Man Bw L27_38 g1z1w

INSTRUCTION BOOK VOLUME I Engine type L27/38

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

Engine After-sales Service Dept. Warranty Service TEL : (82) 52-202-7412~20 FAX : (82) 52-202-7581 (82) 52-250-9841 E-mail : [email protected]

Parts Sales TEL : (82) 52-202-7311~20 FAX : (82) 52-202-7582 E-mail : [email protected]

INSTRUCTION BOOK VOLUME Ⅱ Engine type L27/38

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

Engine After-sales Service Dept. Warranty Service TEL : (82) 52-202-7412~20 FAX : (82) 52-202-7581 (82) 52-250-9841 E-mail : [email protected]

Parts Sales TEL : (82) 52-202-7311~20 FAX : (82) 52-202-7582 E-mail : [email protected]

Page 1 (2)

Project Particulars

L27/38 : Applied : Not applied

Operation of Engine (Plate no. 501) 501-1. Operation a) Woodward made ------------------------------------------------------------ 501.01 Ed.11H b) Europa made ---------------------------------------------------------------- 501.01 Ed.08H

Trouble Tracing (Plate no. 503) 503-1. Trouble Shooting Guide for Air Starter a) Gali made --------------------------------------------------------------------- 503.06 Ed.06H b) TDI made --------------------------------------------------------------------- 503.06 Ed.05H

Control and Safety Systems (Plate no. 509) 509-1. Governor and Governor Drive a) Woodward made ------------------------------------------------------------ 501.01 Ed.11H b) Europa made ---------------------------------------------------------------- 501.01 Ed.08H 509-2. Manual for Governor a) Woodward made b) Europa made

Crankshaft and Main Bearings (Plate no. 510) 510-1. Vibration Damper a) Geislinger made ------------------------------------------------------------ 510-04.00 Ed.06H b) Vulkan made ----------------------------------------------------------------- 510-04.00 Ed.04H 510-2. Vibration Damper with Attachment a) Geislinger made ------------------------------------------------------------ 51004-07H b) Vulkan made ----------------------------------------------------------------- 51004-05H

Turbocharger system (Plate no. 512) 512-1. Manual for Turbocharger a) NR20/S (FOR 5,6L27/38) b) NR24/S (FOR 7,8L27/38) c) NR29/S (FOR 9L27/38)

Compressed Air System (Plate no. 513) 513-1. Compressed Air System a) Gali made --------------------------------------------------------------------- 513.01 Ed.09H b) TDI made --------------------------------------------------------------------- 513.01 Ed.14H 513-2. Overhaul, Test and Inspection of Air Starter a) Gali made --------------------------------------------------------------------- 513-01.30 Ed.05H b) TDI made --------------------------------------------------------------------- 513-01.30 Ed.04H

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

Page 2 (2)

Project Particulars

L27/38

513-3. Turning Gear a) Manual turning gear -------------------------------------------------------- 513-25.00 Ed.02H b) Electric turning gear -------------------------------------------------------- 513-25.00 Ed.01H 513-4. Air Starter a) Gali made (Starter serial no. > 02-0101) ----------------------------- 51309-11H 51309-13H b) TDI made (Output gear ratio 9.25 : 1) --------------------------------- 51309-09H

513-5. Main Starting Valve (* If selected 513-4,b) ------------------------ 51310-04 513-6. Pressure Reduction Valve (* If selected 513-4,a) --------------- 51322-05H 513-7. Turning Gear a) Turning gear with attachment ------------------------------------------- 51325-03E b) Electric turning gear -------------------------------------------------------- 51325-05H

Fuel Oil System (Plate no. 514) 514-1. Fuel Oil Safety Filter ----------------------------------------------------- 51415-01H

Lubricating Oil System (Plate no. 515) 515-1. Centrifugal by- filter ----------------------------------------------- 515-15.00 Ed.04H 51515-03H 515-2. Prelubricating oil pump a) Rickmeier made ------------------------------------------------------------- 515-01.05 Ed.07H 51504-05H b) Yurim made ------------------------------------------------------------------ 515-01.05E Ed.02E 51504-04E

Special equipment (Plate no. 517) 517-1. Flexible coupling 517-2. Torsional vibration damper 517-3. Oil mist detector Graviner MK-6 Schaller VN-115 517-4. Emergency MDO pump unit 517-5. Jacket water preheating unit

Electric type Steam type

517-6. Cooling water thermostatic valve (Pneumatic type) 517-7. L.O.auto back-flushing filter

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

MAN B&W Description Page 1 (2)

500.26

Planned Maintenance Programme

Edition 13H

L27/38

Observations

Monthly 3rd month

Daily

Weekly

32000

8000

16000

2000

„

= Overhaul to be carried out = Check the condition

50

z

Time Between Overhauls 200

Description

Check new/ overhauled parts after - hours

Duties during Operation Working Card No

Operating of Engine Readings of data for Engine and Generator, with reference to "Engine Performance Data", section 502-1 ........ Check for leakages ..........................................................

„ 502-01.00 „ 502-05.00

Specification - Cooling water



Cooling water system - Water samples, see section 504

„

516-01.90

Cylinder Head Inlet and exhaust valve - check and adjustment of valve clearance ......................................................................... Lubricating of operating gear - Check ............................. Check of valve rotators' rotation during engine rotation .



„ 508-01.10 „ „ 505-01.15

Control and Safety System, Automatics and Instruments Safety, alarm and monitoring equipment ........................ Lambda controller - Adjustment ...................................... Governor - Check oil level, see governor instruction book, section 509 ...........................................................

„ „

509-01.00 509-10.00

„

section 509



08028-0D/H5250/94.08.12

Turbocharger System

07.29

Dry cleaning of turbine side ............................................ Water washing of compressor side ................................ Exhaust pipe compensator .............................................. Retightening of all bolts and connections, se special Instruction book ............................................................... Cleaning of air filter - Compressor side, see special instruction book ...............................................................

z z „

512-10.00 512-05.00 512-01.10

MAN B&W

500.26 Edition 13H

Description Page 2 (2)

Planned Maintenance Programme

L27/38

Observations

Montly 3th month

Daily

Weekly

32000

8000

16000

2000

„

= Overhaul to be carried out = Check the condition

50

z

Time Between Overhaul 200

Description

Check new/ Overhauled parts after -hours

Duties during Operation Working Card No

Compressed Air System Function test - Main and emergency starting valve ......... Air filter, draining of bowl (filter element to be replaced when pressure drop exceeds 0,7 bar) .............................

„ z

513-01.40

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

„

513-01.90

„

514-01.90 section 504 514-01.10

513-01.21

Fuel Oil System and Injection Equipment Fuel oil system - Check the system ................................. Fuel oil - Oil samples after every bunkering, see sec.504 Fuel injection valve ..........................................................

„

Lubricating Oil System Lubricating oil filter - Cleaning and replacement ............ Centrifugal filter - Cleaning and replacement paper filter

z z

515-01.10 515-15.00

Lubricating oil - Oil samples ........................................... Lubricating oil system - Check the system ......................

„ „

515-01.90

„ „

516-01.90

„

519-03.00

Cooling Water System Cooling water system - Water samples .......................... Cooling water system - Check the system ......................

Flexible mounting - Check anti-vibration mountings ........ Safety cover - Function test .............................................

08028-0D/H5250/94.08.12

Engine Frame and Bedplate

Alternator - see special instruction book Major overhaul/inspection, see 500.25

07.29

MAN B&W Description Page 1 (3)

500.30

Operation Data & Set Points

Edition 48E

L27/38 Acceptable value at shop Normal Value at Full load test or after repair

Alarm Set point

Autostop of engine

Lubricating Oil System Temp. after cooler (inlet filter)

SAE 40

Pressure after filter(inlet engine) Pressure drop across filter Prelubricating pressure Pressure inlet turbocharger

TI 21

68-73° C

<73° C

TAH 21

80° C

PI 22

4.2-5.0 bar

>4.5 bar

PAL 22

3.5 bar

PDAH 21-22

0.1-1 bar

<0.5 bar

PDAH 21-22

1.5 bar

(PI 22)

0.14-1.4 bar

<1.0 bar

PAL 25

0.12 bar (H)

PI 23

1.5 ± 0.2 bar (C)

>1.5 bar

PAL 23

0.9 bar

LAL 28/ LAH 28

low/high level

Lub. oil level in base frame Pressure before filter

PI 21

PSL 22 (PSL 22) (D)

3.0 bar (2.5 bar)

TSH 29

105

TSH 12 (TSH 12) (D)

95° C (100° C)1

4.5-5.5 bar

Crankcase protection

LSH/LAH 92 High level (K)

Temp. main bearing

TI 29

80-95° C

TAH 29

100

PI 40 PI 40

3-6 bar 5-16 bar (A)

PAL 40 PAL 40

2 bar 4-6 bar (E)

LAH 42

High leakage level

Fuel Oil System Pressure after filter

MDO HFO

Leaking oil Temperature inlet engine MDO HFO

TI 40 TI 40

30-40°C 110-140°C

Press. LT system, inlet engine

PI 01

2.5-4.5 bar

>1.8 bar

PAL 01

0.4 + (B) bar

Press. HT system, inlet engine

PI 10

2.0-4.0 bar

>1.8-<6 bar

PAL 10

0.4 + (B) bar

Temp. HT system, outlet engine

TI 12

75-85°C

<85° C

TAH 12 TAH 12-2

90° C 93° C

Temp. LT system, inlet engine

TI 01

30-40°C

Exh. gas temp. before TC

TI 62

480-530° C

Exh. gas temp. outlet cyl.

TI 60

350-450° C

TAH 62 TAH 62-2 TAH 60

570° C 620° C 465° C

TAD 60

average ± 50° C

TAH 61 TAH 61

450° C 450° C

PAL 70

7.5 bar

PAL 70

15 bar

Cooling Water System

Exhaust Gas and Charge Air

08028-0D/H5250/94.08.12

Diff. between individual cyl.

average ± 30° C

average ±25° C

Exh. gas temp. after TC 330 kW 300-320 kW

TI 61 TI 61

275-400° C 275-375° C

Ch. air press. after cooler

PI 31

2.8-3.1 bar

Ch. air temp. after cooler

TI 31

40-55° C

<55° C

Press. inlet engine (TDI)

PI 70

8- 10 bar

>7.5-<10 bar

Press. inlet engine(Gali)

PI 70

16~30 bar

Compressed Air System

06.34 - ES1

MAN B&W

500.30 Edition 48E

Operation Data & Set Points

Description Page 2 (3)

L27/38 Remarks to Individual Parameters A. Fuel Oil Pressure, HFO-operation.

F. Start Interlock.

When operating on HFO, the system pressure must be sufficient to depress any tendency to gasification of the hot fuel.

The following signals are used for start interlock/ blocking:

B. Cooling Water Pressure, Alarm Set Points. As the system pressure in case of pump failure will depend on the height of the expansion tank above the engine, the alarm set point has to be adjusted to 0.4 bar plus the static pressure. The static pressure set point can be adjusted on the base module SW3.

C. Lub. Oil Pressure, Offset Adjustment. The read outs of lub. oil pressure has an offset adjustment because of the transmitter placement. This has to be taken into in case of test and calibration of the transmitter.

1) 2) 3) 4) 5) 6)

Turning must not be engaged Engine must not be running "Remote" must be activated No shutdowns must be activated. The prelub. oil pressure must be OK, 20 min. after stop. "Stop" signal must not be activated

G. Start Failure. If remote start is activated and the engine is in blocking or local mode or turning is engaged the alarm time delay is 2 sec. Start failure will be activated if revulutions are below 50 rpm within 5 sec. from start or revulutions are below 210 rpm 10 sec. from start. Start failure alarm will automatically be released after 30 sec. of activation. H. Alarm Hysterese.

Software created signal from PI 22, TI 12, SI 90.

On all alarm points (except prelub. oil pressure) a hysterese of 0.5% of full scale are present. On prelub. oil pressure alarm the hysterese is 0.2%.

E. Set Points depending on Fuel Temperature.

I. Engine Run Signal.

D. Software Created Signal.

The engine run signal is activated when engine rpm >710 or lube oil pressure >3.0 bar or TC rpm >5000 rpm. If engine rpm is above 210 rpm but below 710 rpm within 30 sec. the engine run signal will be activated.

Fig 1 Set point curve.

06.34 - ES1

08028-0D/H5250/94.08.12

The system pressure has to be adjusted according to the fuel oil preheating temperature.

MAN B&W Description Page 3 (3)

Operation Data & Set Points

500.30 Edition 48E

L27/38 J. Limits for Turbocharger Overspeed Alarm (SAH 89) Engine type 5L27/38 6L27/38 7L27/38 8L27/38 9L27/38

720 rpm 44,700 44,700 37,300 37,300 31,300

750 rpm 44,700 37,300 37,300 37,300 31,300

K. Crankcase Protection

08028-0D/H5250/94.08.12

For engines above 2250 kW crankcase protection is standard for marine application. This will be done by an oil mist detector (standard) or with a splash oil/crankcase protection system (option)

06.34 - ES1

MAN B&W Description Page 1 (1)

500.35

Data for Pressure and Tolerance

Edition 27H

L27/38 Section 505

Description Safety valve to be adjusted to Maximum inner diameter, valve guide For grinding of valve spindle and valve seat ring (see also working card 505-01.10) Minimum height of valve head, inlet valve and exhaust valve, "H"1

506

Piston and piston ring grooves (see working card 506-01.10) Maximum clearance between connecting rod bush and piston pin

08028-0D/H5250/94.08.12

Maximum ovalness in big-end bore (without bearing) Maximum inside diameter cylinder liner, maximum ovalness 0.1 mm Sealing minimum height above the cylinder liner

mm / bar 230 bar (7 bar at 20°C) 20.2 mm

9.0 mm

0.29 mm 0.02 mm Ø 270.4 mm 0.2 mm

507

Maximum tolerance at the valve cam bearing Maximum tolerance at the fuel cam bearing

0.3 mm 0.35 mm

508

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

0.7 mm 0.7 mm 0.3 mm 0.35 mm

509

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

1 mm

510

Deflection of crankshaft (autolog) (see working card 510-01.00) Minimum axial guide bearing clearance Maximum axial guide bearing clearance Minimum radial main bearing clearance Maximum radial main bearing clearance

0.400 mm 0.663 mm 0.225 mm 0.336 mm

514

07.24 - ES0

Combustion pressure range at full load Individual cylinders; issible deviation from average Fuel valve, adjusment of opening pressure (when new spring)

185 - 200 bar ± 5 bar 400 - 410 bar (420 bar)

Clearance (A) of plunger between thrust plate and plunger base plate / fuel injection pump

0.07-0.11 mm

Total axial clearance of follower / fuel injection pump

0.4 - 0.7 mm

MAN B&W Description Page 1 (1)

500.45

Declaration of Weight

Edition 03H

L27/38

Plate No

Item No

Weight in Kg

027 010/022 021

400

Cylinder unit

50501 50502 50500

506

Piston, complete Connecting rod, complete Cylinder liner, complete

50601 50601 50610

081 068 018

66 115 140

511

Cover for crankcase

51106

010

31.5

512

Turbocharger, NR20/R, complete Turbocharger, NR24/S, complete Turbocharger, NR26/R, complete Air cooler

512 512 512 51201

162

320 505 790 380

514

Fuel injection pump

51401

565

35

515

Lubricating oil pump

51501

031/043

40

516

HT- and LT-cooling water pump

51610

105

30

Section

08028-0D/H5250/94.08.12

505

00.32 - ES0

Component Cylinder head, incl. rocker arms

680

r

Index Page 1 (1)

Operation of Engine

501

Description

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

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

Working Card

Plates

*) Depending on Project Specification

Index Page 1 (1)

Engine Performance and Condition

502

Description Engine Performance and Condition .............................................................................................. 502.01 (03H) Evaluation of Readings Regarding Combustion Condition ........................ . ........................... 502.02 (02H) Condensate Amount ..................................................................................................................... 502.05 (03H)

Working Card

Plates

MAN B&W Description Page 1 (6)

Trouble Shooting / Electrical Failures

503.20 Edition 09H

L27/38

This description is a trouble shooting guide for the automation system on the diesel engine type L27/38 and L32/40.

If the conclusion of a trouble shooting indicates that an exchange of a module is needed, please fill-in the enclosed inspection report, and return the module together with the inspection report to the engine maker.

General

Further, please to inform the software no when ordering a new module.

Trouble Shooting

This guide is a standard guide for engines, where safety system is made by Allen-Bradley only. The number of modules connected to the U module variates from engine type to engine type. The in/outputs described in this guide, will be the same at all application. The following trouble shooting guide is an aid in isolating troubles to the engine built-on safety system and monitoring system incl. the sensors connected to these systems. CAUTION! The control system can be damaged with the wrong voltage. When replacing a control unit, check that the power supply is switched off during replacement and check the power supply for the correct voltage before switching-on.

08028-0D/H5250/94.08.12

Table 1.1 for the safety system and table 1.2 for the monitoring system are general guides for isolating system problems. Each system check assumes that the prior checks have been done properly. Table 1.3 and 1.4 are system error messages which can be a guideline to the problem.

Fig 1 Hardware module. 06.22 - ES0

Safety System The safety system is an independent system and consists of maker Allen-Bradley PLC hardware modules and MAN B&W software. Fig 1 describes the hardware modules. For wiring of the modules and sensors a reference is made to the electrical scheme which can be found in the operation manual, section 509. The safety system consists of two Allen-Bradley PLC modules. The modules named 3P1 is the U module and the module named 5P1 is an I/O-module. Indication of individual input and output can be found on the modules by yellow diodes. The reference number for each input and output can be found in the electrical scheme. On the operation box individual indication of the shutdowns (low lub. oil pressure, high cool. water temp., overspeed and emergency stop) can be found.

MAN B&W

503.20 Edition 09H

Trouble Shooting / Electrical Failures

Description Page 2 (6)

L27/38 Table 1.1 Trouble

Possible cause

Troubleshooting

Engine will not start. Start motor is not engaged.

Supply voltage polarity, or no supply voltage.

Check the supply voltage on the green diode on 3P1. If it is alight the power supply for the PLC modules are OK.

RUN/REM/PROG change-over switch on 3P1 in wrong position.

Put the RUN/REM/PROG change-over switch in RUN position. Check RUN LED on 3P1.

No software in the module.

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

One or several shutdown signals are activated on the monitoring box

Check that diode Out 1 on U module is alight. If Out 1 is not alight check that Out 2 at 5P1 is not alight. Check for loose wires on terminals VAC/DC 1 and Out 1 on 3P1, and 5P1. Reset the shutdowns. If one is still activated on the operation box, check that output Out 8, Out 9, Out 10 and Out 11 on 3P1 are not alight. If one is alight, check the sensor and wiring for short circuit. If Out 8, 9, 10, 11 on 3P1 is not alight but the shutdown signals on the monitoring box is activated the problem is to be found on the internal relays. Switch the power supply for 3P1 on and off several times. the relay will then be OK again.

All shutdown LED are alight on the monitoring box.

Connector is not correctly connected or internal failure in 3P1.

Check the connector J29 on the base module. No red LED must be alight on 3P1. Activate the change-over switch RUN/REM/PROG. Exchange the 3P1 module.

Low lub. oil shutdown occurs when normal stop is activated.

Damaged or wrong adjustment of the rpm pick-up.

Check the pick-up for correct adjustment. Sensing distance = app. 2 mm. Check that the connector is plugged correctly. Be aware that no counternuts prevent from plugging the connector correctly. Replace the pick-up. Note! Diode Out 2 on 3P1 will be alight if actual speed is above nominal speed. If actual speed is below, it will be dark. At start LED In 0 will flash. At steady speed LED In 0 will be permanently alight.

The alarm „System & Power failure“ is activated. Diode Out 0 at 5P1 is not alight or diode Out 1 at 5P1 is not alight.

No program in U, or fault in U. U in stop mode.

Check that power supply is OK. (Green diode must be alight). Switch on the RUN/REM/PROG change-over switch. The problem could be related to an internal component failure and the module must be replaced. Observe that no red diode is alight on 3P1.

The shutdown functions are not working.

Wiring or sensor problem. Internal component failure.

Check the wiring for shutdown sensors. Replace the module.

Overspeed set point is not correct.

Missing jumper or wrong software.

Check that Input 7 is not alight for 720 rpm engines, and ON for 750 rpm engines. Version as described at page one.

06.22 - ES0

08028-0D/H5250/94.08.12

Output relay Out 1 is in failure or loose connections.

MAN B&W Description Page 3 (6)

503.20

Trouble Shooting / Electrical Failures

Edition 09H

L27/38 If a replacement module is needed, the software version must be informed at ordering. To find “software version”, turn upper potentiometer to 3/4 position. Observe diode no Out 3 for flashes. F.ex. three flashes, a pause of 1.5 sec., and one more flash, means software version 3.2. The software version can be with four numbers, ex. 3.1.2.1. (the software version no. is also stated in the electrical scheme)

All sensors are connected to the base module and the Operation Box (OB), Monitor for Temp. and Pressure Module (MTP) and Monitor for Exh. Gas Temp. Module (MEG) are connected via interlink bus connection.

The Monitoring System

The software can be read on the label attached on the Base Module or by pushing the lamp test button for 3 seconds. The software version number will be displayed in the operation box display.

The monitoring system monitors shows all relevant pressures, temperatures and rpm on the engine. The monitoring system consists of four hardware modules as standard and a module as option for bearing temp. monitoring. The monitoring system hardware and software is developed by MAN B&W. Fig 2 describes the hardware.

Interface to the alarm and monitoring system in the control room is made by MODBUS or Interlink to the output module.

The software for engine type L27/38 will start with 3.xx, and the software for engine type L32/40 will start with 6.xx, f.ex. 6.4. Please make sure that the dip switches SW1, SW2, SW5 and SW3 are in correct position acc. to the plant related scheme. See section 509.

Failure LED

2.5 A Fuses

OB

0

1400

ENGINE RPM.

SI90

0

MTP

60000

H.T. WATER TEMP. TI12 OUTLET ENGINE

H.T. WATER PRESS. PI10 INLET ENGINE

TC RPM.

SI89 L.T. WATER TEMP.

0

TI01

40

START AIR PRESS.

INLET AIR COOL. PI70

L.T. WATER PRESS. PI01 INLET AIR COOL.

LUB. OIL TEMP. HOUR

TI22

BAR INLET ENGINE °C

.

.

.

Dip switches

Sensor power LED

LUB. OIL PRESS. PI21

.

INLET FILTER

ALT.

RPM. LUB. OIL PRESS. PI22

OVERSPEED

Display

INLET ENGINE

LOW LUB. OIL PRESS.

LUB. OIL PRESS. PI23 INLET TC

HIGH FRESH WATER TEMP.

FUEL OIL TEMP. TI40

EMERGENCY STOP

INLET ENGINE

FUEL OIL PRESS. PI40

08028-0D/H5250/94.08.12

INLET ENGINE

Push 3 sec. Software version will be indicated in the display

AP (Option)

START

STOP

LAMP TEST

80

0

4

CHARGE AIR TEMP. TI31

3 SEC. Delay

OUTLET COOL.

BLOCKING REMOTE

0

CHARGE AIR PRESS.

LOCAL

PI31 OUTLET COOL.

RESET

MEG

HIGH H.T. WATER TEMP.

LOW FUEL OIL PRESS.

TAH 12.

PAL 40.

HIGH LUB. OIL TEMP.

LOW START/STOP AIR PRESS.

E

TAH 21.

PAL 70/71.

X

HIGH/LOW EXH. GAS TEMP.

OVERSPEED.

TDAH 60.

SAH 81.

HIGH EXH. GAS TEMP.

JET SYSTEM FAILURE.

S

TC. OUTLET. TAH 61.

SX 32.

T

HIGH EXH. GAS TEMP.

POWER & SYSTEM FAILURE.

G

TC. INLET. TAH 62.

UX 95.

A

HIGH ALTERNATOR WINDING

COMMON SHUTDOWN.

TEMP. TAH98

SS 86.

200

400

600

CYL.

1

TI60

CYL.

2

TI60

CYL.

3

TI60

CYL.

4

TI60

CYL.

5

TI60

CYL.

6

TI60

CYL.

7

TI60

CYL.

8

TI60

CYL.

9

TI60

H A U

S

T E

LOW L.T. WATER PRESS.

START FAILURE.

PAL 01.

SX 83.

M P

LOW H.T. WATER PRESS.

STOP FAILURE.

E

PAL 10.

SX 84.

R A

LOW LUB. OIL PRESS.

FUEL LEAKAGE.

PAL 22.

LAH 42.

HIGH DIFF. PRESS. L.O.

LOW L.O. LEVEL BASE

R

FILTER. PDAH 21-22.

FRAME. LAL 28.

E

LOW LUB. OIL PRESS. TC.

HIGH L.O. LEVEL BASE

PAL 23.

FRAME. LAH 28.

T U

Fig 2 Hardware modules. 06.22 - ES0

LOW PRELUB. OIL PRESS.

TURNING GEAR ENGAGED.

PAL 25.

ZS 75.

TC INLET

TC OUTLET

TI62

TI61

MAN B&W

503.20 Edition 09H

Trouble Shooting / Electrical Failures

Description Page 4 (6)

L27/38

Trouble

Possible cause

Troubleshooting

Engine will not start. Start motor is not engaged.

Power supply is not correct, interlock activated or internal component failure

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

Data communication failure.

EMC problem or loose connections.

Check that the green LED on the base module is alight. See also table 1.3 Check that all cable screens are connected correctly in the EMC cable glands. Check that the data communiation cable (MODBUS) is the twisted pair type.

No RPM indication

Defect pick-up or incorrect adjustment.

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

The engine suddenly starts or stops.

Two or more earth failures on the engine and yard installation.

Check for earth failures on all sensors. Special attention should be made to the exh. gas sensors. Check for earth failures in the yard system. Replace the base module.

LED flashing green, yellow or red.

Internal component failure or EMC problem.

See table 1.3. Switch the power ON/OFF. Exchange the base module.

All red diodes on the operation box are alight.

No power supply or software in the safety system.

Check the safety system accoding to table 1.1.

Jet system activated under no load condition and/or jet alarm activated.

The band steel on the lambda arm is adjusted incorrectly.

Adjust the band steel to app. 2-3 mm above the jet pick-up.

Cont.

06.22 - ES0

08028-0D/H5250/94.08.12

Table 1.2

MAN B&W Description Page 5 (6)

Trouble Shooting / Electrical Failures

503.20 Edition 09H

L27/38 Cont. Table 1.2 Possible cause

Troubleshooting

„Frozen“ operation box, MTP and MEG box.

Internal software failure.

See table 1.3. Switch the power supply on/off. Exchange the base module.

Instable behaviour of the output signals for start/stop of prelubricating pump.

Too high voltage on the output circuit terminals J20, 108, 109

Check that the voltage is below 48 VDC. 120 VAC or 220 VAC is not allowed. Note! The voltage must be checked in the prelubricating pump starter .

Temp. indication is too high acc. to calibrated values, or values are abnormal.

Internal component failure.

Replace the base module.

Change-over switch between LOCAL - REMOTE - BLOCKING is not working.

Internal failure in the operation box. Damaged flat cable between print card and front .

See table 1.3 and 1.4. Replace the operation box.

The alarm „System & Power failure“ is activated.

This alarm consists of different alarm possibilities 1) Power & system failure in the safety system. 2) Power supply failure to the pressure sensors. 3) Cable/wire failure for monitor sensors. 4) Cable/wire failure for safety system sensors. 5) Communication link failure. 6) Tacho failure.

1) Check diode Out 1 on the safety system module 5P1. If it is alight, it is OK. No red LED must be alight on 3P1. See also table 1.1. SUPPLY LED and RUN LED must be alight. 2) Check green diode J29/J30 and fuse 2.5 AT. If green diode is alight, it is OK. 3) Check if any analog signals are missing. If all signals are present, it is OK. to check also the spare exh. gas input channels. A jumper must be present. See also table 1.4 4) Check diode Out 0 at 5P1. If it is alight, it is OK. If it is not alight, check the safety system for cable break or loose connections. 5) Check if rpm pick-up is OK, and/or lub. oil pressure is OK. If lub. oil pressure is normal, but no rpm signal is present, the tacho alarm will be activated. 6) Check the diode on the base module to table 1.3 and table 1.4.

OB display indicates OFFLN or ERR-1 or fault.

Cable break on data communication or sensor(s).

See table 1.3. Check cable installation for sensor(s) and/or data communication

08028-0D/H5250/94.08.12

Trouble

06.22 - ES0

MAN B&W

503.20

Trouble Shooting / Electrical Failures

Edition 09H

Description Page 6 (6)

L27/38 Table 1.3 Base Module LED indications On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the Base Module central processor. The following failure LED indications are possible: Observations

Description

GREEN permanent light

OK, all Interlink modules are online

GREEN flash

One or more Interlink modules are offline (disconnected) or incorrect setup on SW2.

RED permanent light

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

YELLOW permanent light

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

RED flash

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

Yellow 4x flash

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

Other yellow flashes

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

Table 1.4

Observations

Description

Ready

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

OFFLN

The OB module is OFFLINE. There is no communication from the base module to the OB module. This message will appear shortly when powering on the system, indicating that the base module has been reset. – Defective link between BM and OB module. – No power on BM – BM fatal hardware or software error. Indicated be red or yellow light or flashes on the BM two-coloured LED.

ERR-1

Indicates cable break or sensor failure on the corresponding input.

FAULT

Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault. Shown if the exhaust temperature is selected for an invalid cylinder number.

06.22 - ES0

08028-0D/H5250/94.08.12

Display indications on the Operation Box (OB)

MAN B&W Description Page 1 (2)

Specific Lubricating Oil Consumption - SLOC

504.07 Edition 03

General Engine type

RPM

SLOC [g/kWh]

L16/24

1000/1200

0.4 - 0.8

L21/31

900/1000

0.4 - 0.8

720/750/900

0.6 - 1.0

L27/38

720/750

0.4 - 0.8

L28/32H

720/750

0.6 - 1.0

V28/32H

720/750

0.6 - 1.0

V28/32S

720/750

0.4 - 0.8

L32/40

720/750

0.8 - 1.0

L23/30H

Please note that only maximum continuous rating (PMCR (kW)) should be used in order to evaluate the SLOC. Please note, during engine running-in the SLOC may exceed the values stated. The following formula is used to calculate the SLOC:

A2: Lubricating oil evaporation Lubricating oil leakages Lubricating oil losses at lubricating oil filter exchange The lubricating oil density, ρ @ 15°C must be known in order to convert ρ to the present lubricating oil temperature in the base frame. The following formula is used to calculate ρ:

SLOC [g/kWh] = (lubricating oil added - A1 - A2 [dm ]) * ρlubricating oil [kg/m ] run.hrs period * PMCR [kW] 3

08028-0D/H5250/94.08.12

In order to evaluate the correct engine SLOC, the following circumstances must be noticed and subtracted from the engine SLOC: A1: Desludging interval and sludge amount from the lubricating oil separator (or automatic lubricating oil filters). The expected lubricating oil content of the sludge amount is 30%. The following does also have an influence on the SLOC and must be considered in the SLOC evaluation:

06.25 - ES0

ρlubricating oil [kg/m3] =

3

ρlubricating oil @15°C [kg/m3] – 0,64 * (tlubricating oil [°C] – 15)

The engine maximum continuous design rating (PMCR) must always be used in order to be able to compare the individual measurements, and the running hours since the last lubricating oil adding must be used in the calculation. Due to inaccuracy *) at adding lubricating oil, the SLOC can only be evaluated after 1,000 running hours or more, where only the average values of a number of lubricating oil addings are representative. Note *) A deviation of ± 1 mm with the dipstick measurement must be expected, witch corresponds uptill ± 0.1 g/kWh, depending on the engine type.

MAN B&W Description Page 2 (2)

Specific Lubricating Oil Consumption - SLOC

504.07 Edition 03

General Plant / Ship Lube oil consumption Engine # :

Engine type: Lube oil brand type: Density @15℃:

08028-0D/H5250/94.08.12

Date

06.25 - ES0

Run. hrs [h]

[kg/m3] Add.Lube oil [dm3]

A1 + A2 [dm3]

LO.Temperature [℃]

SLOC [g/kWh]

Remarks

MAN B&W Working Card Page 1 (2)

505-01.20

Replacement of Valve Guide

Edition 10

L21/31 L27/38 Safety precautions

Special tools

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

Plate no

Item no

52001

120

Note

Description

Hand tools

Dismantling and mounting of valve guide for inlet and exhaust valve.

Hammer / Lead hammer. Liquid Nitrogen (LN2) or equivalent. E7 reamer, 16 mm (L21/31) H7 reamer, 20 mm (L27/38)

Starting position Valve spindle has been removed

505-01.05

Related procedure

08028-0D/H5250/94.08.12

Inspection of inlet valve, exhaust valve and valve guide

07.17

505-01.05

Manpower Replacement and wearing parts Working time Capacity

: :

3/4 hour 1 man

Data Data for pressure and tolerance (Page 500.35) Data for torque moment (Page 500.40) Declaration of weight (Page 500.45)

Plate no

Item no

Qty/

50501 50501

076 088

4/cyl 4/cyl

MAN B&W

505-01.20 Edition 10

Replacement of Valve Guide

Working Card Page 2 (2)

L21/31 L27/38 When to Replace the Valve Guide If the diameter exceeds the max. limit, see page 500.35, the valve guide must be replaced.

7)

Insert a new O-ring in the top of the valve guide, see fig 3.

Tool for valve guides is not a part of the standard tool kit.

Dismounting of Valve Guide 1)

Fig 1

Remove the old valve guide, through the top of the cylinder head using a drift inserted through the valve seat, see fig 1. This is easiest if the cylinder head is inverted, as shown on fig 1.

Fig 2

Mounting of valve guide

Fig 3

Inserting a new O-ring in the valve guide

Dismounting of valve guide

2)

Clean the bore in the cylinder head carefully.

3)

The new valve guide must be cooled down to approx. -70°C with liquid nitrogen (LN2) or equivalent. Insert the valve guide in the bore, see fig 2.

4) 5)

Ensure that the valve guide is fully seated, if necessary by light blows to the drift.

6)

After the guide has been fitted and has returned to room temperature, it is essential that it be reamed to final size using the specified reamer. Please see page 500.35 for tolerances.

08028-0D/H5250/94.08.12

Mounting of Valve Guide

07.17

MAN B&W Plate Page 1 (2)

Kit for Cylinder Unit

50500-02E

08028-0D/H5250/94.08.12

L27/38

E

99.25 - ES0

MAN B&W

50500-02E

Plate Page 2 (2)

Kit for Cylinder Unit

L27/38

Item no

Qty

Designation

Where to find in the engine instruction book

021

1/C

Kit for cylinder unit, complete consisting of:

Plate 50500

Item 021

1/C

O-ring

Plate 50501

Item 040

2/C

O-ring

Plate 50501

Item 064

4/C

O-ring

Plate 50501

Item 076

2/C

O-ring

Plate 50501

Item 111

1/C

O-ring

Plate 50501

Item 135

1/C

O-ring

Plate 50501

Item 135E

2/C

O-ring

Plate 50501

Item 172

1/C

O-ring

Plate 50501

Item 196

2/C

O-ring

Plate 50501

Item 243

1/C

Gasket

Plate 50501

Item 338

2/C

O-ring

Plate 50501

Item 363

2/C

Circlip

Plate 50502

Item 095

4/C

Conical ring 2/2

Plate 50502

Item 178

1/C

O-ring

Plate 50502

Item 237

1/C

O-ring

Plate 50502

Item 250

1/C

Piston ring

Plate 50601

Item 093

1/C

Piston ring

Plate 50601

Item 103

1/C

Oil scraper ring

Plate 50601

Item 127

1/C

Sealing ring

Plate 50610

Item 031

1/C

O-ring

Plate 50610

Item 043

1/C

O-ring

Plate 50610

Item 055

1/C

O-ring

Plate 50801

Item 090

2/V

O-ring

Plate 51402

Item 033

1/V

O-ring

Plate 51402

Item 104

08028-0D/H5250/94.08.12

Ordering Number of Kit for Cylinder Unit According to list below Plate 50500-02E / Item 021

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

Qty/Cylinder Qty/Valve

99.25 - ES0

MAN B&W Plate Page 1 (2)

Cylinder Head

50501-05E

08028-0D/H5250/94.08.12

L27/38

01.09 - ES0

MAN B&W

50501-05E

Plate Page 2 (2)

Cylinder Head

L27/38 Qty

Designation

015

2/C

Guide for valve bridge Styr for ventilbro

027

1/C

Cylinder head

Cylinderdæksel

040

1/C

O-ring

O-ring

052E

1/C

Insert

053E

1/C

Bush

064

2/C

O-ring

O-ring

076

4/C

O-ring

O-ring

088

4/C

Valve guide

Ventilstyr

111

1/C

O-ring

O-ring

123

2/C

Valve seat ring, inlet

Ventilsædering, indstrømning

135

1/C

O-ring

O-ring

135E

1/C

O-ring

O-ring

172

2/C

O-ring

O-ring

184

2/C

Valve seat ring, exhaust

Ventilsædering, udstødning

196

1/C

O-ring

O-ring

206

4/C

Screw

Skrue

218

1/C

Water guide jacket

Kølekappe

243

1/C

O-ring

O-ring

292

1/C

Conn. socket

Forbindelsesstykke

302

1/C

Threaded socket

Gevindstuds

314

1/C

Union nut

Omløbermøtrik

338

1/C

Gasket

Pakning

351

1/C

Safety valve

Sikkerhedsventil

363

2/C

O-ring

O-ring

375

1/C

Connecting piece

Forbindelsesstykke

410E

1/C

Indicator valve

Indikatorventil

422

1/C

Cylinder head incl- Cylinderdæksel inkl. items 015,027,040, items 015, 027, 040, 052,064,076,088,123, 052,064,076,088,123, 172,184,plate 50502 172,184, plate 50502 items 010,022,130, items 010, 022, 130, 178,191,201,213,237 178,191,201,213,237 249,250,262,274 249,250,262,274

Benævnelse

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/C =

* = Qty/C =

Only available as part of a spare parts kit. Qty/Cylinder

Kun tilgængelig som en del af et reservedelssæt. Qty/Cylinder

01.09 - ES0

MAN B&W Description Page 1 (2)

Piston, Connecting Rod and Cylinder Liner

506.01 Edition 03H

L27/38 Piston The piston, which is oil-cooled and of the composite type, has a body made of nodular cast iron and a crown made of forged deformation resistant steel. It is fitted with 3 compressi on rings and 1 oil scraper ring in hardened ring grooves.

Fig. 2 Connecting rod

The piston pin is fully floating and kept in position in the axial direction by two circlips. Fig. 1 Piston

Connecting Rod The connecting rod is of the marine head type.

08028-0D/H5250/94.08.12

By the use of compression rings with different barrelshaped profiles and chrome-plated running surfaces, the piston ring pack is optimized for maximum sealing effect and minimum wear rate. The piston has a cooling oil space close to the piston crown and the piston ring zone. The heat transfer, and thus the cooling effect, is based on the shaker effect arising during the piston movement. The cooling medium is oil from the engine's lubricating oil system. Oil is supplied to the cooling oil space through channels from the oil grooves in the piston pin bosses. Oil is drained from the cooling oil space through ducts situated diametrically to the inlet channels.

98.27 - ES0

The t is above the connecting rod bearing. This means that it is not nessesary to open the big-end bearing when pulling the piston. This is of advantage for the operational safety (no positional changes/no new adaption), and this solution also reduces the height dimension required for piston assembly / removal. Connecting rod and bearing body consist of CrMo steel. They are die-forged products. The bearing shells are identical to those of the crankshaft bearing. Thin-walled bearing shells having an AISn running layer are used. The bearing caps and bearing blocks are bolted together by waisted bolts.

MAN B&W

506.01 Edition 03H

Piston, Connecting Rod and Cylinder Liner

Description Page 2 (2)

L27/38

Cylinder Liner The cylinder liner is made of special centrifugal cast iron and fitted in a bore in the engine frame. The liner is clamped by the cylinder head and rests by its flange on the water jacket. The liner can thus expand freely downwards when heated during the running of the engine. The liner is of the flange type and the height of the flange is identical with the water cooled area which gives a uniform temperature pattern over the entire liner surface. The lower part of the liner is uncooled to secure a sufficient margin for cold corrosion in the bottom end. There is no water in the crankcase area. The gas sealing between liner and cylinder head consists of an iron ring. To reduce bore polishing and lube oil consumption a slip-fit-type flame ring is arranged on the top side of the liner.

08028-0D/H5250/94.08.12

Fig. 3 Cylinder liner

98.27 - ES0

MAN B&W

Separation/Assembly of Piston and Connecting Rod and Fitting of Piston Rings

Working Card Page 1 (3)

506-01.05 Edition 06H

L27/38

Safety precautions

Special tools

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

Plate no

Item no

52000 52000

177 190

Description

Hand tools

Separation of piston and connecting rod for inspection or/and overhaul. Assembly of piston and connecting rod after inspection or/and overhaul.

Wooden wedge, 2 pieces. Wooden . Wire.

Note

Starting position Disassembly of cylinder unit

505-01.01

Related procedure

08028-0D/H5250/94.08.12

Inspection or/and overhaul of piston Inspection or/and overhaul of connecting rod Inspection of connection rod big-end bearing Assembly of cylinder unit

506-01.10 506-01.15 506-01.16 505-01.50

Manpower Working time Capacity

Replacement and wearing parts : :

1 hour 1 man

Data Data for pressure and tolerance (Page 500.35) Data for torque moment (Page 500.40) Declaration of weight (Page 500.45)

06.29 - ES0

Plate no

Item no

Qty/Cyl.

50601 50601

093 127

3 1

MAN B&W

506-01.05 Edition 06H

Separation/Assembly of Piston and Connecting Rod and Fitting of Piston Rings

Working Card Page 2 (3)

L27/38 Separation of Piston and Connecting Rod 1)

Take out the securing ring (Seeger circlips) with the plier (Plate 52000, Item 177). Push out the piston pin and lift the connecting rod away.

Assembly of Piston and Connecting Rod 2) 3)

The piston rings should only be fitted to the piston by the use of a special tool; the so-called piston ring opener. If the rings are opened further than necessary, there is a risk of overstressing which means that the rings will become permanently distorted and will not fit to the cylinder liner's inner running surface.

Lubricate the piston pin before assembling. For assembly of piston and connecting rod, see point 1, but in the opposite direction.

Fittings of Piston Rings

t pin for coil spring

t coil spring to be placed opposite to ring t

The piston rings should be installed with the identification mark which is stamped into the ring close to the ring ts, facing upwards, see fig 2. Before fitting the coil spring loaded scraper ring, the coil spring is dismantled from the ring by removal of the t pin. The coil spring is placed and assembled in the ring groove. The scraper ring then is fitted in the groove in such a way that the ring t is approximately 180° offset to the spring t. Ascertain correct assembling by checking the back clearance. The back clearance is sufficient when the face of the ring is below the groove edge when the ring is pressed against the bottom of the groove.

Fig 1

t coil spring to be placed opposite to ring t

When installed on the piston, the rings should be pushed back and forth in the grooves to make sure that they can move freely. It is also advisable to insert a feeler gauge of adequate thickness between ring and groove. Adequate clearance is present if the feeler gauge can be moved all the way around. To prevent gas leakage through coinciding ring ts, the piston rings should be turned into positions offsetting the ring t 180° to each other. 08028-0D/H5250/94.08.12

Ring t

06.29 - ES0

MAN B&W Working Card Page 3 (3)

Separation/Assembly of Piston and Connecting Rod and Fitting of Piston Rings

506-01.05 Edition 06H

L27/38

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

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

08028-0D/H5250/94.08.12

Marking of Piston and Scraper Rings

Marking Identification marks to face upwards against the piston crown when mounted. Note! The marking may include other figures than mentioned above, for instance trade mark and production codes.

Fig 2

06.29 - ES0

Marking of piston and scraper ring

MAN B&W Working Card Page 1 (4)

506-01.10

Piston

Edition 04E

L27/38

Safety precautions

Special tools

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

Plate no

Item no

52000 52000 52000

153 165 190

Note

Description

Hand tools

Cleaning and inspection of piston. Replacement of piston ring, scraper ring and control of ring grooves.

Tools for cleaning of piston, steel brush, scraper etc. Torque spanner.

Starting position Piston has been dismantled from connecting rod

506-01.05

Related procedure

08028-0D/H5250/94.08.12

Mounting of piston and connecting rod

06.25 - ES0

506-01.20

Manpower Working time Capacity

Replacement and wearing parts : :

1 hour 1 man

Data Data for pressure and tolerance (Page 500.35) Data for torque moment (Page 500.40) Declaration of weight (Page 500.45)

Plate no

Item no

Qty/

MAN B&W

506-01.10

Working Card Page 2 (4)

Piston

Edition 04E

L27/38 Mounting of Piston Crown Piston type „MAHLE“ Note: Always use new bolts when assembling the piston.

1)

Remove the piston and scraper rings.

2)

Clean the piston on the outside and on the inside.

8)

Lubricate the threads and bearing surface with “molycote-paste G-n Plus”.

3)

Inspect the piston ring and scraper ring grooves for wear, see page 3.

9)

Tighten the piston bolts with a torque of 50 Nm in the piston head.

Check of Piston Bolt Tension Piston type „MAHLE“ 4)

Apply a torque spanner to the piston bolts, adjusted to 50 Nm.

5)

Turn the torque spanner.

Note: It may turn out that the bolts do not turn during the test:

If

Then

the bolts do not turn during the test

the tension is ok

the bolts can turn during the test

loosen the bolts and tighten as described in the process of "Mounting of piston crown"

Inspection of Piston Crown Piston type „MAHLE“ For cleaning and inspection of the piston crown, it must be disassembled. 6)

Loosen the bolts and remove the piston crown.

7)

Carefully clean the piston skirt, piston crown and piston bolts.

10)

Tighten the nuts crosswise with 60 Nm.

11)

Loosen the nuts again.

12)

The tightening of the piston bolts with a torque of 50 Nm in the piston head must be controlled.

13)

Pretighten the nuts crosswise with t moment of 20 Nm.

14)

Turn the nuts further 120 degrees.

Check the piston bolt tension, see “check of piston bolt tension”.

Check of Piston Bolt Tension Piston type „KOLBENSCHMIDT“ or „SAM YOUNG“ 4)

Apply a torque spanner to the piston bolts, adjusted to 54 Nm.

5)

Turn the torque spanner.

Note: It may turn out that the bolts do not turn during the test:

If

Then

the bolts do not turn during the test

the tension is ok

the bolts can turn during the test

loosen the bolts and tighten as described in the process of “Mounting of piston crown” 06.25 - ES0

08028-0D/H5250/94.08.12

Inspection of Piston („MAHLE“ and „KOLBENSCHMIDT“ or „SAM YOUNG“)

MAN B&W Working Card Page 3 (4)

Piston

506-01.10 Edition 04E

L27/38 Inspection of Piston Crown Piston type „KOLBENSCHMIDT“ or „SAM YOUNG“ For cleaning and inspection of the piston crown, it must be disassembled. 6)

Loosen the bolts and remove the piston crown.

7)

Carefully clean the piston skirt, piston crown and piston bolts.

Mounting of Piston Crown Piston type „KOLBENSCHMIDT“ or „SAM YOUNG“

08028-0D/H5250/94.08.12

Note: Always use new bolts when assembling the piston. 8)

Lubricate the threads and bearing surface with “molycote-paste G-n Plus”.

9)

Tighten the piston bolts with a torque of 40 Nm in the piston head.

10)

Tighten the nuts crosswise with 67 Nm.

11)

Loosen the nuts again.

12)

The tightening of the piston bolts with a torque of 40 Nm in the piston head must be controlled.

13)

Pretighten the nuts crosswise with t moment of 20 Nm.

14)

Turn the nuts further 90 degrees.

Check the piston bolt tension, see “check of piston bolt tension”.

06.25 - ES0

MAN B&W

506-01.10

Working Card Page 4 (4)

Piston

Edition 04E

L27/38 The piston crown must be scrapped if: A)

Note: At each piston overhaul:

The wear limit on the testing mandrel is exceeded, see fig. 1A

-

The piston and the scraper ring must be replaced.

-

The cylinder liner must be honed according to the instructions.

-

For position and fittings of piston rings, please see working card 506-01.05

or B)

The clearance between the new piston/scraper ring and the ring groove is exceeded, see fig. 1B.

Piston type "MAHLE"

Piston and oil scraper ring. Nominal size. (mm)

New ring grooves. Tolerances. (mm)

Ring grooves. Max. wear limit. (mm)

Piston type "KOLBENSCHMIDT" or "SAM YOUNG"

Piston and oil scraper ring. Nominal size. (mm)

New ring grooves. Tolerances. (mm)

Ring grooves. Max. wear limit. (mm)

Piston ring 1

6

6

+0.20 +0.17

6.42

Piston ring 1

6

6.17 +0.03

6.42

Piston ring 2

6

6

+0.14 +0.12

6.42

Piston ring 2

6

6.12 +0.03

6.42

Piston ring 3

6

6

+0.14 +0.12

6.42

Piston ring 3

6

6.12 +0.03

6.42

Scraper ring

8

8

+0.06 +0.04

8.42

Scraper ring

8

8.04 0.03

8.42

Table 1

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

A) Testing Mandrel for Ring Grooves

B) Clearance Ring/Groove

If the wear limit on the testing mandrel is exceeded, the specified max. wear limits are exceeded, and the piston must be scrapped.

08028-0D/H5250/94.08.12

0.45 mm Wear limit line.

Maximum vertical clearance between new piston ring/scraper ring and ring groove: 0.45 mm. The handle is marked with the nominal size.

Fig 1

Wear limits for ring grooves

06.25 - ES0

MAN B&W Working Card Page 1 (5)

Removal / Mounting of Marine Head from Engine

506-01.24 Edition 01E

L21/31 L27/38 Safety precautions

Special tools

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

Plate no

Item no

52000 52000

060 069

Note

and hydraulic tools according to working card 520-01.06

Description Removal of marine head from engine.

Starting position

Hand tools

Engine out of operation.

Related procedure

Manpower

08028-0D/H5250/94.08.12

Working time Capacity

Replacement and wearing parts : :

½ hour 2 men

Plate no

Data Data for pressure and tolerance Data for torque moment Declaration of weight

03.27 - ES0

(Page 500.35) (Page 500.40) (Page 500.45)

Item no

Qty/

MAN B&W

506-01.24 Edition 01E

Removal / Mounting of Marine Head from Engine

Working Card Page 2 (5)

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

1)

Turn the crank through to about TDC.

2)

Install the brackets in the lower end of the crankcase opening, see fig. 2.

08028-0D/H5250/94.08.12

Fig. 1 Fixation of connecting rod bearing

Fig. 2 Bracket installed

03.27 - ES0

MAN B&W Working Card Page 3 (5)

Removal / Mounting of Marine Head from Engine

506-01.24 Edition 01E

L21/31 L27/38 3)

Place the guide beam on the brackets and secure it by means of the screws, see fig. 3.

08028-0D/H5250/94.08.12

Fig. 3 Placing of guide beam

03.27 - ES0

MAN B&W

506-01.24 Edition 01E

Removal / Mounting of Marine Head from Engine

Working Card Page 4 (5)

L21/31 L27/38

Fig. 4

Turn the crankshaft to the position shown in fig. 4 and remove the nuts by means of the hydraulic tool.

Removal of nuts

08028-0D/H5250/94.08.12

4)

03.27 - ES0

MAN B&W Working Card Page 5 (5)

Removal / Mounting of Marine Head from Engine

506-01.24 Edition 01E

L21/31 L27/38 5)

Install the slide piece as shown in fig. 5 and remove the bracket.

6)

Turn the crankshaft to make the marine head rest against the beam, see fig. 5.

Mounting of Marine Head

Pull out the two halves of the marine head.

Mounting is carried out in reverse order of the above.

7)

8)

Remove the bearing shells from each marine head half.

08028-0D/H5250/94.08.12

Note : Check that the marks "AS" are placed at the same side on both the piston rod and the marine head against the exhaust side.

Fig. 5 Marine head with slide piece

03.27 - ES0

MAN B&W

Dismantling of Piston and Cylinder Liner at Low Overhaul Height

Working Card Page 1 (4)

506-01.50 Edition 06H

L27/38

Safety precautions Stopped engine Shut-off starting air Shut-off cooling water Shut-off fuel oil Stopped lub. oil circul. Press Blocking - Reset

Special tools Plate no

Item no

52000 52000 52000

060 082 104

Note

and hydraulic tools according to working card 520-01.06

Description Dismounting of cylinder unit for inspection and/or overhaul.

Starting position

Hand tools

Engine stopped and cooled down.

Related procedure

08028-0D/H5250/94.08.12

Inlet and exhaust valve - overhaul and regrinding of spindel and valve seat 505-01.10 Valve rotator 505-01.15 Replacement of valve guide 505-01.20 Replacement of valve seat ring 505-01.35 Inspection of piston 506-01.10 Cylinder liner 506-01.35 Separation of piston and connecting rod 506-01.06 Fuel injection valve 514-01.10 Function of hydraulic tools 520-01.05 Application of hydraulic tools 520-01.06

Replacement and wearing parts

Manpower Working time Capacity

: :

2 1/2 hours 2 men

Data Data for pressure and tolerance (Page 500.35) Data for torque moment (Page 500.40) Declaration of weight (Page 500.45)

07.35 - ES0

Plate no

Item no

Qty/

MAN B&W

506-01.50 Edition 06H

Dismantling of Piston and Cylinder Liner at Low Overhaul Heights

Working Card Page 2 (4)

L27/38 Preparing before Dismantling

10)

Push the charge air connections inside the cylinder head which are to be removed.

11)

Remove the cylinder head nuts by means of the hydraulic jacks, see working card 520-01.05. Remove the bolts, which hold the cylinder head and water jacket together, see fig 2.

1)

Drain off the water from the engine.

2)

Take off the top cover.

3)

Take off the side covers on both sides of the engine.

12)

4)

Remove the exhaust gas cover.

Note: This means that the cylinder head now can be removed from the cylinder unit.

Disassembling of Connectings 5)

Disconnect the clamp for connecting cylinder head and exhaust gas receiver.

6)

Disconnect the fuel oil high pressure pipe.

7)

Disconnect the 4 clamps for locking the FW connection between the cylinder heads.

8)

Push the FW connections inside the cylinder heads, which are to be removed.

9)

Disconnect the 2 clamps for locking the charge air connections by removing the locking bolts for the clamps, see fig 1.

Bolts to be removed

Bolts to be removed

13)

Mount the lifting tool on the cylinder head.

14)

Lift the cylinder head and land it carefully on wooden .

15)

Remove the push rods by hand.

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

07.35 - ES0

08028-0D/H5250/94.08.12

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

MAN B&W Working Card Page 3 (4)

Dismantling of Piston and Cylinder Liner at Low Overhaul Height

506-01.50 Edition 06H

L27/38 Removal of Piston and Piston Rod, Cylinder Liner and Water Jacket 16)

Turn the piston into top dead centre.

17)

Mount the turning bracket to the marine head and counterweight, see fig 3.

18)

Loosen the four bolts for the piston rod by means of the hydraulic tools and remove the nuts.

19)

Mount the tool for lifting the piston, see fig 4.

Fig 4

20)

08028-0D/H5250/94.08.12

Fig 3 Turning bracket mounted to the marine head and counterweight

07.35 - ES0

Lifting tool for piston

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

MAN B&W

506-01.50 Edition 06H

Dismantling of Piston and Cylinder Liner at Low Overhaul Heights

Working Card Page 4 (4)

L27/38

22)

Mount the lifting tool for the cylinder liner, see fig 5 and lift the cylinder liner out of the engine. Lifting tool for cylinder liner

Mount the eye bolt in water jacket and lift it off the engine.

Cylinder liner

Lifting tool

Fig 5

08028-0D/H5250/94.08.12

21)

Lifting tool for cylinder liner

07.35 - ES0

Index Page 1 (1)

Camshaft and Camshaft Drive

507

Description

Working Card

Plates Intermediate Wheel ............................. ...........,. . ......... .. . . .. . .. . .,. . .. . .. ..... .. .. ... .. 50701-03H Camshaft (Valve Camshaft) ....................................................................................................50705-05H Camshaft (Injection Camshaft) ................................................................................................ 50705-06H

Index Page 1 (1)

Operating Gear for Inlet Valves, Exhaust Valves and Fuel Injection Pumps

508

Description

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

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

MAN B&W

Index Page 1 (1)

Control and Safety Systems Automatics and Instruments

509 L27/38

Description Safety, Control and Monitoring System ……………………………………………………… 509.01 (11) Lambda Controller ……………………………………………………………………………… 509.10 (06H) Communication from the GenSet ……………………………………………………………… 509.55 (08)

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

Plates *) Governor and Governor Drive ( Europa made ) ………………………………………………… 50901-06H *) Governor and Governor Drive ( Woodward made ) …………………………………………… 50901-07H Regulating Device…………………………………………………………………………………… 50902-05E Instruments ………………………………………………………………………………………… 50907-04E Level Switch in Oil Sump (LAL/LAH 28) ………………………………………………………… 50920-03H Fuel Oil Leakage Alarm (LAH 42) ………………………………………………………………… 50925 - 07 Monitoring Box ……………………………………………………………………………………… 50935-05H Terminal Box ………………………………………………………………………………………… 50936-02H

Instruction Manual for the Governor

*) Depending on Project Specification

MAN B&W Plate Page 1 (2)

Fuel Oil Leakage Alarm (LAH 42)

50925-07 L21/31, L27/38 V28/32S

A-A

058 010

022 034 416 046

404 C

333

178

345

333

357

286

A

08028-0D/H5250/94.08.12

A

06.47 - ES0

C

382

369

394

370

C-C

MAN B&W

50925-07

Plate Page 2 (2)

Fuel Oil Leakage Alarm (LAH 42)

L21/31, L27/38 V28/32S Qty

Designation

Benævnelse

010

1/E

Fuel oil leakage alarm

Br.olielækagealarm

022

1/E

Flange

Flange

034

1/E

Gasket

Pakning

046

1/E

Level switch

Niveaukontakt

058

1/E

Hose connection

Slangeforbindelse

178

1/E

Repair kit for running in filter

Reparationssæt for indkrselsfilter

286

4/E

Screw

Skrue

333

2/E

O-ring

O-ring

345

1/E

Packing ring

Pakningsring

357

1/E

Plug screw

Propskrue

369

1/E

Packing ring

Pakningsring

370

1/E

Plug screw

Propskrue

382

1/E

Packing ring

Pakningsring

394

1/E

Plug screw

Propskrue

404

1/E

Plug screw

Propskrue

416

/I

Glue

Lim

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E =

* Qty/E

Only available as part of a spare parts kit. Qty/Engine

= =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor

06.47 - ES0

Index Page 1 ( 11

Crankshaft and Main Bearings

510

Description

Working Card Checking of Main Bearings Alignment (Autolog) .................................................................. 510-01.OO (09H) Inspection of Main and Guide Bearing Shells ...................................................................... 510-01.05 (06H) *) Vibration Damper (Vulkan made) ........................................................................................ 510-04.00 (04H) *) Vibration Damper (Geislinger made)...............................................................................510-04.00 (06H)

Plates Plates Chankshaft .......................................................................................................................................... 51001-06H Flywheel with Gear Rim ................................................................................................................... ,51003-06H *) Vibration Damper with Attachment (Vulkan made) ..................................................................5100405H *) Vibration Damper with Attachment (Geislinger made)......................................................,51004-07H

*) Depending on Project Specification

Index Page 1 (1 )

Description

Working Card

Plates

Engine Frame and Base Frame

511

MAN B&W Plate Page 1 (2)

Front-end Box

51103-08H L27/38

445

Centrifugal by- filter, see plate 51515

087+

218

935

099

217+

445

242+ 541

577

516

433

959

528 099

494

469

636

504

553

960

457

673 661 648

482 972 229

063

470

719

301

075

624 528

984

195 196

996 038

697 947

099

08028-0D/H5250/94.08.12

026

06.16 - ES0

408

MAN B&W

51103-08H

Plate Page 2 (2)

Front-end Box

L27/38 Item no

Qty

Dæksel

624

4/E

Screw

Skrue

Screw

Skrue

636

1/E

Thrust piece

Trykstykke

4/E

Nut

Møtrik

648

1/E

Covering plate

Dækselplade

075

2/E

Washer

Skive

661

1/E

Screw

Skrue

087+

4/E

Screw

Skrue

673

1/E

Nut

Møtrik

099

8/E

Spring washer

Fjederskive

697

1/E

O-ring

O-ring

195

4/E

Stud

Tap

719

1/E

Spring

Fjeder

196

/I

Loctite 638

Loctite 638

935

1/E

Intermediate piece

Mellemstykke

217+

1/E

Flange

Flange

947

1/E

Intermediate piece

Mellemstykke

218

/I

Packing silicone paste

Packing silicone paste

959

1/E

O-ring

O-ring

960

1/E

Cover

Dæksel

229

1/E

O-ring

O-ring 972

1/E

Casing

Hus

242+

4/E

Nut

Møtrik 984

1/E

Piston

Stempel

301

1/E

O-ring

O-ring 996

1/E

Retaining ring

Sikringsring

408

1/E

O-ring

O-ring

433

10/E

Screw

Skrue

+ To be used if centrifugal by- filter is not mounted

+ Anvendes hvis ikke centrifugal by- filter er monteret

445

2/E

O-ring

O-ring

457

1/E

Bracket for by- centrifugal filter

Konsol for centrifugal by- filter

469

4/E

Screw

Skrue

470

1/E

Plug screw

Propskrue

482

1/E

Packing ring

Pakningsring

494

1/E

Cover

Dæksel

504

1/E

O-ring

O-ring

516

4/E

Screw

Skrue

528

8/E

Spring washer

Fjederskive

541

1/E

Spring

Fjeder

553

1/E

Piston

Stempel

577

1/E

O-ring

O-ring

Qty

026

1/E

Cover

038

4/E

063

Designation

Benævnelse

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E =

* Qty/E

Only available as part of a spare parts kit. Qty/Engine

= =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor

06.16 - ES0

MAN B&W Plate Page 1 (2)

Cover on Frame

51106-08E

08028-0D/H5250/94.08.12

L27/38

99.18 - ES0

MAN B&W

51106-08E

Plate Page 2 (2)

Cover on Frame

L27/38 Qty

Designation

Benævnelse

010

1/E

Cover

Dæksel

022

18/E

Screw

Skrue

083

1/E

Cover

Dæksel

095

1/E

O-ring

O-ring

105

8/E

Screw

Skrue

117

8/E

Lock washer

Låseskive

129

1/E

Sealing ring

Tætningsring

130

1/E

Cover

Dæksel

142

4/E

Screw

Skrue

548

4/E

Lock disc

Låseskive

561

1/E

O-ring

O-ring

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E =

* Qty/E

Only available as part of a spare parts kit. Qty/Engine

= =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor

99.18 - ES0

MAN B&W Plate Page 1 (2)

Covers on Frame

51106-10E

08028-0D/H5250/94.08.12

L27/38

00.37 - ES0

MAN B&W

51106-10E

Plate Page 2 (2)

Covers on Frame

L27/38 Qty

Designation

Benævnelse

1/E 2/E 1/E 2/E 3/E

Cover 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Dæksel 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

166

1/C

O-ring

O-ring

201

1/C

Cover

Dæksel

237

1/C

O-ring

O-ring

75/E 88/E 101/E 114/E 127/E

Screw 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Skrue 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

75/E 88/E 101/E 114/E 127/E

Washer 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Skive 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

154

249

250

274

1/E

O-ring

O-ring

286

1/E

Cover

Dæksel

298

1/E

O-ring

O-ring

308

1/E

Cover

Dæksel

404

1/C

Cover

Dæksel

2/E 2/E 3/E 3/E 3/E

Cover 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Dæksel 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

2/E 2/E 3/E 3/E 3/E

Cover 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Dæksel 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

1/E

O-ring

O-ring

597

607

619

Item No

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item No

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E = Qty/C =

* = Qty/E = Qty/C =

Only available as part of a spare parts kit. Qty/Engine Qty/Cylinder

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor Qty/Cylinder

00.37 - ES0

MAN B&W Plate Page 1 (2)

Lubricating Oil Pipes TC

51231-01E1 L27/38

08028-0D/H5250/94.08.12

106E

00.37 - ES0

MAN B&W

51231-01E1

Plate Page 2 (2)

Lubricating Oil Pipes TC

L27/38 Qty.

Designation

Benævnelse

010

1/E

Steel pipe

Stålrør

022

1/E

O-ring

O-ring

034

4/E

Screw

Skrue

046

1/E

Steel pipe

Stålrør

058

4/E

Pipe clamp

Rørholder

071

8/E

Screw

Skrue

083

1/E

Steel pipe

Stålrør

106E

1/E

EUnion coupling

Vinkelforskruning

129

1/E

Steel pipe

Stålrør

130

2/E

Straight male stud coupling

Ligeforskruning

142

1/E

Plug

Prop

154

1/E

Flange

Flange

166

1/E

Plug screw

Propskrue

178

1/E

Packing ring

Pakningsring

Item No.

Qty.

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item No.

When ordering spare parts, see also page 600.50.

Ved bestilling af reservedele, se også side 600.50.

* = Qty./E =

* = Qty./E =

Only available as part of a spare parts kit. Qty./Engine

Kun tilgængelig som en del af et reservedelssæt. Qty./Motor

00.37 - ES0

MAN B&W Description Page 1 (2)

Compressed Air System

513.01 Edition 14H

L27/38

08028-0D/H5250/94.08.12

Fig. 1 Diagram for Compressed Air System

General

Starting System

The compressed air system on the engine consists of a starting system, starting control system and safety system. Further, the system supplies air to the jet system and the stop cylinders on each fuel injection pump. On 8 and 9 cylinders engines air is supplied to the oil mist detector through a reduction valve.

The engine is started by means of a built-on air starter, which is a turbine motor with gear box, safety clutch and drive shaft with pinion. Further, there is a main starting valve.

The compressed air is supplied from the starting air receivers (30 bar) through a reduction station, where from compressed air at 10 bar is supplied to the engine. The reduction station should be located as near the starting air receiver as possible.

The air starter is activated electrically with a pneumatic 3/2-way solenoid valve. The valve can be activated manually from the starting box on the engine, and it can be arranged for remote control, manual or automatic.

Working pressure for the air starter: min. 8 bar max. 10 bar

For remote activation the starting coil is connected so that every starting signal to the starting coil goes through the safe start function which is connected to the safety system mounted on the engine.

To avoid dirt particles in the internal system, a dirt strainer equipped with a drain valve is mounted in the inlet line to the engine.

03.34 - ES0

Control System

MAN B&W

513.01 Edition 14H

Compressed Air System

Description Page 2 (2)

L27/38

Safety System As standard the engine is equipped with an emergency stop. It consists of one on-off valve, see diagram, which activates the stop cylinder on each fuel injection pump. Air supply must not be interrupted when the engine is running.

Pneumatic Start Sequence When the starting valve is opened, air will be supplied to the drive shaft housing of the air starter. The air supply will - by activating a piston - bring the drive pinion into engagement with the gear rim on the engine flywheel. When the pinion is fully engaged, the pilot air will flow to, and open the main starting valve, whereby air will be led to the air starter, which will start to turn the engine. When the RPM exceeds approx. 158, at which firing has taken place, the starting valve is closed whereby the air starter is disengaged.

08028-0D/H5250/94.08.12

Further, the starting valve also acts as an emergency starting valve which makes it possible to activate the air starter manually in case of power failure.

03.34 - ES0

MAN B&W Working Card Page 1 (3)

513-25.00

Manual Turning Gear

Edition 02E

L27/38 Safety precautions

Special tools

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

Plate no

Item no

Note

Description

Hand tools

Manual turning of engine.

Standard spanner with a long shaft

Starting position Indicator valve in cylinder head has to be open

Plate 50501

Related procedure

08028-0D/H5250/94.08.12

Manpower Working time Capacity

Replacement and wearing parts : :

1/4 hour 1 man

Plate no

Data Data for pressure and tolerance Data for torque moment Declaration of weight

03.13 - E0O

(Page 500.35) (Page 500.40) (Page 500.45)

Item no

Qty. /

MAN B&W

513-25.00 Edition 02E

Manual Turning Gear

Working Card Page 2 (3)

L27/38 Warning: The diesel engine can be started locally on the emergency start arrangement eventhough the turning gear is engaged.

The turning gear will automatically try to find this position once the nut (X) is loosened. It might need a light turning of the nut (Y) in order to reach the position 2 - blocking.

Note: Inform all staff working on the engine that the turning gear is engaged.

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

Fig 3

3)

Fig 1

2)

Position 1 – Engine running position

Engine blocking position. This is the blocking position of the engine when the turning gear is engaged.

Position 3 – Engine turning position

Engine turning position. The turning gear is made ready for turning by loosening the 60 mm nut (X) until the nut is approx. 23 mm from the end of the shaft. The turning gear is pushed into engagement with the gear rim on the flywheel and out of blocking mode. The engine can now be turned by means of the 30 mm nut (Y). Note: The turning gear must be fully engaged during the entire turning of engine. When the new position of the engine is found the turning gear will automatically try to return to the blocking position. When turning the engine is completed the turning gear is dis-engaged by pulling back the turning gear carefully by hand. Finally, the 60 mm nut (X) is tightened.

Trouble tracing Turning gear shaft can not be moved easily: - Dismantle the shaft and clean for rust. New lubrication to avoid rust.

Fig 2

Position 2 – Engine blocking position

Engine is not starting: - Check the microswitch ZS 75 mounted on the turning gear. 03.13 - E0O

08028-0D/H5250/94.08.12

1)

MAN B&W Working Card Page 3 (3)

Manual Turning Gear

513-25.00 Edition 02E

L27/38 TOOL 1) Open spanner : 17, 30, 60mm (with pipe or hammer) 2) Ratchet 3/4", Socket3/4"x30mm, Grease gun

TURNING GEAR-ENGAGE 1) Open all indicator cocks on cylinder heads. 2) Greas before turning.

TURNING GEAR-DISENGAGE 1) Loosen the lock nut(17mm) and the guide bolt with pushing the turning gear shaft to flywheel side. * The turning gear shaft will be moved to disengage position smoothly itself. * If the turning gear is not disengaed, turn the turning gear shaft up and down, and then try again to disengage.

3) Loosen the lock nut(17mm) and the guide bolt.

* If the turning gear is not still disengaged, the turning gear should be inspected.

4) Loosen the cap nut(60mm). * The turning gear shaft will be moved to engage position smoothly itself.

2) Pull out the turning gear shaft by means of tightening the cap nut(60mm). * Do not tighten the cap nut by too much force.

5) Push fully the turning gear shaft to flywheel side.

3) Tighten the cap nut(60mm) completely after pulling out fully the turning gear shaft.

6) Tighten the guide bolt and the lock nut(17mm) when turning gear is fully engaged. * If the turning gear is not engaged, turn the turning gear shaft up and down after turning gear is disengaged, and then try again to engage. * If the turning gear is not still engaged, the turning gear should be inspected. 7) Turn the turning gear slowly by means of ratchet 3/4" and socket 3/4". * If the turning gear is not turned snioothly, the turning gear should be stopped immediately and check the turning gear or engine inside.

4) Tighten the guide bolt and the lock nut(17mm) completely. 5) Close all indicator cocks on cylinder heads.

MAN B&W Plate Page 1 (2)

Main Starting Valve

51310-04 L21/31 L27/38 V28/32S

153 165 141 128

177 189

116

190* 200* 212 224* 236 319 307 320 332

08028-0D/H5250/94.08.12

248*

04.04 - ES0

261* 273 285* 297

MAN B&W

51310-04

Plate Page 2 (2)

Main Starting Valve

L21/31 L27/38 V28/32S Item No

Qty

Designation

Benævnelse

116

1/V

Housing

Hus

128

1/V

Delay timer

Timer

Connectors

Konnektor

141 1/V

Screw

Skrue

165

1/V

Washer

Skive

177

1/V

Retainer

Sikringsring

189

1/V

Screen

Skærm

190*

1/V

O-ring

O-ring

200*

1/V

O-ring

O-ring

212

1/V

Piston

Stempel

224*

1/V

Dampener, shock

Dæmper

236

1/V

O-ring, cap

O-ring

248*

1/V

Spring

Fjeder

261*

1/V

O-ring

O-ring

273

1/V

End cap

Endedæksel

285*

1/V

O-ring

O-ring

297

1/V

Retainer

Sikringsring

307

1/V

O-ring

O-ring

319

1/V

Part of item 320

Del af item 320

320

1/V

Solenoid valve

Magnetventil

332

2/V

Screw

Skrue

344

1/S

Main starting valve, complete

Hovedstartventil, komplet

356

1/V

Spare parts kit, comprising item 190, 200, 224, 248, 261, 285

Reserevedelssæt, bestående af item 190, 200, 224, 248, 261, 285

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

153

Item No

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* Qty/E Qty./S Qty./V

* Qty./E Qty./S Qty./V

= = = =

Only available as part of a spare parts kit. Qty./Engine Qty./Starter Qty./Valve

= = = =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor Qty./Starter Qty./Ventil

04.04 - ES0

Index Page 1 (1)

Fuel Oil System

514

Description

Working Card Dismounting / Mounting of Fuel Injection Pump ..................................................................... 514-01.05 (08H) Disassembly / Assembly and Repair of Fuel Injection Pump ............................................. 514-01.06 (07H) Fuel Injection Valve ....................................................................................................................514-01.10 (06H) Check of Fuel Oil Piping System ............................................................................................514-01.90 (03H)

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

*) Depending on Project Specification

MAN B&W

Working Card Page 1 (3)

515-01.05E

Prelubricating Pump

Edition 02E

General safety precautions : Stopped engine Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. Oil circul

Special tools : Plate no.

Item no.

Note.

Wheel puller for bearing bush. Compressed pin. Protection cover for shaft seal. Compressed pin for shaft seal. (The special tools must be ordered separately from Hyundai Heavy Industries Co.,Ltd)

Description : Dismounting, replacement of the rotary shaft seal and assembly of prelubricating pump.

Starting position :

Hand tools : Bench vice. Spanner. Torque spaner. Plier for lock ring. Soft hammer.

Related procedure :

Man power :

Replacement and wearing parts :

Working time : 2 - 3 Hours Capacity : 1 man

Plate no.

Data : Data for pressure and tolerance Data for torque moment Declaration of weight

Item no.

Q'ty./

MAN B&W

515-01.05E Edition 02E

Prelubricating Pump

Working Card Page 2 (3)

General Overhauls

We advise not to change the bearing bushes. In connection with damages on the bearing it is normal

Overhauls for the purpose of avoiding functional

that also the shafts and the parts in the gear box will

trouble are not normally necessary for the prelubricating pumps, when properly used, there is very little wear on the pump gear shaft.

be damaged. When ordering spare parts, do not forget to state the factory no. of the pump.

Spare Parts

Replacement of mechanical seal

Before any overhaul is done, please note the following

1) Disconnect the cable and pipe connection to the pump.

If a pump gets unusable by wear,it must be replaced

2) Remove the pump from the engine base frame.

installation of spare parts cannot bring it back to

3) Separate the pump and the el-motor.

normal condition

4) Remove the coupling part and key (20), see fig. 1 , from the driving gear shaft (3).

It pays to keep extra pumps in stock or to have

5) Tighten the pump to the flange. Valve housing (6) upwards.

repairs (overhauls) carried out at our repair shop. the shaft seal needs only to be replaced in case of leakage or after dismounting of drive shaft. The marks from the seal do not necessarlly mean that the sealing is defective. But there is a risk of leakage after replacement of sealing.

6) Hex's head bolt (13) and take off the valve housing (6).

MAN B&W

Working Card Page 3 (3)

Prelubricating Pump

515-01.05E Edition 02E

General 7) Take off the gear housing (5), if necessary use a soft hammer for separation. 8) Remove the gear wheels from the driving cover (1), Dismounting is only possible by disturbing the rotor

Mounting 13) The mounting process follows in reverse order. It is stressed that an exact cleaning works is necessary.

shaft seal and by breaking the bearing bush. Especially the sealing faces must be clean. 9) Remove the snap ring (19) and take off the oil seal (18).

In connection with the bearing bush. Attention must be pald to the placement of the but t

10) Press out the driving gear shaft bearing bush, pull out the running bearing bush with the inner wheel puller.

and the mounting depth. The new shaft seal cannot be pressed into the protection cover before exact mounting

11) gear housing (5), Dismounting is only possible by damaging the shaft bush, Press out the shaft bushes. 12) valve housing (6), The valve housing can be dismounted also without dismounting the pump.

of the pump. O-ring must be changed.

MAN B&W

Plate Page 1 (2)

Prelubricating Pump with El-Motor

51504-04E

L27/38

Y[ Z_ Z` YX Y X X]

XX

YW

YZ

Y_

Z]

Y^ Z X`

X_

XY

\

Z\

Y` ZW

Z[

XZ

Y\

]

X^ X\

` _

[ ZZ

^ X[

Y]

YY

XW

MAN B&W

Prelubricating Pump with El-Motor

51504-04E

L28/32H Item No.

Qty.

01

1

DRIVING COVER

02

1

CONNECTION COVER

03

1

DRIVIING GEAR SHAFT

04

1

GEAR SHAFT

05

1

GEAR HOUSING

06

1

VALVE HOUSING

07

2

PLUG

08

1

PISTON

09

1

COMPRESSION SPRING

10

1

SPRING HOUSING

11

1

STOP NUT

12

1

CAP NUT

13

4

HEX'S HEAD BOLT

14

1

O-RING

15

4

BUSH

16

2

PIN

17

4

HEX'S HEAD BOLT

18

1

OIL SEAL

19

1

SNAP RING

20

1

KEY

21

1

JAW COUPLING

22

1

GUIDE PIN

23

3

SOCKET HEAD BOLT

24

1

MOTOR

25

2

WASHER

26

2

WASHER

27

4

HEX'S HEAD BOLT

28

1

O-RING

29

2

RUBBER PLATE

30

2

COVER PLATE

31

1

NAME PLATE

32

4

RIVETS

33

8

HEX'S HEAD BOLT

34

1

SCREW FOR SETTING

35

1

O-RING

36

1

VALVE COVER

37

1

NAMEPLATE

38

1

KEY

39

2

SET SCREW

Designation.

Item No.

Qty.

Designation.

When ordering spare parts, see also page 600.50.

Ved bestilling af reservedele, se ogsa side 500.50

= Only available as part of a spare parts kit Qty./E = Qty./Engine Qty./P = Qty./Pump

= Kun tilg Antal/E = Antal/Motor Antal/P = Antal/Pumpe

Plate Page 2 (2)

MAN B&W Plate Page 1 (2)

Crankcase Venting

51531-03H L27/38

192 202 214 226 238

131 155 167

179 180

143

08028-0D/H5250/94.08.12

251 263 275 287

06.22 - ES0

023 047

MAN B&W

51531-03H

Plate Page 2 (2)

Crankcase Venting

L27/38 Qty

Designation

Benævnelse

023

4/E

Screw

Skrue

047

1/E

Packing, square

Pakning, firkantet

131

1/E

Oil vapour discharge pipe

Ånderør

143

1/E

Bracket

Beslag

155

1/E

Clamps

Klemme

167

2/E

Nut

Møtrik

179

1/E

Oil vapour dischage pipe

Ånderør

180

/I

Glue

Lim

192

4/E

Screw

Skrue

202

2/E

Packing, square

Pakning, firkantet

214

4/E

Screw

Skrue

226

4/E

Nut

Møtrik

238

1/E

Oil vapour discharge pipe

Ånderør

251

1/E

Hexagon nipple

Nippel

263

1/E

Ball valve

Kugleventil

275

1/E

Packing ring

Pakningsring

287

1/E

Plug screw

Propskrue

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E = Qty/I =

* Qty/E Qty/I

Only available as part of a spare parts kit. Qty/Engine Qty/Individual

= = =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor Qty/Individuelt

06.22 - ES0

MAN B&W Plate Page 1 (2)

Prelubricating Oil Arrangement

51535-08H

08028-0D/H5250/94.08.12

L27/38

06.13- ES0

062

086

MAN B&W

51535-08H

Plate Page 2 (2)

Prelubricating Oil Arrangement

L27/38 Qty

Designation

Benævnelse

050

1/E

Ball valve

Kugleventil

062

1/E

Straight male stud coupling

Ligeforskruning

086

1/E

Pipe

Rør

098

1/E

Adjustable elbow

Justerbar vinkel

121

1/E

Reducing adapter

Reduktionsadapter

133

1/E

Non-return valve

Kontaventil

170

1/E

Pipe

Rør

182

1/E

Pipe

Rør

241

4/E

Screw

Skrue

253

4/E

Sleeve

Bøsning

265

1/E

Straight male stud coupling

Ligeforskruning

277

1/E

Adjustable elbow

Justerbar vinkel

289

1/E

Pipe

Rør

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E =

* Qty/E

Only available as part of a spare parts kit. Qty/Engine

= =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor

06.13 - ES0

MAN B&W Plate Page 1 (2)

High- and Low Temperature Freshwater Pumps

51610-10H

08028-0D/H5250/94.08.12

L27/38

04.14 - ES0

MAN B&W

51610-10H

High- and Low Temperature Freshwater Pumps

Plate Page 2 (2)

L27/38 Qty

Designation

Benævnelse

010

1/P

O-ring

O-ring

022

1/P

O-ring

O-ring

034

1/P

Depp groove ball bearing

Radialkugleleje

046

1/P

Ball bearing

Kugleleje

071

1/P

Retaining ring

Sikringsring

083

1/P

Shaft seal

Pakdåse

095

1/P

Slide ring t

Roterende pakning

105

2/E

Freshwater pump, complete as shown on front page

Ferskvandspumpe, komplet som vist på forside

117

4/P

Screw

Skrue

129

1/P

Pump housing

Pumpehus

130*

1/P

Impeller

Løbehjul

142

1/P

Cover

Dæksel

154

3/P

Screw

Skrue

166

3/P

Lock washer

Låseskive

178*

1/P

Shaft

Aksel

191*

1/P

Screw

Skrue

201*

1/P

Disc

Skive

213

1/P

Spur gear

Cylindrisk tandhjul

225*

1/P

Washer

Skive

237*

1/P

Screw

Skrue

250

1/P

O-ring

O-ring

453

1/P

Kit for upgrading incl. items no 130, 178, 191, 201, 225 and 237

Opgraderingskit inkl. item nr. 130, 178, 191, 201, 225 og 237

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* Qty/E Qty/P Qty/I

* Qty/E Qty/P Qty/I

= = = =

Only available as part of a spare parts kit. Qty/Engine Qty/Pump Qty/Individual

= = = =

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor Qty/Pumpe Qty/Individuelt

04.14 - ES0

MAN B&W Plate Page 1 (2)

Cooling Water Connections

51630-07H L27/38

224

212

033 021

045 069 021 033 116 128

021

045 069 045 069 08028-0D/H5250/94.08.12

021

06.43 - ES0

200 212

189

190

212

MAN B&W

51630-07H

Plate Page 2 (2)

Cooling Water Connections

L27/38 Item no

Qty

021

2/E

Flange

Flange

033

2/E

Seal ring

Tætningsring

045

4/E

Screw

Skrue

069

4/E

Locking spring washer

Låsefjederskive

116

1/E

Elbow

Vinkel

128

6/E

Screw

Skrue

189

10/E

Intermediate piece

Mellemstykke

190

10/E

Intermediate piece

Mellemstykke

200

10/E

V-Profile clamp

V-profil klemme

31/E 37/E 43/E 49/E 55/E

Seal ring 5 cyl. engine 6 cyl. engine 7 cyl. engine 8 cyl. engine 9 cyl. engine

Tætningsring 5 cyl. motor 6 cyl. motor 7 cyl. motor 8 cyl. motor 9 cyl. motor

224

1/E

Orifice plate

Måleblænde

236

/I

Packing-silicone paste

Pakningssilicone

Benævnelse

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

212

Designation

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/E = Qty/C =

* = Qty/E = Qty/C =

Only available as part of a spare parts kit. Qty/Engine Qty/Cylinder

Kun tilgængelig som en del af et reservedelssæt. Qty/Motor Qty/Cylinder

06.43 - ES0

MAN B&W Plate Page 1 (2)

Conical Element

51903-03E

08028-0D/H5250/94.08.12

L27/38

99.14 - ES0

MAN B&W

51903-03E

Plate Page 2 (2)

Conical Element

L27/38 Qty

Designation

Benævnelse

013

1/M

Conical element, complete

Konisk understøtning, komplet

025

4/M

Screw

Skrue

049

1/M

Protecting cap

Beskyttelseskapsel

Item no

Qty

Designation

Benævnelse

08028-0D/H5250/94.08.12

Item no

When ordering spare parts, see also page 500.50.

Ved bestilling af reservedele, se også side 500.50.

* = Qty/M =

* = Qty/M =

Only available as part of a spare parts kit. Qty/Conical mounting

Kun tilgængelig som en del af et reservedelssæt. Qty/Conical montering

99.14 - ES0

Index Page 1 (1)

Tools

(Please see " Tool list on final drawing")

520 I

Description

Working Card

Plates

MAN B&W Plate Page 1 (11)

Standard Tools for Normal Maintenance

52000-01E L27/38

Supply per Ship

08028-0D/H5250/94.08.12

Name

Sketch

Working

Spare

Plate

Item no

Valve spring tightening device

1

52000

014

Lifting tool for cylinder unit

1

52000

038

Grinding tool for cylinder head/liner

1

52000

087

Max. pressure indicator

1

52000

134E

00.51 - ES1

Remarks

MAN B&W

52000-01E

Plate Page 2 (11)

Standard Tools for Normal Maintenance

L27/38 Supply per Ship Sketch Working

Spare

Plate

Item no

Removing device for flame ring

1

52000

021

Guide bush for piston

1

52000

045

Fit and removal device for conn. rod bearing, incl. eye screws (2 pcs)

1

52000

069

Remarks

08028-0D/H5250/94.08.12

Name

00. 51 - ES1

Doc. No : K630-IR08B-4231

SHOP TEST RESULT FOR D / G ENGINE

Engine No. Engine type Hull No. Owner Class Ship yard

BA2401/2402 7,9L27/38 1893 C.P. OFFEN GL HYUNDAI HEAVY INDUSTRIES., CO. LTD.

HYUNDAI-MAN Diesel CONTENTS

PAGE NO.

1.Spec. of Engine & Accessory

1

2.Measuring Record(Load test)

2~6

3.Setting Table

7

4.Calculation sheet of F.O

8

5.Parallel running test record

9

6.Governor test record

10

7.Mechanical vibration measurement

11

8.Crankshaft deflection

12

9.Height of resilient

13

QUALITY MANAGEMENT DEPARTMENT HHI-EMD

Rev.

Prepared

Checked

Approved

Description

2 1 0

S.H.KANG

M. H. KIM

2008-06-03

2008-06-04

Y. S. LEE 2008-06-04

First issue

- MAN Diesel OFFICIAL SHOP TEST RESULT

PROJECT

FOR DIESEL GENERATOR ENGINE

ENG. TYPE

1893

OWNER

C.P.OFFEN

9,7L27/38

CLASS

GL

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

SPECIFICATION OF ENGINE & ACCESSORIES

DESCRIPTION ENG.NO.

ENG. MCR

2970/2310㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195㎾

OPERATED BY

K.D.Oh

NO. 1 D/G

NO. 2 D/G

NO. 3 D/G

NO. 4 D/G

NO. 5 D/G

BA2402-1

BA2402-2

BA2401-1

BA2401-2

BA2401-3

TYPE

9L27/38

7L27/38

POWER × rpm

2970 ㎾ x 720 rpm

2310 ㎾ x 720 rpm

FIRING ORDER

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

1-2-4-6-7-5-3

TYPE

HSJ7 805-10P

HSJ7 803-10P

OUTPUT & VOLT.

3760 kVA 2820 ㎾ 6600 V

2926.7 kVA 2195 ㎾ 6600 V

ENGINE

CURRENT & ㎐

GENERATOR

60 ㎐

328.9 A

256 A 10 P

POLE & PF SER.NO.

60 ㎐

3 PHA 0.75 PF

20070193RAH00601 20070193RAH00602 20070193RAH01001 20070193RAH01002 20070193RAH01003

NR29/S072

TYPE MAX. rpm & TEMP.

NR24/S065

650 ℃

31300 rpm

650 ℃

37300 rpm

TURBOCHARGER STX ENPACO-MAN Diesel

MAKER SJL0255

SER.NO.

GOVERNOR

UG-15D

MAKER

WOODWARD 15533414

COOLING SURFACE

15533405

15533417

122 ㎡

SLL0327

SLL0328

15533406

15533413

110.4 ㎡ DongHwa Entec

MAKER DHI7J880-A

SER.NO. COOLING SURFACE

LUB.OIL COOLER

SLL0326

TYPE

SER.NO.

AIR COOLER

SJL0256

DHI7J880-B

DHI7J870-A

DHI7J870-B

13.62 ㎡

DHI7J870-C

11.0 ㎡

MAKER

KPHE CORPORATION

SER.NO.

KPHE-2080816 KPHE-2080817 KPHE-2080873 KPHE-2080874 KPHE-2080875

USED OIL AT SHOP TEST FUEL OIL

DESCRIPTION

Offocal Shop Test Date

2008.05.19

KIND OF OIL

LUB.OIL 2008.05.24

BUNKER - A

SPECIFIC GRAVITY (15/4℃)

2008.05.19 DELO 1000 M 40

0.8996

0.9060

0.8748

67

75

-

50℃/cSt

7.29

8.28

-

100℃/cSt

-

-

13.86

CARBON RESIDUE (wt%)

1.50

1.60

-

ASH (wt%)

0.010

0.01

-

WATER & SEDIMENT (vol%)

0.05

0.05

-

SULFUR (wt%)

0.220

0.25

-

NET.CAL.VALUE (kcal/kg)

10048

10026

-

FLASH POINT (℃) VISCOSITY

- 1 -

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

ENGINE TYPE ENGINE NO.

MEASURING RECORD (NO.1 D/G) Time

hh:mm

Ambient Press. / Temp.

mbar/ ℃

Load Point

%

Engine Speed

rpm

Generator Load

㎾

Generator Efficiency

% ㎾

Engine Load

㎏/h

Fuel oil consumption

specific consumption g/㎾.h at ISO conditions g/㎾.h Governor Indicator Position Turbocharger Speed

% rpm

Generator Winding & BRG' Temp.

L1 L2 L3 ℃

HT-Water Temp. Outlet Engine

℃

HT-Water Press. Inlet Engine

bar

LT-Water Temp. Inlet Air Cooler

℃

LT-Water Press. Inlet Air Cooler

bar

Lub.Oil Temp. Inlet Engine

℃

Lub.Oil Press. Inlet Filter

bar

Lub.Oil Press. Inlet Engine

bar

Lub.Oil Press. Inlet Turbocharger

bar

Fuel Oil Temp. Inlet Engine

℃

Fuel Oil Press. Inlet Engine

bar

Charge Air Temp. Outlet Cooler

℃

Charge Air Press. Outlet cooler

bar

Cylinder Case Press. Exh.gas Temp

Pump Index

Firing Press

08:50 ~09:20 1008 18.5 25% 720 695.5 93.67 742.5 3.4 12,470 -

Cyl.No.

-

℃

mm bar

Exhaust Gas Temp. Outlet T/C

75 75 No.3 230 18.0 75 No.4 254 18.0 75 No.5 234 18.0 72 No.6 237 18.0 72 No.7 220 18.5 71 No.8 231 18.0 72 No.9 215 18.0 73 Guide * * * mean 236 18.1 73 390 ℃ 338 ℃

★Safety Device Test

1. Overspeed Stop

Cylinder Unit

Exhaust Gas Temp. Inlet T/C

-

L1 L2 L3 -

72/76 2.5 37 2.7 63 5.3 4.8 1.1 25 8.9 37 0.20 -

mmWC BRG' Temp

-

BRG

09:20~09:50 1008 19.2 50% 720 1430.6 96.34 1485.0 5.0 19,500

No.1 262

18.0

No.2 240

18.0

-

BRG

-

-

1893

OWNER

C.P.OFFEN

9L27/38

CLASS

GL

PROJECT

-

-

-

TEST DATE

2008.05.19

ENGINE MCR

2970 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820 ㎾

OPERATED BY

K.D.Oh

09:50~10:20 1008 20 75% 720 2161.3 97.03 2227.5 6.4 24,660 L1 L2 L3

BA2402 -1

BRG

-

10:20~10:50 10:50~11:20 1008 20.7 1008 21 100% 720 2887.1 97.21 2970.0 580.000 195.286 191.622 7.9 7.9 28,860 28,840 L1 L2 L3 -

-

-

L1 L2 L3

BRG

-

-

-

-

BRG

-

11:20~11:50 1008 21.5 110% 720 3176.2 97.22 3267.0 8.5 30,370 L1 L2 L3 -

-

-

72/77 2.5 37 2.4 65 5.0 4.5 1.3 24 8.5 39 1.00 -

72/78 3.4 35 3.0 68 4.9 4.4 1.5 24 8.4 42 2.00 -

75/80 3.3 35 3.0 67 4.9 4.4 1.6 24 7.9 44 2.81 -

75/80 3.3 35 3.0 67 4.9 4.4 1.6 24 7.9 44 2.81 -

75/80 3.3 35 3.0 69 4.9 4.4 1.6 25 7.6 45 3.20 -

℃ ℃ mm bar - 267 25.0 119 - 263 25.0 116 - 255 25.0 117 - 279 25.0 116 - 259 25.0 114 - 263 25.0 114 - 251 25.5 114 - 263 25.0 114 - 243 25.0 114 - * * * -- 260 25.1 115 438 346

℃ ℃ mm bar - 291 32.5 160 - 293 32.0 159 - 288 32.0 159 - 296 32.0 160 - 288 32.5 160 - 281 32.0 160 - 272 32.5 159 - 287 32.0 159 - 270 32.0 159 - * * * -- 285 32.2 159 456 314

℃ ℃ mm bar - 327 39.5 194 - 329 39.0 194 - 322 39.0 194 - 337 39.0 193 - 327 39.5 193 - 324 39.0 192 - 306 39.5 194 - 325 39.0 192 - 304 39.0 194 - * * * -- 322 39.2 193 499 310

℃ ℃ mm bar - 325 39.5 194 - 330 39.0 194 - 323 39.0 194 - 338 39.0 193 - 327 39.5 193 - 324 39.0 192 - 308 39.5 194 - 325 39.0 192 - 303 39.0 194 * * * -- 323 39.2 193 498 311

℃ ℃ mm bar - 351 43.0 204 - 356 42.0 204 - 346 42.0 204 - 367 42.0 204 - 353 43.0 203 - 354 42.5 203 - 328 42.5 205 - 355 42.0 203 - 329 42.0 204 - * * * -- 349 42.3 204 537 333

813/828 rpm

2. Lub. Oil Low Pressure Stop

3.10 bar

3. H.T-Water High Temperature Stop

93.8 ℃

4. Emergency Start

OK

5. Oil Mist Detector Stop

OK

6. Start Inderlock

OK

-2-

*Overhaul Inspection: -

Cyl.

9 M/Brg

BRG

-

℃ --

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

ENGINE TYPE ENGINE NO.

MEASURING RECORD (NO.2 D/G) Time

hh:mm

Ambient Press. / Temp.

mbar/℃

Load Point

%

Engine Speed

rpm

Generator Load

㎾

Generator Efficiency

% ㎾

Engine Load

㎏/h

Fuel oil consumption

specific consumption g/㎾.h at ISO conditions g/㎾.h Governor Indicator Position Turbocharger Speed

% rpm

Generator Winding & BRG' Temp.

L1 L2 L3 ℃

HT-Water Temp. Outlet Engine

℃

HT-Water Press. Inlet Engine

bar

LT-Water Temp. Inlet Air Cooler

℃

LT-Water Press. Inlet Air Cooler

bar

Lub.Oil Temp. Inlet Engine

℃

Lub.Oil Press. Inlet Filter

bar

Lub.Oil Press. Inlet Engine

bar

Lub.Oil Press. Inlet Turbocharger

bar

Fuel Oil Temp. Inlet Engine

℃

Fuel Oil Press. Inlet Engine

bar

Charge Air Temp. Outlet Cooler

℃

Charge Air Press. Outlet cooler

bar

Cylinder Case Press. Exh.gas Temp

Pump Index

Firing Press

08:50 ~09:20 1008 18.5 25% 720 695.5 93.67 742.5 3.5 12,120 -

mmWC BRG' Temp

Cyl.No.

℃

-

-

-

-

BRG

-

-

C.P.OFFEN

9L27/38

CLASS

GL

-

-

-

TEST DATE

2008.05.19

ENGINE MCR

2970 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820 ㎾

OPERATED BY

K.D.Oh

09:50~10:20 1008 20 75% 720 2161.3 97.03 2227.5 6.5 24,620 L1 L2 L3

BA2402 -2

BRG

-

10:20~10:50 10:50~11:20 1008 20.7 1008 21 100% 720 2887.1 97.21 2970.0 579.000 194.949 191.292 8.1 8.1 28,750 28,760 L1 L2 L3 -

-

-

BRG

-

L1 L2 L3 -

-

-

BRG

-

11:20~11:50 1008 21.5 110% 720 3176.2 97.22 3267.0 8.8 30,370 L1 L2 L3 -

-

-

74 / 77 2.8 37 2.6 67 4.9 4.5 1.3 27 8.1 38 0.95 -

73 / 80 3.3 35 3.1 68 4.9 4.4 1.5 25 7.8 41 2.00 -

76 / 81 3.2 35 3.1 70 4.8 4.3 1.7 27 7.3 43 2.80 -

76 / 81 3.2 35 3.1 70 4.8 4.3 1.7 27 7.3 43 2.80 -

76 / 82 3.2 35 3.1 71 4.7 4.2 1.5 27 6.8 44 3.10 -

mm bar

℃ ℃ mm bar - 253 25.0 118 - 237 25.0 118 - 251 25.0 115 - 265 25.0 115 - 259 25.0 115 - 282 25.5 118 - 252 25.0 116 - 256 25.0 116 - 271 25.0 115 * * * -- 258 25.1 116 438 346

℃ ℃ mm bar - 282 32.0 159 - 267 32.0 160 - 278 32.0 159 - 287 32.5 160 - 284 32.0 160 - 302 32.5 160 - 277 32.0 161 - 284 32.0 160 - 300 32.0 160 * * * -- 285 32.1 160 498 314

℃ ℃ mm bar - 315 39.0 193 - 304 39.0 194 - 317 39.0 193 - 329 39.5 194 - 329 39.0 194 - 341 39.0 194 - 312 39.5 194 - 319 39.0 194 - 336 39.5 194 * * * -- 322 39.2 194 500 314

℃ ℃ mm bar - 316 39.0 193 - 305 39.0 194 - 317 39.0 193 - 330 39.5 194 - 329 39.0 194 - 341 39.0 194 - 312 39.5 194 - 319 39.0 194 - 336 39.5 194 * * * -- 323 39.2 194 500 314

℃ ℃ mm bar - 339 42.0 204 - 328 42.0 205 - 336 42.5 203 - 357 43.0 204 - 353 42.0 204 - 371 42.5 205 - 338 42.5 205 - 344 42.0 204 - 358 42.0 204 * * * -- 347 42.3 204 534 334

Exhaust Gas Temp. Outlet T/C

★Safety Device Test

1. Overspeed Stop

Exhaust Gas Temp. Inlet T/C

-

L1 L2 L3

OWNER

72 / 77 3.1 37 2.8 61 5.0 4.6 1.1 26 8.4 35 0.20 -

76 76 No.3 229 18.0 76 No.4 248 18.0 75 No.5 231 18.5 75 No.6 269 18.0 76 No.7 225 18.0 75 No.8 227 18.5 74 No.9 246 18.5 75 Guide * * * mean 237 18.2 75 388 ℃ 330 ℃

Cylinder Unit

BRG

09:20~09:50 1008 19.2 50% 720 1430.6 96.34 1485.0 5.0 19,330

1893

PROJECT

No.1 252

18.0

No.2 210

18.0

814/827 rpm

2. Lub. Oil Low Pressure Stop

3.00 bar

3. H.T-Water High Temperature Stop

94.0 ℃

4. Emergency Start

OK

5. Oil Mist Detector Stop

OK

6. Start Inderlock

OK

- 3 -

*Overhaul Inspection: 6 Cyl. 6 M/Brg

BRG

-

℃ --

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

ENGINE TYPE ENGINE NO.

MEASURING RECORD (NO.3 D/G) Time

hh:mm

Ambient Press. / Temp.

mbar/ ℃

Load Point

%

Engine Speed

rpm

Generator Load

㎾

Generator Efficiency

% ㎾

Engine Load

㎏/h

Fuel oil consumption

specific consumption g/㎾.h at ISO conditions g/㎾.h Governor Indicator Position Turbocharger Speed

% rpm

Generator Winding & BRG' Temp.

L1 L2 L3 ℃

HT-Water Temp. Outlet Engine

℃

HT-Water Press. Inlet Engine

bar

LT-Water Temp. Inlet Air Cooler

℃

LT-Water Press. Inlet Air Cooler

bar

Lub.Oil Temp. Inlet Engine

℃

Lub.Oil Press. Inlet Filter

bar

Lub.Oil Press. Inlet Engine

bar

Lub.Oil Press. Inlet Turbocharger

bar

Fuel Oil Temp. Inlet Engine

℃

Fuel Oil Press. Inlet Engine

bar

Charge Air Temp. Outlet Cooler

℃

Charge Air Press. Outlet cooler

bar

Cylinder Case Press. Exh.gas Temp

Pump Index

Firing Press

10:10~10:40 1008 18.6 25% 720 536.3 92.87 577.5 3.0 15,430 -

mmWC BRG' Temp

Cyl.No.

℃

-

-

-

-

BRG

-

-

C.P.OFFEN

7L27/38

CLASS

GL

-

-

-

TEST DATE

2008.05.24

ENGINE MCR

2310 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2195 ㎾

OPERATED BY

K.D.Oh

11:10~11:40 1009 18.4 75% 720 1677.4 96.82 1732.5 5.9 29,420 L1 L2 L3

BA2401 -1

BRG

-

11:40~12:10 12:10~12:40 1009 18.5 1009 18.5 100% 720 2243.0 97.10 2310.0 451.000 195.238 191.289 7.3 7.3 33,800 33,810 L1 L2 L3 -

-

-

BRG

-

L1 L2 L3 -

-

-

BRG

-

12:40~13:10 1009 19.7 110% 720 2467.6 97.11 2541.0 8.0 35,470 L1 L2 L3 -

-

-

73 / 79 4.0 37 3.7 64 4.8 4.5 1.3 32 8.5 38 1.00 -

74 / 79 4.0 36 3.8 65 4.8 4.5 1.6 31 7.2 40 2.00 -

75 / 80 4.0 36 3.9 65 4.7 4.4 1.6 31 6.8 42 2.80 -

75 / 80 4.0 36 3.9 65 4.7 4.4 1.6 31 6.8 42 2.80 -

75 /81 4.0 36 3.9 66 4.8 4.4 1.6 31 6.5 43 3.00 -

mm bar

℃ ℃ mm bar - 269 25.0 117 - 269 25.0 118 - 264 25.0 120 - 266 25.0 118 - 256 25.0 117 - 263 25.0 120 - 259 25.0 120 - - - - - - - * * * -- 264 25.0 119 416 322

℃ ℃ mm bar - 267 32.0 159 - 294 32.0 158 - 289 32.0 159 - 285 32.0 158 - 273 31.5 158 - 280 31.5 160 - 275 31.5 160 - - - - - - - * * * -- 280 31.8 159 424 227

℃ ℃ mm bar - 337 39.0 193 - 345 39.0 193 - 337 39.0 195 - 338 39.0 193 - 323 39.0 193 - 333 39.0 194 - 329 39.0 196 - - - - - - - * * * -- 335 39.0 194 490 301

℃ ℃ mm bar - 337 39.0 193 - 345 39.0 193 - 338 39.0 195 - 338 39.0 193 - 323 39.0 193 - 333 39.0 194 - 329 39.0 196 - - - - - - - * * * -- 335 39.0 194 495 302

℃ ℃ mm bar - 365 42.5 203 - 375 42.5 203 - 367 42.5 204 - 370 42.0 203 - 355 42.0 204 - 361 42.0 204 - 363 42.0 206 - - - - - - - * * * -- 365 42.2 204 535 332

Exhaust Gas Temp. Outlet T/C

★Safety Device Test

1. Overspeed Stop

Exhaust Gas Temp. Inlet T/C

-

L1 L2 L3

OWNER

74 / 77 4.0 37 3.7 62 4.8 4.5 1.0 32 9.0 36 0.20 -

74 75 No.3 241 18.0 75 No.4 242 18.0 74 No.5 230 18.0 73 No.6 238 17.5 75 No.7 226 18.0 74 No.8 - No.9 - Guide * * * mean 238 17.9 74 334 ℃ 297 ℃

Cylinder Unit

BRG

10:40~11:10 1009 18.4 50% 720 1108.2 95.95 1155.0 4.6 23,900

1893

PROJECT

No.1 252

18.0

No.2 239

18.0

812/828 rpm

2. Lub. Oil Low Pressure Stop

3.00 bar

3. H.T-Water High Temperature Stop

93.9 ℃

4. Emergency Start

OK

5. Oil Mist Detector Stop

OK

6. Start Inderlock

OK

- 4 -

*Overhaul Inspection: 2

Cyl.

2 M/Brg

BRG

-

℃ --

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

ENGINE TYPE ENGINE NO.

MEASURING RECORD (NO.4 D/G) Time

hh:mm

Ambient Press. / Temp.

mbar/ ℃

Load Point

10:10~10:40 1008 18.6

10:40~11:10 1009 18.4

11:10~11:40 1009 18.4

25% 720 536.3 92.87 577.5 3.1 15,330

50% 720 1108.2 95.95 1155.0 4.7 23,930

75% 720 1677.4 96.82 1732.5 6.0 29,700

%

Engine Speed

rpm

Generator Load

㎾

Generator Efficiency

% ㎾

Engine Load

㎏/h

Fuel oil consumption

specific consumption g/㎾.h at ISO conditions g/㎾.h Governor Indicator Position Turbocharger Speed

% rpm

Generator Winding & BRG' Temp.

L1 L2 L3 ℃

HT-Water Temp. Outlet Engine

℃

HT-Water Press. Inlet Engine

bar

LT-Water Temp. Inlet Air Cooler

℃

LT-Water Press. Inlet Air Cooler

bar

Lub.Oil Temp. Inlet Engine

℃

Lub.Oil Press. Inlet Filter

bar

Lub.Oil Press. Inlet Engine

bar

Lub.Oil Press. Inlet Turbocharger

bar

Fuel Oil Temp. Inlet Engine

℃

Fuel Oil Press. Inlet Engine

bar

Charge Air Temp. Outlet Cooler

℃

Charge Air Press. Outlet cooler

bar

Cylinder Case Press. Exh.gas Temp

Pump Index

Firing Press

-

mmWC BRG' Temp

Cyl.No.

℃

-

-

-

-

BRG

-

-

C.P.OFFEN

7L27/38

CLASS

GL

L1 L2 L3 -

-

-

BA2401 -2

TEST DATE

2008.05.24

ENGINE MCR

2310 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2195 ㎾

OPERATED BY

K.D.Oh

11:40~12:10 1009 18.5

12:10~12:40 1009 18.5

12:40~13:10 1009 19.7

100% 720 2243.0 97.10 2310.0 452.000 195.671 191.713 7.4 34,280

7.4 34,250 BRG

-

L1 L2 L3 -

-

-

110% 720 2467.6 97.11 2541.0 8.0 35,880

L1 L2 L3

BRG

-

-

-

-

BRG

-

L1 L2 L3 -

-

-

73 / 77 3.9 37 3.7 65 4.9 4.6 1.3 32 8.5 38 1.00 -

73 / 78 3.9 36 3.8 65 4.9 4.5 1.5 31 7.5 40 1.95 -

75 / 80 4.0 36 3.8 66 4.9 4.5 1.6 30 7.0 42 2.80 -

75 / 80 4.0 36 3.8 66 4.9 4.5 1.6 30 7.0 42 2.80 -

76 / 81 4.0 36 3.8 67 4.9 4.5 1.6 30 6.6 42 2.95 -

mm bar

℃ ℃ mm bar - 259 25.0 118 - 265 25.0 118 - 257 25.0 118 - 255 25.0 118 - 254 25.0 120 - 287 25.0 120 - 253 25.0 118 - - - - - - - * * * -- 261 25.0 119 415 323

℃ ℃ mm bar - 276 32.0 157 - 295 32.0 157 - 287 32.0 156 - 279 32.0 158 - 278 32.0 158 - 283 32.0 159 - 272 32.0 159 - - - - - - - * * * -- 281 32.0 158 436 290

℃ ℃ mm bar - 319 39.0 193 - 342 39.0 193 - 331 39.0 193 - 324 39.0 195 - 323 39.0 196 - 329 39.0 194 - 318 39.0 194 - - - - - - - * * * -- 327 39.0 194 497 307

℃ ℃ mm bar - 320 39.0 193 - 343 39.0 193 - 330 39.0 193 - 325 39.0 195 - 323 39.0 196 - 330 39.0 194 - 319 39.0 194 - - - - - - - * * * -- 327 39.0 194 499 309

℃ ℃ mm bar - 349 42.0 203 - 373 42.0 202 - 360 42.0 203 - 352 42.0 204 - 353 42.0 206 - 358 42.0 204 - 345 42.0 206 - - - - - - - * * * -- 356 42.0 204 531 328

Exhaust Gas Temp. Outlet T/C

★Safety Device Test

1. Overspeed Stop

Exhaust Gas Temp. Inlet T/C

-

L1 L2 L3

OWNER

73 / 76 4.0 37 3.7 62 5.0 4.6 1.0 32 8.9 37 0.20 -

74 74 No.3 228 18.0 74 No.4 225 18.0 74 No.5 227 18.0 74 No.6 238 18.0 75 No.7 219 18.0 73 No.8 - No.9 - Guide * * * mean 228 18.1 74 346 ℃ 312 ℃

Cylinder Unit

BRG

1893

PROJECT

No.1 227

18.0

No.2 231

18.5

812/827 rpm

2. Lub. Oil Low Pressure Stop

3.10 bar

3. H.T-Water High Temperature Stop

93.9 ℃

4. Emergency Start

OK

5. Oil Mist Detector Stop

OK

6. Start Inderlock

OK

- 5 -

*Overhaul Inspection: -

Cyl.

2 M/Brg

BRG

-

℃ --

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

ENGINE TYPE ENGINE NO.

MEASURING RECORD (NO.5 D/G) Time

hh:mm

Ambient Press. / Temp.

mbar/ ℃

Load Point

%

Engine Speed

rpm

Generator Load

㎾

Generator Efficiency

% ㎾

Engine Load

㎏/h

Fuel oil consumption

specific consumption g/㎾.h at ISO conditions g/㎾.h Governor Indicator Position Turbocharger Speed

% rpm

Generator Winding & BRG' Temp.

L1 L2 L3 ℃

HT-Water Temp. Outlet Engine

℃

HT-Water Press. Inlet Engine

bar

LT-Water Temp. Inlet Air Cooler

℃

LT-Water Press. Inlet Air Cooler

bar

Lub.Oil Temp. Inlet Engine

℃

Lub.Oil Press. Inlet Filter

bar

Lub.Oil Press. Inlet Engine

bar

Lub.Oil Press. Inlet Turbocharger

bar

Fuel Oil Temp. Inlet Engine

℃

Fuel Oil Press. Inlet Engine

bar

Charge Air Temp. Outlet Cooler

℃

Charge Air Press. Outlet cooler

bar

Cylinder Case Press. Exh.gas Temp

Pump Index

Firing Press

10:10~10:40 1008 18.6 25% 720 536.3 92.87 577.5 3.2 15,350 -

mmWC BRG' Temp

Cyl.No.

℃

-

-

-

-

BRG

-

-

C.P.OFFEN

7L27/38

CLASS

GL

-

-

2008.05.24

2310 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2195 ㎾

OPERATED BY

K.D.Oh

75% 720 1677.4 96.82 1732.5 6.0 29,750 -

TEST DATE

ENGINE MCR

11:10~11:40 1009 18.4

L1 L2 L3

BA2401 -3

BRG

-

11:40~12:10 12:10~12:40 1009 18.5 1009 18.5 100% 720 2243.0 97.10 2310.0 453.000 196.104 192.206 7.4 7.4 34,150 34,200 L1 L2 L3 -

-

-

L1 L2 L3

BRG

-

-

-

-

BRG

-

12:40~13:10 1009 19.7 110% 720 2467.6 97.11 2541.0 8.1 35,760 L1 L2 L3 -

-

-

74 / 78 3.9 37 3.7 67 4.5 4.3 1.3 30 8.0 39 1.05 -

74 / 78 3.9 36 3.8 67 4.6 4.3 1.5 29 7.3 41 2.00 -

75 / 80 3.9 36 3.8 68 4.7 4.4 1.6 28 6.8 43 2.82 -

75 / 80 3.9 36 3.8 68 4.7 4.4 1.6 28 6.8 43 2.82 -

76 / 81 4.0 35 3.9 69 4.7 4.4 1.6 28 6.4 44 3.20 -

mm bar

℃ ℃ mm bar - 273 25.0 117 - 256 25.0 118 - 252 25.0 118 - 273 25.0 117 - 250 25.0 118 - 262 25.0 119 - 249 25.0 118 - - - - - - - * * * -- 259 25.0 118 419 321

℃ ℃ mm bar - 291 32.0 156 - 274 32.0 157 - 269 32.0 158 - 293 32.0 158 - 273 32.0 158 - 277 32.0 159 - 268 32.0 158 - - - - - - - * * * -- 278 32.0 158 433 280

℃ ℃ mm bar - 338 39.0 193 - 324 39.0 195 - 314 39.0 194 - 342 39.0 194 - 319 39.0 193 - 325 39.0 194 - 315 39.0 196 - - - - - - - * * * -- 325 39.0 194 498 304

℃ ℃ mm bar - 340 39.0 193 - 325 39.0 195 - 315 39.0 194 - 343 39.0 194 - 318 39.0 193 - 327 39.0 194 - 318 39.0 196 - - - - - - - * * * -- 327 39.0 194 500 305

℃ ℃ mm bar - 367 42.5 203 - 349 42.5 205 - 338 42.5 206 - 375 42.5 206 - 347 42.5 206 - 354 42.5 206 - 340 42.5 206 - - - - - - - * * * -- 353 42.5 205 534 326

Exhaust Gas Temp. Outlet T/C

★Safety Device Test

1. Overspeed Stop

Exhaust Gas Temp. Inlet T/C

-

L1 L2 L3

OWNER

73 / 76 4.0 37 3.8 62 4.7 4.5 1.0 30 8.3 36 0.20 -

72 72 No.3 216 18.0 73 No.4 238 18.0 73 No.5 219 18.0 73 No.6 238 18.0 74 No.7 215 18.0 74 No.8 - No.9 - Guide * * * mean 227 18.0 73 352 ℃ 309 ℃

Cylinder Unit

BRG

10:40~11:10 1009 18.4 50% 720 1108.2 95.95 1155.0 4.7 24,050

1893

PROJECT

No.1 245

18.0

No.2 221

18.0

813/826 rpm

2. Lub. Oil Low Pressure Stop

3.00 bar

3. H.T-Water High Temperature Stop

94.3 ℃

4. Emergency Start

OK

5. Oil Mist Detector Stop

OK

6. Start Inderlock

OK

- 6 -

*Overhaul Inspection: -

Cyl.

4 M/Brg

BRG

-

℃ --

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

PROJECT

SETTING TABLE

CLEARANCE OF VALVES

1893

OWNER

C.P.OFFEN

ENG. TYPE

9,7L27/38

CLASS

GL

ENGINE NO.

BA2402/2401

TEST DATE

2008.05.19/24

ENG. MCR

2970/2310㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195㎾

OPERATED BY

K.D.Oh

INLET VALVE

: 0.7 mm (COLD CONDITION)

EXHAUST VALVE

: 0.7 mm (COLD CONDITION)

[THICKNESS OF THRUST PLATE]

ADJUSTMENT OF FUEL INJECTION PUMPS

[UNIT : mm]

CYL. NO.

1

2

3

4

5

6

7

8

9

NO.1 D/G

11.30

11.00

11.00

10.75

10.75

11.00

10.60

11.00

10.60

NO.2 D/G

11.00

11.50

11.00

11.00

10.60

11.00

10.40

10.70

10.50

NO.3 D/G

11.00

11.00

11.00

11.00

11.00

11.00

11.00

NO.4 D/G

11.00

11.00

10.75

11.00

11.00

11.00

11.00

NO.5 D/G

11.25

11.00

11.00

11.25

10.60

11.00

10.60

THE THRUST PLATE LOCATES BETWEEN THE FUEL INJECTION PUMP PLUNGER BOTTOM PART AND THE ROLLER TAPPET UPPER PART.

ADJUSTMENT OF FUEL INJECTION CAMSHAFT

FUEL INJECTION CAM TIMING

REMARKS

NO.1 D/G

Before TDC 8.0 Degree

-

NO.2 D/G

Before TDC 8.5 Degree

-

NO.3 D/G

Before TDC 7.5 Degree

-

NO.4 D/G

Before TDC 7.0 Degree

-

NO.5 D/G

Before TDC 8.0 Degree

-

THESE VALUES ARE ACTUAL READINGS AT THE MARKINGS WHICH ARE MARKED ON THE FLYWHEEL CIRCUMFERENTIAL SURFACE. (SEE THE INSTRUCTION BOOK PLATE NO. 507-01.20)

VALVE TIMING

DESCRIPTION

INLET VALVE

EXHAUST VALVE

OPENING

Before TDC 81.3°

Before BDC 51.3°

-

CLOSING

After BDC 61.5°

After TDC 78.3°

-

-7-

REMARKS

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

PROJECT

CALCULATION SHEET OF F.O.

1893

OWNER

C.P.OFFEN

ENG. TYPE

9,7L27/38

CLASS

GL

ENGINE NO.

BA2402/2401

TEST DATE

ENG. MCR

2970/2310㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195㎾

OPERATED BY

K.D.Oh

2008.05.19/24

GENSET NO. NO.1 D/G

NO.2 D/G

NO.3 D/G

NO.4 D/G

NO.5 D/G

DESCRIPTION

OUTPUT

LOAD

%

100%

100%

100%

100%

100%

GEN. OUTPUT

㎾

2887.1

2887.1

2243.0

2243.0

2243.0

GEN. EFFICIENCY

%

97.21

97.21

97.10

97.10

97.10

㎾

2970.0

2970.0

2310.0

2310.0

2310.0

PS

4038.1

4038.1

3140.7

3140.7

3140.7

ENG. OUTPUT TIME

min/sec 30min 0.00s 30min 0.00s

30min

0.00s

30min

0.00s

30min

0.00s

㎏

290.000

289.500

225.500

226.000

226.500

㎏/h

580.000

579.000

451.000

452.000

453.000

g/㎾.h

195.286

194.949

195.238

195.671

196.104

g/PS.h

143.633

143.385

143.598

143.916

144.234

AMBIENT AIR TEMP.

℃

20.7

20.7

18.5

18.5

18.5

(25-Ta)×0.06

%

0.26

0.26

0.39

0.39

0.39

AMBIENT AIR PRESS.

mbar

1008

1008

1009

1009

1009

%

0.0560

0.0560

0.0630

0.0630

0.0630

℃

35

35

36

36

36

%

-0.70

-0.70

-0.77

-0.77

-0.74

LOW CALORIFIC VALUE

kcal/㎏

10048

10048

10026

10026

10026

(LCV/10200-1)×100

%

-1.4902

-1.4902

-1.7059

-1.7059

-1.7059

SUB TOTAL

%

-1.8762

-1.8762

-2.0229

-2.0229

-1.9879

g/㎾.h

191.622

191.292

191.289

191.713

192.206

g/PS.h

140.938

140.695

140.693

141.005

141.367

F.O. CONSUMPTION ACTUAL MEASUREMENT

S.F.O.C.

(Pa-1000)×0.007 ISO CONVERS. C.W. TO AIR COOLER FACTOR (25-Ta)×0.07

S.F.O.C.(ISO)

All values based on ISO 3046/1 conditions Ambient air temperature

: 25 ℃

Ambient air pressure

: 1000 mbar

Cooling water for air cooler

: 25 ℃

Marine diesel oil(MDO). Lower calorific value

: 42,700 kJ/kg (10,200 kcal/kg)

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

rise

10℃

0.6 %

Ambient air pressure

rise

10mbar

-0.07 %

Cooling water for air cooler

rise

10℃

0.7 %

Lower calorific value

rise

1%

-1.0 %

-8-

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

1893

OWNER

C.P.OFFEN

9,7L27/38

CLASS

GL

PROJECT ENG. TYPE

ENGINE NO. BA2402/2401 TEST DATE 2008.05.19/24

GENERATOR TEST

ENG. MCR

2970/2310㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195㎾

OPERATED BY

K.D.Oh

1. PARALLEL RUNNING TEST(9L27/38) LOAD

%

75

100

80

60

40

20

40

60

80

100

75

VOLTAGE

V

6594

6600

6594

6588

6582

6582

6582

6588

6594

6600

6594

FREQUENCY

㎐

60.00 59.20 59.80 60.40 60.90 61.60 60.00 60.40 59.80 59.20 60.00

NO.1 D/G

OUTPUT

㎾

2120

2801

2257

1690

1130

574

1129

1696

2252

2818

2117

NO.2 D/G

OUTPUT

㎾

2130

2801

2265

1721

1166

621

1166

1665

2268

2798

2139

D/G NO.

2. PARALLEL RUNNING TEST(7L27/38) LOAD

%

75

100

80

60

40

20

40

60

80

100

75

VOLTAGE

V

6598

6602

6590

6594

6571

6565

6569

6577

6590

6593

6589

FREQUENCY

㎐

60.04 59.32 59.88 60.42 60.92 61.45 60.93 60.42 59.88 59.30 60.01

NO.3 D/G

OUTPUT

㎾

1658

2190

1768

1328

868

436

880

1323

1758

2193

1645

NO.4 D/G

OUTPUT

㎾

1642

2199

1752

1298

833

374

837

1293

1752

2206

1623

NO.5 D/G

OUTPUT

㎾

1645

2192

1752

1332

860

431

881

1316

1772

2211

1658

D/G NO.

- 9 -

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

PROJECT ENG. TYPE

GOVERNOR TEST

1893

C.P.OFFEN

OWNER

GL

9,7L27/38 CLASS

ENG. NO.

2008.05.19/ BA2402/2401 TEST DATE 24

ENG. MCR

2970/2310㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195㎾

OPERATED BY

K.D.Oh

No. 1 D/G SPEED VARIATION BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. %

FROM

TO

TIME

100

0

60.0

65.2

8.67%

63.0

5.00%

3.4 sec

0

33

63.0

61.0

3.17%

62.1

1.43%

3.5 sec

33

66

62.1

59.0

4.99%

61.1

1.61%

4.6 sec

66

100

62.1

58.0

6.60%

60.0

3.38%

3.9 sec

GOV' SETTING

LOAD %

GOV. TYPE

UG-15D

SERIAL NO.

15533414

SPEED DROOP

51

NEEDLE V/V

7/8 TURN

COMPENSATION

-5

-

-

GOV. TYPE

UG-15D

SERIAL NO.

15533417

SPEED DROOP

50

NEEDLE V/V

7/8 TURN

COMPENSATION

-5

-

-

GOV. TYPE

UG-15D

SERIAL NO.

15533405

SPEED DROOP

45

NEEDLE V/V

4/4 TURN

COMPENSATION

-5

-

-

GOV. TYPE

UG-15D

SERIAL NO.

15533406

SPEED DROOP

45

NEEDLE V/V

4/4 TURN

COMPENSATION

-5

-

-

GOV. TYPE

UG-15D

SERIAL NO.

15533413

SPEED DROOP

45

NEEDLE V/V

4/4 TURN

COMPENSATION

-5

-

-

No. 2 D/G SPEED VARIATION

FROM

TO

BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. %

100

0

60.0

65.2

8.67%

63.0

5.00%

2.9 sec

0

33

63.0

61.0

3.17%

62.1

1.43%

3.3 sec

33

66

62.1

59.0

4.99%

61.1

1.61%

4.5 sec

66

100

61.1

58.0

5.07%

60.0

1.80%

3.4 sec

TIME

GOV' SETTING

LOAD %

No. 3 D/G SPEED VARIATION

FROM

TO

BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. %

TIME

100

0

60.0

64.5

7.50%

62.7

4.50%

2.9 sec

0

33

62.7

60.9

2.87%

61.8

1.44%

2.8 sec

33

66

61.8

59.8

3.24%

61.0

1.29%

3.1 sec

66

100

61.0

58.8

3.61%

60.0

1.64%

3.2 sec

GOV' SETTING

LOAD %

No. 4 D/G SPEED VARIATION BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. %

TIME

FROM

TO

100

0

60.0

64.4

7.33%

62.5

4.17%

3.1 sec

0

33

62.5

60.8

2.72%

61.8

1.12%

2.7 sec

33

66

61.8

59.7

3.40%

61.0

1.29%

3.1 sec

66

100

61.0

58.8

3.61%

60.0

1.64%

3.2 sec

GOV' SETTING

LOAD %

No. 5 D/G SPEED VARIATION

FROM

TO

BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. %

100

0

60.0

64.9

8.17%

62.6

4.33%

3.4 sec

0

33

62.6

60.8

2.88%

61.8

1.28%

2.9 sec

33

66

61.8

59.7

3.40%

61.0

1.29%

3.1 sec

66

100

61.0

58.8

3.61%

60.0

1.64%

3.1 sec

- 10 -

TIME

GOV' SETTING

LOAD %

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

PROJECT

MECHANICAL VIBRATION MEASUREMENT

1893

OWNER

C.P.OFFEN

ENG. TYPE

9,7L27/38

CLASS

GL

ENGINE NO.

BA2402/2401

ENG. MCR

2970/2310㎾

2008.05.19/24

TEST DATE MEASUREDD BY

GEN. MCR

2820/2195㎾

S.H.Kang / Q.M

Measurement equipment Manufacture RION

Type VM - 82

Mechanical connection magnetic

Measured value velocity

Recorded value velocity

Vibration level limits Vibration velocity, 720~1200 rpm

Engine

P≤1250 KVA P＞1250 KVA

18 18

V rms (mm/s)

Generator Value 1 Value 2 20 24 18 22

Engine Generator

: VDI 2063T : ISO 8528-9, DIN 6280-11

* Value 1 or 2 are depending on Gen. maker

Measurement points 1

6

1. T/C fore 2. Governor T/C aft 3. Front 4. Aft

2 7

5

3

z

4

5. Aft generator bearing 6. Generator cooler 7. Intermediate bearing 8. ............................

y

UNIT : V rms (mm/s)

x

Item D/GE

NO.1 D/G

NO.2 D/G

NO.3 D/G

NO.4 D/G

NO.5 D/G

Measuring

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7

Vibration velocity, V rms axial (x) 5.0 5.0 4.0 3.0 8.0 5.0 5.0 5.0 4.0 6.0 6.0 4.0 5.0 4.0 7.0 6.0 5.0 4.0 4.0 6.0 5.0 5.0 5.0 4.0 6.0 -

transverse (y) 9.0 7.0 8.0 10.0 8.0 8.0 7.0 9.0 10.0 7.0 6.0 6.0 6.0 10.0 7.0 10.0 9.0 8.0 14.0 11.0 10.0 7.0 8.0 14.0 10.0 -

vertical (z) 7.0 7.0 9.0 9.0 8.0 7.0 7.0 8.0 8.0 6.0 6.0 6.0 7.0 16.0 10.0 7.0 6.0 9.0 16.0 8.0 6.0 6.0 8.0 17.0 10.0 -

- 11 -

▶ Coupling - Flexible coupled(7,9L), [with Generator] ▶ Erection - Resilient mounting Type : 214SH60

Load % : 100% Running hours : 1 Hr

- MAN Diesel OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

PROJECT

CRANKSHAFT DEFLECTION COUPLING TYPE BETWEEN ENGINE AND GENERATOR CYLINDER NO. COLD CONDITION NO.1 HOT CONDITION

COLD CONDITION NO.2 HOT CONDITION

COLD CONDITION NO.3 HOT CONDITION

COLD CONDITION NO.4 HOT CONDITION

COLD CONDITION NO.5 HOT CONDITION

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

NEAR BOTTOM

X

CAMSHAFT SIDE

P

TOP

T

EXHAUST SIDE

S

NEAR BOTTOM

Y

: 1 0 -2.0 -3.0 -2.0 0 0 -2.0 -3.0 -2.0 0 0 -1.0 -4.0 -1.0 0 0 -2.0 -4.0 -2.0 0 0 -2.0 -5.0 -2.0 0 0 -3.0 -6.0 -3.0 0 0 -2.0 -3.0 -2.0 0 0 -3.0 -4.0 -3.0 0 0 -2.0 -4.0 -2.0 0 0 -2.0 -5.0 -3.0 0

1893

OWNER

C.P.OFFEN

ENG. TYPE

9,7L27/38

CLASS

GL

ENGINE NO.

BA2402/2401

TEST DATE

2008.05.19/24

ENG. MCR

2970/2310 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195 ㎾

OPERATED BY

K.D.Oh

7,9L27/38 - FLEXIBLE COUPLING 2 0 -1.0 -1.0 -1.0 0 0 0 +1.0 0 0 0 -1.0 -1.0 -1.0 0 0 -1.0 -2.0 -1.0 0 0 -1.0 -3.0 -1.0 0 0 -1.0 -2.0 -1.0 0 0 -1.0 -2.0 -1.0 0 0 0 -1.0 0 0 0 -1.0 -2.0 -1.0 0 0 0 -1.0 0 0

3 0 +1.0 +2.0 +1.0 0 0 -1.0 -2.0 -1.0 0 0 0 +1.0 0 0 0 -1.0 -3.0 -1.0 0 0 -1.0 +1.0 +1.0 0 0 -1.0 -1.0 -1.0 0 0 -1.0 0 0 0 0 -1.0 0 0 0 +1.0 +2.0 +1.0 0 0 0 0 0 0

4 0 0 0 0 0 0 -1.0 -3.0 -1.0 0 0 -1.0 -1.0 -1.0 0 0 -2.0 -4.0 -2.0 0 0 +1.0 +2.0 +1.0 0 0 0 0 0 0 0 +1.0 +3.0 +1.0 0 0 0 0 0 0 0 +1.0 +2.0 +1.0 0 0 0 0 0 0

5 0 -1.0 -3.0 -1.0 0 0 -2.0 -5.0 -2.0 0 0 0 +1.0 0 0 0 -1.0 -2.0 -1.0 0 0 -1.0 -1.0 -1.0 0 0 -1.0 -2.0 -1.0 0 0 +1.0 +3.0 +1.0 0 0 -1.0 -1.0 -1.0 0 0 +1.0 +2.0 +1.0 0 0 0 -1.0 0 0

6 0 0 0 0 0 0 -1.0 -2.0 -1.0 0 0 +1.0 +1.0 +1.0 0 0 -1.0 -2.0 -1.0 0 0 -1.0 0 -1.0 0 0 0 -1.0 0 0 0 -1.0 +1.0 -1.0 0 0 -1.0 -2.0 -1.0 0 0 -1.0 +1.0 -1.0 0 0 0 -1.0 0 0

[UNIT : 1/100mm]

7 0 +1.0 +2.0 +1.0 0 0 -1.0 -1.0 -1.0 0 0 +1.0 +1.0 +1.0 0 0 -1.0 -3.0 -1.0 0 0 -3.0 -6.0 -3.0 0 0 -4.0 -7.0 -4.0 0 0 -3.0 -5.0 -3.0 0 0 -4.0 -6.0 -4.0 0 0 -2.0 -4.0 -2.0 0 0 -3.0 -5.0 -3.0 0

8 0 +2.0 +3.0 +2.0 0 0 -1.0 -1.0 -1.0 0 0 0 +1.0 0 0 0 -1.0 -1.0 -1.0 0 -

9 0 -3.0 -4.0 -3.0 0 0 -2.0 -4.0 -2.0 0 0 -3.0 -4.0 -3.0 0 0 -2.0 -4.0 -2.0 0 -

"CLOSING" OF THE

Viewed from the Front End

CRANKTHROW IS

START IN PODITION X.

CONSIDERED NEGATIVE.

TURN COUNTER CLOCKWISE

- 12 -

- MAN Diesel PROJECT

OFFICIAL SHOP TEST RESULT FOR DIESEL GENERATOR ENGINE

HEIGHT OF RESILIENT S IN LOADED CONDITION

1893

OWNER

C.P.OFFEN

ENG. TYPE

9,7L27/38

CLASS

GL

ENGINE NO.

BA2402/2401

TEST DATE

2008.05.19/24

ENG. MCR

2970/2310 ㎾

EVALUATED BY

B.G.Choi

GEN. MCR

2820/2195 ㎾

OPERATED BY

K.D.Oh

MOUNT TYPE

1A

2A

3A

4A

5A

6A

7A

8A

: 214SH60

9A

Front

alternator

end

1B

2B

3B

4B

5B

6B

7B

8B

9B

HL = Height of resilient in loaded condition Note !

This flexible elements must be loaded for at least 48 hours, before measurements are taken

Resilient NO.

NO.1

NO.2

HL

(mm)

NO.3

NO.4

NO.5

1A

2A

3A

4A

5A

6A

7A

8A

9A

1B

2B

3B

4B

5B

6B

7B

8B

9B

166.0

166.0

166.0

166.0

166.5

167.0

167.5

-

-

166.0

166.5

166.0

166.5

166.5

167.0

167.0

-

-

166.0

166.0

166.5

166.5

167.0

167.0

167.5

-

-

166.5

166.0

166.5

166.5

167.0

167.0

167.5

-

-

163.5

163.5

163.0

163.0

163.5

163.5

-

-

-

162.5

162.0

162.0

162.0

162.5

162.5

-

-

-

163.0

163.0

162.5

162.5

162.0

162.5

-

-

-

163.0

163.0

162.5

162.5

162.5

162.0

-

-

-

162.5

162.5

162.0

162.0

162.5

162.5

-

-

-

162.5

162.0

162.0

162.0

162.5

162.0

-

-

-

REMARK.:

- 13 -

Remark