Instruction Book L2738ed080120 PDF

MAN B&W Diesel L27/38
Preface
What does this book contain?
This instruction manual provides general Reliable and safe operation of the engine is
guidance regarding operation and mainte- dependent on correct operation and main-
nance of the engine. It is also to be used as tenance. It is therefore important that the
reference when ordering spare parts. en-gine personnel is fully acquainted with
The manual is divided into a number of the contents of this book.
chapters that correspond to the main com- The equipment is delivered including a war-
ponents/units in the engine. The number of ranty clause which has been contractually
each chapter is determined by our PSPsys- agreed upon.
tem (product specification system) and is the
foundation stone of our EDPsystem. It is, of course, a precondition for the valid-
ity of such a warranty that the equipment is
Each chapter consists of four main ele- op-erated in accordance with agreed require-
ments: ments and recommendations.
y Descriptions (explanatory text con- Spare parts must be original spare parts
cerning design features, functionality purchased directly from MAN B&W Diesel,
and operation) Alpha Diesel or from one of MAN B&W Die-
y Work cards (specifications on how to sels authorized workshops or agents.
perform different maintenance jobs)
20000601
y Data sheets (oil list, tightening torques

etc.)
y Spare part plates (spare part illustra-
tions and additional lists)
Release Preface I
L27/38
How do I order spare parts?

Spare part plates consist of a drawing of the made in correspondence), you must specify
spare part and an accompanying list of the the following data:
items shown on the drawing.
1. Name of vessel (eg M/S WANNSEE)
The drawing may not be completely ident-
ical to your plant and may also show some 2. Type of engine (eg 6L27/38)
items that are not included in your plant. The 3. Engine no or product identification no
additional list of items, however, is always in (eg 17019 or 1000 6769)
accordance with your specific plant.
4. Spare part plate no (incl edition no eg
Note that some items on the spare part 1 101001
drawings may only be delivered as part of a
5. Item no (eg 7)
kit or as a complete, assembled component.
This, however, is generally stated on the 6. Description of part and quantity re-
drawing. quired (eg 2 gaskets)
When ordering spare parts (or reference is
These data are used in order to ensure cor-
rect supply of spare parts for the individual
propulsion plants.
20000601
Plate no A BBCCDD
A: A = 1 for engine
BBCC: BB = chapter (main function)
CC = subfunction
DD: version
II Release Preface
00. Data
Description
Main data for L27/38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-3
General safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-4
Capacities at MCR MDO operation . . . . . . . . . . . . . . . . . . . . . page 00-6
Capacities at MCR HFO operation . . . . . . . . . . . . . . . . . . . . . page 00-7
Maintenance program L27/38 MDO operation
Major overhaul/inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-8
Maintenance program L27/38 HFO operation
Major overhaul/inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-10
Duties during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-12
Duties during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-14
2008-01-10
Operating data and set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-16

Green passport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-17
Data sheet
Shop test report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine no XX XXX
Crankshaft deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . product no XXXX
Inspection sheet gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . s no XXXX
List of lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 74 23-0
Quality requirements for engine cooling water . . . . . . . . . . . . . . . drawing 6680-3.3.7-01E
Quality requirements for MDO . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing D365600E1.21
Quality requirements for HFO. . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing 66803.3.3-01E
Viscosity temperature diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing D365600E-1.25
Settings and limit values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 77 49-0
Weights of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 92 69-5
List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 79 48-0
Tightening specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 95 81-0
Release TOC_1 00 page 00-1

L27/38
2008-01-10
page 00-2 Release TOC_1 00

Main data for L27/38

The main particulars are carefully selected Fig 00.1
in order to reach the optimal compromise
between low operational costs and reliabil-
ity, - and fulfilling future legal emission limit
values.
Cylinder numbers 6-7-8-9
Power range 2040-3060 kW
Engine speed 800 rpm
Bore 270 mm
Stroke 380 mm
Stroke/bore ratio 1.4: 1
Swept volume/cylinder 21.8 l
Bmep 23.5 bar
Mean piston speed 10.1 m/s
Compression ratio 16.5: 1
Max combustion press. 195 bar
20050606
Turbocharger principle Constant

pressure
Fuel quality according to MGO, MDO
& HFO up to
700 cSt/50C
Ignition sequences
Clockwise rotating engines (seen from aft
end):
6 cyl: 1-2-4-6-5-3
7 cyl: 1-2-4-6-7-5-3
8 cyl: 1-2-4-6-8-7-5-3
9 cyl: 1-2-4-6-8-9-7-5-3
Counter clockwise rotating engines (seen Cross section of engine
from aft end):
6 cyl: 1-3-5-6-4-2
7 cyl: 1-3-5-7-6-4-2
8 cyl: 1-3-5-7-8-6-4-2
9 cyl: 1-3-5-7-9-8-6-4-2
Release 1 00A1-01 page 00-3

L27/38
General safety precautions

Proper maintenance, which is the aim of this engine room close to the area of application.
book, constitutes the crucial point in obtain- No major objects must be left unfastened,
ing optimum safety in the engine room. The and the floor and passages should be kept
general measures mentioned here should be clear.
a natural routine to the entire engine room
staff. Spares
Large spare parts should as far as possible
Cleanliness be placed well strapped near the area of
The engine room should be kept clean above application and accessible by crane. The
and below the floor plates. If grit or sand may spare parts should be well preserved against
blow into the engine room when the ship is in corrosion and protected against mechanical
port, the ventilation should be stopped and damage. The stock should be checked at
ventilating ducts, skylights, and doors in the intervals and replenished in time.
engine room should be closed.
Light
In particular, welding or work which causes
spreading of grit and chips must be avoided Ample working light should be permanently
near the engine unless this is closed or cov- installed at appropriate places in the engine
ered, and the turbocharger air intake filters room, and portable low voltage working light,
are covered. in explosion-proof fittings, should be obtain-
2000-11-01
able everywhere.
The exterior of the engine should be kept
clean and the paintwork maintained so that Freezing
leakages can be easily detected.
If there is a risk of damage due to freezing
when the plant is out of service, engines,
Fire
pumps, coolers, and pipe systems should
If the crankcase is opened before the engine be emptied of cooling water.
is cold, welding and the use of naked light
will involve a risk of explosions and fire. The
same applies to inspection of oil tanks and Warning
the space below the floor. Attention is fur-
The opening of cocks may cause discharge
thermore drawn to the danger of fire when
of hot liquids or gasses. The dismantling of
using paint and solvents with a low flash
parts may cause springs to be released. The
point. Porous insulating material drenched
removal of fuel valves (or other valves in the
with oil from leakages is highly inflammable cylinder head) may cause oil to run down
and should be renewed. See also: Ignition to the piston crown; if the piston is hot, an
in crankcase. explosion may then blow out the valve. When
testing fuel valves with the hand pump, do
Other not touch the spray holes, as the jet may
Hand tools should be placed easily acces- pierce the skin. Think out beforehand which
sible on tool boards. Special tools should be way the liquids, gases or flames will move,
fastened to tool panels (if supplied) in the and keep clear.
page 00-4 Release 1 00B1-01

Entering the crankcase or cylinder Slow turning

Check beforehand that the starting air supply After prolonged out-of-service periods or
to the engine is shut off, and that the turning overhaul work which may involve a risk of
gear is engaged. Make sure that the propel- accumulation of liquid in the combustion
ler is disengaged or that the propeller shaft spaces, Slow turning should always be
is mechanically locked. effected, through at least two complete
revolutions.
Turning gear
Before engaging the turning gear, check that Hydraulic tools
the starting air supply is shut off, that the Safety goggles and gloves must be worn
indicator valves are open, and subsequently when using hydraulic tools. If skin is damaged
that the Turning gear in indication is on. by oil jets seek treatment immediately.
Feeling-over Grinding tools

When repairs or alterations have been made Safety goggles and gloves must be worn
to the running gear, apply the Feel-over se- when using grinding tools. Prevent grinding
quence until satisfied that there is no undue particles from entering the engine. After-
heating, oil mist formation, blow-by, or failure wards clean all parts carefully.
2000-11-01
of cooling water or lubricating oil systems.
Check and maintain

Feel-over sequence Engine performance, lubricating and cooling
Feel-over after 5, 15 and 30 minutes idle run- water condition.
ning and finally when the engine is running at
Measuring equipment.
full load. See also Starting-up sequence .
Release 1 00B1-01 page 00-5

L27/38
Capacities at MCR MDO operation

Engine type 6L 7L 8L 9L
MCR (Max continuous rating) kW 2040 2380 2720 3060
Fuel oil system
Fuel oil consumption MDO incl built-on pumps I/h 475 555 635 715
Pump capacity Built-on primary pump m3/h 2.3 2.3 2.3 2.3
Stand-by pump, min m /h3
2.2 2.2 2.8 2.8
Lubricating oil system
Pump capacity Built-on pump m3/h 80 80 115 115
Stand-by pump m /h3
60 60 75 75
Heat dissipation Lub oil cooler (built-on) kW 285 335 380 430
Lub oil volume in oil pan Min m3 1.4 1.6 1.8 1.9
Max m 3
1.6 1.8 2.0 2.2
LT cooling water system
Stand-by pump m3/h 62 62 62 62
Heat dissipation Charge air cooler/LT stage kW 200 230 265 295
Water in engine m 3
0.15 0.15 0.15 0.15
2000-06-01
Expansion tank m 3
0.1 0.1 0.1 0.1
HT cooling water system
Stand-by pump m3/h 62 62 62 62
Heat dissipation Charge air cooler /HT stage kW 430 500 575 645
Jacket water kW 315 370 425 475
Water in engine m 3
0.175 0.2 0.225 0.25
Expansion tank rrv* 0.1 0.1 0.1 0.1
Starting air system
Air consumption Per start Nm3 1.7 1.7 1.9 1.9
Starting air receivers Receiver 1 I 500 500 500 500
Receiver 2 250 250 500 500
Starting air compressors Total capacity m /h3
22.5 22.5 30 30
Charging air system
Turbocharger type MAN B&W NR24/S NR24/S NR26/R NR29/S
Air consumption ISO ambient conditions kg/h 14800 17300 19700 22200
Charge air cooler MBD 58/58 m 2
58/58 58/58 58/58 58/58
Exhaust gas system
Exhaust gas quantity ISO ambient conditions kg/h 15200 17700 20300 22800
Exhaust pipe dimensions Du t mm 500 3 550 3 600 3 600 3
2047392-8.4
Radiated heat kW 65 76 87 98
Engine weight (dry) Approx ton 31.0 34.0 37.0 40.5
page 00-6 Release 1 00C1-01

Capacities at MCR HFO operation
MCR (Max continuous rating) kW 2040 2380 2720 3060
Fuel oil system
Fuel oil consumption* HFO Incl built-on pumps kg/h 430 500 570 640
3
Pump capacity Booster pump (separate) m /h 2.2 2.2 2.8 2.8
bar 4-6 4-6 4-6 4-6
Stand-by pump, min m3/h 2.2 2.2 2.8 2.8
3
Stand-by pump m /h 60 60 75 75
Heat dissipation Lub oil cooler (built-on) kW 285 335 380 430
Lub oil volume in oil pan Min m3 1.4 1.6 1.8 1.9
Max m3 1.6 1.8 2.0 2.2
LT cooling water system
3
Heat dissipation Charge air cooler/LT stage kW 200 230 265 295
2000-06-01
Water in engine m3 0.15 0.15 0.15 0.15

Expansion tank m3 0.1 0.1 0.1 0.1
HT cooling water system
3
Heat dissipation Charge air cooler /HT stage kW 430 500 575 645
Water in engine m3 0.175 0.2 0.225 0.25
3
Expansion tank m 0.1 0.1 0.1 0.1
Starting air system
Air consumption Per start Nm3 1.7 1.7 1.9 1.9
Starting air receivers Receiver 1 I 500 500 500 500
Receiver 2 I 250 250 500 500
3
Starting air compressors Total capacity m /h 22.5 22.5 30 30
Charging air system
Turbochargertype MAN B&W NR24/S NR24/S NR26/R NR29/S
Air consumption ISO ambient conditions kg/h 14800 17300 19700 22200
Charge air cooler MBD 58/58 m2 58/58 58/58 58/58 58/58
Exhaust gas system
Exhaust gas quantity ISO ambient conditions kg/h 15200 17700 20300 22800
Exhaust pipe dimensions Du t mm 500 3 550 3 600 3 600 3
Radiated heat
2047428-0.4
kW 65 76 87 98
Engine weight (dry) Approx ton 31.0 34.0 37.0 40.5
* Depending on fuel oil quality
Release 1 00C2-01 page 00-7

L27/38

Majoroverhaul/inspection
Check new/ overhaauled parts

Time between
overhauls
Description Check the condition

Chapter
Observations
Overhaul to be carried out
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Engine frame and foundation
Foundation bolts retightening, see Tightening
specification 2049581-0 200 10
Safety cover - function test 10
Crankshaft and main bearing
Inspection of main bearing (two by two) 12
Inspection of guide bearing 12
Recording of crankshaft deflection 12
Main and guide bearing cap retightening 200 12
2000-11-01
Vibration damper check sleeve
springs 12
Counterweights retightening, see Tightening
Camshafts and camshaft drive
Camshafts inspect gear wheels, screws,
connections etc 200 14
Camshaft bearings check of clearance 14
Camshaft adjustment check of cam
followers 14
Cylinder unit
Dismountingassembly of cylinder unit
(if space available above engine) 16
Inspection of piston 16
Piston rings and scraper rings
to be replaced 16
Inspection of connecting rod bearing shells 16
Connecting rod retightening 200 16
Cylinder liner borescope inspection Cylinder 16
liner-cleaning, honing and measuring 16
Inlet valves, exhaust valves, valve guides
and valve rotators 16
Safety valve check and adjustment
of opening pressure 16
Indicator valve 16
page 00-8 Release 1 00D1-01


Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Cylinder head nut retightening 200 16
Turbocharger
Charging air cooler cleaning and inspection 18
Retightening all screws and connections 200 18
For turbocharger, refer to special manual 18
Fuel oil system and injection
equipment
Fuel oil injection pumps check
of condition 20
Fuel injection pump retightening 200 20
Fuel injection valves 20
2000-11-01
Starting air system

Air starter inspection and overhauldismantling
and inspection 26
Lubricating oil pump engine driven 28
Lubricating oil cooler 28
Lubricating oil filter 28
Thermostatic valves 28
Cooling water system
Cooling water pumps engine driven
(LT/HT water) 30
Local monitoring, control
and safety systems
Function test of monitoring, control
and safety sensors 84
See Maintenance programme during operation, page 12.
Release 1 00D1-01 page 00-9

L27/38

Majoroverhaul/inspection

Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Foundation bolts retightening, see Tightening
specification 2049581-0 200
Safety cover function test 10
Crankshaft and main bearing
Inspection of main bearing (two by two) 10
Inspection of guide bearing 10
Recording of crankshaft deflection 12
Main and guide bearing cap retightening 200 10
Vibration damper check sleeve
2000-11-01
springs 12
Counterweights retightening, see Tightening
Camshafts and camshaft
drive
Camshafts inspect gear wheels, screws,
connections etc 14
Camshaft bearings check of clearance 14
Camshaft check of cam followers 14
Cylinder unit
Dismounting of cylinder unit
(if space available above engine) 16
Inspection of piston 16
Piston rings and scraper rings
to be replaced 16
Inspection of connecting rod bearing shells 16
Connecting rod retightening 200 16
Cylinder liner bore scope inspection 16
Cylinder liner-cleaning, honing and measuring 16
Inlet valves, exhaust valves, valve guide
and valve rotator 16
Safety valve check and adjustment
of opening pressure 16
Indicator valve 16
Cylinder head nut retightening 200 16


Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Turbocharger
Charging air cooler cleaning and inspection 18
Retightening all screws and connections 200 18
For turbocharger, refer to special manual 18
equipment
Fuel oil injection pumps check
of condition 20
Fuel injection pump retightening 200 20
Starting air system
Air starter inspection and overhaul 26
2000-11-01

Lubricating oil pump engine driven 28
Lubricating oil cooler 28
Lubricating oil filter 28
Cooling water pumps engine driven
(LT/HT water) 30
and safety systems
Function test of monitoring, control
and safety sensors 84
See Maintenance programme during operation, page 14.

L27/38

Duties during operation

Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
General operation of engine
Record engine performance data with reference
to Shop Test Report 00
Draining of water condensate constantly 02
Check for leakages 10
Flexible mounting check rubber mountings 10
2000-11-01
Cylinder unit
Inlet and exhaust valves check and adjustment
of valve clearance 200 16
Lubricating of operating gear check 16
Check rotation of valve rotators
at idle speed 16
Turbocharger
Cleaning of air filter compressor side 18
Water washing of compressor side 18
Exhaust system compensators 18
Retightening of all screws and connections 200 18
By-pass valve and wastegate
check function 18
equipment
Fuel oil system check the system 20
Fuel oil filter replace
filter cartridge 20
Fuel oil injection pumps check free movement
of speed control system 20
page 00-12 Release 1 00E1-01


Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Starting air system
Function test main and emergency
starting valve 26
Air filter, draining of bowl 26
Starting air system drain air receivers
and pipes 26
Lubricating oil filter check function 28
Lubricating oil oil samples 28
Cooling water system water samples 30
Cooling water system check the system 30
2000-11-01

and safety systems
Function test of emergency
stop 82
Governor check oil level, see governor
instruction book 84
See Maintenance programme major overhaul/inspection, page 8.
Release 1 00E1-01 page 00-13

L27/38

Duties during operation

Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
General operation of engine
Record engine performance data with reference
to Shop Test Report 00
Draining of water condensate constantly 02
Check for leakages 10
Flexible mounting check rubber mountings 10
Cylinder unit
2000-11-01
Inlet and exhaust valves check and adjustment
of valve clearance 200 16
Lubricating of operating gear check 16
Check rotation of valve rotators
at idle speed 16
Turbocharger
Cleaning of air filter compressor side 18
Dry cleaning of turbine side 18
Water washing of compressor side 18
Exhaust system compensators 18
Retightening of all screws and connections 200 18
By-pass valve and waste gate check
function 18
equipment
Fuel oil system check the system 20
Fuel oil filter rotate split
filter element 20
Fuel oil filter drain and clean 20
Fuel oil oil samples after each bunkering,
see chapter 00 20
Fuel oil injection pumps check free movement
of speed control system 20


Time between
overhauls

Chapter
Observations
after-hours
Monthly
Weekly
12000
18000
24000
2000
6000
Daily
200
Starting air system
Function test main and emergency
starting valve 26
Air filter, draining of bowl 26
Starting air system drain air receivers
and pipes 26
Lubricating oil filter check function 28
Lubricating oil oil samples 28
Cooling water system water samples 30
Cooling water system check the system 30
2000-11-01

and safety systems
Function test of emergency stop 82
Governor check oil level, see governor
instruction book 84
See Maintenance programme major overhaul/inspection, page 10.

L27/38
Operating data and set points

Normal Alarm set points Reduced Shut
values load of down of
at MCR Low High engine engine

Temp. after cooler (inlet engine) 6873C 80C 85C
Pressure after filter (inlet engine) 4.04.8 bar 3.0 bar 1.8 bar
Pressure before filter 4.25.0 bar
Pressure drop across filter 0.10.3 bar 1.0 bar
Pressure inlet turbocharger 1.41.8 bar 0.9 bar
Lub oil level Low level
Temperature main bearing 8095C 100C 105C
Fuel oil system
Pressure after filter MDO 2.03.0 bar 1 bar
Pressure after filter HFO 410 bar 3 bar
High leakage
Leaking oil
level
Temperature inlet engine MDO 2040C
Temperature inlet engine HFO 80140C
2000-06-01
Fuel oil viscosity HFO 1113 cSt 10 cSt 14 cst
2.03.0 bar 0.4 +
Press. LT system, inlet engine
static
2.03.0 bar 0.4 + Static
Press. HT system, inlet engine
static pressure
Temp. HT system, outlet engine 7585C 92C 92C 97C
Temp. HT system, inlet engine 6570C
Temp. LT system, inlet engine 2540C
Temp. LT system, outlet engine 3545C
Exhaust gas and charge air
Exh. gas temp. before TC 480530C 570C
370450C Average Average Average
Exh. gas temp. outlet cyl
50C +50C 50C
Exh. gas temp. after TC 300350C 450C
Ch. air press. after cooler 2.93.1 bar
Ch. air temp. after cooler 4055C 25C 65C
Starting air system
Press. inlet engine 30 bar 15 bar
Speed control system 920
Engine speed 800
30 000
Turbocharger speed
or 35 000
Safety control air pressure 8 bar 6 bar
page 00-16 Release 1 00F1-01

Green passport
List of potentially hazardous materials of
MAN four-stroke diesel engines that are
relevant to be delivered to recycling facili-
ties according to IMO resolution A.962(23)
Adopted on 5 december 2003.
Asbestos
Type of asbestos Materials Location Approximate quantity/volume
- - None
Plastic Materials
Type Location Approximate quantity/volume
Copolymer, based on acrylnitrile and O-rings (Inside engine) *)
butadiene: NBR
Copolymer, based on vinylidene-fluoride O-rings (Inside engine) *)
and hexafluoro-propene: FPM
FPI 155, Flame retardant according to Cable jacket < 100 m
IEC 332-3 cat. 3
Materials containing PCBs, PCTs, PBBs at levels of 50 mg/kg or more

2007-10-29
None
Gases sealed in the machinery

Argon Exhaust thermometers *)
Chemicals in engine
Anti-seize Compounds Used on high temperature screws *)
Engine Additives None
Water Treatment: Nitrite-borate inhibitor Fresh water system See instruction manual
Other Substances in engine

Fuel oil Engine F.O. pipe system < 0,020 m3
Lubricating oil Engine frame See instruction manual
Filter cartridge Lub. oil filter on engine 2 pcs. 1)
Filter cartridge Lub. oil filter on engine/filter candles 2 pcs./48 pcs. 2)
Mercury None
Lithium battery (if installed) Electronic cabinet 1 pcs.
Lead Pb - for soldering circuit board Electronic cabinet < 10 g/engine 2)
*) The component is most likely bound in an alloy or present at a very low concentration
1
) only valid for GenSets
2
) only valid for Propulsion engines
Release 1 00G1-01 page 00-17

L27/38
2007-10-29
page 00-18
02. Operation of engine

Description
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 02-21
Checks during out-of-service periods .....................................
page 02-24
Starting-up after repair ........................................................
page 02-26
Engine performance and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 02-28
Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 02-31
Bore scope inspection of cylinder liner . . . . . . . . . . . . . . . . . . . . page 02-33
Work card
02 10101 Recording of engine performance data . . . . . . . . . . page 02-35
2008-01-10

L27/38
2008-01-10

Operation
Preparations for starting Fig 02.1
The following describes what to do before
starting when the engine has been out of
service for a period of some hours.

Open for the cooling water supply to the
engine. Start sea water pump(s) for central
Check
cooler. oil level
1 2410-01 L27/38
Warning
To avoid shock effects owing to large tem-
perature fluctuations just after start, it is
required
1. To preheat the engine.
2001-03-21
The HT cooling water must be pre-

heated to: Governor
HFO operation 60-70C
MDO operation Min 40C
Fuel oil system
2. If for some reason starting without pre
heated cooling water, the engine may 1. Open the fuel oil supply.
only be started on MDO. Starting on HFO:
Circulate preheated fuel through the
pumps until correct working tempera-
Lubricating oil system tures have been achieved.
1. Check the oil level in the oil pan. 2. Regulating gear please check:
2. Check the oil level in the governor, see y that all fuel injection pumps are set at
fig 02.1. index "0" when the regulating shaft is
3. Start up the stand-by pump. in STOP position.
The engine must be prelubricated for y o that each fuel injection pump can be
at least 3 minutes prior to startup. pressed by hand to full index when the
4. Check prelubricating oil pressure at in- regulating shaft are in STOP position,
let to engine and to inlet turbo charger and that the pumps return auto mati-
on the operator panel. cally to the "0" index when the hand is
removed.

L27/38
Starting air system and at the same time keeping fuel pump
1. Check the pressure in the starting air index on zero, with a tool on the regulat-
receiver(s). ing shaft.
2. Close indicator valves. Observe pos-
2. Drain the starting air system. sible leakages from indicator valves!
3. Open the starting air supply.
4. Check the air pressure on the operator Starting
panel. 1. Start the engine by turning the start
5. Check that: button on the operator panel until the
engine ignites, see fig 02.2.
Propeller pitch is zero To reduce the exhaust smoke during
Engine is disconnected starting, the load limit knob on the
Propeller is locked (if shaft brake) governor can be activated corre-
sponding to a fuel pump index of 24.
For normal operation the load limit
Turning of engine knob should be set at 10.
1. Open the indicator valves and turn the
engine some few revolutions, check Warning
that no liquid is flowing out from any
indicator valves during the turning. Failure in reset of fuel limit can load to black-
The turning can be done by activating out during shaft alternator operation.
the start button on the operator panel
2001-03-21
Fig 02.2
Operator panel
page 02-22 Release 1 02A1-01

Testing during running exhaust temperatures, see the shop

Check the following on the operator panel test report and sea trial records.
according to shop test report and sea trial 6. Keep the charging air pressure and
records. temperature under control. For normal
1. Check the lubricating oil pressure and values, see the test report from shop
that the stand-by pump has stopped. and sea trial records.
2. Check the cooling water pressure. 7. Recharge the starting air receivers to
30 bar. The air starter operates with a
3. Check the fuel oil feed pressure. pressure of 7-8 bar.
4. Check that the turbocharger is run- 8. To ensure full operational reliability,
ning. the condition of the engine should be
5. Check that all cylinders are firing, see continuously observed so that order to
exhaust gas temperatures. preventive maintenance work can be
carried out before serious break downs
6. Check that all shut-downs are con- occur.
nected and function satisfactorily.
7. Check that all alarms are connected. Stopping
Before stopping, it is recommended to
Operation run the engine at idle speed for 10-15
minutes.
2001-03-21
The engine should not be loaded more than

50% just after start. The increase to 100% 1. The engine is stopped by turning the
should take place gradually over 15 to 20 button on the operator panel.
minutes.
2. Check that the lub oil stand-by pump
When the engine is running, the following is started automatically and runs for 5
should be checked: minutes.
1. The lubricating oil pressure must be
within the stated limits and may not fall Starting and stopping on HFO
below the stated minimum pressure. Starting and stopping of the engine should
2. The lubricating oil temperature must be take place on HFO in orderto prevent any
kept within the stated limits indicated incompatibility problems on changeover to
on the data and set points sheet, see MDO.
page 00-16. MDO should only be used in connection with
3. The fuel oil pressure must be kept at maintenance work on the engine or before a
the stated value. longer period of engine standstill.
4. The cylinder cooling water temperature Before starting on HFO the engine must be
must be kept within the limits indicated properly preheated as described in Prep-
on the data and set points sheet. arations for starting and as described be-
See also shop test report and sea trial low.
records. Stopping the engine on HFO is no problem,
5. The exhaust gases should be free of but it should be ensured that preheated fuel
visible smoke at all loads. For normal is continuously circulated by means of the
booster pump.

L27/38
Checks during out-of-service periods

This section describes how to check the con- 3. Oil sump, crank pin bearings and
dition of the engine while it is stopped. main bearings
Check the bottom of the oil sump for
The responsible chief engineer should always
fragments of bearing metal and similar,
be well-informed regarding the operational
which could indicate incipient dam-
condition of the engine; the results of the
age.
inspections must therefore be recorded.
4. Automatic lub oil filter
The work can be adapted to the sailing
Check that the automatic filter is operat-
schedule of the ship so that it is carried out
ing under oil pressure. (Rotating of the
at suitable intervals, eg as suggested in the
filter shaft can be observed at the end
Maintenance Programme, see chapter 00.
cover of the filter.)
The intervals stated are normal for well-main-
tained machinery. If a period of operational 5. Inspection of cylinder liner
irregularities occurs or the operational condi- Check the cylinder liner running surface
tion is unknown due to repairs or changes, from the crankcase or by borescope
the relevant inspections should be repeated through the hole for the fuel valve.
more frequently until normal operation has 6. Crankshaft
been restored. Carry out deflection measuring of the
The checks are listed in the following order: crankshaft. See Settings and limit val-
2000-06-01
18 to be carried out before over- ues 2047749-0.
haul 7. Oil samples
914 during the overhaul A lub oil sample is to be sent to a labo-
1518 after the overhaul ratory for immediate analysis.
1. Recordings 8. Turbocharger
Make a complete set of recordings of If the recordings show that the charging
the engine performance data at MCR air conditions have changed radically,
load. cleaning or other action should be ef-
2. Check lub oil flow fected. See separate instruction manual
Start the stand-by lub oil pump, remove for turbocharger.
the crankcase covers and check that 9. Nuts and bolts
the oil flows freely from all bearings. Tighten all nuts and bolts in the crank-
Also take off the valve covers on the case, see Tightening specification
cylinder heads and make sure that oil 2049581-0. Also retighten foundation
is supplied for lubrication of the rocker bolts and check the chocks.
arms.
10. Camshaft gear train
Check the various gear wheels.
Warning 11. Pneumatic valves
In case of longer runs (more than 5 minutes) Drain starting air pipes for condensate
with the stand-by lub oil pump, the lub oil water. Check solenoid valve for over-
connection to the turbocharger should be speedstop, charge air by-pass valve
blocked. Do not forget to restore this con- and waste gate.
nection prior to operation.

12. Lub oil sump After cleaning and starting up, keep a
Empty the oil sump and remove sludge. close watch on the pressure drop.
Clean the sump very thoroughly and 16. Turning
inspect for foreign bodies, pieces of After normal lub oil circulation has
bearing metal, etc. been restored, turn the engine at least
13. Automatic lub oil filter 2 revolutions by means of the turning
Remove the complete filter unit from device to control the movability of the
the housing. engines parts.
Dismantle the end cover and candle 17. Speed control system
unit. The filter candles are inspected Lubricate bearings and rod connec-
for possible damages. tions. Disconnect the governor and
Replace if necessary. move the rod connections by hand to
14. Lub oil cooler check that friction in the bearings and
If the performance records indicate fuel injection pumps is sufficiently low.
increased lub oil temperature or pres- Checks which should be made just be-
sure drop, the oil cooler should be fore starting the engine are mentioned
dismantled and cleaned. under Operation, see page 3.
15. Lub oil cleaning 18. Cooling water system
Opening up the engine or the lub oil Add cooling water, keep the system
system may have caused ingress of under pressure and check for leakages
2000-06-01
impurities and a thorough cleaning at cylinder liner and cylinder head seal-
should be carried out before starting ings and at the cooling water joints.
the engine. Do not forget to add cooling water treat-
By means of the stand-by pump and the ment additives.
purifier the lub oil should be circulated
until the impurities are removed.

L27/38
Starting-up after repair

General
The following checks are to be made im-
mediately after starting and during load Note
increase. The overspeed setting should be according
to Operating data and set points.
It is assumed that the plant has been out
of service for some time, for instance due
to overhaul, and that the check during out- To be checked during starting-up, but only
of-service periods (see page 6) has been if required after repairs or alterations
carried out as described.
1. If the condition of the machinery is not
Starting-up after such an out-of-service well-known, especially after repairs or
period is normally carried out as a test run alterations, the feel-over sequence
(quay trial). Priorto the trial run it must be should always be followed, ie:
ascertained that: After 5,15 and 30 minutes idle running,
1. The port authorities allow quay trials open the crankcase and the camshaft
housing and perform feel-over on the
2. The moorings are adequate surfaces of all moving parts where fric-
3. The wheel house is manned during tion may arise and cause undue heat-
quay trials ing.
2000-06-01
Whether a quay trial is carried out or not, in Feel: main bearings, con-rod bearings,
addition to normal supervising and record- camshaft bearings and cylinder liners.
ing, the following checks must be made in After the last feel-over, check lub oil
the order stated. flow from bearings, see also Ignition
To be checked immediately after start- in crankcase .
ing 2. After repair or renewal of cylinder lin-
1. Check that the turbocharger is run- ers, piston rings or bearings, allowance
ning. must be made for a running-in period,
ie the engine load should be increased
2. Check that the lubricating oil pressure gradually as indicated in the table be-
is in order and that the automatic lub low. The engine output is determined
oil filter is operating. on the basis of the fuel pump index
3. Check that all cylinders are firing (see and engine speed. The turbocharger
exhaust temperatures). speed and charge air pressure give
some indication of the engine output.
4. Check that everything is normal for
engine speed, fuel oil, cooling water
and system oil.
Check by simulation of the overspeed
shutdown device that the engine
stops.

Running-in sequence
After the runningin sequence, make sure
Load Time Load Engine that all fuel pumps are set at the same in-
step [hours] [%] [rpm] dex and that the governor can move all fuel
pumps to zero index.
1 0.5 0 500
2 0.5 10 535
3 0.5 20 610
4 0.5 30 670
5 0.5 40 800
6 1.0 50 800
7 1.0 60 800
8 1.0 70 800
9 1.0 80 800
10 1.0 90 800
11 1.0 100 800
2008-09-04

L27/38
Engine performance and condition

Performance data and engine condition Evaluation of performance data
During operation, small changes in the en- Air cooler
gine condition take place continuously as Fouling of the air side of the air cooler will
a result of combustion, including fouling of manifest itself as an increasing pressure
airways and gasways, formation of deposits, drop, lower charge air pressure and an in-
wear, corrosion, etc. If continuously recorded, creased exhaust/charge air temperature level
these changes in the condition can give valu- (with consequential influence on the overhaul
able information about the operation and intervals for the exhaust valves).
maintenance condition of the engine. Con-
tinuous observation can contribute to forming An increase in charge air temperature
a precise and valuable basis for evaluation involves a corresponding increase in the
of the optimum operation and maintenance exhaust gas temperature level by a ratio of
programmes for the individual plant. about 1:1.5, ie 1C higher charge air tem-
perature gives about 1.5C higher exhaust
gas temperature.
Engine performance data Reduction of the charge air pressure results
If abnormal or incomprehensible deviations in in a reduction of the compression pressure
operation are recorded, expert assistance in and max combustion pressure. When check-
the evaluation thereof should be obtained. ing the max pressure adjustment of the
2000-06-01
engine, it is therefore to be ensured that the
We recommend weekly records of the per-
existing charge air pressure is correct.
formance data of the engine plant. During
recording (Inspection sheet 2020734-6 is Fuel injection and load setting
used) the observations are to be compared The amount of fuel injected is equivalent to
continuously in orderto ascertain alterations the supplied energy and is thus an expres-
at an early stage and before these exert any sion of the load and mean effective pres-
appreciable influence on the operation of sure of the engine. The fuel pump index can
the plant. therefore be assumed to be proportional to
As a reference condition for the performance the mean pressure.
data, the shop test report for the engine or The specific fuel consumption, SFOC, (mea-
possibly the measurements taken during the sured by weight) will, on the whole, remain
sea trial from the delivery of the ship can be unchanged whether the engine is operating
used. If considerable deviations from the on HFO or on MDO, when considering the
normal conditions are observed, it will be difference in calorimetric heat value. Howev-
possible, in a majority of cases, to diagnose er, when operating on HFO, the combination
the cause of such deviations by means of a of density and calorific value may result in a
total evaluation and a set of measurements, change of up to 6% in the volumetric con-
after which possible adjustment/overhauls sumption at a given load.
can be decided on and planned.
As the engine is tested with MDO, changing
to HFO will normally result in higher loading
at the same fuel pump index.

To avoid overloading of the engine the charge Fuel valves

air pressure and turbine speed recorded at
Assuming that the fuel oil is purified and
the shop test should not be exceeded.
filtered effectively and that the engine is
At the PCS panel in the engine control room well-maintained, the operational conditions
it is possible to reduce the load by adjusting for the fuel valves and the overhaul intervals
the setting for maximum MCR load limit. will not normally be altered essentially when
Abrasive particles in the fuel oil result in operating on HFO.
wear of fuel injection pumps and fuel valve Abrasive particles in the fuel oil involve
nozzles. Effective treatment of the fuel oil in heavier wear of the fuel valve needle, seat,
the purifier can keep the content of abrasive and fuel nozzle holes. Therefore, abrasive
particles to a minimum. Worn fuel injection particles are to the greatest possible extent
pumps will result in loss of power. to be removed at the purification.
When evaluating performance data a distinc- Exhaust valves
tion is to be made between changes which
The overhaul interval for exhaust valves is
affect the whole engine (all cylinder units)
one of the key parameters when the reliability
and changes which occur in only one or a
of the entire engine is to be judged. The per-
few cylinders.
formance of the exhaust valves is therefore
Deviations occuring for one or a few cylinders extremely informative.
are, as a rule, caused by malfunctioning of
The exhaust valve temperature depends on
individual components, for example a faulty
2000-06-01
the actual maintenance condition and the

fuel valve, a burned exhaust valve, etc.
load of the engine. With correct maintenance,
Turbocharger the valve temperature is kept at a satisfac-
Service experience has shown that the tory, low level at all loads. The air supply to
turbine side is exposed to increased fouling the engine (turbocharger/air cooler) is a key
when operating on HFO. parameter in this connection.
Deposits occur especially on the guide vanes It is important for the functioning of the valves
of the nozzle ring and on the rotor blades. that the valve seats are overhauled correctly
In the long run, fouling will reduce the effi- in accordance with our instructions.
ciency of the turbocharger and thereby also The use of rotocaps ensures a uniform dis-
the quantity of air supplied for the combus- tribution of temperature of the valves.
tion of the engine. A reduced quantity of air
Inlet valves
will result in higher wall temperatures in the
combustion spaces of the engine. The operational conditions of the air inlet
valves are not altered substantially when
Detailed information and instructions regard-
using residual fuel. The rotation of the valves
ing water washing of the turbocharger are
will reduce valve seat wear.
given in chapter 18 as well as in the turbo-
charger manual.

L27/38
Engine room ventilation, exhaust gine room will involve an increased exhaust
system temperature level.
Good ventilation of the engine room and The exhaust back pressure measured after
suitable location of the fresh air intake on the turbochargers at full load must not exceed
the deck is important. Sea water in the intake 250300 mm water column. An increase in
air may cause a corrosive attack and influ- the exhaust back pressure will also cause an
ence the overhaul intervals for the exhaust increased exhaust valve temperature level
valves. and increased fuel consumption.
The fresh air supply (ventilation) to the engine
room should be minimum 1.5 times the air
consumption of the engines and possible
boilers in operation. Sub-pressure in the en-
Fig 02.3
Pressure drop
increasing:
Air filters fouled
Pressure drop
increasing:
2000-06-01
Air side of
cooler fouled.
All cylinders
Exhaust temp. increasing:
Temp difference
Air system fouled too large:
(A ir filter-blo wer-cooler). Water flow too small
Exhaust system fouled
(nozzle ring, turbine wheel).
One cylinder Decreasing charge air

pressure:
Exhaust temp increasing:
Fuel valve needs overhaul. Decreasing air amount.
Compression too low owing Fouled turbocharger,
to leakage of exhaust valve air filter or charge
or piston ring blow-by. air cooler (air side).
MBDH502.02
Evaluating performance data

Condensate
General Example
Air always holds a certain amount of water. Diesel engine 2300 kW
When the air is saturated with aqueous va-
Ambient air condition:
pour, the humidity is said to be 100% and
air temperature 35 C
there is as much water in the air as it can
relative air humidity 90 %
absorb without condensing.
Charge air temperature 50 C
The amount of water in kg/kg air can be found
from the diagram. The ability to absorb water Charge air pressure 2.6 bar
depends on the pressure and temperature As a guidance, an air consumption of 7.25
of the air. kg/kWh (Le) at full load can be used for
Amount of condensate in charge air L27/38.
receiver Solution according to diagram fig 4:
Both higher pressure and lower temperature Water content of air (I) 0.033 kg/
reduce the ability to absorb water. A turbo- kg
charged diesel engine takes air from the Max water content of air (II) 0.021 kg/kg
outside, compresses and cools it.
Amount of condensate in charge air re-
Then the air can normally not absorb the ceiver:
same amount of water as before.
2000-06-01
= (I-II) Le P
Condensation of water in the engines charge
air receiver is consequently dependent on = (0.033-0.021 ) 7.25 2300 = 205
the humidity and the temperature of the kg/h
ambient air. To find out if condensation in the Draining of condensate
charge air receiver will occur, the diagram
can be used. The phenomenon will occur on all turbo-
charged engines.
There is no risk with a small amount of water,
but to avoid overfilling of the air receiver, it
must be drained off.
The drain valve at the bottom of the air cooler
housing shall therefore be kept open.

L27/38
Amount of condensate in air tanks Ambient air temperature 35C.

The volume of condensate in the air tank is Relative air humidity 90%.
determined by means of the curve at the bot- Weight of air in tank:
tom to the right of the diagram, representing
an operating pressure of 30 bar. m = p V = 31 105 1 = 34,5 kg
R T 287 313
Example
Solution according to above diagram:
Amount of condensate in air tank:
Water content of air (I) 0.033 kg/kg
Volumetric capacity of tank (V) 1000 dm2
Max water content of air (III) 0.0015 kg/kg
Temperature in tank (T) 40C = 313 K
Amount of condensate in air tank:
Internal pressure
of tank (p) 30bar = 31105N/m2(abs) = (I - III) m
Gas constant for air (R) 287 Nm/kg K = (0.033 - 0.0015) 34.5 = 1.08 kg
Fig 02.4
Ambient air temperature (1 bar)
2000-06-01
Charge air pressure (Above atmospheric
Water content of air in kg water / kg air
Max water content

of atmosphere
in air tank
Pressure
Relative
air humidity
Charge air temperature after cooler. Air temperature in tank.

MBDH502.05 fig 1
Air temperature in tank.
Nomogram for calculation of condensate amount

Borescope inspection of cylinder liner

In order to check and evaluate the cylinder scope inspection and the necessary mea-
liner condition, a borescope inspection is rec- sures can be decided.
ommended as an easy and efficient method, Scores, polished areas or water leakage may
only by removal of the fuel injection valve. occur in one cylinder only, and it is imperative
Example: to detect which cylinder has to be opened.
Increasing lub oil consumption may be Alpha Diesel will be pleased to carry out the
caused by lacquer deposits on the liner sur- borescope inspection.
face. As the honing marks are filled with lac-
quer, it will result in loss of lub oil control.
This can normally be detected by a bore-
Fig 02.5
2000-06-01
Borescope
AINSUG
Release 1 02F1-01 page 02-33

L27/38
2000-06-01

Work card 02 101-01

Recording of engine performance data
Safety precautions Man power Tools

c Stopped engine
c Shut-off starting air Special tools
c Shut-off cooling water Working time: 1 hour Indicator (Baewert),
Handle for indicator
c Shut-off fuel oil Capacity: 1 man See plate: 1 901206
c Stopped lub oil circul.
c Select local control
Replacement and
Data wearing parts
(See chapter 00 Data)
2000-10-01
Shop test report for engine

Inspection sheet 20207346
Starting position: Engine running.
Procedure
1. Run the engine at MCR load.
2. Stabilise the engine load and keep a Note
straight course.
To obtain reliable records, the engine obser-
3. Record the performance data. vations should be recorded during calm sea,
4. Compare the data with the engine normal weather conditions and with the ship
builders shop test report. operated in normal load condition.
Release 02 101-01 page 02-35

L27/38
Your Notes:
2000-10-01
page 02-36 Release 02 101-01

06. Troubleshooting
Descripcion
Starting failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-39
Faults in fuel oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-40
Disturbances during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-41
Ignition in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-44
Faults in cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-45
Faults in lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . page 06-46
Data sheet
Values for thread tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 95 81-0
2008-01-10

L27/38
2008-01-10

Starting failures
Trouble Possible cause Troubleshooting
Air starter does not respond Empty air receivers. Charge air receivers.
when activating the star t
switch.
Valves closed. Open air valves.
Solenoid valve on air starter Check electrical connections.

does not receive 24 volt.
Emergency stop activated. De-activate emergency stop.
Turning gear engaged. Disengage the turning gear.
Pinion engages, but does not Filter at air starter blocked. Clean the filter.
turn the engine.
Low air pressure. Raise the air receiver pres-
sure.
2000-06-01
Pressure control valve is not Dismantle and repair the

working. pressure control valve.
Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
Release1 06A1-01 page 06-39

L27/38
Faults in fuel oil system

Engine turns, but ignition Stop signal to governor. Check if emergency stop is
fails. Fuel pumps are not activated.
actuated.
Overspeedstop tripped. Cancel over speed stop.
Sticking fuel pumps. Dismantle and clean.
Defective governor. See governor manual.
Check rod connection.

Check that fuel pump index-
es are equal on all pumps.
Engine turns, but no fuel is Fuel oil service tank empty. Pump oil into the tank.
injected owing to failure in fuel
2000-06-01
system.
Engine runs, but does not Air in fuel system. Start electrical stand-by
ignite on all cylinders. pump.
Worn-out fuel pump. Change fuel pumps.
Primary pressure too low. Clean fuel filter.
Water in the fuel. Drain off water.
Fuel valves or nozzles defec- Change defective fuel valves.

tive.
First ignitions are too violent. Sluggish movement of the Lubricate and mobilize rod
Engine runs erratically. fuel pump terminal shaft. connections and bearings on
the terminal shaft.
Fuel pump index too high. Check rod connection from

the terminal shaft. Check that
governor is working properly.

Disturbances during operation

Exhaust gas temperatures Increased charging air tem- Clean air cooler.
increased on all cylinders. perature due to ineffective air
cooler.
Fouling of air and gas pass- Clean air and gas passages.
ages.
Insufficient cleaning of fuel Check separator and fuel

oil or changed combustion filters.
characteristics.
Poor fuel quality. Change fuel.
Exhaust gas temperature Fuel valve or valve nozzle Overhaul fuel valve.
increased on one cylinder. defective.
Leaky exhaust valves. Check the valve clearance

2000-06-01
or
change the cylinder head.
Pressure test the cylinder by
means of special tool.
Note: This manifests itself If

by a rise in the exhaust tem- Stopping of the engine is not
perature and failing of the possible or convenient
compression and maximum
combustion pressure of the
respective cylinder. Then
The fuel pump of the cylinder
concerned should be put out
of operation by moving the
index to stop and locking it in
this position.
Damaged fuel pump cam/ Replace camshaft section

roller. and roller.

L27/38

Crankcase pressure in- Blow-by = leaky combustion Check piston rings.
creased. chamber.
Blow-by means a serious
danger of piston seizure, and
the engine must if possible
be stopped and the piston in
question pulled. Leaky piston
rings will normally result in
heavy excess pressure in the
crankcase.
If
Stopping of the engine is not
possible or convenient.
Then
The fuel pump of the cylinder
concerned should be put out
of operation by moving the
index to stop and locking it in
this position.
2000-06-01
Exhaust gas temperature Decreased charging air tem- Check the thermostatic valve
decreases on all cylinders. perature. in the cooling water system.
Exhaust gas temperature Fuel pump plunger is stick- Change fuel pump plunger/
decreases on one cylinder. ing or leaking. barrel assembly.
Engine speed decreases. Pressure before fuel pumps Raise fuel oil primary pump
too low. pressure to normal
or
check filter.
Fuel valves defective. Change defective valves.
Fuel injection pumps defec- Change or overhaul.

tive.
Water in the fuel. Drain off water from service

and settling tanks. Check
fuel oil centrifuge.
Governor defective. See governor manual.


Engine stops. Shut-down for overspeed. Check fuel pumps.
Check governor.
Check movement of regulat-
ing mechanism.
Shut-down for low lubricating Check pressostat.

oil pressure. Check lubricating oil filter.
Check lubricating oil pump.
Shut-down for high HT cool- Check HT system and pump.

ing water temp. or low HT
cooling water pressure.
Smoky exhaust. Charge air pressure too low. Clean turbine, see turbo-
charger manual.
Check air supply to engine
room.
Air supply too low. Clean air cooler.
2000-06-01
Clean air filter.

Clean compressor.
Clean turbine.
Fuel valves or nozzles defec- Check fuel valves.
tive.
Rising cooling water tem- Thermostat function. Check thermostat.
perature.
Defective pumps. Stop the engine and repair
the pumps.
Fouled cooler. Clean cooler.

Check whether steam has
developed.
Check filling at test cocks.

L27/38
Ignition in crankcase
Cause 1. Stop the engine
During running the atmosphere in the crank- 2. Leave the engine room. Shut doors and
case contains the same gases (N2-O2-CO2) keep away from them. Make ready fire-
in the same proportions as in the ambient fighting equipment.
air, but an intense spray of oil drops is slung
around everywhere. If undue friction arises
between sliding surfaces, the heated surface Warning
will cause evaporation of the lubricating oil
splashed onto it. When the oil vapours con- Do not open crankcase until 10 minutes after
dense, they form a milky white oil mist which stopping the engine. When opening up, keep
can ignite. Such ignition may be caused by clear of possible flames. Do not use naked
the same hot spot that produced the oil light and do not smoke.
mist. If a large quantity of oil mist has devel- 3. Cut off starting air. Take off all doors
oped before ignition, the burning may cause on one side of the crankcase. Set the
considerable pressure rise in the crankcase, switch on the operator panel in position
forcing the relief valves to open. LOCAL.
Every precaution should therefore be taken 4. Locate the hot spot. Powerful lamps
to avoid hot spots and discover oil mist in should be employed at once (in explo-
time. sion-proof fittings). Feel over all sliding
surfaces.
Hot spots in crankcase
2000-06-01
Overheating of bearings is a result of inad- 5. Look for squeezed-out bearing metal
equate or failing lubricating, possibly caused and discoloration by heat (blistered
by pollution of the lubricating oil. paint, burnt oil, heated steel).
It is therefore important that the lubricating 6. Prevent further heating, preferably by
oil filtration equipment is in perfect condition. making a permanent repair. Special
Checking of the oil condition by analysis is attention should be paid to ensure
recommended. lubricating oil supply and the satisfac-
tory condition of the frictional surfaces
Oil mist in crankcase
involved. It is important to replace or
The presence of oil mist may be noted at the clean the filter candles.
vent pipe which is fitted at the aft end of the
crankcase or by an oil mist detector. 7. Start electrically driven lubricating oil
Measures (in case of white oil mist). pump and check oil flow from all bear-
ings and spray pipes in crankcase while
turning the engine through at least two
revolutions.
Warning
8. Start engine. Look out for oil mist.
Keep away from doors and relief valves on
crankcase. Do not stay unnecessarily in Especially the frictional surfaces that caused
doorways near the doors of the engine room the heating should be felt over (5,15 and 30
casing. minutes after starting, and again when full
load is obtained).

Faults in cooling water system

The built-on fresh water pumps in the high
and low temperature circuits are of the cen- Note
trifugal type. They are mounted in the front- Running trouble with the pumps, apart
end box and are driven through gearwheels from mechanical faults, is most often due
from the crankshaft. to leaks in the suction line. It is therefore
The pump bearings are lubricated automati- essential that all packings and gaskets are
cally with oil from the lubricating oil system in order and that they are renewed when
of the engine. necessary. Even a tiny hole in the suction
line will reduce the pump capacity.

Oil or water flows out of the Worn shaft seals. Repair the pump.
telltale holes in the front-end
box.
The pump does not work Pump draws in air at suction Check gaskets and pipes for
2000-06-01
after start. side. tightness.

The system is not filledup. Check the level in the ex-
pansion tank.
Air cannot escape on deli- Check the venting pipe.
very side.
Leaking shaft seal. Check the shaft seal.
Pump capacity drops after Air leakages from shaft seal. Overhaul the shaft seal.
normal operation.
Fouled or worn impeller. Check the impeller.
Pump does not give maxi- Non-return valve not fully Dismantle pump and check
mum delivery. open. the non-return valve.
Defective seals. Replace the seals.
Worn impeller and worn Overhaul the pump.

wear rings.

L27/38
Faults in lubricating oil cooler

Visible leakage
Leakage Insufficient tightening. Tighten up the cooler, but not
(Phase 1) below the minimum distance
and never when the plate
heat exchanger is under
pressure or over 40C.
If the cooler is still leaky,
proceed to phase 2.
Leakage Fouled or deformed plates. Dismantle the cooler and

(Phase 2) Inelastic or deformed gas- check if the plates are de-
kets. formed or fouled. Check that
the gaskets are elastic and
non-deformed, and that the
faces of the joints are clean.
Replace deformed plates
and gaskets. Before assem-
bling clean all plates and
2000-06-01
gaskets very carefully. As-
semble the cooler and start
up again.
Note: Even tiny impurities

such as sand grains may
cause leakage.

Visible leakage
Leakage. Defective gasket. Dismantle the cooler.
(Even after tightening of the Clean the plates very care-
plate heat exchanger to mini- fully.
mum dimension) Replace the gaskets.
Assemble the cooler and
start up again.
Leakage. Defective gasket or badly Dismantle the cooler.

(Through the drain holes of corroded plate. Replace defective plates and
the gaskets) gaskets, if any.
start up again.
2000-06-01
Release 1 06F1-01 page 06-47

L27/38
Non-visible leakage
Reduced heat transmission Fouled plates or choked Dismantle the cooler and
and/or increasing pressure plate channels. check if the plates are fouled.
drop. Clean the plates very care-
fully.
start up again.
Leakage Holes in plates A suspected leakage can

(The fluids get mixed) Corrosion or fatigue fracture. be localized in the following
(Phase 1) way:
Remove the complete cooler
from the engine.
Dismantle the cooler and
check the plates very care-
fully.
Check suspected plates with
a dye penetrant.
2000-06-01
Before assembling, clean all
plates and gaskets.
check to find more defective
plates, if any, by putting one
side under press.
Install the cooler on the en-
gine and start up again.

10. Frame, bearings, oil pan covers

Description
Engine frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10-51
Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10-52
Resilient mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10-53
Work card
10 101-01 Dismantling and mounting of main bearing
and guide bearing . . . . . . . . . . . . . . . . . . . . . . . . . . page 10-55
10 102-01 Functional test of crankcase safety relief valves . . . . page 10-59
Data sheet
Guidance for replacement of bearings . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 36 66-4
Spare part plate

2008-01-10
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1010-01

Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1010-02
Oil pan - dry sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1010-03
Frame aft end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1012-01
Frame front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1012-01
Covers on frame aft view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1014-01
Covers on frame front view . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1014-01
Front end box front view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1016-01
Front end box aft view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1016-01
Covers on aft end front view . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1018-01
Covers on aft end aft view . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1018-01
Covers on aft end front view . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1018-02
Covers on aft end aft view . . . . . . . . . . . . . . . . . . . . . . . . . . . . plane 1 1018-02

L27/38
2008-01-10

Engine frame
The engine frame is made of nodular cast Fig. 10.1
Cylinder head
iron. Distribution of lubricating oil is inte- tie rods
grated in the frame to reduce the number of
pipes to be installed. To reduce the stresses
in the frame, the frame is kept compressed
by heavy tie rods from the main bearing cap Main bearing
to the top of the frame. The tie rods for the tie rods
cylinder head are deeply anchored in the
frame. Tie rods in each side stabilize the
main bearing caps. All tie rods are hydrauli-
cally tightened. The engine frame does not
hold any water.
MBD-H, 511. 01 fig 1
2000-06-01
Side tie rods
Tie rods in engine frame

L27/38
Main bearings
Fig 10.2 Well supported main bearings carry the
crankshaft with generously dimensioned
journals. The combination of the stiff box
design and the carefully balanced crankshaft
ensures a smooth and vibration free running
engine.
Note
Criteria for replacement of main bearing
shells, see Guidance for replacement of
bearings 2043666-4, see chapter 10.
1 1012-01
2000-06-01
Main bearing

Resilient mounting
The engine can be installed resiliently by Fig 10.3
means of bolted-on brackets and rubber
mounts. These are easy to implement and
do not require modification of the engine
except for installation of flexible connections.
The highly elastic rubber coupling between
engine and gearbox will permit the radial
movements.
2000-06-01
PG-L27/38 fig 5.1
Resiliently mounted engine

L27/38
2000-06-01

Work card 10 101-01

Dismantling and mounting of main bearing and guide bearing

Stopped engine
Special tools
Shutoff starting air Working time: 1 hour Turningout tool
Shutoff cooling water Capacity: 2 men Lifting handles
See plate: 1 901205
Shutoff fuel oil For each bearing Hydraulic tools
Stopped lub oil circul. See plate: 1 901215
Select local control
Replacement and
Data wearing parts
(See chapter 00 Data)
2000-11-01
Tightening specification 2049581-0 Plate no: 1 1012

Plate no: 1 1014
Starting position: Engine out of operation.
Procedure
Dismantling of main bearing Fig 10.4
1. Dismantle the crankcase covers on
both sides of the engine fore and aft of
the main bearing in question.
to pump
2. Install the hydraulic tool on the side
tie rods for the main bearing cap to be to pump
lowered. Loosen and remove the nuts

(1), see fig 10.4. Leave the the rods
in to avoid that the main bearing cap
drops down when removing the nuts
for the main bearing cap.
3. Install the hydraulic tool on the tie rods
for the main bearing cap inside the
crankcase. Loosen and remove the nut
(2), see fig 10.4.
AINS
Hydraulic tools mounted on tie rods
Release 10 101-01 page 10-55

L27/38
Fig 10.5 4. Install the lifting tool for the main bear-
ing cap, see fig 10.5.
5. Place a tackle above the handles of
the two lifting tools. Connect it to the
handle and pull tight to carry the weight
of the main bearing cap and screw the
side stay bolts out.
6. Slacken the tackle until the lifting tool
is resting against the engine frame.
7. Remove the lower bearing shell from
the bearing cap.
8. Press the tool for turning the upper
bearing half out into the lubricating oil
bore in the crank journal, see fig 10.6.
9. Turn the upper bearing half out by turn-
ing the crankshaft.
Mounting of main bearing

1. Carefully wash the new bearing in die-
Seen from above sel fuel to remove the preservation.
2000-11-01
2. Add oil to the bearing surface of the
upper bearing shell and slide it by hand
into position as far as possible. Make
sure that the bearing is placed in the
middle of the longitudinal direction of
the bearing bore.
3. If the bearing cannot be brought into
correct position by hand, the tool for
turning out the bearing can be used to
turn in the bearing. Make sure the joint
faces of the bearing shell and the frame
are in line.
AINS
4. Add oil to the bearing surface of the

Installing lifting tool on main bearing cap
lower bearing shell and place it in the
main bearing cap. Make sure the joint
faces of the bearing shell and the bear-
ing cap are in line.
5. Add molykote paste to the surface
around the hole for the side tie rods on
the main bearing cap.
page 10-56 Release10 101-01

6. Lift the bearing cap into position by 7. Fit the nuts on the tie rods for the main
means of the tackle and screw the bearing cap in the crankcase.
side studs in by hand. Add some liquid
sealing compound to the nuts to seal
against the frame and screw on the nuts
but do not tighten.
Fig 10.6
Turning out
bearing
2000-11-01
Turning in
bearing
AINS
Using turning-out tool
Release 10 101-01 page 10-57

L27/38
8. The lifting tool for the main bearing cap Dismantling of guide bearing, fig 10.7
can now be removed.
All 4 thrust ring halves are identical.
9. Install the hydraulic tools on the side
Check or replacement of the thrust rings is
tie rods and tighten with a pressure of
carried out, when checking or replacing the
400 bar and turn the nuts against the
aft main bearing.
frame.
Before lowering the aft main bearing cap, as
10. Install the hydraulic tool on the tie rods
described under Dismantling of main bear-
for the main bearing cap in the crank-
ing, the crankshaft must be moved a little
case and tighten with a pressure of
axially to make sure there is no axial force
1200 bar and turn the nuts against the
bearing cap. on the fore or aft thrust rings.
11. Release the pressure completely and Dismantling of thrust rings

rise the pressure once again to 1200 1. When lowering the main bearing cap,
bar and turn the nuts against the bear- care must be taken that the lower thrust
ing cap. rings do not drop into the oil pan.
12. Release the pressure and remove the 2. The fore and aft upper thrust rings have
hydraulic tools. come down a little at the same time
13. The hydraulic tool on the side tie rods as the main bearing cap was low ered
is now pressurized to 1200 bar and and can easily be turned out while the
the nuts are turned against the engine main bearing cap is resting in the lifting
frame. tools.
2000-11-01
14. Release the pressure completely and Installation of thrust rings
rise the pressure once again to 1200 1. The upper fore and aft thrust rings can
bar and turn the nut against the engine easily be turned in if the crankshaft is
frame. in the right axial position.
15. Release the pressure and remove the 2. Leave the two halves hanging over
hydraulic tools. the main journal with the joint faces in
horizontal position.
3. Add some grease to the back of the
Fig 10.7 lower thrust rings and place the thrust
Upper thrust ring rings on the main bearing cap. Make
sure the guide flaps are located in the
grooves machined in the bearing cap.
4. Lift the bearing cap and assemble as
described under Mounting of main
bearing.
Lower thrust ring

AINS
Guide bearing
page 10-58 Release 10 101-01

Work card 10 102-01

Functional test of crankcase safety relief valves
Stopped engine
Shutoff starting air
Shutoff cooling water Working time: hour No special tools
Shutoff fuel oil Capacity: 1 man
Stopped lub oil circul.
Replacement and
Data wearing parts
2000-11-01
Plate no: 1 1014
Procedure
Functional testing
Functional testing of the crankcase safety
relief valves cannot be performed during op-
eration of the engine, but it must be checked
during overhauls that the valve flap is mov-
able.
When painting
When painting the engine, take care not to
block up the safety relief valves with paint.
Release 10 102-01 page 10-59

L27/38
Fig. 10.8 Check of opening pressure

To check the proper opening pressure, see
fig 10.8.
1. Remove the relief valve cover from the
engine.
2. Place the cover on the floor with the
pressure area upwards.
3. Apply a weight of 26.5 kg on the pres
sure area. The relief valve must open
MBDH-511-01.00 fig 1
under this pressure.

Cover Relief valve
4. Remount the relief valve cover on the
engine.
Cover with relief valve
Warning
If the safety relief valves are actuated, the
engine must be stopped immediately, and
it must not be restarted until the cause and
the fault are detected.
2000-11-01
page 10-60 Release 10 102-01

12. Crankshaft, flywheel, turning gear

Description
Crankshaft and main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12-63
Sleeve spring vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . page 12-64
Work card
12 10101 Recording of crankshaft deflection . . . . . . . . . . . . . . page 12-65
Data sheet
Remote control turning device, complete . . . . . . . . . . . . . . . . . . drawing no 2 03 27 43-3
Spare part plate

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1210-01
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1210-02
Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1212-01
2008-01-09
Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1212-02

Vibration damper arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1214-01
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1216-01
Vulkan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1218-01
Turning gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1220-01
Turning gear manual driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1220-02
Turning gear electrical driven . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1220-03

L27/38
2008-01-09

Crankshaft and main bearings

The crankshaft, which is a one-piece forged provided with counterweights which are
component, is suspended in underslung attached to the crankshaft by means of hy-
bearings. To attain a suitable bearing pres- draulically tightened studs and nuts.
sure and vibration level, the crankshaft is
F ig 12.1
N ut
S tud
C ountelw eijht
2000-06-01
Crankshaft
Plate 1 1 1210-01

L27/38
Sleeve spring vibration damper

In a drive system with a reciprocating diesel The sleeve spring packets positioned be-
engine, attention has always to be paid to tween the inner and the outer part are com-
the influence of the torsional vibrations on pressed due to the twisting of the damper.
the system. Each spring chamber is supplied with
pressurized lub oil from the crankshaft. The
On the L27/38 engine, a so-called sleeve
hydraulic damping is generated due to the
spring damper is installed on the forward
displacement of the oil as well as due to the
end of the engine (in the front-end box). The
friction in the springs. The heat generated by
damper consists of an inner and an outer part
the damping is removed with the oil flowing
with side plates. In between, sleeve springs
through the damper.
are fitted, see fig 12.2.
Maintenance
The inner part is connected to the free end
of the crankshaft and follows the torsional After some years in operation, the spring
vibration amplitudes of the free end. The packets must be removed for inspection. See
outer part is over the springs, flexibly con- Maintenance programme major/overhaul
nected and can therefore follow the torsional inspection, chapter 00.
vibration.
The outer part together with the side plates
form an inertia mass.
2000-06-01
Fig 12.2 Sleeve spring packet
Outer
part
Inner
part
Side plate Side plate

AINS
Vibration damper

Work card 12 101-01

Recording of crankshaft deflection
Stopped engine
Shutoff starting air Special tools
Shutoff cooling water Working time: 1 hour Crankshaft deection
Shutoff fuel oil Capacity: 2 men gauge
Data Replacement and

(See chapter 00 Data) wearing parts
2001-05-01
Settings and limit values 2047749-0

Plate no: 1 9012
Crankshaft control 2020713-1
Starting position: Engine stopped. Turning gear engaged.
Procedure Fig. 12.3
1. Remove the side covers from the crank

casing.
2. Turn the crankshaft to bring the crank
web for cylinder no 1 to position 1, see
fig 12.4.
3. Place the deflection gauge in the
punch marks in the crank web, see fig
12.3.
4. Adjust the dial gauge to 0.
Distance between points of

measurement on the web Deflection gauge
for L27/38: D=113 mm
Crankshaft deflection
Release 12 101-01 page 12-65

L27/38
Fig 12.4 5. Turn the crankshaft to position 2, 3, 4

Pos 3
and 5 and read the dial gauge in each
position and fill in the form Crankshaft
control 2020713-1.
6. Repeat the procedure on the remaining
crank webs.
7. Compare the values to earlier values
Pos 4 Pos 2
taken after the sea trial.
8. Please contact us if the values exceed
the values shown in Settings and limit
values 2047749-0.
Pos 5 Pos 1
Looking forward
Turning the crankshaft
2001-05-01
page 12-66 Release 12 101-01

14. Camshaft, gear wheels, roller guides

Description
Camshaft and camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 14-69
Operating gear for valves and fuel injection pumps . . . . . . . . . . . .page 14-70
Work card
14 10101 Check of camshaft and camshaft drive . . . . . . . . . . . .page 14-71
14 10201 Inspection and replacement
of camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . .page 14-73
14 10301 Settings of camshafts for valve
and injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . .page 14-77
14 10401 Inspection of cam followers and rocker arms. . . . . . . .page 14-79
Spare part plate

Camshaft (valve camshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1410-01
2008-01-10
Camshaft (fuel injection). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1410-02

Camshaft (valve camshaft without pump drive). . . . . . . . . . . . . .plate 1 1410-03
Camshaft (valve camshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1410-04
Camshaft (valve camshaft without pump drive). . . . . . . . . . . . . .plate 1 1410-05
Drive of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1412-01
Drive of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1412-02
Cam follower and push rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 1414-01

L27/38
2008-01-10

Camshaft and camshaft drive

The engine has two camshafts. One for ac- Both camshafts are made of sections. Cam
tuation of valves and one for fuel injection. sections and journal sections are bolted
together. This design makes it possible to
Using two camshafts gives the opportunity
change a cam section through the inspection
to change the fuel injection independently of
openings in the engine frame.
the valve timing.
The camshafts are located in replaceable
The camshaft for valve actuation is located in
bearing bushes, frozen into bores in the
the exhaust side of the engine at a high level
engine frame.
in relation to the engine frame to make the
push rods as short as possible and thereby The gearwheel drive for the camshafts is
reduce the moving masses. located in the flywheel end of the engine.
Lubrication of the gears is supplied from two
The camshaft for fuel injection is located in
spray nozzles.
the manoeuvre side of the engine.
Fig 14.1
Camshaft for
2000-06-01
valve actuator
Camshaft for
fuel injection
MBDH-507.01 fig 1
Camshafts

L27/38
Operating gear for valves and fuel injection pumps

Valve operation Fuel pump operation
The valves are operated from the camshaft The fuel injection pump is operated from the
through cam followers, push rods and rocker fuel camshaft.
arms. In the lower part of the fuel pump housing
The cam follower is a lever. In one end a roller a roller guide has been integrated which
and a bushing are placed on a shaft. means that the fuel pump and roller guide
are one unit.
The shaft is installed in a press fit and se-
cured with a lock screw. A ball shaped thrust Lubricating oil from the camshaft bearing is
piece is mounted in a press fit at the same transferred through a pipe to the roller guide
end. In the opposite end of the link a bushing in the lower part of the pump.
has been frozen in. The lever is installed on
a shaft in a console above the camshaft.
Lubrication takes place through internal
bores.
Fig 14.2
2000-06-01
Rocker arm
Push rod
Fuel pump
Console
Integrated
roller guide
Pl-L17/38 Fig 9
Cam
follower
Cam follower and roller guides

Work card 14 101-01

Check of camshaft and camshaft drive
Stopped engine
Shutoff cooling water Working time: 3 hours No Special tools

2000-11-01
Starting position: Engine out of service.
Procedure
1. Dismantle the side covers at the cam Fig 14.3
shafts and the side covers at the gear
Side covers
wheel drive in the aft, see fig 14.3. camshaft
2. Check the condition of the gearwheels
while turning the crankshaft.
3. Check the surface of the cams and
the rollers while turning. Check the
tightening of all screws, see Tightening
specification 2049581-0.
4. Start the lubricating oil stand-by pump
to check the oil flow from all bearings.
5. Put the covers back on.
PG L27/38 fig 5.2
Side covers
gear wheel drive
Side covers
Release 14 101-01 page 14-71

L27/38
Your notes:
2000-11-01
page 14-72 Release 14 101-01

Work card 14 102-01

Inspection and replacement of camshaft bearings
Stopped engine
One bearing
Shutoff cooling water Working time: 4 hours Feeler gauge
Shutoff fuel oil Capacity: 2 men Extractor
See plate: 1 901201
Replacement and
Data wearing parts
See plate: 1 1012
2000-11-01
Tightening specification 2049581-0

Svee plate: 1 1410
Starting position: Covers for camshaft and gear wheel have been removed.
Procedure
Check of camshaft bearings Fig 14.4
The surface of the camshaft bearings cannot
be checked without dismantling the cam- Feeler gauge
shafts and journals. However, as long as no
visible burrs or discolouring at the circumfer-
ence of the bearing indicate serious damage,
evaluation of the bearing condition can be
done by means of a feeler gauge.
Max tolerance at the valve cam bearings is:
0.3 mm.
Max tolerance at the fuel cam bearings is:
11.10100-1847
0.35 mm, see fig 14.4.
Check of bearing tolerance
Release 14 102-01 page 14-73

L27/38
Fig 14.5 All camshaft sections in one side of the en-

gine are identical, which means that a cam-
shaft section can be installed in any position
regardless of the cylinder number. All journal
sections have locating pins to ensure the
right timing of the cam sections. This means
that the journal sections must remain in their
place as originally installed.
Replacement of bearings for valve cam-
shaft
A camshaft bearing can be replaced after
the camshaft section next to the bearing in
question and towards the engine front and
the journal section has been removed. This
AINS
means that all cam sections from the bear-

Locking screw for rocker arm shaft ing to be replaced and towards the engine
front must be moved about 12 mm towards
the engine front.
Prior to this, the rocker arms and push rods
Fig 14.6
on the cylinder heads related to the cams to
2000-11-01
be moved must be dismantled. To remove the
rocker arms, the crankshaft must be turned
until the cam followers for the rocker arms
in question are resting on the circular part
of the cams. The screw A, see fig 14.5, is
removed and the rocker arm shaft is pushed
to the side to release the rocker arms. The
push rods can now be removed.
1. Unscrew and remove all the screws in
both ends of the camshaft section to be
removed.
MBDH-507-01.05 fig 3
2. Place a screwdriver between the cam

shaft section and the journal section
in the aft end of the section to be re
Tool for removing the camshaft bearing moved and push the camshaft forward
tool is optional about 12 mm.
3. Remove the cam section.
4. Unscrew and remove all screws in the
aft end of the shaft journal and remove
it.
5. The bearing can now be extracted from
its bore by means of a tool similar to the
tool in fig 14.6.
page 14-74 Release 14 102-01

6. A new bearing must be cooled down The procedure is largely the same as for the
to at least 90C by means of liquid valve camshaft bearings. The rocker arms
nitrogen. Make sure the oil pockets are can remain in place, but the fuel pump above
in horizontal position and the bearing the cam section must be dismantled, see
is in the right position to the oil bore. work card 20 101. If the aft bearing is going
to be replaced, the gearwheel and the jour-
nal must be marked to be able to assemble
Note
the two parts in the same position as before
If the aft camshaft bearing has to be replaced disassembling.
and the engine is equipped with a fuel oil
When assembling the camshaft see Tighten-
primary pump, the pump must be removed.
ing specification 2049581-0
The aft side door must be removed and the
camshaft gearwheel dismantled from the
shaft journal. The axial guide bearing at the
aft bearing journal must be dismantled before
the journal can be removed.
Replacement of fuel camshaft bearings
2000-11-01
Release 14 102-01 page 14-75

L27/38
Your notes:
2000-11-01
page 14-76 Release 14 102-01

Work card 14 10301

Settings of camshafts for valve and injection timing
Stopped engine
Shutoff cooling water Working time: 2 hours No special tools
Shutoff fuel oil Capacity: 2 men
Replacement and
Data wearing parts
2000-11-01
Tightening specification 2049581-0 See plate: 1 1014
Starting position: Engine out of operation covers for gearwheel drive removed.
Fig. 14.7
Procedure
Valve camshaft timing
The camshaft for valve timing is adjusted
from the factory and cannot be changed,
unless the engagement of the gearwheels is
changed. The original setting is marked with
punch marks, see fig 14.7.
Injection camshaft timing
The setting of the injection timing must basi-
cally remain unchanged.
However, a minor change in the injection tim-
ing can be done by loosening all the screws
in the aft of the camshaft gearwheel and turn
MBDH-507-01.20 fig 1
the crankshaft in the direction of rotation to

delay the injection or in the opposite direc-
tion to advance the injection. See Tightening
specification 2049581-0. Marks on gearwheels
Release 14 103-01 page 14-77

L27/38
Fig 14.8 Check of injection timing

Plug screw Plug screw 1. A TDC mark on the flywheel indicates
the TDC position of piston number one
(opposite the flywheel end).
2. A second mark in front of the TDC mark
is referring to the cut-off position of the
plunger in the fuel pump.
3. To check if the injection timing for cylin
der number one is correct, the two plug
screws, fig 14.8, in the pump housing
must be removed.
4. By using a light on one side of the fuel
pump and at the same time turning the
crankshaft in normal rotation direction,
it can be observed when the plunger
MBD-H 507-01.20 fig 4
cuts off the light coming through the

pump barrel, see fig 14.8.
5. Stop turning when the light is cut off and
check if the mark in front of the TDC
2000-11-01
Use a flashlight and a mirror
to light through the pump
mark on the flywheel corre sponds
to the TDC indicator, see fig 14.9.
Fig 14.9
TDC indicator
PG Fig 6.11
Check that TDC mark corresponds

to TDC indicator
page 14-78 Release 14 103-01

Work card 14 104-01

Inspection and overhaul of cam followers and rocker arms

Stopped engine
Replacement and
Data wearing parts
2000-11-01
Plate no: 1 1616

Plate no: 1 1620
Starting position: Cyl. unit has been removed from engine. See work card 16 101.
Fig 10
Procedure
1. To be able to inspect the cam followers Remove pipe
it is necessary to gain access by re shielding and
exhaust
moving the arrangement above, see
manifold
fig 10. piece
2. The cam followers can be dismantled
after the rocker arms in the cylinder
head have been removed. Remove
cooling
To remove the rocker arms, the crank- water
pipes
shaft must be turned to a position
where the cam followers are on the Remove cover
circular part of the cams for the cylinder for valve
camshaft
unit in question. After the rocker arms
have been removed, the push rods can
be pulled out.
AINS
Gaining access to cam followers
Release 14 104-01 page 14-79

L27/38
Fig 11 3. Check the condition of the bushings in

the rocker arms and the condition of
the rocker arm shaft. Max clearance is
0.3 mm, see fig 11.
4. To get access to the cam follower, the
cover for the valve camshaft must be
removed.
Dismantle the shaft for the cam follow-
ers by removing the locking screw (1),
fig 12, and push the shaft out of the
console.
5. Check of roller, bushing and shaft: While
pressing in the spring loaded lo cating
pin, the roller shaft can be pressed out,
see fig 13.
If all parts appear in good condition,
Remove screw
16 104 fig 16.16
they can be reused, otherwise defective

parts are to be replaced.
Locking screw for rocker arm shaft 6. Check the tolerance between the shaft
and the bushing in the shaft end of
the cam follower. Max clearance is 0.3
mm.
2000-11-01
Max total tolerance between shaft,
Fig 12 bushing and roller is 0.35 mm.
Fig 13
Roller
Roller pin
Locating pin
MBDH 508-01.00 fig 2
AINS
Locking screw Remove the locating pin for the roller shaft
page 14-80 Release 14 104-01

16. Cylinder unit

Description
Cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16-83
Piston, connecting rod and cylinder liner . . . . . . . . . . . . . . . . . . . page 16-84
Work card
16 10101 Dismantling of cylinder unit from engine . . . . . . . . . . page 16-87
16 10202 Disassembly of cylinder unit . . . . . . . . . . . . . . . . . . . page 16-91
16 10301 Dismantling of piston and cylinder liner . . . . . . . . . . . page 16-93
16 10401 Inspection of inlet and exhaust valve . . . . . . . . . . . . . page 16-95
16 10501 Grinding of valve seat ring and valve spindle seat . . . page 16-99
16 106-01 Replacement of valve guide. . . . . . . . . . . . . . . . . . . . page 16-101
16 107-01 Replacement of valve seat ring . . . . . . . . . . . . . . . . . page 16-103
16 108-01 Inspection of piston . . . . . . . . . . . . . . . . . . . . . . . . . . page 16-105
16 109-01 Removal of marine head from engine . . . . . . . . . . . . page 16-107
16 11001 Inspection of connecting rod big-end bearing . . . . . . page 16-111
2008-01-10
16 111-01 Inspection and honing of cylinder liner . . . . . . . . . . . page 16-115

16 112-01 Grinding of seal faces on cylinder liner,
cylinder head and engine frame . . . . . . . . . . . . . . . . page 16-119
16 113-01 Assembly of cylinder unit . . . . . . . . . . . . . . . . . . . . . page 16-121
16 114-01 Mounting of cylinder unit in engine . . . . . . . . . . . . . . page 16-125
16 115-01 Inspection of valve rotators . . . . . . . . . . . . . . . . . . . . page 16-129
16 116-01 Check and adjustment of valve clearance . . . . . . . . . page 16-131
16 117-01 Check and overhaul of indicator valve . . . . . . . . . . . page 16-133
16 118-01 Check/adjustment of safety valve
opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16-135
Spare part plate

Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1610-01
Cooling water jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1610-02
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1610-03
Cooling water jacket with LTC ring . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1610-04
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1612-01
Piston with piston rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1614-01

L27/38

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1616-01
Safety valve and indicator valve . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1618-01
Valve guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1620-01
2008-01-10

Cylinder unit
Cylinder head Fig 16.1
The cylinder head with integrated charge air Valve rotator
receiver is made of nodular cast iron. It has Charge
air
4 valves and is of the cross flow design, to receiver
ensure a high flow efficiency. The fuel injec-
tion valve is placed in a liner in the centre.
Intensive water cooling of the nozzle tip
area makes it possible to omit direct nozzle
cooling. Gas
outlet
The cylinder head is tightened by means of Inlet
valve
4 nuts and 4 studs. The studs are screwed
Exhaus
into the engine frame. The tightening is done valve
by means of hydraulic jacks. Safety valve
The top cover has two functions. It is a cover
Cooling
for the rocker arm chamber to seal for the water
lubricating oil and a guard to cover the cyl- jacket
inder head.
2003-08-26
Air inlet and exhaust valves

The valve spindles are of heat-resistant
material and the spindle seat has welded-on
hard metal.
All valve spindles are fitted with valve rota-
tors which turn the spindles each time the
valves are activated. The turn of the spindles Valve seat
ring
ensures even temperature levels on the valve
discs and prevents deposits on the seating
surfaces.
The cylinder head has replaceable valve
seat rings. The exhaust valve seat rings are
water cooled in order to ensure low valve
temperatures.
The seat rings are made of heat-resistant
AINS
Cylinder head
steel. The seating surfaces are hardened
in order to minimize wear and prevent dent
marks.

L27/38
Piston, connecting rod and cylinder liner

Fig 16.2 Piston, see fig 16.2
The piston is of two-part design. The piston
crown is made of forged steel and the skirt
is made of nodular cast iron.
The piston has 3 piston rings and 1 oil
scraper ring.
All piston ring grooves are hardened and
placed in the piston crown.
The piston has a cooling oil space at the top,
to ensure efficient cooling of the top land and
piston ring area. Oil from the lubricating oil
system of the engine is used as cooling oil.
Plate 1 1614-01
The piston pin is floating and kept in position

by two circlips.
Piston Connecting rod of marine head design,
see fig 16.3
2003-08-26
Fig 16.3 The connecting rod and the big-end bearing
housing are made of CrMo steel.
To make it possible to pull a piston without
pulling the cylinder liner, the connecting rod
can be separated from the big-end bearing.
The big-end bearing housing is assembled
by means of two hydraulically tightened
studs.
The big end bearing shells are thin-walled
steel shells.
Note
Criteria for replacement of connecting rod
big-end bearing and main bearing shells,
see Guidance for replacement of bearings
2043666-4, see chapter 10.
Plate 1 1612-01
Connecting rod

Cylinder liner, see fig 16.4 Fig 16.4

The cylinder liner is made of cast iron.
Only the upper part of the liner is water-
cooled which gives a uniform temperature
pattern over the entire length of the liner
preventing cold corrosion.
The liner is landed on top of the engine
frame. The cooling water chamber around
the top of the liner holds the cooling water
which means there is no cooling water in the
engine frame.
To reduce bore polishing and lub oil con-
sumption, a slip-fit-type flame ring is installed
in top of the cylinder.
Plate 1 1610-01
2003-08-26
Cylinder liner

L27/38
2003-08-26
page 16-86
Work card 16 101-01

Dismantling of cylinder unit from engine

Special tools
Fixation tool for cyl. liner
and connecting rod
Stopped engine See plate: 1 901203
Shutoff starting air Lever for cooling water con
nections
Shutoff cooling water Working time: 1 hour See plate: 1 901211
Shutoff fuel oil Capacity: 2 men Fork for intermediate piece
See plate: 1 901212
Fixation tool marine head
Select local control See plate: 1 901214
Hydraulic tool
See plate: 1 901215
2003-08-26
Starting position: Engine stopped and cooled down.
Procedure Disassembling of external connections
Before dismantling 5. Dismantle the clamp connecting cylin-

der head and exhaust receiver.
1. Drain off the water from the engine.
6. Dismantle the fuel oil high pressure
2. Remove the top cover from the cylinder pipe.
head.
7. Dismantle the clamps locking the FW
3. Remove the crank case covers on connection between the cylinder
both sides of the engine. heads.
4. Remove the guard over the exhaust gas 8. Push the FW connections into the cyl-
receiver. inder head to be removed.
9. Disconnect the clamps locking the
charge air connections.
Release 16 101-01 page 16-87

L27/38
Fig 16.5 10. Push the charge air connections into

the cylinder head to be removed, see
fig 16.5.
11. Turn the piston into top dead centre.
Disconnecting connecting rod from con-
necting rod bearing
12. Install the tool for fixation of the con-
necting rod bearing, see fig 16.6.
13. Loosen the piston rod from the bearing
by means of the hydraulic tools.
AINS
14. Remove the 4 nuts.
Charge air connection
Fig 16.6
2003-08-26
Remove
nuts
AINS
Fixation of connecting rod bearing
page 16-88 Release 16 101-01

15. Install the fixing tool on both sides of the means of the hydraulic tools.
connecting rod for fixation of cylinder
17. Mount the lifting tool on top of the cyl-
liner and connecting rod, see fig 16.7.
inder head.
16. Remove the cylinder head nuts by
Fig 16.7
2003-08-26
AINS
Mounting of fixing tool
Release 16 101-01 page 16-89

L27/38
Fig 16.8 Lifting of cylinder unit from engine

18. Carefully lift the cylinder unit out of the
Hydraulic tool engine.
Note
Be careful not to harm the threads on the
4 studs on the connecting rod bearing when
lifting the cylinder unit.
19. Remove the push rods from the engine
frame.
20. Land and fasten the cylinder unit upon
the special work table, or on the floor
upon wooden supports and remove the
lifting tool.
AINS
2003-08-26
Cylinder
head
nut
Cylinder
Cylinder head
head bolt
Hydraulic tool for dismounting

of the cylinder head
page 16-90 Release 16 101-01

Work card 16 102-02

Disassembly of cylinder unit

Stopped engine Special tools
Shutoff starting air Lifting tool for cylinder head
See plate: 1 901201
Shutoff cooling water Working time: 1 hour Lifting tool for cylinder liner,
Shutoff fuel oil Capacity: 1 man Fixation tool for cylinder
liner and connecting rod,
Extractor tool for ame ring
Starting position: Cylinder unit is dismantled from engine, see work card 16 101.
2006.03.16
Procedure Fig 16.9

Fixation tool
Before the cylinder unit is dismantled, it must
be placed on the working table.
Removal of piston and connecting rod
1. Turn the unit upside down.
2. Remove the tool fixing the connecting
rod and cylinder liner.
3. Mount an eye bolt at the bottom of the
connecting rod, see fig 16.9.
4. Pull the piston and piston rod out of the
liner by means of a tackle.
MBDH-501-01.01 fig 1
5. Turn the unit back to its starting posi-

tion.
Removal of piston and piston rod
Release 16 102-01 page 16-91

L27/38
Fig 16.10 Removal of cylinder head

Allan screw
Allen screw 6. Remove all 4 allen screws see fig 16.10
keeping the cooling water jacket to the
cylinder head.
7. Mount the lifting tool on the cylinder
head, see fig 16.11.
8. Lift the cylinder head out of the cooling
11.0503-0005
water jacket.
Removal of cylinder liner from water

jacket
Cyl. head and cooling water assembly
9. Lift the cylinder liner out of the water
jacket by means of the lifting tool as
Fig 16.11 shown in fig 16.13.
Lifting tool
10. Remove the flame ring from the cylinder
liner by means of the tool shown in fig
16.12 and a scrapped piston ring.
2006.03.16
505-01.01 Holeby/cdr
Fig 16.13
Lifting tool
Removal of cylinder head
Fig 16.12 Extractor tool for

flame ring
Flame ring
Cylinder
liner
Piston ring
Removal of flame ring Removal of cyl. liner from water jacket
page 16-92 Release 16 102-01

Work card 16 103-01

Dismantling of piston and cylinder liner

Special tools
Stopped engine Lifting tool for piston
Shutoff starting air See plate: 1 901202
Lifting tool for cooling water
Shutoff cooling water Working time: 2 hour jacket and liner
Shutoff fuel oil Capacity: 2 man See plate: 1 901203
Fixation tool marine head
Select local control Hydraulic tools
See plate: 1 901215
Starting position: Complete cylinder unit has not been removed from engine.
Engine stopped and cooled down.
2003-08-26
Procedure Fig 16.14

Prepare dismantling of the cylinder head as
described in work card 16 101.
Lift the cylinder head as described in work
card 16 102.
1. Remove the push rods after the cylinder
head has been removed.
MBDH-506-01.50 fig. 2
2. Turn the crankshaft into a position

where the hydraulic tools can be in
stalled to loosen the nuts on the con
necting rod.
3. Remove the flame ring from the liner,
see work card 16 102-01 fig 16.12.
Fixation tool mounted on the marine head

and counterweight
Release 16 103-01 page 16-93

L27/38
Fig. 16.15 4. Remove the deposits in top of the

liner.
5. Remove the nuts on the connecting rod
and turn the crankshaft into TDC.
6. Install the fixation tool, see fig 16.14.
7. Install the tool for lifting of the piston,
see fig 16.15.
8. Pull the piston out of the liner and land
it on a wooden support.
9. Install the tool for lifting of the cooling
water jacket and cylinder liner, see fig
16.16.
MBDH-506-01.50 fig. 3
10. Lift the cooling water chamber and the

liner out of the engine frame.
Lifting tool for piston
2003-08-26
Fig 16.16
11.49041-0841
Lifting tool for cooling water jacket

and cylinder liner
page 16-94 Release 16 103-01

Work card 16 104-01

Inspection and overhaul of cam followers and rocker arms

Stopped engine
Shutoff cooling water Working time: 1 hour Valve spring compressing
Shutoff fuel oil Capacity: 1 man device
See plate: 1 901201
Replacement and
Data wearing parts
2003-08-26
Plate no: 1 1616
Starting position: Cylinder unit is disassembled, see work card 16 102.
Procedure Fig 16.17
1. Before the valves can be dismantled,

the rocker arms have to be removed.
2. The screw A in fig 16.17 has to be
removed before the rocker arm shaft
can be pushed out to free the rocker
arms.
AINS
Locking screw for rocker arm shaft
Release 16 104-01 page 16-95

L27/38
Fig 16.18 3. By means of the tool shown in fig 16.19,

the valve spring can be com pressed
and the cone ring removed, see fig
16.18.
a) Valve closed
4. The valve rotator and spring can now be
removed and the valve pushed out.
Fig 16.19
Remove
b) Valve spring valve
pressed down locks
AINS
2003-08-26
Tool for dismantling valves
Remove tool so valve

rotator and spring may be
c) Valve spring dismantled
completely
relieved
11.49028-0480A
Dismantling valve step a, b and c
page 16-96 Release 104-01

Inspection of valves/valve seats Fig 16.20

If the valve seat is burned or scarred, it must
be ground using a valve seat grinder, see
work card 16 105.
Inspection of valve guide
Max 20.2 mm
Too much clearance between the valve
spindle and the valve guide may cause:
y o increased lube oil consumption
y o fouling of the spindle guides resulting
in sticking valves
MBD-H, 505-01.05 fig 5

1. Clean the valve guide.
2. Inspect and measure for wear.
If the inner diameter of the valve guide Measurement of valve guide wear
measured below the O-ring exceeds
20.2 mm, the valve guide must be replaced,
see fig 16.20.
Too much clearance means insufficient
guidance of the valve spindle, and thus bad
2003-08-26
alignment between the spindle head and the

valve seat ring.
3. Change the O-ring inside the spindle
guide, see work card 16 106.
Release 16 104-01 page 16-97

L27/38
Your Notes:
2003-08-26
page 16-98 Release16 104-01

Work card 16 105-01

Grinding of valve seat ring and valve spindle seat

Stopped engine
Shutoff cooling water Working time: 3 hours Grinding machine
Replacement and
Data wearing parts
2003-08-26
Plate no: 1 1616
Starting position: Valve spindle has been removed, see work card no 16 104.
Fig 16.21
Procedure
For operation of the grinding machine, see R Grinding limit
separate instructions.
Grinding of valve seat rings
1. All valve seat rings to be ground in an
angle A of 30 +0,1
0 , see fig 16.21.
2. Grind until a clean and uniform surface

is obtained.
3. Carry out final grinding with a feed in
the direction from inside out.
4. When the seat S on the exhaust seat
ring is ground to such an extent that the
recess R disappears, see fig 16.21,
MBDH-505-01.01
the valve seat ring must be renewed,

see work card 16 107.
Valve exhaust seat ring
Release 16 105-01 page 16-99

L27/38
Fig 16.22 5. The inlet valve seat ring can be ground

until the dimension D= 100 mm has
D max = 100 mm
been reached, see fig 16.22.
Grinding of valve spindle seat
The valve spindle to be ground in an angle
of 30 -0,1
0
, see fig 16.23.
AINS
After grinding check the height H, see fig

Valve inlet seat ring
16.23. The height H must be no less than
9.0 mm.
Fig 16.23
MBDH-505-0
2003-08-26
Valve spindle
page 16-100 Release 16 105-01

Work card 16 106-01

Replacement of valve guide

Stopped engine
Special tools
Shutoff cooling water Working time: hour Drift mandrel
topped lub oil circul.
Replacement and
Data wearing parts
2003-08-26
Plate no: 1 1616
Starting position: Valve spindle has been removed, see work card no 16 104.
Fig 16.25
Procedure
If the clearance exceeds the max limit of
20.2 mm, the valve guide must be replaced.
1. Knock the valve guide out from the bot-
tom of the cylinder head by means of a
drift mandrel, see fig 16.25.
MBDH-505-01.20
Dismounting of valve guide
Release 16 106-01 page 16-101

L27/38
Fig 16.26 Mounting of valve guide

2. Clean the bore in the cylinder head
carefully.
3. The new valve guide must be cooled
down to approx 70C with nitrogen.
4. Insert the valve guide in the bore, see
fig 16.26.
5. Make sure the valve guide has come
all the way down.
MBDH-505-01.20
6. Insert a new O-ring in top of the valve

guide, see fig 16.27.
Tool for valve guides is optional.
Mounting of valve guide
Fig 16.27
2003-08-26
MBDH-505-01.20
Inserting a new O-ring in the valve guide
page 16-102 Release 16 106-01

Work card 16 107-01

Replacement of valve seat ring
Stopped engine
Special tools
Extractor
Shutoff cooling water Working time: 1 hour See plate: 1 901201
Shutoff fuel oil Capacity: 1 man Hydraulic tool
See plate: 1 901215
Replacement and
Data wearing parts
Plate no: 1 1616
2003-08-26
Starting position: Cylinder head removed from engine
Fig 16.28
Procedure
The exhaust and inlet valve seat rings are
installed in a press fit.
The seat rings can be pulled out by means
of the hydraulically operated extractor shown
in fig 16.28.
1 9012-01
Extractor
Release 16 107-01 page 16-103

L27/38
Before installing new seat rings the bores The bore for the inlet seat rings does not
in the cylinder head must be cleaned care- need any sealing compound before pulling
fully. in the seat rings.
Do not use emery paper because this will After the valve seat rings have been installed
change the tolerance of the bore. the valve seat must be ground.
Add a little sealing compound (loctite 572.) Regarding valve seat angle and max grinding
to the bore for the exhaust seat rings. limit, see work card 16 105.
Place a new O-ring on the seat ring and
lubricate with oil or copaslip.
It is not necessary to cool down the seat
rings before pulling them in by means of the
pulling deice shown in fig 16.29.
Fig 16.29
2003-08-26
AINS
Pulling device mounted on cylinder head - tool not supplied
page 16-104 Release 16 107-01

Work card 16 108-01

Inspection of piston

Stopped engine
Special tools
Shutoff cooling water Working time: 1 hour Piston ring expander tool

Weights of main components 2049269-5
2003-08-26
Plate no: 1 1614

Starting position: Cyl. unit has been removed from engine, work card 16 101.
Piston has been dismantled from connecting rod.
Procedure Piston Piston and New ring Ring

type oil scraper grooves grooves
Inspection of piston KOLBEN- ring
SCHMIDT Nominal Tolerances Max wear
At major overhauls the piston crown must be size (mm) (mm) limit (mm)
separated from the skirt and cleaned inside. If
there is any sign of wear on the joint surfaces,
Piston ring
the parts must be machined according to our 1 6 6.17 +0.03 6.42
specifications.
Piston ring
1. Remove the piston and scraper rings. 2 6 6.12 +0.03 6.37
2. Clean the piston. Piston ring
3
6 6.12 +0.03 6.37
Scraper
8 8.04 +0.03 8.17
ring
Nominal size, new ring groove tolerance

and max wear limit for ring grooves
Release 16 108-01 page 16-105

L27/38
Fig 16.30 3. Check the ring grooves for wear, see

fig 16.30.
Clearance ring/groove
4. Separate the piston crown from the
skirt.
5. Clean the inside of the piston crown.
0.45 resp. 0.40 mm
maximum clearance with
new piston rings
Note
At each engine overhaul:
y The piston and scraper ring must be
replaced.
y The cylinder liner must be honed ac-
0.20 mm maximum
cording to work card 16 111.
clearance with new y For position and fitting of piston rings
scraper rings
refer to workcard 16 113 and spare part
plate 1 1614.
Assembling of piston, fig 16.31
Wear limits for ring grooves
1. Check the tightening of the 4 studs with
2003-08-26
a torque of 40 Nm.
Fig 16.31 2. Fit a new O-ring on the piston skirt and
add some oil to it.
3. Assemble the piston crown and skirt.
4. Fit the thrust pieces and lubricate the
threads and the nuts with molycote
paste type G-n plus.
5. Tighten the nuts crosswise with a
Thrust torque of 67 Nm.
piece
6. Loosen the nuts again.
Nut
7. Check the tightening of the studs with
Stud a torque of 40 Nm.
8. Tighten the nuts crosswise with a
torque of 20 Nm.
9. Turn each nut 90 crosswise.
11.03455-3412
Piston sectional view Note

The nuts must not turn further when a torque
of 54 Nm is applied.
page 16-106 Release 16 108-01

Work card 16 109-01

Removal of marine head from engine

Stopped engine
Fixation tool for marine
Shutoff cooling water Working time: hour head, Guide beam
Shutoff fuel oil Capacity: 2 men See plate: 1 901214
Hydraulic tools
See plate: 1 901215

2003-08-26
Plate no: 1 1612
Fig 16.32
Procedure
Condition: Piston and connecting rod has
been removed and the fixation tool is in- Fixation tool
stalled, see fig 16.32.
AINS
Fixation of connecting rod bearing
Release 16 109-01 page 16-107

L27/38
Fig 16.33 1. Turn the crank through to about TDC.

2. Install the brackets in the lower end of
the crankcase opening, see fig 16.33.
3. Place the guide beam on the brackets
and secure it by means of the screws,
see fig 16.34.
Bracket installed
2003-08-26
Fig 16.34
Guide
Bracket
AINS
Placing of guide beam
page 16-108 Release 16 109-01

4. Turn the crankshaft to the position

shown in fig 16.35 and remove the nuts
by means of the hydraulic tool.
Fig 16.35
2003-08-26
AINS
Removal of nuts
Release 16 109-01 page 16-109

L27/38
5. Install the slide piece as shown in fig 8. Remove the bearing shells from each
36 and remove the bracket. marine head half.
6. Turn the crankshaft to make the marine Mounting of marine head
head rest against the beam, see fig
Mounting is carried out in reverse order
16.36.
of the above. See Tightening specification
7. Pull out the two halves of the marine 2049581-0.
head.
Fig 16.36
Slide piece
2003-08-26
AINS
Marine head with slide piece
page 16-110 Release 16 109-01

Work card 16 110-01

Inspection of connecting rod big-end bearing

Stopped engine
Special tools
Lifting handles
Shutoff cooling water Working time: 1 hour Fixation tool
Hydraulic tool marine
Stopped lub oil circul. head
Select local control See plate: v1 901215

Guidance for replacement of bearings 2043666-4
2003-08-26
Plate no: 1 161

Starting position: Crankcase opened.
Fig 16.37
Procedure
Check of connecting rod bearing shells Crews Holder
1. Turn the crankshaft into top dead cen-
tre.
2. Install the lifting tool with two screws on
each side of the connecting rod bearing
MBDH-506-01.30 fig 1
housing. The upper screw is screwed

into the upper bearing hous ing and the
other into the lower bearing housing,
see fig 16.37.
Mounting of holders on the marine head
Release 16 110-01 page 16-111

L27/38
Fig 16.38 3. Loosen the two nuts (1) on the marine

head, by means of the hydraulic tool,
see fig 16.41.
4. Remove the hydraulic tool and then the
nuts (1) and studs (2), see fig 16.41.
5. Fit the two pipes for lifting, see fig
16.38.
6. Pull upwards in the two lifting pipes to
carry the weight of the lower bearing
housing while removing the upper
Step 1 screws from the lifting tools.
MBDH-506-01.30 fig 2
7. Lower the bearing cap until the lifting

pipes are resting on the engine frame.
8. The lower bearing shell can now be re
Step 2
moved, see fig 16.38.
9. Install the inspection bracket, see fig
16.39.
10. Slowly turn the crankshaft until the up-
per part of the bearing housing is rest-
ing on the bracket and secure it with a
2003-08-26
Lowering marine head bearing cap
with lifting handles screw, see fig 16.39.
11. Turn the crankshaft until it is possible
to remove the upper bearing shell, see
fig 16.40.
Fig 16.39 Inspection of bearing shells
See Guidance for replacement of bearings
Fixation tool
2043666-4.
Installation of bearing shells
12. Carefully clean the joint faces, the bore
and the bearing shells.
13. Install the upper bearing shell. Make
sure the ends of the bearing shell are
flush with the ends of the bearing cap.
MBDH-506-01.30 fig 3
14. Add some clean engine oil to the crank

journal.
Screw for securing marine

head and inspection bracket
Mounting of the inspection bracket
page 16-112 Release 16 110-01

15. Turn the crankshaft until the journal Fig 16.40

has contact with the bearing, see fig
16.40.
16. Remove the inspection bracket.
17. Turn the crankshaft into top dead cen-
tre.
18. Install the lower bearing shell. Make
sure the ends of the bearing shell are
flush with the ends of the lower bearing
cap.
MBDH-506-01.30 fig 4
19. Add some clean engine oil to the bear
ing shell.
20. Lift the lower bearing cap up against
the upper and fit the two screws to in
terlock the two bearing houses.
Removal of the upper marine head
21. Mount the two assembling studs and fit bearing shell
the nuts.
22. Install the hydraulic tool and tighten,
2003-08-26
see fig 16.41 and Tightening specifica Fig 16.41

tion 2049581-0.
AINS
Hydraulic tool
Release 16 110-01 page 16-113

L27/38
Your notes:
2003-08-26
page 16-114 Release 16 110-01

Work card 16 111-01

Inspection and honing of cylinder liner

Stopped engine


Settings and limit values 2047749-0 Plate no: 1 1610
2003-08-26
Starting position: Piston and connecting rod removed.
Fig 16.42
Procedure
Measuring of cylinder diameter
At any overhaul of the cylinder unit it is very
important to know the condition of the cylin-
der liner.
The inside diameter of the cylinder liner is
measured in 3 levels, see fig 16.42.
The measurements are taken in both trans-
verse and in longitudinal direction.
Max acceptable diameter is 270.4 mm after
honing.
MBDH-506-01.35 fig 1
Max acceptable ovalness after honing is

0.05 mm.
Measuring points
Release 16 111-01 page 16-115

L27/38
Fig 16.43 Honing of cylinder liner

Before honing the cylinder liner must be
cleaned and deposits in the top must be
removed.
The honing must be done with a honing ma-
chine and not a honing brush.
Honing procedure (plateau honing)
The honing angle is 60 5
The honing marks must be of equal depth in
both directions and equidistant.
The surface must be free of smeared material
and free of polished areas.
Roughness:
Rmax = 1216 m
Rz = 610 m
Honing device for cylinder liner (Ra = 1.31.6 m)
tool not supplied
Measuring guidance:
2003-08-26
Measuring length = 5 mm
Fig. 16.44
Cut-off value = 0.8 mm
Plateau area = 5070%
Plateau area to be measured 1.5 m below
the top line.
After the honing, the liner must be carefully
cleaned with gas oil. Make sure that all
MBDH-506-01.35 fig 3
abrasive particles are removed.
Angle between honing grooves
page 16-116 Release16 111-01

Measurement of cylinder liner

Ships name Inspec Sign
date
Engine no Running hours
Engine type Fuel type
Cyl no 1 2 3 4 5 6 7 8 9
Ident no
Running hours
Lengthwise A
mm B
C
Crosswise A
mm B
C
Liner temp C
2003-08-26
Remarks
Release 16 111-01 page 16-117

L27/38
Your notes:
2003-08-26
page 16-118 Release 16 111-01

Work card 16 112-01

Grinding of seal faces on cylinder liner, cylinder head and engine
frame

Stopped engine
Special tools
Shutoff cooling water Working time: hour Grinding tool
Starting position: Disassembly of cylinder unit, see work card 16 102.

2003-08-26
Procedure Fig. 16.45

The grinding tool is used for grinding of the
seal face on the cylinder head, the cylinder
liner and the engine frame.
The intention with the grinding is to ensure
a proper sealing between mating faces in
connection with major overhaul.
If severe damage or corrosion is observed,
a machining of the sealing faces may be
required.
In this case please consult us.
Note Grinding tool
Clean all parts carefully after grinding.
Release 16 112-01 page 16-119

L27/38
Fig 16.46 Fig 16.48

MBDH-506-01.45 fig 2
Grinding tool used on cylinder liner MBDH-506-01.45 fig 4

Grinding tool used on cylinder head
Fig 16.47
2003-08-26
MBDH-506-01.45 fig 3
Grinding tool used on engine frame
page 16-120 Release 16 112-01

Work card 16 113-01

Assembly of cylinder unit

Stopped engine Special tools
Piston ring expander, Lifting
Shutoff starting air tool for piston, Guide ring
Shutoff cooling water Working time: 1 hour for piston
See plate: 1 901202
Shutoff fuel oil Capacity: 1 man Lifting tool for cyl. liner
Stopped lub oil circul. Fixation tool for cyl. unit and
con. rod
See plate: 1 901203

2003-08-26

Weights of main components 2049269-5 Plate no: 1 1616
Starting position: Cylinder unit dismantled, see work card no 16 102.
Fig 16.49
Procedure
1. Place the water jacket on the work
table.
2. Place a new O-ring (1) on the cylinder
liner and oil it.
3. Install the cylinder liner in the water
jacket by means of the lifting tool for
the liner, see fig 16.49.
AINS/ 11.49023-0272
Lifting tool for cylinder liner
Release 16 113-01 page 16-121

L27/38
Fig 16.50
Note
The liner can be marked in two different ways:
Either the letters ASin top of the liner or a
groove below the largest diameter. Be sure
the marking on the cylinder liner points to-
wards the exhaust side of the cooling water
jacket.
Mounting of piston
Machined
4. Place the piston guide ring on the cyl-
inder liner.
AINS/ 11.49023-0272
groove
5. Install the lifting tool on the piston crown

and lift the piston.
6. Install the piston rings using a piston
ring expander.
Marking of liner
7. Lubricate the piston rings and the in
side of the liner.
8. Slowly lower the piston into the cylinder
2003-08-26
liner.
Fig 16.51
Note
Make sure the mark AS on the top of the
piston is pointing in the same direction as
the cylinder liner.
9. Install the fixation tools to lock the con-
necting rod and cylinder liner.
10. Remove the lifting tool from the piston
crown.
11. Place the seals 1, 2, 3, 4, 5 and the
Lmina 1 1610-01
flame ring 6 as shown in fig 16.51.
Mounting of seals in cylinder unit
page 16-122 Release16 113-01

12. Install a new O-ring (1) at the bottom Fig 16.53

of the cylinder head, see fig 16.53.
Before landing the cylinder head on top of the
liner, make sure the exhaust gate is pointing
in the right direction.
13. Install and tighten the 4 long allen
screws, see fig 16.52. Tightening
specification 2049581-0 in chapter 00
Data.
Fig 16.52
AINS
Allen screws
Mounting O-ring on cylinder head bottom
Fig 16.54
2003-08-26
11.05603-0005
IInstall allen screws

AINS/11.49032-0186
Cylinder unit mounted on table
Release 16 113-01 page 16-123

L27/38
Your notes:
2003-08-26
page 16-124 Release 16 113-01

Work card 16 114-01

Mounting of cylinder unit in engine

Special tools
Stopped engine
Lifting tool for marine head
Shutoff starting air See plate: 1 901201
Shutoff cooling water Lever tool for cooling water
Working time: 1 hour
connection
Stopped lub oil circul. Fork for intermediate piece
See plate: 1 901212
Select local control Hydraulic tools
See plate: 1 901215

2003-08-26
Tightening specification 2049581-0 See plate: 1 1012

Weights of main components 2049269-5 See plate: 1 1610
See plate: 1 3016
Starting position: Cylinder unit is completely assembled.

Valve gear of respective cylinder is in position valve closed
Fig 16.58
Procedure
Before installing the cylinder unit, the joint
faces must be cleaned carefully and the
crank throw with marine head must be turned
into top dead centre. See the marks on the
Lmina 1 1012-01
flywheel.
Installation of cylinder unit
1. Place a new seal (1) around the hole for
push rods in the frame, see fig 16.58.
Connecting piece for rocker arm lubrication
Release 16 114-01 page 16-125

L27/38
Fig 16.59 2. Fit new O-rings (2) on the lubricating

oil connection tube for rocker arm lu
Lifting tool
brication and install it in the connecting
piece (3).
3. Replace O-ring (4) under connecting
piece.
4. Place new O-rings on the cooling water
connecting sleeves. Lubricate the O-
rings with grease and install the sleeves
in the cooling water bores pointing
to the aft of the engine. Press in the
sleeves as far as possible.
Replace the O-rings on the cooling
water sleeves belonging to the cylinder
head in front of the unit to be installed
and press in the sleeves as far as pos-
sible. See fig 16.64.
5. Place new O-rings on the charge air
connecting sleeves. Lubricate the O-
rings with grease and press the
2003-08-26
sleeves into the charge air bore in the
AINS
cylinder unit to be installed, and the unit

on the engine.
6. Slowly lower the unit into the engine
frame.
7. Make sure that the connecting rod lands
on the marine head without harming
Installation of cylinder unit
the threads on the studs.
Fig 16.60 8. Remove the fixation tools from the unit,
see fig 16.60.
9. Lubricate the 4 studs on the marine
head with engine oil and install the 4
nuts. Tighten by using a tommy bar.
Note
Check that the IMO marks on the marine
head and connecting rod are pointing in di-
rection of the exhaust side.
AINS
Remove fixation tools
page 16-126 Release 16 114-01

Tightening of connecting rod to marine Fig 16.61

head
Hydraulic tool
10. Install the hydraulic tools and tighten.
Tightening of cylinder head
11. Lubricate the threads on the cylinder
head studs with engine oil.
12. Fit the cylinder head nuts and make
sure they turn easily and tighten with
a tommy bar.
13. Install the hydraulic tools on the cylinder
head studs as shown in fig 16.61.
14. Make sure the slot in the lower end of Cylinder head nut
the distance tube is pointing in a direc
Cylinder head bolt
tion where it is possible to use the
tommy bar. Cylinder
16 101 fig 3
head
Hydraulic tool for mounting of cylinder

Note head nuts
If new studs or nuts are fitted, the assembly
2003-08-26
must be tightened and loosened three times, Fig 16.62

in order to compensate for deformation of the
threads and in order to ensure a safe load
of the studs.
Mounting of push rods
15. Remove the screw on top of the rocker
arm shaft, see fig 62.
16. Push out the rocker arm shaft and re
move the rocker arms.
AINS
17. Place the push rods on the cam fol

lower. Locking screw for rocker arm shaft
18. Remount the rocker arms and secure Fig 16.63

the shaft with the screw shown in fig
16.62.
Assembling of connections
19. Mount the clamp for assembling of
cyl inder head and exhaust pipe, see
fig 16.63.
AINS
Correct mounting of clamps
Release 16 114-01 page 16-127

L27/38
20. Push the connecting sleeves for water 21. Secure the connections with the clamps
and charge air into the bores in the and screws belonging to them.
adjacent units.
Fig 16.64
Normal operation
Water
outlet
Water
inlet
2003-08-26
Lever tool
Remove for
overhaul
O-rings
O-rings
O-rings
PI-L27/38
O-rings
Cooling water connection between cylinder units
page 16-128 Release 16 114-01

Work card 16 115-01

Inspection of valve rotators

Stopped engine
Replacement and
Data wearing parts
2003-08-26
Plate no: 1 1616

Plate no: 1 1620
Starting position: Engine stopped.
Procedure
Valve rotators are installed on all 4 valves in 16.24.
the cylinder head. The function of the valve 4. Stop the engine, and re-install the valve
rotators is of greatest importance for the
lifetime of the valves. Non-functioning valve
rotators must be exchanged.
Fig 16.24
At every overhaul of the cylinder head, the
valve rotators must be checked. Indicator mark
Function test
1. Remove the valve covers from the cyl-
inder heads.
2. Start the engine and let it run idle speed
to avoid oil splash.
3. Watch the indicator mark on top of the
11.11439-0101.0
valve rotator and see that it moves a little

each time the valve is activated. See fig
Valve rotator
Release 16_115-01 page 16-129

L27/38
Your notes:
2003-08-26
page 16-130 Release 16_115-01

Work card 16 116-01

Check and adjustment of valve clearance

Stopped engine
Special tools
Shutoff cooling water Working time: hour Valve feeler gauge,

Settings and limit values 2047749-0
2003-08-26

Plate no: 1 1620
Starting position: Cover for rocker arm removed.

Fig 16.55
Procedure
Valve bridge adjustment
Before adjusting or checking the valve clear-
ance, it has to be checked that the valve
bridge (6) is in contact with both valves si-
multaneously, see fig 16.55.
1. Engage the turning gear and turn the
crankshaft until the cam followers for (Valve bridge)
valve operation rest on the circular
part of the cams for the cylinder head
in question.
2. Loosen the nut (1) and turn the adjust
ing screw (2) a few turns anticlockwise,
see fig 16.55.
3. Do likewise to nut (3) and screw (4).
AINS
Loosen the nut and adjustment screw
Release 16 116-01 page 16-131

L27/38
Fig 16.56 4. Check that the valve bridge (6) rests on

top of the valve opposite the adjusting
screw (4), see fig 16.56.
5. Turn the adjusting screw (4) clockwise
until the thrust piece (5) on the adjust
ing screw is in contact with the valve
(Thrust
stem.
piece)
6. Tighten the nut (3). Tightening torque:
200 Nm. Check that the valve bridge
still is in contact with both valve stems
(Valve
bridge simultaneausly.
AINSP
Adjustment of valve clearance (cold en-

gine)
Clearances for inlet and outlet valves are
the same.
1. Place a feeler gauge size 0.7 mm be
tween the valve bridge (6) and the
thrust piece on the adjusting screw (2),
Valve bridge
see fig 16.55.
2003-08-26
2. Turn the screw (2) clockwise until there
is contact between the valve bridge,
feeler gauge and thrust piece on the
Fig 16.57 screw (2).
1 (nut) 3. Tighten the nut (1). Tightening torque:
2 (screw) 200 Nm.
3 (nut) 4. Check that the clearance is still 0.7 mm
4 (screw)
Feeler gauge
AINSP
Loosen the adjustment screw on the rocker arm
page 16-132 Release 16 116-01

Work card 16 117-01

Check and overhaul of indicator valve

Stopped engine

Replacement and
Data wearing parts
Plate no: 1 1618
2003-08-26
Starting position: Engine stopped.
Procedure
Description
Under normal working conditions the indi- the indicator is tight so that the parts are
cator valves require very little maintenance. not overheated and damaged. It is therefore
However, to minimize toxic gases in the important that the valve connecting surface
engine room and to keep the engine and is in good condition.
engine room clean, it is necessary to keep
the indicator valves tight.
Warning
Also, when taking combustion pressures/ In connection with check of indicator valves,
diagrams, it is important that the mechanical be aware of hot surfaces and possible dis-
connection between the indicator valve and charge of hot gasses.
Release 16 117-01 page 16-133

L27/38
Fig 16.65 Check of indicator valve, see fig 16.65.

1. Visually inspect the valve cone for dam-
age.
Valve cone
2. Ensure that all indicator valves are
closed.
3. Start and run the engine.
4. Observe that the indicator valve is not
leaking.
5. Shortly open the valve and close it
again.
6. Observe if there is a leakage from the
1 1618-01
indicator valve.
7. If the indicator is leaking, stop the en
gine and replace the indicator valve.
2003-08-26
Indicator valve
page 16-134 Release 16 117-01

Work card 16 118-01

Check/adjustment of safety valve opening pressure

Stopped engine
Special tools
Shutoff cooling water Working time: hour Calibrated high pressure
Capacity: 1 man testing equipment
Shutoff fuel oil
(not supplied)
Replacement and
Data wearing parts
Plate no: 1 1618
2003-08-26
Starting position: Engine stopped. Respective side covers on engine manoeuvre

side dismounted.
Procedure
For safety reasons, the safety valves are
normally checked/adjusted at an authorised Note
workshop in connection with overhaul of In connection with check of safety valves,
cylinder heads. do not increase the test pressure to more
However, it is possible to check/adjust the than 250 bar.
valves on board if calibrated high pressure
testing equipment is available. Blow off pressure
for L27/38 is: 230 bar +7 bar at 20 C.
Warning
When using hydraulic equipment, protective
goggles and gloves MUST be used.
Release 16 118-01 page 16-135

L27/38
Fig 16.66 1. Dismount the safety valve.

2. Connect the safety valve to a cali brated
high pressure testing device.
3. Slowly increase the pressure until the
safety valve blows off. Observe the
blow-off pressure and compare with
the factory setting.
4. If necessary, adjust the blow off pres
sure, see fig 16.66:
Remove lead seal (2) and securing
1
wire (3).
Loosen and remove locking screw
(4).
Adjust the blow off pressure by tur
2 ning the outer bushing (1).
Repeat step 3. until the correct low
3
off pressure is reached.
Drill a securing bore for locking
4 screw (4).
Mount locking screw (4).
2003-08-26
Secure locking screw with locking
wire and lead seal.
5. Mount the safety valve with a new gas-
ket.
6. Mount the side covers.
AINS
Safety valve
page 16-136 Release 16 118-01

18. Turbocharger
Description
Turbocharging, charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . page 18-139
Turbocharger See separately supplied manual
Work card
18 101-01 Cleaning of charge air cooler. . . . . . . . . . . . . . . . . . . page 18-141
18 10201 Cleaning of turbine, dry-cleaning . . . . . . . . . . . . . . . . page 18-145
Spare part plate

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-01
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-02
Wastegate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-03
Charge air bypass arrangement . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-04
Mounting off control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-05
2008-01-10
Turbocharger TCR20, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1810-06

Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1812-01
Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1812-02
Charge air connection TC/AC. . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1814-01
Charge air connection AC/Receiver . . . . . . . . . . . . . . . . . . . . . . . plate 1 1814-04
Charge air receiver drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1814-05
Charge air connection AC/Receiver . . . . . . . . . . . . . . . . . . . . . . . plate 1 1814-06
Exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1818-01
Exhaust pipe 170 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1818-04
Exhaust, manifold to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1818-05
Turbocharger turbine cleaning valve. . . . . . . . . . . . . . . . . . . . . . . plate 1 1820-01
Compressor cleaning, arrangement . . . . . . . . . . . . . . . . . . . . . . . plate 1 1822-01
Compressor cleaning, arrangement . . . . . . . . . . . . . . . . . . . . . . . plate 1 1822-02
Exhaust outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1824-01
Exhaust compensator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 1826-01

L27/38
2008-01-10

Turbocharging, charge air cooler

The turbocharging system is based on the The two-stage design provides the possibility
constant pressure principle, using the radial- of utilizing a high percentage of the engine
flow type MAN B&W NR/S turbo-chargers, heat loss for other purposes such as fresh-
lubricated from the engine lub oil system. water generation and heating.
A by-pass connection is arranged from the
turbocharger air outlet to the gas inlet side Fig 18.1
in order to increase the charge air pressure
at part load and thus minimising exhaust
smoke. By-pass
For certain operating conditions requiring

high engine torque at reduced engine speed,
a waste gate arrangement will be incorpo-
rated in the exhaust system.
The charge air cooler is a compact two-stage Waste-gate
plug-in unit. The high temperature water
passes the first stage and the low tempera-
PI-L27/38 Fig 11
ture water is passed through the second

stage of the cooler. Turbocharger by-pass/waste
gate arrangement
2001-08-06
Fig 18.2
Air flow
Outlet
HT
Inlet Outlet
LT
Inlet
MBD-H
Charge air cooler
Release 18A1-01 page 18-139

L27/38
2001-08-06
page 18-140 Release 18A1-01

Work card 18 101-01

Cleaning of charge air cooler

Stopped engine
Special tools
Shutoff cooling water Working time: 2 hours Lifting tool


2001-08-06
Plate no: 1 1812
Procedure
The air cooler is normally cleaned if obser- Fig 18.3
vations prove that the cooler efficiency has
dropped. Do not remove
To clean the cooler on the air and the water

side, it must be dismantled from the en-
gine.
Dismounting
Before the cooler can be dismantled, the
instrument panels must be removed.
1. Unscrew and remove the multiple plug
in the bottom of the instrument pan-
11.32200-0971.A
els.
2. Remove the plate with the instrument
panels from the air cooler.
3. Remove all allen screws from the end
cover of the cooler, except for the 8
End cover of cooler
screws shown in fig 18.3.
Release 18 101-01 page 18-141

L27/38
4. Fit the lifting tool on the 4 studs on

which the instrument panel was in
stalled, see fig 18.4. Note
The greatest care must be taken when
5. Hook on a chain block to the lifting tool, handling the cooler insert. Make sure not
but keep the chain slack. to bend any of the lamellas on the tubes.
6. Press out the cooler insert about 30 If by accident some of the lamellas have
millimetres with the dismantling been bent they must be straightened again,
screws. otherwise the air flow through the cooler will
be reduced and change the performance of
7. Lift the cooler with the chain block, pull it
the engine.
out and land it on a wooden support.
8. Remove the end covers and the side Assembling after cleaning
plates, see fig 18.6. 1. Reinstall the side plates and the end
9. Clean the pipes inside and be sure all covers with new gaskets and a new
deposits have been removed. Use a O-ring, see fig 18.6.
suitable cleaning agent to clean the 2. Pressure test the cooler to see if any
lamellas. of the tubes are leaking. If some pipes
are leaking where the tubes are ex-
panded into the tube plates, they can
Fig. 18.4 possibly be repaired by re-expanding
the tubes. Otherwise, the tubes must
be plugged.
2001-08-06
3. Fit new O-rings on the cooling water
connecting tubes, fig 18.5 and add
some acid free grease to the O-rings.
4. Install the connecting tubes in the bores
inside the aft-end box, see fig 18.5.
5. Put some liquid sealing compound on
the surface against which the insert is
going to be tightened.
6. Lift the cooler insert with the lifting tool
Crankshaft and carefully push it into the cooler
housing and press it in as far as pos-
sible.
7. Because of the O-rings on the connect-
ing tubes and the O-ring on the cooler,
the cooler does not go all the way in,
PG-L27/38 Fig 4.25
therefore it must be pressed into final

position by 4 long screws.
8. Install and tighten all screws with a
torque of 140 Nm.
Lifting tool mounted on charge air cooler
page 18-142 Release 18 101-01

Fig 18.5
11.32200-0971.A
Cooling water connecting tubes
Fig 18.6
2001-08-06
O-ring
1 1812-01
Charge air cooler
Release 18 101-01 page 18-143

L27/38
Your notes:
2001-08-06
page 18-144 Release 18 101-01

Work card 18 102-01

Cleaning of turbine, dry-cleaning

Stopped engine
Shutoff cooling water Working time: hour Dry cleaning device
Capacity: 1 man See plate: 1 901213
Shutoff fuel oil
Starting position: Engine in operation min 75% loaded.

2001-08-06
Procedure
Dry cleaning 3. Connect to the working air system (4).
The device is connected immediately before 4. Connect the dry cleaning device to
the TC gas inlet. valve (1) and open valve (3). Then open
Appropriate cleaning materials are granu- valve (1) slowly until a hissing sound
lates from nut shells or activated charcoal of indicates that the granulate is being
a grain size of 1 mm (max 1.5 mm). injected. Injection period: Approx 2 min
Cleaning sequence or until the container is emtpy.
Please also consult the instruction plate on
the engine. Fig 18.7
The cleaning is to be carried out at high en-
gine load, min 75% MCR. Air
supply
1. Before connecting the cleaning device
(see fig 18.7), open the stop valve
(1) and check that the passage is not
blocked. Close the valve again.
2. Fill the container (2) with granulate.
The amount depending on the type of
turbocharger:
1 1820-01
NR24/S, NR26/R 0.4 litres

NR29/S 0.5 litres
Dry cleaning device connected to blow-in valve
Release 18 102-01 page 18-145

L27/38
Note
If vibrations occure after cleaning the turbine
it is necessary to repeat the cleaning proces
until no vibrations are observed.
2001-08-06
page 18-146 Release 18 102-01

20. Fuel oil system

Description
Fuel oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20-149
Fuel oil system MDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20-150
Fuel oil system HFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20-152
Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20-156
Work card
20 101-01 Dismantling/installation of fuel injection . . . . . . . . . . . page 20-159
20 102-01 Disassembly/reassembly and repair
of fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . page 20-163
20 103-01 Overhaul of fuel valve . . . . . . . . . . . . . . . . . . . . . . . . page 20-169
Spare part plate

Fuel oil prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2010-04
2008-01-10
Cover if no fuel oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2012-01

Fuel oil primary pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2012-05
Fuel oil filter, MDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2014-01
Fuel oil filter duplex, HFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2014-02
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2016-01
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2016-02
Starting air pipes on pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2016-03
Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2018-01
Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2018-02
High pressure fuel oil pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2020-01
Fuel oil pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2020-02
Fuel oil pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2020-03

L27/38
Starting air receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2620-03
2008-01-10
Lub oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2812-01
Lub oil pressure regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-01
Double check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-02
Pressure relief pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-03
Lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2816-01
Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2818-01
Lubricating oil thermostatic valve . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2820-01
Lubricating oil thermostatic valve manual overdrive . . . . . . . . . . . plate 1 2820-02
Lubricating oil pipes on fuel injection pumps . . . . . . . . . . . . . . . . plate 1 2824-01
Lubricating oil pipes from turbocharger . . . . . . . . . . . . . . . . . . . . plate 1 2824-02

Fuel oil system

General
Depending on fuel oil quality the engine can be equipped with different types of equipment.
MDO HFO
For operation on MDO (Marine Diesel Oil), For operation on HFO (Heavy Fuel Oil), the
the standard engine is equipped with built- standard engine is equipped with built-on:
on: Fuel oil duplex slit filter
Fuel oil primary pump Fuel oil back pressure valve
Double filter with paper inserts Lubrication of fuel oil pumps
Lubrication of fuel oil pumps Uncooled fuel injection valves
Fuel oil pumps with leak oil seal The built-on equipment is designed for use
Uncooled fuel injection valves on fuel oil modules, normally referred to as
booster modules. For multi engine installa-
The MDO built-on equipment is designed for
tions, a common fuel oil feed system should
single engine installation. For multi engine in-
cover all engines.
stallations, it is recommended to have either
separate fuel supplies or the built-on pumps
HFO quality
2000-11-22
have to be replaced by electrical pumps.

We recommend to use heavy fuel up to 380
cSt/50C, even though the engine is designed
for operation on HFO up to 700 cSt/50C, de-
pending on the actual fuel quality.
For fuel oil quality, see Quality Requirements
D365600E/D365692E.
The maximum injection viscosity is 1214
cSt.

L27/38
Fuel oil system MDO

Fig 1
LAL
To sluge
To sluge
LSH
1425
2000-11-22
bunker/setting tank
PT PT
bunker/setting
1424 1423
Return to
To fuel oil drain tank

From
tank
PSL
1421
Item Description Connections:

B1 Fuel oil primary pump suction
1 Prefilter for purifier B3 Fuel oil stand-by pump pressure
2 Transfer pump B4 Fuel oil circulation to service tank
3 Purifier B7 Leak oil to drain tank
2047042-0.4 + pg 6.1.1 L27/38
4 MDO service tank

5 Sightglass for MDO overflow
6 Duplex filter (magnetic insert)
7 Stand-by pump
8 Primary pump
9 Duplex filter (paper insert)
Fuel oil diagram MDO

Fuel oil system, see fig 1 sary.

To protect the purifier pump (2), a prefilter is The service tank (4) should be drained daily
inserted before the pump. for water and sludge.
The pump can be driven directly by the puri- A duplex suction filter (6) with magnetic in-
fier or by an independent motor. serts is installed in the suction line of the fuel
oil primary pump to protect the pump. The
For engines operating on MDO, we recom-
filter should be cleaned regularly.
mend cleaning of the oil by a purifier to
remove water. For the blended fuel oil (M3 A stand-by fuel oil pump (7) is installed for
in accordance to BS MA100 fuel oil specifica- circulation of fuel after dismantling or repair
tion) which can be expected in some bunker of the system.
places, the purifier is also an important clean- In case of break-down of the built-on primary
ing device. An automatic self-cleaning type pump, the stand-by pump will take over.
is recommended.
The fuel oil temperatures before engine/fuel
Pre-heating is normally not necessary, but injection pumps should be observed:
a purifying temperature of approx 40C will
improve separation. Some Marine Diesel Oils MDO
have a high content of paraffin which cloggs Viscosity at 40C 2.5cSt max 60C
up filters and can cause the engine to stop.
To avoid this preheating can be necessary. MGO
Viscosity at 40C 2.0cSt max 50C
2000-11-22
A heat exchanger and a thermostatic valve

using the main engine HT cooling water as
heating media can be installed, if neces-

L27/38
Fuel oil system HFO

Fig 20.2
Heavy fuel oil

Marine diesel oil
To sludge To sludge
To sludge
To sludge
2000-11-22
To sludge
Return to bunker tank (HFO)
From bunker tank (HFO)

Return to bunker tank (HFO)

From bunker tank (HFO)
To sludge To sludge
To sludge
2047918-0.3 + PG 6.1.2 L27/38
Fuel oil diagram HFO

Item Description Heavy fuel oil system, fig 20.2

1 HFO settling tank The settling tank (1) should be designed to
2 Prefilterfor purifier/clarifier provide the most efficient sludge and water
3 Transfer pump for purifier/clarifier
4 Preheater for purifier/clarifier separation.
5 HFO purifier The capacity of each settling tank should
6 HFO clarifier
7 HFO day tank be sufficient to ensure minimum 24 hours
8 Prefilter for HFO supply pump operation.
9 Fuel oil supply pump
10 Automatic filter The temperature of the oil settling tanks
11 Flow indicator should be as high as possible to help the dirt
12 Mixing tank to settle. The temperature should be below
13 Automatic deaeration valve
14 Supply pressure control valve 75C in order to avoid the formation of as-
15 Duplex filter (magnetic insert) phaltenes, and min 7C above the pour point
16 Fuel oil booster pump
17 Preheater
of the oil to ensure pumpability.
18 Viscosity control equipment To protect the separator pumps, (3/3A)
19 Duplex slit filter
20 Booster pressure regulating valve
pre-filters (2/2A) are inserted before the
30 Sight glass, HFO day tank overflow pumps.
31 Prefilter for MDO transfer pump
32 MDO transfer pump
The pumps can be driven directly by the puri-
33 MDO purifier fier or by an independent motor.
34 MDO day tank
35 Sight glass, MDO day tank overflow
The preheaters (4/4A) must be able to raise
the temperature of the oil from approx 60C
2000-11-22
to approx 98C, which is the temperature of

Connections: the oil for purifying.
B1 Fuel oil inlet engine
B2 Drain oil from fuel valves
Cleaning of the fuel oil by a purifier and a
B4 Fuel oil circulation to service tank clarifier which remove water and solids. For
B7 Leak oil to drain tank (with alarm)
applications with separators acting as a clari-
fier and purifier at the same time, one sepa-
Pressure regulating valve (item 20): rator should be stand-by. Only the automatic
The pressure regulating valve is to be adjusted to a pressure of 4 bar.
The relief valve for booster pumps (items 16 and 16A) are adjusted to a
self-cleaning type should be used.
somewhat higher pressure Guidance given by the manufacturer of the
separators must be observed.
The service tank (7) should be dimensioned
to contain purified HFO for operating for at
least 12 hours.
The tank must be insulated and the oil
temperature in the tank should be kept at
minimum 60C. Depending on separating
temperature and tank insulation, the tem-
perature may rise to above 90C.
Attention must be paid that the fuel oil suction
pipe is connected to the side of the tank in a
position to avoid sludge and water contami-
nation of the HFO system.

L27/38
The HFO system must be pressurised to gradual temperature balance by mixing the
avoid gas separation in the fuel oil piping. hot oil returned from the engine with the oil
Pressurising is maintained by the pumps from the service tank.
(9/9A) installed between the HFO service Because the capacity of the fuel oil booster
tank and the automatic filter. The prefilters pumps (16/16A) is higher than the consump-
(8/8A) must be cleaned regularly. tion of the engine, the surplus oil from the
The pressure regulating valve (14) is to be engine is returned to the mixing tank.
adjusted to a pressure of approx 4 bar and To protect the fuel oil booster pumps, a duplex
the relief valve setting for supply pumps prefilter (15) is installed between the mixing
(9/9A) is adjusted to a higher pressure. tank and the booster pumps (16/ 16A).
An automatic filter (10) is installed between The filter must be cleaned regularly.
the supply pumps and the mixing tank (12).
In order to heat the HFO to the proper viscos-
As the flow is limited to the consumption of ity before the injection valves (10-14 cSt), the
the engine, a filter with 10 m mesh size oil is led through a preheater.
should be used in order to achieve optimal
filtration. In case of malfunction of the filter, The temperature of the HFO is regulated
a manually cleaned by-pass filter has to be by an automatic viscosity control unit to 85-
installed in parallel to the automatic filter. 150C (depending on the viscosity).
For engines with pressurised HFO system The viscosity control equipment (18) is re-
a fuel consumption meter (11) may be fitted quired for all types of fuel to ensure the opti-
2000-11-22
between the automatic filter (10) and the mum viscosity of approx 10-14 cSt at the inlet
mixing tank (12). A spring loaded valve is to the fuel injection pump. The viscosi-meter
installed in parallel. In case of problem with should not be affected by pressure peaks
the measuring device, the valve will open and produced by the injection pumps.
ensure fuel supply to the engine. The viscosity control equipment must be able
The main purpose of the mixing tank (12) is to switch over to thermostatic control in case
to ensure good ventilation of gas from the of malfunctioning.
hot fuel oil.
Furthermore, the mixing tank ensures a

The MDO treatment and feed system The layout of the MDO treatment and feed
system should be in accordance with the
The engine is designed for pier to pier oper-
recommendations for MDO.
ation on HFO. However, changeover to
MDO might become necessary. For in-stance
during:
Repair of engine and fuel oil system
Docking
More than 5 days stop
Environmental legislation requiringuse
of lowsulphur fuels
2000-11-22
Release1 20B2-01 page 20-155

L27/38
Fig 20.3 Fuel injection system

To injection valve Fuel pump
The fuel pump and the roller guide are one
unit, placed over the fuel cam. A pipe sup-
Delivery valve
Delivery valve housing
plies lubricating oil from the camshaft bearing
to the roller guide.
The barrel is installed with seals on the outer
circumference at various levels to avoid leak-
Barrel
ages and to give the possibility to drain fuel
from the lower part of the barrel bore.
At the same time it also gives the possibility
to add sealing oil to minimize fuel contamina-
tion of the lubricating oil.
Fuel The rack for fuel control is shaped as a pis-
ton at one end. The piston works inside a
cylinder. When the cylinder is pressurized,
the fuel rack will go to zero and the engine
Fuel rack
will stop.
2000-11-22
A delivery valve is installed on top of the
barrel. In the delivery valve housing a sec-
ond valve is installed. This valve will open
for oscillating high pressure waves between
the needle in the fuel injection valve and
the delivery valve on the pump, causing the
needle in the fuel valve to stay closed after
the injection is finished. This will reduce for-
mation of carbon around the nozzle tip and
Lub oil save fuel.
PII 27/38 fig 10
Roller
Fuel pump

Fuel injection valve Fig 20.4

The fuel valve is uncooled and placed in a
sleeve in the centre of the cylinder head.
O-rings around the fuel valve body prevent
fuel and lubricating oil from mixing. From the
side of the cylinder head, a lance for fuel sup-
ply is screwed into the fuel valve. The lance Sleeve
is sealed with a bushing and two O-rings
where the lance goes into the cylinder head.
A double-walled high pressure pipe connects
the fuel pump with the lance. Lance
Leak oil from the fuel valve or from a possible
defective high pressure pipe is led to the bore
for the lance in the cylinder head. From here Fuel inlet
a pipe will drain the fuel either to a leak oil
tank in case of HFO operation, or to the
day tank in case of MDO operation.
2000-11-22
Neefle
Nozzle
complete
PII27/38 fig 10
Injection valve

L27/38
2000-11-22
page 20-158
Work card 20 101-01

Dismantling/installation of fuel injection pump

Stopped engine
Shutoff cooling water Working time: 2 hours Lifting tool
Capacity: 1 man See plate: 1 901204
Shutoff fuel oil

2000-11-22
Starting position: Covers over fuel pumps removed.
Fig 20.5
Procedure
Dismantling
1. Close the valves in the fuel lines and
the air supply for safety stop.
2. Dismantle the high pressure fuel pipe.
3. Remove the pipes for lubrication, drain
and air.
4. Remove the plug screws (1) fig 20.5.
5. Unscrew the 8 screws (3) on the con
necting pieces on the right side of the
fuel pump, see fig 20.5.
AINS
Fuel injection pump
Release 20 101-01 page 20-159

L27/38
Fig 20.6 6. Pull the connecting pieces to the right

to separate the connecting pieces from
the fuel pipes to the left, see fig 20.9.
7. Disconnect the ball head connection
(1) fig 20.6 between the terminal shaft
and the fuel rack shaft.
8. Check if the roller of the fuel pump is on
the circular part of the fuel cam. Other
wise turn the crankshaft.
MBDH-514-01.05 fig 1
9. Loosen and remove the 4 nuts (2) se

curing the pump on the engine, fig
20.6.
10. Install the lifting tool as shown in fig
20.7 and remove the pump.
Fuel injection pump as mounted
Fig 20.7
2000-11-22
MBDH-514-01.05 fig 1
AINS
Removing the fuel injection pump Transporting the dismounted fuel

injection pump
page 20-160 Release 20 101-01

Installation Fig 20.8

11. Clean all the joint surfaces on the en
gine and the pump.
12. Place new O-ring seals (2) fig 20.9 on
the orifice flanges at the inlet and outlet
of the pump and the lower part of the
pump (2) fig 20.5.
Lubricate the O-rings with acid-free
grease.
13. Install the lifting tool on the fuel pump
MBDH-514-01.05 fig 4
and lift it to the place where it is to be
installed.
14. Establish all the connections earlier 14 Order of tightening
disconnected, fit new O-rings (1) fig
20.9. Install and tighten the 4 nuts to Tightening of fuel pump
fasten the pump, fig 20.8. See Tighten
ing specification 2049581-0.
2000-11-22
Fig 20.9
Aft and section

AINS
Removal of fuel oil pipes
Release 20 101-01 page 20-161

L27/38
Your notes:
2000-11-22
page 20-162 Release 20 101-01

Work card 20 102-01

Disassembly/reassembly and repair of fuel injection pump

Stopped engine
Shutoff cooling water Working time: 1 hour Special tools not supplied
Capacity: 1 man
Shutoff fuel oil

2000-11-22
Starting position: Fuel injection pump dismantled from engine, see work card 20 101.
Procedure
Disassembly of fuel injection Fig 20.10
pump
1. Unscrew the allen screws (1), fig 20.10,
and remove the delivery valve housing.
Take care not to loose the valves inside
the housing.
AINS
Delivery valve on fuel pump
Release 20 102-01 page 20-163

L27/38
Fig 20.11 2. Turn the pump upside down and install

the tool (I) shown in fig 20.11 and press
down the roller guide a few millimetres
(II).
3. Unscrew the screw (1), fig 20.11 (III).
4. Turn the spindle (2), fig 20.11 (IV),
counter clockwise until the spring in the
roller guide is completely relieved.
5. Remove the tool.
6. Pull out the roller guide. The plunger
will consequently come out at the same
time.
Mount the tool Press down roller guide
2000-11-22
MBDH-514-01.06 fig 2
Remove the screw Relieve the spring

load
Unloading / loading
the spring in the fuel injection pump
Tool is not supplied
page 20-164 Release 20 102-01

7. Unscrew and remove the allen screws Fig 20.12

(7), fig 12, to separate the plunger from
the roller guide.
Note
If the same plunger and barrel are going
to be reused, the same thrust plate (6), fig
20.12, or one of the same thickness has to
be installed when reassembling the parts.
8. Remove the spring (9), fig 20.12, the
spring retainer (4) and the regulating
sleeve (11) from the pump housing.
2000-11-22
11.20000-0845.A
Fuel injection pump sectional view
Release 20 102-01 page 20-165

L27/38
Fig 20.13 9. Unscrew and remove the two baffle

screws (3), fig 20.13.
10. Remove the thrust ring (2), fig 20.13.
11. Install the extractor tool as shown in
fig 20.14 to remove the barrel from the
pump housing.
12. Unscrew the cylinder (8) fig 20.13, and
pull out the rack (12).
Worn and damaged parts are to be re-
placed.
Fig 20.14
2000-11-22
11.20000-0845.A
Mount the tool

MBDH-514-01.06 fig 3
Fuel injection pump sectional & top view Removing the barrel
Tool is not supplied
page 20-166 Release 20 102-01

Reassembly of fuel injection pump 20.15. Make sure that the locating pin
(2) points in the right direction.
1. Fit new seals on the barrel and lubricate
with acid free grease.
2. IInstall the barrel (1) as shown in fig
Fig 20.15
2000-11-22
MBDH-514-01.06 fig 4
Installing a new barrel Tool is not supplied
Release 20 102-01 page 20-167

L27/38
Fig 20.16 5. Install the rack and the regulating

sleeve. Note the marks M, see fig
20.13.
6. Place a new seal (13) fig 20.13 on the
piston on the rack.
7. Add loctite 243 to the threads on the
cylinder (8), fig 20.13, and install it with
a new gasket.
MBDH-514-01.06 fig 5
8. If the pump housing is placed upside

Delivery valve down, the spring retainer (4), fig 20.12,
Thrust ring can be placed over the regulating
sleeve and on top of this, the spring.
9. Assemble the roller guide and plung-
Order of tightening the fixing bolts for the barrel er.
cylinder (left) and valve support (right)
10. Add some diesel oil to the plunger and
install plunger and roller guide. Make
3. Lubricate the allen screws (1) with co- sure the slot and the hole for the screw
paslip and tighten the thrust ring (2), (5), fig 20.12, are in line.
fig 20.13. Follow tightening sequence 11. Install the tool, fig 11, and press down
2000-11-22
as shown on fig 20.16. Remember to until the screw (5), fig 20.12, can be
tighten in 3 steps. screwed in.
Tightening torque see Tightening speci-
fication 2049581-0.
4. Install the delivery valve on top of the
barrel and lubricate the allen screws
with copaslip. Tightening sequence
as shown on fig 20.16. Remember to
tighten in 3 steps.
Tightening torque see Tightening
pecification 2049581-0.
page 20-168 Release 20 102-01

Work card 20 103-01

Overhaul of fuel valve

Stopped engine
Special tools
Shutoff starting air Grinding device for nozzle-
Shutoff cooling water Working time: 1 hour seat
Capacity: 1 man Extractor
Shutoff fuel oil
Fuel valve test pump
Stopped lub oil circul. Cleaning needles

2000-11-22
Starting position: Side covers and valve covers removed from engine.
Fig 20.17
Procedure
Dismantling fuel injection valve
When the engine is stopped, the fuel supply
to the engine must be cut off.
1. Remove the side cover over the fuel
pump and the cover over the rocker
arms on the cylinder head.
2. Dismantle the delivery pipe between
the fuel pump and the lance (5) fig
20.17.
3. Remove the nuts (1) and the thrust
piece (2).
4. Unscrew the screw (3) and remove the
locking device (4).
AINS
5. Unscrew the lance (5) and remove it

from the cylinder head.
Fuel injection valve assembly
Release 20 103-01 page 20-169

L27/38
Fig 20.18 6. Install the extractor tool, see fig 18, and
pull out the fuel valve.
Overhaul of fuel valve

1. Place the fuel valve in a vice with soft
jaws.
2. Remove the counter nut (1), fig 20.19.
3. Turn the adjusting screw (2) anticlock
wise and remove it from the fuel valve
body.
4. Remove the locating screw (3).
5. Unscrew the union nut (4) and remove
the atomizer.
6. Pull out the intermediate piece (5) by
means of a long 8 mm screw.
7. Remove the spring (6) and the thrust
piece (7) from the fuel valve body.
2000-11-22
AINS
8. Clean all parts carefully and investi gate

for damage. Damaged parts must be
scrapped.
Extractor tool mounted on fuel injection valve
9. Check that the needle in the atomizer
is moving freely. If the needle is worn,
the atomizer must be scrapped.
10. Check all holes in the atomizer by
means of a magnifying glass to see if
the holes are round and of the same
size. If the holes are worn, the atomizer
must be scrapped.
page 20-170 Release 20 103-01

Assembly of fuel valve Fig 20.19

1. Lubricate the threads for the atomizer in
the union nut (4) fig 20.19, with copaslip
and install the atomizer. Tightening
torque: 270 Nm.
2. Put the thrust piece (7) and the spring
(6) into the bore opposite the atom-
izer.
3. Install a new O-ring on the intermedi
ate piece (5) and put it into the bore.
Make sure that the groove for the lo
cating screw (3) is pointing in the right
direction.
4. Add loctite type 243 on the threads of
the locating screw (3) and screw it in.
5. Lubricate the threads on the adjusting
screw (2) with molykote paste type GN
and screw it in.
6. Place the fuel valve in the clamping
2000-11-22
bracket on the fuel valve test pump and

connect the high pressure pipe.
7. Operate the pump to get rid of air. When
perating the pump, the adjust ing screw
is turned down to increase the opening
pressure. When the open ing pressure
is 410 bar, the counter nut (1) is fitted
and tightened with a torque of 180 Nm.
Check that the fuel is spray ing out of
all the holes equally.
8. Fit two new O-rings (8) on the fuel valve
and add some oil before instal ling it in
the engine.
1 2018-01
Fuel injection valve
Release 20 103-01 page 20-171

L27/38
Fig 20.20 Installation of fuel valve

1. Before the fuel valve is installed in the
cylinder head, the sleeve in which the
valve is installed must be cleaned care-
fully. Using bright light inside the sleeve
will reveal any marks on the seat where
the fuel valve is landing. If there are any
marks, it is necessary to grind with the
grinding tool and fine grinding powder,
see fig 20.20.
2. The seat on the union nut for the atom-
izer has to be without marks. If there are
any marks, the seat must be ground us-
ing fine grinding powder and a grinding
ring.
AINS
3. Coat the fuel valve body with copaslip.

4. When installing the fuel valve in the
cylinder head it is important that the
threaded hole for the lance is pointing
in the right direction before it is pressed
down.
5. Fit two new O-rings on the bushing (6),
Grinding device for nozzle-seat fig 17, for the lance and press it into the
2000-11-22
bore in the cylinder head. Add molykote
paste type GN to the threads on the
Fig 17 (repeated) lance (5), fig 20.17 and screw it into the
fuel valve. It might be necess ary to turn
the fuel valve a little to make the threads
catch. Tightening torque for the lance:
75 Nm.
6. Place the thrust piece (2), fig 20.17, on
top of the fuel valve and add molykote
on the threads of the studs (7), fig
20.17, screw on the two nuts (1) and
tighten with a torque of 115 Nm.
7. Place the locking device on the hexa
gon of the lance and secure it with the
screw (4) lubricated with oil. Tighten ing
torque: 115 Nm.
8. Add molykote to the threads on the
lance (5), fig 20.17, and the fuel pump
and install the high pressure pipe. Tight-
ening torque: 50 Nm.
AINS
Fuel injection valve assembly
page 20-172 Release 20 103-01

24. Speed control system

Description
UG8 MAS Governor See separately supplied manual
Spare part plate

Governor and governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2410-01
Governor and governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2410-02
Speed control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2412-01
2008-01-10

L27/38
2008-01-10

26. Starting air system

Description
Starting air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26-177
Spare part plate

Start air connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2616-01
Control air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2616-02
Air starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2618-01
Air starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2618-02
Starting air receivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2620-03
2008-01-10

L27/38
2008-01-10

Starting air system

Ingersoll Rand air starter
Starting air for the engine is supplied from filled. The solenoid valve for start can be
two air receivers. Maximum pressure is 30 activated manually. In this case the safety
bar. precautions will be overruled.
An air operated turbine starter is installed on A pressure control valve and a filter is in-
the engine at the flywheel. stalled in the air inlet pipe at the starter. The
pressure from the air receiver is reduced to
The starter may be activated in two ways: 6.3 bar at the inlet of the starter.
The starter engages with a gear rim on When the solenoid valve for start is activated,
the flywheel on order from a switch in the pinion shaft of the starter is pushed aft
the instrument panel on the engine. to engage with the gear rim on the flywheel.
By remote control. After the pinion has engaged fully with the
In both cases the start will only take place gear rim, air will enter the turbine with a pres-
if all safety precautions for the start are sure of 6.3 bar and the engine will start.
ful-
Fig 26.1
2000-11-22
to consumers
Overspeed stop
to drain
Drain mounted at
lowest point
to drain
Air pressure
of 67 bar
Item Description
1 Compressor
1A Compressor
2 Filter with water trap
3 Starting air receiver
3A Starting air receiver
Connections:
A1 Starting air inlet
4 Filter
A2 Overspeed stop air inlet
5 Pressure reducing valve
A5 Turning motor air inlet (optional)
6 Typhon
PG-L27/38 fig 6.4
Starting air diagram

L27/38
2000-11-22

28. Lubricating oil system

Description
Lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28-181
Lubricating oil filter back-flushing filter . . . . . . . . . . . . . . . . . . . page 28-183
Work card
28 101-01 Overhaul of lubricating oil pump . . . . . . . . . . . . . . . . page 28-185
28 102-01 Dismantling and overhaul of back-flushing filter . . . . page 28-187
28 102-02 Dismantling and overhaul of back-flushing filter . . . . page 28-191
28 103-01 Overhaul of lubricating oil thermostatic valve . . . . . . page 28-195
28 104A-01 Overhaul of lubricating oil cooler . . . . . . . . . . . . . . . page 28-197
Spare part plate

Lub oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2812-01
Lub oil pressure regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-01
2008-01-10
Double check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-02

Pressure relief pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2814-03
Lubricating oil thermostatic valve . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 2820-01
Lubricating oil thermostatic valve, manual override . . . . . . . . . . . plate 1 2820-02
Lubricating oil pipes on fuel injection pumps . . . . . . . . . . . . . . . . plate 1 2824-01
Lubricating oil pipes from turbocharger . . . . . . . . . . . . . . . . . . . . plate 1 2824-02

L27/38
2008-01-10


Lub oil diagram, fig 28.1 to enter the engine, the oil cooler (3) and a
The oil pan contains the oil needed for lubri- self-cleaning, continuously back-flushing fil-
cation and cooling of all moving parts (wet ter (5A) at the top of the front-end box. The
sump). filter mesh is 25 micron. The safety mesh is
50 micron.
A gearwheel pump integrated in the front-
end box and driven by a gear train from the The particles caught in the back-flushing filter
crankshaft supplies the oil needed, see table (5A) are drained to the sump from where they
page 4. must be removed by a purifier (23).
Before the oil enters the bearings, etc, it has
passed a double acting non-return valve
(8), also allowing oil from the stand-by pump
Fig 28.1 Filling from lub oil

storage tank
D N 32
PT
D12 D8 D7
D N 65
D4 DN 125
7 2
PSL
1
2007-03-01
1221
D5
DN 100
LSH
6 8
H 5
TE
A B
DN 65
C
4
TE
PT PT TE 1222
3
DN 32
21 23
20 22
DN 32
Flushing outlet
Cent. water outlet
Connections:
D4 Lub oil stand-by pump, suction
D5 Lub oil stand-by pump, pressure
D7 Lub oil to purifier
D8 Lub oil from purifier
Item Description D12 Filling of lub oil
H Venting of crankcase
1 Lub oil pump, attached
2 Lub oil pump, stand-by
3 Lub oil cooler Automatic back-flushing filter (item 5):
4 Thermostatic valve Filter outlet
5 Automatic back-flushing filter to sump
6 Lub oil pressure control valve
Filter Filter
7 Strainer (magnetic insert) outlet intlet
8 Double acting non return valve
20 Prefilterforlub. oil purifier
21 Lub oil purifier pump 5A Back-flushing filter unit, 25 m
22 Preheaterfor lub. oil purifier 5B Pressure controlled by-pass valve
23 Lub oil purifier 5C Back-up filter in line, 50 m
Lub oil diagram

L27/38
Fig 28.2 The oil temperature is controlled by thermo-

Pilot valve
static elements (4) integrated in the front-end
box. The thermostatic elements are manu-
factured to control a certain temperature and
the set point cannot be changed, but manual
Adjusting override is possible, if required by the clas-
spindle sification society.
An adjustable pressure control valve (6)
Piston keeps the oil under pressure.
By-pass to
oil sump
The oil flow through the turbocharger is
controlled by an orifice at the inlet of the
turbo-charger.
Oil pressure control valve, fig 28.2

Pressure pipe The oil pressure is controlled by means of
a hydraulically loaded piston. Oil from the
pump passes an orifice in the centre of the
piston and pressurizes the chamber behind
the piston. This pressure forces the piston
2000-11-22
Pressure towards its own seat and in this way controls
control valve the oil pressure. To be able to adjust the oil
pressure, a spring loaded pilot valve is con-
nected to the mentioned chamber and the
pressure side after the back-flushing filter.
By adjusting the spring load, the oil pressure
1 2814-01 + 11.62012-0096
can be adjusted.
Seen from fore
Control valve
Pump capacity [m3/h] 80 80 115 115
Volume in oil pan [m3] Max. 1.6 1.8 2.0 2.2
Mn. 1.4 1.6 1.8 1.9

Lubricating oil filter back-flushing filter

The back-flushing filter is integrated in the
front-end box. It has filter candles with a filter If the filter candles become blocked and the
mesh of 25 micron, a safety filter with a filter pressure drop over the filter exceeds 2 bar,
mesh of 50 micron and safety valves. the safety valves will open and the oil will
A lub oil pressure driven turbine in the inlet bypass the filter candles and only be filtered
of the filter operates a worm gear which by the safety filter.
continuously rotates the back-flushing arm.
The rotation can be seen in the centre of Maintenance
the end cover. Rotation indicates that the Under normal conditions, the filter does not
filter works. need any maintenance as long as the pres-
After the oil has passed the filter candles, it sure drop over the filter is less than 1.0 bar
passes the safety filter before it enters the and the shaft is rotating.
bearings. However, it is required to replace all filter
Impurities caught by the filter candles will go candles after 18,000 20,000 hours of op-
to the sump together with the back-flushing eration (or after maximum 4 years) since this
oil. is expected to be the safe life time for the
A purifier must be connected to the sump to filter candles.
remove impurities from the oil.
20051117
Fig 28.3
S afety valves F ilter candle s B ack-fluching arm
W orm gear
R o tating
sha ft
Turb in e
S afety filter
Back-flushing filter

L27/38
20051117

Work card 28 101-01

Overhaul of lubricating oil pump

Stopped engine
Capacity: 1 man
Shutoff fuel oil

2000-11-22
Plate no: 1 2812

Procedure
Dismantling of pump from engine Fig 28.4
1. Remove the screws holding the oil
pump.
Lmina 1 2812-01
2. Press the pump out of the front-end box

by means of two dismantling screws.
Overhaul, see fig 28.4

3. Unscrew the screw (1).
4. Remove the gearwheel (2).
5. Unscrew the screws (3) and remove the
end cover (4).
6. Remove the two gearwheels (5) from
the pump housing.
Lubricating oil pump
Release 28 101-01 page 28-185

L27/38
Fig 28.5 7. Check the gearwheels in accordance

with fig 28.5, as well as the condition
Lmin 122.65 small pump of the flanks.
Lmin 174.65 large pump
8. Check the inside diameter of the bear
Dmin. 128,75
ing bushings. If the diameter exceeds

the measure in fig 28.5, the bearing
bushings must be replaced.
9. New bushings are frozen with nitrogen
before they are placed in the bores.
Make sure the oil inlet holes in the
bushings are located in the right posi
Gearwheels
tion, see fig 28.7.
10. Assemble the pump and fit new O-rings
Dmax. 55,05 mm (1) fig 28.6.
AINS
11. Install the pump.
Bearing bushing Fig 28.6

Gearwheels and bearing bushing
2000-11-22
Fig 28.7
plate 1 2824-02
Fit new O-tings

AINS
Installation of bearing bushing
page 28-186 Release 28 101-01

Work card 28 102-01

Dismantling and overhaul of back-flushing filter

Stopped engine
Shutoff cooling water Working time: 3 hours Lifting tool for oil lter
Capacity: 2 men See plate: 1 901209
Shutoff fuel oil

2000-11-22
Procedure
The oil in the filter can be drained by turning Fig 28.8
the screw (1), fig 28.8, anticlockwise.
1. When all the screws (1), fig 28.9, have
been removed, the filter can be
pressed out by means of two dismantl
ing screws.
2. The filter must only be pressed out 21
mm. This will give enough space to in
stall the lifting tool (10), see fig 28.9.
3. When the lifting tool is installed and the
weight of the filter is carried in a chain
block, the filter can be pulled out.
AINS
Oil drain from filter
Release 28 102-01 page 28-187

L27/38
4. Place the filter on a wooden support in 13. Fit two new O-rings (12) on the centre
vertical position and remove the lifting shaft.
tool. 14. Check that the turbine wheel and the
5. Remove the end cover (2), fig 28.9, and worm drive are moving freely.
the cover plate (3). 15. Fit a new O-ring (5), fig 28.9, and in stall
6. Pull the candle unit (7) out of the hous- the candle unit in the housing.
ing.
7. The filter candles can now be pushed
Note
out one by one.
When lowering the candle into the housing,
8. The filter candles can be cleaned in care must be taken that the gear wheels are
hot soap water. It is advisable to use gently engaged.
high pressure cleaning to ensure that
the candles are completely clean. Max 16. Place the O-rings (6) around the
pressure is 60 bar and the spray dis- candle plate and install the end cover
tance is 20 cm. (2).
9. Check the cleaned candles carefully 17. Fit new O-rings (8) and install the lift
and scrap defective candles. ing tool on the side opposite the turbine
inlet.
10. Install new or cleaned candles in the
candle plate with new O-rings and put 18. Lift the filter and push it into the front-
2000-11-22
the cover plate (3) over the candles and end box as far as the lifting tool al-
secure it with the 3 screws (4). lows.
11. Check that the bushings (9) on the 19. Remove the lifting tool and push the
back-flushing arm does not slide filter all the way in. Lubricate the screws
against the candle plate. If there is any (1) with oil and tighten the screws with
contact, the bushings must be ad justed a torque of 150 Nm.
to make some clearance.
12. If the ball bearings on the centre shaft Note
are worn (11), they must be replaced.
Remember to turn the screws (1), fig 28.8,
clockwise and tighten it before starting the
engine.
page 28-188 Release 28 102-01

Fig 28.9
2000-11-22
21 mm max.
AINS
Fitting of lifting tool
Release 28 102-01 page 28-189

L27/38
Your notes:
2000-11-22
page 28-190 Release 28 102-01

Work card 28 102-02

Dismantling and overhaul of back-flushing filter

Stopped engine
Shutoff cooling water Working time: 3 hours Lifting tool for oil lter
Capacity: 2 men See plate: 1 901209
Shutoff fuel oil

20051117
Procedure
The oil in the filter can be drained by turning Fig 28.8
the screw (1), fig 28.8, anticlockwise.
1. When all the screws (1), fig 28.9, have
been removed, the filter can be
pressed out by means of two dismantl
ing screws.
2. The filter must only be pressed out 21
mm. This will give enough space to in
stall the lifting tool (10), see fig 28.9.
3. When the lifting tool is installed and the
weight of the filter is carried in a chain
block, the filter can be pulled out.
AINS
Oil drain from filter
Release 28 102-02 page 28-191

L27/38
4. Place the filter on a wooden support in 13. Fit a new O-ring (5), fig 28.9, and install
vertical position and remove the lifting the candle unit in the housing.
tool.
5. Remove the end cover (2), fig 28.9, and
Note
the cover plate (3).
When lowering the candle into the housing,
6. Pull the candle unit (7) out of the hous- care must be taken that the gear wheels are
ing. gently engaged.
7. The filter candles can now be pushed 14. Place the O-rings (6) around the
out one by one. candle plate and install the end cover
8. Install new candles in the candle plate (2).
with new O-rings and put the cover 15. Fit new O-rings (8) and install the lift
plate (3) over the candles and secure ing tool on the side opposite the turbine
it with the 3 screws (4). inlet.
9. Check that the bushings (9) on the 16. Lift the filter and push it into the front-
back- lushing arm does not slide end box as far as the lifting tool al-
against the candle plate. If there is any lows.
contact, the bushings must be ad justed
to make some clearance. 17. Remove the lifting tool and push the
filter all the way in. Lubricate the screws
10. If the ball bearings on the centre shaft (1) with oil and tighten the screws with
20051117
are worn (11), they must be replaced. a torque of 150 Nm.
Note
11. Fit two new O-rings (12) on the centre Remember to turn the screws (1), fig 28.8,
shaft. clockwise and tighten it before starting the
12. Check that the turbine wheel and the engine.
worm drive are moving freely.
page 28-192 Release 28 102-02

Fig 28.9
2063552-2.0
20051117
Fitting of lifting tool
Release 28 102-02 page 28-193

L27/38
Your notes:
20051117
page 28-194 Release 28 102-02

Work card 28 103-01

Overhaul of lubricating oil thermostatic valve

Stopped engine
Shutoff cooling water Working time: 1 hour No special tools
Capacity: 1 man
Shutoff fuel oil

2000-11-22
Plate no: 1 2820
Procedure
The temperature of the lubricating oil is con- Fig 28.10
trolled by 4 thermostatic elements placed in a
thermostat housing installed on the front-end
Thermostatic valve
box below the oil cooler, see fig 28.10. housing
The thermostatic elements are not adjust-
able. The elements are supplied with or
without manual override, depending on the
requirements of the classification societies.
If the elements fail to work, they must be
replaced.
1 2820-01
Lub oil thermostatic valve mounted

on front-end box
Release 28 103-01 page 28-195

L27/38
Fig 28.11 Replacement of thermostatic

elements, see fig 28.11
1. Fit two eye bolts in the holes (1) on the
thermostat housing. Put a wire through
the eye bolts and hook it onto a chain
block.
2. Unscrew all the screws (2).
3. Remove the thermostat housing from
the engine.
4. Remove the circlip (7) and pull out the
distance tube (6) and thermostatic el
ement (5).
5. After the elements have been dis
1 2810-01
mantled, they can be checked in hot

water. The elements must start open
Lub oil thermostatic valve ing at about 63C.
without manual override
6. D e f e c t i v e e l e m e n t s m u s t b e
scrapped.
2000-11-22
7. Install new or checked elements in the
housing.
8. Clean the joint surface on the engine
and thermostat housing and apply
some liquid sealing compound.
9. Lift the thermostat housing back onto
the engine. All the screws (2) lubri cated
with oil are tightened with a torque of
140 Nm.
page 28-196 Release 28 103-01

Work card 28 104A-01

Overhaul of lubricating oil cooler

Stopped engine
Capacity: 1 man
Shutoff fuel oil

2000-11-22
Starting position: Cooling water and lub oil have been drained from cooler/engine.
All external pipes are disconnected.
Fig 28.16
Procedure
A plate cooler is placed on top of the front-
end box and secured by allen screws. See
Lub oil cooler
fig 28.16.
Inlet and outlet of water and oil are sealed
with O-rings between the bottom plate of the
cooler and the front-end box.
The cooler plates are made of stainless steel
and the gaskets are of the clip-on type.
1 2818-01
Cooler mounted on front-end box
Release 28 104A-01 page 28-197

L27/38
Fig 28.17 Whenever it becomes necessary to clean

the cooler, this can take place in two differ-
ent ways:
1. The complete cooler can be removed
from the engine and brought to a work
shop for overhaul.
2. The cooler can be dismantled on the
engine.
Disassembling of the cooler

This cooler (see fig 28.17) has long assem-
bling studs and does not need special tools
for disassembling or assembling. In addition,
it has tubes around the studs against which
the top frame plate has to be tightened to
ensure the right compression of the plates.
plate 2 2818-02
Oil cooler Cleaning agent

Kerosene on the oil side. Citric acid on the
water side, or agents that do not harm the
2000-11-22
stainless steel or the nitrile rubber gasket.
Fig 28.18 After cleaning, the condition of the gaskets is

to be checked. Replace gaskets with cracks
or other types of damage.
Replacement of clip-on gasket, see fig
28.18.
The clip-on gasket in the gasket groove
page 28-198 Release 28 104A-01

Assembling of the cooler, fig 28.19 Fig 28.19

1. Place the first cooler plate marked
367317-0483A with the gasket against
the bottom frame plate.
2. The plates marked 367317-4403 are
placed one by one on the foregoing
plate and always with the canal pattern
pointing in the opposite direction of the
foregoing.
3. Place the final plate marked 367317-
0476 A.
4. Place the top frame plate on top of the
cooler plates.
5. Tighten the nuts crosswise in turns and
only a little at the time to ensure that
the top frame plate comes down in par
allel with the bottom frame plate.
2000-11-22
LT cooling water
Lubricating oil
plate 1 2818-02
Lubricating oil
LT cooling water
Lubricating oil cooler viewed from below
Release 28 104A-01 page 28-199

L27/38
Your notes:
2000-11-22
page 28-200 Release 28 104A-01

30. Cooling system

Description
Cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30-203
Work card
30 101-01 Cooling water thermostatic valves . . . . . . . . . . . . . . . page 30-205
30 102-01 Overhaul and replacement
of cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . page 30-207
Spare part plates

High temperature cooling water pump clockwise . . . . . . . . . . . . . plate 1 3010-01
High temperature cooling water pump anticlockwise . . . . . . . . . . plate 1 3010-02
Cooling water thermostat for low temperature system . . . . . . . . . plate 1 3012-01
Cooling water thermostat for high temperature system . . . . . . . . plate 1 3012-01
2008-01-10
Cooling water thermostat for low temperature system

manual override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 3012-02
Cooling water thermostat for high temperature system
Freshwater thermostatic valve 74C with manual override . . . . . . plate 1 3012-03
Cooling water connection for low temperature system . . . . . . . . . plate 1 3012-04
Cooling water connection for low temperature system . . . . . . . . . plate 1 3012-05
Cooling water thermostat for low temperature system . . . . . . . . . plate 1 3012-06
Cooling water thermostat for low temperature system

L27/38
High temperature cooling water pipes . . . . . . . . . . . . . . . . . . . . . plate 1 3016-01

Cooling water connection, gear . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 3016-04
Low temperature cooling water pump . . . . . . . . . . . . . . . . . . . . . plate 1 3210-01
Low temperature cooling water pump . . . . . . . . . . . . . . . . . . . . . plate 1 3210-02
2008-01-10


The engine is designed for freshwater cool- The engine design is almost pipeless, ie the
ing only. Therefore the cooling water system water flows through internal cavities inside
has to be arranged as a centralised/closed the front-end box and the cylinder units. The
cooling water system. front-end box contains all large pipe connec-
tions. On the aft-end, the water to the gear oil
Fig 30.1 cooler has to be connected by the yard.
2002-06-06
Gear box
Item Description
1 Seachest low
2 Seachest high
3 Sea water filter
4 Sea water pump
9 Overboard discharge valve
10 LT pump
11 LT stand-by pump
12 Regulating valve (optional)
13 Charging air cooler, LT section
14 Orifice for cooling water to gearbox
15 Gear oil cooler
16 Engine lubricating oil cooler Connections:
17 LT thermostatic valve
18 Central cooler E1 LT cooling water inlet
29 LT expansion tank E2 LT cooling water outlet
30 HTpump E3 LT cooling water standby pump pressure
31 HT stand-by pump E6 LT cooling water to gear cooler (on gear/engine)
32 Charging air cooler HT section E7 LT cooling water from gear cooler (on gear/engine)
33 Adjustment valve for heat recovery F1 HT cooling water inlet
PG-L27/38 Fig 6.4
34 Thermostatic valve for heat recovery F4 HT cooling water standby pump pressure
35 Heat recovery F5 HT cooling water to heat recovery system
36 HT thermostatic valve F6 HT cooling water from heat recovery system
37 HT freshwater cooler F7 HT cooling water to expansion tank (venting)
38 Circulating pump for preheater F10 Engine preheating inlet
39 Preheater F12 Engine preheating outlet
49 HT expansion tank F13 HT cooling water outlet (to cooler)
Cooling water diagram

L27/38
Fig 30.2 The engine is equipped with built-on fresh-

water pumps for both the high and low tem-
perature cooling water systems. To facilitate
automatic start-up of stand-by pumps, non-
return valves are included.
The freshwater pumps are mounted in the
front-end box and are driven through gear-
wheels from the crankshaft.
The pump bearings are lubricated automati-
cally with oil from the lubricating oil system
of the engine.
Thermostatic valve elements which control
the high and low temperature cooling water
system are also integrated parts of the front-
end box.
plate 1 1812-02
The engine is equipped with a two stage

charge air cooler. The first stage is placed in
the high temperature cooling water system.
The high charging air temperature after the
turbocharger makes a higher degree of heat
2002-06-06
Charging air cooler
recovery possible when the heat is dissipated
to the high temperature cooling water.
The second stage of the charge air cooler is
placed in the low temperature system.
It will cool the charging air further down be-
fore entering the cylinder.
For special applications, ie sailing in arctic
waters with low air temperatures and direct
air intake from deck, a regulating system
can be applied to control the water flow to
the second stage of the charge air cooler in
order to increase the charging air tempera-
ture, at low load.

Work card 30 101-01

Cooling water thermostatic valves

Stopped engine
Capacity: 1 man
Shutoff fuel oil

2002-06-06
Fig 30.3
Procedure
The cooling water system is normally di-
vided into two separated closed circuits.
A low temperature circuit (LT) and a high
temperature circuit (HT) based on freshwa-
ter treated with anti-corrosion agents, see
fig 30.3.
Each circuit has 4 thermostatic elements. The
elements are supplied with or without manual HT LT
override, depending on the requirements of
the classification societies. The elements
are not adjustable. The elements for HT and
1 3012-01
LT have different temperature ranges and

therefore not interchangeable. If they fail to
work, they must be replaced.
Cooling water thermostatic valves
mounted on front-end box
Release 30 101-01 page 30-205

L27/38
Fig 30.4 The pump cover/housing for thermostatic

valves must be dismantled from the front-end
box to replace the thermostatic elements.
Each element is secured with a cir-clip (1),
see fig 30.4.
In case the HT cooler is cooled by water
from the LT circuit, a separate thermostatic
valve is installed in the external piping. In
such cases the LT thermostatic elements
in the thermotat housing on the engine are
replaced by dummies.
Replacement of thermostatic elements,
see fig 30.4
1. Unscrew all the screws (2).
2. Remove the thermostat housing from
the engine.
3. Remove the circlip (1) and pull out the
distance tube (6), thermostatic el
ement (5), supporting ring (4) and O-
2002-06-06
ring (3).
4. After the elements have been dis
mantled, they can be checked in hot
water.
1 3012-01
The LT elements must start opening at

Vlvula termosttica de BT: about 29C.
sin correccin manual The HT elements must start opening at
about 77C.
5. D e f e c t i v e e l e m e n t s m u s t b e
scrapped.
6. Install new or checked elements in the
housing.
7. Clean the joint surface on the engine
and thermostat housing and apply
some liquid sealing compound.
8. Lift the thermostat housing back onto
the engine. All the screws (2) lubricated
with oil are tightened with a torque of
140 Nm.
page 30-206 Release 30 101-01

Work card 30 102-02

Overhaul and replacement of cooling water pumps

Stopped engine
Capacity: 2 men
Shutoff fuel oil
Per pump

2002-06-06
Plate no: 1 3010

Procedure Fig 30.8
The HT and LT cooling water pumps are

centrifugal pumps installed in the front-end
box. The pumps are installed underthether- HT LT
mostatic housing holding the elements and
can therefore not be seen. The pumps are
driven by a gear train from the crankshaft.
A pump can be dismantled after the thermo-
static valve housing has been removed.
AINS
Cooling water pumps

mounted on front-end box
Release 30 102-02 page 30-207

L27/38
Fig 30.9 When the 4 screws (1), fig 9, have been re-
moved, the pump can be pulled out by means
of dismantling screws.
Disassembling of a pump, see fig 30.10
1. Unscrew the 3 screws (6) and remove
the flange (5).
2. Remove the screw (16) and thrust piece
(17).
3. Pull off the impeller (3) and the shaft
seal (14).
4. The gearwheel can be removed after
the screw (20) and disc (19) have been
removed.
5. Remove the circlip (11).
1 3010-02
6. The pump shaft with ball bearings can

now be pressed out.
7. Remove the gland for the shaft seal and
Bomba de agua refrigerante
the lip ring (13) from the housing.
2002-06-06
page 30-208 Release 30 102-02

Assembling of a pump, see fig 30.10 7. Place the gearwheel on the tapered
1. Install 2 new ball bearings (9 and 10) end of the shaft together with the disc
on the shaft. (19).
2. Place a new lip ring seal (13) and a 8. Tighten the screw (20) with a torque
new gland for the shaft seal in the pump of 110 Nm after it has been lubricated
housing. with oil.
3. Add some oil to the shaft in the position 9. Fit two new O-rings (1) in the ring
where the lip ring is going to seal. groves on the pump housing.
4. Install the shaft in the housing and fit Installation

the circlip (11). A new or overhauled water pump is placed in
5. Place the rotating parts of a new shaft the bore in the front-end box and tightened
seal over the shaft and on top of this with 4 screws lubricated with moly-cote paste
the impeller. type GN or copaslip. Tightening torque is
140 Nm.
6. Lubricate the screw (16) with oil and
tighten to 50 Nm. If the screws are lubricated with oil the torque
is 200 Nm.
Fig 30.10
2002-06-06
1 3010-03
Cooling water pump
Release 30 102-02 page 30-209

L27/38
Your notes:
2002-06-06
page 30-210 Release 30 102-02

80. Instrumentation
Description
Local monitoring, control and safety LMCS . . . . . . . . . . . . . . . . . page 80-213
Spare part plate

Operator panel - fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-01
Engine operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-02
Operator panel, fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-05
Operator panel, fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-06
Operator panel, mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-07
Local operator panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-08
Local operator panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8010-09
Engine operator slave panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8012-01
2008-01-10

L27/38
2008-01-10

Local monitoring, control and safety LMCS

General exact value of all parameters. All sensors
The engine is using a fully electronic and re- are continuously monitored to be within the
dundant local instrumentation concept on the specified measuring range. The operator will
engine, thus providing extensive monitoring be made aware, should a sensor exceed its
and a good overview for the operator. validity limits.
The Operator Panel Engine (OP-E) is The measurement and display of the es-
placed next to the governor. This is done to sential parameters are duplicated. The
give the operator the best possible condition duplicated measurements can be identified
for controlling and monitoring the complete on the drawing, where they are marked with
engine from only one position. an S.
The lay-out of the Local Monitoring, Control The hardware of the two Alphacomm units
and Safety systems (LMCS) is shown on marked ACS and ACM-E is identical. The
fig 11. units are acting as self-contained computer
units with their sensors and outputs directly
The computer unit named Alphacomm Safety
connected. The power supply is 24 volt D.C.,
(ACS) is acting as a self-contained safety
coming from a battery-backed outlet. The
system, using the OP-E as its display.
units are communicating with the operator
The computer unit named Alphacomm Moni- panel via a serial connection. Communica-
2004-08-05
toring Engine (ACM-E) is handling the tion between the units takes place via a
following tasks: duplicated network.
Acting as a data collection device, using The ACM-E is connected to the ships alarm
the OP-E as its display system via a serial connection, enabling ac-
Data link to the ship's alarm system cess to all sensor values.
Automatic control functions on the en The ACS is connected to the Propulsion

gine Control System via a serial connection, en-
abling remote display and operation of the
Redundant Safety System Safety System.
Generally, all sensors are analogue, thus of- Lists of sensors connected to the LMCS can
fering the user the possibility to read the be found in chapters 84 and 86.

L27/38
Fig 80.11
Bar graphs marked with en "S" identify
S: Safety Circuit
measurements with dupriceted transducers.
C: Local Contror
Remaining parts: Monitoring Circuit
*: Sensor not dupricated
S* % rpm
S
Cyrinder 1 O 2 O 3 O 4 O 5 O 6 O 7 O 8 O 9 O O O
C C C C C C C C C ber C C
560 560 560 560 560 560 560 560 560 560 WASTE BY- 560
530 530 530 530 530 530 530 530 530 530 GATE PASS 530
500 500 500 500 500 500 500 500 500 500 500
470 470 470 470 470 470 470 470 470 470 OPEN OPEN 470
S
440 440 440 440 440 440 440 440 440 440 440
410 410 410 410 410 410 410 410 410 410 410
WASTE BY-
380 380 380 380 380 380 380 380 380 380 380
350 350 350 350 350 350 350 350 350 350 GATE PASS 350
320 320 320 320 320 320 320 320 320 320 320
290 290 290 290 290 290 290 290 290 290 290
ber ber O 260 260 260 260 260 260 260 260 260 260 260
C
230 230 230 230 230 230 230 230 230 230 TC Speed 230
200 200
Exheust Ges Tempereture

200 200 200 200 200 200 200
TC Lub. Oir
200
TC Temp.
200
TC Temp.
Power Suppry
rpm
ber
O O O O
Press.
O
In
O
Out
24 V D.C.
C ber C C ber C C ber C
6.0 6.0 4.0
5.5 5.5
3.5
5.0 5.0
4.5 4.5 3.0
Press. Press. Temp.

4.0
3.5
3.0
4.0
3.5
3.0
2.5
2.0
Bus to ACM
before efter 2.5 2.5
1.5
Firter Firter 2.0 2.0
1.5 1.5 1.0
Lubriceting Oir 1.0 1.0
0.5
S S From
0.5 0.5
0 0 0
Press. Temp. Press. Temp. Temp. Press. Temp. Temp. Press. Temp.
PCS
S
In Out In Out Cherge Air
Fuer Oir
HT Cooring Weter LT Cooring Weter
ber % rpm %
Sefety 40
SHUT DOWN Active 35
SHUT DOWN Cencerred 30
25
CANCEL RESET 20
Pener / Lemp
SHUT SHUT 15
Test
DOWN DOWN
10
5
Emergency Stop
Overspeed, Engine
STOP
RUN
START
CONTROL POSITION
LOCAL REMOTE
0
Stert Speed Fuer
Safety
Engine Lub. Oir Press. Low
HT Cooring Weter Temp. High
Air Press. Index
Power Suppry
S
HT Cooring Weter Press. Low Stert Brocking
Geer Lub. Oir Press. Low Turning Geer
Oir Mist in Crenk Cese Prop. Pitch not Zero
24 V D.C.
Properrer Locked
rpm Safety
Circuit
C S C Monitoring
Circuit Bus to ACS
Operator Panel- Engine

Local Control, Hardwired
Front
Stop/Run/Start Remote / Local
PCS
2004-08-05
+ 24 V, Emc'y
Lay-out of electronics inside Start Block.

Operator Panel - Engine from ACS
Stop Start
Valve Valve
Engine Operator
Governor
Controls Panel
TC (OP-E)
Valves TC
(in governor)
VIC RPM
START
Valve
STOP
IL-Bus-ME OVER
Cooler LOAD
By-pass Propulsion
S- s u B- LI
Jet STOP Control

Assist System
PI PI (PCS)
Alphacomm Alphacomm Serier

Monitoring Safety
(ACM-E) (ACS)
24Vdc Ship's
24Vdc
(Safety) RPM Alarm
Sensors System
Dupricated Net
Serier
System configuration

Operator panel engine. In order to give a good overview, the

bar graphs are organised in a mimic diagram,
The operator panel for the engine (OP-E) is
showing the approximate location of the sen-
serving three purposes:
sors on the engine.
local monitoring
In addition to the indication on the bar graph,
local control it is possible to show the exact value of each
safety system interface sensor, using the Measurement display and
push buttons. A yellow lamp will indicate the
Local monitoring selected parameter above the corresponding
The local monitoring function is using bar bar graph.
graphs to present all measurements on the
Fig 80.12
% rp m
C ylin d e r 1 O
C 2 O
C 3 O
C 4 O
C 5 O
C 6 O
C 7 C O 8 O
C 9 O
C bar O
C O
C
560 560 560 560 560 560 560 560 560 560 W ASTE BY 560
530 530 530 530 530 530 530 530 530 5 3 0 G AT E PA S S 530
500 500 500 500 500 500 500 500 500 500 500
470 470 470 470 470 470 470 470 470 470 O PEN OPEN 470
440 440 440 440 440 440 440 440 440 440 440
410 410 410 410 410 410 410 410 410 410 W ASTE BY 410
380 380 380 380 380 380 380 380 380 380 380
350 350 350 350 350 350 350 350 350 3 5 0 G AT E PA S S 350
320 320 320 320 320 320 320 320 320 320 320
290 290 290 290 290 290 290 290 290 290 290
bar bar O
C 260 260 260 260 260 260 260 260 260 260 260
230 230 230 230 230 230 230 230 230 230 TC Speed 230
2004-08-05
200 200 200 200 200 200 200 200 200 200 200
E xh au st G a s Te m p e ra tu re T C L u b . O il T C Te m p . T C Te m p .
P re ss. In rp m O ut
O O O O O O
bar C bar C C ba r C C bar C
6 .0 6 .0 4 .0
5 .5 5 .5 3 .5
5 .0 5 .0
4 .5 4 .5 3 .0
4 .0 4 .0 2 .5
3 .5 3 .5
P re ss. P re ss. Te m p . 3 .0 3 .0 2 .0
b e fo re a fte r 2 .5 2 .5
F ilte r F ilte r 2 .0 2 .0 1 .5
1 .5 1 .5 1 .0
L u b rica ting O il 1 .0 1 .0 0 .5
0 .5 0 .5
0 0 0
P re ss . Te m p . P re ss . Te m p . Te m p . P re ss . Te m p . Te m p . P re ss . Te m p .
In O ut In O ut C h a rg e A ir
F u e l O il
H T C o o lin g W a te r LT C o o lin g W a te r
bar % rp m %
S a fe ty 40
S H U T D O W N A ctive 35
S H U T D O W N C a n ce lle d 30
25
CANCEL RESET 20
Panel / Lam p
SHUT SHUT Te st 15
DOWN DOWN
10
C O N T R O L P O S IT IO N 5
E m e rg e n cy S to p RUN 0
O ve rsp e ed , E n g in e S TO P S TA R T LO CAL REM OTE
E n g in e L u b . O il P re ss. L o w S ta rt Spee d Fuel
H T C o o lin g W a te r Te m p . H ig h A ir P re ss. In d e x
H T C o o lin g W a te r P re ss. L o w S ta rt B lo ckin g
G e a r L u b . O il P re ss. L o w Tu rn in g G e a r
O il M ist in C ra n k C a se P ro p . P itch n o t Z e ro
P ro p e ller L o cke d
rp m
Operator panel

L27/38
The digital display marked Measurement Sensor failure

will show the values originating from the (value out of range or cable failure) can be in-
sensors connected to the ACM-E. dicated on the OP-E in the following ways:
The digital display marked Engine Running The upper and lower indicator of a bar
Hours is indicating the total number of hours graph is flashing to indicate that the
where the engine has been running. The corresponding sensor has a failure.
counter can not be reset by the ships crew.
The digital display marked Measure
The push-button marked Panel/Lamp Test ment is displaying FAIL when a sen
will, as long as activated, turn on all indica- sor selected by the yellow LED has a
tors inside the panel. Both indicators for the failure.
safety and the monitoring circuits will be
A single shut down indicator is flashing
activated.
to indicate sensor failure of a shut down
When green, the two indicators marked sensor
Safety Syst. Link OK and Monit. Syst. Link
The Safety system interface, fig 80.13
OK indicate that the communication with the
ACS and the ACM-E respectively is working. The shut down indicators are duplicated. The
If there is a problem with the communication right hand side of the indicators are activated
to one of the Alphacomm units, the corre- via the ACS, while the left hand side is acti-
sponding indicator will be turned off. vated via the ACM-E.
2004-08-05
Fig 80.13
Redundant indicators for Push buttons for local cancel

safety functions and reset of shut down
Status of
Shut Down Memory
Non-cancellable
shut downs
Single
shut down
indicators Cancellable shut
downs
Indications from ACS

Indications from ACM-E
Safety system interface

When one of the shut down sensors is ex- Cancellable shut downs will be initiated by a
ceeding its limit , the corresponding single pre-warning of 6 seconds on the bridge and
shut down indicator will be turned on. Simul- in the ECR. During this time, the operator
taneously, the Shut Down Memory will be set has the possibility, via the Propulsion Control
and the Safety Stop valve will be activated System, to cancel the shut down before it
and the engine will be stopped. stops the engine.
The Shut Down Memory can be reset by Non-cancellable shut downs
activating the push-button RESET SHUT A non-cancellable shut down will always shut
DOWN. down the engine immediately. It can not be
Shut downs are divided into Cancellable shut cancelled.
downs and Non-cancellable shut downs as Sensor failure
indicated above.
Sensorfailure on a shut down sensor will not
Cancellable shut downs lead to a shut down. An alarm will be given
When the push button CANCEL SHUT via the ships alarm system, and the cor-
DOWN is activated, the indicators SHUT responding indicator on the OP-E will start
DOWN Cancelled will be turned on to indi- flashing. The flashing will not stop before the
cate the present status. If one of the cancel- sensor failure has been repaired.
lable shut down sensors should exceed its Local control, fig 80.14
shut down limit, nothing will happen as long
The local control functions are acting directly
as the SHUT DOWN Cancelled indicator
on the machinery components; i e the local
is on.
2004-08-05
controls are operating independently of the

Activating the push button CANCEL SHUT computer units. However, any active start
DOWN will turn the indicator off again. blocking coming from the Safety System, will
inhibit the start of the engine.
Fig 14
Local control switches.
Active independant
of electronics on the engine
Start blocking indicators.

Start blocking is also active
during local control
Local control

L27/38
Speed-setting of the governor

The governor set-point can be controlled Warning
when the CONTROL POSITION switch is In case of failure of the ACS, all start
in position LOCAL. Speed-setting is done by blockings will be released automatically. The
turning the appropriate knob on the governor operator must prevent a dangerous situation
itself. Please refer to the governor manual. when starting the engine, ie check that the
The set-point of the governor is remotely turning gear is not engaged.
controlled by the PCS when the CONTROL Test of the overspeed shut down
POSITION switch is in position REMOTE. function
When changing from REMOTE to LOCAL,
no change of set-point will take place. It is possible to test the overspeed shut
down function, using switches on the two
units ACS and ACM-E. The switches are
Safety system located inside box 1 on the front end of the
engine.
The safety system is acting as an indepen-
dent stand alone system including its own The normal overspeed shut down limit is
sensors. In order to give an even higher 960 rpm. By activating the test-switch, the
safety level, the safety functions are dupli- limit is lowered to 600 rpm.
cated in the ACM-E, ie also in case of a fail-
ure of the actual safety system, the full shut
2004-08-05
down protection of the engine will be intact Fig 80.15
via the ACM-E, acting on the stop valve of SW1
the governor.
In addition to the operator interface on the
local Operator Panels described above, there Switch number 2 is used for
are similar operator facilities on the Operator test of the overspeed shut down
Panels of the Remote Control System. function.
Normal switch position is

OFF giving overspeed shut
Start blocking down at 960 rpm.
The safety system detects possible start
blockings as shown above. The start blocking Test position of the switch is
protection is active during both remote and ON giving overspeed shut
down at 600 rpm.
local operation.
OFF ON
In case of a very high turbo charger speed,
the waste gate valve will be opened in order
to decrease the turbo charger speed. During Switch
remote control, the PCS will normally avoid
the high TC rpm by reducing engine load (ie By setting switch number 2 ON only on the
propeller pitch). ACS, only the shut down system of the ACS
will be tested. Only the safety shut down
The list of all shut down sensors and their valve will be activated when the engine rpm
limits can be found in chapter 86. exceeds 600. The individual fuel pumps will
be pushed to zero position using compressed
air.

After test of the overspeed shut down of the indicator until command and feed-back sig-
ACS, the switch is set back to OFF and the nals coincide again.
shut down memory is reset by the operator
via the RESET SHUT DOWN push button Connection to the ships alarm
of the Operator Panel - Engine. system
By setting switch number 2 ON only on the Generally, all measurements from the ACM-E
ACM-E, only the shut down system of the can be transmitted to the Ships Alarm Sys-
ACM-E will be tested. Only the stop valve tem which will detect possible exceeding of
inside the governor will be activated when alarm limits and emit an alarm throughout
the engine rpm exceeds 600. The fuel pumps the vessel as required. Chapter 84 gives the
will collectively be pushed to zero position exact information of the alarm sensors and
by the governor. After test of the overspeed their limits.
shut down of the ACM-E, the switch is set The connection to the Ships Alarm System
back to OFF and the shut down memory is is realised using a serial point to point con-
reset by the operator via the RESET SHUT nection. Supervision of the communication
DOWN push button of the Operator Panel line must be handled by the ships alarm
- Engine. system, as this is acting as a master in the
communication.
Automatic control functions
The following automatic control functions will
be carried out by the ACM-E unit: Note
2004-08-05
Position of the turbo charger by-pass It is important that all alarms lead to prompt
valve investigation and remedy of the error.
Position of the turbo charger waste gate No alarm is insignificant. It is therefore impor-
valve tant that all engine crew members are familiar
Activation of the Jet Assistance valve with and well trained in use and important of
Position of the Variable Injection timing the alarm system.
Control (VIC) The most serious alarms are equipped with
Position of the charge air low tempera slow-down and/or shut-down functions.
ture cooler by-pass valve
The position of the two turbo charger valves
Connection to the Propulsion
is sensed by feed-back switches, and the cor- Control System
responding position is displayed as WASTE The ACS is connected to the Propulsion Con-
GATE OPEN (or CLOSED) and BY-PASS trol System via a serial connection, enabling
OPEN (or CLOSED) remote display and operation of the Safety
The position of the two turbo charger valves System. In case of a failure of this communi-
is supervised by the ACM-E. If there is a cation line, the PCS will initiate an alarm.
discrepancy between the commanded posi-
tion and the actual position, an alarm will be
given via the ships alarm system. In addi-
tion, the OP-E will flash the corresponding

L27/38
2004-08-05

82. Control equipment

Spare part plate
Engine terminal box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-01
Governor control equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-02
ZS1705 - turning gear indication . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-04
Engine terminal box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-05
Electrical govenor control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-06
Electrical govenor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-06
Governor control equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-07
Plug for local operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .plate 1 8210-08
Operator panel and control unit, Plug local remote . . . . . . . . . . . . .plate 1 8210-09
2008-01-10

L27/38
2008-01-10

84. Monitoring equipment

Description
Sensors used on the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . page 84-225
Oil mist detector see separately supplied manual
Work card
84 101-01 Adjustment and test of pressure controllers . . . . . . page 84-233
84 102-01 Adjustment and test of pressure transmitters . . . . . page 84-235
84 103-01 Adjustment and test of
temperature sensors (Pt 100) . . . . . . . . . . . . . . . . . page 84-237
84 104-01 Adjustment and test
of temperature sensors (NiCrNi) . . . . . . . . . . . . . . . page 84-239
84 105-01 Adjustment and test of level sensors . . . . . . . . . . . . page 84-241
84 106-01 Adjustment and test of
tacho and proximity sensors . . . . . . . . . . . . . . . . . . page 84-243
84 107-01 Adjustment and test of displacement transmitter . . . page 84-245
2008-01-10
Data sheet
Alarm system interface, MODBUS . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 04 92 74-2
Summary of alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 0X XX XX-X
Wiring diagram L27/38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 05 24 10-0
Spare part plate

PT/PSL pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8412-01
PT/PSL pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8412-02
TE temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8416-01
TE temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8416-02
TE12011210 Bearing sensors . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8418-01
LSL1231 level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8420-01
LSL1231 level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8420-02
LSH1332 level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8420-03

L27/38
TE-exhaust temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8424-01

TE12011210 oil mist detector . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8426-01
Crank case monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8427-01
TE - temperature sensors, bearing. . . . . . . . . . . . . . . . . . . . . . . plate 1 8427-01
TE - Temperature sensors, splash oil . . . . . . . . . . . . . . . . . . . . . plate 1 8427-01
SE1704A/B/C tacho sensors . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 8428-01
ZSH/ZT1401 displacement transmitters . . . . . . . . . . . . . . . . . plate 1 8428-02
ZSH/ZT1401 displacement transmitters . . . . . . . . . . . . . . . . . plate 1 8428-03
2008-01-10

Sensors used on the engine

Pressure controllers Fig 84.1
The pressure controller register a deviation
in pressure and will only operate correctly if
the sensor is adjusted to the intended pres-
sure limit, see fig 84.1.
Pressure transmitters
The pressure transmitters register the actual
pressure and transform it into an electri-
cal signal (420 mA) corresponding to the
pressure range specified on the sensor, see
fig 84.1.
2004-02-17
Switch
In
Out N.O.
Out N.C.
Pressure controller
Analog
Pressure transmitter
Pressure sensor

L27/38
Fig 84.2 Temperature sensors (Pt 100)

The Pt 100 sensors consist of a temperature
resistance wire. The mechanical design
may vary depending on type of measuring.
Fig 84.2 shows a typical Pt 100 sensor for
measuring of liquid temperature and fig 84.3
shows a typical Pt 100 sensor for measuring
707 790-2.0
of bearing temperatures.
The sensor is made of a platinum (Pt) thread
with a resistance of 100 ohm at 0C, hence
the name Pt 100. The connection between the
Pt 100 sensor resistance and the measured
3 Wires temperature may be seen in the table.
2004-02-17
PT 100 sensor liquid
Fig 84.3
3 84C2-01
PT 100 sensor bearings
Temperature C 0 10 20 30 40 50 60 70 80 90 100
Resistance 100.00 103.90 107.79 111.67 115.54 119.40 123.24 127.07 130.89 134.70 138.50
Pt resistance 100

Temperature sensors (NiCrNi thermocouple)

The NiCrNi thermocouples consist of two Appearance and construction of the sensor
wires of different material: nickel-chromium can vary depending on the spot where the
and nickel-aluminium, respectively. The temperature is measured, see fig 84.4.
amount of voltage generated between the
The sensors used for measuring of the en-
two depends on the temperature of the me-
gine exhaust gas temperature from each
dium in which the sensor is placed. In the
cylinder contain two independent thermo-
temperature range from 0 C to 600 C, the
couples, one connected to the AlphaComm
generated voltage is from 0 V to 25 mV.
monitoring unit and one connected to the
The NiCrNi thermocouple is mainly used for AlphaComm safety unit.
measuring of engine exhaust temperature.
Fig 84.4
2004-02-17
Nickel - Chromium (Green)

707 780-3.3
Nickel - Aluminium (White)

1669217-1.2
Nickel - Chromium (Green)
Nickel - Aluminium (White)
NiCrNi thermocouples

L27/38
Fig 84.5 Level sensors

The level sensors shown in fig 84.5 are all
used for measuring high/low limits of liquid
levels. They function in the same way and
their design depends on the connection in
which they are to be used.
Normal In principle, they consist of a magnetic float
closed moving according to the liquid level and thus
activate a glass-cased, hermetically sealed
open
Normal
switch in the core of the level device.
2004-02-17
3 84D1-01
Level alarms

Tacho and proximity sensors Fig 84.6

In general, the sensors are used to mea-
sure the position of a movable mechanical GAP 1mm 0.5
part, but also used as a tacho sensor to Brown
detect rotational speed of a shaft. A transis- Black
tor circuit inside the sensor will react when
Blue
a metal object approaches the front of the
sensor, whereby the output signal from the Load
1638345-7.2
sensor is activated. The proximity sensor is
used mainly for relatively low speed mea-
surements and position measurements of
movable parts.
For high speed measurements, a magnetic Tacho and proximity sensor
tacho sensor generating an electrical sig-
nal is used. This sensor type consists of a
permanent magnet and a coil. A voltage is
induced in the coil when ferromagnetic mate-
rial passes the front of the sensor.
The mechanical design of the tacho and
proximity sensors may vary depending on
2004-02-17
type of measuring. Fig 84.6 shows typical

proximity sensors used for measuring of
speed or position of movable parts.

L27/38
Fig 84.7 Displacement transmitter

A displacement sensor is used to measure
the actual position of movable mechanical
parts. The measured displacement can be
angular or linear. The sensor registers the
actual position of the movable mechanical
part and transforms it into an electrical signal
(420 mA) corresponding to the range of dis-
placement specified on the sensor. The sen-
2040134-0.
Bearing sor will normally consist of a ferromagnetic

or magnetic part mounted on the movable
mechanical part and a fixed part incorporat-
ing an electronic circuit for conditioning of
Marks
the measured signal.
The mechanical design of the sensors
may vary depending on type of measuring.
Fig 84.7 shows typical displacement sensors
Fixed to mov-
for measuring of linear displacement.
able part
2004-02-17
4 mA
Mounted on mov-
able part
2049067-0.0
20 mA
Displacement transmitter

Alarm sensors Test of sensors

Generally, all measurements collected by the According to the maintenance program for
Alphacomm units, mounted on the engine the engine, the tests mentioned on the follow-
and the gear, are transmitted to the ships ing work cards should be carried out at every
alarm system where possible exceeding of major overhaul. The test shall make sure that
alarm limits will be detected and alarmed as in case of abnormal operating conditions, a
required throughout the vessel. The list with warning is given in orderto prevent a major
Summary of alarms gives the exact informa- breakdown.
tion of the sensors and their alarm limits.
The list Summary of alarms incorporated in
The connection to the ships alarm system this chapter gives the exact information of
is realised using a serial point-to-point con- the sensors and their alarm limits. The lists
nection. The electrical interface is specified Summary of shut downs, load reductions and
in the document: Alarm system interface, stand-by pump controls incorporated in the
MODBUS. following chapter 86 give the exact informa-
tion of the safety and control sensors and
their limits.
2004-02-17

L27/38
2004-02-17

Work card 84 101-01

Adjustment and test of pressure controllers
Stopped engine
Shut-off starting air
Working time: h/sensor Pressure testing pump with
Shut-off cooling water Capacity: 1 man reference manometer - not
Shut-off fuel oil supplied
Replacement and
Data wearing parts
Data for pressure limits from the list Summary of alarms
Plate no: 1 8412
2004-02-17
Starting position: Local monitoring, control and safety power are switched on.
Procedure sure indicated for high limit of the measured

parameter.
Adjustment
Open the protection cap in the top of the
Warning
sensor and use one of the below-mentioned
If a pressure controller has been replaced
procedures for adjustment of the setpoint.
by a spare unit, the new sensor has to be
Adjustment for decreasing pressure adjusted to the pressure limit specified for
(low limit) the measured parameter.
Pump up the pressure till the switch changes
over. Release the pressure slowly and check
that the switch changes back at the pres-
sure indicated for low limit of the measured
parameter.
Adjustment for increasing pressure
(high limit)
Pump up the pressure till the switch changes
over and check that it happens at the pres-
Release 84 101-01 page 84-233

L27/38
Fig 84.8 Test

Cable connection to It is possible to test the functioning of the
terminal box pressure controller. This is done in the fol-
lowing manner:
1. Cut off the system pressure with the
valve on the test block on which the
Protection sensor is mounted.
cover
2. Dismantle the screw lock on the test
coupling.
3. Connect the testing tool to the test
coupling.
4. Pump up the pressure as described
above and check that the sensor will
change over at the intended pressure
Test coupling limit.
Test block 5. Dismantle the test tool and mount the
screw lock after checking and adjust-
ing.
2004-02-17
6. Connect the system pressure by open-
Valve
ing the valve on the test block.
System pres-
sure
2046576-9.0
Pressure controller
page 84-234 Release 84 101-01

Work card 84 102-01

Adjustment and test of pressure transmitters
Stopped engine
Working time: h/sensor Pressure testing pump with
Shut-off cooling water Capacity: 1 man reference manometer not
Shut-off fuel oil supplied
Replacement and
Data wearing parts
Data for pressure limits from the list Summary of alarms Plate no: 1 8412
2004-02-17
Procedure
Adjustment
A pressure transmitter is adjusted by the
factory and does not need to be adjusted
on board the vessel. The limits for alarm are
set in the ships alarm system, limits for shut
down are set in the AT2000 LMCS safety sys-
tem and limits for automatic load reduction
are set in the remote control system.
Release 84 102-01 page 84-235

L27/38
Fig 84.9 Test

It is possible to test the functioning of the
Cable connection
to terminal box pressure transmitter. This is done in the fol-
lowing manner:
1. Cut off the system pressure with the
valve on the test block on which the
sensor is mounted.
Protection
covers 2. Dismantle the screw lock on the test
coupling.
3. Connect the testing tool to the test
coupling.
4. Pump up a pressure within the range of
the transmitter. If the tested parameter
is incorporated in the local operator
Test coupling panel on the engine, the pressure may
be read here. Measured parameters not
Test block incorporated in the local operator panel
are shown in the ships alarm system.
5. Release the pressure slowly and
2004-02-17
Valve check the pressures for alarm, load re
duction and shut down limits specified
for the tested parameter.
6. Dismantle the test tool and mount the
System pres-
sure
screw lock after checking.
7. Connect the system pressure by open
Job card 84 101
ing the valve on the test block.
Pressure transmitter
page 84-236 Release 84 102-01

Work card 84 103-01

Adjustment and test of temperature sensors (Pt 100)
Stopped engine
Working time: h/sensor Temperature testing tool
Shut-off cooling water Capacity: 1 man with reference termometer
Shut-off fuel oil not supplied

Replacement and
Data wearing parts
Data for temperature limits from the list Summary of Plate no: 1 8416
alarms Plate no: 1 8418
2004-02-17
Procedure
Adjustment
The Pt100 sensor cannot be adjusted. The
limits for alarm are set in the ships alarm
system, limits for shut down are set in the
AT2000 LMCS safety system and limits for
automatic load reduction are set in the re-
mote control system.
Release 84 103-01 page 84-237

L27/38
Fig 84.10 Test

It is possible to test the functioning of the
Pt 100 sensor. This is done in the following
manner:
1. Take the sensor out of its pocket or
Unscrew channel boring.
to remove
the sensor 2. Test the sensor by using a special tem-
perature testing tool.
3. Increase the temperature to the nor-
mal value stated for the measured
parameter. If the tested parameter is
incorporated in the local operator panel
Sensor on the engine, the temperature may be
read here. Measured para meters not
incorporated in the local operator panel
are shown in the ships alarm system.
Sensor pocket
4. Increase the temperature slowly and
check the high temperature alarm, load
reduction and shut down limits speci-
2004-02-17
fied for the tested parameter.
1 8416-01
5. Reduce the temperature slowly and

check the low temperature alarm, load
reduction and shut down limits speci
fied for the tested parameter.
Pt 100 sensor 6. Remount the sensor in the sensor
pocket after test.
page 84-238 Release 84 103-01

Work card 84 104-01

Adjustment and test of temperature sensors (NiCrNi)
Stopped engine
Working time: h/sensor High temperature testing tool
Shut-off cooling water Capacity: 1 man with reference thermometer
Shut-off fuel oil not supplied

Replacement and
Data wearing parts
Data for temperature limits from the list Summary of Plate no: 1 8424
alarms
2004-02-17
Procedure 2. Test the sensor by using a temperature

controlled testing tool.
Adjustment
3. Increase the temperature to a normal
The NiCrNi thermocouple sensor cannot be value stated for the measured para-
adjusted. The limits for alarm are set in the meter. The tested parameter is incor-
ships alarm system and limits for automatic porated in the local operator panel on
load reduction are set in the remote control the engine and the temperature may
system. be read here.
Test 4. Increase the temperature slowly and
It is possible to test the functioning of the check the high temperature alarm and
NiCrNi thermocouples. This is done in the load reduction limits specified for the
following manner: tested parameter.
1. Take the sensor out of the boring in the 5. Remount the sensor in the boring.
exhaust pipe.
Release 84 104-01 page 84-239

L27/38
Your notes:
2004-02-17
page 84-240 Release 84 104-01

Work card 84 105-01

Adjustment and test of level sensors
Stopped engine
Working time: h/sensor
Shut-off cooling water Capacity: 1 man No special tools
Shut-off fuel oil
Replacement and
Data wearing parts
Data for level limits from the list Summary of alarms
Plate no: 1 8420
2004-02-17
Procedure
Adjustment
The level sensors used for alarm operate Note
as a normally closed switch (NC) so that It is important that all alarms lead to prompt
a warning also can be given if the wire is investigation and remedy of the error. No
broken. Switch function normally open (NO) alarm is insignificant. It is therefore important
or normally closed (NC) can be chosen by that all engine crew members are familiar
turning the float 180. with and well trained in the use and impor-
Test tance of the alarm system. The most serious
parametres are additionally protected with
The functioning of the level sensor can be
automatic load reduction.
carried out by the following procedure:
1. Dismantle the level sensor mechani-
cally.
2. Check that the level alarm sets off when
the float is actuated by hand.
3. Remount the level alarm.
Release 84 105-01 page 84-241

L27/38
Your notes:
2004-02-17
page 84-242 Release 84 105-01

Work card 84 106-01

Adjustment and test of tacho and proximity sensors
Stopped engine
Working time: h/sensor No special tools
Shut-off cooling water Capacity: 1 man
Shut-off fuel oil
Replacement and
Data wearing parts
Data for speed limits from the list Summary of alarms Plate no: 1 8428
2004-02-17
Procedure
1. Start rotation of the shaft on which the
Adjustment tacho sensor is measuring.
Correct detection of position or counting of 2. Adjust shaft speed to a wellknown
teeth depends on the size of the gap between rpm, if necessary use a hand ta
the movable mechanical part and the front chometer for reference measurement.
of the sensor. If no signal is detected by the Alternatively, a frequency generator can
sensor, the measuring gap must be adjusted. be used for test of speed limits set in
The gap is expected to be 1.0 mm 0.5 mm. the system.
The number of teeth, relative speed values
and speed limits are set in the AT2000 LMCS 3. Read and check the measured para
system. meter in the local operator panel and/or
in the remote control system.
Test
4. Increase the speed slowly and check
It is possible to test the functioning of the the limits for alarm, control and over-
tacho and proximity sensors. This is done in speed stop specified for the tested
the following manner: parameter.
Release 84 106-01 page 84-243

L27/38
Your notes:
2004-02-17
page 84-244 Release 84 106-01

Work card 84 107-01

Adjustment and test of displacement transmitters
Stopped engine
Working time: h/sensor
Shut-off cooling water Capacity: 1 man No special tools
Shut-off fuel oil
Replacement and
Data wearing parts
Data for displacement from the list Summary of alarms
Plate no: 1 8428
2004-02-17
Procedure position corresponding to 4 mA is adjusted

with the zero setting and the position corre-
Adjustment sponding to 20 mA is adjusted with the gain
A displacement sensor is normally adjusted setting.
by the factory to a specified range of move-
ment and does not need to be adjusted on
Warning
board the vessel. But some sensors have
to be adjusted on board the vessel to fulfil If the engine fuel index displacement trans-
requirements for a plant specific range of the mitter has been replaced by a spare unit, the
measured movement. new sensor always has to be adjusted to the
fuel index range specified for the engine.
For adjustment of a displacement sensor,
the specific instruction for the particular
measurement must be used. In general, the
Release 84 107-01 page 84-245

L27/38
Test 2. Read and check the measured param-

It is possible to test the functioning of the eter in the local operator panel and/or
displacement sensors. This is done in the in the remote control system.
following manner: 3. Move the mechanical part slowly and
1. Move the mechanical part to a well check the control limits specified for the
known reference position for the tested parameter.
measured movement.
2004-02-17
page 84-246 Release 84 107-01

86. Safety equipment

Data sheet
Summary of shut downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 0X XX XX-X
Summary of load reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . drawing no 2 0X XX XX-X
Summary of stand by pump controls . . . . . . . . . . . . . . . . . . . . . drawing no 2 0X XX XX-X
2000-11-22

L27/38
2000-11-22

90. Tools
Spare part plate
Standard tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9010-01
Tools for cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-01
Tools for piston and connection rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-02
Tools for cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-03
Tools for fuel valve and fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-04
Tools for main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-05
Tools for Baewert indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-06
Control instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-07
Mounting device for oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-08
Lifting device for lub oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-09
Lifting tool for charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-10
Lever for cooling water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-11
Fork for intermediate piece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-12
2008-01-10
Dry cleaning device turbine cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-13

Tools for connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-14
Hydraulic tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-15
Closing device for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-17
Peak pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-18
Peak pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . plate 1 9012-19

L27/38
2008-01-10

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MAN B&W Diesel L27/38

y Data sheets (oil list, tightening torques

How do I order spare parts?

Operating data and set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 00-16

Release TOC_1 00 page 00-1

page 00-2 Release TOC_1 00

Main data for L27/38

Turbocharger principle Constant

Release 1 00A1-01 page 00-3

General safety precautions

page 00-4 Release 1 00B1-01

Entering the crankcase or cylinder Slow turning

Feeling-over Grinding tools

of cooling water or lubricating oil systems.

Check and maintain

Release 1 00B1-01 page 00-5

Capacities at MCR MDO operation

page 00-6 Release 1 00C1-01

Capacities at MCR HFO operation

Water in engine m3 0.15 0.15 0.15 0.15

* Depending on fuel oil quality

Release 1 00C2-01 page 00-7

Maintenance program L27/38 MDO operation

Check new/ overhaauled parts

Description Check the condition

page 00-8 Release 1 00D1-01

Check new/ overhaauled parts

Description Check the condition

Starting air system

See Maintenance programme during operation, page 12.

Release 1 00D1-01 page 00-9

Maintenance program L27/38 HFO operation

Check new/ overhaauled parts

Description Check the condition

page 00-10 Release 1 00D2-01

Check new/ overhaauled parts

Description Check the condition

Lubricating oil system

See Maintenance programme during operation, page 14.

Release 1 00D2-01 page 00-11

Maintenance program L27/38 MDO operation

Check new/ overhaauled parts

Description Check the condition

page 00-12 Release 1 00E1-01

Check new/ overhaauled parts

Description Check the condition

Local monitoring, control

See Maintenance programme major overhaul/inspection, page 8.

Release 1 00E1-01 page 00-13

Maintenance program L27/38 HFO operation

Check new/ overhaauled parts

Description Check the condition

page 00-14 Release 1 00E2-01

Check new/ overhaauled parts

Description Check the condition

Local monitoring, control

See Maintenance programme major overhaul/inspection, page 10.

Release 1 00E2-01 page 00-15

Operating data and set points

Lubricating oil system

page 00-16 Release 1 00F1-01

Materials containing PCBs, PCTs, PBBs at levels of 50 mg/kg or more

Gases sealed in the machinery