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Original valid only True Copy

IW'~I(al unbroken Technical NOx File E2

M32

M32C
Engine Serial No.:
38007

Technical Files
and On-board
NOx Verification Procedures

EMISSION CERTIFICATKYi
J--..::.:..:..:.:..::...:..:...:...:......:;___ _ _ _.. ' ~--

Approval No.: Dale:

Do not discard

This document is to be kept on board

en I 21 .08.2003 AA020925 1/1


Table of Contents E2.01
IMO-Engine

Technical NOx File


E2
Table of Contents
IMO-Engine E2.01
Technical Data
Acceptance Test Record E2.05.20.03.64
Engine Group Information
E2.05.30.00.01
Emission Test Report
Parent Engine E2.05.40.00.01
Engine components . .
influencing its NOx emiSSion E2.05.50.03.64

~ Record of changes
to emission related components E2.05.51.00.00
Engine adjustment
E2.05.60.00.00
NOx verification
E2.05.70.00.D1
Piston
E2.05.81.00.01
Cylinder Head
E2.05.82.00.00
Nozzle Element
E2.05.83.00.00
Camshaft Section
E2.05.84.00.00
Fuel Injection Pump
E2.05.85.00.01
Exhaust Manifold Mounting
[2.05.86.00.06
Turbocharger
E2.05.87.00.05
Charge Air Cooler
E2.05.88.00.02

_e_n_/_21-.-08-.-20_0_3--------------------- AA020116
1/1
Technical Data E2.05 .20.03.64
Acceptance Test Record

M32

Technical Data

Acceptance Test Record

en I 21.09.2001 FB021115 1/1


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CATERPILLAR DIESEL-ENGINE

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\Order Ho! qlne S.rlil 110.:
Motoren GmbH & Co. KG Acceptance Test Record 261359 I :uoo1
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Nudle .rtop 20 1& bas1c val. tor Exa~le:


2.3(-:l E:w.ple: 18(+) IMeaSiirad on test bed and coupled to
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1/100- ~ - F1.._- at full lm~~d: 28 abor
_ - . Heu~m~d on buttaa frae and cwphd wtth
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ahead
[bar] ~ B.D. C. 20 2'0 20 20 zo 20 zo 20 jzo FCtllow Max 1R.tT"uctlons fo.t 1M;ta11ation. on jU'esSure at 36ti 'I'J*I and

Ind1c.ator: LEHMKH l !tiCHrt.s told 1


Ia 19 20~5 20 It.5 20~5 2li ZO 19 . .5 3) Heasurecl at 1Jla1n buriq on flywlteel end t. ~ c. p4.9 ,...
Exltaust dda
Type- ~ l1Wi Pi.EHU LS wam 16 .5 18 l!l 18 1& .5 19 18 18.5 19 4) lileaslintd at last c.-shaft bearing

. Hctu: cold 15 1-B 19.!i '20 lt.S 20 IS 19 18.5 Acaptance: ABS


Cranll:(ue puuare 3.0 HZQ T.D.c. HG 53463
Keuured at housing co~ef. Ito.: 4 want 15.5 11 17 17 17 18 17 17.5 18 Jrsn) Ct1culated to ISO 3D46 06. Ot
Spec1f1c fl.l.el conullpt:1611 1nc1uding 1 1ubr1cat1nt
on plllp a.nd l c.;al1n; water puqp. FHU En;1neer- Appt'Clrod
'* Musured .t cot'roi pa~~el Cutt!tatt side
cold 17 lll 19.5 13.5 19 19.5 19 19.5 19.5
,
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OICJ.RE I Version S.iJ I COPYRIGHT .02.96 r.
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!iltt'et J l>f J :
CATERPillAR DIESEL-ENGINE
Ordtr Ho: ~ nu1ne 5er1a1 No.;
r.'lotoren GmbH & Co. KG 261359 l800l
Acceptance Test Record I
8l Run F'aeL Output Fuel COll5UMpt1on: Lub.rlcat1&g;. on Cooi1ng wter Charge air coo1et" c E.Mau.st gas tnp~ature
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turD cool. cool. press after
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Engine Group Information E2.05.30.00.01

M32

Engine Group Information

en I 01.10.2001 FB020908 1/1


Emission Test Report No. 32C

Engine Group Information

Group ldentifikation 6/8/9 M32C


Method of pressure charging single pipe system
Charge air cooling system water
Max. rated power per cylinder 490 kW
Max.permitted range of derating 75 % of max rated power per cvlinder
Rated speed 600 rpm
Bore 320 mm
Stroke 480 mm
Start of delivery (fuel pump) 6,5( +0,5 -1 ,5) 'CA BTDC
End of needlelift (injectionnozzle) 1,5 CABTDC

Combustion cvcle 4- stroke


Cooling medium water
Individual cylinder displacement 38,60 ltr.
Cylinder number and configuration 6/8/9 - In line
Method of air aspiration pressure charged
Fuel type HFO/MDO
Combustion chamber type open chamber
Nominal compression ratio 15,5
Fuel system type single element

Electr. inJection control no


Variable injection timing no
Variable turbocharger geometrie no
Variable valve timing no
Charge cooling system yes

.
Exhaust gas recirculation no
Water injection I emulsion no

.. Air injection
Exhaust aftertreatment
Exhaust aftertreatment type
no
no
-
Dual fuel no

IMOSHEET.XLS
Emission Test Report E2.05.40.00.01

Parent Engine
M32

II

Emission Test Report

Parent Engine

\ ~
~--

"iT

en/07.11.2001 FB020910 1/1


Emission Test Report No. 32C

Engine Information

Engine
Manufacturer Caterpillar Motoren GmbH
Engine type 9 M32C
Group identification 6/8/9 M32C
Serial number 38 061
Rated speed 600 rpm
Rated power 3308 kW
Intermediate speed - rpm
Max. torque at intermediate speed - Nm
Cylinder number and confir:~uration 9 cyl. - inline
Bore 320 mm
Stroke 480 mm
Mean effective pressure at rate! power 19 bar
Max. cylinder pressure at rate! power 145 bar
Auxiliaries 3 pumps

Specified ambient conditions


Max. Seawater temperature 32 oc
Max. Charoe air temperature, if applicable 45 oc
Cooling system spec. intermediate cooler yes
CoolinQ system spec., charr:~e air star:~es 2 star:~e
Low I high temp.cooling system setpoints 30 I 90 oc
Maximum inlet depression 25 mbar
Maximum exhaust backpressure 30 mbar
Fuel oil specification MDO/HFO
Fuel oil temperature MOO 40 oc
Fuel oil temperature HFO 150 oc
Lubricatinr:~ oil specification ace. MaK ,4.05.08.00/3

Application /lntendet for


Customer Surf
Final application/ installation, Ship Multi Purpose
Final application/ installation, Engine main

Emissions test results


Cycle 02 E2

NOx 10,2 10,5 lr:~/kWh


Test identification
Date I time 07.08.01
Test site I bench MaK Stand 4
Test number
Surveyor GL
Date and Place of report
Signature

IMOSHEET.XLS
Emission Test Report No. 32C

Measurement Equipment

Test Cell Information


Diameter 800 mm
Length 50 m
Insulation yes
Probe location 5 m
Remark

Model Meas.ranges

Fuel Characteristic

Fuel type destillate ace. EN 590


Fuel properties Fuel elemental analysis
Density ISO 3675 0,845 kq/1 Carbon 86,85 %mass
Viskosity ISO 3104 3,1 mm 2 /s Hydroqen 13,1 %mass
LHV I Hu 42507 MJ/ko Nitrooen n.n. %mass
Oxvaen n.n. %mass
Sulphur 0,09 %mass

IMOSHEET.XLS
\ J
Emission Test Report No. 32C Ambient and Gaseous Emissions Data

Mode 1 2 3 4 5 6 7 8 9 10
Power I Torque % 100 75 50 25 10 100 75 50 25 10
Speed % 100 100 100 100 100 100 100 100 100 100
Time at beginning of mode 10:01 10:30 10:43 10:57 11:10 12:13 11:55 11:44 11:34 11:21

Ambient Data
Atmosph. pressure mbar 1005 1005 1006 1006 1006 1005 1006 1006 1006 1006
Intake air temp. c 25,4 25,7 29,2 30,2 28,3 25,7 27,8 29 29,5 27,8
Intake air humidity % 47,1 43,7 38 34,9 34,9 44 41 36 33 36
Atmospheric factor (fa) 1,00 1,01 1,02 1,02 1,01 1,01 1,015 1,019 1,024 1,013

Gaseous Emissions Data


NOx cone. wet ppm 897,5 983,8 1012,2 793,3 517,6 983,8 1017,7 946,2 697,9 453,3
co cone. dry ppm 56,2 36,9 42,3 98,7 170,8 36,9 36,4 65,7 134 195
C02 cone. dry % 6,15 6,06 6,46 6,45 4,91 6,06 6,32 6,71 6,11 4,29
02 cone. dry % 12,5 12,6 11,9 11,9 14,1 12,6 12,18 11,6 12,4 15,01
HC cone. wet ppm 154,5 178,5 235,3 264,8 325,2 178,5 217,2 245,1 253,4 329,5
NOx hum.corr.factor - - - - - - - - - -
Fuel spec.factor (FFHl - - - - - - - - - -
Dry/wet corr.factor - - - - - - - - - -
NOx mass flow kg/h 42,77 34,81 23,67 10,31 4,33 34,81 26,8 16,44 7,53 3,5
co mass flow kq/h 1,54 0,75 0,560 0,73 0,84 0,75 0,55 0,65 0,83 0,89
C02 mass flow kglh 2656 1943 1347 748 379 1943 1489 1044 594 306,0
02 mass flow kg/h 3933 2928 1814 1009 790 2928,0 2088 1314 876,0 779
HC mass flow kq/h 2,26 1,93 1,66 1,04 0,84 1,93 1,73 1,3 0,83 0,78
802 mass flow kglh - - - - -
NOx specific <:~/kWh 9,66 10,57 10,69 9,22 9,59 10,57 10,79 9,91 9,12 10,41
490 kW/Zyl 368 kW/Zyl

IMOSHEET.XLS
. . .. . ...... ~.- I . .1 .. .... .

.-, i

Emission Test Report No. 32C Engine Test Data

Mode 1 2 3 4 5 6 7 8 9 10
Power I Torque o/o 100 75 50 25 10 100 75 50 25 10
Speed % 100 100 100 100 100 100 100 100 100 100
Time at beqinning of mode 10:01 . 10:30 10:43 10:57 11:10 12:13 11:55 11:44 11:34 11:21

Engine Data
Speed rpm 602 598 602 602 603 598 601 600 600 600
Power kW 4426 3294 2215 1118 451 3294 2485 1659 826 336
Mean eff. pressure bar 25,4 19,02 12,72 6,4 2,58 19,02 14,28 9,55 4,76 1,93
Fuel rack mm 48,4 41,0 33,7 24,9 15,7 41,0 35,6 30,2 20,9 15,1
Uncorr.spec.fuel cons. q/kWh 190,0 187 193 213 268 187 190 200,0 229 292
Fuel flow kg/h 843 617 428 238 121 617 473,0 332 189 98
Air flow kg/h - - - - - - - - - -
Firinq pressure bar 190 - - - - - - - -
End of needlelift (Noz) CA 1,5 - - - - - - - - -
Charge air pressure bar 2,93 1,925 0,929 0,218 0,00 1,925 1,165 0,51 0,104 0,00
Turbo speed rpm 21765 18767 14561 8969 5212 18767 15787 11881 7322 4631
Exhaust flow (gexhw) kglh 30494 22606 14769 8210 5372 22606 16670 11041 6853 4944
Exhaust temp. c 342 350 392 401 310 350 379 413 377 274
Exhaust backpress. mbar - - - -
LT Coolant temp. in c 38 38 39 39 39 38 39 39 39 39
LT Coolant temp. out c 42 41 41 40 40 41 41 40 40 40
HT Coolant temp. in c 81 83 88 90 89 83 88 89 89 88
HT Coolant temp. out c 90 88 89 91 89 88 89 90 89 90
Cyi.Coolant pressure bar 4,2 4,2 4,2 4,2 4,2 4,2 4,2 4,2 4,2 4,2
Temp. intercooled air c 50 47 46 45 45 47 46 45 45 45
Lubricant tern p. c 59 60 56 57 57 60 58 57 57 58
Lubricant pressure bar 4,7 4,7 4,8 4,8 4,8 4,7 4,7 4,8 4,8 4,8
Inlet depression mbar - - - - - - - - - -
490 kW/Zyl. 368 kWIZyl.

IMOSHEET.XLS
Engine components E2.05.50.03.64
influencing its NOx emission

M32

Engine components

influencing its NOx emission

en I 20.08.2003 FB022681 1/1


.. . . . .. I . .... :;~=~"'~

IDENTIFICATION - LIST OF ENGINE COMPONENTS WHICH INFLUENCES NOX-EMISSIONS CATERPILLAR CONFIDi::NTIAL.: YELLOW

TYPE: 9N32C ENGINE NO.: 38007 DATE: 20.08.03

POSITION COMPONENT DOCUMENT NO. REMARK FOR IDENTIFICATION

0805 PISTON E2.05.81.00.NN MARKING AT BOTTOM EDGE


.OF PISTON SKIN: 9 -18
~----~-------------------------------------------------------------------------------------------------------------
1005 CYLINDER HEAD E2 .05. 82.00.NN MARKING AT TOP OF
CYLINDER HEAD: 9 -05
------------------------------------""':'-----------------------~------------""--------'---------------~----------------~--

1310 NOZZLE ELEMENT E2. 05.83.00 .NN NOZZLE DESIGNJ\cTION AT TOP COLLAR: E2/l

-----,------ .... --------------------------------.---------------------------------------------.--------------------------:


1504 CAMSHAFT SECTION E2.05.84.00.NN MARKING AT FLANGE,
FOR CYL. NO. OR ALTERNATIVE .IN THE SHAFT-AREA: 93 2026
--------------------------------~~~------------.---..:.----------...:. ______ :,._;.. ___________ ____________________
.:_ -:-------- ... ...:---
1960 FUEL !NJECTION PUMP E2.05.85.00.NN SPECIFICATION ON
NAME PLATE: PEO-G058A
--------------~---------------------------------------------------------~-----------~-----------------~------------
.3005 TURBOCHARGER E2.05.87.00.NN SP3CIFICATION ON NAME PLATE:
4GS118Bl93K

3085 CHARGE AIR COOLER E2.05.88 .. 00.NN SPECIFICATION ON NAME PLATE:


108/26/9+9/2-ESV-S99-20N162
. .
------------------------------------------------------------~------------------------------------------------------
3200 EXHAUST MANIFOLD E2.C5.86.00.NN ACCORDING DOCUMENT
MOUNTING
-----.---------------.----------------------------------------------,.---------------------------------------------
!R! PAGE;RES;EXIT;

~-~-,;;.,. -o:\ - '',:<.'-'


Record of changes E2.05.51.00.00
to emission related components

M20/M25/M32/M43

i
!
ci
2
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:.
&
c
6...
0

Q
~

en /17.04.2001 FB020165 1/1


Engine adjustment E2.05.60.00.00

M32

The following installation requirements must be met at rated load and speed to
enable the engine to comply with the nitrogen oxides (NOx) emission limits
of regulation 13 of Annex VI of MARPOL 73/78:

1. Commencement of injection:
Needle bouncing as arithmetic mean value over all cylinders:
Nominal value: 1,5" (+0,5', -1') before TDC
Measured with MaK-EB-Tester

2. Commencement of fuel delivery:


Commencement of fuel delivery as arithmetic mean value over all cylinders:
Nominal value: 6,5' (+0,5', -1') before TDC
Measured according to the overflow method (control travel >30 mm)
or pre-stroke dimension 6,0 mm at the auxiliary device

3. LT cooling water temperature:


l T water inlet temperature:
Nominal value: 30'C (:~:2"C) for PI controllers
Working range: 20 - 30'C for P controllers

4. HT cooling water temperature:


HT water inlet temperature:
Nominal value: 90'C (2 'C) for PI controllers
Working range: 82 - 92 "C for P controllers

5. Charge air temperature:


Nominal value: 40'C (2 'C)

6. Piston distance:
Distance: Piston- cylinder liner:
Nominal value: 20,5 mm (:!:1,0 mm)
Measured: from top edge of piston to liner support

7. Valve timing:
see technical data E2.05.20.nn.nn (acceptance test report/timing data)

en /17.04.2001 FB020181 1/1


NOx verification E2.05. 70.00.01

M32

3 7 4 4 2 -03 HH
II
On-board NOx verification procedure
?nn~ -m~-1 7

Engine Parameter Check Method

Introduction:
The engine parameter check method that follows can be used by the surveyor to
verify that the engine, as installed on board the ship, complies with the nitrogen
oxides (NOx) emission limits of regulation 13 of Annex VI of MARPOL 73/78.
This method is to be used for the initial certification survey, periodic and
intermediate surveys, and initial engines certification survey.

Steps of engine parameter check method:

1. Based on the acceptance test record (E2.05.20.nn.nn) check the thikness of both the
distance plate under the injection pumps (E2.05.85.nn.nn) and of the lever-drive
distance plate (E2.05.85.nn.nn).

2. Compare the marking of the IMO components with the details of


the engine component list (E2.05.50.nn.nn).
The position of the IMO marking is shown on the indicated drawings.

3. Remove Cylinder head and control distance piston-cylinder liner:


measured from top edge of piston to top edge of flame ring.
Nominal value see engine adjustment E2.05.60.nn.nn

4. Check the IMO marking on the flywheel, to make sure that the commencement
of fuel delivery is unchanged.

4.1 Remove screw plUg (1).

4.2 Turn the engine until the bore in the helical gear wheel is centrical
with regard to the bore in the cover.

4.3 IMO check bore hole (thrust ring) turned directly over the groove (cap)
so as to be congruent.
IMO notch checked on the flywheel at dead center indicator.

4.4 After check screw plug (1) screwed into cover again.

If the IMO adjustment does not match the dead centre indication,
inform the MaK Customer Service!

en /17.04.2001 FB020201 1/2


NOx verification E2.05. 70.00.01

M32

en 17.04.2001 FB020201 2/2


Piston E2.05.81.00.01

M32

Marking at bottom edge of piston skirt (X)


II

I
X

~--~-~---

en /17.04.2001 FB020448 1/1


Cylinder Head E2.05.82.00.00

M32

Marking (X)
II

en I 17.04.2001 FB020187 1/1


Nozzle Element E2.05.83.00.00

M32

Nozzle designation at top collar (X)


II

X"

en /17.04.2001 FB020189 1/1


Camshaft Section E2.05.84.00.00

M32

Marking: (X)
II

en /17.04.2001 FB020191 1/1


Fuel Injection Pump E2.05.85.00.01

M32

Pump specification on nameplate (X)


Distance plate ( Y)

r--ll
L __ _ j .
X n

Distance plate ( z)

en I 26.07.2001 FB020912 1/1


Exhaust Manifold Mounting E2.05.86.00.06

M32

II

"'*".

en /19.10.2001 FB021248 1/1


Turbocharger E2.05.87 .00.05

M32

Turbocharger specification on nameplate (X)

0
0


t:1
0

0 0 ...

en /26.07.2001 FB020916 111


Charge Air Cooler E2.05.88.00.02

M32

Charge air cooler specifiation ( X )



0 ~
M

0 0 60 0

en I 26.07.2001 FB020918 1/1