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INSTRUCTION BOOK

VOLUME I

Engine type
L27/38

Hyundai Heavy Industries Co., Ltd.


Engine & Machinery Division
1, Jeonha-Dong, Dong-Gu, Ulsan, Korea
http://www.hhi.co.kr
http://as.hyundai-engine.com

Engine After-sales Service Dept.


Warranty Service Parts Sales
TEL : (82) 52-202-7412~20 TEL : (82) 52-202-7311~20
FAX : (82) 52-202-7581 FAX : (82) 52-202-7582
(82) 52-250-9841
E-mail : engineas@hhi.co.kr E-mail : eservice@hhi.co.kr
INSTRUCTION BOOK
VOLUME

Engine type
L27/38

Hyundai Heavy Industries Co., Ltd.


Engine & Machinery Division
1, Jeonha-Dong, Dong-Gu, Ulsan, Korea
http://www.hhi.co.kr
http://as.hyundai-engine.com

Engine After-sales Service Dept.


Warranty Service Parts Sales
TEL : (82) 52-202-7412~20 TEL : (82) 52-202-7311~20
FAX : (82) 52-202-7581 FAX : (82) 52-202-7582
(82) 52-250-9841
E-mail : engineas@hhi.co.kr E-mail : eservice@hhi.co.kr
Page 1 (2) Project Particulars L27/38

: Applied
: Not applied
Operation of Engine (Plate no. 501)

501-1. Operation
a) Woodward made ------------------------------------------------------------ 501.01 Ed.11H
b) Europa made ---------------------------------------------------------------- 501.01 Ed.08H

Trouble Tracing (Plate no. 503)

503-1. Trouble Shooting Guide for Air Starter


a) Gali made --------------------------------------------------------------------- 503.06 Ed.06H
b) TDI made --------------------------------------------------------------------- 503.06 Ed.05H

Control and Safety Systems (Plate no. 509)

509-1. Governor and Governor Drive


a) Woodward made ------------------------------------------------------------ 501.01 Ed.11H
b) Europa made ---------------------------------------------------------------- 501.01 Ed.08H

509-2. Manual for Governor


a) Woodward made
b) Europa made

Crankshaft and Main Bearings (Plate no. 510)

510-1. Vibration Damper


a) Geislinger made ------------------------------------------------------------ 510-04.00 Ed.06H
b) Vulkan made ----------------------------------------------------------------- 510-04.00 Ed.04H

510-2. Vibration Damper with Attachment


a) Geislinger made ------------------------------------------------------------ 51004-07H
b) Vulkan made ----------------------------------------------------------------- 51004-05H

Turbocharger system (Plate no. 512)

512-1. Manual for Turbocharger


a) NR20/S (FOR 5,6L27/38)
b) NR24/S (FOR 7,8L27/38)
c) NR29/S (FOR 9L27/38)

Compressed Air System (Plate no. 513)

513-1. Compressed Air System


a) Gali made --------------------------------------------------------------------- 513.01 Ed.09H
b) TDI made --------------------------------------------------------------------- 513.01 Ed.14H

513-2. Overhaul, Test and Inspection of Air Starter


a) Gali made --------------------------------------------------------------------- 513-01.30 Ed.05H
b) TDI made --------------------------------------------------------------------- 513-01.30 Ed.04H

---------------------------------HHI/ENGINE AND MACHINERY DIVISION-----------------------------


Page 2 (2) Project Particulars L27/38

513-3. Turning Gear


a) Manual turning gear -------------------------------------------------------- 513-25.00 Ed.02H
b) Electric turning gear -------------------------------------------------------- 513-25.00 Ed.01H

513-4. Air Starter


a) Gali made (Starter serial no. > 02-0101) ----------------------------- 51309-11H
51309-13H
b) TDI made (Output gear ratio 9.25 : 1) --------------------------------- 51309-09H

513-5. Main Starting Valve (* If selected 513-4,b) ------------------------ 51310-04

513-6. Pressure Reduction Valve (* If selected 513-4,a) --------------- 51322-05H

513-7. Turning Gear


a) Turning gear with attachment ------------------------------------------- 51325-03E
b) Electric turning gear -------------------------------------------------------- 51325-05H

Fuel Oil System (Plate no. 514)

514-1. Fuel Oil Safety Filter ----------------------------------------------------- 51415-01H

Lubricating Oil System (Plate no. 515)

515-1. Centrifugal by-pass filter ----------------------------------------------- 515-15.00 Ed.04H


51515-03H

515-2. Prelubricating oil pump


a) Rickmeier made ------------------------------------------------------------- 515-01.05 Ed.07H
51504-05H

b) Yurim made ------------------------------------------------------------------ 515-01.05E Ed.02E


51504-04E

Special equipment (Plate no. 517)

517-1. Flexible coupling

517-2. Torsional vibration damper

517-3. Oil mist detector


Graviner MK-6
Schaller VN-115

517-4. Emergency MDO pump unit

517-5. Jacket water preheating unit Electric type


Steam type

517-6. Cooling water thermostatic valve (Pneumatic type)

517-7. L.O.auto back-flushing filter

---------------------------------HHI/ENGINE AND MACHINERY DIVISION-----------------------------


MAN
B&W

Description
Page 1 (2) Planned Maintenance Programme 500.26
Edition 13H

L27/38
Duties during Operation
Time Between Overhauls

overhauled parts
Working

Observations
3rd month


after - hours
Description

Check new/

Monthly
200

8000
16000
32000

Weekly
z

50

2000
= Overhaul to be carried out Card

Daily

 = Check the condition No

Operating of Engine

Readings of data for Engine and Generator, with refer-  


ence to "Engine Performance Data", section 502-1 ........          502-01.00
Check for leakages .......................................................... 
502-05.00

  
Specication - Cooling water       

Cooling water system - Water samples, see section 504        516-01.90

Cylinder Head

Inlet and exhaust valve - check and adjustment of valve  


clearance .........................................................................   508-01.10
Lubricating of operating gear - Check .............................    
Check of valve rotators' rotation during engine rotation .          505-01.15
 
       
Control and Safety System, Automatics and
Instruments

Safety, alarm and monitoring equipment ........................          509-01.00


Lambda controller - Adjustment ......................................          509-10.00
Governor - Check oil level, see governor instruction
book, section 509 ...........................................................          section 509

         
Turbocharger System
z
08028-0D/H5250/94.08.12

Dry cleaning of turbine side ............................................ 512-10.00


Water washing of compressor side ................................ z 512-05.00
Exhaust pipe compensator ..............................................        512-01.10
Retightening of all bolts and connections, se special      
Instruction book ...............................................................
Cleaning of air lter - Compressor side, see special
instruction book ...............................................................

07.29
MAN
B&W

500.26 Planned Maintenance Programme Description


Page 2 (2)
Edition 13H

L27/38
Duties during Operation
Time Between Overhaul

Overhauled parts
Working

Observations
3th month
Description 

Check new/

after -hours
50

2000
8000
z

200

32000
= Overhaul to be carried out

Weekly
16000
Card

Montly
Daily
= Check the condition No

Compressed Air System

Function test - Main and emergency starting valve .........          513-01.40


Air lter, draining of bowl (lter element to be replaced      
when pressure drop exceeds 0,7 bar) .............................      z   513-01.21

Compressed air system - Check of the system ...............        513-01.90

Fuel Oil System and Injection Equipment

Fuel oil system - Check the system .................................        514-01.90


Fuel oil - Oil samples after every bunkering, see sec.504 section 504
Fuel injection valve ..........................................................   514-01.10

 
Lubricating Oil System

Lubricating oil lter - Cleaning and replacement ............  z 515-01.10


Centrifugal lter - Cleaning and replacement paper lter z 515-15.00

Lubricating oil - Oil samples ...........................................         


Lubricating oil system - Check the system ......................        515-01.90

Cooling Water System

Cooling water system - Water samples ..........................       


Cooling water system - Check the system ......................        516-01.90

Engine Frame and Bedplate


08028-0D/H5250/94.08.12

Flexible mounting - Check anti-vibration mountings ........   519-03.00


Safety cover - Function test .............................................

Alternator - see special instruction book

Major overhaul/inspection, see 500.25

07.29
MAN
B&W

Description 500.30
Page 1 (3) Operation Data & Set Points Edition 48E

L27/38

Acceptable
value at shop
Normal Value at Full load test or after Alarm Set point Autostop of engine
repair

Lubricating Oil System

Temp. after cooler


(inlet lter) SAE 40 TI 21 68-73 C <73 C TAH 21 80 C
Pressure after lter(inlet engine) PI 22 4.2-5.0 bar >4.5 bar PAL 22 3.5 bar PSL 22 3.0 bar
(PSL 22) (D) (2.5 bar)
Pressure drop across lter PDAH 21-22 0.1-1 bar <0.5 bar PDAH 21-22 1.5 bar
Prelubricating pressure (PI 22) 0.14-1.4 bar <1.0 bar PAL 25 0.12 bar (H)
Pressure inlet turbocharger PI 23 1.5 0.2 bar >1.5 bar PAL 23 0.9 bar
(C)
Lub. oil level in base frame LAL 28/ low/high level
LAH 28
Pressure before lter PI 21 4.5-5.5 bar
Crankcase protection LSH/LAH 92 High level (K)
Temp. main bearing TI 29 80-95 C TAH 29 100 TSH 29 105
Fuel Oil System

Pressure after lter MDO PI 40 3-6 bar PAL 40 2 bar


HFO PI 40 5-16 bar (A) PAL 40 4-6 bar (E)
Leaking oil LAH 42 High leakage
level
Temperature inlet engine MDO TI 40 30-40C
HFO TI 40 110-140C
Cooling Water System

Press. LT system, inlet engine PI 01 2.5-4.5 bar >1.8 bar PAL 01 0.4 + (B) bar
Press. HT system, inlet engine PI 10 2.0-4.0 bar >1.8-<6 bar PAL 10 0.4 + (B) bar
Temp. HT system, outlet engine TI 12 75-85C <85 C TAH 12 90 C TSH 12 95 C
TAH 12-2 93 C (TSH 12) (D) (100 C)1
Temp. LT system, inlet engine TI 01 30-40C
Exhaust Gas and Charge Air

Exh. gas temp. before TC TI 62 480-530 C TAH 62 570 C


TAH 62-2 620 C
Exh. gas temp. outlet cyl. TI 60 350-450 C TAH 60 465 C
Diff. between individual cyl. average average TAD 60 average
30 C 25 C 50 C
08028-0D/H5250/94.08.12

Exh. gas temp. after TC


330 kW TI 61 275-400 C TAH 61 450 C
300-320 kW TI 61 275-375 C TAH 61 450 C
Ch. air press. after cooler PI 31 2.8-3.1 bar
Ch. air temp. after cooler TI 31 40-55 C <55 C
Compressed Air System

Press. inlet engine (TDI) PI 70 8- 10 bar >7.5-<10 bar PAL 70 7.5 bar
Press. inlet engine(Gali) PI 70 16~30 bar PAL 70 15 bar

06.34 - ES1
MAN
B&W

500.30 Description
Edition 48E Operation Data & Set Points Page 2 (3)

L27/38

Remarks to Individual Parameters

A. Fuel Oil Pressure, HFO-operation. F. Start Interlock.

When operating on HFO, the system pressure must The following signals are used for start interlock/
be sufcient to depress any tendency to gasication blocking:
of the hot fuel.
1) Turning must not be engaged
The system pressure has to be adjusted according 2) Engine must not be running
to the fuel oil preheating temperature. 3) "Remote" must be activated
4) No shutdowns must be activated.
5) The prelub. oil pressure must be OK, 20 min.
B. Cooling Water Pressure, Alarm Set Points. after stop.
6) "Stop" signal must not be activated
As the system pressure in case of pump failure will
depend on the height of the expansion tank above the G. Start Failure.
engine, the alarm set point has to be adjusted to 0.4
bar plus the static pressure. The static pressure set If remote start is activated and the engine is in
point can be adjusted on the base module SW3. blocking or local mode or turning is engaged
the alarm time delay is 2 sec.
Start failure will be activated if revulutions are
C. Lub. Oil Pressure, Offset Adjustment. below 50 rpm within 5 sec. from start or revulu-
tions are below 210 rpm 10 sec. from start.
The read outs of lub. oil pressure has an offset Start failure alarm will automatically be released
adjustment because of the transmitter placement. after 30 sec. of activation.
This has to be taken into account in case of test and
calibration of the transmitter. H. Alarm Hysterese.

D. Software Created Signal. On all alarm points (except prelub. oil pressure) a
hysterese of 0.5% of full scale are present. On prelub.
Software created signal from PI 22, TI 12, SI 90. oil pressure alarm the hysterese is 0.2%.

E. Set Points depending on Fuel Temperature. I. Engine Run Signal.

The engine run signal is activated when engine


rpm >710 or lube oil pressure >3.0 bar or TC
rpm >5000 rpm.
If engine rpm is above 210 rpm but below 710
rpm within 30 sec. the engine run signal will
08028-0D/H5250/94.08.12

be activated.

Fig 1 Set point curve.

06.34 - ES1
MAN
B&W

Description 500.30
Page 3 (3) Operation Data & Set Points Edition 48E

L27/38
J. Limits for Turbocharger Overspeed Alarm
(SAH 89)

Engine type 720 rpm 750 rpm


5L27/38 44,700 44,700
6L27/38 44,700 37,300
7L27/38 37,300 37,300
8L27/38 37,300 37,300
9L27/38 31,300 31,300

K. Crankcase Protection

For engines above 2250 kW crankcase protection


is standard for marine application. This will be done
by an oil mist detector (standard) or with a splash
oil/crankcase protection system (option)
08028-0D/H5250/94.08.12

06.34 - ES1
MAN
B&W

Description
Data for Pressure and Tolerance 500.35
Page 1 (1) Edition 27H

L27/38

Section Description mm / bar

505 Safety valve to be adjusted to 230 bar


(7 bar at 20C)
Maximum inner diameter, valve guide 20.2 mm
For grinding of valve spindle and valve seat ring
(see also working card 505-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H"1 9.0 mm

506 Piston and piston ring grooves (see working card 506-01.10)
Maximum clearance between connecting rod bush and piston pin 0.29 mm
Maximum ovalness in big-end bore (without bearing) 0.02 mm
Maximum inside diameter cylinder liner, maximum ovalness 0.1 mm 270.4 mm
Sealing minimum height above the cylinder liner 0.2 mm

507 Maximum tolerance at the valve cam bearing 0.3 mm


Maximum tolerance at the fuel cam bearing 0.35 mm

508 Valve clearance, Inlet valve (cold engine 15 - 50C) 0.7 mm


Valve clearance, Exhaust valve (cold engine 15 - 50C) 0.7 mm
Maximum clearance between rocker arm bush and rocker arm shaft 0.3 mm
Maximum total tolerance between shaft bushing and roller 0.35 mm

509 Free spand between pick-up and band steel (Lambda controller) 1 mm

510 Deection of crankshaft (autolog) (see working card 510-01.00)


Minimum axial guide bearing clearance 0.400 mm
Maximum axial guide bearing clearance 0.663 mm
Minimum radial main bearing clearance 0.225 mm
Maximum radial main bearing clearance 0.336 mm

514 Combustion pressure range at full load 185 - 200 bar


08028-0D/H5250/94.08.12

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 0.07-0.11 mm


and plunger base plate / fuel injection pump

Total axial clearance of follower / fuel injection pump 0.4 - 0.7 mm

07.24 - ES0
MAN
B&W

Description
Declaration of Weight 500.45
Page 1 (1) Edition 03H

L27/38

Section Component Plate No Item No Weight in Kg

505 Cylinder head, incl. rocker arms 50501 027 400


50502 010/022
Cylinder unit 50500 021 680

506 Piston, complete 50601 081 66


Connecting rod, complete 50601 068 115
Cylinder liner, complete 50610 018 140

511 Cover for crankcase 51106 010 31.5

512 Turbocharger, NR20/R, complete 512 320


Turbocharger, NR24/S, complete 512 505
Turbocharger, NR26/R, complete 512 790
Air cooler 51201 162 380

514 Fuel injection pump 51401 565 35

515 Lubricating oil pump 51501 031/043 40

516 HT- and LT-cooling water pump 51610 105 30


08028-0D/H5250/94.08.12

00.32 - ES0
r

Index
Page 1 (1) Operation of Engine 501

Description

*) Operation (Europa made) ................................................................................................ 501.01(08H)


*) Operation (Woodward made) .................................................................................................... 501 .O1(1 1H)
Out of Service ............................................................................................................................. 501.05 (05H)
Starting-up after Repair ................................................................................................................. 501.1 0 (03H)
Guidelines for Longterm Low-Load Operation on HFO ............................................................501.15 (02H)
Operating a Diesel Engine at Low Frequency (only startionary engine) ............................ 501.25 (01H)

Working Card

Plates

*) Depending on Project Specification


Index
Page 1 (1) Engine Performance and Condition 502

Description

Engine Performance and Condition .............................................................................................. 502.01 (03H)


Evaluation of Readings Regarding Combustion Condition ........................ . ........................... 502.02 (02H)
Condensate Amount ..................................................................................................................... 502.05 (03H)

Working Card

Plates
MAN
B&W

Description 503.20
Page 1 (6) Trouble Shooting / Electrical Failures Edition 09H

L27/38
Trouble Shooting If the conclusion of a trouble shooting indicates
that an exchange of a module is needed, please
This description is a trouble shooting guide for the ll-in the enclosed inspection report, and return the
automation system on the diesel engine type L27/38 module together with the inspection report to the
and L32/40. engine maker.

Further, please remember to inform the software no


General when ordering a new module.

This guide is a standard guide for engines, where


safety system is made by Allen-Bradley only. The Safety System
number of modules connected to the CPU module
variates from engine type to engine type. The in- The safety system is an independent system and
/outputs described in this guide, will be the same at consists of maker Allen-Bradley PLC hardware
all application. modules and MAN B&W software. Fig 1 describes
the hardware modules.
The following trouble shooting guide is an aid in iso-
lating troubles to the engine built-on safety system For wiring of the modules and sensors a reference
and monitoring system incl. the sensors connected is made to the electrical scheme which can be found
to these systems. in the operation manual, section 509.

CAUTION! The control system can be damaged The safety system consists of two Allen-Bradley
with the wrong voltage. When replacing a control PLC modules. The modules named 3P1 is the CPU
unit, check that the power supply is switched off module and the module named 5P1 is an I/O-mod-
during replacement and check the power supply for ule. Indication of individual input and output can be
the correct voltage before switching-on. found on the modules by yellow diodes. The refer-
ence number for each input and output can be found
Table 1.1 for the safety system and table 1.2 for the in the electrical scheme.
monitoring system are general guides for isolating
system problems. Each system check assumes that On the operation box individual indication of the shut-
the prior checks have been done properly. Table 1.3 downs (low lub. oil pressure, high cool. water temp.,
and 1.4 are system error messages which can be a overspeed and emergency stop) can be found.
guideline to the problem.
08028-0D/H5250/94.08.12

Fig 1 Hardware module.

06.22 - ES0
MAN
B&W

503.20 Description
Edition 09H Trouble Shooting / Electrical Failures Page 2 (6)

L27/38
Table 1.1

Trouble Possible cause Troubleshooting

Engine will not start. Supply voltage polarity, or no sup- Check the supply voltage on the green diode on
Start motor is not engaged. ply voltage. 3P1. If it is alight the power supply for the PLC
modules are OK.

RUN/REM/PROG change-over Put the RUN/REM/PROG change-over switch in


switch on 3P1 in wrong position. RUN position. Check RUN LED on 3P1.

No software in the module. If no diodes on 3P1 and 5P1 - except the power diode,
are alight after having switched on the power supply,
the module is without software. The CPU module
must be replaced with a module incl. software.
Note! After switch-on of the power supply the
initialization takes app. 3 sec. Please wait these
seconds before observation.

Check that diode Out 1 on CPU module is alight.


Output relay Out 1 is in failure or If Out 1 is not alight check that Out 2 at 5P1 is not
loose connections. alight. Check for loose wires on terminals VAC/DC
1 and Out 1 on 3P1, and 5P1.

Reset the shutdowns.


One or several shutdown signals are If one is still activated on the operation box, check
activated on the monitoring box that output Out 8, Out 9, Out 10 and Out 11 on 3P1
are not alight. If one is alight, check the sensor and
wiring for short circuit. If Out 8, 9, 10, 11 on 3P1 is
not alight but the shutdown signals on the moni-
toring box is activated the problem is to be found
on the internal relays. Switch the power supply for
3P1 on and off several times. the relay contact will
then be OK again.

All shutdown LED are alight on the Connector is not correctly connected Check the connector J29 on the base module.
monitoring box. or internal failure in 3P1. No red LED must be alight on 3P1. Activate the
change-over switch RUN/REM/PROG. Exchange
the 3P1 module.

Low lub. oil shutdown occurs when Damaged or wrong adjustment of Check the pick-up for correct adjustment.
normal stop is activated. the rpm pick-up. Sensing distance = app. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly. Replace the pick-up.
Note! Diode Out 2 on 3P1 will be alight if actual speed
is above nominal speed. If actual speed is below, it
08028-0D/H5250/94.08.12

will be dark. At start LED In 0 will ash. At steady


speed LED In 0 will be permanently alight.

The alarm System & Power failure No program in CPU, or fault in Check that power supply is OK. (Green diode
is activated. CPU. must be alight). Switch on the RUN/REM/PROG
Diode Out 0 at 5P1 is not alight or CPU in stop mode. change-over switch. The problem could be related
diode Out 1 at 5P1 is not alight. to an internal component failure and the module
must be replaced. Observe that no red diode is
alight on 3P1.

The shutdown functions are not Wiring or sensor problem. Check the wiring for shutdown sensors.
working. Internal component failure. Replace the module.

Overspeed set point is not correct. Missing jumper or wrong software. Check that Input 7 is not alight for 720 rpm engines,
and ON for 750 rpm engines. Version as described
at page one.

06.22 - ES0
MAN
B&W

Description 503.20
Page 3 (6) Trouble Shooting / Electrical Failures Edition 09H

L27/38
If a replacement module is needed, the software ver- All sensors are connected to the base module and
sion must be informed at ordering. To nd software the Operation Box (OB), Monitor for Temp. and
version, turn upper potentiometer to 3/4 position. Pressure Module (MTP) and Monitor for Exh. Gas
Observe diode no Out 3 for ashes. F.ex. three Temp. Module (MEG) are connected via interlink
ashes, a pause of 1.5 sec., and one more ash, bus connection.
means software version 3.2. The software version
can be with four numbers, ex. 3.1.2.1. (the software Interface to the alarm and monitoring system in the
version no. is also stated in the electrical scheme) control room is made by MODBUS or Interlink to the
output module.

The Monitoring System The software can be read on the label attached on
the Base Module or by pushing the lamp test button
The monitoring system monitors shows all relevant for 3 seconds. The software version number will be
pressures, temperatures and rpm on the engine. displayed in the operation box display.

The monitoring system consists of four hardware The software for engine type L27/38 will start with
modules as standard and a module as option for 3.xx, and the software for engine type L32/40 will
bearing temp. monitoring. The monitoring system start with 6.xx, f.ex. 6.4. Please make sure that the
hardware and software is developed by MAN B&W. dip switches SW1, SW2, SW5 and SW3 are in cor-
Fig 2 describes the hardware. rect position acc. to the plant related scheme. See
section 509.

Failure LED

2.5 A
Fuses OB ENGINE RPM.
0 1400

SI90
MTP H.T. WATER TEMP.

OUTLET ENGINE
TI12

0 60000 H.T. WATER PRESS.


PI10
INLET ENGINE
TC RPM. SI89

L.T. WATER TEMP.


TI01
0 40 INLET AIR COOL.

START AIR PI70 L.T. WATER PRESS.


PRESS. PI01
INLET AIR COOL.

LUB. OIL TEMP.


HOUR BAR TI22
INLET ENGINE

C LUB. OIL PRESS.


PI21
. . . . INLET FILTER

ALT. RPM.
LUB. OIL PRESS.

Dip Sensor power


PI22
OVERSPEED INLET ENGINE

Display LOW LUB. LUB. OIL PRESS.

switches LED
OIL PRESS. PI23
INLET TC
HIGH FRESH
WATER TEMP. FUEL OIL TEMP.
TI40
EMERGENCY INLET ENGINE
STOP
FUEL OIL PRESS.
PI40
INLET ENGINE
08028-0D/H5250/94.08.12

0 80

Push 3 sec. START STOP


3 SEC. Delay
LAMP TEST CHARGE AIR TEMP.

OUTLET COOL.
TI31

Software version REMOTE LOCAL


BLOCKING

RESET
CHARGE AIR PRESS.

OUTLET COOL.
0 4

PI31

will be indicated
in the display
AP HIGH H.T. WATER TEMP.
TAH 12.
LOW FUEL OIL PRESS.
PAL 40.
MEG 200 400 600

(Option) HIGH LUB. OIL TEMP.


TAH 21.
LOW START/STOP AIR PRESS.
PAL 70/71.
E

X
CYL.
1 TI60

H
HIGH/LOW EXH. GAS TEMP. OVERSPEED.
TDAH 60. SAH 81.
A CYL.
2 TI60

HIGH EXH. GAS TEMP. JET SYSTEM FAILURE. S

TC. OUTLET. TAH 61. SX 32. T


CYL.
3 TI60

HIGH EXH. GAS TEMP. POWER & SYSTEM FAILURE. G


TC. INLET. TAH 62. UX 95. A
CYL.
4 TI60

S
HIGH ALTERNATOR WINDING COMMON SHUTDOWN.
TEMP. TAH98 SS 86. T
CYL.
5 TI60

E
LOW L.T. WATER PRESS. START FAILURE.
PAL 01. SX 83.
M CYL.
6 TI60

LOW H.T. WATER PRESS. STOP FAILURE. E


PAL 10. SX 84. R
CYL.
7 TI60

A
LOW LUB. OIL PRESS. FUEL LEAKAGE.
PAL 22. LAH 42.
T CYL.
8 TI60

HIGH DIFF. PRESS. L.O. LOW L.O. LEVEL BASE R

FILTER. PDAH 21-22. FRAME. LAL 28. E


CYL.
9 TI60

LOW LUB. OIL PRESS. TC. HIGH L.O. LEVEL BASE


TC INLET TI62
PAL 23. FRAME. LAH 28.

LOW PRELUB. OIL PRESS. TURNING GEAR ENGAGED.


TC OUTLET TI61
PAL 25. ZS 75.

Fig 2 Hardware modules.

06.22 - ES0
MAN
B&W

503.20 Description
Edition 09H Trouble Shooting / Electrical Failures Page 4 (6)

L27/38
Table 1.2

Trouble Possible cause Troubleshooting

Engine will not start. Power supply is not correct, interlock Check that the power supply is correct 24 V 20%
Start motor is not engaged. activated or internal component on terminals J3; 132, 133.
failure Check that no interlocks are activated
Turning gear not engaged
No start failure activated
No engine run signal
Remote mode is activated
No shutdown activated
Stop valve not activated
No lub. oil pressure
Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98, 99 are
correct.
Check the safety system (see table 1.1)
Check that the ON/OFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is nished.
Replace the base module.

Data communication failure. EMC problem or loose connec- Check that the green LED on the base module is
tions. alight. See also table 1.3
Check that all cable screens are connected correctly
in the EMC cable glands.
Check that the data communiation cable (MODBUS)
is the twisted pair type.

No RPM indication Defect pick-up or incorrect adjust- Check the pick-up for correct adjustment.
ment. Sensing distance = app. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
Replace the pick-up. The thread on the pick-up
is 1 mm.

The engine suddenly starts or Two or more earth failures on the Check for earth failures on all sensors.
stops. engine and yard installation. Special attention should be made to the exh. gas sen-
08028-0D/H5250/94.08.12

sors. Check for earth failures in the yard system.


Replace the base module.

LED ashing green, yellow or red. Internal component failure or EMC See table 1.3. Switch the power ON/OFF.
problem. Exchange the base module.

All red diodes on the operation box No power supply or software in the Check the safety system accoding to table 1.1.
are alight. safety system.

Jet system activated under no The band steel on the lambda arm Adjust the band steel to app. 2-3 mm above the
load condition and/or jet alarm is adjusted incorrectly. jet pick-up.
activated.

Cont.

06.22 - ES0
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Description 503.20
Page 5 (6) Trouble Shooting / Electrical Failures Edition 09H

L27/38
Cont. Table 1.2

Trouble Possible cause Troubleshooting

Frozen operation box, MTP and Internal software failure. See table 1.3. Switch the power supply on/off.
MEG box. Exchange the base module.

Instable behaviour of the output Too high voltage on the output circuit Check that the voltage is below 48 VDC.
signals for start/stop of prelubricat- terminals J20, 108, 109 120 VAC or 220 VAC is not allowed.
ing pump. Note! The voltage must be checked in the prelubri-
cating pump starter panel.

Temp. indication is too high acc. Internal component failure. Replace the base module.
to calibrated values, or values are
abnormal.

Change-over switch between LO- Internal failure in the operation See table 1.3 and 1.4. Replace the operation box.
CAL - REMOTE - BLOCKING is box.
not working. Damaged at cable between print
card and front panel.

The alarm System & Power failure This alarm consists of different alarm 1) Check diode Out 1 on the safety system module
is activated. possibilities 5P1. If it is alight, it is OK. No red LED must be alight
1) Power & system failure in the on 3P1. See also table 1.1. SUPPLY LED and RUN
safety system. LED must be alight.
2) Power supply failure to the pres- 2) Check green diode J29/J30 and fuse 2.5 AT. If
sure sensors. green diode is alight, it is OK.
3) Cable/wire failure for monitor 3) Check if any analog signals are missing. If all
sensors. signals are present, it is OK. Remember to check
4) Cable/wire failure for safety also the spare exh. gas input channels. A jumper
system sensors. must be present. See also table 1.4
5) Communication link failure. 4) Check diode Out 0 at 5P1. If it is alight, it is OK.
6) Tacho failure. If it is not alight, check the safety system for cable
break or loose connections.
5) Check if rpm pick-up is OK, and/or lub. oil
pressure is OK. If lub. oil pressure is normal, but
no rpm signal is present, the tacho alarm will be
activated.
6) Check the diode on the base module to table
1.3 and table 1.4.

OB display indicates OFFLN or Cable break on data communication See table 1.3. Check cable installation for sensor(s)
ERR-1 or fault. or sensor(s). and/or data communication
08028-0D/H5250/94.08.12

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503.20 Description
Edition 09H Trouble Shooting / Electrical Failures Page 6 (6)

L27/38
Table 1.3
Base Module LED indications

On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the
Base Module central processor.

The following failure LED indications are possible:

Observations Description

GREEN permanent light OK, all Interlink modules are online

GREEN ash One or more Interlink modules are ofine (disconnected) or incorrect setup on SW2.

RED permanent light BM internal hardware error (or lockup caused by EMC disturbances).

YELLOW permanent light BM internal hardware error (or lockup caused by EMC disturbances).

RED ash BM software or hardware fault. The number of ashes indicates an internal error code which must be
reported when returning the module. (It may also be caused by EMC disturbances)

Yellow 4x ash MODBUS address error (SW1): Incorrectly set to an illegal address (0 or 255, all switched ON or
OFF).

Other yellow ashes BM internal software fault. The number of ashes indicates an internal error code which must be reported
when returning the module. (It may also be caused by EMC disturbances)

Table 1.4
Display indications on the Operation Box (OB)

Observations Description

Ready Shown for a few seconds when the OB module is powered on, indicating that the internal selftest of the module
was successfully passed.

OFFLN The OB module is OFFLINE. There is no communication from the base module to the OB module. This message
will appear shortly when powering on the system, indicating that the base module has been reset.

Defective link between BM and OB module.


No power on BM
BM fatal hardware or software error. Indicated be red or yellow light or ashes on the BM two-coloured
LED.
08028-0D/H5250/94.08.12

ERR-1 Indicates cable break or sensor failure on the corresponding input.

FAULT Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault.

Shown if the exhaust temperature is selected for an invalid cylinder number.

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Description 504.07
Page 1 (2) Specific Lubricating Oil Consumption - SLOC Edition 03

General

Engine type RPM SLOC [g/kWh]

L16/24 1000/1200 0.4 - 0.8

L21/31 900/1000 0.4 - 0.8

L23/30H 720/750/900 0.6 - 1.0

L27/38 720/750 0.4 - 0.8

L28/32H 720/750 0.6 - 1.0

V28/32H 720/750 0.6 - 1.0

V28/32S 720/750 0.4 - 0.8

L32/40 720/750 0.8 - 1.0

Please note that only maximum continuous rating A2:


(PMCR (kW)) should be used in order to evaluate the Lubricating oil evaporation
SLOC. Lubricating oil leakages
Lubricating oil losses at lubricating oil filter
Please note, during engine running-in the SLOC may exchange
exceed the values stated.
The lubricating oil density, @ 15C must be known
The following formula is used to calculate the in order to convert to the present lubricating oil
SLOC: temperature in the base frame. The following formula
is used to calculate :
SLOC [g/kWh] =
lubricating oil [kg/m3] =
(lubricating oil added - A1 - A2 [dm ]) * lubricating oil [kg/m ]
3 3

run.hrs period * PMCR [kW] lubricating oil @15C [kg/m3] 0,64 * (tlubricating oil [C] 15)

In order to evaluate the correct engine SLOC, The engine maximum continuous design rating (PMCR)
the following circumstances must be noticed and must always be used in order to be able to compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating oil adding must be used
A1: in the calculation. Due to inaccuracy *) at adding
08028-0D/H5250/94.08.12

Desludging interval and sludge amount from the lubricating oil, the SLOC can only be evaluated
lubricating oil separator (or automatic lubricating oil after 1,000 running hours or more, where only the
filters). The expected lubricating oil content of the average values of a number of lubricating oil addings
sludge amount is 30%. are representative.

The following does also have an influence on Note *)


the SLOC and must be considered in the SLOC A deviation of 1 mm with the dipstick measurement
evaluation: must be expected, witch corresponds uptill 0.1
g/kWh, depending on the engine type.

06.25 - ES0
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Description 504.07
Page 2 (2) Specific Lubricating Oil Consumption - SLOC Edition 03

General

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

Lube oil brand type:

Density @15: [kg/m3]


Date Run. hrs Add.Lube oil A1 + A2 LO.Temperature SLOC Remarks
[h] [dm3] [dm3] [] [g/kWh]
08028-0D/H5250/94.08.12

06.25 - ES0
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Working Card
Replacement of Valve Guide 505-01.20
Page 1 (2) Edition 10

L21/31
L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 52001 120
Shut-off fuel oil
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Dismantling and mounting of valve guide for inlet Hammer / Lead hammer.
and exhaust valve. Liquid Nitrogen (LN2) or equivalent.
E7 reamer, 16 mm (L21/31)
H7 reamer, 20 mm (L27/38)

Starting position

Valve spindle has been removed 505-01.05

Related procedure

Inspection of inlet valve,


exhaust valve and valve guide 505-01.05

Manpower
08028-0D/H5250/94.08.12

Replacement and wearing parts


Working time : 3/4 hour
Capacity : 1 man Plate no Item no Qty/

50501 076 4/cyl


Data 50501 088 4/cyl

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

07.17
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505-01.20 Replacement of Valve Guide Working Card


Page 2 (2)
Edition 10

L21/31
L27/38
When to Replace the Valve Guide 7) Insert a new O-ring in the top of the valve guide, see
g 3.
If the diameter exceeds the max. limit, see page
500.35, the valve guide must be replaced. Tool for valve guides is not a part of the standard tool kit.

Dismounting of Valve Guide

1) Remove the old valve guide, through the top of


the cylinder head using a drift inserted through
the valve seat, see g 1.
This is easiest if the cylinder head is inverted,
as shown on g 1.

Fig 2 Mounting of valve guide

Fig 1 Dismounting of valve guide

Mounting of Valve Guide

2) Clean the bore in the cylinder head carefully.


08028-0D/H5250/94.08.12

3) The new valve guide must be cooled down


to approx. -70C with liquid nitrogen (LN2) or
equivalent.
4) Insert the valve guide in the bore, see g 2.

5) Ensure that the valve guide is fully seated, if


necessary by light blows to the drift.

6) After the guide has been tted and has returned


to room temperature, it is essential that it be
reamed to nal size using the specied reamer.
Please see page 500.35 for tolerances. Fig 3 Inserting a new O-ring in the valve guide

07.17
MAN
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Plate
Page 1 (2) Kit for Cylinder Unit 50500-02E

L27/38
08028-0D/H5250/94.08.12

99.25 - ES0
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Plate
50500-02E Kit for Cylinder Unit Page 2 (2)

L27/38

Ordering Number of Kit for Cylinder Unit


According to list below
Plate 50500-02E / Item 021

Item
no Qty Designation Where to find in the engine instruction book

021 1/C Kit for cylinder unit, complete Plate 50500 Item 021
consisting of:

1/C O-ring Plate 50501 Item 040

2/C O-ring Plate 50501 Item 064

4/C O-ring Plate 50501 Item 076

2/C O-ring Plate 50501 Item 111

1/C O-ring Plate 50501 Item 135

1/C O-ring Plate 50501 Item 135E

2/C O-ring Plate 50501 Item 172

1/C O-ring Plate 50501 Item 196

2/C O-ring Plate 50501 Item 243

1/C Gasket Plate 50501 Item 338

2/C O-ring Plate 50501 Item 363

2/C Circlip Plate 50502 Item 095

4/C Conical ring 2/2 Plate 50502 Item 178

1/C O-ring Plate 50502 Item 237

1/C O-ring Plate 50502 Item 250

1/C Piston ring Plate 50601 Item 093

1/C Piston ring Plate 50601 Item 103

1/C Oil scraper ring Plate 50601 Item 127

1/C Sealing ring Plate 50610 Item 031


08028-0D/H5250/94.08.12

1/C O-ring Plate 50610 Item 043

1/C O-ring Plate 50610 Item 055

1/C O-ring Plate 50801 Item 090

2/V O-ring Plate 51402 Item 033

1/V O-ring Plate 51402 Item 104

Please Note that this is a kit supply, and that any exceeding number of o-rings and gaskets
are not accepted as return goods.

Qty/C = Qty/Cylinder
Qty/V = Qty/Valve

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Plate
Page 1 (2) Cylinder Head 50501-05E

L27/38
08028-0D/H5250/94.08.12

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Plate
50501-05E Cylinder Head Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

015 2/C Guide for valve bridge Styr for ventilbro


027 1/C Cylinder head Cylinderdksel
040 1/C O-ring O-ring

052E 1/C Insert

053E 1/C Bush

064 2/C O-ring O-ring

076 4/C O-ring O-ring

088 4/C Valve guide Ventilstyr

111 1/C O-ring O-ring

123 2/C Valve seat ring, Ventilsdering,


inlet indstrmning

135 1/C O-ring O-ring

135E 1/C O-ring O-ring

172 2/C O-ring O-ring

184 2/C Valve seat ring, Ventilsdering,


exhaust udstdning

196 1/C O-ring O-ring

206 4/C Screw Skrue

218 1/C Water guide jacket Klekappe

243 1/C O-ring O-ring

292 1/C Conn. socket Forbindelsesstykke

302 1/C Threaded socket Gevindstuds

314 1/C Union nut Omlbermtrik

338 1/C Gasket Pakning

351 1/C Safety valve Sikkerhedsventil

363 2/C O-ring O-ring

375 1/C Connecting piece Forbindelsesstykke

410E 1/C Indicator valve Indikatorventil


08028-0D/H5250/94.08.12

422 1/C Cylinder head incl- Cylinderdksel inkl.


items 015,027,040, items 015, 027, 040,
052,064,076,088,123, 052,064,076,088,123,
172,184,plate 50502 172,184, plate 50502
items 010,022,130, items 010, 022, 130,
178,191,201,213,237 178,191,201,213,237
249,250,262,274 249,250,262,274

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

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

01.09 - ES0
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Description Piston, Connecting Rod and Cylinder Liner 506.01


Page 1 (2) Edition 03H

L27/38

Piston

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


type, has a body made of nodular cast iron and a
crown made of forged deformation resistant steel. It
is fitted with 3 compressi on rings and 1 oil scraper
ring in hardened ring grooves.

Fig. 2 Connecting rod

The piston pin is fully floating and kept in position in


the axial direction by two circlips.

Fig. 1 Piston
Connecting Rod

The connecting rod is of the marine head type.


By the use of compression rings with different barrel-
shaped profiles and chrome-plated running sur- The joint is above the connecting rod bearing. This
faces, the piston ring pack is optimized for maximum means that it is not nessesary to open the big-end
sealing effect and minimum wear rate. bearing when pulling the piston. This is of advantage
for the operational safety (no positional changes/no
The piston has a cooling oil space close to the piston new adaption), and this solution also reduces the
crown and the piston ring zone. The heat transfer, height dimension required for piston assembly /
and thus the cooling effect, is based on the shaker removal.
08028-0D/H5250/94.08.12

effect arising during the piston movement. The cool-


ing medium is oil from the engine's lubricating oil Connecting rod and bearing body consist of CrMo
system. steel. They are die-forged products.

Oil is supplied to the cooling oil space through The bearing shells are identical to those of the
channels from the oil grooves in the piston pin crankshaft bearing. Thin-walled bearing shells hav-
bosses. Oil is drained from the cooling oil space ing an AISn running layer are used.
through ducts situated diametrically to the inlet chan-
nels. The bearing caps and bearing blocks are bolted
together by waisted bolts.

98.27 - ES0
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506.01 Piston, Connecting Rod and Cylinder Liner Description


Edition 03H Page 2 (2)

L27/38

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 temperature 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.
Fig. 3 Cylinder liner

08028-0D/H5250/94.08.12

98.27 - ES0
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Working Card Separation/Assembly of Piston and 506-01.05


Page 1 (3)
Connecting Rod and Fitting of Piston Rings Edition 06H

L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 52000 177
Shut-off fuel oil 52000 190
Stopped lub. oil circul.
Press Blocking - Reset

Description Hand tools

Separation of piston and connecting rod for in- Wooden wedge, 2 pieces.
spection or/and overhaul. Wooden support.
Assembly of piston and connecting rod after Wire.
inspection or/and overhaul.

Starting position

Disassembly of cylinder unit 505-01.01

Related procedure

Inspection or/and overhaul of piston 506-01.10


Inspection or/and overhaul of
connecting rod 506-01.15
Inspection of connection rod big-end
bearing 506-01.16
Assembly of cylinder unit 505-01.50

Manpower Replacement and wearing parts


08028-0D/H5250/94.08.12

Working time : 1 hour Plate no Item no Qty/Cyl.


Capacity : 1 man
50601 093 3
50601 127 1
Data

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

06.29 - ES0
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506-01.05 Separation/Assembly of Piston and Working Card


Page 2 (3)
Edition 06H Connecting Rod and Fitting of Piston Rings

L27/38
Separation of Piston and Connecting Rod
The piston rings should only be tted to the piston
1) Take out the securing ring (Seeger circlips) with by the use of a special tool; the so-called piston ring
the plier (Plate 52000, Item 177). Push out the opener.
piston pin and lift the connecting rod away.
If the rings are opened further than necessary, there
is a risk of overstressing which means that the rings
Assembly of Piston and Connecting Rod will become permanently distorted and will not t to
the cylinder liner's inner running surface.
2) Lubricate the piston pin before assembling.
The piston rings should be installed with the identi-
3) For assembly of piston and connecting rod, cation mark which is stamped into the ring close to
see point 1, but in the opposite direction. the ring joints, facing upwards, see g 2.
Fittings of Piston Rings
Before tting the coil spring loaded scraper ring, the
coil spring is dismantled from the ring by removal of
the joint pin. The coil spring is placed and assembled
in the ring groove. The scraper ring then is tted in
the groove in such a way that the ring joint is ap-
Joint pin for proximately 180 offset to the spring joint.
coil spring Joint coil spring to be
placed opposite to ring joint
Ascertain correct assembling by checking the back
clearance. The back clearance is sufcient when the
face of the ring is below the groove edge when the
ring is pressed against the bottom of the groove.

When installed on the piston, the rings should be


Ring joint
pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring
Fig 1 Joint coil spring to be placed opposite to ring joint and groove.

Adequate clearance is present if the feeler gauge


can be moved all the way around.

To prevent gas leakage through coinciding ring joints,


the piston rings should be turned into positions off-
setting the ring joint 180 to each other.
08028-0D/H5250/94.08.12

06.29 - ES0
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Working Card Separation/Assembly of Piston and 506-01.05


Page 3 (3)
Connecting Rod and Fitting of Piston Rings Edition 06H

L27/38

Piston Ring
no 1, 2 and 3:
Marked with ident.
no "1606 GOE TOP".

Scraper Ring:
Marked with ident.
no "0297".

Marking of Piston and Scraper Rings


08028-0D/H5250/94.08.12

Marking

Identication marks to face upwards against the piston crown when mounted.

Note! The marking may include other gures than mentioned above, for instance trade mark and
production codes.

Fig 2 Marking of piston and scraper ring

06.29 - ES0
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Working Card
Page 1 (4) Piston 506-01.10
Edition 04E

L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 52000 153
Shut-off fuel oil 52000 165
Stopped lub. oil circul. 52000 190
Press Blocking - Reset

Description Hand tools

Cleaning and inspection of piston. Replacement Tools for cleaning of piston, steel brush,
of piston ring, scraper ring and control of ring scraper etc.
grooves. Torque spanner.

Starting position

Piston has been dismantled from


connecting rod 506-01.05

Related procedure

Mounting of piston and


connecting rod 506-01.20

Manpower Replacement and wearing parts


08028-0D/H5250/94.08.12

Working time : 1 hour Plate no Item no Qty/


Capacity : 1 man

Data

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

06.25 - ES0
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506-01.10 Piston
Working Card
Page 2 (4)
Edition 04E

L27/38
Inspection of Piston Mounting of Piston Crown
(MAHLE and KOLBENSCHMIDT Piston type MAHLE
or SAM YOUNG)
Note: Always use new bolts when assembling the
1) Remove the piston and scraper rings. piston.

2) Clean the piston on the outside and on the 8) Lubricate the threads and bearing surface with
inside. molycote-paste G-n Plus.

3) Inspect the piston ring and scraper ring grooves 9) Tighten the piston bolts with a torque of 50 Nm
for wear, see page 3. in the piston head.

10) Tighten the nuts crosswise with 60 Nm.


Check of Piston Bolt Tension
Piston type MAHLE 11) Loosen the nuts again.

4) Apply a torque spanner to the piston bolts, 12) The tightening of the piston bolts with a torque
adjusted to 50 Nm. of 50 Nm in the piston head must be control-
led.
5) Turn the torque spanner.
13) Pretighten the nuts crosswise with joint moment
Note: It may turn out that the bolts do not turn dur- of 20 Nm.
ing the test:
14) Turn the nuts further 120 degrees.

If Then Check the piston bolt tension, see check of pis-


ton bolt tension.
the bolts do not the tension is ok
turn during the test
Check of Piston Bolt Tension
the bolts can loosen the bolts and Piston type KOLBENSCHMIDT
turn during the test tighten as described or SAM YOUNG
in the process of
"Mounting of piston 4) Apply a torque spanner to the piston bolts,
crown" adjusted to 54 Nm.

5) Turn the torque spanner.


Inspection of Piston Crown
Piston type MAHLE Note: It may turn out that the bolts do not turn during
08028-0D/H5250/94.08.12

the test:
For cleaning and inspection of the piston crown, it
must be disassembled.
If Then
6) Loosen the bolts and remove the piston
crown. the bolts do not the tension is ok
turn during the test
7) Carefully clean the piston skirt, piston crown
and piston bolts. the bolts can loosen the bolts and
turn during the test tighten as described
in the process of
Mounting of piston
crown

06.25 - ES0
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Working Card
Page 3 (4) Piston 506-01.10
Edition 04E

L27/38
Inspection of Piston Crown
Piston type KOLBENSCHMIDT or SAM YOUNG

For cleaning and inspection of the piston crown, it


must be disassembled.

6) Loosen the bolts and remove the piston


crown.

7) Carefully clean the piston skirt, piston crown


and piston bolts.

Mounting of Piston Crown


Piston type KOLBENSCHMIDT or SAM YOUNG

Note: Always use new bolts when assembling the


piston.

8) Lubricate the threads and bearing surface with


molycote-paste G-n Plus.

9) Tighten the piston bolts with a torque of 40 Nm


in the piston head.

10) Tighten the nuts crosswise with 67 Nm.

11) Loosen the nuts again.

12) The tightening of the piston bolts with a torque


of 40 Nm in the piston head must be control-
led.

13) Pretighten the nuts crosswise with joint moment


of 20 Nm.

14) Turn the nuts further 90 degrees.

Check the piston bolt tension, see check of pis-


08028-0D/H5250/94.08.12

ton bolt tension.

06.25 - ES0
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506-01.10 Piston
Working Card
Page 4 (4)
Edition 04E

L27/38
The piston crown must be scrapped if: Note: At each piston overhaul:

- The piston and the scraper ring must be


A) The wear limit on the testing mandrel is ex- replaced.
ceeded, see g. 1A
- The cylinder liner must be honed accor-
ding to the instructions.
or
- For position and ttings of piston rings,
B) The clearance between the new piston/scraper please see working card 506-01.05
ring and the ring groove is exceeded, see g.
1B.

Piston type Piston and oil New ring Piston type Piston and oil New ring
Ring grooves. "KOLBEN- Ring grooves.
scraper ring. grooves. scraper ring. grooves.
Max. wear limit. SCHMIDT" Max. wear limit.
"MAHLE" Nominal size. Tolerances. Nominal size. Tolerances.
(mm) or "SAM (mm)
(mm) (mm) (mm) (mm)
YOUNG"
Piston ring +0.20 Piston ring
6 6 6.42 6 6.17 +0.03 6.42
1 +0.17 1

Piston ring +0.14 Piston ring


6 6 6.42 6 6.12 +0.03 6.42
2 +0.12 2

Piston ring +0.14 Piston ring


6 6 6.42 6 6.12 +0.03 6.42
3 +0.12 3

+0.06
Scraper ring 8 8 8.42 Scraper ring 8 8.04 0.03 8.42
+0.04

Table 1 Nominal size, new ring groove tolerance and wear limit for ring grooves

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

If the wear limit on the testing mandrel is ex-


ceeded, the specied max. wear limits are ex-
ceeded, and the piston must be scrapped.

0.45 mm
08028-0D/H5250/94.08.12

Wear limit line.

Maximum vertical clearance


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

The handle is marked


with the nominal size.

Fig 1 Wear limits for ring grooves

06.25 - ES0
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Working Card
Removal / Mounting of Marine Head from Engine 506-01.24
Page 1 (5) Edition 01E

L21/31
L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 52000 060
Shut-off fuel oil 52000 069
Stopped lub. oil circul.
Press Blocking - Reset and hydraulic tools according
to working card 520-01.06

Description

Removal of marine head from engine.

Starting position Hand tools

Engine out of operation.

Related procedure

Manpower Replacement and wearing parts

Working time : hour Plate no Item no Qty/


Capacity : 2 men
08028-0D/H5250/94.08.12

Data

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.27 - ES0
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506-01.24 Removal / Mounting of Marine Head from Engine


Working Card
Edition 01E Page 2 (5)

L21/31
L27/38
Condition : Piston and connecting rod has been
removed and the fixation tool is installed, see fig. 1.

Fig. 1 Fixation of connecting rod bearing

1) Turn the crank through to about TDC.

2) Install the brackets in the lower end of the


crankcase opening, see fig. 2.
08028-0D/H5250/94.08.12

Fig. 2 Bracket installed

03.27 - ES0
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Working Card
Removal / Mounting of Marine Head from Engine 506-01.24
Page 3 (5) Edition 01E

L21/31
L27/38
3) Place the guide beam on the brackets and
secure it by means of the screws, see fig. 3.

Fig. 3 Placing of guide beam


08028-0D/H5250/94.08.12

03.27 - ES0
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506-01.24 Removal / Mounting of Marine Head from Engine


Working Card
Edition 01E Page 4 (5)

L21/31
L27/38
4) Turn the crankshaft to the position shown in fig.
4 and remove the nuts by means of the hydraulic
tool.

Fig. 4 Removal of nuts


08028-0D/H5250/94.08.12

03.27 - ES0
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Working Card
Removal / Mounting of Marine Head from Engine 506-01.24
Page 5 (5) Edition 01E

L21/31
L27/38
5) Install the slide piece as shown in fig. 5 and 8) Remove the bearing shells from each marine
remove the bracket. head half.

6) Turn the crankshaft to make the marine head


rest against the beam, see fig. 5. Mounting of Marine Head

7) Pull out the two halves of the marine head. Mounting is carried out in reverse order of the above.

Note : Check that the marks "AS" are placed at the


same side on both the piston rod and the marine
head against the exhaust side.
08028-0D/H5250/94.08.12

Fig. 5 Marine head with slide piece

03.27 - ES0
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Working Card Dismantling of Piston and Cylinder Liner 506-01.50


Page 1 (4)
at Low Overhaul Height Edition 06H

L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 52000 060
Shut-off fuel oil 52000 082
Stopped lub. oil circul. 52000 104
Press Blocking - Reset
and hydraulic tools according
to working card 520-01.06
Description

Dismounting of cylinder unit for inspection and/or


overhaul.

Starting position Hand tools

Engine stopped and cooled down.

Related procedure

Inlet and exhaust valve - overhaul and


regrinding of spindel and valve seat 505-01.10
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35
Inspection of piston 506-01.10
Cylinder liner 506-01.35
Separation of piston and
connecting rod 506-01.06
Fuel injection valve 514-01.10
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06
08028-0D/H5250/94.08.12

Manpower Replacement and wearing parts

Working time : 2 1/2 hours Plate no Item no Qty/


Capacity : 2 men

Data

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

07.35 - ES0
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506-01.50 Dismantling of Piston and Cylinder Liner Working Card


Edition 06H Page 2 (4)
at Low Overhaul Heights

L27/38
Preparing before Dismantling 10) Push the charge air connections inside the
cylinder head which are to be removed.
1) Drain off the water from the engine.
11) Remove the cylinder head nuts by means of the
2) Take off the top cover. hydraulic jacks, see working card 520-01.05.

3) Take off the side covers on both sides of the 12) Remove the bolts, which hold the cylinder head
engine. and water jacket together, see g 2.

4) Remove the exhaust gas cover. Note: This means that the cylinder head now
can be removed from the cylinder unit.

Disassembling of Connectings

5) Disconnect the clamp for connecting cylinder


head and exhaust gas receiver. Bolts to be removed

6) Disconnect the fuel oil high pressure pipe.

7) Disconnect the 4 clamps for locking the FW


connection between the cylinder heads.

8) Push the FW connections inside the cylinder


heads, which are to be removed.

9) Disconnect the 2 clamps for locking the charge


air connections by removing the locking bolts
for the clamps, see g 1.
Bolts to be removed

Fig 2 Remove bolts, which hold the cylinder head and water
jacket together

13) Mount the lifting tool on the cylinder head.

14) Lift the cylinder head and land it carefully on


wooden support.
08028-0D/H5250/94.08.12

15) Remove the push rods by hand.

Fig 1 Push the cooling water connection and charge air con-
nections inside the cylinder heads, which are to be removed

07.35 - ES0
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Working Card Dismantling of Piston and Cylinder Liner 506-01.50


Page 3 (4)
at Low Overhaul Height Edition 06H

L27/38
Removal of Piston and Piston Rod, Cylinder 18) Loosen the four bolts for the piston rod by
Liner and Water Jacket means of the hydraulic tools and remove the
nuts.
16) Turn the piston into top dead centre.
19) Mount the tool for lifting the piston, see g 4.
17) Mount the turning bracket to the marine head
and counterweight, see g 3.

Fig 4 Lifting tool for piston

20) Carefully lift the piston and piston rod out of the
cylinder liner and land it on wooden support.

Fig 3 Turning bracket mounted to the marine head and


counterweight
08028-0D/H5250/94.08.12

07.35 - ES0
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506-01.50 Dismantling of Piston and Cylinder Liner Working Card


Edition 06H Page 4 (4)
at Low Overhaul Heights

L27/38

21) Mount the lifting tool for the cylinder liner, see g
5 and lift the cylinder liner out of the engine.
Lifting tool for
22) Mount the eye bolt in water jacket and lift it cylinder liner
off the engine.

Cylinder liner

Lifting tool
08028-0D/H5250/94.08.12

Fig 5 Lifting tool for cylinder liner

07.35 - ES0
Index
Page 1 (1) Camshaft and Camshaft Drive 507

Description

Working Card

Plates

Intermediate Wheel ............................. ...........,. . ......... .. . . .. . .. . .,. . .. . .. ..... .. .. ... .. 50701-03H


Camshaft (Valve Camshaft) ....................................................................................................50705-05H
Camshaft (Injection Camshaft) ................................................................................................ 50705-06H
Index Operating Gear for Inlet Valves,
Page 1 (1) 508
Exhaust Valves and Fuel Injection Pumps

Description

Working Card

Inspection of Valve Camshaft Lower and Upper Rocker Arms ........... .............................. 508-01.OO (04H)
Control and Adjusting of Valve Clearance ............................................................................. 508-01.10 (06H)

Plates

Roller Guide and Push Rods ............................................................................................................50801-05H


MAN
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Index Control and Safety Systems


Page 1 (1) 509
Automatics and Instruments

L27/38

Description

Safety, Control and Monitoring System 509.01 (11)


Lambda Controller 509.10 (06H)
Communication from the GenSet 509.55 (08)

Working Card

Functional Test and Adjustment of Safety. Alarm and Monitoring Equipment 509-01.00 (03H)
Function Test of Shutdown 509-01.05 (05H)
Adjustment and Test of Analogous Pressure Transmitter 509.05.03 (03H)
Adjustment and Test of Analogous Temperature Transmitter 509.05.04 (03H)
Adjustment of Lambda Controller 509-10.00 (10H)

Plates

*) Governor and Governor Drive ( Europa made ) 50901-06H


*) Governor and Governor Drive ( Woodward made ) 50901-07H
Regulating Device 50902-05E
Instruments 50907-04E
Level Switch in Oil Sump (LAL/LAH 28) 50920-03H
Fuel Oil Leakage Alarm (LAH 42) 50925 - 07
Monitoring Box 50935-05H
Terminal Box 50936-02H

Instruction Manual for the Governor

*) Depending on Project Specification


MAN
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Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-07

L21/31, L27/38
V28/32S

A-A 058
022 010
034
416
046
404

C C

333 178
345 333
286 357
C-C

382 369
08028-0D/H5250/94.08.12

394 370

06.47 - ES0
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Plate
50925-07 Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)

L21/31, L27/38
V28/32S
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

010 1/E Fuel oil leakage Br.olielkagealarm


alarm

022 1/E Flange Flange

034 1/E Gasket Pakning

046 1/E Level switch Niveaukontakt

058 1/E Hose connection Slangeforbindelse

178 1/E Repair kit for Reparationsst for


running in lter indkrselslter

286 4/E Screw Skrue

333 2/E O-ring O-ring

345 1/E Packing ring Pakningsring

357 1/E Plug screw Propskrue

369 1/E Packing ring Pakningsring

370 1/E Plug screw Propskrue

382 1/E Packing ring Pakningsring

394 1/E Plug screw Propskrue

404 1/E Plug screw Propskrue

416 /I Glue Lim

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty/Engine Qty/E = Qty/Motor

06.47 - ES0
Index
Page 1 ( 11 Crankshaft and Main Bearings 510

Description

Working Card

Checking of Main Bearings Alignment (Autolog) .................................................................. 510-01.OO (09H)


Inspection of Main and Guide Bearing Shells ...................................................................... 510-01.05 (06H)
*) Vibration Damper (Vulkan made) ........................................................................................
510-04.00 (04H)
*) Vibration Damper (Geislinger made)...............................................................................510-04.00 (06H)
Plates
Plates

Chankshaft .......................................................................................................................................... 51001-06H


Flywheel with Gear Rim ................................................................................................................... ,51003-06H
*) Vibration Damper with Attachment (Vulkan made) ..................................................................5100405H
*) Vibration Damper with Attachment (Geislinger made)......................................................,51004-07H

*) Depending on Project Specification


Index
Page 1 (1 )
Engine Frame and Base Frame 511

Description

Working Card

Plates
MAN
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Plate
Page 1 (2) Front-end Box 51103-08H

L27/38

Centrifugal by-pass filter, 445


see plate 51515
087+ 218 935
099 217+ 445
242+ 577 516
541 433 528
959 099 494
636 469 504
960 553 457
673
661
648 482
972 984 470
229 719 301
624 075 996 697
528 195 038 947
063 196
099

026 408
08028-0D/H5250/94.08.12

06.16 - ES0
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Plate
51103-08H Front-end Box Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

026 1/E Cover Dksel 624 4/E Screw Skrue

038 4/E Screw Skrue 636 1/E Thrust piece Trykstykke

063 4/E Nut Mtrik 648 1/E Covering plate Dkselplade

075 2/E Washer Skive 661 1/E Screw Skrue

087+ 4/E Screw Skrue 673 1/E Nut Mtrik

099 8/E Spring washer Fjederskive 697 1/E O-ring O-ring

195 4/E Stud Tap 719 1/E Spring Fjeder

196 /I Loctite 638 Loctite 638 935 1/E Intermediate piece Mellemstykke

217+ 1/E Flange Flange 947 1/E Intermediate piece Mellemstykke

218 /I Packing silicone Packing silicone 959 1/E O-ring O-ring


paste paste
960 1/E Cover Dksel
229 1/E O-ring O-ring
972 1/E Casing Hus
242+ 4/E Nut Mtrik
984 1/E Piston Stempel
301 1/E O-ring O-ring
996 1/E Retaining ring Sikringsring
408 1/E O-ring O-ring
+ To be used if cen- + Anvendes hvis ikke
433 10/E Screw Skrue trifugal by-pass lter centrifugal by-pass
is not mounted filter er monteret
445 2/E O-ring O-ring

457 1/E Bracket for by-pass Konsol for centrifugal


centrifugal lter by-pass filter

469 4/E Screw Skrue

470 1/E Plug screw Propskrue

482 1/E Packing ring Pakningsring

494 1/E Cover Dksel

504 1/E O-ring O-ring

516 4/E Screw Skrue

528 8/E Spring washer Fjederskive


08028-0D/H5250/94.08.12

541 1/E Spring Fjeder

553 1/E Piston Stempel

577 1/E O-ring O-ring

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty/Engine Qty/E = Qty/Motor

06.16 - ES0
MAN
B&W

Plate
Page 1 (2) Cover on Frame 51106-08E

L27/38
08028-0D/H5250/94.08.12

99.18 - ES0
MAN
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Plate
51106-08E Cover on Frame Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

010 1/E Cover Dksel

022 18/E Screw Skrue

083 1/E Cover Dksel

095 1/E O-ring O-ring

105 8/E Screw Skrue

117 8/E Lock washer Lseskive

129 1/E Sealing ring Ttningsring

130 1/E Cover Dksel

142 4/E Screw Skrue

548 4/E Lock disc Lseskive

561 1/E O-ring O-ring

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty/Engine Qty/E = Qty/Motor

99.18 - ES0
MAN
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Plate
Page 1 (2) Covers on Frame 51106-10E

L27/38
08028-0D/H5250/94.08.12

00.37 - ES0
MAN
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Plate
51106-10E Covers on Frame Page 2 (2)

L27/38
Item Item
No Qty Designation Benvnelse No Qty Designation Benvnelse

154 Cover Dksel


1/E 5 cyl. engine 5 cyl. motor
2/E 6 cyl. engine 6 cyl. motor
1/E 7 cyl. engine 7 cyl. motor
2/E 8 cyl. engine 8 cyl. motor
3/E 9 cyl. engine 9 cyl. motor

166 1/C O-ring O-ring

201 1/C Cover Dksel

237 1/C O-ring O-ring

249 Screw Skrue


75/E 5 cyl. engine 5 cyl. motor
88/E 6 cyl. engine 6 cyl. motor
101/E 7 cyl. engine 7 cyl. motor
114/E 8 cyl. engine 8 cyl. motor
127/E 9 cyl. engine 9 cyl. motor

250 Washer Skive


75/E 5 cyl. engine 5 cyl. motor
88/E 6 cyl. engine 6 cyl. motor
101/E 7 cyl. engine 7 cyl. motor
114/E 8 cyl. engine 8 cyl. motor
127/E 9 cyl. engine 9 cyl. motor

274 1/E O-ring O-ring

286 1/E Cover Dksel

298 1/E O-ring O-ring

308 1/E Cover Dksel

404 1/C Cover Dksel

597 Cover Dksel


2/E 5 cyl. engine 5 cyl. motor
2/E 6 cyl. engine 6 cyl. motor
3/E 7 cyl. engine 7 cyl. motor
3/E 8 cyl. engine 8 cyl. motor
3/E 9 cyl. engine 9 cyl. motor

607 Cover Dksel


2/E 5 cyl. engine 5 cyl. motor
2/E 6 cyl. engine 6 cyl. motor
3/E 7 cyl. engine 7 cyl. motor
3/E 8 cyl. engine 8 cyl. motor
3/E 9 cyl. engine 9 cyl. motor
08028-0D/H5250/94.08.12

619 1/E O-ring O-ring

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

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

00.37 - ES0
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Plate
Page 1 (2) Lubricating Oil Pipes TC 51231-01E1

L27/38

106E
08028-0D/H5250/94.08.12

00.37 - ES0
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Plate
51231-01E1 Lubricating Oil Pipes TC Page 2 (2)

L27/38
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse

010 1/E Steel pipe Stlrr

022 1/E O-ring O-ring

034 4/E Screw Skrue

046 1/E Steel pipe Stlrr

058 4/E Pipe clamp Rrholder

071 8/E Screw Skrue

083 1/E Steel pipe Stlrr

106E 1/E EUnion coupling Vinkelforskruning

129 1/E Steel pipe Stlrr

130 2/E Straight male stud Ligeforskruning


coupling

142 1/E Plug Prop

154 1/E Flange Flange

166 1/E Plug screw Propskrue

178 1/E Packing ring Pakningsring

08028-0D/H5250/94.08.12

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

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty./E = Qty./Engine Qty./E = Qty./Motor

00.37 - ES0
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Description 513.01
Page 1 (2) Compressed Air System Edition 14H

L27/38

Fig. 1 Diagram for Compressed Air System

General Starting System

The compressed air system on the engine consists The engine is started by means of a built-on air
of a starting system, starting control system and starter, which is a turbine motor with gear box, safety
safety system. Further, the system supplies air to the clutch and drive shaft with pinion. Further, there is a
jet system and the stop cylinders on each fuel main starting valve.
injection pump. On 8 and 9 cylinders engines air is
supplied to the oil mist detector through a reduction
valve. Control System

The compressed air is supplied from the starting air The air starter is activated electrically with a pneu-
receivers (30 bar) through a reduction station, where matic 3/2-way solenoid valve. The valve can be
08028-0D/H5250/94.08.12

from compressed air at 10 bar is supplied to the activated manually from the starting box on the
engine. The reduction station should be located as engine, and it can be arranged for remote control,
near the starting air receiver as possible. manual or automatic.

Working pressure for the air starter: For remote activation the starting coil is connected
min. 8 bar so that every starting signal to the starting coil goes
max. 10 bar through the safe start function which is connected to
the safety system mounted on the engine.
To avoid dirt particles in the internal system, a dirt
strainer equipped with a drain valve is mounted in the
inlet line to the engine.

03.34 - ES0
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513.01 Compressed Air System Description


Page 2 (2)
Edition 14H

L27/38
Further, the starting valve also acts as an emer- Pneumatic Start Sequence
gency starting valve which makes it possible to
activate the air starter manually in case of power When the starting valve is opened, air will be sup-
failure. plied to the drive shaft housing of the air starter.

The air supply will - by activating a piston - bring the


Safety System drive pinion into engagement with the gear rim on the
engine flywheel.
As standard the engine is equipped with an
emergency stop. It consists of one on-off valve, see When the pinion is fully engaged, the pilot air will flow
diagram, which activates the stop cylinder on each to, and open the main starting valve, whereby air will
fuel injection pump. be led to the air starter, which will start to turn the
engine.
Air supply must not be interrupted when the engine
is running. When the RPM exceeds approx. 158, at which firing
has taken place, the starting valve is closed whereby
the air starter is disengaged.

08028-0D/H5250/94.08.12

03.34 - ES0
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Working Card
Manual Turning Gear 513-25.00
Page 1 (3)
Edition 02E

L27/38

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Press (Blocking - Reset)

Description Hand tools

Manual turning of engine. Standard spanner with a long shaft

Starting position

Indicator valve in cylinder head


has to be open Plate 50501

Related procedure

Manpower Replacement and wearing parts

Working time : 1/4 hour Plate no Item no Qty. /


08028-0D/H5250/94.08.12

Capacity : 1 man

Data

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

03.13 - E0O
MAN
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513-25.00 Manual Turning Gear Working Card


Edition 02E Page 2 (3)

L27/38
Warning: The diesel engine can be started locally on The turning gear will automatically try to find
the emergency start arrangement eventhough the this position once the nut (X) is loosened. It
turning gear is engaged. might need a light turning of the nut (Y) in order
to reach the position 2 - blocking.
Note: Inform all staff working on the engine that the
turning gear is engaged.

Adjustment of the turning gear

1) Engine running position.


This is the stand-by position of the turning gear
when the engine is running.

Fig 3 Position 3 Engine turning position

3) Engine turning position.


The turning gear is made ready for turning by
loosening the 60 mm nut (X) until the nut is
approx. 23 mm from the end of the shaft.
The turning gear is pushed into engagement
with the gear rim on the flywheel and out of
blocking mode. The engine can now be turned
Fig 1 Position 1 Engine running position
by means of the 30 mm nut (Y).

Note: The turning gear must be fully engaged


2) Engine blocking position. during the entire turning of engine.
This is the blocking position of the engine when
the turning gear is engaged. When the new position of the engine is found the
turning gear will automatically try to return to the
blocking position.
When turning the engine is completed the turn-
ing gear is dis-engaged by pulling back the
turning gear carefully by hand. Finally, the 60
mm nut (X) is tightened.
08028-0D/H5250/94.08.12

Trouble tracing

Turning gear shaft can not be moved easily:


- Dismantle the shaft and clean for rust.
New lubrication to avoid rust.

Engine is not starting:


- Check the microswitch ZS 75 mounted on the
Fig 2 Position 2 Engine blocking position turning gear.

03.13 - E0O
MAN
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Working Card
Manual Turning Gear 513-25.00
Page 3 (3) Edition 02E

L27/38
TOOL TURNING GEAR-DISENGAGE

1) Open spanner : 17, 30, 60mm 1) Loosen the lock nut(17mm) and the guide bolt
(with pipe or hammer) with pushing the turning gear shaft to flywheel
2) Ratchet 3/4", Socket3/4"x30mm, Grease gun side.
* The turning gear shaft will be moved to diseng-
age position smoothly itself.
TURNING GEAR-ENGAGE * If the turning gear is not disengaed, turn the
turning gear shaft up and down, and then try
1) Open all indicator cocks on cylinder heads. again to disengage.
2) Greas before turning. * If the turning gear is not still disengaged, the
3) Loosen the lock nut(17mm) and the guide bolt. turning gear should be inspected.
4) Loosen the cap nut(60mm). 2) Pull out the turning gear shaft by means of tigh-
* The turning gear shaft will be moved to engage tening the cap nut(60mm).
position smoothly itself. * Do not tighten the cap nut by too much force.
5) Push fully the turning gear shaft to flywheel side. 3) Tighten the cap nut(60mm) completely after
6) Tighten the guide bolt and the lock nut(17mm) pulling out fully the turning gear shaft.
when turning gear is fully engaged. 4) Tighten the guide bolt and the lock nut(17mm)
* If the turning gear is not engaged, turn the completely.
turning gear shaft up and down after turning 5) Close all indicator cocks on cylinder heads.
gear is disengaged, and then try again to engage.
* If the turning gear is not still engaged, the turning
gear should be inspected.
7) Turn the turning gear slowly by means of ratchet
3/4" and socket 3/4".
* If the turning gear is not turned snioothly, the
turning gear should be stopped immediately
and check the turning gear or engine inside.
MAN
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Plate
Page 1 (2) Main Starting Valve 51310-04
L21/31
L27/38
V28/32S

153

165
141

128 177
189
116

190*
200*
212

224*
236

319
320 307
332

248*
08028-0D/H5250/94.08.12

261*
273
285*
297

04.04 - ES0
MAN
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Plate
51310-04 Main Starting Valve Page 2 (2)

L21/31
L27/38
V28/32S
Item Item
No Qty Designation Benvnelse No Qty Designation Benvnelse

116 1/V Housing Hus

128 1/V Delay timer Timer

141 Connectors Konnektor

153 1/V Screw Skrue

165 1/V Washer Skive

177 1/V Retainer Sikringsring

189 1/V Screen Skrm

190* 1/V O-ring O-ring

200* 1/V O-ring O-ring

212 1/V Piston Stempel

224* 1/V Dampener, shock Dmper

236 1/V O-ring, cap O-ring

248* 1/V Spring Fjeder

261* 1/V O-ring O-ring

273 1/V End cap Endedksel

285* 1/V O-ring O-ring

297 1/V Retainer Sikringsring

307 1/V O-ring O-ring

319 1/V Part of item 320 Del af item 320

320 1/V Solenoid valve Magnetventil

332 2/V Screw Skrue

344 1/S Main starting valve, Hovedstartventil,


complete komplet

356 1/V Spare parts kit, Reserevedelsst,


comprising item bestende af item
190, 200, 224, 248, 190, 200, 224, 248,
261, 285 261, 285
08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty./Engine Qty./E = Qty/Motor
Qty./S = Qty./Starter Qty./S = Qty./Starter
Qty./V = Qty./Valve Qty./V = Qty./Ventil

04.04 - ES0
Index
Page 1 (1) Fuel Oil System 514

Description

Working Card

Dismounting / Mounting of Fuel Injection Pump ..................................................................... 514-01.05 (08H)


Disassembly / Assembly and Repair of Fuel Injection Pump ............................................. 514-01.06 (07H)
Fuel Injection Valve ....................................................................................................................514-01.10 (06H)
Check of Fuel Oil Piping System ............................................................................................514-01.90 (03H)

Plates

Fuel Injection Pump ............................................................................................................................


514-01 -05H
Fuel Injection Valve ............................................................................................................................
51402-06H
Fuel Injection Pipe ..............................................................................................................................
51404-08H
*) Safety. Filter ...............................................................................................................................
5 1415-02H
Fuel Oil Arrangement .........................................................................................................................
51430-04E
Fuel Injection Pump Connections ..................................................................................................... 51435-02H

*) Depending on Project Specification


MAN
B&W

Working Card
Prelubricating Pump 515-01.05E
Page 1 (3) Edition 02E

General

safety precautions : Special tools :

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water Wheel puller for bearing bush.
Shut-off fuel oil Compressed pin.
Shut-off cooling oil Protection cover for shaft seal.
Stopped lub. Oil circul Compressed pin for shaft seal.
(The special tools must be ordered separately
from Hyundai Heavy Industries Co.,Ltd)
Description :

Dismounting, replacement of the rotary shaft Hand tools :


seal and assembly of prelubricating pump.
Bench vice.
Spanner.
Starting position : Torque spaner.
Plier for lock ring.
Soft hammer.

Related procedure :

Man power : Replacement and wearing parts :

Working time : 2 - 3 Hours Plate no. Item no. Q'ty./


Capacity : 1 man

Data :

Data for pressure and tolerance


Data for torque moment
Declaration of weight
MAN
B&W

515-01.05E Prelubricating Pump Working Card


Edition 02E Page 2 (3)

General
Overhauls We advise not to change the bearing bushes. In
connection with damages on the bearing it is normal
Overhauls for the purpose of avoiding functional that also the shafts and the parts in the gear box will
trouble are not normally necessary for the prelubri- be damaged.
cating pumps, when properly used, there is very
little wear on the pump gear shaft. When ordering spare parts, do not forget to state the
factory no. of the pump.

Spare Parts Replacement of mechanical seal

Before any overhaul is done, please note the following 1) Disconnect the cable and pipe connection to
the pump.
If a pump gets unusable by wear,it must be replaced 2) Remove the pump from the engine base frame.
installation of spare parts cannot bring it back to 3) Separate the pump and the el-motor.
normal condition 4) Remove the coupling part and key (20), see
fig. 1 , from the driving gear shaft (3).
It pays to keep extra pumps in stock or to have 5) Tighten the pump to the flange.
repairs (overhauls) carried out at our repair shop. Valve housing (6) upwards.
6) Hex's head bolt (13) and take off the valve
the shaft seal needs only to be replaced in case of housing (6).
leakage or after dismounting of drive shaft. The
marks from the seal do not necessarlly mean that the
sealing is defective. But there is a risk of leakage
after replacement of sealing.
MAN
B&W

Working Card
Prelubricating Pump 515-01.05E
Page 3 (3) Edition 02E

General

7) Take off the gear housing (5), if necessary use a Mounting


soft hammer for separation.
13) The mounting process follows in reverse order.
8) Remove the gear wheels from the driving cover (1), It is stressed that an exact cleaning works is
Dismounting is only possible by disturbing the rotor necessary.
shaft seal and by breaking the bearing bush.
Especially the sealing faces must be clean.
9) Remove the snap ring (19) and take off the
oil seal (18). In connection with the bearing bush. Attention
must be pald to the placement of the but joint
10) Press out the driving gear shaft bearing bush, and the mounting depth.
pull out the running bearing bush with the inner
wheel puller. The new shaft seal cannot be pressed into the
protection cover before exact mounting
11) gear housing (5), Dismounting is only possible by of the pump.
damaging the shaft bush, Press out the shaft
bushes. O-ring must be changed.

12) valve housing (6), The valve housing can be


dismounted also without dismounting the pump.
MAN
B&W

Plate
Page 1 (2) Prelubricating Pump with El-Motor 51504-04E

L27/38

Y[

Z_
Z`
YX

Y
X

X] XX
YW XY
Y_ YZ
Y^ Z]
Z\
Z Y` ZW
\ XZ Z[
X` Y\
X_ X^ ]

XW
X\ YY
`
[ _

ZZ
^
X[ Y]
MAN
B&W

51504-04E Prelubricating Pump with El-Motor Plate


Page 2 (2)

L28/32H
Item Item
No. Qty. Designation. No. Qty. Designation.

01 1 DRIVING COVER
02 1 CONNECTION COVER
03 1 DRIVIING GEAR SHAFT
04 1 GEAR SHAFT
05 1 GEAR HOUSING
06 1 VALVE HOUSING
07 2 PLUG
08 1 PISTON
09 1 COMPRESSION SPRING
10 1 SPRING HOUSING
11 1 STOP NUT
12 1 CAP NUT
13 4 HEX'S HEAD BOLT
14 1 O-RING
15 4 BUSH
16 2 PIN
17 4 HEX'S HEAD BOLT
18 1 OIL SEAL
19 1 SNAP RING
20 1 KEY
21 1 JAW COUPLING
22 1 GUIDE PIN
23 3 SOCKET HEAD BOLT
24 1 MOTOR
25 2 WASHER
26 2 WASHER
27 4 HEX'S HEAD BOLT
28 1 O-RING
29 2 RUBBER PLATE
30 2 COVER PLATE
31 1 NAME PLATE
32 4 RIVETS
33 8 HEX'S HEAD BOLT
34 1 SCREW FOR SETTING
35 1 O-RING
36 1 VALVE COVER
37 1 NAMEPLATE
38 1 KEY
39 2 SET SCREW

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se ogsa side 500.50

= Only available as part of a spare parts kit = Kun tilg


Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
MAN
B&W

Plate
Page 1 (2) Crankcase Venting 51531-03H

L27/38

192
202
214
226
238

131

155
179
167

180
143

251
263
275
287
08028-0D/H5250/94.08.12

023

047

06.22 - ES0
MAN
B&W

Plate
51531-03H Crankcase Venting Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

023 4/E Screw Skrue

047 1/E Packing, square Pakning, firkantet

131 1/E Oil vapour discharge nderr


pipe

143 1/E Bracket Beslag

155 1/E Clamps Klemme

167 2/E Nut Mtrik

179 1/E Oil vapour dischage nderr


pipe

180 /I Glue Lim

192 4/E Screw Skrue

202 2/E Packing, square Pakning, firkantet

214 4/E Screw Skrue

226 4/E Nut Mtrik

238 1/E Oil vapour discharge nderr


pipe

251 1/E Hexagon nipple Nippel

263 1/E Ball valve Kugleventil

275 1/E Packing ring Pakningsring

287 1/E Plug screw Propskrue

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

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

06.22 - ES0
MAN
B&W

Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-08H

L27/38
08028-0D/H5250/94.08.12

062 086

06.13- ES0
MAN
B&W

Plate
51535-08H Prelubricating Oil Arrangement Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

050 1/E Ball valve Kugleventil

062 1/E Straight male Ligeforskruning


stud coupling

086 1/E Pipe Rr

098 1/E Adjustable elbow Justerbar vinkel

121 1/E Reducing adapter Reduktionsadapter

133 1/E Non-return valve Kontaventil

170 1/E Pipe Rr

182 1/E Pipe Rr

241 4/E Screw Skrue

253 4/E Sleeve Bsning

265 1/E Straight male Ligeforskruning


stud coupling

277 1/E Adjustable elbow Justerbar vinkel

289 1/E Pipe Rr

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty/Engine Qty/E = Qty/Motor

06.13 - ES0
MAN
B&W

Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps 51610-10H

L27/38
08028-0D/H5250/94.08.12

04.14 - ES0
MAN
B&W

Plate
51610-10H High- and Low Temperature Freshwater Pumps Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

010 1/P O-ring O-ring

022 1/P O-ring O-ring

034 1/P Depp groove ball Radialkugleleje


bearing

046 1/P Ball bearing Kugleleje

071 1/P Retaining ring Sikringsring

083 1/P Shaft seal Pakdse

095 1/P Slide ring joint Roterende pakning

105 2/E Freshwater pump, Ferskvandspumpe,


complete as shown komplet som vist
on front page p forside

117 4/P Screw Skrue

129 1/P Pump housing Pumpehus

130* 1/P Impeller Lbehjul

142 1/P Cover Dksel

154 3/P Screw Skrue

166 3/P Lock washer Lseskive

178* 1/P Shaft Aksel

191* 1/P Screw Skrue

201* 1/P Disc Skive

213 1/P Spur gear Cylindrisk tandhjul

225* 1/P Washer Skive

237* 1/P Screw Skrue

250 1/P O-ring O-ring

453 1/P Kit for upgrading Opgraderingskit


incl. items no 130, inkl. item nr. 130,
178, 191, 201, 225 178, 191, 201, 225
and 237 og 237
08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/E = Qty/Engine Qty/E = Qty/Motor
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

04.14 - ES0
MAN
B&W

Plate
Page 1 (2) Cooling Water Connections 51630-07H

L27/38

224 212 033


021

045
069

021
033
116
128

021 200

212 189

190 212
045
069

045
069
021
08028-0D/H5250/94.08.12

06.43 - ES0
MAN
B&W

Plate
51630-07H Cooling Water Connections Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

021 2/E Flange Flange

033 2/E Seal ring Ttningsring

045 4/E Screw Skrue

069 4/E Locking spring Lsefjederskive


washer

116 1/E Elbow Vinkel

128 6/E Screw Skrue

189 10/E Intermediate piece Mellemstykke

190 10/E Intermediate piece Mellemstykke

200 10/E V-Prole clamp V-profil klemme

212 Seal ring Ttningsring


31/E 5 cyl. engine 5 cyl. motor
37/E 6 cyl. engine 6 cyl. motor
43/E 7 cyl. engine 7 cyl. motor
49/E 8 cyl. engine 8 cyl. motor
55/E 9 cyl. engine 9 cyl. motor

224 1/E Orice plate Mleblnde

236 /I Packing-silicone Pakningssilicone


paste

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

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

06.43 - ES0
MAN
B&W

Plate
Page 1 (2) Conical Element 51903-03E

L27/38
08028-0D/H5250/94.08.12

99.14 - ES0
MAN
B&W

Plate
51903-03E Conical Element Page 2 (2)

L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse

013 1/M Conical element, Konisk understtning,


complete komplet

025 4/M Screw Skrue

049 1/M Protecting cap Beskyttelseskapsel

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/M = Qty/Conical mounting Qty/M = Qty/Conical montering

99.14 - ES0
Index
Page 1 (1)
Tools 520
(Please see " Tool list on final drawing") I

Description

Working Card

Plates
MAN
B&W

Plate
Page 1 (11) Standard Tools for Normal Maintenance 52000-01E

L27/38

Supply per Ship


Name Sketch Plate Item no Remarks
Working Spare

Valve spring 1 52000 014


tightening device

Lifting tool for 1 52000 038


cylinder unit

Grinding tool for 1 52000 087


cylinder head/liner

Max. pressure 1 52000 134E


indicator
08028-0D/H5250/94.08.12

00.51 - ES1
MAN
B&W

Plate
52000-01E Standard Tools for Normal Maintenance Page 2 (11)

L27/38

Supply per Ship


Name Sketch Plate Item no Remarks
Working Spare

Removing device 1 52000 021


for flame ring

Guide bush for 1 52000 045


piston

Fit and removal 1 52000 069


device for conn.
rod bearing, incl.
eye screws (2 pcs)
08028-0D/H5250/94.08.12

00. 51 - ES1
Doc. No : K630-IR08B-4231
Engine No. BA2401/2402
Engine type 7,9L27/38
SHOP TEST RESULT
Hull No. 1893
FOR
Owner C.P. OFFEN
D / G ENGINE
Class GL
Ship yard HYUNDAI HEAVY INDUSTRIES., CO. LTD.

HYUNDAI-MAN Diesel

CONTENTS PAGE NO.

1.Spec. of Engine & Accessory 1


2.Measuring Record(Load test) 2~6
3.Setting Table 7
4.Calculation sheet of F.O 8
5.Parallel running test record 9
6.Governor test record 10
7.Mechanical vibration measurement 11
8.Crankshaft deflection 12
9.Height of resilient support 13

QUALITY MANAGEMENT DEPARTMENT


HHI-EMD

Rev. Prepared Checked Approved Description

1
S.H.KANG M. H. KIM Y. S. LEE First issue
0 2008-06-03 2008-06-04 2008-06-04
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

SPECIFICATION OF ENGINE & ACCESSORIES ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

DESCRIPTION NO. 1 D/G NO. 2 D/G NO. 3 D/G NO. 4 D/G NO. 5 D/G

ENG.NO. BA2402-1 BA2402-2 BA2401-1 BA2401-2 BA2401-3

TYPE 9L27/38 7L27/38


ENGINE
POWER rpm 2970 x 720 rpm 2310 x 720 rpm
FIRING ORDER 1-2-4-6-8-9-7-5-3 1-2-4-6-7-5-3

TYPE HSJ7 805-10P HSJ7 803-10P

OUTPUT & VOLT. 3760 kVA 2820 6600 V 2926.7 kVA 2195 6600 V
GENERATOR CURRENT & 328.9 A 60 256 A 60

POLE & PF 10 P 3 PHA 0.75 PF

SER.NO. 20070193RAH00601 20070193RAH00602 20070193RAH01001 20070193RAH01002 20070193RAH01003

TYPE NR29/S072 NR24/S065

MAX. rpm & TEMP. 31300 rpm 650 37300 rpm 650
TURBOCHARGER
MAKER STX ENPACO-MAN Diesel

SER.NO. SJL0255 SJL0256 SLL0326 SLL0327 SLL0328

TYPE UG-15D
GOVERNOR MAKER WOODWARD

SER.NO. 15533414 15533417 15533405 15533406 15533413


COOLING SURFACE 122 110.4
AIR COOLER MAKER DongHwa Entec

SER.NO. DHI7J880-A DHI7J880-B DHI7J870-A DHI7J870-B DHI7J870-C

COOLING SURFACE 13.62 11.0


LUB.OIL COOLER MAKER KPHE CORPORATION

SER.NO. KPHE-2080816 KPHE-2080817 KPHE-2080873 KPHE-2080874 KPHE-2080875

USED OIL AT SHOP TEST


DESCRIPTION FUEL OIL LUB.OIL
Offocal Shop Test Date 2008.05.19 2008.05.24 2008.05.19
KIND OF OIL BUNKER - A DELO 1000 M 40
SPECIFIC GRAVITY (15/4) 0.8996 0.9060 0.8748
FLASH POINT () 67 75 -
50/cSt 7.29 8.28 -
VISCOSITY
100/cSt - - 13.86
CARBON RESIDUE (wt%) 1.50 1.60 -
ASH (wt%) 0.010 0.01 -
WATER & SEDIMENT (vol%) 0.05 0.05 -
SULFUR (wt%) 0.220 0.25 -
NET.CAL.VALUE (kcal/kg) 10048 10026 -

- 1 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENGINE TYPE 9L27/38 CLASS GL

ENGINE NO. BA2402 -1 TEST DATE 2008.05.19

MEASURING RECORD (NO.1 D/G) ENGINE MCR 2970 EVALUATED BY B.G.Choi

GEN. MCR 2820 OPERATED BY K.D.Oh

Time hh:mm 08:50 ~09:20 09:20~09:50 09:50~10:20 10:20~10:50 10:50~11:20 11:20~11:50


Ambient Press. / Temp. mbar/ 1008 18.5 1008 19.2 1008 20 1008 20.7 1008 21 1008 21.5
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 720 720 720 720 720
Generator Load 695.5 1430.6 2161.3 2887.1 3176.2
Generator Efficiency % 93.67 96.34 97.03 97.21 97.22
Engine Load 742.5 1485.0 2227.5 2970.0 3267.0
Fuel oil consumption /h - - - 580.000 -
specific consumption g/.h - - - 195.286 -
at ISO conditions g/.h - - - 191.622 -
Governor Indicator Position % 3.4 5.0 6.4 7.9 7.9 8.5
Turbocharger Speed rpm 12,470 19,500 24,660 28,860 28,840 30,370
L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG
Generator Winding & BRG' Temp.
- - - - - - - - - - - - - - - - - - - - - - - -
HT-Water Temp. Outlet Engine 72/76 72/77 72/78 75/80 75/80 75/80
HT-Water Press. Inlet Engine bar 2.5 2.5 3.4 3.3 3.3 3.3
LT-Water Temp. Inlet Air Cooler 37 37 35 35 35 35
LT-Water Press. Inlet Air Cooler bar 2.7 2.4 3.0 3.0 3.0 3.0
Lub.Oil Temp. Inlet Engine 63 65 68 67 67 69
Lub.Oil Press. Inlet Filter bar 5.3 5.0 4.9 4.9 4.9 4.9
Lub.Oil Press. Inlet Engine bar 4.8 4.5 4.4 4.4 4.4 4.4
Lub.Oil Press. Inlet Turbocharger bar 1.1 1.3 1.5 1.6 1.6 1.6
Fuel Oil Temp. Inlet Engine 25 24 24 24 24 25
Fuel Oil Press. Inlet Engine bar 8.9 8.5 8.4 7.9 7.9 7.6
Charge Air Temp. Outlet Cooler 37 39 42 44 44 45
Charge Air Press. Outlet cooler bar 0.20 1.00 2.00 2.81 2.81 3.20
Cylinder Case Press. mmWC - - - - - -
Exh.gas Pump Firing BRG'
Temp Index Press Temp
Cyl.No. mm bar mm bar mm bar mm bar mm bar mm bar
Cylinder Unit No.1 262 75
18.0 - 267 25.0 119 - 291 32.5 160 - 327 39.5 194 - 325 39.5 194 - 351 43.0 204 -
No.2 240 75
18.0 - 263 25.0 116 - 293 32.0 159 - 329 39.0 194 - 330 39.0 194 - 356 42.0 204 -
No.3 230 18.0 75 - 255 25.0 117 - 288 32.0 159 - 322 39.0 194 - 323 39.0 194 - 346 42.0 204 -
No.4 254 18.0 75 - 279 25.0 116 - 296 32.0 160 - 337 39.0 193 - 338 39.0 193 - 367 42.0 204 -
No.5 234 18.0 72 - 259 25.0 114 - 288 32.5 160 - 327 39.5 193 - 327 39.5 193 - 353 43.0 203 -
No.6 237 18.0 72 - 263 25.0 114 - 281 32.0 160 - 324 39.0 192 - 324 39.0 192 - 354 42.5 203 -
No.7 220 18.5 71 - 251 25.5 114 - 272 32.5 159 - 306 39.5 194 - 308 39.5 194 - 328 42.5 205 -
No.8 231 18.0 72 - 263 25.0 114 - 287 32.0 159 - 325 39.0 192 - 325 39.0 192 - 355 42.0 203 -
No.9 215 18.0 73 - 243 25.0 114 - 270 32.0 159 - 304 39.0 194 - 303 39.0 194 - 329 42.0 204 -
Guide * * * - * * * - * * * - * * * * * * - * * * -
mean 236 18.1 73 -- 260 25.1 115 -- 285 32.2 159 -- 322 39.2 193 -- 323 39.2 193 -- 349 42.3 204 --
Exhaust Gas Temp. Inlet T/C 390 438 456 499 498 537
Exhaust Gas Temp. Outlet T/C 338 346 314 310 311 333

Safety Device Test 1. Overspeed Stop 813/828 rpm


2. Lub. Oil Low Pressure Stop 3.10 bar
3. H.T-Water High Temperature Stop 93.8
4. Emergency Start OK
5. Oil Mist Detector Stop OK *Overhaul Inspection:
6. Start Inderlock OK - Cyl. 9 M/Brg

-2-
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENGINE TYPE 9L27/38 CLASS GL

ENGINE NO. BA2402 -2 TEST DATE 2008.05.19

MEASURING RECORD (NO.2 D/G) ENGINE MCR 2970 EVALUATED BY B.G.Choi

GEN. MCR 2820 OPERATED BY K.D.Oh

Time hh:mm 08:50 ~09:20 09:20~09:50 09:50~10:20 10:20~10:50 10:50~11:20 11:20~11:50


Ambient Press. / Temp. mbar/ 1008 18.5 1008 19.2 1008 20 1008 20.7 1008 21 1008 21.5
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 720 720 720 720 720
Generator Load 695.5 1430.6 2161.3 2887.1 3176.2
Generator Efficiency % 93.67 96.34 97.03 97.21 97.22
Engine Load 742.5 1485.0 2227.5 2970.0 3267.0
Fuel oil consumption /h - - - 579.000 -
specific consumption g/.h - - - 194.949 -
at ISO conditions g/.h - - - 191.292 -
Governor Indicator Position % 3.5 5.0 6.5 8.1 8.1 8.8
Turbocharger Speed rpm 12,120 19,330 24,620 28,750 28,760 30,370
L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG
Generator Winding & BRG' Temp.
- - - - - - - - - - - - - - - - - - - - - - - -
HT-Water Temp. Outlet Engine 72 / 77 74 / 77 73 / 80 76 / 81 76 / 81 76 / 82
HT-Water Press. Inlet Engine bar 3.1 2.8 3.3 3.2 3.2 3.2
LT-Water Temp. Inlet Air Cooler 37 37 35 35 35 35
LT-Water Press. Inlet Air Cooler bar 2.8 2.6 3.1 3.1 3.1 3.1
Lub.Oil Temp. Inlet Engine 61 67 68 70 70 71
Lub.Oil Press. Inlet Filter bar 5.0 4.9 4.9 4.8 4.8 4.7
Lub.Oil Press. Inlet Engine bar 4.6 4.5 4.4 4.3 4.3 4.2
Lub.Oil Press. Inlet Turbocharger bar 1.1 1.3 1.5 1.7 1.7 1.5
Fuel Oil Temp. Inlet Engine 26 27 25 27 27 27
Fuel Oil Press. Inlet Engine bar 8.4 8.1 7.8 7.3 7.3 6.8
Charge Air Temp. Outlet Cooler 35 38 41 43 43 44
Charge Air Press. Outlet cooler bar 0.20 0.95 2.00 2.80 2.80 3.10
Cylinder Case Press. mmWC - - - - - -
Exh.gas Pump Firing BRG'
Temp Index Press Temp
Cyl.No. mm bar mm bar mm bar mm bar mm bar mm bar
Cylinder Unit No.1 252 76
18.0 - 253 25.0 118 - 282 32.0 159 - 315 39.0 193 - 316 39.0 193 - 339 42.0 204 -
No.2 210 76
18.0 - 237 25.0 118 - 267 32.0 160 - 304 39.0 194 - 305 39.0 194 - 328 42.0 205 -
No.3 229 18.0 76 - 251 25.0 115 - 278 32.0 159 - 317 39.0 193 - 317 39.0 193 - 336 42.5 203 -
No.4 248 18.0 75 - 265 25.0 115 - 287 32.5 160 - 329 39.5 194 - 330 39.5 194 - 357 43.0 204 -
No.5 231 18.5 75 - 259 25.0 115 - 284 32.0 160 - 329 39.0 194 - 329 39.0 194 - 353 42.0 204 -
No.6 269 18.0 76 - 282 25.5 118 - 302 32.5 160 - 341 39.0 194 - 341 39.0 194 - 371 42.5 205 -
No.7 225 18.0 75 - 252 25.0 116 - 277 32.0 161 - 312 39.5 194 - 312 39.5 194 - 338 42.5 205 -
No.8 227 18.5 74 - 256 25.0 116 - 284 32.0 160 - 319 39.0 194 - 319 39.0 194 - 344 42.0 204 -
No.9 246 18.5 75 - 271 25.0 115 - 300 32.0 160 - 336 39.5 194 - 336 39.5 194 - 358 42.0 204 -
Guide * * * * * * * * * * * * * * * * * *
mean 237 18.2 75 -- 258 25.1 116 -- 285 32.1 160 -- 322 39.2 194 -- 323 39.2 194 -- 347 42.3 204 --
Exhaust Gas Temp. Inlet T/C 388 438 498 500 500 534
Exhaust Gas Temp. Outlet T/C 330 346 314 314 314 334

Safety Device Test 1. Overspeed Stop 814/827 rpm


2. Lub. Oil Low Pressure Stop 3.00 bar
3. H.T-Water High Temperature Stop 94.0
4. Emergency Start OK
5. Oil Mist Detector Stop OK *Overhaul Inspection:
6. Start Inderlock OK 6 Cyl. 6 M/Brg

- 3 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENGINE TYPE 7L27/38 CLASS GL

ENGINE NO. BA2401 -1 TEST DATE 2008.05.24

MEASURING RECORD (NO.3 D/G) ENGINE MCR 2310 EVALUATED BY B.G.Choi

GEN. MCR 2195 OPERATED BY K.D.Oh

Time hh:mm 10:10~10:40 10:40~11:10 11:10~11:40 11:40~12:10 12:10~12:40 12:40~13:10


Ambient Press. / Temp. mbar/ 1008 18.6 1009 18.4 1009 18.4 1009 18.5 1009 18.5 1009 19.7
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 720 720 720 720 720
Generator Load 536.3 1108.2 1677.4 2243.0 2467.6
Generator Efficiency % 92.87 95.95 96.82 97.10 97.11
Engine Load 577.5 1155.0 1732.5 2310.0 2541.0
Fuel oil consumption /h - - - 451.000 -
specific consumption g/.h - - - 195.238 -
at ISO conditions g/.h - - - 191.289 -
Governor Indicator Position % 3.0 4.6 5.9 7.3 7.3 8.0
Turbocharger Speed rpm 15,430 23,900 29,420 33,800 33,810 35,470
L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG
Generator Winding & BRG' Temp.
- - - - - - - - - - - - - - - - - - - - - - - -
HT-Water Temp. Outlet Engine 74 / 77 73 / 79 74 / 79 75 / 80 75 / 80 75 /81
HT-Water Press. Inlet Engine bar 4.0 4.0 4.0 4.0 4.0 4.0
LT-Water Temp. Inlet Air Cooler 37 37 36 36 36 36
LT-Water Press. Inlet Air Cooler bar 3.7 3.7 3.8 3.9 3.9 3.9
Lub.Oil Temp. Inlet Engine 62 64 65 65 65 66
Lub.Oil Press. Inlet Filter bar 4.8 4.8 4.8 4.7 4.7 4.8
Lub.Oil Press. Inlet Engine bar 4.5 4.5 4.5 4.4 4.4 4.4
Lub.Oil Press. Inlet Turbocharger bar 1.0 1.3 1.6 1.6 1.6 1.6
Fuel Oil Temp. Inlet Engine 32 32 31 31 31 31
Fuel Oil Press. Inlet Engine bar 9.0 8.5 7.2 6.8 6.8 6.5
Charge Air Temp. Outlet Cooler 36 38 40 42 42 43
Charge Air Press. Outlet cooler bar 0.20 1.00 2.00 2.80 2.80 3.00
Cylinder Case Press. mmWC - - - - - -
Exh.gas Pump Firing BRG'
Temp Index Press Temp
Cyl.No. mm bar mm bar mm bar mm bar mm bar mm bar
Cylinder Unit No.1 252 74
18.0 - 269 25.0 117 - 267 32.0 159 - 337 39.0 193 - 337 39.0 193 - 365 42.5 203 -
No.2 239 75
18.0 - 269 25.0 118 - 294 32.0 158 - 345 39.0 193 - 345 39.0 193 - 375 42.5 203 -
No.3 241 18.0 75 - 264 25.0 120 - 289 32.0 159 - 337 39.0 195 - 338 39.0 195 - 367 42.5 204 -
No.4 242 18.0 74 - 266 25.0 118 - 285 32.0 158 - 338 39.0 193 - 338 39.0 193 - 370 42.0 203 -
No.5 230 18.0 73 - 256 25.0 117 - 273 31.5 158 - 323 39.0 193 - 323 39.0 193 - 355 42.0 204 -
No.6 238 17.5 75 - 263 25.0 120 - 280 31.5 160 - 333 39.0 194 - 333 39.0 194 - 361 42.0 204 -
No.7 226 18.0 74 - 259 25.0 120 - 275 31.5 160 - 329 39.0 196 - 329 39.0 196 - 363 42.0 206 -
No.8 - - - - - - - - - - - - - - - - - - - - - - - -
No.9 - - - - - - - - - - - - - - - - - - - - - - - -
Guide * * * - * * * - * * * - * * * - * * * - * * * -
mean 238 17.9 74 -- 264 25.0 119 -- 280 31.8 159 -- 335 39.0 194 -- 335 39.0 194 -- 365 42.2 204 --
Exhaust Gas Temp. Inlet T/C 334 416 424 490 495 535
Exhaust Gas Temp. Outlet T/C 297 322 227 301 302 332

Safety Device Test 1. Overspeed Stop 812/828 rpm


2. Lub. Oil Low Pressure Stop 3.00 bar
3. H.T-Water High Temperature Stop 93.9
4. Emergency Start OK
5. Oil Mist Detector Stop OK *Overhaul Inspection:
6. Start Inderlock OK 2 Cyl. 2 M/Brg

- 4 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENGINE TYPE 7L27/38 CLASS GL

ENGINE NO. BA2401 -2 TEST DATE 2008.05.24

MEASURING RECORD (NO.4 D/G) ENGINE MCR 2310 EVALUATED BY B.G.Choi

GEN. MCR 2195 OPERATED BY K.D.Oh

Time hh:mm 10:10~10:40 10:40~11:10 11:10~11:40 11:40~12:10 12:10~12:40 12:40~13:10


Ambient Press. / Temp. mbar/ 1008 18.6 1009 18.4 1009 18.4 1009 18.5 1009 18.5 1009 19.7
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 720 720 720 720 720
Generator Load 536.3 1108.2 1677.4 2243.0 2467.6
Generator Efficiency % 92.87 95.95 96.82 97.10 97.11
Engine Load 577.5 1155.0 1732.5 2310.0 2541.0
Fuel oil consumption /h - - - 452.000 -
specific consumption g/.h - - - 195.671 -
at ISO conditions g/.h - - - 191.713 -
Governor Indicator Position % 3.1 4.7 6.0 7.4 7.4 8.0
Turbocharger Speed rpm 15,330 23,930 29,700 34,250 34,280 35,880
L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG
Generator Winding & BRG' Temp.
- - - - - - - - - - - - - - - - - - - - - - - -
HT-Water Temp. Outlet Engine 73 / 76 73 / 77 73 / 78 75 / 80 75 / 80 76 / 81
HT-Water Press. Inlet Engine bar 4.0 3.9 3.9 4.0 4.0 4.0
LT-Water Temp. Inlet Air Cooler 37 37 36 36 36 36
LT-Water Press. Inlet Air Cooler bar 3.7 3.7 3.8 3.8 3.8 3.8
Lub.Oil Temp. Inlet Engine 62 65 65 66 66 67
Lub.Oil Press. Inlet Filter bar 5.0 4.9 4.9 4.9 4.9 4.9
Lub.Oil Press. Inlet Engine bar 4.6 4.6 4.5 4.5 4.5 4.5
Lub.Oil Press. Inlet Turbocharger bar 1.0 1.3 1.5 1.6 1.6 1.6
Fuel Oil Temp. Inlet Engine 32 32 31 30 30 30
Fuel Oil Press. Inlet Engine bar 8.9 8.5 7.5 7.0 7.0 6.6
Charge Air Temp. Outlet Cooler 37 38 40 42 42 42
Charge Air Press. Outlet cooler bar 0.20 1.00 1.95 2.80 2.80 2.95
Cylinder Case Press. mmWC - - - - - -
Exh.gas Pump Firing BRG'
Temp Index Press Temp
Cyl.No. mm bar mm bar mm bar mm bar mm bar mm bar
Cylinder Unit No.1 227 74
18.0 - 259 25.0 118 - 276 32.0 157 - 319 39.0 193 - 320 39.0 193 - 349 42.0 203 -
No.2 231 74
18.5 - 265 25.0 118 - 295 32.0 157 - 342 39.0 193 - 343 39.0 193 - 373 42.0 202 -
No.3 228 18.0 74 - 257 25.0 118 - 287 32.0 156 - 331 39.0 193 - 330 39.0 193 - 360 42.0 203 -
No.4 225 18.0 74 - 255 25.0 118 - 279 32.0 158 - 324 39.0 195 - 325 39.0 195 - 352 42.0 204 -
No.5 227 18.0 74 - 254 25.0 120 - 278 32.0 158 - 323 39.0 196 - 323 39.0 196 - 353 42.0 206 -
No.6 238 18.0 75 - 287 25.0 120 - 283 32.0 159 - 329 39.0 194 - 330 39.0 194 - 358 42.0 204 -
No.7 219 18.0 73 - 253 25.0 118 - 272 32.0 159 - 318 39.0 194 - 319 39.0 194 - 345 42.0 206 -
No.8 - - - - - - - - - - - - - - - - - - - - - - - -
No.9 - - - - - - - - - - - - - - - - - - - - - - - -
Guide * * * - * * * - * * * - * * * - * * * - * * * -
mean 228 18.1 74 -- 261 25.0 119 -- 281 32.0 158 -- 327 39.0 194 -- 327 39.0 194 -- 356 42.0 204 --
Exhaust Gas Temp. Inlet T/C 346 415 436 497 499 531
Exhaust Gas Temp. Outlet T/C 312 323 290 307 309 328

Safety Device Test 1. Overspeed Stop 812/827 rpm


2. Lub. Oil Low Pressure Stop 3.10 bar
3. H.T-Water High Temperature Stop 93.9
4. Emergency Start OK
5. Oil Mist Detector Stop OK *Overhaul Inspection:
6. Start Inderlock OK - Cyl. 2 M/Brg

- 5 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENGINE TYPE 7L27/38 CLASS GL

ENGINE NO. BA2401 -3 TEST DATE 2008.05.24

MEASURING RECORD (NO.5 D/G) ENGINE MCR 2310 EVALUATED BY B.G.Choi

GEN. MCR 2195 OPERATED BY K.D.Oh

Time hh:mm 10:10~10:40 10:40~11:10 11:10~11:40 11:40~12:10 12:10~12:40 12:40~13:10


Ambient Press. / Temp. mbar/ 1008 18.6 1009 18.4 1009 18.4 1009 18.5 1009 18.5 1009 19.7
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 720 720 720 720 720
Generator Load 536.3 1108.2 1677.4 2243.0 2467.6
Generator Efficiency % 92.87 95.95 96.82 97.10 97.11
Engine Load 577.5 1155.0 1732.5 2310.0 2541.0
Fuel oil consumption /h - - - 453.000 -
specific consumption g/.h - - - 196.104 -
at ISO conditions g/.h - - - 192.206 -
Governor Indicator Position % 3.2 4.7 6.0 7.4 7.4 8.1
Turbocharger Speed rpm 15,350 24,050 29,750 34,150 34,200 35,760
L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG L1 L2 L3 BRG
Generator Winding & BRG' Temp.
- - - - - - - - - - - - - - - - - - - - - - - -
HT-Water Temp. Outlet Engine 73 / 76 74 / 78 74 / 78 75 / 80 75 / 80 76 / 81
HT-Water Press. Inlet Engine bar 4.0 3.9 3.9 3.9 3.9 4.0
LT-Water Temp. Inlet Air Cooler 37 37 36 36 36 35
LT-Water Press. Inlet Air Cooler bar 3.8 3.7 3.8 3.8 3.8 3.9
Lub.Oil Temp. Inlet Engine 62 67 67 68 68 69
Lub.Oil Press. Inlet Filter bar 4.7 4.5 4.6 4.7 4.7 4.7
Lub.Oil Press. Inlet Engine bar 4.5 4.3 4.3 4.4 4.4 4.4
Lub.Oil Press. Inlet Turbocharger bar 1.0 1.3 1.5 1.6 1.6 1.6
Fuel Oil Temp. Inlet Engine 30 30 29 28 28 28
Fuel Oil Press. Inlet Engine bar 8.3 8.0 7.3 6.8 6.8 6.4
Charge Air Temp. Outlet Cooler 36 39 41 43 43 44
Charge Air Press. Outlet cooler bar 0.20 1.05 2.00 2.82 2.82 3.20
Cylinder Case Press. mmWC - - - - - -
Exh.gas Pump Firing BRG'
Temp Index Press Temp
Cyl.No. mm bar mm bar mm bar mm bar mm bar mm bar
Cylinder Unit No.1 245 72
18.0 - 273 25.0 117 - 291 32.0 156 - 338 39.0 193 - 340 39.0 193 - 367 42.5 203 -
No.2 221 72
18.0 - 256 25.0 118 - 274 32.0 157 - 324 39.0 195 - 325 39.0 195 - 349 42.5 205 -
No.3 216 18.0 73 - 252 25.0 118 - 269 32.0 158 - 314 39.0 194 - 315 39.0 194 - 338 42.5 206 -
No.4 238 18.0 73 - 273 25.0 117 - 293 32.0 158 - 342 39.0 194 - 343 39.0 194 - 375 42.5 206 -
No.5 219 18.0 73 - 250 25.0 118 - 273 32.0 158 - 319 39.0 193 - 318 39.0 193 - 347 42.5 206 -
No.6 238 18.0 74 - 262 25.0 119 - 277 32.0 159 - 325 39.0 194 - 327 39.0 194 - 354 42.5 206 -
No.7 215 18.0 74 - 249 25.0 118 - 268 32.0 158 - 315 39.0 196 - 318 39.0 196 - 340 42.5 206 -
No.8 - - - - - - - - - - - - - - - - - - - - - - - -
No.9 - - - - - - - - - - - - - - - - - - - - - - - -
Guide * * * - * * * - * * * - * * * - * * * - * * * -
mean 227 18.0 73 -- 259 25.0 118 -- 278 32.0 158 -- 325 39.0 194 -- 327 39.0 194 -- 353 42.5 205 --
Exhaust Gas Temp. Inlet T/C 352 419 433 498 500 534
Exhaust Gas Temp. Outlet T/C 309 321 280 304 305 326

Safety Device Test 1. Overspeed Stop 813/826 rpm


2. Lub. Oil Low Pressure Stop 3.00 bar
3. H.T-Water High Temperature Stop 94.3
4. Emergency Start OK
5. Oil Mist Detector Stop OK *Overhaul Inspection:
6. Start Inderlock OK - Cyl. 4 M/Brg

- 6 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

SETTING TABLE ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

CLEARANCE OF INLET VALVE : 0.7 mm (COLD CONDITION)


VALVES EXHAUST VALVE : 0.7 mm (COLD CONDITION)

[THICKNESS OF THRUST PLATE] [UNIT : mm]

CYL. NO. 1 2 3 4 5 6 7 8 9

NO.1 D/G 11.30 11.00 11.00 10.75 10.75 11.00 10.60 11.00 10.60
ADJUSTMENT OF
FUEL INJECTION NO.2 D/G 11.00 11.50 11.00 11.00 10.60 11.00 10.40 10.70 10.50
PUMPS
NO.3 D/G 11.00 11.00 11.00 11.00 11.00 11.00 11.00

NO.4 D/G 11.00 11.00 10.75 11.00 11.00 11.00 11.00

NO.5 D/G 11.25 11.00 11.00 11.25 10.60 11.00 10.60

THE THRUST PLATE LOCATES BETWEEN THE FUEL INJECTION PUMP PLUNGER BOTTOM PART AND

THE ROLLER TAPPET UPPER PART.

FUEL INJECTION CAM TIMING REMARKS

NO.1 D/G Before TDC 8.0 Degree -


ADJUSTMENT OF NO.2 D/G Before TDC 8.5 Degree -
FUEL INJECTION
CAMSHAFT NO.3 D/G Before TDC 7.5 Degree -

NO.4 D/G Before TDC 7.0 Degree -

NO.5 D/G Before TDC 8.0 Degree -

THESE VALUES ARE ACTUAL READINGS AT THE MARKINGS WHICH ARE MARKED ON THE FLYWHEEL

CIRCUMFERENTIAL SURFACE. (SEE THE INSTRUCTION BOOK PLATE NO. 507-01.20)

DESCRIPTION INLET VALVE EXHAUST VALVE REMARKS


VALVE TIMING OPENING Before TDC 81.3 Before BDC 51.3 -

CLOSING After BDC 61.5 After TDC 78.3 -

-7-
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

CALCULATION SHEET OF F.O. ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

GENSET NO.
NO.1 D/G NO.2 D/G NO.3 D/G NO.4 D/G NO.5 D/G
DESCRIPTION
LOAD % 100% 100% 100% 100% 100%

GEN. OUTPUT 2887.1 2887.1 2243.0 2243.0 2243.0

OUTPUT GEN. EFFICIENCY % 97.21 97.21 97.10 97.10 97.10

2970.0 2970.0 2310.0 2310.0 2310.0


ENG. OUTPUT
PS 4038.1 4038.1 3140.7 3140.7 3140.7

TIME min/sec 30min 0.00s 30min 0.00s 30min 0.00s 30min 0.00s 30min 0.00s

290.000 289.500 225.500 226.000 226.500


ACTUAL F.O. CONSUMPTION
/h 580.000 579.000 451.000 452.000 453.000
MEASUREMENT
g/.h 195.286 194.949 195.238 195.671 196.104
S.F.O.C.
g/PS.h 143.633 143.385 143.598 143.916 144.234

AMBIENT AIR TEMP. 20.7 20.7 18.5 18.5 18.5

(25-Ta)0.06 % 0.26 0.26 0.39 0.39 0.39

AMBIENT AIR PRESS. mbar 1008 1008 1009 1009 1009

(Pa-1000)0.007 % 0.0560 0.0560 0.0630 0.0630 0.0630


ISO CONVERS.
C.W. TO AIR COOLER 35 35 36 36 36
FACTOR
(25-Ta)0.07 % -0.70 -0.70 -0.77 -0.77 -0.74

LOW CALORIFIC VALUE kcal/ 10048 10048 10026 10026 10026

(LCV/10200-1)100 % -1.4902 -1.4902 -1.7059 -1.7059 -1.7059

SUB TOTAL % -1.8762 -1.8762 -2.0229 -2.0229 -1.9879

g/.h 191.622 191.292 191.289 191.713 192.206


S.F.O.C.(ISO)
g/PS.h 140.938 140.695 140.693 141.005 141.367

All values based on ISO 3046/1 conditions

Ambient air temperature : 25


Ambient air pressure : 1000 mbar
Cooling water for air cooler : 25
Marine diesel oil(MDO). Lower calorific value : 42,700 kJ/kg (10,200 kcal/kg)

For other reference conditions, the SFOC is to be corrected by :

Ambient air temperature rise 10 0.6 %


Ambient air pressure rise 10mbar -0.07 %
Cooling water for air cooler rise 10 0.7 %
Lower calorific value rise 1% -1.0 %

-8-
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

GENERATOR TEST ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

1. PARALLEL RUNNING TEST(9L27/38)

LOAD % 75 100 80 60 40 20 40 60 80 100 75


D/G NO. VOLTAGE V 6594 6600 6594 6588 6582 6582 6582 6588 6594 6600 6594
FREQUENCY 60.00 59.20 59.80 60.40 60.90 61.60 60.00 60.40 59.80 59.20 60.00
NO.1 D/G OUTPUT 2120 2801 2257 1690 1130 574 1129 1696 2252 2818 2117
NO.2 D/G OUTPUT 2130 2801 2265 1721 1166 621 1166 1665 2268 2798 2139

2. PARALLEL RUNNING TEST(7L27/38)

LOAD % 75 100 80 60 40 20 40 60 80 100 75


D/G NO. VOLTAGE V 6598 6602 6590 6594 6571 6565 6569 6577 6590 6593 6589
FREQUENCY 60.04 59.32 59.88 60.42 60.92 61.45 60.93 60.42 59.88 59.30 60.01
NO.3 D/G OUTPUT 1658 2190 1768 1328 868 436 880 1323 1758 2193 1645
NO.4 D/G OUTPUT 1642 2199 1752 1298 833 374 837 1293 1752 2206 1623
NO.5 D/G OUTPUT 1645 2192 1752 1332 860 431 881 1316 1772 2211 1658

- 9 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL


2008.05.19/
ENG. NO. BA2402/2401 TEST DATE
24
GOVERNOR TEST ENG. MCR 2970/2310 EVALUATED BY B.G.Choi
GEN. MCR 2820/2195 OPERATED BY K.D.Oh

No. 1 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-15D

GOV' SETTING
FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15533414
100 0 60.0 65.2 8.67% 63.0 5.00% 3.4 sec SPEED DROOP 51
0 33 63.0 61.0 3.17% 62.1 1.43% 3.5 sec NEEDLE V/V 7/8 TURN
33 66 62.1 59.0 4.99% 61.1 1.61% 4.6 sec COMPENSATION -5
66 100 62.1 58.0 6.60% 60.0 3.38% 3.9 sec - -
No. 2 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-15D

GOV' SETTING
FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15533417
100 0 60.0 65.2 8.67% 63.0 5.00% 2.9 sec SPEED DROOP 50
0 33 63.0 61.0 3.17% 62.1 1.43% 3.3 sec NEEDLE V/V 7/8 TURN
33 66 62.1 59.0 4.99% 61.1 1.61% 4.5 sec COMPENSATION -5
66 100 61.1 58.0 5.07% 60.0 1.80% 3.4 sec - -
No. 3 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-15D
GOV' SETTING

FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15533405
100 0 60.0 64.5 7.50% 62.7 4.50% 2.9 sec SPEED DROOP 45
0 33 62.7 60.9 2.87% 61.8 1.44% 2.8 sec NEEDLE V/V 4/4 TURN
33 66 61.8 59.8 3.24% 61.0 1.29% 3.1 sec COMPENSATION -5
66 100 61.0 58.8 3.61% 60.0 1.64% 3.2 sec - -
No. 4 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-15D
GOV' SETTING

FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15533406
100 0 60.0 64.4 7.33% 62.5 4.17% 3.1 sec SPEED DROOP 45
0 33 62.5 60.8 2.72% 61.8 1.12% 2.7 sec NEEDLE V/V 4/4 TURN
33 66 61.8 59.7 3.40% 61.0 1.29% 3.1 sec COMPENSATION -5
66 100 61.0 58.8 3.61% 60.0 1.64% 3.2 sec - -
No. 5 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-15D
GOV' SETTING

FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15533413
100 0 60.0 64.9 8.17% 62.6 4.33% 3.4 sec SPEED DROOP 45
0 33 62.6 60.8 2.88% 61.8 1.28% 2.9 sec NEEDLE V/V 4/4 TURN
33 66 61.8 59.7 3.40% 61.0 1.29% 3.1 sec COMPENSATION -5
66 100 61.0 58.8 3.61% 60.0 1.64% 3.1 sec - -

- 10 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

MECHANICAL VIBRATION MEASUREMENT ENG. MCR 2970/2310 S.H.Kang


MEASUREDD BY
/ Q.M
GEN. MCR 2820/2195

Measurement equipment
Manufacture Type Mechanical connection Measured value Recorded value
RION VM - 82 magnetic velocity velocity
Vibration level limits
Vibration velocity, V rms (mm/s)
720~1200 rpm Engine Generator Engine : VDI 2063T
Value 1 Value 2 Generator : ISO 8528-9, DIN 6280-11
P1250 KVA 18 20 24
P1250 KVA 18 18 22 * Value 1 or 2 are depending on Gen. maker

Measurement points

1 6 1. T/C fore 5. Aft generator bearing


2
2. Governor T/C aft 6. Generator cooler
7 3. Front support 7. Intermediate bearing
5
z 4. Aft support 8. ............................
3 4
y
x UNIT : V rms (mm/s)
Item Vibration velocity, V rms
Measuring
D/GE axial (x) transverse (y) vertical (z)
1 5.0 9.0 7.0
2 5.0 7.0 7.0 Coupling - Flexible coupled(7,9L),
3 4.0 8.0 9.0
NO.1 D/G 4 3.0 10.0 9.0 [with Generator]
5 8.0 8.0 8.0 Erection - Resilient mounting
6 - - - Type : 214SH60
7 - - -
1 5.0 8.0 7.0
2 5.0 7.0 7.0
3 5.0 9.0 8.0 Load % : 100%
NO.2 D/G 4 4.0 10.0 8.0 Running hours : 1 Hr
5 6.0 7.0 6.0
6 - - -
7 - - -
1 6.0 6.0 6.0
2 4.0 6.0 6.0
3 5.0 6.0 7.0
NO.3 D/G 4 4.0 10.0 16.0
5 7.0 7.0 10.0
6 - - -
7 - - -
1 6.0 10.0 7.0
2 5.0 9.0 6.0
3 4.0 8.0 9.0
NO.4 D/G 4 4.0 14.0 16.0
5 6.0 11.0 8.0
6 - - -
7 - - -
1 5.0 10.0 6.0
2 5.0 7.0 6.0
3 5.0 8.0 8.0
NO.5 D/G 4 4.0 14.0 17.0
5 6.0 10.0 10.0
6 - - -
7 - - -
- 11 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

CRANKSHAFT DEFLECTION ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

COUPLING TYPE BETWEEN ENGINE AND GENERATOR : 7,9L27/38 - FLEXIBLE COUPLING [UNIT : 1/100mm]
CYLINDER NO. 1 2 3 4 5 6 7 8 9
NEAR BOTTOM X 0 0 0 0 0 0 0 0 0
CAMSHAFT SIDE P -2.0 -1.0 +1.0 0 -1.0 0 +1.0 +2.0 -3.0
COLD
TOP T -3.0 -1.0 +2.0 0 -3.0 0 +2.0 +3.0 -4.0
CONDITION
EXHAUST SIDE S -2.0 -1.0 +1.0 0 -1.0 0 +1.0 +2.0 -3.0
NO.1 NEAR BOTTOM Y 0 0 0 0 0 0 0 0 0
NEAR BOTTOM X 0 0 0 0 0 0 0 0 0
CAMSHAFT SIDE P -2.0 0 -1.0 -1.0 -2.0 -1.0 -1.0 -1.0 -2.0
HOT
TOP T -3.0 +1.0 -2.0 -3.0 -5.0 -2.0 -1.0 -1.0 -4.0
CONDITION
EXHAUST SIDE S -2.0 0 -1.0 -1.0 -2.0 -1.0 -1.0 -1.0 -2.0
NEAR BOTTOM Y 0 0 0 0 0 0 0 0 0
NEAR BOTTOM X 0 0 0 0 0 0 0 0 0
CAMSHAFT SIDE P -1.0 -1.0 0 -1.0 0 +1.0 +1.0 0 -3.0
COLD
TOP T -4.0 -1.0 +1.0 -1.0 +1.0 +1.0 +1.0 +1.0 -4.0
CONDITION
EXHAUST SIDE S -1.0 -1.0 0 -1.0 0 +1.0 +1.0 0 -3.0
NEAR BOTTOM Y 0 0 0 0 0 0 0 0 0
NO.2
NEAR BOTTOM X 0 0 0 0 0 0 0 0 0
CAMSHAFT SIDE P -2.0 -1.0 -1.0 -2.0 -1.0 -1.0 -1.0 -1.0 -2.0
HOT
TOP T -4.0 -2.0 -3.0 -4.0 -2.0 -2.0 -3.0 -1.0 -4.0
CONDITION
EXHAUST SIDE S -2.0 -1.0 -1.0 -2.0 -1.0 -1.0 -1.0 -1.0 -2.0
NEAR BOTTOM Y 0 0 0 0 0 0 0 0 0
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -2.0 -1.0 -1.0 +1.0 -1.0 -1.0 -3.0 - -
COLD
TOP T -5.0 -3.0 +1.0 +2.0 -1.0 0 -6.0 - -
CONDITION
EXHAUST SIDE S -2.0 -1.0 +1.0 +1.0 -1.0 -1.0 -3.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 0 - -
NO.3
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -3.0 -1.0 -1.0 0 -1.0 0 -4.0 - -
HOT
TOP T -6.0 -2.0 -1.0 0 -2.0 -1.0 -7.0 - -
CONDITION
EXHAUST SIDE S -3.0 -1.0 -1.0 0 -1.0 0 -4.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 0 - -
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -2.0 -1.0 -1.0 +1.0 +1.0 -1.0 -3.0 - -
COLD
TOP T -3.0 -2.0 0 +3.0 +3.0 +1.0 -5.0 - -
CONDITION
EXHAUST SIDE S -2.0 -1.0 0 +1.0 +1.0 -1.0 -3.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 - -
NO.4
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -3.0 0 0 0 -1.0 -1.0 -4.0 - -
HOT
TOP T -4.0 -1.0 -1.0 0 -1.0 -2.0 -6.0 - -
CONDITION
EXHAUST SIDE S -3.0 0 0 0 -1.0 -1.0 -4.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 0 - -
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -2.0 -1.0 +1.0 +1.0 +1.0 -1.0 -2.0 - -
COLD
TOP T -4.0 -2.0 +2.0 +2.0 +2.0 +1.0 -4.0 - -
CONDITION
EXHAUST SIDE S -2.0 -1.0 +1.0 +1.0 +1.0 -1.0 -2.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 0 - -
NO.5
NEAR BOTTOM X 0 0 0 0 0 0 0 - -
CAMSHAFT SIDE P -2.0 0 0 0 0 0 -3.0 - -
HOT
TOP T -5.0 -1.0 0 0 -1.0 -1.0 -5.0 - -
CONDITION
EXHAUST SIDE S -3.0 0 0 0 0 0 -3.0 - -
NEAR BOTTOM Y 0 0 0 0 0 0 0 - -

"CLOSING" OF THE Viewed from the Front End


CRANKTHROW IS START IN PODITION X.
CONSIDERED NEGATIVE. TURN COUNTER CLOCKWISE

- 12 -
- MAN Diesel

OFFICIAL SHOP TEST RESULT PROJECT 1893 OWNER C.P.OFFEN

FOR DIESEL GENERATOR ENGINE ENG. TYPE 9,7L27/38 CLASS GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

HEIGHT OF RESILIENT SUPPORTS IN LOADED CONDITION ENG. MCR 2970/2310 EVALUATED BY B.G.Choi

GEN. MCR 2820/2195 OPERATED BY K.D.Oh

MOUNT TYPE : 214SH60

1A 2A 3A 4A 5A 6A 7A 8A 9A

Front alternator
end

1B 2B 3B 4B 5B 6B 7B 8B 9B

HL = Height of resilient support in loaded


condition

Note ! This flexible elements must be loaded for


at least 48 hours, before measurements are taken

1A 2A 3A 4A 5A 6A 7A 8A 9A
Resilient support NO. Remark
1B 2B 3B 4B 5B 6B 7B 8B 9B
166.0 166.0 166.0 166.0 166.5 167.0 167.5 - -
NO.1
166.0 166.5 166.0 166.5 166.5 167.0 167.0 - -
166.0 166.0 166.5 166.5 167.0 167.0 167.5 - -
NO.2
166.5 166.0 166.5 166.5 167.0 167.0 167.5 - -
163.5 163.5 163.0 163.0 163.5 163.5 - - -
HL (mm) NO.3
162.5 162.0 162.0 162.0 162.5 162.5 - - -
163.0 163.0 162.5 162.5 162.0 162.5 - - -
NO.4
163.0 163.0 162.5 162.5 162.5 162.0 - - -
162.5 162.5 162.0 162.0 162.5 162.5 - - -
NO.5
162.5 162.0 162.0 162.0 162.5 162.0 - - -

REMARK.:

- 13 -

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