of ships/inspection time of power plants) allow it. In
case of favourable operating results and conditions, an extension of the
intervals is possible.
Preliminary remarks
Standard tools The following comprehensive standard set of tools comes supplied with
the engine:
- basic tools,
- hydraulic tensioning tools, and
- special tools.
This set of tools permits normal maintenance work to be carried out. A list
specifying the extent and designations of these tools is contained in
Volume B6 of the technical documentation. The tools set intended for the
turbocharger(s) is contained in one case, and a table of contents is also
included.
Tools Explanations
Device for removing/fitting the For maintenance work such as checking the main bearing or replacing the
main bearing cap bearing shells, the main bearing cap has only to be lowered; it need not be
Item no. 10310 removed. This is only necessary in special cases. This tool is provided for
this purpose.
Device for removing/fitting the Maintenance jobs such as the checking of spring assemblies can be done
torsional vibration damper without the complete vibration damper having to be disassembled. This is
(on the crankshaft) only necessary in special cases. This tool is provided for this purpose.
Item no. 10305
Pneumatic honing tool for the Cylinder liners require rehoning when piston rings are replaced or when
cylinder liner the roughness of the running surface has become insufficient. This job can
Item no. 10115 be contracted to a service base or done by the user himself using the
honing tool.
Tool for regrinding the sealing Regrinding of the sealing groove in the top land ring or the cylinder head
groove in the top land ring becomes necessary when the sealing ring is no longer able to provide
Item no. 10110 adequate compensation for deformation/material loss.
Suspension device for the If the engine room is high enough, the cylinder head is dismantled
cylinder head, without rocker completely. If the overhead space is inadequate, the rocker arm casing
arm casing has to be dismantled, and the cylinder head has to be lifted off using this
Item no. ... device.
Assembly/turnover stand Included in the standard set of tools. The turnover stand enables cylinder
for the cylinder head heads to be turned into the positions most favourable for carrying out the
necessary work, e.g. on the top and on valves/valve seats.
Electric valve cone grinder Similarly to valve seats, valve cones showing minimum deficiencies can be
Item no. 10102 corrected by hand using grinding paste. Where no satisfactory result can
be achieved by this method, mechanical remachining is necessary.
Tool for grinding the seats on the A grinding ring is supplied to allow manual regrinding of the seats on the
valve cage shroud valve cage shroud. Adhesive grinding discs provide an effective way of
reworking the seats.
Device for checking start The start and end of delivery of fuel pumps are significant operating values
and end of fuel delivery on for the individual cylinders and the reciprocal load distribution. Although
fuel injection pumps changes due to wear or the installation of spare parts are negligible as a
(pneumatically operating) rule, it is advisable to make a check in such cases.
Item no. 10225
Device for pulling the drive Pumps driven by the Diesel engine directly require no regular
gear of directly driven lube maintenance. If it becomes necessary to disassemble a pump, the drive
oil or cooling water pumps gear has to be pulled. This tool is provided for this purpose.
Item no. 10320
Device for removing and For cleaning the air side, charge air coolers may be flooded in the
installing the pipe bundles as-installed condition. The dummy flanges needed for this purpose are
of the charge air cooler included in the standard set of tools. Should this method of cleaning not
Item no. 10325 yield a satisfactory result, the cooler insert is to be removed, using this
device, and to be cleaned by a more appropriate method.
Grinding device for delivery This device is used for regrinding the seat of the injection pipe in case of
pipe sealing problems.
Item no. 10112
Endoscope with or without video For inspecting all types of internal areas and for checking cams and rollers
camera of the valve camshaft of Vee-type engines, the Olympus endoscope may
Item no. 10230/235 be used. It consists of an eyepiece unit, a jacketed photoconductor and
interchangeable lenses. These permit a direct view onto the illuminated
object or a look to the sides.
Digital pressure gauge for Using the SI digital pressure gauge, differential pressure measurements
measuring the pressure and on the charge air cooler and in the crankcase can be carried out safely
differential pressure and comfortably. Special connections are available. The device can also
Item no. 10215 be used at other measuring points.
Information on tools required for engine accessories such as the oil mist
detector and for systems accessories such as filters, separators, fuel and
lube oil treating modules, water softening equipment, etc. can be gathered
from the documents contained in Volumes E1 to E... of the technical
documentation.
Tip! Maintenance and repair work can only be carried out properly if
the necessary spare parts are available.
The information given below is thought to assist you in quickly and reliably
finding the correct information source in case of need.
Spare parts for engines and turbochargers can be identified using the
spare parts catalogues in Volumes B3 and C3 or the technical
documentation. The illustration sheets enclosed are provided with item
numbers permit to identify the ordering number.
Complete tools can be ordered using the tools list in Volume B6 of the
technical documentation, or the index included in the tools case for
turbochargers. The ordering numbers are also given on the respective
work cards in Volumes B2 and C2. In this way, it is also possible to order
components of tools alone.
When ordering tools, the engine type, the engine works number and the
six-digit tool number which simultaneously serves as ordering number
should be indicated as usual. The first three digits of the tool number stand
for the subassembly for which the tool is used. Tools which are suited for
general use have a figure below 010 instead of the subassembly group
number.
Spare parts for measuring, control and regulating systems, and for engine and systems accessories
Components of high value which have become defective or worn and the
reconditioning or repair of which requires special know-how or facilities can
be replaced by the “Reconditioned-for-old” principle. These include
- piston crowns,
- valve cages and valves,
- fuel injection nozzles and injection pumps,
- governors,
- compressed-air starters, and
- completely assembled rotors of turbochargers (cartridges).
Such components are available from stock as a rule. If not, they will be
reconditioned/repaired and returned to your address. If need arises,
please enquire a corresponding offer from MAN Diesel SE or the nearest
Service Center.
Required personnel
Groups of maintenance works In case of the maintenance schedule (systems) the maintenance works
are grouped according to systems/functional groups whereas in the main-
tenance schedule (engine) they are grouped according to subassemblies.
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
014 Ölprobe untersuchen (Tropfenprobe) Examine oil sample (spot test) 000.05 1 0.15 Motor X
Engine
015 Ölprobe analysieren lassen Take oil sample to be analysed 000.04 1 0.25 Motor X
Engine
016 Ölfüllung wechseln (entsprechend Change oil filling (depending on results 000.04 015 -- 0 Motor 1 1 1 1 1 1 1 1 1 1 1
Analyse), Behälter reinigen of analysis), clean the tank Engine
017 Ölablauf kontrollieren (Sichtprüfung) Check oil drainage of piston, big--end A 018 1 0.2 Zyl./ X
bei Kolben, Pleuel-- und and main bearings, on the gear box 112 Einheit
Kurbelwellenlagern, am Rädertrieb und and the turbocharger (visually) -- refer Cyl./unit
am Turbolader -- siehe auch 401 to 401
018 Ölablauf kontrollieren (Sichtprüfung) Check oil drainage of camshaft A 017 1 2 Motor X
bei Nockenwellenlagern, bearings, injection pumps and valve Engine
Einspritzpumpen und am Ventilantrieb gear in the rocker arm casing (visually)
(im Kipphebelgehäuse) -- siehe auch -- refer to 401
401
020 Schmierölpumpe überholen Overhaul the lube oil pump 300.01 2 10 Pumpe 1 1 1 1 1 1 1 1 1 1 1
Pump
022 Zylinderschmierölaggregat bzw. Check the cylinder lube oil unit or 302.01 1 4 Einheit 1 1 1 1 1 1 1 1 1 1 1
--pumpe, Blockverteiler und pump, the block distributor and the Unit
Überwachungsgeräte überholen monitoring systems
023 Schmieröl--Automatikfilter reinigen Clean the lube oil service filter B 024 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1
(abhängig von Spülintervallen) (depending on scavenging intervals) Filter
024 Schmieröl--Indikatorfilter reinigen Clean the lube oil indicating filter B 023 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1
(abhängig vom Differenzdruck) (depending on differential pressure) Filter
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
025 Schmieröl--Vorwärmer reinigen Clean the lube oil preheater (depending B 1 4 Einheit 1 1 1 1 1 1 1 1 1 1 1
(abhängig von der Separiertemperatur on separating temperature at the flow Unit
bei erforderlichem Durchsatz). rate required).
Reinigung evtl. durch Spezialfirma Cleaning should be carried out by a
special company if possible
026 Schmieröl--Separator Check, clean and overhaul the lube oil B 1 4 Einheit 1 1 1 1 1 1 1 1 1 1 1
(selbstaustragend) kontrollieren, separator (residue--selfdischarging) Unit
reinigen, überholen
027 Schmieröl--Kühler reinigen, evtl. durch Clean the lube oil cooler. C -- 0 Einheit 1 1 1 1 1 1 1 1 1 1 1
Spezialfirma Cleaning should be carried out by a Unit
special company if possible
Kühlwassersystem (Zylinder- und Düsenkühlung) Cooling water system (Cylinder an injection valve cooling)
031 Ausgleichsbehälter: Kühlwasserstand Compensating tank: Check the cooling A 032 1 0.2 Motor X
kontrollieren water level Engine
032 Düsenkühlwasserablauf kontrollieren Check the injection valve cooling water A 031 1 0.1 Motor X
(auf freien Ablauf und eventuelle system for free drainage and fuel Engine
Kraftstoffspuren) leckages
033 Kühlwasser: Korrosionsschutz Check the corrosion protection of the 000.07 1 0.5 Motor X
kontrollieren -- siehe auch 401 cooling water -- refer to 401 Engine
035 Kühlräume kontrollieren, System Check the cooling water spaces, clean 000.08 -- 0 Motor 1 1 1 1 1 1 1 1 1 1 1
chemisch reinigen (Zylinder-- und the system chemically (cylinder and Engine
Düsenkühlung). injection valve cooling system).
Reinigung evtl. durch Spezialfirma Cleaning should be carried out by a
special company if possible
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
036 Kühlwasser--Rückkühler: Kühlräume Heat exchanger: Clean the cooling C -- 0 Einheit 1 1 1 1 1 1 1 1 1 1 1
reinigen, evtl. durch Spezialfirma spaces. Unit
Cleaning should be carried out by a
special company if possible
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
054 Ladeluftumblase--/Ladeluftabblaseein-- Charge air bypass/blow--off device: A 062 1 0.5 Motor 1 1 1 1 1 1 1 1 1 1 1
richtung: Systembauteile auf Dichtheit Check system components for Engine
kontrollieren (Sichtprüfung). Steuer-- tightness (visually). Check control and
und Überwachungselemente auf monitoring elements
Funktionstüchtigkeit prüfen
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
075 Ölnebeldetektor kontrollieren/überholen Check/overhaul oil mist detector B 1 1 Motor 3 3 3 3 3 3 3 3 3 3 3
Engine
076 Abgastemperatur--Meßanlage Check measuring system for exhaust A 1 6 Motor 3
kontrollieren gas temperatures Engine
1, x
12000
24000
30000
36000
per
1500
3000
6000
2,
150
250
500
y
24
3
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
124 Alle Lagerschalen erneuern Replace all bearing shells. 021.01 2 3 Lager X
021.02 Bearing
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
153 Alle Kolben ausbauen, reinigen und Remove, clean and check all pistons. 034.01 154 3 2 Zyl. X
kontrollieren. Ringnuten vermessen. Measure ring grooves. Replace all 034.02 155 Cyl.
Alle Kolbenringe erneuern. piston rings. 050.05 163
Achtung: Wenn Kolbenringe erneuert Caution: If piston rings are replaced the 173
werden, ist die Zylinderbuchse cylinder liner is to be rehoned!
nachzuhonen!
154 1 Kolbenbolzen ausbauen, Remove one piston pin. Check piston 034.03 152 2 0.25 Zyl. X
Kolbenbolzenbuchse kontrollieren, pin bush, measure the clearance. 155 Cyl.
Spiel messen.
155 1 Kolben zerlegen. Bauteile reinigen. Disassemble one piston. Clean 034.02 152 3 2 Zyl. X
Kühlräume und Kühlbohrungen auf components. Check cooling spaces 034.03 154 Cyl.
Koksansatz kontrollieren. Bei and cooling passages for coke 034.04
Schichtdicken über 1 mm alle Kolben deposits. If thickness of layer exceeds
zerlegen. 1 mm, disassemble all pistons.
157 Alle Kolben zerlegen. Bauteile reinigen. Disassemble all pistons. Clean 034.02 153 3 2 Zyl. X
Neue oder regenerierte Kolbenoberteile components. Install new or 034.03 Cyl.
einbauen. reconditioned piston crowns. 034.04
158 Alle Kolben zerlegen. Bauteile reinigen. Disassemble all pistons. Clean 034.02 153 3 2 Zyl. X
Kolbenbolzenlager erneuern. components. Replace piston pin 034.03 Cyl.
bearings. 034.04
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
164 Alle Zylinderbuchsen ausbauen, Remove, clean and check all cylinder 050.01 157 3 4.5 Zyl. X
reinigen und kontrollieren. Dichtringe liners. Replace sealing rings. 050.04 Cyl.
erneuern
165 Alle Zylinderbuchsen mit Dichtringen Replace all cylinder liners and sealing 050.01 3 4.5 Zyl. X
erneuern. rings. 050.04 Cyl.
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
234 2 Einlaßventile ausbauen. Ventilsitze Remove two inlet valves. Check valve 113.01 172 2 1.5 Ventil X
kontrollieren. Ventildrehvorrichtungen seats. Check valve rotators, replace 113.02 242 Valve
kontrollieren, verschlissene Teile wearing parts 113.03
austauschen
235 Alle Einlaßventile ausbauen. Ventilsitze Remove all inlet valves. Check and 113.01 173 2 2.5 Ventil X
kontrollieren und nacharbeiten. overhaul valve seats. Check valve 113.02 243 Valve
Ventildrehvorrichtungen kontrollieren, rotators, replace worn parts. Check 113.03
verschlissene Teile austauschen. valve guides. 113.04
Ventilführungen kontrollieren 113.05
113.06
236 Alle Einlaßventile ausbauen. Remove all inlet valves. Replace valve 055.04 173 2 2.5 Ventil X
Ventilkegel, Ventilsitze und cones, valve seats and valve guides. 113.01 244 Valve
Ventilführungen austauschen. 113.06
242 2 Auslaßventile ausbauen. Ventilsitze Remove two exhaust valves. Check 113.01 172 2 2.5 Ventil X
kontrollieren valve seats 113.03 234 Valve
243 Alle Auslaßventile ausbauen. Remove all exhaust valves. Check and 113.01 173 2 4.5 Ventil X
Ventilsitze kontrollieren und regrind valve seats. Check valve 113.02 235 Valve
nachschleifen. Ventilführungen guides. 113.03
kontrollieren 113.04
113.05
113.06
244 Alle Auslaßventile ausbauen. Remove all exhaust valves. Replace 055.04 173 2 2.5 Ventil X
Ventilkegel, Ventilsitze und valve cones, valve seats and valve 113.01 236 Valve
Ventilführungen austauschen. guides. 113.06
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
275 Hauptanlaßventil ausbauen und Remove and overhaul main starting 162.01 1 2.5 Ventil X
überholen valve Valve
80--100*
10--12*
15--20*
30--40*
60--80*
1, x
per
1--2*
3--4*
5--6*
2,
250
500
24
3 y
1 Introduction
2 Technical details
3 Operation/
Operating media
4 Maintenance/Repair
5 Annex
N 5 Annex
: : N 5.1 Designations/Terms
: : N 5.2 Formulae
: : N 5.3 Units of measure/ Conversion of units of measure
: : N 5.4 Symbols and codes
: : N 5.5 Brochures
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
Standards The terms commonly used in the field of engine building have been de-
fined in the standard DIN 6265, and in the International Standards
ISO 1205-1972 and ISO 2276-1972, and in MAN Quality Specification
Q10.09211-3050. A selection of these terms appearing in the technical
documentation for our Diesel engines is explained in more detail below.
Engines
Dual-fuel engines Dual-fuel engines can be either operated on liquid fuels, or on gaseous
ones (natural gas, town gas, sewage gas etc.), a small amount of fuel
called pilot fuel being injected for ignition.
Otto gas engines Otto gas engines are operated on gas (natural gas, town gas, sewage gas
etc.) and have electric spark ignition.
Common Rail engines In engines which are equipped with a Common Rail injection system, pres-
surised fuel is provided in an accumulator, and the injection is electroni-
cally controlled.
Left-hand engine/ The terms left-hand (LH) engine and right-hand (RH) engine are deter-
Right-hand mined by the exhaust side of the engine. Viewing onto the coupling end, a
engine left-hand engine has the exhaust side at the left, and a right-hand engine
at the right. Figure 1 . This definition can normally only be applied to in-
lines engines.
Designation of cylinders The cylinders are consecutively numbered 1, 2, 3, etc. if viewing from the
coupling end. On V-type engines, the cylinder bank which is the left as
viewed from the coupling end is designated A, and the right one B
(A1-A2-A3 or B1, B2, B3 etc.), Figure 2 .
Designation of crank pins, The crank pins and big end bearings are designated (starting from the
journals and bearings coupling end) 1, 2, 3 etc., and the journals and crankshaft bearings 1, 2, 3
etc. Where an additional bearing is provided between the coupling flange
and the gearwheel for the camshaft drive, this bearing and the associated
journal are designated 01 (see Figure 3 ). For this designation, it is irrel-
evant which of the bearings is a locating bearing.
On V-type engines where two connecting rods are associated with one
crank pin, the big end bearings and the cylinders are termed A1, B1, A2
etc.
Coupling end KS The coupling end is the principal power take-off of the engine, to which the
propeller, the generator or any other machine is connected.
Free engine end KGS The free engine end is opposite the coupling end of the engine.
Left-hand side The left-hand side is the exhaust side on the left-hand engine, and the cyl-
inder bank A side on the V-type engine.
Right-hand side The right-hand side is the exhaust side on the right-hand engine, and the
cylinder bank B side on the V-type engine.
Camshaft side SS The camshaft side is the longitudinal side of the engine on which the injec-
tion pumps and the camshaft are mounted (opposite the exhaust gas
side).
Exhaust gas side AS The exhaust gas side is the longitudinal side of the engine on which the
exhaust gas pipe is mounted (opposite the camshaft side). The designa-
tions camshaft side and exhaust side are in common use for in-line en-
gines only.
Exhaust gas counterside AGS On engines having two camshafts, one on the exhaust side and one on
the opposite side, the term camshaft side would not be unambiguous. The
term exhaust gas counterside is used in such a case, together with the
term exhaust gas side.
Engine
pe ô V H ô n ô z
Effective engine output Pe Pe
1200
1200 ô P e
Mean effective pressure pe pe
VH ô n ô z
VH
D ô ¶ ô s
2
Swept volume VH
4
9550 ô P e
Torque Md Md
n
Overall efficiency ®e ® e
3600
Hu ô be
Propeller
P1 n 3
Propeller law
13
P2 n2
M d1 n 2
12
M d2 n2
Generator
Synchronous speed n
60pô f
Legend
D Cylinder diameter dm
f Frequency Hz
n Speed rpm
P Rating kW
s Stroke dm
z Number of cylinders /
®e Overall efficiency /
Swept volume
Use
Explanation The letter entered at point 1 represents a quantity of the second column of
the table. It can be supplemented by D, F or Q, in which case the meaning
corresponds to the entry in the third column of the table. Second or third in
the combination are letters of the fourth column, if required. Multiple
nominations are possible in this case. The order of use is Q, I, R, C, S, Z,
A. A supplementation by + (upper limit/on/open) or -- is possible; however,
only after O, S, Z and A.
SI units
CoCoS EDS
CoCoS SPC