Table of contents

Introduction

Product Liability
How the Operating Instruction Manual is organized, and how to use it

Technical details
Scope of supply/Technical speci.fication
2.2.1

Characteristics

2.3.1
2.3.2
2.3.3
2.3.4
2.3.5

ComponentsISubassemblies
Standard engine design Crankcase to cylinder head
Camshaft drive to injection valve
Supercharger system through engine controls
Special engine designs
Accessories

2.4.2
2.4.3
2.4.4
2.4.5
2.4.6

Compressed air and starting system

Fuel oil system
Control of Speed and Output
Injection and valve timing adjustment
Lube oil system

2.5.1
2.5.2
2.5.3
2.5.4

Technical data
Ratings and consumption data
Temperatures and pressures
Weights
Dimensions/Clearances/Tolerances-Part 1

OperationIOperating media

3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.10
3.3.11
3.4.1
3.4.2
3.4.3

3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3.5.9
3.5.10
3.5.1 1
3.5.12
3.5.13

Safety regulations
General remarks
Destinationlsuitabilityof ,theengine
Riskstdangers
Safety instructions
Safety regulations
Operating media
Quality requirements on gas oilldiesel fuel (MGO)
Quality requirements for Marine Diesel Fuel (MDO)
Quality requirements for heavy fuel oil (HFO)
Viscosity/Temperature diagram for fuel oils
Qua!ity requirements for lube oil
Quality requirements for lube oil
Quality requirements for engine cooling water
Analyses of operating media
Water quality requirements for fuel-water emulsion
Quality requirements for intake air ( C O ~ ~ I Jair)
S~~O~
Engine operation I - Starting the engine
Preparations for start/ Engine starting and stopping
Change-over from Diesel fuel oil to heavy fuel oil and vice versa
Admissible outputs and speeds

Engine log book/ Engine diagnosis1Engine management

Load curve during accelerationlmanoeuvring
Part-load operation
Determine the engine output and design point
Engine operation at reduced speed
Equipment for optimising the engine to special operating conditions
Bypassing of charge air
Condensed water in charge air pipes and pressure vessels
Load application
Exhaust gas blow-off
Charge air blow-off
Injection of additional charge air
Engine operation Ill - Operating faults

0
0

-.*
0

.
.

.
b $

' .

,7

*:

0.

c\

y,'

.1.

rf.';

t::,>
-sk

+i ..,;;

,,(\ .

-i

..
.
..

"

.b

.*-

e m .

>Y

,* ' a
0

0-

<
I).

-+ze;

:' c
. r

.>
,

.<

':.'.

.:"

. A

-';:-

..J
:>-

;
C

- :.

'f

*;+

.... .
.

3,

,,

...-

Annex

:o

5.1
5.2
5.3
5.4
5.5

DesignationsFTerms
Formulae
Units of measure1Conversion of units of measure
Symbols and codes
Brochures

af -0

.0

:.

:-

. . .
I.

..

-',

.* J

-",,

. . I r .

.1 0
1

<

General remarks
Maintenance schedule (explanations)
Tools/Special tools
Spare Parts
Replacement of components by the New-for-old Principle
Special services/Repair work
Maintenance schedule (signslsymbols)
Maintenance Schedule (Systems)
Maintenance Schedule (Engine)

k
. :-,;.--*

4.1
4.2
4.3
4.4
;'
n
.
, *.
- 0 . 4.5
,
- ' ; o 4.6
- : - . a 4.7
~3 ' ' :- 4.7.1
4.7.2
:
,

.:z;i
:;-i

MaintenanceIRepair

,i

- ;PA

', 0

r e .
0

. <

"'--.

FaultsIDeficiencies and their causes (Trouble Shooting)

Emergency operation with one cylinder failing
Emergency operation on failure of one turbocharger
Failure of the electrical mains supply (Black out)
Failure of the cylinder lubrication
Failure of the speed control system
Behaviour in case operating values are exceeded1 alarms are released
Procedures on triggering of oil mist alarm
Procedures in case a splash-oil alarm is triggered
Procedures on triggering of Slow-Turn-Failure
Engine operation IV - Engine shut-down
Shut down1Preserve the engine

. . :.
%

I'

a'

--

'I

,.

u
j :+ . a
': - :

'iVW>*

,.,;- +, :'j!
.. ". .
:

'

0
' 0
0.
- . ,

0.

3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
3.6.8
3.6.8
3.6.9
3.7
3.7.1

<

'*7.

..,>.

=
:
8

'

C%-

>-ri
'

.
."

'>

.'.
E-

','..,1

<

Categories o f information
4.

>

1".
<

.,!.

->

~;,z

- *.**+

-, ,
,-,,

. .. .-::

',

.
< z*?-zy
--,?. a,Qdc-* <
1~
.,.>-, , &+:
.: ' , .
L
> *
..-L...,
, ' .>.pk ,;*.
..
.".i
i
+
..
cC
- ..
bata/fo&ulasfsymbol~~., : ;
- - .- .
+.

'< %

e*

-"

-*.

a.

*-

5-$

93

>

-*'-:

',Pa

.r:?

?>

-:
I

'

*4.

' ?"'

',

"+

Intended for
Experts

...

-"

-a<--7+c>,-a^'
":

.>
*,

--

$?*

:., ,". 2 &&. 2

t h -

$+'

&x3g3?iC&-;$

."x<;

2:?b;4;$+&;y.<e;

>% : . 5&%&$& i A

:Z '

<-,-..*

<

>

,>
,

j<<
C$%.L:&%,&?/*
'
< :?-" ;~
;
:
:
T
;
g
$
$3 ',"& * T; '
< Y:;z<;->
- $~&:~~~~,$$$g+
I<>*

. ~".
*

Middle management

<*

Upper management

A*"

<,.-%
- 2/:-5:$'
:i; y-SV*3,."

<,.

'

*&

&,>,.+,.
F+
>2%>?y*;~:;zj

-"-%a+

,*<

'.

"

_-- .,,.'"4
...
, rw.!j"'(:
Ci

""

/"% i

%, ,
%'.

Characteristics of engines,
justified expectations,
prerequisites

Engines produced by MAN B&W Diesel AG have evolved from periods of

con,tinuous, successful research and development work. They satisfy high
standards or performance and have ample redundancy of withstanding
adverse or detrimental inf uences. However, to meet all the requirements
of practical service, they have to be used to purpose and serviced
properly. Only with these prerequisites can unrestricted efficiency and long
useful life be expected.

Purpose of the operating and

working instructions

The operating instructions as well as the working instructions (working

cards) are thought to assist you in becoming familiar with the engine and
the equipment. They are also thought to provide answers to questions that
may turn up later on, and to serve as a guidance in your activities of
engine operation, checking and servicing. Furthermore, we attach
importance to familiarising you with the functions, relations, causes and
consequences, and to conveying the empirical knowledge we have. Not
the least, in providing the technical doc~~mentation
including the operating
and working instructions, we comply with our legal duty of warning the
user of the hazards which can be caused by the engine or its components
- in spite of a high level of development and much constructive efforts - or
which an inappropriate or wrong use of our products involve.

Condition 1

The technical management and also the persons in charge of servicing

works (possibly on order) have to be familiar with the operating
instructions and working instructions (work cards). These should all times
be available.

Caution! Missing information and disregard for infonnation

can cause injury to persons, damage to property and the
environment.
Please read the operating and working instructions.
Condition 2

The servicing and overhaul of modern four-stroke engines will in each

case require previous training of the personnel in charge. The level of
knowledge that is acquired during such training is a prerequisite to using
the operating instructions and working instructions (work cards). No
warranty claims can be derived from the fact that a corresponding note is
missing in these.

A
Caution! Untrained persons can cause injury to persons,
damage to property and the environment.
Never give orders which may exceed the level of knowledge and
experience. Access must be denied to unauthorised personnel.
Condition 3

The technical documentation is valid for one certain order only. There can
be considerable differences to other plants. Informations valid in one case
can lead to problems in others.
A Attention! Technical documents are valid for one certain order
only. Using information of another order or from foreign sources can
lead to disturbances/damages.
Only use the correct information, never use information from foreign
sources.

32/40 upw

Table of contents

,:.. _ . .

I:i,l>l 1.0 1
,

Technical details
Scope of supply1Technical specification
MAN B&W Diesel AG's Scope of S~~pplylTechnical
Specification
Engine
Characteristics
PhotographiesIDrawings
ComponentsISubassemblies
Standard engine design Crankcase to cylinder head
Camshaft drive to injection valve
Supercharger system through engine controls
Special engine designs
Accessories
Systems
Fresh airlcharge air1 Exhaust gas systems
Compressed air and starting system
Fuel oil system
Control of Speed and Output
Injection and valve timing adjustment
Lube oil system
Cooling water system
Technical data
Ratings and consumption data
Temperatures and pressures
Weights
DimensionsIClearances~~olerances-Part
1
DimensionsIClearanceslTolerances-Part2
DimensionsIClearanceslTolerances-Part3

Intended for

...

Table of contents

i
0 .
. >

0.

, 0 .

. '

Operationloperating media

3.1
3.1.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.10
3.3.11
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8

Prerequisites
PrerequisitesNVarranty
Safety regulations
General remarks
Destinationlsuitabilityof the engine
Risksldangers
Safety instructions
Safety regulations
Operating media
Quality requirements on gas oilldiesel fuel (MGO)
Quality requirements for Marine Diesel Fuel (MDO)
Quality requirements for heavy fuel oil (HFO)
Viscosityrremperature diagram for fuel oils
Quality requirements for lube oil
Quality requirements for lube oil
Quality requirements for engine cooling water
Analyses of operating media
Water quality requirements for fuel-water emulsion
Quality requirements for intake air (combustion air)
Engine operation I - Starting the engine
Preparations for s t a d Engine starting and stopping
Change-over from Diesel fuel oil to heavy fuel oil and vice versa
Admissible outputs and speeds
Engine Running-in
Engine operation II - Control the operating media
Monitoring the engine1 performing routine jobs
Engine log book1 Engine diagnosislEngine management
Load curve during accelerationlmanoeuvring
Part-load operation
Determine the engine output and design point
Engine operation at reduced speed
Equipment for optimising the engine to special operating conditions
Bypassing of charge air

Categories of information
7

Information
Description

lnstruction
Datalformulaslsymbols
Intended for ...
Experts
Middle management
Upper management

<.

Condensed water in charge air pipes and pressure vessels

Load application
Exhaust gas blow-off
Charge air blow-off
Injection of addi.tionalcharge air
Engine operation Ill - Operating faults
FaultslDeficienciesand their causes (Trouble Shooting)
Emergency operation with one cylinder failing
Emergency operation on failure of one turbocharger
Failure of the electrical mains supply (Black out)
Failure of the cylinder lubrication
Failure of the speed control system
Behaviour in case operating values are exceeded1 alarms are released
Procedures on triggering of oil mist alarm
Procedures in case a splash-oil alarm is triggered
Procedures on triggering of Slow-Turn-Failure
Engine operation IV - Engine shut-down
Shut downIPreserve the engine
Instruments and Automatics
Lambda Controller
Starting Box
Safety System
Lubricating Oil Thermostatic Valve
Lubricating Oil Cooler
Centrifugal By-pass Filter
Resilient Mounting of Generating Sets

Categories of information
I

Information
'

~ e s c r i ~ i o n ,.. . ,'
Instruction
-.
<,-+
.
I

~ata/formulas/symbols"
Intended for ...
,
Experts
+
-,
"
j

.,

... :+.:2,7'
-.[
.

:%kw..
~:,
.::" "... -., . ,., .
c.

L..

, *

I -

:: "-

,<
*:

&

..

. :2.
:,.
'i .Y
.

:..,
.

'.

r
r v

L'-

.,

..

,,z7

'

.:

~ i d d l e ~ : m a n a ~ & e &,;~~~;ri.;zc;, ~ ~ ~ ~ ~2%.

~ ~... .:..;' .
.-:
.
.; .
,:.:.:
;::
upper
i'.
5:
'..
--"
.
.
.
.
.
.
.
*=~-q,.
. . .
>,
. ,'.'.*
,

_ . I

'

:';$

.:.

<

/ .

yo,...-.

-a
$
';

'

&

-.;

..
I

..

,<:a

.< -.?..:

"-

.>

di' . -

>

<,

- . . L

,
'

'Z

'

7-

.<$.-I>.

,.

'

<

<$>,
>

;,

,
?<

:.... .

.,

7,

. .. ,-.

...)
,.ii

., ,

'

. . -.

..

%
.,%
$
-::

,'-

.:,-&

:m<:$.'.

'

"6*. .&{

.. . ,+.;

.. ,' .-., - . . I. . 3; . '

. . - :::.-is&:.*':.?<
~.,
*'

'..

..

*:?.

.- ;.

'

.;

,'

;..-.$.;4>

.<A;

*?

. ,.:.:.;.;:;...
&
."+:

Table of contents

1
J

..-

._

' s z ,'

O - ' e .
.e,~

:<<

<

'

*'a
aa
a

O ~ : - ; ;,
;;
,El
3,",,::.: q
# ~ : . -

.,#J;+,-Q

."
.";

T O

.,2

"

'

: bc

.?

.a

,.:

, ,

<

x!d
"'
,,,
: , .

\,

-. ' '

'

-:

Cl

<,>

nA

.'

MaintenanceIRepair

4.1
4.2
4.3
4.4
4-5
4.6
4.7
4.7.1
4.7.2

General remarks
Maintenance schedule (explanations)
ToolslSpecial tools
Spare Parts
Replacement of components by the New-for-old Principle
Special services1Repair work
Maintenance schedule (signs/symbols)
Maintenance Schedule (Systems)
Maintenance Schedule (Engine)

Categories of information
.".

lnformation

.<
A

'

. . -..

e.-b--a

- A

< - - ,

-.
<,'*

'

--

'

>

- *-

<<

>

s-7.<

+ -

er:

.-

.,%A* .&

...
,,

Middle management
4 '2

;>x"-,4.T

..

Experts
,

'

:A?-

~ata~formulasls~mbo~s
--?
Intended for

. L , L L c

Instruction
I

.-

''-

Description

Upper management

'
.

"
>

&.

..

7-*.r-

>

. ,

&

"

"

-.-

<

'+

>

' 1 2

.--.
I

:c

C
"1

..*, . I.

Ls

"'-+

Table of contents

< ,

.
a
.e

rj

a
-

:-

c- -l : <
I

*-

, .

'

Annex

5.1
5.2
5.3
5.4
5.5

Designationsrrerms
Formulae
Units of measure/ Conversion of units of measure
Symbols and codes
Brochures

r
I

II

Categories of information

.-,

Description
~nstrutjtion.Datdformulas/symbols

'

..

. .

: L+ y -

r'

<=

,I

- Information

. - -:+$
-%,+
"c

<,
&
,
:=
.

\A

=?.
- -cx
r:v"t *

'

.-

.-.

b9

Intended for ...

*,

Expe.@s
:- ,
Middlii management
Upper manageihent

*
\

1-

i ,

..- 9 .-.

..

.-.