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01 - Engine Doc - P-28049 - L2738-P - EN
01 - Engine Doc - P-28049 - L2738-P - EN
Preface
Preface
What does this book contain?
This instruction manual provides general guidance regarding operation and
maintenance of the engine. It is also to be used as reference when ordering
spare parts.
The manual is divided into a number of chapters that correspond to the main
components/units in the engine.
Each chapter consists of four main elements:
▪ Descriptions (explanatory text concerning design features, functionality
and operation)
▪ Work cards (specifications on how to perform different maintenance jobs)
▪ Data sheets (cooling system, lubrication system etc.)
▪ Spare part plates (spare part illustrations and additional lists)
Reliable and safe operation of the engine is dependent on correct operation
and maintenance. It is therefore important that the engine personnel is fully
acquainted with the contents of this book.
The equipment is delivered including a warranty clause which has been con-
tractually agreed upon.
It is, of course, a precondition for the validity of such a warranty that the
equipment is operated in accordance with agreed requirements and recom-
mendations.
Spare parts must be original spare parts purchased directly from MAN Diesel
& Turbo or from one of MAN Diesel & Turbo’s authorized workshops or
agents.
2016-05-25 - en
Description
D100-01
- 1 (4)
L27/38;
D100-01 MAN Diesel & Turbo
Preface
Plate no A BBCC–DD
A: A = 1 for engine
BBCC: BB = chapter (main function)
CC = subfunction
DD: version
5. Item no (ex. 7)
D100-01
2 (4) -
L27/38;
MAN Diesel & Turbo D100-01
Preface
MAN Diesel & Turbo | PrimeServ
The MAN Diesel & Turbo Group offers worldwide round-the-clock service,
365 days a year. Apart from the MAN Diesel & Turbo service headquarters in
Augsburg, Copenhagen, Frederikshavn, Holeby, Stockport, St. Nazaire, Tur-
bocharger and service centres on all continents provide comprehensive and
continuous support. The long service life associated with MAN Diesel &
Turbo products dictates a spare parts programme that ensures components
are available for products in operation for decades. Based on high-capacity
machines, MAN Diesel & Turbo service production facilities are able to com-
ply with special customer requests with the utmost precision and flexibility.
24-hour hotline number:
+49 1801 15 15 15
http://www.mandieselturbo.com/primeserv
2016-05-25 - en
Description
D100-01
- 3 (4)
L27/38;
D100-01 MAN Diesel & Turbo
Preface
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 regula-
tions.
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 emis-
sions related maintenance of the diesel engine shall be performed as speci-
fied in MAN Diesel & Turbo instructions including, but not limited to, the
instructions to that effect included in the Technical File.
2016-05-25 - en
Description
D100-01
4 (4) -
L27/38;
MAN Diesel & Turbo Questionnaire – Technical Documentation
Comprehensibility of contents
Comments/suggestions:
1 (1)
MAN Diesel & Turbo
Data
Description Main Data .................................................................... D100A1-02
General safety precautions ........................................... D100B1-02
List of capacities, HFO/MDO/MGO operation ............... D100C2-04
Maintenance program HFO operation .......................... D100D2-02
Maintenance program - HFO operation ........................ D100E2-01
Operating data and set points ...................................... D100F1-02
“Green passport” ......................................................... D100G1-01
Weights of main components ....................................... D100H1-02
Tightening specification ................................................ D100J1-01
Data for pressure and tolerance ................................... D100J2-05
List of Symbols ............................................................ D100N1-01
Specification of lubricating oil (SAE 40) for heavy fuel
operation (HFO) ............................................................ D010.000.023-11-0001
Specification of heavy fuel oil (HFO) .............................. D010.000.023-05-0001
Viscosity-temperature diagram (VT diagram) ................ D010.000.023-06-0001
Specification of engine coolant ..................................... D010.000.023-13-0001
Specification of water for fuel-water emulsions ............. D010.000.023-16-0001
Specifications of intake air (combustion air) .................. D010.000.023-17-0001
Specification of compressed air ................................... D010.000.023-21-0001
Work Card Coolant ........................................................................ M010.000.002-03-0001
Coolant system ............................................................ M010.000.002-04-0001
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D100A1-02
Main Data
Main Data
Main data for engine
The main particulars are carefully selected in order to
reach the optimal compromise between low operational
costs and reliability, - and fulfilling future legal emission
limit values.
Cylinder numbers 6-7-8-9
Power range 2040-3060 kW
Engine speed 800 rpm
Bore 270 mm
Stroke 380 mm
Swept volume/cylinder 21.8 l
Stroke/bore ratio 1,4 : 1
Bmep 23.4/25.2 bar
Mean piston speed 10,1 m/s
Compression ration 15.9: 1
Max. combustion press. 190/200 bar
Turbocharger principle Constant pressure Figure 1: Cross section of
Fuel quality according to HFO (up to 700 cSt/50° C, engine
RMK700)
MDO (DMB) - MGO (DMA,
DMZ)
according ISO8217-2010
Ignition sequence
Clockwise rotating engines (seen from aft end):
6 cyl: 1-2-4-6-5-3
7 cyl: 1-2-4-6-7-5-3
8 cyl: 1-2-4-6-8-7-5-3
9 cyl: 1-2-4-6-8-9-7-5-3
Counter clockwise rotating engines (seen from aft end):
6 cyl: 1-3-5-6-4-2
7 cyl: 1-3-5-7-6-4-2
8 cyl: 1-3-5-7-8-6-4-2
9 cyl: 1-3-5-7-9-8-6-4-2
2013-06-19 - en
Description
D100A1-02
- 1 (1)
L27/38;
MAN Diesel & Turbo D100B1-02
Signs / Nameplates
Signs and nameplates mounted on the engine are not to be removed, pain-
ted over, or in any other way be made unreadable. This includes safety signs,
signs with serial numbers, signs with instructions, etc.
2017-05-15 - en
Description
D100B1-02
- 1 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
General safety precautions
Special dangers
Cleanliness
The engine and engine room should be kept clean and tidy.
Oily rags must never be left around the engine room spaces as they are
highly flamable and slippery.
Remove any oil spil at once.
If there is a risk of grit or sand blowing into the engine room, stop the ventila-
tion and close the ventilating ducts, skylights and engine room doors.
Welding, or other work which causes spreading of grit and/or swarf, must
not be carried out near the engine unless it is closed or protected, and the
turbocharger air intake filters covered.
The exterior of the engine should be kept clean, and the paintwork main-
tained, so that leakages can be easily detected.
Fire
Keep the areas around the relief valves free of oil, grease, etc.
to prevent the risk of fire caused by the emitted hot air/gas in
the event that the relief valves open.
Do not weld or use naked lights in the engine room, until it has been ascer-
tained that no explosive gases, vapour or liquids are present.
If the crankcase is opened before the engine has cooled down, welding and
the use of naked flames will involve the risk of explosions and fire. The same
applies to inspection of oil tanks and of the spaces below the floor.
Attention is furthermore drawn to the danger of fire when using paint and sol-
2017-05-15 - en
vents having a low flash point. Porous insulating material, soaked with oil
Description
2 (14) -
L27/38;
MAN Diesel & Turbo D100B1-02
Spares
All spares should be protected against corrosion and mechanical damage.
The stock should be checked at intervals and replenished in good time.
Lighting
Ample working light should be permanently installed at appropriate places in
the engine room spaces, and portable working light should be obtainable
everywhere. 24v safety lamps must be available for use inside the engine.
Harmful materials
Always follow the manufactures specific instructions, i.e. the material safety
data sheet.
Use protective gloves, goggles, breathing mask and any other recommen-
ded protective gear, as stated in the material safety data sheet.
While handling harmful materials is it important to secure proper ventilation
and shielding if needed.
In the event of leaks or spillage, spread binding agents immediately and dis-
posal according to the material safety data sheet.
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.
2017-05-15 - en
Description
D100B1-02
- 3 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
General safety precautions
ing to the task trained and qualified personnel. Special attention must be
Description
4 (14) -
L27/38;
MAN Diesel & Turbo D100B1-02
Description
D100B1-02
- 5 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
▪ Working platforms/scaffolds
Description
6 (14) -
L27/38;
MAN Diesel & Turbo D100B1-02
Description
D100B1-02
- 7 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
General safety precautions
Lifting precautions
Lift of engine components needs to be planned through all steps of the lifting
procedure.
When lifting loads below 500 kg the use of a tackle is required.
Lifting attachments are to be tightened into full contact with the component
to be lifted.
Only use designated lifting points, see Instruction Manual for guidance.
Make sure the lowest Safe Working Load (SWL) of the lifting equipment in
the lifting chain is never exceeded.
Keep lifting equipment clear of sharp edges.
Make sure to attach the load correctly on the crane hook.
Always keep clear of the space below a crane with load.
Working air
Use of working air requires safety goggles and gloves.
Avoid blowing pressurised air directly at skin.
Sealing materials
Use gloves made of neopren or PVC when removing O-rings and other rub-
ber/plastic-based sealing materials which have been subjected to abnormally
high temperatures.
First aid measures: In the event of skin contact - rinse with plenty of water -
remove all contaminated clothing - consult a doctor - dispose of all material
and gloves in accordance with laws and regulations.
Hot surfaces
Beware of hot surfaces and use gloves.
Safety valve
Beware of unexpected opening of safety valves and its exhaust opening in
top of the cylinder top cover as hot liquids, gasses and flash flame will be
discharged.
Alarms
2017-05-15 - en
Description
It is important that all alarms lead to prompt investigation and remedy of the
D100B1-02
error. No alarm is insignificant. The most serious alarms are equipped with
slow-down and/or shut-down functions. It is therefore important that all
engine operation personel are familiar with and well trained in the use and
importance of the alarm system.
8 (14) -
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MAN Diesel & Turbo D100B1-02
Special notes
Health Risk!
Health Risk!
Due to vibrations during engine operation, especially in awkward
positions!
Description
D100B1-02
- 9 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
General safety precautions
Tool
Warning!
Air supply!
Warning!
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10 (14) -
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MAN Diesel & Turbo D100B1-02
Figure 2: .
Figure 3: .
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Description
D100B1-02
- 11 (14)
L27/38;
D100B1-02 MAN Diesel & Turbo
General safety precautions
Pressurized cylin-
der
Description
D100B1-02
12 (14) -
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MAN Diesel & Turbo D100B1-02
Low temperature/
freezing
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Description
D100B1-02
- 13 (14)
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D100B1-02 MAN Diesel & Turbo
General safety precautions
2017-05-15 - en
Description
D100B1-02
14 (14) -
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MAN Diesel & Turbo D100C2-04
Temperature basis
Setpoint HT cooling water engine outlet 1) °C 79°C nominal
(Range of mechanical thermostatic element 77°C to
85°C)
Setpoint LT cooling water engine outlet 2) °C 35°C nominal
(Range of mechanical thermostatic element 29°C to
41°C)
Setpoint Lube oil inlet engine °C 66°C nominal
(Range of mechanical thermostatic element 63°C to
72°C)
No of cylinders - 6 7 8 9
Engine output kW 2040 2380 2720 3060
Speed rpm 800
Heat to be dissipated 3)
Cooling water (C.W.) Cylinder kW 311 363 415 467
Charge air cooler; cooling water HT kW 640 725 804 878
Charge air cooler; cooling water LT kW 238 268 298 330
Lube oil (L.O.) cooler kW 276 322 368 413
Heat radiation engine kW 50 59 67 75
Flow rates 4)
Internal (inside engine)
- 1 (2)
L27/38;
D100C2-04 MAN Diesel & Turbo
Air data
List of capacities, HFO/MDO/MGO operation
Pumps
External pumps 8)
For MGO/MDO-operation
Diesel oil pump (3.5 bar at fuel oil inlet B3) m3/h 1.44 1.68 1.92 2.16
For HFO-operation
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.70 0.81 0.93 1.04
Fuel oil circulating pump (8 bar at fuel oil inlet B3) m /h3
1.46 1.70 1.95 2.19
Lube oil pump (4.5 bar) m3/h 60 60 75 75
LT cooling water pump (2.5 bar) m3/h 62 62 62 62
HT cooling water pump (2.5 bar m /h3
62 62 62 62
1. HT cooling water flow first through HT stage charge air cooler, then through water jacket and cylinder
head, water temperature outlet engine regulated by mechanical thermostat.
2. LT cooling water flow first through LT stage charge air cooler, then through lube oil cooler, water tempera-
ture outlet engine regulated by mechanical thermostat.
3. Tolerance: + 10% for rating coolers, - 15% for heat recovery.
4. Basic values for layout of the coolers.
5. Under above mentioned reference conditions.
6. Tolerance: quantity +/- 5%, temperature +/- 20°C.
7. Under below mentioned temperature at turbine outlet and pressure according above mentioned reference
2013-03-20 - en
conditions.
Description
2 (2) -
L27/38;
MAN Diesel & Turbo D100D2-02
Description
D100D2-02
- 1 (2)
L27/38;
Description Maintenance program HFO operation
2 (2)
D100D2-02 D100D2-02
-
L27/38;
MAN Diesel & Turbo
2012-06-15 - en
MAN Diesel & Turbo D100E2-01
Description
D100E2-01
- 1 (2)
L27/38;
Description Maintenance program - HFO operation
2 (2)
D100E2-01 D100E2-01
-
L27/38;
MAN Diesel & Turbo
2015-07-14 - en
MAN Diesel & Turbo D100F1-02
SaCoSone - 1 (4)
L27/38;
D100F1-02 MAN Diesel & Turbo
the expansion tank above the engine, the alarm set point has to be adjusted
to 0.4 bar plus the static pressure. The static pressure set point can be
Description
2 (4) SaCoSone -
L27/38;
MAN Diesel & Turbo D100F1-02
F. Start interlock
The following signals are used for start interlock/blocking:
1. Turning must not be engaged
2. Engine must not be running
3. "Remote" must be activated
4. No shutdowns must be activated.
5. The prelub. oil pressure must be OK, 20 min. after stop.
6. "Stop" signal must not be activated
G. Start failure
If remote start is activated and the engine is in blocking or local mode or
turning is engaged the alarm time delay is 2 sec.
Start failure will be activated if revolutions are below 50 rpm within 5 sec.
from start or revolutions are below 210 rpm 10 sec. from start.
Start failure alarm will automatically be released after 30 sec. of activation.
H. Alarm hysterese
On all alarm points (except prelub. oil pressure) a hysterese of 0.5% of full
scale are present. On prelub. oil pressure alarm the hysterese is 0.2%.
2017-10-13 - en
Description
The engine run signal is activated when engine rpm >780 lube oil pressure
>3.0 bar or TC rpm >5000 rpm.
If engine rpm is above 210 rpm but below 780 rpm within 30 sec. the engine
run signal will be activated.
SaCoSone - 3 (4)
L27/38;
D100F1-02 MAN Diesel & Turbo
Operating data and set points
L. 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 or name plate on turbocharger.
2017-10-13 - en
Description
D100F1-02
4 (4) SaCoSone -
L27/38;
MAN Diesel & Turbo D100G1-01
“Green passport”
“Green passport”
"Green passport"
In 2009 IMO adopted the „Hong Kong International Convention for the Safe
and Environmentally Sound Recycling of Ships, 2009“
Until this convention enters into force the recommendatory guidelines “Reso-
lution A.962(23)” (adopted 2003) apply. This resolution has been implemen-
ted by some classification societies as “Green Passport”.
MAN Diesel & Turbo is able to provide a list of hazardous materials comply-
ing with the requirements of the IMO Convention. This list is accepted by
classification societies as a material declaration for “Green Passport”.
This material declaration can be provided on request.
2012-06-19 - en
Description
D100G1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D100H1-02
Description
D100H1-02
- 1 (1)
L27/38;
MAN Diesel & Turbo D100J1-01
Tightening specification
Tightening specification
Fuel injection system
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Lance for fuel injection valve Threa- M18x1.5 75 Molykote 20 103
ded paste-D
piece
95 Oil
H.P. fuel injection pipe Union M26x1.5 50 Molykote 20 103
nut paste-D
65 Oil
Fuel valve mounting stud Stud M16 30 Loctite 20 103
243
Fuel valve mounting nut Hexagon M16 8.8 In 2 Molykote 20 103
nut steps paste-D
25-115
Fuel atomizer nozzle clamp- Union M36x1.5 270 Molykote 20 103
ing nut paste-D
Fuel injection pump mount- Stud M16 10.9 25 Molykore 20 101
ing paste-D
30 Oil
Fuel injection pump mount- Collar M16 10.9 190 Molykote 20 101
ing nut paste-D
Fuel injection pump delivery Screw M12 12.9 In 3 Molykore 20 101
valve/barrel steps paste-D
25-50-75
see work
card
Fuel injection pump barrel/ Screw M14 10.9 90 Molykote 20 102
housing paste-D
110 Oil
Cylinder head
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Cylinder unit/engine frame Tierod M39x2 By hand Oil O-ring/ 16 114
silicone
oil
Cylinder unit/engine frame Nut M39x2 1200* Oil 16 114
2012-06-19 - en
- 1 (5)
L27/38;
D100J1-01 MAN Diesel & Turbo
Tightening specification
Connecting rod
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Con. rod stem/marine head Stud M27x2 By hand Oil 16 110
Piston
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Piston crown/skirt Stud M16x1.5 See work Molykote 16 108
card paste-D
Piston crown/skirt Collar M14x1.5 See work Molykote 16 108
nut card paste-D
Exhaust system
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
V-clamp cylinder head/ Hexagon M16 80 Copas- 16 114
exhaust screw/- lip-paste
nut
Exhaust manifold section/ Hexagon M16 80 Copas- 16 114
bellow compensator screw/- lip-paste
nut
Exhaust manifold/end cover Hexagon M16 80 Copas- 16 114
screw/- lip-paste
nut
T/C intermediate flange/ Stud/ M16 80 Copas- 16 114
bellow compensator hexagon lip-paste
nut
nut
Engine frame/main bearing Nut M39x2 1200* Oil 10 101
cap
2 (5) -
L27/38;
MAN Diesel & Turbo D100J1-01
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
Tightening specification
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Main bearing cap/side Tierod M30x2 By hand Oil 10 101
bracing
Main bearing cap/side Nut M30x2 1200* Oil 10 101
bracing
Crankshaft
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Crankshaft counter weight Tierod M30x2 130 Oil
Turning gear
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Pinion/shaft Hexagon M20x1.5 260 Molykote
nut paste-
D/oil
Camshaft drive
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Camshaft intermediate gear Tierod M39x2 By hand Oil 14 101
wheel drive 14 103
2012-06-19 - en
14 103
D100J1-01
- 3 (5)
L27/38;
D100J1-01 MAN Diesel & Turbo
Tightening specification
Valve camshaft
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Camshaft section/bearing Hexagon M16 10.9 250 Oil 14 101
journal screw 14 102
4 (5) -
L27/38;
MAN Diesel & Turbo D100J1-01
Tightening specification
LT-cooling control valve
Subject Threaded Thread Property Hydraulic Tighten- Lubricat- Locking Work card
part dimension class pressure ing torque ing type sealing
(bar) (Nm)
Control piston/rod Hexagon M24 8.8 200 Loctite
screw 243
Valve slider/rod Hexagon M20 8.8 200 Loctite
nut 243
Description
D100J1-01
- 5 (5)
L27/38;
MAN Diesel & Turbo D100J2-05
Minimum height of valve head, inlet valve and exhaust valve, "H"1 9.0 mm
Piston and piston ring grooves (see working card 16 108-02)
Maximum clearance between connecting rod bush and piston pin 0.29 mm
Maximum ovalness in big-end bore (without bearing) 0.08 mm
Maximum inside diameter cylinder liner, maximum ovalness 0.1 mm Ø 270.2 mm
Sealing minimum height above the cylinder liner 0.2 mm
2013-04-15 - en
Description
D100J2-05
- 1 (2)
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D100J2-05 MAN Diesel & Turbo
1 20 Combustion pressure range at full load (Measured at indicator cock) 189 - 210 bar
(Depending on rating/ambient condition)
Combustion pressure range at full load (Inside combustion chamber) 185 - 200 bar
Individual cylinders; admissible deviation from average ± 5 bar
Fuel valve, adjusment of opening pressure 400 - 410 bar
(when new spring) (420 bar)
Clearance (A) of plunger between thrust plate and plunger base plate / fuel injection 0.07-0.11 mm
pump
Clearance (B) from roller to mounting surface 160±0.18 mm
Clearance (C) axial and radial clearance of roller on fuelinjection pump 0.4 - 0.7 mm
2013-04-15 - en
Description
D100J2-05
2 (2) -
L27/38;
MAN Diesel & Turbo D100N1-01
List of Symbols
List of Symbols
General
No Symbol Symbol designation No Symbol Symbol designation
1. GENERAL CONVENTIONAL SYMBOLS 2.13 Blank flange
- 1 (11)
L27/38;
D100N1-01 MAN Diesel & Turbo
3.28 Cock, straight through, with bot- 4.10 Manual (at pneumatic valves)
tom conn.
3.29 Cock, angle, with bottom connec- 4.11 Push button
tion
3.30 Cock, three-way, with bottom 4.12 Spring
connection
3.31 Thermostatic valve 4.13 Solenoid
3.32 Valve with test flange 4.14 Solenoid and pilot directional valve
closed
Description
closed
2 (11) -
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MAN Diesel & Turbo D100N1-01
List of Symbols
5.3 Magnetic filter 6. FITTINGS
5.17 Water trap with manual control 7.4 Distance level indicator
5.19 Silencer
Description
D100N1-01
- 3 (11)
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D100N1-01 MAN Diesel & Turbo
List of Symbols
List of Symbols
General
Pipe dimensions and piping signature
Pipe dimenesions
A : Welded or seamless steel pipes. B : Seamless precision steel pipes or Cu-pipes.
Normal Outside Wall Stated: Outside diameter and wall thickness i.e. 18 x 2
Diameter Diameter Thickness Piping
DN mm mm
: Built-on engine/Gearbox
: Yard supply
Items connected by thick lines are built-on engine/ gearbox.
15 21.3 In accordance
20 26.9 with classifica-
25 33.7 tion or other
32 42.4 rules
40 48.3
50 60.3
65 76.1
80 88.9
90 101.6
100 114.3
125 139.7
150 168.3
175 193.7
200 219.1
2018-01-11 - en
Description
D100N1-01
4 (11) -
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General
List of Symbols
Pump, general DIN 2481 Ballcock
Centrifugal pump with electric DIN 2481 Double-non-return valve DIN 74.253
motor
Gear pump DIN 2481 Spectacle flange DIN 2481
Screw pump with electric DIN 2481 Spectacle flange, closed DIN 2481
motor
Description
D100N1-01
- 5 (11)
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D100N1-01 MAN Diesel & Turbo
General
List of Symbols
6 (11) -
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MAN Diesel & Turbo D100N1-01
General
List of Symbols
Specification of ID-no code for measuring signals/devices
Where dublicated measurements are carried out, i.e. multiple similar devices are measuring the same parameter, the
ID specification is followed by a letter (A, B, ...etc.), in order to be able to separate the signals from each other.
2018-01-11 - en
Description
D100N1-01
- 7 (11)
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D100N1-01 MAN Diesel & Turbo
List of Symbols
2229 Mass
Basic Symbol
Valves 584 585 593 588 592 590 591 604 605 579
8 (11) -
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MAN Diesel & Turbo D100N1-01
I - bored
List of Symbols
L - bored
T - bored
2229 Mass
Basic Symbol
Valves 594 595 586 587 599 600 601 602 607 608 606
Description
D100N1-01
- 9 (11)
L27/38;
D100N1-01 MAN Diesel & Turbo
6.25 Air venting to the outside 771 Tank with conical ends
10 (11) -
L27/38;
MAN Diesel & Turbo D100N1-01
List of Symbols
Chimney Pumps
838 Chimney 708 Centrifugal pump
Description
D100N1-01
- 11 (11)
L27/38;
MAN Diesel & Turbo D010.000.023-11-0001
Specification of lubricating oil (SAE 40) for heavy fuel operation (HFO)
Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the limit values in the table below, particularly
in terms of its resistance to ageing:
Properties/Characteristics Unit Test method Limit value
Make-up – – Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 –15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of heating – MAN Diesel & –
up to 135 °C Turbo ageing
oven1)
Insoluble n-heptane Weight % ASTM D 4055 < 0.2
or DIN 51592
Evaporation loss Weight % - <2
Spot test (filter paper) – MAN Diesel & Precipitation of resins or
Operating Instruction
Additives The additives must be dissolved in oil and their composition must ensure that
as little ash as possible is left over after combustion, even if the engine is pro-
visionally operated with distillate fuel.
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D010.000.023-11-0001 MAN Diesel & Turbo
The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
Specification of lubricating oil (SAE 40) for heavy fuel operation
(HFO)
20 Marine diesel oil (MDO) of a lower quality and high sulphur content or heavy fuel oil with a sulphur
content of less than 0.5 %.
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30 generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
51/60DF for exclusively HFO operation only with a sulphur content < 1.5 %.
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MAN Diesel & Turbo D010.000.023-11-0001
Selection of lubricating oils/ Most of the oil manufacturers are in close regular contact with engine manu-
warranty facturers, and can therefore provide information on which oil in their specific
product range has been approved by the engine manufacturer for the partic-
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D010.000.023-11-0001 MAN Diesel & Turbo
Oil during operation There are no prescribed oil change intervals for MAN Diesel & Turbo medium
Specification of lubricating oil (SAE 40) for heavy fuel operation
(HFO)
speed engines. The oil properties must be analysed monthly. As long as the
oil properties are within the defined threshold values, the oil may be further
used. See table Limit values for used lubricating oil.
The quality of the oil can only be maintained if it is cleaned using suitable
equipment (e.g. a separator or filter).
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used
lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.
Limit value Procedure
Viscosity at 40 °C 110 – 220 mm²/s ISO 3104 or ASTM D 445
Base number (BN) at least 50 % of fresh oil ISO 3771
Flash point (PM) At least 185 °C ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat- –
ing conditions
Guide value only
Fe max. 50 ppm
Cr max. 10 ppm –
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Operating Instruction
Tests
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A monthly analysis of lube oil samples is mandatory for safe engine opera-
tion. We can analyse fuel for customers in the MAN Diesel & Turbo Prime-
ServLab.
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MAN Diesel & Turbo D010.000.023-11-0001
General
- 5 (5)
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MAN Diesel & Turbo D010.000.023-05-0001
specification. This particularly applies to the oil property that causes forma-
tion of deposits in the combustion chamber, injection system, gas ducts and
exhaust gas system. A number of fuels have a tendency towards incompati-
bility with lubricating oil which leads to deposits being formed in the fuel
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delivery pump that can block the pumps. It may therefore be necessary to
exclude specific fuels that could cause problems.
Blends The addition of engine oils (old lubricating oil, ULO – used lubricating oil) and
General
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
ple), and residual products of chemical or other processes such as solvents
(polymers or chemical waste) is not permitted. Some of the reasons for this
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D010.000.023-05-0001 MAN Diesel & Turbo
characteristics, poor compatibility with mineral oils and, last but not least,
adverse effects on the environment. The order for the fuel must expressly
state what is not permitted as the fuel specifications that generally apply do
not include this limitation.
If engine oils (old lubricating oil, ULO – used lubricating oil) are added to fuel,
this poses a particular danger as the additives in the lubricating oil act as
emulsifiers that cause dirt, water and catfines to be transported as fine sus-
pension. They therefore prevent the necessary cleaning of the fuel. In our
experience (and this has also been the experience of other manufacturers),
this can severely damage the engine and turbocharger components.
The addition of chemical waste products (solvents, for example) to the fuel is
prohibited for environmental protection reasons according to the resolution
of the IMO Marine Environment Protection Committee passed on 1st January
1992.
Leak oil collector Leak oil collectors that act as receptacles for leak oil, and also return and
overflow pipes in the lube oil system, must not be connected to the fuel tank.
Leak oil lines should be emptied into sludge tanks.
Viscosity (at 50 °C) mm2/s (cSt) max. 700 Viscosity/injection viscosity
Viscosity (at 100 °C) max. 55 Viscosity/injection viscosity
Density (at 15 °C) g/ml max. 1.010 Heavy fuel oil preparation
Flash point °C min. 60 Flash point
(ASTM D 93)
Pour point (summer) max. 30 Low-temperature behaviour
(ASTM D 97)
Pour point (winter) max. 30 Low-temperature behaviour
(ASTM D 97)
Coke residue (Conrad- weight % max. 20 Combustion properties
son)
Sulphur content 5 or Sulphuric acid corrosion
legal requirements
Ash content 0.15 Heavy fuel oil preparation
Vanadium content mg/kg 450 Heavy fuel oil preparation
Water content Vol. % 0.5 Heavy fuel oil preparation
Sediment (potential) weight % 0.1 –
Aluminium and silicon mg/kg max. 60 Heavy fuel oil preparation
content (total)
Acid number mg KOH/g 2.5 –
Hydrogen sulphide mg/kg 2 –
Operating Instruction
Used lube oil (ULO) mg/kg Calcium max. 30 mg/kg The fuel must be free of lube
(calcium, zinc, phos- Zinc max. 15 mg/kg oil (ULO – used lube oil). A fuel
is considered contaminated
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15 ppm.
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MAN Diesel & Turbo D010.000.023-05-0001
Asphalt content weight % 2/3 of coke residue (acc. to Combustion properties This
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- 3 (11)
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D010.000.023-05-0001 MAN Diesel & Turbo
istic method
RM RMB RMD RME RMG RMK
A
10a 30 80 180 180 380 500 700 380 500 700
Pour point
(upper)e
Winter °C Max. 0 0 30 30 30 30 ISO 3016
quality
Summer °C Max. 6 6 30 30 30 30 ISO 3016
quality
Water % Max. 0.3 0.50 0.50 0.50 0.50 0.50 ISO 3733
(V/V) 0
Ash % Max. 0.0 0.07 0.07 0.07 0.100 0.150 ISO 6245
(m/m 40 0 0 0
)
Vanadium mg/k Max. 50 150 150 150 350 450 see 7.7
g IP 501, IP
470
or ISO
14597
Sodium mg/k Max. 50 100 100 50 100 100 see 7.8
g IP 501, IP
470
Aluminium mg/k Max. 25 40 40 50 60 60 see 7.9
plus silicon g IP 501, IP
470
or ISO
10478
Used lubri- – The fuel shall be free from ULO. A fuel shall be considered to contain ULO (see 7.10)
cating oils when either one of the following conditions is met: IP 501 or
(ULO):
calcium mg/k calcium > 30 and zinc > 15 IP 470
and zinc g
or or
calcium calcium > 30 and phosphorus > 15 IP 500
and phos- mg/k
phorus g
a This category is based on a previously defined distillate DMC category that was described in ISO 8217:2005,
Table 1. ISO 8217:2005 has been withdrawn.
b 1mm2/s = 1 cSt
c The purchaser shall define the maximum sulfur content in accordance with relevant statutory limitations. See 0.3
and Annex C.
d See Annex H.
Operating Instruction
e Purchasers shall ensure that this pour point is suitable for the equipment on board, especially if the ship operates
in cold climates.
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Additional information
The purpose of the following information is to show the relationship between
the quality of heavy fuel oil, heavy fuel oil processing, the engine operation
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MAN Diesel & Turbo D010.000.023-05-0001
Selection of heavy fuel oil Economical operation with heavy fuel oil within the limit values specified in
throughout a wide density range with no changeover required, and can sep-
arate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C.
Table Achievable contents of foreign matter and water (after separation)
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shows the prerequisites that must be met by the separator. These limit val-
ues are used by manufacturers as the basis for dimensioning the separator
and ensure compliance.
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Specification of heavy fuel oil (HFO)
is seawater, harmful sodium chloride and other salts dissolved in this water
will enter the engine.
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Water-containing sludge must be removed from the settling tank before the
separation process starts, and must also be removed from the service tank
at regular intervals. The tank's ventilation system must be designed in such a
way that condensate cannot flow back into the tank.
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Vanadium/Sodium If the vanadium/sodium ratio is unfavourable, the melting point of the heavy
cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt
to coke residues reaches the limit 0.66, and if the asphalt content exceeds
8%, the risk of deposits forming in the combustion chamber and injection
system is higher. These problems can also occur when using unstable heavy
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fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an
increased deposition of asphalt (see paragraph Compatibility).
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D010.000.023-05-0001 MAN Diesel & Turbo
products are used as the low viscosity ingredients of heavy fuel oils although
the ignition characteristics of these oils may also be poor. The cetane num-
ber of these compounds should be > 35. If the proportion of aromatic hydro-
carbons is high (more than 35 %), this also adversely affects the ignition
quality.
The ignition delay in heavy fuel oils with poor ignition characteristics is longer;
the combustion is also delayed which can lead to thermal overloading of the
oil film at the cylinder liner and also high cylinder pressures. The ignition delay
and accompanying increase in pressure in the cylinder are also influenced by
the end temperature and compression pressure, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
The disadvantages of using fuels with poor ignition characteristics can be
limited by preheating the charge air in partial load operation and reducing the
output for a limited period. However, a more effective solution is a high com-
pression ratio and operational adjustment of the injection system to the igni-
tion characteristics of the fuel used, as is the case with MAN Diesel & Turbo
piston engines.
The ignition quality is one of the most important properties of the fuel. This
value appears as CCAI in ISO 8217. This method is only applicable to
"straight run" residual oils. The increasing complexity of refinery processes
has the effect that the CCAI method does not correctly reflect the ignition
behaviour for all residual oils.
A testing instrument has been developed based on the constant volume
combustion method (fuel combustion analyser FCA), which is used in some
fuel testing laboratories (FCA) in conformity with IP 541.
The instrument measures the ignition delay to determine the ignition quality
of a fuel and this measurement is converted into an instrument-specific
cetane number (ECN: Estimated Cetane Number). It has been determined
that heavy fuel oils with a low ECN number cause operating problems and
may even lead to damage to the engine. An ECN >20 can be considered
acceptable.
As the liquid components of the heavy fuel oil decisively influence the ignition
quality, flow properties and combustion quality, the bunker operator is
responsible for ensuring that the quality of heavy fuel oil delivered is suitable
for the diesel engine. Also see illustration entitled Nomogram for determining
the CCAI – assigning the CCAI ranges to engine types.
Operating Instruction
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MAN Diesel & Turbo D010.000.023-05-0001
using the
following
formula:
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CCAI = D
- 141 log
log (V
+0.85) -
81
General
Figure 2: Nomogram for determining the CCAI and assigning the CCAI ranges to
engine types
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D010.000.023-05-0001 MAN Diesel & Turbo
Sulphuric acid corrosion The engine should be operated at the coolant temperatures prescribed in the
Specification of heavy fuel oil (HFO)
operating handbook for the relevant load. If the temperature of the compo-
nents that are exposed to acidic combustion products is below the acid dew
point, acid corrosion can no longer be effectively prevented, even if alkaline
lube oil is used.
The BN values specified in 010.005 Engine - Operating instructions
010.000.023-11 are sufficient, providing the quality of lubricating oil and the
engine's cooling system satisfy the requirements.
Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and
remains stable, even after the standard storage period. If different bunker oils
are mixed, this can lead to separation and the associated sludge formation in
the fuel system during which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and a large amount of resi-
due as a result of combustion.
This is due to incompatibility or instability of the oils. Therefore heavy fuel oil
as much as possible should be removed in the storage tank before bunker-
ing again to prevent incompatibility.
Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) or other
residual fuels (e.g. LSFO or ULSFO) to obtain the required quality or viscosity
of heavy fuel oil, it is extremely important that the components are compati-
ble (see section Compatibility). The compatibility of the resulting mixture must
be tested over the entire mixing range. A reduced long-term stability due to
consumption of the stability reserve can be a result. A p-value > 1.5 as per
ASTM D7060 is necessary.
Additives for heavy fuel oils MAN Diesel & Turbo SE engines can be operated economically without addi-
tives. It is up to the customer to decide whether or not the use of additives is
beneficial. The supplier of the additive must guarantee that the engine opera-
tion will not be impaired by using the product.
The use of heavy fuel oil additives during the warranty period must be avoi-
ded as a basic principle.
Additives that are currently used for diesel engines, as well as their probable
effects on the engine's operation, are summarised in the table below Addi-
tives for heavy fuel oils and their effects on the engine operation.
Precombustion additives ▪ Dispersing agents/stabilisers
▪ Emulsion breakers
▪ Biocides
Combustion additives ▪ Combustion catalysts
(fuel savings, emissions)
Post-combustion additives ▪ Ash modifiers (hot corrosion)
▪ Soot removers (exhaust-gas system)
Table 3: Additives for heavy fuel oils and their effects on the engine operation
Operating Instruction
Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul-
sulphur content phur content of heavy fuel oils does not exist. We have not identified any
problems with the low-sulphur heavy fuel oils currently available on the mar-
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ket that can be traced back to their sulphur content. This situation may
change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Diesel &
General
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MAN Diesel & Turbo D010.000.023-05-0001
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
Tests
Sampling To check whether the specification provided and/or the necessary delivery
conditions are complied with, we recommend you retain at least one sample
of every bunker oil (at least for the duration of the engine's warranty period).
To ensure that the samples taken are representative of the bunker oil, a sam-
ple should be taken from the transfer line when starting up, halfway through
the operating period and at the end of the bunker period. "Sample Tec" by
Mar-Tec in Hamburg is a suitable testing instrument which can be used to
take samples on a regular basis during bunkering.
Analysis of samples To ensure sufficient cleaning of the fuel via the separator, perform regular
functional check by sampling up- and downstream of the separator.
Analysis of HFO samples is very important for safe engine operation. We can
analyse fuel for customers at MAN Diesel & Turbo laboratory PrimeServLab.
Operating Instruction
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MAN Diesel & Turbo D010.000.023-06-0001
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- 1 (2)
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D010.000.023-06-0001 MAN Diesel & Turbo
Viscosity-temperature diagram (VT diagram)
Viscosity
The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the
engine must be at least 1.9 mm2/s. If the viscosity is too low, this may
cause seizing of the pump plunger or nozzle needle valves as a result
of insufficient lubrication.
This can be avoided by monitoring the temperature of the fuel. Although the
Operating Instruction
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MAN Diesel & Turbo D010.000.023-13-0001
Requirements
Limit values The properties of untreated coolant must correspond to the following limit
values:
Properties/Characteristic Properties Unit
Water type Distillate or fresh water, free of foreign mat- –
ter.
Total hardness max. 10 dGH1)
pH value 6.5 – 8 –
Chloride ion content max. 50 mg/l2)
Table 1: Properties of coolant that must be complied with
1 dGH (German
1)
≙ 10 mg CaO in litre of water ≙ 17.9 mg CaCO3/l
hardness)
≙ 0.357 mval/l ≙ 0.179 mmol/l
2)
1 mg/l ≙ 1 ppm
Testing equipment The MAN Diesel & Turbo water testing equipment incorporates devices that
determine the water properties directly related to the above. The manufactur-
ers of anticorrosive agents also supply user-friendly testing equipment.
Notes for cooling water check see 010.005 Engine – Work Instructions
010.000.002-03
Additional information
Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
Operating Instruction
ideally be used as the engine coolant. These waters are free of lime and
salts, which means that deposits that could interfere with the transfer of heat
to the coolant, and therefore also reduce the cooling effect, cannot form.
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However, these waters are more corrosive than normal hard water as the
thin film of lime scale that would otherwise provide temporary corrosion pro-
tection does not form on the walls. This is why distilled water must be han-
dled particularly carefully and the concentration of the additive must be regu-
General
larly checked.
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D010.000.023-13-0001 MAN Diesel & Turbo
Hardness The total hardness of the water is the combined effect of the temporary and
Specification of engine coolant
damage.
The engine may not be brought into operation without treating the
coolant.
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MAN Diesel & Turbo D010.000.023-13-0001
Chemical additives
Sodium nitrite and sodium borate based additives etc. have a proven track
record. Galvanised iron pipes or zinc sacrificial anodes must not be used in
cooling systems. This corrosion protection is not required due to the prescri-
bed coolant treatment and electrochemical potential reversal that may occur
due to the coolant temperatures which are usual in engines nowadays. If
necessary, the pipes must be deplated.
Slushing oil
This additive is an emulsifiable mineral oil with additives for corrosion protec-
tion. A thin protective film of oil forms on the walls of the cooling system. This
prevents corrosion without interfering with heat transfer, and also prevents
limescale deposits on the walls of the cooling system.
Emulsifiable corrosion protection oils have lost importance. For reasons of
environmental protection and due to occasional stability problems with emul-
sions, oil emulsions are scarcely used nowadays.
It is not permissible to use corrosion protection oils in the cooling water cir-
cuit of MAN Diesel & Turbo engines.
Antifreeze agents
If temperatures below the freezing point of water in the engine cannot be
excluded, an antifreeze agent that also prevents corrosion must be added to
Operating Instruction
in the table entitled Antifreeze agent with slushing properties (Military specifi-
cation: Federal Armed Forces Sy-7025), while observing the prescribed mini-
mum concentration. This concentration prevents freezing at temperatures
down to –22 °C and provides sufficient corrosion protection. However, the
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D010.000.023-13-0001 MAN Diesel & Turbo
Biocides
If you cannot avoid using a biocide because the coolant has been contami-
nated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific
application.
▪ The biocide must be compatible with the sealing materials used in the
coolant system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-
promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of coolant are not permitted.
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the coolant additive will be able to
General
carry out this work and, if this is not possible, will at least be able to provide
suitable products to do this. If this work is carried out by the engine operator,
he should use the services of a specialist supplier of cleaning agents. The
cooling system must be flushed thoroughly after cleaning. Once this has
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MAN Diesel & Turbo D010.000.023-13-0001
been done, the engine coolant must be immediately treated with anticorro-
Subsequent checks of the coolant are especially required if the coolant had
to be drained off in order to carry out repairs or maintenance.
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Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to
health or the environment if incorrectly used. Comply with the directions in
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D010.000.023-13-0001 MAN Diesel & Turbo
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
Specification of engine coolant
use. If larger quantities spray and/or soak into clothing, remove and wash
clothing before wearing it again.
If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.
Auxiliary engines
If the coolant system used in a MAN Diesel & Turbo two-stroke main engine
is used in a marine engine of type 16/24, 21/ 31, 23/30H, 27/38 or 28/32H,
the coolant recommendations for the main engine must be observed.
Analysis
The MAN Diesel & Turbo can analyse antifreeze agent for their customers in
the chemical laboratory PrimeServLab. A 0.5 l sample is required for the test.
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Operating Instruction
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MAN Diesel & Turbo D010.000.023-16-0001
Specifications
Limit values The characteristic values of the water used must be within the following limit
values:
Properties/ Characteristic value Unit
Characteristic
Water type Distillate or fresh water, free of foreign matter. -
Total hardness max. 10 ºdH*
pH value 6.5 - 8 -
Chloride ion content max. 50 mg/l
Table 1: Fuel-water emulsion - characteristic values to be observed
Testing instruments The MAN Diesel water testing kit contains instruments that allow the water
characteristics referred to above (and others) to be easily determined.
Additional information
Distillate If distillate (e.g. from the fresh water generator) or fully desalinated water (ion
exchanger) is available, this should ideally be used for the fuel-water emul-
sion. These types of water are free of lime and salts.
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. It is largely determined by the calcium and magnesium
salts. The temporary hardness depends on the hydrocarbonate content in
the calcium and magnesium salts. The lasting (permanent) hardness is deter-
mined by the remaining calcium and magnesium salts (sulphates).
Water with hardness greater than 10°dH (German total hardness) must be
blended or softened with distillate. It is not necessary to increase the hard-
ness of extremely soft water.
Operating Instruction
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MAN Diesel & Turbo D010.000.023-17-0001
Requirements
Liquid fuel engines: As minimum, inlet air (combustion air) must be cleaned
by a G3 class filter as per EN779, if the combustion air is drawn in from
inside (e.g. from the machine room/engine room). If the combustion air is
drawn in from outside, in the environment with a risk of higher inlet air con-
tamination (e.g. due to sand storms, due to loading and unloading grain
cargo vessels or in the surroundings of cement plants), additional measures
must be taken. This includes the use of pre-separators, pulse filter systems
and a higher grade of filter efficiency class at least up to M5 according to EN
779.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air)
must be cleaned by a G3 class filter as per EN779, if the combustion air is
drawn in from inside (e.g. from machine room/engine room). Gas engines or
dual-fuel engines must be equipped with a dry filter. Oil bath filters are not
permitted because they enrich the inlet air with oil mist. This is not permissi-
ble for gas operated engines because this may result in engine knocking. If
the combustion air is drawn in from outside, in the environment with a risk of
higher inlet air contamination (e.g. due to sand storms, due to loading and
unloading grain cargo vessels or in the surroundings of cement plants) addi-
tional measures must be taken. This includes the use of pre-separators,
pulse filter systems and a higher grade of filter efficiency class at least up to
M5 according to EN 779.
In general, the following applies:
Operating Instruction
The inlet air path from air filter to engine shall be designed and implemented
airtight so that no false air may be drawn in from the outdoor.
The concentration downstream of the air filter and/or upstream of the turbo-
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Table 1: Typical values for intake air (combustion air) that must be complied with
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MAN Diesel & Turbo D010.000.023-21-0001
Requirements
Compressed air quality of The starting air must fulfil at least the following quality requirements accord-
starting air system ing to ISO 8573-1:2010.
Purity regarding solid particles Quality class 6
Particle size > 40µm max. concentration < 5 mg/m3
Purity regarding moisture Quality class 7
Residual water content < 0.5 g/m3
Purity regarding oil Quality class X
For catalysts
The following specifications are valid unless otherwise defined by any other
relevant sources:
Compressed air quality for Compressed air for soot blowing must meet at least the following quality
Operating Instruction
Compressed air quality for Compressed air for atomisation of the reducing agent must fulfil at least the
General
- 1 (2)
General;
D010.000.023-21-0001 MAN Diesel & Turbo
Clogging of catalysts
To prevent clogging of catalysts and catalyst lifetime shortening, the
compressed air specification must always be observed.
2016-10-27 - de
General
2 (2) -
General;
MAN Diesel & Turbo M010.000.002-03-0001
Coolant
Coolant
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the coolant circuits must satisfy the specifications.
The coolant in the system must be checked regularly in accordance with the
maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the anticorrosive agent con-
centration.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Diesel & Turbo water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Diesel & Turbo or
Mar-Tec Marine, Hamburg).
Equipment for testing the When using chemical additives:
concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.
Work Card
- 1 (2)
General;
M010.000.002-03-0001 MAN Diesel & Turbo
Coolant
2017-03-21 - de
Work Card
2 (2) -
General;
MAN Diesel & Turbo M010.000.002-04-0001
Coolant system
Coolant system
cleaning
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Coolant systems containing deposits or contamination prevent effective cool-
ing of parts. Contamination and deposits must be regularly eliminated.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The coolant system must be checked for contamination at regular intervals.
Cleaning is required if the degree of contamination is high. This work should
ideally be carried out by a specialist who can provide the right cleaning
agents for the type of deposits and materials in the cooling circuit. The clean-
ing should only be carried out by the engine operator if this cannot be done
by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of anticorrosive agents can be removed by flushing the system
with fresh water to which some cleaning agent has been added. Suitable
cleaning agents are listed alphabetically in the table entitled Cleaning agents
for removing oil sludge. Products by other manufacturers can be used pro-
viding they have similar properties. The manufacturer's instructions for use
must be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 – 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 – 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C
Multi Cleaner
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the con-
centration of the anticorrosive agent is too low. A thin lime scale layer can be
left on the surface as experience has shown that this protects against corro-
sion. However, limescale deposits with a thickness of more than 0.5 mm
obstruct the transfer of heat and cause thermal overloading of the compo-
nents being cooled.
M010.000.002-04-0001
Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
the elements that are responsible for water hardness, this forms what is
2016-09-08 - de
known as ferrous sludge which tends to gather in areas where the flow
Work Card
velocity is low.
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
Cleaning agents for removing limescale and rust deposits. Products by other
manufacturers can be used providing they have similar properties. The man-
- 1 (3)
General;
M010.000.002-04-0001 MAN Diesel & Turbo
check whether the cleaning agent is suitable for the materials to be cleaned.
The products listed in the table entitled Cleaning agents for removing lime-
scale and rust deposits are also suitable for stainless steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew SAF-Acid 5 – 10 % 4 h at 60 – 70 °C
Descale-IT 5 – 10 % 4 h at 60 – 70 °C
Ferroclean 10 % 4 – 24 h at 60 – 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 °C
Unitor Descalex 5 – 10 % 4 – 6 h at approx. 60 °C
Vecom Descalant F 3 – 10 % ca. 4 h at 50 – 60 °C
Table 2: Cleaning agents for removing lime scale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used
in exceptional cases if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following
during application:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulphonic acid. This
acid should be added to water in a concentration of 3 – 5 %. The tem-
perature of the solution should be 40 – 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydro-
chloric acid is used as the cleaning agent, there is always a danger that
acid will remain in the system, even when the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore rec-
ommend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dissolved
can prevent the cleaning agent from reaching boiler scale. It is therefore
absolutely necessary to circulate the water with the cleaning agent to flush
away the gas bubbles and allow them to escape. The length of the cleaning
process depends on the thickness and composition of the deposits. Values
are provided for orientation in the table entitled Cleaning agents for removing
limescale and rust deposits.
Following cleaning The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
has been prepared accordingly.
Hot engine parts may not come into contact with cold water. After
refilling the cooling system, open the venting pipes. Blocked venting
2016-09-08 - de
pipes prevent the air from escaping and may cause thermal overload
of the engine.
Work Card
2 (3) -
General;
MAN Diesel & Turbo M010.000.002-04-0001
Coolant system
From cleaning agents poisonous gases and fumes can develop, which
may cause light to severe person injuries.
• Wear protective clothing
• Provide adequate ventilation
• Do not inhale developed gases and fumes
• Observe Safety Data Sheets or Operating Instructions of the relevant
manufacturer
M010.000.002-04-0001
2016-09-08 - de
Work Card
- 3 (3)
General;
MAN Diesel & Turbo
Remarks :
measurement-no: 84
25% FAT Performance Data
09-10-2017, 12:20
engine power 25 %
engine type 7L27/38 air pressure 947 mbar
engine No. P-28049-02-11 ambient air temperature 32 °C
turbocharger type TCR20-42092 abs. humidity 18.91 g/kg
turbocharger No. 7039100 luboil spec. Mobilgard 412
attached pumps 3 fuel spec. MGO
testbed No. 3 LHV fuel oil 43,050 kJ/kg
waterbrake type Froude F63M
Power
engine power 603 kW eng.speed 800 rpm
mean eff.pressure 5.9 bar waterbrake force 7.20 kN
Fuel
fuel temp. engine inlet 28 °C
fuel press. engine inlet 3.0 bar s.f.o.c. (42700 kJ/kg, ISO) 230.5 g/kWh
fuel consumption leak consid. 139 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 3.5 scale
pump index MV 19 mm 19 19 19 19 19 19 19
Charge Air
air temp.comp.inlet 38 °C charge air press. 480 mbar
charge air temp. 30.4 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 326 °C 320 314 341 331 320 334 326
Cooling Water
cw.temp.IC LT inlet 28 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 81 82 81 82 81 80 81 82
splash oil temperature MV 76 °C °C 76 76 76 76 76 76 76
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 1,192 kW eng.speed 800 rpm
mean eff.pressure 11.7 bar waterbrake force 14.2 kN
Fuel
fuel temp. engine inlet 28 °C
fuel press. engine inlet 2.8 bar s.f.o.c. (42700 kJ/kg, ISO) 201.9 g/kWh
fuel consumption leak consid. 241 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 5.0 scale
pump index MV 25 mm 25 25 25 25 25 25 25
Charge Air
air temp.comp.inlet 40 °C charge air press. 1,220 mbar
charge air temp. 34.7 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 108 bar 106 106 106 108 108 110 110
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 360 °C 353 350 380 366 359 360 354
Cooling Water
cw.temp.IC LT inlet 29 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 83 85 84 85 84 83 84 83
splash oil temperature MV 78 °C °C 78 78 78 79 78 79 79
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 1,784 kW eng.speed 800 rpm
mean eff.pressure 17.6 bar waterbrake force 21.3 kN
Fuel
fuel temp. engine inlet 29 °C
fuel press. engine inlet 2.7 bar s.f.o.c. (42700 kJ/kg, ISO) 196.3 g/kWh
fuel consumption leak consid. 352 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 6.5 scale
pump index MV 33 mm 33 33 33 33 33 33 33
Charge Air
air temp.comp.inlet 40 °C charge air press. 2,150 mbar
charge air temp. 39.8 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 147 bar 146 144 148 148 148 148 150
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 387 °C 374 378 401 398 387 390 383
Cooling Water
cw.temp.IC LT inlet 30 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 84 87 86 87 86 86 86 84
splash oil temperature MV 81 °C °C 80 80 81 81 81 81 81
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 2,030 kW eng.speed 800 rpm
mean eff.pressure 20.0 bar waterbrake force 24.2 kN
Fuel
fuel temp. engine inlet 30 °C
fuel press. engine inlet 2.7 bar s.f.o.c. (42700 kJ/kg, ISO) 196.4 g/kWh
fuel consumption leak consid. 401 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 7.0 scale
pump index MV 36 mm 36 36 36 36 36 36 36
Charge Air
air temp.comp.inlet 42 °C charge air press. 2,535 mbar
charge air temp. 42.2 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 162 bar 160 158 162 162 164 164 166
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 407 °C 391 399 421 418 406 411 402
Cooling Water
cw.temp.IC LT inlet 32 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 85 88 87 88 87 87 87 85
splash oil temperature MV 82 °C °C 81 81 82 82 82 82 82
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 2,139 kW eng.speed 799 rpm
mean eff.pressure 21.1 bar waterbrake force 25.6 kN
Fuel
fuel temp. engine inlet 31 °C
fuel press. engine inlet 2.6 bar s.f.o.c. (42700 kJ/kg, ISO) 197.5 g/kWh
fuel consumption leak consid. 426 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 7.5 scale
pump index MV 38 mm 38 38 38 38 38 38 38
Charge Air
air temp.comp.inlet 43 °C charge air press. 2,700 mbar
charge air temp. 43.8 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 170 bar 170 168 170 170 170 170 174
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 420 °C 401 412 436 431 419 425 414
Cooling Water
cw.temp.IC LT inlet 33 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 85 89 88 89 88 87 87 85
splash oil temperature MV 82 °C °C 82 82 82 83 83 83 83
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 2,392 kW eng.speed 799 rpm
mean eff.pressure 23.6 bar waterbrake force 28.6 kN
Fuel
fuel temp. engine inlet 32 °C
fuel press. engine inlet 2.5 bar s.f.o.c. (42700 kJ/kg, ISO) 200.4 g/kWh
fuel consumption leak consid. 484 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 8.0 scale
pump index MV 41 mm 41 41 41 41 41 41 41
Charge Air
air temp.comp.inlet 44 °C charge air press. 3,010 mbar
charge air temp. 46.0 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 184 bar 184 182 182 184 184 184 186
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 452 °C 432 444 471 464 452 457 446
Cooling Water
cw.temp.IC LT inlet 34 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 85 89 88 89 88 88 88 85
splash oil temperature MV 83 °C °C 83 83 83 83 84 84 84
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 2,388 kW eng.speed 798 rpm
mean eff.pressure 23.6 bar waterbrake force 28.6 kN
Fuel
fuel temp. engine inlet 34 °C
fuel press. engine inlet 2.5 bar s.f.o.c. (42700 kJ/kg, ISO) 200.2 g/kWh
fuel consumption leak consid. 483 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 8.0 scale
pump index MV 41 mm 41 41 41 41 41 41 41
Charge Air
air temp.comp.inlet 46 °C charge air press. 3,020 mbar
charge air temp. 46.8 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 184 bar 184 182 182 184 184 184 188
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 455 °C 435 445 474 466 454 459 449
Cooling Water
cw.temp.IC LT inlet 35 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 86 90 88 90 88 88 88 85
splash oil temperature MV 84 °C °C 83 83 84 84 84 84 84
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
Power
engine power 2,622 kW eng.speed 799 rpm
mean eff.pressure 25.9 bar waterbrake force 31.4 kN
Fuel
fuel temp. engine inlet 35 °C
fuel press. engine inlet 2.3 bar s.f.o.c. (42700 kJ/kg, ISO) 204.9 g/kWh
fuel consumption leak consid. 543 kg/h
Governor
cyl. 1 2 3 4 5 6 7 8 9 10
load indicator governor 8.5 scale
pump index MV 44 mm 44 44 44 44 44 44 44
Charge Air
air temp.comp.inlet 46 °C charge air press. 3,255 mbar
charge air temp. 48.3 °C
Firing Pressure
cyl. 1 2 3 4 5 6 7 8 9 10
max. comb. press. (ind. cock) MV 194 bar 194 192 192 194 194 196 198
Exhaust Gas
cyl. 1 2 3 4 5 6 7 8 9 10
exh gas temp.cyl.outlet MV 496 °C 477 487 524 505 494 499 488
Cooling Water
cw.temp.IC LT inlet 37 °C
Bearing 01 1 2 3 4 5 6 7 8 9 10 11
No.
main bearing temperatures °C 86 90 89 90 89 89 89 86
splash oil temperature MV 85 °C °C 84 85 85 85 85 85 86
Remarks LT/HT: low/high temperature IC: intercooler TC: turbocharger MV: mean value
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Operation of engine
Description Operation ..................................................................... D102A1-03
Checks during out-of-service periods ........................... D102B1-03
Starting-up after repair ................................................. D102C1-02
Engine performance and condition ............................... D102D1-02
Condensate ................................................................. D102E1-01
Borescope inspection of cylinder liner .......................... D102F1-01
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D102A1-03
Operation
Operation
Preparations for starting
The following describes what to do before starting when the engine has been
out of service for a period of some hours.
Description
D102A1-03
- 1 (4)
L27/38;
D102A1-03 MAN Diesel & Turbo
Operation
1 Sight glass
Figure 1: Governor
Turning of engine
Description
1. Open the indicator valves and turn the engine some few revolutions,
D102A1-03
check that no liquid is flowing out from any indicator valves during the
turning. The turning can be done by activating the start button on the
operator panel and at the same time keeping fuel pump index on zero,
with a tool on the regulating shaft.
2 (4) -
L27/38;
MAN Diesel & Turbo D102A1-03
Operation
Starting
1. Start the engine by turning the start button on the operator panel until
the engine ignites.
Failure in reset of fuel limit can load to blackout during shaft alternator
operation.
Operation
The engine should not be loaded more than 50% just after start. The
increase to 100% should take place gradually over 15 to 20 minutes.
When the engine is running, the following should be checked:
1. The lubricating oil pressure must be within the stated limits and may not
fall below the stated minimum pressure.
2. The lubricating oil temperature must be kept within the stated limits
indicated on the "Operation data and set points", see Description 00F1.
3. The fuel oil pressure must be kept at the stated value.
4. The cylinder cooling water temperature must be kept within the limits
indicated on the data and set points sheet.
See also shop test report and sea trial records.
5. The exhaust gases should be free of visible smoke at all loads. For nor-
mal exhaust temperatures, see the shop test report and sea trial
records.
6. Keep the charging air pressure and temperature under control. For nor-
2012-04-17 - en
mal values, see the test report from shop and sea trial records.
Description
- 3 (4)
L27/38;
D102A1-03 MAN Diesel & Turbo
Operation
Stopping
Before stopping, it is recommended to run the engine at idle speed for 10-15
minutes.
1. The engine is stopped by turning the button on the operator panel.
2. Check that the lub oil stand-by pump is started automatically and runs
for 5 minutes.
2012-04-17 - en
Description
D102A1-03
4 (4) -
L27/38;
MAN Diesel & Turbo D102B1-03
Maintenance during In periods during standstill of the engine (not in stand-by position) it is recom-
standstill mended to start the prelubricating oil pump for minimum 20 minutes once
every week and to turn the engine during the prelubricating period by 2-3
revolutions.
Laid-up vessels During the lay-up period we recommend that our special instructions for
preservation of the engines are followed.
Propulsion engines
In case of longer runs (more than 5 minutes) with the stand-by lub. oil
pump, the lub. oil connection to the turbocharger should be closed. Do
not forget to open this connection before operation.
3. Open up all filters to check that filter elements are intact. Filter car-
tridges in the lub. oil filter are to be replaced before start, after repair, or
after excessive differential pressure. After removal, dirty elements can
be examined for particles of bearing metal at the bottom of the paper
lamella (paper elements cannot be used again).
4. Lub. oil sump: Empty the oil sump of lubricating oil and check the bot-
tom of the oil sump for fragments of babbitt from bearings. Remove the
sludge, if not done within a period of one year. Clean the sump very
thoroughly and subsequently coat with clean lubricating oil.
2015-03-16 - en
5. Automatic lub. oil filter: Remove the complete filter unit from the hous-
ing. Dismantle the end cover and candle unit. The filter candles are
Description
- 1 (4)
L27/38;
D102B1-03 MAN Diesel & Turbo
Checks during out-of-service periods
2 (4) -
L27/38;
MAN Diesel & Turbo D102B1-03
If overspeed shutdown (SSH 81) are activated, nuts and bolts have to
be retightened before the engine is started, (Nuts and bolts according
to the colomn "Check new/overhauled parts after - hours" in the
planned maintenance program).
1. Check the actuator as follows: start up the engine and run it at the syn-
chronous number of revolutions.
▪ Speed-setting: before switching-in the alternator on the switchboard
please check that the servomotor adjusts the rpm with a suitable quick-
ness after actuation of the synchronizer knob on the switchboard. The
range from - 5% to + 5% from the synchronous rpm should be tested.
▪ Adjustment speed: switch in the alternator on the switchboard and set
the load to about 40%. On reaching normal oil temperatures in actuator
and engine increase the load instantly to about 80% (by starting a major
pump or compressor). This must not cause the frequency to fall by more
than some 8%, and the engine must return to a constant no. rpm after
about 3 seconds (although this rpm will be a little lower than before
owing to the speed drop of the actuator). If the engine is operated in par-
allel with other engines, an even sharing of the load must be established
within about 3 seconds. If the actuator reacts too slowly, compensating
adjustment is effected as indicated in the actuator's instruction manual
(Compensating Adjustment).
It is a condition for this test that the engine and turbocharger are in
perfect operating condition, so that possible sources of error can be
eliminated immediately.
▪ Hunting: run the engine at synchronous rpm, and without load. Provided
that the actuator oil is warm, the regulating lever must not perform any
major periodical movements, and neither must there be any variation in
the engine speed. If that is the case, readjustment of the actuator
according to the actuator instruction manual.
2015-03-16 - en
engines this can be rectified by increasing the speed drop of the engine
D102B1-03
that is subject to the greatest load (or by reducing the setting of the other
engines).
- 3 (4)
L27/38;
D102B1-03 MAN Diesel & Turbo
The setting should normally not be increased beyond the "max" value (stated
Checks during out-of-service periods
2015-03-16 - en
Description
D102B1-03
4 (4) -
L27/38;
MAN Diesel & Turbo D102C1-02
tion in crankcase” .
Description
ance must be made for a runningin period, ie the engine load should
be increased gradually as indicated in the table below. The engine out-
put is determined on the basis of the fuel pump index and engine
speed. The turbocharger speed and charge air pressure give some
indication of the engine output.
- 1 (2)
L27/38;
D102C1-02 MAN Diesel & Turbo
Starting-up after repair
Running-in sequence
After the running–in sequence, make sure that all fuel pumps are set at the
same index and that the governor can move all fuel pumps to “zero” index.
2013-06-19 - en
Description
D102C1-02
2 (2) -
L27/38;
MAN Diesel & Turbo D102D1-02
Air cooler
Fouling of the air side of the air cooler will manifest itself as an increasing
pressure drop, lower charge air pressure and an increased exhaust/charge
air temperature level (with consequential influence on the overhaul intervals
for the exhaust valves).
An increase in charge air temperature involves a corresponding increase in
the exhaust gas temperature level by a ratio of about 1:1.5, i.e. 1°C higher
charge air temperature causes about 1.5°C higher exhaust gas temperature.
Reduction of the charge air pressure results in a corresponding reduction of
the compression pressure and max. combustion pressure.
When checking the max. pressure adjustment of the engine, it is therefore to
be ensured that the existing charge air pressure is correct.
The amount of fuel injected is equivalent to the supplied energy and is thus
Description
an expression of the load and mean effective pressure of the engine. The fuel
D102D1-02
- 1 (4)
L27/38;
D102D1-02 MAN Diesel & Turbo
Turbochargers
Fouling of the turbine side of the turbocharger will, in its first phase, manifest
itself in increasing turbocharger revolutions on account of increased gas
velocity through the narrowed nozzle ring area. In the long run, the charging
air quantity will decrease on account of the greater flow resistance through
the nozzle ring, resulting in higher wall temperatures in the combustion
chambers.
Service experience has shown that the turbine side is exposed to increased
fouling when operating on HFO.
The rate of fouling and thereby the influence on the operation of the engine is
greatest for small turbochargers where the flow openings between the guide
vanes of the nozzle ring are relatively small. Deposits occur especially on the
guide vanes of the nozzle ring and on the rotor blades. In the long run, foul-
ing will reduce the efficiency of the turbocharger and thereby also the quan-
tity of air supplied for the combustion of the engine. A reduced quantity of air
will result in higher wall temperatures in the combustion spaces of the
engine.
Detailed information and instructions regarding water washing of the turbo-
charger are given in the instruction manual.
2012-06-20 - en
Description
Fuel valves
D102D1-02
Assuming that the fuel oil is purified effectively and that the engine is well-
maintained, the operational conditions for the fuel valves and the overhaul
intervals will not normally be altered essentially when operating on HFO.
2 (4) -
L27/38;
MAN Diesel & Turbo D102D1-02
If, for any reason, the surface temperature of the fuel valve nozzle is lower
Exhaust valves
The overhaul intervals for exhaust valves is one of the key parameters when
the reliability of the entire engine is to be judged. The performance of the
exhaust valves is therefore extremely informative.
Especially under unfavourable conditions, fuel qualities with a high vanadium
and sodium content will promote burning of the valve seats. Combinations of
vanadium and sodium oxides with a corrosive effect will be formed during
combustion. This adhesive ash may, especially in the event of increased
valve tem-peratures, form deposits on the seats. An increasing sodium con-
tent will reduce the melting point and thereby the adhesive temperature of
the ash, which will involve a greater risk of deposits. This condition will be
especially unfavourable when the na/va weight ratio increases beyond 1:3.
The exhaust valve temperature depends on the actual maintenance condition
and the load of the engine.
With correct maintenance, the valve temperature is kept at a satisfactory low
level at all loads. The air supply to the engine (turbocharger/air cooler) and
the maximum pressure adjustment are key parameters in this connection.
It is important for the functioning of the valves that the valve seats are over-
hauled correctly in accordance with our instructions.
The use of rotocaps ensures a uniform distribution of temperature on the
valves.
- 3 (4)
L27/38;
D102D1-02 MAN Diesel & Turbo
Engine performance and condition
2012-06-20 - en
Description
D102D1-02
4 (4) -
L27/38;
MAN Diesel & Turbo D102E1-01
Condensate
Condensate
General
Air always holds a certain amount of water. When the air is saturated with
aqueous vapour, the humidity is said to be 100% and there is as much water
in the air as it can absorb without condensing.
The amount of water in kg/kg air can be found from the diagram. The ability
to absorb water depends on the pressure and temperature of the air.
Example
Diesel engine 2300 kW
Ambient air condition:
air temperature 35 °C
relative air humidity 90 %
Charge air temperature 50 °C
Charge air pressure 2,6 bar
Draining of condensate
The phenomenon will occur on all turbocharged engines.
There is no risk with a small amount of water, but to avoid overfilling of the air
receiver, it must be drained off.
2013-08-15 - en
The drain valve at the bottom of the air cooler housing shall therefore be kept
Description
open.
D102E1-01
- 1 (3)
L27/38;
D102E1-01 MAN Diesel & Turbo
Condensate
Example
Amount of condensate in air tank:
Volumetric capacity of tank (V) 1000 dm³
Temperature in tank (T) 40°C = 313 K
Internal pressure of tank (p) 30 bar =
31x105N/m²
(abs)
Gas constant for air (R) 287 Nm/kg K
Ambient air temperature 35°C
Relative air humidity 90%
2013-08-15 - en
Description
D102E1-01
2 (3) -
L27/38;
MAN Diesel & Turbo D102E1-01
Condensate
Figure 1: Nomogram for calculation of condensate amount
2013-08-15 - en
Description
D102E1-01
- 3 (3)
L27/38;
MAN Diesel & Turbo D102F1-01
Example
Increasing lub oil consumption may be caused by lacquer deposits on the
liner surface. As the honing marks are filled with lacquer, it will result in loss
of lub oil control.
This can normally be detected by a borescope inspection and the necessary
measures can be decided.
Scores, polished areas or water leakage may occur in one cylinder only, and
it is imperative to detect which cylinder has to be opened.
MAN Diesel will be pleased to carry out the borescope inspection.
Figure 1: Borescope
2013-06-11 - en
Description
D102F1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo M102101-02
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9002 138 Max. pressure indicator
1 9002 498 Handle for indicator valve
Data
Designation Information
Shoptest report for engine See chapter 00 Data
Starting Position
Engine running
Health Risk!
Health Risk!
Due to vibrations during engine operation, especially in awkward
positions!
2017-08-04 - en
M102101-02
Work Card
Tier II - 1 (3)
L27/38;
M102101-02 MAN Diesel & Turbo
Recording of engine performance data
Procedure
1) Run the engine at MCR load.
2) Stabilise the engine load and keep a straight course.
3) Record the performance data.
4) Compare the data with the engine builder’s shop test report.
Performance data
Engine No: Plant No: Engine Type:
Ship Ship Name: Sign:
Voyage Date: Time:
From To
Bridge Ship speed Wind Wind force О Hard О Mod О Low
knots m/s Wind direction О Head О Abeam О Follow
Ship load О Full О Half О Light
Barometer Air temp.
mbar ºC
Relative humidity Engine Speed Fuel index Propeller pitch Propeller
2017-08-04 - en
% rpm - - rpm
M102101-02
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M102101-02
Turbocharger Turbo speed AC press drop Temp aft Exh. back Exh temp aft.
Com-
ments
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo
Trouble shooting
Description Starting failures ............................................................ D106A1-01
Faults in fuel oil system ................................................ D106B1-01
Disturbances during operation ..................................... D106C1-01
Ignition in crankcase .................................................... D106D1-01
Faults in cooling water system ..................................... D106E1-01
Faults in lubricating oil cooler ....................................... D106F1-01
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D106A1-01
Starting failures
Starting failures
Air starter does not respond when activating the start switch.
Possible cause Troubleshooting
Empty air recievers. Charge air recievers.
Valve closed. Open air valves.
Solenoid valve on air starter does not Check electrical connections.
receive 24 volt.
Emergency stop activated. De-activate emergency stop.
Turning gear engaged. Disengage the turning gear.
Air starter works, but the drive shaft does not rotate.
Possible cause Troubleshooting
Clutch or drive shaft broken. Dismantle the air starter and repair it.
2012-04-17 - en
Description
D106A1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D106B1-01
Description
D106B1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D106C1-01
Then
Description
- 1 (3)
L27/38;
D106C1-01 MAN Diesel & Turbo
Disturbances during operation
Engine stops.
Possible cause Troubleshooting
Shut-down for overspeed. Check fuel pumps.
Check governor.
Check movement of regulating mecha-
nism.
Shut-down for low lubricating oil pres- Check pressostat.
sure. Check lubricating oil filter.
Check lubricating oil pump.
Shut-down for high HT cooling water Check HT system and pump.
temp. — or low HT cooling water pres-
sure.
2012-04-17 - en
Description
D106C1-01
2 (3) -
L27/38;
MAN Diesel & Turbo D106C1-01
Description
D106C1-01
- 3 (3)
L27/38;
MAN Diesel & Turbo D106D1-01
Ignition in crankcase
Ignition in crankcase
Cause
During running the atmosphere in the crankcase contains the same gases
(N2-O2-CO2) in the same proportions as in the ambient air, but an intense
spray of oil drops is slung around everywhere. If undue friction arises
between sliding surfaces, the heated surface will cause evaporation of the
lubricating oil splashed onto it. When the oil vapours condense, they form a
milky white oil mist which can ignite. Such ignition may be caused by the
same “hot spot” that produced the oil mist. If a large quantity of oil mist has
developed before ignition, the burning may cause considerable pressure rise
in the crankcase, forcing the relief valves to open.
Every precaution should therefore be taken to avoid “hot spots” and discover
oil mist in time.
Keep away from doors and relief valves on crankcase. Do not stay
unnecessarily in doorways near the doors of the engine room casing.
3. Cut off starting air. Take off all doors on one side of the crankcase. Set
the switch on the operator panel in position LOCAL.
2012-04-17 - en
4. Locate the hot spot. Powerful lamps should be employed at once (in
Description
- 1 (2)
L27/38;
D106D1-01 MAN Diesel & Turbo
cial attention should be paid to ensure lubricating oil supply and the sat-
isfactory condition of the frictional surfaces involved. It is important to
replace or clean the filter candles.
7. Start electrically driven lubricating oil pump and check oil flow from all
bearings and spray pipes in crankcase while turning the engine through
at least two revolutions.
8. Start engine. Look out for oil mist.
Especially the frictional surfaces that caused the heating should be felt over
(5,15 and 30 minutes after starting, and again when full load is obtained).
2012-04-17 - en
Description
D106D1-01
2 (2) -
L27/38;
MAN Diesel & Turbo D106E1-01
Running trouble with the pumps, apart from mechanical faults, is most
often due to leaks in the suction line. It is therefore essential that all
packings and gaskets are in order and that they are renewed when
necessary. Even a tiny hole in the suction line will reduce the pump
capacity.
Oil or water flows out of the telltale holes in the front-end box.
Possible cause Troubleshooting
Worn shaft seals. Repair the pump.
- 1 (1)
L27/38;
MAN Diesel & Turbo D106F1-01
Description
D106F1-01
- 1 (2)
L27/38;
D106F1-01 MAN Diesel & Turbo
Faults in lubricating oil cooler
Non-visible leakage
Trouble Possible cause Troubleshooting
Reduced heat transmission and/or Fouled plates or choked plate chan- Dismantle the cooler and check if the
increasing pressure drop. nels. plates are fouled.
Clean the plates very carefully.
Assemble the cooler and start up
again.
Leakage Holes in plates A suspected leakage can be localized
(The fluids get mixed) Corrosion or fatigue fracture. in the following way:
2012-04-17 - en
Description
D106F1-01
2 (2) -
L27/38;
MAN Diesel & Turbo
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D110A1-01
Engine frame
Engine frame
General
The engine frame is made of nodular cast iron. Distribution of lubricating oil is
integrated in the frame to reduce the number of pipes to be installed. To
reduce the stresses in the frame, the frame is kept compressed by heavy tie
rods from the main bearing cap to the top of the frame. The tie rods for the
cylinder head are deeply anchored in the frame. Tie rods in each side stabi-
lize the main bearing caps. All tie rods are hydraulically tightened. The engine
frame does not hold any water.
Description
D110A1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D110B1-01
Main bearings
Main bearings
General
Well supported main bearings carry the crankshaft with generously dimen-
sioned journals. The combination of the stiff box design and the carefully bal-
anced crankshaft ensures a smooth and vibration free running engine.
Criteria for replacement of main bearing shells, see work card 10 103.
Description
D110B1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D110C1-01
Resilient mounting
Resilient mounting
General
The engine can be installed resiliently by means of bolted-on brackets and
rubber mounts. These are easy to implement and do not require modification
of the engine except for installation of flexible connections. The highly elastic
rubber coupling between engine and gearbox will permit the radial move-
ments.
Description
D110C1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo M110101-02
Manpower
Number Qualification Duration in h
2 1
Special tools
Plate No. Item No. Note
1 9000-03 806 Hydraulic tool
1 9002-02 035 Dismantling tool for main bearing upper
shell
1 9002-02 557 Lifting handle for main bearing cap
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
2017-02-13 - en
Tier II - 1 (6)
L27/38;
M110101-02 MAN Diesel & Turbo
Dismantling and mounting of main bearing and guide bearing
2017-02-13 - en
M110101-02
Work Card
2 (6) Tier II -
L27/38;
MAN Diesel & Turbo M110101-02
M110101-02
Work Card
Tier II - 3 (6)
L27/38;
M110101-02 MAN Diesel & Turbo
Dismantling and mounting of main bearing and guide bearing
5. Add molykote paste to the surface around the hole for the side tie rods
on the main bearing cap.
6. Lift the bearing cap into position by means of the tackle and screw the
side studs in by hand. Add some liquid sealing compound to the nuts
to seal against the frame and screw on the nuts but do not tighten.
4 (6) Tier II -
L27/38;
MAN Diesel & Turbo M110101-02
7. Fit the nuts on the tie rods for the main bearing cap in the crankcase.
1. When lowering the main bearing cap, care must be taken that the lower
thrust rings do not drop into the oil pan.
M110101-02
Work Card
2. The fore and aft upper thrust rings have come down a little at the same
time as the main bearing cap was low ered and can easily be turned
out while the main bearing cap is resting in the lifting tools.
Tier II - 5 (6)
L27/38;
M110101-02 MAN Diesel & Turbo
Dismantling and mounting of main bearing and guide bearing
2017-02-13 - en
M110101-02
Work Card
6 (6) Tier II -
L27/38;
MAN Diesel & Turbo M110102-01
Manpower
Number Qualification Duration in h
1 1/4
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
-
Starting Position
Engine out of operation.
2016-05-04 - en
M110102-01
Work Card
- 1 (2)
L27/38;
M110102-01 MAN Diesel & Turbo
Functional test of crankcase safety relief valves
Functional testing
Functional testing of the crankcase safety relief valves cannot be performed
during operation of the engine, but it must be checked during overhauls that
the valve flap is movable
When painting
When painting the engine, take care not to block up the safety relief valves
with paint.
If the safety relief valves are actuated, the engine must be stopped
immediately, and it must not be restarted until the cause and the fault
are detected.
2016-05-04 - en
M110102-01
Work Card
2 (2) -
L27/38;
MAN Diesel & Turbo M110103-02
Criteria for replacement of connecting rod big-end and main bearing shells
Manpower
Number Qualification Duration in h
1 1/4
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Bearing sheels removed from bearing, see work card 10 101 or 16 110
General
This Work card gives information about the evaluation of the connecting rod
big-end and main bearing shells when wear appears on the running surface
2016-05-04 - en
• Corrosion
• Overloading, overheating a. s. o. are not described in this Work card.
In these cases, the bearing shells must be exchanged, of course, and in
order to avoid further bearing failures, the cause of the failure must be found
and eliminated.
- 1 (7)
L27/38;
M110103-02 MAN Diesel & Turbo
Criteria for replacement of connecting rod big-end and main
bearing shells
2 (7) -
L27/38;
MAN Diesel & Turbo M110103-02
The bedding-in process will produce a moderate initial wear rate, while geo-
ual appearance and/or operating time. If, on removal and examination, the
bore surface appears overheated, significantly scored, debris contaminated
M110103-02
Work Card
- 3 (7)
L27/38;
M110103-02 MAN Diesel & Turbo
Criteria for replacement of connecting rod big-end and main
bearing shells
4 (7) -
L27/38;
MAN Diesel & Turbo M110103-02
- 5 (7)
L27/38;
M110103-02 MAN Diesel & Turbo
Criteria for replacement of connecting rod big-end and main
bearing shells
Figure 8: Lack of support behind bearing back results in fatigue in the bore.
6 (7) -
L27/38;
2016-05-04 - en
-
L27/38;
Figure 10: Fitting on bearing back. Do not refit.
Work Card Criteria for replacement of connecting rod big-end and main
bearing shells
7 (7)
M110103-02
M110103-02
MAN Diesel & Turbo M110104-01
Manpower
Number Qualification Duration in h
2 4
Hand Tools
Qty Designation Number Status
Ring and open-end spanner, 18/19 mm
Ring and open-end spanner, 30 mm
Ring and open-end spanner, 36 mm
Ring and open-end spanner, 41 mm
Ring and open-end spanner, 90 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Data
Designation Information
Weights of main components Chapter 1 00
Tightening specification Chapter 1 00
Data for pressure and tolerance Chapter 1 00
M110104-01
Work Card
Starting Position
The foundation should be welded and milled off on shim surfaces.
- 1 (7)
L27/38;
M110104-01 MAN Diesel & Turbo
Fitting instructions for resilient mounting
Procedure
Mounting and adjustment instruction for new engines and adjustment
instruction for existing plants.
Alignment instructions
2017-02-13 - en
M110104-01
Work Card
2 (7) -
L27/38;
MAN Diesel & Turbo M110104-01
take place.
The welding is to be carried out according to the rules of the classifica-
M110104-01
Work Card
tion society.
- 3 (7)
L27/38;
Work Card Fitting instructions for resilient mounting
4 (7)
M110104-01 M110104-01
-
L27/38;
MAN Diesel & Turbo
2017-02-13 - en
MAN Diesel & Turbo M110104-01
M110104-01
Work Card
- 5 (7)
L27/38;
M110104-01 MAN Diesel & Turbo
10. Attach the brackets with rubber mountings to the engine. Ensure that all
Fitting instructions for resilient mounting
threads are lubricated with lubricating oil. Item (3) is tightened, prior to
item (1).
11. For compressing the rubber mounting, it is necessary to slide a shim in
between the base casting and the cylindrical distance pieces.
This is done by applying the 4 jacking bolts (6) in the threaded M12.
Compress the rubber mounting until approximately 14 mm gap is ach-
ieved.
12. The central buffer (22) is to be turned upwards until it is in contact with
the base casting at view Y.
Tighten nut (28) to keep the mounting compressed when loosening the
jacking bolts.
13. Loosen the jacking bolts (16) until the shim ( 8) can be installed.
14. Attach the four M20x60 bolts (7) - secure firm hold in the threads - do
not tighten. Ensure that threads are lubricated with lubricating oil.
Tighten the jacking bolts (16) in order to release tension in the central
buffer. Loosen the jacking bolts and the central buffer simultaneously in
order to lower the base casting (21) on the shim (8).
15. Tighten the four M20x60 bolts (7). Check that the central buffer can be
turned easily by applying a spanner to the top hexagon. Remove the
jacking bolts (16).
16. Repeat step 12 to 18 for the remaining rubber mounting.
17. Loosen the 6 engine alignment screws (11).
6 (7) -
L27/38;
MAN Diesel & Turbo M110104-01
M110104-01
Work Card
- 7 (7)
L27/38;
MAN Diesel & Turbo P11010-04-L2738-P
Oil pan
P11010-04-L2738-P
2013-06-24 - en
Plate
- 1 (2)
L27/38;
P11010-04-L2738-P MAN Diesel & Turbo
2013-06-24 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11010-05-L2738-P
Dip stick
P11010-05-L2738-P
2013-06-24 - en
Plate
- 1 (2)
L27/38;
P11010-05-L2738-P MAN Diesel & Turbo
1 Plate
2 Pin
3 Seal
4 Guide pipe
6 Dipstick
7 Crankcase cover
8 Tubular o-ring
9 Cylindrical screw
10 Disc
P11010-05-L2738-P
2013-06-24 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11012-01-L2738-P
Frame
P11012-01-L2738-P
2016-05-30 - en
Plate
- L27/38 1 (4)
P11012-01-L2738-P MAN Diesel & Turbo
40 Main bearing
42 Main bearing
45 O-ring
46 Tierod, main bearing cap
47 Cap nut
48 Nut
49 Cylindrical pin
50 Tierod, main bearing bracing
51 Nut
52 Plug screw
53 Copper ring
54 Plug screw
55 Sealing ring
57 Plug screw
58 Gasket
60 Cylindrical pin
61 Cylindrical pin
63 Tierod, cyl. head
64 O-ring
65 Ring
66 Nut
66A Protection cap
70 Cover with spray-nozzle
71 O-ring
73 Spring washer
74 Stud
75 Nut
77 Connecting piece, komplett
78 O-ring
79 Hexagon bolt
80 Cylindrical pin
81 Spring pin
85 Cover
86 Hexagon screw
87 Lock washer
90 Spray-nozzle, ass.
91 O-ring
93 Protection cap
95 Glue loctite
96 Packing-silicone paste
P11012-01-L2738-P
2016-05-30 - en
Plate
2 (4) - L27/38
MAN Diesel & Turbo P11012-01-L2738-P
Frame
P11012-01-L2738-P
2016-05-30 - en
Plate
- L27/38 3 (4)
P11012-01-L2738-P MAN Diesel & Turbo
2016-05-30 - en
Plate
4 (4) - L27/38
2016-12-12 - en
-
L27/38;
Plate Covers on frame
1 (4)
P11014-05-L2738-P
P11014-05-L2738-P
P11014-05-L2738-P MAN Diesel & Turbo
1 Cover
2 Tubular o-ring
3 Crankcase venting, complete (optional)
4 Turbolar o-ring
5 Cover
7 Cover
8 Turbolar o-ring
10 Cover for crankcase (item B1-B18)
11 Cover for crankcase
12 Turbolar o-ring
13 Cover with safety valve (item A1-A18)
18 Round seal ring
21 Cyl. screws
22 Washers
23 Hexagon screw
24 Locking spring washer
25 Signal plate
26 Adhesive
30 Cover
31 Hexagon screw
32 Cover
41 Covering
42 Covering
43 Covering
44 Covering
45 Covering
46 Hexagon screw
47 Hexagon screw
48 Washer
49 Hexagon screw
50 Washer
52 Cyl. screw
53 Washer
A1 Cover for horbiger safety valve
A5 Safety valve, horbiger
A6 Hexagon screw
A7 Disc
A8 O-ring
A9 Hollow-p. screw
A10 Glue
P11014-05-L2738-P
2016-12-12 - en
Plate
2 (4) -
L27/38;
2016-12-12 - en
-
L27/38;
Plate Covers on frame
3 (4)
P11014-05-L2738-P
P11014-05-L2738-P
P11014-05-L2738-P MAN Diesel & Turbo
2016-12-12 - en
Plate
4 (4) -
L27/38;
2017-05-31 - en
-
L27/38;
Plate Front end box
1 (4)
P11016-01-L2738-P
P11016-01-L2738-P
P11016-01-L2738-P MAN Diesel & Turbo
20 Intermediate piece
21 O-ring
22 O-ring
25 Hexagon bolt
26 Hexagon bolt
101 Loctite
A1 Front end box-press.tested incl.item A2,A3,A4,A5
A2 Closing screw
A3 O-ring
A4 Plug screw
A5 Gasket
A7 Cover, oil filter
A8 Hexagon screw
A9 Spring washer
A10 Cover, small pto
A11 Hexagon screw
A12 Spring washer
A15 Cover
A16 Hexagon screw
A17 Spring washer
A20 Cover, front end box
A21 Hexagon screw
A22 Spring washer
A28 Bleeding, complete
A29 Hexagon socket head cap screw
B1 Casing for bleeding
B2 Screw
B3 Washer
B4 Retaining ring for shaft
B5 O-ring
B6 Gasket
P11016-01-L2738-P
2017-05-31 - en
Plate
2 (4) -
L27/38;
2017-05-31 - en
-
L27/38;
Plate Front end box
3 (4)
P11016-01-L2738-P
P11016-01-L2738-P
P11016-01-L2738-P MAN Diesel & Turbo
20 Intermediate piece
21 O-ring
22 O-ring
25 Hexagon bolt
26 Hexagon bolt
101 Loctite
A1 Front end box-press.tested incl.item A2,A3,A4,A5
A2 Closing screw
A3 O-ring
A4 Plug screw
A5 Gasket
A7 Cover, oil filter
A8 Hexagon screw
A9 Spring washer
A10 Cover, small pto
A11 Hexagon screw
A12 Spring washer
A15 Cover
A16 Hexagon screw
A17 Spring washer
A20 Cover, front end box
A21 Hexagon screw
A22 Spring washer
A28 Bleeding, complete
A29 Hexagon socket head cap screw
B1 Casing for bleeding
B2 Screw
B3 Washer
B4 Retaining ring for shaft
B5 O-ring
B6 Gasket
P11016-01-L2738-P
2017-05-31 - en
Plate
4 (4) -
L27/38;
MAN Diesel & Turbo P11018-04-L2738-P
Plate
Plate
101 Loctite
P11018-04-L2738-P
2017-05-18 - en
Plate
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D112A1-02
Description
D112A1-02
Figure 1: Crankshaft
- 1 (1)
L27/38;
MAN Diesel & Turbo D112B1-02
Vibration damper
Vibration damper
Vibration damper
A vibration damper is mounted on the crankshaft to limit torsional vibrations.
The damper consists of a primary and a secondary part. Between these,
groups of leaf spring packs are arranged, which are clamped at their outer
ends.
These spring packs form, together with the primary and secondary mem-
bers, chambers which are filled with oil. If the exterior member vibrates in
relation to the inner member, the leaf springs are bent and force oil from one
chamber into another, retarding the relative movement of the two parts and
thus damp- ing the torsional vibration. In order to protect the leaf springs
against overloading, their deflection is limited by buffers.
The elasticity is determined by careful choise of the leaf springs, the damping
factor by the gap between primary and secondary members.
2012-06-21 - en
Description
D112B1-02
- 1 (1)
L27/38;
MAN Diesel & Turbo M112101-03
Manpower
Number Qualification Duration in h
2 1
Special tools
Plate No. Item No. Note
1 9002 067 Crankshaft alignment gauge
Data
Designation Information
Limits for crankshaft deflection
Crankshaft deflection
Starting Position
Engine stopped. Turning gear engaged.
2017-07-10 - en
M112101-03
Work Card
Tier II - 1 (6)
L27/38;
M112101-03 MAN Diesel & Turbo
Recording of crankshaft deflection
Procedure
1. Remove the side covers from the crank casing.
2. Turn the crankshaft to bring the crank web for cylinder no 1 to position
X, see fig 8.
3. Place the dial gauge in the punch marks in the counterweight, see fig 1.
4. Adjust the dial gauge to 0.
5. Turn the crankshaft to position P, T, S and Y and read the dial gauge in
each position and fill in the form Checking of Main Bearing Alignment
(Autolog).
6. Repeat the procedure on the remaining crank webs.
7. Compare the values to earlier values taken after the sea trial.
8. Please contact us if the values exceed the values shown in this Working
Card.
2017-07-10 - en
M112101-03
Work Card
2 (6) Tier II -
L27/38;
2017-07-10 - en
Tier II -
L27/38;
Work Card Recording of crankshaft deflection
3 (6)
M112101-03
M112101-03
M112101-03 MAN Diesel & Turbo
Recording of crankshaft deflection
For the crank nearest the flywheel, the permissible deflections are as fol- [1/100 mm]
lows
New or recently overhauled engine, nominal + 8 / - 20
New or recently overhauled engine, max. + 15 / - 23
Operating engine, check alignment immediately + 22 / - 25
2017-07-10 - en
M112101-03
Work Card
4 (6) Tier II -
L27/38;
2017-07-10 - en
Tier II -
L27/38;
Work Card Recording of crankshaft deflection
5 (6)
M112101-03
M112101-03
Work Card Recording of crankshaft deflection
6 (6)
M112101-03 M112101-03
Tier II -
L27/38;
MAN Diesel & Turbo
2017-07-10 - en
MAN Diesel & Turbo M112102-01
Manpower
Number Qualification Duration in h
2 10
Special tools
Plate No. Item No. Note
- No special tools
Data
Designation Information
Tightening specification
Data and pressure tolerance
Starting Position
Engine out of operation.
2016-11-15 - en
M112102-01
Work Card
- 1 (9)
L27/38;
M112102-01 MAN Diesel & Turbo
Dismantling and mounting of vibration damper
Damper dismounting
1. Withdraw the crankshaft bolts (do not remove them), see fig 1.
2. Mount the lifting appliances (730) onto the damper and suspend the
damper on the crane.
3. Remove the crankshaft bolts.
4. Insert forcing bolts into the damper inner star (9) and push back the
damper from the crankshaft flange slowly and evenly.
5. Rest damper onto lateral plate (5). (damper centre line vertical).
Open damper main bolts (750), see fig 1, only if it is required (eg for a
total spring inspection) The concentricity setting of the damper outer
member will be lost, if no centering shoulders exist between the spring
assembly (1, 2, 3) and lateral plates (5, 7).
1. Rest damper onto lateral plate (5). (damper centre line vertical)
2. Remove damper main bolts (750).
3. Remove lateral plate (7).
4. Remove spring assembly (1, 2, 3).
5. Remove inner star (9).
Now a complete inspection of the damper can be carried out.
2 (9) -
L27/38;
MAN Diesel & Turbo M112102-01
All oil supply and venting holes must be clean and free of dirt.
- 3 (9)
L27/38;
M112102-01 MAN Diesel & Turbo
Assembly
Dismantling and mounting of vibration damper
1. Place flange plate (5) onto the centering table (O-rings are visible).
2. Place spring assembly (1, 2, 3) onto the flange plate (5).
3. Insert inner-star (9).
4. Place lateral plate (7) onto spring assembly (1, 2, 3).
5. Center flange plate (5), spring assembly (1, 2, 3) and lateral plate (7)
according to the permissible concentricity values as stated on fig 1.
6. Apply enough LOCTITE (type see assembly drwg.) onto both sides of
the disk spring (810).
The disk springs (810) and the apropriate seat-engaging surfaces must
be dry and free of grease (oil)
7. Mount the damper main bolts (750) according to the following mounting
instructions:
8. Surfaces must be cleaned (degreased).
9. Enough specified Loctite must be applied to both sides of all marked
disc springs (washers), see fig 1.
10. Tighten bolts according to table (tolerance +10%).
Values for tightening torques or initial tightening torques are valid only
if the stated thread and disc spring treatment according to table is
applied!
13. Apply enough LOCTITE 243 onto both sides of the disk springs (810)
and mount the damper main bolts (750).
4 (9) -
L27/38;
MAN Diesel & Turbo M112102-01
Check the concentricity settings (Repeat the assembly of the damper outer
Inspection
O-ring
The total wear must not exceed 10 % of the rope diameter „d“ (see fig 2).
The total wear is the sum of
▪ Wear of the O-ring
▪ Depth of the run-in grooves on inner star
▪ Depth of the run-in grooves on the lateral plates ( 5 or 7 )
▪ O-Ring nominal diameter d = 8 mm
2016-11-15 - en
Figure 2: O-ring
M112102-01
Work Card
- 5 (9)
L27/38;
M112102-01 MAN Diesel & Turbo
Dismantling and mounting of vibration damper
Figure 3: Testing
6 (9) -
L27/38;
MAN Diesel & Turbo M112102-01
Testing tool
Measuring wear
Measure approximately every fourth spring pack.
Place the measuring wedge between the inner ends of the spring blades
resting the wedge on the groove bottom.
Press by hand or use a soft hammer to force the measuring wedge along the
inner star groove, until the spring tips rest on both groove faces.
The further the measuring wedge can be pressed between the spring blades
the greater is the wear of the inner star groove and the spring blades.
M112102-01
Work Card
- 7 (9)
L27/38;
M112102-01 MAN Diesel & Turbo
Dismantling and mounting of vibration damper
Operating conditions
▪ Required oil pressure at oil inlet of damper:
according to torsional vibration calculation the spring tips rest on both
groove faces.
▪ Permissible ambient temperature:
-20°C bis 120°C
Trouble shooting
Inspection condition Corrective measure
Pressure oil supply with the prelubricat- Dismount damper; check oil supply holes
ing pump; No oil escapeccsss from one on the damper and on the crankshaft;
or more ventig holes. free oil discharge must be guaranteed.
Total wear of the O-ring (850) does not Exchange O-ring(s); smooth and polish
exceed the permissible value of wear. the run-in grooves.
Total wear of the O-rings (850) exceeds Exchange O-ring(s) and exchange or
the permissible value of wear. repair worn parts.(Clarfrepair with Gei-
The total wear at the spring tips (engage- slinger or a Geislinger service station).
ment with inner star grooves) exceeds Exchange inner star (see fig 1, item 9)
the permissible value "w" (see fig 4). and spring assembly (1, 2, 3).
Bad oil quality / oil change or higher Remove venting screw /756) (if existing).
water content in the engine oil as permit- Drain damper totally (drain hole in 6
ted. Effect: no damage to the engine o'clock position).Fill up damper with
bearings. fresh engine oil and draindamper again;
Bad oil quality or higher water content in repeat flushing several times.
the engine oil as permitted. Effect: dam- Carry out a 28.000 - 30.000 service
age to the engine bearings. hours inspection according to "Total
inspection of the damper".
8 (9) -
L27/38;
MAN Diesel & Turbo M112102-01
M112102-01
Work Card
- 9 (9)
L27/38;
MAN Diesel & Turbo M112103-01
Manpower
Number Qualification Duration in h
2 10
Special tools
Plate No. Item No. Note
- No special tools
Starting Position
Engine stopped, starter dismounted or disconnected
Warning!
Procedure
Normally is toothed rim not an exchange component and only after damage
2016-11-15 - en
- 1 (3)
L27/38;
M112103-01 MAN Diesel & Turbo
Exchange of toothed rim for starter
2016-11-15 - en
M112103-01
Work Card
1 Connecting rings
2 (3) -
L27/38;
MAN Diesel & Turbo M112103-01
5-parts is nummerized 1-1, 2-2 etc. and must be mounted in the right
order, see fig 1.
M112103-01
Work Card
- 3 (3)
L27/38;
MAN Diesel & Turbo P11210-02-L2738-P
Crankshaft
P11210-02-L2738-P
2013-06-24 - en
Plate
- 1 (2)
L27/38;
P11210-02-L2738-P MAN Diesel & Turbo
2013-06-24 - en
Plate
2 (2) -
L27/38;
2016-05-25 - en
-
L27/38;
Plate Vibration damper arrangement
1 (2)
P11214-01-L2738-P
P11214-01-L2738-P
P11214-01-L2738-P MAN Diesel & Turbo
4 Vibration damper
7 Stud m39x2, torsion vib. damper
8 Nut m39x2
9 Gear wheel, pump drive
10 Tightening flange, vib. damper
11 Spare part kit vib. damper 6 cyl. (Vulcan)
12 Spare part kit vib. damper 7, 8 & 9 cyl. (Vulcan)
13 Spare part kit vib. damper 6 cyl. (Geislinger)
14 Spare part kit vib. damper 7 & 8 cyl. (Geislinger)
15 Spare part kit vib. damper 9 cyl. (Geislinger)
P11214-01-L2738-P
2016-05-25 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11216-02-L2738-P
Flywheel
P11216-02-L2738-P
2014-10-21 - en
Plate
- 1 (2)
L27/38;
P11216-02-L2738-P MAN Diesel & Turbo
1 Flywheel, 6 cyl.
2 Rim for flywheel
2A Toothed rim, 2 part incl. item 4
2B Toothed rim, 5 part incl. item 4
3 Cyl. screw
4 Ring
10 Flywheel, 7 cyl
11 Flywheel, 8 cyl
12 Flywheel, 9 cyl
P11216-02-L2738-P
2014-10-21 - en
Plate
2 (2) -
L27/38;
2015-12-16 - en
-
L27/38;
Plate Turning device
1 (2)
P11220-04-L2738-P
P11220-04-L2738-P
P11220-04-L2738-P MAN Diesel & Turbo
2015-12-16 - en
Plate
2 (2) -
L27/38;
2013-06-24 - en
-
L27/38;
Plate Turning gear - electrical driven
1 (2)
P11220-06-L2738-P
P11220-06-L2738-P
P11220-06-L2738-P MAN Diesel & Turbo
1 Turning gear
5 Stud screw
6 Nut
A1 El-motor
A3 Counter nut for pull rod
A4 Washer
A5 Gear wheel
A6 Shaft
A7 Flange
A8 Cyl. screw
A9 Retaining ring for shaft
A10 Ball bearing
A11 Keys
A13 Worm gear
A14 Cyl. screw
A15 Flange
A16 Cyl. screw
A17 Shaft
A19 Disc
A20 Compression spring
A21 Handle
A22 Disc
A23 Cyl. screw
A24 Cover plate
A25 Cylindrical pin
A28 Plate
A29 Limit switch
A30 Cyl. screw
A31 Washer
A32 Circlip
A33 Pipe
A43 Handle knob with pin
A45 Handle knob with pin
P11220-06-L2738-P
2013-06-24 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D114A1-01
Figure 1: Camshafts
2013-06-24 - en
Description
D114A1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D114B1-02
Description
L27/38
D114B1-02 EN 1 (2)
MAN Diesel & Turbo M114101-01
Manpower
Number Qualification Duration in h
1 3
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
Engine out of service.
2016-11-16 - en
M114101-01
Work Card
- 1 (2)
L27/38;
M114101-01 MAN Diesel & Turbo
Check of camshaft and camshaft drive
Warning!
Procedure
1. Dismantle the side covers at the cam shafts and the side covers at the
gear wheel drive in the aft, see fig 1.
2 (2) -
L27/38;
MAN Diesel & Turbo M114102-02
Manpower
Number Qualification Duration in h
2 4
Special tools
Plate No. Item No. Note
1 9002 940 Mounting device for injection camshaft
1 9002 952 Mounting device valve camshaft
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
Covers for camshaft and gear wheel have been removed.
Tier II - 1 (3)
L27/38;
M114102-02 MAN Diesel & Turbo
Inspection and replacement of camshaft bearings
2017-07-10 - en
M114102-02
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M114102-02
1. Unscrew and remove all the screws in both ends of the camshaft sec-
Data.
M114102-02
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M114103-04
Manpower
Number Qualification Duration in h
2 2
Special tools
Plate No. Item No. Note
1 9002 366 Setting device for fuel injection pump
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Camshaft assembled as per timing order, mounted in frame and roller gear
house. If intermediated gearwheel must be changed, the geneator must be
dismounted.
2017-07-10 - en
M114103-04
Work Card
Tier II - 1 (5)
L27/38;
M114103-04 MAN Diesel & Turbo
Adjustments of camshafts for valve and injection timing
Warning!
Assembly of gear wheels for valve camshaft and Injection valve camshaft, without
mounted flywheel
Following description is for mounting the gearwheels in the control drive
when alternator, flywheel and cover on coupling side are dismantled from the
engine.
2017-07-10 - en
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M114103-04
M114103-04
Work Card
Tier II - 3 (5)
L27/38;
M114103-04 MAN Diesel & Turbo
Adjustments of camshafts for valve and injection timing
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M114103-04
M114103-04
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M114104-02
Manpower
Number Qualification Duration in h
1 2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
Cyl. unit has been removed from engine. See work card 16 101.
2016-11-16 - en
M114104-02
Work Card
- 1 (4)
L27/38;
M114104-02 MAN Diesel & Turbo
Inspection and overhaul of cam followers and rocker arms
Warning!
Procedure
1. To be able to inspect the cam followers it can be necessary to gain
access by removing the exhaust arrangement, water pipes and top
cover.
2 (4) -
L27/38;
MAN Diesel & Turbo M114104-02
M114104-02
Work Card
- 3 (4)
L27/38;
M114104-02 MAN Diesel & Turbo
10. Check of roller, bushing and shaft: While pressing in the spring loaded
Inspection and overhaul of cam followers and rocker arms
guide pin, the roller shaft can be pressed out, see fig 4.
2016-11-16 - en
M114104-02
Work Card
4 (4) -
L27/38;
2016-05-25 - en
-
L27/38;
Plate Camshaft (fuel injection)
1 (2)
P11410-02-L2738-P
P11410-02-L2738-P
P11410-02-L2738-P MAN Diesel & Turbo
2016-05-25 - en
Plate
2 (2) -
L27/38;
2013-07-29 - en
-
L27/38;
Plate Camshaft (valve camshaft – without pump drive)
1 (2)
P11410-05-L2738-P
P11410-05-L2738-P
P11410-05-L2738-P MAN Diesel & Turbo
2013-07-29 - en
Plate
2 (2) -
L27/38;
2013-06-24 - en
-
L27/38;
Plate Drive of pumps
1 (2)
P11412-02-L2738-P
P11412-02-L2738-P
P11412-02-L2738-P MAN Diesel & Turbo
2013-06-24 - en
Plate
2 (2) -
L27/38;
2015-08-18 - en
-
L27/38;
Plate Drive of camshafts
1 (2)
P11412-04-L2738-P
P11412-04-L2738-P
P11412-04-L2738-P MAN Diesel & Turbo
2015-08-18 - en
Plate
2 (2) -
L27/38;
2016-05-25 - en
-
L27/38;
Plate Cam follower and push rods
1 (2)
P11414-01-L2738-P
P11414-01-L2738-P
P11414-01-L2738-P MAN Diesel & Turbo
2016-05-25 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo
Cylinder unit
Description Cylinder unit ................................................................. D116A1-01
Piston, connecting rod and cylinder liner ...................... D116B1-02
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D116A1-01
Cylinder unit
Cylinder unit
Cylinder head
The cylinder head with integrated charge air receiver is made of nodular cast
iron. It has 4 valves and is of the cross flow design, to ensure a high flow effi-
ciency. The fuel injection valve is placed in a liner in the centre.
Intensive water cooling of the nozzle tip area makes it possible to omit direct
nozzle cooling.
The cylinder head is tightened by means of 4 nuts and 4 studs. The studs
are screwed into the engine frame. The tightening is done by means of
hydraulic jacks.
The top cover has two functions. It is a cover for the rocker arm chamber to
seal for the lubricating oil and a guard to cover the cylinder head.
2013-06-24 - en
Description
D116A1-01
- 1 (2)
L27/38;
D116A1-01 MAN Diesel & Turbo
Cylinder unit
The cylinder head has replaceable valve seat rings. The exhaust valve seat
Description
The seat rings are made of heat resistant steel. The seating surfaces are
hardened in order to minimize wear and prevent dent marks.
2 (2) -
L27/38;
MAN Diesel & Turbo D116B1-02
Figure 1: Piston
Connecting rod
The connecting rod is of the marine head type.
The joint is above the connecting rod bearing. This means that it is not nes-
sesary to open the big-end bearing when pulling the piston. This is of
advantage for the operational safety (no positional changes/no new adap-
tion), and this solution also reduces the height dimension required for piston
assembly / removal.
Connecting rod and bearing body consist of CrMo steel. They are dieforged
products.
The bearing shells are identical to those of the crankshaft bearing.
2012-06-21 - en
Thin-walled bearing shells having an AISn running layer are used. The bear-
ing caps and bearing blocks are bolted together by waisted bolts.
Description
D116B1-02
- 1 (3)
L27/38;
D116B1-02 MAN Diesel & Turbo
Piston, connecting rod and cylinder liner
Cylinder liner
The cylinder liner is made of special centrifugal cast iron and fitted in a bore
in the engine frame.
The liner is clamped by the cylinder head and rests by its flange on the water
jacket. The liner can thus expand freely downwards when heated during the
running of the engine. The liner is of the flange type and the height of the
flange is identical with the water cooled area which gives a uniform tempera-
ture pattern over the entire liner surface.
The lower part of the liner is uncooled to secure a sufficient margin for cold
corrosion in the bottom end.
There is no water in the crankcase area. The gas sealing between liner and
cylinder head consists of an iron ring.
To reduce bore polishing and lube oil consumption a slip-fit-type flame ring is
arranged on the top side of the liner.
2012-06-21 - en
Description
D116B1-02
2 (3) -
L27/38;
2012-06-21 - en
-
L27/38;
Description Piston, connecting rod and cylinder liner
3 (3)
D116B1-02
D116B1-02
MAN Diesel & Turbo M116101-02
Manpower
Number Qualification Duration in h
2 1
Special tools
Plate No. Item No. Note
1 9000 060 Tool for fixing of marine head for coun-
terweight
1 9000 212 Supporting device for connecting rod
and piston in the cylinder liner, incl. fork
1 9000 473 Broad chissel
1 9000 806 Hydraulic tool
Data
Designation Information
-
Starting Position
Engine stopped and cooled down.
2017-07-10 - en
M116101-02
Work Card
Tier II - 1 (5)
L27/38;
M116101-02 MAN Diesel & Turbo
Dismantling of cylinder unit from engine
Tool
Before dismantling
1. Drain off the water from the engine.
2. Remove the top cover from the cylinder head.
3. Remove the crank case covers on both sides of the engine.
4. Remove the guard over the exhaust gas receiver.
2017-07-10 - en
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116101-02
M116101-02
Work Card
Tier II - 3 (5)
L27/38;
M116101-02 MAN Diesel & Turbo
Dismantling of cylinder unit from engine
2017-07-10 - en
M116101-02
Work Card
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116101-02
M116101-02
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M116102-03
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 021 Removing device for flame ring
1 9000 038 Lifting tool for cylinder unit
1 9000 082 Lifting device for cylinder
1 9000 212 Supporting device for connecting rod
and piston in the cylinder liner, incl. fork
Data
Designation Information
-
Starting Position
Cylinder unit is dismantled from engine, see work card 16 101.
2017-07-10 - en
M116102-03
Work Card
Tier II - 1 (4)
L27/38;
M116102-03 MAN Diesel & Turbo
Disassembly of cylinder unit
Procedure
Before the cylinder unit is dismantled, it must be placed on the working table.
2 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116102-03
M116102-03
Work Card
Tier II - 3 (4)
L27/38;
M116102-03 MAN Diesel & Turbo
Disassembly of cylinder unit
2017-07-10 - en
M116102-03
Work Card
4 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116103-02
Manpower
Number Qualification Duration in h
2 2½
Special tools
Plate No. Item No. Note
1 9000 060 Tool for fixing of marine head for coun-
terweight
1 9000 104 Lifting device for piston and connecting
rod
1 9000 806 Hydraulic tool
1 9002 474 Lifting tool for cylinder unit
Data
Designation Information
-
Starting Position
Complete cylinder unit has not been removed from engine. Engine stopped
and cooled down.
2017-07-10 - en
M116103-02
Work Card
Tier II - 1 (3)
L27/38;
M116103-02 MAN Diesel & Turbo
Dismantling of piston and cylinder liner
Tool
Procedure
Prepare dismantling of the cylinder head as described in work card 16 101.
Lift the cylinder head as described in work card 16 102.
1. Remove the push rods after the cylinder head has been removed.
2. Turn the crankshaft into a position where the hydraulic tools can be in
stalled to loosen the nuts on the connecting rod.
3. Remove the flame ring from the liner, see work card 16 102-01 fig 5.
4. Remove the deposits in top of the liner.
5. Remove the nuts on the connecting rod and turn the crankshaft into
TDC.
6. Install the fixation tool, see fig 1.
2017-07-10 - en
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M116103-02
Figure 3: Lifting tool for cooling water jacket and cylinder liner
10. Lift the cooling water chamber and the liner out of the engine frame.
2017-07-10 - en
M116103-02
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M116104-02
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 014 Valve spring tightening device
Data
Designation Information
-
Starting Position
Cylinder unit is disassembled, see work card 16 102.
Procedure
1. Before the valves can be dismantled, the rocker arms have to be
2017-07-10 - en
removed.
M116104-02
Work Card
2. The screw “A” in fig 1 has to be removed before the rocker arm shaft
can be pushed out to free the rocker arms.
Tier II - 1 (4)
L27/38;
M116104-02 MAN Diesel & Turbo
Inspection of inlet and exhaust valve
2017-07-10 - en
M116104-02
Work Card
2 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116104-02
M116104-02
Work Card
Tier II - 3 (4)
L27/38;
M116104-02 MAN Diesel & Turbo
Inspection of inlet and exhaust valve
2017-07-10 - en
M116104-02
Work Card
4 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116105-03
Manpower
Number Qualification Duration in h
1 3
Special tools
Plate No. Item No. Note
1 9002 199 Grinding machine
Starting Position
Valve spindle has been removed, see work card no 16 104.
2018-01-03 - en
M116105-03
Work Card
Tier II - 1 (3)
L27/38;
M116105-03 MAN Diesel & Turbo
Grinding of valve seat ring and valve spindle seat
Grinding of valve seat rings should be carried out in the following order:
1) Grind the seating surface with a feed at an angle "A", see fig. 1.
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M116105-03
M116105-03
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M116115-01
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
-
Starting Position
Engine stopped
2017-05-15 - en
M116115-01
Work Card
- 1 (2)
L27/38;
M116115-01 MAN Diesel & Turbo
Inspection of valve rotators
Procedure
Valve rotators are installed on all 4 valves in the cylinder head. The function of
the valve rotators is of greatest importance for the lifetime of the valves. Non-
functioning valve rotators must be exchanged.
At every overhaul of the cylinder head, the valve rotators must be checked.
Function test
1 Indicator mark
2017-05-15 - en
M116115-01
Work Card
2 (2) -
L27/38;
MAN Diesel & Turbo M116106-03
Manpower
Number Qualification Duration in h
1 3/4
Special tools
Plate No. Item No. Note
1 9002 258 Fit and removing device for valve guides
1 9002 748 Reamer for valve guide
Data
Designation Information
-
Starting Position
Valve spindle has been removed, see work card no 16 104.
If the diameter exceeds the max. limit, see page 1 00J2-02, the valve guide
M116106-03
Work Card
must be replaced.
Tier II - 1 (3)
L27/38;
M116106-03 MAN Diesel & Turbo
Replacement of valve guide
2017-07-10 - en
M116106-03
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M116106-03
4. Ensure that the valve guide is fully seated, if necessary by light blows to
M116106-03
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M116107-02
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 806 Hydraulic tool
1 9002 329 Extractor for valve seat rings
Data
Designation Information
-
Starting Position
Cylinder head removed from engine.
2017-07-10 - en
M116107-02
Work Card
Tier II - 1 (3)
L27/38;
M116107-02 MAN Diesel & Turbo
Replacement of valve seat ring
Procedure
The exhaust and inlet valve seat rings are installed in a press fit.
The seat rings can be pulled out by means of the hydraulically operated
extractor shown in fig 1.
Figure 1: Extractor
Before installing new seat rings the bores in the cylinder head must be
cleaned carefully.
Do not use emery paper because this will change the tolerance of the bore.
Add a little sealing compound (loctite 572.) to the bore for the exhaust seat
rings.
Place a new O-ring on the seat ring and lubricate with oil or “copaslip”.
It is not necessary to cool down the seat rings before pulling them in by
means of the pulling deice shown in fig 2.
2017-07-10 - en
M116107-02
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M116107-02
M116107-02
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M116108-04
Inspection of piston
Inspection of piston
Safety precautions
▪ Select local control
▪ Shut-off starting air
▪ Stop lub. oil circulation
▪ Engine stopped
▪ Shut off cooling water
▪ Shut off fuel oil
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 190 Piston ring opener
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Cyl. unit has been removed from engine, work card 16 101. Piston has been
dismantled from connecting rod.
2017-07-10 - en
Inspection of piston
M116108-04
Work Card
Tier II - KS - 1 (4)
L27/38;
M116108-04 MAN Diesel & Turbo
Inspection of piston
It may turn out that the bolts do not turn during the test:
If Then
the bolts do not turn during the test the tension is ok
the bolts can turn during the test loosen the bolts and tighten as descri-
bed in the process of "Mounting of pis-
ton crown"
2 (4) Tier II - KS -
L27/38;
MAN Diesel & Turbo M116108-04
Inspection of piston
Figure 1: Piston - sectional view
M116108-04
Work Card
Tier II - KS - 3 (4)
L27/38;
M116108-04 MAN Diesel & Turbo
Inspection of piston
Piston type Piston and oil scraper New ring grooves. Ring grooves. Max.
ring. Nominal size. Tolerances. (mm) wear limit. (mm)
(mm)
Piston ring 1 6 7.17 +0.03 7.42
Piston ring 2 6 6.12 +0.03 6.42
Scraper ring 8 8.04 +0.03 8.42
Table 1: Nominal size, new ring groove tolerance and wear limit for ring grooves
2017-07-10 - en
M116108-04
Work Card
4 (4) Tier II - KS -
L27/38;
MAN Diesel & Turbo M116109-02
Manpower
Number Qualification Duration in h
2 1/2
Special tools
Plate No. Item No. Note
1 9000 060 Tool for fixing of marine head for coun-
terweight
1 9000 069 Fit and removal device for connecting
rod bearing
1 9000 806 Hydraulic tool
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
2017-07-10 - en
Tier II - 1 (5)
L27/38;
M116109-02 MAN Diesel & Turbo
Removal of marine head from engine
Tool
Procedure
Condition: Piston and connecting rod has been removed and the fixation tool
is installed, see fig 1.
2017-07-10 - en
M116109-02
Work Card
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116109-02
M116109-02
Work Card
Tier II - 3 (5)
L27/38;
M116109-02 MAN Diesel & Turbo
4. Turn the crankshaft to the position shown in fig 4 and remove the nuts
Removal of marine head from engine
2017-07-10 - en
M116109-02
Work Card
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116109-02
M116109-02
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M116110-02
Manpower
Number Qualification Duration in h
1 1 1/2
Special tools
Plate No. Item No. Note
1 9000 069 Fit and removal device for connecting
rod bearing
1 9000 806 Hydraulic tool
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
Crankcase opened.
2017-09-14 - en
M116110-02
Work Card
Tier II - 1 (5)
L27/38;
M116110-02 MAN Diesel & Turbo
Inspection of connecting rod big-end bearing
Tool
Warning!
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116110-02
M116110-02
Work Card
Tier II - 3 (5)
L27/38;
M116110-02 MAN Diesel & Turbo
11. Turn the crankshaft until it is possible to remove the upper bearing shell,
Inspection of connecting rod big-end bearing
see fig 4.
4 (5) Tier II -
L27/38;
2017-09-14 - en
Tier II -
L27/38;
Work Card Inspection of connecting rod big-end bearing
5 (5)
M116110-02
M116110-02
MAN Diesel & Turbo M116111-01
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
-
Starting Position
Piston and connecting rod removed.
The inside diameter of the cylinder liner is measured in 3 levels, see fig 1.
- 1 (4)
L27/38;
M116111-01 MAN Diesel & Turbo
Inspection and honing of cylinder liner
2 (4) -
L27/38;
MAN Diesel & Turbo M116111-01
M116111-01
Work Card
- 3 (4)
L27/38;
Work Card Inspection and honing of cylinder liner
4 (4)
M116111-01 M116111-01
-
L27/38;
MAN Diesel & Turbo
2017-05-15 - en
MAN Diesel & Turbo M116112-02
Grinding of seal faces on cylinder liner, cylinder head and engine frame
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
1 9002 126 Grinding tool for cylinder head/liner
Data
Designation Information
-
Starting Position
Disassembly of cylinder unit, see work card 16 102.
2017-09-14 - en
M116112-02
Work Card
Tier II - 1 (3)
L27/38;
M116112-02 MAN Diesel & Turbo
Grinding of seal faces on cylinder liner, cylinder head and engine
frame
Procedure
The grinding tool is used for grinding of the seal face on the cylinder head,
the cylinder liner and the engine frame.
The intention with the grinding is to ensure a proper sealing between mating
faces in connection with major overhaul.
If severe damage or corrosion is observed, a machining of the sealing faces
may be required.
In this case please consult us.
2017-09-14 - en
M116112-02
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M116112-02
M116112-02
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M116113-02
Manpower
Number Qualification Duration in h
1 1 1/2
Special tools
Plate No. Item No. Note
1 9000 045 Guide bush for piston
1 9000 082 Lifting device for cylinder liner
1 9000 104 Lifting device for piston and connecting
rod
1 9000 190 Piston ring opener
1 9000 212 Supporting device for connecting rod
and piston in the cylinder liner
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
1 1610
M116113-02
1 1616
Work Card
Starting Position
Cylinder unit dismantled, see work card no 16 102.
Tier II - 1 (5)
L27/38;
M116113-02 MAN Diesel & Turbo
Assembly of cylinder unit
Procedure
1. Place the water jacket on the work table.
2. Place a new O-ring (1) on the cylinder liner and oil it.
3. Install the cylinder liner in the water jacket by means of the lifting tool for
the liner, see fig 1.
The liner can be marked in two different ways: Either the letters “AS”in
top of the liner or a groove below the largest diameter. Be sure the
marking on the cylinder liner points towards the exhaust side of the
cooling water jacket.
2017-09-14 - en
M116113-02
Work Card
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116113-02
Make sure the mark “AS” on the top of the piston is pointing in the
same direction as the cylinder liner.
6. Install the fixation tools to lock the connecting rod and cylinder liner.
7. Remove the lifting tool from the piston crown.
8. Place the seals 1, 2, 3, 4, 5 and the flame ring 6 as shown in fig 3.
Before landing the cylinder head on top of the liner, make sure the
exhaust gate is pointing in the right direction.
M116113-02
Work Card
Tier II - 3 (5)
L27/38;
M116113-02 MAN Diesel & Turbo
Assembly of cylinder unit
2017-09-14 - en
M116113-02
Work Card
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M116113-02
M116113-02
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M116116-04
Manpower
Number Qualification Duration in h
1 1 1/2
Special tools
Plate No. Item No. Note
1 9000 010 Feeler gauge
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Cover for valve camshaft is removed. Cover for rocker arms is removed.
Rocker arms are removed.
2017-09-14 - en
Procedure
M116116-04
Work Card
Tier II - 1 (4)
L27/38;
M116116-04 MAN Diesel & Turbo
5. Turn the crankshaft until the cylinder is in ignition TDC (both valves
Control and adjustment of valve clearance
closed).
6. Check that the surfaces are clean.
Figure 1: .
Figure 2: .
7. Loosen the counter nut, pos. 1 and the adjusting screw, pos. 2 on the
valve bridge.
8. Loosen the counter nut, pos. 3 and the adjusting screw, pos. 4 on the
2017-09-14 - en
rocker arm and insert the feeler gauge between valve bridge and rocker
arm, pos. 5.
M116116-04
Work Card
9. Adjust the screw , pos. 4 on the rocker arm until the feeler gauge
makes only slight resistance.
2 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116116-04
10. Tighten the counter nut, pos. 3 on the rocker arm with torque. Re-
Figure 3: .
Please note:
▪ The engine must be cold or cooled down for at leased 30 minutes.
▪ Ensure to have a firm stand before working on the engine.
▪ It is not allowed to turn during the adjustment process.
▪ The torque spanner must be positioned completely on the coupling.
▪ Attach the socket wrench straight on hexagon nut before screwing.
▪ Adjust the torque correctly, see values for tightening on data 1 00J1-01.
▪ Tool consisting of several parts, can fall into pieces.
▪ All bolted joints must to be re-established.
Caution:
▪ Engine parts can be hot, be careful with burns.
▪ Slipping can cause injuries.
2017-09-14 - en
Tier II - 3 (4)
L27/38;
M116116-04 MAN Diesel & Turbo
Figure 4: .
2017-09-14 - en
M116116-04
Work Card
4 (4) Tier II -
L27/38;
MAN Diesel & Turbo M116114-02
Manpower
Number Qualification Duration in h
2 2
Special tools
Plate No. Item No. Note
1 9000 038 Lifting tool for cylinder unit
1 9000 473 Broad chissel
1 9000 806 Hydraulic tool
1 9002 401 Fit and removing device for cooler insert
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
1 3016
M116114-02
Work Card
Starting Position
Cylinder unit is completely assembled. Valve gear of respective cylinder is in
position “valve closed”.
Tier II - 1 (6)
L27/38;
M116114-02 MAN Diesel & Turbo
Mounting of cylinder unit in engine
Procedure
2017-09-14 - en
M116114-02
Work Card
2 (6) Tier II -
L27/38;
MAN Diesel & Turbo M116114-02
2. Slowly land the piston rod on the top of the marine head.
3. Remove the locking tool for the piston rod and the cylinder liner.
Check that the marks “AS” are placed at the same side on both the
piston rod and the marine head against the exhaust side.
2017-09-14 - en
1. Lubricate threads and the contact face of the hydraulic bolts with moly-
cote paste or the like.
2. Mount the nuts and tighten them firmly with a tommy bar.
Tier II - 3 (6)
L27/38;
M116114-02 MAN Diesel & Turbo
Mounting of cylinder unit in engine
If new studs or nuts are fit, the nuts must be tightened and loosened
three times, in order to compensate for deformation of the thread and
in order to ensure a safe minimum load of the studs through the
tightening.
4 (6) Tier II -
L27/38;
MAN Diesel & Turbo M116114-02
Assembling of Connections
Mount the exhaust clamp between the cylinder head and the exhaust pipe.
1. Place new O-rings at the water connections and push the connections
into the cylinder head.
2. Secure the water connections with clamps and tighten bolts on the
clamp.
3. Place new O-rings on the charge air connection and push the connec-
tions into the next cylinder head.
4. Secure the charge air connection with a clamp and tighten the bolts on
the clamp.
5. Mount the high-pressure fuel oil pipe.
M116114-02
Work Card
Tier II - 5 (6)
L27/38;
M116114-02 MAN Diesel & Turbo
Mounting of cylinder unit in engine
Ventilation
The GenSet is self-ventilating. This means that it is not necessary for the
engine to vent the system before start.
However, to avoid problems in the ship’s installation, we recommend venti-
lating. This can be done in the following way:
1. Open connection G1, L.T. fresh water - inlet.
2. Bleed air from the venting screws on the charge air cooler.
3. Bleed air from the venting screws on the water jacket drain cock, or by
the connection F3, venting to expansion tank.
4. Open connection G2, L.T. fresh water - outlet.
5. Check for leakage.
6 (6) Tier II -
L27/38;
MAN Diesel & Turbo M116117-01
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
-
Starting Position
Engine stopped.
Description
Under normal working conditions the indicator valves require very little main-
tenance. However, to minimize toxic gases in the engine room and to keep
the engine and engine room clean, it is necessary to keep the indicator
valves tight.
Also, when taking combustion pressures/ diagrams, it is important that the
2017-05-15 - en
mechanical connection between the indicator valve and the indicator is tight
so that the parts are not overheated and damaged. It is therefore important
M116117-01
Work Card
- 1 (2)
L27/38;
M116117-01 MAN Diesel & Turbo
2 (2) -
L27/38;
MAN Diesel & Turbo M116118-01
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
Calibrated high pressure testing equip-
ment
Data
Designation Information
M116118-01
Work Card
- 1 (3)
L27/38;
M116118-01 MAN Diesel & Turbo
Check/adjustment of safety valve opening pressure
Procedure
For safety reasons, the safety valves are normally checked/adjusted at an
authorised workshop in connection with overhaul of cylinder heads.
However, it is possible to check/adjust the valves on board if calibrated high
pressure testing equipment is available.
Note
In connection with check of safety valves, do not increase the test pressure
to more than 250 bar.
Blow off pressure for L27/38 is:
230 bar +7 bar at 20° C.
2016-04-05 - en
M116118-01
Work Card
2 (3) -
L27/38;
MAN Diesel & Turbo M116118-01
M116118-01
Work Card
- 3 (3)
L27/38;
2013-02-27 - en
-
L27/38;
Plate Cooling water jacket
1 (2)
P11610-02-L2738-P
P11610-02-L2738-P
P11610-02-L2738-P MAN Diesel & Turbo
2013-02-27 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Cylinder liner
1 (2)
P11610-03-L2738-P
P11610-03-L2738-P
P11610-03-L2738-P MAN Diesel & Turbo
1 Cylinder liner
5 Flame ring (for cyl. liner)
7 Sealing ring
9 O-ring, viton
10 O-ring
P11610-03-L2738-P
2013-06-25 - en
Plate
2 (2) -
L27/38;
2017-08-21 - en
-
L27/38;
Plate Connecting rod
1 (2)
P11612-01-L2738-P
P11612-01-L2738-P
P11612-01-L2738-P MAN Diesel & Turbo
2017-08-21 - en
Plate
2 (2) -
L27/38;
2013-11-13 - en
-
L27/38;
Plate Piston with piston rings
1 (2)
P11614-09-L2738-P
P11614-09-L2738-P
P11614-09-L2738-P MAN Diesel & Turbo
1 Piston ring
2 Oil scrape ring
3 Piston ring
13 Piston compl. KS (with piston pin)
14 Piston pin
15 Retaining rings f. boring
A4 Piston compl. KS (without piston pin)
A6* O-ring
A7* Spring ring
A8* Thrust piece, piston
A9* Hexagon nut, piston
A10* Stud, piston
A11* Slide shoe
A12* Pressure spring
A13* Support ring
A15* Retainer ring
P11614-09-L2738-P
2013-11-13 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11616-03-L2738-P
Cylinder head
P11616-03-L2738-P
2017-08-09 - en
Plate
Cylinder head
P11616-03-L2738-P
2017-08-09 - en
Plate
Tier II -
L27/38;
Plate Safety valve and indicator valve
1 (2)
P11618-02-L2738-P
P11618-02-L2738-P
P11618-02-L2738-P MAN Diesel & Turbo
1 Indicator valve
2 Connection socket
3 Cap nut
4 Threaded socket
5 Covering of indicator valve
6 Molykote
A1 Safety valve
A2 Copper gasket
A3 Pipe, safety valve
A4 Protection cap
P11618-02-L2738-P
2017-12-11 - en
Plate
2 (2) Tier II -
L27/38;
MAN Diesel & Turbo P11620-03-L2738-P
Valve guard
P11620-03-L2738-P
2015-03-18 - en
Plate
- 1 (2)
L27/38;
P11620-03-L2738-P MAN Diesel & Turbo
1 Valve cover
4 O-ring
5 Cyl. screw
6 Washer
P11620-03-L2738-P
2015-03-18 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11684-02-L2738-P
L27/38
Item No. Qty Item Designation Where to find in the engine instruction book
Piston ring kit
2016-10-17 - en
L27/38
Turbocharger
Description Turbocharging, charge air cooler .................................. D118A1-02
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D118A1-02
Description
D118A1-02
- 1 (2)
L27/38;
D118A1-02 MAN Diesel & Turbo
Turbocharging, charge air cooler
2012-06-21 - en
Description
D118A1-02
2 (2) -
L27/38;
MAN Diesel & Turbo M118101-02
Manpower
Number Qualification Duration in h
2 2
Special tools
Plate No. Item No. Note
1 9002 401 Fit and removing device for cooler insert
Data
Designation Information
Weights of main components Chapter 1 00
Starting Position
Engine out of service.
Procedure
The air cooler is normally cleaned if observations prove that the cooler effi-
2017-09-14 - en
To clean the cooler on the air and the water side, it must be dismantled from
the engine.
Tier II - 1 (4)
L27/38;
M118101-02 MAN Diesel & Turbo
Cleaning of charge air cooler
Dismounting
Before the cooler can be dismantled, the instrument panels must be
removed.
1. Unscrew and remove the multiple plug in the bottom of the instrument
panels.
2. Remove the plate with the instrument panels from the air cooler.
3. Remove all allen screws from the end cover of the cooler, except for the
8 screws shown in fig 1.
2017-09-14 - en
M118101-02
Work Card
2 (4) Tier II -
L27/38;
MAN Diesel & Turbo M118101-02
6. Press out the cooler insert about 30 millimetres with the dismantling
M118101-02
Work Card
Tier II - 3 (4)
L27/38;
M118101-02 MAN Diesel & Turbo
Cleaning of charge air cooler
The greatest care must be taken when handling the cooler insert. Make
sure not to bend any of the lamellas on the tubes. If by accident some
of the lamellas have been bent they must be straightened again,
otherwise the air flow through the cooler will be reduced and change
the performance of the engine.
6. Lift the cooler insert with the lifting tool and carefully push it into the
M118101-02
Work Card
4 (4) Tier II -
L27/38;
MAN Diesel & Turbo M118102-03
Manpower
Number Qualification Duration in h
1 1/4
Special tools
Plate No. Item No. Note
1 9000 136 Blowgun for dry cleaning of turbocharger
Data
Designation Information
-
Starting Position
Engine in operation — min 75% loaded.
2017-09-14 - en
M118102-03
Work Card
Health Risk!
Health Risk!
Due to vibrations during engine operation, especially in awkward
positions!
Tool
Dry cleaning
The device is connected immediately before the TC gas inlet.
Appropriate cleaning materials are granulates from nut shells or activated
charcoal of a grain size of 1 mm (max 1.5 mm).
Cleaning sequence
Please also consult the instruction plate on the engine.
The cleaning is to be carried out at high engine load, min 75% MCR.
1. Before connecting the cleaning device (see fig 1), open the stop valve
M118102-03
Work Card
(1) and check that the passage is not blocked. Close the valve again.
2. Fill the container (2) with granulate. The amount depending on the type
of turbocharger:
TCR18 0.4 litres
TCR20 0.5 litres
M118102-03
Work Card
Turbocharger
2016-08-04 - en
Data
- L27/38 1 (1)
2014-06-06 - en
L27/38;
TCR20 - Tier II -
Plate Turbocharger TCR20, mounting
1 (2)
P11810-08-L2738-P
P11810-08-L2738-P
P11810-08-L2738-P MAN Diesel & Turbo
2014-06-06 - en
Plate
-
L27/38;
Plate Charge air cooler
1 (4)
P11812-01-L2738-P
P11812-01-L2738-P
P11812-01-L2738-P MAN Diesel & Turbo
2014-02-06 - en
Plate
2 (4) -
L27/38;
2014-02-06 - en
-
L27/38;
Plate Charge air cooler
3 (4)
P11812-01-L2738-P
P11812-01-L2738-P
P11812-01-L2738-P MAN Diesel & Turbo
2014-02-06 - en
Plate
4 (4) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Charge air connection TC/AC
1 (2)
P11814-07-L2738-P
P11814-07-L2738-P
P11814-07-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Condensed water drain for charge air cooler
1 (2)
P11814-10-L2738-P
P11814-10-L2738-P
P11814-10-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P11814-12-L2738-P
Plate
1 Cover, top
2 Cover, pump side
3 Cover, exhaust side
4 Cover, by-pass flange
5 Cover, aft end
6 Cover without by-pass, incl. item 4
10 Covering
11 Covering, TCR 18
12 Covering, TCR 20
20 Countersunk screw
21 Hexagon screw
22 Hexagon head screw
23 Washer
24 Countersunk screw
25 Hexagon head scew
P11814-12-L2738-P
2015-05-12 - en
Plate
Plate
1 Cover, top
2 Cover, pump side
3 Cover, exhaust side
4 Cover, by-pass flange
5 Cover, aft end
6 Cover without by-pass, incl. item 4
10 Covering
11 Covering, TCR 18
12 Covering, TCR 20
20 Countersunk screw
21 Hexagon screw
22 Hexagon head screw
23 Washer
24 Countersunk screw
25 Hexagon head scew
P11814-12-L2738-P
2015-05-12 - en
Plate
TierII -
L27/38;
Plate Exhaust pipe Ø170 mm
1 (2)
P11818-04-L2738-P
P11818-04-L2738-P
P11818-04-L2738-P MAN Diesel & Turbo
A1 Clamp ring
A2 Hexagon screw
A3 Spring pin
A4 Nut, heat resistant
A5 Clamp ring, compl.
A6 Pipe piece
A7 Compensator, axial0t
A8 Hexagon screw
A9 Nut
A10 Cover
A11 Hexagon screw
A14 Sealing ring
A15 Gasket
P11818-04-L2738-P
2014-11-12 - en
Plate
2 (2) TierII -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Exhaust, manifold to turbocharger
1 (2)
P11818-05-L2738-P
P11818-05-L2738-P
P11818-05-L2738-P MAN Diesel & Turbo
1 Compensator
2 Exhaust pipe with wastegate
3 Exhaust pipe without wastegate
5 Gasket
6 Hexagon screw
7 Nut, heat resistant
8 Hexagon screw
9 Nut
11 Hexagon screw
12 Spring washer
13 Nut
14 Sealing ring
A1 Clamp ring
A2 Hexagon screw
A3 Spring pin
A4 Nut, heat resistant
A5 Clamp ring, compl.
P11818-05-L2738-P
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Heat insulation
1 (2)
P11818-06-L2738-P
P11818-06-L2738-P
P11818-06-L2738-P MAN Diesel & Turbo
1 Insulating sheet
2 Insulating sheet
3 Insulating sheet
5 Hex. head screw
10 Connection wire
15 Insulating mat
16 Insulating mat
17 Insulating mat
18 Insulating mat
19 Insulating mat
P11818-06-L2738-P
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Heat insulation
1 (2)
P11818-09-L2738-P
P11818-09-L2738-P
P11818-09-L2738-P MAN Diesel & Turbo
1 Sheet
2 Sheet
3 Heat insulation
4 Insulation mat
5 Heat insulation
6 Heat insulation
7 Insulation mat
8 Hexagon screw
9 Washer
10 Wire
P11818-09-L2738-P
2013-06-25 - en
Plate
2 (2) -
L27/38;
2015-09-16 - en
-
L27/38;
Plate Cover for exhaust pipe
1 (2)
P11818-11-L2738-P
P11818-11-L2738-P
P11818-11-L2738-P MAN Diesel & Turbo
2015-09-16 - en
Plate
2 (2) -
L27/38;
2015-09-16 - en
-
L27/38;
Plate Cover before turbocharger
1 (2)
P11818-12-L2738-P
P11818-12-L2738-P
P11818-12-L2738-P MAN Diesel & Turbo
1 Cover plate
2 Cover plate
3 Sheet
4 Cover plate
5 Cover plate
6 Cover plate
7 Bracket
8 Pipe clamp
9 Cover plate
10 Cover plate
11 Cover plate
12 Sheet
13 Screw
14 Hexagon head screw
15 Locking spring washer
16 Hexagon head screw
17 Hexagon bolt
P11818-12-L2738-P
2015-09-16 - en
Plate
2 (2) -
L27/38;
2013-03-01 - en
-
L27/38;
Plate Turbocharger turbine cleaning valve
1 (2)
P11820-01-L2738-P
P11820-01-L2738-P
P11820-01-L2738-P MAN Diesel & Turbo
2013-03-01 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Compressor cleaning, arrangement
1 (2)
P11822-04-L2738-P
P11822-04-L2738-P
P11822-04-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D120A1-01
MDO
For operation on MDO (Marine Diesel Oil), the standard engine is equipped
with built on:
▪ Fuel oil primary pump
▪ Double filter with paper inserts
▪ Lubrication of fuel oil pumps
▪ Fuel oil pumps with leak oil seal
▪ Uncooled fuel injection valves
The MDO built on equipment is designed for single engine installation. For
multi engine installations, it is recommended to have either separate fuel sup-
plies or the built on pumps have to be replaced by electrical pumps.
HFO
For operation on HFO (Heavy Fuel Oil), the standard engine is equipped with
built on:
▪ Fuel oil duplex slit filter
▪ Fuel oil back pressure valve
▪ Lubrication of fuel oil pumps
▪ Uncooled fuel injection valves
The built on equipment is designed for use on fuel oil modules, normally
referred to as booster modules. For multi engine installations, a common fuel
oil feed system should cover all engines.
HFO quality
We recommend to use heavy fuel up to 380 cSt/ 50°C, even though the
engine is designed for operation on HFO up to 700 cSt/ 50°C, depending on
the actual fuel quality.
For fuel oil quality, see Viscosity temperature (VT) diagram of fuel oil/ Quality
of heavy fuel oil (HFO) in chapter 00 Data. The maximum injection viscosity is
12–14 cSt.
2012-04-17 - en
Description
D120A1-01
- 1 (1)
L27/38;
MAN Diesel & Turbo D120B2-01
Figure 1: Fuel oil diagram - HFO (for guidance only, please see plant specific engine diagram)
2015-04-07 - en
Description
D120B2-01
- 1 (4)
L27/38;
D120B2-01 MAN Diesel & Turbo
Item Description
Fuel oil system — HFO
Connections:
B1 Fuel oil inlet engine
B2 Drain oil from fuel valves
B4 Fuel oil circulation to service tank
B7 Leak oil to drain tank (with alarm)
The settling tank (1) should be designed to provide the most efficient sludge
Description
2 (4) -
L27/38;
MAN Diesel & Turbo D120B2-01
Because the capacity of the fuel oil booster pumps (16/16A) is higher than
Description
the consumption of the engine, the surplus oil from the engine is returned to
D120B2-01
- 3 (4)
L27/38;
D120B2-01 MAN Diesel & Turbo
In order to heat the HFO to the proper viscosity before the injection valves
Fuel oil system — HFO
2015-04-07 - en
Description
D120B2-01
4 (4) -
L27/38;
MAN Diesel & Turbo D120C1-01
Description
D120C1-01
- 1 (3)
L27/38;
D120C1-01 MAN Diesel & Turbo
Fuel injection system
Fuel pump
The fuel pump and the roller guide are one unit, placed over the fuel cam. A
pipe supplies lubricating oil from the camshaft bearing to the roller guide.
The barrel is installed with seals on the outer circumference at various levels
to avoid leakages and to give the possibility to drain fuel from the lower part
of the barrel bore.
At the same time it also gives the possibility to add sealing oil to minimize fuel
contamination of the lubricating oil.
The rack for fuel control is shaped as a piston at one end. The piston works
inside a cylinder. When the cylinder is pressurized, the fuel rack will go to
zero and the engine will stop.
A delivery valve is installed on top of the barrel. In the delivery valve housing a
second valve is installed. This valve will open for oscillating high pressure
waves between the needle in the fuel injection valve and the delivery valve on
the pump, causing the needle in the fuel valve to stay closed after the injec-
tion is finished. This will reduce formation of carbon around the nozzle tip and
save fuel.
2013-06-25 - en
Description
D120C1-01
2 (3) -
L27/38;
MAN Diesel & Turbo D120C1-01
Description
D120C1-01
- 3 (3)
L27/38;
MAN Diesel & Turbo M120101-02
Manpower
Number Qualification Duration in h
1 2
Special tools
Plate No. Item No. Note
1 9002 342 Fit and removing device for fuel injection
pump
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Covers over fuel pumps removed.
2017-09-14 - en
M120101-02
Work Card
Tier II - 1 (5)
L27/38;
M120101-02 MAN Diesel & Turbo
Dismantling/installation of fuel injection pump
Warning!
Dismantling
1. Close the valves in the fuel lines and the air supply for safety stop.
2. Dismantle the high pressure fuel pipe.
3. Remove the pipes for lubrication, drain and air.
4. Remove the plug screws (1) fig 1.
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M120101-02
M120101-02
Work Card
Tier II - 3 (5)
L27/38;
M120101-02 MAN Diesel & Turbo
Dismantling/installation of fuel injection pump
Installation
1. Clean all the joint surfaces on the engine and the pump.
2. Place new O-ring seals (2) fig 5 on the orifice flanges at the inlet and
outlet of the pump and the lower part of the pump (2) fig 1.
Lubricate the O-rings with acid-free grease.
2017-09-14 - en
M120101-02
Work Card
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M120101-02
4. Establish all the connections earlier disconnected, fit new O-rings (1) fig
M120101-02
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M120102-03
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9002 342 Fit and removing device for fuel injection
pump
Data
Designation Information
Tightening specification Chapter 1 00
Starting Position
Fuel injection pump dismantled from engine, see work card 20 101.
2017-10-18 - en
M120102-03
Work Card
Tier II - 1 (8)
L27/38;
M120102-03 MAN Diesel & Turbo
Disassembly/reassembly and repair of fuel injection pump
Do not touch the pump plunger with your bare hands. Protect the
control edges on the pump plunger from damage.
2017-10-18 - en
M120102-03
Work Card
2 (8) Tier II -
L27/38;
MAN Diesel & Turbo M120102-03
14. Unscrew the hexagon socket screws (7) and take the thrust ring (19)
Work Card
off.
15. Put the thrust plate onto the monobloc cylinder and fasten it in place,
see fig 4.
Tier II - 3 (8)
L27/38;
M120102-03 MAN Diesel & Turbo
16. Screw two hexagon head bolts into the thrust plate down to contact
Disassembly/reassembly and repair of fuel injection pump
18. Remove the monobloc cylinder from the casing and put it down on a
clean support.
19. Measure the axial and radial clearance of roller (8), fig 3, note down and
compare with the specified clearances, see data 1 00J2-02. In case of
exceeding values, please replace wearing parts.
20. Check the complete valve support, (20) fig 3, for tightness and verify
that the individual parts move easily. Disassemble the valve support if
necessary.
21. Clean all the parts with clean diesel oil and check them for wear or
damage.
2017-10-18 - en
M120102-03
Work Card
4 (8) Tier II -
L27/38;
MAN Diesel & Turbo M120102-03
M120102-03
Work Card
Tier II - 5 (8)
L27/38;
M120102-03 MAN Diesel & Turbo
5. Treat new sealing rings (9) and o-ring seals (10 and 11) with acid-free
Disassembly/reassembly and repair of fuel injection pump
grease and fit them in ring groove, taking care that the o-ring seals are
evenly tensioned aver the circumference, and not twisted, see fig 3.
6. Assembly of sealing rings, according to fig. 7. Following require that
extra tool are supplied by MAN Diesel & Turbo.
7. Introduce the monobloc cylinder into casing, taking note of the position
of the cylindrical pin, refer to fig 6.
bridge over the thrust plate on the casing, and screw the hexagon nut
down to contact with the thrust plate, see fig 6. Screw the hexagon
M120102-03
Work Card
6 (8) Tier II -
L27/38;
MAN Diesel & Turbo M120102-03
When forcing the monobloc cylinder into the casing, prevent it from
Figure 8: Order of tightening the fixing bolts for the barrel cylinder (left) and valve
M120102-03
Work Card
support (right)
15. Fit the regulating sleeve so that the markings (M), see fig 5, on the fuel
rack and regulating sleeve coincide.
16. Install the spring plate through the regulating sleeve into the casing.
Tier II - 7 (8)
L27/38;
M120102-03 MAN Diesel & Turbo
Prior to installing the spring plate, verify once again that the markings
Disassembly/reassembly and repair of fuel injection pump
Do not touch pump plungers with your bare hands. Protect control
edges on plungers against damage.
19. Put the tappet (16) over the plunger base plate and fasten it by four
hexagon socket bolts (3).
20. Measure the clearance (A), fig 3, of the pump plunger between the
thrust plate (2) and the plunger base plate, note down and compare
with specified value, see data 1 00J2. In case of exceeding values,
please replace wearing parts.
21. Carefully push the plunger and tappet into the monobloc cylinder
and/or casing, taking note of the position of the longitudinal groove in
the tappet for the screw plug (17).
22. Screw the spindle back and place the bridge diagonally onto the casing
and fasten it by hexagon nuts, see fig 2/I.
23. Turn the spindle until the thrust pad contacts the tappet see fig 2/II.
24. Turn the spindle to depress the tappet far enough to allow the screw
plug equipped with a new gasket to be fitted, see fig 2/III.
25. Insert a masuring mandrel in cavitation holes. Depress the tappet spring
until plunger just have contact with measuring mandrel area of 6.5h6,
see fig 3. Check that the clearance (B) from roller to mounting surface
comply the dimension, see fig 3 and data 1 00J2. In case of exceeding
values please exchange the trust plate (2).
26. Remove the complete tool.
27. Screw the baffle screws (6) complete with new gaskets (18) into the
casing specified.
2017-10-18 - en
M120102-03
Work Card
8 (8) Tier II -
L27/38;
MAN Diesel & Turbo M120103-03
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 050 Pressure testing tool
1 9000 074 Grinding device for nozzle seat
1 9000 407 Extractor device for injector valve
Hand Tools
Qty Designation Number Status
Ring- and open end spanner, 12 mm
Ring- and open end spanner, 24 mm
Socket spanner, 24 mm
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
M120103-03
Work Card
Starting Position
Operating media systems closed/depressurised. Engine shut down.
Tier II - 1 (6)
L27/38;
M120103-03 MAN Diesel & Turbo
Removal and refitting of fuel injection valve
Warning!
Procedure
Execute work on time according to the maintenance schedule, enable/
support economic operation, prevent operating problems damages.
Fuel injection valves affect the loading of the injection system and the operat-
ing values of the engine. They are to be checked if there are deviations in the
operating values, to be overhauled if necessary or changed.
An engine that runs usually on heavy oil, should be operated for a short
while on diesel oil before disassembling the fuel injection valves.
Initial state
Stop valves on fuel pipes closed. Oil pump (reserve) shut off, cylinder head
cover removed, indicator valve opened.
1. Remove the side cover over the fuel pump and the top cover over the
rocker arms for the cylinder head.
2. Dismantle the delivery pipe between the fuel pump and the lance (5) fig
1.
2017-09-14 - en
M120103-03
Work Card
2 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120103-03
M120103-03
Work Card
Tier II - 3 (6)
L27/38;
M120103-03 MAN Diesel & Turbo
Removal and refitting of fuel injection valve
4 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120103-03
Initial state
Injection valve, especially cylindrical seat of nozzle bodies cleaned carefully.
Opening pressure, tightness and nozzle bores checked.
1. Fit new round ring seals (8), lubricated with clean lubricating oil, in the
ring groove, ensuring that this is tensioned equally on the entire periph-
ery and not twisted.
2. Fill the inside space (spring room) of the injection valve through leakage
fuel draining hole, with clean fuel.
3. Remove cover for bore in the cylinder head and clean the bore and seat
face in the cylinder head carefully.
4. Assemble injection valve in bore, taking care of correct positioning of
the bore for threaded piece. Fit new round ring seals (8), lubricated with
clean lubricat- ing oil, in the ring groove, ensuring that this is tensioned
equally on the entire periphery and not twisted.
5. Add lubricant pasta to the thread of the lance (5) and screw it into the
fuel valve.
6. Place the thrust collar (2) fig 1 on the fuel injection valve and apply lubri-
cant type GN or similar on screw thread, contact surface and hexagon
nuts (1). Then tighten with hand and after installation of the lance (5) the
hexagon nuts (1) can be tightened to the specified torque of 115 Nm.
Prior to the tightening It might be necessary to turn the fuel valve a little
to make the thread catch. Tightening torque for the lance is 75 Nm.
7. Place the locking device on the hexagon of the lance and secure it with
the screw (4) lubricated with oil. Tightening torque 115 Nm.
8. Ad lubricant type GN or similar to the lance (5) and the fuel pump top
and install the high pressure pipe. Tighten- ing torque: 50 Nm.
9. Close indicator valve.
2017-09-14 - en
Tier II - 5 (6)
L27/38;
M120103-03 MAN Diesel & Turbo
Removal and refitting of fuel injection valve
2017-09-14 - en
M120103-03
Work Card
6 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120104-02
Manpower
Number Qualification Duration in h
1 2
Special tools
Plate No. Item No. Note
1 9000 050 Pressure testing tool
1 9000 074 Grinding device for nozzle seat
1 9000 407 Extractor device for injector valve
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
-
Procedure
Assembly of the fuel injection valve see work card 20 106.
Check components for quality/wear condi- tion ensure/ restore operating
reliability. Fuel injection valve affect the loading of the fuel injection system
and the operating values of the engine. They are to be checked if there are
2017-09-14 - en
Tier II - 1 (6)
L27/38;
M120104-02 MAN Diesel & Turbo
Fuel injection valve to be checked
Preliminary observations
Functioning capability and setting of the injection valve affect the combustion
course, the operating values and the loading of the injection system. If the
operating values are changed (ignition pressure, exhaust temperature) the
opening pressure and tightness of the concerned valves should be checked.
The nozzle test stand allows to pressure- test and adjust the injection valve,
using a hydraulic hand pump. The fixture ensure comfortable working under
reproducible conditions.
In the testing of injection valves of modern 4-stroke engines the atomisation
is no longer a test criterion, because the behaviour of the injection nozzle in
engine operation cannot be verified.
An inferior spray pattern does not say anything about the functioning of the
injection nozzles in the engine. It is fully functional if the criteria for opening
pressure, tightness and free nozzle bores are fulfilled.
4 Test pressure pump for fuel noz- 5 Clamping for injection valve
zle complete
6 Adapter for fuel injection valve 6 High pressure pipe
2 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120104-02
1 Fixation for mounting device 2 Lever for pump Fuel injection valve to be checked
3 Partition of test rig in tabletop 4 Lever with locking mechanism
(GXO-G011a) for rotating of mounting device
5 Device to move showcase up 6 Pockets for eg mounting device
and downwards or tools
7 Oil collecting tank 8 Fan to evacuate oil vapour
9 Showcase to watch spray pat- 10 Connection for high pressure
tern pipe
11 Lever to switch from opening 12 Relief valve lever (to release
pressure to boost test pressure in high pressure pipe)
13 Pressure gauge (with bar and
PSI scaling)
2017-09-14 - en
Tier II - 3 (6)
L27/38;
M120104-02 MAN Diesel & Turbo
Fuel injection valve to be checked
Heavy oil residues in the injection valves can adversely affect test
result and make cleaning more difficult. It is therefore recommended
that the engine run on diesel oil for about 1 hour before disassembling
the injection valves. If that is not possible then it is important to carry
out the described test at once after injection valves are removed from
engine. Otherwise the injection valve has to be sepa- rated and
cleaned before testing.
Initial state
Injection valve is dismantled and cleaned on the outside.
Use anti-corrosion oil for checking the injection valves, so that they
also given the conservation treatment. Only absolutely clean anti-
corrosion oil should be filled in the nozzle test stand otherwise there
could be malfunctioning in the pump or in the injection valve to be
tested. The fill level of the oil container (12) should be checked.
1. Insert injection valve in the adapter head and tighten uniformly with
holder.
2. Thread in connection piece on pressure hose connection of the injec-
tion valve and screw in high pressure hose on connecting piece.
3. Set nozzle jet collector vessel under the injection nozzle and push it up
until the expected jets meet on the outer walls of the nozzle jets collec-
tor vessel.
Never allow injection nozzle to spray into open air but only in the
collector! Do not touch fuel jets, as they penetrate the skin structure
and cause painful inflammation! Do not use any open flames at
workplace! Smoking is absolutely prohibited! Use suction on oil mist
wherever possible.
The checking and setting of the injection valves extends to the following
steps:
▪ Check opening pressure
▪ Check nozzle bores
▪ Set target pressure
▪ Check tightness
2017-09-14 - en
1. Close pressure relief valve (12) if it exist on the test equipment used.
4 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120104-02
2. Actuate hand pump (26) uniformly and raise pressure until the injection
Decision
Opening pressure drop less /greater than 90 bar.
Opening press. drop less than 90 bar:
▪ Continue with the next step.
Opening press. drop greater than 90 bar:
▪ Separate injection valve as mentioned in workcard 20 105.
▪ Carry out visual inspection (spring breakage)
▪ If component is in order, continue with the next step
Decision
All nozzle holes open? See fig 3
2017-09-14 - en
M120104-02
Work Card
Figure 3: Assessment of the nozzle holes. Left – open, right – partly clogged
▪ Yes, continue with the next step
▪ No, Separate the injection valve as mentioned in work card 20 105.
Tier II - 5 (6)
L27/38;
M120104-02 MAN Diesel & Turbo
Fuel injection valve to be checked
2. If the reference value is set reproducibly, lock the adjusting screw (2)
with the hexagonal nut (1) and check the opening pressure again.
Make sure, that no oil drop off from the nozzle leakage bore (9) (see fig
3 workcard 20 105). This may causes a misinterpretation of the tight
nozzle. Avoid this by wrapping a cleaning rag around the injection
nozzle.
Decision
Tightness OK? see fig 4.
2017-09-14 - en
6 (6) Tier II -
L27/38;
MAN Diesel & Turbo M120105-02
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 050 Pressure testing tool
Hand Tools
Qty Designation Number Status
Torque wrench
Ring- and open end spanner, 41 mm
Hexagonal screw driver (set)
Wire brush
Spatula (wood)
Depth gauge
Container with fuel
Polishing medium (wool)
Paper towels
Lubricant (containing molyb- denum disul-
phide)
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
2017-09-14 - en
Starting Position
M120105-02
Work Card
Tier II - 1 (5)
L27/38;
M120105-02 MAN Diesel & Turbo
Fuel injection valve to be separated
Procedure
Check components for quality/wear condi- tion, prevent operating problems/
damages.
Fuel injection valves affect the loading of the fuel injection system and the
operating values of the engine. They are to be checked if there are deviations
in the operating values, to be overhauled if necessary or changed.
The work extends: Separation of components. Checking of parts/ compo-
nents
Preliminary observation
Separate injection valve if, during the test according to work card 20
104, errors are detected and if the nozzle element should be changed
due to the operation time. The separation is done by placing the valve
in a vice with soft jaws.
2017-09-14 - en
M120105-02
Work Card
2 (5) Tier II -
L27/38;
MAN Diesel & Turbo M120105-02
1. When threading out the nozzle tensioning nut (4) use the following
method: Unscrew released nozzle tensioning nuts and at the same time
prevent them from lifting axially from holder by continuously lightly hit-
ting with rubber hammer on nozzle bodies.
2. Thread off nozzle tensioning nut and remove nozzle body. See that noz-
zle needle does not fall out.
3. Extract nozzle needle from nozzle body and place it in fuel for cleaning.
Nozzle needle
1. Remove the injection valve from the vice with soft jaws and place it on
the workbench.
2017-09-14 - en
4. If all internal parts are not loose, screw in suitable eye bolt in thrust
piece (5) and extract thrust piece. Then disas- semble compression
spring (6) and thrust piece (7).
Tier II - 3 (5)
L27/38;
M120105-02 MAN Diesel & Turbo
5. Place all parts for cleaning in diesel oil and wash them off. Then blow
Fuel injection valve to be separated
Check components
The inspection of the components extends to:
▪ The nozzle holes
▪ The quality of fitting faces
▪ The mobility of the needle
▪ Traces of corrosion on the nozzle tensioning nut and the nozzle body
▪ The nozzle specifications
1. Check if nozzle needle can be moved in the nozzle body easily and
without perceivable resistance, see fig 3.
2017-09-14 - en
M120105-02
Work Card
4 (5) Tier II -
L27/38;
MAN Diesel & Turbo M120105-02
M120105-02
Work Card
Tier II - 5 (5)
L27/38;
MAN Diesel & Turbo M120106-02
Manpower
Number Qualification Duration in h
1 1
Special tools
Plate No. Item No. Note
1 9000 050 Pressure testing tool
Hand Tools
Qty Designation Number Status
Torque wrench
Ring- and open end spanner
Hexagonal screw driver (set)
Lubricant (copaslip, containing molybdenum
disulphide)
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
-
Procedure
Impart necessary knowledge, ensure correct execution of work.
2017-09-14 - en
Fuel injection valves affect the loading of the fuel injection system and the
operating values of the engine. They are to be checked if there are deviations
M120106-02
Work Card
Tier II - 1 (3)
L27/38;
M120106-02 MAN Diesel & Turbo
Assembly of the fuel injection valve
Initial situation
Injection valve separated, all individual parts carefully cleaned, damaged
parts changed.
2017-09-14 - en
M120106-02
Work Card
2 (3) Tier II -
L27/38;
MAN Diesel & Turbo M120106-02
M120106-02
Work Card
Tier II - 3 (3)
L27/38;
MAN Diesel & Turbo M120107-02
Manpower
Number Qualification Duration in h
1 1/2
Special tools
Plate No. Item No. Note
1 9000 074 Grinding device for nozzle seat
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
-
Procedure
Ensure correct execution of work, assess contact pattern/wear status,
restore contact pattern again.
The injection valve seat face in the cylinder head should be checked on every
disassembly of the fuel injection valve by means of touching up sampling and
reworked if necessary.
The work extends: Creating of correct contact pattern.
2017-09-14 - en
M120107-02
Work Card
Tier II - 1 (2)
L27/38;
M120107-02 MAN Diesel & Turbo
Grinding of fuel injection valve seat face
Initial state
Fuel injection valve dismantled.
1. Before mounting the fuel valve, clean and inspect the valve sleeve in the
cylinder head.
2. If necessary, grind the seating face with the grinding tool see fig 1.
3. Place grinding tool in cylinder head, paying attention to guide piece (2)
is in correct position inside cylinder head.
4. Rotate grinding tool to and fro, raise in-between and blow off grinding
dust with compressed air.
5. Remove grinding tool see fig 1 after the grinding process is complete
and clean valve seat carefully.
2017-09-14 - en
M120107-02
Work Card
2 (2) Tier II -
L27/38;
MAN Diesel & Turbo M120108-01
Manpower
Number Qualification Duration in h
1 1/2
Hand Tools
Qty Designation Number Status
Combination spanner, 17 mm
Combination spanner, 24 mm
Air gun
Soft brush
Cleaning agent
Data
Designation Information
-
Short Description
Disassembly, cleaning and assembly of fuel oil duplex filter
2016-04-25 - en
M120108-01
Work Card
- 1 (4)
L27/38;
M120108-01 MAN Diesel & Turbo
Cleaning of fuel oil filter
2 (4) -
L27/38;
MAN Diesel & Turbo M120108-01
When using HFO, never let the dirty fi lter element cool down before
soaking into the cleaning agent.
5) After taking the filter element up from the cleaning agent, carefully blow
compressed air through it from the outside to the inside, rinse the filter
element in cleaning fluid and blow through again with air. For obstinate
dirt, use a soft brush that cannot damage the mesh.
Always check the filter element for damage. Filter elements with
damaged, mesh and joint surfaces must be changed. Clean the filter
chamber carefully before inserting a clean filter element to prevent
harmful particles from entering the fuel injection system (Fig. 3).
2016-04-25 - en
M120108-01
Work Card
- 3 (4)
L27/38;
M120108-01 MAN Diesel & Turbo
Cleaning of fuel oil filter
2016-04-25 - en
M120108-01
Work Card
4 (4) -
L27/38;
2016-04-25 - en
L27/38;
25 my, DN40 -
Plate Fuel oil filter, duplex - HFO
1 (2)
P12014-04-L2738-P
P12014-04-L2738-P
P12014-04-L2738-P MAN Diesel & Turbo
2 Screw plug
3 Gasket
4 Screw plug
5 Gasket
6 Screw plug
7 Gasket
11 Bolt
13 Cover
15 O-ring
17 Nut
18 Ball valve
19 Cock
21 O-ring
25 Circlip ring
28 Plug key
30 Gasket
33 Filter element
37 Gasket
41 Bolt
44 Nut
77 Fuel oil filter duplex, complete
P12014-04-L2738-P
2016-04-25 - en
Plate
- L27/38
Plate Fuel injection pump
P12016-02-L2738-P
1 (4)
P12016-02-L2738-P
P12016-02-L2738-P MAN Diesel & Turbo
2013-09-18 - en
Plate
2 (4) - L27/38
2013-09-18 - en
- L27/38
Plate Fuel injection pump
P12016-02-L2738-P
3 (4)
P12016-02-L2738-P
P12016-02-L2738-P MAN Diesel & Turbo
61 Speeder rod
62 Gasket
63 Sealing ring
64 Cylinder for emergency stop
65 Glue loctite 243
69 Molykote-paste, 250 gr.
A1 Pressure control valve, fuel pump
A2 Spring
A3 Steel ball
A4 Spring guide
A5 Spacer sleeve
A6 Pressure valve
A7 Spring
A8 Cylindrical pin
B1 Tappet
B2 Roller
B7 Roller
B8 Threaded pin
B9 Loctite 620
B10 Bush
P12016-02-L2738-P
2013-09-18 - en
Plate
4 (4) - L27/38
2013-06-10 - en
-
L27/38;
Plate Fuel injection valve
1 (2)
P12018-02-L2738-P
P12018-02-L2738-P
P12018-02-L2738-P MAN Diesel & Turbo
2013-06-10 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate High pressure fuel oil pipes
1 (2)
P12020-01-L2738-P
P12020-01-L2738-P
P12020-01-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Fuel oil pipes
1 (2)
P12020-03-L2738-P
P12020-03-L2738-P
P12020-03-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2014-06-11 - en
-
L27/38;
Plate Low pressure fuel oil pipes - HFO
1 (2)
P12020-07-L2738-P
P12020-07-L2738-P
P12020-07-L2738-P MAN Diesel & Turbo
2014-06-11 - en
Plate
2 (2) -
L27/38;
2016-10-17 - en
1 (2)
P12086-01-L2738-P
L27/38
P12086-01-L2738-P MAN Diesel & Turbo
Item No. Qty Item Designation Where to find in the engine instruction book
Kit for inspection of fuel pump
2016-10-17 - en
L27/38
1 (2)
P12088-01-L2738-P
L27/38
P12088-01-L2738-P MAN Diesel & Turbo
Item No. Qty Item Designation Where to find in the engine instruction book
Kit for inspection of fuel valve
2016-10-17 - en
L27/38
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
2015-12-23 - en
-
L27/38;
Plate Governor and governor drive
1 (2)
P12410-07-L2738-P
P12410-07-L2738-P
P12410-07-L2738-P MAN Diesel & Turbo
1 Governor, Europa
4 Hexagon socket head cap screw
7 Governor lever
8 Hexagon screw
9 Spring washer
10 Screw
11 Self-locking hexagon nut
12 Disc spring
13 Pull rod
14 Linkage
15 Ball joint
16 Nut
17 Hexagon socket head cap screw
18 Nut
20 Governor drive, complete
B1 Housing
B2 Spur wheel
B3 Bevel gear wheels
B4 Bearing bush
B5 Castle nut
B6 Shaft
B8 Thrust disc
B9 Washer
B10 Hexagon socket set screw
B11 Key
B12 Copper gasket
B13 Plug screw
B14 Cylindrical pin
B16 Split pin
B19 Sealing ring
B22 Ball bearing
B23 Disc
B25 Expander plug
B26 O-ring
B28 Expander
B29 Bevel gear wheels
B30 Gearwheel incl. item B3 and B4
P12410-07-L2738-P
2015-12-23 - en
Plate
2 (2) -
L27/38;
2015-01-13 - en
-
L27/38;
Plate Speed control system
1 (2)
P12412-01-L2738-P
P12412-01-L2738-P
P12412-01-L2738-P MAN Diesel & Turbo
2015-01-13 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo
Work Card Overhaul, test and inspection of air starter ................... M126101-01
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D126A1-03
Description
D126A1-03
- L27/38 1 (2)
Description Starting air system
2 (2)
D126A1-03 D126A1-03
- L27/38
MAN Diesel & Turbo
2015-04-08 - en
MAN Diesel & Turbo M126101-01
Manpower
Number Qualification Duration in h
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
All connections to the air starter have been removed, and air starter is
removed.
2017-05-15 - en
M126101-01
Work Card
TDI - 1 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Overhaul, test and inspection of air starter
Warning!
Operation
The starters are powered by a pair of axial flow turbines coupled to a simple
planetary gear reduction set. The starters incorporate an inertia bendix drive
coupled to the starter gearbox drive train to provide a means of disengaging
the pinion from the engine’s ring gear.
It is important to properly install and operate the starters to receive the full
benefits of the turbine drive advantages.
2017-05-15 - en
M126101-01
Work Card
2 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
The carrier shaft is mounted on two ball bearings (38) in the gearbox housing
(48). The aft bearing is preloaded by use of spring washers (39). The forward
M126101-01
Work Card
bearing is installed into the bearing housing (43), which is secured by four
screws (44) to the gearbox housing. The spur gear (45) is installed on the
carrier shaft and secured by the bearing locknut (47).
TDI - 3 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Overhaul, test and inspection of air starter
Drive assembly
The drive assembly, please see Fig 3, consists of a piston (53), helical shaft
spline (56), dental clutch (58) and drive pinion shaft (61). The clutch assembly
(56 thru 64) is installed into the spur gear (65). The spur gear (65) is suppor-
ted by the aft bearing (66), which is secured by the retaining ring (67).
The roller bearing (69) is installed into spur gear (65) and secured by retaining
ring (70). The forward bearing (66) is pressed into the drive housing. The lip
seal (75) is pressed into the forward side of drive housing (72).
The pinion collar (76) is installed on pinion shaft (61) behind pinion (77), which
is secured by washer (78) and screw (79).
2017-05-15 - en
M126101-01
Work Card
4 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
General
Always mark adjacent parts on the starter housing;
Nozzle 2/ Containment Ring (11), Turbine Housing (23), Gearbox Housing
(48), and Drive Housing (72) so these parts can be located in the same rela-
tive position when the starter is reassembled.
Do not disassemble the starter any further than necessary to replace a worn
or dama- ged part. Always have a complete set of seals and o- rings on
hand before starting any overall of a the starter. Never use old seals or o-
rings.
The tools listed in Table 1 are suggested for use by technicians servicing the
starters. The best results can be expected when these tools are used, how-
ever the use of other tools are acceptable.
Tool Description No
Spanner wrench 52-20134
Spanner wrench 52-21345
Shaft Removal Tool 2-26945
Stage 2 Rotor Puller Tool 52-20076
Carrier Shaft Holding Tool 52-20202
Tool, Bearing Pressing 52-20143
2017-05-15 - en
TDI - 5 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Overhaul, test and inspection of air starter
Drive housing
Before removing the eight screws (73), install a spacer between pinion
(77) and drive housing (72) to allow for easy installation during
reassembly.
Use only a soft tooth vise to secure the pinion to avoid damaging
pinion.
Gearbox housing
M126101-01
Work Card
6 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
Remove ring gear (27) from turbine (23) or gearbox assembly (48). The ring
Gearbox disassembly
Place gearbox assembly (48), please see Fig 2 on flat surface with aft end
facing up.
Remove four screws (44) and lift carrier shaft assembly (32) from gearbox
housing.
Place carrier shaft assembly on carrier shaft holding tool (52-20202) and use
a screw- driver to remove tang of lock washer (46) from slot of retainer nut
(47).
Place tool No 52-20134 (Spanner Wrench) over shaft and into slots of
retainer nut (47).
Hold carrier shaft assembly down and turn spanner wrench counter clock-
wise to remove retainer nut, lock washer (46), spur gear (45), and woodruff
key (37) from carrier shaft (32). Use an arbor press to remove carrier shaft
(32) from bearing housing (43).
The bearing housing must be elevated and supported to remove carrier
shaft.
Do not support the bearing housing on the four lips as they could
break while pressing on carrier shaft.
Remove spring washer (39), spring retaining plates (40), and bearing spacer
(42) from carrier shaft.
Remove aft bearing (38) from shaft by pressing shaft while supporting bear-
ing.
Turbine Housing
Secure the stage 2 rotor (5) and remove the turbine screw (3) and washer (4).
M126101-01
Work Card
Install the rotor puller tool No 52-20076 and remove the stage 2 rotor.
Remove the woodruff key (6) from the turbine shaft (30).
TDI - 7 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Overhaul, test and inspection of air starter
The jacks will damage the stage 1 rotor if pressure is applied to the rotor
while removing nozzle 2.
Remove stage 1 rotor (13) and o-ring (12) from nozzle 2. Remove the four
screws (16) and nozzle 1 (17) from the turbine assembly. It may be necessary
to tap the screws with a hammer and chisel to loosen.
Remove o-ring (19) from aft end of turbine housing.
Remove the seal spacer (15) from the for- ward side of nozzle 2 (11). Place
the stage 2 nozzle on the exhaust end. Press through the forward lip seal
onto the bearing until it, including the aft lip seal and seal spacer disengages
from the nozzle. Turn the nozzle over and press on the forward lip seal to
remove.
Cleaning
Degrease all metal parts, except bearings, using a commercially approved
solvent.
Clean aluminum parts.
Remove parts, rinse in hot water, and dry thoroughly.
Clean corroded steel parts with a commercially approved stripper.
Clean corroded aluminum parts and rinse in hot water and dry thoroughly.
2017-05-15 - en
M126101-01
Work Card
Inspection
Use Table 2 as a guide to check for acceptable condition of the parts listed.
Check all threaded parts for galled, crossed stripped, or broken threads.
Check all parts for cracks, corrosion, distortion, scoring, or general damage.
8 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
impaired.
Ring Gear Cracks, wear, chipped, or Wear must not exceed
broken gear teeth. limits per Table 3.
TDI - 9 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
are acceptable.
10 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
Replace all screws, O-rings, lip seals, and bearings when the starter is
reassembled.
Always press the inner race of a ball bearing when installing a bearing
on a shaft. Always press the outer race of a ball bearing when installing
into a housing.
The list of kits and components, which are available to aid in rebuilding the
starters. Lubricate all O-rings with petroleum jelly or Parker-O-Ring Lube
before assembly.
The screws that secure the Containment Ring/ Stage 2. Nozzle must
have a drop of Loctite RC290 applied to the threads before being used.
Turbine housing
Nozzle 1 installation
Press the aft seal (15) into nozzle 1 (19) using press tool No 2-26943 per
Table 1, with the lips facing up.
TDI - 11 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Orient the nozzles facing the air inlet (21) and install four screws (16) to
secure the nozzle.
Do not tighten the screws at this time.
Rotor 1 installation
Install the large woodruff key (14) for stage 1 rotor into the turbine shaft (30).
Install the stage 1 rotor (13), while supporting sun gear end of shaft, onto the
turbine shaft by aligning the slot in the rotor with the woodruff key and hand
press the rotor until firmly seated.
Use press tool No 2-26943 if required. Visually inspect that the key was not
pushed out during assembly.
Note that the direction of rotation was oriented properly.
This turbine rotor can be installed backwards. Install spacer (7) onto sun gear
(30). To center nozzle 1, temporarily install Noz- zle 2 (11) on the turbine
housing and tighten the four screws that secure nozzle 1 (17) to 30 in-lb.
The four screws can be accessed via the holes in nozzle 2 and the first stage
turbine rotor.
Remove Nozzle 2 when the four screws are tight.
Nozzle 2 installation
Install the O-ring (9) into the bearing bore of nozzle 2 (11).
Do not lubricate this O-ring. Install O-ring (12) onto the outer diameter of noz-
zle 2 and install nozzle 2 (11) onto the turbine housing (23).
The rotation of the turbine assembly is op- posite from the pinion
rotation, therefore this nozzle must be configured for LH (CCW)
rotation if the pinion rotation is RH (CW), or configured for RH (CW) if
pinion rotation is LH (CCW).
Install the seal spacer (7) onto the shaft and the wavy spring washer (10) into
the bearing bore of the stage 2 nozzle.
While supporting the sun gear end of the shaft, press the aft bearing (8) onto
the shaft by pressing onto the inner and outer race simultaneously.
Use press tool No 2-26943 per Table 1.
2017-05-15 - en
Press until bearing is seated. Install the stage 2 woodruff key (6) into the shaft
M126101-01
Work Card
(30).
12 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
Note that the direction of rotation was oriented properly. This turbine
can be installed backwards.
Install the rotor washer (4) and secure with screws (3). Tighten screw to 100
in-lb.
Install the exhaust screen (2) and secure with six screws (1). Tighten the
screws to 80 in-lb.
Gearbox Housing
Install retainer ring (31) onto planet shaft (36) using a retainer ring tool.
Gearbox reassembly
Install bearing (38) into the bearing housing (43) and secure with retaining
ring (41). Press aft bearing (38) onto carrier shaft (32) using Tool No
2017-05-15 - en
(39), spring retaining plate (40) and bearing spacer (42) onto shaft and locate
against bearing.
Position bearing housing assembly (38, 41, 43) over carrier shaft (32) and
press until firmly seated.
TDI - 13 (15)
L27/38;
M126101-01 MAN Diesel & Turbo
Install woodruff key (37) into slot on carrier shaft (32) and install spur gear
Overhaul, test and inspection of air starter
Drive Housing
Drive reassembly
Install bearing (69), please see Fig 3, into forward end of spur gear shaft (65)
and secure with retaining ring (70).
Press bearing (66) onto spur gear shaft (65) and secure with retaining ring
(67).
Press bearing (68) into drive housing (72) until seated firmly into housing.
Press lip seal (75) into forward end of drive housing (72) and install O-ring
into O-ring groove on drive housing.
Install spur gear assembly (65-67) into gearbox drive housing (72) until firmly
seated. Install bearing (55) onto aft end of drive shaft assembly (56-61) and
secure with retaining ring (54).
Lubricate drive shaft assembly using grease No 9-94121-002.
Lubricate inner diameter of spur gear assembly (65) using grease No
9-94121-002.
Install spacer (62), spring (64), and pinion spacer (76) onto pinion drive shaft
assembly (56-61) then install into aft end of spur gear (65).
The gears on helical shaft (56) must be aligned into the aft end of the spur
gear shaft (65).
Press the helical shaft assembly into the spur gear shaft (65) until end of
shaft protrudes from forward end of drive housing.
Maintain pressing force and install pinion onto drive shaft (61).
Secure with screw (79). Torque to 60 ft. lb. Install spacer between pinion (79)
and drive housing (72) before releasing pressure from helical shaft.
Final assembly
Place turbine assembly (23) with aft end on a flat surface and install ring gear.
Ensure notches on ring gear are aligned with screw positions on turbine
housing.
2017-05-15 - en
Thoroughly grease planet gears (34), ring gear (27), sun gear (30), spur gears
(45, 65) using grease No 9-94121-002.
M126101-01
Work Card
Rotate carrier shaft (35) slightly, and at the same time, align gearbox into the
front of turbine housing (26).
Install six gearbox to turbine assembly screws (25) and torque 113 in-lbs.
14 (15) TDI -
L27/38;
MAN Diesel & Turbo M126101-01
Install drive assembly (72) onto gearbox as- sembly (48) and secure with
M126101-01
Work Card
TDI - 15 (15)
L27/38;
2013-06-17 - en
-
L27/38;
Plate Control air pipe
1 (2)
P12616-02-L2738-P
P12616-02-L2738-P
P12616-02-L2738-P MAN Diesel & Turbo
2013-06-17 - en
Plate
2 (2) -
L27/38;
2013-06-10 - en
-
L27/38;
Plate Control air pipe
1 (2)
P12616-08-L2738-P
P12616-08-L2738-P
P12616-08-L2738-P MAN Diesel & Turbo
2013-06-10 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P12616-09-L2738-P
Plate
TCR20 - 1 (2)
L27/38;
P12616-09-L2738-P MAN Diesel & Turbo
2016-10-18 - en
Plate
2 (2) TCR20 -
L27/38;
MAN Diesel & Turbo P12618-03-L2738-P
Air starter
P12618-03-L2738-P
2015-06-01 - en
Plate
- L27/38 1 (4)
P12618-03-L2738-P MAN Diesel & Turbo
1 Screw*
3 Screw*
7 Bearing spacer*
8 Bearing*
9 O-ring*
10 Spring washer*
13 O-ring*
14 Seal spacer*
15 Lip seal*
18 Screw*
21 O-ring*
22 Screw*
23 Inlet flange*
24 O-ring*
25 Turbine housing*
26 Pipe plug*
27 O-ring*
28 Ring gear*
29 Bearing spacer*
30 Clamping plate*
31 Turbine shaft*
32 Retainer ring*
33 Carrier shaft (11.4:1)
34 Spacer, gear
35 Planet gear
36 Needle bearing*
39 Bearing*
40 Wave spring washer*
41 Spring retaining plate*
45 Screw*
50 Screw*
53 O-ring, piston
56 Bearing*
59A Clutch, Helical (RH)
59B Clutch, helical (LH)
60 Ring, retainer
61 Bearing, needle roller*
62A Shaft (LH)
62B Shaft (RH)
63 Thrust washer*
P12618-03-L2738-P
2015-06-01 - en
Plate
2 (4) - L27/38
MAN Diesel & Turbo P12618-03-L2738-P
Air starter
P12618-03-L2738-P
2015-06-01 - en
Plate
- L27/38 3 (4)
P12618-03-L2738-P MAN Diesel & Turbo
64 Retaining ring*
67 Ball bearing*
69 Ball bearing*
70 Bearing, needle roller*
72 O-ring*
74 Screw*
75 Fitting*
76 Lip seal*
77 Spacer, pinion
78 Pinion
78a Pinion incl. item 79 and 80
79 Washer, pinion*
80 Screw*
160 Air starter complete, output gear ratio 11.7:1
161 Spare parts kit, comprising of item: 1, 3, 7, 8, 9, 10, 13, 14, 15, 18,
21, 22, 24, 27, 36, 39, 40, 41, 45, 50, 56, 61, 63, 64, 67, 69, 70,
72, 74, 75 and 76
162 Spare parts kit, comprising of item: 23, 24, 25, 26, 27, 28, 29, 30,
31 and 32
P12618-03-L2738-P
2015-06-01 - en
Plate
4 (4) - L27/38
MAN Diesel & Turbo P12618-05-L2738-P
Plate
116 Housing
177 Retainer
189 Screen
190 O-ring*
200 O-ring*
212 Piston
224 Dampener, shock*
236 O-ring, cap
248 Spring*
261 O-ring*
273 End cap
285 O-ring*
297 Retainer
307 O-ring
319 Part of item 320
320 Solenoid valve
332 Screw
344 Main starting valve, complete
356 Spare parts kit (190, 200, 224, 248, 261, 285)
P12618-05-L2738-P
2014-10-08 - en
Plate
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D128A1-01
Description
D128A1-01
- 1 (3)
L27/38;
D128A1-01 MAN Diesel & Turbo
Lubricating oil system
Fig 1
Figure 1: Lub oil diagram (for guidance only, please see plant specific engine diagram)
from the pump passes an orifice in the centre of the piston and pressurizes
D128A1-01
the chamber behind the piston. This pressure forces the piston towards its
own seat and in this way controls the oil pressure. To be able to adjust the oil
pressure, a spring loaded pilot valve is connected to the mentioned chamber
and the pressure side after the back flushing filter. By adjusting the spring
load, the oil pressure can be adjusted.
2 (3) -
L27/38;
MAN Diesel & Turbo D128A1-01
Engine type 6L 7L 8L 9L
Fig 2
Description
D128A1-01
- 3 (3)
L27/38;
MAN Diesel & Turbo D128B1-02
Maintenance
Under normal conditions, the filter does not need any maintenance as long
as the pressure drop over the filter is less than 1.0 bar and the shaft is rotat-
ing.
However, it is required to replace all filter candles after 18,000 – 20,000
hours of operation (or after maximum 4 years) since this is expected to be
the safe life time for the filter candles.
2013-06-28 - en
Description
D128B1-02
- 1 (1)
L27/38;
MAN Diesel & Turbo M128101-01
Manpower
Number Qualification Duration in h
1 4
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Engine out of operation.
2. Press the pump out of the front-end box by means of two dismantling
screws.
M128101-01
Work Card
- 1 (3)
L27/38;
M128101-01 MAN Diesel & Turbo
Overhaul of lubricating oil pump
2017-05-15 - en
M128101-01
Work Card
2 (3) -
L27/38;
MAN Diesel & Turbo M128101-01
7. New bushings are frozen with nitrogen before they are placed in the
- 3 (3)
L27/38;
MAN Diesel & Turbo M128102-02
Manpower
Number Qualification Duration in h
2 3
Special tools
Plate No. Item No. Note
1 9012-09 Lifting tool for oil filter
Data
Designation Information
Weights of main components Chapter 1 00
Starting Position
Engine out of operation.
Procedure
The oil in the filter can be drained by turning the screw (1), fig 1, anticlock-
2017-05-15 - en
wise.
M128102-02
Work Card
- 1 (4)
L27/38;
M128102-02 MAN Diesel & Turbo
Dismantling and overhaul of back-flushing filter
When lowering the candle into the housing, care must be taken that
M128102-02
Work Card
2 (4) -
L27/38;
MAN Diesel & Turbo M128102-02
14. Place the O-rings (6) around the candle plate and install the end cover
Remember to turn the screws (1), fig 1, clockwise and tighten it before
starting the engine.
2017-05-15 - en
M128102-02
Work Card
- 3 (4)
L27/38;
Work Card Dismantling and overhaul of back-flushing filter
4 (4)
M128102-02 M128102-02
-
L27/38;
Figure 2: Fitting of lifting tool
MAN Diesel & Turbo
2017-05-15 - en
MAN Diesel & Turbo M128103-01
Manpower
Number Qualification Duration in h
1 1 1/2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Weights of main components Chapter 1 00
Starting Position
Engine out of service.
2017-05-15 - en
M128103-01
Work Card
- 1 (3)
L27/38;
M128103-01 MAN Diesel & Turbo
Overhaul of lubricating oil thermostatic valve
Procedure
The temperature of the lubricating oil is controlled by 4 thermostatic elements
placed in a thermostat housing installed on the front-end box below the oil
cooler, see fig 1.
2017-05-15 - en
M128103-01
Work Card
2 (3) -
L27/38;
MAN Diesel & Turbo M128103-01
M128103-01
Work Card
- 3 (3)
L27/38;
MAN Diesel & Turbo M128104A-01
Manpower
Number Qualification Duration in h
1 4
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Weights of main components Chapter 1 00
Starting Position
Cooling water and lub oil have been drained from cooler/engine. All external
pipes are disconnected.
Warning
2017-05-15 - en
M128104A-01
- 1 (4)
L27/38;
M128104A-01 MAN Diesel & Turbo
Overhaul of lubricating oil cooler
Procedure
A plate cooler is placed on top of the front-end box and secured by allen
screws. See fig 1.
2017-05-15 - en
M128104A-01
Work Card
2 (4) -
L27/38;
MAN Diesel & Turbo M128104A-01
This cooler (see fig 2) has long assembling studs and does not need special
Cleaning agent
Kerosene on the oil side. Citric acid on the water side, or agents that do not
harm the stainless steel or the nitrile rubber gasket.
After cleaning, the condition of the gaskets is to be checked.
Replace gaskets with cracks or other types of damage.
Replacement of clip-on gasket, see fig 3.
5. Tighten the nuts crosswise in turns and only a little at the time to ensure
M128104A-01
that the top frame plate comes down in parallel with the bottom frame
Work Card
plate.
- 3 (4)
L27/38;
M128104A-01 MAN Diesel & Turbo
Overhaul of lubricating oil cooler
2017-05-15 - en
M128104A-01
Work Card
4 (4) -
L27/38;
2015-02-06 - en
-
L27/38;
Plate Lub oil pump
1 (2)
P12812-01-L2738-P
P12812-01-L2738-P
P12812-01-L2738-P MAN Diesel & Turbo
2015-02-06 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Lub. oil pressure regulator
1 (2)
P12814-01-L2738-P
P12814-01-L2738-P
P12814-01-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Double check valve
1 (2)
P12814-02-L2738-P
P12814-02-L2738-P
P12814-02-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2017-10-12 - en
Tier II -
L27/38;
Plate Pressure relief valve
1 (2)
P12814-04-L2738-P
P12814-04-L2738-P
P12814-04-L2738-P MAN Diesel & Turbo
2017-10-12 - en
Plate
2 (2) Tier II -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Lubricating oil filter
1 (2)
P12816-02-L2738-P
P12816-02-L2738-P
P12816-02-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Lubricating oil cooler
1 (2)
P12818-02-L2738-P
P12818-02-L2738-P
P12818-02-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-25 - en
-
L27/38;
Plate Lubricating oil thermostatic valve
1 (2)
P12820-03-L2738-P
P12820-03-L2738-P
P12820-03-L2738-P MAN Diesel & Turbo
2013-06-25 - en
Plate
2 (2) -
L27/38;
2013-06-26 - en
-
L27/38;
Plate Leakage fuel oil pipes, leakage oil pipes, lube oil pipes to high
pressure pump
1 (2)
P12824-05-L2738-P
P12824-05-L2738-P
P12824-05-L2738-P MAN Diesel & Turbo
1 Drain pipe
2 Drain pipe
4 Leakage fuel oil pipe
18 Drain pipe
20 Socket
21 Socket
22 Connection socket
23 Elbow union
24 Socket
25 Bracket for pipe clamp
26 Cyl. head bolt
28 Cap nut
29 Blind plug
45 Socket
P12824-05-L2738-P
2013-06-26 - en
Plate
2 (2) -
L27/38;
2013-06-26 - en
-
L27/38;
Plate Lubricating oil pipe for oil injection pump
1 (2)
P12824-06-L2738-P
P12824-06-L2738-P
P12824-06-L2738-P MAN Diesel & Turbo
2013-06-26 - en
Plate
2 (2) -
L27/38;
2017-10-12 - en
-
L27/38;
Plate Lubricating oil pipes
1 (4)
P12824-08-L2738-P
P12824-08-L2738-P
P12824-08-L2738-P MAN Diesel & Turbo
10 Drain pipe
11 Drain pipe
12 Drain pipe
13 Bracket
14 Arr. of fuel oil drain tank (incl. item A2-A21)
30 Reducing piece
31 Elbow inion
32 Bracket for pipe clamp
33 Bolt
34 Union
35 Socket
36 Connection socket
A2 Flange
A3 Level switch
A4 Plug
A5 Plug
A6 Plug
A9 Screw
A10 Restriction plug
A11 Restriction plug
A12 Straight male stud
A14 Straight male stud
A15 Packing ring
A16 Screw
A17 Cylindrical screw
A18 Seal ring
A19 Seal ring
A20 Equal elbow coupling
A21 Screw
P12824-08-L2738-P
2017-10-12 - en
Plate
2 (4) -
L27/38;
2017-10-12 - en
-
L27/38;
Plate Lubricating oil pipes
3 (4)
P12824-08-L2738-P
P12824-08-L2738-P
P12824-08-L2738-P MAN Diesel & Turbo
10 Drain pipe
11 Drain pipe
12 Drain pipe
13 Bracket
14 Arr. of fuel oil drain tank (incl. item A2-A21)
30 Reducing piece
31 Elbow inion
32 Bracket for pipe clamp
33 Bolt
34 Union
35 Socket
36 Connection socket
A2 Flange
A3 Level switch
A4 Plug
A5 Plug
A6 Plug
A9 Screw
A10 Restriction plug
A11 Restriction plug
A12 Straight male stud
A14 Straight male stud
A15 Packing ring
A16 Screw
A17 Cylindrical screw
A18 Seal ring
A19 Seal ring
A20 Equal elbow coupling
A21 Screw
P12824-08-L2738-P
2017-10-12 - en
Plate
4 (4) -
L27/38;
2013-06-26 - en
-
L27/38;
Plate Lubricating oil pipes
1 (2)
P12824-09-L2738-P
P12824-09-L2738-P
P12824-09-L2738-P MAN Diesel & Turbo
2013-06-26 - en
Plate
2 (2) -
L27/38;
2013-06-26 - en
-
L27/38;
Plate Crankcase venting
1 (2)
P12826-02-L2738-P
P12826-02-L2738-P
P12826-02-L2738-P MAN Diesel & Turbo
1 Pipe
2 Pipe
4 Pipe
6 Pipe
7 Bracket
8 Gasket
9 Disc
10 Disc
11 Disc
12 Screw
13 Bolt
14 Screw
15 Bolt
16 Screw
17 Nut
18 Nut
19 Nut
20 Gasket
21 Pipe clamp
P12826-02-L2738-P
2013-06-26 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo
Cooling system
Description Cooling water system ................................................... D130A1-01
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo D130A1-01
Description
D130A1-01
- 1 (3)
L27/38;
D130A1-01 MAN Diesel & Turbo
Cooling water system
2015-04-07 - en
Figure 1: Cooling water diagram (for guidance only, please see plant specific engine diagram)
Description
The engine is equipped with built on fresh water pumps for both the high and
D130A1-01
2 (3) -
L27/38;
MAN Diesel & Turbo D130A1-01
The pump bearings are lubricated automatically with oil from the lubricating
Description
D130A1-01
- 3 (3)
L27/38;
MAN Diesel & Turbo M130101-01
Manpower
Number Qualification Duration in h
1 2
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Weights of main components Chapter 1 00
Starting Position
Engine out of service.
Procedure
The cooling water system is normally divided into two separated closed cir-
2017-05-15 - en
cuits.
M130101-01
Work Card
A low temperature circuit (LT) and a high temperature circuit (HT) based on
fresh water treated with anti-corrosion agents, see fig 1.
- 1 (3)
L27/38;
M130101-01 MAN Diesel & Turbo
Cooling water thermostatic valves
2017-05-15 - en
M130101-01
Work Card
2 (3) -
L27/38;
MAN Diesel & Turbo M130101-01
8. Lift the thermostat housing back onto the engine. All the screws (2)
lubricated with oil are tightened with a torque of 140 Nm.
- 3 (3)
L27/38;
MAN Diesel & Turbo M130102-02
Manpower
Number Qualification Duration in h
2 4
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Tightening specification Chapter 1 00
Weights of main components Chapter 1 00
Starting Position
Engine out of service.
Procedure
2017-05-15 - en
The HT and LT cooling water pumps are centrifugal pumps installed in the
M130102-02
Work Card
front-end box. The pumps are installed underthether- mostatic housing hold-
ing the elements and can therefore not be seen. The pumps are driven by a
gear train from the crankshaft.
A pump can be dismantled after the thermostatic valve housing has been
removed.
- 1 (4)
L27/38;
M130102-02 MAN Diesel & Turbo
Overhaul and replacement of cooling water pumps
When the 4 screws (1), fig 2, have been removed, the pump can be pulled
out by means of dismantling screws.
2 (4) -
L27/38;
MAN Diesel & Turbo M130102-02
pump housing.
3. Add some oil to the shaft in the position where the lip ring is going to
seal.
4. Install the shaft in the housing and fit the circlip (11).
- 3 (4)
L27/38;
M130102-02 MAN Diesel & Turbo
5. Place the rotating parts of a new shaft seal over the shaft and on top of
Overhaul and replacement of cooling water pumps
Installation
A new or overhauled water pump is placed in the bore in the front-end box
and tightened with 4 screws lubricated with molycote paste type GN or
copaslip. Tightening torque is 140 Nm.
If the screws are lubricated with oil the torque is 200 Nm.
2017-05-15 - en
M130102-02
Work Card
4 (4) -
L27/38;
2014-03-25 - en
-
L27/38;
Plate High temperature cooling water pump - clockwise
1 (2)
P13010-03-L2738-P
P13010-03-L2738-P
P13010-03-L2738-P MAN Diesel & Turbo
2014-03-25 - en
Plate
2 (2) -
L27/38;
2016-05-25 - en
L27/38;
Manual override, 2-string -
Plate Cooling water thermostat for high temperature system
1 (2)
P13012-10-L2738-P
P13012-10-L2738-P
P13012-10-L2738-P MAN Diesel & Turbo
2016-05-25 - en
Plate
L27/38;
Without thermostatic element, 2-string -
Plate Cooling water thermostat for low temperature system
1 (2)
P13012-13-L2738-P
P13012-13-L2738-P
P13012-13-L2738-P MAN Diesel & Turbo
2015-07-29 - en
Plate
-
L27/38;
Plate High temperature cooling water pipes
1 (4)
P13016-03-L2738-P
P13016-03-L2738-P
P13016-03-L2738-P MAN Diesel & Turbo
1 Flange
2 End cover, cooling water
3 O-ring
8 Intermediate piece
9 Intermediate piece
11 O-ring
12 V-profil clamp
20 Cooling water connection housing
22 Cooling water pipe
30 Flange
31 O-ring
32 O-ring
B1 Seat
B2 Flap for check valve
B3 Cylindrical pin
B4 Spring pin
P13016-03-L2738-P
2013-06-26 - en
Plate
2 (4) -
L27/38;
2013-06-26 - en
-
L27/38;
Plate High temperature cooling water pipes
3 (4)
P13016-03-L2738-P
P13016-03-L2738-P
P13016-03-L2738-P MAN Diesel & Turbo
1 Flange
2 End cover, cooling water
3 O-ring
8 Intermediate piece
9 Intermediate piece
11 O-ring
12 V-profil clamp
20 Cooling water connection housing
22 Cooling water pipe
30 Flange
31 O-ring
32 O-ring
B1 Seat
B2 Flap for check valve
B3 Cylindrical pin
B4 Spring pin
P13016-03-L2738-P
2013-06-26 - en
Plate
4 (4) -
L27/38;
MAN Diesel & Turbo
Instrumentation
Data SaCoSonePROPULSION Operating Instructions - See
separately supplied manual ..........................................
Cable plan - SaCoSone ................................................. 4305355
Cable list - SaCoSone .................................................... 4305355
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo
SaCoS_one PROPULSION
Instrumentation
Operating Instructions - See separately supplied manual
2016-08-04 - en
Data
- L27/38 1 (1)
SaCoSone propulsion MAN Diesel & Turbo SE
4305355_Cable plan
4305355_Cable Plan.docx
4305355_Cable plan
4305355_Cable Plan.docx
TERMINAL
CORE
CORE
Main Engine
Control Unit CABLE PER ENGINE Powe supply Plant Ship's Alarm system
X12 14 1 --- W559 --- 1 Yard's Power Supply(24V+)
19 2 --- 3G16 --- 2 24V DC (0V)
GN/
24 PE --- --- YE
Control Module S-safety(-1D1) RA 1 --- W33 --- No common safety system failure
RB 2 --- 2x0,75 --- No common safety system failure
PE SC --- ---
Control Module S-alarm(-3D1) RA 1 --- W34 --- No common monitoring system failure
RB 2 --- 2x0,75 --- No common monitoring system failure
PE SC --- ---
Control Module S-alarm(-3D1) RJ 1 --- W35 --- Engine alarm cut off
RK 2 --- 2x0,75 --- Engine alarm cut off
PE SC --- ---
TERMINAL
CORE
CORE
Main Engine
Control Unit CABLE PER ENGINE Pump Control HT Preheater GearBox
Control Module S-Safety(-1D1) PE 1 --- W46 --- 1 Start LT standby pump
PF 2 --- 2x0,75 --- 2 Start LT standby pump
PE SC --- --- SC
Control Module S-Safety(-1D1) EN 3 --- W150 --- Gear ready for operation
EP 4 --- 2x0,75 --- Gear ready for operation
PE SC --- ---
Revision: 3.0
Cables per Diesel engine Cable list Project 4305355 18.12.2017
TERMINAL
CORE
CORE
Main Engine
Control Unit CABLE PER ENGINE CPP
Plate
010.285.060 - 1 (2)
L27/38;
P18010-11-L2738-P MAN Diesel & Turbo
0 Operator panel
2 Display module
3 Push button
4 Selector switch
7 Selector switch
8 Selector switch
9 Protection cover
12 Plug
P18010-11-L2738-P
2013-07-30 - en
Plate
2 (2) 010.285.060 -
L27/38;
2013-07-30 - en
L27/38;
010.290.155 -
Plate Local operator panel - bracket
1 (2)
P18010-12-L2738-P
P18010-12-L2738-P
P18010-12-L2738-P MAN Diesel & Turbo
2 Rubber damper
3 Disc
4 Screw
5 Washer
6 Hexagon screw
P18010-12-L2738-P
2013-07-30 - en
Plate
2 (2) 010.290.155 -
L27/38;
MAN Diesel & Turbo
Control equipment
Plate ZS1705 - position switch ............................................. P18210-14-L2738-P
Terminal box ................................................................ P18210-15-L2738-P
Control unit .................................................................. P18210-19-L2738-P
Control unit - bracket ................................................... P18210-20-L2738-P
Control unit - splash oil ................................................ P18210-22-L2738-P
Control unit - bracket, splash oil ................................... P18210-23-L2738-P
Operator panel plug ..................................................... P18214-01-L2738-P
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
2013-03-03 - en
-
L27/38;
Plate ZS1705 - position switch
1 (2)
P18210-14-L2738-P
P18210-14-L2738-P
P18210-14-L2738-P MAN Diesel & Turbo
1 Position switch
P18210-14-L2738-P
2013-03-03 - en
Plate
2 (2) -
L27/38;
2015-11-27 - en
-
L27/38;
Plate Terminal box
1 (2)
P18210-15-L2738-P
P18210-15-L2738-P
P18210-15-L2738-P MAN Diesel & Turbo
2015-11-27 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P18210-19-L2738-P
Control unit
P18210-19-L2738-P
2013-07-30 - en
Plate
010.285.020 - 1 (2)
L27/38;
P18210-19-L2738-P MAN Diesel & Turbo
0 Control unit
1 Control module
P18210-19-L2738-P
2013-07-30 - en
Plate
2 (2) 010.285.020 -
L27/38;
MAN Diesel & Turbo P18210-20-L2738-P
Plate
010.290.155 - 1 (2)
L27/38;
P18210-20-L2738-P MAN Diesel & Turbo
4 Rubber damper
5 Disc
6 Screw
7 Washer
8 Hexagon screw
P18210-20-L2738-P
2013-07-30 - en
Plate
2 (2) 010.290.155 -
L27/38;
2013-07-30 - en
-
L27/38;
Plate Control unit - splash oil
1 (2)
P18210-22-L2738-P
P18210-22-L2738-P
P18210-22-L2738-P MAN Diesel & Turbo
0 Control unit
2 Control module
P18210-22-L2738-P
2013-07-30 - en
Plate
2 (2) -
L27/38;
2013-07-30 - en
-
L27/38;
Plate Control unit - bracket, splash oil
1 (2)
P18210-23-L2738-P
P18210-23-L2738-P
P18210-23-L2738-P MAN Diesel & Turbo
3 Rubber damper
4 Disc
5 Cylindrical screw
6 Hexagon bolt
P18210-23-L2738-P
2013-07-30 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P18214-01-L2738-P
Plate
010.290.150 - 1 (2)
L27/38;
P18214-01-L2738-P MAN Diesel & Turbo
50 Connection plug
P18214-01-L2738-P
2013-06-26 - en
Plate
2 (2) 010.290.150 -
L27/38;
MAN Diesel & Turbo
Monitoring equipment
Data List of Measuring and Control Devices ......................... 4305355
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
- Headline / Function Task - - Remarks Module - - - - - - -
Signal tag Signal name Signal shortcut Signal range Signal unit " " Connector tag Connector type - Modb address Modb xScale/.Bit Material number -
Order Row Type Alarm tag - Alarm Type Alarm condition - " " Alarm limit Hysteresis Delay " " - Displ nbr
60 S SE1704C_FQ1 engine speed 0..1200 rpm EC_CMS-ALARM FQ1 pulse 35164 x1 11.99014-0203
140 S SE1704C_FQ2 engine speed 0..1200 rpm EC_CMS-SAFETY FQ2 pulse 11.99014-0203
160 S SE1704B_FQ1 engine speed 0..1200 rpm EC_CMS-SAFETY FQ1 pulse 11.99014-0203
180 L SEZH1704 auto shutdown engine speed high EC_CMS-SAFETY L27/38: 920 rpm,H -30 rpm 0s 35206 .00 50006
200 A SI1704B engine speed indication 0..1600 rpm EC_CMS-SAFETY AO2 4..20mA
260 S SE1335 turbocharger speed 0..70000 rpm EC_CMS-SAFETY FQ3 pulse 35165 x0.1
280 L sensor fault turbocharger speed EC_CMS-SAFETY 35179 .01 50590
300 L SEAH1335 alarm turbocharger speed high EC_CMS-ALARM 97% n(max,cont),H -2% n(max,cont) 2s 35214 .13 50792
320 L SERH1335 load reduction request turbocharger speed high EC_CMS-SAFETY 100% n(max,cont),H -2% n(max,cont) 2s 35208 .06 50320
340 A SI1335 turbocharger speed indication 0..100000 rpm EC_CMS-ALARM AO2 4..20mA
400 S TE1222 lube oil temp lube oil cooler inlet 0..120 °C EC_CMS-ALARM TI06 PT1000 35138 x10 11.99411-0452
420 L sensor fault lube oil temp lube oil cooler inlet EC_CMS-ALARM 35147 .06 51032
440 S PT1223 lube oil pressure filter inlet 0..10 bar EC_CMS-SAFETY AI04 4..20mA 35102 x100 11.99012-0366
460 L sensor fault lube oil pressure filter inlet EC_CMS-SAFETY 35112 .02 50530
480 L PDAH1224 alarm lube oil filter differential pressure high EC_CMS-ALARM 0.8 bar,H -0.1 bar 15s 35214 .05 50784
500 L PDRH1224 load reduction request lube oil filter differential pressure high EC_CMS-SAFETY 1.3 bar,H -0.1 bar 15s 35208 .04 50282
520 S PT1224A lube oil pressure engine inlet 0..10 bar EC_CMS-ALARM AI03 4..20mA 35103 x100 11.99012-0366
540 L sensor fault lube oil pressure engine inlet EC_CMS-ALARM 35112 .03 51035
560 L FDPT1224 sensor deviation lube oil pressure engine inlet EC_CMS-ALARM 35200 .02 51223
L27/38: 2.0 bar,L (n<700 rpm)
580 L PTAL1224 alarm lube oil pressure engine inlet low EC_CMS-ALARM 2.8 bar,L (n>700 rpm) 0.1 bar 4s 35214 .03 50785
L27/38: 1.8 bar,L (n<700 rpm)
600 L PTZL1224 auto shutdown from alarm system lube oil pressure engine inlet low EC_CMS-ALARM 2.5 bar,L (n>700 rpm) 0.1 bar 4s 35206 .07 50096
620 S PT1224B lube oil pressure engine inlet 0..10 bar EC_CMS-SAFETY AI03 4..20mA 11.99012-0366
640 L sensor fault lube oil pressure engine inlet EC_CMS-SAFETY 35111 .00 50531
L27/38: 1.9 bar,L (n<700 rpm)
660 L PTRL1224 load reduction request lube oil pressure engine inlet low EC_CMS-SAFETY 2.6 bar,L (n>700 rpm) 0.1 bar 4s 35208 .02 50382
L27/38: 1.8 bar,L (n<700 rpm)
680 L PTZL1224 auto shutdown lube oil pressure engine inlet low EC_CMS-SAFETY 2.5 bar,L (n>700 rpm) 0.1 bar 4s 35206 .06 50004
700 S TE1224 lube oil temp engine inlet 0..120 °C EC_CMS-ALARM TI07 PT1000 35139 x10 11.99411-0458
720 L sensor fault lube oil temp engine inlet EC_CMS-ALARM 35147 .07 51034
740 L TEAH1224 alarm lube oil temp engine inlet high EC_CMS-ALARM 80°C,H -2K 2s 35214 .04 50783
760 L TERH1224 load reduction request lube oil temp engine inlet high EC_CMS-SAFETY 85°C,H -2K 2s 35208 .03 50284
780 S PT1225 lube oil pressure turbocharger inlet 0..10 bar EC_CMS-ALARM AI06 4..20mA 35104 x100 11.99012-0366
800 L sensor fault lube oil pressure turbocharger inlet EC_CMS-ALARM 35112 .04 51036
820 L PTAL1225 alarm lube oil pressure turbocharger inlet low EC_CMS-ALARM 1.3 bar,L 0.1 bar 4s 35216 .12 50831
840 S LSL1231 oil level in oil pan, level switch EC_CMS-ALARM DI02 binary 11.99417-0011
860 L LSAL1231 alarm oil level in oil pan EC_CMS-ALARM - 4s 35216 .03 50787
900 A PCZ1290 eng. lub. oil start stb. pump EC_CMS-SAFETY PO06 binary
1000 A ZC1224 eng. lub. oil filter by pass valve open EC_CMS-ALARM PO03 binary
1020 L sensor fault eng. lub. oil filter by pass valve open EC_CMS-ALARM 35219 .03 51033
1180 S PT1423 fuel oil pressure filter inlet 0..16 bar EC_CMS-SAFETY AI11 4..20mA 35108 x100 11.99012-0367
1200 L sensor fault fuel oil pressure filter inlet EC_CMS-SAFETY 35112 .08 50540
1220 S PT1424 fuel pressure engine inlet 0..16 bar EC_CMS-ALARM AI09 4..20mA 35109 x100 11.99012-0367
1240 L sensor fault fuel oil pressure engine inlet EC_CMS-ALARM 35112 .09 51051
3.0 bar,L (HFO)
1260 L PTAL1424 alarm fuel oil pressure engine inlet low EC_CMS-ALARM 1.0 bar,L (MDO) 0.1 bar 4s 35214 .11 50795
1280 L PDAH1424 alarm fuel oil filter differential pressure high EC_CMS-ALARM 0.8 bar,H -0.1 bar 15s 35214 .12 50794
1300 S TE1424 fuel oil temp engine inlet 0..200 °C EC_CMS-ALARM TI09 PT1000 35142 x10 11.99411-0452
1320 L sensor fault fuel oil temp engine inlet EC_CMS-ALARM 35147 .10 51052
1340 L TEAH1424 alarm fuel oil temp engine inlet high EC_CMS-ALARM 45°C,H (MDO) -2K 2s 35216 .14 50833
1360 S LSH1426 pump and nozzle leakage, level switch EC_CMS-ALARM DI05 binary 11.99007-1449
1400 L LSAH1426 alarm pump and nozzle leakage EC_CMS-ALARM - 4s 35216 .08 50849
1480 A PCZ1490 eng. fuel start stb. pump EC_CMS-SAFETY PO07 binary
1660 S PT1102A HTCW pressure engine inlet 0..6 bar EC_CMS-ALARM AI02 4..20mA 35101 x100 11.99012-0365
1680 L sensor fault HTCW pressure engine inlet EC_CMS-ALARM 35112 .01 51028
1700 L FDPT1102 sensor deviation HTCW pressure engine inlet EC_CMS-ALARM 35200 .01 51222
L27/38: 1.1 bar,L (n<700 rpm)
1720 L PTAL1102 alarm HTCW pressure engine inlet low EC_CMS-ALARM 1.7 bar,L (n>700 rpm) 0.1 bar 4s 35214 .01 50769
L27/38: 0.9 bar,L (n<700 rpm)
1740 L PTZL1102 auto shutdown from alarm system HTCW pressure engine inlet low EC_CMS-ALARM 1.5 bar,L (n>700 rpm) 0.1 bar 4s 35206 .03 50094
1760 S PT1102B HTCW pressure engine inlet 0..6 bar EC_CMS-SAFETY AI02 4..20mA 11.99012-0365
1780 L sensor fault HTCW pressure engine inlet EC_CMS-SAFETY 35112 .14 50515
L27/38: 1.0 bar,L (n<700 rpm)
1800 L PTRL1102 load reduction request HTCW pressure engine inlet low EC_CMS-SAFETY 1.6 bar,L (n>700 rpm) 0.1 bar 4s 35208 .00 50256
L27/38: 0.9 bar,L (n<700 rpm)
1820 L PTZL1102 auto shutdown HTCW pressure engine inlet low EC_CMS-SAFETY 1.5 bar,L (n>700 rpm) 0.1 bar 4s 35206 .02 50000
1840 S TE1102 HTCW temp charge air cooler inlet 0..120 °C EC_CMS-ALARM TI04 PT1000 35134 x10 11.99411-0452
1860 L sensor fault HTCW temp charge air cooler inlet EC_CMS-ALARM 35147 .02 51027
1880 L TEAH1102 alarm HTCW temp charge air cooler inlet high EC_CMS-ALARM 80°C,H -2K 2s 35216 .10 50828
1900 S TE1103 HTCW temp engine inlet 0..120 °C EC_CMS-ALARM TI05 PT1000 35135 x10 11.99411-0452
1920 L sensor fault HTCW temp engine inlet EC_CMS-ALARM 35147 .03 51029
1940 L TEAL1103 alarm HTCW temp engine inlet low EC_CMS-ALARM 45°C,L 1K 2s 35216 .11 50829
1960 S TE1104A HTCW temp engine outlet 0..120 °C EC_CMS-ALARM TI01 double PT1000 35136 x10 11.99411-0453
1980 L sensor fault HTCW temp engine outlet EC_CMS-ALARM 35147 .04 51030
2000 L FDTE1104 sensor deviation HTCW temp engine outlet EC_CMS-ALARM 10K,H -2K 20s 35201 .00 51211
2020 L TEAH1104 alarm HTCW temp engine outlet high EC_CMS-ALARM 92°C,H -2K 2s 35214 .02 50770
2040 L TEZH1104 auto shutdown from alarm system HTCW temp engine outlet high EC_CMS-ALARM 97°C,H 2K 2s 35206 .05 50100
2060 S TE1104B HTCW temp engine outlet 0..120 °C EC_CMS-SAFETY TI01 double PT1000 11.99411-0452
2080 L sensor fault HTCW temp engine outlet EC_CMS-SAFETY 35147 .12 50516
2100 L TERH1104 load reduction request HTCW temp engine outlet high EC_CMS-SAFETY 95°C,H -2K 2s 35208 .01 50258
2120 L TEZH1104 auto shutdown HTCW temp engine outlet high EC_CMS-SAFETY 97°C,H -2K 2s 35206 .04 50002
2160 A PCZ1190 eng. HTCW start stb. pump EC_CMS-SAFETY PO04 binary
2340 S PT1002A LTCW pressure charge air cooler inlet 0..6 bar EC_CMS-ALARM AI01 4..20mA 35100 x100 11.99012-0365
2360 L sensor fault LTCW pressure charge air cooler inlet EC_CMS-ALARM 35112 .00 51025
2380 L FDPT1002 sensor deviation LTCW pressure charge air cooler inlet EC_CMS-ALARM 35200 .00 51221
L27/38: 1.1 bar,L (n<700 rpm)
2400 L PTAL1002 alarm LTCW pressure charge air cooler inlet low EC_CMS-ALARM 1.7 bar,L (n>700 rpm) 0.1 bar 4s 35214 .00 50768
2420 S PT1002B LTCW pressure charge air cooler inlet 0..6 bar EC_CMS-SAFETY AI01 4..20mA 11.99012-0365
2440 L sensor fault LTCW pressure charge air cooler inlet EC_CMS-SAFETY 35112 .13 50512
2460 S TE1002 LTCW temp charge air cooler inlet 0..120 °C EC_CMS-ALARM TI02 PT1000 35132 x10 11.99411-0452
2480 L sensor fault LTCW temp charge air cooler inlet EC_CMS-ALARM 35147 .00 51024
2500 L TEAH1002 alarm LTCW temp charge air cooler inlet high EC_CMS-ALARM 65°C,H -2K 2s 35216 .09 50827
L21/31: 11.99411-0455
2520 S TE1005 LTCW temp lube oil cooler outlet 0..120 °C EC_CMS-ALARM TI03 PT1000 35133 x10 L27/38: 11.99411-0460
2540 L sensor fault LTCW temp lube oil cooler outlet EC_CMS-ALARM 35147 .01 51026
2600 A PCZ1090 eng. LTCW start stb. pump EC_CMS-SAFETY PO03 binary
2760 S PT1331A charge air pressure before cylinders 0..4 bar EC_CMS-ALARM AI04 4..20mA 35107 x100 11.99012-0370
2780 L sensor fault charge air pressure before cylinders EC_CMS-ALARM 35112 .07 51042
2800 L FDPT1331 sensor deviation charge air pressure before cylinders EC_CMS-ALARM 35200 .03 51224
2820 S PT1331B charge air pressure before cylinders 0..4 bar EC_CMS-SAFETY AI05 4..20mA 11.99012-0370
2840 L sensor fault charge air pressure before cylinders EC_CMS-SAFETY 35112 .11 50536
2860 A PTI1331A charge air pressure indication 0..4 bar EC_CMS-SAFETY AO1 4..20mA
2880 S TE1331 charge air temp after charge air cooler 0..120 °C EC_CMS-ALARM TI08 PT1000 35141 x10 11.99411-0452
2900 L sensor fault charge air temp after charge air cooler EC_CMS-ALARM 35147 .09 51041
2920 L TEAH1331 alarm charge air temp after charge air cooler high EC_CMS-ALARM 55°C,H -2K 2s 35214 .08 50790
3420 S PT1312 starting air pressure 0..40 bar EC_CMS-ALARM AI07 4..20mA 35105 x100 11.99012-0369
3440 L sensor fault starting air pressure EC_CMS-ALARM 35112 .05 51038
3460 L PTAL1312 alarm starting air pressure low EC_CMS-ALARM L27/38: 6 bar (TDI starter),L 0.1 bar 4s 35214 .09 50788
3500 S PT1322 safety and control air pressure 0..10 bar EC_CMS-ALARM AI08 4..20mA 35106 x100 11.99012-0366
3520 L sensor fault safety and control air pressure EC_CMS-ALARM 35112 .06 51039
3540 L PTAL1322 alarm safety and control air pressure low EC_CMS-ALARM 6 bar,L 0.1 bar 4s 35214 .10 50789
3660 A ZC1334 eng. charge air jet assist EC_CMS-ALARM PO05 valve
3680 L sensor fault eng. charge air jet assist EC_CMS-ALARM 35219 .06 51044
5500 C TE16_MV exhaust gas temp mean value calculated 35017 x10
6140 S TE1203 eng. main bearing 3 temperature 0..120 °C EC_CMS-SAFETY TI04 PT1000 35062 x10 11.99011-0976
6160 L sensor fault main bearing temp 3 EC_CMS-SAFETY 35071 .02 50521
6180 L TEAH1203 alarm main bearing temp 3 high EC_CMS-ALARM 103°C,H -2K 4s 35074 .02 50773
6200 L TERH1203 load reduction request main bearing temp 3 high EC_CMS-SAFETY 105°C,H -2K 4s 35073 .02 50264
6220 L TEZH1203 auto shutdown main bearing temp 3 high EC_CMS-SAFETY 108°C,H -2K 4s 35072 .02 50014
L21/31: 11.99011-0976
6240 S TE1204 eng. main bearing 4 temperature 0..120 °C EC_CMS-SAFETY TI05 PT1000 35063 x10 L27/38: 11.99011-1040
6260 L sensor fault main bearing temp 4 EC_CMS-SAFETY 35071 .03 50522
6280 L TEAH1204 alarm main bearing temp 4 high EC_CMS-ALARM 103,H -2K 4s 35074 .03 50774
6300 L TERH1204 load reduction request main bearing temp 4 high EC_CMS-SAFETY 105,H -2K 4s 35073 .03 50266
6320 L TEZH1204 auto shutdown main bearing temp 4 high EC_CMS-SAFETY 108,H -2K 4s 35072 .03 50016
6340 S TE1205 eng. main bearing 5 temperature 0..120 °C EC_CMS-SAFETY TI06 PT1000 35064 x10 11.99011-1040
6360 L sensor fault main bearing temp 5 EC_CMS-SAFETY 35071 .04 50523
6380 L TEAH1205 alarm main bearing temp 5 high EC_CMS-ALARM 103°C,H -2K 4s 35074 .04 50775
6400 L TERH1205 load reduction request main bearing temp 5 high EC_CMS-SAFETY 105°C,H -2K 4s 35073 .04 50268
6420 L TEZH1205 auto shutdown main bearing temp 5 high EC_CMS-SAFETY 108°C,H -2K 4s 35072 .04 50018
L21/31: 11.99011-1040
6440 S TE1206 eng. main bearing 6 temperature 0..120 °C EC_CMS-SAFETY TI07 PT1000 35065 x10 L27/38: 11.99011-1041
6460 L sensor fault main bearing temp 6 EC_CMS-SAFETY 35071 .05 50524
6480 L TEAH1206 alarm main bearing temp 6 high EC_CMS-ALARM 103°C,H -2K 4s 35074 .05 50776
6500 L TERH1206 load reduction request main bearing temp 6 high EC_CMS-SAFETY 105°C,H -2K 4s 35073 .05 50270
6520 L TEZH1206 auto shutdown main bearing temp 6 high EC_CMS-SAFETY 108°C,H -2K 4s 35072 .05 50020
6540 S TE1207 eng. main bearing 7 temperature 0..120 °C EC_CMS-SAFETY TI08 PT1000 35066 x10 11.99011-1041
6560 L sensor fault main bearing temp 7 EC_CMS-SAFETY 35071 .06 50525
6580 L TEAH1207 alarm main bearing temp 7 high EC_CMS-ALARM 103°C,H -2K 4s 35074 .06 50777
6600 L TERH1207 load reduction request main bearing temp 7 high EC_CMS-SAFETY 105°C,H -2K 4s 35073 .06 50272
6620 L TEZH1207 auto shutdown main bearing temp 7 high EC_CMS-SAFETY 108°C,H -2K 4s 35072 .06 50022
6640 S TE1208 eng. main bearing 8 temperature 0..120 °C EC_CMS-SAFETY TI09 PT1000 35067 x10 11.99011-1041
6660 L sensor fault main bearing temp 8 EC_CMS-SAFETY 35071 .07 50526
6680 L TEAH1208 alarm main bearing temp 8 high EC_CMS-ALARM 103°C,H -2K 4s 35074 .07 50778
6700 L TERH1208 load reduction request main bearing temp 8 high EC_CMS-SAFETY 105°C,H -2K 4s 35073 .07 50274
6720 L TEZH1208 auto shutdown main bearing temp 8 high EC_CMS-SAFETY 108°C,H -2K 4s 35072 .07 50024
8780 S ZT1401 fuel index, position sensor 0..120 % EC_CMS-SAFETY AI07 4..20mA
8800 L sensor fault fuel index, position sensor EC_CMS-SAFETY 35179 .02 50537
9060 A ZSI1401 engine overload (index > 102%) EC_CMS-SAFETY DO05 binary
9080 S SC1706 eng. speed order L27/38: 500..800 rpm EC_CMS-ALARM AI12 4..20mA
9100 S SC1709 constant speed request by external system EC_CMS-SAFETY DI04 binary
9680 A SC1703 eng. stop command (governor stop) EC_CMS-ALARM PO01 binary
9700 L sensor fault eng. stop command (governor stop) EC_CMS-ALARM 35219 .00 51064
9720 S ZS3725 prop. pitch not in zero position, external start blocking EC_CMS-ALARM DI12 binary
9760 S ZS1705 turning gear engaged, limit switch EC_CMS-ALARM DI07 binary 11.99417-0008
10700 S ZS3701A eng and propeller local control DM_LOP1 DI01 binary
10720 S ZS3701B eng and propeller local control DM_LOP2 DI01 binary
10740 S ZS3702A eng and propeller remote control DM_LOP1 DI02 binary
10760 S ZS3702B eng and propeller remote control DM_LOP2 DI02 binary
11080 A SZR1740 load reduction req. EC_CMS-SAFETY DO06 binary 35204 .01
11340 A SZ1733 eng. safety stop command EC_CMS-SAFETY PO01 valve 35204 .00
11360 L sensor fault eng. safety stop command EC_CMS-SAFETY 35210 .00 50563
11400 S ES4743A additional shut down signal, gear luboil pressure low Optional EC_CMS-ALARM DI09 binary
11420 L sensor fault additional shut down signal EC_CMS-ALARM 35224 .10 51138
11440 L ESZ4743 auto shutdown from alarm system additional shut down signal EC_CMS-ALARM 0s 35206 .14 50104
11460 S ES4743B additional shut down signal, gear luboil pressure low Optional EC_CMS-SAFETY DI09 binary
11480 L sensor fault additional shut down signal EC_CMS-SAFETY 35211 .11 50573
11500 L ESZ4743 auto shutdown additional shut down signal EC_CMS-SAFETY 0s 35206 .13 50088
11770 A no alarm active open if any alarm (engine, LPCS) active DM (all) DO03 binary
-
L27/38;
Plate PT - Pressure sensor
1 (2)
P18412-03-L2738-P
P18412-03-L2738-P
P18412-03-L2738-P MAN Diesel & Turbo
3 Pressure transmitter
P18412-03-L2738-P
2013-07-30 - en
Plate
2 (2) -
L27/38;
2015-09-30 - en
-
L27/38;
Plate PT - Pressure sensors
1 (2)
P18412-06-L2738-P
P18412-06-L2738-P
P18412-06-L2738-P MAN Diesel & Turbo
2015-09-30 - en
Plate
2 (2) -
L27/38;
2015-10-19 - en
L27/38;
010.290.040 -
Plate TE - Temperature sensors
1 (4)
P18416-04-L2738-P
P18416-04-L2738-P
P18416-04-L2738-P MAN Diesel & Turbo
2015-10-19 - en
Plate
2 (4) 010.290.040 -
L27/38;
2015-10-19 - en
L27/38;
010.290.040 -
Plate TE - Temperature sensors
3 (4)
P18416-04-L2738-P
P18416-04-L2738-P
P18416-04-L2738-P MAN Diesel & Turbo
2015-10-19 - en
Plate
4 (4) 010.290.040 -
L27/38;
2013-03-04 - en
-
L27/38;
Plate LSH1332 – level sensor
1 (2)
P18420-04-L2738-P
P18420-04-L2738-P
P18420-04-L2738-P MAN Diesel & Turbo
1 Level alarm
A60 Level switch
A110 Sealing ring
P18420-04-L2738-P
2013-03-04 - en
Plate
2 (2) -
L27/38;
MAN Diesel & Turbo P18420-06-L2738-P
Plate
5 Level switch
7 Cable gland
10 Cable head
P18420-06-L2738-P
2015-09-15 - en
Plate
-
L27/38;
Plate TE - Exhaust temperature sensors
1 (2)
P18424-06-L2738-P
P18424-06-L2738-P
P18424-06-L2738-P MAN Diesel & Turbo
2013-07-30 - en
Plate
2 (2) -
L27/38;
2013-06-26 - en
L27/38;
010.290.310 -
Plate TE - temperature sensors - Bearings
1 (2)
P18427-02-L2738-P
P18427-02-L2738-P
P18427-02-L2738-P MAN Diesel & Turbo
1 Temperature sensor
9 Clamping ring
10 Seal ring
P18427-02-L2738-P
2013-06-26 - en
Plate
2 (2) 010.290.310 -
L27/38;
2013-06-26 - en
L27/38;
010.290.120 -
Plate TE - temperature sensors - Splash oil
1 (2)
P18427-03-L2738-P
P18427-03-L2738-P
P18427-03-L2738-P MAN Diesel & Turbo
2013-06-26 - en
Plate
2 (2) 010.290.120 -
L27/38;
2013-06-26 - en
L27/38;
010.290.010 -
Plate SE1704B/C - Tacho sensor
1 (2)
P18428-05-L2738-P
P18428-05-L2738-P
P18428-05-L2738-P MAN Diesel & Turbo
1 Impulse transmitter
2 Angle plug
4 Seal ring
P18428-05-L2738-P
2013-06-26 - en
Plate
2 (2) 010.290.010 -
L27/38;
MAN Diesel & Turbo
Tools
Work Card Function of the hydraulic tools ...................................... M190101-01
Application of hydraulic tools ........................................ M190102-02
Table of contents
2018-01-12 - en
1 (1)
P-28049 - L27/38-P EN
MAN Diesel & Turbo M190101-01
Manpower
Number Qualification Duration in h
- -
Special tools
Plate No. Item No. Note
- - No special tools
Data
Designation Information
Weights of main components Chapter 1 00
Tightening specification Chapter 1 00
Data for pressure and tolerance Chapter 1 00
Starting Position
Application of hydraulic tools, see work card M190102.
Procedure
Safety hints and function of hydraulic tools.
2017-01-24 - en
M190101-01
Work Card
- 1 (10)
L27/38;
M190101-01 MAN Diesel & Turbo
Function of the hydraulic tools
Safety hints
Beside regarding the general accident-prevention rules, the safe handling of
the device and the hydraulic accessories demand especially the considera-
tion of the following hints. When disregarding even single items, you can
cause danger to life and/or danger of injuries!
1. When leakages occur during the pressurization, bleed pressure immedi-
ately and seal the leakage or replace defect parts.
2. In case of repair, use exclusively original spare parts. Inexpert substitu-
tion of damaged parts by non-original spare parts is prohibited.
3. All assembly parts are to be handled in correspondence to the working
cards only. A change in the procedure or another operation of the
device is not allowed.
4. Make sure that the components to be tensioned do not exceed the
admissible strain.
5. In order to use the device, the thread has to be sufficiently exceeding in
order to avoid that the turn of a thread cracks, see item 4.
6. During the pressurization the people involved have to remain in an
appropriate distance. Staying in direction towards the bolt axis is forbid-
den.
7. Tensioning pressures or tensioning forces are to be given or changed
by authorized personnel only while considering the admissible compo-
nent loads, see item 4.
8. The operation and handling of the device are to be carried out by expert
staff only.
9. The given max. operation pressure is not to be exceeded in any case
and is to be watched at the manometer of the pressure generator dur-
ing the complete tensioning or loosening procedure. When having ach-
ieved the given pressure, stop the pressurization immediately.
10. During the pressurization when tensioning or loosening the bolt connec-
tion, always watch the admissible stroke of the device. Exceeding this
stroke is connected with insufficient generating of tensioning force
because the device is tensioned in itselve or the hydraulic pressure is
bleeded automaticly.
11. On principle, when connecting high-pressure hoses it has to be taken
care that the connections are correct (see also separate hints).
2017-01-24 - en
12. The hydraulic hoses have to be installed in a way that they are not run
over by vehicles or unnecessarily walked over by people. Never lay
M190101-01
Work Card
hoses across sharp objects (danger of cuts) and never bend or jam
them in.
13. Never hold or transport the device by using the high-pressure hoses.
2 (10) -
L27/38;
MAN Diesel & Turbo M190101-01
14. An incorrect working manometer that doesn´t show the right pressure
Working Hints
In order to achieve a bolt connection of high precision, it is vital to consider
the following working hints:
▪ Prior to setting the device, clean all threads and remove possible dam-
ages in order to avoide a “freeze on”.
▪ The base plate for the device must be plain and free of dirt. Further
check the squareness towards the bolt axis in order to avoid that the bolt
has a bending stress during the pressurization (tensioning).
▪ The stroke of the device may not at any point be exceeded.
▪ For transporting the device it is necessary to uncouple all high-pressure
hoses.
▪ After each pressurization, bring the device back to zero, see also Piston
Return Stroke.
M190101-01
Work Card
- 3 (10)
L27/38;
M190101-01 MAN Diesel & Turbo
Function of the hydraulic tools
For a correct measuring the dial gauge has to be mounted with the
magnetic bracket on the housing of the hydraulic tool
2017-01-24 - en
4 (10) -
L27/38;
MAN Diesel & Turbo M190101-01
Figure 4: .
The bolts must be replaced in the following cases:
M190101-01
Work Card
- 5 (10)
L27/38;
M190101-01 MAN Diesel & Turbo
▪ In case the maximum limit for the elongation is exceeded during the
tightening of the bolt
▪ In case the total length of the unloaded bolt, please see description
D100.
Loosening Procedure
In order to loosen an existing bolt connection, screw the device onto the
bolt. First put the support sleeve on the bolt and align it centrically to the bolt
axis. When screwing on the device take care that the support sleeve at the
cylinder is correctly centered (consider centering shoulder).
The piston of the device must be at its zero position. Having screwed the
device down until the support sleeve or the support cylinder fits tight to the
flange, turn back the device by at least the value (slit measure) which the bolt
and the components spring back elastically during the loosening procedure.
2017-01-24 - en
Hint:
The adjusted slit measure may never exceed the admissible stroke of the
M190101-01
Work Card
device! Furthermore, take care that the window for the adjusting rod are well
accessible.
Having made all hydraulic connections correctly, see fig. 2, start the pressuri-
zation.
6 (10) -
L27/38;
MAN Diesel & Turbo M190101-01
sioning force and the components are being edged. The result is that the
main nut does no longer fit to the flange.
M190101-01
Work Card
Having achieved the necessary pressure, adjust the main nut - when tension-
ing - until it fits to the flange again before bleeding the pressure, see Tension-
ing Procedure. When loosening the bolts, turn back the main nut after the
pressurization according to the bolt and component deformations, (see
Loosening Procedure.
- 7 (10)
L27/38;
M190101-01 MAN Diesel & Turbo
Hint:
Function of the hydraulic tools
During the loosening procedure, never turn back the main nut until it fits to
the piston or the cylinder since the main nut sticks after the depressurization.
The main nut is equipped with several radial bores where the adjusting rod
can be put in. The main nut is accessible through the window in the support
sleeve.
Should leakages occur at the piston of the device, an exchange of the seals
might be necessary.
Drive out the piston by carefully beating with a hammer while using a plastic
8 (10) -
L27/38;
MAN Diesel & Turbo M190101-01
- 9 (10)
L27/38;
M190101-01 MAN Diesel & Turbo
– Check the components of the device and its accessories for comple-
Function of the hydraulic tools
tion.
– The operating manual has to be read by all users.
2017-01-24 - en
M190101-01
Work Card
10 (10) -
L27/38;
MAN Diesel & Turbo M190102-02
Manpower
Number Qualification Duration in h
- -
Special tools
Plate No. Item No. Note
- - See page 2-4
Data
Designation Information
Weights of main components Chapter 1 00
Tightening specification Chapter 1 00
Data for pressure and tolerance Chapter 1 00
Starting Position
Function of hydraulic tools, see work card M190101.
2017-02-15 - en
Procedure
M190102-02
Work Card
This working card gives the information for application of hydraulic tools, to
be used in connection with working card 90 101-01.
TierII - 1 (4)
L27/38;
M190102-02 MAN Diesel & Turbo
Application of hydraulic tools
2017-02-15 - en
M190102-02
Work Card
2 (4) TierII -
L27/38;
MAN Diesel & Turbo M190102-02
TierII - 3 (4)
L27/38;
M190102-02 MAN Diesel & Turbo
Application of hydraulic tools
2017-02-15 - en
4 (4) TierII -
L27/38;
MAN Diesel & Turbo P19000-03-L2738-P
P19000-03-L2738-P
2016-10-18 - en
Description
Tier II - 1 (10)
L27/38;
P19000-03-L2738-P MAN Diesel & Turbo
Standard tools (unrestricted service)
2016-10-18 - en
Description
2 (10) Tier II -
L27/38;
MAN Diesel & Turbo P19000-03-L2738-P
Description
Tier II - 3 (10)
L27/38;
P19000-03-L2738-P MAN Diesel & Turbo
Standard tools (unrestricted service)
2016-10-18 - en
Description
4 (10) Tier II -
L27/38;
MAN Diesel & Turbo P19000-03-L2738-P
P19000-03-L2738-P
2016-10-18 - en
Description
Tier II - 5 (10)
L27/38;
P19000-03-L2738-P MAN Diesel & Turbo
Standard tools (unrestricted service)
Turbocharger system
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Eye screw for lifting 1 036
2016-10-18 - en
Description
6 (10) Tier II -
L27/38;
MAN Diesel & Turbo P19000-03-L2738-P
Description
Tier II - 7 (10)
L27/38;
P19000-03-L2738-P MAN Diesel & Turbo
2016-10-18 - en
Description
8 (10) Tier II -
L27/38;
MAN Diesel & Turbo P19000-03-L2738-P
P19000-03-L2738-P
2016-10-18 - en
Description
Tier II - 9 (10)
L27/38;
P19000-03-L2738-P MAN Diesel & Turbo
2016-10-18 - en
Description
10 (10) Tier II -
L27/38;
2013-07-05 - en
-
L27/38;
Plate Dry cleaning device – turbine cleaning
1 (2)
P19012-13-L2738-P
P19012-13-L2738-P
P19012-13-L2738-P MAN Diesel & Turbo
0 Blowgun complete
1 Snap coupling
2 Hexagon nipple
3 Tee
4 Ball valve
5 Snap coupling
6 Snap coupling
7 Packing rings
8 Pipe
9 Container complete
10 Socket
P19012-13-L2738-P
2013-07-05 - en
Plate
2 (2) -
L27/38;