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L28/32H
Instruction Manual
465 pgs8.58 Mb0

MAN Diesel & Turbo L28/32H Instruction Manual

L28/32H Instruction Manual - Marine
Four-stroke GenSet compliant with IMO Tier II
MAN Diesel
Preface Description A6000 Warning Description A6001 Questionnaire Description A6002 Main particulars Description 600.00 (07H) Introduction Description 600.01 (08H) Safety Description 600.02 (06H) Cross section Description 600.05 (07H) Key for engine designation Description 600.10 (02H) Designation of cylinders Description 600.11 (01H) Engine rotation clockwise Description 600.12 (02H) Code identification for instruments Description 600.20 (03H) Introduction to planned maintenance programme Description 600.24 (02H) Planned maintenance programme Description 600.25 (33H) Operation data & set points Description 600.30 (50H) Green Passport Description 600.33 (02H) Data for pressure and tolerance Description 600.35 (16H) Data for tightening torque Description 600.40 (18H) Declaration of weight Description 600.45 (01H) Ordering of spare parts Description 600.50 (06H) How to return spare parts Description 600.51 (05H) Service letters Description 600.55 (01H) Conversion table Description 600.60 (01) Basic symbol for piping Description 600.65 (01H)
IndexGenSet
L28-2
Text Index Drawing No.
Operating Description 601.01 (21H) Out of service Description 601.05 (17H) Starting-up after out of service periods Description 601.10 (17H) Guidelines for longterm low-load operation on HFO Description 601.15 (03H) Guidelines regarding MAN Diesel GenSets operating on low sulphur fuel oil
Engine performance and condition Description 602.01 (12H) Evaluation of readings regarding combustion condition Description 602.02 (11H) Condensate amount Description 602.05 (08H) Engine performance data Working card 602-01.00 (03H)
Starting failure Description 603.01 (08H) Faults in fuel oil system Description 603.02 (09H) Disturbances during running Description 603.03 (08H) Ignition in crankcase Description 603.04 (09H) Trouble shooting guide for centrifugal by-pass filter Description 603.05 (08H) Trouble shooting guide for turbine starter Description 603.06 (09H) Trouble shooting guide for cooling water system Description 603.09 (08H) Trouble shooting guide for lubricating oil cooler Description 603.10 (01H)
Quality requirement for lube oil (SAE30) for heavy fuel oil operation (HFO)
Description 601.16 (02H)
Description 604.01 (27H)
Index GenSet
L28-2
Text Index Drawing No.
MAN Diesel
Quality requirem. for lube oil (SAE30) for operation with gas oil, diesel oil (MGO/MDO) and biofuel Treatment and maintenance of lubricating oil Description 604.03 (11H) Criteria for cleaning/exchange of lubricating oil Description 604.04 (17H) Lubricating points Description 604.05 (01H) Lubricating points Description 604.05 (02H) Lubricating oil in base frame Description 604.06 (16H) Specific lube oil consumption - SLOC Description 604.07 (02H) Heavy fuel oil (HFO) specification Description 3.3.3-01 Diesel oil (MDO) specification Description 3.3.2-01 Gas oil / diesel oil (MGO) specification Description 3.3.1-01 Bio fuel specification Description 3.3.1-02 Viscosity-temperature diagram (VT diagram) Description 3.3.4-01 Fuel oil cleaning Description 604.30 (01H) Engine cooling water specifications Description 3.3.7-01 Cooling water inspecting Description 000.07-01 Cooling water system cleaning Description 000.08-01 Water specification for fuel-water emulsions Description 3.3.10-01 Specifications for intake air (combustion air) Description 3.3.11-01
Cylinder head 505/605
Cylinder head Description 605.01 (14H) Dismantling of cylinder head Working card 605-01.00 (01H) Inspection of inlet valve, exhaust valve and valve guide Working card 605-01.05 (06H) Reconditioning of valve spindle seat and valve seat ring Working card 605-01.10 (01H) Valve rotator Working card 605-01.15 (01H) Replacement of valve guide Working card 605-01.20 (05H) Safety valve Working card 605-01.25 (04H) Indicator valve Working card 605-01.26 (02H) Replacement of sleeve for fuel injector Working card 605-01.30 (04H) Replacement of valve seat ring Working card 605-01.35 (06H) Mounting of cylinder head Working card 605-01.40 (06H) Inspection of cylinder head cooling water space Working card 605-01.45 (01H) Cylinder head Plate 60501-19H Valve spindles and valve gear Plate 60502-31H Safety valve and indicator valve Plate 60508-11H Cylinder head, top cover Plate 60510-12H
Description 604.01 (26H)
Piston/connecting rod 506/606
Piston, connecting rod and cylinder liner Description 606.01 (10H) Dismounting of piston and connecting rod Working card 606-01.00 (01H) Separation of piston and connecting rod Working card 606-01.05 (03H) Piston Working card 606-01.10 (09H) Connecting rod Working card 606-01.15 (04H) Criteria for replacement of connecting rod big-end and main bearing shells Mounting of piston and connecting rod Working card 606-01.20 (01H) Hydraulic tightening of connecting rod screws Working card 606-01.25 (04H) In-situ inspection of connecting rod big-end bearing Working card 606-01.30 (01H) Inspection and honing of cylinder liner Working card 606-01.35 (08H) Replacement of cylinder liner Working card 606-01.40 (01H) Grinding of seal face on cylinder liner and cylinder head Working card 606-01.45 (01H) Dismounting of piston and cylinder liner at low overhaul heights Working card 606-01.50 (01H) Piston and connecting rod (hydraulic tightened) Plate 60601-34H Cylinder liner Plate 60610-09H
Working card 606-01.16 (02H)
MAN Diesel
Camshaft and camshaft drive Description 607.01 (05H) Camshaft and camshaft drive Working card 607-01.00 (01H) Inspection and replacement of camshaft bearing Working card 607-01.05 (01H) Adjustment of camshaft for valve and injection timing Working card 607-01.20 (04H) Intermediate wheel Plate 60701-06H Camshaft and camshaft bearing Plate 60705-22H
Operating gear for valves and fuel injection pumps Description 608.01 (12H) Inspection of valve roller guides Working card 608-01.00 (01H) Inspection of fuel injection pump roller guide Working card 608-01.05 (01H) Control and adjustment of valve clearance Working card 608-01.10 (01H) Roller guide and push rods Plate 60801-17H
IndexGenSet
L28-2
Text Index Drawing No.
Control and safety system Description 609.01 (20H) Instruments and automatics Description 609.05 (11H) Lambda controller Description 609.10 (15H) Starting box Description 609.35 (06H) Converter for engine- and turbocharger RPM signal Description 609.40 (01H) Functional test and adjustment of safety, alarm and monitoring equipment Functional test and adjustment of overspeed trip Working card 609-01.05 (01H) Adjustment and test of ON/OFF pressostate Working card 609-05.00 (02H) Adjustment and test of ON/OFF thermostate Working card 609-05.01 (02H) Function and test of level switch (LAL 25) Working card 609-05.02 (02H) Adjustment and test of analogous transmitter Working card 609-05.03 (02H) Adjustment and test of analogous temperature transmitter Working card 609-05.04 (02H) Adjustment of lambda controller Working card 609-10.00 (16H) Governor and governor drive Plate 60901-13H Governor and governor drive Plate 60901-14H Governor and governor drive Plate 60901-15H Regulating mechanism Plate 60902-18H Overspeed device Plate 60903-38H Instrument panel Plate 60905-20H Instrument panel Plate 60905-27H Instrument panel Plate 60905-32H Thermometer Plate 60907-19H Pressostate, thermostate, diff. pressostate and pressure transmitter Plate 60907-02H Prelubricating oil alarm (LAL 25) Plate 60919-01H Level switch in oil sump (LAL/LAH 28) Plate 60920-01H Local starting box - No 1 Plate 60935-13H Local starting box - No 1 Plate 60935-16H Local starting box - No 2 Plate 60935-14H Local starting box - No 2 (incl. high lub. oil temp.) Plate 60935-15H Engine control box Plate 60936-08H Termnal box Plate 60936-07H Converter Plate 60956-01
Working card 609-01.00 (01H)
Crankshaft and main bearings Description 610.01 (12H) Checking of main bearings alignment (deflection), hydraulic tigthened connecting rod
Working card 610-01.00 (10H)
MAN Diesel
Index GenSet
L28-2
Text Index Drawing No.
Inspection of main bearing shells Working card 610-01.05 (05H) Inspection of guide bearing shells Working card 610-01.10 (08H) Vibration damper Working card 610-04.00 (01H) Crankshaft Plate 61001-15H Crankshaft Plate 61001-21H Resilient gear wheel Plate 61002-07H Coupling for central drive lub. oil pump Plate 61002-11H Coupling for central drive lub. oil pump Plate 61002-12H Coupling for central drive lub. oil pump Plate 61002-13H Coupling for central drive lub. oil pump Plate 61002-14H Resilient gear wheel Plate 61002-15H Resilient gear wheel Plate 61002-16H Resilient gear wheel Plate 61002-17H Flywheel with gear rim Plate 61003-02H Flywheel with gear rim Plate 61003-05H Flywheel with gear rim Plate 61003-06H Torsional vibration damper Plate 61004-05H Torsional vibration damper Plate 61004-12H Torsional vibration damper Plate 61004-13H Torsional vibration damper Plate 61004-14H Torsional vibration damper Plate 61004-15H Torsional vibration damper Plate 61004-16H Tuning wheel Plate 61004-06H
Engine frame/Oil pan 511/611
Engine frame and base frame Description 611.01 (07H) Functional test of crankcase safety relief valves Working card 611-01.00 (04H) Frame with main bearings Plate 61101-11H Front cover for lubricating oil pump Plate 61102-09H Front cover for lubricating oil pump and cooling water pump Plate 61102-07H Front cover for lubricating oil pump and cooling water pumps Plate 61102-10H Covers on frame Plate 61106-20H Cover on frame Plate 61106-14H
Turbocharger 512/612
Turbocharger system Description 612.01 (28H) Cleaning the turbocharger in service, water washing of compressor Description 612.05 (07H) Cleaning the turbocharger in service, dry cleaning - turbine Description 612.10 (09H) Cleaning the turbocharger in service, water washing - turbine side Description 612.15 (02H) Overhaul of charging air cooler Working card 612-01.00 (02H) Charge air cooler housing - draining Working card 612-01.05 (02H) Water washing of compressor side - turbochager type NR15/R ­NR20/R - NR24/R - NR26/R Dry cleaning of turbocharger - turbine side Working card 612-10.00 (02H) Water washing of turbine side Working card 612-15.00 (01H) Charging air cooler - freshwater Plate 61201-12H Charging air cooler - freshwater Plate 61201-13H Charging air cooler - freshwater Plate 61201-14H Charging air cooler - freshwater Plate 61201-15H Charging air cooler - seawater Plate 61201-16H Charging air cooler - seawater Plate 61201-17H Charging air cooler Plate 61201-29H Exhaust pipe arrangement Plate 61202-23H Exhaust pipe arrangement with welded compensator Plate 61202-32H Exhaust pipe arrangement Plate 61202-26H
Working card 612-05.00 (03H)
MAN Diesel
Exhaust pipe arrangement with welded compensator Plate 61202-28H Exhaust pipe arrangement Plate 61202-27H Exhaust pipe arrangement with welded compensator Plate 61202-42H Water washing of compressor side Plate 61205-02H Steam trap Plate 61208-01H Blowgun for dry cleaning of turbocharger Plate 61210-02H
Compressed air system Description 613.01 (20H) Air filter Working card 613-01.21 (02H) Overhaul, test and inspection of turbine starter Working card 613-01.30 (02H) Main starting valve Working card 613-01.40 (01H) Check of compressed air piping system Working card 613-01.90 (02H) Turbine starter Plate 61309-05H Main starting valve Plate 61310-03H Muffler Plate 61312-02H Emergency starting valve Plate 61313-03H Starting valve Plate 61314-03H Main stop valve Plate 61315-03H Air strainer Plate 61316-03H Safety valve Plate 61319-01H ON-OFF valve for jet system Plate 61320-05H ON-OFF valve for jet system Plate 61320-06H Air filter Plate 61321-03H Pressure reduction valve Plate 61322-04H Turning gear Plate 61325-07H Pneumatic turning gear (motor power unit) Plate 61325-08H Pneumatic turning gear (spindle, gear case and gearing) Plate 61325-09H
IndexGenSet
L28-2
Text Index Drawing No.
Internal fuel oil system Description 614.01 (25H) Fuel injection pump and fuel injection pipe Working card 614-01.05 (02H) Fuel injection pump and fuel injection pipe Working card 614-01.05 (05H) Fuel injection valve Working card 614-01.10 (03H) Fuel oil split filter Working card 614-01.15 (01H) Check of fuel oil piping system Working card 614-01.90 (01H) Adjustment of the maximum combustion pressure Working card 614-05.01 (02H) Fuel injection pump Plate 61401-03H Fuel injection pump Plate 61401-09H Fuel injection valve Plate 61402-04H Fuel injection valve, cooled Plate 61402-07H Fuel oil filter duplex Plate 61403-15H Fuel injection pipe Plate 61404-06H Pipes on cylinder section - forced lubrication with cooling oil pipes Plate 61430-03H Nozzle cooling pump Plate 61440-05H
Internal lubricating oil system Description 615.01 (29H) Lubricating oil cooler Description 615.06 (02H) Centrifugal by-pass filter Description 615.15 (05H) Crankcase ventilation Description 615.31 (03H) Lubricating oil pump, engine driven Working card 615-01.00 (01H) Prelubricating pump Working card 615-01.05 (02H) Lubricating oil filter Working card 615-01.10 (01H)
MAN Diesel
Index GenSet
L28-2
Text Index Drawing No.
Lubricating oil, thermostatic valve Working card 615-01.20 (01H) Check of lubricating oil piping system Working card 615-01.90 (01H) Lubricating oil cooler Working card 615-06.00 (02H) Centrifugal by-pass filter Working card 615-15.00 (01H) Lubricating oil pump (central driven) Plate 61501-12H Lubricating oil pump (gear driven) Plate 61501-22H Lubricating oil filter (Type A) Plate 61502-11H Lubricating oil filter (Type B) Plate 61502-12H Lubricating oil filter (suppl. for plate 61502-11H/12H) Plate 61502-15H Lubricating oil thermostatic valve Plate 61503-08H Prelubricating pump with el-motor Plate 61504-04H Lubricating oil cooler Plate 61506-10H Centrifugal by-pass filter Plate 61515-09H Hand wing pump Plate 61525-02H Lubricating oil separator Plate 61530-07H Lubricating oil pipes on engine Plate 61530-02H
Cooling water system 516/616
Cooling water system Description 616.01 (17H) Cooling water thermostatic valve Description 616.04 (15H) Check of cooling water system Working card 616-01.90 (01H) Cooling water thermostatic valve Working card 616-04.00 (01H) Cooling water thermostatic valve Plate 61604-07H High temperature fresh water pump Plate 61610-05H Low temperature fresh water pump Plate 61610-07H Low temperature fresh water pump Plate 61610-10H Sea water pump Plate 61615-04H Pipes on cylinder head Plate 61625-04H Cooling water pipes on engine Plate 61630-01H Preheater - fresh water Plate 61635-06H
Special equipment 517/617
Kit for cylinder unit Kit 61704-02H Kit for overspeed device Kit 61743-01H Kit for covers on frame Kit 61751-01H
Specific plant information 519/619
Resilient mounting of generating sets Description 619.03 (10H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (21H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (22H) Fitting instructions for resilient mountings of gensets Working card 619-03.00 (23H) Replacement of conicals Working card 619-03.05 (01H) Maintenance of conicals Working card 619-03.10 (01H) Flexible external connections Plate 61902-03H Conical element Plate 61903-04H
Tools 520/620
Introduction to spare part plates for tools Description 620.01 (01H) Function of the hydraulic tools Working card 620-01.05 (03H) Application of hydraulic tools Working card 620-01.06 (01H) Hand lever pump Working card 620-01.07 (01H) Maintenance of hydraulic tools Working card 620-01.10 (01H) Tightening with torque spanner Working card 620-01.15 (01H)
MAN Diesel
Tool combinations for tightening of connecting rod screws Working card 620-01.20 (01H) Max. pressure indicator Working card 620-01.25 (02H) Tools for cylinder head Plate 62005-03H Tools for piston, connecting rod and cylinder liner Plate 62006-11H Tools for operating gear for inlet valves, exhaust valves and fuel injection pumps Tools for control and safety systems, automatics and instruments Plate 62009-02H Tools for crankshaft and main bearing Plate 62010-07H Tools for crankshaft and main bearing Plate 62010-10H Tools for crankshaft and main bearing Plate 62010-11H Tools for fuel oil system and injection equipment Plate 62014-02H Tools for lubricating oil system Plate 62015-02H Hydraulic tools Plate 62021-08H Tools for low overhaul height, piston, cylinder liner and connecting rod Operating manual for testing tool (Fuel injection valve) Description GXO-D001
IndexGenSet
L28-2
Text Index Drawing No.
Plate 62008-03H
Plate 62050-01H
Engine data
500/600
MAN Diesel & Turbo
Instruction Manual for:
MAN Diesel & Turbo Identification No. for Instruction Manual.
Identification No. for Description: 000 . 00
Function
Section No.
Identification No. for Working Card: 000 - 00 . 00
Sub-function
Function
Section No.
Identification No. for Plates: 00000 - 00 H
H for Holeby
Edition
Section No. and Function
For ordering of spare parts, see page 500.50 / 600.50
All data provided in this document/manual is non-binding. This data serves informational purposes only and is especially not guaranteed in any way.
Depending on the subsequent specic individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteri­stics of each individual project, especially specic site and operational conditions.
If this document/manual is delivered in another language than English and doubts arise concerning the
translation, the English text shall prevail.
Original instructions
2011.06.28
MAN Diesel & Turbo
MAN Diesel & Turbo | PrimeServ
The MAN Diesel & Turbo Group offers worldwide round-the-clock service, 365 days a year. Apart from the MAN Diesel & Turbo service headquarters in Augsburg, Copenhagen, Frederikshavn, Holeby, Stockport, St. Nazaire, Tur­bocharger and service centres on all continents provide comprehensive and continuous support. The long service life associated with MAN Diesel engines dictates a spare parts programme that ensures components are available for engines in operation for decades. Based on high-capacity machines, MAN Diesel & Turbo service production facilities are able to comply with special customer requests with the utmost precision and flexibility.
24-hour hotline number: +49 1801 15 15 15 http://www.mandieselturbo.com/primeserv
Copyright 2011 © MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany, registered with the Danish Commerce and Companies Agency under CVR Nr.: 31611792, (herein referred to as “MAN Diesel & Turbo”).
This document/manual must not, either wholly or partly, be copied, reproduced, made publich or in any other way made available to any third party without the written to this effect from MAN Diesel & Turbo.
MAN Diesel & Turbo
H. Christoffersensvej 6 4960 Holeby
Denmark
Phone: +45 54 69 31 00
Fax: +45 54 69 30 30
mandieselturbo-hol@mandieselturbo.com
www.mandieselturbo.com
PrimeServ Holeby GenSet & Powerplant
Service & Spare Parts
Fax : +45 54 69 30 31
After ofce hours : +45 40 14 40 45
PrimeServ-hol@mandieselturbo.com
MAN Diesel & Turbo
Branch of MAN Diesel & Turbo SE, Germany CVR No.: 31611792 Head ofce: Teglholmsgade 41 2450 Copenhagen SV, Denmark German Reg.No.: HRB 22056 Amtsgericht Augsburg
2011.06.28
MAN Diesel & Turbo
Description
Page 1 (1)
Warning !
(Marine engines only)
It is important that all MAN Diesel & Turbo engines are operated within the given specifications and performance tolerances specified in the engines' Technical Files and are maintained according to the MAN Diesel & Turbo maintenance instructions in order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the die­sel engine shall be performed as specified in MAN Diesel & Turbo instructions including, but not limited to, the instructions to that effect included in the Technical File.
Warning
General
12.06 - ES0
MAN Diesel & Turbo
Questionnaire – Technical Documentation
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1 (1)
MAN Diesel & Turbo
Description
Page 1 (1)
Main Particulars
Cycle : 4-stroke
Configuration : In-line
Cyl. Nos. available : 5-6-7-8-9
Power range : 1050-1980 kW
Speed : 720/750 rpm
Bore : 280 mm
Stroke : 320 mm
Stroke/bore ratio : 1.14:1
Piston area per cyl. : 616 cm
600.00
Edition 07H
L28/32H
2
Swept volume per cyl. : 19.7 ltr.
Compression ratio : 13.9:1
Max. combustion pressure : 130 bar
Turbocharging principle : Constant pressure system and inter cool ing
Fuel quality acceptance : HFO (up to 700 cSt/50° C, RMK700) MDO (DMB) - MGO (DMA, DMZ) according ISO8217-2010
Power lay-out
Speed
Mean piston speed
Mean effective pressure
Max. combustion pressure
Power per cylinder
rpm
m/sec.
bar
bar
kW/cyl.
MCR version
720
7.7
17.8
130
210
750
8.0
17.9
130
220
Overload rating (up to 10%) allowable in 1 hour for every 12 hours
Power per cylinder
11.36 - ES1 - Tier II - WB2 - GenSet
kW/cyl.
230 240
MAN Diesel & Turbo
Description
Page 1 (1)
Introduction
Introduction
This instruction book provides general information on the engine design, operation and maintenance. It can also be used as a reference when ordering spare parts. Reliable and economical operation of the plant is conditional upon its correct operation and maintenance in accordance with MAN Diesel & Turbo’s instructions. Emissions-related maintenance of the diesel engine shall be performed as speci­fied in MAN Diesel & Turbo’s instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room personnel are fully acquainted with the contents of this book and the Technical File.
Every care is taken to ensure that all information in this instruction book is present and correct.
600.01
Edition 08H
General
Description
The book is a basic instruction manual for the particu­lar engine supplied, with plant-adapted infor mation such as basic media-system drawings, electrical wiring diagrams and test bed reports.
The first five sections (500-504) of the book serve as a guide to engine operation, and the next fifteen sections (505-519) contain technical de scrip tions, spare parts illustrations with appurtenant parts lists, as well as working cards.
The last section (520) comprises tools.
The engine is divided into a number of main com­ponents/as semblies, each of which is described in a section of this book (section 505-519).
This book must not, either wholly or partly, be copied, reproduced, made public or in any other way made available to any third party without the written consent to this effect from MAN Diesel & Turbo.
If an instruction book is delivered in another language than English and doubts arise concerning the trans­lation, the English text shall prevail.
Each of these sections starts with technical de­scriptions of the systems/components, followed by working cards and the spare parts illustration plates and parts lists.
08028-0D/H5250/94.08.12
10.47 - ES0
Fig. 1. Structuring of instruction book.
MAN Diesel
Description
Page 1 (2)
General
Proper maintenance, which is the aim of this book, constitutes the crucial point in obtaining optimum safety in the engine room. The general measures mentioned here should therefore be a natural routine to the entire engine room staff.
Cleanliness
The engine room should be kept clean above and below the fl oor plates. If grit or sand blows into the engine room when the ship is in port, the ventilation should be stopped and ventilating ducts, skylights, and doors in the engine room should be closed.
In particular, welding or work which causes spread ing of grit and chips must be avoided near the engine, unless this is closed or covered, and the turbo char­ger air intake fi lters are covered.
The exterior of the engine should be kept clean and the paintwork maintained so that leakages can easily be detected.
Safety
600.02
Edition 06H
General
Spares
Large spare parts should, as far as possible, be pla­ced well strapped near the area of application and accessible by crane. The spare parts should be well preserved against corrosion and protected against mechanical damage. The stock should be checked at intervals and replenished in time.
Light
Ample working light should be permanently installed at appropriate places in the engine room, and port­able working light, in explosion-proof fi ttings, should be obtainable everywhere.
Freezing
If there is a risk of damage due to freezing when the plant is out of service, engines, pumps, coolers, and pipe systems should be emptied of cooling water.
Warning
Fire
If the crankcase is opened before the engine is cold, welding and the use of naked light will involve the risk of explosions and fi re. The same applies to inspec tion of oil tanks and the space below the fooler. Attention is furthermore drawn to the danger of fi re when using paint and solvents with a low fl ash point. Porous insulating material drenched with oil from leakages is easily infl ammable and should be re newed. See also: "Ignition in crankcase" in section 603.
Order
Hand tools should be placed easily accessible on tool boards. Special tools should be fastened to tool panels (if supplied) in the engine room close to the area of application. No major objects must be left unfastened, and the fl oor and passages should be
08028-0D/H5250/94.08.12
kept clear.
The opening of cocks may cause discharge of hot liquids or gases. The dismantling of parts may cause springs to be released.
The removal of fuel valves (or other valves in the cylinder head) may cause oil to run down to the piston crown, and if the piston is hot, an explosion may then blow out the valve.
When testing fuel valves with the hand pump, do not touch the spray holes, as the jet may pierce the skin. Think out beforehand which way the liquids, gases or fl ames will move, and keep clear.
Crankcase work
Check beforehand that the starting air supply to the engine is shut off.
91.12 - ES0U
MAN Diesel
600.02
Edition 06H
General
Feeling over
Whenever repairs or alterations have been made to the running gear, apply the "Feel-over sequence" until ensured that there is no undue heating, oil­mist formation, blow-by, or failure of cooling water or lubricating oil systems.
Feel-over sequence
Feel-over after 5-15 and 30 minutes' idle running and fi nally when the engine is running at full load. See also "Starting-up sequence" in the section 602.
Safety
Description
Page 2 (2)
Turning with air
After prolonged out-of-service periods or overhaul work which may involve a risk of accumulation of liquid in the combustion spaces, turning with open indicator cocks should always be effected, through at least two complete revolutions.
Check and maintain
Lubricating oil condition, fi lter elements and mea­suring equipment.
91.12 - ES0U
MAN Diesel & Turbo
Description
Page 1 (1)
Cross Section
600.05
Edition 07H
L28/32H
10.36 - ES1
MAN Diesel
Description
Page 1 (1)
Key for Engine Designation
Engine Type Identifi cation
The engine types of the MAN B&W programme are identifi ed by the following fi gures:
6 L 28/32 H MCR
No of cylinders
5, 6, 7, 8, 9 12, 16, 18
600.10
Edition 02H
General
Engine Type
L : In-line V : V-built
Cyl. diam/stroke
16/24 : 160/240 21/31 : 210/310 23/30 : 225/300 27/38 : 270/380 28/32 : 280/320 32/40 : 320/400
Design Variant
Rating
MCR : Maximum continuous rating ECR : Economy continuous rating
08028-0D/H5250/94.08.12
04.08 - ES1
MAN Diesel
Description
Page 1 (1)
Front End
Designation of Cylinders
600.11
Edition 01H
L28/32H
Flywheel end
08028-0D/H5250/94.08.12
Exhaust Side / Right Side
Control Side / Camshaft Side / Left Side
89.17 - ES1S-L
MAN Diesel & Turbo
Description
Page 1 (1)
Engine Rotation Clockwise
600.12
Edition 02H
General
Direction of rotation seen from flywheel end “Clockwise”
Engine
Alternator
10.39 - ES1
MAN Diesel & Turbo
Description
Page 1 (2)
Explanation of Symbols
TI
40
PI
22
TAH
12
Code Identification for Instruments
Measuring device Local reading
Temperature Indicator
No. 40 *
Measuring device Sensor mounted on engine/unit Reading/identification mounted in a panel on the engine/unit
Pressure Indicator
No. 22 *
Measuring device Sensor mounted on engine/unit Reading/identification outside the engine/unit
600.20
Edition 03H
General
PT 22
Temperature Alarm High
No. 12 *
Measureing device Sensor mounted on engine/unit Reading/identification in a panel on the engine/unit and reading/indication out­side the engine/unit
Pressure Transmitting
No. 22 *
* Refer to standard location and text for instruments on the following pages.
Specification of letter code for measuring devices
1st letter Following letters
F Flow A Alarm
L Level D Differential
P Pressure E Element
S Speed, System H High
T Temperature I Indicating
11.19 - ES1
U Voltage L Low
V Viscosity S Switching, Stop
X Sound T Transmitting
Z Position X Failure
V Valve, Atuator
MAN Diesel & Turbo
600.20
Edition 03H
Code Identification for Instruments
General
Standard Text for Instruments
Diesel Engine/Alternator
LT Water System
01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler 02 outlet from air cooler 05 outlet from alternator 08 inlet to fresh water cooler (SW) 03 outlet from lub. oil cooler 06 outlet from fresh water cooler (SW) 09
HT Water System
10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler 10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler 11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater 12 outlet from engine 15 outlet from HT system 19A inlet to prechamber 13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber
Lubricating Oil System
20 inlet to cooler 24 sealing oil - inlet engine 28 level in base frame 21 outlet from cooler / inlet to filter 25 prelubricating 29 main bearings 22 outlet from filter / inlet to engine 26 inlet rocker arms and roller guides 23 inlet to turbocharger 27 intermediate bearing / alternator bearing
Description
Page 2 (2)
Charging Air System
30 inlet to cooler 34 charge air conditioning 38 31 outlet from cooler 35 surplus air inlet 39 32 jet assist system 36 inlet to turbocharger 33 outlet from TC filter / inlet to TC compr. 37 charge air from mixer
Fuel Oil System
40 inlet to engine 44 outlet from sealing oil pump 48 41 outlet from engine 45 fuel-rack position 49 42 leakage 46 inlet to prechamber 43 inlet to filter 47
Nozzle Cooling System
50 inlet to fuel valves 54 58 oil splash 51 outlet from fuel valves 55 valve timing 59 alternator load 52 56 injection timing 53 57 earth/diff. protection
Exhaust Gas System
60 outlet from cylinder 64 68 61 outlet from turbocharger 65 69 62 inlet to turbocharger 66 63 compustion chamber 67
Compressed Air System
70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system 71 inlet to stop cylinder 75 microswitch for turning gear 79 72 inlet to balance arm unit 76 inlet to turning gear 73 control air 77 waste gate pressure
Load Speed
80 overspeed air 84 engine stop 88 index - fuel injection pump 81 overspeed 85 microswitch for overload 89 turbocharger speed 82 emergency stop 86 shutdown 90 engine speed 83 engine start 87 ready to start
Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating 97 remote 92 oil mist detector 95 voltage 98 alternator winding 93 knocking sensor 96 switch for operating location 99 common alarm 100 inlet to MDO cooler 101 outlet to MDO Cooler 102 alternator cooling air
11.19 - ES1
MAN Diesel
Description
Page 1 (1)
Introduction to Planned Maintenance Programme
General
The overhaul intervals are based on operation on a specifi ed fuel oil quality at normal service output, which means 70-100% of MCR.
In the long run it is not possible to obtain a secure and optimal economic running without an effective main tenance system.
With the structure and amount of information in the maintenance programme, it can be integrated in the entire ship's/power station's maintenance system or it can be used separately.
The crux of the maintenance system is the key dia­gram, see page 600.25, indicating the inspection intervals for the components/systems, so that the crew can make the necessary overhauls, based on the engines' condition and/or the time criteria.
600.24
Edition 02H
General
4. Related procedures - indicates other works, depending on this work - or works which would be expedient to carry out.
5. Indicates x number of men in x number of hours for accomplishing the work.
The stated consumption of hours is only intended as guide.
Experience with the specifi c station/crew may lead to a bringing up-to-date.
6. Refers to data, which are required for carrying out the work.
7. Special tools, which must be used. Please note that not all tools are standard equip ment.
8. Various requisite hand tools.
The stated, recommended intervals are only for guidance as different service conditions, the quality of the fuel oil and the lubricating oil, treatment of the cooling water, etc, will decisively infl uence on the actual service results and thus the intervals between necessary overhauls.
Experience with the specifi c plant/crew is to be used for adjustment of time between overhaul. Further it is to be used for adjusting the timetable stated for guidance in the working cards.
Working cards
Each of the working cards can be divided into two: a front page and one or several pages, describing and illustrating the maintenance work.
The front page indicates the following:
1. Safety regulations, which MUST be carried through before the maintenance work can start.
2. A brief description of the work.
08028-0D/H5250/94.08.12
3. Reference to work, which must be carried out, if any, before the maintenance work can start.
9. Indicates the components/parts, which it is advisible to replace during the maintenance work. Please note, that this is a condition for the intervals stated.
1
2
3
4
5
6
7
8
9
94.35 - ES0S
Fig 1. Guidance instruction for working cards.
MAN Diesel
Description
Page 1 (4)
Description
Planned Maintenance Program
● = Overhaul to be carried out
■ = Check the condition
Operating of Engine:
Readings of data for Engine and Generator, with refe-
rence to "Engine Performance Data", section 602-1 .......
Cylinder Head:
Inlet and exhaust valve - Overhaul and regrinding of
spindel and valve seat .....................................................
Inspection of inlet, exhaust valves and valve guide .........
Check of valve rotators rotation during engine rotation ...
Sleeve for fuel injector .....................................................
Safety valve - Overhaul and adjustment of opening
pressure ..........................................................................
Indicator valve .................................................................
Time Between Overhaul
50
200
8000
2000
16000
32000
Check new/
Overhauled parts
after -hours
■
●
■
■
■
■
■ ■
Daily
Weekly
Montly
3th month
600.25
Edition 33H
L28/32H
Working
Card
No.
Observations
602-01.00
605-01.10 605-01.05 605-01.05 605-01.30
605-01.25 605-01.26
Cylinder head cooling water space - Inspection ..............
Cylinder head nut - Retightening ..................................... 200
Piston, Connecting Rod and Cylinder Liner:
Inspection of piston .........................................................
Piston ring and scraper ring ............................................
Piston pin and bush for connecting rod - Check of
clearance .........................................................................
Connecting rod - Measuring of big-end bore ...................
Inspection of big-end bearings shells ..............................
Connecting rod - Retightening ......................................... 200
Cylinder liner - Cleaning, honing and measuring ............
Cylinder liner removed - Check the water space and
guide ring in frame ...........................................................
Camshaft and Camshaft Drive:
08028-0D/H5250/94.08.12
Camshaft - Inspection of gear wheels, bolt, connections
etc. ................................................................................... 200
Camshaft bearing - Inspection of clearance ....................
Camshaft adjustment - Check the condition ....................
■
■
●
■
■
■
■
●
■
■
■
■
605-01.45 605-01.40
606-01.10 606-01.10
606-01.15 606-01.15 606-01.16
606-01.25 606-01.35
606-01.40
607-01.00 607-01.05 607-01.20
09.48 - ES0
Lubrication of camshaft bearing - Check .........................
■
607-01.00
MAN Diesel
600.25
Edition 33H
Planned Maintenance Program
L28/32H
Description
Operating Gear for Inlet Valves, Exhaust Valves and Fuel Injection Pumps:
Roller guide for valve gear ...............................................
Valve gear - Valve bridge, spring, push rod, etc ..............
Roller guide for fuel injection pump .................................
Roller guide housing ........................................................
Inlet and exhaust valve - Check and adjustment of valve
clearance .........................................................................
● = Overhaul to be carried out
■ = Check the condition
Time Between Overhaul
50
200
2000
8000
16000
Check new/
Overhauled parts
after -hours
■
■
■
■
■
Daily
32000
Weekly
Montly
3th month
Description
Page 2 (4)
Working
Card
No.
Observations
608-01.00 608-01.10 608-01.05
608-01.10
608-01.10
Lubricating of operating gear - Check .............................
Control and Safety System, Automatics and Instruments:
Safety, alarm and monitoring equipment ........................
Jet system - Adjustment ..................................................
Pick-up - Adjustment .......................................................
Governor - Check oil level, see governor instruction
book, section 609 ............................................................
Crankshaft and Main Bearing:
Checking of main bearings aligment, (autolog) ...............
Inspection af main bearing ..............................................
Inspection of guide bearing .............................................
Vibration damper - Check the condition ..........................
Lubricating of gear wheel for lub. oil pump and cooling
water pump etc. ...............................................................
Counter weight - Retightening, see page 600.40 ............ 200
■
■
■
■
■
■
■
■
■
■
■
608-01.00 608-01.05
609-01.00
609-01.00 609-10.00
610-01.00 610-01.05 610-01.10
610-04.00
Main- and guide bearing cap - Retightening ................... 200
■
610-01.05 610-01.10
09.48 - ES0
08028-0D/H5250/94.08.12
MAN Diesel
Description
Page 3 (4)
Description
Planned Maintenance Program
● = Overhaul to be carried out
■ = Check the condition
Engine Frame and Bedplate:
Holding down bolts - Retightening, see page 600.40 ...... 200
Bolts between engine frame and base frame -
Retightening, see page 600.40 ....................................... 200
For flexible mounted engines - Check anti-vibration
mountings ........................................................................ 200
Safety cover - Function test .............................................
Time Between Overhaul
50
200
2000
8000
16000
Check new/
Overhauled parts
after -hours
■
■
■
■
Daily
32000
Weekly
Montly
3th month
600.25
Edition 33H
L28/32H
Working
Card
No.
Observations
619-03.00 611-01.00
Turbocharger System:
Dry cleaning of turbine side .............................................
Wet cleaning of turbine side ............................................
Water washing of compressor side .................................
Cleaning of air filter - Compressor side (see turbo-
charger instruction book) .................................................
Turbocharger complete - Dismantling, cleaning, inspec-
tion etc. (see turbocharger instruction book) ...................
Charging air cooler - Cleaning and inspection ................
Charging air cooler housing - Draining ............................
Exhaust pipe - Compensator ...........................................
Compressed Air System:
Air starter motor - Dismantling and inspection ................
Function test - Main starting valve, starting valve, main
valves and emergency start valve ...................................
Dirt separator - Dismantling and cleaning .......................
Muffler - Dismantling and cleaning ..................................
●
●
●
■
●
■
■
■
●
●
612-10.00 612-15.00 612-05.00
612-01.00
613-01.30
613-01.40
Compressed air system - Draining ..................................
Compressed air system - Check of the system ...............
08028-0D/H5250/94.08.12
Drain of bowl ....................................................................
(filter element to be replaced when pressure drop exceeds 0.7 bar)
09.48 - ES0
●
■
●
613-01.90 613-01.90
613-01.21
MAN Diesel
600.25
Edition 33H
Planned Maintenance Program
L28/32H
Description
Fuel Oil System and Injection Equipment:
Fuel oil filter - Dismantling and cleaning ..........................
Fuel oil feed pump ...........................................................
Fuel oil injection pump - Dismantling and cleaning .........
Fuel injection valve - Adjustment of opening pressure .... 200
Fuel oil high-pressure pipe - Dismantling and check .......
Adjustment of the maximum combustion pressure ..........
Fuel oil system - Check the system .................................
Nozzle cooling system - Check the system .....................
● = Overhaul to be carried out
■ = Check the condition
Time Between Overhaul
50
200
2000
8000
32000
16000
Check new/
Overhauled parts
after -hours
●
●
●
■
■
●
■
■
Daily
Weekly
Montly
3th month
Description
Page 4 (4)
Working
Card
No.
Observations
614-01.15 614-10.00 614-01.05
614-01.10 614-01.05 614-05.01
614-01.90 614-01.90
Fuel oil - Oil samples after every bunkering, see sec.604
Lubricating Oil System:
Lubricating oil pump - Engine driven ...............................
Lubricating oil filter - Cleaning and exhange ...................
Lubricating oil cooler .......................................................
Prelubricating pump - El. driven ......................................
Thermostatic valve ..........................................................
Centrifugal filter - Cleaning and exhange of paper ..........
Lubricating oil - Oil samples, see section 604 .................
Lubricating oil system - Check the system ......................
Cooling Water System:
Cooling water pump - Engine driven (sea water and
fresh water)......................................................................
Thermostatic valve ..........................................................
Cooling water system - Check the system ......................
Cooling water system - Water samples, see sec. 604 .....
■
●
●
■
■
●
■
■
■
■
■
■ ■
615-01.00 615-01.10 615-06.00
615-01.05 615-01.20 615-15.00
615-01.90
616-01.90
09.48 - ES0
08028-0D/H5250/94.08.12
MAN Diesel & Turbo
Description
Page 1 (2)
Lubricating Oil System
Temp. before cooler SAE 30 (outlet engine) SAE 40
Temp. after cooler SAE 30 (inlet engine) SAE 40
Pressure after filter (inlet eng)
Elevated pressure i.g. when centrifugal filter installed
Pressure drop across filter
Prelubricating pressure Pressure inlet turbocharger
Lub. oil, level in base frame
Temp. main bearings
Fuel Oil System
Pressure after filter MDO HFO
Leaking oil
Press. nozz. cool. oil, inlet eng. Temp. nozz. cool. oil, outlet eng.
Cooling Water System
Press. LT-system, inlet engine
Press. HT-system, inlet engine
Temp. HT-system, inlet engine
Temp. HT-system, outl. cyl.units
Temp. HT-system, outlet engine
Temp. raise across cyl. units
Exhaust Gas and Charge Air
Exh. gas temp. before TC
Exh. gas temp. outlet cyl. Diff. between individual cyl.
Exh. gas temp. after TC
Ch. air press. after cooler Ch. air temp. after cooler
Compressed Air System
Press. inlet engine
Operation Data & Set Points
Acceptable
value at shop
test or after
repair
<75° C <82° C
<65° C <72° C
>4.0 bar
>4.5 bar
<0.5 bar
>1.5 bar
<85° C
>1.3 bar
>1.8-<6 bar
<85° C
average
±25° C
<55° C
>7.5-<9 bar
PDAH 21-22
Normal Value at Full load
at ISO conditions
TI 20 TI 20
TI 22 TI 22
PI 22
PI 22
PDAH 21-22
PI 23
TE 29
PI 40 PI 40
PI 50 TI 51
PI 01
PI 10
TI 10
TI 11
TI 62
TI 60
TI 61
PI 31 TI 31
PI 70
60-75° C 65-82° C
45-65° C 50-72° C
3.5-4 bar
4-5 bar
0.5-1 bar
1.5 ±0.2 bar
75-85° C
2.5-5 bar
5-16 bar (A)
2-3 bar
80-90° C
1-2.5 bar (D)
1.5-4.6 bar
60-75° C
70-85° C
max. 10° C
425-475° C
270-380° C
275-350° C
2-2.5 bar 35-55° C
7-9 bar
Alarm Set point Autostop of engine
TAH 20 TAH 20
TAH 22 TAH 22
PAL 22
PAL 22
LAL 25
LAL 28/ LAH 28
TAH 29
PAL 40 PAL 40
LAH 42
PAL 50
PAL 01
PAL 10
TAH 12
TAH 12-2
TAH 62
TAH 62-2
TAH 60 TAD 60
TAH 61
TAH 31
PAL 70
90° C
100° C
75° C 85° C
3 bar
3.5 bar
1.5 bar
level switch
low/high level
95° C
1.5 bar 4 bar
leakage
1.5 bar (B) 95° C (B)
0.4 bar + (C)
0.4 bar + (C)
90° C 93° C
550° C 600° C 410° C
average (F)
±50° C
500° C
65° C
7 bar
TSH 22 TSH 22
PSL 22
PSL 22
TSH 12
600.30
Edition 50H
L28/32H
85° C 95° C
2.5 bar
3.0 bar
95° C
Specific plants will not comprise alarm equipment and autostop for all parameters listed above. For specific plants additional parameters can be included. For remarks to some parameters, see overleaf.
10° C change in ambient temperature correspond to approx. 15° C exhaust gas temperature change
11.33 - ES1
MAN Diesel & Turbo
600.30
Edition 50H
L28/32H
Normal Value at Full load
Speed Control System
Engine speed GenSets for 60 Hz Mechanical Elec. GenSets for 50 Hz Mechanical Elec.
Turbocharger speed
Remarks to individual Parameters
A. Fuel Oil Pressure, HFO-operation.
SI 90
SI 90
SI 89
Operation Data & Set Points
Acceptable
at ISO conditions
720 rpm
750 rpm
(G)
value at shop
test or after
repair
820 rpm
855 rpm
E. Limits for Turbocharger Overspeed Alarm (SAH 89)
Alarm Set point Autostop of engine
SAH 81
SAH 81
SAH 89
815 rpm
850 rpm
(E)
SSH 81 SSH 81
SSH 81 SSH 81
Descriptoin
Page 2 (2)
825 rpm 815 rpm
860 rpm 850 rpm
When operating on HFO, the system pressure must be sufficient to depress any tendency to gasification of the hot fuel.
The system pressure has to be adjusted according to the fuel oil preheating temperature.
B. Nozzle Cooling Oil System
The nozzle cooling oil system is only applied for Tier II marine and stationary engines.
C. Cooling Water Pressure, Alarm Set Points.
As the system pressure in case of pump failure will depend on the height of the expansion tank above the engine, the alarm set point has to be adjusted to 0.4 bar plus the static pressure.
D. Press. LT -system, inlet engine (PI 01)
With two-string cooling water system the normal value can be higher, max. 4.0 bar.
Engine type 720 rpm 750 rpm 5L28/32H 42,680 42,680 6L28/32H 42,680 42,680 7L28/32H 34,900 34,900 8L28/32H 34,900 34,900 9L28/32H 36,180 36,180
F. Exhaust Gas Temperatures
The exhaust gas temperature deviation alarm is normally ±50° C with a delay of 1 min., but at start-up the delay is 5 min. Furthermore the deviation limit is ±100° C if the average temperature is below 200° C.
G. Turbocharger Speed
Normal value at full load of the turbocharger is de­pendent on engine type (cyl. no) and engine rpm. The value given is just a guide line. Actual values can be found in the acceptance test protocol.
11.33 - ES1
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