MAN Diesel & Turbo L28/32H User Manual

MAN Diesel & Turbo L28/32H

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L28/32H

Instruction Manual - Marine

Four-stroke GenSet

compliant with IMO Tier II

Table of Contents

Index2
Table of Contents4
Engine Data9
Warning12
Main Particulars14
Manual Description15
Safety Information16
Cylinder Head16
Cross Section18
Key for Engine Designation19
Engine Type Identification19
Designation of Cylinders20
Engine Rotation Clockwise21
Code Identification for Instruments22
Explanation of Symbols22
Introduction to Planned Maintenance Programme24
Working Cards24
Planned Maintenance Program25
Cylinder Head25
Operation Data & Set Points29
Exhaust Gas Temperatures30
Turbocharger Speed30
Limits for Turbocharger Overspeed Alarm30
Cooling Water Pressure, Alarm Set Points30
Green Passport31
Data for Pressure and Tolerance32
Camshaft32
Camshaft33
- Data for Tightening Torque34
- Declaration of Weight36
- Ordering of Spare Parts37
- How to Return Spare Parts And/Or Tools39
- Service Letters40
- Conversion Table41
- Basic Symbols for Piping44
- Operation of Engine47
- Preparations for Starting48
- Start and Stop on HFO49
- Starting49
- Stopping49
- Tending During Running49
- Starting on MDO50
- Maintenance During Standstill51
- Out-Of Service51
- Stand-By Engines51
- Works before Major Repairs51
- Add Cooling Water and Check with Pressure52
- After Restoring Normal Lubricating Oil Circulation52
- Check the Governor52
- Lubricate Bearings and Rod Connections52
- Starting-Up after out of Service Periods53
- To be Made During the Starting-Up53
- To be Made Immediately after Starting53
- Guidelines for Longterm Low-Load Operation on HFO54
- Part Load/Low Load Operation54
- Guidelines Regarding Gensets Operating on Low Sulphur Fuel Oil55
- Low Sulphur Distillates55
- Low Sulphur HFO55
- Performance and Condition56
- Air Cooler57
- Evaluation of Performance Data57
- Fuel Injection Pump57
- Exhaust Valves58
- Fuel Valves58
- Turbochargers58
- Engine Room Ventilation, Exhaust System59
- Fuel Injection Pumps59
- Evaluation of Readings Regarding Combustion Condition60
- Amount of Condensation Water in the Charge Air Receiver61
- Condensate Amount61
- Amount of Condensate Water in Air Tanks62
- Draining of Condensation Water62
- Engine Performance Data63
- Troubleshooting67
- Starting Failures68
- Faults in Fuel Oil System69
- Disturbances During Running72
- Ignition in Crankcase75
- Trouble Shooting Guide for Centrifugal By-Pass Filter76
- Trouble Shooting Guide for Turbine Starter77
- Trouble Shooting for Cooling Water System79
- Trouble Shooting for Lubricating Oil Cooler80
- Media Specification82
- Specification for Lubricating Oils for Heavy Fuel Oil Operation83
- Lubricating Oil Selection84
- Cylinder Lubricating Oil85
- Lubricating Oil Additives85
- Operation with Low Sulphur Fuel85
- Speed Controller85
- Oil During Operation86
- Temporary Operation with Gas Oil86
- Lube Oil Requirements for Operation with Gas Oil/Diesel Oil/Biofuel88
- Doped Oil Quality89
- Bypass Equipment93
- Operation on Heavy Fuel Oil (HFO)93
- Operation on Marine Diesel Oil (MDO) & Marine Gas Oil (MGO)93
- Treatment and Maintenance of Lubricating Oil93
- Cleaning Capacity94
- Lubricating Oil Preheating94
- Separator94
- The Required Flow94
- Check of Lubricating Oil System95
- Separator Installation95
- Deterioration of Oil96
- Oxidation of Oils96
- Water in the Oil96
- Criteria for Cleaning/Exchange of Lubricating Oil97
- Evaluation of the Lubricating Oil Condition97
- Replacement of Lubricating Oil97
- Viscosity97
- Lubricating Oil Types Used in the Engine99
- Lubricating Points99
- Lubricating Oil in Base Frame101
- Specific Lubricating Oil Consumption - SLOC102
- Heavy Fuel Oil (HFO) Specification104
- Leak Oil Collector105
- Heavy Fuel Oil Processing109
- Selection of Heavy Fuel Oil109
- Separators109
- Settling Tank109
- Combustion Properties111
- Homogeniser111
- Pump Characteristics111
- Vanadium/Sodium111
- Ignition Quality112
- Sulphuric Acid Corrosion113
- Additives for Heavy Fuel Oils114
- Blending the Heavy Fuel Oil114
- Compatibility114
- Heavy Fuel Oils with Low Sulphur Content114
- Analysis of Samples115
- Sampling115
- Tests115
- Diesel Oil (MDO) Specification116
- Marine Diesel Oil116
- Lubricity117
- Gas Oil / Diesel Oil (MGO) Specification118
- Bio Fuel Specification120
- Improper Handling of Operating Fluids121
- Determining the Required Preheating Temperature122
- Determining the Viscosity-Temperature Curve122
- Viscosity-Temperature Diagram (VT Diagram)122
- Fuel Oil Cleaning124
- Purification Recommendations124
- Distillate126
- Engine Cooling Water Specifications126
- Damage to the Cooling Water System127
- Hardness of the Water127
- Processing of Engine Cooling Water127
- Additives for Cooling Water128
- Anti-Freeze Agents128
- Chemical Additives128
- Slushing Oil128
- Biocides129
- Clean Cooling System129
- Prerequisite for Effective Use of an Anticorrosive Agent129
- Concentrations of Chemical Additives130
- Nitrite-Containing Chemical Additives131
- Permissible Cooling Water Additives131
- Emulsifiable Slushing Oils132
- Nitrite-Free Additives (Chemical Additives)132
- Anti-Freeze Solutions with Slushing Properties133
- Cooling Water Inspecting134
- Testing the Typical Values of Water134
- Testing the Concentration of Anti-Freeze Agents135
- Testing the Concentration of Anticorrosive Agents135
- Testing the Concentration of Chemical Additives135
- Cooling Water System Cleaning136
- Lime and Rust Deposits136
- Oil Sludge136
- Cleaning Agents for Removing Limescale and Rust Deposits137
- Following Cleaning137
- Water Specification for Fuel-Water Emulsions139
- Specifications for Intake Air (Combustion Air)140
- Cylinder Head141
- Air Inlet and Exhaust Valves142
- Valve Rotator142
- Dismantling of Cylinder Head143
- Inspection of Inlet Valve, Exhaust Valve and Valve Guide145
- Dismantling of Inlet and Exhaust Valve146
- Inspection of Inlet Valve, Exhaust Valve and Valve Guide147
  - Inspection of Valves/Valve Seats147
  - Reconditioning of Valve Spindle Seat and Valve Seat Ring148
  - Valve Rotator Inspection151
- Valve Rotator152
- Replacement of Valve Guide153
  - Dismounting of Valve Guide154
  - Safety Valve155
  - Indicator Valve158
  - Replacement of Sleeve for Fuel Injector160
  - Dismounting of Sleeve for Fuel Injector161
  - Inspection of Bore in Cylinder Head and Mounting of the Sleeve161
- Replacement of Valve Seat Ring162
  - Dismounting of Valve Seat Rings163
  - Procedure for Dismounting a Valve Seat Ring163
  - Mounting of Valve Seat Rings164
- Mounting of Cylinder Head166
- Inspection of Cylinder Head Cooling Water Space168
- Cylinder Head Exploded View170
- Valve Spindles and Valve Gear172
- Safety Valve and Indicator Valve174
- Cylinder Head, Top Cover176
- Piston/Connecting Rod178
- Piston, Connecting Rod and Cylinder Liner179
- Dismounting of Piston and Connecting Rod180
- Separation of Piston and Connecting Rod183
- Assembly of the Piston and Connecting Rod184
- Piston (with Flame Ring)185
- Removal of Piston Ring186
- Inspection of Piston186
- Testing Mandrel for Ring Grooves187
- Clearance Ring/Groove187
- Position of Piston and Scraper Rings188
- Marking of Piston and Scraper Rings188
- Connecting Rod189
- Cleaning and Inspection of Big-End Bore190
- Measurement of Big-End Bore190
- Connecting Rod Bush191
- Bearing Shells for Big-End191
- Criteria for Replacement of Connecting Rod Big-End/Main Bearing Shells193
- Bearing Shells for Re-Use195
- Limiting Case - Wear197
- Limit Case - Levelling198
- Limit Case - Permanent Breakage of the Running Surface199
- Limit Case - Empty Slots200
- Assembling of Piston and Connecting Rod201
- Fitting of Piston and Scraper Rings203
- Hydraulic Tightening of Connecting Rod Screws205
- In-Situ Inspection of Connecting Rod Big-End Bearin207
- Inspection and Honing of Cylinder Liner210
- Measurement of Cylinder Diameter211
- Replacement of Cylinder Liner214
- Dismounting of Cylinder Liner215
- Mounting of Cylinder Liner216
- Grinding of Seal Face on Cylinder Liner and Cylinder Head217
- Dismounting of Piston and Cylinder Liner at Low Overhaul Heights219
- Piston and Connecting Rod (Hydraulic Tightened)221
- Cylinder Liner and Water Guide Jacket223
- Camshaft and Camshaft Drive226
- Inspection and Replacement of Camshaft Bearing229
- To Check Roller Path of Cams230
- Adjustment of Camshaft for Valve and Injection Timing231
- Measure of Fuel Pump Lead232
- Intermediate Wheel235
- Camshaft and Camshaft Bearing237
- Operating Gear for Valve and Fuel Injection Pumps240
- Roller Guides240
- Operating Gear for Inlet and Exhaust Valves240
- Inspection of Valve Roller Guides241
- Dismounting of Roller Guide242
- Replacement of Roller, Bush and Shaft Pin242
- Mounting of Roller Guide242
- Inspection of Fuel Injection Pump Roller Guide243
- Control and Adjusting of Valve Clearance245
- Roller Guide and Push Rods248
- Control and Safety Systems251
- Governor251
- Pick-Up for Engine RPM251
- Regulating Shaft251
- Main Instrument Panel253
- Instruments and Automatics253
- Instrumentation254
- Pressostates and Thermostates254
- Shut-Down Switches/Alarm Switches254
- Leakage Alarm (LAH 42)254
- Alarm for Prelubricating (LAL 25)255
- Alarm and Shut-Down for Overspeed255
- Lambda Controller256
- Starting Box258
- Tacho Fail259
- Engine Run259
- Engine RPM Signal259
- Converter for Engine- and Turbocharger RPM Signal259
- Functional Test and Adjustment of Safety, Alarm/Monitoring Equipment260
- Maintenance of Monitoring and Safety Systems261
- Functional Test and Adjustment of Overspeed Trip262
- Adjustment and Test of On/Off Pressostate264
- Alarm for Falling Pressure265
- Alarm for Rising Pressure265
- Adjustment and Test of On/Off Thermostate266
- Function and Test of Level Switch (LAL 25)268
- Adjustment and Test of Analogous Pressure Transmitter270
- Adjustment and Test of Analogous Temperature Transmitter272
- Adjustment of the Lamda Controller275
- Adjustment of the Stop Screw275
- Governor and Governor Drive276
- Regulation Mechanism282
- Overspeed Device285
- Instrument Panel287
- Thermometer293
- Thermostate Difference Pressostate and Pressure Transmitter296
- Prelubricating Oil Alarm (LAL 25)298
- Level Switch in Oil Sump (LAL/LAH 28)300
- Local Starting Box - no 1302
Local Starting Box - no303
- Local Starting Box - no 2306
- Local Starting Box - no 2 (Incl. High Lub. Oil Temp.)308
- Engine Control Box310
- Terminal Box312
- Converter314
- Crankshaft and Main Bearings317
- Vibration Damper317
- Checking of Main Bearings Alignment (Deflection)318
- Checking the Deflection Measurement319
- Engines Equipped with Turning Gear319
- Effecting the Deflection Measurement319
- Alignment of Main Bearings319
- Measurement of Crank Throw Deflections by Means of Dial Indicator321
- Vertical and Horizontal Deflections of Crank Throws321
- Vertical Deflection of Crank Throw at Flywheel321
- Inspection of Main Bearing Shells324
- Make Ready for Dismantling of the Main Bearing325
- Dismantling of the Main Bearing Cap325
- Dismantling of the Main Bearing Shells325
- Mounting of the Main Bearing Shells326
- Mounting of the Main Bearing Cap326
- Inspection of Guide Bearing Shells327
- Dismantling of the Guide Bearing Cap328
- Dismantling of the Guide Bearing Shells328
- Mounting of the Guide Bearing Shells329
- Bearing Cap330
- Crankshaft View334
- Resilient Gear Wheel338
- Coupling for Central Driven Lub. Oil Pump340
- Resilient Gear Wheel View348
- Flywheel with Gear Rim354
- Torsional Vibration Damper360
- Engine Frame/Oil Pan374
- Engine Frame and Base Frame375
- Functional Test of Crankcase Safety Relief Valves376
- Frame with Main Bearings378
- Front Cover for Lubricating Oil Pump380
- Front Cover for Lubricating Oil Pump and Cooling Water Pump382
- Covers on Frame386
- Turbocharger System391
- Cleaning the Turbocharger in Service Water Washing of Compressor393
- Compressor393
- Cleaning the Turbocharger in Service Dry Cleaning - Turbine394
- Dry Cleaning of Turbochargers395
- Cleaning the Turbocharger in Service Water Washing - Turbine Side397
- Water Washing System397
- Overhaul of Charging Air Cooler398
- Charge Air Cooler Housing - Draining400
- Water Washing of Compressor Side Turbocharger402
- Dry Cleaning of Turbocharger - Turbine Side405
- Water Washing of Turbine Side407
- Charging Air Cooler - Freshwater409
- Charging Air Cooler - Seawater417
- Exhaust Pipe Arrangement423
- Exhaust Pipe Arrangement with Welded Compensator425
- Water Washing of Compressor Side435
- Steam Trap437
- Blowgun for Dry Cleaning of Turbocharger439
- Compressed Air System441
- Compressed Air System442
- Starting System442
- Control System442
- Emergency Starting Valve443
- Pneumatic Start Sequence443
- Air Filter444
- Cleaning Air Filter445
- To Replace Filter Element445
- Overhaul, Test and Inspection of Turbine Starter446
- Housing Exhaust Cover, Motor Assembly, and Motor Housing447
- Drive Housing448
- Assembly of the Starter450
- Gear Case450
- Intermediate Gear Case, Motor Assembly and Housing Exhaust Cover452
- Motor and Gearing Freeness454
- Pinion Engagement454
- Confirm Drive Rotation454
- Main Starting Valve455
- Check of Compressed Air Piping System457
- Turbine Starter459
- Muffler464

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MAN Diesel & Turbo L28/32H Specifications

General

Brand	MAN Diesel & Turbo
Model	L28/32H
Category	Inverter
Language	English

Summary

Engine data

Main particulars

Key specifications of the engine, including bore, stroke, power range, and speed.

Safety

General safety guidelines for engine operation and maintenance.

Operation of engine

Operating

Procedures for normal engine operation, including start-up and monitoring.

Starting-up after out of service periods

Detailed checks required before starting the engine after extended downtime.

Trouble shooting

Starting failure

Common causes and solutions for engine starting problems.

Faults in fuel oil system

Troubleshooting guide for issues related to the fuel oil system.

Heavy fuel oil (HFO) specification

Engine cooling water specifications

Cylinder head

Dismantling of Cylinder Head

Step-by-step procedure for disassembling the cylinder head.

Piston, Connecting Rod and Cylinder Liner

Dismounting of Piston and Connecting Rod

Procedure for removing the piston and connecting rod assembly.

Camshaft and Camshaft Drive

Adjustment of Camshaft for Valve and Injection Timing

Procedure for adjusting camshaft timing for valves and injection.

Control and Safety Systems

Mechanical Overspeed (SSH 81)

Description and function of the mechanical overspeed protection.

Starting Box

Crankshaft and Main Bearings

Checking of Main Bearings Alignment (Deflection) (Hydraulic Tightened Connecting Rod)

Procedure for checking crankshaft alignment via dial indicator.

Engine Frame and Base Frame

Turbocharger System

Cleaning the Turbocharger In Service Water Washing of Compressor

Procedure for cleaning the turbocharger compressor using water.

Dry Cleaning of Turbocharger - Turbine Side

Procedure for cleaning the turbocharger turbine side using dry methods.