MAN Operating Instructions

MAN Diesel & Turbo

Technical Documentation
Engine
Operating Instructions

Engine ................................................ V28/33D
Works No. of engine ........................... 1062103

1062104
1062105
1062106
Plant No. ............................................ 4301599

2013-02-19 - de

010.005

Translation of the original instructions

6739 B1-02 EN 1 (2)

MAN Diesel & Turbo

MAN Diesel & Turbo SE
86224 Augsburg
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-49 4180
[email protected]
www.mandieselturbo.com/primeserv
Copyright © 2013 MAN Diesel & Turbo
All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) 6739 B1-02 EN
010.005
2013-02-19 - de

MAN Diesel & Turbo

Table of contents
2013-02-19 - de
1 Introduction
Table of contents
1.1 Preface
1.2 Manufacturer's liability
1.3 Structure and use of the Operating Instructions
1.4 Addresses/Telephone numbers

2 Technology

2.1 Scope of supply/Technical specifications
2.1.1 Scope of supply of MAN Diesel & Turbo SE Technical specifica-
tions
2.2 Engine
2.2.1 Characteristic features
2.2.2 Drawings
2.3 Components/Sub-assemblies
2.3.1 Normal version of engine Crankcase up to cylinder head
2.3.2 Standard design of engine Camshaft-drive to injection valve
2.3.3 Standard engine design Supercharging system up to engine con-
trol
2.3.4 Special versions of the engine
2.3.5 Additional equipment
2.4 Systems
2.4.1 Fresh air/charge air/exhaust gas system
2.4.2 Compressed air and starting system
2.4.3 Fuel system
2.4.6 Lube oil system
2.4.7 Cooling water system
2.5 Technical data
2.5.1 Performance and consumption specifications
2.5.2 Temperatures and pressures
2.5.3 Weights
2.5.4 Dimensions/Clearances/Tolerances - Part 1
2.5.5 Dimensions/Clearances/Tolerances - Part 2
2.5.6 Dimensions/Clearances/Tolerances - Part 3

3 Operation/Operating fluids

3.1 Prerequisites

3.1.1 Prerequisites/Guarantee

6739 B1-02 EN 1 (3)

MAN Diesel & Turbo

Table of contents 3.1.2 Transport/On site measures
3.1.3 Assembly/Installation
2013-02-19 - de3.1.4 Commissioning
3.2 Safety
3.2.1 General notes
3.2.2 Design/suitability of the engine
3.2.3 Risks/Dangers
3.2.4 Safety Instructions
3.2.5 Safety Regulations
3.3 Operating fluids
3.3.1 Gas oil / diesel oil (MGO) specification
3.3.5 Lubricating oil specification for operation with gas oil (MGO)
3.3.7 Engine cooling water specifications
3.3.8 Analysis of operating fluids
3.3.11 Specifications for intake air (combustion air)
3.4 Operative management I - Starting the engine
3.4.1 Starting preparations/Starting and stopping the engine
3.4.3 Permissible outputs and speeds
3.4.4 Engine run-in
3.5 Operative Management II - Monitoring Operating Data
3.5.1 Monitoring the engine/Performing routine work
3.5.2 Engine Log Book
3.5.3 Load curve during acceleration/manoeuvring
3.5.4 Part-load operation
3.5.5 Calculating the engine output and locating the engine operating
point
3.5.7 Equipment for engine modification for special operating condi-
tions
3.5.8 Bypass charge air
3.5.9 Condensate water in charge air pipes and pressure vessels
3.6 Operative Management III - Operating faults
3.6.3 Emergency operation upon failure of a turbocharger
3.6.4 Failure of the power supply (blackout)
3.6.7 Response in the event that operating data are exceeded when
alarms occur
3.6.8 Response in the event of a splash oil alarm
3.7 Operative Management IV - Shutting down the Engine
3.7.1 Shutting down/Preserving the engine
3.7.2 Decommissioning, dismantling and disposal

2 (3) 6739 B1-02 EN

MAN Diesel & Turbo

4 Maintenance/repair

4.1 General remarks
4.2 Maintenance schedule (explanatory notes)
4.4 Spare parts
4.5 Replacement of Components on the New-for-Old Principle
4.6 Services/repair work
4.7 Maintenance schedule (Signs/Symbols)
4.7.1 Maintenance schedule (systems)
4.7.2 Maintenance schedule (engine)
2013-02-19 - de
5 Appendix
Table of contents
5.1 Designations/Terms
5.2 Formulae
5.3 Conversion of units
5.4 Symbols and abbreviations
5.5 Brochures

6739 B1-02 EN 3 (3)



MAN Diesel & Turbo

1 Introduction
2 Technology
3 Operation/Operating fluids
4 Maintenance/repair
5 Appendix

2013-02-19 - de

Introduction

6739 1 B1-02 EN 1 (1)



MAN Diesel & Turbo 1.1
Preface
Introduction
Preface MAN Diesel & Turbo SE engine installations are the result of decades of
ongoing successful research and development. They cope admirably with
Engine installations - their high levels of demand and have reserves in hand to cope with interfering and
characteristics, justified damaging influences. In order to be able to fulfill expectations they must be
expectations, assumptions used as intended and maintained properly. You can expect uninterrupted
Intent and purpose of the performance and a long life if these requirements are met.
Operating and Work The Operating and Work Instructions will help you to be familiar with the
Instructions engine. They are intended to provide answers to questions which arise at a
later date and to be a handbook for operation of the engine and during main-
Condition 1 tenance. We consider the understanding of the methods of action, the pro-
motion of cause and effect and the passing on of experience to be an aim of
equal value. Last, but by no means least, the handover of the Operating and
Work Instructions signifies our fulfillment of the legal obligation to provide
advice concerning the dangers arising from the engine or its components -
despite its high level of development and despite all design endeavors - or
which arise from handling which is improper and in contravention of the
instructions.
The operating personnel and servicing and overhauling personnel must be
familiar with the Operating and Work Instructions, which must be available at
all times for reference.

Lack of information

Lack of information and non-observance of information can cause
serious injury to persons and serious damage to property and the
environment! Please therefore: Observe Operating and Work
Instructions!

Condition 2 The maintenance and overhaul of modern four stroke engines requires prior
comprehensive training of the personnel. The knowledges, which correspond
to this training are asumed in the Operating and Work Instructions. Guaran-
tee and liability claims cannot be accepted resulting from the lack of relevant
instructions.

Untrained staff

Untrained persons can cause serious personal injury and serious
material and environmental damage! Do not assign any tasks that
exceed the level of knowledge and experience! Refuse access/
involvement to unauthorized persons!

2011-03-04 - de Condition 3 The technical documentation is tailored to the specific installation. This Introduction
means that there can be considerable differences in comparison with other
systems. The data valid for certain plant may not be applied for the other General
plants.

6680 1.1-01 EN 1 (2)

Introduction1.1 MAN Diesel & Turbo

Also observe... Scope of technical documents

Technical documents have plant-specific validity! The use of
information for another plant or from an outside source can cause
malfunctions or damage! Use only relevant information, and not
information from an external source!

Please also observe the tips concerning product liability provided in the next
section, as well as the safety regulations in section 3.

Introduction 2011-03-04 - de

General

2 (2) 6680 1.1-01 EN

MAN Diesel & Turbo 1.2
Manufacturer's liability
Introduction
Manufacturer's liability

Safe efficient operation of the engine installation presupposes comprehensive
knowledge. In a similar way, functionality can only be maintained or recov-
ered by maintenance or repair if these tasks are carried out by trained per-
sonnel having technical understanding and skill. The rules of sound technical
practice must be observed to preclude negligence.

The Technical Documentation supplements this skill with special information,
draws attention to hazards and points out the safety regulations which are to
be observed. MAN Diesel & Turbo SE requests that you observe the follow-
ing rules:

Non-observance of the technical documentation

Non-observance of the technical documentation, especially of the
Operating and Work Instructions and the safety regulations, use of the
system for a purpose not intended by the manufacturer, or any other
improper use or negligent application, can cause serious damage to
property and serious personal injury, for which the manufacturer
rejects all liability.

The parts package supplied by MAN Diesel & Turbo SE must be set up and
fastened taking sound and well-proven engineering aspects into considera-
tion. This must include the observance of the binding stipulations quoted in
the following documents in the sequence given:
▪ Order-specific engineering documents supplied by MAN Diesel & Turbo

SE
▪ Assembly documents from our subcontractors for accessories
▪ Operating instructions for engines, turbochargers and accessories
▪ MAN Diesel & Turbo SE Project Guides
Any deviation from the principles specified in the documentation quoted
above requires our prior approval. Fitting brackets and/or supporting equip-
ment to the parts package supplied by us, which are not illustrated or men-
tioned in the above documents, and which are not approved by us is not
permitted. We accept no responsibility for damage which may arise as a
result.

2011-02-28 - de Introduction

General

6680 1.2-01 EN 1 (1)



MAN Diesel & Turbo 1.3
Structure and use of the Operating Instructions
Introduction
Tips for use

The Operating Instructions contain information in words and images: Some
which are useful and some which it is imperative to follow. This information is
meant to expand the current knowledge and existing skills of those who
▪ are familiar with the operative management,
▪ with monitoring and checking,
▪ with the maintenance and repair
of the engine. Training received at school or practical experience is not ade-
quate.
The Operating Instructions must be accessible to this group. In turn, the per-
sons in charge have the task of familiarising themselves with the structure of
the operating instructions to such an extent that they can find the required
information without having to search for long periods.
We will also try to provide you with a clearly organised structure in an easy-
to-understand language.

Structure and special features

The Operating Instruction is comprised of 5 sections:
1. Introduction
2. Technology
3. Operation/Operating media
4. Maintenance/Repairs
5. Appendix

It is mainly oriented to the understanding of complex
▪ Functions and contexts,
▪ Starting and stopping the engine,
▪ Planning engine operation, controlling according to operating results and

economic criteria,
▪ Maintaining the engine in operational readiness, carrying out preventive

or scheduled maintenance.
The following are not covered:
▪ Transport, assembly and disassembly of the engine or major parts of it,
▪ Work steps and checks at the time of the initial start-up of the engine,
▪ Repairs requiring special tools, facilities and experience,
▪ Actions to be taken during and after a case of fire, water penetration,

serious damage and disaster.

2007-04-13 - de What is also important The operating instructions are continually updated to be state-of-the-art and Introduction
to be matched to the ordered version of the engine. There may be apparent
Engine version gaps in the chapter numbering of the operating and working instructions as a General
result of the version of engine purchased. This situation does not represent

6680 1.3-01 EN 1 (2)

1.3 MAN Diesel & Turbo

Introduction an error and is governed by the structuring system. Even so, there nay be
differences between the pages with the primary described/represented con-
Technical data tent and the actual execution.
Maintenance schedule / There is normally a thematic differentiation between main marine engines,
Work Cards auxiliary marine engines and engines for stationary applications. In positions
where the differences in content are slight, the treatment is kept to a general
mode. Read such points selectively, keeping in mind the listed limitations.
You will find technical data for your engine
▪ in section 2 under "Technical data",
▪ in Volume 010.005 Engine - Work Instructions in Work Card 000.30,
▪ in Volume 010.330 in the test run report as well as in the certificate of

acceptance,
▪ in Volume 010,290 Control and Monitoring Device in the list of the meas-

uring, control and regulating devices,
▪ in Volume 000 Systems Information in the installation drawing.
All documents listed are tailored to the corresponding engine.
The maintenance schedule is closely related to the Work Cards in Volume
010.005 Engine - Work Instructions. The Work Cards describe how to carry
out a task and which tools and auxiliary equipment are required. The mainte-
nance schedule in turn contains the repeat intervals and the average person-
nel and time requirement.

Introduction 2007-04-13 - de

General

2 (2) 6680 1.3-01 EN

MAN Diesel & Turbo 1.4
Addresses/Telephone numbers
Introduction
Contact information

You can rely on MAN Diesel & Turbo Group Customer Services 24 hours a day 365
days of the year. The MAN Diesel & Turbo Customer Service Centres in Augsburg,
Copenhagen, Stockport and St. Nazaire and the Customer Service Centres in all
continents provide a comprehensive service. The proverbially long service life of
MAN Diesel & Turbo engines requires that are also always available over decades
for engines that are in use. Customer requirements can be implemented to a high
degree of precision at MAN Diesel & Turbo Service production facilities.

24 hour hotline
Tel: +49 1801 15 15 15

Company headquarters MAN Diesel & Turbo SE
Augsburg 86224 Augsburg
Germany
Technical Service Tel: +49 821 322-0
Spare parts Fax: +49 821 322-3382
Turbocharger Service E-mail: [email protected]
24-hour hotline
2010-04-29 - de Tel: +49 821 322-1499 Introduction
Fax: +49 821 322-3838
E-mail: [email protected] General
24-hour hotline
Tel: +49 821 322-1799 1 (1)
Fax: +49 821 322-3574
E-mail: [email protected]
24-hour hotline
Spare parts
Tel: +49 821 322-4030
Technical Service (radial)
Tel: +49 821 322-4020
Technical Service (axial)
Tel: +49 821 322-4010
Fax: +49 821 322-3998
E-mail:
[email protected]
[email protected]
[email protected]

6680 1.4-01 EN



MAN Diesel & Turbo

1 Introduction
2 Technology
3 Operation/Operating fluids
4 Maintenance/repair
5 Appendix

2013-02-19 - de

Technology

6739 2 B1-02 EN 1 (1)



MAN Diesel & Turbo 2.1

Scope of supply/Technical specifications

2.1 Scope of supply/Technical specifications
2.2 Engine
2.3 Components/Sub-assemblies
2.4 Systems
2.5 Technical data

2013-02-19 - de Technology

6739 2.1-02 EN 1 (1)



MAN Diesel & Turbo 2.1.1

Scope of supply of MAN Diesel & Turbo SE Scope of supply/Technical specifications
Technical specifications

Scope of supply by MAN Diesel & Turbo SE/technical specification

Items supplied The items we have supplied are listed on the following page. This purpose of
this list is to ensure that you obtain information/support from the right part-
ner.

With all parts we have Your contact partner who can answer all questions on parts supplied by us is
supplied ... ▪ MAN Diesel & Turbo SE in Augsburg
and for service-related questions,

With all parts we have not ▪ MAN Diesel & Turbo SE Service Center,
supplied ... ▪ the agencies and
▪ authorised repair workshops round the world.
For all parts not supplied by us, please consult your supplier, unless the
parts/systems supplied by MAN Diesel & Turbo SE are significantly affected
or contacting us is the obvious course of action for other reasons.

Technical specification The order confirmation, technical specification that accompanies the order
confirmation and technical specification of the engine contain additional infor-
mation.

2008-10-28 - de Technology

General

6680 2.1.1-01 EN 1 (1)



MAN Diesel & Turbo 2.2

Engine

2.1 Scope of supply/Technical specifications
2.2 Engine
2.3 Components/Sub-assemblies
2.4 Systems
2.5 Technical data

2013-02-19 - de

Technology

6739 2.2-02 EN 1 (1)



MAN Diesel & Turbo 2.2.1

Characteristic features Engine

Characteristic features

Characteristics defined by Engines with the designation V28/33D are four-stroke Diesel engines with
key words turbocharger, a cylinder bore of 280 mm and a stroke of 330 mm. They are
used for ship's propulsion systems, auxiliary equipment and as stationary
engines in power stations. These engines benefit from the engineering design
principle and comprehensive experience of MAN Diesel & Turbo SE.

Charge air coolers, exhaust-gas and charge air distributors are installed
between the cylinder banks when viewed from the coupling side.

The engine has many innovative functions that reduce the number of individ-
ual components required and simplify maintenance work. These include e. g.
the internal holes that reduce the number of pipes to a minimum and the hol-
low camshafts (one per cylinder bank) that are the main distribution path for
lubricating oil and also operate the inlet and exhaust valves and fuel-injection
pumps.

The turbocharger and all service pumps for the primary and secondary cool-
ing water circuit, lubricating oil circuit and fuel circuit are located at the free
engine end.

The engine is operated with diesel fuel supplied as DMA or equivalent
according to CIMAC standards. However, DMB can also be used subject to
approval by MAN Diesel & Turbo SE.

The electronic injection system, oil cooler mounted on the engine, filter and
all service pumps are integrated into 28/33D-type engines. They are com-
pact and have an extremely favourable performance/weight ratio. Due to
these characteristics, this engine is particularly suitable for applications in
which low weight and/or compact size are an advantage.

The engines are equipped with MAN diesel turbochargers from the TCA ser-
ies.

2009-10-26 - de

Technology

V28/33D

6739 2.2.1-02 EN 1 (1)



MAN Diesel & Turbo 2.2.2

Drawings Engine

Drawings

2010-02-05 - de

Technology

V28/33D
Figure 1: 20-cylinder four-stroke Diesel engine V28/33D
6739 2.2.2-02 EN 1 (3)

Engine2.2.2 MAN Diesel & Turbo

Figure 2: V28/33D - cross-section
2 (3) 6739 2.2.2-02 EN
Technology

V28/33D
2010-02-05 - de

MAN Diesel & Turbo 2.2.2

Engine

2010-02-05 - de

Technology

V28/33D
Figure 3: V28/33D - longitudinal section
6739 2.2.2-02 EN 3 (3)



MAN Diesel & Turbo 2.3

Components/Sub-assemblies

2.1 Scope of supply/Technical specifications
2.2 Engine
2.3 Components/Sub-assemblies
2.4 Systems
2.5 Technical data

2013-02-19 - de Technology

6739 2.3-02 EN 1 (1)



MAN Diesel & Turbo 2.3.1

Normal version of engine Components/Sub-assemblies
Crankcase up to cylinder head

Crankcase

Crankcase Figure 1: Static main components/Tie rod
The crankcase is a single-piece design made of nodular graphite cast iron.
Cooling water/Lubricating oil Partition walls reinforce the main structure and serve as support for the
Access crankshaft and camshaft bearings.
The torsional vibration damper and the camshaft gear drive as well as all aux-
iliary pumps are located on the free engine end.
The crankcase has no water jackets. The lubricating oil is fed to the engine
via the hollow camshafts.
Light inspection doors are provided on both sides of the crankcase, permit-
ting access to the main-bearing, connecting-rod and camshaft sub-assem-
blies. The crankcase doors are equipped with safety valves (generally in the
case of marine engines, partly in the case of stationary engines).

2012-07-17 - de Oil pan Technology

The oil pan is made up of welded steel plate. It collects the oil dripping down V28/33D
from running-gear components, using the engine-driven oil pump to feed it
back into the circuit via a central suction point.

6739 2.3.1-02 EN 1 (8)

2.3.1 MAN Diesel & Turbo

Components/Sub-assemblies Crankshaft bearing The crankshaft main bearings are comprised in each case of an upper and
lower bearing shell and the main bearing cap. The main bearing cap in the
Bearing cap/Tie rod suspended position is braced to the crankcase using tie rods and cross tie
rods.

Locating bearing Figure 2: Crankshaft bearing/Locating bearing/External bearing
Bearing shells The axial position of the crankshaft is controlled via two thrust bearings. Both
bearings consist of a steel semi-circular ring and a bronze running layer. They
are located in a recess in the crankcase next to the upper half of crankshaft
bearing No. 1 at the flywheel end.
The bearing shells of all crankshaft bearings are supplied ready for fitting.
They consist of a steel support shell and a leaded bronze running layer.

Crankshaft The crankshaft is manufactured from special steel. It is an overhead cam- 2012-07-17 - de
shaft with two counterweights on each crank held in place by undercut bolts
Crankshaft/Counterweights/ that compensate for the rotating and oscillating masses. The crankshaft gear
Drive gear is at the free engine end and drives the camshafts as well as the freshwater,
sea water, lubricating oil and diesel oil supply pumps. The single-piece gear
Technology wheel is attached with cap bolts to a flange forged onto the crankshaft.

V28/33D

2 (8) 6739 2.3.1-02 EN

MAN Diesel & Turbo 2.3.1

Components/Sub-assemblies

Figure 3: Crankshaft with drive wheel, locating bearing flange and screwed-on
counterweights
The flywheel is made of spheroidal graphite iron and is on the coupling side
of the crankshaft. A toothed ring on the perimeter of the flywheel serves to
start and turn the diesel engine using a separate compressed air motor. The
engine speed is also recorded via the teeth of the gear wheels and the
engine is controlled via the bores in the lateral surface.

Torsional vibration damper

Torsional vibrations, to which the crankshaft is prone, are reduced with a tor-
sional vibration damper on the free engine end of the crankshaft. Depending
on the number of cylinders in the engine, the damper may be a viscous
damper or a torsional vibration damper with leaf springs.

Figure 4: Viscous damper – with 12- or 16-cylinder engines

2012-07-17 - de Technology

V28/33D

6739 2.3.1-02 EN 3 (8)

2.3.1 MAN Diesel & Turbo

Components/Sub-assemblies

Connecting rod Figure 5: Torsional vibration damper with leaf springs – with 20-cylinder engines

Diagonally split connecting The connecting rod is forged from high-strength steel alloy and is split at the
rod big end.
To reduce downtime during overhaul and maintenance work, the connecting
rod, piston and cylinder liner can be removed from and reinstalled in the
engine as one unit.

Technology 2012-07-17 - de

V28/33D

4 (8) 6739 2.3.1-02 EN

MAN Diesel & Turbo 2.3.1

Components/Sub-assemblies

Bearing shells Figure 6: Two-part connecting rod
Bearing shells are supplied ready for fitting. Thin-walled bearing shells with a
Piston light metal running layer are used. The bearing housing is secured by four
hydraulically-tensioned undercut bolts and nuts.
Engineering design
characteristics Two-part pistons consist of a cast steel skirt and a forged crown. The two
sections are connected by four undercut bolts, nuts and spacers. This com-
Cooling ponent is extremely resistant to deformation occurring as a result of combus-
tion pressures owing to the engineering design and materials selected. This
means that the distance between the piston and cylinder liner is reduced, the
ring characteristics are improved, the ingress of abrasive particles is preven-
ted and the oil film is protected more effectively from hot gases.
The piston is cooled with oil, which is directed through the connecting rod via
a bore. The oil is directed from here via the piston pins and internal channels
to the outer chamber of the piston crown. The oil can flow through the radial
bores back into a central cooling chamber from where it passes through a
central outlet and back into the oil pan.
The special design of the piston crown and piston skirt, in conjunction with
the vibration effect ensures effective oil cooling in the inner and outer cham-
bers. This allows the temperatures and resulting distortion to be controlled.

2012-07-17 - de Technology

V28/33D

6739 2.3.1-02 EN 5 (8)

2.3.1 MAN Diesel & Turbo

Components/Sub-assemblies

"Stepped piston" Figure 7: Piston two-piece, oil-cooled
Piston rings The diameter of the upper section of the piston crown above the piston rings
Piston pin is slightly smaller than the diameter of the lower section. Pistons with this
design are referred to as stepped pistons. The purpose of the step is
explained under "Cylinder liner".
The upper section is fastened to the lower section with tension undercut
bolts and nuts. Two piston rings and an oil scraper ring form a seal between
the piston and cylinder liner. The piston rings have a chrome ceramic coating
and the third ring is chrome-plated. All rings are installed in a wear-resistant
effectively cooled steel piston crown.
The piston pin has a floating bearing and is fastened axially with circlips in the
piston skirt.

Cylinder liner The cylinder liners are made of special cast iron and are provided with a high
upper ring enclosed in a water jacket. In this space, water is fed directly from
Cylinder liner/Backing ring/ the internal channels of the crankcase to cylinder liner cooling. It then flows
Flame ring to the cooling chambers in the cylinder head. The lower part of the cylinder
liner is not cooled and serves to position the liner on the upper and lower
cover of the crankcase.
A recess in the upper part of the cylinder liner bore contains a flame ring.

Technology 2012-07-17 - de

V28/33D

6 (8) 6739 2.3.1-02 EN

MAN Diesel & Turbo 2.3.1

Components/Sub-assemblies

Figure 8: Cylinder liner, flame ring and support ring

Combined effect of stepped Figure 9: Cylinder liner cooling
piston/flame ring The flame ring extends into the cylinder liner bore and, together with the
step-shaped design of the piston, removes deposits from the upper part,
2012-07-17 - de which would polish and damage the cylinder liner surface. This prevents pol- Technology
ishing of the bore and hence poor adhesion of the lubricating oil.
V28/33D

6739 2.3.1-02 EN 7 (8)

2.3.1 MAN Diesel & Turbo

Components/Sub-assemblies Cylinder head/Rocker arm casing

Valves in the cylinder head Figure 10: Cylinder head with valves
The cylinder heads are made of nodular graphite cast iron. They are fit into
Connections the water-conducting sleeve of the cylinder liner, located directly on the cylin-
Rocker arm casing/Valve der liner, and supported by four threaded studs. The sturdy channel-cooled
gear lower cover of the cylinder head and the rib-reinforced inner section ensure a
high level of stability.
The cylinder head has two intake valves, two exhaust valves and one indica-
tor valve. The fuel injector is positioned centrally between the valves. It is
located in a sleeve, the lower part of which is sealed against the cooling
water chamber and also against the combustion chamber.
The connections between cylinder head, exhaust pipe, cooling water and
charge air system are made using four screws and two pipe clamps.
The upper side of the cylinder head is protected by a single-piece cover,
which is easily removable by releasing the four nuts if necessary.

Technology 2012-07-17 - de

V28/33D

8 (8) 6739 2.3.1-02 EN

MAN Diesel & Turbo 2.3.2

Standard design of engine Components/Sub-assemblies
Camshaft-drive to injection valve

Timing drive/Camshaft drive

Arrangement of the gear Figure 1: Control drive, arrangement of drive wheels and intermediate gear wheels
drive at the free end All driving pinions are located at the free engine end and installed in the
crankcase and below the casing. The timing drive is effected via an inter-
Lubrication oil supply mediate gear with double gear ratio for every cylinder bank, engaging in the
crankshaft gear and camshaft gear.
Camshaft The next two gears also engage in every double-ratio gear, for the actuation
of the seawater pump, low-temperature water pump and lubricating oil
Two camshafts pump.
The camshaft does not have external oil-supply lines. The camshaft bearings
2012-07-17 - de and the gear wheels are supplied with lubricating oil via a channel at the cen- Technology
tre of the camshaft. Therefore, no external or internal oil-supply lines must be
detached or removed when maintenance work is carried out on the camshaft V28/33D
or gear wheels.

The engine has two camshafts, each consisting of separate, identical cylin-
der sections. Every camshaft is equipped with three cams per cylinder,
actuating the inlet and exhaust valves and the fuel pumps.
The camshafts run in tunnel bearings which are shrunk-fit into the crankcase.
The bearing consists of a steel shell with a thin aluminium-alloy running layer.
There are thrust bearings for the axial positioning of the camshafts; these are
located at the free engine end.

6739 2.3.2-01 EN 1 (7)

2.3.2 MAN Diesel & Turbo

Components/Sub-assemblies The camshafts are integrated into the engine crankcase and are located
behind the light aluminium-alloy covers, which can be easily lifted off by
removing the four cylinder head bolts.

Figure 2: Camshaft
The camshafts are hollow and both drive the engine and act as main lubri-
cating-oil suppliers via the internal bores and channels. This helped to reduce
the number of parts and the time required for maintenance.

Valve drive The camshaft actuates iinlet and exhaust valves via push rods and cam-fol-
lower valve tappets which are located in the joint tappet casing. The fuel
Camshaft/cam follower/push pump also uses the tappet casing and is actuated exactly the same way as
rods the valves.
The movements of the push rods are transmitted onto the rocker arms in the
Valve actuation cylinder head. The rocker arms then actuate two valves of the same type.
The rocker arm casing is bolt-connected to the cylinder head. The ball and
articulate joints of the rocker arm control, the valve tappets and the bearing
are supplied with lubricating oil via the internal bores in the push rods and the
rocker arms.

Technology 2012-07-17 - de

V28/33D

2 (7) 6739 2.3.2-01 EN

MAN Diesel & Turbo 2.3.2

Components/Sub-assemblies

Valves Figure 3: Cam followers for intake and exhaust valves/actuation of the rocker arms
Each cylinder head has two inlet and two exhaust valves. They are mounted
Valves/Valve guides in valve guides in the cylinder heads.

2012-07-17 - de Technology

V28/33D

6739 2.3.2-01 EN 3 (7)

2.3.2 MAN Diesel & Turbo

Components/Sub-assemblies

Valve seat/seat insert Figure 4: Inlet and exhaust valve
The valve seat rings are armoured. The exhaust valve seat rings are cooled.
Valve rotator For this purpose, cooling water flows through a cooling channel formed by
the outer sides of the inlet valve seat rings and seat bores in the cylinder
Fuel injection pump head.
Intake and exhaust valves are rotated using valve rotators.
Arrangement/Drive
The fuel injection pumps are located on the upper side of the camshaft cas-
Operating method ing above the camshaft. Power is transmitted by the fuel cam via a tappet
roller. The stroke movement of the valve tappet is transferred directly to a
Technology spring-loaded pump piston. 2012-07-17 - de
The fuel is continuously pumped into the pump chamber via the internal
V28/33D bores; excessive fuel cools the pump and is fed back into the low-pressure
fuel line. The fuel-pump cylinder is a single-piece design and is provided with
the already mentioned internal bores for the fuel supply and return flow and a
bore on the upper side through which fuel is directed to the injection nozzle
depending on the piston movement. The engine control and the manage-
ment system activate a solenoid overflow valve to insert the required injection
volume. This depends on many factors, for example load and speed. The
engine stop function is activated by simultaneously switching off the power
supply to all solenoid valves.

4 (7) 6739 2.3.2-01 EN

MAN Diesel & Turbo 2.3.2

Components/Sub-assemblies

Figure 5: Fuel injection pumps with solenoid valve
A fuel leakage drain between the fuel pump cylinder and the low-pressure
fuel system prevents the contamination of the lubricating oil with fuel.

Control rack/fuel governor control linkage

An electronic governor The electronic solenoid valve is located on one side of the fuel pump.
actuates the solenoid valve Depending on the requested engine output and speed, the governor sends a
of the fuel pump. signal to the solenoid valves of all pumps to increase or decrease fuel supply
and also to adjust or optimise the fuel injection duration.

2012-07-17 - de Technology

V28/33D

6739 2.3.2-01 EN 5 (7)

2.3.2 MAN Diesel & Turbo

Components/Sub-assemblies Injection pipes

High-pressure injection pipe
with external protection tube

Injector Figure 6: Fuel injection pipe
The injection pipes between the injection pumps and injectors are sheathed
Injector in single-piece protective tubing for safety reasons. The protecting tubes pre-
vent fuel which has leaked from the high-pressure pipes from getting into the
engine room (danger potential) and direct it to a common leak pipe. 2012-07-17 - de

The fuel injector is positioned centrally in the cylinder head. Fuel is is supplied
by the pump via a high-pressure line to a hollow line located in the cylinder
head which contains the screwed-in injection valve casing. The fuel is injec-
ted directly into the combustion chamber.

Technology

V28/33D

6 (7) 6739 2.3.2-01 EN

MAN Diesel & Turbo 2.3.2

Components/Sub-assemblies

Figure 7: Injection valve with multiple hole nozzle

2012-07-17 - de Technology

V28/33D

6739 2.3.2-01 EN 7 (7)



MAN Diesel & Turbo 2.3.3

Standard engine design Components/Sub-assemblies
Supercharging system up to engine control

Turbocharger system

Turbocharger Figure 1: Arrangement of turbocharger, charge air cooler and charge air distributor
The turbocharger is mounted in the longitudinal direction of the engine. Tur-
bochargers from the TCA series are used, i.e. turbochargers with radial com-
pressors and axial turbines.

2012-09-19 - de Technology

V28/33D

6739 2.3.3-03 EN 1 (6)

2.3.3 MAN Diesel & Turbo

Components/Sub-assemblies

6 Radial-flow compressor 9 Plain bearing
7 Axial turbine 19 Compressor casing
8 Silencer 20 Turbine casing

Figure 2: Turbochargers in the TCA series
Fresh air is drawn in via a silencer or inlet spigot. The turbocharger rotor runs
in floating plain bearings on both sides.

Charge air pipe/charge air cooler

The charge air induced by the turbochargers is compressed and supplied via
charge-air lines to the two-stage intermediate coolers located in the centre of
the engine above the air distributor. Depending on the engine operating con-
ditions, the air is cooled and supplied to the cylinders by the common air dis-
tributor.
The charge-air distributor is located on the top of the engine between the
cylinder banks. The distributor distributes the air supplied from the intermedi-
ate coolers to the cylinders. This engineering solution allows the cylinder
heads to be removed independently from the charge-air system.

Polar Blow Off

At lower temperatures, air has a higher density due to its physical nature. 2012-09-19 - de
Therefore the combustion in the engine is affected as follows. At an inlet air
temperature <5°, a higher air density will lead to unacceptable high charge
pressures and thus also to unacceptable high ignition pressures. Therefore,
to prevent this, a so called "Polar Blow Off" valve is installed, which will blow
off air at too high charge pressures caused by too cold inlet air.

Technology

V28/33D

2 (6) 6739 2.3.3-03 EN